manual de referencia de la ihm

Original Instructions

HMI Reference Manual

HyPET and HyPET HPP

Issue: Polaris — v2009.3

ii Polaris — v2009.3

This equipment manual is intended to provide information for safe operation and maintenance. Husky reserves the right to make changes to equipment in an effort to continually improve the equipment, features, and/or performance. These changes may result in different and/or additional safety measures that are communicated to customers through bulletins as changes occur.

This document contains information which is the exclusive property of Husky Injection Molding Systems Limited. Except for any rights expressly granted by contract, no further publication or commercial use may be made of this document, in whole or in part, without the prior written permission of Husky Injection Molding Systems Limited.

Notwithstanding the foregoing, Husky Injection Molding Systems Limited grants permission to its customers to reproduce this document for limited internal use only.

Adept®, Altanium™, CoolJet™, CoolPik®, FlexFrame®, Husky®, Hylectric®, HyMET™, HyPAC™, HyCAP™, HyPET™, Index®, ITS®, MicroPitch®, Mixcel®, Polaris™, Pronto®, ProPET®, Quadloc™, QuadMET™, Reflex™, RobotWare®, ServiceLink™, ShotScope™, SimPET™, SmartLink™, SmartStart®, Tandem®, Thixosystems®, Tracer™, UltraFlow®, UltraGuide®, UltraSeal® and UltraSync™ are trademarks of Husky Injection Molding Systems Limited.

Moldflow Plastics Insight®, Moldflow Plastics Advisers® and Simalink® are trademarks of the Moldflow Corporation.

Beckhoff™ and TwinCAT® are trademarks of Beckhoff Industrial Electronics.

Quad-ring® is a trademark of Minnesota Rubber a Quadion Company.

Teflon® is a trademark of DuPont Company.

Molykote® is a trademark of Dow Corning Corporation.

Repro Rubber® is a trademark of Flexbar Machine Corporation.

Loctite® is a trademark of Loctite Corporation.

Scotch-Brite® is a trademark of 3M Corporation.

Copyright © 2009, Husky Injection Molding Systems.

All Rights Reserved.

Machine Functions iii

HMI Reference Manual Polaris — v2009.3

Machine Functions

Machine functions are grouped into seven main screen groups. There may be a few additional or optional screen groups based on your machine type and the features you have installed.

The following is a list of HMI screen groups:

• ALARMS• MACHINE• PRODUCTION• CLAMP• MOLD FUNCTIONS• INJECTION• HEATS• PRODUCT HANDLING • SPC (Optional)

Screens

Each screen group has several screens (also referred to as tabs throughout this manual).

Common functions on the Toolbar are also discussed in separate sections.

NOTE: Screens shown are representative, and may vary depending on the type of machine and how the machine is configured.

Polaris — v2009.3

iv Screens

v

HMI Reference Manual Polaris — v2009.3 Table of Contents

Table of Contents

Machine Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iiiScreens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iii

Chapter 1: Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11.1 ALARMS Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.1.1 Displaying Alarm Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21.2 EVENTS HISTORY Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.2.1 EVENT TYPE FILTER Pop-up Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-61.3 REPORTS SELECTION Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

1.3.1 Alarm Report Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-101.3.2 Creating On-Demand Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-111.3.3 Viewing On-Demand Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-121.3.4 Printing On-Demand Report(s). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-121.3.5 Saving On-Demand Report(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-121.3.6 Enabling Scheduled Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-131.3.7 Printing Scheduled Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-131.3.8 Saving Scheduled Report(s). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

1.4 REPORT VIEW Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-141.4.1 Selecting a Report to View or Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

1.5 LOG TRANSFER Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-161.6 REASON EDIT Screen (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19

1.6.1 REASONS LIST Pop-up Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-211.6.2 Creating/Modifying a Reasons List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-221.6.3 Copying a Reasons List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-231.6.4 Enabling Setpoint Change Reason Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-231.6.5 Changing a Setpoint Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23

Chapter 2: Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12.1 MACHINE SPECIFICATIONS Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12.2 CYCLE TIME BREAKDOWN Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

2.2.1 CYCLE BREAKDOWN CONFIGURATION Pop-up Window . . . . . . . . . . . . . . . . . . 2-72.2.2 Setting Cycle Time Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-92.2.3 Saving a Cycle Time Breakdown Benchmark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

2.3 PROCESS SETUP Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-92.4 GRAPH Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

2.4.1 CURVE SELECTION Pop-up Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-172.4.2 GRAPH PROPERTIES Pop-up Window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

Polaris — v2009.3 Polaris Control

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2.4.3 PLOT CONFIGURATION Pop-up Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-192.5 SERVO DRIVE Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

2.5.1 GENERAL Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-212.5.1.1 Displaying General Servo Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23

2.5.2 FAULTS Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-242.5.2.1 Displaying Servo Fault Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26

2.5.3 PROFIBUS Tab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-272.5.4 NC STATUS Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-282.5.5 PARAMETER Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29

2.5.5.1 Downloading Drive Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-312.5.5.2 Uploading Drive Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-322.5.5.3 Downloading All Drive Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-322.5.5.4 Verifying Drive Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-332.5.5.5 Importing Drive Parameter File. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-342.5.5.6 Exporting Drive Parameter File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35

Chapter 3: Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13.1 PRODUCTION SETUP Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.1.1 Viewing and Changing Part Count and Setup Information . . . . . . . . . . . . . . . . 3-33.1.2 Resetting Shift Count and Parts Completed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33.1.3 HUSKY HOST LINK TERMINAL Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3.2 MOLD SETUP Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53.2.1 Creating New Mold Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63.2.2 Saving Mold Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-73.2.3 Recalling Mold Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-83.2.4 Copying Mold Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-83.2.5 Deleting Mold Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-103.2.6 Using Mold Setup From a Different Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

3.3 SMART STOP SETUP Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-123.3.1 Activating Smart Stop on Machine Cycle Fault. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-133.3.2 Activating Smart Stop After Producing Extra Parts . . . . . . . . . . . . . . . . . . . . . . . 3-143.3.3 Activating Smart Stop After Completing Production . . . . . . . . . . . . . . . . . . . . . 3-143.3.4 Activating Smart Stop On Specific Day At a Specific Time . . . . . . . . . . . . . . . . 3-153.3.5 Aborting Smart Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-163.3.6 Disabling Smart Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

3.4 SMART START SETUP Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-173.4.1 Running Smart Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-203.4.2 Stopping Smart Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

3.5 MOLD INSTALLATION Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-213.5.1 Installing Mold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-223.5.2 Calibrating Mold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

3.6 OUTPUTS Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

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Chapter 4: Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14.1 OVERVIEW Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14.2 CLAMP Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4.2.1 Setpoint Profile Graph Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-64.2.2 Step Type Setpoint Profiles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-64.2.3 Modifying Step Type Setpoint Profiles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-74.2.4 ADAPTIVE TONNAGE Pop-up Window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-84.2.5 COOLING SETUP Pop-up Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

4.3 GRAPH Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-94.4 VALVES STATUS Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Chapter 5: Mold Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15.1 EJECTOR SETUP Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15.2 AIR Screen (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35.3 VALVE GATES Screen (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Chapter 6: Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16.1 OVERVIEW Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16.2 INJECTION Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6.2.1 Modifying Injection Setpoint Profiles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-96.2.1.1 Profile Graph Drag and Drop Method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

6.2.2 CUSHION CONTROL Pop-up Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-126.3 INJECTION GRAPH Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-136.4 RECOVERY Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15

6.4.1 Recovery Screen for the P-Injection Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-166.4.2 Recovery Screen for RS Injection Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19

6.4.2.1 CARRIAGE DETAILS Pop-up Window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-246.4.2.2 SHUT-OFF NOZZLE Pop-up Window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26

6.4.3 Modifying Injection Setpoint Profiles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-276.4.4 Setting Up the Adaptive Cooling Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27

6.5 EXTRUDER GRAPH Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-306.6 RECOVERY GRAPH Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-336.7 VALVES STATUS Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35

Chapter 7: Heats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17.1 SETUP, MACHINE, MOLD and NOZZLE TIPS Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7.1.1 HEAT ZONE SETUP Pop-up Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-77.1.2 Self Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-97.1.3 Adaptive Tune (HPP only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

7.1.3.1 Setting Up Adaptive Tune. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-117.1.3.2 Performing Adaptive Tune . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-117.1.3.3 Stopping Adaptive Tune . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12


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7.1.4 HEATS SCHEDULER Pop-up Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-127.1.5 MOLD TYPE Pop-up Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-137.1.6 GLOBAL CHANGE Pop-up Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13

7.2 COOLING SETUP Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15

Chapter 8: Product Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-18.1 SETUP Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8.1.1 CONFIGURATION Pop-up Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-58.1.2 TOOLING PLATE STAGE POSITIONS CALCULATOR . . . . . . . . . . . . . . . . . . . . . . . . 8-6

8.2 CONFIGURATION Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-88.3 DIAGNOSTIC Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-128.4 SEQUENCE Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-148.5 VALVES STATUS Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-158.6 CONVEYOR Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17

Chapter 9: HMI Administrator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19.1 USERS Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

9.1.1 OPEN ACCOUNT Pop-up Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-39.1.1.1 Programming the DataKey. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4

9.2 GROUPS Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-49.2.1 CREATE NEW GROUP Pop-up Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-69.2.2 ADD/REMOVE USER IN GROUP Pop-up Window . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7

9.3 RIGHTS Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-89.4 OTHERS Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9

9.4.1 Creating New User Account and User Group - Example . . . . . . . . . . . . . . . . . . 9-11

Chapter 10: HMI Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110.1 PASSWORD Tab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110.2 UNITS Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210.3 LANGUAGE Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4

10.3.1 LANGUAGE SELECTION Popup Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-510.4 SHIFTS Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-510.5 PRINTER Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6

10.5.1 BACKGROUND PRINTING CONFIGURATION Pop-up Window . . . . . . . . . . . . . 10-710.6 REMOTE Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8

10.6.1 Basic Network Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1010.6.2 Husky Host Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-10

10.7 BACKUP Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1110.8 OTHERS Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-13

Chapter 11: Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-111.1 Calibration Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-111.2 When to Calibrate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2

ix


11.3 Clamp Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-211.3.1 Calibrating the Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3

11.4 Injection Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-411.4.1 Calibrating the Injection Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4

11.5 Carriage Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-411.5.1 Calibrating the Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5

11.6 Transfer Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-511.6.1 Calibrating the Transfer Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6

11.7 Tooling Plate Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-611.7.1 Calibrating the Tooling Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-7

11.8 CoolPik Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-711.8.1 Calibrating the CoolPik . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-8

11.9 CoolPik Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-811.9.1 Aligning the CoolPik. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-9

Chapter 12: SmartLink (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-112.1 MACHINE PRODUCTION STATUS Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2

12.1.1 Selecting Machine in a Work Centre. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-412.1.2 Closing or Restarting a SmartLink Session . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4

12.2 DATA ENTRY Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-512.2.1 Entering Production Data for a Job. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6

12.3 DOWNTIME Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-712.3.1 Selecting Downtime Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-9

Chapter 13: SPC (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-113.1 SPC Quick Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-113.2 SUMMARY Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-313.3 DETAILS Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-5

13.3.1 DISTRIBUTION AND TREND Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-613.3.2 XBAR AND R/s Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-8

13.4 HISTORY Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-1013.5 GROUP Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-1313.6 SETUP Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-1413.7 CONTROL LIMITS Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-2213.8 SPC Concepts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-24

13.8.1 Functional Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-2413.8.2 SPC Variables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-2413.8.3 Monitoring Variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-2413.8.4 Machine Cycles and Sampling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-2513.8.5 Trend and Distribution Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-2513.8.6 Process Variability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-2613.8.7 Specification Limits and Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-2613.8.8 Process Quality Factor (Cpk) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-26


x

13.8.9 Control Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-2913.8.10 Xbar Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-2913.8.11 R/s Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-3113.8.12 SPC Alarms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-3213.8.13 SPC Formulas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-3413.8.14 SPC Statistical References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-36

Chapter 14: Auxiliary Equipment Interface (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-114.1 Euromap 17 Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-2

14.1.1 DEVICE SETUP Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-214.1.1.1 Set Up Auxiliary Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-414.1.1.2 Configuring COM Port for Euromap 17 Devices . . . . . . . . . . . . . . . . . . . . . 14-4

14.1.2 Device (THERMOLATOR) Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-514.2 SPI Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-7

14.2.1 DEVICE SETUP Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-714.2.1.1 Set Up Auxiliary Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-914.2.1.2 Configuring COM Port for SPI Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-9

14.2.2 Device (DRYER) Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-1114.2.3 Mold Temperature Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-16

14.2.3.1 Command Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-1614.2.3.2 SPI Device I/O List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-17

14.2.4 Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-3014.2.4.1 Command Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-3014.2.4.2 SPI Device I/O List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-31

14.2.5 Volumetric Blender. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-4514.2.5.1 Command Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-4514.2.5.2 SPI Device I/O List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-46

Chapter 15: Third-Party Integration (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1

HMI Reference Manual Polaris — v2009.3 Alarms

ALARMS Screen 1–1

Chapter 1 Alarms

The Alarms screens are used to display current alarm messages, alarm history, view or print on-demand and scheduled reports, transfer logs, and enable or disabled the optional Setpoint Change Reasons function.

NOTE: All screens shown are representative, and may vary depending on how the machine is configured.

1.1 ALARMS Screen

The ALARMS screen displays alarm messages, and alarm help.

Press <ALARMS> key to display the ALARMS screen. Refer to Figure 1-1.

NOTE: The terms "Click" and "Touch" can be used interchangeably. However, the term "Touch" relates specifically to the touch screen on the HMI.

Figure 1-1 ALARMS Screen

Polaris — v2009.3

1–2 Displaying Alarm Help

Up to 22 most recent alarms can be displayed on the screen. Alarm messages are displayed in reverse order of occurrence, with the most recent alarm at the top.

NOTE: Touch the column heading to re-sort the information in the column in ascending or descending order. The Date/Time column re-sorts numerically. The Source and Description columns sort alphabetically. The Status column sorts chronologically with the active alarms followed by inactive alarms.

1.1.1 Displaying Alarm Help

Each alarm listed on the ALARMS screen has a help message attached to it. To view a help message, touch the row containing the alarm. The main HMI display area turns into a split window – refer to Figure 1-2. The top panel of this window displays the HMI alarms, and the selected alarm is highlighted. The bottom panel displays the alarm help for the highlighted alarm.

Table 1-1 ALARMS Screen Descriptions

Element Description

Alarm Count Displays the total number of active alarms.

Clear Inactive Alarms

Touch this button to clear all inactive alarms from the display.

Status Displays a status icon for each alarm. Refer to Table 1-3 for details.

Date/Time Displays the date and time of the alarm.

Source Displays the name of the machine component where the alarm originated.

Description Displays the alarm message.

Figure 1-2 Split Window

1. Top panel 2. Bottom panel 3. Header 4. Exit button

1

2

3 4

EVENTS HISTORY Screen 1–3


You can select other alarms, and the bottom panel will update automatically. When you are finished, touch the Exit button to close the split window.

NOTE: You can also press any Screen key (other than the Alarm key) to close the split window.

1.2 EVENTS HISTORY Screen

The EVENTS HISTORY screen displays the machine Event Log.

Press <ALARMS> key, then touch the EVENTS HISTORY tab. Refer to Figure 1-3.

NOTE: User access rights of Operator, Processor, Maintenance or Administrator required to select or modify functions.

Figure 1-3 EVENTS HISTORY Screen

Table 1-2 EVENTS HISTORY Screen Descriptions

Element Description

Events Count Displays the total number of events displayed on the screen.

Filter Touch this button to display the EVENT TYPE FILTER pop-up window. Use this screen to display one or more event types. Refer to Section 1.2.1.

NOTE: A button labelled "All" appears beside the Filter button if the user has previously filtered by event type or date. Touch the All button to display all events.

Status Displays a status icon for each event. Refer to Table 1-3 for details.

Date/Time Displays the date and time of the event.

Polaris — v2009.3

1–4 EVENTS HISTORY Screen

NOTE: The EVENTS HISTORY screen has a scroll bar on the side. The position of the scroll button in the scroll bar indicates the position of the event relative to the entire displayed events.

NOTE: Touch the column heading to re-sort the information in the column in ascending or descending order. The Date/Time column re-sorts chronologically. The Source and Description columns sort alphabetically.

A direction arrow appears in each column heading to indicate in what direction the data is sorted, as in the example below.

NOTE: 20,000 messages can be stored in the Event Log.

Source Displays the name of the machine component where the event originated.

Description Displays the details of the event.

• For a User Access event, displays the access details – login or logout, and the user name.

• For an Machine Stop alarm event, displays the alarm message, the status of the alarm – active or inactive, and the date and time when the alarm became active.

• For a Machine Warning alarm event, displays the alarm message, the status of the alarm – active or inactive, and the date and time when the alarm became active.

• For a Benchmark event, displays the name of the user who captured the benchmark event.

• For an Cycle Interruption event, displays the alarm message, the status of the alarm – active or inactive, and the date and time when the alarm became active.

• For a machine Mode Change event, displays the date and time, and names of the modes.

• For a SPC event, displays the SPC variable alarm state.

• For a Setpoint Change event, displays the setpoint variable name, the unmodified and modified values along with units, and the name of the user who made the changes.

• If the Setpoint Change Reasons option is enabled, the Reason Codes and comments are also displayed.

• For a Mold Setup event, displays the Recall Mold Setup status.

Figure 1-4 Column Sort Direction Arrows

Table 1-2 EVENTS HISTORY Screen Descriptions (Continued)

Element Description

EVENTS HISTORY Screen 1–5


Table 1-3 EVENT STATUS Icons

Icon Icon Description

Indicates a User Access event.

(red background) Indicates an active Machine Stop alarm.

(grey background) Indicates an inactive Machine Stop alarm.

(yellow background) Indicates an active Machine Warning alarm.

(grey background) Indicates an inactive Machine Warning alarm.

Indicates a Benchmark event.

(red lightning bolt) Indicates an active Cycle Interruption event.

(grey lightning bolt) Indicates an inactive Cycle Interruption event.

Indicates a Machine Mode Change event.

Indicates a SPC event.

Indicates a Setpoint Change event.

Indicates a Mold Setup event.

Polaris — v2009.3

1–6 EVENT TYPE FILTER Pop-up Window

1.2.1 EVENT TYPE FILTER Pop-up Window

The EVENT TYPE FILTER pop-up window allows the user to select the event types over a range of dates for display on the EVENTS HISTORY screen.

Figure 1-5 EVENT TYPE FILTER Pop-up Window

Table 1-4 EVENT TYPE FILTER Screen Descriptions

Element Description

Access check box Select the check box to display the events, or clear the check box to hide the events.

Alarm check box

Benchmark check box

Cycle Interruption check box

Log check box

Machine check box

HMI Start check box

SPC check box

Setpoint check box

Setup check box

Warning check box

Select All button Touch this button to select all check boxes.

Deselect All button Touch this button to clear all check boxes.

EVENT TYPE FILTER Pop-up Window 1–7


Time

All option button Select this option button to display all selected event types contained in the Event Log.

Date option button Select this option button to display the date and time fields, as shown below. All selected event types in the Event Log that fall within the defined date and time range will be displayed on the EVENTS HISTORY screen.

1 – Touch the button to display the Calendar touchpad. Select the date using the Calendar touchpad.

2 – Touch the appropriate portion of the time field first to highlight it. Then use the spin buttons to adjust the value.

Table 1-4 EVENT TYPE FILTER Screen Descriptions (Continued)

Element Description

Year

Month

HourDay Minute

Second

1

2

spinbutton

Polaris — v2009.3

1–8 REPORTS SELECTION Screen

1.3 REPORTS SELECTION Screen

The REPORTS SELECTION screen allows the user to generate reports on demand, or schedule the generation of reports.

Press <ALARMS> key, then touch the REPORTS SELECTION tab. Refer to Figure 1-5.


Figure 1-6 REPORTS SELECTION Screen

Table 1-5 REPORTS SELECTION Screen Descriptions

Element Description

On-Demand Schedule

Cycle Interruption Report

Select this check box to enable the Cycle Interruption Report. Clear the check box to disable the report.

NOTE: To generate the report, touch the Generate Report button. To view the report see Section 1.4.

Setpoint Change Report

Select this check box to enable the Setpoint Change Report. Clear the check box to disable the report.


Machine Events Report

Select this check box to enable the Machine Events Report. Clear the check box to disable the report.


REPORTS SELECTION Screen 1–9


Period

From/To Set the “From” and “To” date and time values to select the data covering that period.

On-Demand Reporting Actions

Generate Report button – touch this button to generate the selected on-demand report(s).

Print Report button – touch this button to print the generated on-demand report(s).

Save Report button – touch this button to save the generated on-demand report(s) to floppy diskette(s) or a USB device (if available).

On Schedule

Cycle Interruption Report

Select this check box to enable the scheduled Cycle Interruption Report. Clear the check box to disable the report.

Setpoint Change Report

Select this check box to enable the scheduled Setpoint Change Report. Clear the check box to disable the report.

Machine Events Report

Select this check box to enable the scheduled Machine Events Report. Clear the check box to disable the report.

Schedule

End Of Each Shift Select this check box to enable automatic generation of reports at the end of each shift. Clear the check box to disable automatic generation of reports.

NOTE: Shifts are defined in the Section 10.4.

Daily

Sunday Select the required day(s) on which to automatically generate the report(s). Select as many days as required. Clear the check box to disable.

The generated report(s) cover the period preceding the time in the Daily At field for each selected day.

The following examples illustrate how this feature works:

If "Wednesday" is selected, the report covers the period Wednesday <time> to Wednesday <time>.

If "Monday" and "Friday" are selected, the Friday report covers the period Monday <time> to Friday <time>. The Monday report covers the period Friday <time> to Monday <time>.

Monday

Tuesday

Wednesday

Thursday

Friday

Saturday

Daily At Enter the time in HH:MM:SS format at which to generate the report(s). This field works in conjunction with the day selection check boxes above.

Table 1-5 REPORTS SELECTION Screen Descriptions (Continued)

Element Description

Polaris — v2009.3

1–10 Alarm Report Types

1.3.1 Alarm Report Types

There are three types of reports which can be generated either on-demand or at scheduled intervals. The reports are:

• Cycle Interruption Report• Setpoint Change Report• Machine Events Report

All reports have the same header, which includes the report name, page number, reporting period, machine type, serial number, report creation date and time.

At the end of each report there is a summary of counts that list the total number of event entries within the reporting period, followed by the total included in the report.

In all reports the first column lists the time of the event in HH:MM:SS format. The date of the event is listed on a separate line at the beginning of the report, and then again only when it changes. All other columns of the report are report-specific, and are discussed below.

Cycle Interruption Report: includes two types of machine events – Cycle Interruptions, and Machine State Change. Table 1-6 describes additional information found in the report.

A Frequency of Occurrence in Report summary follows the main body of the report. It lists the total number and duration of each event.

Setpoint Change Report: lists all Setpoint changes. Table 1-7 describes additional information found on the report.

Options

Enable Scheduled Reporting

Select this check box to enable generation of the selected On-Schedule report(s). Clear the check box to disable generation of scheduled reports.

Print Scheduled Reports

Select this check box to enable printing of scheduled report(s). Clear the check box to disable printing of scheduled reports.

Save Scheduled Report(s) to Floppy

Select this check box to enable saving of selected On-Schedule report(s) to floppy diskette or a USB device (if available). Clear the check box to disable saving of scheduled reports.

Table 1-5 REPORTS SELECTION Screen Descriptions (Continued)

Element Description

Table 1-6 Machine Cycle Interruptions Report Descriptions

Header Description

Duration For Cycle Interruption events, duration is the length of time between start of cycle interruptions and when the cycle resumes.

For Machine State Change events, duration is the length of time in a given machine state.

Message Describes the event.

Response time Only applies to Cycle Interruption events. It is the length of time between an active and an inactive state.

Creating On-Demand Reports 1–11


A Frequency of Occurrence in Report summary follows the main body of the report. It lists the total number of occurrences for each event.

Machine Events Report: lists all types of machine events in chronological order. Table 1-8 describes additional information found on the report.

A Frequency of Occurrence in Report summary follows the main body of the report. It lists the total number of occurrences for each event.

1.3.2 Creating On-Demand Reports

Create on-demand reports using the instructions below.

NOTE: User access rights of Operator, Processor, Maintenance or Administrator required to create reports.

1. Press <ALARMS> key, then touch the REPORTS SELECTION tab.

2. Select one or more of the following check boxes listed under On-demand Reports: "Cycle Interruption Report", "Setpoint Change Report" or "Machine Events Report".

3. Select the From and To date, and time period for the report.

4. Press the Create On-Demand Report button.

NOTE: If several reports are enabled, they are generated one after another.

Table 1-7 Setpoint Change Report Descriptions

Header Description

Setpoint Describes the setpoint change.

From Setpoint value before it was changed.

To Setpoint value after it was changed.

Units Units of measure.

Reason This column will only appear if Setpoint Change Reason option is enabled. Reason Code and optional comments appear in the language they were created in.

Table 1-8 Machine Events Report Descriptions

Header Description

Type Lists the type of event.

Source Displays the name of the machine component where the event originated.

Message Describes the event. See Description in Table 1-2.

NOTE: If Setpoint Change Reason option is enabled, Reason Code and comments will also be included. Reason Code and comments appear in the language they were created in.

Polaris — v2009.3

1–12 Viewing On-Demand Reports

1.3.3 Viewing On-Demand Reports

See Section 1.4.1.

1.3.4 Printing On-Demand Report(s)

Print on-demand report(s) using the instructions below.

NOTE: User access rights of Operator, Processor, Maintenance or Administrator required to print reports.

1. Press <ALARMS> key, then touch REPORTS SELECTION tab.




5. Press the Print On-Demand Report button.

NOTE: If several reports are enabled, they are printed one after another.

1.3.5 Saving On-Demand Report(s)

Save on-demand report(s) to floppy diskette using the instructions below.

NOTE: User access rights of Operator, Processor, Maintenance or Administrator required to save reports.





5. Press the Save to Floppy Diskette button to save the report(s).

NOTE: If several reports are enabled, they are saved one after another.

Enabling Scheduled Reports 1–13


1.3.6 Enabling Scheduled Reports

Enable scheduled reports using the instructions below.

NOTE: User access rights of Operator, Processor, Maintenance or Administrator required to enable Scheduled Reports.


2. Select one or more of the following check boxes listed under Scheduled Reports: "Cycle Interruption Report", "Setpoint Change Report" or "Machine Events Report".

3. Select "End Of Each Shift" check box under Schedule.

NOTE: Shift definitions are set in the HMI CONFIGURATION screen.

4. Select one or more days of the week using the check boxes.

5. Enter the time in the "Daily At" field in HH:MM:SS format to create the scheduled report. This enables automatic creation of a report for the period preceding the time in the “Daily At” field for each selected day.

6. Select "Enable Scheduled Reporting" check box under Options.

1.3.7 Printing Scheduled Reports

Print scheduled reports using the instructions below.

1. First enable the scheduled reports – refer to Section 1.3.6.

2. Select "Print Scheduled Reports" check box under Options.

The report(s) will be printed at the scheduled time.

1.3.8 Saving Scheduled Report(s)

Save scheduled report(s) to floppy diskette using the instructions below.

1. First enable the scheduled reports – refer to Section 1.3.6.

2. Select "Save Scheduled Report(s) to Floppy" check box under Options.

The report(s) will be saved to floppy diskette at the scheduled time.

Polaris — v2009.3

1–14 REPORT VIEW Screen

1.4 REPORT VIEW Screen

The REPORT VIEW screen allows the user to view and print the most recently created on-demand or scheduled reports.

Press <ALARMS> key, then touch the REPORT VIEW tab. Refer to Figure 1-7.


Figure 1-7 REPORT VIEW Screen

Table 1-9 REPORT VIEW Screen Descriptions

Element Description

Touch this button to view the current on-demand report.

Touch this button to view the current scheduled report.

Touch this button to print the current report displayed in the view window.

Reporting Period This field displays the From and To reporting periods for the selected report.

Cycle Interrupt Select this option button to view the current cycle interruption report.

Selecting a Report to View or Print 1–15


1.4.1 Selecting a Report to View or Print

Select a report for viewing or printing using the instructions below:

1. Press <ALARMS> key, then touch REPORT VIEW tab. Refer to Figure 1-7.

2. Select one of the following option buttons: "Cycle Interrupt", "Setpoint" or "Machine Events".

3. Select On-Demand or Scheduled button to display the report. The status field displays the reporting period.

4. To print the selected report, touch Print Report button.

NOTE: After a report is selected for printing, it is sent to a job queue. Several reports can be selected one after the other for printing.

Setpoint Select this option button to view the current setpoint report.

NOTE: If Setpoint Change Reason option is enabled, the Reason Code and Comments will appear in a separate column. Reason Code and comments appear in the language they were created in.

Machine Events Select this option button to view the current machine events report.

Table 1-9 REPORT VIEW Screen Descriptions (Continued)

Element Description

Polaris — v2009.3

1–16 LOG TRANSFER Screen

1.5 LOG TRANSFER Screen

The LOG TRANSFER screen allows the user to transfer Data or Event Logs to a single 1.4 Mb floppy diskette or to a USB device (if available). Each Data or Event Log is a Comma Separated Value (.CSV) file in a self-extracting compressed format.

Press <ALARMS> key, then touch the LOG TRANSFER tab. Refer to Figure 1-8.


Figure 1-8 LOG TRANSFER Screen

Table 1-10 LOG TRANSFER Screen Descriptions

Element Description

Log Type

Event Log Select the Event Log option button to transfer data from the Event Log.

Data Log (All) Select the Data Log (All) option button to transfer data from the Data Log. All records will be transferred.

Data Log (SPC) Select the Data Log (SPC) option button to transfer only SPC data from the Data Log. This is a subset of the above.

NOTE: Only variables configured for monitoring in the SPC program are recorded.

NOTE: This option is only available if the SPC option is installed on the machine.

Since Last This field displays the number of entries in the Data Log since the last transfer. The counter will stop incrementing when the maximum count is reached. The counter is reset to zero when the log is transferred successfully.

LOG TRANSFER Screen 1–17


Max This field displays the maximum number of entries the logs can hold. The Event Log can hold up to 20,000 entries, and the Data Log can hold up to 10,000 entries.

Date and Time

(1)

Indicates the date and time of the oldest entry in the Event and Data Logs.

Date and Time

(2)

Indicates the date and time of the newest entry in the Event and Data Logs.

Transfer Type

Since Last Select the option button to transfer the entries made to the Data Log since the previous "Since Last" transfer. The Since Last counter is reset to zero when the log is transferred successfully.

The button is greyed out if Event Log is selected.

Entire Log Select the option button to transfer all the entries in the selected log. The Since Last counter is not reset after the transfer.

Time Range Select the option button to transfer all the entries in the selected log for the specified time range. The Since Last counter is not reset after the transfer.

The date and time fields are displayed when this option is selected. Selecting the drop-down "From" or "To" fields displays the calendar touchpad.

Table 1-10 LOG TRANSFER Screen Descriptions (Continued)

Element Description

1 2

Polaris — v2009.3

1–18 LOG TRANSFER Screen

Transfer Actions

Touch the button to display the pop-up window shown below. Select a destination device (local hard disk, floppy diskette, USB device, or network drive). If necessary, touch the Expand Button ( ) and use the file browser to select a destination folder. Touch the Confirm button to transfer the selected log to the destination device. Touch the Cancel button to abort file transfer.

NOTE: Devices that are unavailable will be greyed out.

NOTE: USB devices can be plugged into the USB ports located on the outside of the electrical cabinet.

The log is saved to a single floppy diskette as a compressed self-extracting file. Double-clicking the self-extracting (.EXE) file will uncompress the file to a Comma Separated Value (.CSV) file.

Table 1-10 LOG TRANSFER Screen Descriptions (Continued)

Element Description

Remove cap to access USB port

REASON EDIT Screen (Optional) 1–19


1.6 REASON EDIT Screen (Optional)

The REASON EDIT screen is an optional screen which allows an administrator to create/modify the Reasons List, save or restore the Reasons List, and enable/disable the Setpoint Change Reason function. A machine operator can view the Reasons List on this screen.

NOTE: This screen will be displayed only if the Setpoint Change Reasons option is installed and enabled.

Press <ALARMS> key, then touch the REASON EDIT tab – refer to Figure 1-9.

NOTE: User access rights of Administrator required to select or modify functions.

Figure 1-9 REASON EDIT Screen

Table 1-11 REASON EDIT Screen Descriptions

Element Description

Administrator Settings

Setpoint Change Reason Enable

Select this check box to enable the Setpoint Change Reason function. When this function is enabled, the operator must select a Reason Code after making a setpoint change.

NOTE: The operator does not need to enter a Reason Code if Permit Operator Repeat Reasons (see below) is selected.

When the check box is cleared, the operator can make setpoint changes without having to enter Reason Codes.

Polaris — v2009.3

1–20 REASON EDIT Screen (Optional)

Permit Operator Repeat Reasons

Select this check box to permit the machine operator to assign the previous Reason Code to the current setpoint change.

If the check box is cleared, the machine operator must select a Reason Code from the Reasons List.

NOTE: If the check box is cleared, the operator will not see the Enable Repeat Reason check box (described below).

Operator Settings

NOTE: This frame will be active only if the Administrator selects the Permit Operator Repeat Reasons check box.

Enable Repeat Reasons

Select this check box to automatically assign the previous Reason Code and comments to setpoint changes. The Reasons List will not appear when a setpoint change is made. All setpoint changes will be automatically assigned the same Reason Code and comments until this check box is cleared.

If the check box is cleared, the machine operator must select a Reason Code from the Reasons List.

Copy

NOTE: The Reasons List is stored under the default file name "Reason.dat". Copying the Reasons List overwrites any Reasons.dat file on the destination device. If the Reasons.dat file is not found on the device, a warning message will be displayed indicating that the file is missing.

NOTE: Any device that is unavailable will be greyed out. Touch the Refresh button to refresh all removable devices if they become temporarily unavailable.

Select the local hard disk as the source or destination device. The default folder/file name is displayed in the text box.

Select the floppy drive, or USB device as the source or destination device, as applicable. If necessary, use the Expand Button ( ) and use the file browser to select a path. The selected device/path is displayed in the text box.

Select the appropriate transfer button to copy the file from the source to destination device.

Reasons List Displays the list of Reason Codes and reasons. Up to 100 reasons can be configured. Any unconfigured fields will be displayed as blank.

NOTE: Only the administrator can create/modify the Reasons List – refer to Section 1.6.2.

NOTE: The Reasons List displayed in this window will show all configured Reason Codes and any unconfigured fields. However, the Reasons List displayed in the REASONS LIST pop-up window will only show the configured Reason Codes.

Table 1-11 REASON EDIT Screen Descriptions (Continued)

Element Description

REASONS LIST Pop-up Window 1–21


1.6.1 REASONS LIST Pop-up Window

The REASONS LIST pop-up window displays a list of Reason Codes and reasons that have been configured by the administrator – refer to Figure 1-10. Up to 100 Reason Codes can be configured and displayed in the REASONS LIST pop-up window. The machine operator can select a Reason Code and an existing comment, or create a new comment. Comments are optional.

When Setpoint Change Reason is enabled, the REASONS LIST pop-up window is displayed whenever a setpoint event is generated. Setpoint events are typically generated whenever an operator changes setpoint values, enables or disables a check box or option button that affects a PLC process, presses a button that generates an event, or modifies a combo box setting.

If the Permit Operator Repeat Reasons check box is selected by the administrator, and the Enable Repeat Reasons is selected by the machine operator the REASONS LIST pop-up window will not be displayed if a setpoint change is made. The previous Reason Code and comments are automatically saved to the Event Log.

NOTE: User access rights of Operator Level 2 or Processor required to use this function.

Figure 1-10 REASONS LIST Pop-up Window

1. Current selection

1

Polaris — v2009.3

1–22 Creating/Modifying a Reasons List

1.6.2 Creating/Modifying a Reasons List

The default "Reason.dat" file located on the local hard disk contains a set of default reasons which you can edit to create a new Reasons List. Create a Reasons List to suit your production requirements.

NOTE: User access rights of Administrator required to use this function.

Create a Reasons List using the instructions below:

1. Press the <ALARMS> key, then touch the REASON EDIT tab.

2. Select any reason from the default list of reasons shown. The selection is highlighted, and the REASON INPUT pop-up window is displayed.

NOTE: You can also highlight a blank line and modify it.

3. Modify/replace the existing phrase with a suitable phrase. The phrase must be alpha-numeric, and can be up to 64 characters long. Close the pop-up window. The Reasons List is saved and updated on the REASON EDIT screen.

4. Repeat step 2 and step 3 to configure as many reasons as required. You can create up to 100 reasons.

Table 1-12 REASONS LIST Pop-up Window Descriptions

Element Description

Reason Code Displays the list of Reason Codes configured by the administrator. The last selected Reason Code is highlighted when the REASONS LIST pop-up window is first displayed. When another Reason Code is selected, the newly selected item is highlighted. The current selection is also displayed in the greyed out text box at the top of the screen.

NOTE: The REASON EDIT screen displays all the Reason Codes – including the ones that have not been configured.

NOTE: The scroll-bar will not appear if less than 16 Reason Codes are configured in the Reasons List.

Comments

No Comment Select this option if you do not want to include any comments with the currently selected Reason Code.

NOTE: This is the default selection when the REASONS LIST pop-up window is displayed.

Last Comment Select this option to include the previous comment with the currently selected Reason Code. The text box adjacent to this button displays the previous comment.

New Comment Select this option to create a new comment for the currently selected Reason Code. The COMMENT INPUT pop-up window is displayed to create a new comment.

Touch this button to accept the currently selected Reason Code and comment. The Reason Code and comment are then saved to the Events Log.

Copying a Reasons List 1–23


NOTE: You cannot delete the first reason, however you can modify it.

1.6.3 Copying a Reasons List

Copy the Reasons List from a source device to a destination device using the instructions below:

NOTE: User access rights of Administrator required to use this function.


2. Select the appropriate source device.

NOTE: Any device that is unavailable will be greyed out.

3. Then select the appropriate destination device.

4. Then select the appropriate transfer button to copy the Reasons List.

The HMI then displays a confirmation window to verify the selection. It then overwrites the Reasons.dat file on the destination device according to the selection above.

1.6.4 Enabling Setpoint Change Reason Function

The Setpoint Change Reason function can be enabled or disabled by an administrator. When the function is enabled a machine operator must assign Reason Codes when changing setpoint values. When the function is disabled the operator can modify setpoint values without having to enter Reason Codes.

NOTE: User access rights of Administrator required to modify this function.

Enable/disable the Setpoint Change Reason function using the instructions below:


2. Select the Setpoint Change Reason Enable check box.

3. Select the Permit Operator Repeat Reasons check box if you wish to permit the machine operator to assign the previous Reason Code for setpoint changes. If this check box is cleared, the machine operator must select a Reason Code from the Reasons List.

If the Reasons List has already been created, the operator can now assign Reason Codes and comments when changing setpoint values.

1.6.5 Changing a Setpoint Value

When Setpoint Change Reason function is enabled by the administrator, the function is activated whenever an operator changes setpoint values, enables or disables a check box or option button that affects a PLC process, presses a button that generates an event, or modifies a combo box setting.

Assign a Reason Code and comment after making a setpoint change using the instructions below:

Polaris — v2009.3

1–24 Changing a Setpoint Value


1. Select any input field and change the setpoint value using the pop-up numeric pad. Accept the change and exit the numeric pad.

NOTE: If the change is not accepted, the setpoint value will be reset to the old value.

The REASONS LIST pop-up window is then displayed on the HMI. The last selected Reason Code is highlighted.

2. You can accept the last selected Reason Code, or select another Reason Code from the displayed list. The selected Reason Code and reason are highlighted, and also displayed in the greyed out text box at the top of the screen.

3. Select a comment to include with the current selection. Comments are optional.

By default, the No Comment option button is selected. If this option is selected, no comments are included with the currently selected Reason Code.

Or, select the Last Comment option button to include the previous comment with the currently selected Reason Code.

Or, select the New Comment option button to create a new comment. The COMMENT INPUT pop-up window is then displayed. Comments must be alpha-numeric, and can be up to 256 characters long. Close the pop-up window.

4. Touch the Accept button. The Reason Code and comments are stored in the Event Log along with the rest of the setpoint change details.

NOTE: When modifying any setpoint profile, the REASONS LIST pop-up window will be displayed only upon exiting the setpoint profile screen. All modified fields in the profile will be assigned the same Reason Code and comment.

NOTE: If the Permit Operator Repeat Reasons check box is selected on the REASON EDIT screen, the REASONS LIST pop-up window will not be displayed. The previous Reason Code and comment will be assigned automatically to the current setpoint change.

NOTE: If the Enable Repeat Reasons check box is selected on the REASON EDIT screen, the REASONS LIST pop-up window will not be displayed. The previous Reason Code and comments will be assigned automatically to current setpoint changes.

NOTE: The operator is reminded to clear the Enable Repeat Reasons check box after making the necessary setpoint changes so that the Event Log is not filled with invalid Reason Codes and comments.

HMI Reference Manual Polaris — v2009.3 Machine

MACHINE SPECIFICATIONS Screen 2–1

Chapter 2 Machine

The Machine screens allow the user to view and adjust various machine operational parameters, and view general performance in graphical form.

2.1 MACHINE SPECIFICATIONS Screen

The MACHINE SPECIFICATIONS screen allows a user to view general machine information, and selected factory-set machine setpoints.

Press <MACHINE> key to display the MACHINE SPECIFICATIONS screen. Refer to Figure 2-1.

NOTE: Screen shown is representative, and may vary depending on how the machine is configured.

Figure 2-1 MACHINE SPECIFICATIONS Screen

Polaris — v2009.3

2–2 MACHINE SPECIFICATIONS Screen

Table 2-1 MACHINE SPECIFICATIONS Screen Descriptions

Element Description

General

Model Displays the machine model number. The following two examples show how a machine model number is interpreted:

1. machine type: HyPET

2. maximum clamp tonnage (in metric tons)

3. injection unit type: RS - Reciprocating Screw; P - Packaging

4. injection unit model number

5. shooting pot diameter (in millimeters)

6. extruder

7. screw diameter (in millimeters)

8. machine type: HPP

9. screw L/D ratio - only for HyPET HPP machines

Serial Number Displays the machine serial number.

Build Date Displays the physical machine build date.

Tester Displays the name of the Husky personnel who tested the machine.

Software Version

Screen Version Displays the HMI software version number currently installed on the machine.

MACHINE SPECIFICATIONS Screen 2–3


Clamp

Mold Stroke - Maximum (1)

Displays the maximum mold stroke. This value varies depending on the mold shutheight.

Mold Shutheight (2) Displays the minimum and maximum shutheight. Shutheight is the distance between the stationary and moving platens when the clamp is fully extended.

Ejector Stroke Maximum (3)

Displays the maximum ejector stroke value.

Distance Between Tiebars (4)

Displays the vertical and horizontal distance between tiebars.

Injection

Screw Stroke (1) Displays the maximum screw stroke.

Screw Diameter (2) Displays the screw diameter.

Maximum Screw Speed

Displays the maximum screw speed.

Maximum Injection Pressure

Displays the maximum hydraulic pressure of the screw against the process material at the maximum force of the injection piston.

Injection Capacity Displays the maximum volume that can be injected by the screw at maximum stroke.

Table 2-1 MACHINE SPECIFICATIONS Screen Descriptions (Continued)

Element Description

1

2

4

3

21

Polaris — v2009.3

2–4 CYCLE TIME BREAKDOWN Screen

2.2 CYCLE TIME BREAKDOWN Screen

The CYCLE TIME BREAKDOWN screen allows a user to save a cycle time benchmark, and view the cycle times for saved and current cycles.

Press <MACHINE> key, then touch the CYCLE TIME BREAKDOWN tab. Refer to Figure 2-2.

