STREAMLINE CONTROLS PVT.LTD.

BLOkon 03 Manual

OPERATING MANUAL
FOR CONTROL
SYSTEM OF BLOW
MOLDING MACHINE

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 STREAMLINE CONTROLS PVT.LTD.
BLOkon 03 Manual

Business Mission

Streamline Controls Pvt. Ltd. (SCPL) is in the business of providing electronic &
computerized automation solution for different industries so as to enhance the
quality and productivity. Our motto is to provide indigenous, reliable and proven
products & hence to ensure consistent performance. Our concept of value to the
customers is to supply indigenous control systems designed with latest
technology, developed through extensive R & D, incorporating state of art
technology (world technology trend), manufactured under strictest quality control
system and duly tested, at competitive prices, delivered in time and supported by
service teams.

We feel it to be our responsibility to ensure that our business operates at a

reasonable profit, as profit provides opportunity for R&D, growth and job security.
Therefore we are dedicated to profitable growth - growth as a company and
growth as an individual.

For detailed inquiry and trouble shooting please contact:

STREAMLINE CONTROLS PVT.LTD.

401/402,”meghansh”complex, opp.Oxford tower,
Gurukul road, Memnagar, Ahmedabad-380 052.
Gujrat, India.

Ph.No. – 9328808665,,9328808669

E-mail –
[email protected]

web - www.streamlinecontrols.com

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 STREAMLINE CONTROLS PVT.LTD.
BLOkon 03 Manual

PREFACE

BLOkon is multi functional controller incorporating micro controller, making it most versatile and
cost effective solution optimally designed to best suit the automation needs of blow molding machines.

For letter usage and maintenance of control system, detail study of this operating manual will be
helpful.

We would be glad to assist your quarries.

Specification are subject to change without prior notice.

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BLOkon 03 Manual

CONTENTS

(A) SYSTEM SPECIFICATIONS

(B) INTRODUCTION

(C) FEATURES

(D) SCOPE OF SUPPLY

(E) PROGRAMMING OF THE SYSTEM

(F) OPERATING PANEL DESCRIPTION

(G) MANUAL MODE OF OPERATION

(H) PRECAUTIONS

(I) ON LINE VIEW SCREEN DESCRIPTION

(J) LIST OF PROGRAMMABLE PARAMETERS

(1) TEMPERATURE CONTROLLER

(2) TIMERS
(3) MISC.FUNCTIONS
(K) LIST OF INPUTS AND OUTPUTS
(L) WIRING DIAGRAM AND BLOCK DIAGRAM
(M) SEQUENCE OF OPERATION
(N) INTERLOCKS

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(A) SPECIFICATIONS:

Input

Power:
Voltage -- 0-24Vac
Frequency -- 49-50 Hz
Consumption -- 30 VA Max.

Control:
Thermocouple -- J / K type - Isolated
Proximity/ -- NPN (NO type)
Limit switches 10-30Vdc - 50mA Max.

Output

For Solenoids -- For 24VDC - 2 Amp. Max. – MOSFET Driver Output

For Heater -- For 24VDC - 2 Amp. Max. – MOSFET Driver Output

Environment

Temperature -- 0ºC to 55ºC

Humidity -- 5 to 95% RH non condensing

MECHANICAL DIMENSIONS (All are in MM)

Operating Box -- Depth X Width X Height

144 mmx144mm

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BLOkon 03 Manual
(B) INTRODUCTION
Blokon is a complete proven & reliable control system for Blow Molding Machine.
System consists of two units.
(1) MMI unit
(2) C.V.T. (Optional)/Transformer

(1) Operating Panel:

This is small lightweight Display unit with soft touch keypad & LCD display, digital input, digital
output and temperature section.

This package has some obvious advantages over existing conventional Electrical
Systems. This occupies lesser space then conventional system. The simplicity of wiring from
solenoids to systems or limit switches to system and from Thermocouples to system makes it
easier and less time consuming for commissioning. This system has no moving parts, so
periodical maintenance is drastically reduced and there for reliability is definitely improved.
Function like Heating ON-OFF and Cycle Time Interlock makes this system much more superior
then the conventional system.

