Doku MacromateXX Professional S7 English 10 1

Manual
Extruder control
MacromateXX professional S7
Siemens Panel PC Touch
Leistritz Extrusionstechnik GmbH

Contents
1 General information............................................................................................ 4
2 System hardware description ............................................................................ 5
3 Screen layout ...................................................................................................... 6
4 Functions ............................................................................................................ 7
5 ON/OFF buttons .................................................................................................. 8
6 Screen selection buttons ................................................................................. 11
7 Password protection ........................................................................................ 12
8 Operation / Screens .......................................................................................... 13
8.1 Overview (Screen 10) ............................................................................................16
8.2 Report-Screen ........................................................................................................17
8.3 Analog values display (Screen 11) .......................................................................18
8.4 Alarm screens ........................................................................................................19
8.4.1 Currently active alarms (Screen 20) ............................................................................ 19
8.4.2 Alarm history (Screen 21) ............................................................................................. 20
8.5 Temperature control ..............................................................................................21
8.5.1 Temperature controllers 1 – 16 (Screen 30) ................................................................ 21
8.5.2 Temperature limits (Screen 32) .................................................................................... 22
8.5.3 Automatic heat up (Screen 33) ..................................................................................... 23
8.5.4 Screen saver (Screen 34) .............................................................................................. 24
8.6 Charts (Screens 60…66) .......................................................................................25
8.6.1 Chart 1 (Screen 60) ........................................................................................................ 26
8.6.2 Chart 2 (Screen 61) ........................................................................................................ 26
8.6.3 Chart 3 (Screen 62) ........................................................................................................ 26
8.6.4 Chart 4 (Screen 63) ........................................................................................................ 26
8.6.5 Chart 5 (Screen 64) ........................................................................................................ 27
8.6.6 Chart 6 (Screen 65) ........................................................................................................ 27
8.6.7 Chart 6 (Screen 66) ........................................................................................................ 27
8.7 Limits for analog inputs (Screen 67) ....................................................................28
8.8 Melt pressure /melt temperature limits (Screen 68) ............................................29
8.9 Recipes User data (Screen70) ..............................................................................30
8.10 Process data logging (Screen 71) ........................................................................35
8.10.1 Temperature logging selection (Screen 72) ................................................................ 37
8.10.2 Process data logging selection (Screen 73) ............................................................... 38
8.11 Start automatic ......................................................................................................39
8.11.1 Start automatic analog values (Screen 80) ................................................................. 39
8.11.2 Start automatic feeders (Screen 81) ............................................................................ 41
8.11.3 Stop automatic (Screen 82) .......................................................................................... 42
8.12 Option – Brabender RC4, LM3 odder OP5 feeders ..............................................43
8.12.1 Brabender Feeder Status (Screen 40).......................................................................... 43
8.12.2 Brabender Feeder configuration (Screen 41) ............................................................. 45
8.13 Option – Brabender OP1 feeder (Screen 47)........................................................47
8.14 Option – K-Tron Feeders .......................................................................................48
8.14.1 K-Tron Feeder status (Screen 42) ................................................................................ 48
8.14.2 K-Tron Feeder configuration (Screen 43) .................................................................... 50
8.15 Option – Colortronic / Scholz feeders ..................................................................52
8.15.1 Colortronic Feeder Status (Screen 44) ........................................................................ 52
Edition 02/2012 for SW Version 10.1
Doku_MacromateXX_professional_S7_english_10_1.doc Page 2 of 98
8.15.2 Colortronic/Scholz Feeder configuration 1 (Screen 45 ) ........................................... 54
8.15.3 Colortronic / Scholz Feeder configuration 2 (Screen 46) .......................................... 56
8.16 -Option- Underwater pelletizer ..............................................................................58
8.16.1 Underwater pelletizing operator (UWP) (Screen 90) ................................................. 58
8.16.2 Underwater pelletizing (UWP) technician (Screen 91) ............................................... 61
8.17 -Option- Melt pump ................................................................................................63
8.17.1 Melt pump (Screen 94) .................................................................................................. 63
8.17.2 Melt pump Parameter (Screen 95) ................................................................................ 65
8.18 -Option- Roving-monitoring (Screen 97) .............. Fehler! Textmarke nicht definiert.
8.19 Technician configuration (Screen 100) ................................................................67
8.19.1 Machine configuration (Screen 110) ............................................................................ 68
8.19.2 Button positions (Screen 111) ...................................................................................... 69
8.19.3 Maintenance list (Screen 112) ...................................................................................... 70
8.19.4 Positions analog displays (Screen 113) ...................................................................... 71
8.19.5 Control parameters (Screen 120) ................................................................................. 72
8.19.6 Heating optimisation 1 – 8 / 9 – 16 (Screen 122 / 123 ) ............................................. 75
8.19.7 Heat current monitoring (Screen 121) ......................................................................... 77
8.19.8 Scaling analog outputs (Screen 130) ........................................................................... 78
8.19.9 Scaling analog inputs (Screen 131) ............................................................................. 79
8.19.10 Scaling analog inputs MT/MD (Screen 132) ................................................................ 80
8.19.11 PLC (Screen 140) ........................................................................................................... 81
8.19.12 PLC Diagnosis (Screen 141) ......................................................................................... 82
8.19.13 - Option- Diverter valve operation (Screen 145) ......................................................... 83
8.19.14 User administration (Screen 150) ................................................................................. 84
8.19.15 System settings (Screen 151) ....................................................................................... 86
8.19.16 Machine settings (Screen 152) ..................................................................................... 87
9 Alarm display and operation ........................................................................... 88
9.1 Alarm list ................................................................................................................89

1 General information
About the operating manual
This operating manual contains the functionality of the operating panel.

The illustrations shown do not always match the screen displays of your controller, as the screen lay-
out is dependent on the type and scope of the system. However, the logical relationship to your sys-
tem is present on each screen.
The instructions given in this manual cannot replace sufficient technical understanding.
The instructions given in this manual cannot replace sufficient technical understanding.
LEISTRITZ Extrusionstechnik GmbH

Markgrafenstraße 29-39
90459 Nürnberg
Tel: +49-911/4306-562 or -381 or -627
Fax: +49-911/4306-505
Internet: http://www.leistritz.com
E-Mail: extruder@leistritz.com
General precautionary topics
 Never open the controller and touch electronic components while energised.
 Work on electronic components may only be conducted by specially trained experts.
 Never use petrol, thinner or cleaner containing solvents to clean the controller. Only clean the
operating unit with a neutral cleaner and a soft cloth.
 Do not press the keys of the touch-screen with a pointy object (biro, pencil).
 Keep the USB-socket closed to provide dust inlet
Switching on
To boot the control the main switch must be on and all emergency-stop buttons must be released.
The Windows operating system and the HMI-Runtime application program on the operating unit are
started automatically. (That may take ca. 3 minutes)

2 System hardware description
This schematic description not necessarily consists in reality of these displayed units.
Operation panel
Siemens Panel PC
Profibus DP
Feeder
controller
converter
8-chanel
Temp.controller KS 800
S7-300 ET200s
I/O-Unit

3 Screen layout
The screens are divided basically in three parts
Permanent area
Screen content
Touch buttons
Permanent area The content of the permanent area is similar on all screen pages. Up to 8 actual
values can be displayed numerically and by a bar chart. Configuration of this is
performed on Technicians screen 131 and 132.
Display of the active screen

Machine-No. and Name
Current time and date
If there is no connection to the control unit (S7-PLC) the upper right dot does not
blink green and grey. So there is no operation possible.
Screen content The screen content pane is screen specific, so it is different on all the screens.
Touch buttons ON/OFF functions

4 Functions
Language setting
Toggle-button to change to available screen languages
Screen cleaning
To clean the screen manually during operation to avoid any operation this
button calls a clean-screen.
Log-in/off
(incl. Display of the current level)
If a user is logged in this button leads to log-of (level 0)
Calculator
Launches the Windows-calculator
Start/Stop of data logging

Green blinking dot = Process data logging activated
Hardcopy
The current screen will be saved as a graphic file
The setting at the “Hardcopy-program” is the second USB interface.
Attention: To save the screen, press the button two times!
Report-Screen
Report of current actual values and setpoints
A hardcopy file can be stored on USB-stick
Start/stop automatic button with status display
Back to previous selected screen

5 ON/OFF buttons
Operation and status display of machine units
The frame and inner filling display the status of the specific unit.
The following shows the main drive button as an example

The device is not configured
or emergency-off is active
The device is ready to switch ON
The device is switched ON and is running
The device is switched ON, but no running feedback available

e.g. feeder is switched on, but not yet running (feedback)
The device is switched OFF and interlocked with other devices,

e.g. the main drive can be switched on when the heating is on and heated up.
The device is switched OFF and a failure occurred.

