Measuring and control technology for the high-voltage cable production

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Content
Introduction 1 CSS 2 CSS 2 for a continuous purity inspection of the XLPE insulation in HV and EHV power cables 2 ULTRATEMP 6000 Ultrasonic temperature measurement system for XLPE-insulated medium and high voltage cables 3 CV-INTUBE 6000 Diameter measurement in steam and nitrogen CV-lines 2 3 12 ECOCONTROL 600/1000/2000/6000 Premium processor systems for the display and control of production data 4 20 11 REMOTE/DISPLAY 2000 Basic processor system, display device 18

4 X-RAY 8000 NXT 6 X-ray measuring devices for MV-, HV- and EHV-cables, manufactured on CCV-, VCV- and MDCV-lines 5 LASER Series 2000 XY/T/SR LASER Series 2000 XY-models for 2-axis diameter measurement LASER Series 2000 T-models for 3-axis diameter measurement LASER Series 2000 S/R-models for sectors and round cables 6 LASER Series 6000 High-speed diameter measurement Detection of lumps and neckdowns 7 STRANDSHIELD 2000 Detection of interruptions of the inner semiconductor at medium voltage cables 9

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8 X-RAY 6000 PRO/BASIC 14 Measurement of the wall thickness, eccentricity, diameter and ovality of single and multi layer products 9 SPARK 2000 BS Alternating current (AC) spark tester 10 LENGTH 6000 Length measuring system 16

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Introduction

Since 1973 the Bremen based SIKORA AG has been setting worldwide the standard as manufacturer of premium measuring and control devices for the optical fiber and wire and cable industry. Modern Laser and X-ray technologies measure precisely and reliably product parameters such as diameter, ovality, wall thickness and eccentricity. Integrated into the extrusion line the measuring devices increase quality, profitability and process efficiency of the production. A continuous calculation of production data helps avoiding wall thickness over sizes. The cable manufacturer consumes less insulation material while achieving a more efficient material consumption. Every micrometer of insulation material that can be saved by the use of measuring and control technology makes the production more economic and protects at the same time the scarce resources. Innovation, technological know-how, quality and service are the four pillars of SIKORAs company philosophy. A strong team in research and development is working continuously on the development of new technologies that help manufacturers of high-voltage cables to run their production lines more efficiently and to remain competitive. SIKORA is headquartered in Bremen, Germany. Here the high-quality devices are developed and manufactured. Regarding service and sales SIKORA is globally active with offices in Brazil, China, France, India, Italy, Japan, Korea,

Russia, Turkey, the Ukraine, USA and the United Arabic Emirates. In cooperation with more than 30 local representatives worldwide SIKORA serves all customer demands with regard to quality, productivity and cost saving. In addition, international service locations assure fast and reliable customer support on site. Since 1993 SIKORA has been meeting the requirements according to DIN EN ISO 9001. The certification confirms SIKORAs focus on continuous improvement. Customer satisfaction is SIKORAs primary objective.

Measuring technology for the high-voltage cable production The manufacture of high-voltage cables requires compliance with high quality standards and numerous specifications. In addition, cable manufacturers aim at producing economically. Against this background, manufacturers chose very well the measuring devices, which are used in their lines for quality control. Specifically for the energy market SIKORA has developed efficient and innovative technologies that assure quality during the complete production process. The measuring and control devices are suitable for application in CCV-, VCV-, MDCV-lines and sheathing lines.

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CSS 2 Flawless insulation for highest quality

CSS 2

CSS 2 for monitoring of the cleanliness of the PE insulation during the production of XLPE insulated high and extra-high voltage cables The cleanliness of the insulation material is a primary quality charcteristic at the production of high-voltage cables. SIKORA offers an intelligent solution to detect contamination in the PE-insulation. With the unique CSS 2 camera system, the entire XLPE-material is examined online for purity in the flow channel directly before the crosshead. Improvement of the process After a controlled bleed-off of the extruder prior to the production the CSS 2 reliably shows when the operator can start the line. Due to its online inspection for cleanliness during the production the CSS 2 informs early about contamination and detects combustion particles such as ambers and scorches in the PE melt. The CSS 2 guarantees a quality control for a perfect timing for the start and stop of the production. A quantitative and graphical display of the faults guarantees a cleanliness concept for highest quality and long operation time of the cable. Should you as well be interested in the pellet inspection, please contact our team of SIKORA in Bremen.

