3014_Supercolor V4 user manual.pdf
152
dispensing systems ® SUPERCOLOR SER S MANUAL U ’ ATTURA ABORATORIOS DE N L S.A. C.V. ERIAL N S . 3014
Transcript of 3014_Supercolor V4 user manual.pdf
d i s p e n s i n g s y s t e m s
®
SUPERCOLOR
SER S MANUALU ’
ATTURA ABORATORIOS DEN L S.A. C.V. ERIAL NS . 3014
USER’S MANUAL
1 SUPERCOLOR
User’s Manual
SUPERCOLOR
04.2012
USER’S MANUAL
2 SUPERCOLOR
USER’S MANUAL
3 SUPERCOLOR
SummaryIntroduction .....................................................................................7Constructor details............................................................................8
Name and address ..................................................................8Technical Assistance................................................................8
Glossary ..........................................................................................9pictographs used in this manual have the following meaning:.....11
Supercolor employment...................................................................13Additional preventative measures ...........................................13Product characteristics...........................................................14
Performance and characteristics. ..........................................14Configuration .................................................................................15
main features .......................................................................15optional accessories ..............................................................18electrical power ....................................................................18
Electricity...........................................................................18Compressed Air ..................................................................18Lan: ..................................................................................18
ambient characteristics..........................................................18Emissions from the machine.............................................................19
Protection against possible dust emission...............................19Access to the box................................................................19
Using the apertures...............................................................32Normal functioning..............................................................32Product loading...................................................................32Treating aspirated air ..........................................................32Air conditioning inside the housing ........................................32Characteristics of the filter cartridges ....................................32
Transport and Installation................................................................33Machine handling and moving conditions ...............................33Storage Conditions..............................................................33Transport and handling information.......................................33Assembly ...........................................................................33Floor capacity .....................................................................34Connections and electrical wiring ..........................................34Control operations before start-up ........................................34Check guards and safety devices. .........................................34
Instructions for the operator ............................................................35Guidelines to safe machine usage ...........................................35
Information and training ......................................................35Qualified personnel .............................................................35PPE (Personal Protective Equipment) .....................................35Guards and safety devices ...................................................35
Safety and health labels ..................................................................36Warning signs ......................................................................36Mandatory signs ...................................................................36Stop signs............................................................................37
Residual and Behavioural regulations ................................................38Risk of slipping and falling......................................................38Risk of cutting ......................................................................38Risk of dust inhalation ...........................................................38Risk of electric shock.............................................................38Risk of crushing ....................................................................39
Operator working areas ...................................................................40noise ...................................................................................40
Knowing the machine ......................................................................42Command and control panel...................................................42loading panel........................................................................44
USER’S MANUAL
4 SUPERCOLOR
Bag sealing position ............................................................45Loading panel.....................................................................49Loading pump ....................................................................50
Start-up procedure .........................................................................51Temporary stop ....................................................................52emergency stop....................................................................52shutdown procedure..............................................................53
Software........................................................................................54OperatiNG SYSTEM ..............................................................54General parameter definitions ................................................54
Setup program ...............................................................................551-LANGUAGE........................................................................572-SECURITY .........................................................................583-FILEPATHS........................................................................594-Peripherals........................................................................605-General ............................................................................616-SYSTEM............................................................................637-Silos.................................................................................648-DISPENSING .....................................................................659-SENSORS..........................................................................67Loading program ..................................................................68
Touch screen panel for product loading..................................74Entering data .....................................................................75Main program window .........................................................76Setup ................................................................................76Product loading...................................................................80Loading panel faults ............................................................83
Special functions ............................................................................84Security...............................................................................85Dispensing parameters ..........................................................88
Anticipated stop..................................................................88Micro-dispensing.................................................................88Percentage tolerance...........................................................88Absolute tolerance ..............................................................88
Stock updating .....................................................................89Printers ...............................................................................90
Supercolor program ........................................................................91Main Screen:........................................................................91FUNCTION LIST:...................................................................93
First button scheme ............................................................94Second button scheme ........................................................94Third button scheme ...........................................................94Fourth button scheme .........................................................95Fifth button scheme ............................................................95Active buttons on all schemes ..............................................95
Machine editor......................................................................96Product editor.......................................................................97F6 = Stock...........................................................................98Rapid withdrawing .............................................................. 100batch editor ....................................................................... 102Recipe editor ...................................................................... 103processes on waiting list ...................................................... 104executing a batch ............................................................... 105
Faults.......................................................................................... 106Functional faults ............................................................... 106RESUMING THE DISPENSING CYCLE ................................... 108
Error messages ............................................................................ 110Component index in alphabetical order .................................. 110
USER’S MANUAL
5 SUPERCOLOR
Weigh trolley zeroing........................................................... 111Stop.................................................................................. 112Manually opening the side cover panel................................... 113Emergency......................................................................... 114Weigh trolley limit switch ..................................................... 115Weigh trolley motor translation............................................. 116Dispensing motor................................................................ 118Scale lifting ........................................................................ 119Dispensing cap ................................................................... 120Interface............................................................................ 121Screw coupling ................................................................... 122Aspiration bulkhead............................................................. 123Loading trolley centering...................................................... 124Nozzle insertion .................................................................. 125Detecting bucket presence on the scale ................................. 126Open/close scale protection panel door.................................. 127Manual weighing................................................................. 128Dispensing ......................................................................... 129Reset ................................................................................ 130Lawer90 pneumatic island.................................................... 131Manual loading and unloading .............................................. 132Insufficient air pressure ....................................................... 134Miscellaneous ..................................................................... 135PLC error diagnostics........................................................... 136
Reading the technical documentation .................................. 137Safety measures to adopt when using the machine........................... 139
Information and training .................................................... 139PPE (Personal Protective Equipment) ................................... 139Guards and safety devices ................................................. 139Safety and health labels .................................................... 139Machine start up ............................................................... 139
Residual and Behavioural regulations .............................................. 140Risk of slipping and falling.................................................... 140Risk of cutting .................................................................... 140Risk of dust inhalation ......................................................... 140
Risk of electric shock ......................................................... 140Risk of crushing ................................................................ 140
Ordinary maintenance ................................................................... 142Switches .......................................................................... 142
routine controls .................................................................. 144Weekly maintenance ......................................................... 144
Four monthly maintenance................................................... 147Dyestuff Silos ..................................................................... 148
Extra Maintenance ........................................................................ 149Substituting the PLC battery................................................. 149
Lubrication....................................................................... 150Demolition and disposal................................................................. 151
Demolition ......................................................................... 151Disposal............................................................................. 151
USER’S MANUAL
6 SUPERCOLOR
USER’S MANUAL
7 SUPERCOLOR
IntroductionThe object of this technical manual is to provide the user with the necessaryinformation in order to operate the machine at its full potential. It providesinstallation, maintenance and safety instructions which must be carefully read priorto working with the machine.The operating instructions hereunder explained must be applied correctly in orderto avoid hazardous situations, damage and premature wear of the machine and it’sparts.
This manual contains safety rules to adopt while operating or working on themachine which must also comply to the valid regulations in force in the countrywhere the machine is installed. This technical manual must be made available tousers and stored in a location that can be easily accessed by all machine users.
USER’S MANUAL
8 SUPERCOLOR
Constructor details
NAME AND ADDRESS
LAWER S.p.A.
Via Amendola 12/1413836 COSSATO (Biella) – Italia
Tel: (int.+39) 015.98.99.511Fax (int.+39) 015.98.42.211
TECHNICAL ASSISTANCE
Lawer Technical Assistance
Tel: (int.+39) 015.98.99.511Fax (int.+39) 015.98.42.211
E-mail:Technical support service: [email protected] parts, orders and information: [email protected] documents: [email protected]
USER’S MANUAL
9 SUPERCOLOR
Glossary
To fully understand the instructions it is necessary to explain some of thedefinitions used in this technical manual.
PERSONAL PROTECTIVEEQUIPMENT (P.P.E.)
Refers to safety equipment to protect theoperators when working with dye stuff productsthat may be hazardous to health and must bein compliance with the safety regulations of thedestination country.
DYESTUFFRefers to any product which imparts coloursuch as powder, granules or micro-pearldyestuff.
DRUMCommercial drum containing the powderdyestuff.
SILO
Storage silo for the dyestuff, the number ofsilos varies according to the customer’s needs.These silos are mounted on the SUPERCOLORstructure.
SUPERCOLOR HOUSING
The structure that surrounds the machine. Withthe help of an aspirator provides the rightdepression ambient which prevents dyestuffparticles to be released in the atmosphereduring the dispensing or loading operations.
LOADINGOperation that transfers the dyestuff from thedrums to the storage silos.
LOADING TROLLEY
Sliding trolley situated behind the machine.Equipped with a platform to support the colourpackage and a vacuum pump for refilling thesilos with a suction lance.Optional:Barcode Check System and Weight DetectionSystem.
VACUUM LOADINGBy means of a pump transfers the dyestufffrom the drums to the storage silos.
SUCTION LANCE Flexible pipe with a nozzle.
SUPERCOLOR STORAGEConsists of silos containing the dyestuff thatis managed by the machine control software.
RECIPECombination of dyestuff which must bedissolved together to obtain the requiredcolour.
BUCKETContainer into which dyestuff or a recipe isdispensed.
USER’S MANUAL
10 SUPERCOLOR
WEIGHING TROLLEY
Sliding structure equipped with a weighing andsuction system. It automatically searches forthe silos that contain the dyestuff to dispensefor each recipe then takes the bucket to theunloading area.
ASPIRATORFilter/suction unit which prevents dyestuffparticles to be released in the atmosphereduring dispensing or loading operations
LABELLER Prints the labels of the weighing cycle.
MANUAL LOADINGCONVEYOR
Conveyor on which to deposit the buckets touse for manual weighing and dissolvingoperations.
MANUAL UNLOADINGCONVEYOR
Conveyor from which the buckets used formanual weighing and dissolving operations arecollected.
LOADING/UNLOADINGCONVEYOR FOR STAINLESSSTEEL BUCKETS
Conveyor for stainless steel buckets thatoperates between the MSA and SUPERCOLOR.
MSAMechanical bucket handling device that movesthe buckets from the MGS to SUPERCOLOR.
MGSModular storage system for the stainless steelbuckets.
PNEUMATIC ACTUATORDevice that pneumatically produces longitudinalor rotating mechanical movements
PNEUMATIC ISLAND
Electric solenoid valves mounted on apneumatically powered base, control thepneumatic actuators, together these form thepneumatic island.
ELECTRIC SHOCK
Mild electric shock, brief exposure to current,causes slight injury characterized by pain andreddening of the skin, spray with cold waterand if necessary apply an ointment.Severe electric shock, passage of electriccurrent through the body which causes theinability of the injured person to detach fromthe current. Immediately disconnect the flow ofelectricity by acting on the main switch, if thisis not possible, the person must be detachedfrom the electricity by using a non-conductorsuch as wood or other isolating material. Theheat developed by prolonged exposure to suchelectrical discharges may cause severe burnswhich must be immediately treated.
IGNITION Combustion
USER’S MANUAL
11 SUPERCOLOR
PICTOGRAPHS USED IN THIS MANUAL HAVE THE FOLLOWING
MEANING:
Attention, observe at all costs, special instructions for safe and trouble-free operations.
Denotes a warning against possible explosion.
Denotes caution in using products or apparatus that may catch firecausing injury and property damage.
Danger, used when life or health of the operator are at risk when usingvoltage operated devices.
Caution in using machinery or part of it. Keep hands away from partswhich may cause crushing.
Keep clear of running conveyors or belts as they may entangle hands orloose clothing.
Danger of slipping.
Personal protective equipment: wear safety shoes.
Personal protective equipment: wear gloves.
Personal protective equipment: wear overalls.
Personal protective equipment: wear a mask to protect eyes andrespiratory tract.
USER’S MANUAL
12 SUPERCOLOR
CHARACTERISTICS
SUPERCOLOR III
USER’S MANUAL
13 SUPERCOLOR
Supercolor employment
Automatic weighing and dispensing plant for powder, granule or micro-pearldyestuffs.
Supercolor is the latest weighing system for powder products designed for highreliability in preparing and controlling the products to dispense for the recipes.The machine does not produce risk of explosion when operating, however theinstallation site must be hazard free and must not present risks of explosiveatmosphere according to the regulation 99/92/CE.The storage silos, made of treated and reinforced fibre glass (PRFV), withtransparent front and back panels are fully detachable and have a capacity of 150litres. Silo refilling is done by means of a vacuum pump then dispensed by ascrew/vibration dispensing device which guarantees excellent weighing accuracy.An efficient aspiration system connected to a filtering unit automatically starts whendispensing operations begin, this prevents powder dust particles to be dispersed inthe working environment. The electronic scale, is placed on the computer controlledweigh trolley equipped with an advanced hydraulic scale positioning system thatruns in parallel along the front of the machine, stopping automatically incorrespondence to the selected silo. Bucket movement is automatic duringdispensing operations. The plant is operated by a computer, interfaced to two PLC’sthat control mechanical movements. Original software Lawer Copyright is availablefor connections to external management systems. The Supercolor system can beconnected at any time to automatic Dissolving and Dispensing Systems and linkedto the Lawer Equipment Integrated Management System
ADDITIONAL PREVENTATIVE MEASURES
Installation site must be hazard free and must not present risks of explosiveatmosphere.(powders, gas or other dangerous materials)
Do not use products that may ignite due to friction or heat.Periodical checks are compulsory. Pay careful attention to monitor rotatingmechanical parts that may overheat due to excessive stress, thus causingdestruction or damage.
USER’S MANUAL
14 SUPERCOLOR
PRODUCT CHARACTERISTICS
Supercolor is designed to manage nearly all pigments and chemical productssuch as powders, crystals or micro-pearls that have a granulometry above 1µ. Tostore the products safely, refer to the technical data supplied with the product orcontact the producer for the necessary information.
The Supercolor’s dispensing system is not equipped with means for crushingproducts.
PERFORMANCE AND CHARACTERISTICS.
Action Values
Loading capacity 8÷12 Kg/min.
Maximum dispensing load 5 kg/min(specific weight 1 kg/dm³)
Approximate time for dispensing three colours(1 kg x colour).
3 min
Dispensing tolerance Min. threshold 0.01 g.Varies according to theproduct characteristics.
Maximum weigh trolley speed 70 mt/min
USER’S MANUAL
15 SUPERCOLOR
Configuration
MAIN FEATURES
MODULAR FRAME FOR SUPPORTING 10 SILOS OF 150 LITRES EACH: Frame length 1450 mm. Distance between silos 145 mm. (for correct scale positioning) Support frame, in iron and spray painted with an anti-acid varnish, which
spans tubular and iron He beams. AISI 304 cross beams for connecting and the supporting the silos beams
which are made by precision numeric controlled machines. Cable trough in AISI 304. N°2 head modules for each Supercolor with protective panels in AISI 304.