Description of buttons to operate the specific devices
Heating/ Cooling
Heating OFF
Heating ON / Heating up active (dot green blinking)
Eating ON / heated up (Setpoints reached tolerance band)
Heating OFF/ automatic heat-up activated
Extruder main drive ON/OFF
Vacuum pump ON/OFF
Vacuum valve ON/OFF
Side feeder 1 ON/OFF

Feeder line ON/OFF
Pre-condition to switch on single feeders.
Switch off all feeders by this button
Single feeder ON/OFF
Pelletizer ON/OFF
Under water pelletizing water system ON/OFF
Under water pelletizing PRE AUTOMATIC/AUTOMATIC
Melt pump ON/OFF
Melt stuffer ON/OFF

6 Screen selection buttons
Touch Grey buttons enable to call main chapters.

buttons
for Dark orange buttons display the active chapter.
screen
selection Light orange buttons enables to call the designated sub-
screen.
Always leads to “Overview screen” 10.

7 Password protection
After booting the system, two variations are possible:
(Settings for auto-logon on screen “User administration” 150)
Login screen:
No access to the system without password
Password entry
Skip login screen:

“Overview screen” 10 will be called automatically after booting.
Generally all inputs are denied in level “0”

If the user wants to select functions or screen assigned to a
higher password level, a "Login window" is opened. A pass-
word can be entered. If the password is correct, the desired
function can be selected. If the password is incorrect, the
lowest password level is automatically selected by the system.
User administration On screen “User administration” 150 password administration

and auto-logon settings can be.

8 Operation / Screens
The structure of the sections and screen selection are illustrated in the table below.
Chapter Screens No. Description
Alarms
20 Currently active alarms
21 Alarm history
Overview
10 Overview
11 Analog values display
90,91 Under water pelletizing
94,95 Melt pump
Temperature control
30 Temperature controllers 1 – 16
31 Temperature controllers 17 – 32
32 Temperature limits
33 Automatic heat up
34 Screen saver
Feeders
40 Feeder status
41 Feeder configuration
Charts and limits
60 Chart 1
61 Chart 2

62 Chart 3
63 Chart 4
64 Chart 5
65 Chart 6
66 Chart 7
67 Limits for analog inputs
68 Melt pressure /melt temperature limits
Recipes and data logging
70 Recipes User data
71 Process data logging
72 Temperature logging selection
73 Process analog data selection
Start automatic
80 Start automatic analog values
81 Start automatic feeders
Technician configuration
100 Technician configuration: Machine configuration
110 Machine configuration
111 Button positions
112 Maintenance list
113 Positions analog displays

Technician configuration: Heating
120 Control parameters
121 Heat current monitoring
122 Heating optimisation controller 1 – 8
Technician configuration: Analog signals
130 Scaling analog outputs
131 Scaling analog inputs
132 Scaling analog inputs MP/MT
67 Limits for analog inputs
68 Melt pressure /melt temperature limits
Technician configuration: Control
140 PLC inputs/outputs
141 PLC diagnosis
145 Diverter valve operation
Technician configuration: System
150 User administration
151 System settings
152 Machine settings
Application call :Windows-Explorer
Shut down visualization -> go to Windows

8.1 Overview (Screen 10)
Display of configured units (with options)
Touch sensitive areas lead to detail screens
gravimetric
feeders
Temperature control Analog values

display

8.2 Report-Screen
Report of current actual values and setpoints.

A hardcopy file can be stored on USB-stick

8.3 Analog values display (Screen 11)
Display of the most relevant actual values and setpoints
A final setpoint can be entered to be stored in a user recipe.

This is to memorize a value to be entered manually.
The button copies all actual setpoints in the designated field.
Setpoint actual value

decrease increase
The “Step” value can be changed on “Scaling analog outputs” 130

8.4 Alarm screens
8.4.1 Currently active alarms (Screen 20)

Current alarms are displayed with number, time, date, status and text.
acknowledge alarm,
Status: quit alarm
K = alarm occurred
G = alarm gone
Q = alarm acknowledged

8.4.2 Alarm history (Screen 21)
Historical alarm display of the latest 100 alarms.
This list exists also after restart.
The alarms will be stored as a ring puffer in chronological list.
Status:
K = alarm occurred
G = alarm gone

8.5 Temperature control
8.5.1 Temperature controllers 1 – 16 (Screen 30)
heating active
Cooling active
Set Setpoints
The set temperatures are entered in °C. The individual heat zones are heated up to
these specified values when the heating is switched on.
Copies Setpoint 1 to all other zones
Act. The actual temperatures are current temperatures of the individual heat zones
Diff. The difference is the setpoint minus the actual value.
Output The output is a measure in percent for the heating capacity of the heat zones. When a
zone is initially heated up, this measure is 100 %. As the actual value approaches the
setpoint, the switch-on time decreases in order to optimally reach the selected setpoint. A
positive output indicates that the zone is being heated. A negative output is indicative of
the zone being cooled.
The individual heat zones can be switched on or off with the I/O pre-selection. The set or
decrease temperatures and the limits are not taken into account for switched-off zones.
Temperature controllers 17 – 32 (optional)

8.5.2 Temperature limits (Screen 32)
Limit entry
On this screen the upper and lower temperature value limits for the heat can be entered. The tempera-
ture differences of the heat zones are displayed as numerical values and as bar graphs. With the pre-
selection Alarm I/O the limit-value fault messages of the individual heat zones can be switched on and
off.
The temperature limit values are relative values used for limit value monitoring of the respective heat
zone. A tolerance range can be set for each heat zone. The violation of the tolerance range triggers an
alarm.
Example: Set temp. = 200 °C
+ Alarm Max. = 15 °K
- Alarm Min. = -20 °K
|
215 °C |------------------------- + Alarm Max.
| +15 °K
200 °C |------------------------- Setpoint
| -20 °K
180 °C |------------------------- - Alarm Min.
|
Violation of the tolerance range triggers an alarm. When the temperature lies within the tolerances again
the fault message disappears.
If a setpoint or decrease value is changed, the tolerances are automatically adapted taking the limit value
into account. While the system heats up, all heat zones must reach the lower minimum alarm limit before
the main motor can be started.

8.5.3 Automatic heat up (Screen 33)
Automatic extruder heat up at pre-set time.

(The PC must be running and all emergency off switches needs to be pulled)
button: Copies time from Monday to

0: off all others
I: active
time
Activate each desired day of week by button I/0: green background means activated status
Set desired start time to heat up automatically
The copy-button enables to copy the start time of Monday to all other days
For the automatic heat up the computer has to be in operation.

8.5.4 Screen saver (Screen 34)
This page avoids operation of the machine while the PC is on (password protection)
To re-enter operation at least password level 1 is needed.

8.6 Charts (Screens 60…66)
Selection of
other trends
The scaling of the value-axis can be set as desired from –999 to 9999.
Display of the different measured variables (here actual speed of extruder).

The colour of the text in the button (blue here) matches the curve colour.
Time backward and forward Time zoom in/out ruler
Values at the ruler position

8.6.1 Chart 1 (Screen 60)
Shortcut Value
n Ext Actual speed of extruder screw
M Ext Actual load of the extruder
MD 1 Melt pressure 1
MT Melt temperature
Dos Total throughput feeder line
Vacu Vacuum pressure
SB 1 Feed rate/speed of side feeder 1
SB 2 Feed rate/speed of side feeder 2
Shortcut Value
Dos 1 Throughput feeder 1
Dos 2 Throughput feeder 2 (if available)
Shortcut Value
HZ 1 Actual temperature of Heat Zone 1
Dos 4 Actual temperature of Heat Zone 4
Shortcut Value

Shortcut Value
Shortcut Value
Option Underwater pelletizing
Shortcut Value
n Gran Speed pelletizer
M Gran Load pelletizer
P AnfW Melt pressure diverter valve
MT Melt pressure 1
T AnfW Temperature diverter valve
T LP Temperature plate
T Tank Temperature water tank
T Rohr Temperature water pipe

8.7 Limits for analog inputs (Screen 67)
This screen contains all important analog limit values used for system monitoring and protection.
These parameters are only to be entered by the authorised personnel with the corresponding care.
An upper and a lower limit value can be defined for each measured value. The corresponding alarms are
switched on or off with the pre-selection I/O.
Main drive underload :

If this value is set <> 0 the extruder will be turned off automatically in case of low motor load.
This warning will appear:
Attention low motor load, extruder cuts off in 20 sec !