Typical features Continuous online monitoring of the polyethylene melt for 100% cleanliness Quality assurance

Technical Data CSS 2

Measuring principle Optical, with high-resolution CCD-camera Application 100 % monitoring of the insulation material for impurities (such as metal, wood, amber, scorches) during high voltage and extra high voltage cable production

Maximum material flow 400 kg/h Minimum size of detected contaminant 20 m (depending on type of contamination) Power supply 110 ... 240 V AC 10%, 50/60 Hz

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ULTRATEMP 6000 Ultra-strong temperature measurement

ULTRATEMP 6000

Ultrasonic temperature measurement system for polyethylene melts The ULTRATEMP 6000 is an ultrasonic temperature measuring device for the reliable measurement of polyethylene melts. The melt temperature of the polyethylene, which is used at the insulation of cables, is extremely critical. A few degrees decide between a homogeneous and thus optimum melt and the risk of unmelted or burnt material. ULTRATEMP 6000 is a temperature measuring system, which continuously measures the teperature of polyethylene melt precisely, directly before the cross head during extrusion. It works on a non-contact basis. Besides temperature measurement the ULTRATEMP 6000 detects inhomogenities in the melt. Early cross-linking after screens which may lead to ambers and scorches in the polyethylene material is avoided. The high measuring rate allows a fast response time as well as the registration of small temperature variations. The system does not influence the melt flow properties, as the ultrasonic sensors are positioned outside of the flow channel. Therefore, melt shear heating effects do not occur. ULTRATEMP 6000 importantly contributes to process optimization and costs reduction in CV or VCV-lines.

Typical features Maximization of the extruder output through optimum melt temperature Elimination of scorches and early cross-linking in the extruder head Detects inhomogenities in the melt Non-contact, no melt shear heating effects

Technical data ULTRATEMP 6000

Measuring principle Non-contact, non-invasive temperature measurement based on ultrasonic technology Measuring range 100C to 180C Accuracy < 1C Interfaces Serial interface RS485 Setup and diagnosis interface RS232 Profibus-DP , analog output Power supply 110 ... 230 V AC 10%, 50/60 Hz

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CV-INTUBE 6000 Sovereign diameter measurement in CV-lines

CV-INTUBE 6000

In-tube diameter measurement at steam and nitrogen CV-lines With the CV-INTUBE 6000 SIKORA presents a diameter measuring device, perfectly suited to the specific conditions at steam and nitrogen CV-lines. Directly integrated in the telescopic tube, after the cross head, the system provides reliable and precise diameter values for quality assurance and fast control. Typically the CV-INTUBE is used in high-speed insulating lines and for products that require a diameter measurement and control, but that do not need eccentricity measurement directly in the telescopic tube. CV-INTUBE 6000 includes a CV-gauge head and a sight glass assembly with an infrared light source integrated in the CV-tube. Due to this sophisticated technology only one sight glass is necessary. The CV-INTUBE 6000 can easily be integrated into any steam and nitrogen CV-line and can be adapted to any system control via serial or analog interfaces. The sight glass assembly is mounted approximately 200 mm after the extruder in the moving part of the splice box. Equipped with an automatically controlled sight glass heating and rinsing system the sight glass is kept free from contaminations.

Typical features Measurement of the diameter directly after the cross head Reliable control Continuous operation of the sight glass for many months No calibration

Technical data CV-INTUBE 6000

Measuring principle Non-contact, optical with state-of-the-art CCD-lines and an infrared light source integrated in the CV-tube Applications Steam and nitrogen CV-lines Gauge head CV-INTUBE 6050 CV-INTUBE 6075 CV-INTUBE 6100 CV-INTUBE 6120 Measuring rate 250/sek. Interfaces RS485, RS232 diagnosis interface, Profibus-DP (option) Power supply a) Gauge head: 100 to 240 Volt, 50/60 Hz b) Sight glass assembly: 230 V AC, + 7 % / - 10 %, 50 to 60 Hz Prod.-diam. 0.5 - 40 mm 1.0 - 50 mm 1.0 - 80 mm 1.0 - 100 mm Accuracy 5.0 m, + 0.01% 10 m, + 0.01% 15 m, + 0.01% 15 m, + 0.01%

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X-RAY 8000 NXT The best at the high-voltage cable production

X-RAY 8000 NXT

X-ray measuring system for MV-, HV- and EHV-cables in CCV-, VCV- and MDCV-lines

The X-RAY 8000 NXT assures precise measuring values of the cable parameters With the X-RAY 8000 NXT, visions were transferred into advantages. The X-ray based measuring system, installed in the moving part of the telescopic tube directly after the crosshead, provides efficiency on the highest level. It is applicable for steam and nitrogen lines and it measures precisely the measuring values of the wall thickness of all 3 insulation layers, the concentricity the diameter and ovality of XLPE and EPR insulated cable. Immediately after starting-up the line the measuring values are available for centering and control. The system does not require any warm-up period and calibration. As a result of modern analysis technology the X-RAY 8000 NXT is particularly powerful and reliable. By means of the Multi-Sensor-Technology (MST) and two high-speed scanner a reliable online measurement is ensured. With every scan of the MST records the movement of the cable, compensates vibrations and provides twice the number of measurements with every scan. The masterpieces of fine engineering is the use of ceramic and NTX windows (Non Toxic X-RAY window), which separate the scanners from the pressure of the CV-line. The surface of the windows does not react with any by-products resulting from the cross linking of the polyethylene material and remain permanently clean. The X-RAY 8000 NXT is used in CCV-, VCV- and MDCV-lines.

