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1. gt lt 392 M 76 E gt 3761 1 e p B 1 96 B a screw p d L _ j uc Gr p ut 6 Al oS 36 2 gt 99 oS 10 0 32 224 Is eed VU E H 3 E E H E Hlo o m HIR il 1 e HIE 9 kd lo e D E lt gt d 9 e Bis 9 i tu H AH 3 Le H al E e Ale amp s Co H ELE BIB 5 9 lol B p 0 m m 9 We i E Bly B E p H o 19 eo o ls Ji St 288 L 84 5 Fig 2 1 Mounting dimensions for SIJECT 15 16 OP15B and C116 also applicable for C115 2 4 SIJECT 15 16 Start up June 2003 Installing the Control System Fig 2 2 Section dimension for OP15B SIJECT 15 16 Start up June 2003 2 5 Installing the Control System 2 2 Interfaces and cabling Position of interfaces and front panel elements j
2. Table 2 9 Pin assignments of connector X202 Pin Name Type 1 LS1 V 2 LS1 V 3 LS1 V 4 LS2 V 5 LS2 V 6 LS2 V 7 LS3 V 8 LS3 V 9 LS3 V 10 LS4 V 11 LS4 V 12 LS4 V Sensor Type linear scale Resistance value 1KQ 10KQ Accuracy 1 A D characteristics Resolution 12bit Sampling rate 2ms Connecting sensor LS4 LS4 LS4 LS3 LS3 LS3 LS2 152 LS2 LS1 LS1 LS1 Fig 2 9 Connecting the linear scales SIJECT 15 16 Start up June 2003 2 21 Installing the Control System Signal description 2 22 The analog inputs are assigned with the following signals LS1 LS1 LS1 linear scale 1 0 10v Mold LS2 LS2 LS2 linear scale 2 0 10v Injection LS3 LS3 LS3 linear scale 3 0 10v Ejector LS4 LS4 LS4 linear scale 4 0 10v Carriage SIJECT 15 16 Start up June 2003 Installing the Control System 2 3 8 Connecting the Digital outputs X300 X301 X302 Pin assignments Interface for digital outputs for connector Connector designation X300 X301 X302 Out Connector type 10 pin plug connector Table 2 10 Pin assignments of SIJECT 15 16 connector X300 Name 1L 1M 000 0 000 1 000 2 000 3 000 4 000 5 000 6 000 7 5 lt qQ o 4 0 0 o O O Oo lt lt X301 Name 2L 2M DQ1 0 DQ1
3. m NJ 5007 x554 NJ NJ 0056 NJ 0156 NJ 500 5 m 5015 NJ 004 N 014 NJ 503 NJ DI 3 NJ 002 N 012 NJ 001 N Dna NJ 000 Dno N a M iF 7LU7M S NJ 027 NJ 037 NJ 017256 X206 NJ 013 6 NJ DI25 NJ 013 5 NJ DI24 NJ DI34 023 NJ 033 NJ DI22 NJ DI32 NJ DI24 NJ DBA NJ DI20 NJ 1030 Note Bipolar possible Fig 2 7 Connecting the digital inputs SIJECT 15 16 Start up June 2003 Installing the Control System Signal description 2 18 The digital inputs are assigned with the following signals DI 0 0 DI 0 1 DI 0 2 DI 0 3 DI 0 4 DI 0 5 DI 0 6 DI 0 7 I lI lI cl NOORWNAO0 spare spare spare spare spare spare spare spare Safety door 2 short cut available Rear safety door short cut available Emergency stop short cut available Carriage advance end Carriage retract end Ejector advance end Ejector retract end Mold lock end Mold adjustment advance end Mold adjustment retract end Core 1 in end Screwing 1 Core 1 out Core 2 in end Screwing 2 Core 2 out Injection door short cut available Motor overload Safety door 1 Lubrication error Mold adjustment photo sensor Full auto photo sensor Robot Core 3 in end Screwing 3 Core 3 out Screw speed sensor SIJECT 15 16 Start up June 2003 Installing the Control System 2 3 6 Connecting the Therm
4. QOO V 200 navaisble QQOOe oN A 2og Oleo Z 2002002010 20000 IDDADO AAAA 2220224 6 2222 gt 7 Fig 2 3 User interfaces for SIJECT 16 16DP international for reference 2 6 SIJECT 15 16 Start up June 2003 Installing the Control System Interfaces CI e Power supply connector AC220V 3 pin screw terminal block for connecting the AC220V load power supply e X11 OP interface 9 pin sub D plug connector for connecting OP and providing power supply for OP e X12 MPI RS232 interface 9 pin sub D socket for communicating with PC PG and other standard OP e X14 P bus 25 pin sub D socket for periphery extension e 15 Profi bus 9 pin sub D socket for connecting controller Profi bus protocol e X200 X201 Temperature input 8 pin front connector 2 sets for connecting thermocouple inputs e X202 Analog input 12 pin front connector 1 set for connecting linear scale inputs e X203 X204 X205 X206 Digital input 10 pin front connector 4 sets for connecting digital inputs 1 pin of them DI3 7 X206 is adapted for connecting high speed input including proximity switch e X300 X301 X302 D
5. 88 3 Lub Count 65536 55536 Lub Status oO LubOilLey el Fig 3 15 Service Screen 2 2 lubrication picture On service screen 1 press softkey F2 to enter service screen 2 linear scale setting Then press F3 to enter lubrication setting screen See Fig 3 15 Service Screen 2 2 lubrication picture Lubrication time and lubrication count can be set here Lubrication Time every lubrication time can be set here ranged from 0 0 99 9sec Lubrication Count set one cycle here and the system will be lubricated automatically The range is from 1 to 9999 Lubrication Status Press softkey F1 manual lubrication to start the lubrication then the box will backlight and is flashing Lubrication Oil Level Inform the user to add lubrication oil when the oil level is very low then the box will backlight and alarm occurs i e is flashing SIJECT 15 16 Start up June 2003 3 27 Start up 3 4 9 Temperature setting General Operating sequences 3 28 User can set temperature channel and temperature tolerance TmpTolPlus ec Channel 1 or TmpTolMinus eC Channel 2 or Oil Upper C Channel 3 ot vw Oil Lower Channel 4 or TmpComoen C Channel 5 Nozzle Mode CloLoop vw Oil Tmp amp lm Fig 3 16 Service Screen 2 3 Temperature setting On service screen 1 press softkey F2 to enter service screen 2 B line
6. Caution 1 There is an isolation transformer JBK3 63VA with SIJECT 15 system Refer to Figure 2 14 Connection Diagram for its wiring 2 Neutral line and Protection earth line must not be connected at any time 3 Power supply cable and signal cable should be seperated i e linear scale and thermocouple signal cable can not be assigned to the same conduit with power supply cable Note The DC24V power supply should meet the requirements of the safe separation in accordance with DIN EN 50178 The terminal M in the DC24V power supply for the digital output Signals 1M 3M are to be earthed additionally SIJECT 15 16 Start up June 2003 2 31 Installing the Control System 2 5 Grounding Grounding The following grounding connections must be implemented Connections e 15 e CI16 The grounding connection for the OP must be taken into account when installing the machine EN e x302 502 p PECIM 2M 3M mas 3M 5 a FSI Fuse 10A NIS E o4 M 8 E IR 4 tol zh amp kes 2L4 X300
7. Ejector it is the ramp before and after the actions of ejector set pressure and flow for each and the range is from 0 to 99 The values should be the differences for pressure and flow between every two PLC cycles when there is action switch Decompression they are the ramps when decompression begins and decompression completes set pressure and flow for each and the range is from 0 to 99 The values should be the differences for pressure and flow between every two PLC cycles when there is action switch Core 1 it is the ramp for core 1 in out set pressure and flow for each and the range is from 0 to 99 The values should be the differences for pressure and flow between every two PLC cycles when there is action Switch SIJECT 15 16 Start up June 2003 3 31 Start up 3 5 Up download PLC program General Preconditions Up Download Procedure 3 32 The highlight of SIJECT15 16 consists in that the PLC program can be up downloaded whenever you wish You can modify the program in your PC PG after you come into the programming environment SIJECT Project Tool is complete PLC programming environment for system development SIMATIC Manager is the basic programming and configuration software for SIMATIC It is made up of a series of applications intended to create and test user program To up download the PLC program you need the following A PC PG with RS232 interface RS232 adapter and a s
8. bate spare DB1 select thermo 00 type J thermocouple pem FF type thermocouple DB1 select alarm 00 no process alarm FF have process alarm DB1 life ctr Life counter incremented by PLC program DB1 DBB32 DB1 finish start 00 PLC start up not finished and ready FF PLC start up finished and ready SIJECT 15 16 Start up June 2003 5 3 Technical Appendix DB1 flags1 BitO0 Machine ready 0 ready 1 running Bit1 OP selection 0 0P15 1 Simatic OP Bit2 PV selection 0 0P15 1 Simatic OP DB1 Shot counter Shot counter actual value DB1 do trans8 15 M40_0 Mold close valve DB1 DBX40 7 M40_7 Ejector retract valve 7 7 DB1 DBX41 3 M41_3 Core 2 out valve DB1 DBX41 4 M41 4 Carriage advance valve DB1 DBX41 5 M41 5 Carriage retract valve DB1 DBX41 6 M41 6 Charge valve DB1 DBX41 7 M41 7 Injection valve M42 0 Heater output 1 Heater output 2 Heater output 3 Heater output 4 DB1 DBX42 4 M42 4 Heater output 5 M43 0 Decompression valve Q Pump 2 Pump 2 M44 7 Zero back pressure valve M43 3 Robot Core 3 out valve 5 4 SIJECT 15 16 Start up June 2003 Technical Appendix pa DB1 DBX45 4 Spare DB1 DBW46 DB1 a_out_0 Analog output 0 pressure 0 100 DB1 DBW48 DBia out Analog output 1 flow 0 100 DB1 f indicate 0 1 power supply for linear scale failure DB1 1 7 battery alarm
9. Installing the Control System 2 3 1 Connecting the Operator Panel X11 Pin assignments Operator panel interface for connector on Connector designation X11 CI side OP15 Connector type 9 pin sub D plug connector Table 2 1 Pin assignments of connector X11 X11 Signal Type M V XBOOT TXD RXD P24 V XRES RXD TXD 24 V 5 olo Or B G Nh U Pin assignments Cl interface for connector on Connector designation X21 OP side 15 16 Connector type 9 pin sub D socket connector Table 2 2 Pin assignments of connector X21 X21 Signal Type M V XBOOT RXD TXD P24 V XRES TXD RXD 24 V 5 R O Nh U 2 12 SIJECT 15 16 Start up June 2003 Installing the Control System 2 3 2 Pin assignments of the RS232 MPI Interface X12 Pin assignments for connector MPI RS232 interface Connector designation Connector type X12 Rs232 MPI 9 pin sub D socket connector Table 2 3 Pin assignments of CI15 connector X12 X12 RS232 Pin Signal Type 1 RS232 DIAG 2 RS232 TXD SOFTPLC 3 RS232 RXD SOFTPLC 4 RS232 TXD DIAG 5 V 6 No connection N C 7 No connection N C 8 No connection N C 9 No connection N C Table 2 4 Pin assignment of CI16 connector
10. Spare pares See pares See pares See Deiner Input 8 Safety door 2 Input 9 Back door Input10 DB1 DBX60 3 Input11 Carriage advance end SIJECT 15 16 Start up June 2003 5 5 Technical Appendix Address Type Description DB1 DBX60 4 Input12 Carriage retract end DB1 DBX60 5 Input13 Ejector advance end DB1 DBX60 6 Input14 Ejector retract end DB1 DBX60 7 Input15 Mold close end DB1 d 7 DB1 DBX61 0 Input 0 DB1 DBX61 1 Input 1 DB1 DBX61 2 Input 2 DB1 DBX61 3 Input 3 DB1 DBX61 4 Input 4 DB1 DBX61 5 Input 5 DB1 DBX61 6 Input 6 DB1 DBX61 7 Input 7 DB1 d in24 31 DB1 DBX62 0 Input24 Safety door 1 DB1 DBX62 1 Input25 Lubrication error DB1 DBX62 2 Input26 Mold adjustment photo sensor DB1 DBX62 3 Input27 Full auto photo sensor DB1 DBX62 4 Input28 Robot DB1 DBX62 5 Input29 Core 3 in end counter sensor DB1 DBX62 6 Input30 Core 3 out end DB1 DBX62 7 Input31 Screw speed sensor DB1 d in16 23 DB1 DBX63 0 Input16 Mold adjustment advance end DB1 DBX63 1 Input17 Mold adjustment retract end DB1 DBX63 2 Input18 Core 1 in end counter sensor DB1 DBX63 3 Input19 Core 1 out end DB1 DBX63 4 Input20 Core 2 in end counter sensor DB1 DBX63 5 Input21 Core 2 out end DB1 DBX63 6 Input22 Injection safety door DB1 DBX63 7 Input23 Motor overload DB1 DBW64 DB1 screw speed speed actual value DB1 thermo ARRAY T O0 7 of word DB1
11. Weight Table 1 3 Weight Component Weight Kg component 4 1 OP component 1 8 Dimensions Table 1 4 Component Dimensions Dimensions HXWXD Cl component 390 288 X 70 CI15 390 X 288 X 84 5 C116 OP component 392 X 202 36 Environmental operating conditions Table 1 5 Environmental operating conditions Parameter Temperature range 0 50 C Permissible relative humidity 5 95 without condensation Air pressure 700 1 060hPa Transport and storage conditions Table 1 6 Transport and storage conditions Parameter Temperature Transport 40 70 Storage 20 55 Permissible relative air humidity 5 95 without condensation Air pressure 700 1 060hPa Transport height 1 000 3 000 m 1 4 SIJECT 15 16 Start up June 2003 SIJECT 15 16 Control System Free fallin transport package SIJECT 15 16 Start up June 2003 1 5 SIJECT 15 16 Control System Protective quality and degree of protection Class of protection level to IEC 536 CI IP20 OP IP54 PE terminal required Foreign matter and water protection to IEC 529 System characteristics Table1 7 System characteristics System SIJECT 15 SIJECT 16 SIJECT16 SIJECT16 DP Type SIJECT 15 International International PLC controller SIJECT Project SIMATIC S7 SIMATIC S7 Tool 314 315 Main controller CI 15 116 116 Digital inp
