FAQs
Name | Description |
|---|---|
What are the hardware requirements? | |
What are the software requirements? | |
Can a zone heat in case of sensor failure? | |
How can I redirect the output of heating and cooling signals? | |
How can I redirect the acquisition of the actual temperature? | |
How does the Idle Load Tuning work? | |
How does extruder compensation work? | |
What should I do in case of malfunction? |
FAQ#1: Hardware requirements
An IPC with x86 architecture and hardware FPU. Computing power requirements and fieldbus support must be clarified in each case. Examples:
- DIN-rail PCs of the types CX1010, CX1020 or CX1030.
- DIN-rail PCs of the types CX50xx.
- DIN-rail PCs of the types CX51xx.
- DIN-rail PCs of the types CX20xx.
- Control cabinet PCs of the families C41xx, C61xx, C62xx, C69xx.
- Panel PCs of the families CP62xx, CP72xx, CP67xx, CP22xx, CP32xx and CP37xx.
- Other PC families are usually suitable as well. This must be clarified in each individual case.
Alternatively, an IPC with iXP architecture and FPU emulation. Here, there may be restrictions on the number of zones and/or the cycle time.
- DIN-rail PCs of the types CX9010 or CX9020.
- Panel PCs of the families CP66xx and CP26xx.
A fieldbus architecture with suitable performance:
- Preferably EtherCAT
- Alternatively, one of the following fieldbuses (cycle times of 10 ms or less should be aimed for):
- LightBus
- RT Ethernet
- Profibus with 12 MBaud
FAQ#2: Software requirements
A Microsoft operating system of the type Windows CE 6, Windows Embedded Compact 7, Windows XP, Windows XPe or Microsoft Windows Embedded Standard 7, 32-bit.
An executable and licensed TwinCAT system, released for at least TwinCAT PLC.
A licensed copy of the Plastics Temperature Control Framework Library PfwLib_TempControl.LIB, version V1.0.1 or higher.
A provided Plastics Framework AppExtension project PfwLib_TempControlAppExtension.PRO whose version matches the Plastics Temperature Control Framework Library version.
FAQ#3: Heating in case of sensor failure
In the event of a temperature sensor failure, it may be necessary to continue operating the machine. In such a case, the library can be made to estimate the power demand of the zone and output the corresponding heating signal. A number of preconditions have to be met:
- The signal type must be set to eTcPfwTcOut_PWM.
- The zone must be fully commissioned beforehand. Above all, the IdleLoad Tuning must have been done with sufficient accuracy.
- This option should not be enabled in adjacent zones. Otherwise, the risk of overheating of the heating tapes and the material increases due to the uncontrolled output of the power.
Note | |
This option must never be activated in zones that receive excess energy (friction, discharge from neighboring zones) from the process during operation. |
To enable the option, set EnableErrorHeating to TRUE in the machine data. A value in the range 0...1 in ErrorHeatingFactor can be used to specify which portion of the estimated power should be output.
 | If the set temperature of the zone is changed, ErrorHeatingFactor does not need to be adjusted. The estimation will automatically adjust the required power. |
FAQ#4: Redirecting heating and cooling signals
If a digital output of the PLC is defective, the operator can connect this digital output to another free output and then redirect the corresponding signal to the other output in the HMI. In order to use this feature, various settings must be made in the temperature library. Since the commissioning of the I/O redirection is somewhat more sophisticated, contact the support in this case. If you do not want to use this feature, the settings in the step-by-step commissioning are to be applied.
FAQ#5: Redirect actual temperature acquisition
If an analog input of the PLC is defective, the operator can connect this analog input to another free input and then redirect the corresponding signal to the other input in the HMI. In order to use this feature, various settings must be made in the temperature library. Since the commissioning of the I/O redirection is somewhat more sophisticated, contact the support in this case. If you do not want to use this feature, the settings in the step-by-step commissioning are to be applied.
FAQ#6: The Idle Load Tuning
The prerequisite for determining the base load is:
- the system must be stable (control deviation of less than 1 °C)
- the setpoint must be greater than 70 °C
- there must be no disturbances acting on the system (rotating screw).
The actual value is not excited during base load determination. Only internal calculations take place. The determination takes several seconds, after which the determined value is automatically included in the control.
FAQ#7: Extruder compensation
Prerequisite for determining the extruder compensation:
- the system must be stable (control deviation of less than 1 °C)
- the screw speed must have reached the working speed
After the extruder compensation has been determined, it is not active. Only when the parameter ExtruderCompEna from the machine parameters receives a TRUE, it also becomes effective. With correct extruder compensation, the actual temperature behaves much more smoothly when the screw is switched on or off than without compensation.
FAQ#8: Behavior in case of malfunction
Take screenshots of the machine and product parameters.
Record the behavior using the scope.