AVEOMAT IGS - Hardware 5 Technical data ‘The SAVEOMAT IGS consists of the IGS board and the master board, details of which are provided below. 5.1. SAVEOMAT IGS Interconnection of the master and IGS boards Master board IGS slave board Figure 2: Top view of SAVEOMAT IGS electronicsPN OE X one rune oF ecrrusion SAVEOMAT IGS - Hardware - 5.2 Layout of the IGS board ‘There are 2 IGS for 2 stations implemented on each IGS board. These have been colour-coded in the overview below. The components of IGS 1 are shown in biue and those of IGS 2 are shown in red. 2 3 i +5 7 17. ailsleld alelals lasers =FFF I slelele | LABREI) alalale 2{2)5 5 as|3/5 5) ala ie); 3 @) as is 7 alg 1. ici. 8 elas 3 83 8x0 8 a ofa || £8 23 | (S38& Figure 3: Overview of the IGS boardSAVEOMAT IGS - Hardware Figure 4: Top view of the IGS slave board Dimensions: SAVEOMAT IGS slave board (W*H) 70"108 (2,8" 4,25 (inch)) 5.2.1 Assignment of DIP switches Ji _ PWM instead of analog output for the motor of component 1 J2_ PWM instead of analog output for the motor of component 2 s DIP1.1] Component 1: Calibrate , pre-set of pulses per revolution, delete mass storage DIPT.2| 82 DIP2.1] Component 2: Calibrate, pre-set of pulses per revolution, delete mass storage DIP22|PIN OE X se rurune oF exrnusion SAVEOMAT IGS Hardware - $1 | Total reset station 1, if $4 pressed during system start ‘S2_| Total reset station 2, if $3 pressed during system start Dip $1.2] Advanced operation mode for component 1 Dip $2.2] Advanced operation mode for component 2 5.2.2 Assignment of plug connector Pia 8 | 3 Function a1 | 21 leav 1.2 | 22 | Digital input tor speed pulses 1.2 | 23 |Diaital input for material sensor above weigher init 2 “| (= material available, 1 = no material available) (option) 1.4 | 24 | Digital input for manual operation, motor speed plus 1.5 | 2.5 | Digital input for manual operation, motor speed minus 1.6 | 26 | Digital output for RAS openiclosed 1.7 | 2.7. | Digital output for dosing motor enable (1 = motor enable) 1.8 | 28 | Digital output for motorised potentiometer plus (for PWM) 1.9 | 2.9 | Digital output for motorised potentiometer minus (for PWM) 110 | 210 |ov 1.11 | 2.11 | Analog output 0 - 10 V for motor speed setting ase | 212 jovPN OE X se curune of exrnusion SAVEOMAT IGS - Hardware Function West Component 1 is 2 ‘Component 2 a1 | 41 iev 32 | 42 [bv 3.3 | 4.3 [Analog input A (for differential signal) 3.4 | 4.4 |Analog input B (lor differential signal) as | 45 leno 36 | 46 |GND 5.2.3 7-segment display ‘The IGS board features a 7-segment display for each station. The segments are assigned as follows: - Jorma operation 1 [Analog/digtal converter error 2 Patatoss 3 [Radial stripper slide not closing 4 [Radial stripper slide not opening/no material 5 Bpeed=0 © (RAS inmanual moae 7 [Scales in lower power rangeSAVEOMAT IGS AN tHe FUTURE OF EXTRUSION Hardware - 5.24 Meaning of LEDs 5.3 Meaning Stand still / screw change OW | Weighing Ho Filling oo Calming Layout of master board Ethemet CAN ‘Manual RS coeraton |) 495 avy 2 | —~J pip 21 on te Dipee ral spp J det 2aVv I 3 Dip 14 Figure 5: Overview of the master boardEN OE X sue surune oF extrusion SAVEOMAT IGS - Hardware - 5.3.1 Assignment of DIP switches loipzs — [Trotalreset [Delete all data by performing a restart loipz_2 Reserved