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SIMATIC 505 TurboParison Module User Manual

1. 12345 67 8 9 1011 12 13 14 15 16 Download the configuration table Download profile setpoint table for axis 1 Download profile setpoint table for axis 2 Download profile setpoint table for axis 3 profile control or Download position and velocity tables for axis 1 ram control Download profile setpoint table for axis 4 profile control or Download position and velocity tables for axis 2 ram control Enable auto weight control for axis 1 Force profile SP to purge value specified in configuration table Profile 1 is controlled by bit 1 profile 2 by bit 2 profile 3 by bit 3 and profile 4 by bit 4 Purge takes precedence over RUN When module is in RUN mode enables profile 1 bit 5 profile 2 bit 6 profile 3 bit 7 or profile 4 bit 8 Time based systems and Mode 5 Profile is enabled when bit 1 Position based systems Profile is enabled on the rising edge when bit transitions from 0 to 1 Force profile SP to phase check value when the current profile SP step matches the step in the phase check location field of the configuration table Profile 1 is controlled by bit 9 profile 2 by bit 10 profile 3 by bit 11 and profile 4 by bit 12 Provides internal synchronization pulse rising edge for axis 1 bit 13 axis 2 bit 14 axis 3 bit 15 or axis 4 bit 16 in time based systems External synchronization i
2. Profile setpoint table Profilesetpoint tablelength Process vari CE table starting address Sync delay phaseshift time delay phase shift time ei a E E E wrom 0 3 o fe o mesam fe f fe mesasa m f fe ELIT III a a FERENT ee ERN EMT Profile time calculation method calculation method Number of K eal to needed average profile time Profile time out value Profile step coincidence location 24 64 Number of steps to hold profile coincidence output em OC L 25 65 Table Configuration Worksheets SIMATIC 505 TurboParison Module User Manual lt Configuration Table Worksheet O Time based Operation Page 2 of 3 V memory start address WY 5 Note In this table V memory address start address offset For example if start address V100 offset 4 Then V memory address V100 4 V104 Axis 3 Axis 4 V memory V memory Parameter description address address Configuration word Ts loop sample time 81 121 Calibration zero for analog input 82 122 84 124 Tr input filter time constant Reve 5 T fes T Pt initial Initial profile time 86 126 Kc proportional gain constant Tj integral time constant Tg derivative time constant Output zero Output span Profile setpoint table length Process variable table starting address Sync delay phase shift time Purge value Weight control Phase
3. 0 0 e eee eee 1 8 List Of Setup Tasks 22d obere aet enden d nh bbs e Ead teed apad tenet 1 9 Howchartof Installation iet ee RR RR COR bob ble UR ERR be ees 2 2 Setting DIDSWIECheS 2 oo iere ce p ebd led Peg br Fa pedore ba d pasce deat 2 4 Dipswitch and JumperLocations suiras saima ant agia ie gi waa aiena atA a dia 2 5 Terminal Blocksand Pinouts aaka e eaa e re 2 6 Wire Gauge and Stud Sizes 1 enn nnns 2 7 Module Input Output Wiring ssssssssseeeeeee m 2 9 Inserting the Module into the Base sssssssseseeeeeeeens 2 10 Sample VO Definition CHAM 2 24 cs sia rese ekeren r RE RR Ren ERE RE bara a 2 12 V O Configuration Chath sedeo ot eter de Eee ee Oed ac Rede aet 2 12 Relationship of TurboParison Module to the Machine aaus 3 3 Controller Module Information Exchange sssssssssse ee 3 4 Bit Layouts for WX Words Data from Module 0c cece cece eee en 3 6 Bit Layouts for WY Words Commandsto Module sss 3 7 V Memory Transfer of Configuration and Status aaa 3 9 Configurable Elements within the Module ssssssssss teens 3 10 Setpoint Generator Operation sssssssssss eee 3 11 Axis ControlerOperation ssssssssssssssssseee eee 3 12 Timing fora Forced Table Download ssssssseeeeeeenn en 3 15 Relationship of Synchronization Pulse to Profile Setpoints 0 ceca 4 3 Machine Sequence Timing Example
4. Connect terminal block Insert module into base Power up Figure 2 1 Fowchartof Installation 2 2 Installing the Module SIMATIC 505 TurboParison Module User Manual Handling the Many integrated circuit IC devices are susceptible to damage by the Module discharge of static electricity The suggestions listed below reduce the probability of damage to these devices whenever you handle a controller a base controller or any of the I O modules Ensure that both the module and the person who handles the module are at the same ground potential To accomplish this fulfill the following conditions e Transport the module in an anti static container or with anti static material e Ensurethat the work area has a conductive pad with a lead that connects it to a common ground e Ground yourself Make contact with the conductive pad or wear a grounded wrist strap Visual Inspection If thereis any visible damage to the module or if you need additional information and assistance contact your Siemens Industrial Automation Inc distributor or sales office If you need assistance in contacting your U S sales office call 1 800 964 4114 SIMATIC 505 TurboParison Module User Manual Installing the Module 2 3 2 2 Setting Options Selecting Module Use the dipswitch to set the module operational mode listed in Table 2 1 Operation Type The dipswitch assembly is labeled either OFF or OPEN Either
5. Table Configuration Worksheets SIMATIC 505 TurboParison Module User Manual Configuration Table Worksheet Position based Operation Mode 4 Only Page 2 of 6 V memory start address WY 5 Note In this table V memory address start address offset For example if start address V100 offset 4 Then V memory address V100 4 V104 Axis 3 profile control only Axis 4 profile control only m V memory Value V memory Value Parameter description address Fe address Configuration word 80 120 loop sample time 81 121 Calibration zero for analog input 82 122 Tr input filter time constant 84 124 Reed s J sl peio z Kc proportional gain constant Tj integral time constant Tg derivative time constant Output zero Output span Profile setpoint table starting address Profile setpoint table length Process variable table starting address Reserved Purge value Weight control Phase check locati on Phase check setpoint Number of steps to hold phase check Reserved Reserved Profiletime out value Profile step coincidence locati on Number of steps to hold profile coincidence output Reserved 19 SIMATIC 505 TurboParison Module User Manual Table Configuration Worksheets V memory start address WY5 Parameter description Configuration Table Worksheet Position based Operation Mode 3 Only Page 3
6. seen n n n n n n n n n n Determining Configuration Para meters Determining the V Memory Required Entering Data into V Memory 5 4 Preparing the Module forOperation 5 5 Operating the Module in Position based Mode eee nnn nnn Putting the Module in RUN Mode Ena bling Disa bling Profile Execution 5 6 Changing Configuration and Profile Data ssssssssssssssnnnsnnnnnnnnsnnnnn 5 7 Monitoring the Operation of the Module SIMATIC 505 TurboParison Module User Module Position based Operation 5 1 5 1 Overview of Position based Operation The TurboParison module provides control of position based equipment such as found on industrial blow molding machines This chapter describes position based operation and shows you how to configure the module for this mode of operation Definition of In position based mode the module links profile execution to the position of Position based the accumulator ram or reciprocating screw The total shot sizeis divided Operation by the number of setpoint entries N for the profile This results in N zones where each zone has a corresponding setpoint in the Profile Setpoint table Figure 5 1 Shot Zones 1 16 Shot Size End of Shot 32000 28000 0 Accumulator Ram Profile Note In this example the shot size is 28000 Profile steps 1 16 Figure 5 1 Relationship Between Ram Position and Profile Figure 5
7. sssssssssseeeeeerr e Controlling Ram Velocity Mode 3 Only iisssssssssss e Open Loop vs Closed Loop Velocity Control ccc ees Controlling Mandrel Position Wall Thickness cece cece n Monitoring MandrelPosition 0 cece eee 5 2 Characteristics of Position based Modes ssssssssssnssnsnsnunnnnnnnnnnnnann Two Head Operation with Accumulator Control Mode 3 ccc cece eee eee Four Head Operation without Accumulator Control Mode 4 Two Head Operation with Automatic Restart Mode 5 ccc cece eee eee eee Differencesin Mode 5 ccc ccc cet ee 5 3 Determining Module Configuration Parameters cceee cece eee Determining Configuration Parameters 60 6 eae Determining the V Memory Required 0 0 cca Entering Data into V Memory 0 0 cece 5 4 Preparing the Module for Operation enn nnn nnn n nnn 55 Operating the Module in Position based Mode eee nnn Putting the Module in RUN Mode sssssssseeeeee eee Enabling Disabling Profile Execution srrisirrsecrrisisrre tribo A n 5 6 Changing Configuration and Profile Data eseeeeeennnn nn n n n n nnn 5 7 Monitoring the Operation ofthe Module s seen n n n n n n n n n nn Chapter6 Calibration and Loop Tuning 6 1 OVEIVIOW pM di eae bed Lee ee ee eae es eae dete eed de eke es Areasof COnlTOl cese ostessdibrsib d CER REO Ra du RO dUbs Madd doce
8. Output Voltage Range Pins 1 2 0 to 5V J17 axis 4 out Pins 2 3 0 to 10 V Factory setting J16 axis 2 out J15 axis 1 out axis 2 in axis 1 in Input Voltage Range Pins 1 2 0 to 10 V Factory setting axis 4 in Pins 2 3 0 to 5 V axis 3 in aux in E101 E100 SW1 i i WU ee X amp Figure 2 3 Dipswitch and Jumper Locations NOTE J umper pins E 100 and E 101 are for manufacturing test purposes only Do not attempt to install jumpers across them SIMATIC 505 TurboParison Module User Manual Installing the Module 2 5 2 3 Field Wiring Field wiring consists of wiring for the user supplied power and wiring for the input or output signal Keep the two types of wiring separate to prevent noise on the signal wiring Use shielded twisted pair cable 14 24 AWG or 0 18 1 5 mm either stranded or solid type See Figure 2 4 and Figure 2 5 I Axis 2 output Axis 1 output GV OV V Axis 4 output 9v Axis 3 output ev i CO E EO yv EV Axis 2 input Axis 1 Input
9. Jg 8 298 8V V G GO GO S GO S GO GO GO S S GO GO g Axis 4 input 8 Axis 3 input V V 99 1 88 Shield go vH 8 CH M J See Table 2 1 for Auxiliary input axis assignment c 99 SQ CO amp 69 CO amp G9 eo 69 YO Common DC return ps s Muni For discrete inputs discrete BORGO DUPUIS ONIY outputs and 24 VDC L Axis 1 Axis 1 Ja 01120 8211479 Ld 9d 6 Axis 2 Discrete Axis 2 Discrete e outputs inputs P Axis 3 E SESBSESESESBSESESESESESESESESESESESESES SMS GV GP RS S SS RSS MS S MS V8 SL Aaa Eo vd fd 2 L Axis 4 Axis 4 P
10. 0 50 A 40 C 0 40 A 60 C Rated voltage 15 to 24 VDC Operating voltage range 12 to 30 VDC Temporary overload 2 0 A for 1 ms Maximum current per output Maximum on state voltage drop 0 5 VDC Maximum delay time through module i D 1 ms on to off 1 ms off to on with 5 ma minimum load Type of outputs non latching unprotected Output fuse rating 1 amp 125 V normal blow 5x20 mm Table D 5 Discrete Input Specific ations mem 9 7 Rated voltage 24 VDC Input voltage range for ON 14 0 VDC minimum 30 0 VDC maximum Input voltage range for OFF 0 0 VDC minimum 5 0 VDC maximum Input current limits during ON 2 0 mA minimum 15 0 mA maximum Maximum input current for OFF 0 5 mA Delay time through module 3 ms minimum 1 ms maximum D 4 Specifications SIMATIC 505 TurboParison Module User Manual Appendix E Table Configuration Worksheets The worksheets in this appendix help you configure your TurboParison module and enable you to keep a written record of the configuration The worksheets are arranged in the following categories Worksheets for Time based Operation Use these worksheets to help you configure your module for a time based parison process With these worksheets you can record data for the Configuration Table and Profile Setpoint Table Worksheets for Position based Operation Use these worksheets to help you configure your module for a position based parison process With these worksheets yo
11. Bit 4 indicates that either the Profile Setpoint Table profile control for axis 3 has been downloaded to the module or the Position and Velocity Setpoint Tables accumulator control for axis 3 have been downloaded to the module Axis 4 setpoint table download complete Bit 5 indicates that either the Profile 1234567 89101 1121341415 16 Setpoint Table profile control for axis 3 has been downloaded to the module or the Position and Velocity Setpoint Tables accumulator control for axis 3 have been downloaded to the module Interpolation complete Bit 6 indicates that an interpolation command request is complete This bit is reset when you turn off the interpolation command bit in WY 7 Table expansion complete Bit 7 indicates that a table expansion command request is complete This bit is reset when you turn off the expand table command bit in WY7 Modulein RUN mode Indicates the module is in RUN mode Profile 1 PV Table upload in progress Bit 9 indicates that the PV Table for profile lis being uploaded to the controller Profile 2 PV Table upload in progress Bit 10 indicates that the PV Table for profile 2 is being uploaded to the controller Profile 3 PV Table upload in progress Bit 11 indicates that the PV Table for profile 3is being uploaded tothe controller Profile 4 PV Table uploa
12. s ow us mem o NENNEN s fafo BENIN NEM uos 13 53 93 133 Profile Setpoint Table length 2 4 8 16 32 64 128 256 4 5 134 Process Variable starting address 0 to 65 000 15 55 95 135 Reserved 0 17 57 97 137 Weight control 32 000 to 32 000 18 58 98 138 Phase check location 0 to 255 19 59 99 139 Phase check setpoint f 0t0 32 000 20 60 100 140 LIII GIL MAE MEN L 145 Number of steps to hold profile coinci dence 0 to 256 output SIMATIC 505 TurboParison Module User Module Position based Operation 5 15 Determining Module Configuration Parameters continued Table 5 4 Configuration Table for Position based Operation All Modes V memory offsets 93S eem 000000000 B am qemessesmmie 0 namismumme mum eem E H ead A die gap continuously downloaded O to 32 000 H ead B die gap continuously downloaded O to 32 000 Back pressure setting for profile A mode 3 or Head C 0 to 32 000 die gap mode 4 continuously downloaded i 182 Back pressure setting for profile B mode 3 or Head D ie die gap mode 4 continuously downloaded 0 t0 32 000 184 Axis 1 manual override value continually downloaded 32000 to 432000 186 Axis 3 manual override value continually downloaded 32000 to 32000 187 Axis 4 manual override value continually downloaded 32000 to 432000 Mode 4 and Mode 5 only If a parameter value is zero the module uses the
13. 0 32000 24000 23800 30400 5600 16000 1400 6400 0 Percent of maximum velocity Percent of total stroke A value of 16000 50 A value of 16000 50 A value of 8000 25 A value of 8000 25 Figure 5 4 Specifying a Ram Velocity Profile The values in the Velocity Setpoint Table can range from 0 32000 Therefore 16000 2 5096 of maximum velocity Create a Velocity SP Table for each ram one or two that you want to control Specify the starting address for a Velocity SP Table by entering an address into the velocity SP starting address field for axis 3 or 4 in the Configuration Table Specify table length for a Velocity SP Table by entering a value 2 4 8 16 32 64 128 256 into the Velocity SP Table length field in the Configuration Table The values in the ram Position Table can range from 0 32000 Therefore 16000 5096 of total stroke Create a ram Position Table for each ram one or two that you want to control You specify the starting address for a Position Table by entering an address into the Position Table starting address field for axis 3 or 4 in the Configuration Table The length of the ram Position Tableis the same as the Velocity SP Table The Velocity Setpoint Table and the Position Table are downloaded to the module automatically upon transition to RUN mode or by user command SIMATIC 505 TurboParison Module User Module Position based Operati
14. hexadecimal 5000 decimal 20480 the modules enters RUN mode All setpoint tables and configuration information is automatically downloaded from the controller All axis controllers are enabled the RUN LED comes on and the RUN mode bit WY 4 Bit 8 is set to 1 3 6 Understanding Module Operation SIMATIC 505 TurboParison Module User Manual Communicating with the Controller continued Current Profile Execution Step For Each Axis 1 45 11 12 13 14 15 te wx2 1 2 s 4 s e 7 A P Ne i Y Current step number for axis 3 0 255 Current step number for axis 4 0 255 Current step number for axis 1 0 255 Current step number for axis 2 0 255 Handshaking Error and Status Information 1 a 5 JE T 12 13 14 15 16 WXA 1 2 3 45 6 7 JE 12 15 3 P WERE SEES J5 J A Illegal pointer Configuration Table download complete Illegal data in Configuration Table Profile Setpoint Table download complete for axis 1 2 Y Calibration error Interpolation complete Y i Fatal error Table expansion complete Y i Profile 1 2 3 or 4 time out Module in RUN mode i Profile 1 2 3 or 4 running PV Table upload in
15. 4 17 Grounding recommendati ons 2 9 Guidelines calibrating rams 6 10 errors and alarms 3 17 tuning loops tuning loops and calibration 6 4 Index 2 H High speed operation 1 4 4 6 1 0 configuration chart definition chart 2 12 Installation field wiring 2 6 task flow 2 2 Integral ti me 6 14 Interpolation overview procedure J umper locations 2 5 L LEDs MOD GOOD 2 11 RUN 2 11 Linear interpolation 7 2 M Machine sequence time based operation 4 3 timing example in position based 5 3 Mandrel controlling position position control 4 4 Memory allocating guidelines 3 16 Miscellaneous functions automatic weight correction 7 6 discrete outputs interpolation 7 2 table expansion MOD GOOD LED 2 11 Mode 1 high speed typical application 1 4 Mode 2 standard speed typical application 1 5 Mode 3 two head two accumulator 5 8 Mode 3 two head two accumulator typical application 1 6 Mode 4 four head position based operation typical application 1 7 1 8 Mode 4 four head position based 5 9 Mode 5 calibrating aux 5 6 13 Mode 5 two head automatic restart 5 1045 12 Model 535 2 10 Modes operation 1 3 Module avoiding electrostatic damage 2 3 error conditions fail codes 2 11 inserting into base 2 10 LEDs operation overvi ew 3 2 Monitoring operation in position based 5 21 O Open loop calibration
16. 48 8 128 Ti integral time contant 9 49 8 129 Tg derivative time constant Profile setpoint table starting address 13 53 93 133 Profile setpoint table length 2 4 8 16 32 64 128 256 14 54 94 134 Process variable table starting address Oto 65 000 15 55 95 135 Reserved 0 o 16 56 96 136 Purge value 0t032000 Uu 5 9 17 wegtentro 32000t0432000 18 58 98 138 Phase check locati on Oto 255 19 59 99 139 Phasechecksetpoint 0to32000 20 60 10 140 Number of steps to hold phase check 21 61 101 141 0 Reserved Reeve 23 63 103 143 Profile time out value 0 to 65 535 milliseconds Profile step coincidence location Oto 255 Number of steps to hold profile O to 256 coincidence output Reeve Parameters listed in this table for Axis 3 and Axis 4 are valid only when used for profile control Table B 6 lists the valid parameters for Axis 3 and Axis 4 when they are used for accumulator ram control B4 Configuration Table Data SIMATIC 505 TurboParison Module User Manual Table B 6 Configuration Table for Position based Operation Accumulator Mode 3 only V Memory offsets WY5 offset IE As E iss Ailsa o parameter name varia vaes Ts ep sample time 1 to 32 767 milliseconds Calibration zero for analog input 0 to 10 000 mv Calibration span for analog input 0 to 10 000 mv NA NA 8 124 Ty input fi
17. 00 ccc ee 1 9 Chapter 2 Installing the Module 2 1 Overview of Installation ccc cece nnnm 2 2 Fow of TASKS o eis eut nre ice echa ee PARIS a ere ee woke ace Rc dS 2 2 Handling the Module eor RR Ree RE ike ee CE ER n e Ea x ecc 2 3 Visualnspection seseina na ee RE teint E eR IP R GE SOR midge dictate sicat 2 3 22 Setting OpUOnS 225i 2sics e odas a riReRSERAREEEERERERERERAZCRSUR RS GRRITG cease Selecting Module Operation Type sssssseee s 2 4 Selecting a Voltage Range sssssssssee mnn 2 4 UEM CO CU PERCENT Minimizing NOISe acissebiien i RR backs eke e Ru CR ERE EXER E E Rn 2 7 2 4 Power Supply and Grounding Recommendations seen nnn nnn Power Budgeting cu etc Eee pe ERR RA ER E E eR WR CR REIR bu 2 8 2 5 Cable Connections and Grounding ccceeee cece cece n nnn 2 6 Inserting the Module into the Base eseeeen nnn nnn n nnn nn nnn Inserting the Module sssssssseeseeeeeeee emere 2 10 G uidelinesfor CPU T1535 resres rehab hr RR ERE REA eR Ra er E PADO DOLEO 2 10 Checking Status Indicator eee eem ben ie Ea Re a Rc 2 11 2 Logging the Module into Controller Memory seen nnn n n n n n n n n n n nn 2 12 Configurnng l O iit orae ete Ret aa Che Ria D Roe NEUE UR LS E RUE RUE NEU e Rua din 2 12 Selecting the I O Definition Chart 00 ccc eects 2 12 Viewing the I O Configuration Chart 6 0060 2 12 Contents iii Chapter3 Understandi
18. 1 Enable broken transmitter alarm PID bias calculation method 0 Freeze bias 1 Back calculate bias recommended Differentiate process variable 0 PV scaled analog input x 1 PV dx dt x 32000 VSF x Ts Open d osed loop control 0 Open loop 1 Closed loop Direct Reverse acting control 0 Direct acting control loop PV increases when output increases 1 Reverse acting control loop PV decreases when output increases Filter analog signal 0 Nofiltering 1 First order exponential filter Ts loop sample time Specifies the sample time for the analog input and output For closed loop operation the module calculates the PID after every sample and updates the corresponding output The default valueis 1 millisecond Calibration zero for analog Specifies the zero analog input signal where the values 0 10000 input correspond to 0 10 volts if you select the 0 to 10 volt range with the jumpers on the module board The values 0 10000 correspond to 0 5 volts if you select the 0 to 5 volt range with the jumpers The default valueis O TheMode column lists the mode of operation for which the parameter is valid T time based operation P position based operation SIMATIC 505 TurboParison Module User Manual Configuration Table Data B 7 Parameter Descriptions for Configuration Table continued Table B 10 Parameter Descriptions for Configuration Table continued Calibration span for analog Specifies the span an
19. 1 if the operation was successful Set bit 15 of WY 6 to O when the status bit in High limit bit 10 11 12 13 14 15 16 WX3 indicates a successful high limit 1 0 Jo fo calibration The module then clears the status bit in WX3 High limit bit Calibrate remaining axes Repeat steps 2 through 6 to calibrate the remaining axes Exit CALIBRATE mode SIMATIC 505 TurboParison Module User Manual Set bit 13 of WY6 to O The module checks the 10 11 12 13 14 15 16 calibration data If the limits are valid they are WY6 8 9 0 o 0 0 0 0 written to the appropriate V memory locations in the Configuration Table If the limits areinvalid e g zero span the previous calibration data remains in effect and the calibration error status bit in WX3 is set to 1 Figure 6 9 Ram Calibration Procedure Calibration enable bit Calibration and Loop Tuning 6 11 Calibrating Rams continued Calibrating Maximum Ram Velocity The automatic maximum velocity calibration feature calculates the value of the velocity scaling factor VSF which is entered in the velocity scale factor field of the configuration table The VSF determines the maximum velocity of the ram measured in counts 0 32000 per second To use this feature you must purge at full velocity open loop The module monitors the
20. 2 7 paying attention to the minimum torque required to help prevent noise The module is a special function module and capable of high speed block transfers Install the module in the local base the base containing the controller for best performance Guidelines for C PU Do not install this module in slot one of any 505 base controlled by a 535 T1535 CPU If you doinstall this module in slot one discrete modules in base zero do not register in controller memory If the controller is a 545 or 565 you can install the module in any slot of any base Minimum torque 2 6 in Ib 0 3N m Maximum torque 4 12 in Ib 0 6N m SESS SSSI BSS SSIS 9 0 9 SSS SSDS SS SSS SEC SSIS SOS SOS SISOS SOIT SOLOS SESS STS Figure 2 7 Inserting the Module into the Base 2 10 Installing the Module SIMATIC 505 TurboParison Module User Manual Checking Status Indicator Within approximately three seconds of powerup the MOD GOOD LED on the bezel comes on indicating that the module is good If the LED fails to come on check your wiring If the problem persists contact your distributor NOTE If LEDs blink refer to Table 2 3 If any fail codes occur except for the factory test jumper the module should not be used Table 2 3 Module Fail Codes 8 MeMefmcinnnrmaly a EWemirem SBanNSS a 7 SFIC ram 9 Digital analog conversion 10 Analog digital conversion Continuous Factory test jumper install
21. 2 contains a machine timing diagram for a machine operating in position based mode 3 In this example the module provides open loop velocity control for a ram To control the die head the module uses a profile consisting of eight steps In this example the following events occur e Thecontroller commands the module to run profile A by setting Bit 5 in WY8 e The module responds by setting Bit 9 in WX3 This response indicates that profile A is active e The module sets the voltage to the ram s proportional amplifier toa value corresponding to the first setpoint in the Velocity Setpoint Table e Astheram moves from shot size to zero the module monitors the position of the ram and steps through the die head profile accordingly e When the ram reaches End of Shot zero position the profile running bit Bit 9 in WX3 returns to 0 indicating profile execution is complete 5 2 Position based Operation SIMATIC 505 TurboParison Module User Manual e When Bit 9 in WX3 returns to zero the module forces the ram velocity amplifier voltage to zero until the profile run bit Bit 5 in WY8 is reset to zero At that time the ram velocity goes to the back pressure setting hold value RUN Command from controller Enable profile A Bit 5 in WY8 Profile Running Indication to controller Profile A l active i Bit 9 in WX3 32000 77 Ram Velocity
