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Related Manuals for Proton InteliSENS PH600 MKII Series
Summary of Contents for Proton InteliSENS PH600 MKII Series
- Page 1 Instruction Manual InteliSENS PH600 MKII Series Wire Preheater Issue 6d 1 March 2023 Proton Products Co. Ltd. 10 Aylesbury End Beaconsfield Buckinghamshire HP9 1LW England www.protonproducts.com Page 1 of 63 PH600 MKII Series Wire Preheater Instruction Manual (Issue 6d)
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Page 2: Table Of Contents
Table of Contents (CE) ............4 ECLARATION OF ONFORMITY (CSA) ............5 ECLARATION OF ONFORMITY ..................6 NTRODUCTION .......................... 6 PERATING PRINCIPLE ............................6 ECHNOLOGY ..................7 PECIFICATIONS ............................. 8 ERFORMANCE PH600-34-400/480 MKII ..........................8 PH600-60-400/480 MKII ..........................9 ................. 10 IMENSIONAL RAWINGS ................ - Page 3 RS232/RS422 C ...................... 43 OMMUNICATIONS RS232/RS422 Interface ..........................43 ......................44 THERNET COMMUNICATIONS Ethernet interface ............................44 Ethernet LED indicator ..........................44 ................ 45 LECTRICAL NTERFACES DOOR LOCK ............................ 45 DOOR LOCK interface ..........................45 Electrical connection ........................... 45 START/STOP ........................... 46 START/STOP Interface ..........................
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Page 4: Declaration Of Conformity (Ce)
Electrical equipment of machines IEC 60204-1:1997 General requirements Limitations to use Heavy industrial equipment It is declared for and on behalf of Proton Products Ltd that the equipment specified below conforms to these EC directives: 2014/30/EU Electromagnetic compatibility directive Conforms to EC directives... -
Page 5: Declaration Of Conformity (Csa)
Proton Products International Limited 10 Aylesbury End Beaconsfield Bucks HP9 1LW ENGLAND Proton Products is an ISO9001:2015 registered company. The declaration is signed by: ……………………… Paul Sives Page 5 of 63 PH600 MKII Series Wire Preheater Instruction Manual (Issue 6d) -
Page 6: Introduction
NTRODUCTION The Proton Products PH600 series wire preheaters are designed for use on continuous cable production lines for the preheating of bare solid and stranded wire prior to the application of extruded insulation. Wire preheating prior to insulation extrusion aids in the adhesion of the insulation to the wire. -
Page 7: Specifications
automatically adjusted according to the wire size to deliver all the available power to the wire for maximum temperature at high line speeds. Line inductors are fitted to improve the power factor and wave shape of the current drawn from the mains supply and also minimise the effect of phase imbalances. -
Page 8: Performance
ERFORMANCE Thermal conduction from the wire to the pulleys imposes a minimum line speed below which the preheater is unable to heat the wire to the set temperature. The minimum line speed is defined such that the pulley rim reaches 63% of the final temperature within 100s and 95% of the final temperature within 300s. -
Page 9: Ph600-60-400/480 Mkii
PH600-60-400/480 MKII Copper wire Line speed / (m / min) Wire Area / Diameter Minimum Maximum (inlet temperature = 10℃) Range Frequency type (mm) / mm speed 100° C 120° C 150° C 180° C 1.00 1.13 1.20 1.24 1.50 1.38 2.00 1.60... -
Page 10: Dimensional Drawings
IMENSIONAL RAWINGS Page 10 of 63 PH600 MKII Series Wire Preheater Instruction Manual (Issue 6d) -
Page 11: Annotated Drawings
NNOTATED DRAWINGS Right side Front Left side Description Lifting eyelet (×4) Door (×2) Interface and communications wiring box Door handle (×2) Interface display unit and emergency stop button Wire inlet / outlet Stand Jacking screw (×4) Page 11 of 63 PH600 MKII Series Wire Preheater Instruction Manual (Issue 6d) -
Page 12: Precautions
RECAUTIONS Operating temperature range Specification Minimum Typical Maximum Units ° C Operating temperature +113 ° F • Do not operate the unit in temperatures outside the above range or position the unit near high temperature surfaces or objects which may cause it to overheat. Protect from impact and movement •... -
Page 13: Installation
NSTALLATION Unpack the unit and check for missing accessories and shipping damage. ECHANICAL NSTALLATION Warnings • The preheater and floor-stand have a combined weight of 1320kg and MUST be installed on concrete floor rated to carry this load. • The floor-stand MUST be levelled and then securely bolted through all 4 jacking bolts (Ø13mm clearance hole, depth 140mm) to the concrete floor beneath using appropriate- length concrete anchor studs. - Page 14 Hoist the preheater main unit onto the floor-stand: All 4 hoisting attachments must be >60° from the top surface of the preheater main unit: Preheater main unit weight: 1200 kg Locate the preheater main unit onto the 4 location cones on the floor-stand: Page 14 of 63 PH600 MKII Series Wire Preheater Instruction Manual (Issue 6d)
