Movacolor MCTC Manual
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Movacolor MCTC Manual

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Software version : 2.11.x
Manual revision : rev.00
Language
: ENG
Date
: February 2021
MCTC manual

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Summary of Contents for Movacolor MCTC

  • Page 1 MCTC manual Software version : 2.11.x Manual revision : rev.00 Language : ENG Date : February 2021...
  • Page 2 Start-up & Login 3.2.1 Configuration wizard 3.2.2 Home screen 3.2.3 Help function 3.2.4 User levels System Configuration The MCTC production screen 3.4.1 Injection Molding mode 3.4.2 Extrusion mode 3.4.1 Batch Mode System performance 3.5.1 General 3.5.2 MCBalance, MCPowder, MCHigh Output and MCLiquid 3.5.3 MCHybrid...
  • Page 3 Batch mode production screen Connection examples batch unloading 6.3.1 Example 1 – Batch with unloading controlled manually 6.3.2 Example 2 – Batch with unloading controlled by MCTC 6.3.3 Example 3 – Batch with unloading option activated by pushbutton 7 MCTwin...
  • Page 4 1 Introduction Thank you for purchasing a Movacolor metering device. This manual is addressed to operators and qualified technicians taking care of the metering of dry additives to ensure correct use of the Movacolor dosing unit.  This manual must be read before installing the dosing unit. Keep this manual in a place accessible for all operators.

  • Page 5: General Information

    Ensure that all parts are securely fixed to the extruder, injection molding machine or machine support. Always switch off the Movacolor control cabinet and disconnect the mains power plug from electrical power before performing maintenance. Dangerous voltages are present inside the control cabinet for up to 2 minutes after it has been switched off.

  • Page 6: General Operation

    3 General operation The Interface 3.1.1 MCTC Touchscreen 1. Alarm LED 2. Input signal LED 3. Start LED (blinking = standby / waiting for start input, steady = motor running) External communication / network USB Port Load cell CAN bus cable...
  • Page 7 The image below shows the MC-BC in a standard configuration. In multicomponent or remote setups, refer to chapter Multicomponent. 1. Load cell 2. CAN bus cable 3. Motor cable 4. Valve output for hopper loader 5. Mains power cable 6. Mains power switch 7. Mains power indicator MCTC manual...
  • Page 8 Start-up & Login After switching on the mains power of the MCTC, the screen will remain black for about 15 seconds, followed by various loading screens. After about 90 seconds the home screen appears. When the unit is used for the first time, a Configuration Wizard appears.
  • Page 9 3.2.4 User levels The MCTC controller has three user levels, each level has other rights to access or change functions and/or options. The three user levels are: Operator, Tooling and Supervisor For changing to another user level, press on the menu icon (left bottom corner) and the user button appears.
  • Page 10 System Configuration For initial setup, or a big change in the setup, the MCTC controller needs to be configured. This can be done manually by the changing the settings of the system, or by using the configuration wizard. Both options can be found in the “System Configuration”...
  • Page 11 - side of the generator. The maximum voltage that can be applied to the MCTC is 30 VDC. The tacho voltage has to be reduced to 30 VDC if the tacho generator has a higher voltage output than 30 VDC at the maximum extruder output capacity.
  • Page 12 • The maximum voltage that can be applied to the MCTC tacho input is 30 VDC; • The tacho signal must be a clear signal. Any failure in the voltage signal will be followed by dosing variations.
  • Page 13 This IP-address has to correspond with the IP-address of your computer. Ask your network administrator for a unique address. System Configuration: Netmask Netmask for use in a network environment (TCP/IP protocol). (For example 255.255.255.0) When the Movacolor dosing system is part of a network, the controller must have a Netmask for accessing the TCP/IP network. System Configuration: Gateway Gateway address for use in a network environment (TCP/IP protocol).
  • Page 14 * MCWeight can only be selected when production mode equals EXT. ** MCWeight, MCHybrid and MCNumera can only be assigned to the first position in a group. Group Configuration: Unit name Unit name, for example: UNIT 1 (max 8 characters). System Configuration: Recipe enabled Enable/Disable the recipe functionality. MCTC manual...
  • Page 15 Enable external communication, NONE, ANALOG, PROFIBUS or PROFIBUS (requires a special hardware extension board).  Modbus TCP/IP is enabled by default. System Configuration: Modbus Device address If the controller is used in a Modbus network, the unique identity can be filled in here (1-231). MCTC manual...
  • Page 16 The MCTC production screen 3.4.1 Injection Molding mode Material selection button. Through this button the material can be stored during production. Percentage of additive to be dosed in relation to the entered shot weight. Shot weight of the injection molding machine. Used for calculating the additive to be dosed.
  • Page 17 Start/Stop button. When the button is colored green, the system is OFF (safe). In red condition the system is ON. Toggle button. With this button you can toggle between the normal and the detailed view. Actual RPM. Actual Hopper weight. 10. Actual tacho voltage. MCTC manual...
  • Page 18 Number of pellets to be dosed in one batch. Start/Stop button. When the button is colored green, the system is OFF (safe). In red condition the system is ON. Toggle button. With this button you can toggle between the normal and the detailed view. Actual dosing MCTC manual...
  • Page 19 • Changing more production parameters during production within 10 seconds after each other will cause the MCTC regulation to reset. This is necessary for the system to adjust quickly to these big changes in the settings; •...
  • Page 20 Periodical cleaning of the dosing valves, weigh bin and mixer is necessary for proper operation. Reset regulation • Reloading the material file resets the actual learned material flow characteristics; • Switching the power OF and ON again will cause a total reset of the regulation. MCTC manual...
  • Page 21 Confirm all screens Open the device configuration menu Make all required settings, consult the appropriate chapter for setting the right settings (motor type, loader type, valves, etc.) Perform a load cell calibration (follow the onscreen instructions) Ready for production! MCTC manual...
  • Page 22 Material files To optimize the dosing system, the MCTC uses material files. These files contain information for different purposes and can be generated by the user. The information in a material file varies, depending on the type of dosing system which is used. For gravimetric units, the file contains information about the flow characteristics of the material.
  • Page 23 Recipe function With the MCTC it is possible to store the current production settings into a recipe. All production settings of all components will be stored within this recipe. An easy recall of the production settings is possible by loading a previous stored recipe.
  • Page 24 The mix to the injection molding machine will contain: Regrind = 100gr * 20% = 20gr AddV = (100gr – 20gr) * 5% = 4gr AddV = (100gr – 20gr) * 2% = 1,6gr Virgin = 100gr – 20gr – 4gr – 1,6gr = 74,4gr MCTC manual...

