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Optifeed Manual - TSM Control Systems

1. Filling system unable to load material a Low level A a Empty level High high level Here you can select if the error will act as an alarm or warning by pressing the warning symbol you can toggle between alarm and warning 5 3 History The alarm history can be opened through the home screen by pressing mode A list with the alarms that occurred will appear We have the following Errors Fill system is not working correct Material is below the hopper start filling weight Material is below the hopper empty weight Hopper weight has reached the EX HH level Calculated motor speed is too low not in operator Maximum deviation exceeded The deviation of the material output is too high Master slave connection failure Connection failure between multi component controllers Code Alarms Description gt Z o S 8 Maximum RPM exceeded change dosing Calculated motor speed is too high tool for higher capacity 8 o 100 Motor connection failure Motor not connected Motor or connection damaged 102 Load cell connection failure Load cell connection is not correct 39 5 4 Warnings All vvarnings are self eliminating It is possible to cancel a warning but when the error remains the warning will return after 60 seconds This gives the operator the time to solve the problem without having the alarm on Filling system unable to load material If this warning appears the alarm t
2. 24 Tacho set Scope Global Writable at each configured unit Extrusion tacho mode Extruder capacity lt gt Tacho voltage ratio Voltage setpoint see Ext cap 28 51 Future use 8 Optifeed Manual 52 Device Commands Scope Unit Writable at each configured unit Control bits to control the selected unit By setting clearing bits in this register several actions can be made Bit Description Function Scope 0 Prime start Activate dosing tool prime function Per unit 1 Prime stop Cancel stop the current prime action Per unit 2 Manual filling Opens the fill valve activates loader Per unit 3 Reset cons batch Reset batch consumption counter Per unit 4 Reset cons total Reset total consumption counter Per unit Prime start Setting this bit will start the prime function With the prime function the dosing tool will be filled with material Motor starts running at prime speed setpoint register 68 Can only be started when system status Is off Prime stop Setting this bit will stop the prime function Manual fill In some cases it is required to fill the hopper before starting the process This can be done by setting the manual fill bit CAUTION using this bit can cause overfilling of the hopper Reset cons Batch Reset the batch consumption counter selected component only Reset cons Total Reset the total consumption counter selected component only 53 63 Future use 64 Color setpoint Scope Unit Writable at each configured u
3. 14 3 5 Recipe function With the Optifeed it is possible to store the current production settings into a recipe All production settings of all units will be stored within this recipe An easy recall of these production settings Is possible by loading the previous stored recipe The Recipe function must be enabled in the System Configuration screen 3 5 1 Creating a new recipe From the home screen press the recipe button The Recipe screen will appear select the New Recipe button The following screen will appear Recipe Select d De O L Device ID Material GEO Que al EO x Unit 3 x select 0 000 b gle Recipe name Enter desired recipe name Injectionmolding Shot weight Extrusion Extruder throughput kg h Injectionmolding Timer only Shot time Component name Prelearned material curve Select the pre learned material curve per component G In case of no prelearned materials it is recommended to select the Optifeed default curve Dosing percentage Enter dosing percentage per component Select button Loads the current recipe as active production setting Save recipe Saves current recipe settings Cancel leave this screen N eee aS 15 3 5 2 Load edit a recipe From the HOME screen press the recipe button Select the desired recipe by using the up and down butons lt When the list of recipes is big it can be time consuming to find the recipe It is possible to sea
4. Opti feed Manual 1 11 UK 01 Software version I V1 11 Manual revision 0 1 Date July 2013 TSM Control Systems The Demesne Dundalk Co Louth Ireland Internet www tsm conrols com Email info tsm controls com r 353 42 9335560 h 353 42 9334422 1 INDEX 1 Introduction 1 1 Symbols 1 2 Terms 1 3 Transport 1 4 Receipt 2 General information 2 1 Safety 2 2 Certification 2 3 Operating environmental conditions 3 Operation 3 1 The Interface 3 2 Start up amp Login 3 3 System Configuration 3 4 Material curves 3 4 1 Offline Material curve learn function 3 4 2 Selecting a learned material curve 3 4 3 Save data function 3 5 Recipe function 3 5 1 Creating a new recipe 3 5 2 Load edit a recipe 3 5 3 Delete a recipe 3 6 USB menu 3 6 1 Backup Restore 3 6 2 Remove USB stick 3 7 Screenlock 3 8 Consumption counters 3 8 1 Batch consumption counter 3 8 2 Total consumption counter 4 Overview Dosing and Measuring units 4 1 Optifeed 4 1 1 Optifeed Component overview 4 1 2 Optifeed motor and dosing system 4 1 3 Optifeed metering principle 4 1 4 Optifeed dosing system capacities 4 1 5 Optifeed mechanical installation 4 1 6 Optifeed electrical installation 4 1 7 Optifeed loadcell calibration 4 1 8 Optifeed device configuration 4 1 9 Optifeed production 4 1 10 Optifeed hopper filling 5 Alarms 5 1 General 5 2 Configuration 5 3 History 5 4 Warnings 5 5 Alarms 6 System performance 6 1 General 6 2 Reset regula
5. INP 1 Bit 3 Alarm Bit 4 Valve Bit5 Learn OK 130130 Optifeed Modbus Subject Optifeed Modbus TCP IP register TSM Date overview Page 2 of 2 IP address Optifeed Menu setting Multi component Device address 1 5 Modbus function codes 04 06 Tested and functional Tested not functional 130130 Optifeed Modbus Gravimetric Blending amp Control Support frame User Manual EX ENG 01 Manual revision I 01 Date 16 04 2009 SFG 6 SFG 12 Installation Operation Maintenance Trouble shooting TSM Control Systems The Demesne Dundalk Co Louth Ireland Internet www tsm conrols com Email info tsm controls com des 353 42 9335560 bt 353 42 9334422 INDEX 1 Introduction 1 1 1 Symbols mb 1 2 Terms 1 8 Safety 2 Description 2 1 What is the Support Frame 3 Overview of parts 3 1 Basic parts Support frame 4 Installation 4 1 Mechanical installation 4 2 Electrical installation 4 3 Compressed Air requirements 5 Operation 5 1 Starting up the EX support frame after installation 6 Cleaning 7 Troubleshooting 8 Technical specifications O OO N N O ON A A A OH WO N N 9 General dimensions Support frame SFG 12 o 10 General dimensions Support frame SFG 6 1 Introduction Thank you for purchasing a TSM product This manual is addressed to operators and qualified technicians taking care of the metering of dry additives to ensure corre
6. Motor On Off Press to start dosing The motor on off switch will turn from green to red when dosing is started The start LED blinks when the unit is waiting for an input signal If the unit is dosing the Start LED lights continuously For stopping production press again The motor on off switch will turn to green again Please note that it is possible that the first dosing s are not sufficient because of the cylinder filling with material It takes some time to stabilize 31 Extrusion Gravimetric mode Actual production data Using the scroll button a you can switch between production settings and production data dl 2 had Extruder act 100 2 kg h Tacho act 9 97 V Set and actual output Set Calculated output gr sec Act Actual color output gr sec D actual color output is only visible after the first automatic RPM adjustment Speed Actual motor speed RPM Hopperweight Material weight in the hopper Actual extruder capacity kg h G only visible in Tacho mode In Relay mode the set extruder capacity is displayed Actual tacho voltage only visible in Tacho mode Extrusion RPM mode Production settings In RPM mode the dosing can be done in relay mode or in tacho mode In relay mode dosing is done at a set rom The RPM of the motor has to be entered manually In tacho mode the tacho voltage with corresponding RPM can be entered manually Or with the synchronize function the tacho voltage can
7. To increase reliability and safety there are no moving parts except for the pneumatic operated closing valve of the MV system ME hopper loader How the ME works The ME system blows the material from the bag drum or container into the hopper of the dosing unit The hopper lid of the housing has a simple and easy to clean dust filter to keep any dust particles in the hopper The system is triggered by the filling start weight 4 1 8 Hopper Levels This parameter also generates a low level alarm if the hopper is empty How the MV works The MV system uses a 3 stage vacuum generator driven by compressed air to create a vacuum that draws material into a chamber that closes Once the chamber is filled with material the cone that closes the chamber will open and the material will be discharged into the hopper The system is equipped with a superior filter to ensure that the finest particles gt Smicron stay in the system and are not released into the atmosphere This makes the MV system the most practical and user friendly system for both powders and granules 33 How the EX support frame for External hopper loader works aa EEE Dies a The function of the support frame is to use a foreign hopper loader in combination with the Optifeed The support frame is equipped with a knife gate valve for filling the hopper The valve Is normally closed If the filling start level is reached default 800gr the valve opens and
8. s fe Brown Min OVDC to Max 30VDC Hopper loader system Valve output 24VDC 29 White Outp 2 24VDC Brown Status outputs Warning Alarm and Run Alarm Warning Output Potential contact 24VDC 27 Outp 1 24VDC Alarm Output Potential free contact Run Output Potential free contact wnite 28 Brown 32 33 35 36 The numbers can be found on the printed circuit board MECHANICAL INSTALLATION All mechanical parts are pre assembled making installation quick and simple 1 Remove transport protection under side of the load frame before installation 2 Install the neckpiece directly on top of the entrance of the production machine a Make sure that the complete unit is mounted horizontally leveled water level and fixed securely b Assure proper grounding to control cabinet neckpiece and dosing unit Connect the unit to the neckpiece by turning curled knob clockwise Mount the controller vibration free and conform specified temperatures po Mount the unit in a 90 degree angle to the machine barrel Horizontally leveled Water level As shown in the picture Transport protection Gravimetric Blending amp Control OPTIFEED PROFIBUS PROFINET Manual 1 11 UK 03 Softvvare version I V1 11 Manual revision 0 3 Date November 2013 TSM Control Systems The Demesne Dundalk co Louth Ireland Internet www tsm controls com Email info tsm controls com G
9. 1 indicating device 1 is representing a Opti Weight The Profibus Profinet master issues a packet with the first byte set to value 2 float starting at offset 64 set to 5 6 The Optifeed will respond with a 96 byte data package byte 1 set to value 2 indicating device 2 is selected byte 36 set to 2 value 2 indicating device 2 is representing a Opti Balance float starting at offset 60 corresponding the calculated dosing setpoint in gram per second The Profibus Profinet master issues a packet with the first byte set to value 4 The Optifeed will respond with a 96 byte data packet with the first byte set to value 255 indicating an Invalid device is selected When the Optifed can is equipped with a Profibus Profinet card it is not recommended to use Modbus TCP IP in conjunction with one of these optional interface cards 4 6 Data types The Optifeed uses different data types Data type Length Number of Modbus registers Bit 1 bit 0 1 Packed in a Byte Byte 8 bits 0 255 1 Word 16 bits 0 65535 1 Float 32 bits 2 4 7 Global Unit The scope of each parameter register can be Global or Unit Global means that it is a parameter for the whole system Example Shot weight this is a setting which is global for the whole system since the system is installed on a single injection molding machine In most cases the global parameters can be read written at each unit Device register 6 Optifeed M
10. Ask your network administrator for a unique address System Configuration Netmask Netmask for use in a network environment TCP IP protocol For example 255 255 255 0 When the Optifeed dosing system is part of a network the controller must have a Netmask for accessing the TCP IP network System Configuration Gateway Gateway address for use in a network environment TCP IP protocol For example 192 168 1 1 When the Optifeed dosing system is part of a network the controller must have a Gateway for accessing the TCP IP network This Gateway address has to correspond with the Gateway address of your computer Ask your network administrator for the correct gateway setting 10 System Configuration Date Time Actual date dd mm yy Actual time hh mm Date and Time will be stored for minimal 1500 hrs with controller switched OFF System Configuration Number of controllers Select the number of dosing units 1 5 System Configuration kg h units Kilogram per hour units enable disable Setpoints and actuals displayed in kg h or g s gram per second System Configuration Imperial units Imperial units enable disable Setpoints and actuals displayed in Ib h or kg h System Configuration Profibus Enable the Profibus communication ON OFF requires a special hardware extension board System Configuration Device address If the controller is used in a Modbus or Profibus network the unique identity can be fill
