gefran I3 Series Manual de usuario
1
80175G_MAN_I3-IE-IN-IX_I7_11-2018_ENG
I3 - IE - IN - IX - I7
INSTRUCTION MANUAL
cod. 80175G Edit. 11/2018 - ENG
ATTENTION!
This manual is an integral part of the product,
and must always be available to operators.
This manual must always accompany the
product, including if it is transferred to another user.
Installation and/or maintenance workers MUST
read this manual and scrupulously follow all of the
instructions in it and in its attachments.
GEFRAN will not be liable for damage to
persons and/or property, or to the product itself, if the
following terms and conditions are disregarded.
The customer must respect trade secrets.
Therefore, this manual and its attachments may
not be tampered with, changed, reproduced, or trans-
ferred to third parties without GEFRAN’s authorization.
This document is the property of GEFRAN and may not be reproduced or transferred to third parties without authorization.
280175G_MAN_I3-IE-IN-IX_I7_11-2018_ENG
1. General informations pag 3
2. Mechanical dimensions pag 3
3. Installation and positioning on the machine pag 4
3a. Installation seat pag 4
3b. Torquing the sensor pag 7
3c. Connecting amplifier pag 8
3d. Wiring and calibration pag 9
3e. Electrical output connections pag 10
3f. Maintenance pag 13
3g. Transport, storage and disposal pag 13
4. Electronic features and procedures pag 14
4a. Autozero function pag 14
4b. NE21 and NE43 specifications compatibility pag 15
5. Autocompensation effect on IMPACT series pag 15
6. Sensor technical specifications pag 16
6a. IN series pag 16
6b. I3 series pag 17
6c. IX series pag 18
6d. IE series - IE Performance Level “c” series pag 19
6e. I7 Performance Level “c” series pag 20
7. Safety Manual for Performance Level “c” sensors pag 21
8. Relay application notes pag 33
CONTENTS
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80175G_MAN_I3-IE-IN-IX_I7_11-2018_ENG
1. GENERAL INFORMATION
This manual applies to IN-I3-IX-IE series and to IE - I7 performance level “c” series produced by Gefran spa,
via sebina 74-25050 Provaglio di’Iseo - BS- Italy.
1.1 General information
This manual must be kept near the equipment for easy reading and consultation.
It must be read, understood, and strictly follow in order to avoid and prevent accidents and/or malfunctions.
Gefran will not be liable for any injury to people and/or damage to property deriving from disregard of
this manual.
1.2 Copyright
Any re production of this document, even partial or for internal use, requires Gefran’s approval.
1.3 Correct use
Gefran Melt pressure sensors with amplified or non-amplified electrical output are designed and built
to measure the pressure and temperature variable of melted plastic at different temperatures according
to the filling fluid used.
The correct temperature range is: 350°C.
If the sensors are used as a safety component in compliance with the Machinery directive, it’s
necessary to read carefully the “Safety Manual” in annex.
2. MECHANICAL DIMENSIONS
For the mechanical dimensions keep as reference the product datasheets or Gefran website www.gefran.com
480175G_MAN_I3-IE-IN-IX_I7_11-2018_ENG
3. INSTALLATION AND POSITIONING ON THE MACHINE
3a - Installation seat
TECHNICAL DATA
Extrusion processes require very high temperatures. Extrusion pressure can be checked by means of espe-
cially designed transducers.
The IMPACT series sensors are suitable for pressure measurements with high temperature and are based
on the piezoresistive technology.
Following advice for extending the sensors lifetime.
a) Avoid shocks and abrasions to the in contact diaphragm. Protect the transducer with its cover each time
you remove it from its seat.
b) The seat must be prepared perfectly and with appropriate tools in order to respect the depth and axiality
of the holes and tapping.
Pay particular attention to the coaxiality of the holes to the thread, because diaxialities greater than 0.2 mm
will break the transducer during assembly.
It is essential that hole depth guarantee the absence of chambers or air pockets in which extrusion material
may be trapped.
To prevent contact with the extrusion screw or with tools used to clean the extrusion chamber, the front
diaphragm must not extend from the inner wall of the extruder.
c) Before assembling the transducer in machines already in operation, make sure that the housing is clean.
