INJkon 03 2.0 Manual
INJkon 03 2.0 Manual
INJkon 03 2.0 Manual
LTD
INJkon 03/2.0/ Manual
OPERATING
MANUAL FOR
CONTROL SYSTEM
OF INJECTION
MOLDING MACHINE
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STREAMLINE CONTROLS PVT. LTD
INJkon 03/2.0/ Manual
Business Mission
E-mail –
[email protected]
Web - www.streamlinecontrols.com
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STREAMLINE CONTROLS PVT. LTD
INJkon 03/2.0/ Manual
PREFACE
For letter usage and maintenance of control system, detail study of this operating
manual will be helpful.
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STREAMLINE CONTROLS PVT. LTD
INJkon 03/2.0/ Manual
CONTENTS
(L) INTERLOCKS
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STREAMLINE CONTROLS PVT. LTD
INJkon 03/2.0/ Manual
(A) SPECIFICATIONS:
Input
Power:
Voltage -- 230vac + 10%vac
Frequency -- 49-50 Hz
Consumption -- 30VA Max.
Control:
Thermocouple -- J / K type - Isolated
Proximity/ -- NPN (NO type)
Limit switches 10-30 Vdc - 50 mA Max.
Output
Environment
(B) INTRODUCTION
INJkon is a complete proven & reliable control system for Injection Molding Machine.
System consists of two units.
(1) MMI unit
(2) C.V.T. (Optional)/Transformer
This package has some obvious advantages over existing conventional Electrical Systems. This occupies
lesser space then conventional system. The simplicity of wiring from solenoids to systems or limit switches to system
and from Thermocouples to system makes it easier and less time consuming for commissioning. This system has no
moving parts, so periodical maintenance is drastically reduced and there for reliability is definitely improved. Function
like suck back ON-OFF, Heating ON-OFF and Cycle Time Interlock makes this system much more superior then the
conventional system.
(C) FEATURES
¾ Inherently reliable high speed Micro controller based technology C8051F120 CPU.
¾ Offers up to 16 digital inputs, Up to 16digital outputs, 8-zone time Proportional controlled Temperature Controllers,
timers, Extensive feather touch membrane keypad for user interface for manual/Semi auto/fully auto functions of the
machine.
¾ Latest E2PROM Technology ensures security of programmed parameters.
¾ User friendly programming through an extensive membrane keypad for easy operator interface (Details of manual
mode operations available is appended on separate sheet)
¾ Six digits shot counter to count Number of Pieces.
¾ Facility for counting cycle time helpful in production analysis.
¾ Three different programs for Ejector operations provide to suit the operational needs with various molds.
¾ Thermocouple "Open" & "Reverse" conditions are self detected and are displayed as "Opn" and "rev" respectively.
¾ Programmable High & Low limits for all temperature zones.
¾ Automatic cold junction compensation for Thermocouple inputs.
¾ Mold Safety interlock provided in case of abnormal pressure rise while the mold is getting closed (For that pressure
switch input has to be provided.)
¾ Inbuilt interlocks for Low & High temperature, Front and/or Back guards, Maximum Cycle Time, Emergency stop.
¾ Built in 25 sets of mold memory.
¾ Operating Input/Output diagnosis.
¾ Central lubrication control with precisely On/Off timer.
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STREAMLINE CONTROLS PVT. LTD
INJkon 03/2.0/ Manual
INJkon
S Mold S e rie s
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STREAMLINE CONTROLS PVT. LTD
INJkon 03/2.0/ Manual
KEY’S DESCRIPTION
1. CURSOR KEY
Push this key to move cursor from left to right direction for parameter setting in any me
With help of this key you should toggle your screen from shot counter to proportional
or proportional to shot counter.
2. MENU SELECTOR
Injection Key
Push for activate of Injection action manually.
(Disable by any zone of barrel temperature is lower than alarm low setting)
Refill Key
Push for activate of Refill action manually.
(Disable by any zone of barrel temperature is lower than alarm low setting)
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STREAMLINE CONTROLS PVT. LTD
INJkon 03/2.0/ Manual
(G) PRECAUTIONS
To prevent damage from human and machine, please obey the following safety caution.
¾ Equipment must be operating under correct power. (Install a voltage stabilizer while need)
¾ Earth terminal must be connected to qualified terminal.
¾ All electrical elements with EARTH terminal, it is necessary for users to connect with the EARTH terminal.
¾ The high power cables should be separated from the low power cables to avoid interferes.
¾ To prevent fire or hazard shock, do not expose the unit to rain or moistly place.
¾ Please understand the operating process before use.
¾ When system shut down, wait 10seconds for re-start.
¾ Thermocouples used for this system must be isolated (ungrounded) Fe/k,J, type.
¾ The wiring of each zone starting from thermocouple of heater must be verified.
For ex: first zone thermocouple must be connected to first channel of the system and heater of first zone must be
connected to heater 1of the system.
¾ The limit switch and solenoids wiring must be done as per given wiring diagram.
