MACO Breeze IIc installation manual

Transcription

MACO Breeze II C
Installation Manual
Table of Contents
Contents
1.
General ........................................................................................................... 2
2.
Installation ....................................................................................................... 4
2.1
CE EMC Compliance .................................................................................... 4
2.2
Installing the Breeze IIc ................................................................................. 4
2.3
Mounting the Breeze IIc ................................................................................ 5
3.
Wiring the High Speed Analog Processor Board .......................................... 11
3.1
Introduction ................................................................................................. 11
3.2
Analog Input/Output Wiring Guidelines ....................................................... 11
3.2.1
Injection Control Ram Position and Ram Pressure Inputs ...................... 11
3.2.2
Wiring DC Inputs & Outputs ..................................................................... 12
3.3
Specifications .............................................................................................. 14
4.
The Servo Amplifier Card .............................................................................. 18
5.
Breeze IIc Wiring Layout ............................................................................... 20
5.1
Time-Based Applications (Continuous Extrusion) ...................................... 20
5.2
Position-Based Applications (Accumulator/Reciprocating Screw) .............. 24
5.3
Position-Based Applications (Accumulator/Reciprocating Screw) .............. 28
5.4
Encoder Based Applications (Wheel) ......................................................... 32
5.5
Encoder Based Applications (Wheel) ......................................................... 36
5.6
Internal Wiring Cable Assemblies ............................................................... 39
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Figures
Figure 1 Breeze IIc Enclosure Dimensions ................................................................................................... 7
Figure 2 Breeze IIc Terminal Identification (1-4 Head Time Based, 1-4 Head Pos. 1 Accum.) ................... 8
Figure 3 Breeze IIc Terminal Identification (2 Head 2 Accum. Position Based) ........................................... 9
Figure 4 Breeze IIc Terminal Identification (1- 2 Head Encoder Based) ................................................... 10
Figure 5 A-60194 High Speed Processor Board Block Diagram ................................................................ 13
Figure 6 A-60194 High Speed Analog Processor Board ............................................................................ 16
Figure 7 Wiring the High Speed Analog Processor Board .......................................................................... 17
Figure 8 A-13441 Servo Amplifier Card ...................................................................................................... 19
Figure 9 Time Based DC I/O Connector ..................................................................................................... 20
Figure 10 Time Based APU Analog I/O Channels 1 & 2 ............................................................................ 20
Figure 11 Time Based APU Analog I/O Channels 3 & 4 ............................................................................ 21
Figure 12 Time Based APU Analog Input Channels 5 & 6 ......................................................................... 21
Figure 13 Time Based Analog wiring .......................................................................................................... 22
Figure 13 Time Based DC IO Wiring .......................................................................................................... 23
Figure 15 Position Based DC I/O Connector .............................................................................................. 24
Figure 16 Position Based APU Analog I/O Channels 1 & 2 ........................................................................ 24
Figure 17 Position Based Analog I/O Channels 3 & 4 ................................................................................ 25
Figure 18 Position Based APU Analog Input Channels 5 & 6 .................................................................... 25
Figure 19 Position Based Analog Wiring 1 Accumulator ............................................................................ 26
Figure 20 Position Based DC IO Wiring 1 Accumulator ............................................................................. 27
Figure 21 Position Based DC I/0 Connector ............................................................................................... 28
Figure 22 Position Based APU Analog I/O Channels 1 & 2 ........................................................................ 28
Figure 23 Position Based Analog Option Slot B Digital I/O ........................................................................ 29
Figure 24 Position Based Analog Input Channels 5 & 6 ............................................................................. 29
