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SIJECT 16i Start-Up - Service, Support

1. 7 Mid Clo 5 5 5 5 5 5 5 5 5 5 5 s s 5 5 5 5 5 5 5 5 Dec 5 5 Inject 5 5 5 5 5 5 Core 1 5 5 Charge 5 5 Core 2 5 5 5 5 Core3 5 5 _ d d d 2 Fig 3 17 Service Screen 2 4 setting ramp data On service screen 1 press softkey gt to enter service screen 2 RAMP linear scale setting Then press softkey F5 yA to enter ramp setting screen See Fig 3 17 Service Screen 2 4 setting ramp data The ramp data for every movement can be set accordingly Mold Close there are four ramps to be set pressure and flow for each ramp and ranged from 0 to 99 The values should be the differences for pressure and flow between every two PLC cycles when there is action switch Carriage it refers to the ramps during carriage advance and carriage retract set pressure and flow for each and ranged from 0 to 99 The values should be the differences for pressure and flow between every two PLC cycles when there is action switch Inject it refers to the ramps when injection starts and injection completes set pressure and flow for each and the range is from 0 to 99 The values should be the differences for pressure and flow between every two PLC cycles when there is action switch Charge it refers to the ramps when charging starts and charging complete
2. 3 50 3 1 4 3 51 3 2 Switching on and Booting the control 3 52 3 2 1 55 5 3 53 done t ast tae not 3 56 9 3 Checking VOS ne oe te th er 3 59 34 Setting important 3 61 3 4 1 3 62 3 4 2 Service stud tu Mu 3 63 QE OG Settinglinear ud wpb beac od at a 3 65 oraa 3 67 2590 Savelpad ues 3 68 3 4 6 X Proportional valve sessi 3 69 3 4 7 Pump Combination Setting csset indocti a esi EN 3 71 3 4 8 Lubrication Set Ngz 3 72 3 4 9 3 73 3 4 10 Setting the ramp nein tonis deitate tiis 3 75 3 5 Up Downloading and Deleting PLC 3 77 3 5 1 Up Downloading and Deleting PLC Program 3 77 3 5 2 Automatic uploading of PLC application to PLC
3. 9 b S 5 m A a G amp la a e T gt Da4 7 IS C C 25 aus TENES Sia waj SE eS S Da T N 004 0 2 PE 2 AC DC2LV c 5 x CONAN CDN CNC amp Ist A Gu JQ I DC 2 X303 5 a 3 A d 003 E C LB CITT 2 X206 S 003 2 N 7 003 1 4 39g dus S 003 0 013 6 S Ww S os SIP 8 S 013 4 013 3 5 013 2 5 X302 013 1 9 T S SIEMENS 013 0 002 A d F T S yen 002 3 IG 012 7 Sy 9 002 2 S 5 4 012 6 9 S Made in Germany J S S S T 9 S a E o 012 2 STAT O 012 1 S d Y Ws bes B is pel Sl leac v G 001 6 Eess 001 5 X204 9 dati S 2 2290 5 001 3 I 16 5 001 2 Do SED 01 ae 011 5 Uf 011 6 5 6 gt DI 6 06 FORCE ae n s EC DI1 0 S X300 L k ak Ae 9 000 7 S Exchange battery with power on X203 S L S Dao 6 S Otherwise program will be lost aoe D80 5 5 0107 RE us 010 6 5 S 5 010 5 6 3 212 bd S 01 1 M 010 3 5 S z S S IL 010 1 S
4. Table1 6 System characteristics System SIJECT CI 16i SIJECT CI 16iP PLC module 314 314 2DP Programming SIMATIC STEP7 SIMATIC STEP 7 Guaranteed Load memory 256 Kbytes 524 Kbytes memory Work memory 163 Kbytes 460 Kbytes Prog memory Load memory 498 Kbytes after loaded technology Work memory 437 5 128 256 Counter 64 256 Digital input DC24V 31 31 High speed counter 1 1 Digital output 2A 40 40 Short circuit protection Yes Yes Thermocouple input 16 Bit 8 8 Inputs for linear scales 4 4 1 10 12 Bit 2 x207 Analog output 4 4 10V 12 Bit OP interface serial 1 1 MPI interface 1 1 P_Bus interface 1 1 Profibus DP interface 1 Memory card slot 1 1 System power supply DC 24V DC 24V correspondent technology blocks for Cl 161 For 16 two outputs can only be used alternatively as voltage output 10V or as current outputs 0 75 1 4A 1 5 SIJECT 161 Control System 1 3 Order Number General The SIJECT series product can be ordered in the form of package But you also can receive the components separately if you only order the option It depends on the configuration and can meet your requirements Please see the order number of all components in the following table Table 1 7 Order Number MLFB Order No No Component SNC No 1 SIJECT15 OP15B 185010901
5. C re 010 0 Fo C E OO 2 H ZW CES 7 s gt lt N Sh Fig 2 4 User interfaces for SIJECT 16 for reference 2 12 SIJECT 16i Start up Installing the Control System e 004 71 C D ET V JW 2 004 31 6 S 090 21 C z 0044 S C N 2 dies 2 ES S He m ON C DES XO x 5 ae l AQ3 C C S A824 X303 303 7 9 093 6 7 at 093 5 N nos C j Dq 2 003 4 m3 5 DP STA GHD E 5 ui 03 b Tl IM 003 111 E C 9 IC 013 7 e 003 0 IQ S 013 6 C bod 24 013 5 N 8L 9 013 4 5 B P 013 3 Ms o SE Sipe X302 013 1 502 7 SIEMENS 1016 0a2 6 3 202
6. Table 2 13 Terminal assignments of terminal board Terminal P24 DC24V M DC24V PE Protective earth Table 2 14 Input specification Parameters Min Max Units Rated input voltage 20 4 28 8 V Fuse On board fusing Ripple Input filter The operator panels does not have separate power supply terminals It is supplied via the signal cable from the CI The digital inputs outputs require an external DC24V switch power The proportional valves need a separate switch power It can be chosen in accordance with the type of proportional valve Caution Power supply cable and signal cable should be seperated i e linear scale and thermocouple signal cable can not be assigned to the same conduit with power supply cable Notice The 24VDC power supply should meet the requirements of the safe separation in accordance with DIN EN 50178 The terminal M in the 24VDC power supply for the digital output Signals 1M 3M 8M 9M are to be earthed additionally SIJECT 16i Start up Installing the Control System 2 5 Grounding Grounding The following grounding connections must be implemented Connections e OP15B e CI16i iP The grounding connection for the OP must be taken into account when installing the machine 16i iP Fuse 10A the above four are same To chassis Fig 2 16 Grounding diagram for OP and Cl SIJECT 16i Start up 2 41 Installing t
7. 51 5 DI1 7 1 5 DI1 6 DI1 5 DI1 4 DI1 3 DI1 2 DI1 1 DI1 0 X300 270060075060 707 ai 4L 4M 010 7 010 6 2020202 010 5 010 4 010 3 010 2 010 1 010 0 26262656262 do Fig 2 8 2 18 Note The tightening torque range of each clamping screw in terminal connector X200 X207 X300 X306 is 0 5 0 6 Nm Connection diagram for CI16iP SIJECT 16i X305 X202 Start up Installing the Control System 2 3 Connecting the Individual Components of Cl Connecting the Components SIJECT 16i Start up Please note the following Caution Use only shielded cable and make sure that the shield is connected with the metal or metal plated connector casing on the control side The cable offered as accessories provides optimum protection against interference Proceed as follows to connect the individual components 1 Connect the lines to the components as shown in Fig 2 7 2 8 2 Fixthe sub D connector using screws 2 19 Installing the Control System 2 3 1 Connecting the Operator Panel X11 Pin assignments Operator panel interface for connector on Connector designation Cl side
8. 5 88 SIJECT 16i Start up Technical Appendix DB1 DBB1189 Virtual cotnin nitcati n Rx meaning instruction according to the protocol specification DB1 DBB1 IDB1 DBB1190 Virtual communication communication Rx Rx length length of valid data in Rx buffer length Rx length length of valid data in Rx buffer valid data in Rx buffer eee 191 Visual communiation _ communication Rx buffer DB1 DBB1206 DB1 DBB1207 Virtual communication Tx flag the software sets this flag to indicate to the PLC that there is a new message in Tx meaning Tx length and Tx buffer The PLC resets this flag after processing the buffer DB1 DBB1208 Virtual communication Tx meaning instruction according to the protocol specification DB1 DBB1209 Virtual communication Tx length length of valid data in Tx buffer DB1 DBB1209 Virtual communication Tx length length of valid data in Tx buffer DB1 DBB1210 Virtual communication Tx buffer DB1 DBB1225 SIJECT 16i Start up 5 89 Technical Appendix Comparator Mode DB1 22222 Location Function Description DBW1238 Enable Exit status of 0x00 disable 0 00 Comparator 1 1 1 0 01 threshold 1 Status 0x01 enable already reached when comparator 1 starting 0 02 Time out 0 03 Invalid configuration DBW1240 Timer Timer value in multiples of the the periodic timer int
9. 3 79 4 Programming ROOM 4 81 41 SIMATIC ence d ce 4 81 5 Technical 5 83 5 1 Definition of ete def 5 83 5 2 Glossary abbreviatiori 5 92 Operator Panel SIJECT OP15B SIEMENS ord 2 e 1 le ESTES 1 1 SIJECT 16i Control System 1 1 Components of SIJECT 16i What is SIJECT 16i The SIJECT 161 is a controller for injection molding machine It offers solutions for injection molding machines from low end applications to high end applications Hardware components It consists of the following hardware components in which the parts marked with a star symbol can be ordered separately e Compact interface main controller i e CPU and I O board OP Operator panel with LCD display and membrane keyboard i e CPU LCD and membrane Keyboard e Cable Communication cable between Cl and OP e Multimedia card MMC The memory space of MMC card is 32 Mbytes It can install PLC application programs maximum 50 sets recipe data OP menus and a customer specific picture max 16KB CI 16i iP Fig 1 1 Hardware components of SIJECT 16i Software components e System software on the permanent Flash
10. X306 No marking is required when intended for connection to control circuit conductors only For the parts marked with a star symbol please use terminal blocks made by PHOENIX CONTACT GMBH amp CO E60425 catalog number MVSTBR2 5 X ST 5 08 where X can be 6 8 10 OR 12 It is only applicable for SIJECT CI 16iP It is only applicable for SIJECT CI 16iP It is only applicable for SIJECT Cl 16i 2 14 SIJECT 16i Start up LEDs Operating elements Connecting cables A Installing the Control System OP e X21 interface 9 pin sub D female connector for connecting Cl 10 LEDs for fault and status displays Mode selector S1 The components are wired up as shown in the following Connection Diagram Please refer to this figure for the type of cables required Warning In practical use the length of those wires transmitting digital and analog input output signals should be less than 30 meters In case the wire length is more than 30 meters corresponding measures should be taken against surge interference SIJECT 16i Start up 2 15 Installing the Control System 6AT1131 For updating system OFA00 0AA0 Software 6ES7368 3BC51 0AA0 2 5m 6ES7368 3BF01 0AA0 5 0m 6ES7972 0BA40 0XA0 Other 6ES7972 0BB40 0XA0 controllers Switch 1 Switch 2 Digital input s Switch 32 Valve 1 Valve 2 Valve 40 Digital output igital output P V 1 Analog output S P
