STREAMLINE CONTROLS PVT.

LTD
INJkon 00/1.0/ Manual

OPERATING
MANUAL FOR
CONTROL SYSTEM
OF INJECTION
MOLDING MACHINE

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 STREAMLINE CONTROLS PVT. LTD
INJkon 00/1.0/ 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 contact:

STREAMLINE CONTROLS PVT.LTD.

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

Phone. – (079) 27411463(O)

E-mail –
customercare@Streamlinecontrols.com

Web - www.streamlinecontrols.com

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PREFACE

INJkon is multi functional controller incorporating micro controller, making it most

versatile and cost effective solution optimally designed to best suit the automation needs of
injection 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.

Specifications are subject to change without prior notice.

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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) SETTING PROCEDURES FOR:

(1) TEMPERATURE CONTROLLER

(2) TIMERS
(3) MISC.FUNCTIONS
(4) PRESSURE
(5) FLOW

(J) DESCRIPTION OF TEST MODES:

(1) INPUT
(2) OUTPUT
(3) TEMPERATURE
(K) FUNCTIONAL DESCRIPTION OF:
(1) MOULD SAFETY
(2) FAST APPROACH
(3) HEAT OFF
(4) HAND
(5) SEMI AUTO
(6) FULLY AUTO
(7) ONLINE PARAMETERS
(L) INTERLOCKS

(M) LIST OF I/P AND O/P

(N) SEQUENCE OF OPERATION
(O) WIRING DIAGRAM AND BLOCK DIAGRAM

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(A) SPECIFICATIONS:

Input

Power:
Voltage -- 0-440Vac ± 10%
Frequency -- 49-50 Hz
Consumption -- 30VA Max.

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

Output

For Solenoids -- For 230VAC 2 Amp. Max. - SSR Output

-- For 24VDC - 2 Amp. Max. – MOSFET Driver
Output
For Heater -- SSR Output - 2 Amp max 230Vac
Contactors

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

95 mm 133 mm 280 mm

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(B) INTRODUCTION
INJkon is a complete proven & reliable control system for Injection Molding Machine.
System consists of three units.
(1) Display unit
(2) Input/Output drivers
(3) C.V.T. (Optional)/Transformer

(1) Operating Panel:

This is small lightweight Display unit with soft touch keypad & LCD display. This unit
is connected to Input/Output drivers via 25core factory assembled flexible cable.

(2) Input/Output Drivers:

System provide with Junction card, Digital Input card, Digital Output card, Contactor output
card, Analog Output with Driver card (Optional), Analog Input card (Optional) &
interconnecting cables (factory assembled).

Junction card
Junction card is junction between all Input/Output driver cards & Display unit.
Require Power supply for driver cards and display unit provide by this junction card.
Thermocouples for measuring barrel temperature are also connected to this card.

Digital Input Card (Standard for 2, available extend to 6)

All the inputs to the system are connected to digital input cards. Each input card
accepts 8nos. of digital inputs.

Digital Output Card (Standard for 2, available extend to 6)

All the outputs of the system are connected to digital output cards. Each output card
is provided with 8nos. of digital output.

Heater Output Card (Standard for 1, available extend to 2)

All the Heater controlling contactors are connected to heater output card. Each card
is provided with 8nos. of outputs.

Analog Output Card (Standard for 2, available extend to 3)

Analog output driver card is driver unit that gives proportional output to drive the
Proportional valve. One card is able to drive only one Proportional valve.

Analog Input Card (Standard for 2, available extend to 2)

Analog Input Card is 4 Channel A/D voltage input interface card.

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 suck back ON-OFF, Heating ON-OFF and Cycle Time Interlock makes this
system much more superior then the conventional system.

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(C) FEATURES

Inherently reliable Micro controller based technology 8051 / 20MHz CPU.

Offers up to 64 digital inputs, Up to 64 digital outputs, 8-zone time Proportional controlled

Temperature Controllers, timers, Extensive feather touch membrane keypad for user interface
for manual/Semi auto/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)

Six digit shot counter to count Number of Pieces.

Facility for counting cycle time helpful in production analysis.

Three different programs for Ejector operations provide to suit the operational needs with
various molds.

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.

Mold Safety interlock provided in case of abnormal pressure rise while the mold is getting
closed (For that pressure switch input has to be provided.)

Inbuilt interlocks for Low & High temperature, Front and/or Back guards, Maximum Cycle
Time, Emergency stop.

Built in 25 sets of mold memory.

Operating Input/Output diagnosis.

Central lubrication control with precisely On/Off timer.

(D) SCOPE OF SUPPLY

Streamline Controls 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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(F)OPERATING PANEL DESCRIPTION

Front Key Board Sticker

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Push this key to move cursor from left to right direction for parameter setting in any menu.
With help of this key you should toggle your screen from shot counter to proportional to
RPM counter to shot counter.

To increase parameter value in any menu

Also use for function on/Off
Rolls up temperature channel display in temperature channel freez status.

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3. OPERATING MODE SELECTOR

Push this key to start or stop the heating.

Machine operating at fully automatic production mode.

Restarted by cycle delay timer.

Operate machine in semi-auto recycling and

re-started by front safety door open and close again.

For select mold adjustment function.

In this mode fast approach function is not activate for mold open & close.

Operating machine by manual key.

4. Manual Operation Key

Mold Open Key

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

Carriage Forward Key

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

Injection Key
Push for activate of Injection action manually.
(Disable by any zone of barrel temperature is lower than alarm low setting)
Refill Key
Push for activate of Refill action manually.
(Disable by any zone of barrel temperature is lower than alarm low setting)

Ejector Forward Key

Push for activate of Ejector Forward action manually.
Ejector Backward Key
Push for activate of Ejector Backward action manually.