11. HIM J To delete all recipes in the list at once 16 3 6 USB menu The Optifeed is equipped with a USB host port This port can be used for production and configuration settings backup restore and Optifeed software updates D For software updates contact your local Optifeed representative Q Your USB memory stick should be formatted FAT32 3 6 1 Backup Restore Insert your USB memory device into the USB host port See chapter 3 1 Press Zm e The USB menu will be shown containing 3 options 1 Copy files from USB to Controller Restore files from USB stick to Controller 2 Copy files from Controller to USB Backup files from Controller to USB stick 3 Remove USB stick Safely remove USB stick When choosing option 1 restore or option 2 backup a new screen will be shown with the next options 1 Materials and Recipes Transfer of material recipe and configuration files 2 Configuration and Settings Transfer of production log event log and configuration files 3 All Transfer of all files materials recipes configuration log After copy of the files to the USB stick you can store the backup files to a network drive or backup folder The USB stick contains a folder named MC TC this folder contains the backup files The restore function can also be used to copy configuration system and recipes to other Optifeed devices with the same hardware configuration it is not recommended to copy material files between Optife
12. In the advanced loader settings menu Fill time empty time alarm time and alarm mode can be changed Fill time Fill time sec during this time the MV system sucks material into the vacuum chamber Empty time Empty time sec during this time the cone that closes the chamber will open and material falls down 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 cannot set lower than the fill time Alarm mode MV hopper loader is ON OFF during fill alarm MV Hopper loader stays activated during a filling alarm MV Hopper loader will be deactivated during a filling alarm O lt l HI EX hopper loader support frame for external hopper loader The EX HH levelis the Highest level If this level is reached a High High level warning appears EX H level is the level where the knife gate valve will be closed again Filling start level Hopper empty level Manually fill Advanced loader settings In the advanced loader settings menu alarm time and alarm mode can be changed Alarm time Fill Alarm sec if the hopper weight is not above the 800gr within this time the alarm starts Alarm mode EX hopper loader is ON OFF during fill alarm ON EX Hopper loader stays activated during a filling alarm OFF EX Hopper loader will be deactivated during a filling alarm 36 Output signals Du
13. Main mat ext capacity Kg h Opti Weight 12 Float Total ext capacity Kg h Opti Weight 16 Float Total color percentage Opti Weight 20 35 Byte Future use 36 Byte Unit type See note 4 37 Byte Alarm code See manual 38 Byte Production status See note 5 39 Byte Device status bits See note 6 40 Float Dosing time Seconds 44 Float Actual extruder capacity Kg h 48 Float Actual tacho voltage LV 52 Float Actual hopper weight Gram 56 Float Actual motor speed RPM 60 Float Color capacity setpoint g s 64 Float Color capacity actual g s 68 Float Batch consumption Kg 72 Float Total consumption Kg 76 Float Actual regrind percentage 96 Regrind 80 Float Actual filling level Gram Regrind 84 95 Byte Future use 7 Optifeed Manual Notes 3 System status bits 4 Unit type Bit O System started 1 Opti VVeight Opti Bit 1 System alarm active 2 Balance Opti Bit 2 System start error 3 High Output Bit 3 System start input 4 Opti Balance Regrind Bit 4 7 Future use 5 Opti High Output 6 Regrind Future use 5 Production status 6 Device status bits 0 Invalid Bit 0 On 1 Off Bit 1 Alarm 2 Standby Bit 2 Prime busy 3 Dosing Bit 3 Fill valve 4 Filling Bit 4 Learn OK 5 Filling not used Bit 5 Status start input 6 Unlo
14. Type Normal or micro granules e PRODUCTION parameters Shotwth Shot weight color Color amount dos time Dosing time sec Ext cap Extruder capacity kg h e CALIBRATION parameters Material name Name of calibrated material How to start the material curve learn function 1 Press lt In multicomponent setups it can be necessary to use the button to select the unit to be used 2 Press the material name button and enter a material description 3 Enter the production settings recommended is to use the same settings as will be used in the final production For injection moulding the shot weight the dosing time dosing percentage For extrusion extruder capacity production rate dosing percentage The ideal situation is to choose the same settings as used during actual production however when the output is to high and learn function cannot be completed within one hopper fill choose a lower capacity 4 Press the start button 5 A question will appear that you need to check if the motor is connected the hopper is filled and if you want to prime the dosing tool confirm the question 6 The learning will take minimal about 3 minutes but can take more time depending on the used material and production parameters It is possible to stop during the learning for example to refill the hopper When Stop amp Save is selected the learning will pause There are 3 options Stop
15. be read from extruder and corresponding RPM of the dosing unit can be entered Actual production data During production the motor RPM hopper weight and tacho voltage only in tacho function will be displayed 4 1 10 Optifeed hopper filling MANUAL FILLING The controller automatically detects vvhen the hopper is manual filled In the period that the hopper is being filled the Optifeed is dosing with a fixed RPM this means the unit runs temporarily volumetric As soon as the hopper filling is ready the Optifeed immediately continues to work gravimetric AUTOMATIC FILLING Only use Optifeed hopper loaders to fill the hopper automatically Foreign hopper loaders can influence the gravimetric function of the dosing Introduction Optifeed dosing units are capable of handling a variety of dry materials Two different filling systems are available depending on the material properties The Optifeed Ejector ME system for dust free or nearly dust free materials The Optifeed Vacuum MV system for materials that are NOT entirely dust free The Support frame for external foreign hopper loaders EX The ME and MV systems are both driven by low pressure compressed air and mounted directly on top of the hopper lid of the Optifeed dosing unit The Optifeed controls the operation of the ME or MV systems All parts are aluminium or stainless steel and are virtually maintenance free Only the filter needs to be cleaned periodically
16. 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 material can be normal or micro The granular material and powder material has to be free flowing non static and not sticky There are mainly two dosing systems the dosing cylinder and the feed screw for more information see chapter 4 1 4 TSM Gravimetric Blending amp Control The serial number of the motor can be found on the backside of the motor www tsm controls com email info tsm controls com Motor axle The motor shaft is equipped with one flat side which fits exact in shaft of the dosing cylinder To connect the dosing cylinder just put it on the motor axle while turning it to find the flat side than press the dosing cylinder completely backwards 4 1 3 Optifeed metering principle The Dosing Cylinder of Optifeed combined with a very precise adjustable stepper motor ensures that the additive output is accurate and regular The neckpiece a mixing chamber is designed to blend the main material and the additive homogeneously Optifeed has on stock a large range of machine neckpieces that usually make a perfect fit to the injection moulding machine or extruder The most common mounting of the neckpiece is between the production machine and t
17. for the first time ensure that the mains power voltage applied is between 80 and 260Vac electrical power before performing maintenance A Always switch off the Optifeed control cabinet and disconnect the mains power plug from A 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 Optifeed dosing unit is designed and produced in conformity with the following European regulations e CEstandards for machinery health safety environment e EMC electromagnetic compatibility e VEM safety electric material e 2006 42 EG 2 3 Operating environmental conditions e The unit must be protected against weather conditions e Operating temperature 20 to 70 degr C e Protection class IP 50 2 OPTIFEED 3 Communications Setup 3 1 Ethernet connection location Standard Ethernet port Modbus TCP IP I Profibus Profinet module location 3 2 Module installation The Profibus or Profinet communications module can be built in afterwards Picture below explains the position of the communications card Depending on the type of Optifeed casing you have it can be necessary to use a special adapter plate which is included in the package Module connection ribbon Profibus module The Profinet module requires a certain board revision and Optifeed hous
18. level will be set automatically to operator level In OPERATOR LEVEL the following functions are available PRODUCTION e PRIME s LOGIN k El rn propueon gt gj The following parameters can be seen in the production screen depending on operation or settings made in supervisor mode Injection molding Extrusion Recipe Name of the Recipe Recipe Name of the Recipe Set speed Rotating speed of the motor RPM mode Set speed Rotating speed of the motor RPM mode Dos Time Dosing time sec Timer mode Tacho Tacho voltage V settings Material Name of material calibration Material Name of material calibration Color Color amount Color Color amount Shot wth Shot weight gr Ext cap Maximum extruder capacity kg hr Production Motor On Off If the cylinder needs filling before production press and confirm ES Press lo start production The start stop button will turn from green to red to indicate that the unit has been activated Presa again to stop production The start stop button will turn from red to green When the unit is started the actual production data will be shown when the Toggle button is pressed O 4 The start LED blinks when the unit is waiting for an input signal The unit is dosing if the Start LED lights continuously m e fu LI kuma The Hopper loader can be selected in the device configuration menu Supervisor mode Followi
19. max in increments of 0 1 RPM Time Manual settings from 0 1 to 999 sec in increments of 0 1 sec 3 keyboard lock levels Integrated hopper loader controller Monitoring System Information External communication External Communication PC link using TCP IP internet protocol ModBus TCP IP Optional Profibus DP slave Alarm 2 user alarm levels Specifications Standards amp Directives Technical data Power supply Operating power from 95 VAC to 250 VAC 50 and 60 Hz by integrated automatic voltage selector Power consumption 150 Watt maximum Stepper motor 1 8degr step max 2A or 4A high output at 40 Volt Operating Temperature 20 to 70 degr C Load cell and electronics 20 bits A D resolution with a full digital filtering Input signal s Injection moulding Start Stop trigger input potential free or 24VDC Extrusion Start 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 torque 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 total output power 12 Watt Valve output alarm output Standard Directives Protection class IP 50 According to CE standards Safety e Incase of overload due to
20. setups it can be necessary to use the button to select the unit to be used INJECTION MOLDING Injection moulding gravimetric mode Production settings The following parameters can be seen in the production screen depending on operation or settings The production data can be entered by touching the corresponding field GLX NG shot weight 5 000 25 0g set time 10 0 s 4 e LE la IES 1 Ref Curve material Optifeed pre programmed curve dosing tool granule type or USER defined curve material name is displayed not available when recipe function is activated Color amount Shot weight gr Dosing set time sec Dosing set time only visible in Timer mode otherwise relay time will be displayed Prime Filling the dosing cylinder before start The prime menu appears by pressing s Settings speed time can be changed Press confirm v to start priming 6 Production Motor On Off Press to start dosing The motor on off switch will turn from green to red when dosing is started The start LED blinks when the unit is waiting for an input signal If the unit is dosing the Start LED lights continuously For stopping production press again The motor on off switch will turn to green again OS Please note that it is possible that the first dosing s are not sufficient because of the cylinder filling with material It takes some time to stabilize 28 Injection moulding gravimetric mode Actual p
21. short circuit or incorrect connection the power supply automatically shuts down e Opto insulated start input for connection to production machine Optifeed Machine connection flange Standard flange NSt40 neckpiece with cleaning opening Inlet outlet 50mm 140mm steel epoxy coated RAL 3002 Load frame Balance frame Steel epoxy coated RAL 3002 Weighing frame Aluminium epoxy coated RAL 9005 Loadcell Nominal Load 20 kg Temp Compensated Temp Range 20 60 gr Celsius Protection level IP63 EN60529 Optional parts e External Alarm Flash light e External Alarm Siren Profibus DP slave module 45 APPENDIX D Optifeed Declaration of Conformity DECLARATION OF CONFORMITY According to 2006 42 EC Manufacturer s name TSM Control Systems Address The Demesne Dundalk Co Louth The Netherlands Declare under our sole responsibility that the product Name Optifeed Model KE EEE Year 20 Serial nr Goo o oiean Complies with the definition of the Machine Directive 2006 42 EC and complies with the national legislation to enforcement of this directive complies with the requirements of Low Voltage Directive 2006 95 EC EMC Directive 2004 108 EC complies with the following standards or other normative documents NEN EN 12100 2010 Safety of machinery general principles for design risk assessment and risk reduction Signature Place Dundalk Ireland Managing D
