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CENTRAL MACHINERY &

PLASTIC PRODUCTS
OPERATION & MAINTENANCE

MANUAL
FOR

a .

OFFICE : 1, LAJYA ESTATE MOGRA ROAD, ANDHERI (EAST), BOMBAY - 400 069. INDIA. i PH. 9l -ZZY$Z-6t42,w36-6tg8/

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CONTBNTS ].. 2. 3. 4. 5. 6. 7. 8. 9.
BRIEF DESCRIPTION
SPECIFICATION
2 2 4
7

I !-i-' l> l.\

1.-

& BACK DESCRIPTION POWER ON & RESET CONDITION PROGRAI{I4ING & USING THE SYSTEM STARTING & USING THE SYSTEI4
FRONT

I
18
18 22 38 39 40 43 45
46

TESTING THE SYSTEM SERVICING & MAINTENANCE CARD ARRANGEMENTS PowER SUPPLY coNNEcTroN DETAILS oF TIIIER MACHINE SELECTION (}IODES)

r0. 11.
T2. 13. 14. 15.

E E

TEST MODE CH. NOS.

ERRoR coDES

F
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WIRING CHART a. MAIN CARD TO DISPI"AY CARD - CARD-I b. ADM CARD TO BACK PANEL CARD-2 C. OUTPUT CARD 1 TO BACK PANEL CARD 3 d. OUTPUT CARD 2 to BACK PANEL CARD 4 e. OUTPUT CARD 3 to BACK PANEL CARD 5 f. OUTPUT CARD 4 to BACK PANEL CARD 6 g. INPUT CARD TO BACK PANEL CARD 7

47 47 48

49
50 51 52

53 54 55
57

h.

CO!,IPOSITE OUTPUT,

INPUT,

THERMOCOUPLE

F l-..

:!.6. 1?. BA,CK PAI{EL DIAGRAI4 Ig. TTRf,.rc DIAGRAH FoR HEATER M P e ].9. TTEr!re DHGRAH FOR BLO$rER M P E 20. r[nIre DI.TGRA}I FOR ITYD. U P C 2]. . D. E. DNIIrE rITE FORCE EOOLING.
***rrt****

WIRING CHART i. BACK PANEL TO LED PI,ATE WIRING CHART j. BUS CARD WIRING CHART FRONT PF}IEL DIAGRAM

58 59
60 51 62 63

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TIIPORTANT POINTS

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F-a

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!

F--.

-se ELCB at mains Input to protect personal & damage due to earth leakage, overvoltage slngle Use servo controlled voltage stabillzer with High E of rating 1 KVA minimum. Low cutt OFF should be High at 250V. 2.

machlne from

phaslng etc. Low cutt OFF set at 2LOV &

f--,

F,

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Connect spike Buster at the output of stabiliser. Output of spike Buster should be connected to system supply. See supply wiring diagram for proper connectlon.

t-= F= F>
F=
j

3.

Always put off power before removing or inserting cards. Observe correct placing of cards. See inslde card arrangement diagram for proper guidance.?
Before removing any IC, make note of its position and polarity on paper. Remove IC one by one only. That is after first one is removed and again inserted. Then only remove second one. Never leave any conducting metal parts or solder spills on PCB or inside the unit, always clean the PCB, carefully check lt and then only insert. Remove all fresh unwanted parts from panel.

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4.

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\

5.

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fi

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Firmly check & double check all outside wirlng before starting Lre system. tJrong connection may damage the system.
*,.l.rays use correct fuse rating of minimum 300 mA & maximum 500 ul f:r unit. fuse holder is at back of unit near supply
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"a:,s.fs ; r: r i:ht adhesive such as stickfast at the PCB, edEe, -: =-s3e : r : channel after every removal and insertion of -!:-E:s- :$s ulltr prevent loosing of cards due to sl.ight vibraLio,n
*e

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-2rtfr.ffi: : " fgre;

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BL.{2

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Thlnner to clean membrane swltch front panel and lts =r-:ectors. use Kerosln or very ttght cleaning agent such as Mix
use

:.

lfever use screw driver, Nalls, finger Nalls, hot bottles or any sharp or hot aJect to operate key pad. It will permanenily damage the keypad. Use only your finger with little pressure.

F
E

F
F
F F

1. BRIEF DE9CRIPTION: This programmable control system operates and controls different functions of Blow Moulding Machlnes. It includes Temperature controllers. fimers,Countersr drrd. Input contacts for Interlocking and logic solutions. AU the parameters are programmable from keyboard and result of process values are displayed in 4 sets of digital displays. Another 3 sets of LED's indicates, power to system and operatlng modes and programmlng functions of the system. Self test features allow operator to check arl outputs, rnputs, keys and displays. Faults in any output, rnput, keys, and displays can be diagonised from Front Panel. AU Timers operate with built in crystal Freguency accuracy. This gives excellent timing accuracy and
repeatability. Battery backup. provision ensures that programmed value is nct lost during intermittant power failure.
Constuction is completely modular with detachable Front and plug in Cards. This faclll.tates ease ln servicing and maintenance. System ls ;orered through 230 V Mains.

2.

SPECIFICATIONS:

1000/w2

so00/H/L
8 7 4

{.

No.of Temperature Channels !{o. of Heater Output !{o. of Blower Output

7 6 3

F
F

!io. of Timer I,, 6f limtt switches :--l 3aLrol Srltches

T28
&

T19

18

16

--.3

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h
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-3-

l{o. of Control output for

Solenolds. Counters

23.8y

.24Y

/2A Tt ansistors.
99999

t'=o

h
F. l:r
Fl-

1,5 dlgits. Upto

Counts

48 - 3 digits - hourly counters.

8. 9.
10. 11. 12. 13. 14. 15. 16. L7. 18.
19.

t-*'

Temperature Range Type of Thermocouple Accuracy of Indication

0 to

400oC.

Fe/Const. 'J' type.

Control Accuracy Control Action

Ambient compensation

:loC,+ldigit. Typlcal 1%
Time proportional Automatic

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I.-'

Lineraisation of
Thermocouple

By Software

Timer's

Range

Accuracy & Repeat6!ility Time Base Counting Mode for Timer Sequence of operation Counter Pulse Operatlng lviode Operating Temperature Supply of voltage

: 00.0, to 99.9 : +.01%. : : : :

seconds.

F. l= F

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20.

Ouartz Crystal. Down Counting Type As per Customers requirement Internally from Timing
Sequence.

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2L.

22.

: Auto E Manual. : 0-50oC. : a) Isolated 230VA + 10% 1A, 50H2, Use Isolation
Transformer.

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b) For larger v.riation in supply use servo controlled Automatic Stabilizer with Upper & Lower cutt
OFF.

Lr-

.J:!!EsIIEI

Rack Mountable.

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-4OTHEA FEATURES: 1.

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ia
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2.

of all Parameters through Keyboard. Battery Back-up RAM for protectlng programmed parameters
Programmlng

durlng power fallure.

3.

FFF-

Key Locklng
operation.

to prevent unauthorised

access

of

Keyboard

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F-,

4.

Testing of all Input, Output, devlces, such as Output Solenoids, Llmlt Switches, Thermocouple Inputs, Keyboard and Dlsplays.
Hold Function to check partlcular Temperature Zone of interest.

F-t
\:

5. 6,

F:t
FF\:t
3.

Exclusion of any Tenlrerature channels and Timers from sequence of operation. FE()[T t BACT
DESICTIPTIOT:

rRefer Fri,8t{T
Diagramsl

PA-tiEI"

BACX. PANEL as

1.

FRONT

: Front coosists of various sestions rhich are

fol-lors:a) Dlsplay sectlon b) Keyboard sectLon c) Indlcatl.on Section.

F.

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a) Dlsplay section: As shown in FRONT PANEL diagram, there are four sets of displays. These are as follows:Set 1 Ch. No. E Temperature Set 2 Ch. No. E Timer Set 3 Blow Left Tlmer Set 4 Blow Rlght Timer,/ Error Code.
sET 1: This set of 5 displays are multipurpose. various dlspray formates for thls set Ls given below.

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t{hlle programmlng Temperature values thls lndlcates Ch.No. ..^d @rrespondlng set rr or set r value belng programmed.

f..-

...5

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rlt

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?a
+-.

-R_

BL42

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u) whrte programmlng mode of operadon thls set rndrcates type of modes belng programmed. Flrst two dlglts wtll show for mode I or mode 0 and last two dlglts wlll show mode value of that pardcular mode type. For detall see programmlng secH.on, mode programmlng.
c)

h
E

not being programmed normally thls set wlll indicate Ch.No. and lts actual process temperature ln sequential manner.
When

d)

c- Displays key rs pressed Ooc lndicatlon wirl got oFF and this set will show counter value for particular hour or totar csunter value, for detail see programming sectlon.
when

F
F
F F F
F

sEl 2: l5s st of 5 arcptrats s.hors prograrnmlng of r 0 to T 18 AIl' Li-E." ra]'ues aie;ra;racr'ec i,-tr fhis set. First rro J..i.3i.ts shors Cts.lts.:r'j Last 31n+ts s,b,srs tiring varnsg5. if:en tct being prqran*ec :.'d systee ru,o.,uLc.3, thic, st sb.ors doru 6,gq6ting timing of tic'er 3 to L0. For descriprir*r of tL6gr nuo5gls see attached sheet on details of Timers.
SEt 3: Thts set is used to lndicate set value of temperature (set I only).

