Siemens SIMATIC 505 User & Programmers Manual
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Siemens SIMATIC 505 User & Programmers Manual

Siemens SIMATIC 505 User & Programmers Manual

Turboplastic module
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SIMATIC 505
TurboPlastic Module
User/Programmer Manual
Order Number: PPX:505–8117–3
Text Assembly Number: 2586546–0041
Third Edition

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Summary of Contents for Siemens SIMATIC 505

  • Page 1 SIMATIC 505 TurboPlastic Module User/Programmer Manual Order Number: PPX:505–8117–3 Text Assembly Number: 2586546–0041 Third Edition...
  • Page 2 All Rights Reserved — Printed in USA Reproduction, transmission, or use of this document or contents is not permitted without express consent of Siemens Energy & Automation, Inc. All rights, including rights created by patent grant or registration of a utility model or design, are reserved.
  • Page 3 MANUAL PUBLICATION HISTORY SIMATIC 505 TurboPlastic Module User/Programmer Manual Order Manual Number: PPX:505–8117–3 Refer to this history in all correspondence and/or discussion about this manual. Event Date Description Original Issue 05/91 Original Issue (2592530–0001) Second Edition 07/93 Second Edition (2592530–0002)
  • Page 4 LIST OF EFFECTIVE PAGES Pages Description Pages Description Cover/Copyright Third History/Effective Pages Third iii — ix Third 1-1 — 1-12 Third 2-1 — 2-33 Third 3-1 — 3-20 Third 4-1 — 4-7 Third 5-1 — 5-24 Third A-1 — A-14 Third B-1 —...

  • Page 5: Table Of Contents

    Contents Chapter 1 Overview Introduction ..............References .
  • Page 6 PLC Output Words: PLC Data Module ......... . WY5 = Pointer to V-memory .
  • Page 7 Chapter 4 Discrete Outputs Description ..............Specifications .
  • Page 8 5.10 End-of-Profile Conditions ............5-18 Checking End-of-Profile Condition .
  • Page 9 List of Figures 1-1 Operator Safety Switch Shutoff ........... . . 1-2 TurboPlastic Module Closed Loop Control .
  • Page 10 B-1 Sample RLL for Noise Check ............B-2 Ejector Logic Diagram for RLL Implementation .
  • Page 11 List of Tables 2-1 WX1 = Module Cycle Status ............2-2 WX2 = Cycle Complete Codes .
  • Page 12 Chapter 1 Overview Introduction ..............References .

  • Page 13: Introduction

    The TurboPlastic module functions in any base of the SIMATIC 545 and SIMATIC 555 PLCs. For other controllers, contact your Siemens Energy & Automation, Inc. distributor or sales office. If you need assistance in contacting your U.S.

  • Page 14: Agency Standards

    73/23/EEC and Electro-Magnetic Compatibility Directive 89/336/EEC). A Approval declaration of conformity is included with each CPU. Technical For technical assistance, contact your Siemens Energy & Automation, Inc., Assistance distributor or sales office. If you need assistance in contacting your U.S. distributor or sales office, call 1–800–964–4114.

  • Page 15: Who Should Read This Manual

    If problems are encountered that cannot be resolved by use of this manual, please contact your Siemens Energy & Automation, Inc. distributor or sales office. If you need assistance in contacting your U.S.

  • Page 16: Operator Safety Switch Shutoff

    Siemens recommends providing a means of disconnecting power from the output loads when the machine is not operating or when it is necessary for the operator to reach into the machine. Power must be removed by a non-semiconductor switch or hard-wired relay contact placed to interrupt power to the output load.

  • Page 17: List Of Terms

    List of Terms Closed Loop Mode The mode in which the module reads a feedback signal value and uses that value to modify the output signal to achieve the desired result. Boundary Those conditions that must be present (such as maximum time reached or Conditions maximum position attained) at the time the module changes profiles or makes the transition to the next profile.

  • Page 18: Module Functional Diagrams

    Module Functional Diagrams The TurboPlastic module closed loop control is shown in Figure 1-2. Position Ram Position Feedback Transducer Pressure Hydraulic Pressure Transducer Feedback Motion Hydraulic Pressure TurboPlastic Injection Proportional Process Valve Valve Hydraulic Control Command Pressure & Module Flow Injection Cylinder Clamp...

  • Page 19: Machine Control Diagrams

    Machine Control Diagrams The module inputs and outputs are shown in Figure 1-3. Analog Inputs Analog Outputs Clamp Turbo Amplifier Clamp pressure source valve Plastic Clamp Clamp position source Amplifier GOOD valve Ram pressure source Amplifier valve Ram position source Amplifier valve Cavity pressure source...

  • Page 20: Plastic Injection Molding Machine Control Points

    The plastic injection molding machine control points are shown in Figure 1-4. Clamp end Water circulates Injection end of machine to cool and solidify of machine plastic in mold 0–10V Heater bands melt Mold pellets to liquid plastic position sensor Screw motor Hopper Injection ram...

  • Page 21: Turboplastic Injection Molding Cycle

    Machine Control Diagrams (continued) The TurboPlastic injection molding cycle is shown in Figure 1-5. Clamp profile control Ram profile control Clamp profile control Ram forward inject Ram retract Clamp close Injection Pack and hold Plasticate Clamp open Pressure Pressure Back Pressure Velocity Pressure Velocity...

  • Page 22: Analog Performance Specifications

    Analog Performance Specifications Four high-speed analog outputs Clamp hydraulic flow Clamp hydraulic pressure Injection ram hydraulic flow Injection ram hydraulic pressure Voltage ranges: 0 to +10 V, or 0 to –10 V; 0 to +5 V, or 0 to –5 V 12-bit resolution, 0.25% accuracy 5 mA output current Five high-speed analog inputs...

  • Page 23: Environmental Specifications

    Environmental Specifications Operating temperature 0 C to 60 C (32 F to 140 F) Storage temperature –40 C to 70 C (–40 F to 158 F) Relative humidity 5% to 95% noncondensing Vibration Sinusodial IEC 68–2–6, Test Fc; 0.15 mm peak-to-peak, 10–57 Hz; 1.0 g, 57–150 Hz Random NAVMAT P–9492 or IEC 68–2–34, Test...