22. the controller will give an alarm signal and message in the display If the set point it not reached within the set percentage this can be caused by Partial or complete blockage by sticky or hard flowing material Inaccurate dosing because material is not uniform in size Disturbance of the weight signal for example by mechanical blocking of the Optifeed load frame Deviation alarm xx 1 99 limit Setpoint gram sec limit O O Dn mel ker Q 5 O Example The Deviation alarm setting in the configuration menu is default set to 25 The set point colour set is set to 1 000 gr sec the MAXIMUM limit value will be 1 250 gr sec the MINIMUM limit value will be 0 750 gr sec When the maximum deviation message Error 08 appears in the display of the controller it shows the measured deviation in percentage of the set point Calibration deviation The maximum allowed deviation from the Calibration Set point can be set with this Parameter For more information see chapter 3 4 2 4 1 9 Optifeed production D The rotation direction of the dosing at the front view must be to the right When all configuration settings have been entered production can start For Injection moulding and extrusion the operating differs Both processes will therefore be explained separately The production menu can be accessed by pressing the Home button ry In multicomponent
23. time in combination with granule size and weight If relatively big and heavy granules have to be dosed in a very short time it will influence the shot accuracy and repeatability because if only a few granules are dosed during the shot one granule more or less makes a big difference on the total shot weight System is NOT starting up when switched ON by main power switch 1 Main fuse inside the controller can be blown Color variations Unstable relay or tacho signal Bridging or rat holing of the material inside the hopper can happen if the material is not free flowing Bridging or rat holing of the material inside the hopper can happen if the material is extremely static Extremely static material can contaminate the dosing cylinder In case of water cooled neckpiece check if there is material build up around the dosing cylinder and the water cooled pipe Check also the water supply to the neckpiece sl al N Weighing is not correct 1 Check if transport protection is removed 2 Weighing platform is touched by something that influences the weighing 3 Hopper loader tubes are not fixed in the right way 4 Safety bolts are not free touching the frame ELECTRICAL INSTALLATION Input signal to the OPTI FEED can be made in the following ways in accordance with the configuration Potential free contact Potential contact Tacho Min 18VDC to Max 30VDC Sales e LT be rg Green INP1 24Vdc GND INP1 GND Tr White
24. timebase 10mS User Prm Data 0x00 Modular Station 1 Max Module 2 Max Input Len 96 Max Output Len 96 Max Data Len 488 Status Tx 96bytes Rx 96 bytes Module MCTC PB1 OxCO 0x3F 0x3F EndModule Module MCTC PB2 OxCO 0x1F 0x1F EndModule 5 2 Profinet GSDML file The Profinet GSDML file can be obtained by contacting TSM Engineering personnel at 353 42 9335560 or alternatively service tsm controls com 12 Optifeed manual 6 Document revision history Revision Notes Date 01 Initial release October 23 2012 02 Changed to Optifeed software version v1 10 March 25 2013 Added protocol example Added register description Added connector pinout Added GSD file description 03 Added Profinet November 21 2013 Changed to Optifeed software version v1 11 Changed document layout Added detailed register description 13 Optifeed manual Subject Optifeed Modbus TCP IP register TSM Date overview Page 1 of 2 Optifeed Modbus TCP IP register description Software revision 1 09 0005r Last document update 25 02 2013 Status preliminary Weight 1 Unit type Alarm number See manual 5 Command bits Bit 0 Start Master Bit 1 Stop Master 2 Bit 2 Reset alarm Bit3 Remote start input Bit4 Reset cons Batch Bit5 Reset cons Total Bit 6 Manual fill production off Filling Unloading Opti Weight 3 Status bits BitO System on Bit1 Start input Bit 2 Sensor
25. 2 Low hopper level Material is below the hopper start filling weight 3 Empty hopper level Material is below the hopper empty weight 4 Hi Hi level Hopper weight has reached the EX HH level 5 Minimum motor speed lt 0 1 RPM Calculated motor speed is too low 6 Maximum RPM exceeded change dosing tool for higher capacity Calculated motor speed is too high 8 Maximum deviation exceeded The deviation of the material output is too high 9 Master slave connection failure Connection failure between multi component controllers Alarms Non adjustable 100 Motor connection failure Motor not connected Motor or connection damaged 102 Load cell connection failure Load cell connection is not correct It is possible to push the warnings away but when the error remains it will be back after 60 seconds OPTI FEED F A Q and Trouble shooting GENERAL The following variables may influence the accuracy and repeatability of the system 1 Material properties Easy flowing non sticky and non static material that comes in the form of small regular shaped granules or powder can be dosed very accurate and regular 2 Periodical cleaning of the dosing cylinder and seals is necessary for proper operation 3 Extreme vibrations and shocks can have negative influence on system performance 4 Vacuum or overpressure in the neckpiece caused by driers or hopper loaders Besides the variables mentioned so far with injection molding the shot to shot accuracy depends on the shot
26. 5 i I z 3 I a I dl _ i I TT fo T ad i inny inay OTHE JAWA SNINHYM I ok ee ee ee A I i T 1NO FLNO I wd TV i i Alddfs NIYIN SINdINO AYYNIXNY SINidLNO OYVONYVIS GE F EG EL 101010101 i l I I I HOLO dia ee ee a S 5 sass S 1 a s 6 aa a a a quem a a a al w saa i i doppauuos i i E 139 peog i peneste bonnnnponensnennen Janne enerne Mt dem P ms Sa aa ss i i l I I I e a i ajs i 3 p p den T i Op rue Tre bh 7 L F L P 7 LL gala 1 Bik 6 kul l fir L 7 senge w IT s a a E E a d 5 mit Ll o y PP OLON GYVOSNIVN ls Ie i mme re t 43 APPENDIX B MC Weight MCHO Pneumatic Diagr 6MM HOSE MM HOSE 05L M56 1 2 4 IOSL 1866 HM 1 686 100 292 14 1056 M56 KM 09510 HN QSYR86 Standard operation Knife gate operated by controller Air SUPPLY 4 6 Bar Manual override operation Knife gate open 44 APPENDIX C Optifeed Technical Specifications Controls Set and actual setting for injection moulding and extrusion Extrusion control by relay or tacho Injection moulding control Automatic metering time synchronization or by manual timer Manual speed and time setting Speed Manual setting from 0 1 to 200 RPM
27. Excessive build up of material on the dosing cylinder may have impact on proper dosing To avoid this be sure that the seals and dosing cylinder are clean Check if there is no tension on the cables connected to the weighing platform Use the weight check function with the reference weight to determine the correct function of the weighing system If the weight check gives the correct result check if the material flow into the cylinder has been blocked Another cause may be an obstruction to the weighing system Check if there is at least 1mm space between all the pointed screws and the load cell frame or platform and that there is no material or dirt blocking the movement In case of a water cooled neckpiece check if there is material build up around the dosing cylinder and the water cooled pipe that can obstruct the free movement of the weighing system Check if the input signal is stable 12 If none of the above causes the problem recalibrate the system and try the weight check again Problem The dosing system does come into specification but seems to be slow Possible causes 1 2 3 Extreme vibrations and shocks to the system Extreme low Set point See Chapter 7 SYSTEM PERFORMANCE 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 unit does not recognize this start signal Possible causes 1 2 Check if
28. N button and enter the password 4 numerals and confirm The passwords for the Tooling and Supervisor user levels can be defined by the supervisor in the System Configuration menu USER LEVEL Can be changed in LOGIN menu SUPERVISOR TOOLING OPERATOR Description Default code Default code Default code 2222 1111 0000 LOGIN To enter the different user levels CONFIGURATION To configure the dosing system PRODUCTION To do the production settings VEG Gre VEG In OPERATOR level jobs and materials are read only HOPPER LOADER To do the hopper loader settings wes ee only visible when a hopper loader is selected LEARN To learn material properties only visible when control oes w mode is set to GRAVI Gravimetric LOAD CELL To calibrate the load cell WEIGHT CHECK To check the hopper or object weight ADVANCED To configure the dosing system and change language VEG G o SETTINGSI number of components etc ALARMS View of the alarm history Recommended to note the passwords Forgot your supervisor password enter the overall supervisor password 1689 When entering a wrong password the user level will be set automatically to operator level 3 3 System Configuration For initial setup the Optifeed controller needs to be configured The following settings are for the entire system and there for needs to be altered once It is not possible to change these settings for each separate configured com
29. ONFIGURATION 3 Es Tooling Supervisor level parameters will be in visible in case they are not relevant Explanation of the parameters The production data can be entered by touching the corresponding field Motor type LT is Low Torque motor HT is High Torque motor kitain anida Cylinder type Type of dosing cylinder feed screw see manual for all types njection Moulding Material type Type of material normal granules NG and micro granules MG RE I ae Fill System Filling system OFF ME MV EX S elr Movacolor pre programmed curve or USER defined curve material name is displayed Loader settings Level settings of the loader advanced loader settings 3 Shot weight gr Control ode Gravimetrical mode GRAVI or Volumetric mode RPM 4 Dosing time sec Dosing time only visible in Timer mode otherwise relay time will be displayed Loadcell I Perform a loadcell calibration and check the weight 5 Prime Filling the dosing cylinder before start The prime menu appears by pressing FF Tolerance settings Deviation alarm setting Calibration deviation setting v ADVANCED CONFIGURATION gt K Supervisor level Extrusion Language Standard language is English On request also different languages are available 5 AS a Movacolor pre programmed or USER defined curve material name is displayed Prod Mode Extruder EXT or injection molding INJ olor amount o de eps Input mo
30. X HH level should be set higher then the EX H level For example 6ltr hopper 700 x 6 4200 gr Overfilling of the hopper should be avoided because it influences the measurement So it is very important that the levels are set correctly EX HH level EX H level Filing start level SS Hopper empty level 5 Manual Support frame EX Do not take the dosing unit away before the compressed air of the A valve is disconnected and press STOP QJon the controller to disable the valve because the Rnife gate valve can movel If started with a empty hopper the hopper can be filled by opening the knife gate valve manually by selecting Manual fill YES in the HOPPER LOADER menu Manual fillis only visible with the controller in STOP mode ALARMS e Hopper empty warning This message appears if the material weight in the hopper is below the set hopper empty weight The dosing will go on because it is a warning It is also possible to stop the dosing during this alarm by setting this message from warning to alarm in the ALARM menu of the controller see for specific description the controllers manual e High High level warning This message appears when the HH Level is reached e Unable to load material warning This message appears if during the filling no material is added into the hopper within the set EX alarm time If the EX alarm mode is set to OFF the knife gate valve will close during this alarm If the EX ala
31. ading Opti W eight Bit 6 Status sensor input INP 1 4 9 Register description 4 9 1 Master gt Optifeed 0 Device Scope Unit Writable at each configured unit Device selection selects one of the configured components Data will be send to the component selected vvith this byte 1 Future use Scope Global Writable at each configured unit Reserved for future 2 Valid Scope Unit Writable at each configured unit To be defined 3 System commands Scope Global Writable at each configured unit Device selection selects one of the configured components Bit Description Function Type Scope 0 Start System is started start button SW bit Global 1 Stop System is stopped stop button SW bit Global 2 Remote start input Start dosing HW bit Global 3 Reset active alarm Active alarm notification SW bit Global 4 11 Future use 12 Shot weight set Scope Unit Writable at each configured unit Injection molding only the weight of the total material fed into the mould during one shot In grams 16 Dosing time set Scope Global Writable at each configured unit Injection molding timer mode only Duration of one shot time the barrel injects material in the mould not the total cycle time In seconds 20 Extruder capacity set Scope Global Writable at each configured unit Extrusion relay mode Extruder total throughput setpoint in kg h Extrusion tacho mode Extruder capacity lt gt Tacho voltage ratio kg h setpoint see Tacho set
32. anual 4 8 Register Overview Master gt OPTIFEED request V f Offset Data type Description Units Remarks 0 Byte Device 1 through 5 E Byte Future use 2 Byte Valid 3 Byte System commands See note 1 4 11 Byte Future use 12 Float Shot weight set Gram Injection 16 Float Dosing time set Seconds Injection 20 Float Extruder capactity set Kg h Extrusion 24 Float Tacho set LV Extrusion 28 51 Byte Future use 52 Byte Device commands See note 2 53 63 Byte Future use 64 Float Color percentage setpoint 26 68 Float Prime speed setpoint RPM 72 Float Motor speed setpoint RPM Used in RPM mode only 76 95 Byte Spare Notes 1 System command bits 2 Device command bits Bit 0 Start Bit 0 Prime start Bit 1 Stop Bit 1 Prime stop Bit 2 Remote start input Bit 2 Manual filling opens fill valve Bit 3 Reset active alarm Bit 3 Reset batch consumption Bit 4 7 Future use Bit 4 Reset total consumption Bit 5 7 Future use Offset Datatype Description Units Remarks 0 Byte Device 1 through 5 1 Byte Future use 2 Byte Data valid Valid data can be used by PLC 3 Byte CPU running indicator 0 255 counter 4 Byte System status bits See note 3 5 7 Byte Future use 8 Float
