PROCON GL

Type 4966

User Manual

Software: EB 1.1
Revision: V 2.0 e / 06.97
Document: G4966031.BE0
Contents subject to change.

All rights regarding this document, in particular the right to reproduce, or distribute or
translate it, are reserved.

No part of this document may, in any form, (by photocopying, via microfilm or any
other process) be reproduced, copied, distributed, or processed on any electronic
system without prior consent in writing from STRATEC GmbH.

In case of technical problems please contact our service:

STRATEC CONTROL SYSTEMS GMBH

Durlacher Str. 35
D - 75172 Pforzheim

Tel.: (0049) 7231 / 1377-46

Fax: (0049) 7231 / 1377-25

Please make sure to have the completed parameter list available.

Table of Contents i

TABLE OF CONTENTS i

SAFETY INSTRUCTIONS iii

IMPORTANT SYSTEM INSTRUCTIONS iv

1 INTRODUCTION 1
1.1 About this manual 1

2 GENERAL 2
2.1 Set-up of the computer system 2
2.2 Control principle 2

3 INDIVIDUAL OPERATING MODES 5

3.1 Filling Mode 5
3.2 Normal Mode 5
3.3 Run Empty 6
3.4 Synchronisation 6
3.5 Emergency-Stop 6
3.6 Service Mode 6

4 OPERATION 7
4.1 Operation Using Terminal (OPTION) 7
4.1.1 Setting Numerical Parameters 9
4.1.2 Setting Binary Masks 10
4.2 Operation Using Integrated LCD Display 11
4.2.1 Setting Nummercial Parameters 12
4.2.2 Setting Binary Mask 13
4.3 Operation Using a Laptop (Serial Interface) 13

5 EXPLANATION OF THE DISPLAYS 14

5.1 Operation Data 14
5.2 Installation 16
5.3 Servicemode 25
5.3.1 Adjustable Menu Points 25
5.3.2 Diagnostic Values (No Changes Possible) 26

6 HOOK SWITCHES 29

7 ALARM MESSAGES 31
7.1 General Alarms 31
7.2 Min., Max. and Default Values 33

PROCON GL
Table of Contents ii

7.3 Average Alarm 34

7.4 Emergency-Stop Alarm 34

8 INPUT AND OUTPUT SIGNALS 35

8.1 Meaning of Input and Output Signals 35
8.2 Input Signals 36
8.3 Output Signals 38
8.3.1 Digital Outputs 38
8.3.2 Analog Outputs 39
8.4 The Input signal MACH.READY (E4) 40
8.5 Logic Table for Programming the PLC. 41

9 INSTALLATION 42
9.1 Calculation example for conveyor speed and parameters 46

10 SERVICE NOTES 48

APPENDIX A : TECHNICAL SPECIFICATIONS I

APPENDIX B : MENU STRUCTURE FOR LCD DISPLAY II

PROCON GL
Safety Instructions iii

Safety Instructions

Please do always act according to the following safety instructions, before as well as
during operation of the system:

1. The system may only be operated by authorised personnel who are instructed for
this purpose.

2. The system is designed only for operation at a voltage of 24 V / DC.

3. For safety reasons the system has to be disconnected from main supply before
opening and reparing.

4. Only service staff from STRATEC or persons authorized by STRATEC are

allowed to carry out any kind of maintenance on the system.

5. STRATEC does not guarantee for the safety of staff or third persons caused by
incorrect handling of the system.

6. The system is not designed for operation in areas endangered of explosion.

7. The system is designed according to the regulations of IEC 1010-1 for electrical
systems.

PROCON GL
Important System Instructions iv

Important System Instructions

Follow these precautions:

• Do n o t s w i t c h o f f the device after production ends. This will help to

avoid malfunction due to condensation inside of the system.

• Device must n o t be w a s h e d or s t e a m e d down.

PROCON GL
Chapter 1 Introduction 1

1 Introduction

1.1 About this manual

Befor starting your work, this chapter gives you a short overview of the typographical
conventions used in this manual.

Syntax
The following parts of text are formatted in a special way:

Messages, that are displayed, will be printed in uppercase italics:

SERVICE MODE

Signal-Names will be shown in capitals:

CONVEYOR

Parameter-Names will be printed in capitals as well:

DETECTION RATIO

Keyboard-Entries normally are shown using the keyboard symbols in a separated

line.

If two keys have to be pressed at once, this appears as follows

ENTER and .

PROCON GL
Chapter 2 General 2

2 General
The conveyor control system PROCON GL ensures low-noise bottle conveyor
regulation from a single-track link between two machines.

A technically sohpisticated microcomputer system controls the speed of the drive

motors and also ensures a continuous supply of bottles in high-performance plant for
up to 100,000 bottles/hour.

Scuff marks and broken bottles are avoided through the smooth regulation of the
bottles.

The conveyor control system PROCON GL regulate the conveyors and the accepting
machine dependence to the feeding machine.

In the acceleration conveyor section gaps in the bottle flow and bottle jams are
detected by light barriers and reported to the microcomputer. It in turn calculates the
required conveyor speeds and transmits the values to the control electronics of the
conveyor belt motors and accepting machine.

The operation of this microcomputer are described in this operating manual.

2.1 Set-up of the computer system

The computer system comprises:

• Control electronics unit 4966 with integrated LCD display for installation in a control
cabinet

2.2 Control principle

Control is performed with 4 superimposed control circuits:

• gap control
• sliding control
• drift control
• synchronisation

PROCON GL
Chapter 2 General 3

Gap control
The control unit attempts to maintain a preset target gap size between the bottle stop
of the machine and the light barrier unit LS1, LS2, the gap section being located near
the light barriers.

The size of gap (GAP SIZE NOW) is determined by the machine clock (MT 1) and the
light barriers LS1 and LS2.
It is necessary for the signals LS1, LS2 and MT1 to function reliably.

If the actual gap size deviates from the preset target size, the conveyors are made to
run correspondingly faster or slowly.

The rate of rise of the characteristic can be parameterised.

Example :

Target gap = 2; actual value gap = 4 => 4% faster

Target gap = 2, actual value gap = 1 => 2% slower

Sliding control
If the bottle feed is so great that the gap control is no longer adequate to brake the
conveyors (actual value of gap = 0) and if the conveyor in the section of the light
barriers LS1, LS2 is slide under the bottles, this is detected by the set DETECTION
RATIO (switch-over to A 2) and the sliding control is activated.

The conveyors and the accepting machine are then accelerate by a certain
percentage (parameterisable).
The correct setting of the DETECTION RATIO is important for this. The outputs A 1
and A 2 are indicators for the setting.

Bottle speed = conveyor speed => A 1

Bottle speed < conveyor speed => A 2

Drift control
Long-term control corrects within certain limits an incorrect setting of the adaptation
values for dosing and drift. The so-called AVERAGE VALUE CNT. (normal value =
10000) serves as an indicator of this.

