CD Series (English) - Sysmetric. Simply accurate.
Contents
1. 38 6 3 3 Mixer Overload Protection Trips Repeatedly eee 38 6 3 4 The Unit Does Not Stay Calibrated Over sese 39 APPENDIX A DIMENSIONS AND VOLUMES eere eese eee re 40 APPENDIX B SPARE PART 18 002 2 42 APPENDIX C ELECTRICAL DIAGRAM OF CD CONTROLLER eere 2000202 49 APPENDIX D SYSTEM SPECIFICATION eerte 22200022200022 serene ce ree ren sio nio zeonenneceeene 50 APPENDIX E CERTIFICATES OF CONFORMITY eeeeee eese enses enses ense 200020 000002 51 www sysmetric ltd com 3 User Manual CD Series 1 Introduction The CD series of Gravimetric Dosers is Sysmetric s solution to raw material dosing for extrusion and injection molding processes The CD doser reduces material cost utilizing its high accuracy to lower the amount of expensive additives in the product The batch weighing nature of the doser offers calibration free operation and up to the gram accumulation of raw material flowing through the system The mechanical simplicity of the CD series units and its practical design ensures easy maintenance free operation The control unit combines automatic adaptive tuning and noise filtering algorithms with the ruggedness open architecture and extensibility of an industry standard PLC The CD Series dosing units are divided into 5 models for different capacities e CD100 for up to 100Kg h e CD400 for up to 4002. CD100 CD400 800 Figure 4 3 1 Purging Material Clean the containers with compressed air with a vacuum cleaner Turn the main switch off 7 Open the mixing chamber service door Clean both the interior and the exterior of the weighing bucket with compressed air Note try not to touch the bucket In any event careful not to apply pressure on the weighing bucket or the loadcell may be damaged 8 Drain the mixing chamber by opening the drainage outlet and clean with compressed air Close the service door and turn the main switch back on 9 Close all service doors www sysmetric ltd com 21 User Manual CD Series 4 4 Entering a New Formula into the Unit Press the PROGRAM key on the display Set the desired percentage for each additive channel Remember that the main channel can be zero or 20 100 and that the formula must add up to 100 3 Pressthe Formula Replace key to activate the new formula Ne Note it is recommended that the mixing chamber be drained whenever the formula is changed It is obvious that the mixing chamber should be drained and cleaned while changing materials especially colors but it is less obvious if only a change in percentage is needed The reason behind this is that the mixing chamber always contains blended material This is done to improve the accuracy of the unit as well as to facilitate the use of the unit as an active hopper above the process machine If
3. manually operating the current channel Cycle the vibration cycle time of the current channel s vibrator Flow parameter controls the vibration power Act frequency the working frequency of the current channel s vibrator Act power the current power of the current channel Calibrate de frequency 55 6 Hz MAIN creme senes ALARM Figure 5 2 1 Vibrator Tuning Screen The cycle time of each channel is set by Sysmetric during manufacturing and should not be changed without consulting Sysmetric technicians The default Cycle times are CD100 CD400 CD800 16 18 16 18 20 21 5 2 2 Manually Operating the Vibrators Bring the unit to a complete stop Switch to vibrator tuning screen press the SERVICE button and then press Vibrators Select the desired Channel 2 5 by entering its number i e Channel 2 Change the vibration amplitude up to maximum by entering Power 19z Check that the act power is 100 Power 19z 100 If not enter a higher unit number Check all channels to make sure that the vibrators are running properly Que VES www sysmetric ltd com 25 User Manual CD Series Note entering the Service screen requires an access code The default code is 4321 5 2 3 Sleeve Height Adjustment Above each vibrator on the output of the container there is a sleeve that controls the flow of material down to the vibrator Adjust
4. 2 Check if the green power LED indicators on the amplifier card are on If they are go to step 3 Otherwise resume power to the amplifier card 3 Open the service door See that the bucket isn t touching anything Make sure that the bucket is fastened to the load cell and that the load cell is fastened to the chassis 4 Stop the unit and perform a calibration check as described in 3 4 6 2 8 Formula Not Replaced Meaning The formula in the program screen is different from the working formula Causes 1 The operator has forgotten to press the Formula Replace key 2 The operator started to replace the formula and didn t finish Action 1 Press the PROGRAM button and verify that the working formula is the correct one Either replace the formula by pressing Formula Replace or change the percentages in the program screen so that they are identical to the working formula 6 2 9 Mixer is Empty Meaning The material level in the mixer chamber is below the Demand sensor for a long time usually more than 90 seconds Causes The system s throughput is not sufficient Action Consult with Sysmetric about increasing the system throughput 6 2 10 Mixer Not Rotating Meaning The mixer overload protection has turned on Causes 1 There was a disruption in the power supply 2 The mixer is rotating in the wrong direction Action 1 Open the power cabinet and turn the overload protection back on 2 Veri
5. 6 E CQM51CPU NL CPU for CQM PLC 7 COMI 10212 Input COM card 8 COM OD212 Output COM card 9 AB 100 M05 Mixer motor contactor 10 AB 140M C2M 1 1 6 CD100 CD400 Mixer motor overload 10 AB 140M C2M 2 5 1 6 CD800 Mixer motor overload 11 AB B S27IMIA Semi automatic fuse 1 Amp for power supply 12 AB B S191C6 Semi automatic fuse 6Amp for PLC 13 E NT11S SF12 Omron NT11 screen 14 AB 800EP LSM23 Selector switch green lighted head 15 AB 800EP LSM25 Selector switch orange lighted head 16 AB 800E 3DLOXIO Lighted switch complete 17 AB 800EP LF4 Lighted push button head red 18 AB 800EP FA6 Lighted push button head blue 19 AB 800E 3LX10 Switch complete 20 AB 194L E12 1753 Main contactor 21 M M4 3 Gear Motor for CD100 21 M M4 5 Gear Motor for CD400 21 M M4 7 Gear Motor for CD800 22 Pil Air cylinder 16x80 ISO Weighing basket CD400 amp CD800 23 P2 Air cylinder 16x25 ISO Weighing basket CD100 24 P3 Air Cylinder 16x50 ISO Filing Valve CD100 25 P200 Air regulator with filter 26 231 3 Transparent cover rear for CD100 26 231 Transparent cover rear for CD400 26 231 1 Transparent cover front for CD800 27 232 3 Transparent cover side for CD100 27 232 Transparent cover side for CD400 27 232 1 Transparent cover side for CD800 28 M400 Spring Lock 6701 29 M3 Adjustable foot pad M16 30 M300 Screw with plastic head M6 31 E1040x15 Load Cell 15kg Tedea 1042 for CD100 amp CD400 31 E1040x30 Load Cell 30kg Tedea 1042 for CD800 31 E1040x50 Load Cel
6. performed on December 2010 February 2011 on a representative sample of the specified product Product description Tested item Gravimetric Doser Models CD800 CD400 CD100 Serial number Sample Applicant Manufacturer details Name Sysmetric Ltd Address 26 Hatasia St P O Box 1122 Afula 18550 ISRAEL Telephone number 072 4 6405857 Fax number 972 4 6405011 This is to certify that the tested product sample satisfies the requirements of the above listed standard Measurement test results are contained in the test report SYSSAF EN 21445 The comments in the associated test report sha be taken into account and used in conjuncbon with this certificate Hermon Laboratories Ltd February 23 2011 Page 1 of 1 EXPERTS IN GLOBAL COMPLIANCE SOLUTIONS 4 Hermon Laboratories Ltd ee na UR 4 Hatachana St 23 Binyamina 30500 Israel Radio Tec Product Phone 072 4 628 8001 Fax 972 4 628 8277 Safety Approvals Emait mail hermonlabs com www hermonlabs com www sysmetric ltd com 51 User Manual 52 CD Series CERTIFICATE OF CONFORBUTY With EN 61326 1 2006 industrial locations equipment Class A standard harmonized under article 6 2 of EMC Directive 2004 108 EC Certificate Number SYSEMC EN 21424C rev1 This certificate of conformity has been granted to the applicant based on the results of tests and evaluations performed by Hermon Laborat
7. 12 3 push 1 2 followed by 3 3 Press the Enter key to confirm the change The keypad screen will close and the item will have the new value Cancel editing by pressing the X button in the keypad screen Figure 2 3 2 Numeric keypad 8 www sysmetric ltd com CD Series User Manual 2 3 2 Main Screen Pressing the MAIN button shows the main screen on the display which is used for monitoring the system This screen shows the active formula the actual performance of the system formula accuracy and the total amount of material that was dispensed at each channel and by the whole system Active Actual Total 60 00 60 02 342 114Kg KA 30 00 29 99 170 943Kg 5505 545 Figure 2 3 3 Main Screen The ACTIVE column shows the current active formula with the desired percentage of each channel and the ACTUAL column shows the actual percentage achieved in the last cycle Note that since several batches are mixed together in the mixer the actual accuracy obtained is better than the one displayed because the errors have a tendency to cancel out The TOTAL column displays the total amount of material that was dispensed at each channel and by the whole system The accumulators never reset themselves Reset them by pressing the Reset button on the main screen Note that the same set of accumulators may be read and reset through the Host Link interface to manage the material consumption
