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NovaTec MCS-600 Series Instruction Manual

Conveying control
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MCS-648 & -696 SERIES
Conveying Control
© 2018 NOVATEC, Inc. All Rights Reserved
222 E. Thomas Ave. Baltimore, MD 21225 USA
Phone 410-789-4811
Toll Free: 800-938-6682
Main Fax: 410-789-4638
MCS-649 & -696 IM 9 FEB 2018
Parts Email: parts@novatec.com
Service: service@novatec.com
Sales: sales@novatec.com

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Summary of Contents for NovaTec MCS-600 Series

  • Page 1 MCS-648 & -696 SERIES Conveying Control © 2018 NOVATEC, Inc. All Rights Reserved MCS-649 & -696 IM 9 FEB 2018 222 E. Thomas Ave. Baltimore, MD 21225 USA Phone 410-789-4811 Parts Email: parts@novatec.com Toll Free: 800-938-6682 Service: service@novatec.com Main Fax: 410-789-4638...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS ECTION PURPOSE OF THIS MANUAL ......................4 Explanation of Symbols........................4 SAFETY PRECAUTIONS AND WARNINGS ..................5 GENERAL DESCRIPTION ........................6 SPECIFICATIONS ..........................7 PLC OVERVIEW ..........................8 General............................. 8 Startup And Power Loss ........................8 OPERATING PRINCIPLES ......................... 9 Material Conveying System (MCS) ....................
  • Page 3 11.3 MCS Station Status ........................25 11.4 Station Setup ..........................27 11.5 Alarm Banner ..........................30 11.6 Alarm History ..........................31 11.7 System Setup Screen ........................32 11.8 Install Stations ..........................35 MAINTENANCE ..........................36 12.1 At Startup ............................36 12.2 Monthly ............................

  • Page 4: Purpose Of This Manual

    PURPOSE OF THIS MANUAL This manual describes the installation and operation of Novatec’s MCS-600 Series Material Conveying System controller. Before installing this product, please read in their entirety, this guide and any additional guides associated with the system’s auxiliary equipment.

  • Page 5: Safety Precautions And Warnings

    The customer is required to operate the equipment with all safety features in proper working condition.  Novatec shall provide no further guarantee for function and safety in the event of unauthorized modifications. MCS-648 & -696 IM 9 FEB 2018...

  • Page 6: General Description

    GENERAL DESCRIPTION The Novatec MCS-600 Series controller is a custom-programmed Allen-Bradley PLC-based control system designed to incorporate existing and future equipment. The Material Conveying System (MCS) will control up to120 JIT chambers and 20 Vacuum Pump Units (VPU). Future loading stations are made available to operations on a password protected screen. Assignments for current and future VPUs and Stations may be changed via a password-protected screen on the HMI.

  • Page 7: Specifications

    SPECIFICATIONS Description Material Conveying System Controller Model No MCS-648 MCS-696 Performance Specifications Max No. of Dryers Max No. of Vacuum Power Units Max No. of Vacuum Receivers Main PLC Allen-Bradley CompactLogix L32E Base Operator Interface Allen-Bradley PanelView Plus 1000 Remote Operator Interface Communications DeviceNet, Ethernet Output Voltage to Devices...

  • Page 8: Plc Overview

    PLC OVERVIEW General The MCS-600 Series Material Conveying System Controller utilizes a centrally mounted PLC that sends commands over the DeviceNet network to various conveying system components. A remote I/O block controls each pump, station, loader, etc. The physical device and its associated electronics form a ‘node’.

  • Page 9: Operating Principles

    OPERATING PRINCIPLES Material Conveying System (MCS) The program controls the operation of loading the Dryers from the Gaylords to filling the JIT chambers on the Molding Machines from the Dryers. The MCS controls the operation of the Vacuum Pump Units (VPU), the station “Tee” valves and the Purge (Source) valves. The MCS must be in RUNNING mode for any conveying to take place.

  • Page 10: Vpu Fifo Queue

    running and the station T valve will open at the start of the fill cycle. Pellets will be conveyed from the source to the vacuum chamber. The T valve will remain open for the load and purge times. When the load time expires the dryer source valve closes and the purge time begins. The purge time allows any pellets in the conveying line to be carried into the JIT chamber.