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Mold Height + Key

Push for activate of Mold Height + action manually.
(Work only in Die set mode)
Mold Height - Key
Push for activate of Mold Height - action manually.
(Work only in Die set mode)

Core In Key
Push for activate of Core In action manually.
Core Out Key
Push for activate of Core Out action manually.

Suck Back Key

Push for activate of Suck Back action manually.
(Disable by any zone of barrel temperature is lower than alarm low setting)
F1 Key
Spare key.

Air Jet Punch Key

Push for activate of Air Jet Punch action manually.(For moveable platen)
Air Jet Cavity Key
Push for activate of Air Jet Cavity action manually.(For fix platen)

(G) MANUAL MODE OF OPERATIONS

1. Mould Close 9. Mould Open
2. Unit forward 10.Unit backward
3. Injection 11.Refilling
4. Suck back 12.Ejector forward
5. Ejector Backward 13.Air jet punch
6. Core In 14.Air jet cavity
7. Core Out 15.Dieset
8. Mould Height (+) 16.Mould Height (-)

(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 interferes.
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 NPN-NO type proximity switches.

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(I) SETTING PROCEDURES

(1) TEMPERATURE CONTROLLERS:

Here two different levels of programming is provided

1. Operator Level.
2. Engineers Level.
In case of operator level only set value of temperature can be changed Where as in case of
other level all other parameters can be changed.

Set Temperature
In case of operator level
Press SET TEMP. key.
First line of LCD shows TEMPERATURE C
Second line of LCD shows zone number & set temperature.
Select require zone using NEXT/ PREV key.
Set require temperature using INC, DEC and SHIFT key.
On pressing NEXT key the set value will be saved and display will show the next function.
List of temperature parameters are given below.
Message In
Zone Message In Default
Second Description Range Level
No. First Line Value
Line
1 Temperature C Zone 1 Zone 1 set temperature 0-500 C 200 C User
2 Temperature C Zone 2 Zone 2 set temperature 0-500 C 200 C User
3 Temperature C Zone 3 Zone 3 set temperature 0-500 C 200 C User
4 Temperature C Zone 4 Zone 4 set temperature 0-500 C 200 C User
5 Temperature C Zone 5 Zone 5 set temperature 0-500 C 200 C User
6 Temperature C Zone 6 Zone 6 set temperature 0-500 C 200 C User
7 Temperature C Zone 7 Zone 7 set temperature 0-500 C 200 C User
8 Temperature C Zone 8 Zone 8 set temperature 0-500 C 200 C User

Set Temperature
In case of Engineer level
Press SET TEMP key and keep it pressed for at least ten seconds.
First line of LCD shows parameter name.
Second line of LCD shows zone number & parameter value.
Select require parameter using NEXT/ PREV key.
Set require value using INC, DEC and SHIFT key.
On pressing NEXT key the set value will be saved and display will show the next function.
On pressing set temp key the zone number can be changed. Again pressing the NEXT key the
different parameter of the same zone can be checked.
List of temperature parameters are given below.
Message In
Message In Default
ZoneNo. Second Description Range Level
First Line Value
Line
Temperature C Zone 1 Set temperature 0-500 C 200 C Engineer
Prop. Band C Zone 1 Proportional band 0-100 C 030 C Engineer
Integr. Time Sec Zone 1 Integral time 0-999 Sec 900 Sec Engineer
Derivt. Time Sec Zone 1 Derivative time 0-999 Sec 000 Sec Engineer
1
Cycle Time Sec Zone 1 Cycle time 0-200 Sec 15 Sec Engineer
Alarm Low C Zone 1 Alarm low 0-200 C 025 C Engineer
Alarm High C Zone 1 Alarm High 0-999 C 025 C Engineer
Blower Point C Zone 1 Blower Operating Point 0-999C 000 C Engineer

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Temperature C Zone 2 Set temperature 0-500 C 200 C Engineer

Prop. Band C Zone 2 Proportional band 0-100 C 030 C Engineer
Integr. Time Sec Zone 2 Integral time 0-999 Sec 900 Sec Engineer
Derivt. Time Sec Zone 2 Derivative time 0-999 Sec 000 Sec Engineer
2
Cycle Time Sec Zone 2 Cycle time 0-200 Sec 15 Sec Engineer
Alarm Low C Zone 2 Alarm low 0-200 C 025 C Engineer
Alarm High C Zone 2 Alarm High 0-999 C 025 C Engineer
Blower Point C Zone 2 Blower Operating Point 0-999C 000 C Engineer

Temperature C Zone 3 Set temperature 0-500 C 200 C Engineer

Prop. Band C Zone 3 Proportional band 0-100 C 030 C Engineer
Integr. Time Sec Zone 3 Integral time 0-999 Sec 900 Sec Engineer
Derivt. Time Sec Zone 3 Derivative time 0-999 Sec 000 Sec Engineer
3
Cycle Time Sec Zone 3 Cycle time 0-200 Sec 15 Sec Engineer
Alarm Low C Zone 3 Alarm low 0-200 C 025 C Engineer
Alarm High C Zone 3 Alarm High 0-999 C 025 C Engineer
Blower Point C Zone 3 Blower Operating Point 0-999C 000 C Engineer