33. chine Qualified Technician specialized suitable trained person authorized to execute the installation non routine maintenance or repairs requiring special knowledge of the machine and how it operates Multi component Two ore more dosing systems on one machine 1 3 Transport To protect the Optifeed unit against damage during transport the unit is packed in a cardboard box filed with polyurethane foam Delivery terms are Ex Works Sneek The Netherlands Buyer is responsible for the transport Optifeed cannot be held liable for any damage during transport 1 4 Receipt Check the unit thoroughly upon receipt Pass any remarks to the local agent or Optifeed within 8 days upon receipt of goods 1 5 Manual description This manual is a supplement of the general Optifeed manual Please check the Optifeed website for this manual or ask your local Optifeed representative This manual describes Profibus and Profinet implementation At moment of writing the Profinet interface is preliminary Depending on Optifeed software version some settings can differ as described in this manual 1 OPTIFEED manual 2 General information 2 1 Safety A The equipment is only designed and may only be used for the dosing of dry additives Any use that is not in conformity vvith the instructions is considered improper and as such frees the manufacturer from any liability regarding damage to things and or persons Before switching on the unit
34. ct use of the TSM dosing unit IMPORTANT NOTE THIS MANUAL MUST BE READ BEFORE INSTALLING THE UNIT KEEP THIS MANUAL IN A PLAGE ACCESSIBLE FOR ALL OPERATORS 1 1 Symbols Important note A Attention safety regulations for the operator 1 2 Terms Operator A person in charge of operating adjusting maintaining and cleaning the machine Qualified Technician A specialized suitable trained person authorized to execute the installation non routine maintenance or repairs requiring special knowledge of the machine and how it operates 1 3 Safety Slide gate Do not take the dosing unit away before the compressed air of the valve is disconnected and press STOP QJon the controller to disable A the valve because the knife gate valve can move 1 Manual Support frame EX 2 Description 2 1 VVhat is the Support Frame 2 How the Support frame EX for External hopper loader works The function of the support frame is to use an foreign hopper loader or hopper in combination with the Optifeed The support frame is equipped with a knife gate valve for filling the hopper The valve is normally closed If the filling start level is reached default 800gr the valve opens and the hopper is filled until the EX H level default 2500gr is reached Then the valve will close automatically so the support frame works independently from the hopper loader If for some reason the weight reaches the EX HH level default 3500 gr a warning w
35. d screw A 20 0 5 to 20 1 8 to 72 Feed screw A 30 2 to 50 7 2 to 180 Feed screw Note measured with normal granular master batch 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 22 N gt Na L N x my A D s lt k amp Z x gt gt as y x Z amp Z E 7 gt aQ Z 4 2 ay Wer sy M Z Z Which type of dosing system do I need with which neckpiece STANDARD NECKPIECEORSUPPORT NECKPIECE AND SUPPORT NECKPIECE FRAME FRAME A30 TYPE CODE FOR CODE FOR WATERCOOLED CODE FOR WATERCOOLED 4 1 5 Optifeed mechanical installation Most mechanical parts are pre assembled making installation quick and simple 1 When installing a foreign main material hopper on top of a neckpiece the top flange of the neckpiece needs to be adapted The lid of the neckpiece can be dismounted for easy machining Dismountable top 2 Install the neckpiece directly on top of the flange for easy entrance of the production machine u Install the neckpiece in a 90 degree angle Take au the window i to the machine barrel This will optimize the 8 a 45 angle for easy dosing accuracy in relation to vibrations of cleaning the production machine Make sure that the complete unit is mounted horizontally levelled and fixed securely Assure proper grounding to control cabinet neckpiece and dosing unit 23 3 Conn
36. de Type of input signal Relay Timer or Tacho only with extruder 3 ee capacity kg h In tacho mode the actual capacity is displayed In Relay mode the extruder capacity can be Recipe Enable disable recipe functionality PETEN ER hi 4 Tacho Voltage only visible in tacho mode SE a 4 sr kl ae Pehla Fa a arse a ae Manual Tacho voltage with corresponding extruder capacity can be entered manually S g P de p d for S 9 14 j default 2222 Synchronize Tacho voltage can be read from extruder and actual extruder capacity can be entered Oper Sor pass WONG 0 E DC Su ME 5 Prime Filling the dosing cylinder before start The prime menu appears by pressing a IP IP address for use in a network environment Modbus unit Unique identity when used in modbus network Production Motor On Off Date Time Actual date and time dd mm yy hh mm ss Number of controllers Number of controllers Press to start stop dosing The motor on off switch will turn from green to red when dosing is started The start LED blinks when the unit is waiting for an input signal If the unit is dosing the Start LED lights continuously m For stopping production press again The motor on off switch will turn to green again LOAD CELL gt Tooling Supervisor level o In this menu it is possible to perform a load cell calibration 500gr Calibration weight required or perform a weight check Loadcell Ca
37. ect the hopper assembly to the Curled knob neckpiece by turning the curled knob clockwise Make sure that the curled knob Is tightened firmly J Hopper 4 Mount the controller vibration free and assembly conform specified temperatures 8 Horizontally leveled Install the neckpiece in a Water leveled gt 90 degree angle to the machine barrel i I As shown in the picture Barne 4 1 6 Optifeed electrical installation The Optifeed or MC BC controller delivered together with the Optifeed is standard equipped with 3 connections e Mains power cable Before switching on the unit for the first time ensure the mains power voltage being applied is between 80 and 250Vac 50 60Hz e Input cable e Motor cable In case of a multi component system the controller can be equipped with an additional CANbus cable to interconnect between the Optifeed and other MC BC s 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 not hot The Optifeed is standard equipped with 2 connections e Loadcell cable e Motor cable Connect the loadcell connector to the Optifeed or MC BC and tighten the locking screws gently The motor connectors are equipped with a positioning notch and can be connected in one way only Fixate the connector with the locking mechanism to prevent loosening of the connector due to vibrations To con
38. ed controllers 3 6 2 Remove USB stick When you are ready with the required USB operations it is mandatory to press the Remove USB stick button prior to unplugging the USB memory stick You will be prompted when the synchronisation is finished and it is safe to remove the USB memory stick This synchronizes the files of your USB stick for safe removal A Risk of damaging your USB stick when not safely removed 3 7 Screenlock To avoid any unwanted modification in the production settings by an unauthorized person the touchscreen can be locked With this function enabled you are still able to see actual production data but you cannot change production settings To enable and disable the lock function You need to be logged on with at least TOOLING level To unlock follow the same sequence 17 3 8 Consumption counters The MCTC is equipped consumption counters counting the consumed material of each unit To reset the consumption counters you need at least TOOLING level login In multicomponent setups it can be necessary to use the bee button to select the unit to be shown The consumption counters can have an error due to inaccurate measurement during hopper filling 3 8 1 Batch consumption counter This counter can be used for batch counting of material consumption It counts the amount of consumed material for the selected unit The batch counter can be reset separately for each configured unit To reset the counter just pr
39. ed in here 1 231 3 4 Material curves 3 4 1 Offline Material curve learn function Each material has its own flowing characteristic This results in a material curve which is used for accurate volumetric dosing During system start when there is not enough measurement info available the dosing system uses this curve The speed of the dosing tool is then adjusted according to the learned curve Using a pre calibration results in a faster system start the system will operate faster within the set specification The material curve learn function can be performed offline to avoid waste of material The pre calibration can be done in two ways see below 1 Unit with option slide frame 2 Unit without optional slide mechanism Slide the frame with unit backwards till the click Take out the dosing unit and put it on the frame like shown In case of a MC High output the dosing tube drain can be opened to avoid material waste 11 Before starting the material curve learn function be sure that e during calibration the dosing unit is horizontally fixed and also vibration free the correct dosing tool is mounted the hopper is filled with sufficient material the loadcell cable is connected to the controller the loadcell is calibrated The following parameters will be stored with a Material calibration depending on the configuration e CONFIGURATION parameters Cylinder type type of dosing cylinder or feed screw Material
40. em will be activated as long as the button is pressed For more detailed information about hopper loading see chapter 4 1 10 Advanced loader settings When the system is unable to load material the decision can be made to stop the filling cycle after a certain time period and generate an Alarm per cycle material into the hopper Maximum fill time period 180s default Fill alarm mode Continue filling or stop filling ON continue fill OFF stop fill 26 r 4 Control mode GRAVI RPM GRAV Loadcell menu See paragraph 4 1 7 Tolerance settings Deviation alarm 25 Calibration deviation 5 loadcell Highlight is default setting Control mode The Optifeed is able to run in Gravimetric mode or in RPM mode In gravimetric mode the unit will control its motor speed to achieve an accurate stable output in gr sec In RPM mode the user can set the motor speed in the production settings the motor speed will not automatically be adjusted to achieve an accurate stable output In both Gravimetric and RPM mode the automatic filling system can be used Tolerance settings Deviation alarm Setting for the Maximum deviation exceeded message The Optifeed automatically adjusts his motor speed to the desired set point The controller is able to detect and alarm when the set point is not reached within a set percentage If after the normal performed speed adjustments the set point is consistently not reached
41. ess the RESET button next to the counter The batch consumption counter can be used for example e Order consumption registration e Daily consumption registration e Week consumption registration 3 8 2 Total consumption counter This second counter can be used for total material consumption It counts the amount of consumed material for the selected unit By resetting the Total consumption counter the batch counter is also reset To reset the Total counter just press the RESET button next to the counter The Total consumption counter can be used for example e Daily consumption counter when the batch counter is used for shifts batches e Week consumption counter e Total counter counting all consumed material by the unit For MC Weight MC TC s the consumption counters display only the material fed through the MC Weight not the complete total consumed by the extruder For a grand total you need to summarize the totals of all units 18 4 Overview Dosing and Measuring units 4 1 Optifeed 4 1 1 Optifeed Component overview 1 Stepper motor 2 Dosing system Dosing cylinder 3 Hopper 6 litre 4 Curled knob M10x40 5 Standard NST40 Neckpiece 6 Material discharge slide in closed position 7 Optifeed Load frame 8 OPTIONAL Slide frame 9 Slide loching 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 toget
42. he current production status of the selected dosing unit a number represents a status 1 Off System off no action 2 Standby System on waiting for start signal 3 Dosing Motor is running and dosing material into the neckpiece 4 Filling Filling is detected hopper is being filled 5 Filling Not used 6 Unloading MCWeight only system is unloading material and measuring throughput 39 Device status bits Scope Unit Readable at each configured unit Indicates the current device status of the selected unit each bit represents a function Bit Description Function 0 On The unit is on standby or dosing 1 Alarm Unit has active alarm 2 Prime busy Priming activated 3 Fill valve Filling system activated 4 Learn OR 0 learn 1 OK 5 Status start input Status of HW input of selected unit 6 Status sensor input INP 1 Status of sensor input of selected unit 10 Optifeed manual 40 Actual dosing time Scope Global Readable at each configured unit Shows the elapsed dosing time in seconds Injection molding only in Extrusion configuration this value Shows 0 44 Actual Extr Capacity Scope Global Readable at each configured unit Shows the actual extruder capacity material flow through the whole system in kg h Used in extrusion mode only 48 Actual tacho voltage Scope Global Readable at each configured unit Actual voltage supplied to the tacho input of the selected component Used in extrusion mode only Units Volts 52 Actual h
