PU Rotary Machine

R75-S48

HMI
Ver 2.0
Jan. 19, 2019
Control software manual PU Rotary machine

This instruction shows how to use the software program of PU rotary machine
If you have any problems with using, please contact the nearest branch of Korea Automation Co., Ltd.
The red color block on the picture is useful only for explanation regardless of software’s function.

1. Start program

Fig. 1-1

- Turn on PC and run the program(click ‘Polaris.exe’ file), then the screen displays as Fig.1-1.
- It takes 25~30 seconds to transfer DATA between PC and PLC when the program start running. The
program shows a message of ‘Data transfer’ and turns on the loading bar. (see no.② on Fig. 1-1)
- The message and the loading bar disappear after program loading. From that time, all function of
program can be used normally.
- No.①’ALARM’ on Fig.1-1 shows an abnormal condition of machine. If any trouble in machine, this lamp
is turns on. If normal, this lamp is turns off.
Regarding the ‘ALARM’ lamp’s function, please refer to chapter ?? ALARM DISPLAY in this instruction
book.

- The main screen of program consists of 3 parts as Fig.1-2(see no ①,②,③)

The contents from F1 to F8 under the screen are just an explanation on Keyboard setting in Program.

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Control software manual PU Rotary machine

2. Main screen (Fig. 2.1)

2.1 Display ①
This is a working data at present and will be changed as the rotary machine rotate one by one.
This is just displayed and cannot be input. For the details, please refer to the chapter 4.

Fig. 2.1

2.2 Display ②

2.2.1 Casting position

This shows a position of casting head, this is changed as the casting head moves.

2.2.2 Material pump RPM(Round Per Minutes, pump rotation speed)

This shows each material pump’s RPM.
L : Left, R : Right

2.3 Display ③

‘Working Display’ tab is shown firstly when the program start running, That is, it’s basic and initial
mode(F8).
The screen ③ is changed as Function key(F1~F8). Also, it is changed by click a tab with the mouse. A
function of each key is shown at bottom of screen. Each key match each tab as next.

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Control software manual PU Rotary machine

KEY TAB
F1 CORRECT Correct Cycle
F2 TIMES Times
F3 PRODUCT Production sheet
F4 ALARM Alarm Display
F5 MATERIAL Material Info.
F6 MODEL Model Input
F7 RPM RPM
F8 Working Disp. Working Display

2.4 Finished data transfer

- When a data transfer between the computer and PLC is finished, the machine can be operated
normally. And the initial screen is as Fig.2.2.

Fig. 2.2

① TOTAL MOLD
That means the number of molds that is working at present. The machine can hold 48 sets of mold.

② MATERIAL SELECTION
Mold name turns red when POL1 material is used. Mold name turns blue when POL2 material is
used.

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Control software manual PU Rotary machine

③ MOLD CARRIER NUMBER

This shows the number of mold carriers from 1 to 48. The red square on the number is turns on to
note which mold carrier is working at present. This number is same as carrier number on the right
screen.

④, ⑤ Working condition
This is a name of mold that is on the mold carrier.
Working condition Color ④ Color ⑤
Auto Pouring Green
Auto Cleaning Light blue Light blue
Non working `Background
Auto Pre-casting Blue

⑥ Note for each function key.

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Control software manual PU Rotary machine

3. Program close

- The program can be terminated only under main screen. The message box appears as Fig. 3.1 when
‘ESC’ key or ‘X’ button on the top of screen is pushed. To close a program, enter a password.
- A password is fixed and cannot be changed. Supplier gives a password to user.
- If a password is not correct, the program will not be terminated.

Fig. 3.1

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Control software manual PU Rotary machine

4. Function mode (from F1 to F8)

Mode Function
F1 CORRECT Input and change data
F2 TIMES Set a subordinate working condition
F3 PRODUCT Production counting
F4 ALARM Alarm Display
F5 MATERIAL Note for Material information(ratio, brand)
F6 MODEL Input a working data of each mold
F7 RPM Material pump and Mixing motor’s speed
F8 Working Disp. Main display

4.1. F1 CORRECT

* If F1 key is pushed, the correct screen is displayed. See Fig. 4.1.

