NovaTec MCS-600 Series Manuel utilisateur

Phone 410-789-4811 Parts Email: parts@novatec.com

Toll Free: 800-938-6682 Service: servi[email protected]m

Main Fax: 410-789-4638 Sales: sales@novatec.com

222 E. Thomas Ave. Baltimore, MD 21225 USA

MCS-649 & -696 IM 9 FEB 2018

MCS-648 & -696 SERIES

Conveying Control

MCS-648 & -696 IM 9 FEB 2018 Page 2 of 40

TABLE OF CONTENTS

SECTION PAGE

1PURPOSE OF THIS MANUAL ............................................................................................................4

1.1 Explanation of Symbols....................................................................................................................4

2SAFETY PRECAUTIONS AND WARNINGS......................................................................................5

3GENERAL DESCRIPTION .................................................................................................................. 6

4SPECIFICATIONS ...............................................................................................................................7

5PLC OVERVIEW.................................................................................................................................. 8

5.1 General.............................................................................................................................................8

5.2 Startup And Power Loss ..................................................................................................................8

6OPERATING PRINCIPLES ................................................................................................................. 9

6.1 Material Conveying System (MCS)..................................................................................................9

6.2 Vacuum Power Unit (VPU)...............................................................................................................9

6.3 Molding Machine (MMS)..................................................................................................................9

6.4 VPU FIFO Queue...........................................................................................................................10

6.5 Alarms............................................................................................................................................10

7ADDING NODES (DEVICENET PLUG & PLAY)..............................................................................11

7.1 DeviceNet Remote I/O...................................................................................................................11

7.2 DeviceNet I/O Data Map................................................................................................................11

7.3 Status Lights ..................................................................................................................................11

7.4 Network Switches...........................................................................................................................11

7.5 Connector Pin-Outs........................................................................................................................12

7.6 Typical Field Wiring........................................................................................................................12

8NODE ADDRESSES..........................................................................................................................14

8.1 Loading Station Nodes...................................................................................................................14

8.2 VPU Nodes ....................................................................................................................................14

8.3 Unused Nodes ...............................................................................................................................14

9INSTALLATION .................................................................................................................................15

9.1 Mechanical Installation...................................................................................................................16

9.1.1 Material Conveying Lines......................................................................................................16

9.1.2 Vacuum Power Unit...............................................................................................................16

9.1.3 Cyclone Filter.........................................................................................................................17

9.1.4 Station Valves........................................................................................................................17

9.1.5 Single Inlet Vacuum Chamber...............................................................................................17

9.1.6 Compressed-Air Blowback....................................................................................................17

9.1.7 Purge Valves.........................................................................................................................17

9.2 Electrical Installation ......................................................................................................................18

10 CONTROLS EXPLANATION ............................................................................................................19

10.1 PanelView Plus 1000.....................................................................................................................19

10.2 Startup............................................................................................................................................19

11 OPERATOR SCREENS..................................................................................................................... 20

11.1 Main Menu .....................................................................................................................................20

11.2 Vacuum Pumps..............................................................................................................................22

MCS-648 & -696 IM 9 FEB 2018 Page 3 of 40

11.3 MCS Station Status........................................................................................................................25

11.4 Station Setup..................................................................................................................................27

11.5 Alarm Banner .................................................................................................................................30

11.6 Alarm History..................................................................................................................................31

11.7 System Setup Screen ....................................................................................................................32

11.8 Install Stations................................................................................................................................35

12 MAINTENANCE................................................................................................................................. 36

12.1 At Startup .......................................................................................................................................36

12.2 Monthly...........................................................................................................................................36

12.3 Every 3 Months ..............................................................................................................................36

13 TROUBLESHOOTING....................................................................................................................... 38

13.1 DeviceNet Network ........................................................................................................................38

WARRANTY ...............................................................................................................................................39

WARRANTY PERIODS:............................................................................................................................. 39

LIST OF TABLES PAGE

Table 8-1: Node Addresses .......................................................................................................................14

Table 11-1: Alarm Messages.....................................................................................................................30

Table 13-1: Indicator Lights.........................................................................................................................38

MCS-648 & -696 IM 9 FEB 2018 Page 4 of 40

1 PURPOSE OF THIS MANUAL

This manual describes the installation and operation of Novatec’s MCS-600 Series Material Conveying

System controller. Before installing this product, please read in their entirety, this guide and any

additional guides associated with the system’s auxiliary equipment.

