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BLOW- 01
BLOW MOULDING MACHINE CONTROLLER
The BLOW01 MICROCONTROLLER based controller is capable of controlling stretch blow
moulding machines. The BLOW01 performs the following functions:
1) Thermocouple Heaters
2) Sequence control
3) Production counting
4) Displaying set temp, timing and piece counters.
The BLOW01 consists of the following modules:
MICROCONTROLLER
This module controls the entire system, stores the user settings, displays the desired parameters,
responds to a keyboard activation, performs the timing, counting and logic functions and activates
the outputs based on the status of inputs.
DC INPUTS
This module is connected to external pushbuttons, selector switches, proximity switches, limit
switches and other ON/OFF type of sensors. This module informs the microprocessor of the status of
all switches connected to this module. The BLOW01 supports upto 16 DC INPUTS.
TC INPUTS
This module is connected to the Thermocouple. The J(Fe-K)type thermocouples are supported by the
INJ01.The temperature range is from 00C to 4000C.The voltage of the thermocouple is input to the
Microcontroller, which converts it to the equivalent temperature in degree centigrade.
DC OUTPUTS
This module is connected to the solenoid valves in the system. There are 16 Transistor which are
capable of driving loads of 3 Amps at 24VDC.
THERMOCOUPLE HEATER OUTPUTS
This module is connected to the Heater in the machine. There are 4 heater outputs with low limit and
high limit setting.
KEYBOARD AND DISPLAY
The BLOW01 has a front panel keypad and display. This enables the user to view and set the various
parameters of the machine sequence. The user can continuously monitor the power setting of each
zone, view the active timer, and check the status of all outputs, while the machine cycle is on. In
addition the outputs can be activated from the keypad, in the manual mode. The user can check the
status of the inputs from the front panel.
The list of inputs and outputs and their numbers as supported by the BLOW01 are shown below.
DC INPUTS
00
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
MOULD OPEN I/P
BLOW PIN UP I/P
MOULD OUT I/P
EMERGENCY I/P
MOULD OPEN P/B
MOULD CLOSE P/B
MOULD IN P/B
MOULD OUT P/B
PIN DOWN P/B
EXTRA INPUT
MOULD IN I/P
EXTRUDER I/P
EXTRA I/P
EXTRA I/P
EXTRA I/P
EXTRA I/P
DC OUTPUTS
00
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
MOULD IN
MOULD CLOSE
CUTTER 1
MOULD OUT
BLOW PIN DOWN
BLOWING
MOULD OPEN
BIG PUMP
SMALL PUMP
EXTRUDE MOTOR
CUTTER
HEATER 1
HEATER 2
HEATER 3
HEATER 4
HEATER 5
TC INPUTS
00
01
02
03
ZONE 1
ZONE 2
ZONE 3
ZONE 4
ZONE 1 THERMOCOUPLE INPUT
ZONE 2 THERMOCOUPLE INPUT
ZONE 3 THERMOCOUPLE INPUT
ZONE 4 THERMOCOUPLE INPUT
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FRONT PANEL SETTING
SELECTING THE MOULD (DIE)
The user has an option of setting parameters for thirty different moulds. These parameters can then
be recalled by selecting the corresponding JOB. In order to change the current job setting
Press the JOB key.
The display will show Jb <job number>. If the current job number is 1, the unit will display Jb01
Press the UP or DOWN arrow key to set the desired job number and press ENTER to confirm the
selection.
The parameters programmed earlier for that job will now be used.
SETTING THE TEMERATURE
In INJ01 to set temperature control function, it required 6 parameters to be set. This parameters are
for the set points of the four heater zones, The 5th parameter is low limit and 6th parameter is high
limit. The low limit and high limit parameters desides the temperature range above and below set
points, at which the heater will be off and on respectively .i. e .if the set point is 2000C,and the low
limit set is 200C,then low limit error will be showed on at temp below than 1800C.If high limit is 10
then high limit error will be showd on temp higher than 2100C. The setting parameters are the same
for all the zones. In order to set these parameters, follow the instruction outlined below.
In order to set temperature of each zone, follow the steps outline below
Press the SET TEMP key.
