How it Works
Magnum Venus Plastech
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RTM Pro
User Manual
72 pgs4.63 Mb0

Magnum Venus Plastech RTM Pro User Manual

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Plastech Manufacturing Facility
www.mvpind.com
www.plastech.co.uk
Table of contents
Section 1 – Introduction
1.1. Machine Overview
Section 2 – Commissioning
2.1. Connecting to Services
2.1.1. Electrical Supply
2.1.2. Air Supply
2.2. Loading Materials
2.3. Switching on the machine
2.4. Priming the system
2.5. System test
2.6. Pump calibration
Section 3 – Machine Operating Procedures
3.1. Emergency Stop
3.2. Emergency Flush
3.3. Connection Options
3.4. Recirculation
3.5. Manual Injection Setup
3.6. Manual Mould Pressure Controlled Injection
3.7. Manual Head Pressure Controlled Injection
3.8. Manual Flush
3.9. Working with recipes
3.10. Automatic injections
4.11. Shutdown
4.12. Graphs
4.13. Values screen
Section 4 – Configuration
4.1. Recirculation
4.2. Flush
4.3. Catal Alarm
4.4. Resin Alarms
4.5. Head Pressure Clipping
4.6. Calibration
Section 5 – Alarms & Faults
5.1. Release E-Stop and press reset button
5.2. Recirculation pump stall
5.3. Resin gel alarm (RGA) – Flush machine!
5.4. Autosprue 1 position error
5.5. Autosprue 2 position error
5.6. Autosprue 3 position error
5.7 Autosprue 4 position error
5.8. Motor comms error
5.9. Motor fault
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5.10. Catal alarm!
5.11. Cat over pressure
5.12. Air pressure < 5 bar
5.13. Air pressure > 7 bar
5.14. Resin low
5.15. Catalyst level low
5.16. Solvent level low
5.17. Motor reference lost – re-home
5.18. Head valve position fault
Section 6 – Maintenance
6.1. Health & Safety
6.2. Routine Maintenance of Fluid and Mechanical Systems
6.2.1. Resin Pump
6.2.2. Catalyst Pump
6.2.3. Resin & Catalyst Pipework
6.2.4. Solvent Pump System
6.3. Resin System Re-priming
6.4. Preparing the Machine for a Period of Inactivity
6.5. Replacing Resin Pump Seals
6.6. Replacing Catalyst Pump Seals
6.7. Catalyst Over-pressure Valve Service
6.8. Solvent Pump Service
6.9. Injection Head Assembly Service
6.10. Progressive Catalyst Ratio (PCR) System
6.11. Maintenance Screens
6.11.1. Motor configuration screen
6.11.2. I/O check screen
6.11.3. Diagnostics
Section 7 – Fault Finding
7.1. Programmable Logic Controller (PLC) System
7.2. Wiring Fault – Diagnosis Example
7.3. Common Problems – Non-electrical
Appendices
Appendix A – Air Circuits Appendix B – Electrical Schematics Appendix C – PLC I/O Connections Appendix D – Motor connector pin-out Appendix E – Megaject RTM Pro Manual Revision History Appendix F – Contact Plastech TT Ltd
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Safety Notes
• Read all instructions before operating machine.
• Keep cabinet doors locked at all times unless maintenance is being carried out
by qualified personnel.
• Always wear suitable protective equipment for operating and maintaining
machine.
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1. Introduction
The RTM Megaject Pro, has been designed for injecting polyester, vinylester and methacrylate resin systems under automatic control. The unit uses the proven Megaject pumping system, which mixes resin and catalyst on demand at the injection head, with the catalyst ratio adjustable from 0.5% to 4.5%.
The machine incorporates the programmable progressive catalyst ratio (PCR) facility, which is motor driven and provides automatic catalyst ratio adjustment between 200:1 and 22:1. Interfaced with the machine’s control system, it responds to individual mould programs and adjusts the percentage of catalyst based upon the settings in the selected program.
A summary of the machine’s specification is as follows:
• Resin and catalyst pump system with automatic adjustable ratio.
• On board 25 litre solvent and catalyst containers with non intrusive level
sensors.
• Compact automatic injection head with re-circulation and low mix wastage.
• Full colour 6” Allen & Bradley PanelView 600 touch screen operator terminal.
• Allen & Bradley CompactLogix PLC system with Ethernet connectivity.
• Multi-level user interface with password protection.
• In-built commissioning and testing software.
• Automatic control of injection/flushing cycle.
• User inputs of required injection pressure (mixing head or mould selectable)
and volume.
• Safe Closed loop control of injection head pressure with injection progress
indication.
• Connection for PV sensor to allow precise closed loop control of mould
pressure.
• Program control for individual settings for multiple moulds.
• Programs are stored in the PLC memory for selection recall.
• Automatic re-circulation feature.
• Easy connection to stand alone data logging system via Ethernet.
• Catalyst alarm and monitoring system (Catal).
• Catalyst temperature compensation system, automatically adjusts catalyst
percentage based on workshop temperature and user predefined table of values.
• Fully enclosed lockable wheeled enclosure with separate internal bays for
electronic and fluid systems.
• Heavy-duty stainless steel top, with centrally positioned heavy duty e-stop.
• Touch screen is mounted in rotational and adjustable screen housing,
incorporating push start and stop buttons, providing ease of access to operator.
• Automatic flush sequencer capable of flushing up to 4 autosprues.
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1.1. Machine overview
The touch screen, or Human Machine Interface (HMI) is mounted in an adjustable housing on the top of the machine, along with the START and STOP buttons. This unit, shown in Figure 1.0 provides the operator interface for the machine, from which all machine operations are controlled.
The e-stop button is mounted next to the screen housing on the top of the machine, to facilitate easy access in an emergency.
Start button
Stop button
E-Stop
Figure 1.0 – Operator interface.
Bay 1 is shown in Figure 1.1 and contains all of the electrical control equipment such as the Programmable Logic Controller (PLC).
Figure 1.1 – Bay 1
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E-Stop RESET
Resin level sensor connection
Air supply
Figure 1.2 illustrates the main electrical isolator, power and air connections for the Megaject RTM Pro. These are located on the side of Bay 1.
Power indicator
Isolator switch
Electrical supply
Figure 1.2 – Electrical isolator and service connections
Above the electrical isolator, towards the top of the machine, is the panel shown in Figure 1.3. A connector is provided to allow an external resin level sensor to be connected to the machine in addition to an Ethernet socket, which allows a PC to connect to the control system. The blue RESET button is used for the safety circuit, and must be pressed when the machine is first powered-up, or after an emergency stop condition, when the e-stop button has been released.
Button
Ethernet socket
Bay 2 contains the resin pump, catalyst pump, progressive catalyst ratio system and pneumatic control and preparation components, and is shown in Figure 1.4.
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Figure 1.3 – Reset button and external connections
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Solvent
Emergency
Figure 1.4 – Bay 2
Bay 3 is shown in Figure 1.5 and holds the catalyst and solvent containers. The sounder beacon and connection for the emergency flush system are also in this bay.
Flush Sounder Beacon
Container
Catalyst Container
Figure 1.5 – Bay 3
The injection head is shown in Figure 1.6, with the key elements identified.
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Resin
Catalyst
Head Pressure
Electrical Head
Injection/Recirculation Valve
Injection/Recirculation Valve
Mixer
Connector
Sensor
Figure 1.6 – Injection head
Pneumatic Head Connector
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2. Commissioning
CAUTION
Overalls and eye protection must be worn at all times during operation of the machine. Suitable gloves must be worn when carrying out operations which may result in contact with fluids.
The Megaject RTM Pro is tested and secured against leaks prior to dispatch. It is essential that all pipes and fittings remain tight and sealed at all times to prevent air ingress into or leakage from the system.
2.1. Connecting to services
Air and electrical connections must be made by a suitably qualified person.
2.1.1. Electrical Supply
The machine should be connected to either a 110VAC 60Hz or 220VAC 50Hz
0.8kVA single phase supply, depending on the voltage specified on the machine. This machine must be correctly earthed.
2.1.2. Air Supply
The supply must be dry filtered clean air. A lubricator must NOT be used in the air supply to the machine. When the machine is powered up and the safety circuit has been reset, the regulator in bay 2 should be set to approximately 6 bar. This value can also be read on the touch screen human machine interface (HMI) in the VALUES screen.
Connection of the air supply should be made to the fitting on the side of bay 1. Supply pressure should be between 6 - 9 bar and capable of supplying a flow of between 350 l/min to 1200 l/min for maximum injection flow rate.
2.2. Loading materials
Resin Pump Lubricant (Bay 2)
Half fill resin pump upper collar (item 0546) with Plastech Pump Lubricant (supplied) to maintain pump shaft and top seal in a clean and lubricated condition.
Acetone (Bay 3 – Rear of Machine – White polypropylene tank)
NOTE: Solvents are flammable; follow all applicable health and safety regulations when using solvents.
Remove small white filler cap from solvent tank. Fill tank to approximately 4/5 full. Solvent level must always be high enough to cover the top of the internal pump chamber inside the tank. Replace cap.
Sufficient solvent levels are essential for the correct flushing of the machine. The solvent level must not be allowed to fall below 5 litres as this may cause inefficient flushing. Level is monitored by a non-intrusive proximity level sensor.
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We recommend the use of Acetone as the primary choice of cleaning solvent. If a different solvent system is to be used please contact Plastech for details of changes required.
Catalyst
SAFETY NOTE: The catalyst flow sensor in bay 2 and the catalyst over pressure sensor mounted on the small catalyst ratio pump should remain without adjustments having to be made. Do not adjust this overpressure valve. If in any doubt about operation or adjustment of any part of this machine please contact Plastech TT.
When priming pump from empty condition, first loosen catalyst flow output pipe union. This is necessary to ensure sufficient suction is created to first lift catalyst into pump. Disconnect the catalyst piston from the upper ratio arm, and operate the pump manually until catalyst flows from the outlet union. This should be done into a suitable container to avoid spillage. Retighten the union and reconnect the piston to the upper ration arm.
