ONS ONS Direct Locking/RAM Operating Manual v1.0 May11 Vignan Electronics Pvt. Ltd.
DIRECT LOCKING MACHINE OPERATING MANUAL
www.vignanelectronics.com VIGNAN ELECTRONICS PVT. LTD.©
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ONS Direct Locking/RAM Operating Manual v1.0 May11 Vignan Electronics Pvt. Ltd.
Contents Contents.......................................................................................................................... 2 ONS PLC SPECIFICATIONS ................................................................................................ 4 KEYS SPECIFICATION AND OPERATION ........................................................................... 9 GENERAL OPERATING INSTRUCTIONS .......................................................................... 10 STARTUP SCREEN .......................................................................................................... 11 HOME PAGE/PG: 00 ...................................................................................................... 12 MOULD CLOSE PAGE/PG: 01 ......................................................................................... 13 MOLD OPEN PAGE/PG: 02 ............................................................................................ 14 HYDRAULIC EJECTOR PAGE/PG: 03 ............................................................................... 15 CORE SETTING PAGE/PG: 04 ......................................................................................... 16 AIR EJECTORS SETTINGS PAGE/PG: 05 .......................................................................... 18 INJECTION SETTINGS PAGE/PG: 06 ............................................................................... 19 HOLD ON SETTINGS PAGE/PG: 07 ................................................................................. 20 REFILL SETTING PAGE/PG: 8 .......................................................................................... 21 CARRIAGE PAGE SETTING/PG: 09 ................................................................................. 22 HEATERS SETTING PAGE/PG: 10 ................................................................................... 23 HEATER SELECTION PAGE/PG: 11 ................................................................................. 24 TIMERS SETTINGS PAGE/PG: 12 .................................................................................... 26 SERVICE MENU PAGE/PG: 14 ........................................................................................ 27 INPUTS PORT-1 STATUS PAGE/PG: 15........................................................................... 28 INPUTS PORT-2 STATUS PAGE/PG: 16........................................................................... 29 INPUTS PORT-3 STATUS PAGE/PG: 17........................................................................... 30 KEYPAD CHECK PAGE/PG: 18 ........................................................................................ 31 OUTPUTS PORT-1 STATUS PAGE//PG: 19 ..................................................................... 32 OUTPUTS PORT-2 STATUS PAGE/PG: 20 ....................................................................... 33 OUTPUTS PORT-3 STATUS PAGE/PG: 21 ....................................................................... 34 2
ONS Direct Locking/RAM Operating Manual v1.0 May11 Vignan Electronics Pvt. Ltd.
OUTPUTS PORT-4 STATUS PAGE/PG: 22 ....................................................................... 35 SENSOR CALIBRATION PAGE/PG: 23 ............................................................................. 36 ANALOG OUTPUT CALIBRATION SETTING PAGE/PG: 24 ............................................... 37 MAXIMUM VALUES 1 SETTING PAGE/PG: 25 ................................................................ 38 MAXIMUM VALUES 2 SETTING PAGE/PG:26 ................................................................ 39 REAL TIME CLOCK SETTING PAGE/PG: 27 ...................................................................... 40 MANUFACTURER SETTING PAGE/PG: 28 ...................................................................... 41 DIGITAL OUTPUTS CONTROL PAGE/PG: 29 ................................................................... 42 PRODUCTION COUNTERS PAGE/PG: 31 ........................................................................ 43 MONTHLY PRODUCTION PAGE/PG: 32 ......................................................................... 44 LAST 10 CYCLE TIMINGS PAGE/PG: 33 .......................................................................... 45 ZONE TEMPERATURE PROFILE PAGE/PG: 34 ................................................................ 46 PASSWORD PAGE/PG: 36.............................................................................................. 47 LUBRICATION CONTROL PAGE/PG: 38 .......................................................................... 48 DIRECTORY PAGE/PG: 39 .............................................................................................. 49 HAND MODE SOLENOID ENERGISATION PAGE/PG: 60 ................................................. 50 DEFAULT HAND MODE SOLENOID ENERGIZATION ....................................................... 51 AUTO MODE SOLENOID ENERGISATION PAGE/PG: 61 ................................................. 53 DEFAULT AUTO MODE SOLENOID ENERGIZATION ........................................................ 54 ONSITE RE-PROGRAMMING OF ONS PLC ..................................................................... 56 OPERATING MESSAGES OF ONS PLC ............................................................................. 57 TROUBLESHOOTING PROCEDURE FOR ONS SYSTEM .................................................... 59 STANDARD DIRECT LOCKING DIGITAL INPUTS (24 Nos.) ............................................... 68 STANDARD DIRECT LOCKING DIGITAL OUTPUTS (32 Nos.) ........................................... 69 WIRING CIRCUIT FOR STANDARD DIRECT LOCKING ...................................................... 70
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ONS Direct Locking/RAM Operating Manual v1.0 May11 Vignan Electronics Pvt. Ltd.
ONS PLC SPECIFICATIONS ONS PLC SYSTEM CPU Processor Clock Frequency
32-bit ARM7 Embedded Processor 72MHz
MAIN MEMORY Program Memory Mold Data Memory
512Kb Program Flash 30 Mold Data
DISPLAY Type Size Resolution Backlit
Graphical Monochrome LCD 3.5” (diagonal) 320 x 240 pixel resolution LED for longer life
KEYPAD Interface
Status Indication Keys Material Type
47 Total Keys=23 Machine operation + 13 General functional keys + 11 Alphanumeric Red LED for Machine operation mode & Green LED for Machine operation stage Feather-touch buttons with tactile feedback Industrial Grade Polycarbonate with Dust & Oil Resistance
COMMUNICATIONS USB Interface
1xUSB(back)V2.0 Standard
DIGITAL INPUTS
24 Nos. Optically-Isolated NPN-NO type Can be configured as Regular DI or High speed counters High Intensity Red LED Inverse polarity
Type Configuration Status Indication Protection
DIGITAL OUTPUTS Type Current Rating Status Indication Protection
32 Nos. Programmable Type, Optically-Isolated Max. 2A High Intensity Green LED To be provided by external fuse
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ONS Direct Locking/RAM Operating Manual v1.0 May11 Vignan Electronics Pvt. Ltd.
ANALOG INPUTS No. of Temperature Inputs Resolution Calibration method Type of Temperature Sensor Interface Temperature Closed-Loop Control Method Temperature Open-Loop Control Method Temperature Control Accuracy Temperature Sensor Failure Detection No. of Linear Potentiometer Inputs Resolution Type of Linear Potentiometer Interface Linear Potentiometer Accuracy No. of Pressure Transducer Inputs
8 Nos. 5 Total Inputs=4 + 1(User selectable between Barrel/Hydraulic Oil) 10-bit Resolution Through Software RTD type-Pt 100 Adaptive PID Control Duty Cycle based ±1 ⁰C Sensor Short, Sensor Open 2 Total Inputs(1 Clamp + 1 Screw) 12-bit Resolution Resistive, can be used up to 6K potentiometers 0.05mm 1
ANALOG(PROPORTIONAL) OUTPUTS No. of Outputs Output Voltage Range Resolution Calibration
2 Channels ,Flow + Pressure 0 to +10VDC 12-bit resolution OEM/End User Software Configurable
ERGONOMICS User Interface Aesthetics
Easy to Setup & Operator friendly Ultra compact, Industrial grade with Elegant International styling
MECHANICAL SPECIFICATIONS Enclosure Casing Dimensions(LxWxD) Mounting Layout Weight
Aluminum with ventilation holes 305*178*55mm Vertical From Rear side 1480 gms(appx.)
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ONS Direct Locking/RAM Operating Manual v1.0 May11 Vignan Electronics Pvt. Ltd.
PROPORTIONAL AMPLIFIER DRIVER CARD INPUT SPECIFICATIONS No. of Proportional Channels Input Command Signal Range
2 (1 Flow +1 Pressure) 0 to +10VDC
OUTPUT SPECIFICATIONS Valve Solenoid Drive Current Valve Solenoid Compatibility
0 to 3A (Configurable) +6VDC to +48VDC/3Ω to 45Ω
ERGONOMICS Independent unit for modularity and optional for non proportional machines Appropriate Labeling for Signal Wiring
Analog Amplifier Card Form Labeling
POWER SUPPLY Nominal Supply Voltage
+24VDC Idle:2.4W, Instant. Typical:24W@[12ΩLoad&1.2A], Instant. Max:42W@[12ΩLoad&1.6A]
Power Consumption
MECHANICAL SPECIFICATIONS Enclosure Casing Dimensions(LxWxD) Weight
DIN Rail mount 114*67*27mm 200 gms(appx.)