The temperature window will blink the current set temperature for zone1.Also the zone1 led will be
lit.
Press the ENTER key to change this parameter. The most significant digit blinks.
Press the UP or DOWN key to set the blinking digit to the desire value.
Press the RIGHT arrow key.
The first digit stops blinking and the digit to its right starts blinking. Use the UP or DOWN keys, to
set the digit.
Similarly all four digit of this zone are set to their desired values. On completion of this setting, press
the ENTER key. All four digits will blink again.
Press the down key.
The temperature window will blink the current set temperature for zone2.Also the zone 2 led will be
on. Use the procedure listed above, to set the desired temperature for this zone.
Similarly set the remaining zones and parameter also.
In order to exit the temperature setting mode, press the CANCEL key. The temperature window, will
now display, the actual temperature in each of the zones. The display continuosly shows the
temperature for the zones, one after the other.
The ejector stroke setting is given
TC OPEN
In case of breakage of the thermocouple connection to the unit temperature display for that zone will
be 1 and the heater is switched off.
TC REVERSE
In case of the thermocouple is connected reverse, the display will start decrementing from room
temperature, as long as the heater is on. At some point, the temperature will be less than zero. The
display will show that the temperature is negative sign to the left most significant digit. The heater
will be switched off, till the temperature is positive again.
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TIMER SETTINGS
The following timers which are used in auto mode have to be set by the user.
1. MOULD IN DELAY
2. MOULD CLOSE DELAY
3. CUTTER DELAY
4. CUTTER ON TIME
5. PIN DOWN DELAY
6. AIR THROW DELAY
7. BLOW DELAY
8. BLOWING TIME
9. EXHAUST TIME
10. THROW ON TIME
11. MOULD IN TIME
12. MOULD CLOSE TIME
13. SEALING DELAY
14. SEALING TIME
15. EXTRA TIMER
16. EXTRA TIMER
These timers are set in multiples of 0.01 seconds, and have a maximum value of 99.99 seconds. In
order to set the timers, follow the procedure described below.
Press the SET TIMER key to initiate programming of the various timers.
The current value of mould slow delay will be displayed in the timer window.
Press the ENTER key to change this parameter. The cursor blinks at the most significant digit.
Press the UP or DOWN key to set the blinking digit to the desired value.
Press the RIGHT arrow key.
The first digit stops blinking and the digit to it’s right starts blinking. Use the UP or DOWN keys, to
set this digit.
Similarly all four digits for this timer are set to their desired values. On completion of this setting,
press the ENTER key.The cursor disappears.
Press the DOWN key.
Follow the steps outlined above to set the seal (low) timing to the desired value.
In order to exit the timer setting mode, press the CANCEL key .The timer window will display the
current value of the timer which has started timing .The timer/counter window will display the cycle
time.
COUNTER SETTINGS
The PLC counts the number of moulding cycles that have taken place. The various counters and their
functions are described below.
TOTAL NUMBER OF CYCLES in TOTAL 1 and TOTAL 0.
TOTAL CYCLES = ( TOTAL1 x 10000 ) + TOTAL0.
This counter increments by 1 for every cycle. The total count is an 8 digit value, distributed
between TOTAL1 and TOTAL0. When the total cycle count reaches 99999999, the counter will
overflow to 00000000
/HOUR2
This counter display the number of moulding cycles that have taken place in the present hour. The
hour timer starts, when the machine is switched on. When the unit is switched off, the time elapsed
in the current hour is stored in memory. When the machine is switched on again, the hour timer starts
timing from the stored value.
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/HOUR4
This counter displays the number of moulding cycles that have taken place in the hour previous to
the current hour.
/HOUR6
This counter displays the number of moulding cycles that have taken place, in the hour, two hours
prior to the current hour.
/HOUR8
This counter displays the number of moulding cycles that have taken place, in the hour, three
hours prior to the current hour.
And so on we can go upto /Hour13.After hour13 the next counter displays the time elapsed in the
present hour in seconds.
Each of these counters can be initialized, using the PIECE COUNTER key. This is described below.
Press the PIECE COUNTER key to modify the current value of any of the counters.