Resin
Place the resin pick-up and resin recirculation pipes into resin drum. Firmly anchor both pipes. The resin pump should generate sufficient suction to self-prime during recirculation.
2.3. Switching On the Machine
Ensure bay doors are closed and that air at the correct pressure is being supplied to the machine. Turn mains isolator ON (side of bay 1). The touch screen will begin to load the application. To reset the machine’s safety circuit, the e-stop must be released (pulled upwards) and then the reset button on the side of the machine must be pressed to supply air and power to the system. This can be done while the screen is starting.
Figure 2.0 – Welcome screen
When welcome screen, shown in Figure 2.0, has appeared on the display, touch anywhere on the touch screen to move to the login screen shown in Figure 2.1.
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NOTE: At the bottom left of the welcome screen, the current versions for the PAC (Programmable Automation Controller, which is also referred to as a Programmable Logic Controller (PLC)) and the Human Machine Interface (HMI) are shown. Please refer to these versions when seeking technical assistance from Plastech.
NOTE: If any alarms are generated when the system is started, please refer to section
5. A common error is the “Emergency Stop” alarm, which will be triggered if the safety circuit has not been reset, as described above, before the welcome screen has been displayed on the HMI.
Figure 2.1 – Login screen
Press the LOGIN button to bring up the login screen, shown in Figure 2.2, and then enter your user name and password. These details will have been supplied to you when the machine was commissioned by a Plastech employee and must be entered correctly before the machine can be operated. Version 1.00 of the screen software supports only one level of security i.e. when the operator has logged on, all features can be accessed.
To enter the username, press the User button, and enter the username on the keypad followed by return. The keypad is shown in Figure 2.3. If you make an error while entering the username, simply press the backspace key to delete the character that was entered last. To navigate away from the screen, without making an entry, press the ESC key. Repeat these steps for the password and then press return on the login screen to attempt to log onto the machine.
Figure 2.2 – Login screen
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Return key (Enter)
Backspace
Figure 2.3 - Alphanumeric keypad
After the user has successfully logged in to the machine, an INITIALISE button will appear on the login screen. Press this button in order to navigate to the initialise screen shown in Figure 2.4. Press the Yes button to begin the initialisation sequence, which will perform a number operations to prepare the machine for service, including homing the motors that drive the Progressive Catalyst System (PCR).
NOTE: If any alarms are generated before or during the initialisation process, please refer to section 5 for guidance.
Figure 2.4 – Initialisation screen
If the machine is successfully initialised, a confirmation message will be displayed, and an OK button will be displayed. Press this to advance to the main menu screen, shown in Figure 2.5, which is the central access point for all of the screens used to operate the Megaject RTM Pro system.
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Figure 2.5 – Main menu screen
2.4. Priming the system
In order to correctly prime the resin and catalyst systems, it is necessary to operate the machine in recirculation mode. To navigate to the recirculation screen illustrated in Figure 2.6, press the RECIRCULATION button on the main menu screen.
Figure 2.6 – Recirculation screen
Press the Recirculation on time button, and enter 15 on the numeric keypad shown in Figure 2.7 and then press return. Then enter a recirculation off time of 1 minute and an initial recirculation rate of 10%.
Press the START button on the screen housing to start the machine. The sounder beacon will operate to warn the operator the machine is about to start, and then the pumps should start to recirculate.
If the pumps do not move, increase the recirculation rate. If the pumps are recirculating too quickly, reduce the recirculation rate. If the pumps do not move at all, when a recirculation rate of 100% has been entered, please refer to sections 3.4 and 4.1 for further information as it is possible that configuration settings may be incorrectly set.
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When the machine is recirculating, it will run for 15 minutes and then rest for 1 minute using these settings. To stop the machine press the STOP button located on the screen housing. The Catal bar should rise and fall to indicate catalyst flow, refer to section 3.4 for further information.
Recirculate until a bubble free fluid flow is observed at both the resin and catalyst containers, and pump output is even on both strokes. If any air is observed in either return pipes press red STOP button and check tightness and vacuum security of all intake pipe-work and fittings from containers to lower pump inlets.
Return key (Enter)
Figure 2.7 – Numeric input keypad
2.5. System Test
To check that the machine is working correctly, a manual head pressure controlled injection should be carried out. Refer to section 3.5 and 3.7 for a detailed description of how to run the machine in this mode.
In the manual injection setup screen, ensure all the sprues are disabled, and then press the HEAD PRESSURE CONTROL button to navigate to the head pressure controlled manual injection screen.
Enter the following values:
• Head pressure SP = 1000mbar
• Pump power = 15%
• Catalyst = 2% (or other suitable value for the resin system being used)
Once the machine has been correctly configured, direct the injection nozzle into a waste container.
Press the START button and dispense from the mixer at least 1 litre of fluid into the waste container and then press STOP.
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Next, place the injection nozzle into a suitable test cup
Press START button and pump approximately 0.2 litres into the test cup and then press STOP. DO NOT STIR!
The injection head must then be flushed. Direct the injection nozzle into a safe waste container. Press the FLUSH button and allow the machine to complete it’s solvent/air flush cycle.
Ensure that the resin in the test cup is suitably catalysed and that the mixture gels as expected for the resin system in use.
2.6. Pump calibration
The Megaject RTM Pro gives the user the facility to enter a calibration value to adjust how the volume of delivered resin is calculated, based upon the volume of liquid per stroke.
The volume of resin is generally referred to, when injecting components, and is the reference volume used for manual and automatic injections. However, it must be remembered that the volume of fluid being delivered through the mixing head also includes the volume of catalyst. However, in most cases the quantity of catalyst can be considered to be negligible. For example, if 2 litres of resin is dispensed during calibration tests, with a catalyst ratio of 2%, a theoretical volume of 2040 millilitres would be dispensed. The accuracy of the machine is at best +/-100 millilitres, and therefore it is acceptable to ignore the catalyst percentage in the resin volume calculation.
To calibrate the machine, please refer to sections 3.9 and 3.10. Use the 2 litre bucket example in section 3.9 as a starting point for machine calibration.
It is advised that the operator performs the following steps to calibrate the machine:
1. Set up the “2 litre bucket” example recipe.
2. Perform an automatic injection into a sample container using this recipe.
Please remember to have a suitable waste container available for the flush sequence after the injection.
3. Measure the volume of the sample, and record the result.
4. Repeat steps 2-3 until 3 samples have been produced.
5. Calculate the average volume using the following equation (all volumes in
millilitres): (VOLUME
6. The theoretical volume of resin per pump stroke is 100 millilitres, therefore
use the following equation to calculate the actual volume of resin per stroke: VOLUMEAV / (1000 * Litres) = VOLUMEAV / 2000 = Litres per pump stroke.
7. Enter this value on the resin calibration screen (see section 4.6).
8. Perform a further 3 tests to ensure that calibration has been performed
correctly. The volume delivered should be within +/- 100 millilitres of the quantity of resin specified in the recipe.
Sample1
+ VOLUME
Sample2
+ VOLUME
)/3 = VOLUMEAV
Sample3
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3. Machine Operating Procedures
This section discusses all of the operating modes of the Megaject RTM Pro in addition to common procedures.
3.1. Emergency Stop
The emergency stop button is provided to allow the machine to be rapidly de­energised in the result of an emergency. When this button is pressed air pressure is vented from the system, mechanical movement is ceased and the DC electrical supplies to components outside of Bay 1 and the screen housing are de-energised.
The safety circuit also comprises of a reset button on the side of Bay 1. To reset the safety circuit (after an e-stop or on power-up), the e-stop button must be de-activated (pulled up) and then the reset button pressed. If these steps do not reset the safety circuit, check that the machine is correctly connected to a suitable air and electrical supply. If these steps do not clear the fault, a qualified maintenance technician should inspect the machine.
NOTE: The safety circuit is designed to protect the operator and prevent reset if a component has failed. Modifying the safety circuit in order to make the machine operate, could result in serious injury or death.
3.2. Emergency Flush
This procedure should be carried out in the event of electrical supply failure when the machine has mixed resin in the injection head.
Ensure injection head or flush line is attached securely to a suitable waste tank.
Connect factory mains air supply (6-9 bar pressure, clean dry air) to emergency flush port (6mm connector) located in bay 3 above the solvent tank. Turn on supply. The solvent pump will operate and flush injection head. Keep air supply on for 30-40 seconds.
Turn off supply and remove pipe from the emergency flush connector.
This operation may be repeated if necessary. The main air line must be exhausted after each flush operation in order to enable the solvent pump to refill. This can be done by removing the main air line from the emergency flush connector.
NOTE: Flush sequence valves signals are not operated during an emergency flush operation. In these cases it will be necessary to repeat the above for each set of autosprue and sequence valves in order to flush them. Connect air to each sequence valve in turn and re-flush through the head. Repeat this operation for all autosprues in turn, until all are flushed clean.
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3.3. Connection Options
This machine features the following connections at the mixing head:
• Fluid line (for delivering catalysed resin to autosprue(s))
• 6 – way pneumatic connector
• 12 – way electrical connector
For the most basic dispensing operations, such as filling a container with a pre­defined quantity of resin for calibration purposes, the air and electrical connections may be ignored. However, for more sophisticated procedures, these connections must be made.
The electrical connector allows the machine to monitor the open/closed status of up to four autosprues. This connector also allows a mould pressure transducer to be connected to the machine, to enable closed-loop mould pressure injections to be performed. It is recommended that a connection box, supplied by Plastech is used to make the electrical connections between the mould and the machine.
The pneumatic multi-way connector allows six 4mm air lines to be connected to the machine. The connections are numbered and are utilised as follows:
1. Autosprue open/close signal
2. Autosprue open/close signal
3. Flush sequencer valve 1
4. Flush sequencer valve 2
5. Flush sequencer valve 3
6. Flush sequencer valve 4
The autosprue signal has been doubled-up to increase flow and should be connected to in common to all of the autosprues in the system.