8. 2 D 9 8 y o Hi d b IR mar ep Kos Power and control cabinets CD400 CD800 interior 42 www sysmetric ltd com CD Series User Manual Oooo aoe Power and control cabinets CD400 CD800 exterior www sysmetric ltd com 43 User Manual CD Series KU General View CD400 CD800 44 www sysmetric ltd com CD Series User Manual DEL LU _ EUM TH SS Ve git EJ General View CD100 Vibration channel CD400 CD800 www sysmetric ltd com 45 User Manual CD Series Main channel Weighing bucket CD400 CD800 46 www sysmetric ltd com CD Series User Manual 37 Weighing bucket CD100 Item Catalog Number Description 1 E50 Weighing load cell amplifier 2 Al5 CD Controller vibrators operating card 3 E62 Transformer 230V 10 0 10 20 20 230 4 P101 Solenoid Valve 24V DC 5x2 1 8 5 E 100 Power Supply 2 5amp
9. 40 for relatively large systems up to 80 for small systems with high accuracy 5 3 System and Batch Parameters The unit has parameters that are factory set These parameters are system constants and are never altered by the software To modify those parameters press SERVICE and then press Param to reach the parameters screen The parameters in this screen are e Bucket size the maximum weight of material that the bucket can contain e Batch size the set weight for batch preparation e Mixing time defines the mixing time at the end of batch cycle e Max Dosing Error the alarm threshold Above this value the system will alarm 26 www sysmetric ltd com CD Series User Manual Mixing time 20 05 Max Dosing Error 0 50 MAIN PROGRAM creme senes Figure 5 3 1 Parameters Screen Note entering the Service screen requires an access code The default code is 4321 5 3 1 Bucket Size and Batch Size The bucket size determines the maximum weight of material that can enter the bucket without overflow It is factory set to fit the bucket s physical dimensions and materials used in the process It may be necessary to change this value if you detect that your material is overfilling the bucket during operation This happens in particular when working with large amounts of reground material The Batch Size value determines the batch size in grams The amount per batch from e
10. amplifying card the new card should be adjusted e Difficulties in loadcell calibration The amplifying card is located inside the power cabinet of the dosing unit Figure 5 6 1 Amplifying Card The following procedure describes how to adjust the amplifying card to work with the loadcell l Bring the unit to a full stop by turning SYSTEM switch to off wait for the system to finish the current batch and for the bucket to open 2 If the unit is floor mounted disable blend conveying from the unit The air flow may exert pressure on the loadcell 3 Open the service door on the mixing chamber and clean the weighing bucket with compressed air Also clean the space between the loadcell and the plate above it Make sure nothing is touching the bucket and that there s nothing above the loadcell 4 Press the SERVICE button on the display and then press Calibrate to switch to the calibrate screen Open the power cabinet to gain access to the amplifying card 5 Make sure that the gain jumper is closing the pins marked 10 and that the offset jumpers are at the center closing the pins marked 0 6 Turn Zero trimmer counterclockwise about 20 turns 7 Turn Cal trimmer counterclockwise about 20 turns 8 Using a voltmeter read the voltage at the output terminals of the amplifying card and adjust it to 0 0 1V by turning the Zero trimmer clockwise The voltage at the calibrate screen should also read 0 0 1V 9 Open the servi
11. because the mixer is clogged up with material 3 Overload protection malfunction 1 Check that the mixer motor is rotating in the direction pointed to by the arrow on the back of the motor If not switch between two power phases See 2 7 2 See if the motor is overheating or if grease is dripping out of the gearbox These are signs of overload should they occur check for possible reasons mixer clogged up with material or some other mechanical problem 3 Replace the overload protection unit with a new one of identical specification ATTENTION ALL OPERATIONS CONCERNING CHECKS AND REPLACEMENT OF ELECTRICAL PARTS MUST BE PERFORMED BY QUALIFIED PERSONNEL ONLY 6 3 4 The Unit Does Not Stay Calibrated Over Time Description The unit often fails the calibration test and needs to be recalibrated The hysterasis and linearity checks have been found to be ok Possible Cause The power supply to the unit is not stable typically too low Action Measure the AC power supply to the amplifying card The voltage between the two 9V terminals located on the upper left side of the card and the OV terminal located between the two 9V terminals should be 9 10V AC If it is less than 9VAC check the power supply to the dosing unit The voltage should be within 10 of the rated voltage of the dosing unit If the voltage is ok perform calibration and check voltages periodically for an occasionally unstable supply www sysmetric ltd com 3
12. is calibrated by adjusting the sensitivity screw on the back of the sensor On some sensors the screw is covered with a plastic cap which should be removed first Turning the screw clockwise increases the sensitivity and turning counterclockwise decreases the sensitivity Note It is a common error to turn the cap instead of turning the calibration screw This is because the cap has the shape of a screw itself Be sure to remove the cap first 5 7 1 Sensitivity Calibration Follow this procedure to calibrate the sensor s sensitivity 1 Make sure the sensor doesn t have any raw material in its vicinity For a channel s container sensors first empty the container For the Demand sensor first clean out the system 2 Turn the sensitivity screw clockwise to increase the sensitivity until the LED lights up 3 Slowly turn the sensitivity screw counterclockwise to decrease the sensitivity until the LED extinguishes Turn the screw counterclockwise half a turn more 32 www sysmetric ltd com CD Series User Manual 6 Troubleshooting An alarm condition exists whenever the system recognizes that a fault has occured When an alarm condition occurs the unit does the following 6 1 The alarm relay closes Refer to the wiring list for details on how to connect a siren or main alarm indicator to this contact Pressing the ALARM CANCEL button opens the relay but if the alarm condition continues the contact closes again after 1 minute While
13. of the process machine If such a setup is used the accumulators should not be reset from the display An optional key can be provided to prevent reset of totals via the display Note the number of channels that appear in the main screen 5 channels in the above example depends on the actual number of channels in the dosing system The number of channels is determined by the customer www sysmetric ltd com 29 User Manual CD Series 2 3 3 Program Screen The PROGRAM button is used to display the program screen In this screen the next formula to be used is entered The next formula is specified by entering the weight percentage for each channel If the sum of the new SET formula is 100 the Formula Replace button will appear enabling replacing the ACTIVE formula with the new SET formula If the Formula Replace button is pressed when the unit is in the middle of a batch preparation cycle the new formula will be activated on the start of the next cycle Entering values in this screen does not affect the operation of the unit as long as the Formula Replace button is not pressed The new formula will only be active after the Formula Replace button is pressed and a new batch is prepared Changing the formula may not immediately change the output of the unit because the mix chamber contains an amount of blended material equal to several batches It is recommended to clean the mixing chamber prior to any formula change Formula MAIN en
14. positive pressure mixers CD100 CD400 CD800 80 mm 105 mm 105 mm 2 7 2 Negative Pressure Mixer Negative pressure mixer mixes the batch by pulling material upwards at the center of the mixing chamber The material then flows back downwards at the sides of the chamber This type of mixer rotates clockwise and usually works for 20 30 seconds after the batch has dropped down to the mixing chamber from the weighing bucket The following table details the diameters of negative pressure mixers CD100 CD400 CD800 mm150 mm200 mm250 14 www sysmetric ltd com CD Series User Manual 2 8 Hopper Flange and Bottom Flange Hopper Flange Bottom Flange 60mm Figure 2 8 1 Hopper and Bottom Flanges for CD400 CD800 The mixing chamber has a standard bottom flange e With floor mounted units the flange can be mounted on an optional vacuum takeoff assembly with a bottom slide gate for emptying the unit e With machine mounted units the flange should be bolted to the machine s hole pattern usually by using an adapter An optional magnet chamber with a slide gate a drainage outlet and a custom made bottom flange for the machine can be supplied 2 9 Demand Sensor The Demand sensor is located in the mixing chamber and its purpose is to trigger a new batch preparation cycle when the material level in the mixing chamber is below the sensor s height This sensor is a capacitive normally closed N C pro