Compressed air drier (ZENDER mod. KM5): Capacity 5 Nmc/h Atmospheric dew point –40°C
ELTRON labeller: Adhesive labels 100x60 mm Automatic cutter
VARNISHED STEEL ELECTRICAL PANEL CABINET (800X500 H1900) WITH PLC
SILO 150 LITRES CAPACITY
Standard characteristics: Detachable container of 150 litres made of reinforced fibre glass (PFRV),
with front and back panels in transparent Plexiglas. Dimensions 680 x 2080 mm. Distance from the silo centre points 145 mm. N° 2 interchangeable high efficiency filtering cartridges, with automatic
cleaning system with dry air blowing system. Filtering unit in polyester impregnated in synthetic resins, filtering surface
1,2 sm, 95% Ashrae efficiency. Combined screw/vibration dispensing system which enables controlled and
accurate product dispensing, are a patented device Vibrados. Thediaphragm can be changed according to the type of product to dispense.
Inlet pressurised dry air inside the silos from 0,02 bar (one inlet for everymodule of 10 silos).
Lance in AISI 316 with flexible antistatic pipe, for silo loading. Product flowdevice (vibrator), which functions pneumatically, to help the flow ofdifficult products (equipped on 10% of the silos on the plant).
USER’S MANUAL
16 SUPERCOLOR
MANUAL LOADING CONVEYOR: Standard length 1585 mm. Accumulates max 4 buckets with a ø of max 250 mm. Structure in C channel iron in AISI 304. Bucket dragging chain. Bucket guide edges in AISI 304. Photocells for controlling bucket movements.
Manual unloading conveyor: Standard length 1585 mm. Accumulates max 4 buckets with a ø of max 250 mm. Structure in C channel iron in AISI 304. Bucket dragging chain.
WEIGH TROLLEY. Motorised translation trolley, with tubular inox frame in AISI 304. Aspirator vent for volatile dust reception during dispensing operations. Pneumatic group for screw control docking. Brushless KEB 04 motor, for dispensing screw control. Brushless KEB 14 motor, for weigh trolley translation; max translation
speed 70 m/min. Resolver for trolley positioning. Scale support platform with advanced hydraulic system for ground resting
and disengagement from the plant frame. Mettler Multirange scale model with a capacity of 32 Kg and a resolution of
0,01 gr, data interface RS232, with ID7 display. Paralleling device for bucket loading/unloading Compressed air control and adjustment for the Vibrados system. Pneumatic interface for compressed air distribution to the “vibrados”
system and to the vibrators (front/rear). Steel cabinet for the electrical panel varnished with anti-acid paint IP65
with PLC for controlling the weigh trolley (translation and dispensing).
USER’S MANUAL
17 SUPERCOLOR
LOADING TROLLEY: Manual sliding trolley, with AISI 304 frame and folding platform for
supporting the package. Multistage centrifugal aspirator for dye stuff aspiration: Prevalence up to 3000 mm/H²O, limited to 2500 mm/H2O Average capacity 165 m³/hour Limit valve for prevalence control. Safety filter Pneumatic centering of the silo to be loaded. Docking and dry air injection for cleaning the filter cartridges on the silos. Button panel for dye stuff control, with start/stop loading, start/stop pump
buttons and acoustic alarm
PROTECTIVE STRUCTURE: Structure in aluminium. Hardboard panels. Transparent Lexan panels. Safety micro switch on the access doors.
ASPIRATION SYSTEM CONSISTING OF: n° 1 centrifugal aspirator of 2,3 Kw, Prevalence 160daPa, capacity 3000
m³/h Corrugated pre-filter with large filtering surface, frame in chadless
cardboard, filtering partition in cotton and polyester, Filtration Class(EN779) G4, gravimetric efficiency 92% ASHRAE 5µ
High efficiency filter, with frame and separator in polypropylene, filterpartition in polypropylene, Filtration Class (EN779) F8, Efficiency 90-95%ASHRAE 1µ
N° 2 differential manometers to control the pre-filter and filter efficiency. N° 1 butterfly valves for reducing the flow during the various cycle
operations.
USER’S MANUAL
18 SUPERCOLOR
Hardware CharacteristicsPC Desk top1 HDD 3,2 GB or higher128 MB RamCPU PENTIUM 3 or higher1 FDD 3,5” 1,44 MB1 CD-ROM drive 48X EIDEIntegrated network card Ethernet 10/100Colour monitor 15”KeyboardConnection interface with the main electrical panel.
OPTIONAL ACCESSORIES
Vibrator for difficult products (equipped on 10% of the silos on the plant);pneumatic functioning, can be installed in the appropriate seats either on the frontor the rear of the silos.
ELECTRICAL POWER
ELECTRICITY
400 Volt; three-phaseFrequency: 50 HzTotal power installed: 10 KW230 Volt50 Hz300 Watt from UPS (for 20 minutes)
COMPRESSED AIR
Line DN15 min. connected to the regulation/dryer group supplied by Lawer.Pressure feeder: 6÷8 barConsumption 250 NL/min (Normal litres per minute).
LAN:
Recommended the use of FTP category 5 cable
AMBIENT CHARACTERISTICS
Minimum temperature : 5°C.Maximum temperature : 40°C.Minimum humidity : not importantMaximum humidity :60% a 25°C.
USER’S MANUAL
19 SUPERCOLOR
Emissions from the machinePROTECTION AGAINST POSSIBLE DUST EMISSION.
In correspondence to the weighing point there is a suction inlet through which dustis aspired when weighing.The containers are part of the aspiration device, therefore only use containerssupplied with the plant.
The machine is installed inside a protective housing in order to avoid dispersingdust in the environment. The housing is equipped with an ante- room for changinginto the appropriate PPE before starting loading and maintenance operations, andan aspiration device for cleaning shoe soles.
With the aid of the aspirator, the internal atmosphere is kept in constant slightdepression.
The aspiration unit is designed to maintain the right depression inside the structureeven if the doors are left open. The aspirator will slow down should it detect anygaps in the structure caused by mounting defects that will allow air to get through.
ACCESS TO THE BOX
The box is equipped with two access doors and two openings (pneumaticallyactuated) for inserting empty containers and the removal of containers withdispensed product.
A deviation composed of three butterfly valves aremounted on the aspiration inlet, operated by pneumaticactuators, which deviate or reduce aspiration flowduring the various working cycles of the plant (see pag.20 and following)).
Fig. 1
USER’S MANUAL
20 SUPERCOLOR
MAINTAINING DEPRESSION INSIDE THE HOUSING.
ASPIRATION IN NORMAL USE CONDITIONS, WITH ACCESS DOORS CLOSED AND POSSIBILITY TO
INSERT EMPTY CONTAINERS AND WITHDRAWAL OF THE DISPENSED ONES.The aspiration unit allows to maintain, in correspondence to the containerinserting\withdrawal opening, an deal air flow inside the housing, including localaspiration in the weighing area avoiding emission of polluting particles into theambient atmosphere. In this case a butterfly valve will reduce the capacity ofaspirated air in order to limit turbulence that may disturb the weighing device.
ASPIRATION WHEN BOTH ACCESS DOORS ARE OPEN WHEN LOADING PRODUCTS AND/OR WHEN
CONTROLLING THE PLANT, WITH WORKERS INSIDE THE HOUSING. The reducer valvecompletely opens the aspiration inlet to obtain the maximum aspiration groupcapacity, even with three access doors open, (doors and manual bucketwithdrawal), the air entrance speed into the housing is ideal for avoidingemission of polluting particles into the ambient atmosphere.
The position of the reducer and deviation valves, in the various working phases, areillustrated from Fig. 2 to Fig. 23 .
Fig. 2
USER’S MANUAL
21 SUPERCOLOR
Fig. 3
Fig. 4
USER’S MANUAL
22 SUPERCOLOR
Fig. 5
Fig. 6
USER’S MANUAL
23 SUPERCOLOR
Fig. 7
Fig. 8
USER’S MANUAL
24 SUPERCOLOR
Fig. 9
Fig. 10
USER’S MANUAL
25 SUPERCOLOR
Fig. 11
Fig. 12
USER’S MANUAL
26 SUPERCOLOR
Fig. 13
Fig. 14
USER’S MANUAL
27 SUPERCOLOR
Fig. 15
Fig. 16
USER’S MANUAL
28 SUPERCOLOR
Fig. 17
Fig. 18
USER’S MANUAL
29 SUPERCOLOR
Fig. 19
Fig. 20
USER’S MANUAL
30 SUPERCOLOR
Fig. 21
Fig. 22
USER’S MANUAL
31 SUPERCOLOR
Fig. 23
USER’S MANUAL
32 SUPERCOLOR
USING THE APERTURES.
NORMAL FUNCTIONING
During normal functioning it is necessary to keep the access doors always closed.
PRODUCT LOADING
The operator enters the loading area through thechamber where the personal protective equipment mustbe worn. Opening the internal access door automaticallystarts the aspiration unit. One or more infrared sensorsdetects the presence of the operators in the housing andkeeps the aspiration on until they exit the housing. Theaspiration stops after thirty seconds.
Operators must clean the soles of their shoes in thechanging chamber by using the clearing device. (seepicture).
Fig. 24
THE PRODUCTS MUST NOT BE LOADED WHILE THE MACHINE IS DISPENSING.
TREATING ASPIRATED AIR
ASPIRATED AIR MUST BE CONDUCTED OUT OF THE LOCATION WHERE THE PLANT IS INSTALLED,KEEPING IN MIND THE CHARACTERISTICS OF THE POLLUTANTS PRESENT AND EVENTUAL TREATMENT
TO WHICH THE AIR CAN BE SUBJECTED TO.
AIR CONDITIONING INSIDE THE HOUSING
Because of their physical chemical characteristics some powder products may alterand have a clotting disposition if subjected to sudden rise\fall of the temperature orif the relative humidity rate is too high. These alterations may determine inaccuracyin the weighing phase.To improve weighing accuracy according to the characteristics of the products usedin the weighing system, it may be necessary to install an air conditioning groupinside the housing.
CHARACTERISTICS OF THE FILTER CARTRIDGES
The cartridges are made with filtering material COL 270B, in unwoven polyestermade through the spun-bonded procedure. This process method avoids airpermeability variations therefore improving filtration efficiency and stability. TheBIA certification of the filtering material COL 270B applies to the regulationZH1/487, which demands an inferior release of 0,5% for granulometric powdersbetween 0,2 and 2 micron, with transit rate of 0,056 m/s which corresponds tothe category USG classification. The material COL 270B has a high mechanicalresistance (transversal traction lengthening 40%), and has an excellent resistanceto a variety of chemical products. The smooth surface ensures that the dust iseasily detached. The maximum temperature when functioning continuously is 130°C.
USER’S MANUAL
33 SUPERCOLOR
Transport and Installation
MACHINE HANDLING AND MOVING CONDITIONS
When delivered the machine is dismantled and packed on pallets; move with forklift or crane. Consult the packing list for information regarding the number ofpackages, contents and weight of each, and read the indications displayed on thesingle packages. If necessary, detailed movement instructions are also displayed.
Average component weight:Silos: joint weight 21 kg.Aspirator/filter: gross weight 120 kg.Electrical panel: weight 200 kg.Bucket loading system: 110 kg.Bucket unloading system: 110 kg.
STORAGE CONDITIONS
The storage location must situated inside a building in a dry atmosphere so as toavoid temperature changes, corrosive atmosphere, excessive humidity, water orrain :Minimum temperature: 5°C.Maximum temperature: 40°C.Maximum humidity: 70% a 25°C.
TRANSPORT AND HANDLING INFORMATION.
Lifting and transporting must be done with the appropriate equipment according tothe size and weight of the parts to move.Lifting and moving equipment, such as cranes and fork-lifts, must be regularlyserviced in order to avoid accidents.When lifting and moving parts make sure there is enough room for manoeuvres.Transport and lifting equipment must be entrusted to authorized personnel.When lifting and transporting parts use the necessary precautions in order to avoidparts falling or overturning of the equipment
ASSEMBLY
Transport and assembly of the machine must be done by the Constructor with thehelp of personnel provided by the customer.
During machine assembly, apply all safety measures and instructions fortransporting and moving the parts as described above.
USER’S MANUAL
34 SUPERCOLOR
FLOOR CAPACITY
Required floor capacity, more than 2000 kg/m2.
CONNECTIONS AND ELECTRICAL WIRING
To complete machine installation; connect the pneumatic, network and powersources, as described on page 19.
CONTROL OPERATIONS BEFORE START-UP
Before machine start-up check the following: machine parts have been correctly and safely assembled. electrical wiring and connections are safe before applying power. external power source connection. air discharge system from the aspirator has been correctly connected. electrical grounding.
Before start-up make sure that no object obstructs the running of themachine, and that personnel is at a safe distance.
CHECK GUARDS AND SAFETY DEVICES.
At start-up the following devices must function correctly:Main switchEmergency stop devicesAll command buttonsInterlock devicesPhotoelectric barriersAll safety devices applied to the machine.
Do not attempt to start the machine if the safety devices do not function orare faulty, contact the Constructor.
USER’S MANUAL
35 SUPERCOLOR
Instructions for the operator
GUIDELINES TO SAFE MACHINE USAGE
INFORMATION AND TRAINING
Operators must be supplied with the necessary information and training beforeworking with the machine, as stated by the current legislation, and thereforemust have a good knowledge of the machine and how it functions.Safety measures and machine handling precautions must be followed as describedin this manual. This also includes storage, assembly, installation and transport andmaintenance instructions.Operators must adopt correct safety behaviours in order to prevent occupationalaccidents by respecting the safety and work hygiene regulations in force in thecountry where the machine is installed.
QUALIFIED PERSONNEL
Instruction and maintenance work that require special technical knowledge, mustbe performed by specialized personnel. The customer must declare responsibility,competence and control of the personnel. If the workers do not have sufficientknowledge for operating the machine, the necessary measures must be taken toprovide training. Training can be provided by the Constructor at customer’srequest. It is the customer’s responsibility to convey to machine workers all usageand instruction manuals obtained by the Constructor and to ensure that workersfully understand the instructions.
PPE (PERSONAL PROTECTIVE EQUIPMENT)
When indicated, use the appropriate personal protective equipment.
Use of PPE is determined by the type of product used, the worker must adopt thecorrect PPE according to the indications recommended by the safety or warningsigns and also follow the instructions given by the Competent Medical Officer basedon the results of atmospheric testing done in the working area.
Personal Protective Equipment must be looked after and substituted whendamaged.
GUARDS AND SAFETY DEVICES
Rotating parts that may be dangerous for personal safety are protected by guardsor other protective devices. Do not remove or tamper with these protection devices.For functional reasons, the chains used for the bucket moving system cannot becovered; to reduce possible risks, the chains run on a U profile form which preventsaccess to the inferior section. The conveyor chains must be at a complete stopbefore removing the buckets
USER’S MANUAL
36 SUPERCOLOR
Safety and health labelsObserve all indications provided by the warning/safety signs displayed on themachinery
WARNING SIGNS
Pictograph Location
On the housing entrance door.