The current value of TOTAL1 will be displayed in the counter window, with all the four digits
blinking. The LED beside TOTAL1 will also be lit.
Press the ENTER key to change this parameter. The most significant digit blinks.
Press the UP or DOWN key to set the blinking digit to the desired value.
Press the RIGHT arrow key.
The first digit stops blinking and the digit to it’s right starts blinking. Use the UP or DOWN keys, to
set this digit.
Similarly all four digits for this counter are set to their desired values. On completion of this setting,
press the ENTER key. All four digits will blink again.
Press the DOWN key.
The LED beside TOTAL1 will be off and the LED beside TOTAL0 will be lit.
Follow the steps outlined above to set the TOTAL0 counter to the desired value.
In order to exit the counter setting mode, press the CANCEL key. The counter window will display
the current value of the cycle timer.
PRODUCTION RESET
Reset the production press emergency switch, and then press BLOWING and PARISON A key at a
time for 2-3 seconds then hourly production will reset.To reset total production press keys F1,F2 and
F3 at a time then total production will be reset.
HEATER ON/OFF KEY
HEATER ON/OFF key is used for ON/OFF the HEATER OUTPUTS.
AUTO/MANUAL KEY
The Auto mode of operation, is selected by the auto key, provided on the
Display board. When key is pressed correspondingly led will glow on and machine goes in auto
mode. Machine is manual mode when key is off.
EXTRUDER ON
This key is used for ON/OFF the extruder motor.
DOUBLE CUT
This key is used for to operate single or double cut function.
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MANUAL(HAND) MODE
The manual mode of operation, is selected by the auto/manual selector switch, provided on the
display board. In the manual mode of operation, the user can switch the various solenoids on or off
from the front panel, by pressing the corresponding keys. The manual functions incorporated are :
1.
MOULD CLOSE
2.
MOULD OPEN
3.
CUTTER
4.
MOULD IN
5.
MOULD OUT
6.
BLOW PIN DOWN
7.
BLOWING
8.
PARISON A
9.
PARISON B
In order to actuate a particular solenoid, the corresponding key, should be pressed. The LED in the
key will be switched on, and the solenoid will be switched on. The solenoid will remain on, as long
as the corresponding key is pressed.
TROUBLESHOOTING
The controller allows the user to check the status of inputs, and to exercise the outputs.
CHECKING THE INPUTS
In order to check the inputs, follow the procedure outlined below.
Press the INPUT STATUS key
The DISPLAY shows the name of the first input,and whether it is on or off. The user can actuate the
corresponding push button/limit switch and check if the unit displays the status of the button
correctly. If this is not the case, check if the wiring is done correctly. Also check if the voltage at the
input00 pin on the DC INPUT MODULE is between 20–24VDC (with respect to COM on the same
connector). Otherwise check the voltage of 24VDC with respect to COM. If it is not between 2024VDC, there could be a short between 24VDC and COM, or the INPUT unit has failed, and
requires to be repaired.
To check other inputs, press the UP arrow key.
The display shows the name of the next input and whether it is on or off, in top two windows. The
user can actuate the corresponding pushbutton/limit switch and check if the display displays the
status of the button correctly Thus the user can check all the 127inputs.
Press CANCEL to return to normal display.
CHECKING THE OUTPUTS
In order to check the outputs put the machine in manual mode and follow the procedure outlined
below.
Press the OUTPUT STATUS key..
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The display shows the name of the first output, and whether it is on or off. The user can switch the
output on by pressing the ENTER key once, and can switch the output off by pressing the ENTER
key again in manual mode.
Press the UP arrow key.
The display shows the name of the next output and whether it is on or off .The user can switch the
output on by pressing the ENTER key once, and can switch the output off by pressing the ENTER
key again.
Thus the user can check all 127outputs. Press CANCEL to return to normal display.
ADD: 142-B, NAHAR & SETH IND. ESTATE,
PANNALAL COMPOUND, L.B.S.MARG,
BHANDUP (W),MUMBAI 400078.
PHONE : 022 25965535/ 67974356
EMAIL : [email protected]
HELPLINE: +91 9594993870/1/2/3/4/5/6
WEBSITE: www.ultrainstruments.org
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