Manual hp 14

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CENTRAL MACHINERY & PLASTIC PRODUCTS

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OPERATION & MAINTENANCE MANUAL

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FOR

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HP-14

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OFFICE

:

LAJYA ESTATE, MOGRA ROAD, ANIImRI @AST), 1,

MUMBAI - 400 069, INDTA.

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F'irgt lio.

DescriPtion

-

1

I\IPORTANI POINTS

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BRIEF DESCRIPTIO\

2

.1

SPECIFICATIO\S

2

J

OTHER FE.{TL'RES

J

5

POS,ER

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6.

PROGRAN{ML\IG OF TE\{P , TI.\{ERS &

7.

PROGRAMIVIING

ET

8.

STARTING & USING THE SYSTEM.

9.

SERVICING

10,

DETAILS OF TIMERS

l-5

IIvIPORTANT NOTES FOR TIMERS.

17

12

\,iACHTTiE SETTINIG.

l8

i3

PAGE DESCRIPTION.

19

14

ERROR CODES.

20

]5

C,ARD

\O.1

21

16.

CARD

\O 2 .{D\{ C.ARD \VIRT.\JG DETAILS.

22

1'7.

CARD

\O 3

23

18.

CARD NO 4

'+

19.

CARD NO.

5

25

20.

CARD NO. 6

?6

21.

SCREW INTERLOCK.

27

22"

TEST MODE

28

23.

LNLOCKING

29

24.

COUNITERS.

30

25.

PARISON PROGRAN4

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F E

F E

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F Fr

b H b b h b

F H

h,

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F

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F.

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1.

O\ & RESET CO\DITIO\S

&

&

4

,\t\CHi\E

USING THE SYSTE\I

MAINTENCE

SETTING

5

6 -7

8

I}TPORTAN_T POINTS

ELCB at mains Inpr-ri to protect personal & rnachine frotn darnage due to earth lea-kage. oven'oltage, single phasing etc" Use sen/o controlled voltage stabilizer with iiigh & Lou cut OFF of rating 1 KVA minimum. Low cLtt OFF should be set at 210 \i & Hi_sfi at 250 V.

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Earthing is very important. Use industrial earth to connect machine and panel both.

Use proper size of bare copper wire (as per yotrr. machine KW rating) for earthing.

l

Connect spike Buster at the or@ut of stabilizer. Output of spike buster should be connected to system supply. See supply wiring diagram for proper connection.

Always switch put offpower before removing or inserting cards. Observe correct placing of cards. See inside card arrangement diagram for proper guidance.?

4.

Before removing any IC, make note of its position and polarit)'on paper. Remove IC one by one only. That is after first one is removed and again inserted. Then only remove second one.

Never leave any conducting metal parts or solder spills on PCB, or inside the utit, always clean the PCB, carefully check it and then only insert. Remove all fresh unwanted parts from panel.

6.

Firnrly check & double check all outside wiring before starting the system. Wrong connection may damage the system.

7.

Always use correct fuse rating of minimum 300 mA & maximum 500 mA for unit.

Fuse holder is at front of unit near supply terminals.

8.

Always put light adhesive such as stick fast at the PCB, edge, card guide and channel after every removal and inserrion of cards. This will prevent loosing of cards due to slight vibration etc.

WARNING :

1. Never use thinner to clean membrane switch front panel and its connectors. Use Kerosin or very

2.

light cleaning

agent such as Min cream.

Never use screw driver, Nails, Finger nails, or Hot bottles or any sharp or hot aject to opeate key pad. It will permanently damage the keypad. Use only finger with little pressLrre.

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HP.T4

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BRIEF DESCRIPTION Tlls pr'''grarunable control system operates and controls different fimcttons of Blou \toulding \f achines. It includes Temperature controllers, Timers, Counters and lnput contacts for inrerlocking and logic solutions. Allthe parameters are progtammable from keyboard and

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result of process values are displayed in display. Another 1 set of LED's indicates, po\Yer to s\.srem. Self test fearures allow operator to check all outputs, inputs, keys and displays.

Faults in any output, inputs, keys & displays can be diagonised from front panel. All timers operate rrith built in crystal frequency accuacy. This gives excellent timing accuracy and repeatability. Non volatile memory ensures that programmed value is not lost during intermittent power failure.

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Construction is completely modular with detachable front and plug in cards. This facilitates easf in servicing and maintenance. System is powered tluough 24V DC supply.

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SPECTFICATTONS

3.

No.

of

Temperature Charurels

8

to

12

No.

of

Heater Output

6to

11

No. of Blower Output

4.. No. of Timer 5.

50

No. of Limit Switches & Hand Control

6.

No.

of

Control Output for Solenoids

IJpto 99999999 counts, 24 hourly counters.

Temperature Range

0 to

9

Type ofThennocouple

Fe/Const'J'

10.

Accuracy of Indication

+loc, tldigit.

I I

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l l. Control Accuracy

:

FI

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32 to 48hy 24Y l2A Transistors.