FF irs fpesewea per pire « Reserved lorr [ie2s [Reserved FF Joip2_6 —|caN Protocol [oN old standard, OFF new standard (default) Jorz7 — usa switch lUse American units for calculations pire Reserved pr pis Prsaresso Joirr2 — [adresse.1 laddress Bit-code0 = invalid - ‘Address for RS 485 interface loip1_3 — [address.2 ‘Address offset for the 4. Bylo of IP address (Basis IP address attr total reset: 192,168.100.20) ie1_4 —Jaddress.3 (Example Basis-address=192.168.100.20 set address=3 loie:_s —_faddress.4 resuling IP-address= 192.168.100.23) iPr frctoss.s = 125 kbit/s; 1 = 250 kbit/s; loip1_7 psn 0 _|CAN baud rate; bit-coded "AN_Baud Rate.1 [2 = 500 kbiv’s; 3 = 1000 kbit/s ip1_sJumper 7 TRACO POWER Jumper 1 Jumper 36 Figure 6: Top view of the master board Dimensions: SAVEOMAT master board 5.3.2 Jumper of Master Board (W'H) 109°108 (4,29 * 4,25 (inch)) Description ‘Jumper t _| Set during system start: software update Not set (pro-sol)_:_ standard operation Jumper? | Set: terminating resistor CAN active Not set: terminating resistor CAN not active Jumper 36 | Set = terminating resistor AS 485 active Not set: terminating resistor RS 485 not activeEN OE X sc surune oF exrausion SAVEOMAT IGS - Hardware - 5.3.3 Setting the node address for RS 485 /Address offset of IP Address With a bus system, itis important to be able to identify every station participating in the system. ‘The set address is the node address of the RS 485 network. Furthermore the set address will be added to the 4. Byto of the IP address. Node address switches DIP 1.1 to 1.6 Pl le lel? lele Node address value DiPi_[bIP2 [Dips |DiPa [DIPS | DIPE T{L2]4]8 || a On| of | on | Of | of | Of 1 On_[-On | on [On | On | Of 2 On| On | on | Of | on | on 3 on_|-on [On | Of | On | Of 4 On | of | On | Of | OM | Of 5 on_[ on | on | on | on | of é ‘On | On | On | Of | Of | Of 7 ‘on | of | of [On | Of | Of 8 ‘On_|-of [Of [On | Of | Of 3 On [On | Of | On | On | of 10 On [On | On | On | On| On 68 Once the node address has been set, the system will need to be restarted in ord q for for setting to be activated. = Node address "0" must not be used!PN OE X sc rurune oF exrnusion SAVEOMAT IGS - Hardware - 5.3.4 Setting the baud rate DIP switch 1.7 [DIP switch 1.8 |Baud rate | Max. bus length [feet] 0 o 125kbivs | 1640.4 1 ° 250kbivs | 20,2 0 1 S00 kbivs | 328,2 1 1 tooo kbivs | 131,1PNOE X suc rurune of extnusion SAVEOMAT IGS - Hardware - 5.4 CAN II board (only for SAVEOMAT IGS D with multidrive C) ‘The CAN Il board hereunder is exclusively used for multidrive C motors. Please check which motor type you currently use. This is written on the label as shown hereunder which is usually positioned on one side of the motor console. ow reset button for defaults first out 7Seg 1 7Seg2 LED's Figure op view GAN Il boardPN OE X se rune oF ecrusion SAVEOMAT IGS - Hardware ‘The CAN II board is configured as follows: 2 78eg1 | 7Seg2 ‘Status description s display | display cs NK _|, status no. 0 F Motor not recognized x 1 Power supply voltage insufficient x 2 Excess temperature x 3 Motor excess current x 4 ‘Others x 5 x motors recognized Note: x = Side component no. In case several defaults occur, they are alternately ‘Status description 1 at frein| {2rehn] [Seein] [4 rein] [5 rein baer om eer care ore tre Trt 11 