UIPET-03

STRETCH BLOW
MOULDING
MACHINE
CONTROLLER

ULTRA INSTRUMENTS
142-B, NAHAR & SETH IND. ESTATE, PANNALAL COMP.
L.B.S MARG,BHANDUP (W),MUMBAI 400
PHONE : 022 25965535/ 67974356
EMAIL : ultra_utpalshah@rediffmail.com
 HELPLINE: +91 9594993870/1/2/3/4/5/6
The UIPET-03 microprocessor based controller is capable of controlling stretch blow moulding
machines. The UIPET-03 performs the following functions :
1) Infrared lamps power control
2) Sequence control
3) Production counting
4) Displaying set power, timing and piece counters.

The UIPET-03 consists of the following modules:

MICROPROCESSOR
This module controls the entire system, stores the user settings, displays the desired parameters,
responds to a keyboard activation, performs the timing, counting and logic functions and activates
the outputs based on the status of inputs.
DC INPUTS
This module is connected to external pushbuttons, selector switches, proximity switches, limit
switches and other ON/OFF type of sensors. This module informs the microprocessor of the status of
all switches connected to this module. The UIPET-03 supports upto 16 DC INPUTS.
RELAY OUTPUTS
This module is connected to the solenoid valves in the system. There are 8 relays which are capable
of driving loads of 2 Amps at 24VDC/230VAC.
TRIAC OUTPUTS
This module is connected to the infrared lamps in the machine. There are 7 triac outputs which are
capable of driving loads of 10Amp at 230VAC. The triac outputs are used in conjunction with
external triacs, which are supplied separately.
KEYBOARD AND DISPLAY
The UIPET-03 has a front panel keypad and display. This enables the user to view and set the various
parameters of the machine sequence. The user can continuously monitor the power setting of each
zone, view the active timer, and check the status of all outputs, while the machine cycle is on. In
addition the outputs can be activated from the keypad, in the manual mode. The user can check the
status of the inputs from the front panel.
The list of inputs and outputs and their numbers as supported by the UIPET-03 are shown below.

DC INPUTS

00 START PUSH BUTTON (LEFT)

01 START PUSH BUTTON (RIGHT)
02 EMERGENCY STOP
03 KEY LOCK
04 NOT USED
05 MOULD CLOSE LIMIT SWITCH(IF ACTIVATED)
06 MOULD OPEN LIMIT SWITCH (IF ACTIVATED)
07 NOT TO BE USED

DC OUTPUTS

00 MOULD CLOSE
01 MOULD OPEN
02 BLOW PIN DOWN

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03 STRETCH IN SOLENOID
04 BLOW (LOW PRESSURE)
05 MOULD LOCK SOLENOID
06 BLOW (HIGH PRESSURE) SOLENOID
07 MOULD SLOW
08 AIR RECOVERY
09 EXHAUST
10 NOT USED
11 NOT USED
12 NOT USED
13 NOT USED
14 NOT USED
15 NOT USED

TRIAC OUTPUTS

00 ZONE 1 ZONE 1 INFRARED LAMP

01 ZONE 2 ZONE 2 INFRARED LAMP
02 ZONE 3 ZONE 3 INFRARED LAMP
03 ZONE 4 ZONE 4 INFRARED LAMP
04 ZONE 5 ZONE 5 INFRARED LAMP
05 ZONE 6 ZONE 6 INFRARED LAMP
06 ZONE 7 ZONE 7 INFRARED LAMP

FRONT PANEL SETTINGS

SELECTING THE MOULD (DIE)

The user has an option of setting parameters for thirty different moulds. These parameters can then
be recalled by selecting the corresponding JOB. In order to change the current job setting :
Press the JOB key.
The display will show Jb <job number>. If the current job number is 1, the unit will display Jb01
Press the UP or DOWN arrow key to set the desired job number and press ENTER to confirm the
selection.
The parameters programmed earlier for that job will now be used.
SETTING THE POWER
The UIPET-03 is capable of controlling the power supplied to seven infrared lamps. This is done by
phase angle firing, wherein, a portion of the 230VAC sine wave is applied to the lamp, and the
remaining portion is blocked. The user can set the power delivered to the lamp in percentage of full
power.
Note : All the lamps have to be connected to the same phase.
In order to set the power of each zone, follow the steps outlined below:
Press the SET POWER key.
The Display will display the current power set for zone1
Press the ENTER key to change this parameter. The cursor blinks at the most significant digit.
Press the UP or DOWN key to set the blinking digit to the desired value.

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Press the RIGHT arrow key.
The cursor stops blinking at the first digit and the digit to it’s right starts blinking. Use the UP or
DOWN keys, to set this digit.
Similarly all four digits for this zone are set to their desired values. On completion of this setting,
press the ENTER key.the cursor will disappear.
Press the DOWN key.
The Display will display the current set point for zone 2. . Use the procedure listed above, to set the
desired temperature for this zone.
Similarly, by pressing, the DOWN key, (when all four digits are blinking), one can set the zone3,
zone4,zone5,zone6 and zone7 parameters also.
In order to exit the power setting mode, press the CANCEL key. The Display, will now display, the
set power in each of the zones in the first line of the display.. The display continuously shows the set
power for the seven zones, one after the other..
TIMER SETTINGS
The following timers which are used in auto mode have to be set by the user.
1. MOULD SLOW
2. SEAL (LOW) delay.
3. SEAL (HIGH) delay.
4. BLOW delay.
5. BLOW (LOW PRESSURE) time.
6. BLOW (HIGH PRESSURE) time.
7. PIN UP delay.
8. STRETCH OUT delay.
9. CYCLE time.