If the actual gap size deviates form the preset target size, the value is counted
correspondingly up or down.

PROCON GL
Chapter 2 General 4

If the drift control deviates by more than 6%, an alarm is given (A6 Ctrl. Drift).

Synchronisation
In order to guarantee that the actual value of the gap size is correct, the bottles are
automatically forced to slide (A 2) from time to time, i.e. the target gap is set internally
to 0 and conveyors decelerated. If sliding is now detected (A 2), the actual value of
the gap is set to 0 and again switched internally to the preset target gap size.

This process is repeated in the rhythm of the set number of bottles in parameter
SYNCHRONISATION unless no switch-over is made to A 2 for other reasons in the
meantime.

PROCON GL
Chapter 3 Individual Operating Modes 5

3 Individual Operating Modes

3.1 Filling Mode

If all the conveyors are empty before the start of production, they must first be filled
with bottles before the accepting machine can start its normal operation.

Switch on signal MACH. READY (E 4) =>

The computer system switches to the so-called slow filling mode (STATUS: slow filling
(0)).

The conveyors start to move. The speed can be parameterised with MINIMUM
SPEED 1 up to MINIMUM SPEED 8.

The slow filling mode is retained until LS3 is damped for x (BTL. STOP OPEN)
conveyor clocks and at the same time LS1 and LS2 no longer detect any movement
(bottle flow detection).

Operability is signalled, CTRL.READY (A 3) and normal mode are activated

(STATUS: normal mode (2)).
The conveyors stop until MACHINE CLOCK 2 (E 11) comes and the signal BOTTLE
STOP (E 10) is emitted.

3.2 Normal Mode

As soon as the MACHINE CLOCK 2 (E 11) comes and the signal BOTTLE STOP
(E 10) is emitted, the analog values are output. The size of the analog values depends
on the parameterś SPEED CONVEYOR 1 TO 8 (installation menu) and the controlled
variables.

When the MACHINE CLOCK 2 (E 11) is off, the conveyors continue to run until to a
gap, set in parameter BOTTLES TO STOP. Then the conveyors stop (analog voltage
= 0).

If the signal MACH.READY (E 4) disappears, the signal CTRL.READY (A 3) also

disappears and the analog output voltage of the conveyors reverts with the preset
RAMP DOWN to the minimum speed. The MINIMUM SPEED is then run until the
preset target GAP SIZE has been reached.

If, during this process, no bottle flow is detected, (LS3 damped for x conveyor clocks,
LS1, LS2 detect no motion), the conveyors are immediately switched off (analog

PROCON GL
Chapter 3 Individual Operating Modes 6

value = 0).
(x =BTL. STOP OPEN).

3.3 Run Empty

If the line is to be run empty, the signal RUN EMPTY (E 12) and then the signal
MACH.READY (E 4) can be given.

The signal CTRL.READY (A 3) is emitted and the STATUS empty conveyors (6)
signalled. If the signal BOTTLE STOP (E10) is on, the conveyors and the accepting
machine running with the adjustable parameter LINE EMPTY SPEED.

3.4 Synchronisation

If the control is synchronised, the STATUS is : synchronisation (4)

3.5 Emergency-Stop

The conveyors stop immediately when LS3 (E3) is damped for a adjustable number
(parameter EMERGENCY SET ) of MACHINE CLOCKS (E9) without LS1 or LS2
detecting a movement or LS5 (E5) is damped for a adjustable number (parameter
DELAY JAM-SWITCH) of CONVEYOR CLOCKS (E8) without LS4 (E6) detecting a
movement.

The signal CTRL.READY (A 3) then disappears.

The alarm output EMERG.STOP (A 5) is active.

The display flashes the fault message EMERG.STOP.

The STATUS is emergency-stop (7).

In order to start up again, the signal MACH.READY (E 4) must be switched off for
approximately 1sec. (for example bottle stop with the switch on/off).

3.6 Service Mode

For service purposes an operating mode is provided where the conveyors can run
individually with a freely selectable analog voltage.

The DETECTION RATIO can be established automatically.

PROCON GL
Chapter 4 Operation 7

4 Operation
The PROCON GL control unit can be operated in 3 different ways.

4.1 Operation Using Terminal (OPTION)

1 LS 1 1 STANDING
2 LS 2 2 SLIDING
3 LS 3 3 CTRL READY
4 MACH. READY 4 MON. ENABLE

5 JAM-SWITCH 5 EMERG. STOP

6 BOTTLEPRES. 6 CTRL DRIFT
7 REJECT INSP. 7 ALARM
8 CONVEYOR 8 RES OUT
9 MACH. CLK 1 9 ANALOG 1
10 BOTTLE STOP 10 ANALOG 2
11 MACH CLK 2 11 ANALOG 3
12 RES IN 12 ANALOG 4
13 TYPE SEL. A 13 ANALOG 5
14 TYPE SEL. B 14 ANALOG 6
15 TYPE SEL. C 15 ANALOG 7
16 TYPE SEL. D 16 ANALOG 8

ESC ENTER
PROCON GL

Figure 4-1: Front Panel

For the operation of the system a 16 x 20 lines alphanumeric LCD display and four
keys are available.

The display values (counter statuses and parameters) are selected by different
menues.

The following menu items can be selected:

Operating data => STATUS, SPEED, BOTTLETYP

PARAMETERMODE => Parameters
SERVICEMODE => Parameters serving service purposes

Apart from the menu item Operation data, all the others are only accessible after
initiation of a certain operating mode.

PROCON GL
Chapter 4 Operation 8

This mode is activated by simultaneously pressing the keys

ENTER and .

Then the menu item PARAMETERMODE is displayed.

The individual menu items can be selected with the arrow keys.

To get into the relating submenu the key

ENTER

is pressed for two seconds.

With the arrow keys, a particular item can be selected.

If at the first display position the arrow key

or at the last display position the arrow key

is pressed, the display automatically scrolls to the previous or next page.

With the key

ESC

the submenu is quit. The new value under this menu item will be confirmed and stored.

PROCON GL
Chapter 4 Operation 9

4.1.1 Setting Numerical Parameters

If a parameter has to be changed, select the parameter and press

ENTER

for appr. 2 second.

The display value then starts to flash.

With the arrow keys the value can be increased or decreased until the wanted value
or the fixed minimum or maximum values are reached.

If the arrow keys are pressed longer, a multi-stage fast run is started which counts the
individual values up or down in increments of 10 or 100. Some values are only
changed up or down in increments of 10 or 100.

Press

ENTER

to confirm the new value. The display will stop to flash.

The changed value is taken over directly by the computer and processed.

With the key

ESC

the editing end. The old value is indicate.