43. he 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 rotating cylinder is dosing additive Additive is added directly into the center of the virgin material flow just before it enters the production machine This is a great advantage over metering devices that use Fig 3 batch pre mixing because pre mixing can 1 Color 2 Virgin material 3 Neckpiece 4 Dosing cylinder actually cause material separation 4 Cover plate 5 Mixing zone 6 To production machine Separation of materials results in an irregular additive flow into the production machine 4 1 4 Optifeed dosing system capacities Depending on the application a different dosing system might be needed Use the follovving table to determine roughly the best system for the application For more detailed information please contact your agent or Optifeed Dosing system Granular Powder Accuracy Dosing capacity Dosing capacity materials Materials Gram sec Kg hour 0 02 to 1 6 0 07 to 5 8 GX 0 2 to 5 0 0 72 to 18 0 HX 0 01 to 1 67 0 04 to 5 8 A 8 0 02 to 1 0 0 07 to 3 6 Feed screw A 15 0 2 to 5 0 0 72 to 18 0 Fee
44. her with the optional slide mechanism 19 Weighing frame Safety bolts total of 5 VVeighing frame Q _ gt Hopper loader tube support des a Balance frame The black part is the weighing frame Do not touch this weighing frame and dosing unit while dosing It will have influence on the dosing Do not touch the safety bolts under the weighing platform These are for overload protection There must be some space between de safety bolts and the frame 4 1 2 Optifeed motor and dosing system The Optifeed dosing units are standard equipped with the stepper motor 2A LT in case of using the feed screw A30 the stepper motor 4 5A HT will be supplied Also a screw A20 can be connected to the HT motor During configuration of the software do not select the HT motor if LT motor is connected This will damage the motor If LT motor is selected and HT motor is connected there will be less motor torque and this can influence the dosing 20 The controller of the dosing unit makes a distinction between two groups of materials normal granules and micro granules To determine the kind of material in your application use the description below Material types Normal Granules NG 25 lt 4mm L lt 4mm Micro Mini Granules MG N The term Micro Mini Granules also includes free flowing powder ge g2 5 mm L lt 3 mm For other sizes contact Optifeed The actual
45. ight glass in the back of the hopper Overfilling of the hopper should be avoided Recommended settings for EX hopper loader support frame The Volume of the hopper is 6 litres 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 litre x bulk density gr litre For example If the bulk density 700 gr litre 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 because it influences the measurement 38 5 1 General To reset an alarm vvarning during production press to Stop dosing or and confirm When an error occurs using the Optifeed the display will indicate an error code and description Together with the displayed error an output contact will be switched The controller itself gives a beeping signal and the alarm LED will lighten up We distinguish Warning and Alarm Warning Alarm warning output is ON but the dosing unit continues running Alarm Alarm warning output is ON and the dosing unit stops running 5 2 Configuration Free programmable errors can be configured to an Alarm or Warning For setting the free programmable outputs into alarm or warning enter the ALARMS menu The alarm menu can be accessed in the advanced settings menu In the alarm configuration menu a list of warnings alarms is displayed Alarm Configuration
46. ill be given This can happen if for example the valve doesn t close or the EX H level is set too close to the EX HH level The hopper empty weight default 700 gr generates a low level warning If the hopper is empty This can happen if the external hopper loader is empty or the valve doesn t open D It could be necessary to use a customer specific intermediate plate between the hopper loader and the support frame to make a good fit Support frame 6lltr SFG 6 Mounted on the Optifeed 2 Manual Support frame EX 3 Overview of parts 3 1 Basic parts Support frame Rnife gate valve Cylinder for open close the valve Solenoid valve Support frame base frame Support frame hopper lid 4 Solenoid vave 6 3 Manual Support frame EX 4 Installation 4 1 Mechanical installation JP Install the Support frame assembly between the Optifeed and the neckpiece with the 4 supplied bolts 2 Connect a g6x4mm compressed air hose for the air supply from a compressed air source to the hose what is coming out of the frame 1 4 2 Electrical installation Solenoid valve The in build solenoid valve cable 2 needs to be connected to the controller of the dosing unit Clamp 24 White wire amp 25 Brown wire The wiring diagram for this connection can be found in the user manual of the dosing unit 4 3 Compressed Air requirements The compressed air source must deliver a maximum of 4 6 bar of clean dry n
47. ime ME hopper loader or alarm cycles MV hopper loader are exceeded Check if there is enough material Check if the material is stuck somewhere Check the operation of the hopper loader Check the hopper loader settings Low level Level is less than xxx g If this warning appears the material in the hopper is below the hopper low weight 800 gr In DEVICE CONFIGURATION this setting can be changed Check if there s enough material in the hopper Check the hopper Low setting in DEVICE CONFIGURATION lt menu gt Check if the hopper loader is working right Empty level Level is less than xxx g If this warning appears the material in the hopper is below the hopper empty weight 700 gr In CONFIGURATION lt menus this setting can be changed Check if there s enough material in the hopper Check the hopper empty setting in CONFIGURATION lt menu gt Check if the hopper loader is working right High High level Level is higher than xxx g Check if the knife gate valve is in closed position Check if the knife gate is sliding Check if the parameters EX H level and EX HH level are set OK Minimum motor speed lt 0 1 RPM Calculated motor speed is lower than the minimum of 0 1 RPM Check if there s enough material in the hopper Check the production settings Decrease the dosing time if possible Take another dosing type with lower output for example a GLX cy
48. ime consuming to find the material It is possible to search in the list of materials using the search button You can enter part of the material name you need to search for Example you need to load the material named pp color 145 when you enter pp in the search field al material names containing pp will be displayed in the list g Deleting materials curves can be done by selecting it from the material list followed by the delete selected button Renaming materials can be done by selecting it from the material list followed by the rename selected button To go back to the production menu without selecting a material from the list press the cancel button The standard Mova curve can be selected by pressing the default material button located below the material list 13 3 4 3 Save data function This function allovvs to store the actual data during production 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 memory of the controller under the entered name Starting a new production run with a previous stored material calibration speed is now possible GX NG Ext Cap set 2 000 50 0 kg h V DOSING EEE NE Press on the curve description 1 when the unit is activated The SAVE MATERIAL screen appears Enter a material description max 10 positions and oss gt Z to store the material curve
49. ing Please refer to Optifeed service department to check compatibility with your Optifeed 3 Optifeed Manual 3 3 Cabling 3 3 1 Profibus Use proper Profibus certified cabling and connectors to establish the Profibus network connection 3 3 2 Profibus electrical connection 1 Shield Ground connection 2 NC Not connected 3 RxD TxD P Data line plus B line 4 NC Not connected 5 DGND Data ground 6 VP 5V supply for terminating resistors 7 NC Not connected 8 RxD TXD N Data line minus A line 9 NC Not connected Case Shield Ground connection See for more information http www profibus com 3 3 3 Profinet Use proper Ethernet cabling type CAT5e to establish a network connection to your plant machine or corporate network The Optifeed Profinet module is equipped with 2 standard RJ45 type connector 3 4 Profibus Profinet setting The profibus and profinet module needs to be enabled This can be done in the System Configuration menu I O module NONE ANALOG PRO BUS PRO NET Highlighted is default setting 3 4 1 Profibus address The Profibus protocol requires a device address The address of the Optifeed Profibus interface can be set with the System Configuration setting Device ID 1 231 Highlighted is default setting This setting is shared with MODbus TCP IP 4 Optifeed Manual 4 Optifeed Profibus Profinet 4 1 General informa
50. ing setpoint in Used in Twin closed loop regrind configuration This percentage can differ from the regrind setpoint and depends on available regrind 80 Actual regrind filling level Scope Unit Readable at each configured unit Future use 84 95 Future use 11 Optifeed manual 5 1 Profibus GSD file The Profibus GSD file can be obtained by contacting TSM Engineering personnel at 353 42 9335560 or alternatively service tsm controls com Type Optifeed DP slave Model MCTC Revision 1 7 Description Dosing controller File Create Date 25 oct 2012 Author Hans Helmhout Profibus DP Station Type 0 Protocol Ident 0 Vendor Name Optifeed Model Name MCTC Revision 0 1 Ident Number 0x1122 Hardware Release A01 Software Release Z01 9 6 supp 1 19 2 supp 1 93 5 supp 1 18 5 supp 1 500 supp 1 1 5M supp 1 3M supp 1 6M supp 1 12M_supp 1 MaxTsdr_9 6 60 MaxTsdr 19 2 60 MaxTsdr 93 75 60 MaxTsdr 187 5 60 MaxTsdr 500 100 MaxTsdr 1 5M 150 MaxTsdr 3M 250 MaxTsdr 6M 450 MaxTsdr_12M 800 Repeater_Ctrl_Sig 2 skkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk 3 ca Slave Data skkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkkk 3 XX Freeze Mode supp 0 Sync Mode supp 0 Auto Baud supp 1 Set Slave Add supp 0 Min Slave Intervall 5 Maximum length of user parameter User Prm Data Len 1 Watchdog
51. ing variables influence system performance Material properties Easy flowing non sticky and non static material that comes in the form of small granules or powder can be dosed very accurate and regular The accuracy and regularity of material output drops with increased granule size However this is only a problem with extreme low outputs Periodical cleaning of the dosing cylinder and seals is necessary for proper operation Extreme vibrations and shocks influence system performance noticeably Normally the system will be able to compensate for vibrations and shocks The dosing algorithm needs a certain time to weigh material loss and adjust the RPM accordingly This time depends largely on the set point and the above mentioned two variables The system constantly adjusts itself to reach the best possible accuracy for current conditions Over time it can reach accuracy within 1 Under normal circumstances the unit will be more accurate than 10 after the first adjustment of the RPM Before the unit makes its first 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 cannot be guaranteed because material properties can vary substantially from material to material An unstable relay or tacho signal has a negative effect on the accuracy repeatability and speed of the system because it will adjus
52. ion moulding Tacho voltage Read actual tacho voltage set tacho voltage ratio Extruder throughput Read actual extruder capacity write extruder capacity setpoint Regrind setpoints Read actual regrind setpoints Production commands Write production commands start stop reset alarm fill Prime Start stop prime at set motor speed 5 Optifeed Manual 4 5 Optifeed OPTIFEED Profibus Profinet protocol It is possible to operatate op to 5 different components color additives with one Touchscreen controller The Optifeed has only one Profibus Profinet slave address which represents all upto 5 configured components Each component can be selected by the appropriate number in the first byte of the 96 bytes data packet The complete packet is written to the selected device on the Optifed The Optifeed will respond with the same 96 bytes packet containing the actual settings and process values When an invalid unconfigured device is selected the Optifeed will respond with the value 255 in the first byte of the 96 bytes data packet indicating an invalid unconfigured device is requested Example OPTIFEED is configured vvith 3 components the first component is a Opti VVeight the second and third components are Opti Balances The Profibus Profinet master issues a packet with the first byte set to value 1 The Optifed will respond with a 96 bytes data packet byte one set to the value 1 indicating device 1 is selected and byte 36 set to
53. irector Date 46 OPTI FEED Quick Reference 1 0 UK 00 Operation Reference For more detailed information please consult the User Manual External communication Network Mains power switch ON OFF WWW TSMCONTROLS COM Mains power cable Load cell Output for Alarm Start input cable Motor cable Warning Valve output Running for hopper loader Alarm LED is lighted alarm warning Input LED is lighted input signal is ON Start LED blinking motor is stand by waiting for start signal Start LED lighted motor is running GENERAL 1 Operation software version V1 00r production date December 2011 2 Connect motor and load cell before svvitching on the controller 3 All changes have to be confirmed with w START UP After switching on the mains power of the OPTI FEED the screen will remain black for about 15 seconds followed by various screens where the last is showing the software version After about 90 seconds the home screen appears and the unit is ready for operation pow a The OPTI FEED has 3 user levels defined User Level Access level 1 Operator production settings 2 Tooling same as operator material pre calibration and access to the device configuration menu 3 Supervisor same as tooling access to the Advanced Configuration menu and the Alarm Log When entering a wrong password user