8.8 Melt pressure /melt temperature limits (Screen 68)
This screen contains melt pressure and melt temperature values to be configured. These parameters are
only to be entered by the authorised personnel with the corresponding care.
The number of values are configured at screen 110.
Just Alarm message

at limit I/O
Limit alarm
Extruder-off

8.9 Recipes User data (Screen70)
Production data of the machine (User) can be saved and loaded. In the "User" recipe type all prod-
uct-relevant parameters,( see following table ) such as temperature setpoints, scaling of the measured
value curves, analogue limit values and temperature limit values, are saved.
Internal memory and a USB-Stick are available as storage media.
Recipe handling:
Create a new recipe:
The current control data are read from the controller to the visualization
system
„Save as“ appears.

Enter a recipe name by using the keyboard and ENTER

Save existing recipe and overwrite the existing one:
Choose a recipe name.
The current control data are read from the controller to the visualization sys-
tem
Data record already exists

Overwrite data record?
YES
NO
Message
Successful transfer ends up with „ready“
If „Error“ occurs“ the recipe is not valid

Load saved recipes to the controller
The selected recipe will be transferred to the controller
Message
Successful transfer ends up with „ready“
If „Error“ occurs the recipe is not valid

Delegate an existing recipe
Push „Delete recipe“
USB-Transfer of all recipes:
Copy all recipes from the internal memory to a USB-Stick.

The recipes are saved on the USB-Stick under the file name "User". This
file name may not be changed, as otherwise the system will not recognise
the data.
Copy all recipes from a USB-Stick to the internal memory.
The recipes are located in the file "User".
Important:
All recipes are always transferred from the internal memory to the USB-Stick or vice versa. This
means that the above transfer actions overwrite recipes of the same name without asking for confir-
mation. This problem can be remedied by using different USB-Sticks (exactly dated backup cop-
ies).

Table of data, stored in a user-recipe:
Item Related device / function

Total throughput Feeders general
Installation mode (Single, 100%) Feeders general
Fill level minimum Feeders 1-8
Fill level maximum Feeders 1-8
Maximum refill time Feeders 1-8
Check max. output Feeders 1-8
Name of feeder Feeders 1-8
Bulk density Feeders 1-8
Mode (GF,VF,....) Feeders 1-8
Throughput (setpoint for single mode) kg/h Feeders 1-8
Throughput (setpoint for group mode) % Feeders 1-8
Alarm limits on/off Temperature controller 1-

16
Alarm low limit Temperature controller 1-
16
Alarm high limit Temperature controller 1-
16
Temperature controller on/off Temperature controller 1-
15
Temperature setpoint Temperature controller 1-
15
Limits active/inactive analogue inputs Analogue values

High limit of displayed value Analogue values
Low limit of displayed value Analogue values
Trend curve display on/off Trend curve

Trend curve scaling Trend curve
Various product related parameters of options,

e.g. melt pump or underwater pelletizer are also included.

8.10 Process data logging (Screen 71)
Data logging of selected values to a file on an USB stick.

Selection of these values via screens 71 and 72.
One file can store 50 000 values. Once a file reached 200MB, the system creates a new one automat-
ically. A total of 40 files can be created.
These files are stored at USB at E:\Arch\...
The archive files start with the name Archiv0.csv, Archiv1.csv, Archiv2.csv, ..., Archiv40.csv.
If there are created more than 40 files the system will continue to overwrite the oldest files beginning
with the file Archiv0.csv.
The files are .csv formatted, so it is possible to open and handle them with e.g. MS Excel
A batch name can be entered to be stored at the logging files
Logging interval of all selected values (recording interval from 5 to 60 seconds).
The machine number is displayed to be stored at the logging files

Selection of temperature data to be logged (Screen 72)
Selection of other analogue data to be logged (Screen 73)
Start/Stop of data logging

The dot at the pushbutton is blinking and the message "data logging active" appears on
screen while data logging is active.
Copy all logging files Archiv0.csv to Archiv40.csv to the second USB-stick (F:\)
Creation of a new archive file.

The existing file will be closed and a new file is created. Now it is possible to handle the
old archive file by Windows-Explorer to copy or to move it.
Deleting of all archive files.
Password protected, all archive files in E:\Arch\... Archiv0 to Archive40 are deleted.
ATTENTION: Before deleting, copy or move all desired files to another storage medi-
um.

8.10.1 Temperature logging selection (Screen 72)
Selection of process data values to be logged in a file
activated no logging
logging

8.10.2 Process data logging selection (Screen 73)
Selection of process data values to be logged in a file
activated no logging
logging
Within gravimetric feeders 1-8 following data are logged:

Actual throughput in kg/h
Setpoint throughput in kg/h
Feeder screw speed in %
Hopper weight in kg

8.11 Start automatic
8.11.1 Start automatic analog values (Screen 80)
Automatic start for devices with analog setpoints
For automatic start, up to 8 time steps can be configured S1 – S8.

Activation of Start/Stop automatic
Start/Stop automatic not activated
Button to initiate the automatic start, when activated
Status: automatic start is running
Status: automatic start is finished
Status: Stop automatic activated
Star automatic ready to run again
Example:
The Setpoint is set from S1 up to S8
The device will be switched on if the setpoint is not 0
Step
after 6 s start
with 400 U/min
Hold time: the specific

Setpoint will stay for 6 s
start immediately
with100 %

8.11.2 Start automatic feeders (Screen 81)
With existing gravimetric feeders, the devices could be started time delayed
“Hold times” and “total throughput in kg/h” belong to the previous screen “Start automatic analog val-
ues“.
starts the selected feeder
Feeders are not switched off, even there is in the upper row a „O“ setting

8.11.3 Stop automatic (Screen 82)
The stop automatic is customized.

Stop row is initiated in a pre-programmed way.
Pressing this button initiates the stop automatic to switch off all devices automatically.

8.12 Option – Brabender RC4, LM3 odder OP5 feeders
8.12.1 Brabender Feeder Status (Screen 40)
Screen "Feeder configuration”, Screen 41 for additional settings
Drives interlocked: Feeders are able to run only with running extruder
Drives not interlocked: Feeders are able to run without extruder.

The extruder cannot be started

Display:
According to the projected number of feeders the data lines are displayed.
Name Name entry on screen „Feeder configuration“
Group-mode: Entry of each feeder's throughput setpoint in %

Throughput
Single-mode: Entry of separate throughput setpoint of each feeder in kg/h
Set %
Group-mode: Display of the actual setpoint of the feeder's throughput in kg/h.
Throughput
Single-mode: Entry of separate throughput setpoint in kg/h.
Set Kg/h
Throughput
Actual value of throughput of each feeder in kg/h
Act. Kg/h
Deviation Actual %-value of the regulation deviation (setpoint - actual value)

%
Speed Actual %-value of the feeder rotational speed.

%
Hopper weight
Actual hopper weight in kg
kg
Total throughput Summation of the already fed product of each feeder

kg
Setting and actual operating mode display:
GF: gravimetric feeding
VR: volumetric regulating
Modus VS: volumetric setting
Set Act DI: discharge
CM: calc. maximum output
GD: gravimetric discharge
VF: volumetric feeding
Refill manually Start/Stop

Blinking green frame : refilling active
Status
grey: feeder off, green: feeder on
If the feeder line is locked, this sign is displayed
Total setpoint Group-Mode: Display and entry of the total throughput setpoint of all feeders
in kg/h.
Single-Mode: Display of the total throughput setpoint of all feeders in kg/h.
Total actual value Display of the actual total throughput of all feeders in kg/h.
Summation of the already fed product of all feeders.