PROCON GL
Chapter 4 Operation 10

4.1.2 Setting Binary Masks

If a binary value has to be changed, select the parameter and press

ENTER

for appr. 2 seconds

A flashing cursor appears at the left digit of the mask.

With the keys

or

every position inside the mask can be selected.

With the key

ENTER

the actual value can be toggled to 1 or 0.

With the key

ESC

the new value will be confirmed and stored.

PROCON GL
Chapter 4 Operation 11

4.2 Operation Using Integrated LCD Display

For the operation of the system a A 2-line alphanumeric LCD display and four keys
are available.

PROCON GL

STRA TEC

ESC ENTER

TYP 4966

The display values (counter statuses and parameters) are selected by different
menues.

The following menu items can be selected:

MAIN MENU => Operating status etc.

INSTALLATION => Parameters
SERVICE MODE => Parameters serving service purposes

Apart from the menu item MAIN MENU, all the others are only accessible after
initiation of a certain operating mode.

To begin with the key

ESC

This operating mode is activated by simultaneously pressing the keys

ENTER and .

PROCON GL
Chapter 4 Operation 12

Then the menu item INSTALLATION is displayed.

This mode is quit by pressing the key combination again.

The individual menu items can be selected with the arrow keys.

To get into the relating submenu the key

ENTER

is pressed for two seconds.

The first display value then appears in the relevant submenu.

With the arrow keys, a particular item can be selected.

With the key

ESC

the submenu is quit. The new value under this menu item will be confirmed and stored.

The individual display values in the submenus are indicated in the Appendix C 'Menu
Structure for LCD Display'.

4.2.1 Setting Nummercial Parameters

If a parameter has to be changed, select the parameter and press

ENTER

for appr. 2 second.

The display value then starts to flash.

With the arrow keys the value can be increased or decreased until the wanted value
or the fixed minimum or maximum values are reached.

If the arrow keys are pressed longer, the value is changed faster.

Press

ENTER

to confirm the new value. The display will stop to flash.

PROCON GL
Chapter 4 Operation 13

4.2.2 Setting Binary Mask

If a binary value has to be changed, select the parameter and press

ENTER

A flashing cursor appears at the left digit of the mask.

With the key

ENTER

every position inside the mask can be selected.

The cursor moves to the right and then flashes at the appropriate position.

With the keys

or

the actual value can be toggled to 1 or 0.

The operation is completed when the right bit position is quit with the key

ENTER

4.3 Operation Using a Laptop (Serial Interface)

A software package for a commercially available personal computer is provided for

operating and parameterising the PROCON GL control unit.

This PC is connected to the control unit via the serial interface (RS232) or (RS422).

Important :
If the PC is connected via the serial interfaces RS 422, the connection to the terminal is not
possible.

More information on this program you will find on the diskette.

PROCON GL
Chapter 5 Explanation of the Displays 14

5 Explanation of the Displays

The unit be operated by menu guidance. A total of 4 keyś are available for operation.

5.1 Operation Data

This menu is selected after the unit has been switched on and it shows the production
speed, the operating status and the bottle type selected.

STATUS
The status indicates which operating mode the computer is currently in.

Slow filling (0): Slow filling mode

Fast filling (1): Fast filling mode
Normal mode (2): Normal mode control activ
No Regulation (3): Normal mode no control
Synchronisation (4): Control is synchronised
Back up control (5): Jam switch is damped (jam control)
Run Empty (6): Run Line empty
EMERG. STOP (7): Emergency stop
Standby mode (8): Idle condition
Service mode (9): Service mode is active

SPEED
Here the machine speed is displayed in bottles/hour. This value is calculated from the
time between 2 MACHINE CLOCKS 1 (E 9). Values under 1800 bt/hr => 0.

PROCON GL
Chapter 5 Explanation of the Displays 15

BOTTLE TYPE
It is possible to store the parameter blocks of 16 different types of bottles and call
them up with external switches. To this end a so-called BCD switch is used with which
it is possible to signal 16 different switch positions via 4 lines.

A parameter block can be copied into another parameter block if the bottle selection
switch is switched over in the setting mode (a value flashes) and the setting mode is
quit again [ENTER].

Meaning of the switch position and condition of Bottle type

the line
E 13 E 14 E 15 E 16

off off off off 1

on off off off 2
off on off off 3
on on off off 4
off off on off 5
on off on off 6
off on on off 7
on on on off 8
off off off on 9
on off off on 10
off on off on 11
on on off on 12
off off on on 13
on off on on 14
off on on on 15
on on on on 16

PROCON GL
Chapter 5 Explanation of the Displays 16

5.2 Installation

In this Parametermode all necessary parameter can be selected and performed.

SPEED CONVEYOR 1 to SPEED CONVEYOR 8

This value is the adaptation value between the analog voltage output to the conveyors
and the resultant conveyor speed or number of bottles to be transported in bottles per
hour.

It indicates how many mV of analog voltage are required for the conveyors in order to
make enough bottles available at a machine speed of 30,000 bottles/hour.

Min. possible value: 500 = 0.5 V

Max. possible value: 30000 = 30.0 V

It should be noted that the reference value is 30,000 bt/hr. As a result the value to be
set may well be higher than the actual max. possible analog output voltage.

There are slow plant which only convey 20,000 bt/hr, for example, at an analog
voltage of 10 V. Therefore, it must be possible to select a higher value to be set than
10 V.

Example 1 clarifies this:

7 V analog voltage is required to convey 15,000 bt/hr. The reference value is,
however, 30,000 bt/hr. This means:

Value to be set = 30,000 / 15,000 x 7V = 14 V => 14000

Example 2:

7 V analog voltage is required to convey 60,000 bt/hr. The reference value is,
however, 30,000 bt/hr. This means:

Value to be set = 30000 / 60000 x 7V = 3.5V => 3500

The adaptation values are different for each type of bottle.

With small bottle diameters the conveyor speed is correspondingly lower at the same
nominal output.

Note :
Half the bottle diameter => half the conveyor speed of the acceleration
conveyor

PROCON GL
Chapter 5 Explanation of the Displays 17

a quarter of the conveyor speed of the dosing

conveyor

PROCON GL
Chapter 5 Explanation of the Displays 18

MINIMUM SPEED 1 to MINIMUM SPEED 8

This value is the minimum analog voltage output to the conveyors and the machine.
This value is displayed in mV.

This value is valid for fill up mode and normal mode when the feeding machins stop.

Min.: 0= 0V

Max.: 10000 = 10 V

Default: 1000 = 1 V

The values can be set in increments of 100 mV.

DETECTION RATIO
The DETECTION RATIO is the quotient of the bottle speed and the conveyor speed.

