| Melt Extruder
Control Panel #2 |
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This incorporates the FACTS MINI by FACTS INC
Other systems are
available by facts.
The Facts Mini incorporates a Mitsubishi FX PLC
4 analog ins and 2 analog outputs. The temperature
controller
is a Resotec unit with 10
thermocouple inputs and 10 Heat and
Cool outputs of which only 7 are available for use. Go
figure?
May have something to do with the P.L.C. or the display
panel which
is also a Resotec.
You can click the images to see a larger version. |
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Here you can see the
power distribution contactors and the 10HP
A.C. Closed Vector Drive by IDM
Controls. Which is a relabeled
Yaskawa Drive.
You can also see the Mitsubishi P.L.C.and Resotec unit.
You can click the images to see a larger version. |
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Here you see the nine
Solid State Relays mounted on 3 large Heatsinks.
7 Heat zones from the Mini system and 2 from independent
Fuji PYX4
Temperature controllers.
You can click the images to see a larger version. |
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This is the Resotec
control OIT. |
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Supply
list
Facts
Inc.
P.L.C. with software.(includes Analog modules
and Resotec unit
24VDC Power Supply.
Resotec OIT screen
70Amp current transformer
Automation Direct.
All Terminal Blocks, Fuse Blocks and Din Rail.
Wire Ferrules and lugs
Contactors
Allied
Electronics.
Main power disconnect.
Circuit Breakers (Now available at Automation Direct)
Wire way and covers.
Heatsinks
Wire
Fuses
IDM Controls.
IDM G5+ 10HP Drive.
PG-X2 Feedback Card
Northstar 1024PPR Encoder
10HP Marathon Blue Max Vector Duty Motor.
Butler and Land.
Continental I/O SSR's
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About
this System
This control system was first
electrically designed by me to get the basic electrical
systems required after
reviewing the documentation from Facts Inc.
I then drew up the first electrical prints using Autocad 2000i. After
that I laid out the panel, again using
Autocad, with 1:1 scale drawings of the parts. This
allows me to move things around and find the best fit
and logical layout before any parts are even ordered or
placed on the panels.
After the layout drawings are completed
to my satisfaction I order the parts from my suppliers.
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So
What does it do and how does it work?
This controls a 9 temperature zone melt
extruder.
The original Berlyn Extruder had all of its controls
built into the extruder's body. This was quickly
impossible
to accomplish again with the new controls, which added
many safety and operational features.
The original temperature controllers were old Dial type
Barber Coleman types. They had horrible control
resolution and repeatability. There were 3 Heat and cool
zones and 3 extra heat zones which did not fill our
process needs.
The choice was made to use the Facts Mini extrusion pack
system and to add 2 extra independent temperature
controllers to give us 9 total control zones.
Information about the Mini can be obtained here. 
The drive system was updated to the 10HP A.C. Closed Loop
Vector Drive from the original 5HP DC Drive
which was running at greater than 90% on some products.
The 10HP Marathon motor was smaller in size than the 5HP
D.C. This saved on extra weight that made it
easier to move the extruder around.
The drive gets its run and speed reference signals from
the P.L.C. The drive in turn sends its speed and
load signals back to the P.L.C.
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