(C) FEATURES

 Inherently reliable Micro controller based technology 8051 / 100MHz CPU.

 Offers up to 8 digital inputs, Up to 8digital outputs, 3zone time Proportional controlled
Temperature Controllers, timers, Extensive feather touch membrane keypad for user interface for
manual/Set/fully auto functions of the machine.
 Latest E2PROM Technology ensures security of programmed parameters.
 User friendly programming through an extensive membrane keypad for easy operator interface
(Details of manual mode operations available is appended on separate sheet)
 Five digit counters to count Number of Pieces.
 Facility for counting cycle time helpful in production analysis.
 Thermocouple "Open" & "Reverse" conditions are self detected and are displayed as "Opn" and
"rev" respectively.
 Programmable High & Low limits for all temperature zones.
 Automatic cold junction compensation for Thermocouple inputs.
 Inbuilt interlocks for Low & High temperature, Right and/or Left doors, Maximum Cycle Time,
Emergency stop, Hydro motor overload and many others.
 Built in 25 nos. mold memory.
 Operating Input/Output diagnosis.

(D) SCOPE OF SUPPLY

SCPL to provide:
1 Hand Panel.
2 Input & Output cards.
3 Inter connecting cables.
4 Operating Manual.

(E) PROGRAMMING OF THE SYSTEM

The system will be programmed to suit your application by us.

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BLOkon 03 Manual
Operating Panel Description :
Front key board Sticker

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BLOkon 03 Manual
Key’s Description
1. Cursor Key

Press this key to move cursor from left to right direction for parameter
Setting in any menu.
Also use to open the password menu in online display

To increase parameter value in any menu

Also use for function on/Off

To decrease parameter value in any menu.

Also use for function on/Off.
Alarm Reset for all mode.

For Data input confirmation, save parameter & shift to next parameter.
Also Use to scroll online display.

PROG MODE: To Shift previous parameter

PROG MODE: To Shift next parameter

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2. Manu Selector

Set temperature key for set all zones set point.

Set timer key for set all function’s timer.

Set misc key to do set on/ off for selectable function.

3. Operating Mode Selector

Machine operating at fully automatic production mode.

Re-started by cycle delay timer.

Operating machine by manual key.

Push this key to start or stop the heating

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BLOkon 03 Manual

4. Manual Operation Key

Mold Open Key

Press for activate of mold opening action manually.
Mold Close Key
Press for activate of mold clamping action manually.

Carriage Forward Key

Press for activate of Carriage Forward action manually.
Carriage Backward Key
Press for activate of Carriage Backward action manually.

Blow Pin IN Key

Press for activate of Blow pin action manually.
Blow Pin Out Key
Press for activate of Blow Pin Out action manually.

Blowing Key
Press for activate of blowing action manually.
Ejector Backward Key
Press for activate of Ejector Backward action manually.

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BLOkon 03 Manual

5. Common Function

Cutter Key
Press for activate of Cutter Left/Right action manually.

Parison Key
Press for activate of Extruder UP/Down action manually.

(G) MANUAL MODE OF OPERATIONS

1. Mould Open
2. Mould Close
3. Carriage In
4. Carriage Out
5. Blow Pin In
6. Blow Pin Out
7. Air Blowing
8. Cutter in/out
9. Extruder up/down

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BLOkon 03 Manual
(H) PRECAUTIONS

To prevent damage from human and machine, please obey the

following safety caution.

 Equipment must be operating under correct power.(Install a voltage stabilizer while need)

 Earth terminal must be connected to qualified terminal.

 All electrical elements with EARTH terminal, it is necessary for users to connect with the EARTH
terminal.

 The high power cables should be separated from the low power cables to avoid interfere.

 To prevent fire or hazard shock, do not expose the unit to rain or moistly place.

 Please understand the operating process before use.

 When system shut down, wait 10seconds for re-start.

 Thermocouples used for this system must be isolated (ungrounded) Fe/k type.