Remove any residual with the suitable cleaning device.
d) The transducer should be removed only with the machine empty (without pressure) but still hot.
e) The transducer should be cleaned with solvents for the material being processed.
Any mechanical action on the contact diaphragm modifies its operation and could break it.
The installation seat has to be realized:
Incorrect working or shape of the side can result in properties out of specification, bad behaviour
or damage to the sensor.
The side should be clean and without any polymer residual.
D1 1/2-20UNF M18x1.5
D2 .313 ±.001” .398 ±.001”
[7.95 ±0.02mm] [10.10 ±0.02mm]
D3 .454 ±.004” .634 ±.004”
[11.53 ±0.1mm] [16.10 ±0.1mm]
D4 .515” [13mm] .790” [20mm]
minimum minimum
A.225” [5.72mm] .240” [6.10mm]
minimum minimum
B.17” [4.3mm] .16” [4.0mm]
maximum maximum
C.75” [19mm] .99” [25mm]
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80175G_MAN_I3-IE-IN-IX_I7_11-2018_ENG
Drilling kit
A drilling kit with formed tools for drilling, reaming and tapping is available to facilitate correct preparation of
the assembly seat. The assembly seat must be perfect to assure proper transducer function and long lifetime.
Drilling kits are available in the following versions: KF12, KF18.
Drilling procedure
1) To drill hole (D4) up to a distance from the hole equal to the sum of (A+B+C) (tool 3).
2) Make the pass through hole (D2) by the tool 1.
3) To create the seal seat at a distance from the hole equal to dimension (A) (tool 4).
4) With a roughing tap, create threading 1/2-20UNF-2B (recognizable from the greater number of threads
beveled at the mouth) (tool 5).
5) With a finishing tap, go over threading 1/2-20UNF-2B up to a distance from the bottom equal to the sum
of (A+B) (tool 6).
6) To ream the hole (D2) with reamer (tool 2).
Installation seat check
The dimensions of the assembly seat have to be checked after preparation and before the transducer
installation.
Use dummy plug SC 12/18 as follows:
1) Coat the end of the rod with the appropriate ink.
2) Lubricate the threaded part to prevent friction.
3) Insert the dummy plug and screw it fully down.
4) Remove the rod and examine it.
With the exception of 45° surfaces, the ink should be intact on the entire surface.
DRILLING TOOL KIT
CORRECT SEAL
contact surface
CORRECT INSTALLATION
VERSION
CODE KF12 KF18
THREADING
TYPE 1/2-20UNF-2B M18x1.5
1Ø 7.6 Ø 9.75
2Ø 7.95 Ø 10.1
3Ø 13 Ø 20
4Ø 11.5 with
pilot guide
Ø 16 with
pilot guide
51/2-20UNF-2B
roughing
M18x1.5
roughing
61/2-20UNF-2B
finishing
M18x1.5
finishing
WRONG
WRONG
WRONG
CORRECT
680175G_MAN_I3-IE-IN-IX_I7_11-2018_ENG
TRANSDUCER INSTALLATION
Installation procedure
1) Make sure the drilling procedure has been realized correctly. If the sensor is installed in a previously used
hole, make sure the hole is completely clean and free of any plastic residual.
2) Remove the protective cap from the sensor top.
3) Lubrificate the thread with non-grip grease such as Neverseez (Bostik), or C5A (Felpro), or equivalent.
4) Insert firmly the sensor into the hole, first by hand and then with a wrench, 1/4 turn at a time.
Recommended torque: 40 Nm.
NOTE: Please pay particular attention to the sensor installation when it’s provided in its fixed mechanis con-
figuration.
In this case, during the clamping phase any misalignment. Has tube avoided, otherwise a possible interferen-
ce of the sensor mechanical coupling can occur.
Removal (Figure 1)
To remove the transducer from its seat and carry on the working process, dummy plugs with identical mecha-
nical dimensions are available.
The dummy plugs differ by type of threading; max pressure range is 2000 bar for all rods.
