YM:PROCESS CONTROL WXA

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1 Checkup material

• 0,2 - 1 Kg reference weight

• The flash memory card for software (version WX 1.26.2)

• The flash memory card for configuration (block 1)

• PROFIBUS Software CDROM (HILSCHER)

• The serial cable

2 Overview

The picture above shows the open Process Control. To make the zeroing and the calibration you need to open it. Be carefull with the door and the Batch Flap. When you open the door, the savety switch (it is indicated in the picture with a X) is open. This will disable the mixer and the Batch Flap. If you want to check them or fill granulat into the suction system, you have to unmount the savety key from the door and put it back into the safety lock. But be carefull, the 'mixer and flap are now able to run!!!

1. If you see dirt insight the mixer, clean it with the compressed air. There can also be dirt inside the Flaps, clean them too.
2. On the backside of the controll unit you have the check, if the Profinet address is the same like in the HdwCfg.
3. Furthermore check, if the whole hardware has a good connection to the ground. Check all connections of the ground cables in and outside of the process control.

The picture shows the User Interface of the process control. The Logo in the left bottom corner is also a key.

• Check, if the PCMCIA-cards are in the deposit.
  

To check the Version of the Process Controller press the "PC-Logo" and use the up and down keys to go to this menue.

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Normaly, the version should be on the PCMCIA-cards

3 Check the connection according to wiring drawing

Take care that really every single Part(Hopper,Socket,Control Unit,connected Pipes) of the Unit is connected to Ground.

File:ProcessControl Grounding02.JPG File:ProcessControl Grounding03.JPG File:ProcessControl Grounding04.JPG

4 Switch on the “Process Control” device

The system will boot from the onboard FlashROM. Please compare the installed Firmware version with the version of the Flash Memory Card. If the Firmware version at the Flash Memory Card in newer than the installed version please update the system like Point 8.

• The default PROFIBUS address is 80. If you have more Process Control devices, they will follow with Address 81, 82 …

• If the SIMATIC Manger project hardware configuration PROFIBUS address is different than the “Process Control” default PROFIBUS address, so the easiest way is to change the SIMATIC Manager hardware configuration.

• If there are some more problems at the communication please see Point 7.

5 Calibrate hopper

• Press “Lock” key with password “111111" to go to supervisor level
  

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• If the Password is correct, the security level will be set to supervisor
  

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• To enter the calibration mode, typ in 985 and "Enter"
  

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• After this, you will enter the calibration Menue. Type "Enter"
  

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• Choose WEIGH HOPPER. To go to the menue use the up and down keys
  

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• After this, the System will guid you during the calibration Process
  

• The Process Controll will start with the Zero Calibration
  

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• The Process Controll will ask you, if the flap is empty. Check it and then press 'Enter'

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• After showing the Information, the system start with the calibration, DO NOT TOUCH THE BATCH HOPPER
  

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• When the system is finished with zeroing, it has to been calibrated with a weigh. Type in the load of your calibration weight.

• Put the weight into the flap and press Enter. Be carefull that you don't harm the weight system.

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• The Process Controll will calibrate itself. Like the Zero calibration, DO NOT TOUCH THE FLAP.

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• If this is finished, you can choos "EXIT" and press 'ENTER'

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• After the calibration process press the "LOCK" Key to go to 'Operator Level'. Accept it with 'ENTER'

• After calibrating the Batch Hopper, verify the accuracy of calibration by using the “MONITOR” key. There are two menues, which you can enter. One shows the weight of the Flaps (2xx) and the other one shows the weight of the Batch Hopper (1xx). Press the "MONITOR" key as often as you see 0xx in the left corner of the display. To navigate use the up and down keys or type in "001". Now put a weight insight the hopper and check if the Process Control shows you the correct weight.

6 Calibrate the Proxi Switch

The Proxiswitch indicate, if there is granulate insight the mixer. The problem is, that the granulate get a electrostatic charge and makes a deposition insight the mixer. For this reason the Proxiswitch need to be calibrated.

• To simulate the deposition take a tape and put granulate on it. Then put the tape on the sensor like in the picture.
  

• On the backside you have the potentiometer where you can calibrate the sensor.
  