The bottle speed is derived from the time which the bottle requires to pass from
LS1 to LS2. The conveyor speed is calculated from the time between two
CONVEYOR CLOCK PULSE (E8)

TV = T1 / T2 T1 = Bottle speed
T2 = Conveyor speed
TV = DETECTION RATIO

If the bottle speed decreases relative to the conveyor speed, the DETECTION
RATIO increases (the bottle slides).

The DETECTION RATIO actually measured is continuously displayed in the menu

item Servicemode - MEASURING DETECTION RATIO.

The switch-over threshold from a standing bottle to a sliding bottle is set in this page.

With a DETECTION RATIO of 1:1 1000 must be set. With the DETECTION RATIO
the computer calculates the relative motion to the conveyor for every second bottle.

The evaluation as to whether sliding or standing is detected and displayed takes place
with every second bottle, i.e. two consecutive bottles must slide or stand before
switch-over takes place.

PROCON GL
Chapter 5 Explanation of the Displays 19

The result of the sliding evaluation is displayed by the LEDs A 1 and A 2.

LED A 1 = Bottle standing

LED A 2 = Bottle sliding

By changing the DETECTION RATIO during operation and observing the LEDs A 1
and A 2, detection of the sliding time of the bottle can be determined exactly.

The DETECTION RATIO can be learned automatically.

Min. possible value: 250 = 1:4

Max. possible value: 4000 = 4:1

SYNCHRONISATION
As the jam point is normally between the light barriers and the machine and a
difference between the number of bottles which move through the light barriers
LS1 and LS2 and the number of bottles which enter the machine can occur (e.g. due
to bottles which have fallen over or out), the control must synchronise itself from time
to time, i.e. the jam must move towards the light barriers.

This ensures that no gaps arise.

The number of bottles after which SYNCHRONISATION is to take place is set with
this parameter.

Normally the value can be set quite high (> 5000). However, if too large gaps form
with increasing frequency between the light barriers and the machine without these
gaps closing, the value should be selected smaller.

However, fluctuations are to be avoided.

Min. value 100

Max. value 10000
Default 5000

PROCON GL
Chapter 5 Explanation of the Displays 20

GAP SIZE
The control normally operates with a GAP SIZE of 2 bottles, i.e. it is controlled so that
a gap of about 2 bottles occurs between the light barriers and the jam point.

If the acceleration conveyor is extremely short, this target value can be reduced by
this parameter. In this way gaps which occur are closed at an earlier point.

E.g. the value 1 means a target gap size of 1.

Min. value 1
Max. value 4
Default 2

CONTROL CHAR. GAP / SLIDE

In order to adapt to local conditions, it is sometimes necessary to change the control
characteristics. To this end various characteristics are available, separate for the
gaps and the sliding control. Please observe the enclosed characteristics.

RAMP DOWN
The RAMP DOWN indicates after how many seconds the conveyor are to stop after
the signal MACHINE READY (E 4) goes off. The value is set in 1/10 sec. and relates
to 10 V analog output voltage.

Example:

RAMP DOWN = 30 => 3.0 sec.

This means that when the signal MACHINE READY (E 4) goes off, 10V analog
voltage are emitted, the analog voltage is reduced so that the conveyors would stop
after 3 sec. At 5V this would be 1.5 sec. If, during this reduction process, no bottle
flow is detected (LS3 damped for x clocks, LS1, LS2 do not detect any movement),
the conveyor are immediately switched off (x = BTL. STOP OPEN).

Min. 0 => Conveyors stop immediately (or min. sped)

Max. 250 => 25 sec. ramp
Default 0

PROCON GL
Chapter 5 Explanation of the Displays 21

BTL. STOP OPEN

Here, the number of BTL. STOP OPEN is set for 'Bottle stop open' or for bottle flow
detection, i.e. for how many clocks LS3 is damped and at the same time LS1, LS2 do
not detect any movement.

Min. value 2
Max.value 10
Default 5

BRAKE VALUE
The BRAKE VALUE indicates how much percent per bottle the system decelerate if a
signal REJECT (E 7) has been given.

Example:

If the value 2 is set, each bottle is braked by 2% in a jam so that the jam is eliminated.

Min. 0 => 1% / bt.

Max. 10 => 10% / bt.
Default 1 => 1% / bt.

MAX BRAKE VALUE

The value indicates the maximum percent per bottle, the system decelerate if a signal
REJECT (E 7) has been given.

Min. 10 => 10% / bt.

Max. 100 => 100% / bt.
Default 50 => 50% / bt.

DELAY JAM
The value indicates after how much conveyor clock pulse the EMERGENCY STOP
(A5) is active, when LS5 (E5) is always on and LS4 (E6) do not detect any movement.

Min. value 1
Max.value 20
Default 5

PROCON GL
Chapter 5 Explanation of the Displays 22

MAX. % SLIDE
indicates the max. percentage the control is slowed down by slide regulation.

Min. : 10%
Max. : 50%
Default : 50%

MAX. % GAP
indicates the max. percentage the control is slowed down by gap regulation.

Min. : 10%
Max. : 50%
Default : 40%

BOTTLES TO STOP
Dependent on position of the hook switch JP1/4 this Parameter have the following
meanings:

JP1/4 open:

When the feeding machine (E 11 no signals) stop, the conveyors and the accepting
machine continue to run with MINIMUM SPEED until to a gap between LS1, LS2, LS3
and accepting machine set in parameter BOTTLES TO STOP. Then the bottle stop
close (A3 off)

JP1/4 closed:

When the feeding machine (E 11 no signals) stop, the conveyors and the accepting
machine continue to run with MINIMUM SPEED until to a number of bottles set in
parameter BOTTLES TO STOP. Then the bottle stop close (A3 off)

The conveyors, except AN7 (Infeed accepting machine), AN2 (accepting machine)
and AN3 (outfeed conveyor feeding machine), stop.

Min. value 1
Max. value 100
Default 10

PROCON GL
Chapter 5 Explanation of the Displays 23

MAX GAP SIZE

indicates the gap size, between LS1, LS2, LS3 and accepting machine, where output
A8 (max. Gap) is activated.

Min. value 10
Max. value 100
Default 25

EMERGENCY SET
indicates the number of machine clock pulse LS3 is damped and LS1, LS2 do not
detect any movement.

All Analog voltage outputs set to 0V immediately.

Signal CTRL. READY (A3) goes off.
Alarm output EMERG. STOP (A5) is set.
In the display shows status EMERGENCY STOP (7)

Acknowledgment with MACH READY (E 4) off / on for approximately 1 sec. cancels

the alarm.

Min. value : 0 (emergency stop function disabled)

Max. value : 25
Default : 10

LINE EMPTY SPEED

This value is the analog voltage output to the conveyors and the accepting machine
when the signal RUN EMPTY (E12) and MACH. READY (E4) is given. This value is
displayed in mV.