  • Page 24: Module Functions

    Chapter 2 Software Interface Module Functions ............. . . 2.1.1 Operator Interface .

  • Page 25: Operator Interface

    Module Functions The TurboPlastic module is a table-driven controller that operates on an algorithm and requires no programming or setup. A choice of algorithms is provided, and many flexibilities are available in addition to the actual profile capability. These flexibilities can be accessed by storing appropriate values in a table.

  • Page 26: Module Integrity Indicators

    2.1.4 Module Integrity There are two LEDs on the front panel of the module: Indicators indicates overall module integrity. MOD GOOD (Pgm/Run) indicates that the module is in run mode and the following conditions are met: – WY7 contains value 1121 –...

  • Page 27: Normal I/O Interface

    Normal I/O Interface The normal I/O interface is used for handshaking and status reporting between the PLC and the TurboPlastic module. The TurboPlastic module is mapped as a four-word-in, four-word-out, special function I/O module with assignments as illustrated in Figure 2-1. PLC word address Module status...

  • Page 28: Plc Input Words: Module Data

    PLC Input Words: Module Data 2.3.1 WX1 = Module The module-cycle-status word continuously reports both the profile and the step that the module is currently executing to the PLC. See Table 2-1. For Cycle Status example, WX1 = 305 means the module is currently executing Step 5 of Pack and Hold.

  • Page 29: Wx2 = Cycle Complete Codes

    PLC Input Words: Module Data PLC (continued) 2.3.2 WX2 = Cycle The cycle-complete-code word immediately reports the completion of each Complete Codes cycle to the PLC. See Table 2-2. For example, WX2 = binary value 0000 0000 0001 0000 means that the Clamp Open profile just completed. Table 2-2 WX2 = Cycle Complete Codes (16-Bit Word) Bit 1(MSB)

  • Page 30: Wx3 = Status Codes

    2.3.3 WX3 = Status The status-code word continuously reports status and error information to Codes the PLC. All error bits are checked prior to starting a cycle. See Table 2-3. For example, WX3 = binary value 1100 0000 0000 0000 indicates that the module is in the run mode and is running a profile.

  • Page 31: Data Validation

    PLC Input Words: Module Data PLC (continued) 2.3.4 Data Validation The module validates the following data from normal I/O and the upload table within certain limits before a cycle starts; an error code is returned to WX3 if any discrepancy is found (see section 2.3.3 for bit codes). There is an illegal V-memory pointer in WY5 or WY6.

  • Page 32: Plc Output Words: Plc Data

    PLC Output Words: PLC Data Module 2.4.1 WY5 = Pointer to WY5 contains the V-memory start location for the profile download of the data table to the module. For example, WY5 = 101 means download table V-memory begins at V-101. Zero is not a valid value.

  • Page 33: Cycle Initiation Codes And Mode Select

    PLC Output Words: PLC Data Module (continued) A non-zero value in WY8 implies the functions identified in Table 2-5. Table 2-5 Cycle Initiation Codes and Mode Select (16-Bit Word) Cycle Initiation Codes Bit 1(MSB) Bit 16(LSB) and Mode Select Clamp close [1...

  • Page 34: Block Transfer I/O Assignments

    Block Transfer I/O Interface In order to provide control, the module reads 300 V-memory locations from the PLC and writes up to 100 V-memory locations to the PLC. See Figure 2-2. Block read table begins at Block write table begins at location location specified by word in WY5.

  • Page 35: V-Memory Block Read

    Block Read Data: PLC Module The module performs a block read of 300 consecutive V-memory locations starting at the V-memory location specified by WY5. See Figure 2-3. Table 2-8 contains all the information necessary for the module to perform a complete machine cycle, if so instructed.

  • Page 36: Definitions Of Constants

    2.6.1 Definitions of The constants (V-memory locations 1–14 of each of the five profiles) are Constants 1–14 defined in the following paragraphs. 2.6.2 Constant 1 Constant 1 contains the module sample rate for this profile: 0–32767 in PLC = 0–32.767 ms. The normal value is 5000 or 5 ms; the minimum value is 1500 or 1.5 ms.

  • Page 37: Constant 3

    Block Read Data: PLC Module (continued) 2.6.5 Constant 4 For clamp close profile, constant 4 contains the lock-over pressure value used in the clamp lock-over feature: 0–32000 in PLC = 0–10 V output (see constant 3). For inject and pack and hold profiles, constant 4 contains the maximum cavity pressure to transition value.

  • Page 38: Description

    2.6.10 Constant 9 Constant 9 contains the velocity loop reset (integral) value. Reset constant for PID calculation: 0–32767 in PLC = 0–327.67 ms. For example, 20000 = 200 ms reset factor. NOTE: The larger the reset value the smaller the reaction time on the PID calculation.
  • Page 39 Block Read Data: PLC Module (continued) Constant 10 Bit 5 (continued) Flow Output Voltage Polarity Velocity Byte Pressure Byte Description Select 0 to +10 V output range for flow [..0...] [..] command during profile* Select 0 to –10 V output range for flow [..
  • Page 40 Constant 10 Bits 9–10 (continued) Pressure Algorithm Velocity Byte Pressure Byte Description Select standard PID algorithm for [..] [00..] pressure calculation (default) Select dynamic PID algorithm for [..] [01..] pressure calculation Reserved [..] [10..] Reserved [..
  • Page 41 Block Read Data: PLC Module (continued) Constant 10 Bits 14–16 (inject and pack and hold profiles only) (continued) Pressure Transition Inhibit Velocity Byte Pressure Byte Description Permits transition on pressure during steps: 1 through 10 [..] [..000] 2 through 10 [..
  • Page 42 Constant 14 If changes to the default selection are required, the bit assignments are (continued) described below: Bits 1–3 Description (Reserved for future use) [xxx.....] Bits 4–7 Velocity Filter Constants Description Filter constant = 0.0 [...0 000..] Filter constant = 0.1 [...0 001.

  • Page 43: Step Data Entry Format

    Block Read Data: PLC Module (continued) Constant 14 Bit 9 (continued) Reverse Acting for Velocity Loop No reverse acting [..0..] Reverse acting [..1..] Bit 10 Reverse Acting for Pressure Loop No reverse acting [..0..] Reverse acting [..