Typical features 8-point display of wall thickness and eccentricity for three insulation layers XLL (eXtra Long Life) X-ray tubes Ceramic windows and NTX windows (Non Toxic X-ray) for lifelong operation without cleaning Optimized Multi-Sensor-Technology Fast centering of the cross head and optimum quality and process control Measuring values immediately after starting-up the line, no calibration, no warm-up

X-RAY 8000 NXT monitor image

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X-RAY 8100 NXT

X-RAY 8100 NXT measures cable parameters in MDCV-lines For the measurement of the wall thickness, eccentricity, diameter and ovality of high-voltage cables in a MDCV line, SIKORA recommends the X-RAY 8100 NXT.

X-RAY 8700 NXT

X-RAY 8700 NXT assures cold measuring values of the final cable parameters While the X-RAY 8000 NXT provides information for a fast centering and direct control, the X-RAY 8700 NXT supplies precise quality data about the final product. The X-RAY 8700 NXT measures the diameter, wall thickness and eccentricity and is suitable for all cable types with solid, stranded or Milliken conductor and with single, double or triple layer insulation. For highest demands, the X-RAY 8000 NXT and X-RAY 8700 NXT are available as a set.

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X-RAY 8000 NXT - convincing technology With the use of the X-RAY 8000 NXT directly after the crosshead for collection of the hot measuring values and the XRAY 8700 NXT at the end of the line for measuring the cold values, 3 shrinking values are analyzed for every insulation layer of the cable. Consequently, an optimum process is assured. In addition, all measuring systems of the X-RAY 8000 NXT family are equipped with XLL X-ray tubes (eXtra Ling Life) that contribute to a long operation time with highest accuracy abd reliability.

Technical data X-RAY 8000 NXT

Measuring principle X-Ray with multi-sensor technology Application MV-, HV-, EHV-cables with VPE-, EPR-, EPDM-, HYPALON insulation etc. Gauge head Product diameter X-RAY 8000 NXT Up to 180 mm for CCV-lines X-RAY 8000 NXT Up to 220 mm for VCV-lines X-RAY 8700 NXT Up to 180 mm at the end of MDCV-, CCV-, VCV-lines SIXRAY 8000 Up to 60 mm for SILAN-lines X-RAY 8100 NXT On demand for MDCV-lines Accuracy Wall thickness 15 m, 0.02 % Diameter 5 m, 0.02 % Repeatability Wall thickness 7.5 m, diameter 3 m Display TFT-color monitor with 15 (optional 19) Interfaces (option) RS485, USB, OPC, Ethernet, Profibus-DP , Profinet, DeviceNet, analog outputs Power supply 230 V AC 10%, 50/60 Hz

Statistics

Trend

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LASER Series 2000 Having the process under control at any time

LASER 2100 T

LASER Series 2000 XY-models for 2-axis diameter measurement LASER Series 2000 T-models for 3-axis diameter measurement LASER Series 2000 S/R-models for the measurement of sector and round cables The LASER Series 2000 includes measuring devices for the measurement of the diameter of cables in 2 or 3 planes. Integrated at the end of CCV-, VCV- MDCV- or insulating and jacketing lines the gauge heads are characterized by precision, reliability and functionality. The technical base of these gauge heads is a state-of-the-art CCD-line sensor technology combined with laser diodes as light sources and intelligent powerful analysis software. The outstanding feature of the non-contact measuring technology is the extremely high single value precision, which is an important aspect for the calculation of the standard deviation. The short exposure time assures reliable readings at all common line speeds. Product vibrations have no influence on the measurement. There are no guide rollers needed. The gauge heads of the LASER Series 2000 are free from moving parts and have a nearly unlimited life cycle. Even after years of operation the devices measure as precise as on the first day of delivery. Due to the optical measuring principle without any moving parts, the Mean Time Between Failures (MTBF) of this series is 15 years. Calibration or maintenance procedures are not necessary.