22. 6 3 velocity control 5 6 Operation differences between time based modes 4 10 four head operation without accumulator 1 7 high speed 1 4 mode 1 high speed time based 4 6 monitoring in position based 5 21 monitoring in time based mode 4 17 position based 1 3 1 6 zu preparing the module in position basedj 5 18 preparing the module in time based 4 14 putting module in RUN mode in positi on based 5 19 standard speed 1 5 4 8 task flow time based 1 3 4 2 two head two accumulator mode 1 6 Outputs position coincidence step coincidence p Phase check 7 10 Position coincidence output 7 8 Position table 5 5 Position based operation Position based configuration table all modes configuration table mode 3 configuration table mode 4 5 15 controlling ram velocity mode 3 two head two accumulato mode 4 four head operation mode 5 two head operation 5 10 operation 1 6 NN betwen ram position and profile 5 2 four head machine operation 1 7 1 8 r two head two accumulator mode 1 6 velocity control 5 6 Power budgeting consumed from base 2 8 external supply recommendations 2 8 Process variable table 3 8 starting address for position based 5 7 Product overview features 1 2 Index 3 Profile execution enabling disabling in position based 5 19 ti me based 4 15 Profile setpoint table starting address in position based
23. 6 6 You do not need to adjust amplifier gain to modify performance SIMATIC 505 TurboParison Module User Manual Calibration and Loop Tuning 6 5 6 3 Calibrating the Die Heads Overview For die heads the calibration process typically involves raising or lowering the mandrel and setting the zero and span value See Figure 6 4 Numeric Value Stored in TurboParison Module Minimum CC Zero Value 0 Span Value 4 4 32000 Maximum Leave a small gap between the zero span value and the minimum and maximum range of the mandrel when setting zero and span values Doing this ensures that you avoid equipment damage caused by a mandrel overshooting the zero or span location Ensure that you leave the gap when you set the zero and span values Converging vs Tooling affects calibration Figure 6 5 shows the mandrel positions for both Diverging Tooling types of tooling during calibration Zero value 0 corresponds to the closed tooling position span value 32000 corresponds to the open tooling position Keep these factors in mind when you calibrate the module Span Value 32000 4 4 Zero Value 0 b d 7 Zero Value 0 Gi ous Span Value 32000 Diverging Converging Figure 6 5 Die Positions for Diverging and Converging Tooling 6 6 Calibration and Loop Tuning SIMATIC 505 TurboParison Module User Manua
24. Heads sssssssse nnn 6 15 Guidelinesfor Tuning LOOPS 0 eee mnn 6 16 Chapter7 Using the Module s Optional Features Interpolation and Expansion of Profile Data seen nnnm OVENWIEW dc ERR 7 2 Interpo lation cui o ee ede bro eel deed deir de tle de Al a Racine d 7 2 Table EXPANSION iius ehe eek RR RR GR RU CERE TE RU Ud eee RE KR 7 5 Automatically Maintaining the Weight of the Parison enne Desc rnptlonh oret P PRETEREA REC ERBEN ERES EERECSREPUCRRER E Man ER E NER cated 7 6 diee M 7 7 Using the Module s Discrete Outputs ssesnn nn nmn Descrnption oie ike RE RR HR Ue RR e ho ed E ebd a Ed eR a p Rd dee ts 7 8 Procedure MEET 7 9 Checking the Phase Between a Profile and a Parison esee 7 10 prre EEUU 7 10 Procedule iis tis eere eg der eric idw obo iR a e QUEE RE e Da id 7 11 Appendix A WX WY Word Descriptions A 1 A 2 OVerVieW 9 3 RR DGRECEFOISRCEREKNRRRIRREESRRDEPRREECREREREIRFCFERYORE Tera WX1 Current Profile Execution Step for Axes 1 and 3 WX2 Curent Profile Execution Step Axes 2 and 4 WX3 Handshaking Eror and Status Information WX4 Handshaking Eror and Status Information Contents A 3 WY WOES tia do ea o 88 RR CR EC E R CR ROC LR QR REL DOLAR RE RR RN JR x QR n WY5 Configuration Table Starting Address WY6 Module Operational Mode sssssesssssss nnns WY7 MiscellaneousFunction Control ss rris kirri rereiiaieia ataia kii
25. Module Operation 3 5 WX WY Words WY5 V Memory Address of Configuration Table WY6 Module Operational Mode The WX words report status and error information to the controller The WY words are used by the controller to control the module operation Figure 3 3 shows the bit layouts for the WX words Figure 3 4 shows the bit layouts for the WY words WY 5 and WY6 must be set correctly to ensure that the module operates properly Refer to Appendix A for detailed descriptions of the other WX WY words WY 5 provides the starting address of the Configuration Table The module reads the Configuration Table from the controller upon transition to RUN mode Ensure that WY 5 contains a valid V memory address and that confi guration information exists at this location before going to RUN mode Setting WY 6 selects the mode of operation for the Module IDLE CALIBRATE or RUN e IDLE When all bits are equal to 0 off the moduleis idle outputs are turned off e CALIBRATE When Bit 13 is equal to 1 the module enters calibration mode Use Bits 14 16 to store calibration data Zero Span ram velocity into temporary storage Resetting Bit 13 to 0 loads calibration data into the appropriate V memory locations NOTE When you exit CALIBRATE mode by changing WY6 Bit 13 to 0 the module goes to either IDLE or RUN mode as determined by the value of WY 6 See Figure 3 2 e RUN When Bits 2 and 4 are equal to 1 and all other bits equal to 0
26. Profile step coincidence location coincidence location 0t0255 to 255 N ELM of steps to hold profile ES to 256 coincidence output 26 39 66 79 mems ie mo Remwd Mode2 only B 2 Configuration Table Data SIMATIC 505 TurboParison Module User Manual Table B 2 Configuration Table for Time based Operation Auxiliary Input 5 V Memory offsets WY5 offset Parameter name Valid values Calibration zero for analog input 5 0 to 10 000 mv Calibration span for analog input 5 0 to 10 000 mV rus meme 7 0 Table B 3 Configuration Table for Time based Operation Miscellaneous Functions V Memory offsets WY5 offset Parameter name Valid values 1 curvelinear interpolation Length of expanded table 2 4 8 16 32 64 128 256 vers Ree 7070000000000 9 1 Table B 4 Configuration Table for Time based Operation Continuous Download Segment V Memory offsets WY5 offset Parameter name Valid values Axis 4 manual override value continually downloaded Gmus ree SOS SIMATIC 505 TurboParison Module User Manual Configuration Table Data B 3 B 2 Configuration Tables for Position based Operation Table B 5 Configuration Table for Position based Operation Die Head TAAL ASI ASS xs parameter name Calibration zero for analog input Calibration span for analog input 4 4 a 1 4 Ty input filter time constant imus p Ls e 9 p 9 ees rcc Kc proportional gain constant 8
27. Profile time calculating 4 2 Proportional gain 6 14 R Ram calibrati ng 6 10 calibrating maximum velocity 6 12 setting zero and span position velocity profile 5 5 Reverse acting control 6 7 RUN LED 2 11 RUN mode position based 5 19 time based operation 4 15 S Setpoint generation 3 10 operation 3 11 Setpoint tables 3 8 downloading to controller 4 16 downloading to the module 3 14 Setting options dipswitch location 2 5 dipswitch settings jumper locations 2 5 module operational mode 2 4 voltage range Shielding recommendations 2 9 Shuttle machine 1 5 Specifications analog input output discrete output input D 4 Index 4 physical and envi ronmental D 2 Standard speed mode 4 8 Standard speed mode operation 1 5 Static electricity Step coincidence output 7 8 Sync pulse minimum maxi mum 4 5 relationship to profile setpoi nts 4 3 T Table expansion 7 5 Task flow installation operation 1 9 Terminal blocks and pinouts Time based configuration table 4 11 differences between modes 4 10 operation 4 2 preparing the module for operation profile execution RUN mode Time based operation controlling mandrel position 4 4 monitoring mandrel position 4 4 TISOFT configuring I O 2 12 Tooling calibration 6 6 selecting diverging convergi ng 6 7 Transducer excitation 2 8 Tuning loops description 6 14 g
28. Y Calibrate die heads and accumulator 1002830 Figure 6 1 Areasof Control for Calibration and Tuning For dies the calibration process involves raising or lowering the mandrel and setting the zero value and the span value See Figure 6 2 Numeric Value Stored in Turbo Parison Module Minimum Zero Value o gt Span Value 4 1 32000 Maximum I 1002831 Figure 6 2 Calibrating Zero and Span Values 6 2 Calibration and Loop Tuning SIMATIC 505 TurboParison Module User Manual Using Open Loop vs Closed Loop Mode for Calibration Setting the module to open loop control in effect bypasses the loop controller and places the axis into manual operation Closed loop control allows the loop controller to determine the output level based on feedback from the process See Figure 6 3 Select open or closed loop mode in the axis configuration word See Chapter 3 Open Loop Closed Loop Position and or Velocity Position and or Velocity Feedback Feedback Process Process Variable Variable Setpoint Setpoint or Hold Value Loop or Hold Value Loop gt Control 9 9 Control Figure 6 3 Open Loop vs Closed Loop Contol e Advantage of Configuring in Closed Loop Mode If your tooling must be calibrated to precise positions rather than to maximum minimum po
29. alarm Indicates whether a broken transmitter alarm is on for one or more of the axes Bits 1 through 12 are not used Bit 13 corresponds to axis 4 Bit 14 corresponds to axis 3 Bit 15 corresponds to axis 2 Bit 16 corresponds to axis 1 Pt calculated for axis 1 time based operation only a Pt calculated for axis 2 time based operat only p Pe ans 3 re ase pation ca E Pt calculated for axis 4 repere operation only Weight correction for profile A 225 Weight correction for profile B 226 Weight correction for profile C 227 Weight correction for profile D 229 Current setpoint for axis 2 230 Current setpoint for axis 3 231 Current setpoint for axis 4 CERTI SIMATIC 505 TurboParison Module User Manual General Status Table Data C 3 Appendix D Specifications D 1 Physical and Environmental Specifications ccccceeeeee eee eee n n n n n n n n nn D 2 Analog Performance Specifications sssseeeene nnn nen nnn nn nnn D 3 Disc rete Output and Input Specifications ccc cece cece eee eee nn n n n n n n n n n n nn SIMATIC 505 TurboParison Module User Manual Specifications D 1 D 1 Physical and Environmental Specifications Table D 1 Physical and Environmental Specific ations Minimum torque for bezel screws 2 6 in Ib 0 3N m Maximum torque for bezel screws 4 12 in Ib 0 6N m Input signal wiring Shielded twisted pair cable 12 26 AWG or 0 16 3 2 mm stranded or solid Relative humidity 5 to 95 nonc
30. axis 2 die head B Step O refers to the first entry in the Setpoint Table WX3 Handshaking Enor and Status Information Bit s set Description 234 5 67 8 9 1011 12 13 14 15 16 Illegal pointer Bit 1 indicates that an illegal starting address has been specified for WY 5 or within the Configuration Table Illegal data Bit 2 indicates that illegal data exists in the Configuration Table This error usually occurs when a table parameter is out of the specified range In most cases the module uses the default parameter value and continues to operate Calibration error Bit 3 indicates that a calibration error occurred For example the low calibration limit may equal the high calibration limit The module dears this bit when the calibration process completes successfully Fatal error Bit 4 indicates that a fatal error occurred Profile x time out Bits 5 through 8 indicate that the accumulated time from the start of profile 1 bit 5 2 bit 6 3 bit 7 or 4 bit 8 exceeded the profile time out value specified in the Configuration Table For time based operation the module resets this bit when the next sync pulse occurs For position based operation the module resets the bit when the next RUN command is issued Profile x active Bits 9 through 12 indicatethat profile 1 bit 9 2 bit 10 3 bit 11 1234567 89101 112131415 16 Or
31. by the RLL to verify that the 0000 Model dipswitch was set correctly 0001 Mode2 0010 Mode3 0011 Mode4 0100 Mode5 Bit5 At shot size for profile B Bit 6 At end of shot for profile B Bit 7 At shot size for profileA Bit 8 At end of shot for profile A Bits 9 12 Discrete output is on for the following Bit9 step coincidence for profile A Bit 10 step coincidence for profile B Bit 11 position coincidence for ram A step coincidence for profile C Bit 12 position coincidence for ram B step coincidence for profile D Discrete input is on for the following Bit9 input 1 not typically used for position based operation Bit 10 input 2 not typically used for position based operation Bit 11 input 3 not typically used for position based operation Bit 12 input 4 not typically used for position based operation SIMATIC 505 TurboParison Module User Module Position based Operation 521 Monitoring the Operation of the Module continued Table 5 5 General Status Table Contents continued V memory offsets rs oat Broken transmitter alarm Indicates whether a broken transmitter alarm is on for one or more of the axes MSB LSB 1 3 4 s5 6 a 9 qz 13 16 25 Bits 1 through 12 are not used Bit 13 corresponds to die D ram B axis 4 Bit 14 corresponds to die C ram A axis 3 Bit 15 corresponds to die B axis 2 Bit 16 corresponds to dieA axis 1 La
32. enable bit bit 13 in WY6to 1 10 11 12 13 14 15 16 8 9 o olo o ofi o o o Calibration enable bit Select an axis for calibration Set bits 10 through 12 in WY 6 to one of the values listed below 10 11 12 13 14 15 16 8 9 0 0 1 0 0 0 001 Axis 1 010 Axis 2 jm 011 Axis 3 100 Axis 4 101 Aux 5 Set the zero calibration limit After setting the ram to the zero End of Shot 10 11 12 13 14 15 16 position set bit 14 in WY6 to 1 The module reads 111 o o the analog input for the specified axis and records thezero value The module then sets the zero calibration status bit in WX3 to Lif the operation was successful Set bit 14 of WY6 to O when the status bit in WX3 Low limit bit 10 11 12 13 14 15 16 indicates a successful zero calibration When you 11o o o set bit 14 to 0 the module clears the status bit in WX3 Low limit bit Set the span calibration limit After setting the ram tothe span position set bit 10 11 12 13 14 15 16 15in WY6 to 1 The module reads the analog BONO input for the specified axis and records the span value The module then sets the span calibration status bit in WX3 to
33. for detailed instructions l O MODULE DEFINITION FOR CHANNEL 1 BASE 00 I O NUMBER OF BIT AND WORD 1 O SPECIAL SLOT ADDRESS X Y WX WY FUNCTION 1 0000 00 00 00 00 NO 2 0001 00 00 04 04 YES 3 0009 00 00 00 00 NO 4 0000 00 00 00 00 NO 5 0017 00 00 00 00 NO Figure 2 8 Sample I O Definition Chart Viewing the I O Use SHOW or a similar TISOFT menu selection to display the I O Configuration Configuration Chart The configurations in Figure 2 8 appear as shown in Chart Figure 2 9 l O CONFIGURATION CHART FOR CHANNEL 1 BASE I O POINTS 1 2 3 4 5 6 SLOT 1 SLOT2 WxX0001 WxX0002 WxX0003 WX0004 WYO0005 WY0006 WY0007 WYOO08 SLOT 3 SLOT 4 Figure 2 9 I O Configuration Chart 2 12 Installing the Module SIMATIC 505 TurboParison Module User Manual Chapter 3 Understanding Module Operation 3 1 IntioducBoln nol i y x ic ete Bede Cheer ie Sache boone eek thee ees 3 2 Communicating with the Controller sees m nnnm OVEVIEW cp TP IMT PAR HET WY5 V Memory Addressof Configuration Table cece cece eee WY6 Module Operational Mode 0 nett nnn V Memory Block Transfers 0 c cc ap A R aiea a Configuration Table 2 oues rete sea etd een te bet Read eae OA er eat General Status Table ss siii mieia tr bre Raga Be agde ed Oe ed ee t ob Setpoint Tables i 2ccstijccadiatinntse nig hang a Reena Rae daa ed ea aod Puedes Process Vala ble Tables cts neue Eae ted
34. for profile control The remaining two axes are available for accumulator control e The position and velocity of the accumulator ram determines when the module moves to the next profile step The module monitors ram position to determine the profile step In this mode the module can also control accumulator push out velocity Figure 5 6 shows a typical application of two head accumulator mode Profile A Profile B Position Position transducer transducer Proportional Proportional valve and valve and cylinder cylinder Position coincidence Accumulator output Accumulator Position coincidence output Position Axis Position transducer inpu transducer d Val Extruder Servo Valves Screw valve and valve and cylinder cylinder AMP 2 Extruder Screw Step coincidence output Die Axis 1 head Step outputs Sy coincidence lt ___ _ Plastic output TurboParison Plastic parison parison module Figure 5 6 Example of Two Head Operation wit
35. loop mode and enabling calibration move tooling by incrementing or decrementing the hold value die gap setting ACAUON Inputs to the Turbo Parison modules are unipolar 0 to 10 V using negative voltages may cause improper operation Improper operation can cause damage to your equipment Use only positive voltage as input from position transducers to monitor the position of the mandrel 6 8 Calibration and Loop Tuning SIMATIC 505 TurboParison Module User Manual Put module in CALIBRATE mode Set the calibration enable bit bit 13 in WY6to 1 10 11 12 13 14 15 16 ojojo 1 o o o 8 9 040 Calibration enable bit Select an axis for calibration Set bits 10 through 12 in WY6 to one of the values listed below 8 9 10 11 12 13 14 15 16 ojo Toy 1 0 0 0 001 Axis 1 010 Axis 2 011 Axis 3 100 Axis 4 101 Aux5 Set the zero calibration limit After setting the mandrel to the closed position Set bit 14 of WY6 to O when the status bit in WX3 10 11 12 13 14 15 16 i 1 o fo 8 9 040 set bit 14 in WY6to 1 The module reads the analog input for the specified axis and records the zero value The module then sets the zero calibration status bit in WX3 to Lif the operation was successful Low limit bit 10 1
36. need information that is not included in this manual or if you have problems using the TurboParison module contact your Siemens Industrial Automation Inc distributor or sales office If you need assistance in contacting your U S sales office call 1 800 964 4114 Preface xi Chapter 1 Product Overview 1 1 Features ois i cise isa x dx le Rag aea x UAARUEENR REG GR RGRG C EE EA NR GRAN RR RR dS 1 2 D SCMDUON vis ART 1 2 12 Time based Operation c ccc cece cece eee eee eee eee eee eee rn nn High Speed Operation Mode 1 sssssssssssseeeee ee eee 1 4 Standard Speed Operation Mode 2 ieee ccc cece tenet enn 1 5 13 Position based Operation ssssssssssssssssuununnunnnnnnnnnnnnnunnunnunn Two Head Operation with Accumulator Control Mode 3 cece cece eee 1 6 Four Head Operation without Accumulator Control Mode 4 ccc eee eee 1 7 Wheel Machine Operation with Position Input Mode 5 cece eee 1 8 14 Background Knowledge cccseeceeeceeeeeeeeeee nnne nnn nnn Prerequisitesand Assumptions 0 ccc eee 1 9 SIMATIC 505 TurboParison Module User Manual Product Overview 1 1 1 1 Features Description The TurboParison module controls the wall thickness of parisons created by blow molding machines This module provides closed loop control for both continuous extrusion machines and accumulator machines The TurboParison module e Operates as a special function module t
37. of 6 Note Inthis table V memory address start address offset start address V 100 offset 4 For example if Then V memory address V100 4 V104 Axis 3 accumulator control only Axis 4 accumulator control only V memory address Value V memory address Configuration word loop sample time Calibration zero for analog input Calibration span for analog input Tr input filter time constant Velocity scale factor Shot size proportional gain constant Tj integral time constant Tg derivative time constant Output zero Output span Velocity setpoint table starting address Velocity setpoint table length Position table starting address Reserved Position coincidence location Hold position coincidence on until Reserved Table Configuration Worksheets Value entered 80 120 SIMATIC 505 TurboParison Module User Manual Configuration Table Worksheet Position based Operation Modes 3 and 4 Page 4 of 6 V memory start address WY 5 Note In this table V memory address start address offset For example if start address V100 offset 4 Then V memory address V100 4 V104 V memory Parameter description Offset Value entered address Calibration zero for analog input 5 160 Calibration span for analog input 5 161 Shot size 162 Reserved 163 169 Interpolation master table starting address 170 Interpolation calculate
38. of these is equivalent to zero in Table 2 2 Figure 2 2 shows how to set the switch Use a ball point pen to set dipswitches Table 2 1 Operational Modes of Module Auxiliary ProfileA ProfileB Time based high speed 2 heads diahead die head Not used Not used Not used ProfileA ProfileB ProfileC ProfileD Time based standard speed 4 heads die ead diehead diehead die head Not used I Profile A Profile B Profile A Profile B T Profile A Profile B Profile C ProfileD m Profile A Profile B age Table 2 2 Dipswitch Settings for Operational Modes Mode and description Swithi Switch 2 Switch 3 1 Two high speed timebased profiles 0 0 0 ExIIDILIIJLILLIC Nm NS NS NA ME ND S oj O O m Position Position not selected Selected e gt gt Push down Note Ensure that switch 4 is off Figure 2 2 Setting Dipswitc hes Selecting a Figure 2 3 shows jumper locations for selecting a voltage range Selectable Voltage Range voltage ranges for analog inputs are 0 to 5 VDC and 0 to 10 VDC default Selectable voltage ranges for analog outputs are 0 to 5 VDC and 0 to 10 VDC default 2 4 Installing the Module SIMATIC 505 TurboParison Module User Manual Figure 2 3 shows the locations of the dipswitches and jumpers Component side of board See Table 2 1 for axis assignment J18 axis 3 out
39. outputs with a software resident dosed loop controller to provide four independent closed loop control axes The module uses these axes to control either parison wall thickness or accumulator ram speed depending on the module operation mode you select See Figure 1 1 Time based Operation Position based Operation 2 die heads 2 high speed W LU E 2 rams with die heads Mode 1 push out control J n Mode 3 4 die heads 1 ram without push out control 4 standard speed die heads Mode 2 0000 D 2 high speed die heads with position input Mode 5 Wheel Figure 1 1 Modes of Operation for TurboParison Module The module uses the auxiliary analog input mode 4 to monitor accumulator ram position when the module does not control ram push out control as well as to monitor position input mode 5 The remainder of this chapter describes the five operational modes and shows you how the blow molding hardware connects to the module axes SIMATIC 505 TurboParison Module User Manual Product Overview 1 3 1 2 Time based Operation With ti me based operation a synchronized pulse triggers the start of a parison drop Because a time based machine extrudes continuously the length of time between sync pulses determines the length of the parison In time based mode you can control up to two die heads in high speed mode or up to four die heads in standard speed mode For a deta
40. progress for profile 1 2 3 or 4 Y Profile 1 2 3 or 4 automatic weight acknowledge Module is in CALIBRATE mode Calibration zero limit is set Calibration span limit is set Calibration maximum velocity is set Figure 3 3 BitLayouts for WX Words Data from Module SIMATIC 505 TurboParison Module User Manual Understanding Module Operation 3 7 V memory Address of Configuration Table Module Operation Mode 1 2 3 a s 6 7 JE 10 411 12 13 14 15 16 1 2 3 45 6 7 JE 10 t1 12 15 E S Y q J Reserved must be 0 Designates the starting address of Configuration Tabl Puts module in RUN mode bits 2 and 4 both must 1 all others must be 0 Y Reserved must be 0 Reserved must be 0 Selects axis for input calibration Miscellaneous Functions 1 2 53 4 s 6 7 JE 10 11 12 13 AN Sets the zero limit during calibration Downloads the Configuration Table Sets the span limit during calibration Puts module in CALIBRATE mode Downloads one or more setpoint tables for axis 1 2 3 or 4 T 1 Sets the maximum ram velocity during calibration Executes interpolation feature Executes table expansio
41. sssssseeeeeeeee e n 4 3 Profile SP and PV Tables ete kaneis RH RR IET iad toca Fa ck e e dc Relationship of Synchronization Pulse to Profile Time ssssssssllssseeeeeese 4 5 Example of High Speed Operation 0 cece 4 7 Example of Standard Speed Operation 0 0 c cea Downloading Tablesin RUN Mode sssssseeee eee ee ene ees 4 16 Relationship Between Ram Position and Profile 00 0 c eee 5 2 Machine Sequence Timing Example ssssssseeeeeeee e e 5 3 Example of the Relationship Between Ram Velocity and Position 5 4 Specifying a Ram Velocity Profile ssssssssee Ree 5 5 Profile Pand PV Tables oe ea hades eh ERU REREPREEEPL 4 e iE IK e ER 5 7 Example of Two Head Operation with Accumulator Control sssaaa 5 8 Example of Four Head Operation without Accumulator Control 05 5 9 Contents 5 8 5 9 5 10 6 1 6 2 7 7 7 8 A 1 Timing Example fora 4 Mold Wheel 000 e Two Head Operation with Automatic Restart 0 0 Downloading Tablesin RUN Mode sssssseeee eee eee Areas of Control for Calibration and Tuning 00 0 cee eee Calibrating Zero and Span Values sssssssssssses nnns Open Loop vs Closed Loop Control suuuussssssssssss naaa Calibrating Zero and Span Values 20 cc nnns Die Positions for Diverging and Converging Tooling sess Selecting looling YPE ues
42. the Weight of the Parison Description The automatic weight control feature allows you to make small changes in Mean weight Fr Weight control value 7 6 the profile setpoints without altering the total weight of the parison After you have adjusted the profile setpoints to provide adequate parison quality and have adjusted the weight control value to provide appropriate parison weight enable automatic weight control done by setting the automatic weight enable bits in WY 7 The module then calculates a mean weight W for the parisons based on the profile setpoints according to the following equation N X Setpoints W n 1 N The module then compensates for any further changes that you makein the profile setpoints by adding a weight correction factor to the profile so that Wt does not change As long as the automatic weight control is enabled the module provides a weight correction factor in addition to the weight control value in the configuration table that holds W constant when a new profile setpoint table is downloaded Figure 7 6 shows how the module handles a modified profile when the automatic weight control feature is enabled The module calculates the weight correction factor to maintain the overall part weight Original profile Modified profile Weight 4 correction factor Figure 7 6 Automatic Weight Control Example To monitor the value of the weight correction factor
