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Movacolor MC-BALANCE, User Manual

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Movacolor MC-BALANCE User Manual Download Page 3

 

 

INDEX 

1. Introduction ______________________________________________________________________________________________ 1

 

1.1 Symbols_______________________________________________________________________________________________ 1

 

1.2 Terms ________________________________________________________________________________________________ 1

 

2. General information________________________________________________________________________________________ 2

 

2.1 Safety ________________________________________________________________________________________________ 2

 

2.2 Certification ____________________________________________________________________________________________ 2

 

2.3 Operating environmental conditions _________________________________________________________________________ 2

 

3. Overview Dosing unit ______________________________________________________________________________________ 3

 

3.1 MC-Balance Component overview __________________________________________________________________________ 3

 

3.2 Weighing frame _________________________________________________________________________________________ 4

 

3.3 Motor and dosing system _________________________________________________________________________________ 4

 

4. Metering principle _________________________________________________________________________________________ 5

 

5. Dosing systems / Capacities ________________________________________________________________________________ 6

 

6. Installation _______________________________________________________________________________________________ 8

 

6.1 Transport ______________________________________________________________________________________________ 8

 

6.2 Receipt _______________________________________________________________________________________________ 8

 

6.3 Mechanical Installation ___________________________________________________________________________________ 8

 

6.4 Changing from Dosing cylinder to Feed screw _________________________________________________________________ 9

 

6.5 Electrical installation ____________________________________________________________________________________ 10

 

7. Operation _______________________________________________________________________________________________ 12

 

7.1 Navigation ____________________________________________________________________________________________ 12

 

7.2 Start up & Login________________________________________________________________________________________ 13

 

7.3 Keyboard lock _________________________________________________________________________________________ 14

 

7.4 Configuration __________________________________________________________________________________________ 15

 

7.5 Loadcell calibration _____________________________________________________________________________________ 21

 

7.6 Material Pre-calibration __________________________________________________________________________________ 22

 

7.7 Production ____________________________________________________________________________________________ 24

 

7.8 Auto/Manual regulation mode & Save data function ____________________________________________________________ 27

 

7.9 Production JOB ________________________________________________________________________________________ 28

 

7.10 Filling the hopper. _____________________________________________________________________________________ 29

 

7.11 Consumption _________________________________________________________________________________________ 33

 

7.12 Alarms ______________________________________________________________________________________________ 34

 

7.13 Files ________________________________________________________________________________________________ 36

 

7.14 Event LOG___________________________________________________________________________________________ 37

 

8. System performance ______________________________________________________________________________________ 38

 

8.1 Reset regulation _______________________________________________________________________________________ 38

 

9. Trouble shooting _________________________________________________________________________________________ 39

 

APPENDIX A:

 

MC-Bal. Print view __________________________________________________________________________ 40

 

APPENDIX B:

 

MC-Bal. Wiring Diagram _____________________________________________________________________ 41

 

APPENDIX C:

 

MC-Bal. Technical Specifications ______________________________________________________________ 42

 

APPENDIX D:

 

MC-Bal. Drawings General Dimensions _________________________________________________________ 43

 

APPENDIX E:

 

MC-Bal. Decl. of Conformity __________________________________________________________________ 47

 

 

Summary of Contents for MC-BALANCE

Page 1: ...MC Balance User Manual 4 0 UK 00 Software version V4 0 Manual revision 0 0 Date April 2008 ...

Page 2: ......

Page 3: ..._______12 7 1 Navigation ____________________________________________________________________________________________12 7 2 Start up Login________________________________________________________________________________________13 7 3 Keyboard lock _________________________________________________________________________________________14 7 4 Configuration____________________________________________...

