Operator Manual:
Injection molding machine
SIJECT OP37/CPU614
Release: 2001-11-09
Chapter 1 : Basic Operation……………………………………………...2
1.1How to call screens?…………………………………………………………2
1.2How to set the parameters in screens?……………………………………….3
1.3How to get the information from the permanent window?………………….5
Chapter 2 : Process Operation……………………………………………7
2.1 How to set the process for clamp?…………………………………………..7
2.2How to set the process for ejector?…………………………………….…..12
2.3 How to set the process for carriage?……………………………………….18
2.4 How to set the process for inject/holding?…………………………………21
2.5 How to set the process for charging?………………………………………26
2.6 How to set the process for air blast?……………………………………….30
2.7 How to set the process for mold adjustment?………………………...……32
2.8 How to set the process for barrel heating?………………………..………..40
2.9 How to set the process for core?………………………………………...…43
2.10 How to start fully auto cycle?…………………………………………….46
2.11 How to start purge cycle?…………………………………………………50
Chapter 3 : Function Operation…………………………………………52
3.1 How to use oil pre heating function?………………………………………52
3.2 How to use the functions relative to heating?………………………………...
3.3 How to use the diagnosis function?…………………………………………..
3.4 How to use the part counter?…………………………………………………
3.5 How to set the proportional valve curve?…………………………………….
3.6 How to set the clock and date?……………………………………………….
3.7 How to change the language?……………………………………………….
3.8 How to change the measure unit……………………………………………...
3.9 How to get to the service password…………………………………………..
3.10 How to monitor the quality data…………………………………………..
3.11 How to monitor curve?…………………………………………………….
3.12 How to operate the mold data? ……………………………………………
3.13 How to calibrate the transducer?…………………………………………..
3.14 How to start up the power………………………………………………….
Chapter 4 : Alarm and message
(unavailable)
Chapter 3 : Function Operation
3.1 How to enable the Oil pre heat function?
Step 1: Call screen No.2010 “Heater Functions”, ref. to “How to call the screens”;
Step 2: Notice the status of the box for “Pre selection oil pre heat mode”, if the box is blacken, that means the function already enabled. Otherwise Press F3 to active this function. If you want to disable this function, Press F3 to whiten the status box.
Step 3:If the Oil pre heat function is active, the safety gates must be closed, otherwise, the function can not be executed.
After switch on the machine, if the actual oil temperature below 36℃, the machine will come into the oil pre heat mode automatically.
At this time, the system will output the high pressure and flow which set in screen No.5311 “Miscellaneous parameter 1/9” and open all the pumps. When the actual oil temperature reaches 36°C, the system returns to manual mode automatically.
If during normal operation oil temperature drops below 30°C, machine mode will switch over to oil pre heating mode again.
Attention: the temperature 36°C and 30°C are recommend and could be modified in Screen No.5313 “Miscellaneous parameter 3/9” .
‘
3.2 How to use the functions relative to heating?
Function 1 : Temperature keeping;
Function description : This function allows the barrel temperature keeping on the set value when the normal product stops and it can avoid damaging the material in the barrel by the too high or too low temperature.
Step 1: Setting the keeping temperature for each barrel zone in screen No. 2000 “Heater” ;
Step 2: Call screen No.2010 “Functions heater”, ref. to “How to call the screens?”;
Step 3: Push button F2 toggles between standard and keeping mode, the actual keeping function status can be monitored by the status box;
Hint: After the keeping is active, the screw movement is disable.
Function 2 : Alarm reaction;
Function description : This function allows setting the reaction of the heating if any alarm happens in the auto mode.
Step 1: Call screen No.2010“Heater functions”, ref. to “How to call the screens?”;
Step 2: Moving the cursor to the setting section for “Alarm reaction”;
Setting the reaction delay time and enable the function.
The reactions are selected in the “Heater off version”:
Shut off : when the alarm happens and the delay time runs out, the heating will shut off automatically.
Keeping : when the alarm happens and the delay time runs out, the heating will come into the keeping mode automatically.