6: This set is used to lndlcate tlmer T11, Tl, T14 & T2 in that order this set also indlcates Errore codes.
SE'T

b) Kevboard section: see Front panel dlagram for numbers and name of keys used. For details of key functions see programming section.

c) rndlcatlon sectron: This secdon consists of varrous indicate operation of system. These are as forlows:

LED,s

to

nust be present.

1. +5V, +12V, -5V, ' -t2V these LED's lndlcate status of vanlous supplles system is uslng. For proper functlonlng all these suFprt-<

-. .6

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r-- f r : g-r 3 F 3 h=J

i

:' :k: thls LED tndlcates that keyboard ls ln Locked condluon rrj no programmlng can be done through keyboard
::J:ed '
3

BL-2

unless rock ls

+t-+-=

h.,

can be selected using hold key.

' HOLD: This LED lndicates that the temperature lndicator ls showlng only the current channel and lt ls not sequenclng. This
programmed

4. sET rr: Thls LED's indicates High set point being for that selected channel.

s.

sET

Thts LED Indicates Low Set point being programmed for the channel. This Indicates system is in Emergency
conditions.
stop

h +-t
+-'
f.-, tl-

6. ryP
7.&
8. Manual 9.

operation.

This Indicates system is running in

Auto

This Indicates system is running In Manual

operation.

b !\. *>
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i

LPM

This indicates that locking pressure mode is

selected.

It

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10. TEST
11.
:iEottom

Thls indicates system is In Test Operation.

f--. Ft"
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This Indicates bottom blow operation ls

selected.

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This indicate that there was mains power Fluctuation and supply to System was off. Press enter key and this LED wilL be off. S.ee BACK PANEL Diagram, Back panel =esists of followlng: :. 3{ Ffn HCL connector for thermocou;le aad coatactor coils.
e

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tb
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n- =.fr:I

+-

i-. +-

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-72.

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3. 4.

34 Ptn HCL connector for Outputs,. 60 Pln HCL Connector for LEDS. 34 Pln HCL connector for Input.

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g

5.

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Heat 51nk wlth power supply devlce. 6. 2 Way Termlnals for +24V & OV DC supply. 7. 3 way Termlnals for 230 V AC mains supply 8. Fuse Holder wlth 500 MA Fuse. 9. Mov (27s/L4) at 230 V AC Malns, L.N. Termlnals.
4.
POT'ER ON

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R.LSET CONDITIONS:

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Before swltchlng the power of the system ol{ verify that all connections are made proper & flrm. gJrong connectlons may damage the unit or can cause malfunction of the system. Always use three wire power system (phase 230V, Neutral & Earth j. Use Cument fuse rating of 500 mA. After the power ON Dlsplay wlll
show

ry

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Arl other Display wirl remaln blank. The system LEDrs wr,rr be follors: +5V, +L2Y, -5V, -12V all on.
ON tf prevlously system otherwlse OFF.
OFF
;". -J

rl

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in Dlsplay set I
as

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was

Iocked

ts:
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OFF OFF OFF OFF

ON

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ND
n

ot{
sel,ected

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EFE/I-PI I flIGI{IITES? [ rs grer!.msly

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Afrer power on, alr the setting such as Temp . control polnt E Ttmer val.ues are unknovln, unless tt has been programmed earrler. so f or tirst time operation, all these values rnust be programmed. See programming section for detall on programmlng. is provided with battery backup to preserve programmed values in case of povrer failure. gut if the system is kept oFF for lonEer period, (for more than a week) these values may be erased.
Systern

':t
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>-' "-'t
\,

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It is necessary after Power oN operator must check that all the needed parameters are entered & its value are proper before starting the
system.

After all parameters are entered & checked system is ready for starting. A Systen Reset key is provided en the Front of the unit. If this key is pressed then system will start from beginlng as if povrer ON has occured and display vrilt shovr
)

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.This is as good as starting the system from power oN as explalned earlier' only difference is that in this case prcErammed values are Dot erased r r1o matter hcvr many times Reset key ls pressed. This 4.e7 is provided to help the operator to start the system from beglntng r"!tr ca- of any problem ln system operation caused by heavy distru!:-ces in malns Power supply or by any mechanical or electrical jam, :rEE tlris key is pressed and released system will always start from :'aE:':'ang rnci all the conditions as explalned earller for povrer on will ::na* r'li:..

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:. PTTEDrrrcre rID

UsIlrG THE

SYSTEM

,1!] t.c;q:-'r'!:t:s sf, the system can be programmed throuEh keyboard. A-s ccsc=:bcc ca;i-lcr lreryboard is organised ln two groups one ls called 9lXA arlC scc@ i.s aefl.c COMI{AND.

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-9:ata Group conslsts of key 0 - 9 and ENTER and ls used fcl enterlng numerl.c values lnto system's memory.
COMMAND

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Group conslsts of TIMER, CH.NO, HOLD, START, LOCK, CODISPLAY, C-RESET, AUTO, MAN, SET II SET.I, MODE and ls used to glve command to system to operate speclflc Jobs. Any Parameter can be programmed any tlme even when system ls running.

tst
+-=

Fl

(a)

Programml.ng

of Tlmers:

fr

.:-{\
tr i

+=
-+-'

"1-" r--J

There are total of 19 Timers In System T 0 tp T 18, Timer 0 ls used for scannlng the Temp. Channel numbers 1 to I in steps. If Tlmer 0, is programmed 02.0 seconds then every 2 seconds ch. no wLI[ keep advancing to next ch.no. and its value will be dlsplayed for 2 seconds before advancing to next ch.no. Timers 1 to 18 are used ln machine. For details see attached sheet on fimers. For Programming any Timer follow followlng steps:

t J\
-*

(r)

Press I'IMER key. Now prevlously entered Timer No. will be

dlsplayed ln ch.no. and value display wlll be blank,

such as:
o2
I

as

+=
=-+-'

XX. X Blank (Dlsplay Set 2)

+= t:'1\= ,#*
\

Fte'riously Programmed ri:e of Timer No.

-' l::cre: b.as not been programmed previously then it will

q-t-(f:.:;:

be

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.h:t ->t -t
r\s

IT.X

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'ht -h5
.
1,1

+a
+t
hs

*=s
li:! --..

:e:::3: l(_=:=-:
r:' -5|'| ::mre i:s, 5:l:u3
!t tr" ?
|

---eIs. .{s ke;' i.s pressed and released lts -ic:'r-r I! :;erator has pres-d No. 04

>5
].llrp ]}:f51!:S

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--5-r1=.

L, --

F..$

+r

i-' #
J-'

t-han q0 and presses l' r""le :trE:?.:= r-trt-:t ! 3":t'rhE: =ea=: I=3 :--rr =sglcy r:: q;1:'r ;le*r!:u,sJ,y programmed =lEE[.

-'+--

H
* *=

{-

g--n:'=rc *=s fey' Norr ,1-:i" A-ftcr :eg:l,r"cC l!s'c; I =Ji:=? :f t:'ai :-is;tray ri-Ll. 5:l;'rr ;lcrr:'alg]1 ;;:q:amr+e.: ri:e "i-Eel no. fcr Ex. i-f 3!:ra@ l's Fr='e: \ tbec' EJ:EE' The Dlsplay wi-ll shor:
C4

15.6 rlisplay -t

2,

E-s

Previotrsly Program med Value of Tlmer 4.

--h

{-'

qq +=
-\

*=

(iv) If operator does not want to change the previous values, then just press ENTER Key Tvrice and same value wlll remain. If operator wants to change lts value then press Numerlc keys and check the disPlay for values. Dtsplay wlll show onty latest three keys entered. For Ex. operator enters 324 then dlsPlays wlll show:

+T
*

{=

04 32.4 (Dlsplay Set 2)

Scrr

+=
3\,s

if operator pressed
04

key I then dlsplay wlll show:

24.8

hs sg
*=f

-.: i.s out of 3248, 3 ls lost ;res-reC and shown on display.

and

latest (g

keys

24e is

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!