Temperature C Zone 4 Set temperature 0-500 C 200 C Engineer

Prop. Band C Zone 4 Proportional band 0-100 C 030 C Engineer
Integr. Time Sec Zone 4 Integral time 0-999 Sec 900 Sec Engineer
Derivt. Time Sec Zone 4 Derivative time 0-999 Sec 000 Sec Engineer
4
Cycle Time Sec Zone 4 Cycle time 0-200 Sec 15 Sec Engineer
Alarm Low C Zone 4 Alarm low 0-200 C 025 C Engineer
Alarm High C Zone 4 Alarm High 0-999 C 025 C Engineer
Blower Point C Zone 4 Blower Operating Point 0-999C 000 C Engineer

Temperature C Zone 5 Set temperature 0-500 C 200 C Engineer

Prop. Band C Zone 5 Proportional band 0-100 C 030 C Engineer
Integr. Time Sec Zone 5 Integral time 0-999 Sec 900 Sec Engineer
Derivt. Time Sec Zone 5 Derivative time 0-999 Sec 000 Sec Engineer
5
Cycle Time Sec Zone 5 Cycle time 0-200 Sec 15 Sec Engineer
Alarm Low C Zone 5 Alarm low 0-200 C 025 C Engineer
Alarm High C Zone 5 Alarm High 0-999 C 025 C Engineer
Blower Point C Zone 5 Blower Operating Point 0-999C 000 C Engineer

Temperature C Zone 6 Set temperature 0-500 C 200 C Engineer

Prop. Band C Zone 6 Proportional band 0-100 C 030 C Engineer
Integr. Time Sec Zone 6 Integral time 0-999 Sec 900 Sec Engineer
Derivt. Time Sec Zone 6 Derivative time 0-999 Sec 000 Sec Engineer
6
Cycle Time Sec Zone 6 Cycle time 0-200 Sec 15 Sec Engineer
Alarm Low C Zone 6 Alarm low 0-200 C 025 C Engineer
Alarm High C Zone 6 Alarm High 0-999 C 025 C Engineer
Blower Point C Zone 6 Blower Operating Point 0-999C 000 C Engineer

7 Temperature C Zone 7 Set temperature 0-500 C 200 C Engineer

Prop. Band C Zone 7 Proportional band 0-100 C 030 C Engineer
Integr. Time Sec Zone 7 Integral time 0-999 Sec 900 Sec Engineer
Derivt. Time Sec Zone 7 Derivative time 0-999 Sec 000 Sec Engineer
Cycle Time Sec Zone 7 Cycle time 0-200 Sec 15 Sec Engineer
Alarm Low C Zone 7 Alarm low 0-200 C 025 C Engineer
Alarm High C Zone 7 Alarm High 0-999 C 025 C Engineer

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Blower Point C Zone 7 Blower Operating Point 0-999C 000 C Engineer

Temperature C Zone 8 Set temperature 0-500 C 200 C Engineer

Prop. Band C Zone 8 Proportional band 0-100 C 030 C Engineer
Integr. Time Sec Zone 8 Integral time 0-999 Sec 900 Sec Engineer
Derivt. Time Sec Zone 8 Derivative time 0-999 Sec 000 Sec Engineer
8
Cycle Time Sec Zone 8 Cycle time 0-200 Sec 15 Sec Engineer
Alarm Low C Zone 8 Alarm low 0-200 C 025 C Engineer
Alarm High C Zone 8 Alarm High 0-999 C 025 C Engineer
Blower Point C Zone 8 Blower Operating Point 0-999C 000 C Engineer

Set Miscellaneous
Press set MISC key.
Third line of LCD show function’s name and it’s value/status.
Select require function using NEXT/ PREV key.
Set require value/ status using INC, DEC and SHIFT key.
On pressing NEXT key the set value will be saved and display will show the next function.
List of miscellaneous parameters are given below.
Default
No. Message Description Range Level
Value
1 Mold Safty Mold Safety Operation On/Off On / Off Off Supervisor
2 MCls Bost Mold Close Boost Option 0000-0003 0000 Supervisor
3 Lock Ton2 Locking Tonnage 2 On/Off On / Off Off User
4 Auto Carrg Auto Carriage On/Off On / Off Off Supervisor
5 Carr W Inj Carriage With Injection Function On / Off On Supervisor
6 Flow Inj Flow Injection Option On/Off On / Off Off Supervisor
7 Inj. Boost Injection Boost Option 0000-0002 0000 Supervisor
8 Refil Boost Refill Boost On/Off 0000-0002 0000 Supervisor
9 RPM Intlk RPM Interlock On/Off On / Off Off Supervisor
10 LoRPM Scrw Minimum RPM limit to operate screw 0-20 0000 Supervisor
11 PPR Screw Screw pulse per revolution 0-4 0001 Supervisor
12 Suckback Suck Back On/Off On / Off On Supervisor
13 Decomp On Decompression On/Off On / Off Off Supervisor
14 Ejct Prog Ejector Operating Program 0-2 0002 Supervisor
15 Ejct Shot Ejector Shot 0-5 0001 User
16 EjBak I/L Ejector backward interlock On/Off On / Off Off Supervisor
17 Core 1 On Core 1 On/Off On / Off Off Supervisor
18 Core 2 On Core 2 On/Off On / Off Off Supervisor
19 Cor In Pos Core In Position 0000-0002 0000 Supervisor
20 CorOut Pos Core Out Position 0000-0002 0000 Supervisor
21 Core 1 I/L Core 1 interlock On/Off On / Off Off Supervisor
22 Core 2 I/L Core 2 interlock On/Off On / Off Off Supervisor
23 Clamp Advnc Clamp advance On/Off On / Off Off Supervisor
24 Slide Slide On/Off On / Off Off Supervisor
25 % Heat Zn1 Set Temperature of % Heating Zone 1 0-100% 0000 User
26 % Zn1 CyTm Cycle time of % Heating Zone 1 0-100Sec 0000 User
27 % Heat Zn2 Set Temperature of % Heating Zone 2 0-100% 0000 User
28 % Zn2 CyTm Cycle time of % Heating Zone 2 0-100Sec 0000 User
29 Purge Mode Purge Mode On/Off On / Off Off Supervisor
30 TestIn/Out Test Mode On/Off On / Off Off Supervisor
31 Test Temp Test Temperature Mode On/Off On / Off Off Supervisor
32 Count Rst Reset the Shot Counter On / Off Off User