Counters

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24 or 48

Switches.

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3to5

12.

I

400"C.

Typical lon.

Time proportional.

Control Action

3. -{mbient Compensation

Autornatic.

I

F

b

l-1. Lineraisation

of

f-ype.

Thermocoltple

[3y sollware.

I digits

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HP- t.+

l_i Trmer's

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{ccurar:i

1'. Time

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Base

19 Sequence of 10. Counter

Timer

Operation

Pulse

:

00.t!0 to 99 99 >econd.

.

+.0iqo.

:

Quartz crystal.

:

Dolvn counting npe

:

As per customers requkement.

:

internally from timrrg sequence'

21. Operating

Mode

:

Auto

22. Operating

Temperature

:

0-50"C

Voltage

.

24YDC +

:

Rack Mountable.

23. Supply 24.

of

Dirnentions

&

Manual'

T59'o

OTHER FEATURES :

1.

Progrzunming of all parameters through keyboard.

2.

Non volatile memory for protecting programmed parameters during power failure.

3.

Key locking to prevent LlnaLlthorized access of keyboard operation.

4.

Testing of all Input, Output devices, such as Output Solenoids, Limit Switches.

Thermocouple lnputs, Key'board & Displays.

5.

Clear text for all Timers, Inputs, Outputs, for early programming & operation.

6.

Exclusion

-

t

& Repeatability

18 Counting i!{ode of

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Range

of

any temperature channels and timers from sequance of operation.

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HP-I4

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POWER ON

&

RESET CO^_DITIOJ"S

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Before snitching the power of the system ON, verify that all connection,r are made proper & firm. \Vron-q connecions may damage the trnit or can cause malfi.mcnon of the :-\'Stâ‚Źffi.

After the power ON, Display will show power ON page.

LOCK

ON if previously system was locked otherwise OFF

AL]TO

OFF.

\4ANUAL

.

OFF.

After power ON, all the setting sucli as Temp. Control point & Timer values are unkno*r. urless it has been programmed earlier. So for first time operation, all these values must be progmmmed. See programming section for detail on progamming-' Systern is provided with Non volatile memory to preserve prograilrmed values in case of poner failure. But if the system is kept OFF for longer period, (for more than a month ) these values may be erased.

It is necessary after power ON, operator must check that all the needed parameters are entered & its values are proper before starting the system.

After all parameters are entered & checked rystem is ready for starting.

A system Reset Key is provided on the front of the unit. If this key is pressed then system will start from beginning as if power ON has occurred and display will show - power ON page.

This is as good as starting the system from power ON as explained earlier. Only difference is that in this case progliunmed values are not erased. No matter how many times Reset Key pressed. This key ii provided to help the operator to start the system from beginning in case of an,r- problem in system operation caused by heavy distrubances in mains power supply or be any mechanical or electrical jam. Once this key is pressed and released system rvill always start from beglnning and all the conditions as explained earlier for power ON will remain valid.

-5HP-1-1

PROGRAilTfuIING

OF TEilTPERATURE, TIfofERS & MACHINE SETTING

\\henever operator starts the rnain's MCB, power ON page will be displayed. Press MAN (manual) key from the keyboard. Now display will show manual page. After that press FUNC (Function) key to scroll through pages. \\tre1 any page is selected by pressirrg the FUNC (Function) key cursor (^- ) will be at upper left corner of the LCD display. Move this cursor with the help of J t + +- keys. ..g. tf op.rutor wants to change zone} set i value. Select the temperature page with the pUNC (Function) key. Now move the cursor on the zone 2 by using f J I downward key & then press right direciional key. Now the cursor will be at the place of set 1 value of zone 2.

Now feed the desired data using data t or data J tey. After that operator has r*o choice. one is ilhe wants to change an1' other setting then press Enter ke1' one trme & goto set other parameters. and second is press Enter ke1' nilce.

After pressing dc'uble enter cursor sill be a home position \\henever cursrfr is on its move displar"rrill not be updated"

&

displai riili update

.

selecting that

pa-ee.

l t + <- key move the cursor ( - ) to the particular sLritable parameter 4. Using the DATA t g pafR I change the value as desired.

lille.

Similarlr operaror can chanse an)-pafirmetsr like timer. machine selting

b1.

Folion the follosing steps to prograrune any parameters.

1.

Decide rvhich parametff to programme

2.

Select the page using FUNC (frurction) key

3.

Using

5.

Press Enter Key only once. Now page follow steps 3 to 5 again.

6.

If all entry in that Position.

.

if operator wants to change more

parametel-s in that

page is over press entry key once again. Now cursor

will be at home

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P.ROGRAMMING Al\iD LISII{G THE SYSTE.\I

I

the parameters of the s,v-'stem can be prograrnrnedthrough keyboard. (As described earlier ke1'board is organized in tr,vo grolrps one is called DATA and second is called CO\1\1.\ND).

All

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FUNC., DATA

t, OA-la J,

+-

, -+, t,

J, l,XfEn KEYS

are usetl for enterins numeric

value into system's memory.