¾ If the proximity switches are used then use only NPN-NO type proximity switches.
Set Temperature
In case of operator level
Press SET TEMP. key.
First line of LCD shows TEMPERATURE C
Second line of LCD shows zone number & set temperature.
Select require zone using NEXT/ PREV key.
Set require temperature using INC, DEC and SHIFT key.
On pressing NEXT key the set value will be saved and display will show the next function.
List of temperature parameters are given below.
Zone Message In First Message In Default
Description Range Level
No. Line Second Line Value
1 Temperature C Zone 1 Zone 1 set temperature 0-500 C 200 C User
2 Temperature C Zone 2 Zone 2 set temperature 0-500 C 200 C User
3 Temperature C Zone 3 Zone 3 set temperature 0-500 C 200 C User
4 Temperature C Zone 4 Zone 4 set temperature 0-500 C 200 C User
5 Temperature C Zone 5 Zone 5 set temperature 0-500 C 200 C User
6 Temperature C Zone 6 Zone 6 set temperature 0-500 C 200 C User
7 Temperature C Zone 7 Zone 7 set temperature 0-500 C 200 C User
8 Temperature C Zone 8 Zone 8 set temperature 0-500 C 200 C User
Set Temperature
In case of Engineer level
Press SET TEMP key and keep it pressed for at least ten seconds.
First line of LCD shows parameter name.
Second line of LCD shows zone number & parameter value.
Select require parameter using NEXT/ PREV key.
Set require value using INC, DEC and SHIFT key.
On pressing NEXT key the set value will be saved and display will show the next function.
On pressing set temp key the zone number can be changed. Again pressing the NEXT key the different parameter of the
same zone can be checked.
List of temperature parameters are given below.
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STREAMLINE CONTROLS PVT. LTD
INJkon 03/2.0/ Manual
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STREAMLINE CONTROLS PVT. LTD
INJkon 03/2.0/ Manual
Cycle Time Sec Zone 8 Cycle time 0-200 Sec 15 Sec Engineer
Alarm Low C Zone 8 Alarm low 0-200 C 025 C Engineer
Alarm High C Zone 8 Alarm High 0-999 C 025 C Engineer
Blower Point C Zone 8 Blower Operating Point 0-999C 005 C Engineer
Set Miscellaneous
Press set MISC key.
Third line of LCD show function’s name and it’s value/status.
Select require function using NEXT/ PREV key.
Set require value/ status using INC, DEC and SHIFT key.
On pressing NEXT key the set value will be saved and display will show the next function.
List of miscellaneous parameters are given below.
Default
No. Message Description Range Level
Value
1 Suckback Suck Back On/Off On / Off On Supervisor
2 Ejct Prog Ejector Operating Program 0-2 0002 Supervisor
3 Ejct Shot Ejector Shot 0-5 0001 User
4 % Heat Zn1 Set Temperature of % Heating Zone 1 0-100% 0050 User
5 % Zn1 CyTm Cycle time of % Heating Zone 1 0-100Sec 0010 User
6 TestIn/Out Test Mode On/Off On / Off Off Supervisor
7 Count Rst Reset the Shot Counter On / Off Off User
8 Mold Memry Mold Memory Selection 0-25 0000 Supervisor
9 Fast Appro Fast Approach On/Off On Supervisor
Set Timer
Press set TIMER key.
Third line of LCD show function’s name and it’s set value.
Select require function using NEXT/ PREV key.
Set require time using INC, DEC and SHIFT key.
On pressing NEXT key the set value will be saved and display will show the next function.
List of timer parameters are given below.
Default
No. Message Description Range Level
Value
1 Injct Dely Injection delay 0-999.9 Sec 000.2 User
2 Inject 1 Injection 1 time 0-999.9 Sec 003.0 User
3 Inject Hld Injection Hold time 0-999.9 Sec 000.1 User
4 Refil Dely Refill delay 0-999.9 Sec 000.1 User
5 Sukbk2 Dly Suck back 2 Delay 0-999.9 Sec 000.1 User
6 Sukbk Time Suck back time 0-999.9 Sec 010.0 User
7 Cool Time Cool time 0-999.9 Sec 004.0 User
8 Ejct Dely Ejector delay 0-999.9 Sec 000.1 User
9 Ejct Forwd Ejector Forward time 0-999.9 Sec 000.5 User
10 Ejct Hold Ejector Hold time 0-999.9 Sec 000.0 user
11 Ejct Bakwd Ejector Backward time 0-999.9 Sec 000.5 User
12 Cycle Dely Cycle delay 0-999.9 Sec 001.0 User
13 Cycle Time Cycle time 0-999.9 Sec 999.9 Supervisor
14 Tot Inj Tim Total Injection time 0-999.9 Sec 010.0 User
15 EjBak@MCls Set Ejector Backward time before mold close function 0-999.9 Sec 000.2 User
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STREAMLINE CONTROLS PVT. LTD
INJkon 03/2.0/ Manual
(4) HAND:
System (after power on) starts in HAND MODE. In this mode all the functions (like mold open, mold close, unit
forward etc) can be done using different function keys.