POWER SUPPLY MODULE 24VDC, 15A SMPS(Accessories Included: Power Line HF Suppressor:Emitech E.M.I Filter) Input Supply Voltage Output Dimensions(LxWxD) Weight
180 to 270VAC(1Ø), 47-63Hz +24VDC, 15A 215*115*50mm 1400 gms(appx.)
OPERATING CONDITIONS Operating temperature Storage temperature Relative air humidity Vibration Resistance
+5 °C to +60°C -30 °C to +75°C Max. 95% (non-condensing) upto 10G
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ONS Direct Locking/RAM Operating Manual v1.0 May11 Vignan Electronics Pvt. Ltd.
SOFTWARE HIGHLIGHTS MACHINE CONTROL Machine Scan Time MMI Scan Time No. of Mold Programs
Maximum HP Control Maximum System Pressure Special Power Saving Options Protected Full Auto-mode Outputs Configurable Unscrew Motor No. of Cores No. of Core Sequences
Cores Operation Core Priority Sequence Temperature Control No. of Air Ejectors
Air Ejectors Operation Speed & Pressure Ramps Injection Back Pressure function Auto-Die Feature Production History Default Mold Data Data Entry check Data Entry Ease
400 times/sec(2.5msec) 1000 times/sec(1msec) 30 Fully Implemented(To avoid max. motor power consumption to avoid stalling of motor) & Configurable by the OEM Machine manufacturer programmable from 140200bar Adaptive Locking Flow Control(Only RAM Type M/Cs) & Auto Mold Opening Correction Full Auto mode can be password enabled/disabled for die safety purposes The outputs can be configurable ON/OFF for each functional stage in all modes of operation Single Single 6 Cores function 'IN' & 'OUT' independently as well as function parallelly with Mold Close & Open stages in all modes of operation Core 'IN' & Core 'OUT' priority can be programmed by the user as per requirement Advanced Adaptive PID Control with -1 to +1 ºC accuracy 2 The air ejectors can be configured with a programmable delay, ON & OFF periods and required number of strokes Up ramps are programmable for each & every major operational stage Digital Solenoid can be end-user selected as per die requirement Available Last 30 days shot counter on hourly basis Default Mold Data is provided for easy setting of machine All operator input parameters are validated/checked to ensure proper settings For ease of data entry valid range of values are displayed for every input parameter 7
ONS Direct Locking/RAM Operating Manual v1.0 May11 Vignan Electronics Pvt. Ltd.
USB FEATURE On-site programmable
User can reprogram PLC sequence logic on-site through USB with quick ease
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ONS Direct Locking/RAM Operating Manual v1.0 May11 Vignan Electronics Pvt. Ltd.
KEYS SPECIFICATION AND OPERATION GENERAL KEYS: PAGE LOCK HOME SERVICE DIRECTORY PASSWORD+FUN PAGE UP PAGE DN SET HAND SEMI AUTO Left Arrow(←) Right Arrow(→) Down Arrow(↓) Up Arrow(↑) 0 to 9/A to Z INC -Digit 9 DEC -Digit 3 _/+/- -Digit0 CLEAR ENT
- To lock/unlock page selection for hand keys - Display HOME screen - Displays Service menu page - Displays Programs Directory for selecting a program - Page for changing password level+Function Key - Page up (Display previous Page data) - Page down (Display next Page data) - Put PLC in Set mode - Put PLC in Hand mode - Put PLC in Semi Auto mode - Put PLC in Auto mode - Left arrow to shift cursor on to the left side of the data - Right arrow to shift cursor on to the right side of data - Down arrow to shift cursor below the present data - Up arrow to shift cursor above the present data - AlphaNumeric keys for data entry -Select next option/increase a settable numerical value - Select previous option/decrease a numerical value -Space character/Plus symbol/Minus symbol on Digit 0 -Clear last entered digit/alphabet during data entry - Executes entered data
MACHINE FUNCTION KEYS: MOULD OPEN MOULD CLOSE CORE OUT CORE IN INJECT SUCK BACK EJECT RETRACT EJECT FORWARD UNSCREW LUB HEATER REFILL MOULD HT+ MOULD HTMOVING AIR BLAST FIXED AIR BLAST UNIT FORWARD UNIT RETRACT
- Manual start Mould Open - Manual start Mould Close - Manual start Core OUT - Manual start Core IN - Manual start Injection - Manual start Suck Back - Manual start Hydraulic Ejector Retract - Manual start Hydraulic Ejector Forward - Manual start Unscrewing motor for certain moulds - Manual Lubrication pump ON - Heaters ON/OFF - Manual Start Refilling - Manual Start Increase Mould height (Only in Set Mode) - Manual Start Decrease Mould height(Only in Set Mode) - Manual Start Moving platen Air blast - Manual Start Fixed platen Air blast - Manual Start Injection unit forward - Manual Start Injection unit retract
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ONS Direct Locking/RAM Operating Manual v1.0 May11 Vignan Electronics Pvt. Ltd.
GENERAL OPERATING INSTRUCTIONS 1. To change any data values currently set a. Go to the required screen by using , keys, by using data screen symbols or by using hand mode keys (You must disable page lock). b. Go to the required data parameter using up, down, left & right arrow keys. c. Enter data using keys (Either numeric 0-9 or Alphanumeric A-Z). d. Press key to start to operate with new changed data. e. If no data change is accepted, then the password access level for that page may be low. Change password level and retry the same.
2. When PLC is repowered, the last selected (running) mould data is automatically loaded for execution. 3. If no key is pressed for 120 seconds, the LCD backlit goes off to increase the life span of LCD and it comes on when any key is pressed.
4. To enter new data on any screen corresponding level of password must be entered. The present password level automatically reduces by level 1 after each 15 minutes interval.
5. Reset password as soon as you complete data entry to avoid unauthorized or wrong data entry. 6. When page lock led is off you can go to the required page directly by using hand mode keys and data can be saved in backup memory.
7. If at any time data is saved in the backup memory the page lock led comes on to avoid resaving.
8. If no RTD is connected or sensor is open, that zone temperature displays 999 so that corresponding contactor goes off. 9. To execute either semi auto or full auto cycle, the heaters must be put on.
10. Whenever a new mould program is loaded, heaters are put off automatically. 11. Whenever machine stops at any stage, check flag no., operating message and error message on the screen and rectify the problem accordingly.
12. All zone set temperatures must be above minimum temperature set in machine parameter screen.
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ONS Direct Locking/RAM Operating Manual v1.0 May11 Vignan Electronics Pvt. Ltd.
STARTUP SCREEN
VIGNAN ELECTRONICS PVT. LTD. F-36, Marol Nanddham Indl.Estate, Marol, Andheri (E), Mumbai - 400059. Ph:(022)33411657,66935061. Fax:66935062 Website:www.vignanelectronics.com Injection Moulding Machine Controller Model:ONS SW: ONSRAM01 Type: Ram Type M/c POWER ON BOOT..CHECKING SYSTEM..PLS.WAIT System Fail Detected...Call Service Engg
MACHINE TYPE
SOFTWARE NAME 1) The above screen is “STARTUP SCREEN” visible for only 5 seconds every time the PLC power cycles.
2) This screen displays VIGNAN logo & contact details along with the PLC model: ONS 3) On the seventh line of this screen, PLC displays the software name installed in it. 4) Here for a toggle machine SW name: ONSRAM01. 5) On PLC error: “System Fail Detected...Call Service Engg” is displayed on last line of this screen. In such cases call service technician on above phone numbers listed.
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ONS Direct Locking/RAM Operating Manual v1.0 May11 Vignan Electronics Pvt. Ltd.
HOME PAGE/PG: 00 Mould Program Name
Mode of Operation Date
Day of Week Real-Time Clock
Stage Name Stage Flow, Pressure, Position & Time
GANESH AUTO 01-08-2009 Sat 13:27:02 Stage:Injection Stage 1 Flag:16 F=60.0% P=070 bar D=220.0 mm t=01.03 sec Zone Set Actual Clamp:213.2
Zone 1
1.
235
234
(mm)
Zone 2
2.
230
229
(mm)
Zone 3
3.
220
220
Zone 4
4.
200
199
5.
190
190
Flag/Stage Number Clamp Scale Reading Screw Scale Reading
Screw:214.7
Zone 5/ Hydraulic Oil Temp.