On the head of the tunnel for bucketloading/unloading
MANDATORY SIGNS
Pictograph Location
Placed on the outside of the housing access door whichmust be locked at all times by the plant supervisorwho will give the key to the workers who areauthorized to operate inside the machine box
Placed inside the box, must be visible to the workerswho access the box.For the use of PPE refer to pag.12
USER’S MANUAL
37 SUPERCOLOR
STOP SIGNS
Pictograph Location
Placed on the access door. Opening the door causesthe machine to stop temporarily. Access must only beallowed to authorized workers.
Placed inside the housing. Do not start maintenanceoperations without securing the machine as explainedon pag.142. It is forbidden to remove any safetydevices or guards when the machine is electricallypowered.
Placed inside the housing; in this area it is strictlyforbidden to smoke and to consume food and /orbeverages
Placed on the power and command panels. Electricalcabinets or panels must always be locked. The key isto be kept by the plant maintenance personnel. Donot use the panels or cabinets as storage spaces.
USER’S MANUAL
38 SUPERCOLOR
Residual and Behavioural regulationsWhen using machinery, it is necessary to provide the correct informationconcerning the risks and how to avoid them.
RISK OF SLIPPING AND FALLING
On the floor by the machine, it is possible that the process of loading orunloading products, or lubricating oils that have been used for maintenancereasons, may spill on the floor therefore causing a serious risk of slipping. It isnecessary to keep the floor around the working area clean of any oil stains byusing the appropriate absorbing materials. Protective footwear with rubbersoles must always been worn in and around the working area.
RISK OF CUTTING
When manually moving he containers, care must be taken to wear protectivegloves to avoid being cut by any sharp edges that may be present.
RISK OF DUST INHALATION
For all working operations inside the housing and in particular loading andcleaning operations, it is necessary to give the workers information regardingthe product they are working with so that the proper precautions can beadopted. Provide the company doctor with an accurate report stating thetypes of products used so that a pollution survey can be made. Wearprotective clothing and respiratory mask. To remove dust use aspirationmethods only, do not blow the dust. For this purpose a cleaning station isavailable equipped with an aspirator, see description on pag.
RISK OF ELECTRIC SHOCK
The machine is powered by two different voltage phases, 380 Volt three-phase and 220 Volt single-phase, which is in compliance with the Electricalpower regulation standards. Before powering, check the integrity of theelectrical panel or cabinet, including the power cables and doors. If any ofthe above listed elements should present signs of damage call the companymaintenance staff.
USER’S MANUAL
39 SUPERCOLOR
RISK OF CRUSHING
Buckets in movement on the conveyor may injure fingers or hands. Keephands away from the conveyor when in movement.
Buckets that are accidentally dropped when handling, may cause feet injury,use protective footwear with reinforced lining.
USER’S MANUAL
40 SUPERCOLOR
Operator working areas
There are two working areas provided for the operators to ensure the correct use ofthe Supercolor machine.WORKING AREA: in the front of the machine, where the control panels, loadingconveyor and bucket removal station is situated.LOADING AREA: at the back of the machine where the loading trolley is situated.
NOISE
Positions Leq in dB (A)
P1 (position of the operator during dyestuff weighing operations) 75.5
P2 (position of the operator during dyestuff loading operations) 82.5
A Loading area 81.5
B Aspirator area 74.0
USER’S MANUAL
41 SUPERCOLOR
USER’S MANUAL
42 SUPERCOLOR
Knowing the machine
COMMAND AND CONTROL PANEL
Pos. Descrizione
1 Main switch; powers the plant
2Green led on; indicates that the plant is electrically connected to avoltage source. Control panel is energized
3 Key selector; use to RESET the plant
4 PC power selector; powers the PC
5PC midi tower, RAM 256 Mb, Hard disk 80 Gb, Drive CD, 6+2 portsUSB, lodged at the back of the command station .
6 Monitor TFT 15”
7 Keyboard :102 keys
8 Mouse :three button with scroller
9 Scanner barcode (optional)
USER’S MANUAL
43 SUPERCOLOR
Pos. Descrizione
10 Visual/acoustic alarm
11 STOP ALARM; stops the acoustic/visual alarm triggered by a fault.
12
STOP; STOP BUTTON. Stops all machine movements, only the diagnosticfunctions of the plant remain active.
1st STOP BUTTON; stops DBS-DTS dissolving system.
2nd STOP BUTTON; Stops MSA-MGS-LGS handling and storagesystem.
3rd STOP BUTTON; stops SUPERCOLOR dyestuff dispensing system.
13EMERGENCY BUTTON; emergency stop, cuts power to the command circuit.Use only in emergency situations; for normal plant stop use the STOPbutton.
14 BUCKET UNLOADING; to unload buckets from manual discharge conveyor.
15 START BUTTON; STARTS THE PC.
16 CD DRIVE
17 USB PORTS
The control panel has two separate power sources: turning off the mainswitch (1) leaves the computer under power. To turn off the PC it isnecessary to switch off the circuit breaker (4).
USER’S MANUAL
44 SUPERCOLOR
The electrical panel is powered by two separate currentphases: when cutting off current using the main switch thecomputer is still powered. To cut off power to the PC use theswitch .
LOADING PANEL
Item Description Color
1
<Stop> button: stops the loading pump. Use fortemporary stops during color loading operations (forexample when an empty color pack must besubstituted).
Red
2 <Emergency> button: stops the plant. Red/Yellow
3 Acoustic alarm.
4Barcode reader: checks that the loading trolley is inthe correct position and enables connection to thesilo. (optional)
5<Start Load>: mechanically connects the loadingtrolley to the silo
Green
6Load consent led: illuminates when the loading trolleyis correctly positioned to the silo.
Green
7 <Start pump> button: starts the suction pump . Green
8 <Load end> button. Blue
9<Stop Alarm> button: stops the acoustic alarmtriggered by a fault.
Yellow
4 1
7
2
6
3
9
8
5
USER’S MANUAL
45 SUPERCOLOR
BAG SEALING POSITION
Fig. 25
POS. DESCRIPTION
1 Parking conveyor for buckets waiting for the product to be dispensed.
2 Guillotine panel for bucket insertion.
3 Bucket with water-soluble bag for recipe dispensing.
Tab. 1
USER’S MANUAL
46 SUPERCOLOR
Fig. 26
POS. DESCRIPTION
4 Unloading conveyor for buckets that contain dispensed product.
5 Bucket with dispensed recipe bag.
6 Elevator that lifts the bucket to the sealing position, if present.
7 Clip container for bag sealing.
8 Clip hopper.
9 Latex gloves for bag and clip handling.
Tab. 2
USER’S MANUAL
47 SUPERCOLOR
Fig. 27
Pos. Description
10 Re-usable bag clips.
11 Sealed water-soluble bag.
12 Label that indicates the recipe characteristics.
Tab. 3
USER’S MANUAL
48 SUPERCOLOR
Fig. 28
Pos. Description
13 Bucket identification device (TAG).
Tab. 5
USER’S MANUAL
49 SUPERCOLOR
LOADING PANEL
Fig. 29
POS. DESCRIPTION
1BARCODE READER FOR CONTROLLING THAT THE CORRECT SILO TO LOAD HAS
BEEN INDIVIDUATED.2 OPTIONAL BARCODE READER, FOR COMMERCIAL PACKAGE CONTROL.
3PLANT EMERGENCY STOP BUTTON, SEE Errore. L'origine riferimento non èstata trovata., PAG. ERRORE. IL SEGNALIBRO NON È DEFINITO., REFERENCE 2.
4 LOADING PUMP STOP BUTTON.
5 LUMINOUS LED FOR STARTING THE PRODUCT LOADING PUMP.
6 TOUCH SCREEN PANEL, FOR PLANT MANAGEMENT AND DATA VIEWING.Tab. 6
USER’S MANUAL
50 SUPERCOLOR
LOADING PUMP
Fig. 30
USER’S MANUAL
51 SUPERCOLOR
Start-up procedure
Power the PC by moving the blackswitch to the <ON> position.
On the power panel move the mainswitch from the <OFF> position to<ON> as indicated aside.
This generates an acoustic soundthat can be silenced by pressing theyellow <Stop Alarm> button.
Run the Supercolor program fromthe <Start > menu.
USER’S MANUAL
52 SUPERCOLOR
The initial window of the program<Supercolor.exe> appears.
The software starts with the defaultfunction <Local> activated; pressthe <F12> key to change to<Auto>. The software is ready toreceive data from an externalmanagement system.
TEMPORARY STOP
To stop the machine temporarily use the <Stop> button,this stops machine movement maintaining only thediagnostic functions active.
EMERGENCY STOP
To stop the machine immediately in case of danger, use the<Emergency> button. There are two emergency buttons onthe machine, one on the control panel and another on theloading trolley which is situated inside the Supercolorhousing. To restart the machine, rotate the button in ananticlockwise direction.
For security reasons it is recommended to acquire full familiarity with the positionof these emergency buttons in order to act immediately in case of necessity.
Before starting the machine after an emergency stop, be sure to have resolvedwhatever problem triggered the fault and check that no foreign matter orperson is present in or around potentially dangerous areas.
USER’S MANUAL
53 SUPERCOLOR
SHUTDOWN PROCEDURE
Before you begin the shutdownprocedure, check that no dispensingoperations are running. If theprogram <Supercolor.exe> isfunctioning in <Auto>, it must bechanged to <Local> by pressing the<F12> key (A); then press <Esc>(B) and confirm with <OK> on thedialog window that appears whenpressing the <Enter> key.
Power down the PC by moving theswitch (indicated by the arrow) tothe <OFF> position.
On the power panel rotate the mainswitch from the <ON> position to<OFF> as indicated aside.
USER’S MANUAL
54 SUPERCOLOR
Software
OPERATING SYSTEM
Supercolor uses WINDOWS operating system for the management of thecontrol software. The operating system is installed by our technicians incharge of the plant start-up.
GENERAL PARAMETER DEFINITIONS
After the program has been installed, the Lawer technician will configure themachine using the setup program from which it is possible to:
Select the language. Define users that are authorized to modify the setup parameters and
related passwords Choose the Btrieve filepaths. Set the communication parameters between the various peripherals. Configure silos and conveyor belt settings. Decide if Supercolor is network or locally operated. Regulate timing and delays of the machine photocells. Consider dispensing volumes.
USER’S MANUAL
55 SUPERCOLOR
Setup program
The general machine settings must be configured by running <SSetup.exe>. Thesesettings are configured by our technician at start-up; contact our SUPPORT OFFICEbefore modifying any settings. Consult the last page of this manual for the contactoptions.
Access to the various program sections are protected by three differentpasswords:
USER PASSWORD: allows access with the lowest privilege level forchanging program settings. This password is set by the program as<lawer> and can be modified as described later on .
Default password = lawer
MAINTENANCE PASSWORD: allows access with a medium privilege levelfor changing program settings. This password is set by the program as<lawtec> and can be modified as described later on. Some critical settingsmay not be modified with this password ; contact our Support Service if it isnecessary to modify these settings.
Default password = lawtec
LAWER TECHNICIAN PASSWORD: allows full control of the program;normally this password is used by the constructors technicians and is notrevealed to the end user .
USER’S MANUAL
56 SUPERCOLOR
Run the setup program as shown below
Enter the appropriate password (User or Maintenance).The setup program thatappears is divided in nine different folders:
1 Language. 2 Security. 3 File paths. 4 Peripherals. 5 General. 6 System. 7 Silos. 8 Dispense. 9 Sensors.
To select the different folders press the <F2> button, or use the keyboard shortcutby pressing <Alt>+<underlined letter> .
USER’S MANUAL
57 SUPERCOLOR
1-LANGUAGE
Use the arrows < to select the language. Press Enter to confirm changes.
If the text files are not available, error messages will appear as shown below.Please contact the Lawer Support Office for the correct text files, if available.
USER’S MANUAL
58 SUPERCOLOR
2-SECURITY
Use this folder to set or modify the passwords; each password has a differentsecurity level (logon with the user password will not permit the user to modify thetechnician password).To modify the password move from one field to another by
pressing <Tab> or <> , modify the password then press Enter.
USER’S MANUAL
59 SUPERCOLOR
3-FILEPATHS
ATTENTION: maximum attention must be used when changing thedatabase filepath, incorrect filepaths will generate errors as the program willnot find the necessary information to function properly.
Use this folder to set the program filepaths : Btrieve files, Access archives, Textfiles. To change filepaths, select the file and use one of the following keys <Tab> o
<> until the focus is on the Change button.
USER’S MANUAL
60 SUPERCOLOR
4-PERIPHERALS
Use this folder to set the communication parameters of the peripheral devicespresent:
Inverter dispensing trolley. Inverter loading trolley. PLC conveyor. PLC loading. PLC dispensing. Barcode loading. Scale loading. Label printer.
USER’S MANUAL
61 SUPERCOLOR
5-GENERAL
Use this folder to configure the following functions:
LeimS CONNECTION: determines if the Supercolor is a stand-alone (operatesindependently) or if the batches are transferred by an external automaticsystem (Leims) that manages the various working phases of the colorkitchen.
BATCH RECEPTION BY Lawer interface: determines if the Supercolor receivesthe batches from an external system, which is normally the customersmanagement system. This option cannot be enabled from the “LeimsConnection”.
RECIPE EDITOR: enables or disables the Recipe Editor (program used forsetting the basic recipes that are used for the composition of the individualbatches).
EXECUTED DISPENSING TRANSMISSION: enables writing on an ASCII (doseff.txt)network file on which dispensing data is stored concerning all the Lawersystems of the color kitchen. The information on this file must be read bythe program <Report.exe>, that is on the Leims PC, but is not included inthe plant configuration, or can be read by a program developed on thesystem by the Customers management system.
Visualize ACTX controls: visualizes the control status that manages thecommunication between the PLC and the scales.
diagnostic WRITING: if enabled, saves in a database the errors that mayoccur during the dispensing or working phase. A special functiondisplays a list of dispensing errors.
PLANT CODE: identification code of the weighing plant with two or moreplants. The code is used by LEIMS. With only one plant, enter the code<ROT>.
INCREASE WEIGHING: if selected, Supercolor will weigh the batches startingwith those with the lowest order number.
SEQUENTIAL WEIGHING: Supercolor will weigh the batches with the oldesttransfer date.
USER’S MANUAL
62 SUPERCOLOR
PACKAGE MANAGMENT: enable only if Leims is not present; if enabled, and thequantity to weigh is more or equal to the weight of the pack, the full packsto be used will be indicated, Supercolor will only weigh the excess product.For example: quantity of color to be used for the recipe 38 kg. quantity of the pack 35 kg. packs to be used n°1 quantity dispensed by Supercolor 3 kg.
PACKAGE WARNING: (can be used only if <Pack Management> is selected) ifset to zero, the message that requests the preparation of the packsremains selected until the operator intervenes, and the automaticweighing cycle does not proceed. If a value is set, the request messageremains displayed for the pre-set time, and the cycle automaticallyrestarts when this time expires. If the operator intervenes before the timeexpires, the cycle will restart from the moment of intervention.
