iNOEX GmbH

Maschweg 70
D- 49324 Melle
Tel.:+49(0)5422-60507-0
Fax: +49(0)5422-60507-101
info@inoex.de
www.inoex.de

Instruction manual

IGS - Hardware -
SAVEOMAT

Translation of the original instruction manual

SAVEOMAT IGS - Hardware -

Preface

 Before commissioning of the iNOEX automation system, the Instruction manual must
be carefully read.

 It is important that the contents of the present Instruction manual is understood by all
persons who work with the system. All information contained in the Instruction manual
must be observed.

 This applies in particular to the safety instructions. Observation of these instructions

helps to avoid accidents, disturbance and defects.

 This Instruction manual was established with utmost care and to the best of our
knowledge. We checked its correctness with the best possible care. Nevertheless,
errors or mistakes cannot be completely excluded.

 This Instruction manual corresponds to the design of the product at the date of issue.
Changes in technology, equipment and technical data are reserved by the manufacturer.

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Content
1 System description ........................................................................................................................6
2 Important information ....................................................................................................................7
2.1 Instruction manual accessibility .............................................................................................7
2.2 How to proceed in the event of problems ..............................................................................7
3 Safety rules .....................................................................................................................................8
3.1 Basics .....................................................................................................................................8
3.2 Appropriate use of the SAVEOMAT IGS ...............................................................................8
3.3 User training requirements .....................................................................................................9
3.4 Safety instructions for assembly/disassembly .......................................................................9
3.4.1 Electrics/Electronics ................................................................................................9
3.4.2 Permissible loss of operating quality in the event of faults .....................................9
4 Unpacking the equipment ...........................................................................................................10
4.1 Packaging ............................................................................................................................10
5 Technical data ..............................................................................................................................11

5.1 SAVEOMAT IGS ..................................................................................................................11

5.2 Layout IGS Master board .....................................................................................................12
5.2.1 24V power supply ..................................................................................................12
5.2.2 Ethernet-interface for connection of B&R terminal with VNC Viewer ...................13
5.2.3 Ethernet interface for BDE and remote service ....................................................13
5.2.4 USB Interface ........................................................................................................13
5.2.5 CANopen interface to the 15“ Terminal ................................................................13
5.2.6 CAN2 interface for the dosing motors ...................................................................13
5.2.7 RS232 interface ....................................................................................................13
5.2.8 RS485 interface ....................................................................................................14
5.2.9 Joystick..................................................................................................................14
5.2.10 Display...................................................................................................................14
5.2.11 Status LEDs ..........................................................................................................14
5.3 Display with Joystick ............................................................................................................15
5.3.1 Configuration and status .......................................................................................15
5.4 Status informationen of the gravimetric board .....................................................................16
5.5 Configuration of the gravimetric board .................................................................................19
5.6 Configuration of the gravimetric ...........................................................................................21
5.6.1 Fast-Start...............................................................................................................23
5.6.2 Integration .............................................................................................................23

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5.7 ABZ ......................................................................................................................................24

5.8 Update ..................................................................................................................................25
5.9 Jumper of IGS Master board ................................................................................................27
5.10 Layout of the IGS board .......................................................................................................28
5.10.1 Assignment of DIP switches..................................................................................29
5.10.2 Assignment of plug connector / LED .....................................................................30
5.10.3 7-segment display .................................................................................................31
5.10.4 Meaning of LEDs ...................................................................................................32
5.11 Layout of the ABZ board ......................................................................................................33
5.12 Connection conditions ..........................................................................................................35
5.12.1 Installation location/Conditions..............................................................................35
5.12.2 Connections ..........................................................................................................35
5.12.3 Electrical documentation .......................................................................................35
6 Basic settings ...............................................................................................................................36
6.1 Setting the nodal address for RS 485 / Address offset of IP address ................................36
6.1.1 Setting the node address for CAN ........................................................................36
7 Recording the screw speed.........................................................................................................37
7.1 Entering the number of pulses per screw revolution ............................................................38
7.1.1 Entering the hundreds value .................................................................................38
7.1.2 Storing the hundreds value ...................................................................................38
7.1.3 Entering the tens value .........................................................................................39
7.1.4 Storing the tens value ...........................................................................................39
7.1.5 Entering the units value .........................................................................................39
7.1.6 Storing the units value...........................................................................................39
7.1.7 Transferring the value entered to the processor memory .....................................40
7.2 Clearing the mass memories ...............................................................................................40
7.2.1 How to clear the mass memory:............................................................................40
8 Faults, diagnostics and maintenance ........................................................................................41

8.1 Functional test ......................................................................................................................41

8.1.1 Check the following points: ...................................................................................41
8.2 Error messages ....................................................................................................................42
8.3 Other potential faults ............................................................................................................43
8.4 Maintenance .........................................................................................................................44

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9 Service ...........................................................................................................................................45
9.1 Basic calibration of the hopper scales with SAVEOMAT IGS .............................................45
9.2 Calibration of the hopper scales via WEB – Interface .........................................................47
9.3 Checking the load cell ..........................................................................................................49
9.4 Total reset ............................................................................................................................50
9.5 Total reset of all data............................................................................................................50
10 Appendix .......................................................................................................................................51
10.1 Technical data ......................................................................................................................51
10.2 Spare parts ...........................................................................................................................52
11 Table of figures .............................................................................................................................52
12 List of tables .................................................................................................................................52