Pressure Transducer
6. Locking 050 Pressure
Screw RPM: 020 Tot.Count:0000000 Bat.Cnt:0000/0000 Batch(2000):0437 Cyc.Tm=07.2→09.5 Rem.Tm(Min):0248 Hourly Prod:0378
Screw Speed in RPM Total Production Count Batch Size Counter Status Set & Present Batch Count Cycle Time
Error message if any...................Page:00
Error Message
Hourly Production in Units
Remaining Time to complete Batch production
Page Number
1) The above screen is “HOME PAGE” or PG:00, accessible by pressing on keypad
2) Password Level Required to Access=0.No values are settable/configurable on this screen. 3) This is the main observation screen during machine operation indicating all real-time values of temperature zones, scales, screw speed & production counters details. 4) The top line denotes Mould Program Name, Mode of machine operation i.e. Hand/Semi/Auto, Present Date, Day & Time. This line is shown on all screens. 5) The second line denotes the present stage in machine operation with its corresponding stage number. 6) The third line denotes the present stage's set Flow, Pressure, Position & Time (if operating in timer mode). 7) The last line denotes any machine error condition detected by the PLC. 8) The cycle time of each production shot is indicated in resolutions of 0.1 of a second. 9) Zone 5 Set description changes to “Hydraulic Oil” if selected so on PG:15 10) Item 6 shows the real-time locking pressure of the machine provided a PT sensor is connected to the PLC.
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ONS Direct Locking/RAM Operating Manual v1.0 May11 Vignan Electronics Pvt. Ltd.
MOULD CLOSE PAGE/PG: 01
Flow/Speed Adjustment
Mould Close Stage
Mould Close Timing Adjustment
Pressure/Force Adjustment
GANESH AUTO 01-08-2009 Sat 13:27:02 Type of Clamp movement Sensor Mould Close Data Lin.Pot. Stage Speed Press Position ----(%) (bar) (mm) Position Adjustment Slow1 20.0 030 245.0 Fast 65.0 075 125.0 Fast End Slow2 30.0 040 070.0 Sft Start Safety 20.0 020 030.0 Sft End Clamp Selection In Hand : Locking Int-1 00.0 000 P1:000 bar Locking Stage parameters Int-2 00.0 000 P2:000 bar adjustments Mould Close Time: 08.00 Act: 07.12 sec Mould Safety Time: 03.00 Act: 02.03 sec Stage Speeds Act.Speeds: 245 230 250 216 mm/s Actual Clamp Position: 216.6 mm Valid Range for Selected Data Mn:00.00 Mx:19.99 New Val: 08.00 Error message if any..............Page:01
1) The above screen is PG:01, accessible by pressing key on keypad 2) Password Level Required to Access=01.All Mould Close setting are settable/configurable on this screen. 3) The top line denotes Mould Program Name, Mode of machine operation i.e. Hand/Semi/Auto, Present Date, Day & Time. 4) The last line denotes any machine error condition detected by the PLC. 5) On this screen flow, pressure, position & times are configurable for each stage of mould closing operation. 6) The line above the last line indicates the valid range of values acceptable for the selected particular settable parameter.Eg: Mn=Minimum=00.00 & Mx=Maximum=19.99 for Mould Close time. 7) To fine tune any parameter value & keys are pressed to increase or decrease respectively. 8) The type of Clamp sensor (“Linear Potentiometer”/”Limit switch”) is machine manufacturer settable from PG: 32. This is indicated on the second line of the screen. 9) Clamp Selection in Hand (Mode) is settable between “Locking” or “No Locking”. If Clamp Selection=Locking then Mould Locks after closing for locking time specified. 10) Intensification 1 & 2 locking stages flow/pressure/locking pressure values can be adjusted on this page. 11) The maximum values for flow & pressure can be settable from PG:25 12) Actual Speeds for all stages of Mould Closing operation are indicated in terms of mm/s 13) Actual Mould Close Position & timings are also indicated.
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ONS Direct Locking/RAM Operating Manual v1.0 May11 Vignan Electronics Pvt. Ltd.
MOLD OPEN PAGE/PG: 02 Pressure/Force Adjustment
Flow/Speed Adjustment Position Adjustment
Mould Open Stages
GANESH AUTO 01-08-2009 Sat 13:27:02 MOULD OPEN DATA:Lin.Pot. Stage Speed Press Position DCPRE ----(%) (bar) (mm) (bar) Decomp 30.0 00.0 ----000 Slow 1 40.0 00.0 00.0 Hold Fast 65.0 070 140.0 Time Slow 2 30.0 040 230.0 0.00 Slow 3 20.0 030 290.0 --Start Hyd.Ejector at the end of:Slow 2 Act.Speeds: 234 412 324 123 mm/s Actual clamp position: 241.3 mm Mn:Slow 2 Mx:Slow 3 New Val:Slow 2 Error message if any........... Page:02
Type of Clamp movement Sensor
Stage Speeds Valid Range for Selected Data
1) The above screen is PG:02, accessible by pressing key on keypad 2) Password Level Required to Access=01.All Mould Open setting are settable/configurable on this screen. The top line denotes Mould Program Name, Mode of machine operation i.e. Hand/Semi/Auto, Present Date, Day & Time. 4) The last line denotes any machine error condition detected by the PLC. 5) On this screen flow, pressure, position & times are configurable for each stage of mould opening operation. 6) The line above the last line indicates the valid range of values acceptable for the selected particular settable parameter.Eg: Mn=Minimum=slow 2 & Mx=Maximum=Slow 3 for -Start Hyd. Ejector at the end of . 7) To fine tune any parameter value & keys are pressed to increase or decrease respectively. 8) The type of Clamp sensor (“Linear Potentiometer”/”Limit switch”) is machine manufacturer settable from PG: 28. This is indicated on the second line of the screen. 9) Start Hyd. Ejector at the end of- is settable between “Slow2” or “Slow3”.If Slow 2 is selected then ejector operates at the end of Slow 2 Set Position. If Slow 3 is selected then ejector operates at the end of Slow 3 Set Position. 10) The maximum values for flow & pressure can be settable from PG:25 11) Actual Speeds for all stages of Mould Opening operation are indicated in terms of mm/s 12) Actual Mould Open Position & Hold times are also indicated. 3)
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ONS Direct Locking/RAM Operating Manual v1.0 May11 Vignan Electronics Pvt. Ltd.
HYDRAULIC EJECTOR PAGE/PG: 03
Ejector Operation Mode Ejector Strokes
Ejector Retract Operation Mode
GANESH AUTO 01-08-2009 Sat 13:27:02 Ejector Selection: Repeated Pres.Stg:0 No. of strokes Set : 2 Executed: 1 Speed Press Time (%) (bar) (sec) Ejector Fwd 1 50.0 060 0.25 Ejector Fwd 2 30.0 030 0.25 Ejector Rev 1 45.0 045 0.25 Ejector Rev 2 20.0 025 0.25 Ejector Sensor Selection:Timers Ejector Auto Retraction:Disable (When Timer Operation Mode is Selected) Actual Clamp Position: 445.4 mm Mn:0 Mx:9 New Val: 8 Error message if any..............Page:03
Type of Ejector Sensor/Timers-Based Stage Speeds
Valid Range for Selected Data
1) The above screen is PG:03, accessible by pressing or key on keypad 2) Password Level Required to Access=01.All Hydraulic Ejector settings are settable/configurable on this screen. 3) The top line denotes Mould Program Name, Mode of machine operation i.e. Hand/Semi/Auto, Present Date, Day & Time. 4) The last line denotes any machine error condition detected by the PLC. 5) On this screen flow, pressure & times are configurable for each stage of hydraulic ejector operation. 6) The line above the last line indicates the valid range of values acceptable for the selected particular settable parameter.Eg: Mn=Minimum=0 & Mx=Maximum=0 for -No. of strokes Set . 7) To fine tune any parameter value & keys are pressed to increase or decrease respectively. 8) The type of Ejector Sensor Limit switch10+Limit switch09, Limit switch10 or Timerbased function is machine manufacturer settable from PG: 28. This is indicated on the second line of the screen. 9) The mode of Ejector Selection is selectable between Inactive/Repeated/Stay Forward. 10) The No. of Strokes Set is selectable between 0-9. 11) The Ejector Auto Retraction Function can be Enabled/Disabled when Hydraulic Ejector is functioning on Timers. 12) The maximum values for flow & pressure can be settable from PG:25 13) Actual Strokes executed & Present Stage of Hydraulic Ejector is indicated. 14) Actual Clamp Position is also indicated.
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ONS Direct Locking/RAM Operating Manual v1.0 May11 Vignan Electronics Pvt. Ltd.