- Page 15 Secure the preheater main unit to the floor-stand using the supplied fixing hardware: Supplied fixing hardware Quantity Description Type Hex bolt M16×50 Spring washer Ø16 Flat washer Ø16 Required tools Quantity Description Type Open-ended spanner 24mm Page 15 of 63 PH600 MKII Series Wire Preheater Instruction Manual (Issue 6d)
- Page 16 Level the preheater and adjust the wire line height using the 4 jacking screws and then fully tighten the floor bolts: Page 16 of 63 PH600 MKII Series Wire Preheater Instruction Manual (Issue 6d)
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Page 17: Electrical Installation
LECTRICAL NSTALLATION 1. Install the 3-phase mains power supply cable. 2. Install communications interface connections as required (RS-232 or optional PROFIBUS). 3. Install electrical interface connections as required (emergency stop input, start and stop preheat inputs, relay outputs, temperature set input, optional loop current output). 4. - Page 18 Unscrew the 6 screws indicated by the arrows and remove the cover plate. Cover plate Insert the 3-phase mains supply cable through the cable clamp. Cable clamp Earth Attach the four conductors to the terminal block as shown. Note: the earth wire must be connected to the yellow / green coloured terminal. Standard models Canadian CSA compliant models Do NOT disconnect these wires...
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Page 19: Communications And Electrical Interface Connections
Communications and electrical interface connections The communications and electrical interface connections are made via screw terminal blocks located in a junction box on the left side of the unit. • Remove the four screws as indicated by the arrows to access the junction box. •... -
Page 20: Powering The Unit On Or Off
Powering the unit on or off The unit may be powered on or off by turning the mains isolator switch located on the rear of the unit. Mains isolator switch Power on indications LED status Indication Power LED (located in the communications and electrical interface Unit is powered on junction box) Extinguished... -
Page 21: Configuration Interface
ONFIGURATION INTERFACE HOME PAGE The home page is used for monitoring the preheating process and displaying the following data: • Preset wire temperature, material and cross-sentional area. • Wire temperature calculated from the delivered electrical power. • Measured loop voltage and current as a percentage. •... - Page 22 Press the button on the home page to access Preset page 1. If the “Range selection mode” is If the “Range selection mode” If the “Range selection mode” set to “Auto[Area]”, Preset page 1 is set to “Auto[AWG]”, Preset is set to “Manual”, Preset page will be: page 1 will be: 1 will be:...
- Page 23 To configure the preheater for operation with To configure the preheater for operation with copper (including solid copper, tin-plated copper copper-clad wire: or silver-plated copper) or aluminium wire: To configure the preheater for operation with wire materials other than copper, aluminium or copper- clad: Label Description...
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Page 24: Function Menu
Press the button to advance to next Preset page to preset the input temperature. If the input temperature type is set to “Preset” on System page 3, the preset input temperature value can be set on this page. FUNCTION MENU Press the Home icon to return to the home page;... -
Page 25: System
SYSTEM Press the System icon on the function menu page to access System-Tuning page. Label Description Set the tuning gain to compensate the wire temperature at high line speed (> 2 Gain 0 ~ 999 × minimum speed). Set the tuning zero to compensate the wire temperature at low line speed (< 2 × Zero 0 ~ 999 minimum speed). -
Page 26: Wire Break Detection
Press the button on System page 1 to advance to System page 2. Label Description Disable wire break detection. Wire break Enable wire break detection. Wire break time 0~65535ms Set the wire break delay time. In “Auto [Area]” mode, the wire range will be automatically Auto[Area] calculated by the wire size set on Preset page 1. - Page 27 Press the button on System page 2 to advance to System page 3. Label Description Ambient The preheater inlet cable temperature is ambient temperature. Input temperature The preheater inlet cable temperature can be preset on type Preset “Preset” page. Door Open The light in the preheater will be on when the door is open.