1.1 Explanation of Symbols

This manual includes both general and task-specific safety precautions. These precautions are

highlighted in the manual by the following categories:

WARNING: This symbol identifies situations thatare potentially hazardous to

personnel or equipment.

NOTE Highlights information provided in text or procedures. This information may

or may not be related to safety.

MCS-648 & -696 IM 9 FEB 2018 Page 5 of 40

2 SAFETY PRECAUTIONS AND WARNINGS

These operating instructions must be read, understood, and implemented by all personnel responsible for

this system.

All mechanical and electrical work must be performed by qualified personnel only.

Always disconnect power before servicing.

Refer to the machine nameplate and drawings supplied with this system for actual power requirements.

Be sure to install the equipment in the proper electrical area according to the NEMA rating

specified. Care must be taken to adhere to all national and local regulations.

Electric power supply should be through a separate disconnect switch with properly sized

overload/fuse protection.

Thread protectors and caps provided on solenoid valves, traps, pipe ends, etc. must be removed

prior to start-up.

The customer is required to operate the equipment with all safety features in proper working

condition.

Novatec shall provide no further guarantee for function and safety in the event of unauthorized

modifications.

MCS-648 & -696 IM 9 FEB 2018 Page 6 of 40

3 GENERAL DESCRIPTION

The Novatec MCS-600 Series controller is a custom-programmed Allen-Bradley PLC-based control

system designed to incorporate existing and future equipment. The Material Conveying System (MCS)

will control up to120 JIT chambers and 20 Vacuum Pump Units (VPU).

Future loading stations are made available to operations on a password protected screen. Assignments

for current and future VPUs and Stations may be changed via a password-protected screen on the HMI.

Figure 1: MCS-600 Series Enclosure and Back-Panel.

Optional Ethernet

Module

MCS-648 & -696 IM 9 FEB 2018 Page 7 of 40

4 SPECIFICATIONS

Description

Material Conveying System Controller

Model No

MCS-648

MCS-696

Performance Specifications

Max No. of Dryers

Max No. of Vacuum Power Units

Max No. of Vacuum Receivers

Main PLC

Allen-Bradley CompactLogix L32E

Base Operator Interface

Allen-Bradley PanelView Plus 1000

Remote Operator Interface

N/A

Communications

DeviceNet, Ethernet

Output Voltage to Devices

24 VDC

Input Voltage from Devices

24 VDC

Dimensions (H x W x D) Inches

Main Base Unit

24 x 20 x 8

Remote I/O Base Unit

N/A

Power Requirements

Electrical Classification

NEMA 4 / 12

Base Unit

115 / 1 PH / 60HZ

DeviceNet I/O Power Supply

90 - 264 VAC, 50 - 60 HZ or 110 - 375 VDC, 2-4 Amps

Program Information

Operator Interface

PLC

MCS-648 & -696 IM 9 FEB 2018 Page 8 of 40

5 PLC OVERVIEW

5.1 General

The MCS-600 Series Material Conveying System Controller utilizes a centrally mounted PLC that

sends commands over the DeviceNet network to various conveying system components. A

remote I/O block controls each pump, station, loader, etc. The physical device and its associated

electronics form a ‘node’. Refer to the specifications page for the maximum number of Loading

Station and Vacuum Pump nodes supported by this system.

This type of control system requires much less wiring in order to install and maintain the material

conveying system.

The MCS’s programming allows for additional equipment to be installed at a later date without re-

programming.

5.2 Startup And Power Loss

When power is first applied to the PLC following a power loss, the system will automatically start loading

enabled stations that have material demand if the AUTO START ON POWER UP mode has been

selected. If a Loading Station or Vacuum Pump is enabled, as indicated by ON, it will remain enabled.

This prevents the operator from having to restart each piece of equipment. When first starting up, each

station will have to be configured with the proper vacuum pump assignment, load, fill and dump times, no

load alarm cycles, material number, and be enabled.

In the System Setup page is the button defining the power up mode:

This button allows the user to select the start-up mode for the

control panel: AUTO or MANUAL power up. In AUTO START ON

POWER UP, the control panel will automatically start filling

stations if they are enabled and demand material when power is applied to the panel. In MANUAL

START ON POWER UP, the system is paused and the user must press the SYSTEM START button to

begin loading stations.

When the system is paused, a large red indicator

button will appear on top of all screens to indicate

that the system is in PAUSED mode. Pressing the

red button will enable the system and put it in

SYSTEM RUNNING mode.