Typical features Highest precision and reliability No moving parts No calibration MTBF of 15 years

Swivel gauge head function

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Specific measuring systems for your application LASER Series 2000 XY With the LASER Series 2000 XY SIKORA offers gauge heads for a precise diameter measurement in 2 planes. The diameter is calculated by diffraction analysis directly from the shadow image. LASER Series 2000 T With the LASER Series 2000 T SIKORA offers gauge heads for a precise diameter measurement, including the minimum/ maximum values, the ovality and its orientation. The ovality is accurately calculated independently from the orientation of the minimum and maximum values to the 3 measuring axes. LASER Series 2000 S/R The LASER Series 2000 S/R (Sector cable/Round cable) is most suitable for the precise measurement of the height of straight and prespiralled sector conductors, as well as for round cables. The fascinating triple axis concept of the S/R heads requires no rotation of the gauge head and thus no maintenance. Typically one of the S/R gauge heads is installed before and after the extruder, whereby the average wall thickness is calculated, based on the two diameter values. For a perfection in wall thickness control, the two gauge heads are combined with the processor system ECOCONTROL 2000 oder 6000.

Intelligent design Interesting is the design of the LASER Series 2000 devices. The smaller gauge heads are equipped with a unique and proven multi-slot protection. The gauge heads for bigger measuring ranges as well as all triple-axis and S/R devices are open at the bottom, which prevents water and dirt falling into the gauge head. A special feature of the larger models is the swivelling gauge head design, which allows the head to be moved up and out of the extrusion line. The measuring heads are free from wearing parts, remain with high precision throughout their lifespan and do not require any calibration or maintenance.

Technical data LASER Series 2000

Gauge head LASER 2050 XY/T LASER 2100 XY/T LASER 2200 XY LASER 2300 XY LASER 2500 XY LASER 2050 S/R LASER 2100 S/R Product diameter 0.5 - 50 mm 1.0 - 100 mm 5.0 - 190 mm 50 - 300 mm 50 - 500 mm 1.0 - 35 mm (sector) 0.5 50 mm (round) 1.0 - 35 mm (sector) 1.0 100 mm (round) Accuracy 2.5 m/ 1.0 m 5.0 m 10 m 20 m 50 m 5.0 m 5.0 m Repeatability 0.5 m 1.0 m 1.0 m 1.0 m 2.0 m 1.0 m 1.0 m Exposure time 0.2 s 0.2 s 0.2 s 0.2 s 0.2 s 0.2 s 1,0 s

Measuring rate 500 Hz (higher measuring rates on demand) Interfaces Serial interface RS485, Setup and diagnosis interface RS232, optional analog interfaces, Profibus-DP or alternatively industrial field busses such as CANopen, Ethernet/IP , DeviceNet, ProfiNet Power supply 100 ... 240 V AC 10 %, 50/60 Hz

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6 LASER Series 6000 A milestone in diameter measurement

W-LAN (WiFi) ready

LASER 6080 XY

LASER 6080 XY for high-speed diameter measurement and detection of lumps and neckdowns The LASER 6080 XY combines a variety of new technological features for a diameter measurement with an impressive precision and reliability to improve productivity of the production line sustainably. 2,500 measurements per second, all with extremely high single value precision allow for an optimum line control and provide reliable statistical data. Integrated display and automatic diameter control in the gauge head The devices include an integrated LCD display with control panel. This provides the operator with diameter values at one glance, directly at the measuring device. At the control panel the diameter nominal value can be entered and the control module activated. Via line speed or extruder rpm the module controls the diameter automatically to the specified value. Lump detector function The high measuring rate of the diameter devices also permits the detection of lumps and neckdowns. With the two-inone system investment costs are reduced. In addition, there is more space in the line as only one gauge head has to be installed.

Typical features Wide gauge head opening 2,500 measurements per second Integrated LCD Display with control panel Integrated lump detection function Universal interface module for all connections Optimum feeding and protection of the connection cables W-LAN interface SIKORA App

Swivel gauge head function

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Interfaces Directly integrated in the gauge heads is a universal interface module for all connections such as RS485, RS232, ProfibusDP or alternative industrial field busses such as CANopen, Ethernet/IP , DeviceNet, ProfiNet. As the interface module as well as all connectors are completely integrated in the gauge head, they are perfectly protected against dirt, water or mechanical influences during the production. Gauge head design The opening of the gauges is twice as big as the measuring range to ensure an easy product feed through. A special feature is the swivel type gauge head. It allows for the gauge head to be easily moved up out of the extrusion line. The measuring heads are open at the bottom to prevent dirt and water from falling into the measuring area. The feeding of the connection cables to the interface module is protected, directly in the gauge head stand. W-LAN Interface The LASER Series 6000 has common interfaces as well as an optional WLAN-interface, which allows for a direct connection to a smart phone or laptop. The W-LAN-interface is used for diagnosis and quality control. Measuring values, trend and statistical data, but also video signals are transferred. SIKORA App SIKORA offers a free app for displaying measuring values, trends, statistics or video signals at smart phones. The operator can easily log in via the W-LAN interface and receives immediately production data of the particular gauge head at the smart phone. The app allows also the calibration of the gauge head. The values of the test probes are read by a QR code and the measured values listed in a log file, ready to W-LAN transfer to the QM departement.
SIKORA App for LASER Series 6000 LASER 6080 XY on a comfort stand