12. 50922 M DQ2 1 DQ2 0 3M 4 NJ 3L Fig 2 11 Connecting the digital outputs in SIJECT 16 Int P Switch 2 24 SIJECT 15 16 Start up June 2003 Installing the Control System Signal description The digital outputs are assigned with the following signals DQ 0 0 Core 1 in valve DQ 0 1 Core 1 out valve 0 2 Core 2 in valve DQ 0 3 Core 2 out valve DQ 0 4 Carriage advance valve DQ 0 5 Carriage retract valve DQ 0 6 Charge valve DQ 0 7 Injection valve DQ 1 0 Mold close valve DQ 1 1 Mold close fast valve DQ 1 2 Mold open valve DQ 1 3 Mold open fast valve DQ 1 4 Mold adjustment advance valve DQ 1 5 Mold adjustment retract valve DQ 1 6 Ejector advance valve DQ 1 7 Ejector retract valve DQ 2 0 Suck back valve DQ 2 1 Pump 2 DQ 2 2 Zero back pressure valve DQ 2 3 Air blow 1 DQ 2 4 Air blow 2 DQ 2 5 Core 3 in DQ 2 6 Core 3 out DQ 2 7 Robot Note The DC24V power supply should meet the requirements of the safe separation in accordance with DIN EN 50178 The terminal M in the DC24V power supply for the digital output Signals 1M 3M are to be earthed additionally Danger The positive terminal of digital outlet lines terminal 1L 3L must be protected through a 10A fuse See Fig 2 14 The connection from DC24V power supply to the line L and M may not be exchanged otherwise it can bring about a destruction in the Cl board SIJECT 15 16 Start up June 2003 2 25 Installing the Con
13. Example in IL LD 20 LE 30 ST Var1 Result is TRUE GE Greater than or equal to Example in IL LD 60 GE 40 ST Var1 Result is TRUE EQ Equal to Example in IL LD 40 EQ 40 ST Var1 Result is TRUE SIJECT 15 16 Start up June 2003 4 9 Programming Tool Address Operators Calling Operator Type Conversion Functions 4 10 NE Not equal to Example in IL LD 40 NE 40 ST Var1 Result is FALSE ADR Address Function Example in IL LD Var1 ADR ST Var2 man fun1 Content Operator A pointer can be dereferenced by adding the content operator after the pointer identifier Example in ST ptPOINTER TO INT var int1 INT var int2 INT pt ADR var_int1 var_int2 pt CAL Calling a function block or a program Example Calling up the instance Inst from a function block where input variables Par1 and Par2 are 0 and TRUE respectively CAL INST PAR1 0 PAR2 TRUE It is forbidden to implicitly convert from a larger type to a smaller type for example from INT to BYTE or from DINT to WORD Special type conversions are required if one wants to do this One can basically convert from any elementary type to any other elementary type Syntax lt elem Typ1 gt _TO_ lt elem Typ2 gt BOOL TO Conversions Conversion from type BOOL to any other type Example in IL LD TRUE Result is 1 BOOL TO INT ST BOOL Conversions
14. ROR in n erg in and n should be of the type BYTE WORD or DWORD in will be shifted one bit position to the right n times while the bit that is furthest to the left will be reinserted from the left Example in IL LD 16 245 ROR 2 ST erg byte All selection operations can also be performed with variables For purposes of clarity we will limit our examples to the following which use constants as operators SEL Binary Selection OUT SEL G INO IN1 means OUT INO if G FALSE OUT IN1 if G TRUE Example in IL LD FALSE SEL 3 4 ST Var1 Result is 3 MAX Maximum function Returns the greater of the two values OUT MAX INO IN1 Example in IL LD 90 MAX 30 MAX 40 MAX 77 ST Var1 Result is 90 MIN Minimum function Returns the lesser of the two values OUT MIN INO IN1 Example in IL LD 90 MIN 30 SIJECT 15 16 Start up June 2003 Programming Tool Comparison Operators MIN 40 MIN 77 ST Var1 Result is 30 LIMIT Limiting OUT LIMIT Min IN Max means OUT MIN MAX IN Min Max Example in IL LD 90 LIMIT 30 80 ST Var1 Result is 80 MUX Multiplexer OUT MUX K INO INn means OUT INK Example in IL LD 0 MUX 30 40 50 60 70 80 ST Var1 Result is 30 GT Greater than Example in IL LD 20 GT 30 ST Var1 Result is FALSE LT Less than Example in IL LD 20 LT 30 ST Var1 Result is TRUE LE Less than or equal to
15. in SIJECT 16DP lights up Flashes in case of SIJECT16DP DP STAT Green Flashes in case of SIJECT16 STAT 1 Red BATF Red DC5V Green SF Red FORCE Yellow STOP Yellow RUN Green Fig 3 1 LED signal For any other case you can refer to Table 2 19 in section 2 6 You also can check the booting status on the Information screen 2 as follows 1 Use the Information key to open the Information screen 1 Push the PgDn key to call the Information screen 2 Check the messages on the screen PLC Switch PLC Startup PLC LifeCnt OP Communication CI EEPROM In case that the display brightness doesn t match with the environment you can adjust the brightness using the Function key Steps are as follows SIJECT 15 16 Start up June 2003 Start up 1 Press Function key a to enter function picture 2 Press softkey F3 to increase the brightness and press softkey F4 to decrease brightness In addition screen back light can also be set on this screen If selected the screen will be black automatically in 3 minutes if not selected the screen will always have display Refer to SIJECT 15 16 Operation Manual for detailed operation procedure Note For the first operation password class 1 1111 should be entered Display seque
16. lt X OOo MN T lt lt Output characteristics Max output current 1 42A Max valve Voltage 40V DC SIJECT 15 16 Start up June 2003 Installing the Control System Connecting sensor and actuators X305 without integrated amplifier board X306 X307 with integrated amplifier board 20060606505 Fig 2 13 Connecting the analog outputs Signal description The analog outputs are assigned with the following signals AQ1 AQ1 Pressure valve 0 140bar AQ2 AQ2 Flow valve 0 100 AQ3 AQ3 Back pressure valve 0 140bar AQ4 AQ4 4 proportional valve Or PV1 Pressure valve 0 140bar PV2 Flow valve 0 100 PV3 Backpressure valve 0 140bar PV4 4 proportional valve SIJECT 15 16 Start up June 2003 2 29 Installing the Control System 2 4 Power supply Screw terminal block The AC220V load power supply unit required for supplying Cl and OP is wired to screw terminal block The minimum cross section of the wire is 0 75m Three phase power supply input PE N U SIJECT 15 Mold injection JBK3 63 transformer Machine Controller 380V 220V L N Fig 2 14 Connection diagram of system power supply Terminal assignments Table 2 14 Term
17. 580 7 S S Fuse 10A X lo 6 d amp cl a SE IM mell Tu S E3 100 5 a A 1 2 Fig 2 15 Grounding diagram for OP and CI 2 32 SIJECT 15 16 Start up June 2003 Installing the Control System To ensure the normal operation of equipment good grounding is required Users are recommended to take following actions according to GB T5226 1 1996 eqv IEC204 1 1992 1 The grounding wire should be Yellow Green wire with cross section 2 5 mm Linear scale and both sides of the shield of thermocouple signal wire must be grounded well on the injection molding machine The shield of the AC380V 220V transformer within injection molding machine must be grounded well on the injection molding machine Metal sheet embedded underground can be used as earth wire Water pipe or metal frame of building which are grounded well can also be used as earth wire To ensure the reliability of the grounding copper lead should be welded with earth wire A Danger The grounding wiring must be finished prior to connecting AC220V SIJECT 15 16 Start up June 2003 2 33 Installing the Control System 2 6 LEDs and Mode selector S1 Error and There are 10 LEDs on the front panel of the Cl status LEDs DP sF DP STAT ote he symbol means that this LED is only used in SI
18. DBW66 DB1 thermo 0 Analog input TC 0 nozzle DB1 DBW68 DB1 thermo 1 Analog input TC 1 DB1 DBW70 DB1 thermo 2 Analog input TC 2 DB1 DBW72 DB1 thermo 3 Analog input TC 3 DB1 DBW74 DB1 thermo 4 Analog input TC 4 DB1 DBW76 DB1 thermo 5 Analog input TC 5 DB1 DBW78 DB1 thermo 6 Analog input TC 6 DB1 DBW80 DB1 thermo 7 Analog input TC 7 oil 5 6 SIJECT 15 16 Start up June 2003 Technical Appendix DB1 lin scaleO Analog put linear scale 0 0 NAAA mold input linear scale 3 TOV carriage DB1 DBB92 DB1 mem comm Semaphore MEM COMM 0 finished 1 put recipe into DB2 2 7 get recipe from DB2 DB1 DBB93 DB1 recipe nr Recipe number DB1 DBW94 DB1 recipe len Length of recipe unit byte DB1 DBW96 DB1 recipe data The starting address for recipe ARRAY 0 1023 DB1 DBB96 DB1 DBB1119 byte DB1 comm errors DB1 DBW1120 DB 1 DBW1 150 15 of word DB1 io_errors io errors DBIDBW1182 _ DBW1152 DB1 BIZ errors sce a DBW1154 ELE can errors 0955 DBW1156 DB1 DBW1186 ARRAY O 15 of word SIJECT 15 16 Start up June 2003 5 7 Technical Appendix 5 2 Glossary abbreviation AC Alternating current Al Analog input AO Analog output ADC Analog digital conversion BATF Battery fault CORA Coupling RAM Arbiter Cl Compact interface CPU Central processing unit CAN BUS Controller Area Network BUS CSP Customer specific picture DAC Digital Can
19. Enum_1 gt lt Enum_n gt END_TYPE Example TYPE TRAFFIC_SIGNAL Red Yellow Green 10 The initial value for each of the colors is red 0 yellow 1 green 10 END_TYPE Structures Structures are created as objects in the Object Organizer under the register card Syntax TYPE lt Structurename gt STRUCT lt Declaration of Variables1 gt END STRUCT END TYPE Example TYPE Polygonline STRUCT Start ARRAY 1 2 OF INT Point1 ARRAY 1 2 OF INT Point2 ARRAY 1 2 OF INT Point3 ARRAY 1 2 OF INT Point4 ARRAY 1 2 OF INT End ARRAY 1 2 OF INT END STRUCT END TYPE References You can use the user defined reference data type to create an alternative name for a variable constant or function block Syntax TYPE lt lIdentifier gt lt Assignment term END TYPE Example TYPE message STRING 50 END TYPE SIJECT 15 16 Start up June 2003 4 5 Programming Tool 4 1 3 Operators IEC Operators 4 6 SIJECT Project Tool supports all IEC Operators In contrast with the standard functions these operators are recognized implicitly throughout the project Operators are used like functions in POU implemented Arithmetic Operators ADD Addition of variables of the types BYTE WORD DWORD SINT USINT INT UINT DINT UDINT REAL and LREAL Example in IL LD 7 ADD 24 7 ST Var 1 MUL Multiplication of variables of the types BYTE WORD DWORD SINT
20. a series of libraries whose POUs data types and global variables you can use just like user defined variables The library standard lib is a standard part of the program and is always at your disposal POU consists of a declaration part and a body The body is written in one of the IEC programming languages which include IL ST SFC FBD and LD The programming languages are comprehended as follows Instruction List IL An instruction list IL consists of a series of instructions Each instruction begins in a new line and contains an operator and SIJECT 15 16 Start up June 2003 Programming Tool depending on the type of operation one or more operands separated by commas Structured Text ST The structured text consists of a series of instructions which as determined in high level languages or in loops can be executed Sequential Function Chart SFC The Sequential Function Chart is a graphically oriented language which makes it possible to describe the chronological order of different actions within a program Function Block Diagram FBD The Function Block Diagram is a graphically oriented programming language It works with a list of networks whereby each network contains a structure which represents either a logical or arithmetic expression the call of function block a jump or a return instruction Ladder Diagram LD The Ladder Diagram is also a graphics oriented programming language which appro
21. by a warning triangle and depending on the degree of hazard represented as shown below Danger indicates that loss of life severe personal injury or substantial material damage will result if the appropriate precautions are not taken Warning indicates that loss of life severe personal injury or substantial material damage may result if the appropriate precautions are not taken Caution indicates that minor personal injury or material damage may result if the appropriate precautions are not taken Note Is used to draw your special attention to an important information on the product the handling of the product or the corresponding part of the documentation Start up and operation of a device may only be carried out by qualified personnel Qualified personnel as referred to in the safety notices provided in this Manual are persons who are authorized to start up ground and tag devices systems and circuits according to the relevant safety standards Usage as per intended purpose A Please observe the following Warning The device may only be used for the cases of application as intended by the Catalog and only in conjunction with third party devices and components recommended or approved by Siemens The proper and safe operation of the product requires transport storage and installation according to the relevant instructions and qualified operation and maintenance at the prescribed intervals Table of