NOTE: User access rights of Operator, Processor, or Maintenance required to select or modify functions.


Screw L/D Ratio Displays the length to diameter ratio of the screw.

Shooting Pot Stroke Displays the maximum shooting pot stroke.

NOTE: This field is only displayed on machines with P-Injection units.

Shooting Pot Diameter

Displays the shooting pot diameter.


Melt Channel Diameter

Displays the melt channel diameter.


Table 2-1 MACHINE SPECIFICATIONS Screen Descriptions (Continued)

Element Description

Figure 2-2 CYCLE TIME BREAKDOWN Screen

CYCLE TIME BREAKDOWN Screen 2–5


Table 2-2 CYCLE TIME BREAKDOWN Screen Descriptions

Element Explanation

Display Options Touch the drop-down box to choose from the following display types:

• Start and Duration

• Start, Duration and End

• Duration

• Start

• Name Only

The Start, Duration and End columns beside the machine event list change depending on your selection.

Machine Event List

Machine Event Legend:

1 – Column displays saved start time (green) for event.

2 – Column displays actual start time (red) for event.

3 – Column displays saved duration (green) for event.

4 – Column displays actual duration (red) for event.

5 – Column displays saved end time (green) for event.

6 – Column displays actual end time (red) for event.

7 – Event in red characters (check box cleared) indicates the current real-time event.

8 – Event in black characters (check box selected) indicates the finished event in the current cycle.

9 – Event in black characters (check box cleared) indicates the event has not been run in the current cycle.

10 – Graph depicts start time and duration for both actual and saved.

Mold Closing Start of Mold Close is the reference point for all machine cycle times.

1 2 3 4

7

8

9 10

5 6

Polaris — v2009.3

2–6 CYCLE TIME BREAKDOWN Screen

Clamp Lock Engage Actual time from Start of Mold Close to when the clamp lock is fully engaged.

Clamp Up Actual time from Start of Mold Close to the fully clamped position.

Unclamp Actual time from Start of Mold Close to start of clamp cylinder retracting.

Clamp Lock Disengage

Actual time from Start of Mold Close to when the clamp lock is out.

Mold Opening Actual time from Cycle Start to Mold Open position.

Ejector Forward Actual time from Start of Mold Close to when the ejector starts forward.

Ejector Back Actual time from Start of Mold Close to when the ejector starts back.

Mold Open Actual time from Start of Mold Close to when the mold is in the open position.

Cooling Actual time during cooling.

Carriage Forward Actual time from Start of Mold Close to Carriage Forward position. The actual carriage forward position must be less than or equal to the Forward setpoint on the RECOVERY screen.

Nozzle Open Actual time from Cycle Start to when the shut-off nozzle is open.

Injection Fill Actual time from Cycle Start to Injection Start.

Injection Hold Actual time from start of Injection Hold to end of Injection Hold.

Pre-Pullback Actual time from Cycle Start to End of Pullback (Before Recovery).

Screw Run Actual time that the screw rotates during Recovery.

Post Pullback Actual time for pullback (after Recovery).

Cycle Time Actual time from Start of Mold Close to the next Start of Mold Close.

Touch the Configuration button to display the CYCLE BREAKDOWN CONFIGURATION pop-up window – refer to Section 2.2.1.

Touch this button to save a cycle time breakdown benchmark. The field just below the Save button displays the date and time of the last benchmark save.

Cycle Time Limit Enter the time limit for a machine cycle. When the time limit is exceeded, the machine interrupts the Auto cycle, and resets itself to the mold open position.

Pie Chart

Table 2-2 CYCLE TIME BREAKDOWN Screen Descriptions (Continued)

Element Explanation

CYCLE BREAKDOWN CONFIGURATION Pop-up Window 2–7


2.2.1 CYCLE BREAKDOWN CONFIGURATION Pop-up Window

The CYCLE BREAKDOWN CONFIGURATION pop-up window allows a user to select the variables for display on the CYCLE TIME BREAKDOWN screen – refer to Figure 2-3.

Touch the Configuration button on the CYCLE TIME BREAKDOWN screen to display this pop-up window.

Touch this button to display a pie chart showing the percentage of time spent in part removal, process and clamp. The time is shown in the text boxes below the pie chart.

Parts Removal Parts removal time is equal to the time that the mold remains open.

Process In Normal cycle mode, if injection does not start before the end of Clamp Up, Process time is equal to time at end of cooling minus the time at end of Clamp Up. If injection starts before the end of Clamp Up, Process time is equal to time at end of cooling minus the time at which injection first starts to occur.

In Dry Cycle mode, Process time is equal to Cooling Time.

Clamp Clamp time is equal to Cycle Time minus Process time, minus Parts Removal time.

Table 2-2 CYCLE TIME BREAKDOWN Screen Descriptions (Continued)

Element Explanation

Polaris — v2009.3

2–8 CYCLE BREAKDOWN CONFIGURATION Pop-up Window


NOTE: User access rights of Operator, Processor, or Maintenance required to use this function.

Figure 2-3 CYCLE BREAKDOWN CONFIGURATION Pop-up Window

Table 2-3 CYCLE TIME BREAKDOWN CONFIGURATION Screen Descriptions

Element Explanation

Variables The following is a list of variables that can be selected: Mold Closing, Clamp Lock Engage, Clamp Up, Carriage Forward, Nozzle Opening, Injection Fill, Injection Hold, Cooling, Pre-Pullback, Transfer Time, Screw Run TIme, Unclamp, Clamp Lock Disengage, Mold Opening, Ejector Forward, Ejector Back, Mold Open, Tooling Plate - In - Stage 1, Tooling Plate - In - Stage 2, Tooling Plate - In - Stage 3, Tooling Plate - In - Stage 4, Tooling Plate - Out - Stage 1, Tooling Plate - Out - Stage 2, Tooling Plate - Out - Stage 3, Tooling Plate - Out - Stage 4, CoolPik - Vertical, CoolPik - Horizontal, Part Drop.

NOTE: A maximum of 19 variables can be selected at any given time.

Touch this button to move the highlight up through the list of available variables.

Touch this button to select/clear a highlighted variable. The checkbox beside the variable displays a check mark ( ) if the variable is selected.

Touch this button to move the highlight down through the list of available variables.

Setting Cycle Time Limit 2–9


2.2.2 Setting Cycle Time Limit

Set Cycle Time Limit using the following instructions:

NOTE: Cycle Time Limit can also be set on the PRODUCTION SETUP screen. The timer starts when the <CYCLE START> key is pressed.


1. Press <MACHINE> key, then touch the CYCLE TIME BREAKDOWN tab.

2. Select the field Cycle Time Limit, and enter a suitable value.

2.2.3 Saving a Cycle Time Breakdown Benchmark

Set Cycle Time Breakdown Benchmark using the following instructions:

NOTE: The machine must be in Semi or Auto cycle mode to save a cycle time breakdown benchmark.


1. Press <MACHINE> key, then touch the CYCLE TIME BREAKDOWN tab.

2. Touch the Save button. The field just below the Save button displays the date and time of the last benchmark save.

2.3 PROCESS SETUP Screen

The PROCESS SETUP screen allows an operator to select and view some of the more common machine process settings in one location, without having to navigate to different parts of the HMI.

Press <MACHINE> key, then touch the PROCESS SETUP tab. Refer to Figure 2-4.

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2–10 PROCESS SETUP Screen



Figure 2-4 PROCESS SETUP Screen

PROCESS SETUP Screen 2–11


Table 2-4 PROCESS SETUP Screen Descriptions

Element Explanation

Clamp

Mold Open and Mold Close Setpoint

Profiles

The Mold Open setpoint profile controls how the mold speed changes as the mold opens. Starting from the right, and moving left to the next position in the profile constitutes one step. The mold moves to the second position at the first speed indicated in Mold Open setpoint profile. Then it moves to the next position at the next speed in the profile, and so on.

The Mold Close setpoint profile controls how the mold speed changes as the mold closes. Starting from the left, and moving right to the next position in the profile constitutes one step. The mold moves to the second position at the first speed indicated in Mold Close setpoint profile. Then it moves to the next position at the next speed in the profile, and so on.

Both profiles are displayed side by side on the screen if each profile has 4 steps or less. If the number of steps exceed this value, the profiles are displayed on two separate tabs. Each tab can display up to 9 steps.

Mold Open and Mold Close setpoint profiles are step type profiles. These are similar to step type profiles used in the injection screens. Step type profiles share some common characteristics which are discussed in Section 4.2.2.

To modify the number of steps in step type profiles, refer to Section 4.2.3.

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2–12 PROCESS SETUP Screen

Injection

Injection Hold and Injection Fill

Setpoint Profiles

NOTE: The Hold and Fill tabs will appear when there are more than three setpoints in either the Injection Hold or Fill setpoint profile.

The Injection Fill setpoint profile controls how injection speed changes as the material is injected into the mold. The Injection Hold setpoint profile controls how long, and how much pressure is applied by the injection piston after the transition from Fill to Hold.

The Injection Fill and Injection Hold profiles can be configured as either step type profiles or as linear interpolated profiles. Step type profile is the default selection. In step profiles changes in the process are defined in terms of abrupt speed or pressure changes, which result in step-like profiles. With a step type profile it is not easy to control the rate of change. A linear interpolated profile, on the other hand, is defined as a set of points that are connected together by straight lines to define the characteristics of the process. This results in greater control over the rate of change.

The Injection Fill and Injection Hold profiles are displayed side by side or on two separate tabs on the screen. If the Injection Fill profile has 4 steps or less, and the Injection Hold profile has 4 steps (5 points) or less then they are displayed side by side; otherwise they are displayed on two separate tabs.

For step type setpoint profile characteristics refer to Section 4.2.2.

To modify the number of steps/points in injection setpoint profiles refer to Section 6.2.1.

Table 2-4 PROCESS SETUP Screen Descriptions (Continued)

Element Explanation

PROCESS SETUP Screen 2–13


Recovery

Recovery Speed and Recovery Back

Pressure Setpoint Profiles

The Recovery Speed setpoint profile controls how the screw rotation speed changes during recovery. The top and middle rows in the profile make up the Recovery Speed setpoint profile. Starting from the left, and moving right to the next position in the profile constitutes one step. The injection piston moves to the second position at the first screw rotation speed indicated in the profile. Then it moves to the next position at the next screw rotation speed in the profile, and so on.

The Recovery Back Pressure setpoint profile controls how the back pressure changes during plasticizing. The middle and bottom rows in the profile make up the Recovery Back Pressure setpoint profile. Starting from the left, and moving right to the next position in the profile constitutes one step. The injection piston moves to the second position while maintaining the back pressure indicated in the first field in the Recovery Back Pressure setpoint profile. Then it moves to the next position while maintaining the back pressure indicated in the next field in the profile, and so on.

Both profiles are step type profiles. Up to 9 steps can be displayed in each of the profiles. Step type setpoint profiles share some common characteristics. These are discussed in Section 4.2.2.

To modify the number of steps in the profiles, refer to Section 4.2.3.

Tonnage Enter the clamping tonnage to be used when running the Smart Start sequence. The light grey field displays the normal tonnage setpoint value as configured on the CLAMP screen.

Transition

Hydraulic Pressure The hydraulic pressure value determines when the switch from Injection Fill to Injection Hold phase occurs.

Mold Open Time Mold Open Time is the minimum amount of time the mold must remain open before it can start to close again.

Effective Cooling Time

Effective Cooling Time is the time that the mold halves remain together at the end of the Hold phase when running the Smart Start sequence. Effective Cooling Time is equal to the Cooling setpoint (from INJECTION screen) plus the Unclamp time.

Cushion Control Cushion control determines the amount of plasticizing material left in front of the injection screw when injection is completed.

Mold Break Mold Break is the distance that the clamp cylinder moves to open the mold after the mold is unclamped.


Element Explanation

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2–14 GRAPH Screen

2.4 GRAPH Screen

The (Machine) GRAPH screen allows a user to select and view continuous traces of pressure, speed and position data for stroke, injection or extruder, along with clamp tonnage and screw rpm. All graphs on this screen are user-configurable.

Press <MACHINE> key, then touch the GRAPH tab. Refer to Figure 2-5.


Pullback Distance

Before Touch the Up or Down button to increase or decrease the Pullback Distance Before Recovery value.

After Touch the Up or Down button to increase or decrease the Pullback Distance After Recovery value.

Sprue Break Sprue Break is the additional distance the carriage moves back from the Carriage Forward position after pullback is complete. This is typically used to separate the injection nozzle from the mold sprue in stack mold applications.

Ejector Forward Enter the Ejector Forward position when running the Smart Start sequence. The light grey field displays the normal Ejector Forward setpoint value as configured on the EJECTOR SETUP screen.


Element Explanation

Figure 2-5 GRAPH Screen

GRAPH Screen 2–15



NOTE: All curves are auto-scaled along the Y-axis to display at maximum size.

Table 2-5 GRAPH Screen Descriptions

Element Explanation

Use these buttons to start, stop or pause the machine graphing display.

1 – Start button. Touch this button to start graphing display.

NOTE: If graphing is stopped, the old graph is cleared from the screen and plotting starts again. However, if graphing is paused, plotting resumes where it left off.

2 – Pause button. Touch this button to pause graphing action on the screen.

3 – Stop button. Touch this button to stop graphing action on the screen.

Use these buttons to display and control the vertical cursor bar.

1 – Move Left button. Touch this button once to move the cursor bar to the left by one pixel. Touch and hold down to rapidly move the cursor bar to the left.

2 – Toggle Cursor button. Touch this button to display or hide the cursor bar.

3 – Move Right button. Touch this button once to move the cursor to the right by one pixel. Touch and hold down to rapidly move the cursor to the right.

NOTE: The cursor can also be moved manually. Touch and hold the cursor bar and drag it to the desired horizontal location on the screen.

NOTE: If the cursor is hidden, the buttons will also be hidden.

Touch this button to select the curves for displaying on the graph. Refer to Section 2.4.1.

Touch this button to define the properties of the graph. Refer to Section 2.4.2.

Touch this button to define the properties of each curve on the graph. Refer to Section 2.4.3.

1 2 3

1 2 3

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2–16 GRAPH Screen

Time Base Select this option button to display graphing data based on the time it takes to complete each selected data curve.

NOTE: Time Base display information can be further modified with the following two pop-up screens. Activate the pop-ups by right-clicking on the Time Base option button or its field name.

1 – Select this option button to display graphing data based on a single cycle time base.

2 – Select this option button to display graphing data based on a multi-cycle time base.

3 – The Cycle Number field indicates the number of machine cycles the graphing data uses for each sweep.

4 – Touch the Up and Down arrow buttons to modify the number of machine cycles that will be used for graphing data.

5 – Select this check box to display graphing data with a sweeping bar. The sweeping bar erases parts of the old curves that it touches.

Position Base Select this option button to display graphing data based on the position of moving components in the machine.

NOTE: If the stroke position is displayed on the graph, the stroke position becomes the X-axis. If injection position is displayed, then injection position becomes the X-axis, and stroke position is not shown on the graph.

Auto Scale X Select this check box to automatically scale the curves along the X-axis. When the check box is cleared, the curves are scaled according to the minimum and maximum values defined in Section 2.4.2.

Curve Displays name of variable selected in Section 2.4.1. Each curve is color-coded.

X-Value Displays the corresponding horizontal value of the point where the cursor bar intersects with the curve.

Y-Value Displays the corresponding vertical value of the point where the cursor bar intersects with the curve.

Table 2-5 GRAPH Screen Descriptions (Continued)

Element Explanation

12

3 4

5

CURVE SELECTION Pop-up Window 2–17


2.4.1 CURVE SELECTION Pop-up Window

The Curve Selection pop-up window allows a user to choose which curves to display on the GRAPH screen — refer to Figure 2-6. Currently the graph can display up to a maximum of 8 curves.


NOTE: When a variable is selected for display, it will be plotted on the graph after the next cycle.

Figure 2-6 CURVE SELECTION (Machine) Pop-up Window

Table 2-6 CURVE SELECTION Pop-up Window Descriptions

Element Explanation

Stroke Pressure Select the check box to display the Stroke Pressure curve on the graph. Clear the check box to hide the curve.

Stroke Speed Select the check box to display the Stroke Speed curve on the graph. Clear the check box to hide the curve.

Stroke Position Select the check box to display the Stroke Position curve on the graph. Clear the check box to hide the curve.

Clamp Tonnage Select the check box to display the Clamp Tonnage curve on the graph. Clear the check box to hide the curve.

Injection Pressure Select the check box to display the Injection Pressure curve on the graph. Clear the check boxes to hide the curve.

Injection Speed Select the check box to display the Injection Speed curve on the graph. Clear the check boxes to hide the curve.

Injection Position Select the check box to display the Injection Position curve on the graph. Clear the check boxes to hide the curve.

Screw RPM Select the check box to display the Screw RPM curve on the graph. Clear the check boxes to hide the curve.

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2–18 GRAPH PROPERTIES Pop-up Window

2.4.2 GRAPH PROPERTIES Pop-up Window

The GRAPH PROPERTIES pop-up window allows a user to define the properties of the graph on the (Machine) GRAPH screen — refer to Figure 2-7.

Screw Torque Select the check box to display the screw torque curve on the graph. Clear the check box to hide the curve.

NOTE: This check box is only displayed on machines with electric screw drive units.

Extruder Pressure Select the check box to display the Extruder Pressure curve on the graph. Clear the check box to hide the curve.

NOTE: This check box is only displayed on machines with P-Injection units.

Extruder Speed Select the check box to display the Extruder Speed curve on the graph. Clear the check box to hide the curve.


Extruder Position Select the check box to display the Extruder Position curve on the graph. Clear the check box to hide the curve.


Table 2-6 CURVE SELECTION Pop-up Window Descriptions (Continued)

Element Explanation

Figure 2-7 GRAPH PROPERTIES Pop-up Window

Table 2-7 GRAPH PROPERTIES Pop-up Window Descriptions

Element Explanation

Axis X Visible Select the check box to display the X-axis. Clear the check box to hide the X-axis.

Grid Visible Select the check box to display the background grid. Clear the check box to hide the background grid.

PLOT CONFIGURATION Pop-up Window 2–19


2.4.3 PLOT CONFIGURATION Pop-up Window

The PLOT CONFIGURATION pop-up window allows a user to set up properties of each individual curve shown on the (Machine) GRAPH screen — refer to Figure 2-8.

Right To Left Select the check box to plot the curves from "right to left". Clear the check box to return to the default "left to right" plotting.

Axis X Maximum Enter a maximum scale value for the X-axis.

NOTE: This value and the one below are used to scale the X-axis when the Auto Scale X check box is cleared on the (Machine) GRAPH screen.

Axis X Minimum Enter a minimum scale value for the X-axis.

Axis X Color Touch this box to change the X-axis color (i.e., numeric references across bottom of graph). A standard Microsoft Windows color selection pop-up window is displayed for selecting colors.

Grid Color Touch this box to change the grid color. A standard Microsoft Windows color selection pop-up window is displayed for selecting colors.

Plot Area Color Touch this box to change the plot area color (background color). A standard Microsoft Windows color selection pop-up window is displayed for selecting colors.

Table 2-7 GRAPH PROPERTIES Pop-up Window Descriptions (Continued)

Element Explanation

Figure 2-8 PLOT CONFIGURATION Pop-up Window

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2–20 SERVO DRIVE Screen

2.5 SERVO DRIVE Screen

The SERVO DRIVE screen allows a user to view the status, perform diagnostics and modify parameters in Siemens 611U or Sinamics servo drives and motors. This screen consists of a common list box which shows all available servo drives/motors on the machine, as well as a Help button (refer to Figure 2-9). The details of each servo drive/motor are displayed on five tabs, which are discussed in separate sections below.

NOTE: HyPET HPP machines use the Sinamics Drives.

Press <MACHINE> key, then touch the SERVO DRIVE tab. Refer to Figure 2-9.


Table 2-8 PLOT CONFIGURATION Pop-up Window Descriptions

Element Explanation

Curves

(various option buttons)

Select the curve for which to define properties.

NOTE: Only those curves selected in the Section 2.4.1 are displayed in this area.

Properties

NOTE: Select each curve and assign its properties individually.

Show Curve Select the check box to display the selected curve on the graph. Clear the check box to hide the selected curve.

Overlay Select the check box to display the curve as an overlay.

Line Width Enter the display line width for the curve. Line width is measured in screen pixels.

Line Color Touch the box and select the display color for the curve. A standard Microsoft Windows color selection pop-up window is displayed for selecting colors.

Line Style All curves are displayed as solid lines by default.

Show Scale Select the check box to display the Y-axis scale for the selected curve.

Auto Scale Select this check box to automatically scale the curve along the Y-axis. Clear the check box to switch off auto scaling. The curve is then scaled according to the maximum and minimum values defined below.

Y Axis Maximum Enter a maximum scale value for the selected curve along the Y-axis.

NOTE: This value and the one below are used to scale the Y-axis when the Auto Scale check box above is cleared.

Y Axis Minimum Enter a minimum scale value for the selected curve along the Y-axis.

GENERAL Tab 2–21


2.5.1 GENERAL Tab

The GENERAL tab allows a user to view the status of a servo drive/motor.

Press <MACHINE> key, then touch the SERVO DRIVE tab. Refer to Figure 2-9. Select a drive from the list box to see its details.

Table 2-9 SERVO DRIVE Screen Descriptions

Element Explanation

Drive Name list box Displays the list of servo drives/motors on the machine. Select a servo drive/motor from the displayed list to view its status, diagnostics and other details in the tabs below.

Touch the Help button to display context-sensitive help specific to the tab — refer to Section 2.5.1.1.

Figure 2-9 SERVO DRIVE - GENERAL Tab

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2–22 GENERAL Tab


Figure 2-10 SERVO DRIVE - GENERAL Tab for HyPET HPP Machines

Table 2-10 SERVO DRIVE - GENERAL Tab Descriptions

Element Explanation

Drive Terminals

NOTE: The digital input indicator ( ) lights up when the machine controller receives a signal from a device; otherwise it remains grey.

NOTE: All labels shown in the dark grey boxes beside the indicators correspond to the device designations shown in the electrical schematics.

Controller Enable (65.A or 65.B)

Displays the status of the +24V drive terminal signal (65.A or 65.B) that enables the selected servo drive.

Pulse Enable (663) Displays the status of the +24V drive terminal signal (663) that enables the drive pulse.

Infeed Terminals

Contactor On (48) Displays the contactor status (Terminal 48) for the Infeed module.

Controller Enable

(64)

Displays the status of the +24V infeed terminal signal (64) that enables all drives.

Displaying General Servo Help 2–23


2.5.1.1 Displaying General Servo Help

Display general servo help using the following instructions:

1. Press <MACHINE> key, then touch the SERVO DRIVE tab.

2. Touch the Help button.

The HMI displays the general servo help in a split window — refer to Figure 2-11.

Pulse Enable (63) Displays the status of the internal +24V infeed terminal signal (63) that supplies Pulse Enable to all drives.

Control Unit (HPP Only)

Operation Displays the status of the Control Unit. The digital input indicator ( ) lights up when receives a signal from a device; otherwise it remains grey.

Ready

Compact Flash OK

Line Module (HPP Only)

Pulse Enable Displays the status of the internal +24V infeed terminal signal (63) that supplies Pulse Enable to all drives.

Regenrative Mode Displays if the line module is in a regenerative mode.

Motor Module (HPP Only)

Pulse Enable Displays the status of the internal +24V infeed terminal signal (63) that supplies Pulse Enable to all drives.

Drive I/O

NOTE: The digital input indicator ( ) lights up when the machine controller receives a signal from a device; otherwise it remains grey. The digital output indicator ( ) lights up when the device receives a signal from the machine controller; otherwise it remains grey.

(I/O status) Displays the status of various configurable I/O that can be set up for diagnostics on the selected drive. Up to 4 input and 4 output bits can be used for each drive.

Motor

Actual Speed Displays the actual speed of the selected servo motor.

Setpoint Speed Displays the servo motor speed setpoint.

Current Iq (rms) Displays the actual motor current used to generate torque.

Torque Usage Displays the percentage of actual motor torque used.

Temperature Displays the actual motor temperature.

DC Bus Voltage Displays the actual DC bus voltage for the selected servo drive.

Table 2-10 SERVO DRIVE - GENERAL Tab Descriptions (Continued)

Element Explanation

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2–24 FAULTS Tab

NOTE: To display general servo help for any of the other sub-tabs on the screen, first select the tab then touch the Help button.

3. Touch the Exit button to close the help window.


2.5.2 FAULTS Tab

The FAULTS tab allows a user to diagnose servo drive and motor encoder errors.

Press <MACHINE> key, touch the SERVO DRIVE tab then select the FAULTS tab. Refer to Figure 2-12. Select a drive from the list box to see its details.

Figure 2-11 General Servo Help

FAULTS Tab 2–25



Figure 2-12 SERVO DRIVE - FAULTS Tab

Table 2-11 SERVO DRIVE - FAULTS Tab Descriptions

Element Explanation

Drive Faults

Drive Fault Active Displays the fault logic status for the selected servo drive/motor.

NOTE: The indicator ( ) lights up when a fault logic condition is true; otherwise it remains grey.

Fault Code Displays a list of all active drive fault codes. The fault values are also displayed for each code.

NOTE: Touch the line containing a fault code to display help for it — refer to Section 2.5.2.1.

Encoder Diagnostics

Encoder Fault Active

Displays the fault logic status for the encoder on the selected servo motor.

NOTE: The indicator ( ) lights up when a fault logic condition is true; otherwise it remains grey.

Motor Encoder Select the option button to display details of the motor encoder. This is the default selection.

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2–26 Displaying Servo Fault Help

2.5.2.1 Displaying Servo Fault Help

Display servo fault help using the following instructions:

1. Press <MACHINE> key, touch the SERVO DRIVE tab then select the FAULTS tab.

2. Touch a line on the screen where it displays a fault code.

The HMI then displays the fault help in a split window — refer to Figure 2-13.

NOTE: You can similarly display help for NC errors on the NC STATUS tab.

3. Touch the Exit button to close the help window.


Load Encoder Select the option button to display details of other encoders, if installed.

(Encoder bits) Displays the status of encoder bits for the selected servo motor. A check mark indicates a particular encoder error.

Table 2-11 SERVO DRIVE - FAULTS Tab Descriptions (Continued)

Element Explanation

Figure 2-13 Servo Fault Help

PROFIBUS Tab 2–27


2.5.3 PROFIBUS Tab

The PROFIBUS tab allows a user to view the Profibus address and the state of a servo drive. It also displays the details of Control Words and Status Words used in the Siemens 611U servo drives.

Press <MACHINE> key, touch the SERVO DRIVE tab then select the PROFIBUS tab. Refer to Figure 2-14. Select a drive from the list box to see its details.


Figure 2-14 SERVO DRIVE - PROFIBUS Tab

Table 2-12 SERVO DRIVE - PROFIBUS Tab Descriptions

Element Explanation

Profibus Address Displays the Profibus address for the selected servo drive/motor.

DP State Displays the state of the servo drive/motor.

ProfiDrive Control Words

Displays details of the various Control Words specific to the Siemens 611U servo drive.

ProfiDrive Status Words

Displays details of the various Status Words specific to the Siemens 611U servo drive.

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2–28 NC STATUS Tab

2.5.4 NC STATUS Tab

The NC STATUS tab allows a user to view details of the actual data from the servo motor.

Press <MACHINE> key, touch the SERVO DRIVE tab then select the NC STATUS tab. Refer to Figure 2-15. Select a drive from the list box to see its details.


Figure 2-15 SERVO DRIVE - NC STATUS Tab

Table 2-13 SERVO DRIVE - NC STATUS Tab Descriptions

Element Explanation

Actual Position Displays the actual position reported by the motor encoder.

Setpoint Position Displays the setpoint value for the position.

Lag Distance Displays the difference between the actual position and the setpoint value.

Actual Velocity Displays the actual velocity reported by the servo drive.

Setpoint Velocity Displays the setpoint value for the velocity.

Override Displays the velocity override value. The range is 0 to 100%.

NC Error Displays the error code for NC errors. Displays the value 0 (zero) when there is no error.

Logical Status

NOTE: The indicator ( ) lights up when the logic condition is true; otherwise it remains grey.

PARAMETER Tab 2–29


2.5.5 PARAMETER Tab

NOTE: The HyPET HPP machines do not have a Parameters tab.

The PARAMETER tab allows a user to update drive parameters to any servo drive on the machine. In addition, the user can backup current drive parameters from the servo drive to the hard disk, compare all the existing parameters on a selected servo drive against the contents of its corresponding drive parameter file, download drive parameters to all servo drives using a batch process, and import/export drive parameter files.

All servo drives on the machine are configured before the machine is shipped from the factory. However, if a servo drive is replaced or retrofitted in the field the servo drives must be reconfigured again.

Each servo drive has a drive parameter file which contains an internal file header which identifies the drive name, firmware version number etc., and other motor codes. The drive parameter file must be downloaded to the servo drive to configure it. Drive parameter files are named after their corresponding servo drive names, and are located on the hard disk of the machine (D:\Drive). All drive parameter files are in the Husky Parameter Text (HPT) format and include the file extension .HPT.

Press <MACHINE> key, touch the SERVO DRIVE tab then select the PARAMETER tab. Refer to Figure 2-16. Select a servo drive from the list box to see its details.

Ready Displays the Drive Ready status.

Calibrated Displays the Calibration status.

Has Job Displays the Command Received status.

Not Moving Displays the Move command processing status.

Moving Forward (Fw)

Displays the Motor Forward motion status (positive direction).

Moving Backward (Bw)

Displays the Motor Backward motion status (negative direction).

Physical Status

Coupled Mode Displays the Axes Coupled status

In Target Position Displays the In Target Position status.

In Position Range Displays the In Position Range status.

Enabling

NOTE: All indicators must be ON before any axis can move.

Controller Displays the controller status.

Feed Forward (Fw) Displays the Feed Forward Enable status.

Feed Backward (Bw) Displays the Feed Backward Enable status.

Table 2-13 SERVO DRIVE - NC STATUS Tab Descriptions (Continued)

Element Explanation

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2–30 PARAMETER Tab


NOTE: User access rights of Maintenance required to select or modify functions.

Figure 2-16 SERVO DRIVE - PARAMETER Tab

Table 2-14 SERVO DRIVE - PARAMETER Tab Descriptions

Element Explanation

Parameter File

Firmware Version Displays the firmware version number of the drive parameter file (located at D:\Drive) for the selected servo drive.

Modified Displays the date and time the drive parameter file was created/modified.

Drive

Firmware Version Dynamically reads and displays the firmware version number directly from the selected servo drive.

Touch the Download Parameters button to transfer drive parameters from the selected drive parameter file to its corresponding servo drive. Refer to Section 2.5.5.1.

Downloading Drive Parameters 2–31


2.5.5.1 Downloading Drive Parameters

Download drive parameters from a single drive parameter file to its corresponding servo drive using the instructions below:

NOTE: User access rights of Maintenance required to use this function.

1. Check that the machine is in Manual mode and idling.

2. Press <MACHINE> key, touch the SERVO DRIVE tab then select the PARAMETER tab.

3. Select the drive name from the displayed list.

4. Touch the Download Parameters button. A pop-up window is displayed to prompt you to confirm the download.

5. Touch the Yes button to confirm download, otherwise touch the No button.

NOTE: The system checks the integrity of the drive parameter file on the hard disk. If the Checksum calculation is invalid a pop-up message is displayed, and downloading is stopped.

NOTE: Downloading will only be permitted if firmware version of the drive parameter file matches the firmware version on the corresponding servo drive.

You can stop downloading at any time by touching the Abort button. A pop-up message is then displayed to prompt you to confirm the abort. Touch the No button to continue, or the Yes button to confirm the abort. If downloading is aborted the Alarm screen will display the "Parameter Download Incomplete" error.

NOTE: If parameter download is aborted the drive parameters must be downloaded again successfully to the drive before the machine can be restarted.

Touch the Upload Parameters button to transfer existing drive parameters from the selected servo drive to its corresponding drive parameter file. Refer to Section 2.5.5.2.

Touch the Download All Parameters button to individually transfer drive parameters from each drive parameter file to its corresponding servo drive. Refer to Section 2.5.5.3.

Touch the Verify Parameters button to compare the drive parameters on the selected servo drive against the contents of its corresponding drive parameter file. Refer to Section 2.5.5.4.

Touch the Import File button to import a drive parameter file to the hard disk. Refer to Section 2.5.5.5.

Touch the Export File button to export a drive parameter file from the hard disk. Refer to Section 2.5.5.6.

Table 2-14 SERVO DRIVE - PARAMETER Tab Descriptions (Continued)

Element Explanation

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2–32 Uploading Drive Parameters

NOTE: If a power failure occurs while downloading the drive parameters the "Parameter Download Incomplete" error is displayed. The drive parameters must be downloaded again successfully to the drive before the machine can be restarted.

6. When downloading is complete a pop-up message notifies the successful completion of the task. All drive parameters on the servo drive are over-written with data from the drive parameter file.

2.5.5.2 Uploading Drive Parameters

Upload existing drive parameters from a single servo drive to its corresponding drive parameter file on the hard disk using the instructions below:





4. Touch the Upload Parameters button. A pop-up window is displayed to prompt you to confirm the upload.

5. Touch the Yes button to confirm upload, otherwise touch the No button.

The Upload Parameter pop-up window is displayed, which shows the progress of the uploading.

You can stop uploading at any time by touching the Abort button. A pop-up message is then displayed to prompt you to confirm the abort. Touch the No button to continue, or the Yes button to confirm the abort. If uploading is aborted the existing drive parameter file on the hard disk is retained.

6. When uploading is complete a pop-up message notifies the successful completion of the task. The existing drive parameter file is over-written with parameters from the servo drive.

NOTE: A backup copy of the existing drive parameter file is saved to the hard disk in the format 'FileName_backup.HPT' before the existing file is over-written.

2.5.5.3 Downloading All Drive Parameters

Download drive parameters from each individual drive parameter file to its respective servo drive using the instructions below:





4. Touch the Download All Parameters button. A pop-up window is displayed to prompt you to confirm the download.

5. Touch the Yes button to confirm download, otherwise touch the No button.

Verifying Drive Parameters 2–33


NOTE: The system checks the integrity of each drive parameter file on the hard disk. If the Checksum calculation is invalid a pop-up message is displayed, and downloading is stopped.

NOTE: Downloading will only be permitted if firmware version of the drive parameter file matches the firmware version on the corresponding servo drive.

The Download All Parameters pop-up window is displayed, which shows the progress as each drive parameter file is downloaded individually.

You can stop downloading at any time by touching the Abort button. A pop-up message is then displayed to prompt you to confirm the abort. Touch the No button to continue, or the Yes button to confirm the abort. If downloading is aborted the Alarm screen will display the "Parameter Download Incomplete" error.

NOTE: If parameter download is aborted the drive parameters must be downloaded again successfully to all the drives before the machine can be restarted.

NOTE: If a power failure occurs while downloading the drive parameters the "Parameter Download Incomplete" error is displayed. The drive parameters must be downloaded again successfully to all the drives before the machine can be restarted.

6. When downloading is complete a pop-up message notifies the successful completion of the task. All drive parameters on each servo drive are over-written with data from its corresponding drive parameter file.

2.5.5.4 Verifying Drive Parameters

Verify drive parameters on a single servo drive against the contents of its corresponding drive parameter file using the instructions below:





4. Touch the Verify Parameters button. A pop-up window is displayed to prompt you to confirm the verification.

5. Touch the Yes button to confirm verification, otherwise touch the No button.

The Verify Parameter pop-up window is displayed, which shows the progress of the verification process.

You can abort verification at any time by touching the Abort button. A pop-up message is then displayed to prompt you to confirm the abort. Touch the No button to continue, or the Yes button to stop verification.

6. When verification is complete a pop-up message notifies the results of the verification. If there are no differences between all the parameters on the servo drive and the contents of its corresponding drive parameter file the message: "No Differences Found" is displayed. Otherwise, the pop-up window shown below is displayed — refer to Figure 2-17.

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2–34 Importing Drive Parameter File

2.5.5.5 Importing Drive Parameter File

Import a drive parameter file to the hard disk using the instructions below:





4. Touch the Import File button. A pop-up window is displayed to prompt you to browse the drives/directories and select the file. All drive parameter files have a.HPT file extension.

NOTE: The name of the selected file can be different from the drive parameter file on the hard disk; however the internal file headers in the selected file and the drive parameter file must match. If there is no match importing will not be allowed.

5. Touch the Confirm button.

NOTE: The system checks the integrity of the selected drive parameter file. If the Checksum calculation is invalid a pop-up message is displayed, and importing is stopped.

6. When importing is complete a pop-up message notifies the successful completion of the task.

NOTE: Only one drive parameter file can exist on the hard disk for each servo drive. However a backup copy of the existing drive parameter file is saved to the hard disk in the format 'FileName_backup.HPT'. The contents of the imported file are written over the contents of the existing drive parameter file.

Figure 2-17 PARAMETER DIFFERENCES Pop-up Window

Exporting Drive Parameter File 2–35


2.5.5.6 Exporting Drive Parameter File

Export a drive parameter file from the hard disk using the instructions below:





4. Touch the Export File button. A pop-up window is displayed to prompt you to select the drive/directory to where the file should be saved. Enter a new file name, if necessary.

NOTE: When entering a new file name use a name that easily identifies the drive name so that it can be readily imported the next time. For example, LinearX_ver2.

5. Touch the Confirm button. The selected drive parameter file on the hard disk is then exported to the selected location, and a pop-up message notifies the successful completion of the task.

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2–36 Exporting Drive Parameter File

HMI Reference Manual Polaris — v2009.3 Production

PRODUCTION SETUP Screen 3–1

Chapter 3 Production

The Production screens allow the user to change certain production information, perform the Smart Start or Smart Stop procedure, save and recall mold setups, and install/calibrate molds.

3.1 PRODUCTION SETUP Screen

The PRODUCTION SETUP screen allows the user to change certain production information, and part count setpoints.

Press <PRODUCTION> key to display the PRODUCTION SETUP screen. Refer to Figure 3-1.


Figure 3-1 PRODUCTION SETUP Screen

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3–2 PRODUCTION SETUP Screen

NOTE: User access rights of Operator Level 2, or Processor required to select or modify functions.

Table 3-1 PRODUCTION SETUP Screen Descriptions

Element Description

Setup Information

Mold ID Enter a name to identify the mold.

Setup ID Enter a name to identify the machine setup.

Machine ID Enter a name to identify the machine.

Resin Type Enter a name to identify the resin type.

Part Count Control

Enable Alarm Select this check box to enable any alarms linked to part count control.

Number of Cavities Enter the number of cavities in the mold.

Parts Required Enter the number of parts required.

Parts Completed Displays the number of parts completed.

Parts Completed Reset

Touch this button to reset the Parts Completed field to zero.

Parts Remaining Displays the number of parts remaining.

Shift Count Displays the number of parts completed during the current shift.

Shift Count Reset Touch this button to reset the Shift Count field to zero.

Cycle Time Limit Enter the time limit for a machine cycle. When the time limit is exceeded, the machine interrupts the Auto cycle, and resets itself to the mold open position.

NOTE: Cycle Time Limit can also be set on the CYCLE TIME BREAKDOWN screen — refer to Section 2.2.

Job Number Enter a value up to 12 alphanumeric characters in length to identify the job number for the current part run.

Setup Date/Time Displays the date and time.

Touch this button to open the HUSKY HOST LINK TERMINAL window – refer to Section 3.1.3.

NOTE: This button is only available if Husky Host Interface is enabled. Refer to Section 10.6.

Viewing and Changing Part Count and Setup Information 3–3


3.1.1 Viewing and Changing Part Count and Setup Information


View or change setup information and part counts using the following instructions:

1. Press the <PRODUCTION> key to display the PRODUCTION SETUP screen.

2. Select the appropriate field, and enter a suitable value.

3.1.2 Resetting Shift Count and Parts Completed


Reset the "Shift Count" and "Parts Completed" fields using the following instructions:

1. Press the <PRODUCTION> key to display the PRODUCTION SETUP screen.

2. Touch the Shift Count Reset button to reset the counter to zero, or the Parts Completed Reset button to reset the counter to zero. Select Yes to confirm the reset.

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3–4 HUSKY HOST LINK TERMINAL Window

3.1.3 HUSKY HOST LINK TERMINAL Window

The HUSKY HOST LINK TERMINAL window is used for bi-directional data communication between the Husky molding machine and a host computer. The contents of this screen is dependent on how Husky Host Interface is implemented on the host computer.

Touch the Husky Host Link Terminal button on the PRODUCTION SETUP screen to display the HUSKY HOST LINK TERMINAL window – refer to Figure 3-2.

NOTE: Except for the elements described below, the functionality of the remaining buttons, numeric keys and function keys on the screen may differ from their standard functions depending on how Husky Host Interface is implemented on the host computer. Refer to the appropriate Host Link implementation documents for details.

Figure 3-2 HUSKY HOST LINK TERMINAL Window

Table 3-2 HUSKY HOST LINK TERMINAL Window Descriptions

Element Explanation

Touch this button to capture screen images and save it to a file, or print it.

Touch this button to close the Husky Host Link Terminal window.

MOLD SETUP Screen 3–5


3.2 MOLD SETUP Screen

The MOLD SETUP screen allows the user to save, recall, copy, or delete mold setups. Mold setups consist of injection molding machine setups, SPC settings (if applicable), CoolPik and Tooling Plate program files.

By default, mold setups are always saved from the RAM in the PC to the local hard disk. When a mold setup is recalled, it is always loaded from the local hard disk into the RAM in the PC, where it is referred to as the active setup. Any changes to the active setup are saved internally in the computer when the computer is shut down properly, and only written to the machine setup on the local hard disk when the Save Setup function is used – refer to Section 3.2.2.

Press <PRODUCTION> key, then touch the MOLD SETUP tab. Refer to Figure 3-3.


NOTE: User access rights of Processor required to use the functions on this screen.

Figure 3-3 MOLD SETUP Screen

Table 3-3 MOLD SETUP Screen Descriptions

Element Description

Machine Setup Displays the name of the last saved or last recalled machine setup file.

Machine List Box

Machine Setup Displays a list of all machine setup files located on the local hard disk.

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3–6 Creating New Mold Setup

3.2.1 Creating New Mold Setup

NOTE: When it is necessary to make mold-specific process changes to an active setup, it is always a good idea to save the setup as a new mold setup.

NOTE: User access rights of Processor required to use this function.

Create a new mold setup from the active mold setup using the following instructions:

1. Press <PRODUCTION> key, then touch the MOLD SETUP tab to display the MOLD SETUP screen.

2. Touch the Save Setup button and save the active mold setup to the local hard disk under a different name – refer to Section 3.2.2.

Mold ID Displays the mold identification.

NOTE: The Mold ID can only be entered in the PRODUCTION SETUP screen — refer to Section 3.1.

Resin Displays the resin type used with the mold.

NOTE: The resin type can only be entered in the PRODUCTION SETUP screen — refer to Section 3.1.

Date/Time Displays the file modification date and time in the current date/time format.

Touch the Recall Setup button to recall the highlighted machine setup file from the local hard disk to the RAM in the PC.

Refer to Section 3.2.3.

Touch the Save Setup button to save the active machine setup from the RAM in the PC to the local hard disk.


Touch the Delete Setup button to delete the highlighted machine setup.


Touch the Copy Setup button to copy one or more machine setups from a storage device to the same storage device under a different name, or to another storage device. A file cannot be copied to the same storage device under the same name.


Table 3-3 MOLD SETUP Screen Descriptions (Continued)

Element Description

Saving Mold Setup 3–7


3.2.2 Saving Mold Setup


NOTE: Active setups are always saved from the RAM in the PC to the local hard disk.

