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6500-UM001A-US-P, Pro-Set 200 Design Manual

1. Clamp Clamp Clamp Clamp Clamp Clamp Clamp Clamp Clamp Clamp Clamp Clamp Decomp Open Fast Open Fast Low Hold Low Hold active pit Decomp Open Open Active Bit Comp Bit Open Open Open Slow Open Slow Decel Comp Bit Comp Bit Breakaway Breakaway Decel Decel Active Bit Comp Bit Active Bit Active Bit Comp Bit Active Bit Comp Bit B146 208 B146 13 00 B146 224 B146 14 00 B146 272 B146 17 00 B146 288 B146 18 00 B146 336 B146 21 00 B146 352 B146 22 00 B146 337 B146 21 01 B146 353 B146 22 01 B146 338 B146 21 02 B146 354 B146 22 02 B146 339 B146 21 03 B146 355 B146 22 03 Complete Bit Tonnage Profile Done Bit Clamp Low Hold Profile Active B146 223 B146 13 15 B146 239 Clamp Low Hold Profile Done B146 14 15 Clamp Decompress Profile Active B146 287 B146 17 15 B146 303 Clamp Decompress Profile Done B146 18 15 B146 351 Clamp Open Profile Active B146 21 15 Clamp Open Profile Done Bit B146 367 N161 30 N165 30 N169 30 N169 38 N169 46 N169 54 B146 22 15 N161 31 N165 31 N169 31 N169 39 N169 47 N169 55 N161 32 N165 32 N169 32 N169 40 N169 48 N169 56 N161 33 N165 33 N169 33 N169 41 N169 49 N169 57 Publication 6500 UM001A US P November 1999 F 10 Eject Forward and Retract Using Profile Status and Complete Bits The following bar chart describes the operation of the output coils
2. and Name Floating Point us Output Instructions EQU Equal 1 12 12 5 nstruction is true when source A source B NEQ Not Equal 1 12 12 18 nstruction is true when source A source B LES Less Than 1 12 13 94 nstruction is true when source A lt source B LEQ Less Than or Equal 1 12 13 93 nstruction is true when source A lt source B GRT Greater Than 1 12 12 62 nstruction is true when source A gt source B GEQ Greater Than or Equal 1 12 14 31 nstruction is true when source A gt source B MEQ Masked Comparison 22 75 NA Compares 16 bit data of a source address to 16 bit data at a reference for Equal address through a mask If the values match the instruction is true LIM Limit Test 1 68 20 19 True false status of the instruction depends on how a test value compares to specified low and high limits Instruction Mnemonic Math Instructions Execution Times us Function and Name Floating Point us Output Instructions ADD Add 1 50 18 22 When rung conditions are true the ADD instruction adds source A to source B and stores the result in the destination SUB Subtract 1 50 19 50 When rung conditions are true the SUB instruction subtracts source B from source A and stores the result in the destination MUL Multiply 17 75 When rung conditions are true the MUL instruction multiplies source A 21 94 by source B and stores the result
3. ey until ae LE FT musee Injection Input Output Device Ame Pos Input Pl G 84 GARR Counts G en Pos a rrhcen 7S We Pos Input P2 GH RE Counts press io urrent Counts BHH PSI Input Pi AT 5 2 rges use PST Input P2 GHEE PT BE Counts BO press I po Type D MME Current Counts GHEH PSI Output Min G RH AT BRR HH PSI Output Man GH AT GHH Vi Fress F3 to Advance Injection Sereens i 2 Enter configuration values When selecting volts or amps go to the selector make your selection then press enter Publication 6500 UM001A US P November 1999 Determining Sensor and Valve Operation 11 3 For this phase Do the following injection 1 Bottom the injection ram P 1 press F 3 2 Enter 0 into field 1 3 Enter the counts that the fast analog module is returning from the current counts field 5 into field 2 Move the injection ram to its full back position P 2 Measure the distance travelled from P 1 to P2 Enter this measurement in inches into field 3 Enter the counts that the fast analog module is returning from the current counts field 5 into field 4 8 Select the appropriate voltage or amperage for your input module in field 6 Yo wo amp clamp 1 Close or nearly close the clamp press F 1 2 Measure the distance from the stationary platen to the moving platen P1 3 Enter the measurement into field 1 4
4. A 1747 PIC is required when connecting to a DH 485 channel Publication 6500 UM001A US P November 1999 c 4 Processor Specifications Programming Instructions The following programming instructions are used with the SLC 5 04P processor Included are instruction execution times us for the processor when the instruction is true and instruction execution times us when floating point math is used For more information about programming instructions see SLC 500 and MicroLogix 1000 Instruction Set Reference Manual publication number 1747 6 15 Basic Instructions Instruction Mnemonic Execution Times us ien and Name Floating Point us Input or Output XIC Examine if Closed 0 37 Conditional instruction True when bitis on 1 XIO Examine if Open 0 37 Conditional instruction True when bitis off 0 OTE Output Energize 0 56 Output instruction True 1 when conditions preceding it are true False when conditions preceding it go false OTL Output Latch 0 56 Output instruction Addressed bit goes true 1 when conditions preceding the OTL instruction are true When conditions go false OTL remains true until the rung containing an OTU instruction with the same address goes true OTU Output Unlatch 0 56 Output instruction Addressed bit goes false 0 when conditions preceding the OTU instruction are true Remains false until the rung containing an OTL instruction with th
5. Moving Stationary Clamp Platen Platen Cylinder open open open open slow decel fast break away lt a 4 4 4 full open open open full open slow decel fast close pos pos pos pos pos XX XX XX XX XX XX XX XX xx xx ee za ec Nea psi 4 psi 3 psi 2 psi 1 XXXX XXXX XXXX XXXX You can specify positions in your clamp open profile that let you e pull cores e add or remove pumps to change available volume e stop for a part retrieval device then finish opening start the ejectors before the mold is fully open You can specify the pressure and flow setpoints for all segments in this profile Publication 6500 UM001A US P November 1999 3 14 Introduction to the Injection Molding Process Eject Phase During the eject phase the part is ejected pushed from the mold You can advance and retract the ejector in a single step or in multiple steps using open loop control Tonnage Clamp Close 3 Clamp LPMP_ gt Typical Hydraulic Clamp Clamp Close Clamp Low Hold ae Phase On daisi Ejector retract Eject Lias Hedat Phase ee y Plastication ney Ejector forward Clamp y Sa Post decompression Phase Clamp Open Clamp pei Tonnage can vary between toggle and hydraulic machines For this hydraulic example tonnage is
6. _ Chapter 9 Start up the machine _ _ _______________ _ Chapter 10 Determine valve and sensor operation Chapter 11 Quick tune el Chapter 12 Use mold part recipes _ Chapter 13 Production monitor Chapter 14 continued Publication 6500 UM001A US P November 1999 P 4 For Reference Appendix A lt _ Use alarms to troubleshoot your system Appendix B Understand SLC processor addresses Appendix C lt _ __ _ __ ______ Processor specifications Appendix D _ Understand specialized hydraulic configurations AppendixE Use internal and external trigger setpoints Appendix F Use profile status and complete bits Publication 6500 UM001A US P November 1999 What Abbreviations Acronyms and Initialisms Are Used in this Manual What Conventions Are Used in This Manual P 5 Throughout this manual we use abbreviations acronyms or initialisms Use this table to become familiar with our terminology This stands for CV Con
7. To stop a profile prior to the completion of all of its segments turn off its profile permit bit For example to stop injection mid profile turn off B101 1 0 No ramp is used in this case The valve outputs are immediately set to the values in phase setpoint block emergency stop values N104 0 N104 1 If a ramp graceful stop is desired use the suspend resume feature instead of turning off the profile permit bit At any time during a profile if the current position N105 0 is past the suspend profile position setpoint N109 4 the profile is configured to suspend N109 0 9 and the resume bit B101 2 2 is not set the valves ramp to the end of profile setpoints N109 16 NO9 17 using the ramp rate configured in the currently active segment Publication 6500 UM001A US P November 1999 8 12 Configuring Pro Set 200 Profiles Understanding the Ramping Formula The following diagram shows the ramping formula Deceleration Ramp Rate 5 00 in sec sec Setpoint 1 10 in sec ra Beginning of lt 7 Setpoint 2 Segment 2 i 5 in sec lt 1 second Assumption Ramp of 5 in sec sec Total time to ramp to new setpoint New Old Ramp Rate Time required to ramp to new setpoint in this example 10 in sec 5 in sec 5 in sec sec 1 sec Setting Ramps to On or Off Use this field to turn ramps on and off for the entire profile Word 0 of the Setpoint B
8. This Islocated This Is located field in field in 1 N193 32 9 N189 39 2 189 32 10 190 07 3 N189 40 u mon 4 189 30 12 92 05 5 N193 38 13 N84 13 14 6 190 06 14 185 00 7 N190 10 15 N185 01 8 189 31 Publication 6500 UM001A US P November 1999 Core Selections Screen A Core Setup Core Set 1 OFF Position OR In Position Alarm Timer ORJ Alarm Vo Fress Pos Core Pull 2 cas In a Ejector Forward Screen 7 Ejector Forward Profile Fud Full Ret pd 2 W Pos In QAF E im Vel ALEE ELFE In Sec oe Press oe Start FSI cme Ejectors 2HE Press Pos ee In S OEI PSI Understanding SLC 5 04P Processor Addresses This field Is located in N193 32 N197 32 N189 40 N193 30 N197 30 N194 06 N198 06 N193 31 WO CO NM DD By Ww Nje N197 31 m N194 07 11 N198 07 Ejector Retract Screen 1 B 7 a Ejector Retract Profile Ret Tip full Posin HF RELH GEEF Vel CEF CLH In Sec 6 HH GX 7 HH ress 8 FEF FRE PSI aKO BHI gE N185 00 This field N185 01 Is located in N193 32 N189 40 N193 30 N194 06 N193 31 N194 07 1 2 3 4 5 6 7 8 N185 00 N185 01 Fos oe VE Fress In PSI Ejector Retract Scre
9. conditional bit gt File 12 Clamp STI conditional bit gt File 15 EjectSTI gt File 254 ERC2 Update DO not write code in this file Notice the following relationships between the files in the figures Files 5 and 95 are optional files you can remove if your application does not require certain functionality Removing these files frees up memory in the SLC 5 04P processor which can be used for other purposes The initialization file for the ladder code and ERC2 algorithms is located in file 3 This file is scanned when the first scan bit is set File 3 also contains a JSR to file 255 to initialize ERC2 This occurs when the processor is first powered up or when the keyswitch is turned from PROG to RUN Do not program any ladder logic in files 254 and 255 Publication 6500 UM001A US P November 1999 6 4 Customizing Ladder Logic Customizing Your System You must modify Pro Set 200 ladder logic file 2 3 and 8 to match your molding machine File Number File Description Customize If Changes Needed 2 0 definition always change I O address 3 initialize enon commanded value output counts are erevise source value in MOV statements from required to be a different value than zero zero to desired value eyour analog cards are not placed in the erevise analog output addresses Pro Set 200 standard configur
10. project planning 1 p electrical components 1 3 hydraulic components 1 3 mechanical components 1 3 other considerations 1 3 simplified plan 1 4 Publications Related P 7 publications related P 7 PV small and large deviation alarms A 4 Q quick start 1 1 quick tune procedure 12 1 coarse tune 12 3 fine tune 12 4 learning during productior 12 4 quick tune screen 12 4 response and OLT status word 12 4 R ramp rates setting 8 2 ramping 8 4 enabling selectively 8 10 formulal 8 12 ramps coordinated coordinating turning on and off 8 uncoordinated 8 13 using 8 9 relief valve settings 7 9 requirements software 5 4 restoring machine setup dat 10 4 11 13 mold recipes 13 5 recipe configuration 8 3 S me sep if LT mold recipes 13 5 recipe configuration 8 4 scanning control tagg 6 39 Screen and Font Settings P 7 screen settings P 7 segment active bits F J segment complete bit F 3 F 4 segment needs OLT bif A 4 segment too short bi A J selecting CV max 8 2 auto mode ERC2 8 4 direction of profile position 8 19 learned value 8 20 manual mode open loop control 8 8 method of pressure contro pressure valve 8 22 profile 8 4 8 7 profile mode 8 recipe numbel 8 2 setting external position over under bit E 5 external position trigger setpoints E 5 external pressure over under bit E 6 external pressure
11. Proportional Bidirectional econtrols the flow speed Control Valve eswitches cylinder direction Electronically Adjustable controls flow and or pressure to the cylinder Pump Electronically Adjustable psi controls the pressure in the circuit Valve Publication 6500 UM001A US P November 1999 Specialized Hydraulic Configurations Supported by Pro Set 200 D 3 Figure D 2 Pro Set 200 Specialized Hydraulic Configuration with Electronically Adjustable Flow Control Valves Position Injection Sensor Clamp or Ejector Axis P T Pressure Transducer Electronically Adjustable Flow Control Valves Meter In Meter Out Circuit Directional Control Valve Tank To support this configuration you need to add eladder logic to control the pump eadditional FIO4V or FI04I module A Electronically Adjustable PSI Valve D This Electronically Adjustable Flow Control Valves Does this controls speed of flow in and out of the cylinder Position Sensor measures cylinder position Pressure Transducer esenses hydraulic pressure in the cylinder esends back 0 10 volts or 4 20 milliamps proportional to the pressure Directional Control Valve switches the cylinder direction Electronically Adjustable psi Valve controls the pressure in the circuit Publication 6500 UM001A US P November 1999 D 4 Specialized Hydraulic Configuration
12. Throughout this manual we use notes to make you aware of safety considerations ATTENTION Identifies information about practices or circumstances that can lead to personal injury or death property damage or economic loss Attentions help you e identify a hazard e avoid the hazard recognize the consequences Important Identifies information that is especially important for successful application and understanding of the product DH MicroLogix PLC Panel View Pro Set and SLC are trademarks of Allen Bradley Company Inc Windows 95 is a tradement of Microsoft What s New In this Document Release 1 02 Changes to Ladder Logic What if You Need More Help Summary of Changes This document has undergone no major changes since the February 1998 printing Changes to this document are marked with a revision bar in the margin of the page It is advised that you thoroughly read this manual before upgrading from Release 1 00 1 08 or 1 01 Release 1 02 contains modifications to ladder logic files 4 and 96 The new code corrects the Ejector Not Retracted alarm and MO file synchronization problem ATTENTION This software is a starting point for an injection molding system The user5 must modify the software to comply with any applicable standards governing the final product application If you have any questions regarding Release 1 01 call Pro Set 200 Technical Support at 440 646 6800 Publication 6500 UM001
13. enabling ramping selectively 8 10 ERC2 2 1 Expert Response Compensation ERC2 position over under bit setting E 4 position trigger setpoints E 4 pressure over under bil E 4 external pressure trigger setpoints setting Ed externa externa externa external time trigger setpoints setting E d F Mme G getting started procedures 1 4 grounding the chassis guidelines 4 4 running ground connections 4 4 H hardware installation 1 5 high and low psi and velocity Cv alarms A d hold profile 3 q hydraulic concepts 7 1 hydraulic configurations Pro Set 200 7 10 specialized I O modules installing 4 9 injection dynamic phase permit block F injection modling process clamp close phasd 3 2 3 4 clamp close profile 3 5 clamp LPMP profile 3 4 tonnage profile 3 5 clamp open phase 3 2 eject shase 3 4 four main phases 3 1 inject phase 3 4 injection molding process clamp open phase 3 12 clamp open profile 3 13 eject phasef 3 14 ejector advance profile 3 15 ejector retract profil 3 15 other eject features 3 14 inject phase 3 4 clamp nae chee clamp low hold profile 3 9 hold profile 3 injection profile 3 7 pack profile 3 8 plastication profil 3 10 post decompress profil 3 11 pre decompress profile 3 9 injection phase 2 4 injection profile 3 7 installing I O modules 4 9 power supply 4 programming terminal interface card
14. p gt RARE loop control If you select manual mode the control output is calculated through interpolation we refer to this as CV Max If you select this option the SLC 5 04P processor does not try to correct any errors during the shot or movement it interpolates the output percentage based on the CV max curve For example if you select this option and the maximum speed of the profile is 5 in sec at 10Vdc and you enter a 2 5 in sec setpoint the controller outputs 5Vdc 5 in sec 2 5 in sec 5Vdc 10Vdc CV Turning Ramps On or Off Ramping is useful to smooth out jerking motion that results from quick increases in pressure or flow You can selectively apply ramping to any process profile Pro Set 200 applies individual velocity and pressure ramp rates at the beginning of each profile segment to reach setpoint There are two optional ramp rates e acceleration ramp rates e deceleration ramp rates Ramping works like this e Ramping is supported for all phases e Each profile segment has its own acceleration and deceleration ramp rate Configuring Pro Set 200 Profiles 8 9 e A ramp value of zero disables ramping Setpoint steps immediately to segment setpoint e Ramp values are stored as part of the mold part storage information e Velocity ramp values have a range from 0 to 327 inches second second including deceleration ramps e Pressure ramp values
15. 20 19 20 2l Null Character 22 3 1 2 23 3 4 24 5 6 25 7 8 26 9 10 21 11 12 28 13 14 29 15 16 30 17 18 31 19 70 32 Null Character 33 4 1 34 3 135 5 36 7 13 9 38 11 39 13 40 15 41 17 Publication 6500 UM001A US P November 1999 Saving and Restoring Mold Part Recipes Using Mold Part Recipes 13 5 Data Tabl Reci eae fo baia Character Character 42 4 19 0 43 Null Character 44 5 1 7 45 3 4 46 5 6 47 7 3 48 9 10 49 ll D 50 13 14 51 15 16 52 17 18 93 19 0 54 Null Character You can save or restore a recipe by using the Pro Set 200 mold part storage screen Access this screen by loading the following files e ps2ol e ps2bi L02 pva 02 pva e ps2c 02 pva Press the F9 function key to access the mold part storage screen la until F Press oa 9 you see Part Storage Mold Part Storage is Active ee S elect Recipe B 2 ame HHEH HHH Gy Letter Selection and Position D EI ka m 5 D BGEA ot Act ave ave Machine Stopped Restore Enabled ve ive O ecipe Recipe As Selected Recipe Publication 6500 UM001A US P November 1999 13 6 Using Mold Part Recipes Use this field View which recipe number Pro S et 200 is currently using 1 To Select a recipe number 1 Cursor to this field by using
16. Er Allen Bradley Pro Set 200 l es igr d Cat No 6500 PS2102 vai Important User Information Solid state equipment has operational characteristics differing from those of electromechanical equipment Safety Guidelines for the Application Installation and Maintenance of Solid State Controls Publication SGI 1 1 describes some important differences between solid state equipment and hard wired electromechanical devices Because of this difference and also because of the wide variety of uses for solid state equipment all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable In no event will the Allen Bradley Company be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment The examples and diagrams in this manual are included solely for illustrative purposes Because of the many variables and requirements associated with any particular installation the Allen Bradley Company cannot assume responsibility or liability for actual use based on the examples and diagrams No patent liability is assumed by Allen Bradley Company with respect to use of information circuits equipment or software described in this manual Reproduction of the contents of this manual in whole or in part without written permission of the Allen Bradley Company is prohibited
17. Plastication Machine profile when the screw rotates and backs up to load plastic for another shot the process of melting and liquifying plastic pellets Post decompression Length of ram screw pullback after plastication to avoid drooling melt during ejection Pre decompression Length of injection screw pullback before plastication to isolate cushion melt left in barrel Pressure limited Velocity A type of velocity vs position profile in which control changes to pressure vs position when injection pressure exceeds a preset limit Process Variable measured value from a process such as velocity pressure or temperature Publication 6500 UM001A US P November 1999 G 4 Glossary Publication 6500 UM001A US P November 1999 Profile Setpoints to control a portion of the machine cycle Select from clamp close inject pack hold pre decompress plastication post decompress clamp open eject clamp low hold clamp low pressure mold protect tonnage ejector forward ejector reverse ejector tip storage For example e velocity and position setpoints for velocity vs position profile to open clamp e pressure and position setpoints for a pressure vs position LPC profile to close clamp pressure and time setpoints for pressure vs time profile to pack the melt Rise Time The time required for the output of a system to change from a small specified percentage typical 5 10 of the steady state i
18. The pressure that is measured when the cylinder has stopped moving Dead Time The interval of time between initiation of an input change or stimulus and the start of the resulting observable response Display Area The touch screen on the front of the operator interface where video displays appear during operation Ejector Cycle Machine phase when parts are extracted from the mold Same as ejector phase Publication 6500 UM001A US P November 1999 G 2 Glossary Publication 6500 UM001A US P November 1999 Ejector Phase The axis of motion which controls the ejectors It is usually comprised of 3 profiles forward profile retract profile tip stroke profile Flash Melted plastic forced out of mold halves due to excessive pressure Hold Machine profile when pressure is applied to melted plastic in the mold to cure the part Injection Machine profile when the plastic is forced into the mold Injection phase The axis controlling injection The injection phase is typically made up of 6 profiles injection profile pack profile hold profile pre decompress profile plasticate profile and post decompress profile Injection Ram Injection Screw The plastication device typically a threaded screw like device which heats and liquifies plastic pellets Jog Constant speed and pressure setting used to move the machine while setting a mold or configuring the machine While jogging in manual
19. 14 AWG Keep wire length as shortas possible A 2mm 14AWG co bc0ojo0o000 5 2 mm 10 AWG Preferred Grounding Method 20231 ATTENTION You must properly ground the 1746 chassis the enclosure and other control devices Observe all applicable codes and ordinances when wiring the system You should run ground connections from the chassis and power supply on each adapter and expansion unit to the ground bus Exact connections will differ between applications United States An authoritative source on grounding requirements for most installations is the National Electrical Code Also see Allen Bradley Programmable Controller Grounding and Wiring Guidelines publication number 1770 4 1 Publication 6500 UM001A US P November 1999 4 6 Setting Up the Hardware Installing the To install the power supply do the following Power Supply 1 Align the circuit board of the power supply with the card guides on the left side of the chassis and slide the power supply in until it is flush with the chassis Use these screws to fasten the power supply to the chassis 20913 M 3 If you are using a 1746 P2 power supply make a jumper selection for 120 240V ac Publication 6500 UM001A US P November 1999 Setting Up the Hardware 4 7 4 Place the input voltage jumper to match the
20. CV Max curve 3000 psi If you defined 3000 psi as the max pressure at 1500 psi 10 VDC and you request 1500 psi the f SLC 5 04P processor O psi outputs 5 VDC 3 O 45 VDC 10 VDC Configuring Pro Set 200 Profiles 8 23 XT Making and Recording In the following tables we show you system default values for each Your Selections field in each phase We also provide blank tables so you can record your machine selections for reference Injection Phase Defaults Selector Injection Pack Hold Pre Decomp Plasticate Post Decomp Profile of on On On On On On On Active profile is velocity psi Velocity psi psi Velocity psi Velocity Profile in Auto or Manual Ramps off 0n On On On On On On Ramps coordinated No No 0 No No No No Yes Link to another profile Yes Yes No No No No No Yes Suspend profile No Yes 0 No 0 No 0 No Direction of profile Decrease Decrease Decrease ncrease ncrease ncrease Decrease Increase Use Learned CV Maxon Learned Learned Learned Learned Learned Learned primary controlled variable f psi is selected variable then Learn Learn Learn Learn Deadhead Learn Learn psi use Deadhead f velocity is selected variable then CV Max CV Max CV Max CV Max CV Max CV Max Run psi as CV Max Use Deadhead psi run the profiles using ERC2 hese files are initially set to CV Max for machin
21. Enter the counts that the fast analog module is returning from the current counts field 5 into field 2 5 Open the clamp to its near full open position 6 Measure the distance from the stationary platen to the moving platen 7 Enter this measurement in inches into field 3 8 Enter the counts that the fast analog module is returning from the current counts field 5 into field 4 9 Select the appropriate voltage or amperage for your input module in field 6 ejectors 1 Place the ejectors in the fully retracted position P1 press F6 2 Enter 0 into field 1 3 Enter the counts that the fast analog module is returning from the current counts field 5 into field 2 Move the ejectors to their full forward position P2 Measure the distance travelled from P 1 to P2 Enter this measurement in inches into field 3 Enter the counts that the fast analog module is returning from the current counts field 5 into field 4 8 Select the appropriate voltage or amperage for your input module in field 6 aN WW Publication 6500 UM001A US P November 1999 11 4 Determining Sensor and Valve Operation Spanning Pressure Inputs To span pressure inputs do the following 1 Go to the injection clamp or ejector input scaling screen oe ae til i e A For clamp io Pi ices es Injection Input Output Device Setup GHEE Co urd Clamp close Pos Input Pi BE AT until Fos Input P2 B A
22. Overall Injection Time Includes the time required for injection pack and hold and delay injection timers for the most recent shot Range 0 to 327 67 seconds Transfer to pack Displays what condition caused the transition from injection to pack It can display 4 transitions 1 Did Not Occur 2 On Position 3 On Pressure 4 OnTime will show the value at which transition occurred Cure Time Includes the time from the end of the hold profile until the clamp opens Range 0 to 327 67 seconds Displays the shot size setpoint being used Displays the actual shot size from the most recent shot a Do gt Overall Clamp Time Includes the time required for Clamp Close LPMP Tonnage Low Hold Decompress and Clamp Open and delay timers Range 0 to 327 67 seconds Publication 6500 UM001A US P November 1999 14 4 Using Production Monitor Screens Using Production Monitor Screen 3 Publication 6500 UM001A US P November 1999 Press od Part Storage AO 71 Temp 26 amp 2 HH Currse g 6WH Production Monitor 22 HE H HE 23 25 z Temp 27 Arpe GDh t CurrsP HOR K10 HH pama DF amp ar Fress F3 To Advance Production OTARRE This field Monitors this 1 The mode of the machine setup manual semi auto or full auto 2 Displays the current temperature for zone 1 3 Dis
23. Press PSI Sec Eject Ramp Rates N Fud Fud Ret Tip Spd2 Spd OR On ap CW OHE ORR COE D LOFFE LOR LO COR A BTM Configuration Screens This field Is located in 1 N97 40 2 N97 39 3 N97 41 04 4 N97 50 F10 Save N97 41 03 not shown This field Is located in 1 N97 40 2 N97 38 03 3 N97 38 05 4 N97 00 00 Understanding SLC 5 04P Processor Addresses B 29 Zone Selection Screen 1 J No done Selected Zone Selected ration Complete aar uan Download MI Auto Tune Block Download R le tle Block ee Press FE to Advance Screen eS Zone Selection Screen 2 7 Gt sere Output Image Configuration Bits Auto Tuning Ramping Temperature Units Fress F6 to Advance Screen u Publication 6500 UM001A US P November 1999 B 30 Understanding SLC 5 04P Processor Addresses This Is located This Is located field in field in 1 N97 40 8 N97 01 06 2 97 01 01 9 87 01 08 3 N97 01 00 10 N97 01 07 4 97 01 05 11 97 01 11 5 N97 01 04 12 N97 01 10 6 N97 01 03 13 N97 01 13 7 N97 01 02 This field Is located in 97 40 N97 02 97 03 N97 04 97 06 DH of el Ww rn ke N97 07 Publication 6500 UM001A US P November 1999 Zone Selection Screen 3 owe Mi Flle Configuration Bits Operation Mode Input Typ
24. Setup Screens Chapter 1 0 Starting Up the Machine This chapter explains how to e access the setup screens e enter values to verify hydraulics e save and restore machine setup data e verify correct hydraulic operation To move all machine axes so that you can properly calibrate the valves to the control we suggest that you start up your machine by following these steps 1 Enter values that will let you verify correct hydraulic operation 2 Verify correct hydraulic operation Important For safety considerations complete all previous chapters Access the Pro Set 200 setup screens by loading the setup file ps2sl102 pva In the procedure you will use this pair of screens e Input Output Device Setup only the output values for each phase e Velocity Spanning Values for each phase Use these screens To Input Sensor Nameplate and Enter min max pressure output values from the Output Nameplate Values nameplate omit entering sensor values at this time Velocity Spanning Values Enter min max values for the corresponding valve Machine Setup Storage Save entered values In the procedures that follow we suggest that you enter values on screens associated with one phase of operation Then repeat the procedure for each of the other phases Publication 6500 UM001A US P November 1999 10 2 Starting Up the Machine Entering Values to Verify Hydraulics For clamp press For injection press For plastica
25. TPO Bit Off Transition Pressure position or time when machine changes from one phase profile or segment to another such as injection to pack same as Trigger Trigger A position pressure or time which when needed permits the transfer from one phase profile or segment to the next same as Transition Publication 6500 UM001A US P November 1999 G 6 Glossary Publication 6500 UMO01A US P November 1999 Publication 6500 UM001A US P November 1999 ON Rockwell Automation Allen Bradley a Rockwell Automation Business has been helping its customers improve productivity and quality for more than 90 years We design manufacture and support a broad Allen Bradley range of automation products worldwide They include logic processors power and motion control devices operator interfaces sensors and a variety of software Rockwell is one of the world s leading technology companies Worldwide representation ze M Argentina e Australia e Austria e Bahrain e Belgium e Brazil e Bulgaria e Canada e Chile e China PRC e Colombia e Costa Rica e Croatia e Cyprus e Czech Republic e Denmark e Ecuador e Egypt e El Salvador e Finland e France e Germany e Greece e Guatemala e Honduras e Hong Kong e Hungary e Iceland e India e Indonesia e Ireland e Israel e Italy e Jamaica e J apan e J ordan e Korea e Kuwait e Lebanon e Malaysia e Mexico e Netherlands e New Zealand e Norway e Pakistan e Peru e Philippines
26. The following chapter provides information for using production monitor screens Publication 6500 UM001A US P November 1999 Chapter 1 Al Using Production Monitor Screens What s in This chapter explains how to use the Production Monitor Screens to This Chapter e Monitor cycle times fill times cure times overall clamp time idle time and cycle counts e Examine temperatures and monitor pressure and velocity values from ERC2 e determine which profile is being executed by ERC2 for the Injection Clamp and Ejector phases You can access the Pro Set 200 Production Monitor Screens by loading this file ps20102 pva Accessing Production Monitor Screens Press i F9 until I e E a Part Storage Production Menu Recipe Save Restore Timer Setup Counter Setu crore reese cooper S P4 1 Using the up and down arrow keys on the PanelView screen highlight Production Monitor from the Production Menu 2 Press the Enter key Publication 6500 UM001A US P November 1999 14 2 Using Production Monitor Screens Using Production Monitor Screen 1 Sup Production Monitor n Cycle Counter g2 HH Cycle Time G3 iH Seconds Largest g4 4 Idle Time G5 He Seconds Largest g6 HH e Counter eset Largest Lycle ime Reset Largest Idle Time Press F3 To Advance Production Monitor This field Monitors this 1 The mode of the machine setup manual semi auto or full a
27. as suckback After pre decompression is complete you can program Pro Set 200 either to start the plastication profile immediately or to wait for a command from the ladder logic to continue Publication 6500 UM001A US P November 1999 3 10 Introduction to the Injection Molding Process y Clamp Decompress Publication 6500 UM001A US P November 1999 Pre decompression Injection Plastication Pack Segment1 y y Segment 2 y Hold Segment 3 y Segment 4 y Segment5 Clamp Low Hold Post decompression Plastication Profile During plastication the molding machine reloads by drawing plastic pellets into the barrel containing the screw As the screw rotates it moves plastic down the flights Barrel heat combined with the friction generated by the rotating screw helps to liquify the plastic As plastic moves down the screw flights the plastic starts to build up in front of the screw tip The plastication profile controls the pressure on H the back side of the ram as the screw turns EAA AAA AI NN BH i As the plastic builds up in front of the screw tip the material pushes the screw backwards The screw is tied to an injection cylinder ram The plastication profile controls backpressure on the ram by controlling the flow of hydraulic oil leaving the cylinder Th
28. e file3 e file 8 e file 9 if inject analog card is not in slot 1 e file 12 if clamp analog card is not in slot 2 e file 15 if ejector analog card is not in slot 3 e file 99 Gf BTM modules are not in slots 5 and 6 e file 20 software travel limits loss of sensor if analog cards are not in assigned slots It should go without saying that there are an unlimited number of valve combinations however there are a number of combinations that are generally encountered The following are examples of common valve configurations and the basic necessary ladder logic customization that is needed to allow Pro Set 200 to perform This is to provide basic examples of how your ladder logic will need to be manipulated for using other valve combinations than those supplied by Pro Set 200 For the examples the following conventions apply Instructs you to move data table je value to stated location i MOV Injection Functions N102 01 Location of data table value Velocity Valve Valve location on your machine where you will send data table value Many smaller machines have only single velocity and pressure valves These two valve machines can range from both valves controlling only injection functions to both valves controlling injection clamp and ejector speeds and pressures The following Publication 6500 UM001A US P November 1999 6 22 Customizing Your System examples show the concepts of how to mo
29. e waits for a command from Pro Set 200 ladder logic to continue default selection Injection Pre decompression y y Pack Plastication y y Hold Post decompression y y Clamp Low Hold Clamp Decompress see Pre decompression Injection Segment 1 y y Pack Plastication y Hold Post decompression Clamp Low Hold Yy Clamp Decompress Introduction to the Injection Molding Process 3 9 Clamp Low Hold Profile Typically Hydraulic Clamp Only The clamp low hold profile is typically turned off for a toggle clamp machine For a hydraulic clamp machine it is active after the hold profile is complete The clamp low hold profile is designed to allow the hydraulic clamp pressure to be reduced while decompression or plastication phases are occurring This can be thought of as an energy savings feature if you want to lower the clamp pressure while the part is curing If you do not want to reduce the pressure during this phase set the pressure and velocity setpoints equal to the clamp tonnage setpoint Clamp low hold is actually part of the clamp profile but we show it here to clarify how the injection process works Pre decompression Profile optional Pre decompress is the single backward movement of the ram or screw before plastication occurs This profile is also referred to
30. plasticate and post decompress Inject Profile Active B106 1 Solenoid I Pump Load 15 Pack Profile Active B10675 15 Hold Profile Active B106 9 LS Pre Decompress Profile Active B106 13 15 Plasticate Profile Active B106 17 15 Post Decompress Profile Active B106 21 LS Publication 6500 UM001A US P November 1999 6 14 Customizing Your System Publication 6500 UM001A US P November 1999 Solenoid J This row shows conditions in which solenoid J is ON during the injection forward pack and plastication profiles and OFF all other times Since the I O definition file does not include any rungs that match these requirements you need to write the ladder logic By using the profile active bits you can create the following ladder logic Inject Profile Active Pump Load B106 1 Solenoid J 15 Pack Profile Active B106 5 15 Plasticate Profile Active B106 17 15 Solenoid K and L These rows show solenoid K and L which are proportional valves that controls flow valves If you use the recommended hardware layout shown in chapter 3 you do not need to modify any programming Pro Set 200 contains ladder logic in files 3 8 9 and 20 which handle these outputs If you have not used the recommended layout you need to change the rungs in files 3 8 9 and 20 which write to these outputs Solenoid M This row shows a proportional valv
31. press F4 V Set OLT Open Loop Test ON press F 3 v Run a complete cycle and check to see of all active segments OLT successfully If not refer to page 12 7 for corrective actions All profile OLTs must be successful before continuing to the next step V Set OLT OFF press F3 V SetRamps ON press F4 V Turn learning on press F6 F7 or F8 V Set the profile in Auto Mode press F2 V Run 4 cycles Y Continue to chapter 12 for the Fine Tune procedure ime Use mold part recipes Reference V Name mold part recipes Chapter 13 Using Mold Part Recipes V Save and restore mold recipes Vv Increase the number of mold part recipes Using Production Monitor Screens Reference V Accessing Production Monitor Screens Chapter 14 Using J Using Production Monitor Screens Production V Status Indicators Monitor Screens Pro Set 200 System Quick Start Publication 6500 UM001A US P November 1999 1 10 Pro Set 200 System Quick Start What s Next In the next chapter we cover the system overview Publication 6500 UM001A US P November 1999 What s in This Chapter What Does the Pro Set 200 System Do Chapter 2 System Overview This chapter presents an overview of the Pro Set 200 Injection Molding Control System This chapter explains e what Pro Set 200 does e the components of a molding control system e how Pro Set 200 works e the capabilities of Pro Set 200 e what you need to do Pro Set 200 syste
32. see the SLC 500 Modular Hardware Style Installation and Operation Manual publication number 1747 6 2 Publication 6500 UM001A US P November 1999 Installing the I O Modules F a Setting Up the Hardware 4 9 To install the I O modules do the following for each module 1 Align the circuit board of the module with the card guide in the chassis Retainer Clip Circuit Board Side View me E 2 m Retainer Clip 2 Gently slide the module in until both top and bottom retainer clips are secured Card Guides g x Jis WW T D Ws S x W Qi w ES pi 2 a IF pr ores N TESNO Se N a 1 a Top and Bottom Releases 20915 M For more information about installing the I O modules see the SLC 500 Modular Hardware Style Installation and Operation Manual publication number 1747 6 2 Publication 6500 UM001A US P November 1999 4 10 Setting Up the Hardware Connecting the Programming Terminal to the SLC 5 04P Processor Publication 6500 UM001A US P November 1999 Installing the Programming Terminal Interface Card If you have a See 1784 KT card Communication Interface Module 1784 KT B Installation nstructions publication 1784 2 31 to install the 1784 KT communication card 1784 KTX card Communication Interface Card 1784 KT B Installation nstructions publication 1784 6 5 22 to install the 1
33. 1999 6 32 Customizing Your System Conceptual Model of Variation C 1 Pressure Valve for Clamp Injection and Ejector 1 Velocity Valve for Injection 1 Velocity Valve for Clamp Injection and Ejector Injection Clamp Ejector Electronically Adjustable A Velocity Valve V2 77 A Manual Pressure Valve and or v N y Directional Control N Electronically Adjustable Velocity Valve V1 W mf Electronically Adjustable System Relief Valve psi e 4 L Tank w This conceptual model is intended to be used as an aid in understanding ladder code modifications for the example scenario It is not a complete hydraulic diagram Tu rning Analog Outputs For analog outputs the last value sent out to the channel will remain Off there until you change the value ATTENTION Incorrect use of analog outputs can lead to personal injury or death property damage or economic loss If you do not understand the details of turning analog outputs off contact technical support at 1 440 646 6800 This means that if you were to write a rung of logic as follows Injection MOV Forward 32767 0 01 0 32767 will be sent out to the output card when inject forward is active If you turn inject forward off the preceding rung is now false Publication 6500 UM001A US P November 1999 Correct Placement of Analog Rungs Is Crucial
34. 200 controls the pressure closed loop and uses open loop control on velocity Use pressure for profiles that do not use motion such as hold To indicate that the profile 4 type is a i j EES pressure profile set bit 1 select gt ERZE velocity profile set bit1 0 Select gt EATR Publication 6500 UM001A US P November 1999 8 8 Configuring Pro Set 200 Profiles Profile Control Model gt EERE Word 0 of the Setpoint Block 0000 0000 0000 ag bit 3 Ramps are D GERM and Coordinated D GER Publication 6500 UM001A US P November 1999 Selecting Auto or Manual Mode When you select either of these modes auto or manual Pro Set 200 applies this selection globally to the profile For example if you select manual open loop mode for the injection profile then all 5 segments of the injection profile will use open loop control However you are not limited to run other profiles associated with the phase in manual mode The other profiles in the injection phase pack hold plastication pre and post decompress can still be controlled via ERC2 Auto Mode To choose 000 ia mmi iw mmj I 0 ooogg Bgo E m 200A cl i auto mode ERC2 setbit3 0 select P EN If you select this mode the control output is determined by bits 4 5 and 6 in word 0 and bit 14 in word 1 manual mode open set bit 3 0 select
35. 3 N96 26 20 N96 11 4 N96 27 21 N96 36 5 N96 00 22 N96 37 6 N96 01 23 N96 38 7 N96 02 24 N96 39 8 N96 03 25 N96 40 9 N96 28 26 N96 41 10 N96 29 27 N96 42 11 N96 30 28 N96 43 12 N96 31 29 N96 44 13 N96 32 30 N96 45 14 N96 33 31 N96 46 15 N96 34 32 N96 47 16 N96 35 33 N96 48 14 17 N96 08 Publication 6500 UM001A US P November 1999 Temperature Setpoints 1 4 Screen zi Temp 83 Ctt e CurrSP ae A Temperature Control SF SF gt se K se e 7 Ww a te Giz Dev on 5 cy SEN He on CIDHE 20H HH Hode ae ee Huta Temperature Setpoints 5 8 Screen g m Tene DC t o o O CurrSP a5 TO Q HH BOAR Run SP EIEEE REE FOE EB Dey 13 14 45 6 OHHLTHE DHKIORE GH19 8H DHCOHH Cl 4 Nan ORO ROR OUR tC a 29 En i CA OA Et Sim B aij This field Is located in 1 N93 05 2 N93 30 3 N93 55 4 N93 80 5 N95 48 01 6 N95 48 02 7 N95 48 03 8 N95 48 04 9 N94 05 10 N94 30 11 N94 55 12 N94 80 13 N96 48 01 14 N96 48 02 15 N96 48 03 16 N96 48 04 Understanding SLC 5 04P Processor Addresses B 35 Zone Selection Screen 11 i ala Wie TEF i SP Select Solan SP 2 leot gt ER u B o all F 10 omar Ie TEE ENET f CHER eT om F OTA n Bum F O
36. 5 04P Processor Addresses B 13 This field Is located in N80 09 N80 28 N80 29 N80 30 N185 00 N185 01 N102 05 1 2 3 4 5 6 7 8 This field N102 06 Is located in B14 0 01 B14 0 03 B14 0 04 B14 0 05 B14 0 06 B14 0 07 1 2 3 4 5 6 7 B14 0 08 Production Monitor Screen 5 no Production Monitor N Velocity CU G7 HHH Pos 5 In Press C6 PSI Pressure CU G8 HHH Press F3 To Return To Production Menu ERC2 Alarm Setup Screen a ERC2 Alarm Setup Report Minor Errors Report Segments Needing OLT Report Segments That Are Too Short Report Velocity CY Limit Alarms Report PY Deviation Alarms Report PSI CU Limit Alarms Report CU Deviation Alarms C Fress FL To Return To Alarm Menu Publication 6500 UM001A US P November 1999 B 14 Understanding SLC 5 04P Processor Addresses This field Is located in N81 00 81 01 00 N81 01 01 81 01 02 N81 01 03 81 02 N81 01 13 81 03 Wo Col NM ola By Ww NY 81 01 14 m ai N81 04 m m 81 05 m N N81 01 14 m w This field 1 Publication 6500 UM001A US P November 1999 81 06 Is located in Refer to files B11 and B12 in the Pro Set 200 Data Table Reference Manual publication 6500 6 4 4 Quick Tune Screen Seg 1 G gment Skip