Page 4: ...IS MANUAL MUST BE READ BEFORE INSTALLING THE DOSING UNIT KEEP THIS MANUAL IN A PLACE ACCESSIBLE FOR ALL OPERATORS 1 1 Symbols Important note Attention safety regulations for the operator 1 2 Terms Operator A person charged to operate adjust maintain and clean the machine Qualified Technician A specialized suitable trained person authorized to execute the installation non routine maintenance or rep...

Page 5: ...er plug from electrical power before performing maintenance Ensure that all parts are securely fixed to the extruder or injection molding machine Dangerous voltages are present inside the control cabinet for up to 2 minutes after it has been switched off 2 2 Certification The Movacolor dosing unit is designed and produced in conformity with the following European regulations standards for machiner...

Page 6: ...tr 4 Curled knob M10x40 5 Standard NST40 Neckpiece 6 Material discharge slide in closed position 7 MC Balance Load frame 8 OPTIONAL Slide frame 9 Slide locking bolt locking the slide out position Only supplied together with the optional slide mechanism 10 Slide locking bar locking the slide in position Only supplied together with the optional slide mechanism ...

Page 7: ...d dosing system There are mainly two dosing systems the dosing cylinder and the feed screw for more information see chapter 5 Safety bolts total of 4 Balance frame Hopper loader tube support Transport protection The serial number of the motor can be found on the backside of the motor Motor axle The motor shaft is equipped with one flat side which fits exact in shaft of the dosing cylinder To conne...

Page 8: ...ting of the neckpiece is between the production machine and the hopper In the figure below a cut through of the NST40 neckpiece can be seen Standard neckpiece During operation the virgin material runs from the machine hopper through the neckpiece into the machine Inside the neckpiece the Virgin material flow is divided into two streams by the cover plate In the space below the cover plate the rota...

Page 9: ...6 0 07 to 5 8 GX YES YES 0 2 to 5 0 0 72 to 18 0 HX NO YES 0 01 to 1 6 0 04 to 5 8 A 20 Feed screw YES YES 0 5 to 20 1 8 to 72 A 30 Feed screw YES YES 2 to 50 7 2 to 180 Note measured with normal granular masterbatch 0 8 kg dm3 Note measured with free flowing powder 0 65 kg dm3 Note only available with high torque 4 5 Amp stepper motor Which type of dosing system do I need with which neckpiece TYP...

Page 10: ...granules and micro granules To determine the kind of material in your application use the description below For other sizes contact Movacolor The actual capacity of the dosing system depends on The volume weight of the material bulk density The specific weight of the material specific density The granular shape of the material The granule size The surface structure of the material Granular materia...

Page 11: ...al hopper on top of the neckpiece the top flange of the NST40 neckpiece need to be adapted The lid of the neckpiece can be dismounted for easy machining 2 Install the neckpiece directly on top of the entrance of the production machine Install the neckpiece in a 90 degree angle to the machine barrel This will optimize the dosing accuracy in relation to vibrations of the production machine Make sure...

Page 12: ...neckpiece connection flange 1 by removing 4 socket head screws 3 For use with a dosing cylinder the neckpiece connection flange 1 is equipped with a ball bearing When using a feed screw system the ball bearing must be taken out The metal ring 2 which is fixed on the feed screw tube fits directly on the neckpiece connection flange 4 Dismount the dosing cylinder 3 and mount the screw 4 with the M5 b...

Page 13: ...stallation The MC Balance controller is standard equipped with 3 connections Mains power cable Before switching on the unit for the first time ensure the mains power voltage being applied is between 80 and 260Vac Input cable Motor cable Be aware that the cables will not be influenced by external circumstances as electromagnetic fields Mount the controller on a place which is vibrations free and no...

Page 14: ...put Potential 24 Vdc start input Tacho 0 30 Vdc start input 5 MOTOR The MC Balance can control 2 motor types LT low torque standard motor for normal dosing HT high torque motor for high output dosing See chapter 5 for more details and wiring diagram for electrical connections appendix C 6 OUTPUTS The MC Balance has following outputs available clamp 24 25 Valve output for hopper loader Solid state ...