Save the active setup using the following instructions:


2. If you wish to overwrite an existing machine setup file on the local hard disk, select the appropriate machine setup from the list box on the MOLD SETUP screen.

Otherwise, leave it unselected.

3. Touch the Save Setup button to display the SAVE MOLD SETUP pop-up window – refer to Figure 3-4.

4. Enter a suitable name in the text box for the machine setup file, or leave it as displayed.

The file names can be up to 32 characters long, and cannot contain the word "Template".

5. Touch the Save button to write the active setup to the local hard disk, or touch the Cancel button to abort.

If a machine setup file with the same file names exists on the local hard disk, a warning message is displayed prompting you to confirm the overwrite. Touch the Yes button to overwrite the file, or the No button to abort.

When the mold setup is saved successfully to the hard disk, the Machine Setup text box and list box on the MOLD SETUP screen are updated to display the new file name.

Figure 3-4 SAVE MOLD SETUP Pop-up Window

CAUTION!Risk of overwriting existing machine setup with the same name on the local hard disk. If you do not wish to overwrite the existing files, enter a name that is not used already.

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3–8 Recalling Mold Setup

3.2.3 Recalling Mold Setup

NOTE: User access rights of Processor required to use this function.

NOTE: The machine must be idle to recall the mold setup.

NOTE: Mold setups are always recalled from the local hard disk to the RAM in the PC.

Recall the mold setup using the following instructions:


2. Select the appropriate machine setup file from the list box on the MOLD SETUP screen. The selected file is highlighted.

NOTE: All machine setup files available on the local hard disk are displayed in the list box.

3. Touch the Recall Setup button to recall the mold setup.

4. If a machine setup file is selected for recall, a warning message is displayed prompting you to confirm the overwrite. Touch the Yes button to overwrite the active machine setup, or the No button to abort.

Next, the machine sizes are checked for compatibility. If machine sizes are not compatible, file recall is aborted.

If machine sizes are compatible, the machine serial numbers are then checked. If the machine serial numbers are different, a warning message is displayed prompting you to confirm if you wish to continue. Touch the Yes button to continue, or the No button to abort.

After the machine serial number check is completed, a file integrity check is performed. If the test is successful, the mold setup is downloaded to the machine.

5. When mold setup is recalled successfully, the Machine Setup text box on the MOLD SETUP screen is updated to display the new file name.

NOTE: After recalling a mold setup calibrate the mold stroke before running the machine.

3.2.4 Copying Mold Setup

NOTE: User access rights of Operator Level 2, or Processor required to use this function.

NOTE: The active setup in the RAM of the computer cannot be copied directly. Use the Save Setup function instead to save the active setup to the local hard disk – Section 3.2.2.

NOTE: Mold setups are always copied from a permanent storage device such as the local hard disk, floppy diskette, USB device, network drive, host computer (if Husky Host Interface option is enabled) to another permanent storage device such as another

CAUTION!Unsaved active setup will be overwritten. Save it first to the hard disk, if necessary, before recalling another mold setup.

Copying Mold Setup 3–9


local hard disk, floppy diskette, USB device, network drive, host computer. Any device that is unavailable will be greyed out.

Copy a mold setup from one storage device to the same storage device under a different name, or to another storage device using the following instructions.


2. Touch the Copy Setup button to display the COPY MOLD SETUP pop-up window – refer to Figure 3-5.

3. Select the source icon – local hard disk, floppy diskette, USB device, network drive, host computer. If necessary, use the Expand Button ( ) and use the file browser to select a path.

NOTE: Touch the Refresh button to refresh all removable devices if they become temporarily unavailable.

NOTE: A network drive will be available only if it is configured by an Administrator.

4. The list box displays all machine setup files.

NOTE: When the Husky Host Interface option is enabled a supervisor can load a single mold setup for the next job to a specific location on the host computer. The machine operator is then able to download this mold setup to the Husky machine.

5. Select as many machine setup files as required. All selected files are marked with a check mark ( ).

6. Select the destination icon – local hard disk, floppy diskette, USB device, network drive, host computer.

NOTE: If a network drive is selected, only it’s contents can be browsed.

Figure 3-5 COPY MOLD SETUP Pop-up Window

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3–10 Deleting Mold Setup

NOTE: When the Husky Host Interface option is enabled the operator can upload a single mold setup to the location selected by the supervisor on the host computer. Only one mold setup can be uploaded at a time.

7. If the local hard disk or floppy diskette is selected two additional fields appear on the screen. Enter a new file name.

8. Touch the Copy button to copy the mold setup, or the Cancel button to abort.

If the file names already exist on the destination device a warning message is displayed prompting you to confirm the file overwrite. Touch the Yes button to overwrite the file(s), or the No button to abort.

3.2.5 Deleting Mold Setup


NOTE: The active setup in the RAM of the PC cannot be deleted. Only the machine setups from the local hard disk, floppy diskette, USB device, network drive, host computer can be deleted.

NOTE: A network drive will be available only if it is initially set up by an Administrator.

Delete machine setup files using the following instructions:


2. Touch the Delete Setup button to display the DELETE pop-up window – refer to Figure 3-6.

CAUTION!If the same file name exists on the destination drive, the file on the destination drive may be overwritten. Enter a new file name if necessary.

Figure 3-6 DELETE Pop-up Window

Using Mold Setup From a Different Machine 3–11


3. Select the storage device – local hard disk, floppy diskette, USB device, network drive, host computer.

The list box displays all machine setup files on the selected storage device.

4. Select as many machine setup files as required. All selected files are marked with a check mark ( ).

5. Touch the Delete button to delete the selected file(s), or the Cancel button to abort.

A warning message is displayed prompting you to confirm the file deletion. Touch the Yes button to delete the file(s), or the No button to abort.

3.2.6 Using Mold Setup From a Different Machine

Mold setup can be recalled from a different machine providing both machines are of the same size – refer to Section 3.2.3 for details.

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3–12 SMART STOP SETUP Screen

3.3 SMART STOP SETUP Screen

The SMART STOP SETUP screen allows the user to enable or disable SmartStop, and to configure the Smart Stop parameters. The Smart Stop function is used to automate the shutdown of the injection molding machine. Smart Stop can be used to shutdown the machine anytime there is a critical machine cycle fault, or when one of the operator-initiated machine events is completed. The operator can choose to shutdown the machine after producing an additional number of parts, or after a production run is completed, or on a specific day at a specific time. In all cases, the machine has to be running in Auto cycle mode for at least a period of 2 minutes before Smart Stop becomes active.

Smart Stop permits minimal operator intervention to shutdown the machine. It provides a safe way to shutdown the machine in the event of a critical machine cycle fault, and reduces the probability of human error by automating the shutdown procedure. Stopping the machine in this way ensures that subsequent machine startup is smooth and easy.

Press <PRODUCTION> key, then touch the SMART STOP SETUP tab. Refer to Figure 3-7.



Figure 3-7 SMART STOP SETUP Screen

Activating Smart Stop on Machine Cycle Fault 3–13


3.3.1 Activating Smart Stop on Machine Cycle Fault

The following steps describe how to enable Smart Stop so that the shutdown sequence will be activated when a critical machine cycle fault occurs:


1. Press the <PRODUCTION> key, then touch the SMART STOP SETUP tab – refer to Figure 3-7.

2. Enter a value for the delay timer in the Activate on Cycle Fault field.

3. Select the Enable check box in the Cycle Fault Option frame.

The warning message "Smart Stop Will Be Active When a Cycle Fault Occurs" is displayed. When a machine cycle fault occurs the warning message is cleared, and the

Table 3-4 SMART STOP SETUP Screen Descriptions

Element Description

Cycle Fault Option

Enable Select the check box to enable Smart Stop so that it will activate when a cycle fault error occurs. Clear the check box to disable. When SmartStop is enabled the text boxes in the frame are greyed out.

Activate on Cycle Fault Enter the cycle fault delay time. The default value is zero, and the maximum value is 99 minutes. When a machine cycle fault occurs Smart Stop becomes active after this timer elapses. The adjoining field displays the current value of the timer as it counts up.

Operator Initiated Options

Enable Select the check box to enable Smart Stop so that it will activate when one of the user-initiated events (explained below) is completed. When Smart Stop is enabled the text boxes in the frame are greyed out.

Clear the check box to disable this function.

After Extra Parts Select this option button to activate Smart Stop after completing an additional number of parts. This option is selected by default. Enter the number of additional parts required in the text box. The adjoining grey field displays the current part count.

After Total Parts Select this option button to activate Smart Stop after completing the production run. Enter the total number of parts that must be produced in the text box. The adjoining grey field displays the current part count.

On Specified Day and Time

Select this option button to activate Smart Stop on a specific day at a specific time. Select the day from the drop-down list. Enter the hour and minute in the adjoining fields.

Machine Status

(Various) The indicators light up to show which stage of the Smart Stop sequence is currently active.

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3–14 Activating Smart Stop After Producing Extra Parts

message "Smart Stop Will Be Active After Delay Timer Elapses" is displayed. Smart Stop will become active after the delay timer elapses.

NOTE: Machine must be cycling in Auto cycle mode for a minimum of 2 minutes before machine shutdown is activated.

NOTE: Pressing the E-Stop button on the machine, or opening any safety gates while Smart Stop is running will abort the shutdown sequence.

3.3.2 Activating Smart Stop After Producing Extra Parts

The following steps describe how to enable Smart Stop so that the shutdown sequence will be activated after producing an additional number of parts:



2. Select the After Extra Parts option button, and enter a value for the number of extra parts required.

3. Select the Enable check box in the Operator Initiated Options frame.

The warning message "Smart Stop Enabled. Hopper Will Be Shut Off After Producing Extra Parts" is displayed. When the required number of additional parts is completed the hopper is closed, and the machine continues to produce parts until the barrel is empty. Then the shutdown sequence is activated, and the alarm message "Smart Stop Active" is displayed.


NOTE: If Smart Stop is also enabled to activate on machine cycle fault, it will default to the Smart Stop on Machine Cycle Fault sequence (Section 3.3.1) if a cycle fault occurs while producing the extra parts.


3.3.3 Activating Smart Stop After Completing Production

The following steps describe how to enable Smart Stop so that the shutdown sequence will be activated upon completion of production:



2. Select the After Total Parts option button, and enter a value for the number of total parts required.


The warning message "Smart Stop Enabled. Hopper Will Be Shut Off After Producing Extra Parts" is displayed. When the required number of total parts is completed the

Activating Smart Stop On Specific Day At a Specific Time 3–15


hopper is closed, and the machine continues to produce parts until the barrel is empty. Then the shutdown sequence is activated, and the alarm message "Smart Stop Active" is displayed.


NOTE: If Smart Stop is also enabled to activate on machine cycle fault, it will default to the Smart Stop on Machine Cycle Fault sequence (Section 3.3.1) if a cycle fault occurs while producing the extra parts to complete production.


3.3.4 Activating Smart Stop On Specific Day At a Specific Time

The following steps describe how to initiate Smart Stop so that the shutdown sequence will be activated on a specific day at a specific time:



2. Select the On Specified Day and Time option button, and select the day and enter a value for time.


The warning message "Smart Stop Enabled. Hopper Will Be Shut Off On Specified Day and Time" is displayed. On the specified day and time the hopper is closed, and the machine continues to produce parts until the barrel is empty. Then the shutdown sequence is activated, and the alarm message "Smart Stop Active" is displayed.


NOTE: If Smart Stop is also enabled to activate on machine cycle fault, it will default to the Smart Stop on Machine Cycle Fault sequence (Section 3.3.1) if a cycle fault occurs while the machine continues to run before the scheduled shutdown date and time.


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3–16 Aborting Smart Stop

3.3.5 Aborting Smart Stop

The following steps describe how to abort Smart Stop at any time once it has been enabled:



2. Clear the appropriate Enable check boxes on the screen. In addition, the shutdown sequence can also be aborted by switching the machine to Manual cycle mode.

NOTE: If Smart Stop is aborted before the shutdown sequence is activated the machine continues as usual. If the machine is in the midst of running the shutdown sequence it will stop after the current stage in the Smart Stop sequence is completed. The alarm message "Smart Stop Aborted by User" will also be displayed.

3.3.6 Disabling Smart Stop

The following steps describe how to disable Smart Stop:



2. Clear both Enable check boxes on the screen. The alarm message "Smart Stop Disabled" will be displayed on the ALARM screen if any of the Smart Stop sequences is not currently active.

SMART START SETUP Screen 3–17


3.4 SMART START SETUP Screen

The SMART START SETUP screen allows the user to configure the semi-automated startup parameters and initiate/stop the Smart Start sequence. It also guides the user through the Smart Start sequence.

Smart Start is a semi-automatic feature which allows a user to start up a Husky HyPET machine with minimal human intervention. When Smart Start is initiated the machine guides the operator through the machine startup sequence and automatically executes a set of predetermined steps. The machine uses a set of parameters defined on the SMART START SETUP screen during the startup sequence, and switches to normal settings when the startup sequence is completed.

The semi-automated machine startup feature allows for better operator time management and minimizes the possibility of human error during machine startup.

Press <PRODUCTION> key, then touch the SMART START SETUP tab. Refer to Figure 3-8.



Figure 3-8 SMART START SETUP Screen

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3–18 SMART START SETUP Screen

Table 3-5 SMART START SETUP Screen Descriptions

Element Description

Start-up Settings

NOTE: Normal settings are shown beside the Smart Start settings. When the machine runs the Smart Start sequence it uses the latter settings and switches back to normal settings when the startup sequence is completed.

Tonnage Enter the clamping tonnage to be used when running the Smart Start sequence. The light grey field displays the normal tonnage setpoint value as configured on the CLAMP screen.

Cooling Time Enter the time duration that the mold halves remain together at the end of the Hold phase when running the Smart Start sequence. The light grey field displays the normal Cooling Time setpoint value as configured on the CLAMP screen.

Fill Pressure Limit Enter the maximum allowable pressure that can be applied to the injection piston when running the Smart Start sequence. The light grey field displays the normal Fill Pressure Limit setpoint value as configured on the INJECTION screen. The dark grey field displays the latched value from the previous cycle.

Extruder Back Position Enter the Extruder Back position when running the Smart Start sequence. The light grey field displays the normal Extruder Back setpoint value as configured on the INJECTION screen.

Ejector Forward Enter the Ejector Forward position when running the Smart Start sequence. The light grey field displays the normal Ejector Forward setpoint value as configured on the EJECTOR SETUP screen.

Ejector Forward Delay Enter the time delay for the ejector to move forward after the mold opens when running the Smart Start sequence.

Ejector Forward Dwell Enter the time duration that the ejector remains in the Forward position when running the Smart Start sequence. The light grey field displays the normal Ejector Forward Dwell setpoint value as configured on the EJECTOR SETUP screen.

SMART START SETUP Screen 3–19


Nozzle Tips Enter a percentage value between 0 and 100%.

Touch the Expand button to display the pop-up window shown below. Select the Nozzle Tip Increase option to manually increase the temperature by the entered percentage value, or select the Nozzle Tip Setpoint option to increase the temperature by a percentage of the setpoint value defined on the NOZZLE TIP HEATS screen.

Other Startup

Nozzle Tips Warmup The grey field on the right displays the Nozzle Tip warm-up setpoint value from the NOZZLE TIP HEATS screen. The field on the left displays the elapsed time.

Auto Purge Cycles Enter the number of auto purge cycles when running the Smart Start sequence. The light grey field displays the elapsed auto purge cycles.

Press the Start button to initiate the Smart Start sequence - refer to Running Smart Start for additional details. The button will only be active when the following conditions are true: the machine is in Manual cycle Normal function mode without any active alarms, all heats are enabled, all gates are closed, the pump is switched On, the mold is open and the Tooling Plate is outside the mold area.

Press the Stop button at any time to abort the Smart Start sequence.

Semi Cycles, Tooling Plate

Disengaged Enter the number of Semi cycles the machine should run with the Tooling Plate switched Off. The light grey field displays the number of completed cycles.

Engaged Enter the number of Semi cycles the machine should run with the Tooling Plate switched On. The light grey field displays the number of completed cycles.

Table 3-5 SMART START SETUP Screen Descriptions (Continued)

Element Description

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3–20 Running Smart Start

3.4.1 Running Smart Start

The following steps describe how to run the Smart Start sequence:


NOTE: Smart Start sequence can only be initiated when the following conditions are satisfied: machine is in Manual cycle Normal mode without any active alarms that would prevent Auto cycling; machine and mold heats are up to normal operating temperature; clamp, injection unit and Tooling Plate/PMC are set up for normal operation; all gates are closed; pump is switched On; mold is open and Tooling Plate/PMC is outside the mold area.

1. Press the <PRODUCTION> key, then touch the SMART START SETUP tab – refer to Figure 3-8.

2. Enter the following startup setpoint values for the Smart Start sequence: Tonnage, Cooling Time, Fill Pressure Limit, Extruder Back Position, Ejector Forward Position, Ejector Forward Delay, Ejector Forward Dwell, configures Nozzle Tip heating, enters Nozzle Tip Warm-up time, number of Auto Purge Cycles, and the number of Semi cycles with the Tooling Plate engaged and disengaged.

3. Check the mold cavities are clear, dryer is switched On and PET material is completely dry, and hopper/feed tube is in position.

4. Touch the Start button on the screen.

5. Follow instructions displayed in the Status Message area of the screen.

NOTE: If a machine alarm occurs while the Smart Start sequence is running, the sequence will be suspended while the alarm is active. The sequence will resume when the alarm condition is cleared. Follow instructions in the Status Message area of the screen.

NOTE: Pressing the E-Stop button on the machine, or opening any safety gates while Smart Start is running will suspend the startup sequence. The sequence will resume when the E-Stop button is released or the safety gate is closed.

Actuals Displays the current value for each of the parameters shown.

Displays Smart Start sequence status messages, as well as prompts to the operator.

The Confirm button in this area of the screen will only appear when the operator is required to confirm that it is OK to continue.

Table 3-5 SMART START SETUP Screen Descriptions (Continued)

Element Description

Stopping Smart Start 3–21


3.4.2 Stopping Smart Start

Once Smart Start has been initiated, touch the Stop button at any time to abort the Smart Start sequence. The message "Smart Start Aborted" is displayed on the ALARMS screen.

3.5 MOLD INSTALLATION Screen

The MOLD INSTALLATION screen allows the user to install a mold, and calibrate the Mold Close position.

Press <PRODUCTION> key, then touch the MOLD INSTALLATION tab. Refer to Figure 3-9.

NOTE: User access rights of Processor, or Maintenance required to select or modify functions.

Figure 3-9 MOLD INSTALLATION Screen

Table 3-6 MOLD INSTALLATION Screen Descriptions

Element Description

Shutheight Position Displays the actual shutheight position.

Mold Stroke Position Displays the actual mold stroke position.

Clamp Piston Position Displays the actual clamp piston position.

Mold Close Speed Enter the required mold close speed during mold installation.

Mold Close Pressure Enter the required mold close pressure during mold installation.

Tonnage Enter the required clamp tonnage during mold installation. The grey field displays the actual tonnage.

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3–22 Installing Mold

3.5.1 Installing Mold

NOTE: User access rights of Processor, or Maintenance required to install mold.

Install the mold according to the instructions below:

1. Check that the machine is in Manual cycle and Mold Set function mode.

2. Press the <PRODUCTION> key, then touch the MOLD INSTALLATION tab.

3. Touch the Start button and follow the instructions on the screen.

3.5.2 Calibrating Mold

NOTE: User access rights of Processor, or Maintenance required to calibrate mold.

Calibrate the mold according to the instructions below:

1. Check that the machine is in Manual cycle and Mold Set function mode.

2. Press the <PRODUCTION> key, then touch the MOLD INSTALLATION tab.

3. Touch the Start button and follow the instructions on the screen.

Carriage Jump Back When Safety Gate

Opened

Select the check box to allow the carriage to jump back when the safety gate is opened; otherwise clear the check box.

Mold Open Speed Enter the required mold open speed during mold installation.

Clamp Lock Override This option is only available if machine in mold set mode, the alarm "Clamp Lock Not Out" is active and access level is Operator or Administrator.

Use only as directed by the alarm Help.

Touch this button to start installation/calibration. The screen displays step by step instructions to install and calibrate the mold.

Touch this button to stop installation/calibration.

Table 3-6 MOLD INSTALLATION Screen Descriptions (Continued)

Element Description

OUTPUTS Screen 3–23


3.6 OUTPUTS Screen

The OUTPUTS screen allows a user to set up to eight process monitoring outputs from a predefined list of 24 event triggered functions. Press <F11> key. Refer to Figure 3-10.

Figure 3-10 OUTPUTS Screen

Table 3-7 PRODUCTION SETUP Screen Descriptions

Element Description

Status

Outputs 1 - 8 Select the option button to customize the name of the monitored output and customize the condition that will trigger the output to go On and Off. Enter the customized name in the text box. Customize the triggering condition in the Configuration frame.

Configuration

The values in this section will vary with each of the outputs selected in the Status section.

Go On When

Go On When Displays the predefined event trigger that will start the monitoring process.

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3–24 OUTPUTS Screen

Click on the Expand button to view the list of 24 predefined event triggers. Select the appropriate item in the list to that will start the monitoring process.

After Time Delay Enter the time delay (OPTIONAL).

And Machine Is In

All selections in this section are OPTIONAL. Not selecting an option will cause the triggered output to stay On (regardless of the Time Delay and Machine Mode selected).

Auto Mode Select this check box to specify monitoring in Auto Mode.

Semi-Automatic Mode

Select this check box to specify monitoring in Semi-Automatic Mode.

Manual Mode Select this check box to specify monitoring in Manual Mode.

Go Off When

Go Off When Select this option button to stop the monitoring process with an event.

The text box displays the predefined event trigger that will stop the monitoring process.

Click on the Expand button to view the of 24 predefined event triggers. Select the appropriate item in the list that will stop the monitoring process.

After Time Duration Select this option button to stop the monitoring process after a specified time period. Enter the time period in the text box.

Whichever comes first

Select this option button to stop the monitoring process with whichever condition (specified event or time period) that occurs first.

Table 3-7 PRODUCTION SETUP Screen Descriptions (Continued)

Element Description

HMI Reference Manual Polaris — v2009.3 Clamp

OVERVIEW Screen 4–1

Chapter 4 Clamp

The Clamp screens allow a user to view and modify machine clamp setup, view clamp parameters in graphical form, and monitor the status of the clamp valves.

4.1 OVERVIEW Screen

The (Clamp) OVERVIEW screen allows a user with limited user access rights to modify selected setpoint values normally displayed on the CLAMP screen.

Press <CLAMP> key to display the OVERVIEW screen. Refer to Figure 4-1.

NOTE: User access rights of at least Operator Level 1 required to use sliders. User access rights of Operator Level 2, or Processor required to view and modify the selectable fields on this screen.


NOTE: When the slider is active a white stripe appears in the middle of the slider.

Figure 4-1 (Clamp) OVERVIEW Screen

Polaris — v2009.3

4–2 CLAMP Screen

4.2 CLAMP Screen

The CLAMP screen allows a user to view and change clamp settings within a predetermined range.

Press <CLAMP> key, then touch the CLAMP tab. Refer to Figure 4-2.

Table 4-1 (Clamp) OVERVIEW Screen Descriptions.

Element Description

The following general description applies to all sliders described below.

1 – Touch this button to increase the setpoint value

2 – Enter slider limit for operators who only have access to sliders for modifying setpoint values

NOTE: Users with user access rights of View or Operator Level 1 cannot view or modify this field.

NOTE: The slider limit represents the maximum and minimum value that the setpoint value can be adjusted up or down. The slider has a total range of 20 steps – 10 up and 10 down. Each slider step is equal to 1/10th of the slider limit value.

NOTE: If the slider value is set to zero, the slider will disappear from the screen.

3 – Touch this button to decrease the setpoint value

Mold Close Deceleration

Touch the Up or Down button to increase or decrease the Mold Close Deceleration value.

Mold Open Deceleration

Touch the Up or Down button to increase or decrease the Mold Open Deceleration value.

Tonnage Touch the Up or Down button to increase or decrease the Tonnage value.

Cooling Time Touch the Up or Down button to increase or decrease the Cooling Time value.

Mold Open Time Touch the Up or Down button to increase or decrease the Mold Open Time value.

Part Interference Touch the Up or Down button to increase or decrease the Part Interference value.

Mold Break Touch the Up or Down button to increase or decrease the Mold Break value.

1

2

3

CLAMP Screen 4–3




Figure 4-2 CLAMP Screen

Table 4-2 CLAMP Screen Descriptions

Element Description

Mold Open, Mold Close Graphs

NOTE: For general notes on setpoint profile graphs, refer to Section 4.2.1.

Mold Open Graph

The Mold Open graph displays the mold open speed versus mold position setpoint profile, and the corresponding actual curve from the previous cycle. The setpoint profile is displayed as a thick line in the color Fluorescent Green, and the actual curve is displayed in the same color as a thin line.

Polaris — v2009.3

4–4 CLAMP Screen

Mold Close Graph

The Mold Close graph displays the mold close speed versus mold position setpoint profile, and the corresponding actual curve from the previous cycle. The setpoint profile is displayed as a thick line in the color Fluorescent Green, and the actual curve is displayed in the same color as a thin line.

Progress Bar

The progress bars display the current mold position during Mold Open and Mold Close. The underlaid arrow turns Blue to indicate the currently active profile, and the direction of movement of the mold for that profile.

Mold Open and Mold Close Setpoint

Profiles

The Mold Open setpoint profile controls how the mold speed changes as the mold opens. Starting from the right, and moving left to the next position in the profile constitutes one step. The mold moves to the second position at the first speed indicated in Mold Open setpoint profile. Then it moves to the next position at the next speed in the profile, and so on.

The Mold Close setpoint profile controls how the mold speed changes as the mold closes. Starting from the left, and moving right to the next position in the profile constitutes one step. The mold moves to the second position at the first speed indicated in Mold Close setpoint profile. Then it moves to the next position at the next speed in the profile, and so on.

Both profiles are displayed side by side on the screen if each profile has 4 steps or less. If the number of steps exceed this value, the profiles are displayed on two separate tabs. Each tab can display up to 9 steps.

Mold Open and Mold Close setpoint profiles are step type profiles. These are similar to step type profiles used in the injection screens. Step type profiles share some common characteristics which are discussed in Section 4.2.2.

To modify the number of steps in step type profiles, refer to Section 4.2.3.

Table 4-2 CLAMP Screen Descriptions (Continued)

Element Description

CLAMP Screen 4–5


Touch the Expand button located on the lower right corner of the profile panel/tab to display the PROFILE CONFIGURATION pop-up window – refer to Section 4.2.3 to modify the number of steps in the profile.

Low Pressure Start Low Pressure Start is the stroke position at which the stroke cylinder switches to reduced pressure while closing the mold. The low pressure zone extends from the Low Pressure Start position until the Part Interference limit is reached.

NOTE: Low Pressure Start and Low Pressure setpoints work together with the Part Interference setpoint to help protect the mold from damage.

Low Pressure Low Pressure is the reduced pressure at which the mold stroke cylinder closes the mold. This reduced pressure is applied from the Low Pressure Start position to the Mold Close position.

Mold Close Deceleration

Mold Close Deceleration is the rate at which the mold slows down just before the mold closes.

Mold Close Final Speed

Mold Close Final Speed is the speed just before the mold halves make contact.

Part Interference Part interference is the maximum user-defined distance (0 to 1mm) between mold halves (as they come together at low pressure) after which the clamp is allowed to build up tonnage. If the gap between the mold halves do not drop below this value the machine cycle is interrupted.

Enter a numeric value for the maximum distance between the mold halves when Part Interference must be activated.

Tonnage The Tonnage setpoint sets the desired clamp tonnage while the mold is clamped up. The light grey field displays the actual tonnage. The dark grey field displays the latched value from the previous cycle.

Touch the Expand button to display the ADAPTIVE TONNAGE pop-up window – refer to Section 4.2.4.

Effective Cooling Effective Cooling is the duration that the mold halves remain together at the end of the Hold phase to allow molded parts to cool down. The actual value shown is the current value of the timer as it counts down.

Touch the Expand button to display the COOLING SETUP pop-up window Refer to Section 4.2.5.

Mold Break Mold Break is the distance that the clamp cylinder moves to open the mold after the mold is unclamped.

Mold Open Deceleration

Mold Open Deceleration is the rate at which the mold slows down as it reaches the Mold Open position.

Mold Open Final Speed

Mold Open Final Speed is the mold speed just before it reaches the Mold Open position.

Mold Open Time Mold Open Time is the minimum amount of time the mold must remain open before it can start to close again.


Element Description

Polaris — v2009.3

4–6 Setpoint Profile Graph Characteristics

4.2.1 Setpoint Profile Graph Characteristics

Setpoint profile graphs used throughout the HMI share the following general characteristics:

• A light grey grid is overlaid on a black background• The x-axis is auto-scaled and rounded off to the next larger hundred number, but the y-

axis is scaled to display maximum value of the variable being displayed• For large graphs that cover the width of the screen the grid is spaced so that each axis is

divided into eight equal parts. For all other graphs the grid is spaced so that each axis is divided into four equal parts

• The tick marks on the scales line up with the grids. The minimum, maximum and alternate tick marks are labelled

• Units are displayed in the lower half of the vertical axis, and in the middle of the horizontal axis

• All labels are displayed in the standard screen text color (black)• All setpoint profile graphs are two pixels wide, and actual curves are single pixel wide.

Speed versus position setpoint profiles and actual curves are displayed in the color Fluorescent Green, pressure versus position and pressure versus time setpoint profiles and actual curves are displayed in the color Red.

• The shapes of the setpoint profile graphs are determined by the type of profile selected. If step type profile is selected the graphs will appear step like, and if linear interpolated is selected the graphs will appear as a set of points connected together by straight lines.

NOTE: By default all setpoint profiles are step type profiles. However, you can select either a step type or linear interpolated profile on the INJECTION screen.

4.2.2 Step Type Setpoint Profiles

Step type setpoint profiles are used on the CLAMP screen, INJECTION screen, and RECOVERY screen. In general, they are used to control speed or pressure characteristics of a certain process.

Step type setpoint profiles share the following basic characteristics:

• The shape of the profile resembles a set of steps in a staircase, hence the name Step Type profile.

• The zero or reference point of a profile is displayed as a latched value field with a fixed value of zero

Mold Stroke Position Displays the actual position of the mold stroke cylinder relative to the Mold Close position.

Mold Stroke Pressure Displays the actual pressure in the rod side of the mold stroke cylinder.

Shutheight Position Displays the actual shutheight position.


Element Description

Modifying Step Type Setpoint Profiles 4–7


• Zeros cannot be used as setpoint values, and values in the profile cannot be left blank• The Expand button located on the lower right corner of the profile panel/tab is used to

modify the setpoint profile configuration – refer to Section 4.2.3.

4.2.3 Modifying Step Type Setpoint Profiles

The Mold Open and Mold Close setpoint profiles are discussed below, although these instructions are generic to all step type setpoint profiles used in the HMI. Modify the number of steps in a setpoint profile using the instructions below:


NOTE: The number of steps in the profiles cannot be reduced unless the machine is stopped. However, the machine does not need to be stopped in order to increase the number of steps in the profile.

1. Touch the Expand button located on the lower right corner of the profile panel/tab to display the PROFILE CONFIGURATION pop-up window – refer to Figure 4-3.

2. Select Step as the Profile Type.

3. Modify the number of steps in each profile as required.

NOTE: The number of steps in the profile can be increased up to 9, or reduced down to 1.

4. Exit the pop-up window.

If the number of steps are increased, new steps are added to the end of the profile. In position and pressure-based profiles new steps are populated with values from the step next to it. In time-based profiles new steps are populated with the value “Zero”.

If the number of steps are reduced, fields are removed from the end of the profile. The values in the remaining fields are left as they are.

5. Modify the values of the steps in the profile, as required.

Figure 4-3 PROFILE CONFIGURATION Pop-up Window

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4–8 ADAPTIVE TONNAGE Pop-up Window

4.2.4 ADAPTIVE TONNAGE Pop-up Window

The Adaptive Tonnage function allows a user to define a higher startup tonnage and switch to a lower optimized tonnage after completing a set number of auto cycles. This function only works when the machine is Auto cycling.


Touch the Expand button beside the Tonnage field to display the ADAPTIVE TONNAGE pop-up window – refer to Figure 4-4.

Figure 4-4 ADAPTIVE TONNAGE Pop-up Window

Table 4-3 ADAPTIVE TONNAGE Pop-up Window Descriptions

Element Description

Enable Select the check box to enable the Adaptive Tonnage function. Clear the check box to disable.

Startup

Tonnage Enter the startup tonnage.

NOTE: This tonnage value is the same as the value on the CLAMP screen.

Auto Cycles Enter the number of Auto cycles that must be completed using the startup tonnage.

Auto Cycle Remaining

Displays the number of remaining Auto cycles.

Optimized Auto Cycle Tonnage

Enter the tonnage value at which the machine continues Auto cycling after the initial startup sequence.

NOTE: This tonnage value is lower than the startup tonnage, and is not connected to the value on the CLAMP screen.

COOLING SETUP Pop-up Window 4–9


4.2.5 COOLING SETUP Pop-up Window

The COOLING SETUP function allows a user to define the unclamp times during and after cooling. This function only works when the machine is Auto cycling.


Touch the Expand button beside the Cooling Time field to display the COOLING SETUP pop-up window – refer to Figure 4-5.

4.3 GRAPH Screen

The (Clamp) GRAPH screen allows a user to view continuous traces of up to five machine variables plotted against time (clamp tonnage) or position (mold open and mold close). All Y-axes can be automatically scaled.

Press the <CLAMP> key, then touch the GRAPH tab. Refer to Figure 4-6.

Figure 4-5 COOLING SETUP Pop-up Window

Table 4-4 COOLING SETUP Pop-up Window Descriptions

Element Description

Unclamp After Cooling

Select the check box to enable the Unclamp After Cooling function. Clear the check box to disable.

Cooling Time Enter the Cooling Time.

Unclamp During Cooling

Select the check box to enable the Unclamp During Cooling function. Clear the check box to disable.

Effective Cooling Enter the Effective Cooling Time.

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4–10 GRAPH Screen

NOTE: User access rights of Operator Level 2, or Processor required to select or modify functions

NOTE: All curves are auto-scaled to display at maximum size.


The three graphing grids shown above are used to plot variables for mold close, mold open and clamp. The graphs are plotted against an evenly spaced grid.

Figure 4-6 (Clamp) GRAPH Screen

1. Mold Close graph 2. Mold Open graph 3. Clamp graph

1 2

3

GRAPH Screen 4–11


Table 4-5 (Clamp) GRAPH Screen Descriptions

Element Description

Mold Close Graph

1 – Speed Scale, 2 – Pressure Scale, 3 – Position Scale

Mold Open Graph

NOTE: The same scales apply as in the Mold Close Graph above.

Clamp Graph

1 – Tonnage Scale, 2 – Time Scale

Touch this button to save the mold open, mold close, or clamp graphing data as a group of ideal curves. Pressing this button also displays the Ideal Curves button shown below.

When the Ideal Curves button appears beneath a particular graph it indicates that a group of ideal curves is saved in the machine for the mold close, mold open, or tonnage graphs.

This button does not appear if there is no saved curve data.

Touch this button to display or hide the ideal variable data button shown below, and the ideal curve data on the graph.

1 2 3

1 2

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4–12 VALVES STATUS Screen

4.4 VALVES STATUS Screen

The (Clamp) VALVES STATUS screen allows a user to view the actual voltage signals, pressure, and ON/OFF status of clamp valves, relays and pressure transducers. The status indicators light up when the components are active, and remain greyed out when they are inactive.

Press the <CLAMP> key, then touch the VALVES STATUS tab. Refer to Figure 4-7.

When this button appears beneath a particular graph it indicates that "ideal" values for stroke pressure, stroke speed and clamp tonnage are displayed along with the real-time machine variable data. The ideal values remain plotted on the graph.

Stroke Speed Displays the actual stroke speed for mold open and close.

Stroke Pressure Displays the actual mold stroke pressure.

Stroke Position Displays the actual position of the moving platen.

Tonnage Displays the actual generated tonnage for the cycle.

Cooling Time Displays the actual cooling time for the cycle.

Touch this button to display a graph legend similar to the example below. This allows the user to identify the curves.

Table 4-5 (Clamp) GRAPH Screen Descriptions (Continued)

Element Description

VALVES STATUS Screen 4–13



The grey text boxes display actual voltage values at the digital valves.

The digital input indicator ( ) lights up when the machine controller receives a signal from a device; otherwise it remains grey.

The digital output indicator ( ) lights up when the device receives a signal from the machine controller; otherwise it remains grey.

Table 4-6 describes the abbreviations used to represent the valves and pressure transducers on the screen.

Figure 4-7 (Clamp) VALVES STATUS Screen

Table 4-6 (Clamp) VALVES STATUS Screen Descriptions

Abbreviation Description

DP Digital pressure control

DQ Digital flow control

Kxx Relay/Contactor number

PC Pressure (Clamp)

PE Pump (Extruder)

PI Pressure (Injection)

PP Proportional pressure valve

PQ Proportional flow valve

PS Pump (System)

PT Pressure transducer

Polaris — v2009.3


SD Servo valve

PX Proximity Switch

M Motor

Table 4-6 (Clamp) VALVES STATUS Screen Descriptions (Continued)

Abbreviation Description

HMI Reference Manual Polaris — v2009.3 Mold Functions

EJECTOR SETUP Screen 5–1

Chapter 5 Mold Functions

The Mold Functions screens allow a user to view and control the ejectors, air, and the optional valve gates.

5.1 EJECTOR SETUP Screen

The EJECTOR SETUP screen allows a user to view and change ejector settings.

Press <MOLD FUNCTIONS> key, then touch the EJECTOR SETUP tab. Refer to Figure 5-1.


NOTE: User access rights of Processor or Maintenance required to select or modify functions.

Figure 5-1 EJECTOR SETUP Screen

Polaris — v2009.3

5–2 EJECTOR SETUP Screen

Table 5-1 EJECTOR SETUP Screen Descriptions

Element Description

Ejector Forward

Position Enter the Ejector Forward position. The grey field displays the actual position.

Speed Enter the speed at which the ejector moves forward.

Pressure Enter the pressure

Deceleration Enter the deceleration rate of the ejector as it moves forward.

Pressure-Ramp Enter the pressure ramp for the ejector forward motion.

Final Speed Enter the final speed of the ejector during the forward motion.

Final Pressure Enter the final pressure of the ejector.

Forward Dwell Enter the amount of time that the ejector remains in the forward position.

Position for Booster Retract

Enter the ejector position for the booster to start retracting.

Start Delay Enter the start delay time.Once the delay time is reached the ejectors move forward.

Mold

Mold Stroke Position

Displays the actual mold stroke position.

Ejector Back

Position Enter the Ejector Back position. The grey field displays the actual position.

Speed Enter the speed at which the ejector moves back.

Deceleration Enter the deceleration rate of the ejector as it moves back.

Final Speed Enter the final speed of the ejector during the return motion.

Valve Status

Speed Displays the voltage output for the valve used in speed control.

Pressure Displays the voltage output for the valve used in pressure control.

Booster

Booster Enable Select the check box to enable the booster function. When enabled, the booster cylinders extend to provide additional force to remove preforms off the cores. The booster cylinders stop extending when the ejector reaches the "Position for Booster Retract" position. Once the process has stabilized the additional force provided by the booster cylinders is no longer required, so the booster function can be deselected. This function is available in all machine modes.

Clear the check box to disable the booster function.

Booster Forward The indicator lights up when the Booster Forward output signal is High.

AIR Screen (Optional) 5–3


5.2 AIR Screen (Optional)

The optional AIR screen allows a user to program valves on the moving and/or stationary platens. The machine can have from one to four valves on both the moving and stationary platens.

Press <MOLD FUNCTIONS> key, then touch the AIR tab. Refer to Figure 5-2.

Ejector Pressure Delay

Select the check box to enable the ejector pressure delay function. When selected the boosters will move the ejectors forward with zero pressure until the Pressure Start Position is reached.

Pressure Start Position

Enter the pressure start position. Once this position is reached the ejectors will ramp up to the ejector forward pressure.

Ejector Override

Enable Select the check box to allow the ejector to move forward manually and eject parts on the core when clamp or mold calibration is lost. The "Parts on Core" alarm is reset to allow the clamp or mold to be recalibrated.


Table 5-1 EJECTOR SETUP Screen Descriptions (Continued)

Element Description

Polaris — v2009.3

5–4 VALVE GATES Screen (Optional)



5.3 VALVE GATES Screen (Optional)

The optional VALVE GATES screen allows a user to control the filling material flow to the mold during the injection phase of the molding process using valve gates. Valve gates provide better control over dimensions, size and weight of parts.

Figure 5-2 AIR Screen

Table 5-2 AIR Screen Descriptions

Element Description

Function Displays the name assigned to the air ejector function and the icon displays its location on the stationary or moving platen.

Start Trigger Displays the event that triggers the start of air blowing.

Delay Time Enter the delay period after the mold starts to open.

Blow Time Enter the duration for which air blows.

VALVE GATES Screen (Optional) 5–5


Valve gate control uses a single directional valve to control one or more valve gates to create a continuos flow pattern. Each valve gate can be triggered either when the mold is fully open or just as the mold is starting to close.

NOTE: At least one valve gate must be opened to permit plastic flow during injection.

Press <MOLD FUNCTIONS> key, then touch the VALVE GATES tab. Refer to Figure 5-3.

Figure 5-3 VALVE GATES Screen

Polaris — v2009.3

5–6 VALVE GATES Screen (Optional)



NOTE: In Manual mode, all valve gates are controlled using a single button on the HMI sidebar.

Table 5-3 VALVE GATES Screen Descriptions

Element Description

Function Displays the name assigned to the valve gate.

NOTE: If multiple valve gates are configured on the machine they will be listed one below the other.

Open Trigger Touch the drop-down list box, and select the trigger to open the valve gate. The available choices are Mold Open End, and Mold Close Start.

Open Delay Enter the time delay to open the valve gate for the selected trigger.

Neutral During Displays the stage at which the valve gates are neutral.

Close Delay Enter the time delay to close the valve gate at the end of Injection Hold.

Open Valve Displays the status when the valve gate is open.

Close Valve Displays the status when the valve gate is closed.

Interlock Valve Gate Open With Injection

At Shot Size

Select the check box to interlock the valve gate opening with the shot size. The injection must be at shot size before the valve gate is allowed to open. This can prevent short shots.


Disable Valve Gate Select the check box to disable the valve gate. Clear the check box to enable.

Note: The valve gates will be enabled when switching to Semi or Auto cycling, or when they are operated manually from the sidebar.

HMI Reference Manual Polaris — v2009.3 Injection

OVERVIEW Screen 6–1

Chapter 6 Injection

The Injection screens allow a user to view and control the various parameters required during the machine injection process.

6.1 OVERVIEW Screen

The (Injection) OVERVIEW screen allows an operator with limited user access rights to adjust selected setpoint values displayed in the INJECTION screen.

Press <INJECTION> key to display the OVERVIEW screen. Refer to Figure 6-1.


NOTE: User access rights of at least Operator Level 1 required to use sliders. User access rights of Operator Level 2, or Processor required to view and modify the selectable fields on this screen.

NOTE: When the slider is active, a white stripe appears in the middle of the slider.

Figure 6-1 (Injection) OVERVIEW Screen

Polaris — v2009.3

6–2 OVERVIEW Screen

Table 6-1 (Injection) OVERVIEW Screen Descriptions

Element Description

The following general description of sliders applies to all sliders described below.