  • Page 44: Download Table Memory Map

    Table 2-8 contains information on the download table memory map. Table 2-8 Download Table Memory Map Clamp Closing Profile Data Location Description Range Constants Module sample rate 0—32.767 ms Max profile time 0—327.66 seconds (327.67 = ) Lock-over velocity 0—32000 Lock-over pressure 0—32000 Lock-over time**...

  • Page 45: Download Table Memory Map

    Block Read Data: PLC Module (continued) Table 2-8 Download Table Memory Map (continued) Injection Profile Data Location Description Range Hydraulic Pressure Setpoint Data Step 1 pressure 0—32000 Step 2 pressure 0—32000 Step 3 pressure 0—32000 Step 9 pressure 0—32000 Step 10 pressure 0—32000 Constants WY5+44...
  • Page 46 Table 2-8 Download Table Memory Map (continued) Pack and Hold Profile Data Location Description Range Ram Hydraulic Pressure Setpoint Data Step 1 pressure 0—32000 Step 2 pressure 0—32000 Step 3 pressure 0—32000 Step 9 pressure 0—32000 Step 10 pressure 0—32000 Constants WY5+88 Module sample rate...
  • Page 47 Block Read Data: PLC Module (continued) Table 2-8 Download Table Memory Map (continued) Plasticate Profile Data Location Description Range Ram Hydraulic Pressure Setpoint Data Step 1 pressure 0—32000 Step 2 pressure 0—32000 Step 3 pressure 0—32000 Step 9 pressure 0—32000 Step 10 pressure 0—32000 Constants...
  • Page 48 Table 2-8 Download Table Memory Map (continued) Clamp Opening Profile Data Location Description Range Ram Back Pressure Setpoint Data Step 1 pressure 0—32000 Step 2 pressure 0—32000 Step 3 pressure 0—32000 Step 9 pressure 0—32000 Step 10 pressure 0—32000 Constants WY5+176 Module sample rate 0—32.767 ms...
  • Page 49 Block Read Data: PLC Module (continued) Table 2-8 Download Table Memory Map (continued) Hold Values Location Description Range Hydraulic Pressure Setpoint Data Step 1 pressure 0—32000 Step 2 pressure 0—32000 Step 3 pressure 0—32000 Step 9 pressure 0—32000 Step 10 pressure 0—32000 WY5+220 Channel 1 output...
  • Page 50 2.6.16 Description of Word 225 determines the output polarity during hold mode as follows. Word 225 Bit 1 Word 225 Description Channel 1 output 0 to +10 V [0....] Channel 1 output 0 to –10 V [1....] Bit 2 Word 225 Channel 2 output 0 to +10 V...
  • Page 51 Block Read Data: PLC Module (continued) Table 2-8 Download Table Memory Map (continued) Scaling Constants and Discrete Outputs Location Description Range WY5+225 Clamp close positive scale (future) 0—32000 Clamp close negative scale (future 0—32000 Injection positive scale 0—32000 Injection negative scale 0—32000 Pack and hold positive scale 0—32000...

  • Page 52: Download Table

    Table 2-8 Download Table Memory Map (continued) I/O Mapping and Scaling Location Description Valid Upload table entry 4: channel 1 (output) Physical channel number 1, 2, 5, 6 Minimum scale value 0—32000 Maximum scale value 0—32000 Upload table entry 6: channel 2 (output) Physical channel number 1, 2, 5, 6 Minimum scale value...

  • Page 53: V-Memory Block Write

    Block Write Data: Module The module performs a block write of 100 consecutive V-memory locations starting at the V-memory location specified by WY6. See Figure 2-4. Table 2-9 lists real-time variables and process values. The values in this table are updated in V-memory every PLC scan. Real-time process variables (11 words) Cycle status bits...

  • Page 54: Upload Table Memory Map

    Table 2-9 Upload Table Memory Map Real-time Process Variables, Cycle Status, SPC/SQC Data, Discrete Status Location Description Range (WY6) Actual loop calculation time 0—32767 microseconds Clamp position feedback (CH9) 0—32000 Clamp velocity calculated by module Clamp hydraulic flow output (CH1) Clamp hydraulic pressure feedback (CH4) Clamp pressure output signal (CH2) Ram position feedback (CH7)
  • Page 55 Block Write Data: Module PLC (continued) Table 2-9 Upload Table Memory Map (continued) Real-time Process Variables, Cycle Status, SPC/SQC Data, Discrete Status Location Description Range (WY6+29) Accumulated inject fill time 0—655.35 seconds Accumulated pack and hold time 0—655.35 seconds Peak inject cavity pressure 0—32000 Peak pack and hold cavity pressure Cavity pressure feedback (CH3)
  • Page 56 2.7.1 Real-time Process Bit 1 Status Bits for Description Words 12–16 End of profile at step #10 [1....] Bit 2 Description End of profile before Step 10 due to [.1....] 0 value in next step Bit 3 Description Max time exceeded except for Pack and...
  • Page 57 Chapter 3 Installation and Startup Machine Configurations ............Input/Output Configuration Switch Settings .

  • Page 58: Plastic Injection Molding Machine Control Points, Machine Configuration

    Machine Configurations The first step in preparation for use of the TurboPlastic module is to determine the machine control and valve configuration. Figure 3-1, Figure 3-2, and Figure 3-3 show diagrams of the three most common configurations. Although some differences will be noted between the examples and actual machine configurations, one of the three examples should be functionally appropriate.

  • Page 59: Plastic Injection Molding Machine Control Points, Machine Configuration

    Clamp end Injection end of machine of machine Water circulates to cool and solidify 0–10V plastic in mold Heater bands melt Mold pellets to liquid plastic position sensor Screw motor Hopper Injection ram Mold position sensor 0–10V Clamp actuator Pressure 0–10Vdc 0–10Vdc Flow...

  • Page 60: Plastic Injection Molding Machine Control Points, Machine Configuration

    Machine Configurations (continued) Clamp end Injection end of machine of machine Water circulates to cool and solidify 0–10V plastic in mold Heater bands melt Mold pellets to liquid plastic position sensor Screw motor Hopper Injection ram Mold position sensor 0–10V Pressure control valve Clamp actuator...