15. 400 are reduced size and power version of model CD800 mentioned above Our conclusion is according to Sysmetric s declaration That models CD100 and CD400 also meets IEC EN 61010 1 requirements Ami Friedman Technical manager 54 www sysmetric ltd com
16. 9 User Manual CD Series Appendix A Dimensions and Volumes CD Series CD 100 CD 400 CD 800 E m EL IL KA E m 3 i R 9 Ble 9 Sis SEI E Vas 635mm 25 00 367 7mm 14 48 960mm 37 80 1052mm 41 42 General dimensions 40 www sysmetric ltd com CD Series User Manual Hopper Flange Bottom Flange Flanges dimensions CD800 Hopper Flange Bottom Flange Flanges dimensions CD400 CD100 CD100 CD400 CD800 CD800HD200 CD800HD400 Main Channel Container 3 3 Liter 3 3 Liter 7 3 Liter 7 3 Liter 7 3 Liter Vibrator Channel Container 1 2 Liter 3 3 Liter 7 3 Liter 7 3 Liter 7 3 Liter Weighing Bucket 4 2 Liter 9 Liter 20 Liter 50 Liter 50 Liter Mixer Chamber 11 Liter 20 Liter 60 Liter 60 Liter 90 Liter Volumes Table www sysmetric ltd com 41 User Manual CD Series Appendix B Spare Part List When ordering spare parts specify the item number catalog number and description Opes Beg ra o Edo Power and control cabinets CD100 3 10 1 zl d 12 5 ele colit HB 5 A Il 7
17. ANCEL continuously for ten seconds SYSTEM switch should be off 7 Holding ALARM CANCEL push button pressed for three seconds will turn on all the lamps for testing the lamps Alarm Indicator This indicator is a red lamp located in the ALARM CANCEL push button It flashes whenever there is an active alarm Programming Monitoring display The display has three major functions 8 Monitoring the unit s performance 9 Entering recipes and operation parameters 10 Performing maintenance tasks www sysmetric ltd com aTe User Manual CD Series 2 3 System Display Figure 2 3 1 System Display The system display is a color touch screen panel Every operation on the display is carried out by pressing gently on the display Activating a button is carried out be pressing gently on the display where the button appears Changing numeric values is carried out by pressing gently on the display where the value is written 2 3 1 Entering Numeric Values Several screens e g PROGRAM screen have one or more editable numeric items e g the percentage of each component To modify the value of an item carry out the following steps 1 Select the item that you want to edit by pressing gently on the display where the item is shown A pop up screen with a numeric keypad will appear on the display 2 Enter the new value using the numeric keypad If the item has a decimal point use the key to move to the fractional part For example to enter
18. CD Series GRAVIMETRIC DOSERS USER MANUAL Hatasia St Afula Illit 1857617 ISRAEL Tel 972 4 6069700 Fax 972 4 6405911 info Esysmetric ltd com www sysmetric ltd com MANUAL NUMBER NS5V5 April 2013 User Manual CD Series Table of Contents 1 INTRODUC HON ipM 4 1257 STANDARD EI G EE 4 TI E OC 5 L FEATURES ei ii cai b ee eter els 5 1 4 En We Ke E 5 2 SYSTEM OVERVIEW seneese b a erae Po se menat esp DEP FE SURE Yn EE TE Re ariani 6 21 Ramp ESINGEN dee E A eR EIER RE NICO NI 6 22 OPERATOR PANELES spe PERI ri NIS EIE 7 2 3 SYSTEM DISPLAY sila rte per ere RR ENS 8 2 3 1 Entering Numeric Valu s eet etes Leer Aen amp 2 3 2 Main Sereen cims Fos a abv olii alal 9 2 3 3 Program Screens Diana dei Ede t i EE Dee Pt dettes 10 2 3 4 Operate iu s 11 2 3 5 RR RR OR 12 2 4 MAIN RAW MATERIAL CHANNEL EE 13 2 5 RAW MATERIAL VIBRATIONAL 8 2 1 eene eene nsns ertet nnne nen 13 2 6 NVEIGHINGBUCRE Rent rea ei E e teo atate 14 Zeta MIXER ii a aen een 14 2 7 1 Positive Pressure MIX CP sie ce eolie 14 2 7 2 Negative Pressure Mixer eiie ee ime eum eo bea 14 2 8 HOPPER FLANGE AND B
19. Checkthe vacuum system 6 2 2 No Flow Channel Meaning The load on the load cell does not change when material is supposed to be flowing into the bucket The channel that should be feeding the material is indicated in the alarm message Causes 1 The channel is empty 2 The channel doesn t work main channel If a vibrational channel is not working there are separate alarms for that 3 The weighing bucket is open 4 The weighing bucket isn t free to press the load cell Action 1 In accordance with the type of channel that is not working do the following e Vibrational channel check the working channel to see if it is empty If it is refill the raw material container of the channel If material is flowing and the alarm persists go to step 2 e Main channel check if the channel is open and whether material is flowing If the channel is empty refill the raw material container of the channel If material is flowing and the alarm persists go to step 2 If the valve is closed make sure the unit is connected to the air supply check pressure level of 6 5Bar on the air regulation unit 2 If there is raw material flowing from the channel and the No Flow alarm is on it is possible that the unit is clogged up with raw material If it is first perform the cleaning procedure described in section 4 3 apart from clearing the containers of the channels then restart the system If the problem persists procee
20. ER ALARM BUCKET PROX DOORSW 1 BUCKET MIXER AUX SW SW ALARM CH 2 CH 46 CH 7 C10 peuo Aug HOLIMS dOLS NNY WALSAS YAWHYOSSNVYL QvO TH3AO HOLOW H3XIN ALINIXOHd LIINI HIXIN Cit TANNVHO HO1VH8IA ER TANNVHO HOLVUAIA TANNVHO HO1VH8IA Sit TANNVHO HOLVHSIA YOLOVLNOO YOLOW HIXIN www sysmetric ltd com 49 User Manual Appendix D System Specification Power Supply e Voltage 3 Phases 380VAC e Frequency 50 60Hz Current 2 Amp Air Pressure e Supply 6 8Bar dry air e 8mm fast connectors Dimensions e CD100 600x635x1158mm e CD400 980x960x1511mm e CD800 1175x1052x1756mm Weight e CDIO00 110kg CD400 130kg e CD800 150kg Environmental Conditions e Storage o Temperature 20 C to 80 C o Humidity 0 90 o Altitude up to 5000m e Operation o Temperature 0 C to 50 C o Humidity 0 85 o Altitude up to 5000m Standards e CE Approved EN61010 EN61326 50 CD Series www sysmetric ltd com CD Series User Manual Appendix E Certificates of Conformity HERMON LABORATORIES CERTIFICATE OF CONFORMITY With EN 60204 1 2006 IEC 60204 1 2005 ISO EN 12100 1 2005 ISO EN 12100 2 2003 Certificate Number SYSSAF EN 21445C This certificate of conformity has been granted to the applicant based on the results of tests performed by Hermon Laboratories on October 2004 December 2004 and on further evaluations
21. Kg h e CD800 for up to 800Kg h o CD800HD200 for up to 1000Kg h o CD800HD400 for up to 1200Kg h The stated capacities refer to granulated material with 0 5 Liter Kg density and may vary for different materials Note all of the information on CD800 in this manual also refers to the CD800HD200 and the CD800HD400 models unless otherwise specified 1 1 Standard Features e Works with extruders and injection molding machines Vibrational feeders for all but the main channel accommodates most existing raw materials in granule powder and regrind forms Highly accurate gravimetric dosing utilizing automatic adaptive tuning for each ingredient Specifies percentage for each ingredient Special vibrators controller for high accuracy at high throughputs Single Off center load cell maintains high accuracy without the need for frequent calibrations Screw type vertical mixer Color touch screen display for programming and monitoring system operation OMRON host link interface support enables integration with standard HMI SCADA Human machine interface software Alarms for system failures and hardware malfunctions Monitors total amount of material for each channel Easy system cleanup when changing jobs Material hoppers channels and mixer are all made of stainless steel All unit parts are easily replaceable Optional Vision MES Extrusion or Injection PC software for remote system operation and data acquisition 34 www sysmetric l
22. OTTOM LANGER 15 2 9 DEMAND SENSOR c tette bie e RR tede etico 15 2 10 POV RAND CONTROL ciris i ie EE ie cues de itin 15 2 11 NORMAL OPERATING SEQUENCE cc cicci 16 3 INSTALLATION AND 220 20000 17 Sl OVERVIEW ite its teta Let eterns tenia 17 32 ANSTALLATION teer ee eire irte de deep PU 17 3 3 MIXER CHECK OUT 555 anali 18 3 4 CHECKING THE Be Ar ei OO 19 4 SYSTEM OPERXTIQON sim EENS 20 421 STARTING THE UNIT tee ree aaa 20 4 2 BRINGING THE UNIT TO A FULL Stop 20 4 3 CLEANING THE UNIT FROM A PREVIOUS Jop 21 4 4 ENTERING A NEW FORMULA INTO THE UNIT ii 22 5 SERVICE AND MAINTENANCE eee 2002 002020000000000000000020000502 002000000 00200000000000000002 23 5 1 LOAD CELL CALIBRATION e eech EEN NEE meteo LOL Oe re 23 5 2 MIBRATOR ete RERO OPE IR VIERTE CIS E Ex Para 25 5 2 1 Vibrator SGreen i oue et lane lanciate nene cen MEM 25 23 2 2 Manually Operating the Vibrators ii 25 5 2 3 Sleeve Height Adjustment tee sh ne teer Wests eo tae bein aes 26 5 2 4 Flow Parameter eI dI Nei DI ha 26 5 3 SYSTEM AND BATCH 6 1 220 1 202 2 0 01 000000000000000000000 26 5 3 1 Bucket Size and Batch Size 27 2 3 2 Mixing