* The data on the ‘CORRECT’ screen is same as the current data on the left screen.
* If you want to work with new data, you must save the data.(About save, we will explain later.)
* If you want to turn back main screen, press F8 key. You can use only F8 key. If you use the mouse, you
can click only two ‘Working Display’ tab and ‘Correct Cycle’ tab.

Fig. 4.1

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Control software manual PU Rotary machine

* Input Carrier number in ①, press ‘Enter’ key. Then the full screen is activated like Fig. 4.2.

Fig. 4.2
* Detail is as below.

1) Carrier No. :
- It is carrier number at the current working station.
- If rotary conveyor rotates, this number will be changed.
- All data of ‘Correct Cycle’ in left screen will be changed as rotary conveyor rotates.

2) Mold Name
- It is the name of mold on the mold carrier. You can make a name as your rule.

3) Plan Pcs.
- The target quantity of product

4) Product Pcs.
- It displays a produced quantity.
- If a produced quantity is same as a plan quantity, the head return to the zero position, and then
do a pre-casting and the conveyor rotate for next working..

5) Shoot Method (1 or 2):

- You can select the moving direction of head when head pours PU material into the mold.

Selection “1” : Toe Position  Heel Position

Selection “2” : Heel Position  Toe Position

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Control software manual PU Rotary machine

6) Divide Shoot (1 or 2 or 3)
- You can select how many shoot into the mold.

Selection “1” : I time pouring in a mold

Selection “2” : 2 times pouring in a mold
Selection “3” : 3 times pouring in a mold

7) Total ThroughPut(Left/Right)
- That means total weight of poured PU material. You can set both left and right separately.

8) Start ThroughPut(Left/Right)
- That means start pouring weight at the starting position.
- If the start throughput is much than the total throughput, the material will be poured as much as
total throughput as starting position

9) Heel Position(front)
- It is the distance from zero position to heel position. ( x 0.1㎜)

10) Toe Position(rear)

- It is the distance from zero position to toe position. ( x 0.1㎜)

11) Standby Position (0 or 1)

- You can select whether you use a standby-function or not.

Selection “0” : no use ‘Standby’ function

Selection “1” : use ‘Standby’ function
** About ‘Standby’ function, we will explain later

12) Moving Speed (Input value 0 ~ 9)

- That means the speed of head driving unit.

“0,1,2” : for low speed

“3,4,5,6,7,8,9” : Head moving speed come to faster gradually according to the number by the equal
interval.
Value Speed(mm/sec)
0 50
1 100
2 150
3 1001
4 1168
5 1335
6 1502
7 1669
8 1836
9 2003

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Control software manual PU Rotary machine

13) Material Select (Input value 1,2)

- You can choose PU Polyol material.

Selection “1” : Polyol 1

Selection “2” : Polyol 2

14) Auto Cleaning (Input value 0,1)

- That means automatic head cleaning.
- If you set “1”, the machine clean the head automatically at set station during the working. Then
the machine rotates and starts working at station that you set “1” in Auto Pouring.
- In case of “0”, it’s no influence to working.

15) Auto Pouring (Input value 0, 1)

- If you want Auto Pouring again at the same station which was cleaned, you should input “1”

16) Auto Pre-casting (Input value 0, 1)

- If you input “1” during the auto working, that station mold will net be worked. The head returns to
zero position to do a dummy shoot, and then the machine rotates one step and start working
again.

▶ Input buttons in F1 CORRECT mode.

Please see Fig. 4.2

No. Button name Function
③ Mold list You can call a data you already input
④ Head positioning You can fix a head moving position easily.
⑤ Save It saves all data.