Figure 25 Position Based Analog Wiring 2 Accumulators .......................................................................... 30
Figure 26 Position Based DC I/O Wiring 2 Accumulators ........................................................................... 31
Figure 27 Encoder Based (Wheel) DC I/O Connector ................................................................................ 32
Figure 28 Encoder Based (Wheel) Analog I/O Channels 1 & 2 .................................................................. 32
Figure 29 Encoder Based (Wheel) APU Analog Channels 3 & 4 ............................................................... 33
Figure 30 Encoder Based (Wheel) APU Analog Input Channels 5 & 6 ...................................................... 33
Figure 31 Encoder Based (Wheel) Analog wiring ....................................................................................... 34
Figure 32 Encoder Based (Wheel) DC I/O wiring ....................................................................................... 35
Figure 33 Encoder Based (Wheel) DC I/O Connector ................................................................................ 36
Figure 34 Option Slot A Encoder Based (Wheel) DC I/O Connector.......................................................... 36
Figure 35 Encoder Based (Wheel) APU Analog I/O Channels 1 & 2 ......................................................... 37
Figure 36 Encoder Based (Wheel) APU Analog I/O Channels 3 & 4 ......................................................... 37
Figure 37 Encoder Based (Wheel) APU Analog wiring .............................................................................. 38
Figure 38 Encoder Based (Wheel) DC I/O wiring ....................................................................................... 39
Figure 39 Internal Wiring Cable Assemblies ............................................................................................... 40
1. General
This controller must be installed in a suitable place which will minimize or prevent
the accumulation of dust, dirt, or other particles which could build up and clog
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ventilation slots. Periodic inspections must be scheduled to insure that slots do
not become clogged. Cleaning should be done using a vacuum cleaner. Do not
use compressed air as this could force particles into the controller and actually
worsen conditions. Air temperature within the enclosure must not exceed 50°C
(122°F). Allow adequate space for air to flow around the controller. It is strongly
recommended that a full four inches or more be maintained on all sides wherever
possible. This space allows for wiring installation and free flow of air. A typical
control system requires approximately 0.5 KVA.
Caution!
Unit is EXTREMELY front heavy and will tip forward when opened. The operator station must be
supported when opening a unit that is not bolted in place!
Caution!
Do Not Operate Without Cover in Place.
Cover must be in place both for operator safety and to insure proper cooling of internal components.
Refer to xxxx-xx-xx-x-xx for an up-to-date list of UL approved board assemblies.
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2. Installation
2.1
CE EMC Compliance
The Breeze IIc meets CE EMC requirements. For additional wiring information,
refer to the following publications:
Recommended Guideline for Wiring & Grounding Machine Controls
Society of the Plastics Industry, Inc.
1275 K Street, N.W.–Suite 400
Washington, D.C. 20005
(202) 371-5200
IEEE Guide for the Installation of Electrical Equipment to Minimize
Electrical Noise Inputs to Controllers from External Sources
(IEEE Std 518-1982)
2.2
Installing the Breeze IIc
This Breeze IIc is rated at 24 Vdc (20 to 30 Vdc), 3.0 Amps maximum current at
24 Vdc (excluding all I/O); operating temperature of 0 to 55 C (32 to 131 F);
storage temperature of -40 to 85 C (-40 to 185 F); 0 to 95% rh, non-condensing
@ 55 C (131 F).
These systems are Installation Category 3 and Pollution Degree 2 devices.
They are intended for panel mounting only.
Where external power supplies are required, a CE recognized supply must be
used. Test results on CE power supplies have shown that they may emit noise
above 30 MHZ. Install a ferrite bead suitable for power cord use at the output
terminals of the supply.
“Bonding” requires the removal of all non-conductive plating or coatings between
the surfaces to be bonded (as well as the application of pressure).
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2.3
Mounting the Breeze IIc
Do not enclose the Breeze IIc in a small or tightly sealed cabinet or panel which
would cause the surrounding temperature to exceed the rated temperature.
Consideration must also be given to protecting the display surface. Do not mount
the system so that the display is subject to mechanical damage or dust and dirt
particles. Periodic cleaning using a soft, water-dampened cloth is recommended.
Do NOT spray liquid cleaning agents directly onto the screen. Allow adequate
room for vibration, air circulation and easy access. Pay particular attention to the
accessibility of cable connectors.
Note that inadvertent power loss (or shutdown) may cause application problems.
A battery-backed power supply (or UPS) is recommended in order to keep the
system running during times of power loss.