37. 500 PSI 200 PSI 300 PSI CENE i 50 GPM Tank Pump Pressure Relief Valve Filter Lt Tank 20867 M Publication 6500 UM001A US P November 1999 Concept The greater the pressure differential across an orifice such as a flow control valve the greater the flow to the cylinder Load Pressure and its Affects on Flow Rate Understanding Hydraulic Pressure and Flow Concepts 7 7 In Figure 7 7 the pressure relief valve is set to 500 psi and the load pressure is 200 psi The amount of flow to the cylinder is limited by the setting of the pressure relief valve and thus the velocity of the cylinder is controlled If you increase the pressure relief valve setting it increases the pressure differential resulting in increased flow of oil and increased cylinder velocity You can increase the flow of oil to a cylinder by increasing the pressure valve setting In an injection molding machine however load pressures are always changing and this affects the pressure differential An increase in the pressure differential increases flow while a decrease in the pressure differential decreases flow Look at Figure 7 8 and compare the pressure differential to Figure 7 7 the flow to the cylinder is less therefore the velocity of the cylinder is slower Figure 7 8 Pressure Differential Example Injection Cylinder Gauge 2 Moving 400 PSI lt Relief Valve Gauge rset at 500
38. 55 2 N125 40 15 N126 63 3 N125 48 16 N126 07 4 N125 56 17 N126 11 5 N125 28 18 N126 15 6 N125 30 19 N126 19 7 N125 38 20 N126 23 8 N125 46 21 T4 11 PRE 9 N125 54 22 T4 11 ACC 10 N125 62 23 N105 00 11 N125 31 24 N125 06 12 N125 39 25 N125 07 13 N125 49 26 N105 01 _ This Is located This Is located field in field in 1 N121 32 N121 31 2 N125 32 12 N121 31 3 N182 17 13 N122 07 4 N122 08 14 N130 07 5 N126 00 15 T4 9 PRE 6 N130 08 16 T4 9 ACC 7 N121 30 17 N105 00 8 N129 30 18 T4 10 ACC 9 N122 06 19 T4 10 ACC 10 N130 06 20 N105 01 Understanding SLC 5 04P Processor Addresses B 5 Plastication Profile Screen 1 E Plastication Profile Shot 1 2 3 4 alee Pos In LESH 2 7 83088 40 FES ae Wel eee ae rege O DEET OIRO 15 Fe zk B EB a8 02 Seren K OHH Pos o2 In veL MoR PSI BE Press G26 PSI Plastication Profile Screen 2 r Plastication Profile N Pre Decomp ShotSize Post Decomp ORI OAI i Fos In BH 4 BGY Whe E P Pass OFF 9 3 13 Bld Pre Delay ISH axle D Post Delay 18H FF aHx19 Press B208 a S r Publication 6500 UM001A US P November 1999 This field Understanding SLC 5 04P Processor Addresses B3 18 Is located in B3 19 B3 18 B3 19 N92 04 N92 03 T4 17 PRE T4 18 PRE o Col N ola By Ww Nje N145 00 m ai N145 01
39. 6500 UM001A US P November 1999 Appendix D Specialized Hydraulic Configurations Supported by Pro Set 200 What s in This appendix shows three specialized hydraulic configurations that This Appendix Pro Set 200 can support Certain components in the hydraulic circuit require that you e write special ladder logic e include an additional output module 0 10 volts or 4 20 milliamps Figures D 1 D 2 and D 3 show common hydraulic configurations Publication 6500 UM001A US P November 1999 D 2 Specialized Hydraulic Configurations Supported by Pro Set 200 Specialized Hydraulic In the following circuit diagrams the specialized feature is Diagrams highlighted with a gray box Figure D 1 Pro Set 200 Specialized Hydraulic Configuration with an Electronically Adjustable Pump ld Position Sensor P T Pressure Transducer Injection Clamp or Axis Ejector Axis SPX Se A esata Bidirectional Control Valve 4 Electronically Adjustable zai PSI Valve Tank eee ee See cee a To support this configuration you need to add Electronically Lo eladder logic to control the pump Adjustable Tank eadditional FIO4V or FI04I module Pump This Does this Position Sensor measures cylinder position Pressure Transducer esenses hydraulic pressure in the cylinder esends back 0 10 volts or 4 20 milliamps proportional to the pressure
40. AUT Position Sensor pa Pressure Transducer Axis Injection Clamp or Ejector Axis xK i t Directional Control Valve Electronically Li Adjustable Tank psi Valve a Ee i Tank Pump 20874 M This Does this Directional Control Valve switches the cylinder from forward or reverse Position Sensor measures cylinder position Pressure Transducer esenses hydraulic pressure in the cylinder esends back 0 1 10 volts or 4 20 milliamps proportional to the pressure Electronically Adjustable controls the pressure in the circuit psi Valve Other Hydraulic Configurations Some machines require that only the injection portion of the machine be controlled by Pro Set 200 In these applications you may want to leave the existing clamp and ejector directional control valves intact In cases such as these you can still use many of the bits in Pro Set 200 which indicate which phase is active However you must also supply a linear positioning device for the clamp and ejector You also need to write your own ladder logic for controlling the sequencing of the clamp and ejector hydraulics Publication 6500 UM001A US P November 1999 7 14 Understanding Hydraulic Pressure and Flow Concepts What s Next Publication 6500 UM001A US P November 1999 In Appendix D Specialized Hydraulic Configurations Supported by Pro Set 20
41. Deviation Alarm Profile 3 Small Deviation Alarm Profile 4 Small This diagram also applies to large Deviation Alarm PV deviation alarms and large and small CV deviation alarms Publication 6500 UM001A US P November 1999 A 8 Using Alarms to Troubleshoot Your System el i 0000 0000 CV Small and Large Deviation Alarms bits 11 and 12 These bits indicate that the valve setting required to obtain the profile setpoint have changed from the usually required values This may be due to wear temperature or viscosity changes The CV deviation band is set in the phase wide setpoint table N104 20 24 N144 20 24 N184 20 24 To set the usual CV when the process is running well set B101 2 4 for injection CV deviation band for at least one STI period ERC2 Learned CV This segment causes a Small Deviation Alarm B106 00 12 e e eee e o o N104 20 eme o o o o o o o N104 20 UsualCV a N111 04 Large CV Deviation N104 22 Small CV Deviation N104 20 e o o o o o o o Small Deviation e m m m Lae Deviation Publication 6500 UM001A US P November 1999 N104 22 This segment causes a large deviation alarm What s in This Appendix Operator Screens This field Is located in N88 16 N88 17 N88 20 00 N88 15 N88 14 88 13 ss olal eIl WwW NN ke N88 18 Appendix B Understanding
42. During clamp movement must one velocity value be moved so that the other can control clamp velocity During ejection what happens to the clamp velocity valves If the clamp and ejectors are moving simultaneously what should their valves be set at Do you treat manual mode differently than semi or full automatic mode Customizing Your System 6 29 Ladder Logic Modifications 3 Valve Variation B Injection Clamp Ejector ERC2 Injection Functions Functions Functions AtTonnage MOV Velocity Output N102 01 MA y I Velocity Valve V1 ERC2 Injection Manual Mode 7 MOV Pressure Output N102 02 Pressure Valve You must create your own system MOV pressure setpoint for injection clamp and ejector functions S ystem Velocity Setpoint During Injection Velocity Valve V2 Clamp Injection Ejector ERC2 Clamp Functions Functions Functions AtTonnage ov Velocity Output N102 03 I iy y Velocity Valve V2 ERC2 Clamp ov Pressure Output N102 04 Pressure Valve OV System Velocity Setpoint During Clamp Pressure Valve V1 Ejector Clamp Injection ERC2 Ejector Functions Functions Functions MOV Velocity Output N102 05 v v Velocity Valve V1 ERC2 Ejector MOV Pressure Output N102 06 Pressure Valve MOV System Velocity Setpoint During Eject Velocity Valve V2 Publication 6500 UM00
43. If this alarm remains set after an open loop test is performed check the phase setpoint file N104 N144 and N184 This bit is When set ON process dynamics are not identified during an open loop test reset OFF the reset all segment done bits are pulsed or valid open loop test performed This bit remains reset OFF until you run an open loop test Using Alarms to Troubleshoot Your System A 5 0000 0000 ooo 0000 Segment Too Short Bit bit4 This bit when set indicates that the segment was not long enough for the machine to achieve the segment setpoint Pro Set 200 does not learn optimal CV values for segments that are too short to reach a steady state To correct a segment too short condition do the following e ensure the segment has a valid open loop test e reduce velocity and or pressure setpoints e lengthen segment time or position SP A Segment end Segment start CV oe Actual Velocity ae Segment still has not reached final velocity This bit is When set ON a segment is unable to reach its final velocity in the allotted time reset OFF you use the reset all segment phase complete bit Publication 6500 UM001A US P November 1999 A 6 Using Alarms to Troubleshoot Your System 0000 0001 1110 0000 __ bits 5 6 7 and 8 Current Profile CV Max Phase CV Current Profile CV Min Phase CV High Limit not latched phase cv High and Low psi and Velocity
44. Ladder Logic Relates to the Module Positions in the I O Chassis The baseline Pro Set 200 ladder logic accommodates the module locations shown in figure 4 1 Pro Set 200 uses a variety of MOV Move COP Copy IOM Immediate Output and IIM Immediate Input instructions in conjunction with the fast analog and BTM modules Important We do not recommend changing the locations of the fast analog modules and BTM modules located in the first six slots of the I O chassis because it increases the number of changes that you must make to the ladder program If you want to change the locations for the fast analog modules and BTM modules first six slots modify the MOV COP IOM and IIM instructions contained in these files e file 2 e file 3 e file 8 e file 9 if inject analog card is not in slot 1 e file 12 if clamp analog card is not in slot 2 e file 15 if ejector analog card is not in slot 3 e file 20 software travel limits loss of sensor if analog cards are not in assigned slots e file 99 Gf BTM modules are not in slots 5 and 6 Publication 6500 UM001A US P November 1999 4 4 Setting Up the Hardware Grounding the Chassis Grounding Guidelines In solid state control systems grounding helps limit the effects of electrical noise due to electromagnetic interference EMD Normal Electrical Noise Conditions Severe Electrical N
45. N109 47 N109 55 109 63 Setpoint Position N109 32 N109 40 N109 48 109 56 N109 64 Setpoint Time 109 33 N109 41 N109 49 N109 57 N109 65 Setpoint Publication 6500 UM001A US P November 1999 Using Profile Status and Complete Bits Pack Pack Pack Pack Hold Hold Hold Hold Segment Segment1 Segment2 Segment2 Segment 1 Segment 1 Segment 2 Segment 2 1 Active Comp Bit Active Bit Comp Bit Active Bit Comp Bit Active Bit Comp Bit Bit B106 80 B106 96 B106 81 B106 97 B106 144 B106 160 B106 145 B106 161 Injection Profile Done Bit B106 95 Pack Profile Active B106 111 Pack Profile Done Bit B106 159 Hold Profile Active B106 175 Hold Profile Done Bit N113 30 N113 38 N117 30 N117 38 N113 31 N113 39 N117 31 N117 39 N113 32 N113 40 N117 32 N117 40 N113 33 N113 41 N117 33 N117 41 Publication 6500 UM001A US P November 1999 F 6 Using Profile Status and Complete Bits Pre Decompress Plasticate and Post Decompress The following bar chart describes the operation of the output coils in the pre decompress plasticate and post decompress profiles Bar Chart Pre Decomp Pre Decomp Plasticate Plasticate Plasticate Plasticate Plasticate Plasticate Segment 1 Segment 1 Segme
46. PSI A Fl ar 500 PSI Pressure Differential 500 PSI 400 PSI 100 PSI Deadheaded Pressure Vs Learned Pressure During a Phase gt Control i L 4 50 GPM Tank Pum P Pressure Relief Valve Filter Li Tank 20868 M The SLC 5 04P processor allows you to select a method of pressure control The SLC 5 04P processor has the ability to e learn or adapt the pressure during the current phase e or apply the learned deadheaded pressure The next section explains a pressure profile Pressure profiles control the pressure applied to a cylinder not the velocity of the cylinder Publication 6500 UM001A US P November 1999 7 8 Understanding Hydraulic Pressure and Flow Concepts Injection Cylinder Using Deadheaded Pressure Deadheaded pressure is measured when the cylinder has stopped moving and all the oil is being dumped over the pressure relief valve see Figure 7 9 Figure 7 9 Deadheaded Pressure Example Gauge 2 Not Moving 500 PSI z Gauge 1 Relief Valve 9 Setat500 PSI gt A a Flow Control 500 PSI o gt Dead Headed Pressure A Les L 50 GPM Tank Pump Pressure Relief Valve Filter e Tank Publication 6500 UM001A US P November 1999 20869 M We know that when a cylinder has stopped moving the pressure measured at the cylinder and the pressure measured at the relief valve will be approximately the same This can be a
47. Post Decompress BarChart Clamp Bar Chan ces ip dwe dt ae eh demande eedek asd Eject Forward and RetractBarChart ccc cece eee eee Publication 6500 UM001A US P November 1999 toc vi Table of Contents Notes Publication 6500 UM001A US P November 1999 What s in This Chapter Before You Begin Chapter 1 Pro Set 200 System Quick Start This chapter can help you get started using Pro Set 200 software with your application Because it is a start up guide this chapter does not contain detailed explanations about the procedures listed We provide references to other chapters in this book where you can get more information This chapter e explains what to do before you begin e provides procedures to get you started If you have any questions or are unfamiliar with the terms used or concepts presented in the procedural steps always read the referenced chapters and other recommended documentation before trying to apply the information Before you begin make sure that you e understand the injection molding process e are familiar with Allen Bradley SLC family of controllers e are familiar with the fast analog modules 1746 FIO4V or 1746 FIO4I e are familiar with the barrel temperature control module 1746 BTM e are familiar with PanelView 550 900 operator terminals e are able to write and interpret the ladder logic required to control your application e have a basic knowledge of hydraulics inc
48. Pro Set 200 software We show references to a chapter within the same manual like this This chapter can help you to get started modifying Pro Set 200 software for your application What Screen and Text Settings Are Used in This Manual What Other Publications Are Available Contacting Technical Support When discussing and using examples of RSLogix 500 programming software we expect you to follow these conventions e Font type Times New Roman e Font size 10 e Display 800 x 600 e Colors 256 This table lists other publications you might need for more information about Pro Set 200 software Publication Publication Number Pro Set 200 J ob Setting Guide 6500 QRO01A US P Pro Set 200 Data Table Reference Manual 6500 RM001A US P SLC 500 Modular Hardware Style Installation and 1747 6 2 Operation Manual Getting Started with PanelBuilder 550 900 Software 2711 6 2 PanelView 550 900 Operator Terminals 2711 6 1 PanelBuilder 550 900 Software 2711 6 0 Barrel Temperature Control Module User Manual 1746 6 10 RSLogix 500 Step by Step Guide for Project Development 9399 RLOSSG SLC 500 MicroLogix 1000 Instruction Set Reference Manual 1747 6 15 Pro Set 200 technical support can be contacted at 440 646 6800 Publication 6500 UM001A US P November 1999 P 8 Notes Publication 6500 UM001A US P November 1999 Using Pro Set 200 Documentation System Overview Introduction to the Injection Molding Process Sett
49. Return To Alarm Menu A 15 12 11 8 7 4 3 0 0000 0000 0000 0000 A A A A A A A A _ t Reserved Minor Error Reserved Reserved CV Small Deviation __ Open Loop Test Alarm CV Large Deviation Alarm Segment Too Short Pv Small Deviation Alarm Velocity CV High Limit Alarm Pv Large Deviation Alarm Velocity CV Low Limit Alarm psi CV Low Limit Alarm psi CV High Limit Alarm Publication 6500 UM001A US P November 1999 A 2 Using Alarms to Troubleshoot Your System Processor Faults The following table lists the SLC 5 04P processor s major faults These faults are reported via the SLC user defined fault When any of these faults occur the fault light blinks and the processor halts These faults are in addition to the standard SLC 5 04 processor cat no 1747 L542 faults listed in SLC 500 and MicroLogix 1000 Instruction Set Reference Manual publication number 1747 6 15 Description Fault Codes Probable Cause Corrective Action Found in File S 6 nternal Software Error 0xa0 Internal software error Call Customer Support achine File Bad Oxal N100 bad Call Customer Support achine CV Output File Bad Oxa2 N102 not found or too short 1 Check N102 length 2 Check N100 6 achine Status File Bad Oxa3 N103 not found or too short 1 Check N103 length 2 Check N100 6 achine Command Permit 0xa4 B101 not found or t
50. SLC 5 04P Processor Addresses Use this appendix to become familiar with SLC 5 04P processor addresses for all Pro Set 200 screens Mold Part Storage Screen a Mold Part Storage gt Recipe 1 is Active Select Recipe Name EO HHHEEFHHHHER HHRH Letter Selection and Position ave Hotive Recipe Save Active Recipe As Selected Recipe M Thine Stopped Restore Enabled a Publication 6500 UM001A US P November 1999 This Is located This Is located field in field in 1 N169 56 N149 31 2 14932 f 15 149 39 3 N149 40 16 N149 47 4 149 48 17 153 31 5 N153 32 18 N150 07 6 N149 30 19 N150 11 7 N149 38 20 N150 15 8 N149 46 21 N154 07 9 153 30 22 92 07 10 150 06 23 83 13 14 11 150 10 24 145 00 12 N150 14 25 N92 07 13 154 06 Understanding SLC 5 04P Processor Addresses Clamp Close Profile Screen Clamp Close Profile oe feral HoN Fast Decel Pol pa Full Open Mold Touch Pos In EERO TED ST irala ved orators In Sec OKOP GIDE acne Press oe ous PSI Pi o ae Pos 2 Pos 824 In Press Clamp Tonnage Screen ya Clamp Tonnage Profile LPMP Malfunction Timer Clamp Decompress Delay OR gaily BHH 13 n Tonnage Low Hold Decompress Adi Fress PSI g7 D aO This Is located This Is located field in field in 1 N157 30 T4 05 ACC 2 161 30 12
51. Set the profiles that require ramping to 1 bit 7 word 0 of the setpoint block to 0 Example Selectively Enabling Ramping Set the ramp rates for those segments that do not require ramping If your machine requires ramping only for the beginning and ending segments of the injection profile such as Segment Ramping required 1 yes 2 no 3 no 4 no 5 yes then enable ramping for the injection profile global ramping and put a zero value no ramp in those segments that do not need ramping Segment Ramping required Ramp rate Data table location I yes 2000 N109 34 35 2 no 0 N109 42 43 3 no 0 N109 50 51 4 no 0 N109 58 59 5 yes 2000 N109 66 57 Configuring Pro Set 200 Profiles 8 11 Ramp Acceleration and Deceleration The following diagrams illustrate which ramp setpoint is applied during the ramp for various segments These diagrams assume the Permit bit example B101 1 0 remains set for the entire profile and the profile is not linked to another profile This is typical of a clamp open profile Segment 1 Segment 2 Segment 3 Segment4 End Seg Seg 3 Accel Seg 4 Decel Seg 2 Accel Seg 4 Decel Seg 1 Accel Segment 1 Segment 2 Segment3 Segment4 End Seg Seg 3 Decel Seg 2 Accel Seg 4 Accel Seg 4 Decel Seg 1 Accel
52. This data is written to the data table from the ladder logic and operator interface What Are the To create an automated molding control system you need the Com ponenis ofa Molding components shown below The Pro Set 200 ladder logic program and Control System Panel View screens when used with these components let you create profiles to control the plastic molding process This system also provides production flexibility and reporting capabilities Pro Set 200 PanelView Screens Clamp Close Profile PanelView 550 or 900 Fast Analog 1 0 Module Fast Analog Seo 1 0 Module BES 8 0 ee seme pie eet are ro Typical chassis have 10 ey eseey a e gion man and 13 slots However ows nn oe a aa prem ier SS other variations may be e ale S S i a K A 1746 BTM E Modules ac dc relay SLC 5 04P S Power Supply Processor Fast Analog 1 0 Module 20803 reserved Pro Set 200 Ladder Logic O H fC I m i Publication 6500 UM001A US P November 1999 You need 1747 5 04P processor System Overview 2 3 To execute the sequence logic which controls the injection molding machine Embedded within this processor are the ERC2 for a explanation of ERC2 see p
53. Valve controls the flow velocity Electronically Adjustable psi Valve Publication 6500 UM001A US P November 1999 controls the pressure in the circuit Understanding Hydraulic Pressure and Flow Concepts 7 11 Figure 7 11 Pro Set 200 Typical Hydraulic Configuration with a Bi directional Control Valve Cylinder prt Pressure A I Transducer Axis Position Injection Sensor Clamp or Ejector Axis y _ Bidirectional oe Proportional Control Valve Electronically fans Adjustable psi Valve Pum ump Tank 20872 M This Does this Bi directional Proportional proportionally controls the flow velocity of the axis Control Valve ecan change direction Position Sensor measures cylinder position Pressure Transducer esenses hydraulic pressure in the cylinder esends back 0 10 volts or 4 20 milliamps proportional to the pressure Electronically Adjustable controls the pressure in the circuit psi Valve Publication 6500 UM001A US P November 1999 7 12 Understanding Hydraulic Pressure and Flow Concepts Figure 7 12 Pro Set 200 Typical Hydraulic Configuration with a Load Sense Valve and Directional Control Valve Cylinder P T Pressure ae r Transducer Positi Axis ha on Injection Snor Clamp or
54. Your System JY Modify initialization file file 3 J Modify files 8 9 12 15 20 and 99 if the fast analog modules and BTM are notin the standard slot see page 1 5 V Customize modify PanelView screens optional a Configure Pro Set 200 Profiles Reference V Load the Pro Set 200 configuration screens ps2c102 Chapter 8 Configuring V Selecta recipe Pro Set 200 F9 until o Mold Part Storage hi Profiles Press oa you see Recipe G is Active Select Recipe QG Name SHEE Hee Letter Selection and Position O Selecta recipe number recipe configuration ave Ive Recipe _ Sawe Active Recipe As Selected Recipe a Machine Stopped Restore Enabled M Restore a Publication 6500 UM001A US P November 1999 Pro Set 200 System Quick Start 1 7 V Configure profiles until F8 Press si eva ERC2 Profile Configuration N No Profile Selected D Selecta profile 2 Save a profile s configu ration reads Operation Complete after Save s Press FS to Advance to Ment Soreen B until F8 res pp Ho Profile Selected Profile is Q Turn profiles on Profile Type is a and off Profile Control Mode 3 2 Select profile type Ramps are OWES and Coordinated CHA Select profile Link Profile 6MM to Profile Number 7J control mode Suspend Profile 3 WEEN at Position DERK 4 Turn ramps on and Directi
55. a user defined file MOV Move 1 12 11 44 When rung conditions are true the MOV instruction moves a copy of the source to the destination MVM Masked Move 17 40 NA When rung conditions are true the MVM instruction moves a copy of the source through a mask to the destination AND And 1 5 NA When rung conditions are true sources A and B of the AND instruction are ANDed bit by bit and stored in the destination OR Inclusive Or 1 5 NA When rung conditions are true sources A and B of the OR instruction are ORed bit by bit and stored in the destination XOR Exclusive Or 1 5 NA When rung conditions are true sources A and B of the XOR instruction are Exclusive ORed bit by bit and stored in the destination NOT Not 1 5 NA When rung conditions are true the source of the NOT instruction is NOTed bit by bit and stored in the destination First In First Out FIFO The FFL instruction loads a word into a FIFO stack on successive FFL Load FFL 40 75 NA false to true transitions The FFU unloads a word from the stack on successive false to true transitions The first word loaded is the first to FFU Unload FFU 60 2 be unloaded per word NA Last In First Out LIFO The LFL instruction loads a word into a LIFO stack on successive LFL Load LFL 40 70 NA false to true transitions The LFU unloads a word from the stack on successive false to true transitions The last word loaded is the first to LFU Unload LFU 34 70 NA be unloaded Publica
56. aalan The Relationship Between Hydraulics and Pro Set200 Understanding Pressure Differential and the Effects on Flow Rates Understanding Load Pressure Concepts 0000005 Understanding Deadheaded Pressure Readings Controlling Velocity Using Relief Valves and Flow Control Valves Understanding Relief Valve Settings and How They Affect Flow Rates Load Pressure and its Affects on Flow Rate 04 Deadheaded Pressure Vs Learned Pressure During a Phase What Hydraulic Configurations Does Pro Set 200 Support What s Next are ws atone boceas oon oire volte cen ae wooed Configuring Pro Set 200 Chapter 8 Profiles Whats in THIS Chapter wn dese ona suse ees ade Few Reb eee Before You Begin Configuring Profiles 000005 Accessing the PanelView Configuration Screens Selecting RECIPE vsisi td ude a iea a a e Configuring PHONES neei arire eeu dee leek T eaa Configuring Primary Controller Variables 1 anaana Making and Recording Your Selections ccc eee eee Configuring Deviation Alarm Limits 00 cee e eee eens Whats NeXt 2 0 c0teverdeesbeas toni tiratan dirit aeiia Publication 6500 UM001A US P November 1999 Using Barrel Temperature Modules BTM Starting Up the Machine Determining Sensor and Valve Operation Quick Tune Procedure Table of Contents toc iii Chapter 9 What s in This Chapter 0 sss0deeaeee aus vastava
57. achieve the rated pressure Publication 6500 UM001A US P November 1999 Most pressure valve manufactures give the rating of the valve and the command signal to achieve the rated pressure Determining Sensor and Valve Operation 11 7 Example Spanning a Pressure Valve to Less Than its Rated Output Suppose the maximum range of a pressure valve is 0 3000 psi and you want to use it over a range of 0 2000 psi To span the Pro Set 200 system s output to a maximum limit of 2000 psi the output should be very near 67 Realize that your initial output of 67 will produce a psi that is near 2000 but probably not exact due to system variations Table 11 A Pressure vs output for an Example 3000 psi Valve Max Rating output Used 3000 100 10 0 2500 83 8 3 2000 67 6 7 2000 1500 50 5 0 1500 1000 33 3 3 1000 500 17 1 7 500 0 0 0 0 To produce a precise 2000 psi you must adjust the control output voltage and or adjust the valve s min and max potentiometer so that the valve delivers 2000 psi at an output of 67 high end and 500 psi low end at an output of 17 Adjust Pro Set 200 outputs with the jog screens by entering the jog values for the output You need to adjust the upper and lower end of the valve to span correctly For each upper and lower output alternately adjust the maximum then minimum output value until the valve delivers the desired pressure range Spanning Velocity Valve Outputs
58. addressing flash PROM provides firmware upgrades without physically changing EPROMS keyswitch RUN REMote PROGram clear faults Publication 6500 UM001A US P November 1999 C 2 Processor Specifications General Specifications Communication Options Publication 6500 UM001A US P November 1999 The following table summarizes the general specifications for the SLC 5 04P processor Description Power Supply Loading at 5V dc Specification 1 0A for the SLC 5 04P processor Power Supply Loading at 24V dc 200 mA for the SLC 5 04P processor Program Scan Hold up Time after Loss of Power 20 ms to 3 s dependent on power supply loading Clock Calendar Accuracy or 54 sec month 25 C 77 F or 81 sec month 60 C 140 F Noise Immunity NEMA Standard ICS 2 230 Vibration Displacement 0 015 inch peak to peak at 5 57 Hz Acceleration 2 5Gs at 57 2000 Hz Shock operating 30Gs Ambient Temperature Rating Operating 0 to 60 C 32 F to 140 F Storage 40 C to 85 C 40 F to 185 F Humidity 5 to 95 without condensation Certification when product or packaging is marked UL listed CSA approved Class 1 Groups A B C or D Division 2 CE marked for all applicable directives The following table summarizes the available memory back up options for the SLC 500 processors EEPROM and UVPROM memory modules provide non volatile memory back u
59. and a restore cannot be performed e enabled means the machine is not currently running and a restore can be performed Auto Tune the BTMs Once you have configured all the zones and have downloaded the M1 configuration files to the BTM you are ready to Auto Tune Before you Auto Tune check and ensure that M1 configuration files you downloaded are valid and free of error This is accomplish by using the following screens If all zones have valid M1 files without parameter error you can Auto Tune If not refer to the error code in the BTM manual for corrective action When all zones are configured error free begin the Auto Tune process by pressing F1 When the Auto Tune is complete the Tune Complete and Tune Successful will report Yes If Auto Tune is not successful refer to the error codes in the BTM manual for corrective action until you see a Auto Tune Ka Fl Auto Tune F Abort Auto Tune F3 Reset Error Codes Fd Reset Auto Tune gi 2 2 ead 3 Walid Mi File Yes Yes Yes Yes es x Press F7 To Advance Sereen Parameter Error Wo Ho Ho Ho Tune Complete Yes Yes Yes Yes Tune Successful Yes Yes Yes Yes __ Error Code CH OHHH OHH OHHH A Publication 6500 UM001A US P November 1999 58 000G Using Barrel Temperature Modules BTM 9 19 Use this field To 1 Use the F1 key to auto tu
60. and continues throughout the inject phase No clamp low hold is necessary and has been turned off Clamp decompress is turned on to gradually release toggle pressure prior to opening Clamp low hold and decompress are actually part of the clamp profile but we show them here to make it clear how the process works Introduction to the Injection Molding Process 3 7 Injection Injection Profile se During injection the ram or screw injects plastic into the mold Segment 2 cavity The ram or screw should force plastic through the mold TEE cavity as fast as possible without flashing the mold or burning plastic y seamen as it goes through the mold gates Y Pre decompression Segment5 Mold Cavity Plastication Pack Ram screw y y m Flow into mold lt RQQRQQYN Post decompression Hold Shoki Clamp Decompress Clamp Low Hold To control this process you can vary the velocity or pressure of the injection ram with the injection profile as shown in the illustration below The table that follows the illustration describes the injection profiles that you can select Injection Profile usevel5 amp usevel4 amp usevel3 amp usevel2 amp usevell amp psi 5 psi 4 psi 3 psi 2 psi 1 There is a corresponding velocity WY lt TR setpoint and pressure setpoint SX Ram screw N asso
61. atthe corresponding voltage or milliamperage 2 units in volts or mA 3 max close 99 99 in sec at the corresponding voltage or milliamperage 4 min open zero in sec at the corresponding voltage or milliamperage 5 units in volts or mA 6 max open 99 99 in sec at the corresponding voltage or milliamperage Publication 6500 UM001A US P November 1999 10 4 Starting Up the Machine 5 In the lower half of the screen enter values as shown in the following table The velocity spanning values that you have entered cause the jog values for velocity to read as a percent value In the next chapter the jog values will be scaled into inches per second The jog values you enter here will be written to the analog output card s for initial machine movements gt 6 To apply the entered values press y ATTENTION Unexpected machine movement could result in personal injury or property damage When entering jog values use low enough percentages so that unexpected machine motion does not occur In this field Enter jog values that move the phase at slow to moderate speed 7 Close J og Vel in sec 8 Open J og Vel in sec 9 Close J og psi psi 10 Open J og psi psi w i It is important to Cores remember that anytime you change a pressure or velocity output entry you must press F7 for changes to take effect 7 Repeat this procedure for each of the other phases The setup for the plastica
62. either 4 20 milliamps or 0 10 volts through the use of high speed analog input modules 1746 FIO4V and 1746 FIO4D Important At a minimum you must have an injection position transducer and a clamp position transducer Pro Set 200 does not work with limit switches on the clamp and inject unit Limit switches are supported for ejector control only Publication 6500 UM001A US P November 1999 System Overview How Does Pro Set 200 Work Step 1 Pressure and position feedback are received by their The following diagram illustrates how Pro Set 200 works Step 3 Raw pressure and position data are scaled to engineering Step 2 Raw pressure and position data are respective transducers and are written to the data units read by the ladder logic in the table STI An files COLCICI Fast Analog SSeS 1 0 Module es Position Feedback Seoces tos IVVV IVVV santa i epon Production Raw Data lt Position SLC 5 04P Processor grees Pressure Feedback O STI Data DH p J Rau ma amie Communications T Pressure ogic nes si position sealed Processor Step 4 During the STI pressure Overhead the ERC2 algorithms T ERC2 receive or read the fl Algorithms scaled pressure and Pressure Valve aa ean position feedback x calculate the new 4 FastAnalog Pressure pressure scaled pressure and flo
63. explains how to span pressure and velocity valve outputs Span outputs for each phase injection clamp and ejector We show injection phase screens if you are spanning the clamp or ejectors phase or the plasticate profile substitute those screens Spanning Pressure Valve Outputs To span pressure valve outputs do the following 1 Go to the injection clamp or ejector output scaling screen a pq until For clamp you see Injection Input Output Device Setup press Clamp Cl Sa Pos Input Pi G8 AT BR Counts until iied EPS yeusee Pos Input P2 GH AT GH Counts press eco Type gt Current Counts OHHH wi PSI Input Pi G AT EHH lt For olsticote lt q FB you se PSI Input P2 E AT j Plasticate Type gt 3 F6 For ejectors el press Ei ectors 2 Enter these configuration values When selecting volts or amps go to the selector make your selection then press enter In this field Do this 1 Enter the minimum pressure rating of the valve In most cases the minimum is 0 psi 2 Enter the corresponding voltage or amperage command signal to achieve the rated pressure In most cases this is 0 volts or 4 milliamps 3 Select voltage or milliamps for the corresponding sensor This tells the SLC 5 04P processor which analog output card has been placed in the system FIO4V or FIO4I 4 Enter the maximum pressure rating of the valve 5 Enter the corresponding voltage or amperage command signal to
64. in Bar Chart the eject forward and retract profiles Ejector Ejector Ejector Ejector Ejector Ejector Forward Forward Forward Forward Retract Forward Segment 1 Segment 1 Segment 2 Segment 2 Segment 1 Segment 1 Active Bit Comp Bit Active Bit Comp Bit Active Bit Comp Bit B186 16 B186 01 00 B186 32 B186 02 00 B186 17 B186 01 01 B186 33 B186 02 01 B186 80 B186 05 00 B186 96 B186 31 Eject Forward Profile Active B186 16 00 B186 01 15 Eject Forward Profile Done B186 02 15 Eject Retract Profile Active B186 95 B186 05 15 B186 111 Eject Ret Profile Complete B186 06 15 Velocity 189 30 189 38 N193 30 Setpoint Pressure 189 31 189 39 N193 31 Setpoint Position 189 32 189 40 N193 32 Setpoint Time 189 33 189 41 N193 33 Setpoint Publication 6500 UM001A US P November 1999 A accessing configuration screens8 1 setup screens 11 1 12 1 acessing setup screens alarm bits A 1 alarms 2 4 analog outputs placementis crucial 6 33 turning o B bar charts clamp F d clamp close sequence modifying ladder pail Iq clamp open sequence modifying ladder al 19 ejector forward ejector retrac F 14 injection sequence modifying ladder logic 6 11 injection pack hold F 4 machine sequenced 6 10 pre decompree plasticate postdecompress F 4 basic features 2 7 BTM ee configuring 9 4 creating a new mold recipe 9 4 creating a new
65. in the Suspend Idle mode The suspend ID number is placed in word S 7 and the program file number is placed in S 8 IM Immediate Input with 51 0 When conditions preceding it in the rung are true the IIM instruction is Mask enabled and interrupts the program scan to write a word of masked external input data to the input data file IOM Immediate Output with 75 74 When conditions preceding it in the rung are true the IOM instruction Mask is enabled and interrupts the program scan to read a word of data from the output data file and transfer the data through a mask to the corresponding external outputs Instruction Mnemonic and Name BSL BitShift Left BSR Bit Shift Right Application Specific Instructions Execution Times us Floating Point us 31 5 2 31 per word Function Output Instructions On each false to true transition these instructions load a bit of data into a bit array shift the pattern of data through the array and unload the end bit of data The BSL shifts data to the left and the BSR shifts data to the right SQO Sequencer Output 44 1 On successive false to true transitions the SQO moves a step through the programmed sequencer file transferring step data through a mask to a destination word SQC Sequencer Compare 33 2 On successive false to true transitions the SQC moves a step through the programmed sequencer file comparing the data through a mask to
66. in the destination DIV Divide 25 9 23 27 When rung conditions are true the DIV instruction divides source A by source B and stores the result in the destination and the math register DDV Double Divide 29 6 NA When rung conditions are true the DDV instruction divides the contents of the math register by the source and stores the result in the destination and the math register NEG Negate 1 5 11 87 When rung conditions are true the NEG instruction changes the sign of the source and places it in the destination CLR Clear 1 5 5 94 When rung conditions are true the CLR instruction clears the destination to zero SQR Square Root 28 8 18 87 When rung conditions are true the SQR instruction calculates the Square root of the source and places the result in the destination Publication 6500 UM001A US P November 1999 C 6 Processor Specifications Math Instructions continued Instruction Mnemonic Execution Times us Function and Name Floating Point us Output Instructions SCL Scale 33 06 NA When rung conditions are true the SCL instruction multiplies the source by a specified rate The result is added to an offset value and placed in the destination SCP Scale with 29 85 Produces a scaled output value that has a linear relationship between Parameters 94 15 the input and scaled values CPT Compute 7 7 NA Evaluates an expression and stores the result in the destination SWP S
67. mode the same command value is sent to the valves regardless of position or pressure feedback values The profile s velocity and pressure segment setpoints are not used Trigger setpoints are ignored Segment and profile active and done bits are set according to the profile segment position and time setpoints Kp Roughly equivalent to a proportional term Provides in shot correction i e makes changes to the valve in response to error Low Pressure Mold Protect Last clamp close operation to protect the mold if a plastic part is stuck in it Manual Machine Control Control of the machine by an operator Glossary G 3 Manual Temperature Temperature control of a loop with fixed output setpoints no feedback Mode Machine Select from manual semi auto one cycle or automatic production Open Slow Last clamp open operation when clamp decelerates to fully open position Open Loop Test OLT Used by ERC2 to determine System Gains Dead Times and Time Constants for profiles Operator Panel Device where machine status is displayed and the operator enters setpoints also called operator interface OI Pack Machine profile when the melt is pressured to complete filling mold cavity Phase An axis of control In injection molding there are typically three phases injection clamp and eject Phases are often referred specifically as injection phase ejector phase and clamp phase
68. of your position and pressure inputs you will need to zero them The following steps explain how to zero position and pressure inputs in this example we describe clamp zeroing if you are zeroing injection or ejectors substitute those phase zeroing menu components Phase Zeroing gt Pos BH In ero Lomplete Press B H PSI gt Pos GH 4 In ero Lomplete Press BH PSI Pos B In Press BEF PSI Zeroing A Phase Zeros Position And ko Pressure J 1 For clamp zeroing begin by completely closing the clamp If you are using a toggle machine lock the toggle over For injection zeroing bottom out the screw and for ejector zeroing fully retract ejector pins into mold 2 From the PanelView screen use the left and right arrow keys select s o era Lomplete 3 Using the up and down arrow keys select zero clamp ea 4 Press the enter key C 5 Repeat the above steps substituting injection and ejection for clamp The zeroing function zeros position and pressure If you want zero pressure to be true shut pumps off before performing the zeroing process If you want idle pressure to be the zero pressure perform the zeroing process with the pumps running but without motion Publication 6500 UM001A US P November 1999 11 6 Determining Sensor and Valve Operation Spanning Outputs This section
69. or N103 42 to find the offending profile Profile Actuals File Bad Oxab N110 N114 N18 profile 1 Look in N103 to determine if problem is on inject Publication 6500 UM001A US P November 1999 actuals file not found or clamp or eject too short 2 Use N103 16 N103 29 or N103 42 to find the offending profile Description Profile Engineering Actuals Bad Fault Codes Found in File S 6 Oxac Using Alarms to Troubleshoot Your System Probable Cause N111 N115 N119 profile engineering actuals file not found or too short Corrective Action 1 Look in N103 to determine if problem is on inject clamp or eject 2 Use N103 16 N103 29 or N103 42 to find the offending profile Profile ERC2 Memory File Bad Oxad F112 F116 F120 profile 1 Look in N103 to determine if problem is on inject ERC2 memory file not found clamp or eject or too short 2 Use N103 16 N103 29 or N103 42 to find the offending profile Wrong Processor Type Oxae Processor is not an L54xP You might have a normal L54x processor Pro S et 200 requires a L542P processor Invalid Profile Count Oxaf N100 1 N100 3 or N100 5 Look in N103 to determine if problem is on inject contains an invalid value clamp or eject Invalid SR to ERC Subroutine Oxb0 ERC2 update subroutine 1 Remove JSR 255 from any DII or Main scan SR254 has been called ladder files again before completing the 2 Call this subrou
70. permissive bits work eyou want to change how the short shot user specific alarm functions eyou want to modify how the jog user specific bit s function 12 clamp STI your clamp position and or pressure sensor is change I O address to match your not wired to analog card in slot 2 card address 13 clamp interpolation file different velocity and or pressure minimums change appropriate minimum maximum CV and maximums are required for each profile and or PV ladder rung 14 clamp permissive you want to modify how clamp phase user specific permissive bits work 15 eject STI your ejector position and or pressure sensor is change I O address to match your not wired to the analog card in slot 3 card address 16 eject interpolation file different velocity and or pressure change appropriate minimum maximum CV minimums maximums are required for and or PV ladder rung each profile 17 ejector permissive you want to modify how ejector phase user specific permissive bits work 18 quick tune do not modify Publication 6500 UM001A US P November 1999 Customizing Your System File Number File Description Customize If Changes Needed 19 core permissive you need different core sequences The user specific Pro Set 200 standard core sequences are eSPIA B C D set eSPI A B C D pull 20 loss of sensor eyou want different limit values for a loss of emodify corresponding limit value sensor for inject
71. points to BitPattem F the permissive N109 02 0000 0000 0000 0010 anit ___ bit pattern of the next block vA to be executed Hold Setpoint in this case The link profile word in the injection N117 0 Block the hold block setpoint block contains the permissive bit pattern for the pack profile The permissive blocks and bit patterns are 3 located in B101 Set N113 0 8 1 This enables profile linking for the pack profile the pack profile is linked to the hold profile Note that this is the default out of the box configuration for Pro Set 200 4 Place the permissive bit pattern for the hold profile in the link profile identification word in the back setpoint block N113 02 0000 0000 0000 0100 The link profile word in the pack setpoint block contains the permissive bit pattern for the hold profile Publication 6500 UM001A US P November 1999 Link Profile gt GEM to Profile Humber Suspend Profile Word 0 of the Setpoint Block Configuring Pro Set 200 Profiles 8 17 Setting Link Profile Identification Use this field to specify the profile that you want to link to In order to use this field enable profile linking set bit 8 in configuration word 0 For information about enabling profile linking see page 8 14 ATTENTION You can only link profiles in the same phase For example you can link the pack profile to the
72. ps2s102 pva and ps2s102 pba files on the Panel View screens disk After the initial power up sequence of the Panel View terminal the Pro Set 200 Title Screen appears Clamp 1 0 Device i Clamp Tonnage Setup Screen 305 Sensing Setup Screen 307 F1 F1 Injection 1 0 Device Setup Screen 302 F3 Machine Setup Utility Screen 301 F9 Eject I O Device Ejector Position g Spanning Values Sensing Setup seu Eea Setup Screen 309 Screen 310 F6 F6 Plastication Phase Zeroing Screen 311 F8 Alarm History Screen 313 Alarm Menu F10 Screen 312 F10 ERC2 Alarm Setup Screen 31 E10 Publication 6500 UM001A US P November 1999 6 38 Customizing Your System Publication 6500 UM001A US P November 1999 Layout for Pro Set 200 BTM Screens This screen layout applies to the ps2b102 pva and ps2b102 pba files on the Panel View screens disk After the initial power up sequence of the Panel View terminal the Pro Set 200 Title Screen appears Mold Part Storage Screen 201 F9 F6 Auto Tune Screen 210 Auto Tune Screen 211 F6 Control Setpoint F8 Alarm History Screen 216 F10 Screen 207 F7 Tune Block Screen 208 F7 MO PID Gains Block Screen 209 F7 Screen 213 F8 Screen 214 Alarm Menu Screen 215 ERC2 Alarm Setup Screen 217 F10 Customizing Your System 6 39 Optimizing Screen Update Time The Panel View sends groups of data in packets The