11. 1 PV1 V 2 PV1 V 3 Vit V 4 V1 V 5 V2 V 6 V2 V Output characteristics Voltage range 24V 38V Current output 0 75 1 4A Resolution 12 Bit Notice The output current for proportional valve depends on the inner resistance of valve and the external supplied DC power voltage For instance if the inner resistance of valve is 20 the supplied voltage is 24V then the maximum output current for valve is 1 2A The output current for other type valve should comply with Ohm s Law Fig 2 15 Connecting the proportional valve current output 8 The interface for proportional valve current output X306 is only applicable for CI16i 2 38 SIJECT 16i Start up Installing the Control System Signal description The proportional valve current outputs are assigned with the following signals V1 Proportional pressure valve V2 Proportional flow valve SIJECT 16i Start up 2 39 Installing the Control System 2 4 Power Supply Screw terminal block Terminal assignments Characteristics of the load power supply Operator panel Digital input output Proportional valve 2 40 SIJECT 161 system DC24V power supply unit required for supplying and OP is wired to screw terminal block and should be from an isolated secondary circuit The minimum cross section of the wire is 0 75m
12. 6 TI3 V 7 Tl4 V 8 4 V X201 Pin Name Type 1 TI5 V 2 TI5 V 3 TI6 V 4 TI6 V 5 V 6 TI7 V 7 TI8 V 8 TI8 V Sensor Thermocouple K J Temperature range 0 700 Absolute accuracy 3K A D characteristics Resolution 16Bit Sampling rate 2s SIJECT 16i Start up 2 27 Installing the Control System Connecting sensor and actuators Signal description 2 28 x200 201 TI8 TI3 TI7 TI3 TI2 6 2 TI6 TN 5 TH TI5 Fig 2 10 Connection of the thermocouple The analog inputs are assigned with the following signals TI1 TI1 Nozzle TI2 2 2 TI3 TI3 TC 3 TI4 T14 4 TI5 5 TI6 6 temperature TI7 TI7 spare 8 8 SIJECT 161 Start up Installing the Control System 2 3 7 Connecting the linear scale X202 Pin assignments Interface for linear scale for connector Connector designation X202 Input Connector type 12 pin male connector Table 2 8 Pin assignments of connector X202 2 5 151 151 LS1 LS2 LS2 LS2 LS3 LS3 LS3 10 LS4 11 LS4 12 LS4 COINI gt lt lt lt lt lt lt lt lt lt lt lt lt Sensor Type Linear scale Resistance value 1KOQ 10KQ Accuracy 1 A D characteristics Resolution 12Bit Sampling rate 2ms SIJECT 16i St
13. Connector type Table 2 1 Pin assignments of connector X11 X11 OP15B 9 pin sub D male connector X11 5 Signal Type M XBOOT TXD RXD P24 XRES RXD TXD NN 24 for connector Connector designation OP side Connector type Table 2 2 Pin assignments of connector X21 X21 16i 16iP 9 pin sub D female connector X21 5 Signal Type M XBOOT RXD TXD P24 XRES TXD RXD o AI OJNIJ gt M24 2 20 SIJECT 16i Start up Installing the Control System 2 3 2 Pin assignments of the RS232 MPI Interface X12 Pin assignments MPI RS232 interface for connector Connector designation X12 RS232 MPI Connector type 9 pin sub D female connector Table 2 3 Pin assignment of CI16i iP connector X12 X12 MPI Pin Signal Type RS232_RXD_DIAG 24 MPI_P RS232_TXD_DIAG M P5 P24 MPI_N 5 lt lt lt lt lt lt gt SIJECT 16 Start up 2 21 Installing the Control System 2 3 3 Pin assignments of the P BUS Interface X14 Pin assignments P BUS interface
14. Development Zone 211100 Nanjing People s Republic of China Company Dept Address Telephone Fax Suggestions and or corrections Suggestions Corrections For Publication Manual SIJECT 16i Start up Manufacturer Documentation Technical Manual Order No 184000000058 Edition 08 2004 Should you come across any printing errors when reading this publication please notify us on this sheet Suggestions for improvement are also welcome
15. Warning Do not install when the equipment is live Do not dismantle when the equipment is live The modules contain electrostatically sensitive devices must be ensured that persons without ESD protection never touch printed circuit boards or components when handling operator panel and Cl unit Prior to installation you should prepare 4 nuts M3 for OP installation and 4 cross head screws M4 for CI installation The sheet metal can not have any paint The thickness of a sheet metal for mounting shall not be less than 2 mm 1 Install the CI within the electrical cabinet 2 Install the Operator Panel on the control rack of injection molding machine Connect CI and OP with communication cable Connect the wiring of periphery circuit I Os thermocouple linear scale proportional valve etc 5 Connect entry wire of power supply The control components are dismantled as described above in the reverse order Danger Install grounding connection before plug in of screw terminal block to DC24V mains Make sure that all delivered interface connectors female are plugged in before operation The back up battery is not connected to the Cl board in original package It is necessary to connect the back up battery to Cl board and reset the memory prior to the system start up Please refer to operation sequences of battery set up as follows Operating sequence 1 When the system is firstly power on obs
16. to select system then input recipe number from 1 to 30 then press Enter key to confirm your entry Lastly press soft key F3 to load the recipe data External data saving Apart from internal data saving the recipe data can also be saved externally i e in MMC card Max 50 sets of recipe data with the relevant mould number can be saved External data saving should be performed whenever series start up has to be done Saving data externally Plug the MMC card in the slot after the controller is switched off Use the Save Load key to open the save load screen Use Selection key to select MMC card Enter the value with the recipe number in the range from 1 to 50 Press Enter key to confirm your entry Press soft key F3 to do the saving The system will display message when saving operation is finished Press Lack to acknowledge it 7 If the number exceeds 30 the data can only be displayed and can not be saved The screen will give message during operation SIJECT 16i Start up 3 51 Start up 3 2 Switching on and Booting the control system Procedure Mode selector 1 hardware Booting the control system 3 52 Visual inspect the system for proper mechanical installation with tight electrical connections power supply connection connection for shielding and grounding Turn on the control system Notice If memor
17. 1 0 RUN P 1 1 2 44 SIJECT 16i Start up Installing the Control System Meanings Table 2 17 Meaning of Mode selector 51 Position Designation Meaning 5 Memory Momentary contact position of the mode Reset selector for resetting the CPU memory A special sequence must be observed when resetting the CPU memory with the mode selector refer to section 3 5 STOP STOP Mode The CPU does not scan user programs Programs can e read out of the CPU with a programming device gt e loaded into the CPU with a programming device gt RUN RUN Mode For internal use only The PLC stops any communication in this mode Don t use this mode on customer side RUN P RUN The CPU scans the user program Program Programs can Mode e read out of the CPU with programming device CPUPG e Be loaded into the CPU with programming device gt Note This mode is inapplicable to CI16iP If in CI16iP the Mode Selector S1 is set in RUN position CPU will NOT work in order SIJECT 16i Start up 2 45 3 Start up 3 1 General Start up requirements The following is required e User Manual Operation Manual SIJECT 16i e PC PG Data exchange with control system With MPI adapter and SIMATIC S7 300 programming tool for down upload PLC program for SIJECT16i e MMC card can be used to store customer specific picture CSP r
18. 12 Connection of Fast Analog Inputs 5 Fast analog inputs X207 are only applicable for CI16iP SIJECT 16i Start up 2 31 Installing the Control System Remarks Filter configuration DBW1226 M Rm mE Bit 7 to 4 always 0000 gin g n Bit 3 to 0 0 Filter is disabled 1 to 15 different Filter characteristics Filter configuration DBW1228 EU m 3 Bit 7 to 4 always 0000 gn gin Bit 3 to 0 0 Filter is disabled 1 to 15 different Filter characteristics DBW1230 X207 analog_in_fast 0 In Volts 0 10 process data to PLC DBW1232 X207 analog_in_fast 1 In Volts 0 10 process data to PLC DBW1234 analog_in_fast 2 In Volts 0 10 process data to PLC DBW1236 analog_in_fast 3 In Volts 0 10 process data to PLC Example If the second channel of Fast Analog Inputs is connected with Pressure Sensor the actual value of Pressure Sensor can be read out DB1 DBW1232 the correspondent software Filter can then be set in DB1 DBB1227 where 0 refers to disabling of Filter while 1 to 15 refer to enabling of different Filter characteristics The Filter is intended for noise removal 2 32 SIJECT 16i Start up Installing the Control System 2 3 9 Connecting the digital outputs X300 X301 X302 X303 X304 Pin assignments Interface for digital outputs for connector Connector designation X300 X301 X302 X303 X304 Output Connector type 10 pin male connector Table 2 10 Pi
19. 15 1 Simatic DBIDBW30 Shotcouneractul value DB1 DBX41 0 X300 090 0 Core 1 in valve DB1 DBX41 1 X300 000 1 DB1 DBX41 2 X300 000 2 DB1 DBX41 3 X300 000 3 DB1 DBX41 4 X300 000 4 DB1 DBX41 5 X300 000 5 DB1 DBX41 6 X300 000 6 DB1 DBX41 7 X300 DQ0 7 DB1 DBX42 0 X303 DQ3 0 Heater Nozzle DB1 DBX42 1 X303 DQ3 1 DB1 DBX42 2 X303 DQ3 2 DB1 DBX42 3 X303 DQ3 3 DB1 DBX424 X303 DQ3 4 DB1 DBX42 5 X303 DQ3 5 DB1 DBX42 6 X303 DQ3 6 EE DB1 DBX42 7 X303 293 7 MEE Decompression valve DB1 DBX43 0 X302 DQ2 0 DB1 DBX43 1 X302 DQ2 1 DB1 DBX43 2 X302 DQ2 2 DB1 DBX43 3 X302 DQ2 3 DB1 DBX43 4 X302 DQ2 4 DB1 DBX43 5 X302 DQ2 5 DB1 DBX43 6 X302 DQ2 6 SIJECT 16i Start up 5 85 Technical Appendix DB1 DBX43 7 X302 DQ2 7 Air blow 2 DB1 DBX44 0 X304 DQ4 0 Motor star start beo eee REPE IDB1 DBx45 1 Analog output O type 0 unipolar 0 10V 1 bipolar 10V 10V IDB1 DBx45 3 Analog output O type 0 unipolar 0 10V 1 bipolar 10V 10V pibus piss poe __ DB1 DBWw48 7 305 442 Analog output 2 flow 0 100 __ eee pum pummyi2 E DB1 DBX59 0 7 1 failure of power supply of the linear scale DBIDBX5991 Jp battery normal 1
20. Lub Count 32767 32767 Lub Status C LubOilLevel 1 d 1 Fig 3 15 Service Screen 2 2 lubrication setting On service screen 1 press softkey c to enter service screen 2 4 linear scale setting Then press softkey F3 to enter lubrication setting screen See Fig 3 15 Service Screen 2 2 lubrication setting Lubrication time and lubrication count can be set here Lubrication Time every lubrication time can be set here ranged from 0 9995 Lubrication Count set numbers of injection cycle The system will be lubricated automatically when the set injection cycles have been finished The range is from 1 to 32767 Lubrication Status Press softkey F1 manual lubrication to start the 4 lubrication then the box will backlight is flashing Lubrication Oil Level Inform the user to add lubrication oil when the oil level is very low then the box will backlight and alarm occurs i e flashing SIJECT 16i AJ Start up Start up 3 4 9 Temperature setting General Operating sequences SIJECT 16i Start up User can set temperature channel and temperature tolerance TmpTolPlus Channel 1 off TmpTolMinus S Channel 2 or Oil Upper 9 Channel 3 Off Oil Lower Channel 4 399 9 5 Off Nozzle Mode CloLoop Oil TmpAlm