In order to flush multiple autosprues individually, which are supplied by the same line, a suitable normally closed pneumatically operated process valve should be fitted in the flush line of the autosprue. The signal port on the process valve should then be connected to the corresponding flush sequencer output on the machine. Thus, when all connected autosprues are in the closed position, and a flush has be initiated, fluid can only flow through the autosprues that have their corresponding flush sequencer valves open. See the Appendix A for a drawing showing suggested flush sequencer connections.
It is recommended that an electrical connection box, pneumatic connector and autosprue system are permanently mounted on each mould. This machine has been designed to allow an operator to safely connect the machine to a mould in three simple steps:
1. Connect fluid line
2. Connect electrical cable
3. Connect pneumatics
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3.4. Recirculation
Recirculation of the machine should be carried out on a regular basis to ensure resin and catalyst flows are even, free of air bubbles (observed through recirculation returns) and to prevent if used, sedimentation of any fillers/additives in the resin system.
Recirculation should be carried out at the start of each shift or if new material has been added to either the resin or catalyst containers.
NOTE: Unnecessary and excessive use of recirculation will result in unnecessary pump seal wear.
The recirculation screen shown in Figure 3.0, can be reached by pressing the RECIRCULATION button on the main menu screen.
Figure 3.0 – Recirculation screen
It is possible for the user to set the on and off durations during a recirculation cycle, in addition to the rate at which the pumps operate.
Change the recirculation on and off times by pressing the appropriate button, and then entering the required value on the numeric input.
The recirculation rate can also be modified, and represents the percentage of air pressure supplied to the air cylinder. The maximum amount of pressure available is determined by the recirculation configuration (see section 4.1 for more information). These settings will be dependent on the viscosity of the resin being used as well as the desired circulation rate. The higher the recirculation rate % is set, the faster the pumps will recirculate.
To begin recirculation, press the START button. Before the machine starts, the machine will operate the sounder beacon as a warning.
The Catal bar at the right hand side of the screen ranges from 0-100%, and should be used in addition to visual checks to ensure catalyst is flowing correctly. The bar should rise for each stroke of the pump, and fall momentarily at the end of a stroke.
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All three values can be changed while the machine is recirculating.
3.5. Manual Injection Setup
When the user wishes to perform a manually controlled injection, they must firstly press the MANUAL INJECTION button on the main menu screen. This will navigate to the manual injection setup screen, which can be seen in Figure 3.1. This screen gives the operator the ability to select what is connected to the mixing head, manually flush the machine and select between either a mould pressure or head pressure controlled injection modes.
Initially the user should configure what is connected to the system. Pressing a sprue button will toggle it between disabled and enabled. When a sprue is enabled, the operator also has the option to enable or disable the limit switch checking function. Once any sprue is enabled, the machine will provide the open/close signal to control the action of any connected sprues.
This system allows a great deal of flexibility for the user and configures how the machine will flush in manual mode. Connection options range from a simple dispense from the head into a container with no signal to open a sprue (all sprues disabled), through to a fully sequenced and monitored configuration featuring four Turbo Autosprues (TASs) with position monitoring and flush sequencing. See section 3.3 to review the connection options.
Figure 3.1 – Manual injection setup screen
3.6. Manual Mould Pressure Controlled Injection
Once the sprue configuration has been set on the manual injection setup screen (see section 3.5), the MOULD PRESSURE CONTROL button can be pressed to access the manual injection screen for mould pressure control, which can be seen in Figure
3.2.
The four square indicators at the top right of screen illustrate the configuration of each sprue, from left to right sprue 1 to sprue 4 respectively. A grey box containing a D indicates the sprue is disabled. A green filled box indicates an enabled sprue; while a
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green box, containing an L shows that the sprue is enabled with limit switch monitoring.
The screen displays the volume of resin injected, elapsed time of injection, actual pressure in the mould cavity and the current resin flow rate. The resin volume and elapsed time readings retain there final values from the previous injection, which can be useful, and are only reset when a new injection is commenced by pressing the START button.
Figure 3.2 – Manual injection screen, mould control
The mould pressure set point (SP) value is the desired pressure to be maintained in the mould during the injection. This value is in mbar absolute, and for a typical LRTM injection, it is suggested that good starting point would be to set this value to approximately 100mbar below atmospheric pressure (around 910 mbar).
Pump power sets the maximum air pressure available to the air cylinder to drive the resin and catalyst pumps. This value will vary depending on the type of resin used, length of pipe to the mould and tooling design etc. It is recommended that a low percentage is entered initially (<10%) and then modified based upon the response of the machine.
During the initial phase of the injection, as resin is first introduced into the mould, the mould pressure will take some time to build. At this time the flow rate will be mainly determined by the pump power setting. If head pressure clipping is enabled (see section 4.5), unsmooth operation of the pumps may indicate that the pump power should be reduced. If head clipping is disabled, care should be taken not to over pressurise the supply line by increasing the pump power value excessively.
The catalyst ratio can be changed to a value between 0.5% - 4.5%.
To begin the injection, press the START button. The sounder beacon will operate for a period, to warn the operator that the machine is about to start. The catalyst pump will then move to the position on the ratio arms specified by the current catalyst percentage. At this point the head valves change over to the inject position, if enabled any connected sprues are opened, and then the machine begins to inject.
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The injection parameters can be modified during the injection and the machine can be paused or restarted, by pressing the STOP and START buttons respectively.
When the injection is paused, a FLUSH button appears at the bottom right of the screen. To finish the injection the user must press the FLUSH button (see section 3.8) to close any connected autosprues, return the head valves to the recirculate position and to initiate the flush sequence.
3.7. Manual Head Pressure Controlled Injection
Once the sprue configuration has been set on the manual injection setup screen (see section 3.5), the HEAD PRESSURE CONTROL button can be pressed to access the manual injection screen for head pressure control, illustrated in Figure 3.3.
The four square indicators at the top right of screen illustrate the configuration of each sprue, from left to right sprue 1 to sprue 4 respectively. A grey box containing a D indicates the sprue is disabled. A green filled box indicates an enabled sprue; while a green box, containing an L shows that the sprue is enabled with limit switch monitoring.
Figure 3.3 – Manual injection screen, head control
The screen displays the volume of resin injected, elapsed time of injection, actual head pressure and the current resin flow rate. The resin volume and elapsed time readings retain there final values from the previous injection, which can be useful, and are only reset when a new injection is commenced by pressing the START button.
Select the head pressure SP button to enter the desired head pressure for the injection. A catalyst percentage between 0.5% - 4.5% can also be set.
The pump power value represents the maximum air pressure available to the air cylinder operating the pumps. This can be adjusted to change the behaviour of the machine and affects both the flow rate and response of the control system.
It is advised that an initially a low value (<10%) is chosen, and then adjusted to optimise the performance of the system.
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To begin the injection, press the START button. The sounder beacon will operate for a period, to warn the operator that the machine is about to start. The catalyst pump will then move to the position on the ratio arms specified by the current catalyst percentage. At this point the head valves change over to the inject position, if enabled any connected sprues are opened, and then the machine will begin to inject.
If head pressure clipping is enabled (see section 4.5), unsmooth operation of the pumps may indicate that the pump power should be reduced. If head clipping is disabled, care should be taken not to over pressurise the supply line by increasing the pump power value excessively.
The injection parameters can be modified during the injection and the machine can be paused or restarted, by pressing the STOP and START buttons respectively.
When the injection is paused, a FLUSH button appears at the bottom right of the screen. To finish the injection the user must press the FLUSH button (see section 3.8) to close any connected autosprues, return the head valves to the recirculate position and to initiate the flush sequence.
3.8. Manual Flush
Under manual operation, the machine can be flushed by pressing the FLUSH button on the manual injection setup screen (see section 3.5), or by pressing the FLUSH button on either the manual injection mould pressure control or head pressure control screens.
The machine has been designed to encourage the user to flush machine correctly after an injection, and therefore the user has to initiate a flush after an injection to navigate back to the main menu screen.
To flush the machine during maintenance or in order to perform additional flushes after an injection, the FLUSH button has been placed on the manual injection setup screen to prompt the user to configure what autosprues are connected to the system. This is information is required by the machine to configure the flush sequencer.
When a flush has been initiated, the screen shown in Figure 3.4 will be displayed and the sounder beacon will operate. This screen gives the user a countdown to commencement of the flush sequence, and during this time the user may press the ABORT button to stop the flush and return to the main menu screen. The ABORT button can be useful in certain circumstances. For example, if an automatic injection is performed and the operator wishes to introduce more resin into the mould at the end of the injection, the user may abort the flush and then perform a further manual injection before flushing the machine.
NOTE: If the user aborts the flush, this will cancel the Resin Gel Alarm (RGA). Extreme care must be taken not to let the catalysed resin gel in the system.
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Figure 3.4 – Flush countdown screen
When the machine starts flushing, it will perform differently dependent on how the machine has been configured.
If the machine is setup for single autosprue or no autosprue operation, then the machine will perform a single flush.
If more than one autosprue is selected, the machine will perform a sequenced flush operation.
Example 1 – Sprues 1 & 2 connected, initial & final flush enabled.
Sequence step Sprue 1 Sprue 2 Sprue 3 Sprue 4
1 FLUSH 2 RECHARGE SP3 PUMP 3 FLUSH 4 RECHARGE SP3 PUMP 5 FLUSH 6 RECHARGE SP3 PUMP 7 FLUSH
Example 2 – Sprues 2, 3 & 4 connected, initial flush disabled & final flush enabled.
Sequence step Sprue 1 Sprue 2 Sprue 3 Sprue 4 1 FLUSH 2 RECHARGE SP3 PUMP 3 FLUSH 4 RECHARGE SP3 PUMP 5 FLUSH 6 RECHARGE SP3 PUMP 7 FLUSH
Table 3.0 – Flush sequencer examples
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For all flush operations, information is provided on the display to inform the user as to what action is being carried out. Progress indicators are also supplied to make the operator aware of the machines progress through an action.
Table 3.0 shows a series of flush sequences based upon different autosprue configurations.