Sum
Press the <Reset>-button to reset all throughputs to zero.
Mode: Group 100%, Group or Single

Mode:
Selectable at Screen 41 "Feeder configuration"

8.12.2 Brabender Feeder configuration (Screen 41)
Name Name entry (max 12 characters)
Bulk densi- Entry of product weight in kg/l to calculate the fill level.
ty kg/l Entry is only possible at stopped feeder.
Check max.
Maximum output in kg/h :
output kg/h
Entry is only possible in turned off mode of each feeder. (blue displayed values)
Level min. Fill level, which enables the controller to switch from feeder mode to refill mode.
% Entry in %, related to the useable weight range.
Level max. Fill level, which enables the controller to switch from refill mode to stabilization time.
% Entry in %, related to the useable weight range.
All configuration data of that screen will be written (transferred) to the feeder controller.
Push button "write values" to write these data to the feeder controller!

Mode
Changeable when feeder-line is off

Refilling automatic AUTO/ MAN
AUTO: automatic refilling by existing devices at minimum level.
MAN: Reaching the minimum level an alarm appears to do a manual refill at the specif-
ic feeder hopper.
Feeder alarm configuration:

Selection which alarms lead to cut off the extruder or cut
off the feeder line.
This not depends on any settings at the feeder control-

ler.
Selection:
grey: only alarm message
red: cut off
Characters a – m:
Correlation to possible alarms
Selected feeders interlocked with side feeders.

To avoid running feeder with stopped belonging side
feeder.
If the selected feeder is off, all others are not able to run
To enable the communication via Profibus to the PLC following settings has to be done at the feeder
controller:
Host comp operation
Host computer Parameter
Procedure Siemens RK512 –L

Identnumber 01
Baud rate 38400 (not relevant)
Bus-Address 05 COM DPS V01.034
Bus Mode 01

8.13 Option – Brabender OP1 feeder (Screen 47)
I/O Status ON/OFF
Throughput Set Setpoint throughput
Throughput Act
Actual Throughput

%
Speed Actual %-value of the feeder rotational speed.

%
Total throughput Summation of the already fed product of the feeder

kg
Hopper weight
kg
Mode Mode GD, VR, VS, LF, EF, GL, VD, AT, M

8.14 Option – K-Tron Feeders
8.14.1 K-Tron Feeder status (Screen 42)
Screen "Feeder configuration”, Screen 43 for additional settings


Display:
According to the projected number of feeders the data lines are displayed.
Name Name entry on screen „Feeder configuration“

Throughput
Set %
Throughput
Set Kg/h
Throughput
Act. Kg/h

%
Output
Actual output of the controller in %
%
Speed Actual feeder screw speed in rpm

%
Hopper weight
kg

kg
Set-mode: gravimetric volumetric

Modus
Act.-mode: gravimetric volumetric
Refill manually Start/Stop

Blinking green frame : refilling active
Status
in kg/h.

Sum
Mode: Group or Single

Mode

8.14.2 K-Tron Feeder configuration (Screen 43)
Name
Name entry (max 12 characters)
Actual value Average Feed factor in kg/h

Value determined by the respective metering unit, which is constantly updated
Feed factor
during the metering.
kg/h
The initial value must be adapted to the mean value in order to regulate the meter-
Feed factor Ini-
ing unit after switching on in order to ensure that it settles at the desired set value.
tial kg/h
Calibration
Cal
Starts determining maximum output.
Tar Push Button to set the Hopper weight to zero
Hopper weight
Actual hopper weight
kg
kg Entry in kg

Level max. Fill level, which enables the controller to switch from refill mode to gravimetric
kg mode. Entry in kg

MAN: Reaching the minimum level an alarm appears to do a manual refill at the
specific feeder hopper.

Mode


ler.
Selection:
red: cut off
Characters a – m:

feeder.
If the selected feeder is off, all others are not able to run.

8.15 Option – Colortronic / Scholz feeders
Colortronic and Scholz feeders have similar operation screens.
The internal programming is different, so the selection must be done at page
“Machine configuration” 110 : Feeder Type Colortronic or Scholz
8.15.1 Colortronic Feeder Status (Screen 44)
Screen "Feeder configuration 1”, Screen 45 for additional settings
Screen "Feeder configuration 2”, Screen 46 for additional settings


According to the projected number of feeders the data lines are displayed
Name Name entry on screen „Feeder configuration 1“ 45

Throughput
Set %
Throughput
Set Kg/h
Throughput
Act. Kg/h

%
Speed Actual feeder screw speed in % (controller output)

%
Hopper weight
kg

kg
Mode Setp. Act. mode: gravimetric volumetric
Button with actual mode

Dis/enable
refilling
= refilling enabled = refilling disabled
Manual refill button

Blinking green frame: refilling active
This action can be stopped by pushing
Status
in kg/h.

Sum
Mode: Group or Single

Mode

8.15.2 Colortronic/Scholz Feeder configuration 1 (Screen 45 )
Name Name entry (max 12 characters)
Average: actual value

Feeder factor
Initial: Entry (max. feeder screw throughput)
Calibration
Cal
Starts determining maximum output.
Tara Push Button to set the Hopper weight to zero
Hopper weight
Actual hopper weight
kg
kg Entry in kg
Level max. Fill level, which enables the controller to switch from refill mode to gravimetric
kg mode. Entry in kg

MAN: Reaching the minimum level an alarm appears to do a manual refill at the
specific feeder hopper.

Mode

8.15.3 Colortronic / Scholz Feeder configuration 2 (Screen 46)
Selection and display of feeders:
Within active communication to the feeder controller these values overwrite automatically always the
values at the feeder controller. So, these values needs to be entered only at the Panel PC
Description of parameters: see feeder manual
All other parameters are only available and accessible at the feeder controller


ler.
Selection:
red: cut off
Characters a – k:

feeder.
If the selected feeder is off, all others are not able to run.

8.16 -Option- Underwater pelletizer
8.16.1 Underwater pelletizing operator (UWP) (Screen 90)
ON-/OFF-Status
Status
Status Pelletizer:
dismounted
mounted
Operation of the UWP system by buttons:
Pelletizer
Water system start/stop (auxiliary devices UWP):

exhaust air fan, dryer, process water pump, …
Pre-automatic / automatic

1. Operation to flush the die:
Button Condition, status, operation Status text
Extruder needs to be heated up

Start water system Pelletizing system off state
Water system is running Water system operating
Water system is running

Pelletizer is dismounted Pre-automatic ready to start
Extruder and feeders are running
Pushing button „Pre-automatic“, the diverter valve Pre-automatic running

moves to production and the die is flushed
Pushing button „Pre-automatic“, flushing is stopped Pre-automatic ready to start
2. Operation blade adjustment:

Water system is running Mode “blade adjustment” ready

Pelletizer is mounted to start
Extruder is off
Pushing the button „Pelletizer“ water flushes the die. Mode “blade adjustment” ready
The pelletizer starts running with “Speed blade ad- to start
justment”
Blade adjustment is running Mode “blade adjustment” run-

ning
Pushing the button „Pelletizer“ or time delayed, Mode “blade adjustment” run-
blade adjustment will end ning
3. Operation production:
Water system is running Automatic ready to start

Pelletizer is mounted
Extruder and feeders are on
Pushing button „Automatic“, the diverter valve
moves to production and the die is flushed
Production Automatic running
Pelletizer starts running automatically with „produc-
tion speed“
4. Operation finishes production:
Pushing button „Automatic“, lead to “Pre-automatic” Automatic ready to start
Diverter valve and water to bypass, pelletizer off

Delay time settings:
Start water (automatic) Start delay time water system
Start pelletizer (automatic) Start delay time pelletizer
Start diverter valve (automatic) Start delay time position change diverter valve
Stop water Stop delay time water system
Stop pelletizer Stop delay time pelletizer

Speed settings:
Initial speed pelletizer Initial speed pelletizer in rpm
Speed mode “blade adjustment” Speed pelletizer for blade adjustment

Displays:
Actual current-limit of pelletizer
Current limit Initial value:90%.
After 5s the value will be calculated
Motor current Actual current of pelletizer motor in %
With analog measuring:
Water flow
Water-throughput in m³
Water tank temperature Actual water tank temperature
Water level
Water tank level in %