CORE SETTING PAGE/PG: 04 GANESH AUTO 01-08-2009 Sat 13:27:02 Core Present Stage: 1 (0,2,4-Idle, 1-Forward, 3-Retract) Core Seq.Sel: 2 (1 to Stage Speed Press Posit. -----(%) (bar) (mm) Core In 50.0 060 102.0 Core Out 50.0 075 270.0
6 or 0-Off) Time Limit (sec) Switch 01.00 LSW19 01.00 LSW20
Unscrewing Motor On Position:000.0 mm On Time :00.00 sec Actual Clamp Position: 216.3 mm Mn:0 Mx:6 New Val: 2 Error message if any..............Page:04
Core Present Stage Status
Core Sequence Number Setting
Unscrewing Motor ON Setting
Valid Range for Selected Data
1) The above screen is PG:04, accessible by pressing or or keys on keypad
2) Password Level Required to Access=01.All CORE/Unscrew motor settings are settable/configurable on this screen. 3) The line above the last line indicates the valid range of values acceptable for the selected particular settable parameter.Eg: Mn=Minimum=0 & Mx=Maximum=6 for CORE Sequence Number 4) The CORE Sequence Number can be set to: 0 = CORE Disabled(OFF) 1 = During Closing, First CORE IN operation takes place & then MOULD CLOSE operation takes place. During Opening, CORE OUT operation takes place & then MOULD OPEN operation takes place. 2 = During Closing, First MOULD CLOSE operation takes place & then CORE IN operation takes place. During Opening, MOULD OPEN operation takes place & then CORE OUT operation takes place. 3 = During Closing, First CORE IN operation takes place & then MOULD CLOSE operation takes place. During Opening, MOULD OPEN operation takes place & then CORE OUT operation takes place. 4 = During Closing, First MOULD CLOSE operation takes place & then CORE IN operation takes place. During Opening, CORE OUT operation takes place & then MOULD OPEN operation takes place. 5 = During Closing, First MOULD CLOSE operation takes place to Set Position, STOPS & then CORE IN operation takes place & then MOULD CLOSES further. During Opening, MOULD OPEN operation takes place to Set Position, STOPS & then CORE OUT operation takes place & then MOULD OPEN further. 6 = During Closing, First MOULD CLOSE operation takes place to Set Position, & then PARALLELY CORE IN operation takes place & then MOULD CLOSES further. During Opening, MOULD OPEN operation takes place to Set Position, PARALLELY & then CORE OUT operation takes place & then Mould OPEN
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ONS Direct Locking/RAM Operating Manual v1.0 May11 Vignan Electronics Pvt. Ltd.
further. 5) In certain dies, where Unscewing motor is required to be operated, the ON position w.r.t the clamp & ON time can be configured. 6) CORE IN is sensed by LSW 19, CORE OUT is sensed by LSW 20. 7) The top line denotes Mould Program Name, Mode of machine operation i.e. Hand/Semi/Auto, Present Date, Day & Time. 8) The last line denotes any machine error condition detected by the PLC. 9) On this screen flow, pressure, position & times are configurable for each stage of hydraulic ejector operation. 10) The line above the last line indicates the valid range of values acceptable for the selected particular settable parameter.Eg: Mn=Minimum=0 & Mx=Maximum=6 for - Core Present Stage. 11) To fine tune any parameter value & keys are pressed to increase or decrease respectively. 12) Actual real-time Set CORE sequence are indicated. 13) Actual Clamp Position are also indicated in mm.
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ONS Direct Locking/RAM Operating Manual v1.0 May11 Vignan Electronics Pvt. Ltd.
AIR EJECTORS SETTINGS PAGE/PG: 05
Moving Platen Section On Delay Setting Stroke ON Time
GANESH AUTO 01-08-2009 Sat 13:27:02 Air Ejectors Present Stage: MP=0 FP=0 Moving Platen Air Blast: Enable Clamp Position : 100.0 mm (Clamp Open) On Delay : 00.00sec Reqd. Strokes : 0 Executed: 0 Stroke On Time : 00.00 Off Time: 00.00 Fixed Platen Air Blast: Disable On Delay : 00.00 sec Reqd. Strokes : 0 Executed:0 Stroke On Time : 00.00 Off Time: 00.00 Actual Clamp Position: 216.3 mm Mn:0 Mx:9 New Val: 5 Error message if any..............Page:07
Moving & Fixed Platen Status Clamp Position Setting Required. Strokes Setting Fixed Platen Section
Valid Range for Selected Data
1) The above screen is PG:05, accessible by pressing or keys on keypad
2) Password Level Required to Access=01.MOVING/FIXED AIR EJECTOR settings are settable/configurable on this screen. 3) The line above the last line indicates the valid range of values acceptable for the selected particular settable parameter.Eg: Mn=Minimum=0 & Mx=Maximum=9 for -Air Blast Required Strokes. 4) The two air ejectors, Moving Platen Air Blast/Fixed Platen Air Blast can be set “Enable”/ “Disable”. 5) ON DELAY, i.e. Total Time to keep the air ejector operation ON can be configurable in seconds. 6) REQUIRED STROKES, i.e. Number of times the air ejector pumps air can be configurable. 7) STROKE ON TIME, i.e. Time to keep the air blast ON can be configurable in seconds. 8) STROKE OFF TIME, i.e. Time to keep the air blast OFF can be configurable in seconds. 9) Whether the Moving Platen Air Ejectors/Fixed Platen Air Ejectors are Enabled (MP=1, FP=1)/Disabled (MP=0, FP=0) is indicated on the second line. 10) Actual Clamp Position is also indicated in mm. 11) The line above the last line indicates the valid range of values acceptable for the selected particular settable parameter.Eg: Mn=Minimum=0 & Mx=Maximum=0 for -No. of strokes Set . 12) To fine tune any parameter value & keys are pressed to increase or decrease respectively. 13) The top line denotes Mould Program Name, Mode of machine operation i.e. Hand/Semi/Auto, Present Date, Day & Time. 14) The last line denotes any machine error condition detected by the PLC.
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ONS Direct Locking/RAM Operating Manual v1.0 May11 Vignan Electronics Pvt. Ltd.
INJECTION SETTINGS PAGE/PG: 06 Injection Mode Selection
Intrugen Setting
GANESH AUTO 01-08-2009 Sat 13:27:02 Intrugen & Injection Profile Data– Injection Mode : Position Lin.Pot. Total Inj.Time : 005.00 sec Stage Speed Press Position Time (%) (bar) (mm) (sec) Intrugen 50.0 065 240.0 01.00 Injection1 60.0 070 130.0 01.00 Injection2 75.0 070 080.0 01.00 Injection3 60.0 065 040.0 01.00 Injection4 60.0 065 000.0 01.00 Act.Speeds: 320 234 530 454 354 mm/s Actual Screw Position : 232.0 mm Mn:Position Mx:Time New Val:Position Error message if any...............Page:06
Total Injection Time Setting
Time settings for each stage during Time Mode
Valid Range for Selected Data
1) The above screen is PG:06, accessible by pressing key on keypad 2) Password Level Required to Access=01.All Injection Operation settings are settable/configurable on this screen. 3) On this screen flow, pressure, position & times are configurable for each stage of Injection operation. 4) The Injection Operation can be settable to operate in Position or Time Mode. 5) When Position Mode selected, the Injection operates as per the set position. 6) When Time Mode selected, the Injection operates as per the set time. 7) The total maximum Injection Time can be settable for Time Mode in terms of seconds. 8) The top line denotes Mould Program Name, Mode of machine operation i.e. Hand/Semi/Auto, Present Date, Day & Time. 9) The type of Injection Position Sensor (“Linear Potentiometer”/”Limit switch”) is machine manufacturer settable from PG: 28. This is indicated on the third line of the screen. 10) The line above the last line indicates the valid range of values acceptable for the selected particular settable parameter.Eg: Mn=Minimum=0 & Mx=Maximum=0 for -No. of strokes Set . 11) To fine tune any parameter value & keys are pressed to increase or decrease respectively. 12) The last line denotes any machine error condition detected by the PLC. 13) Actual Speeds for all stages of Injection operation are indicated in terms of mm/s 14) Actual Screw Position is also indicated in mm.
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ONS Direct Locking/RAM Operating Manual v1.0 May11 Vignan Electronics Pvt. Ltd.
HOLD ON SETTINGS PAGE/PG: 07 GANESH AUTO 01-08-2009 Sat 13:27:02 Hold On (RIP) Speed Pressure Time ----(%) (bar) (sec) Hold On-1 40.0 050 00.50 Hold On-2 ---040 00.50 Hold On-3 ---030 00.50 Init Decom 00.0 000 0.00
Hold ON Timing Setting
Full Auto Cycle Select: Disable
Actual Hold On Time : 00.00 sec. Act.Speeds: 000 000 000 000 mm/s Actual Screw Position : 000.0 mm Mn:Enable Mx:Disable New Val: Enable Error message if any..............Page:07
Actual Hold ON Time Selection
Valid Range for Selected Data
1) The above screen is PG: 07, accessible by pressing & then key on keypad.