54. l is ON External communication Optional communications Network USB Host port Mains power indicator ON OFF Mains power switch ON OFF Valve output for hopper loader CAN bus cable Load cell Output for Alarm Warning Running Mains power cable Start input cable MC BC Blind controller j Mains power indicator ON OFF Mains power switch ON OFF Load cell CAN bus cable Mains power cable Valve output for hopper loader 3 2 Start up amp Login After switching on the mains power of the Optifeed the screen will remain black for about 15 seconds followed by various screens where the last is showing the software version After about 90 seconds the home screen appears shot weight 0 09 set time 0 05 Shot vveight Set time Act time 52 69 705 0 0 s a EES at Iss J EE Single component Multi component The Optifeed controller has three user levels 1 Operator 2 Tooling 3 Supervisor The functions which are accessible per user level is shown in the table below The operator level is the standard level only the important settings for production can be done The rest of the settings menus are invisible or locked For changing to another user level press on the menu icon left bottom corner and the user button appears When pressing the user button the login menu is entered lt Press the LOGI
55. learning and save the collected data x Stop learning without saving Continue with learning 7 The unit will execute the calibration procedure the procedure will stop when the dosing is within the calibration deviation range default 5 the material curve will be stored This material is now automatically selected for the current unit 12 During the calibration the unit is regulating to his Setpoint VVhen this point is reached the calibration will be saved automatically On the basis of this point a complete curve is made on bases of default pre programmed curves Material Calibration 0 500 0 700 Single point calibration on basis of pre programmed MOVA curve Qutput gr sec o o o e in m o o o o o o s nm vw o amp o amp gt o Eu 125 Es Es Motor Speed RPM 3 4 2 Selecting a learned material curve When more material curve calibrations have been made a curve can be loaded to the device To do this 1 Ina multi component setup select from the home screen the unit to load the material 2 Press the material selection button 1 shot weight 25 0 g set time Unit 1 b HE pe Bee La AEE 1 Optifeed material selection button 1 High Output material selection button 3 Select vvith the up and dovvn buttons the required material name and confirm you vvill be prompted when the wrong dosing tool is configured When the list of materials is big it can be t
56. libration Always perform a load cell calibration after the machine is installed with an empty hopper the motor and hopper lid mounted Make sure that the controller is ON for at least 15 minutes and the system must be stable during calibration e Press the Calibrate button e Follow the instructions on the screen Weight check The following parameters will be shown in this menu Weight Actual weight on the weighing scale If the Object weight is not corresponding with the real weight perform a new load cell calibration Supervisor level ALARM HISTORY 3 Display of the alarm history Scroll through the stored alarms to see the log When a problem occurs using the OPTI FEED the display will indicate an error code and description Also the alarm LED lights up Together with the displayed error an output contact can be switched To reset an alarm warning during production press to Stop or and confirm LJ Free programmable errors can be configured to an Alarm or Warning Warning Alarm Alarm output is ON and the dosing unit stops running 7 l i configuration menu A list with the available alarms warnings will be displayed Pressing on the alarm warning button behind the description will change the status Alarm Warning Warning output is ON but the dosing unit continues running Code Warnings alarms programmable Description 1 Filling system unable to load material Fill system is not working correct
57. linder Q Check the rotation direction of the dosing cylinder Front view to the right Maximum RPM exceeded change dosing tool for higher capacity Change dosing tool for higher capacity Calculated motor speed is higher than the maximum of 200 RPM Check the material output on 200 RPM Check the production settings Increase the dosing time if possible Take another dosing type with higher output for example a feed screw A20 Error 08 Maximum deviation exceeded If this warning appears the dosing output grams sec is consistently not within set percentage See page 18 for more information Master Slave connection failure ul Connection failure betvveen multi component controllers Check wiring 5 5 Alarms Motor connection failure Motor connection is not correct Make sure the motor is connected Check cable and connectors for damage Loadcell connection failure Load cell connection is not correct Load cell connector is not connected to the controller 40 6 System performance 6 1 General System performance can be characterized by the time it takes the unit to reach the desired set point the accuracy of the set point and the regularity of the material output The algorithm is self adjusting to the conditions and because the conditions vary it cannot be predicted how long it will take the unit to adjust itself and reach a set point with certain accuracy The follow
58. lways a set dosing time relay function is not functional Actual production data Using the scroll button a you can switch between production settings and production data Speed Actual motor speed RPM Hopperweight Material weight in the hopper Set Time set dosing time sec Act Time count down of the actual dosing time sec Please note that it is possible that the first dosing s are not sufficient because of the cylinder filling with material It takes some time to stabilize 30 EXTRUSION Extrusion Gravimetric mode Production settings The production data can be entered by touching the corresponding field GLX NG 2 5 000 Extruder act 100 0 kg h 1 Ref Curve material Optifeed pre programmed curve dosing tool granule type or USER defined curve material name is displayed not available when recipe function is activated 2 Color amount 3 Extruder capacity kg h In tacho mode the actual capacity is displayed In Relay mode the extruder capacity can be entered 4 Tacho Voltage only visible in tacho mode Manual Tacho voltage with corresponding extruder capacity can be entered manually Synchronize Tacho voltage can be read from extruder and actual extruder capacity can be entered 5 Prime Filling the dosing cylinder before start The prime menu appears by pressing s Settings speed time can be changed Press confirm v to start priming 6 Production
59. nect the input cable please see Appendix A Optional are e Alarm flash light complete with cable e Compressed air solenoid valve complete with cable for automatic hopper loader 24 4 1 Optifeed loadcell calibration When using a Optifeed for the first time perform a initial load cell calibration as follows The unit must be mounted horizontally water levelled Avoid vibrations during the load cell calibration This will influence the calibration Do not touch the unit during load cell calibration When using a slide the whole unit has to be slid in against the neckpiece and fixed When a ME or MV hopper loader is used be sure it is in place and the tubing is fixed to the tube support and not interfering by any surrounding object Be sure that the Balance load cell is connected to the controller Enter the Device configuration menu and press the loadcell button Select calibrate Confirm to start calibrating the load cell of the Optifeed 500gr calibration weight required Follow the instructions on the screen and place the weight ull when instructed After approx 1 minute the load cell calibration is ready press confirm to go back to the home menu To check if the load cell calibration was OK the weight check menu will be shown Check the current object weight for example the 500gr calibration weight Recommended is to perform a weight check a regular basis To do to the WEIGHT CHECK enter the De
60. ng parameters can be set in the loader settings menu x Available settings for ME hopper loader TSM hopper loader operated by compressed air SN MV hopper loader Movacolor hopper loader operated by vacuum 1 Max filling level 25009r 2 Hopper loader start level 8009r 3 Hopper empty level 7009r default settings Manually activate the hopper oaser A The manual filling function can be used to fill the hopper before start of production Press a for the advanced loader settings dx Advanced loader settings for ME ME alarm time Alarm time sec Time between hopper empty weight CONFIG and start of alarm alarm time gt fill time ME alarm mode ME hopper loader is ON OFF during fill alarm Advanced loader settings for MV MV Fill time Time the MV system sucks material into the vacuum chamber MV Empty time Opening time off the cone for material to fall down into the hopper of the dosing unit MV Alarm time if the hopper weight is not above the 800gr within this time the alarm starts MV Alarm mode MV hopper loader is ON OFF during fill alarm Available settings for EX hopper loader Support frame for external hopper loader 1 The EX HH level is the Highest level If this level is reached a High High level warning appears 3500gr 2 EX H level is the level where the knife gate valve will be closed again 2500917 3 Filling start level 800gr 4 Hopper empty level 700gr Ma
61. nit Additive dosing amount setpoint Percentage of the total material flow shot weight added by the selected component Injection molding example shot weight 25 gram 10 additive will give a additive shot weight of 2 5 gram Extrusion example total extruder material flow of 100kg h 15 additive setpoint will give an additive dosing of 15kg h virgin 85kg h additive 15kg h Note when set at 0 the unit will be switched off 68 Prime speed setpoint Scope Unit Writable at each configured unit Motor speed setpoint used during prime function see register 52 bit 0 Speed in revolutions per minute 72 Motor speed set Scope Unit Writable at each configured unit Volumetric RPM mode only Motor speed setpoint in revolutions per minute 76 95 Future use 4 9 2 Optifeed gt Master 0 Device Scope Unit Readable at each configured unit Device selection in request selected unit Data in this package belongs to the selected unit If 255 is returned an invalid unit is selected in request 1 Future use 2 Valid Scope Unit Readable at each configured unit To be defined 3 CPU running indicator Scope Global Readable at each configured unit Running counter continuously increasing Can be used to monitor the Profibus Profinet connection 9 Optifeed manual 4 System status bits Scope Global Readable at each configured unit Status bits indicating status of the whole system Bit Description Function Scope 0 System started Sys
62. nually fill the hopper El The manual filling function can be used to fill the hopper before start of production Press for the advanced settings di EX alarm time EX alarm mode if the hopper weight is not above the 800gr within this time the alarm starts EX hopper loader is ON OFF during fill alarm Installation Reference OPTI FEED For more detailed information please consult the User Manual po LEARN MATERIAL Tooling Supervisor level GENERAL INFORMATION Use the equipment only for what it is designed for The metering of dry additives The OPTI FEED can be started in mainly two ways Before switching on the unit for the first time ensure that the main power voltage being applied is between 80 and 260Vac cia etat Always switch off the Movacolor control cabinet and disconnect from electrical power before performing maintenance I he n MO Ut Earning or Marenial e tari i After pressing the START button the unit starts dosing on a speed that is based on default materials which are pre programmed in the o The C E symbol certifies that the machine conforms to the European Union regulations on minimum safety standards controller Make sure all parts are securely fixed to your extruder or injection molding machine 2 Start the unit with learning of material before start LOGIN 3 Operator Tooling Supervisor level ed pr the START button the unit starts dosing on a speed that is based on learned material
63. of goods 2 General information 2 1 Safety A P P P P The equipment is only designed and may only be used for the dosing of dry additives Any use that is not in conformity with the instructions is considered improper and as such frees the manufacturer from any liability regarding damage to things and or persons Before switching on the unit for the first time ensure that the mains power voltage applied is between 80 and 260Vac Always switch off the Optifeed control cabinet and disconnect the mains power plug from electrical power before performing maintenance Ensure that all parts are securely fixed to the extruder or injection moulding machine Dangerous voltages are present inside the control cabinet for up to 2 minutes after it has been switched off 2 2 Certification The Optifeed dosing unit is designed and produced in conformity with the following European regulations Standards for machinery health safety environment EMC electromagnetic compatibility VEM safety electric material 2006 42 EG 2 3 Operating environmental conditions The unit must be protected against vveather conditions Operating temperature 20 to 70 degree C Protection class IP 50 3 Operation 3 1 The Interface Optifeed Touchscreen Alarm LED is lighted alarm vvarning Start LED blinking motor is stand by waiting for start signal Start LED lighted motor is running Input LED is lighted input signa