TAI recognized motors without Braue [3 aus) [raus| [5 eus| [6 reus detaut snus a Default Figure 8: Configuration CAN Il board S1or$2: Acknowledgment of pending defaults CAN connection to motors: 1 raus, connection from the board to the first motor 4 rein 1 connection from the first motor to the board aus ‘connection from the board to the second motor 2rein + [connection from the second motor to the board, etc.EN OE X sue ruruse oF exrsusion SAVEOMAT IGS - Hardware 5.5 Connection conditions 5.5.1 _ Installation location/Conditions + Ambient temperature max. 131 F = Degree of protection IP 54 5.5.2 Connections = Powersupply 24+ 10% DC - Current consumption 0.5 A (without digital inputs and rotary pulse encoder supply) Wiring for the SAVEOMAT IGS electronics is already in place in the wiring box for the dosing station. ‘The prewired connections include: 1, Connection: Load cell electronics 2. Connection: Electronics shut-otf device 3. Connection: Dosing motors (secondary components) For details of how to connect the power supply, interface and throughput display, please refer to the electrical documentation = Cable material The following cables should be used for connecting the electronics: Connection Cable type Miscellaneous details IGS interface (RS 485) uycy 2x2x0.25mm? | shielded/twisted pairs \GS/power supply unit 24 V HoSVV5__-F 3G0.75mm* _|Shielded IGSidigital display (option) Livcy 2x 0.5 mm? IGSvalarm lamp (option) Livey 2x05 mm? IGS/inductive proximity switch Pvc 3x 0.35 mm? Equipotential bonding cable Ho7 VK 1x 10mm? 5.5.3 Electrical documentation (Please refer to the electrical documentation that has been enclosed with this instruction manual.)PNOE X sc rotate oF exrnusion SAVEOMAT IGS - Hardware - 8 Faults, diagnostics and maintenance 8.1 Functional test ‘Switch on the SAVEOMAT IGS electronics. *-" will appear on the LED 7-segment display. This indicates normal operation. 8.1.1 Check the following points: 1) Green LED and red LED must be illuminated (scales ready). 2) The power supply LED (green) must be illuminated. Now start up the extruder. 8) After a while, the shut-off device will close. 4) Green LED and red LED will go out. 5) LED D6 (IGS 1) / (IGS 2) will licker in time with the speed pulses. 6) After a while, red LED will go out, although green LED will remain illuminated. The weighing procedure will commence. (Once the above points have been successfully checked, the system is ready for operation,PN OE X sc curne oF exrnusion SAVEOMAT IGS - Hardware 8.2 Error messages Error messages are indicated on the LED 7-segment display: List of errorsisystem messages Display [Meaning ‘Ration i Normal operation = 7 ‘Analogidigital converter not [Check connecting cable; working ‘check load cell wiring on SAVEOMAT IGS; ‘check load coll 2 Data loss Rocalibrate SAVEOMAT IGS; re-enter the number of pulses per revolution; i necessary, re-enter system seltings via interface; if problem stil occurs, replace battery 3 ‘Shutoff device not closing | Check compressed air, check cable connection 4 ‘Shutoff device not opening, no | Check material inlet for bridging; release solenoid material valve lock; check hopper scales fil time 5 ‘Screw speed failure, alimough | Check cable connection between induclive proxmiy extruder is running switch/SAVEOMAT