23. PASSED 18 www sysmetric ltd com CD Series User Manual 3 4 Pa 6 Checking the Load cell Make sure the MAIN SWITCH is on and that the SYSTEM switch is off In the display press SERVICE enter the access code 4321 and press Calibrate The display should switch to the Calibration screen The Mass field should show 0 zero If not refer to chapter 5 1 Load cell Calibration to calibrate the unit Open the service door and gently press and release the bucket The value of Mass should rise and then drop back to zero plus or minus 2 grams Gently pull the bucket upwards and release it The value should decrease below zero and then rise back to zero plus or minus 2 grams Press the MAIN key on the display If the weight does not return to its original value then something is touching the weighing bucket or the load cell The unit cannot work reliably in this condition Calibrate MAIN senes Figure 3 4 1 Calibration Screen Note the steps described here are the first steps in the calibration procedure For more information and details see 5 1 www sysmetric ltd com 19 User Manual CD Series 4 System Operation 4 1 Starting the Unit The following procedure is used to start the unit Make sure that the SYSTEM switch is off 2 Turn MAIN SWITCH on to connect the main power supply 3 Verify that each channel is programmed with the correct per
24. Time cca eil eased nth E Ue eR RE EAE ene 27 5 4 SYSTEM MONITORING EE 28 ddt VACUUM NC 29 5 6 AMPLIFYING CARD ADJUSTMENT i 30 5 7 RAW MATERIAL SENSOR 32 5 7 1 Sensitivity CalibratiOW etes ttt it ee ee tete ees 32 6 TROUBLESHOOTING w scccscicsisoctsnsdsssnsssencsvenssssoncssasesvessessecshscessxstsoscsscenssusvesdaccevsnsssastsovese 33 d e www sysmetric ltd com CD Series User Manual DL EM TEE eege et esca ioni coli alain e coli oe 33 6 2 JALARMSEIST inne eri i INNI aes 34 6 2 1 Bad Conveying Hopper Loader MI 34 6 2 2 No Elow Channel csi ate e eg De ee RE es 34 6 2 3 Short Circuit in Vibrator HIT 35 6 2 4 Open Circuit in Vibrator BT 35 6 2 5 Vibrator Card is Not Responding A 33 6 2 6 Material Leaking From Channel AT 35 6 2 7 Weighing Error T oe ae i AG ERR OE e HR RE OU GRE nies 35 6 2 6 Formula Not Replaced esses eene nennen eterne trennen 36 6 2 9 Mixer is Empty iei Oe pesi et br EDT P RE Yer paene 36 6 2 10 Mixer Not Kotatiug neen trennen eene en ne 36 37 6 2 12 Emergency Stop siete teer e e Ie CHEER D Op AE ere e Ie vec testes 37 6 2 13 Bucket Not Close isses secet edis be scere prona Fender apto 37 6 3 OTHER PROBLEMS eed eee eee e etie e eter tee ee 38 6 3 1 Unit Does Not Make Batches iii 38 6 3 2 Unit Doesn t iride
25. ach channel is the corresponding percentage of this amount Normal values depend on the materials used and the bucket s physical dimensions The following table details the recommended values for the Bucket size and Batch size CD100 CD400 CD800 CD800HD200 400 Bucket Volume 4 2 Liter 9 Liter 20 Liter 50 Liter Bucket size 2 100g 4 100g 8 100g 22 00kg Batch size 1 000 2 000g 3 000 4 000g 6 000 8 000g 15 00 20 00kg Note If the bucket size is smaller than the batch size the batch will be prepared in several weighing cycles This is an incorrect procedure since the space between the bucket and the mixer is limited As a tule set the batch size to 600 grams less than the bucket size 5 3 2 Mixing Time The Mixing Time parameter determines how long the mixer works during each cycle Normal values are between 20 and 35 seconds The minimum mixing time is 10 seconds www sysmetric ltd com 27 User Manual 5 4 System Monitoring CD Series Whenever the unit appears to be malfunctioning the best thing to do is to watch the batch cycle and look for irregularities or deviations from the normal cycle as described in section 2 11 Watching the weighing bucket and channels shows you what the unit is doing The monitor screen on the display shows you what the unit is supposed to do A combination of both plus a general understanding of how the unit works is sufficient to solve most of the problems To
26. ach hopper loader Material level proximity switch e Orange if it senses material the hopper loader is full e Yellow if it does not sense material the hopper loader is empty Vacuum valve e Blue if the valve is closed the hopper loader is not vacuuming currently e Green if the valve is open the hopper loader is currently vacuuming Flap door e Closed when the flap door is closed the reed switch on the flap door is closed Opened when the flap door is open the reed switch on the flap door is open Vacuum pump e Gray when the vacuum pump is off the control switch of the vacuum pump on the OPERATE screen is turned off e Green when the vacuum pump control switch is turned on e Flashing green if the vacuum pump is currently working Red when the vacuum pump is in error Vacuum Pump valves e Blue if the valve is closed e Green if the valve is open Figure 5 5 1 Vacuum Screen Note the various contents of the vacuum screen i e hopper loader and vacuum pump are available only if they are present and controlled by the dosing system Entering the Service screen requires an access code The default code is 4321 www sysmetric ltd com 29 User Manual CD Series 5 6 Amplifying Card Adjustment The amplifying card is factory set to work with the system s loadcell In the following cases the amplifying card should be readjusted e Replacement of the loadcell e Replacement of the
27. and the vibrator controller Causes Blown fuse in the vibrator controller card Action Check the fuses on the vibrator controller card If a fuse is blown replace it with a new one Note only use glass cylinder fuse 5x20mm of 3 15Amp 6 2 6 Material Leaking From Channel Meaning Material is leaking from the channel Causes 1 On channel 1 no air supply air valve failure or mechanical interference 2 On channels 2 6 vibrator controller malfunction Action 1 If the alarm is for channel 1 check Air pressure supply check pressure level of 6 5Bar on the air regulation unit e Check intactness of the air valve e Verify no mechanical interference disturbs the channel from closing 2 Ifthe alarm is for channels 2 6 check the vibrator controller 6 2 7 Weighing Error Meaning An illegal voltage from the amplifier card has reached the Analog Digital converter on the PLC www sysmetric ltd com 35 User Manual CD Series 1 The unit is clogged up with material 2 No power reaches the amplifier card 3 The load on the load cell is outside the allowed range either overload or negative load 4 The load cell is not properly connected Action 1 Check whether the unit is clogged up If it is stop the unit and clean it It may become clogged if the Demand sensor is malfunctioning or if one of the channels is constantly feeding material due to a malfunction of some other component
28. at the conversion factor has changed because the amplifying card s gain is very stable and so is the load cell Recommended reference weights for the various models CD100 1 000 2 000g CD400 3 000 4 000g CD800 7 000 8 000g CD800HD200 400 10 00 12 00kg Calibration after performing steps 1 through 8 while the reference weight is still on the tray press CAL The unit calibrates it self and the Mass value will match the Ref value 1g Linearity test place a weight that is different from the weight used for the calibration on the tray Check that the Mass value matches that of the new weight This can be repeated with additional reference weights in order to verify the whole range www sysmetric ltd com CD Series User Manual Recommended reference weights for the various models CD100 CD400 CD800 CD800HD200 400 400 600g 1 500 2 500g 3 500 4 500g 5 00 8 00kg 11 Remove the calibration tray and close the service door When the SYSTEM switch is turned back to on the unit will automatically exit calibration mode Alternatively exit calibration screen by pressing any of the menu buttons 5 2 Vibrator Tuning 5 2 1 Vibrator Screen The vibrator tuning screen enables adjusting the vibration cycle time of each vibrator and manually operating each vibrator for testing This screen shows the following parameters e Channel selecting the channel to tune and test Power
29. batch and for the bucket to open 2 If the unit is floor mounted disable blend conveying from the unit The air flow may exert pressure on the load cell 3 Open the service door on the mixing chamber and clean the weighing bucket with compressed air In addition clean the space between the load cell and the plate above it Make sure nothing is touching the bucket and that there is nothing above the load cell 4 Press the SERVICE button on the display and then press Calibrate The display switches over to the calibration screen This screen has the following fields e Ampl displays the weighing amplifier output voltage e Mass shows the actual net weight e Ref the reference weight used in the calibration procedure e Calibrate Mode press this button to enable calibration of the system Once you press the Calibration Mode button two more buttons will appear o TARE this button sets the zero point of the load cell o CAL this button calibrates the weighing Figure 5 1 1 Calibration Screen www sysmetric ltd com 23 User Manual CD Series Note when activating calibrate mode the bucket door will close and will remain closed while the system is in calibrate mode Entering the Service screen requires an access code The default code is 4321 10 24 When there s no load on the bucket the voltage display Amp should show 0 00 0 1V If the value exceeds this tolerance make sure the weighing b