  • Page 61: Dipswitch Sw1

    Input/Output Configuration Switch Settings Table 3-2 TurboPlastic Module Input/Output Configuration Input/Output Configurations Channel Number SW1–1 = On SW1–1 = Off SW1–1 = On SW1–2 = On SW1–2 = On SW1–2 = Off Clamp flow Clamp/ram flow Camp flow Clamp pressure Clamp/ram pressure Clamp pressure Cavity pressure...

  • Page 62: Jumper/Switch Locator

    Input/Output Voltage Range Setup Implementation of the bipolar input option is entirely in the hardware and is transparent to the firmware except for the application results. There are three jumpers that are located in the lower middle of the module board that control this option.

  • Page 63: Inserting The Module Into The Base

    Installing the Module Insert the module in any slot of a base using a 545 or 555 controller when the power is off. See Figure 3-6. Power consumption for the purpose of power budgeting on the base is 7 watts. WARNING To minimize potential shock, turn off power to the I/O base and to any modules installed in the base before inserting or removing a...

  • Page 64: Power Supply And Grounding Recommendations

    Power Supply and Grounding Recommendations Because of the high-speed update of the TurboPlastic module, the amount of movement of the ram and/or platen between module samples is very small, even on fast machines. This means that very small changes in the analog input signal must be accurately detected in order to perform smooth closed loop control.

  • Page 65: Module Input/Output Wiring

    Cable Connections and Grounding Use twisted shielded cable routed away from high voltage circuits and routed away from electrically noisy areas. Module Inputs (Channels 3, 4, 7, 8, 9) TurboPlastic module V+ In Input Shielded twisted V– In pair Drain Ground Cable shield NOTE: If cable has additional foil wrap and...

  • Page 66: Connector Pinout Table

    Connector Pinouts Table 3-3 Connector Pinout Table Voltage Channel Signal Connector Range Number Function In/Out Function Terminal Jumper V Out Clamp flow Ground V Out Clamp pressure Ground V+ Input Cavity pressure V– Input Ground V+ Input V– Input Clamp hydraulic pressure Ground V Out Ram flow...

  • Page 67: Connector Pinout Diagram

    CH2 Ground CH1 Ground CH2 Vout CH1 Vout CH6 Ground CH5 Ground CH6 Vout CH5 Vout CH4 Ground CH3 Ground CH4 V+ input CH3 V+ input CH4 V–input CH3 V– input CH8 Ground Typical wire socket, CH7 Ground labeling, and screw CH8 V+ input CH7 V+ input CH8 V–...

  • Page 68: Startup Values And Examples

    Startup Values and Examples Read this entire section before attempting to energize the module. If you are using any of the discrete output circuits, also read Chapter 4 before energizing the module. The module reads in and validates the entire 300-word download table before executing any profile.

  • Page 69: Module Fail Codes

    With the PLC configured for a 4WX/4WY, SF module in Slot #1 with the above values loaded; the LEDs on the module front MODULE GOOD panel should be lighted. NOTE: If LEDs blink, refer to Table 3-4. Should any fail codes occur (except for the factory test jumper), the module should not be used.
  • Page 70 Startup Values and Examples (continued) Table 3-5 Download Table Location Value Description of Function Clamp Close Profile 5000 Sets module scan to 5 ms during close 300 Sets low pressure close at 3 seconds 0 Lock over velocity 0 Lock over pressure 0 Lock over time not used 30 Velocity scaling factor = 30 counts/ms 50 Velocity loop gain...
  • Page 71 Table 3-5 Download Table (continued) Location Value Description of Function Inject Profile 5000 Sets module scan to 5 ms during inject 32767 Sets max profile time to infinity 32000 Sets inject transition pressure to maximum 32000 Sets cavity transition pressure to maximum if equipped 0 Not used 30 Velocity scaling factor = 30 counts/ms...
  • Page 72 Startup Values and Examples (continued) Table 3-5 Download Table (continued) Location Value Description of Function Pack and Hold Profile 5000 Sets module scan to 5 ms during pack and hold 0 Sets minimum profile position to end of stroke 32000 Sets hold transition pressure to maximum 32000 Sets cavity transition pressure to maximum if equipped 0 Not used...
  • Page 73 Table 3-5 Download Table (continued) Location Value Description of Function Plasticate Profile V133 5000 Sets module scan to 5 ms during plasticate V134 32767 Sets max profile time to infinity V135 32767 Sets cure timer to infinity if so equipped V136 0 Not used V137...
  • Page 74 Startup Values and Examples (continued) Table 3-5 Download Table (continued) Location Value Description of Function Clamp Open Profile V177 5000 Sets module scan to 5 ms during open V178 Sets opening time to 3 seconds maximum V179 Not used V180 Not used V181 Not used...
  • Page 75 Hold values are output to the respective channels whenever those channels are not actively controlled in a profile. Hold values are usually zero for toggle machines, as shown in Table 3-5. Table 3-5 Download Table (continued) Location Value Description of Function Hold Values V221 Channel 1 output...

  • Page 76: Status Words

    Startup Values and Examples (continued) Several status words are provided to monitor the process operation, determine if the cycle is complete, how it completed, or if something is wrong. To take advantage of this information, display these words on your operator interface and/or build a status table in TISOFT to monitor locations.

  • Page 77: Specifications

    Chapter 4 Discrete Outputs Description ..............Specifications .

  • Page 78: Discrete Output Circuits

    Description The module includes four fast-response discrete outputs. The outputs are updated by the module, thus avoiding delays caused by PLC scan rates. This provides you with a means to control auxiliary processes or functions without the additional cost and space requirements of a separate module. The discrete output circuits are of the sourcing configuration, acting as a switch to supply voltage/current (from a user-provided power supply) to the application load.
  • Page 79 Specifications Discrete Output Specifications Item Value 0.90 A (40 C) Total output current (all outputs on) 0.75 A (60 C) 0.50 A (40 C) Maximum current per output 0.40 A (60 C) Rated voltage 15 to 24 VDC Operating voltage range 12 to 30 VDC Temporary overload 2.0 A for 1 ms...

  • Page 80: Sample Discrete Output Control Values

    Discrete Output Control 4.3.1 Download Table Control of each discrete output is done in ten steps. These ten steps Words 236–255 correspond with the analog ten-step profile. Each profile is assigned a 16-bit word for each discrete output. See Figure 4-2. Bit 6 is the enable/disable bit for each word.