Min. value : 500 => 0.5V

Max. value : 10000 =>10.0V
Default : 1000 => 1.0V

These values can be set in increments of 100 mV.

The set values refer to the AN1 conveyor. The analog voltages that are output to the
other conveyors in this mode are calculated from the preset speed values.

Example:

PROCON GL
Chapter 5 Explanation of the Displays 24

Analog voltage for AN 2 = LINE EMPTY SPEED x SPEED CONVEYOR 2

SPEED CONVEYOR 1

PROCON GL
Chapter 5 Explanation of the Displays 25

5.3 Servicemode

You reach this mode by selecting the menu item SERVICEMODE

5.3.1 ADJUSTABLE MENU POINTS

ANALOG VOLTAGE
This value applies to all analog outputs selected together.

Min. possible value: 0 = 0.0 V

Max. possible value: 10000 = 10.0 V

ANALOG OUTPUT
The analog output to be checked is selected with this menu point.

The controller release is linked to conveyor 1, i.e. conveyor 1 must always be

switched on in addition to the other conveyors.

Selection of the outputs with the keys see Chapter 4.4.2.

DIGITAL OUTPUT
The digital output to be checked is selected in this menu point.

Selection of the outputs with the keys see Chapter 4.4.2.

CAUTION : !! Important for normal mode !!

No regular operation is possible in SERVICEMODE. Serves only for service
purposes. It is imperative to switch the outputs off and after completion of the work the
service menu is to be quit.

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Chapter 5 Explanation of the Displays 26

5.3.2 DIAGNOSTIC VALUES (NO CHANGES POSSIBLE)

GAP SIZE NOW

The GAP SIZE NOW indicates the number of gaps determined by the computer
between the light barriers LS1, LS2 and the machine.

This value is compared with the preset target gap size and in the event of deviations
readjustment is performed in accordance with the set control characteristic.

TIME LS1 / LS2

Time in ms between LS1 and LS2

TIME CONVEYOR
Time in ms between 2 conveyor clock pulses (E 8)

TIME MT 2
Time in ms between 2 machine clocks pulses (E 11)

SYNCHRONCOUNTER
If this value reach the parameter SYNCHRONISATION, the system start to
synchronize by itself.

AVERAGE COUNTER
Responsible for the average value control

CNT. FILLING
Counts the difference in the bottles between outfeed machine and LS1 / LS2.

OUTPUT ANALOG 1
Here, the analog voltage currently output is displayed in mV.

MEASURED RATIO
The measured values are displayed the current DETECTION RATIO.

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Chapter 5 Explanation of the Displays 27

Percentages of the individual controlled variables :

The values indicate by how many percent the individual controlled variables act on the
100%-value of the analog figure. The values relate to the dosing conveyor.

PERCENTAGE REJECT

This value indicates by how many % the following conveyors become slower in case
there is a REJECT (E7).

PERCENTAGE JAM
The value indicates what percentage effect the jam control has on the dosing
conveyor. This value is not use in this version.

PERCENTAGE SLIDE
The value indicates what percentage effect the sliding control has on the analog
voltage.

The control responds when a jam arises at LS1 / LS2. It is then reduced differentially
until the jam is eliminated (see characteristic of sliding control).

PERCENTAGE GAP
It indicates what percentage influence the gap controller has on the analog voltage
(see characteristic of gap control).

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Chapter 5 Explanation of the Displays 28

PERCENTAGE AVER.
The value can be both positive and negative and indicates the percentage effect of
the average value controller on the analog voltage. The average value controller
depends on the AVERAGE COUNTER, whose normal value is 10000.

The AVERAGE COUNTER can change its value up or down.

After 500 points difference the analog voltage becomes 1% faster or slower. If the
average value runs over the limit of 13000 or under 7000, an alarm is given
(A 6 on display shows AVERAGE ALARM).

The AVERAGE COUNTER can be switch off with hook switch JP1-2.

The alarm can be switched off by:

- switching the unit off

- switching over to a different type of bottle
- pressing simultaneously the keys

ENTER and and

PERCENTAGE SYN.
The value indicates what percentage effect SYNCHRONISATION has on the analog
voltage.

PERCENTAGE ALL
It indicates what percentage influence is on the SPEED CONVEYOR 1.

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Chapter 6 Hook Switches 29

6 Hook Switches
The hook switches are located on the inserted processor card and have the following
function:

com 1 com 2
J2
J3

8
7
6
5 JP 4
4
3
2
1
J1 4966-200

St 7 St 6 4966-210

JP 1-1 Language change-over

open: German
closed: English

JP 1-2 CTRL. DRIFT (A6)

open: CTRL. DRIFT alarm active
closed: CTRL. DRIFT alarm not active

JP 1-3 Outfeed from feeding machine

open: the conveyors run in NORMAL MODE proportional with
the feeding machine
closed: the conveyors run in every MODE proportional with
the feeding machine but minimum with MINIMUM
SPEED.

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Chapter 6 Hook Switches 30

JP 1-4 Feeding machine stop

open: When the feeding machine (E 11 no signals) stop, the
conveyors and the accepting machine continue to run
with MINIMUM SPEED until to a gap between LS1, LS2,
LS3 and accepting machine set in parameter BOTTLES
TO STOP. Then the bottle stop close (A3 off)

closed: When the feeding machine (E 11 no signals) stop, the

conveyors and the accepting machine continue to run
with MINIMUM SPEED until to a number of bottles set in
parameter BOTTLES TO STOP. Then the bottle stop
close (A3 off)

JP 1-5 Function of Slave-Machine and Infeed-Conveyor in

Stand-by-mode or Slow-filling-mode.
open: Machine runs with minumum-speed
Infeedconveyor runs with minimum-speed
closed: Machine and Infeedconveyor stops
(Stand-by-mode)
Machine and Infeedconveyor runs up to minimumspeed
(slow-filling-mode)

JP 1-6 Function if signal MACH READY goes off

open: Conveyors are running until gapsize=0
closed: Conveyors stops

Note :
JP 1-7 and JP 1-8 have no function, but they must be kept open.

PROCON GL
Chapter 7 Alarm Messages 31

7 Alarm Messages

7.1 General Alarms

In case of an error message the ready signal (A7) is disactivated.

Signal error check

Whether the conveyor is working correctly is continuously monitored, i.e. a check is
made to see whether the conveyor is missing or has intermittent errors.

The display flashes the following :

CONVEYOR ERROR

Operating voltage check

The system voltages for the analog outputs (+15V) and the serial interface (+5Vp1)
are constantly monitored.

The display flashes the following:

SYSTEM VOLTAGES

Parameter check
The unit conducts a parameter check. If there are any errors, e.g. values have gone
missing, an error message is output. The display shows:

PARAMETER ERROR

The parameter have not been saved correctly in the EEPROM.