22. constant to store times of the day Example TIME_OF_DAY 15 36 30 123 DATE_AND_TIME Date constants and the time of day can also be combined to form so called DATE_AND_TIME CONSTANTS Example DATE_AND_TIME 1996 05 06 15 36 30 Number Number values can appear as binary numbers octal numbers decimal numbers and hexadecimal numbers Example 14 Decimal number REAL LREAL REAL and LREAL constants can be given as decimal fractions and represented exponentially Example 7 4 instead of 7 4 STRING A string is a sequence of characters STRING constants are preceded and followed by single quotation marks You may also enter blank spaces and special characters They will be treated just like all other characters Example Abby and Craig Variables can be declared either locally in the declaration part of a POU or in a global variable list SIJECT 15 16 Start up June 2003 4 17 Programming Tool System Flags System flags are implicitly declared variables that are different on each specific PLC To find out which system flags are available in your system use the command Insert Operand An Input Assistant dialog box pops up select the category System Variable Accessing variables for arrays structures and POUs Two dimensional array components can be accessed using the following syntax lt Fieldname gt Index1 Index2 Structure variables can be accessed using the following syntax lt Structur
23. level 1 and 2 When setting the parameters via operator panel the screen will display Enter Password XXXX User should enter the password of class 1 Factory setting for the password class 1 is 1111 Then push the Enter key to confirm the entry After Switch On of control system if there is no action for 5 minutes the system will require password entry for the second time when you operate again User class 2 requires the password 2 2000 on the Service screen It is set up so as to avoid the accidental modification of function parameters by the operator They are the most important parameters with the influence on the machine function Only the service engineer has the accessible right Caution When changing the recipe parameters every machine movement must be stopped SIJECT 15 16 Start up June 2003 3 3 Start up 3 1 2 Structure of recipe data Definition User class Unit Standard data 3 4 Recipe data is consisted of diverse values with different units Usually one set of recipe data contains the following parameters Hydraulic pressure P Hydraulic flow F Movement position S Settime and actual time T Set temperature value and actual temperature value Counter number Mode selection number To set and change the general recipe data user class 1 must be activated Start up of the service parameters generally requires user class 2 The physical units of the rec
24. memory reset RUN RUN Flashes at 2Hz during CPU restart green Mode e Atleast continue 3s however CPU restart can be shorter after CPU restart e During the CPU restart the STOP LED always lights up when the STOP LED goes dark the outputs are enabled Mode selector S1 Mode selector S1 has 4 different positions It depends on the Gray code Table 2 19 Mode selector S1 GRAY 2 GRAY 1 MRES 0 1 STOP 0 0 RUN 1 0 RUN P 1 1 Meanings Table 2 20 Meaning of Mode selector S1 Position Designation Meaning MRES Memory Momentary contact position of the mode Reset selector for resetting the CPU memory A special sequence must be observed when resetting the CPU memory with the mode selector which is applicable for CPU312 IFM 314 IFM STOP STOP Mode The CPU does not scan user programs Programs can e read out of the CPU with a programming device CPU gt PG e Be loaded into the CPU with a programming device PG CPU RUN RUN Mode The CPU scans the user program Programs in the CPU can be read out with a programming device CPU gt PG You cannot change the program in the load memory in the RUN mode RUN P RUN The CPU scans the user program Program Programs can Mode e read out of the CPU with a programming device CPU gt PG e Be loaded into the CPU with a programming device PG CPU SIJECT 15 16 Start up June 2003 2 35 3 Start up Contents E Section Heading 3 1
25. the PLC version in MMC To select Menus in Program types Steps are as follows 1 Press cursor key A or Y to enter program type selection 2 Press Selection Key and the cursor moves to the left 3 Press cursor key A or v to select Menus 4 Press Enter Key to confirm Download Menus from MMC Steps are as follows 1 Plug in MMC card in the CI 2 Select Menus in Program Type ES 3 Press softkey F4 to start data transfer 4 Restart the system after the transfer process is finished The operation is over SIJECT 15 16 Start up June 2003 3 23 Start up 3 4 6 Proportional valve adjustment General Operating sequences Operating sequences 3 24 Users can adjust the proportional valve and test it Adjustval o Val Type Fow v ValLimit Min v PressTest bar FlowTest BckPreTest bar Fig 3 13 Service Screen 1 3 proportional valve adjustment Press softkey F5 to enter proportional valve adjustment screen See Fig 3 13 Service Screen 1 3 proportional valve adjustment Proportional valve can be adjusted here and you can test pressure flow and backpressure under force output mode Adjust Valve select On Off to start valve adjustment Valve Type select the type of valve flow pressure back pressure reserved Valve Limit select min max value Pressure Test in force output mode input pressure value ranged from 0 1
26. the function is type INT Example in IL LD SUSI LEN ST VarINT1 Result is 4 LEFT Left returns the left initial string for a given string Input STR is type STRING SIZE is of type INT the return value of the function is type STRING Example in IL LD SUSI LEFT 3 ST VarSTRING1 Result is SUS RIGHT Right returns the right initial string for a given string Input STR is type STRING SIZE is of type INT the return value of the function is type STRING Example in IL LD SUSI LEFT 3 ST VarSTRING1 Result is USI MID Mid returns a partial string from within a string Example in IL LD SUSI RIGHT 2 2 ST VarSTRING1 Result is US CONCAT Concatenation combination of two strings Example in IL LD SUSI CONCAT ST VarSTRING1 Result is SUSIWILLI INSERT INSERT inserts a string into another string at a defined point Example in IL LD SUSI CONCAT XY 2 ST VarSTRING1 Result is SUXYSI DELETE DELETE removes a partial string from a larger string at a defined position Example in IL LD SUXYSI DELETE 2 23 ST Var1 Result is SUSI SIJECT 15 16 Start up June 2003 Programming Tool Bistable Function Blocks Trigger REPLACE REPLACE replaces a partial string from a larger string with a third string Example in IL LD SUXYSI REPLACE k 2 2 ST VarSTRING1 Result i
27. value It is the difference from actual value to reference point SIJECT 15 16 Start up June 2003 3 19 Start up Linear scale ejector Switch Proximity switch signal When ejector retract is at position the box will backlight showing the reference point of linear scale Reference point setting value Ejector retract end should be the reference of linear scale Length setting value The length of linear scale can be set here ranged from 1 6553mm Actual value displayed value Display the actual value of linear scale Current value displayed value It is the difference from actual value to reference point Linear scale ejector Linear scale ejector can be selected or deselected here 3 20 SIJECT 15 16 Start up June 2003 Start up 3 4 4 Setting Password General Operating sequences The password has three levels Password level 1 for factory setting is 1111 level 2 is 2000 and refer to manufacturer for password of highest level Higher Pwd Retype 2 Higher Pwd New Pwd 1 Retype Pwd 1 Fig 3 11 Service Screen 1 1 password setting Press softkey F3 to enter password setting screen See Fig 3 11 Information screen 1 1 password setting password can be set and changed on this screen Upper Higher password the highest level The default value of this system is xxxx Please ask manufacturer then confirm by Enter Key New Passw
28. 1 DQ1 2 DQ1 3 DQ1 4 DQ1 5 DQ1 6 DQ1 7 5 lt o BR o OlO O O OJjO O lO lt lt X302 Name 3L 3M DQ2 0 DQ2 1 DQ2 2 DQ2 3 002 4 002 5 002 6 002 7 lt NIAT o OlO O O OJjO O lO lt lt Voltage Rated load voltage 24V Max load voltage 28 8V Current Rated load current 2A Max load current 24A Short circuit protection Yes Simultaneity factor 5096 SIJECT 15 16 Start up June 2003 2 23 Installing the Control System Connecting sensor and actuators 2 Fig 2 10 Connecting the digital outputs in 51 15 X300 KJ du DQ1 7 000 6 NJ 509156 000 5 NJ 501 5 NJ 59044 N 50914 NJ 50903 NJ 0913 NJ 0002 NJ 50912 LY 090 1 001 1 NJ 50000 001 0 N 1M ARAN 2M RE 1 2 Sas DQ2 7 RS DQ2 6 002 5 NJ 50924 N 50923 NJ
29. 40bar Flow Test in force output mode input flow value ranged from 0 740096 BackPressure Test in force output mode input pressure value ranged from 0 140bar Firstly start valve adjustment Select ON in Adjust Valve mode 1 Use cursor key A or Y to enter valve adjustment selection L1 2 Press selection key and the cursor moves to the left 3 Use cursor key A or Y to select ON 4 Press Enter key to confirm SIJECT 15 16 Start up June 2003 Start up Secondly select valve type such as pressure valve then select valve limit such as maximum Choose Max in valve limit and change its value by softkey 1 Use cursor key A or v to enter valve adjustment selection L1 2 Press selection key and cursor moves to left 3 Use cursor key A or v to select Max 4 Confirm it with Enter Key 5 Press softkey F3 to increase the Max or use softkey F4 to reduce Max This process can be observed by external amperemeter Lastly check the adjustment result In the Force Output mode implement the Pressure Test 1 Press softkey F2 Force Output and the upper box will backlight 2 Set the value of 140bar in Pressure Test 3 Check if the external amperemeter reaches the maximum such as 1Amp A Caution The handling with the Proportional valve is subject to the prerequisites that all the electrical wiring is completed and the powe
30. 6AT1931 5AB61 0KAO0 06 2001 6AT1931 5AB61 0KAO0 07 2002 6AT1931 5AB61 0KA1 06 2003 Tested Siemens quality for software and training to DIN ISO 9001 Reg No 2160 01 This publication was made with WinWord V 7 and Designer V 6 0 Passing on and reproduction of this document and utilization and disclosure of its contents is not allowed unless specifically authorized Violations shall be cause for damage liability All rights reserved particularly in the event a patent is issued or a utility model patent is registered Siemens AG 2003 All Rights Reserved Order No Printed in People s Republic of China Remark Other functions which are not described in this Documentation can possibly also be performed on the control system However the customer is not entitled to demand these functions when new equipment is supplied or servicing is carried out Although we have checked the contents of this publication for agreement with the hardware and software described we do not accept liability for total agreement since differences cannot be totally ruled out The information in this publication is checked at regular intervals and necessary correction included in the next release Suggestions are welcome Subject to change without prior notice Siemens Aktiengesellschaft Safety Notice Qualified Personnel This Manual contains notices intended to ensure your personal safety and to avoid material damage The notices are highlighted