Function 3 : Heating zone pre setting;
Function description : This function allows setting the zone number, control type and graphic according the actual barrel configuration. Normally this function is set by the manufacturer.
Step 1: Call screen No.2010“Heater functions”, ref. to “How to call the screens?”;
Step 2: Setting the actual zone as “ON” below the “Function”. If the zone is active, the according setting values, for example, setting temperature, +tol etc, will displayed in screen No. 2000 “Heater”;
Step 3: Setting the control type for each active zone, for HaiTian machine, the standard setting should be close loop which means the thermocouple is installed, so set the “Open Loop” as “Off”;
The open loop can be used in some conditions, for example, if the thermocouple for this zone is destroyed and one spare part can be found in time, so the open loop can be selected for continuing the producing. For this use, the manual heating percentage should be set in screen No.2000 “Heater”.
Step 4: Selecting the graphic symbol for each zone;
You can select a graphic for each zone from the following choices:
Barrel, Nozzle/Big/End, Nozzle/Big/Middle, Nozzle/Small;
Function 4 : Calendar heating;
Function description : This function allows the heater switch to ON automatically by the pre set date and time.
Condition: the power for control system should be on and heater switch is off.
Step 1: Call screen No.2011“Heater timer”, ref. to “How to call the screens?”;
Step 2: Moving the cursor to the week data setting line;
Setting the heating on time and enable the calendar as “ON”;
3．3 How to use the diagnosis function ?
Description: This function is used to monitor the actual data for all Digital input, Digital output, Analog input and Analog output;
3．3．1 How to monitor the digital input ?
Step 1 : Call screen No.1411“Digital In”, ref. to “How to call the screens?”;
Step 2 : Monitor the actual status for each digital input.
Status Box:Indication of input status. If the status box is black, it indicates the according digital input signal is effective.
Hint: Input number consists of Byte number and bit number 0 to 7. The number is used for programming.
3．3．2 How to monitor the digital output ?
Step 1 : Call screen No.1421“Digital Out”, ref. to “How to call the screens?”;
Step 2 : Monitor the actual status for each digital output.
Status Box:Indication of input status. If the status box is black, it indicates the according digital output signal is effective.
Output forcing function:
Function description: This function is useful for service. The service engineer can check the hardware circuit problem such as wire break, short connect etc by forcing effective the digital output.
Step 1: Push the emergency button;
Hint: For safety, the emergency button should be pushed and the motor is shut off.
Attention: During the function is working, the emergency button should be kept! All movement will be disable under this condition!
Step 2: Set the “Output forcing function” as “On”;
Step 3: Input the address of the favorite output;
The address includes two parts: the first is the Byte number, and the next is the bit number, the dot is between the two numbers.
The byte and bit number are easy gotten from the screen.
status for each digital input.
Status Box:Indication of input status. If the status box is black, it indicates the according digital input signal is effective.
Hint: Input number consists of Byte number and bit number 0 to 7. The number is used for programming.
Step 4: Push F6 to active the output, the according status box will be black.
Step 5: Press F7 to stop the outputting after the circuit checking finished. The according status box will be white.
Hint: It is impossible to outputs two valves at the same time!
Step 6: If the next output is necessary to check, start from Step 3;
If the next output the near the actual output, the following softkeys are useful:
Using the soft-key “UP” (F2) or “DOWN”(F3) can increase or decrease the byte number automatically. So it is easy to check the next output wiring circuit after this circuit is finish.
Using the soft-key “UP” (F4) or “DOWN”(F5) can increase or decrease the bit number automatically.
Step 7: After all outputs checked, set the “Output forcing function” as “Off” ;then release the emergency button.
3．3．3 How to monitor the analog input for transducer?
Step 1 : Call screen No.1432“Analog input”, ref. to “How to call the screens?”;
Step 2 : Monitor the actual position for each transducer.
3．3．4 How to monitor the analog output?
Step 1 : Call screen No.1441“Analog output”, ref. to “How to call the screens?”;
Step 2 : Monitor the actual voltage output for each proportional valves.
3．4 How to set the part counter?