73. pushing against a load and the pressure in the system is low enough that no movement occurs the relief valve will open once the system pressure reaches the set value 500 psi Once the relief valve is open the pressure of the injection cylinder circuit measured at gauge 2 and the relief valve circuit measured at gauge 1 are the same During this state the entire system measures the value of the pressure relief valve and the pressure differential between gauge 1 and gauge 2 is zero Deadheaded pressure is the pressure measured during this state when the oil flow of the cylinder circuit has all but stopped yet continues to flow across the relief valve circuit The purpose for learning deadheaded pressure values is that regardless of where the hydraulic pressure transducer is located the true characteristics of the pressure relief valve can be determined By ensuring the cylinder is not moving during the profile you are guaranteeing that pressure drops are not occurring between the transducer and the pressure relief valve Publication 6500 UM001A US P November 1999 7 6 Understanding Hydraulic Pressure and Flow Concepts Controlling Velocity Using As stated earlier the velocity of the cylinder can be controlled by Relief Valves and Flow adjusting the relief valve Unfortunately controlling cylinder Control Valves velocity with a relief valve may yield poor results One reason is that the characteristic of a pressure valve applied t
74. range of 0 to 3276 7 When you press F6 from this screen you will return to the screen on page 9 6 Press F5 to save the zone you just configured and then select another to configure Repeat this process until all zones are configured Once all zones have been configured select M1 Configuration download and press enter This sends the configuration data to the BTM modules If at any time you change any configuration data you must re download the M1 Configuration file for the changes to take effect Creating a New Mold Recipe Based on an Existing Recipe You can create a new mold recipe by using a previously created recipe as a template First you must restore the mold recipe you want to modify Then you need only to change the recipe parameters that you need modified Finally you must save the active recipe as an recipe number other than the original restored recipe Publication 6500 UM001A US P November 1999 Using Barrel Temperature Modules BTM 9 17 Restoring a Previously Run Mold Recipe In order for the previously run recipe to become active you must first restore it Press the F9 function key to access the mold part storage screen E Mold Fart Storage s Part Storage Recipe 8 is Active Select Recipe G Name FFFFHHHRHHHHH HEHE EH Letter Selection and Pon ition Press Sore Apel pei As Selected Recipe 4 Machine Stopped Restore Enabled A Use this field To 1 V
75. result in unpredictable operation Modify these bits while the machine is idle Access the Pro Set 200 configuration screens by loading this file ps2cl02 pva Publication 6500 UM001A US P November 1999 8 2 Configuring Pro Set 200 Profiles Selecting a Recipe til Press Cet P ices E Mold Part Storage gt Part Storage Recipe 84 is Active Select Recipe G Hame aH HE EH Letter Te and Position gt E otive Recipe Sore Active Recipe As Selected Recipe a Machine Stopped Restore Enabled From this screen you can See page select a recipe number 8 2 restore and save a recipe configuration 8 3 Select Recipe G Selecting a Recipe Number Use this field to select a recipe number Pro Set 200 is configured from the factory to support up to 5 recipes To select a recipe number do the following 1 Cursor to this field Select Recipe B by using the left and right arrow keys x J 2 Press the enter key The scratch pad appears Enter value 1 to 5 3 Enter the new recipe number through 5 4 Press the enter key The recipe name associated with the recipe number appears in the name area The recipe does not become active until you perform a restore function Publication 6500 UM001A US P November 1999 Configuring Pro Set 200 Profiles 8 3 Saving a Recipe Configuration To save a recipe configuration that you made changes to do the followin
76. schematics based on existing schematic and improvements for Pro Set 200 Creating bill of materials based on review and development of electrical schematics Mounting wiring and testing of the complete electrical system Programming Pro Set 200 using Panel View and RSLogix500 For the hydraulic components of your project plan you will need personnel capable of accomplishing the following Understanding the intricate details involved in sizing and setting up valves specifically for injection molding machines Reviewing existing hydraulic schematics of your molding machine Developing new hydraulic schematics based on existing schematics and improvements for Pro Set 200 Creating a bill of materials based on review and development of hydraulic schematics Mounting plumbing and testing of the hydraulic system For the mechanical components of your project plan you will need personnel capable of accomplishing the following Determining necessary mechanical rebuild Creating a bill of materials based on rebuild specifications Installing and testing of rebuild Consider the following when creating your project plan Communication between system experts Lead times for ordering new parts equipment System testing Publication 6500 UM001A US P November 1999 1 4 Pro Set 200 System Quick Start Simplified Pro Set 200 Project Plan Electrical Component Projection Review o Create Bil
77. screens included in the Pro Set 200 setup screens We show injection phase screens if you are jogging the clamp or ejectors phase substitute those screens 1 Go to the injection phase jog screen 7 MIN Fud BE F IN SEC f Velocity Spanning ae MAX Fud DF FF 1 SEC AT EFF STR MIN Ret E 88 IN SEC AT OHE FF cA FE MAX Ret BH IN SEC AT GHH Forward Jog Man Wel AH HH In Sec Vel Uel EFE PSI BF l PSI BE o oO Fress F3 to Advance Injection Sereens oe Make sure the max fwd field 1 is 99 99 in sec 2 3 Enter 1 00 in field 3 4 Jog the injection ram forward and watch field 4 5 Increase the jog velocity field 3 typically by 1 00 in sec until field 4 does not increase i e you have reached maximum velocity 6 Read the value in field 4 and record it here For example assume the following e you enter max fwd 99 99 in sec at 10 00 volts field 1 and you increase the jog value to 50 00 vel fwd field 3 you record 10 00 in sec recorded during jog field 4 as the maximum velocity Publication 6500 UM001A US P November 1999 11 10 Determining Sensor and Valve Operation 7 Place the max recorded velocity field 4 into the max fwd field 1 field In the example enter 10 00 in sec in the max fwd field 1 field 8 Enter the maximum voltage required to achieve maximum velocity Maximum Voltage Maximum Jog
78. the left and right arrow keys 2 Press the enter key The scratch pad appears Enter value Lo 1 to 5 3 Enter a recipe number between 1 5 Pro Set 200 lets you use up to 5 recipes View the recipe name of the selected recipe This field is a display only field you cannot enter a new name in this field Use fields 4 and 5 to enter a new name Change the letter selection 1 Select the letter 2 Cursor to this field by using the left and right arrow keys 3 Selecta letter by pressing the up and down arrow keys 4 Press the enter key when you reach the correct letter Select the position of a letter in the name field 1 Cursor to this field by using the left and right arrow keys 2 Selecta position by pressing the up and down arrow keys 4 3 Press the enter ky when you reach the correct position number This field relates to the following positions on the name display Name eee eee position 1 position 20 Save a mold recipe that you configured or retrieve a previously stored recipe Publication 6500 UM001A US P November 1999 Using Mold Part Recipes 13 7 Increasing the Number of The number of mold part recipe files that can be stored in Pro Set Mold Part Recipes 200 depends on the available memory and unused data table file space Use the following method for calculating the number of recipes you can store 1 Calculate the number of data table files available for mold
79. trigger setpoints E external time trigger setpoints internal pressure over under bil E 4 internal trigger mask position setpoint mie maximum node address 6 40 gt suspend profile position 8 14 setting ramp rates 8 29 setting up the hardware 4 1 setting up the software 5 1 setup screens accessing 10 1 11 1 layout 6 37 SLC 5 04P processor installing 4 4 SLC processor addresses arm history scree arm setup screen B uto tune screen B 33 TM configuration screens B 29 amp close profile screen B 2 amp close ramp rates scree aca ane device setup screen w N O O wo wD clamp open profile screen B 3 clamp open ramp rates scree clamp tonnage ramp rates scree amp tonnage screen a mp e device setup screen B 2q ejector forward screen B 4 ejector position sensing screen B 2 ejector retract screens B 7 ejector selections screen B 4 ERC2 alarm setup scree ERC2 profile configuration screen B 29 injection profile screen B 3 injection ramp rates screen B 24 input output device setup scree machine setup sel8 1d mold part storage screen B 1 operator screens pack hold profile screen B 4 pack hold ramp rates screen B 27 phase zeroing scree plasticate ramp rates scree plastication profile screen plastication sensor nameplate screen production monitor screens profile selected scree profile selection screen B 23 quick tune screen B 14 se
80. v k rjo m ock for Remove drain wire and foil x Modules SI shield at casing Limit braid length to 12 or less Solder braids to lugs attached to bottom row of I O chassis bolts For cable shields grounded at the I O device output channels do this Ungrounded End at Output of Module Grounded End at I O Device 3 8 Noe Keep the length of unshielded s wires as short as possible Remove drain f Cable Clamp Wires wire and foil shield at casing Connect to caz 1 4 braid Cable Terminal Solder drain wire Block for I O to braid at casing Modules a For more information about wiring a 1746 FIO4V or 1746 FIO4I module see SLC 500 Fast Analog I O Module User Manual publication number 1746 6 9 el Publication 6500 UM001A US P November 1999 4 17 Wiring the 1746 BTM Modules The BTM module contains a green 18 position removable terminal block The terminal pin out is shown below ATTENTION Disconnect power to the SLC 5 04P processor before attempting to install remove or wire the removable terminal wiring block To avoid cracking the removable terminal block alternate the removal of the slotted terminal block release screws Terminal Block Spare Part Catalog Number 1746 RT32 Rel CJC A elease Screw CJC Assembly gt Channel 0 CJC A Channel 0 a Channel 1 Do NOT Channel 1 use these connection
81. values press y 7 It is important to Cores remember that anytime you change a pressure or velocity output entry you must press F7 for changes to take effect 11 Important Save your machine setup data See the next section Publication 6500 UM001A US P November 1999 10 6 Starting Up the Machine Saving and Restoring Machine Setup Data press CCF Mold Part Storage Verifying Correct Hydraulic Operation Publication 6500 UM001A US P November 1999 You can save machine setup data or restore the original configuration b Machine Setup Utility Setup Save Machine Setup Machine Stopped Restore Save Enabled a A To Do this save machine 1 Select Restore Machine Setup setup data gt EAE 2 Press enter restore machine Restore Machine Setup setup data l Select B Save Machine Setup 2 Press enter This section helps you verify correct hydraulic operation and helps you ensure that the jog setpoints that you just loaded are in control of your machine At this point you have not scaled the sensors You have entered values to enable your machine to move ATTENTION Unexpected machine movement could result in personal injury or property damage Ensure all machine safety guards are in place Use care when activating each phase Starting Up the Machine 10 7 To verify hydraulic operation 1 Switch your machine to setup mode 2 Using sw
82. 0 we show other hydraulic configuration that Pro Set 200 can support The configuration shown in this appendix require you to write additional ladder logic In the next chapter we explain how to configure Pro Set 200 profiles What s in This Chapter Before You Begin Configuring Profiles Accessing the PanelView Configuration Screens Chapter 8 Configuring Pro Set 200 Profiles This chapter explains how to e select a recipe e configure profiles e configure primary controller variables The bits that determine configuration information are located in configuration word 0 and word 1 of the setpoint block for each of the profiles The locations of the setpoint blocks are listed in the following table Profile Data Table Location Profile Data Table Location Injection N109 Tonnage N157 Pack N113 Low Hold N161 Hold N117 Decompress N165 Pre Decompress N121 Clamp Open N169 Plastication N125 Ejector Forward N189 Post Decompress N129 Ejector Retract N193 Clamp Close N149 Eject Tip Stroke N197 Clamp LPMP N153 You can configure these bits through either Panel View screens or ladder logic programming software To configure these bits using Use this column throughout this section ladder logic programming software PanelView screens ATTENTION Do not change these bits while the machine is performing a cycle or it could
83. 0 0000 bit 8 Publication 6500 UM001A US P November 1999 Linking to Another Profile Profile linking ties related setpoint blocks together It tells the ERC2 algorithms what the next profile block will be by pointing to the permissive bit pattern of the next profile For example inject pack and hold are usually linked together to provide seamless transitions from inject to pack to hold Pro Set 200 automatically starts the linked profile when the current profile ends The permissive bit for the linked profile does not need to be set Conceptually linking several profiles combines all of the segments into one continuous profile Do not link profiles if e you are changing the direction of the axes of motion e you are using a different valve set to control the next action e you are not using a profile in the same phase as the current profile e the current profile does not end on position or time for example tonnage clamp low hold or decompress In most cases you will probably use the default values for profile linking You can change profile linking to skip certain machine phases For example you could eliminate the pack phase and go from the injection profile directly to the hold profile If you a want to link to the next profile set bit 8 1 select gt EZA When linking is selected Pro S et 200 links to the profile shown in word 2 of the setpoint block d
84. 0 to 32 767 View and modify the integral gain value for the heat loop 1 Cursor to this field by using the left and right arrow keys 2 Press the enter key 3 The scratch pad appears Enter value _x xxxy 0 to 3 2767 3 Enter a value in a range of 0 to 3 2767 View and modify the derivative gain value for the heat loop 1 Cursor to this field by using the left and right arrow keys Le J 2 Press the enter key 4 The scratch pad appears Enter value xxxx x 0 to 3276 7 3 Entera value in a range of 0 to 3276 7 Publication 6500 UM001A US P November 1999 9 16 Use this field Using Barrel Temperature Modules BTM To View and modify the proportional gain value for the cool loop 1 Cursor to this field by using the left and right arrow keys 2 Press the enter key he scratch pad appears E XX XXX Enter value 0 to 32 767 3 Enter a value in a range of 0 to 32 767 View and modify the integral gain value for the cool loop 1 Cursor to this field by using the left and right arrow keys e 2 Press the enter key The scratch pad appears Enter value L_X XXxXXx 0 to 3 2767 3 Enter a value in a range of 0 to 3 2767 View and modify the derivative gain value for the cool loop 1 Cursor to this field by using the left and right arrow keys _ lt _ 2 Press the enter key The scratch pad appears Enter value xxxx x OQ to 3276 7 3 Enter a value in a
85. 1 Enter the injection velocity large deviation CV in a range from 0 to 32767 12 Enter the ejection velocity small deviation CV in a range from 0 to 32767 13 Enter the clamp psi small deviation PV in a range from 0 to 3000 14 Enter the clamp psi large deviation PV in a range from 0 to 3000 15 Enter the injection psi small deviation PV in a range from 0 to 3000 16 Enter the injection psi large deviation PV in a range from 0 to 3000 17 Enter the ejection psi small deviation PV in a range from 0 to 3000 18 Enter the ejection psi large deviation PV in a range from 0 to 3000 19 Enter the clamp psi small deviation CV in a range from 0 to 32767 20 Enter the clamp psi large deviation CV in a range from 0 to 32767 21 Enter the injection psi small deviation CV in a range from 0 to 32767 22 Enter the injection psi large deviation CV in a range from 0 to 32767 Publication 6500 UM001A US P November 1999 8 30 Configuring Pro Set 200 Profiles In this field Do this 23 Enter the ejection psi small deviation CV in a range from 0 to 32767 24 Enter the ejection psi large deviation CV in a range from 0 to 32767 What s Next In the next chapter we discuss BTMs Publication 6500 UM001A US P November 1999 What s in This Chapter Placing the BTM in the I O Chassis Chapter 9 Using Barrel Temperature Modules BTM This chapter explains the Barrel Temperature module 1746 BTM You use the Barrel Temperature module to control the t
86. 169 61 6 N169 51 14 N169 53 7 N169 43 15 N169 45 8 N169 35 16 N169 37 This Islocated This Is located field in field in 1 N109 66 11 N109 68 2 N109 58 12 109 60 3 N109 50 13 N109 52 4 N109 42 14 109 44 5 N109 34 15 N109 36 6 N109 67 16 109 69 7 N109 59 17 N109 61 8 N109 51 18 109 53 9 N109 43 19 N109 45 10 N109 35 N109 37 Publication 6500 UM001A US P November 1999 Clamp Open Ramp Rates Screen a Ace Wel In Sec2 Dec Wel In Sec2 Ace Press PSI Sec Dec Press Clamp Open Ramp Rates Full agen en Open Open O Decel Open Fast feu Clore an Gn Gn ee Guus O OTER A Injection Ramp Rates Screen A Ace Vel Inert Dec Vel In Sec2 Peleee Injection Ramp Rates a 4 3 2 1 CUA CH CH W Se Ace press HARA 22 A 1 HR LA 15 HA Dec 26 FFA 17 KSF LOFE COE a a Understanding SLC 5 04P Processor Addresses B 27 Pack hold Ramp Rates Screen a This Is located This Is located a Pack Ho ld Ramp Rates field in field in Pack 1 Pack 2 Hold 1 Hold 2 1 N113 34 9 N113 36 N113 42 10 N113 44 Hoc ve Oa 3 o N117 34 li N117 36 N117 42 12 N117 44 pee el Ou N113 35 13 N113 37 asas fua EE press OHHH OFF LHN 12 N117 35 15 N113 37 PS Sec N117 4
87. 1A US P November 1999 6 30 Customizing Your System Conceptual Model of 3 Valve Variation B 1 Pressure Valve for Clamp Injection and Ejector 1 Velocity Valve for Clamp 1 Velocity Valve for Clamp Injection and Ejector Injection Clamp Ejector Electronically Adjustable y Velocity Valve V2 N Manual Pressure Valve and or v N AY Directional Control WV j j i eed ee 7 gt _4 Electronically Adjustable System elocity Valve Relief Valve psi o L Tank M This conceptual model is intended to be used as an aid in understanding ladder code modifications for the example scenario It is not a complete hydraulic diagram Publication 6500 UM001A US P November 1999 1 System Pressure Valve for Clamp Injection and Ejector 1 Velocity Valve for Injection 1 System Velocity Valve for Clamp Injection and Ejector Variation C If your system is configured in this way there are a number of questions that you must answer before you can begin configuration Key configuration questions are e During injection which valve will control speed and must you move one valve out of the way e During clamp functions what is done with the injection velocity valve e During ejector functions what will be done with the injection velocity valve e What is done is the clamp and ejectors are moving simultaneously e Do you treat
88. 3 Eject Setup Screen 14 F6 Timer Setup Screen 20 F9 Timer Setup Screen 21 F9 Production Monitor 1 Screen 22 F9 Production Monitor 2 Screen 23 F9 Production Monitor 3 Screen 24 F9 Production Monitor 4 Screen 25 F9 Production Monitor 5 Screen 26 F9 Storage Screen 1 F9 Mold Part Quick Tune F8 Temp Setpoint 2 Screen 16 F8 Temp Setpoint 3 Screen 17 F8 Temp Setpoint 4 Screen 18 F8 F9 Alarm History Screen 30 F10 ERC2 Alarm Setup Screen 31 F10 Publication 6500 UM001A US P November 1999 6 36 Customizing Your System Layout for Pro Set 200 Configuration Screens This screen layout applies to the ps2c102 pva and ps2c102 pba files on the Panel View screens disk After the initial power up sequence of the Panel View terminal the Pro Set 200 Title Screen appears Screen 107 F1 F2 Publication 6500 UM001A US P November 1999 Deviation Alarm Limit Screen 105 Plasticate 1 Ramp Rates Screen 111 Eject Accel Decel Screen 113 F5 F6 F7 Profile Config 1 Screen 103 F8 Plasticate Decompress Ramp Rates Screen 112 Alarm History Screen 115 F10 Profile Config 2 Screen 104 F8 Alarm Menu Screen 114 F10 ERC2 Alarm Setup Screen 116 F10 Customizing Your System 6 37 Layout for Pro Set 200 Setup Screens This screen layout applies to the
89. 3 16 N117 45 press DFH LOF C ec 2 3 4 5 6 7 8 Plasticate Ramp Rates Screen 1 This Is located A Plasticate Ramp Rates L This Is located field in field in 1 N12534 11 N2536 l 2 3 4 S 2 N125 42 12 N125 44 Ace vel 3 N125 50 13 N125 52 fuss e wise Tasen Oi e e ee peress i d ec 8 N125 51 18 N125 53 s masso w mse press 10 N125 67 20 N125 69 N Dog E Publication 6500 UM001A US P November 1999 B 28 Understanding SLC 5 04P Processor Addresses This field Is located in N121 34 129 34 N121 35 129 35 N121 36 129 36 N121 37 ojl NI olal e wI N e 129 37 This Islocated This Is located field in field in 1 N193 34 9 N193 36 2 197 34 10 197 36 3 N189 42 11 N189 44 4 189 34 12 189 36 5 N193 35 13 N193 37 6 197 35 14 197 37 i N189 43 15 N189 45 8 189 35_ 16 189 37 Publication 6500 UM001A US P November 1999 Plasticate Ramp Rates Screen 2 r Ace Vel In Sec Deg Wel In Sec2 Ace Press PSI1 Sec Dec Press Keren Plasticate Ramp Rates a Pre Decompress Post Decompress T j E EE J Eject Ramp Rates Screen A Ace Vel In Sec2 Dec Wel In Sec2 Ace Press PSI Sec Dec
90. 3 Profile Control Mode N90 01 07 90 01 13 N90 01 08 N90 03 WO CO NS DD S WwW NY N90 01 09 m oO N90 04 ji m N90 01 10 Press FS to Advance to Nest Soreen A Publication 6500 UM001A US P November 1999 B 24 Understanding SLC 5 04P Processor Addresses a i a Ne Press FS E Advance ta ter Soreen This field Is located in 1 N90 07 2 N90 01 01 3 N 90 01 04 4 N90 01 05 5 N90 01 06 This Islocated This Is located field in field in 1 N1416 B 104 18 2 N144 20 14 N104 22 3 14417 15 104 19 4 N144 21 16 N104 23 5 14418 v 184 16 6 N144 22 18 N184 20 7 14419 184 17 8 N144 23 N184 21 9 N104 16 184 18 10 N104 20 N184 22 ll 104 17 184 19 12 Nuo4 21 ff 24 N184 23 Publication 6500 UM001A US P November 1999 Profile Selected Screen 1 Dho Profile Selected Use Learned or 4CUMay U2 bedty 3 EEE If Pressure Profile then Learn PSI during Profile or Use PSI learned during Deadhead If Velocity Profile then Run PSI as CUMAR or Use PSI Learned during Deadhead Be achead Press F8 to Advance to Next Sereen a Profile Selected Screen 2 S Deviation Alarm Limits Velocity FSI porata Deviation Y Py Cy Clamp Small L ORF sarae BROJ ERKE Inject Small ona 10 HHH Large EKLE ERF B
91. 4 Publication 6500 UM001A US P November 1999 Use this field to define if the SLC 5 04P processor uses the learned value or CV Max interpolated open loop value to control primary variable depends on which selection you made for profile type To select 4 H setbit4 0 Select gt ERSE This option tells the SLC 5 04P processor to use the special ERC2 algorithm during the profile We recommend that you select this option set this bit to zero or select Learned set bit4 1 Select gt Ex a learned value CV max If Pressure Profile then Learn PSI during Profile or Use PSI learned during l Deadhead Word 0 of the Setpoint Block 0000 0000 0010 0000 pressure during bit5 Configuring Pro Set 200 Profiles 8 21 Selecting a Pressure Value Source for Pressure Profiles Use this field when you are running a pressure profile in automatic control mode the profile is set to Auto on page 8 8 The SLC 5 04P processor allows you to select a method of pressure control The SLC 5 04P processor has the ability to e learn or adapt the pressure during the current profile e or apply the learned dead headed pressure To have ERC2 learn 4 0 0o00 OO H 0 LO000 a a ae ae me ae ce deadheaded conditions set bit5 1 select gt EREE This is the preferred method if there is any motio
92. 41d 1784 K 1784 PCMK 4 10 SLC 5 04P processor 4 4 internal position mask E 4 internal pressure over under bit example E 4 setting E 4 internal trigger mask setting E 4 J jogging phases 11 9 L adder files 6 1 adder logic modifying 8 supplied programming 2 earned pressure 7 4 oad pressurd 7 7 1 machine phases clamp phase 3 3 ejector phase 3 3 inject phase 3 3 machine setup 1 4 major error bif A 4 minimizing number of data packets 6 39 minimum and maximum spanning values forward directio minor error bif A 4 modifying I O definition file 6 7 ladder logic 8 4 PanelView screens 6 34 program file 2 I O definition file 6 4 modifying ladder logic clamp close sequence bar chart 6 16 clamp open sequence bar chari 6 19 injection sequence bar cha module layout 4 4 relationship to Pro Set 200 ladder logic open break away segment 3 13 open decel segment 3 13 open fast segment 3 13 open loop o 24 corrective actions 12 5 open slow segment 3 13 operator screens layouf 6 35 optimizing screen update timd 6 39 over operation E 4 E 9 p pack profile 3 4 PanelView screens customizing 6 34 layout configuration screeng 6 36 operator screen setup screens status screens modifying 6 34 phase active bits F d phase done bi F 4 Index 1 3 phases Pro Set 200 clamp phase 2 4 ejector phase 2 injection phase 2 4 p
93. 5 B6 Eert aii ria Ee Large BR2DF BRF BHR24 we r This Is located This Is located field in field in 1 N149 34 f9 N14936 2 N149 42 10 N149 44 3 N149 50 11 N149 52 4 N153 34 12 N153 36 5 N149 35 13 N149 37 6 N149 43 14 N149 45 7 N149 51 15 N149 53 8 N153 35 16 N153 37 This field Is located in N157 34 N161 34 N165 34 N157 35 N161 35 N165 35 N157 36 N161 36 1 2 3 4 5 6 7 8 9 N165 36 m oO N157 37 m m N161 37 m N N165 37 Understanding SLC 5 04P Processor Addresses Clamp Close Ramp Rates Screen B 25 Ace Yel In Secz Dec Vel In Sec2 Ace Press PS1 Sec Dec Clamp Close Ramp Rates Full Close Fast Open SH Ko Close Decel Low Ou Ou Full Mold Close CH A s Clamp Tonnage Ramp Rates Screen r Ace Wel In Sec2 Dec Wel In Sec2 Ace Press PS1 Sec Dec Press i igg Low Hold 3 FRE Clamp Tonnage Ramp Rates Decompress D ox TEE Publication 6500 UM001A US P November 1999 B 26 This Understanding SLC 5 04P Processor Addresses Is located This Is located field in field in 1 N169 58 9 N169 60 2 N169 50 10 169 52 3 N169 42 11 N169 44 4 169 34 12 169 36 5 N169 59 13 N
94. 68 03 19 N96 14 10 94 169 03 20 N96 15 Understanding SLC 5 04P Processor Addresses B 33 Auto Tune Screen 1 Auto Tune Fi Auto Tune F Abort Auto Tune F3 Reset Error Codes Fe Reset Auto Tune A 2 B Qs O Os Gs Q O D Gs Ds 1 Gs es Bit g 19E GOH Press F7 To Advance Screen Walid Mi File Parameter Error Tune Complete Tune Successful Error Code iz Auto Tune Screen 2 l a Auto Tune F3 Reset Error Codes 25 Ds O D Auto Tune F Abort Auto Tune F4 Reset Auto Tuns 2b ar 23 o Qs 4 s a O Ws Gs Ws 135 46 Error Code gly 184 194 20 Press F7 To Advance Sereen Walid Mi File Parameter Error Tune Complete Tune Successful Pi Publication 6500 UM001A US P November 1999 B 34 Understanding SLC 5 04P Processor Addresses This Is located This Is located field in field in 1 N95 24 17 N95 08 2 N95 25 18_ _N95 09 3 N95 26 19 N95 10 4 N95 27 20 N95 11 5 N95 00 21 N95 36 6 N95 01 22 N95 37 7 N95 02 23 N95 38 8 N95 03 24 N95 39 9 N95 28 25 N95 40 10 N95 29 26 N95 41 11 N95 30 27 N95 42 12 N95 31 28 N95 43 13 N95 32 29 N95 44 14 N95 33 30 N95 45 15 N95 34 31 N95 46 16 N95 35 32 N95 47 This Is located This Is located field in field in 1 N96 24 18 N96 09 2 N96 25 19 N96 10
95. 7 Use this field To 1 View the currently selected zone Select enable or disable auto tuning 1 Cursor to this field by using the left and right arrow keys 2 2 Make your selection by pressing the up and down arrow keys zs 3 Press the enter key when you reach the correct selection Select enable or disable ramping 1 Cursor to this field by using the left and right arrow keys 3 2 Make your selection by pressing the up and down arrow keys 3 Press the enter key lt when you reach the correct selection Select degrees Fahrenheit F or Celsius C 1 Cursor to this field by using the left and right arrow keys 2 Selecta position by pressing the up and down arrow keys a 3 Press the enter key when you reach the correct selection Publication 6500 UM001A US P November 1999 Using Barrel Temperature Modules BTM 9 7 SFG until Prepa E yousee No Zone Selected Y Ejectors D M1 FIle Configuration Bits 1 i 4 Operation Mode atm 2 Input Type Ta ere Alarm Enabled 4 TAC Break Config 5 Autotune Gains 6 Loop Zone Select F T Press FE to Advance Soreen L Use this field To 1 View the currently selected zone Select the operating mode Choose from 00 monitor only 01 PID loop control no control action no alarms set 10 disable loop is off no temperature reported no alarms set 2 1 Cursor to this field by usin
96. 784 KTX communication card 1784 KTXDcard Communication Interface Card 1784 KT B Installation nstructions publication 1784 6 5 22 to install the 1784 KT communication card 1784 PCMK card PCMK Communication Card User Manual publication 1784 6 5 19 to install the 1784 PCMK communication card Connecting the Programming Terminal Interface Card to the SLC 5 04P Processor If you have a See 1784 KT card Communication Interface Module 1784 KT B Installation nstructions publication 1784 2 31 to connect the 1784 KT communication card to the SLC 5 04P processor 1784 KTX card Communication Interface Card 1784 KT B Installation nstructions publication 1784 6 5 22 to install the 1784 KTX communication card to the SLC 5 04P processor 1784 KTXDcard Communication Interface Card 1784 KT B Installation nstructions publication 1784 6 5 22 to install the 1784 KT communication card to the SLC 5 04P processor 1784 PCMK card PCMK Communication Card User Manual publication 1784 6 5 19 to connect the programming terminal interface card to the SLC 5 04P processor Setting Up the Hardware 4 11 Connecting the PanelView Panel View 550 Terminal to the Programming Terminal On the RS 232 version of the Panel View 550 terminal 2711 K5A9 and SLC 5 04P Processor series E for version 2 0 or greater use the following cables to t
97. 99 Corrective Actions Based on Open Loop Status Quick Tune Procedure 12 5 Depending on the Open Loop Status OLT corrective action may be needed before the quick tune procedure can be completed with successful results Based on the segment Seg information from the quick tune screen the following corrective actions should be taken Perform corrective action and run another complete cycle i e repeat step 4 of coarse tune and fine tune until OLT is successful Sedment Status on Pangi iew Corrective Action Required Screen Check time and position setpoints make certain time is not 0 Segment Skipped Check trigger settings itis possible to trigger and never get to a segment Lengthen segment by changing position slowing velocity or increasing time Turn Ramps OFF No Step Seen Reduce dead time thresholds in Phase Setpoint table N104 8 N104 9 Increase step size Lengthen segment BENE Oe Increase step size make segment have different setpoint than previous segment Lengthen segment Tc Never Seen Check N104 10 and N104 11 value should be 370 Check N104 12 and N104 13 value should be 3 OLT Successful Good J ob No Action Required No action required This is to inform you that the segment NotUsed profile does not exist for the selected profile If you are running a small shot size or a short clamp stroke it may not be possible to use all of the segments provided in Pro Set 200 The OLT status will inform
98. A US P November 1999 soc 2 Notes Publication 6500 UM001A US P November 1999 What s in this Preface How to Use the Documentation Set Pro Set 200 Design Manual 6500 UM001A US P Intended for design engineers AALLS Setup hardware and software Customize your system Configure profiles Determine sensor and valve operation Use mold part recipes Preface Using Pro Set 200 Documentation This preface describes how to use this manual as part of the Pro Set 200 documentation set including e how to use the documentation set e who should use this manual e how to use this manual e what abbreviations acronyms and initialisms are used in this manual e what conventions are used in this manual e what other publications are available e what to do next Use this documentation to install and use your Pro Set 200 System Pro Set 200 Data Table Reference Manual 6500 R M001A US P Intended for design engineers Y Become familiar with data table locations for all Pro Set 200 data files NT ALE ERAMLEY Pro Set 200 J ob Setting Guide Pro Set 200 Job Setting Guide 6500 QR001A US P Intended for machine operators v Enter setpoints on process profile screens v View and acknowledge alarms Publication 6500 UMO01A US P November 1999 P 2 Who Should Use This Manual Publication 6500 UM001A US P November 1999 Use this manual if you are an engin
99. A musa usa perenne a e SS have 10 and 13 slots However other variations may be am sa ey required s 7 _ Power SLC 5 04P oe ae oe Empty slot BTM BTM Ba ra jo X Processor 4 Loops 4 Loops ac dc relay Supply Float rioa Fiog_ eserved i P S Injection _ Clamp Ejectors required optional required optional optional A Eject Position Up to 4 J or K thermocouples Input CH1 on each module Eject Pressure Input CHO Eject Velocity Output CH0 Eject PS Output CH1 Clamp Position Input CH0 Clamp Pressure Input CH1 Clamp Velocity Output CH0 Clamp PSI Output CH1 T N Optional FIO4V F10 41 modules are Injection Position Input CH0 required if Clamp or Ejector Injection Pressure Input CH1 velocity pressure valves are present Injection Velocity Output CHO Injection PSI Output CH1 Publication 6500 UM001A US P November 1999 Setting Up the Hardware 4 3 Module Location Function Inputs Outputs FI04V slot 1 injection position psi velocity psi FI04V Slot 2 clamp position psi velocity psi Flo4v slot 3 ejectors position psi velocity psi slot 4 reserved BTM slot 5 barrel temp thermocouple separate module BTM slot 6 barrel temp thermocouple separate module optional Indicates that you can also use an FIO4I Understanding How Pro Set 200
100. Advance Production Monitor Publication 6500 UM001A US P November 1999 B 12 This Is located This Is located field in field in 1 N80 09 14 N96 24 2 N95 24 15 N96 25 3 N95 25 16 N96 26 4 N95 26 17 N96 27 5 N95 27 18 N96 00 6 N95 00 19 N96 01 7 N95 01 20 N96 02 8 N95 02 21 N96 03 9 N95 03 22 N96 40 10 N95 40 23 N96 41 11 N95 41 24 N96 42 12 N95 42 25 N96 43 13 N95 43 26 N95 48 14 27 N96 48 14 This field Is located in 1 80 09 2 N80 22 3 80 23 4 N80 24 5 80 25 6 N80 26 7 N80 27 8 N145 00 9 N145 01 10 102 01 11 N102 04 12 80 16 13 N80 17 14 80 18 15 N80 19 16 80 20 17 N80 21 18 105 00 19 N105 01 20 102 01 21 N102 02 Publication 6500 UM001A US P November 1999 Understanding SLC 5 04P Processor Addresses Production Monitor Screen 3 oT Production Monitor zi 22 Temp 26 G2 ee CurrsP oe HHH pus O Gh af 27 23 Temp 27 o dstr a L16 hk H o Curr5P ALA cae 20 21 Routo nual Vaa rae To en Production Monitor Production Monitor Screen 4 Our ca F a Pos 8 HH In Press PSI Velocity CU G10 G10 HH Pressure cu KIH Pos B18 In Press K19 PSI Velocity CU G20H Pressure CU G2 HHH _ Press F3 To Advance Production Monitor Production Monitor Understanding SLC
101. BHHFF E a 8 View the currently selected zone 1 2 3 View and modify the minimum cool TPO on time in a range of 0 100 seconds Cursor to this field by using the left and right arrow keys Press the enter key The scratch pad appears Enter value 0 to 100 Enter a value in a range of 0 to 100 seconds 1 2 3 View and modify the total cool TPO on time in a range of 0 100 seconds Cursor to this field by using the left and right arrow keys gt Press the enter key L The scratch pad appears Enter value 0 to 100 Enter a value in a range of of 0 to 100 seconds 1 2 View and modify the value of the PV rate alarm in a range from 3276 8 to 3276 7 This alarm is set if the PV deviates from the value specified here Cursor to this field by using the left and right arrow keys lt J Press the enter key The scratch pad appears Enter value XXXX X 3276 8 to 3276 7 Enter a value in a range of 3276 8 to 3276 7 Publication 6500 UM001A US P November 1999 Using Barrel Temperature Modules BTM Use this field To View and modify the low temperature alarm value If Then the PV falls below this value an alarm is set in the discrete output table and an alarm banner appears this alarm condition is present you cannot select semi automatic or automatic mode and injection unit is turned on 5
102. CV Alarms These bits indicate that the ERC2 algorithm has calculated a control output that exceeds a CV minimum or CV maximum limit setpoint The control output has been restricted to the CV limits e g N109 8 and N109 10 Low Limit Profile CV High Limit Profile CV latched Low Limit Segment CV High Limit Segment CV Reset segment phase ee ee complete bits B106 4 7 N111 0 7 Low Limit 0000 0110 0000 0000 bits 9 and 10 _ N111 0 8 PV Small and Large Deviation Alarms These bits indicate that the actual velocity or pressure differs from the setpoint PV deviations are specified in the phase wide setpoint tables N104 16 19 N144 16 19 N184 16 19 Small deviation Velocity Publication 6500 UM001A US P November 1999 Sag Large deviation small deviation alarm large deviation alarm Using Alarms to Troubleshoot Your System A 7 The following diagram shows the ladder equivalent of small PV deviation alarms Segment 1 S mall Segment 1 Done Deviation Alarm Sis Error gt PV Small Dev Alarm Profile Small Segment 1 Small Deviation Alarm Deviation Alarm Segment 2 Small Deviation Alarm Segment 3 Small Deviation Alarm Segment 4 Small Deviation Alarm Phase PV Small Profile 1 Small Deviation Alarm Deviation Alarm Profile 2 Small
103. Customizing Your System 6 33 This does not mean the output will return to zero Until the processor scans a new value for the output card the value will remain the same To return the output to zero you must add a rung of logic as follows Injection mov Forward y 0 01 0 This is true for any analog output values that you send to the valves If you write ladder code to send values out to an analog output you must also write logic to turn the analog output off Before you write your analog code you should carefully plan the placement of the rungs ATTENTION Incorrect placement of analog rungs can lead to personal injury or death property damage or economic loss If you do not understand the details of analog rung placement contact technical support at 1 440 646 6800 The SLC scans the program from top to bottom and the last value sent to an output register will be sent to the card MOV 1000 Rung placed at the Ce top of the file 0 02 1 MOV 32767 Rung placed at the bottom 2 2 of the file 0 02 1 overwriting the earlier rung Publication 6500 UM001A US P November 1999 6 34 Customizing Your System Customizing Modifying PanelView Screens Publication 6500 UM001A US P November 1999 This is critical because it is possible to send a value to the analog output only to overwrite it by a later rung of code as shown above You should write the code so that only one M
104. D Onia is a a en Ge eae Injection Forward Delay BH26 HH Pos o428 HH In Press 029 PSI Publication 6500 UM001A US P November 1999 B 4 Understanding SLC 5 04P Processor Addresses Transfer Profile Screen This field Is located in a Transfer Profile 1 N109 18 Pos In a 2 110 00 Press 3 N109 19 poy C a4 4 110 01 5 N109 21 Popin 6 109 20 if 7 N110 02 Time aa 8 109 06 or Jas oe Vel OLE Vel OLAN Pos BH OH In 1 109 07 PSI Miia PSI G Press G13 H PSI 12 N129 07 E 13 105 01 Pack Hold Profile Screen kH This Is located This Is located a Fack i ae field in field in Hold 2 Ho o Fack 1 1 N117 38 15 N114 11 Wel Ors Bra Ozu ORJ 2 117 30 16 114 07 Insect A Ad or TOT 3 N113 38 17 N117 41 4 113 30 18 114 33 Fress om D 5 N118 10 19 N117 41 FSI D 6 118 06 20 113 33 7 N114 10 21 N118 13 Time 8 wii406 ll 22 Niie 09 rere Poe ee Cae 9 N117 39 23 N114 13 Cure Timer 253 FF 6426 Pos o In 10 N117 31 24 N114 09 cass 28 Fz 11 113 39 25 T4 2 PRE A 12 N113 31 26 T4 2 ACC 13 N118 11 27 N105 00 14 N118 07 28 N105 01 Publication 6500 UM001A US P November 1999 This Is located This Is located field in field in 1 N125 32 N125
105. DH485 Link SLC 5 04P Processor O O 0 O 6 T 5 5 B8 S888 BE 3818888 RBBB B88 BEBE EP 88 BRE BEBE BBE 8888 85 68 888 DH 485 Link O REJER e PE BE l SLC 5 02 or SLC 5 03 processor communicating to the SLC 5 04P processor using a DH485 link Figure 9 2 Communicating over DH Link SLC 5 04P Processor 5 5 0 O O O izzy lgs leet alee BE eRe EB sees eae a ee ee g Sass SSS DH Link O 0 EE B88 8888 8 BR o o i a gooi SLC 5 04 processor communicating to the SLC 5 04P processor using a DH link or RS 232 link ATTENTION Do not put the BTM in a remote rack with a 1747 ASB adapter The 1747 ASB adapter will not support the large M file transfers required by the BTM Publication 6500 UM001A US P November 1999 Wiring Considerations Changing BTM Module Locations in the I O Chassis Using Barrel Tem
106. Ejector Axis b i t Directional p Control Valve Tark Load S Electronicall Tank oad Sense ectronically Valve ag Adjustable Flow JIN Control Valve Electronically Adjustable e psi Valve o e Publication 6500 UM001A US P November 1999 This Load Sense Valve Pum p Tank 20873 M Does this keeps constant pressure across the flow control value if there are big changes in the load due to viscosity changes in the material Position Sensor measures cylinder position Pressure Transducer esenses hydraulic pressure in the cylinder esends back 0 10 volts or 4 20 milliamps proportional to the pressure Directional Control Valve switches the cylinder from a forward or reverse position Electronically Adjustable Flow Control Valve controls the flow velocity Electronically Adjustable psi Valve controls the pressure in the circuit Pro Set 200 also has the capability to perform velocity control of an axis using a pressure valve instead of the traditional velocity control valve The following figure shows this configuration Understanding Hydraulic Pressure and Flow Concepts 7 13 Important Figure 7 13 is not the preferred method of controlling an injection molding machine You may not see the desired results with this type of hydraulic configuration Figure 7 13 Pro Set 200 Hydraulic Configuration Using a Pressure Valve Cylinder IT
107. In the example 10 00 volts 50 00 10 00 volts 50 5 00 volts to achieve 10 in sec 9 Enter the calculated value in the max fwd field 1 field In the example enter 5 00 volts When selecting volts or amps go to the selector make your selection then press enter 10 Press F7 Load Values 11 Repeat steps 3 through 10 for injection retract clamp forward clamp retract ejector forward and ejector retract The process above will convert the units of velocity jog values to in sec From this point forward you must remember to enter your velocity jog values as in sec Publication 6500 UM001A US P November 1999 Determining Sensor and Valve Operation 11 11 Selecting How Tonnage To select how tonnage is sensed do the following is Sensed 1 Go to the tonnage sensing screen This is the third clamp setup screen Press you see preescse Clamp Close Tonnage Sensing Selection Pes i ate POU Ger Pressure BS Limit Suitsh wae Toggle By Position Tf you select Tonnage sensing bry ERT but 3 pressure transducer amp Low Hol and Oecompress ee Setup as a time Forile Press Fl to Advance Clamp Sereens XS r 2 Using the up and down arrow keys select how the machine senses tonnage 3 Press the enter key C Publication 6500 UM001A US P November 1999 11 12 Determining Sensor and Valve Operation Selecting How Ejector To select how ejector position
108. OLT Report Segments That Are Too Short Report Velocity CU Limit Alarms Report Plu Deviation Alarms Report PSI CY Limit Alarms Report CU Deviation Alarms e Press FL To Return To Alarm Menu old Ejector Position Sensing Screen Ejector Position Sensing If you are using Limit Switches to sense Ejector post an then voy can not use ERCZ for Open or Close loop control of the Ejectors L Press F amp to Advance Ejector Screens A Publication 6500 UM001A US P November 1999 B 22 Understanding SLC 5 04P Processor Addresses Phase Zeroing Screen This field Is located in a Phase Zeroing b 1 N83 13 14 H 2 H 2 145 00 e TR EET n a A 3 N145 01 ene 4 TER 7 Fos TOT In 5 N105 00 ero Complete Press G 6 PSI 6 105 01 7 N84 13 14 Mero Ejection Pos GH 8 In u Press BHO PSI 185 01 zeroing A Phase Zeros Position And Pressure NS 7 Publication 6500 UM001A US P November 1999 Understanding SLC 5 04P Processor Addresses B 23 Configuration Screens ERC2 Profile Configuration Screen Tus nerde 1S ocated In ERC2 Profile Configuration N 1 N90 07 2 N90 07 OT Profile Selected 3 N90 06 01 a Press F to Advance to Ment Screen wl Profile Selection Screen This field Is located in g DHe Frofile Selected N90 07 N90 01 00 Profile is N90 01 01 Profile Type is 4 N90 01 0
109. OV instruction may be active as shown below MOV 1000 Clamp Cores K 0 02 1 In this example the code is properly written only one in f struction may be active at a time MOV 32767 Clamp Cores 0 02 1 You can edit other files and screens as necessary to customize your system You can e change position location of any object on any screen e add objects e build your own screens If you change screen numbers check the ladder logic Certain screens call program files with Jump to Subroutine instructions JSRs Use RSLogix 500 software to search for N88 12 current screen tag from PanelView and modify Compare instructions to reflect screen number changes Customizing Your System 6 35 Pro Set 200 PanelView Screens Layout for Pro Set 200 Operator Screens This screen layout applies to the ps20102 pva and ps20102 pba files shipped on the PanelView screens disk After the initial power up sequence of the Panel View terminal the Pro Set 200 Title Screen appears Eject Forward Profile Production Menu Screen 19 Cores Setup Screen 10 Injection Profile Screen 5 Temp Setpoint 1 Screen 15 Clamp Close Clamp Open Profile Profile Clamp Tonnage Profile Screen 3 F1 F2 F3 Transfer Profile Screen 6 F3 Plasticate Profile 2 Screen 9 F5 Screen 11 F7 Eject Ret with Tip Screen 12 F6 F6 Eject Ret without Tip Screen 1