31. 945 200 5 Mi pols C 2925 MG 2035 2045 p r t Eh 017 po27 937 3 po43 0 Force output Fig 3 7 Information Screen 3 DO Use current parameters to check the LED status Press different button in manual mode to observe the changing status On Fig 3 7 Information Screen 3 DO Force Output is for the force output of certain point For example enter 3 4 and press F2 Force Output then the box will backlight At this moment 003 4 is backlighting on the screen and in the system this point will have output and LED lights up 3 14 SIJECT 15 16 Start up June 2003 Start up 3 4 Setting important parameters In this chapter we will give a description of how OEMs set the most important parameters for injection molding machine It contains how to select language and service how to set each parameter such as linear scale password saving mode start up of proportional valve combination of pumps lubrication temperature and ramp Warning Never pull out or plug in the connector while the equipment is live Otherwise this can result in the damage of data loss or control failure Note Password of level 2 2000 must be entered prior to parameter setting During operation do not transfer the parameter SIJECT 15 16 Start up June 2003 3 15 Start up 3 4 1 Language selection General It is very important for operators to find the desired menus as soon as possible As the first ste
32. AMP linear scale setting Then press softkey F5 to enter ramp setting screen See Fig 3 17 Service Screen 2 4 setting ramp data The ramp data for every movement can be set accordingly Mold Close there are four ramps to be set pressure and flow for each ramp and ranged from 0 to 99 The values should be the differences for pressure and flow between every two PLC cycles when there is action switch Carriage it refers to the ramps during carriage advance and carriage retract set pressure and flow for each and ranged from 0 to 99 The values should be the differences for pressure and flow between every two PLC cycles when there is action switch Inject it refers to the ramps when injection starts and injection completes set pressure and flow for each and the range is from 0 to 99 The values should be the differences for pressure and flow between every two PLC cycles when there is action switch Charge it refers to the ramps when charging starts and charging completes set pressure and flow for each and the range is from 0 to 99 The values should be the differences for pressure and flow between every two PLC cycles when there is action switch SIJECT 15 16 Start up June 2003 Start up Mold Open there are four ramps to be set pressure and flow for each ramp and ranged from 0 to 99 The values should be the differences for pressure and flow between every two PLC cycles when there is action Switch
33. BYTE WORD or DWORD Example in IL Var1 BYTE LD 2 1001_0011 OR 2841000 1010 ST Var1 Resultis 221000 1011 XOR Bitwise XOR of bit operands The operands should be of the type BOOL BYTE WORD or DWORD Example in IL Var1 BYTE LD 2 1001_0011 OR 24000 1010 ST Var1 Result is 220001 1001 NOT Bitwise NOT of bit operands The operands should be of the type BOOL BYTE WORD or DWORD Example in IL Var1 BYTE LD 24001 0011 NOT ST Vari Resultis 240110 1100 SHL Bitwise left shift of an operand erg SHL in n The input variables erg in and n should be of the type BYTE WORD or DWORD in will be shifted to the left by n bits and filled with zeros on the right Example in IL LD 16 45 SHL 2 ST erg_byte SIJECT 15 16 Start up June 2003 4 7 Programming Tool Selection Operators 4 8 SHR Bitwise right shift of an operand erg SHR in n erg in and n should be of the type BYTE WORD or DWORD in will be shifted to the right by n bits and filled with zeros on the left Example in IL LD 16 245 SHR 2 ST erg byte ROL Bitwise rotation of an operand to the left erg ROL in n erg in and n should be of the type BYTE WORD or DWORD in will be shifted one bit position to the left n times while the bit that is furthest to the left will be reinserted from the right Example in IL LD 16245 ROL 2 ST erg byte ROR Bitwise rotation of an operand to the right erg
34. Contents 1 SIJECT 15 16 Control System nnn 1 1 Components of SIJECT 15 16 1 2 Technical Data 1 3 dde dt hee ae eae hee 2 Installing the Control 2 1 Installing and Dismantling eeeeeeeeee 2 2 Interfaces and cabling 2 3 Connecting the Individual Components of Cl esses 2 3 1 Connecting the Operator Panel X11 2 3 2 Pin assignments of the RS232 MPI Interface X12 2 3 3 Pin assignments of the P bus Interface X14 2 3 4 Pin assignments of the Profi bus Interface X15 2 3 5 Connecting the Digital inputs X203 X204 X205 X206 2 3 6 Connecting the Thermocouples X200 X201 2 3 7 Connecting the linear scale X202 2 3 8 Connecting the Digital outputs X300 X301 X302 2 3 9 Connecting the relay outputs X303 X304 2 3 10 Connecting the analog outputs X305 X306 X307 24 Power Supply 2 5 ai ee 2 6 LEDs and Mode selector 51 3 M 3 1 ee ee 3 1 1 Access levels 3 1 2 Structure of recipe data 3 1 3 Handling of recipe data 3 1 4 Recipe Data Saving 3 2 Switching on and Booting
35. Conversion from another variable type to BOOL Example in IL LD 213 Result is TRUE BYTE TO BOOL ST b SIJECT 15 16 Start up June 2003 Programming Tool Numeric Functions Conversion between Integral Number Types Conversion from an integral number type to another number type Example in IL LD 2 INT TO REAL MUL 3 5 REAL TO LREAL TO Conversions Conversion from the variable type REAL or LREAL to a different type Example in IL LD 2 7 REAL TO INT GE 9 MW8 TIME TO TIME OF DAY Conversions Conversion from the variable type TIME or TIME OF DAY to a different type Example in IL LD T 12ms Result is T 12ms TIME TO STRING ST str DATE TO DT TO Conversions Conversion from the variable type DATE or DATE AND TIME to a different type Example in ST b DATE TO BOOL D 1970 01 01 Result is FALSE STRING TO Conversions Conversion from the variable type STRING to a different type Example in ST b STRING TO BOOL TRUE Result is TRUE TRUNC Conversion from REAL TO INT The whole number portion of the value will be used Example in IL LD 2 7 TRUNC GE 969MW8 ABS Returns the absolute value of a number ABS 2 equals 2 Example in IL LD 2 ABS ST Result is 2 SQRT Returns the square root of a number Example in IL LD 16 SQRT ST q Result is 4 SIJECT 15 16 Start up June 2003 4 11 Programming Tool 4 12 LN Returns the natural l
36. General 3 2 3 1 1 Access levels 3 314 36 3 2 Switching on and booting the control 3 7 system SIJECT 15 16 Start up June 2003 3 1 Start up 3 4 General Start up requirements The following is required e User Manual Operation Manual SIJECT 15 16 e PC PG Data exchange with control system With RS232 adapter and SIMATIC 7 300 programming tool for down upload PLC program for SIJECT15 With MPI adapter and SIMATIC 7 300 programming tool for down upload PLC program for SIJECT16 With SIJECT adapter and Toolbox for updating system software MMC card be used to transfer customer specific picture recipe data and PLC program The mechanical and electrical installation of the equipment must be completed Note For installation refer to the installation description provided in the chapter 2 in this manual The control system with its components boots without errors Start up A possible start up sequence for the SIJECT 15 16 is as follows Sequence Check whether the boots Check the diverse versions of PLC CI and OP Check the I Os via display and the LEDs in Cl Set recipe data Optimize the data Ox Qv Wm Coo ct Save the data 3 2 SIJECT 15 16 Start up June 2003 Start up 3 1 1 Access levels User class User class 1 User class 2 The SIJECT 15 16 implements user class concept to enable certain data areas The user classes have protection
37. Heater 7 Heater 8 Relay output Note P V 7 proportional valve T thermocouple L S linear scale Fig 2 4 Connection Diagram for SIJECT 15 16 2 8 SIJECT 15 16 Start up June 2003 Installing the Control System AC220V Mains with Op Amp DATTA X303 Heating relay X305 P V without Op Amp nonno eu 0000020020000 020002 000200 X201 T couple MITT NAAT ALANA uua Multimedia card MMC 2202020202020 02 0002 Note Tightening torque range of each clamping screw in terminal connector 200 206 X300 307 is 0 5 0 6 Nm proportional valve S V solenoid valve L S linear scale T couple thermocouple Fig 2 5 Connection Diagram for CI of SIJECT 15 SIJECT 15 16 Start up June 2003 2 9 Installing the Control System AL Pa wi
38. JECT16 DP Fig 2 16 Position of LEDs and mode selector S1 Meaning of LEDs Table 2 18 Meaning of LEDs LED Meaning Description Remarks DP SF System Lights up if system is fault For CI16DP red Fault DP STAT System Lights up if system works normally For CIT6DP green Normal STATO CI Flashes at 1 second interval if Cl is normal green Normal STAT1 CI Lights up if CI is fault red Fault BATF Battery Lights up if the battery is defective or not Only for 16 and red Fault inserted CI16DP DC5V Power LED will be bright all the time if the DC Check DC5V circuit green Supply 5V circuit is normal Error SF System LED flashes when there is You must use a red Error Fau e Hardware faults programming device It e Firmware errors and read out the e Programming errors contents of the e Parameter assignment errors diagnostics buffer to e Arithmetic errors determine the exact e Timer errors nature of the Defective memory card error fault e Battery failure or no backup on power on e fault error external I O only 2 34 SIJECT 15 16 Start up June 2003 Installing the Control System LED Meaning Description Remarks FORCE Force job Lights up if a force job is active yellow STOP STOP Lights up when CPU is not scanning the yellow Mode user program Flashes at 1 second interval when CPU requests a
39. L CTUDInst CU VarBOOL2 RESET VarBOOL3 LOAD VarBOOL4 PV VarINT1 LD CTUDInst QU ST VarBOOL5 LD CTUDInst QD ST VarBOOL6 LD CTUDInst CV ST VarINT2 TP The function block Timer is a trigger Example in IL CAL TPlnst IN VarBOOL1 PT T 5s LD TPInst Q ST VarBOOL2 TON The function block Timer On Delay implements a turn on delay Example in IL CAL TONInst IN VarBOOL1 PT T 5s LD TONInst Q ST VarBOOL2 TOF The function block TOF implements a turn off delay Example in IL CAL TOF Inst IN VarBOOL1 PT T 5s LD TOFInst Q ST VarBOOL2 RTC The function block Runtime Clock returns starting at a given time the current date and time SIJECT 15 16 Start up June 2003 Programming Tool 4 1 5 Operands Overview Constants Variables Constants variables addresses and possibly function calls can appear as operands BOOL BOOL constants are the logical values TRUE and FALSE TIME TIME constants can be declared in SIJECT Project Tool These are generally used to operate the timer in the standard library A TIME constant is always made up of an initial t or T and a number sign H Example TIME1 T 14ms DATE These constants can be used to enter dates A DATE constant is declared beginning with a D DATE or date followed by You can then enter any date with format Year Month Day Example DATE 1996 05 06 TIME_OF_DAY Use this type of
40. SIEMENS SIJECT 15 16 Start Up Software Version 1 Technical Manual 06 2003 Edition F3 F l rs ire o 1 IG t bos Rafal gt f ER 3 e ea 4 a 2 ga 3 Manufacturer Documentation SIJECT 15 16 Document Structure General Documentation Catalog Short Guide for Start up User Manual Operation manual Operation Manual Technical Manual Start Up Start up SIEMENS SIJECT 15 16 Start Up Software Version 1 Technical Manual Valid for Control System Software Version SIJECT 15 16 1 08 06 2003 Edition SIJECT15 16 Control System Installation of Control System Start up Programming Tool Technical Appendix SIJECT Documentation Key to editions The editions listed below have been published prior to the current edition The column headed Note lists the amended sections with reference to the previous edition Marking of edition in the Note column New documentation B Unchanged reprint with new order number C Revised edition of new issue If any technical details presented on one of these pages have been changed with reference to the previous edition it is indicated by another edition number in the header of the respective page Edition Order No 12 2000
41. SIJECT is delivered in a compensated state In case it should be necessary to re compensate the thermocouple i e the displayed temperature is different from the actual temperature value please perform the following steps 1 Measure the outside temperature with a thermometer before starting the heater Type in the outside temperature value Check the heater temperature on Temperature Screen 1 2 The displayed value must be exactly the measured outside temperature A Caution The thermocouple input is scanned every 100ms at intervals and the displayed temperature values on the screen will be refreshed every 800ms for all 8 thermocouple inputs The broken wire detection is done every 40 seconds at intervals It makes a clicking sound at the same time SIJECT 15 16 Start up June 2003 3 29 Start up 3 4 10 Setting the Ramp data General Operating Sequences 3 30 All the ramp data are assigned in order to moderate the running shake of the machine during the movement switch so that the product service life can be extended Users should observe the machine movement diversification when adjusting the setting data and optimizing the parameters until the machine can run smoothly VATED a Sa ED ERU Mid Clo Car MidOpn Ejector Dec Inject Charge Core 1 Care 2 Care 3 Fig 3 17 Service Screen 2 4 setting ramp data On service screen 1 press softkey F2 to enter service screen 2 R