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1 System description
The SAVEOMAT IGS system can be used to record and control mass throughput and the amount of
material consumed during the extrusion process.
The measured values are recorded directly on the weighing hopper before being processed and made
available on higher-level automation systems such as SAVEOMAT, AUREX or third-party systems via
interfaces or bus interface modules.
Radial stripper slide (RAS)

SAVEOMAT IGS M1
SAVEOMAT IGS D6

RS 485
CAN
Ethernet

Figure 1: Overview SAVEOMAT IGS

The SAVEOMAT IGS guarantees the required functionality and system reliability. Moreover, its
decentralised and self-optimising intelligence ensures reliable results when controlling mass
throughputs and the dosing of material components.

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2 Important information
This instruction manual assumes that users have the relevant technical qualifications and that they
have either already been trained or are being trained in SAVEOMAT IGS operation. It contains
relevant information on commissioning, operation, maintenance and your personal safety.
The instruction manual has been designed to help you use the system safely and efficiently.

2.1 Instruction manual accessibility

For safety reasons, a copy of the instruction manual must be made available to the user at his or her
workstation.
It is also advisable to keep a copy in a dry, clean room.

Should the iNOEX automation system get passed on to a third party, it is your responsibility
to include the original version of this instruction manual (see designation – Original
Instruction Manual – on the cover sheet) when you pass on the equipment itself. The
instruction manual is an important part of the system.

2.2 How to proceed in the event of problems

If you encounter any issues that cannot be resolved on the basis of this documentation, please contact
the specialists at iNOEX GmbH immediately.

iNOEX GmbH
Maschweg 70
49324 Melle, Germany
Tel.: +49(0)5422-60507-0
Fax: +49(0)5422-60507-101

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3 Safety rules
3.1 Basics
The SAVEOMAT IGS automation system from iNOEX left the factory in perfect condition and has
been designed to ensure high levels of technical safety. The system reflects the current state of the art
and meets the applicable health and safety regulations.

However, using it incorrectly or misusing it will result in a number of risks

- To the life and limb of users or third parties
- To the system itself and other physical assets of the operating company
- In terms of making efficient use of the system

3.2 Appropriate use of the SAVEOMAT IGS

The SAVEOMAT IGS system has been specifically developed for the purpose of recording the
throughput of free flowing granules in accordance with DIN EN ISO 6186 within the context of
continuous extrusion processes.

The basic version offers the following options:

 Recording of process variables

- Mass throughput (lb/h)
- Material consumption (lb)
- Screw speed (rpm)
- Feed rate (lb/revolution)

 Output of all process and system variables

- Via RS 485 interface
- Via Ethernet
- Via CAN interface

 Display of system status and error messages on the attached boards

- Using high-luminosity LED 7-segment display and LEDs

Appropriate use also means:

- Heeding the safety instructions and complying with the safety rules referred to in this
instruction manual
- Complying with the servicing and maintenance instructions in this manual

The use of the equipment for any other purpose or use beyond the scope described here
constitutes inappropriate use and may result in serious injury or damage to the equipment.
The manufacturer, iNOEX GmbH, assumes no liability for any injuries or damage arising
from such instances of inappropriate use (or similar) of the SAVEOMAT IGS.
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3.3 User training requirements

The personnel that operate the automation system or carry out work in connection with it must be
authorised to do so by the operating company and must have received the relevant training. They
must be capable of identifying potential hazards, interpreting such hazards correctly and also
preventing them.
This includes being aware of what the accident prevention regulations have to say, knowing what first-
aid measures to take and knowing about local life-saving equipment.

Inspection, maintenance and repair work may only be carried out by technical experts who
have received product-specific training and who have the basic mechanical and electrical
engineering background, both in terms of qualifications and experience.

3.4 Safety instructions for assembly/disassembly

In applications on dosing stations, the SAVEOMAT IGS evaluation electronics are integrated into the
relevant wiring boxes.

3.4.1 Electrics/Electronics

You must always remember to disconnect the power supply before working on
the electronics of the SAVEOMAT IGS.

The user is responsible for ensuring that no contact can be made with the system, with its attachments
or with its actuating components while it is energised.
System assembly, disassembly and maintenance work must only be carried out when the system is
de-energised; otherwise there is a potential risk of serious injury or even death.

3.4.2 Permissible loss of operating quality in the event of faults

If the SAVEOMAT IGS is used in an environment contaminated by electromagnetic interference, its

operation may be impaired in the following way:
- Fluctuations in the measuring accuracy when recording process variables

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4 Unpacking the equipment

On receipt of the consignment, the packaging must be checked externally for basic signs of damage. If
the packaging is damaged, special care should be taken when opening it. The contents should be
inspected for signs of damage.

The system must not be put into operation if it has been damaged! For an
assessment of any damage, please contact iNOEX immediately.

4.1 Packaging
To ensure an adequate level of protection during shipping, this product was packaged appropriately
with due care and to protect it against impacts.
The equipment may only be returned in its original packaging/if wrapped in appropriate additional
packaging.

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5 Technical data
The SAVEOMAT IGS consists of the master board, IGS board and the ABZ board details of which are
provided below.