110. PRE C5 08 PRE ojl NS DD WO e wI NY Re C5 09 PRE Setup Screens This field Is located in 1 N90 09 2 N90 00 Publication 6500 UM001A US P November 1999 Counter Setup Screen la Spare Spare Spare Spare Spare Spare Spare Spare Counter Counter Counter Counter Counter Counter Counter Counter C Press F9 To Counter Setup 2 cs C5 CS CS C5 La C5 Return To Production cs wom of E oJ Machine Setup Utility Screen a a MMRestore Machine Setup Save Machine Setup 1 Machine Setup Utility 2 achine Stopped Restore Save Enabled a This Is located This Is located field in field in 1 N82 00 10 N82 08 2 N82 01 J 11 N82 13 01 3 N82 02 12 N82 09 4 N82 03 13 N82 18 5 N82 13 01 14 N82 19 6 N82 04 15 N82 13 02 7 N82 05 16 N82 20 8 N82 06 17 N82 21 9 N82 07 This Islocated This Is located field in field in 1 N82 22 9 N8228 2 N82 23 82 29 3 N82 13 03 N109 06 4 N82 24 1 N129 06 5 N82 25 13 N109 07 6 N82 26 N129 07 7 N82 27 N82 30 8 N82 13 04 Understanding SLC 5 04P Processor Addresses B 17 Injection Input Output Device Setup Screen mg Injection Input Output Device Setup E Pos Input Pi AT Counts Pos Input P2 3 AT Counts Current B PSI Input Pi AT Counts PSI In
111. Profile gt GEMM at Position EE Setting the Suspend Profile Position The suspend profile position stops the motion of the a phase During the period of time when the movement of the phase is stopped you can perform special operations such as setting cores e is used in conjunction with the resume bits to restart the motion of the phase e ramps to end of profile setpoints words 16 and 17 of setpoint block You must enable the suspend profile position To f suspend i e stop the profile segment setbit9 1 select gt EZ that is being executed at the suspend position in word 3 of the setpoint block execute the profile without interruption set bit9 0 Select gt Xm Example Suspend Profile Position You can 1 Move the clamp from the full open position to 23 4 inches Moving Stationary 2 Stop Platen Platen Perform a special core sequence 4 Resume movement to the full close position vw full open 23 40 in full close The clamp open setpoint block located in N169 0 contains the following information Clamp Open Setpoint Block N169 0 Configuration word 0 0000 0010 0000 0000 N169 3 Suspend Profile Position 2340 The resume bit in this example looks like this During the close sequence but BEFORE the clamp actually stops the resume bit located in the dynamic phase permit b
112. Pump lt gt Filter Lt Tank It is important to understand that if you are controlling an injection molding machine using pressure control and your hydraulic relief valve is plumbed without a flow control between the cylinder and relief valve pressure control will be based only on load pressure In this case the relief valve is used to control velocity and the machine will perform poorly An example of this configuration is described by Figure 7 5 Publication 6500 UM001A US P November 1999 Understanding Deadheaded Pressure Readings Understanding Hydraulic Pressure and Flow Concepts 7 5 Earlier we learned that the greater the pressure differential across an orifice such as a flow control valve the greater the flow However in the Figure 7 6 the oil from the pump dumps across the relief valve circuit when the hydraulic cylinder stops moving and the pressure measured at the relief valve and at the cylinder is approximately the same this is referred to as deadheaded pressure Figure 7 6 Deadheaded Pressure Example A 2 Gauge 2 Injection Cylinder 500 PSI Not Moving Relief Valve Gauge 1 Setat500 PSI A Flow Control 500 PSI o Ly L_ 50 GPM Tank Pump Pressure Relief Valve Filter E 3 Tank Concept Deadheaded pressure is the pressure that is measured when the cylinder has stopped moving 20866 M Stated another way if the hydraulic cylinder is
113. T eee For injection 7X F3 you see aN DR Injection PSI Input Pl ounts NFS Unt PSI Input P2 F DHF ounts e a pS Type rent Counts GHHH ectors E PS Output Min G AT ET ts PSI Output Man BEFFE AT BHH F te Vi Press F3 to Advance Injection Sereens O 000G 2 Enter configuration values gt When selecting volts or amps go to the selector make your selection then press enter In this field Do the following 1 Enter 0 for the psi input P 1 when the machine pumps are off 1 Enter the counts that the analog module returns for P 1 read from the current counts field 5 2 There are two ways to determine pressure and counts Method 1 1 Apply pressure to the transducer then read with a pressure gauge 2 Enter this value into field 3 3 Enter the counts that the fast analog module is returning from the current counts field 5 into field 4 when pressure is applied 3 4 Method 2 1 Enter nameplate values into field 3 2 If you have a maximum pressure value at 10 v dc enter 4095 into field 4 5 v dc enter 2047 into field 4 20 mA enter 2047 into field 4 3 Repeat steps 1 2 to span the clamp and ejector inputs Publication 6500 UM001A US P November 1999 Zeroing Position and Pressure Inputs F8 S Temperatures Press until you see ry Determining Sensor and Valve Operation 11 5 Once you have spanned all
114. T m OT fi Orr fi J Publication 6500 UM001A US P November 1999 B 36 Understanding SLC 5 04P Processor Addresses Notes Publication 6500 UM001A US P November 1999 What s in This Appendix SLC 5 04P Processor Catalog Number 1747 L542P Appendix C Processor Specifications This appendix describes the SLC 5 04P processor specifications The SLC 5 04P processor provides program memory size 32K high speed performance 0 90 ms K typical control of up to 960 local I O online programming includes runtime editing built in DH channel supporting high speed SLC 5 04P to SLC 5 04P communication messaging capability between PLCs and SLCs built in RS 232 channel supporting DFI Full Duplex for remote or point to point communication or direct connection to IBM compatible programming devices DFI Half Duplex Master Slave for SCADA type communication DH 485 serves as a second DH 485 channel using a 1747 PIC or direct connection to IBM compatible programming devices ASCII for connection to other ASCII devices such as bar code readers printers and weigh scales passthru capability to Panel View 550 and PanelView 900 remote I O passthru built in real time clock calendar 1 ms Selectable Timed Interrupt STD 0 50 ms Discrete Input Interrupt DID advanced math features trigonometric PID exponential floating point and the compute instruction indirect
115. T4 14 PRE 3 N165 30 13 T4 14 ACC 4 15731 14 149 06 5 N161 31 15 N169 06 6 165 31 16 145 00 7 158 07 17 145 07 8 N162 07 18 N169 07 9 N166 07 19 N145 01 10 T4 05 PRE Publication 6500 UM001A US P November 1999 ORT vel E Pos ail Ht In Cka i7 F PSI 18H Press Elly This Is located This Is located field in field in 1 N169 56 15 N169 47 2 N169 48 16 N169 39 3 N169 40 17 N169 31 4 N169 32 18 N170 19 5 N92 07 19 N170 15 6 N169 54 20 N170 11 7 N169 46 21 N170 07 8 N169 38 22 T4 01 PRE 9 N169 30 23 T4 01 ACC 10 N170 18 24 N145 00 11 N170 14 25 T4 16 PRE 12 N170 10 26 T4 16 ACC 13 N170 06 27 N145 01 14 N169 55 This Is located This Is located field in field in 1 N109 56 16 N109 55 2 N109 48 17 N109 47 3 N109 40 18 N109 39 4 N109 32 19 N109 31 5 N109 62 20 N110 23 6 N109 54 21 N110 19 7 N109 46 22 N110 15 8 N109 38 23 N110 11 9 N109 30 24 N110 07 10 N110 22 25 T4 15 PRE 11 N110 18 26 T4 15 ACC 12 N110 14 27 N82 13 14 13 N110 10 28 N105 00 14 N110 06 29 N105 01 15 N109 63 Understanding SLC 5 04P Processor Addresses B 3 Clamp Open Profile Screen a Clamp Ope Pos DORH In Fress PS SS Injection Profile Screen a Injection Profile m 4 3 2 1 Pos In DaB Daaa Vel IHH Onia Oris Inet HOOF GHIDRH GH12 KH
116. UM001A US P November 1999 F 8 Using Profile Status and Complete Bits Clamp Bar Chart The following bar chart describes the operation of the output coils in the clamp profiles Clamp Clamp Clamp Clamp Clamp Clamp Clamp Clamp Tonnage Tonnage Close Close Initial Close Fast Close Fast Close Decel Close LPMP LPMP Active Bit Comp Bit Initial Comp Bit Active Bit Comp Bit Active Bit Decel Active Bit Comp Bit Active Bit Comp Bit B146 16 B146 01 00 B146 32 B146 02 00 B146 17 B146 01 01 B146 33 B146 02 01 B146 18 B146 01 02 B146 34 B146 02 02 B146 80 B146 05 00 B146 96 B146 06 00 B146 144 B146 09 00 B146 160 B146 10 00 B146 31 Clamp Close Profile Active Bit B146 01 15 Clamp LPMP Profile Active B146 95 B146 05 25 B146 111 Clamp LPMP Profile B146 06 15 Tonnage Profile Active Bit B146 159 B146 09 15 B146 175 B146 10 15 Velocity N149 30 B149 38 N149 46 N153 30 N157 30 Setpoin Pressure N149 31 N149 39 N149 47 N153 31 N157 31 Setpoin Position N149 32 N149 40 N149 48 N153 32 N157 32 Setpoin Time N149 33 n149 41 N149 49 N153 33 N157 33 Setpoin Publication 6500 UMO01A US P November 1999 Using Profile Status and Complete Bits F 9
117. You can span the velocity valve outputs by running the injection clamp or ejector phase at the minimum and maximum speeds to record the values Enter starting values into the min max fields so the SLC 5 04P processor can establish the performance limits of your machine Publication 6500 UM001A US P November 1999 11 8 Determining Sensor and Valve Operation Publication 6500 UM001A US P November 1999 Defining Minimum and Maximum Spanning Values for Forward Direction Establish the maximum speed of the phase you are trying to control ATTENTION Use caution when running the injection clamp or ejector phase at the maximum speed This section helps to determine the maximum operating speed of the phase that is used as the SLC 5 04P processor limit To record the maximum speed move the injection clamp or ejector phase at full flow and pressure To move the injection clamp or ejector phase at maximum flow and pressure check that e all the pumps available from the hydraulic system are energized to insure that maximum pump volume is being sent to the cylinder e the correct maximum signal is being sent to your pressure relief valve to insure that all the flow is going to the cylinder This insures that the oil is not diverting across the system pressure relief valve while the cylinder is in motion e the correct maximum signal is being sent to your flow control valve You should also check if you are using a bidirec
118. a Fi Use this field 1 To View the actual temperature for zones 5 8 2 View the current run time or stand by setpoint View or modify the run setpoint 1 Cursor to this field by using the left and right arrow keys e 2 Press the enter key The scratch pad appears Enter value 0 to 3276 7 3 Enter a value in a range of 0 to 3276 7 View the temperature deviation for each zone If Then the field shows a plus sign forthe zone the temperature is above the deviation you have established the field shows a minus sign forthe zone the temperature is below the deviation you have established Publication 6500 UM001A US P November 1999 9 22 Using Barrel Temperature Modules BTM Use this field To 5 View the CV output for each zone View or modify the manual CV output for each zone 1 Cursor to this field by using the left and right arrow keys 2 Press the enter key 6 The scratch pad appears Enter value 100 00 to 100 00 3 Entera value in a range of 100 00 to 100 00 7 View the mode selection for each zone manual auto or off Enter a mode selection Choose from manual auto or off 1 Cursor to this field by using the left and right arrow keys L lt 8 2 Make your selection by pressing the up and down arrow keys 3 Press the enter key C when you have entered the correct selection Publication 6500 UM001A US P Novem
119. a source word or file for equality SQL Sequencer Load 33 2 On successive false to true transitions the SQL moves a step through the sequencer file loading a word of source data into the current element of the sequencer file Publication 6500 UM001A US P November 1999 Processor Specifications c 9 Communication Instructions Instruction Mnemonic Execution Times us Function and Name Floating Point us Output Instructions MSG Message Read Write 183 This instruction transfers data from one node to another on the communication network When the instruction is enabled message transfer is pending Actual data transfer takes place at the end of the scan SVC Service 200 When conditions preceding it in the rung are true the SVC instruction Communications interrupts the program scan to execute the service communication portion of the operating cycle Proportional Integral Derivative Instruction Instruction Mnemonic Execution Times us Function and Name Floating Point us Output Instructions PID Proportional Integral 169 82 This instruction is used to control physical properties such as Derivative temperature pressure liquid level or flow rate of process loops ASCII Instructions Instruction Mnemonic Function and Name Execution Times us Output Instructions ABL Test Buffer for Line 156 0 Determines the numbe
120. age 2 1 algorithms which control the pressure and flow valves for the injection clamp and ejector phases Appendix C contains the specifications for the SLC 5 04P processor 1746 F104V or 1746 F1041 modules accept position and pressure feedback in the form of 0 10v or 4 20 milliamp signals and provide analog signals out to the proportional valves which control the flow and pressure Use FIO4V modules if your valves require 10 volt control signals use F104 modules if your proportional valves require 4 20 milliamp control signals You need a least one FIO4V or FIO4I module for each controlled phase pressure and position inputs and pressure and flow outputs 1746 BTM modules provide temperature control for the barrel of the injection molding machine These modules contain specialized start up and auto tuning algorithms which have been optimized for barrel temperature control Each module controls four temperature loops using either or K thermocouples grounded or ungrounded The ladder logic and PanelView screens accommodate eight temperature loops if you need more expand the logic Important The BTM modules do not have analog or digital outputs on them You need to use 4 discrete or analog outputs from another output module for each BTM module PanelView 550 900 modify profiles configure temperature setpoints set pull cores examine alarms bits view production data etc Important Be sure that time critical fun
121. all the injection seg ments are complete i bit 0 4 are set or triggered to another profile Figure F 2 Using Reset Segment Segment Done Bits Inj Example ect Segment 1 Complete Bi B016 32 B106 33 B106 34 ject Segment 2 Complete Bi ject Segment 3 Complete Bi B106 35 B106 36 ject Segment 5 Complete Bi B106 47 jection Profile Done Bit B101 2 2 3 3 3 Injection Reset Bit Publication 6500 UM001A US P November 1999 F 4 Using Profile Status and Complete Bits Injection Pack Hold The following bar chart describes the operation of the output coils in Bar Chart the injection pack and hold profiles Injection Injection Injection Injection Injection Injection Injection Injection Injection Injection Segment Segment Segment Segment Segment Segment Segment Segment Segment Segment 1 Active 1Comp 2Active 2Comp 3Active 3Comp 4Active 4Comp 5 Active 5 Comp Bit Bit Bit Bit Bit Bit Bit Bit Bit Bit B106 16 B106 32 B106 17 B106 33 B106 18 B106 34 B106 19 B106 35 B106 20 B106 36 B106 31 Injection Profile Active Bit B106 47 Velocity N109 30 N109 38 N109 46 N109 54 109 62 Setpoint Pressure N109 31 N109 39
122. and 5 are as follows Status Indicator Description Fud Status indicator 1 is non blinking profile is not active Status indicator 2 is blinking profile active and not suspend active Status indicator 3 is blinking profile active and suspend active Status indicator 4 is blinking profile active and suspend done Status indicator 5 is non blinking Fd profile complete with no internal h trigger Status indicator 6 is non blinking Fud profile complete due to internal aa trigger Fud Status indicator 7 is non blinking profile not on Publication 6500 UM001A US P November 1999 14 8 Using Production Monitor Screens What s Next In the following appendix we explain about using alarms to troubleshoot your system Publication 6500 UM001A US P November 1999 Appendix A Using Alarms to Troubleshoot Your System What s in Use this appendix to read and interpret alarm codes to identify This Appendix system problems Alarm Bits The following screen shows the alarm bits that you can disable during setup until you get the machine up and running You can use this screen for phase wide alarms es ERC2 Alarm Setup D Report Minor Errors D EM Report Segments Needing OLT D EME Report Segments That Are Too Short D EA Report Velocity CU Limit Alarms D EE Report PW Deviation Alarms D E Report PSI CU Limit Alarms D E Report CU Deviation Alarms gt E K Fress FL To
123. and or lower end of the valve curve you must span the output to control the valve over the linear range between the deadband s The objective of spanning is to determine the location of the upper and lower points in the valve curve at which flow rate levels off span the output to the valve so that the valve operates only in the linear range Here is an example flow valve curve showing an upper and lower deadband 10 0 Upper deadband co co fai els Lower deadband 0 10 20 30 40 50 60 70 80 90 100 gt Publication 6500 UM001A US P November 1999 Command To remove deadbands from a valve you should jog the appropriate phase To span to remove upper and lower deadbands follow these steps for the upper and lower ends of the valve curve 1 On the output scaling screen set the jog rate to zero and raise the minimum volts milliamps by 01 volts milliamps until the axis begins to move Once the axis begins to move lower the value back to the value that did not move the cylinder If you have not determined the maximum velocity of the phase set jog to the maximum velocity Then start incrementing the max volt amp by 01 increments until the cylinder speeds do not increase Once the cylinder speed no longer increases with an increase in volts amps return the value back to the amount that caused the maximum speed What s in This Chapter Before You Begin Quick Tune Proce
124. ase Increase Use Leaned CV Maxon Learned Learned Learned Learned Learned Learned primary controlled variable If psi is selected variable then Learn Deadhead Learn Learn Learn Learn Learn psi use Deadhead If velocity is selected variable then CV Max CV Max CV Max CV Max CV Max CV Max Run psi as CV Max Use Deadhead psi Publication 6500 UM001A US P November 1999 8 26 Configuring Pro Set 200 Profiles Selector Profile of On Clamp Phase Your Selections Clamp Close Clamp LPMP Tonnage Low Hold Decompress Clamp Open Active profile is velocity psi Profile in Auto Of Manual Ramps off 0n Ramps coordinated No Yes Link to another profile No Yes Suspend profile No yes Direction of profile Decrease Increase Use Learned 3CV Max On primary controlled variable f psi is selected variable then Learn psi use Deadhead f velocity is selected variable then Run psi as CV Max Use Deadhead psi Publication 6500 UM001A US P November 1999 Configuring Pro Set 200 Profiles 8 27 Eject Phase Defaults Selector Eject Forward Eject Retract Eject Tip Stroke Profile off on Velocity Velocity Velocity Active profile is velocity psi On On On Profile in Auto Of Manual Manual Manual Manual Ramps off 0n On On On Ramps coordinated No No No No Yes Link to another pr
125. ation see page 4 2 eremoving or adding BTMs eRemove or add rungs relative to BTM eyou do not have all three analog cards to edelete unused outputs control injection clamp and ejectors 4 alarms eyou want to change the operation of the euser specific standard Pro Set 200 alarms eyou want to add alarms to the system euser specific 5 power gate your machine has power gates Allen Bradley user specific does not supply logic for power gates Itis up to you to provide this logic 6 machine modes you want to modify the Pro Set 200 standard user specific machine mode logic 7 permissive pointer your application does not use all phases remove the appropriate J SR statement or cores 8 STI file eyour fast analog card s differ from the echange fast analog module addresses standard Pro Set 200 configuration see page 4 2 euser specific eyour application requires additional analog output logic eyour application requires special analog user specific output logic 9 inject STI your injection position and or pressure sensor change the I O address to match your is not wired to the analog card in slot 1 card address 10 injection different velocity and or pressure minimums change appropriate minimum maximum CV interpolation file and maximums are required for each profile and or PV ladder rung 11 injection permissive eyou want to change deadheaded emodify ladder code user specific segment logic eyou want to modify how the injection phase euser specific
126. ation for Zones 1 4 N239 old Part 4 Vault 8 BTM setpoints calibration for Zones 5 8 N240 Spare F241 old Part 5 Vault 1 ERC2 Memory N242 old Part 5 Vault 2 Injection and Pack N243 old Part 5 Vault 3 Hold Pre Plast Post N244 old Part 5 Vault 4 Clamp Close LPMP Tonnage N245 old Part 5 Vault 5 Clamp Low Hold Dec Open N246 old Part 5 Vault 6 Eject File N92 Customer Additions N247 old Part 5 Vault 7 BTM setpoints calibration for Zones 1 4 N248 old Part 5 Vault 8 BTM setpoints calibration for Zones 5 8 N249 Spare What s in Each Recipe File Each recipe is laid out according to the following table This formula is used to determine storage area current recipe number 1 x 9 205 starting file for recipe File Word Size in Words Data Table Location between words 205 214 223 F108 2 Oand 1 232 241 F112 31 2 and 32 F116 13 33 and 45 F120 13 46 and 58 F124 7 59 and 65 F128 31 66 and 96 F132 7 97 and 103 F148 2 104 and 105 F152 19 106 and 124 F156 7 125 and 131 F160 7 132 and 138 F164 7 139 and 145 F168 7 146 and 152 F172 25 153 and 177 F188 2 178 and 179 F192 13 180 and 192 F196 7 193 and 199 F200 7 200 and 206 206 215 224 N104 28 0 and 27 233 and 242 Using Mold Part Recipes 13 3 File Word Size in Words Data Table Location
127. ber 1999 Using Barrel Temperature Modules BTM 9 23 Press Temperatures Stand E Temperature Control a zi z2 23 24 By sp Gaaee F GHHee F CHAFF F DHARE Feree L Stand Etant sun eure Bo DEF NRE TEEI ET TERRI TEEF TEEI ETF E Select Beati Geant Seang Seana u i i Use this field To 1 View the setpoint selections for zones 1 4 Select setpoint for zones 1 4 Choose run time or stand by 1 Cursor to this field by using the left and right arrow keys lt J Le 2 2 Make your selection by pressing the up and down arrow keys C G 3 Press the enter key when you reach the correct selection If you change a standby setpoint you must re download the M1 configuration file for the changes to take place 3 View the setpoint selections for zones 5 8 Select setpoint zones for zones 5 8 Choose run time or stand by 1 Cursor to this field by using the left and right arrow keys 4 2 Make your selection by pressing the up and down arrow keys EA 3 Press the enter key when you reach the correct selection If you change a standby setpoint you must re download the M1 configuration file for the changes to take place Publication 6500 UM001A US P November 1999 9 24 Using Barrel Temperature Modules BTM What s Next In the next chapter we explain how to start up the machine Publication 6500 UM001A US P November 1999 What s in This Chapter Accessing the
128. between words 109 70 28 and 97 N113 46 98 and 143 207 216 225 117 46 0 and 45 234 and 243 N121 38 46 and 83 125 70 84 and 153 N129 38 154 and 191 208 217 226 144 28 0 and 27 235 and 244 N149 54 28 and 81 153 38 82 and 119 N157 38 120 and 157 209 218 227 161 38 0 and 37 236 and 245 N165 38 38 and 75 169 62 76 and 137 210 219 228 N184 28 0 and 27 237 and 246 189 46 28 and 73 N193 38 74 and 111 197 38 112 and 149 N92 12 150 and 162 T4 PREs 25 163 and 187 C5 PREs 10 188 and 198 211 220 229 N93 196 0 and 204 238 and 247 212 221 230 N94 196 0 and 204 239 and 248 213 222 231 Reserved Reserved Reserved 240 and 249 Publication 6500 UM001A US P November 1999 13 4 Using Mold Part Recipes Naming Mold Part Recipes Each mold part recipe can have a file name with a maximum of 20 alpha numeric characters A Z 0 9 The mold part recipe names are stored sequentially in file N204 The following table shows a breakdown of mold part file names Data Tabl Reci aie ne Niner Character Character 0 1 1 7 1 3 4 2 5 6 3 7 8 ui 9 10 3 1 12 i 13 14 2 15 16 4 17 18 2 19 20 10 Null Character i 2 1 2 i12 3 4 13 5 6 14 7 8 alls 9 10 16 11 12 17 B 14 18 15 16 19 17 18
129. chassis mounting bolt 6 Connect the signal wires of each channel to the terminal block Important Only after verifying that your connections are correct for each channel trim the lengths to keep them short Avoid cutting leads too short 7 At the source end of cables from mV devices remove the drain wire and foil shield apply shrink wrap as an option connect to mV devices keeping the leads short Important If noise persists try grounding the opposite end of the cable instead Ground one end only Cable Preparation and Connections to Minimize Electrical Noise Interference Grounded End at I O Chassis Terminal Block Keep the length of unshielded wires as short as possible ROY at casings o gt Some Se Connect I O chassis bolt to earth ground rere Son S gt Cables amp RN Q a KYOLOlofololofelelo SS na aN For more information about wiring a 1746 BTM module see the Barrel Temperature Control Module user manual publication number 1746 6 10 What s in This Chapter Understanding the Pro Set Chapter 5 Installing Pro Set 200 Software This chapter explains how to set up the software for your Pro Set 200 system It helps you e understand what is shipped on the Pro Set 200 software disk set e understand what the software and hardware requirements are e locate publications to help you install the so
130. ciated with each position setpoint You use the corresponding velocity and pressure setpoints to go from one Pos 4 Pos 3 Pos 2 Pos 1 position to the next and to the next Reus TEA pre XXK profile Transfer is a transition to the Vel 5 y Vel 3 Vel 2 Vel 1 next selected profile xx xx xx xx xx xx xx xx xx xx psi 5 psi 4 psi 3 psi 2 psi 1 XXXX XXXX XXXX XXXX XXXX Transfer to the pack profile can occur during any part of the injection phase Transfer criteria is based on o position xxxx pressure xx xx position mask xx xx time velocity vs position speed length of the shot size pressure vs position pressure length of the shot size Publication 6500 UM001A US P November 1999 3 8 Introduction to the Injection Molding Process Injection Pre decompression Pack y Segment1 y Plastication Segment 2 Post decompression Hold Clamp Decompress Clamp Low Hold Injection Pre decompression Pack Plastication Hold y Segment 1 Post decompression Segment 2 Clamp Decompress Clamp Low Hold Publication 6500 UM001A US P November 1999 Pack Profile The pack profile lets the molding machi
131. close fast segment active clamp close decel segment active you can use the clamp close profile active bit instead The clamp close profile active bit remains ON as long as any of the segment bits are ON Publication 6500 UM001A US P November 1999 6 18 Customizing Your System Method 2 The following ladder logic shows an equivalent logic circuit using the individual segment active bits Clamp Close Initial Segment Active Clamp Directional B146 1 Solenoid A 0 Clamp Close Fast Segment Active B146 1 1 Clamp Close Decel Segment Active B146 1 3 Clamp LPMP Profile Active B146 5 0 Tonnage Profile Active B146 9 15 Solenoid C This row shows solenoid C which is a pump load that is only active during the close initial clamp close fast and clamp tonnage profiles You need to write the logic shown below Clamp Hi Volume Time Delay T4 13 Solenoid C Pump Load DN Clamp Close Fast Segment Active B146 1 Tonnage Profile Active B146 9 1S Publication 6500 UM001A US P November 1999 Customizing Your System 6 19 Solenoid D These rows show a proportional control valve solenoid D which performs flow control of the clamp hydraulic circuit If you use the standard Pro Set 200 layout as shown in chapter 3 you do not need to write any ladder logic to support this solenoid If you have changed the physical hardware layout you need to modify file
132. ct information The total time necessary for ERC2 to learn depends greatly on the on the cycle time of your product Publication 6500 UM001A US P November 1999 Quick Tune Procedure 12 7 To avoid the previous scenario you can turn learning off once ERC2 yields desirable results However by turning learning off Pro Set 200 s ability to adjust to minor variations in process variables will be disabled The decision to leave learning on or off is highly dependent on your individual application and the inherent repeatability of your product and machine Another alternative method is to only turn learning on when you believe it would be beneficial possibly when you have introduced some new variable and you want ERC2 to compensate In this case to get your actuals closer to the setpoints while you are running the machine in production mode follow the procedures below Conditions these settings should already be in use peltorm These Actions Run a complete cycle Press the Learn button turn on Repeat steps 1 and 2 until setpoints reached Press the Learn button turn off Velocity P rofiles only Set Kp ON F5 Run a complete cycle Press the Learn button turn on Repeat steps 1 and 2 until setpoints reached Press the Learn button turn off Pressure Profiles only Set Kp OFF F5 Publication 6500 UM001A US P November 1999 12 8 Quick Tune Procedure What s Next In the next chapter w
133. ct is tested to meet Council Directive 89 336 EEC Electromagnetic Compatibility EMC and the following standards in whole or in part documented in a technical construction file e EN 50081 2 EMC Generic Emission Standard Part 2 Industrial Environment e EN 50082 2 EMC Generic Immunity Standard Part 2 Industrial Environment This product is intended for use in an industrial environment Low Voltage Directive This product is tested to meet Council Directive 73 23 EEC Low Voltage by applying the safety requirements of EN 61131 2 Programmable Controllers Part 2 Equipment Requirements and Tests Publication 6500 UM001A US P November 1999 4 2 Setting Up the Hardware For specific information required by EN 61131 2 see the appropriate sections in this publication as well as the following Allen Bradley publications e Industrial Automation Wiring and Grounding Guidelines For Noise Immunity e Guidelines for Handling Lithium Batteries e Automation Systems Catalog Determining the Layout of Here is the recommended module layout for a basic system with the 1 0 Chassis T O modules Figure 4 1 Module Layout slot 5 slot a i slot 4 ie a RUN C I FoRee POWER CTO PewER CO Power CO BARREL TEMP BARREL TEMP a eee me Oo mee oo ook Typical chassis configurations RUN neu prea ALS
134. ction cylinder will not go above the load pressure If the injection cylinder is pushing against a load that requires 200 psi to move the load the pressure measured at the cylinder will not go above 200 psi until the required load pressure increases Example Figure 7 3 assumes that a fixed amount of oil is being supplied to the cylinder and no additional pressure is being applied to the load end of the cylinder Figure 7 3 Load Pressure Example Load is moving at 200 PSI Figure 7 4 shows an additional load and the pressure required to move the increased load You can only control pressures only up to 400 psi at the injection cylinder because the load pressure is 400 psi In this example if you entered an injection profile setpoint of 600 psi you would not achieve the setpoint because the required load pressure is only 400 psi Figure 7 4 Additional Load Example Load is moving at 400 PSI 20865 M ONV A Publication 6500 UM001A US P November 1999 7 4 Understanding Hydraulic Pressure and Flow Concepts Figure 7 5 Pressure Controlled Velocity Example Relief Valve psi Controlling A Velocity Hydraulic Cylinder a N a ht L Tank LI System Relief Valve psi Flow Control A This example describes a control configuration that is possible but not desirable 1 A En 50 GPM Tank
135. ctions are not controlled by the PanelView Pro Set 200 software which contains eladder logic eP V550 P V900 screens works in conjunction with the ERC2 algorithms which are embedded in the SLC 5 04P processor The ladder logic program contains sequence logic for the injection clamp and ejector phases Modify this logic to accommodate your specific machine operate the machine configure profiles modify monitor temperatures Save restore recipes perform calibration and perform troubleshooting Although these screen sets are fairly complete you may wish to modify them for your specific machine features Miscellaneous discrete input and output modules monitor limit switches control heaters control directional valves pilot lights push buttons control manual functions and machine modes etc Pro Set 200 can accommodate all discrete I O modules in the SLC 500 product line including 120 vac input and output modules 24 vdc 1 0 relay contact output modules etc If you want to use block I O modules with Pro Set 200 you need to write ladder code to support the 1747 SN subscanner module which communicates with the block 1 0 Important Be sure that time critical functions are not controlled by the PanelView Sensors Used with Pro Set 200 For every phase that Pro Set 200 controls there must be at least one corresponding position transducer Pro Set 200 accommodates pressure and position transducers which have a range of
136. daranti aein eA Installing the Power Supply oaa Installing the SLC 5 04P Processor annaua Installing the I O Modules nnana Connecting the Programming Terminal to the SLC 5 04P Processor Connecting PanelView the Programming Terminal and SLC 5 04P_ Pro Set 200 Function Key Legend Kits 00e eee 4 1 Wiring the FastAnalog I O Modules ccceeee ee ueees 4 14 Publication 6500 UM001A US P November 1999 toc ii Table of Contents Installing Pro Set 200 Chapter 5 Software What s in This Chapter 0 0 cece cece teens Understanding the Pro Set 200 Software Disk Set 05 Hardware Requirements cece eect eens WACS NEXE disi aise ware ainiaan a aE a hae Ai Customizing Your System Chapter 6 Whats m This Chapter 34 4 2x cnet beeh due Sean ee iein Understanding Pro Set 200 Ladder Files cccueeuuuee Customizing LadderLogic 00c ee eeeeeee eee Using Machine Sequence Bar Charts ccc cece ees How to Modify Your Analog STI Code 00e eee 2 Valve Configurations isc cctccaeded vende wed endure wens 3 Valve Configurations sckcteidean ds deag eet aeag ease es Turning Analog Outputs Off 2 0 ccc cece eee eee Correct Placement of Analog Rungs Is Crucial Customizing Modifying PanelView Screens cece eee ee Whats NeXt 22egrdaeue estiss terieri disan rr Understanding Hydraulic Chapter 7 Pressure and Flow Concepts whats in This Chapter
137. dauvess Placing the BTM in the I O Chassis cece cece eens Wiring Considerations 1 sc wears ab tee cwd sues a Changing BTM Module Locations in the I O Chassis BTM Ladder Logic and Data Tables 000 eee Whats NEXU siaaa adaa tae Wanda aie il onsen are EATA Chapter 10 What s in This Chapter 2 0 ccc eect eee a Accessing the Setup Screens cece eee e eee teens Entering Values to Verify Hydraulics 1 0 cece eee ee eee Saving and Restoring Machine Setup Data seen Verifying Correct Hydraulic Operation ccc eee eee What s Next 4 a aa ce sida esa bee Sede Rad eae Ree a ee ere es Chapter 11 What s in This Chapter s 0 2 dw anions cw aawanedurewad wwaate Accessing the Setup Screens cee cece eee tne SPaMMINGINOU saes h aaoo dys cue dale dpe Zeroing Position and Pressure Inputs 0 eee aee SPAMMING OWNS siasa dnd girs dot acpi aap bh oped Jogging Mie Phase is sw ices eRe sorudan eek eae aed Selecting How Tonnage is Sensed cece eee e eee ees Selecting How Ejector PositionisSensed ce eevee Saving and Restoring Machine Setup Data eee Spanning to Remove Upper and Lower Deadbands Chapter 12 What s in This Chapter 0 0 cc cece cece eee eee eens Before You Begin 4wi0cds sca ewsakes ne es obee be dadae eea4 QUICK Tune PIOCEUIG cae te sets Capwede See nereeewaie re The Coarse TUNG STED rrasa ewew eds eeataew
138. ded as the permit bit for that profile For example the pressure segment hold profile is binary 00000100 or Decimal 4 Invalid Deadhead Segment 4 N104 4 N144 4 or N184 4 Change ladder program to place the correct contain a segment number segment number in this field The first segment of a larger than the number of profile is segment 1 segments in the profile Invalid Segment State 5 N103 21 34 or 47 Remove any ladder program or Data Highway are invalid writes to these locations Invalid Segment Number 6 N103 21 33 or 46 Remove any ladder program or Data Highway are invalid writes to these locations Invalid Profile Link 7 Profiles are linked in a 1 Examine link ID words a circle 2 Remove links to any earlier profile For example remove any link from hold to inject Improper call to ERC SUBR 253 8 Invalid call to ERC Remove calls to J SR 253 Subroutine 253 Improper Data File configuration 1000 1256 ERC data table file not Subtract 1000 from error detail value This value 0000 0000 0000 m bit3 Publication 6500 UM001A US P November 1999 found or too short Segment Needs OLT Bit yields the offending file number For example if the error detail value is 1109 the inject profile setpoint file N109 is not configured properly This bit when set indicates that you need to run an open loop test so that ERC2 can identify the system dynamics Profile setpoint word 0 bit 12 enables the open loop test
139. dify the analog section of the STI file to support a two valve system Injection Only The following example describes the ladder logic modifications necessary for a simple 2 valve configuration for injection only To help understand the relationship between the ladder logic modifications and the hydraulic configuration see the following examples Ladder Logic Modifications 2 Valves Injection Only Injection Functions MOV N102 01 Conceptual Model of 2 Valves Injection Only Injection Electronically 7 Adjustable Velocity Valve d Electronically Adjustable System Relief Valve psi Tank Velocity Valve MOV N102 02 Pressure Valve Ejector Ao Manual Pressure Valve AV and or Directional Control ERC2 Injection Velocity Output ERC2 Injection Pressure Output Clamp This conceptual model is intended to be used as an aid in understanding ladder M code modifications for the example scenario It is not a complete hydraulic diagram Publication 6500 UM001A US P November 1999 Injection and Clamp Customizing Your System 6 23 The following example describes ladder logic modifications for a 2 valve configuration for injection and clamp To help understand the relationship between the ladder logic modifications and the hydraulic configuration see the example on the opposite
140. dure Chapter 1 2 Quick Tune Procedure Once you can cycle the machine in the automatic or semi automatic mode you are ready to run the quick tune procedure The quick tune procedure e captures your machine s response characteristics e automatically tunes the control system Run the procedure during initial machine setup or during the installation of a new mold The quick tune procedure is comprised of two steps coarse tune e fine tune Important Do not run the quick tune procedure unless you are certain that you can cycle the machine in automatic and semi automatic mode Before you perform the quick tune procedure be certain that you e Load the machine with plastic e Use the actual profile that you ll be running with the mold it is alright to run a short shot if you re concerned about the mold Start the quick tune procedure by displaying the quick tune screen on your Panel View terminal Publication 6500 UM001A US P November 1999 12 2 Quick Tune Procedure How to get to the Quick From the PanelView terminal display Tune Screen Press until iy F9 Ce yousee Mold Part Storage Production Menu ety F Counter Setup Quick Tune Production Monitor 1 Using the up and down arrow keys select quick tune from ca the production menu 2 Press the enter key C The next screen you see will be the quick tune screen T Tune D IRAE Auto OLT Off Ramps Off Kp Of
141. e Alarm Enabled T C Break Config Autotune Gains Loop Zone Select a Press FE to Advance Screen Zone Selection Screen 4 O eme Mi File Configuration Words High CU Limit Low CU Limit Forced CW Value ON T C Break Heat Min On Time Heat TPO Period a Press FE to Advance Screen A Understanding SLC 5 04P Processor Addresses This field Is located in N97 40 N97 08 N97 09 N97 10 N97 11 N97 12 N97 13 CO N DD Ot e wI NM e This field 1 N97 14 Is located in N97 40 N97 15 N97 16 N97 17 j amp Ww N N97 18 Zone Selection Screen 5 B 31 a l Ho gone Selected Mi File Configuration Words Cool Min On Time Cool TPO Period Pl Alarm Rate Low Temperature Alarm Value Hish Temperature Alarm Value a Press FE to Advance Screen Low Deviation Alarm Value THREF High Deviation Alarm Value 8 HELF N Zone Selection Screen 6 a Ho Zone Selected M1 File Configuration Words Temperature Alarm Dead Band Thermal Integrity Temperature Change Thermal Integrity Period In Minutes Set Point Ramp Rate a Press F6 to Advance Screen Publication 6500 UM001A US P November 1999 B 32 Understanding SLC 5 04P Processor Addresses Zone Selection Screen 7 This field Is located in iz l Ho zone Selected Mu
142. e solenoid M which controls the injection pressure If you use the recommended Pro Set 200 layout you do not need to do any programming Customizing Your System 6 15 Solenoid N This row shows a directional control valve solenoid N which is energized only during the pre decompression and post decompression profiles The I O definition file contains the following ladder rung which supports these logic conditions Pre Decompress Profile Active B106 13 with Injection Retract Solenoid 15 Post Decompress Profile Active B106 21 15 Modify this rung to include solenoid N as shown below Pre Decompress Post Decompress Profile Active Profile Active B106 13 Solenoid N T 15 Post Decompress Profile Active B106 21 15 Solenoid O This row shows a directional control valve solenoid O which is energized during the plastication profile The I O definition file contains the following rung which has this condition Plasticate with Screw Profile Active Rotate Solenoid B106 17 15 Modify this rung to include solenoid O as shown below Plasticate Profile Active Directional Valve Solenoid O B106 17 15 Publication 6500 UM001A US P November 1999 6 16 Customizing Your System Modifying Pro Set 200 Ladder Logic for a Clamp Close Sequence Bar Chart The following table shows a clamp close sequence bar chart for a hypothetical molding machine Solenoid Clam
143. e Poland e Portugal e Puerto Rico e Qatar e Romania e Russia CIS e Saudi Arabia e Singapore e Slovakia e Slovenia e South Africa Republic e Spain e Sweden e Switzerland e Taiwan e Thailand e Turkey e United Arab Emirates United Kingdom e United States e Uruguay e Venezuela e Yugoslavia Allen Bradley Headquarters 1201 South Second Street Milwaukee WI 53204 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Publication 6500 UM001A US P November 1999 PN 957236 79 Superceedes 6500 6 2 3 February 1998 6500 6 2 3 RN3 J anuary 1998 Copyright 1997 Allen Bradley Company Inc Printed in USA
144. e enter key The scratch pad appears Enter value 0 to 999 9 3 Enter a value ina range of 0 to 999 9 View the temperature deviation for each zone 4 If Then the field shows a plus sign forthe zone the temperature is above the deviation you have established the field shows a minus sign for the zone the temperature is below the deviation you have established 5 View the CV output for each zone Publication 6500 UM001A US P November 1999 Using Barrel Temperature Modules BTM 9 21 Use this field To View or modify the manual CV output for each zone 1 Cursor to this field by using the left and right arrow keys 2 Press the enter key The scratch pad appears Enter value XXX XXI 100 00 to 100 00 3 Entera value in a range of 100 00 to 100 00 View the mode selection for each zone manual auto or off Enter a mode selection Choose from manual auto or off 1 Cursor to this field by using the left and right arrow keys 2 Make your selection by pressing the up and down arrow keys 3 Press the enter key C when you have entered the correct selection Press FG 25 26 77 29 pene Temp F GEEH H DEKHE H OHHH OHHH H CurrSP DEEH H DEHE H DREHER OHHH H Run SP ET RT Dey CU so GSR GARR PR GHEE HHO OHHH HH until r ousee Temperature Control S gt GOOGE Man H EFFE DHE FH GE HR GRRE HH YO Node Manual DD a a
145. e explain how to use mold part recipes Publication 6500 UM001A US P November 1999 Chapter 1 3 Using Mold Part Recipes What s in This chapter explains This Chapter e mold part recipe storage e how to name mold part recipes e how to save and restore mold part recipes e how to increase the number of mold part recipes Understanding Mold Part Pro Set 200 ladder logic supports storage of 5 mold part recipes It Recipe Storage in stores these recipes in the file range N205 N249 The layout of Pro Set 200 these recipe files is as follows Each mold part recipe contains nine files called File Mold Part Recipe vaults one floating point and eight integer files N203 achine setup parameters The vaults contain setpoint information for each z phase calibration constants for ERC2 and 204 Recipe name storage temperature module information File space is F205 old Part 1 Vault 1 ERC2 Memory Se eit ae iaaa e N208 Mola Part Vaut 2 neta and Pct nine files to store a mold part recipe before N207 old Part 1 Vault 3 Hold Pre Plast Post customer additions 208 old Part 1 Vault 4 Clamp Close LPMP Tonnage N209 old Part 1 Vault 5 Clamp Low Hold Dec Open 210 old Part 1 Vault 6 Eject File N92 Customer Additions N211 old Part 1 Vault 7 BTM setpoints calibration for Zones 1 4 212 old Part 1 Vault 8 BTM setpoints calibration for Z
146. e open circuit detector generates approximately 20 nano amperes into the thermocouple cable A total lead resistance of 25 ohms 12 5 one way will produce 0 5uV of error e Follow system grounding and wiring guidelines found in your SLC 500 Installation and Operation Manual The ladder logic supplied with Pro Set 200 is designed to accommodate BTM refer to chapter 6 Customizing Your System Publication 6500 UM001A US P November 1999 9 4 Using Barrel Temperature Modules BTM BTM Ladder Logic and Data Tables Configuring the BTM for Use until Press am F6 you see eee erove Ejectors Publication 6500 UM001A US P November 1999 C Press Fe to Advance Screen E The ladder logic which controls the BTM is located in files 94 95 96 97 98 and 99 You can remove files 95 and 98 and update files 96 and 99 if you have only one BTM If you have more than 8 temperature loops you will need to expand the ladder logic to support the new BTMs You will also need to modify the mold part storage logic contained in file 92 to accommodate the additional BTM recipe storage requirements Follow this procedure to configure the BTM to control temperature loops Creating a New Mold Recipe If you are not restoring a previously run mold you need to configure all temperature zones Follow the steps outlined in the following tables to configure temperature zones If at any time you do not understand a configuration