Description: This function is used to count the products. In the auto mode, the actual counter increases one after the holding phase finishes. If the set counter expires, the auto mode finishes after the actual cycle and a message pops up.
Step 1 : Call screen No.1101“Part counter”, ref. to “How to call the screens?”;
Step 2 : Enable the part counter function;
In case pre selection PART COUNTER SHUT OFF is ON machine will stop if the number of actual parts is reaching the part counter preset value. An alarm will show up accordingly.
Step 3 : Set the relative parameters;
“Part count pre set” is used for the value of product number;
Number of produced moldings is been collected. The number of moldings per mold is taken into account.
How to reset the counter:
Shot counter detects the total number of automatic cycles and it is not to be reset. The reset sequence is as following:
Step 1: Push F2 Reset Start (Password level 2 required);
Step 2: Push F3 Reset C1 to zero or push F4 reset C2 to zero;
3．5 How to set the proportional valve curve:
Before setting the proportional valve curve, the curve type should be set first;
Step 1: call screen 5200;
In this screen, we recommend setting as following:
Line 1 for valve curve type set “4 point 1”, Enable set “ON”; this means the analog output channel 1 (normally used for system pressure output, refer to screen 5250 for detailed setting”)
Line 2 for valve curve type set “4 point 2”, Enable set “ON”; this means the analog output channel 2 (normally used for system flow output, refer to screen 5250 for detailed setting”)
Step 2: if the proportional valve for back pressure controlling is installed, then:
Line 3 for valve curve type set “Standard linear”, Enable set “ON”;
Otherwise, jump to step 3.
Step 3: set the other lines for Enable as “OFF”, and don’t care about the valve curve type for other lines because they are disable.
Background:
There are 4 kinds of valve curve type can be selected: offset and gain,4 point curve, standard linear, free programmable, refer to “proportional valve curve type” for more detail. Here, we just want to say the 4 point curve for pressure and flow valve, standard linear for back pressure are enough according our experience.
Step 4: call screen 5220 to set the analog output channel 1&2;
According the HaiTian hydraulic circuit design, normally the machine only install one pressure proportional valve for all pressure control and one flow proportional valve for all flow control. Usually an additional pressure proportional valve installed for back pressure control, but it is not standard for all machine. So we always use analog output channel 1 as system pressure control, channel 2 as system flow control and channel 3 as back pressure control.
Step 5~Step 9: set 4-point curve 1 for system pressure control;
Step 5: decide the 4 pressure points, these 4 points will decide the curve as following drawing:
Pressure
4
P4
3
P3
2
P2
P1 1
Act1 Act2 Act3 Act4 Analog output (V)
For example:
To setting the curve, we select 4 points in this curve: 100% pressure, 70%, 40% and 0.So we set CONT for 4-point curve 1 from up to down( from 4 to 1) as 1000, 700, 400 and 0.
Attenetion:1000 represents 100% of pressure.
the max system pressure is 140 Bar which set in screen 5200 Norm for channel 1, so the pressure points, so the according 4 point pressure are 140bar, 98bar(equal to 140*0.7), 56bar(equal to 140*0.4) and 0bar. From the drawing, we can see P1 is 0, P2 is 56, P3 is 98 and P4 is 140.
Step 6: adjusting the point 4 to find the Act 4 value;
Sub step A: Set 1000 which represents 10V output in Act 4( Line 4 under ACT of 4-point curve 1). Then set 140 bar and 10s for holding step1 in screen 400, that means we will use holding pressure to set the curve.
Recommend: holding step had better set only one step so that avoiding mistake.
Background: we can use other movement, for instance, core etc to setting the curve too. We think the best way is using holding because it is good for holding pressure close-loop control.
Sub step B: If the barrel temperature is OK, press the inject key K55. Look the identify of system pressure gauge.
Sub step C: If the real pressure is more than 140 bar, for example, 150bar, then you should reduce the value Act 4, for instance, from 1000 to 950…until the real pressure is just 140 bar;
Sub step D: If the real pressure is less than 140 bar, for example, 130bar, you should adjust the pressure max volume in the proportional amplify board until the real pressure is just 140 bar. You should avoid over-adjusting the max volume, otherwise a “dead zone”(in this zone, the current output from the amplify board not change even the input voltage from PLC changed) maybe occurs. Refer to “how to adjust proportional amplify board”.