IGS; check operating distance (0,04 — 0,12 inch); check connection on SAVEOMAT IGS 6 [Shut-off device in_manual| "Shut-off device in manual mode” system status mode triggered by switch function (only relevant for dosing stations) 7 ‘Scales in Tower power range [Inadequate change in weight during weighing (deltaENOE X snc curune oF exrausion SAVEOMAT IGS - Hardware - 8.3 Other potential faults Fault [Action segment display not on = Check power supply | Check 24 V supply cable | Check power supply unit Check fuse Displayed throughput and actual throughput|- Check that the load cell is free to move and sitfer significantly, wildly fluctuating) check stop screw gap {throughput — Recalibrate scales — Check load cell Check the pulses per revolution setting and, correct it necessary = Check operating distance of inductive proximity switch (should be: 0,04 — 0,12 inch) ‘AS of @ certain screw speed, only half the throughput is displayed = Gheck the operating distance of the inductive proximity switch. — Ensure that only one pulse is actually being ‘generated per mark; hence, do not use hexagon socket screws. |- Ensure that the max. permissible frequency of 2 kHz is not exceeded. Material has a tendency to form clumps = Increase the size of the impact cone discharge gap; the fastener allows changes to be made in 5 mm increments — In extreme cases, the impact cone can be removed and a reducing insert” can be fited on the collecting hopper; however, this will impair the accuracy of the system, * Note: The decision to use a reducing insert is generally made at the project planning stage. I necessary, the reducing insert can be ordered at alater date Rough ground stock ‘Seo abovePN OE X sc rurune oF exrmusion SAVEOMAT IGS - Hardware - Fault ‘Aetion ‘Shut-off device not opening, ‘no material, but no error message Immediate remedy: Switch off voltage, valve has to open in the de-energised state I the problem occurs again, recalibrate the scales Check gap between stop screw/load cell Check load cell SAVEOMAT IGS not sending any data via the intertace ‘Check cable connection; check nade address setting ‘SAVEOMAT IGS is refusing to run, although no error message is being output and there ‘are no problems in terms of the power supply, speed sensing, etc. Carry out a total reset (see Section 9.4); then recalibrate the device 8.4 Maintenance Electronics The SAVEOMAT IGS electronics are maintenance-free.tation reproduction af Wi amen ube ad nonar of Thecrdnl are probed was speily Torna G 2 I 3 I 4 I 5 6 7 d _] INOEX GMBH ELECTRICAL DOCUMENTATION FOR BORWEG 27 SAVEOMAT IGSD6 MONO Se aaa TELEFAX 05731/9 67 66 Denomination INNOVATIONS AND COVER SHEET 4319003000_CE1 EQUIPMENT FOR THE EXTRUSION TECHNOLOGY LAYOUT FUNNEL WEIGHER 4319003000_AEO LAYOUT TERMINAL 4319003000_LE1 WIRING SCHEME 4319003000_RE1 TERMINAL CONNECTING PLAN | 4319003000_DE1 SPARE PARTS LIST 4319003000_EEO rarer : COVER SET EES z r Fai = Sone a en om Scdeer tT, Ale ede or en Fl er Palelertlug ode Gobraucamsner = EnregyvrbealDati an epredion of Ths doin oe vd Gane of he fens ara ONDE ules NCard Coravetons vl be laaieA paln As ots on regard anrarerneved I 2 I 3 T 4 5 6 T 7 I LAYOUT FUNNEL WEIGHER SIDE VIEW, RIGHT REAR VIEW =Y190 & -B191 [Esmee fINOEX cy oT | LWEGHER [ugh = INOEX 3 pose cmon FEF