147. e same address goes true OSR One Shot Rising 9 10 Conditional instruction Makes rung true for one scan upon each false to true transition of conditions preceding it in the rung TON Timer On Delay 1 31 Counts time intervals when conditions preceding it in the rung are true Produces an output when accumulated value count reaches the preset value TOF Timer Off Delay 1 31 Counts time intervals when conditions preceding it in the rung are false Produces an output when accumulated value count reaches the preset value RTO Retentive Timer 1 31 This is an On Delay timer that retains its accumulated value when Rung conditions go false The mode changes to program from run or test The processor loses power A fault occurs CTU CountUp 1 31 Counts up for each false to true transition of conditions preceding it in the rung Produces an output when accumulated value count reaches the preset value CTD Count Down 1 31 Counts down for each false to true transition of conditions preceding it in the rung Produces an output when accumulated value count reaches the preset value RES Reset 1 31 Used with timers and counters When conditions preceding it in the rung are true the RES instruction resets the accumulated value and control bits of the timer or counter Publication 6500 UM001A US P November 1999 Instruction Mnemonic Processor Specifications Cc 5 Comparison Instructions Execution Times us Function
148. e setup purposes After the machine has been jogged and run in a CV Max you may want to Publication 6500 UM001A US P November 1999 8 24 Configuring Pro Set 200 Profiles Selector Profile of On Injection Injection Phase Your Selections Pack Hold Pre Decomp Plasticate Post Decomp Active profile is velocity psi Profile in Auto or Manual Ramps off 0n Ramps coordinated No Yes Link to another profile No Yes Suspend profile No Yes Direction of profile Decrease Increase Use Learned CV Maxon primary controlled variable f psi is selected variable then Learn psi use Deadhead f velocity is selected variable then Run psi as CV Max Use Deadhead psi Publication 6500 UM001A US P November 1999 Configuring Pro Set 200 Profiles 8 25 Clamp Phase Defaults Selector Clamp Close Clamp LPMP Tonnage Low Hold Decompress Clamp Open Profile of on On On On On On On Active profile is velocity psi Velocity psi psi psi psi Velocity Profile in Auto Of Manual Ramps off 0n On On On On On On Ramps coordinated No No No No No No No Yes Link to another profile Yes Yes No No No No No Yes Suspend profile No Yes No No No No No No controlled by core programming Direction of profile Decrease Decrease Decrease Decrease ncrease ncrease Decre
149. e your selection by pressing the up and down arrow keys 3 Press the enter key when you reach the correct selection Select inner or outer zones 1 Cursor to this field by using the left and right arrow keys C lt 2 Make your selection by pressing the up and down arrow keys 3 Press the enter key when you reach the correct selection Publication 6500 UM001A US P November 1999 Using Barrel Temperature Modules BTM Press el ay Mi File Configuration Words Press FE to Advance Soreen a until A seessss Ho gone Selected High CU Limit BRHF FH Low CU Limit BRHF FF Forced CU Walue ON T C Break BERR FE Heat Min On Time BER FF Heat TPO Period BHR FE DOCOS P Use this field 1 To View the currently selected zone 1 2 3 View and modify the high CV limitin a range of 100 00 to 100 00 Cursor to this field by using the left and right arrow keys Press the enter key The scratch pad appears Enter value XXX XX 7100 00 to 100 00 Enter a value between 100 00 and 100 00 1 2 3 View and modify the low CV limitin a range of 100 00 to 100 00 Cursor to this field by using the left and right arrow keys Press the enter key The scratch pad appears Enter value XXX XX 100 00 to 100 00 Enter a value between 100 00 and 100 00 1 2 View and modify the forced CV on thermocouple brea
150. ecreasing Pack decreasing Low Hold decreasing Hold decreasing Decompress increasing Pre Decompress increasing Clamp Open increasing Plastication increasing Ejector Forward increasing Post Decompress increasing Ejector Tip Stroke decreasing Clamp Close decreasing Eject Retract decreasing Clamp LPMP decreasing To select the direction of the profile position do one of the following To tell the SLC 5 04P A processor to expect an l AES r i REESE Soe increasing position profile set bit 10 0 Select gt EREZA decreasing position profile set bit10 1 Select gt PERRE Publication 6500 UM001A US P November 1999 8 20 Configuring Primary Controller Variables Press Use Learned or CUMan Configuring Pro Set 200 Profiles a Ho Profile Selected N until A yousee Use Learned or XCUMay Velocity D_E ig A aoe l iene tes If Pressure Profile then Learn PSI during Profile or D IEE Hise PSI learned during gt Deadhead If Velocity Profile then Run PSI as CUMHAS or Use D EE PSI Learned during Deadhead Press FS to Advance to Next Sereen From this screen you can See page select learned or CV Max 8 20 select the pressure value source for pressure profile 8 21 select the pressure value source for velocity profile 8 22 Velocity gt Ween Selecting Learned or CV Max Word 0 of the Setpoint Block 0000 0000 a 0000 bit
151. ed by the trigger mask position Publication 6500 UM001A US P November 1999 E 4 Word 1 of the Setpoint Block 0000 0000 0000 1000 bit 3 Word 1 of the Setpoint Block 0000 0000 a 0000 bit 4 Publication 6500 UM001A US P November 1999 Using Internal and External Trigger Setpoints Setting the Internal Trigger Mask Position Setpoint To tt set bit3 1 enable the internal trigger mask position setpoint disable the internal trigger mask position setpoint set bit 3 0 Setting the Internal Pressure Over Under Bit When using internal or external pressure trigger setpoints you must indicate whether you want the actual pressure to be an under operation current pressure less than or under the trigger pressure to trigger to the next profile e or over operation current pressure greater than or over the trigger pressure to trigger to the next profile If you want the actual pressure to be a setbit4 1 lt the current pressure under gt the current pressure over set bit 4 0 Example Internal Pressure Over Under When setting the internal pressure trigger over under bit If bit 4 equals Then 1 actual V SP MM nan The actual pressure must be less than or under the setpoint for the trigger to occur 0 SP actual w E The actual pressure must be greater than or over the setpoint for the trigger
152. eer who designs builds and configures plastic molding machinery You should understand the injection molding process be familiar with Allen Bradley SLC family of controllers be familiar with the fast analog modules 1746 FIO4V or 1746 FIO41 be familiar with the barrel temperature control module 1746 BTM be familiar with Panel View 550 or 900 operator terminals be able to write and interpret the ladder logic required to control your application have a basic knowledge of hydraulics including the ability to read the hydraulic diagrams for your injection molding machine Contact your local Allen Bradley representative for more information about available training courses concerning Allen Bradley products How Do Use This Manual your system Get Started with Pro Set 200 Software Quick start A YNYjYj A System overview AAD We designed this manual so you can follow it to customize P 3 Chapter 1 Introduction to the injection molding system ______________ Chapter 3 Set Up the Pro Set 200 System Set up the hardware ____ SPJ_ gt Set up the software ltl Customize your system ____ gt Chapter 5 Chapter 6 Understand hydraulic conces e Configure Pro Set 200 profiles __ _e Chapter 8 Use barrel temperature modules _ _ _ _
153. egeen cant oy dosha ety aed ene ae ek ea Processor Fouls Lets s pranie gos cea een E a cee Minor Eror BIU instore damck den a hanse ecu e A Segment Needs OLT Bit nuaa Segment Too Short Bit naaa aaa High and Low psi and Velocity CV Alarms cee eve PV Small and Large Deviation Alarms ccc ueeeue CV Small and Large Deviation Alarms 0 cece eee Understanding SLC 5 04P Appendix B Processor Addresses What s in THIS Appendix cacy seunacvs wees eee Been ak ea aes Operator SCreENS sisia conserve tha wdnthes watw aE aiaa SWPS CEENS prs die gamada eevee de a en heey edb ee owe CONMGUMEHON SCANS 2 scale piad sda dae ue salen dane ative BTM Configuration SCREENS 43 cccen4 cea sees dbavaeedezas Processor Specifications Appendix C What s in This Appendix ccc cect eee a SLC 5 04P Processor Catalog Number 1747 L542P General Specifications 0 cece cece Communication OPUONS 2s ees desks wed Meng weG sag ease a es Data Highway Plus DH channel offers ccc eeu Publication 6500 UM001A US P November 1999 Specialized Hydraulic Configurations Supported by Pro Set 200 Using Internal and External Trigger Setpoints Using Profile Status and Complete Bits Table of Contents toc v Programming Instructions kaw wie daw aes dalees ea Oee ease Ze Basic INSUMCHONS sinss deae bor amia hive apa umes Comparison Instructions saaa Math INStUCUONS t 22 ctce tianara bima me
154. emperature of the barrel of the injection molding machine For more information about the 1746 BTM module see the Barrel Temperature Control Module user manual publication number 1746 6 10 The following shows the Barrel Temperature modules located in slots 5 and 6 in a Pro Set 200 system slot 5 porn mer wera rer mer Typical chassis configurations have 10 and 13 slots However other variations may be required n N hy A eae aooo aa 1746 BTM Discrete I O N SLC 5 04P Modules ac dc relay Processor The above figure also shows a discrete output module which is used in conjunction with the BTM The discrete output module is used to drive the heater contactors You need up to eight outputs from a discrete output module for each BTM which depends on if you have heat only or heat cool zones Heat only will require four outputs and heat cool will require eight outputs You can use any type of discrete output module and can place the discrete output module in any slot in the range of 7 30 Publication 6500 UM001A US P November 1999 9 2 Using Barrel Temperature Modules BTM If your Pro Set 200 system uses more than 30 slots of I O and you need to add BTM put the BTM in another rack with its own processor We show an example of this configuration in the following two figures Figure 9 1 Communicating over
155. en 2 E Ejector Retract Profile Full Ret Fud a o Wi _ E e S Th Win Tt Er S 4 an LoT eae wi g Pos G7 In Press 048 PSI S Publication 6500 UM001A US P November 1999 This Is located This Is located field in field in 1 T4 3 PRE 9 N92 01 05 2 92 02 10 92 01 04 3 N92 06 11 N193 06 4 92 01 00 12 189 06 5 N92 01 02 13 N189 07 6 N92 01 01 14 N193 07 7 N92 00 15 N189 07 8 N92 01 03 16 N185 01 This Islocated This Is located field in field in 1 N95 24 17 N95 08 2 N95 25 18 N95 09 3 N95 26 19 No510 4 N95 27 20 N95 21 5 N95 00 21 N9536 6 N95 01 22 N9537 7 N95 02 23 N95 38 8 N95 03 24 N95 39 9 N95 28 25 N9540 10 N95 29 26 N95 41 11 N95 30 27 N95 42 12 N95 31 28 N95 43 13 N95 32 29 N95 44 14 N95 33 30 N95 45 15 N95 34 31 N95 46 16 N95 35 32 N95 47 33 N95 48 14 Publication 6500 UM001A US P November 1999 Understanding SLC 5 04P Processor Addresses Ejector Selections Screen a Ejector Setup j Eject Ti Multi i th Buell Sio Stroke CH G Off EDn son Off OFF Ott Off Pos 13 8 In Press O16 PSI PS Temperature Control Screen 1 g p zi 22 o o Temp33 ORCH OHOLE ORGIE GHH4 4 Cur
156. en objects The legend kit for the Panel View 550 terminal contains 5 inserts that are preprinted on one side with the labels F1 F10 with SPI symbols for various machine functions e g clamp close injection alarm etc You can create custom labels using the other set of inserts The following diagram illustrates how to insert the function key legends into the Panel View 550 terminal 5 Slots for Legend Inserts Publication 6500 UM001A US P November 1999 4 14 PV900 Function Key The legend kit for the Panel View 900 terminal contains 1 insert that Legend Kit Catalog Nos is preprinted on one side with the labels F1 F16 with SPI symbols 6500 PS2LBL9C and for various machine functions e g clamp close injection alarm 6500 PS2LBL9M etc You can create custom labels using the other set of inserts The following diagram illustrates how to insert the function key legend into the Panel View 900 terminal Important Catalog No 6500 PS2LBL9C is used for color Panel View 900 terminals 6500 PS2LBL9M is used for monochrome Wiring the Fast Analog Wiring 1746 FlO4V or FIO4I Modules I O Modules Important Remember e to connect only one end of the cable shield to earth ground e that channels are not isolated from each other all analog commons are connected together internally e that the module does not provide loop power for analog inputs e to use a power supply that matches the transmitt
157. ensor software over travel code Hydraulic pre fill logic Publication 6500 UM001A US P November 1999 2 8 System Overview What Do Need to Do As an Allen Bradley injection molding customer you e detail a project plan to organize your installation e provide the injection molding machine and its hydraulics e modify the ladder logic that controls sequential machine operation not included in Pro Set 200 handles permissives responds to hard wired safeties and E stops e modify the PanelView 550 900 screens optional e determine profile setpoints process limits and other application specific parameters used by the SLC 5 04P processor to control your injection molding process e comply with ANSI B151 1 1984 safety standards What s Next In the next chapter we introduce the injection molding process Publication 6500 UM001A US P November 1999 What s in This Chapter What is the Injection Molding Process Chapter 3 Introduction to the Injection Molding Process This chapter introduces the Pro Set 200 Injection Molding Control System Read this chapter before you set up molding profiles so that you are familiar with e the injection molding process e controlling the molding process with the SLC 5 04P processor To proper
158. er sensor specifications Publication 6500 UM001A US P November 1999 4 15 For each axis injection clamp ejectors wire the 1746 FIO4V or 1746 FIO4I module like this eee Module Position O Transducer O eth 1 IN 0 ground ee 2 O ANL COM P 1O ea aC a l 3 QO Wit earth 4 Use Belden 8762 ground se Belden O ant com m 6 O not used Valve Dri d RT valve 7 B 1 outo EL eamh 8 ANL COM ground O 9 C notused Valve Dri d oo O B Of on Y earth a C ANL COM ground Publication 6500 UM001A US P November 1999 4 16 Grounding the Cable Shield In CE applications use the following to ground the shields on the fast analog modules e ground the cable shield to the earth ground at only one end e use 1 4 inch 6 35mm wide braid for grounding the cable shield keep all unshielded wires as short as possible e ground the opposite end instead ground one end only if noise persists For cable shields grounded at the I O chassis input channels do this Ungrounded End at Source Device Grounded End at I O Chassis le Nee FE Keep the length of unshielded wires as short as possible 1 4 braid ZARA Solder drain R iiaea K wire to braid ae onnect I O chassis p at casino Wires bolt to earth ground B A ne Cable by Cable Note W 4 k
159. et a copy of the bar chart which shows the sequencing of the solenoids which control the hydraulic valves for your machine 3 Based on the requirements of your bar chart modify file 2 to perform the necessary control actions In some cases your machine may have special control requirements which are not handled in file 2 In these cases write custom ladder logic Use the Data Table Reference Manual publication number 6500 RM001A US P supplied with the Pro Set 200 documentation set as a guide in writing this logic Solenoid Name Solenoid Description Forward Injection Customizing Your System 6 11 Modifying Pro Set 200 Ladder Logic for an Injection Sequence Bar Chart The following diagram shows a bar chart for the injection phase for a hypothetical molding machine This is an example of a simple machine and should be used as for reference only Plastication Post Decompression Pack Hold Pre Decompression Solenoid H directional zj i ain ROO YY ILL Solenoid pump load H vor ie GYM ee eet jj PR pr Solenoid proportional me YY yy ff Y nnn V oe Solenoid H This row shows solenoid H a directional control valve is ON for all of the injection forward pack and hold profiles It is OFF during the pre decompression plastication and post decompression profiles The I O definition file contains this rung which supports these logic condi
160. eters psi output max from the valve specifications 3000 psi e e psi output min a value of zero zero e psi max volts or amps 10 volts or 20 milliamps e psi min volts or amps O volts or 4 milliamps This example spans the valve for full scale If you do not want to span to full scale refer to page 11 6 When entering values first press the enter key to display the scratch pad Then enter your value Wart Velocity Spanning Values MinC lose B8 IN SEC AT GRH DE t ManC lose BH IN SEC AT GH E Starting Up the Machine 10 3 When selecting volts or amps go to the selector make your selection then press enter 3 Press F1 to advance to the second clamp setup screen Mindpen BE IN SEC AT G88 ID BE MaxOpen BE IN SEC AT BHH i Close Jog deen Jog Vel BF Vel EEFE 0 PS G PS BREE __ May Yel B4 4 In Sec K Fress Fl to Advance Clamp Soreens E y 4 In the upper half of the screen enter spanning values as shown in the following table When selecting volts or amps go to the selector make your selection then press enter In this step you entered limits to allow your machine to move These limits define the minimum and maximum volts milliamps that will be sent to the valve s You will span valves in later chapters In this field Enter these min max valve spanning values 1 min close zero in sec
161. etpoint is 0 psi and you want the ramp to take 0 5 second enter 2000 psi sec Range 0 32767 Configuring Deviation Alarm Limits Configuring Pro Set 200 Profiles 8 29 1 Dewiation Alarm Limits press Y Velocity PSI Cores Deviation Deviation Clamp Small h Large Inject Smal Lara Eject Smal L ary Y Cy Y Cy l ll EE aiak E RRR i The deviation alarm limits screens allows you to set up small and large deviations for clamp injection and ejection pressure and velocity Refer to Appendix A for details regarding deviations Enter these configuration values In this field Do this 1 Enter the clamp velocity small deviation PV in a range from 0 to 99 99 2 Enter the clamp velocity large deviation PV in a range from 0 to 99 99 3 Enter the injection velocity small deviation PV in a range from 0 to 99 99 4 Enter the injection velocity large deviation PV in a range from 0 to 99 99 5 Enter the ejection velocity small deviation PV in a range from 0 to 99 99 6 Enter the ejection velocity large deviation PV in a range from 0 to 99 99 7 Enter the clamp velocity small deviation CV in a range from 0 to 32767 8 Enter the clamp velocity large deviation CV in a range from 0 to 32767 9 Enter the clamp velocity small deviation CV in a range from 0 to 32767 10 Enter the injection velocity small deviation CV in a range from 0 to 32767 1
162. f F2 F3 F4 FS Seg Segment Skipped Learn OFF Seg 2 ed L Off Seq 3 Clamp F Seg 4 er Seq 5 OLT Suocesstul Eject F8 Press F3 To Return To Production Menu Once you have reached the quick tune screen you must choose a profile to tune Publication 6500 UM001A US P November 1999 Quick Tune Procedure 12 3 3 Using the up and down arrow keys select a profile 4 Press the enter key C p When you first enter the quick tune screen no profile is selected You must select a profile The Coarse Tune Step Do the following to complete the coarse tune of the selected profile Step Description Function Key 1 Make certain that Kp is off F5 Make certain that each profile being tuned is set to the 2 F2 Manual Mode SetRamps OFF F4 SetOLT Open Loop Test ON F3 Run a complete cycle and check to see if all active segments OLT successfully If not refer to page 12 5 5 for corrective actions All profile being used must have successful OLTs before continuing to the next step 6 Set OLT OFF F3 7 Set Ramps ON F4 8 Turn learning on F6 F7 orF8 9 Set the profile in Auto Mode F2 10 Run 4 cycles At the completion of the coarse tune step speeds and pressures should be roughly close to the desired setpoints Publication 6500 UM001A US P November 1999 12 4 Quick Tune Procedure Fine Tune Step Complete the fine tune step after you ve completed the coarse tune step or after ma
163. for clamp injection and ejector 1 velocity for injection 1 system velocity for clamp injection and wectol 6 54 1 system pressure 1 velocity and 1 pressure 6 25 injection and clamp 6 23 injection onl injection clamp and ejectors 6 24 Publication 6500 UM001A US P November 1999 verifying hydraulic 10 4 W wiring fast analog I O mo 1746 BTM 1746 F104V or 1746 F grounding cable shield X dules lo4l 4 14 Glossary Glossary Actual The current status of a machine parameter such as current velocity acceleration pressure change rate etc showing how the machine responded to the setpoint Axis A major moveable part of the machine A typical injection molding machine has 3 axes injection clamp and ejectors Barrel The chamber in which plastication takes place houses the injection screw Clamp Phase The axis of motion which controls clamp It is typically comprised of 6 profiles close profile Low Pressure Mold Protect LPMP profiltonnage profile low hold profile decompress profile and open profile Control Output The output from the ERC2 algorithm Typically these control values CV are pressure or velocity signals which are sent to drive the appropriate value driver cards Cycle Time Average time taken by the machine to complete the operation Deadband The range through which an input can be varied without initiating an observable response Deadheaded
164. ftware Pro Set 200 contains five floppy disks 200 Software Disk Set This diskette Contains These Files That Let You Ladder Logic ePro Set 200 Ladder Logic Files emonitor and modify system logic Disk 3 of 3 erung address and symbol comments eunderstand the ladder program PanelView Pro Set 200 screens to be displayed on the PanelView 550 including emodify temperature velocity and pressure 550 Screens eoperator screens ps20102 pvaand ps20102 pba setpoints Disk 1 of 1 esetup screens ps2s102 pvaand ps2s102 pba espan input sensors and output valves eBTM configuration screens ps2b102 pvaand ps2b102 pba edefine BTM mode and gain values during setup econfiguration screens ps2c102 pba and ps2c102 pva define profile types PanelView Pro Set 200 screens to be displayed on the PanelView 900 including emodify temperature velocity and pressure 900 Screens eoperator screens ps20102 pvaand ps20102 pba setpoints Disk 1 of 1 esetup screens ps2s102 pvaand ps2s102 pba espan input sensors and output valves eBTM configuration screens ps2b102 pva and ps2b102 pba edefine BTM mode and gain values during setup econfiguration screens ps2c102 pba and ps2c102 pva edefine profile types Software Requirements ATTENTION This software is a starting point for an injection molding system The user5 must modify the software to comply with any applicable standards governing the final product application Before you
165. fy file 2 the I O definition file to do the following e identify input and output addresses used with your machine e define the specific inputs you want to use for example a front gate closed limit switch e use profile status bits to define the specific outputs you want to use for example a solenoid Next you must modify file 8 the STI file to direct the control signals from ERC2 to the appropriate Fast Analog card Finally you may also modify file 3 to initialize your specialty cards on power up Publication 6500 UM001A US P November 1999 6 2 Customizing Your System File 2 Main program file I O Definition File gt conditional bit Initialization file Gi o gt File 3 Tells ERC2 the number of phases and profiles l in each phase set outputs to 0 and other variables needed by the ladder logic program Lo File 255 Initializes ERC2 Do not write any code in this file Recipe Mold part File 88 gt File 92 recipe stored management upload download gt File 20 Software travel limits Loss of sensor detection gt File 94 Barrel temperature control module 1 Barrel temperature control
166. g 1 Cursor to this field bi Restore Selected Recipe by using the left and right arrow keys 2 Select Save Active Recipe by using the up and down arrow keys 3 Press the enter key to save the active recipe oe selected Recipe Restoring and Saving a Recipe Configuration Use this field to save or restore a recipe configuration Restoring a Recipe Configuration Restoring a recipe will make the selected recipe the active recipe To restore a recipe configuration do the following 1 Cursor to this field Restore Selected Recipe by using the left and right arrow keys ce 2 Select Restore Selected Recipe by using the up and down arrow keys 4 3 Press the emter key to restore the selected recipe to the active recipe Saving Active Recipe As Selected Recipe To save an active recipe as a selected recipe do the following 1 Cursor to this field Select Recipe B by using the left and right arrow keys Publication 6500 UM001A US P November 1999 8 4 Configuring Pro Set 200 Profiles Publication 6500 UM001A US P November 1999 2 Press the enter key The scratch pad appears Enter value 1 C6 5 Enter the recipe number 1 through 5 which you want to save the active recipe to Press the enter key C Cursor to this field by using the left and right arrow keys Select Save Active Recipe As Selected by using the up and down arrow
167. g the left and right arrow keys 2 Make your selection by pressing the up and down arrow keys C2 3 Press the enter key _ when you reach the correct selection Select the thermocouple type Choose from 0000 type J 0001 type K 3 1 Cursor to this field by using the left and right arrow keys 2 Make your selection by pressing the up and down arrow keys 3 Press the enter key when you reach the correct selection Enable or disable alarming for this zone 1 Cursor to this field by using the left and right arrow keys 4 2 Make your selection by pressing the up and down arrow keys 3 Press the enter key when you reach the correct selection Select the action to take on thermocouple break Choose from 00 disable loop control and set CV to zero 01 set the output to the forced CV value on thermocouple break 5 10 set output to the manual mode CV value 1 Cursor to this field by using the left and right arrow keys lt 2 Make your selection by pressing the up and down arrow keys 3 Press the enter key when you reach the correct selection Publication 6500 UM001A US P November 1999 Use this field Using Barrel Temperature Modules BTM To Select the auto tune gains you want to use Choose from 00 low gains 01 medium gains 10 high gains 11 very high gains We recommend that you first select low gains test then change gain settings if necessary 1 Cursor to this field by using the left and right arrow keys lt 9 2 Mak
168. gle Clamp Clamp Decompress Switch gt lt gt lt gt lt gt lt gt lt gt lt x x x lt Clamp Close Solenoid Clamp Open Solenoid Clamp Proportional Valves Additional Pump Solenoids gt lt gt lt gt lt gt lt Plate Hyd Ejector Retract Push Button S elector Switch Plate Hyd Ejector Forward Push Button S elector Switch gt lt Hydraulic Plate Ejector Proportional Valve Core Set Push Button Selector Switch Core Pull Push Button Selector S witch Core Set Limit Switch Core Pull Limit Switch Inject Forward Push Button S elector Switch Inject Retract Push Button S elector Switch Screw Rotate Push Button Selector Switch Inject Screw Unit Off On Dry Cycle Publication 6500 UM001A US P November 1999 O O PF PF VP DLO O O O O 0 F O 0 0 0 00 FB DIO VD VD VP Oo FIO FI O O O gt lt gt lt gt lt gt lt gt lt gt lt o lt lt Pro Set 200 Features ject Unit Forward Limit Switch Customizing Your System 6 9 Out of the Box nut Output Reserved Additional Optional Required put pur Programming Required 0 ject Unit R etract Limit Switch ject Unit Forward Push Button Selector Switch ject Unit Retract Push Button Selector S witch urge Guard Closed gt lt x gt lt gt lt gt lt S AS ISS ject Forward So
169. h valve second screen e enter jog values V Verify correct hydraulic operation and make sure the jog setpoints that you loaded are in control of your machine ta Determine sensor and valve operation Reference For the injection clamp and eject phases Chapter 11 V Span inputs Determining os Sensor and V Enter minimum and maximum forward and retract values Vale V Span outputs to remove upper and lower deadbands Operation V Save machine setup data V Configure primary controller variables LE Complete the Quick Tune Procedure Reference Chapter 12 J Select Quick Tune from the Production Menu Quick Tune Procedure F9 until a D Press a yousee Production Menu 2 Select Quick Tune etup Counter Setup Press the Enter key pe ate Monitor on the PanelView screen Publication 6500 UM001A US P November 1999 V Choose a profile Quick Tune l gt etig Ruxe aa aff a Off Kee Select a profile Seq 1 Seament Skipped Learn Off to tune o Step Seen Inject F 2 Press the Enter key on seq 2 aT the PanelView screen Seg 3 Dt Never Seen Clamp FF Seq 4 Te Never Seen e Seq 5 OLT Successful Eject FS Ka F3 To Return To Production Menu m Follow Coarse Tune Procedure V Make certain that Kp is off press F5 J Make certain that each profile being tuned is set to the Manual Mode press F2 V SetRamps OFF
170. have a range from 0 to 32767 psi second Every profile step has its own acceleration and deceleration ramp rates for both velocity and pressure Velocity Ramp Rate acceleration ramp rate deceleration ramp rate Pressure Ramp Rate acceleration ramp rate deceleration ramp rate Using Ramps If required by your application you can configure Pro Set 200 to ramp both velocity and pressure during a profile Pro Set 200 applies configured ramp rates at the beginning of each profile segment for both velocity and pressure to reach setpoint Apply ramping with the following considerations e Disable ramp rates while tuning applicable pressure and velocity loops Ramp rates control selected and unselected valves Although you may be controlling velocity you can also ramp injection pressure during an injection profile Publication 6500 UM001A US P November 1999 8 10 Configuring Pro Set 200 Profiles Word 0 of the Setpoint Block 0000 0000 a 0000 bit 7 Publication 6500 UM001A US P November 1999 e When using ramping make the acceleration and deceleration rates as aggressive as possible If the rates are too slow the setpoint might not be attained this could cause a segment to short alarm acceleration ramp rate too slow desired setpoint is never reached e Make sure that valve driver cards with ramping have ramping disabled Selectively Enabling Ramping To selectively enable ramping 1
171. held until the clamp low hold profile is permitted Publication 6500 UM001A US P November 1999 Ejector retract Ejector forward Segment 1 y Segment 2 Ejector retract Segment 1 y Ejector forward Introduction to the Injection Molding Process 3 15 Ejector Forward Profile The ejector forward profile moves the ejector pins toward a configured position to eject the part from the mold The standard Pro Set 200 ejector profile shown below allows the ejector plate to be extended at two different velocities and pressures As the ejector begins to extend velocity 1 and pressure setpoint 1 become active Once the ejector reaches the start forward speed position 2 the velocity 2 and pressure setpoint 2 remain active until the full forward position is reached Ejector 0 Fully Forward Position start fwd full fwd stop retract speed 2 eject forward Position XX XX XX XX XX XX N Vel 1 ee f psi 1 psi 2 XXXX XXXX You can choose to advance the ejector while the clamp is still opening or wait until the clamp is fully open Ejector Retract Profile The ejector retract profile moves the ejector pins back into the mold The figure below shows a typical retract profile Once the retract profile is active the ejector plate is commanded to retract at the selected velocity and pressure The
172. hold profile since both of these profiles are in the injection phase However you can not link the hold profile to the clamp open profile because these two profiles are in different phases To nl B poa a 55548 CBO enable linking enter 1 to link to injection enter 2 to link to pack enter 4 to link to hold enter 8 to link to pre decompress enter 1 6 to link to plastication enter 32 to link to post decompress enter 1 to link to clamp close enter 2 to link to clamp LPMP enter 4 to link to clamp tonnage enter 8 to link to clamp low low hold enter 1 6 to link to clamp decompress enter 32 to link to clamp open enter 1 to link to ejector forward enter 2 to link to ejector retract enter 4 to link to ejector tip stroke disable linking enter 0 enter 0 gt GEMM at Position EE Using the Suspend Profile at Position Use this field to enable or disable the suspend profile capability If this capability is enabled you can stop the phase at the position defined in configuration word 3 of the setpoint block You can enter the interrupt profile position setpoint in the configuration screen 0000 0040 0000 0000 bit 9 To i I EE enable the interrupt profile capability set bit9 1 select gt ES disable the interrupt profile capability setbit9 0 select gt R Publication 6500 UM001A US P November 1999 8 18 Configuring Pro Set 200 Profiles Suspend
173. iew which recipe number P ro Set 200 is currently using Selecta recipe for which you want to configure the BTM 1 Cursor to this field by using the left and right arrow keys 2 Press the enter key 2 The scratch pad appears Enter value 1 to 5 3 Enter a recipe number between 1 5 Pro Set 200 lets you use up to 5 recipes 3 View the recipe name of the selected recipe This field is a display only field you cannot enter a new name in this field Use fields 4 and 5 to enter a new name Change the letter selection 1 Select the letter 4 2 Cursor to this field by using the left and right arrow keys Ce 3 Selecta letter by pressing the up and down arrow keys 4 Press the enter key when you reach the correct letter Publication 6500 UM001A US P November 1999 Use this field Using Barrel Temperature Modules BTM To Select the position of a letter in the name field 1 Cursor to this field by using the left and right arrow keys 2 Selecta position by pressing the up and down arrow keys a 3 Press the enter key lt when you reach the correct position number This field relates to the following positions on the name display Name Cee ee ee ee position 1 position 20 Save a mold recipe that you configured or retrieve a previously stored recipe Press Cores Determine whether a restore can be performed e disabled means the machine is currently running
174. ing Up the Hardware Table of Contents Chapter 1 What s in This Chapter ccc cece eect eee e eens Before You BUI otid viet et ana endunihvedunay aoe es Project PlanAiNO ciirsa na bhbataud deer eee eee ae Electrical Components of the Project Plan 0004 Hydraulic Components of the Project Plan cee eee Mechanical Components of the Project Plan Other Project Plan Considerations cece cence eens PROCCHUICS oaar ean iaia a aawebe Meet a diana edeean Whats NeXt sivciacdavdateedaddadaeaudatdeenesteeae Chapter 2 What s in This Chapter cccdtu cee eas eed tae e os bweadae os os What Does the Pro Set 200 System Do 00008 What Are the Components of a Molding Control System How Does Pro Set 200 Work cece cece eee ees What are the Capabilities of Pro Set 200 ccc eee eee What Do I Need to Do icc casaceesci sddansenicdaaw deed Whats NEXT e tasea ei uae ade been ads Coma ead a Sa ss Chapter 3 What s in This Chapter scisescateiaeestaws wait wea wade ad What is the Injection Molding Process 1 ccc cece ee eeees How is the Injection Molding Process Controlled What S NEXE oipapa E EE RETE RE Chapter 4 What s in This Chapter cc ceuccdus dees dee wee ba eee wee aqae a Compliance to European Union Directives ccc eee ees Determining the Layout of the I O Chassis ccc ee vues Grounding the Chassis cckgitnnaces
175. input voltage ATTENTION Set the input jumper before applying power Hazardous voltage is present on exposed pins when power is applied contact with the pin may cause injury to personnel Catalog Number 1746 P2 POWER Fuse a J umper Selection E m4 100 120 Volts i e 200 240 Volts 5 Wire the power to power supply ATTENTION Turn off incoming power before connecting wires failure to do so could cause injury to personnel and or equipment Catalog Number 1746 P 2 120 240 vac Incoming Poner VAC NEUT CHASSIS GROUND For more information about installing the power supply see the SLC 500 Modular Hardware Style Installation and Operation Manual publication number 1747 6 2 Publication 6500 UM001A US P November 1999 4 8 Setting Up the Hardware Installing the SLC To install the processor do the following 5 04P Processor 1 Make sure system power is off 2 Insert the processor into the 1746 chassis Important You must insert the SLC 500 modular processors into the left slot slot 0 as shown below Remove the protective label after installing the processor Protective Label Module Release Card Guide BE 20914 M ka For more information about installing the SLC 5 04P processor
176. install Pro Set 200 software make sure you have this additional software Important Pro Set 200 software runs on Microsoft Windows 95 only To You will need run PanelBuilder and RS Logix i 500 software Microsoft Windows 95 modify Pro Set 200 PanelView PanelBuilder software catalog no 2711 ND3 screens version 2 3 1 or later v peel vee Seat RSLogix 500 programming software version 2 00 57 Publication 6500 UM001A US P November 1999 5 2 Installing Pro Set 200 Software Hardware Requirements Installing the Software Aras What s Next Publication 6500 UM001A US P November 1999 Neither PanelBuilder software nor RSLogix 500 programming software is supplied with Pro Set 200 you must order these items separately Contact your Rockwell Automation or Rockwell Software representative for more information Important This procedure does not tell you how to install or run PanelBuilder or RSLogix 500 software For more information on these packages refer to these manuals For information on Refer to RS Logix 500 software the instructions enclosed with RSLogix 500 software PanelBuilder 550 900 Software publication number 2711 6 0 PanelBuilder software We recommend that you install Pro Set 200 software on an IBM compatible personal computer that has at least e a60 MHz pentium processor e 15 Megabytes available hard drive space for PanelBuilder software 8 Megabytes available hard drive s
177. ion clamp or ejector position or pressure sensors The standard Pro Set 200 program checks for a count value of minimum to a count value of maximum for a sensor loss eyour fast analog cards differ from the echange fast analog module addresses standard Pro Set 200 configuration see page 4 2 21 plastication deadtime do not modify delay 22 complete bit test do not modify 88 mold part do not modify 90 configuration screen do not modify management 91 setup screen do not modify management 92 storage you need to add files or data table information add MOV and or COPY instructions to a recipe as needed 93 alarm setup alarms for do not modify Pro Set 200 94 temperature zones you do not have a BTM in slot 5 remove file if not using a BTM 1 4 BTM 95 temperature zones you do not have a BTM in slot 6 remove file if not using a BTM 5 8 BTM 96 BTM configuration eyou do not have BTMs eremove files eyou have moved the BTMs from the Pro Set emodify the M location to match the 200 standard configuration see page 4 2 output address eyou do not have both BTMs eremove the ladder rung that references the unused module 97 auto tune 1 4 you do not have BTMs for zones 1 4 remove file 98 auto tune 5 8 you do not have BTMs for zones 5 8 remove file 99 M1 M0 up download eyou have moved the BTMs from the Pro Set emodify the M location to match the output 200 standard configuration address eyou are not using both BTMs eremove the ladde
178. ion Molding Process 3 5 Clamp Close Phase During clamp close the moving platen advances or moves forward toward the stationary platen During the clamp close phase there are three profiles They are Profile Description Clamp Close clamp close This profile is made up of three segments eclose initial speed segment use this segment to enter an initial gt a gt Clamp y Tonnage speed and pressure setting that starts the clamp moving You can a gt LPMP use this segment to smoothly start accelerating the clamp eclose fast segment use this segment to traverse the clamp close quickly toward the stationary platen This segment occurs after the close initial segmentis complete There are some machines that do not require a close initial segment and can be set up to start the closing segment immediately with the close fast segment eclose decel segment use this segment to tell the clamp to begin the deceleration before beginning the LP MP close profile There are some machines that do not require a close decel segment in these cases omit this segment Clamp Close clamp LPMP Use this profile to decelerate the moving platen as it approaches the Stationary mold half This profile is very important and is used to sense gt pe gt ce gt Tonnage if a partis stuck in the mold Adjust the pressure for the profile high enough to make it to full clo
179. is pressure profile allows you to control the amount of pressure applied to the plastic as the screw turns You can use plastication profiles to achieve the desired backpressure with respect to the distance of the length of the shot You can control the backpressure by using pressure vs position Use psill Y Use Use Use Use Vel 1 psi2 psi3 psi4 psi5 Vel 2 Vel 3 Vel 4 Vel5 lt XQ QC Fain screw NOY Pos 1 Pos 2 Pos 3 Pos 4 BLA ey NV BL 7 7 psi3 4 psi 4 AE XXX XX XX XX XX XX XX XX XX Shot size can occur anywhere in this profile When shot size is reached plastication stops After the last segment of the plastication profile is complete the SLC 5 04P processor either immediately starts the post decompression profile or waits for a command from the ladder logic before continuing Pre decompression Injection Plastication Pack Post decompression Hold Segment y y Clamp Low Hold Clamp Decompress Pre decompression Injection Plastication Pack Post decompression Hold y y Clamp Decompress Segment1 Clamp Low Hold Introduction to the Injection Molding Process 3 11 Post decompression P
180. itches on the machine control panel activate each axis of machine motion in the forward and reverse directions For example clamp open and close ejectors forward and reverse injection ram forward and reverse screw rotation 3 Use your own troubleshooting techniques to correct problems such as no motion or reverse motion when forward motion is commanded Important Complete this part of setting up machine operation before starting to the next chapter For safety reasons you should verify correct hydraulic operation and know that your setpoints are in control of the machine before proceeding further Publication 6500 UM001A US P November 1999 10 8 Starting Up the Machine What s Next In the next chapter we explain how to span your sensors and valves Publication 6500 UM001A US P November 1999 Chapter 1 1 What s in This Chapter Accessing the Setup Screens Spanning Inputs Determining Sensor and Valve Operation For proper system operation you must determine the range of your input sensors for position and pressure You must also adjust your machine s pressure and velocity output valves to match the analog output module linear signal range This is called spanning This chapter tells you how to e span inputs e span outputs e span to remove upper and lower deadbands e test valve linearity Important Do not span valves until you have completed all previous chapters Access the Pro Set 200 set
181. ition Mask Use the trigger mask position setpoint to prevent an internal pressure trigger setpoint from being executed until a certain position has been reached The Pro Set 200 trigger mask position setpoint applies only to internal pressure triggers The internal trigger mask position setpoint is often used to prevent the injection profile from prematurely transferring into the pack profile due to pressure spikes The following picture shows how this works Transfer is prohibited until after The trigger mask position prevents the trigger mask position has this pressure spike from prematurely been reached transferring to the pack phase a Pack Phase Pressure Trigge ware 1900 psi Injection Pressure etime trigger setpoint 30 seconds eposition trigger setpoint 1 0 inch pressure trigger setpoint 1900 psi etrigger mask position 2 0 inches 1 0 2 0 3 0 40 5 0 Ram Position Transfer Trigger to Pack Mask Position The internal mask position setpoints are located in word 21 of the profile setpoint block Address Description Range Nxx 21 trigger mask position 32767 7 in Nxx 1 3 internal pressure trigger position mask enable Decimal point is implied gt Internal trigger mask positions only apply to pressure trigger setpoints Time and position trigger setpoints are not affect