Attention: at this time, you must confirm that the min volume in the proportional amplify board is minimum, otherwise the 0 bar maybe not accuracy.
Step 7: adjusting the point 3 to find the Act 3 value;
Set 98 bar and 10s for holding step1 in screen 400, then:
If the barrel temperature is OK, press the inject key K55. Look the identify of system pressure gauge.
If the real pressure is more than 98 bar, for example, 110bar, then you should reduce the value Act 3, for instance, from 700 to 650…until the real pressure is just 98 bar;
If the real pressure is less than 98 bar, for example, 90bar, you should increase the value Act 3, for instance, form 700 to 720… until the real pressure is just 98 bar;
Step 8: adjusting the point 2 to find the Act 2 value;
Like step 7, get the Act 2 value by the holding pressure 56bar;
Step 9: adjusting the point 1 to find the Act 1 value;
Normally the CONT 1 is 0 bar, so the Act 1 can set a very small voltage.
Step 10~Step 14: set the 4-point curve 2 for flow proportional valve;
Step 10: decide the 4 flow points, these 4 points will decide the curve as following drawing:
Flow
4
F4
3
F3
2
F2
F1 1
Act1Act2 Act3 Act4 Analog output (V)
For example:
To setting the curve, we select 4 points in this curve: 100% flow, 70%, 40% and 0.So we set CONT for 4-point curve 2 from up to down( from 4 to 1) as 1000, 700, 400 and 0.
Attenetion:1000 represents 100% of pressure.
The max system flow is 99% which set in screen 5200 Norm for channel 2.
We recommend that you can use the screw speed to set the flow curve. The max screw speed is set in screen 1301 machine data. The easy way to know the max screw speed is input the a very big value, for example, 1000RPM in screen 500 charging, then a system message pop up, for example:
452 Value exceeds upper variable
limit.250
So the max screw speed is 250 RPM, the according 4 point flow are 250RPM, 175RPM(equal to 250*0.7), 100RPM(equal to 250*0.4) and 0RPM. From the drawing, we can see F1 is 0, P2 is 100, P3 is 175 and P4 is 250.
Background: we can use inject speed to setting the curve too. If you decide setting the curve by screw rotate, checking the screw sensor before the next step is required.
Step 11: adjusting the point 4 to find the Act 4 value;
Sub step A: Set 1000 which represents 10V output in Act 4( Line 4 under ACT of 4-point curve 1). Then set 250 RMP and a long distance for charging step1 in screen 500.
Attention: the material should exist in barrel while rotate the screw.
Recommend: holding step had better set only one step so that avoiding mistake.
Sub step B: If the barrel temperature is OK, press the charge manual key K58. Look the real screw speed in the screen 500.
Recommend: The best way is use a test measurer to get the real RPM, because the screen display RPM has a difference comparing with the real RPM.
Sub step C: If the real RPM is more than 250, for example, 260, then you should reduce the value Act 4, for instance, from 1000 to 950…until the real RPM is just 250;
Sub step D: If the real pressure is less than 250, for example, 220, you should adjust the flow max volume in the proportional amplify board until the real RPM is just 220.
You should avoid over-adjusting the max volume, otherwise a “dead zone”(in this zone, the current output from the amplify board not change even the input voltage from PLC changed) maybe occurs. Refer to “how to adjust proportional amplify board”. The method to check the dead zone is set a little low speed, for example, 240 in charging step 1, then charging in manual mode, if the real RPM display value is a little lower than 250, it identifies no dead zone exist; if the real RPM display value is as same as before, you must re-adjust the max flow volume to lower in proportional amplify board.
Attention: at this time, you must confirm that the min volume in the proportional amplify board is minimum, otherwise the 0 bar maybe not accuracy.
Step 12: adjusting the point 3 to find the Act 3 value;