30. ce door and install the calibration tray 30 www sysmetric ltd com CD Series CD100 Figure 5 6 2 Calibration Tray CD400 800 1 Calibration tray 2 Reference weight User Manual 10 Put a reference weight on the tray and using the Cal trimmer on the amplifying card adjust the voltage according to the following table CD100 CD400 CD800 CD800HD200 400 Reference Weight 1 000kg 4 000kg 8 000kg 8 000kg Voltage Kg 2 0Volt 2Volt Kg 1Volt Kg 0 3Volt Kg 11 Perform the standard calibration procedure See 5 1 Note amplifying card adjustment is no substitute for calibration Always perform calibration after amplifying card adjustment even if exact calibration is not needed www sysmetric ltd com 31 User Manual CD Series 5 7 Raw Material Sensor Raw material sensors are found in various places in the system All systems have the Demand sensor some have channel container sensors and some have a low level sensor The sensors are normally closed N C connected which means that they activate the input to the PLC when the sensor does not detect material The sensor has an indicator LED and there are two types one where the LED is on when the sensor detects material and one where the LED in on when the sensors does not detects material This manual refers to the type of sensors where the LED is on when material is not detected The Sensor s sensitivity
31. centage If not move to the program screen and set the correct formula 4 Make sure that all the raw material containers contain the correct raw material 5 Turn SYSTEM switch to the on position 4 2 Bringing the Unit to a Full Stop The following procedure describes how to stop the unit after which the unit can be serviced It is assumed that the unit is working 1 Turn SYSTEM switch to the off position 2 Wait for the system status indicator to go off Note to stop the unit in the middle of a batch preparation cycle move SYSTEM switch to off and continuously press the ALARM CANCEL push button for 10 seconds 20 www sysmetric ltd com CD Series User Manual 4 3 Cleaning the Unit from a Previous Job The following procedure is to be used when a complete cleaning of the unit is required Bring the unit to a full stop See 4 2 2 Turn off the hopper loader of the system via program screen 3 Empty the main channel by pushing the CHANNEL 1 EMPTYING button in the operate screen The valve stays open as long as the button is pressed 4 Empty vibrational channels e Cannels 2 5 CD400 CD800 units unlock the clamps at the bottom of the vibrator s support and rotate the vibrator backwards The material flows from the rear of the funnel Channel CD400 CD800 same as channels on CD100 e On the CD100 rotate the vibrator sideways and start it manually by pressing the pushbutton on the vibrator
32. core iii SERVICE Figure 2 3 4 Program Screen Note the number of channels that appear in the program screen 5 channels in the above example depends on the actual number of channels in the dosing system The number of channels is determined by the customer 10 www sysmetric ltd com CD Series User Manual 2 3 4 Operate Screen Pressing the OPERATE key will switch the display to the operate screen This screen contains various control buttons for setting the system operation 1 Default Controls Channel 1 Emptying manually drains material from the main channel Holding this button pressed will open channel 1 and will keep it open as long as the button is pressed 2 Optional Controls Program Local Remote activating remote PC control This option is available when the dosing unit is connected to a remote PC and is used to enable formula replacement and totals reset only via the remote PC Machine Conv activating hopper loader on the production machine for conveying material from the dosing unit to the production machine This hopper loader is used when the dosing unit is not installed on top of the production machine Recycled available when working with recycled re ground material Activating this option takes the recycled channel percentage out of the dosing formula Low Level preparing batches according to a low level proximity switch When working at low level mode the syste
33. ctivation button is used for draining the container www sysmetric ltd com WER User Manual CD Series 2 6 Weighing Bucket CD100 CD400 CD800 Figure 2 6 1 Weighing Bucket l Loadcell 2 Weighing Bucket ATTENTION DO NOT APPLY FORCE ON THE WEIGHING BUCKET THE BUCKET DRAIN DOORS CLOSES ON POWER OFF AND WHEN CALIBRATING The weighing bucket 2 sits on an offset center type loadcell 1 The bucket is situated inside the mixing chamber which shields the bucket and the loadcell from knocks The signal from the loadcell is amplified by an electrical circuit that filters out noise and high frequency vibrations A pneumatic valve controls the weighing bucket s doors 2 7 Mixer The mixer is a vertical screw operated after each batch preparation for mixing the ingredients A safety interlock switch disables the mixer rotations when the service door is opened There are two types of mixers positive pressure mixer and negative pressure mixer ATTENTION ALWAYS TURN THE MAIN SWITCH OFF BEFORE SERVICING THE MIXER DO NOT BYPASS THE SAFETY INTERLOCK OR SERIOUS INJURIES MAY RESULT 2 7 1 Positive Pressure Mixer Positive pressure mixer mixes the batch by pushing material downwards at the center of the mixing chamber The material then flows back upwards up the sides of the chamber This type of mixer rotates counterclockwise and can work without synchronization with the batch preparations The following table details the diameters of
34. d to the following Open the mixing chamber service door and check if the bucket is closed If it is proceed to step 3 If the bucket door is open during a No Flow alarm it means that something is preventing the weighing bucket from closing Check that the air pressure is okay and that nothing is mechanically preventing the bucket from closing If nothing can be found replace bucket pneumatic valve 3 Check that the bucket is fastened to the load cell and that the load cell is fastened to the chassis of the unit Make sure that the bucket does not come in contact with anything but the load cell If everything seems fine stop and clean the unit and perform a calibration procedure as described in 5 1 34 www sysmetric ltd com CD Series User Manual 6 2 3 Short Circuit in Vibrator Meaning One of the vibrators is electrically shorted Causes The vibrator is malfunctioning 2 The vibrator s wires are electrically shorted Action 1 Check the vibrator s wires and verify no short circuit 2 Replace the vibrator 6 2 4 Open Circuit in Vibrator Meaning The vibrator is disconnected Causes 1 The vibrator s wires are disconnected from the vibrator controller 2 The vibrator is malfunctioning Action 1 Verify the connections of the vibrator s wires with the vibrator controller 2 Replace the vibrator 6 2 5 Vibrator Card is Not Responding Meaning No communication between the PLC
35. e hopper loaders and vacuum pumps See 5 5 for details ETN IP edit IP address Figure 2 3 6 Service Screen Note Vacuum maintenance is available only if the dosing system controls the hopper loader and or a vacuum pump 12 www sysmetric ltd com CD Series User Manual 2 4 Main Raw Material Channel Figure 2 4 1 Main Channel The gravitational main channel has a valve that is operated by air cylinder When the cylinder is in the position the valve is closed When the cylinder is in the position the valve is open The cylinder is operated by a pneumatic valve that is mounted on side of the control cabinet An indicator shows the valve s position 2 5 Raw Material Vibrational Channels fil CD100 CD400 CD800 Figure 2 5 1 Vibrational Cannel l Material container 2 Adjustable sleeve 3 Vibrational feeder 4 Locking knob Each channel has an adjustable automatically controlled vibration level Above the vibrator funnel sits the raw material container that can be filled up using manual or automatic means usually a hopper loader or venturi valve type loader that is mounted on the hopper flange The container has an adjustable sleeve on its exit that allows better control over the material flow rate On CD400 and CD800 units the channel s vibrator can be rotated backwards for easy emptying and cleaning of the container On CD100 units the vibrator is rotated sideways and a manual a