Technical Data LASER Series 6000

Product name LASER 6080 XY Measuring rate 2,500 measurements/s Interfaces RS485, RS232, LAN (Ethernet); optional: W-LAN (WiFi), Profibus-DP , analog interface or alternatively industrial field busses such as CANopen, Ethernet/IP , DeviceNet, ProfiNet Power supply 100 ... 240 V AC 10 %, 50/60 Hz Product diameter Accuracy 1.0 - 78 mm 1.0 m Repeatability 0.5 m Exposure time 0.2 s

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STRANDSHIELD 2000 No interruption at the production of medium-voltage cable production lines

STRANDSHIELD 2000

Detection of interruptions of the inner semi-conductor Short interruptions of the inner semi-conductor (strand shield) during production of medium voltage cables may specifically occur in very thin insulation layers. In the best case they are detected at a discharge test. However, if such faults are only detected by the end-users the costs are tremendous. With the STRANDSHIELD 2000 SIKORA presents a system which detects and reports any short interruptions of the semiconductor during the production process of the cable. The measuring system is installed in a separate short cooling trough after the CV-line, typically combined with a diameter gauge head such as the LASER 6080 XY. Detected are the shortest interruptions with a length of 100 mm. The STRANDSHIELD 2000 is an attractive tool for the active quality control for the optimization of your production line. Very common is the monitoring of the strandshield interruptions at the processor system of the X-RAY 8000 NXT.

Typical features Continuous online inspection of the inner semi-conductor Detection of short interruptions of a length of 100 mm Continuous quality control

Technical data STRANDSHIELD 2000

Measuring principle Capacitive Product diameter 10 - 60 mm Measuring rate 1,000 measurements/s Interfaces RS485, RS 232, Profibus-DP Power supply 115 ... 230 10% V AC, 47-440 Hz

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X-RAY 6000 PRO/BASIC Intelligent partner at jacketing lines

X-RAY 6120 PRO

Measurement of the wall thickness, eccentricity, diameter and ovality of single and multi layer products For quality control of cables in jacketing lines the X-RAY 6000 continuously ensures compliance with requested cable specifications regarding wall thickness, eccentricity, diameter and ovality. Jacketing lines In jacketing lines the X-RAY 6000 is typically installed between two cooling trough sections. In this position the device measures the outer jacket of the cable. An additional diameter gauge head at the end of the production line, combined with a Hot-Cold-Control, considers the shrinkage of the diameter. X-ray measuring technology for single- and multi-layer products The X-ray measuring systems X-RAY 6000 are fascinating in general and in detail. Customers who measure up to three cable layers during production, choose the X-RAY 6000 PRO. For cable production lines where only one cable layer is measured, the X-RAY 6000 BASIC is available. X-RAY 6000 BASIC for single-layer products The X-RAY 6000 BASIC measures the wall thickness, the eccentricity, and the outer diameter of single-layer cables. In particular, in jacketing lines where only the outer jacket is applied, the X-RAY 6000 BASIC is interesting. The production data are clearly displayed at a 7 monitor, which is integrated directly in the measuring system. The operation is intuitive via touch screen. In combination with the processor system ECOCONTROL 600, 1000, 2000 or 6000 an automatic control of the line is possible. By controlling line speed or extruder rpm the cable parameters are controlled to the nominal value. The BASIC device is an economic and at the same time powerful alternative to the X-RAY 6000 PRO and provides exactly the functions that are of importance for quality control. For cables where only one material layer needs to be controlled, the X-RAY 6000 BASIC proves to be an efficient and reliable partner.

X-RAY 6035 BASIC with integrated 7 monitor.

Typical features X-RAY 6000 BASIC Measurement of the wall thickness, eccentricity, the inner and outer diameter and ovality of single layer products Automatic control of the line speed and extruder rpm under consideration of the minimum values (in combination with the processor systems ECOCONTROL 600/6000) Selectable measuring rate from 1 to 3 Hz Integrated monitor for measuring value display Intuitive touch-screen operation No calibration

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X-RAY 6000 PRO for multi-layer products The X-RAY 6000 PRO measures the wall thickness, the eccentricity, the diameter and ovality of up to 3 different cable layers. Very typical is its use at tandem extrusion lines. The system includes as a standard the display and control device ECOCONTROL 6000 with a vertical arranged 22 TFT monitor. It is either mounted directly at the X-RAY gauge head, a separate stand, or is remotely integrated in the control cabinet of the line control. The ECOCONTROL 6000 is conveniently operated via touch screen and shows all measuring values numerically and graphically as well as trend and statistical data. A line presentation with pictograms of the connected devices provides a clear overview. The PROfessional device becomes most efficient with the already included automatic control of the line speed or extruder rpm under consideration of the minimum values. From the very first day of operation, both X-ray devices, the X-RAY 6000 PRO and the X-RAY 6000 BASIC underline their power and assure a continuous online quality control at the cable production. Simultaneously, the systems reduce the wall thickness to a minimum value. Quality assurance and the reduction of material lead to a significant increase of productivity and cost savings.

