This file \TEXT\INST\ICONTROLS.TXT upd 26/10/01 To whom it may concern. The following information it the intellectual property of Autopack and it should not be passed onto other manufacurers of similar equipment. 1-In line with current trends in production line control and integration, Autopack Shrink Systems are available with a single operator interface for control of both the Sleeve wrapper and Shrink Tunnel. It is a simple and easy to understand operator panel which eliminates multitude of Pushbuttons otherwise required to bring the machine to operating state. With just two Pushbuttons, the operator is able to pre-energise AC drives, Pre-heat Welding bar and Tunnel, Pressurise pneumatics and put the machine into production. When stopping, the machine is brought to rest at the completion of machine cycle, thus allowing for immediate restart without resetting. The operating panel also contains Emergency stop and Reset Buttons. Alarm are displayed by Blue/Orange/Red Tower light visible from distance to alert the operator if machine is in need of assistance. 1.1 Step Up Step down control Generally two steps or three steps on more complex machines are used to control The Step UP -designated by Up arrow Step 0: With Main switch On 24v DC powere supply is On, the up button is blinking prompting the operato to Step Up Step 1: Pre-heat - With all doors Closed, Pressing the Up buton will cause: - Welding bar to Raises, - Welding bar is pre-heating, - Tunnel Conveyor Starts, - Tunnel is pre-heating During the pre-heat the doors may be opened for machine setting or loading raw material (film or cardboard). When the temperature has reached set point, the Step up button and Run light start blinking in succesion-prompting the operator to step up. Step 2: Pressurize / Run - Collation area is pressurized after small delay Infeed conveyor starts Step 3:Autopack Traypackers or Shrink Wrappers with Pad insertion The infeed is started in Step 3 The Step Down button works in reverse order when momentarily pressed. If pressed for longer time it will drop down to 0 level. 2-Operator Panel (Can be remote) ------------------------------ - Emerg Stop Button - Alarm/Reset Button (illuminates if machine needs to be reset) - Operation Indicator Pilot.- Permanently on when running. - Step UP Button (Illuminated with up arrow. - Step Down Button - Safety door - drops the machine to level 1 (preheat on) - Eemerg Stop - drops the machine to Level 0 for safety reasons. As such emergency stop should be used only for emergency. If any problem with machine, operator should open the door. 3-Tower light - (Blue/Amber/Red-on top) Red-Machine Stopped-Need immediate operator or Technical assistance as Dangerous condition occured. -Emergency stop pressed -Motor overload tripped -Malfunciton of heating system control relays stays too long of or On. Amber-machine operation malfunction -need immediate operato assistance -Product jam -monitoring timers exceeded on either: Film feed/Pusher/Welding bar/Lifter/outfeed back up detection Broken film detected Blue-Machine is working but Need operator assistance. Low film Detection Outfeed back up detected 4-MMI -Optional --- (Man Machine Interface) Touch screen-functions may vary with model. the display panel is used for: Display Messages: Text and graphic display of major alarm conditions: - Door Open/Emergency Stop/ Text/graphic display of operational alarm conditions - display of operational errors. Text/graphic display of low Raw material conditions or upstream or downstream line conditions - Low blank level -(WLC models) - low film level - Outfeed queue full Input operating parameters: - input Welding Bar contact time. (Dwell Time) - Input No of Rows for horizontal collator ounter. - Input No of layers for Vertical Collator counter. - Input Glue patch position and length on Traypackers - Machine life cycle counter - good for service - Batch counter with "stop at count" option Input Safety parameters: - Input of Monitor Timers (for technical staff only) Now being developed - Input of Welding bar Temperature - Input Shrink tunnel Temperature (using thermocuple input module on PLC to eliminate external temp controllers) 5-Elite option ------------ This option is offered for total line integration and icludes the following features: -Solid State relay control of Weld Bar heater (Croydom Matchbox style) -Solid State relay control of Tunnel heaters (Croydom Matchbox style) -Tower light machine status indication (Telemechanique) -Sealed Cabinet with 8mm Keylocked Control cubicle Line intgration interface: -Emergency Stop relay (Normally Open Contact) -Machine Stopped or paused (normally open contact) -Extra wiring on Tunnel outfeed to provide for external input -Tunnel outfeed Back up detector PE Cell -Low film alarm Photocells -Temperature controls alam circuits monitoring. Cable marking Wire marking on terminals can be done in two ways: Standard: IM-NN M=Module, NN=Input number OM-NN M=Module, NN=Output number Optional: Wire number=terminal position number Pneumatic tube marking : VN-P VN Valve Nunmber, P=port number Pushbuttons: Standard : Telemacanique ZB4 range Optional : EAO 704 range Emergency stops : Telemecanique ZB4 Pilot lamps : Telemecanique ZB4 LED Long life type Tower lamp Blue/Amber/Red: Telemecanique XVA Motors: : Siemens or ABB : 0.18KW 3Phase 380/415 4p 63 Flange 0.37Kw 3Phase 380/415 4p 71 Flange Contactors, 4p relays : 24v DC coil Klockner Moeller DIL-EM-10-G 24v DC coil Telemecanique LP1D12008BW Solid state relay : 480V 45A Croydom (standard Matchbox size) 600V 40A with LED Overload relays : GV2 Telemecanique PKZMO Klockner Moeller PLC Standard : National FP0 46-62 I/O Optional : Allen Bradley uLogix 1500 Power supplies : Omron 2.1A S82K-05024 : Omron 4.2A S82K-10024 Proximity Sensors Inductive Standard : Festo 12dia 35Long 5mm Sensing 24V PNP Optional : Omron 12dia 35Long 4mm Sensing 24V PNP Photoelectric Short range Standard : Festo 12mm dia 0-100mm sensing 24vPNP SOERT M12 PSKL Optional : Omron E3S CL2 24vPNP PE Long range : Omron E3S CT61 24V Through Beam. Accessories ----------- Cable glands : Skintop Flex conduit : Entrelec Polyurothene Black 116 deg C Cable ducts : Entrelec gray Terminals : Entrelec gray 6mm 240/380V, Blue 5mm 24DC Cabinet locks Standard : Emka, 8mm Square Key, 20mm Panel cutout. Optional : Triangular Key Cable/Wire markers Single core markers : Weidmiller yellow wire markers Optional : Grafoplast white Multicore cable/conduit: Weidmiller yellow cable markers Pneumatic tube marking : Weidmiller yellow cable markers