36. el S Telephone number 972 4 6405857 RO This Certificate of Conformity has been granted to the applicant based on the results of tests and evaluations performed by Hermon Laboratories on representative sample of the above Se mentioned product from October to December 2004 The tested products satisfy the requirements of IEC 61010 1 01 The standard covers full safety demands to the product NS st bal y Evaluationsitasts results are contained in the test reports had SYSSAF EN 16034 SEC RS Es 20 Ami Friedman 59 Technical Manager Hermon Laboratories Ltd 6 October 2005 The comments in the associated if applicable test report s shall be taken into account and used in conjunction with this certificate The A2LA logo endorsement applies only to the test methods and the standards that are listed in the scope of Hermon Labor atories accreditation Zone P O Box 23 Binyamina 30550 Israa 972 0 4 6288001 Fax 972 0 4 6288277 mail Sharmontabs com www sysmetric ltd com 53 User Manual CD Series 23 Binyamina 30500 Israel Tel 4972 4629 8001 Fax 972 4628 8277 HERMON LABORATORIES Email mailhermoniabs com 12 10 2005 To whom it may concern Hermon Laboratories has tested Sysmteric s Gravimetric Doser model CD800 according to IEC EN 61010 1 standard and found it to be in compliance with the standard s requirements Sysmetric has declared that models CD100 and CD
37. f the system and the neutral wire to the blue terminal block marked N in the power cabinet e Using a ring wrench fasten the ground wire to the screw marked on the side of the power cabinet ATTENTION USE AN EXTERNAL 3 PHASE CIRCUIT BREAKER OF AT LEAST 6AMP AND AN EXTERNAL OVER CURRENT PROTECTION RATED MAXIMUM 6AMP FOR THE POWER SUPPLY USE A CABLE OF AT LEAST 1 5mm 16A WG RATED FOR AT LEAST 6AMP THAT IS SAFETY APPROVED MAKE SURE THAT THE GROUND WIRE OF THE POWER SUPPLY CABLE IS COLORED YELLOW GREEN www sysmetric ltd com 7 User Manual CD Series AIR PRESSURE IT IS THE RESPONSIBILITY OF THE INSTALLER TO ENSURE BY MEANS OF PRESSURE REGULATOR PRESSURE RELIEF VALVE OR ANY OTHER MEANS THAT THE AIR SUPPLY PRESSURE WILL NOT EXCEED 10 BAR 6 Turn the MAIN SWITCH to 1 At this stage nothing should happen and all indicators should be off Figure 3 2 1 Power supply connection 3 3 Mixer Check Out Make sure that the mixer s service door is closed and secure Manually operate the mixer using the contactor in the power cabinet Make sure that the mixer rotates in the direction pointed to by the arrow on the mixer motor If the mixer does not rotate at the correct direction switch one of the phases of the power supply See 2 7 for details on the mixer rotation direction ATTENTION DO NOT OPERATE THE MIXER WHEN THE SERVICE DOOR IS OPEN WHEN OPERATING THE MIXER DIRECTLY FROM THE CONTACTOR THE SAFETY INTERLOCK SWITCH IS BY
38. fy that the mixer is rotating in the right direction positive pressure mixer clockwise negative pressure mixer anticlockwise see 2 7 If the mixer is not rotating in the right direction change the phase order 3 Check the power supply 380 V 3 Phase A missing phase causes the mixer to rotate in the wrong direction 4 Verify that the mixer door is shut 36 www sysmetric ltd com CD Series User Manual 5 Verify that the mixer door magnetic safety sensor is working properly 6 2 11 Low Battery in PLC Meaning The power of the backup battery of the Omron PLC is low Action Replace the battery in the PLC Note use only Omron s original battery 3G2A9 BATOS 6 2 12 Emergency Stop Meaning The emergency stop switch on the power cabinet is pressed Action Release the emergency stop switch and press the alarm cancel push button for 3 seconds The system will resume working from where it stopped 6 2 13 Bucket Not Close Meaning The weighing bucket is not empty when starting a new batch Causes 1 Material level in the mixing chamber is too high 2 The weighing bucket is not draining material Action 1 Check that nothing interferes with material draining from the weighing bucket 2 Check operation of the Demand sensor in the mixer chamber 3 Check the air pressure supply check pressure level of 6 5Bar on the air regulation unit 4 Check the air valve and the air piston of the weigh
39. ing bucket s door www sysmetric ltd com 37 User Manual CD Series 6 3 Other Problems The following are problems not detected by the system Each problem is described along with its possible causes and the appropriate troubleshooting procedure 6 3 1 Unit Does Not Make Batches Description The machine needs material but the system is idle Possible Causes 1 SYSTEM switch is off 2 Analarm condition prevents the unit from working 3 Demand sensor senses material therefore no new batch is being prepared See 2 9 for a description of the Demand sensor 4 The PLC is not in RUN mode Action 1 Check the SYSTEM switch If it is off toggle it If it is on go to step 2 When the SYSTEM switch is on the system status indicator lamp should be either on or flashing if it is neither check the SYSTEM switch itself and the indicator lamp 2 Check the system alarm indicator If it is flashing see section 6 2 Otherwise go to step 3 3 Check if the Demand sensor detects material If it is open the service door on the mixing chamber and check if the sensor is indeed immersed in raw material e Ifitis immersed in material then the mixer is full and the unit is OK If the dosing unit is floor mounted check the conveying system from the unit to the processing machine e If there is no material recalibrate the sensor or replace it if necessary see 5 7 4 Try switching screens on the display If there
40. ing the sleeve s height affects the material flow rate As a rule the sleeve height should be as follows e Down to the minimum for very small percentages below 2 unless the pellets do not come out in which case the sleeve should be lifted slightly e Half way up for most other cases e the way up for hard flowing materials such as re ground or when the unit has a throughput problem 5 2 4 Flow Parameter The Flow Parameter determines the vibrator power and can be adjusted for different materials The four digits of this parameter are divided into two groups with the format of xx yy e the second two digits define the minimum vibration power The minimum power is calculated as a percentage by the ratio between the yy parameter and the cycle time Minimum Power gt x 100 Cycle Time For example for a relative power of yy 04 when the cycle time is 20msec the minimum vibrator power will be 2096 Normal values for yy are between 03 for small systems that require high accuracy to 08 for relatively large systems that work with high throughputs and or recycled material e xx the first two digits determine the threshold for maximum vibrator power The system changes the vibration power linearly from the minimum power for 0 percent material up to the maximum power for xx percent material If the set percentage of a channel is higher than xx the vibrator will always work at the maximum power Normal values for xx are
41. is no response the CPU is probably not in RUN mode Turn the power off wait 10 seconds and turn the power back on 6 3 2 Unit Doesn t Stabilize Description One of the product s attributes e g color is varying Alternatively the product is uniform most of the time but once in a while a major deviation occurs No unit alarms are active Possible Causes It must be noted that any part of the unit could be causing the problem For example even if there is a color problem the problem may be in the main channel which may be working in parallel with the color channel and thereby causing the desired amount of color to be reached too soon These are the main causes 1 Two channels are working in parallel due to a malfunction of some component 2 Aproblem with the weighing unit Action 1 Check whether any alarm is being reported by the system You can press the ALARM CANCEL button to see whether there is an active alarm or press ALARM to check the alarm log and see if there was an alarm in the system 2 Perform calibration check as described in 3 4 6 3 3 Mixer Overload Protection Trips Repeatedly Description The mixer s motor overload protection trips several times a day or it trips every time the motor is started Possible Causes 1 The mixer is rotating in the wrong direction 38 www sysmetric ltd com CD Series User Manual 2 The load on the mixer motor is too high because of a mechanical problem or
42. l 50kg Tedea 1042 for CD800 HD www sysmetric ltd com 47 User Manual CD Series 32 El 30mm Capacity switch 24V DC 33 E2 Mixer door sensor 34 B1303 CD100 vibration channel assembly 34 B1300 CD400 vibration channel assembly 34 B1301 CD800 vibration channel assembly 35 M2101 Vibrator FMC FT 0 36 A3503 1 CD100 Central channel assembly 36 A3502 CD400 Central channel assembly 36 A3501 CD800 Central channel assembly 37 B2010 CD100 Weighing basket 37 A2001 CD400 Weighing basket 37 A2002 CD800 Weighing basket 38 A1200 18 CD100 Mixer standard auger 38 A1200 19 CD100 Mixer double auger 38 A1200 20 CD100 Mixer pushing auger 38 A1200 10 CD400 Mixer standard auger 38 A1200 11 CD400 Mixer double auger 38 A1200 12 CD400 Mixer pushing auger 38 A1200 14 CD800 Mixer standard auger 38 A1200 15 CD800 Mixer pushing auger 38 A1200 16 CD800HD 200 Mixer standard auger 39 100 Plastic glass 40 MI Locking washer 6mm starlock 41 M400 1001 CD100 Vibrator locXing handle 48 www sysmetric ltd com CD Series User Manual Appendix C Electrical Diagram of CD Controller OUTPUT 00 00 OUTPUT 00 01 OUTPUT 00 02 OUTPUT 00 03 INPUTO00 05 OUTPUT 00 04 OUTPUT 00 05 OUTPUT 00 06 INPUT000 04 INPUT000 03 F B O L AUX CD CONTROLLER CH VALVE MIXER PROX PROX MIXER CONTROL MIX