8.16.2 Underwater pelletizing (UWP) technician (Screen 91)
Positions Status display for diverter valve and pelletizer

diverter valve
and Pelletizer
After reaching the both end positions of the diverter valve the solenoid
valves remain for this time longer open and also the hydraulic pump
Hydraulic pump off delay
runs that time longer, to be sure to open or close the diverter valve
fully.
The maximum running time for the hydraulic pump diverter valve. Is
Max. movement time di-
one end position not reached within this time, an alarm appears. To
verter valve
quit this error message press button RESET on this page.
Time settings water sys- Entry of start-delay and stop-delay times for the water system aggre-
tem gates after starting and stopping the water system.
Max. time mode “knife Entry of max. Time of running knife adjustment Knife adjustment mode
adjustment stops after this time or after pushing Pelletizer stop.
Is one end position (bypass or production) of one solenoid valve by-
Max. movement time by-
pass system not reached within these time, an error message hap-
pass solenoids
pens. To quit this error message press button RESET on this page.
Speed dryer Setpoint speed of the dryer

Water flow rate: Entry of minimal flow rate with time delay for alarm at low flow rate

Level water tank Alarm and warning values and refill limits
Analog value settings for

Water flow Scaling of optional analog values of water flow and water level
Water level

8.17 -Option- Melt pump
8.17.1 Melt pump (Screen 94)
Functionality for pressure pump-speed control
The pump always starts in manual mode, i.e. control is inactive

(yellow back rounded value).
The pump runs with the constant speed “Setpoint speed pump”
In "AUTO mode" the pressure is controlled by varying the melt pump speed with a pressure setpoint
entry in bar.
Chart display:
MP1 : act. mass pressure 1
P diff : act. differential pressure
M: act. load of melt pump motor
n: act. speed of melt pump
Q: act. gravimetric throughput in kg/h
Settings for minimum and maximum chart value scaling.

Change from manual- to automatic mode is possible by pushbutton or by following described automat-
ic (Screen 95)
Change from manual- to automatic mode is possible by pushbutton or by following

MAN/AUTO
described automatic (Screen 95)
-Button
Output melt
pump %-Value of melt pump speed for starting
Output melt
In AUTO-mode the speed of the melt pump is controlled automatically by the PID-
pump
pressure controller
Speed melt
pump
Actual speed of the melt pump
M melt
pump
Actual load of the melt pump

8.17.2 Melt pump Parameter (Screen 95)
Pressure control If pressure control on-automatic is on “I”:

On-automatic When the controlled pressure reaches the limit = %-value of the pres-
sure setpoint,
The controller will be switched to automatic control
On-level MAN to AUTO e.g. Limit 80 % pressure set point 50 bar, at 40 bar actual pressure, the
controller will go to automatic mode
Once the low value is reached, or the set time is reaches the alarm is
Alarm delay activated.
Low pressure limits If now the low pressure value is reached (with hysteresis) the pump will
be switched off
Input pressure = MP1

Reselection, which melt pressure sensors are used physically
Input pressure = MP1
Input pressure control Preselect ion which pressure “input” or “output” needs to be automatical-
Output pressure control ly controlled

PID control parameters
P gain:
P-gain is calculated in linear ratio to the actual pressure control deviation (bar):
In the control deviation range from 0 to Deviation max. , P-gain will be calculated in a linear way
between P-gain max. and P-gain min.
Exceeding control deviation Deviation. max. , P-gain max. is used
Pdevi.
Pgain
Pmin. Pmin
Ti Integration time
Manual output Manual met pump speed input

Band the controller is not changing its output value
Dead zone
Upper limit of the controller’s output
High output limit
Lower limit of the controller’s output
Low output limit
Standard setting: RUN
RUN/RESET-Button For initialization of the controller press once RESET
Filter PID control input signal
To prevent peaks at the pressure input signal a filter can be used
Filter on/off Filter active / inactive
Filter constant 1= no filter … 0.001 = high damping
Filter output Pressure output value as input value for controller

Alarm limits:
Functionality:
With activated alarms and reached alarm value the melt pump and the extruder is shut off.
High limit: immediate shut off is initiated.
Low limit:
Once the low value is reached, or the set time is reaches the alarm is activated.
If now the low pressure value is reached (with hysteresis) the pump will be switched off
(Alarm delay time on screen 95)

8.18 Technician configuration (Screen 100)
On this screen pre-settings for the system are made by responsible operating personnel.
Drives interlocked: auxiliary devices are able to run only with running extruder
Drives not interlocked: auxiliary devices are able to run without extruder.
Launch „Windows Explorer“ in a separate window
Exit the visualization program and return to the Windows level.

Caution, after exiting no machine operation is available until restart.

8.18.1 Machine configuration (Screen 110)
Machine Machine type or

number customer
Feeder type No grav. Feeders, Brabender CS (OP1), Brabender RC4, LM3, OP5
K-Tron, Colortronic, Scholz
Number of feeders Number of gravimetric feeders 1…8
Granulator Type of pelletizers
Activation/deactivation of devices and signals
(at deactivated device all belonging alarms and functions are reactive)
Printer configured Report printout of current actual values and setpoints

A current printout could be generated if a printer is connected.
Heating off with emer- The heating can run on optional with emergency stop
gency off
Off delay motor cool- With water-cooled motor, after drive off the valve is still open
ing valve
Alarm horn signal im- Optional alarm horn impulse time
pulse

8.18.2 Button positions (Screen 111)
Positioning of device buttons in the lower bar (1 – 13)

8.18.3 Maintenance list (Screen 112)
10 configurable maintenance intervals (hours) can be activated.

When reaching the set value, a message will appear on screen.
After done maintenance, press “->0” to reset the desired value and message.
Set value = 0  the message function is deactivated.
Display of actual working hours of the extruder’s main drive
With gravimetric feeding:

Totalizer in tons (resettable)
permanent: Totalizer in tons (not resettable)

8.18.4 Positions analog displays (Screen 113)
Positioning of actual values and setpoints at screen “Analog values display” 11
Anzeige Analogwerte (Screen 11)

8.18.5 Control parameters (Screen 120)
The controller parameters for the 8-channel temperature controllers are entered on this screen.
Selection of single temperature controllers
Pushing this button transmits the settings for the currently selected control-
ler to the corresponding controller with a Profibus telegram. As long as the
transmission is running, the "Controller" field flashes (approx. 3 seconds).
Create a copy of parameters to from to selected controllers

Controller-specific settings in upper screen area:
Description Here a name can be assigned to each zone.
Function Controller status on/off

Selection of two-point controllers (heating only) or three-point controllers (heat-
ing and cooling).
Input Selection of the kind of sensor
Auto tuning Selection of whether the heat zone is used for group optimisation
Integral Time TN Value range for integral time (Ti) 0 to 3276.7 s. If a value of 0 is set, the inte-
(Heating/cooling) gral time is deactivated
Differential Time TV Value range for the differential time (Td) 0 to 3276.7 s. If a value of 0 is set,
(Heating/cooling) the differential time is deactivated
Proportional Band XP Proportional gain for heating/cooling. Value range 0.1 to 999.9
(Heating/cooling)
Switch period Shortest switch-on time Value range 0.4 to 999.9 s.

(Heating/cooling)
Device-specific settings in lower screen area:
Number of KS-800 Number of installed 8-channel controller devices (max. 4)

devices
Temperature unit The unit of the temperature (°C or °F) is selected with the selection field.
Heat Current Cycle Here the time between 2 heat current measurements is set for each regulator.
The factor is a multiple of 2.25 sec. The value is pre-set to 5 -> for 8 planned
controllers on a device the heat current is measured every 5 x 8 x 2.25 sec. =
90 sec.
Multiplier heat current Here it is specified which heat current (in A) actually flows when the current
converter outputs 30 mA.
Pushing this button transmits all regulator settings to the two regulator
units via Profibus telegram. During transmission (approx. 3 minutes) the
input fields of this screen are inactive.
Reset controller functions

All temperature setpoints will be ramped in the entered speed (s/°C),
Heat up ramp to prevent too fast heating up of the machine parts
in s/°C
After reaching the setpoint temperatures (i an tolerace band) the waiting

time will be started.
Heat up waiting time
in minuten
After that time the extruder or other units can be started.
If the heating will be switched off during waiting time, the standby time will
be started. If during that time the heating will be switched on again the wait-
Heat up standby timet ing time continues to run.
in minutes
If the heating will be switched off, heated up, this time also starts.