21. V 2 110 P V 3 P V 4 T 1 T 2 T 3 TA T 5 T 6 T 7 T 8 1 5 1 Analog input 1 52 1 5 3 1 5 4 st FAI Fast analog 2nd FAI input FAI Reference power output DC10V Note P V Proportional valve T Thermocouple L S Linear scale Fig 2 6 Cable diagram for SIJECT 16i 2 16 SIJECT 161 Start up Installing the Control System Fig 2 7 Note The tightening torque range of each clamping screw in terminal connector Connection Diagram for 6 SIJECT 161 Start up DC 24V 206 204 203 304 S 004 7 S DQ4 6 2945 0944 aN 004 3 DC24V Power supply 0942 004 1 004 0 9L X303 DQ3 7 S DQ3 6 R DQ3 5 R DQ3 4 R 093 3 093 2 gt 093 1 093 0 N 8M i NJ 8 P BUS X302 lt pa27 Mj Do26 R DQ2 5 R DQ2 4 R DQ2 3 KO 0922 N DQ2 1 M Do20 RI 3M 12 STATO X301 0917 STATi Date MP pais made pata S Rs DQ1 2 N Gai Dcsv Nj Dato a SF M FORCE i N 2 Sed STOP RUN X300 S DQ0 7 NJ 0
22. for 5 minutes the system will require password entry for the second time when you operate again User class 2 requires the password 2 2000 on the Service screen It is set up so as to avoid the accidental modification of function parameters by the operator They are the most important parameters with the influence on the machine function Only the service engineer has the accessible right Caution When changing the recipe parameters every machine movement must be stopped Notice Protection level 1 and 2 are only for OP15B not for SIMATIC OP s SIJECT 16i Start up Start up 3 1 2 Structure of recipe data Definition Recipe data is consisted of diverse values with different units Usually one set of recipe data contains the following parameters Hydraulic pressure Hydraulic flow F Movement position S Settime and actual time T Settemperature value and actual temperature value Counter number Mode selection number User class To set and change the general recipe data user class 1 must be activated Start up of the service parameters generally requires user class 2 Unit The physical units of the recipe data are set as follows Table 3 1 Recipe data unit Parameter Unit Pressure P bar Flow F Position 5 second Temperature Counter No unit Mode selection No unit Standard data For convenience of the user we deliver t
23. for connector Connector designation X14 P BUS Connector type 25 pin sub D female connector Table 2 4 Pin assignments of connector X14 X14 Pin Signal Type 1 RS ALARM N 2 3 IM_ADR1_N 4 ADR2 5 V 6 KBUS B N B 7 RS OD N 8 RS DIDO B 9 RS CLK N 10 11 RS_LST_N 12 RS_READY_N 13 No connection N C 14 RS_ALARM 15 IM_ALARMO 16 ALARM1 17 IM_ALARM2 18 lt 2 gt 19 KBUS B B 20 RS OD 21 RS_DIDO B 22 RS_CLK 23 RS COM 24 RS_LAT 25 RS_READY Notice For CI 16i this interface can not be used as K BUS interface SIMATIC K BUS because the internal pin 6 and 19 have no wire For CI 16iP this interface is K BUS integrated 2 22 SIJECT 16i Start up Installing the Control System 2 3 4 Pin assignments of the Profibus Interface X15 Pin assignments Profibus interface for connector Connector designation X15 Profibus Connector type 9 pin sub D female connector Table 2 5 Pin assignments of connector X15 X15 Pin Signal Type 1 No connection N C 2 No connection N C 3 DPP B 4 No connection 5 V 6 P5 V 7 Noconnection N C 8 DPN B 9 Noconnection N C Profibus interface X15 is only applicable for CI16iP SIJECT 16i Start up 2 23 Installing the Control System 2 3 5 Connecting the digital inputs X203 X204 X205 X206 Pin a
24. in Germen 012 IS S 0123 S IS 012 2 f x Di24 5 Lo f 012 0 IS s esl 9 S Te X204 5 k S S 48 015 b ogy Dit 5 4 IS SF 011 3 IS p 0112 5 FORCE pina 5 b 9 LIE R Caution oe Us ta 5 Enchatge battery vith pover X203 s progran will be lost IS 6 010 7 5 5 010 6 S S 0105 5 000 2 010 4 S 2004 5 0103 S 00 S C 2C 2 gt 002 e 001 Is 1 N C C 010 0 Is x IB 1 k Y e 288 84 5 Fh Jo cxb c ef DB ly 14 2 D CUD C 2 pud DC Fig 2 2 Mounting dimensions of CI 2 10 SIJECT 161 Start up Installing the Control System 3624 0 15 357 1 221 251 8 0 15 6 1 1 710 5 2 a 8 c ime oe o js bef _ 2 5 gt gt lt Pi 3 Fig 2 3 Section dimension for OP15B SIJECT 16i Start up 2 11 Installing the Control System 2 2 Interfaces and Cabling Position of interfaces and front panel elements
25. 00 6 R 090 5 R 090 4 N 5003 2902 DQ0 1 Nj R 1M T N 1 X200 X207 X300 X306 is 0 5 0 6 Nm LO X A e A A 7L 7M DI3 7 DI3 6 013 5 013 4 013 3 013 2 013 1 013 0 6L 6M 012 7 012 6 012 5 012 4 012 3 012 2 012 1 012 0 5 DI1 7 DI1 6 DI1 5 DI1 4 DI1 3 DI1 2 DI1 1 DI1 0 4L 4M 010 7 010 6 010 5 010 4 010 3 010 2 010 1 010 0 PV1 4 AQ4 AQ3 AQ3 AQ2 AQ2 1 1 154 154 54 LS3 LS3 163 LS2 152 152 LS1 LS1 151 8 718 TI7 6 TI6 TI5 TIS TM TI4 TI3 TI2 12 TH TH 12029720202 v2 V4 X306 X305 X202 X201 X200 2 17 Installing the Control System X304 DC24V Power supply pea x10 20262659562 292 297 X303 7L 7M DP SF 013 7 DP_STAT DI3 6 DI3 5 DI3 4 DI3 3 DI3 2 Profibus 013 1 013 0 X302 ITAA 5050 6L 6M 012 7 012 6 012 5 012 4 012 3 012 2 012 1 5 N S LO X A e A A DI2 0 X301 STATO STAT1
26. 002 5 19 205 S 154 002 4 S eS 6L 6M 9 154 002 3 012 7 5 S lisi 002 2 G DI2 6 9 id 0 2 1 0 012 5 153 092 0 0 RE Mode 110 Germany 012 4 153 M 5 O 0123 52 3 S 012 2 152 5 0 012 1 152 T L SS 012 0 6 ist 3 E 5 001 7 E TES S x 001 6 55 7 T 0015 X204 S 001 4 2 EN A 011 7 091 2 Q DITE S CERA 11 5 9 T18 001 01 ME 5 DIA st 014 3 117 011 2 17 FORCE 011 1 16 o st DIO 9 116 300 F 9 5 000 7 S Exchonge battery with power on X203 15 3 000 6 S Otherwise program will be lost 4L 74M m 99051 007 S X209 000 4 010 6 020 3 amp 010 5 00 2 010 4 901 S 010 3 00 0 6 C Di M S S 12 1 C 2 4 2 D 010 0 ON FR M J A H Fig 2 5 User interfaces for SIJECT CI16iP for reference SIJECT 16i Start up 2 13 Installing the Control System Interfaces Cl Power supply connector DC24V 3 pin screw terminal block for connecting the power supply X11 OP interface 9 pin sub D male connector for connecting OP and providing power supply for OP X12 MPI RS232 int
27. 0A fuse See Fig 2 16 The connection from 24VDC power supply to the line L and M may not be exchanged otherwise it can bring about a destruction in the CI board 2 36 SIJECT 161 Start up Installing the Control System 2 3 10 Connecting the analog outputs X305 Pin assignments Interface for analog outputs for connector Connector designation X305 Output Connector type 8 pin male connector Table 2 11 Pin assignments of connector X305 Pin Name Type 1 AQ1 V 2 AQ1 V 3 AQ2 V 4 AQ2 V 5 V 6 V 7 AQ4 V 8 AQ4 V Output characteristics Voltage range 10V 10V Max output current 5mA Gain error 1 Offset error 100mV Resolution 12Bit Connecting sensor and actuators Fig 2 14 Connecting the analog outputs Signal description The analog outputs are assigned with the following signals AQ1 AQ1 Pressure valve 0 140bar AQ2 AQ2 Flow valve 0 100 AQ3 AQ3 Back pressure valve 0 140bar AQ4 4 4 proportional valve SIJECT 16i Start up 2 37 Installing the Control System 2 3 11 Connecting the proportional valve current output 306 Pin assignments for connector Connecting sensor and actuators Interface for proportional valve current output Connector designation X306 Output Connector type 6 pin male connector Table 2 12 Pin assignments of connector X306 Pin Name Type
28. 12 0 013 0 Bipolar possible Fig 2 9 Connection of digital inputs SIJECT 16i Start up 2 25 Installing the Control System Signal description The digital inputs are assigned with the following signals DI 0 0 DI 0 1 DI 0 2 DI 0 3 DI 0 4 DI 0 5 DI 0 6 DI 0 7 DI 1 0 DI 1 1 DI 1 2 DI 1 3 DI 1 4 DI 1 5 DI 1 6 DI 1 7 DI 2 0 DI 2 1 DI 2 2 DI 2 3 DI 2 4 DI 2 5 DI 2 6 DI 2 7 DI 3 0 DI 3 1 DI 3 2 DI 3 3 DI 3 4 DI 3 5 DI 3 6 DI 3 7 2 26 Safety door 2 short cut available Rear safety door short cut available Emergency stop short cut available Carriage advance end Carriage retract end Ejector advance end Ejector retract end Mold lock end Mold adjustment advance end Mold adjustment retract end Core 1 in end Screwing 1 Core 1 out Core 2 in end Screwing 2 Core 2 out Injection door short cut available Motor overload Safety door 1 Lubrication error Mold adjustment photo sensor Full auto photo sensor Robot Core 3 in end Screwing 3 Core 3 out Screw speed sensor SIJECT 16i Start up Installing the Control System 2 3 6 Connecting the thermocouples X200 X201 Pin assignments Interface for thermocouple for connector Connector designation X200 X201 Connector type Table 2 7 Pin assignments of connector X200 Pin Name Type 1 TI1 V 2 TI1 V 3 TI2 V 4 TI2 V 5 TI3 V
29. 20020000 20207 02 207207 29 Fig 2 13 Connecting the digital outputs SIJECT 16i The digital outputs are assigned with the following signals DQ 0 0 Core 1 in DQ 0 1 Core 1 out DQ 0 2 Core 2 in DQ 0 3 Core 2 out DQ 0 4 Carriage advance DQ 0 5 Carriage retract DQ 0 6 Charging DQ 0 7 Injection DQ 1 0 Mold close DQ 1 1 Mold close fast DQ 1 2 Mold open DQ 1 3 Mold open fast DQ 1 4 Mold adjustment advance DQ 1 5 Mold adjustment retract DQ 1 6 Ejector advance DQ 1 7 Ejector retract 2 0 Suck back DQ 2 1 Pump 2 DQ 22 Zero back pressure DQ 2 3 Robot DQ 2 4 Core 3 in DQ 2 5 Core 3 out DQ 2 6 Air blow 1 DQ 2 7 Air blow 2 2 35 Installing the Control System DQ 3 0 Heater nozzle DQ 3 1 Heater output 2 DQ 3 2 Heater output 3 DQ 3 3 Heater output 4 DQ 3 4 Heater output 5 DQ 3 5 spare DQ 3 6 spare DQ 3 7 spare DQ 4 0 Motor star start DQ 4 1 Motor triangle start DQ 4 2 Motor start DQ 4 3 Alarm light DQ 4 4 Lubrication pump DQ 4 5 Alarm buzzer DQ 4 6 spare DQ 4 7 spare Notice The 24VDC power supply should meet the requirements of the safe separation in accordance with DIN EN 50178 The terminal M in the 24VDC power supply for the digital output Signals 1M 2M 3M 8M and 9M are to be earthed additionally Danger A N The positive terminal of digital outlet lines terminal 1L 3L 8L 9L must be protected through a 1
30. 6i Installing the Control System The dimensions shown below are important when installing the control components Mounting dimensions of OP15B Start up 2 9 Installing the Control System 32 224 eg at N 2 E 2C 2 i N C 2 24 2C C 2 S Jic C 2 2 S C bua 2C De 2 S z H DG 2 2 paca v We gt 3 0 amp He DC 2C 2 Y 5 ac S fff D E e C B CT 2 X206 J e C 29 2 013 7 IS S N 0136 5 0125 5 S 0134 5 0133 5 L1 013 2 S 013 1 IS S SIEMENS IS X205 s S 0127 S S 012 5 5 5 0125 5 IS Mode
31. 7 battery alarm i S y 17777 71 LL U 5 86 SIJECT 16i Start up Technical Appendix DB1 DBX61 1 X203 010 1 DB1 DBX61 5 203 010 5 DB1 DBX61 6 X203 010 6 DB1 DBX61 7 X203 010 7 206 013 0 Safety door 1 DB1 DBX62 1 Lubrication error Mold adjustment photo sensor Full auto photo sensor w UJ X X 051616 DB1 DBX62 5 X206 DI3 5 Core 3 in end counter sensor X206 DI3 6 Core 3 out end 206 013 7 Screw speed sensor X205 012 0 Mold adjustment advance DB1 DBX63 1 Mold adjustment retract end X205 D12 2 1 in end counter sensor X205 D124 2 in end counter sensor DBi DBX635 X205 DI25 Core2outend DB1 DBX63 6 Injection safety door DB1 DBX63 7 Motor overload DB1 DBW64 PS crew speed actual value DB1 DBW66 X200 TI1 Analog input TC 1 nozzle DB1 DBwes X20 TI2 input TC 2 DB1 DBW70 X20tTi3 Analog input TC 3 DB1 DBW72 X200TM Analog input TC 4 Edel rd rdi acd Deere Be olojo w W W UJ w W FIDID N SIJECT 16i Start up 5 87 Technical Append