43. m holds one prepared batch at the weighing bucket which is dropped down to the mixing chamber according to the low level Demand proximity switch instead of holding the mixing chamber filled with prepared material This option requires the installation of a low level proximity switch Empty Program Channel 1 Local Remote Figure 2 3 5 Operate Screen Note Machine Conv Program Local Remote Recycled Low Level and other optional control switches are available only if specified by the customer www sysmetric ltd com 11 User Manual CD Series 2 3 5 Service Screen The SERVICE key is used to access the service screen in order to adjust display parameters and access various maintenance screens Note entering the Service screen requires an access code The default code is 4321 Display Parameters Language select the interface language Brightness set the screen brightness Contrast set the screen contrast Time and Date set the current time and date for the alarm log Imperial Metric select units Maintenance Screens Calibrate calibrating and checking the weighing amplifier and load cell See 5 1 for details Vibrators manually activating the vibrators in order to tune the vibration level See 5 2 for details Parameters setting system and batch parameters See 5 3 for details Monitor view the batch cycle See 5 4 for details Vacuum activating and monitoring th
44. ntain any new components then the system will be accurate from the first batch Repeat steps f h for each component Wait for mixer to stop mixing Usually the mixer has stopped mixing by now 3 Bucket opens batch falls into the mixing chamber usually covering the Demand sensor so the unit returns to the initial condition If the new batch doesn t cover the sensor the unit immediately moves to step 1 Otherwise the unit will start again when the material level drops below the sensor level 16 www sysmetric ltd com CD Series User Manual 3 Installation and Check out The following is an overview of the steps required to install the unit and check that it is working properly The description assumes some prior technical knowledge For more information contact Sysmetric 3 1 Overview The unit is configured at the factory ready to start working as soon as it is unpacked However to ensure proper operation follow the procedures in this section The installation and check out procedure is composed of the following steps e Installation In this step you position the unit in its place and plug it into the power and air supplies e Mixer checkout This step ensures that the mixer rotates in the right direction e Load cell checkout This step ensures that the load cell hasn t been damaged during shipment 3 2 Installation 1 Positioning the unit e If the unit is floor mounted it comes with two legs attached to
45. of weighing units in continuous feeding systems introduces the need for frequent component calibration If one of the load cells loses calibration it will continuously feed the wrong amount of material causing damage to product quality or raising material costs without the system ever knowing about it Some of the higher end loss in weight systems are capable of calibrating themselves which makes them more costly The batch system doesn t have this problem at all since one load cell weights all ingredients thus ensuring accurate proportioning of the ingredients The single weighing unit approach also lowers the cost of the system e batch system always operates in closed loop mode The weighing unit is continuously weighing and can determine the system s accuracy and correct it as needed A loss in weight system on the other hand has refill periods where the feeder switches to the volumetric mode of operation since it can t determine how much material has passed through it batch system can accurately total the amount of each ingredient that passed through it to allow automatic reliable inventory and waste control Loss in weight systems can only estimate the total The CD doser employs a special kind of batch dosing The ingredients are divided into a main component and additives The main component is fed through the main channel and the additives are fed through the additive channels The main channel uses gravita
46. ories on November 22 2010 on representative sample of the specified product Product description Tested item Gravimetric Dozer Models CD100 CD400 CD800 Applicant Manufacturer details Name Sysmetric Ltd Address Box 1122 Afula 118 18550 Israel Telephone number 072 4640 5857 Fax number 972 4640 5911 This is to certify that the tested product sample satisfies the requirements of the above listed standard s Measurementitest results are contained in the test report SYSEMC_EN 21424_rev1 The comments in the associated if applicable test reports shall be taken into account and used in conjunction with this certificate 2 Michael Nikishin EMC amp Radio Group Hermon Laboratories December 7 2010 Page 1 of 1 EXPERTS IN GLOBAL COMPLIANCE SOLUTIONS MG Hermon Laboratories Ltd 9 H P CE Hatachana St POB 23 Binyamina 30500 Israel DH Zeen Phone 072 4 628 8001 Fax 972 4 628 8277 Email mail hermonlabs com www hermonlabs com www sysmetric ltd com CD Series User Manual A y me x lt lt HERMON LABORATORIES xa Certificate of Conformity P with EN 61010 1 standard Key N SYSSAF EN 16034C Product definition Gravimetric Doser des CD800 Applicant Manufacturer Sysmetric Ltd Addrass sens Afula Isra
47. r a time specified by one of the unit s parameters usually between 20 and 35 seconds The following steps occur in parallel with mixer operation a b i j Bucket closes Unit waits for weight to stabilize Zero weight level adjusted Desired percentage for main channel converted to desired weight Fast coarse flow of main component until the weight in the bucket reaches a certain level and the flap closes At this stage there s some in flight material so that when the weight settles the bucket will presumably contain the desired amount The valve of the main channel closes and the system waits for the weight to stabilize Based on the actual amount of main component the control unit computes the desired amounts for the other components Fast coarse flow of first additive channel until the amount in the bucket is near the desired amount around 90 of the desired amount Slow fine flow until desired weight is very near the desired amount Vibrator stops the system waits for all the material to drop into the bucket and checks for an overshoot or undershoot condition In cases of undershoot a correction is attempted a few times If needed a special tuning algorithm corrects the pre closing variable and the fast flow to slow flow variable The corrections will take effect in the next batch Normally after inserting a new recipe it will take 2 3 batches to achieve the best accuracy If the new recipe doesn t co
48. reach the monitor screen press the SERVICE button on the display and the Monitor button in the service menu The screen content continually updates during batch preparation showing the following parameters Channel the current working channel Set the set weight of material for the current channel Actual the actual weight of material from the current channel Weight the current total weight in the weighing bucket Power vibration level of the vibrator when the vibrator of the current channel is working Cycle the current batch cycle time Mixing the current mixing time Last work time last batch cycle time Channel Actual eight ower Cycle Mixing EN HEN 22s0gr Last work time MAIN Figure 5 4 1 Monitor Screen Note entering the Service screen requires an access code The default code is 4321 28 www sysmetric ltd com CD Series User Manual 5 5 Vacuum The vacuum screen enables monitoring the status of the hopper loaders and the vacuum pump Press the SERVICE button on the display and the Vacuum button in the service menu to reach the Vacuum screen The screen shows the following 1 Hopper loaders e Transparent if the hopper loader is off the control switch of the hopper loader at the PROGRAM screen is off e Filled gray if the hopper loader is switched on Vacuuming time the last vacuum time of e
49. td com CD Series User Manual 1 2 Hazards e The Mixer is driven using substantial torque Never place your hand in the mixer chamber while power is on Serious injury could result e The main channel valve can slam closed without warning It will cause injury to your fingers e The power and the control cabinets contain high voltage electricity The key to these cabinets should be in the possession of service personnel only 1 3 Safety Features The service door is equipped with a safety interlock switch that prevents the mixer motor from running when the door is opened Do not attempt to bypass this switch 1 4 Safety Symbols Below are examples of safety symbols and their meanings Consider those warning where the symbols appear on the system 1 Caution consult accompanying documents 2 Caution risk of electric shock 3 Ground connect power supply ground wire here www sysmetric ltd com 25 User Manual CD Series 2 System Overview 2 1 Batch Dosing Batch dosing is a method of dosing whereby the system prepares the blend in batches as opposed to continuous feeding of various kinds In each batch the ingredients are fed one at a time into a weighing bucket according to their percentage in the batch and the batch is then mixed Batch dosing offers several advantages over continuous loss in weight dosing e Single weighing unit as opposed to multiple weighing units in continuous feeding systems The multitude