- Page 28 Label Description Group number Enter the group number (0~50). Save Click this button to save changes to the current active group after modifying the input parameter values. Recall Click this button to recall the stored input parameter values in the group. The following parameters can be set and stored in a group: •...
- Page 29 Press the button on System page 4 to advance to System page 5. Label Description Unit Select the unit from options: Metric; Imperial. Language Select the language from options: English; French. Factory default Click this button to restore all parameters to factory default settings. Press the button on System page 5 to advance to System page 6, 7.
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Page 30: Communications
RS232 baud rate Select the RS232 baud rate from options: 4800; 9600; 19200; 38400; 115200. RS422 protocol Select the RS422 protocol from options: PROTON; Modbus; MD5 TG. RS422 baud rate Select the RS422 baud rate from options: 4800; 9600; 19200; 38400; 115200. - Page 31 Press the button on Communication page 2 to advance to Communication page 3. Label Description Disabled Disable DHCP allocation of the Ethernet IP address. DHCP Enabled Enable DHCP allocation of the Ethernet IP address. IP address Enter the IP address assigned to the preheater. Subnet mask Enter the subnet mask for the network.
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Page 32: Interface
“FB TEMP” input. Temp control source Preheating temperature is controlled by a PROTON TG PROTON Temperature Gauge. Preheating temperature is controlled by an MD5 MD5 TG Temperature Gauge. Set the temperature control full scale value (only if “External Analogue”... - Page 33 Press the button to advance to Interface page 4 and 5 for relay configuration. Label Description Select the relay function from options: General fault; Heating State; Relay 1 (2, 3, 4) function Switch State; Emergency Stop; Ambient temp high. Heating state threshold Set the load current threshold at which the relay operates.
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Page 34: Access Levels
ACCESS LEVELS Press the Access levels icon on the function menu page to enter Access levels page. Input the password “18018” then select to lock or unlock the respective pages. The “Access level” menu is a password protected menu which controls which parameters may be adjusted by the operator. -
Page 35: Operation
PERATION MERGENCY STOP CONTACT OUTPUT The emergency stop button installed on the front panel of the preheater provides an isolated push-to- break switch contact that is opened when the button is pressed (emergency stop condition). This push-to-break contact may be used to stop other equipment on the production line (such as a capstan drive) whenever the emergency stop button on the preheater is pressed. -
Page 36: Wire Threading
HREADING Standard wire threading sequence The wire may be run in either direction (left-to-right or right-to-left) through the preheater. Thread the wire in the following sequence: User Action Insert the wire horizontally through the wire inlet port. Run the wire under and around the BACK groove of the lower (shorting copper) pulley. CAUTION: The rim of this pulley may be hot;... -
Page 37: Enhanced Contact Wire Threading Sequence
Enhanced contact wire threading sequence If sparking or poor electrical contact with the copper shorting pulley is experienced (especially with thicker gauge wires), then electrical contact may be enhanced by using the threading sequence below (this threading sequence will result in greater heat loss from the wire to the shorting pulley than the standard threading sequence): User Action Insert the wire horizontally through the wire inlet port. -
Page 38: Start - Up Configuration
TART UP CONFIGURATION Step Action Interface display unit “Preset” page 2 or 3 Set the wire material “Preset” page 1 Set the preheating temperature “System” page 2 Set the start speed Set the wire size range (in “Manual” mode) or enter the wire size (in “Auto” “Preset”... -
Page 39: Troubleshooting
(e.g from 4 to 3). Allow the preheater to cool IGBT overheat down before resuming operation. Contact your Proton Products IGBT failure. service representative. Contact your Proton Products Mains power supply fault service representative. The solenoid door lock is... - Page 40 Inspect mains power supply Mains power supply phase for phase loss and remedy loss. accordingly. Coupling capacitor voltage at Contact your Proton Products maximum value. service representative. Page 40 of 63 PH600 MKII Series Wire Preheater Instruction Manual (Issue 6d)
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Page 41: Communication Interfaces
This CAN-bus interface is fitted as standard. It operates independently of the other communication interfaces and may be used at the same time as them. The CAN-bus interface uses a proprietary Proton Products protocol. It is exclusively used to communicate between the unit and other Proton Products modules. The unit automatically detects connection to other modules and configures the bus appropriately;... -