These timers are set in multiples of 0.01 seconds, and have a maximum value of 99.99 seconds. In
order to set the timers, follow the procedure described below.
Press the SET TIMER key to initiate programming of the various timers.
The current value of mould slow delay will be displayed in the timer window.
Press the ENTER key to change this parameter. The cursor blinks at the most significant digit.
Press the UP or DOWN key to set the blinking digit to the desired value.
Press the RIGHT arrow key.
The first digit stops blinking and the digit to it’s right starts blinking. Use the UP or DOWN keys, to
set this digit.
Similarly all four digits for this timer are set to their desired values. On completion of this setting,
press the ENTER key.The cursor disappears.
Press the DOWN key.
Follow the steps outlined above to set the seal (low) timing to the desired value.
In order to exit the timer setting mode, press the CANCEL key .The timer window will display the
current value of the timer which has started timing .The timer/counter window will display the cycle
time.

COUNTER SETTINGS

The PLC counts the number of moulding cycles that have taken place. The various counters and their
functions are described below.

TOTAL NUMBER OF CYCLES in TOTAL 1 and TOTAL 0.

TOTAL CYCLES = ( TOTAL1 x 10000 ) + TOTAL0.
This counter increments by 1 for every cycle. The total count is an 8 digit value, distributed
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 between TOTAL1 and TOTAL0. When the total cycle count reaches 99999999, the counter will
overflow to 00000000
/HOUR2
This counter display the number of moulding cycles that have taken place in the present hour. The
hour timer starts, when the machine is switched on. When the unit is switched off, the time elapsed in
the current hour is stored in memory. When the machine is switched on again, the hour timer starts
timing from the stored value.
/HOUR4
This counter displays the number of moulding cycles that have taken place in the hour previous to
the current hour.
/HOUR6
This counter displays the number of moulding cycles that have taken place, in the hour, two hours
prior to the current hour.
/HOUR8
This counter displays the number of moulding cycles that have taken place, in the hour, three
hours prior to the current hour.
And so on we can go upto /Hour13.After hour13 the next counter displays the time elapsed in the
present hour in seconds.
Each of these counters can be initialized, using the PIECE COUNTER key. This is described below.
Press the PIECE COUNTER key to modify the current value of any of the counters.
The current value of TOTAL1 will be displayed in the counter window, with all the four digits
blinking. The LED beside TOTAL1 will also be lit.
Press the ENTER key to change this parameter. The most significant digit blinks.
Press the UP or DOWN key to set the blinking digit to the desired value.
Press the RIGHT arrow key.
The first digit stops blinking and the digit to it’s right starts blinking. Use the UP or DOWN keys, to
set this digit.
S imilarly all four digits for this counter are set to their desired values. On completion of this setting,
press the ENTER key. All four digits will blink again.
Press the DOWN key.
The LED beside TOTAL1 will be off and the LED beside TOTAL0 will be lit.
Follow the steps outlined above to set the TOTAL0 counter to the desired value.
In order to exit the counter setting mode, press the CANCEL key. The counter window will display
the current value of the cycle timer.
KEY LOCK
When the KEY LOCK input to the unit is on, the user can view the various settings, but the user
cannot change any of the parameters. The KEY LOCK input must be off, to enable the user to change
the settings.

MANUAL MODE
The manual mode of operation, is selected by the auto/manual selector switch, provided on the
machine. In the manual mode of operation, the user can switch the various solenoids on or off from
the front panel, by pressing the corresponding keys. The manual functions incorporated are :
1. MOULD CLOSE.
2. MOULD LOCK
3. MOULD OPEN
4. SEAL (LOW)
5. SEAL (HIGH).
6. STRETCH IN.
7. BLOW (LOW PRESSURE).
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8. BLOW (HIGH PRESSURE).
In order to actuate a particular solenoid, the corresponding key, should be pressed. The LED in the
key will be switched on, and the solenoid will be switched on. The solenoid will remain on, as long
as the corresponding key is pressed.

TROUBLESHOOTING
The controller allows the user to check the status of inputs, and to exercise the outputs.
CHECKING THE INPUTS
In order to check the inputs, follow the procedure outlined below.
Press the INPUT STATUS key
The DISPLAY shows the name of the first input,and whether it is on or off. The user can actuate the
corresponding pushbutton/limit switch and check if the unit displays the status of the button
correctly. If this is not the case, check if the wiring is done correctly. Also check if the voltage at the
input00 pin on the DC INPUT MODULE is between 20–24VDC (with respect to COM on the same
connector). Otherwise check the voltage of 24VDC with respect to COM. If it is not between 20-
24VDC, there could be a short between 24VDC and COM, or the INPUT unit has failed, and
requires to be repaired.
To check other inputs, press the UP arrow key.
The display shows the name of the next input and whether it is on or off, in top two windows. The
user can actuate the corresponding pushbutton/limit switch and check if the display displays the
status of the button correctly Thus the user can check all the 127inputs.
Press CANCEL to return to normal display.
CHECKING THE OUTPUTS
In order to check the outputs put the machine in manual mode and follow the procedure outlined
below.
Press the OUTPUTSTATUS key..
The display shows thename of the first output, and whether it is on or off. The user can switch the
output on by pressing the ENTER key once, and can switch the output off by pressing the ENTER
key again in manual mode.
Press the UP arrow key.
The display shows the name of the next output and whether it is on or off .The user can switch the
output on by pressing the ENTER key once, and can switch the output off by pressing the ENTER
key again.
Thus the user can check all 127outputs. Press CANCEL to return to normal display.