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Gefran
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Software
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Applications 1 0 1010
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• Small laboratory extruders 1010
GF PACK
• Extruders for producing compounds
• Extrusion lines for pipes and profiles
• Extrusion lines for plastic films and sheets
EXTRUSION
Characteristics
• Graphics pages dedicated to machines and extrusion
lines
• Dynamic configurability of temperature control zones and
motors
• Management of temperature, current, pressure and
preventive maintenance alarms
• Closed loop for Melt pressure and control of roller
tension
• Management of motors in synch
• Recipes for work parameters and machine parameters
• Configurable trends of process variables
• Exportable historical files
• Weekly programmer for programmed on/off
• Scalability of application on many hardware architectures
• Tested solutions based on Gefran Hardware/Software

Profile
GF_PACK EXTRUSION is Gefran’s solution for complete control of extruders and extrusion lines.
GF_PACK EXTRUSION is supplied as preinstalled software on Gefran HW, within which Gefran has inserted a series of preconfigured
functions.

GF_PACK EXTRUSION consists of standard hardware and software modules:

• Operator interface with terminals and Gefran Industrial PCs, 6.5”, 10.4”, 12.1” and 15” colour monitors and touch screen
• Gefran GILOGIK II I/O modules with digital and analogue inputs and outputs and temperature sensors
• Temperature control modules, Gefran Geflex single loop and multiloop, with on-board SSRs
• Application software preconfigured and preloaded on operator interface

GF_PACK EXTRUSION contains all typical functions for managing an extruder and an extrusion line.
 gf_pack extrusion

Functions
» Thermoregulation
• Max 96 configurable temperature control zones
• Division of temperature control zones into groups
• Parameterisation and configuration of temperature control loop from
dedicated application pages
• Distributed temperature control with Geflex controllers
• Centralized temperature control with GILOGIK II (R-TC8 modules)
• Pages with trend graphics on all enabled temperature zones, with acquired
setpoint/value trend

» Motors control and management

• Up to 16 preconfigured motors (extrusion, hopper, mixer, vacuum pump, drag,
cut, auxiliary)
• Dedicated pages for motors Start/Stop, with status feedback, from operator
panel
• Preconfigured synchronism function activated from operator panel
• Automatic management of gear ratio for motors enabled for synchronism
• Dedicated pages for scaling analogue input and output values
• Pages with trend graphics for all acquired analogue variables
• Configuration of up to 4 setpoints on analogue input
• Up to 4 closed loops for speed control

As default, machine movement control signals are managed with analogue values
(-10 / +10 Vdc).
For use of drives in Fieldbus (CANopen) connection, reference values can be
managed with read/write on the bus.

» Other functionality
In addition to machine control functions, the packet offers:
• Recipe management (exportable via USB port)
• Printing of configurable parameters and pages
• Videocamera via Ethernet (Netcam) for real time remote control of system
“hot points”
• Tele-assistance via modem and Internet
• Complete diagnostics of hardware (PLC) with function state and information
on version of configured I/O modules
• Multilanguages management with UNICODE support (Italian, English, French,
German, Chinese, etc.)
• Password level management for access to pages or change of data items
• Easy access to system from local and remote by Ethernet (centralisation,
diagnostics, upgrade)
• Availability of a user setting log
• Quality control of defined parameters
• Programmed system autostart
• Counters for managing maintenance of significant data, configurable
runtimes

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The following diagram shows a film extrusion line, highlighting its main functions with specific reference to use of devices in the
Gefran catalogue.

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Supply
GF_PACK EXTRUSION is uspplied on a DVD, with which you can install the data and information needed to programme an extrusion
line.

The installation DVD contains the following:

• User manual with information on functions and operation of pages used to manage an extrusion line
• Configuration manual with information on source software structure and instructions for possible changes. A list of available
data/variables and of standard functions is included
• General electrical diagram for connecting the operator panel, I/Os and possible connection in case of distributed temperature
control
• Graphic utility for guided configuration of structure for passage to various application pages. The utility is also used to configure
access levels for page call

To programme and implement special functions, the development PC requires the configuration tools contained in Gefran Automation
Builder (G.A.B.).
By using the programming languages you can change the standard functions contained in GF_PACK EXTRUSION to adapt them to
specific machine needs.

The information and data on the DVD are subject to a user license that is inserted with the supply.