:11

*t :t

irrlAfterpropervaluehasbeenenteredandverule'dFltgs ENTERkeytwlce.Nowoldvaluewlllbereplacedvl'thngr value.DlsplaywlllnowshowtheactualTlmeroperatlcalf thesystemlsstartedorltwlllshowlastvalueentered. (v1) Repeat Steps (1) to (v) to enter next deslred Tlmer value' exlt frorn After all the deslred Tlmer value has been entered step(v)bypresslngENTERKey-Twlceorgotoprogramme TemP. values as exPlalned below: (b) proqtamtnt.nq of Cht-!e-'s' for Temperature: ThereatetotalofSTemperatureZonetobeprogrammed. ProgrammlngofTemperaturevaluesareslmllartothatof programming of Tlmers' Follow followlng steps: (i)Pressch.No.Key.Nowprevlouslyenteredch.No.willbe dtsplayed and value display wlIt be blank' 3
I

'"t

-t
*l

!
-

:t T t
\t !
-

=$
\
I

x X x (DtPlaYSetl)

Prevlotrsly Programmed Ch' No'

I{
It
I I

:If Ch.No. has not been programmed prerrlously then dlsplay 1 X X X wlll show; (11)PressdeslredNumerlcKey,Dlsplaywlllshowthatvalue.It x X (Disoperator presses 2 then dlsplay wlll show 2 x greater than 3 a:: Play set 1) - If operator enters a Number PressesENTERKeythendlsplaywillshowprevlouslyFrc;rgE. med Ch. No. Value' (flt) Press SET I or SET II Key. Now dtsPlaY rill sl':r F:tffi':f, -ii.rc ouslY Programmed value of SET I or SET I1 set::-=; Ch. At the same tlme SET I or SET fr. l;: u:: nr@t Lud1:atlng whlch settlng ls belng Progra-oocC"

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(1v) sET r can be programmed upto 3gg only, above thls wlll not accept new value and old value wlll remaln.
system

(v) SET II settlng can be done only upto O1g. Any settlng above thls value wlll be rejected and old set value wlll remaln valld. rn actual operatlon thls value wlll be added to 5E? I value to get flnal SET II value. (vl) Only Ch.No. l to 3,4 have SET II channels thls settlng ls not valld. settlngs. For other

(vit) rf operator does not want to change the value, then just press ENTER key twice and same value will remain. rf operator wants to change value then press numeric keys to get desired value. As exprained earlier only latest 3 varues wirl be preserved and shown on display. For ex. if operator presses 23L62,then final display wil.l show. 162 (Display set l)

(vili) After desired remp. varue ls entered press ENTER key twice. Now old value wrll be replaced by new varue. Display will now show actual ch. no being scanned and its value if the system ls ln operatlon or it will show previously programmed
va]ues.

Pepeat steps (f ) to (v) to enter next deslred Temperature ah. No. value.

hoga,ni.nq *=:

Modes:

tt#.e (ey display wil.l ft.-.j rt

show:

i-\,

EX
Mocie

XX Btank

iyF.e o, j. _ L e=_

>r
*t
b
,.rysini, ..;,;effiiii*amr;s.,*i

fb b

T F:'
S
l'-,
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:13:
(rr)
Press Numeric

key to get deslred mode

tYPe.

(ru)

Press ENTER, Now prevlouslY P rogr ammed values of that mode type wlll srtow such as O ,92

!= l-t

(lv

I I
l-*-

key to get deslred mode value ln display After getting desired mode value press ENTER key tvrlce. For detail on mode types, their value and descrlption see
Now press Numerlc

attached sheet. (v)

Mode can be programmed Mode

ln

MANUAL

only'

(vl)

dtsplay will come ln display window of Set 1'

t-,

OTHER COMMANDS:

h
H

(d)

Eold :

k ++
+-.

++-* +-"
+-=
\
.,c*

Thls command !s used to monltor the Temperature of any particular channel. During the scannlng when the desired ch. No. is being dlsplayed, Press thls key. Now Channel Number wltl stop advanclng and selected Channel Number and lts Temperature value will be continously displayed. When ln HOLD Command mode, HOLD LED will be ON ' To remove hold, press Hold key once agaln. Now Channel Humber will ad,vance to next channel Number and HoLD LED riu go oFF. Now system will start scanning al.l the channej. $:-!ers. This way by pressing Hold key once, operator cai ::"r"::reustry rnonitor any deslred Temperature Channel a:-i !rr=<'-g i! second time releases Hold and scanning starts.
C-{Em0rv: -rffi :g-L eltler tstal cotrnt value i: ::e:-f ::L.uG lqc:,tlc rai-.rr :E 5rt rrsllc" {'i' i:.Fl,ays for c'Llli':gr s-l- :ar- & +-""t'"-y r* :" ;D-hlr lcircr ne:tl'meC siE{,:!;

+-n,
\

t\t

+s
F-t
!.-,

:14:

-t \f
= -S -! \r -y

(1) Press C-Dtsplay Key: Now Temperature sca!:1:l r:stop and OoC LED wlll go OFF and two dtgit vi':e r:-. declmal polnt wlll come in display set 1 ' Pres d - 3 c-Display second time operator wif I enter Temperat::e scan mode. In C-Dlsplay mode di5ptay will be:

23. XXX
Previously Programmed value of hour locatim
I

-t
\

-! \t
\ \ \
Li

(2, Enter numerlc keys to get deslred hour No. (maxlmum t+8 hours are valid). (3) Enter key pressed. Now display wllt show count vallc during that Partlcular hours.
23.058 Count value during 23rd hour'

!s
I

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L

(4) Operator can check any partlcular hour or all 48 hours by entering proper numerlc keys to select hour and then
presslng ENTER key.

il_r
I

F
\

(5) For getting total counter value, press 00 and then ENTER. Now decimal polnt wtll be OFF and aU 5 dlglts will show total Production value. (5) Hour countlng starts from pressing of C-RESET key rhile counter value ls belng dlsplayed- It wlll reset aU counter values and start the clock for hour counter'
Q) Press C-Display key agaln, now dlsplay show Temperature Ch. nos. and lts value.
set 1 rt':

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\q

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-;n

\s -s
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'*

) ) ) ) ,
$

:15:
(f

C-Beset:

Press

t
$

f
3

thls key to reset the counter value to 00000. Thls key should be pressed only when counter dlsplay ls selected as explained above. counter wlll be reset only when lt has been selected by presslng C-Dlsplay key'

(g) Locking Kevboard:

Keyboard can be locked any Time by just presslng lock key' once thls key ls pressed entire keyboard is locked and LOCK LED wlll be oN. Novr no value can be entered or no command

t t
b
.tt

t t t
{ {

canbegivenexceptstart,Manual,Auto,'Test'through keyboard unless lock is lifted' (h) Unlockinq:

The keyboard can be unlocked by pressing specific sequenae of keys. This sequence ls 5, 0, 1' Keys must be pressed in this sequenoe only. Any ciange in seguen@ wlll nd lift the lock. Once lock !s lifted LOCK LED wlll go OFF and keyboard

':t

b -t -t
'.!' ,

wtll be avallable for further operation'

VABIFYING TEE-IEOGRAMMED VALTIES:

"s
-

\t
.:F

All the programmed Temperatures and Tlmer values can be varlfted by using same steps (1) to (iv) as explatned ln programmlng sections of Tlmers and Ch. no. Only dlf ference ls t}at ln steP (rv) do not enter any numerlc key but just Press ENTER key tricc after verifying the content on respecclve display sets.

rt -3 '!t
\

x
-!3 \

Y
In

,,.J

-:r
:}n
\

-s
\ l.
6. STARTING

-16S USINE 1'HE-$STEM:

BL{I2

!= !=
!-=

Before starting the system operator should verify that all the Temperature and Tlmer parameters lncluding Tlmer 0 for

I t k

scannlng speed ls entered and are ProPer' Once all parameters are entered Press START key' System's operation once started Temp. Parameter will operate and particular zones Relay will go oN-oFF to achleve set temperature. This actlon |s contlnuous and not dependent on display speed of Temperature which can be programmed ln Timer 0'
Timer actlon ls dependent upon the conditions of limit switch input.

L
F
;1{5

During Machlne operation all or any particular 1'emperature or Timer value can be varified and modified as described in programming section. See Section 5(a) S 5(b) ' After modification is over operator should Press ENTER key Twice as described earlier.

After pressing ENTER Twice Display will show Actual Values of Temperature or Tlmers in oPeratlonAlt Timers are down counting tyPe. That means counting will start from set value & stoP at zero count'
Display set 2 will lndicate Tlnrer values from T3 to 10 while Diplayset4willlndicateTimervalueofTll'T1'T14'12 in that order. white programming all the Timers are to be programmed on Display Set 2 only' Relatlon of Timer No' aldtheiractualoperationlsseperatelydescribed.See s:et attached.

,l-= {-t

F
-l'a

.H

+=

tu
+r

..L7

\3
IJ

f* l-.+-=

I L-

zt?: ls taken from system delay Tlmer. Counter wlll count ln upward mode and after five dlgtts are full that ls after 99999 it wtll automaHcally reset to 00000. It can be reset to Zero before also. See sectJon 5(f) (C-RESET). For displaying the counter values in dlsplay set 1 see section
Counter pulse

H
+>
+-"

I
le

s(e)

(C-DISPLAY).

{--...