 The wiring of each zone starting from thermocouple of heater must be verified.
For ex: first zone thermocouple must be connected to first channel of the system and heater of
first zone must be connected to heater 1of the system.

 The limit switch and solenoids wiring must be done as per given wiring diagram.

 If the proximity switches are used then use only PNP-NO type proximity switches.

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BLOkon 03 Manual
(I) Online View Screen

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BLOkon 03 Manual

View Screen 2

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View Screen 3
To go this page press save key in view screen2

1 2

View 3/5 Heat Off

BarZ1 BarZ2 BarZ3 5
3 6
Sp 000 H 000 H 000 H 8
4 7
Pv 000 Al 000 Al 000 Al

10 12 14
9 11 13

Description of Page

Screen Display View Description

Number
1 View 3/5 No. of Display View
2 Heat Off Display heating off or on
3 Display barrel zone 1 set temperature
4 H Display heater or blower on status
5 000 Display barrel zone 2 set temperature
6 H Display heater or blower on status
7 000
8 H Display heater or blower on status
9 000 Display barrel zone 1 actual temperature
10 Al Display alarm low or high status
11 000 Display barrel zone 2 actual temperature
12 Al Display alarm low or high status
13 000 Display barrel zone 3 actual temperature
14 Al Display alarm low or high status

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View Screen 5
To go this page press save key in view screen4

1 2

View 5/5 Heat Off 3

DieZ3 Die 000%H 4
6
Sp 000 H Hotw 000%H 8
5 7
Pv 000 Al OIL 000

9 10 11

Description of Page

Screen Display View Description

Number
1 View 5/5 No. of Display View
2 Heat Off Display heating off or on
3 Display die ring set temperature
4 H Display heater or blower on status
5 000 Display die zone 3 set temperature
6 H Display heater or blower on status
7 000
8 H Display heater or blower on status
9 000 Display die zone 3 actual temperature
10 Al Display alarm low or high status
11 000 Display oil temperature

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View Screen 6

This page is useful to view the presence of each input. (Limit switch Or proximity
switch or push button)

Changes in the input status as per sensing of input indicates that the wiring and
electronic path of that input is functioning correctly.

Press save key once again to exit from VIEW: INPUT & enter in next page

View Screen 7

When any output is activated, Number is shown on LCD opposite activated output
number in digital output block. Please refer list of outputs for more information.

Press Save key once again to exit from VIEW: OUTPUTS & enter in Next Page

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BLOkon 03 Manual

Password Entry
Press Shift key in any of online display.
It is require to exit from any menu at the time of password entry.
First line of LCD will show “ Enter Password”.
Second line of LCD show Enter Password and it’s value.
Set require password value using INC, DEC and SHIFT key.
On pressing SAVE key the set value will be saved.
List of password entry parameter is given below.
No. Message Description Range Level
1 Entr Paswd Enter Password 0-9999 User

(J)List of Programmable Parameters

Set Temperatures
Press set TEMP key.
First line of LCD will show “ Set Temperatures”.
Second, third and forth lines of LCD show zone number and set temp.
Select require zone using UP/ DOWN key.
Set require temperature using INC, DEC and SHIFT key.
On pressing SAVE key the set value will be saved.
List of temperature parameter is given below.
No. Message Description Range Level
1 SetTmp Z1 C Set Temperature of Barrel Zone 1 0-400 C User
2 SetTmp Z2 C Set Temperature of Barrel Zone 2 0-400 C User
3 SetTmp Z3 C Set Temperature of Barrel Zone 3 0-400 C User
4 SetTmp DR % Set Temperature of Die Ring 0-100 % User
5 SetTmp HW % Set Temperature of Hot Wire 0-100 % User
6 SetTmp Oil C Set Temperature of Oil 0-100 C User
7 Zone 1 Zone 1 On/Off On/Off User
8 Zone 2 Zone 2 On/Off On/Off User
9 Zone 3 Zone 3 On/Off On/Off User
10 Die Ring Die Ring On/Off On/Off User
11 Hot Wire Hot Wire On/Off On/Off User
12 Oil Temp Oil Temperature On/Off On/Off User
13 LoAlrm Z1 Low Alarm of Zone 1 0-400 C User
14 LoAlrm Z2 Low Alarm of Zone 2 0-400 C User
15 LoAlrm Z3 C Low Alarm of Zone 3 0-400 C User
16 HiAlrm Z1 C High Alarm of Zone 1 0-400 C User
17 HiAlrm Z2 C High Alarm of Zone 2 0-400 C User
18 HiAlrm Z3 C High Alarm of Zone 3 0-400 C User
19 BloPont Z1 C Blower Point of Zone 1 0-100 C User
20 BloPont Z2 C Blower Point of Zone 2 0-100 C User
21 BloPont Z3 C Blower Point of Zone 3 0-100 C User
22 BloPont Z4 C Blower Point of Zone 4 0-100 C User
23 ProBand Z1 C Proportional Band of Zone 1 0-100 C Supervisor