2) Password Level Required to Access=01.All Hold On Function settings & Special function: Full Auto Cycle Protect are settable/configurable on this screen. 3) On this screen flow, pressure, & times are configurable for each stage of Hold ON operation. 4) Full Auto Cycle Select can be settable to “Enable”/“Disable”. Enabling this function under supervisor password level will disallow Auto Cycle to protect Mould Die life. 5) Actual Speeds for all stages of Hold ON operation are indicated in terms of mm/s 6) The line above the last line indicates the valid range of values acceptable for the selected particular settable parameter.Eg: Mn=Minimum=Enable & Mx=Maximum=Disable for -Full Auto Cycle Select . 7) To fine tune any parameter value & keys are pressed to increase or decrease respectively. 8) Actual Hold ON Time is indicated in terms of seconds. 9) Actual Screw Position is also indicated in mm. 10) The last line denotes any machine error condition detected by the PLC.
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ONS Direct Locking/RAM Operating Manual v1.0 May11 Vignan Electronics Pvt. Ltd.
REFILL SETTING PAGE/PG: 8 Refill & Suckback Mode Selection
Suckback 1 Enable/Disable
Suckback 2 Enable/Disable
GANESH AUTO 01-08-2009 Sat 13:27:02 Refill + Suckback Mode: Position Cooling Time : 005:00 sec Stage Sel Speed Press Posit. Time ----(%) (bar) (mm) (sec) Suckback1 0 00.0 000 000.0 00.00 Refill 1 65.0 075 070.0 01.00 Refill 2 60.0 070 150.0 00.00 Refill 3 55.0 060 220.0 00.00 Suckback2 0 60.0 065 300.0 00.00 Back Pressure Solenoid: Disable Act.Speeds: 234 230 234 342 332 mm/s Actual Screw Position : 231.2 mm Mn:0 Mx:1 New Val: 1 Error message if any.............Page:10
Total Cooling Time Setting
Refill Backpressure Solenoid Enable/Disable
Valid Range for Selected Data
1) The above screen is PG:08, accessible by pressing or keys on keypad
2) Password Level Required to Access=01.All Refill & Suckback 1 /2 Operation settings are settable/configurable on this screen. 3) On this screen flow, pressure, position & times are configurable for each stage of Refill, Suckback operations. 4) On this screen, Directional solenoid valve can be configurable for Refill Back Pressure operations. 5) Suckback 1 /2 can be enabled or disabled by setting corresponding parameter 1 or 0. 6) The Refill & Suckback Operations can be settable to operate in Position or Time Mode. 7) When Position Mode selected, the Refill function operates as per the set position. 8) When Time Mode selected, the Refill function operates as per the set time. 9) The total maximum Cooling Time can be settable here in terms of seconds. This parameter can also be settable from Timers page PG:12 10) The top line denotes Mould Program Name, Mode of machine operation i.e. Hand/Semi/Auto, Present Date, Day & Time. 11) The line above the last line indicates the valid range of values acceptable for the selected particular settable parameter.Eg: Mn=Minimum=0 & Mx=Maximum=1 for SuckBack1 . 12) To fine tune any parameter value & keys are pressed to increase or decrease respectively. 13) The last line denotes any machine error condition detected by the PLC. 14) Actual Speeds for all stages of Refill operation are indicated in terms of mm/s 15) Actual Screw Position is also indicated in mm.
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ONS Direct Locking/RAM Operating Manual v1.0 May11 Vignan Electronics Pvt. Ltd.
CARRIAGE PAGE SETTING/PG: 09
Carriage Move Selection
GANESH AUTO 01-08-2009 Sat 13:27:02 Carriage (Unit) Setting Data Speed Press Time (%) (bar) (sec) Fast Farward 40.0 050 2.00 Slow Farward 30.0 040 ---Fast Retract 40.0 050 2.00 Slow Retract 40.0 040 1.00 Carriage Mode Select : Fixed Carriage Move Select : After Refill Car. Fwd During Refil/Suckback: Disable
Carriage Mode Selection Carriage Forward Enable/Disable
Mn:Fixed Mx:Moving New Val: Fixed Error message if any..............Page:09
1) The above screen is PG:09, accessible by pressing or key on keypad 2) Password Level Required to Access=01.All Carriage Movement Operation settings are settable/configurable on this screen. 3) On this screen flow, pressure & times are configurable for each stage of Carriage operation. 4) The Carriage Operation can be settable to operate in Time Mode. 5) The Carriage Movement Function can be enabled/disabled by setting Carriage Mode Select to Moving/Fixed respectively. 6) The time point of Refill function when the Carriage movement operates is set by Carriage Move Select. 7) The Carriage Forward function during Refill/Suckback can be Enabled/Disabled. 8) The top line denotes Mould Program Name, Mode of machine operation i.e. Hand/Semi/Auto, Present Date, Day & Time. 9) The line above the last line indicates the valid range of values acceptable for the selected particular settable parameter.Eg: Mn=Minimum=Fixed & Mx=Maximum=Moving for - Carriage Movement Function. 10) To fine tune any parameter value & keys are pressed to increase or decrease respectively. 11) The last line denotes any machine error condition detected by the PLC.
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ONS Direct Locking/RAM Operating Manual v1.0 May11 Vignan Electronics Pvt. Ltd.
HEATERS SETTING PAGE/PG: 10
Zone Setting
Nozzle Duty Cycle Setting
GANESH AUTO 01-08-2009 Sat 13:27:02 Heaters Setting:Zone Set Duty Low High Act. No. Temp % Alarm Alarm Temp Zone 1 000 00 -20 < +10 000 Zone 2 000 00 -20 < +10 000 Zone 3 000 00 -20 < +10 000 Zone 4 000 00 -20 < +10 000 Zone 5 000 00 -20 < +10 000 Hyd.Oil 20 --55 000 Hydraulic Oil Preheating: Disable Nozzle Duty Cycle: 00% ----Minimum Injection Temp. : 100 Deg.C Mn:Enable Mx:Disable New Val: Enable Error message if any..............Page:10
Actual Temperatures
Valid Range for Selected Data
1) The above screen is PG:10, accessible by pressing key on keypad 2) Password Level Required to Access=01.All Heater Zones, Nozzle & Hydraulic Oil Temperature settings are settable/configurable on this screen.
3) PLC Digital Outputs 25-29 are assigned to Zone1-Zone5 Heating zones. 4) All Zones can also be operated either in Duty Cycle % mode i.e. Timing or a Closed Loop i.e. Sensor manner. This mode can be set from PG: 11. 5) Duty Cycle % can be configurable for each zone & Nozzle from 00 to 99%. 6) Low & High Alarms Limits can be set with respect to Production Temperature. 7) Zone 6 can be configured to be either a regular Heating Zone or for monitoring Hydraulic Oil only. This can be set from PG: 11. 8) Hydraulic Oil Preheating can be Enabled/Disabled here. 9) Only High Alarms Limit can be set for Hydraulic Oil in this screen. 10) Only Duty Cycle can be configurable for Nozzle. Duty Cycle for Nozzle can also be set on PG: 11. For Nozzle heating usage, Output 30 should be used. 11) Minimum Injection Temperature at which the Injection can take place can also be defined here. 12) The top line denotes Mould Program Name, Mode of machine operation i.e. Hand/Semi/Auto, Present Date, Day & Time. 13) The line above the last line indicates the valid range of values acceptable for the selected particular settable parameter.Eg: Min=Minimum=Enable & Mx=Maximum=Disable for - Hydraulic Oil Preheating. 14) To fine tune any parameter value & keys are pressed to increase or decrease respectively. 15) The last line denotes any machine error condition detected by the PLC. 16) Actual Temperatures for all Heating Zones are indicated in terms of Degree Celsius.
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ONS Direct Locking/RAM Operating Manual v1.0 May11 Vignan Electronics Pvt. Ltd.
HEATER SELECTION PAGE/PG: 11 Sensor Present/Absent Setting
Nozzle %
Zone is Open/Close control
GANESH AUTO 01-08-2009 Sat 13:27:02 Heater Sel.Data:- On High Alarm: Run M/C Zone.No: Sensor Operation Output -------Select Method Duty % Zone-1 Present Close 70 Zone 2 Present Close 60 Zone 3 Absent Open 50 Zone 4 Present Close 40 Zone 5/HyOil Absent Open 30 Nozzle ----------80 Temp.Sensor-5 Is Used for: Zone 5 Note: Only One of Zone-5 or Hyd.Oil can be Used at Any One Time. Mn:00 Mx:99 New Val: 50 Error message if any.............Page:11
Machine Operation on High alarm
Duty cycle for each zone
Sensor 5 mode Selection
Valid Range for Selected Data
1) The above screen is PG:11, accessible by pressing & then key twice on keypad.
2) Password Level Required to Access=02.All Heater Zones, Nozzle & Hydraulic Oil Temperature Sensors & Duty cycle are settable/configurable on this screen. 3) PLC Digital Outputs 25-29 are assigned to Zone1-Zone5 Heating zones. 4) All Zones can also be operated either in Duty Cycle % mode i.e. Timing or a Closed Loop i.e. with Sensor manner. This can be configured by setting the Sensor Select for each zone.