{'-,

f'-.t

h f'{"=

If any Temperature Channel is open or Thermocouple ls broken tben display set 1 wi-Il shovr OPEN for that channel. For Ex. zore 2 Thennocouple is not connected or bmken, then di<play scannes Ch. 2. It will show: 2 0 PX (Dispfay St
1)

+..=

Similarly if there ls large variatims in Input from Thermocouple or Thermocouple is loose ftt causing rapid change of Temperature in sensing, display for that channel wlll show:

$-=
|.\

f-'

r- l:

(Display Set

1)

q
+-t +-t

If any Temperature Channel has gone over ADC Range due to any fault ln Thermocouple wlre or loose connections or failure of heater to go OFF etc. Then display for that Ch. will show:

ch. No. [l l-l r (Diplay set t)

If any Temperature Channel is programmed to value 000 then that channel wi-Il be out and lt will not be read and dlsplay for it rvlll show.

+-'
t--,

F +-s

t
+= +-" +-t

D l-l b (Display set 1)

t
lr

LJ

t L
LJ I
-t

:18:
channel dlsplay

trf any Temperature Zone ls not programmed then that wlll show:

(Dtsplay Set 1) Ch,No. (Set polnt out)

sPO

a
-r
\t

t.h

In all these cases Output Relay wtll be dlenerglsed to prevent shoot up of temperature and after remedlal measure ls taken and channel ls corrected system wlll agaln start operatlng that channel normally.

t.'
:\" ;\"

Simllarly ln case of Tlmers tf any timers value has been programmed 00.0 then that Tlmer vrill. be out from seguence and lts output relay will not be energlsed.
For proper operation of system tt ls necessary that all the
parameters

of

Temp. 'Iimers

&

modesbe programmedproperly and

;*!

j-*
Fr
7.

correctly. So verlfy these parameter in case of any doubt in systems operation and start the system from master RESET.
TESTIIIG OF SYSTEM:

;-s l. i-s ;-s ;:s

!\]"

l\. F:
-

This system has faclltty to Test all thg Input and Output devices as weJI as Testing of keyboards and Dlsplays. Test Mode can be selected only after Master Reset. To Enter Test Mode press master reset key. Nor Press key '5'Now all the dlsplays should be blank and ordy last display of set 3 wlll be -l to lndicate system has entered lnto TestJ.ng mode. Novr there are three Test modes. These ale:

(a) TEST mode for keyboard and dlsplay. (b) TEST mode for Outputs. (c) TEST mode fgr Input Channels Temp. Channels
Ltmtt Swltch.es.

and

ni' Slr
Fq?
)

tu
-5 !\3 !lr

:19: (a) After enterlng Test Mode as descrlbed earller press key B{TER, Now aU the dlsplay wlll show 'Er to slgnlfy key response of ENTER and dlsplay response of all dlsplays. Now enterlng any key wlll glve slmilar response by showlng their respectlve codes on all the
displays. Key value and thelr codes are glven below:
KEY

DISPLAY

KEY

DISPLAY

\ \ \ l.o \ \"

0
1

0 1

I
ENTER

TIMER

t
E

3
4

c.H.NO.
HOLD

H
5

5 6

START

C-DISPLAY
C-RESET

d
ttr
L
A

F
\ \

I
SET SET

MO'E

l-*
-'

II I

LOCK AUTO

!'-o

MANUAL

n
BIANK

h
\ \

l'\

This way key response of all keys and dlsplays can' be checked by operator. Presslng :/pt key ;l[l lfrrl all the displays. To come out of thls routine Fress Master reset to go to start of system operation.

h
l=
\
I
1i

-.)

t-.. ': . -g L*

t20:
(b) for Outputs-i Ftrst enter lnto Test mode as descrlbed earller. Now press 'Timer, key. Presslng thls key display wtll. show 01 ln the flrst two dtgits of dlsplay Set 1.
TEST mode

-t
l-

\,

\.t -t a -t.
\, \,

0lxxx
|
Blank

(Display Set

1)

t's
\t
\,

r\" r\"
\ i; \ \ \ {

At the same time TR No. l will be energisedand its LED will be on. Now Press numeric keys to change output number. After output number is entered press ENTER key. Pressing Enter key vrill make selected output oN and all other OFF.

For output numbers and their identificalion see system

Outputs Chart.

LE

In this way selectlng all the Outputs one by one operator can check whether all the Outputs are good or any partlcular Output is bad. To come out of this FIes s
master reset.

r\a

\,:s
\, t\,"

(c)

for input Channel: First Fntq :::= k=r mode as descrlbed earlier. Now Fress a: - ft . rsr Presslng thls key dlsplays rrlll shcr.
TEST Mode

h\

X X X (E:;"-"r 3c:
I

1"

t-" hf,

Value cf

'E,!-

- I: -:
G>-..f rL:+

ri-- .l\*E desired Ch.No. kess Fqrr* fry - Isr rgJtCh.No. riLl. Le *.!:l*yec. !8" ery jay- Fcc

Now Press Nuneric ke--i' = -?.rrirf 3

prrrFb

-9 t+:r r\l
E...GI

ta

t2l:
cFerator presses Ch.No. 3 and ENTER key then dlsplay wiLl. s:-:r:

i
a

F,,

3 X X X (ntptaysetr)
I

!\"

1,
l+t

Value of Ch. No.

f\:
t\5
*

For Test purpose these values are dlrect reading and are without amblent compensatlon. That means these readings are referred to 0oC. Ref. of Thermocouple Table. For ease in Testing Ch. Nos. are organlsed as follows:

cH.NO.

,\s
ti*g

fr
E-rt

1. 2. 3.

t=t i*t t+t i't tqt f:t

4. 5. 6.
7. 8. 9.
10. 11.

1 2 ZONE 3 ZONE 4 ZONE 5 ZONE 6 ZONE 7 ZONE 8

ZONE ZONE

TEMP. TEMP. TEMP: TEMP. TEMP. TEMP. TEMP. TEMP.

SYSTEM GROUND (G) SYSTEM FULL SCALE (F)

AMBIENT (A)

irt
t-\
Fq

ttr t-5
FEr
:if
[tF t\}l

and f l are useful for dlagnoslic purFos r-d r;nding out proper worklng of A/D card of the systen. Inis ls also useful in callbratlon of the system.
No.

?,

lD

From l.lonwards operatlon can check li i! sritcb condltlons. If Itmlt swltch ls closed dtsplay vlll sbor cL or tf limlt swltch ls open dlsplay wlll show 6p For ch. No. and limlt swltch relatlon see attached sheet on Test node Ch. No.

tt-ry

Fs
r*

\.t
>J

F3 Fl

z22z For example lf operator has pressed Ch.No. 12 and thei pressed ENTER key then dlsplay wIlI shovr:
12
I

fr

st
f.q Fq

L (Dtsplay Set 1)

q> 3\\ F:'

t\5

f't\

Thls means 1st contact LS 1 ls ON. If display shows L2 op. (Display Set f) - This means contact is OFF. To come out of thls mode press Master reset key. This vray operator can check all conditions of system for its proper functloning.

t-s
l\" t\tr
=!t

D t\5
t-f
-$

Thus the system ls versatile, Accurate and SeIf Testing facilities make fault finding easier. As it is a new and sophlstlcated system operator should go through this manual carefully to understand each and every point. This vrill help him to operate the system without dif ficutty. This will also hetp him ln understandlng the operatlon of system and take correctlve actlon ln case he finds any prob len: in system operalion. Thls wlll also help him in utlllsing the system for
maximum advantage and benefits.

tis t!{ tir

i^r'

8.

SERVICING

MAINTENANCE:

l-r,
Da{

ttr
!tr!f

In case of problem flrst carry out the vlsual inspecLion to see that no connectlon is broken, power line voltage is correct and there ls no loose connectlon ln supply or any other connectlons Observe fault to determlne lts nature. gore common faults and their solutl.ons are glven below. These should be suf flclent to solve the normally enccrinteres problem ln flelds. Solutlons should be attempteC. ty technlcally qualtfled persons only. In case of doult csrs:l:
factory.
FAULT

lar
iQ!:
ftl*

1: No LED display, +5V, -5V, +L2Y, -12t L=- s :-

Fc
Fc
tb

#'

-.-3
t\

\ \ 223:
SOLUTION

H
Ls
\3

F,,
\

(a) (b) (c) (d) (e)

Check 230 V AC, tt should be vrlthin 210 V E 250 V maxi;;r-. Check fuse at the back of unit. Check for burnt wire ln mains llne. Check for filter contlnulty and transformer primary continuity Check for transformer Outputs. These are connected to 6 way

terminal on transformer. Check these supply also. All 'Indlcated Voltage. supplies should be wlthin +3V AC of
10vAc

ov

ov

15V

15V

(f)

Check 4 way connector for

TRANSFORMER

PS

LED connected on PS Card.

->PS Card. ->PS LED Connector

FAULT

2 : As soon as power ls switched on f use blows. 2

:

SOLUTION

(a) (b) (c) (e)

Check for short ln Malns llne. Check fuse ratJ.ng. It should be 300 mA minimlm and 500
maxlmum.

B.A

xt
\, \ -, \ \, \"

Check for short at ftlter termlnal. It should show some lor reslstance. In case lt shows dead short. Replace filter.