The operational behaviour of the flush system can be modified by adjusting values using the flush configuration screen (see section 4.2).
3.9. Working with Recipes
Recipes allow the user to store all the variables required to perform an injection, and associate them with a descriptive title. Up to fifty recipes may be stored in the machine’s memory at any one time, which may be recalled by the user and used to perform an automatic injection.
Figure 3.5 – Edit recipes menu screen
Such a system makes it possible to write a recipe suitable for each mould, which can then be used to perform automated injections. This approach reduces the possibility if user errors while inputting data and performing an injection.
To copy, delete or edit recipes, the operator must press the RECIPES button on the main menu screen to navigate to the edit recipes menu shown in Figure 3.5.
A list showing recipes, five a time, can be seen towards the top on the screen. The number of each recipe is displayed (00-49), followed by its name. The currently selected recipe entry is highlighted with a white bar. To select a different entry, simply press the up or down buttons at the lower left of the screen to scroll through the list. If the number of the desired recipe is known, the user may press the NUM button and enter the number directly.
Recipe entries that have not yet been used, or that have been deleted are named “EMPTY”.
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To create a new recipe, select an “EMPTY” entry or, to modify an existing entry, simply select the recipe that you wish to change. When the target recipe entry is highlighted, press the EDIT key to display the first screen of the recipe editing interface, which is shown in Figure 3.6.
Figure 3.6 – Recipe edit screen 1
The initial screen allows the operator to set a name for the recipe, and to enter a short description to give anybody modifying the recipe at a later date, useful information. Press the recipe name button to edit the name or the EDIT button to enter comments. To progress the next screen, press the right arrow at the bottom right of the display.
The second screen of the recipe editing interface is illustrated in Figure 3.7, and allows the required head connections for the injection to be specified.
The buttons on this screen are identical to those used in the manual injection modes, in order to define what autosprue configuration is connected to the machine. Please review section 3.5 for a description of how to configure this screen correctly. When the required selections have been made, press the right button in the lower right of the display to advance to the next screen. If at any time, you wish to navigate to a previous screen, to change or check a value, simply press the left arrow in the lower left of the screen.
The third recipe edit screen allows the user to specify whether the injection should be controlled by head or mould pressure. Variables to define the injection can then be entered, including pressure set point (SP) and target volume of resin to inject.
The button towards the top of the screen specifies the type of control to be used during the injection. Pressing this button will toggle between mould pressure control and head pressure control. The remainder of the display will show the variables, which can be configured to define the injection catalyst ratios, pressure SP, available pump power and volume to be injected.
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Figure 3.7 – Recipe edit screen 2
A major difference between manual operation and automatic recipe control is that recipes give the user the ability to utilise a Progressive Catalysation Ratio (PCR). This is where the user can specify a desired start and end percentage for the catalyst ratio. During an automatic injection, the machine will linearly vary the percentage of catalyst, based upon the volume of resin injected.
Figure 3.8 – Recipe edit screen 3 (head pressure control)
Figure 3.8 shows the appearance of the display when head pressure control is selected, while Figure 3.9 illustrates the mould pressure set up screen.
Select the required control mode and then set all of the variables for the injection, including the required volume of resin to inject. Press the right arrow button to advance to the next screen.
The penultimate screen, illustrated in Figure 3.10, is concerned with temperature compensation. This feature allows the user to configure the machine to automatically adjust the start catalyst percentage and the end catalyst percentage, based upon the ambient temperature in the workshop.
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Figure 3.9 – Recipe edit screen 3 (Mould pressure control)
This feature can be used to more accurately control process times, when temperature controlled tooling is not being utilised.
This mode can be enabled or disabled by toggling the button at the bottom of the screen.
When enabled, a list of temperatures and adjustments is shown in the centre of the screen. The temperatures range between 15 °C and 30 °C, and represent possible
ambient temperatures at the beginning of an automatic injection. For each temperature a corresponding start and end catalyst compensation value is shown.
Figure 3.10 – Recipe edit screen 4 (Temperature compensation enabled)
If temperature compensation is enabled, when an injection begins, the machine reads the ambient temperature in the workshop, and then uses the start and stop percentage compensation values related to the closest temperature entry in the table. The compensation values are added to the corresponding start and end percentages specified in the recipe. If the result of this addition is below 0.5% or above 4.5% (out of range) the closest in range percentage is used.
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The final screen, shown in Figure 3.11, allows the user to either save the changes made to the recipe or to quit the recipe editing interface without committing changes to memory.
Simply press the SAVE button to save the recipe that has been created or modified. A message confirming the data has been saved successfully will be displayed, and the operator may leave the recipe editing mode by pressing the OK button.
If the user wishes to quit editing a recipe, without saving changes, press the CANCEL button.
Figure 3.11 – Final recipe edit screen
NOTE: If the PLC battery is not replaced when necessary, all recipe information will be lost.
NOTE: Upgrading the PLC application will result in the loss of recipe information.
Example: 2 litre bucket recipe
This example explains how to create a recipe named “2 litre bucket”. This is a simple recipe that will dispense 2 litres of catalysed resin into a container using head pressure control. It is suggested that this recipe, or a variation on it, is used to calibrate the machine, as described is section 2.6.
To create the recipe, complete the following steps:
1. From the edit recipes menu, select an “EMPTY” recipe and then press the
EDIT button.
2. On edit recipe screen 1, press the recipe name button and enter “2 litre
bucket”. Add the comment “Machine calibration recipe”. Press the right arrow.
3. On edit recipe screen 2, ensure all the sprues are disabled (grey). Press the
right arrow.
4. On edit recipe screen 3, select the head pressure control mode. Enter 2% for
the catalyst start and end percentage values, which will cause the machine to use the same catalyst percentage throughout the injection. Enter 1000 mbar (1
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bar) for the head pressure SP, 2 litres for the required quantity of resin to inject and 15% for the pump power setting. Press the right arrow button.
5. On edit recipe screen 4, ensure that temperature compensation is disabled.
Press the right arrow button.
6. On the final edit recipe screen, press the SAVE button to retain the settings
which have been entered. Press the OK button to finish creating the “2 litre bucket” recipe.
3.10. Automatic Injections
To perform an automatic injection, select the AUTOMATIC INJECTION button on the main menu to navigate to the automatic injection recipe selection screen shown in Figure 3.12. The currently selected recipe is highlighted with a white bar. To select a different recipe, use the up or down arrows at the bottom left of the screen to scroll through the list. If the number of the required recipe is known, the operator can also select the recipe by pressing the NUM button and entering the recipe number. When the correct recipe has been selected, press the SELECT button to proceed.
Figure 3.12 – Automatic injection recipe selection
When a recipe has been selected, the screen displayed will depend upon the type of injection configured in the recipe; namely, mould pressure controlled or head pressure controlled.
The screen displayed for head pressure control is shown in Figure 3.13. At the top right of the display, four status indicators illustrate the sprue configuration of the recipe, from left to right sprue 1 to sprue 4 respectively. A grey box containing a D indicates the sprue is disabled. A green filled box indicates an enabled sprue; while a green box, containing an L shows that the sprue is enabled with limit switch monitoring. Care should be taken by the user, to ensure that these settings agree with the hardware actually connected to the system.
Below the screen title, and sprue configuration indicators the name of the selected recipe is displayed for operator reference.
The elapsed time timer begins running when the user starts the injection. This timer continues to run until the injection has completed or been aborted by flushing the
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machine early. It should be noted that this timer will continue to operate if the injection is paused.
The resin volume set point (SP) value shows the target volume of resin, specified in the recipe to inject. The actual volume that has been injected is shown below, and is updated continuously throughout the injection.
The catalyst start the end percentages, defined in the recipe are shown. During the injection the current catalyst ratio is also displayed for reference.
The head pressure set point defined in the recipe, shows the desired head pressure to be maintained during the injection. Below this, the actual head pressure is displayed.
Resin flow rate gives the operator the opportunity to monitor the flow rate of the resin during the injection.
At the right of the screen, below the recipe title is an indicator displaying HD. This indicator is intended to inform the user at a glance that the machine is in head pressure control mode. If temperature compensation was enabled within the recipe, a second indicator would appear under the HD indicator containing the letters TC.
Figure 3.13 – Automatic injection using head pressure control
The GRAPHS button can be pressed to view process graphs of the injection operation.
The VALUES button can be used to display a screen displaying a range of useful operational parameters.
To return to the main menu without commencing the injection, the user may press the CANCEL button.
To start the injection, press the START button. The sounder beacon will operate to warn users of machine start up, and then the catalyst ratio arms will move the catalyst pump to the start percentage value. The head valves will then move to the injection position, selected sprues will open and the injection will start.
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In order to pause the machine during the injection, press the STOP button. If you wish to end the injection prematurely, press the FLUSH button when the machine is in the paused state.
To restart the machine when paused, simply press the START button once again.
When the machine has finished injecting the quantity of resin specified in the selected recipe, it will move the head valves back to the recirculation position and closed any selected sprues. The machine will then proceed to flush the system automatically, using the same system described in section 3.8.
Figure 3.14 – Automatic injection using mould pressure control
When the recipe selected utilises mould pressure control, the user may operate the machine in an identical way to that described above.
The only differences to the display, an example of which can be seen in Figure 3.14, are the mould pressure set point (SP) and actual mould pressure values are displayed instead of the head pressure SP and actual head pressure values. Additionally, and indicator containing the letters MD, is displayed below towards the top right of the screen, below the recipe title.
3.11. Logout/Shutdown
When the user wishes to stop using the machine, they must firstly logout of the system. The machine should not be left unsupervised when a user is logged on; in order to ensure that unauthorised users do not use the machine irresponsibly. To logout select the LOGOUT/SHUTDOWN button from the main menu to navigate to the login screen, which will appear as shown in Figure 3.15.
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Figure 3.15 – Login screen showing logout button
Press the LOGOUT button to logout. The buttons on the screen will change to the format shown in Figure 3.16. Press the SHUTDOWN button to navigate to the shutdown screen illustrated in Figure 3.17.