32. 9 9 999 9 999 9 2000 Ref Mid End of MidClo LS Eject Ref Inj End of Inj Ref Eje End of EjeRet Fig 3 10 Service Screen 2 linear scale setting Operating sequences Press softkey 2111 enter the next screen Fig 3 10 Service SIJECT 16i Start up Screen 2 linear scale setting Linear Scale mold Switch Proximity switch signal When mold close is at position the box will backlight showing the reference point of linear scale Reference point setting value Mold lock end should be the reference of linear scale Length setting value The length of linear scale can be set here ranged from 1 6553 Actual value displayed value Display the actual value of linear scale Current value displayed value It is the difference from actual value to reference point Linear scale injection Reference point setting value Reference point of linear scale can be set here Length setting value The length of linear scale can be set here ranged from 1 6553mm Actual value displayed value Display the actual value of linear scale Current value displayed value It is the difference from actual value to reference point 3 65 Start up Linear scale ejector Switch Proximity switch signal When ejector retract is at position the box will backlight showing the reference point of linear scale Reference point setting value Ejector re
33. 900 China only 2 SIJECT 16i 16 15 6AT1131 6CD21 0XBO 3 SIJECT OP15B FV1 6AT1131 5BB20 0XBO English Chinese Turkish Russian SIJECT OP15B FV2 6AT1131 5BC20 0XBO English Chinese Spanish Reserve SIJECT 16 6AT1131 6DD21 0ABO SIJECT 6AT1131 6DE21 0ABO 6 Communication cable 185010900200 China only 7 SIJECT adapter 6 1131 00 Multimedia 6AT1131 OGA00 0AA0 9 SIJECT PTPS SIJECT Project Tool 185010901800 English Version SW China only 10 SIJECT Sijload SIJECT Loader 185010755002 English Version SW China only 11 SIMATIC Manager V5 2 6 57810 4 06 0 0 12 Short Guide for Start up 184000000060 China only 13 Operation Manual OP15B 184000000059 SIJECT 16i English China only 14 Operation Manual OP15B 184000000062 SIJECT 16i Chinese China only 15 Start Up Manual OP15B 184000000058 SIJECT 16i English China only 16 Start Up Manual OP15B 184000000061 SIJECT 16i Chinese China only 17 BUS cable 2 5m 6ES7368 3BC51 0AA0 18 P BUS cable 5 0m 6ES7368 3BF01 0AA0 19 Profi bus cable 6XV1830 0EH10 1ABO 20 Profi bus Connector 1 6ES7972 0BA40 0XA0 21 Profi bus Connector 2 6ES7972 0BB40 0XA0 22 Lithium battery for SIJECT Cl boards 6FC5247 0AA18 0AA0 1 6 SIJECT 16i Start up 2 Installing the Control System 2 1 Installing and Dismantling A Procedure Dismantling the control system A Battery set up SIJECT 16i Start up
34. Connecting the Individual Components of CI 2 19 2 3 1 Connecting the Operator Panel 11 2 20 2 3 2 assignments of the RS232 MPI Interface 12 2 21 2 3 3 Pin assignments of the P BUS Interface 14 2 22 2 3 4 Pin assignments of the Profibus Interface 15 2 23 2 3 5 Connecting the digital inputs X203 X204 X205 206 2 24 2 3 6 Connecting the thermocouples X200 201 2 27 2 3 7 Connecting the linear scale X202 2 29 23 05 Los aiuto iei cece ea Ite HUE 2 31 2 3 9 Connecting the digital outputs X300 X301 X302 X303 2 33 2 3 10 Connecting the analog outputs 05 oia De diea 2 37 2 3 11 Connecting the proportional valve current output 2 38 24 Power oU pply tt ede en eol nde ftcut 2 40 2 5 Cernere 2 41 2 6 LEDs and Mode selector 1 ai oie AEE A SEEE NEE ARE 2 43 StartUp ore 3 47 Sel 5 e RE 3 47 3 1 1 3 48 3 1 2 Structure of recipe eode 3 49 3 1 3 Handling of recipe
35. EPROM of the Loading kernel SIJECT Sijload loads all the remaining part of the software of micro controller It is available in PRODIS system that can be free downloaded from Internet Please refer to Notice on next page for details PLC application program executes the Integrated PLC User Program cyclically Before machine set up customers should firstly install PLC application program by themselves 1 2 SIJECT 16i Start up User data PLC program SIJECT 16i Start up SIJECT 16i Control System e Programming tool SIMATIC STEP7 V5 x OP15B menu editor tool program for OP15B there is a HMI engineering tool for menu editor MECO program is also in PRODIS system together with Sijload program Refer to Notice below User data are e Customer specific picture e Recipe data e PLC program STEP7 PLC program for 16i 16iP is backed up by battery delivered Cl 16i 16iP does not include STEP7 PLC program and the battery is not plugged in The customer should prepare PLC program first plug in battery then download STEP7 PLC program to CI16i 16iP unit Please see section 3 5 2 Automatic uploading of PLC application to PLC module for detailed function descriptions Notice Actual information documentation only English and application examples in STEP 7 are on Internet available Actual Link http www4 ad siemens de Please input 51 in S
36. Enter Key to confirm the entry Download Menus from MMC Steps are as follows 1 Plug in MMC card in the CI the operation should be done after turning off the power 2 Select Menus in Program SE 3 Press softkey F4 to start data transfer 4 Restart the system after the transfer process is finished The operation is over SIJECT 16i Start up 3 4 6 Proportional valve adjustment General Users can adjust the proportional valve and test it AdjustVal Val Type ValLimit PressTest FlowTest BckPreTest Flow Min 140 bar 100 bar Force Output Fig 3 13 Service Screen 1 3 proportional valve adjustment Start up d Operating sequences Press softkey F5 to enter proportional valve adjustment screen See Fig 3 13 Service Screen 1 3 proportional valve adjustment Proportional valve can be adjusted here and you can test pressure flow and Operating sequences SIJECT 16i Start up backpressure under force output mode Adjust Valve select On Off to start valve adjustment Valve Type select the type of valve flow pressure back pressure reserved Valve Limit select min max value Pressure Test in force output mode input pressure value ranged from 0 140 Flow Test in force output mode input flow value ranged from 0 100 BackPressure Test in force output mode inpu
37. I 16iP lights up Flashes in case of CI16iP DP SF DP STAT Green WE SG 2 STAT Red Flashes in case of 16 BATF Red DC5V Green SF Red FORCE Yellow STOP Yellow RUN Green Fig 3 1 signal For any other case you can refer to Table 2 15 in section 2 6 You can also check the booting status on the Information screen 2 as follows 1 Use the Information key to open the Information screen 1 Push the PgDn key r to call the Information screen 2 Check the messages on the screen PLC Switch PLC Startup PLC LifeCnt Communication 3 53 Start up Contrast adjustment Display sequence 3 54 In case that the display contrast doesn t match with the environment you can adjust the contrast using the Function key Steps are as follows 1 Press Function key enter function picture 2 Press softkey F3 to increase the contrast and press softkey F4 to decrease contrast In addition screen back light can also be set on this screen If selected then back light will be turned off automatically if there is no key pressed during 3 minutes otherwise back light will be turned off if there is no key pressed during 10 minutes Notice For the first operation password class 1 1111 should be entered Dis
38. IJECT16i consists in that the PLC program can be up downloaded whenever you wish In addition users can clear the memory of PLC CPU memory as required You can modify the program in your PC PG after you are in the programming environment SIMATIC Manager is the basic programming and configuration software for SIMATIC It is made up of a series of applications intended to create and test user program To up download the PLC program you need the following APC PG with RS232 interface adapter and an appropriate cable SIMATIC programming tool CD MMC card The Mode Selector S1 must be set in RUN_P position prior to up downloading PLC program Notice The MMC card can be used to save load the PLC program Carry out external data saving before you up download the program See 3 1 4 recipe data saving Uploading and downloading of PLC program should be done by use of SIMATIC Manager Upload PLC program in SIJECT 16i 1 Start the SIMATIC Manager PC PG 2 Choose the menu PLC in the tool bar 3 Select the menu command Upload 4 Press on the symbol and then release Now the Uploading process is finished Download PLC program in SIJECT 16i 1 Start the SIMATIC Manager in PC PG 2 Click the menu PLC in the tool bar 3 Select the menu command Download 4 Press on the symbol Download and then release Now the Downloading process is finished 3 77 Start up D
39. SIEMENS SIJECT 161 Start Up Technical Manual 08 2004 Edition Manufacturer Documentation SIJECT 161 Document Structure General Documentation Catalog Short Guide for Start Up User Documentation Operation Manual Operation Manual Technical Documentation Start Up SIEMENS SIJECT16i Control System 1 Installation of Control System 2 SIJECT 16i 3 Start up Start Up Programming Tool 4 Technical Manual Technical Appendix 5 Valid for Control System Firmware Version SIJECT 161 1 12 08 2004 Edition SIJECT Documentation Key to editions The editions listed below have been published prior to the current edition The column headed Note lists the amended sections with reference to the previous edition Marking of edition in the Note column A New documentation Unchanged reprint with new order number Revised edition of new issue Edition Order No 12 2000 6AT1931 5AB61 0BAO 01 2004 6AT1931 5AB61 0BA1 08 2004 6AT1931 5AB61 0BA1 Copyright SIEMENS AG 2004 All right reserved The reproduction transmission or use of this document or its contents is not permitted without express written authority Offenders will be liable for damages All rights including rights created by patent grant or registration of a utility model are reserved SIEMENS Aktiengesellschaft Note gt Exclusion of liability We have checked t
40. art up 2 29 Installing the Control System Connecting sensor and actuators LS4 LS4 LS4 LS3 LS3 LS3 LS2 LS2 LS2 LS1 LS1 151 Fig 2 11 Connection of the linear scales Signal description The analog inputs are assigned with the following signals 151 LS1 LS1 linear scale 1 0 10V Mold LS2 LS2 LS2 linear scale 2 0 10V Screw 153 153 LS3 linear scale 3 0 10V Ejector LS4 LS4 LS4 linear scale 4 0 10V Carriage 2 30 SIJECT 161 Start up Installing the Control System 2 3 8 Fast analog inputs X207 Pin assignments Interface for fast analog input FAI for connector Connector designation X207 Input Connector type 6 pin male connector Table 2 9 Pin assignments of connector X207 Pin Name Type 1 Viet V 2 V 3 0 V 4 MO V 5 1 V 6 M1 V A D characteristics Resolution 14Bit Polarity Unipolar Signal description The Fast Analog Inputs are assigned with the following signals MO first channel FAI 0 10 1 M1 second channel FAI 0 10 Viet Manatog reference power output DC 10V Connecting sensor and actuators pressure sensor Note This figure is only for your reference MO shows the connection of Linear Scale and M1 shows the connection of Pressure Sensor You can connect the interface according to your requirements Fig 2