Page 15: ...ning Arrow up down Scroll through parameters Arrow left right Scroll through menus settings Alphanumerical buttons Set values descriptions Enter Confirm settings Pick up a JOB Start Start unit Stop Stop unit Load cell External communication Network Mains power switch ON OFF Mains power cable Start input cable Motor cable Valve output for hopper loader Output for Alarm Warning Running 7 Operation 7...

Page 16: ...N SUPERVISOR Default code 2222 TOOLING Default code 1111 OPERATOR Default code 0000 LOGIN To enter the different user levels YES YES YES CONFIGURATION To configure the dosing system YES NO NO PRODUCTION To do the production settings In OPERATOR level jobs and materials are read only YES YES YES FILES To look for rename or delete jobs and curves YES NO NO HOPPER LOADER To do the hopper loader setti...

Page 17: ...lect Locked or Unlocked and press Enter to confirm When Locked selected the unit will automatic be set to OPERATOR level This screen will appear when a user is trying to change settings while the keyboard is locked To unlock the supervisor code needs to be entered in the LOGIN menu With the keyboard lock ON it is still possible to Shift between the LOGIN PRODUCTION and HOPPERLOADER menu To START a...

Page 18: ...For example 192 168 001 001 Name xxxxxxxxxxxxxx Start user Operator Tooling Supervisor Tooling passw xxxx 1111 Supervisor passw xxxx 2222 Conversion Metric Imp kg h Full scale xx xx kg Modbus unit 1 231 Date dd mm yy Time hh mm ss Configuration Language Standard language is English On request also different languages are available Configuration Motor type LT is Low Torque motor and HT is High Torq...

Page 19: ...J Relay is selected the dosing machine will follow the machine relay time The controller will filter small changes out so that the regulation is not being influenced Big changes will be followed The screen shows the real machine relay time Input start signal The MC Balance needs an input signal from the production machine in order to operate Three different input signals can be used to control the...

Page 20: ...is function can be used with extrusion when it is necessary that the dosing rate is automatically adjusted to the extruder speed In tacho mode an input voltage is linked to a dosing speed setting If the extruder speed changes the tacho input voltage and speed of the dosing unit will change accordingly A linear correlation between extruder speed tacho input signal and the needed dosing speed is ass...

Page 21: ...ling system will switch on The filling system will start loading when the weight in the hopper is 800 grams default or less The default value can be changed manual if necessary depending on the material properties Also with EX hopper loader selected this is the weight level for opening the knife gate valve to fill the hopper Only visible when a filling system is selected Configuration EX H level T...

Page 22: ... in the display of the controller it shows the measured deviation in percentage of the setpoint Configuration Jobs enabled Enable disable production job functionality see chapter 7 9 Configuration Auto start Enable disable auto startup after Voltage dip or mains power has been switched OFF When enabled the unit will continue dosing automatically after a Voltage dip or mains power has been switched...

Page 23: ...efault 2222 Configuration Conversion Selection of Units Metric European gr s Imperial US lbs hr Kg h In extrusion mode the capacity will be shown in kg h instead of gr s Configuration Full scale Selected loadcell will be shown read only Configuration Modbus unit If the controller is used in a Modbus network the unique identity can be filled in here 1 231 Configuration Date Actual date dd mm yy Con...

Page 24: ...oad cell calibration Progress After a few minutes the following screen appears Place calibration weight 500 gr on the hopper and press the START button After approx 1 minute the load cell calibration is ready press the MENU button to continue To check if the load cell calibration was OK go to the WEIGHT CHECK menu Standstill sign When the vibrations are too big this sign disappears Weight Actual w...

Page 25: ...f course you want the dosing unit to reach his setpoint with the matching speed of the motor RPM as quick as possible Starting the unit with a speed that is already most near to the set point will achieve quick regulation The correct RPM at the start of the dosing unit can be determined automatically with a pre calibration The pre calibration can be done in two ways see below 1 Unit with option sl...