43. weight bias and 16000 correction if applicable 24000 Profile enabled 24000 18000 ES To axis 14000 Hold value controller 14000 die gap 8000 e Profile not enabled Weight control profile bias Note The value of the resulting setpoint is clamped between 0 and 32000 Figure 3 7 Setpoint Generator Operation Table 3 1 describes each of the configurable elements in Figure 3 6 that define setpoint generator operation These elements are selectable and can be added or removed depending on the needs of the process Table 3 1 Setpoint Generator Description Element Description Setpoint ramping Module ramps between setpoint entries providing very smooth transitions mode 2 only between setpoints available in mode 2 only Purge control Allows you to specify the die gap during an accumulator or extruder purge This value overrides the current profile setpoint Phase check Allows you to mark a parison while running a profile You specify the number of steps for which the die opens to the phase check value This value overrides the current profile setpoint Weight control Allows you to control the weight of a parison This element determines the absolute weight bias for a parison Automatic weight Allows you to manipulate the profile of a parison without changing the overall correction weight For more information about automatic weight control see Section 7
44. you may cause equipment damage It is to your advantage to shut down in a controlled manner before you perform an ESTOP Enabling Disabling To start profile execution set the corresponding profile enable bit in WY8 Profile Exec ution to 1 The module then sets a corresponding bit in WX3 to signify the profile is active For mode 3 ram push out also begins and continues until End of Shot is reached The module then resets the profile active bit in WX3 to O The setpoint remains at the last profile step until the profile enable bit in WY8 returns to 0 The setpoint returns to the die gap hold value when the profile is disabled 1234 56 7 8 9 1011 12 18 14 15 16 1234 5 6 7 8 9 1011 1213 14 15 16 WY8 WX3 pum em ae Enables Profile Module Response ProfileA Bit 5 ProfileA Bit 9 ProfileB Bit 6 Profile B Bit 10 Profile C Bit 7 Profile C Bit 11 ProfileD Bit 8 ProfileD Bit 12 See Appendix A for a complete description of WX WY words and more information about profile operation SIMATIC 505 TurboParison Module User Module Position based Operation 5 19 5 6 Changing Configuration and Profile Data To change data in the Configuration Table Profile Setpoint Table Velocity Setpoint Table or Position Table access the V memory locations that you want to change and enter the new data If you have an operator interface access t
45. 1 12 13 14 15 16 indicates a successful zero calibration When you 11o Jo o set bit 14 to 0 the module clears the status bit in WX3 Low limit bit Set the span calibration limit After setting the mandrel to the open position set Set bit 15 of WY6 to O when the status bit in 10 11 12 13 14 15 16 bit 15 in WY6 to 1 The module reads the analog E 0j1 0 input for the specified axis and records the span value The module then sets the span calibration status bit in WX3 to Lif the operation was successful High limit bit 10 11 12 13 14 15 16 WX3 indicates a successful high limit 1 0 Jo fo calibration The module then clears the status bit in WX3 High limit bit Calibrate remaining axes Repeat steps 2 through 6 to calibrate the remaining axes Exit CALIBRATE mode SIMATIC 505 TurboParison Module User Manual Set bit 13 of WY6 to 0 The module checks the 10 11 12 13 14 15 16 calibration data If the limits are valid they are WY6 0 0j0 0 written to the appropriate V memory locations in 4 the Configuration Table If the limits are invalid e g Zero Span the previous calibration data remains in effect and the calibration error status bit in WX3 is set to 1 8 9 0 o Calibration enable bit Fi
46. 15 Bits 1 through 12 are not used Bit 13 corresponds to die D axis 4 Bit 14 corresponds to die C axis 3 Bit 15 corresponds to die B axis 2 Bit 16 corresponds to die A axis 1 220 Last profile time for die A axis 1 Last profile time for die B axis 2 Last profile time for die C axis 3 Last profile time for die D axis 4 Pt calculated for die A axis 1 221 Pt calculated for die B axis 2 222 Pt calculated for die C axis 3 223 Pt calculated for die D axis 4 224 Weight correction for profile A 225 Weight correction for profile B 226 Weight correction for profile C 227 Weight correction for profile D 728 793 4 18 Time based Operation SIMATIC 505 TurboParison Module User Manual Chapter 5 Position based Operation 5 1 Overview of Position based Operation Definition of Position based Operation Controlling Ram Velocity Mode 3 Only Open Loop vs Closed Loop Velocity Control cee eee Controlling Mandrel Position Wall Thickness cece cee cece teens Monitoring Mandrel Position 5 2 Characteristics of Position based Modes s nnn nnnm nans Two Head Operation with Accumulator Control Mode 3 ccc cece eee eee Four Head Operation without Accumulator Control Mode 4 0 cece eee Two Head Operation with Automatic Restart Mode 5 cc ccc eects Differencesin Mode 5 s sss 53 Determining Module Configuration Parameters
47. 186 187 is 3a valve or dew omms owned Table Configuration Worksheets SIMATIC 505 TurboParison Module User Manual Worksheets for Position based Operation f SIMATIC 505 TurboParison Module User Manual Table Configuration Worksheets Configuration Table Worksheet Position based Operation Modes 3 and 4 Page 1 of 6 V memory start address WY 5 Note In this table V memory address start address offset For example if start address V100 offset 4 Then V memory address V100 4 V104 m V memory Value V memory Configuration word 0 40 1 loop sample time 41 Calibration zero for analog input 2 42 5l n oe o d E E Tr input filter time constant 4 6 Reeve 1 1 Reserved Calibration span for analog input L proportional gain constant 7 Ti integral time constant 8 Tg derivative time constant 9 Output zero 10 Output span 11 Profile setpoint table starting address 12 Profile setpoint table length 13 Process variable table starting address 14 Reserved 15 Purge value 16 Weight control 17 Phase check location 18 Phase check setpoint 19 Number of steps to hold phase check 20 Reserved 21 Reserved 22 Profiletime out value 23 Profile step coincidence locati on 24 Number of steps to hold profile 25 65 coincidence output ene 59 1 L851 L
48. 2 Hold value die gap For die heads specifies the die gap setting when profiling is disabled F or accumulator ram specifies the hold value to the axis controller when not running the velocity profile 3 12 Understanding Module Operation SIMATIC 505 TurboParison Module User Manual Operating the Module continued Axis Controller Figure 3 8 illustrates the operation of the axis controller section of the module Each axis consists of an axis controller that provides feedback control to a die head or ram depending on the operational mode of the module The elements depicted in this diagram affect the operation of the module and are configurable F or example the dosed loop open loop element allows you to choose the type of loop the module uses to control a die head or ram Analog input Filter Velocity position control Scaling Closed open loop control Direct reverse acting control Input signal from machine Setpoint data from setpoint generator Figure 3 8 Axis Controller Operation Manual override Value Scaling Output signal to machine Table 3 2 describes each of the configurable elements in Figure 3 8 that define axis controller operation These elements are configurable and can be added or removed by manipulating the configuration word for each axis See Appendix B for more information on the confi
49. 3 in the configuration word for that axis e Ensure that the loop sample time Ts allows enough ram movement so that differences in position can be monitored 20 ms 40 ms may be adequate 5 6 Position based Operation SIMATIC 505 TurboParison Module User Manual Controlling The module uses profile data stored in the Profile Setpoint Table to control Mandrel Position the mandrel position that determines the wall thickness of a parison This Wall Thic kness table Figure 5 5 is downloaded from the controller to the module when you put the module in RUN mode Create a Profile Setpoint SP Table for each die and specify the starting address for the table by entering an address into the profile SP starting address field in the Configuration Table To specify the length of each Profile Setpoint Table enter a value choices are 2 4 8 16 32 64 128 or 256 in the Profile SP Table length field in the Configuration Table Profile SP Table PV Table start address start address Profile SP Table PV Table To Module From Module Setpoint 1 gt PV1 Setpoint 2 PV 2 Setpoint 3 PV 3 Setpoint 4 PV 4 pto e pto Setpoint 256 PV 256 Figure 5 5 Profile SP and PV Tables Monitoring The module enables you to compare the actual mandrel position to the Mandrel Position profile data To monitor the actual position set up a table in V memory in
50. 320007100 96 output Back pressure setting 32000 Shot size Shot in progress Accumulator fill Ram 0 Position Die remains at the last setpoint value until the profile run command Bit 5 in WY8 returns to Profile step Die returns to die Die remains at die gap gap when profile until the run profile bit in run command Bit 5 WY8 transitions from 0 in WY8 transitions to 1 from 1 to 0 Profile Figure 5 2 Machine Sequence Timing Example SIMATIC 505 TurboParison Module User Module Position based Operation 5 3 Overview of Position based Operation continued Controlling Ram Velocity Mode 3 Only 432000 Ram Velocity Ram velocity can be handled through either open or closed loop control n open loop control the module directly drives the output based on the velocity setpoint n closed loop control the module attempts to match the velocity of the ram to a velocity setpoint In either case you can specify a velocity profile for ram push out during profile execution Figure 5 3 shows a typical velocity profile shot size equal to 28000 where transitions between velocity settings are specified by ram position The TurboParison module allows you to specify up to a 256 step velocity profile however most applications require no more than 8 or 16 steps Velocity Profile ex
51. 4 Figure 5 10 Downloading Tables in RUN Mode 5 20 Position based Operation SIMATIC 505 TurboParison Module User Manual 5 7 Monitoring the Operation of the Module The General Status Table enables you to monitor the operation of the module This table consists of module related data that is uploaded from the module to the controller Like the Configuration Table the parameters in the General Status Table are offset from the V memory address specified by WY 5 Table 5 5 shows the contents of the General Status Table Table 5 5 General Status Table Contents V memory offsets WY5 offset Parameter description Xp currentanaloginputtromanst Wega Current analog oe from axis 3 A or Head z caren V6 as Teal RR RT Current PV for axis 1 Head A Current PV for axis 2 Head B Current PV for axis 3 ram A velocity or Head C position Current PV for axis 4 ram B velocity or Head D position Current output for axis 1 Head A Current output for axis 2 Head B Current output for axis 3 ram A or Head C Current 23 Current outputforaxis4 ramBorHeadD for axis 4 ram B or Head D ree re discrete inputs and outputs Indicates the status of the discrete inputs and outputs The word contained in this V memory location has the following breakdown MSB LSB 1 2 3 4 5 6 8 9 10 11 12 13 14 15 16 Bits 1 4 Dipswitch settings these bits may be used
52. 4 bit 12 is active For time based operation this bit indicates the condition of the RUN command bit set in WY 8 For position based operation this bit is set by the RUN command bit in WY 8 and is reset at the end of the cycle Profile x automatic weight acknowledge Bits 13 through 16 indicate that the automatic weight enable command bit in WY 8 has been set and the weight basis has 1 2 3 8 5 6 7 8 9101 12131415 16 been calculated for profile 1 bit 13 2 bit 14 3 bit 15 or 4 bit 16 The acknowledge bit remains set until you turn off the corresponding automatic weight enable command bit in WY8 SIMATIC 505 TurboParison Module User Manual WX WY Word Descriptions A 3 WX Words continued WX4 Handshaking Enor and Status Information Configuration Table download complete Bit 1 indicates that the Configuration Table has been downloaded to the module 234 5 6 7 8 9 1011 12 13 14 15 16 Axis 1 setpoint table download complete Bit 2 indicates that the Profile Setpoint Table for axis 1 has been downloaded to the module 23 4 5 6 7 8 9 1011 12 13 14 15 16 Axis 2 Setpoint table download complete Bit 3 indicates that the Profile Setpoint Table for axis 2 has been downloaded to the module Axis 3 setpoint table download complete
53. 7 Weight control 32 000 to 32 000 58 Phase check location 0 to 255 59 Phase check setpoint 0 to 32 000 60 Number of steps to hold phase check 0 to 256 a Reed ae Reed 63 Profile time out value 0 to 65 535 milliseconds 64 Profile step coincidence location 0 to 255 65 Number of steps to hold profile coincidence output 0 to 256 en Rem 0 SIMATIC 505 TurboParison Module User Module Position based Operation 5 13 Determining Module Configuration Parameters continued Table 5 2 Configuration Table for Position based Operation Mode 3 Only V memory offsets WY5 offset Rama Rame TT MT aS Rater aceon NN um nomt temecnum Yona 7a ws sse 0000000 emm 0000 5 us W deae meonsn ono 3 9 e O TD x m foem ummnenpow s m WdeetySeipeintTablestrtmgaddres 0060 93 133 Velocity Setpoint Table length 2 4 8 16 32 64 128 256 95 103 135 143 Reserved 0 105 145 Hold position coincidence on until O to 32 000 5 14 Position based Operation SIMATIC 505 TurboParison Module User Manual Table 5 3 Configuration Table for Position based Operation Mode 4 Only V memory offsets WY5 offset Parameter name Valid values Ts loop sample time 1to 32 767 milliseconds Calibration zero for analog input 0 to 10 000 mV Calibration span for analog input 0 to 10 000 mV 4 4 8 amp T input filter time constant 0 to 32 767 milliseconds
54. B Extruder screw Die head 1 Servo valve and hydraulic cylinder Plastic parison Extruder screw Die head 3 Profile C ali E Sync pulse optional Step 4 71 coincidence output P ulnis Sync pulse optional M Step coincidence output Servo valve and hydraulic cylinder Extruder screw r Die head 2 Profile D Servo valve and hydraulic cylinder Plastic parison Ei Sync pulse optional Step coincidence output si l t i QO GO GO m u od an VQ GG UN 22 3t Sync pulse optional m Step output SIMATIC 505 TurboParison Module User Manual Plastic parison Servo valve and hydraulic cylinder Extruder screw r Die head 4 coincidence Figure 1 3 Example of Standard Speed Operation Plastic parison Product Overview 1 3 Position based Operation With position based operation the position of an accumulator ram or reciprocating screw sequences the execution of the die head profile The die head profile determines the p
55. C 505 TurboParison Module User Manual 1 4 Background Knowledge Prerequisites and Assumptions You understand the operation and programming of the 545 565 controllers You understand how to use TISOFT to create and modify controller programs Before you begin to use the TurboParison module ensure that the following prerequisites and assumptions are true You are familiar with the interaction of Operator Interface devices with the controller You understand the operation of blow molding machines and their associated hydraulic and electrical systems Figure 1 7 lists a sequence of tasks that we suggest you perform before trying to operate your machine with the TurboParison module Configure and install the module Chapter 2 Read Understanding Module Operation Chapter 3 Set up V memory according to the operational model of the module Chapters 4 and 5 Calibrate and tune the die heads and or accumulator rams Chapter 6 Use any of the features that are appropriate to your machine Chapter 7 Figure 1 7 Listof Setup Tasks SIMATIC 505 TurboParison Module User Manual Product Overview 1 9 2 1 2 2 2 3 2 4 2 5 2 6 2 7 Chapter 2 Installing the Module Overview of Installation sssssseeen nmn 2 2 FloW of Iasks iiec tede re rece o trece ec ec adi oes aq ea duca c eoa SCR oa a 2 2 Handling the Module 225 53 ebore c
56. F aC MEET ee ee eee ed we eee EE EE MR ER Definition of Time based Operation sssssssssseeeeeeesee ene Controlling Mandrel Position Wall Thic kness Monitoring MandrelPosition sasava iiaii aa daia ae Providing a Sync Pulse for Profile Timing sssssssseeeneeen n Characteristics of High Speed and Standard Speed Operation High Speed Operation Mode 1 2 0 ccc cece cece ence n 4 6 Standard Speed Operation Mode 2 ci cece ccc ccc nn 4 8 Differencesin High Speed and Standard Speed Operation 00 0c eae 4 10 Determining Module Configuration Parameters s eee eee nnn n n n n n n n 4 11 Determining Configuration Parameters sssssssssse esses 4 13 Determining the V Memory Required s esses eene 4 13 Entering Data into V Memory serer repress irpreni eee ees 4 13 Contents 4 4 Preparing the Module for Operation een nnn n nnn n nnn 4 5 Operating the Module in Time based Mode een nn nnn Putting the Module in RUN Mode ssssssseeeeeeee ee Enabling Disabling Profile Execution ssssssseeeeeeee m n 4 6 Changing Configuration and Profile Data iseeeeeennnn nnne 4 7 Monitoring the Operation ofthe Module sseeeeeeen n nnn nnn Chapter5 Position based Operation 5 1 Overview of Position based Operation cccccc cece cece cece eens Definition of Position based Operation
57. MATIC 505 TurboParison Module User Manual 7 1 7 2 7 3 7 4 Chapter 7 Using the Module s Optional Features Interpolation and Expansion of Profile Data seen nm nnn nnn eU MR PRIEST ntepola tion Jcecrdatsassdrdearncnasioacshuadndesdmnga dean dt edi ah ene hea iteh TablB EXparisigl ucxostiose tecta uai equ mo pA R Dekor a A REE E d Ha dia Qus Automatically Maintaining the Weight of the Parison sse nnn DES npon elvai e pr oda Rl rac rado E ide Ea Eu dare valence tH E PAREN PIOGECUIIC lt 3 i E Using the Module s Discrete Outputs sseeeennn nnm Dies npn oo ra si sid darc dac Sp dcr can dd Euge deba cR ER indi Red deoa PIOCOGUIG cus octies eoe ey ted 0 eee ERR ol OT c Ta iu C on d e hd Rd d a aad DR RR Checking the Phase Between a Profile and a Parison cccceeeeeeeeeenueeeees 7 10 P tejsipmc ETT 7 10 ie Tr M 7 11 SIMATIC 505 TurboParison Module User Manual Using the Module sOptional Features 7 1 7 1 Interpolation and Expansion of Profile Data Overview The TurboParison module can interpolate master profile setpoints using either linear or curvilinear interpolation It also has the capability to expand a profile with fewer steps into one having finer resolution You may use these features in conjunction with one another or separately The following explains the procedures Interpolation Theinterpolation feature Figure 7 1 allows you to interpolate between ma
58. SIEMENS SIMATIC 505 TurboParison Module User Manual Order Number PPX 505 8118 3 Manual Assembly Number 2586546 0069 Third Edition ADANGER DANGER indicates an imminently hazardous situation that if not avoided will result in death or serious injury DANGER is limited to the most extreme situations A WARNNG WARNING indicates a potentially hazardous situation that if not avoided could result in death or serious injury and or property damage A CAUTION CAUTION indicates a potentially hazardous situation that if not avoided could result in minor or moderate injury and or damage to property CAUTION is also used for property damage only accidents Copyright 1995 by Siemens Industrial Automation Inc All Rights Reserved Printed in USA Reproduction transmission or use of this document or contents is not permitted without express consent of Siemens Industrial Automation Inc All rights including rights created by patent grant or registration of a utility model or design are reserved Since Siemens Industrial Automation Inc does not possess full access to data concerning all of the uses and applications of customer s products we do not assume responsibility either for customer product design or for any infringements of patents or rights of others which may result from our assistance MANUAL PUBLIC ATION HISTORY SIMATIC 505 TurboParison Module User Manual Order Manual Numb
59. User Manual Understanding Module Operation 3 9 Configuration Table transferred to module Setpoint Tables transferred to module Misc functions Hold values continually downloaded Manual override values continually downloaded General Status Table Process Variable Tables reported from module reported from module WY54200 Current analog input status Current process values Current output Machine and module status Figure 3 5 V Memory Transfer of Configuration and Status 3 10 Understanding Module Operation SIMATIC 505 TurboParison Module User Manual 3 3 Operating the Module The TurboParison module controls the wall thickness of a parison by adjusting the position of the mandrel in the die bushing You create a table of values that correspond to each position of the mandrel called the Profile Setpoint Table This table can consist of up to 256 profile steps The module uses the data in this table in conjunction with configuration information execution status and other commands to determine the correct setpoint to be passed to the axis controller The axis controller determines the appropriate signals to send to the die head servo amplifier based on the configuration options selected current setpoint and feedback signal Figure 3 6 TurboParison module Confi
60. a iehi ia da WY8 Profile Operation Control spissi riiis isene ii si E RERA AA AppendixB Configuration Table Data B 1 Configuration Tables for Time based Operation sssssssssssssnsnsnnnnnnnnnnn B 2 Configuration Tables for Position based Operation eene B3 Parameter Descriptions for Configuration Table seeseseeeeeeee Appendix C General Status Table Data C 1 General Satus Table Contents sssseesseee nnne C 2 Appendix D Specifications D 1 Physical and Environmental Specifications seeeeenn n nn n n n n n n n n D 2 Analog Performance Specifications sssseee enn nnne nnn nnn D 3 Disc rete Outputand Input Specifications eee nnn nn AppendixE Table Configuration Worksheets n sosser eenean E1 Contents vii List of Figures 1 1 1 2 1 3 1 4 1 5 1 6 1 7 2 1 2 2 2 3 2 4 2 5 2 6 2 7 2 8 2 9 3 1 3 2 3 3 3 4 3 5 3 6 3 7 3 8 3 9 4 1 4 2 4 3 4 4 4 5 4 6 4 7 5 1 5 2 5 3 5 4 5 5 5 6 5 7 viii Modesof Operation for TurboParison Module s sess enn 1 3 Example of High Speed Operation 0 cece 1 4 Example of Standard Speed Operation ccc ccc cece tee eee eee enn 1 5 Example of Two Head Operation with AccumulatorControl 0 cece eens 1 6 Example of Four Head Operation without Accumulator Control usus 1 7 Example of High Speed Operation with Position Input
61. able starting address Profile Setpoint Table length Velocity Setpoint Table starting address Velocity Setpoint Table length Position Table starting address Process Variable Table starting address Sync delay phase shift time Purge value Weight control Specifies the analog output span signal value where the values 10000 to 10000 correspond to 10 to 10 volts if you select the 10 to 10 volt range with the jumpers on the module board The values 10000 to 10000 correspond to 5 to 5 volts if you select the 5 to 5 volt range with the jumpers The default value is 10000 Specifies the first V memory location of the Profile Setpoint Table This table contains the profile step information Specifies the length number of profile steps of the Profile Setpoint Table The last profile step resides at the location determined by the following equation Setpoint Table pointer table length 1 The default length is 256 Specifies the first V memory location of the Velocity Setpoint Table This table contains the velocity setpoint data that controls the accumulator ram or reciprocating screw The default length is 256 Specifies the length of the Velocity Setpoint Table for position based control The last table entry resides at the location determined by the following equation Velocity Setpoint Table starting address table length 1 Specifies the first V memory location of the Position Table This table conta
62. ailable for profile control but can be configured for either closed loop operation or open loop operation Open loop operation enables you to configure these axes as analog O e A minimum sample rate of one millisecond is available e Each axis can have a unique profile and weight constant or axes can share profiles e A minimum profile time of 512 milliseconds is available for up to 256 profile steps e Theuse of a hardware generated sync pulse is recommended Figure 4 5 shows a typical application of high speed mode 4 6 Time based Operation SIMATIC 505 TurboParison Module User Manual TurboParison module Profile A Position transducer Profile B not shown Servo valve and hydraulic cylinder Arp SS Die head High speed wheel Plastic parison Axis 1 discrete i inpu Proximity sensor or other device to give pulse at start of parison for each mold pair Mold gt Note The TurboParison module can control up to two wheel machines with independent ed NN profile control for each Product Figure 4 5 Example of High Speed Operation SIMATIC 505 TurboParison Module User Manual Time based Operation 4 7 Characteristic s of High Speed and Standard Speed Operation continued Standard Speed When configured for standard speed operation the TurboPar
63. al 5 3 Determining Module Configuration Parameters As discussed in Chapter 3 the Configuration Table contains process parameters that determine the operation of the TurboParison module The module uses these parameters to calculate loop variables offsets and other numeric values that are essential to Parison control To determine which parameters are available for use with the TurboParison module when operating it in position based mode refer tothe following tables For mode 3 refer to Table 5 1 and Table 5 2 For mode 4 refer to Table 5 3 Both modes use Table 5 4 The bold parameters are essential for proper operation Table 5 1 Configuration Table for Position based Operation Mode 3 Only V memory offsets Parameter name Valid values Calibration span for analog input 0 to 10 000 mV 4 4 Tr inputfiltertimeconstant 0to32767miliseonds 4 Reserved 0 E Reed e o eo 0 N By w 5 6 4 Reserved 0 7 7 K proportional gain constant 0 to 327 67 8 4 Ti integral time constant 0 to 32 767 milliseconds 9 9 Tq derivative time constant 0 to 327 67 milliseconds 10 5 Oktptzro 1000t0H000mv E 1 51 Ouputspn ss 1000tos31000mv E x 582 Profile Setpoint Table starting address 0 to 65 000 53 Profile Setpoint Table length 2 4 8 16 32 64 128 256 54 Process Variable Table starting address 0 to 65 000 ss Reserved re 5