  • Page 25: Quick Start

    Component name (can be set in configuration menu). Pre-learned material curve Select the pre-learned material curve per component.  In case of no pre-learned materials it is recommended to select the Movacolor default material file. Material/component function how the material should be treated, regrind, virgin, additive.
  • Page 26 By pressing this button, the recipe editor screen will be shown where you can decide to accept and save the changes to the current or a new recipe. MCTC manual...
  • Page 27 From the HOME screen, press the recipe button, from the recipe editor screen choose the list button(1). Select the desired recipe by using the up and down buttons: To delete the selected recipe. To delete all recipes in the list at once. MCTC manual...
  • Page 28 2) Purging when unit is “ON” This mode can be used In cases where the MCTC is not stopped in between two production runs, purging can be started in between two Injection molding cycles. Therefore a separate signal is required to start the purging (connected to INP-3), the so called “purge signal”...
  • Page 29 Tools menu To activate the purge mode, press the purge button. A “Purge mode active” pop-up will appear. When the “OK” button is pressed, purging is stopped and the display goes back to the home screen. MCTC manual...
  • Page 30 3.10.2 Setting the required purging RPM The MCTC material file calibration procedure can be used to determine a starting point for the purging speed. When the material calibration has ended successfully, the last used speed is copied to the purging speed parameter.
  • Page 31 When the purge mode is active, the MCTC will now wait for a start input signal or a purge signal. As soon the one of the signals is activated, the dosing tool will rotate as long as the signal is active.
  • Page 32 No data will be saved to the remote support servers. Once the MCTC is connected to the remote server, a 3-digit ID will be displayed on this screen. A support employee will ask for this ID as it's used to identify the MCTC.
  • Page 33 USB menu The MCTC is equipped with a USB port. This port can be used for exporting consumption reports, material, recipe and configuration files. Material, configuration and configuration setting files can also be imported for backup/restore purposes. This USB port is also used for MCTC software updates.
  • Page 34 3.12.4 Insert USB memory stick When the Remove USB stick option is used, but the USB stick is not physically removed from the MCTC, it is possible to “insert” the USB stick again. In this way the USB stick does not have to be reinserted to be activated again.
  • Page 35 Consumption counters The MCTC is equipped consumption counters, counting the consumed material of each component. To reset the consumption counters you need at least TOOLING level login. 3.13.1 Consumption counter by order Consumption can be counted by order number. By changing the order number all consumption counters will...
  • Page 36 Each time an order number has been changed the consumption counters will be reset. At the same time a consumption report will generated and stored to the MCTC internal memory. The last 15 generated reports will be stored at the controller. See chapter USB menu for the data export function.
  • Page 37 4 Events General In case of an error, the MCTC can generate events. When an error occurs using the MCTC, an event display will pop up indicating the event type, code, source and description. Together with the displayed event an output contact will be switched (Warning/Alarm output), this event screen can be confirmed with the acknowledge button: The controller itself gives a beeping signal and the red alarm LED will lighten up.
  • Page 38 Main hopper is empty 2501 Extruder capacity deviation! LineControl Extruder capacity deviation between set Warning* and act capacity. 2502 Minimum extruder speed! LineControl Extruder speed below minimum Warning* 2503 Maximum extruder speed! LineControl Maximum extruder speed exceeded Warning* MCTC manual...
  • Page 39 MCNexus deviation between set and act detected. 4016 Pellets Missing MCNexus is missing pellets during dosing cycle. Warning 4017 Filling limiting measurement time! Time between filling cycles too short, system cannot Warning measure accurately. * This event cannot be configured. MCTC manual...
  • Page 40 5 System Main Material Sensor The MCTC or MCBC can be provided with a Main Material Sensor. This sensor can be used to detect a low material level in the main hopper. 5.1.1 Alarm settings When a Main Material Sensor is used, the alarm (event 2001) for this sensor needs to be set.