5) Machine operation condition can be configured on detection of high alarm on any of the Temperature Zones. 6) Machine can either be selected Running or Stopped on High temperature detection. 7) To operate heater/s in Closed loop mode i.e. with sensor, set Sensor Select=Present & Operation Method= Close.
8) To operate heater/s in Open loop mode i.e. without sensor, set Sensor Select=Absent & Operation Method= Open & set corresponding Duty cycle %. 9) Duty Cycle % can be configurable for each zone & Nozzle from 00 to 99%. 10) Zone 5 can be configured to be either a regular Heating Zone or for monitoring Hydraulic Oil only. The option selected is indicated on the Home Page also. 11) Only Duty Cycle can be configurable for Nozzle. Duty Cycle for Nozzle also is set from PG:10. For Nozzle heating usage, Output 30 should be used. 12) The top line denotes Mould Program Name, Mode of machine operation i.e. Hand/Semi/Auto, Present Date, Day & Time. 13) The line above the last line indicates the valid range of values acceptable for the selected particular settable parameter.Eg: Mn=Minimum=00 & Mx=Maximum=99 for –
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ONS Direct Locking/RAM Operating Manual v1.0 May11 Vignan Electronics Pvt. Ltd.
Output Duty %.
14) To fine tune any parameter value INC & DEC keys are pressed to increase or decrease respectively.
15) The last line denotes any machine error condition detected by the PLC.
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ONS Direct Locking/RAM Operating Manual v1.0 May11 Vignan Electronics Pvt. Ltd.
TIMERS SETTINGS PAGE/PG: 12 Set Timing for each stage
GANESH AUTO 01-08-2009 Sat 13:27:02 Timers (Seconds) Set Actual 1. Car. Farward Delay: 0.10 0.10 2 Injection Delay: 0.10 0.11 3. Total Inject. Time : 005.00 005.00 4. Car. Retract Delay: 0.10 0.10 5. Refill/Dosing Delay: 0.10 0.10 6. Cooling Time : 005.00 005.00 7. Ejector Start Delay: 0.10 0.10 8. Ejector Forward Dly: 0.10 0.10 9. Cycle Delay Time : 01.00 1.02 10.Total Cycle Time : 100.00 11.53 Mn:000.00 Mx:999.9 New Val: 100.00 Error message if any.................Page:12
Actual Timing
Valid Range for Selected Data
1) The above screen is PG:12, accessible by pressing & then key on keypad.
2) Password Level Required to Access=01.All Stage Operation & Cycle Timings (Delays) are settable/configurable on this screen. 3) All timings & delays are specified in terms of seconds. 4) Ejector Starting Delay as well as Forward Delay can be set to provide a smooth & non-jerk hydraulic ejector movement. 5) The line above the last line indicates the valid range of values acceptable for the selected particular settable parameter.Eg: Mn=Minimum=000.00 & Mx=Maximum=999.99 for – Total Cycle time. 6) To fine tune any parameter value & keys are pressed to increase or decrease respectively. 7) The top line denotes Mould Program Name, Mode of machine operation i.e. Hand/Semi/Auto, Present Date, Day & Time. 8) The last line denotes any machine error condition detected by the PLC.
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ONS Direct Locking/RAM Operating Manual v1.0 May11 Vignan Electronics Pvt. Ltd.
SERVICE MENU PAGE/PG: 14
GANESH AUTO 01-08-2009 Sat 13:27:02 Service Menu Selection - ? 1. Digital Input Status 2. Digital Output Status 3. Lin.Transducer & RTD Calibration 4. Speed & Pressure Calibration 5. Maximum Values 6. Real Time Clock Setting 7. Manufacture Settings 8. Transferring & Checking of Outputs 9. History (Counters,Prod.Data etc) Mn:1 Mx:9 New Val: 5 Error message if any...............Page:14
1) The above screen is PG:14, accessible by pressing key on keypad. 2) Password Level Required to Access=02.All service oriented items like PLC 3) 4)
5) 6) 7)
Inputs/Outputs Status, Sensor calibration, Real Time clock, Machine Settings, Maximum values of all variables can be selected from this page. As per the required item choice from the menu list, one has to enter values between 1-9. The user will be redirected automatically to the page of valid choice entered. The line above the last line indicates the valid range of values acceptable for the selected particular settable parameter.Eg: Mn=Minimum=1 & Mx=Maximum=9 for – Service Menu Selection. The top line denotes Mould Program Name, Mode of machine operation i.e. Hand/Semi/Auto, Present Date, Day & Time. The last line denotes any machine error condition detected by the PLC.
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ONS Direct Locking/RAM Operating Manual v1.0 May11 Vignan Electronics Pvt. Ltd.
INPUTS PORT-1 STATUS PAGE/PG: 15
Inputs List
GANESH AUTO 01-08-2009 Sat 13:27:02 Input Status - (Field Inputs) - Port: 1 LSW01 Mould Open Limit.............OFF LSW02 Mould Close Fast End.......ON LSW03 Mould Close Safety Start......OFF LSW04 Mould Close Safety End........ON LSW05 Intensifier-1 Stage End(PS1)...OFF LSW06 Intensifier-2 Stage End(PS2)...ON LSW07 Mould Decompression End(PS3)...OFF LSW08 Mould Open Fast End........ON All Inputs:00000000 01111111 11122222 12345678 90123456 78901234 01010101 00000000 00000000 Error message if any..............Page:15
Status of Inputs
Input Status of all 24 DI
1) The above screen is PG:15, accessible by pressing key on keypad & selection Option 1.
2) Password Level Required to Access=02.All Inputs from Port:1 i.e. Digital Inputs 01-08 status can be viewed from this page. 3) An “ON” Status indicates PLC is sensing the corresponding signal at the instant. 4) An “OFF” Status indicates PLC is not sensing the corresponding signal at the instant. 5) All Digital Inputs 01-24 status can also be viewed at the bottom of the screen by vertically reading the Input number and checking whether it is '0' or '1'. 6) A '0' indicates that Input is OFF while a '1' indicates Input is ON. 7) No values are settable/configurable on this screen. 8) The top line denotes Mould Program Name, Mode of machine operation i.e. Hand/Semi/Auto, Present Date, Day & Time. 9) The last line denotes any machine error condition detected by the PLC.
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ONS Direct Locking/RAM Operating Manual v1.0 May11 Vignan Electronics Pvt. Ltd.
INPUTS PORT-2 STATUS PAGE/PG: 16 GANESH AUTO 01-08-2009 Sat 13:27:02 Input Status - (Field Inputs) - Port: 2 LSW09 Ejector Forward Limit...........OFF LSW10 Ejector Retract Limit...........ON LSW11 Front Safety Guard..............ON LSW12 Rear Safety Guard..............OFF LSW13 Carriage Forward Limit..........ON LSW14 Carriage Retract Limit..........ON LSW15 RIP Start Position..............OFF LSW16 Dosing/Refill End...............OFF All Inputs:00000000 01111111 11122222 12345678 90123456 78901234 00000000 01101100 00000000 Error message if any..............Page:16
Status of Inputs
Input Status of all 24 DI
1) The above screen is PG:16, accessible by pressing key on keypad & selection Option 1 & then
2) Password Level Required to Access=02.All Inputs from Port:2 i.e. Digital Inputs 09-16 status can be viewed from this page. 3) An “ON” Status indicates PLC is sensing the corresponding signal at the instant. 4) An “OFF” Status indicates PLC is not sensing the corresponding signal at the instant. 5) All Digital Inputs 01-24 status can also be viewed at the bottom of the screen by vertically reading the Input number and checking whether it is '0' or '1'. 6) A '0' indicates that Input is OFF while a '1' indicates Input is ON. 7) No values are settable/configurable on this screen. 8) The top line denotes Mould Program Name, Mode of machine operation i.e. Hand/Semi/Auto, Present Date, Day & Time. 9) The last line denotes any machine error condition detected by the PLC.
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ONS Direct Locking/RAM Operating Manual v1.0 May11 Vignan Electronics Pvt. Ltd.
INPUTS PORT-3 STATUS PAGE/PG: 17 GANESH AUTO 01-08-2009 Sat 13:27:02 Input status- (Field Inputs) - Port: 3 LSW17 Suck Back End...................OFF LSW18 Spare............................ON LSW19 Core In Limit..................OFF LSW20 Core Out Limit..................ON LSW21 Spare...........................OFF LSW22 Screw Speed Sensor (Proxy)......ON LSW23 Electric Motor On Input.........OFF LSW24 Emergency Push Button (NC)......ON All Inputs:00000000 01111111 11122222 12345678 90123456 78901234 00000000 00000000 01010101 Error message if any..............Page:17
1) The above screen is PG:17, accessible by pressing key on keypad & selection Option 1 & then twice.