The display shows:

EEPROM ERROR

⇒ Check values and, if nec., re-program them. If the values are o.k. in spite of the
error message, a parameter is overprogrammed again.

PROCON GL
Chapter 7 Alarm Messages 32

In addition, the computer conducts a check toensure that the values entered make
sense.

If the parameters entered do not lie within the minimum and maximum values possible,
the relevant parameters are set to their defaults. A 7 (READY) is deactivated., the
display flashes:

TEST PARAMETER

The parameter block should then be checked again by the operator. This error
normally occurs only on initial commissioning or possibly when the Eprom is
exchanged.
The flashing can be cancelled by:

• reprogramming the parameter(s)

• switching over to another valid parameter block

• switching the computer off briefly.

PROCON GL
Chapter 7 Alarm Messages 33

7.2 Min., Max. and Default Values

Value Min. Max. Default

SPEED CONVEYOR 1 500 30000 3500

SPEED CONVEYOR 2 500 30000 3500
SPEED CONVEYOR 3 500 30000 3500
SPEED CONVEYOR 4 500 30000 3500
SPEED CONVEYOR 5 500 30000 3500
SPEED CONVEYOR 6 500 30000 3500
SPEED CONVEYOR 7 500 30000 3500
SPEED CONVEYOR 8 500 30000 3500
MINIMUM SPEED 1 0 10000 1000
MINIMUM SPEED 2 0 10000 1000
MINIMUM SPEED 3 0 10000 1000
MINIMUM SPEED 4 0 10000 1000
MINIMUM SPEED 5 0 10000 1000
MINIMUM SPEED 6 0 10000 1000
MINIMUM SPEED 7 0 10000 1000
MINIMUM SPEED 8 0 10000 1000
DETECTION RATIO 250 4000 950
SYNCHRONISATION 100 10000 5000
GAP SIZE 1 4 2
CHARACTERISTIC GAP 0 3 0
CHARACTERISTIC SLIDE 0 3 0
RAMP DOWN 0 250 0
BTL. STOP OPEN 2 10 5
BRAKE VALUE 0 10 1
MAX BRAKE VALUE 10 100 50
DELAY JAM 1 20 5
BOTTLES TO STOP 1 100 10
MAX GAP SIZE 10 100 25
EMERGENCY SET 0 25 10
LINE EMPTY SPEED 500 10000 1000

PROCON GL
Chapter 7 Alarm Messages 34

7.3 Average Alarm

If the average value of the control exceeds its limits, the output (A 6) (CTRL DRIFT)
comes on. The display shows:

AVERAGE ALARM

7.4 Emergency-Stop Alarm

If an emergency-stop (bottle jam stop) has occurred (STATUS EMERGENCY-STOP

(7)), the output (A 5) (EMERG. STOP) is set.

The display shows:

EMERGENCY-STOP

Acknowledgment with MACH READY (E 4) off / on cancels the alarm.

PROCON GL
Chapter 8 Input and Output Signals 35

8 Input and Output Signals

The proper exchange of signals between the SPC of the machine, the connected
sensors and the control card is necessary for the control to function correctly.

8.1 Meaning of Input and Output Signals

Inputs indicate by green LED.

1 LS1 light barrier bottle flow dedection

2 LS2 light barrier bottle flow dedection
3 LS3 light barrier bottle flow dedection
4 MACH. READY machine ready signal from plc, accepting machine
5 JAM-SWITCH back jam switch behind feeding machine
6 BOTTLE PRES. bottle present behind feeding machine
7 REJEKT reject signal from a system between the two machines
8 CONVEYOR conveyor clock pulse
9 MACH. CLK 1 machine clock pulse 1 (accepting machine)
10 BOTTLE STOP bottle stop is open (feedback signal)
11 MACH. CLK 2 machine clock pulse 2 (feeding machine)
12 RUN EMPTY signal to run the line empty
13 TYPE SEL. A bottle type selector Bit 1
14 TYPE SEL. B bottle type selector Bit 2
15 TYPE SEL. C bottle type selector Bit 3
16 TYPE SEL. D bottle type selector Bit 4

Outputs indicate by red LED.

1 STANDING bottle stand on the conveyor

2 SLIDING
3 CTRL. READY
4 MOT. ENABLE
5 EMERG. STOP
6 CTRL. DRIFT
7 READY
8 MAX GAP
bottle slide on the conveyor
open bottle stop to plc
ready signal for frequency converter
alarm signal emergency stop to plc
alarm signal average value
ready signal to plc
gap is to large, signal to plc

PROCON GL
Chapter 8 Input and Output Signals 36

8.2 Input Signals

All inputs signals are active positive-switching (PNP) 24 V.

The following input signals are required:

LS1, LS2, L 3 ( E 1, E 2, E 3 )

The light barriers LS1, LS2 and LS3 are responsible for bottle flow detection and are
to be installed at a location just downstream of the glide section.

LS1, LS2 serve to measure the bottle speed. The time between the response of LS1
and LS2 is measured and the bottle speed derived from this.

=> LS1 must first respond in the running direction of the conveyor,
otherwise change over connections LS1, LS2.

The light barriers used are transparent light barriers which also largely prevent
multiple triggering in the case of white bottles.

LS3 (E 3) serves to detect whether bottles are on the conveyor. The light barrier
should be arranged centrally under the light barriers LS1 and LS2 so that damping
takes place when the bottles are very close together. Here, too, a transparent light
barrier is to be installed.

MACH. READY ( E 4 )

The MACH.READY signal must be given when the machine is able to start and the
bottle stop can open. See further below for a more detailed description of this signal.

JAM -SWITCH ( E 5 )

Light barrier signal indicates a bottle jam in the outfeed section behind the feeding
machine.

BOTTLEPRES. ( E 6 )

Light barrier signal to detect the output of the feeding machine.

Serves together with E 5 as a jam detection facility.

REJECT ( E 7 )

Registers the number of rejects of a control system between the feeding machine and
the accepting machine. for every reject a single signal.

PROCON GL
Chapter 8 Input and Output Signals 37

CONVEYOR ( E 8 )

Conveyor clock pulse is required to determine the speed of the acceleration conveyor

A signal is expected for every 2-4 cm of conveyor path covered.

The signal must not exhibit any intermittent errors or interference.

MACHINE CLK 1 ( E 9 )

In normal mode to count the number of bottles entering the machine. 1 signal is
expected per pitch clock pulse. The signal must not exhibit any intermittent errors or
interference.

BOTTLE STOP ( E 10 )

The signal BOTTLE STOP is a feedback signal from the bottle stop device.

Without this signal normal mode is not possible. If the signal is given without CTRL.
READY (A 3) being signalled, normal mode is activated, i.e. without starting conditions
(filling mode) theconveyor run at machine speed +/- controlled variables.

MACHINE CLK 2 ( E 11 )

The machine clock is required to determine the machine speed.