1 – Touch this button to increase the setpoint value

2 – Enter slider limit for operators who only have access to sliders for modifying setpoint values

NOTE: Only users with access rights of Processor can view and modify this field.

NOTE: The slider limit represents the maximum and minimum value that the setpoint value can be adjusted up or down. The slider has a total range of 20 steps – 10 up and 10 down. Each slider step is equal to 1/10th of the slider limit value.

NOTE: If the slider value is set to zero, the slider will disappear from the screen.

3 – Touch this button to decrease the setpoint value

Injection Fill Speed Touch the Up or Down button to increase or decrease the Injection Fill Speed profile.

Shot Size Touch the Up or Down button to increase or decrease the Shot Size.

InjTrans By Position Touch the Up or Down button to increase or decrease the InjTrans By Position value.

Injection Hold Time Touch the Up or Down button to increase or decrease the Injection Hold Time profile.

Hold Pressure Enter the limit value for adjusting Hold Pressure.

NOTE: Only users with access rights of Processor can view and modify this field.

NOTE: There is no slider for this function. This value affects the first field in the Hold Pressure profile on the INJECTION screen shown below. When the field is selected, a numeric touchpad appears. For users with limited access, the range of adjustment allowed with the Up/Down arrows on the numeric touchpad is determined by this limit value.

Pullback Distance Before Recovery

Touch the Up or Down button to increase or decrease the Pullback Distance Before Recovery value.

1

2

3

INJECTION Screen 6–3


6.2 INJECTION Screen

The INJECTION screen allows a user to set Injection Fill and Injection Hold profiles, transition type, cushion control and other functions. The Injection Fill and Injection Hold graphs are displayed at the top of the screen. Closed loop control is optional for injection.

Press <INJECTION> key, then touch the INJECTION tab. Refer to Figure 6-2.


Screw Speed Touch the Up or Down button to increase or decrease the Screw Speed profile.

Back Pressure Touch the Up or Down button to increase or decrease the Back Pressure profile.

Pullback Distance After Recovery

Touch the Up or Down button to increase or decrease the Pullback Distance After Recovery value.

Table 6-1 (Injection) OVERVIEW Screen Descriptions (Continued)

Element Description

Figure 6-2 INJECTION Screen

Polaris — v2009.3

6–4 INJECTION Screen

NOTE: User access rights of Operator Level 2, or Processor required to select and modify functions.

Table 6-2 INJECTION Screen Descriptions

Element Description

Injection Hold and Injection Fill Graphs

For general notes on setpoint profile graphs, refer to Section 4.2.1.

Injection Fill Graph

The Injection Fill graph displays the Injection Fill speed versus injection piston position setpoint profile, and the actual Injection Fill curve from the previous cycle. Both the setpoint profile and actual curve are displayed in the color Fluorescent Green.

The transition from Injection Fill to Injection Hold is indicated on the graph by a vertical line.

Injection Hold Graph

The Injection Hold graph displays the Injection Hold pressure versus time setpoint profile, and the actual Injection Hold curve from the previous cycle. Both the setpoint profile and actual curve are displayed in the color Red.

The Injection Hold graph covers the region to the left of the transition line in the Injection Fill graph.

Progress Bars

The progress bar under the Injection Fill profile displays the injection position during Injection Fill.

The progress bar under the Injection Hold profile displays the time into the Injection Hold profile.

The underlaid arrow turns Blue to indicate the currently active profile, and the direction of movement of the profile.



Injection Hold and Injection Fill

Setpoint Profiles

NOTE: The Hold and Fill tabs will appear when there are more than three setpoints in either the Injection Hold or Fill setpoint profile.

The Injection Fill setpoint profile controls how injection speed changes as the material is injected into the mold. The Injection Hold setpoint profile controls how long, and how much pressure is applied by the injection piston after the transition from Fill to Hold.

The Injection Fill and Injection Hold profiles can be configured as either step type profiles or as linear interpolated profiles. Step type profile is the default selection. In step profiles changes in the process are defined in terms of abrupt speed or pressure changes, which result in step-like profiles. With a step type profile it is not easy to control the rate of change. A linear interpolated profile, on the other hand, is defined as a set of points that are connected together by straight lines to define the characteristics of the process. This results in greater control over the rate of change.

The Injection Fill and Injection Hold profiles are displayed side by side or on two separate tabs on the screen. If the Injection Fill profile has 4 steps or less, and the Injection Hold profile has 4 steps (5 points) or less then they are displayed side by side; otherwise they are displayed on two separate tabs.

For step type setpoint profile characteristics refer to Section 4.2.2.

To modify the number of steps/points in injection setpoint profiles refer to Section 6.2.1.

Touch the Expand button located on the lower right corner of the profile panel/tab to display the PROFILE CONFIGURATION pop-up window – refer to Section 6.2.1 to modify the injection setpoint profile configurations (or to switch the profile type between step and interpolated).

Touch the Maximize Graph button located on the lower right corner of the profile panel/tab to display either the Fill or Hold Profile Graph – refer to Section 6.2.1.1 to modify the injection setpoint profile configurations.

Touch the Minimize Graph button located on the lower right corner of the profile panel/tab to return to the normal Fill and Hold Profile Graphs - refer to Section 6.2.1.1.

Touch the Move button located on the upper right corner of the profile panel/tab to move a graph profile setpoint in any direction – refer to Section 6.2.1.1 to modify the injection setpoint profile configurations.

Touch the Move Horizontally button located on the upper right corner of the profile panel/tab to move a graph profile setpoint horizontally – refer to Section 6.2.1.1 to modify the injection setpoint profile configurations.

Table 6-2 INJECTION Screen Descriptions (Continued)

Element Description

Polaris — v2009.3


Touch the Move Vertically button located on the right side of the profile panel/tab to move a graph profile setpoint vertically – refer to Section 6.2.1.1 to modify the injection setpoint profile configurations.

Touch the Add Setpoint button located on the right side of the profile panel/tab to add a new setpoint to either the Fill or Hold Profile Graph – refer to Section 6.2.1.1 to modify the injection setpoint profile configurations.

Touch the Remove Setpoint button located on the right side of the profile panel/tab to remove an existing setpoint from either the Fill or Hold Profile Graph – refer to Section 6.2.1.1 to modify the injection setpoint profile configurations.

Touch the Confirm Profile Changes button located on the lower right corner of the profile panel/tab to save the changes made to either the Fill or Hold Profile Graph – refer to Section 6.2.1.1 to modify the injection setpoint profile configurations.

Touch the Cancel Profile Changes button located on the lower right corner of the profile panel/tab to cancel the changes made to either the Fill or Hold Profile Graph – refer to Section 6.2.1.1 to modify the injection setpoint profile configurations.

Transition

Transition determines when the switch from Injection Fill to Injection Hold phase occurs.

There are four transition options – Position, Hydraulic Pressure, Fill Time, and Cavity Pressure (optional). Only one transition option can be selected at any given time.

Regardless of which option is selected, all of the latched transition values are updated after transition occurs (e.g., if Transition By Position option is selected, the injection position, hydraulic pressure, fill time and cavity pressure values at transition are updated).

Position Transition occurs when the injection piston reaches a specified position.

Select the option button to enable Transition By Position. A confirmation window is displayed to verify the selection.

The latched injection position at transition from the previous cycle is displayed.


Element Description



Hydraulic Pressure Transition occurs when injection hydraulic pressure reaches a specified limit.

Select the option button to enable Transition By Hydraulic Pressure. A confirmation window is displayed to verify the selection.

The latched injection hydraulic pressure value at transition from the previous cycle is displayed.

Select the related Expand button to display the HYDRAULIC PRESSURE pop-up window. Specify the hydraulic pressure enable position.

Hydraulic Pressure Enable Position is the injection position during Fill when hydraulic pressure monitoring will start. The purpose of this setting is to eliminate pressure spikes at the start of injection from falsely triggering transition from Fill to Hold.

Fill Time Transition occurs when a specified amount of time has passed since the start of Injection Fill.

Select the option button to enable Transition By Fill Time. A confirmation window is displayed to verify the selection.

The latched fill time value from the previous cycle is displayed.

Cooling Time Cooling Time is the duration that the mold halves remain together at the end of the Hold phase to allow molded parts to cool down. The actual value shown is the current value of the timer as it counts down.

Enable Fill Speed Open Loop

Select the check box to enable open loop control for Injection Fill speed. When enabled, the speed at which the injection piston moves is controlled by factory presets that correspond to the Injection Fill setpoint profile. However, the injection piston may not react as required, so the actual Injection Fill speed may deviate from the setpoint profile.

When the check box is cleared, the injection piston speed is controlled to attempt to match the actual Injection Fill speed to the Injection Fill setpoint profile.


Element Description

Polaris — v2009.3


Others Touch the Expand button to display the OTHERS pop-up window displayed below.

Select the check box to enable Cycle Compression. When cycle compression is selected, the machine "learns" how long each part of the machine cycle takes. From the information collected during the learning cycles the time of injection is predicted, based on the fact that a maximum of 33% of shot size can be injected before clamp tonnage is reached. The earliest injection can start is when the mold reaches the closed position. The machine is allowed to inject while clamp lock is engaging and tonnage is building up, thereby saving cycle time. Use cycle compression when the machine is ready to run in Auto mode. Cycle compression is disabled when the machine stops Auto cycling.

Clear to disable cycle compression.

Cushion Control

Cushion control determines the amount of plasticizing material left in front of the injection screw when injection is completed.

Enable Select the check box to enable cushion control. When cushion control is enabled Shot Size is adjusted from cycle to cycle to achieve the required cushion.

When the check box is cleared cushion control is ignored, and the injection piston stops after Recovery when it reaches the Shot Size setpoint.

Specify the target cushion distance. The latched value from the previous cycle is also displayed.

Touch the Expand button beside the Enable check box to display the CUSHION CONTROL pop-up window – refer to Section 6.2.2.

Fill Pressure Limit Fill Pressure Limit is the maximum allowed pressure that can be applied to the injection piston during Injection Fill.

The latched value from the previous cycle is displayed.

Purge Pressure Purge Pressure is the exact pressure applied to the injection piston during Injection Fill.


Element Description

Modifying Injection Setpoint Profiles 6–9


6.2.1 Modifying Injection Setpoint Profiles

There are two methods for modifying step type setpoint profiles:

• Profile Configuration Method• Profile Graph Drag and Drop Method

NOTE: To modify setpoint profiles using the Profile Configuration Method refer to Section 4.2.3.

6.2.1.1 Profile Graph Drag and Drop Method

1. Select either the Hold or Fill tab as appropriate.

2. Touch the Maximize Graph button located on the lower right corner of the profile panel/tab to expand the GRAPH PROFILE window – refer to Figure 6-2.

Injection Fill Injection Fill is the maximum time allowed for the Injection Fill phase to be completed. If this time limit is exceeded while the machine is in Auto or Semi Cycle mode, injection is stopped and the "Fill Time Limit Exceeded" alarm is displayed.

Injection Position Displays the actual injection position as measured from its fully forward position.

Injection Pressure Displays the actual injection hydraulic pressure.


Element Description

Figure 6-3 GRAPH PROFILE Window

Polaris — v2009.3

6–10 Profile Graph Drag and Drop Method

3. Modify the setpoint profile.

The profile setpoint control buttons (located down the right-hand side of the profile panel/tab) will permit five different types of setpoint modification:

• Add a setpoint.• Remove a setpoint.• Modify setpoint along the horizontal axis.• Modify setpoint along the vertical axis.• Modify setpoint along either axis.

To add a setpoint:

i. Touch the Add Setpoint button.

ii. Touch the appropriate location on the setpoint curve within the Graph Profile window where the new point is to be added.

To remove a setpoint:

i. Touch the Remove Setpoint button.

ii. Touch the appropriate setpoint on the setpoint curve within the Graph Profile window.

To modify an existing setpoint along the horizontal axis:

i. Touch the Move Horizontally button.

ii. Touch an existing setpoint on the setpoint curve within the Graph profile window and drag it horizontally to a new location.

To modify an existing setpoint along the vertical axis:

i. Touch the Move Vertically button.

ii. Touch an existing setpoint on the setpoint curve within the Graph Profile window and drag it vertically to a new location.

To modify an existing setpoint along either axis:

i. Touch the Move button.

ii. Touch an existing setpoint on the setpoint curve within the Graph Profile window and drag it to a new location.

NOTE: While a setpoint profile is being modified, the previous setpoint profile will be displayed in the Graph Profile window as a dashed-line. Refer to Figure 6-4.

Profile Graph Drag and Drop Method 6–11


4. Confirm or cancel the modified setpoint profile.

When a setpoint profile has been modified, the new profile can either be confirmed or cancelled.

To confirm a modified setpoint profile and apply it to the machine:

i. Touch the Save Profile button (located along the right-hand side of the profile panel/tab). The system will display the Expanded Graph Profile Pop-Up Window.

ii. Touch the Yes button (located within the Expanded Profile Graph Pop-Up window) to Save the modified setpoint profile.

To cancel a modified setpoint profile (and lose all changes):

i. Touch the Cancel Profile button (located along the right-hand side of the profile panel/tab).

ii. Touch the Yes button to cancel the setpoint profile changes.

Figure 6-4 MODIFIED SETPOINT PROFILE

Figure 6-5 EXPANDED PROFILE GRAPH POP-UP WINDOW (Save Changes)

Polaris — v2009.3

6–12 CUSHION CONTROL Pop-up Window

5. Minimize the Graph Profile window.

When the modifications to the setpoint profile have been completed, the operator can minimize the Graph Profile window and return to the regular Injection tab view.

To minimize the Graph Profile window:

i. Touch the Minimize Graph button - refer to Figure 6-4.

6.2.2 CUSHION CONTROL Pop-up Window

The Cushion Control pop-up window allows a user to set the cushion control parameters.

Touch the Expand button beside the (Cushion Control) Enable check box to display the CUSHION CONTROL pop-up window – refer to Figure 6-7.

NOTE: User access rights of Processor required to select and modify functions.

Figure 6-6 EXPANDED PROFILE GRAPH POP-UP WINDOW (Cancel Changes)

Figure 6-7 CUSHION CONTROL Pop-up Window

INJECTION GRAPH Screen 6–13


6.3 INJECTION GRAPH Screen

The INJECTION GRAPH screen allows the operator to view continuous traces of various machine variables plotted against time (Hold graph) and position (Fill graph).

Press <INJECTION> key, then touch the INJECTION GRAPH tab. Refer to Figure 6-8.


NOTE: Curves displayed on this screen are selected on the CURVE SELECTION pop-up window - refer to Section 2.4.1.

NOTE: All curves are auto-scaled to display at maximum size.

Table 6-3 CUSHION CONTROL Pop-up Window Descriptions

Element Description

Distance Enter the value for the target cushion distance.

Gain Enter the required gain value. Gain is defined as the cushion correction factor that is applied each cycle to the difference between the actual and target cushion to obtain the corrected Shot Size.

High Limit Enter the maximum cushion limit. When the amount of cushion exceeds this limit a warning message is displayed.

Low Limit Enter the minimum cushion limit. When the amount of cushion drops below this limit a warning message is displayed.

Figure 6-8 INJECTION GRAPH Screen

Polaris — v2009.3

6–14 INJECTION GRAPH Screen

Table 6-4 INJECTION GRAPH Screen Descriptions

Element Description

Injection Hold Pressure Profile

1 – Speed Scale, 2 – Pressure Scale, 3 – Time Scale

Injection Filling Speed Profile

1 – Distance Scale, 2 – Transition Bar

NOTE: The same speed and pressure scales apply as in the Injection Hold Pressure Profile above.

NOTE: The transition bar indicates the time when the transition from Filling phase to Hold phase occurs.

Touch this button to save the injection graphing data as a group of ideal curves. Pressing this button also displays the Ideal Curves button shown below.

When the Ideal Curves button appears beneath a particular graph it indicates that there is a group of ideal curves saved in the machine for the injection and hold graphs.


Touch this button to display or hide the ideal variable data button shown below, and the ideal curve data shown on the graph.

When this button appears beneath a particular graph it indicates that "ideal" values for speed and pressure are displayed along with the real-time machine variable data. The ideal values remain plotted on the graph.

1 2 3

1

2

RECOVERY Screen 6–15


6.4 RECOVERY Screen

The RECOVERY screen allows a user to view and set up injection recovery speed, position and back pressure profiles, as well as set up the carriage and the nozzle shut-off. For machines that use P-Injection units it also allows a user to set up the transfer of molten resin from the extruder into the shooting pot.

Press <INJECTION> key, then touch the RECOVERY tab. The contents of the RECOVERY screen will depend on the type of injection unit installed on the machine. For machines with RS injection units refer to Figure 6-10. For machines with P-Injection units refer to Figure 6-9.

Fill Speed Displays the actual fill speed.

Injection Pressure Displays the actual fill pressure.

Injection Position Displays the actual injection position.

Cushion Displays the actual cushion from the previous cycle.

Touch this button to display a graph legend similar to the example below. This allows the operator to identify the curves.

Transition Pos. Displays the actual transition position from the previous cycle.

Injection Fill Time Displays the actual injection fill time from the previous cycle.

Fill Pressure Limit Displays the actual maximum fill pressure from the previous cycle.

Shot Size Displays the actual shot size from the previous cycle.

Table 6-4 INJECTION GRAPH Screen Descriptions (Continued)

Element Description

Polaris — v2009.3

6–16 Recovery Screen for the P-Injection Unit

6.4.1 Recovery Screen for the P-Injection Unit

NOTE: Screens shown are representative, and may vary depending on how the machines are configured.


Figure 6-9 RECOVERY Screen (P-Injection Unit) For HyPET HPP

Table 6-5 RECOVERY Screen (P-Injection Units) Descriptions

Element Description

Hopper/ Distributor

Hopper Open (optional)

Select the check box to enable the optional auto-shutoff valve to open the resin hopper. Clear the check box to close the hopper.

Nozzle Open Delay Enter a value for the delay in distributor operation.

The two digital input indicators ( ) display the status of distributor. The indicator labelled S289PX lights up when it is open to transfer, and S29PX lights up when it is open to the mold.

Recovery Screen for the P-Injection Unit 6–17


Pre-Pullback

Pre-Pullback allows the injection piston to move backward to permit the mold to decompress. The recovery sequence is as follows:

1. Inject

2. Hold

3. Pullback

4. Recovery

Speed (Pre-Pullback) Speed is the speed at which the injection piston moves back to the (Pre-Pullback) Distance.

Distance (Pre-Pullback) Distance is the injection position to which the piston moves back to.

Dwell Time (Pre-Pullback) Dwell Time is the amount of time that the injection piston remains at the (Pre-Pullback) Distance before starting recovery.

Transfer

Speed Enter the speed at which the molten resin is transferred from the extruder to the shooting pot. The grey field displays the actual transfer speed.

Transfer Pressure Limit

Enter the maximum pressure at which the molten resin is transferred from the extruder to the shooting pot.

Transfer Packing Pressure

Enter the pressure at which the molten resin is packed into the shooting pot while transferring it.

Transfer Shooting Pot Packing Time

Enter the time duration for packing the molten resin into the shooting pot.

Screw Speed for Transfer

Select and enter a speed for the screw during transfer. This option is for HyPET HPP only.

Plasticizing

Screw Rotation Speed

Enter the speed at which the extruder screw turns to plasticize the resin. The grey field displays the actual rotational speed of the screw.

Extruder Position Enter the extruder screw position at which plasticizing stops. Plasticizing occurs whenever the extruder screw position is less than this value even when while molten resin is being transferred into the shooting pot.

The grey field displays the actual position of the extruder screw.

Plasticizing Back Pressure

Enter the back pressure maintained by the extruder transfer cylinders during plasticizing. This pressure opposes the backward motion of the extruder screw as molten resin accumulates in front of the screw.

Continuous Recovery

Select the check box to enable continuous recovery. This option is for HyPET HPP machines only.

Table 6-5 RECOVERY Screen (P-Injection Units) Descriptions (Continued)

Element Description

Polaris — v2009.3

6–18 Recovery Screen for the P-Injection Unit

Carriage

(Carriage) Forward The (Carriage) Forward position is the position that the carriage must be at before injection can start. The grey field displays the actual position of the carriage.

(Carriage) Too Far Forward

(Carriage) Too Far Forward is the maximum forward position of the carriage. If the carriage moves beyond this position, the cycle will be interrupted.

This is a safety feature for stack molds with a moving sprue. The Too Far Forward position ensures that the carriage does not travel too far forward and damage the mold sprue or injection nozzle.

Sprue Break Sprue Break is the additional distance the carriage moves back from the Carriage Forward position after pullback is complete. This is typically used to separate the injection nozzle from the mold sprue.

Transfer/Back/ Pack Pressure

Displays the actual pressures in the extruder cylinder during transfer, recovery and packing phases.

Recovery Time Displays the actual time taken to complete plasticizing during the previous cycle.

Screw Run Time Displays the actual amount of time (in seconds) that the transfer screw was turning during the previous cycle.

Screw Idle Time Displays the actual amount of time (in seconds) that the transfer screw was idle during the previous cycle.

Transfer Time Displays the actual amount of time (in seconds) it took to transfer molten resin into the shooting pot during the previous cycle.

Transfer Cushion Displays the actual amount of resin in front of the transfer screw (in mm) during the previous cycle.

Auto Purge Cycles This feature is used to purge the barrel when the machine is in Auto Purge mode.

Enter the desired number of auto purge cycles. The grey field displays the actual number of completed auto purge cycles.

Adaptive Cooling (HyPET HPP only)

Enable Select to enable Adaptive Cooling

Press the Expand button beside the Adaptive Cooling text box to display the Adaptive Cooling pop-up window – refer to Section 6.4.4.

Table 6-5 RECOVERY Screen (P-Injection Units) Descriptions (Continued)

Element Description

Recovery Screen for RS Injection Units 6–19


6.4.2 Recovery Screen for RS Injection Units

Figure 6-10 RECOVERY Screen (RS Injection Unit)

Table 6-6 RECOVERY Screen (RS Injection Units) Descriptions

Element Description

Recovery Graph

NOTE: For general notes on setpoint profile graphs, refer to Section 4.2.1.

Recovery Graph

The Recovery graph displays the screw rotation speed versus injection piston position setpoint profile, and the corresponding actual curve from the previous cycle. The setpoint profile and actual curve are displayed in the color Fluorescent Green.

In addition, it also displays the back pressure versus injection piston position setpoint profile, and the corresponding actual curve from the previous cycle. The setpoint profile and actual curve are displayed in the color Red.

Polaris — v2009.3

6–20 Recovery Screen for RS Injection Units

Progress Bar

The progress bar displays the injection position during Recovery. The underlaid arrow turns Blue during Recovery, and indicates the direction of movement of the Recovery profile.

Hopper Open (optional)

Select the check box to enable the optional auto-shutoff valve to open the resin hopper. Clear the check box to close the hopper.

Pullback Before (Recovery)

The Pullback Before (Recovery) function allows the injection piston to be moved backwards to decompress the plastic in the sprue or hot runners before the shutoff nozzle (if installed and enabled) is closed, and the screw starts to rotate.

The following is the sequence of events for Pullback Before (Recovery):

1. Injection Hold completes.

2. Injection piston moves back to the Pullback Before Position, and remains at that position for the length of time specified by Pullback Before Dwell Time setpoint. Pullback is then completed.

3. Shutoff nozzle (if installed) closes.

4. Recovery starts.

Pullback Before Speed

Pullback Before Speed is the speed at which the injection piston moves back to the Pullback Before Position before the start of Recovery.

Pullback Before Position

Pullback Before Position is the injection position to which the piston moves back.

Pullback Before Dwell Time

Pullback Before Dwell Time is the amount of time that the injection piston remains at the Pullback Before Position before continuing the Recovery sequence.

Pullback After (Recovery)

The Pullback After (Recovery) function allows the ring check valve on the plasticizing screw to be seated.

The following is the sequence of events for Pullback After (Recovery):

1. Injection Hold completes.

2. Recovery starts (i.e. screw starts turning) and continues until the Shot Size setpoint position (on the INJECTION screen) is reached.

3. Injection piston moves back to the Pullback After Position, and remains at that position for the length of time specified by Pullback After Dwell Time setpoint. Pullback is then completed.

4. Shutoff nozzle (if installed) closes.

Pullback After Speed

Pullback After Speed is the speed at which the injection piston moves back to the Pullback After Position when the profile is complete.

Pullback After Position

Pullback After Position is the injection piston position to which the injection piston moves back.

Table 6-6 RECOVERY Screen (RS Injection Units) Descriptions (Continued)

Element Description



Auto Purge Cycles This feature is used to purge the barrel when the machine is in Auto Purge mode.

Enter the desired number of auto purge cycles. The grey field displays the actual number of completed auto purge cycles.

Recovery Speed and Recovery Back

Pressure Setpoint Profiles

The Recovery Speed setpoint profile controls how the screw rotation speed changes during recovery. The top and middle rows in the profile make up the Recovery Speed setpoint profile. Starting from the left, and moving right to the next position in the profile constitutes one step. The injection piston moves to the second position at the first screw rotation speed indicated in the profile. Then it moves to the next position at the next screw rotation speed in the profile, and so on.

The Recovery Back Pressure setpoint profile controls how the back pressure changes during plasticizing. The middle and bottom rows in the profile make up the Recovery Back Pressure setpoint profile. Starting from the left, and moving right to the next position in the profile constitutes one step. The injection piston moves to the second position while maintaining the back pressure indicated in the first field in the Recovery Back Pressure setpoint profile. Then it moves to the next position while maintaining the back pressure indicated in the next field in the profile, and so on.

Both profiles are step type profiles. Up to 9 steps can be displayed in each of the profiles. Step type setpoint profiles share some common characteristics. These are discussed in Section 4.2.2.

To modify the number of steps in the profiles, refer to Section 4.2.3.


Element Description

Polaris — v2009.3

6–22 Recovery Screen for RS Injection Units

The Expand button located on the lower right corner of the profile panel/tab is used to modify the setpoint profile configuration to increase or reduce the number of steps in the profiles. The HMI displays the PROFILE CONFIGURATION pop-up window shown below – refer to Section 4.2.3 to modify the number of steps in the profiles.

Screw Rotation Delay

Screw Rotation Delay is the time delay from when the screw would normally start to rotate. On machines with a shutoff nozzle, if the Maintain Nozzle Open check box is cleared (i.e. shutoff nozzle closed) it is the delay from when the nozzle is closed. On machines without a shutoff nozzle, or if the Maintain Nozzle Open check box is selected it is the delay from the time when Pullback Before Recovery Dwell Time is completed.

Screw Rotation Delay has the effect of reducing the amount of time between the end of Recovery and the start of the next injection cycle. This can be used to control the amount of time the processed material sits in the barrel before being injected, and hence the melt properties and final part quality. Further, reducing the time between injection cycles can also help minimize possible driftback of the screw, and hence improve the cycle-to-cycle repeatability.

Screw Rotation Speed

Displays the actual rotational speed of the screw.

Screw Torque Displays the actual screw torque.

NOTE: This field is only displayed on machines with electric screw drive.

Back Pressure Displays the actual hydraulic back pressure maintained on the injection piston.

Injection Position Displays the actual injection piston position as measured from its fully forward position.

Recovery Time Recovery Time is the length of time taken to prepare enough material for the next injection cycle. It is measured from the time the screw starts rotating until it stops (Shot Size is reached).

The latched value from the previous cycle is displayed.


Element Description



Hopper Level Monitoring (optional)

Select the check box to enable the optional hopper level monitoring. Clear the check box to disable the option.

Carriage

(Carriage Control Selection)

Displays the option selected in the CARRIAGE pop-up window – refer to Section 6.4.2.1.

Press the Expand button beside the Carriage Control Selection text box to display the CARRIAGE pop-up window – refer to Section 6.4.2.1.

(Carriage) Forward The (Carriage) Forward position is the position that the carriage must be at before injection can start. The grey field displays the actual position of the carriage.

(Carriage) Too Far Forward

(Carriage) Too Far Forward is the maximum forward position of the carriage. If the carriage moves beyond this position, the cycle will be interrupted.

This is a safety feature for stack molds with a moving sprue. The Too Far Forward position ensures that the carriage does not travel too far forward and damage the mold sprue or injection nozzle.

Sprue Break Sprue Break is the additional distance the carriage moves back from the Carriage Forward position after pullback is complete. This is typically used to separate the injection nozzle from the mold sprue in stack mold applications.

Shut-off Nozzle

Nozzle Open Delay Nozzle Open Delay is the time that the shutoff nozzle remains closed from the start of Mold Close.

(Shut-off Nozzle Selection)

Displays the option selected in the SHUT-OFF NOZZLE pop-up window – refer to Section 6.4.2.2.

Press the Expand button beside the Shut-off Nozzle Selection text box to display the SHUT-OFF NOZZLE pop-up window – refer to Section 6.4.2.2.


Element Description

Polaris — v2009.3

6–24 CARRIAGE DETAILS Pop-up Window

6.4.2.1 CARRIAGE DETAILS Pop-up Window

The CARRIAGE pop-up window allows a user to select the sprue type based on the mold type and carriage valve type.

Press the Expand button beside the Carriage Control Selection text box to display the CARRIAGE pop-up window – refer to Figure 6-11. Based on the mold and carriage valve type the pop-up window displayed can differ.


Figure 6-11 CARRIAGE Pop-up Window - Proportional Carriage Valve

CARRIAGE DETAILS Pop-up Window 6–25


Figure 6-12 CARRIAGE DETAILS Pop-up Window - Digital Carriage Valve

Table 6-7 CARRIAGE Pop-up Window Descriptions

Element Description

Mold Type Based on the mold type installed, select Moving Sprue or Stationary Sprue.

If Moving Sprue is selected, Sprue Contact only with Clamp force is selected.

If Stationary Sprue is selected, the selection of Sprue Contact only with Clamp force is active an can be enabled or disabled.

Too Far Forward Position

Too Far Forward is the maximum forward position of the carriage. If the carriage moves beyond this position, the cycle will be interrupted.

This is a safety feature especially for stack molds with a moving sprue. The Too Far Forward position ensures that the carriage does not travel too far forward and damage the mold sprue or injection nozzle.

Forward Speed Forward Speed is the carriage speed when moving forward.

The forward speed and the forward touch speed are used to generate the forward speed profile

Forward Touch Speed

Enter the value for the Forward Touch Speed. The Forward touch speed is the carriage speed when the carriage touches the sprue.

Retract Speed Retract Speed is the carriage speed when moving away from the sprue.

Forward High Pressure

Enter the value for the Forward High Pressure. The Forward High Pressure is the pressure on the sprue during injection.

Polaris — v2009.3

6–26 SHUT-OFF NOZZLE Pop-up Window

6.4.2.2 SHUT-OFF NOZZLE Pop-up Window

The SHUT-OFF NOZZLE pop-up window allows a user to set up the shut-off nozzle characteristics for when the machine is cycling in Auto mode.

Press the Expand button beside the Shut-off Nozzle Selection text box to display the SHUT-OFF NOZZLE pop-up window – refer to Figure 6-13.


Figure 6-13 SHUT-OFF NOZZLE Pop-up Window

Table 6-8 SHUT-OFF NOZZLE Pop-up Window Descriptions

Element Description

Open at End of Recovery

Select this option button to open the shut-off nozzle at the end of Recovery when the screw stops turning.

Open at Building Tonnage

Select this option button to open the shut-off nozzle on building tonnage.

Open at Mold Closed

Select this option button to open the shut-off nozzle when the mold is fully closed.

Disabled Select this option button to disable the nozzle shut-off function. The nozzle will then remain open all the time.

Open at Mold, Carriage and Recovery Set

Position

Select this option button to open the shut-off nozzle when the carriage, mold and recovery are at their preset positions.

Distance to Carriage Forward

Enter the distance from the Carriage Forward position that the shut-off nozzle should open. This field works in conjunction with the Open at Mold, Carriage and Recovery Set Position option.

Modifying Injection Setpoint Profiles 6–27


6.4.3 Modifying Injection Setpoint Profiles

There are two methods for modifying step type setpoint profiles:

• Profile Configuration Method• Profile Graph Drag and Drop Method

NOTE: To modify setpoint profiles using the Profile Configuration Method refer to Section 4.2.3.

NOTE: To modify setpoint profiles using the Profile Graph Drag and Drop Method refer to Section 6.2.1.1.

6.4.4 Setting Up the Adaptive Cooling Parameters

To setup the Adaptive Cooling parameters, do the following:

1. On the HMI, press the <INJECTION> key and touch the RECOVERY tab to display the Recovery screen.

Distance to Mold Close

Enter the distance from the Mold Closed position that the shut-off nozzle should open. This field works in conjunction with the Open at Mold, Carriage and Recovery Set Position option.

Distance to Recovery Complete

Position

Enter the distance of before recovery is complete. Recovery complete is shot size plus pullback distance (if applicable).This field works in conjunction with the Open at Mold, Carriage and Recovery Set Position option.

Table 6-8 SHUT-OFF NOZZLE Pop-up Window Descriptions (Continued)

Element Description

Polaris — v2009.3

6–28 Setting Up the Adaptive Cooling Parameters

2. Under Adaptive Cooling, select the Enable check box.

3. Touch the More button. The Adaptive Cooling dialog box appears.

NOTE: Note the setpoint value for Adaptive Cooling can only be modified through the Adaptive Cooling dialog box.

Figure 6-14 Recovery Screen

1. Enable Check Box 2. More Button

1

2

Setting Up the Adaptive Cooling Parameters 6–29


4. Select the Enable Adaptive Cooling check box.

5. Use the slider to increase or decrease the setpoint value. Increasing the value will maximize the roundness correction, while lowering the value will lower the exit temperature of the preform.

6. Touch the Exit button to close the dialog box.

Figure 6-15 Adaptive Cooling Dialog Box

1. Slider 2. Enable Adaptive Cooling Check Box 3. Setpoint Value 4. Actual Value 5. Exit Button

1

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3

Polaris — v2009.3

6–30 EXTRUDER GRAPH Screen

6.5 EXTRUDER GRAPH Screen

The EXTRUDER GRAPH screen allows a user to view continuous traces of extruder transfer speed and transfer pressure.

NOTE: This screen is only available on machines with P-Injection units.

Press <INJECTION> key, then touch the EXTRUDER GRAPH tab. Refer to Figure 6-16.


NOTE: Curves displayed on this screen are selected on the CURVE SELECTION pop-up window - refer to Section 2.4.1.

Figure 6-16 EXTRUDER GRAPH Screen

EXTRUDER GRAPH Screen 6–31


Table 6-9 EXTRUDER GRAPH Screen Descriptions

Element Description

Transfer Pressure Graph

Transfer Speed Graph

Touch this button to save the extruder graphing data as a group of ideal curves. Pressing this button also displays the Ideal Curves button shown below.

When the Ideal Curves button appears beneath the graph it indicates that a group of ideal curves for the extruder is saved in the machine.



When this button appears beneath the graph it indicates that "ideal" values are displayed along with the real-time machine extruder data. The ideal values remain plotted on the graph.

Transfer Speed Displays the real-time transfer speed.

Transfer Pressure Displays the real-time transfer pressure.

Extruder Position Displays the actual position of the extruder.

Polaris — v2009.3

6–32 EXTRUDER GRAPH Screen

Touch this button to display the color-coded legend for Extruder Pressure, Extruder Velocity, Ideal Extruder Pressure, and Ideal Extruder Velocity.

Touch the button again to dismiss the legend.

Transition Position Displays the actual transition position value from the previous cycle.

Injection Fill Time Displays the actual injection fill time from the previous cycle.

Transfer Cushion Displays the actual transfer cushion value from the previous cycle.

Table 6-9 EXTRUDER GRAPH Screen Descriptions (Continued)

Element Description

RECOVERY GRAPH Screen 6–33


6.6 RECOVERY GRAPH Screen

The RECOVERY GRAPH screen allows a user to view continuous traces of screw rpm, back pressure, screw rpm profile, and back pressure profile plotted against position.

Press <INJECTION> key, then touch the RECOVERY GRAPH tab. Refer to Figure 6-17.


NOTE: Curves displayed on this screen are selected on the CURVE SELECTION pop-up window - refer to Section 2.4.1. On machines with electric screw drive the screw torque can also be selected for graphing.

Figure 6-17 RECOVERY GRAPH Screen

Polaris — v2009.3

6–34 RECOVERY GRAPH Screen

Table 6-10 RECOVERY GRAPH Screen Descriptions

Element Description

Recovery Graph

1 – Screw Recovery rpm Scale, 2 – Recovery Back Pressure Scale,

3 – Recovery Distance Scale

Touch this button to save the recovery graphing data as a group of ideal curves. Pressing this button also displays the Ideal Curves button shown below.

When the Ideal Curves button appears beneath the graph it indicates that a group of ideal curves for recovery is saved in the machine.



When this button appears beneath the graph it indicates that "ideal" values for screw recovery rpm, back pressure, and recovery distance are displayed along with the real-time machine recovery data. The ideal values remain plotted on the graph.

Screw Speed Displays the real-time screw speed.

Back Pressure Displays the real-time back pressure.

Injection Pos. Displays the actual position of the injector.

Touch this button to display the color-coded legend for Injection Pressure, Screw rpm (actual), Screw rpm Setpoint, Ideal Injection Pressure, Ideal Screw rpm, and Back Pressure Setpoint.

Touch the button again to dismiss the legend.

Shot Size Displays the actual shot size from the previous cycle.

Screw Run Time Displays the actual amount of time (in seconds) that the screw was turning during the previous cycle.

Max Fill Pres. Displays the actual maximum fill pressure from the previous cycle.

1 2 3




The (Injection) VALVES STATUS screen allows a user to view the actual voltage signals, pressure, and on/off status of injection valves and pressure transducers.

Press <INJECTION> key, then touch the VALVES STATUS tab. For RS injection units refer to Figure 6-18, and for P-Injection units refer to Figure 6-19.

NOTE: Screens shown are representative, and may vary depending on how the machine is configured.

Figure 6-18 VALVES STATUS Screen (RS Injection)

Polaris — v2009.3


The grey text boxes display actual voltage values at the digital valves.

The digital input indicator ( ) lights up when the machine controller receives a signal from a device; otherwise it remains grey.

The digital output indicator ( ) lights up when the device receives a signal from the machine controller; otherwise it remains grey.

Table 6-11 describes the abbreviations used to represent the valves and pressure transducers displayed on screen.

Figure 6-19 VALVES STATUS Screen (P-Injection)

Table 6-11 (Injection) VALVES STATUS Screen Descriptions

Abbreviations Description

DP Digital pressure control

DQ Digital flow control

Kxx Relay/Contactor number

PC Pressure (Clamp)

PE Pump (Extruder)

PI Pressure (Injection)

PP Proportional pressure valve

PQ Proportional flow valve

PS Pump (System)

PT Pressure transducer

SD Servo valve



PX Proximity Switch

M Motor

Table 6-11 (Injection) VALVES STATUS Screen Descriptions (Continued)

Abbreviations Description

Polaris — v2009.3


HMI Reference Manual Polaris — v2009.3 Heats

SETUP, MACHINE, MOLD and NOZZLE TIPS Screens 7–1

Chapter 7 Heats

The Heats screens allow a user to enable and disable machine heats, heats standby modes, and view/change temperature settings.

7.1 SETUP, MACHINE, MOLD and NOZZLE TIPS Screens

The SETUP, MACHINE, MOLD and NOZZLE TIPS screens allow a user to view and control the heats and heats standby modes for the machine, mold and nozzle tips.

Press the <HEATS> key to display the heats screens, then touch the appropriate tab to display the desired screen. Refer to Figure 7-1 for machines with RS injection units, and Figure 7-2 for machines with P-Injection units.


NOTE: The general principles of machine heats control as described here are valid no matter how the machine is configured.


7–2 SETUP, MACHINE, MOLD and NOZZLE TIPS Screens

Figure 7-1 HEATS Screens (RS-Injection Units)

1. Zone Setup Box 2. Heat Zone Bar 3. Heats Enable check box 4. Soft Start check box 5. Self Tune check box 6. Use Heats Scheduler check box 7. Heats Scheduler button 8. Soak time input field 9. Standby check box 10. Machine Idle Standby Delay check box 11. Mold Type button 12. Global Setpoint Adjuster 13. Nozzle Tips Zone Duty Cycle

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7

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13



Figure 7-2 HEATS Screens (P-Injection Units)

1. Zone Setup Box 2. Heat Zone Bar 3. Heats Enable check box 4. Soft Start check box 5. Self Tune check box 6. Use Heats Scheduler check box 7. Heats Scheduler button 8. Soak time input field 9. Standby check box 10. Machine Idle Standby Delay check box 11. Mold Type button 12. Resin Temperature 13. Global Setpoint Adjuster 14. Nozzle Tips Zone Duty Cycle

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13

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14





Table 7-1 HEATS Screen Descriptions

Element Description

Touch the Zone Setup box to setup the temperature and other control parameters for each heat zone. Refer to Section 7.1.1.

The heat zone bar provides a graphical representation of the zone temperatures and setpoint values.

1 – Actual temperature

NOTE: The temperature will only be displayed if a thermocouple is used to control temperature.

2 – Setpoint temperature

3 – Current heater power output as a percentage of total available heater power

4 – Heater temperature indicator (Blue = low, Green = normal, Red = high, Yellow = low/high deviation)

NOTE: The indicator will be displayed only if temperature control is in Auto mode.

Heats Enable Select the check box to enable power globally to all heaters on the displayed screen. Clear the check box to disable heats.

Soft Start Select the check box to enable the heater soft start feature. Soft start allows the heaters to heat up progressively without surging. Clear the check box to disable soft start.

Adaptive Tune Select the check box to enable adaptive tuning. To use the adaptive tune refer to Section 7.1.3.

This option is available on HyPET HPP machines only.

Self Tune Select the check box to enable self tuning. The check box will be cleared automatically when self tuning is completed successfully. To use self tuning refer to Section 7.1.2.

NOTE: All temperature zones come with default tuning parameters.

Heats Scheduler Displays if the Heat Scheduler is in use.

Touch the Heat Scheduler button to display the HEATS SCHEDULER pop-up window to set up events to turn the heaters On and Off. Refer to Section 7.1.4.

Soak Time Enter the value for Soak Time. Soak time starts after the setpoint temperature is reached.

3

12

4



Standby Select this check box to enable heats standby. Clear the check box to disable.

Enter the value of the Standby setpoint temperature in the adjacent field.

When heats are on standby, the temperature of all heat zones on the current screen is reduced and maintained at the standby setpoint temperature.

Machine Idle Standby Delay

Select this check box to enable the machine heats to go into standby mode when the machine is idling. Enter the Standby delay time in the adjacent field.

When standby mode is enabled on the MACHINE or MOLD screens, the machine waits for the period of time set in the Standby Delay field before switching to standby heats.


Mold Type button Select this button to display the MOLD TYPE pop-up window and select the type of mold used on the machine - refer to Section 7.1.5.

Machine Idle Shutoff Delay

Select this check box to enable shutoff delay. Clear the check box to disable this function.

Enter the Shutoff delay time in the adjacent field.

When shutoff delay is enabled on the NOZZLE TIPS screen, the nozzle heats switch off after the period of time set in the Shutoff Delay field.

Resin Temperature Displays the actual resin temperature.

NOTE: This field is only displayed on the Machine heats screen.

Nozzle Tip Zone Duty Cycle

Enter the percentage of time that the temperature is turned On and Off for Nozzle Tip temperature control.

NOTE: This field is only displayed on the NOZZLE TIPS screen.

Use the Global Setpoint Adjuster to globally set the temperature setpoint, high and low alarm setpoints, and set up soft start for all heat zones on the selected screen.

Touch the Global Change button to display the GLOBAL CHANGE pop-up window - refer to Section 7.1.6.