LOAD CONTROL SYSTEM: if enabled, it requests the barcode reading of theproduct during the loading phase.
LOADING SCALE: enable this function if a dyestuff loading scale is provided. MOTOR OPERATED LOADING: enable this function if the product loading trolley
is supplied with a function that enables it to automatically search for thesilo to reload.
INCOMPLETE BATCH WARNING: during the preliminary control before executinga batch, the operator is warned if the same batch is detected on a manualloading terminal. The warning informs the operator that a batch must beweighed on that terminal.
WEIGHING PRIORITY CA: assigns the execution priority of the batches fromLEIMS (automatic). Locally prepared batches will be queued to the Leimsbatches.
Griphon Barcode READER: enables the wireless barcode reader, modelGriphon.
PRINT TO Zebra: sends data to be printed to the Zebra printer. Do not usethis option unless the network printer is not working ; the paper formatwill make it difficult to read data.
USER’S MANUAL
63 SUPERCOLOR
6-SYSTEM
The functions available on this folder can only be accessed with the < LawerTechnician> password
total Silos: total number of silos configured on the Supercolor. DISTANCE BETWEEN THE SILOS: distance between the centre of the silos (in
mm). TOTAL LENGTH: total length of the Supercolor silos (in mm). LEFT Supercolor, RIGHT Supercolor: indicates the position of the machine
zero point. DISTANCE BETWEEN ZERO POINT AND FIRST silo: (dispensing side) quota in mm. DISTANCE BETWEEN ZERO POINT AND FIRST silo : (loading side) quota in mm.
The following parameters indicate the position quotas, with reference to the zeropoint on the dispensing side (all quotas are expressed in mm).
Manual dispensing position.. Bucket cleaning position. MSA conveyor position. Manual loading conveyor position. Manual unloading conveyor position. Bucket capacity: parameter for setting the maximum quantity of product
for the bucket (in litres). Is used only without Leims, from the batcheditor, to distribute the batch to various buckets.This applies to the version without MSA and with commercial buckets.
Default minimum dispensing quantity: minimum dispensing quantity thatcan be set (separately for each product) by the loading program. Thisvalue appears as default when a new product is entered.
Default maximum dispensing quantity: maximum dispensing quantity thatcan be set (separately for each product) by the loading program. Thisvalue appears as default when a new product is entered.
Number of additional buckets: (with Leims) used to set the number ofbuckets for supplement dyestuff. If the number of empty buckets on MSAdrops to this value, Supercolor will not dispense the batches but only thesupplements.
USER’S MANUAL
64 SUPERCOLOR
7-SILOS
This folder makes it possible to change the position of the silos; this function canonly be accessed with the < Lawer Technician> password.Silos: select the required silo.
PosiTION: indicates the position, in mm, between the zero position and theselected silo. It is automatically calculated by the program according to thedistance between the silo set on the previous folder ;this is useful in casethe silos do not have the same centre distances .
LOADING POSITION: as above, but the quotas refer to the zero from theloading side.
Volume: dimension of the silo expressed in litres. REFERENCE VOLUME FOR WITHDRAWAL AVAILABILITY: quantity below which
dispensing is not possible; below this value the product is catalogued asinsufficient and is printed as an insufficient product.
MINIMUM REMAINING VOLUME: minimum volume in the silo; if more than onesilo contains the same product which is below this minimum value, theproduct will be withdrawn from the next silo.
REQUIRED VOLUME FOR WITHDRAWAL: required volume in the silo in order tostart withdrawing.
Functions that are accessible with the <Maintenance> password.
COPY DISPENSING QUOTAS TO LOADING: copies and assigns to the loadingpositions the same quotas of the dispensing front.
MODIFY SILO QUOTAS: modifies the silo quotas of both fronts (dispensing andloading). It is necessary to select the first silo and the last one, and givethe Offset field a positive or negative value; when <Run> is pressed theprogram will ask on which front to modify the quotas.
USER’S MANUAL
65 SUPERCOLOR
8-DISPENSING
This folder makes it possible to set the parameters for each silo to ensure that thedispensing unit operates correctly.
Silos: selects the silo. OPTIMIZE DISPENSING FOR PRECISION OR FOR SPEED: precision dispensing will
dispense the product until the required weight is reached, however, thisprocedure is very slow. Speed dispensing ensures that the systemcompletes the dispensing cycle when the weight reached is in the pre-setprecision range.
F6=ENABLE VIBRATOR, ACTIVATION THRESHOLD: this option enables the use of thevibrator (if present) to shift the dyestuff in the silo while dispensing. Thevibrator will stop when the threshold value is reached so as to avoid out oftolerance dispensing.
T.ON/OFF VIBRATOR: is used to set the on/off time of the vibrator solenoidvalve (if present) during the operating cycle. Values must be 1/100 of asecond.
f7=front. vibrajet, f8=rear vibrajet, activation threshold: selecting thisoption enables the use of the front or rear vibrajets or both. Thepneumatic vibrajet shifts the dyestuff in the silo while dispensing. Thevibrator will stop when the threshold value is reached so as to avoid out oftolerance dispensing.
T.ON/OFF FRONT VIBRAJET: sets the on/off time of the vibrajet solenoid valvesduring the dispensing cycle. Values must be 1/100 of a second.
T.ON/OFF REAR VIBRAJET sets the on/off time of the vibrajet solenoid valvesduring the dispensing cycle. Values must be 1/100 of a second.
DISPENSING SPEED: increases or decreases dispensing speed of the selectedsilos (this changes the dispensing curve)
SPEED REDUCTION: at the lowest speed level communicates to the PLC toapply percentage speed reduction, the maximum value must be 1%.
F9=VIBRATION WHILE DISPENSING: if enabled, a grid on the delivery outlet willvibrate, this avoids dyestuff clinging to the surfaces therefore ensuringbetter dispensing conditions.
F11=HIGH PRESSURE: enables a more powerful vibration. MAXIMUM SPEED: sets the maximum rotation speed for the selected silo. The
maximum speed must be adapted according to the diaphragm used.
USER’S MANUAL
66 SUPERCOLOR
WEIGHT THRESHOLD: (if set) this value is expressed in grams and indicatesthat normal dispense speed must not be reduced, speed reduction willstart when the pre-set value is reached.
F5=GRAPH: displays the dispensing graph according to the parameters set. Press <Enter > to save the values of the silo.
USER’S MANUAL
67 SUPERCOLOR
9-SENSORS
Use this folder to set photocell times, changes and settings can only be done withthe < Lawer Technician> password.
Scale photocell delay from MSA (SQ202 1/100). Unloading on MSA photocell delay (SQ203 1/100). Scale photocell delay for manual buckets (SQ202 1/100). Photocell delay for manual bucket unloading(SQ209 1/100 sec.). Photocell delay for scale labeller (SQ208 1/100). Max.time for new bucket loading (1/10) Max.time for manual bucket unloading from scale to the start unloading
photocell (1/10). Max.time load/unload for MSA tanks from MSA photocell to scale photocell
(1/10). Max.time conveyor P/P load (bucket from SQ204 to SQ205 1/10). Max.time bucket loading from P/P load to end conveyor photocell (1/10). Max.time bucket loading from end of loading conveyor to scale (1/10). Max.unloading conveyor time from conveyor start to scale (bucket from
SQ207 to SQ208 1/10). Max. open/close time for scale door (SQ9 SQ10 1/10).
Using the <Tab> or <> keys, select the option from the photocell list, this is
displayed with its Data memory (DM) with the delay or control time.
Use the <Tab> or <> keys to move to the time input box (delay), change the
value (the size order is to the right of the box) press enter to save. The new valuewill be transmitted to the PLC when the Supercolor program is next started upagain.
USER’S MANUAL
68 SUPERCOLOR
LOADING PROGRAM
Il programma di carico imposta i prodotti presenti sull’impianto. Permette inoltre dicambiarne il tipo o di caricare e scaricare quantità di prodotto dai sili.
If the touch screen terminal is enabled (see pag. 68), some of the functions in thiswindow are disabled and must be executed by the control panel.(Fig. 29, pag. 49, rif. 6)
Fig. 31The silos configured on the plant appear in the upper section of the window. The lowersection indicates the parameters of the selected silo and further down the buttons to pressfor accessing the various functions. For example, on the above example 20 silos are listed (9 of which can be seen). The bigger fields in the lower section of the window indicate theTotal capacity, Stock quantity and Loadable quantity. The silo (002) has a total capacity 47,5kg, contains 21,1 kg of product and can contain 26,4 kg more.The first time the program is started the products have not yet been associated to the silo asshown in Fig. 32:
Fig. 32The silos configured on the plant are indicated in the first column on the left-handside of the example, followed by [Code] and [Description]. The [Quantity] columnindicates the quantity of products present in the various silos (at the moment 0.0).
USER’S MANUAL
69 SUPERCOLOR
Fig. 33Use the cursor as indicated in Fig. 33, to view the list of virtual silos (see theGlossary on pag. Errore. Il segnalibro non è definito.) . These allow batches tobe made even with products not physically present in the Supercolor, and must bemanually dispensed by the operator when the container reaches the dispensingposition.From [Silos loading] the following operations are possible:
Fig. 34
Modify a product
Select a product from the top section of the window Fig. 35.
Fig. 35
The button [F6=MODIFY] is enabled.
Press keyboard [F6] or press [F6=MODIFIY].
Enter the password and the [Modifiy Silo] window appears (Fig. 33).]
Fig. 36
Select a value enter the password and press [OK].
By clicking the [Limits] button the [Dispensing limits] window appears (Fig. 37).
USER’S MANUAL
70 SUPERCOLOR
Fig. 37
Load a new productSelect an empty silo as in Fig. 38.The [Load] button is enabledPress [Alt+C] on the keyboard or clock [LOAD].
Fig. 38Enter the password to access the [Products list] window.
(Fig. 39).
Fig. 39Use the cursor as shown in Fig. 39 to search and select the product you want toassign to the selected silo.Confirm with [OK] to complete the silo\product pairing.
USER’S MANUAL
71 SUPERCOLOR
To change silo/product pairing
Fig. 40To change an existing silo/product pairing, the silo must be completely empty. Ifnecessary the silo must be thoroughly cleaned before introducing new product.Select the silo you want to change (Fig. 40).The [F5=Change] button is enabled.Press keyboard [F5] or click [F5=Change].Enter the requested password to access the [Product list] window.Follow the instructions as for Fig. 39, on pag. 70 to match a new product.
Fig. 41If the silo is paired to other silos, the above message will appear Fig. 41.
USER’S MANUAL
72 SUPERCOLOR
Setting dispensing parameters
When the product has been loaded, configure the minimum and maximumdispensing parameters (applies to both versions with or without Leims): Select aproduct from the list, press F6 = Modify enter the user password.
The first field contains the product description. In the second field enter the specificweight calculated for half a litre (0,5 dm³) of dyestuff.This parameter is used to determine the volume that the product will occupy, andtherefore to calculate the maximum loadable quantity of the selected silo.Enter the minimum and maximum dispensing values.All these parameters can be changed by the Supercolor program (Product editor)function if Supercolor is working in local mode, or through the Leims product editorof the program version that works in remote.To avoid having to enter the minimum and maximum dispensing parameters everytime, press [Limits]. It is also possible to enter
USER’S MANUAL
73 SUPERCOLOR
The product lot description; select package management and set the weight.(Quantity kg). Package management is only possible if Supercolor is not connectedto Leims. This window appears when pressing <Limits>:
After the product has been inserted and parameters configured, the dyestuff mustbe loaded into the silo. More than one procedure can be followed: Standard loading management, the operator must only read the silo barcode. “Load control system” , the operator must read both the silo and product
barcode. “Loading scale”, barcode reading depends on the settings of the “load control
system”, if barcode reading is correct, product load in the silo is controlled bythe scale; when the maximum loadable quantity has been reached, Supercolorautomatically blocks product aspiration.
To physically load the products see instructions on page 80 and following.
To physically load the products see instructions on page 68.If the scale is present on the loading trolley, the operation will automatically stopwhen at one kg under the maximum loadable quantity (taking in account thequantity already present in the silo). Pressing the end weighing button it is stillpossible to modify the weight acquired by the scale, if present, or to enter theloaded product weight ; therefore the program will return to the initial loadingscreen.It is also possible to change or delete one of the products contained in the silos. Todo this it is necessary that the weight of the product in the silo is equal to zero(zero the Supercolors special functions).
USER’S MANUAL
74 SUPERCOLOR
TOUCH SCREEN PANEL FOR PRODUCT LOADING
Icon descriptions
Access to the main screen, press his icon to return to the mainprogram window. (Fig. 43, pag. 76)
Access to the [FAULTS] screen.
Opens the password screen to access the touch panel Setup.
Access to the [Setup] screen you will be prompted to enter thepassword.
Press the side arrow to view the icons shownon the right.
Press to access the configuration bar. Data contained in the variouspages must not be modified, any changes must first be agreed withthe Lawer Support Service.
Access to the [INPUT/OUTPUT] screen, Data contained in the pagemust not be modified, any changes must first be agreed with theLawer Support Service.
Scroll the list up or down.
Access to the [SEARCH SILO] screen.
Start loading operation.
Stop loading operation.
USER’S MANUAL
75 SUPERCOLOR
The grey icon indicates that the system is inactive.
The green flashing icon indicates that the system is ready to loadthe selected product.
The icon flashing stops and becomes a static light when the loadingpump has started.
Cancels the list from the [FAULTS] window.
Silences the alarm buzzer that signals a fault.
Tab. 7
ENTERING DATA
Use the virtual keyboard, whichappears when an alphanumeric fieldis touched, to enter the requesteddata.
Use the virtual keyboard, whichappears when numeric field istouched, to enter the requesteddata.
Fig. 42
USER’S MANUAL
76 SUPERCOLOR
MAIN PROGRAM WINDOW
When the panel is powered thescreen appears as shown here andindicates:
Progressive silo number.
All plant product codes.
Product description.
Quantity contained in each silo,expressed in kilograms.
The lower section of the window (B)displays the characteristics of theselected product (A).
Fig. 43
SETUP
The touch screen panel is configured by the constructor therefore it does not needany intervention by the end user. Access to setup is password protected.Inappropriate changes to setup parameters will compromise system functions; anychanges which may be necessary must be agreed and followed with the help of theLawer Support Service. The setup password must be communicated to the operatorin charge of the machine and must be only to revealed to trained operators whoare aware of the risk caused by configuration changes.
Press this icon to enter the setup password prompt (Fig. 45).
Fig. 44
Use the virtual numeric pad to enter the password [111](Fig. 42)
The password cannot be changed.
Confirm with [ENT]
Fig. 45
USER’S MANUAL
77 SUPERCOLOR
Press this icon to access setup.
[Setup] appears, divided in twocolumns.
Fig. 46
Press to chose the language youwant to set (English or Italian).
Fig. 47
Press these input boxes to changethe cleaning parameters of theloading filter.