64. al Features SIMATIC 505 TurboParison Module User Manual Procedure Tousethe phase check feature enter values into the following fields in the Configuration Table e Phase Check Location this field specifies the profile step or range of steps where the phase check should start e Phase Check Setpoint this field specifies the setpoint at which the die should be set to mark the parison e Number of Steps To Hold Phase Check this field specifies the number of profile steps that the die should remain at the specified setpoint All values you enter in these fields are downloaded to the module when the Configuration Table is downloaded If you make changes to these values you must download the Configuration Table see Appendix B SIMATIC 505 TurboParison Module User Manual Using the Module s Optional Features 7 11 A 1 A 2 A 3 Appendix A WX WY Word Descriptions WX1 Curent Profile Execution Step for Axes 1 and 3 WX2 Curent Profile Execution Step Axes 2and 4 eee eee WX3 Handshaking Eror and Status Information 0 00 cece eee WX4 Handshaking Eror and Status Information 0 00 cece eee WY5 Configuration Table Starting Address 1 0 eee tees WY6 Module Operational Mode ketene eens WY7 Miscellaneous Function Control 1 0 cet nns WY8 Profile Operation Control 1 eR eek b E E a RE SIMATIC 505 TurboParison Module User Manual WX WY Word Descriptions A 1 A l Overview This appendi
65. alog input signal where the values 0 10000 input correspond to 0 10 volts if you select the 0 to 10 volt range with the jumpers on the module board The values 0 10000 correspond to 0 5 volts if you select the 0 to 5 volt range with the jumpers The default value is 10000 Tf input filter time constant Specifies the input filter time constant for a first order filter The module implements the first order filter with the following equations If K Ts Ts Tr then Vout 2 K X Vin 1 K X Vout previous Pt initial Initial profile time Specifies the profile time Pt initia that the module uses when you begin running time based profiles When the controller downloads the Configuration Table to the module it copies Pt initial to Pt Depending on the P calculation method you specify later in this table the profile time either stays constant at Pt initial changes to thelast profile time measured or changes to a value based on a average of previously measured profile times Velocity scale factor P Specifies the velocity scale factor for scaling the differentiated input signal to the 0 to 32000 range The resulting process variable is scaled to 32000 when the maximum velocity occurs The automatic calibration feature of the TurboParison module can determine the value of the velocity scale factor VSF for you To determine the VSF on your own use the following formula VSF number of counts moved by ram or screw time neede
66. ap continually downloaded 0 to 32 000 184 fren ae override value continually down _ 35999 to 4320000 185 Axis 2 manual override value continually down _35999 to 432000 loaded 186 Axis 3 manual override value continually down _35999 to 432000 loaded 187 Axis 4 manual override value continually down _35999 to 432000 loaded If a parameter value is zero the module uses the default value For detailed descriptions of the parameters and their default values refer to Appendix A 4 12 Time based Operation SIMATIC 505 TurboParison Module User Manual Determining Configuration Parameters Determining the V Memory Required Entering Data into V Memory After you determine which parameters are required for your machine turn to Appendix E and make a copy of the worksheets that correspond to the time based mode These worksheets enable you to record parameters and values that you intend to enter into the Configuration Table Before you enter the worksheet information into V memory you must determine the amount of memory to set aside To determine the amount of required V memory refer to the worksheets you filled out and usethe data from those worksheets to fill out the V memory Allocation Worksheet found in Appendix E For example if WY5 is V100 and you want to enter the starting address of the Profile Setpoint Table for die head C mode 2 enter data in V memory location 192 WY 5 92 After you set aside the ap
67. arison wall thickness whilethe shot size determines the overall length of the parison In position based operation you can select one of three modes depending on whether or not closed loop profiled push out is required or you are using a wheel machine For a detailed description of position based operation refer to Chapter 5 Two Head The two head two accumulator mode allows you to control positi on based Operation with parisons on two head accumulator or reciprocating screw type machines Accumulator each having its own independently controlled die head profile of up to 256 Control Mode 3 steps In addition this mode provides synchronized closed loop profiled push out for up to two accumulators or screws Each accumulator can have its own velocity profile of up to 256 steps Figure 1 4 shows a typical application of two head accumulator control Profile A Profile B Position Position transducer transducer Proportional Proportional valve and valve and cylinder cylinder Position Accumulator gt coincidence Accumulator output Position coincidence j output Position Position ii transducer transducer Valv Valves Extruder Servo Servo ee a screw valve and valve and 2 cylinder cylin
68. art nurrber PPX 2587705 8006 Shipped with nodule Part nurrber PPX 2587705 8002 Order separately Figure 2 4 Terminal Blocks and Pinouts 2 6 Installing the Module SIMATIC 505 TurboParison Module User Manual Wire Gauge 12 26 both connectors Stud Size 4 2 5 mm Amp Part 321462 Use with connector e tom Max Width 5 54 mm 218 in 0 25 in PPX 2587705 8002 Stud Size 4 2 5 mm Amp Part 327891 Use with connector PPX 2587705 8002 Specify 2pt Connector O Max Width 4 62 mm 182 in Figure 2 5 Wire Gauge and Stud Sizes A WARNING Use supply wires suitable for at least 75 C Signal wiring connected to this module must be rated at least 300 V Wiring that does not meet the requirements could cause death and or serious injury or damage to equipment Ensure that your wire is suitable for at least 75 C and that signal wiring con nected to this module is rated at least 300 V Minimizing Noise To minimize noise problems follow these guidelines e Ensurethat the controller power ground lug is wired to system ground e Usethe shortest possible wires e Avoid placing signal wires parallel to high energy wires If the two must meet cross them at right angles e Avoid bending the wire into sharp angles e Use wireways for wire routing e When you use shielded wires ground shields at onl
69. ating with controller configuration table general status table 3 8 overview En process variable tabl e 3 8 setpoint tables 3 8 V memory block transfers 3 4 3 8 WX WY words 3 5 WX WY words bit layouts 3 6 3 7 Configuration allocating V memory in position based 5 17 configuring ijo 2 12 Configuration table3 8 changing values in 4 16 download complete A 4 downloading in position basedj 5 20 downloading to the controller 4 16 downloading to the module 3 14 memory requirements parameter descriptions position based B 4 time based B 2 B 3 time based operation cde n table all modes positi on based Configuration table mode 3 position based oS table mode 4 position based 5 15 Connector field wiring 2 6 Convergi ng diverging tooling Curvilinear interpolation 7 2 D Die heads calibration 6 6 tuning loops 6 14 Index 1 Dipswitch location 2 5 setting Discrete outputs 7 8 Diverging converting tooli ng 6 7 Downloading tables to the module 3 14 Electrical noise minimizing shielding recommendations 2 7 Errors fatal 3 17 guidelines 3 17 2 11 Expansion table 7 5 E Fatal errors 3 17 Features 1 2 Field wiring cable connections 2 9 grounding recommendations 2 9 terminal blocks and pinouts 2 6 2 wire gauge and stud sizes G General status table 3 8 memory requirements position based time based
70. bRek RARE eR CERE cided dc bid agita de aki ds Die Head Calibration Procedure no iiris rinii idaga dai eee e Calibrating Zero and Span Values 20 nnns Ram Calibration Procedure ssssssssseseee eee e LOOP RESPONSE uo uae pacesadedobg EEE eec deci da CR POTE RC aS Interpolation Example esisi errio arpinaama ian Hm Intermpolating D tai eere e erasan nce rn nca n Picea case a e ee Setting Up Interpolation Options ssssssssse e interpolation Procedure iicet eal beta been ee aad dac ned Expanding Tables cre de ek tdg ade ier ed Automatic Weight Control Example sssssssss eee Discrete Output Generation ssssssssssssseeee eese Phase Check Example sssssseeseeeeeee emm Bt Map for WX and WY Words isse RR a FREIER E e RS Contents ix List of Tables 2 1 2 2 2 3 3 1 3 2 4 1 4 2 4 3 4 4 5 1 5 2 5 3 5 4 5 5 6 1 7 1 B 1 B 2 B 3 B 4 B 5 B 6 B 7 B 8 B 9 B 10 C 1 D 1 D 2 D 3 D 4 D 5 Operational ModesofModule ssssssssssss s nnn Dipswitch Settings for Operational Modes 6 6 cece Module Fail Codes serene reme race acera ad e fex RR EDI eS PR Setpoint GeneratorDescription sssssssssse mes Axis Controller Description sssssssssssssseeeeee eee mm Methods for Calculating Profile Time ssssssssse ee eee nnes Profile Time vs Number of Profile Steps 0 0 0 Configuration Table for Time based Operatio
71. ch 3 to closed and switches 1 2 and 4 to open e The profile can have between 8 and 256 steps Polarity The polarity of the position input Aux input 5 can be either positive or negative Bit 8 in WY7 controls this feature zero selects a positive ramp and one selects a negative ramp This feature is only availablein Mode 5 Position Shift n Mode 5 you can shift the position of the parison relative to the Aux 5 input ramp This allows you to adjust the position of the parison relative to a mold on the wheel The range of this valueis from 32000 to 432000 0 432000 32000 For normal use this value is from 16000 to 16000 A positive number delays the parison behind the position input ramp a negative number advances the parison ahead of the position input ramp The location of the position of the shift values follows Profile 1 position shift WY 54 182 Profile 2 position shift WY 54 183 This location is the same as the CH3 and CH4 Hold Value locations that are not used in Mode 5 Span and Zero Adjustment Adjusting zero and span for the position input is critical for Mode 5 operation e Thespan must be less than the maximum ramp value 50 mv below maximum e Zero must be greater than the minimum ramp value 50 mv above minimum These conditions must be met in order so that the profile can move from Step to step otherwise it holds at one value 5 12 Position based Operation SIMATIC 505 TurboParison Module User Manu
72. check locati on Phase check value setpoint Number of steps to hold phase check Profile time calculation method Number of cycles to needed average profile time Profiletime out value Profile step coincidence location 104 144 Number of steps to hold profile coincidence output ene ce fea 1 Parameters listed in this tablefor Axis 3 and Axis 4 are valid for profile control only 105 145 SIMATIC 505 TurboParison Module User Manual Table Configuration Worksheets lt Configuration Table Worksheet O Time based Operation Page 3 of 3 V memory start address WY 5 Note In this table V memory address start address offset For example if start address V100 offset 4 Then V memory address V100 4 V104 V memory Parameter description Offset address Value entered Calibration zero for analog input 5 160 Calibration span for analog input 5 161 Reserved 162 169 Interpolation master table starting address 170 Interpolation calculated table starting address 171 Interpolation table length 172 Starting address of original table 174 Humendewn iue 000 um Axis 4 hold value or die gap continuously downloaded Axis 1 manual override value continually downloaded Axis 2 manual override value continually downloaded Axis 3 manual override value continually downloaded Axis 4 manual override value continually downloaded 175 176 177 180 181 182 183 184 185
73. cycles needed to average profile time Profile time out value Profile step coincidence location Number of steps to hold profile coincidence output Position coincidence location Hold position coincidence on until B 10 Configuration Table Data Specifies the offset in the Profile Setpoint Table to start a phase check operation Note that this is typically the desired profile step 1 The phase check feature is enabled only if the phase check command bit in WY8 is set Specifies the setpoint value to force the loop controller when the module reaches the phase check location in the Profile Setpoint Table The phase check value remains forced for the number of steps specified by the next parameter Specifies the number of steps to hold the forced phase check value If you set the number of steps to zero the phase check value remains forced until the end of the profile Specifies the calculation method if any to be used for profile time calculations You can enter the value 0 1 2 or 3 for this parameter and these values correspond to the following calculation methods P initial default value Pt previous previous measured Pt is used Pt Ptpreviou 2 running average Pt average of the number of profiles specified by the next parameter Specifies the number of cycles used to calculate the average profile time when you select option 3 for the profile time calculation method This parameter is valid only if opti
74. d in progress Bit 12 indicates that the PV Table for profile 4 is being uploaded to the controller Calibration mode Bit 13 indicates that the module is currently in the CALIBRATION mode The module remains in this mode until you turn off the calibrate enable bit in WY 6 Calibration Zero limit set Bit 14 indicates that the zero limit for an input has been calibrated The module must be in the CALIBRATE mode before this bit is valid The module resets this bit when you turn off the set zero limit command bit in WY 6 Calibration Span limit set Bit 15 indicates that the span limit for an input has been calibrated The module must bein the CALIBRATE mode before this bit is valid The module resets this bit when you turn off the set span limit command bit in WY6 Calibration maximum velocity set Bit 16 indicates that the maximum velocity for 1234567 8 9 101112131415 16 inputs connected to an enabled differentiating block has been set The module must bein the CALIBRATE mode before this bit is valid The module resets this bit when you turn off the set maximum velocity bit in WY 6 A 4 WX WY Word Descriptions SIMATIC 505 TurboParison Module User Manual A 3 WY Words WY5 Configuration This word determines the first V memory location of the Configuration Table Starting Table Refer to Appe
75. d to move those counts in seconds Shot size P Specifies the accumulator shot size where total stroke 32000 Kc proportional gain constant Specifies the closed loop proportional gain for PID calculations This parameter is not used in open loop mode Note that a value of 100 specifies K 1 00 i e there is an implied decimal point Tj integral time constant Specifies the closed loop integral time constant for PID calculations A larger constant increases integral reset activity If you leave the value of this field at zero nointegral activity occurs This parameter is not used in open loop mode Tg derivative time constant Specifies the closed loop derivative time constant for PID calculations For most applications leave the value of this parameter at zero This parameter is not used in open loop mode Note that a value of 100 specifies Ty 1 00 ms i e there is an implied decimal point Output zero Specifies the analog output zero signal value where the values 10000 to 10000 correspond to 10 to 10 volts if you select the 10 to 10 volt range with the jumpers on the module board The values 10000 to 10000 correspond to 5 to 5 volts if you select the 5 to 5 volt range with the jumpers The default valueis O B 8 Configuration Table Data SIMATIC 505 TurboParison Module User Manual Table B 10 Parameter Descriptions for Configuration Table continued Parameter name Profile Setpoint T
76. default value For detailed descriptions of the parameters and their default values refer to Appendix B 5 16 Position based Operation SIMATIC 505 TurboParison Module User Manual Determining Configuration Parameters Determining the V Memory Required Entering Data into V Memory After you determine which parameters are required for your machine turn to Appendix E and make a copy of the worksheets that correspond to the position based mode These worksheets enable you to record parameters and values that you intend to enter into the Configuration Table These worksheets also help determine the amount of V memory that must be set aside to operate the module Before entering the worksheet information into V memory determine the amount of memory to set aside to run your machine For example mode 3 requires from 2 5K to 3 0K bytes of V memory To determine the amount of required V memory refer to the configuration worksheets and use that data to fill out the V memory Allocation Worksheet found in Appendix E After setting aside the appropriate amount of V memory you are ready to enter the values from the worksheets into memory To enter the configuration values from an operator interface read the user manual for the operator interface To enter the configuration values from TI SOFT follow these steps 1 Run TISOFT and display the screen that allows you to edit V memory 2 Enter the values from the Configuration Table Workshe
77. der AMP Step I coincidence output Die head Step coincidence 4 1 output EL TurboParison E Plastic parison Plastic parison module Figure 1 4 Example of Two Head Operation with Accumulator Control 1 6 Product Overview SIMATIC 505 TurboParison Module User Manual Four Head The singl e accumulator mode allows you to control position based parisons Operation without on four head machines each head having its own independently controlled Accumulator profile of up to 256 steps Although the module monitors the accumulator Control Mode 4 screw position and sequences the execution of the profile the module cannot control the motion of an accumulator screw Use analog I O modules and controller logic to control the accumulator screw motion Figure 1 5 shows a typical application of four head no accumulator control TurboParison module 1 Screw Ram contro position from other transducer controller I O Servo valve and hydraulic cylinder Die Profile A nea l Plastic parison Profi
78. dtablestartingaddress fat FP Wepiimuhmgn E Interpolation method 173 C 3m Axis 1 hold value or die gap continuously downloaded Axis 2 hold value or die gap continuously downloaded Axis 4 hold value or die gap continuously downloaded Axis 1 manual override value continually downloaded Axis 2 manual override value continually downloaded Axis 3 manual override value continually downloaded Axis 4 manual override value continually downloaded 164 189 Mode 4 only 174 175 176 177 180 181 182 183 184 185 186 187 is 3a value or die oap entraaisy owned SIMATIC 505 TurboParison Module User Manual Table Configuration Worksheets Configuration Table Worksheet Position based Operation Mode 5 Only Page 5 of 6 V memory start address WY 5 Note In this table V memory address start address offset For example if start address V100 offset 4 Then V memory address V100 4 V104 Axis 1 accumulator control only Axis 2 accumulator control only m V memory Value V memory Value Parameter description address eec addis Configuration word 0 40 1 loop sample time 41 Calibration zero for analog input 2 42 5l n oe o d E E Tr input filter time constant 4 6 Reeve 1 1 Reserved Calibration span for analog input L proportional gain co
79. dule User Manual Using the Module s Optional Features 7 3 Interpolation and Expansion of Profile Data continued Master Table V Memory 00000 00000 Clear the 1 Enter zero into every memory location of master table the master table The interpolation feature does a calculation between every DODOD pair of non zero values in the master table If you do not remove every non zero 00000 value the module cannot interpolate your 00000 data correctly Original table Master table Enter data Copy the data to be interpolated into the V Memory TTR rem master table into master 00000 00000 table 24000 5 24000 00000 00000 20000 20000 10 11 12 13 14 15 16 0j0 0 0 0 0 0 Set bit 6 of WY7 to 1 to interpolate the master 4 56 table The module sets bit 6 in WX4 to 1 when 0j0 1 interpolation is complete 4 Start interpolation 5 0 8 9 0j0 Start interpolation bit Calculated Table Runtime Table Move data Copy theinterpolated data into the into runtime proper location for runtime operation table Figure 7 4 Interpolation Procedure 7 4 Using the Module sOptional Features SIMATIC 505 TurboParison Module User Manual Table Expansion You can also expand a table before interpolati
80. e Provides a method to control an axis output independent of the operation of the axis controller Bits 9 10 11 and 12 in WY 7 For more information on configuring axes refer to Appendix B Notein particular the description of the configuration word 3 14 Understanding Module Operation SIMATIC 505 TurboParison Module User Manual 3 4 Downloading and Uploading Tables Downloading Ensure that you have entered the required configuration information in the Configuration and controller s V memory before you download the Configuration Tabletothe Setpoint Tables module You can download the Configuration Tabletothe module two ways e You can place the module in RUN or CALIBRATE mode the module then automatically downloads the Configuration Table and related Setpoint Tables e Whilethe moduleis in RUN or CALIBRATE mode you can force a download by setting bits in WY 7 to 1 Bit 1 automatically downloads the Configuration Table Bits 2 5 download Setpoint Tables When the download is complete the module sets corresponding bits 1 configuration 2 5 setpoint in WX4 The acknowledge bits in WX4 are not cleared until the corresponding command bit in WY 7 returns to 0 See Figure 3 9 NOTE The TurboParison module does not automatically enter the RUN mode when you power it up This characteristic enables you to determine the V memory addresses of the Configuration Table the General Status Table and related tables before the module atte
81. e Section 4 3 4 Determine the machine sequence for your process and then write an RLL program to sequence the machine and interact with the module Y Load the Configuration Table with the parameter values that correspond to the axis or axes Appendix B lists and describes all of the available parameters 4 Ensure that all data relevant to your parison process exists in the V memory locations reserved for the Configuration Table and Profile Setpoint Table These tables are automatically downloaded to the module when you place the module in RUN mode See Section 4 5 V Provide an external or internal sync pulse For an external sync pulse ensure that the signal or signals are attached to the appropriate input on the module and that Bits 13 through 16 in WY8 are set to zero For an internal sync pulse ensure that your RLL program toggles the bits 13 through 16 in WY 8 for the corresponding profile s The internal sync bit must remain high for at least one controller scan 4 Ensurethat the die heads are calibrated and tuned Refer to Chapter 6 for information about calibrating and tuning die heads 4 Manually step the machine through its sequence before you run the RLL and sequence the machine automatically 4 14 Time based Operation SIMATIC 505 TurboParison Module User Manual 4 5 Operating the Module in Time based Mode Putting the Module WY 6 controls putting the module into RUN mode in RUN Mode 4 Writing a value of 5000
82. e available for die control only in mode 2 The bold parameters are essential for proper operation Table 4 3 Configuration Table for Time based Operation V memory offsets WY5 offset Parameter name Valid values Head A Head B Head C Head D 0 40 80 120 Configuration word See descri pti on 41 81 121 Ts loop sample time 1 to 32 767 milliseconds B22 Ewe RECs ce 6 0 to 65 535 milliseconds N e Kc proportional gain constant 0 to 327 67 Ti integral time constant 0 to 32 767 milliseconds Tq derivative time constant 0 to 327 67 milliseconds Output zero 10 000 to 410 000 mV Oupuzeo 10000toM000mv E Sync delay phase shift time ing of cydes needed to average profile 2 4 8 16 Profile time out value 0 to 65 535 milliseconds Profile step coincidence location 0 to 255 Number of steps to hold profile coinci dence 0 to 256 output 239 06 79 106 39 Red 0 Profile execution available only for mode 2 SIMATIC 505 TurboParison Module User Manual Time based Operation 4 11 Determining Module Configuration Parameters continued Table 4 3 Configuration Table for Time based Operation continued V memory offsets eae ew 7700000000 9 1 curvilinear interpolation 181 Head B die gap continually downloaded 0 to 32 000 182 Head C die gap continually downloaded 0 to 32 000 183 Head D die g
83. e do E eb EA a Reel orae datae d dac 3 3 Operating the Module seen nnn nennen aan Setpoint Generator 5er eek Hc a ie dac E Ra dnce dott td RP Ed AXSCONGOlE n oee E A A E A A E A E eE E A E Ma MUA Ovetride i cbr co edi diete e ACA Re BRA re e Pede deis ed ade Ace 3 4 Downloading and Uploading Tables een n n n n n n n n n nn Downloading Configuration and Setpoint Tables ccc cece eee eee Uploading General Status and ProcessVariable TableS ccc cece eee eee 3 5 Guidelines for Allocating V Memory nnn n mmm mmn 3 6 Guidelines for Errors and Alarms s nnnm nnam narrans Fatal BITO S cocco atch atc ane a peptide somos a Ee Ld a DE LEE Alanis ea ea TU SIMATIC 505 TurboParison Module User Manual Understanding Module Operation 3 1 3 1 Introduction This chapter describes overall module operation and how to configure the module for your application Chapters 4 and 5 describe operation that is specific to time based and position based machines respectively If your application is time based you do not need to read the chapter about position based applications and vice versa The TurboParison module controls the parison wall thickness and in some cases ram velocity according to your configuration data and depending on the module mode TurboParison is an intelligent module capable of machine control independent of direct supervision by the controller The modu