41. e the commisioning process as an example provided that the resistance of the proportional valve is 100 and 24VDC power supply is adopted Therefore it means that the max output value of PV is reached when the pointer in the amperemeter indicates the maximal value of 1A and the min output value is reached when the pointer indicating 100mA proportional flow valve and 0 mA proportional pressure valve 3 70 SIJECT 16i Start up 3 4 7 Pump Combination Setting General Start up User can set the pump combination according to different machine type so as to optimize the energy Pump2 Flow Pump3 Flow Pump4 Flow 30 Note Pump1 always On _ i Fig 3 14 Service Screen 2 1 pump combination setting Operating sequences On service screen 1 press softkey to enter service screen 2 SIJECT 16i Start up linear scale setting Then press softkey F2 combination setting screen See Fig 3 14 Service Screen pump combination setting Pump2 pump3 pump4 can be selected here and the flow can be set accordingly 2 Flow flow range 0 100 Pump3 Flow flow range 0 100 Pump4 Flow flow range 0 100 to enter pump 3 71 Start up 3 4 8 Lubrication setting General Operating sequences 3 72 User can set the time and interval of lubrication Lub Time 999 s 999 5
42. earch box For more information or proposals you can link http www siemens com motioncontrol http Awww ad siemens de csinfo Or contact Europe Email wolfgang radermacher siemens com Email wolfgang zapf siemens com Technical support Email dietmar antwerpen siemens com 1 3 SIJECT 161 Control System 1 2 Technical Data Connected load Table 1 1 Connected load Parameter Power of Cl and OP 20 35 W Current consumption of each output 2 Digital input output 24 V Proportional valve 24 38 V tdepends on the resistance of proportional valve Weight Table 1 2 Weight weight Ko Dimensions Table 1 3 Component Dimensions Cl component 390 288 84 5 OP component 392 202 36 Environmental Operating conditions Table 1 4 Environmental operating conditions 5 95 without condensation 700 1 060hPa Transport and storage conditions Table 1 5 Transport and storage conditions Temperature Transport 40 70 C Storage 20 55 C Permissible relative air humidity 5 9595 without condensation Transport height 1 000 3 000 m 1 4 SIJECT 16i Start up Protective qua lity and degree of protection System characteristics SIJECT 16i Start up Class of protection level to IEC 536 IP20 OP IP54 PE terminal required Foreign matter and water protection to IEC 529 SIJECT 16i Control System
43. echnical Appendix DB1 221 Locati n Function Description DBW1264 Enable Exit status of 0x00 disable 0 00 Comparator 2 Comparator 2 comparator 2 0 01 threshold 2 Status 0x01 enable already reached when comparator 2 starting 0 02 Time out 0x03 Invalid configuration DBW1266 Timer Timer value in multiples of the the periodic timer interrupt multiples of 1ms 0 Timer disabled DBW1268 which Dummy 17 An selected analog LS AI FAI to input for comparator s read poll polling by PLC 0 00 selection 0 01 LS AIO 0 02 LS AI OxO3 LS Al2 0 04 15 Ox11 FAIO 0x12 FAI1 DBW1270 Define which Define which The first AQ selected second AQ AQ is the first AQ is the by PLC selected by PLC must AQ to write second AQ to 0x00 no selection be different from the write first AQ 0 00 selection 0 01 1 0 02 2 0x04 AQ4 0x03 AQ3 0x04 AQ4 DBW1272 Define first Define second 0 00 selection 0 00 selection to write DQ to write 0 01 0 28 selects 0x01 0x28 selects DQ1 DQ40 DQ1 DQ40 DBW1274 Define third DQ Define fourth 0 00 selection 0x00 no selection to write DQ to write 0 01 0 28 selects 0 01 0 28 selects DQ1 DQ40 DQ1 DQ40 DBW1276 Comparator value threshold 1 Value for starting Comparator Mode DBW1278 Comparator value t
44. ecipe data and PLC application program Detailed operation steps can be found in Operation Manual section 3 1 10 The PLC menus CSP can be saved loaded to from MMC card The mechanical and electrical installation of the equipment must be completed Notice For installation refer to the installation description provided in the Chapter Two of this manual The control system with its components boots without errors Start up Sequence A possible start up sequence for the SIJECT 16i is as follows Check whether the boots Check the diverse versions of PLC Cl and OP Check the I Os via display and the LEDs in Cl Set recipe data Optimize the data oa F Save the data Warning For SIJECT Cl 16iP PLC module can not run normally when Mode Selector S1 is indicated to RUN mode at power on Therefore make sure that S1 is not at RUN position when electrifying the system SIJECT 16i Start up 3 47 Start up 3 1 1 Access levels User class User class 1 User class 2 A 3 48 The SIJECT 16i implements a user class concept to enable certain data areas The user classes have protection level 1 and 2 When setting the parameters via operator panel the screen will display Enter Password XXXX User should enter the password of class 1 Factory setting for the password class 1 is 1111 Then push the Enter key to confirm the entry After Switch On of the control system if there is no action
45. ed 1 The photo sensor is damaged SIJECT 161 Start up Start up Alarm Name Description Remedy Can not open mold to end position MidOpnErr 1 Check the limit switch 1 Clear the obstacle in the mold Ejector is not in the back position 1 Check if the ejector is at end limit switch 2 Check pressure flow Cores are not back to the start position 1 Check the limit switch for core in out Charging is not finished Low pressure mold protection time is up 1 Clear the obstacle in the mold 2 Extend the mold protection time Injection safety door is not closed 1 Check the setting of lubrication Waiting for robot 1 Waiting for robot downward Robot is failed 1 Check the sensor of robot 2 Check the setting of robot Injection time has been exceeded 1 Check the material 2 Check the nozzle Screw speed is abnormal ScwSenErr 1 Close the safety door when injection 2 Check the switch of safety door Lubrication oil level is too low 1 Check if there is any material in the barrel 2 Power supply of linear scale is failure 1 2 Thermocouple of channel 1 nozzle is broken 1 No material in hopper 2 Check if the backpressure is too high SIJECT 16i Start up 3 57 Start up 3 58 Alarm Name Description Remedy Thermocouple of channel 2 heater is broken TC2 Fault Thermocouple of channel 3 heater is broken TC3 Fault 1 Thermocou
46. eleting PLC program 3 78 If you want to delete PLC program two choices are available Method One Use SIMATIC STEP7 1 Open STEP7 V5 2 SP1 2 From PLC menu in the tool bar choose command Start gt Diagnostic Setting gt Clear Reset Method Two Use screwdriver 1 Switch the mode selector S1 to position MRES by screwdriver 2 Hold the switch at this position until the yellow STOP LED on Cl module lights up for the second time and stays when switch 51 from RUN P position to MRES S1 will pass by STOP position and the STOP LED will light on once Then turn the mode selector S1 to position STOP 3 After 3 seconds switch the mode selector S1 back to MRES The STOP LED will flash rapidly and the CPU memory is reset 4 Turn the mode selector S1 to STOP When the STOP LED lights up permanently the CPU memory reset is finished 5 Switch the mode selector S1 to RUN P Note Sometimes there will be message to inform system error when PLC program has been deleted Under the circumstances you can use screwdriver to clear CPU memory once more as mentioned above SIJECT 16i Start up Start up 3 5 2 Automatic uploading of PLC application to PLC module General Operating sequence SIJECT 161 Start up In addition to save load PLC application by OP menu stated in Section 3 4 5 PLC application can also be uploaded to PLC module from MMC card automatically when there is no PLC application in PLC module Swi
47. erface 9 pin sub D female connector for communicating with PC PG and other standard OP X14 P BUS 25 pin sub D female connector for periphery extension X15 Profibus 9 pin sub D female connector for connecting controller Profibus protocol X200 X201 Temperature input 8 pin male connector 2 sets for connecting thermocouple inputs X202 Analog input 12 pin male connector 1 set for connecting linear scale inputs X203 X204 X205 X206 Digital input 10 pin male connector 4 sets for connecting digital inputs 1 pin of them DI3 7 X206 is adapted for connecting high speed input including proximity switch X207 Fast Analog Inputs 6 pin male connector 1 set for two fast analog inputs 10V and for the reference power output supplied by the system DC 10V X300 X301 X302 X303 X304 Digital output 10 pin male connector 5 sets for connecting digital outputs X305 Analog output 8 pin male connector 1 set for connecting analog output for proportional pressure and flow valve with external driver card X306 Current output for proportional pressure and flow valve 6 pin male connector 1 set for connecting power output for proportional pressure and flow valve with integrated driver card Notice Temperature rating of field installed conductor shall be 75 C only for the Digital Outputs X300 X301 X302 X303 and X304 and Analog Output
48. errupt multiples of 1ms 0 Timer disabled DBW1242 Define which Dummy 15 An selected analog LS AI FAI to input for comparator s read poll polling by PLC 0 00 selection 0 01 15 10 0 02 LS OxO3 LS Al2 0 04 15 AI3 Ox11 FAIO Ox12 FAI DBW1244 Define which Define which The first AQ selected The second AQ AQ is the first AQ is the by PLC selected by PLC must AQ to write second AQ to 0 00 selection be different from the write first AQ 0x01 AQ1 0 02 2 0 00 selection 0x01 AQ1 2 0 02 2 04 0 03 0x04 AQ4 DBW1246 Define first DO Define second 0 00 selection 0 00 selection to write DQ to write 0 01 0 28 selects 0 01 0 28 selects DQ1 DQ40 DQ1 DQ40 DBW1248 Define third DQ Define fourth 0 00 selection 0 00 selection to write DQ to write 0 01 0 28 selects 0x01 0x28 selects DQ1 DQ40 DQ1 DQ40 DBW1250 Comparator value threshold 1 Value for starting Comparator Mode DBW1252 Comparator value threshold 2 Value for triggering outputs DBW1254 output value 1 Value for first AQ selected above DBW1256 AQ output value 2 Value for second AQ selected above DBW1258 DQ output value DQ output value Value for first DQ Value for second DQ selected above selected above DBW1260 DQ output value DQ output value Value for third DQ Value for fourth DQ selected above selected above 5 90 SIJECT 161 Start up T