Before changing the defaultparameters contact the LawerSupport Service.
Fig. 48
This icon enables or disables thebarcode reader function forautomatic silo detection.
With the barcode reader disabled, itis possible to manually enter thecode of the silo you want to load.
After having positioned the loadingtrolley, press [Code] and enter thesilo code, follow instructions on pagepag. 80.
Be careful to enter the correct codeotherwise different type productsmay be mixed together.
Fig. 49
Enable this icon if the loading trolley is equipped with a scale forautomatic loaded quantity control (optional).
Fig. 50
USER’S MANUAL
78 SUPERCOLOR
Enables barcode reading.
OFF ON
Barcode reader icon enables productcode reading from the package.
Barcode reader icon enables productlot code reading.
In the (A) input field, indicate howmany numbers, before the code isacquired, that must be ignored.
With the product barcode readingenabled, the button (1) must appearas in the picture; press the button,(that will change as in 2) when bothoptions are enabled.
Fig. 51
Press to return to the main page (Fig. 43).
Fig. 52
Press to view the setup task bar.
Press to access the [SYSTEM SETTING]window.
Fig. 53
Use the virtual keyboard to enter thepassword [11111111]
The password cannot be changed.
Confirm with [OK]
Fig. 54
USER’S MANUAL
79 SUPERCOLOR
[Network] tab indicating the IPaddresses of the terminal.
In case of IP conflicts contact theLawer Support Service to arrange adifferent IP address.
For the terminal to function properlythe parameters present in the varioustabs (Security, History etc.) must notbe changed.
Fig. 55
USER’S MANUAL
80 SUPERCOLOR
PRODUCT LOADING
Before starting their assignments the operators incharge of the loading operations must at all times wearthe appropriate Personal Protective Equipment, asdescribed in the previous chapters (pages 19, Errore. Ilsegnalibro non è definito., Errore. Il segnalibronon è definito., Errore. Il segnalibro non èdefinito.)It is important that all Personal Protective Equipment isintact, efficient and must be immediately substituted incase of deterioration.
Press the torch icon.
The barcode reader will enable (Fig.29, pag. 49, rif. 1)
Fig. 56
The dyestuff search window appears.
Manually move the loading trolley tothe silo to be loaded.
Confirm by pressing the green icon asshown here.
Fig. 57
The main window appears with theproduct highlighted in blue, seearrow.
Press the [Load] icon s indicated bythe hand.
The loading trolley is coupled to thesilo.
Fig. 58
USER’S MANUAL
81 SUPERCOLOR
For a few seconds this little windowappears.
Pressing the red icon as shown it ispossible to cancel the loadingoperation.
Fig. 59
The green led button [Start Pump](1) lights in different modes:
Flashing; the system is ready tostart the loading pump
Static light; the loading pump isfunctioning.
Fig. 60
Place the container in the safetycabin and close the panel.
Use the gloves to open the container.
Press (1) [START PUMP] Fig. 60.
Insert the suction lance in the cabinand start product transfer.
Fig. 61
USER’S MANUAL
82 SUPERCOLOR
USER’S MANUAL
83 SUPERCOLOR
When finished loading press button(2) [STOP] to stop the pump(Fig. 60, pag. 81).
Use the virtual keypad to enter theloaded quantity.
The value must be expressed inkilograms.
Fig. 62If the loading trolley is equipped with a scale, the operation will automatically stopone kilogram short of the maximum loadable quantity (taking in account thequantity of product already present in the silo). The numeric keypad appearsdisplaying the loaded quantity, press to access the given value, or enter a newvalue and confirm with [ENT].
LOADING PANEL FAULTS
If a fault occurs during the loadingprocess, an acoustic signal goes off andon the main program screen a messageappears (see arrow Fig. 63,)
Press the icon indicated by the hand toopen the [ALARMS] window.
Fig. 63
Press icon (A) to silence the buzzer.
After the fault has been resolved,press icon (B) to cancel the alarms. Ifthe fault has not been resolved thebuzzer will go off again.
Press icon (C) to go back to the mainpage.
USER’S MANUAL
84 SUPERCOLOR
Special functions
This program is used to configure certain silo parameters, such as data “Backup”and “Restore”, updating loaded quantity and to enable/disable printers or printingoptions .
Start the <Supercolor> program
Enter the <User> password
The following window will appear.
The program is divided in “folders”, one for each function: Security Paired silo Dispensing parameters Stock update Printers
To browse the folders press <F2>. To obtain “focus” (if not present) press <F3>(the “focus” will move to the first object selected in the folder).
USER’S MANUAL
85 SUPERCOLOR
SECURITY
F5 = Backup database: Saves data in a directory selected by theoperator.
F6 = Restore database: Restores database from the directory selectedby the operator.
F11 = Format Disk: Formats the 3,5” floppy disk in drive A.
F7 Modify Password: Access the function by entering the old password,when prompted enter the new password.
USER’S MANUAL
86 SUPERCOLOR
PAIRED SILOS
The same product can be loaded in more than one silo, this operation is called“Paired silos” and is used mainly for two reasons:
When large quantities of the same color are used and the capacity of one silo is notenough.
When a color is used in small amounts which require high precision, and if used inlarge amounts where precision is not the prime factor. It is possible to calibratedifferently the dispensing parameters of the two silos.
Associate a product to more than one silo, with the same dispensing parameters.Define the number of silos to be associated according to the product’s specificweight and amount to be stored. Exit the loading function and enter the Specialfunctions by pressing the <F3> button until <F6=Specials> appears, enter theuser password and select the Paired Silos folder which will appear as below.
In the black section of the window you will see the silos (listed by number) thathave the same product; to view other series of paired silos (if present) press<F6=Group>.Silo information consists of the color code, description, silo number and theminimum and maximum dispensing values. The aim of this setting is to ensure aconstant product supply in order to satisfy the customer’s needs. Each silos in agroup can dispense from the minimum to the maximum values that have previouslybeen set in the Loading program.
USER’S MANUAL
87 SUPERCOLOR
Introduction: Supercolor will signal an empty silo when the default minimum levelvalue of 6 litres is reached and will therefore refuse the dispense order, the usercannot alter this value.Before each dispensing operation the system will check the contents of thecombined silos (considers out of tolerance values as well) and will assign thedispensing operation to the silo that best suits the request. To avoid stocking aproduct for too long in a silo, the combined silos are emptied in chronological orderand not in sequential order.Assigning a product to more than one silo having different dispensing parameters.Define the number of silos to combine according to the product’s specific weightand the quantity you want to stock, exit the loading function and enter the Specialfunctions, by repeatedly pressing <F3> until the <F6=Specials> button appears.Enter the user password and open the Paired silos folder (see the folder printbelow)This setting is used to stock the same product in different silos that have differentdispensing parameters. These settings will guarantee an adequate tolerancewhether the products to weigh are small or large quantities. Normally a silo isassigned to high precision dispensing by setting the minimum and maximumdispensing parameters. To achieve accurate dispensing it may be necessary tochange the standard diaphragm with a precision diaphragm.To obtain these settings, determine the maximum high precision quantity for thedispensing. From the group, select the silo that must dispense high precisionquantities, press <F4 = Max.Limit> and enter the value. This value will be themaximum that can be dispensed by the silo in a range that goes from the minimumvalue (see the Loading program) and the maximum value. Press <ENTER> or<Ok> the program will insert this value (see window below) as a maximumthreshold value; and enters the same value (incremented by 0,1 g) as a minimumthreshold on the combined silo. For the other silos it is possible to insert a definiterange, or for the maximum dispensing the highest settable quantity. As in theexample below the product Prova Lawer uno is assigned to three silos, the firstone (for small quantities) will dispense from 0,1 to 100 g, the second will dispensefrom 100,1 to 200 g, the third from 200,1 g to the maximum value set for thatproduct.
USER’S MANUAL
88 SUPERCOLOR
DISPENSING PARAMETERS
Use this folder to set the following parameters:
ANTICIPATED STOP
Value expressed in grams and indicates how much in advance of the pre-set timethe system must stop dispensing. This value allows dyestuff time to settle afterdispensing to ensure precise weighing. This value is determined by experimentingwith each product. Reduce or increase this value if dispensing exceeds or goesbelow the tolerance values.
MICRO-DISPENSING
Not available with this machine version.
PERCENTAGE TOLERANCE
Tolerance value used to execute dispensing.
ABSOLUTE TOLERANCE
On screen values that indicate out of tolerance dispensing.
USER’S MANUAL
89 SUPERCOLOR
STOCK UPDATING
Use this folder to update the quantity of product in the silos. Press the <F4> key tofocus the input box <F4=Withdrawn Qty> and enter the value which must besubtracted from the value in the Qty column; the numbers after the comma are ofno importance therefore must not be entered.Press <OK> or <Enter> to confirm ; press <Exit> or <Esc> to exit without makingchanges to the database.
USER’S MANUAL
90 SUPERCOLOR
PRINTERS
From this folder enable or disable the printers or the prints.
<F8 = PRINTER >: Enable or disable the printer that manages the dispensing andstock prints.
<F9 = LABEL PRINTER>: Enable or disable the label printer that prints the labels forthe manual batches, these labels are dropped into the bucket when dispensing isfinished.
<F5 = DISPENSING PRINTS>: If this option is enabled a report will be printed afterdispensing operations, including general batch information, requested quantitiesdispensed and out of tolerance values if any.
<F6 = STOCK PRINTS>: Prints a list of the products in the silos, including remainingquantity and quantity that can still be loaded. This is printed, if confirmed, whenexiting the loading program, if products have been loaded, or if requested by theSupercolor function <F6 = Stock>.
<F7 = INSUFFICIENT PRODUCT PRINT>: Prints a list of the products that are under theminimum level, or if they have reached the minimum dispensing threshold (6litres), Supercolor will issue the prints during the preliminary controls when thedispensing cycle starts, if the quantity of a batch product is less than the requestedamount.
PACKAGE PRINT: Prints a report that lists the number of full packages (not dispensedby Supercolor) that have been used to create particular batches.
BATCH EDITOR PRINT: Prints a report of the batches created by the <Batch Editor>program.
USER’S MANUAL
91 SUPERCOLOR
Supercolor program
MAIN SCREEN:
The application is divided in two sections (as shown above): the upper sectionvisualizes a list of batches received from an external system or edited by the localbatch editor, the lower section visualizes the list of products of the selected batchand underneath a series of buttons to press for accessing the various functions.
Stop: The machine is in STOP mode
Press <F12=Start> to START
Run: The machine is ready to operate.
Local: The machine will only process local operations and not thosegenerated by Leims or other external management systems.
To use Remote mode repeatedly press <F3> until the<F11=Remote> button is visible.
USER’S MANUAL
92 SUPERCOLOR
Password: Enter the user password.
RemotE: The machine will only process operations generated by LEIMS orother external management systems
PROCESS HEADINGS (upper section): Contains information concerning batchelements, processes, drops. There are three different icons for this plant:
Indicates the automatic processes to be executed by Supercolor,whether requested or not.
Indicates the manual processes to be executed by Supercolor.
Indicates the processes suspended by Supercolor due to productshortage.
Other information is also available from this window:Machine code, Batch, Processes, Drops, Customer, Item, Color.
To view the products of a process move to the upper section of the window bypressing F2, select the process and on the lower section “product window” you canview a list of products listed by product code. Other information includes: bucketnumber, product code, description and quantity to dispense.
BottonS: due to the various functions the program uses, it is not possible to view allthe function buttons simultaneously, for this reason they have been divided intogroups of three and displayed separately, with the exception of the buttonsStart/Stop, Exit, F3 other functions.
USER’S MANUAL
93 SUPERCOLOR
FUNCTION LIST:
The buttons on the window change when <F3> is repeatedly pressed and can beused when active. See example below:
Common buttons:
Exit
To exit, press this button and confirm by clicking “Yes” onthe dialog box, the program will close and be removed fromthe memory. This function is available only if there are nocycles being processed.
F3 = >> Allows you to browse the buttons.
F12 = Start
Start/Stops the application. Access to the functions thatallow movement are only allowed if the system is in START.You can only use this button if there are no cycles beingprocessed. If the program is in Stop, the only activefunctions are Stock and Special Functions if Leims is present.If Leims is not present the active functions are: ProductEditor, Special Functions, Machine Editor and the button withwhich the dissolving unit status can be viewed.
USER’S MANUAL
94 SUPERCOLOR
FIRST BUTTON SCHEME
F5 = StartRuns the weighing cycle (active only in local with theprogram in start on the manual batch selection if Leimsis not present).
F6 = StockRuns the Stock program from which you can view andprint the amount of product present on Supercolor andhow much product can still be loaded. (always active)
F7 = BatchesRuns the Batch Editor with out using Leims. (active onlyin local if Leims is not present).
SECOND BUTTON SCHEME
F5 = WithdrawCreate a product list and use this function that allowsimmediate rapid withdrawing. (active only in local withthe program in Start).
F6 = LoadRuns the loading program by downloading Supercolorfrom the memory, Supercolor will restart when you exitthe loading program.
F7 = ProductsAllows access to the product configuration function(active only if Leims is not present).
THIRD BUTTON SCHEME
F5 = DiagnosticsEnables diagnostics, where faults and dispensingoperations are recorded. Function available only in STOPphase.
F6 = SpecialSpecial functions for plant configuration. (Functionavailable only if there are no cycles being processed.
F7 = MachinesRuns the machine configuration function. (active only ifLeims is not present).
USER’S MANUAL
95 SUPERCOLOR
FOURTH BUTTON SCHEME
F5 = CleaningMoves the weighing trolley to the cleaningposition
F6 = CancelCancels the selected batch from the upper window(active only locally if Leims is not present).
F6=Restore/Suspend
Restores or suspends a process; only withSUPERCOLOR in local mode and without LEIMS.Suspended processes appear on the process listbut cannot be executed.
FIFTH BUTTON SCHEME
F11 = Remote/Local Dissolving units manual functions, press F5 andselect the dissolving unit.
F6 = Load Runs the loading program allowing thedispensing cycle to proceed. Active only withSupercolor in remote mode with a dispensingcycle running.
F7 = List Function that selects the idle batches ready tobe scheduled for execution. Active only ifSupercolor is not connected to Leims.
ACTIVE BUTTONS ON ALL SCHEMES
F2 = Process selection Makes it possible to select a process and to viewa list of products for that process.
F9 = Process/Machinestatus
Makes it possible to view the batch list ordispensing status.
Before accessing the process phase, it is necessary to configure all the parametersso that the machine can operate correctly, these parameters include: machineconfiguration, products and silos (as explained in the loading program and specialfunctions), and Supercolor setup. Product and machine configuration must be doneon Supercolor only if Leims is not present on the system. If Leims is present usethe appropriate editors from the Leims folder ( C:\Leims on the local computer) orfrom the main program screen. This section of the manual refers to machine andproduct settings without Leims, for the program version with Leims, refer to themachine and product configuration manuals.