Any parameter can be programmed an-v time even rvhen svstem is running AL-TO. LOCK . keys are for s1'stem operation.

\1.\\.

DISPLAY ORGAAIISATION In this modirle all the parameters are divided in Different pages For details see page description chapter.

PROGR.LV.}11,\'G OF TE.'TPER4TLTRE, TIME

:

& MACHINE SETTING

\\:eieiirt:.i:-,rirrill star:thenr-iairs \IC8. Poueronpageuill comeondisplal. Press \1A\ ker :r:':' ,,e-"i:a:1. i,:,,i :he Jisria". *ill shoii *unr.,.ipaee (rihich is page 2) After that r:ess FL \C ..:". ::": s<l:;: 3:." :ii3 There

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.ri toll'l\i inr ker s :-

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STARTTNG

&

ASTNG THE SI'STE.'I

Before srarting tire srstern operator should verify that ali the telnperature antj ttmer parameters is entered and are proper. Once all parameters are entered press Iv{AN ke1'. S1'stem's operation once started Temp. parameter will operate and particular zones Relay' riill go ONOFF to achile set temperature. This action is continuous.

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Trmer action is dependent upon the conditions of limit switch input.

During fu{achine operation all or any particular Temperahre or Tirner value can be venfied and modifled. After modification is over operator should press ENTER key Twice as described earlier.

After pressing ENTER key Twice display will show Achral values of Temperarure or Timers in operation.

All Timers are down counting type. That means counting will start from set value zero count.

&

stop at

Courter pulse is taken from system delay Tirner. Counter will count in upward mode and after eight digits are full rhat is after 99999999 it will automatically reset to 00000. It can be reset to zero before also.

If any Temperature Channel is open or Thermocouple is broken then display will shorv OPEN for that channel. For ex. Zone2 Thermocouple is not connected or broken, then display will show: Set I Zone2

120

Set 2

Actual.

042

Open

If any Temperature Channel is programmed to vaiue 000 then that charurei wrll be out and it will not be read and displal' for it uill show :

ZoneT

000

005

OUT

In all these cases outputrelay willbe dienergised to prevent shoot up of,temperature and after remedial measure is taken and channel is corrected ry.'stem mll agarn operatmg that channel normally.

=

Similarly in case of Timers if any timers value has been programmed 00.0 then that tirner be out from sequence and its output relay will not be energized.

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For proper operation of system it is necessary that all the parameters of Temp., Timers & modes be programmed properly and correctiy. So verify these parameters. In case of any doubt in systerns operation start the system for master RESET.

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Fr

SER',7CING

&

fuTAINTENANCE

In case oiprobienr first cary'out the visual rnspection to see that Ito ccnneciion ts broken. power line volta-qe is correct and there is no loose connection in supply or an-v- other connections observe fault to determine its nature. Some common faults and their solutions are given below. These should be sufficient to solve the normally encountered problem in fields.

Solutions should be attempted by technically qualified persons only. In case of doubt consult factory.

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I : No LED display, +5Y, -5V, +12V , -lzV LED's OFF in P. S . Card.

SOLUTION I : (a) Check 24 VDC, it should be within 1l1o maximum. (b) Check fuse at the front of unit. (c) Check for burnt wire in power line.

FALTLT

FA{ILT 2

SOLUTION

a b

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:

Check for short in supply line.

(b)

Check fuse rating. It should be 300 mA minimum and 500 mA maximum.

i

c)

{d}

Check for short befw'een D.C. voltage and OV. Replace P. S. Card

F.'IL-LT

&

check.

3 : -5\-- -11\-. -11\- LED's Olr and +5V LED

SOLL-TIO}-3

Check if ry-siern is natrng.

Check LED connecnon-s

(b)

If

(c)

Replace P. S. card

tilrorilng

system not working then check powEr

:

SOLUTION

&

+5V ON, but

4

OFF.

:

b)

then there is loose connection rn LED's.

srppl] ,;ard is prope{ in:erted in bus card.

check.

-5Y. -12\'

not comrng:

:

(a)

Check whether AvD card is working. that is Temperarure coming and relay is energizing properly. If yes then there is loose comection.

(b)

If temperature not comfug andrelay is not energizing then check

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2

(a)

FAULT 4

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: As soon as power is switched on fuse below.

as per 3b

&

3c.

tb b b b F ET

b tr h b b b b b b h b F F

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f *

9f{ [,-1 4

1..11'LT

SOLL'TIOI-

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PS

5

O\

but system is not gettrng po!\er

O\

page. No dispiay or rardom dispiai'

:

{a)

Check s}'stem reset key is not pressed or shorted. If sirorted or pressed all the display' will be blank. Check that reset key connections are not shorting with body.

{b)

Check r5V supply is within 4.7 Y and 5.2\'. If not go to soiution 3-b, 3-c.

ic) (d)

Check card

I properly inserted in Bus

card.