42. Signal Type 1 Not connect N C 2 Not connect N C 3 DP P B 4 Not connect 5 M V 6 P5 V 7 Not connect N C 8 DP N B 9 Not connect N C SIJECT 15 16 Start up June 2003 2 15 Installing the Control System 2 3 5 Connecting the Digital inputs X203 X204 X205 X206 Pin assignments Interface for digital inputs for connector Connector designation X203 X204 X205 X206 In Connector type 10 pin plug connector Table 2 7 Pin assignments of connector X203 Name Type 010 0 010 1 010 2 010 3 010 4 010 5 010 6 010 7 24 5 gt Olo 4 O0 N U X204 Name Type 011 0 DI1 1 011 2 011 3 DI1 4 011 5 DI1 6 DI1 7 24 V 5 gt X205 Name Type DI2 0 DI2 1 012 2 012 3 012 4 012 5 012 6 012 7 24 V 5 lt X206 Name Type DI3 0 013 1 013 2 013 3 013 4 013 5 013 6 013 7 24 V 5 NIAAA OIN gt U 2 16 SIJECT 15 16 Start up June 2003 Installing the Control System Input voltage Signal 1 9V 30V Signal 0 0 5 Input current Signal 1 6mA Connecting sensors and actuators N iE
43. USINT INT UINT DINT UDINT REAL and LREAL Example in IL LD 7 MUL 2 4 7 ST Var 1 SUB Subtraction of one variable from another of the types BYTE WORD DWORD SINT USINT INT UINT DINT UDINT REAL and LREAL Example in IL LD 7 SUB 2 4 7 ST Var 1 DIV Division of one variable by another of the types BYTE WORD DWORD SINT USINT INT UINT DINT UDINT REAL and LREAL Example in IL LD 8 DIV 2 ST Var1 Result is 4 MOD Modulo Division of one variable by another of the types BYTE WORD DWORD SINT USINT INT UINT DINT UDINT REAL and LREAL The result of this function will be the remainder of the division This result will be a whole number Example in IL LD 9 MOD 2 ST Var1 Result is 1 INDEXOF Perform this function to find the internal index for a POU Example in ST var1 INDEXOF POU2 SIZEOF Perform this function to determine the number of bytes required by the given data type SIJECT 15 16 Start up June 2003 Programming Tool Bitstring Operators Bit Shift Operators Example in IL arr1 ARRAY 0 4 of INT Var1 INT LD arr1 SIZEOF ST Var1 Result is 10 AND Bitwise AND of bit operands The operands should be of the type BOOL BYTE WORD or DWORD Example in IL Var1 BYTE LD 2 1001_0011 2 1000_1010 ST Var1 Result is 221000 0010 OR Bitwise OR of bit operands The operands should be of the type BOOL
44. X12 X12 MPI Pin Signal Type 1 RS232 RXD DIAG 2 M24 M 3 MPI P V 4 RS232 TXD DIAG 5 6 5 V 7 P24 V 8 MPI N M 9 MPI RTS SIJECT 15 16 Start up June 2003 Installing the Control System 2 3 3 Pin assignments of the P bus Interface X14 Pin assignments P bus interface for connector Connector designation Connector type X14 P bus 25 pin sub D socket connector Table 2 5 Pin assignments of connector X14 X14 5 Signal Type RS ALARM N IM ADRO N IM ADR1 IM ADR2 N M KBUS B N RS OD N RS DIDO N olo On B G Nh U RS CLK N 10 RS COM 11 RS LST N 12 RS READY N 13 No connection 14 RS ALARM 15 IM ALARMO 16 IM ALARM1 17 IM ALARM2 18 lt 2 gt 19 KBUS B 20 RS OD 21 RS DIDO 22 RS CLK 23 RS COM 24 RS LAT 25 RS READY ClO OOoUooooo z oo o 5ou rzooo This interface can not be used K Bus interface SIMATIC K Bus because the internal pin 6 and 19 have no wire 2 14 SIJECT 15 16 Start up June 2003 Installing the Control System 2 3 4 Pin assignments of the Profi bus Interface X15 Pin assignments Profi bus interface for connector Connector designation X15 Profi bus Connector type 9 pin sub D socket connector Table 2 6 Pin assignments of connector X15 X15 Pin
45. a project Within this project the data are structured according to their function and represented objects Note To operate the SIMATIC Manager please order the software and program according to the Operation Manual SIJECT 15 16 Start up June 2003 4 19 5 Technical appendix Contents Section Heading Page Definition of DB1 Glossary abbreviation SIJECT 15 16 Start up June 2003 5 1 Technical Appendix 5 1 Definition of DB1 DB1 Definition DB1 DBX0 0 8 Cycle stop Heater start Heater stop Mold open Key12 Mold close Key13 Ejector retract Key14 Ejector advance Key15 Carriage advance DB1 keysO 7 Key 7 Motor stop DB1 keys24 31 Air blow 2 Mold adjustment retract Mold adjustment advance Lubrication Key29 Purge start Key30 Purge stop Key31 ACK DB1 keys16 23 Key18 Decompression Key23 Core 2 out DB1 keys spare 5 2 SIJECT 15 16 Start up June 2003 Technical Appendix Injection reset Confirm update time Force output Type of value 0 recipe byte 1 recipe word 2 actual value DB1 dummy1 DB1 val_index DB1 op value Data from OP to PLC DB1 op spare1 Semaphore OP COMM FF data from OP are in DBWO DBW10 00 PLC has read the data and stored in DBW20 DBW24 DB1 dummy3 Spare LED1 Mold adjustment mode Cycle run Photo sensor full auto mode Timer full auto mode
46. aches the structure of an electric circuit Standard The standard IEC 1131 3 is an international standard for programming languages of Programmable Logic Controllers Main window The following elements are found in the main window of SIJECT Project Tool from top to bottom see Fig 4 1 The menu bar The Tool bar optional with buttons for faster selection of menu commands The Object Organizer with register cards for POUs Data types Visualizations and Resources A vertical screen divider between the Object Organizer and the Work space of SIJECT Project Tool The Work space in which the editor windows are located The message window optional The Status bar optional with information about the current status of the project WA ES Does Exar Dire Window Heb alex Alsie aens x mitia i 81212 COCececcesese FDO 060 23 0203 uA 3 L Lx 23 Nem Message Powers SUECT Projet BY Mcxoick Wad D M Fig 4 1 Main window of SIJECT Project Tool SIJECT 15 16 Start up June 2003 4 3 Programming Tool 4 1 2 Data types General Standard data types Defined Data types You can use standard data types and user defined data types when programming Each identifier is assigned to a data type which dictates how much memory space will be reserved and what type of values it stores It contains the fol
47. alog conversion DC Direct current DI Digital input DO Digital output DPSF CPU 315DP system fault DPSTAT CPU 315DP system status DRAM Dynamic RAM FRCE Force HW Hardware LCD Liquid crystal display LED Low Emitting Diode LS Linear scale MMC Multi media card MPI Multi port input MRES Reset memory OP Operator panel PC PG Programming device PV Proportion valve PROFIBUS PROFI Bus PBUS Periphery Bus PLC Program logic controller RECIPE Recipe RUN P Program run SRAM Static RAM SF System fault SW Software TC Temperature control 5 8 SIJECT 15 16 Start up June 2003 To SIEMENS NUMERIC CONTROL LTD NANJING CHINA R amp D Division No 18 Siemens Road Jiangning Development Zone 211100 Nanjing People Republic of China Company Dept Address Telephone Fax Suggestions and or corrections Suggestions Corrections For Publication Manual SIJECT 15 16 Start up Software Version 1 Manufacturer Documentation Technical Manual Order No 6AT1931 5AB61 0KA1 Edition 06 2003 Should you come across any printing errors when reading this publication please notify us on this sheet Suggestions for improvement are also welcome
48. ar scale setting Then press softkey F4 i so as to enter temperature setting screen Temperature channel can be set from 1 to 5 and temperature can be set accordingly Temperature Tolerance Plus set the tolerance plus for each temperature channel Temperature Tolerance Minus set the tolerance minus for each temperature channel Oil Upper set the upper limit of hydraulic oil temperature Oil Lower set the lower limit of hydraulic oil temperature Temperature Compensation set the temperature compensation The system has been set compensation before delivery and it is unnecessary for users to set it Nozzle Mode two modes are available it can be assigned as close loop or open loop Channel 1 select or deselect Channel 2 select or deselect Channel 3 select or deselect Channel 4 select or deselect Channel 5 select or deselect Oil Temperature Alarm If oil temperature alarm is selected when the upper lower limit of oil temperature has been set there is no alarm if oil temperature is within the specification and alarm occurs if it is out of specification SIJECT 15 16 Start up June 2003 Start up Note The default type of the thermocouples is K unless otherwise programmed in the PLC application Normally the themperature compensation is intended only for the controller manufacturer to calibrate the offset of the electronic measurement device on the controller and every
49. ating sequences Press Information Key to enter information screen Then press softkey F3 or F4 to check the actual status of digit input output SIJECT OP15B System Information OP Version CI Version PLC Version Siemens Numerical Control Ltd Fig 3 5 Information Screen 1 Then press softkey F3 to enter DI screen digit input 5 153 0 ss 2203 204 20205 puo gg Do n i 011 O 21 DIO2 1212 D 103 O O 110128 O L1 Bg 2105 O Dis 25 O DOs NM pis 01025 ml 102 O L1 L1 Fig 3 6 Information screen 2 DI Use current parameters to check the LED status SIJECT 15 16 Start up June 2003 3 13 Start up Press different button in manual mode to observe the changing status On information screen 1 Fig 3 5 Information Screen 1 press softkey F4 to enter DO screen digit output or on information screen 2 Fig 3 6 Information Screen 2 DI press softkey F1 to enter DO screen a gt s x300 X301 3302 3303 X304 00 2000 M 01 DQLH C DOZ O Doat DQ41 0 2 M po2 Do22 2932 2042 M 903 L1 bQ13 LJ DpQ23 1 DnQ33 O 29430 2004 NM vow 20034 pow 290 O 12015 pgs O 0935 10
50. ename gt lt Variablenname gt Function block and program variables can be accessed using the following syntax lt Functionblockname gt lt Variablenname gt Addresses Address The direct display of individual memory locations is done through the use of special character sequences These sequences are a concatenation of the percent sign 96 a range prefix a prefix for the Size and one or more natural numbers separated by blank spaces Example QX75 and Q75 Output bit 75 Memory location You can use any supported size to access the memory location Functions In ST a function call can also appear as an operand Example Result Fct 7 3 4 18 SIJECT 15 16 Start up June 2003 Programming Tool 4 2 SIMATIC Manager Introduction STEP7 is the basic programming and configuration software for SIMATIC It is made up of a series of applications each of which does a specific job within the scope of programming an automation task such as configuring and assigning parameters to the hardware creating and debugging user programs configuring networks and connections The basic package can be extended by a range of optional packages for example additional programming language packages such as SCL S amp Graph or HiGraph The graphic user interface provided for these tasks is known as the SIMATIC Manager The SIMATIC Manager collects all the data and the settings necessary for an automation task together in
51. ensor can be set as Normal Open mode Nopn mode or Normal Close NClo mode Lubrication error not standard LubErrNSTD Switch contact in the alarm circuit can be set as Normal Open mode Nopn mode or Normal Close NClo mode Fast mold open FastMldOpn It can be set as Normal mode fast mold open and special mode slow mold open Motor protection MotStrPro Motor protection can be selected i e whether to extend time during the start up of star triangle Motor protection also can be deselected Special selection 1 SpecSel 1 Spare Special selection 2 SpecSel 2 Spare Screw cam number ScrewCam During screw speed measurement cam numbers set on the screw Range 1 255 Motor shut When there is alarm it is the time passing by from alarm occurring to motor shut Range 30 999 Heat Off When alarm occurs user selects whether to switch off the heater SIJECT 15 16 Start up June 2003 3 17 Start up Operation Example 3 18 Ejector retract tolerance EjeRetTol When ejector selects linear scale the tolerance of ejector retract can be set from 0 1 9 9 mm Mold open tolerance MidOpnTol The tolerance of mold open can be set from 1 0 99 9 Special parameter 3 SpecPar 3 Spare Special parameter 4 SpecPar 4 Spare To select position in carriage retract mode you can do as follows 1 Press cursor key A or v to enter CarRetMod selection 2 Press se