8.18.6 Heating optimisation 1 – 8 / 9 – 16 (Screen 122 / 123 )
The controller self-optimisation is a process for determining optimised controller parameters for the
respective heating and cooling segments. In the program it is possible to optimise the individual zones
separately or to combine certain control zones in groups and to optimise them together. A group may
consist of a maximum of 8 controllers, as only the respective controllers of a device can be optimised
together.
Before beginning with self-optimisation, the following conditions must exist:
1. The temperature setpoints of the heat zones to be optimised must be at least 180°C.
2. The machine must be cold (actual temperatures less than 40°C).
3. Actual temperature value may not fluctuate.
Operate self-optimisation for group optimisation:
Select and press the Start button in the upper right field (Group self-
optimisation). All selected regulator zones (LED lights up green) are
switched on and the <Cancel> button appears. Pressing the <Cancel>
button cancels the self-optimisation process once. Now all regulator zones
to be optimised are switched on. Pressing the Start button again starts the
optimisation process once and for all.
The current state of optimisation can be output per regulator via the selection
field at the left in the lower right screen area.

Self-optimisation Self-optimisation is finished when the message "Self-optimisation success-
finished fully finished" appears in the two output fields. The optimised regulator pa-
rameters are automatically entered in the parameter list on screen 7110 by the
system. Following optimisation the different heat zones remain switched on
and continues to operate in the normal regulator mode. Therefore, the heating
should be switched off by the user with the <Heater On/Off> button.
Self-optimisation de- If a fault occurs while running the self-optimisation, the system ends the pro-
fective cess and a corresponding fault text appears in the two status fields:
Operate the single optimisation:
The control zone to be optimised is selected with the "Regulator 1" field in
the upper left screen area (Single self-optimisation). The single optimisa-
tion is started with the Start button.
Regulator state The current state of regulator optimisation is output in the lower left screen
area.
Self-optimisation Self-optimisation is finished when the message "Self-optimisation success-
finished fully finished" appears in the two output fields. The optimised regulator pa-
rameters are automatically put in the parameter list on screen 7110 by the
system. Following optimisation the heat zone remains switched on and con-
tinues to operate in the normal regulator mode. Therefore, the heating should
be switched off by the user with the <Heater On/Off> button.
The single or group optimisation can be cancelled at any time with the
<Reset> button.
Option at up to 24 controllers
Optimisation controllers 17 – 24 (Screen 124 )
Option at up to 32 controllers
Optimisation controllers 25 – 32 (Screen 125 )

8.18.7 Heat current monitoring (Screen 121)
The heat current monitoring of the individual controllers is parameterised and activated on this screen.
Possible causes for heat current alarms are:

- Fuse defective
- Heat element defective
- Electrical connection not available (e.g. plug disconnected)
- Semiconductor-relay defective
Actual Actual value display of the last heat current measurement in amps.
Min.-Alarm Limit value which the heat current must exceed with the solid-state relay
switched through. If this value is not exceeded, an alarm message is output.
If the value 0 is entered here, the heat current measurement is deactivated.
Multiplier The heating current multiplier adapts the heat current detection to 2 and 3-
phase systems and to real measured values

8.18.8 Scaling analog outputs (Screen 130)
Setpoint
Initial = 0 Starts the device with setpoint 0
Initial = HMI Starts with a preset initial setpoint
Initial =Setp. The latest setpoint is stored and the device will start with that setpoint
Limit Entry limit to this value
Display
Begin Begin value of displayed setpoint

End End value of displayed setpoint
+/- Step to in-or decrease the setpoint by +/- pushbuttons at screen “Analog values dis-
Step play” Screen 11

8.18.9 Scaling analog inputs (Screen 131)
Display
Position Position settings of values in the upper permanent area:
Permanent Position 1 Position 5
area Position 2 Position 6
Position 3 Position 7
Begin Initial display value setting
End End display value setting
Unit rpm, bar, mbar, A, kg/h, l/m, l/h, %, °C, °F, psi, m/min
Value
Begin % Lower value of the analog signal
End % Upper value of the analog signal
Actual value Actual value in %

8.18.10 Scaling analog inputs MT/MD (Screen 132)
These settings are available for values configured at „Machine configuration“ 110.
Display
Position Position settings of values in the upper permanent area:
Permanent Position 1 Position 5
area Position 2 Position 6
Begin Initial display value setting
End End display value setting
Unit rpm, bar, mbar, A, kg/h, l/m, l/h, %, °C, °F, psi, m/min
Value
Begin % Lower value of the analog signal
End % Upper value of the analog signal

8.18.11 PLC (Screen 140)
For service and monitoring, hardware in-and outputs can be displayed.
Bit-display of selectable input-and output word of the PLC
e.g. : Bit I 0.0 is on (at 24VDC)

8.18.12 PLC Diagnosis (Screen 141)
For service :
Access to the PLC

8.18.13 - Option- Diverter valve operation (Screen 145)
Status display
Manual movement of the diverter valve for service purpose
After reaching the both end positions of the diverter valve the sole-
noid valves remain for this time longer open and also the hydraulic
Hydraulic pump off delay
pump runs that time longer, to be sure to open or close the diverter
valve fully.
Max. movement time diverter The maximum running time for the hydraulic pump diverter valve. Is
valve one end position not reached within this time, an alarm appears.
Diverter valve is in automatic mode.

Push to change in manual mode
Starting the extruder the mode is witched automatically to automatic mode
Diverter valve is in manual mode.
Push to change in automatic mode
Move diverter valve in bypass position (Heating must be heated up)
Move diverter valve in production position (Heating must be heated up)
At undefined position, e.g. after emergency off, the diverter valve will be moved in bypass position with
the button “Heating on”
.

8.18.14 User administration (Screen 150)
Four different levels for operating are available:
Level Authorization
Level 0 All screens, but settings in the technician configuration are selectable.
No user No entry ore change of values are allowed
Level 1 Switch on/off devices
Operator Change of process values, e.g. temperature setpoints, speeds, throughput, …
Level 2 Recipe administration, Alarm limits

Foreman
Level 3 All settings changeable
Technician Machine configuration, parameter, scaling, …
Superuser User administration and all lower level funktions
Upper levels include lower levels operation

User administration:
The logged in user can change his password

A password must have at least 3 characters or numbers
Create, change or delete users only can be done within „Administrator level“.
Therefore select the desired row and do the action.
The groups are preset to be selected.
Logoff time (in minutes): 0 = inactive

<> 0: after X minutes after no screen operation the user is logged off.
(this setting is not recommended)
Automatic log-on:
To enable the operator immediately to start at screen “Overview” 10 and log-on automatically, the
function Auto log-on can be activated
After system start, screen „Overview“ 10 is called and user with level 1 to operate will be logged in
automatically.
e.g. User: 111 das Password: 111.
Exports the Password list to an USB stick
Imports the Password list from an USB stick

8.18.15 System settings (Screen 151)
Language change Change of

(toggle through available languages) Date and Time

8.18.16 Machine settings (Screen 152)
Machine data and parameters can be saved and loaded.

Data record type “machine” contains all machine related data which can be changed by an technician
at the operation panel, e.g. Type and number of feeders, selectable devices, control parameters etc. .
The actions to handle the data records are similar to the user recipe handling described an screen 70
Only the data record name machine is different.
Load data from the PC to the machine
Read actual settings from the machine and save them

9 Alarm display and operation
Alarm indicator The alarm indicator is a graphic symbol displayed on the screen when a fault
message is received. The symbol flashes as long as fault messages are pre-
sent.
The number below the triangle indicates how many fault messages are currently
active.
Message window Each fault or system message is displayed in its own message window on the
screen when a message is received. It is output in a message window with the
character set of the current language.
State:
K = alarm received (currently active)
G = alarm gone
Acknowledge alarms
Current alarms (Screen 20)
Historical alarms (Screen 21)

9.1 Alarm list
Depending on the machinery and integrated devices following alarms are available to be displayed
and stored.
Miscellaneous alarms :
Fault text Cause Remedy
Error chiller cabinet or operation panel electrical contact open Check chiller, check circuit breaker
Error 24V DC current surveillance electrical contact open Check to shortcut 24V DC
Emergency at XX XX XX XX X Emergency button pushed, Pull respective emergency button,