182. jection ramp rate screen for reference feed E Peccved E Ace Press PSI Sec Dec Fress GH PSI Sec Injection Ramp Rates D T 4 7 1 Lore Lea GoHAE C D BHFF DHEHH CHEER BHEE A Enter these configuration values for each segment on each ramp rates screen Enter a zero to step immediately to the new setpoint in this segment Do this Enter the ramp rate for increasing velocity setpoints For example if the previous segment velocity setpoint is 5 00 in sec and this segment velocity setpoint is 10 00 in sec and you want to ramp from 5 00 in sec to 10 00 in sec over one second then enter 5 00 in sec2 Range 0 327 in sec sec Enter the ramp rate for decreasing velocity setpoints For example if the previous segment velocity setpoint is 10 00 in sec and this segment velocity setpoint is 5 00 in sec and you want to ramp from 5 00 in sec to 10 00 in sec over one second then enter 5 00 in sec2 Range 0 327 in sec sec Enter the ramp rate for increasing pressure setpoints For example if the pressure setpoint in the previous segment is 1000 psi and the setpoint in this segment is 200 psi and you want to reach the new setpoint in two seconds enter 400 psi sec Range 0 32767 Publication 6500 UM001A US P November 1999 Enter the ramp rate for decreasing pressure setpoints For example if the previous segment psi setpoint is 1000 and this segment s psi s
183. k in a range of 100 00 to 100 00 Cursor to this field by using the left and right arrow keys lt gt Press the enter key The scratch pad appears Enter value XXX XX 100 00 to 100 00 Enter a value between 100 00 and 100 00 3 Publication 6500 UM001A US P November 1999 Using Barrel Temperature Modules BTM Use this field To View and modify the minimum heat TPO on time in a range of 0 100 seconds 1 Cursor to this field by using the left and right arrow keys 2 Press the enter key 5 The scratch pad appears Enter value 0 to 100 3 Enter a value in a range of 0 to 100 seconds View and modify the total heat TPO on time in a range of 0 100 seconds 1 Cursor to this field by using the left and right arrow keys 2 Press the enter key 6 The scratch pad appears Enter value 0 to 100 3 Enter a value in a range of of 0 to 100 seconds Publication 6500 UM001A US P November 1999 Press Use this field 1 Jm F6 D al jectors Oneal Mi File Configuration Words To Using Barrel Temperature Modules BTM 9 11 until you see Ho Zone Selected Press F to Advance Soreen a gf Cool Min On Time BER FF aS Cool TPO Period BER 4 PU Alarm Rate CHANSO Low Temperature Alarm Value BRHF 5 High Temperature Alarm Value BHHEE E Low Deviation Alarm Value BRHF E RO High Dewiation Alarm Value
184. keys Press the enter key Configuring P Press Profile Selection Configuring Pro Set 200 Profiles 8 5 rofiles ERCZ Profile Configuration No Profile Selected Profile Selection gt Le Press F8 to Advance to Hent Screen A Selecting a Profile Select the profile that you want to configure Select any of these profiles Profile Phase einjection injection epack ehold e pre decompress eplastication e post decompress eclamp close clamp eclamp LPMP etonnage elow hold edecompress eclamp open eeject forward eject eeject tip stroke eeject retract Publication 6500 UM001A US P November 1999 8 6 Configuring Pro Set 200 Profiles Press E Mo Profile Selected ma Profile is Profile Type is a Te Profile Control Mode D Ec Ramps are gt DERM and Coordinated D ME Link Profile Pa to Profile Number er Suspend Profile D MES at Position BHE Direction of Profile Pooh I gt L Fress F8 to Advance to Nest Screen From this screen you can See page selecta profile 8 5 turn profiles on or off 8 7 select velocity or pressure control 8 7 select auto or manual mode 8 8 turn ramps on or off 8 8 coordinate ramps 8 13 link to another profile 8 14 set link profile identification 8 17 use suspend profile 8 17 select the direction of the profile position 8 19 Modifying Ladder Logic if You Have Less Phases or Profi
185. king big changes to the primary or secondary setpoints From the quick tune screen Step Description Function Key 1 Set the profile in Auto Mode F2 2 Set Kp OFF F5 3 Turn Ramps OFF F4 4 Set OLT ON F3 Run a complete cycle and check to see if all active segments OLT successfully If not refer to page 12 5 5 for corrective actions All profile being used must have successful OLTs before continuing to the next step 6 Set OLT OFF F3 7 Turn Ramps ON F4 8 Turn Kp ON F5 Turn learning on if learning is still on from coarse tune 9 f F6 F7 or F8 you can leave iton Automatic Mode ERC2 Built into the quick tune screen are status areas that report tuning Open Loop Test Status success The engineering actual word blocks are 1 17 33 49 and 65 Word Engineering Actual Segment Statua an Extended Description PanelView Screen Word Values 0 Segment Skipped Segment Skipped 1 No Step Seen Segment didn t progress through dead time threshold 2 Dt Never Seen Segment didn t progress through dead time 3 Te Never Seen Segment didn t progress through Time Constant 4 OLT Successful Segment reached steady state Open Loop Test successful You will also see a status of Segment Not Used Segment Not Used is displayed when a profile being tuned does not have five segments for example Pack and Hold This is determined by ladder logic and not by ERC2 Publication 6500 UM001A US P November 19
186. l Ho Auto Tune Block 2 97 26 3 97 27 Process Heat Gain G2 HH 4 97 28 Process Heat Time Constant GH 3 5 N Process Heat Dead Time OR 6 97 30 ai Process Cool Gain BH Process Cool Time Constant Oe H Process Cool Dead Time HH 7H a Press F amp to Advance Screen A Zone Selection Screen 8 This field Is located in 1 Ho Zone Selected M PID Gains Block 2 N97 32 3 97 33 Heat Proportional Gain 4 N97 34 Heat Integral Gain Heat Derivative Gain f ET Cool Proportional Gain Cool Integral Gain Cool Derivative Gain a Press F to Advance Screen Publication 6500 UM001A US P November 1999 This Islocated This Is located field in field in I N93 164 03 11 N93 170 03 2 93 165 03 12 N93 171 03 3 N93 166 03 13 N93 168 04 4 93 167 03 14 N93 169 04 5 N93 164 04 15 N93 170 04 6 N93 165 04 16 N93 171 04 7 N93 166 04 17 N95 12 8 N93 167 04 18 N95 13 9 93 168 03 19 N95 14 10 N93 169 03 20 N95 15 This Islocated This Is located field in field in 1 94 164 03 11 94 170 03 2 N94 165 03 12 N94 171 03 3 94 166 03 13 N94 168 04 4 N94 167 03 14 N94 169 04 5 94 164 04 15 N94 170 04 6 N94 165 04 16 N94 171 04 7 94 166 04 17 N96 12 8 N94 167 04 18 N96 13 9 94 1
187. l Install System __ Pro Set 200 Dan _ o _ gs Drawings of Materials Components Programming Hydraulic Component Projection Review CreateNew Create Bill Receive Install System oad Revise Drawings Drawings Hydraulic of Materials New Parts Components Ee Based on Testing Drawings Testing Mechanical Component Projection Review Create New Create Bill Receive New Install System Drawings M Mechanical of Materials Parts Components Drawings Time The above illustration is a simplified example of an installation plan for Pro Set 200 Your actual project plan should be detailed to include every reasonable factor that may influence the success of your installation Publication 6500 UM001A US P November 1999 Pro Set 200 System Quick Start 1 5 Procedures iS Plan for the project pa Set up the hardware Reference V Determine the layout of the 1 0 chassis aah etting Up V Ground the chassis the Mariners V Install the power supply V Install the SLC processor V Install the 1 0 modules Y Connect the programming terminal to the SLC processor Y Connect the PanelView terminal to the SLC processor slot 5 slot 2 slot3 slot 4 AN eee e eee me ae m ee fine oo iw oo 552 Typical chassis have 10 mun Ret ppoe Mee oe mone mar soo and 13 slot
188. ladder logic e Ifyou want to add more screens you need to download with minimal amounts of information That way you ll have more memory to add screens In the next chapter we explain hydraulic concepts What s in This Chapter The Relationship Between Hydraulics and Pro Set 200 Chapter 7 Understanding Hydraulic Pressure and Flow Concepts This chapter helps you understand the the following e pressure differential and its effect on flow rates e load pressure concepts e relief valve settings and how they affect flow rates e load pressure and its effect on flow rate e deadheaded pressure vs learned pressure during a profile e hydraulic configurations that Pro Set 200 supports The relationship between the hydraulics of any injection molding machine and Pro Set 200 cannot be overemphasized the success of an efficiently functioning machine depends on this successful interaction It is possible to correctly setup Pro Set 200 on a machine and because of poor hydraulic design still have an inefficient poorly functioning machine Unfortunately Pro Set 200 cannot make up for poor hydraulic design This chapter was written to assist someone with substantial hydraulic knowledge as it is specifically applied to injection molding machines This chapter is not designed to teach you hydraulic design for injection molding machines If you are unfamiliar with hydraulics as they apply to injection molding machines you are
189. lastication profild 3 10 position sensors 2 3 post decompress profile 3 1 power supply installing 4 4 pre decompress profile 3 9 pressure differential 7 4 Pro Set 200 capabilities 2 6 how it works 2 4 ladder files ladder logic relationship to 1 0 module layout phases clamp phase 2 4 eject phase 2 injection phase 2 4 Pro Set 200 disk set 5 1 Pro Set 200 profile configuring 8 1 data table locations Pro Set 200 system 2 T components 2 2 1746 BTM 2 3 1746 F104V_or 1746 F104l 2 3 1747 5 04P 2 4 miscellaneous discrete input and output modules 2 3 PanelView 550 or PanelView 900 2 4 software 2 4 processor addresses B 1 processor specifications C 1 realt SLC 5 04P C 1 production monitor screens accessing screens profile status and complete bits F J Publication 6500 UM001A US P November 1999 Index Publication 6500 UM001A US P November 1999 profiles amp close 3 4 amp decompression 3 1 amp low hold 3 9 amp LPMP 3 5 amp ope onfiguring ata table locations 8 1 isabling 8 7 jector advancel 3 15 ejector retract 3 15 8 1 hold injection 3 1 plastication 3 10 post decompres 3 1 pre decompress 3 9 tonnage 3 4 programming instructions C 4 application specific C cs ofa 0 0 0 0 0 ASCII C 9 basic C 4 communication C 9 comparison C 9 data handling C 7 moray PID C 9 program flow C 9
190. ld in 1 N84 00 10 N84 08 2 84 01 u 84 13 01 3 N84 02 12 N84 09 4 84 03 13 84 20 5 N84 13 00 14 N84 21 6 N84 04 15 N84 13 02 7 N84 05 16 N84 18 8 N84 06 17 N84 19 9 84 07 This Islocated This Is located field in field in 1 Ne4 22 9 N84 28 2 84 23 84 29 3 N84 13 03 11 N189 06 4 84 24 193 06 5 N8425 N189 07 6 84 26 14 193 07 7 N84 27 15 N8430 8 84 13 04 Publication 6500 UM001A US P November 1999 Ejection Input Output Device Setup Screen e Ejection Input Output Device Setup ey Pos Input Pi AT Counts Pos Input P2 AT 4 3 Counts Volts Pee Counts O PSI Input Pi ait AT oft Counts PSI Input P2 AT Counts Type 1 ee ae G12 PS Qutput Min ga AT ARF PSI Output Man AT ior CA L Press F6 to Sa Ejector Screens w Velocity Spanning Values Screen 3 o Spanning Values MIN Fud KFF MAX Fud ALFF IN SEC AT MIN Ret LELE LEE msec AT THF Wel Wel PSI 3HE PSI E Man Yel o In 5Seg K Fress F6 to Advance Ejector Screens This field Is located in B14 00 01 B14 00 03 B14 00 04 B14 00 05 B14 00 07 B14 00 06 1 2 3 4 5 6 7 This field 1 B14 00 08 Is located in N84 13 11 Understanding SLC 5 04P Processor Addresses B 21 ERC2 Alarm Setup Screen M ERC2 Alarm Setup Report Minor Errors Report Segments Needing
191. ld Cavity M0 Ram screw OX Then the injection ram screw rotates to reload plastic for the next shot The screw acts like an auger by forcing plastic down the screw flights in front of the screw tip As plastic is pushed in front of the screw tip the ram is forced to retract We call this plastication The distance the injection ram moves is the shot size Mold Cavity KY Ram screw N Clamp Open During the clamp open phase the clamping cylinder pulls the moving platen from the stationary platen to open the mold Clamp M Moving Stationary Cylinder Platen Platen How is the Injection Molding Process Controlled Introduction to the Injection Molding Process 3 3 Eject During the eject phase of the operation the ejector plate in the mold advances the ejector pins to the ejector forward position to eject the part from the mold Ejector and then the ejector pins are retracted to the ejector retracted position Ejector The SLC 5 04P processor lets you solve complex molding problems by controlling each phase of the injection molding process You can vary the velocity or pressure of the injection ram clamp or ejector to achieve quality parts with rapid machine cycles You can select the SLC 5 04P processor to control different operations on the molding machine The SLC 5 04P processor communicates with fast analog cards to
192. le Publication 6500 UM001A US P November 1999 7 10 Understanding Hydraulic Pressure and Flow Concepts What Hydraulic Configurations Does Pro Set 200 Support Pro Set 200 is designed to provide open or closed loop control signals to the proportional valves controlling the pressure and flow circuits on an injection molding machine While Pro Set 200 has the capability to control proportional pressure and flow values for all 3 axes the minimum Pro Set 200 configuration controls the injection axis Pro Set 200 handles hydraulic configurations which have separate proportional valves for pressure and flow Figures 7 10 7 11 and 7 12 show these configurations Figure 7 10 Pro Set 200 Typical Hydraulic Configuration with a Directional Control Valve Position Sensor Cylinder m O py Pressure 7 Transducer Axis Injection Clamp or Ejector Axis Directional Control Valve Electronically L Adjustable Flow Electronically Tank Control Valve Adjustable psi Valve gt Ld ul rump Tank 20871 M This Does this Position Sensor measures cylinder position Pressure Transducer esenses hydraulic pressure in the cylinder esends back 0 10 volts or 4 20 milliamps proportional to the pressure Directional Control Valve switches the cylinder from a forward or reverse position Electronically Adjustable Flow Control
193. le Link Pattern Plastication 9000 0000 0001 0000 Post Decompress 900 0000 0010 0000 Clamp Phase Link Pattern Table Close 0000 0000 0000 0001 LPMP 0000 0000 0000 0010 Tonnage 0000 0000 0000 0100 Low Hold 0000 0000 0000 1000 Profile Link Pattern Decompress 0000 0000 0001 0000 Open 0000 0000 0010 0000 Ejector Phase Link Pattern Table Eject Forward 0000 0000 0000 0001 Eject Retract 0000 0000 0000 0010 Profile Link Pattern Eject Tip Stroke 0000 0000 0000 0100 Publication 6500 UM001A US P November 1999 8 16 N109 0 N109 1 N109 2 Configuring Pro Set 200 Profiles Injection Setpoint Block Pack Permissive Bit Pattern B101 1 1 The link profile m word points to the permissive bit pattern of the next block to be executed in this Example Profile Linking To link the injection profile to the pack profile and the pack profile to the hold profile do this Set N109 0 8 1 This enables profile linking for the injection profile the injection profile is linked to the pack profile Note that this is the default out of the box configuration for Pro Set 200 N113 0 Pack Setpoint l Case the pack Block block 2 Place the permissive bit pattern for the pack profile in the link N113 1 E The link profile profile identification word in the injection setpoint block N113 2 Hold Permissive word
194. lenoid Pack Solenoid Hold Solenoid Inject R etract Solenoid Inject Proportional Valves Screw Rotate Solenoid Back psi Solenoid nject Unit Forward Solenoid nject Unit Retract Solenoid gt lt gt lt gt lt x x x x x x Barrel Heat on Switch alfunction Reset Push Button alfunction Beacon Light alfunction Audible Alarm Clamp Enable Solenoid Ejector Enable Solenoid gt lt gt lt gt lt gt lt Die Height Forward Push Button Die Height Retract Push Button Die Height Forward Solenoid Die Height Retract Solenoid Die Height Forward Overstroke Limit Switch Die Height Retract Overstroke Limit Switch Linear Transducer Clamp Linear Transducer Injection DI DLO OD O O D SO D O OS DIO ALO ODO D O FLO Ol OD OD O O Alo gt lt gt lt gt lt x gt lt gt lt Linear Transducer Eject eo Pressure Transducer Clamp X Pressure Transducer Injection Pej X Pressure Transducer Ejectors 0 X If your application does not have this feature you can m additional ladder logic that is not included in this manual If your application uses limit switches for ejectors the lin linear transducer ake this feature optional instead of required However to do so you need to write ear transducer is not required If y
195. les The baseline Pro Set 200 ladder logic accommodates a maximum Pro Set 200 system A standard system includes injection clamp and eject phases with the following e 6 profiles in the injection phase e 6 profiles in the clamp phase e 3 profiles in the eject phase If your application has less than three phases and or profiles modify the ladder logic in file 3 to decrease the number of phases and or profiles Publication 6500 UM001A US P November 1999 Profile is D M33 Word 0 of the Setpoint Block 0000 0000 0000 0001 bit 0 Profile Type is a ID Word 0 of the Setpoint Block 0000 0000 0000 0010 bit 1 Configuring Pro Set 200 Profiles 8 7 Turning Profiles On or Off Use this field to turn profiles on or off To k enable profiles setbit0 1 select gt PA disable profiles set bit0 0 select gt E23 Turn profiles off when you are not going to use a profile For example if you are not going to use the pack profile go from injection to hold turn the profiles bit to 0 for the pack profile Selecting Velocity or Pressure Profile Use this selection to tell Pro Set 200 that the profile is either a velocity or pressure profile In a velocity profile Pro Set 200 controls the velocity closed loop and uses open loop control on pressure Use velocity for profiles that use motion such as injection In a pressure profile Pro Set
196. lock B101 looks like this B101 5 2 0000 0000 0000 0000 AFTER your core sequence has been executed the ee ans the the dynamic phase permit B101 5 2 0000 0000 0000 0100 Publication 6500 UM001A US P November 1999 Direction of Profile Position D_E Word 0 of the Setpoint Block 0000 a 0000 0000 bit 10 Configuring Pro Set 200 Profiles 8 19 You can selectively suspend the motion of a phase by using the resume bit For instance if you want the phase to stop if some event did not occur but wanted the phase to continue if the event did occur program the resume bit off until the event occurs If the event occurs before reaching the suspend profile position turn the resume bit on and the phase will not stop at the interrupt position but will continue moving Selecting the Direction of the Profile Position Use this field to tell the SLC 5 04P processor whether to expect an increasing position profile or a decreasing position profile For example the injection profile is a decreasing position profile because the profile begins at a larger injection position and moves towards the injection zero point The plastication profile is an increasing position profile because as the screw rotates the position increases until shot size is reached The following table shows typical position values Profile Expected Position Profile Expected Position Value Value Injection decreasing Tonnage d
197. lock To i 0000 0000 1000 0000 p Ese bit 7 turn on ramps set bit7 1 select gt Rey turn off ramps set bit7 0 select gt 3 Publication 6500 UM001A US P November 1999 Configuring Pro Set 200 Profiles 8 13 Ramps are DERA and Coordinated gt tg Coordinating Ramps The following diagram shows the difference between coordinated and uncoordinated ramps Uncoordinated Ramps Coordinated Ramps psi psi i Velocity Velocity EO DNN With uncoordinated ramping psi and With coordinated ramps ER C2 picks the velocity setpoints may end ramps at ramp rate of the primary controlled variable different times and applies it to both outputs This selector allows the ramps for both the pressure and the velocity valve to end at the same time regardless of the amount of ramp rates applied to each control variable If during the profile the pressure valve has a longer ramp than that of the velocity valve both outputs are coordinated to reach the end of the ramp at the same time Word 0 of the Setpoint Block To lS 0010 0000 0000 0000 2 L 7 BEBES sae bit 13 coordinate ramps set bit 13 1 select gt ON use independent ramps Set bit 13 0 select gt Ra Publication 6500 UM001A US P November 1999 8 14 Configuring Pro Set 200 Profiles Link Profile gt GEMS to Profile Number G Word 0 of the Setpoint Block 0000 0001 000
198. luding the ability to read the hydraulic diagrams for your injection molding machine Contact your local Allen Bradley representative for more information about available training courses concerning Allen Bradley products Publication 6500 UM001A US P November 1999 1 2 Pro Set 200 System Quick Start Project Planning Publication 6500 UM001A US P November 1999 Project planning is absolutely necessary for a successful installation of Pro Set 200 and cannot be overemphasized Although details concerning the installation will vary from customer to customer there are three main areas of the project plan that will remain the same You will need qualified expertise in the areas of electrical engineering hydraulic engineering and mechanical engineering The following sections address these main project areas in limited detail and are designed to be a starting point for you to create a detailed project plan If you are lacking expertise in any of the following areas we suggest that you hire a qualified consultant Electrical Components of the Project Plan Hydraulic Components of the Project Plan Mechanical Components of the Project Plan Other Project Plan Considerations Pro Set 200 System Quick Start 1 3 For the electrical components of your project plan you will need personnel capable of accomplishing the following Reviewing existing electrical schematics of your injection molding machine Developing new electrical
199. ly configure molding profiles you must understand the injection molding process This diagram helps you understand the four main phases of the injection molding process e clamp close e inject e clamp open Clamp Close Ejector retract Ejector forward e eject Tonnage Camp LPMP Typical Hydraulic Clamp Clamp Close Clamp Low Hold ae Phase On e Eject Inject Pre decompression Phase Pack Phase y y Plastication Hold Clamp y Open Post decompression Phase P Clamp Open Clamp pai Tonnage can vary between toggle and hydraulic machines For this hydraulic example tonnage is held until the clamp low hold profile is permitted The difference between toggle tonnage and hydraulic tonnage is outlined later in this chapter Publication 6500 UM001A US P November 1999 3 2 Introduction to the Injection Molding Process Publication 6500 UM001A US P November 1999 Clamp Close During the clamp close phase the clamping cylinder pushes the moving platen toward the stationary platen to close the mold A A Clamp 4 Moving Stationary Cylinder Platen Platen Yt Inject During the inject phase the injection ram advances to shoot plastic into the mold cavity pressurizes it to fill any voids pack and holds pressure as the part cools Mo
200. m e lets you control and monitor the injection molding process e lets you set up the control system to match your machine e lets you monitor machine capability e lets you perform general machine diagnostics The SLC 5 04P processor contains enhanced firmware that controls an injection molding machine The molding sequence is configured and controlled by placing machine configuration and operation data in the SLC 5 04P data table This data is written to the data table from the ladder logic and operator interface The following tables outline the features of Pro Set 200 What is ERC2 Expert Response Compensation ERC2 is a model predictive control algorithm for control of pressure and flow loops injection clamp and ejectors It e eliminates the need to manually tune the pressure and flow loops for the clamp and injection units e minimizes overshoot and steady state error e provides comprehensive control over pressure and velocity profiles e provides machine performance metrics The ERC2 algorithms are embedded in the SLC 5 04P processor and are part of the operating system ERC2 algorithms receive data in the form of pressure and position information from the ladder logic included in Pro Set 200 This information is used to calculate new output values pressure and flow Publication 6500 UM001A US P November 1999 2 2 System Overview The data that the ERC2 uses comes from the data table in the SLC 5 04P processor
201. manual mode differently than semi or full automatic mode Ladder Logic Modifications 3 Valve Variation C Injection Clamp Functions Functions Ejector Functions At Tonnage Customizing Your System 6 31 MOV V Clamp Inject Functions Functions y Ejector Functions At Tonnage N102 01 Injection Velocity Valve V2 MOV ERC2 Injection Velocity Output ERC2 Injection N102 02 F Pressure Output System Pressure Valve MOV System Velocity Valve Setpoint During Injection System Velocity Valve V1 OV V Vou must create the setpoint to send to the injection velocity valve during clamp Ejector Functions y Clamp Functions my Injection Functions N102 03 System Velocity Valve V1 OV N102 04 System Pressure Valve OV e lnjection Velocity Valve Setpoint During Clamp Injection Velocity Valve V2 MOV A You must create the setpoint to send to the inject velocity valve during eject y N102 05 System Velocity Valve V1 MOV N102 06 System Pressure Valve MOV ERC2 Clamp Velocity Output ERC2 Clamp Pressure Output ERC2 Ejector Velocity Output ERC2 Ejector Pressure Output A Inject Velocity Valve Setpoint During Ejection Inject Velocity Valve V2 Publication 6500 UM001A US P November
202. module 2 gt File 95 optional file that you can remove if you don t have any zones 5 8 gt File 4 Alarm logic gt File 93 Alarm setup gt File 6 Machine mode logic manual mode auto mode semi auto mode gt File 10 Zeroing injection File 13 Zeroing clamp gt File 16 __ Zeroing eject Permissive pointer contains cia 14 Injection and File 11 J File 7 J SRs to other files gt i plastication permissives File 14 Clamp permissives gt File 23 Controls Production Monitor screens gt File 17 Plate ejector permissives gt File 99 Controls PV screens 101 113 gt File 19 Core Permissives configuration screens gt File 91 Controls screens 301 310 setup screens gt File 96 BTM configuration screens 201 213 gt File 97 BTM auto tune zones 1 4 gt File 98 BTM auto tune zones 5 8 gt File 99 BTM M1 M0 file up downloading gt File 18 Quick tune file gt File 22 Complete Bit Test gt File 21 Plastication Deadtime Delay Code Vv EE Publication 6500 UM001A US P November 1999 Customizing Your System 6 3 Pro Set 200 ladder logic also makes use of an STI file This STI file file 8 is used to control the operation of the clamp injection and ejector logic as well as the ERC2 algorithms The STI file interrupts the main ladder program logic every 10 milliseconds conditional bit gt File 9 Inject STI
203. more packets which need to be sent over the DH485 link the longer the time required to update a screen The following are some suggestions for reducing the number of packets which must be sent These suggestions apply to read only data data which is read from the SLC objects such as multistate indicators message displays numeric data displays and bar graphs Scanning Control Tags Tags fall into two different categories e those that are constantly scanned such as control tags in the Terminal Setup Dialog e those that are scanned only when needed such as when a screen is displayed Any control tag assigned in terminal setup is scanned no matter what screen is being displayed which requires additional DH485 packet s If you do not need the control tags in terminal setup do not assign tag addresses to them Minimizing the Number of Data Packets A packet can have only 40 words of data In order to minimize the number of packets the 40 words must be contiguous and in the same scan class By contiguous we mean that they must be consecutive words in the same SLC data table file For example N7 0 N7 39 is a contiguous packet of data In this case only 1 packet of data needs to be sent provided that all of the data is in the same scan class Panel View terminals provide 9 different scan classes However those scan classes can be reduced to 3 major groups Group Update Rate Update Frequency scan classes 1 2 a
204. municate to the SLC 5 04P controller Personal Computer PanelBuilder Serial Port a COM or COM2 Node 2 PanelView 900 RS 232 Terminal Node 1 Catalog No 2711 K9A9 or 2711 K9C9 SLC 5 04P Controller ani fF Cable Catalog No 2711 NC13 Catalog No 2711 NC14 Catalog No 2706 NC13 To channel 0 roy The same cable is used for transferring applications to the terminal and for connecting the terminal to the SLC5 04P Controller After downloading the application disconnect the cable from the computer and connect to Channel 0 20917 M Portof SLC 5 04P a For more information about connecting a Panel View 900 terminal to the programming terminal see PanelBuilder PanelView 900 Operator Terminal Getting Started Guide publication a number 2711 6 2 Publication 6500 UM001A US P November 1999 Pro Set 200 Function Key Legend Kits PV550 Function Key Legend Kit Catalog No 6500 PS2LBL5 4 13 The following describes the function key legend kits that are available for the PanelView 550 and Panel View 900 keypad terminals These legend kits contain e a set of preprinted labels e aset of blank labels Using the blank labels you can create your own custom labels for the function keys on these terminals and then use them to identify keys associated with scre
205. n during the profile e g plastication the performance of this profile set bit5 0 select gt FAE This is the preferred method if there is no motion during the profile e g clamp tonnage Publication 6500 UM001A US P November 1999 8 22 Configuring Pro Set 200 Profiles 4 n I If Ru se PS arned during Deadhead Word 0 of the Setpoint Block 0000 0000 0400 0000 bit 6 Publication 6500 UM001A US P November 1999 pat toy Eonar ee hee Demm Selecting a Pressure Value Source for Velocity Profiles e Use this selector for velocity profiles to determine how the pressure output will be calculated To control the pressure valve based on the values learned during the deadheaded condition 1 H H FEE oe i eal _ ESEEE oS set bit0 1 select p gt PREETI If you are running a velocity profile and you want the pressure valve to be set to a value that was derived by Pro Set 200 during a deadheaded profile then set the selector to this option The SLC 5 04P processor applies a voltage to the pressure valve that reflects what the processor has learned during a deadheaded profile CV Max set bit 0 0 select D gt ESA AS If you are running a velocity profile and you want the pressure valve set based on the min max settings you have defined then set the selector to this option The output to the pressure valve will be based on the
206. n tdri Kaa PIMC MMNG Stepe Gewese ceed ransa di ede ads shew ese 3 Automatic Mode ERC2 Open Loop Test Status Word Corrective Actions Based on Open Loop Status Quick Tune Response And Understanding ERC2 OLT Status Words Learning During Production 2s cis fase bead de te eaddew eee ae Whats NeXt nice boty hd amas ede ek eee teed Publication 6500 UM001A US P November 1999 toc iv Table of Contents Using Mold Part Recipes Chapter 13 What s in This Chapter 0 cece cece cette teens Understanding Mold Part Recipe Storage in Pro Set200 Naming Mold Part Recipes cc cece eee eee ees Saving and Restoring Mold Part Recipes cece eens Increasing the Number of Mold Part Recipes Whats NEXE niiit a montaia td aia a aa Mated irae Sane aah a Using Production Monitor Chapter 14 Screens What s in This Chapter ccc anaa Accessing Production Monitor Screens n a Using Production Monitor Screen l a naaa Using Production Monitor Screen 2 cece eee ees Using Production Monitor Screen 3 cc cece eee ees Using Production MonitorScreen4 1 cc cece eee eee ees Using Production Monitor Screen 5 aaa cece eee eee ee ees Status MICHIONG peana kaea bed REE ae eases eve nies Whats Next cecs vee ueas asepe bars wees ue same wea ee Using Alarms to Appendix A Troubleshoot Your System What s in This Appendix cccccceeeeeeeueeeeeeeees Alarm Noe etre d
207. na eiia enn Data Handling Instructions aoaaa aaa Program FIOW INStuUCtONS cieri id wadwpdd edad wbaed Application Specific Instructions ccc cece Communication Instructions ccc eects Proportional Integral Derivative Instruction 0ee uae ASCIMINSIUCHONS saisan d addin deuaa canera aa ai eens Appendix D What s in This Appendix D 1 Specialized Hydraulic Diagrams 0 0 cc eve eee eee D 2 Appendix E Whats in This ADpendiIX acct dimiveitupwney odes epee ata Using Internal Trigger Setpoints cece cece ee ees Using the Internal Position Mask cece eects Setting the Internal Trigger Mask Position Setpoint Setting the Internal Pressure Over Under Bit 00 Using External Trigger Setpoints ccc cece eee ees Setting External Velocity Trigger Setpoints Setting the External Velocity Over Under Bit Setting External Pressure Trigger Setpoints Setting the External Pressure Over UnderBit 005 Setting External Time Trigger Setpoints 004 Appendix F What s in This Appendix 0 0 0 cc cece cece eevee een How Do Segment Active Segment Complete Profile Active and Profile Done Bits Work sas kana wtasece gm 4b de deihe eho Ore bot aoe Segment Complete BMS 2a cicaciaadandarcavsadeeues ncbae Injection Pack HOW Bar Chant tensed teees ivedudekeeewdas Pre Decompress Plasticate and
208. nal velocity less than or under or equal to the external trigger velocity to trigger to the next profile e or over operation external velocity greater than or over or equal to the external trigger velocity to trigger to the next profile To set the external velocity trigger to i4 lt under set bit9 1 gt over setbit9 0 Publication 6500 UM001A US P November 1999 E 6 Using Internal and External Trigger Setpoints Word 1 of the Setpoint Block 0000 0000 0100 0000 bit 6 Word 1 of the Setpoint Block 0000 T 0000 0000 bit 10 Word 1 of the Setpoint Block 0000 0000 1000 0000 bit 7 Publication 6500 UM001A US P November 1999 Setting External Pressure Trigger Setpoints Use this field to enable or disable the external pressure trigger setpoint To ma M a H enable the external pressure trigger setpoint setbit6 1 disable the external pressure trigger setpoint setbit6 0 Setting the External Pressure Over Under Bit When using external pressure trigger setpoints you must indicate whether you want the actual pressure to be an e under operation external pressure less than or under the external trigger pressure to trigger to the next profile or over operation external pressure greater than or over the external trigger pressure to trigger to the next profile The internal pressure over under example on page E 4 illust
209. ncrement to a large specified percentage typical 90 to 95 Setpoint A preset targeted machine parameter such as velocity acceleration pressure change rate etc that serves as the benchmark for ERC2 Setting Time The time required following the detection of a specified stimulus to a system for the output to enter and remain within a specified narrow band centered about its steady state value Shot Size Length the injection screw travels to load the next shot of plastic cushion NOT included Shot Size 100 Length including cushion that the injection screw travels to load the next shot of plastic Segment A pair of velocity and pressure setpoints which comprise an increment Multiple segments make up a profile Time Constant The time required to complete 63 of the total rise or decay at any step of the process Tip Strokes Optional ejector strokes to dislodge a part after first ejector advance and before last retract Glossary G 5 Timed Proportional Output TPO The control variable output of each loops is sent from the 1746 BTM module to the SLC data table as the duty cycle of a bit that is cycled at a regular period We call this bit a time proportioned output TPO bit The ladder logic can send this signal to a digital output module to generate the control variable output signal to the temperature control actuator X On Time X y Bury eyele y Y TPO Period id On
210. nd psi 2 are active until the ejector pins fully retract full fwd stop First Full Advance eject forward a Tip Retract xx xx Tip Advance p Tip Retract XX XX psil i ai xxxx a Last Retract lt Tip Strokes Vel 2 When the tip stroke cycle is Full Back Full Forward xx xx complete and it is time to psi 2 fully retract the ejector these XXX x positions velocities and pressures are active In the next chapter we explain how to set up the hardware for your Pro Set 200 system Publication 6500 UM001A US P November 1999 What s in This Chapter Compliance to European Union Directives Chapter Al Setting Up the Hardware This chapter explains how to set up the hardware for your Pro Set 200 system It tells you how to e determine the modules position in the I O chassis e ground the chassis e install the power supply e install the SLC 5 04P processor e install the I O modules e connect the programming terminal to the SLC 5 04P processor e connect the PanelView terminal to the programming terminal e wire the I O modules e configure the rack e configure the power supply e configure the I O modules If this product has the CE mark it is approved for installation within the European Union and EEA regions It has been designed and tested to meet the following directives EMC Directive This produ
211. nd3 high updated on every pass of the scanner scan classes 4 5 and6 medium updated on every other pass of the scanner scan classes 7 8 and9 low updated on every fourth pass of the scanner In order to minimize the number of packets make sure the data is in the same scan class and in the same group of 40 words For example in order to minimize the number of packets to one packet of data put all of the data in the file range N7 0 N7 39 and put that file range in scan class 1 2 or 3 Publication 6500 UM001A US P November 1999 6 40 Customizing Your System What s Next Publication 6500 UM001A US P November 1999 Setting the Maximum Node Address In general you should set the maximum node address configured on the terminal address screen to the lowest number possible We recommend you set it at the maximum node address of any device present on the DH485 network For example assign node address one to the SLC 5 04 P processor and node 2 to the Panel View terminal Recommendations Important Keep in mind the following when modifying Panel View screens e Don t reuse the tag names e Create a pva file that is not uploadable to conserve PanelView memory Do this by adding the following lines after the upload section in the PB550 ini file and be careful to type in correct case as shown upload UploadableApp 0 e Do not change addresses tag names because they are used extensively within the Pro Set 200
212. ne all loops simultaneously when auto tuning is enabled The ladder logic driving the BTM auto tune routine requires that you enable all zones on a module 2 Use the F2 key to abort autotuning for all loops that have auto tuning enabled 3 Use the F3 key to reset all error codes to zero 4 Use the F4 key to reset the ladder logic controlling auto tuning first abort auto tuning with the F2 key Determine whether e the M1 file is valid 5 e parameter errors are present You must have a valid M1 file and no errors present to start auto tuning 6 Determine that auto tuning is complete for each zone 7 Determine that auto tuning was successful for each zone 8 View error codes for each zone When you have fixed an error clear the error code by pressing F3 then download the M1 file There must be no errors to start auto tuning F7 until Press y you aa Auto Tune NO oo es Fl Auto Tune F Abort Auto Tune F3 Reset Error Codes Fd Reset Auto Tune 4 og 35 O F g a Valid Mi File Yes Yes Yes Yes Le Parameter Error No No No No Tune Complete Yes Yes Yes Yes 1 16 Tune Successful Yes Yes Yes Yes Error Code HH GREH GH GHH a C Press F7 To Advance Sereen J Use this field To 1 Use the F1 key to auto tune all loops simultaneously when auto tuning is enabled The ladder logic driving the BTM auto tune routine requires that you enable all zones on a module 2 Use the F2 key to abort autotuning for all loops that have auto tuni
213. ne finish packing plastic into the mold by filling any voids left after the injection phase Pack can be thought of as a final fill phase Pro Set 200 controls the pack profile with a pressure vs time or velocity vs position profile You can control either the hydraulic pressure against the ram or e pack velocity In most typical applications after the last segment of the pack profile is complete Pro Set 200 automatically begins the hold phase Hold Profile The hold profile maintains pressure on the plastic as the part cools You should adjust the pressure so that e the ram does not continue to fill the part or e the ram does not back up You can use the hold profile to hold enough pressure on the plastic to allow the part to cure do not use the hold profile to fill the part If the ram does not have enough pressure during this segment the ram will bounce backwards and cause possible shrinkage or sinks in the parts You can hold at predetermined pressures and times throughout the hold profile Pro Set 200 controls the hold profile with a pressure vs time segment You can control the hydraulic pressure against the ram Typically after the last segment of the hold profile is complete you can program the SLC 5 04P processor so that it automatically e starts the optional pre decompression movement e skips the pre decompression movement if none is required e starts the plastication profile immediately or
214. ne to go into the next profile as defined by the Link Profile Word word 2 of the setpoint block Trigger setpoints are available for all profiles of the clamp inject and eject phases and may be position pressure or time triggers There are two types of trigger setpoints Type of trigger setpoint Definition internal The position pressure or time supplied by a sensor This sensor is physically located on or attached to the axis which is being controlled for example inject position external The position pressure or time supplied by an external sensor This sensor is not directly attached or connected to the axis For example a mold cavity pressure transducer physically located inside the mold is an external triggering device If several trigger setpoints are enabled at the same time whichever trigger setpoint is reached first causes the machine to go to the next profile Trigger setpoints are commonly used to transfer from the injection profile to the pack profile or from the pack profile to the hold profile Other applications include those that use external sensors such as mold cavity pressure transducers There are three types of internal trigger setpoints They are e position pressure e time When an internal trigger is reached it forces the current profile to go to the next linked profile Publication 6500 UM001A US P November 1999 E 2 Using Internal and External Trigger Setpoints Injection Se
215. ng enabled 3 Use the F3 key to reset all error codes to zero 4 Use the F4 key to reset the ladder logic controlling auto tuning first abort auto tuning with the F2 key Use the F5 key to save configured zones Use the F6 key to return to the zone and channel configuration screen Determine whether 5 e the M1 file is valid e parameter errors are present You must have a valid M1 file and no errors present to start auto tuning 6 Determine that auto tuning is complete for each zone Publication 6500 UM001A US P November 1999 9 20 Using Barrel Temperature Modules BTM Use this field To 7 Determine that auto tuning was successful for each zone 8 View error codes for each zone When you have fixed an error clear the error code by pressing F3 then download the M1 file There must be no errors to start auto tuning Temperature Zone Control and Monitoring until you see Sees Temperature Control Temperatures al 22 ad a4 Temp F OHHH H OHHH H GRH HO OHHH H CurrSP GHEHE H GHH OGHHEHH HO OHHH H Run SP EFF A EET N GER EERE EH EA EET Dey CU 4 mr er HHRH HH ne ail Man DFH H cal LRH ER AERE HH BRRR HE C te FR pa Ea p pi a ANANAS Use this field To 1 View the actual temperature for zones 1 4 2 View the current run time or stand by setpoint View or modify the run setpoint 1 Cursor to this field by using the left and right arrow keys 2 Press th
216. nt 1 Segment 1 Segment 2 Segment 2 Segment 3 Segment 3 Active Bit Comp Bit Active Bit Comp Bit Active Bit Comp Bit Active Bit Comp Bit B106 208 B106 13 00 B106 224 B106 14 00 B106 272 B106 17 00 B106 288 B106 18 00 B106 273 B106 17 01 B106 289 B106 18 01 B106 274 B106 17 02 B106 289 B106 18 02 Pre Decompress Phase Active Bit B106 223 B106 13 15 B106 239 Pre Decompress Profile Done B106 14 15 B 106 287 Plastication Profile Active B106 17 15 Velocity N121 30 N125 30 N125 38 N125 46 Setpoint Pressure N121 31 N125 31 N125 39 N125 47 Setpoint Position N121 32 N125 32 N125 40 N125 48 Setpoint Time N121 33 N125 33 N125 41 N125 49 Setpoint Publication 6500 UM001A US P November 1999 Using Profile Status and Complete Bits F 7 Plasticate Plasticate Plasticate Plasticate Post Decomp Post Decomp Segment 4 Segment 4 Segment 5 Segment 5 Segment 1 Segment 1 Active Bit Comp Bit Active Bit Comp Bit Active Bit Comp Bit B106 275 B106 17 03 B106 290 B106 18 03 B106 276 B106 17 04 B106 291 B106 18 04 B106 336 B106 21 00 B106 292 B106 22 00 B106 303 Plastication Profile Done B106 18 15 Post Decompress Profile Active B106 351 B106 21 15 B106 367 Post Decomp Profile Done B106 22 25 N125 54 N125 62 N129 30 N125 55 N125 63 N129 31 N125 56 N125 64 N129 32 N125 57 N125 65 N129 33 Publication 6500
217. nts Pos Input P2 37 AT Counts 3 A Type Current Counts G6 PSI Input Pi TR A T HF Counts PSI Input P2 oza T OHF o Jolt o Counts PS eee Min DE AT ett FSI Output Max AT 17 om V Press Fl a Bianc oe Sereens i Understanding SLC 5 04P Processor Addresses B 19 This Is located This Is located field in field in 1 N83 22 9 N83 28 2 N83 23 10 N83 29 3 N83 13 03 11 N149 06 4 N83 24 12 N169 06 5 N83 25 13 N149 07 6 N83 26 14 N169 07 7 N83 27 15 N83 30 8 N83 13 04 This field Is located in 1 N83 17 Velocity Spanning Values Screen 2 es Velocity Spanning Values MinClose 1 R IN SEC AT 2 4 8 Oru IN SEC AT Gurus 3 Ee Mindpen 6 IN SEC e ne MaxOpen 9 IN SEC aT cE Wolts Close Jog 3 Vel HERF Wel LFF PSI 13 3H PSI Man Yel ot In See Ka Press Fl to Advance Clamp Screens Tonnage Sensing Selection Screen iz Tonnage Sensing Selection gt LE nans ducer by Pres W1 By aie Suiteh nae Toggle By Position If you select Tonnage beta by anotan but 3 pressure transducer Clamp Low Hol and Decompress ae Ee Setup as a time rofile Press Fl to Advance Clamp Screens A Publication 6500 UM001A US P November 1999 20 B Understanding SLC 5 04P Processor Addresses This Is located This Is located field in fie