Figure 3.16 – Login screen showing shutdown button
Press the button in the centre of the screen to prepare the machine for shutdown. Wait until the “IT IS NOW SAFE TO TURN OFF THE MACHINE” is displayed before removing the electrical and air supply from the machine. The “QUIT APPLICATION” button should only be used when maintenance is being carried out by trained personnel.
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Figure 3.17 – Shutdown screen
4.12. Graphs
The graphs screens can be reached from any of the injection screens, and display a different series of variables depending on whether the machine is in mould or head pressure control modes.
The display for graphs, when the machine is in mould pressure control, is shown in figure 3.18. The variables currently being displayed are specified on the button positioned to the right, at the top of the screen. Pressing this button will advance to the next set of variables, which can be displayed.
Figure 3.18 –Mould pressure mode graphs screen.
If two traces are displayed, the green line indicates a set point value, while the red line shows the process variable in real-time.
For example, in mould pressure mode, the user has access to the followings graphs:
1. Mould pressure & mould pressure set point
2. Flow rate
3. Catal & Catal threshold
4. Head pressure
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To exit the graphs screen, and return to the prior screen, press the back arrow at the top right of the screen.
4.13. Values screen
Figure 3.19 shows the values screen, which can be reached from any of the injection screens.
This display has been designed the give the user access to data that may be of use during an injection.
To return to the previous screen, press the DONE button.
Figure 3.9 – Values screen
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4. Configuration
The configuration and maintenance menu screen shown in Figure 4.0, can be accessed by pressing the CONFIGURATION & MAINTENANCE button on the main menu screen. These buttons allow the operator to select various screens, which allow the user to configure how the machine functions and can also be used assist maintenance operations. To return to the main menu, press the DONE button.
Figure 4.0 – Configuration & maintenance menu
4.1. Recirculation
The recirculation configuration screen can be seen in Figure 4.1 and gives the user the ability to adjust how the recirculation function operates.
Figure 4.1 – Recirculation configuration screen
The maximum recirculation pressure button is used to set the maximum amount of pressure, which can be selected to operate the pumps on the recirculation screen. If for example, this value is set to 2 bar, when the recirculation rate is set to 100% on the recirculation screen, 2 bar would be delivered to the air cylinder driving the pumps. If the recirculation rate was adjusted to 50%, 1 bar would be supplied to the air cylinder and so on.
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The recirculation start warning time is the amount of time in seconds that the sounder beacon operates before recirculation begins. This feature is provided as a safety feature to warn operators the machine is about to start.
The recirculation stall time is used to set the maximum duration in seconds, which is permitted to elapse before a recirculation stall fault is triggered. Therefore, if the pumps stop during recirculation due to inadequate pressure being supplied to the air cylinder, the user will know.
4.2. Flush
The flush configuration screen shown in Figure 4.2, allows the duration of flushes to be set for both single flush and flush sequencer configurations.
The first button, flush warning time, is used to set the duration of the flush warning count down timer in seconds. When adjusting this value, it should be remembered that during this warning is the only opportunity for the user to cancel the flush.
Figure 4.2 – Flush configuration screen
The initial flush duration, sequenced flush time and final flush duration values are all used by the flush sequencer when multiple autosprues are used. The initial flush duration and final duration additionally have associated enable and disable buttons. To change the duration of a flush, simply press the required button and enter the desired time in seconds. It is recommended that a flush should last for at least 30 seconds; hence this is the minimum value which may be entered.
When multiple autosprues are connected to the system, if desired, the flush sequencer can be used to control which autosprues are flushed. Table 4.0 illustrates the operation of the flush sequencer when four autosprues are connected to the system (solvent system recharge between flushes not illustrated). The initial flush and final flush, where all of the autosprues are flushed together, can be separately disabled if required by toggling the associated enable/disable buttons. The duration of the individual flushes is determined by the sequenced flush time value.
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Sequence Step Autosprue 1 Autosprue 2 Autosprue 3 Autosprue 4
1 FLUSH FLUSH FLUSH FLUSH 2 FLUSH 3 FLUSH 4 FLUSH 5 FLUSH 6 FLUSH FLUSH FLUSH FLUSH
Table 4.0 – Four autosprue flush sequence
For single autosprue operation or for use without autosprue the single sprue flush duration is used.
4.3. Catal Alarm
The Catal configuration screen can be seen in Figure 4.3 and allows the user to adjust the threshold of the Catal alarm. On each complete stroke of the catalyst pump, the maximum output from the Catal transducer in the outlet line from the catalyst pump is recorded and compared with the Catal threshold value. If this reading falls below this threshold an alarm is raised.
Figure 4.3 – Catal configuration screen
The reading from the Catal has no units, and is an indicator of flow. The full range of this unit has been calibrated to give a range of 0-100%. It must be remembered that depending on the percentage of catalyst used and flow rate, the value of this threshold will vary and it should be set to accommodate the lowest catalyst percentage at the lowest flow rates being used. This value should be set by monitoring the Catal graph during an injection to get an indication of what setting should be used.
If the threshold is set to 0, an alarm will never be generated. This value should only be used for maintenance procedures, which may include determining an appropriate threshold value.
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4.4. Resin Alarms
The resin alarms configuration screen is shown in Figure 4.4.
The Resin Gel Alarm (RGA) is used to warn the operator of the possibility of mixed resin and catalyst gelling in the mixing head. When an injection has been commenced, if a complete pump stroke is not registered in the time specified by the RGA timer value, an alarm is raised. This value must be set by the user based upon the type of resin system being utilised, and the gel time of that system under the operating conditions in which the machine is put into use.
Figure 4.4 – Resin alarms configuration screen
If required, an external resin level sensor may be connected to the machine, to prevent an injection from being started if insufficient resin is available. This feature may be enabled or disabled by toggling the resin level sensor button.
The injection start warning time, is a value in seconds that specifies the elapsed time after the injection start button is pressed, before the injection starts. This is provided as a safety feature to warn operators that the machine is about to start and during this time the sounder beacon operates.
4.5. Head Pressure Clipping
Head pressure clipping is provided as a safety feature to prevent the pressure at the mixing head from remaining at an unsafe limit. This option protects the supply line to the mould by removing power from the pumps when a maximum level is reached and is predominately used in mould pressure control mode. However, if enabled the function also limits the line pressure in the head pressure control mode.
The head pressure clipping enable/disable button, which is shown in Figure 4.5 can be toggled to control whether head pressure clipping is active.
If the clipping is enabled, the head pressure clip value specifies the maximum pressure in mbar, which should be delivered at the mixing head.
The deadband value is used to set the value to which the head pressure must fall in order for power to be reapplied to the pumps. To determine this lower value the
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deadband pressure is subtracted from the head pressure. The deadband value can be used to provide a more stable reaction of the control system to clipping. As a general rule, as the deadband value is reduced towards 0, the pumps will run less-smoothly.
Figure 4.5 – Head pressure clipping configuration screen
For example, if the head pressure clip value is set to 10000 mbar (10 bar) and the head pressure clip deadband is set to 1000 mbar (1 bar); power will be removed from the pumps if 10 bar is reached in the supply line to the mould. Power will not be re­supplied to the pumps until the supply line pressure drops to 9 bar.
It is recommended that head pressure clipping is always enabled.
4.6. Calibration
The calibration configuration screen shown in Figure 4.6, allows the user to set the volume of resin per stroke. This value will directly affect all volume calculations carried out by the machine and therefore should only be adjusted with caution.
For more information regarding pump calibration, please see the relevant paragraphs in the commissioning section of this manual.
Figure 4.6 – Calibration configuration screen
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5. Alarms & Faults
This section describes all of the alarms and faults, to which the machine may alert the user during operation. When an alarm is triggered, the alarm screen will be displayed, an example of which can be seen in Figure 5.0. This screen can also be viewed by pressing the ALM button, which can be found on a number of screens including the main menu screen. All active alarms are shown is the list, along with the time that the alarm occurred. If there are too many alarm messages to fit on the screen at any one time, the up and down arrows may be used to scroll through the list. The currently selected alarm is highlighted by the blue bar, and this is the alarm which will be acknoweledge if the user presses the ACKNOWELEDGE button. To return the previous screen, press the CLOSE button.
Figure 5.0 – Alarms screen
5.1. Release E-Stop and press reset button
This alarm will be displayed when the e-stop button is pressed. It may also be displayed if the user does not reset the e-stop circuit on power up, before the HMI application has loaded.
To clear the alarm, firstly ensure it is safe to re-start the machine. Then disengage the e-stop button (pull up) and then press the reset button on the side of the machine.
If these actions fail, firstly check that air is correctly being supplied to the machine. If the safety circuit still fails to reset, a suitably trained technician should be called.
This alarm stops the machine.
5.2. Recirculation pump stall
This alarm is shown if the pumps do not complete a full stroke in the time specified in the recirculation configuration (see section 4.1).
Acknowledge the alarm to clear it. This alarm stops the machine.
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5.3. Resin gel alarm (RGA) – Flush machine!
If during an injection, the pumps do not move a complete stroke in the time specified in resin alarms configuration screen (see section 4.4), this alarm is generated. This alarm is designed to prevent the user accidentally allowing resin to gel in the mixing head, and indicates the pumps have stalled during an injection.
To clear the alarm either flush the machine or adjust machine settings to make the pumps start pumping once again.
5.4. Autosprue 1 position error
This alarm is produced if a sprue is enabled with limit switch monitoring, but fails to report the correct position during an injection. To clear the alarm the fault must be corrected. See Table 5.0 for a list of possible problems and suggested actions to provide a solution.
This alarm will prevent the operator from starting the machine and stops the machine.
Problem Suggested solution
Sprue mechanically prevented from moving between open/closed states Sprue does not change position Ensure air line is correctly connected Sprue moves correctly Are electrical connections connected
No limit switches in use Disable limit switch monitoring
Service auto sprue
correctly/wiring fault
Table 5.0 – Possible causes for autosprue position errors and remedies
5.5. Autosprue 2 position error
See section 5.4.