No connection Check electrical connections
Maintenance: XX XX XX XX X Maintenance time activated Do respective maintenance, then quit at screen 112
Error circuit breaker 230V cooling valves electrical contact open Check valves, check circuit breaker
Error chiller cabinet +S1 electrical contact open Check chiller, fuse or circuit breaker
Error chiller operation panel electrical contact open Check chiller, fuse or contact
Drives interlock "off", first interlock "on" Drive not interlocked Interlock at screen 100 „on“= „green“
at technician page !
Error Profibus: ET200s at cabinet +S1 no BUS connection Check PROFIBUS plugs, termination switch, ad-
dress-setting, cable
Error Profibus: ET200s at terminal box no BUS connection Check PROFIBUS plugs, termination switch, ad-
+K1 dress-setting, cable
Error heat exchanger Failure, electrical contact open Check reason at device (LED), e.g. Water min.
Check electrical connection
Error Profibus: heat exchanger no BUS connection Check PROFIBUS plugs, termination switch, ad-
Error metal separator XX failure contact open Check or reset device, connection
Safety switch XX XX XX XX electrical contact open Switch “on”, check connection
Heating / Temperatures
Heat zone XX lower temperature limit Temperature too low Increase heat-up time, check solenoid valve
exceeded respective temperature zone, prevent energy loss
Heat zone XX Upper temperature limit Temperature too high Switch on cooling unit, open throttle valve of
exceeded temperature control zone if present, excessive
melt friction
Heat zone XX Heater current alarm Current too low Heating element defective or cable break, fuse
defective, semiconductor defective
Heat zone XX temperature sensor failure no electrical contact, Check sensor for proper seating, replace defec-
sensor failure tive sensor, and check electrical connection
Melt temperature XX sensor failure no electrical contact, Check sensor for proper seating, replace defec-
sensor failure tive sensor, and check electrical connection
Extruder temperatures are still too low ! One or more temperatures too Wait to reach the temperatures
low
Error Profibus: Multitemperature control- no BUS connection Check PROFIBUS plugs, termination switch,
ler XX address-setting, cable
Error heating-current short circuit con- At least one semiconductor Heating unit XX – XX semiconductor defective
troller XX relay is defective
Heat zone XX Failure output tempera- Output of controller defective Eliminate fault in controller output, replace con-
ture controller troller if necessary

Analog inputs :
Warning upper limit melt pressure 1 XX Maximum limit reached Set reasonable limit value,
Try to rise melt pressure
Warning lower limit melt pressure XX Minimum limit reached Set reasonable limit value,
Try to reduce melt pressure
Melt pressure XX sensor failure no electrical contact, Check sensor for proper seating, replace defec-
-> Extruder off sensor failure tive sensor, and check electrical connection
Error melt pressure XX too high Maximum limit reached Reduce melt pressure, empty extruder and re-
duce throughput, increase temperature profile
Main drive :
Error lower limit speed extruder Minimum limit reached Set reasonable limit value
Check main drive functionality
Error upper limit speed extruder Maximum limit reached Set reasonable limit value
Check main drive functionality
Error low motor load extruder Minimum limit reached Do not run the extruder too long without material,
Set reasonable minimum load limit value
Error upper limit extruder load Maximum limit reached Set reasonable limit value
Reduce material throughput,
increase extruder speed,
increase temperature profile
Error circuit breaker main drive controller electrical contact open, Check setting at circuit breaker, check converter
power supply overcurrent
(DC-motor)
Error field current supervision main drive electrical contact open, Check fuse, check cooling, check converter
(DC-motor) overcurrent
Error tach main motor no electrical contact, Check connection, check sensor and connection
(DC-motor) overcurrent
Error power converter main drive failure See failure display at converter, e.g. overload
Error overtemperature main motor electrical contact open Check cooling, check thermosensor connection
Error circuit breaker cooling fan main electrical contact open, Check setting at circuit breaker,
drive overcurrent Check mechanical movement
Error Profibus: Converter main drive no BUS connection Check PROFIBUS plugs, termination switch,
address-setting, cable
Extruder cuts off, because of low motor lower limit reached Extruder more than one minute in low motor load
load
Error cooling water flow meter main electrical contact open Check water flow, check monitoring device, check
drive connection, check filter
First, turn on main drive, or Interlock At first start main drive.
drives off ! At Screen 100 Interlock „off“.
Start main drive first ! At first start main drive.
Cover clutch demounted electrical contact open Mount cover, check electrical contact
Error overload clutch Overload, Check material, decrease material throughput,

electrical contact open increase temperature profile
at sensor

Oil pump gear box:
Error circuit breaker oil pump electrical contact open Check setting at circuit breaker, check oil type,
check oil pump motor
Error oil flow low electrical contact open Check unit , quantity of oil, oil pump, electrical
contact
Error oil difference pressure high electrical contact open Check oil flow, check filter,
check electrical contact
Error oil temperature > 80°C electrical contact open Check contact, replace temperature sensor, pro-
duce water feed, check solenoid valve, check heat
exchanger for lime deposits
Side feeder -optional- :

Error lower limit site feeder XX " Minimum limit reached Set reasonable limit value at creed 67
Check drive functionality
Error upper limit site feeder XX " Maximum limit reached Set reasonable limit value at creed 67
Error side feeder XX converter Failure, e.g. disconnection, See failure display at converter,
overload check connection
Error ProfibusDP: side feeder XX con- no BUS connection Check PROFIBUS plugs, termination switch, ad-
verter dress-setting, cable

Feeders -optional- :
volumetric :
Error feeder XX General error Check contact, check motor connection–
Error lower limit feeder XX Limit reached Set reasonable limit value at creed 67
Error upper limit feeder XX Limit reached Set reasonable limit value at creed 67
Error Profibus: feeder XX converter no BUS connection Check PROFIBUS plugs, termination switch, ad-
General error feeder -> Feeder line off electrical contact open Check feeder
Feeder XX refill manually !
Feeders Brabender CS / RC4, OP5 :
General error feeder electrical contact open See feeder controller
Error Profibus: Feeder controller RC4 no BUS connection Check PROFIBUS plugs, termination switch, ad-
Feeder XX load cell signal error no electrical signal Restart system, check connection, check interface,
check or change weight cell module
Feeder XX refill error Maximum level within set time Check refilling, check refill contact and connection,
not reached set reasonable refill levels and refill time
Feeder XX underload Underload level reached Check refilling, set reasonable limit, correct tara
value
Feeder XX overload Overload level reached Rise value between overload and max. level,
reduce mechanical material flow
Feeder XX control deviation negative Time delayed deviation Correct control parameter, check screw size and
material, avoid external mechanical vibration
Feeder XX control deviation positive Time delayed deviation Correct control parameter, check screw size and
material, avoid external mechanical vibration
Feeder XX speed minimum Limit reached Reduce parameter, check rpm detection, check
control parameter, check screw size
Feeder XX speed maximum Limit reached Check material output (blocking ?)