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Figure 1 Breeze IIc Enclosure Dimensions
Note: Include a switch or circuit breaker in the installation. It must be placed in close proximity to the
equipment within easy reach of the operator and must be marked as the disconnecting device for the
equipment.
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Figure 2 Breeze IIc Terminal Identification (1-4 Head Time Based, 1-4 Head Pos. 1 Accum.)
Note: BEFORE applying power to the unit, the Ethernet crossover cable (supplied) must be installed
between the CE.NET and APU terminals.
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Figure 3 Breeze IIc Terminal Identification (2 Head 2 Accum. Position Based)
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Figure 4 Breeze IIc Terminal Identification (1- 2 Head Encoder Based)
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3. Wiring the High Speed Analog Processor Board
3.1
Introduction
The A-60194 high speed analog card (also referred to as „Analog Processor Unit‟
or APU) can have as many as 4 channels of control. The number of channels
required will depend on the amount of control needed by the process.
Regardless of the number of channels required, wiring from one channel to
another will be similar (the difference being the type of sensor used to provide
the input). Current or voltage inputs can be used. Outputs are voltage only and
are intended for use with a drive package or amplifier.
3.2
Analog Input/Output Wiring Guidelines
1. Use braided shield cables on ALL analog inputs and outputs. Use separate
cables for each function and keep cables less than 3 meters in length. If
cables are over 3 meters long, an overbraid is required. If overbraid has been
used, terminate both the internal braided shield and the overbraid at the
ground distribution block.
2. Excitation voltage for potentiometers is provided by the card. Excitation
voltage is +10 Vdc @ 20 mA. Potentiometer resistance should be 1kΩ to
20kΩ.
3.2.1 Injection Control Ram Position and Ram Pressure Inputs
If this card is to be used for Injection Process Control, under normal conditions,
the Ram Position Input must be connected to ANA IN1 and the Ram Pressure
Input must be connected to ANA IN2. The exception would be if there were nonzero entries used for the Ram_Position_Reg_Id or Ram_Pressure_Reg_Id
setpoints:
A zero (default) entry for the Ram_Position_Reg_Id setpoint causes the software
to use ANA IN1 (the Loop_1_Process_Value) as the Ram Position input.
A non-zero entry for the Ram_Position_Reg_Id setpoint causes the software to
use that non-zero entry (which is actually the item name minus 400,000) to locate
the alternate source for the Ram Position input.
A zero (default) entry for the Ram_Velocity_Reg_Id setpoint causes the software
to use the rate of change of ANA IN 1 as the Ram Velocity input.
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A non-zero entry for the Ram_Velocity_Reg_Id setpoint causes the software to
the alternate source for the Ram Velocity input. Note that even if the Ram
Position input has been redirected, Ram Velocity will STILL be derived from ANA
IN 1 as long as the Ram_Velocity_Reg_Id setpoint is zero.
A zero (default) entry for the Ram_Pressure_Reg_Id setpoint causes the
software to use ANA IN2 (the Loop_2_Process_Value) as the Ram Pressure
input.
A non-zero entry for the Ram_Pressure_Reg_Id setpoint causes the software to
the alternate source for the Ram Pressure input.
3.2.2 Wiring DC Inputs & Outputs
The DC Input and Output functions require an external, regulated DC power
supply capable of providing a nominal voltage of plus (+) 24 Vdc. The power
supply must be CE recognized. The power supply and its ground distribution
block must be located within 30 cm of the bottom of the controller chassis. There
must be NO other (external) devices powered from the supply. The current rating
of the power supply will depend on the loads being driven. Note that there are
only four input and output functions and they are shared by all four channels.
Connect (+) DC to Pin 9 of P15. This supplies the voltage for the output circuits.
Connect (-) DC to Pin 11 of P15. This supplies DC Common for both the input
and output circuits.
Connect the outputs to one side of the loads. Connect the other side of the loads
to DCIN-.
18 gauge wire is recommended as a minimum, but make certain to satisfy all
local and national code requirements.