  • Page 81: Discrete Output Hold Values

    Discrete Output Hold Values 4.4.1 Download Table Bits 13 to 16 of word 225 determine the state of the discrete outputs in idle Word 225 mode. When the bit is set to 1, the discrete output will be on until the beginning of the next profile.

  • Page 82: Discrete Output Status

    Discrete Output Status 4.5.1 Upload Table Bits 13 to 16 of word 56 report the status of the discrete outputs to the PLC. Word 56 The module does not have LEDs to indicate output conditions, so these bits are provided to permit monitoring by the user. CAUTION Bits 13–16 indicate commands sent to the logic side of the module only;...

  • Page 83: Module Connections

    Module Connections 4.6.1 Discrete Table 4-2 contains the discrete output connector pinout table. Connectors Table 4-2 Discrete Output Connector Pinout Table Function Connector Terminal Output 1550 Output 2 Output 3 Output 4 DC supply (+)* DC return (–) * See Figure 3-5 for fuse location. See Figure 3-8 for connector pinout diagram. 4.6.2 Functional Wiring Figure 4-3 shows the functional wiring diagram.
  • Page 84 Chapter 5 Selected Functions Overlapping Cycle ............. 5.1.1 Module Sample Rate .

  • Page 85: Overlapping Cycle

    Overlapping Cycle The overlapping cycle functionality of the TurboPlastic module provides the capability to perform plasticate during the clamp open profile, and part removal in addition to the normal plasticate profile. The feature is activated by setting bit numbers 4, 5, and 6 of word WY8 to 1 which enables plasticate, clamp open, and overlapping cycles.

  • Page 86: Step Numbers

    5.1.2 Step Numbers Each profile can be programmed with as few as one or as many as ten steps. Word WX1, module cycle status, is continuously updated with the profile number and step number within that profile. See Table 2-1 for WX1 details. Step numbers, while the plasticate cycle is running by itself, are reported as 401, 402, 403, etc., as in normal operation.

  • Page 87: Pid Algorithms

    PID Algorithms The TurboPlastic module provides two distinct user-selectable PID algorithms that give different control responses (see PID, Section 1.3). Algorithm selection depends on the machine controlled by the user and the response desired. 5.2.1 Standard PID The standard PID algorithm is one of several offered in the 505 series of Algorithm controllers, except that when a change of set point is requested, this new setpoint value is immediately output.

  • Page 88: Standard Pid Algorithm Trace

    5.2.2 Standard PID Figure 5-1 shows the trace of a typical response for the standard PID Algorithm Trace algorithm. 10 V = Max Output to valve 0 V = Min (Hold valve) 10 V = Back Start inject Ram position 0 V = Forward Figure 5-1 Standard Velocity PID Algorithm Selected Functions...

  • Page 89: Dynamic Pid Algorithm

    PID Algorithms (continued) 5.2.3 Dynamic PID The dynamic PID algorithm is a variation of the implementation suggested Algorithm for use with the DSP chip applications. As is suggested by its name, this algorithm is faster-reacting and consequently does not require that the setpoint be forced into the output upon change.

  • Page 90: Dynamic Pid Algorithm Trace

    5.2.4 Dynamic PID Figure 5-2 shows the trace of a typical response for the dynamic PID Algorithm Trace algorithm. 10 V = Max 20,000 20,000 Output to valve 5000 4000 0 V = Min 10 V = Back Start inject Ram position 0 V = Forward Figure 5-2 Dynamic Velocity PID Algorithm...

  • Page 91: Software Filters

    Software Filters The TurboPlastic module provides several distinct user-selectable software filters to allow operation in spite of noisy input signals. These filters are provided for use when ambient noise is slightly above normal and when random spikes on the input might occur. These filters are not effective for noise levels substantially above recommended levels.

  • Page 92: Filter On Position

    5.3.2 Filter on Position A filter on position* is provided for cases where low levels of harmonics are present. While this filter has its constants specifically chosen for 60 Hz harmonic rejection, it does work with many other harmonics as well. The formula for this first order filter and an example with values follows: new input filter constant (read input...

  • Page 93: Ramping Function

    Ramping Function The TurboPlastic module provides a ramping function for both velocity and pressure control functions during open loop operation of all profiles. The ramping function is activated by setting appropriate bits in Constant 10 in the download table of each profile. In normal open loop operation, the setpoints are output as step changes for both pressure and velocity.

  • Page 94: Open Loop Output Without Ramping

    POSITION Figure 5-3 Open Loop Output without Ramping NOTE: Pressure ramping not shown but works the same POSITION Figure 5-4 Open Loop Output with Ramping Selected Functions 5-11...

  • Page 95: Cavity Pressure

    Cavity Pressure The cavity pressure function reads the pressure of the plastic material as it fills the mold cavities. 5.5.1 Cavity Pressure A pressure sensor must be installed in one of the mold cavities and wired to Sensor the appropriate TurboPlastic module channel to provide the input signal value.

  • Page 96: Cushion Control

    Cushion Control Cushion control is an attempt to maintain a consistent end-of-inject position. Its goal is to eliminate rejects due to short shots. The cushion control loop retains an actual screw position at the end of injection profile and compares it with the required value (location V136 in the download table).

  • Page 97: Spc/Sqc

    SPC/SQC 5.7.1 Data Collected by SPC/SQC profile data is concentrated from memory locations (WY6)+V35 to All Profiles (WY6)+V55 of the Upload table: Profile ID V36 – V45 Velocity Input Average data V46 – V55 Pressure Input Average data NOTE: These locations are updated at the end of a profile after it has completely executed.

  • Page 98: Additional Data Collected By Injection And Pack/Hold Profiles

    Pressure Input Average. These 10 locations correspond to a profile step data. (For example: if reporting data for a Clamp Close profile, location 36 is the average pressure input for clamp close step 1 position data.) Averaging of each location is based on a 10-sliding-window value method.

  • Page 99: Scaling Constants

    Scaling Constants With machine configuration #3, a single valve controls flow and pressure. At different intervals in the profile, control is switched between flow and pressure; because of the valve design, there is more gain during pressure control mode than during flow control mode. Constants are provided in the Download table to allow you to reduce a pressure output.