5.1 SAVEOMAT IGS

Interconnection of the master and IGS boards and the ABZ board.

Master board IGS Slave board ABZ board

Figure 2: Top view of SAVEOMAT IGS electronics

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5.2 Layout IGS Master board

CANopen interface to the 15“ terminal

CAN2 interface for the dosing motor

USB
Ethernet for RS 232
BDE and RS 485
remote
service
Joystick

Ethernet to
the B&R
terminal Display

Status LEDs

24V power supply

Figure 3: Top view IGS Master board

5.2.1 24V power supply

The IGS master board is connected to the 24V power supply by a triple-pole connector (pin
assignment from left to right: +, -, GND).

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5.2.2 Ethernet-interface for connection of B&R terminal with VNC Viewer

By default, the IP-Address of the Ethernet interface for connecting the B&R terminal is set to
192.168.100.21. The IP-Address can be configured through the display under „SETTING / IP-ETH0“.
At dosing stations the manual control with display is connected to the interface Eth0.

5.2.3 Ethernet interface for BDE and remote service

By default, the IP-Address of the Ethernet interface for BDE and remote service is obtained from a
DHCP-Server. The IP-Address can be configured through the display under „SETTING / IP-ETH1“, if
“no” is entered in „SETTING / DHCP-ETH1“.

5.2.4 USB Interface

An update of the software, the operating system, and the software of the manual control can be done
through the USB interface. The TGZ-file the system shall be updated with must be located in the root
directory of the USB –stick so that the update function of the display recognizes and shows it.

5.2.5 CANopen interface to the 15“ Terminal

The baudrate of the CANopen interface (default:250Baud) is configured through the display under
„SETTING / BAUDRAT CAN0“. At this interface the 15” terminal or if available further ATUM stations
are connected. (Remark: When using the IGS master board in a WH station, the WH IPC is connected
here). The termination resistor is enabled by the jumper located on the left side beside the interface.
(The termination resistor must be enabled when the CAN bus cable ends at this connector and no
other termination resistor follows).

5.2.6 CAN2 interface for the dosing motors

The baudrate of the CAN2 interface (default: 125Baud) is configured through the display under
„SETTING / BAUDRAT CAN1“.
At this interface the outgoing CAN bus cable for the first dosing motor is connected. The return cable
is plugged to the CAN2-distributor. As the CAN bus connection to the dosing motors always starts at
this interface the termination resistor on the left side beside the interface must always be enabled.

5.2.7 RS232 interface

The RS232 interface can be used for a BDE connection or for connecting a manual control without
display via a serial cable.

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5.2.8 RS485 interface

Through the RS485 interface process data can be read and written with the UKI-Protocol. The
corresponding termination resistor can be enabled with the jumper on the right side beside the
interface.

5.2.9 Joystick

See chapter Fehler! Verweisquelle konnte nicht gefunden werden. Fehler! Verweisquelle konnte
nicht gefunden werden..

5.2.10 Display

See chapter Fehler! Verweisquelle konnte nicht gefunden werden. Fehler! Verweisquelle konnte
nicht gefunden werden..

5.2.11 Status LEDs

Next to the display are LED arranged with the following meaning:
Table 1: Meaning Status LEDs

OK System running

Warning  battery low

 version mismatch

 MMC lifetime <10%

Error Indicates that error messages are available.

RDD Flashes during initialisation

The status LED RDD is flashing as long as the operating system is loaded. After the operating system
including device tree and bit stream has been loaded properly the LEDs RDD and OK are lit up
permanently. If an error occurs during loading, the LED error will shine instead of LED OK.
If the battery power is too low, or the version of device tree and bit stream are incompatible, or the
MMC lifetime is <10% the LED warning will be lit up permanently instead of the LED OK.

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5.3 Display with Joystick

The menu on the display of the master board is operated by using the joystick located next to the
display. By moving the joystick in the appropriate direction, the menu items are sequentially displayed.
The bottom line of the submenus displays the current value of the respective option.

5.3.1 Configuration and status

By pressing the joystick the change mode is enabled if available. The value of the option is then
highlighted and can be changed with moving the joystick up and down. In case of complex
configurations (e.g. time, date, IP addresses) the following sub-options can be called by moving the
joystick to the right. Pressing the joystick accepts and saves the changed configuration.

To abort a change, move the joystick to the left. A joystick movement to the left also leads back to the
parent menu.

You can switch between menu items which are explained below.

Info

Settings

Update

ATUM

ABZ

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5.4 Status informationen of the gravimetric board

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5.5 Configuration of the gravimetric board

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The settings IP, netmask, gateway and DNS of interfaces eth0 or eth1 can only be changed if no
DHCP is active for the respective interface.
If DHCP is active, the current values are displayed and not the ones stored in EEPROM. With active
DHCP on at least one interface, the DNS address allocated via DHCP is displayed, and not the one
stored in the EEPROM.

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5.6 Configuration of the gravimetric

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5.6.1 Fast-Start

Fast start-up of the components is enabled with DIP switch 4. Then the weigher hoppers of type TW20,
TW60 and TW200 report “throughput good” already after two measurement cycles instead of five. If a
controller mode is set, the component will be controlled to the set point.

5.6.2 Integration

The function „Integration“ contains following gravimetric peculiarities:

 After starting the ATUM board the feeding rate of the station at IGS 1 is the default feeding rate of
the extruder.