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33 Maxm Pres Maximum Pressure Setting 0-100bar 100 bar Supervisor

34 Mold Memry Mold Memory Selection 0-25 0000 Supervisor
35 Cor In Inj Core in with injection time On/Off Off Supervisor
36 Cor In1 I/L Core 1 In Interlock On/Off On/Off Off Supervisor
37 Cor In2 I/L Core 2 In Interlock On/Off On/Off Off Supervisor
38 EjBk @Mcls Ejector Backward with Mold Close On/Off Off Supervisor
39 Fast Appro Fast Approach On/Off On Supervisor
40 Ej.Plate Ejector Plate back interlock On/Off On/Off Off Supervisor
41 MopnIL WEj Mold Open Interlock for Ejector Function On/Off On Supervisor
42 Ejct Boost Ejector Boost Option 0000-0003 0000 Supervisor
43 Cor1 Boost Core 1 Boost Option 0000-0003 0000 Supervisor
44 Cor2 Boost Core 2 Boost Option 0000-0003 0000 Supervisor
45 MOpn Boost Mold Open Boost Option 0000-0002 0000 Supervisor
46 Zon 8: Oil Temperature zone 8 select as oil temperature On/Off On Supervisor
47 Oil Temp. Set oil temperature 0000-0060 0060 Supervisor

STANDARD EJECTOR PROGRAM :

1. Program 00: Ejector disable.

2. Program 01: Ejector Forward only after mould gets fully open.
3. Program 02: Ejector Forward/Hold/Backward
i.e. Full Shot after mould gets fully open.
No of shots is programmable.

Set Timer
Press set TIMER key.
Third line of LCD show function’s name and it’s set value.
Select require function using NEXT/ PREV key.
Set require time using INC, DEC and SHIFT key.
On pressing NEXT key the set value will be saved and display will show the next function.
List of timer parameters are given below.
Default
No. Message Description Range Level
Value
1 Mold Close Mold slow close time 0-999.9 Sec 001.0 User
2 Mold Safty Mold safety time 0-999.9 Sec 002.0 User
3 Carr.Forwd Carriage Forward time 0-999.9 Sec 003.0 User
4 Pre-Inject Pre Injection time 0-999.9 Sec 001.0 User
5 Flow Inj Flow Injection time 0-999.9 Sec 001.0 User
6 Injct Dely Injection delay 0-999.9 Sec 001.0 User
7 Inject 1 Injection 1 time 0-999.9 Sec 001.0 User
8 Inject 2 Injection 2 time 0-999.9 Sec 001.0 User
9 Inject 3 Injection 3 time 0-999.9 Sec 001.0 User
10 Inject 4 Injection 4 time 0-999.9 Sec 001.0 User
11 Inject Hld Injection Hold time 0-999.9 Sec 001.0 User
12 Sukbk1 Dly Suck back 1 Delay 0-999.9 Sec 001.0 User
13 Sukbk1 Tim Suck back 1 Time 0-999.9 Sec 001.0 User
14 CarrBk Dly Carriage backward delay 0-999.9 Sec 003.0 User
15 Intens Dly Intensifier delay 0-999.9 Sec 001.0 User
16 Intens Tim Intensifier time 0-999.9 Sec 001.0 User
17 Air Cavity Air Cavity time 0-999.9 Sec 001.0 User
18 Refil Dely Refill delay 0-999.9 Sec 001.0 User
19 Refil Time Refill time 0-999.9 Sec 001.0 User

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20 Sukbk2 Dly Suck back 2 Delay 0-999.9 Sec 001.0 User

21 Sukbk Time Suck back time 0-999.9 Sec 001.0 User
22 Cool Time Cool time 0-999.9 Sec 005.0 User
23 Carr.Bakwd Carriage backward time 0-999.9 Sec 001.0 User
24 Mold Open Mold open slow time 0-999.9 Sec 001.0 User
25 Ejct Dely Ejector delay 0-999.9 Sec 000.5 User
26 Ejct Forwd Ejector Forward time 0-999.9 Sec 002.0 User
27 Ejct Hold Ejector Hold time 0-999.9 Sec 000.5 user
28 Ejct Bakwd Ejector Backward time 0-999.9 Sec 002.0 User
29 Air Punch Air Punch time 0-999.9 Sec 001.0 User
30 Cycle Dely Cycle delay 0-999.9 Sec 005.0 User
31 Cycle Time Cycle time 0-999.9 Sec 999.9 Supervisor
32 Core 1 In Core 1 In time 0-999.9 Sec 001.0 User
33 Core 1 Out Core 1 Out time 0-999.9 Sec 001.0 User
34 Core 2 In Core 2 In time 0-999.9 Sec 001.0 User
35 Core 2 Out Core 2 Out time 0-999.9 Sec 001.0 User
36 Lub. On Lubrication On time 0-999.9 Sec 001.0 User
37 Lub. Delay Lubrication delay 0-999.9 Min 001.0 User
38 To Heat On To Heat On delay 0-999.9 Sec 010.0 Supervisor
39 Prop On Dly Delay between direction valve & prop. On time 0-999.9 Sec 000.1 Supervisor
40 Unscr Dely Unscrew Delay Time 0-999.9 Sec User
001.0
41 Unscr Time Unscrew Time 0-999.9 Sec 001.0 User
42 Tot Inj Tim Total Injection time 0-999.9 Sec 001.0 User
43 Cor1 P Dly Core 1 partial out delay 0-999.9 Sec 001.0 User
44 Cor1 P Tim Core 1 partial out time 0-999.9 Sec 001.0 User
45 Cor2 P Dly Core 2 partial out delay 0-999.9 Sec 001.0 User
46 Cor2 P Tim Core 2 partial out time 0-999.9 Sec 001.0 User
47 AirCav Dly Air Cavity 1 delay 0-999.9 Sec 001.0 User
48 AirCav2 Dl Air Cavity 2 delay 0-999.9 Sec 001.0 User
49 AirCav2 Tm Air Cavity 2 time 0-999.9 Sec 001.0 User
50 InjBost Dl Injection Boost delay time 0-999.9 Sec 001.0 User
51 InjBost Tm Injection Boost On time 0-999.9 Sec 001.0 User