Page 26: ...save the actual material calibration during a running production process This function is called the Save data Function for more information see chapter 7 8 How can I select a calibrated material When one or more material calibrations are made one of these can be selected as follows Go to PRODUCTION menu Use the cursor to go to Material Press 2 seconds on the enter button A list will appear with s...

Page 27: ...de the unit will dose 30 seconds Do a test as follows Go to PRODUCTION menu Fill in the production settings Use the arrow buttons to go to Test Select YES and confirm The unit will run with the set parameters It is possible to stop the test with the stop button START MENU PRODUCTION Regulation mode Auto Manual Save data NO YES PRODUCTION SETTINGS Ref Curve MOVA Prod Job xxxxxxxx Material xxxxxxxx ...

Page 28: ...ing time sec when working TIMER input mode average dosing time sec when working in RELAY input mode Speed Actual motor speed RPM Status Status of the dosing Standby Dosing Filling Injection molding RPM mode Production Settings Prod Job Name of the production Job Set speed Set motor speed RPM Dos time Actual dosing time sec measured from relay Save job Save production settings into a job Test Initi...

Page 29: ... too big this sign disappears Speed Actual motor speed RPM Status Status of the dosing Standby Dosing Filling Extrusion RPM mode Production Settings Prod Job Name of the production Job Set speed Set motor speed RPM Max tacho Maximum tacho voltage v only visible in Tacho mode Set tacho Autom voltage take over from tacho generator only visible in Tacho mode Save job Save production settings into a j...

Page 30: ...to mode after saving data manual entered speed the unit will first keep the manual set speed but will self calibrate to the entered setpoint Save data Function This function allows to store the actual data once the dosing unit shows an actual value color actual A material description needs to be entered to save this data A full material curve on basis of the stored point will be saved in the memor...

Page 31: ... with enter All the settings as described above will be stored The Job will be selected in the PRODUCTION settings screen immediately How can I select a production job When one or more jobs are made one of these can be selected as follows Go to PRODUCTION menu Use the cursor to go to Prod job Press 2 seconds on the enter button A list will appear with stored Job files Select one with arrow buttons...

Page 32: ... Balance controls the operation of the ME or MV systems All parts are aluminum or stainless steel and are virtually maintenance free Only the filter needs to be cleaned periodically To increase reliability and safety there are no moving parts except for the pneumatic operated closing valve of the MV system How the ME works The ME system blows the material from the bag drum or container into the ho...

Page 33: ... support frame works independently from the hopper loader If for some reason the weight reaches the EX HH level a warning will be given This can happen if for example the valve doesn t close Do not take the dosing unit away before the compressed air of the valve is disconnected and press STOP on the controller to disable the valve because the knife gate valve can move It could be necessary to use ...

Page 34: ...sec during this time the system blows material into the hopper of the dosing unit Alarm time Fill Alarm sec if the hopper weight is not above the 800gr within this time the alarm starts The alarm time can not set lower than the fill time Alarm mode ME hopper loader is ON OFF during fill alarm ON ME Hopper loader stays activated during a filling alarm OFF ME Hopper loader will be deactivated during...

Page 35: ...nce is working volumetric during a hopper filling it is recommended to reduce the amount of filling cycles Or in other words to enlarge time between a filling moment and the next filling moment This can be performed when using the correct settings of the Filling start level and the Filling stop level When the unit is started with the autostart function enabled and the unit is switched OFF and ON a...

Page 36: ...r support frame The Volume of the hopper is 6 liter To set the EX H level stop filling It is recommended to take a safety margin to prevent the hopper of overfilling EX H gr 5 liter x bulk density gr liter For example If the bulk density 700 gr liter the EX H should be set to 700 x 5 3500 gr The EX HH gr should be set higher recommended 700 x 6 4200 gr Overfilling of the hopper should be avoided b...