(e)

Check transformer primary wlndlng. It should shor ler reslstance from 30 ohm to 100 ohm. It should not shor deaC short 000 ohm. Check for short between D.C. voltage and OV. This ca- 3 checked at supply LED lndicatl.on point. All D.C. vcJlta;= 13: OV ls comlng there.

a a\,
F.

+' ,-T
..d'

\g

f,=

;i\

rt-t+--

z24z

d*
*-"

J+>

;l-

h l-.
{-"

FAULT

3 : -5V, +12V, -l2V LED's ON and +5V LED

OFF'

SOLUTION 3:

(a) (b)

+-

b ri+-t +-t

(c)

l='
\
t

(d)

check lf system Is worklng. If worklng then there ls loose connectlon ln LED's. Check LED connectlons. check battery ln card 1. If its lnsulation ls worn oFF, then tt wlll become short. Remove battery and then check. If al,l OK, then rePlace batterY. If system not worklng then check secondary voltage of transformer as explalned ln solution 1 - e. Check rectlfler output at the back of the system. It should

be approx. 11 V to 13 V.
Becttfler

h*
\

Red--------->
+-----

11 to

'E

10 vAc------

13V DC

,E

E. E.

--10

Ac

-r !\.
i\\
E\f,

+, l.\
r_-t"

hqr

\5
r.l

t h
h

-.

t25:
(e)

#*

If rectlfled Output voltage ls less than IOV check g,Uc: capacltor connectlon. It should not be loose.

J-t*=

g-v'
(f

*Ve - vc

Fllter Capacltor.

b ru r\,
r\t

Fr tt tu F

Ft
t\o
,\E !-:!

rf rectlfled output ts proper then check regulator output. rt should be between 4.7 v and s.2 v. Thts can be checked at the back of bus card. Where blue or black I sq.mm. wlre ls -ve and Red I sq.mm. wlre ls +ve (+sv). rf voltage ls not proper (wlthln 4.7 V to 5.2 V) then remove all cards , and check voltage. rf voltage ls stilr not proper then change the regulator. rf voltage becomes oK after removing the card, then lnsert card one by one and ftnd out by lnserllng which card voltage drops. There ls a short in that card. Flnd out the short with visual inspection or by
multimeter and remove.

WARNING

tt

REMOVE OR INSERT CARDS ONLY

cards posltlon, thls wlll damage

after power OFF. Do not the cards.

+12V

change

F
-t -t
\

FAULT4:+5VON, but -5V, -lzV or

SOLUTION 4:

nd

comlnE.

tf
\ *,
F\,"

(a)

Check whether A/D card ls working, that is Temperab,ue coming and relay ls energislng properly. If yes then tLe:e ls loose connectlon. Check LED's conection as explatned n.o solutlon 1-f.

(b)

If temperature not

,q\

and relay ls not ener;as:.:; ::F check secondary output of Transformer, as e-t;i..:-: -? solutlon 1-e.
coming

a
\,

-5 h. L.

+-

:26:
(c)

'l{* a\q *n -r. \, \, \ \ \, \, \,

ta

Check unregulated voltage on Ps card and change ca:acltor

lf requlred. (d) If unregulated voltages are proper check regrilator Output. If not proper replace regulator and check. Tl,ere are three regulators one each for +LZY, -LzV and -5V. Replace thebaci
one. FAUL?

5: PS ON but system not getting ready. No disptay or

random display.
SOLUTIOI{ 5:

(a)

\,f

Check systen reset key is not pressed or sharted. If shorted or pressed alr the display vrill be blanit. check tnat reset

\s
\t
!\,
tb)

key connections are not shorting with bcdy. Check LED on card 1 is blinking. If yes go to step 5C.

green

qt -t
-,

Check +5V supply is within 4.7 V and 5.2 V. If not go to solutian 3-b, 3-C, 3-d, 3-e, and 3-f.

a
ry

{c)

Ensure tbat the battery ls OK. If battery ls bad then 5\l snpp!.y wiil be down. See Solutlon 3-b.
Check Hed LED in card brc'lien or 3oose.
1

(d)

ls glowi.ng and it i.egs ere nct

!{ARHISG:

n
Q; -

rq,
Pr\.

i-erirove

cr lnsert card cnly after

Poy,'er GFF. Do not charise

caij

:,--sitioi;.
.ei\
^. L.'l!-'-li C:Sp.tay
!-.-^.---

Flr
Its:
fi"

ccnre:ior ls firn:ely inse:te:i

Ifu

J*

.27:
(f) check all cards are ln proper position and are fully tight.

Firmly but gently set card in guide and lnsert it lnto back side connector fully. Check Euro connector pins of any carc is not bend. rf yes staighten the pins and then insert the card. Always observe correct pracing and side while inserting the cards.
(e)

check Euro connector sordering on lst and 2nd card. rf there is any doubt of short circuit between two pins, remove it or if any pin is not making proper connection vrith track, solder it properly . Take care not to spilr solder on card or leave air gap in solder. Reconfirm cards insertion is proper and tight.
Remove

(h)

all other cards except lst card. using this card, system can be started and r E [:l El ,J should come.

\i

+s -r \,
\, \,

(i)

If vrith onty first card r E Fl Cl !| is not coming, then check alf IC's on the card 1 are properly connected to socket. If any socket shows execcessive lacker scratch tt by hnife and clean IC legs by knife.
DO NOT REMOVE IC FROM SOCKET, WITHOUT NOTII-IG ITS POSITION AND POLARITY ON PAPER. IF NECESSARY REMOVE IC oNE BY oNE only and after inserttng lst orre, rr1syE second ONE. WRONG INSERTION WILL DAMAGE THE IC, AftCT

-t
-\ \5

t"
\, t\\ \ \

removing lacker or rust insert rc lnto socket genily but firmly. see that all regs are rnserted properry and not a single leg is bend inside socket or are left out side the
socket.

(:l

ts
Fl

check that bus card tracks are not short by any piece of connection or solder sprtls or any wlre on bus card ls troL broken. Check that bottom most and up most corrnecliccs :i

n!
hlr
h!

--L

i=
;\-, 228:
bus card do not touch the moutrng rarrs. rn case of doubt place a lnsulating tap on mounting rall or insert sleevs ln connector plns to lsolate tt. check for loose wlre or dry solder on bus card connectlons.
FAULT

;?-:t

F.t
+*t

+-' += ?-,
+-'

E Fl d 5 cornrns but system not working no starting and no acceptance of key.

6: f

+*t

L,
\

SOLUTION 6:

(a)

\:g

check that lock is not pressed. rf rock LED's is oN. Then remove lock. See unlocking sequence.

i:
\,

(b)

\t \t F
\,

check tf any key is remaining pressed. under normar vrorking all the keys should be in released conditions. rf any key is pressed or shorted, then system will not accept any other key. put oFF the system and check with multimeter for short on any key. Remove bad key and start the system. check lf any wire from keyboard ls not broken. check connectlon and continulty between wtres from keyboard and dlsplay to KB and dlsplay connector on Card 1. check for any short betvreen tracks connected to 40 pln connector by conducting piece or solder sprlls on card l. check for any short on 40 pin connector soldered into
Card 1.

(c)

F
tr

-S
'

(d)

t
* \,, -," (e)

nL

ft
#*

check for, short between tracks by wire, sorder spills etc. or key connection tracks in KB and display panel. KB and dlsplay sectlon is connected by tracks or frat cable. see for short betvreen tvro tracks or cable. Remove shcrt u found. check these vrlth multimeter. clean the caros rithinner and dry lt and then insert and check.
jl

F
L

#r
#*"

(f)

Go

to step 5 (a) to 5 (r)

lt

,jl

IF,

t-.
t\
I 29
FAULT
:

tr\

F.\
t-g !-."
-r
\

z 7 system worklng but certaln key ls not be&,; a:3s;ir.:

by. .system.

SOLUTION 7:

r?
+r
-r
'Qg +k
i.L

(a) (b)

Go to system test mode and check respons of all keys. Check vrhich keys are not givlng response.

+r

Check that flat connector for keyboard ls ftrmly anC properly inserted lnto matlng connector on dlsplay card and all the points are maklnE connectlons.
see that tracks are not broken near connector. check that there ls no excesslve dust on the card. clean the card and the connector portlon wlth thinner and dry it.
. Check solutions

(c)

LJ

Ag
^!,

+.t FI
\ \

(d)

6-c, G-d, 6-e.

FAULT

I : Particular segment of display is not coming.

SOLUTION 8:

aT
,_ =L

(a)

-s +s
*

to test mode and check that same problem exlsls for all. dlsplay. rf not put off system and check dlsplay by aultimeter. rf that display segment oK then check solce-i.E and check tts contlnulty wlth same segment of Epoc display. There should be continulty between saFie sqEs: of all display.
Go

11

j,

t"

(b)

Put Off system and check that segments tra:i._s r

properly connected to wlre comlng from KB a-d.*.iiT
connector.

