RUN OFF start with the Test from the Extruder!

1) Check the Emergency Stop function:

Press the emergency button

On that relay you can see LED all must be one when the button is pressed. After you have
released the button all Led must be on.

2) Change the settings in the ABB converter for the Main drive:
3) Overview page 100 information

4) Entry password
Press here where you can see “0”

Press here where you can see “******”

Password level 1 = 1 confirm with “ENTER”

Password level 2 =22 confirm with “ENTER”

Confirm by press the “ hook button “

Here you can see now the actual password level.

5) Check the PLC is RUN Mode

Press on the page numbers a navigation windows open

Press page “ 910”

Press “ CPU”
Here you can see the PLC status now it is in “STOP” mode you have to switch into the “ RUN “
mode. In the case the PLC is in “ RUN “ it is ok

On that picture the PLC is in “RUN“ mode don’t worry about the red LED what is on “EXTF” it
means an not critical mistake is activate. Maybe the thermo couple are not connected,…..
6) PLC description

On the ET 200SP that leds are should be green “DP”, “PWR”, “RN”!

“ER” is red and is indicate on: Thermocouples are not connect or you have another mistake on
any modules.

Don’t worry about that red LED that are the contact for the thermos couples, in the case no
senor is connect then you got that indication.

That modules has an mistake nothing is connect normally when you have connect everything the
“MAX“ res is gone.
That inputs are very important.

Emergency Stop. Is for the safety!

24 Volts OK is must be on!

Fault supply in the case the extruder is shut down by yourself after start please check that
input.

7) Start with testing the Extruder

Look into the manual for handling the Theysohn Extruder Control by operating with Siemens
PLC.
8) Entry the alarm page 010

On that page you can see all actual faults try to eliminate all faults.

After you have eliminate all faults you can test as example. Turn off the motor protecting switch
from the Vacuum pump 3Q1 a fault appears on that page, the same make with all other motor
protecting switches!

9) Reset Fault G120 Siemens Frequency converter

Press ESC Press 2 times arrow up

Press ok press ok
10) Calibrate back pressure

Login with password access 2, afterwards go the page 481.

Page for calibration back pressure

Press Default Siwarex WP321 and wait few seconds

The default is now finished

Start calibration and confirm with the

Done! Don’t be confused values can be different do the pictures ( RAW value, Display value,
Measure value 1, Measure Value 2, Display Value 1) Display Value 2 must be 130!
11) Calibrate melt pressure

Login with password access 2, afterwards go the page 482.

Go to page 482 push the arrow right

Page for calibration meltpressure

Press Default Siwarex WP321 and wait few seconds

The default is now finished
Start calibration and confirm with the

Done! Don’t be confused values can be different do the pictures ( RAW value, Display value,
Measure value 1, Measure Value 2, Display Value 1) Display Value 2 must be 560!
12) Check the heating zones

Go the page 211

In the case you see the press on the ICON ( that icon has the function for
unintentional stop the drive ) When you push the stop and start it does not respond.
Here start the heating for all activate heating zones!
Here activate the heating group as look on the screen “ Screw , Barrel, Tool “

Activate the heating zones one by one and wait until the temperature is going up, then the
heating zone are should be ok.
13) Temperature self-tune

Go to page 231 is barrel zones

The self-tune is a function from the heater software before you start the Extruder it is helpful
to make the self-tune.

Important: Make sure no PVC material is in the screw barrel and tool, also check the
connection plugs from the thermo couples und heater belts!
Here turn “ON” which zone you want to make a self-tune from the heating system.

Page 232 is for tool zones

Here turn “ON” which zone you want to make a self-tune from the heating system.

Go back to page 211

Change the temperature to 150 degree Celius.

Turn on each heater where you want make the self-tune you have activate heat system.
Turn on each heater where you want make the self-tune you have activate heat system!

The melt temperature must be turned off no heating function on that channel!
Start the heating, when you go to page 231 you can see the current status, the self-tune it
should be finished approximately in one hour it depends on your tool what is installed on
that extruder.
Current status from the tooling zones.

In the case everything is finished and the self-tune was properly then you can read the
message in the status information “ self-tune done finished”

You got more details when you press the “question mark on the screen”
14) Start the drive

Make that only when the Extruder have reached the production temperature or the screw
and barrel are clean and no PVC powder is inside!

Log in with password access 2.

Go to page 310, press the button do unlock

Here you can see now the single arrow up that is slowly speed adjustment

Start the main drive

That button is for adjustment the actual choice drive as example you want only make an
adjustment on that drive.

With the plus, minus button you can make the adjustment on the
speed.
With double arrow up you can make the speed adjustment faster.

When all drives are running with speed then activate the after you activate the
“ SYNC “ button you can control all drives with the synchronization.