Moog IMI220-145D001 Manual 

Revision History Document Revision Hardware Software Rev. Author Date Preliminary Preliminary Preliminary Lstrabla - nfrassine 6th Dec 2004 1.02 1.02 1.02 rfacchi - nfrassine 31st Aug 2005 MAN145-UM-A02A-EN IMI220-145A002 2.01 rfacchi - nfrassine 5th Oct 2005 MAN145-UM-A03A-EN IMI220-145A003 3.01 sverga - nfrassine 29th May 2006 MAN145-UM-A03B-EN IMI220-145A003 3.01 - 3.02 sverga - nfrassine June 2006 MAN145-UM-B01A-EN IMI220-145B001 3.04 - 3.05 4.01 - 4.02 - 4.03 - 4.04 – 4.05 sverga - nfrassine June 2010 MAN145-UM-C01A-EN IMI220-145C001 5.01 nfrassine July 2012 MAN145-UM-D01A-EN IMI220-145D001 6.07 sverga – mamoruso July 2017 Revision: Number of the current revision application inside in the PLC. Revision Date: Date of the current revision application inside in the PLC. MASS Release: MASS version related to the actual application. Firmware: Firmware release; can differ from MASS release

MAN145-UM-D01A-EN 3 1 Installation. 1.1 Installation Overview. Since there are many makes, models and vintages of blow moulding machines it is impossible to give specific instructions as to the mounting, wiring and plumbing schemes to use. Different machines have different requirements that the installer must ascertain before beginning the actual physical installation of the system. A careful examination of the machine and some thoughtful planning beforehand will usually produce a good, serviceable installation. There are some suggestions that hopefully will make your installation smooth and provide many years of trouble free operation. It is recommended that, if space is available on the machine, the programmer and its various electrical components be mounted in a separate enclosure. While it might be possible to mount these components in the machine’s main electrical cabinet, quite a bit of electrical “noise” and heat is usually generated there. While the Parison Controller was designed with some degree of tolerance for these conditions it must be remembered that it is, in essence, a computer. To minimize any detrimental effects on the system that can be sometimes caused in such an environment, it may be easier and wiser to circumvent any problems before they are created. The old adage “An ounce of prevention…” can definitely apply here. If using a separate enclosure or not, thoughtful layout of components is quite important. Remember, for future troubleshooting it is important to consider accessibility to terminals to allow for voltage readings and the ability to reach fasteners so components can be removed and replaced. Cable routing should also be considered to prevent stretching of cables, straining of connections, pinch points and sharp edges that could damage a wire or cable. Transducer and valve cables should be run through a “Seal-Tite” type of flexible, liquid tight conduit. Although it is much faster and easier to run them over the machine unprotected, enclosing them in conduit provides protection against physical damage as well as protection against insulation breakdown due to airborne chemical. Cabling should also be run away from sources of heat (extruders, accumulators, and heater bands) and strong electrical fields (motors, transformers, etc.). The programmer can be mounted anywhere convenient to the operator station but should be located away from areas where it could be damaged by falling objects or flooded by broken coolant or hydraulic lines. Cable lengths to valves and transducers should be kept as short as possible to minimize line loss and signal corruption, but long enough to provide movement of machine members for unrestricted operation and machine maintenance. When routing cables it is wiser to avoid possible noise sources or areas of potential damage than to minimize cable lengths.

1.2 Hydraulic Installation. Hydraulic installation involves the mounting and plumbing of filters, servo-valve manifolds, cylinders, etc. If the programmer is being installed as a replacement for another programmer all the necessary components should already be in place. If not, the following suggestions are offered:  Do not reuse old hose, pipe fittings or tubing. Contamination in old plumbing is almost impossible to effectively remove and can cause problems in future servo-valve reliability. Old fittings that have been painted and assembled with old thread sealing compounds will not only introduce contamination, but are harder to work with and can contribute to added installation time.  Before assembling any new plumbing, inspect it carefully to insure that there are no metal filings or foreign matter left over from cutting or assembly. Now is the best time to clean it out, before it can get into the hydraulic system.  Replace the hydraulic oil or have it analyzed by a reputable lab. Depending on your maintenance program, the oil may not have been checked for some time. Now is a good time to perform any oil-related maintenance BEFORE the servo-valves are installed.  If you are replacing the oil remember to filter it as you pump it into the machine. New oil right from the refinery is sometimes the dirtiest oil in the shop. 1.3 Hydraulic Filtration. Clean oil is the key to reliable hydraulic system operation. Dirt, silt and sludge in the system increase operating temperatures by decreasing heat exchanger efficiency and create excessive wear on pumps, directional and relief valves and valve seats. Contamination breeds contamination by wearing hoses and other hydraulic components from the inside. Moog servo-valves are designed to operate with an ISO code of 14/11. While this may be lower than what you are accustomed to, the benefits of improved filtration will show up not only in increased servo-valve life but will help to reduce premature machine wear and the frequency of oil related failures. Moog offer a full line of filters and filter systems with element ratings starting at 3 microns, flow-rates from 10 to 100 gallons per minute, and operating pressures as high as 3,000 psi. There are a number of good filter systems available and, even if a Moog filter is not chosen, it is strongly urged you employ one of these other filter systems on your machine. High-pressure filter assemblies should be plumbed between the high-pressure hydraulic supply and the “P” (pressure) port of the servo-valve manifold(s). Plumbing from the filter outlet to the “P” port should be completed with steel tubing or pipe. If the machine employs a hydraulic accumulator to maintain stability in the machine’s hydraulic system, the filter should be installed after the accumulator and before the valve manifold(s). 1.4 Servovalve Manifolds. Servo-valve mounting is accomplished with the use of manifolds for each head. These manifolds allow for easy removal of the valves to facilitate system flushing or valve replacement in the event of failure.

MAN145-UM-D01A-EN 5 Moog servo-valves used in blow moulding Parison control are most often internally piloted devices. This means that the manifolds used will have 4 ports that connect to the machine’s hydraulic system: “P” port is the incoming high-pressure supply to the valve. “T” or “R” port is the servo-valve return to tank. “A” or “C1” port is one of the controlled ports. This should plumb to one end of the programming cylinder. “B” or “C2” port is the other controlled port. This should plumb to the other end of the programming cylinder. Some manifolds may be supplied with an additional fifth port labeled “X”. These manifolds are designed for use with hydraulic systems capable of supplying an independent source of pilot pressure. If the need for this port is uncertain, contact Moog Field Engineering for additional information. There is no specification as to which controlled port should plumb to which end of the programming cylinder. The following suggestions are offered concerning plumbing:  Try to keep the overall length of the controlled port lines as close to equal as possible.  Keep the servo-valve manifold as close to the programming cylinders as possible. The shorter the length of the control lines, the more accurate position control will be.  Try to plumb all the valves the same way. (All “A” ports to the top of the cylinders or all “B” ports to the top of the cylinders.) This will reduce confusion and make wiring easier later. It is EXTREMELY IMPORTANT that plumbing between the controlled ports of the manifolds and the programming cylinders be completed with solid tube or pipe. Do Not Use Hoses To Make These Connections! Hydraulic supply up to the filter and the return lines from the servo-valve manifolds can be done with hose if desired. In a great number of cases, the solid hydraulic lines that connect the controlled ports to the programming cylinders will provide enough support for the servo-valve and manifold combination. If the machine is prone to excessive vibration it would be wise to fabricate some type of bracket to support the servo-valve assembly. A typical servo-valve and manifold installation is depicted below: Figure 1