(c)

Check for contlnulty between connector pbt polnt.

i*.La

F-;lnqrrf'

n
-., \ :30:
(d

l-*-

r"
11*

Check that connector ls properly soldered on te P:B !.i,3 lts plns are not shorted to adJacent ptns.
Check for contlnuity betvreen translstor of that seEnent r:.:

f: \1
L:. L\
\ *\, \,

(e)

segment polnt after removing the card from bus i'r.i connecting the KB and display connector. If no contin":dty check for loose connectlon, bad solder or broken connectc! pln etc.

(f)
FAULT

Check for Transistor and replace lt lf bad.

9 : Any particular display not comlng.

ry +t
^.' '\!

SOLUTION 9:

(a)

Go to test mode for keyboard and display and note

dorrn,

which dtsplay ls not coming.

I\

(b)

=t
a

Put

of

f system and check by multimeter tJrat display

i.s

+t +t
tt

ProPer.

(c)

<, +t
(d)

Put off the system and check all solder connectlons of that dlsplay. See that common track of that display ls coonecteC properly to wlre coming from KB and display connector.
Check for contlnuity between connector polnt and disptray polnt.
Check solution 8-c and 8-d.

i':t
+t
(e) -16 \

t
-

FAULT 10

: Temperature showing open in partictrlar &:e.

a
tu
r\,lr r*c

SOLUTION 10:

(a)

Cheek for Thermocouple open.

_,f

h r\

E\ EA

:31
(b)

f'*E+t E+t

check for non connection of thermocouple wire or L--ie:

compensating vrlre.

nr t-t
tet
lqt

(c)

short the thermocouple rnput connection of that channe.l. and see if now temperature shows rc,,38. Temperature. rf yes then check for broken thermocouple wire, and its connecting compensatinE vrire etc.
Check tf ambient Temperature ln test mode is proper. If not go to solution 15-a to 15-c.

FI rq
lqt

(d)

t-r

nr Iqt
t+t F f.t r-t
;_,

(e)

check that thermocouple connection from back connector to PCB connector ls firm. See thermocouple wiring dlagram.
check for 25 pln connector on card is connected properJ.y or any point of that connector is not broken. Resolder the

(f)

points check the Reed relay of par ti q.rrar channel ls oK. check coll resistance of that reed reraycheck rc's on that cards are properly fitted lnto socket. Change the card and check.
doubtf

ul

ir
l-rt

(g)
FAULT

Check and replace the card 2.

11 : Temperature showlng otrr ln particular

zone.

-tt
\t-> \" \
Fets

SOLUTION 11:

(a) (b)

Check

for loose connectlon ln

thermocouple

a q
r::s
{r} \

Check that thermocouple type standard.

Go

is proper and cT :s as ]E:

(c)

to solutlon 10-b to 10-g.

232:
FAULT r2z Temperature showlng
SOLUTION 12:

-vE rn partcular

zone.

Thermocouple rs reverse connected. change the thermocouple wlre.

FAULT 13: Very
SOLUTTON 13:

polarlty of

rapid variation in

Temperafure.

check for roose connections go to soru*on rO-b to 10-g.

FAULT 14: Temperature conHnuously showtng amblent or 0000 in

particular

zone.

SOLUTION 14:

(a)

Heat the thermocouple. Now readrng should rnaease if Dot, then check for short thermocouple wire or compensalrng 'n cable or termlnal connectlons. Check all these connections and remove the short.

(b)

check that card 2 ts flrmly and properly connected t9 bus

card.
Check all IC's are properly fitted lnto socket. Go to test mode and check the calrbration of thermocoupre.
Go to solution 10-f and

(c) (d) (e)

l0-g.

FAULT 15: Ambrent remperature not showrng properry i-n res:

mode.

-rtrll

:33:
!

lrc,
o

SOLUTION 15:

+t, \,

(a)

If amblent ls shovrlng open, then check ambient, -::,ssn wlrlng to bus card. See wlrlng chart.
Check that sensor ls not touchlng the body and connecti.m, ls firm. Replace the sensor and check.

nt qt
*t qt
\

(b)

(c)

If reading ls not proper, then recalibrate ttre senso!.

Ql qt

(d)
(e)
FAULT

If wlde varlation in readlng and lt ls not getting callbrated then go to solution 15.b.
Replace

3t lr
d,

the card and check.

@tr

at
-rt
^-

Fi

16: All Temperature zone showing open OUr , F F, 000 high remperature value.

-r
|!l

SOLUTION 16:

(a)
(b)

<l
:ql

check that 25 pin connector on card 2 is correc[y titrc and lts contacts ale proper and firm.
Check all IC's are properly fttted lnto sockeG ln card 2.

-t

(c) (d)
(e)
FAULT

it:t

:lt
:el !,i!
*

Check card 2 ls properly inserted and is i-o pE6;: posltion. Insert the card Brmly into bus card if Loce.
check for loose wlre or connections on card 2.
Check for supply. Go to step 4 (b) to 4 (dj.

a n
*
*i'

l7z Particular outputs such as

solenoj.Cs

a-r=i.: :t[ :tr :F?.

ltr

r=, i-

*lt

'+\

t-"

+
\

:34:
SOLUTION 17:.

Fg f.la

(a)

n al
{!.

to test mode for Timer and check all outputs. Find out and note down whlch outputs are always ON or OFF.
Go

(b)

+g
\

ad +T
A\T

connectlon and recheck outputs.

(c)

wirlng chart for output, lt gives detalls of output type, lts connector numbers and card no. For example lf DC Contactor 2 is always ON, then from wiring diagram it ls clear that rt ls connected to output connector. output connector rs connected to 25 ptn connector of card 6. check all wlrlng con*nurty from coil of contactor No.2 to card 6 connector. rf no continulty then find out faurt and make
Now see

.a
l-

Ar +t

+, tt +t
tt
tg
i

If wiring ls OK then check that particular card. Check if fuse ls OK. Check transistor is proper. Check for dry solder or broken tracks. Check LED is OK.
Replace card and then check. For replacing the card necessary that jumper should be properry selected.

(d)

rt is
There

.q
*$

li

# +* ft

are four output cards. Each card has g outputs. card 3 glves first I outputs, Card 4 glves next. That is from gth to 16th and so on. cards can be lnterchanged by changing jumper. Jumper is having four different posltions for card 3, 4, 5 and 6. place the cap of jumper where you want to place the card. For example rn above mentioned case card 6 ls to be replaced.
the jumper marked 6 with jumper cap and then insert this card in 6th card posltlon.
Now short

Note: 25 pln connectors are fixed for every position. whrre cards can be lnterchanged, 6th no connector should got to Eth position only and so on.

= ,t*

qr

a .t
qi qL

:35:
OUTPUT CARDS FROM

3 TO 6

r?
qt
\ \
+,

c c

k o u o
o

n t__l
o o o o

tb
+s

(J

+r
{{ {.

J t{ c q
$t
(I)

t{

o3 o4 o5 o6

I r{-rl
llr thl
I I

rlilttr i;
''ihrR
''ihF

IJ

[[
TR.
TRANSISTOR

l '.lliltE

{t+

+t tu
+r
tf

F.

FUSE.

FAULT

18: Particular Input alvrays on or off.

+
+f

SOLUTION 18:

(a)

Go to test mode for Ch. no. and test all Input contacts. Find out and note down - Input nos. vrhich are alra",-s open or close. Now see wrrrng chart f or rnput. rt grves detai,r. s :l

(b)

Input type, ferrule Nos. Connector No. and ca:: S:. For example rf left Rtght tllow pln Lrnr.t sr::::: always open then probably LS g is alra,is s:tu1.t,. open. Wlth help of **:r wlrln; Cla::.= contlnultyfrom Input wlre to cata ::::e::::' s :: wl rlng contlnulty ts not ::-le, :_&q @j,lr.r connectlons and recheck Input s.

:36:
(c)

BL.@

slgnal (wlth respect of OV) on that and when switch ls open tt glves OV. comlng, then check ltmit swltch and limit switch and its wirlng ls proper slgnal on the same wire should come, pressed and released.
(d)

Now check that when swltch ls closed

lt glven 24 V partlcular wire If this is not Its wiring. If then +24y, OV

when swltch ls

Now check that the card is proper and lts 25 pln connector rs properly fitted and no two rnput lines are short, check for dry solder, loose connection or broken tracks on the card. Check Input transistor ls
OK.
ii I'
1

,l

j,

Ar

ny

+r
q! {! \

237:
FAULT 19: No
SOLUTION 19:

rnput or No output or Both no rnput and no outpuL

{t {t

r?
{t {t
\

(a)

Check +24Y supply ls proper. If not check fuse, rectifier capacitor and transformer. check 230 v Ac to transformer.

{t {t -t
NP *t

(b)

Check Output and Input connector at back is properly

connected.

(c)

Check Output and Inputs cards are properly ,rrr* check these cards are getting +24V supply.

and

FAULT

20: LED coming but solenoid not energising.

SOLUTION 20:

+t
{t

(a)

{t -t

Check Output wire going to solenoid is switching to (w.r. to OV) when ON and switching Lo 24 V when OFF.