64. on lubricated air pressure Make sure everything is connected firmly A CAUTION Be sure to provide hazard free routing of the tubing keep it away from hot or moving surfaces and out of the way of personnel 4 Manual Support frame EX 5 Operation 5 1 Starting up the EX support frame after installation For safety reason the hopper loader is only activated when the dosing unit is in the START amp mode To deactivate the hopper loader in case of emergency press the STOP amp button on the controller Be aware that also the dosing unit will stop also CONTROLLER SETTINGS 1 Go to the CONFIGURATION menu 2 Select EX as Fill System 3 Set the right levels as follows Hopper empty weight is the lowest level If this level is reached a warning appears Filling start weight is the start filling level If this level is reached the knife gate valve opens The filling start weight should be set higher than the hopper empty weight EX H level is the level where the knife gate valve will be closed again To set the EX H level stop filling It is recommended to take a safety margin to prevent the hopper from overfilling If the volume of the hopper is 6 liter For example EX H level gr 5 liter x bulk density gr liter If the bulk density 700 gr liter the EX H level should be set to 700 x 5 3500 gr The EX HH level is the Highest level If this level is reached a High High level warning appears The E
65. opper weight Scope Unit Readable at each configured unit Gives the actual hopper weight in grams An empty hopper should equal 0 gram 56 Actual motor speed Scope Unit Readable at each configured unit Gives the actual motor speed in RPM For MCVVeight this value reads 0 60 Color capacity setpoint Scope Unit Readable at each configured unit Gives the calculated dosing rate setpoint of the unit in gram per second 64 Color capacity actual Scope Unit Readable at each configured unit Gives the actual dosing rate of the unit in gram per second 68 Batch consumption Scope Unit Readable at each configured unit Shows the total material consumption for the current batch in kg This value is an approximation and can have a small deviation caused by theoretical calculated value during filling of the hopper The shown value is for the selected component only The batch counter can be reset by setting bit 3 of the Device command register 72 Total consumption Scope Unit Readable at each configured unit Shows the total material consumption for the selected component in kg This value is an approximation and can have a small deviation caused by theoretical calculated value during filling of the hopper The shown value Is for the selected component only in multicomponent setup The batch counter can be reset by setting bit4 of the Device command register 76 Actual regrind Scope Unit Readable at each configured unit Shows the actual regrind dos
66. per lid and fill the hopper by hand filling will be detected automatically The warning message Low hopper level appears when the material level in the hopper is below the set level default 800 gr The levels settings for the hopper loader can be checked and adjusted if necessary Enter the device configuration 4 1 8 Hopper Levels menu and press The available settings vary per loader model ME hopper loader Optifeed hopper loader operated by compressed air Max filling level Hopper loader start level Hopper empty level Manually activate the hopper loader The Manual filling function can for example be used to fill the hopper before start of production 5 Advanced loader seitings a In the advanced loader settings menu alarm time and alarm mode can be changed Alarm time Fill Alarm sec if the hopper weight is not above the 800gr within this time the alarm starts 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 a filling alarm MV hopper loader Optifeed hopper loader operated by vacuum 35 OK 1 Max filling level 2 Hopper loader start level 3 Hopper empty level 4 Manually activate the hopper loader The Manual filling function can for example be used to fill the hopper before start of production 5 Advanced loader settings Lv x
67. ponent For component specific configuration Optifeed High Output Weight see the device specific chapters The global settings can be changed in the System Configuration menu to enter this menu Language ENG DE FR Production mode INJ EXT Input type Timer Relay Tacho Auto start OFF ON Recipe function OFF ON Start login Operator Tooling Supervisor Tooling passw xxxx 1111 Supervisor passw xxxx 2222 IP address 0 0 0 0 For example 192 168 1 100 Netmask 0 0 0 0 For example 255 255 255 0 Gateway 0 0 0 0 For example 192 168 1 1 Date Time dd mm yy hh mm Number of contr 1 XXXX Kg h units ON OFF Imperial units OFF ON Profibus OFF ON Device address 1 231 Restart of controller required Optional profibus module required System Configuration Language Standard language is English If your language is not listed you can put a request at your local Optifeed representative for a translation System Configuration Production mode Selection of type of machine on which the Optifeed dosing system is placed EXT extruder or INJ injection moulding System Configuration Input type Type of input signal Relay Timer or Tacho Timer mode is the standard setting for Injection moulding BT N timer o In RPM prod Mode Timer is used automatically a geno x It __ GRAVI RPM GRAVI RPM D For INJ in timer mode the
68. previous stored voltage and the graph will change accordingly During production the voltage P1 can be adjusted to the current tacho input voltage manually or automatically as shown above The new voltage is linked to the previous stored speed and the graph will change accordingly The maximum voltage that can be applied to the Optifeed tacho input is 30 VDC The tacho signal must be a clear signal Any failure in the voltage signal will be followed by dosing variations System Configuration Auto start Enable disable auto start up 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 OFF and ON again System Configuration Recipe function Enable disable recipe functionality System Configuration Start login User level to start up with when switching on the controller s mains power Operator Tooling or Supervisor System Configuration Tooling passw Password for Tooling user level 4 numerals default 1111 System Configuration Supervisor passw Password for Supervisor user level 4 numerals default 2222 System Configuration IP address IP address for use in a network environment TCP IP protocol For example 192 168 1 100 When the Optifeed dosing system is part of a network the controller must have an IP address for identification This IP address has to correspond with the IP address of your computer
69. rch in the list of recipes using the search button You can enter part of the recipe name you need to search for Example you need to load the recipe named Recipe RED 1 when you enter RED in the search field all recipes names containing RED will be displayed in the list Confirm the selection with the accept button The next screen will show the settings of the selected recipe Here you can check the settings of the recipe By pressing the accept button Yx the recipe will be loaded OR g Edit the production parameters within the recipe to your needs and save the recipe To save the recipe just press the save recipe button you will be promted to overwrite the recipe Overwrite current selected recipe changes in the recipe will be saved Do not overwrite you will be promted to enter a new recipe name create a copy new recipe x lt The new recipe is not immediately selected go back to the main recipe screen to select the new recipe A recipe can also be edited from the HOME screen When a recipe is loaded and a production setting is changed the recipe button icon will change ee By pressing this button you will be prompted to overwrite the recipe or to store the current settings under a new recipe name 3 5 3 Delete a recipe From the HOME screen press the recipe button Select the desired recipe by using the up and down outons lt To delete the selected recipe mi lt
70. ricated air pressure pressure The capacities are measured with normal granules with a bulk density of 0 8 kg dm3 Granule size 3 4 mm De mentioned capacities are orientation values because capacity depends on material properties 8 Manual Support frame EX 9 General dimensions Support frame SFG 12 ls 10 General dimensions Support frame SFG 6 11 Manual Support frame EX
71. ring fill time there will be a 24VDC signal between connection 29 and 30 on the main board to activate the pneumatic solenoid valve When the Fill Alarm is activated there will be a 24VDC signal between connection 27 and 28 on the main board to activate the flash light The controller itself gives a beeping signal and the alarm LED will light up GENERAL RECOMMENDATIONS FOR OPTIMAL HOPPER FILLING To guarantee the optimal working of the gravimetric Optifeed dosing unit it is important to use the correct rate of hopper filling The higher the output of the dosing unit kg h the more important becomes the rate of hopper filling During hopper filling the electronics of the Optifeed controller recognize automatically that the hopper Is being filled This automatic filling detection is working for manual filling of the hopper and filling with an automatic hopper loader In the period that the hopper is being filled the Optifeed is dosing with a fixed RPM this means the unit runs temporarily volumetric As soon as the hopper filling is ready the Optifeed immediately continues to work gravimetric Because the Optifeed 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
72. rm mode is set to ON the knife gate valve stays open during this alarm These settings can be done in the HOPPER LOADER menu 6 Manual Support frame EX 6 Cleaning The Support frame assembly can easily be cleaned 1 Disconnect power and air sources The knife gate valve will close automatically 2 Take out the dosing unit 3 Blow out the support frame assembly with clean shop air 7 Troubleshooting A VVARNING Disconnect povver and air sources Alvvays disconnect the controller from its main povver source and disconnect the compressed air course before servicing This prevents the loader from starting during servicing vvhich could cause personal injury Problem Possible cause hopper loader is full vvith material Check if there is material what blocks the knife gate valve High High level Warning appears The Hopper is possible overfilled Check the level settings in the CONFIGURATIONS menu Max deviation message appears Decrease the EX H level weight Max Rpm message appears Check if there is enough compressed air pressure Check if there is material what blocks the knife gate valve 7 Manual Support frame EX 8 Technical specifications specifications Suitable for 12 liter hopper 6 liter hopper Total maximum load 50 kg 50 kg Max throughput in combination with 120 kg h Optifeed Compressed air tubing Compressed air requirements 4 to 6 bar clean dry non lubricated air 4 to 6 bar clean dry non lub
73. roduction data Using the scroll button 2 you can switch between production settings and production data GLX NG shot weight 0 333 g s 50 0 g 0 324 g s set time act time 6 9 s DOSING S lt TS ss E Set and actual output Set Calculated output gr sec Act Actual colour output gr sec actual colour output is only visible after the first automatic RPM adjustment Speed Actual motor speed RPM Hopperweight Material weight in the hopper Time set dosing time sec when working TIMER input mode The average dosing time sec when working in RELAY input mode Act Time count down of the actual dosing time sec 29 Injection moulding RPM mode Production settings The production data can be entered by touching the corresponding field ad ed 15 7 rpm lt set time 35 85 act time 0 0s mM e Set motor speed RPM Dosing time sec Prime Filling the dosing cylinder before start The prime menu appears by pressing s Settings speed time can be changed Press confirm v to start priming Production Motor On Off Press to start dosing he motor on off switch will turn from green to red when dosing is started he start LED blinks when the unit is waiting for an input signal If the unit is dosing the Start LED lights continuously For stopping production press again The motor on off switch will turn to green again RPM mode needs a
74. s made by the user which are stored in the controller The OPTI FEED has 3 operation user levels defined NE EEE he NE ER User level Default code Access i Operator 0000 production settings Login Go to the LEARN menu by opening the menu bar and select the learn function EE i Tooling Thi ea r amp hopper loader SENGS weight check load cell calibration consumption Enter Material name and your production Parameters by pressing on the correspondino fields All fields must be filled in material calibrations job functionality before learning can start Supervisor 2222 same as tooling amp advanced device configuration alarm configuration alarm history Start learning A screen will appear asking to check the motor connection and if the cylinder needs filling prime e Thelearn function will take minimal about 3 minutes but can take more time depending on the used material and production parameters When the setpoint is reached within the set calibration deviation Cal dev default 5 the learn procedure can be completed by pressing Finish The learned material will be saved automatically After saving you will automatically go to the PRODUCTION screen and stored material is automatically selected PRODUCTION 3 Tooling Supervisor level file management Paeewnrd faranttan C anaiilt neer man tal Entered the wrong password user level will be set automatically to operator level C