 The feeding rate of the station is calculated by the SAVEOMAt task. If the total feeding rate of a
component is changed by more than 5%, the calculation of the feeding rate of the station will be
locked for 20 sec. During a ramp the calculation of the feeding rate of the station is locked for the
ramping time + 5 sec. For the time the feeding rate of the station is locked the feeding rate of the
main component is not measured but calculated. This function can be enabled separately through
cell Zs 2105

 After starting the ATUM board the recipe SM-Index is not zero, but the last recipe SM-Index is
retained.

 To start-up a component from zero in mode2, 3, 4 or 6 no ramping time must be set anymore. If
no ramping time is set, the component will be started with a default ramping time of 10 sec. (Zs
2056).

 For the throughput control only the controller mode 3 is supported for main- and side component.

 For the weight per meter control extruder only the controller mode 2 is supported for main- and
side component.

 The maximum rpm is only calculated newly in a range of +/-10% around the transmitted nominal
speed.

 The TX-PDO5 does not only transmit the analog voltage U-Soll of the component but also the
mass throughput of the whole station.

 Controller mode 1 controls the weight per meter of the whole station by the haul-off. The side
components must be operated in controller mode 2 in this case (weight per meter control extruder).

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5.7 ABZ

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5.8 Update

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5.9 Jumper of IGS Master board

Jumper 1 Jumper 2 Jumper 3

Figure 4: Jumper of IGS Master board

Table 2: Jumper IGS master board

Description
Jumper 1 Set: terminating resistor CAN 0 active
Not set: terminating resistor CAN 0 not active
Jumper 2 Set: terminating resistor CAN 1 active
Not set: terminating resistor CAN 1 not active
Jumper 3 Set: terminating resistor RS 485 active
Not set: terminating resistor RS 485 not active

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5.10 Layout of the IGS board

There are 2 IGS for 2 stations implemented on each IGS board. These have been colour-coded in the
overview below. The components of IGS 1 are shown in blue and those of IGS 2 are shown in red.

1.10
1.11
1.12
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
2.10
2.11
2.12
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9

LED 10
LED 11
LED 12
LED 1
LED 2
LED 3
LED 4

LED 9

LED 13
LED 14
LED 15
LED 16
LED 5
LED 6
LED 7
LED 8
Dip S1.1
Dip S1.2
J1

Dip S2.1
Dip S2.2
S1

J2
S2
7-segment
7-segment

display
display

LED 2

LED 2
green
LED 1

LED 1
green

red

S1
red

S1

4.1
4.2
4.3
4.4
4.5
4.6
3.1
3.2
3.3
3.4
3.5
3.6

Figure 5: Overview of the IGS board

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Figure 6: Top view of the IGS slave board

Dimensions: SAVEOMAT IGS slave board (W*H) 70*108 (2,8* 4,25 (inch))

5.10.1 Assignment of DIP switches

Table 3: Assignment of DIP-switches

J1 PWM instead of analog output for the motor of component 1

J2 PWM instead of analog output for the motor of component 2

S1
DIP1.1 Component 1: Calibrate , pre-set of pulses per revolution, delete mass storage
DIP1.2

S2
DIP2.1 Component 2: Calibrate, pre-set of pulses per revolution, delete mass storage
DIP2.2

S1 Total reset station 1, if S4 pressed during system start

S2 Total reset station 2, if S3 pressed during system start

Dip S1.2 Advanced operation mode for component 1

Dip S2.2 Advanced operation mode for component 2

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5.10.2 Assignment of plug connector / LED

Table 4: Assignment of plug Connector / LED

IGS 1 / Component 1

IGS 2 / Component 2
LED / Component 1

LED / Component 2

Function

1.1 2.1 24 V

1.2 1 2.2 9 Digital input for speed pulses

2 2.3 Digital input for material sensor above weigher inlet

1.3 10
(0 = material available, 1 = no material available) (option)

1.4 3 2.4 11 Digital input for manual operation, motor speed plus

1.5 4 2.5 12 Digital input for manual operation, motor speed minus

1.6 5 2.6 13 Digital output for RAS open/closed

1.7 6 2.7 14 Digital output for dosing motor enable (1 = motor enable)

1.8 7 2.8 15 Digital output for motorised potentiometer plus (for PWM)

1.9 8 2.9 16 Digital output for motorised potentiometer minus (for PWM)

1.10 2.10 0V

1.11 2.11 Analog output 0 – 10 V for motor speed setting

1.12 2.12 0V

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Component 1

Component 2
IGS 1

IGS 2
Function

3.1 4.1 5V

3.2 4.2 5V

3.3 4.3 Analog input A (for differential signal)

3.4 4.4 Analog input B (for differential signal)

3.5 4.5 GND

3.6 4.6 GND

5.10.3 7-segment display

The IGS board features a 7-segment display for each station. The segments are assigned as follows:
Table 5: 7-segment display

- Normal operation

1 Analog/digital converter error

2 Data loss

3 Radial stripper slide not closing

4 Radial stripper slide not opening/no material

5 Speed = 0

6 RAS in manual mode

7 Scales in lower power range

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5.10.4 Meaning of LEDs

Table 6: Meaning LED

Meaning
Bedeutung

Stand still
Stillstand / screw change
/ Schneckenwechsel

Weighing
Verwiegen

Filling
Befüllen

Calming
Beruhigen

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5.11 Layout of the ABZ board