  • Page 11: Adding Nodes (Devicenet Plug & Play)

    ADDING NODES (DEVICENET PLUG & PLAY) Each network device is assigned its own DeviceNet Node by installing a remote busstop® station at the device. Refer to the wiring diagrams included with this manual for additional information. DeviceNet Remote I/O The DeviceNet busstop station has four inputs and four outputs. The input and output circuits are combined in one connector.

  • Page 12: Connector Pin-Outs

    Set the network switches to the unique address assigned to the equipment as described in Section 8. Connector Pin-Outs DeviceNet Connector Through Bus Connector: 5-Pin minifast 1 = Shield 2 = V + 3 = V - 4 = CAN_H 5 = CAN_L Combined I/O Connectors Single Sensor...
  • Page 13 Output – Station Valve Output – Vacuum Receiver Proportioning Valve Output – Vacuum Receiver Blowback MCS-648 & -696 IM 9 FEB 2018 Page 13 of 40...

  • Page 14: Node Addresses

    NODE ADDRESSES Refer to the table below for a complete list of addressable nodes. Loading Station Nodes Each loading station has its own DeviceNet Node. The node number must match the default station number. Station 1 is node 1 and station 17 is node 17, for example. The program is written as if all loading stations are installed.

  • Page 15: Installation

    **Module 2 (NODE 59) – Sources 17 through 32 mapped to Network 1 Nodes 17 – 32. **Module 2 (NODE 60) – Destinations mapped to Network 2 Nodes 1 – 48. INSTALLATION After unpacking and inspecting the MCS Controller, four basic activities will be performed. These activities are: 1.

  • Page 16: Mechanical Installation

    Mechanical Installation 9.1.1 Material Conveying Lines The single most important activity performed to ensure satisfactory operation of a pneumatic conveying system is the actual installation of the equipment. All components should be located so that material lines and vacuum lines are as short as possible. Elbows or other changes in direction should be minimized.

  • Page 17: Cyclone Filter

    9.1.3 Cyclone Filter Locate the cyclone filter as close as possible to the vacuum power unit. Provide access for the material catch pan or fines drum as necessary. Secure the cyclone filter to the floor. Attach vacuum lines from the conveying system to the cyclone inlet (tangential inlet on the side of the cyclone body).

  • Page 18: Electrical Installation

    Electrical Installation Always disconnect and lock out the main power supply before wiring power and communication cables between the MCS controller and the network devices. Refer to the wiring diagram and general arrangement drawings supplied with this system before making electrical connections. ...

  • Page 19: Controls Explanation

    CONTROLS EXPLANATION 10.1 PanelView Plus 1000 The PanelView Plus 1000 is an operator interface with touch-screen entry. The color screens are graphical in nature and display information in text and/or color change. The screens permit data entry via touch. The PanelView is equipped with DeviceNet and Ethernet I/P communication. The PanelView communicates with the Allen-Bradley CompactLogix L32E PLC using Ethernet.

  • Page 20: Operator Screens

    When an administrator is logged on, additional pushbuttons become visible. These buttons allow access to maintenance and setup screens. Figure 3: Novatec Logon These buttons allow the user to view, log in, and log out of the current user log in level.
  • Page 21 The STATION STATUS button will take the user to the station overview status page. This page allows stations to be enabled ON and OFF as well as show the status of a large number of stations on one page. The STATION SETUP button will take the user the parameter setup page for a station. The setup page allows the user to view and adjust (if logged in to the correct level) any stations parameters like: load time, purge time, dump time, material selection, and vacuum blower assignment.

  • Page 22: Vacuum Pumps

    11.2 Vacuum Pumps This overview status screen displays the operation of the Vacuum Pump Units. Sixteen vacuum pumps can be seen. The status of each VPU is displayed. This includes the current station being serviced in a station icon that appears above the vacuum pump icon. ...
  • Page 23 The STATION STATUS will navigate back to the Station 1-40 Status overview page – see 11.3 The PREV and NEXT buttons will scroll to other status screens as needed. You can only scroll to screens for vacuum pumps that the system can control.
  • Page 24 The load and purge times are shown as a countdown in seconds remaining. The next station in the queue (if any) is also shown. A station and material purge valve icon show what station the vacuum pump is currently servicing and what material is being used. The icons will change color like on the station status page with blue for loading, orange for purging, green for on (idle) and grey for off.