49. erve the status of LEDs BATF red DC5V green and SF red are lighting on and STOP yellow is flashing PLC should be reset 2 Switch the mode selector S1 to position MRES by screwdriver and observe the status of LEDs BATF red and DC5V green are still on SF red is off STOP yellow will flash rapidly at first then stay on 3 Switch the mode selector S1 to RUN_P and you will find that STOP yellow is off and RUN_P green is on 2 7 Installing the Control System 4 Put the plug at the end of the battery cable into the connector of the Cl board pay attention to the pole of battery and BATF red is off 5 Insert the battery into the battery holder and the battery installation is finished You can download the PLC program Caution In case that SF red keeps bright and STOP yellow is always flashing in the above mentioned process you should repeat step 2 and step 3 until both LEDs go dark Battery Replacement Operating steps 1 When battery alarm occurs a flag DB1 DBX59 1 will be set to 1 the lithium battery must be replaced 2 Pull out the used lithium battery 3 Replace it with a new one Warning 1 Exchange battery with power on Otherwise program will be lost 2 There is risk of fire explosion or combustion Do not recharge disassemble crush heat above 212 F 100 C or incinerate 2 8 SIJECT 16i Start up Mounting dimensions Fig 2 1 SIJECT 1
50. fic job within the scope of programming an automation task such as configuring and assigning parameters to the hardware creating and debugging user programs configuring networks and connections The basic package can be extended by a range of optional packages for example additional programming language packages such as SCL S amp Graph or HiGraph The graphic user interface provided for these tasks is known as the SIMATIC Manager The SIMATIC Manager collects all the data and the settings necessary for an automation task together in a project Within this project the data are structured according to their function and represented objects Notice To operate the SIMATIC Manager please order the software and program 4 81 5 Technical Appendix 5 1 Definition of DB1 Address Type Description DB1 DBX1 0 Key Semi auto mode DB1 DBX1 5 Mold adjustment mode DB1 DBX1 6 Motor start DB1 DBX1 7 Motor stop DB1 DBX2 0 Key Air blow 1 DB1 DBX2 5 Purge start DB1 DBX2 6 Purge stop DB1 DBX3 0 Key Carriage retract DB1 DBX4 0 Key Core 3 in SIJECT 161 Start up 5 83 Technical Appendix DB1 DBX4 5 Injection reset DB1 DBX4 6 Confirm update time DB1 DBX4 7 Force output 0 recipe byte 1 recipe word 2 actual value 252 packed variable DB1 dummy1 DB1 val index Data from OP to PLC DB1 op value DB1 op spare1 Type of value DB1
51. ghlights part of the documentation for special attention Qualified Person Proper use A The unit may only be started up and operated by a qualified person or persons Qualified persons as referred to in the safety guidelines in this document are those who are authorized to start up earth and label units systems and circuits in accordance with relevant safety standards Please note the following Warning The unit may be used only for the applications described in the catalog or the technical description and only in combination with the equipment components and devices of other manufactures as far as this is recommended or permitted by SIEMENS This product must be transported stored and installed and maintained and operated with care to ensure that it functions correctly and safely Contents 1 SIJECT 16i Control ceateeeeonedesseesstncstendderserrecteteannddssduevetearentidessuere 1 2 14 Components of 1 2 1 2 Technical Data coire oeeie e Le RE ed el 1 4 1 3 Order eh ean eaten elec eee ce eb tet 1 6 Installing the Control System 2 7 2 1 Installing and Dismantlin Gis o e ette aed o e eed 2 7 2 2 nterfaces and Cabling iere E teorie te bones 2 12 2 3
52. hat the contents of this document correspond to the hardware and software described Nonetheless differences might exist and we cannot therefore guarantee that they are completely identical The information contained in this document is reviewed regularly and any necessary changes will be included in the next edition We welcome suggestions for improvement SIEMENS AG 2004 Subject to technical changes without notice SIJECT 16i Safety Guidelines This Manual contains notices intended to ensure your personal safety as well as to protect products and connected equipment against damage Safety notices are highlighted by a warning triangle and presented in the following categories depending on the degree of risk involved Danger Indicates an imminently hazardous situation which if not avoided will result in death or serious injury or in substantial property damage Warning Indicates a potentially hazardous situation which if not avoided could result in death or serious injury or in substantial property damage Caution Used with the safety alert symbol indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury or in property damage Caution Used without safety alert symbol indicates a potentially hazardous situation which if not avoided may result in property damage Notice Indicates important information relating to the product or hi
53. he Control System To ensure the normal operation of equipment good grounding is required Users are recommended to take following actions according to GB T5226 1 1996 eqv IEC204 1 1992 1 The grounding wire should be Yellow Green wire with cross section of 2 5 2 Linear scale and both sides of the shield of thermocouple signal wire must be grounded well on the injection molding machine 3 Metal sheet embedded underground can be used as earth wire Water pipe or metal frame of building which are grounded well can also be used as earth wire 4 To ensure the reliability of the grounding copper lead should be welded with earth wire Danger ZN The grounding wiring must be finished prior to connecting the power supply 2 42 SIJECT 16i Start up Installing the Control System 26 LEDs and Mode selector 54 Error and There are 10 LEDs on the front panel of the Cl status LEDs DP_SF DP_STAT Note The symbol means that this LED is only used SIJECT CI16iP Fig 2 17 Position of LEDs and mode selector 51 Table 2 15 Meaning of LEDs LED Meaning Description Remarks DP_SF System Fault Lights up if system is fault For Cl16iP red DP_STAT System Lights up if system works normally For Cl16iP green Normal STATO Cl Flashes at 1 second interval if Cl i
54. he controller with the integrated PLC program You should set and adjust the recipe data in compliance with the program No default recipe data exist in the control system with the version of the control supplied unless otherwise programmed SIJECT 16i Start up 3 49 Start up 3 1 3 Handling of recipe data Handling methods Display Input via keys and MMC card Making back up copies and saving to MMC card Loading the recipe data from MMC card Alarm when If the process of loading recipe data from MMC card has errors there will loading recipe be system message to inform the error data User can execute related operation according to the alarm Notice You should press Enter key to confirm your setting whenever any parameter has been changed 3 50 SIJECT 16i Start up Start up 3 1 4 Recipe data saving Internal data saving The recipe data on the screen can be automatically saved in the memory during operation After power on for the next time the saved recipe data will be recovered To avoid loss of the setting parameters the recipe data should be saved internally before the control system is switched off In the permanent memory max 30 sets of recipe data with the relevant mould number can be saved It is recommended to carry out internal data saving whenever important data changes have been made Saving data internally Use the Save Load key to enter save screen and use Selection key L1
55. hreshold 2 Value for triggering outputs DBW1280 AQ output value 1 Value for first AQ selected above DBW1282 output value 2 Value for second AQ selected above DBW1284 DQ output value DQ output value Value for first DQ Value for second DQ selected above selected above DBW1286 DQ output value DQ output value Value for third DQ Value for fourth DQ selected above selected above SIJECT 161 Start up 5 91 Technical Appendix 5 2 Glossary abbreviation AC Al AQ ADC BATF CORA Cl CPU CSP DAC DC DI DQ DPSF DPSTAT DRAM FRCE HW LCD LED LS MMC MPI MRES OP PC PG PV PROFIBUS P BUS PLC RECIPE RUN P SRAM SF SW 5 92 Alternating current Analog input Analog output Analog digital conversion Battery fault Coupling RAM Arbiter Compact interface Central processing unit Customer specific picture Digital analog conversion Direct current Digital input Digital output CPU 3xxDP system fault CPU 3xxDP system status Dynamic RAM Force Hardware Liquid crystal display Light Emitting Diode Linear scale Multi media card Multi port input Reset memory Operator panel Programming device Proportion valve Profi_Bus Periphery Bus Program logic controller Recipe Program run Static RAM System fault Software Temperature input SIJECT 16i Start up SIEMENS NUMERICAL CONTROL LTD NANJING CHINA R amp D Division No 18 Siemens Road Jiangning
56. ix DB1 DBW80 X201 DBIDBW90 02 4 input linear scale 4 0 10 carriage Semaphore MEM_COMM 0 finished 1 put recipe into DB2 2 get recipe from DB2 DB1 recipe_len Length of recipe unit byte DB1 recipe_data The starting address for recipe ARRAY 0 1023 of byte DB1 DBB96 DB1 DBB1119 Error DB1 comm errors ARRAY 0 15 of word for internal use only Don t use on customer side Error DB1 io errors for internal use only Don t use on customer side Error DB1 perf errors for internal use only Don t use on customer side Filter configuration Filter for Filter for Bit 7 to 4 always 0000 analog in fast 0 analog in fast 115 4 to 0 Filter is disabled 1 to 15 different Filter characteristics Filter configuration Filter for Filter for Bit 7 to 4 always 0000 analog in fast 2 analog in fast 3s to 0 0 Filter is disabled 1 to 15 different Filter characteristics X207 analog in fast 0 In Volts 0 10 process data to PLC X207 analog in fast 1 In Volts 0 10 process data to PLC analog in fast 2 In Volts 0 10 process data to PLC analog in fast 3 In Volts 0 10 process data to PLC Rx flag the PLC sets this flag to indicate to the IO software that there is a new instruction Virtual communication in Rx meaning Rx length and Rx buffer The IO software resets this flag after processing the buffer
57. ld In case of malfunction the alarm symbol will flash and user can enter alarm picture to check the alarm Notice For the meaning of each indicator on this screen please refer to Chapter Two of Operation Manual for details 3 55 Start up 3 2 2 Alarm General Alarm list 3 56 Up to 32 alarms can be displayed in SIJECT16i The active alarm will pop up on the Alarm screen You can see the alarm text and remedy in following table Table 3 3 Alarm list Mold adjustment is over limit AdjLimit 1 Check the limit switch Mu Seamer Auto mold adjustment finished AutAdjFin 1 Manual operation is permitted Photo sensor for mold adjustment is invalid 1 Photo sensor is invalid in mold adjustment advance retract 2 Check if the photo sensor is damaged Temperature is not in permitted range 1 Check the heating status of barrel 2 Check if the heating LED lights up Oil temperature is out of the range 1 Check the oil temperature 2 Check the oil thermocouple Hydraulic pump is overload 1 Check the hydraulic system 2 Check the circuit breaker Safety door is not closed 1 Check the limit switch of safety door 2 Close the safety door Product counter is full PartCount 1 Enter a big value Actual cycle time surpasses the setting TmCyc 1 One step occupies too much time during the cycle 2 Cycle time is too short Cycle photo sensor is covered CycSenCov 1 The photo sensor is damag