Use the Up/Down buttons to globally change all the temperature setpoint values on the screen.

Touch the Up button to increase the setpoint value by a value of "1"

Touch the Down button to decrease the setpoint value by a value of "1"

NOTE: On the NOZZLE TIPS screen only, you can adjust the setpoint value by any value between 1 and 100. Enter the desired value in the Heat Adjuster field. Use the Up or Down button to adjust the setpoint value of all zones on that screen by that amount.

Table 7-1 HEATS Screen Descriptions (Continued)

Element Description



For larger molds the Heats screen is divided into tabs to accommodate the number of zones. The table below defines the abbreviations for the zones used.

Figure 7-3 Mold Heats Screen - For Large Molds

Table 7-2 Heat Zone Naming Conventions

Zone Location Definition Abbreviation Example

Sprue Sprue SB SB

Top Manifold

Top Cross Sprue TXS TXS

Top Cross Manifold Body TXMB TXMB2

Top Cross Manifold (Drop) TXM TXM1

Cross Manifold

Cross Sprue XS XS1

Cross Manifold Body XMB XMB1

Cross Manifold (Drop) XM XM1

Transition Bushing Transition Bushing TB TB1

Main Manifold Main Manifold MM MM2

HEAT ZONE SETUP Pop-up Window 7–7


7.1.1 HEAT ZONE SETUP Pop-up Window

The HEAT ZONE SETUP pop-up window allows a user to set up temperature and other control parameters for the zone heaters. There are two types of HEAT ZONE SETUP pop-up windows as shown in Figure 7-4.

NOTE: The type of heat zone setup window displayed will depend on the component type (i.e., nozzle extension, nozzle adaptor, shutoff head, barrel head, barrel zone, feed throat, mold, or nozzle tip). They all share the same basic characteristics regardless of whether they are found on the MACHINE, or MOLD screen.

NOTE: User access rights of Processor, or Maintenance required to select and modify functions.

Figure 7-4 HEAT ZONE SETUP Pop-up Window

1. HEAT ZONE SETUP pop-up window (type 1 – used with barrel head, extruder, adapter, distributor and shooting pot) 2. HEAT ZONE SETUP pop-up window (type 2 – used with mold heat zones)

1

2


7–8 HEAT ZONE SETUP Pop-up Window

Table 7-3 HEAT ZONE SETUP Pop-up Window Descriptions

Element Description

The heat area provides a graphical representation of the zone temperatures and setpoint values.

1 – Enter maximum temperature deviation value above setpoint.

The alarm setpoint high deviation value represents the upper threshold value for temperature. When temperature exceeds this value normal cycling stops, and the HMI displays an alarm.

2 – Enter temperature setpoint value.

3 – Enter minimum temperature deviation value below setpoint.

The alarm setpoint low deviation value represents the lower threshold value for temperature. When temperature falls below this value normal cycling stops, and the HMI displays an alarm.

4 – Heater temperature bar. Refer to TEMPERATURE BAR LEGEND Pop-up window at the end of the table for details.

NOTE: The HMI will auto-scale the temperature bar.

High Alarm Displays the maximum heat range the heater is capable of. When temperature exceeds this value, the HMI displays an alarm message.

NOTE: For the feed throat, enter the maximum heat range value.

Low Alarm Displays the minimum heat range the heater is capable of. When temperature falls below this value, the HMI displays an alarm.

NOTE: For the feed throat, enter the minimum heat range value.

Temperature Displays actual temperature.

Range Enter adjustment limit for operators who only have limited access to modify setpoint values.

NOTE: Only users with sufficient access rights can view and modify this field.

NOTE: There is no slider for this function. This value affects the temperature setpoint. When the field is selected, a numeric touchpad appears. For users with limited access, the range of adjustment allowed with the Up/Down arrows on the numeric touchpad is determined by this value.

Control

Auto Select this option button to activate machine temperature control (i.e., the controller attempts to maintain the setpoint temperature).

NOTE: This option button is default for machine heat zones, and cannot be selected or deselected.

Auto Tune Enable Select this check box to enable the self-tune or adaptive tune feature for this zone only. Clear the check box to disable.

12

34

Self Tuning 7–9


7.1.2 Self Tuning

Self tuning can be used to optimize temperature control for the machine, mold or nozzle tips. Self tuning allows greater thermal stability and faster machine warm up from room temperatures.

Self tuning should be performed when the machine is started up for the very first time, or whenever a heat zone is modified, or a mold is replaced, or whenever thermal characteristics are significantly different, or when troubleshooting heat problems.

NOTE: Self tuning is performed at the factory before the machine is shipped.

NOTE: Typically, heat zones that are physically adjacent to one another should be tuned together.

NOTE: User access rights of Processor or Maintenance required to use this function.

Set up self tuning for individual heat zones using the following instructions:

1. Allow the machine to cool down to room temperature.

2. Press the <HEATS> key and select the appropriate tab – Machine, Mold or Nozzle Tips. Refer to Figure 7-2.

3. Set the temperature setpoints for all heat zones that need to be tuned to processing temperature values.

NOTE: It is important to ensure that there is a temperature difference of at least 160 °C (320 °F) between room temperature and setpoint values.

Enable Select this check box to enable power to the individual heat zone. Clear the check box to disable.

NOTE: This check box is only available on mold heat zones.

NOTE: When the check box is cleared, the icon for the zone setup box changes to indicate that it is disabled.

Touch this button to display the TEMPERATURE BAR LEGEND pop-up window shown below. It describes what the different colors indicate.

Table 7-3 HEAT ZONE SETUP Pop-up Window Descriptions (Continued)

Element Description


7–10 Self Tuning

4. Touch the Heat Zone Setup box to display the pop-up window – refer to Figure 7-5. Check that Auto Tune Enable and Enable check boxes are selected. Close the pop-up window.

5. Select the Heats Enable check box on the appropriate heats tab.

6. Then select the Self Tune check box on the SETUP tab. The check box will remain selected while self tuning is in progress. When self tuning is completed successfully the zone temperature will stabilize around the setpoint value, and the check box will be cleared automatically.

If self tuning fails, the "Self Tuning Failed" alarm will be displayed for each failed zone, and parameters from the last successful tuning will then be applied for those zones.

NOTE: The "Machine (or Mold, or Nozzle Tips) Heats Self Tuning Selected But Not Enabled" alarm will be displayed if self tuning did not initiate successfully. Manually clear the Self Tune check box, and repeat the self tuning procedure.

NOTE: Altering any settings while self tuning is in progress will terminate self tuning.

Figure 7-5 HEAT ZONE SETUP Pop-up Window

Adaptive Tune (HPP only) 7–11


7.1.3 Adaptive Tune (HPP only)

Adaptive Tune is available on HyPET HPP machines instead of Self Tune. Adaptive tune is used to tune the mold heats controllers only.

7.1.3.1 Setting Up Adaptive Tune

To setup specific mold heats to use Adaptive Tune, do the following:

1. Press the <HEATS> key and select the MOLDS tab. Refer to Figure 7-2.

2. Set the temperature setpoints for all heat zones that need to be tuned to the desired setpoint.

3. Touch the Heat Zone Setup box to display the pop-up window – refer to Figure 7-5. For each controller to be tuned, make sure that Auto Tune Enable and Enable check boxes are selected. Close the pop-up window.

7.1.3.2 Performing Adaptive Tune

To tune the mold heats using Adaptive Tune, do the following:

1. Make sure the machine is not cycling.

NOTE: It is recommended that the mold heats are close to the desired operating temperature.

2. Press the <HEATS> key and select the SETUP tab. Refer to Figure 7-2.

NOTE: Adaptive tune takes up to one hour. This time does not include the time required to heat up the mold heats to the operating temperature setpoints.

Figure 7-6 HEAT ZONE SETUP

IMPORTANT!The machine can not be cycling during the Adaptive Tune process and should be stopped prior to starting the Adaptive Tune


7–12 Stopping Adaptive Tune

3. Select the Adaptive Tune check box. A confirmation dialog box appears.

4. Touch OK to continue or Cancel to cancel adaptive tuning.

5. In the ALARMS screen, a message appears for each zone that is tuning and the check box will remain selected while Adaptive Tune is in progress.

6. Once Adaptive Tune is complete, the check box is cleared and the alarm messages are greyed out.

If adaptive tune fails to complete, the "Adaptive Tune Failed" alarm will be displayed for each failed zones.

7.1.3.3 Stopping Adaptive Tune

To stop Adaptive Tune while it is in progress, do the following:

1. Press the <HEATS> key and select the Setup tab. Refer to Figure 7-2.

2. Deselect the Adaptive Tune check box. A confirmation message appears.

3. Click OK to cancel Adaptive Tune or click OK to continue tuning.

The Adaptive Tune check box will be unchecked and the alarm messages on the Alarm screen will be greyed out.

7.1.4 HEATS SCHEDULER Pop-up Window

The Heats Scheduler is used to set up events to turn the heaters On and Off.

Touch the Heats Scheduler button for the machine or mold heats on the SETUP heat screens to display the HEATS SCHEDULER pop-up window. Refer to Figure 7-7.

NOTE: The Heats Scheduler for machine and mold heats are similar, but they are accessed separately from their respective screens. The status bar displays a black stripe to

Figure 7-7 HEATS SCHEDULER Pop-up Window

1. Active heats scheduler 2. Inactive heats scheduler

12

MOLD TYPE Pop-up Window 7–13


indicate the currently active Heats Scheduler; the other is greyed out. The red triangle indicates the current day of the week.


7.1.5 MOLD TYPE Pop-up Window

The MOLD TYPE pop-up window is used to select the type of mold used on the machine. Selecting the mold type allows automatic mold heats zone configuration on the HMI screen.

Touch the Mold Type button on the SETUP screens to display the MOLD TYPE pop-up window. Refer to Figure 7-8. Select the appropriate mold type installed on the machine.


7.1.6 GLOBAL CHANGE Pop-up Window

The GLOBAL CHANGE pop-up window is used to globally set the temperature setpoint, high and low alarm setpoints, and set up soft start for all heat zones on the selected screen.

Touch the Global Change button on the MACHINE, MOLD, or NOZZLE TIPS heat screens to display the GLOBAL CHANGE pop-up window for that screen. Refer to Figure 7-9.

Table 7-4 HEATS SCHEDULER Pop-up Window Descriptions

Element Description

Setting "n"

Use Select a check box to enable a Heats Scheduler event.

NOTE: Up to seven events can be enabled – one for each day of the week.

On From the drop-down menu select the day of the week to start the Heats Scheduler event.

Start Time Enter the start time in HH:MM (24-hour) format.

Standby/Off Select to put the heats into Standby or Off.

From the drop-down menu select the day of the week for the Heats Scheduler event to stop or go into standby.

End Time Enter the stop time in HH:MM (24-hour) format.

Figure 7-8 MOLD TYPE Pop-up Window


7–14 GLOBAL CHANGE Pop-up Window

NOTE: The Global Setpoint Adjuster for Machine, Mold and NOZZLE TIPS are similar, but they are accessed separately from their respective screens.


Figure 7-9 GLOBAL CHANGE Pop-up Window

Table 7-5 GLOBAL CHANGE Pop-up Window Descriptions

Element Description

Setpoint Enter the temperature setpoint value.

High Alarm Enter the maximum heat range the heater is capable of. When temperature exceeds this value, the HMI displays an alarm message.

Low Alarm Enter the minimum heat range the heater is capable of. When temperature falls below this value, the HMI displays an alarm.

Soft Start

Soft start is used primarily to reduce heater band failure. At the conclusion of soft start, normal heat control is restored. Soft start temperature is controllable up to the normal setpoint temperature, and heating power can be adjusted up to the normal limit (i.e., 100%).

Maximum Duty Cycle

During soft start, the power level to the heating band is limited to the percentage value shown in this field.

Enter the desired value of the corresponding heat zone. "Max Duty Cycle" is expressed as the percentage of time that the heater is switched on. Power to the heater is either switched on or off to vary heat output.

Soak Setpoint Enter the value of the Soak Setpoint temperature.

Soak Deviation Band

Enter the value of the Soak Deviation Band temperature.

Soak Time Enter the value of the soak time. The timer starts to count down when the temperature defined in Soak Setpoint is reached.

Soft Start concludes when the timer reaches zero.

COOLING SETUP Screen 7–15


7.2 COOLING SETUP Screen

The COOLING SETUP screen allow a user to view valve status and water flow monitoring as well as setup as the cooling auto shutoff.

Press the <HEATS> key to display the heats screens, then touch the COOLING SETUP tab to display the desired screen.

NOTE: This screen is representative and may vary depending on how the machine is configured.

NOTE: This setup screen is only available on the HyPET machine.


Figure 7-10 COOLING SETUP Screen

Table 7-6 COOLING SETUP Screen Description

Element Description

Valve Status

Stationary Platen Cooling Valve The indicator ( ) lights up when the valve receives a signal to turn On; otherwise it remains grey.

Moving Platen Cooling Valve

Tooling Plate Cooling Valve


7–16 COOLING SETUP Screen

Water Flow Monitoring

Stationary Platen Water Flow Normal

The indicator ( ) lights up when a signal from the device sensing flow in the circuit; otherwise it remains grey.

Moving Plate Water Flow Normal

Tooling Plate Water Monitoring

Cooling Auto Shutoff

Delay Timers Enable Select the checkbox to enable the auto shutoff option. This option will turn off the valves after the machine has been in idle mode with the valves On for a specified amount of time. The time is specified by the Mold Cooling Delay Off Time and the Tooling Plate Cooling Delay Off Time. This helps prevent mold sweating.

Mold Cooling Off Delay Time Enter the value for the time delay for the auto shutoff option.

Tooling Plate Cooling Off Delay Time

Displays the time delay of 1 minute. This is not an adjustable value.

Table 7-6 COOLING SETUP Screen Description (Continued)

Element Description

HMI Reference Manual Polaris — v2009.3 Product Handling

SETUP Screen 8–1

Chapter 8 Product Handling

The Product Handling screens allow a user to set up the Tooling Plate, CoolPik, safety interlocks, and photoeyes.

Press the <PRODUCT HANDLING> key to display the product handling screens.

8.1 SETUP Screen

The (Product Handling) SETUP screen is used to set up the Tooling Plate, CoolPik and safety interlocks.

Press the <PRODUCT HANDLING> key to display the SETUP tab – refer to Figure 8-1.


NOTE: User access rights of at least Operator required to select and modify functions.

Figure 8-1 (Product Handling) SETUP Screen

Polaris — v2009.3

8–2 SETUP Screen

CAUTION!Improper settings will cause severe equipment damage.

• Setup procedure must be performed by qualified personnel.• After changing a mold, verify clearances between Tooling Plate and molding

machine before cycling molding machine.

Table 8-1 (Product Handling) PRODUCTION Screen Description

Element Description

Tooling Plate In/Out

Stage Enabled The stage indicators light up when the stage is enabled. To enable the stage refer to Section 8.1.1.

In Position Enter the Tooling Plate In position for each stage. Use the TOOLING PLATE STAGE POSITIONS CALCULATOR to determine the correct stage position values – refer to Section 8.1.2.

Out Position Enter the Tooling Plate Out position for each stage. Use the TOOLING PLATE STAGE POSITIONS CALCULATOR to determine the correct stage position values – refer to Section 8.1.2.

Occupied The indicators light up when each stage is occupied by preforms.

Vacuum The indicators light up when vacuum is turned on for each stage.

Air Blow The indicators light up when air blowing is turned on for each stage.

In The indicators light up when the Tooling Plate is in the In position at each stage.

Out The indicators light up when the Tooling Plate is in the Out position at each stage.

Tooling Plate In/Out Speeds

Auto/Manual Enter the speed at which the Tooling Plate moves in or out of the mold area in Auto, Semi or Manual mode.

Jog Enter the speed at which the Tooling Plate moves in the Setup mode.

SETUP Screen 8–3


Tooling Plate

Configuration Touch the button to display the CONFIGURATION pop-up window to configure and enable the stages refer to Section 8.1.1.

In/Out Stage Calculator

Touch the button to display the TOOLING PLATE STAGE POSITIONS CALCULATOR pop-up window – refer to Section 8.1.2.

Clear Occupied Stages

Touch the button to display the CLEAR OCCUPIED STAGES pop-up window shown below.

Click on the appropriate checkboxes that require clearing as indicated by the Occupied lights.

This function is used primarily when a cycle is interrupted.

CoolPik Rotation

Vertical Enter the angle at which the CoolPik picks up preforms from the Tooling Plate. The grey field displays the actual angle.

The indicator lights up when the CoolPik is in the vertical position.

Horizontal Enter the angle at which the CoolPik releases preform onto the conveyor. The grey field displays the actual angle.

The indicator lights up when the CoolPik is in the horizontal position.

CoolPik Rotation Speed

Auto/Manual Enter the rotational speed of the CoolPik in Auto, Semi or Manual mode.

Jog Enter the rotational speed of the CoolPik in the Setup mode.

Machine Protection

Mold Position for Tooling Plate Safe

to Enter

Enter the minimum mold stroke position at which the Tooling Plate can safely enter the mold area. The grey field displays the actual mold position.

The indicator lights up when the mold stroke position is equal to greater than this setpoint value.

Table 8-1 (Product Handling) PRODUCTION Screen Description (Continued)

Element Description

Polaris — v2009.3

8–4 SETUP Screen

Mold Position for CoolPik Safe to

Enter

Enter the minimum mold stroke position at which the CoolPik can safely rotate.

The indicator lights up when the mold stroke position is equal to greater than this setpoint value.

Ejector Position for Tooling Plate Safe

to Enter

Enter the minimum ejector stroke position at which the Tooling Plate can safely enter the mold area. The grey field displays the actual ejector position.

The indicator lights up when the ejector stroke position is equal to less than this setpoint value.

Tooling Plate Out of Mold Area Position

Enter the minimum Tooling Plate position at which it is considered to be safely out of the mold area. The grey field displays the actual Tooling Plate position.

The indicator lights up when the Tooling Plate is outside the mold area.

Table 8-1 (Product Handling) PRODUCTION Screen Description (Continued)

Element Description

CONFIGURATION Pop-up Window 8–5


8.1.1 CONFIGURATION Pop-up Window

The CONFIGURATION pop-up window allows a user to configure the number of Tooling Plate stages, and enable or disable each stage and to select a standard HyPET mold vacuum mapping or a custom vacuum configuration.

NOTE: User access rights of at least Operator required to use this function.

Touch the Configuration button to display the CONFIGURATION pop-up window – refer to Figure 8-2.

Figure 8-2 CONFIGURATION Pop-up Window

Table 8-2 CONFIGURATION Pop-up Window Descriptions

Element Description

Tooling Plate Stage Configuration

Number of Tooling Plate Stages

Enter the number of Tooling Plate stages. Enter a value between 1 and 3.

NOTE: You cannot change the number of stages unless all configured stages are clear and unoccupied.

Vacuum Configuration

Standard HyPET Configuration

Select this option for Standard Generation 3.5 HyPET molds.

Custom Configuration

Select this option for molds other than standard Generation 3.5 HyPET molds.

Polaris — v2009.3

8–6 TOOLING PLATE STAGE POSITIONS CALCULATOR

8.1.2 TOOLING PLATE STAGE POSITIONS CALCULATOR

The TOOLING PLATE STAGE POSITIONS CALCULATOR pop-up window allows a user to calculate the Tooling Plate In and Out stage positions.

NOTE: User access rights of at least Operator required to use this function.

Touch the In/Out Stage Calculator button to display the TOOLING PLATE STAGE POSITIONS CALCULATOR pop-up window – refer to Figure 8-3.

Tooling Plate Setup

Stage Enabled Select the appropriate check box to enable the stage. For example, stage 1, 2 or 3 individually, or stages 1 and 2, or stages 1 and 3, or stages 2 and 3, or stages 1, 2, and 3.

Clear the check box to disable the stage.

Occupied The occupied lights display the current part status of preforms in each stage of the Tooling Plate. If a stage is occupied, the Tooling Plate configuration cannot be modified (i.e. a stage cannot be disabled while it is occupied)

Vacuum Valve Connections

If Standard HyPET Configuration is selected, the boxes display the standard configuration.

If Custom Configuration is selected, the valve configuration can be mapped. Refer to the Tooling Plate Drawings to verify vacuum connections

NOTE: A vacuum connection of 0 means no vacuum is currently configured.

Vacuum Mapping

HyPET Vacuum Mapping

Displays the standard mapping for a Generation 3.5 HyPET mold.

Custom Configuration

No mapping is displayed.

NOTE: Refer to the Tooling Plate Drawings to verify vacuum connections

Table 8-2 CONFIGURATION Pop-up Window Descriptions (Continued)

Element Description

TOOLING PLATE STAGE POSITIONS CALCULATOR 8–7


Figure 8-3 TOOLING PLATE STAGE POSITIONS CALCULATOR Pop-up Window

Table 8-3 TOOLING PLATE STAGE POSITIONS CALCULATOR Pop-up Window Descriptions

Element Description

Actual Position Displays the actual Tooling Plate stage position values. Refer to the image on the screen to determine the stage number.

Tooling Plate Horizontal Pitch

Enter the value from the label on the Tooling Plate.

In Position Select the check box to enter a Tooling Plate In position value.

Enter one Tooling Plate In position value in the appropriate stage field. Refer to the image on the screen to determine the stage number.

The remaining stage positions are automatically calculated and displayed on the screen.

Out Position Select the check box to enter a Tooling Plate Out position value.

Enter one Tooling Plate Out position value in the appropriate stage field. Refer to the image on the screen to determine the stage number.

The remaining stage positions are automatically calculated and displayed on the screen.

Polaris — v2009.3

8–8 CONFIGURATION Screen

8.2 CONFIGURATION Screen

The CONFIGURATION screen allows a user to select the CoolPik Transfer Type (i.e. vacuum or bladders), set up the bladder, enable or disable the photoeyes used in the Tooling Plate, CoolPik and mold, and perform CoolPik optimization for Generation 3.5 molds.

Press <PRODUCT HANDLING> key, then touch the CONFIGURATION tab. Refer to Figure 8-4.


NOTE: User access rights of at least Operator required to select and modify functions.

Figure 8-4 Product Handling Configuration Screen

Table 8-4 CONFIGURATION Screen Description

Element Description

Part Drop Signal

Enable Select the check box to enable a 1 second pulse to the downstream conveyor. This signal occurs after the CoolPik drops preforms on the conveyor and the conveyor is set to run in the Forward direction. The indicator lights up when the output to the conveyor goes High.

Clear the check box to disable the signal.

Cycle Time Optimization

Enable Select the check box to enable run a more aggressive tooling plate overlap (i.e. optimization) learning algorithm.

CONFIGURATION Screen 8–9


CoolPik

Transfer Type Each time the mold is changed the Transfer Type must be set. Enter the Transfer Type used in the CoolPik from the drop-down list (i.e. Vacuum or Bladders). A warning message will appear any time a selection has been made. The operator has the choice to accept or reject the selection.

Part Drop Angle Enter the angle at which point the CoolPik releases the preforms onto the conveyor. On a vacuum system, the vacuum is turned off. On a bladder system, the bladder deflates. The minimum value is 135 degrees while the maximum value is the CoolPik horizontal position setpoint.

Part Drop Duration Enter the time duration allowed for the part to drop to ensure the preforms are out of the way before the CoolPik is rotated back to the vertical position. The minimum value is 0.3 seconds while the maximum value is 5 seconds.

Tooling Plate

Ejector Position to Start Vacuum

Enter a percentage of the maximum Ejector stroke at which parts are transferred from the Ejector to the Tooling Plate.

Air Blow Start Prior to End of Cooling

Enter the time (in seconds) for the Air Blow valve setpoint. This helps to push the preforms out of the mold. If the Bladders type is selected, the Air Blow Start Prior to End of Cooling setpoint is disabled (i.e. greyed out). A fixed value of 0.5 seconds is used instead.

PhotoEyes Enable

Mold Sensor Enable Select the check box to enable monitoring of preforms in the mold. The photoeyes ensure all parts have been transferred by the ejector to the Tooling Plate. The system checks for a "Blocked" status first, indicating the parts are being transferred, and then for a "Clear" status indicating all parts have been transferred to the Tooling Plate and the Tooling Plate is clear to move out. The Tooling Plate is allowed to move out as soon as the "Clear" status is received.

NOTE: When the mold sensors are enabled the ejector is not required to be back before the Tooling Plate is allowed to move out.

Clear the check box to disable the mold sensors.

NOTE: When the mold sensors are disabled the ejector has to be retracted to the "Ejector Position for Tooling Plate Safe to Exit" position before the Tooling Plate is allowed to move out.

(Enable photoeye) Select the appropriate check box to enable the photoeye to monitor preforms in the Tooling Plate and CoolPik, and in the Mold.

NOTE: The photoeyes are number starting from the Non-Operator Side to the Operator Side of the machine.

Table 8-4 CONFIGURATION Screen Description (Continued)

Element Description

Polaris — v2009.3

8–10 CONFIGURATION Screen

For the HyPET HPP machine the cycle time optimization section is different.

Ignore Ejector Position

Select the check box to set the mandatory ejector retract value to 20 mm less than the ejector forward position and to ignore the Ejector Position Safe to Exit value.

NOTE: This feature must be disabled for interlocked molds (2 -stage Tooling Plates).

NOTE: The Mold Sensors Enabled must be selected to use this feature.

CoolPik Optimization

Enable Mold Gen. 3.5 Optimization

Select the check box to enable optimization of CoolPik for Generation 3.5 molds. The indicator lights up when optimization is turned on by the PLC.

NOTE: If the check box is selected but the indicator remains switched Off, it is likely that a non-Gen 3.5 Mold is selected or the mold stroke is less than the Minimum Mold Open for Optimization value. When this happens CoolPik optimization is not allowed. The "CoolPik Optimization is Not Allowed" alarm is also displayed.

Minimum Mold Open for

Optimization

Displays the minimum mold open position for optimization to occur. Any value less than this will disable optimization, and will only allow the CoolPik to rotate once it has passed the "CoolPik Safe to Rotate Mold Position" shown on the SETUP screen.

Mold Gen. Selected Displays the generation number of the selected mold. If the correct mold heats file has not been set up, this text box will display "unknown."

Figure 8-5 HyPET HPP Optimization

Table 8-5 Cycle Time Optimization

Element Description

CoolPik To Horizontal/Mold Open Optimization

Select this option to enable a learning routine which optimizes (i.e. save cycle time) the CoolPik moving to the horizontal position with the mold opening motion.

CoolPik To Vertical/Mold Close Optimization

Select this option to enable a learning routine which optimizes (i.e. save cycle time) the CoolPik moving to the vertical position with the mold closing motion.

Table 8-4 CONFIGURATION Screen Description (Continued)

Element Description

CONFIGURATION Screen 8–11


Tooling Plate In/Ejector Forward Overlap

Select to enable the Tooling Plate In/Ejector Forward optimization, which will automatically begin a learning routine with the current setup of the tooling plate and ejector, optimizing the time taken for part transfer.

Tooling Plate Speed-Up Optimization

Select to enable the Tooling Plate Speed-Up optimization, which will automatically begin a learning routine with the Tooling Plate which will optimize your current cycle configuration.

Minimum Mold Open for Optimization

Displays the minimum mold open position for optimization to occur. Any value less than this will disable optimization, and will only allow the CoolPik to rotate once it has passed the "CoolPik Safe to Rotate Mold Position" shown on the SETUP screen.

Thermal Position Compensation

Select to enable Thermal Position Compensation which enables compensation to the transfer and part pick position based on the thermal expansion of the mold, CoolPik and Tooling Plate.

Table 8-5 Cycle Time Optimization (Continued)

Element Description

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8–12 DIAGNOSTIC Screen

8.3 DIAGNOSTIC Screen

The DIAGNOSTIC screen allows a user to monitor the status of the interface signals between product handling and molding machine, as well as the state of the inputs and outputs of the Tooling Plate, CoolPik, conveyor and photoeyes.

Press the <PRODUCT HANDLING> key, and touch the DIAGNOSTIC tab – refer to Figure 8-6.


Figure 8-6 DIAGNOSTIC Screen

Table 8-6 DIAGNOSTIC Screen Description

Element Description

Machine Status

(status) Displays the status of machine signals to product handling equipment. The indicators light up when the logic is True.

Product Handling Status

(status) Displays the status of product handling equipment signals to the machine. The indicators light up when the logic is True.

DIAGNOSTIC Screen 8–13


Tooling Plate

(status) Displays the status of Tooling Plate preform cooling, vacuum relief and calibration switch signals. The calibration switch indicator lights up when the calibration switch senses the cam used for calibrating the Tooling Plate servo position. The output indicators light up when the signal to the solenoid goes High.

CoolPik

(status) Displays the status of CoolPik optimization and calibration switch signals. The calibration switch indicator lights up when the calibration switch senses the cam used for calibrating the CoolPik servo position. The optimization indicator lights up when optimization is turned on by the PLC.

NOTE: If optimization is selected but the indicator remains switched Off, it is likely that a non-Gen 3.5 Mold is selected or the mold stroke is less than the Minimum Mold Open for Optimization value. When this happens CoolPik optimization is not allowed. The "CoolPik Optimization is Not Allowed" alarm is also displayed.

Conveyor

(status) Displays the direction in which the conveyor is supposed to be moving. Each indicator lights up when the appropriate output signal to the conveyor goes High.

Photoeyes Clear

(status) Displays the status of photoeyes that monitor preforms in the Tooling Plate, CoolPik or mold. Each indicator lights up when the sensor is clear or the individual photoeye is deselected.

Table 8-6 DIAGNOSTIC Screen Description (Continued)

Element Description

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8–14 SEQUENCE Screen

8.4 SEQUENCE Screen

The SEQUENCE screen allows a user to view the different stages of the product handling sequence. Each indicator lights up as the corresponding stage is active.

Press the <PRODUCT HANDLING> key, and touch the SEQUENCE tab – refer to Figure 8-7.


Figure 8-7 SEQUENCE Screen




The VALVES STATUS Screen allows a user to monitor the status of the valves in the CoolPik system. This screen can be used as a troubleshooting tool to confirm that vacuum/blow is being supplied to the proper valves and stages.

Press the <PRODUCT HANDLING> key, and touch the VALVES STATUS tab – refer to Figure 8-8.

NOTE: Screen shown is representative and may vary depending on how the machine is configured.

Figure 8-8 VALVES STATUS Screen

Table 8-7 VALVE STATUS Screen Description

Element Description

Robot Air Circuit Status

Stage 1 Displays the status of the Stage 1 valve position. The indicators light up when the valve is in either the Blow Position or the Vacuum Position.


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CoolPik Vacuum Displays the CoolPik Vacuum status. The indicator lights up when the valve is in the CoolPik Vacuum Position.

Tooling Plate Blow Displays the Tooling Plate Blow status. The indicator lights up when the valve is in the Tooling Plate Blow Position.

Vacuum Motor On Displays the Vacuum Motor status. The indicator lights up when the Vacuum Motor is On.

CoolJet Motor On Displays the CoolJet Motor status. The indicator lights up when the CoolJet Motor is On.

Vacuum Relief Valve Displays the Vacuum Relief Valve status. The indicator lights up when the Vacuum Relief Valve is Open.

CoolPik Bladder Valve

Displays the CoolPik Bladder Valve status. The indicator lights up when the CoolPik Bladder Valve is Open.

Table 8-7 VALVE STATUS Screen Description (Continued)

Element Description

CONVEYOR Screen 8–17


8.6 CONVEYOR Screen

This screen is used to set the default direction for the product handling conveyor.

The conveyor starts to move in the Conveyor Default Direction when the operating mode is switched from manual to auto or semi.

Figure 8-9 CoolPik Conveyor Screen

Table 8-8 Product Handling Conveyor Screen Descriptions

Field Description

Conveyor Default Direction

Reverse If selected the default direction of the conveyor is reverse. If not selected the default direction will be forward.

Polaris — v2009.3

8–18 CONVEYOR Screen

HMI Reference Manual Polaris — v2009.3 HMI Administrator

USERS Tab 9–1

Chapter 9 HMI Administrator

The HMI Administrator functions are used to manage the various users, user groups, assigned rights and passwords needed to allow access to the machine.


NOTE: User access rights of Administrator required to view, select or modify functions.

9.1 USERS Tab

The USERS tab allows an administrator to manage the various users and the groups to which they are assigned within the HMI.

Touch the Administrator button on the toolbar to display the USERS tab of the ADMINISTRATOR ACCESS screen. Refer to Figure 9-1.

Figure 9-1 ADMINISTRATOR ACCESS – USERS Tab

Polaris — v2009.3

9–2 USERS Tab

Table 9-1 ADMINISTRATOR ACCESS – USERS Tab Descriptions

Element Description

User Name Displays the user name selected in the User Name list box.

Full Name Displays the actual user name of the user selected in the User Name list box.

(List Box) Displays all users in the HMI user Database.

HMI Users

Touch this button to display all HMI users in the list box.

Touch this button to create a new user account. Refer to Section 9.1.1.

Touch this button to change the full name of a current user.

NOTE: Click on the name of the user you want to change, or type the user’s name into the User Name field. Make the change to the full name, then touch the Set Name button.

Touch this button to remove a user from the HMI User database.

NOTE: Select the name of the user to be removed, or type the user’s name in the User Name field before pressing the Remove button.

Member Of

Touch this button to list all the HMI groups of which the selected user is a member.

Touch this button to remove the selected user from a selected group.

NOTE: To use this function, the administrator must first choose the user, list the groups the user is a member of, select a group from the groups list, then touch the Remove button.

NT Users

Touch this button to display all registered users in the local NT User Management and Security database.

Touch this button to add a user defined in the NT system to the HMI system.

OPEN ACCOUNT Pop-up Window 9–3


9.1.1 OPEN ACCOUNT Pop-up Window

The OPEN ACCOUNT pop-up window allows an administrator to create a new HMI user account. Refer also to the example in Section 9.4.1.

Touch the Create button on the USERS tab of the ADMINISTRATOR ACCESS screen to display this screen. Refer to Figure 9-2.

Figure 9-2 OPEN ACCOUNT Pop-up Window

Table 9-2 OPEN ACCOUNT Pop-up Window Descriptions

Element Description

User Name Enter the user name as it will appear on the HMI.

Full Name Enter the actual user’s name.

Password Enter the password the new user will need to log on to the machine.

Confirm Password Re-enter the new user’s password.

Domain Enter the domain name defined for the machine if you connect over a network.

NOTE: Local machine users should leave this field blank.

Save To DataKey Select this check box to save the new user name and password information to the datakey.

NOTE: DataKey fields are activated only when a datakey is used to access the machine.

Load DataKey Touch this button to load current user name and password information from the datakey.

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9–4 Programming the DataKey

9.1.1.1 Programming the DataKey

To program an operator’s datakey, follow these instructions.

1. Log on as Administrator.

2. Touch the Administrator button on the toolbar to display the ADMINISTRATOR ACCESS screen.

3. Touch the USERS tab.

4. Remove the Administrator datakey from the machine.

5. Insert the operator’s datakey that needs to be programmed into the machine.

6. Program the datakey as required.

7. Remove the operator’s datakey.

8. Re-insert the administrator datakey.

9. Log off.

9.2 GROUPS Tab

The GROUPS tab allows an administrator to manage the various groups, group members and group rights defined within the HMI.

Touch the Administrator button on the toolbar to display the ADMINISTRATOR ACCESS screen, then touch the GROUPS tab. Refer to Figure 9-3.

Figure 9-3 ADMINISTRATOR ACCESS – GROUPS Tab

GROUPS Tab 9–5


Table 9-3 ADMINISTRATOR ACCESS – GROUPS Tab Descriptions

Element Description

Group Info

Group Name Displays the name of the currently selected group.

Comments Displays any comments assigned to the currently selected group.

HMI Groups

Touch this button to display all HMI groups in the list box.

Touch this button to create a new group account. Refer to Section 9.2.1.

Touch this button to change the comments defined for the selected group.

NOTE: Select the group whose comment information you want to change or type the group name into the Group Name field. Make the change to the comment information, then touch the SetComm button.

Touch this button to remove a group from the system.

NOTE: The administrator must select the name of the group to be removed, or type the group name in the Group Name field before pressing the Remove button.

Group Members

Touch this button to list all users in the selected HMI group.

Touch this button to add or remove users in the selected group. For details, refer to Section 9.2.2.

NT Group Rights

Touch this button to display all rights currently assigned to the group displayed in the NT GroupName field.

Touch this button to remove rights from a selected group.

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9–6 CREATE NEW GROUP Pop-up Window

9.2.1 CREATE NEW GROUP Pop-up Window

The CREATE NEW GROUP pop-up window allows an administrator to create a new HMI group. Refer also to the example in Section 9.4.1.

Touch the Create button on the GROUPS tab of the ADMINISTRATOR ACCESS screen to display this screen. Refer to Figure 9-4.

Figure 9-4 CREATE NEW GROUP Pop-up Window

Table 9-4 CREATE NEW GROUP Pop-up Window Descriptions

Element Description

New Group

Group Name Enter the group name as it will appear on the HMI.

Description Enter a comment or description to identify the group.

Members

(List Box) Lists all the members (users) assigned to the group.

Touch this button to add a user to the selected HMI group. For details, refer to Section 9.2.2.

Touch this button to remove a user from the selected group.

NOTE: To use this function, the administrator must first choose the user from the user list then touch the Remove button.

ADD/REMOVE USER IN GROUP Pop-up Window 9–7


9.2.2 ADD/REMOVE USER IN GROUP Pop-up Window

The ADD & REMOVE USER IN GROUP pop-up window allows an administrator to view and manage users in each defined HMI group account. Refer also to the example in Section 9.4.1.

To access this screen, touch the Add button on the CREATE NEW GROUPS screen. Refer to Figure 9-5.

Figure 9-5 ADD/REMOVE USER IN GROUP Pop-up Window

Table 9-5 ADD/REMOVE USER IN GROUP Pop-up Window Descriptions

Element Description

Users In Group Displays the name of the selected group.

(List Box) Lists all current members of the group.

Users

(List Box) Displays the user names and full names of all users not currently assigned to the selected group.

Touch this button to add a selected user to the group.

Touch this button to remove a selected user from the group.

Polaris — v2009.3

9–8 RIGHTS Tab

9.3 RIGHTS Tab

The RIGHTS tab allows the administrator to assign rights to users and groups and to remove rights from users and groups.

NOTE: Only those rights currently defined in the HMI can be assigned or removed. Rights cannot be created or deleted using this screen.

Touch the Administrator button on the toolbar to display the ADMINISTRATOR ACCESS screen, then touch the RIGHTS tab. Refer to Figure 9-6.

Figure 9-6 ADMINISTRATOR ACCESS – RIGHTS Tab

Table 9-6 ADMINISTRATOR ACCESS – RIGHTS Tab Descriptions

Element Description

Right Info

Right Name Displays the name of the right currently highlighted in the list box.

Comments Displays any comment or description associated with the right currently highlighted in the list box.

Rights List Touch the Rights List button to list all rights currently defined for the HMI.

OTHERS Tab 9–9


9.4 OTHERS Tab

The OTHERS tab allows an administrator to change user passwords.

NOTE: This screen enables the administrator to change a user’s password without having to know the user’s current password. This function can be used to permit access to users who have forgotten their passwords, or to "lock out" a user to prevent machine access.

Touch the Administrator button on the toolbar to display the ADMINISTRATOR ACCESS screen, then touch the OTHERS tab. Refer to Figure 9-7.

User Rights

(User Rights drop-down list)

Use this drop-down list to select a user currently defined within the HMI.

User Rights List Touch this button to display all rights currently assigned to the user selected in the User Rights drop-down box.

Assign User Privilege

Touch this button to assign additional rights to the user selected in the User Rights drop-down box.

Deny User Privilege

Touch this button to remove specific rights from the user currently selected in the User Rights drop-down box.

Group Rights

(Group Rights drop-down list)

Use this drop-down list to select a group currently defined within the HMI.

Group Right List Touch this button to display all rights currently assigned to the group selected in the Group Rights drop-down box.

Assign Group Right

Touch this button to assign a new right to the group selected in the Group Rights drop-down box.

NOTE: Use the GROUPS tab to remove rights from a specific group.

Table 9-6 ADMINISTRATOR ACCESS – RIGHTS Tab Descriptions (Continued)

Element Description

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9–10 OTHERS Tab

Figure 9-7 ADMINISTRATOR ACCESS – OTHERS Tab

Table 9-7 ADMINISTRATOR ACCESS – OTHERS Tab Descriptions

Element Description

Change Password

User Name Enter the user’s name currently recognized by the HMI.

Password Enter the new password for the user.

Domain Enter the domain only if you are connecting over a network.

NOTE: Local machine users should leave this field blank.

Touch this button to change the password for the selected user.

Touch this button to cancel the change in password for the selected user.

Update DataKey Select the check box to save the new user name and password information to the datakey.


Change System Time

User Name Enter the name of the user whose privileges you would like to modify.

Creating New User Account and User Group - Example 9–11


9.4.1 Creating New User Account and User Group - Example

In general, when you create a new user account and assign a password for the account, you also assign it certain user access rights. There are two ways to assign user access rights. You can assign the user account to a user group, which then allows it to take on all the user access rights that the user group enjoys, or you can assign individual user access rights to the user account. You can also assign both group and individual user access rights to a user account.

A user access right is a specific set of permissions that can be assigned to a user account. The machine comes with a set of user access rights such as View, Slider, Operator, Processor, Maintenance etc. The View access right allows a user to only view the screens, whereas the Slider access right allows a user to use the sliders and switch language and units. The Operator access right allows a user to change operator setpoints and switch language and units, and so on. You cannot modify, create or delete user access rights, however you can create user groups with different combinations of user access rights.

The example below discusses in detail a variety of tasks:

• Creating a new user account and assigning a password• Creating a new user group• Assigning specific user access rights to the newly created user group• Adding (or removing) a new user account to a newly created, or other existing user

groups • Assigning (or revoking) individual user access rights to new user account

Use the following instructions to create a new user account "John Doe", and add the user account to a newly created user group "Operator-3".

NOTE: User access rights of Administrator required to perform these tasks.

1. Log in as Administrator, or insert the Administrator datakey into the HMI, and select the HMI Administrator button on the toolbar in the HMI.

2. Select the Users tab.

Enable Touch this button to assign system time modification privilege to the user.

Disable Touch this button to revoke system time modification privilege from the user.

Table 9-7 ADMINISTRATOR ACCESS – OTHERS Tab Descriptions (Continued)

Element Description

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9–12 Creating New User Account and User Group - Example

3. Touch the Create button to display the Open Account pop-up window shown below.

4. Enter a user name, the user’s full name, and assign a password.

Figure 9-8 Users Tab

1. Create Button

Figure 9-9 Open Account Window

1. Confirm Button

1

1



To program a datakey for the new user account, remove the Administrator datakey and insert a new (blank) datakey into the HMI. Select the Save to Datakey check box.

NOTE: You can only program blank datakeys that are pre-formatted by Husky.

5. Select the Confirm button to complete the creation of a new user account. Remove the new user datakey and insert the Administrator datakey into the HMI.

6. Touch the List button in the HMI Users frame in the Users tab. The newly created user account is then displayed in the list.

7. Select the Groups tab.

Figure 9-10 Users Tab

1. List Button

1

Polaris — v2009.3


8. Select the Create button to display the Create New Group pop-up window shown below.

9. Enter a name ("Operator-3") for the new user group, along with a description. Touch the Add button to display the Add/Remove User in Group pop-up window.

Figure 9-11 Groups Tab

1. Create Button

Figure 9-12 Create New Group Window

1. Add Button

1

1



10. To add a new user account to the group, move the new entry "John Doe" to the list on the left. Touch the Confirm button.