Page 37: ...u can set the alarm or warning output with and confirm ALARMHISTORY All alarms and warnings will be stored in the alarm history Go to the ALARMS menu Press to scroll to the stored alarms max 50 The alarm history can be reset by the supervisor in CONFIGURATION menu by Master reset Alarm We have the following Errors Error Code Warnings 00 Low hopper level Material is below the hopper empty weight 01...

Page 38: ...ng see chapter 7 6 Check if there s enough material in the hopper Check if the material is stuck in the dosing cylinder Check if the load cell is connected correctly Check the weight data by doing a weight check see chapter 7 5 Check if there are no vibrations that may have influence Check the rotation direction of the dosing cylinder Front view to the right Error 06 EX Hi Hi level Check if the kn...

Page 39: ...ame or delete them If the Job or Material curve you search for is not in the list fill in the first letter s or complete name and confirm Now a filtered list appears To go back to the main list fill in spaces and confirm It is also possible to fill in the Job or Material description immediately in the File Manager and confirm To clear the description fill in spaces or select an empty job out of th...

Page 40: ... be logged when an alarm or warning occurs The error codes can be found in paragraph 7 12 To effectively use the Event Log be aware that the correct data an time must be set in the CONFIGURATION menu EVENT LOG Rec nr 0093 0093 01 01 06 20 53 Log ALARM NR Old 8 0 New 0 0 EVENT LOG Rec nr 0078 0078 01 01 06 20 53 Log COLOR PCT Old 2 0 New 1 8 Show latest events Steps of 1 event Show previous event s...

Page 41: ... RPM adjustment it might be running already very close to the desired set point because it uses a cylinder and material reference system to determine the first RPM setting This accuracy however can not be guaranteed because material properties can vary substantially from material to material With injection molding the shot to shot accuracy depends besides the variables mentioned so far on the shot...

Page 42: ...problem recalibrate the system and try the weight check again Problem The balance does come into specification but seems to be slow Possible causes 1 Extreme vibrations and shocks to the system 2 Extreme low Setpoint See Chapter 8 SYSTEM PERFORMANCE 3 Check in case of use of an automatic hopper loader if the hoses are connected in the right way Problem The input start signal is connected but the u...

Page 43: ...ts 3 Connection to PC or Network TCP IP 5 Motor 7 Power supply 6 Outputs 1 Processor board Incl Mac address Terminal display Flat cable connection between terminal and mainboard Flat cable connection between mainboard and load cell board Load cell board 8 Identification maninboard version ...

Page 44: ...ut for alarm level max 230Vac 30Vdc 5A Potential free relay normally open output for running contact max 230Vac 30Vdc 5A This contact will be closed simultaneously when the motor of the dosing unit is running Important note The maximum total output power may be 12 Watt Valve output alarm output pink green grey brown green yellow yellow white Load cell connector POTENTIAL FREE POTENTIAL 24Vdc TACHO...

Page 45: ...Stop trigger input potential free or 24VDC Tacho input 0 30VDC Note potential contact Guaranteed OFF 0 8VDC Guaranteed ON 18 30VDC Output s Stepper motor max output 2A or 4A high output at 40VDC Solid state 24VDC 0 5 A output for valve hopper loader Solid state 24VDC 0 5 A output for external warning Relay for alarm level max 230Vac 30Vdc 5A Relay for running contact max 230Vac 30Vdc 5A Maximum to...

Page 46: ...MC Balance manual 43 APPENDIX D MC Bal Drawings General Dimensions General dimension MC Balance NST40 Neckpiece ...

Page 47: ...MC Balance manual 44 General dimension MC Balance ME25G NST40 Neckpiece ...

Page 48: ...MC Balance manual 45 General dimension MC Balance MV25G NST40 Neckpiece ...

Page 49: ...MC Balance manual 46 General dimension MC Balance Support frame NST40 Neckpiece ...

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