Connector

1.10
1.11
1.12
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
X1

2.10
2.11
2.12
Connector
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
X2

LED 10
LED 11
LED 12
LED 1
LED 2
LED 3
LED 4

LED 9

LED 13
LED 14
LED 15
LED 16
LED 5
LED 6
LED 7
LED 8
7 Segment

7 Segment
Display 1

Display 2

Figure 7: Top view ABZ board

Dimension: SAVEOMAT ABZ board (B*H) 70*108

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Connector pin assignment

Connector Connector
X1 X2

1.1 24 V 2.1 24 V
1.2 Bleeding 2.2 Roll change
1.3 Short ramping 2.3 Input 6
1.4 Wall thickening 2.4 Signal A
1.5 Input 4 2.5 Signal B
1.6 Alarm lamp 2.6 Output 5
1.7 User Output 1 2.7 Output 6
1.8 User Output 2 2.8 Motor potentiometer +
1.9 User Output 3 2.9 Motor potentiometer -
1.10 0V 2.10 0V
1.11 - 2.11 -
1.12 0V 2.12 0V

Meaning of the LED‘s

LED
1 Bleeding
2 Fast ramping
3 Wall thickening
4 In 4
5 Alarm
6 User Alarm 1
7 User Alarm 2
8 User Alarm 3
9 Roll change
10 Roll change
11 Impuls A
12 Impuls B
13 Out 5
14 Out 6
15 Motor potentiometer +
16 Motor potentiometer -

7-Segment display 1: Counter display (the increments of the encoder are counted and used for
diagnostic)
7-Segment display 2: Display of the version number

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5.12 Connection conditions

5.12.1 Installation location/Conditions

- Ambient temperature max. 131 °F

- Degree of protection IP 54

5.12.2 Connections

- Power supply 24 V  10% DC

- Current consumption 0.5 A (without digital inputs and rotary pulse encoder supply)

Wiring for the SAVEOMAT IGS electronics is already in place in the wiring box for the dosing station.
The prewired connections include:
1. Connection: Load cell electronics
2. Connection: Electronics shut-off device
3. Connection: Dosing motors (secondary components)

For details of how to connect the power supply, interface and throughput display, please refer to the
electrical documentation.

- Cable material
The following cables should be used for connecting the electronics:
Table 7: Cable material

Connection Cable type Miscellaneous

details
IGS interface (RS 485) LIYCY 2 x 2 x 0.25 mm2 shielded/twisted
pairs
IGS/power supply unit 24 V H 05 V V5 - F 3G 0.75 mm2 Shielded
IGS/digital display (option) LIYCY 2 x 0.5 mm2 Shielded
IGS/alarm lamp (option) LIYCY 2 x 0.5 mm2 Shielded
IGS/inductive proximity switch PVC 3 x 0.35 mm2 Shielded
Equipotential bonding cable H07 V-K 1 x 10 mm2

5.12.3 Electrical documentation

(Please refer to the electrical documentation that has been enclosed with this instruction manual.)

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6 Basic settings

The power supply must be disconnected before carrying out any work on the
electronic components of the SAVEOMAT IGS.

The SAVEOMAT IGS system is self-optimising, i.e. the system parameters are constantly adapted
during operation in line with the prevailing situation.
However, the following must be ensured prior to initial start-up:
 The node address must be set

 The terminating resistor in the RS 485/CAN network: Should be set at last participant.
(Master Board, Jumper 3)

 The terminating resistor in the CAN network: Should be set at last participant.

6.1 Setting the nodal address for RS 485 /

Address offset of IP address
In a bus system it is necessary that each participating unit can be identified.
Therefore each participant (dosing station) receives a nodal address. Permissible nodal addresses are
from 1 to 63; double assignments are not permitted.
The node address is setting on the SAVEOMAT master board over the function ATUM „Number of
IGS“ at the display.

6.1.1 Setting the node address for CAN

The setting of the CAN node address is done on the SAVEOMAT master board over the function
ATUM „Number of IGS“ at the display. The node address for the RS485 and the CAN interface is set
in the submenu “Number of IGS” for both interfaces and thus is always the same for both interfaces.

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7 Recording the screw speed

The SAVEOMAT IGS system has a speed-synchronised feature for recording mass throughput. The
number of encoder pulses/screw revolution can be set directly on the IGS board as described below or,
if you are using a higher-level control system such as SAVEOMAT or AUREX, via the control system’s
user interface.

Switch 1
Switch 2
IGS 1
DIP 1.1 / 1.2 IGS 2
DIP 2.1 / 2.2

Figure 8: Overview of the IGS board – Top view

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7.1 Entering the number of pulses per screw revolution

The setting of the number of pulses per screw revolution (as described in the following) is
exemplary for IGS 1. The handling for the other IGS is identical to the corresponding
switches and DIP switches.

Before starting to enter the values both DIP-switches have to set to „OFF“.

To enter the number of pulses per screw revolution, proceed as follows:

1. Switch on the SAVEOMAT IGS.

2. Set DIP 1.1 to ON.

 "A" will appear on the LED display.