The dummy plugs are available in the following versions: SC12 1/2-20UNF seat - SC18 M18x1,5 seat
Brackets (Figure 2)
Models with flexible sheaths require the housing precise fixing. Suitable fastening brackets (SF18) are recom-
mended.
Remember that the fastening point must be vibration-free (vibrations affect the measurement) and that tem-
peratures must not exceed the maximum temperature range for the strain gauge housing (as stated on the
sensor technical sheet).
Extruder starting
Bring the system to working temperature with the transducer installed and without any pressure applied.
Wait until all the material is at the same temperature to prevent the transducer damage by semi-solid material.
Seat cleaning & Cleaning tool
As mentioned in the notes, the seat must be cleaned before the transducer installation.
The cleaning tool is a hard metal cutting tool specially designed to remove working materials residuals.
Recommended procedure (Figure 3)
The following procedure must be implemented with the material in a fluid condition.
1) Insert the tool in the seat and screw down the cutting rod (normally a 1/4 turn at a time).
2) Turn the pilot cutter clockwise until there is no resistance to cutting.
3) Repeat the procedure until the seat is completely clean.
For constructive reasons, the maximum torque applicable to the cutter is 15 Nm (1.5 Kgm).
If the hole occlusion requires higher torque for removal, use the drilling kit and follow the recommended
procedure.
The cleaning tool is available in the following versions: CT12 1/2-20UNF seat - CT18 M18x1,5 seat.
Figure 2Figure 1 Figure 3
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80175G_MAN_I3-IE-IN-IX_I7_11-2018_ENG
ORDER CODES FOR TOOLS and ACCESSORIES
CLEANING TOOL KIT
1/2-20UNF 12
M18x1,5 18
CT
MOUNTING BRACKET SF 18 DUMMY PLUG
1/2-20UNF 12
M18x1,5 18
SC
DRILL KIT
1/2-20UNF 12
M18x1,5 18
KF
3b - Torquing the sensor
Screw the sensor after checking the correct shape of the side.
Hold the flexible part while screwing the jam bushing.
For safety operations at least 6 pitch of the jam bushing must be screwed into the hole.
The torque must be 40 Nm.
880175G_MAN_I3-IE-IN-IX_I7_11-2018_ENG
3c - Connecting amplifier (only for modular versions)
Fix the flexible sheath to the machine. Take care not to fix the sheath to parts heated at over than
220°C.
Screw the electrical cable connector to the electronics and switch on the sensor.
Wait 60 seconds before starting to operate the transducer.
To disconnect the electronics from the primary sensor, take care to handle the two connectors next to the
red points and not to force the disconnection.
The electronics must be connected to the primary part by aligning the 2 red points on each connector.
Take care not to force the connectors together: check the correct aligning of the 2 red points.
Remark:
In modular versions the decoupling between the electronics and the primary element is not
allowed.
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80175G_MAN_I3-IE-IN-IX_I7_11-2018_ENG
3d - Wiring and calibration
Connections
The sensors have to be connected as shown in the diagram on the next page.
To obtain a higher immunity from field noise, connect the cable shield to the female connector case on sen-
sor side.
Calibration procedure
Bring the system to the working temperature with the transducer installed and connected to the measure-
ment instrument without any pressure applied.
The measurement chain connected to the transducer is calibrated as follows:
1) To reset the offset on the instrument by eliminating the thermal drift with the autozero function. With the
sensor installed and the extruder at working temperature, wait until the temperature itself is stable, with
a possible variation of +/- 1°C. Consequently Autozero can be activated.
This delay gives the system time to recognize and compensate all the signal drifts caused by tightening
and temperature.
Additional Autozero activations could be run once the temperature stability is reached, with +/- 1°C of
possible variation.
2) Calibrate the instrument and have it display the calibration value shown on the transducer data plate
(80% of full scale). With the external autozero function the calibration procedure is not feasible.
3) If the instrument does not exactly indicate zero, repeat points 1) and 2).
In this way, the instrument is calibrated to give the exact indication in the chosen engineering unit.
10 80175G_MAN_I3-IE-IN-IX_I7_11-2018_ENG
3e - Electrical output connections
IE series
I3 series
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4
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