At the vertical, 22 wide-screen monitor of the X-RAY 6000 PRO production data are clearly displayed

Which X-RAY 6000 fits your production line? For quality control at tandem extrusion lines, in which cables get a filler and an outer jacket, the X-RAY 6000 PRO is the first choice. Cables with a metal reinforcement under the outer jacket, are measured by the X-RAY 6000 BASIC.

Technical Data X-RAY 6000 PRO/BASIC

Measuring principle Non-contact with modern X-ray technology Product name Product diameter* Accuracy X-RAY 6020 PRO 0.65 - 15 mm 5 m X-RAY 6035** 5.0 - 30 mm 5 m/ 10 m X-RAY 6070** 6.0 - 65 mm 10 m/ 15 m X-RAY 6120** 10 - 110 mm 10 m/ 15 m X-RAY 6200 PRO 20 - 180 mm 20 m X-RAY 6300 PRO 30 - 270 mm 30 m * Bigger measuring ranges up to 500 or 650 mm on demand ** X-RAY 6000 PRO/BASIC Measuring rate X-RAY 6000 PRO: 1 to 3 Hz (optional 10, 25, 100 Hz) X-RAY 6000 BASIC: 1 to 3 Hz Interfaces X-RAY 6000 PRO X-RAY 6000 BASIC RS232, USB RS485, RS232 Option: LAN (Ethernet) Option: LAN (Ethernet) Industrial field busses such as CANopen, Ethernet/IP , DeviceNet, ProfiNet, Profibus-DP Power supply 100V 240V AC, +/- 10% 50 Hz (60Hz)

X-RAY 6120 PRO with 22 monitor.

Typical features X-RAY 6000 PRO Measurement of the wall thickness, eccentricity, the inner and outer diameter and ovality of up to 3 different material layers Automatic control of the line speed or extruder rpm under consideration of the minimum values Selectable measuring rate from 1 to 3 Hz (optional 10, 25, 100 Hz) 22 wide-screen Monitor Intuitive touch-screen operation No calibration

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SPARK 2000 BS Successful without breakdowns

SPARK 2000 BS

Alternating-current sparktester (AC) At the extrusion of cables their insulation is inspected by sparktesters (high-voltage sparktesters) and possible insulation defects are detected and documented at an early stage. For the testing, the dry cable runs through the sturdy bead chain electrode of the sparktester that is installed after the cooling section. Here the cable insulation is exposed to the selected test voltage and defects (pin holes) in the insulation are reliably detected. The quality management system assures that only faultless cables are delivered. SIKORA offers 7 models of the SPARK 2000 BS, covering the diameter range from 1 to 220 mm. For all systems, the test voltage is continuously adjustable from 1.6 to 35 kV. The sturdy electrode and the electronic box of the SPARK 2000 BS form one integral unit, that is easy to install in new or existing lines. Optionally, the SPARK 2000 BS can be combined with the display and control device REMOTE 2000. The REMOTE 2000 includes the keypad for the setting of the test voltage, a fault counter and allows for a length related recording of the detected spark faults. The sparktester conforms to approved test standards (AS, BS, CS, CENELEC, EN, UL, VDE) and safety regulations (as demanded by DIN/VDE 0800, IEC 479-1). Typical features Reliable fault detection Controlled test voltage Fulfills all important test and safety standards

Technical data SPARK 2000 BS

Measuring principle Test device with bead chain electrode Gauge head SPARK 2060 BS SPARK 2075 BS SPARK 2100 BS SPARK 2120 BS SPARK 2140 BS SPARK 2170 BS SPARK 2200 BS Product diameter 1 60 mm 1 75 mm 1 100 mm 1 120 mm 1 140 mm 1 170 mm 1 220 mm

Interfaces RS485, RS232, Profibus-DP (option), electrically isolated contacts, analog in- and outputs Test voltage 1.625 kV (30/35 kV option) Power supply 100 230 10% V AC, 50/60 Hz

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10 LENGTH 6000 Perfect length

LENGTH 6000

Length measuring systems - new defined The LENGTH 6000 is a reliable non-contact online length measuring device for strand-shaped products. With the LENGTH 6000 cable manufacturers measure the cable length already during production and assure that the accurate length is supplied or further processed. The technology of the LENGTH 6000 is based on an optical measuring principle. The surface structure on the bottom side of the passing product is defined by two neighboring CCD-image sensors. The length is measured and speed is calculated from the correlation of both images. The technology of the LENGTH 6000 is reliable for all types of strand-shaped products with reflective and rough surfaces. A very typical application is its use at insulating and jacketing lines. The system recognizes whether the product is moving forward or reverse and measures the length always precisely from zero line speed. Typical features Length measurement independent of the product direction (forward/reverse) Measurements start from zero line speed Highest reliability and precision