3. Press the S1 input key.

 "b" will appear on the LED display (entry of screw pulses).

4. Set DIP 1.2 to ON.

 "b" will change to "0" on the LED display.
 Wait until the LED indicates that it is ready for you to enter the hundreds value
(it will display the letter “d”).

7.1.1 Entering the hundreds value

To enter the hundreds value, proceed as follows:

1. Press and hold down the S1 input key until the LED display switches from “d” to “0”.
 Wait until the “0” character appears on the LED display.
 Press the S1 key repeatedly to select a hundreds value of between 0 and 9.

7.1.2 Storing the hundreds value

1. Press and hold down the S1 input key until the selected number on the LED display changes to the
letter “d”.
 After a brief delay, “d” will appear.
This means that the hundreds value has now been stored.

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7.1.3 Entering the tens value

To enter the tens value, proceed as follows:

1. Press the S1 input key.

 “E” will appear on the LED display to indicate that it is ready for you to enter the tens value.

2. Press and hold down the S1 input key until the LED display switches from “E” to “0”.
 Wait until the “0” character appears on the LED display.
 Press the S1 key repeatedly to select a hundreds value of between 0 and 9.

7.1.4 Storing the tens value

1. Press and hold down the S1 input key until the selected number on the LED display changes to
the letter “E”.
 After a brief delay, “E” will appear.
This means that the tens value has now been stored.

7.1.5 Entering the units value

To enter the units value, proceed as follows:

1. When you press the S1 input key, the number “1” will flash on the LED display to indicate that it is
ready for you to enter the units value.
2. Press and hold down the S1 input key until the LED display switches from “1” to “0”.
 Wait until the “0” character appears on the LED display.
 Press the S1 key repeatedly to select a units value of between 0 and 9.

7.1.6 Storing the units value

1. Press and hold down the S1 input key until the selected number on the LED display changes to
the letter “d”.
 After a brief delay, “d” will appear.
This means that the units value has now been stored.

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7.1.7 Transferring the value entered to the processor memory

1. Set DIP 1.2 to Off.

 If a valid entry has been made, the display will switch from “b” to “0”.
 After a brief delay, “b” will reappear.

2. Set DIP 1.1 to Off.

This means that the IGS has accepted the value set and is now ready for operation again.
In case that before calibration the DIP switch 1.2 was set, it now has to be set to „ON“ again.

If an invalid entry has been made: “b” will switch to “1”.

If this happens, set DIP 1.1 to On and repeat the process.

7.2 Clearing the mass memories

The SAVEOMAT IGS uses two independent memories to keep track of the total mass of the material
being fed into the extruder by constantly adding new mass values. These memories can be accessed
via the digital data interface, as well as cleared. However, it is also possible to clear the memories on
the SAVEOMAT IGS itself. This process is described below using the first station as an example.

Before you start entering any values, both Dip switches have to be set to OFF.

7.2.1 How to clear the mass memory:

1. Set DIP 1.1 to ON.

 “A” will appear on the 7-segment display.

2. Press the S1 input key twice.

 "C" will appear on the segment display.

3. Set DIP 1.2 to ON.

 “C” will change to “0” on the 7-segment display.
 Wait until the “0” character appears on the 7-segment display.

4. Set DIP 1.2 to OFF.

 “C” will change to “0” on the 7-segment display.

5. Set DIP 1.1 to OFF.

 The mass memories will have now been cleared.

In case that before calibration the DIP switch 1.2 was set, it now has to be set to „ON“ again.

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8 Faults, diagnostics and maintenance

8.1 Functional test
Switch on the SAVEOMAT IGS electronics. "-" will appear on the LED 7-segment display. This
indicates normal operation.

8.1.1 Check the following points:

1) Green LED and red LED must be illuminated (scales ready).

2) The power supply LED (green) must be illuminated.

Now start up the extruder.

3) After a while, the shut-off device will close.

4) Green LED and red LED will go out.
5) LED D6 (IGS 1) / (IGS 2) will flicker in time with the speed pulses.
6) After a while, red LED will go out, although green LED will remain illuminated. The weighing
procedure will commence.

Once the above points have been successfully checked, the system is ready for operation.

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8.2 Error messages

Error messages are indicated on the LED 7-segment display:
Table 8: List of errors/system messages

Display Meaning Action

- Normal operation -
1 Analog/digital converter not Check connecting cable;
working check load cell wiring on SAVEOMAT IGS;
check load cell

2 Data loss Recalibrate SAVEOMAT IGS;

re-enter the number of pulses per revolution; if
necessary, re-enter system settings via interface; if
problem still occurs, replace battery

3 Shut-off device not closing Check compressed air;

check cable connection

4 Shut-off device not opening, no Check material inlet for bridging; release solenoid
material valve lock; check hopper scales fill time

5 Screw speed failure, although Check cable connection between inductive proximity
extruder is running switch/SAVEOMAT IGS;
check operating distance (0,04 — 0,12 inch);
check connection on SAVEOMAT IGS

6 Shut-off device in manual “Shut-off device in manual mode” system status

mode triggered by switch function (only relevant for dosing
stations)

7 Scales in lower power range Inadequate change in weight during weighing (delta
digit < 80); check screw speed

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8.3 Other potential faults

Table 9: List potential faults

Fault Action
7-segment display not on  Check power supply
 Check 24 V supply cable
 Check power supply unit
 Check fuse

Displayed throughput and actual throughput  Check that the load cell is free to move and
differ significantly, wildly fluctuating check stop screw gap
throughput  Recalibrate scales
 Check load cell
 Check the pulses per revolution setting and
correct if necessary
 Check operating distance of inductive proximity
switch (should be: 0,04 — 0,12 inch)

As of a certain screw speed, only half the  Check the operating distance of the inductive
throughput is displayed proximity switch.
 Ensure that only one pulse is actually being
generated per mark; hence, do not use hexagon
socket screws.
 Ensure that the max. permissible frequency of 2
kHz is not exceeded.