84. e en od ein ade eoe aede bead a br ead 2 3 Visuals ecto M iet epa OR bte dr Ric UR dU E RONDE eo e dnd 2 3 Setting Options cece serra a n Selecting Module Operation Type sssssee eh 2 4 Selecting a Voltage Range sssssssse mnn 2 4 Piet Wings teas ccdid ercnancnewedaduasnaresdasbwosateseadiedaasacdin Champs Minimizing NOUS ocius RERRRURRRERIGEEERRELEROEY Ree ee Rie eee ke ER ERR bkn 2 7 Power Supply and Grounding Recommendations ccceeeceeeeeueneeeeeeags Power Budgeting code Rep et ER ERU RM RC eR da a ERU T CR D RO eR p d 2 8 Cable Connections and Grounding sseseeeeee nnn Inserting the Module into the Base sssseeeeennn nnn n nnn nn nnn Inserting the Module 03 46 ccc seed e eR RR RR Pewee bee ee REPEAT Ka cR acci d 2 10 Guidelinesfor CPU Tlb35 ise meon n Er RR Pee Rhet e e D ce es 2 10 Checking Status Indicator 0 ene nnn 2 11 Logging the Module into Controller Memory seen nn nn n n n n n n n n n nn 2 12 Config rnng l Q and a a itae L2 ERREUR RE RE ated ead BOER ERE AUR RR 2 12 Selecting the I O Definition Chart sssssssssses e 2 12 Viewing the I O Configuration Chart 00 00 2 12 SIMATIC 505 TurboParison Module User Manual Installing the Module 2 1 2 1 Overview of Installation How of Tasks Figure 2 1 shows the organization of the tasks described in this chapter Set options Wire power and I O connector
85. e of process value to setpoint change A CAUTION A die can overshoot the zero or span location Die overshoot can cause damage to your equipment To help avoid potential equipment damage caused by a die overshooting the zero or span location leave a small gap between the zero span value and the minimum and maximum range of the die when setting zero and span values Loose Tuning Parameters Tight Tuning Parameters Ideal Tuning Parameters Over damped Setpoint Under damped Critically Damped diesen Overshoot Process Value PCT Setpoint Process Value Process Value 6 14 Calibration and Loop Tuning Figure 6 10 Loop Response SIMATIC 505 TurboParison Module User Manual Typical Tuning Table 6 1 shows typical loop parameter values for tuning die response Parameters for Die where Ke is the proportional gain constant and T isthe integral time Heads constant in milliseconds Table 6 1 Typical Loop Tuning Parameters for Dies Large Machines Dies as heavy as 15 Ib or more Loose Tuning Values Ti 1000 Tight Tuning Values Kc 2 0 Tj 2300 Shuttle and Wheel Machines Loose Tuning Values Kc 0 5 Tj 2500 Tight Tuning Values T 2200 SIMATIC 505 TurboParison Module User Manual Calibration and Loop Tuning 6 15 Tuning Loops continued Guidelines for Tuning Loops Create a step change program for toggling setpoint Y Toaid in monitori
86. ea carae acea idracrnr a od ide obi eraat toa Re ado eee a 6 8 Calibrating Rams 2 cece cece aaa ia a n n n an Calibrating Ram Position sssssssssssssssssee nnn 6 10 Guidelines vices ices eek ee orte eed dad eR ca REOR Aa ORC RR d Rache ee Rn 6 10 Calibrating Maximum Ram Velocity 0 e 6 12 Calibrating Aux 5 Inputin Mode 5 cc cece eee eee eee n m m nnn Description of the Calibration ssis ssai eia iaia aradi aea m m 6 13 Example of the Calibration 0c cece eem rre 6 13 Tuning LOOPS usui rex chess cess seen RORIS idee aes eee een RO RR RR CR ene eee DESCMPUOM c Pantanal ne hams alate Naot Wid lp dee aaa eee gies 6 14 Typical Tuning Parameters for Die Heads 6000s 6 15 Guidelinesfor Tuning LOOPS 06 eee mH 6 16 SIMATIC 505 TurboParison Module User Manual Calibration and Loop Tuning 61 6 1 Overview Areas of Control Figure 6 1 shows the various areas of control for calibration and tuning Adjust amplifier Ensure transducer output provides unipolar offset and gain voltage range over entire die travel TurboParison Module Input Position alias NEn Screw transducer B 1 Extruder Loop 2 MN Servo valve and i i Setpoint data control Spinder Calibrate the maximum for axis velocity of accumulator i i if applicable Plastic Tune die head and i Parison accumulator loops
87. ecuted when profile is enabled 95 32000 100 output Total Stroke 32000 4 Shot Size SS 280004 85 SS 23800 20 SS 5600 5 SS 1400 Back pressure setting specified by hold value Accumulator fill 0 Ram Position Figure 5 3 5 4 Position based Operation Ram push out Example of the Relationship Between Ram Velocity and Position NOTE The velocity profile is executed during the ram push out cycle which begins upon transition to profile enable When profile execution is disabled the module forces the setpoint of the ram axis controller to the value specified in the hold location of the Configuration Table SIMATIC 505 TurboParison Module User Manual Figure 5 4 illustrates how the velocity profile shown in Figure 5 3 might be specified The velocity setpoint information is entered into the Velocity Setpoint Table and the position transition data is entered into the Position Table These tables are located in the controller s V memory The module uses each velocity valuein the table which is a percentage of the maximum ram velocity as a setpoint for the axis controller for the ram Each velocity setpoint is used until the corresponding position location in the Position Table is reached Velocity SP Table Position Table start address start address Velocity SP Table Position Table Range 0 32000 Range
88. ed The Module Good and Run LEDs blink simultaneously if the factory test jumper is in place To correct this problem remove the shorting block from the two pins labeled E 100 located near the bottom edge of the circuit board see Figure 2 3 If both LEDs blink alternately a fatal error has occurred Check the communication link between controller and module If the problem persists contact your distributor SIMATIC 505 TurboParison Module User Manual Installing the Module 2 11 2 7 Logging the Module into Contoller Memory Configuring I O The TurboParison module has four 16 bit word inputs WX and four 16 bit word outputs WY When you configure controller I O you assign addresses to each of the eight words The controller then references a word via the I O address For example if you configure the module so that its I O address begins at 0001 you can reference the first word an input word with the address WX1 and the fifth word an output word with the address WY 5 We refer to words WX1 WX4 and WY5 WY8 throughout this manual If you assign an I O address other than 0001 to the module your WX WY words will be different Refer to the SIMATIC 500 505 Programming Reference Manual or the SIMATIC 505 TISOFT User Manual for more information about configuring 1 0 Selecting the I O Figure 2 8 shows a sample I O definition chart with a parison module Definition Chart installed in slot 2 Refer to your TISOFT manual
89. en or closed loop Bit 14 in configuration word Direct or reverse acting Provides selection for direct or reverse acting processes This feature is typically control used to select either converging or diverging tooling See Section 6 4 for more information about converging diverging tooling Bit 15 in configuration word Bipolar or unipolar loop Selects either bipolar or unipolar loop operation When bipolar is selected the selection loop controller output is in the range 32000 to 32000 When unipolar is selected the loop controller output is in the range 0 to 32000 Bipolar loop outputs are typically used for controlling servo amps such as used in die position control Bit 10 in configuration word Velocity or position Provides differentiation to convert position readings into velocity data Bit 13 in control configuration word Analog input filtering Provides first order exponential filtering for input data Filtering helps reduce the adverse effects of noise on the input If you do not select this feature the module does not filter the incoming data Bit 16 in configuration word Scaling zero to span Provides scaling of input and output values The scaling element scales the 0 to value 32000 range used by the module to the zero to span voltage used by the machine Broken transmitter alarm Provides a method for signaling an alarm condition for a broken transmitter Bit 11 in configuration word Manual overrid
90. eneral guidelines 6 4 guidelines 6 15 6 16 Uploading tables to the controller Vv bit map operationa mode A 5 V memory overview allocating 3 16 profile operation control A 6 Ee WX1 current profile execution step A 3 block transfers 3 4 3 8 WX2 current profile execution step A 3 Valve amplifier adjusting offset and gain 6 5 WX3 handshaking error and status Velocity control 5 4 information WX4 handshaking error and status Velocity setpoint table 5 5 nformation Aca Voltage range WY 5 configuration table starting address jumper locations 2 5 setting 2 4 Nc ration table starting address A 5 WY6 module operation mode 3 5 W WY 6 module operation mode 6 9 WY 7 miscellaneous function control A 6 Wall thickness control 4 4 Wheel machi ne 1 4 4 7 Z WX WY words bit layouts 3 6 3 7 Zero span setting 6 4 Index 5 Customer Response We would like to know what you think about our user manuals so that we can serve you better How would you rate the quality of our manuals Excellent Good Fair Poor Accuracy Organization Clarity Completeness Graphics Examples Overall design Size Index Would you be interested in giving us more detailed comments about our manuals Yes Please send me a questionnaire No Thanks anyway Your Name Title Telephone Number Company Name Company Addr
91. er PPX 505 8118 3 Refer to this history in all correspondence and or discussion about this manual Event Date Description Original Issue 11 91 Original Issue 2591795 0001 Second Edition 09 93 Second Edition 2591795 0002 Third Edition 06 95 Third Edition 2591795 0003 LIST OF EFFECTIVE PAGES Pages Description Cover Copyright Third History Effective Pages Third iii xi Third 1 1 1 9 Third 2 1 2 12 Third 3 1 3 17 Third 4 1 4 18 Third 5 1 5 22 Third 6 1 6 16 Third Tq Third A 1 A 6 Third B 1 B 11 Third C 1 C 3 Third D 1 D 15 Third E 1 E 4 Third Index 1 Index 5 Third Registration Third Pages Description Contents Chapterl Product Overview 1 1 Featuies serino ois sain na ku x hono A CRO UA RR RC RURAL OR RACER ORTU CR RE a T 1 2 prelo LETT 1 2 12 Time based Operation ccc cece cece cece High Speed Operation Mode 1 sssssssssssseeeee ee ere 1 4 Standard Speed Operation Mode 2 issssssssssse nen 1 5 13 Position based Operation 0cccccee eee e cece eee eee eee eee nn nn nnn Two Head Operation with Accumulator Control Mode 3 ccc cece eee eee 1 6 Four Head Operation without Accumulator Control Mode 4 cece eee eee 1 7 Wheel Machine Operation with Position Input Mode 5 cece eee eee 1 8 1 4 Background Knowledge sssssnssssnnnnnnnnnunnnnnnnunnunnnnnnnnnnnnnnnnn Prerequisitesand Assumptions
92. er Manual Using the Module sOptional Features 7 7 7 3 Using the Module s Disc rete Outputs Description Each axis of the module has a corresponding discrete output that you can use to control a discrete device or application e g ink jet to mark parison Figure 7 7 illustrates how the module produces a discrete output signal for both modes of operation The step coincidence output is based on the profile step affecting the die position and the position coincidence output is based on the ram position Step coincidence output Profile steps Step coincidence location step number 8 Number of steps to hold on the coincidence output 5 Position coincidence output IN NN NN NN NN ANNNNANAAN NNNNNSNANSNNNANAAANANAAXAAXAAANANAXANN Ram position pU 32000 28000 24000 20000 16000 12000 8000 4000 0 Shot size End of shot Position coincidence address absolute position 18000 Hold position coincidence on until ram position 8000 Figure 7 7 Discrete Output Generation 7 8 Using the Module sOptional Features SIMATIC 505 TurboParison Module User Manual Procedure To generate a discrete output signal for either a die or ram enter values intothe following fields in the Configuration Table For a die e Profile Step Coincidence Location this field specifies the step within the Profi
93. er of steps used Table 4 2 shows time values for the number of profile steps Table 4 2 Profile Time vs Number of Profile Steps High Speed Mode Standard Speed Mode Mode PONE steps Minimum Maximum sse wea 4 ms 750 ms 8ms 65 seconds 8ms ms 15 L5seconds 16 ms 65 16ms 65secnds 8 I 16 ms 3 pue 32 ms a 65 seconds 16 32 ms 6 seconds 64 ms 65 seconds 32 64 ms 13 seconds 128 ms 65 seconds 128ms ms 26 26seconds 256 ms 65 256ms 65seconds NL ms 53 EXE SS ms 512 ms 65 seconds a ms When the module is in high speed mode only two axes numbers one and two are available for profile control The two remaining axes are still operational but they cannot be configured for closed loop control If you want to use these axes to control a die you must program the controller so that it generates the profile setpoints 4 10 Time based Operation SIMATIC 505 TurboParison Module User Manual 4 3 Determining Module Configuration Parameters As discussed in Chapter 3 the Configuration Table contains process parameters that determine the operation of the TurboParison module The module uses these parameters to calculate loop variables offsets and other numeric values that are essential to parison control To determine which process parameters are available for use with the TurboParison module when operating it in time based mode refer to Table 4 3 Remember that dies C and D ar
94. er screw and and hydraulic hydraulic cylinder cylinder Q JL Ca Sync pulse Die head 3 axis 4 Die head 4 at dk 2 L 0 Sync pulse axis 3 Plastic Plastic parison Q Step parison coincidence output Step lt coincidence output Figure 4 6 Example of Standard Speed Operation SIMATIC 505 TurboParison Module User Manual Time based Operation 4 9 Characteristic s of High Speed and Standard Speed Operation continued Differences in High Speed and Standard Speed Operation The high speed and standard speed modes operate essentially in the same way except for a few important differences In high speed mode the module controls up to two die heads in standard speed mode the module controls up to four die heads In addition the speed capability and the profile times differ for the two modes These differences occur because of the resolution and maximum values of the timers When the module is configured for two high speed profiles a dedi cated hardware timer with a 12 8 microsecond period is used to time the transitions between profile steps In standard speed mode the module uses a one millisecond timer Because the transition time between profile steps is determined by both the number of steps and the total profiletime the minimum and maximum profile times depend on the numb
95. ess Manual Name SIMATIC 505 TurboParison Module User Manual Edition Third Manual Assembly Number 2586546 0069 Date 06 95 Order Number PPX 505 8118 3 FOLD BUSINESS REPLY MAIL FIRST C LASS PERMITNO 3 JOHNSON CMY TN POSIAGE WILL BE PAID BY ADDRESSEE ATTN Technical Communications M S 519 SIEMENS INDUSTRIAL AUTOMATION INC 3000 BILL GARLAND RD P O BOX 1255 JOHNSON CITY TN 37605 1255 FOLD NO POSIAGE NEC ESSARY IF MAILED IN THE UNITED STATES SIMATIC is a trademark of Siemens AG TurboParison Series 505 and TISOFT are trademarks of Siemens Industrial Automation Inc
96. et into the V memory locations listed on the worksheet 3 f you do not have an operator interface enter values for the Profile Setpoint Table Velocity Setpoint Table and Position Table now NOTE f you change any values in the Configuration Table Profile Setpoint Table Velocity Setpoint Table or Position Table while a profile is running you must instruct the module to download the tables again before the changes can affect the operation of the module SIMATIC 505 TurboParison Module User Module Position based Operation 5 17 5 4 5 18 Preparing the Module for Operation Before you operate the TurboParison module complete and check off the following tasks Y Set the dipswitches for the correct operational mode set the voltage jumpers to match the voltage for your I O devices install the module in the base and make the appropriate field connections to the front of the module See Chapter 2 Run TISOFT and configure the controller 1 0 for the TurboParison module s location and type After you log the module into the controller determine the controller V memory allocation requirements for your configuration See Section 5 3 Determine the machine sequence for your process and then write an RLL program to sequence the machine and interact with the module Load the Configuration Table with the parameter values that correspond to the axis or axes Appendix B lists and describes all of the available parameters Ens
97. file B Bit 10 Profile C Bit 7 Profile C Bit 11 ProfileD Bit 8 ProfileD Bit 12 See Appendix A for a complete description of WX WY words and more information about profile operation SIMATIC 505 TurboParison Module User Manual Time based Operation 415 4 6 Changing Configuration and Profile Data To change data in the Configuration Table or the Profile Setpoint Table access the V memory locations to change data and enter the new data If you have an operator interface access the parameters and or setpoints with the screen and enter the new data Before any changes can become effecti ve however you must download the tables from the controller to the module When you place the module in RUN mode the tables are automatically downloaded to the module If the module is already in RUN mode and you make changes to one or more of the tables your RLL program must instruct the module to download one or more of the tables The procedure outlined in Figure 4 7 shows you how to download the tables when the module is in RUN mode Download 1 Set bit 1 in WY7 to download the Configuration q 1 Table to the module After the table download 1234567 8 9 10111213 14 15 16 Configuration e Table is complete the module sets bit 1in WX4to 1 acknowledge the successful download You iy should then reset bit 1 in WY 7 to 0 and ensure the acknowledge is cleared Download Configuration Table b
98. fora 4 Mold Wheel 5 10 Position based Operation SIMATIC 505 TurboParison Module User Manual Figure 5 9 shows a typical application of two head operation with automatic restart TurboParison module Profile A Position transducer Profile B not shown Servo valve and hydraulic cylinder cM Die head High speed wheel Plastic parison l Position Sensor up to two wheels on the same axle with independent profile control for Product each Note The TurboParison module can control SS Figure 5 9 Two Head Operation with Automatic Restart SIMATIC 505 TurboParison Module User Module Position based Operation 5 11 Characteristics of Position based Modes continued Differences in Mode 5 Mode 5 is similar to position based M ode 4 except that the profile automatically restarts when the position input returns to the profile starting value This allows position control of the parison profile for continuous parison generation when needed by the wheel machine In this mode the module expects the position input to be a saw tooth waveform with the active part of the input representing the time it takes for the wheel to revolve by one mold The active part of the input can have either a positive or negative slope e You select Mode 5 by setting swit
99. guration data from controller Setpoint generator Axis controller Profile setpoint o position velocity setpoint data from controller Setpoint ramping mode 2 only Purge control Phase check Weight control and automatic weight offset Hold value die gap Closed or open loop control Direct or reverse acting control Bipolar or unipolar outputs Velocity or position control Analog input filtering Scaling zero and span values Broken transmitter alarm Manual override Servo amplifier output Figure 3 6 Configurable Elements within the Module NOTE The module is also capable of controlling the velocity of a ram See Chapter 5 for more information SIMATIC 505 TurboParison Module User Manual Understanding Module Operation 3 11 Setpoint Generator Figure 3 7 illustrates the operation of the setpoint generator section of the module When the profile is enabled the module reads the appropriate profile value from the Profile Setpoint Table adds the weight settings and sends the resulting setpoint to the axis controller When the profile is not enabled the hold value typically the die gap setting becomes the controller setpoint Automatic weight correction optional Profile setpoints 12000 Module reads a setpoint and calculates a new setpoint based on the
100. guration word SIMATIC 505 TurboParison Module User Manual Understanding Module Operation 3 13 Manual Ovenide Each control axis ouput has a manual override control bit and value associated with it This allows the analog output to be forced to a manual override value whenever the corresponding control bit is set to one The conrol bits are 9 10 11 and 12 in WY 7 The manual override values for each axis are located in the continuous download portion of the configuration table in V memory see Appendix B These values are automatically downloaded to the module usually once every controller scan When one or more of bits 9 12 of WY 7 are set the manual override for the corresponding axis is are enabled This causes the associated output to be forced to the manual override value When the bit returns to zero normal axis operation resumes and if the axis is configured for closed loop operation it causes a bumpless transfer Table 3 2 Axis Controller Description Element Description Closed loop or open loop Provides closed loop control for the die head or accumulator ram Closed loop control control allows the module to manipulate the output in order to maintain the position or velocity specified by the setpoint You can bypass this feature and provide open loop control setpoint drives output directly Mandrel position wall thickness control is usually controlled in closed loop Ram velocity may be controlled in either op
101. gure 4 4 Minimum Maximum Nominal Synchronization pulse min Input Low voltage 0v 2V OV 1ms voltage High voltage 20V 28V 24V Pt Synchronization pulse max lt Pt 1 ms Figure 4 4 Relationship of Sync hronization Pulse to Profile Time Alternatively you may choose to generate the sync pulse in your RLL program by toggling bits 13 14 15 and 16 in WY8 These bits correspond to Profiles A through D respectively Refer to Appendix A for a description of the bit locations in WY8 For a software generated sync pulse to work the pulse length must be greater than one controller scan NOTE For high speed operation you must input the synchronization pulse through the module s discrete I O points because the controller scan time is usually not fast enough to allow the RLL to generate a sync pulse SIMATIC 505 TurboParison Module User Manual Time based Operation 4 5 4 2 Characteristics of High Speed and Standard Speed Operation The module can operate in either a high speed or a standard speed mode depending on the length of the total profile time required by your process This section describes the two modes and their differences High Speed When configured for high speed operation the TurboParison module has the Operation following characteristics Mode 1 e Axes 1 and 2 are available for profile control e Axes 3 and A are not av
102. gure 6 7 Die Head Calibration Procedure Calibration and Loop Tuning 6 9 6 4 Calibrating Rams Calibrating Ram Calibrating rams is a process of first defining the End of Shot position zero Position value filling the accumulator with plastic moving the ram and defining the span value See Figure 6 8 Numeric Value Stored in TurboParison Module Maximum e Span Vale c 32000 Zero Value End of Shot Minimum Figure 6 8 Calibrating Zero and Span Values Zero corresponds to the End of Shot position span corresponds to the ultimate fill position Leave some margin between the zero span positions and the minimum maximum as shown Keep these factors in mind when you calibrate the module Guidelines Figure 6 9 shows the basic steps required for calibrating rams Consider also the following guidelines 4 Entering 10000 for output span in the Configuration Table defines the maximum voltage either 10 V or 45 V selected by jumper settings If the 0 5 V range was selected entering 10000 defines the maximum output voltage to be 5 V entering 5000 defines the maximum voltage to be 42 5 V 50 of jumper selection not 5000 mV 4 Configure your amplifiers and valves so that positive voltage shoots plastic 6 10 Calibration and Loop Tuning SIMATIC 505 TurboParison Module User Manual Put module in CALIBRATE mode Set the calibration
103. h Accumulator C ontol 5 8 Position based Operation SIMATIC 505 TurboParison Module User Manual Four Head When configured for four head no accumulator control the TurboParison Operation without module has the following characteristics Accumulator e Control Mode 4 Up to four axes axes 1 4 are available for profile control e Auxiliary input 5 monitors the position of the accumulator ram The module does not perform push out control You must provide some other means e g with the controller to do this Figure 5 7 shows a typical application of four head no accumulator mode TurboParison n module module i Aux 5 Qal 4 A E inputs Q a Screw Ram contro Extruder screw Valve position from other o transducer controller O LVDT Axsi Qa inputs Q a Axsi Servo outputs Q AMP valve and hydraulic Axs2 O4 cylinder inputs Q a LVDT Axs2 Die outputs gt Profile A 1 head Servo ual valve and AMP hydraulic cylinder Plastic parison Die m head Pr
104. hat you can use either with any Series 505 controller for example models 535 545 and 555 or with models 560 565 or 575 and a Series 505 remote base controller RBC e Controls up to four independent profiles in time based mode By operating the module in high speed mode you can execute a 256 step parison profile in as little as 0 5 seconds e Controls up to four independent profiles in position based mode with one accumulator or up to two independent profiles with two accumulators when profile push out is required e Provides closed loop control of the shot speed for an accumulator e Provides up to 256 profile steps zones for each profile e Operates down to a one millisecond sample rate while providing closed loop control on all four axes e Provides linear and curvilinear interpolation with unlimited master points e Allows you to easily increase the number of profile steps and improve resolution without re entering the profile data e Provides automatic weight control that maintains part weight both before and after profile modification e Provides automatic phase checking that quickly indicates whether a parison is placed properly in the mold e Allows you to operate a high speed discrete output signal for each profile 1 2 Product Overview SIMATIC 505 TurboParison Module User Manual The TurboParison module has five analog inputs and four analog outputs The module combines four of the analog inputs and four analog