Technical Data LENGTH 6000

Measuring principle Non-contact, optical, comparison of image patterns Product diameter 5 to 180 mm (additional diameters on demand) Line speed Up to 500 m/min (higher speeds on demand) Accuracy < 0.05 % deviation Interfaces Serial interface RS485, Diagnosis interface RS232, Pulse output Optional: LAN (Ethernet), Profibus-DP , Ethernet/IP , ProfiNet etc., all common industrial field busses, alternatively analog output Power supply 100 ... 240 V AC 10%, 50/60 Hz

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11 REMOTE/DISPLAY 2000 Visualization and control of the production data

REMOTE 2000

DISPLAY 2000

Standard display and control device REMOTE 2000 In addition to the innovative measuring and testing systems SIKORA offers compatible display and control devices. The REMOTE 2000 is the basic display and control device and universally applicable for all SIKORA diameter measuring devices and spark testers. The display of the measuring values is on a five-digit 20 mm high clear LED display. It is perfectly suitable for panel mounting or for building on the gauge head. LASER Series 2000/6000 in combination with the REMOTE 2000 The REMOTE 2000 can be combined with a diameter gauge head of the LASER Series 2000 or LASER Series 6000. The average diameter value of the connected measuring device is clearly displayed at the LED display. Via a control key the average diameter value or the display of the ovality can be selected. The REMOTE 2000 includes a product library for up to 50 cable recipes. Nominal values and tolerances can easily be recalled. In combination with the control module SET POINT an automatic control of the line speed or extruder rpm during the production is ensured. Optionally, a length-related print out of the measuring values as well as statistical data are available. Furthermore, the REMOTE 2000 provides an interface, to support a connection to an external PC for data gathering or PLC line control operations. In this way a targeted and direct control is assured. SPARK 2000 in combination with the REMOTE 2000 Combined with the SPARK 2000 the REMOTE 2000 serves as a device for the display and setting of parameters such as the nominal testing voltage. User-friendly symbols and numeric displays clearly show the current testing voltage and the number of breakdowns.

Typical features REMOTE 2000 Large, clearly arranged display and keypad Easy building at any distance to the measuring head Automatic control module SET POINT (optional) Serial interface for the connection to a measuring head, a computer and a protocol printer (optional)

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Basic display device DISPLAY 2000 DISPLAY 2000 is a display unit to be used in combination with SIKORA diameter measuring devices of the LASER Series 2000 or the LASER Series 6000. It is suitable for panel mounting as well as for the installation at the gauge head. The digital display of the measuring value is five-digit and device-specific configurable. Connected to one diameter measuring head, the DISPLAY 2000 shows the diameter values or the ovality. In particular for applications where the measuring systems are connected to a system control via Profibus interface or where a second display is requested, DISPLAY 2000 is an interesting and excellent value supplement.

Typical features DISPLAY 2000 Digital display Selectable monitoring parameter (diameter, ovality) Installation at any distance to the gauge head Serial interface for the connection to a gauge head

Technical Data REMOTE 2000

Measuring value display Digital, 5-digit e.g. 00.000 ... 99.999 Display update Programmable, factory setting 1/ sec. Nominal value/ Tolerance selection Via key pad (operation guided via a 4-digit LED-display) Product storage Up to 50 product types, comfortable programming via the diagnosis software Tolerance message/ Control action a) In clear text on LED-display b) Dry contacts Interfaces RS485 (gauge head), RS232 (printer) Analog output (option) 0 to10 V, deviation output if not used for control (010V according to the deviation output +5=0

Technical Data DISPLAY 2000

5-digit-display Digit height of 25 mm The bright, big figures are easy to read even from a distance of 12 m Interfaces (Bi-directional serial interface) RS485 Power supply 100 ... 240 V AC, 10 %, 50/60 Hz

Power supply 100 ... 240 V AC, 10 %, 50/60 Hz

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12 Partner of the measuring systems Premium processor systems