GF_PACK EXTRUSION is available in various configurations according to the type

and complexity of the application:

EXTRULABO
• Application software packet for small/medium extruders
• Dynamic pages configurable for up to 16 temperature control zones, up to 3
motors in synch, 1 fast control loop

EXTRUCOMP
• Application software packet for estruders
• Dynamic pages configurable for up to 24 temperature control zones, up to 10
motors in synch, 1 fast control loop

EXTRUPIPE
• Application software packet for extruder lines
• Dynamic pages configurable for up to 48 temperature control zones, up to 16
motors in synch, up to 4 fast control loops

The various configurations (EXTRULABO, EXTRUCOMP and EXTRUPIPE)

are matched with one of the terminals of the GF_VEDO ML, GF_VEDO HL or
DIGISTAR II series equipped with the VxWorks operating system.
The selected terminal is supplied with the OS and selected operative packed
preinstalled.

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Technical Data
The automation architecture required for the GF_PACK EXTRUSION solution calls for:

Operator interface based on the following terminals of the GF_VEDO ML series

Model GF_VEDO ML 65 GF_VEDO ML 104 GF_VEDO ML 121 GF_VEDO ML 150

Type 262K TFT colors

Dimension 6.5” 10.4” 12.1” 15”
VGA SVGA SVGA XGA
Resolution
(640x480) (800x600) (800x600) (1024x768)
Processor Type Geode LX900 / Frequency 600MHz / Core x86
2 x Ethernet 10/100 Mbps
4 x USB 2.0 Host
Standard 1 x RS485
2 x PS2
1 x TF keyboard

Operator interface based on the following terminals of the GF_VEDO HL series

Model GF_VEDO HL 121 GF_VEDO HL 150

Type 262K TFT colors

Dimension 12.1” 15”
SVGA XGA
Resolution
(800x600) (1024x768)
Processor Type Intel Pentium Celeron - Intel Celeron Mobile / Frequency 600 - 1500MHz
2 x Ethernet 10/100 Mbps
2 x USB 1.1 Host
Standard 1 x RS485
2 x PS2
1 x TF keyboard

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 gf_pack extrusion

GILOGIK II series remote I/O modules with GDNet (Ethernet) connection to operator interface

R-D/A4
Code R-E16 R-U16 R-EU16 R-A/D8 R-MA6 R-TC8 R-C3
R-D/A8
Characteristics,
Channels number
24Vdc PNP digital inputs 16 8
24Vdc 2A
16 8 16
PNP digital outputs
mA, V analog inputs,
potentiometer, strain gauge 8 6
(16bit)
mA, V analog outputs
4-8 6
(16bit)
Temperature inputs
8
(18bit) (J, K)
1 3
Counter inputs
(5KHz) (250KHz)

All Input / Output signals are optically isolated.

Geflex controllers

Model GFX GFXTERMO4 GFX4

1 channel (hot/cold) 4 channels (hot/cold) 4 channels (hot/cold)

Characteristics Solid state relay embedded Solid state relay command Solid state relay embedded
DIN rail mounting DIN rail mounting DIN rail mounting

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 gf_pack extrusion

Distributed control using Geflex controllers, with serial Modbus connection to operator interface.

GF_VEDO

GEFLEX

Modbus RS485

GILOGIK II

Distributed solution

Centralized control using R-TC8 modules in the GILOGIK II series, with GDNet (Ethernet) connection to operator interface.

GF_VEDO

GILOGIK II
R-TC8 temperature control

Centralized solution

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Order code

PRECONFIGURED SOLUTIONS

Application software package for small/medium extruders. Dynamically configurable up to 16

F039561 EXTRULABO temperature control loops, up to 3 motor control loops with synchronization and 1 fast closed
control loop.

Standard application software package for extruders. Dynamically configurable up to 24

F039562 EXTRUCOMP temperature control loops, up to 10 motor control loops with synchronization and 1 fast closed
control loop.

Application software package for complete extrusion lines. Dynamically configurable up to

F039563 EXTRUPIPE 48 temperature control loops, up to 16 motor control loops with synchronization and 4 fast
closed control loops.

Note:
The EXTRULABO, EXTRUCOMP, EXTRUPIPE, packages must be ordered together with a DIGISTAR II series
industrial PC with VxWorks O.S.

SOLUTIONS FOR SYSTEM INTEGRATORS

Open application software package for complete extrusion lines. Dynamically configurable up
to 96 temperature control loops, up to 30 motor control loops with synchronization and 10
F039564 EXTRUSYS fast closed control loops. Includes SEVEN programming environment for PLC and HMI, and
a 3 days technical training in our laboratories in Provaglio d’Iseo (Italy). (travel and lodgings
expenses excluded).

GEFRAN spa
Via Sebina, 74
25050 Provaglio d’Iseo (BS) - Italy
Ph. +39 030 9888.1 - Fax +39 030 9839063
Email: info@gefran.com - Web: www.gefran.com DTS_GF_PACK-EXTRUSION_1209_ENG