Fig. 4.3

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Control software manual PU Rotary machine

1) Mold List button

- If you click ③ ‘List’ button on Fig. 4.2, the mold data list you already saved before is open as
Fig. 4.3. One screen can show 100 molds information and a duplicated mold name cannot
be used. In case of that the mold information is over 100, you can use ‘Prev’ and ‘Next’
button.
- If you want to return to main page, click ‘Return to Main’.
- If you want to choose mold data in the list, click that mold name. Then working data will be
revised.

2) Head positioning
- When the cursor is on ‘Heel position’ and ‘Toe position’, the ‘Stop’ button is activated as Fig.
4.4.

Fig. 4.4

- Click ‘Stop’ button, then the name of button is changed from ‘stop’ to ‘Run’. At the same time,
the rest 3 buttons(Rev, fwd, Jog) are activated as Fig 4.5.

Fig. 4.5
- If you click ‘Run’ button again, the name of button is changed from ‘Run’ to ‘Stop’’
- You can read the position of head under ‘Run’ mode, but you cannot do under ‘Stop’ mode.

- Under ‘Run’ mode, you can move the head backward and forward with ‘Rev’ and ‘Fwd’
button. During you press ‘Fwd’,’Rev’ button, the head move forward and backward. If you
release those buttons, the head stop.
- Click ‘Jog’ button, to call the position of head in the current cursor position.

3) Save
- To save data, click ‘Save’ button.
- During the data is transferring to PLC, the message “Wait. Data Transfer Now!” is shown as
Fig. 4.6.

Fig. 4.6

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Control software manual PU Rotary machine

- If data transfer is successful, the message is shown as Fig. 4.7. Press ‘Enter’ key or Click
‘check’ button. Then the message will disappear.

Fig. 4.7

- If you forget to input data somewhere, the error message appear when you click ‘Save’ as Fig.
4.8. Click ‘Check’ to find an empty data

Fig. 4.8

※ If you want to change other carrier’s data continuously, click ‘Carrier No.’ button and input a carrier
no. you want to change. If you just change carrier no. without saving, the machine is operated by
the former data

4.2. F2 Times

Press F3 key or click tab of ‘Times’ in the top and right side to change the time data. The screen is
shown as Fig. 4.9.

[1] Work Delay Time

1) Manual Rotation
- When the rotary conveyor is rotated by manual mode, this can control the delay time of
conveyor.(x 0.01sec)
- If the value is 200, the conveyor will be rotated after waiting for 2 seconds.

2) Auto Rotation
- When the rotary conveyor is rotated by auto mode, this can control the pouring delay time of
next mold.(x 0.01sec)

3) Auto Blank Rotation

- When the rotary conveyor is rotated by auto mode but without pouring, this can control the
rotation delay time.(x 0.01sec)

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Control software manual PU Rotary machine

Fig 4.9
[2] Blank Shoot Time

1) Manual Shoot
- Material blank pouring time(x 0.01sec) under manual mode.
- This function is useful for calibration or PU material test.

2) Auto Start
- Material blank pouring time(x 0.01 sec) when the machine start a working under auto mode.
Usually, the pouring position is on the zero point.

3) Production End :
- Material blank pouring time(x 0.01sec) when it is exceeded the target production quantity
during the working. Usually, the pouring position is on the zero point.
※ It is used by ‘Auto Pre-casting’ mode and ‘Mold Pass’ mode.

[3] Shoot Limit Time

1) Max Shoot Time (x 0.01sec)

- This means the maximum limited time can pour material in a mold.
For example, if the time is 600, the head can pour material for 6 second maximum in a mold.
If the total pouring time is over 6 seconds, the machine gives warning.

2) Max Shoot Interval

- This means the limited time from the current pouring is finished to the next pouring is started.
If the time is over, the machine gives warning.
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Control software manual PU Rotary machine

[4] Auto Cleaning Time

1) Detergent
- The time(x 0.01sec) is that the detergent (BIO-190SF) gets out of the mixing head to clean it
under ‘Auto Cleaning’ mode.