5.6. Autosprue 3 position error
See section 5.4.
5.7. Autosprue 4 position error
See section 5.4.
5.8. Motor comms error
This alarm is displayed if the motors fail to respond to a communications request from the PLC. If this error occurs, it implies that an equipment failure has occurred and a suitably trained maintenance technician should be informed. Acknowledge the fault to clear it.
5.9. Motor fault
This is a general motor fault condition. Ensure the e-stop button is not activated and safety circuit has been reset. Powering the machine down and then restarting after waiting for 60 seconds can be tried, if the alarm persists.
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If the alarm continues to be generated, a suitably trained maintenance technician should be informed.
Acknowledge the fault to clear it.
5.10. Catal alarm!
This alarm is raised if the flow of catalyst is under the threshold specified in the Catal alarm configuration screen (see section 4.3). This alarm is has been designed to prevent the operator from producing an under-catalysed part, due to incorrect machine setup or failure of catalyst fluid system.
To clear the alarm, acknowledge it when the catalyst flow has risen above the threshold level.
5.11. Cat over pressure
If the catalyst fluid system exceeds a safe operating pressure, this alarm will be displayed. A suitably trained technician must ensure the catalyst line is free form blockages etc.
Correct the fault to clear the alarm. This alarm will stop the machine and prevent it from being started.
5.12. Air pressure < 5 bar
The machine must operate on an air pressure of between 5 – 7 bar. Adjust the regulator in bay 2 to clear this fault.
This alarm will prevent the operator from starting the machine.
5.13. Air pressure > 7 bar
See 5.12.
5.14. Resin low
If a resin level sensor is connected and enabled in the resin alarms configuration screen (see section 4.4), this alarm will be displayed if an injection is started with insufficient resin available.
Top-up the resin supply to clear the alarm. This alarm will prevent the operator from starting the machine.
5.15. Catalyst level low
If the catalyst level is too low when an injection is commenced, this alarm will be triggered and the injection will be prevented from starting.
To clear the alarm, top-up the catalyst container. This alarm will prevent the operator from starting the machine.
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5.16. Solvent level low
If the solvent level is too low when an injection is commenced, this alarm will be triggered and the injection will be prevented from starting.
To clear the alarm, top-up the solvent container. This alarm will prevent the operator from starting the machine.
5.17. Motor reference lost – re-home
When the machine is initialised at start up, the motors are homed to establish an index position. If the motors use this reference during operation, this alarm is displayed.
To clear the alarm, home the motors. This alarm will prevent the operator from starting the machine.
5.18. Head valve position fault
Before and after an injection, the head valves will move from recirculate to inject and vice versa. These valves are electrically monitored to ensure that they are in the correct position. If the position of either the resin or catalyst valves is incorrect, this alarm will be triggered.
This alarm will stop the machine and prevent the operator from starting the machine.
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Section 6 – Maintenance
The Megaject RTM Machine range has proved to be extremely reliable in service. To maximise service life, it is important to keep the machine free from dirt and contamination, and follow correct procedures for use and maintenance as instructed in this manual.
This section discusses routine maintenance and fault finding procedures which can be used on the machine, in addition to screens which have been built into the system to make this process easier. Maintenance should be carried out by properly trained and authorised personal only. Improper use of some of the operations described may cause damage to the machine or injury to personnel.
To order spare parts for your machine, please indicate the relevant part number shown on the drawing for the part required.
6.1. Health & Safety
Please read this section before attempting any maintenance of your machine.
We advise that you adhere to the following guidelines when servicing your RTM Megaject Pro:
• Eye Protection and protective clothing and gloves MUST be worn for all
maintenance operations.
• Before carrying out any maintenance on this equipment, remove air supply
from machine.
• Be aware that residual pressures may exist in fluid lines even when the
machine is isolated from the air supply. Take care when removing fittings.
• We recommend that if any work is to be carried out on the fluid sections (i.e.
resin, catalyst or solvent) that they are pumped empty prior to maintenance.
• Ensure there are no sources of ignition present when working on the solvent
system.
• All work must be carried out by a suitably qualified person
6.2. Routine Maintenance of Fluid and Mechanical Systems
By following a series of simple common-sense guidelines, the machine can be correctly maintained, and failures due to neglect can be avoided. General guidelines, which should be applied to maintaining the machine, are as follows:
• Ensure all working parts of the machine are kept clean.
• Remove all spillages from machine.
• Immediately correct any air leaks.
• Immediately correct seepage of any fluid from machine.
• Ensure all mechanical parts are free to move and correctly lubricated
• Ensure all external electrical connectors are free from debris and correctly
covered when not in use.
• Ensure all exposed pneumatic connectors are suitably plugged when not in
use.
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• Ensure that after maintenance has been performed, the doors to bay 1 and bay
2 are locked to prevent access by unauthorised personnel.
6.2.1. Resin pump
During normal use the resin pump lubrication cup needs to be topped-up with pump lube. This should be checked at least once a week during normal daily production use.
Check the shaft seal (0549) for signs of wear, such as cracks and leaks. A calibration test can be performed in order to ensure that the piston seal (0555) is not badly worn or damaged. If less resin is delivered than expected, resin is leaking over the seal as the piston moves in the pump, and therefore the seal should be replaced.
Seal lifetimes will vary between customers based upon operating environment, resin system used and operational practices etc. Each customer should develop their own service schedule based upon their experiences, to find the optimum replacement period.
It should be noted that unnecessary use of recirculation can shorten the lifetime of seals.
6.2.2. Catalyst Pump
The catalyst pump needs no regular maintenance. However, any seepage producing catalyst spillage from the machine through the top seal indicates the catalyst pump top seal should be replaced. Seepage of catalyst NOT producing leakage onto the workshop floor from this point on the catalyst pump is acceptable.
Visually check security and condition of catalyst feed pipe from Catalyst bottle and recirculation pipe and all associated fittings. If any show signs of wear, seepage or distortion, replace with new parts immediately.
The catalyst inlet filter located within the catalyst bottle should be removed and cleaned in solvent and water at least every 4 months.
The Catalyst bottle internals must remain clean. If catalyst appears to be discoloured or any form of sediment is observed within the catalyst bottle, remove and clean as necessary. Dry out the catalyst bottle before refilling with fresh catalyst and placing back into service.
Replace worn or damaged components in the catalyst system only with the genuine replacements from Plastech. Failure to observe this guidance could cause adverse material reactions which result in the failure of the catalyst system.
6.2.3. Resin & Catalyst Pipework
If air is being drawn into the system and air bubbles are observed in the recirculation return lines, check the integrity of all inlet pipes, joints and connections.
Joints should be tight and sealed correctly using a proprietary thread sealant. Do not use sealant on cone and seat type joints.
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6.2.4. Solvent Pump System
The Solvent tank requires no routine maintenance. However, if dirt particles and sediment accumulate within the solvent tank base, remove the solvent pump and clean the solvent container before refilling the tank with fresh solvent.
The remaining solvent system should only be routinely maintained by weekly checks to locate any leaks or damaged pipes which should be rectified immediately.
6.3. Resin System Re-priming
This procedure is to be carried out when the operator wishes to change the resin in a machine that has already been commissioned.
To re-prime the system, perform the following steps:
1. Remove the resin pick-up pipe from the resin and then recirculate the machine
to empty the fluid lines.
2. In order to clean the lines and pump, place the pick pipe into a solvent
container and recirculate until clean solvent is observed at the recirculation pipe. This step may be skipped, if the new resin is used to chase through and purge the older resin from the lines.
3. Place the recirculation pipe into a waste container and then put the pick-up
pipe into the new fluid. Recirculate the machine until all the solvent is discharged for the system and new fluid is observed at the recirculation pipe.
4. Place the recirculation pipe into the fluid container with pick up pipe.
5. Continue recirculating until material is free of all air bubbles.
NOTE: If the new material is of a similar chemical type to the existing material, then it may not be necessary to clean the system with solvent before loading the new material.
NOTE: DO NOT leave the machine empty OR full of solvent for extended periods.
6.4. Preparing the Machine for a Period of Inactivity
If the RTM Megaject Pro is likely to be unused for a long period of time, such as during a factory shutdown, care must be taken to prepare the machine against accelerated resin gelling inside the entrance to the mixing head. The fittings from the resin recirculate valve to the first NRV are always static and not recirculated. It is important therefore to flush this forward with unaccelerated resin when setting the machine for close down.
This is achieved by firstly purging the machine of accelerated resin and the refilling the machine with un-accelerated resin by using the recirculate mode. The operator should then use the manual injection mode to inject a small quantity (1-2 strokes) of unaccelerated resin into a suitable container. The machine should then be flushed normally, taking care to direct the mixing head outlet into a suitable receptacle. This will ensure that resin that remains in the mixing head at NRV 1 (see section 4.3), is unaccelerated and therefore will not react with surrounding materials and catalyse.
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6.5. Replacing Resin Pump Seals
In order to service internal resin pump seals first pump out any resin from internals by placing system on recirculation. It is also advisable to clean internals with solvent after resin removal before service. Do this by re-circulating 5 litres solvent through resin pump and finally pumping the solvent out from the system.
NOTE: Before disassembling pumps, Switch Off machine and Isolate machine from air supply.
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To access Piston seal (part 0555) remove 4 x M8 securing bolts (Part 0559). Slide Pump cylinder (0548) and lower gold block assembly (0558) from piston.
The piston seal may now be removed by unscrewing seal retainer nut (0556). Replace seal observing that the seal lip must face UP and valve ball (0554) is placed back into cage (0551)
The piston is re assembled in reverse order to the above.
NOTE: If the shaft seal (0549) is to be replaced proceed further without re assembling the Piston and seal as above
To replace the shaft seal (0549) it is necessary to remove the top block (0546) from the machine. To do this first remove piston bolt (0342) and the four M8 retaining bolts accessed from the underside of top block.. This will allow the top block to be drawn down shaft away from the four square air motor pillars.
Using circlip pliers remove large circlip (0544). Remove washer (0545). Remove old seal (0549) and discard. Install new seal and re assemble pump in reverse order.