52. ftware includes menus customer specific picture and recipe data e Toolbox programming tool SIJECT project tool SIJECT PTPS it is the programming tool only applicable to SIJECT 15 SIMATIC S7 300 it is the programming tool only applicable to SIJECT 16 e Multimedia card MMC card It contains the PLC application programs max 2 MB maximum 50 sets recipe data 50KB OP menus max 64KB and a customer specific picture max 8KB User data are e Customer specific picture e Recipe data e PLC program Modified user data are saved in the Flash EPROM so that the power off or power failure has no influence on the user data The differences between SIJECT 15 and SIJECT 16 lie in their different PLC configuration Table 1 1 Differences between SIJECT15 and SIJECT16 PLC configuration SIJECT 15 SIJECT 16 Hardware No Hardware SIMATIC S7 300 Software SIJECT Project Tool SIMATIC Manager SIJECT 15 16 Start up June 2003 1 3 SIJECT 15 16 Control System 1 2 Technical Data Connected load Table 1 2 Connected load Parameter Min Type Max Unit Remarks Supply voltage 100 220 250 V Input frequency Power of and Current consumption of 2 A outputs Digital input output 24 V Proportional valve 24 38 Relays 24 220 v It depends on the resistance of proportional valve It can be supplied with DC24V or AC220V
53. gram will be saved in EEPROM Now the PLC downloading process is finished A Caution Uploading can not be implemented in SIJECT15 Therefore PLC applications must be saved in disk and then modified in PC PG Step 2 Up download PLC program in SIJECT16 1 Start the SIMATIC Manager in PC PG 2 Locate the mouse pointer at the symbol PLC in the menu bar and click the mouse 3 Select the menu command Upload 4 Press on the symbol and then release Now the Uploading process is finished 1 Start the SIMATIC Manager in PC PG 2 Locate the mouse pointer at the symbol PLC in the menu bar and click the mouse 3 Select the menu command Download 4 Press on the symbol Download and then release Now the Downloading process is finished SIJECT 15 16 Start up June 2003 3 33 4 Programming Tool Contents Section _ Page Purpose This chapter describes the following process SIJECT Project Tool basic subject for programming in SIJECT15 SIMATIC Manager a brief introduction for programming in SIJECT16 SIJECT 15 16 Start up June 2003 4 1 Programming Tool 4 1 SIJECT Project Tool General 4 1 1 Introduction Preliminary Project com ponents Programming Languages 4 2 SIJECT Project Tool is a complete development environment for your PLC SIJECT Project Tool stands for Controller Development System SIJECT Project Tool puts a simple approach to the powerf
54. heck the limit switch for core in out SIJECT 15 16 Start up June 2003 3 11 Start up 3 12 Wane Description Remedy TmCha Charging is not finished 1 No material in hopper lul o NN TmMldPro Low pressure mold protection time is up 1 Clear the obstacle in the mold 2 Extend the mold protection time Injection safety door is not closed 1 Close the safety door when injection 2 Check the switch of safety door Lubrication oil level is too low 1 Check the setting of lubrication Waiting for robot 1 Waiting for robot downward ob Robot is failed 1 Check the sensor of robot 2 Check the setting of robot In Injection time has been exceeded 1 Check the material 2 Check the nozzle R Tc ScwSenErr Screw speed is abnormal Check if there is any material in the barrel LS p of channel 1 nozzle is broken hermocouple of channel 2 heater is broken pese of channel 3 heater is broken hermocouple of channel 4 heater is broken hermocouple of channel 5 heater is broken TC6 Fault Thermocouple of channel 6 oil is broken la Err j Power supply of linear scale is failure rm 31 rm 32 SIJECT 15 16 Start up June 2003 Start up 3 3 Checking I Os Overview After booting without any error the control system can be put into operation Check I Os status prior to setting the parameters which can avoid the unnecessary troubleshooting Oper
55. igital output 10 pin front connector 3 sets for connecting digital outputs e X303 X304 Relay output 10 pin front connector 2 sets for connecting heating relay and common relay e X305 Analog output 8 pin front connector 1 set for connecting analog output for proportional pressure and flow valve with external driver card e X306 X307 Power output 6 pin front connector 2 sets for connecting power output for proportional pressure and flow valve with integrated driver card OP e X21 Cl interface 9 pin sub D socket for connecting CI LEDs 10 LEDs for fault and status displays Operating elements selector S1 3 It is only applicable for SIJECT 16 international 16DP international It is only applicable for SIJECT 16DP international SIJECT 15 16 Start up June 2003 2 7 Installing the Control System Connecting cables components are wired up as shown in the Connection Diagram 2 4 Please refer to this Figure for the type of cables required Wire 1A OP15 15B 6AT1131 0EA00 0AA0 PU 6ES7368 3BC51 0AA0 2 5m 6ES7368 3BF01 0AA0 5 0m 6ES7972 0BA40 0XA0 Other Profi_bus 6ES7972 0BB40 0XA0 controller 6AT1131 0GA00 0AA0 Switch 1 Switch 2 Digital input switch 32 Digital output Valve 24 Analog output Thermocouple input Analog input Heater 1 Heater 2 Heater 3 Heater 4 Heater 5 Heater 6
56. inal assignments of terminal board Terminal 1 L Live 2 N Neutral 3 PE Protective earth Characteristics of the load power supply Table 2 15 Input specification Parameters Min Max Units Rated input 100 250 V voltage Range 90 270 V Frequency 47 63 Hz Fuse On board fusing Ripple Second level Table 2 16 Output specification Output Rated Voltage Load Remarks voltage current range regulation Output 1 24 5 1 5 1 1 Output 2 15V 0 3A 5 5 Max 40W Output 3 15V 0 1A 5 5 Linear regulation 2 Ripple and noise 196 20MHz BW Supervision All outputs have protection for over current and voltage 2 30 SIJECT 15 16 Start up June 2003 Installing the Control System Operator panel Digital input output Relay output Proportional valve A Table 2 17 General specification Parameter Min Max Unit MTBF 50 000 Hour Storage 40 80 environment Operation 0 55 environment EMC FCC class B requirements CISPR 22 class S The operator panels does not have separate power supply terminals It is supplied via the signal cable from the CI The digital inputs outputs require an external DC24 switch power The relay outputs are rated at 250Vac 0 5A They need a supply line of AC220V or DC24V The proportional valves need a separate switch power It can be chosen in accordance with the type of proportional valve
57. ipe data are set as follows Table 3 1 Recipe data unit Parameter Unit Pressure P bar Flow F Position S mm Timer T second Temperature Counter No unit Mode selection No unit For convenience of the user we deliver the controller with the integrated PLC program You should set and adjust the recipe data in compliance with the program No default recipe data exist in the control system with the version of the control supplied unless otherwise programmed SIJECT 15 16 Start up June 2003 Start up 3 1 3 Handling of recipe data Handling methods Display Input via keys and MMC card Making back up copies and saving to MMC card Loading the recipe data from MMC card Alarm when If the process of loading recipe data from MMC card has errors an alarm Loading recipe is output data User can execute related operation according to the alarm Note You should press Enter key to confirm your setting whenever any parameter has been changed SIJECT 15 16 Start up June 2003 3 5 Start up 3 1 4 Recipe Data Saving Internal data saving External data saving The recipe data on the screen can be automatically saved in the memory during operation After power on for the next time the saved recipe data will be recovered To avoid loss of the setting parameters the recipe data should be saved internally before the control system is switched off In the permanent memory max 30 set
58. lection key and the cursor moves to left 3 Press cursor key A or to select Pos 4 Confirm by Enter key SIJECT 15 16 Start up June 2003 Start up 3 4 3 Setting linear scale General Operating sequences Users can select two linear scales or three linear scales and set reference point and length Current Ref Actual Length LS Mod n LS inject Ls Eject o LS Eject or Y Ref Mid End of MidC lo Ref Inj End of Inj Ref Eje End of EjeRet Fig 3 10 Service Screen 2 setting linear scale Press softkey t to enter the next screen See Fig 3 10 Service screen 2 linear scale Linear Scale mold Switch Proximity switch signal When mold close is at position the box will backlight showing the reference point of linear scale Reference point setting value Mold lock end should be the reference of linear scale Length setting value The length of linear scale can be set here ranged from 1 6553mm Actual value displayed value Display the actual value of linear scale Current value displayed value It is the difference from actual value to reference point Linear scale injection Reference point setting value Reference point of linear scale can be set here Length setting value The length of linear scale can be set here ranged from 1 6553mm Actual value displayed value Display the actual value of linear scale Current value displayed
59. low end applications to high end applications Hardware components It consists of the following hardware components e Compact interface main controller i e CPU and I O board e OP Operator panel with LCD display and keyboard i e CPU LCD and Keyboard e Cable Communication cable between Cl and OP CI15 16 Fig 1 1 Hardware components of SIJECT 15 16 Software components SIJECT15 16 comprises the following software components in which the parts marked with a star symbol can be ordered separately e System software on the permanent Flash EPROM of the CI System frame is the basic programming environment for all program modules Loading kernel SIJECT Sijload loads all the remaining part of the software of micro controller Firmware includes I O message Memory card object communication with OP application program executes the Integrated PLC User Program cyclically It is usually stored in MMC and delivered to customer 1 2 SIJECT 15 16 Start up June 2003 SIJECT 15 16 Control System User data Data saving Differences between SIJECT 15 and 16 e System software on the Flash EPROM of the OP System frame is the basic programming environment for all program modules Loading kernel SIJECT Sijload loads all the remaining part of the software of micro controller Firmware includes display code key scanning and communication with CI Application so
60. lowing data Bool TRUE and FALSE 8 bits Integer Data Types BYTE 0 255 8bits WORD 0 65535 16bits DWORD 0 4294967295 32bits SINT 128 127 8bits USINT 0 255 8bit INT 32768 32767 16bits UINT 0 65535 16bits DINT 2147483648 2147483647 UDINT 0 4294967295 32bits REAL LREAL floating point types REAL 32bits LREAL 64bits STRING can contain any string of characters default size 80 characters Time data types TIME millisecond 32bits TIME OF DAY millisecond 32bits DATE second 32bits DATE AND TIME second 32bits It contains the following data ARRAY One two and three dimensional fields arrays are supported as elementary data types Arrays can be defined both in the declaration part of a POU and in the global variable lists Syntax lt Field_Name gt ARRAY lt 111 gt lt u11 gt lt 112 gt lt u12 gt OF lt elem Type gt Example Card_game ARRAY 1 13 1 4 OF INT Pointer Variable or function block addresses are saved in pointers while a program is running Syntax Identifier POINTER TO lt Datatype Functionblock gt Example pt POINTER TO INT var_int1 INT 5 var int2 INT pt ADR var_int1 var int2 pt var int2 is now5 SIJECT 15 16 Start up June 2003 Programming Tool Enumeration Enumeration is a user defined data type that is made up of a number of string constants Syntax TYPE lt ldentifier gt lt Enum_0 gt lt