Set Pressure
Press set Pressure key.
Third line of LCD show function’s name and it’s set Pressure.
Select require function using NEXT/ PREV key.
Set require pressure using INC, DEC and SHIFT key.
On pressing NEXT key the set value will be saved and display will show the next function.
List of pressure parameters are given below.
Default
No. Message Description Range Level
Value
1 Mclos Slow Mold close slow (Open side) 0-100 bar 50bar User
2 Mclos Fast Mold close fast 0-100 bar 70bar User
3 Mclos Slo2 Mold close slow 2 (Close side) 0-100 bar 50bar User
4 Mold Safty Mold safety 0-100 bar 10bar Supervisor
5 Lokin Ton1 Locking Tonnage 1 0-100 bar 90bar User
6 Lokin Ton2 Locking Tonnage 2 0-100 bar 100bar User
7 Carr.Forwd Carriage Forward 0-100 bar 30bar User
8 Carr.Bakwd Carriage Backward 0-100 bar 30bar User
9 Pre-Inject Pre Injection 0-100 bar 30bar User

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10 Inject 1 Injection 1 0-100 bar 30bar User

11 Inject 2 Injection 2 0-100 bar 30bar User
12 Inject 3 Injection 3 0-100 bar 30bar User
13 Inject 4 Injection 4 0-100 bar 30bar User
14 Inject Hld Injection Hold On 0-100 bar 50bar User
15 Intensifier Intensifier Charging 0-100 bar 30bar User
16 Suck back 1 Suck back 1 0-100 bar 30bar User
17 Refilling Refilling 0-100 bar 70bar User
18 Suck back 2 Suck back 2 0-100 bar 30bar User
19 Decompres Decompression 0-100 bar 80bar User
20 Mopen Slow Mold open slow (Close side) 0-100 bar 50bar User
21 Mopen Fast Mold open fast 0-100 bar 70bar User
22 Mopen End Mold open end (Open side) 0-100 bar 30bar User
23 Ejct Forwd Ejector Forward 0-100 bar 30bar User
24 Ejct Bakwd Ejector Backward 0-100 bar 30bar User
25 Core In Core In 1 0-100 bar 30bar User
26 Core Out Core Out 1 0-100 bar 30bar User
27 Core 2 In Core In 2 0-100 bar 30bar User
28 Core 2 Out Core Out 2 0-100 bar 30bar User
29 M.Height+ Mold Height + 0-100 bar 30bar User
30 M.Height- Mold Height - 0-100 bar 30bar User
31 Purg Inj Purge Injection 0-100 bar 40bar User
32 Purg Refil Purge Refill 0-100 bar 40bar User
33 Die M.Clos Die set Mold close 0-100 bar 30bar User
34 Die M.Open Die set Mold open 0-100 bar 30bar User
35 Unscrew Unscrew 0-100 bar 30bar User
36 Cor1 P.Out Core 1 partial out 0-100 bar 10bar User
37 Cor2 P.Out Core 2 partial out 0-100 bar 10bar User

Set Flow
Press set Flow key.
Third line of LCD show function’s name and it’s set Flow.
Select require function using NEXT/ PREV key.
Set require flow using INC, DEC and SHIFT key.
On pressing NEXT key the set value will be saved and display will show the next function.
List of flow parameters are given below.
Default
No. Message Description Range Level
Value
1 Mclos Slow Mold close slow (Open side) 0-100 % 50% User
2 Mclos Fast Mold close fast 0-100 % 70% User
3 Mclos Slo2 Mold close slow 2 (Close side) 0-100 % 50% User
4 Mold Safty Mold safety 0-100 % 10% Supervisor
5 Lokin Ton1 Locking Tonnage 1 0-100 % 90% User
6 Lokin Ton2 Locking Tonnage 2 0-100 % 100% User
7 Carr.Forwd Carriage Forward 0-100 % 30% User
8 Carr.Bakwd Carriage Backward 0-100 % 30% User
9 Pre-Inject Pre Injection 0-100 % 30% User
10 Inject 1 Injection 1 0-100 % 30% User
11 Inject 2 Injection 2 0-100 % 30% User
12 Inject 3 Injection 3 0-100 % 30% User
13 Inject 4 Injection 4 0-100 % 30% User
14 Inject Hld Injection Hold On 0-100 % 50% User

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 STREAMLINE CONTROLS PVT. LTD
INJkon 00/1.0/ Manual