50. the alarm is active a corresponding alarm message is displayed on the display Pressing the ALARM CANCEL button also deletes this message Further pressing the ALARM CANCEL button toggles the alarm messages of all active alarms The alarm is written in the alarm log The alarm indicator on the operator panel keeps blinking until the alarm is resolved The system keeps trying to make batches as if an alarm has not occurred except during weighing errors Alarm Log The system creates an alarm log Press the ALARM button on the display to switch to the alarm log Screen 17 UNSTABLE SPEED 11 17 VIBRATOR NOT CONNECTED Figure 6 1 1 Alarm Screen The alarm log shows the following details The alarm that was activated The time at which the alarm was activated The status of the alarm red if the alarm is still active or blue if the alarm was stopped In addition the log can be cleared by marking some or all the alarms and pressing the delete button www sysmetric ltd com 33 User Manual CD Series 6 2 Alarms List The following is a list of alarm messages that can appear on the display according to the active alarm the possible causes for the alarm and the action to take 6 2 1 Bad Conveying Hopper Loader Meaning Malfunction in one of the hopper loaders Causes 1 Material is not available for the hopper loader 2 Malfunction in the vacuum system 1 Check material availability 2
51. the formula is changed without draining the mixing chamber the new batches will mix with the old ones causing a very slow and gradual change 22 www sysmetric ltd com CD Series User Manual b Service and Maintenance 5 1 Load cell Calibration Load cell calibration is carried out in order to verify that the load cell is operating properly and to ensure that the weight reported by the unit is identical to the actual weight of raw material in the bucket It is recommended to perform this calibration every six months During the calibration procedure three checks are performed e Hysterasis Test ensures that there is no friction in the load cell and weighing bucket e Calibration Test ensures the correct ratio used by the unit to convert from the load cell voltage output to the actual displayed weight e Linearity Test ensures the linearity of the load cell There are two important notes about these tests 1 Each of these tests must be performed in order to ensure proper functioning of the unit 2 There is no point in performing a test if the unit failed a previous test For example if the unit fails the hysterasis test then there is no point in performing the calibration test because there is some friction mechanical or otherwise that is preventing the load cell from working properly Calibration Procedure 1 Bring the unit to a full stop by turning SYSTEM switch to off wait for the system to finish the current
52. the unit s chassis e Ifthe unit is machine mounted bolt the unit to the machine an adapting flange should be supplied see 2 8 Note when choosing the location and the orientation for the unit make sure that the operator panel and the mixing chamber service doors are not obstructed 2 CD400 CD800 only open the service door the weighing bucket is inside the mixing chamber and is not connected to the loadcell to prevent damage to it during shipment Remove any shipping materials from the weighing bucket and mount it to the loadcell using the two bolts on the loadcell Use a 5mm Allen wrench to fasten the bolts Note for the unit to work properly the weighing bucket must have NO physical contact with anything except for the loadcell on which it is mounted Make sure that the bucket is free Also verify that the air hoses surrounding the bucket don t come in contact with the walls of the mixing chamber 3 Connect air pressure supply to the unit through the air filter regulator with at least 6 5Bar Lubricated air is NOT recommended At this stage both the weighing bucket doors and the main channel valve should be closed Adjust the pressure regulator to 6Bar 4 Make sure that the power MAIN SWITCH and the SYSTEM switch are both in the OFF position 5 Connect the unit to the power supply 3 phases 380VAC 50Hz e Using a screwdriver fasten the 3 phase wires to the brown terminal blocks marked L L2 and L3 in the power cabinet o
53. tional feeding and the additive channels are fed using vibrational feeders The main component is fed first and the actual amount that has been fed serves as the basis for calculating the amounts of the additional components This method increases the doser s production rate while retaining accuracy Note Although the term Additive Channels is used each of the additive channels can feed the full range 0 100 of the batch The main channel on the other hand can be zero or 20 to 100 of the batch The reason for this is that the main channel is less accurate than the additive channels 6 www sysmetric ltd com CD Series User Manual 2 2 Operator Panel SYSTEM ALARM 0 1 CANCEL Omron NS 5 Display The operator panel contains the following components 1 2 SYSTEM switch for activating and stopping the system Note switching the SYSTEM switch to 0 position stops the unit only after it finishes the current batch System Status Indicator This indicator is a green lamp located in the SYSTEM switch It has three modes 1 Off The unit is stopped 2 On The unit is waiting for a demand from the processing machine 3 Blinking The unit is preparing a batch ALARM CANCEL push button This push button has four functions 4 Inhibiting unit alarm R11 potential free contact 5 Display and toggle unresolved alarms on the display 6 Stopping the unit in the middle of a batch preparation cycle by pressing ALARM C
54. ucket is empty and has no forces exerted on it If the value is still not zero perform amplifying card calibration see 5 6 and perform a complete calibration procedure see 5 1 Open the service door on the mixing chamber and install the calibration tray Wait 10 seconds for the weight to stabilize Press TARE so the unit can learn the weight of an empty bucket The Mass value should show 0 zero CD100 CD400 800 Figure 5 1 2 Calibration Tray 1 Calibration Tray 2 Calibration Weight Hysterasis test gently press the weighing bucket and release it The value Mass should increase and then drop back to zero meaning that it returned to its original weight Allow a tolerance of 2 grams Gently pull the bucket up and let go of it the value should now drop below zero and then return to zero Calibration test press TARE to counter any residual effects from the hysterasis check Put a reference weight according to unit model on the calibration tray The weight of the reference weight must be known within 1g Make sure the Ref value matches that of the reference weight or change the Ref value accordingly If the load cell is calibrated the Mass value should match that of the Ref value allow a tolerance of 2 grams If the weight reported matches that of the reference weight skip to step 10 If not perform steps 5 8 again before continuing to step 9 The reason for redoing steps 5 8 is that it s not likely th
55. ximity switch with an indicator LED and sensitivity tuning screw 2 10 Power and Control The power cabinet and the control cabinet of the dosing unit hold the following main parts e Programmable Logic Controller PLC e Vibrator controller card this is a module responsible for activating the vibrators at the desired vibration level It also has some auxiliary relays for the mixer and a potential free contact for signaling alarm status Load cell amplification card e Mixer motor contactor and overload protection www sysmetric ltd com 15 User Manual CD Series 2 11 Normal Operating Sequence The following is a schematic description of how the unit prepares one batch Its purpose is to give a general understanding of how the various elements in the unit interact and which factors affect the unit s throughput and accuracy Initial condition bucket is open mixer is stopped and the Demand sensor is covered with material This means that the last prepared batch is lying unmixed in the mixing chamber above several mixed batches The new batch preparation cycle starts when the Demand sensor is not covered with material and triggers the following sequence 1 Demand sensor is not covered This means that the entire last prepared batch is inside the mixer and there is no material between the Demand sensor and the weighing bucket The mixer therefore can start mixing and the bucket can close 2 The mixer starts mixing fo
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