2) Air
- The time(x 0.01sec) is that the air gets out of the mixing head to clean it under ‘Auto
Cleaning’ mode.

[5] Work Once Time Stop

▶ Usually, this function can be used when the PU material has long curing time. To keep curing
time, it is needed that the machine is stop for some time in a cycle.

1) Carrier No.
- Input the number of carrier will be stopped. At that time, the data of the carrier that will be
stopped should be by 1 of ‘Auto Cleaning’ and ‘Auto Pouring’. You can make two stop points in
a cycle.

2) Stop Time (sec) :

- Input the time for stop at the fixed position.

[6] Standby Position (x 0.1mm)

- This function is can be used when you want to change the position of mixing head’s standby
under auto working mode. For example, if you set 1000, the mixing head backwards and standby
at 100mm distance away from zero position. But the Standby position should be selected by ‘1’.

[7] Throughput (L/R)

- Input the throughput weight(x 0.1g) of material in a second. Both right and left head are
separated.
※ If the working conditions(ex, a kinds of material, temperature, pressure, etc..) are changed, you
must check the throughput weight again carefully in manual working mode. And then input the
weight correctly.

To save data, click ‘Save’ button.

During the data is transferring to PLC, the message “Wait. Data Transfer…” is shown as Fig. 4.10.

Fig. 4.10

If data transfer is successful, the message is shown as Fig. 4.11. Press ‘Enter’ key or Click ‘check’
button. Then the message will disappear.

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Control software manual PU Rotary machine

Fig. 4.11

If you forget to input data somewhere, the error message appears when you click ‘Save’ as Fig.
4.12. Click ‘Check’ to find an empty data

Fig. 4.12

If you want to return the main page, press F8 key or click a tab of’ Working Display’.

4.3. F3 Production Sheet

This mode is useful when you want to check the production quantity at present. Press F3 key or click
tab of ‘Production Sheet’ in the top and right side. The screen is shown as Fig. 4.13.

Fig. 4.13

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Control software manual PU Rotary machine

The information of all 48 carriers’ production quantity is shown in a screen at the same time. You can
check the name of mold, target quantity, actual produced quantity.

The total quantity in this lot working is displayed on the bottom of screen.

There are two buttons for input. One is ‘F6 Save’, the other is ‘F7 Print’. The ‘Save‘ button is used
when you want to save a data of production quantity in a computer file. Later you can find this file from
computer. ‘Print’ button is used when you want to print out the current data of production quantity

▶ Save
The program will save in a MS Excel file. Basically the file is created by time that the file is saved. As
Fig. 4.14, you can see file mane ‘050311-1521’. That means 2005, March, 15th, 15:21.

Fig. 4.14

To save a file, click ‘저장(save)’ , then the file is saved at folder as you want and Fig. 4.15 will be
shown. This message box shows that the file was saved successfully as shown path. Click ‘확인
(confirm)’, then the message box will disappear.

Fig. 4.15

If you don’t want to save, press ‘ESC’ key or click ‘cancel’ button. Fig 4.16 will be shown.

Fig. 4.16

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Control software manual PU Rotary machine

▶ Print

Fig. 4.17 is shown if you click ‘Print’ button or press F7 key. And the screen shows that which
printer is connected with system(computer). If no printer is connected, you cannot print out. Both
Local print and Network printer is available. The print format will be the current production quantity
of each carrier and total quantity and print time.

Fig. 4.17

To print, click ‘인쇄(print)’ , then the printer make a sheet and Fig. 4.18 will be shown. This message
box shows that the file was printed out successfully. Click ‘확인(confirm)’, then the message box will
disappear.

Fig. 4.18

If you don’t want to print, press ‘ESC’ key or click ‘cancel’ button. Fig 4.19 will be shown.