15 Intensifir Intensifier Charging 0-100 % 30% User

16 Suckback 1 Suck back 1 0-100 % 30% User
17 Refiling Refilling 0-100 % 70% User
18 Suckback 2 Suck back 2 0-100 % 30% User
19 Decompres Decompression 0-100 % 80% User
20 Mopen Slow Mold open slow (Close side) 0-100 % 50% User
21 Mopen Fast Mold open fast 0-100 % 70% User
22 Mopen End Mold open end (Open side) 0-100 % 30% User
23 Ejct Forwd Ejector Forward 0-100 % 30% User
24 Ejct Bakwd Ejector Backward 0-100 % 30% User
25 Core In Core In 1 0-100 % 30% User
26 Core Out Core Out 1 0-100 % 30% User
27 Core 2 In Core In 2 0-100 % 30% User
28 Core 2 Out Core Out 2 0-100 % 30% User
29 M.Height+ Mold Height + 0-100 % 30% User
30 M.Height- Mold Height - 0-100 % 30% User
31 Purg Inj Purge Injection 0-100 % 40% User
32 Purg Refil Purge Refill 0-100 % 40% User
33 Die M.Clos Die set Mold close 0-100 % 30% User
34 Die M.Open Die set Mold open 0-100 % 30% User
35 Unscrew Unscrew 0-100 % 30% User
36 Cor1 P.Out Core 1 partial out 0-100 % 10% User
37 Cor2 P.Out Core 2 partial out 0-100 % 10% User

(J) DESCRIPTION OF TEST MODES

1. INPUT TEST MODE:
This mode is useful for testing of each input. (Limit switch Or proximity switch or push button)
This mode is enabled when Test In/out in set misc. menu is made on.
First two line of LCD display shows the input, which is being tested.
When Input is sensed LCD display shows its particular count on LCD.
For Ex: When we apply first input on input card LCD display will show 0(Zero). i.e. every input has
it’s own count. Please refer list of inputs & outputs for more information. Every input is
provided with particular count.
Changes in the input status as per sensing of input indicates that the wiring and electronic path of
that input is functioning correctly.
During this mode no other cycle function can operate.
To disable the test mode made off the test In/Out in set misc menu.
(2) OUTPUT TEST MODE:
This mode is useful for testing each output of the system.
This mode is enabled when Test In/Out in set misc. menu is on.
Third line of LCD shows output being checked. When any output is activated, its particular count
is shown on LCD. Please refer list of inputs & outputs for more information. Every output is
provided with particular count.
The output can be made ON or OFF using SHIFT key.
The O/P under test can be changed using INC/DEC key.
If the O/P goes ON and OFF as per the status show on the display, we can say that the wiring &
electronic path of the system for that O/P is correct.
During this mode all other functions are disabled.
To disable the test mode made off the test In/Out in set misc menu.

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 STREAMLINE CONTROLS PVT. LTD
INJkon 00/1.0/ Manual

(3) TEMPERATURE TEST MODE

This mode is useful for testing individual temp loop

This mode can be enabled by making Test Temp. in set misc. menu ON.

During this mode only one channel is displayed.

The zone under testing can be changed using INC or DEC key.

To disable the test TEMP. mode made off the Test TEMP. in set misc menu.

During this test mode all other functions are disabled.

(K) FUNCTIONAL DESCRIPTIONS

(1) MOULD SAFETY:
This feature is enabled when Mould Safety in set misc. menu is switched ON
At the time of mould closing if the delay between mold safety start switch & mold safety end
switch is more then the set value of mould safety timer the cycle brakes here mould gets
opened and machine comes into hand mode.
(2) Heat off function:
Heating off function can be enabled or disabled using HEAT OFF‚ key. When heating off is
active HOFF indicate in second line of display. And all output of heater goes OFF. When
heating is ON PV indicate in second line of display. And all heater outputs operate as per
control action of temp. Controller.
(4) HAND:
System (after power on) starts in HAND MODE. In this mode all the functions (like mould
open, mould close, unit forward etc) can be done using different function keys.
For ex. : Mould can be opened using mould open key. When any interlock appears during
cycle the machine transferred in to hand mode.
(5) SEMI AUTO:
On pressing SEMI AUTO key cycle starts.
Cycle stops after completion of one cycle. Here cycle can be restarted by opening and closing
of front guard.

(6) AUTO:
On pressing AUTO key the auto cycle starts.
Here after completion of one cycle, cycle delay timer starts after completion of cycle delay
cycle restarts.

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 STREAMLINE CONTROLS PVT. LTD
INJkon 00/1.0/ Manual

(L) 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.

Interlocks Messages Type Of Mode

Sr.No. Operation Description Of Messages
On Screen
Hand Semi Auto Fully Auto
IL Mold Open End Mold fully open end y y
1 Mold Open
IL Mold Open/Clos On Mold open close limits on y y y
IL Mold Close End Mold fully Close end y y
2 Mold Close IL Mold Safty Tm Ovr Mold Safety time over y y y
IL Mold Open/Clos On Mold open close limits on y y y
3 Unit Forward IL Carriage For End Carriage Forward End y y y
4 Unit Backward IL Carriage Back End Carriage Backward End y y y
IL Temperature Low Temperature is low y y y
5
Injection IL Temperature High Temperature is High y y y
IL Refill End Refill End y y y
IL Temperature Low Temperature is low y y y
6
IL Temperature High Temperature is High y y y
Refill IL RPM too Low. Screw RPM is low y y y
IL Temperature Low Temperature is low y y y
7 Suck Back IL Temperature High Temperature is High y y y
IL Suckback End Suck back End y y y
8 Ejector Forward IL Eje Forward End Ejector Forward end y y y
IL Eje Backward End Ejector Backward end y y y
9 Ejector Backward
IL Ejector Not Back Ejector not back y y y
10 Core 1 In IL Core 1 In End Core 1 in End y y y
IL Core 1 Out End Core 1 out End y y y
11
Core 1 Out IL Core 1 not Out Core 1 not out y y y
12 Core 2 In IL Core 2 In End Core 2 in End y y y
IL Core 2 Out End Core 2 out End y y y
13
Core 2 Out IL Core 2 not Out Core 2 not out y y y
IL Mold Hght Min End Mold Height minimum End y y y
14 Mold Height Min.
IL Mold Height Min. Mold Height minimum y y y
IL Mold Hght Max End Mold Height maximum End y y y
15 Mold Height Max.
IL Mold Height Max. Mold Height maximum y y y
IL Slid In End Slide in End y y y
16 Slide IL Slid Out End Slide out End y y y
IL Slid Not In Posi Slide not in position y y y
IL Temperature Low Temperature is low y y y
17 IL Temperature High Temperature is High y y y
Temperature IL Oil Temp. High Oil temperature is high y y y
IL Front Guard Open Front door open y y y
IL Back Guard Open Rear door open y y y
18 Common IL Cycle Time Over Cycle time over y y y
IL Emergency Press Emergency press y y y
IL Motr not on Delta Hydraulic motor not on Delta y y y
19 Die Set IL DieSet Mode On Die set mode is on y y