Check RI connector cable between lr,{ain card & Displal unit

I4IARNING : Remove or insert card only after switching OFF por\.er Do not change card position.

(e)

Check display connector is

flrmlf inserted and no *jre is broken

(fl

Check all cards are in proper position and are fuII1, tiglt. Frnnli' but gentll' set card in guide and insert it into back side connector full1'. Check Euro connector pins of any card is not berd. If yes taigiten the pins and then insert the card. Always obsen'e correct position w'hile inserting the cards.

(g)

Check Euro connect soldering on 1't and 2"d card. If there is any doubt of short between two pins, remove it or if any pin is not making proper connection with track, solder it properly. Take care not to spill solder on card or leave air gap on solder.

Reconfirm cards insertion is proper and tight.

(h) (i)

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5:

Remove all other cards except power on page should come.

If

l't card. Using this card, system can be started

and

with only first card power on page is not coming, then check all IC's on the card on Display urit are properly connected to socket. If any socket shows execcessive lacker scratch it by knife and clean iC legs by knife.

I&

DO NOT REMOVE IC FROM SOCKET, \&'ITHOUT NOTING ITS POSITION & POLARITY ON PAPER. IF NECESSARY REMOVE IC ONE BY ONE only and after inserting 1't one, remove second one. SRONG INSERTION WII-L DAMAGE THE IC, After removing lacker or rust insert IC into socket gently but firmly. See that all legs are inserted properly and not a single leg is bend or are left oLrt side the socket.

Ut

Check that bus card tracks are not short by any piece of connection or solder spills or any wire on bus card is not broken. Check that bottom most and top most connections of Lrus card do not touch the momting rails. In case of doubt place a insulating tap on mountmg rail or insert sleeves in connector pins to isolate it. Check for loose wire or dr1 solder on bus card connections.

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b b b b b b b b b b b b b F r

b b b

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Power ON page comrng but sy'stern not uorkirg. tio starting and no acceptailce

T-ALILT 6

of SOLUTION 6 (a)

key.

:

Check that lock is not pressed. If lock LED's is

O\.

Then remove

lock.

See

unlocking sequencs. (b)

Check

if

any key is remaining pressed. Under normai uorliuig all the ke1,'s should be in

released conditions.

(c)

any wire from keyboard is not broken. Check connecdon & continuiry wires from keyboard and display to KB and displal connector on card l. between

(d)

Check for an-v- short between tracks connected to 6 pin connector b1 conducting piece Check for an1'' short on 6 pin connctor scldered into card 1. or solder spills on card

(e)

Check for short benl'een tracks

(fl

Go to step -i 1a)ier,i rir.

Check

if

I

bi uire. scrlder spil1s etc . .rr k* connectlon tracks in KB and displai'panel. I.-B and displal >ection is con-net'ted b1 ilat cable See for shorf benveen nro racks or cab{e Rsmove shor-t if t-ould" Che,ck the:e xith multimeter.

Clean the cards sith thinner and dn it thgn insen and check.

FAL-LT 7

:

S;-stem

*orking but certain key is not being accepted by systan.

SOL{-TIOI 7 :

(a) (b)

Check that flat connector for keyboard is firmly and properly inserted into rnaking connector on display card and all the points are making connections.

See that tracks are not broken near connector. Check there is no excessive dust on the card. Clean the card and the connector portion with thinner and dry it.

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Er b

!a

(c)

Check solutions 6-c, 6-d, 6-e.

FAULT

8:

Blankdisplay.

SOLUTION 8 :

(a)

Adjust the intensity knob.

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(b)

Check the 5 PIN cable. It should be properll' connected to keyboard

{-

(c)

Press Master Reset

h

ht

"!t + !41

.d h

E

&

check.

&

CPU card both

tb b b b F EI

b b b

tb

b b b b b Fr b b b e

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F,4{|LT 9

Randomdispial.

9

SOLUTION

(a) (b)

:

Check the 6 PIN cable. it should be Press the Master Reset and then

: Temperatue sho*ing open in particular

SOLUTION IA

:

Check for thermocouple open.

(b)

Check for non connection of thennocouple wire or broken compensatl'nq u.ire.

(c)

Short the thermocouple input connection of that channel and see if norv temperafure shows room temperature. If yes then check for broken thermocouple wire, and its connecting compensating wire etc.

(d) (e

i

)

fi

{ft

if ambient temp. in test mode is proper. If not go to solution l5-a to l5-c.

Check

Check that thermocouple connection from thermocouple to PCB connector is thermocouple wiring diagram.

Cha,-k an,J replace the card

F.4L-LT I tr

:

SOLL'TIO-\'

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Tanper:t-,re

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(b) (c) (d) (e)

See

l.

sh,-rnrn_J

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tn particular zone.

l-herir.,.'.up,ie is rer 3tric cu-ro-n3cted Change the polan[ of thermocouple

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Temperarure ;cinnn!l,r'risi"' sh;'-nrnc

SOLUTIO\ 12

(a)

firm.