58. le Motor protection also can be deselected Special selection 1 SpecSel 1 Spare Special selection 2 SpecSel 2 Spare Screw cam number ScrewCam During screw speed measurement cam numbers set on the screw Range 1 255 Motor shut When there is alarm it is the time passing by from alarm occurring to motor shut Range 30 999 Heat When alarm occurs user selects whether to switch off the heater Ejector retract tolerance EjeRetTol When ejector selects linear scale the tolerance of ejector retract can be set from 0 1 9 9 mm Mold open tolerance MidOpnTol The tolerance of mold open can be set from 1 0 99 9 SIJECT 16i Start up 3 63 Start up Special parameter 3 SpecPar 3 Spare Special parameter 4 SpecPar 4 Spare Operation Example select position in carriage retract mode you can do as follows 1 Press cursor key A or v to enter CarRetMod selection L1 2 Press selection key and the cursor moves to left 3 Press cursor key A or v to select Pos 4 Confirm by Enter key 3 64 SIJECT 16i Start up Start up 3 4 3 Setting linear scale General Users can select two linear scales or three linear scales and set reference point and length Switch Current Ref Actual Length LS Mold 1999 9 999 9 1999 9 2000 LS Inject 1999 9 999 9 1999 9 2000 LS Eject 99
59. n assignments of connector X300 Name Type 2 5 1L 1M 000 0 000 1 000 2 000 3 000 4 000 5 000 6 000 7 lt lt hm gt e X301 Name Type 2 5 2L 2M 001 0 001 1 001 2 001 3 001 4 001 5 001 6 001 7 lt lt O LOIN D O AIIN gt e X302 Name Type 2 5 3L 3M DQ2 0 002 1 002 2 002 3 002 4 002 5 002 6 002 7 lt lt e SIJECT 16i Start up 2 33 Installing the Control System 2 34 0 5 8L Name X303 Type 8M DQ3 0 DQ3 1 DQ3 2 DQ3 3 DQ3 4 DQ3 5 gt 003 6 003 7 I 5 Name X304 Type 9L 9M DQ4 0 DQ4 1 DQ4 2 004 3 004 4 004 5 OD 004 6 004 7 Voltage Rated load voltage Max load voltage Current Rated load current Max load current Short circuit protection Simultaneity factor 24V 28 8V 2A 2 4A Yes 50 SIJECT 161 Start up Connecting sensor and actuators Signal description SIJECT 161 Start up Installing the Control System LIZ 262 7 07 07 07 07 07
60. of 1 Fig 3 16 Service Screen 2 3 Temperature setting On service screen 1 press softkey to enter service screen 2 a linear scale setting Then press softkey F4 50 temperature setting screen Temperature channel be set from 1 to 5 and temperature can be set accordingly Temperature Tolerance Plus set the tolerance plus for each temperature channel Temperature Tolerance Minus set the tolerance minus for each temperature channel Oil Upper set the upper limit of hydraulic oil temperature Oil Lower set the lower limit of hydraulic oil temperature Temperature Compensation set the temperature compensation The system has been set compensation before delivery and it is unnecessary for users to set it Nozzle Mode two modes are available it can be assigned as close loop or open loop Channel 1 select or deselect Channel 2 select or deselect Channel 3 select or deselect Channel 4 select or deselect Channel 5 select or deselect Oil Temperature Alarm If oil temperature alarm is selected when the upper lower limit of oil temperature has been set there is no alarm if oil temperature is within the specification and alarm occurs if it is out of specification 3 73 Start up 3 74 Notice The default type of the thermocouples is K unless otherwise programmed in the PLC ap
61. p 3 60 On information screen 1 Fig 3 5 Information Screen 1 press softkey F4 to enter DO screen digital output or on information screen 1 2 Fig 3 6 Information Screen 1 2 Dl press softkey F1 to enter DO screen X300 X301 X302 X303 X304 000 0 002 0 E 09030 0040 E 090 1 091 1 092 1 093 1 094 1 000 2 0901 2 002 2 0032 000 3 091 3 0092 3 093 3 094 3 000 4 0014 HM 0024 0034 0044 090 5 091 5 092 5 093 5 094 5 200 6 BM pate 002 6 0046 B 090 7 091 7 092 7 093 7 094 7 L L1 Force output 3 7 _ Fig 3 7 Information Screen 1 3 DO Use current parameters to check the LED status Press different button in manual mode to observe the changing status On Fig 3 7 Information Screen 1 3 DO Force Output is for the force output of certain point For example enter 3 4 and press F2 Force Output then the box will backlight At this moment DQ3 4 is backlighting on the screen and in the system this point will have output and LED lights up SIJECT 161 Start up Start up 3 4 Setting important parameters SIJECT 16i Start up In this chapter we will give a description of how OEMs set the most important parameters for injection molding machine It contains how to select lang
62. play screen 1 Customer specific picture SIJECT 16 Tel 86 25 52101888 Fax 86 25 52101666 Siemens Numerical Control Ltd Nanjing P R China Starting please wait Fig 3 2 Customer Specific Picture CSP This picture is presented for 3 seconds SIEMENS can make every specific picture according to the requirements of users SIJECT 161 Start up SIJECT 16i Start up Start up Menu 2 Information screen 1 SIJECT OP15B System Information OP Version 1 10 CI Version 1 10 PLC Version 2 08 Siemens Numerical Control Ltd 8 4 ur Fig 3 3 Information screen 1 This picture will last 3 seconds Menu 3 Monitoring screen st lt 140 bar 100 yt iot MidPos 1500 0 mm PartCount 65535 ScwPos 999 9 mm CurStartup 65535 EjePos 999 9 mm CycTime 999 s ScwSpd 1200 0 50 Fig 3 4 Monitoring screen This screen is the main picture of the system This screen is always displaying until it is switched to the desired menu by pressing the other keys The operator can supervise the production process with reference to the parameters displayed on the screen The current operation state is displayed in the status fie
63. ple of channel 4 heater is broken TC4 Fault 1 Thermocouple of channel 5 heater is broken TC5 Fault 1 Thermocouple of channel 6 oil is broken SIJECT 16i Start up 3 3 Checking I Os Overview Operating sequences aa SIJECT 16i Start up After booting without any error the control system can be put into operation Check l Os status prior to setting the parameters which can avoid the unnecessary troubleshooting Press Information Key to enter information screen Then press softkey F3 or F4 to check the actual status of digital input output OP Version CI Version PLC Version Fig 3 5 Information Screen 1 SIJECT OP15B System Information 1 10 1 10 2 08 Siemens Numerical Control Ltd Slaa Then press softkey to enter DI screen digital input X203 X204 010 0 010 DI 0 1 O D11 010 2 NM 012 DI 0 3 DI 1 3 BM 014 DI 0 5 DI 1 5 010 6 01 6 010 7 DI 1 7 X205 DI 2 0 DI 2 1 DI 2 2 DI 2 3 DI 2 4 DI 2 5 DI 2 6 DI 2 7 X206 DI 3 0 DI 3 1 DI 3 2 DI 3 3 DI 3 4 DI 3 5 DI 3 6 DI 3 7 Use current parameters to check the LED status 1 1 1 er Fig 3 6 Information screen 1 2 DI Press different button in manual mode to observe the changing status 3 59 Start u
64. plication Normally the themperature compensation is intended only for the controller manufacturer to calibrate the offset of the electronic measurement device on the controller and every SIJECT is delivered in a compensated state In case it should be necessary to re compensate the thermocouple i e the displayed temperature is different from the actual temperature value please perform the following steps 1 Measure the outside temperature with a thermometer before starting the heater 2 Type in the outside temperature value Check the heater temperature on Temperature Screen The displayed value must be exactly the measured outside temperature Caution The thermocouple input is scanned every 80ms at intervals and the displayed temperature values on the screen will be refreshed every 720ms for all 8 thermocouple inputs and the ambient temperature The broken wire detection is done every 40 seconds at intervals It makes a clicking sound at the same time SIJECT 161 Start up Start up 3 4 10 Setting the ramp data General Operating Sequences SIJECT 16i Start up All the ramp data are assigned in order to moderate the running shake of the machine during the movement switch so that the product service life can be extended Users should observe the machine movement diversification when adjusting the setting data and optimizing the parameters until the machine can run smoothly
65. read or write Semaphore COMM DB1 op comm FF data from OP are in DBW0 DBW10 00 PLC has read the data and stored in DBW20 DBW24 Dummy 2 Motor start Mold adjustment mode Manual mode m ITI ITI TI gt Cycle run Photo sensor full auto mode Timer full auto mode Im Semi auto mode m Heater start Data from PLC to OP DB1 plc_value DB1 plc_spare 00 type J thermocouple DB1 DBB29 00 process alarm FF have process alarm DB1 DBW30 Po Life counter incremented by PLC program 00 PLC start up not finished and ready BELPER SS es FF PLC start up finished and ready DB1 DBB33 Screw pulses round ud per ure d Pearl we ber ard ce edd ier e eed sr er ral ce gt 00 00 UJ uvv vvv UJ gt lt gt lt gt lt gt lt gt lt 50 w 51515 NINININININININ a 9 RU Pose pese o 5o0 x 9 N NIL oa p SIJECT 16i Start up Technical Appendix Machine ready 0 ready 1 running DB1 DBW37 Bit1 OP selection 15 1 Bit2 PV selection
66. reen will display a message Press Acknowledgment Key ck to finish the operation Lower Higher password it is the password level 2 The default value of this system is 2000 then confirm by Enter Key New password 1 a new password 1 can be set here then confirm by Enter Key The default value of this system is 1111 Retype password 1 retype the new set password 1 then confirm it by Enter Key When the password has been successfully changed the screen will display message Press Acknowledgment Key to finish the operation 3 67 Start up 3 4 5 Save load setting General Users can save load the PLC menus and CSP customer specific picture by this function It can save load information to from MMC Program Types PLC v MMC PLC version 2 00 Fig 3 12 Service Screen 1 2 save load setting Operating sequences Press softkey F4 to enter save load screen The PLC menus CSP can be saved loaded to from MMC Program types User can select PLC menus or CSP MMC PLC version displayed value Press softkey F2 PLC version to show the PLC version in MMC Operating examples select Menus in Program types Steps are as follows 3 68 1 Press cursor key A or v to enter program type selection L1 2 Press Selection Key the cursor moves to the left 3 Press cursor key to select Menus 4 Press