NOTE: O ring top and bottom seals (0547) may be replaced during these service operations if found to be damaged.
Reassemble in reverse order. Observe that medium strength thread lock should be used on piston bolt (0342)
Ensure pump assembly is evenly retightened with M8 tie bolts (0559)
When Pump is reinstalled in machine, renew pump seal lubricant in top seal block (0546)
6.6. Replacing Catalyst Pump Seals
Remove catalyst pump from ratio arms. Disconnect inlet and outlet hoses at swivel fittings (0153 and 0388)
Unscrew bottom (0522) and top (0528) from outer tube (0526). .
Slide pump cylinder (0525) out of top block and remove from piston and shaft (0539)
Unscrew piston seat (0531) from shaft locking against turning seal body (0529). Examine piston ball and spring. Replace if necessary.
Remove piston seal (1712) and piston bush (0530) from piston seat (0531).Replace piston seal and bush (1712 and 0530)
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Before reassembling the piston and in order to replace piston shaft seal (0535) remove Piston assembly by unscrewing seal body (0529) from shaft (0539). To prevent Shaft turning lock and hold lock nut (1698).
Slide Piston shaft out of top block (0528). Unscrew top seal block (0536) from top block. Remove shaft seals (0535) from top seal block (0536) and replace.
Remove felt washers (0538) and replace. Re assemble entire pump in the reverse order
6.7. Catalyst Over-pressure Valve Service
See catalyst Pump assembly drawing 22412-1.
Under normal operational circumstances the catalyst overpressure valve is maintenance free.
If catalyst leaks constantly from O/P valve body (1032), O rings (0750) must be replaced
Important Note: It is essential that the internal spring tension is not disturbed or readjusted in the event of servicing this unit.
To renew front O rings (0750) disconnect red signal pipe from OP valve body (fitting
0646). Unscrew whole assembly from catalyst pump using a 19 AF spanner on the forward stainless steel body (1032) taking care of any small residual pressurised catalyst as thread seal is broken. DO NOT turn or disturb the spring tension end cap (0671).
Hold brass body (1035) and unscrew stainless steel body (1032). Pull shaft (1033), and stainless steel tube (1034) from body, replace O rings (0750) and reassemble. Ensure washer (0338) is replaced and shaft is reinserted with rounded end into body. (1032)
Reassemble observing order illustrated. Ensure bodies (1032) and factory set brass body (1035) are correctly screwed together using PTFE tape or similar thread sealant.
Reattach valve to catalyst pump using thread sealant.
Reattach 4mm red signal pipe into fitting (0646) and re prime catalyst system to remove any air from the system.
6.9. Solvent Pump Service
Warning! Before commencing any work on the solvent system, ensure that the working area is free from any sources of ignition.
To test the solvent system, place injection nozzle in a waste container. Flush machine and check solvent output from injection nozzle.
To service solvent pump foot valve seal 0464, carry out the following procedure.
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Remove air supply from machine.
Remove pump form solvent tank by unscrewing red top. Pump will withdraw on end of two 6 mm nylon pipes.
Empty pump of all solvent by gently depressing foot valve (4481) through base plate (4446).
To open pump unscrew M12 Nut and capscrew (4463 and 4476).
Remove M6 foot valve retaining screw (4475) and lift foot valve retainer (4482) to access foot valve .
Renew O ring seal (0464).
Place small amount PTFE sealant tape onto thread of M6 screw (4475) and re assemble in reverse order ensuring foot valve retainer is positioned to centralise foot valve over inlet hole in base plate. Use new nylon seal washer (5745) under M12 washer (4479) and securing nut (4463) Replace pump assembly in tank and refit to machine frame.
6.9. Injection Head Assembly Service
NOTE: During maintenance avoid any cross contact of residue resin and catalyst.
Remove automatic catalyst recirculation valve and NRV 4 by loosening 2x M6 cap heads (6331) (illustrated and shown in pro head drawing below) and rotate S clamp (4112) . Pull whole assembly from head.
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Remove top head block bolts. Split head into two sections. Remove head block O ring.(0742) To remove NRV 3 (0042), first remove spring retaining pin ()503) Screw M8 bolt partially into the valve body (0493) and pull body to remove it from head. Block (0727)
NRV 2 may be unscrewed from the side port after removing 6 mm clear pipe at union (0665)
To remove Resin valve/actuator Assembly, unscrew swivel joint here (Note – small amount of resin will leak)
To split head blocks (0728 and 0727) Remove 2 x M6
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NRV1
NRV 2
To remove NRV 1 unscrew resin recirculation valve swivel fitting and then remove from top head block. It is not necessary to remove resin pipes. Note, a few drops of resin will leak out so be prepared with rag. When replacing this fitting, eliminate traces of resin in fitting with solvent then grease threads before re assembly
Inspect all head block and NRV galleries. If catalysed resin is evident, remove or replace parts as necessary.
To disassemble all NRV’s, remove spring retaining pin. PTFE cone (0489) can be replaced by removing spring from seat retainer (0490).
When using a new PTFE cone, press and turn into NRV seat using thumb pressure only to ensure a good seal. On re-assembly a suitable hook must be used to stretch the spring sufficiently to enable the retaining pin to be replaced.
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Re-assembly is a reversal of above procedures. Inspect head block O ring (0742), NRV 3 O ring (0747) and NRV 4 O ring (0693). Replace using a small amount of silicon grease to lubricate.
After re-assembly head must be flushed to check all seals are tight and head galleries are clean.
Mixer tubes will only require replacement if partial or full gellation/sedimentation has occurred in the injection head. They cannot be repaired and must be replaced.
To replace, first unscrew the over pressure protection sensor screw and plug.
Remove retaining screw and unplug over­pressure protection sensor plug before removing mixer tube
Remove mixer shroud (0060) from head. Remove mixer tube (0705) from shroud. Lightly grease new mixer tube AND shroud threads with silicon grease, ensure O ring (0696) is in position and replace in mixer shroud.
Re-attach to mixer head. Replace MPG pressure transducer O ring and refit plug ensuring electrical plug central screw is tightened.
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6.10. Progressive Catalyst Ratio (PCR) System
It should be ensured that the stepper motor assemblies used to position the catalyst pump on the ratio arms are regularly maintained. All bolts should be correctly tightened, with particular care that coupling between the motor shaft and catalyst drive is tight. Failure to ensure this could result in slippage and misalignment of the catalyst pump.
It should be noted that the top and bottom motors communicate with the PLC via an RS485 bus, and have each been given a different addresses. Therefore, the motors can not be interchanged. The top motor is has the address 1, while the bottom motor has the address 2.
Motors can be supplied already addressed, or the address of the motor can set on site. This must be done using specialised software running on a Laptop. Please contact Plastech for further information.
A dedicated screen is provided on the machine to trouble shoot motor faults. Please refer to section 6.11.1 for more information.
6.11. Maintenance screens
The machine has a number of screens which can be used to aid fault finding and maintenance procedures. All of these screens can be accessed from the configuration and maintenance screen, which can be selected by pressing the CONFIGURATION & MAINTENANCE button on the main menu screen.
6.11.1. Motor configuration screen
The motor configuration screen, shown in Figure 6.11.1, should only be used with caution. It is possible to damage or reconfigure the motors to prevent them working with the system from this screen, if the CMD buttons are used incorrectly. It is therefore recommended that the CMD buttons are only used by Plastech employees or under guidance from a Plastech representative. If a CMD button is press accidentally then simply cancel the pop up string entry dialogue, without pressing the enter key.
Figure 6.11.1 – Motors configuration screen
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The RESET button for each motor will send an initialisation string to reset the motor. This can be used to aid motor maintenance procedures. Please note; if a RESET button is pressed the motors MUST be re-homed before the machine is operated.
The series of flags, labelled Bk through to Bt are status flags for each motor. The meaning of each flag is described in Table 6.11.1.
The HOME button allows the operator to re-home the motors to the 0.5% catalyst position. This button can be used to clear a “Motor reference lost – re-home motors” fault.
The + button allows the user to increment the catalyst percentage; the motors will move to update the position.
The – button allows the operator to decrement the catalyst percentage.
In combination, the + and – buttons allow the user to drive the motors up and down the ratio arm to test the ratio drive is moving freely and as expected.
Motor System
Event State Flag Bk EEPROM I/O error Ba Over current Bs Syntax error Bu User array index error Bd Math overflow occurred Bm Negative limit Bp Positive limit Bx Index Bo Motor off Bh Overheat Be Position error Bw Position wrap around Bi New index available Bl Negative limit crash Br Positive limit crash Bt Trajectory in progress
Table 6.11.1 – Servo Step motor status flags
6.10.2. I/O check screen
The I/O check screen, which can be seen in Figure 6.11.2, has been provided to give the user access to all of the digital and analogue input signals. By pressing either the up or down arrows, the operator can scroll through list of machine inputs and monitor their values.
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Toggle buttons are provided to test the follows outputs:
• Flush sequencer valves 1 to 4
• Head position valves
• Autosprue open/close signal
The user must ensure that all valves are off (grey) before leaving this screen; otherwise unexpected machine operation may occur.
Figure 6.11.2 – I/O check screen
6.10.3. Diagnostics
The diagnostics screen gives information regarding the Allen Bradley PanelView Plus 600 human machine interface (HMI). This screen is illustrated in Figure 6.11.3 and should only be used by Plastech employees or under the direction of a Plastech representative.
Figure 6.11.3 – Diagnostics display
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Section 7 – Fault Finding
The Megaject RTM Pro machine has been found to be highly reliable, however when faults occur it can normally be traced to inappropriate operation or poor maintenance.
7.1. Programmable Logic Controller (PLC) System
The PLC machine controller can only operate correctly with the correct input signals, therefore unexpected faults have often been found to be due to poor connections.
Each digital PLC module has indicator lights, which can be used to determine the status of the various inputs and outputs. The I/O tables, listed in Appendix C, can be used to find the source of faults that may prevent the machine from operating correctly.