  • Page 100: Reverse Acting

    Reverse Acting The Reverse Acting option is available only in closed-loop mode for velocity loop and pressure loop. You select this option with bits 9 and 10 of constant #14: Bit 9 Velocity Loop 0 = No Reverse Action 1 = Reverse Acting Bit 10 Pressure Loop 0 = No Reverse Acting...

  • Page 101: Locations For Conditions Causing Profile Termination

    5.10 End-of-Profile Conditions 5.10.1 Checking Different conditions cause profiles to terminate execution. You can End-of-Profile determine the condition when the profile terminated by checking the Condition following: (WY6)+ V12 for Clamp Close status bits V13 for Inject status bits V14 for Pack and Hold status bits V15 for Plasticate status bits V16 for Clamp Open status bits Table 5-1 shows the types of conditions causing termination for the different...

  • Page 102: Clamp Close Profile

    5.10.2 Clamp Close The following conditions cause termination of the Clamp Close profile: Profile Maximum Time: the profile execution time exceeds the maximum profile time. Check location (WY5)+V2. Position: either the profile step position data encounters a zero value in one of the steps, or it goes past the last step position data (past step #10).

  • Page 103: Pack And Hold Profile

    End-of-Profile Conditions (continued) 5.10.4 Pack and Hold The following conditions cause termination of the Pack and Hold profile: Profile Time: either the profile step time encounters a zero value in one of its steps, or it goes past the last step time data (past step #10). Check locations (WY5)+V103 to (WY5)+V112.

  • Page 104: Clamp Open Profile

    5.10.6 Clamp Open The following conditions cause termination of the Clamp Open profile: Profile Maximum Time: the profile execution time exceeds the maximum profile time. Check location (WY5)+V178. Position: either the profile step position data encounters a zero value in one of the steps, or it goes past the last step position data (past step #10).

  • Page 105: Suggestions For Tuning Loops

    5.11 Suggestions for Tuning Loops These suggestions assume that you have some knowledge of PID terminology and are familiar with the operation of the TurboPlastic module. Use them as guidelines in tuning a loop, but understand that each application has its own characteristics. Understanding of the PID loops available in the TurboPlastic module, as well as how the loops react, is helpful.

  • Page 106: Initial Loop-Tuning Parameter Values

    5.11.3 Before Tuning Check the following items before tuning loops: Loops Clamp and ram position inputs must be steady (not more than 16 counts). If the counts exceed this range, the loop cannot be tuned correctly. Adjust zero and span of the valve amplifier cards. Have on hand a strip chart recorder (2 channels or more).

  • Page 107: Symptoms And Actions

    Suggestions for Tuning Loops (continued) 5.11.4 Symptoms and Table 5-3 shows symptoms, probable causes, and some corrective actions. Actions Table 5-3 Tuning Loops Symptom Probable Cause Remedy Valve command does not Incorrect zero span on follow the TurboPlastic Zero span the valve amplifier card output command Velocity setpoint too high,...

  • Page 108: Clamp Closing Profile

    Appendix A Sample Operator Interface Screens Sample Injection Machine Supervisor Power-up Graphic ....... . . Sample Main Menu .

  • Page 109: Sample Injection Machine Supervisor Power-Up Graphic

    The following pages show sample operator interface screens that can be used to input profile and other data to PLC memory for use by the TurboPlastic module. INJECTION MACHINE SUPERVISOR Figure A-1 Sample Injection Machine Supervisor Power-up Graphic Sample Operator Interface Screens...

  • Page 110: Sample Main Menu

    MAIN MENU F1 – MACHINE OVERVIEW F2 – MACHINE ALARMS F3 – MACHINE UTILIZATION F4 – PROCESS PROFILE SET–UP F5 – TEMPERATURE LOOPS F6 – GRAPHIC ALARM PAGE – MAINTENANCE FUNCTIONS – R.E.A.C.H. REQUESTS – ENTER/CLEAR PASSWORD Figure A-2 Sample Main Menu Sample Operator Interface Screens...

  • Page 111: Machine Overview

    MACHINE OVERVIEW CURRENT OPERATING CONDITIONS BARREL HEATERS STATUS ....> SHUT DOWN 1) REAR ZONE (DEG F) CYCLE ....>...

  • Page 112: Machine Overview

    MACHINE ALARMS FRONT GATE OPEN REAR ZONE LIMIT REAR GUARD OPEN MIDDLE ZONE LIMIT PURGE GUARD OPEN FRONT ZONE LIMIT SCREW NOT BACK NOZZLE ZONE LIMIT LOW OIL LEVEL OIL TEMP HIGH LOW GREASE LEVEL KNOCKOUTS NOT SCREW NOT FWD BACK MACHINE MACHINE...

  • Page 113: Machine Overview

    MACHINE ALARMS TEMP GUARD OPEN SCREW OIL TEMP/ LUBE .PRESSURE FILTER LEVEL TEMPERATURES ZONE NO. TEMP _F ZONE NO. TEMP_F MACHINE MACHINE PROCESS TEMP ALARM MAIN OVERVIEW UTILIZE PROFILES LOOPS MENU Figure A-5 Graphic Machine Alarms Sample Operator Interface Screens...

  • Page 114: Machine Utilization

    MACHINE UTILIZATION SETUP VALUES: (F2 TO CHANGE) PERFORMANCE: JOB NUMBER ... > 12345 COMPLETED CYCLES ..> 12386 MATERIAL ID ... . >...
  • Page 115 CLAMP CLOSING PROFILE STEP NO. POSITION VELOCITY PRESSURE ALARM(+/–V) ALARM(+/–P) (inches) (ips) (psi) OPEN 108.55 –––– –––– –––– –––– 98.50 10.5 1995 88.50 12.3 1995 69.50 14.7 1600 48.60 15.0 1200 36.58 15.3 2050 28.89 15.9 1500 20.25 16.0 1475 14.75 14.0 1300...

  • Page 116: Injection Profile

    INJECTION PROFILE STEP NO. POSITION VELOCITY PRESSURE ALARM(+/–V) ALARM(+/–P) (inches) (ips) (psi) START 110.25 –––– –––– –––– –––– 108.00 12.3 1995 66.52 25.6 1800 55.25 40.0 1550 32.50 45.0 1800 23.98 45.0 1995 15.45 45.0 1995 10.75 35.5 1000 8.00 20.0 4.50 1.25...