Page 42: I-Bus Communications
I-BUS COMMUNICATIONS This I-BUS communication interface operates independently of the other communications interfaces and may be used at the same time as them. This I-BUS interface supports three types of standard industrial bus interfaces, PROFIBUS, PROFINET and EtherNet/IP for connection to PLCs and other process control instrumentation. The I-BUS communication interface may be end-user enabled through the purchase of a license key. -
Page 43: Rs232/Rs422 Communications
RS232/RS422 C OMMUNICATIONS This RS232/422 interface is fitted as standard. It operates independently of the other communication interfaces and may be used at the same time as them. RS232/RS422 Interface The RS232/422 interface may be accessed through the “RS232/RS422” connector. Connector type: DB9 female Comment RS232... -
Page 44: Ethernet Communications
THERNET COMMUNICATIONS This Ethernet interface is fitted as standard. It operates independently of the other communications interfaces and may be accessed at the same time as them. Ethernet interface The Ethernet interface may be accessed through the RJ45 connector. Connector type: RJ45 8P8C female Designation Comments LAN TX+... -
Page 45: Lectrical Nterfaces
LECTRICAL NTERFACES DOOR LOCK Under normal operation, the solenoid door lock is automatically controlled by the preheater software; no external connection should be made to the lock control input. If it is necessary to open the door when the preheater is not connected to a mains power supply, then connecting a +24V DC power supply across the “DOOR LOCK”... -
Page 46: Start/Stop
START/STOP Preheating may be remotely started and stopped by voltages applied to the “START/STOP” interface. START/STOP Interface Electrical connection The “START/STOP” interface may be accessed through the “START/STOP” screw terminal block: START/STOP θ ■ Factory-installed shorting link θ The preheater unit is factory-fitted with a shorting link between terminal “+V” and “ ”... - Page 47 START and STOP inputs behaviour Input state Preheater state START STOP LOW / unconnected LOW / unconnected Stop LOW / unconnected HIGH Set by interface display panel HIGH LOW / unconnected Stop HIGH HIGH Start For operation using the interface display panel only: •...
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Page 48: Analogue O/P
ANALOGUE O/P The analogue interface provides 4 analogue voltage outputs corresponding to: • Loop voltage • Loop current • Wire temperature • Primary voltage • Primary current • Line speed ANALOGUE O/P interface Electrical connection The analogue outputs may be accessed through the “ANALOGUE O/P” screw terminal block: Connector type: screw terminal block Designation Description... -
Page 49: Emergency Stop
EMERGENCY STOP Operation of the preheater may be enabled or disabled by a voltage applied to the “EMERGENCY STOP” interface. EMERGENCY STOP interface Electrical connection Connector type: Screw terminal block Designation Description +24V output voltage Emergency stop input (in normal condition, this terminal is shorted to +24V; when pressing the emergency stop button, the emergency stop function will be enabled to stop the preheater;... -
Page 50: Relay O/P
ELAY Four relay outputs are fitted as standard for indication of preheater state and fault conditions. RELAY O/P interface Electrical connection The 4 relay outputs may be accessed through the “RELAY O/P” screw terminal block. Connector type: Screw terminal block Designation Description Each individual relay output can be independently configured to... -
Page 51: Temperature Set Input (Set Temp)
(SET TEMP) EMPERATURE SET INPUT The preheating temperature may be remotely set by an analogue voltage applied to the “SET TEMP” input. SET TEMP interface Electrical connection The “SET TEMP” input may be accessed through the screw terminal block. Connector type: Screw terminal block Designation Description Notes... -
Page 52: Measured Temperature Feedback Input (Fb Temp)
(FB TEMP) EASURED TEMPERATURE FEEDBACK INPUT The preheating temperature is adjusted to approach the set temperature value according to the signal generated by the temperature device connected to the “FB TEMP” interface. FB TEMP interface Electrical connection The “FB TEMP” input may be accessed through the screw terminal block. Connector type: Screw terminal block Designation Description... -
Page 53: Interface Terminal Block
NTERFACE TERMINAL BLOCK Designation Description Functional group ■ Not connected DOOR LOCK Door lock control input Apply 24V to unlock the door Ground reference +24V (drive signal for logic inputs) ■ Ground reference Start preheating input Stop preheating input (this Logic inputs (not isolated from START/STOP terminal is shorted by a factory-... - Page 54 Relay contact outputs (all RELAY O/P User programmable isolated from earth and voltage- free) 0 to +10V control voltage input SET TEMP Temperature set voltage input Ground reference 0 to +10V control voltage input FB TEMP Feed-back temperature input Ground reference DB9 (male) CAN-bus communications I-BUS...