NOTE: To remove a user account from the selected group, transfer the entry from the list on the left to the list on the right.

11. Touch the Confirm button in the Create New Group pop-up window to close the window.

NOTE: To add the user account to other existing groups, first select the group from the list on the Groups tab. If necessary, touch the List button to update the list. Then touch the Change button to display the Add/Remove User in Group pop-up window shown above. Add the user account to an existing group as discussed in step 10.

12. The Groups tab now shows the newly created user group "Operator-3".

Figure 9-13 Add Remove User in Group Window

Polaris — v2009.3


13. Select the Rights tab. From the drop-down list in the Groups Rights frame select the newly created user group "Operator-3".

14. Touch the Rights List button to display the full list of available rights that can be assigned to a group.

15. Select a Right Name in the list on the left, then touch the Assign Group Right button. The selected right is assigned to the user group "Operator-3".

16. Repeat step 15, as necessary, to assign other rights to the group.

Figure 9-14 Groups Tab

Figure 9-15 Rights Tab

1. Rights List button 2. Group Rights List 3. Assign Group Right Button

1

2

3



17. Touch the Group Rights List button to display all the user rights assigned to the group "Operator-3". All users in the group "Operator-3" will now have all the rights assigned to the group.

A user can belong to several user groups and enjoy the privileges of each group. In addition to that, the Administrator can also assign a user individual rights that may not be enjoyed by other users.

18. To assign an individual right to a user, first select the user account ("John Doe") from the User Rights drop-down list.

19. Select the Rights List button to display the full list of available rights that can be assigned to a group/individual.

20. Select a user right from the list on the left and touch the Assign User Privilege button. The selected user right is assigned to the user account.

NOTE: To revoke a specific user right first list the rights for the user account by selecting the User Rights List button. Then select the user right and touch the Deny User Privilege button.

21. Repeat step 20, as necessary, to assign or revoke other rights.

22. Select the User Rights List button to display all the rights assigned to the new user account "John Doe".


1. Group Rights List 2. User Rights List 3. Assign User Privilege button

1

2

3

Polaris — v2009.3



HMI Reference Manual Polaris — v2009.3 HMI Configuration

PASSWORD Tab 10–1

Chapter 10 HMI Configuration

The HMI Configuration function allows a user to modify a password, select display units, select a language, define shift start times, set up the printer defaults, control remote monitoring, backup or restore machine data, set the system time and date, or use other user-defined functions.


10.1 PASSWORD Tab

The PASSWORD tab allows a user to modify the existing password, and to save the information to a datakey.

Touch the HMI Configuration button to display the PASSWORD tab in the HMI CONFIGURATION screen. Refer to Figure 10-1.

NOTE: User access rights of at least Operator Level 1 required to select or modify functions.

Figure 10-1 HMI CONFIGURATION – PASSWORD Tab

Polaris — v2009.3

10–2 UNITS Tab

10.2 UNITS Tab

The UNITS tab allows a user to select the units for all display on the HMI screens, and to save the preferences to the datakey.

Touch this button to display the HMI CONFIGURATION screen, then touch the UNITS tab. Refer to Figure 10-2.

Table 10-1 HMI CONFIGURATION – PASSWORD Tab Descriptions

Element Description

User Name Enter the user name.

Old Password Enter the old password.

New Password Enter the new password.

Confirm Password Enter the new password again.

Touch this button to save the new user name and password information to the datakey.


Save to DataKey Select this check box to enable the Save to DataKey button shown above.

Load DataKey Touch this button to load current user name and password information from the datakey.

Figure 10-2 HMI CONFIGURATION – UNITS Tab

UNITS Tab 10–3



Table 10-2 HMI CONFIGURATION – UNITS Tab Descriptions

Element Description

Unit System Selection

SI–System Select this option button to use metric (System International) units exclusively. Note that the fields in the UNITS area are greyed out when this button is active.

Imperial–System Select this option button to use Imperial units exclusively. Note that the fields in the UNITS area are greyed out when this button is active.

Custom–System Select this option button to select a custom assortment of measurement units from the UNITS area of the tab.

Special Unit Settings

Process Select this check box to display all process type variables as process values (e.g., mm, cubic cm, etc.)

Units

Distance Select the type of unit for distance displays (metric or Imperial).

Pressure Select the type of unit for pressure displays (metric or Imperial).

Temperature Select the type of unit for temperature displays (metric or Imperial).

Tonnage Select the type of unit for tonnage displays (metric tonnes, US tons, or Imperial).

Save To DataKey Touch this button to update the current unit data on the datakey.


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10–4 LANGUAGE Tab

10.3 LANGUAGE Tab

The LANGUAGE tab allows a user to select the language for display on the HMI, and to save the preferences to the datakey.

Touch the HMI Configuration button to display the HMI CONFIGURATION screen, then touch the LANGUAGE tab. Refer to Figure 10-3.


Figure 10-3 HMI CONFIGURATION – LANGUAGE Tab

Table 10-3 HMI CONFIGURATION – LANGUAGE Tab Descriptions

Element Description

Touch this button to open the LANGUAGE SELECTION pop up window. Refer to Figure 10-4.

Save to Datakey Touch this button to update the current language data on the datakey.


LANGUAGE SELECTION Popup Window 10–5


10.3.1 LANGUAGE SELECTION Popup Window

Touch the Language Selection button on the LANGUAGE Tab or on the toolbar to display the LANGUAGE SELECTION popup window.

NOTE: The languages displayed depend on the languages configured for the machine.

10.4 SHIFTS Tab

The SHIFTS tab allows a user to define the start times for various production shifts.

Touch the HMI Configuration button to display the HMI CONFIGURATION screen, then touch the SHIFTS tab. Refer to Figure 10-5.

Figure 10-4 LANGUAGE SELECTION Pop Up Window

Figure 10-5 HMI CONFIGURATION – SHIFTS Tab

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10–6 PRINTER Tab

NOTE: User access rights of Processor, or Administrator required to select or modify functions.

10.5 PRINTER Tab

The PRINTER tab allows a user to configure the printer for the PC.

Touch the HMI Configuration button to display the HMI CONFIGURATION screen, then touch the PRINTER tab. Refer to Figure 10-6.


Table 10-4 HMI CONFIGURATION – SHIFTS Tab Descriptions

Element Description

2 Shifts Select this option button to display only fields for two shifts.

3 Shifts Select this option button to display fields for three shifts.

1st Enter the start time for the first operator shift.

2nd Enter the start time for the second operator shift.

3rd Enter the start time for the third operator shift.

Figure 10-6 HMI CONFIGURATION – PRINTER Tab

BACKGROUND PRINTING CONFIGURATION Pop-up Window 10–7


10.5.1 BACKGROUND PRINTING CONFIGURATION Pop-up Window

The BACKGROUND PRINTING CONFIGURATION pop-up wIndow allows the Administrator to select files for printing in the background. Refer to Figure 10-7.

To access this screen, touch the Configuration button on the Printer tab.

Table 10-5 HMI CONFIGURATION – PRINTER Tab Descriptions

Element Description

Add Printer Double-click on this icon to add a new printer.

No Connection Window When Add Printer

Touch this box to enable/disable the Windows printer wizard.

Show Print Pop-Up Window When Printing

Select this check box to show the printer pop-up window.

Delete Printer Click this button to delete the selected printer.

Set Default Printer Click this button to set the selected printer as the default printer.

Default Printer The default printer is displayed in this field.

Background Printing

Click this button to save all screens to a removable device.

Click this button to print all screens to the default printer.

Click this button to configure print settings. Refer to Section 10.5.1 for details.

Figure 10-7 HMI CONFIGURATION – BACKGROUND PRINTING CONFIGURATION Pop-up WIndow

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10–8 REMOTE Tab

10.6 REMOTE Tab

The REMOTE tab allows a user to enable or disable remote monitoring of the machine over a modem or TCP/IP connection, and to configure the remote connection. In addition, when the Husky Host Interface and SmartLink options are installed an administrator can configure and enable/disable them.

Touch the HMI Configuration button to display the HMI CONFIGURATION screen, then touch the REMOTE tab. Refer to Figure 10-8.

Table 10-6 HMI CONFIGURATION – BACKGROUND PRINTING CONFIGURATION Pop-up Window Descriptions

Element Description

Screen Print Select this check box if you would like to print the whole screen (including the toolbar and sidebars) in the background.

NOTE: You can double-click the Print All label to view a drop-down list of all HMI screens. You can then select the screens you wish to print in the background.

Print All Select this check box is you would like to print all the HMI screens (without the toolbar and sidebars) in the background.

NOTE: You can also double-click the Print All label to view a drop-down list of all HMI screens, then select only those screens you wish to print in the background.

CAUTION!Only plug in the modem that has been validated by Husky and shipped with the machine. Using a different modem may affect the machine functionality, performance or reliability.

REMOTE Tab 10–9



Figure 10-8 HMI CONFIGURATION – REMOTE Tab

Table 10-7 HMI CONFIGURATION – REMOTE Tab Descriptions

Element Description

Remote Connection

Enable Select this option button to enable remote monitoring using the software application NetOp.

NOTE: Select the Connection Type option button prior to selecting this field.

Disable Select this option button to disable remote monitoring.

NOTE: Select the Connection Type option button prior to selecting this field.

Connection Type

Modem Select this option button to monitor remotely over a modem connection.

NOTE: Connect the modem to the COM port, communication line and power source prior to selecting this button.

TCP/IP Select this option button to monitor remotely over a TCP/IP connection.

Computer Information

Computer Name Displays the computer name.

TCP/IP Address Displays the TCP/IP address.

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10–10 Basic Network Troubleshooting

10.6.1 Basic Network Troubleshooting

The following is a list of suggested tips to troubleshoot network problems:

1. Check basic connectivity – use the "Ping" command from the host computer to verify the connection to the Husky machine.

2. Check that Host Interface is enabled.

3. Check that host-side software is configured properly (i.e. IP address, Serial number of machine).

10.6.2 Husky Host Interface

The Husky Host Interface is an optional communications protocol that allows bi-directional data communications between a central host computer and a Husky molding machine hooked up to an Ethernet network supporting TCP/IP. The protocol supports several standard functions such as read process and machine data, and exchange mold setups. It also supports the display of text and graphics. For additional details refer to the Husky Host Interface Protocol Specifications document.

The protocol allows a host computer to initiate a job, read a list of supported languages, read process data, machine status, cycle interruptions, machine events (including alarms, setpoint changes, and machine state changes), SPC data and any SPC parameter changes made by the machine operator. It also allows the machine operator to copy the mold setup from the host computer to the Husky machine or from the machine to the host computer.

The Husky Host Interface option includes all the necessary hardware and software to support the protocol on the Husky molding machine. All other hardware (including the host computer and network) and host-side software must be provisioned by the Customer.

Host-side functions are not discussed here, as they depend on the implementation.

Host Link

Enable Select the check box to enable Husky Host Interface communications between the host computer and the Husky molding machine. Clear the check box to disable communications.

Data Displays the status of the data connection type between the machine and the host computer. Status changes are logged to the Event Log in the machine.

Terminal Displays the status of the terminal connection type between the machine and the host computer.

SmartLink

Enable Select the check box to enable the SmartLink function. Clear the check box to disable it.

Enter the path name for the SmartLink server in the adjoining text field.

Table 10-7 HMI CONFIGURATION – REMOTE Tab Descriptions (Continued)

Element Description

BACKUP Tab 10–11


10.7 BACKUP Tab

The BACKUP tab allows a user to backup and restore all machine parameters, mold setups and robot programs to and from the PC on board the machine.

NOTE: Mold Setups only save a portion of the machine/robot parameters.

Touch the HMI Configuration button to display the HMI CONFIGURATION screen, then touch the BACKUP tab. Refer to Figure 10-9.

NOTE: If the HMI is unable to start up, double-click the icon "Shortcut to Restore.exe" on the desktop to begin the restore procedure.


Figure 10-9 HMI CONFIGURATION – BACKUP Tab

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10–12 BACKUP Tab

Table 10-8 HMI CONFIGURATION – BACKUP Tab Descriptions

Element Description

Backup Destination Folder

Touch the field to display the Storage Device Selector pop-up window shown below.

Touch the Expand Button ( ) and use the file browser to select a path for the backup destination folder.

NOTE: The destination location can be a floppy drive, USB device, local hard disk, or network drive. A network drive will be available only if it is configured by an Administrator.

Restore Source File Touch the field to display the Storage Device Selector. Use the file browser to select a path for an existing backup (source) file.

NOTE: The source file can be located on a floppy drive, USB device, local hard disk, or network drive.

NOTE: The existing source file must be a backup file from the same machine, with the same software version as that currently running on the machine.

Backup Schedule Select the appropriate check box to perform backup. Then enter the start time.

Number of Backups Enter a value from 1 to 10 for the number of backups.

NOTE: The default value is 5.

Backup Touch this button to backup machine data.

Restore Touch this button to restore machine data.

NOTE: The machine must be calibrated after restoring machine data from a backup.

OTHERS Tab 10–13


10.8 OTHERS Tab

The OTHERS tab allows a user to set the system time and date.

Touch the HMI Configuration button to display the HMI CONFIGURATION screen, then touch the OTHERS tab. Refer to Figure 10-10.

NOTE: User access rights of Processor, Maintenance, or Administrator required to select or modify functions.

Figure 10-10 HMI CONFIGURATION – OTHERS Tab

Table 10-9 HMI CONFIGURATION – OTHERS Tab Descriptions

Element Description

Settings

Show Title Bar Select this check box to display the Windows NT title bar at the top of the screen.

Time

Time Enter the current time in HH:MM:SS format.

NOTE: Only the administrator can change these values.

Date Enter the current date in MM:DD:YY format.

NOTE: Only the administrator can change these values.

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10–14 OTHERS Tab

HMI Reference Manual Polaris — v2009.3 Calibration

Calibration Screen 11–1

Chapter 11 Calibration

The calibration function is used to calibrate a number of machine components such as the clamp, ejector, injection, extruder, carriage, and product handling.

NOTE: Ejector and mold shutheight calibrations are done after installing the mold. Refer to the Machine Manual for details.

11.1 Calibration Screen

Touch the Calibration button on the toolbar to display the CALIBRATION MENU screen – refer to Figure 11-1. Each button on the CALIBRATION MENU screen allows you to calibrate an individual machine component.


NOTE: User access rights of Maintenance required to use the calibration function.

When a component is calibrated, the button displays a large green check mark. If it is not calibrated, the button will display a large red "X". If the component cannot be calibrated, the button will be greyed out.

Select any calibration button to display the individual calibration screen for that component.

Figure 11-1 CALIBRATION MENU Screen

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11–2 When to Calibrate

11.2 When to Calibrate

The following table describes when to calibrate the different components:

11.3 Clamp Calibration

Calibrate the clamp every time the clamp, stroke position sensor rods, magnets or mounting brackets for the magnets are replaced, or when the HMI indicates that the clamp must be calibrated.

NOTE: All manual clamp functions are allowed even if the clamp is uncalibrated.

Touch the Clamp button to display the CLAMP CALIBRATION pop-up window – refer to Figure 11-2.

Table 11-1 Calibration Conditions

Component When to Calibrate

Clamp Every time the clamp, stroke position sensor rods, magnet or mounting brackets are replaced. Refer to Section 11.3.

Injection Every time the stroke position sensor rod is replaced, or the plasticizing screw is changed. Refer to Section 11.4.

NOTE: This only applies to HyPET RS machines.

Ejector Every time a mold is installed in the machine. Refer to the Machine Manual for details.

Carriage Every time the stroke position sensor rod is replaced. Refer to Section 11.5.

Transfer Every time the transfer cylinder position sensor rod is replaced. Refer to Section 11.6.

NOTE: This only applies to HyPET P-Inj machines

Tooling Plate Every time a drive, motor or encoder is replaced. Refer to Section 11.7.

CoolPik Every time a drive, motor or encoder is replaced, or a mold is installed. Refer to Section 11.8.

CoolPik Alignment Every time a mold is installed. Refer to Section 11.9.

Error Message Whenever the machine displays an error message informing the operator to perform a calibration on a component.

Calibrating the Clamp 11–3



11.3.1 Calibrating the Clamp


Calibrate the clamp using the following instructions:

1. Check that the machine is in Manual cycle mode, and the Mold Set function mode is selected. Also, check that the pump is running.

2. Touch the Calibration button on the toolbar to display the CALIBRATION MENU screen – refer to Figure 11-1.

3. Touch the Clamp button to display the CLAMP CALIBRATION pop-up window – refer to Figure 11-2.

4. Touch the Start button and follow the instruction on the HMI screen.

When calibration is completed, the field beside the Start button displays "Calibrated".

Figure 11-2 CLAMP CALIBRATION Pop-up Window

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11–4 Injection Calibration

11.4 Injection Calibration

Calibrate the injection piston every time the stroke position sensor rod, or the plasticizing screw is replaced, or when the HMI indicates that the injection piston must be calibrated.

Touch the Injection button to display the INJECTION CALIBRATION pop-up window – refer to Figure 11-3.


11.4.1 Calibrating the Injection Piston


Calibrate the injection piston using the following instructions:

1. Check that the machine is in Manual cycle mode.


3. Touch the Injection button to display the INJECTION CALIBRATION pop-up window – refer to Figure 11-3.



11.5 Carriage Calibration

Calibrate the carriage every time the stroke position sensor rod is replaced, or when the HMI indicates that the carriage must be calibrated.

Figure 11-3 INJECTION CALIBRATION Pop-up Window

Calibrating the Carriage 11–5


Touch the Carriage button to display the CARRIAGE CALIBRATION pop-up window – refer to Figure 11-4.


11.5.1 Calibrating the Carriage


Calibrate the carriage using the following instructions:



3. Touch the Carriage button to display the CARRIAGE CALIBRATION pop-up window – refer to Figure 11-4.

4. Touch the Start button and follow the instructions on the HMI screen.


11.6 Transfer Calibration

Calibrate the transfer cylinder when the stroke sensor rod is replaced, or when the HMI indicates that the transfer cylinder must be calibrated.

Touch the Transfer button to display the EXTRUDER CALIBRATION pop-up window – refer to Figure 11-5.

Figure 11-4 CARRIAGE CALIBRATION Pop-up Window

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11–6 Calibrating the Transfer Cylinder


11.6.1 Calibrating the Transfer Cylinder


Calibrate the transfer cylinder using the following instructions:



3. Touch the Transfer button to display the EXTRUDER CALIBRATION pop-up window – refer to Figure 11-5.



11.7 Tooling Plate Calibration

Calibrate the Tooling Plate every time a drive, motor or encoder is replaced.

Touch the Tooling Plate button to display the TOOLING PLATE CALIBRATION pop-up window – refer to Figure 11-6.

Figure 11-5 EXTRUDER CALIBRATION Pop-up Window

Calibrating the Tooling Plate 11–7



11.7.1 Calibrating the Tooling Plate

NOTE: User access rights of Operator required to use the calibration function.

Calibrate the Tooling Plate using the following instructions:



3. Touch the Tooling Plate button to display the TOOLING PLATE CALIBRATION pop-up window – refer to Figure 11-6.



11.8 CoolPik Calibration

Calibrate the CoolPik every time a drive, motor or encoder is replaced, or a different mold is installed.

Touch the CoolPik button to display the COOLPIK CALIBRATION pop-up window – refer to Figure 11-7.

Figure 11-6 TOOLING PLATE CALIBRATION Pop-up Window

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11–8 Calibrating the CoolPik


11.8.1 Calibrating the CoolPik

NOTE: User access rights of Operator required to use the calibration function.

Calibrate the CoolPik using the following instructions:



3. Touch the CoolPik button to display the COOLPIK CALIBRATION pop-up window – refer to Figure 11-7.



11.9 CoolPik Alignment

Align the CoolPik every time a different mold is installed.

Touch the Alignment button to display the ALIGN COOLPIK pop-up window – refer to Figure 11-8.

Figure 11-7 COOLPIK CALIBRATION Pop-up Window

Aligning the CoolPik 11–9



11.9.1 Aligning the CoolPik

NOTE: User access rights of Operator required to use the CoolPik alignment function.

NOTE: The machine is allowed to run in Dry Cycle mode if the CoolPik is not aligned.

NOTE: Check that the Tooling Plate, CoolPik and Mold Stroke are calibrated, and the robot is at the Home position before starting alignment. Also check that the 2mm spacers are installed on the CoolPik rods – refer to the Machine Manual for details.

Align the CoolPik using the following instructions:


2. Touch the Alignment button to display the ALIGN COOLPIK pop-up window – refer to Figure 11-8.

3. Touch the Start button, and follow the instructions on the HMI screen.

When alignment is completed the field beside the Start button displays "Aligned".

NOTE: Open the mold and remove the 2mm spacers when alignment is completed.

Figure 11-8 ALIGN COOLPIK Pop-up Window

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11–10 Aligning the CoolPik

HMI Reference Manual Polaris — v2009.3 SmartLink (Optional)

12–1

Chapter 12 SmartLink (Optional)

SmartLink is a Husky option that allows a user to monitor machine and auxiliary equipment performance at a plant level. All historical machine performance and production data is stored in a SQL database and viewed through a Java Script-enabled web browser.

SmartLink has three main components — Husky Host Link enabled on the machine, a network connection, and a server on a local area network. Refer to Figure 12-1. Machine data is translated through Husky Host Link and stored on the server. The user then accesses the data using a web browser running on the HMI or a PC connected to the network. The web browser is used to display, enter, and store production data on the server.

The operator has limited access to the SmartLink data at the HMI — production status, data entry and downtime reporting are the only tasks permitted from within the HMI. The Plant Manager can review and modify all data and generate reports, while Company Management can view all machine and production reports.

SmartLink comes with three standard modules for handling data — Process Monitoring, Graphical Reporting, and Notification. Other optional modules are also available for Statistical Process Control (SPC), Production Monitoring, and Advanced Scheduling. Currently SmartLink only supports the English language. Future versions may support multiple languages.

Since SmartLink functionality will vary from implementation to implementation all further discussions in this chapter will be limited to the base functionality available to the operator on the HMI. For any other information refer to the appropriate SmartLink implementation documents.

Figure 12-1 SmartLink Overview

1. Operator input at HMI 2. Plant Manager access via PC 3. Management access via PC 4. Server 5. Husky Host Link 6. Standard modules 7. Optional modules 8. Internet connection 9. Husky Service

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12–2 MACHINE PRODUCTION STATUS Screen

NOTE: SmartLink must be enabled by the Administrator to use this functionality — refer to Section 10.8.

12.1 MACHINE PRODUCTION STATUS Screen

The MACHINE PRODUCTION STATUS screen allows the operator to look at the list of scheduled jobs for a workcell, view details of current job, and update the status of the current job.

Touch the SmartLink button on the toolbar to display the MACHINE PRODUCTION STATUS screen – refer to Figure 12-2. You can also access this screen by touching the Status button on the bottom of any SmartLink screen.

NOTE: User access rights of Operator, or Processor required to select or modify functions.

NOTE: Screen shown is representative, and may vary depending on how SmartLink is implemented. Only base functionality of this screen is discussed in this section.

Figure 12-2 MACHINE PRODUCTION STATUS Screen

MACHINE PRODUCTION STATUS Screen 12–3


Table 12-1 MACHINE PRODUCTION STATUS Screen Descriptions

Element Description

Work Centre Select a work centre from the drop-down list.

Machine Select a machine from the list of all available machines for the selected work centre.

Job Schedule Displays the list of scheduled jobs for the selected machine. Jobs are displayed in the order in which they are to be run. The first job in the list is the active job.

Active Job

Work Centre These fields display details of the active job shown at the top of the Job Schedule list.

Job No.

Mold No.

Part No.

Part Description

Parts Required

Parts Remaining

Scrap Pieces

Current Status

Setup This button is active when a job becomes active. Touch this button when starting the mold setup. The Current Status field displays the updated status.

Run This button is active after the Setup button is pressed. Touch this button to indicate that the current job is ready to run. The Current Status field displays the updated status.

Suspend This button is active when the Run button is pressed. Touch this button to suspend the current job. The next scheduled job in the Job Schedule list then becomes the active job, and the Setup button becomes active.

Complete This button is active when the Run button is pressed. Touch this button to indicate that the current job is completed. The next scheduled job in the Job Schedule list then becomes the active job, and the Setup button becomes active.

Status Touch this button to display the MACHINE PRODUCTION STATUS screen. This button is available on all SmartLink screens.

Updates Touch this button to display the DATA ENTRY screen. This button is available on all SmartLink screens.

Downtime Touch this button to display the DOWNTIME screen. This button is available on all SmartLink screens.

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12–4 Selecting Machine in a Work Centre

12.1.1 Selecting Machine in a Work Centre

NOTE: User access rights of Operator, or Processor required to use this function.

Select a machine in a work centre using the instructions below:

1. Touch the SmartLink button on the toolbar to display the MACHINE PRODUCTION STATUS screen.

NOTE: You can also select a work centre and machine from any of the SmartLink screens.

2. Check that the correct work centre name is displayed in the Work Centre field. If necessary, select the correct name from the drop-down list.

3. Check that the correct machine name is displayed in the Machine field. If necessary, select the correct name from the drop-down list.

12.1.2 Closing or Restarting a SmartLink Session


Close or restart the SmartLink session using the instructions below:

1. Touch the button shown on the bottom of any SmartLink screen to close the session.

NOTE: If you exit SmartLink before selecting the Submit button on the DATA ENTRY or the DOWNTIME screen all entered data will be discarded.

Touch the Refresh button to refresh the SmartLink data on the screen.

Touch the Capture button to perform a screen capture of the current SmartLink screen.

Touch the Disconnect button to exit the SmartLink session and return to the normal HMI screen.

Table 12-1 MACHINE PRODUCTION STATUS Screen Descriptions (Continued)

Element Description

DATA ENTRY Screen 12–5


12.2 DATA ENTRY Screen

The DATA ENTRY screen allows the operator to enter production data for a job and save it to the server.

Touch the SmartLink button on the toolbar, then touch the Updates button to display the DATA ENTRY screen – refer to Figure 12-3. You can also access this screen by touching the Updates button on the bottom of any SmartLink screen.



Figure 12-3 DATA ENTRY Screen

Table 12-2 DATA ENTRY Screen Descriptions

Element Description



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12–6 Entering Production Data for a Job

12.2.1 Entering Production Data for a Job

Enter production data for a job and save it to the server using the instructions below:


1. Touch the SmartLink button on the toolbar, then touch the Updates button to display the DATA ENTRY screen. You can also access this screen by touching the Updates button on the bottom of any SmartLink screen

2. Check that the correct machine is selected — refer to Section 12.1.1.

3. Touch the Time Stamp icon to display the correct date and time.

Touch the Time Stamp icon to display a calendar pop-up window. Select the current date and time using the pop-up window.

Touch the button beside each data entry field to display the numeric key pad shown below.

Submit Touch this button to save the entered data to the server.

Status Refer to Table 12-1.

Updates

Downtime

Table 12-2 DATA ENTRY Screen Descriptions (Continued)

Element Description

DOWNTIME Screen 12–7


4. Touch the button beside each data entry field to display a numeric key pad. Enter the required data.

5. Touch the Submit button to save the data to the server.

NOTE: If you exit SmartLink before selecting the Submit button all entered data will be discarded.

12.3 DOWNTIME Screen

The DOWNTIME screen allows the operator to select a reason for a production interruption.

Touch the SmartLink button on the toolbar, then touch the Downtime button to display the DOWNTIME screen – refer to Figure 12-4. You can also access this screen by touching the Downtime button on the bottom of any SmartLink screen.



Figure 12-4 DOWNTIME Screen

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12–8 DOWNTIME Screen

Table 12-3 DOWNTIME Screen Descriptions

Element Description

Shift Displays the shift number.

User Displays the name of the user logged into the machine.

Shift Start Displays the date and time of the start of shift.

Shift End Displays the date and time of the scheduled end of shift.



Retrieve New Downtime

Touch this button to retrieve any new downtime events that occurred during the current shift. The rows in the table are then populated with new events that have yet to be assigned downtime reasons.

Review Stored Downtime

Touch this button to review all stored downtime events that occurred during the current shift. The rows in the table are then populated with events that have been assigned downtime reasons.

NOTE: The downtime reasons for these events cannot be modified as they have already been assigned and saved.

Split Touch this button to split the current downtime event so multiple reasons can be assigned to it.

Start Time Displays the date and time of the start of the machine interruption event from the Event Log.

End Time Displays the date and time of the end of the machine interruption event from the Event Log.

Machine Reason Displays the reason for the interruption from the Event Log.

Assigned Reason Select a reason from the list of pre-assigned reasons in the drop-down list.

NOTE: Once the Submit button below is selected the reason assigned to the downtime event cannot be changed by the operator.

Root Cause Select a root cause from the list of pre-assigned causes in the drop-down list.

NOTE: Once the Submit button below is selected the root cause assigned to the downtime event cannot be changed by the operator.

Select the buttons to scroll through the downtime events.

Submit Touch the button to save the data to the server.

Selecting Downtime Reason 12–9


12.3.1 Selecting Downtime Reason


Select a reason for a production interruption and save it to the server using the instructions below:

1. Touch the SmartLink button on the toolbar, then touch the Downtime button to display the DOWNTIME screen. You can also access this screen by touching the DOWNTIME button on the bottom of any SmartLink screen

2. Check that the correct machine is displayed in the Machine field. If necessary, select the correct machine — refer to Section 12.1.1.

3. Touch the Retrieve New Downtime button. Any new downtime events that occurred during the current shift are displayed in the table.

4. Select a reason from the drop-down list in the Assigned Reason field.

5. Select a cause from the drop-down list in the Root Cause field.

6. If it is necessary to assign multiple downtime reasons to an event touch the Split button beside it. This creates a new row below the current row. Select an additional reason and cause for the current event.

7. Use the scroll buttons to move to other events, and repeat step 4, step 5 and step 6.

8. Touch the Submit button to save the data to the server.

NOTE: If you exit SmartLink before selecting the Submit button all entered data will be discarded.

Status Refer to Table 12-1.

Updates

Downtime

Table 12-3 DOWNTIME Screen Descriptions (Continued)

Element Description

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12–10 Selecting Downtime Reason

HMI Reference Manual Polaris — v2009.3 SPC (Optional)

SPC Quick Start 13–1

Chapter 13 SPC (Optional)

The optional SPC screens are available when the Statistical Process Control (SPC) option package is purchased. SPC is a tool that applies basic statistical analysis to monitor processes. It assists to diagnose and pin point quality and productivity problems.

The SPC program monitors a process and determines when it has deviated from the process standard. A process is considered to be deviated from the standard when one or more monitored SPC variables are outside specified operating ranges. An operator can define a course of action for each variable when it deviates from the process standard (e.g., turn on the SPC alarm light, stop the machine, or turn on an auxiliary output).

13.1 SPC Quick Start

Use the following instructions to quickly set up and run SPC. For a detailed description of all the features of SPC read Section 13.8, and the individual SPC screens.

1. First select SPC variables for monitoring.

Press <SPC> key, then select the SETUP tab. Select the field beside each variable to select it. You can choose variables from the list of process variables displayed on the screen. Refer to Section 13.6 for details.

2. Specify Sample Size and Sampling Period.

The default Sample Size and Sampling Period are 5 and 15 respectively. A Sample Size of 5 means that 5 consecutive machine cycles make up a sample. A Sampling Period of 15 means that after one sample is collected, there is a 10 cycle pause before the next sample is collected.

To change the default sample settings, press <SPC> key and select the SETUP tab. Refer to Section 13.6 for details.

3. Produce "good" parts, and reset all SPC variables so the SPC program can automatically set specification limits based on "good" parts.

Start up the machine, and adjust the process until part quality is satisfactory.

Press <SPC> key, then select the DETAILS tab. Select the Reset All Variables button on the DISTRIBUTION AND TREND tab.

4. Sample the process, and allow the process to settle.

Data points will appear on the control charts as samples are collected. When at least two samples have been collected, control limits will appear on the control charts as horizontal red lines, and 3σ limits will appear on the Trend chart as horizontal purple lines. At the default sampling period setting, control limits will appear about 30 cycles after the machine starts.

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13–2 SPC Quick Start

NOTE: Initially, the control limits and 3σ limits will not be very accurate. It will take some time for them to settle (usually within 10 to 25 samples, depending on the sampling period).

5. Select specification limits to be set automatically.

After the machine produces "good" parts, and the process has settled, select the Set All Limits button on the DETAILS screen. Before changing limits, the program displays a prompt. Select Yes to confirm the change.

The specification limits appear as horizontal yellow lines on Trend charts.

6. Configure SPC alarms for each monitored SPC variable.

Press <SPC> key, then select the SETUP tab. Refer to Section 13.6 to enable specification and control alarms for monitored variables.

At this point you should have a working SPC package. The SUMMARY, DETAILS and GROUP screens can be used to check monitored SPC variables. The HISTORY screen can be used to display historical data for all SPC variables.

After setting up the basic SPC package, there are some additional steps that can be set up.

7. Specify known control limits for monitored SPC variables.

When a set of Xbar and R/s chart control limits is available for a known batch of good parts, it may be suitable to monitor machine variations against these known control limits, rather than have the SPC program calculate them automatically.

Press <SPC> key, then select the CTRL LIMITS tab. Refer to Section 13.7 to set control limits.

8. Enter known upper and lower specification limits for monitored SPC variables.

When a set of Trend specification limits is available for a known batch of good parts, it may be suitable to monitor machine variations against these known specification limits, rather than have the SPC program calculate them automatically.

Refer to Section 13.3 to enter specification limits for any of the monitored variables.

SUMMARY Screen 13–3


13.2 SUMMARY Screen

The SUMMARY screen allows the operator to monitor, at a glance, the status of 20 monitored SPC variables. The screen displays the alarm state of each SPC variable, the current reading and limits, the current Cpk, and if the variable is in a state of statistical control.

Press <SPC> key to display the SUMMARY screen. Refer to Figure 13-1.

NOTE: You cannot select variables or buttons, or modify any of the selectable fields if you do not have access rights.

Figure 13-1 SUMMARY Screen

Table 13-1 Summary Screen Descriptions

Field Description

Variables Displays a list of monitored SPC variables.

LSL and USL The Lower Specification Limits (LSL) and Upper Specification Limits (USL) list the lower and upper specification limits for each SPC variable. The specification limits are usually set automatically using the Set Limits or Set All Limits functions on the DETAIL screen. However, it is also possible to enter LSL and USL values in the SUMMARY screen by selecting the individual fields. A numeric touchpad appears when a field is selected.

If both specification limits are zero, the SPC program assumes that the limits are not defined and the limit values are greyed out.

If the value of a SPC variable is greater than its USL, then its USL value turns red.

If the value of a SPC variable is less than its LSL, then its LSL value turns red.

Actual Displays the most recent values of monitored SPC variables. For process variables, the value displayed is the value from the last machine cycle. For part variables, the value displayed is the most recently entered value.

Polaris — v2009.3

13–4 SUMMARY Screen

Cpk Displays the current Cpk value for each SPC variable. Cpk will be zero if either the control limits or specification limits are not defined for a variable. Cpk is recalculated whenever a new sample is collected.

If the Cpk value of an SPC variable is less than the Cpk threshold, its Cpk value turns red.

In Ctrl This column displays the status of the listed variables. The indicators are color coded as follows:

• Dark grey = first two samples have not been collected

• Green = the variable is in statistical control

• Red = the variable is out of statistical control

SPC Alarms status The three indicators at the bottom of the screen show the current state of the Machine Stop, SPC alarm light, and auxiliary outputs. One or more of these indicators may be turned on when a specification alarm occurs. The indicators are color coded as follows:

• Green = functioning normally

• Red = machine/auxiliary devices stopped, and SPC alarm light on

Cycle Number Displays the number of the current machine cycle. This number is used to correlate part data with process data.

Alarm Delay Displays the number of cycles that the SPC program will wait before taking alarm measures when the machine is in Auto cycle mode.

Table 13-1 Summary Screen Descriptions (Continued)

Field Description

DETAILS Screen 13–5


13.3 DETAILS Screen

The DETAILS screen displays in graphical form all SPC information about a single monitored variable. The screen contains two tabs where data is displayed in a trend chart, trend distribution histogram, Xbar graph, and R/s chart. It also allows the operator to set specification limits manually or automatically, and reset variables.

Press <SPC> key, then select the DETAILS tab. Refer to Figure 13-2.


Figure 13-2 DETAILS Screen

Table 13-2 DETAILS Screen Descriptions

Field Description

(Variable Drop Down Box)

Use the drop down box to select a variable from the list.

The distribution and trend data, and the Xbar and R/s data information is immediately displayed on the screen.

NOTE: The variable only appears on this list if it has been selected on the SETUP screen.

X-bar Alarms

The four status indicators light up when the Xbar average is out of control. The colors of the indicators are summarized below:

• Dark grey – indicates sampling in progress. Remains grey while the first two samples are collected

• Green – indicates the condition is not active

• Red – indicates the condition is active

Polaris — v2009.3

13–6 DISTRIBUTION AND TREND Screen

13.3.1 DISTRIBUTION AND TREND Screen

The trend chart displays SPC variable values over 400 machine cycles. The horizontal axis represents machine cycles, and the vertical axis represents range of process values. New process data may be plotted across the screen either from left to right, or right to left, depending on the setting on the SPC Setup screen. Old process data is scrolled off the chart at the opposite edge. The time of the most recent cycle is displayed under the chart at the entry point on the chart.

The two fields located to the left of the chart, at the top and bottom of the vertical axis, display the current range of the vertical axis.

The variable’s Upper and Lower Specification Limits are displayed graphically as two yellow horizontal lines. The two input fields with yellow legends to the left of the chart may be used to change the limits.

The variable’s ±3σ limits are displayed graphically as two purple horizontal lines. The two fields to the left of the chart display the 3σ values.

The Xbar average value is displayed graphically as a green horizontal line, and the numeric value is also displayed in the output field to the left of the chart.

For process variables, the Xbar average and 3σ limits are only displayed over a 25 sample data range. This is intended to show that the values of these lines are based only on the data that the program displays in the Xbar control chart.

The SPC program shows sampled readings in purple, and the remaining readings in white. If the sampling period is equal to the sampling size, all readings are purple.

The chart displays the most recent variable value and the variable’s Cpk in "Current" and "Cpk" fields across the top of the trend chart.

The Distribution histogram shows the distribution of data points currently displayed on the trend chart. The vertical range for the variable’s distribution is the same as the range for the trend chart.

Limit This indicator lights up when one sample average is outside the Xbar control limits.

See indicator status summary above.

Run This indicator lights up when nine or more consecutive averages are above or below the Xbar average.


Trend This indicator lights up when six or more consecutive averages are trending upward or downward.


Alt. Data This indicator lights up when fourteen or more consecutive alternating Xbar points have occurred.


Table 13-2 DETAILS Screen Descriptions (Continued)

Field Description

DISTRIBUTION AND TREND Screen 13–7


A number of the SPC calculations assume that the distribution for a variable is bell shaped, showing a Normal distribution. This assumption is correct in most cases and can be easily verified by visually checking the shape of the distribution. If a variable does not have a Normal distribution, the SPC program may be unable to correctly determine whether or not it is in a state of statistical control.

Table 13-3 DISTRIBUTION AND TREND Screen Descriptions

Field Description

Current Displays most recent variable value.

Cpk Displays the most recent Cpk for the variable.

Old Displays the time of the oldest displayed distribution and trend data.

New Displays the time of the newest displayed distribution and trend data.

Trend

1 – displays the upper display limit of the trend chart

2 – enter USL value, if you desire to set it manually

3 – displays the upper 3σ limit

4 – displays the Xbar value

5 – displays the lower 3σ limit

6 – enter the LSL value, if you desire to set it manually

7 – displays the lower display limit of the trend chart

The Distribution histogram shows the distribution of data points currently displayed on the trend chart.

Settings

Press this button to reset the displayed variable, and restart sampling of the variable. The Xbar, R/s chart, and any active alarms are cleared.

The HMI prompts the operator to confirm the action.

Press this button to reset all monitored variables, and restart sampling of all variables. This is the equivalent of using the Reset button individually for each variable.


Press this button to automatically determine specification limits for the current variable based on its current trend, Control Limits and Cpk multiplier.


1234567

Polaris — v2009.3

13–8 XBAR AND R/s Screen

13.3.2 XBAR AND R/s Screen

The Xbar and R/s control charts are displayed in their own tab on the DETAILS screen. These charts graphically display the averages, ranges or standard deviations of the samples, which let the operator determine if a variable is in a state of statistical control.

The Xbar and R/s screen allows the operator to specify Xbar and R/s chart control limit values for SPC variables rather than have the SPC program calculate it automatically. This is useful when a set of control limits is available for a known process. The machine variations can then be monitored against these known control limits.

Press <SPC> key, select the DETAILS tab, then select the XBAR and R/s tab. Refer to Figure 13-3.

Press this button to set limits for all monitored SPC variables.


Press this button to clear all specification limits, and set them to zero. Use this function after installing a new mold to clear specifications from previous runs with a different mold.


Scale Trend By

Data Press this option button to scale the trend chart so that all the data and limits fit within the chart. Scaling can be applied individually to each variable.

Limits Press this option button to scale the trend chart so that it only displays the current specification and ±3σ limits. Scaling Trend by Limits allows the operator to ignore peaks in the data, and see more detail in the "normal" range. Scaling can be applied individually to each variable.

Table 13-3 DISTRIBUTION AND TREND Screen Descriptions (Continued)

Field Description

XBAR AND R/s Screen 13–9



The current variable’s Upper and Lower Control Limits are displayed graphically as two red horizontal lines, and the Xbar average value is displayed as a green horizontal line. The numeric values corresponding to these lines are also displayed in the output fields to the left of the chart.

Below each chart there are two time stamps which display event time in HH:MM:SS format. The time stamps display the time of the oldest displayed sample, and the most recent sample. The elapsed time between the most recent sample and the oldest displayed sample is displayed between the two time stamps. New process data may be plotted across the screen either from left to right, or right to left, depending on the setting on the SPC Setup screen.

Although the horizontal axis displays the time spanned by the control chart, the SPC program does not plot the samples by time. The samples are plotted so that there is equal space between samples.

Figure 13-3 XBAR and R/S Screen

Polaris — v2009.3

13–10 HISTORY Screen

13.4 HISTORY Screen

The HISTORY screen allows an operator to select up to four SPC variables for an extended period of time. These variables can be any of the defined SPC variables, and not just the monitored variables. However, the variable must still be defined on the SETUP screen before it can be selected here. It is intended to answer questions such as "How long did the machine run during yesterday afternoon’s shift?"

Press <SPC> key, then select the HISTORY tab. Refer to Figure 13-4.


NOTE: User access rights of Processor are required to select and modify functions.

The information displayed on this screen is read from the Data and Event Logs. The Event Log contains the previous 20,000 events. The Data Log contains SPC variable values for the previous 10,000 cycles. The duration of this data depends on the cycle time, as indicated in the table below.

The upper area of the screen is divided into four charts. Each chart can graphically display one SPC variable. Any configured variable (selected on the SETUP screen) can be viewed on the HISTORY screen even if it is currently not monitored. Up to 48 hours of data can be viewed

Figure 13-4 HISTORY Screen

Table 13-4 Data Log Duration

Cycle Time (seconds) Cycles/Day Log Duration (Days)

60 1440 7

30 2880 3.5

15 5670 1.7

HISTORY Screen 13–11


at any time. However, if the number of data points exceeds the available pixels in the chart some data points may not be visible.