61. ms can be displayed in SIJECT16 The active alarm will pop up on the Alarm screen You can see the alarm text and remedy in following table Table 3 3 Alarm list Name Description Remedy AdjLimit Mold adjustment is over limit 1 Check the limit switch AutAdjFin Auto mold adjustment finished AdjSenErr Photo sensor for mold adjustment is invalid 1 Photo sensor is invalid in mold adjustment advance retract p Check if the photo sensor is damaged TmpLimit Temperature is not in permitted range 1 Check the heating status of barrel uui Check if the heating LED lights up OilTmp Oil temperature is out of the range 1 Check the oil temperature Check the oil thermocouple MotLoad Hydraulic pump is overload 1 Check the hydraulic system ME Check the circuit breaker MidSg Safety door is not closed 1 Check the limit switch of safety door Close the safety door roduct counter is full TmCyc i ing 1 One step occupies too much time during the cycle Cycle time is too short CycSenCov photo sensor is covered 1 The photo sensor is damaged CycSenErr 1 The photo sensor is damaged MidOpnEm 1 Check the limit switch M o TmMidLck 1 Clear the obstacle in the mold und EjeNotBck Ejector is not in the back position 1 Check if the ejector is at end limit switch ee Check pressure flow CorNotBck Cores are not back to the start position 1 C
62. nce Display screen 1 Customer specific picture OEM t Ys PF Beals SIJECT 15 16 Tel 86 25 2101888 Fax 86 25 2101666 Siemens Numerical Control Ltd Nanjing P R China Starting please wait Fig 3 2 Customer Specific Picture CSP This picture is presented for 3 seconds Siemens can make every specific picture according to the requirements of users SIJECT 15 16 Start up June 2003 3 9 Start up 3 10 Menu 2 Information screen 1 Silt SIJECT OP15B System Information PLC Version 2 Siemens Numerical Control Ltd Fig 3 3 Information screen 1 This picture will last 3 seconds Menu 3 Monitoring screen gt 4 E z 0 a 10 VEN ET 5o m MidPos 1500 0 m PartCount 65535 ScwPos 999 9 m CurStartup 55535 EjeP os 999 9 CycTime 99 SewSpd 1200 0 pm RedpeNo Fig 3 4 Monitoring screen This screen is the main picture of the system This screen will display all the time until it is switched to the desired menu by pressing the other keys The operator can supervise the production process with reference to the parameters displayed on the screen The current operation state is displayed in the status field In case of malfunction the alarm symbol will appear and user can enter alarm picture to check the alarm SIJECT 15 16 Start up June 2003 Start up 3 2 2 Alarm General Alarm list Up to 32 alar
63. ocouples X200 X201 Pin assignments Interface for thermocouple for connector Connector designation Connector type Table 2 8 X200 X201 In 8 pin plug connector Pin assignments of connector 5 X200 TI1 TI1 TI2 TI2 TI3 TI3 4 oO o h gt U 14 5 X201 TI5 TI5 TI6 6 TI7 TI7 TI8 OD or BO Ph 0 TI8 lt lt lt lt lt lt lt lt 4 lt lt lt lt lt lt lt lt Thermocouple Temperature range Absolute accuracy A D characteristics Resolut Sampling rate Connecting sensor ion K J 0 700 3K 16bit 2s T14 14 TI3 TI3 TI2 112 T11 TH RS e X201 Fig 2 8 SIJECT 15 16 Start up June 2003 Connecting the thermocouple Installing the Control System Signal description 2 20 The analog inputs are assigned with the following signals 11 11 2 12 14 14 TI5 TI5 TI6 TI6 TI7 TI7 T18 TI8 SIJECT 15 16 Start up June 2003 Installing the Control System 2 3 7 Connecting the linear scale X202 Pin assignments Interface for linear scale for connector Connector designation Connector type X202 In 12 pin plug connector
64. ogarithm of a number Example in IL LD 45 LN ST q Result is 3 80666 LOG Returns the logarithm of a number in base 10 Example in IL LD 314 5 LOG ST q Result is 2 49762 EXP Returns the exponential function Example in IL LD 2 EXP ST q Result is 9 7448 009 COS Returns the cosine of number The value is calculated in arch minutes Example in IL LD 0 5 COS ST q Result is 0 877583 TAN Returns the tangent of number The value is calculated in arch minutes Example in IL LD 0 5 TAN ST q Result is 0 546302 ASIN Returns the arc sine inverse function of sine of a number Example in IL LD 0 5 ASIN ST q Result is 0 523599 ACOS Returns the arc cosine inverse function of cosine of a number The value is calculated in arch minutes Example in IL LD 0 5 ASIN ST q Result is 1 0472 ATAN Returns the arc tangent inverse function of tangent of a number The value is calculated in arch minutes Example in IL LD 0 5 ATAN ST q Result is 0 463648 SIJECT 15 16 Start up June 2003 Programming Tool EXPT Exponentiation of a variable with another variable Example in IL LD 7 EXPT 2 ST vari Result is 49 SIJECT 15 16 Start up June 2003 4 13 Programming Tool 4 1 4 Standard Library Elements String functions 4 14 LEN Returns the length of a string Input STR is a type STRING the return value of
65. ord 2 A new password 2 can be set here then confirm by Enter Key The default value of this system is 2000 Retype Password 2 retype the new password 2 and confirm it with Enter Key When the password has been successfully changed the screen will display message Press Acknowledgment Key 51 to finish the operation Lower Higher password it is the password level 2 The default value of this system is 2000 then confirm by Enter Key New password 1 a new password 1 can be set here then confirm by Enter Key The default value of this system is 1111 Retype password 1 retype the new set password 1 then confirm it by Enter Key SIJECT 15 16 Start up June 2003 3 21 Start up When the password has been successfully changed the screen will display a message Press Acknowledgment Key X to finish the operation 3 22 SIJECT 15 16 Start up June 2003 Start up 3 4 5 Savelload setting General Operating sequences Operating examples Users can save load the PLC menus and CSP customer specific picture by this function It can save load information to from MMC Program Types PLC MMC PLC version Fig 3 12 Service Screen 1 2 save load setting Press softkey F4 to enter save load screen The PLC menus CSP can be saved loaded to from MMC Program types User can select PLC menus or CSP MMC PLC version displayed value Press softkey F2 PLC version to show
66. p you should select the appropriate language You can select the language Chinese English on this screen EAA 9 a5 t te ERU es CO 37 Robot Con Back Light v Language Enaiish v Fig 3 8 Function Screen Change language first move the cursor to the third line then press softkey F1 to choose Chinese or English and confirm with Enter Key Fig 3 8 Function Screen language can be changed Steps are as follows 1 Press cursor key A or to enter language selection box L1 2 Press selection key if it is the first entry then input passward of level one of 1111 then press Enter key to return to Function Screen 3 The cursor moves to left and choose by key A or 4 Select Chinese or English 5 Press Enter Key to confirm 3 16 SIJECT 15 16 Start up June 2003 Start up 3 4 2 Service selection General Users can execute some basic setting and selections by this function 90 421 ces CarRetMod ScrewC am CycSenNSTD Motor Shut LubErrNSTD Heat Off FastMIdOpn EX EjeRetTol MotStrP ro MlIdOpnTol SpecSel 1 SpecPar 3 SpecSel 2 SpecPar 4 Fig 3 9 Service Screen 1 service selection Operating Sequences Press Service Key to enter Service screen See Fig 3 9 Service Screen 1 service selection Carriage retract mode CarRetMod Carriage retract can select position mode or time mode Cycle sensor not standard CycSenNSTD S
67. pecific cable for SIJECT15 MPI adapter and an appropriate cable for SIJECT16 CD with SIJECT Project Tool for SIJECT15 SIMATIC 57 300 programming tool in CD SIJECT16 The Mode Selector S1 must be set in RUN P position prior to up downloading PLC program Note The MMC card can be used to save load the PLC program Carry out external data saving before you up download the program See 3 1 4 recipe data saving PLC program can only be uploaded downloaded after SIJECT Project Tool for SIJECT15 or SIMATIC Manager for SIJECT16 has been ordered Step 1 Up download PLC program in SIJECT 15 1 Start SIJECT Project Tool in PC PG 2 Open Project 3 Locate the mouse pointer at the symbol Online in the menu bar and click the mouse Select the menu command Communication parameter Check following parameters Port COM1 Baudrate 19200 Parity Even Stop bits 1 Motorola byteorder No 6 Locate the mouse to Online again Select menu command Login SIJECT 15 16 Start up June 2003 Start up 8 The screen will display following information The program has been changed Do you want to download new program Yes No 9 Select Yes and click the mouse to download the new program 10 Put the mouse pointer to Online for the third time 11 Select menu command Create boot project 12 Display following information Yes No or Abort 13 Select Yes then the pro
68. r 6AT1131 5CA00 0BAO English Version SW 14 SIMATIC Manager V5 0 6ES7810 4CC04 0YX0 15 Short Guide for Start up SNC 184 000 000 028 16 Operation Manual SIJECT 15 16 6AT1931 5AB41 0BA1 English 17 Operation Manual SIJECT 15 16 6AT1931 5AB41 0KA1 Chinese 18 Start Up Manual SIJECT 15 16 6AT1931 5AB61 0BA1 English 19 Start Up Manual SIJECT 15 16 6AT1931 5AB61 0KA1 Chinese 20 P bus cable 2 5m 6ES7368 3BC51 0AAO0 21 P bus cable 5 0m 6ES7368 3BF01 0AAO 22 Profi bus cable 6XV1830 0EH10 1ABO 23 Profi bus Connector 1 6ES7972 0BA40 0XA0 24 Profi_bus Connector 2 6ES7972 0BB40 0XA0 25 Lithium battery SNC_000 000 575 332 SIJECT 15 16 Start up June 2003 1 7 2 Installing the Control System Contents Section Heading Page Pin assignments of the RS232 MPI interface 2 13 X12 Pin assignments of the P bus interface X14 Pin assignments of the Profibus interface 2 15 X15 Connecting the Digital Inputs X203 X204 X205 X206 Connecting the digital Ce X301 2 23 X302 3 Connecting the Analog outputs X305 X306 2 28 X307 Power supply 2 30 Grounding 2 32 LEDs and Mode selector S1 SIJECT 15 16 Start up June 2003 2 1 Installing the Control System 2 1 Installing and Dismantling A Procedure Warning Do not install when the equipment is live Do not dismantle when the equipment is live The modules contain electrostatically sensitive devices It must be ensured
69. r supply DC 24V DC 38V is connected We describe the commisioning process as an example provided that the resistance of the proportional valve is 10Q and DC24V power supply is adopted Therefore it means that the max output value of PV is reached when the pointer in the amperemeter indicates the maximal value of 1A and the min output value is reached when the pointer indicating 100mA proportional flow valve and 0 mA proportional pressure valve SIJECT 15 16 Start up June 2003 3 25 Start up 3 4 7 Pump Combination Setting General Operating sequences 3 26 User can set the pump combination according to different machine type So as to optimize the energy IB 4 Pump2 Flow Pump3 Flow T Pump4 Flow Note Pump1 always On Fig 3 14 Service Screen 2 1 pump combination setting On service screen 1 press softkey F2 to enter service screen 2 FUP linear scale setting Then press softkey F2 to enter pump combination setting screen See Fig 3 14 Service Screen pump combination setting Pump2 pump3 pump4 can be selected here and the flow can be set accordingly Pump2 Flow flow range 010096 Pump3 Flow flow range 0 410096 Pump4 Flow flow range 0 10096 SIJECT 15 16 Start up June 2003 Start up 3 4 8 Lubrication setting General Operating sequences User can set the time and interval of lubrication 900 4E Lub Time X9
70. s SKYSI FIND FIND searches for a partial string within a string Example in IL LD SUXYSI FIND XY ST VarINT1 Result is 3 SR Making Bistable Function Blocks dominant Q1 SR SET1 RESET means Q1 NOT RESET AND Q1 OR SET1 Example in IL CAL SRinst SET1 VarBOOL1 RESET VarBOOL2 LD SRInst Q1 ST VarBOOL3 RS Resetting Bistable Function Blocks Q1 SR SET1 RESET1 means Q1 NOT RESET1 AND Q1 OR SET Example in IL CAL RSInst SET VarBOOL1 RESET1 VarBOOL2 LD RSInst Q1 ST VarBOOL3 SEMA A Software Semaphore Interruptible Example in IL CAL SEMAInst CLAIM VarBOOL1 RELEASE VarBOOL2 LD SEMAInst BUSY ST VarBOOL3 R_TRIG The function block R_TRIG detects a rising edge Example in IL CAL RTRIGInst CLK VarBOOL1 LD RTRIGInst Q ST VarBOOL2 F TRIG The function block F TRIG detects a falling edge Example in IL CAL FTRIGInst CLK VarBOOL1 LD FTRIGInst Q ST VarBOOL2 SIJECT 15 16 Start up June 2003 4 15 Programming Tool Counter Timer 4 16 CTU The function block Incrementer Example in IL CAL CTUInst CU VarBOOL1 RESET VarBOOL2 PV Var INT1 LD CTUInst Q ST VarBOOL3 LD CTUInst CV ST VarlNT2 CTD The function block Decrementer Example in IL CAL CTDInst CD VarBOOL1 LOAD VarBOOL2 PV Var INT1 LD CTDInst Q ST VarBOOL3 LD CTDInst CV ST VarlNT2 CTUD The function block Incrementer Decrementer Example in IL CA