(b)

Put

at

f power and check continuity between output wire and solenoid coll.
of

(c)

Check

continuity of solenold coll.

(d)
FAULT

Check supply accrose solenoid ls proper.

21: Solenold energising but LED is not comlng.

SOLUTION 21:

(a) (b)

Check.

LED's vrlre ls proper.

Put off supply check LED,s is proper by !l'-ll:-::=:. replace lf bad.

Check +24Y ls comlng to that LED.

fi

'il

(c)

ll

-?*-

lf,

:38:
rmportant: Put oFF supply before removlng or lnserLing caris :s before dorng any contlnurty check. Be carefur da 3:r short or mix AC and DC part of supply.

I
H

CAND ARRANGEMENT

B qck.

I f f
{

TRANS.
FORMER

*
'f,

1i

g a -i
q

&,

id

POWER

{
{
"

SUPPLY

f 3
Ir Ir
tus

Left Front

Di

-L.

Cardl Card 2 Card 3 Card6 CardT

to

: :

MainCard
Temperature Card

: Outputscards : InputCard
Rlght hand side.

Component cin

POWER SUPTLY

FILIIR
ma

TRANSF0RMER

AC RtCTtFIER
OV

eE6J!{"::

:5oo

rtr*

t
E

AC 15V

OY

p S.
CAR:

--lr ll

0*

ffi

15V

r
F

:39:
POWER SUPPLY CONNECTION

ir {t

SERVO

SPIKE
BUSHER

STABILIZER

I
L F |lr g L f,
E
Note: EARTH PROPER (INDUSTRIAL EARTH)

b rb
{I

(1) Earthlng is very important. It should be firm and connectec t: all instruments. (2) Never interconnect or mix input and output wire o! if:-rinstrument. AII cable should be seperate, as short as possille,!-3; as near to sYstem as possible. (3)
Use

? + ? + {t) ? *$

only 1 sq.mm.

core cable for all connections.

ii

fl

il
$

t->
4U

E!{r--[d.

h >t

DETAILS OF TIIIERS

F
--... -

S.No. Type l.
2. 3. 4. 5. 6. 7. 8.
o

Descrlptlon Scan Timer Alr Blowing Exaust Delay Mould In Delay Mould Close Delay Mould Out Mould Out Delay Cutter Return Cutter
Delay

Max.tLme
19

Default TL@
02.6
00 .0 00 .5 00 .0 00 .0 00 .0 00 .0 00 .0 00 .0

1'0

.9

T1
'L^2

19.9 20.o 20.0

10

i-:
f*

T3 T4 T5

.0 .0 .0

10.0
10 10

T6
'L^7

T8

02.0 10.0
10

10. 11.

1.'9

T10

Delay Blowpin Fast Blow Pin

Down

00.0
00 .0

.0 .0 .0 .0

72.
13.

t'11
TL2
T13 T14

Delay Blowing Delay Sealing

Ej

10 10 10

00 .0 00 .0

14. 15.

ect

00.0 00.0
00 .0 00 .0

Blow Pin Pressure

Cut

99.9 99.9 99.9 99.9 99.9

F\. l-.g i-t

16.

T1s
T16

Sealing

77.
18. 19.

t-b
;-t

t'l7
1'18

Parlson Control Parlson Control

Delay

0!.0

Pre-Blow delay

ci. !

ia
-r\
f

'-t +.
*

Indication f imer: Ct - Cyc1e tlme - This indicates time of previously co:-:l:=: cycle. This comes only in Auto.

+
I

I .I F\
i

ir--

F{.,

Er-

\q.-

r=
:r\

4t
IMPORTANI'NOTEs
FOR TIMERS

E --el

>.

>'
F
Fr,

For proper functionlng of machlne and its optimum utlllsatlon lt ls important that selected timlng should be proper. Some lmportant polnts are given below. 1.
1'.O ls teml>erature scan time. Each zone's temperature 1s indicated for this set time and after thls tt changes to lndicate next zone's temperature. Open, In, Close, and Out timings should be selected by proper observations. So that machine does not remain tdle after completion of particular operation.
system delay timing should be selected so that machine does

i:
\"
hf*

2.
\R

h.

5,
trl\

3.

L-' '\,

tq"
\,

not remaln idle after completion of blowing. rf this time is less then blowing timing will be terminated in between and if this timing is more then machine wiu remain idle af ter completion of blowing.
4.

ttd
\ :ei \ { *,

By manlpulation of Delay Blow ptn (1 9) and delay Blowlng (r' 1r) timinEs, preblow or post blow can be achleved. rf t 9<T 11, then browing will start after blowprn comes down fully. Thls ls called post blowing. on the other hand if rg>T 11, then blowing will start before blow pin comes down. Thts ls called pre-blowing.
For Cutter operation check following timings:
a)

ai
*

5.

i
* * !tsIr *
b)

+ l.I < T4 + T5, then cutter may operate before closure of mould. If
'L^7

If T7 + TB > T4 + T5, then Cutter wiU. operate

mould closure.

af

ter

J.

c)

If T7 + 18 > T5 + T6 then cutter sill all.

proper tlmlng for cutter cperatice.

not c;:a:

a:

f,
T

So observe

,\ :_ =

42

6.
^.-ll

T13

bottom blow operation timers have no count down display.

ls valid only tf

ls serectec. r.:esc

r]:*\

7.

'-t
Fl '-t .:+t -i-r Frt C+t
,a,

:+, -at

T3, T7, T8, L^IZ, T13, T 15, T16, .L^17, Tlg are set timers' lhat ls these timers can be set by keyboarc setting can be seen on display but there is not count display for these Hmers.

!!!,t

alld down

8.

Tl1, T1, T14, T2, are dlsplayed ln dlsplay set 4 ln the order given. There ls no lndicatlon for timers no. As soorl as one is over another will start and after T14 it will stop.

Display Order is as follows:

Delay Blowpin (T11) Exaust (T2)

Fr
:r5
:it
:-

:+
qit -r\ ts\
* *

r*:
it\
*

fa'
f\
d

:
,l-,,

43

\ .- ^r

MACHINE SELECTIONS

MODES

\tv
F -, C+, _ iI tr\t -t C.t.* ta C\ ttg

-\

is Provided with various types of machlne f uncticns. l -:e:.: reatures can be selected by the operator to sult lts require:-::s. These can be done using mode keys in followinE manner.
System

1.

Mode

- o - station selectlon. Not valid for stngle statio::

Machtne. Top,/Bottom Blow selection. Hydraullc selection cutter setection Seml Auto Selection. Not valt_d.

2.. Mode -12 3. Mode - 2 4. Mode - 3 5. Mode - 4 6. Mode - 5 7. liode - 7 8. Mode - 8 (A)
Mode

Searing selecHon Moutd Memory IN Mould Memory Out

F' eft
;it

- I

Press key in follovring sequence. Mode - 01 - Enter - 00 or 01.

F F

Display wlll show 01 00 - Top Blowing

or 01 - Bottom Blowlng. After Selectlon' ls over press Enter Twlce.

+$ F
]t',,
ij:t * ;a 1a * $L i\ g||r. *

{B) Mode - 2 Press key ln followlng

Mode

sequence

- 02 -

ENrER

oo

or

o1

Dtsplay wILl show 02 00 Mould Locklng pressure oFF during Blori::3 01 Mould close and lockl.lng pressure oN cu:=; 3'-"r--:.; After selectlonurs over press enter key twice.

(c)

Mode - 3 Press key

tn followlng sequence Mode-03-00or01or02

DlsPlaY show
,i

Jl

t-. It\
44

B: -02

3.
:\

q
rfr
:ir

00 - Normal Cutter Operatlon 01 - One slded (From A-B-A) Operation 02 - One slded (From B-A-B) Operation After Selection press Enter key twlce.

03

f-^" L,,

q
4r

(D)

Mode

Press Key ln foliowtng seguence Mode * ?- - 00 - 01

q
tq
:ih
.J

.) !r\

Display wiII show 05 00 - No Seallng 01 - Seallng After selectlon press Enter key twlce.

r.;

(E)

lroae

-{ FT\

oz

:ar

Memory IN : Press key ln the foltowing seguences. Mode - 07 - Enter 01 to 0g Enter - Enter

F\
*, .-\-

There are Nine Memory Locatlotn for Nine different moulds. These locations are 01 to 09. Au temperature data. sET rr and sET r, arl rlmes and Mode varues are stored ln these

ta
t1

locatlons. If Tlmer values are wrongly, programmed,, then

zero

rlLL be entered.

it ta x
-\ -q

6. llode 9
out : Press Key ln the followtng Mode-09-Enter-01 +009
Memory
seguence.