Material has a tendency to form clumps  Increase the size of the impact cone discharge
gap; the fastener allows changes to be made in
5 mm increments
 In extreme cases, the impact cone can be
removed and a reducing insert* can be fitted on
the collecting hopper; however, this will impair
the accuracy of the system.
* Note:
The decision to use a reducing insert is
generally made at the project planning stage. If
necessary, the reducing insert can be ordered at
a later date.

Rough ground stock See above

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Fault Action
Shut-off device not opening,  Immediate remedy: Switch off voltage, valve has
no material, but no error message to open in the de-energised state
 If the problem occurs again, recalibrate the
scales
 Check gap between stop screw/load cell
 Check load cell

SAVEOMAT IGS not sending any data via the Check cable connection;
interface check node address setting

SAVEOMAT IGS is refusing to run, although Carry out a total reset (see Section 9.4);
no error message is being output and there then recalibrate the device
are no problems in terms of the power supply,
speed sensing, etc.

8.4 Maintenance
Electronics
The SAVEOMAT IGS electronics are maintenance-free.

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9 Service
9.1 Basic calibration of the hopper scales with SAVEOMAT IGS
The SAVEOMAT IGS system has already been calibrated at the factory. The basic calibration
procedure will only need to be repeated if error message 2 (“Calibration data lost”) appears on the 7-
segment display or is output on the monitor.
The extrusion system will need to be shut down and the hopper scales emptied before calibration can
be performed.

The system has already been calibrated at the factory. If you do need to repeat the
calibration procedure yourself, the electronics will need to be switched on at least half an
hour before starting the procedure. Make sure that the separating plate has been installed in
the weighing hopper. Do not move the weighing hopper during the calibration procedure; it
must remain in place.

If you are using a higher-level system such as SAVEOMAT or AUREX, you can use this
system to calibrate the hopper scales. The calibration procedure is described in the relevant
instruction manual.

Before carrying out the calibration procedure, check and make a note of the DIP switch
settings so that you can set them back to their original status once calibration (step 9) is
complete.

Before starting to enter the values both DIP-switches have to be set to „OFF“.

Once the hopper scales have been emptied, proceed as follows:

1. Open the electric box

2. Set DIP 1.1 to ON.
-> "A" will appear on the 7-segment display.

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Switch 1
Switch 2
IGS 1
DIP 1.1 / 1.2 IGS 2
DIP 2.1 / 2.2

7 – segment display

Figure 9: Overview of the IGS board – Top view

3. Set DIP 1.2 to ON.

-> "A" will change to "0" on the display.
-> Wait until "0" appears on the display.

4. Press and hold down the S1 input key until “0” changes to "-".
The computer will now store the empty weight of the hopper scales.
-> Wait until “0” appears.

5. Give the S1 input key one short press.

-> "2" will appear on the display.

6. Attach standard weights:

Attach a 1 kg (2,2 lb) ( different weights for different hopper sizes, see table calibration weight)
standard weight to each side (left and right) of the hopper scales, making sure that the hopper
outlet does not come into contact with the collecting hopper.
Press and hold down the S1 input key until “2” changes to "-".
The computer will now store the standard weight.
-> Wait until "2" appears on the display.

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7. Set DIP 1.2 to OFF.

-> If the calibration factor has been determined correctly, "A" will change to "0".
-> After a brief delay, "0" will appear.
-> If the calibration factor has not been determined correctly, "A" will change to "1".
If this happens, repeat the calibration procedure.
Remove the standard weights.

8. Set DIP 1.1 to OFF.

-> Calibration is now complete.
-> "-" will appear on the display.

9. If DIP 1.2 was set prior to calibration, it will need to be set to “ON” again now.

10. Switch the SAVEOMAT IGS off and then back on.

9.2 Calibration of the hopper scales via WEB – Interface

To calibrate the weigher hopper via the WEB - Interface the SAVEOMAT IGS D has to be connected
to a PC via Ethernet (Web browser and Java, from version 1.7 has to be available).
The set IP address has to be entered to the browser. The following SAVEOMAT IGS home page will
be opened.

Open the WEB – service page and push the button „Calibrate“.

Figure 10: Home WEB – service page

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1
3
5
6

Lastly calibrated component

Determined empty weight t

Determined calibration factor

Figure 11: WEB – service page calibrate

1. Insert number of component which you want to calibrate (MC=1, SC1=2, etc.)

2. Empty the weigher hopper.

3. Enter 1.

4. Put the weight in the weigher hopper. (Make sure that the hopper outlet does not come into
contact with the collecting hopper.)

5. Enter the weight in column.

6. Enter 1.

Calibration is done for this component.