cca EE 7 L 31003000 AD Pa] sve arch zoesanden, Zvierandlungen verTicfen ron Schedeneaalz Ale Reef en Fl der Ptenertlung oder Gebrnhamaater ~ Envagug rebealen. a [ae — Rane eters sovieVevnFitipng Ser Zeng un ng res al“nn sd SB kB nd Une Th ens are prone ness HpeaTiclyoaharned Cenravenians wl be denied Al pe Paha wr ig raged Gigs We Tearee 1 I 2 3 I 4 I 5 I 6 I 7 [ | sve: | ] 7 POTeNtAL EQULIBRATIN E-] . Note! Potential equiibration (function earth) Due to EMC reasons and in order to avoid static loading, pote arranged racially from the dosing station to Potential equilibration lines hove to have a minimum cross section of 10 qmm and shoud be of grey colour. equilibration lines n earth) have to be TT feces FNOEX 5 neve Ex LAYOUT FUNNEL WEKGHER— [Tulnea”™ i — Papa mane Wega sve Ver? dsr Zour wl tung ies Walls Bt el SSpN000 He i St Act ah zeae Zorandlagen eter rm Shaders, Ale ae fr dn Fall Pleterleing oder Gebroanarir~Enrageg wvbealonDaten and reproduction of coer ve ad Serre of Te conn ar rOWDTe les Spec arta ConiTaverions vil bende Al pat Neo he oo repetered ssw reread I 2 T 3 4 5 se 7 I LAYOUT TERMINAL | LAYOUT A nw24 was Wa aweae yoo 4 ws TSE 12 aa. oa LAYOUT TERMINAL Paneer: fase fest | GINGOEEX cree or mon PEF ote es rages — rie ar le T Tras TE] ig sae Vrligog deve Tad gre Hm Tia i ign Tavares Sdn Mae GF ae kn ee GSTS“‘inion and veyed in of Ts cme, us td coir of Te oles re PONDS, oneatSpeStEaly euthrza Cnavnions vl be remit PONS a regard dal re reared z 3 T « i 6 1 Mostr-Medu Roxwry smc iss a BTR NTAUDER SPEED SERRA FUSE PAGTECTON DS ESA VARIN SEE TERNAL COMET PL = ene? 181/21 alzlale : e AIA &} 18 ALO i faa] [eli] [lg] xt] f2}3[4]5]6]7] 2] epi 4 a bp Ge fsiand v2 [Pelle] 5] ]7]"| hp f g x1 5 . 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NUMBERING THE INDICATED CABLE TYPES ARE. PROPOSMONS. NOTE! CHOICE OF UNE TYPES, WIRNG AND UNE CONNECTIONS HAVE TO BE IN COMPLANCE WITH REGULATIONS AND RESPECTVE SUNOAROS OF THE ELECTRIGTY BOARD IN CHARGE 2 XL iNOEX Ex TERHNAL COWECTINGPLAN [EGR oe re ne oF ormsin Tt toa — —— — CONNECTIONS / PERIPHERY oa etergae sie Varatigg ese Zeng Wig re toa a mn pte Toda vie a Ser eats Rinleeheg ee arian“ Erogeg enTain ad repro fis econ nd Seon of he nena we WONG aie seca bred Cntavevons vl be ded Al pal FNS WTR os eed dpa wt REOTOT I 2 I 3 I 4 I 5 6 I Z I = RELEASE SGNAL BY 195 TO THE OxTRUDER SPEED ACTUATION BY 16S TO THE EXTRUDER ( 2 OPTIONS FOR CONNECTION 20 00 TRALOGUE SIGNAL 0.107 PULSE WIDEN SIGNAL 47—ZaV THOFTONE ETOH FOR CONNECTION 1 “=OPTORT™ E ETON FOR CONTECH FSO 3x1 ue ERE Cc 1 IGS_— HOUSING Ch ¢ al CABLE TYPE: LCY 4:05 grim ——— or ——+ =e Els Els wa ws. € § 5 | c g 7 -K2.2 3 g 5 |) £ ski} E ah i la} sell y | aR lal & coe al oH comecron connecrion comer SPEED ACTUATION SPEED ACTUATION SPEED AcTUATON 10 Tie EXTRUDER tome exer | —— OR ——e 0. exrmuoeR RELEASE SIONAL ANALOGUE SIONAL PULSE WIDEN SONAL THE INDICATED CABLE TYPES ARE PROPOSTTONS. NOTE! CHOICE OF LINE TYPES, WIRING AND LINE CONNECTIONS HAVE TO BE IN COMPLANCE WITH REGULATIONS AND RESPECTVE STANDARDS OF THE ELECTRICITY BOARD IN CHARGE. cope a iNOEX Ex. TERMINAL CONNECTING PLAN ee SLi td ‘= ouenm | EXTRUDER SPEED Toe F Tare — Tne Tots ra i ‘Sion et sign ve er iigng deae Tehy Sigh ua oe HO er Ten Tn er on alr ica real Palos os ov oamaieEomye