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Figure 5 A-60194 High Speed Processor Board Block Diagram
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3.3
Specifications
The following is a list of specifications that should be observed when installing
and wiring this card. The specifications apply to all functions of the same type.
Analog Inputs
Input Signal:
±10 Vdc (nominal) or ±20 mA (nominal) (jumper selectable)
Input Impedance:
1M Ω minimum voltage input: 500 Ω current input
Input Function:
Accumulator Position, Die Position, or Hydraulic Pressure (user configurable)
Analog Outputs
Output Signal:
±10 Vdc
Output Current:
3 mA maximum into a 3.3k ohm load
Input/Output Isolation:
Each Input/Output pair is isolated from all other pairs
DC Discrete Logic Inputs/Outputs
Isolation:
Optically isolated as a group
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DC Inputs
DC Outputs (Requires External Supply)
Input Voltage:
-0.6 (minimum)
to 40 Vdc (maximum)
On Voltage:
10 Vdc
Voltage:
24 Vdc maximum
Switched voltage
Current:
20 mA maximum
Switched current
Off Voltage:
5 Vdc
Input Current Less than 10 mA
at 24 Vdc
Class 2 Wiring must be separated a minimum of
¼ inch from Class 1 conductors.
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Figure 6 A-60194 High Speed Analog Processor Board
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Figure 7 Wiring the High Speed Analog Processor Board
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4. The Servo Amplifier Card
Note that all internal wiring comes complete from the factory.
This servo amplifier card contains 4 amplifier circuits, each capable of ±150
mAdc output for servo devices that operate with parison control. The 12 Vdc
auxiliary circuit, is capable of ±100 mA output, and provides excitation voltage for
transducers. Total power supply load must not exceed 500 mA.
Before using these amplifiers, the zero and gain of each output must be matched
to the driven device. Check the following:
From the manufacturer's documentation, obtain the specifications for the amount
of current needed to drive the device.
Connect a current meter in series with the servo output.
Connect a volt meter in parallel to the parison output.
Set the parison output to zero volts and adjust the amplifier zero pot to 0
mA.
Set the parison output to 10 Volts and adjust the amplifier gain pot to the span
specified by the manufacturer.
Repeat this process for each channel used.
Terminals accept 14 to 22 AWG wire. Line voltage connections should be made
with 14 AWG wire. All four amplifiers share a common reference. Zero and gain
for each amplifier is easily adjusted by on-board potentiometers.
The board is held in a "snap-track" mounting device. Mount the device in a
horizontal position either on a flat top surface, or on a vertical surface. Do not
mount the device in a vertical (lengthwise) position.
Operating Specifications
Amplifier Characteristics
Input Voltage: -10 to 10 Vdc nominal (no damage at ±3 times span)
Input Impedance: 100k Ω minimum
Zero Adjust (Bias): ±2 Vdc (reference to input)
Span Adjust (Gain): 5 mA / Volt to 150 mA / Volt (typical). Factory spanned to
80mA @ 10 Vdc In
Temperature Drift: 100 PPM/°C (typical)
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Reference Accuracy: 0.1% of upper range limit (max. span)
Frequency Response: 400 Hz (< -3 db) with output within saturation limits
Figure 8 A-13441 Servo Amplifier Card
Note that the board is pictured as it appears inside the enclosure.