2) Password Level Required to Access=02.All Inputs from Port: 3 i.e. Digital Inputs 17-24 status can be viewed from this page. 3) An “ON” Status indicates PLC is sensing the corresponding signal at the instant. 4) An “OFF” Status indicates PLC is not sensing the corresponding signal at the instant. 5) All Digital Inputs 01-24 status can also be viewed at the bottom of the screen by vertically reading the Input number and checking whether it is '0' or '1'. 6) A '0' indicates that Input is OFF while a '1' indicates Input is ON. 7) No values are settable/configurable on this screen. 8) The top line denotes Mould Program Name, Mode of machine operation i.e. Hand/Semi/Auto, Present Date, Day & Time. 9) The last line denotes any machine error condition detected by the PLC.
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ONS Direct Locking/RAM Operating Manual v1.0 May11 Vignan Electronics Pvt. Ltd.
KEYPAD CHECK PAGE/PG: 18 GANESH AUTO 01-08-2009 Sat 13:27:02 Input Status-(Bits for keyboard keys) Dig0 Dig1 Dig2 Dig3 Dig4 Dig5 Dig6 Dig7
Dig8 Dig9 ENTR CLR LEFT RIGH DOWN UP
SAVE MTR ------SET HAND SEMI AUTO
PGDN PGUP FUN DIR SERV HOME LOCK ----
SKBK INJE CRIN CROT MCLS MOPN -------
RFLL HTRS LUBR UNSC EJFW EJRT -------
IURE IUFA FPAB MPAB MHTMHT+ -------
Press to change this page Error message if any..............Page:18
1) The above screen is PG:18, accessible by pressing key on keypad & selection Option 2 & then
2) Password Level Required to Access=02.All MMI keys can be checked for proper functionality from this page. 3) When a key is pressed/hit, the corresponding key text is highlighted & flashed along with a buzzer tone. 4) No values are settable/configurable on this screen. 5) To exit this page & return to home screen, one has to press & keys together. 6) The top line denotes Mould Program Name, Mode of machine operation i.e. Hand/Semi/Auto, Present Date, Day & Time. 7) The last line denotes any machine error condition detected by the PLC.
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ONS Direct Locking/RAM Operating Manual v1.0 May11 Vignan Electronics Pvt. Ltd.
OUTPUTS PORT-1 STATUS PAGE//PG: 19
Outputs List
GANESH AUTO 01-08-2009 Sat 13:27:02 Output Status - (Field Outputs) - Port:1 V01 Mould Close....................ON V02 Mould Open ....................ON V03 Injection......................ON V04 Suck Back......................ON V05 Refill/Dosing..................OFF V06 Carriage Forward...............OFF V07 Carriage Retract...............OFF V08 Back Pressure (During Refill)..OFF All Outputs:00000000 01111111 11122222 22222333 12345678 90123456 78901234 56789012 11110000 00000000 00000000 00000000 Error message if any.............Page:19
Status of Outputs
Status of 32 Outputs
1) The above screen is PG:19, accessible by pressing key on keypad & selection Option 2.
2) Password Level Required to Access=02.All Outputs from Port:1 i.e. Digital Outputs 0108 status can be viewed from this page. 3) An “ON” Status indicates PLC is outputting the corresponding signal at the instant. 4) An “OFF” Status indicates PLC is not outputting the corresponding signal at the instant. 5) All Digital Outputs 01-32 status can also be viewed at the bottom of the screen by vertically reading the Input number and checking whether it is '0' or '1'. 6) A '0' indicates that Output is OFF while a '1' indicates Output is ON. 7) No values are settable/configurable on this screen. 8) The top line denotes Mould Program Name, Mode of machine operation i.e. Hand/Semi/Auto, Present Date, Day & Time. 9) The last line denotes any machine error condition detected by the PLC.
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ONS Direct Locking/RAM Operating Manual v1.0 May11 Vignan Electronics Pvt. Ltd.
OUTPUTS PORT-2 STATUS PAGE/PG: 20 GANESH AUTO 01-08-2009 Sat 13:27:02 Output Status - (Field Outputs) - Port:2 V09 Ejector Forward..................OFF V10 Ejector Retract..................OFF V11 Prefill Valve....................OFF V12 Mould Close/Open Fast............OFF V13 Intensifier-1....................ON V14 Intensifier-2....................ON V15 Small Pump (H.P.) Vent...........ON V16 Big Pump (L.P.) Vent...........ON All Outputs:00000000 01111111 11122222 22222333 12345678 90123456 78901234 56789012 00000000 00001111 00000000 00000000 Error message if any.............Page:20
1) The above screen is PG:20, accessible by pressing key on keypad & selection Option 2 & then .
2) Password Level Required to Access=02.All Outputs from Port:2 i.e. Digital Outputs 09-16 status can be viewed from this page. 3) An “ON” Status indicates PLC is outputting the corresponding signal at the instant. 4) An “OFF” Status indicates PLC is not outputting the corresponding signal at the instant. 5) All Digital Outputs 01-32 status can also be viewed at the bottom of the screen by vertically reading the Input number and checking whether it is '0' or '1'. 6) A '0' indicates that Input is OFF while a '1' indicates Input is ON. 7) No values are settable/configurable on this screen. 8) The top line denotes Mould Program Name, Mode of machine operation i.e. Hand/Semi/Auto, Present Date, Day & Time. 9) The last line denotes any machine error condition detected by the PLC.
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ONS Direct Locking/RAM Operating Manual v1.0 May11 Vignan Electronics Pvt. Ltd.
OUTPUTS PORT-3 STATUS PAGE/PG: 21
GANESH AUTO 01-08-2009 Sat 13:27:02 Output Status - (Field Outputs) - Port:3 V17 Moving Platen Air Blast.........OFF V18 Fixed Platen Air Blast.........OFF V19 Core In (Forward)............OFF V20 Core Out (Retract)............OFF V21 Unscrewing......................OFF V22 Lubrication Pump Start..........OFF V23 Spare (User Defined)............OFF V24 Hooter..........................OFF All Outputs:00000000 01111111 11122222 22222333 12345678 90123456 78901234 56789012 00000000 00000000 00000000 00000000 Error message if any.............Page:21
1) The above screen is PG:21, accessible by pressing key on keypad & selection Option 2 & then key twice.
2) Password Level Required to Access=02.All Outputs from Port:3 i.e. Digital Outputs 173) 4)
5) 6) 7) 8)
9)
24 status can be viewed from this page. An “ON” Status indicates PLC is outputting the corresponding signal at the instant. An “OFF” Status indicates PLC is not outputting the corresponding signal at the instant. All Digital Outputs 01-32 status can also be viewed at the bottom of the screen by vertically reading the Input number and checking whether it is '0' or '1'. A '0' indicates that Input is OFF while a '1' indicates Input is ON. No values are settable/configurable on this screen. The top line denotes Mould Program Name, Mode of machine operation i.e. Hand/Semi/Auto, Present Date, Day & Time. The last line denotes any machine error condition detected by the PLC.
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ONS Direct Locking/RAM Operating Manual v1.0 May11 Vignan Electronics Pvt. Ltd.
OUTPUTS PORT-4 STATUS PAGE/PG: 22
GANESH AUTO 01-08-2009 Sat 13:27:02 Output Status - (Field Outputs) - Port:4 V25 Zone-1 Temperature Contactor.....ON V26 Zone-2 Temperature Contactor.....ON V27 Zone-3 Temperature Contactor.....ON V28 Zone-4 Temperature Contactor.....ON V29 Zone-5 Temperature Contactor.....ON V30 Nozzle Temperature Contactor.....ON V31 Electric Motor Start Enable......ON V32 Transferable Output..............ON All Outputs:00000000 01111111 11122222 22222333 12345678 90123456 78901234 56789012 00000000 00000000 00000000 11111111 Error message if any.............Page 22
1) The above screen is PG:22, accessible by pressing key on keypad & selection Option 2 & then key thrice. 2) Password Level Required to Access=02.All Outputs from Port:4 i.e. Digital Outputs 2532 status can be viewed from this page. 3) An “ON” Status indicates PLC is outputting the corresponding signal at the instant. 4) An “OFF” Status indicates PLC is not outputting the corresponding signal at the instant. 5) All Digital Outputs 01-32 status can also be viewed at the bottom of the screen by vertically reading the Input number and checking whether it is '0' or '1'. 6) A '0' indicates that Input is OFF while a '1' indicates Input is ON. 7) Output V32 can be used for transferring any of the existing output from PG:29. 8) No values are settable/configurable on this screen. 9) The top line denotes Mould Program Name, Mode of machine operation i.e. Hand/Semi/Auto, Present Date, Day & Time. 10) The last line denotes any machine error condition detected by the PLC.
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ONS Direct Locking/RAM Operating Manual v1.0 May11 Vignan Electronics Pvt. Ltd.