Check fot 25 pin connector on card is connected properly or any point ofthat connector is not broken. Resolder the doubtful points check the reed relay of particular channel is OK. Check coil resistance of that reed relay. Check IC's on that cards are properly fineC into socket. Change the card and check.

=

b

zone.

(a)

i

{

properll connected to CPU card & key board botlt,

\{{\.

FAULT 10

I

a

:

ii.iritiini cr

{-!000 Ln parricular zone.

:

Heat the thermocouple \ori temperarure should tncreasi. if not. then check for short in thermocoupie wre or compensanng cabie or termrnal conaechons. Check all these connections and remove the shon Check that card 2 is firrnl1'and properh connected to bur card.

Check all IC's are properll-fined into socket.

Go to test mode and check the calibration of thermocouple.

Go to solution 10-f and l0-g.

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iar ib

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it

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c.)

rnode

.

:

If ambient is showing open, then check ambient sensor in Temp. Card (AD\{ Card) Check that sensor is not touching the body and connection is and check.

firm.

Replace the sensor

If reading is not proper, then recalibrate the sensor.

tdr

If wide variation in reading and it is not getting calibrated then go to solution 13b

te)

Replace the card and check.

FAULT 14

: All temp. zone showing open, OUT, 000 or high temperature value.

SOLUTION 14 :

(a)

Check that 25 pin connector on ADM Card 2 is correctly fitted and its contacts are proper and firm.

(b)

Check all IC's are properly fitted into sockets in ADM Card..

(c)

Check ADM Card is prope ly inserted and is in proper position. Insert the card firmly into bus card if loose.

(d)

Check for loose wire or connections on ,{Dlv{ Card

FAULT

l5 :

.

Parficular outputs such as solenoids alwa."-s ON or OFF.

SOLUTION 15 :

ta)

Go to test mode for D/O and check all outputs. Find out and note down which outputs are always ON or OFF.

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\orv

wiring chart for output, it gives details of output type, its connector numbers and card no. For example If DC contactor 2 is always ON, then from wiring diagram it is clear that it is connectedto25 pin connecfor of card 3. Check all wiring continuity hom coil of contactor No. 2 to card 3 connector. If no continuity then find out fault and malie connection and recheck outputs.

ILJ

Ii riinas is OK then check that particular card. Check transistor is proper. Check for dry solder or broken uacks. Check LED is OK.

(d)

Repiace card and then check.

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.\nbieni remperature not showing properll. in tesi

SOLL'TIO\ 13

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FAL

LT 16 :

Particular input always OI'J or OFF.

SOLUTION 16 :

(a)

Go to test rnode for DI and test all Input contacts. Find out and note Which are always open or close.

(b)

Now see wiring chart for Input, it gives details of Input t1pe, and card no. \\'ith help of wiring diagram check continuif from lnput wire to card connections, if niring continuity is not there, then make connection and recheck inputs'

(c)

Norv check that wten switch is closed it gives 24V signal (with respect of O\') on that particular wire & when switch is open it gives OV. If this is not coming then check proximiry switch and its wiring. If proximity switch and its wiring is proper- then +24Y, OV signal on the same wire should come, when switch is pressed and released.

(d)

Now check that the card is proper and its 25 pn connector is properly fined and no fw'o Input lines are short, check for dry solder, loose connection or broken tracks on the card. Check Input transistor is OK.

FAULT 17

.'

do*l

Input Nos.

No Input or No Output or both No Input and l'{o Output.

SOLUTION 17 :

(a)

Check +24Y supply is proper.

(b)

Check VO back is properly connected.

(c)

Check I"O cards are properll" fitted & check these cards are getting +24\' suppll'.

(d)

Clieck factory provided shortrng in 25 pin corutector has not come oul.

FAULT 18

:

SOLUTION

I8

LED glowing but solenoid not energizing" :

(a)

Check Output wre going to solenoid is svirtchin-e to 0 switching to 24 Y when OFF.

(b)

Put OFF power and check continuitl'betw.een oufput wire and solenoid coil.

(c)

Check continuit-v of solenoid coil.

(d)

Check suppiy across solenoid is proper.

(ri.r to O\r)when

ON and

t4-

FALTLT

U:

SQLEEQN.

t{P-r.1

Solenoi<i is energizing but LED is not comirlg.

Ie

:

(a)

Check LED's rvire is Proper.

(b)

Put OFF supply. check LED's is proper by multirneter, replace if bad.

(c)

Check +24Y is coming to that LED.

Important .. Plt OFF supply before removing or inserting cards or before doing any continuity check. Be careful do not short or mix AC & DC part of supply.

CARD ARRANGEMENT Bagk

n llil FO\\ER. SL PPL\-

ilt1 ri

C.{R.D

l

I I

I'

tr

h

I

6

Front

brl -

ii li tl

L-

{

I I

I

b-

tt ii

I

=1 E ba

l-l

Clard I

:

ir{ain Card

Card 2

.

Temperature Card.

Card 3 tcr 6

: iio Cards

Compcrnent on Right iiand side.