Page 20 of 27
 STREAMLINE CONTROLS PVT. LTD
INJkon 00/1.0/ Manual

Wiring Diagram

24VDC Power Supply

(ML 533A)

0V 24V
24V AC
INPUT

Page 21 of 27
 DIGITAL DIGITAL DIGITAL DIGITAL DIGITAL DIGITAL DIGITAL DIGITAL
INPUT INPUT INPUT INPUT INPUT INPUT INPUT INPUT
CARDN0. CARDN0. CARDN0. CARDN0. CARDN0. CARDN0. CARDN0. CARDN0.

L9 L9 L9 L9 L9 L9 L9 L9

L10 L10 L10 L10 L10 L10 L10 L10

LS 1
LS 3
LS 5
LS 7
LS 33
LS 35
LS 37
LS 39

LS 25
LS 27
LS 29
LS 30
LS 57
LS 59
LS 61
LS 63

LS 9
LS 11
LS 13
LS 15
LS 17
LS 19
LS 21
LS 23
LS 41
LS 43
LS 45
LS 47
LS 49
LS 51
LS 53
LS 55

IN 1IN 3IN 5IN 7 +24V IN 1IN 3IN 5IN 7 +24V IN 1IN 3IN 5IN 7 +24V IN 1IN 3IN 5IN 7 +24V IN 1IN 3IN 5IN 7 +24V IN 1IN 3IN 5IN 7 +24V IN 1IN 3IN 5IN 7 +24V IN 1IN 3IN 5IN 7 +24V

PNP/NPN
PNP/NPN
PNP/NPN
PNP/NPN
PNP/NPN
PNP/NPN
PNP/NPN
PNP/NPN

IN 2IN 4IN 6IN 8 GND IN 2IN 4IN 6IN 8 GND IN 2IN 4IN 6IN 8 GND IN 2IN 4IN 6IN 8 GND IN 2IN 4IN 6IN 8 GND IN 2IN 4IN 6IN 8 GND IN 2IN 4IN 6IN 8 GND IN 2IN 4IN 6IN 8 GND

LS 2
LS 4
LS 6
LS 8
LS 34
LS 36
LS 38
LS 40

LS 10
LS 12
LS 14
LS 16
LS 18
LS 20
LS 22
LS 24
LS 26
LS 28
LS 30
LS 32
LS 42
LS 44
LS 46
LS 48
LS 50
LS 52
LS 54
LS 56
LS 58
LS 60
LS 62
LS 64

Page 22 of 27
INJkon 00/1.0/ Manual
STREAMLINE CONTROLS PVT. LTD
 DIGITAL DIGITAL DIGITAL DIGITAL DIGITAL DIGITAL DIGITAL DIGITAL
INPUT INPUT INPUT INPUT INPUT INPUT INPUT INPUT
CARDN0. CARDN0. CARDN0. CARDN0. CARDN0. CARDN0. CARDN0. CARDN0.

L9 L9 L9 L9 L9 L9 L9 L9

L10 L10 L10 L10 L10 L10 L10 L10

LS 1
LS 3
LS 5
LS 7
LS 33
LS 35
LS 37
LS 39

LS 25
LS 27
LS 29
LS 30
LS 57
LS 59
LS 61
LS 63

LS 9
LS 11
LS 13
LS 15
LS 41
LS 43
LS 45
LS 47

LS 17
LS 19
LS 21
LS 23
LS 49
LS 51
LS 53
LS 55

IN 1IN 3IN 5IN 7 +24V IN 1IN 3IN 5IN 7 +24V IN 1IN 3IN 5IN 7 +24V IN 1IN 3IN 5IN 7 +24V IN 1IN 3IN 5IN 7 +24V IN 1IN 3IN 5IN 7 +24V IN 1IN 3IN 5IN 7 +24V IN 1IN 3IN 5IN 7 +24V

PNP/NPN
PNP/NPN
PNP/NPN
PNP/NPN
PNP/NPN
PNP/NPN
PNP/NPN
PNP/NPN

IN 2IN 4IN 6IN 8 GND IN 2IN 4IN 6IN 8 GND IN 2IN 4IN 6IN 8 GND IN 2IN 4IN 6IN 8 GND IN 2IN 4IN 6IN 8 GND IN 2IN 4IN 6IN 8 GND IN 2IN 4IN 6IN 8 GND IN 2IN 4IN 6IN 8 GND