Increase parameter, check rpm detection, check
control parameter, check screw size
Feeder XX memory module error Internal Brabender failure Contact Brabender-Hotline
Feeder XX soft start error Increase speed for soft start
Feeder XX AV-error (filter violation) Increase filter parameter, avoid external vibration,
correct control parameter settings
Feeder XX CM-error (check max.) Wrong calculated value See Brabender manual
Feeder XX FC-error (frequency convert- overload Release mechanical blocking of the screw, check
er) converter
Feeder XX communication error ISC failure ISC-bus Configure ID-No. of ISC-CM
Check ISC-CM supply, check ISC-BUS connection
Feeder XX refill manually ! Minimum level reached Refill hopper manually

With automatic refilling set button to “AUTO”

Feeders K-Tron :
Feeder XX feed factor failure See manual K-Tron
Feeder XX external channel failure See manual K-Tron
Feeder XX board battery low Battery load too low Change battery
Feeder XX weight below 2% Underload level reached Check refilling, set reasonable limit, correct tara
value
Feeder XX refill timeout has occurred Maximum level within set time Check refilling, check refill contact and connection,
Feeder XX actual value is too high Maximum speed level reached Check max. value and alarm limit , check screw,
check refilling, check initial feed factor
Feeder XX actual value is too low Minimum speed level reached Check min. value and alarm limit , check screw,
Feeder XX motor speed is too high Limit reached Check max. value and alarm limit , check screw,
Feeder XX motor speed is too low Limit reached Check min. value and alarm limit , check screw,
Feeder XX weight processor failed no electrical signal Restart system, check connection, check interface,
Feeder XX MDU failure No speed response Check rpm detection, check screw
Error Profibus: Feeder controller K-Tron no BUS connection Check PROFIBUS plugs, termination switch, ad-

Feeders Colortronic / Scholz:

Error Profibus: Feeder controller Co- no BUS connection Check PROFIBUS plugs, termination switch, ad-
lotronic dress-setting, cable
Error Communication: Feeder controller Ethernet disconnected Check Ethernet connection (cross-cable)
SCHOLZ Check SCHOLZ parameters (enable , protocol,
addresses)
Feeder XX weight below 2% Underload level reached Check refilling, set reasonable limit, correct tara
value
Feeder XX refill timeout has occurred Maximum level within set time Check refilling, check refill contact and connection,
Feeder XX actual value is too high Maximum reached Check max. value and alarm limit , check screw,
Feeder XX actual value is too low Minimum reached Check min. value and alarm limit , check screw,
Feeder XX motor speed is too high Maximum speed level reached Check max. value and alarm limit , check screw,
Feeder XX motor speed is too low Minimum speed level reached Check min. value and alarm limit , check screw,
Feeder XX weight processor failed no electrical signal Restart system, check connection, check interface,
Feeder XX motor failure no speed response Czech gear cover, safety switch, rpm detector,
screw
Feeder XX feeder error Feeder is on and Pert-value is Check mechanical movement of motor, refill flap
higher than Pertlimit-value closed, too high Setpoint change, avoid external
vibration


Pelletizers :
Start pelletizer first ! interlocked At first, start pelletizer
Pelletizer cover open ! electrical contact open Close cover, check limit switch and connection
General error pelletizer failure Check connection and contacts, circuit breaker
General error pelletizer -> Extruder off failure Check connection and contacts, circuit breaker
Error lower limit speed pelletizer Lower limit reached Set reasonable limit value at creed 67
Error upper limit speed pelletizer Upper limit reached Set reasonable limit value at creed 67
Error frequency converter pelletizer Failure, e.g. overload See failure display at converter,
check connection
Error overload pelletizer Pelletizer blocked Check material parameters
Error circuit breaker pellet drier electrical contact open Check setting at circuit breaker, mechanical
movement
Error cover pellet drier open electrical contact open Close cover, check limit switch and connection
Vacuum pump:
Error lower limit "vacuum" Lower limit reached Set reasonable limit value at creed 67
Check drive functionality and pipes
Error upper limit "vacuum" Upper limit reached Set reasonable limit value at creed 67
Check drive functionality and pipes
Error vacuum pump electrical contact open Check setting at circuit breaker, mechanical
movement of drive
Melt pump :

Start melt pump first ! Melt pump is off At first, start melt pump
Error Profibus: Converter melt pump no BUS connection Check PROFIBUS plugs, termination switch,
address-setting, cable
Input pressure low limit Lower limit reached Change process parameter or limit
Input pressure high limit Upper limit reached Change process parameter or limit
Difference pressure low limit Lower limit reached Change process parameter or limit
Difference pressure high limit Upper limit reached Change process parameter or limit
Output pressure lower limit Lower limit reached Change process parameter or limit
Output pressure upper limit Upper limit reached Change process parameter or limit
Error melt pump converter Failure, e.g. overload See failure display at converter,
check connection

Underwater pelletizer (UWP)
Warning water level minimum UWP Water level to low Check refill parameter, check refilling, check
sensors
Error diverter valve not in bypass mode Limit switch not reached, Check valves and hydraulic, check monitoring
Monitor time too short time
Error diverter valve not in production Limit switch not reached, Check valves and hydraulic, check monitoring
mode Monitor time too short time
Error diverter valve: wrong position Limit switch not reached Check valves and hydraulic, check limit switches
Error agglomerate screen UWG Limit switch not reached Check valves and hydraulic, check limit switches
Error water level water tank UWP Water level to low Check refill parameter, check refilling, check
sensors
Error water flow rate UWP Water flow rate too low Check water flow, min. setting, sensor or device
Error safety switch pellet dryer UWP Safety key not in right position Key switch to “on”
Error speed pellet dryer UWP No speed signal Check drive (belt), monitoring unit
Error overcurrent pelletizer UWP Motor blocked clean, check speed
Error frequency converter pelletizer Failure, e.g. overload See failure display at converter,
UWP check connection
Error circuit breaker fan pellet dryer electrical contact open Check setting at circuit breaker, mechanical
UWP movement of drive
Error circuit breaker dryer UWP electrical contact open Check setting at circuit breaker, mechanical
movement of drive
Error circuit breaker process water pump electrical contact open Check setting at circuit breaker, mechanical
UWP movement of drive
Error circuit breaker water pump pellet electrical contact open Check setting at circuit breaker, mechanical
filter UWP movement of drive
Error circuit breaker hydraulic pump electrical contact open Check setting at circuit breaker, mechanical
diverter valve movement of drive
Error limit switch valve filter UWP Wrong position Check mechanic, clean, check limit switch
Bypass solenoids not in bypass position Limit switch not reached, Check valves and air, check monitoring time
UWP Monitor time too short
Bypass solenoids not in production Limit switch not reached, Check valves and air, check monitoring time
position UWP Monitor time too short
Error Profibus: ET200-Station pelletizing no BUS connection Check PROFIBUS plugs, termination switch,
system address-setting, cable

2000
+/-
MacromateXX professional S7
Notes:
Passwords:
User name Group Level Password

---------- ----------- 0 ---------- no operation
possible
111 Operator 1 111
222 Foreman 2 222
333 Technician 3 333
Superuser Superuser 8 100 for user
administration
Admin Administrator 9 user not to

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Manual

Leistritz Extrusionstechnik GmbH

Edition 02/2012 for SW Version 10.1

This operating manual contains the functionality of the operating panel.

LEISTRITZ Extrusionstechnik GmbH

General precautionary topics

Edition 02/2012 for SW Version 10.1

Edition 02/2012 for SW Version 10.1

The screens are divided basically in three parts

Display of the active screen

Touch buttons ON/OFF functions

Edition 02/2012 for SW Version 10.1

Start/Stop of data logging

Start/stop automatic button with status display

Back to previous selected screen

Edition 02/2012 for SW Version 10.1

Operation and status display of machine units

The following shows the main drive button as an example

The device is ready to switch ON

The device is switched ON and is running

The device is switched ON, but no running feedback available

The device is switched OFF and interlocked with other devices,

The device is switched OFF and a failure occurred.

Edition 02/2012 for SW Version 10.1

Heating ON / Heating up active (dot green blinking)

Eating ON / heated up (Setpoints reached tolerance band)

Heating OFF/ automatic heat-up activated

Extruder main drive ON/OFF

Vacuum pump ON/OFF

Vacuum valve ON/OFF

Side feeder 1 ON/OFF

Edition 02/2012 for SW Version 10.1

Single feeder ON/OFF

Under water pelletizing water system ON/OFF

Under water pelletizing PRE AUTOMATIC/AUTOMATIC

Melt pump ON/OFF

Melt stuffer ON/OFF

Edition 02/2012 for SW Version 10.1

Touch Grey buttons enable to call main chapters.

Always leads to “Overview screen” 10.

Edition 02/2012 for SW Version 10.1

Skip login screen:

Generally all inputs are denied in level “0”

User administration On screen “User administration” 150 password administration

Edition 02/2012 for SW Version 10.1

Chapter Screens No. Description

20 Currently active alarms

11 Analog values display

90,91 Under water pelletizing

94,95 Melt pump

Charts and limits

Edition 02/2012 for SW Version 10.1

67 Limits for analog inputs

68 Melt pressure /melt temperature limits

Recipes and data logging

70 Recipes User data

71 Process data logging

72 Temperature logging selection

73 Process analog data selection

80 Start automatic analog values

81 Start automatic feeders

100 Technician configuration: Machine configuration

110 Machine configuration

111 Button positions