Rrelit

tb h h F F fr

b b l_ F trr F Er

b b h b F

b h F Fr F

b

f

- lf

HP-1-1

DETAILS OF TIXTERS \i

'\rr

Description

T]

AIR BLOWING

T]

EXHAUST

T3

DELAY MOULD IN

T4

DELAY CLOSE

T5

DELAY OUT

T6

MOULD OUT

T'7

CUTTER DELA}'

T8

CUTTER RETURN DELAY

T9

DELAY BLO\\' PI\

Tl0

FAST BLOWPN DOWN

T11

DELAY BLOWING

Tl2

DELAY SEALING

T13

EJECT

T14

BLO\A'PIN PRESSURE CUT

Tl,s

SEALING

T16

PARISON CONTROL

T17

PARISION CONTROL DELAY.

-

REMOVED

REN4OVED T18

PREBLOW TIMER

Tt9

DELAY NECK CUT FORWARD

T:,i

NECK CUT

e

T21

NECK COOLING

b b{

Tl2

DELAY NECK CUT BACK

b h € --=1 :r. lrj.

h

16HP-1{

DETATLS OF TITTERS

Sr.

\o.

Description

T23

DELAY BLOWING UP

T24

DELAY NECK CUT

T2s

SPARE

T26

NECK CUT FORWARD

T27

SPARE

T28

SPARE

T29

SPARE

T30

SPARE

T3l

SPARE

T32

SPARE

T33

SPARE

T34

SPARE

T45

SPARE

T49

SPARE

T50

CYCLE TIME

T51

TEST AUTO TIMER

O]\J

E=r

EI trr trr

-lt*iP-1.4

Er tsr I

IilTPORTANT NOTES FOR TINIERS

Fr

tr

b br

For proper firnctioning of rnachine and its optimum utilization it is irnportant that selected timlng should be proper. Some important points are given below .

tf

1. Open . in Close, and out timing should be selected by proper obsen'ations. So that machine does not remain idle after completion of particular operation.

H

2

k b H

b

th F H F

b h h F H b

brt b

q, E

Fr

b

H

Bl'rnanipulation of Delay Blorv pin and delay Blowing timings, preblow or post can be achieved. If delay blow pin is less than delay blowing, then blowing will start after blowpin comes down fi.rlly. This is called post blowing- On the other hand if delay blow pin is greater then delay blowrng, then blowing will start before blow pin comes down. This is called pre-blowing.

3.

For cufter operation check following timings

:

(a) If cufter delay + cutter retum delay < delay

mould close

*

delay mould out, then cutter

delay > delay mouid close

f

delay mould out, then cutter

may operate before closure of mould.

(b) If cutter delal'' + cutter refurn

will operate after mould closure.

(c) If cutter delay operate at all.

cutter return deiar > dela,v mould out

- mould out, then cutter will not

t8HP-I4

TTACHINE SETT'ING

trt

F F Er

S_r

stem is provided with various types of machine functions. These f,rnctions can be

I

!t Fr

b b F b a a e e F h Er a

selected b1 the operator to suit its requirements. For machine setting select machine setting page by' pressing page key and its increment or decremart key.

\{achine setting is given in following manner.

Sr.

\o

Description

I

Blowing Selection ( Top, Bottom )

2

Locking Selection ( ON, OFF

3

Cutter Selection ( It{ormal., Left. Right )

4

Deflashing Selection ( ON, OFF )

)

Sealing Selection ( ON, OFF )

f

These can be selected

by <- H -+

and Enter Key for example

If the operator want to

J select one station then following steps :-

Bmg the cursor (--) at select position and the press + key (right direction key). Now the cursor rvill be at the place of left, right or both. Select the required data by pressing Dam

Data

I

and then press Enter one

time. To select another selection follow above guidelines or

press Enter tlvo time for display update.

b

{_ E

ET

a E

b b EJ

ts, r{l"

ts Lf_

IH

h

tor

Simrlarll operator can set Blowing, Locking, Cutter and sealing selections of machine.

tH b

19HP-I4

E

F

P EI

b b b b H

b b h h b h h b b F

b b b a

t ?

=r

e

tr F

PAGE DESCRIPTION

In this rnodrde all the parameters are divided iir different pages, To goto particular page press page up and page down key or direct page key

Page description is given bellow

PAGE

1

:

Power ON Page.

PAGE 2

\lanual

PAGE

Timer

3

Page.

Page.

PAGE 4

Output

PAGE

Input

5

:

Page.

Page.

PAGE 6

Temperature Page.

PAGE

fulachine Selection.

7

PAGE 8

Counter

PAGE 9

Unlock

PAGE

10

Auto

Page.

PAGE 1I

Auto

Page.

PAGE

Test

12

Page.

Page.

Page.

tb F Er,

b b e E

h ET b

rH

b b b F Er b

tb

F Fr

b b F F =r T

p F E

s

-20t{P-14

ERROR CODES

Error codes have been provided in the system to help diagnose logic interlock failue in machine operation. This will help the operator to locate the problematic input faster thereby reducing the down time considerably.