Output Drive Capability: ±150 mAdc per amplifier; 500 mA total (four amplifiers,
plus 12 Vdc auxiliary output)
Output Saturation Current: Dependent on load resistance as follows:
I = 12/(50 + RL), RL in ohms
12 Vdc Auxiliary Supply
Accuracy: ±5%
Maximum Output Current: 150 mAdc
Load Regulation: 30 mV typical, from 1 mA to 150 mA
Line Regulation: 5 mV typical, from 102 Vac to 132 Vac
Temperature Drift: 1.5 mV/°C
Long
Term
Stability:
24
mV/1000
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5. Breeze IIc Wiring Layout
5.1
Time-Based Applications (Continuous Extrusion)
P2
DC IN1
DC IN2
DC IN3
DC IN4
DC OUT 1
DC OUT 2
DC OUT 3
DC OUT 4
V1-4
DIG COM
Description
Time Sync
N/A
Pumps Running or Safe to Run (This input must be on for the control to function)
Purge Input
Selectable via Comparator 1 setup
24 Vdc supplied from external supply
24 Vdc Common
Figure 9 Time Based DC I/O Connector
P3
ANALOG IN 1+
ANALOG IN 1ANALOG IN 2+
ANALOG IN 2ANALOG OUT 1+
ANALOG OUT 2+
EX1+
EX2+
ACOM
SHLD
Description
LVDT for Head Tooling 1 Sig +
LVDT for Head Tooling 1 Sig LVDT for Head Tooling 2 Sig +
LVDT for Head Tooling 2 Sig (+) 10 Vdc Output for Servo/Prop. Valve for Head 1
(+) 10 Vdc Output for Servo/Prop. Valve for Head 2
Excitation + used only if a Resistive (500 to 10K potentiometer) Normally not used
Analog Common for all Analog Inputs
Shield Ground
Figure 10 Time Based APU Analog I/O Channels 1 & 2
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P4
ANALOG IN 3+
ANALOG OUT 4+
EX3+
EX4+
ACOM
SHLD
Description
Shield Ground
Figure 11 Time Based APU Analog I/O Channels 3 & 4
Note: This connector wiring is optional and is only used if a 3 or 4 head application is ordered.
P5
ANALOG IN 5+
ANALOG OUT 6+
EX5+
EX6+
ACOM
SHLD
Description
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
Figure 12 Time Based APU Analog Input Channels 5 & 6
Note: This connector wiring is not used for Time-based applications.
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Figure 13 Time Based Analog wiring
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Figure 14 Time Based DC IO Wiring
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5.2
Position-Based Applications (Accumulator/Reciprocating
Screw)
(1-4) Head and 1 Accumulator or Reciprocating Screw only.
P2
DC IN1
DC IN2
DC IN3
DC IN4
DC OUT 1
DC OUT 2
DC OUT 3
DC OUT 4
V1-4
DIG COM
Description
External Shoot Input ( The use of this Input is selectable in the screen set )
N/A
External Purge Input
Shooting 1 Output
Filling 1 Output
24 Vdc Common
Figure 15 Position Based DC I/O Connector
P3
ANALOG IN 1+
ANALOG OUT 2+
EX1+
EX2+
ACOM
SHLD
Description
Shield Ground
Figure 16 Position Based APU Analog I/O Channels 1 & 2
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P4
ANALOG IN 3+
ANALOG OUT 4+
EX3+
EX4+
ACOM
SHLD
Description
Shield Ground
Figure 17 Position Based Analog I/O Channels 3 & 4
P5
ANALOG IN 5+
ANALOG IN 6NC
NC
EX5+
EX6+
ACOM
SHLD
Description
Linear Position Signal + for Accumulator or Recip. Screw Transducer 1
Linear Position Signal - for Accumulator or Recip. Screw Transducer 1
N/A
N/A
N/A
N/A
Excitation + used only if a Resistive (500 to 10K potentiometer)
N/A
Figure 18 Position Based APU Analog Input Channels 5 & 6
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Figure 19 Position Based Analog Wiring 1 Accumulator
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Figure 20 Position Based DC IO Wiring 1 Accumulator
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5.3
Position-Based Applications (Accumulator/Reciprocating
Screw)