F}
t-r."
F--' --!:lr

Enter - Enter

Au remperature values (set rr, set r) Au tlmer, modes ri.!.I be restored from selected area and machlne wi-Ll sta::
operatlon wlth these recalled values.
l{ote:

:"\ \

E3
:* -

It ls lmportant to stores tlre present values t ' - r r:ir--"l, memory area before recalllng data froc etle: !sca*c. I =rrw ls not done all ![g present data rlIL b.e lcs:-

.dtlr

{5
TEST MODE CHANNEL NUMBERS

Press key ln the followlng sequence: SYSTEM RESET - 5 - Ch.No. ENTER. Now system wlII enter in:c i=:t mode for Temperature channels as well as for Input contacts. t-rEss

the deslred Number then press Enter Key. Channel number their data ls shown below:
Ch.No.
01 02 03 04 05 06

di.ic

Date

07 08 09
10 11

Temperature Temperature Temperature Temperature Temperature Temperature Temperature

Zone t Zone 2 Zone 3 Zone 4 Zone 5 Zone 6 Zone 7 Temperature Zone 8 System Zeto. tt System Galn F.

Ambient
N.C

t2
13 14 15 16 L7

LS8 LS9 ES
N.C N.C

18
19

LSs LS6
LS
11

20
2L

22 23 24 25 26 27 28
29

B.P. B.P.

UP

Down

Bottom Blow Swltch Open Rlght l

In rlght
Close Rtght Out Rlght
NC NC NC

l l
I

Hand Control,
Swltch

30
31

LS7

.L { *.,

a
+5 *

!t6

m.=E
ERROR CODES

+r
j

|\

+$

t F +g
{t

Error codes have been provlded ln the system to-help diagnose .: loglc lnterrock farlure ln machlne operadoln. Ttrls wru hel.p th"e operator to locate the problama[c rnput faster thereby redr.rci-n3 the down tlme conslderably. Error
E0s
E06
EA7

Codes

Descrlptlon
LS5 not pressed LS6 not pressed LS7 not pressed LS8 not pressed LS9 not pressed

q
{|

-t
;P qt
{

808

809
811 EL2
E13

LSll not pressed

NO

t
!.1t

I,/P Card

BPD Switch

not pressed

El4

tt "

Emergency Stop

'lt
I

+ ? ? ;'p
q3 {

r5

+ -'it
:.:t
I

+
{

47

cARp NO.l
Data

CPU CARD (UArX CARp)

40

pln

FRC Connector

Pln

40 pln Connect,c=
on

No.

dlsplay

PCB

scl
sc2 sc0 Rtl
RLO
+5V

RL7

cc9
RL6
10
11

10
11

cc 10
RL5

cc ll
RL4

t2
13
74 15

l2
13

t4
15

cc cc cc
GND

12 13
14

RL3 RL2

16 77
18

16

t7
18 19

19

cc cc
NC

15 16

20 2L 23 25 26

20

2t
22 23 24 26 27 28
30
31 32

RST IN

ccl
cc2
cc3

30

cc4 cc5 cc6

cc7
DP

31

32 33 34 36 37 38 39

cc8
Xote: NC - No connectlon.

{0
CC - CCn.l..,r. ..rein;r

{U

-. -'."

48

u--.GtlD,

-$

{s .5
-5
_i3
I

D NO.2 ADH CAru) TIRING

Data

DETA

(IEERXOOOUpI.S

Back Panel 34 pln, Heater

Thermocouple Connector (ptn nos)

25 pln
Conacstor
PLC

:p
_.,

No.2 lnsldc

tpln nos. )
t3
25

I t

THERMOCOUPLE

l9
20

"t tr
-lt rp
'!

THERMOCOUPLE

2+

2l
22

l2
24

THERMOCOUPLE

.t
-t)
F1'
THERMOCOUPLE

23 24

ll
23

4+

'lt -I ':t
,l

25 26

l0
22

THERMOCOUPLE

27 28

I
2L

-{}

a
-t
{

THERMOCOUPLE

6+

29 30

20

,1

1'HERI\iOCOUPLE

31

I
TG

32

't :t
t't

TIiERI{OCOUPLE

33
34

{t
!

F'!a
49

q+\

E-.{E

s
*

CAND NO.

OUI'PUT CARD HIRING DETAILS

={t

3t
!I
-ai

O./P

No. Valves type

Back Panel 34 pln

HCL O./P Connector

Back Pane.l 60 ptn ECL

qp
1.
BLOWPIN
UP

type

25 pln D type No.3 Inslde

PLC

LED

Conaector

Connector

:it
-

2.
3. 4. 5. 6. 7. 8.

FAST BLOW PIN

SEALING

DOWN

74

22

tt

_{r

25

40

-3
t{3

PRE-BLOW

-l r!
F' + -t
{i
-at

N.C. N.C.
MOULD OPEN MOULD IN

15

23

26

47

10 16

-t
-

24

11

+ 24 VDC

!,2,L3,23,24
!2,22,34
60

\r

ov

25

it
\rl
fra

l{ote: Card No. 3 is lst output Card.

rt
i.1 -ha

tr5
a

tb50

E--.fa

CARD

llo. { -

OUTPUT CARD

IIRING DEI'AILS

r
O./f,o.

v1f3es tvne

Back Panel 3,t Pln HCL

f++,t-

Back Pane.l 25 PLu 60 pln ECL connestor O/P Connector LED Connector Xo.t Iaslde

PIf

9.
10.

MOULD CLOSE MOULD OUT BLOW

27

42

ft1

11.

PIN

DOWN

L7

25

--\
-t

12.
13.
14.

AIR

BLOWING

28

43

PARISON CONTROL CUTTER

18

26

9'
10

t-\l*U

15.

MAIN SOLENOID
LOCKING PRESSURE

29

44

1
-ig

16.

I
,2,13 ,23 ,24

tt

+24VDC
ov

-9 .-!
-\

t2,22,34

60

Note: Card No. 4 ls 2nd Output Card

-} H
tEfl ft{

n rfa
H
tr'
ii

F1
F--+
,p

Jr

-+ 5t

-+..

-f.
o/P
No.

CAND NO.s

OUTPUT CARD TINIXG DEIAII

L: t

Valve or Contactor Type

Back Panel Back Panel Back 34 pln PaneI HCL O/P Heater t 50 pln Connector ThermoLEI) couple Connector Connector

34 pln

25 pln
Connector No.5

lnslde
PLC

t7

HYDRAULIC
CONTROL

--! 3ql
-iu .t: !-3/

::r s n s l"

I
t2
19

27

18

BLOWER 4
C,UTTER 2

45

19

20

BOTTOM LEFT OR H7

30

28

2t
22

BOIA'OM RIGHT

46
20
o

fr
-ilil

EJECI' LEFT
EJECT RIGITT
BLOV.'EP. 3

23

::t
*

3l
11

29

t0

24

17

:!r
:F
..r"

1l

+24VDC

1,2,13,23 ,24
L2,22,31
60

+
{ .T{ T { {F . '{ { .? *
l

-}

ov

25

Note : Card Ns.5 ls 3rd Output Card

-l{ .f

i!

'rI

<t

Gu-s1-

:\ *
q, a'
4\

CARD NO.6

OUTPUT CARD

TIRING DETAILS Back Panel 25 ptn 60 pln Connector

tr

O/P

No.

Sr

Connector Type

Back Panel 34 rrln

f +t

Heater Thermocouple Connector

LED No.6 lnslde Connector PLb

10

# 5 5
$

25

HEATER

26

HEATER 2 HEATER HEATER HEATER

30

27

48

.5

28

11

29

31

30

HEATER 6 BLOWER
1

49

31

I
10

t2
32

l0
11

I 5
I f l
{

32

BLOWER 2

+ 24

VDC

ov
Note
:

60

25

Card No.5 ls 4th Output Card.

'tit6

t/t

t-, ' /t"

:.tr

53

: :*

I
-.
t"

Date

Back Panel 34 PlD ncl, VP Connector

Back Pane.l 60 Ptn LED

C.onnector
14

25 Ph Conr:estor No. 7, Indde

PLC

r'q
'a

NIL

l3

F
< .

LS 8 BLOW PIN LS 9 MOULD IN

E.S.EMERGENCY STOP

13

51

14

il
\
J

15

N.c. N.c.

t4

lq ;li

34

15

LS. 5 LS. 6

MOULD OUT MOULD OPEN

16

16

s
ilh

LS. 11 SLW DOWN

B.P.UP

53
L7
15

t7

5 5

B.P.

DOWN

36

19

BOTTOM BLOW SWITCH OPEN RIGHT

21

IN

RIGITT

HAND CONTROL
SWITCH

T7

11

{ LOSE RIGHT

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60 Pln
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14

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33
51 15 34

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L511

BP4
BPD
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52

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35

53

t7
36
54 18 37

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LS7

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Open Right

55
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20
39

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PRB

Blow Pln Up Solenold 2 Fast Blow Down Solenold 22

E!(.
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gsartng PreBlow Exhaust No Connectlon Open Rght Solenoid In Right Solenold Close Right Solenold Out Rlght Solenold Blov; Pln rlght Solenotd

40
3

23
41
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24 42
5

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Hyd

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29

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st
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H3
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H4
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0

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0 ES 0

BPD
0

FPD
0

PC
0

H7
0

PRB

0
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0

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BT
0

H7
0

BBS
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