71. s of recipe data with the relevant mould number can be saved It is recommended to carry out internal data saving whenever important data changes have been made Saving data internally Use the Save Load key m to enter save screen and use Selection key to select system then input recipe number from 1 to 30 then press Enter key to confirm your entry Apart from internal data saving the recipe data can also be saved externally i e in MMC card Max 50 sets of recipe data with the relevant mould number can be saved External data saving should be performed whenever series start up has to be done Saving data externally Plug the MMC card in the slot after the controller is switched off Use the Save Load key to open the save load screen Use Selection key to select MMC card Enter the value with the recipe number in the range from 1 to 50 Press Enter key to confirm your entry 5 If the number exceeds 30 the data can only be displayed and can not be saved The screen will give message during operation 3 6 SIJECT 15 16 Start up June 2003 Start up 3 2 Switching on and Booting the control system Procedure Mode selector S1 hardware Booting the control system Visual inspect the system for proper mechanical installation with tight electrical connections power supply connection connection for shielding and grounding Turn on the control system No
72. start 004 2 Motor start DQ4 3 Alarm light DQ4 4 Lubrication pump DQ4 5 Alarm buzzer DQ4 6 spare 004 7 A Warning Special care must be taken when connecting the relay to AC220V power supply AC220V should never be connected to digital input output otherwise the circuit will be burned out Note It is strongly recommended that SSR Solid State Relay should be used to control barrel heating in the plastic machine in order that the relay life time can be extended considerably SIJECT 15 16 Start up June 2003 2 27 Installing the Control System 2 3 10 Connecting the analog outputs X305 X306 X307 Pin assignments for connector 2 28 Interface for analog outputs Connector designation X305 X306 X307 Out Connector type 8 pin and 6 pin plug connector Table 2 12 Pin assignments of connector X305 without integrated Op Amp For 4 proportional valves Pin Name Type 1 AQ1 V 2 AQ1 V 3 AQ2 V 4 AQ2 V 5 AQ3 V 6 AQ3 V 7 AQ4 V 8 AQ4 V Output characteristics Voltage range 10V 10V Max output current 5mA Gain error 1 Offset error 100mV Resolution 10bit Table 2 13 Pin assignments of connector X306 with integrated Op Amp For PV 1 and PV 2 in Name Type 4L 4M PV1 PV1 PV2 PV2 307 with integrated Op Amp For PV 3 and PV 4 in Name Type 5L 5M PV3 PV3 PV4 PV4 olal ajn o lt
73. t Mounting dimensions 2 Switch on the system and observe the status of LEDs SF red and STOP yellow At this time the SF red should light up and the STOP yellow flash PLC should be reset 3 Switch S1 to position 1 MRES then to position 2 STOP and wait for one second Switch S1 to position 1 MRES again then to position 4 RUN P Observe the status of LEDs SF red STOP yellow and RUN green The system is ready if SF red and STOP yellow are Switched off and the green RUN LED is switched on Battery installation is finished and assemble the cover Download the PLC program Note In case that SF red keeps bright and STOP yellow is always flashing in the above mentioned process step 3 and 4 must be repeated until both LEDs go dark Steps 1 When battery alarm occurs the lithium battery must be replaced 2 Open the cover of the battery when power on 3 Pull out the used lithium battery 4 Replace it with a new one 5 Assemble the cover and screw it Warning During operation the system must be always powered on There is risk of fire explosion or combustion Do not recharge disassemble crush heat above 212 F 100 C or incinerate The dimensions shown below are important when installing the control components It is only applicable for SIJECT 16 international 16DP international SIJECT 15 16 Start up June 2003 2 3 Installing the Control System
74. te If memory and Mode selector S1 are set correctly the control system boots The CI is provided with the Mode selector to assist start up of the control system This switch can be operated by a screwdriver Table 3 2 Mode selector setting Position Status Meaning MRES Reset CPU memory STOP STOP mode RUN mode RUN P RUN PROGRAM mode The switch should be in the RUN position when the control system works normally The position RUN P must be held during the down uploading PLC program When the control system is turned on for the first time an initial state of the control system is established automatically All memory areas are initialized and are loaded with previously stored default data This initial state is the precondition for error free start up of the control system SIJECT 15 16 Start up June 2003 3 7 Start up 3 2 1 Boot messages Displays on the screen LED signal Brightness adjustment 3 8 When the control system is booting the booting process will be displayed on the screen as follows 1 Atfirst the customer specific picture is displayed for 3 seconds 2 Then on the screen shows the Information menu for 3 seconds 3 After this the Monitoring window will be opened If the control system has booted without errors the green DC5V LED will light up and the green STAT1 LED in SIJECT 15 15 16 flash at 1 second interval or the green DP STAT LED
75. th ddadadddadd AAAI RRL uuu Note Tightening torque range of each damping screw in terminal connector X200 X206 X300 307 is 0 5 0 6 Nm Fig 2 6 Connection Diagram for Cl of SIJECT 16 Int 16DP Int P Switch 2 10 SIJECT 15 16 Start up June 2003 Installing the Control System 2 3 Connecting the Individual Components of CI Connecting the Please note the following Components Note Use only shielded cable and make sure that the shield is connected with the metal or metal plated connector casing on the control side The cable offered as accessories provides optimum protection against interference Proceed as follows to connect the individual components 1 Connectthe lines to the components as shown in Fig 2 5 2 6 2 Fixthe sub D connector using screws SIJECT 15 16 Start up June 2003 2 11
76. that persons without ESD protection never touch printed circuit boards or components when handling operator panel OP and CI unit Prior to installation you should prepare 4 nuts M3 for OP installation and 4 cross head screws M4 for CI installation The sheet metal can not have any paint The thickness of a sheet metal for mounting shall not be less than 2 mm 1 Install the CI within the electrical cabinet 2 Install the Operator Panel on the control rack of injection molding machine Connect CI and OP with communication cable Connect the wiring of periphery circuit I Os thermocouple linear scale proportional valve etc 5 Connect entry wire of power supply AC220V Dismantling the control system A Battery set u The control components are dismantled as described above in the reverse order Danger Install grounding connection before plug in of screw terminal block to AC220V mains Make sure that all delivered interface connectors female are plugged in before operation Do not interchange connectors special in case of AC220V in use for X303 and X304 Operating sequence 1 Open the battery cover Plug in the plug on the end of the battery cable into the connector of the Cl board Pay attention to the pole of battery only applicable for SIJECT 16 international 16DP international 2 2 SIJECT 15 16 Start up June 2003 Installing the Control System Battery Replacemen
77. the control 3 2 1 Boot messages 3 2 2 Alarm 3 3 Checking l OS sentent LLL sa ae v P redeo e risu 3 4 Setting important parameters 3 4 1 Language selection 3 4 2 Service selection 3 4 3 Setting linear scale 3 4 4 Setting Password 3 4 5 Save load setting 3 4 6 Proportional valve adjustment 3 4 7 Pump Combination Setting 3 4 8 Lubrication setting 3 27 3 4 9 Temperature setting 3 28 3 4 10 Setting the Ramp data 3 30 3 5 Up download PLC eee 3 32 4 Programming Tool c get eei deeds 4 1 4 1 SECT Project 4 2 4 1 1 Introduction 4 2 4 1 2 Data types 4 4 4 1 3 Operators 4 6 4 1 4 Standard Library Elements 4 14 4 1 5 Operands 4 17 4 2 SIMATIC nnns nnne nnns 4 19 5 Technical appendix 2 22 1 eintritt inue 5 1 5 1 Definition OF DBA i E RE RERO ERE pe ndn 5 2 5 2 Glossary AARE E nnne 5 8 1 SIJECT 15 16 Control System Contents secon Components of SIJECT15 16 Technical Parameter SIJECT 15 16 Start up June 2003 1 1 SIJECT 15 16 Control System 1 1 Components of SIJECT 15 16 What is SIJECT15 16 The SIJECT 15 16 is a controller for injection molding machine It offers solutions for injection molding machines from
78. trol System 2 3 9 Connecting the relay outputs X303 X304 Pin assignments Interface for relay outputs for connector Connector designation Connector type X303 X304 Out 10 pin plug connector Table 2 11 Pin assignments of connector Name 5 X303 Heating relay Type 1W DQ3 0 DQ3 1 DQ3 2 DQ3 3 2W DQ3 4 DQ3 5 DQ3 6 KQo o o oj N U 093 7 lt OOO O 5 X304 Common relay Type 3W DQ4 0 DQ4 1 DQ4 2 DQ4 3 4w DQ4 4 DQ4 5 DQ4 6 NIAAA U 004 7 lt lt Switching capacity Max switching voltage Rated current Max switching current Min switching capacity Switching frequency Connecting sensor and actuators 250VAC 110VDC 0 5A 3A 250VAC 30VDC 100uA 100mVDC 1Hz Fig 2 12 Connecting the relay outputs 2 26 SIJECT 15 16 Start up June 2003 Installing the Control System Signal description The relay outputs are assigned with the following signals DQ 3 0 Heater output 1 DQ 3 1 Heater output 2 DQ 3 2 Heater output 3 DQ 3 3 Heater output 4 DQ 3 4 Heater output 5 DQ 3 5 Heater output 6 DQ 3 6 Heater output 7 DQ 3 7 Heater output 8 004 0 Motor star start 004 1 Motor triangle
79. ul IEC language at the disposal of the PLC programmer Use of the editors and debugging functions is based upon the proven development program environments of advanced programming languages such as Visual SIJECT Project Tool is a complete development tool used to program your PLC which will save you a measurable amount of time setting up your applications A project contains all of the objects in a PLC program A project is saved in a file named after the project The following objects are included in a project POUs Program Organization Units data types visualizations resources and libraries You have to follow the most important concepts mentioned above in order to make starting easier Functions function blocks and programs are POUs Data types Along with the standard data types the user can define his own data types Structures enumeration types and references can be created Visualization SIJECT Project Tool provides visualizations so that you can display your project variables You can plot geometric elements off line with the help of the visualization They can then change their form online depending upon certain variable values Resources You need the resources for configuring and organizing your project and for tracing variable values Global Variables PLC Configuration Task Configuration Sampling Trace Watch and Receipt Manager Libraries You can include in your project
80. ut 23 31 31 High speed counter 1 1 1 input Digit output 24 24 24 Relay output 6 8 8 Temperature zone 5 1 8 8 Thermocouple type K J K J K J Linear scale 3 4 4 Proportional valve 2 4 4 HMI 320x240 320x240 320x240 Back light CCFL CCFL CCFL Programming RS232 MPI MPI interface OP interface 1 1 1 P bus 1 1 Profibus 1 MMC card 1 1 1 Power supply AC100 250V AC100 250V AC100 250V 1 6 SIJECT 15 16 Start up June 2003 SIJECT 15 16 Control System 1 3 Order Number General The SIJECT series product can be ordered in the form of package But you also can receive the components separately if you only order the option It depends on the configuration and can meet your requirements furthest Please see the order number of all components in the following table Table 1 8 Order Number MLFB Order No No Component SNC No 1 SIJECT15 OP15B 6AT1131 5CC20 0XBO 2 SIJECT15 6AT1131 5CC20 0XA0 3 SIJECT16 international 6AT1131 6CD20 0XA0 4 SIJECT16DP international 6AT1131 6CE20 0XA0 5 OP15B 6AT1131 5BB20 0XBO 6 CI15 6AT1131 5DC20 0AA0 7 C116 international 6AT1131 6DD20 0AA0 8 CI16DP international 6AT1131 6DE20 0AA0 9 Communication cable 6AT1131 0EA00 0AAO0 10 SIJECT adapter 6AT1131 0FA00 0AAO 11 Multimedia Card MMC card 6AT1131 0GA00 0AAO0 12 SIJECT PTPS SIJECT Project Tool 6AT1131 5DA00 0BAO English Version SW 13 SIJECT Sijload SIJECT Loade

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