  • Page 41: Batch Mode

    6 Batch mode In batch mode, the system doses a predefined batch when a start input is supplied. When dosing is ready, the MCTC gives a dosing ready signal. Batch mode component configuration Each component in the batch setup can be configured separately. When the unloading option is required, this should be set in component 1 of the system.
  • Page 42 When the option Batch unloading is enabled (5), potential free output 3 of the MCTC will close when batch dosing is ready. Now the batch can be unloaded by closing input 1 of the MCTC. When this input is activated, output 1 of the MCTC closes after the unloading delay time (6).
  • Page 43 3. Set point unit 1, percentage of the total batch weight 4. Set point unit 2, percentage of the total batch weight 5. Toggle button. With this button you can toggle between the normal and the detailed view. MCTC manual...
  • Page 44 When dosing is ready, a light turns on and unloading can be activated by pushing the unloading button. 6.3.2 Example 2 – Batch with unloading controlled by MCTC In this example, the systems starts dosing when an external start input is given. When a batch is ready, output 1 will activate input 1 and the batch is unloaded after the loading delay time.
  • Page 45 This relay will interrupt the start input when the unloading valve is activated. When unloading is finished, the relay will give a new start input to the system for the next batch. No external start input is used. MCTC manual...
  • Page 46 In open loop mode, the regrind fed to the dosing system from a big regrind storage tank, assuming there is more than enough regrind available. Closed loop regrind Virgin Virgin Regrind Color Regrind Color Neckpiece Neckpiece Grinder Inj. Molding machine Inj. Molding machine Closed loop Open loop MCTC manual...
  • Page 47 In case no regrind is available anymore, the regrind unit stops and attempts to load material with a time interval. The nominal regrind percentage is the weight part of the sprue / runner.  Closed loop configuration requires a MV, ME, MFD or 3PH hopper loader to be used with the regrind dosing unit. MCTC manual...
  • Page 48 7.2.1 Configuration The MCTC needs to be configured as double station, see chapter 6 for more information about multicomponent configuration. MCTwin functionality is not available when a MCWeight is configured in the system MCBalance settings: See chapter MCBalance component configuration for more detailed MCBalance configuration.
  • Page 49 Method 2: Take the hopper from the machine and fill manually with material until the mark shown in picture below and put back the hopper on the machine. Read out the weight on the MCTC . Regrind level [default 3500gr]: The weight used to calculate all internal fill start levels and regrind dosing rate levels.
  • Page 50 The following parameters can be seen in the production screen, depending on operation or settings: The production data can be entered by touching the corresponding field 1. Material Movacolor pre-programmed curve (dosing tool/granule type), or USER defined curve (material name) is displayed. (not available when recipe function is activated) 2. Nominal regrind amount (%) 3.
  • Page 51 Material weight in the hopper. 4. Time: Set dosing time (sec), when working TIMER input mode. The average dosing time (sec), when working in RELAY input mode. 5. Act. Time: Count down of the actual dosing time (sec). MCTC manual...