105. have your RLL read the Weight Correction field in the General Status Table This field must correspond to the profile you are modifying Using the Module sOptional Features SIMATIC 505 TurboParison Module User Manual Procedure Toinitiate automatic weight control follow these steps 1 Ensure that the profile setpoints Profile Setpoint Table and the weight control value configuration table are approximately correct Also ensure that the overall part weight is close to your required value 2 Enable automatic weight control by setting the appropriate bit in WY 7 to one See Table 7 1 Table 7 1 Automatic Weight Contol Enable Bits WY7 sitse sU isis 14 5 16 Automatic weight control is enabled when Bits 13 through 16 are set to 1 After the bit is set the module determines the mean weight of the corresponding profile If any changes are made to the profile the module adds a positive or negative weight correction factor to the profile NOTE When you first enablethe automatic weight control feature you will not notice any changes in the profile Before any changes can ocaur the Profile Setpoint Table must be downloaded again to the module You can make changes to the Profile Setpoint Table and as long as the automatic weight control is enabled the module calculates a weight correction factor whenever it reads the Profile Setpoint Table SIMATIC 505 TurboParison Module Us
106. he parameters and or setpoints with the screen and enter the new data Before any changes can become effecti ve however you must download the tables from the controller to the module When you place the module in RUN mode the tables are automatically downloaded to the module If the module is already in RUN mode and you make changes to one or more of the tables your RLL program must instruct the module to download one or more of the tables The procedure outlined in Figure 5 10 shows you how to download the tables when the module is in RUN mode 1 Set Bit 1in WY 7 to download the Configuration Table to the module After the table download 1234567 8 9 1011 12 13 14 15 16 is complete the module sets Bit 1in WX4 to 1 acknowledge the successful download You 4 should then reset Bit 1 in WY 7 to 0 and ensure the acknowledge is cleared Download Configuration Table Download Configuration Table bit Set Bit 2 3 4 or bin WY7 to download the 1 2 83 4 5 6 7 8 9 10 11 12 13 14 15 16 Download Profile Setpoint Table or Position and Setpoint Velocity Setpoint Tables if applicable After V Tables the table is downloaded the module sets Bit 2 A 3 4 or 5 in WX4 to acknowledge the Download Setpoint Table s bit successful download You should then reset Bit 2 3 4 or 5 to O and ensure the Bit 2 Axis 1 Bit 4 Axis 3 acknowledge is cleared Bit 3 Axis 2 Bit 5 Axis
107. hexadecimal 20480 decimal in WY 6 puts the module in RUN mode All configuration information is automatically downloaded from the controller and the module enables all axis controllers The module RUN light comes on and the RUN acknowledge bit WX4 Bit 8 is set to one 4 Writing a zero to WY6 takes the module out of RUN mode All analog outputs are forced to O V all discrete outputs are turned off the module RUN light turns off and the RUN acknowledge bit is reset to zero This corresponds to an Emergency Stop ESTOP condition A caution Ensure that you do not require a controlled shutdown before you perform an ESTOP If you do not initiate a controlled shutdown procedure before performing an ESTOP you may cause equipment damage It is to your advantage to shut down in a controlled manner before you perform an ESTOP Enabling Disabling To start profile execution set the corresponding profile enable bit in WY8 Profile Exec ution to 1 The module then sets a corresponding bit in WX3 to signify the profile is active Profile execution begins at the start of the first sync pulse The setpoint returns to the die gap hold value when the profile is disabled 1234 56 7 8 9 10111213 14 15 16 1234 56 7 8 9 1011 12183 14 15 16 WY8 WX3 pl WEE Enables Profile Module Response ProfileA Bit 5 ProfileA Bit 9 ProfileB Bit 6 Pro
108. iding potential for the output trying to drive the mandrel beyond some mechanical stop in an attempt to achieve setpoint 4 Entering 10000 for span in the Configuration Table defines the maximum voltage either 10 V or 45 V selected by jumper settings If the 0 5 V range was selected entering 10000 defines the maximum output voltage to be 5 V entering 5000 defines the maximum voltage to be 42 5 V 50 of jumper selection not 5000 mV Y When calibrating rams always use open loop manual control to move ram tothe zero position fill accumulator with plastic to move ram to span position 4 Inputs on the TurboParison module are unipolar 0 V to 5 V or 10 V Ensure that feedback signals to the module inputs are within the unipolar input range throughout the entire stroke If feedback device is a bipolar LVDT either Use the unipolar e g O V to 10 V range of the stroke or Install a signal conditioner to convert voltages from bipolar to unipolar Z When setting zero and span values leave a small gap between the zero span value and the minimum and maximum range of the mandrel This helps to avoid potential equipment damage caused by a mandrel overshooting the zero or span location V You can set zero and span for outputs in the Configuration Table Reference Appendix B 4 In CALIBRATE mode the new zero and span values are stored during calibration exiting from CALIBRATE mode writes the new zero and span values t
109. iled description of time based operation refer to Chapter 4 High Speed The high speed mode allows you to control up to two independent die heads Operation each having its own profile of up to 256 program steps zones For a Mode 1 256 step profile a parison drop as fast as 512 milliseconds can be controlled High speed mode is used typically for wheel type machines See Figure 1 2 TurboParison module Profile A Position transducer Profile B not shown Servo valve and hydraulic cylinder NER Li Die head High speed wheel Plastic parison a Proximity sensor or dr 5 other device to give pulse at start of parison for each mold pair Mold gt Note The TurboParison module can control N up to two wheel machines with Ce independent profile control for each Product Figure 1 2 Example of High Speed Operation 1 4 Product Overview SIMATIC 505 TurboParison Module User Manual Standard Speed Operation Mode 2 The standard speed mode allows you to control up to four independent die heads each having its own profile of up to 256 program steps For a 256 step profile a parison drop as fast as 1 second can be controlled Standard speed mode is ideal for most shuttle type machines SeeFigure 1 3 TurboParison module Profile A Profile
110. ins the position information that controls transitions between velocity setpoints This table is used in conjunction with the Velocity Setpoint Table and has the same length Specifies the first V memory location of the profile PV Table This table contains the actual profile value at the end of a step The TurboParison module uploads this tabletothe controller at the end of every profile The PV Tableis the same length as the Profile Setpoint Table You must allocate enough V memory for the PV Table so that important data is not overwritten If you set this parameter to zero the module does not upload the PV Table Specifies the amount of time to shift the phase of a profile with respect to the incoming sync pulses The default value is 0 which does not produce a phase shift Specifies the purge setpoint value to which the loop controller is set when you set the purge command bit in WY8 Specifies the weight value that is added to all Profile Setpoint Table entries before they are fed to the loop controller This value provides a weight offset that biases the profile either up or down SIMATIC 505 TurboParison Module User Manual Configuration Table Data B 9 Parameter Descriptions for Configuration Table continued Table B 10 Parameter Descriptions for Configuration Table continued Parameter name Phase check locati on Phase check setpoint Number of steps to hold phase check Profile time calculation method Number of
111. int Table Axis 2 Process Variable Table Profile Setpoint Table Process Variable Table Axis 3 Velocity Setpoint Table position mode only Position Table position mode only UILLAM CNN NU eret me E memimumberofVmemoryaddremesreered Profile iin nt Table Axis 4 Temporary Memory Addresss Table name Memory reserved Em hein Interpolation Master Table a ee ee Interpolation Calculated Table OOO O E Total number of V memory addresses reserved MEN SIMATIC 505 TurboParison Module User Manual Table Configuration Worksheets A Agency approvals D 2 Alarms guidelines 3 17 Amplifier adjusting offset and gain 6 5 Assistance telephoning for 2 3 Automatic restart mode 5 two head 5 1045 12 Automatic weight correction 7 6 Aux 5 input calibrating in mode 5 6 13 Axis controller operation manual override 3 13 Axis controller 3 10 description 3 13 Bit layouts WX WY words 3 6 3 7 C Cable connection 2 9 Calibration aux 5 input in mode B 6 13 die heads general guide ines 6 4 guidelines for open closed loop 6 8 maximum ram velocity 6 12 open loop vs closed loop 6 3 overview 6 2 ram position 6 10 setting zero and span for die heads 6 9 setting zero and span for ram position Closed loop calibration 6 3 tuning loops 6 14 velocity control 5 6 Index Closed loop control direct reverse acting 6 7 Communic
112. ion Table Data B 11 Appendix C General Status Table Data C 1 General Status Table Contents ss esee C 2 SIMATIC 505 TurboParison Module User Manual General Status Table Data C 1 C 1 General Status Table Contents Table C 1 General Status Table Contents V memory offset WY5 ad Parameter Description O o orero Current output for axis 4 Current discrete inputs and outputs Indicates the status of the discrete inputs and outputs The word contained in this V memory location has the following breakdown MSB LSB 1 10 11 12 13 14 15 16 Bits 1 4 Dipswitch settings these bits may be used by the RLL to verify the dipswitch was set correctl y 0000 Model 0001 Mode2 0010 Mode3 0011 Mode4 0100 Mode5 Bit 5 At shot size for profile 2 Bit 6 At end of shot for profile 2 Bit 7 At shot size for profile 1 Bit 8 At end of shot for profile 1 Bits 9 12 Output on for following axes Bit 9 corresponds to axis 4 Bit 10 corresponds to axis 3 Bit 11 corresponds to axis 2 Bit 12 corresponds to axis 1 Bit 13 16 Input on for following axes Bit 13 corresponds to axis 4 Bit 14 corresponds to axis 3 Bit 15 corresponds to axis 2 Bit 16 corresponds to axis 1 C 2 General Status Table Data SIMATIC 505 TurboParison Module User Manual Table C 1 General Status Table Contents continued V memory offsets WY5 offset Parameter Description Broken transmitter
113. ison module Operation has the following characteristics Mode 2 e Four independent axes are available for profile control e Each axis can have a unique profile and weight constant or axes can share profiles e A minimum sample rate of one millisecond is available e Aminimum profile time of one second is available for up to 256 profile steps This time is adequate for most time based applications e Either a hardware generated sync pulse or a software trigger in RLL is used to start a new parison drop Figure 4 6 shows a typical application of standard mode This mode is adequate for most time based applications 4 8 Time based Operation SIMATIC 505 TurboParison Module User Manual TurboParison module Axis 2 Profile A inpute Profile B Qu Qa 0 gt Q Extruder screw Servo Extruder screw valve and hydraulic cylinder JL Sync pulse Die head 1 axis 2 4 Die head 2 Sync pulse axis 1 Plastic Plastic Step rison Ys cn arison pariso coincidence output Step coincidence output Profile C Profile D Da Qa Q Axis3 Q outputs Extruder screw Servo valve Servo valve Extrud
114. it Set bit 2 3 4 or 5in WY 7 to download the 1 2 3 4 5 6 7 8 9 1011 12 13 14 15 16 Download Profile Setpoint Table or Position and Setpoint Velocity Setpoint Tables if applicable After Tables the table is downloaded the module sets bit 4 2 3 4 or 5 in WX4 to acknowledge the Download Setpoint Table s bit successful download You should then reset bit lin WY7 to 0 and ensure the acknowledge is Bit 2 Axis 1 Bit 4 Axis 3 cleared Bit 3 Axis 2 Bit 5 Axis 4 Figure 4 7 Downloading Tables in RUN Mode 4 16 Time based Operation SIMATIC 505 TurboParison Module User Manual 4 7 Monitoring the Operation of the Module The General Status Table enables you to monitor the operation of the module This table consists of module related data that is uploaded from the module to the controller Like the Configuration Table the parameters in the General Status Table are offset from the V memory address specified by WY 5 Table 4 4 shows the contents of the General Status Table Table 4 4 General Status Table Contents V memory offset WY5 sA Parameter description 200 Current analog input from Head A axis 0 Current analog input from Head A axis 1 iain Current analog input from Head B axis 2 Current analog input from Head C axis 3 Current analog input from Head D axis 4 Current analog input from auxiliary input 5 35 curetPVWonHexCiws3 X35 c
115. l Selecting Tooling Selecting the proper loop operational mode is essential when changing Type tooling type Figure 6 6 assumes that applying positive voltage to the servo amplifier moves the die upward If your tooling type is converging select direct acting loop control if toolingtypeis diverging select reverse acting loop control Select direct or reverse acting control by manipulating Bit 15 in the configuration word 0 direct 1 reverse see Appendix B NOTE f your system is set up opposite from this example i e applying positive voltage to the servo amplifier moves the die downward you should swap the direct reverse acting selection shown Position Feedback Process Variable Loop Setpoint Control or Hold Value Diverging Tooling Converging Tooling DZ Voltage to Process Voltage to Process Servo Amp Variable Servo Amp Variable Span Value 32000 lt _ Zero Value 0 4 Span Value 32000 Zero Value 0 lt Select Reverse Acting Select Direct Acting Figure 6 6 Selecting Tooling Type SIMATIC 505 TurboParison Module User Manual Calibration and Loop Tuning 6 7 Calibrating the Die Heads continued General Guidelines Consider the following guidelines when calibrating die heads Figure 6 7 shows the basic steps required for calibra
116. le B Plastic parison Profile C Servo valve and hydraulic cylinder Plastic parison Die head Profile D 4 Plastic parison Figure 1 5 Example of Four Head Operation without Accumulator Control SIMATIC 505 TurboParison Module User Manual Product Overview 1 7 Position based Operation continued Wheel Machine Mode 5 allows control of one or two parisons on a high speed wheel machine Operation with based on the position of the wheel Automatic restart of the parison occurs Position Input when the ramp input indicates the start of the next mold See Figure 1 6 Mode 5 TurboParison module Profile A Position transducer Profile B not shown Servo valve and hydraulic cylinder Die head High speed wheel o Plastic parison a Position Sensor Mold gt Note The TurboParison module can control up to two wheels on the same axle A with independent profile control for Product each Figure 1 6 Example of High Speed Operation with Position Input 1 8 Product Overview SIMATI
117. le Setpoint Table where the discrete output transitions from off to on e Number of Steps To Hold Profile Coincidence Output this field specifies the number of steps to hold on the discrete output For a ram e Position Coincidence Location this field specifies the position of the ram where the discrete output transitions from off to on e Hold Position Coincidence on Until this field specifies the ram position at which the discrete output transitions from on to off All values you enter in these fields are downloaded to the module when the Configuration Table is downloaded If you make changes to these values you must download the configuration table see Appendix B SIMATIC 505 TurboParison Module User Manual Using the Module s Optional Features 7 9 7 4 Checking the Phase Between a Profile and a Parison Description The phase check feature enables you to determine what section of a parison corresponds to a step or range of steps in the associated profile Figure 7 8 shows a typical application of the phase check feature Phase check location 64 Phase check setpoint 24000 Number of steps to hold phase check 8 Die head Profile Jo Phase check setpoint is 75 open 24000 for 8 steps 64 72 Profile steps Parison will be noticeably thicker a 25 50 75 100 Profile position Figure 7 8 Phase Check Example 7 10 Using the Module s Option
118. le is also a special function module that can do high speed block transfers of data to and from the controller The module has five analog inputs and four analog outputs The analog outputs and four of the analog inputs are combined with a software resident closed loop controller to provide four independent closed loop control axes These axes are used to control either wall thickness or accumulator ram velocity depending on the module operation mode you select Figure 3 1 The fifth analog input is used to monitor either the position of an accumulator ram in M ode 4 or a wheel in Mode 5 Unused outputs can be used as general purpose analog outputs by placing the unused output s in M anual mode and moving the value to the manual override value location Unused inputs can be used as general purpose analog inputs by reading their value from the general status table This applies to all models Configuration information is stored in the controller battery backed variable memory V memory Communication between the module and the controller illustrated in Figure 3 1 is provided in two ways e Four 16 bit WX input words report status and error information to the controller Four 16 bit WY output words are used to control the module e V memory data e g configuration information is transferred as high speed block data transfers The module reads analog and discrete signals from the process through its onboard I O points The module send
119. le that you want to starting address interpolate Interpolation calculated table T P Specifies the first V memory location of the resulting interpolated starting address table Interpolation table length T P Specifies the length number of V memory locations of the resulting interpolated table Interpolation method TP Specifies the type of interpolation to be performed on the original table The valid values are 0 linear interpolation Starting address of original TP Specifies the first V memory location of the table that you want to table expand Length of original table TP Specifies the length number of V memory locations of the table that you want to expand T P T P DP 1 curvilinear interpolation table Starting address of expanded ES Specifies the first V memory location of the expanded table Specifies the length number of V memory locations of the expanded table Length of expanded table T P Specifies the setpoint to which the axis controller returns when profile execution is disabled Note that these hold values are continually downloaded to the module usually once every controller scan Axis x hold value or die gap x 1 2 3 0r 4 enabled This overrides all other settings for each axis These values are continually downloaded Axis x manual override value T Specifies the value of the output when manual override is x 1 2 3 or 4 SIMATIC 505 TurboParison Module User Manual Configurat
120. lter time constant 0 to 32 767 milliseconds Velocity scale factor 0 to 32 000 counts mS Kc proportional gain constant 0 to 327 67 Ti integral time contant 0 to 32 767 milliseconds NA NA 8 129 Tg derivative time constant 0 to 327 67 milliseconds Velocity setpoint table starting address 0 to 65 000 N A N A 93 133 Velocity setpoint table length 2 4 8 16 32 64 128 256 N A N A 94 134 Position table starting address 0 to 65 000 N A N A 95 103 135 143 Reserved 0 N A N A 104 144 Position coincidence location 0 to 32 000 N A N A 105 145 Hold position coincidence on until 0 to 256 Parameters listed in this table are invalid for Axis 1 and Axis 2 for accumulator ram control See Table B 5 SIMATIC 505 TurboParison Module User Manual Configuration Table Data B 5 Configuration Tables for Position based Operation continued Table B 7 Configuration Table for Position based Operation Auxiliary Input 5 V Memory offsets WY5 offset Parameter name Valid values 160 Calibration zero for analog input Otolo0O mV to 10 000 mV 180 C Calibration span for analog input Oto PELLI aic n 000 mV 162 Shot size Mode 4 only 0 to 32 000 Wrmp wem 9 Table B 8 Configuration Table for Position based Operation Miscellaneous Functions V Memory offsets YS ense offset Peramemrmame 1 name idws values L in wesiswcsci
121. mpts to control a machine SIMATIC 505 TurboParison Module User Manual Understanding Module Operation 3 15 Download Configuration Table bit 1 in WY7 Download complete bit 1 in WX4 Configuration Table Bit stays on until download is complete corresponding bit in WY7 is reset to 0 Figure 3 9 Timing fora Forced Table Download Uploading General The General Status Table is uploaded to the controller typically once every Status and Process controller scan Certain operations such as interpolation or the download of Variable Tables other tables may delay this upload Process Variable Tables are uploaded to the controller either upon completion of profile execution or when a synchronization pulse is received signifying the start of a new parison The module notifies the controller that an upload of PV Table 1 2 3 or 4is in progress by setting Bits 9 10 11 or 12 respectively in WX4 to 1 The corresponding bit remains set for at least 1 controller scan When the bit returns to 0 the upload is complete 3 16 Understanding Module Operation SIMATIC 505 TurboParison Module User Manual 3 5 Guidelines for Allocating V Memory The module reads data from several tables that are located in various areas of V memory Other operations such as interpolation and table expansion also require blocks of V memory You need to map V memory carefully to be sure that the memory allocation does not cause tables to ove
122. mum voltage from the wheel position sensor 2 Convert this number to integer millivolts 3 Add 50 to the number 4 Enter the number in V memory location WY 5 160 Maximum voltage reading 9 65 V Minimum voltage reading 0 45 V Convert to integer millivolts 9 65 9650 0 45 0450 Subtract 50 from the maximum reading 9650 50 9600 Enter 9600 in location WY5 161 Add 50 to the minimum reading 0460 50 500 Enter 500 in location WY5 160 Determine the minimum and maximum voltage by rotating the wheel to the positions where these values are output by the position sensor These two values are very close to each other during the rotation of the wheel If you can rotate the wheel slowly enough you can use a controller interrupt routine to determine the minimum and maximum values that are seen at the Aux 5 input SIMATIC 505 TurboParison Module User Manual Calibration and Loop Tuning 6 13 6 6 Description Tuning Loops The TurboP arison module uses Proportional Integral Derivative PID control PI D controllers can be tuned by using three different parameters the proprotional gain integral time constant and derivative time constant These parameters are stored in the Configuration Table for each axis Adjusting the loop tuning parameters effects system performance adjust your tuning parameters to provide the desired response for your process Figure 6 10 shows relationships between loop tuning philosophies and the respons
123. n cece General Status Table Contents 0 eee eens Configuration Table for Position based Operation Mode 3 Only Configuration Table for Position based Operation Mode 3 Only Configuration Table for Position based Operation Mode 4 Only Configuration Table for Position based Operation All Modes 005 General Status Table Contents 0 ccc ccc cece te te een E a a aa Typical Loop Tuning ParameterSforDieS ccc cece nn Automatic Weight Control Enable Bits WY7 cece cee eee eens Configuration Table for Time based Operation Axes 1 2 3 and 4 00005 Configuration Table for Time based Operation Auxiliary Input5 Configuration Table for Time based Operation Miscellaneous Functions Configuration Table for Time based Operation Continuous Download Segment Configuration Table for Position based Operation Die Head Configuration Table for Position based Operation Accumulator Mode 3only Configuration Table for Position based Operation Auxiliary Input 5 Configuration Table for Position based Operation Miscellaneous Functions Configuration Table for Position based Operation Continuous Download Segment Parameter Descriptions for Configuration Table 0 ee General Status Table Contents iississssee e en Physical and Envir
124. n feature Profile Operation Control Y 1 2 s 4 s e 7 s o to ui r2 o Mode 5 polarity control m J A AX Y Forces profile setpoint to purge value i Enables automatic weight control for axis 1 2 3 or 4 Enables profile 1 2 3 or 4 Manual override mode Enables phase check operation Provides internal RLL sync pulse when toggled Figure 3 4 Bit Layouts for WY Words Commands to Module 3 8 Understanding Module Operation SIMATIC 505 TurboParison Module User Manual Communicating with the Controller continued V Memory Block Tansfers Configuration Table General Status Table Setpoint Tables Process Variable Tables TurboParison module uses high speed block transfers to exchange both configuration and runtime status with the controller See Figure 3 5 The module configuration is stored in a section of V memory called the Configuration Table This table holds configuration information for each control axis pointers to other tables that reside in V memory and other operational information WY 5 must contain the starting address of the Configuration Table Figure 3 5 The Configuration Table is automatically downloaded to the module upon transition to RUN or CALIBRATE mode If configuration information is changed the table must be downloaded again before the changes will take affect See Sec