LS 2
LS 4
LS 6
LS 8
LS 34
LS 36
LS 38
LS 40

LS 10
LS 12
LS 14
LS 16
LS 26
LS 28
LS 30
LS 32
LS 42
LS 44
LS 46
LS 48
LS 58
LS 60
LS 62
LS 64

LS 18
LS 20
LS 22
LS 24
LS 50
LS 52
LS 54
LS 56

Page 23 of 27
INJkon 00/1.0/ Manual
STREAMLINE CONTROLS PVT. LTD
 P-OUT P-OUT P-OUT P-OUT P-OUT P-OUT P-OUT P-OUT
AN ALOG A NA LOG AN A LOG A NALOG A NA LOG AN A LOG A N ALOG A NA LOG
AC INPUT OUTPUT OU T AC INPUT OUTPUT OU T AC INPUT OUTPUT O UT AC INPUT OUTPUT OU T AC INPUT OUTPUT OU T AC INPUT OUTPUT O UT AC INPUT OUTPUT OU T AC INPUT OUTPUT OUT

AC IN AC IN COIL C OIL A-OUT AC IN A C IN COIL COIL A-OUT AC IN AC IN COIL C OIL A-OUT A C IN A C IN C OIL COIL A-OUT AC IN A C IN COIL COIL A-OUT A C IN AC IN C OIL C OIL A-OUT A C IN A C IN C OIL COIL A-OUT AC IN A C IN COIL COIL A-OUT

A C IN
A C IN
A C IN
A C IN
A C IN
A C IN
A C IN
A C IN

A A A A A A A A

Maximum 35VAC/DC COIL 10VDC/50mA Maximum 35VAC/DC COIL 10VDC/50mA Maximum 35VAC/DC COIL 10VDC/50mA Maximum 35VAC/DC COIL 10VDC/50mA Maximum 35VAC/DC COIL 10VDC/50mA Maximum 35VAC/DC 10VDC/50mA Maximum 35VAC/DC COIL 10VDC/50mA Maximum 35VAC/DC COIL 10VDC/50mA
COIL
Input From Transformer Analog Output Input From Transformer Analog Output Input From Transformer Analog Output Input From Transformer Analog Output Input From Transformer Analog Output Input From Transformer Analog Output Input From Transformer Analog Output Input From Transformer Analog Output
or SMPS Maximum or SMPS Maximum or SMPS Maximum or SMPS Maximum or SMPS Maximum or SMPS Maximum or SMPS Maximum or SMPS Maximum

Page 24 of 27
INJkon 00/1.0/ Manual
STREAMLINE CONTROLS PVT. LTD
 Page 25 of 27
OUTPUT-1
OUTPUT-2
OUTPUT-3
OUTPUT-4
CARDN0.

OUTPUT-5
OUTPUT-6
OUTPUT-7
OUTPUT-8
LIVE
NEUTRAL
SSR (230VAC)OUTPUT MODULE

0-230VAC IN
From Transformer

OUTPUT-1
OUTPUT-2
OUTPUT-3
OUTPUT-4
CARDN0.

OUTPUT-5
OUTPUT-6
OUTPUT-7
OUTPUT-8
LIVE
NEUTRAL
SSR (230VAC)OUTPUT MODULE

0-230VAC IN
From Transformer

OUTPUT-1
OUTPUT-2
OUTPUT-3
OUTPUT-4
CARDN0.

OUTPUT-5
OUTPUT-6
OUTPUT-7
OUTPUT-8
LIVE
NEUTRAL
SSR (230VAC)OUTPUT MODULE

0-230VAC IN
From Transformer

OUTPUT-1
OUTPUT-2
OUTPUT-3
OUTPUT-4
CARDN0.

OUTPUT-5
OUTPUT-6
OUTPUT-7
OUTPUT-8
LIVE
NEUTRAL
SSR (230VAC)OUTPUT MODULE

0-230VAC IN
From Transformer

OUTPUT-1
OUTPUT-2
OUTPUT-3
OUTPUT-4
CARDN0.

OUTPUT-5
OUTPUT-6
OUTPUT-7
OUTPUT-8
LIVE
NEUTRAL
SSR (230VAC)OUTPUT MODULE

0-230VAC IN
From Transformer

OUTPUT-1
OUTPUT-2
OUTPUT-3
OUTPUT-4
CARDN0.

OUTPUT-5
OUTPUT-6
OUTPUT-7
OUTPUT-8
LIVE
NEUTRAL
SSR (230VAC)OUTPUT MODULE

0-230VAC IN
From Transformer
OUTPUT-1
OUTPUT-2
OUTPUT-3
OUTPUT-4
CARDN0.

OUTPUT-5
OUTPUT-6
OUTPUT-7
OUTPUT-8
LIVE
NEUTRAL
SSR (230VAC)OUTPUT MODULE

0-230VAC IN
From Transformer
OUTPUT-1
OUTPUT-2
OUTPUT-3
OUTPUT-4
CARDN0.
OUTPUT-5
OUTPUT-6
OUTPUT-7
OUTPUT-8
LIVE
NEUTRAL

SSR (230VAC)OUTPUT MODULE

0-230VAC IN
From Transformer
INJkon 00/1.0/ Manual
STREAMLINE CONTROLS PVT. LTD
 Junction Card(ML-538A)

From MMI

To Analog Input
Module
To Input Module

Page 26 of 27
INJkon 00/1.0/ Manual
STREAMLINE CONTROLS PVT. LTD
 STREAMLINE CONTROLS PVT. LTD
INJkon 00/1.0/ Manual

O
OUUR
RPPR
ROOD
DUUC
CTTR
RAAN
NGGE
E

• 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.

Page 27 of 27