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24 ProBand Z2 C Proportional Band of Zone 2 0-100 C Supervisor
25 ProBand Z3 C Proportional Band of Zone 3 0-100 C Supervisor
26 IntGain Z1 S Integral Gain of Zone 1 0-1000 Sec Supervisor
27 IntGain Z2 S Integral Gain of Zone 2 0-1000 Sec Supervisor
28 IntGain Z3 S Integral Gain of Zone 3 0-1000 Sec Supervisor
29 CyTime Z1 S Cycle Time of Zone 1 0-100 Sec Supervisor
30 CyTime Z2 S Cycle Time of Zone 2 0-100 Sec Supervisor
31 CyTime Z3 S Cycle Time of Zone 3 0-100 Sec Supervisor
32 CyTime DR S Cycle Time of Die Ring 0-100 Sec Supervisor
33 CyTime HW S Cycle Time of Hot Wire 0-100 Sec Supervisor

Set Timers
Press set TIMER key.
First line of LCD will show “Set Timers'.
Second, third and forth lines of LCD show timer’s name and it’s set value.
Select require timer using UP/ DOWN key.
Set require timer using INC, DEC and SHIFT key.
On pressing SAVE key the set value will be saved.
List of timer parameter is given below.
No. Message Description Range Level
0 Blow time Blow time 0-100.00 sec
Exhaust Tm Exhaust Time 0-100.00 sec
Cycle Dely Cycle Delay 0-10 Sec
Paris Ontm Parison Time 0-10 Sec
Cutter Dly Cutter Delay 0-10 Sec
Cutr Impls Cutter Impulse 0-10 Sec
CarIn Fast Carriage In fast time 00-10 Sec
Car Out Fas Carriage Out fast time 00-10 Sec
Car Out End Carriage out end time 00-10 Sec
MCls Fast Mold Close Time 00-10 Sec
Mopn Fast Mold Open Time 00-10 Sec
MCls Dely Mold Close Delay Time 00-10 Sec
Tonnage Tim Tonnage time 00-10 Sec
Blopin Dly Blow Pin In Delay 00-10 Sec
Blopin Fas Blow Pin In Fast Time 00-10 Sec
Blopin Int Blow Pin In Intermediate Time 00-10 Sec
Blopin Slo Blow Pin In Slow Time 00-10 Sec
BPOut DI Blow Pin Out Delay Time 000-100 Sec
Blow delay Blow Delay 000-100 Sec
Eject Time Ejector Time 000-100 Sec
BPOut Rel Blow Pin Out Release Time 00-10 Sec
Deflash In Deflash In Time 00-10 Sec
DefOut Dly Deflash OutDly 00-10 Sec
Deflash Mov Deflash move time 00-10 Sec
Cy Ovr Tim Cycle Over Time ( Limit for Total Cycle Time) 00-10 Sec

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Set Miscellaneous
Press set MISC key.
First line of LCD will show “ Set Miscellaneous'.
Second, third and forth lines of LCD show function’s name and it’s value/status.
Select require function using UP/ DOWN key.
Set require value/ status using INC, DEC and SHIFT key.
On pressing SAVE key the set value will be saved.
List of miscellaneous parameter is given below.