  • Page 117: Pack And Hold Profile

    PACK & HOLD PROFILE STEP NO. TIME VELOCITY PRESSURE ALARM(+/–V) ALARM(+/–P) (seconds) (ips) (psi) MIN VALUE 0.00 –––– –––– –––– –––– 1.04 12.3 1500 1.58 1200 1.36 8.90 1000 5.89 1250 2.38 1300 2.80 1000 3.25 3.55 3.20 MAX VALUE 327.67 ––––...

  • Page 118: Plasticate Profile

    PLASTICATE PROFILE STEP NO. POSITION VELOCITY BACK PRES ALARM(+/–V) ALARM(+/–P) (inches) (ips) (psi) MIN VALUE 1.15 –––– –––– –––– –––– 1.47 2.85 9.50 20.00 35.50 58.88 65.00 85.50 95.60 100.00 MAX VALUE 108.55 –––– –––– –––– –––– MODE –––– MANUAL AUTO STEP CURRENT...

  • Page 119: Clamp Opening Profile

    CLAMP OPENING PROFILE STEP NO. POSITION VELOCITY PRESSURE ALARM(+/–V) ALARM(+/–P) (inches) (ips) (psi) CLOSED 1.25 –––– –––– –––– –––– 1.75 1500 11.55 1995 25.65 10.5 1995 31.30 15.8 1995 42.80 15.8 1995 55.45 15.8 1995 78.60 14.0 1500 85.50 10.5 90.00 100.00 OPEN...

  • Page 120: Temperature Control

    TEMPERATURE CONTROL ZONE ON/0FF ACTUALSETPT GAIN RATE RESET LLALM LOALM HIALM HHAL 1) B–1 00055 00082 00105 00158 00158 00158 00140 00105 00055 2) B–2 01500 01995 01995 01995 01995 01995 01500 00800 00500 3) B–3 00000 00000 00000 00000 00000 00000 00000...

  • Page 121: Analog Maintenance

    ANALOG MAINTENANCE DESCRIPTION TYPE LOCATION UNSCALED SCALED VOLTAGE RANGE ZONE 1 TEMP INPUT WX–33 200 F 7.50 0–10V ZONE 2 TEMP INPUT WX–34 225 F 7.55 0–10V ZONE 3 TEMP INPUT WX–35 250 F 7.60 0–10V ZONE 4 TEMP INPUT WX–36 275 F 7.65...
  • Page 122 Appendix B Sample RLL and Logic Diagrams Sample RLL for Noise Check ........... . . Ejector Logic Diagram .

  • Page 123: Sample Rll For Noise Check

    Sample RLL for Noise Check Compare ram position from V307 to high register CMP1 V307 V1000 GT = If V307 is greater than V1000 then store higher V307 V1000 N = 1 Compare ram position from V307 to low register V307 V1001 LT =...

  • Page 124: Ejector Logic Diagram

    Ejector Logic Diagram Clamp open complete Clamp Load open clamp Timer open timer value Activate stroke Eject return required? solenoid Load Number number Ejector of strokes home? strokes into counter Enough strokes completed? Activate stroke forward solenoid valve Clamp open timer completed? End of...

  • Page 125: Auto Cushion Control Logic Diagram

    Auto Cushion Control Logic Diagram Pack complete Auto cushion control (Optional block) Shot Load auto Just put size shot size into run into T-mold mode? plasticate table Current average shot Cushion last 10 Preload Previous end-of-shot setpoint running positions average average to cushion Average...