MCS-648 & -696 IM 9 FEB 2018 Page 9 of 40

6 OPERATING PRINCIPLES

6.1 Material Conveying System (MCS)

The program controls the operation of loading the Dryers from the Gaylords to filling the JIT

chambers on the Molding Machines from the Dryers. The MCS controls the operation of the

Vacuum Pump Units (VPU), the station “Tee” valves and the Purge (Source) valves. The MCS

must be in RUNNING mode for any conveying to take place. The MCS will default to STOPPED

mode on power loss. Starting or stopping the MCS will not reset the various station controls.

6.2 Vacuum Power Unit (VPU)

Each VPU is hard piped to multiple stations. Stations may be assigned to any VPU.

CAUTION: Care must be taken to verify that the mechanical connection of a station

valve to a VPU matches the VPU assignment of thatparticular station

A VPU will start when an associated loading station calls for material. The VPU will run for the

LOAD and PURGE portions of a fill cycle, plus a settable SEEK time. If no other station calls for

material, the VPU will shut down after the seek time expires. A new station calling for material

will reset the seek timer and begin a new fill cycle. The seek timer is accessible from the HMI

and has a default value of 120 seconds.

6.3 Molding Machine (MMS)

Each molding machine/press is equipped with a JIT Chamber complete with level switch.

The MMS control station consists of an Enable/Disable maintained pushbutton, Station Status

readout, Source okay/mismatch indication, and connected source readout. Enabling of a MMS

permits it to be automatically serviced by the conveying subroutine. A MMS may be Enabled or

Disabled at any time. If a MMS is in a fill cycle when it is disabled, the cycle will continue to

completion. MMS status indications are:

OFF – The MMS is Disabled

ENABLED – The MMS enabled, not in the fill cycle and the level switch is satisfied

DEMAND – The MMS is not in the fill cycle and the level switch calls for material

LOAD – The MMS is in the load portion of the fill cycle

PURGE – The MMS is in purge portion of the cycle

DUMP – The MMS is in the dump portion of the fill cycle

ALARM – MMS has gone through the no load alarm setpoint of consecutive fill cycles

without satisfying the level prox sensor.

The MMS number is moved into the appropriate VPU FIFO queue if the MMS is in demand. The

default setting for MMS VPU assignment is VPU1. The MMS fill cycle consists of three states,

LOAD, PURGE and DUMP. When the MMS is first in line, the VPU will start if not already

MCS-648 & -696 IM 9 FEB 2018 Page 10 of 40

running and the station T valve will open at the start of the fill cycle. Pellets will be conveyed from

the source to the vacuum chamber. The T valve will remain open for the load and purge times.

When the load time expires the dryer source valve closes and the purge time begins. The purge

time allows any pellets in the conveying line to be carried into the JIT chamber. When the purge

timer expires the station T valve is closed and the dump timer started. The VPU FIFO stack

advances to service the next station at the end of the purge time. Any pellets in the vacuum

chamber will be gravity conveyed into the press hopper.

If the level switch is not satisfied at the end of the dump time, the MMS will be placed back at the

end of the VPU queue. The load, purge, and dump setpoints are changeable via the HMI and

have default values of 15 seconds.

6.4 VPU FIFO Queue

Each VPU has a First In/First Out (FIFO) queue. Any station may be assigned to any VPU. The

queue contains the MMS number (1 to 120). The VPU services each station in the order in which

the demand was entered. A station is removed from the queue at the end of the purge cycle. At

this time the VPU begins to service the next station in the queue, if any. A station is still in

demand at the end of the dump cycle will be reentered into the queue. If there are no other

stations in the queue, the fill cycle will repeat as soon as the dump cycle is complete.

6.5 Alarms

Each MMS has a No Load fault. If the station is serviced the setpoint number of times in

succession without satisfying the level switch, the alarm flag is set. The alarm will be cleared

when the demand is satisfied, or the station is disabled. The number of cycles is field changeable

through the HMI, with the default value set at 3. Entering a value of zero (0) will disable the

alarm. A station will continue to load if the alarm is on.

The VPUs have motor failure alarms. The motor failure alarm is set whenever the motor is called

to run, but the motor aux contact input is not made after 3 seconds. The alarm is cleared only by

pressing the “ALARM RESET” button on the alarm history or banner page or the vacuum pump

status pages. Once a vacuum pump is in an alarm state, the controller will not allow that vacuum

pump to attempt to convey until the alarm is cleared.

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