For ex. : Mold can be opened using mold open key. When any interlock appears during cycle the machine
transferred in to hand mode.
(L) INTERLOCKS
It is a one type of alarm system which activate when cycle or any other function does not operate properly because of
those abnormal condition it indicate INTERLOCK
Following are the different interlock messages.
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STREAMLINE CONTROLS PVT. LTD
INJkon 03/2.0/ Manual
0
0 24
230VAC
MLX-130
INPUT 0 35V AC 35V AC
230
35 35V AC 35V AC
+
_ +_
TH 8 TH 7 TH 6
TH 8 INPUT
TH 7 INPUT +
_ +_
TH 6 INPUT +
_ _+
+
_ +_
TH 5 TH 4 TH 3 TH 2
TH 5 INPUT
TH 4 INPUT +
_ +
_
TH 3 INPUT +
_ +_
TH 2 INPUT +
_ _
+
+_ _
+
TH 1
OUT-2 2l angi s
S S R O u tp u t C A R D
OUT-3
3l angi s
INPUT-1 OUT-4
4l angi s
INPUT-2 5l angi s
OUT-5
INPUT-3 OUT-6
6l angi s
INPUT-4
7l angi s
OUT-7
INPUT-5 OUT-8
8l angi s
INPUT-6
cdv42+
INPUT-7
INPUT-8
2 30vac in put
OUT-9
1l angi s
OUT-10 2l angi s
S S R O u tp u t C A R D
OUT-11 3l angi s
INPUT-9 OUT-12
4l angi s
OUT-14
6l angi s
INPUT-11
OUT-15
7l angi s
INPUT-12
OUT-16
8l angi s
INPUT-13
cdv42+
INPUT-14
INPUT-15
INPUT-16
+24V DC 2 4 V D C
IN P U T
GND
GND
MLX 130
From
+24VDC
24VAC
24VAC
GND
ML 533A
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STREAMLINE CONTROLS PVT. LTD
INJkon 03/2.0/ Manual
24vdc input
35V AC 35V AC
35V AC 35V AC
+
_ +_
TH 8 TH 7 TH 6
TH 8 INPUT
TH 7 INPUT +
_ +
_
TH 6 INPUT +
_ _+
+
_ +_
TH 5 TH 4 TH 3 TH 2 TH 1
TH 5 INPUT
TH 4 INPUT +
_ +
_
TH 3 INPUT +
_ +_
TH 2 INPUT +
_ +
_
TH 1 INPUT +
_ _
+ OUT-1
OUT-2
OUT-3
INPUT-1 OUT-4
INPUT-2 OUT-5
INPUT-3 OUT-6
INPUT-4 OUT-7
INPUT-5 OUT-8
INPUT-6
INPUT-7
INPUT-8
OUT-9
OUT-10
SL 181A
OUT-11
INPUT-9 OUT-12 230vac
INPUT-10 OUT-13 inpu t
INPUT-11 OUT-14
INPUT-12 OUT-15
24V DC SMPS 20AMP.
INPUT-13 OUT-16
INPUT-14
INPUT-15
INPUT-16
+24V DC 2 4 V D C
IN P U T
GND
GND
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STREAMLINE CONTROLS PVT. LTD
INJkon 03/2.0/ Manual
35V AC 35V AC
35V AC 35V AC
+
_ +
_
TH 8 TH 7 TH 6
TH 8 INPUT
TH 7 INPUT +
_ +
_ 0
0
22
TH 6 INPUT +
_ +
_ 440V AC
380
MLX-173
24
+
_ +
_ INPUT 400
TH 5 TH 4 TH 3 TH 2
32
TH 5 INPUT 415
0
TH 4 INPUT +
_ +
_ 440
220
TH 3 INPUT +
_ +
_
TH 2 INPUT +
_ +
_
+
_ _
+
TH 1
TH 1 INPUT OUT-1
OUT-2
OUT-3
INPUT-1 OUT-4
INPUT-2 OUT-5
INPUT-3 OUT-6
INPUT-4 OUT-7
INPUT-5 OUT-8
INPUT-6
INPUT-7
INPUT-8
OUT-9
OUT-10
OUT-11
INPUT-9 OUT-12
INPUT-10 OUT-13
INPUT-11 OUT-14
INPUT-12 OUT-15
INPUT-13 OUT-16
INPUT-14
INPUT-15
INPUT-16
+24V DC
+24VDC
V0 V4 2
2 4 V D C
IN P U T
GND
GND
+UR
NI C A
V4 2
GND
dr a C
yl ppu S
r e wo P
A3 3 5 L M
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STREAMLINE CONTROLS PVT. LTD
INJkon 03/2.0/ Manual
O
OUURR PPRRO
ODDU
UCCTT RRA
ANNG
GEE
• Dedicated Controller for Plastic Injection/Blow molding Machines
• DC Stepper Drives
• Profile Generator
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