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• Turn the potentiometer as long as the indication light goes out.
  

After the calibration remove the tape and press the "PC-Logo" taste on the User Interface.

Press Enter until you go to this display.

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• The "PRX" indicates the Proxiswitch.
  

Y = Mixer full

N = Mixer empty

Put in a plastic bag full with granulate to check the function.

If the Proxiswitch is calibrate corectly, the "PRX" change from "N" to "Y".

Refer to Manual: Adjustment of Proxiswitches

7 Troubleshooting

7.1 Loading “software” from flash memory card to onboard Flash-ROM

• Switch off the power
• insert software flash memory card in PCMCIA slot
• Switch on power again, the system will copy software from software flash memory card to onboard Flash-ROM
• After finished copy, please remove the software flash memory card
• Waiting till the “Process Control” device finished the automatic re-booting with new software from onboard Flash-ROM

7.2 Loading “configuration” from memory card to process control

• insert configuration memory card inside slot
• press “Lock” key with password “111111" go to supervisor level
• press “setup” and 960 ("System Restore")
• with arrow select “Receive Configuration From PCMCIA”, press “Enter” then select “block 1” (if you have more then one batch dosing device, there may more configuration then block1 stored on the card, in this case the different config. should be written on the PCMCIA card e.g. WXA025 – block1 , WXGA050 – block2) and follow the direction displayed on the control Panel
• after finished copy configuration from flash memory card, please remove the Memory card, the system will re-booting again
• Check if a calibration of the hopper is necessary.

7.3 System Backup

• insert configuration memory card inside slot
• press “Lock” key with password “111111” go to supervisor level
• press “setup” and 955
• with arrow select “Save Configuration To PCMCIA”, press “Enter” then select “block 1” or where ever you want to store the configuration (there are up to 20 blocks to save the configuration), and follow the direction displayed on the control panel
• after finished copy configuration to flash memory card, please remove the memory Card and label the card, as you saved the configuration

7.4 PROFIBUS communication Problem

• If a factory reset was made, then first load the configuration from the memory card, before you reconfigurate the profibus settings.
• If the profibusaddress on the process control isn't correct, then the easier way it's to change the profibus address in the hardwareconfig of the plc!

In case the SIMATIC Manager hardware configuration is correct, maybe the problem is in the “Process Control” PROFIBUS address or PROFIBUS configuration, so we have to change the PROFIBUS address and re-configure the “Process Control”

• Install PROFIBUS Configuration software from CDROM
• Start Software “SyCon”
• Go to menu File -> new and select PROFIBUS
• Insert Master with any one module, example: CIF50-PB

Check the PROFIBUS communication module type, open the “Process Control” cover, we can see the type on the board

• Insert slave as same hardware type of the PROFIBUS communication module, example: CIF30-DPS / CIF104-DPS /-R, press “Add>>”, the right pane will Display which slaves insert (in case the actual hardware type of the PROFIBUS communication module is not in the slave selecting list, then have to download GSD file from internet)
• Change “Station address” as same like SIMATIC Manager hardware configuration
• Double click on “Slave1”, the configuration should be same like SIMATIC Manager hardware configuration

File:Processcontrolsoft1.png File:Processcontrolsoft2.png

• Go to Menu Online -> download, select “CIF Serial Driver”
• Click “Connect COM1”, display which CIF is connected with serial com, it must be the same type as slave module type
• Press “OK” and “Download”

7.5 General Faults

Fault Description	Solution
Fault Message "Hopper A critical low" appears, but Hopper A is not empty	Check if the Flap under the Hopper A is working fine, by moving it manually (Switch the Keyswitch to "Manual-Operation"). In the case it makes some strange noises during moving, take it out and check if some Granulate blocks the Flap or if there is some other mechanical reason which blocks it.
Fault Message "Can not Dump Material" appears, and the Unit is full of Material	Check the Adjustment of the Proxi-Switch and adjust it according to the Calibrate the Proxi Switch-Chapter of this Article.
Batch Weigh Hopper Cannot Dump Material	* Check if no material is sticks on the hopper * Check if the hopper is emtpy the weight of the empty hopper (should be 0.00 kg)