The data can be viewed as a Trend, Xbar, or R/s chart. The horizontal axis represents time, and the vertical axis represents the variable data values. The two output fields to the left of each chart display the range of the vertical axis. The fields just below the charting area show the time range of the charts. The four charts always cover the same time range. The order of these fields depends on the plot direction. If the plot direction is left to right, the most recent time will be displayed under the left edge of the charts. If the plot direction is right to left, the most recent time will be displayed under the right edge of the charts.

A dark grey grid is drawn on each chart. This puts a horizontal line at the midpoint of the chart, and vertical lines marking each hour specified in the time range.

The various modes that the machine was operating in during a specific time range can be display behind all other features of a chart. Each mode is identified by a specific color. The following modes are defined:

• Black: Auto Mode.• Cyan: Not Auto Mode (i.e. Manual/Idle/Semi Mode).• Grey: Power Off (i.e. power to the machine was off).• Dark Grey: Out of Range (i.e. setpoint changes that occur beyond the time range

contained in the Event Log).• Yellow: Setpoint changes that occur within the specified time range are displayed as

yellow lines.

Trend data are shown as connected purple lines.

Xbar or R/s data appear as purple dots connected by white lines.

Recent Xbar and R/s data is synchronized with the Xbar and R/s charts shown on the DETAIL screen. This synchronization is maintained across machine mode changes, but not across a machine shutdown.

When a monitored variable is plotted, the current limits of the variable are superimposed on the data according to the following scheme:

Trend – specification limits

Xbar – current Xbar control limits

R/s – current R/s control limits

NOTE: For the limits to be visible, the variable must be monitored and have appropriate control limits. The limits are not updated dynamically. They are redrawn whenever a search is started, or when the operator moves to another screen and returns back to it.

IMPORTANT!Changing the time setting on the HMI may result in inaccurate SPC variable plotting. When this occurs within the time range of the SPC History charts, a message to the operator will describe the affected time range, and all mode changes will be displayed with a hatched pattern instead of a solid color. Do not change the time settings unless absolutely necessary.

Polaris — v2009.3

13–12 HISTORY Screen

Table 13-5 HISTORY Screen Descriptions

Field Description

Variable Select a variable from the drop down box associated with each display chart.

NOTE: The same variable can be viewed in the other charts. This allows the variable to be viewed simultaneously as a trend, Xbar, and R/s chart.

(Chart Type) Select the appropriate trend, Xbar or R/s option button at the top of each chart. The variable displays accordingly in the chart below.

NOTE: The chart type selected is independent of the selection in other charts.

Old Earlier date and time of the reporting period.

New Later date and time of the reporting period.

Expand Button Press the Expand button to display the Reporting Period pop-up window.

Reporting Period Pop-Up Window

Use the Reporting Period pop-up window to select the display period for the four charts. The options are:

• Last 4 Hours

Select to retrieve and display the previous four hours of data starting from the current system time. The previous 4 hours of data are retrieved from the log and plotted in the charts.

• Last 12 Hours

Select to retrieve and display the previous 12 hours of data starting from the current system time. The previous 12 hours of data are retrieved from the log and plotted in the charts.

• Start Date/Duration

Set the Start Date, Time, and Duration (in hours) to retrieve and display data for the range specified. The data within the range is retrieved from the log and plotted in the charts. If the specified time range is outside of the ranges recorded in either the Event Log or the Data Log, the system will display a message.

NOTE: Click on the Exit button to close the Reporting Period pop-up window.

NOTE: Selecting the Date option displays the date and time touchpads.

Search Press this button to start searching the Event and Data Log.

NOTE: Searches may sometimes take a few moments to a few minutes to complete – depending on the amount of data to be examined.

Cancel Press this button to cancel the search.

Scroll Bar When a search is finished, the two scrolling buttons can be used to move to either newer or older historical data (by the amount of time displayed in the chart duration field). Searching will start again as soon as a scroll button is pressed.

GROUP Screen 13–13


13.5 GROUP Screen

The GROUP screen allows the operator to directly compare 8 monitored SPC variables and check for any correlations. The screen can display trend, Xbar, R/s charts depending on the specification on the SETUP screen.

NOTE: Only eight monitored SPC variables can be compared at one time using the graphs on screen.

Press <SPC> key, then select the GROUP tab. Refer to Figure 13-5.


Legend Button Press this button to toggle the display of colors used to represent mode and setpoint changes.

Legend Pop-Up Window

The Legend pop-up window displays the legend of colors used to represent mode and setpoint changes. The legend remains displayed until either the Exit button is pressed, or the Legend button is pressed again.

Table 13-5 HISTORY Screen Descriptions (Continued)

Field Description

Figure 13-5 GROUP Screen

Polaris — v2009.3

13–14 SETUP Screen


The charts are updated in real time as new data become available. New data is plotted from across the screen either from left to right, or right to left, depending on the setting on the SPC Setup screen.

Depending on the "Scale Trend by Data" or the "Scale Trend by Limits" input selected on the DETAIL screen, each trend chart is scaled and plotted accordingly.

13.6 SETUP Screen

The SETUP screen allows the operator to select variables for monitoring, specify alarm configuration settings for monitored variables, and other miscellaneous configuration settings for the SPC program.

Press <SPC> key, then select the SETUP tab. Refer to Figure 13-6.

Table 13-6 GROUP Screen Descriptions

Field Description

Trend Press this option button to display statistical information for variable data by trend.

Xbar Press this option button to display statistical information for variable data using Xbar patterns.

R/s Press this option button to display statistical information for variable data using R/s sample range plotting.

(Variable graphs) There are eight variable graphs on the screen to allow simultaneous display of eight selected variables. Select the drop down box at the top of a graph to choose the variable to display.

NOTE: A variable must be selected on the SETUP screen in order to appear in the drop down list.

SETUP Screen 13–15




Figure 13-6 SETUP Screen

Table 13-7 SETUP Screen Descriptions

Field Description

Configure (Cfg) Select the field beside the variable name to enable/disable monitoring of that variable. A pop-up window appears to prompt you to verify the action. When the variable is enabled a check mark appears in the field. Otherwise, the field is left blank, and the specification alarm and Xbar fields are greyed out.

All variables Use this option button to display all SPC variables. Table 13-8 lists all available SPC variables.

Configured variables Use this option button to restrict the display list to those variables that have been configured.

Specification Alarms

To enable/disable specification alarms, select the applicable alarm fields corresponding to each SPC variable. A pop-up window appears to prompt you to verify the action. When the alarm is enabled, a check mark appears in the field; otherwise the field is left blank.

Polaris — v2009.3


Enable (En) Select this field to enable/disable the specification alarm for the SPC variable. When the specification alarm is enabled, the following events can occur:

• The HMI displays the message "SPC variable(s) outside specification limits" when the variable is outside the limits.

• The HMI displays the message "SPC variable(s) have Cpk below threshold" when the variable’s Cpk is below the Cpk threshold.

• The SPC program will take the appropriate alarm action defined for the variable.

Threshold (Th) Select the field to display a numeric touchpad to enter the value for the alarm threshold.

The specification alarm threshold specifies how many times in a row the SPC variable can exceed specification limits before the alarm is activated.

Light (Lt) Select this field to enable/disable the warning light when the SPC variable exceeds specification limits.

Stop (St) Select this field to enable/disable the machine stop when the SPC variable exceeds specification limits.

Auxiliary (Au) Select this field to enable/disable the auxiliary output when the SPC variable exceeds specification limits.

Xbar

Enable (En) Select this field to enable/disable monitoring of out-of-control conditions for process averages.

The HMI triggers an alarm when such a condition is encountered. The HMI displays the message "SPC variable(s) out of control", and the status indicator on the SUMMARY screen turns red.

The detected out-of-control condition can be seen above the Xbar chart on the DETAIL screen when the variable is displayed.

Specifications

Sample Size Enter a value between 2 and 25 for the number of cycles over which samples are acquired. All process variables have the same sample size.

NOTE: Changing the sample size resets any part variables that are being monitored.

Sample Period Enter a value between the value of Sample Size and 999 cycles.

NOTE: Changing the sampling period resets any process variables that are being monitored.

Desired Cpk When Learning Limits

Enter a Cpk value in this field. When the Set Limits button on the DETAILS screen is selected, the specification limits are calculated so that the resulting Cpk is approximately equal to this value.

Table 13-7 SETUP Screen Descriptions (Continued)

Field Description



Cpk Warning Threshold

Enter a Cpk warning threshold value. If the calculated Cpk for a monitored variable goes below this threshold value, the variable’s Cpk indicator on the SUMMARY screen turns red. In addition, if specification alarms are enabled, an alarm message will be generated.

Alarm Light On For Enter the minimum time that the alarm light must remain on after the specification alarm has gone inactive.

Auxiliary On For Enter the minimum time that the auxiliary output can remain on after the specification alarm has gone inactive.

Delay Spec. Alarm For Enter the number of cycles that the SPC program must wait, while in Auto mode, before activating the specification alarm. This delay allows the machine to stabilize before the SPC program starts to monitor the variables.

Table 13-8 Variable Definition List - Machine

Screen Text Description

Cycle Time Time duration from the Start of Mold Close to the next Start of Mold Close

Injection Start Time Difference Difference between start time of injection unit A and injection unit B

Oil Temperature Oil temperature when full tonnage is achieved

Table 13-9 Variable Definition List - Clamp


Effective Cooling Time Cooling setpoint (from INJECTION screen) plus

Unclamp time

Ejector Back Time Time duration between signal to valve to move the ejector backward, and when ejection backward position is reached

Ejector Forward Time Time duration between signal to valve to move the ejector forward, and when ejection forward position is reached

Ejector Max. Forward Position Ejector position at maximum forward position

Mold Closing Time Time duration from the Start of Mold Close to when clamp tonnage is achieved

Mold Heats Temperature - 1 Temperature in zone 1 when full tonnage is reached





Table 13-7 SETUP Screen Descriptions (Continued)

Field Description

Polaris — v2009.3





















Mold Open Time Time duration between Mold Open setpoint and signal to valve to close the mold

Mold Opening Time duration between Start of Unclamp and when Mold Open position is reached

Tonnage Measurement of pressure when full tonnage is reached

Table 13-10 Variable Definition List - RS Injection


Back Pressure Pressure measured at 75% of stroke during Recovery

Barrel Head Temperature

Temperature in barrel head when full tonnage is reached

Cushion Injection barrel volume at the end of Hold

Extr. Temperature - 1 Temperature of the 1st extruder zone when full tonnage is reached

Extr. Temperature - 2 Temperature of the 2nd extruder zone when full tonnage is reached

Table 13-9 Variable Definition List - Clamp (Continued)




Extr. Temperature - 3 Temperature of the 3rd extruder zone when full tonnage is reached

Extr. Temperature - 4 Temperature of the 4th extruder zone when full tonnage is reached

Extr. Temperature - 1 Pressure measured at the end of Hold zone 1










Injection Fill Time Time duration from the Start Of Injection to Transition

Injection Hold Time Time duration from the Transition to end of hold

Injection Pressure At Transition

Injection pressure of transition from fill to hold

Maximum Fill Pressure Pressure measured in the time period between Start of Injection to just before transition

Nozzle Adapter Temperature

Temperature in nozzle when full tonnage is reached

Nozzle Shutoff Temperature

Temperature in nozzle shutoff when full tonnage is reached

Recovery Time Time duration between Screw Rotation Start and Screw Rotation Stop

Resin Temperature Temperature for resin when full tonnage is reached

Screw Run Time Time duration between Screw Rotation Start and Screw Rotation Stop

Screw RPM Measured in rpm at 75% of stroke during Recovery

Shot Length The difference between Shot Size and Cushion

Shot Size Injection barrel volume just before Start Of Injection

Transition Position Injection barrel volume at the transition between Fill and Hold

Table 13-10 Variable Definition List - RS Injection (Continued)


Polaris — v2009.3


Table 13-11 Variable Definition List - Two-Stage Injection


B/Head Ext. Temperature Temperature in barrel head extension when full tonnage is reached

Back Pressure Pressure measured at 75% of stroke during Recovery

Barrel Head Temperature Temperature in barrel head when full tonnage is reached

Cushion Injection barrel volume at the end of Hold

Distr. Temperature Temperature in distributor when full tonnage is reached

Extr. Temperature - 1 Temperature of the 1st extruder zone when full tonnage is reached

Extr. Temperature - 2 Temperature of the 2nd extruder zone when full tonnage is reached

Extr. Temperature - 3 Temperature of the 3rd extruder zone when full tonnage is reached





Hold Pressure Zone - 1 Pressure measured at the end of Hold zone 1










Injection Fill Time Time duration from the Start Of Injection to Transition

Injection Hold Time Time duration from the Transition to end of hold

Injection Position At Transition

Injection position of transition from fill to hold

Injection Pressure At Transition

Injection pressure of transition from fill to hold

Max. Fill Pressure Pressure measured in the time period between Start of

Injection to just before transition

Max Transfer Pressure Pressure measured in the time period between Start of

Transfer to just before transition



Nozzle Adapter Temperature

Temperature in nozzle when full tonnage is reached

Recovery Time Time duration between Screw Rotation Start and Screw

Rotation Stop

Resin Temperature Temperature for resin when full tonnage is reached

S/Pot Temperature - 1 Temperature of the 1st shooting pot zone when full tonnage is reached

S/Pot Temperature - 2 Temperature of the 2nd shooting pot zone when full tonnage is reached

Screw Run Time Time duration between Screw Rotation Start and Screw Rotation Stop

Screw RPM Measured in rpm at 75% of stroke during Recovery

Shot Length The difference between Shot Size and Cushion

Shot Size Injection barrel volume just before Start Of Injection

Transfer Cushion Extruder barrel volume at the end of Hold

Transfer Time Time duration from the Start Of Transfer to Transition

Transfer Position Extruder barrel position at the transition between Fill and

Hold

Transfer Pressure Extruder pressure of transition from fill to hold

Transition Position Extruder barrel volume at the transition between Fill and Hold

Table 13-12 Variable Definition List - Robot


ToolingPlate - In - Stage 1 Time duration between Tooling Plate Out Stage 1 and Tooling Plate In Stage 1



ToolingPlate - Out - Stage 1 Time duration between Tooling Plate In Stage 3 and Tooling Plate Out Stage 1



CoolPik - Horizontal Time duration between CoolPik Vertical and CoolPik Horizontal

Table 13-11 Variable Definition List - Two-Stage Injection (Continued)


Polaris — v2009.3

13–22 CONTROL LIMITS Screen

Plot Direction: : The charts on the SPC Detail, SPC Group, and SPC History screens can be drawn so that the newest value appears at the left edge of the chart (Plot Left to Right) or so that the newest value appears at the right edge of the chart (Plot Right to Left).

The operator can use these buttons to specify the direction to be used to plot the charts.

13.7 CONTROL LIMITS Screen

The CONTROL LIMITS screen displays the values for the currently assigned upper control limits and lower control limits for Xbar and R/s. It allows the operator to select or deselect fixed limits for each variable in the list, rather than let the SPC program calculate it automatically.

Press <SPC> key, then select the CONTROL LIMITS tab. Refer to Figure 13-7.


CoolPik - Vertical Time duration between CoolPik Horizontal and CoolPik Vertical

Part Drop Time duration to drop the part from the CoolPik

Table 13-12 Variable Definition List - Robot (Continued)


Figure 13-7 CONTROL LIMITS Screen

CONTROL LIMITS Screen 13–23


Table 13-13 CONTROL LIMITS Screen Descriptions

Field Description

Variables Displays the SPC variables selected for monitoring. Variables are selected on the SETUP screen. Control limits cannot be set for any variable that is not selected.

Fixed Limits Select the field to enable/disable fixed control limits for the variable. A pop-up window appears to prompt you to verify the action. When fixed control limits are enabled, a check mark appears in the field. Otherwise, the field is left blank.

The DETAILS screen charts will be redrawn with the new control limits after the next sample is collected.

Xbar Chart, R/s Chart

Lower Control (Ctl) Limits

Select the field, and enter/modify the Lower Control Limit value for the SPC variable.

Upper Control (Ctl) Limits

Select the field, and enter/modify the Upper Control Limit value for the SPC variable.

Polaris — v2009.3

13–24 SPC Concepts

13.8 SPC Concepts

13.8.1 Functional Overview

The SPC program monitors a process and determines when it has deviated from the process standard. A process is considered to have deviated from the standard when one or more monitored SPC variables are outside specified operating ranges.

When a process has deviated from the process standard, an operator can define a course of action, such as turn on the SPC alarm light, stop the machine, or turn on an auxiliary output.

The SPC allows an operator to:

• Select SPC variables to monitor from a list of process variables• View a summary of monitored SPC variables, their process limits, process capability

(Cpk), and state of statistical control• "Learn" the process standard, and monitor machine performance based on a set of

process criteria• View a 400-cycle trend for each monitored variable, the process average, the "spread",

the specification limits, and the Cpk• View process averages (Xbar chart), process variability (R/s chart), and current control

limits• Specify fixed control limits for Xbar and R/s charts for any monitored variable• Be alerted to changes in the process with Xbar statistical control tests (samples outside

the control limits, trends, runs, alternating data)• Specify for each monitored variable the alarm action to take when the process is out of

control• View Trend, Xbar, R/s charts simultaneously for all monitored variables• View Trend, Xbar, R/s data along with machine mode and setpoint change information

for any SPC variable from the previous 10,000 cycles• View the historic log of SPC warnings and alarms• Archive a Data Log containing process data for off-line analysis.

13.8.2 SPC Variables

The SPC program can provide statistical analysis for process variables.

A process variable tracks machine performance at the end of each machine cycle. Process variable examples are Cycle Time, Clamp Tonnage, Screw Speed, etc.

13.8.3 Monitoring Variables

The SPC program can contain numerous process variables. By default, data for all SPC variables are collected and logged to the Data Log.

In order to monitor SPC variables, they must be selected or defined. Process variables are selected and configured on the SETUP screen.

Machine Cycles and Sampling 13–25


The SPC program can simultaneously monitor numerous SPC variables. After variables have been selected or defined, all SPC functions are applied to those variables. The data are trended, control charts are plotted, and alarms are activated when a process has deviated from the process standard.

13.8.4 Machine Cycles and Sampling

The SPC program examines process variables at the end of every machine cycle. A single process variable value is called a Reading. For some calculations, the SPC program groups Readings into Samples. The operator can configure the size of samples and how often to take samples.

For example, a Sample Size of 5 means that 5 consecutive machine cycles make up a sample. A Sampling Period of 15 means that after one sample is collected, there is a 10 cycle pause before the next sample is collected.

As another example, a Sample Size of 5 and a Sampling Period of 5 indicates that 5 consecutive cycles make up a sample, and the next sample is taken immediately afterwards without any pause.

Each machine cycle is numbered, and this information is used to correlate part information with process information.

13.8.5 Trend and Distribution Charts

Trend charts graphically display SPC variable data for the last 400 machine cycles. The Trend charts indicate "spread" of the readings by plotting +3σ and -3σ limits. The spread indicates the statistical upper and lower ranges for the trend. 99.7% of readings should fall between the two limits. Refer to Figure 13-8.

A Distribution chart divides the range of readings into sub-ranges and displays them graphically. Refer to Figure 13-8. The Distribution chart indicates where most of the values in the trend fall, and if they are concentrated in a narrow band or distributed evenly.

For example, consider a set of data that varies between 1500 and 1800 units. A Distribution chart divides the range of values into 30 sub-ranges each 10 units wide, and displays the data distribution as shown in Figure 13-8.

Figure 13-8 Trend and Distribution Charts

S01

-100

152.

eps

Trend Chart

400 cycles

+3σ

-3σ

Distribution Chart

1800

1500

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13–26 Process Variability

A number of SPC calculations assume that the data follows a bell-shaped Normal (or Gaussian) distribution. This assumption is correct in most cases, and can be easily verified by visually checking the shape of the distribution.

13.8.6 Process Variability

SPC variable readings vary from machine cycle to machine cycle. Every process exhibits some degree of variability. Variability is the result of common causes and assignable causes.

Common causes cannot be changed without altering the manufacturing process. Measurement methods, and inherent repeatability limitations in mechanical components such as hydraulic valves are examples of common causes.

An assignable cause may be detected and identified. Changes in material properties, environmental conditions, and tool wear are some examples of assignable causes.

13.8.7 Specification Limits and Standards

Specification limits define the desired range for a process. When a process variable is outside the range, the operator can configure the machine to turn on the SPC warning light, and/or stop the machine, and/or turn on the auxiliary output.

For example, if it is known that transition pressure must be between 1500 and 1800 psi in order to properly mold a part, then an operator may choose to stop the machine and check the actual transition pressure.

The SPC program has a "learn specification limits" feature, which simplifies setting of standards.

If the process varies from the standard, part quality may or may not be affected. The operator can then determine how the change in process affected the part quality, and if specification limits should be widened or narrowed.

NOTE: When saving or recalling machine setups, SPC specification limits and configurations are included in the machine setup data.

13.8.8 Process Quality Factor (Cpk)

The process capability index (Cpk) for a process variable is a measure of the deviation from the specification limits. The larger the Cpk number, the further away the specification limits are from the current operating range for the process.

Cpk is defined as the ratio between the distance from the nearest specification limit to the current process average, and the 3σ limit of the process variable.

or,

Cpk USL X–3σ̂

----------------------=

Process Quality Factor (Cpk) 13–27


Refer to Section 13.8.13 for details.

In the example in Figure 13-9, the process spread is ± 50 psi. The process can deviate 100 psi up or down before the specification limits are exceeded.

In the example in Figure 13-10, the process spread is ± 50 psi. The process is at the specification limits, and any further downward shift in the process average will cause the process to be outside limits.

In the example in Figure 13-11, the process spread is ± 50 psi. The process is partially outside the specification limits.

Figure 13-9 Process Capability Index, Cpk = 3


Cpk X LSL–3σ̂

---------------------=

Cpk 1800 1650–50------------------------------ 3= =

S01

-100

153.

eps

Cpk = 3

+3σ

-3σ

1800

1500

1700

1650

1600

Cpk 1550 1500–50------------------------------ 1= =

S01

-100

154.

eps

Cpk = 1

+3σ

-3σ

1800

1500

1600

1550

Cpk 1525 1500–50------------------------------ 0.5= =

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13–28 Process Quality Factor (Cpk)

In the example in Figure 13-12, the process is completely outside the specification limits. The Cpk is 0.

In the example in Figure 13-13, the process spread is ± 75 psi. The process can deviate 75 psi up or down before the specification limits are exceeded.

Figure 13-11 Process Capability Index, Cpk = 0.5

Figure 13-12 Process Capability Index, Cpk = 0S

01-1

0015

5.ep

s

Cpk = 0.5

+3σ

-3σ

1800

1475

15251500

1575

S01

-100

156.

eps

Cpk = 0

+3σ

-3σ

1800

1350

1400

1500

1450

Cpk 1800 1650–75------------------------------ 2= =

Control Charts 13–29


In the example in Figure 13-14, the process spread is ± 20 psi. The process can deviate 80 psi down and 180 psi upward before the specification limits are exceeded.

13.8.9 Control Charts

Control charts display the average and range of process variable samples. The sample average consists of the sum of the readings in the sample divided by the number of readings. The sample range is the difference between the lowest and highest reading.

13.8.10 Xbar Charts

The purpose of Xbar charts is to determine if the process is in a "state of statistical control". The process is in "control" if all samples behave in a "random" manner, and therefore the variation in the process is most likely due to inherent process limitations (common causes).



S01

-100

157.

eps

Cpk = 2

+3σ

-3σ

1800

1500

1650

1575

1725

Cpk 1600 1500–20------------------------------ 5= =

S01

-100

158.

eps

Cpk = 5

+3σ

-3σ

1800

1500

16001580

1620

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13–30 Xbar Charts

The SPC program looks for patterns in the Xbar charts that indicate that the variability in the process is not random, and may be due to problems that can be rectified.

The Upper Control Limit (UCL) and Lower Control Limit (LCL) define the spread of the sample averages. Refer to Figure 13-15. If the variation in the process is random, in almost all cases (99.7%) the averages should fall within the control limits.

The SPC program looks for the following patterns:

• Limits – one sample average outside the control limits• Run – nine or more consecutive averages above or below the Xbar average• Trend – six or more consecutive averages trending upward or downward• Alternating data – fourteen or more consecutive alternating Xbar points

Figure 13-16 shows an example of an Xbar chart with one sample average outside the control limits.

Figure 13-17 shows an example of an Xbar chart with nine or more consecutive sample averages above or below the Xbar average.

Figure 13-15 Xbar Chart

Figure 13-16 Xbar Chart - Limits

Figure 13-17 Xbar Chart – Run

S01

-100

159.

eps

Xbar Chart

UCL

LCL

Average

S01

-100

160.

eps

Xbar Chart - Limits

UCL

LCL

Average

S01

-100

161.

epsXbar Chart - Run

UCL

LCL

Average

R/s Charts 13–31


Figure 13-18 shows an example of an Xbar chart with six or more consecutive sample averages trending upwards or downwards.

Figure 13-19 shows an example of an Xbar chart with 14 or more consecutive alternating sample averages.

13.8.11 R/s Charts

The purpose of the Range (R) or Standard Deviation (s) chart is to display the process variability by plotting the sample ranges. If the sample size is 10 or less, the program calculates the range "R" as the measure of sample variability. For sample sizes greater than 10, the range calculation does not accurately represent the sample variability. In such cases, the program calculates the standard deviation "s" as a measure of sample variability.

Figure 13-20 shows an example of an R/s chart.

Figure 13-18 Xbar Chart - Trend

Figure 13-19 Xbar Chart - Alternating Data

S01

-100

162.

eps

Xbar Chart – Trend

UCL

LCL

Average

S01

-100

163.

eps

Xbar Chart – Alternating Data

UCL

LCL

Average

Figure 13-20 R/s Chart

S01

-100

164.

eps

R/s Chart

UCL

LCL

Average

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13–32 SPC Alarms

The range of a sample is defined as the difference between the lowest and highest readings. For example, the range for a sample of 5 readings 1550, 1599, 1571, 1583 and 1499 is 100.

Sample range, R = largest observation - smallest observation.

The standard deviation of a sample is defined as the square root of the sum of squares of the difference between readings and the sample average, divided by the number of readings less 1.

If the difference between the low and high sample values varies significantly, the process variability is changing and may be a problem. The R/s chart samples should not cross the upper control limit (UCL) on the range chart.

Figure 13-21 shows how changes in the homogeneity of incoming material may show up as changes in process variability on the R/s chart.

NOTE: The R chart shows the "spread" of the process, and is not affected by changes in the process average. For example, if the process average of a process that is in control changes from 1500 psi to 1600 psi, the change will be indicated in the Trend and Xbar charts, but not in the R chart. However, if the process average remains the same, but the "spread" changes, the Trend and R chart will reflect the change, but not the Xbar chart.

The control charts display about 25 sample averages. The program calculates the chart limits, and checks for patterns whenever a new sample becomes available. The charts provide a window of 25 samples into the process, and reflect the current state of the process. In contrast, the specification limits provide a fixed frame of reference against which the current process "window" may be compared.

13.8.12 SPC Alarms

The SPC program generates up to four machine alarms. The operator can define which variables should be monitored for alarm conditions, and what the SPC program should do if there is an alarm.

The operator configures alarms on the SETUP screen. For each of the monitored variables, the operator can configure the SPC program to turn on the SPC warning light, and/or stop the

Figure 13-21 R/s Chart - Process Variability

s Xi X–( )2 n 1–( )⁄∑=

S01

-100

165.

eps

R/s Chart - Process Variability

UCL

LCL

Average

SPC Alarms 13–33


machine, and/or turn on an auxiliary output when the specification limits are exceeded. The SUMMARY screen summarizes the alarm settings for the SPC variables.

When an alarm occurs, an alarm message is displayed on the ALARMS screen, and a more specific message is logged to the Event Log. When the alarm is cleared, an alarm off message is also added to the Event Log.

Table 13-14 lists the different SPC alarm types.

Table 13-14 SPC Alarm Types

Alarm Condition SPC Alarm Message

SPC variable(s) outside specification limits

"Variable Name" - Point below Specification Limits

"Variable Name" - Point above Specification Limits

SPC variable(s) have Cpk below threshold

"Variable Name" - Cpk below Threshold

SPC variable(s) out of statistical control

"Variable Name" - Outside Xbar Control Limits

"Variable Name" - Run

"Variable Name" - Trend

"Variable Name" - Alternating Data

SPC cycle interruption "The machine has been stopped because of a SPC specification limit or Cpk threshold alarm".

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13–34 SPC Formulas

13.8.13 SPC Formulas

The following is a list of formulas used by the SPC program:

1. Sample Average, Xbar

where Xi is the process variable reading, n is the number of readings in the sample.

2. Xbar chart average,

where k is the number of samples in the Xbar or R/s chart

3. Xbar chart control limits – see range chart

where A2 is a control chart factor – see Table 13-15, is range chart average

4. Xbar control limits – see standard deviation chart

where A3 is a control chart factor – see Table 13-15

5. Range chart (for sample size ≤ 10)

Sample range, R = largest observation minus smallest observation

Range chart average,

where k is the number of samples in the Xbar or R/s chart

6. Range chart control limits

UCLrange = D4( )

LCLrange = D3( )

where D3, D4 are control chart factors – see Table 13-15

XXi∑

n-------------=

X

XX∑

k-----------=

UCLx bar– X A+= 2 R( )

LCLx bar– X A–= 2 R( )

R

UCLx bar– X A+= 3 s( )

LCLx bar– X A–= 3 s( )

R

RR∑

k-----------=

R

R

SPC Formulas 13–35


7. Sigma (population estimate),

where d2 is a control chart factor – see Table 13-15

8. Standard deviation (s) chart (for sample size >10)

where Xi is process variable reading, is sample average, and n is number of readings in the sample

9. Standard deviation chart average,

where k is the number of samples in the S chart

10. Standard deviation chart control limits

UCLs = B4( )

LCLs = B3( )

where B3, B4 are control chart factors – see Table 13-15

11. Sigma (population estimate),

where c4 is a control chart factor – see Table 13-15

12. Process Capability (Cpk)

or

use whichever specification limit is closer to

Table 13-15 Control Chart Factor Table

n A2 A3 B3 B4 c4 d2 D3 D4

2 1.880 2.659 0 3.267 0.7979 1.128 0 3.267

3 1.023 1.954 0 2.568 0.8862 1.693 0 2.574

4 0.729 1.628 0 2.266 0.9213 2.059 0 2.282

5 0.577 1.427 0 2.089 0.9400 2.326 0 2.114

6 0.483 1.287 0.030 1.970 0.9515 2.534 0 2.004

7 0.419 1.182 0.118 1.882 0.9594 2.704 0.076 1.924

σ̂ Rd2-----=

s Xi X–( )2 n 1–( )⁄∑=

X

s

ss∑

k---------=

s

s

σ̂ sc4-----=

Cpk USL X–3σ̂

----------------------=

Cpk X LSL–3σ̂

---------------------=

X

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13–36 SPC Statistical References

13.8.14 SPC Statistical References

• Griffith, Gary K. Statistical Process Control Methods, USA, ASQC Quality Press, 1989• American National Standard, Definitions, Symbols, Formulas, and tables for Control

Charts, USA, ASQC Quality Press, 1987• American National Standard, Guide for Quality Control Charts, Control Chart Method of

Analyzing Data, Control Chart Method of Controlling Quality During Production, USA, ASQC Quality Press, 1985

• Burr, John T. SPC Tools for Operators, USA, ASQC Quality Press, 1989.

8 0.373 1.099 0.185 1.815 0.9650 2.847 0.136 1.864

9 0.337 1.032 0.239 1.761 0.9693 2.970 0.184 1.816

10 0.308 0.975 0.284 1.716 0.9727 3.078 0.223 1.777

11 0.285 0.927 0.321 1.679 0.9754 3.173 0.256 1.774

12 0.266 0.886 0.354 1.646 0.9776 3.258 0.283 1.717

13 0.249 0.850 0.382 1.618 0.9794 3.336 0.307 1.693

14 0.235 0.817 0.406 1.594 0.9810 3.407 0.328 1.672

15 0.223 0.789 0.428 1.572 0.9823 3.472 0.347 1.653

16 0.212 0.763 0.448 1.552 0.9835 3.532 0.363 1.637

17 0.203 0.739 0.466 1.534 0.9845 3.588 0.378 1.622

18 0.194 0.718 0.482 1.518 0.9854 3.640 0.391 1.608

19 0.817 0.698 0.497 1.503 0.9862 3.689 0.403 1.597

20 0.180 0.680 0.510 1.490 0.9869 3.735 0.415 1.585

21 0.173 0.663 0.523 1.477 0.9876 3.778 0.425 1.575

22 0.167 0.647 .0534 1.466 0.9882 3.819 0.434 1.566

23 0.162 0.633 0.545 1.455 0.9887 3.858 0.443 1.557

24 0.157 0.619 0.555 1.445 0.9892 3.895 0.451 1.548

25 0.153 0.606 0.565 1.435 0.9896 3.931 0.459 1.541

Table 13-15 Control Chart Factor Table (Continued)

n A2 A3 B3 B4 c4 d2 D3 D4

HMI Reference Manual Polaris — v2009.3 Auxiliary Equipment Interface (Optional)

14–1

Chapter 14 Auxiliary Equipment Interface (Optional)

The optional Auxiliary Equipment screens allow Husky machines to communicate with auxiliary equipment such as thermolators, hot runners, chiller, dryers, and additive feeders using one of two communication protocol, either SPI or Euromap 17.

NOTE: Specific parameters and device data may vary with equipment manufacturer. Consult the device manufacturer’s documentation for further information.

• For a description of the Euromap 17 interface, refer to Section 14.1• For a description of SPI interface, refer to Section 14.2

Polaris — v2009.3

14–2 Euromap 17 Interface

14.1 Euromap 17 Interface

14.1.1 DEVICE SETUP Screen

The DEVICE SETUP screen allows a user to enable and configure the devices attached to the auxiliary equipment (Euromap 17) network.

Press <F11> key to display the DEVICE SETUP screen. Refer to Figure 14-1.

NOTE: Depending on how the machine is configured the Auxiliary Equipment screens may be under the <F10> key.



Figure 14-1 DEVICE SETUP Screen

DEVICE SETUP Screen 14–3


Table 14-1 DEVICE SETUP Screen Descriptions

Element Description

Enable Touch the check box to enable communications to the device at the specified address. Clear the check box to disable communications to the device.

NOTE: The address and/or channel configuration for a device can only be modified when communication to the device is disabled.

Device Displays a list of devices that can be connected to the Euromap 17 network. This list of devices is pre-configured at the factory by Husky.

The following is a list of five auxiliary device types and the maximum number of devices that are currently supported: thermolators (10), hot runners (32), chillers (2), dryers (2), and additive feeders (2).

Address Enter the physical device address for the device on the Euromap 17 network. Valid Address numbers are 0-99. Address numbers cannot be duplicated for enabled devices.


Starting Channel Enter the value for the starting channel at the specified address. Valid Starting Channel numbers are 0-99. This is usually zero or one, and is specified by the manufacturer.


Channels Enter the number of channels. The upper limit for the number of supported channels per address is 16.


Conflict The Red indicator lights up when the enabled device’s setpoint value stored in the HMI is different from the value stored in the field device. A conflict can arise when a new device is connected to the network, or if a setpoint value is changed directly at the field device.

(Synchronize Settings)

Use Device/ Use HMI

Select the Use Device or Use HMI option button to globally synchronize all setpoint values to the field device value or HMI value according to the selection made. The Conflict indicator (mentioned above) remains lit until synchronization is complete, at which time the indicator and the option buttons are greyed out.

NOTE: The Use Device and Use HMI option buttons are normally greyed out until a conflict occurs between the device’s setpoint value in the HMI and the field device.

NOTE: Device parameters can be synchronized individually, if necessary, on the device screens discussed below; however it is not necessary to do so.

Polaris — v2009.3

14–4 Set Up Auxiliary Devices

14.1.1.1 Set Up Auxiliary Devices


Set up auxiliary devices using the following instructions:

1. Press the <F11> key to display the DEVICE SETUP screen. Refer to Figure 14-1.

2. Clear the Enabled check box to disable the appropriate device.

3. Then enter values for the Starting Channel and Address for the device.

4. Enter a value for the number of Channels for the device.

5. Select the Enabled check box to enable the device.

6. Check for any conflicts between the HMI and Device setpoint values. If necessary, select the Use Device or Use HMI option button to globally synchronize all setpoint values to the field device value or HMI value as appropriate.

NOTE: Certain manufacturer-specific bits may need to be enabled for remote operation of the device. Refer to the equipment manual. Also refer to the equipment manual for a list of supported parameters.

14.1.1.2 Configuring COM Port for Euromap 17 Devices


The following instructions apply to the settings for the BrainBoxes Serial Solutions Velocity Dual Opto-Isolated RS422/485 card. Use the following instructions to configure the COM port on the IPC to run Euromap 17 communications:

1. Open the Control Panel in the Windows operating system, and double-click the Serial Solutions icon.

2. Verify that the COM5 (for P4 IPCs) is configured for "Velocity Dual Opto-Isolated RS422/485 card" on the PCI bus.

NOTE: For P3 IPCs use port COM3.

3. Select the Settings button. A pop-up window is displayed.

4. In the General tab verify that the Hardware Information displays "Velocity Dual Opto-Isolated RS422/485 Card - Firmware Revision 3".

5. Select the Port Settings tab, and verify that the settings are as follows:

Bits per second: 9600

Data bits: 8

Parity: Even

Stop Bits: 1

Flow control: None

6. Then select the Advanced button on the same tab, and verify the following:

Receive trigger level: 100%

Software transmit limit: 24%

Duplex operation: RS485 half-duplex autogating mode

CTS True: not selected

Device (THERMOLATOR) Screen 14–5


UART Type: 750

FIFO off: not selected

7. Select Apply, OK, then Close.

NOTE: It may be necessary to reboot the IPC if changes have been made to the configuration.

14.1.2 Device (THERMOLATOR) Screen

The device screens allows a user to view various parameters for each enabled device attached to the auxiliary equipment (Euromap 17) network. Each one of the enabled devices is grouped under a separate device type tab (THERMOLATORS, HOT RUNNERS, CHILLERS, DRYERS, and ADDITIVE FEEDERS).

This section discusses the THERMOLATOR screen, however all the other auxiliary device screens are similar.

Press <F11> key, and touch the THERMOLATOR tab. Refer to Figure 14-2.



NOTE: The device screens can support all device parameters defined by the Euromap 17 protocol, however not all parameters are supported by the device manufacturers. Refer to the equipment manual for a list of supported device parameters.

Figure 14-2 Device (THERMOLATOR) Screen

Polaris — v2009.3

14–6 Device (THERMOLATOR) Screen

Table 14-2 Device (THERMOLATOR) Screen Descriptions

Element Description

Enable Select the check box to enable the parameter. Clear the check box to disable the parameter. By default all parameters are enabled, but the user may choose to only use certain parameters.

NOTE: All status bits and mode bits are read from the field devices regardless of whether the parameter is enabled or not. However, communications to and from the field device pertaining to the parameter only occur when the parameter is enabled.

Show All/ Show Enabled

(Parameters)

Select the Show All option button to display all parameters including those that are disabled; otherwise select the Show Enabled option button.

Touch the Expand button to display the FILTER pop-up window shown below to further filter the list of enabled parameters by their

data types – Values (Setpoint or Actual), Status, or Mode. Or select All to display all enabled parameters.

(Parameter Values) The column headings display the device name and channel number for those devices that are configured and enabled on the DEVICE SETUP screen.

Parameter values are of three basic type – Analog values (Setpoint or Actual), Status, and Mode. Each type is described below:

• Actual values are read from the field devices and displayed in a non-editable box with a grey background.

• Setpoint values are editable by the user and are displayed in a white text box.

• Status values are displayed as indicator lights. The indicator lights up Green when the value is "True" (ON), and Grey when the value is "False" (OFF).

• Mode values are displayed through the use of check boxes. The check box is selected when the value is "ON", and cleared when the value is "OFF".

NOTE: Unsupported parameters always display a value of "???".

SPI Interface 14–7


14.2 SPI Interface

14.2.1 DEVICE SETUP Screen

The DEVICE SETUP screen allows a user to enable and configure the devices attached to the auxiliary equipment (SPI) network.

Press <F11> key to display the DEVICE SETUP screen. Refer to Figure 14-1.

NOTE: Depending on how the machine is configured the Auxiliary Equipment screens may be under the <F10> key.

Compare With Device Values

Select the check box to automatically compare the parameter values stored in the HMI against the field device values. An additional column is displayed with a suitable heading to indicate whether the displayed data is for the HMI or field device. Normally the values displayed in these columns are identical, however if parameters are modified remotely at the field device or a new device has just been added to the network the value may be different. HMI parameter values can be modified individually to match the field device values; however this is not necessary.

(Message Bar) Display a message in this space if a command is rejected or not supported.

Table 14-2 Device (THERMOLATOR) Screen Descriptions (Continued)

Element Description

Figure 14-3 DEVICE SETUP Screen

Polaris — v2009.3

14–8 DEVICE SETUP Screen



Table 14-3 DEVICE SETUP Screen Descriptions

Element Description

Enable Touch the check box to enable communications to the device at the specified address. Clear the check box to disable communications to the device.


NOTE: Disable disconnected devices to prevent the controller making calls to unconnected devices and slowing communications down.

Device Displays a list of devices that can be connected to the SPI network. This list of devices is pre-configured at the factory by Husky. Currently three device types are supported, they are:

• thermolator

• dryer

• additive feeder

Address Enter the physical device address for the device on the SPI network. Valid Address numbers are 20 to 255. Address numbers cannot be duplicated for enabled devices.

NOTE: Device vendors can specify addresses in hexadecimal notation rather than decimal, such as 20 hex (32 decimal). The HMI expects decimal values.

NOTE: The address configuration for a device can only be modified when communication to the device is disabled.

Channels This column is reserved for future use and always displays "1" for the current set of supported SPI devices.

Version Displays the device’s firmware version as reported by the device.

Active If this indicator is green, the HMI is communicating with the SPI device.

If the indicator is red, communications could not be established0.

Set Up Auxiliary Devices 14–9


14.2.1.1 Set Up Auxiliary Devices


Set up auxiliary devices using the following instructions:

1. Press the <F11> key to display the DEVICE SETUP screen. Refer to Figure 14-1.

2. Clear the Enabled check box to disable the appropriate device.

3. Then enter values for the Starting Channel and Address for the device.

4. Enter a value for the number of Channels for the device.

5. Select the Enabled check box to enable the device.

6. Check for any conflicts between the HMI and Device setpoint values. If necessary, select the Use Device or Use HMI option button to globally synchronize all setpoint values to the field device value or HMI value as appropriate.

NOTE: Certain manufacturer-specific bits may need to be enabled for remote operation of the device. Refer to the equipment manual. Also refer to the equipment manual for a list of supported parameters.

14.2.1.2 Configuring COM Port for SPI Devices


The following instructions apply to the settings for the BrainBoxes Serial Solutions Velocity Dual Opto-Isolated RS422/485 card. Use the following instructions to configure the COM port on the IPC to run SPI communications:

Conflict The Red indicator lights up when the enabled device’s setpoint value stored in the HMI is different from the value stored in the field device. A conflict can arise when a new device is connected to the network, or if a setpoint value is changed directly at the field device.

(Synchronize Settings)

Use Device/ Use HMI

Select the Use Device or Use HMI option button to globally synchronize all setpoint values to the field device value or HMI value according to the selection made. The Conflict indicator (mentioned above) remains lit until synchronization is complete, at which time the indicator and the option buttons are greyed out.

NOTE: The Use Device and Use HMI option buttons are normally greyed out until a conflict occurs between the device’s setpoint value in the HMI and the field device.