SENSOR CALIBRATION PAGE/PG: 23
Count value
Zero Setting
Span Setting
GANESH AUTO 01-08-2009 Sat 13:27:20 Analog Input Calibration Channel: Count Zero Span Value Clamp Scale: 3619 0000 5000 441.0mm Screw Scale: 3628 0000 4000 345.0mm Zone-1 RTD: 2800 0000 3000 319.0°C Zone-2 RTD: 0956 0800 4000 023.0 C Zone-3 RTD: 1045 0800 4000 024.0°C Zone-4 RTD: 1245 0800 4000 300.0°C Zone-5/HydOil: 2217 0800 4000 300.0°C Pres.Trans: 2210 0800 4000 300.0bar
Sensor Channels
Actual Values of Sensor reading
Mn:1000 Mx:4000 New Val: 4000 Error message if any.............Page:27
1) The above screen is PG:23, accessible by pressing key on keypad & selection Option 3.
2) Password Level Required to Access=03.All Temperature Sensors and Linear Potentiometer Scales connected to the PLC are calibrated from this page.
3) The four columns i.e. Count, Zero, Span & Value against each sensor form the basis of 4) 5)
6) 7)
calibration. Only Zero & Span columns are settable/configurable. Count & Actual Values columns are for monitoring purposes. To calibrate any sensor for the first time: a. Make the sensor reading minimum, ideally to zero(check from Actual Value column) b. Now observe the Count value from the Count column against the sensor, & enter the 4-digit count number into Zero column against the sensor. c. Now make the sensor reading maximum as per the required application (check from Actual Value column) d. Now observe the Count value against the sensor from the Count column, & enter the 4-digit count number into Span column against the sensor. e. Now, turn back the sensor to its minimum reading, ideally to zero(check from Actual Value column) & check whether the actual value reflects the minimum value(Zero).If not redo Step(b) f. Now, turn back the sensor to maximum reading as per the required application (check from Actual Value column) & check whether the actual value reflects the maximum value. If not redo Step(d). The last line denotes any machine error condition detected by the PLC. IMPORTANT: All unused ADC channels should be looped between + & -
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ONS Direct Locking/RAM Operating Manual v1.0 May11 Vignan Electronics Pvt. Ltd.
ANALOG OUTPUT CALIBRATION SETTING PAGE/PG: 24 Flow Calibration
Offset correction/fine tuning
Pressure Calibration
GANESH AUTO 01-08-2009 Sat 13:27:02 Linearise DAC Outputs:- Curve Fitting) Voltage Flow DAC Press DAC 0.00 00.00 00.00 2.00 02.00 02.00 4.00 04.00 04.00 6.00 06.00 06.00 8.00 08.00 08.00 10.00 09.99 09.99 Offset 0.50 0.40 Act. O/P: 05.50 09.50 Volts
Actual Analog Output
Error message if any.............Page:24
1) The above screen is PG:24, accessible by pressing key on keypad & selection Option 4.
2) Password Level Required to Access=03.The 2 analog outputs/PWM outputs of the PLC are calibrated from this page only by the machine manufacturer.
3) Each analog outputs gives out a voltage output in range of 0 to +10 VDC. 4) DAC1 channel corresponds to required Flow output while DAC2 channel corresponds to required Pressure output during each stage of machine operation. By default, all DAC channels are linearly calibrated i.e. 50% of a analog parameter(Flow/Pressure) outputs 5V of magnitude. 6) To reduce the linear calibration scale by 50% i.e. to get a maximum magnitude of 5V at 99.99% of an analog parameter(Flow/Pressure); one can recalibrate the DAC column scale as follows: Voltage DAC1 0.00 00.00 2.00 01.00 4.00 02.00 6.00 03.00 8.00 04.00 10.00 05.00 5)
7) The actual voltages generated & outputted at the DAC channels outputs is shown at the end of the calibration table. 8) To fine tune or allow correction margin on the end output voltage one can set the Offset value for the required DAC channel. 9) Any settings made on this screen required a restart of the PLC. 10) The last line denotes any machine error condition detected by the PLC.
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ONS Direct Locking/RAM Operating Manual v1.0 May11 Vignan Electronics Pvt. Ltd.
MAXIMUM VALUES 1 SETTING PAGE/PG: 25 Max. Flow Setting
Operation Stage
Max. Pressure Setting
GANESH AUTO 01-08-2009 Sat 13:27:20 Maximum Values 1 Speed Press Operation Speed Press Delay Delay -------(%) (bar) (msec) (msec) 1.Mold Cls/Open 99.9 140 010 010 2.Safety 99.9 140 010 010 3.Intensifier-1 99.9 140 010 010 4.Intensifier-2 99.9 140 010 010 5.Carriage 99.9 140 010 010 6.Injection 99.9 140 010 010 7.Refill 99.9 140 010 010 8.Suckback 99.9 140 010 010 9.Ejector 99.9 140 010 010 10.Cores 99.9 140 010 010 Error message if any..............Page:25
Pressure Up Delay
Speed Up Delay
1) The above screen is PG:25, accessible by pressing key on keypad & 2) 3) 4) 5) 6) 7) 8)
selection Option 5. Password Level Required to Access=03. All maximum values/upper limit for flow & pressure for each stage of machine operation can be set from this page only by the machine manufacturer. The maximum possible limit for pressure is prefixed by the machine manufacturer on PG:28/Manufacturer Settings. Up Ramping/Acceleration: How fast in time a parameter(Flow/Pressure) reaches its set point from zero. The Up Ramping times for each stage of machine operation can be set from this page only by the machine manufacturer. The Up Ramping times can be set in range of 010 to 999 milliseconds. The last line denotes any machine error condition detected by the PLC.
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ONS Direct Locking/RAM Operating Manual v1.0 May11 Vignan Electronics Pvt. Ltd.
MAXIMUM VALUES 2 SETTING PAGE/PG:26
GANESH AUTO 01-08-2009 Sat 13:27:20 Max. Values 2 1.Cooling Time : 005.00 sec 2.Total Injec.Time : 300.00 sec 3.Hold on Time : 99.99 sec 4.Cycle Time : 100.00 sec 5.Cycle Delay Time : 05.00 sec SET MODE- Clamp Close/Open Flow:00.0% SET MODE- Clamp Close/Open Pres:000 bar Maximum Main Ram Locking Press:000 bar Main Ram Pressure Adaptive:00.0 bar Mold Open Distance Adaptive:00.0 mm Mn:000.00 Mx:600.00 New Val: 5.00 Error message if any..............Page:26
1) The above screen is PG:26, accessible by pressing key on keypad & selection Option 5 & then key. 2) Password Level Required to Access=03. 3) All maximum values/upper limit for times/delays for different stage of machine operation can be set from this page. 4) Total Cooling Time & Injection Time can also be set from PG:8 & PG:6 respectively. 5) All times/delays are set in terms of seconds. 6) The screen also shows the Mould Open Distance Adaptive done automatically by the PLC over 10 continuous auto cycle shots/upto 25.0mm. 7) The mould open correction is done to prevent moving Mould slip beyond the final opening position. 8) Main Ram Pressure Adaptive display the locking correction control for smooth & quick locking control. 9) This mould opening correction is expressed in millimetres. 10) The last line denotes any machine error condition detected by the PLC.
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ONS Direct Locking/RAM Operating Manual v1.0 May11 Vignan Electronics Pvt. Ltd.
REAL TIME CLOCK SETTING PAGE/PG: 27
GANESH AUTO 01-08-2009 Sat 13:27:20 Real Time Clock Setting:Time : Hours 13
Minutes 27
Date : Date 01
Month 08
Day
Seconds 20 Year 2009
: Saturday
Press Key to set New Time. Mn:00 Mx:23 New Val: 13 Error message if any..............Page:27
1) The above screen is PG:27, accessible by pressing key on keypad & selecting Option 6.
2) Password Level Required to Access=03. Time, Date & Day of the Week can be set on 3) 4)
5) 6) 7)
this page. Time & Date can be set by changing the value, press Key & arrow keys on the keypad. Time is to be set in 24 hour format while Date is to be set in DD-MM-YYYY format Day of Week can be changed by using & keys of the keypad & then pressing key. To put the new time into effect, press key on the keypad. The last line denotes any machine error condition detected by the PLC.
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ONS Direct Locking/RAM Operating Manual v1.0 May11 Vignan Electronics Pvt. Ltd.
MANUFACTURER SETTING PAGE/PG: 28
Max. System Pressure Setting
GANESH AUTO 01-08-2009 Sat 13:27:20 Machine Manufacturer Settings:Core Pull Selection : Disable Air Ejection Selection : Disable Auto Tonnage Selection : Disable Pump Selection (Based on Set Flow):Small Pump On Flow Range>00.1% & 25.1% & 75.0% & 00.1% & 41.7% & 58.4% &