2 Head and 2 Accumulators or Reciprocating Screw only.
P2
DC IN1
DC IN2
DC IN3
DC IN4
DC OUT 1
DC OUT 2
DC OUT 3
DC OUT 4
V1-4
DIG COM
Description
External Shoot Input ( The use of this Input is selectable in the screen set )
N/A
Shooting 1 Output
Filling 1 Output
24 Vdc Common
Figure 21 Position Based DC I/0 Connector
P3
ANALOG IN 1+
ANALOG OUT 2+
EX1+
EX2+
ACOM
SHLD
Description
Shield Ground
Figure 22 Position Based APU Analog I/O Channels 1 & 2
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P4
DC IN1
DC IN2
DC IN3
DC IN4
DC OUT 1
DC OUT 2
DC OUT 3
DC OUT 4
V1-4
DIG COM
Description
External Shoot 2 Input ( The use of this Input is selectable in the screen set )
N/A
N/A
External Purge Input 2
Shooting 2 Output
Filling 2 Output
24 Vdc Common
Figure 23 Position Based Analog Option Slot B Digital I/O
P5
ANALOG IN 5+
ANALOG IN 6-
EX5+
EX6+
ACOM
SHLD
Description
N/A
N/A
N/A
Figure 24 Position Based Analog Input Channels 5 & 6
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Figure 25 Position Based Analog Wiring 2 Accumulators
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Figure 26 Position Based DC I/O Wiring 2 Accumulators
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5.4
Encoder Based Applications (Wheel)
Note: This is for an encoder that uses digital Input 1 for the pulse and digital input
2 for the home. This is equivalent to what the Maco 6000 Breeze used to be.
P2
DC IN1
DC IN2
DC IN3
DC IN4
DC OUT 1
DC OUT 2
DC OUT 3
DC OUT 4
V1-4
DIG COM
Description
Pulse (from Incremental Encoder)
Home (from Incremental encoder)
N/A
N/A
24 Vdc Common
Figure 27 Encoder Based (Wheel) DC I/O Connector
P3
ANALOG IN 1+
ANALOG OUT 2+
EX1+
EX2+
ACOM
SHLD
Description
N/A
N/A
Shield Ground
Figure 28 Encoder Based (Wheel) Analog I/O Channels 1 & 2
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P4
ANALOG IN 3+
ANALOG OUT 4+
EX3+
EX4+
ACOM
SHLD
Description
N/A
N/A
Shield Ground
Figure 29 Encoder Based (Wheel) APU Analog Channels 3 & 4
Note: This connector wiring is optional and is only used if a 3 or 4 head application is ordered
P5
ANALOG IN 5+
ANALOG IN 6NC
NC
EX5+
EX6+
ACOM
SHLD
Description
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
Figure 30 Encoder Based (Wheel) APU Analog Input Channels 5 & 6
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Figure 31 Encoder Based (Wheel) Analog wiring
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Figure 32 Encoder Based (Wheel) DC I/O wiring
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5.5
Encoder Based Applications (Wheel)
Note: This is the wiring if the Slot A high speed quadrature encoder board option
is used in the model number.
P2
DC IN1
DC IN2
DC IN3
DC IN4
DC OUT 1
DC OUT 2
DC OUT 3
DC OUT 4
V1-4
DIG COM
Description
N/A
N/A
N/A
N/A
24 Vdc Common
Figure 33 Encoder Based (Wheel) DC I/O Connector
P5
A
/A
B
/B
H
/H
F
5V
ENC COM
NC
Description
A
NOT A
B
NOT B
H
NOT H
N/A
5 Vdc Excitation
Common
N/A
Figure 34 Option Slot A Encoder Based (Wheel) DC I/O Connector
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P3
ANALOG IN 1+
ANALOG OUT 2+
EX1+
EX2+
ACOM
SHLD
Description
N/A
N/A
Shield Ground
Figure 35 Encoder Based (Wheel) APU Analog I/O Channels 1 & 2
P4
ANALOG IN 3+
ANALOG OUT 4+
EX3+
EX4+
ACOM
SHLD
Description
N/A
N/A
Shield Ground
Figure 36 Encoder Based (Wheel) APU Analog I/O Channels 3 & 4
Note: This connector wiring is optional and is only used if a 3 or 4 head application is ordered.
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Figure 37 Encoder Based (Wheel) APU Analog wiring
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Figure 38 Encoder Based (Wheel) DC I/O wiring
5.6
Internal Wiring Cable Assemblies
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MACO Breeze II C
Installation Manual
Figure 39 Internal Wiring Cable Assemblies
Eurotherm USA
1670-IN-037-0-00
Page 40 of 40

MACO Breeze IIc installation manual

Transcription

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