125. ndix B for more information about this table Address WY6 Module Operational Mode mesa 0 Beenplon 12345 6 7 8 9 1011 12 13 14 15 16 Set module to the RUN mode Both bits must 1 all others must be 0 hexadecimal 5000 decimal 20480 Reserved Use Bits 10 11 and 12 to select axis input for calibration 001 Select Input 1 1234 56 7 8 9 1011 12 13 14 15 16 010 Select Input 2 011 Select Input 3 100 Select Input 4 101 Select Input 5 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Set module to the CALIBRATE mode Set the low limit during calibration 12 34 5 6 7 8 9 10111213 14 15 16 i2 3 4 5 6 7 8 9 1011 12 13 14 15 16 Set the high limit during calibration 12345 6 7 8 9 10111213 14 15 16 Set the maxi mum velocity for a ram during calibration SIMATIC 505 TurboParison Module User Manual WX WY Word Descriptions A 5 WY Words continued WY7 Miscellaneous Function Control E ee o 2345 6 7 8 9 1011 12 13 14 15 16 WY8 Profile Operation Control 12345 6 7 8 9 1011 12 13 14 15 16 12345 67 8 9 1011 12 13 14 15 16 1234 5 6 7 8 9 1011 12 13 14 15 16
126. ng Module Operation 3 1 3 2 3 3 3 4 3 5 3 6 InBioducton 5 12 v sas eh E Er asa ees NA e cR cO RO sales Seen ER RR Communicating with the Controller sees nnnnnnn OVETVIEW rem WHIWY WOKS ota tactis mind bh Se eek UE Pee Ree ERU aed aha sug cas WY5 V Memory Addressof Configuration Table 0 cece eee a WY6 Module Operational Mode 0 tenets V Memory Block Transfers 0 6 eese Configuration Table 2e eie katie ead date ada seed dee ete General Status Ta Dle se itis ce ies ee er Sea ale e e i ee CRT Setpoint Tables 2i eR eee Berek mea iced tado Kaze Gee ERR d ERR Process Variable TableS 0 0 ccc eect s Operating the Module s seen nnn nennen hannah Setpoint Generator usse ee er Ree Rt Re ROC ed en edet ed pa ea ee ee Axis Controller eR added ad each nace CERRO RENT C3 EE EY o ede o ManualOvetnde 5 yate beaten c KR eee VR ed t onde ota PR bae kab Downloading and Uploading Tables een n n nn n n n n n n n nn Downloading Configuration and Setpoint Tables sssssse eee Uploading General Status and ProcessVariable TableS cece aes Guidelines for Allocating V Memory enn m mmm mnn Guidelines for Errors and Alarms s nnn hh hh nara n aaa rara Fatal EITOIS 5 2 ed b teet elk ce En Cte der kx CO Ec Raa TA URP TERT RTT TERT Chapter4 Time based Operation 4 1 4 2 4 3 OVGIVIOW ilii a Xx RARRRRARRARR APR CR
127. ng it The table expansion feature Figure 7 5 allows you to increase the number of entries in a table automatically in order to increase the resolution of a profile To expand a table create an original table in V memory and reserve another area in V memory to store the expanded table Store the starting addresses and table lengths in the Configuration Table When you send the command to expand the table the module copies the original table into the expanded table filling in the intervening points with zeroes You can then use the interpolation feature to calculatethe intervening points Original Table Expanded Table start address start address Expanded Table To Module Original Table To Module H 100 500 1000 5000 Figure 7 5 Expanding Tables The V memory addresses and corresponding table lengths for the original and expanded tables are stored in the Configuration Table Be sure to download the Configuration Table after performing this initial setup After initial setup is complete you can expand the table by setting Bit 7 in WY7 to 1 When the expansion is complete the module sets Bit 7 in WX4 to 1 You can then copy the expanded table into the master table and interpolate it See section on Interpolation SIMATIC 505 TurboParison Module User Manual Using the Module s Optional Features 7 5 7 2 Automatically Maintaining
128. ng system response to changes in loop tuning parameters program a step change in the setpoint e g from 20 to 40 Toggling the setpoint helps show the effects of adjusting the loop parameters Turn off derivative action Tq V Set Tq 20 Derivative action has not been found useful for most motion loops Determine proportional gain Ko V Start with a small proportional gain and no integral action e g Kc 0 25 and T 0 Although using a smaller number for Tj results in more integral action setting T 0 results in no integral action 4 Doublethe proportional gain Kc until you see a slight oscillation when the setpoint step change occurs the tooling may chatter and settle out After you notice the oscillation reduce Kc by half Determine integral action Tj V After determining the proportional gain Ko introduce integral action by using a large number for Tj e g T 2 10000 Reduce T by half until you see a slight oscillation when the setpoint step change occurs After you notice the oscillation double T For additional tuning V After determining approximate values for Kc and Tj you can fine tune system response by incrementing loop parameters by nominal amounts less than 10 Y You can also fine tune a machine profiling parisons Assure that any fine tuning parameters entered are capable of controlling the most difficult profiless run on that machine 6 16 Calibration and Loop Tuning SI
129. nputs must be grounded or disconnected If external synchronization inputs are used then bits 13 16 must be set 0 A 6 WX WY Word Descriptions SIMATIC 505 TurboParison Module User Manual Appendix B Configuration Table Data B l Configuration Tables for Time based Operation ssssssssssrsensnsnnnnnsnnnnn B 2 Configuration Tables for Position based Operation eese B3 Parameter Descriptions for Configuration Table seen SIMATIC 505 TurboParison Module User Manual Configuration Table Data B1 B 1 Configuration Tables for Time based Operation Table B 1 Configuration Table for Time based Operation Axes 1 2 3 and 4 V Memory offsets WY5 offset Axis 1 Axis 2 Axis 3 Axis 4 Parameter name Levee cj values ci nel ration word Reserved Reed 13 53 93 133 Profile setpoint table length 2 4 8 16 32 64 128 256 14 54 94 134 Process variable table starting 0 to 65 000 address 15 55 95 135 Sync delay phase shift time 0 to 65 535 milliseconds 16 56 96 136 Purge value 0 to 32 000 17 57 97 137 Weight control 32 000 to 32 000 18 58 98 138 Phase check location 0 to 255 19 59 99 139 Phase check Phase check setpoint J 0to32 000 nt 0 to 32 000 Number of steps to hold Number of steps to hold phase check check TII ME Profile time calculation method 0 1 2 3 profile time Profile time out value 0 to 65 535 milliseconds Profile
130. nstant 7 Ti integral time constant 8 Tg derivative time constant 9 Output zero 10 Output span 11 Profile setpoint table starting address 12 Profile setpoint table length 13 Process variable table starting address 14 Reserved 15 Purge value 16 Weight control 17 Phase check location 18 Phase check setpoint 19 Number of steps to hold phase check 20 Reserved 21 Reserved 22 Profiletime out value 23 Profile step coincedencee locatiion 24 Number of steps to hold profile 25 65 coincidence output Reserved 26 39 66 79 Table Configuration Worksheets SIMATIC 505 TurboParison Module User Manual Configuration Table Worksheet Position based Operation Mode 5 Only Page 6 of 6 V memory start address WY 5 Note In this table V memory address start address offset For example if start address V100 offset 4 Then V memory address V100 4 V104 V memory Parameter description ELS s address Value entered Length of original table Starting address of expanded table 176 Length of expanded table 177 Reserved 178 179 The following values are continuously downloaded to module Axis 1 hold value or die gap 180 Axis 2 hold value or die gap 181 Axis 1 parison position shift 182 Axis 1 manual override value 184 SIMATIC 505 TurboParison Module User Manual Table Configuration Worksheets Table Configuration Worksheets SIMATIC 505 TurboParison M
131. ntroller Overview TurboParison is a special function module The controller uses WX and WY words to report status and issue commands to the module See Figure 3 2 TurboParison also has the capability to transfer blocks of V memory where configuration data and setpoint data are stored Runtime status is updated in blocks to the controller Controller lO TurboParison registers Use WX1 Reports current profile step for profiles 1 and 3 Reports current profile step for profiles 2 and 4 Reports error codes and status information Reports status information and acknowledgement bits Designates the Configuration Table starting address Puts the module in RUN or CALIBRATE mode and sets the calibration limits Starts table downloads and enables auto weight interpolation and table expansion features Purges profiles runs profiles checks the phase of profiles and sets clock synchronization bits V memory Configuration Controller downloads configuration data and profile data and setpoints to the module upon transition to RUN or profile ram CAL mode or on command setpoints Module uploads status information and process Module variable data status and PV data Figure 3 2 Contoller Module Information Exchange SIMATIC 505 TurboParison Module User Manual Understanding
132. o the Configuration Table overwriting the previous entries vy Ifthe moduleis not in RUN mode or CALIBRATE mode outputs are driven to 0 V 6 4 Calibration and Loop Tuning SIMATIC 505 TurboParison Module User Manual 6 2 Adjusting the Offset and Gain for Valve Amplifiers Adjusting Offset Adjusting Gain Usethe following steps to set the amplifier offset 1 Put the module into open loop manual control see description of configuration word in Appendix B 2 Setthehold valueto 0 this drives the outputs to the zero output value The module constantly scans this value you do not need to download the Configuration Table Adjust the amplifier until there is zero current output or until the mandrel does not creep in either direction For proportional amplifiers see manufacturer s specifications NOTE f you plan on using closed loop push out and your proportional valve amplifier has ramping control ensure ramping is disabled to achieve optimum performance Typically the TurboParison module requires minimal amplifier gain setting Refer to manufacturer s specifications for the amplifier Ensure that the maxi mum voltage from the module drives the amplifier such that the valve is at full open or maximum flow is achieved NOTE After initially setting gain for the amplifiers you can modify loop performance or system response by adjusting loop tuning parameters stored in V memory and save as part of a recipe See Section
133. odule User Manual Worksheets for Module related Notes woe SIMATIC 505 TurboParison Module User Manual Table Configuration Worksheets Terminal Block Connections Worksheet v Module related Notes Page 1 of 2 Connection Connection E Axis 2 ground Axis 1 ground Axis 2 V out Axis 1 V out is 4 ground Axis 3 ground is 4 V out Axis 3 V out is 2 ground Axis 1 ground is 2 V input Axis 1 V input is 2 V input Axis 1 V input is 4 ground Axis 3 ground is 4 V input Axis 3 V input is 4 V input Axis 3 V input Auxiliary input 5 ground Auxiliary input 5 V Auxiliary input 5 V 24 VDC supply DC return Discrete output 1 Discrete input 1 Discrete output 2 Discrete input 2 Discrete output 3 Discrete input 3 Q 5o 5 eH e y e e og e e e e e e Sh Discrete output 4 Discrete input 4 PH OPNGYPOYP Se G e e e N e I e YP GY YG amp J Table Configuration Worksheets SIMATIC 505 TurboParison Module User Manual V memory Allocation Worksheet V Module related Notes Page 2 of 2 Permanent Memory Addresss a addresses Table name e Rd reserved Configuration Table Table General Status Table Profile Profile Setpoint Table nt Table Axis 1 Process uL oc RANT Table Profile Setpo
134. ofile B nos Plastic dL d parison LVDT Axis3 Q lt inputs Q a Axs3 Senor valve an oup t o AMP hydraulic cylinder Axs4 Qa inputs Ea LVDT Axs4 De tputs Q outputs Profile C ee Servo valve and AMP hydraulic cylinder Plastic parison i Die head Profile D maT l a Plastic parison Figure 5 7 Example of Four Head Operation without Accumulator C ontol SIMATIC 505 TurboParison Module User Module Position based Operation 5 9 Characteristic s of Position based Modes continued Two Head Operation with Automatic Restart Mode 5 When configured for two head operation with automatic restart the TurboParison module has the following characteristics e Oneor two axes axis 1 and axis 2 are available for profile control e Auxiliary input 5 monitors the position of the mold and restarts the parison profile for each new mold Mold position control speed of the wheel is not provided by this module Figure 5 8 shows a timing example for a 4 mold wheel illustrating the relationship between wheel position input position ramp and parison profile Wheel Rotation Positive Ramp Only a positive or negative ramp is used Negative Ramp Ne Pie I Se a Profile Enable A WX8 Bit 5 Profile A Active WX3 Bit 9 Parison Profile from V memory table First parison Start of is bad parison Wheel Mold Number Figure 5 8 Timing Example
135. on 3 is selected Specifies the time out value for a profile If a profile does not complete before the time out occurs the module sets the corresponding time out bit in WX3 The bit is not cleared until the beginning of the next cyde If the value is zero the module does not use a time out time out infinity Specifies the offset in the Profile Setpoint Table where the profile step coincidence output discrete output turns on Note that this is typically the desired profile step 1 This discrete output remains on for the number of steps specified by the parameter Number of steps to hold profile coincidence output Specifies the number of steps to hold on the profile coincidence output If you enter zero for this parameter the output remains on until the beginning of the next cycle The default value is 0 Specifies the ram position where the position coincidence output discrete output turns on This discrete output remains on for the number of steps specified by the parameter Hold Position Coincidence On Until Specifies the ram position where the position coincidence output turns off If you enter zero for this parameter the output remains on until the end of shot occurs The default value is 0 SIMATIC 505 TurboParison Module User Manual Table B 10 Parameter Descriptions for Configuration Table continued Parameter name Mode Derim O Interpolation master table TP Specifies the first V memory location of the tab
136. on 5 5 Overview of Position based Operation continued Open Loop vs Closed Loop Velocity Control In open loop control the velocity setpoint directly drives the module output A loop tuning procedure is not required thus making setup less difficult You may specify the output span for the axis by entering this data into the Configuration Table This determines the maximum output voltage to be sent to the valve amplifier In closed loop control the module attempts to match the velocity of the ram to the velocity setpoint The module calculates the velocity of the ram based on the derivative of the ram position and the velocity scale factor that you provide The velocity scale factor establishes the maximum ram speed which is designated as a setpoint value of 32000 The velocity scale factor may be interpreted as the number of counts 0 32000 that the ram can move in one second where the full stroke is equivalent to 32000 counts Enter this value in the velocity scale factor field for axis 3 or 4in the Configuration Table Alternatively you may use the automatic maximum velocity calibration feature see Section 6 4 Guidelines for closed loop control e Select closed loop control by setting Bit 14 in the configuration word for that axis You may need to use open loop control for accumulator fill the RLL may need to switch between open and closed loop control e Select the differentiate process variable feature by setting Bit 1
137. ondensing Pollution degree 2 IEC 664 664 A Vibration Sinusoidal IEC 68 2 6 Test Fc 0 15 mm peak to peak 10 57 Hz 1 0g 57 150 Hz Random IEC 68 2 34 Test F dc equivalent to NAVMAT P 9492 0 04 g2 Hz 80 350 Hz Electrostatic discharge EC 801 Part 2 Level 4 15 kV Shock EC 68 2 27 Test Ea Noise immunity conducted EC 801 Part 4 Level 3 Noise immunity radiated EC 801 Part 3 Level 3 MIL STD 461B RSO1 and RSO2 Isolation inputs to controller 1500 Vrms Corrosion protection All parts of corrosion resistant material or plated or painted as corrosion protection Agency approvals U L listed UL 508 CSA certified C22 2 No 192 FM approved for Class Div 2 Hazardous Locations D 2 Specifications SIMATIC 505 TurboParison Module User Manual D 2 Analog Performance Specifications Table D 2 High Speed Analog Outputs mm Me Voltage ranges 0 to 10 V or Oto 10 V Oto 5V orOto 5V Resolution ution 12 12bit Q2596accuray 0 2596 12bit Q2596accuray pe 5 mA output current Table D 3 High Speed Analog Inputs em M e 0 Voltage range O to 10 V Oto 45V Resolution 0 ution 12 12 bit 0 1 accuracy 0 1 accuracy SIMATIC 505 TurboParison Module User Manual Specifications D 3 D 3 Disc rete Output and Input Specifications Table D 4 Discrete Output Specifications Ooi SOTOA 090A MO C Total output current all outputs on 0 75 A 60 C
138. onmental Specifications 6600s High Speed Analog OutputsS 0 0 aaa eee rr High Speed Analog Inputs bre tre e Eee erae d ea in Discrete Output SpecificationS 0 e a aE ie Discrete Input Specifications cece eee Contents Other Manuals Agency Approvals Telephoning for Assistance Preface This manual shows you how to install and operate the SIMATIC 505 TurboParison Module PPX 505 5103 Refer to the manuals listed below for instructions on installing programming and troubleshooting your Series 505 controller and 1 0 e SIMATIC 545 System Manual PPX 545 8101 x e SIMATIC 500 505 Programming Reference M anual PPX 505 8104 x e SIMATIC 505 TISOFT User Manual PPX TS505 8101 x This module meets the standards of the following agencies e Underwriters Laboratories nc UL Listed Industrial Control Equipment e Canadian Standards Association CSA Certified Process Control Equipment e Factory Mutual Approved Class Div 2 Hazardous Locations e Verband Deutscher Elektrotechniker VDE 0160 Clearance Creepage for Electrical Equipment Self Compliance Series 505 products have been developed with consideration of the International Electrotechnical Commission standard 1131 2 for programmable controllers For a list of the latest standards to which Series 505 complies contact your Siemens Industrial Automation Inc distributor or sales office If you
139. position of the moving ram for one second determines the proper velocity scale factor and writes the factor to the Configuration Table Usethe following procedure to calibrate maxi mum ram velocity 1 Putthemodulein CALIBRATE mode 2 Selec an axis for calibration 3 With theram traveling at its maximum attainable velocity set Bit 16 in WY6 4 Themodule responds approximately one second later by setting Bit 16 in WXA This indicates the operation was successful 5 Set Bit 13 in WY6 to zero to take the module out of CALIBRATE Mode Calibration data is automatically written to the Configuration Table If you prefer to set the maximum velocity manually use TI SOFT or your operator interface to enter the maximum velocity directly intothe Velocity Scale Factor field in the Configuration Table 6 12 Calibration and Loop Tuning SIMATIC 505 TurboParison Module User Manual 65 Calibrating Aux 5 Inputin Mode 5 Description of the Calibration Process Example of the Calibration Process The TurboParison does not provide automatic calibration of the Aux 5 input in mode 5 Follow the procedures described below to calibrate Aux 5 input in mode 5 To set the span on the Aux 5 input l Determinethe maximum voltage from the wheel position sensor 2 Convert this number to integer millivolts 3 Subtract 50 from the number 4 Enter the number in V memory location WY 5 161 To set the zero on the Aux 5 input l Determinethe mini
140. power supply 2 8 Installing the Module SIMATIC 505 TurboParison Module User Manual 2 5 Cable Connections and Grounding Module V In Shielded N twisted V In pair Drain Ground Cable shield V Earth chassis Analog Ground common NOTE If cable has additional foil wrap and drain wire connect drain as shown by the dashed line Outputs Servo Amplifier Output amp Shielded twisted pair Drain Cable shield ZG Analog Earth chassis common ground Earth chassis ground NOTE If cable has additional foil wrap and drain wire connect drain as shown by the dashed line Figure 2 6 Module Input Output Wiring SIMATIC 505 TurboParison Module User Manual Installing the Module 2 9 2 6 Inserting the Module into the Base a WARNNG O To minimize risk of potential shock hazard turn off power to the I O base and to any modules installed in the base before inserting or removing a module or installing a terminal block Failure to do so may cause unexpected shock equipment startup which could result in death and or potential injury to personnel or damage to equipment Ensure that power is turned off to the base and any modules installed in the base before you insert or remove a module or install a terminal block Inserting the The TurboParison module is a single wide module Insert the module as Module shown in Figure
141. propriate amount of V memory you are ready to enter the values from the worksheets into memory To enter the configuration values from an operator interface read your user manual for the operator interface To enter the configuration values from TI SOFT follow these steps 1 Run TISOFT and display the screen that allows you to edit V memory 2 Enter the values from the Configuration Table Worksheet into the V memory locations listed on the worksheet 3 f you do not have an operator interface enter values for the Profile Setpoint Table now NOTE f you change any values in the Configuration Table or Profile Setpoint Table while a profile is running you must instruct the module to download the tables again before the changes can affect the operation of the module SIMATIC 505 TurboParison Module User Manual Time based Operation 413 4 4 Preparing the Module for Operation Before you operate the TurboParison module complete and check off the following sets of tasks Set the dipswitches for the correct operational mode set the voltage jumpers to match the voltage for your I O devices install the module in the base and make the appropriate field connections to the front of the module See Chapter 2 4 Run TISOFT and configure the controller I O for the TurboParison module s location and type After you log the module into the controller determine the controller V memory allocation requirements for your configuration Se
142. rlap Lay out your memory map according to these guidelines Although each table must consist of contiguous memory locations the individual tables do not have to be contiguous e The Configuration and General Status Tables require 300 contiguous memory locations e Thesizeof the Profile Setpoint Table depends upon the number of setpoints that an axis requires Be sureto allocate a table for each configured axis see Chapters 4 and 5 Consider allocating enough memory to allow for table expansion e Thesizeof the profile Process Variable Table is the same as the size of the Profile Setpoint Table for an axis see Chapters 4 and 5 Be sure that you allocate a table for each axis that you configure e Thesizeof the Velocity Setpoint Table position based configurations only depends upon the number of different velocities needed to control a ram see Chapter 5 Consider allocating enough memory to allow for table expansion e Thesizeof the Position Setpoint Table positi on based configurations only depends upon the number of different positions needed to control a ram see Chapter 5 Consider allocating enough memory to allow for table expansion e f you intend to use the interpolation or table expansion features allow enough V memory for the master table and the calculated table see Chapter 7 You may want to allocate memory for these features for each configured axis The worksheets in Appendix E can help you lay out the memo
143. rofile Sync pulse Profiling does not begin until the profile is put into run mode and a sync pulse occurs Run profile Figure 4 2 Machine Sequence Timing Example SIMATIC 505 TurboParison Module User Manual Time based Operation 4 3 Overview of Time based Operation continued Controlling The module uses profile data stored in a table to control the mandrel Mandrel Position position that determines the wall thickness of a parison This table called Wall Thic kness the Profile Setpoint SP Table Figure 4 3 is downloaded from the controller to the module either when you put the module in RUN mode or by your command Create a Profile Setpoint Table for each die Specify the starting address for the table by entering an address into the Profile SP Starting Address field in the Configuration Table Tables do not have to be contiguous To specify the length of each Profile Setpoint Table enter a value choices are 2 4 8 16 32 64 128 or 256 in the Profile SP Table Length field in the Configuration Table Profile SP Table PV Table start address start address Profile SP Table PV Table To Module From Module Setpoint 1 PV 1 Setpoint 2 PV 2 Setpoint 3 PV3 Setpoint 4 PV4 pto pto Setpoint 256 PV 256 Figure 4 3 Profile SP and PV Tables Monitoring The module enables
144. ry maps SIMATIC 505 TurboParison Module User Manual Understanding Module Operation 3 17 3 6 Guidelines for Erors and Alarms Fatal Errors Alarms If a fatal error is detected the module drives all analog outputs to zero volts and turns off all discrete outputs If possible the moduleturns off the RUN or CALIBRATE mode bit in WX4 and sets the Fatal Error bit in WX3 Bit 4 to one All communication activity with the controller halts The MOD GOOD and RUN LEDs then flash in an alternating pattern indicating that a fatal error has been detected A power up reset can restore operation provided that the error does not persist Some causes of fatal errors follow e The module loses communication with controller e g the module is installed in a remote base and the I O cable is disconnected e The watch dog time out occurs this could be caused by spurious electrical noise or component failure The module provides a broken transmitter alarm for each control axis E ach broken transmitter alarm is enabled by setting Bit 11 in the configuration word for that axis see Appendix B If enabled the module checks the analog input for zero volts If a zero volts is detected the corresponding alarm bit in the General Status Table is set See Appendix C To clear the alarm reset the alarm enable bit to zero To use this feature ensure that your input range does not indude zero volts 3 18 Understanding Module Operation SIMATIC 505 T