218. o UP Part Storage 0 Production Monitor ro Jon o Velocity CU K1OHHH Inisi D r e e Pos G18 HH In Press B ii CU 20 HH Press Fg jon Pressure CU GLH G19 PSI Pressure CU rays To Advance Production Monitor This field Monitors this The mode of the machine setup manual semi auto or full auto Shows the status of the clamp close profile Shows the status of the clamp LPMP profile Shows the status of the clamp tonnage profile Shows the status of the clamp low hold Shows the status of the clamp decompress Shows the status of the clamp open Shows the current position of the clamp phase Wy CO MI l OT A WW NI Fe Shows the current pressure of the clamp phase m Shows the current velocity CV for clamp in counts m pan Shows the current pressure CV for clamp in counts Publication 6500 UM001A US P November 1999 14 6 Using Production Monitor Screens This field Monitors this 12 Shows the status of the injection profile 13 Shows the status of the pack profile 14 Shows the status of the hold profile 15 Shows the status of the pre decompress profile 16 Shows the status of the plastication profile 17 Shows the status of the post decompress profile 18 Shows the current position of injection phase 19 Shows the current pressure of injecti
219. o not want to link to the set bit 8 0 select gt FGM next profile The out of the box factory defaults for profile linking are Injection Clamp Close Pack Low Pressure Mold Protect Hold Tonnage Configuring Pro Set 200 Profiles 8 15 You can link other profiles together if your application requires it The profile link words are located in the setpoint block for each profile The following table shows the data table locations and default values for the link profile word Profile Data Table Comments Location Injection N109 2 Default value 0000 0000 0000 0010 Pack bit permissive pattern as in B101 1 Pack N113 2 Default value 0000 0000 0000 0100 Hold bit permissive pattern as in B101 1 Hold N117 2 Pre Decompress N121 2 Plastication N125 2 Post Decompress N129 2 Clamp Close N149 2 Default value 0000 0000 0000 0010 Clamp LPMP bit permissive pattern as in B101 4 Clamp LPMP N153 2 Default value 0000 0000 0000 0100 Clamp Tonnage bit permissive pattern as in B101 4 Clamp Tonnage N157 2 Clamp Low hold N161 2 Clamp Decompress N165 2 Clamp Open N169 2 gt Notice that the link profile bit pattern is the same pattern found in B101 permissive block Injection Phase Link Pattern Table Injection 0000 0000 0000 0001 Pack 0000 0000 0000 0010 Hold o000 0000 0000 0100 Pre Decompress 0000 0000 0000 1000 Profi
220. o velocity control is not linear you can t double the pressure setting and expect double the velocity Also when the relief valve setting is increased as a means of increasing velocity once the cylinder has stopped moving the psi relief valve may be set to high for your application To put it simply the pressure relief valve is incapable of simultaneously controlling velocity and effectively regulating system pressure The most reliable and effective way to increase cylinder velocity is to increase the flow to the cylinder through the use of a flow control valve located between the cylinder and the relief valve Increasing the flow to the cylinder by adjusting the flow control valve will increase cylinder velocity as long as there is enough pressure to overcome the load This is the preferred method for adjusting the velocity of the cylinder Controlling velocity with a flow control valve is preferred because the characteristic of flow is usually more linear which results in better control characteristics In addition using the flow control valve to regulate velocity allows the relief valve to safely regulate system pressure Understanding Relief Figure 7 7 analyzes a moving cylinder Valve Settings and How They Affect Flow Rates Figure 7 7 Moving Cylinder Example Injection Cylinder Gauge 2 Not Moving 200 PSI lt Gauge 1 Relief Valve Set at 500 PSI Flow A NE Control ad Pressure Differential
221. ocessor Addresses This Is located This Is located field in field in 1 N94 05 14 N94 37 2 N94 30 15 N94 62 3 N94 55 16 N94 87 4 N94 80 17 N94 13 5 N96 48 01 18 N94 38 6 N96 48 02 19 N94 63 7 N96 48 03 20 N94 88 8 N96 48 04 21 N94 14 9 N94 11 22 N94 39 10 N94 36 23 N94 64 11 N94 61 24 N94 89 12 N94 86 25 N97 50 13 N94 12 This field N80 00 Is located in 80 05 N80 00 80 10 N80 07 80 11 1 2 3 4 5 6 7 Publication 6500 UM001A US P November 1999 N80 06 Temperature Control Screen 4 fa Stand By SP Select Temperature Control 2g Low Production Monitor Screen 1 Production Monitor 2 Dup Cycle Counter G2 iH Cyole Time 3 HH Seconds Largest COR Idle Time g5 HH Seconds Largest g6 HH Q e Counter et Largest Cycle ime Reset Largest Idle Time Press F3 To Advance Production Monitor This field Is located in N80 09 N80 01 N80 08 N80 03 N125 18 N126 00 1 2 3 4 5 6 7 N80 04 Understanding SLC 5 04P Processor Addresses B 11 Production Monitor Screen 2 or Production Monitor Injection Time G2 HH Seconds Transfer To Pack On Position G3 HH Cure Time g4 HH Seconds Shot Size Sp 5 Shot Size Act G6 Overall Clamp Time amp 7 4 Seconds Press F3 To
222. ofile No No No No Yes Suspend profile No yes No No No Direction of profile ncrease Decrease Decrease Decrease Increase Use Learned CV Max on primary controlled Learned Learned Learned variable If psi is selected variable then Learn psi use Learn Learn Learn Deadhead If velocity is selected variable then Run psi as CV Max CV Max CV Max CV Max Use Deadhead psi Eject Phase Your Selections Selector Eject Forward Eject Retract Eject Tip Stroke Profile of On Active profile is velocity psi Profile in Auto Of Manual Ramps off 0n Ramps coordinated No Yes Link to another profile No Yes Suspend profile No yes Direction of profile Decrease Increase Use Learned CV Max on primary controlled variable If psi is selected variable then Learn psi use Deadhead If velocity is selected variable then Run psi as SCV Max Use Deadhead psi Publication 6500 U 001A US P November 1999 8 28 F1 until For clamp E T you see press GOOT Clamp Close For other profiles press F2 through F5 until F6 For ejectors you See pi Ejectors gt In this field Configuring Pro Set 200 Profiles Setting Ramp Rates Once you have completed configuring your profiles you may set up ramp rates To go to a profile s ramp rate setup screen press the function key of the profile ramp rate you want to configure We show the in
223. oise Conditions 5 2 mm2 10 AWG ff to Ground Bus a Mounting Tab Chassis mee 0 or 12 aoe Size M4 or M5 A or Lug Ize or T 10 or 12 Size M4 or M5 i rails a y i A l 10 or 12 Size M4 or M5 a Internal Star 10 or 12 Washer gt lt Internal Star Washers lt gt gt lt P Tapped Hole 2 N Minimum of Three AN Tapped Hole Threads Minimum of Three Threads Scrape paint off panel to insure Metal Panel electrical connection between Must be connected to Scrape paint off panel to insure Metal Panel chassis earth ground electrical connection between chassis Must be connected to and grounded metal panel and grounded metal panel earth ground a For more information about grounding the chassis see the SLC 500 Modular Hardware Style Installation and Operation Manual publication number 1747 6 2 f Ayas Publication 6500 UM001A US P November 1999 Setting Up the Hardware 4 5 Running Ground Connections This figure shows you how to run ground connections from the chassis to the ground bus Two acceptable grounding methods are shown we recommend using a ground bus because it reduces the electrical resistance at the connection 77 a Earth Ground 5 2 mm 10 AWG A 2 mm 14 AWG 2 mm
224. on of Profile Position 10MH off Select whether ramps Press FS to Advance to Hest Soreen are coordinated zi 6 Select whether to link to another profile CT Set link profile identification Use suspend profile Set the position at which to suspend profile Set the direction of profile position until Press are YOUSEE a o Profile Selecte gt SE e Profite ee Use Learned or 4CUMay Velocity Ea Select learned or if Fregeyre Profile phen earn uring Profile or CV Max Use PSI learned during CH Deadhead Selecta pressure valve source for pressure If Velocity Profile then profiles Run PSI as CUMAK or Use PSI Learned during Deadhead Selecta pressure valve source for velocity profiles ke Press F8 to Advance to Hent Sereen P V Configure deviation alarm limits Publication 6500 UM001A US P November 1999 1 8 Pro Set 200 System Quick Start Mm Configure the Barrel Temperature Module BTM Reference V Configure the BTM for use Chapter 9 Using Barrel Temperature Modules Age Start Up the Machine e V Load the Pro Set 200 setup screens ps2s102 ae i ee in V Starting with the clamp phase go to the setup screens for each phase Me scans and enter values that tell the SLC processor the following valve parameters e pressure nameplate max values for the valves e whether the output signal is in volts dc or mA e maximum velocity values for outputs to eac
225. on phase 20 Shows the current velocity CV for injection in counts 21 Shows the current pressure CV for injection in counts Using Production Monitor Screen 5 Press FQ until L Part Storage There are seven status indicators Depending on the state of the profile the indicator will appear differently See following status indicator descriptions atthe end of this chapter Dur Pos eee 2 4 Eisotion g5 In Press K6 PSI Velocity CU G7 HHH Production Monitor Pressure CW G8 HHH Press F3 To Return To Production Menu This field Monitors this he mode of the machine setup manual semi auto or full auto Shows the status of the eject forward profile Shows the status of the eject retract profile Shows the status of the eject tip stroke profile Shows current position of ejection phase Shows current pressure of ejection phase Publication 6500 UM001A US P November 1999 Nyi OH al By WW NI FR Shows current velocity CV for ejection in counts Using Production Monitor Screens 14 7 This field Monitors this 8 Shows current pressure CV for ejection in counts There are seven state indicators Depending on the state of the profile the indicator will appear differently See previous status indicator descriptions below Status Indicators The state indicators noted in Production Monitor Screens 4
226. ones 5 8 N213 Spare F214 old Part 2 Vault 1 ERC2 Memory N215 old Part 2 Vault 2 Injection and Pack N216 old Part 2 Vault 3 Hold Pre Plast Post N217 old Part 2 Vault 4 Clamp Close LPMP Tonnage N218 old Part 2 Vault 5 Clamp Low Hold Dec Open 219 old Part 2 Vault 6 Eject File N92 Customer Additions N220 old Part 2 Vault 7 BTM setpoints calibration for Zones 1 4 221 old Part 2 Vault 8 BTM setpoints calibration for Zones 5 8 N222 Spare F223 old Part 3 Vault 1 ERC2 Memory N224 old Part 3 Vault 2 Injection and Pack 225 Mold Part 3 Vault 3 Hold Pre Plast Post N226 old Part 3 Vault 4 Clamp Close LPMP Tonnage 227 old Part 3 Vault 5 Clamp Low Hold Dec Open N228 old Part 3 Vault 6 Eject File N92 Customer Additions 229 old Part 3 Vault 7 BTM setpoints calibration for Zones 1 4 N230 old Part 3 Vault 8 BTM setpoints calibration for Zones 5 8 231 Spare F232 old Part 4 Vault 1 ERC2 Memory N233 old Part 4 Vault 2 Injection and Pack Publication 6500 UM001A US P November 1999 13 2 Using Mold Part Recipes Publication 6500 UM001A US P November 1999 File Mold Part Recipe N234 old Part 4 Vault 3 Hold Pre Plast Post N235 old Part 4 Vault 4 Clamp Close LPMP Tonnage N236 old Part 4 Vault 5 Clamp Low Hold Dec Open N237 old Part 4 Vault 6 Eject File N92 Customer Additions N238 old Part 4 Vault 7 BTM setpoints calibr
227. ons and the hydraulic configuration see the following examples Ladder Logic Modifications 2 Valves Injection Clamp and Ejectors Injection Clamp Ejector ERC2 Injection Functions Functions Functions At Tonnage MOV Velocity Output N102 01 y V Velocity Valve oo Manual Mode ERC2 Injection ip MOV Pressure Output N102 02 Pressure Valve Clamp Injection Ejector ERC2 Clamp Functions Functions Functions AtTonnage MOV Velocity Output N102 03 VA MA Vi Velocity Valve ERC2 Clamp MOV Pressure Output N102 04 Pressure Valve You must prioritize clamp or ejector Ejector Clamp Injection E RC2 Ejector functions i e clamp velocity is Functions Functions Functions MOV Velocity Output more important than eject N102 05 V y Velocity Valve ERC2 Ejector MOV Pressure Output N102 06 Publication 6500 UM001A US P November 1999 Pressure Valve Customizing Your System 6 25 Conceptual Model of 2 Valves Injection Clamp and Ejector Injection Clamp Ejector N Manual Pressure Valve Ny N and or Directional Control N Electronically Adjustable Velocity Valve ly d Electronically Adjustable System Relief Valve psi e L L Tank M This conceptual model is intended to be used as an aid in understanding ladder code modifications for the e
228. oo short 1 Check B101 length File Bad 2 Check N100 6 Phase SetPoint File Bad 0xa5 N104 N144 or N184 not 1 Look in N103 to determine if problem is on inject found or too short clamp or eject Create file of correct length 3 Check N100 7 N100 9 N100 11 for correct number of profiles Phase Actuals File Bad Oxa6 N105 N145 or N185 not 1 Look in N103 to determine if problem is on inject found or too short clamp or eject 2 Create file of correct length 3 Check N100 7 N100 9 N100 11 for correct number of profiles Phase Engineering Actuals Oxa7 F107 F147 or F187 not 1 Look in N103 to determine if problem is on inject File Bad found or too short clamp or eject 2 Create file of correct length 3 Check N100 7 N100 9 N100 11 for correct number of profiles Phase ERC2 Memory File Bad 0xa8 F108 F148 or F188 not 1 Look in N103 to determine if problem is on inject found or too short clamp or eject 2 Create file of correct length 3 Check N100 7 N100 9 N100 11 for correct number of profiles Phase Status File Bad 0xa9 B106 B146 or B186 not 1 Look in N103 to determine if problem is on inject found or too short clamp or eject 2 Create file of correct length 3 Check N100 7 N100 9 N100 11 for correct number of profiles Profile SetPoint File Bad Oxaa N109 N113 N117 Profile 1 Look in N103 to determine if problem is on inject Setpoint files not found or clamp or eject too short 2 Use N103 16 N103 29
229. or Phase B101 8 1 2 The profile is re executed This occurs when the machine completes a cycle and starts a new one As the new cycle is Started the segment and profile done bits are reset to zero The segment complete bit is not set if the profile permissive bit is turned off prior to segment completion Profile Active Bits These bits are ON when any segment in the profile is ON For example B106 31 the injection profile active bit is ON when any of the injection segment active bits are ON i e when any of B106 16 B106 17 B106 18 B106 19 or B106 20 is ON See the bar charts for the injection phase for further details Profile Done Bit Publication 6500 UM001A US P November 1999 This bit becomes enabled ON when the last segment complete bit in the profile becomes true For example the Profile Done bit for the injection profile B106 57 is set when B106 36 is set See the bar charts for the injection phase for further details Segment Complete Bits Using Profile Status and Complete Bits F 3 The segment complete bit indicates that a velocity or pressure segment has been executed when set to one ON Figure F 1 Segment Complete Bits for Injection Phase Example 0000 0000 0000 0000 i Injection Segment 1 Complete Bit Reserved Injection Segment 2 Complete Bit Injection Segment 5 Complete Bit Injection Profile Done Bit When this bit is Set it indicates that
230. orward Clamp Yy Open Post decompression Phase Clamp Decompress Tonnage can vary between toggle and hydraulic machines For this hydraulic example tonnage is held until the clamp low hold profile is permitted Publication 6500 UM001A US P November 1999 Introduction to the Injection Molding Process 3 13 Clamp Open Profile The clamp open profile is divided into four segments Profile Description Clamp Open clamp open This profile is made up of four segments a Open Open pes breakaway segment the clamp cylinder moves the platen Fast Break away rom the full close to the open fast position The segment allows you to enter separate pressure and flow valves for the initial opening This is normally set up to open the clamp slowly with enough pressure to break away the mold halves eopen fast segment this segment occurs after the open breakaway segment is complete and is used to save cycle time Once the clamp reaches the open fast position the clamp travels quickly to the open decel position This segment also has separate pressure and flow settings to allow flexibility eopen decel segment during open decel the clamp decelerates to the open slow position Some machines may not require this step eopen slow segment the open slow segment allows the clamp to smoothly move to the full open position
231. oss the valve would be less 500 psi 400 psi 100 psi pressure differential The main point is that flow is related to the pressure differential however it is not a direct relationship You cannot expect to double the pressure and make the cylinder go twice as fast The reason for this can be found in the equation of flow relating to a pressure drop across an orifice Q C A 24P pP Where Q Flow in sec C Orifice discharge coefficient A Area of orifice in AP Pressure drop across the orifice bs in p Density of the fluid passing through the orificelhs sec in Notice that P is buried in a square root function This means that it is not possible to double the pressure and achieve twice the flow Understanding Hydraulic Pressure and Flow Concepts Understanding Load Pressure Concepts The load pressure is the amount of pressure psi required to move the load In an injection molding machine the load pressure is L Concept The load pressure is 200 PSI and will not increase until an additional load is added Concept The load pressure is the amount of pressure to move L the load Concept The pressure measured at the cylinder will not go above the load pressure gt assuming no additional pressure is being applied to the opposite side of the cylinder always changing as the plastic is being pushed into the mold cavity The pressure measured at the inje
232. our ejectors require position feedback you will use a gt If you require power gates you need to write the ladder logic yourself Program file 5 has been set aside for this purpose there is a JSR to file 5 from file 2 that already exists gt You can edit other files to implement custom features in your ladder program Publication 6500 UM001A US P November 1999 6 10 Customizing Your System Using Machine Sequence Bar Charts Publication 6500 UM001A US P November 1999 This section e provides an example that shows how to use the Pro Set 200 ladder logic and the data table with a machine sequence bar chart e shows how to write and modify the Pro Set 200 ladder logic for an injection clamp open and clamp close bar chart This section shows an example of a machine sequence chart Most machine manufacturers provide a sequence chart to show when solenoids should be energized and de energized The example shows typical directional solenoids and proportional signals required for our example machine The SLC code examples show how to modify the code to make the example machine operate as specified in the bar chart Most of these conditions are provided in the I O definition file file 2 of the SLC code All you need to do is substitute the solenoids in place of the dummy ranges as required Getting Started To get started 1 Print a copy of file 2 I O definition file from the Pro Set 200 ladder logic 2 G
233. p Flash EPROMs Flash Erasable Programmable Read Only Memory combine the versatility of EEPROMs with the security of UVPROMs Memory Backup Option Flash SLC 5 04P 1747 L542P 1747 M11 1747 M12 0S401 only The SLC 5 04P processor supports different types of communication options The following sections describe the available physical connections used by the SLC 5 04P processor Data Highway Plus DH channel offers communication rates of 57 6K 115 2K and 230K baud e maximum network length of 3 048 m 10 000 ft e Belden 9463 blue hose cable connection between nodes daisy chain connection e built in isolation Processor Specifications C 3 DH 485 channel offers e communication configure rates up to 19 2K baud e electrical isolation via the 1746 AIC e maximum network length of 1219 m 4 000 ft RS 485 electrical specifications e Belden 9842 cable connection between nodes daisy chain connection RS 232 channel offers e communication rates up to 19 2K baud e maximum distance between devices is 15 24 m 50 ft e RS 232C electrical specifications e modem support e built in isolation The following table summarizes the SLC 5 04P processor channel connections Physical Communication Channel DH 485 RS 232 DH DH 485 DF1 Full Duplex SLC 5 04P Channel 0 NA DF 1 Half Duplex NA Master Slave and ASCII protocols Channel 1 NA NA DH protocol Processor
234. p Clamp Initial Clamp Close Deceleration Low Clamp Solenoid Name Description Close Time Delay for Fast Pressure Tonnage Initial Pump Volume Mold Protect Solenoid A directional Solenoid B pump load Yy gg bidirectional proportional flow valve 0 to 10VDC Solenoid E lt SYYYYY YYW 0 to 10VDC H A A Solenoid A and B These rows show directional control solenoids A and B which are ON for the duration of the clamp close sequence Since the I O definition file does not contain logic which meets these conditions you need to write your own logic There are two methods you can use to meet these control requirements e method 1 use profile active bits e method 2 use individual segment active bits for all segments in a profile Publication 6500 UM001A US P November 1999 Customizing Your System 6 17 Method 1 The following ladder logic shows the technique for using profile active bits for solenoid A and B Clamp Close Profile Active B146 1 Solenoid A T Clamp Directional LS Clamp LPMP Profile Active B146 5 LS Tonnage Profile Active B146 9 LS Clamp Hi Volume Time Delay T4 13 DN The advantage of this method is that the profile active bits remain ON for each segment in the phase Instead of using 3 individual segment active bits to control the clamp close profile i e clamp close initial segment active clamp
235. pace for RSLogix programming software e 7 Megabytes available hard drive space for Pro Set 200 software e 16 Megabytes RAM To install Pro Set 200 software refer to the Installation Instructions publication number 6500 IN001A US P supplied with the Pro Set 200 diskettes In the next chapter we explain how to customize your system What s in This Chapter Understanding Pro Set 200 Ladder Files Chapter 6 Customizing Your System This chapter helps you customize the software for your molding machine It helps you e understand Pro Set 200 ladder files e customize your ladder logic e understand ladder logic use machine sequence bar charts e customize modify PanelView screens ATTENTION This software is a starting point for an injection molding system The user5 must modify the software to comply with any applicable standards governing the final product application Before you begin modifying the Pro Set 200 ladder logic it s important to understand how the ladder files work The figure on the next page shows the relationship of each ladder file in Pro Set 200 Pro Set 200 ladder logic contains code that controls the injection ram clamp and ejectors The ladder logic files contain e machine mode code i e manual semi automatic and full automatic modes e simple machine alarms such as gate opened in cycle plastication short shot To use the supplied ladder logic you must modi
236. page Ladder Logic Modifications 2 Valves Injection and Clamp Conceptual Model of 2 Valves Injection and Clamp Injection Clamp ERC2 Injection Functions Functions At Tonnage Velocity Output N102 01 1 i Velocity Val elocity Valve Manual Mode y ERC2 Pressure I MOV Velocity Output N102 02 Pressure Valve Clamp Injection ERC2 Clamp Functions Functions At Tonnage MOV Velocity Output N102 03 SS Velocity Valve ERC2 Clamp MOV Pressure Output N102 04 Pressure Valve Injection Clamp Ao Manual Pressure Valve av and or Directional Control v Electronically Adjustable pr Velocity Valve Ejector i Manual Pressure Valve Np and or Directional Control v Electronically Adjustable System Relief Valve psi Tank o M This conceptual model is intended to be used as an aid in understanding ladder code modifications for the example scenario It is not a complete hydraulic diagram Publication 6500 UM001A US P November 1999 6 24 Customizing Your System Injection Clamp and Ejectors The following example describes ladder logic modification for a two valve configuration set for injection clamp and eject Understand that for this configuration you must prioritize clamp or ejector functions To help understand the relationship between the ladder logic modificati
237. parameter refer to the 1746 BTM User Manual a N Ho zone Selected i Entia Complete Configuration Download Auto Tune Block Download 0 M HE pels Block Down load Using Barrel Temperature Modules BTM 9 5 Use this field To 1 View the zone number you have selected Select the zone that you want to configure For one BTM you can choose zones 1 through 4 1 through 8 for two BTM modules No Zone Selected is the default 1 Cursor to this field by using the left and right arrow keys lt 3 Selecta number by pressing the up and down arrow keys 4 Press the enter key C when you reach the correct number 5 Press F6 to go to the remaining configuration screens Select the appropriate download or upload Choose from the following M1 Configuration Download MO Auto Tune Block Download MO Gains Block Download MO Auto Tune Block Upload 3 MO Gains Block Upload 1 Cursor to this field by using the left and right arrow keys 3 Select a number by pressing the up and down arrow keys a C 4 Press the enter key when you reach the correct selection When an operation upload or download is complete Operation Complete is highlighted Publication 6500 UM001A US P November 1999 9 6 Using Barrel Temperature Modules BTM until Press fer mse No Zone Selected x Qutput Image Configuration Bits Auto Tuning _ DHM Ramping DEA On On XI Press FE to Advance Soreen
238. ped earn Off ra Step Seen 7 ject F Seg Zk Seg 3 GO Newer Seen Seq 4 Never Seen isa Of Seg 5 131 Successful ject FE Press F3 To Return To Production Menu A Alarm History Screen Alarms epi e LH MM SS PM CST MM DD 4Y 0 H MM SS PM CST Injection Unit Not n MpD LH MM SS PA CST MMe DOAYY HH MM SS PM CST Injection Phase Minor Error LO Press Fi To Return To Alarm Menu J This field Is located in T4 4 PRE T4 6 PRE T4 7 PRE T4 8 PRE T4 12 PRE T4 13 PRE SLD BY WwW N e This field 1 T4 0 PRE Is located in T4 21 PRE 2 T4 23 PRE 3 T4 24 PRE Understanding SLC 5 04P Processor Addresses B 15 Timer Setup Screen 1 Timer Setup Note ALL Timer Are In Seconds Mechanical Safety Malf Timer Flasher On Timer Flasher OFF Timer Injection High Volume Delay Plastication Watch Dog Timer Clamp High Volume Delay Clamp Tonnage Watch Dog Timer a Press F9 To Advance Timer Screen Timer Setup Screen 2 Timer Setup Hote All Timer Are In Seconds Pre Fill Shift Delay URE Eject Watch Dog Timer COKI Clamp Open Watch Dog Timer Press F9 To Return To Production Menu A Publication 6500 UM001A US P November 1999 B 16 This field Understanding SLC 5 04P Processor Addresses Is located in C5 02 PRE C5 03 PRE C5 04 PRE C5 05 PRE C5 06 PRE C5 07
239. perature Modules BTM 9 3 Thermocouple inputs are highly susceptible to electrical noise due to the small signal amplitudes microvolt C Most applications require that the processor and I O chassis be installed in an industrial enclosure to reduce the effects of electrical interference Consider the following conditions when selecting a slot location for the module Position the module away from other modules that e connect to sources of electrical noise such as relays and AC motor drives e generate significant heat such as 32 point I O modules Follow these guidelines to wire your input signal cables e To limit the pickup of electrical noise keep thermocouple and millivolt signal wires as far as from power and load lines as possible e For high immunity to electrical noise use Alpha 5121 shielded twisted pair or equivalent wire for millivolt sensors or use shielded twisted pair thermocouple extension lead wire specified by the thermocouple manufacturer Using the incorrect type of thermocouple extension wire or not following the correct polarity may cause invalid readings e Ground the shield drain wire at only one end of the cable The preferred location is at the I O chassis ground Refer to IEEE Std 518 Section 6 4 2 7 or contact your sensor manufacturer for additional details Keep all unshielded wires as short as possible e Tighten screw terminals with care Excessive tightening can strip a screw e Th
240. plays the current temperature for zone 2 4 Displays the current temperature for zone 3 5 Displays the current temperature for zone 4 6 Displays the current temperature setpoint for zone 1 7 Displays the current temperature setpoint for zone 2 8 Displays the current temperature setpoint for zone 3 9 Displays the current temperature setpoint for zone 4 10 Displays the current mode for zone 1 11 Displays the current mode for zone 2 12 Displays the current mode for zone 3 13 Displays the current mode for zone 4 14 Displays the current temperature for zone 5 15 Displays the current temperature for zone 6 16 Displays the current temperature for zone 7 17 Displays the current temperature for zone 8 18 Displays the current temperature setpoint for zone 5 19 Displays the current temperature setpoint for zone 6 20 Displays the current temperature setpoint for zone 7 This field 21 Using Production Monitor Screens 14 5 Monitors this Displays the current temperature setpoint for zone 8 22 Displays the current mode for zone 5 23 Displays the current mode for zone 6 24 Displays the current mode for zone 7 25 Displays the current mode for zone 8 26 Shows the temperature units in Degrees Celsius or Fahrenheit for zones 1 4 27 Using Production Monitor Screen 4 Shows the temperature units in Degrees Celsius or Fahrenheit for zones 5 8 Press j F9 until A oT you see
241. put P2 AT Counts Molts ETE cu a g12 FSI Qutput Min PS Output Man au AT Dees V Fress F3 to Advance Injection Soreens Velocity Spanning Values Screen 1 6 Velocity Spanning Values MIN Fud 1 8 IN SEC AT 29 F MOY Fud B 4 IN SEC AT BRS HF MIN Ret oa IN SEC AT 7 MAX Ret BKO IN SEC AT PRUO CA Wel Wel 12 38 PS aT PSI ARR Man Yel o InSee K Press F3 to Advance Injection Screens A Publication 6500 UM001A US P November 1999 B 18 Understanding SLC 5 04P Processor Addresses This Is located This Is located field in field in 1 N82 34 8 N82 13 06 2 82 35 9 82 36 3 N82 13 05 10 N82 37 4 82 32 11 125 08 5 6 N N82 33 12 N125 06 N82 28 13 N125 07 N82 39 This Is located Is located field in in 1 83 00 83 08 2 N83 01 N83 13 01 3 83 02 83 09 4 N83 03 N83 20 5 83 13 00 83 21 6 N83 04 N83 13 02 7 83 05 83 18 8 N83 06 N83 19 9 83 07 Publication 6500 UM001A US P November 1999 Plastication Sensor Nameplate Values Screen i Plastication Output Devices PSI Output Min 1 F AT PSI Output Mas o AT 53E RPM Spanning Values MIN RPM OFFF AT MAN RPM 9y AT io we Shot Size BKD e Clamp Input Output Device Setup Screen A Clamp Input Output Device Setup ry Pos Input Pi AT 2 HF Cou
242. r of characters in the buffer up to and including the end of line characters termination ACB Number of Characters 131 0 Determines the total characters in the buffer in Buffer ACI String to Integer 56 0 Converts an ASCII string to an integer value ACL ASCII Clear Receive 332 8 Clears the ASCII buffer and or Send Buffer ACN String Concatenate 56 2 5 per character Combines two strings using ASCII strings as operands AEX String Extract 43 4 4 0 per character Creates a new string by taking a portion of an existing string and linking it to a new string AHL ASCII Handshake 115 1 Sets or resets the RS 232 Data Terminal Ready and Request to Lines Sender handshake control lines for the modem AIC Integer to String 110 0 Converts an integer value to an ASCII string ARD ASCII Read 151 0 Reads characters from the buffer and stores them in a string Characters ARL ASCII Read Line 156 0 Reads characters from the buffer up to and including the end of line characters and stores them in a string ASC String Search 43 5 2 5 per character Searches an existing string for an occurrence of the source string ASR ASCII String Compare 43 5 Compares two ASCII strings AWA ASCII Write with 307 8 Adds the two appended characters set from the ASCII configuration Append menu AWT ASCII Write 217 3 Writes characters from a source string to a display device Publication 6500 UM001A US P November 1999 C 10 Processor Specifications Notes Publication
243. r rung that references the unused module eyou are adding BTMs eexpand code to accommodate more BTMs 254 ERC2 enable do not modify Do not code here 255 initialize ERC2 do not modify Do not code here Publication 6500 UM001A US P November 1999 6 6 Customizing Your System File 2 I O Definition File Modifying Program File 2 I O Definition File The I O definition file contains buffer bits that are used to drive the logic in the remainder of the Pro Set 200 ladder logic You need to replace the buffer bits with actual inputs and outputs in the I O definition file The following picture shows how Pro Set 200 works Assign actual inputs and outputs Do Not This Rung Jumps t Clamp Logic IA Buffer Bit ESHE 7 tI Injection Logic sole a oa E Cmi i ee Ejector Logic Buffer Bit cua used in other files Examine each rung in program file 2 e Read the rung comment e Look for the symbol in the address comment The symbol identifies the address that needs your attention Based on rung comments and the symbol decide how each rung matches your application as follows Remove the rung e Do not remove the rung Modify the rung For example Figure 6 1 Example Remove This Rung o Subroutine 20 Which Performs Loss of Sensor Checking Jump to Lo
244. ransfer PanelBuilder 550 applications between the RS 232 port of the terminal and the RS 232 port of a personal computer and communicate to the SLC 5 04P controller e 16 4 foot 5 meter catalog no 2711 NC13 e 32 7 foot 10 meter catalog no 2711 NC14 e 10 foot 3 meter catalog no 2706 NC13 Personal Computer PanelBuilder To COM comm 2 port 9 pin to 25 pin adapter L if required i l i Node 1 PanelView 550 Terminal SLC 5 04P Controller z Catalog No 2711 K5A9 5 Q O Q 5 Cable a 25 Catalog No 2711 NC13 Catalog No 2711 NC14 a Catalog No 2706 NC13 2 a i F A To channel ot 2 o To RS 232 port 20916 M a For more information about connecting a Panel View 550 terminal to the programming terminal see PanelView 500 Operator Terminals User Manual publication number 2711 6 1 Publication 6500 UM001A US P November 1999 4 12 PanelView 900 On the RS 232 version of the Panel View 900 monochrome terminal 2711 K9H9 firmware version 2 0 or greater and color terminal 2711 K9C9 firmware version 2 0 or greater use the following cables to transfer PanelBuilder 900 applications between the RS 232 port of the terminal and the RS 232 port of a personal computer and com
245. rates this concept as well To set the external pressure trigger to 4 lt under set bit10 1 gt over setbit10 0 Setting External Time Trigger Setpoints Time triggers transfer to the next profile when the external time is greater or equal to the external time trigger The time range is 0 to 65535 Use this field to enable or disable the external time trigger setpoint To oy enable the external time trigger setpoint set bit7 1 disable the external time trigger setpoint set bit 7 0 What s in This Appendix How Do Segment Active Segment Complete Profile Active and Profile Done Bits Work Appendix F Using Profile Status and Complete Bits This appendix provides bar charts which show you the operation of the following segment active bits segment complete bits e profile active bits e Profile Done bits emergency stop bits e reset bits A bit contained in a shaded area 8186 30 indicates that the bit is ON or set All non shaded areas indicate that bits are turned OFF or reset At the bottom of each bar chart we show data table addresses for velocity pressure position and time These addresses are taken from the setpoint block for the affected phase The values are the velocity pressure position or time which when reached cause a transition into the next active segment or phase Pro Set 200 contains bits in the pha
246. read critical inputs and send outputs to the corresponding valves These fast analog cards can be used to control these machine phase combinations e inject phase injection pack hold pre decompression plastication and post decompression profiles e clamp phase clamp close clamp low pressure mold protect clamp tonnage clamp low hold clamp decompress and clamp open profiles e ejector phase ejector forward ejector tip stroke and ejector retract profiles Let s take a closer look at each of the phases in the order they occur in the machine cycle and discuss how you can control each phase using profiles Publication 6500 UM001A US P November 1999 3 4 Introduction to the Injection Molding Process Clamp Close During clamp close the mold closes Clamp Close 3 ClampLPMP gt Tonnage Hydraulic Clamp without Clamp Low Hold Clamp Close Pre decompression Injection Phase Yy y Ejector retract E Inject Phase Plastication Pack ase y y Post decompression Hold Ejector forward Clamp Open Clamp Low Hold Phase Off Clamp Open Clamp a For this hydraulic example tonnage is held until the clamp decompress profile is permitted Instead of moving from tonnage to clamp low hold tonnage is maintained throughout Publication 6500 UM001A US P November 1999 Introduction to the Inject
247. recipe storage as follows 256 data table files maximum of files in a SLC 5 04P processor data table files used by your application total of data table files available for mold part storage 2 Calculate the number of recipes you can store as follows number of recipes you can store total of data table files available 9 data table files per recipe The number of recipes you can store cannot exceed the available memory in the processor See item 3 below 3 Determine how much memory is available in the SLC 5 04P processor after you add all your ladder code and miscellaneous memory storage requirements You can check this number with your ladder logic programming software number of recipes you can store available memory 2000 words per recipe Important This number is the amount of memory each recipe requires before customer additions If you are adding data to be stored add that amount to 2000 4 After calculating steps 2 and 3 determine which number is the smaller of the two This number represents the number of recipes you can store gt Each controlled phase in Pro Set 200 requires 29 files If you are not using Pro Set 200 to control a particular phase you can reuse its file space for mold part storage gt If you increase the number of mold part recipes modify the mold part storage screens and ladder file 92 Publication 6500 UM001A US P November 1999 13 8 Using Mold Part Recipes What s Next
248. recipe based on an existing recipe 9 16 ladder logic and data tables 9 4 ot location locations changing 9 4 placement 9 1 restoring a mold recipe 9 17 wiring considerations 9 3 C clamp close profile 3 4 clamp initial speed i meni 3 4 close decel segment 3 5 close fast segment 3 5 clamp decompress profil 3 11 clamp dynamic phase permit block F clamp low hold profile 3 9 Index clamp LPMP profile 3 4 clamp open profilel 3 13 clamp phase 2 4 communication options C 4 configuration screens g 8 Aaa configuring the BTM 1 4 configuring Pro Set 200 profiles 8 1 configuring primary controller variables configuring profiles 8 4 connecting programming terminal interface card to processor 4 10 connection PanelView terminal to programming terminal PanelView 550 4 11 PanelView 900 sa Used in This Manual P 3 coordinating ramp 8 13 customizing ladder logic 6 4 PanelView screeng 6 34 Pro Set 200 oe CV small and large deviation alarms A d D dat table locations Pro Set 200 profiles deadheaded pressur 7 4 7 7 4 determining sensor and valve operation 1 deviation alarm limits configuring 8 29 ejector advance profild 3 15 ejector dynamic phase permit block F ejector phase 2 4 ejector position sensing 11 12 ejector retract profild 3 15 Publication 6500 UMO01A US P November 1999 Index Publication 6500 UM001A US P November 1999
249. requires a breakaway time delay and is also active during the clamp open fast segment Because the I O definition file file 2 does not contain a bit to enable this functionality you must write ladder logic as shown in the following example Clamp Open Breakaway Solenoid Delayed with T4 16 Pump Load B9 14 Solenoid q 2 Clamp Open Fast Solenoid B9 14 0 Solenoid E and F This row shows proportional control valve solenoid E which performs flow control of the clamp hydraulic circuit and solenoid F which controls pressure If you use the standard Pro Set 200 layout as shown in chapter 3 you do not need to write any ladder logic to support this solenoid If you have changed the physical hardware layout you need to modify files 3 8 and 12 Publication 6500 UM001A US P November 1999 How to Modify Your Analog STI Code to Support Your Valve Configurations Represents any or all phase functions that are required for your machine You may need to include functions like pack hold pre post decompression and plastication Remember for each function listed in the following examples you will need to think about your machine s needs and modify the ladder logic accordingly 2 Valve Configurations Customizing Your System 6 21 If you want to change the locations for the fast analog modules and BTM modules first six slots modify the MOV COP IOM and IIM instructions contained in these files e file2
250. rity Period In Minutes Set Point Ramp Rate Press F6 to Advance Screen BFF oa d606 J S View the currently selected zone View and modify the temperature alarm deadband 1 Cursor to this field by using the left and right arrow keys gt 2 Press the enter key The scratch pad appears Enter value 1 to 10 0 3 Enter a value in a range of 1 to 10 0 View and modify the thermal integrity temperature change value The thermal integrity measures the change in temperature over a specified period this period is called the thermal integrity period which is when the loop is in auto mode at 100 output If this condition exists an alarm banner appears 1 Cursor to this field by using the left and right arrow keys 2 Press the enter key The scratch pad appears Enter value XXX 1 to 100 3 Enter a value in a range of 1to 100 Publication 6500 UM001A US P November 1999 9 14 Use this field Using Barrel Temperature Modules BTM To View the thermal integrity period in minutes The thermal integrity period is the time you specify to measure temperature change described in item 7 1 Cursor to this field by using the left and right arrow keys 2 Press the enter key The scratch pad appears Enter value 1 to 100 a 3 Enter a value in a range of 1 to 100 Press er Ejectors o View the rate at which temperat
251. rofile optional This single backward movement of the ram guards against the plastic running into the open mold during the clamp profiles drooling This profile is also referred to as plastic decompress or suckback To configure this profile you define a length of the post decompression pull back of the ram Clamp Decompression Profile The clamp decompression profile is active before the clamp begins to open This profile allows the clamp pressure on a hydraulic clamp to decay before opening Typically a hydraulic or toggle clamp machine opens more smoothly if the pressure on the clamp cylinder is allowed to bleed down to a minimum before trying to open the clamp Pro Set 200 contains a cure timer A cure timer allows a part to cool The clamp will not decompress until the timer expires Clamp decompress is actually part of the clamp profile but we show it here to clarify how the injection process works Publication 6500 UM001A US P November 1999 3 12 Introduction to the Injection Molding Process Clamp Open Phase During the clamp open phase the mold opens in preparation to eject the part Tonnage Clamp Close p gt Clamp LMP gt Typical Hydraulic Clamp Clamp Close Clamp Low Hold acti Phase On koi Ejector retract Eject n Pre decompression bade Phase oe y y Plastication Hold Ejector f
252. rsP OHHO OHHOH GHHK 7H GHHH S Run SP K Fee EOE i ee ae On ae CW X Man Mode 2 ET 30 ET em Tenperature Control Understanding SLC 5 04P Processor Addresses B 9 Temperature Control Screen 2 m e a Tema Dg sail ae field in field in N9624 17 N9608 Temp 33 10 0 z0 z0 m E ue CurrSP acs GHHK 6 GHHH 7H aO e eet Run SP K Dr E OE a 5 N96 00 21 N9636 Dew 13 16 6 no601 22 N9637 CU X GOR HH OH ORE OHH HH 7 N96 02 f 23 N96 38 Man 2DRHE FF ERE 20 HA FE WHE FF HAE Hae FODHA FF 8 N96 03 24 N96 39 10 96 29 26 96 41 Select T 11 96 30 27 96 42 2 31 or 12 N96 31 28 N96 43 13 96 32 29 96 44 14 N96 33 30 N96 45 15 96 34 31 96 46 16 N96 35 32 N96 47 33 96 48 14 Temperature Control Screen 3 ame pea POr i field in field in a Stand Le Eee EEE 2 93 30 15 93 62 un un ness Se fa e E 4 N93 80 17 N93 13 L TH 1 Teint 1 Obl Pe Tr TT Pe Tr T 5 N95 48 01 18 N93 38 a FE E 20 6 N95 48 02 19 N93 63 13 i 7 95 48 03 20 93 88 Dey HHF a Da 8 N95 48 04 21 N93 14 Dey gua JREF F meia 9 93 11 72 93 39 10 N93 36 23 N93 64 ll 93 61 24 93 89 U 12 N93 86 25 N9750 B 93 12 Publication 6500 UM001A US P November 1999 B 10 Understanding SLC 5 04P Pr
253. ruction the calculation is 8 8 1 70 1 70 2 3 01 18 22 Publication 6500 UM001A US P November 1999 Instruction Mnemonic Processor Specifications Data Handling Instructions Execution Times 1s Function and Name Floating Point us Output Instructions TOD Convert to BCD 34 06 NA When rung conditions are true the TOD instruction converts the source value to BCD and stores it in the math register or the destination FRD Convert from BCD 23 88 NA When rung conditions are true the FRD instruction converts a BCD value in the math register or the source to an integer and stores it in the destination RAD Degrees to Radians 24 65 NA When rung conditions are true RAD converts degrees source to radians and stores the result in the destination DEG Radians to Degrees 24 70 NA When rung conditions are true DEG converts radians source to degrees and stores the result in the destination DCD Decode 8 88 NA When rung conditions are true the DCD instruction decodes 4 bit value 0 to 16 turning on the corresponding bit in 16 bit destination COP File Copy 20 2 2 0 per word NA When rung conditions are true the COP instruction copies a user defined source file to the destination file FLL File Fill 21 9 2 5 per word NA When rung conditions are true the FLL instruction loads a source value into a specified number of elements in