Sr. No.

Description

0l

El -

02

E2 - Blowpin LS OFF

03

E3

-

Safeg Gate ON.

04

E4

-

Open LS not Olrl.

05

E5

- Error

5.

06

E6

- Error

6.

01

E7

08

E8 - Error

09

E9

10

Eli:)

1l

El1 -Error

t2

E

13

El3

- Blow Prn Dowr Swrtchoff.

14

E14

-

Emergenq O\.

15

E15

-

Open LS

16

EI6 - IN LS OFF.

17

E

l7 -

Out Slori' OFF.

18

El8 -

Close LS OFF.

Out LS OFF

- Enor

-

l:

7.

Error

8.

9.

- Enor 10.

il

- D€flchrrlg ba* l^S not Press€d

O\.

-21 HP-I4

CARD NO.

Sr.

No.

1

6 Pin Connection (CPtr to KBDSP)

DOi Rr (TXD) -r-5V

DOi Rr (RXD) GND RESET 6.

GNI)

I

:l :l

:t ir :l :l

!r n

HP.I4

C.IRD ^\-O.2 ADTT CAR.D WIRING DETAILS qHER}TOCOL'PLE C,4RDI

25 Pin connector ( pin nos. )

Data

!l ,

THERN,IOCOUPLE 1 + aa

I

il il T I

t I I I

THERMOCOUPLE 2 +

" THERMOCOUPLE 3 + a(

THERMOCOUPLE 4 + 1(

THERMOCOUPLE 5 +

I I

12

24

ll 23

10

22

9 21

:r l

I3 25

THERMOCOUPLE 6 + aa

THERMOCOUPLE 7 + aa

THER\{OCOLIPLE 8 +

I 20

7 19

6 18

I

r t

23HP-11

I I I *

r

C]ARD NO. 3

Sr. No.

Outnut

25 pin I/O conn.

lnput

25 nin I/O conn.

20

,

1.

HEATER

1

13

OUT LS4

t I I

)

HEATER

2

25

BLOW'PIN LS

J.

a

HEATER

3

24

SAFETY GATE

19

4.

HEATER 4

t2

SPARE

06

5.

HEATER

5

23

SPARE

18

6.

HEATER

6

l1

SPARE

05

7.

22 FAST BLO\\| PN,i (FOR STANDARD MACHINE)

SPARE

17

8.

SCREW INTERLOCK

t0

SPARE

04

:

+24 V DC

9

T

o\'.DC.

I

3

t I I f I

T

I

DOWN

:

t I I t I f

t

b

ft-

ts

8, 21

1

07

I -'74 F{P-14

CARN NO.

4

n UO conn.

25 nin I/O conn.

BUTTON

20

BUTTON

07

9.

MOULD OPEN

13

OPEN PUSH

10.

MOULD CLOSE

25

CLOSE PUSH

11.

MOULD IN

24

IN PUSH

12.

MOULD OUT

l2

OUT PUSH

13.

BLOWPIN DOWry

23

BLOW PIN DOWN BUTTON

14.

BLOWING

11

EMERGENCY

15.

CU"I"TER

1

22

OPEN LS

16.

CUTTER 2

10

IN LS,2

+24Y DC

9

OV, DC.

8, 27

SO

J

SI

15

S2

2

+5V. GND

1,14

BUTTON

3

BUTTON PUSH

STOP

19

06

18

05

17

Q4

I T

f I I I I

r

-25

-

'{-tP-14

CARD NO.

Sr. No.

25 pin I/O

Output

conn.

5

Input

25 pin I/O conn"

5

I I

17

\{AIN

r

18

LOCKING PRESSURE 25

CLOSE LS

I

19

BLO\&?IN UP

24

BLOWPIN UP SIVITCH

t9

]O

PARISON

12

SPARE

06

i1

BLOWER I

23

SPARE

18

BLOWER 2

l1

SPARE

05

BLOWER

22

SPARE

t7

HYDRAULIC

l0

SPARE

04

-2.1 \r DC

I

OY

8,

a

I I I I f I

t I

t t I I I

E

I I

il I

t I

F

ll

SOLENOID

DC

CONTROL

3

OUT SLO\\'

13

21

LS

6

20

07

EI ET

t il

-25HP-1,1

ir

CARD NO.

Ir

il

E

6

25 pin UO conn.

f

i

bt I

h b

r

t il

25

NECK CUT FORWARD 13

26

I'Ari't' BL0wPt N ut)wf{ 25

CUTTING

NECK CUT FORWARD SWITCH

NECK CI I'f B,\{]K LS

20

07

24

NECK CUT SWITCH

l9

NECK COOLING

t2

SPARE

06

29

SEALING

23

SPARE

18

30

PREBLOW

1i

SPARE

05

31

BOTTOM BLOWING

22

BOTTOM BLOW S1VITCH

t7

32

EJECT

10

SPARE

04

+24 V DC

9

27

NECK

28

!T

t

Fr

t

il

tr fi

lr t ir t il I

t

il I il b il F I

I

OV. DC.