It registers whether the feeding machine is turning.

RUN EMPTY ( E 12 )

If this signal AND the signal MACH READY (E4) is active, the system switch over to
run the line empty.

TYPE SEL A - D ( E 13 - E 16 )

Signals for bottle type switch-over from the control unit of one machine.

PROCON GL
Chapter 8 Input and Output Signals 38

8.3 Output Signals

8.3.1 Digital Outputs

All outputs are positive-switching (high-side) 24 V/0.5 A.

STANDING ( A 1 )

The signal A 1 comes on when the bottle is standing on the conveyor, i.e. conveyor
speed = bottle speed.

SLIDING ( A 2 )

The signal A 2 indicates when the bottle is sliding on the conveyor, i.e. conveyor
speed > bottle speed.

CTRL. READY ( A 3 )

The signal indicates that the control is ready, i.e. operates in normal mode.

Equivalent to bottle stop open, i.e. when signal is on, the bottle stop device must be
open, when the signal is off, the bottle stop must be closed (apart from manual mode).

MOT.ENABLE ( A 4 )

The signal indicates that an analog value of > 0 V is output.

EMERG. STOP ( A 5 )

(See chapter 7, Alarm Messages, Page 31).

CTRL. DRIFT ( A 6 )

(See chapter 7, Alarm Messages, Page 31).

READY ( A 7 )

In case of an error message the ready signal (A7) is disactivated.

MAX GAP ( A 8 )

If a gap > parameter MAX GAP SIZE, the signal is activated until MACH. READY is
off.

Serves as a signal for the accepting machine that a very large gap has occurred
which can probably not be closed. The accepting machine should now reduce its
speed and eliminate the signal MACH.READY.

PROCON GL
Chapter 8 Input and Output Signals 39

8.3.2 Analog Outputs

There are 8 analog outputs (0-10 V/10mA).

The output resistance is 47 Ohm.

An1 conveyor 1 acceleration conveyor(controlled)

An2 conveyor 2 accepting machine (controlled)
An3 conveyor 3 outfeed feeding machine (not controlled) * )
An4 conveyor 4 Discharge conveyor (controlled)
An5 conveyor 5 Discharge conveyor (controlled)
An6 conveyor 6 Discharge conveyor (controlled
An7 conveyor 7 infeed conveyor (controlled)
An8 conveyor 8 Discharge conveyor (not controlled) * )

*) not controlled means that the conveyors only run proportionally to the machine
speed.

AN4 and AN5 without sliding control

AN5 half control percentage of AN4

PROCON GL
Chapter 8 Input and Output Signals 40

8.4 The Input signal MACH.READY (E4)

The signal MACH.READY informs the control card that the master machine is ready.

The signal is made available to the master machine by the SPC.

Example for generating the signal 'MACH.READY':

A difference is made between 3 operating modes:

- automatic mode
- manual mode
- off

These operating modes are set on the control panel of the master machine using a
switch.

a) Automatic mode (production operations)

The following signals should be linked in automatic mode:

- jam discharge machine *)

- no bottles feed conveyors *)
- machine voltage on *)
- protective doors *)
- etc.

* hereinafter termed auto-ok

- feed light barrier (gap switch) (gaps > 5-10 cm should be detected)

- CTRL. READY signal from STRATEC control card

b) Manual mode
For running the plant empty and for maintenance work on the machine.

The signal auto-ok is dispensed with.

The bottle stop can be opened manually (even without the CTRL. READY signal).

c) Off

No operation
MACH. READY signal is off.

PROCON GL
Chapter 8 Input and Output Signals 41

8.5 Logic Table for Programming the PLC.

INPUT PLC OUTPUT PLC

1) A3 * E4
auto-ok manuell gap switch CTRL.READY MACH.READY Bottle stop open
0 0 0 0 0 0
0 0 0 1 0 1
0 0 1 0 0 0
0 0 1 1 0 1
0 1 0 0 1 1
0 1 0 1 0 1
0 1 1 0 1 1
0 1 1 1 1 1
1 0 0 0 1 0
1 0 0 1 0 1
1 0 1 0 1 0
1 0 1 1 1 1

* In the event of a status change a delay of about 1 sec. should take place before
the following status is requested.

Acknowledge emergency stop with MACH.READY ( E 4 ) off / on with switch or

button.

1) Gap switch (accepting machine)

0 ⇒ Gap
1 ⇒ no Gap

PROCON GL
Chapter 9 Installation 42

9 Installation
READ USER MANUAL !

The light barriers LS1, LS2 and LS3 are to be installed at a location just in the
beginning of the acceleration section.

The terminal (OPTION) is mounted on a base near the light barrier unit.

It contains terminals for the intermediate connection of the signals LS1-3, conveyor
clock puls and jam-switch in order to have one common cable leading to the control
cabinet.

The terminals are supplied with 24 V DC filtered.

The actual control is accommodated in a control cabinet. The necessary mounting

frame is available from Phö
nix Kontakt under the order No. 2270032, type SKBI-
C342/C32.

CAUTION !
Do NOT install in the direct vicinity of equipment causing severe interference
(transformers, frequency converters, contactors etc.).

The control unit is connected to the terminal or Laptop via a serial data transmission
interface (RS232 or RS 422).

RS422 connection with a twisted pair cable.

Connect input and output signals in accordance with the enclosed wiring diagram.

Connect supply voltage.

CAUTION:!
Unit only requires 24 V DC filtered.

Switch unit on and check whether the input signals are correct.

Special attention must be paid to the clocks (conveyor clock, machine clock). They
must under no circumstances fluctuate with uniform running of the machine and the
conveyor.

PROCON GL
Chapter 9 Installation 43

Check with constant value in DIAGNOSTIC PARAMETERS or uniform illumination of

the LEDs E 8 and E 9 at high speed - if necessary, measure with oscilloscope.

PROCON GL
Chapter 9 Installation 44

Check linearity of the frequency converter.

For this purpose, select SERVICEMODE and let the conveyors run at low speed
(approx. 2000 mV). Measure the conveyor speed with a tachometer and record.

Let the conveyors run at a higher speed and measure the conveyor speed again.

It is important that with double analog voltage the conveyors also run twice as fast.
Otherwise, set the linearity of the frequency converters.

The transmission ratios of the gearboxes and the setting of the frequency converter
should be selected so that at approx. 7 V analog voltage the conveyors run at nominal
power; this ensures that there is still enough reserve to fill up gaps.

These figures relate to the bottle type which requires the highest conveyor speed.
This can be set with the SPEED CONVEYOR1 TO 8 values.

With smaller bottle diameters the conveyor speed is correspondingly lower at the
same nominal power.

The following applies:

half the bottle diameter => half the conveyor speed for the acceleration
conveyor

The acceleration conveyor should run approx. 10% faster than the nominal speed in
order to obtain a jam more reliably.