USER’S MANUAL
96 SUPERCOLOR
MACHINE EDITOR
Press F7 = Machines (from the third button scheme) to access the machineconfiguration function
This window contains a list of all the machines of the plant for which it is possible todispense to. Other information consists of machine number, code and description.To insert a new machine press F4 = New, enter the machine number (max 3numbers), code (max 8 characters), description (max 25 characters) in the entryfields provided and press F5 = Save.To cancel a machine, select it from the list and press F6 = Cancel, confirm bypressing “Yes” on the dialog box that will appear.
USER’S MANUAL
97 SUPERCOLOR
PRODUCT EDITOR
Press F7 = Products (from the second button scheme of the main screen) toaccess the product configuration function.
This window contains a list of the products that can be loaded in the Supercolorsilos. Other information consists of product code and description.To insert a new product press F4 = New, enter the code (max 8 characters),description (max 25 characters), the specific weight of half a litre of product(expressed in grams) and the minimum and maximum dispensing quantities (whenpressing F4 = New the default value that is visible is the value previously enteredin the setup program on folder 6=System range), press F5 = Save, to save theproduct to the list.To change the parameters of a product on the list, select the product you want tomodify, change the parameters and press F5 = Save.To cancel a product select it from the list, press F6 = Cancel and confirm bypressing “Yes” on the dialog box that will appear.The F7 = Limits button, is used to enter the function which allows you to set thedispensing limits ( as previously explained in the loading program when pressingF6=Modify for the Limits button.
USER’S MANUAL
98 SUPERCOLOR
F6 = STOCK
This function makes it possible to check the products loaded in the Supercolor silosgiving details such as product quantity stored in each silos and how much productthey can still receive. If enabled by the program configuration, the abovementioned details can be printed.
To access this function press F6 = Stock ( 1° button scheme).
To access special functions press F6 = Special (3° button scheme). This action willclose the Supercolor program and run the special functions, as previously describedin this manual, Exiting the special functions will automatically restart the Supercolorprogram.
Once the silos have been configured by the loading program and special functions itis possible to dispense with Supercolor, there are different methods for dispensingwith Supercolor:
1) Plant with Leims Batches from Leims Rapid withdrawing
2) Stand alone plant (without Leims) Batches received from an external system or prepared with the local
batch editor Rapid withdrawing
USER’S MANUAL
99 SUPERCOLOR
The batches may be received from the Leims batch editor or from anexternal management system, therefore automatically executed if theplant operates in remote.
If locally operated, the plant can only execute batches for machinesthat are not connected to color dispensing plants and it is possible towithdraw products instantly using plastic buckets. Rapid withdrawingmust be created with the appropriate function by pressing F5 =Withdraw (see 2° button scheme).
Batches can be prepared with the editor or can be received from anexternal system by using the Lawer Interface application. The batcheswill appear on the list of processes to be executed, press F8=List toaccess this function. The batches are organized according to themachines and it is the operator who schedules the weighing sequence.The selected batches will pass from the waiting phase to the mainscreen where they are executed by the operator by pressing F5 = Run(see 1° button scheme). If Supercolor runs in remote, the batches willbe executed automatically.
With the plant operating locally, it is possible to withdraw productsinstantly using plastic buckets. Rapid withdrawing must be created withthe appropriate function by pressing F5 = Withdraw (see 2° buttonscheme).
USER’S MANUAL
100 SUPERCOLOR
RAPID WITHDRAWING
Press F5 = Withdraw to open the rapid withdraw editor and to dispense locally onSupercolor.
This window displays the following information: operator name, batch number,batch dissolving machine, product drop down list and quantity to dispense ingrams. It is possible to prepare batches that have more than one product as longas the total amount of these products does not exceed the limit of 5 Kg’s.To execute a rapid withdraw enter the requested information: Operator, batchnumber, machine, select the product and the quantity. Press Enter to add theselected product to the batch, repeat the above described operation if the batchcontains more than one product then press F5 = Run to execute the rapidwithdraw instantly. Before this operation starts there must be a bucket on theconveyor to allow Supercolor to start dispensing, if no bucket is present a messagewill appear on the application status bar indicating that the program is waiting forthe bucket.Press F6=Cancel should it be necessary to cancel a product that has been addedto the list by mistake.
USER’S MANUAL
101 SUPERCOLOR
When weighing starts, a screen appears displaying information concerning thebatch to process, scale position (represented by the drawing), the product in thesilo, requested quantity and the quantity read by the scale
When the dispensing cycle is finished, the start cycle screen appears where thebatches to execute are displayed. During the dispensing cycle it is possible to viewthe batches to execute by pressing F9.
USER’S MANUAL
102 SUPERCOLOR
BATCH EDITOR
To access the editor press F7 = Batch ( see 1° button scheme).
To create a batch fill in the appropriate information, select a product from the list,enter the requested quantity (expressed in grams), enter the drop number andpress enter. Repeat the above instructions for each product you want to add to thebatch.It is possible to create batches for more than one drop, therefore the differentbatches will be created in the same way: Batch, process, machine with differentdrop numbers, that can be executed at different times.When all the necessary products have been entered press F5 = Run to save thebatch in the process waiting list.To cancel a product, select it from the list and press F6=Cancel.The F7=Recipes % button runs the recipe editor if present.
Basic recipe editor. This function is used to create batches from a basic recipe thatcan be set and configured from the program. The procedure for creating thesebatches will be explained further on in this manual.
USER’S MANUAL
103 SUPERCOLOR
RECIPE EDITOR
Recipes for Supercolor are created by products expressed in percentages (the sumof these products must be 100%). From the batch editor enter the total productweight and the program will automatically calculate the single quantities thattogether form the batch.To insert a new recipe press F5 = New, enter the recipe code and description (thenote column is optional) and select the products for that recipe. Enter the quantityin the Q.ty field and the unit of measurement % (U.M), the drop number anddestination tank, press ENTER to add the product to the list. It is also possible tomodify or cancel existing recipes using the appropriate buttons. When all changeshave been made, the new recipe will be automatically saved in the recipe list.
In the example above a recipe has been saved with code “R1” - description “Ricettauno” made of three products with percentages of 15, 65, 20, for a total of 100% -destination tank number 1 (it is important to enter the tank number if the recipeeditor is associated to a dissolving plant or to Leims)
When the basic recipes have been created press ESC to go back to the batch editorwhere the new recipes will be automatically saved in the existing list. Usingpredefined recipes when creating batches avoids having to enter the same productevery time, just enter the total batch quantity and according to the percentages theprogram will calculate the weight of each product and displays the list in the lowersection of the screen. It is also possible to add other products by selecting themfrom the products list, see the previous instructions.
When a batch has been created (whether recipe created or by manually enteringthe products), press F5 = Save to save to the batch database, the operator will beasked if a batch print is required. All the batches can be saved in order to scheduledispensing according to customer’s needs .
USER’S MANUAL
104 SUPERCOLOR
PROCESSES ON WAITING LIST
To access the process waiting list press F8 = List .To run or cancel a process from the list:
Select the machine from the list in order to view the batches. From the batch list select the batch. Press F6=Cancel to cancel the selected batch. Press F12=Start to move the batch to the list of batches to be executed,
these batches will be displayed in the main screen.
This function is active only if Leims is not present.
USER’S MANUAL
105 SUPERCOLOR
EXECUTING A BATCH
If Supercolor is operating locally, select the batch from the list and press F5=Run.If Supercolor is operating in Remote, the batches are executed one after the other.
When a batch starts, whether local or remote, a bucket will be placed in thedispensing position by the conveyor, the weighing trolley will position itself underthe appropriate silo and dispensing begins.
USER’S MANUAL
106 SUPERCOLOR
Faults
FUNCTIONAL FAULTS
If functional faults occur, it is necessary to contact the maintenance service.
Do not under estimate functional faults, as they may cause the system tomalfunction therefore creating insecure working conditions for the operators.
In case of functional faults do not attempt to resolve the problems withoutthe help of specialized personnel.
In order to manage the plant faults correctly (software o mechanical), aMAINTENANCE AND SPARE PARTS manual has been written for the use ofqualified personnel in charge of maintenance. The manual contains thealarm messages and possible solutions, a list of spare parts with codenumbers, electrical and pneumatic schemes etc.
USER’S MANUAL
107 SUPERCOLOR
Electrical or mechanical faults are displayed in the FAULT window from which youcan try to fix the errors. Error messages may be generated by faulty mechanicalbucket movement (Conveyor PLC) or by the dispensing system (Dispensing PLC).The screen that appears is similar to the print screen below; where it is possible toview the code, description and the system that generated the fault. Faults can becaused for two reasons, fault communication between computer and PLC ormachine cycle faults.
To resolve the problem proceed as indicated below:Identify the fault, the component and the system that generatedthe error message (Refer to the chapter “Error Messages” of theMaintenance and spare parts manual) and if possible resolve theproblem. If the problem has been resolved press the <Enter>button on the window or from the keyboard.The system restarts.
It is not advisable to restart the system if you have not followedthe above instructions.
The following paragraph describes how to fix the faults that mayoccur during the dispensing cycle.
USER’S MANUAL
108 SUPERCOLOR
RESUMING THE DISPENSING CYCLE
If faults occur while dispensing, a window will appear (as shown below). The uppersection holds information on the possible causes of the fault and underneath thevarious options available for resuming the dispensing operations.
Interruptions of the dispensing cycle and resume options are reported on thefollowing page.
USER’S MANUAL
109 SUPERCOLOR
Options Action
Continue withdrawing.Continues dispensing from where it wasinterrupted.
Interrupt dispensing and go to thenext color.
Interrupts current product dispensingand continues with the next product ofthe recipe
Suspends the process that isrunning.
Cancels the recipe currently dispensing.
Continues withdrawing from thepaired silo.
If the product to dispense is stocked intwo silos, dispensing will continue fromthe second one.
When dispensing has finished but is not in the pre-set tolerance limits for thatproduct, a message will appear (see example below). In blue the product code anddescription appears and below the message that informs the operator that theproduct dispensed is out of tolerance and specifies the weight. As stated in themessage it is possible to manually correct the weight and resume dispensing theother products of the batch. If the weight indicated is irrelevant for the out come ofthe process select the <NO> button then press <ENTER> to continue or to enddispensing.
When dispensing has finished the bucket is delivered under the label printer (ifconfigured on the plant), and then taken to the unloading position. The aboveoperation does not apply to processes involved in automatic dissolving operations.If printing is configured, a record containing batch information is printed includingrequested and dispensed quantities and out of tolerance values if any.
USER’S MANUAL
110 SUPERCOLOR
Error messages
COMPONENT INDEX IN ALPHABETICAL ORDER
On the left of each column you will find the identification code of the electro-pneumatic component that generated the error message; on the right, the pagenumber where it is possible to find a reference to the codes.
Apn01....................................... 120; 131Apn02...............................................131Apn03...............................................131Apn04....................................... 122; 131Apn05....................................... 121; 131Apn10....................................... 124; 125Apn13...............................................124Apn2.................................................123Apn3.................................................123Apn6.................................................127Apn7.................................................127DT ....................................................135DT11 ................................................135DT5050.............................................135DT5095.............................................135M2....................................................116M3....................................................118M4....................................................119PLC...................................................135SQ01 ................................................119SQ02 ........................................ 123; 131SQ03 ........................................ 123; 131SQ04 ........................................ 120; 131SQ05 ........................................ 120; 131SQ06 ................................................127SQ07 ................................................131SQ09 ................................................119SQ101 ..............................................124SQ107 ...................................... 124; 125SQ12 ........................................ 121; 131SQ13 ........................................ 121; 131SQ14 ........................................ 122; 131SQ15 ........................................ 122; 131
SQ200 ..............................................115SQ201 ..............................................115SQ202 ..............................................126SQ204 ..............................................132SQ205 ..............................................132SQ206 ...................................... 132; 133SQ208 ...................................... 132; 133SQ209 ...................................... 132; 133SQ210 ..............................................115U1 ....................................................116U2 ....................................................118X0 ....................................................134X1 ....................................................118X2 ....................................................116X3 ....................................................112X5 ....................................................118X6 ............................................ 114; 115X8 ....................................................130YV01.................................................131YV02.................................................131YV04......................................... 120; 131YV06.................................................131YV07.................................................131YV08.................................................131YV09.................................................131YV10.................................................131YV101 ...............................................124YV107 ....................................... 124; 125YV12......................................... 121; 131YV13......................................... 121; 131YV14......................................... 122; 131YV15......................................... 122; 131
USER’S MANUAL
111 SUPERCOLOR
WEIGH TROLLEY ZEROING
Emergency Push Button
Procedure
To restore the position of the weigh trolley to the silos followthe instructions here below:Press the <Emergency> button, indicated by the arrow above.Wait for about 30 seconds.Restart by using the <Enter> button that appears on thedialog window, or press the <Enter> key on the keyboard.The following message will appear <Waiting for zeropositioning ...>
Before using the <Enter> key, make sure that thereare no workers in potentially dangerous areas.
USER’S MANUAL
112 SUPERCOLOR
STOP
Stop Button
Faults and solutions
Dispensing: Stop (X3)Stop pressed
The machine has been stopped by pressing the <Stop> button.The machine can be re-started by pressing the <Enter> buttonthat appears on the dialog window, or by pressing the <Enter>key on the keyboard.
Before using the <Enter> button make sure that thefault has been detected and cleared and that thereare no workers near potentially dangerous areas.
USER’S MANUAL
113 SUPERCOLOR
MANUALLY OPENING THE SIDE COVER PANEL
Manual opening selector
Procedure
The protective side panel of the weighing trolley that protects the scale, isopened pneumatically. If necessary it can be opened manually by using theselector indicated by the arrow. During normal cycle working the manualselector is to be used only in case of an emergency due to scale or internalsensor malfunctions. Before working inside this panel, stop the machine bypressing the <Stop> button and wear the appropriate personal protectiveequipment.
Make sure the panel has been safely replaced before restartingthe machine.
USER’S MANUAL
114 SUPERCOLOR
EMERGENCY
Emergency button
Faults and solutions
Dispensing: Emergency (X6)Emergency pressed
The machine has been stopped with the <Emergency> button. Torestart the machine follow the instructions below:Release the button by rotating it in an anti-clockwise direction,this triggers an acoustic signal that can be silenced by pressingthe yellow <Stop Alarm> button.To restart the machine use the <Enter> button on the dialogwindow that appears on screen, or press the <Enter> key on thekeyboard.The weighing trolley will run a zeroing cycle and automaticallyreturns to the original position.
Before restarting the machine, make sure the fault thattriggered the emergency stop has been cleared and thatno workers are near any potentially dangerous areas
The <Emergency> message appears, but the button has not beenpressed:The fault is generated by the position sensors <SQ200>,<SQ201> or <SQ210> (See pag. 114)
USER’S MANUAL
115 SUPERCOLOR
WEIGH TROLLEY LIMIT SWITCH
Commands and controls
Function Position sensor
Right limit switch SQ200
Left limit switch SQ201
Zeroing sensor SQ210
Limit switch position
Faults and solutions
Dispensing: Emergency (X6)
The weigh trolley has exceeded the limit to the right and the sensor<SQ200> has interrupted power to the motor <M2> and to the PLC <U1>.