  • Page 52: Working Principle

    EMPTY level, the regrind unit will stop dosing. The color unit dosing amount will increase to nominal to maintain color level. To restart the regrind dosing, the manual activation of the loader system is required. MCTC manual...
  • Page 53 The following parameters can be seen in the production screen, depending on operation or settings: The production data can be entered by touching the corresponding field 1. Material: Movacolor pre-programmed material (dosing tool/granule type), or USER defined material is displayed (not available when recipe function is activated).
  • Page 54 Material weight in the hopper 4. Time: Set dosing time (sec), when working TIMER input mode. The average dosing time (sec), when working in RELAY input mode. 5. Act. Time: Count down of the actual dosing time (sec) MCTC manual...
  • Page 55 With this system it is possible to connect up to 15 different devices to one neckpiece and directly to your injection molding machine or extruder With the MCTC it is possible to control and monitor the mixing ratio of these different components from one screen.
  • Page 56 In this example co-extrusion of 3 extruders, each with a MCWeight 500 and one MCBalance. All controlled from one MCTC. This example is used in the next paragraph. The units are equipped with MC Blind Controllers (2 MCBC’s per extruder, 6 in total)
  • Page 57 The MCTC is used as main controller and uses a CAN bus to communicate to the blind controllers. GROUP A...
  • Page 58 Alarm/warning output In a multicomponent configuration, all alarms are centralized to the first unit (MCTC UNIT 1). In case of an alarm on a blind controller unit X, the alarm output of unit 1 and the alarm output of unit X are activated.
  • Page 59 The multi-component setup needs only one input cable to supply the start and/or tacho signal to the system. This input cable needs to be connected to Unit 1 In a multi-group setup each first unit in a group needs an input cable to supply start and/or tacho signal. MCTC manual...
  • Page 60 This also useful when your machine (and touchscreen panel) is difficult to reach. You can order at Movacolor a special modification kit to convert your MCTC controller into a “remote” version. Ask your Movacolor representative for detailed information.

  • Page 61: Recipe Menu

    For stopping production press again. The motor on/off switch will turn to green again.  Please note that it is possible that the first dosing(s) are not sufficient, because of the cylinder filling with material. It takes some time to stabilize. MCTC manual...

  • Page 62: Unit Button

    For stopping production press again. The motor on/off switch will turn to green again.  Please note that it is possible that the first dosing(s) are not sufficient, because of the cylinder filling with material. It takes some time to stabilize. MCTC manual...
  • Page 63 For stopping production press again. The motor on/off switch will turn to green again.  Please note that it is possible that the first dosing(s) are not sufficient, because of the cylinder filling with material. It takes some time to stabilize. MCTC manual...
  • Page 64 41 – 42 output CLOSED during fill time No action No Action Activation of blower loading sequence 41 – 42 output CLOSED during filling Activation of compressed air filter cleaning 41 – 42 output CLOSED during blowback time MCTC manual...
  • Page 65 Production status = STANDBY or DOSING → output 36 and 37 are OPEN. Production status = OFF  In case of alarm, the alarm output (OUT-13) is switched (on) and the system is stopped. This also switches output OUT-14 (off). MCTC manual...

  • Page 66: Troubleshooting

    Problem: USB copy function does not work properly. Possible causes: 1. Some brands of USB memory sticks are not correctly detected by the MCTC. Please try another brand of USB memory stick. 2. The USB memory stick is not properly formatted, be sure the USB memory stick is formatted FAT32.

  • Page 67: Appendix A: Mctc Technical Specifications

    APPENDIX A: MCTC Technical Specifications Controls: Input: Set and actual % setting for injection molding and extrusion Extrusion control: By relay or tacho Injection molding control: Automatic metering time synchronization or by manual timer Manual speed and time setting Speed: Manual setting from 0,1 to 200 RPM max, in increments of 0,1 RPM.

  • Page 68: Appendix B: Mctc Dimensional Drawing

    APPENDIX B: MCTC Dimensional drawing MCTC manual...

  • Page 69: Appendix C: Standard Electrical Connections

    APPENDIX C: Standard electrical connections MCTC manual...
  • Page 70 8600 DA Sneek The Netherlands www.movacolor.com Declare under our sole responsibility that the product: Product description : Dosing equipment Product designation : MCTC, MCBC In combination with : MCBalance, MCHighOutput, MCWeight, MCLiquid, MCPowder, MCHybrid, MCNexus, MCNumera Year : 2021 Identification...
  • Page 71 MCTC manual...

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