254. s However other variations may be sunny 1 bi q required PS Power SLC 5 04P FIO4V FIO4V FIO4V Empty slot BTM BTM Any mix of discrete 1 0 Injection PS Processor oF or or reserved 4 Loops 4 Loops ac dc relay Supply FIO4 FIO4I FIO4I i P njection Clamp _ Ejectors required optional required optional optional EjectPosition Input Up to 4 or K thermocouples f on each module Eject Pressure Input Eject Velocity Output Eject PS Output Clamp Position Input Output Clamp Pressure Input Clamp Velocity Output Clamp PS Output Injection Position Input Injection Pressure Input Injection Velocity Output Optional FIO4V F104I modules are required if Clamp or Ejector velocity pressure valves are present Publication 6500 UM001A US P November 1999 1 6 Pro Set 200 System Quick Start Km Install the software Reference JV Install PanelBuilder software Chapter 5 Setting Up V Install RSLogix 500 software the Software Vv Install the Pro Set 200 software The Are stored in this default location PanelView screens c AB PBWIN PS2102 ladder programs c RSI Logix500 Project PS2102 3am Customize your system V Customize ladder logic Chapter 6 Customizing vA Modify the I O definition file file 2
255. s 3 8 12 and 20 Solenoid F This row shows a proportional pressure valve solenoid F which controls clamp pressure If you have used the standard Pro Set 200 layout you do not need to write any ladder logic to support this valve Modifying Pro Set 200 Ladder Logic for a Clamp Open Sequence Bar Chart The following table shows a clamp open sequence bar chart for a hypothetical molding machine Solenoid Name Solenoid Clamp Open Breakaway Time Delay Clamp Open Clamp Open Clamp Open Description Breakaway for Pump Volume Fast Deceleration Slow Solenoid A directional Oy Solenoid B pump load Hy yy A 1 Wy Yi Solenoid C pump load S S S A bidirectional Solenoid D eaa flow valve 0 to 10VDC bidirectional Wj 7 Yj Solenoid E proportional UY Yy flow valve 0 to 10VDC WA VA Hf proportional Solenoid F oe UY UY valve 0 to 10VDC Solenoid G directional V4 4 Vf Solenoid A B and G These rows show solenoids A B and G all of which are ON during the entire clamp open sequence You can modify your logic as follows Publication 6500 UM001A US P November 1999 6 20 Customizing Your System Clamp Open Solenoid Clamp Directional B9 13 13 Solenoid A Clamp Open Solenoid Pump Load B9 13 13 Solenoid zi Clamp Open Solenoid B9 13 73 Solenoid G Clamp Directional Solenoid C This row shows a pump load solenoid C which
256. s Channel 2 Channel 2 Channel 3 CJC B CJC Assembly gt Channel 3 CJC B Ground terminal Release Screw After the module is properly installed in the chassis follow the wiring procedure using the proper thermocouple extension cable Cut foil shield and drain wire then insulate at both ends of cable Signal Wires Drain Wire Foil Shield Signal Wires Twist together shrink wrap and connect to designated channel shield screw To wire the module follow these steps 1 At each end of the cable strip some casing to expose individual wires Publication 6500 UM001A US P November 1999 4 18 Ungrounded End at Source Device Wires Yy Remove drain wire and 3 8 foil shield at casing Cables Keep the length of unshielded wires as short as possible Limit braid length to 12 or less Solder braid to lug attached to bottom row of I O chassis bolts Publication 6500 UM001A US P November 1999 2 Trim signal wires to 5 inch lengths beyond the cable casing Strip about 3 16 inch 4 7 mm of insulation to expose the ends of the wires 3 At the module end of the cables extract the drain wire and signal wires remove the foil shield bundle the input cables with a cable strap 4 Connect drain wires together and solder them to a 3 8 inch 9 5 mm wire braid 12 inches 304 8 mm long Keep drain wires as short as possible 5 Connect the 3 8 wire braid to the nearest
257. s Supported by Pro Set 200 Figure D 3 Pro Set 200 Specialized Hydraulic Configuration with an Electronically Adjustable Pump Position Injection Sensor Clamp or Ejector Axis P T Pressure Transducer 2 lt Directional Control Valve Tank To support this configuration you need to add eladder logic to control the pump eadditional FIO4V or FIO4I module Publication 6500 UM001A US P November 1999 al Electronically Adjustable Flow A Electronically Control Valve D Adjustable PSI Valve Ib ey Slee St _ Electronically Adjustable Tank Pump This Does this Position Sensor measures cylinder position Pressure Transducer esenses hydraulic pressure in the cylinder esends back 0 10 volts or 4 20 milliamps proportional to the pressure in that signal Directional Control Valve switches the cylinder from a forward to reverse position Electronically Adjustable Flow Control Valve controls the flow speed Electronically Adjustable Pump controls flow and pr pressure to the cylinder Electronically Adjustable psi Valve controls the pressure in the circuit What s in This Appendix Using Internal Trigger Setpoints Appendix E Using Internal and External Trigger Setpoints This appendix explains how to e use internal trigger setpoints use external trigger setpoints Trigger cause the machi
258. s of the injection molding machine e injection phase e clamp phase e ejector phase You can select open or closed loop control for any profile in the injection clamp or ejector phase You can also select either velocity or pressure control for any of the profiles in the process The following table lists the controllable profiles and the number of segments in each profile Injection Phase Profile Number of Segments Default Type of Control Injection 5 Velocity Pack 2 Pressure Hold 2 Pressure Pre Decompress 1 Velocity Plastication 5 Pressure Post Decompression 1 Velocity Clamp Phase Profile Number of Segments Type of Control Close 3 Velocity Clamp LPMP 1 Pressure Tonnage 1 Pressure Low Hold 1 Pressure Decompress 1 Pressure Clamp Open 4 Velocity Ejector Phase Profile Number of Segments Type of Control Ejector Forward 2 Velocity Ejector Reverse 1 Velocity Tip Stroke 1 Velocity System Overview 2 7 In addition Pro Set 200 also comes complete with other basic features including pre programmed alarms ladder logic and operator screens Other Basic Features Eject multi stroke capability Die height fwd retract logic Manual semi automatic and full automatic mode machine code SPI cores A B C D set pull Overall cycle timer Dry cycle clamp only Automatic clamp injection tuning Autotune heat cool Eject by limit switch or linear po
259. se setpoints remain active until the ejectors reach the fully retracted setpoint Ejector 0 Fully Forward Position full fwd stop retract eject forward Position xx xx XX XX Vel 1 psi 2 XXXX Publication 6500 UM001A US P November 1999 retract Introduction to the Injection Molding Process tip stroke Positions xx xx XX XX What s Next 7 Use an ejector retract profile to control the ejector moving back into the mold with either velocity or pressure Other Eject Features Pro Set 200 lets you e use multistroking to repeat ejector cycles automatically Multistroking is controlled automatically from the ladder logic e use an ejector forward dwell timer to pause the ejector after each ejector forward stroke This feature lets a robot pick off a part when the ejectors are fully extended use ejector tip strokes to shake the part off the ejector You can program interim single segment advance and retract tip strokes that occur after the first advance stroke and before the last retract stroke b gt Note If you are using limit switches to detect injector position the Vel 1 tip stroking feature is not available During a tip stroke cycle the ejector retracts to the tip stroke position and Vel 1 and psi 1 are active Once the tip stroke cycle is complete and the ejector pins are ready to fully retract Vel 2 a
260. se wide status blocks which can be used by your ladder logic to tell when a profile or segment is being executed or has completed execution There are 3 phase wide status blocks in Pro Set 200 one for each phase of control These blocks are shown in the following table Phase Wide Status Blocks Data Table Location Injection Phase Permit Status Block B106 Clamp Phase Permit Status Block B146 Ejector Phase Permit Status Block B186 Publication 6500 UM001A US P November 1999 F 2 Using Profile Status and Complete Bits The operation of these bits is as follows Bits Segment Active Bits Operation These bits are turned ON when the segment is being executed by the ERC2 engine They turn OFF after the segment has been executed Examples of segment active bits are injection segment active bits B106 16 thru B106 20 Segment Complete Bits These bits remain OFF until a segment has been completed When the ERC2 engine finishes executing a particular segment it signals that it is done by setting the segment complete bit The complete bit will remain on until one of the following conditions resets it 1 The reset all segment and profile done bit is set When this bit is set for a particular phase it automatically resets all of the segment and Profile Done bits Note There are 3 Reset all segment and phase done bits They are located in the dynamic phase permit block elnjection Phase B101 2 1 eClamp Phase B101 5 1 eEject
261. sed position if no parts are stuck in the mold but low enough not to make it to full closed if a partis lodged in the mold If a part is stuck the machine should not continue to smash the part and make it to the full closed position Clamp Close tonnage Use this profile to adjust the tonnage pressure that the machine builds cl on the clamp The tonnage profile occurs after the molds are closed rt oe Tonnage and while injection occurs Tonnage is usually handled differently between hydraulic clamping machines and mechanical toggle clamping machines You can change the clamp velocity or pressure in each profile Moving Clamp Close Profile Low Pressure Stationary Platen Close Profile Platen oe a Full Close Close Low psi Mold Open Fast Decel Mold Protect Touch Close Initial Close Fast Close Decel Low psi Mold Segment Segment Segment Segment Positions XX XX XX XX XX XX XX XX XX XX Vel 1 Vel 2 ee ice psi 1 psi 2 psi 3 psi 4 XXX XXX XXX XXXX Clamp Cylinder After completing the low psi mold profile you can program the SLC 5 04P processor to e automatically execute the tonnage profile e wait for the ladder logic to command the cycle to continue Publication 6500 UM001A US P November 1999 3 6 Introduction to the Injection Molding Proce
262. sensed do the following Position is Sensed 1 Go to the ejector position sensing screen This is the third ejector setup screen until a A a F6 pres E youses Ejectors Ejector Position Sensing With Linear Transducer Imit gt uitches If you are using Limit Switches to sense Ejector position then voy can not use ERC for Open or Close loop control of the Ejectors a Fress Fe to Advance Ejector Soreens P 2 Using the up and down arrow keys select how the machine senses ejector position 3 Press the enter key C Publication 6500 UM001A US P November 1999 Saving and Restoring Machine Setup Data Mold Part Storage Determining Sensor and Valve Operation 11 13 You can save your machine s setup data or restore the original configuration 1 Press the F9 function key to access this screen g b Machine Setup Utility MRestore Machine Setup Save Machine Setup Machine Stopped Restore Sayve Enabled x A 2 To Do this save machine 1 Select Restore Machine Setup setup data i gt EE 2 Press enter restore machine setup data 1 Select Restore Machine Setup gt Save Machine Setup 2 Press enter Publication 6500 UM001A US P November 1999 11 14 Determining Sensor and Valve Operation Spanning to Remove Upper and Lower Deadbands When your control valve has a deadband at the upper
263. ss Tonnage Tonnage differs from machine to machine according to the type of clamping mechanism being used In a mechanical clamping system toggle tonnage is applied to lock the toggles In the case of a typical toggle machine clamp low hold is usually unnecessary and can be turned off Clamp decompress can be used to gradually release pressure on the toggle before going to clamp open In the case of a hydraulic clamping system clamp low hold and clamp decompress are optional and may be turned on if desired Tonnage is used to begin the injection phase and can be sensed by pressure transducer pressure switch limit switch or by position Inject Phase During the inject phase the ram injects plastic into the mold pressurizes the plastic to fill voids and reloads the barrel with plastic for the next shot This diagram shows the steps of the inject phase Clamp Close gt ClampLpmp ee Typical Toggle Clamp Ejector retract Ejector forward Clamp Close Pre decompression Injection Phase y y Efect Inject jec Phase Plastication Pack Phase y y Post decompression Hold Clamp pan Clamp Low Hold Turned Off Clamp Open Clamp Decompress lt Turned On Publication 6500 UM001A US P November 1999 This example demonstrates a typical toggle clamp tonnage profile Tonnage begins after clamp LPMP
264. ss of Sensor Routine JSR Publication 6500 UM001A US P November 1999 Jump to Subroutine SBR File Number U 20 Customizing Your System 6 7 e Retain the rung and replace the input contact address B9 0 xx B9 5 xx identified by the symbol with your real input address For example Figure 6 2 Example Motors Running Input Remove this rung if this input is not installed jor retain this rung and assign your own real input address Motors Motors Running Running Input Input B9 0 B9 0 4 4 e Retain the rung and replace the output coil address B9 13 xx B9 16 xx identified by the symbol with your real output address For example Figure 6 3 Example Clamp Close Profile Active This will remain energized from Clamp Close Initial to Clamp Close Decel Remove this rung if Clamp Close profile active bit is not required or retain this rung and assign your own real output address or use this bit to build additional ladder logic Clamp Close Clamp Profile Close Profile Active Active Output Bits B146 1 B9 13 15 12 e Build additional logic to support the conditions required to control your real outputs gt gt If you need to add additional logic place the logic at the end of file 2 but before the First Scan rung and the Clear Minor Overflow Math Error rungs Using Optional Features in Pro Set 200 The following are included in the Pro Se
265. stion Idle cycle timer Tonnage deadband window Supplied Alarms Short shot alarm Purge guard opened in cycle alarm Inhibit screw rotation with low temperature interlock alarm Tonnage loss alarm Mode inhibit alarm Die height overstroke alarm Tonnage malfunction alarm Gate opened in cycle alarm Ejector not retracted alarm Safety flap malfunction alarm Clamp not full open alarm Temperature deviation alarms Low psi mold protect alarm Profile not capable alarm Temperature interlock code alarm Clamp forward overstroke inhibit alarm Core not set pulled alarm Clamp not in correct position for ejector Injection unit not forward alarm alarm Multiple permit bit check alarm Supplied Logic and Programming P re engineered setup and configuration 31 pre engineered operator screens Screeie Clamp close permissive logic Clamp close tonnage permissive logic Clamp low hold permissive logic Clamp decompress permissive logic Clamp open permissive logic Ejector forward permissive logic Ejector tip stroke permissive logic Ejector retract permissive logic Injection forward permissive logic Pre decompress permissive logic Plastication permissive logic Post decompress permissive logic Cure timer permissive logic Injection high volume delays Clamp open delays Clamp full automatic mode Full open delay timer Clamp open close suspend support Injection suspend support S
266. strongly advised to contact the machine manufacturer or contract your hydraulic work to a qualified hydraulics engineer Publication 6500 UM001A US P November 1999 7 2 Understanding Hydraulic Pressure and Flow Concepts Understanding Pressure Differential and the Effects on Flow Rates Concept The measured pressure at point A is 500 psi The pressure E after the flow control valve is 200 psi therefore the pressure differ ential between the two points is 300 psi Concept The greater the pressure differential the greater the flow The lower the pressure differential the lower the flow Publication 6500 UM001A US P November 1999 In a hydraulic system a pressure differential is the difference in pressure between two points in the system Figure 7 1 shows the measured pressure between point A and point B has a pressure differential of 300 psi Figure 7 1 Pressure Differential Example PointA Point B LY Flow through an orifice such as the flow control valve in Figure 7 1 is affected by the pressure differential The greater the pressure differential across this orifice the greater the actual flow If you measured only 100 psi at point B in Figure 7 1 the flow across the flow control valve would be greater 20864 M Figure 7 2 Load Pressure Example 500 psi 100 psi 400 psi pressure differential If the load pressure was measured at point B to be 400 psi the flow acr
267. t 200 I O definition file Review this list of features and determine if your application requires them To modify the I O definition file do the following 1 Print a copy of file 2 to examine 2 Review the I O definition file program files in conjunction with your sequence bar charts 3 Mark up the printed copy of the I O definition file so that it accommodates the requirements of your sequence bar chart Publication 6500 UM001A US P November 1999 6 8 Customizing Your System Using your RS Logix 500 programming software modify file 2 After you have made the required modifications print out another copy of the I O definition file Ensure that your modifications are correct Pro Set 200 Required The following are required or optional I O for Pro Set 200 Optional Inputs and Outputs Pro Set 200 Features Manual Out of the Box Input Output Reserved Additional Optional Required put puss Programming Required R X Semi Auto gt gt lt Manual Lights Semi Lights Auto Lights Motors Running Clamp Open Overstroke Front Safety Gate Closed gt lt Motors Running Light Safety Ratchet Up Input Safety Ratchet Down Input Front Gate Open Mold Set Switch Clamp Open Push Button S elector Switch Clamp Close Push Button Selector Switch Clamp at Tonnage Pressure Switch Clamp Locked Limit Switch Tog
268. t Tonnage ERC2 Injection You must create your own system pressure setpoint for injection clamp and ejector functions Clamp Functions y Injection Functions M Manual Mode Ejector Functions At Tonnage MOV Velocity Output N102 01 Velocity Valve ERC2 Injection MOV Pressure Output N102 02 Pressure Valve MOV S ystem Pressure Setpoint During Injection Pressure Valve or Variable Volume Pump y Ejector Functions y y Clamp Injection Functions Functions ERC2 Clamp ov Velocity Output N102 03 Velocity Valve ERC2 Clamp OV Pressure Output N102 04 Pressure Valve OV S ystem Pressure Setpoint During Clamp Pressure Valve or Variable Volume Pump ERC2 Ejector Publication 6500 UM001A US P November 1999 v n MOV Velocity Output N102 05 Velocity Valve ERC2 Ejector MOV Pressure Output N102 06 Pressure Valve MOV S ystem Pressure Setpoint During Clamp Pressure Valve or Variable Volume Pump Customizing Your System 6 27 Conceptual Model of 3 Valve Variation A1 1 System Pressure Valve 1 Velocity Valve and 1 Pressure Valve for Injection Clamp and Ejector Injection Clamp Ejector ONG ENS Manual Pressure Valve Oxi N N and or Directional Control Ns Velocity Valve Elec
269. te press For ejectors press a Fi gt Clamp Close a ne KSR Injection ae Fs Plasticate ne Ejectors until ee esoo Publication 6500 UM001A US P November 1999 Starting with the clamp phase go to the setup screens and enter values that tell the SLC processor the following valve parameters e pressure nameplate max values for the valves e whether the output signal is in volts dc or mA e maximum velocity values for outputs to each valve second screen Do this as follows 1 Go to the first clamp setup screen ee Clamp Input Output Device Setup _ Pos Input Pi G AT GH Counts Pos Input P2 GH AT GH Counts olts Current Counts GH PSI Input Pi G AT B Counts PSI Input P2 G AT GHHF Counts Tyre gt DERE Current Counts GH PSI Output Min OFI E 61 ae PS Qutput Man 4 HH ATS HH FF Press Fl to Advance Clamp Sereens 2 In the output nameplate values lower part of the screen enter In this field Enter 1 psi output min enter 0 2 psi output min voltage or current from the valve specifications whether the output signal is volts or milliamps put sig p 4 psi output max from the valve specifications or maximum pressure allowed for maximum 5 psi output max from the valve specifications or maximum pressure allowed for maximum For example your valve could have these param
270. te phase has only one screen 8 Press lt F5 to go to the plasticate screen Plasticate la Plastication Output peviess JO PSI Output Min G H AT BHH HF s PSI Output Man GH H AT BHR HE A MAX RPM DEFF AT B Vel H gt RPM Spanning Malues MIN RPM BH AT BHE Shot Size B8 P i 6656 amp EAREN K FSI BHH Publication 6500 UM001A US P November 1999 Starting Up the Machine 10 5 9 For the plasticate screen enter these values as shown in the following table Min max RPM velocity units are in percent For this step in the machine setup enter a max RPM velocity of 99 99 When selecting volts or amps go to the selector make your selection then press Enter In this field Enter 1 psi Output Min enter zero psi Output Min or current or voltage from valve specifications whether the output signal is volts or milliamps psi Output Max from the valve specifications psi Output Max or current or voltage from valve specifications in RPM zero at corresponding voltage or milliamperage in voltage current for maximum RPM whether the output signal is volts or milliamps WwW CO MI GD OT S WG N ax RPM 99 99 at corresponding voltage or milliamperage ax voltage current for maximum RPM ke oOo og Vel Re eRe og psi psi Re N 10 To apply the entered
271. the unit is on and in manual mode you cannot select injection forward retract or screw rotate 1 Cursor to this field by using the left and right arrow keys 2 Press the enter key The scratch pad appears Enter value 3276 8 to 2376 7 3 Enter a value in a range of 3276 8 to 3276 7 View and modify the high temperature alarm value If the PV exceeds this value the loop is disabled and turned off 1 Cursor to this field by using the left and right arrow keys gt 2 Press the enter key 6 The scratch pad appears Enter value 32 76 8 0 2376 7 3 Enter a value in a range of 3276 8 to 3276 7 View and modify the low deviation alarm value 1 Cursor to this field by using the left and right arrow keys 2 Press the enter key 7 The scratch pad appears Enter value xxxx x 3276 8 to on x 2376 7 3 Enter a value in a range of 3276 8 to 3276 7 View and modify the high deviation alarm value 1 Cursor to this field by using the left and right arrow keys 2 Press the enter key 8 The scratch pad appears Enter value xxxx x 3276 8 to 2376 7 3 Enter a value in a range of 3276 8 to 3276 7 Publication 6500 UM001A US P November 1999 Press l Use this field 1 g jectors Using Barrel Temperature Modules BTM a Ho Zone Selected 9 13 Mi File Configuration Words a Temperature Alarm Dead Band Thermal Integrity Temperature Change B Thermal Integ
272. tine only from the STI first time Wrong OS Firmware OxC0 Pro Set 200 operating Obtain an SLC 5 04P processor with Pro S et 200 system is not installed in SLC 5 04P processor firmware extensions Minor Error Bit 0000 0000 0000 0010 bit 1 The minor error bit indicates a segment in one of the phase profiles has a minor error condition For example the following diagram shows how the minor error bit works on the injection profile Minor Error Bit B106 65 3 0 An error occurred in a segment in the injection profile Reset All Segment P rofile Cmplete Bits B101 2 1 The following minor error conditions are reported through file N103 Publication 6500 UM001A US P November 1999 Description N103 18 N103 31 or N103 44 Detail Value Using Alarms to Troubleshoot Your System Probable Cause Corrective Action Invalid Profile Number 1 N103 19 32 45 contain Remove any writes to N103 19 32 or 45 Do not invalid values alter these values from ladder program or Data Highway Zero Gain 2 F107 4 10 F147 4 10 or Remove any writes to these locations from the F187 4 10 are zero ladder program Not Deadhead Segment 3 N104 3 4 N144 3 4 or Change ladder program to place the identifiers for a N184 3 4 refer to a deadheaded pressure segment in these fields The segment that appears not profile ID field N104 3 uses the same bit pattern to be a deadhea
273. tion 6500 UM001A US P November 1999 C 8 Processor Specifications Instruction Mnemonic Program Flow Instructions Execution Times 1s Function and Name Floating Point us Conditional or Output Instructions JMP Jump to Label 37 44 Output instruction When rung conditions are true the MP instruction causes the program scan to jump forward or backward to the corresponding LBL instruction LBL Label 0 18 This is the target of the correspondingly numbered J MP instruction JSR Jump to Subroutine 112 0 Output instruction When rung conditions are true the SR instruction causes the processor to jump to the targeted subroutine file SBR Subroutine 0 18 Placed as first instruction in a subroutine file Identifies the subroutine file RET Return from 20 0 Output instruction placed in subroutine When rung conditions are Subroutine true the RET instruction causes the processor to resume program execution in the main program file or the previous subroutine file MCR Master Control Reset 3 0 Output instruction Used in pairs to inhibit or enable a zone within a ladder program TND Temporary End 13 05 Output instruction When rung conditions are true the TND instruction stops the program scan updates I O and resumes scanning at rung 0 of the main program file SUS Suspend 10 31 Output instruction used for troubleshooting When rung conditions are true the SUS instruction places the controller
274. tional valve Ensure that the proper command signal to the valve gives you the expected motion Most valve manufacturers list the command signal input to the valve and the corresponding flow path such as 0 to 10 VDC may give a flow path from the pressure port to the A port while another valve manufacturer may tell you that a 0 to 10 VDC may give you a path from the pressure port to the B port The hydraulic plumbing dictates if flow from port A or port B extends or retracts a cylinder if your flow control valve has a feedback mechanism such as a valve position transducer Check to see that the spool cartridge has fully shifted during cylinder motion Jogging the Phase gt pr until For clamp p gi you see eee Clamp Close Se until For injection 7X F8 yousee _ press a Injection p until 5 gt F6 For ejectors sil YOU SEE press m jectors Determining Sensor and Valve Operation 11 9 So far you have done the following e defined the linear position spanning values e defined the pressure transducer spanning values e defined the pressure valve output limits e set minimum forward and retract velocity to zero in sec e set the maximum forward and retract velocity to 99 99 inches second in order to record the actual maximum velocities Now we explain how to jog the injection clamp ejector phases to record the maximum velocity Use the jog
275. tions Inject Profile Active B106 1 Injection Forward Solenoid Bowes 1S 14 Pack Profile Active B106 5 15 Hold Profile Active B106 9 15 Publication 6500 UM001A US P November 1999 6 12 Customizing Your System Modify this rung to include solenoid H as shown below Inject Injection Profile Forward Solenoid Active B106 1 Solenoid H Publication 6500 UM001A US P November 1999 15 Pack Profile Active B106 5 I5 Hold Profile Active B106 9 T3 Solenoid I This row shows a condition in which solenoid I is continuously energized through the entire injection cycle Since the I O definition does not provide any rungs which fit these logic conditions you need to write ladder logic Since the requirement shown on the bar chart is for solenoid I to remain ON during all of the various profile segments use the profile active bits for each phase to accomplish this task Refer to Appendix F for details concerning active bits The profile active bits are ON during the time when any segment in that phase is ON For example the injection profile active bit B106 1 0 is ON during the entire time that the injection profile is being executed This means that it will be ON if any of the injection segments are active Customizing Your System 6 13 Using the profile active bits for each phase energizes the pump load solenoid for inject pack hold pre decompress
276. to occur Using External Trigger Setpoints Word 1 of the Setpoint Block 0000 0000 oy 0000 bit5 Word 1 of the Setpoint Block 0000 0010 0000 0000 bit 9 Using Internal and External Trigger Setpoints E 5 External triggers are sent from devices that are not directly attached to the axis which is being controlled For example external timers mold cavity pressure transducers etc are triggering devices The units of measure for external trigger setpoints are user defined Depending on the type of ladder logic you write to handle the external trigger setpoints you can use raw counts or traditional units of measure such as psi inches seconds etc External trigger are compared to external actual values in phase wide screen actuals e g N105 Address Description Range Nxx 22 external position trigger setpoint user defined Nxx 23 external pressure trigger setpoint user defined Nxx 24 external time trigger setpoint user defined Setting External Velocity Trigger Setpoints Use this field to enable or disable the external velocity trigger setpoint To 7 enable the external velocity trigger setpoint set bit5 1 disable the external velocity trigger setpoint set bit5 0 Setting the External Velocity Over Under Bit When using external velocity trigger setpoints you must specify whether you want the actual velocity to be an under operation exter
277. tpoint Block The internal trigger setpoints are located in words 18 20 of the profile setpoint block Address Description Range Nxx 18 position trigger setpoint 327 67in NXxx 19 pressure trigger setpoint 0 9999 psi Nxxx 20 time trigger setpoint 327 67 sec Decimal place is implied Example Internal Trigger Setpoints Configuration Word 1 of the profile setpoint block contains the following bits to enable or disable internal trigger conditions This address Contains Nxxx 1 0 internal position trigger enable Nxxx 1 1 internal pressure trigger enable Nxxx 1 2 internal time trigger enable For example suppose you want to transfer from the injection profile to the pack profile using one of these triggers e ram position 0 5 inch e hydraulic pressure 1900 PSI e or time 30 seconds N109 1 Enable position pressure timer triggers XXXX XXXX XXXX x111 30 seconds N109 2 Link profile word 0000 0000 0000 0010 pack N109 18 Position trigger setpoint 00050 N109 19 Pressure trigger 1900 N109 20 Time trigger 03000 0 5 inches Publication 6500 UM001A US P November 1999 1900 psi Whichever trigger is reached first causes the machine to transfer into the next linked profile in this case the pack profile Using Internal and External Trigger Setpoints E 3 Using the Internal Pos
278. trol Value EOI Electronic Operator Interface ERC2 Expert Response Compensation version 2 0 1 0 nput output K Kilobyte 1024 210 bytes Kp n shot correction factor LCD Liquid Crystal Display LPMP Low Pressure Mold Protect LED Light Emitting Diode MB egabyte 1 048 576 bytes or 1024K PS Pounds S quare Inch PV Process Value RA Random access memory SEG Segment SLC Small Logic Controller SP Set Point SPI Society of the Plastics Industry STI Selectable Timed Interrupt Vel Velocity In this manual we use these conventions We call your attention to helpful information like this Use RSLogix 500 programming software to edit the Pro Set 200 ladder logic We show examples like this Example This convention presents an example P ublication 6500 UM001A US P November 1999 Publication 6500 UM001A US P November 1999 We show pathnames commands and filenames like this AB PBWIN PS200 ps2s101 pba We show variable text that you type like this filename pva or FILENAME PVA We show active menu selections like this 1 From the Comm menu select Communications Hardware We show concept information like this Concept The load pressure is 200 PSI and will not increase until an dL additional load is added We show references to other Allen Bradley manuals like this This table shows you some other publications you might need if you have other questions about
279. tronically Adjustable Pressure Valve Electronically Adjustable 7 J fan SoS Benes Ay Byes E SS SS Manual Pressure Valve NS and or Directional Control o Li Tank Electronically Adjustable System Relief Valve psi Tank M This conceptual model is intended to be used as an aid in understanding ladder code modifications for the example scenario It is not a complete hydraulic diagram Publication 6500 UM001A US P November 1999 6 28 Customizing Your System Example 3 Valve Variation A2 1 Variable Volume Pump 1 Velocity Valve and 1 Pressure Valve for Injection Clamp and Ejector Injection Clamp Ejector N Manual Pressure Valve Ny N and or Directional Control N Electronically Adjustable Velocity Valve Yer A Electronically Adjustable System Relief Valve psi o L J Li Tank A Variable Volume Pump used as system pressure setting This conceptual model is intended to be used as an aid in understanding ladder code modifications for the example scenario It is not a complete hydraulic diagram Publication 6500 UM001A US P November 1999 1 Pressure Valve for Clamp Injection and Ejector 1 Velocity Valve for Clamp 1 Velocity Valve for Clamp Injection and Ejector Variation B Key configuration questions are What is done with the second clamp value during injection
280. tup screens B 16 temperature control screeng B 8 B 9 temperature setpoint screeng B 34 timer setup screen B 15 Index l 5 tonnage sensing selection scree transfer profile screen B 4 sas gn values scree 198 20 zone selection screen B 35 zone selection screen B 29 B 30 software installation 1 software requirements 5 4 Spanning inputs 11 1 linear position inputg 11 4 outputs 11 4 pressure inputs 11 4 pressure valve outputs 11 6 upper and lower deadbandg 11 14 velocity valve outputs 11 7 starting the machine 10 1 status screens layoul 6 34 STI file 6 J 2 valve configuration 6 2 3 valve configuration 6 25 modification of analog codd 6 21 STI interrupts 2 4 suspend profile capability diabling 8 17 enabling 8 17 suspend profile position example 8 19 system customization 1 4 T technical support P tonnage profild 3 3 3 4 non hydraulic compared toggle clamp profile 3 typical hydraulic clamp profile 3 1 B 12 tonnage sensing selection 11 11 trigger setpoints internal example E d troubleshooting using alarms A 1 U under operation E 4 E 9 Publication 6500 UMO01A US P November 1999 l 6 Index using ramps 8 9 V valve and sensor setup 1 4 Valve Configurations 1 pressure for clamp injection and ejector 1 velocity for clamp 1 velocity for clamp injection and ejecto 1 system pressure
281. up screens by loading this setup file ps2s102 pva You use these setup screens for this procedure e input output screens e velocity spanning jog screens Use this type of screen To input output screens eenter setpoints for position sensors and pressure transducers eenter nameplate or min max values for the corresponding valve velocity spanning jog eenter velocity and pressure setpoints for the screen corresponding phase espan velocity valves machine setup save all the values that you have configured in the storage screen input output and jog screens Remember that the spanning parameters found on the calibration screens for each applicable machine phase are the following e maximum limit in sec or psi pressure or velocity e maximum output volts milliamps to obtain the maximum limit e minimum limit in sec or psi pressure or velocity e minimum output volts milliamps to obtain the minimum limit This section explains how to span linear position and pressure inputs Span inputs for each phase clamp injection and ejector Publication 6500 UM001A US P November 1999 11 2 Determining Sensor and Valve Operation bea In the examples we show injection phase screens if you are spanning the clamp or ejectors phases substitute those screens Spanning Linear Position Inputs To span linear position inputs do the following 1 Go to the injection clamp or ejector input scaling screen
282. ures are ramped in minute 1 Cursor to this field by using the left and right arrow keys 2 Press the enter key he scratch pad appears Enter value XXX 1 to 100 3 Enter a value in a range of 1 to 100 you see Process Process Process Process Process Process Ne MG Auto Tune Block Heat Gain Heat Time Constant Heat Dead Time Cool Gain Cool Time Constant Cool Dead Time Press F6 to Advance Screen Ho Zone Selected nN HHH FF HHHH BRHF OHH H OHHH OHHH 7 b o bd Use this field To 1 View the currently selected zone 2 7 View the values returned by the auto tune gain block after a successful auto tune was performed Publication 6500 UM001A US P November 1999 Using Barrel Temperature Modules BTM 9 15 until F6 on Press ial a Ho zone Selected EEE M PIO Gains Block EEO il s Heat Proportional Gain BE FHF G Heat Integral Gain B H FE Heat Derivative Gain BRF 4 Cool Proportional Gain BEE Cool Integral Gain B HHFF m6 Cool Derivative Gain BRHF C Fress F6 to Advance Soreen j Use this field To 1 View the currently selected zone View and modify the proportional gain value for the heat loop 1 Cursor to this field by using the left and right arrow keys 2 Press the enter key 2 The scratch pad appears Enter value 0 to 32 767 3 Enter a value in a range of
283. uto 2 Cycle Counter Indicates the number of cycles which have occurred during the production run Reset by pressing F1 the largest count is 32767 Cycle Time Cycle Time range is from 0 to 327 67 seconds and is measured from 3 the moment that the time Permit Clamp Closed Bit Bit B101 4 0 is set until the Cycle Complete Bit B3 12 3 is set 4 Longest Cycle Range 0 to 327 67 seconds Idle Time Idle time is used in the semi automatic mode to measure the elapsed 5 time between the start of 2 successive cycles With a range of 0 to 327 67 seconds the Idle time is measured from the moment the Cycle Complete Bit B3 12 3 is set until the gate is cycled B3 1 0 6 Longest Idle Time Displays the longest idle time which has occurred during the production run range 0 to 327 67 seconds Resets the cycle counter largest cycle time or largest idle time To reset counter 7 and times Publication 6500 UM001A US P November 1999 Using Production Monitor Screen 2 Using Production Monitor Screens 14 3 Press i F9 until cnt se Sup Part Storage Injection Time g2 H Seconds Transfer To Pack On Position 3 HH Cure Time a4 HH Seconds Shot Size Sp 5 Shot Size Act G6 Overall Clamp Time G7 44 Seconds Production Monitor Fress F3 To Advance Production Monitor This field 1 Monitors this The mode of the machine setup manual semi auto or full auto 2
284. valuable tool for limiting the pressure once the cylinder has stopped its motion If the cylinder has stopped moving and we read the pressure at the cylinder we can learn the characteristics of the pressure relief valve If the cylinder is moving we cannot learn the correct pressure limits and characteristics of the pressure valve because of the pressure drop across all orifices Learning Pressure During the Cycle Learning pressure during the cycle is a mode of control that should not be done while the cylinder is moving The exception is that you can learn pressure settings during profiles that have no movement such as clamp tonnage injection hold etc Concept If you learn the pressure while the cylinder is moving you run the risk of the pressure valve setting being too high once the cylinder has stopped moving Understanding Hydraulic Pressure and Flow Concepts 7 9 The Pro Set 200 system if selected to Learn Pressure During Cycle tries to adapt the pressure to achieve the requested pressure setpoint You should select this mode only if there is no movement occurring during the profile If you select the Pro Set 200 system to Learn Pressure During Cycle and the cylinder is moving you risk the relief valve being set too high once the cylinder has stopped moving In summary to control the velocity of a cylinder setup the profile as a velocity profile To control pressure setup the profile as a pressure profi
285. w lt 1 0 Module Command command ition commands for the valve ze a Bae elites drive cards and write I m sete _ eae Ztow pressure elas back into the Valve Command Rete AES Commands flo La Main command Flow Valve n Ladder l a Logic lt pressure command Sea E oo Flow Valve Commands Discrete Outputs Step 5 During the STI the data 0 D fos from the ERC2 algorithm is sent to na Update __ Directional the output channels on the fast a Valves analog I O module Pilot Lights e a eee oOo Pumps User Program Operating and Data System Heaters Discrete Inputs y Pushbuttons M Limit Switches Publication 6500 UM001A US P November 1999 System Overview 2 5 The following diagram illustrates the Pro Set 200 program scan and STI interrupts Input Scan 1 a gt File 8 Main Ladder Logic Read Sensors ERC2 Stl Write to output Timer for valves i aia File 8 Read Sensors Output Scan ERC2 Write to output stl for valves Data Highway Communication Timer y STI Pe File 8 Processor Overhead Read Sensors ERC2 Write to output for valves Publication 6500 UM001A US P November 1999 2 6 System Overview What are the Capabilities of Pro Set 200 Publication 6500 UM001A US P November 1999 Pro Set 200 controls all three phase
286. wap 22 6 12 13 per word Swaps the low and high bytes of a specified number of words in a bit integer ASCII or string file ABS Absolute Value 8 60 Calculates the absolute value of the source and places the result in the 4 35 destination XPY X to the Power of Y 335 10 NA Raises a value to a power and stores the result in the destination Register Data LOG Log to the Base 10 54 55 NA Takes the log base 10 of the value in the source and stores the result in the destination LN Natural Log 51 35 NA Takes the natural log of the value in the source and stores it in the destination SIN Sine 38 05 NA Takes the sine of a number and stores the result in the destination COS Cosine 37 20 NA Takes the cosine of a number and stores the result in the destination TAN Tangent 43 00 NA Takes the tangent of a number and stores the result in the destination ASN Arc Sine 41 45 NA Takes the arc sine of a number and stores the result in radians in the destination ACS Arc Cosine 51 90 NA Takes the arc cosine of a number and stores the result in radians in the destination ATN Arc Tangent 40 15 NA Takes the arc tangent of a number and stores the result in radians in the destination To get the total execution time for a CPT instruction take the CPT execution time plus each additional math instruction execution time plus the number of math instructions times 3 01 For example if a CPT instruction calls one ADD and one SUB inst
287. xample scenario It is not a complete hydraulic diagram 3 Valve Configurations Many machines have three analog valves to control machine movements The following section provide examples of some three valve configurations and the ladder logic modifications necessary In addition common configuration questions are proposed as a means of discovering key configuration points 1 System Pressure Valve 1 Velocity Valve and 1 Pressure Valve Variation A1 and A2 Some systems will have system pressure valve or a variable volume pump a velocity valve to control the axis speed and an additional pressure valve downstream Key configuration questions are During injection what is the system pressure valve setting During clamp what is the system pressure valve setting During eject what is the system pressure valve setting During clamp is the system pressure valve used to control the clamp pressure valve If so should you send N102 04 to this valve During eject is the system pressure valve used to control the eject pressure valve If so should you send N102 06 to this valve Is the system pressure valve set higher than the other pressure valves during all movements Do you treat manual mode any different than semi or full automatic mode Publication 6500 UM001A US P November 1999 6 26 Customizing Your System Ladder Logic Modifications 3 Valve Variation A1 and A2 Injection Functions Clamp Functions Ejector Functions A
288. you if you are trying to run a segment that will not reach steady state This is a valuable diagnostics tool that informs you of unobtainable segments in your profile If you cannot get all of your segments to reach a successful OLT try using fewer segments Publication 6500 UM001A US P November 1999 12 6 Quick Tune Procedure Quick Tune Response And The graphic below displays the relationship between CV output and Understanding ERC2 OLT the PV response Note that the numbers correlate with the open loop Status Words test status word CV Steady State CV Output Beginning of segment gt 37 Slope Max Slope PV Response bn psi or Vel Actual Block Values gt gt 0 1 2 3 4 ty Dead Time Time Constant Steady State Segment Status Learning During With learning turned on ERC2 will continuously adapt as it works to Production make your process meet your setpoints At this point you may or may not want to turn learning off If the combined variables of your process gives you good repeatability leaving learning turned on will not harm anything as long as your process is relatively consistent However if your machine encounters a major problem such as a clogged sprue ERC2 will try to compensate for the problem thereby learning incorrect information After you discover and fix the problem ERC2 will operate with the values learned during the problem period and will have to relearn the original corre

6500-UM001A-US-P, Pro-Set 200 Design Manual

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