8, 21

t

t n I

11 HP.14

b

b

SCREW INTERLOCK

I I

ht

Screw interlock facility is provided in the rnachine so that operator do not start the

b

machine and damage the screw without glving sufficient heat to heaters.

h

Following points are given below for proper operation of screw interlock

r

t I It

b

I b

L

Set proper temperature

2.

Unused zones should not be left open but

:

for all zones according of screw used for processing.

it should be set out by programming

Value to 000. by 20 C or more screw motor will trip. Find out going down so much & reaify the fault before starting the the reason for temperature

3. If any zone temperature goes below machine.

If proper care is taken for this facility screw damage will

be minimised.

T

t :

b

I h

t

L

t l ;

I 3 T

I t

I

set I

IMPTORTANT NOTE

: Always check all zones setting for particular Starting the machine.

material before

-28 -

TEST MODE

To enter Test Mode proceed as follows :-

1.

Press Master Reset Key.

2.

Press FN Key.

Now Test Mode page will open uP. Take the cursor to required line no. such as, Temp., ( Digital lnputs ) etc.

DO ( Digital

I

Oufputs ), DI

*> Key cursor will move to Ch: No. position.

1.

Press

5.

Feed required Ch: No. 01, 02 ... ... .etc.

6.

Press Enter.

Now selected Nos. data will be displayed & in case of Digital Output selected Output will turn on & rest of outputs will be off.

5&

6 to check other Ch: No. data

7.

Repeat step

8.

Repeat steps 3 to 6 to check other parameter.

9.

Press Master Reset

to Exit from Test Mode.

t I

29-

Ir

tiP-t4

?

I

T,INLOCKING

l

h

r &t

A. L,\LOCKING :

T

01.

F h D

I f

I

For unlocking proceed as follows :-

Goto unlocking page.

02.

\{ove cursor to unlock line.

03.

Feed 4

0-1.

Press Enter Ke-v-.

05.

Lock is removed.

06.

Factory programmed unlocking code is 0204.

digit unlock code programmed previously.

B. CHANGING OF UNLOCKING CODE: For changing

code proceed as follows

D

01.

Go to unlocking page.

T T

02.

lvlove cursor to Old code in change code line.

03.

Feed old code numbers ( 4 digits ).

04.

Press Enter Ke,y.

h h

05.

Again move cursor to New in change code line.

06

Enter 4 digits number as New code.

F h

07.

Press Enter once.

08.

\on'oid

09.

Press Lock Key once again. Now programming of New code is over.

r

I' L f I I il il f

r H

NO

code

:

will also show new code. This means new code has been accepted.

IE :-

In case mistake is made w'hile unlocking or changing the code. Error will be displayed in both lines. Check your code properly and proceed with unlocking or changing code as explained above.

r p

I 30-

IJ

HP-l,t

b

t

C(}LTNTERS

L

It

I b

I L-

l'

There are fwo fypes of counters

1.

8 digit total counter.

2.

4 digit hourly counters. Hourly counters are for

24 hts. from

Checkine Counters :-

I

1.

f

2.

Last Reset line shows date

T

3.

Reset line is for Reseting the counter.

l

4.

Total count line shorv total count value from last Reset.

5.

Hr. No. line shows hourly value of counters from iast Reset.

L

t I

Reset time

Go to counter page.

& time of Reset. Counting for hours starts from this time

T

Resetins Counters :-

I

1.

Bring cursor to Reset line.

2.

Press

+

3.

Data

t Data J & select No. Hourly, or all.

4.

Press Enter Key to execute the selected couunand.

5.

Press Home Key to bring cursor to home position.

I

:

t I

t I

I I t T

t I I

it F

Key. Cursor will move to command colunn.

NOTES :-

L

If hourly is selected only hourly valves will

be reset to 0000

Tota! count value rvill

Remain unchanged.

2.

If all is selected all counters, including total count value will

be reset to zeros.

-31 F{P-

PARISON COI{'I'R.O I, SE'T'T

System is having 20 setting for parison tune.

INI

1

G

control. It is on or off & is calculated

as

o/o

of cycle

Parison control page is given in following format'

Cycle

Time

50.01 ( Set

)

50.01 ( Act )

PC

% oFF

%oN

PCl

10

20

PC2

11

12

) at PCl froln upper left corner by To set the value of parison control bring the cursor ( will be pressing dorvn amow key ( I ). Press right directional alrow key ( + )' Now cursor keys' data or pressing data by at % ofrvalue position.'Set the value of % off in trvo digit Similarly set 7o ox value in two digit and press enter key twiceLike that operator can set all the parison control setting from PCI to PC10

Note

:-

+ Parison confrol value can be programmed up to 1\A%only i' e' PC1 ON OFF to PC10. ON + OFF should be equal to 100% or less than 100%'

If it exceeds rc1% New value will not

be accepted

& old value will remain valid'

'1