No. Message Description Range Level

1 Station Select Station Left/Right User
2 Set Mode Set Mode to activate On / Off User
3 Cutter Cutter Operation On/Off On / Off User
4 Memory No Active Memory No. 0-25 Supervisor
5 Motor Cont Motor count activate On / Off
6 Deflash Deflash Operation On/Off On / Off User
7 Batch Count Batch Counter On/Off On / Off User
8 Batch Count 5 Digit Batch Counter 0-65535 User
9 Reset Count Deflash Operation On/Off On / Off User
10 Test Mode Batch Counter On/Off On / Off User
11 BPOut Option Select Blow pin Out function to operate After Opn/Before Opn Supervisor
12 Batch Count 5 Digit Batch Counter 0-65535 User

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(N) INTERLOCKS
It is a one type of alarm system which activate when cycle or any other function does not operate
properly because of those abnormal condition it indicate INTERLOCK

Following are the different interlock messages.

Type Of Mode
Interlocks Messages
Sr.No. Operation Description Of Messages Fully
On Screen Hand
Auto
IL.Lt MOpen End Left Mold fully open end y y
1 Left Mold Open IL.Lt Mold Not Open Left Mold is not fully open y
IL.Lt Mld Opn/Cls On Left Mold open and close input on y y
IL.Lt Mclose End Left Mold fully Close end y y
2 Left Mold Close IL.Lt Blow Pn no Out Left Blow pin is not out y y
IL.Lt Mld Opn/Cls On Left Mold open and close input on y y
IL.Lt Cariage In End Left Carriage in end y y
IL Lt Blo Pn no Out Left Blow pin is not out y y
3 Left Carriage In
IL.Rt Station no Out Right station is not out y y
IL.Lt Carr In/Out On Left carriage in and out input is on y y
IL.Lt Carige Out End Left Carriage out end y y
IL.Lt Cariage no Out Left Carriage is not out y y
4 Left Carriage Out
IL Lt Blo Pn no Out Left Blow pin is not out y y
IL.Lt Carr In/Out On Left carriage in and out input is on y y
5 Left Blow Pin In IL Lt Cariage no Out Left Carriage is not out y y
6 Left Blow Pin Out IL.Lt Blo Pn Out End Left Blow pin out end y y
7 Emergency IL.Emergency Press Press Emergency Push Button y y
8 Hydro Motor IL.Hyd Motor Not On Hydro motor is not on y y
9 Hydro Motor Overload IL.Hyd Motr Ovr load Hydro motor is overload y y
10 Left Safety Door IL.Lt Safty door Opn Left safety door open y y
11 Right Safety Door IL.Rt Safty door Opn Right safety door open y y
Actual cycle time is exceed from set
12 Cycle Time Over IL.Cycle Time Exceed y
cycle time
13 Batch Count IL.Batch Count Over Set batch count is over y
IL.Extruder Up End Extruder up end y y
14 Extruder IL.Extruder Dn End Extruder down end y y
IL.Extrudr Motr Trip Extruder motor is trip y y
IL.Low Temperature Temperature is Low y y
15 Heating IL.High Temperature Temperature is High y y
IL.Oil Temp High Oil Temperature is high y y

IN case of 24vdc output

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OUR PRODUCT RANGE

 Dedicated Controller for Plastic Injection/Blow molding Machines

 DC Stepper Drives

 PID Temperature Controllers - 6 CH/1CH

 Profile Generator

 Pre Programmable Logic Controllers - PPLCs

 Digital Timers & Counters

 Dedicated Controller for Plastic Bag /Pouch Making Machines

 Dedicated Controller for Food / Pharma labeling Machines

 Dedicated Controller for Grinding Machines

 2/3/4 Axes Motion Controller (Using DC Stepper / AC Servo Drives)

AUTOMATION... PRODUCTIVITY THROUGH TECHNOLOGY.

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