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Page 55: Proton Standard Rs-232 Parameter Access Protocol
• Output parameters are read only and provide access to preheater status and measured data. They may be requested to stream continuously from the preheater. The Proton standard RS-232 protocol data format is as follows: Number of data bits Parity... -
Page 56: Modbus Parameter Access Protocol
ODBUS PARAMETER ACCESS PROTOCOL This protocol provides access to individual parameters or blocks of parameters and is typically used in a production environment where the Proton Products instrument is connected to a computer, Modbus connected PLC or similar device. The parameters consist of 16-bit words (DW) and are divided into input and output groups: •... -
Page 57: Input Parameters
NPUT PARAMETERS 1x 16-bit word = 2x 8-bit bytes Comments Unit Range/Remark Default Value Heating Switch 0=OFF;1=ON Preset Temperature 1=1° C{° F} 0~999 1=0.001mm {0.0001in Wire Size 0~65535 1000 {AWG} Wire Size Range 0~3(1~4) Selection 0=Solid Copper,1= Copper Clad,2=Alu minium,3=Special 1 ;... - Page 58 Comments Unit Range/Remark Default Value Relay 3 Function Relay 4 Function 0=Auto[Area]; Wire Size Range 1=Auto[AWG] Selection Mode 2=Manual Analogue OP1 0=Loop Function Voltage;1=Loop Analogue OP2 Current;2=Wire Function Temperature;3=Pri mary Analogue OP3 Function Voltage;4=Primary Current;5=Line Analogue OP4 Speed; Function Analogue OP1 Full 1~65535 Scale Analogue OP2 Full...
- Page 59 0~125 CAN Address 0~255 0=250; 1=500; CAN Baud Rate 2=1000; other=500 CAN Terminator 0=OFF;1=ON 0=4800;1=9600;2= RS232 Baud Rate 19200;3=38400;4= 115200 0=Proton; RS232 Mode 1=Modbus 0=Proton; RS422/RS485 Mode 1=Modbus; 0=4800;1=9600;2= RS422/RS485 Baud 19200;3=38400;4= Rate 115200; 0=Disabled;1=Enab ETH DHCP C0A801A0(19 ETH IP Address 2.168.1.160)
- Page 60 Comments Unit Range/Remark Default Value MAC address for Ethernet Page 60 of 63 PH600 MKII Series Wire Preheater Instruction Manual (Issue 6d)
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Page 61: Output Parameters
UTPUT PARAMETERS 1x 16-bit word = 2x 8-bit bytes Comments Units Range/Remark Preheater Status 0=OFF,1=ON,2=Ready Reserved Unit 0=Metric;1=Imperial Type of preset temperature 0=Preset input input,1=Analogue input State of Door 1=Closed,0=Opened State of Lock 1=Locked,0=Unlocked Mains Relay 1=Closed,0=Opened Relay 1 1=Closed,0=Opened Relay 2 1=Closed,0=Opened Relay 3... - Page 62 Comments Units Range/Remark Reserved 1=1° C Wire Temperature 0~999 1=1% Heating Voltage 0~9999 1=1% Heating Current 0~9999 1=1m/min{ft/min) Line speed 0~3000 1=0.1° C Ambient Temperature 0~99 1=1° C Preset Temperature 0~999 Reserved Reserved 1=0.001mm2{0.0001in2} Range 1 Wire Size 0.000~99.000 Range 2 Wire Size 0.000~99.000 Range 3 Wire Size 0.000~99.000...
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Page 63: Contact Details For Enquiries , Sales And Service
Proton Products is not responsible for consequential or incidental damage related to the provision or use of the information contained in this manual. • The information contained in this manual is the property of Proton Products and may not be circulated or distributed to third parties. •...
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