Figure 7.0 shows the PLC system located in Bay 1, while Figure 7.1 illustrates the order, model numbers an type of modules in the system.
Figure 7.0 – PLC system in bay
The digital inputs can also be monitored using the IO check screen (see section 6.11) and some of the digital outputs can also be tested.
In order to read the input values of the analogue input signals, the IO check screen can also be used.
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Figure 7.1 – Module configuration
Some of the inputs are alarmed and will cause the screen to display an error message if a mal-function occurs.
7.2. Wiring Fault – Diagnosis Example
If a “Head valve position incorrect” alarm is generated, this immediately focuses the fault to be either with the resin and/or catalyst valve being stuck in the wrong position, or the valve’s associated sensor switch being out of position or the switch’s wiring being faulty
As the machine mixing head is the main mobile part of the machine with several sensors and moving parts, connection faults may occur in this zone more readily as the head may be dropped or damaged against a mould.
In this example and any others concerning equipment and sensors associated with the machine head, checks can be made on the signals at the white head terminal box.
A system check should follow the following steps:
1. Locate the machine equipment part/section being flagged as faulty and check its correct mechanical function. In the case of the resin and/or catalyst valve example check that the valve changes from recirculation position to injection position by selecting IO check screen and operating the head valve test by touching the appropriate button on the screen. If the valve is seen to operate through 90º correctly proceed to the next stage. If not then service the valve.
2. Navigate to the IO check screen and ensure the digital inputs for the head valves are correct for the position of the head valves. Check the signals change correctly when the head vale is operated. If any of these conditions is not met then proceed to next stage.
3. Check the limit switch sensors on the valves actuators are in position and held tight with the locking screws. If any are found loose, or easily moved, then reposition until the appropriate signal switches at the appropriate valve position. If these sensors are found to be correct then proceed to the next stage
4. Remove the lid from the grey head terminal box and check terminals for loose wires. If these are all found to be tight and the inputs are still incorrect, proceed to next step.
5. Use a Digital volt meter (DVM) to check continuity of the circuit at the head terminal box with the aid of the head box schematic.
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Other signal fault conditions can be first traced by checking for correct inputs signal conditions during machine activity.
7.3. Common Problems – Non-electrical
This section describes a series of problems that have been encountered while using the Megaject RTM Pro, and suggests possible solutions.
1. Machine will not inject, when all sensors are correct. Possible causes: a. Injection pressure incorrectly set b. Gelled resin in static mixer or Resin valve head inlet c. Autosprue blockage d. Resin pump top seal dry and un-maintained
2. Autosprue is blocked. Possible causes: a. Insufficient air pressure available for efficient flushing b. Autosprue feed and or drain pipe too long or restricted c. High resin filler loading prevents efficient single flush cleaning.
3. Machine pumps run unexpectedly slowly. Possible causes: a. Resin injection pressure set too low b. Pump Power (%) set too low c. Excessive use of recirculation has led to ice build up on air motor and caused air starvation to motor
4. Poor catalysation resulting in wet patches in part. Possible causes: a. Catalyst system not primed sufficiently b. External head non return valve O ring not seating due to dirt or worn seal c. Catalyst system “gassing” in system d. Worn piston seal in catalyst pump
6. Small air bubbles in resin mix. Possible causes: a. Loose or poor sealing on pump inlet pipes or fittings
7. Short volume resin mix from head. Possible causes: a. Resin filter requires cleaning b. Resin filler loading too high or mix flow rate set too high for viscosity of mix. c. Worn piston seal in resin pump. d. Machine incorrectly calibrated.
NOTE: If the pumps do not run when signalled to do so, and all the checks made above have been carried out, one final check can be made to observe what pressure is being fed to the air motor which drives pumps. At the top and bottom of the main air cylinder in bay 2, a quick fit chrome connector can be located. This accepts a pressure gauge supplied with the machine. The pressure gauge is used in these circumstances
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to plug into the top or bottom connector. When the pump is signalled to run a pressure will be indicated on this test gauge and should read at least 0.5 to 1.2 bar before the pump will move. A pressure at the top fitting will indicate the pump should move down. A pressure reading at the bottom fitting will indicate the pump should move up.
If no pressure is observed under these circumstances it is necessary to trace the air circuit to locate the restriction and rectify. The digital indicator on the electro pneumatic regulator in bay 2 should indicate the pressure being fed to the air cylinder.
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Appendices
Appendix A – Air Circuits Appendix B – Electrical Schematics Appendix C – PLC I/O Connections Appendix D – Motor connector pin-out Appendix E – Megaject RTM Pro Manual Revision History Appendix F – Contact Plastech TT Ltd
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Appendix A – Air circuits
1. AB PRO AIR_03.dwg
2. AB PRO AIR – SEQ CON_01.dwg
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Appendix B – Electrical Schematics
1. AB PRO ELEC _03.dwg
2. AB PRO HEAD CIRCUIT_03.dwg
3. AB PRO PLC IO_03.dwg
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Appendix C – PLC I/O Connections
Module 1 - 1769-OB16 : 16 point digital output module
Terminal Signal description
+VDC OUT0 Head inject/recirculate valve OUT1 Flush valve OUT2 Autosprue valve OUT3 Flush sequencer valve 1 OUT4 Flush sequencer valve 2 OUT5 Flush sequencer valve 3 OUT6 Flush sequencer valve 4 OUT7 Alarm beacon OUT8
OUT9 OUT10 OUT11 OUT12 OUT13 OUT14 OUT15
DC COM
Module 2 - 1769-OF2 : 2 point analogue output module
Terminal Signal description
V out 0+ ITV control signal (0-10V : 0-8 bar)
I out 0+
ANLG
Com
V out 1+
I out 1+
ANLG
Com
+24V dc
dc NEUT
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Module 3 - 1769-IQ32 : 32 point digital input module
Terminal Signal description
IN 0 Resin valve - recirculate IN 1 Resin valve – inject IN 2 Catalyst valve – inject IN 3 Catalyst valve - recirculate IN 4 Safety relay status (E-Stop) IN 5 Catalyst over-pressure IN 6 Start IN 7 Stop
DC COM
IN 8 Air cylinder switch HI
IN 9 Air cylinder switch LO IN 10 Solvent level IN 11 Catalyst level IN 12 Resin level IN 13 Top motor home IN 14 Bottom motor home IN 15
DC COM
IN 16 Autosprue 1 open IN 17 Autosprue 1 closed IN 18 Autosprue 2 open IN 19 Autosprue 2 closed IN 20 Autosprue 3 open IN 21 Autosprue 3 closed IN 22 Autosprue 4 open IN 23 Autosprue 4 closed
DC COM
IN 24 24VDC CONTROL POWER CHECK IN 25 IN 26 IN 27 IN 28 IN 29 IN 30 IN 31
DC COM
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ANLG COM
ANLG COM
ANLG COM
ANLG COM
ANLG COM
ANLG COM
ANLG COM
ANLG COM
Module 4 - 1769-IF8 : 8 point analogue input module
Terminal Signal description
V IN 0+ Air preparation pressure sensor (1-5V : 0-10 bar)
V/I IN 0-
I IN 0+
V IN 1+ Catal sensor (0-5V)
V/I IN 1-
I IN 1+
V IN 2+ ITV pressure
V/I IN 2-
I IN 2+
V IN 3+ Mixing Head Pressure (0-10V : 0 - 10 bar)
V/I IN 3-
I IN 3+
V IN 4+
V/I IN 4-
I IN 4+ Mould Pressure (4-20mA : 0-2 bar absolute)
V IN 5+
V/I IN 5-
I IN 5+ Ambient temperature (4-20mA)
V IN 6+
V/I IN 6-
I IN 6+
V IN 7+
V/I IN 7-
I IN 7+
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Appendix D - Motor Connector Pin-out
Animatics Servo Step ST233
PIN Description Connection
1 User Port A N.C. 2 User Port B N.C. 3 User Port C N.C. 4 User Port D N.C. 5 User Port E N.C. 6 User Port F N.C. 7 User Port G N.C. 8 Main ground 0V (48V dc supply) & 0V (24V dc supply)
9 Main power +48V dc 10 Encoder A / step input N.C. 11 Encoder B / direction input N.C. 12 Ground (Isolated) 13 RS-485A (Isolated) 14 Brake control output N.C. 15 Busy trajectory output N.C. 16 User 5VDC reference N.C. 17 Main ground 18 Main power 19 Encoder A output N.C. 20 Encoder B output N.C. 21 RS-485B (Isolated) 22 Isolated 5VDC N.C. 23 Servo off output N.C. 24 Control power in +24Vdc 25 Main ground 0V (48V dc supply) 26 Main power +48V dc
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Appendix E – Megaject RTM Pro Manual Revision History
Date
1/6/98 1_0 New Manual 17/7/98 1_1 NT30 screen cover note amended 18/5/99 2_0 Updated to match PLC_05 and NT Ver 2_0 revisions. 27/9/99 2_2 Safety Note added
17/11/99 2_3 Emergency Flush Notes Added
3/4/00 2_4 Manual flush and Set date/time screens removed
04/11/03 3.1 Add flow control, setup, configure screens change.
20/03/04 4.0 Add Latest pneumatic circuit diagram – overall slight
05/04 5.0 Megaject V version updated with 3 valve head 12/04 5.1 Pages 15 and 16
19/05/05 6.0 Significant rewrite for special model with new PLC 04/08/2005 6.1 Changes made to machine during site visit documented 13/04/2006 7.0 Manual rewritten to reflect hardware change to Allen
Revision
Code
Revised Content
Parts drawings included in manual
grammar changes
Bradley control system
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Appendix F – Contact Plastech TT Ltd
If you have a query regarding your machine contact:
Machinery Technical Support Plastech Thermoset Tectonics Limited Manufacturing Technology Centre Chilsworthy Beam Gunnislake Cornwall PL18 9AT
Tel: +44 (0)1822 832621 Fax: +44(0)1822 833999
E-mail: support@plastech.co.uk Website: http://www.plastech.co.uk
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