Fig. 4.19

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Control software manual PU Rotary machine

4.4. F4 Alarm

If the machine has some problem, it gives warning and alarm on the screen as Fig. 4.20.
Firstly, the lamp (see no.① on Fig. 4.20) turns red. Then the part in that have a problem turns red on
the right screen as Fig.4.21.
No.② on Fig.4.20 shows the alarm code with number when the servo motor has some problem.

Fig. 4.20

Fig. 4.21

When the machine gives alarm, press F7 key or click turned red message box. You can see simple
troubleshooting as Fig. 4.22.

▶ Troubleshooting message on each alarm

1) Casting Servo Trouble

FIRST, CHECK UP SERVO DRIVER IN MAIN PANEL. AND THEN REFER TO THE MANUAL BOOK FOR
DETAILED REPAIRING. AFTER CHECKING THE ERROR CODE IN THE CASTING SERVO,
PUSH THE RESET BUTTON OF HEAD SERVO AND 'MD71'IN THE MAIN PANEL

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Control software manual PU Rotary machine

Fig. 4.22

2) Hydraulic Motor Overload

CHECK UP EOCR IN MAIN PANEL AND THEN LOOK UP THE POWER OF MAGNET AND
HYDRAULIC MOTOR. IF NORMAL, RESET EOCR BUTTON. REFER TO THE MANUAL BOOK FOR
DETAILED REPAIRING.

3) Raw Feeding Motor Trouble

CHECK UP PRESSURE GAUGE OF WORKING TANK AND EOCR IN PANEL.
IF PRESSURE IS HIGHER THEN STANDARD, EXAMINE STRAINER AND HEAD IN CIRCULATING
HOSE AND MOTOR. IF EOCR WORKS, CHECK UP THE POWER OF MAGNET AND AT MOTOR.
AND THEN PUSH RESET BUTTON. THIS TIME, PLC NOTE WHETHER TO DISCONNECT
THE INPUT LINE PLC AND MAGNET. REFER TO THE MANUAL BOOK FOR DETAILED REPAIRING.

4) Mixing Servo Trouble

CHECK UP EOCR IN MAIN PANEL AND THEN LOOK UP THE POWER OF MAGNET AND MIXING
MOTOR. AFTER CHECKING THE ERROR CODE IN THE MIXING SERVO, PUSH THE RESET BUTTON
OF MIXING SERVO AND 'MD71' IN THE MAIN PANEL.
REFER TO THE MANUAL BOOK FOR DETAILED REPAIRING.

5) Max. Shoot Time excess

RECALL THE SCREEN FOR STANDARD MOTION AND THEN CHECK UP WHETHER MAXIMUM
POURING TIME IS CORRECT OR NOT. MODIFY IF IT'S ANYTHING WRONG.
REFER TO THE MANUAL BOOK FOR DETAILED REPAIRING.

6) Max. Shoot Interval excess

RECALL THE SCREEN FOR STANDARD MOTION AND THEN CHECK UP WHETHER MAXIMUM
POURING INTERVAL TIME IS CORRECT OR NOT. MODIFY IF IT'S ANYTHING WRONG.
REFER TO THE MANUAL BOOK FOR DETAILED REPAIRING."

7) Rotary Position Incorrect - Actuating Part Incorrect

REPLACE AUTO S/W INTO MANUAL S/W, AND TURN OFF LINE MANUAL S/W.
REPLACE ACTUATING PART MOVING S/W INTO MANUAL TYPE AND MOVE LIKE BELOW
STATEMENTS. TURN NOTCH S/W TO THE BACKWARD. TURN LINK S/W TO THE BACKWARD.
TURN NOTCH S/W TO THE FORWARD. REPLACE ACTUATING PART S/W INTO AUTO S/W &
TURN ON LINE MANUAL S/W.
REFER TO THE MANUAL BOOK FOR DETAILED REPAIRING.