ECOCONTROL 6000

ECOCONTROL 2000

ECOCONTROL 2000/6000 The power of the ECOCONTROL 6000 processor system becomes obvious by its fascinating combination of its capabilities, attractive design and intuitive operation. All measuring values of the connected diameter and eccentricity devices are in clear focus. Up to 8 measuring and testing devices can be connected to the ECOCONTROL 2000/6000 at once. The measuring values are displayed numerically as well as graphically on a 15 (ECOCONTROL 2000) or vertical, 22 (ECOCONTROL 6000) TFT monitor. A clear line presentation with pictograms of the connected devices provides additional information. Moreover, it contains a time or length-related trend diagram for all values, a graph of the distribution of the single values (statistical distribution curve) and comprehensive statistics with the minimum, maximum and mean value, standard deviation, Cp and Cpk values. The operation is intuitive, menudriven via touch screen. ECOCONTROL 1000 The ECOCONTROL 1000 offers two serial interfaces for the connection of measuring devices such as SIKORAs LASER Series 2000 or LASER Series 6000 Additionally, two testing devices such as the SPARK 2000 can be connected. The measured values are displayed on a 15-TFT touch screen monitor. The ECOCONTROL 1000 also includes a time or lengthreleated (optional) trend diagram of all values, combined with a graph of the distribution of the single values (statistical distribution curve) and comprehensive statistics with the

minimum, maximum and mean value, standard deviation, Cp and Cpk values. The operation is intuitive, menu-driven via touch screen. ECOCONTROL 600 ECOCONTROL 600 offers one serial interface for the connection of a SIKORA measuring device. Additionally, via two digital contacts events from a SPARK 2000 for the detection of break downs can be read. The measuring values are displayed numerically and graphically on a clear 8.4-TFT-monitor. Also there is a graphical time- or length-related (optional) trend diagram for all values combined with a graph of the distribution of the single values (statistical distribution curve) and statistics with the minimum, maximum value, the mean, standard deviation, Cp and Cpk values. The operation is menu-driven via touch screen.

Automatic diameter/ Wall thickness control A special feature of all ECOCONTROL models is the control module SET POINT. It ensures a continuous, automatic control of the diameter or wall thickness to the nominal value by controlling either the line speed or the extruder rpm. Hot/Cold Module HC 2000 (ECOCONTROL 1000/2000/6000) With the HC 2000 the material shrinkage is continuously calculated and considered automatically for the control of the diameter and/or wall thickness.

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Technical Data ECOCONTROL

Display TFT-color monitor In/ and outputs Serial interface RS485 Electrically isolated digital inputs for the connection to testing devices Analog outputs 16 Bit; 0 ...10 V or +/- 10 V (unipolar/bipolar) Contact outputs for tolerance and status messages (max. 30 V, max. 0.5 A) Serial interface RS232 for communication with an external computer USB interface for a printer Electrically isolated input for rotary pulse generators (0 / 15 V) Electrically isolated interface module for control of the diameter (HC 2000) USB customer interface Profibus-DP as well as alternative field busses Ethernet interface (selectable OPC/Suitelink) W-LAN (WiFi) Storage Power supply

6000
22 (vertical)

2000
15

1000
15

600
8.4

4 (8 option) 4 (8 option) 4 (option) 4 (8 option)

4 (8 option) 4 (8 option) 4 (option) 4 (8 option)

2 (4 option) 4 (option) - 4 (option)

1 4 (option) 4 (option)

1 (option) 1 (option) 1 1 (option) 1 Yes (option) 1 (option) 1 (option)

1 (option) 1 (option) 1 1 (option) 1 Yes (option) 1 (option) -

1 (option) 1 (option) 1 (option) 1 (option) 1 No 1 (option) -

1 (option) 1 (option) 1 (option) No 1 (option) -

Hard disk

Hard disk

Flash disk (option) -

100 240 V (+/-10%) 50 / 60 Hz

100 240 V (+/-10%) 50 / 60 Hz

100 240 V (+/-10%) 50 / 60 Hz

100 240 V (+/-10%) 50 / 60 Hz

VIRTUAL 2000 - Intelligent software concept The virtual gauge technology is suitable for all applications, where a fast wall thickness control is required, but where due to the line configuration or the product structure a diameter or wall thickness measurement directly after the extruder is not possible. Reasons could be a lack of space for a hot diameter gauge head or the need for an immediate cooling of the product after the extrusion. In these cases the intelligent software concept VIRTUAL 2000 is the solution: the measuring device is installed at the end of the cooling trough section. Up to now, the control of the extruder at the end of the line was very slow. The reason was the big delay time, a result of the low line speeds and the big distance between the measuring device and the extruder crosshead. This delay time is eliminated by the VIRTUAL 2000.

Already at the start-up of the line an extruder model of the VIRTUAL 2000 calculates the expected cold wall thickness for a defined core diameter and a predefined material depending on the specified extruder rpm and the line speed. The VIRTUAL 2000 displays the cold wall thickness even before the product reaches the measuring system at the end of the line. Already during the start-up process the VIRTUAL 2000 controls the required extruder rpm, in order to achieve the cold wall thickness, set by the operator. The control and the regulation of the extruder is done under consideration of the line speed, selected by the operator. There is no need for any shrinkage setting.

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Technical data is subject to change

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