NOTE: Device parameters can be synchronized individually, if necessary, on the device screens, refer to Section 14.2.4; however it is not necessary to do so.

Table 14-3 DEVICE SETUP Screen Descriptions (Continued)

Element Description

Polaris — v2009.3

14–10 Configuring COM Port for SPI Devices

1. Open the Control Panel in the Windows operating system, and double-click the Serial Solutions icon.

2. Verify that the COM5 (for P4 IPCs) is configured for "Velocity Dual Opto-Isolated RS422/485 card" on the PCI bus.

NOTE: For P3 IPCs use port COM3.

3. Select the Settings button. A pop-up window is displayed.

4. In the General tab verify that the Hardware Information displays "Velocity Dual Opto-Isolated RS422/485 Card - Firmware Revision 3".

5. Select the Port Settings tab, and verify that the settings are as follows:

Bits per second: 9600

Data bits: 8

Parity: Even

Stop Bits: 1

Flow control: None

6. Then select the Advanced button on the same tab, and verify the following:

Receive trigger level: 100%

Software transmit limit: 24%

Duplex operation: RS485 half-duplex autogating mode

CTS True: not selected

UART Type: 750

Figure 14-4 Configuring COM Port for SPI Devices

Device (DRYER) Screen 14–11


FIFO off: not selected

7. Select Apply, OK, then Close.

NOTE: It may be necessary to reboot the IPC if changes have been made to the configuration.

14.2.2 Device (DRYER) Screen

The device screens allows a user to view various parameters for each enabled device attached to the auxiliary equipment (SPI) network. Each one of the enabled devices is grouped under a separate device type tab (THERMOLATORS, HOT RUNNERS, CHILLERS, DRYERS, and ADDITIVE FEEDERS).

This section discusses the DRYER screen, however all the other auxiliary device screens are similar.

Press <F11> key, and touch the DRYER tab. Refer to Figure 14-2.



NOTE: The device screens can support all device parameters defined by the SPI protocol, however not all parameters are supported by the device manufacturers. Refer to the equipment manual for a list of supported device parameters.

Figure 14-5 Device (DRYER) Screen

Polaris — v2009.3

14–12 Device (DRYER) Screen

Table 14-4 Device (DRYER) Screen Descriptions

Element Description

Enable Select the check box to enable the parameter. Clear the check box to disable the parameter. By default all parameters are enabled, but the user may choose to only use certain parameters.

NOTE: All status bits and mode bits are read from the field devices regardless of whether the parameter is enabled or not. However, communications to and from the field device pertaining to the parameter only occur when the parameter is enabled.

Show All/ Show Enabled

(Parameters)

Select the Show All option button to display all parameters including those that are disabled; otherwise select the Show Enabled option button.

Touch the Expand button to display the FILTER pop-up window shown below to further filter the list of enabled parameters by their

data types – Values (Setpoint or Actual), Status, or Mode. Or select All to display all enabled parameters.

(Parameter Values) The column headings display the device name and channel number for those devices that are configured and enabled on the DEVICE SETUP screen.

Parameter values are of three basic type – Analog values (Setpoint or Actual), Status, and Mode. Each type is described below:

• Setpoint values are editable by the user and are displayed in a white text box.

• Actual values are read from the field devices and displayed in a non-editable box with a grey background.

• Status values are displayed as indicator lights. The indicator lights up Green when the value is "True" (ON), and Grey when the value is "False" (OFF).

• Mode values are displayed through the use of check boxes. The check box is selected when the value is "ON", and cleared when the value is "OFF".

NOTE: Unsupported parameters always display a value of "???".



Compare With Device Values

Select the check box to automatically compare the parameter values stored in the HMI against the field device values. An additional column is displayed with a suitable heading to indicate whether the displayed data is for the HMI or field device. Normally the values displayed in these columns are identical, however if parameters are modified remotely at the field device or a new device has just been added to the network the value may be different. HMI parameter values can be modified individually to match the field device values; however this is not necessary.

(Message Bar) Display a message in this space if a command is rejected or not supported.

Table 14-4 Device (DRYER) Screen Descriptions (Continued)

Element Description

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14–14 Device (DRYER) Screen

Table 14-5 SPI Auxiliary Equipment Events and Alarms

Event Description

Device Not Responding An enabled device does not respond to any command as detected by the underlying communications driver.

Here are the most common reasons for communications failure:

1. Hardware:

• The device is not connected

• The device is connected but not to the SPI port

• The device is connected to a machine SPI port, but there are no ‘link’ connectors for unused ports (plug in the device to the first SPI port instead to correct this problem).

• There is a RS485 cable fault (e.g. wrong cable, broken cable)

2. Configuration:

• The device’s address is not correct

• The device’s type is not supported

• The device’s baud rate is not 9600

• The device is not compatible with the SPI protocol

• The device is not enabled on the device screen

Recommendations:

1. If the device has previously worked with the HMI screens, and other devices are working, focus on cabling, hardware, or configuration

2. If devices have worked before, and now all devices are not working, check the SPI server is running (no alarm that the server is not running), and check the cabling from the Husky SPI connections box to the Polaris controller.

3. If this is a new device that has not previously worked, check the device’s documentation to make sure it supports the SPI protocol and that it is configured properly.

4. Try to communicate to each device on its own, while other devices are disconnected.

5. If you cannot resolve the problem, call Husky Service for further assistance.

Setpoint Conflict This warning indicates the device’s setpoints are different than the HMI’s image of the device setpoints. An operator can either,

1. Compare and resolve the setpoints individually on the device details screen, or

2. Select to globally set the setpoints using either the HMI or the device’s values on the device setup screen.

Device Process Warning The device is enabled, the ‘Status – Alarm, Process’ status bit is enabled and the device reported that the status bit is on.



Device Machine Warning The device is enabled, the ‘Status – Alarm, Machine’ status bit is enabled and the device reported that the status bit is on.

SPI Server Not Running This indicates an internal software problem, report this error to Husky Service if this alarm persists beyond HMI startup.

Table 14-5 SPI Auxiliary Equipment Events and Alarms (Continued)

Event Description

Polaris — v2009.3

14–16 Mold Temperature Controller

14.2.3 Mold Temperature Controller

14.2.3.1 Command Summary

The table below specifies the commands that are supported for the standard SPI Mold Temperature Controller screen. Some customer specials require that not all commands be shown (e.g., the device being used does not support all the commands), in which case only the commands with their corresponding data on the screen are supported.

In any case where an alarm is activated by the data read from the device, the alarm is always deactivated if the Enable Device SPI Communications option on the SPI Mold Temperature Controller screen is deselected.

Table 14-6 SPI Mold Temperature Controller Supported Commands

# Name Supported Notes

1.1 Echo Yes

1.2 Version No

1.3 Setpoint Process Temperature Yes

1.4 Alarm, High Temperature Deviation Yes

1.5 Alarm, Low Temperature Deviation Yes

1.6 Status, Process Yes When any of the “Alarm” bits are set, the alarm “SPI Mold Temperature Controller Process Alarm” is activated

1.7 Status, Machine 1 Yes When any of the “Alarm” bits are set, the alarm “SPI Mold Temperature Controller Machine Alarm 1” is activated

1.8 Status, Machine 2 Yes When any of the “Alarm” bits are set, the alarm “SPI Mold Temperature Controller Machine Alarm 2” is activated

1.9 Mode, Machine Yes only bit 1 is used.

1.10 Temperature, To Process Yes

1.11 Temperature, From Process Yes

1.12 Pressure, To Process Yes

1.13 Pressure, From Process Yes

1.14 Flow, To Process Yes

1.15 Blanket Poll 1 Yes

1.16 Protected Mode, Machine Yes Only bits 0 and 1 are used.

SPI Device I/O List 14–17


14.2.3.2 SPI Device I/O List

The following pages are the SPI Device I/O List for the Mold Temperature Controller (device ID 20). They can be found in the SPI Communication Protocol specification from the Society of the Plastics Industry Inc., Machinery Division, as identified in the Introduction above.

1.0 Mold Temperature Controller

1.1 Echo

1.2 Version

1.3 Setpoint Process Temperature

1.4 Alarm, High Temperature Deviation

1.5 Alarm, Low Temperature Deviation

1.6 Status, Process

1.7 Status, Machine 1


1.9 Mode, Machine

1.10 Temperature, To Process

1.11 Temperature, From Process

1.12 Pressure, To Process

1.13 Pressure, From Process

1.14 Flow, To Process

1.15 Blanket Poll 1

1.0 Mold Temperature Controller

Dev ID: 20

Description: Water or Oil Mold Temperature Controller

1.1 Echo

Poll: 20 20

Select: 20 21

Format: Open 4 bytes ASCII

Units: ASCII

Required: Yes

Description: Controller integrity command. Controller will accept and retain the data provided. The controller will provide the retained data in response to a poll inquiry.

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14–18 SPI Device I/O List

1.2 Version

Poll: 20 22

Select: N/A


Units: ASCII

Required: Yes

Description: Controller version command. The controller will provide a version number according to the following format: AABB, where

AA = SPI assigned version level

BB = Vendor assigned version level (use optional). If not used BB = 00.


Poll: 20 30

Select: 20 31

Format: Numeric

Units: °F

Required: Yes

Description: Temperature at which the process is to be maintained.


Poll: 20 32

Select: 20 33

Format: Numeric

Units: °F

Required: Yes

Description: This value in conjunction with the process setpoint, determines what temperature the high alarm will occur. It must always be positive.




Poll: 20 34

Select: 0 35

Format: Numeric

Units: °F

Required: Yes

Description: This value in conjunction with the process setpoint, determines what temperature the low alarm will occur. It must always be positive.

1.6 Status Process

Poll: 20 40

Select: N/A

Format: 16 Bits

Units: None

Required: Yes

Description:

Figure 14-6 SPI Mold Temperature Controller, Status Process

11 10 9 8 7 6 5 4 3 2 1 015 14 13 12

ProcessingAlarm, SystemAlarm, ProcessAlarm, MachineAlarm, High Temp.Alarm, Low Temp.Alarm, High PressureAlarm, Low PressureReservedAlarm, Low FlowReservedReservedReservedReserved

OpenOpen

Polaris — v2009.3


1.6.1 Processing

Bit #: 0

Required: Yes

Description: This status bit states whether this unit is currently processing.

0 = not current processing

1 = processing

1.6.2 Alarm, System

Bit #: 1

Required: Yes

Description: This status bit states an alarm is present. The logical OR of process alarm and machine alarm.

1.6.3 Alarm, Process

Bit #: 2

Required: Yes

Description: This bit indicates that an alarm that affects the process has occurred.

1.6.4 Alarm, Machine

Bit #: 3

Required: No

Description: This bit indicates that an alarm that affects machine operation has occurred.

1.6.5 Alarm, High Temperature

Bit #: 4

Required: Yes

Description: This status bit states the mold temperature controller has exceeded its over setpoint deviation.



1.6.6 Alarm, Low Temperature

Bit #: 5

Required: Yes

Description: This status bit states the mold temperature controller has exceeded its below setpoint deviation.

1.6.7 Alarm, High Pressure

Bit #: 6

Required: No

Description: This status bit states that a high pressure condition has been detected in the mold temperature controller. If not supported, bit should be set to zero.

1.6.8 Alarm, Low Pressure

Bit #: 7

Required: No

Description: This status bit states that a low pressure condition has been detected in the mold temperature controller. If not supported, bit should be set to zero.

1.6.9 Alarm, Low Flow

Bit #: 9

Required: No

Description: This status bit states that low flow has been detected in the mold temperature controller. If not supported, bit should be set to zero.


Poll: 20 42

Select: N/A

Format: 16 bits

Units: None

Required: No

Description:

Polaris — v2009.3


Figure 14-7 SPI Mold Temperature Controller, Status Machine 1

1.7.1 Processing

Bit #: 0

Required: Yes

Description: This status bit states whether the mold temperature controller is currently processing.

0 = not currently processing

1 = processing

1.7.2 Alarm, System

Bit #: 1

Required: Yes

Description: This status bit states an alarm is present. This bit is set on the logical OR of process alarm and machine alarm.


Bit #: 2

Required: Yes


11 10 9 8 7 6 5 4 3 2 1 015 14 13 12

ProcessingAlarm, SystemAlarm, ProcessAlarm, MachineAlarm, High Temp.Alarm, Low Temp.Alarm, High PressureAlarm, Low PressureReservedReservedAlarm, High VoltageAlarm, Low VoltageAlarm, High CurrentAlarm, Low Current

OpenAlarm, Phase




Bit #: 3

Required: Yes



Bit #: 4

Required: No

Description: This status bit states that a high temperature safety limit has been activated.


Bit #: 5

Required: No

Description: This status bit states that a low temperature safety limit has been activated.

1.7.7 Alarm, High Pressure

Bit #: 6

Required: No

Description: This status bit states that a high pressure safety limit has been activated.

1.7.8 Alarm, Low Pressure

Bit #: 7

Required: No

Description: This status bit states that a low pressure safety limit has been activated.

1.7.9 Alarm, High Voltage

Bit #: 10

Required: No

Description: This status bit states that a high voltage condition has been detected.

Polaris — v2009.3


1.7.10 Alarm, Low Voltage

Bit #: 11

Required: No

Description: This status bit states that a low voltage condition has been detected.

1.7.11 Alarm, High Current

Bit #: 12

Required: No

Description: This status bit states that a low current condition has been detected.

1.7.12 Alarm, Low Current

Bit #: 13

Required: No


1.7.13 Alarm, Phase Reversed Or Lost

Bit #: 14

Required: No

Description: This status bit states that improper phase has been detected.


Poll: 20 44

Select: N/A

Format: 16 bits

Units: None

Required: No

Description:



Figure 14-8 SPI Mold Temperature Controller, Status Machine 2

1.8.1 Processing

Bit #: 0

Required: Yes

Description: This status bit states whether the mold temperature controller is currently processing.


1 = processing

1.8.2 Alarm, System

Bit #: 1

Required: Yes

Description: This status bit states an alarm is present. This bit is set on the logical OR of process alarm and machine alarm.


Bit #: 2

Required: Yes


11 10 9 8 7 6 5 4 3 2 1 015 14 13 12

ProcessingAlarm, SystemAlarm, ProcessAlarm, MachineFault, SensorFault, CalibrationReservedReservedReservedReservedReservedReservedReservedReserved

OpenOpen

Polaris — v2009.3



Bit #: 3

Required: Yes


1.8.5 Fault, Sensor

Bit #: 4

Required: No

Description: This status bit states that a sensor error has been detected.

1.8.6 Fault, Calibration

Bit #: 5

Required: No

Description: This status bit states that a sensor calibration error has been detected.

1.9 Mode, Machine

Poll: 20 48

Select: 20 49

Format: Status

Units: 2 8-bit bytes

Required: No

Description:

Figure 14-9 SPI Mold Temperature Controller, Mode Machine

Machine, On/OffAlarm, AcknowledgeReservedReservedReservedReservedReservedReservedReservedReservedReservedReservedReservedReserved

ReservedReserved

11 10 9 8 7 6 5 4 3 2 1 015 14 13 12



1.9.1 Machine, On/off

Bit #: 0

Required: No

Description: This mode bit commands the mold temperature controller to be turned on (1) or off (0). When polled, this bit states if the machine is on or off.

1.9.2 Alarm Acknowledge

Bit #: 1

Required: Yes

Description: This bit is used to allow the master to inform the slave that it has recognized the alarm condition(s) presented in the status words. Setting this bit to a one (1) acknowledges the alarm bit will always read back as a 0. Note that it is not intended that this command clear any alarm indication (horn, bell, light) at the auxiliary device.


Poll: 20 70

Select: N/A

Format: Numeric

Units: °F

Required: Yes

Description: Returns the To Process Temperature.


Poll: 20 72

Select: N/A

Format: Numeric

Units: °F

Required: No

Description: Returns the From Process Temperature.

Polaris — v2009.3



Poll: 20 74

Select: N/A

Format: Numeric

Units: PSIG

Required: No

Description: Returns the To Process Pressure.


Poll: 20 76

Select: N/A

Format: Numeric

Units: PSIG

Required: No

Description: Returns the From Process Pressure.


Poll: 20 78

Select: N/A

Format: Numeric

Units: GPM

Required: No

Description: Returns the To Process Flow Rate.

1.15 Blanket Poll 1

Poll: 20 E0

Select: N/A

Format: Open

Units: Command Specific

Required: No

Description: The blanket poll provides a mechanism to scan the required poll commands with one poll. The format of the blanket poll is:

<20><30><NV> <20><32><NV> <20><34><NV>

<20><40><SV> <20><70><NV>



<NV> is some numeric value associated with the two bytes that precede it.

<SV> is some status value associated with the two bytes that precede it.

1.16 Protected Mode, Machine

Poll: 20 4A

Select: 20 4B

Format: Status

Unit: 2 8-bit bytes

Required: No

Description:

Figure 14-10 SPI Mold Temperature Controller, Protected Mode, Machine


Bit #: 0

Required: No

Description: This mode bit commands the mold temperature controller to be turned on (1) or off (0), when the on/off action allowed bit is set high. When the on/off action allowed bit is low the machine on/off bit command has no effect. When polled, this bit states if the machine is on or off.

1.15 Blanket Poll 1

Machine, On/OffOn/Off AllowedAlarm, AcknowledgeReservedReservedReservedReservedReservedReservedReservedReservedReservedReservedReserved

ReservedReserved

11 10 9 8 7 6 5 4 3 2 1 015 14 13 12

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14–30 Dryer

14.2.4 Dryer


The table below specifies the commands that are supported for the standard SPI Dryer screen. Some customer specials require that not all commands be shown (e.g., the device being used does not support all the commands), in which case only the commands with their corresponding data on the screen are supported.

In any case where an alarm is activated by the data read from the device, the alarm is always deactivated if the Enable Device SPI Communications option on the SPI Dryer screen is deselected.

1.16.2 On/off Action Allowed

Bit #: 1

Required: No

Description: This mode bit provides a safety to the use of the machine on/off action. To allow on/off action, set this bit high and to inhibit this action, set this bit low. During a poll, this bit returns to zero (0).


Bit #: 1

Required: Yes

Description: This bit is used to allow the master to inform the slave that it has recognized the alarm condition(s) presented in the status words. Setting this bit to a one (1) acknowledges the alarm bit will always read back as a 0.

Note that it is not intended that this command clear any alarm indication (horn, bell, light) at the auxiliary device.




The following pages are the SPI Device I/O List for the Dryer (device ID 22). They can be found in the SPI Communication Protocol specification from the Society of the Plastics Industry Inc., Machinery Division, as identified in the Introduction above.

Table 14-7 SPI Dryer Supported Commands


3.1 Echo Yes

3.2 Version No

3.3 Setpoint Process Temperature Yes

3.4 Alarm, High Temperature Deviation Yes

3.5 Alarm, Low Temperature Deviation Yes

3.6 Status, Process Yes when any of the “Alarm” bits are set, the alarm “SPI Dryer Process Alarm” is activated

3.7 Status, Machine 1 Yes when any of the “Alarm” bits are set, the alarm “SPI Dryer Machine Alarm 1” is activated

3.8 Status, Machine 2 Yes when any of the “Alarm” bits are set, the alarm “SPI Dryer Machine Alarm 2” is activated


3.10 Temperature, To Process Yes

3.11 Temperature, From Process Yes

3.12 Pressure, To Process Yes

3.13 Pressure, From Process Yes

3.14 Flow, To Process Yes

3.15 Dewpoint °F Yes

3.16 Setpoint, High Dewpoint Alarm Yes


3.18 Protected Mode, Machine Yes only bits 0 and 1 are used.

Polaris — v2009.3


3.0 Dryer

3.1 Echo

3.2 Version




3.6 Status, Process



3.9 Mode, Machine






3.15 Dewpoint °F

3.16 Setpoint, High Dewpoint Alarm

3.17 Blanket Poll 1

3.0 Dryer

Dev ID: 22

Description: Material Drying Units

3.1 Echo

Poll: 20 20

Select: 20 21

Format Open 4 bytes ASCII

Units ASCII

Required: Yes




3.2 Version

Poll: 20 22

Select: N/A


Units: ASCII

Required: Yes


AA=SPI assigned version level

BB=Vendor assigned version level (use optional). If not used BB=0.


Poll: 20 30

Select: 20 31

Format: Numeric

Units: °F

Required: Yes

Description: Temperature at which the process is to be maintained.


Poll: 20 32

Select: 20 33

Format: Numeric

Units: °F

Required: Yes

Description: This value in conjunction with the process setpoint, determines what temperature the high alarm will occur. It must always be positive.

Polaris — v2009.3


3.5 Alarm, Low Level Deviation

Poll: 20 34

Select: 20 35

Format: Numeric

Units: °F

Required: Yes

Description: This value in conjunction with the process setpoint, determines what temperature the low alarm will occur. It must always be positive.

3.6 Status Process

Poll: 20 40

Select: N/A

Format: 16 bits

Units: None

Required: Yes

Description:

Figure 14-11 SPI Dryer Controller, Status Process

3.6.1 Processing

Bit#: 0

Required: Yes

Description: This status bit states whether this unit is currently processing.

ProcessingAlarm, SystemAlarm, ProcessAlarm, MachineAlarm, High Temp.Alarm, Low Temp.ReservedReservedAlarm, Clogged FilterAlarm, Low FlowAlarm, High DewpointReservedReservedReserved

OpenOpen

11 10 9 8 7 6 5 4 3 2 1 015 14 13 12



3.6.2 Alarm, System

Bit#: 1

Required: Yes



Bit#: 2

Required: Yes



Bit#: 3

Required: Yes



Bit#: 4

Required: Yes

Description: This status bit states the dryer has exceeded its over setpoint deviation.


Bit#: 5

Required: Yes

Description: This status bit states that the dryer has exceeded its below setpoint deviation.

3.6.7 Reserved

Polaris — v2009.3


3.6.8 Alarm, Clogged Filter

Bit#: 7

Required: No

Description: This status bit states that a clogged filter condition has been detected in the dryer. If not supported, bit should be set to zero.


Bit #: 9

Required: No

Description: This status bit states that a low flow condition has been detected in the dryer. If not supported, bit should be set to zero.

3.6.10 Alarm, High Dew Point

Bit #: 10

Required: NO

Description: This status bit states that a high dew point condition exists in process air.


Poll: 20/42

Select: N/A

Format: 16 Bits

Units: None

Required: No

Description:



Figure 14-12 SPI Dryer Controller, Status Machine

3.7.1 Processing

Bit#: 0

Required: Yes

Description: This status bit states whether the dryer is currently processing.


1 = processing

3.7.2 Alarm, System

Bit #: 1

Required: Yes


3.7.3 Alarm Process

Bit#: 2

Required: Yes


ProcessingAlarm, SystemAlarm, ProcessAlarm, MachineAlarm, High Temp.Alarm, Low Temp.ReservedReservedReservedAlarm, Low FlowAlarm, High VoltageAlarm, Low VoltageAlarm, High CurrentAlarm, Low Current

OpenAlarm, Phase

11 10 9 8 7 6 5 4 3 2 1 015 14 13 12

Polaris — v2009.3



Bit#: 3

Required: YES

Description: This bit indicates that an alarm that affects machine operations has occurred.


Bit#: 4

Required: No

Description: This status bit states that a high temperature safety limit been activated.


Bit#: 5

Required: No

Description: This status bit states that a low temperature safety limit has been activated.


Bit#: 9

Required: No

Description: This status bit states that a low flow condition has been detected.

3.7.8 Alarm, High Voltage

Bit#: 10

Required: No

Description: This status bit states that a high voltage condition has been detected.

3.7.9 Alarm, Low Voltage

Bit#: 11

Required: No

Description: This status bit states that a low voltage condition has been detected.



3.7.10 Alarm, High Current

Bit#: 12

Required: No

Description: This status bit states that a high current condition has been detected.

3.7.11 Alarm, Low Current

Bit#: 13

Required: No


3.7.12 Alarm, Phase Reversed Or Lost

Bit #: 14

Required: No

Description: This status bit states that improper phase has been detected.


Poll: 20 44

Select: N/A

Format: 16 Bits

Units: None

Required: No

Description:

Figure 14-13 SPI Dryer Controller, Status, Machine 2

ProcessingAlarm, SystemAlarm, ProcessAlarm, MachineAlarm, SensorAlarm, CalibrationReservedReservedReservedReservedReservedReservedReservedReserved

OpenOpen

11 10 9 8 7 6 5 4 3 2 1 015 14 13 12

Polaris — v2009.3


3.8.1 Processing

Bit#: 0

Required: Yes

Description: This status bit states whether the dryer is currently processing

0= not currently processing

1 = processing

3.8.2 Alarm, System

Bit#: 1

Required: Yes

Description: This status bit states an alarm is present. The logical OR of process and machine alarm.


Bit#: 2

Required: Yes



Bit#: 3

Required: Yes


3.8.5 Fault, Sensor

Bit#: 4

Required: No

Description: This status bit indicates that a sensor error has been detected.

3.8.6 Fault, Calibration

Bit#: 5

Required: No

Description: This status bit states that a sensor calibration error has been detected.



3.9 Mode, Machine

Poll: 20 48

Select: 20 49

Format: Status

Units: 16 Bit

Required: None

Description:

Figure 14-14 SPI Dryer Controller, Mode, Machine


Bit#: 0

Required: No

Description: This mode bit commands the dryer to be turned on (1) or off (0).

When polled, this bit states if the machine is on or off.

3.9.2 Alarm, Acknowledge

Bit#: 1

Required: Yes

Description: This bit is used to allow the master to inform the slave that it has recognized the alarm condition(s) presented in the status words. Setting this bit to one (1) acknowledges the alarm. Bit will always read back as a 0. Note that it is not intended that this command clear any alarm indication (horn, bell, light) at the auxiliary device.


ReservedReserved

11 10 9 8 7 6 5 4 3 2 1 015 14 13 12

Polaris — v2009.3



Poll: 20 70

Select: N/A

Format: Numeric

Units: °F

Required: Yes

Description: Returns the to process temperature.


Poll: 20 72

Select: N/A

Format: Numeric

Units: °F

Required: No

Description: Returns the from process temperature.


Poll: 20 74

Select: N/A

Format: Numeric

Units: PSIG

Required: No

Description: Returns the to process pressure.


Poll 20 76

Select: N/A

Format: Numeric

Units: Inches of H20 (water)

Required: No

Description: Returns the from process pressure.




Poll: 20 78

Select: N/A

Format: Numeric

Units: Cubic feet per minute (CFM)

Required: No

Description: Returns to the process Flow Rate.

3.15 Dewpoint, °F

Poll: 20 7c

Select: N/A

Format: Units °F

Required: No

Description: Returns the to process dewpoint temperature.

3.16 Setpoint, High Dewpoint Alarm

Poll: 20 80

Select: 20 81

Format: Numeric

Required: No

Description: Value at which high dewpoint alarms will occur.

3.17 Blanket Poll 1

Poll: 20 E0

Select: N/A

Format: Open


Required: No

Description: The blanket poll provides a mechanism to scan the required poll commands with one poll. The format of the blanket poll is:

<20><30><NV> <20><32><NV> <20><34><NV>

<20><40><SV> <20><70><NV>

<NV> is some numeric value associated with the two bytes that precede it.

<SV> is some status value associated with the two bytes that precede it.

Polaris — v2009.3



Poll: 20 4A

Select: 20 4B

Format: Status

Units: 2 8-BIT BYTES

Required: No

Description:

Figure 14-15 SPI Dryer Controller, Protected Mode Machine


Bit#: 0

Required: No

Description: This mode bit commands the dryer to be turned on (1) or off (0), when the on/off action allowed bit is set high. When the on/off action allowed bit is low the machine on/off bit command has no effect. When polled, this bit states if the machine is on or off.


Bit#1: 1

Required: No

Description: This mode bit provides a safety to use the machine on/off action. To allow on/off action, set this bit high and to inhibit this action, set this bit low. During poll, this bit returns zero (0).

Machine, On/Off

Alarm, AcknowledgeReservedReservedReservedReservedReservedReservedReservedReservedReservedReservedReserved

ReservedReserved

On/Off Action Allowed

11 10 9 8 7 6 5 4 3 2 1 015 14 13 12

Volumetric Blender 14–45


14.2.5 Volumetric Blender


Refer to Section 14.2.5.2 for a description of the SPI Volumetric Blender screens data entry fields. The following subsections describe which commands are supported by the Husky Injection Molding Machine and, if necessary, any special handling that is performed.

The table below specifies the commands that are supported for the standard SPI Volumetric Blender screen. Some customer specials require that not all commands be shown (e.g., the device being used does not support all the commands), in which case only the commands with their corresponding data on the screen are supported.

In any case where an alarm is activated by the data read from the device, the alarm is always deactivated if the Enable Device SPI Communications option on the SPI Volumetric Blender screen is deselected.


Bit#: 1

Required: Yes

Description: This bit is used to allow the master to inform the slave that it has recognized the alarm condition(s) presented in the status words. Setting this bit to a one (1) acknowledges the alarm bit will always read back as a 0.

Note that it is not intended that this command clear any alarm indication (horn, bell, light) at the auxiliary device.

Polaris — v2009.3



The following pages are the SPI Device I/O List for the Volumetric Blender (device ID 28). They can be found in the SPI Communication Protocol specification from the Society of the Plastics Industry Inc., Machinery Division, as identified in the Introduction above.

Table 14-8 SPI Volumetric Blender Supported Commands


9.1 Echo Yes

9.2 Version No

9.3 Setpoint Process Temperature Yes when any of the “Alarm” bits are set, the alarm “SPI Volumetric Blender Alarm” is activated

9.4 Status, Process Hopper Yes when any of the “Alarm” bits are set, the alarm “SPI Volumetric Blender - Unit x Process Alarm” is activated where x is A or B or C or D or E or F or G or H

9.5 Mode, Process Yes


9.7 Protected Mode, Machine Yes only bits 0 and 1 are used

9.8 Setpoint, Ingredient Blend Percentages

Yes

9.9 Setpoint, Calibration Yes

9.10 Setpoint, Total Rate Yes

9.11 Setpoint, Quantity Yes

9.12 Measured Value, Ingredient Blend Percentages

Yes

9.13 Measured Value, Ingredient Rates Yes

9.14 Measured Value, Total Rate Yes

9.15 Measured Value, Quantity Yes

9.16 Measured Value, Inventory Yes

9.17 Measured Value, Total Inventory Yes




9.0 Volumetric Blender

9.1 Echo

9.2 Version

9.3 Status, Process Summary

9.4 Status, Process Hopper

9.5 Mode, Process

9.6 Mode, Machine



9.9 Setpoint, Calibration

9.10 Setpoint, Total Rate

9.11 Setpoint, Quantity


9.13 Measured Value, Ingredient Rates

9.14 Measured Value, Total Rate

9.15 Measured Value, Quantity

9.16 Measured Value, Inventory

9.17 Measured Value, Total Inventory

9.18 Blanket Poll 1

9 Blender, Volumetric

Dev ID: 28

Description: Volumetric Blender Controlling Units

9.1 Echo

Poll: 20 21

Select: 20 21


Units: ASCII

Required: Yes


Polaris — v2009.3


9.2 Version

Poll: 20 22

Select: N/A


Units: ASCII

Required: Yes


AA = SPI assigned version level

BB = Vendor assigned version level (use optional). If not used BB = 00.

9.3 Status, Process Summary

Poll: 20 40

Select: N/A

Format: 16 bit

Units: None

Required: Yes

Description: This status word is a summary of all alarms or status conditions for the entire unit.

Figure 14-16 SPI Volumetric Blender Controller, Status Process Summary

ProcessingAlarm, SystemAlarm, ProcessAlarm, MachineOpenStatus, Qty CompleteStatus, Mat DemandAlarm, Mixer FailureAlarm, Feed FailureAlarm, Low MaterialStatus, High MaterialReservedReservedReserved

OpenOpen

11 10 9 8 7 6 5 4 3 2 1 015 14 13 12



9.3.1 Processing

Bit#: 0

Required: Yes

Description: This status bit states whether the unit is currently processing.


1 = processing

9.3.2 Alarm, System

Bit#: 1

Required: Yes

Description: This data bit states whether an alarm is present. This bit is set on the logical OR of process alarm and machine alarm.


Bit#: 2

Required: Yes



Bit#: 3

Required: Yes


9.3.5 Status, Quantity Complete

Bit#: 5

Required: No

Description: This bit indicates that the desired quantity has been metered and the blender has stopped.

Polaris — v2009.3


9.3.6 Status, Material Demand

Bit#: 6

Required: No

Description: This bit indicates that the blender is currently operating due to material demand requirements.

9.3.7 Alarm, Mixture Failure

Bit#: 7

Required: No

Description: This bit indicates that a mixer failure condition has been detected.

9.3.8 Alarm, Feed Failure

Bit#: 8

Required: No

Description: This bit indicates that a feed failure condition has been detected for one of the hoppers or the entire unit.

9.3.9 Alarm, Low Material

Bit#: 9

Required: No

Description: This bit indicates that at least one hopper is low on material.

9.3.10 Status, High Material

Bit#: 10

Required: No

Description: This bit indicates at least one hopper is in a high material condition.


Poll: 20 42

Select: N/A

Format: 16 bit, 8 values

Units: None



Required: No

Description: These status words describe conditions for each hopper. The status word for hopper A is received first. The lower 8 bits are a copy of the process summary status words.

Figure 14-17 SPI Volumetric Blender Controller, Status, Process Hopper

9.4.1 Processing

Bit#: 0

Required: Yes

Description: This status bit states whether this hopper is currently processing.


1 = processing

9.4.2 Alarm, System

Bit#: 1

Required: Yes

Description: This status bit states an alarm is present for this hopper. This bit is set on the logical OR of process alarm and machine alarm.


ProcessingAlarm, SystemAlarm, ProcessAlarm, MachineOpenStatus, Qty CompleteStatus, Mat. DemandAlarm, Mixer FailureAlarm, Feed FailureAlarm, Low MaterialStatus, High MaterialReservedReservedReserved

OpenOpen

11 10 9 8 7 6 5 4 3 2 1 015 14 13 12

Polaris — v2009.3



Bit#: 2

Required: Yes

Description: This bit indicates that an alarm that affects the process has occurred for this hopper.


Bit#: 3

Required: Yes

Description: This bit indicates that an alarm that affects machine operation has occurred for this hopper.

9.4.5 Status, Quantity Complete

Bit#: 5

Required: No

Description: This bit indicates that the desired quantity has been metered and the blender has stopped. This bit is the same as the STATUS, PROCESS SUMMARY bit #5.

9.4.6 Status, Material Demand

Bit#: 6

Required: No

Description: This bit indicates that the blender is currently feeding material. This bit is the same as the STATUS, PROCESS, SUMMARY bit #6.

9.4.7 Alarm, Mixer Failure

Bit#: 7

Required: No

Description: This bit indicates that a mixer failure condition has been detected. This bit is the same as the STATUS, PROCESS SUMMARY bit #7.



9.4.8 Alarm, Feed Failure

Bit#: 8

Required: No

Description: This bit indicates that a feed failure condition has been detected for the corresponding hopper.

9.4.9 Alarm, Low Material

Bit#: 9

Required: No

Description: This bit indicates that the corresponding hopper is low on material.

9.4.10 Status, High Material

Bit#: 10

Required: No

Description: This bit indicates that the corresponding hopper is in high material condition.

9.4.11 Status, Hopper Present

Bit#: 11

Required: Yes

Description; This bit indicates that the corresponding hopper is present in the blender.

9.5 Mode, Process

Poll: 20 46

Select: 20 47

Format: 16 BIT

Units: None

Required: No

Description:

Polaris — v2009.3


Figure 14-18 SPI Volumetric Blender Controller, Mode Process

9.5.1 Mixer On/off

Bit#: 4

Required: No

Description: This bit commands the mixer to turn on (1) or off (0), when the on/off action allowed bit is set high. When the on/off action allowed bit is low the mixer on/off bit command has no effect. When polled, this bit states if the mixer is on or off. If the unit has no mixer, this bit always returns to zero.


Bit#: 5

Required: No

Description: This mode bit provides a safety to the use of the mixer on/off action. To allow on/ off action, set this bit high and to inhibit this action, set this bit low. During a poll, this bit returns to zero.

9.5.3 Reset, Quantity

Bit#: 6

Required: No

Description: Setting this bit commands the blender to reset the quantity measured value to 0. If the blender is currently running a quantity, it will continue to do so until the quantity is complete or the set value quantity is set to 0 in which case the blender runs continuously.

ReservedReservedReservedReservedMixer, On/OffOn/Off AllowedReset, QuantityReset, All TotalsReset, Hop A TotalsReset, Hop B TotalsReset, Hop C TotalsReset, Hop D TotalsReset, Hop E TotalsReset, Hop F Totals

Reset, Hop H TotalsReset, Hop G Totals

11 10 9 8 7 6 5 4 3 2 1 015 14 13 12



9.5.4 Reset, All Totals

Bit#: 7

Required: No

Description: Setting this bit commands the blender to reset the inventory totals for all hoppers.

9.5.5 Reset, Hopper A Totals

Bit#: 8

Required: No

Description: Setting this bit commands the blender to reset the inventory total for hopper A.

9.5.6 Reset, Hopper B Totals

Bit#: 9

Required: No

Description: Setting this bit commands the blender to reset the inventory total for hopper B.

9.5.7 Reset, Hopper C Controls

Bit#: 10

Required: No

Description: Setting this bit commands the blender to reset the inventory total for hopper C.

9.5.8 Reset, Hopper D Totals

Bit#: 11

Required: No

Description: Setting this bit commands the blender to reset the inventory total for hopper D.

9.5.9 Reset, Hopper E Totals

Bit#: 12

Required: No

Description: Setting this bit commands the blender to reset the inventory total for hopper F.

Polaris — v2009.3


9.5.10 Reset, Hopper F Totals

Bit#: 13

Required: No

Description: Setting this bit commands the blender to reset the inventory total for hopper G.

9.5.11 Reset, Hopper G Totals

Bit#: 14

Required: No

Description: Setting this bit commands the blender to reset the inventory total for hopper G.

9.5.12 Reset, Hopper H Totals

Bit#: 15

Required: No

Description: Setting this bit commands the blender to reset the inventory total for hopper H.

9.6 Mode, Machine

Poll: 20 48

Select: 20 49

Format: 16 bit

Units: None

Required: No

Description:



Figure 14-19 SPI Volumetric Blender Controller, Mode Machine

9.6.1 Machine On/off

Bit#: 0

Required: No

Description: This bit commands the blender to turn on (1) or off (0). When polled, this bits states if the machine is on or off.

9.6.2 Alarm, Acknowledge

Bit#: 1

Required: Yes

Description: This bit is used to allow the master to inform the slave that it has recognized the alarm condition(s) presented in the status words. Setting this bit to a one (1) acknowledges the alarm Bit will always return to zero (0). Note that it is not intended that this command clear any alarm indication (horn, bell, light) at the auxiliary device.

9.7 Protected, Mode Machine

Poll: 20 4A

Select: 20 4B

Format: 16 bit

Units: None

Required: No

Description:


ReservedReserved

11 10 9 8 7 6 5 4 3 2 1 015 14 13 12

Polaris — v2009.3


Figure 14-20 SPI Volumetric Blender Controller, Protected, Mode Machine

9.7.1 Machine On/off

Bit#: 0

Required: No

Description: This bit commands the blender to turn on (1) or off (0), when the on / off action allowed bit is set high. When the on / off action allowed bit is low the machine on/off bit command has no effect. When polled, this bit states if the machine is on or off.


Bit#:

Required: No

Description: This mode bit provides a safety to the use of the machine on/off action. To allow on/off action, set this bit to high and to inhibit this action, set this bit low. During a poll, this bit returns zero (0).


Bit#: 1

Required: Yes

Description: This bit is used to allow the master to inform the slave that it has recognized that alarm condition(s) presented in the status words. Setting this bit to a one (1) acknowledges the alarm. Bit will always read back as a (0). Note that it is not intended that this command clear any alarm indication (horn, bell, light) at the auxiliary device.

Machine, On / Off

Alarm, AcknowledgeReservedReservedReservedReservedReservedReservedReservedReservedReservedReservedReserved

ReservedReserved

On / Off Allowed

11 10 9 8 7 6 5 4 3 2 1 015 14 13 12




Poll: 20 50

Select: 20 51

Format: Numeric, 8 values

Units: Percents

Required: Yes

Description: The desired percentages by weight of the individual components. The factor for hopper A is sent or received first. Hoppers not present should be set to 0.0.

9.9 Setpoint, Calibration

Poll: 20 54

Select: 20 55


Units: Vendor Specific

Required: No

Description: Calibration factor for each of the individual components. The factor for hopper A is sent or received first. Hoppers not present should be set to 0.0.

9.10 Setpoint, Total Rate

Poll: 20 56

Select: 20 57

Format: Numeric

Units: lbs / hr

Required: No

Description: The desired rate at which the blender delivers material.

Polaris — v2009.3


9.11 Setpoint, Quantity

Poll: 20 58

Select: 20 59

Format: Numeric

Units: Lbs

Required: No

Description: The desired amount of material to blend, after which the blender stops. Enter 0 to command the blender to run continuously (default). Entering a non-zero value, commands the blender to blend the specified amount and then stop. This value may be changed in the fly, If set larger than the measured quantity the blender will continue to blend. If set smaller than the measured quantity the blender will stop.


Poll: 20 60

Select: N/A


Units: Percents

Required: Yes

Description: The measured percentages by weight of the individual components. The percentage for hopper A is received first. Hoppers not present or ingredients not in the present blend should return to 0.

9.13 Measured Value, Ingredient Rates

Poll: 20 62

Select: N/A


Units: Lbs / Hr

Required: No

Description: The measured rates of the individual components. The rate for hopper A is received first. Hoppers not present or ingredients not in the present blend should return 0.0. May be an average for batch type blenders.


Poll: 20 64

Select: N/A

Format: Numeric



Units: Lbs / Hr

Required: No

Description: The rate at which the blender is delivering materials. May be an average for batch type blenders.

9.15 Measured Value, Quantity

Poll: 20 66

Select: N/A

Format: Numeric

Units: Lbs

Required: No

Description: The amount of material which has been blended in the quantity. This value is reset to 0 by setting MODE, PROCESS bit #6.

9.16 Measured Value Inventory

Poll: 20 6C

Select: N/A


Units: Lbs

Required: No

Description: The amount of material which each hopper has fed since the value has last been cleared. Hopper A received first, hoppers nor present should return 0.

9.17 Measured Value, Total Inventory

Poll: 20 6E

Select: N/A

Format: Numeric

Units: Lbs

Required: No

Description: The total amount of material which the blender has fed since the hopper totals have been cleared.


Polaris — v2009.3


9.18 Blanket Poll 1

Poll: 20 E0

Select: N/A

Format: Open


Required: No

Description: The blanket poll provides a mechanism to scan the required poll command with one poll. The format of the blanket poll is:

<20><40><SV> <20><48><SV>

<20><50><NV><NV>...<NV><NV>

<20><60><NV><NV>...<NV><NV>

<20><64><NV>

<NV> is some numeric value associated with the command bytes preceding.

<SV> is some status value associated with the command bytes preceding.

HMI Reference Manual Polaris — v2009.3 Third-Party Integration (Optional)

15–1

Chapter 15 Third-Party Integration (Optional)

The optional Third-Party Integration screens allow users to view and control select third-party equipment through the HMI on Husky machines.

Refer to third-party equipment vendor documentation for details of these screens.

Polaris — v2009.3

15–2

manual de referencia de la ihm

Documents

isolated rs422 485 card

lbs hrrequired

velocity dual opto

customer specials require

local hard disk

element explanationpolaris v2009

element descriptionpolaris v2009

ingredient blend percentagesyes9