The bottom glide conveyor runs approx. 10% faster than the acceleration conveyor to
ensure reliable sorting of the bottles.

The acceleration and deceleration times of the frequency converter are to be set to
minimum.

Determine DETECTION RATIO

Quit SERVICEMODE (normal menu) => normal mode

Let the line run.

Set operation NO CONTROL (PARAMETERMODE, page 6)

Select SPEED CONVEYOR1 TO 8 values so that the jam location is between the
machine and the light barriers (LS1 and LS2) and a gap of about 2 bottles occurs
(with target gap = 2).

PROCON GL
Chapter 9 Installation 45

The adaptation values indicate how much analog voltage (in mV) is required to let the
conveyors run at a speed of 30,000 bottles/hour.

PROCON GL
Chapter 9 Installation 46

9.1 Calculation example for conveyor speed and parameters

Type Volume Diameter Production Production Required

bottles / h bottles / min conveyor speed

1 0,2l 54 mm 28000 467 25 m/min

2 0,5l 70 mm 24000 400 28 m/min **

3 0,75l 75 mm 18000 300 22 m/min

4 1,0l 86 mm 13000 217 19 m/min

**Basic setting with this type

Single lane conveyors :

Required conveyor speed [m/min] = Diameter [mm] * Production [bottles/min] /1000

From this follows : type 2 requires the highest conveyor speed.

The frequenz converters now have to be adjusted, that this conveyor speed plus 20%
is matched with 7V input voltage.

From this follows parameter SPEED ACCELERATING for type 2

Parameter [type x] = 30000 / production [type x] * voltage [type x]

30000 bottles/h / 24000 bottles /h * 7V = 8,750 => 8750

The parameters for the other types are calculated with :

parameter [type x] = diameter [ type x] / diameter [ type 2 ] * parameter [type 2]

Following output voltages at nominal production performance of the individual types

are achieved :

voltage [type x] = conveyor speed [type x] / conveyor speed [type 2] * 7V

Type Voltage Parameter

1 6,25 V 6750
2 7V 8750 (Basic setting with this type)
3 5,6 V 9370
4 4,75 V 10750

PROCON GL
Chapter 9 Installation 47

Multiple lane conveyors :

Conveyor speed = Conveyor speed [single line] / number of bottles side by side

Es ergeben sich die Einstellwerte fü

r die weiteren Sorten aus :

parameter [type x] = (diameter [type x] / diameter [type 2 ] )2 * parameter [type 2]

Result :

Assumed : 4 bottles of type 2 side by side

Type parameter voltage at nominal conveyor speed at nominal

performance performance

1 5200 4,8 V 4,8 m/min

2 8750 7V 7 m/min ***
3 10050 6,0 V 6 m/min
4 13200 5,8 V 5,8 m/min

***(Basic setting with this type)

PROCON GL
Chapter 10 Service Notes 48

10 Service Notes
The following points are to be observed if the unit does not function properly or not at
all:

Clocks
MACH. CLK 2 (E 11) is required to determine the machine speed and in normal mode
to count the number of bottles entering the machine. 1 signal is expected per pitch
clock pulse. The signal must not exhibit any intermittent errors or interference.

CONVEYOR (E 8) is required to determine the speed of the acceleration conveyor.

A signal for roughly every 4 cm of conveyor path covered is expected.
The signal must not exhibit any intermittent errors or interference.

Light barrier signals

LS1, LS2 (E 1 and E 2) serve to measure the bottle speed.

The time between the response of LS1 and LS2 is measured and the bottle speed
derived from it.

=> LS1 must respond first in the running direction of the conveyor,
otherwise change over the connections LS1 and LS2.

The light barriers used are transparent light barriers which also largely prevent
multiple triggering in the case of white bottles.

The sensitivity of the light barriers is to be set so that multiple triggering is avoided.

LS3 (E 3) serves to detect whether bottles are on the conveyor. The light barrier
should be arranged centrally under the light barriers LS1 and LS2 so that damping
takes place when the bottles are close together. Here, too, a transparent light barrier
is to be used.

MACH. READY
MACH. READY signal (E 4) must be given when the machine is ready to start up and
the bottle stop can open.

PROCON GL
Chapter 10 Service Notes 49

JAM-SWITCH
The JAM SWITCH (E 5) indicates together witch BOTTLE PRESENT (E6) a bottle
jam in section of the outfeed of the feeding machine.

BOTTLE STOP
The signal BOTTLE STOP (E 10) is a feedback signal from the bottle stop device .

Without this signal no normal mode is possible. If the signal is given without
CTRL.READY (A 3) signalling, normal mode is activated, i.e. the conveyors run
without starting conditions (filling mode) at machine speed +/- controlled variables.

Parameters
The parameters are to be checked.

PROCON GL
Appendix A : Technical Specifications I

Appendix A : Technical Specifications

Technical data
Control section:

Supply voltage: 24 V DC filtered (±

20%)

Power input: 5W

Operating temperature: 0-50°C

Type of enclosure: open

Dimensions: Dual Euro-card format

230 x 160 x 35 (LxWxH)

Weight: 0.2 kg

I/O: 16 digital inputs 24V positive switching

8 digital outputs 24V positive switching
8 analog outputs 0..10V / 10mA

Terminal (OPTION):

Supply voltage: 24 V DC filtered (±20%)

Power input: 3W

Operating temperature: 0-50°C

Type of enclosure: IP 55

Dimensions: 160 x 260 x 180 mm (LxWxH)

Weight: 4 kg

PROCON GL
Appendix B : Menu Structure for LCD Display II

Appendix B : Menu Structure for LCD Display

Main Menue Installation Servicemode

Status Speed Conveyor 1 Contr. Char. Gap Analog Voltage

Bottle Type Speed Conveyor 2 Contr. Char. Slide Analog Output

Speed Speed Conveyor 3 Ramp Down Digital Output

Speed Conveyor 4 Btl. Stop Open Gap Size now

Speed Conveyor 5 Brake Value Time LS 1/2

Speed Conveyor 6 Max Brake Value Time BT

Speed Conveyor 7 Delay Jam Time MT

Speed Conveyor 8 Max. % slide Synchron Counter

Minimum Speed 1 Max. % gap Average Counter

Minimum Speed 2 Bottles to Stop Cnt. Filling

Minimum Speed 3 Max Gap size Output Analog 1

Minimum Speed 4 Emergency set Measured Ratio

Minimum Speed 5 Line Empty Speed Percentage Rej.

Minimum Speed 6 Percentage Jam

Minimum Speed 7 Percentage Slide

Minimum Speed 8 Percentage Gap

Delection Ratio Percentage Average

Synchronisation Percentage Synchron

Gap Size Percentage All

PROCON GL