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8) Rotary Position Incorrect - Sensor Incorrect

CHECK UP THE CONDITION OF PROXIMITY AND BRASS BOLTS WHICH ARE ATTACHED ON POWER
SUPPLY UNIT IN THE CENTER OF ROTARY. IF IT'S NOT GOOD, REPLACE IT.
REFER TO THE MANUAL BOOK FOR DETAILED REPAIRING.

9) Operation Miss
SWITCH OPERATING GOES WRONG. CHECK UP THE CONDITION OF SWITCH IN THE O.P PANEL
AND MAIN PANEL.

10) PLC Battery Alarm

CHANGE THE BATTERY OF THE INSIDE OF CPU IN THE PLC.

4.5. F5 Material information

Press F5 key or click tab of ‘Material Info’ in the top and right side. The screen is shown as Fig. 4.23.
You can input the data concerning about PU material at present. The contents are ‘Material name’
and ‘ Mixing Ratio’

Fig. 4.23

To save a data, press F7 key or click ‘Input’ button. Then Fig. 4.24 will be shown. This message box
shows that the data was saved successfully. Click ‘확인(confirm)’, then the message box will
disappear.

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Control software manual PU Rotary machine

Fig. 4.24

If you forget to input data somewhere, the error message appears when you click ‘Input’ as Fig.
4.25. Click ‘Check’ to find an empty data

Fig. 4.25

4.6. F6 Model Input

This is a newly added function for this machine. Because you can change the data that was saved
already and add new data, you don’t need to input same data so often and complicatedly. Press F6
key or click tab of ‘Model Input’ in the top and right side. The screen is shown as Fig. 4.26.

Fig. 4.26

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Control software manual PU Rotary machine

When you enter into F6 mode, only ‘Mold Name’ box (no.① of Fig. 4.26) is activated. Input mold
name you want and press ‘enter’ key, and then other contents are activated too. If you press ‘Enter’
key without mold name, the message box is shown as Fig.4.27.

Fig. 4.27
To return former screen, click ‘확인(confirm)’.

If the mold name you input is new, the message box is shown as Fig.4.28. If this is new name and
you want to input data, click ‘Y’. But if you don’t want to make new data, click ‘N’.

Fig. 4.28
You can see all input data concerning about mold name if you click ‘List’ button.

Fig.4.29 is the screen when you input mold name that was saved already. The data format is same
as F2 Correct mode except carrier no., auto cleaning, auto pouring, auto pre-casting.

To save a data, press F7 key or click ‘Input’ button. Then Fig. 4.29 will be shown. This message box
shows that the data was saved successfully. Click ‘확인(confirm)’, then the message box will
disappear.

Fig. 4.29

If you forget to input data somewhere, the error message appears when you click ‘Input’ as Fig.
4.30. Also the cursor is positioned on that box.

Fig. 4.30
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4.7. F7 RPM

This is a newly added function for this machine. This shows the revolution speed of PU material
pump and head mixing motor. Press F7 key or click tab of ‘RPM’ in the top and right side. The screen
is shown as Fig. 4.31.

Fig. 4.31
As you can see no.① in Fig. 4.31, there are 6 pump rpm (ISO 2 & POL 4) and one mixing motor
RPM. Each RPM can be changed and added newly, and correspond to no.② in the bottom of right
screen.

To save a data, press F7 key or click ‘Input’ button. The message box is shown as no.① in Fig.4.32.
This shows that the data was saved successfully. In the no.② of Fig.4.32, you input 3000 for the
right pump’s RPM of POL1. But the PRM at present is 400 as no.③ of Fig.4.32. If you click ‘확인
(confirm)’, The value 3000 will be in the RPM(no.② in Fig.4.33) at present of pump’s RPM of POL1.
as Fig

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Fig. 4.32

Fig. 4.33

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If you forget to input data somewhere, the error message appears when you click ‘Input’ as Fig.
4.34. Also the cursor is positioned on that box.

Fig. 4.34

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