The weigh trolley has exceeded the limit to the left and the sensor<SQ201> has interrupted power to the motor <M2> and to the PLC <U1>.
The zeroing sensor <SQ210> is faulty and has not stopped the weightrolley, this has triggered the sensor <SQ201> of the left limit switch.
Manually move the weigh trolley so as to release the sensor roller<SQ200> or <SQ201>.Press <Enter> on the keyboard when prompted from the screen dialogwindow.The system will automatically run the weigh trolley zeroing cycle.
If, during the zeroing cycle the emergency message repeats, substitute thesensor <SQ210>
Before pressing <Enter> on the keyboard make sure that thereare no workers near potentially dangerous areas.
USER’S MANUAL
116 SUPERCOLOR
WEIGH TROLLEY MOTOR TRANSLATION
Item Function
M2 Weigh trolley motor translation
U1 Inverter for weigh trolley translation command
Component location
Faults and solutions
Dispensing: Dispensing trolley not positioned (X2)
The weigh trolley is not correctly positioned on the silo from which theproduct must be dispensed:
USER’S MANUAL
117 SUPERCOLOR
Check the inverter error code on thedisplay (see chart on pag.94).
Press <Enter> on the keyboard to restorethe position. If the problem persists run azeroing cycle (see pag. 111).
Check that the toothed belt is not loose. Check that the motor (M2) rotates freely. Check that mechanisms controlled by the
motor (gears, chains, belts, reductionsetc.) do not present signs of hardeningand that they have no difficulty inrotating or running.
Check that absorption does not exceedthe values on the data plate.
Check that the motor winding is not inshort circuit.
USER’S MANUAL
118 SUPERCOLOR
DISPENSING MOTOR
Item Function
M3 Dispensing rotation motor
U2 Dispensing command Inverter
Component location
Faults and solutions
Dispensing: Dispensing motor Inverter fault (X5)
On the display check the Inverter error code (see chart on pag.94).Check that the motor (M3) revolves freely.Check that mechanisms controlled by the motor (gears, chains, belts,reductions etc.) have no difficulty in rotating or running.Check that absorption does not exceed the values on the data plate.Check that the motor winding is not in short circuit.
Dispensing: Disconnected thermal relays (X1)
Overload protection has interrupted motor rotation:Check that the motor revolves freely.Check that absorption does not exceed the values on the data plate.Check that the motor winding is not in short circuit.
USER’S MANUAL
119 SUPERCOLOR
SCALE LIFTING
Function Motor Position sensor
Scale in low position (rest position)
M4
SQ09
Scale in high position (weighingposition)
SQ01
Component location
Faults and solutions
Dispensing: Scale not lowered (SQ9=OFF)
The scale support platform has not lowered.Check the magnetic sensor <SQ09>Check that mechanisms controlled by the motor (gears, chains, belts,reductions etc.) have no difficulty in rotating or running.Check that absorption does not exceed the values on the data plate.Check that the motor winding is not in short circuit.
Dispensing: Scale has not lifted (SQ1=OFF)
The scale support platform has not lifted.Check the magnetic sensor <SQ01>Check that mechanisms controlled by the motor (gears, chains, belts,reductions etc.) have no difficulty in rotating or running.Check that absorption does not exceed the values on the data plate.Check that the motor winding is not in short circuit.
USER’S MANUAL
120 SUPERCOLOR
DISPENSING CAP
Commands and controls
FunctionElectrovalve
Pneumaticcylinder
Position sensor
Dispensing cap openingYV04 Apn01
SQ05
Dispensing cap closure SQ04
Component location
Faults and solutions
Dispensing: Cap not open (SQ5=OFF)
Dispensing cap is not open:Check the magnetic sensor <SQ05> on the pneumatic cylinder <Apn01>Check the electro valve <YV04 > on the pneumatic island <Lawer 90> seepag. 131
Dispensing: Cap not closed (SQ4=OFF)
The cap is not closed:Check the magnetic sensor <SQ04> on the pneumatic cylinder <Apn01>Check the electro valve <YV04 > on the pneumatic island <Lawer 90> seepag. 131
USER’S MANUAL
121 SUPERCOLOR
INTERFACE
Commands and controls
FunctionElectrovalve
Pneumaticcylinder
Position sensor
Interface lifting YV12Apn05
SQ13
Interface lowering YV13 SQ12
Component location
Faults and solutions
Dispensing: Interface has not lifted (SQ12=OFF)
The dispensing compressed air feeder interfacing has not lifted:Check the magnetic sensor <SQ12> on the pneumatic cylinder <Apn05 >Check the electro valve <YV12> on the pneumatic island <Lawer 90>
Dispensing: Interface has not lowered (SQ13=OFF)
The dispensing compressed air feeder interfacing has not lowered:Check the magnetic sensor <SQ13> on the pneumatic cylinder <Apn05>Check the electro valve <YV13> on the pneumatic island <Lawer 90>
USER’S MANUAL
122 SUPERCOLOR
SCREW COUPLING
Commands and controls
Function Electro valvePneumaticcylinder
Position sensor
Screw coupling in rest position YV15Apn04
SQ14
Screw coupling working YV14 SQ15
Component location
Faults and solutions
Dispensing: Screw has not coupled (SQ14=OFF)
The rotation gearing that controls the dispensing screw has not lifted:Check the magnetic sensor <SQ14> on the pneumatic cylinder <Apn04>Check the electro valve <YV14 > on the pneumatic island <Lawer 90 >
Dispensing: Screw has not unlinked (SQ15=OFF)
The rotation gearing that controls the dispensing screw has not lowered:Check the magnetic sensor <SQ15> on the pneumatic cylinder <Apn04>Check the electro valve <YV15 > on the pneumatic island <Lawer90>
USER’S MANUAL
123 SUPERCOLOR
ASPIRATION BULKHEAD
Commands and controls
Function Electro valvePneumaticcylinder
Position sensor
Checks the position of thesliding aspiration tray
YV02 Apn2-Apn3SQ02
SQ03
Component location
Faults and solutions
Cleaning tray not open (SQ3=OFF)
The magnetic sensor <SQ03> signals that the cylinders <Apn2 e Apn3>are not extended therefore the tray was not opened.Check the magnetic sensor <SQ03> on the pneumatic cylinder <Apn3>Check the electro valve <YV02 > on the pneumatic island <Lawer90>
Cleaning tray is not closed (SQ2=OFF)
The magnetic sensor <SQ02> signals that the cylinders <Apn2 e Apn3>are extended therefore the tray is open.Check the magnetic sensor <SQ02> on the pneumatic cylinder <Apn3>Check the electro valve <YV02 > on the pneumatic island <Lawer90>
USER’S MANUAL
124 SUPERCOLOR
LOADING TROLLEY CENTERING
Commands and controls
Function Electro valvePneumaticcylinder
Position sensor
Loading trolley coupled YV101 Apn13 SQ101
Nozzle insertion YV107 Apn10 SQ107
Component location
Faults and solutions
Loading trolley not coupled
The centering wheel of the loading trolley that is positioned on the silo to beloaded, is not in the correct position:Manually shift the trolley to put the wheel back on the guide.Check the magnetic sensor <SQ101> on the pneumatic cylinder <Apn13>Check the electro valve <YV101>
USER’S MANUAL
125 SUPERCOLOR
NOZZLE INSERTION
Commando and controls
FunctionElectrovalve
Pneumaticcylinder
Position sensor
Nozzle Insertion YV107 Apn10 SQ107
Component location
Faults and solutions
Alarm - nozzles have not moved forward
The nozzles that connect the trolley to the silo have not moved forward :Check the magnetic sensor <SQ107> on the pneumatic cylinder <Apn10>Check the electro valve <YV107>
Alarm – nozzles have not retracted
The nozzles that connect the trolley to the silo have not retracted to therest position:Check the magnetic sensor <SQ107> on the pneumatic cylinder <Apn10>Check the electro valve <YV107>
USER’S MANUAL
126 SUPERCOLOR
DETECTING BUCKET PRESENCE ON THE SCALE
Commando and controls
Function Position sensor
Detecting bucket presence on the scale SQ202
Component location
Faults and solutions
Dispensing: No bucket on the scale (SQ202=OFF)
The photocell <SQ202> does not detect a bucket on the scale:If there is a bucket on the scale, check that it does not interrupt thephotocell beam. In some cases, the form of the bucket or the transparencyof the plastic material is unsuitable for use on the Supercolor.
Dispensing: Bucket not unloaded by the scale (SQ202=ON)
The photocell <SQ202> detects a bucket on the scale:If there is a bucket on the scale, manually move it on the unloadingconveyor. Check the correct alignment between the emitter and thephotocell receiver. Clean the emitter and receiver with a dry cloth.
USER’S MANUAL
127 SUPERCOLOR
OPEN/CLOSE SCALE PROTECTION PANEL DOOR
Commands and controls
Function Position sensors
Position control (Closed/Open) of the scale protectionpanel door
SQ06
Component location
Faults and solutions
Panel door not open (SQ6=OFF)
The magnetic sensor <SQ06> signals that the cylinders <Apn6 e Apn7>are not extended and therefore the panel door did not open.Check the magnetic sensor <SQ06> on the pneumatic cylinder <Apn7>Check the electro valve <YV05 > on the pneumatic island <Lawer90>
Panel door not closed (SQ6=ON)
The magnetic sensor <SQ06> signals that the cylinders <Apn6 e Apn7>are extended therefore the panel door is open.Check the magnetic sensor <SQ06> on the pneumatic cylinder <Apn7>Check the electro valve <YV05 > on the pneumatic island <Lawer90>
USER’S MANUAL
128 SUPERCOLOR
MANUAL WEIGHING
Supercolor without MSA Supercolor with MSA
Faults and solutions
Access door for manual weighing is open.
The safety sensor detects that the door has not been closedClose the doorCheck that the sensor is working properly, if not, replace it.
USER’S MANUAL
129 SUPERCOLOR
DISPENSING
Faults and solutions
The system does not dispense dyestuff
The message is generated by the dispensing system, that does not registera weight increase:
Check that there is sufficient product in thesilo, if not, proceed with re-filling.Check that the product has not formed a“bridge” that may obstruct dyestuff passage.To free the passage of any obstructionsfollow the below instructions:Manually open the lid of the silo to clean.On the loading trolley, remove the lance capand for a few seconds, impulse start thepump used for loading.
Do not attempt to shift the silo contents by banging on the wallsof the silo, these are made of resin which is sensitive to impacts.The use of blunt objects on the silos walling will void theConstructor’s warranty.
Check the silo number and if necessary update the contents by using thespecial functions (Restore Contents).
This message is generated by the fault < System not withdrawing dyestuff>(see above).Before starting a dispensing operation the database checks that thequantity is sufficient. If supply has been interrupted because of productscarcity, this message calls for a database data restore.
USER’S MANUAL
130 SUPERCOLOR
RESET
Component location
Faults and solutions
Dispensing: Reset (X8)
The message appears when the program is restarted, afterhaving reset the machine. Press <Enter> on the keyboard tocontinue.
Resetting the machine is considered a potentially dangerousoperation which nulls data status with the Plc, and must only beused if manual attempts to recover from a fault situation havefailed. Reset must be done by qualified personnel. The key forthe <Reset> switch must be kept by the supervisor in charge ofthe plant who will remove the key after each operation.
To reset the machine follow the instructions below:Exit the plant management program.Shut down the computer.Turn the main switch to the <OFF> position (B)Insert the appropriate key in switch (A) and keep it rotated.Turn to <ON> the main switch (B) without releasing the key (A)Wait for the acoustic signal and release the key (A)Remove the reset key and entrust it to the plant supervisorRestart the plant and press the <Enter> key on the keyboard whenprompted by the dialog window that appears on the screen.
USER’S MANUAL
131 SUPERCOLOR
LAWER90 PNEUMATIC ISLAND
Commands and controls
Item Function Electro valvePneumaticcylinder
Positionsensor
A Scale access panel YV06Apn06
SQ07Apn07
B High interface YV12Apn05
SQ12
C Low interface YV13 SQ13
D Dispensing screw working YV14Apn04
SQ15
E Dispensing screw resting YV15 SQ14
F Dosing unit cleaning tray YV02Apn02 SQ02
SQ03Apn03
G Dispensing cap YV04 Apn01SQ04
SQ05
H Unblocking screw coupling YV01
I Low vibration YV08
L High vibration YV07
M Front Vibrajet YV09
N Rear Vibrajet YV10
Component location
USER’S MANUAL
132 SUPERCOLOR
MANUAL LOADING AND UNLOADING
Commands and controls
Function Sensor
Bucket presence control
SQ204
SQ205
SQ206
SQ208
SQ209
Component location
Faults and solutions
Manual bucket loading : No bucket movement from the conveyor starting point(SQ204=ON)
The <SQ204> sensor detects a bucket:The bucket is not presentCheck that the photocells are correctly orientated.With a dry cloth, clean the emitter and the receiver of the photocellThe bucket is presentCheck that no mechanical obstructions interfere with the bucket movement.
Manual bucket loading: No bucket movement from the step-by-step position(SQ205=ON)
The <SQ205> sensor detects a bucket.The bucket is not presentCheck that the photocells are correctly orientated.With a dry cloth, clean the emitter and the receiver of the photocell
The bucket is presentCheck that no mechanical obstructions interfere with the bucket movement.
USER’S MANUAL
133 SUPERCOLOR
Manual bucket loading: Bucket not arrived on the step-by-step position(SQ205=OFF)
The system detects that the bucket has left the sensor <SQ204> but has notarrived to the <SQ205>sensor.Retrieve the bucket from the end of the conveyorCheck that the photocells are correctly orientated.With a dry cloth, clean the emitter and the receiver of the photocellPlace the bucket on the conveyor
Manual bucket loading: There is no empty bucket (SQ206=OFF).
The system needs an empty bucket but the loading conveyor is empty:The bucket is presentWith a dry cloth, clean the emitter and the receiver of the photocellCheck that the photocells are correctly orientated
The bucket is not presentLoad at least one bucket on the conveyor
Manual bucket loading: Bucket did not leave the end of the conveyor(SQ206=ON)
The <SQ206> sensor detects a bucket.The bucket is not presentCheck that the photocells are correctly orientated.With a dry cloth, clean the emitter and the receiver of the photocell
Manual bucket unloading: Bucket did not leave from the labeller position(SQ208=ON)
The <SQ208> sensor detects a bucket.The bucket is not presentCheck that the photocells are correctly orientated.With a dry cloth, clean the emitter and the receiver of the photocell
The bucket is presentCheck that no mechanical obstructions interfere with the bucket movement.