67. ry then input passward of level one of 1111 then press Enter key to return to Function Screen The cursor moves to left and choose by key A or Select one language Press Enter Key to confirm 3 62 SIJECT 16i Start up 3 4 2 Service selection General Users can execute some basic setting and selections by this function CarRetMod Time Y CycSenNSTD NOpn Y LubErrNSTD NOpn Y FastMIdO pn Norm MotStrPro On 1 Off v SpecSel 2 Off v Fig 3 9 Service Screen Operating Sequences e Press Service Key to enter Service screen 1 See Fig 3 9 1 ScrewCam Motor Shut Heat Off EjeRetTol MidOpnTol SpecPar 3 SpecPar 4 255 999 Off 20 0 a 9 Start up Carriage retract mode CarRetMod Carriage retract can select position mode or time mode Cycle sensor not standard CycSenNSTD Sensor can be set as Normal Open mode Nopn mode or Normal Close NClo mode Lubrication error not standard LubErrNSTD Switch contact in the alarm circuit can be set as Normal Open mode Nopn mode or Normal Close NClo mode Fast mold open FastMldOpn It can be set as Normal mode fast mold open and special mode slow mold open Motor protection MotStrPro Motor protection can be selected i e whether to extend time during the start up of star triang
68. s green Normal normal STAT1 Cl Lights up if Cl is fault red Fault BATF Battery Fault Lights up if the battery is defective or not red inserted DC5V Power Supply The LED will be bright all the time if the Check DC5V green Error DC circuit is normal circuit SIJECT 16i Start up 2 43 Installing the Control System LED Meaning Description Remarks SF System LED flashes when there is You must use a red Error Fault programming Fire faults device and read Firmware errors out the contents e Programming errors of the diagnostics e Parameter assignment errors buffer to determine the rithmetic errors exact nature of e errors the error fault e Defective memory card e Battery failure or no backup on power on e O fault error external I O only FORCE Force job Lights up if a force job is active yellow STOP STOP Mode Lights up when CPU is not scanning the yellow user program Flashes at 1 second interval when CPU requests a memory reset RUN RUN Mode Flashes at 2Hz during CPU restart green e Atleast continue seconds however CPU restart can be shorter after CPU restart e During the CPU restart the STOP LED always lights up when the STOP LED goes dark the outputs are enabled Mode selector S1 Mode selector S1 has 4 different positions It depends on the Gray code Table 2 16 Mode selector S1 GRAY 2 GRAY 1 MRES 0 1 STOP 0 0 RUN
69. s set pressure and flow for each and the range is from 0 to 99 The values should be the differences for pressure and flow between every two PLC cycles when there is action switch 3 75 Start up 3 76 Mold Open there are four ramps to be set pressure and flow for each ramp and ranged from 0 to 99 The values should be the differences for pressure and flow between every two PLC cycles when there is action switch Ejector it is the ramp before and after the actions of ejector set pressure and flow for each and the range is from 0 to 99 The values should be the differences for pressure and flow between every two PLC cycles when there is action switch Decompression they are the ramps when decompression begins and decompression completes set pressure and flow for each and the range is from 0 to 99 The values should be the differences for pressure and flow between every two PLC cycles when there is action switch Core 1 it is the ramp for core 1 in out set pressure and flow for each and the range is from 0 to 99 The values should be the differences for pressure and flow between every two PLC cycles when there is action switch Core 2 Core 3 the operating sequence is same as Core 1 SIJECT 16i Start up Start up 3 5 Up Downloading and Deleting PLC Program 3 5 1 Up Downloading and Deleting PLC Program General Preconditions Up Download Procedure SIJECT 161 Start up The highlight of S
70. ssignments Interface for digital inputs for connector Connector designation X203 X204 X205 X206 Input Connector type 10 pin plug connector Table 2 6 Pin assignments of connector X203 Name Type 0 5 010 0 010 1 010 2 010 3 010 4 010 5 010 6 010 7 4L 4M V gt 204 0 5 011 0 011 1 011 2 011 3 011 4 011 5 011 6 011 7 5L 5M V D O jo NI 205 0 5 012 0 012 1 012 2 012 3 012 4 012 5 012 6 012 7 6L 6M V OD oO AIIN gt 2 24 SIJECT 161 Start up Installing the Control System X206 Pin Name Type 1 DI3 0 2 013 1 3 013 2 4 013 3 5 013 4 6 013 5 7 013 6 8 013 7 9 7L 7M V 10 Input voltage Signal 1 15V 30V Signal 0 0 5V Input current Signal 1 6mA Connecting sensors and actuators N 4 N 5 00 7 204 017 NJ 00 6 NJ 0156 I 010 5 NJ 54 010 4 gt N 014 LL Di2 N 012 lt NJ DIM NJ NJ Dno SS NJ 6L 6M 7L 7M Xogs NJ DI27 DI3 7 NJ 026 X206 DI3 6 NJ 012 5 013 5 NJ 0724 013 4 NJ 023 013 3 NJ 022 013 2 NJ 0241 013 1 N 0
71. t pressure value ranged from 0 140bar Firstly start valve adjustment Select ON in Adjust Valve mode 1 Use cursor key A or to enter valve adjustment selection 2 Press selection key Use cursor key A or to select ON Press Enter key to confirm and the cursor moves to the left 3 69 Start up Secondly select valve type such as pressure valve then select valve limit such as maximum Choose Max in valve limit and change its value by softkey 1 Use cursor key A or to enter valve adjustment selection L1 2 Press selection key and cursor moves to left Use cursor key Or Y to select Max 4 Confirm it with Enter Key 5 Press softkey to increase the or use softkey F4 to reduce Max This process can be observed by external amperemeter After finishing the adjustment of the valves select OFF to stop valve adjustment Lastly check the adjustment result In the Force Output mode implement the Pressure Test 1 Press softkey F2 Force Output and the upper box will backlight 2 Set the value of 140bar in Pressure Test 3 Check if the external amperemeter reaches the maximum such as 1Amp Caution The handling with the Proportional valve is subject to the prerequisites that all the electrical wiring is completed and the power supply DC 24V DC 38V is connected We describ
72. tch the machine Plug in a MMC card with PLC application in it Switch the machine on Set the Mode Selector S1 in RUN P position The PLC application can only be uploaded automatically if ak WN gt PLC module does not contain PLC application Green Run LED should be on stably at least for 6 seconds to give the PLC application enough time to startup APLC application matching the used type of PLC module is stored on the MMC card Switch the machine off Remove the MMC card from the CI Switch the machine on again and continue the normal operation Notice Same as downloading a new PLC program from MMC after downloading PLC application from PC PG also be sure to switch the machine off then switch on again Note Since the uploading operation is not triggered by the OP there will be no indication of the progress of uploading on an OP15 or OP15B operator panel and any request from those OP s will be ignored On a Simatic OP connected to the 1 there will be no indication anyway since the PLC module is kept in RESET and no service available In both cases termination of the upload can be detected only by monitoring the LED s of the PLC module on the CI board 3 79 4 Programming Tool 41 SIMATIC Manager Introduction SIJECT 161 Start up STEP7 is the basic programming and configuration software for SIMATIC It is made up of a series of applications each of which does a speci
73. tract end should be the reference of linear scale Length setting value The length of linear scale can be set here ranged from 1 6553mm Actual value displayed value Display the actual value of linear scale Current value displayed value It is the difference from actual value to reference point Linear scale ejector Linear scale ejector can be selected or deselected here 3 66 SIJECT 16i Start up Start up 3 4 4 Setting password General Operating sequences SIJECT 16i Start up The password has three levels Password level 1 of factory setting is 1111 and level 2 is 2000 Refer to manufacturer for password of the highest level Higher Pwd New Pwd 2 Retype Pwd 2 Higher Pwd New Pwd 1 Retype Pwd 1 1 1 1 Fig 3 11 Service Screen 1 1 password setting Press softkey F3 enter password setting screen See Fig 3 11 Information screen 1 1 password setting and password can be set and changed on this screen Upper Higher password the highest level The default value of this system is please ask the manufacturer then confirm by Enter Key New Password 2 A new password 2 can be set here then confirm it by Enter Key The default value of this system is 2000 Retype Password 2 retype the new set password 2 and confirm it by Enter Key When the password has been successfully changed the sc
74. uage and service how to set each parameter such as linear scale password saving mode start up of proportional valve combination of pumps lubrication temperature and ramp Warning Never pull out or plug in the connector while the equipment is live Otherwise this can result in the damage of data loss or control failure Caution Password of level 2 2000 must be entered prior to parameter setting During operation do not transfer the parameter 3 61 Start up 3 4 1 Language selection General It is very important for operators to find the desired menus as soon as possible As the first step you should select the appropriate language You can select the language on this screen Robot on Back Light om Y Language English Fig 3 8 Function Screen Notice For SIJECT OP15B FV1 English Chinese Turkish and Russian are available for your selection For SIJECT OP15B FV2 English Chinese Spanish and one reserved language are available for your selection Operating Sequences Change language first move the cursor to the third line then press softkey F1 to choose the desired language and confirm with Enter Key Refer to Fig 3 8 Function Screen language be changed Steps as follows 1 Press cursor key A or to enter language selection box L1 2 Press selection key if it is the first ent
75. y and Mode selector S1 are set correctly the control system boots The Cl is provided with the Mode selector to assist start up of the control system This switch can be operated by a screwdriver Table 3 2 Mode selector setting Meaning Reset CPU memory STOP mode RUN mode RUN PROGRAM mode When starting up the control system Mode Selector S1 should be at RUN P position Do not use RUN mode RUN mode is only for internal debugging The PLC stops any communication in RUN mode The position RUN P must be held during the down uploading PLC program When the control system is turned on for the first time an initial state of the control system is established automatically All memory areas are initialized and loaded with previously stored default data This initial state is the precondition for error free start up of the control System SIJECT 16i Start up Start up 3 2 1 Boot messages Displays on the screen LED signal SIJECT 16i Start up When the control system is booting the booting process will be displayed on the screen as follows 1 At first the customer specific picture is displayed for seconds 2 Then on the screen shows the Information menu for 3 seconds 3 After this the Monitoring screen will be opened If the control system has booted without errors the green DC5V LED will light up and the green STAT1 LED in CI 16i flash at 1 second interval or the green DP STAT LED in C

SIJECT 16i Start-Up - Service, Support

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