Table 10: Table calibration weight

TW 20 ca. 1 kg = 2,2 lb

TW 60 – TW 750 ca. 2 kg = 4,4 lb

TW 1000 und TW 1400 ca. 5 kg = 11 lb

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9.3 Checking the load cell

The component tolerances result in a certain degree of spread as far as the calibration factors are
concerned.
Experience has shown this spread to be somewhere in the region of +/- 3% (see table below).
Hopper scales for monoextrusion, coextrusion and dosing stations:
Table 11: Standard calibration factor

Type Vol. [l] Load cell Standard Min. empirical value Max. empirical value
calibration
factor
[g/digit]
TW 20 1 3 kg 0.044 0.043 0.048

TW 60 3 5 kg 0.076295 0.074006 0.078584

TW 200 6 10 kg 0.15259 0.14801 0.15717

TW 350 10 20 kg 0.30516 0.29602 0.31434

TW 500 15 20 kg 0.30516 0.29602 0.31434

TW 750 25 30 kg 0.45777 0.44404 0.47150

TW 1000 35 50 kg 0.7762 0.760 0.780

TW 1400 45 75 kg 1.1444 1.09 1.17

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9.4 Total reset

Following a processor crash (caused, for example, by considerable fluctuations in the mains voltage),
you may need to clear the processor’s internal memory completely.

Example for IGS 2:

1. Switch off the mains voltage.
2. Press button S2 on the IGS board and keep down.
3. Switch the mains voltage back on.
4. Release button S2, if on the 7 segment display on the slave board is counting up
5. The SAVEOMAT IGS 2 will now report error “2” (data loss).

Now re-calibrate the hopper scales and re-enter the number of pulses per screw revolution. Following
calibration, switch the mains voltage off and then back on (once).

9.5 Total reset of all data

Following a processor crash (caused, for example, by considerable fluctuations in the mains voltage),
you may need to clear the processor’s internal memory completely.
This is done via the function “Total reset” under ATUM at the display of the master board.

Now re-calibrate the hopper scales and re-enter the number of pulses per screw revolution for each
component!
The number of components and the CAN start address have to be entered via SAVEOMAT IGS D
service page.
For acceptance of all data the supply voltage has to be switched off and on again. The IPC sends the
calibration data of all funnel weighers to the IGS 2015.

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10 Appendix
10.1 Technical data
Interfaces RS 485 (UKI protocol) two-wire with connectable
terminating resistor
CAN with connectable terminating resistor
Ethernet

Digital inputs Four electrically isolated inputs

(per station) Input voltage 24V  20%
Input current 8 mA  20%
Max. input frequency 2 kHz
Min. pulse length 0.25 ms
Additional 2*24 V connection for rotary pulse encoder

Digital outputs Four electrically isolated outputs

(per station) Output voltage 24V
Max. output current 500mA, short-circuit proof

Analog input Input for strain gauge load cells, 4-wire technology
(per station) Bridge resistance 350 ohms
Nominal characteristic value 2 mV/V
Bridge supply voltage 5V, R > 170 ohms

Analog/digital converter 24-bit resolution

Analog output Output voltage 0 - 10V,

Load resistance >2000 ohms
12-bit resolution
Electrically isolated from processor on 24V side

Supply Voltage 24 V DC  10% (master board)

Current consumption 0.5 A (maximum configuration)
Electrical isolation of 24V supply in relation to
SAVEOMAT IGS board

Ambient temperature Max. 131°F

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10.2 Spare parts

Table 12: List spare parts

Item Designation iNOEX no.

1.1 IGS Slave board 1136135202

1.2 IGS Master board 1136135030

1.3 Digital I/O board 1136135101

Please also note the spare part list of the electrical documentation

11 Table of figures
Figure 1: Overview SAVEOMAT IGS ...................................................................................................... 6
Figure 2: Top view of SAVEOMAT IGS electronics .............................................................................. 11
Figure 3: Top view IGS Master board ................................................................................................... 12
Figure 4: Jumper of IGS Master board .................................................................................................. 27
Figure 5: Overview of the IGS board ..................................................................................................... 28
Figure 6: Top view of the IGS slave board ............................................................................................ 29
Figure 7: Top view ABZ board ............................................................................................................... 33
Figure 8: Overview of the IGS board – Top view .................................................................................. 37
Figure 9: Overview of the IGS board – Top view .................................................................................. 46
Figure 10: Home WEB – service page .................................................................................................. 47
Figure 11: WEB – service page calibrate .............................................................................................. 48

12 List of tables
Table 1: Meaning Status LEDs .............................................................................................................. 14
Table 2: Jumper IGS master board ....................................................................................................... 27
Table 3: Assignment of DIP-switches .................................................................................................... 29
Table 4: Assignment of plug Connector / LED ...................................................................................... 30
Table 5: 7-segment display ................................................................................................................... 31
Table 6: Meaning LED ........................................................................................................................... 32
Table 7: Cable material ......................................................................................................................... 35
Table 8: List of errors/system messages ............................................................................................... 42
Table 9: List potential faults ................................................................................................................... 43
Table 10: Table calibration weight ......................................................................................................... 48
Table 11: Standard calibration factor .................................................................................................... 49
Table 12: List spare parts ...................................................................................................................... 52

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