75. start pulse should be min 0 2 seconds For INJ in relay mode the start signal should be as long as the dosing time If INJ 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 production screen shows the real machine relay time Input start signal The Optifeed needs an input signal from the production machine in order to operate Three different input signals can be used to control the Optifeed 1 A potential free relay contact Use the white and brown wire for the potential free contact 2 A relay signal 24 Volt DC In case of a powered relay signal connect the white wire to 24 VDC and the yellow wire to the 0 VDC Note potential contact Guaranteed OFF 0 8VDC Guaranteed ON 18 30VDC 3 A tacho signal up to 30 Volt DC This is used when the dosing system needs to be connected to an extruder that has a tacho generator that produces a voltage linear to the extruder speed When using a tacho generator signal make a connection between the white and brown wire It will function as a start signal Connect green to VDC and yellow to the side of the generator The maximum voltage that can be applied to the Optifeed is 30 VDC The tacho voltage has to be reduced to 30 VDC if the tacho generator has a higher voltage output than 30 VDC at the maximum extruder output capacity See
76. t to these parameter changes A long cycle time combined with low dosage per shot can result in a slow system 6 2 Reset regulation e Changing one parameter during production will cause the Optifeed to adjust to the changes but it will not reset the regulation totally e Changing more production parameters during production within 10 seconds after each other will cause the Optifeed regulation to reset This is necessary for the system to adjust quickly to these big changes in the settings e Switching the power OFF and ON again will also cause the regulation to reset e Motor OFF and ON again will only cause the regulation to pause The start up RPM will be the same as the last RPM before the stop e Changing one parameter with motor OFF causes total reset of the regulation e With auto start ON CONFIGURATION lt menu gt the motor follows the last status motor Standby or motor Stop status and causes total reset of the regulation 41 7 Trouble shooting Problem The dosing system does not come into specification or a Maximum deviation alarm occurred Possible causes 1 2 3 4 5 10 11 Check if all cables are connected correctly Check if the transport protection is removed from the load cell safety bolt Check if the hopper assembly is fixed tightly to the weighing platform and that the neckpiece Is fixed tightly to the production machine Check if the dosing cylinder is tightly fixed to the motor shaft
77. tem is started components dosing or standby Global 1 System alarm active One or more components generate alarm Global 2 System start error Fault occurred caused by wrong parameters Global 3 System start input Start input activated Global 5 7 Future use 8 Main mat Ext capacity Scope Unit Readable at each configured unit Value representing the main material flow measured by the Opti Weight in Rg h Opti Weight and extrusion mode only 12 Total ext capacity Scope Unit Readable at each configured unit Gives the total material flow through the extruder Main material all dosed components Opti Weight Opti Bal in kg h Opti Weight and extrusion mode only 16 Total color Scope Unit Readable at each configured unit Gives the total added color percentage of the main material through the extruder in Opti Weight only Total color 100 sum of dosing equals part of flow through the Opti Weight 20 35 Future use 36 Unit type Scope Unit Readable at each configured unit Indicates which kind of Optifeed device is configured at selected position Opti Weight Opti Balance Opti High Output Opti Balance Regrind Opti High Output Regrind le kr 37 Alarm code Scope Unit Readable at each configured unit In case of alarm the active alarm number is displayed in this register For a description of the alarm see Optifeed manual 38 Production status Scope Unit Readable at each configured unit Indicates t
78. the correct wires are connected for potential free contact potential contact or tacho Also check if the and side are connected correctly Automatic fuse is activated this can for example happen when there was a short circuit at the input connection To deactivate the automatic fuse the controller needs to be switched OFF for a while and ON again but first check and repair the short circuit Problem The hopper weight is not stable Possible causes 1 2 3 4 Check if the weighing signal is not influenced by external circumstances for example that the loadcell cable passes near to electromagnetic fields or electro motors Extreme vibrations and shocks to the system Check if there is no obstruction to the weighing frame Check in case of use of an automatic hopper loader if the hoses are connected in the right way 42 iagram D iring Optifeed Wi APPENDIX A LL OJ adong us8153 MA BAIS f AO A paso euuon x Pal EE e O J T F PILL t i i I I i I i I i I i i i i i i I i I I I I I I I I i I I I i I i i I i I i I i I I I I I I I I I T l uado AJJEULIOM l i i I i I i I I I I I I i I i I i I i i I i I i I i I I I I I I I I i I i I i I i i I i I i I i I I Es UE m ELISA PLA a p MEET a l I ami den LOZOCOP ayeuray I Jopauuod ka delslsls El i s
79. the diagram below Input Green wire Resistor RX Tacho generator connection Yellow wire EXTRUDER Rx kilo Ohm 2 684 x Max tacho output VDC 5 66 If the extruder stops when connected to the metering unit an isolated signal converter is needed Contact your agent or Optifeed for more information Tacho function The tacho function is only available in extrusion mode This 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 assumed See graph Tacho graph Example Speed RPM 10 42 t 16 8 20 3 4 39 Tacho input voltage VDC The tacho function can be set in the PRODUCTION screen Tacho can be set manually or be synchronized Manual Fill in the voltage the tacho produced by the tacho generator at maximum extruder speed Synchronize Let the extruder run and select synchronize The tacho voltage P1 will be taken over automatically enter the actual extruder capacity This is linked to the set motor speed P2 in RPM mode or calculated motor speed in GRAVI mode During production the motor speed P2 can be changed The new speed is linked to the
80. the hopper is filled until the EX H level default 2500gr Then the valve will close automatically L so the support frame works independently from the hopper loader a 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 EX hopper loader A Do not take the dosing unit away before the compressed support frame air of the valve is disconnected and press STOP on the controller to disable the valve because the knife gate valve can move D It could be necessary to use an customer specific intermediate plate between the hopper loader and the support frame to make a good fit Knife gate valve Cylinder for open close the valve Solenoid valve Connection Nuts M10 for hopper loader mounting 34 General The hopper loader is only activated when the motor is On Emergency stop To stop the hopper loader the motor must be switched off In the device configuration menu the ME MV EX can then be switched off Hopper loader settings This part of the manual describes how to configure the hopper loader For further technical information about the hopper loader consult the specific hopper loader manual There are four ways to fill the hoppers 1 Manual 2 Automatic with ME hopper loader 3 Automatic with MV hopper loader 4 Automatic with EX external hopper loader in combination with the support frame Manual Open the hop
81. tion In Profibus modus the START STOP button is disabled on the touch screen The input start dosing signal is given via Profibus Profinet or Input wire on TC controller mainboard connection 9 10 The OPTIFEED will behave as a Profibus Profinet slave 4 2 Touchscreen functions The following functions must be operated on the touchscreen and cannot be altered activated using Profibus Profinet Configuration Loadcell calibration Learn material Material selection Recipe management Recipe selection 4 3 Touchscreen configuration The communications module must be enabled in the configuration see chapter 3 4 When Profibus or Profinet is enabled all settings listed in the register overview are not accessible at the touchscreen itself These settings are overwritten by the Profibus Profinet protocol 4 4 Available parameters You will be able to read write the following parameters Production status Off Standby Dosing Filling Current machine status System on Start input Sensor input Alarm active Read unit type Opti Balance Opti Weight Opti High Output Active alarm numbers Read active alarms reset alarm condition Setpoints Read actual setpoints set dosing setpoints Consumption Read total consumption read batch consumption reset counters Hopper weight Read current hopper weight Motor speed Read write the motor speed of the dosing unit Dosing time Read write the dosing time for inject
82. tion 7 Trouble shooting APPENDIX A Optifeed Wiring Diagram APPENDIX B MCWeight MCHO Pneumatic Diagr APPENDIX C Optifeed Technical Specifications APPENDIX D Optifeed Declaration of Conformity CON CI OTA A A 09 OH G 1 Introduction Thank you for purchasing a Optifeed metering device This manual is addressed to operators and qualified technicians taking care of the metering of dry additives to ensure correct use of the Optifeed dosing unit IMPORTANT NOTE THIS MANUAL MUST BE READ BEFORE INSTALLING THE DOSING UNIT KEEP THIS MANUAL IN A PLACE ACCESSIBLE FOR ALL OPERATORS 1 1 Symbols Important note A Attention safety regulations for the operator 1 2 Terms Operator A person charged to operate adjust maintain and clean the machine Qualified Technician specialized suitable trained person authorized to execute the installation non routine maintenance or repairs requiring special knowledge of the machine and how it operates Multi component Two ore more dosing systems on one machine 1 3 Transport To protect the Optifeed unit against damage during transport the unit is packed in a cardboard box filled with polyurethane foam Delivery terms are Ex Works Dundalk Ireland Buyer is responsible for the transport Optifeed cannot be held liable for any damage during transport 1 4 Receipt Check the unit thoroughly upon receipt Pass any remarks to the local agent or Optifeed within 8 days upon receipt
83. vice configuration menu and press the loadcell button followed by the weight check button Place 500 gr calibration weight on the Hopper and check the displayed weight If the actual weight is not corresponding with the placed weight perform a new load cell calibration In multicomponent setups it can be necessary to use the button to select the unit to be calibrated 25 4 1 8 Optifeed device configuration When the Optifeed is used for the first time it needs to be configured The unit is delivered pre configured but some settings need to be altered to the process needs mm In multicomponent setups it can be necessary to use the button to select the unit to be configured Optifeed settings j LT HT amp gt LOADER OFF ME MV EX a Dosing tool HX GLX GX A8 A15 A20 See Hopper level settings NG MG Cs p Material type NG MG x ia x Do not select HT motor if LT motor is connected d D Highlighted is default setting 5 Max fill level Hi alarm L EX 3500 gr 2 Fill stop level L EX ME MV 2500 gr L 800 gr L 700 gr 6 Advanced loader settings To adjust the hopper levels determine the Max fill level by manual filling the hopper to the maximum hopper level Recommended settings for the other 3 levels is 75 25 and 10 respectively To manual fill the hopper the manual fill button can be used The EX knife gate valve will be open or the ME MV syst
84. with the Autostart function enabled and the unit is switched OFF and ON again the filling will start automatically if the hopper weight is too low L lt sy Sight glasses Filling start level Filling stop level The moment when the automatic filling starts depends on Filling stop level is depending on the entered stop the entered start level level for the ME MV EX system Filling stop Xxx gr Filling start xxx gr Configuration menu For the MV system Filling stop xxx gr hopper loader menu Recommended settings for ME hopper loader Use for the filling start weight a level like shown in the filling start figure above when using a to high weight level the amount of filling cycles will increase Use a fill stop weight so that the material covers at least the sight glass in the back of the hopper Overfilling of the hopper should be avoided 3 Recommended settings for MV hopper loader Use for the filling start weight a level like shown in the filling start figure above when using a too high weight level the amount of fill cycles will increase Use a fill time so that the vacuum chamber of the MV Loader is filled almost completely Overfilling of the vacuum chamber should be avoided Use for the empty time not a longer time that necessary but a to short empty time can cause decrease of the capacity of the MV hopper loader Use a fill stop weight so that the material covers at least the s
85. x 953 42 9335560 a 353 42 9334422 INDEX 1 Introduction 1 1 Symbols 1 2 Terms 1 3 Transport 1 4 Receipt 1 5 Manual description 2 General information 2 1 Safety 2 2 Certification 2 3 Operating environmental conditions 3 Communications Setup 3 1 Ethernet connection location 3 2 Module installation 3 3 Cabling 3 3 1 Profibus 3 3 2 Profibus electrical connection 3 3 3 Profinet 3 4 Profibus Profinet setting 3 4 1 Profibus address 4 Optifeed Profibus Profinet 4 1 General information 4 2 Touchscreen functions 4 3 Touchscreen configuration 4 4 Available parameters 4 5 Optifeed Profibus Profinet protocol 4 6 Data types 4 7 Global Unit 4 8 Register Overview 4 9 Register description 4 9 1 Master gt Optifeed 4 9 2 Optifeed gt Master 5 GSD 5 1 Profibus GSD file 5 2 Profinet GSDML file 6 Document revision history om OND Q CI OQ CI Q 8 B EB A HO CON N N N lt Q am cO _ G S N 1 Introduction Thank you for purchasing a Optifeed metering device This manual is addressed to operators and qualified technicians taking care of the metering of dry additives to ensure correct use of the Optifeed dosing unit IMPORTANT NOTE THIS MANUAL MUST BE READ BEFORE INSTALLING THE DOSING UNIT KEEP THIS MANUAL IN A PLACE ACCESSIBLE FOR ALL OPERATORS 1 1 Symbols Important note A Attention safety regulations for the operator 1 2 Terms Operator A person charged to operate adjust maintain and clean the ma

Optifeed Manual - TSM Control Systems

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