  • Page 126: Decompression/Suck-Back Logic Diagram

    Decompression/Suck-Back Logic Diagram Plasticate complete Decomp required Add suck-back distance to position current ram position Distance Is max position position position exceeded? Suck-back Load velocity velocity and pressure values to hold Suck-back outputs pressure Is ram current Suck- position suck-back back position? complete...
  • Page 127 Appendix C Process Variable and Profile Log Sheets Clamp Closing Profile Data Log Injection Profile Data Log Pack and Hold Profile Data Log Plasticate Profile Data Log Clamp Opening Profile Data Log Hold Values Data Log Scaling Constants Data Log Discrete Output Data Log Upload Table Memory Map Data Log Process Variable and Profile Log Sheets...
  • Page 128 The master forms contained in this appendix may be reproduced as needed for use in recording application data. Process Variable and Profile Log Sheets...
  • Page 129 Clamp Closing Profile Data Log Process/Part:: Machine: Mold: Date: Function Address Loc Description Set Value Constants 1 (WY5) Module sample rate Max profile time Lock-over velocity Lock-over pressure Lock-over time Lock-over scaling factor (velocity loop gain) (velocity loop rate) (velocity loop reset) Velocity/pressure operation bits Bits 1–2 PID algorithm for velocity...
  • Page 130 Clamp Closing Profile Data Log Process/Part:: Machine: Mold: Date: Function Address Loc Description Set Value Clamp Position Profile Step Data Step 1 position Step 2 position Step 3 position Step 4 position Step 5 position Step 6 position Step 7 position Step 8 position Step 9 position Step 10 position...
  • Page 131 Injection Profile Data Log Process/Part:: Machine: Mold: Date: Function Address Loc Description Set Value Constants 1(WY5+44) Module sample rate Max profile time Max pressure to transition Max cavity pressure to transition Cavity fill pressure setpoint Velocity scaling factor (velocity loop gain) (velocity loop rate) (velocity loop reset) Velocity/pressure operation bits...
  • Page 132 Injection Profile Data Log Process/Part:: Machine: Mold: Date: Function Address Loc Description Set Value Pack Time Profile Step Data Step 1 position Step 2 position Step 3 position Step 4 position Step 5 position Step 6 position Step 7 position Step 8 position Step 9 position Step 10 position...
  • Page 133 Pack and Hold Profile Data Log Process/Part:: Machine: Mold: Date: Function Address Loc Description Set Value Constants 1(WY5+88) Module sample rate Profile end position Max pressure to transition Max cavity pressure to transfer Cavity fill pressure setpoint Velocity scaling factor (velocity loop gain) (velocity loop rate) (velocity loop reset)
  • Page 134 Pack and Hold Profile Data Log Process/Part:: Machine: Mold: Date: Function Address Loc Description Set Value Pack/Hold Time Profile Step Data Step 1 time Step 2 time Step 3 time Step 4 time Step 5 time Step 6 time Step 7 time Step 8 time Step 9 time Step 10 time...
  • Page 135 Plasticate Profile Data Log Process/Part:: Machine: Mold: Date: Function Address Loc Description Set Value Constants 1(WY5+132) Module sample rate Max profile time Cure timer Cushion value Cushion correction Velocity scaling factoror (velocity loop gain) (velocity loop rate) (velocity loop reset) Velocity/pressure operation bits Bits 1–2 PID algorithm for velocity...
  • Page 136 Plasticate Profile Data Log Process/Part:: Machine: Mold: Date: Function Address Loc Description Set Value Plasticate Profile Step Data Step 1 position Step 2 position Step 3 position Step 4 position Step 5 position Step 6 position Step 7 position Step 8 position Step 9 position Step 10 position Ram Velocity Setpoint Data...
  • Page 137 Clamp Opening Profile Data Log Process/Part:: Machine: Mold: Date: Function Address Loc Description Set Value Constants 1(WY5+176) Module sample rate Max profile time Future use Future use Future use Velocity scaling factoror (velocity loop gain) (velocity loop rate) (velocity loop reset) Velocity/pressure operation bits Bits 1–2 PID algorithm for velocity...
  • Page 138 Clamp Opening Profile Data Log Process/Part:: Machine: Mold: Date: Function Address Loc Description Set Value Clamp Open Profile Step Data Step 1 position Step 2 position Step 3 position Step 4 position Step 5 position Step 6 position Step 7 position Step 8 position Step 9 position Step 10 position...
  • Page 139 Hold Values Data Log Process/Part:: Machine: Mold: Date: Function Address Loc Description Set Value WY5+220 Channel 1 output Channel 2 output Channel 5 output Channel 6 output Output directional bits/discretes Bit 1 Channel 1 output polarity Bit 2 Channel 2 output polarity Bit 3 Channel 5 output polarity Bit 4...
  • Page 140 Discrete Output Data Log Process/Part:: Machine: Mold: Date: Function Address Loc Description Set Value WY5+235 Clamp close discrete output 1 output 2 output 3 output 4 Inject discrete output 1 output 2 output 3 output 4 Pack and hold discrete output 1 output 2 output 3 output 4...
  • Page 141 Upload Table Memory Map Data Log Process/Part:: Machine: Mold: Date: Function Address Loc Description Comments/Notes Actual loop calculation time Clamp position feedback Clamp velocity calculated by module Clamp hydraulic flow output Clamp hydraulic pressure feedback Clamp pressure output signal Ram position feedback Ram velocity calculated by module Ram hydraulic flow output Ram hydraulic pressure feedback...
  • Page 142 Upload Table Memory Map Data Log Process/Part:: Machine: Mold: Date: Function Address Loc Description Comments/Notes WY6+34 Profile indicator for SPC/SQC Average of 10 velocity inputs Average of 10 velocity inputs Average of 10 velocity inputs Average of 10 velocity inputs Average of 10 velocity inputs Average of 10 velocity inputs Average of 10 velocity inputs...
  • Page 143 Index Block read data: 2-12 transfer I/O interface: 2-11 Algorithm, trace, standard PID: 5-5 write data: 2-30 Analog, standard voltage range input: 3-6 output: 3-6 Assistance: 1-4 Cable, connections, grounding: 3-9 Auto cushion control Cavity bit: 2-16 fill time: 5-12 RLL implementation: B-4 pressure sensor: 5-12 Clamp closing profile: 2-21...
  • Page 144 Environmental specifications: 1-12 Error codes, download table: 2-8 Data block read: 2-12 write: 2-30 Fail codes (module): 3-13 clamp closing profile: C-3 clamp opening profile: C-11 Filters discrete output: C-14 bit: 2-15 hold values: C-13 software injection profile: C-5 description of: 5-8 pack and hold profile: C-7 position: 5-9 plasticate profile: C-9...
  • Page 145 range bit: 2-17 words: 2-9 Log, data Overlapping cycle clamp closing profile: C-3 description of: 5-2 clamp opening profile: C-11 module sample rate: 5-2 discrete output: C-14 hold values: C-13 injection profile: C-5 pack and hold profile: C-7 plasticate profile: C-9 Pack and hold profile: 2-23 scaling constants: C-13 profile data log: C-7...
  • Page 146 Profile (continued) Start cycle: 2-9 data Startup, values, examples: 3-12 clamp closing profile: 2-21 Status clamp opening profile: 2-25 bits: 2-33 hold values: 2-26 codes: 2-7 injection profile: 2-22 words: 3-20 pack and hold: 2-23 plasticate profile: 2-24 Step data entry format: 2-20 clamp closing profile: C-3 numbers: 5-3 clamp opening profile: C-11...
  • Page 147 WX1, module cycle status: 2-5 WX2, cycle complete codes: 2-6 Wiring WX3, status codes: 2-7 connector pinout: 3-11 WX4, reports selected channel value: 2-8 functional: 4-7 WY5: 2-9 Word pointer to download start location: 2-9 225: 2-26 WY6: 2-30 description of: 2-27 pointer to upload start location: 2-9 discrete output, hold values: 4-5 56, discrete output status: 4-6...
  • Page 148 Would you be interested in giving us more detailed comments about our manuals? Yes! Please send me a questionnaire. No. Thanks anyway. Your Name: Title: Telephone Number: Company Name: Company Address: Manual Name: SIMATIC 505 TurboPlastic Module User/Programmer Manual Edition: Third Text Assembly Number: 2586546-0041 Date: 07/98 Order Number: PPX:505–8117–3...
  • Page 149 FOLD SIEMENS ENERGY & AUTOMATION INC NO POSTAGE NECESSARY 3000 BILL GARLAND ROAD IF MAILED PO BOX 1255 IN THE JOHNSON CITY TN 37605–1255 UNITED STATES BUSINESS REPLY MAIL PERMIT NO.3 FIRST CLASS JOHNSON CITY, TN POSTAGE WILL BE PAID BY ADDRESSEE ATTN TECHNICAL COMMUNICATIONS M/S 519 SIEMENS ENERGY &...

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