145. s acies ades Using Open Loop vs Closed Loop Mode forCalibration sees GeneralGuideli es 5 dm cr er tem Re x dece E e dee e E OR RT UR 6 2 Adjusting the Offset and Gain for Valve Amplifiers esr Ad sting Offsets crni eieaa haar he IM aea E Ie Ilo oe thers delegates ea Adjusting Gall 2223 hacia Meas EC ecu aor en der Lar tuere wets Kur i oe n Contents v 6 3 6 4 6 5 6 6 7 1 7 2 73 7 4 Calibrating the Die Heads s ssusssssusnunnunnnnnnnnnnnnnsnnnnuunuununnnnn 6 6 6 6 enu c Em Converging vs Diverging Tooling sssssssss me Selecting Tooling TPE siiis circa ber a eani a ai anai hiai na e i bee eade ed eade 6 7 General ullas vuccioedcdok iced ee Eae e DEDI Ed EA REAA E Joe Id R RS 6 8 Calibrating Rams ssssssssssss enne nennen naa aaa a i a a n n n n an Calibrating Ram POSTON ne perseEREIVERERERFREENOREREX ERE ER A E RXCER RACER 6 10 GUID SINGS oscar eter ROLE eie erbe eto Anode AD Ae E RA at 6 10 Calibrating Maximum Ram Velocity 0 ee 6 12 Calibrating Aux 5 Inputin Mode 5 seeeoeeen n n mnn Description of the Calibration ssssssssseeeeeee m A EA 6 13 Example of the Calibration 0 cece eem rr 6 13 Tuning LOOPS nc cee c cece cece cece eee e en en eens eee seen ee eeneeeeeseeaeesnaeenauas Descnption iu ek REGERE ER bead ecu E cede kd abe cast oce e cid 6 14 Typical Tuning Parameters for Die
146. s analog output signals that typically drive a servo or proportional valve amplifier to control the mandrel position or accumulator ram velocity The module also has four discrete inputs and outputs used for various machine functions e Theinputs are used for sync pulses in time base mode discussed in Chapter 4 3 2 Understanding Module Operation SIMATIC 505 TurboParison Module User Manual e Theoutputs are coincident outputs that may be triggered from either a profile step or the accumulator position discussed in Chapter 7 SIMATIC 505 TurboParison Module User Manual Understanding Module Operation 3 3 Configuration and profile data set up in V memory WY words vai V memory block data control module eporretatus transfers error conditions to and from the controller TurboParison module closed loop control software O points for monitoring and controlling a die or accumulator Time based Operation Position based Operation lU LU 2 die heads mode 3 mode 1 high speed Gp meee QUU A 4 die heads 1 ram mode 4 2 high speed die heads with position input Mode 5 Wheel Figure 3 1 Relationship of TurboParison Module to the Machine 3 4 Understanding Module Operation SIMATIC 505 TurboParison Module User Manual 3 2 Communicating with the Co
147. seriiessisirer n W2 meimiuleengh 2481632088 6 a i NN 1 curvelinear ise ee L 1s teh tenga abe iA RR ras Length of expanded table 2 4 8 16 32 64 128 256 Table B 9 Configuration Table for Position based Operation Continuous Download Segment V Memory offsets WY5 offset Parameter name Valid values 180 AWsihoddvaweordegp sid Axis 1 hold value or die gap 0to32000 _ med Axis 2 hold value or die gap 0 to 32 000 Axis 3 hold value or die gap or axis 1 position shift 0 to 32 000 32000 to 32000 183 Axis 4 hold value or die gap or axis 2 position shift 0 to 32 000 32000 to 32000 184 Axis 1 manual override value 32000 to 432000 185 Axis 2 manual override value 32000 to 432000 186 Axis 3 manual override value 32000 to 4 332000 187 Axis 4 manual override value 32000 to 4 332000 B 6 Configuration Table Data SIMATIC 505 TurboParison Module User Manual B 3 Parameter Descriptions for Configuration Table Table B 10 Parameter Descriptions for C onfiguration Table Configuration word TP MS tsB Configuration word 45 Not used Setpoint ramping 0 Disable setpoint ramping 1 Enable setpoint ramping Bipolar unipolar outputs 0 Unipolar outputs 0 to 232000 1 Bipolar outputs 32000 to 32000 Enable disable broken transmitter alarm 0 Disable broken transmitter alarm and clear alarm flag
148. sitions closed loop mode provides accurate control of mechanical position For example if you set the mandrel halfway between zero and span and then moved the mandrel up 0 120 the feedback into the loop controller would hold the mandrel in position In open loop mode the mandrel may drift e Advantage of Configuring in Open Loop Mode Calibration in open loop mode is less complicated you set the output feeding the servo amplifier and the mandrel moves to a mechanical stop Always calibrate rams in open loop mode ACAUON Large output signal levels can cause damage to your equipment if the mandrel is overdriven into the mechanical limits Use small output signal values to move the mandrel Use small percentage increments less than 5 when moving the mandrel to mechanical limits To avoid equipment damage ensure that you use percentages of less than 5 when you move the mandrel to mechanical limits During operation die heads are typically run in closed loop mode while rams arerun in either open loop or closed loop based on the equipment and process requirements SIMATIC 505 TurboParison Module User Manual Calibration and Loop Tuning 6 3 Overview continued General Guidelines Consider the following guidelines when calibrating or tuning your process 4 When calibrating dies in closed loop mode use an initial setpoint value of 5096 This ensures the setpoint falls within the zero and span range avo
149. st profile time for profile A Last profile time for profile B Last profile time for profile C Last profile time for profileD Reserved 221 Reserved 222 Reserved 223 Reserved Weight correction for profile B NET ME Weight correction for profile A 226 Weight correction for profile C 227 Weight correction for profile D 228 Current setpoint for axis 1 Head A 229 Current setpoint for axis 2 Head B 230 Current setpoint for axis 3 ram A 231 Current setpoint for axis 4 ram B 1 35 5 22 Position based Operation SIMATIC 505 TurboParison Module User Manual 6 1 6 2 6 3 6 4 6 5 6 6 Chapter Calibration and Loop Tuning MOMCQUIUPEETTPCEEEUIDUUMDUUDITPIIT Are sof Control oc cick eee ek nea hera haga Rad bed na hb a ee E 6 2 Using Open Loop vs Closed Loop Mode forCalibration ssseesseeeee 6 3 General G idelhas onbteeed esent ee R A at Dead Ur SERRE A ENTE GU ROO d liebe gra 6 4 Adjusting the Offset and Gain for Valve Amplifiers einn Adjusting Offset ese dese bp eta ees a bte hc iet ee bip Econ Pe P digas 6 5 Adjusting GIN ccc cere enee eed e ege CRF CERE UMEN ERR tede 6 5 Calibrating the Die Heads sssesesesenn nnn nnnm OVERVIEW s icto oho bd E ila peda d KO qubd or da M dor asta lr dea 6 6 Converging vs Diverging Tooling sssssssser m 6 6 Selecting Tooling TyDe cissseskter pines erga eee EG ache e e KG ae 6 7 General Guidelines 2 1 4taic
150. ster points in a profile You do this by copying the master points into a master table you created in V memory The calculated points are stored in a second table called the calculated table that you can then copy into any of the other data tables The starting address and table lengths of the master and calculated tables are stored in the Configuration Table Master profile points Linear interpolation Curvelinear interpolation i i Figure 7 1 Interpolation Example You can interpolate any set of data e g the profile setpoints ram position values etc by copying the set of data into the master table interpolating the data and then copying the interpolated values into the proper location for runtime operations Two algorithms are available e Thelinear interpolation algorithm determines the equation of a straight line between adjacent points in the master table All intervening points that lie along this line are determined The process is repeated for each pair of points in the table e Theaurvilinear interpolation algorithm develops a set of cubic polynomial equations one for each area lying between two points in the master table Adjacent equations pass through the master point between them making the curve smooth and continuous 7 2 Using the Module sOptional Features SIMATIC 505 TurboParison Module User Manual Tousethe interpolation feature copy the master setpoints into the master table non ma
151. ster points should be zero When you command the module to interpolate it downloads the master table and interpolates the data The module stores the resulting interpolated data in the calculated table in the controller See Figure 7 2 Master Table Calculated Table start address start address Master Table Calculated Table To Module From Module 100 100 0 300 500 Figure 7 2 Interpolating Data The V memory addresses for the master and calculated tables are stored in the Configuration Table See Figure 7 3 Select the interpolation method by entering 0 for linear or 1for curvilinear in the interpolation method field Be sure to download the Configuration Table after performing this initial setup After initial setup is complete interpolate data by performing the procedure outlined in Figure 7 4 Configuration Table Enter table Enter valid data in the following fields of addresses for the Configuration Table These values interpolation determine the V memory addresses of the Interpolation master table address master table and the resulting Interpolation calculated table address interpolated table The valid values for Interpolation table length the interpolation method are 0 linear Interpolation method and 1 curvelinear Figure 7 3 Setting Up Interpolation Options SIMATIC 505 TurboParison Mo
152. time based equipment e g wheel machines shuttle machines and other types of continuous extrusion machines This chapter describes time based operation and shows how to configure the module for this mode of operation Definition of In the time based mode the module uses a synchronization pulse to start a Time based new parison Because a time based machine extrudes continuously the Operation length of time between the synchronization pulses determines the length of the parison This pulse also determines the length of time between profile steps zones A user provided synchronization pulse starts a new parison by causing the module to reset to the first profile setpoint The module then processes all setpoints and holds at the last setpoint until a new synchronization pulse is received Thetotal profile time P is the time it takes for the module to execute a profile Determine the initial value for Pt by entering a value in the Initial Profile Time field of the Configuration Table The module then enables you to either set a fixed profile time or select a variable profile time To specify whether the initial profile time is used continually or is changed by a math calculation enter one of the codes from Table 4 1 in the Profile Time Calculation Method field of the Configuration Table Table 4 1 Methods for Calculating Profile Time Calculation Method 0 Use value in Initial Profile Time field for Pt Use time between last t
153. ting die heads in open loop mode 4 Entering 10000 for span in the Configuration Table defines the maximum voltage either 10 V or 45 V selected by jumper settings If the 0 5 V range was selected entering 10000 defines the maximum output voltage to be 5 V entering 5000 defines the maximum voltage to be 42 5 V 50 of jumper selection not 5000 mV Z When setting zero and span values leave a small gap between the zero span value and the minimum and maximum range of the mandrel This helps to avoid potential equipment damage caused by a mandrel overshooting the zero or span location Dies heads are typically calibrated in open loop mode If your application requires using closed loop mode for calibration for example calibrating tooling to precise locations rather than to maximum and minimum positions consider the following guidelines Refer also to Figure 6 7 Y Drivethe controller setpoint to mid value by setting the hold value die gap setting to 16000 5099 V Selec either reverse or direct acting loop action depending on tooling type Y Openthe calibration limits to allow tooling travel over the entire range by setting Calibrate Zero to 0 and Calibrate Span to 10000 10 V for direct acting or set Calibrate Zero to 10000 and Calibrate Span to 0 for reverse acing V4 Iftuning parameters have not yet been established set them to be very loose e g Kc 20 25 and T 21000 V After putting the axis in dosed
154. tion 3 4 Runtime status is reported by the module typically once every controller scan to a block of V memory directly following the Configuration Table This block is called the General Status Table and is located at WY5 200 The table contains I O status for each control axis profile execution status and other information For more information see Appendix C Each control axis has a table of Profile Setpoint Table associated with it The starting address is specified in the Profile Setpoint Table starting address field of the Configuration Table see Appendix B Setpoint data is stored in these tables and downloaded to the module The Setpoint Tables are automatically downloaded to the module upon transition to RUN mode If setpoint data is changed the table must be downloaded again before the changes will take affect See Section 3 4 Normally each control axis has a Process Variable Table associated with it except in mode 3 when axis is used for accumulator control The starting address is specified in the Process Variable Table starting address field of the Configuration Table see Appendix B When executing a profilethe module saves the last process variable attained before transitioning to the next setpoint This data is collected by the module during profile execution U pon completion of profile execution the data is transferred to the Process Variable Table in the controller See Section 3 4 SIMATIC 505 TurboParison Module
155. to which the module writes the actual position process variable attained at the end of each profile step This table is called the Process Variable PV Table Specify the starting address for the PV Table by entering an address into the PV Table starting address field in the Configuration Table Tables for the various profiles do not have to be contiguous During operation the entire table of process variables is uploaded to the controller automatically by the module at the completion of a profile If you enter zero into the PV Table starting address field notableis uploaded for the corresponding profile Thetable length is automatically set to the same as that of the Profile SP Table When you assign table addresses for the various data tables be sure to allocate V memory carefully sothat no data can be overwritten SIMATIC 505 TurboParison Module User Module Position based Operation 5 7 5 2 Characteristics of Position based Modes In the position based configuration the module can e Control up to two dies axes 1 and 2 closed loop control with automatic restart of the profile from the position input Aux 5 e Control up to four dies axes 1 4 closed loop control and monitor the position of the accumulator ram Two Head When configured for two head accumulator control the TurboParison Operation with module has the following characteristics Accumulator Control Mode 3 e Uptotwo axes axis 1 and axis 2 are available
156. u can record data for the Configuration Table Profile Setpoint Table Position Table and Velocity Setpoint Table Worksheets for Module related Notes Use these worksheets to record additional information about your TurboParison Module This section includes a worksheet for recording V memory allocation data and a sheet for recording terminal block information NOTE Make copies of the worksheets before writing configuration data in them This will ensure that you always have clean worksheets for new configuration data SIMATIC 505 TurboParison Module User Manual Table Configuration Worksheets Table Configuration Worksheets SIMATIC 505 TurboParison Module User Manual Worksheets for Time based Operation SIMATIC 505 TurboParison Module User Manual Table Configuration Worksheets Configuration Table Worksheet dU Time based Operation Page 1 of 3 V memory start address WY 5 Note In this table V memory address start address offset For example if start address V100 offset 4 Then V memory address V100 4 V104 m V memory Value V memory Configuration word 0 40 1 41 loop sample time Calibration zero for analog input 2 CEEE 2 Ll L ee ee a Tr input filter time constant mens E Pt initia Initial ill time ic serine Pa 31 U M S L p op ee e p 0 d a n m p o C a jJ poumeem RS ee 1 qus d p Haier e E M 1 787 1
157. urboParison Module User Manual 4 1 4 2 4 3 4 4 4 5 4 6 4 7 Chapter 4 Time based Operation OVEIVICW PEE c 0 00D Definition of Time based Operation 0 ee Controlling Mandrel Position Wall Thic kness Monitoring MandrelPosition 0 cece n Providing a Sync Pulse for Profile Timing sssssssss eese Characteristics of High Speed and Standard Speed Operation High Speed Operation Mode T iuiccioamibadadce dad acida oclo d abaco 4 6 Standard Speed Operation Mode 2 cic ccc ccc n 4 8 Differencesin High Speed and Standard Speed Operation sirsiran 4 10 Determining Module Configuration Parameters s een n n n n n n n n n 4 11 Determining Configuration Parameters sssssssssseeee eese 4 13 Determining the V Memory Required s esses 4 13 Entering Data into V Memory 000 ccc eee ener 4 13 Preparing the Module for Operation sss nnn Operating the Module in Time based Mode een nnn nnn Putting the Module in RUN Mode ssssssseeee eee i ioia aE A ai 4 15 Ena bling Disabling Profile Execution ssssssssseeeeen e nn 4 15 Changing Configuration and Profile Data sssese nnn nnns Monitoring the Operation ofthe Module eeeeee n n nnn nnn 4 17 SIMATIC 505 TurboParison Module User Manual Time based Operation 4 1 4 1 Overview The TurboParison module provides control of
158. ure that all data relevant to your machine exists in the V memory locations reserved for the Configuration Table Profile Setpoint Table Velocity Setpoint Table and Position Table These tables are automatically downloaded to the module when you place the module in RUN mode See Section 5 5 Ensure that the dies are calibrated and tuned Refer to Chapter 6 for information about calibrating and tuning die heads Manually step the machine through its sequence before you run the RLL and sequence the machine automatically Position based Operation SIMATIC 505 TurboParison Module User Manual 5 5 Operating the Module in Position based Mode Putting the Module WY 6 controls putting the module into RUN mode in RUN Mode e Writing a value of 5000 hexadecimal 20480 decimal in WY 6 puts the module in RUN mode All configuration information is automatically downloaded from the controller and the module enables all axis controllers The module RUN light comes on and the RUN acknowledge bit WX4 Bit 8 is set tol e Writing a0 to WY6 takes the module out of RUN mode All analog outputs are forced to 0 V all discrete outputs are turned off the module RUN light turns off and the RUN acknowledge bit is reset to 0 This corresponds to an Emergency Stop ESTOP condition A caution Ensure that you do not require a controlled shutdown before you perform an ESTOP If you do not initiate a controlled shutdown procedure before performing an ESTOP
159. urrent PV ronnie eis 0 35 peas o m 7 Current output for H ead A axis 1 Current output for H ead B axis 2 212 Current output for H ead C axis 3 Current 23 Current output for Head D axis for Head D axis 4 Current E E HR inputs and outputs Indicates the status of the discrete inputs and outputs The word contained in this V memory location has the following breakdown MSB LSB 112 3 4 5 6 7 a 101 12 13 14 15 16 Bits 1 4 Dipswitch settings these bits may be used by the RLL to verify that 0 Model the dipswitch was set correctly 0001 Mode 2 0010 Mode 3 0011 Mode 4 0100 Mode5 Bit 5 8 Not used Bits 9 12 Discrete output is on for the following Bit 9 step coincidence for Profile A Bit 10 step coincidence for Profile B Bit 11 step coincidence for Profile C Bit 12 step coincidence for Profile D Bit 13 16 Discrete input is on for the following Bit 9 input for Profile A Bit 10 input for Profile B Bit 11 input for Profile C Bit 12 input for Profile D SIMATIC 505 TurboParison Module User Manual Time based Operation 4 17 Monitoring the Operation of the Module continued Table 4 4 General Status Table Contents continued V memory offsets u WY5 offset Parameter description Broken transmitter alarm Indicates whether a broken transmitter alarm is on for one or more of the axes MSB LSB HE BHE e 7 8 9 1o n r 1 u n 2
160. wo synchronization pulses previous Pt Usea running average determined by the following equation P P P previous 2 3 Usethe mean of the last n profile times You specify n in the of Cycles to Average Profile Time field of the Configuration Table The time that the module holds at each setpoint S is determined by dividing Pt by the number of setpoints N The relationship between the profile setpoints and the synchronization pulse is shown in Figure 4 1 4 2 Time based Operation SIMATIC 505 TurboParison Module User Manual Synchronization pulse Profile setpoints TIT v Mp Setpoint hold time S Figure 4 1 Relationship of Synchronization Pulse to Profile Setpoints Because sync pulses determine the start of a new parison drop any variation in the time between the pulses can affect how the module handles a profile If the time between two sync pulses is greater than the current Pt the die remains at the position determined by the last profile setpoint until the next pulse occurs If a sync pulse occurs in the middle of a profile that profile stops execution and a new one begins Figure 4 2 shows the machine sequence for a fixed profile time If a sync pulse occurs in the middle of a profile a new profile starts i Die position remains at last profile step until next sync pulse occurs Pt n Pt Die remains at die gap until first sync pulse occurs P
161. x describes the bits in the WX WY words used by the TurboParison module The WX input words represent data sent to the controller from the TurboParison module The WY output words represent data sent from the controller to the module The WX WY words contain commands error codes and status information FigureA 1 shows the bit layout for both types of words The most significant bit is Bit 1 and theleast significant bit is Bit 16 Figure A 1 Bit Map for WX and WY Words A 2 WX WY Word Descriptions SIMATIC 505 TurboParison Module User Manual A 2 WX Words WAX1 Curent Profile Exec ution Step for Axes 1 and 3 Bits 1 through 8 report the value of the current profile execution step for axis 3 die head C or ram A Step 0 refers tothe first entry in the Setpoint Table 123456 7 8 91011221314 15 16 Bits 9 through 16 report thy value of the current profile execution step for axis 1 die head A Step O refers to thefirst entry in the Setpoint Table WX2 Curent Profile Execution Step Axes 2and 4 Bit s set Description 123456 7 8 9 101112131415 16 Bits 1 through 8 report the value of the current profile execution step for axis 4 die head D or ram B Step O refers to the first entry in the Setpoint Table 123456 7 8 9 101112131415 16 Bits 9 through 16 report the value of the current profile execution step for
162. y one end for better noise immunity e Label the wires and place them so that they do not interfere with existing wiring SIMATIC 505 TurboParison Module User Manual Installing the Module 2 7 2 4 Power Supply and Grounding Recommendations Because of the high speed update of the module the amount of movement of the ram between module samples is very small even on fast machines This means that very small changes in the analog input signal must be accurately detected in order to perform smooth closed loop velocity control Special differential input stages have been installed in the module which provide extremely high common mode noise rejection However it is imperative that electrical noise both direct and induced on the inputs be kept below 0 05 mV Usethe following minimum guidelines e Provide a separate highly filtered power supply for the transducer exitation This supply should be capable of furnishing 0 to 10 VDC at 0 005 regulation and 0 250 mV ripple or better e Run twisted shielded wiring for all analog signals including power supply connections Then run all wiring in separate metallic conduit or flex that has been properly grounded with minimal exposed lengths at connection e Ground all shields at the module or amplifier input end as shown in Figure 2 6 Power Budgeting The module consumes 7 W of 5 VDC power from the base Be sure that your system does not exceed the maximum power available from the 505 base
163. you to compare the actual mandrel position to the Mandrel Position profile data To monitor the actual position you must set up a tablein V memory into which the module writes the actual position process variable attained at the end of each profile step This tableis called the Process Variable PV Table Specify the starting address for the PV Table by entering an address into the PV Table Starting Address field in the Configuration Table Tables for the various profiles do not have to be contiguous Figure 4 3 During operation the entire table of process variables is uploaded to the controller automatically at the completion of a profile If zero is entered into the PV Table Starting Address field no table is uploaded for the corresponding profile The table length is automatically set to the same as that of the Profile Setpoint Table When you assign table addresses for the various data tables be sure to allocate V memory carefully so that no data can be overwritten 4 4 Time based Operation SIMATIC 505 TurboParison Module User Manual Providing a Sync The TurboParison module has four 24 VDC discrete inputs These inputs Pulse for Profile recei ve hardware generated sync pulses for running time based machines Timing These pulses can be supplied by a programmable limit switch or other device The pulse must be greater than one millisecond in duration and the time between pulses must be greater than one millisecond as is shown in Fi

SIMATIC 505 TurboParison Module User Manual

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