  • Page 25: Mcs Station Status

    11.3 MCS Station Status This screen permits the control and status display of up to 96 loading stations. Only a station that is “installed” is visible. The icon for each station is a PB that calls up the Setup Station screen.
  • Page 26 The SHOW VP ASSIGNMENTS button allows the operator to see quickly which stations are assigned to a particular vacuum pump. When the button is pressed, a pull-down menu appears allowing the operator to select which vacuum pump to view station assignments for. For example, when SHOW VP1 is selected, all the stations assigned to vacuum pump 1 remain visible.

  • Page 27: Station Setup

    11.4 Station Setup The STATION SETUP screen is evoked when an operator either touches a loading station icon on the MCS STATION STATUS screen or pressing the STATION SETUP button on the Main Menu screen. This screen displays the various parameters for each station and allows changes if the user log in level is high enough.
  • Page 28 Touching a numerical entry button will call up a keypad for data entry for that parameter. The time in seconds that material enters the convey air stream. It is the time the material purge valve is open. The station Tee valve is open. This setting is proportional to the size of the station hopper and how difficult the material flows.
  • Page 29 The Regrind Percent setting tell what proportion of regrind will be injected into the hopper. This value is a percentage of the LOAD time. For example, if the LOAD time was 10 seconds and the Regrind Percent was 30%, then the proportioning valve will energize for 3 seconds to fill regrind material and then virgin material will fill for the other 7 seconds.

  • Page 30: Alarm Banner

    11.5 Alarm Banner A new alarm will be displayed in a message banner that runs along the top width of the screen. The Alarm Banner will be superimposed on the current screen. Text denoting the specific Alarm will be displayed on the banner. Alarms may be ACKNOWLEDGED or CLEARED as required. ALARM SILENCE will only turn off the horn.

  • Page 31: Alarm History

    11.6 Alarm History The ALARM HISTORY screen displays the last 150 alarm conditions. Figure 8: Alarm History Screen The ALARM RESET button resets the vacuum pump starter faults. If a vacuum pump start fault occurs because of a failed starter or tripped overload, the ALARM RESET button MUST be pressed to reset the alarm and return the pump to normal operation.

  • Page 32: System Setup Screen

    11.7 System Setup Screen This administrator access screen allows the user to enable stations, set station priority, and perform simple I/O testing. Figure 9: Maintenance Screen This button will toggle the HIDDEN or VISIBLE status of the Blow Back cycle button on the Station Setup page and the Blow Back ON Time and OFF Time on this page.
  • Page 33 This button will toggle the HIDDEN or VISIBLE status of the Auto ID Proofing button on the Station Setup page. This button will toggle ON/OFF the Auto ID Proofing to scan only. The material setpoint and feedback values will be displayed on the Station Setup page but a mismatch in values will not inhibit the conveying of material.
  • Page 34 This button allows the user to select the start-up mode for the control panel: AUTO or MANUAL power up. In AUTO START ON POWER UP, the control panel will automatically start filling stations if they are enabled and demand material when power is applied to the panel. In MANUAL START ON POWER UP, the system is paused and the user must press the SYSTEM START button to begin loading stations.

  • Page 35: Install Stations

    11.8 Install Stations This administrator access screen allows for the installation of additional loading stations. A station that is ”future” or not currently installed is not shown until an administrator enables operator access to that station by touching the INSTALL pushbutton. An operational station is green while an uninstalled station is red.

  • Page 36: Maintenance

    MAINTENANCE It is recommended that maintenance and inspection be performed on a scheduled basis. Maintenance requirements may vary widely for each installation and specific operating conditions. It is suggested that a complete inspection be performed with necessary maintenance at the end of the first month, the first three months, and the first six months.
  • Page 37  Check all electrical connections to make sure that they have not become loose, especially those connections at contactors, motor starters, and heater elements. MCS-648 & -696 IM 9 FEB 2018 Page 37 of 40...

  • Page 38: Troubleshooting

    If you have questions concerning troubleshooting or the dryers operation, contact Novatec and ask for the "Service Department". If you need to place an order for a part, contact Novatec and ask for the "Parts Department” or visit our web store.

  • Page 39: Warranty

    **5-Year Extended Warranty - When a MachineSense® data plan is activated for products with **, Novatec automatically extends the warranty to 5 years. The data plan must be activated within 60 days after product shipment, and remain active through the warranty period to maintain extended warranty eligibility.
  • Page 40 Wear resistant options may be available to extend usable service life with abrasive materials. Novatec reserves the right to limit the warranty if the customer installs replacement parts that do not meet the specifications of the original parts supplied by Novatec.

This manual is also suitable for:

Mcs-648 seriesMcs-696 series

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