Manual bucket unloading: Bucket not arrived to the labeller (SQ208=OFF)
The system detects that the bucket left the dispensing trolley, but did notarrive to the sensor <SQ208>.Retrieve the bucket from its positionCheck that the photocells are correctly orientated.With a dry cloth, clean the emitter and the receiver of the photocellThen place the bucket before the first pair of photocells
Manual bucket unloading: Conveyor is full (SQ209=ON)
A bucket must be unloaded from the loading trolley but the unloading conveyorcannot receive other buckets:Unload at least one bucket
USER’S MANUAL
134 SUPERCOLOR
INSUFFICIENT AIR PRESSURE
Component location
Faults and solutions
Dispensing: Insufficient air pressure (X0)
The pneumatic circuit pressure is less than requested:Check the pressure of the central distribution lineCheck that the pressure regulator has not been tampered with.If there are flexible pipe connections between the central distribution andthe pressure regulator, check that there are no constrictions that mayimpede air flow
USER’S MANUAL
135 SUPERCOLOR
MISCELLANEOUS
Faults and solutions
Dispensing: fault not recognized (DT5003). Fault n. =
Note the error number and contact the Lawer Support Service
Dispensing: Dispensing parameters not found (DT5050 DT5095)
Exit and restart the program, if the problem persists contact the LawerSupport Service
Dispensing PLC setup parameters are missing (DT 5100-5111)
Exit and restart the program, if the problem persists contact the LawerSupport Service
Silos not found
Make sure that the silo is configured in the <Setup> program, if not, proceedwith the silo configuration as described on pag. 55
PLC: Switched off or disconnectedPLC: Time-OutPLC: Received incomplete stringPLC: Data does not existPLC: Address errorPLC: Security errorPLC: Mode errorPLC: Set errorPLC: Data, contact or area errorPLC: Wrong parameterPLC: Process errorPLC: Command not recognizedPLC: String format errorPLC: BCC error
Check that the connection cables and communication ports are in goodconditions and function properly.
Power failure alarm
Check the main switchCheck the fuses
PLC error n.
Note the error number and contact the Lawer Support Service
PLC: Flat batteryPLC Conveyor: flat batteryPLC Dispensing: flat batteryPLC Load DT11=
Check the PLC battery and if necessary substitute; see the Extra Maintenancechapter
Dispensing: Scale communication time out
Check the scale connection cables
Dispensing: Maximum waiting time for bucket from PLC conveyor (X27)
The system needs a bucket on the conveyor to proceed with the dispensing
USER’S MANUAL
136 SUPERCOLOR
PLC ERROR DIAGNOSTICS
Error messages are represented with an <E> followed by a suffix; see the charthere below:
E. UP
Low voltage: occurs when the intermediate circuit voltage fallsbelow the permissible value. Possible causes are:-input voltage too low or instable-inverter power too low-voltage loss due to incorrect cabling-power supply by generator/transformer breaks down becauseramps are too short
E. OP
Overvoltage: occurs when the intermediate circuit voltage risesabove the permissible value. Possible causes are:-input voltage too high-disturbance voltage at the input-delay ramps too short
E. OCOvercurrent: occurs when exceeding the peak current or with aground fault
E. OL
Overload: occurs when the load is too high >150% for more than30s, > 130% for more than 2 min. or > 110% for more than 5min. Possible causes are:-error or overload in the application-inverter incorrectly dimensioned-motor incorrectly wired
E.nOL
Cooling down phase completed: After error <E. OL> you must waitfor a cooling down timeThis message appears after the cooling down phase is completed.The error can be reset.
E. OH
Overheat: occurs when the inverter temperature >70°C. Possiblecauses are:-insufficient cooling-surrounding temperature too high-ventilator clogged
E.dOH
Ext.Overheat: occurs when external temperature changes. Possiblecauses are:-resistor on terminals OH/OH > 1650 Ohm-motor overload-cables interrupted
E.nOHNo Overheat: Internal or external temperature errors do not occuranymore. Error <E. OH> or <E.dOH> can be reset.
E.L SF
Current limit resistor error: Current limit resistor not bridged,occurs for a short time during the turn on phase and is resetimmediately. If the error message remains the following may bethe cause:-incorrect or input voltage too low-high loss in the supply line-brake resistor incorrectly connected-braking module defective
USER’S MANUAL
137 SUPERCOLOR
Maintenance
Maintenance operations which require knowledge of the procedures andobservance of the safety regulations, must be done by skilled personnel whohave been authorized and approved by the company that uses the plant.Maintenance personnel must carefully read through the instructionspreviously described in “Guidelines to safe machine usage” before operatingon the machinery for maintenance reasons. Please observe the followingdirections.
READING THE TECHNICAL DOCUMENTATION
It is the customer’s responsibility to ensure that operations such as maintenance,inspection and assembly are done by qualified personnel, who prior to working withthe machine must carefully read the technical manual in all it’s parts. Specialattention must be applied to the safety measures and warning signs. The plantstructure or any part of it must not be modified without the constructors consent.
LAWER remains at the customers complete disposal should any further assistancebe needed.
USER’S MANUAL
138 SUPERCOLOR
Routine maintenanceSupercolor is equipped with devices that limit as far as possible product dispersion,technical criteria has been adopted to avoid forming ignition sources such as:
Grounding the electrostatic flow through appropriate conductors and sparkfree materials.
The dispensing group can limit the motor breakdown torque afterprolonged strain in order to avoid overheating.
A continuous ventilation system inside the Supercolor housing avoids theformation of dangerous dust concentrations.
The vacuum loading device transfers the product directly from thepackages therefore no spilling is possible.
To remove dust deposits, clean the scale trolley at least once a week. Once amonth clean the aspiration ducts that convey the dust to the filters and removedust deposits. Clean products accidentally spilt during loading operations and makesure no dust deposits can be formed due to malfunctions.
For trouble free and safe maintenance operations, a MAINTENANCE ANDSPARE PARTS MANUAL has been issued for qualified maintenance personnel. Inthe following section of this chapter you will find a copy of a section of theMaintenance and Spare parts manual.
USER’S MANUAL
139 SUPERCOLOR
Safety measures to adopt when using the machineINFORMATION AND TRAINING
Machine, maintenance, installation and inspection personnel must have thenecessary qualification for each specific job. The customer must declareresponsibility, competence and control of the personnel. If the workers do not havesufficient knowledge for operating the machine, the necessary measures must betaken to provide training. Training can be provided by the Constructor atcustomer’s request. It is the customer’s responsibility to convey to machineworkers all usage and instruction manuals obtained by the Constructor and toensure that workers fully understand the instructions.
PPE (PERSONAL PROTECTIVE EQUIPMENT)
When indicated, use the appropriate personal protective equipment.
Use of PPE is determined by the type of product used, the worker must adopt thecorrect PPE according to the indications recommended by the safety or warningsigns and also follow the instructions given by the Competent Medical Officer basedon the results of atmospheric testing done in the working ar.
Personal Protective Equipment must be looked after and substitutedwhen damaged
GUARDS AND SAFETY DEVICES
Do not remove or tamper with the machine protection devices.
SAFETY AND HEALTH LABELS
Observe all indications by the warning/safety signs displayed on the machinery.
MACHINE START UP
Before machine start up, check that no workers are present in potentiallydangerous areas.
USER’S MANUAL
140 SUPERCOLOR
Residual and Behavioural regulationsWhen using machinery, it is necessary to provide the correct informationconcerning the risks and how to avoid them.
RISK OF SLIPPING AND FALLING
On the floor by the machine, it is possible that the process of loading orunloading products, or lubricating oils that have been used for maintenancereasons, may spill on the floor therefore causing a serious risk of slipping. It isnecessary to keep the floor around the working area clean of any oil stains byusing the appropriate absorbing materials. Protective footwear with rubbersoles must always been worn in and around the working area.
RISK OF CUTTING
When manually moving he containers, care must be taken to wear protectivegloves to avoid being cut by any sharp edges that may be present.
RISK OF DUST INHALATION
For all working operations inside the housing and in particular loading andcleaning operations, it is necessary to give the workers information regardingthe product they are working with so that the proper precautions can beadopted. Provide the company doctor with an accurate report stating thetypes of products used so that a pollution survey can be made. Wearprotective clothing and respiratory mask. To remove dust use aspirationmethods only, do not blow the dust. For this purpose a cleaning station isavailable equipped with an aspirator
RISK OF ELECTRIC SHOCK
The machine is powered by two different voltage phases, 380 Volt three-phase and 220 Volt single-phase, which is in compliance with the Electricalpower regulation standards. Before powering, check the integrity of theelectrical panel or cabinet, including the power cables and doors. If any ofthe above listed elements should present signs of damage call the companymaintenance staff.
RISK OF CRUSHING
USER’S MANUAL
141 SUPERCOLOR
Buckets in movement on the conveyor may injure fingers or hands. Keephands away from the conveyor when in movement.
Buckets that are accidentally dropped when handling, may cause feet injury,use protective footwear with reinforced lining.
USER’S MANUAL
142 SUPERCOLOR
Ordinary maintenance
Plant maintenance must be done by qualified personnel who has received theinstructions by a LAWER technician on how to proceed with the variousoperations.Before starting maintenance operations make sure to cut off electricity byputting the main switches (of all the electrical panels) to the OFF position.Wear the appropriate personal protective equipment.
IMPORTANT
SWITCHES
To avoid accidental powering, block the main switch with a lock or use thewarning sign "DO NOT OPERATE men at work " making sure to thread thesign string through the blocking hole.
To work inside the electrical panel cut off powerto the computer as well by using the appropriateswitch.
Before starting any operations use the appropriate energy instruments to verify ifthe power has been cut off.After having isolated the plant from the power source. Check that there is noresidual power.Discharge any residual energy that may cause dangerous risks.
USER’S MANUAL
143 SUPERCOLOR
After start up and testing, the technicians sent by the Constructor LAWER S.p.A.,will deliver to the plant supervisor, the keys and tools for opening the electricalpanel of the housing etc. which must be kept in a safe place away from the plant
Keep the electrical cabinets, panels and machine protection deviceslocked. Do not use empty spaces as storage units.
Any protection panel or device that is removed for maintenancereasons MUST be replaced before starting the plant.
USER’S MANUAL
144 SUPERCOLOR
ROUTINE CONTROLS
To guarantee efficiency and durability, it is necessary to control the machine andit’s components. Hereunder you will find a list of main controls to carry outexplaining when and how to execute them.
WEEKLY MAINTENANCE
Clean the Supercolor scale
Clean the dispensing devicediaphragm
Check that no foreign matter hasbeen accidentally introduced withthe product (plastic wrapping etc.)
USER’S MANUAL
145 SUPERCOLOR
Clean the conveyor photocells usinga clean dry cloth.
USER’S MANUAL
146 SUPERCOLOR
Discharge any condensation thatmay have formed in the ampulla ofthe compressed air regulationgroup.
Foto ATo clean the aspiration channelsfollow the instructions below:Repeatedly press <F3> until the<F5=Clean> button appears (photoA), then press the <F5> button onthe keyboard to bring the weighingtrolley to the cleaning position(photo B).
Do not blow air for cleaning, but usea means of aspiration
Foto B
USER’S MANUAL
147 SUPERCOLOR
FOUR MONTHLY MAINTENANCE
Check deterioration state and tensionof the MSA and scale trolleytranslation belt; if the belt is loosetense it. Distance between the washerand stop ferrule must be between 2and 5 mm.
Oil the bucket transport chains
Check chain tension and if necessarytense them using the appropriatetools.
USER’S MANUAL
148 SUPERCOLOR
DYESTUFF SILOS
1 Pull out and recover the screws ø M5x25 mm.
2 Pull out the cap in black resin PF21114
3 Pull out the gasket holder K3048
4 Pull out the spring PF21117
5 Pull out and recover the basket PF20002
6
Remove the filter element PF20007 taking care that the dust particlesdeposited on the filter are not dispersed in the environment. Depositthe filter element that has been removed, in an appropriate wastecontainer.Substitute the filtering element and check that the seals are in goodcondition.
Re-assemble all parts in reverse order.
7 Replace the second cartridge as above described
ATTENTION!!: Filtering elements that have been removed
must be disposed of as industrial wastes according to theapplicable regulations in force and therefore the appropriate wastecontainers must be used.
USER’S MANUAL
149 SUPERCOLOR
Extra Maintenance
Substituting the PC fanThe fan inside the Pc guarantees an adequate airflow to the components in order toprevent overheating. For this reason it is necessary that the fan operates correctly.To substitute the fan follow the instructions :Cut off power on the control panel.Open the control panel cover.Remove the fan and replace with the new one.Power the control panel.Check that the new fan is functioning.Replace the cover of the control panel.
SUBSTITUTING THE PLC BATTERY
The battery keeps the memory RAM active when the PLC is not powered. When thebattery is flat an error message “FLAT BATTERY” will appear (see the "UserManual" – PLANT DIAGNOSTICS in function 5) an a led on the PLC in the controlpanel will also signal the flat battery:Led on = Flat batteryLed off = Battery is charged
WARNING
It is important to change the battery within two days when the led comeson.
Do not short circuit, damage or expose the battery to heat sources as thismay cause explosion and fire.
If the battery must be changed after the plant has not been working for along time, power the PLC for at least 1 minute, then switch off.
IT IS NECESSARY TO CHANGE THE BATTERY WITHIN 3 MINUTES.
INSTRUCTIONS TO FOLLOW:
PLC MODEL FP-M:1) Obtain a lithium battery (CR2032).2) Cut power to the control panel.3) Open the control panel cover.4) Localize the battery: on the front of the PLC.5) Remove the PLC protection panel.6) With the help of INSULATED PLIERS remove the battery.7) Check that the poles "+" and "-" of the new battery are clean.8) Place the new battery with the pole "+" facing upwards.9) Replace the cover and power the control panel.10) The ERROR led will be off and the function 5 message will disappear.
USER’S MANUAL
150 SUPERCOLOR
Changing and disposing of lubricants and general chemical productsOperate in compliance with the products “Safety Instructions” for handling anddisposing.Disposing of such chemical products must take place in compliance with the localregulations in force which govern handling and disposal rules.
LUBRICATION
Speed reducers mounted on the plant do not require periodical lubrication controls
MAKE TYPE
ESSO GP grease
CHEVRON CL medium
Lubrication oils
USER’S MANUAL
151 SUPERCOLOR
Demolition and disposal
DEMOLITION
INFORMATION for putting the machine out of service and dismantling.
The silos and any part of the machine that was in contact with the products, mustbe carefully washed to avoid disposing of these parts as hazardous waste materials.
Silos: dispose as plastic material. Oils and lubrication grease: dispose as used oils. Electrical panel, control panel, micro switches, motors etc.: dispose as
electronic waste.
DISPOSAL
Prior to sending the machine parts for scrapping, remove any lubricants anddispose of them according to the local Environment and Heath regulations.Disposal and/or recycling the various dismantled parts must take place incompliance with the local regulations in force which govern recycling and disposalrules.
![PC1864 v4[1] (1).1 Installation Manual.pdf](https://static.fdocuments.in/doc/165x107/577c86ad1a28abe054c22e94/pc1864-v41-11-installation-manualpdf.jpg)
