® ®

A seamless conversion from the Pathfinder to the DPG VDU controller

VAN DORN
VDU® CONTROLLER
OPERATOR’S QUICK GUIDE

UNIVERSAL
VDU-QG-10/09
 Contact Info

For any questions or comments that fall outside the scope of this
guide, please contact Demag Plastics Group Training department.

Phone: 440.876.6203

Fax: 440.876.8900

E-mail: [email protected]

For machine service and parts, contact the DPG Service and Parts
departments.

Phone: 1.866.491.1045

Service Fax: 440.238.4982

Parts Fax: 440.238.4668

Service E-mail: [email protected]

Parts E-mail: [email protected]

I
VDU® Controller Introduction

About this guide:

This manual is designed to assist operators in quickly learning the interface of the new
®
VDU controller. As you are already aware, countless hours, downtime and scrap are lost due to
®
the learning curve associated with a new controller. The screens on the VDU controller use
®
nearly the same graphical flow as the Pathfinder . The screens have been designed this way to
®
assist the operator with learning the VDU , while at the same time, leveraging the faster
®
processing speeds and advanced closed loop algorithms inherent in the VDU controller.

The purpose of this quick guide is to give you instant access to basic questions that may arise
during setup and operation of your injection molding machine. It will help to clarify the meanings
of terminology that may not be readily apparent. Based on input from previous customers, we
have included a section on commonly misunderstood terms and settings.

Some of the information will assist you in setting up certain parameters of the machine, while
other information will help to identify symbols, buttons and other objects associated with PC-
based controllers.

The graphical approach of this guide is used to enable a quick comparison of the screen
displayed on the controller with the screen in the quick guide. This approach has proven to be an
effective method of increasing the retention levels of the operator.

This guide is not intended for personnel who have just started out in the set up position. It is
highly recommended that the user has already completed a basic molding training program.

For greater detail of the VDU®, please refer to the VDU® Operator’s Manual.

Note: Please call the training department manager - Mark Lepole (440.876.6203) - with any
questions concerning this guide.

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VDU® Controller Table of Contents

VDU® Control Panel Page 1

VDU® Screen Interface Overview Page 2

VDU® Screen Interface Interaction Page 3-4

Clamp Setup Page 5

Injection Setup Page 6

Boost and Hold Graphs Page 7

Recovery Page 9

Temperatures Page 10

Setup File Manager Page 11

Glossary Page 12-14

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VDU® Control Panel Function Keys

Setup Overview Process Control User Defined

Screen Statistics Home Screen
Injection Options/Peripheral
Setup Equipment Printer

Access Code
Temperatures Maintenance
Clamp Entry
Setup Production Alarms

Main Screens Navigation

Main Component Machine Modes Gate/Die Height

Switches
Mold Heats Barrel Heats Setup Manual Gate Gate
On/Off On/Off mode mode open close

Touch screen
enable/disable

Manual and Setup Aux 1 On/Off Aux 2 On/Off Semi- Full- Die Height Die Height
(customized (customized
options) options) automatic automatic reverse forward
Functions mode mode

Clamp open/close
Core pull/set Injection Unit #1 Injection Unit #2
Ejector forward/retract
Carriage forward/retract Carriage forward/retract

Inject forward/decompress Inject forward/decompress

Additional optional Screw rotate Screw rotate

Air poppets 1 - 4 cores 2 - 4
Optional

1
 VDU® Screen Interface Overview

Screen number and name

User defined
Screen list Day/Date/Time
start page Print screen
drop down Help

Alarms

Notes
Password screen
access
Entry field
(on-screen
keypad)

4
Message field
5

Current access level

Machine status

Current user

Page back Page forward

Navigation/Function keys

1 - System Setup Screen

Shortcut to “System Setup”. This screen is
used to configure units of measure and personal 4 - Service
preferences. Shortcut to valve and sensor calibration
screens.

2 - File Manager
Shortcut to the “File Manager”. This screen is
used to create and manage all setup-related files.
5 - Options
Any optional equipment and software being
3 - Production and Process Data controlled by the VDU® can be accessed through
Shortcut to the production screen. From this this shortcut.
screen other production and process data screens
can be accessed.

2
VDU® Screen Interface User Interaction

Buttons, Fields and List Box Interaction

Enable (on)

Disable (off)

Active
input field

Input field

Actual value

List box field

Screen Listing

List Box field: Any field with a bottom right corner

arrow indicates that a list of selections will be
presented when the field receives focus (is
touched).

Screen List:
Touch the i
symbol to
open the
Screen List
box. Use the
slider on the
right side of
the box to
page down
until the
desired screen
is found. As
you page
down, you will
see that the
active screen
listing will be highlighted. Touch the desired screen listing,
or press the Enter key on the control panel to navigate to
the screen.

3
VDU® Screen Interface User Interaction

Entry Field Interaction

Control Tip

Entry/Edit command
disabled: When a field is
highlighted with the
command off, a control tip
will appear displaying
information about the set
point. Any set point entries
must be made with the key
pad on the panel.

Entry/Edit command
enabled: When a field is
highlighted with the
command on, the edit
keypad will appear. Use the
keypad to change the set
point. Then press the Enter
key.

4
 Screen 11 Clamp Setup

Clamp Setup Screen

Close Fast: Pressure setting should be set between 1200 - 1500.

However, to obtain higher clamp speeds, the pressure will have to be increased
above the suggested setting.
Overall Cycle: Set slightly higher than actual cycle
time.

Mold Open: Open

stop position and
time to remain open
until closing again.

Clamp Closed: This is the

cure timer. The timer is
triggered when the Hold timer
(screen 13) has timed out.
Try Again:
See glossary.

Start
Pos/Count:
Initiates the
ejector stroke
at this position Breakaway/Open Fast: Reduced speed and
when the elevated pressure may be needed to break the
clamp is Core sequence list box: Touch the field to clamp away from the stationary half of the mold.
opening. The display the list of available sequences. To The Open Fast speed will be initiated at the
ejectors will select, touch the desired sequence. position specified in the Open Fast “IN” field.
then stroke the
number of
times specified
in the count
field.
Forward Hold: Enable
the Hold button to hold
the ejectors forward for
Clamp Lockup: The pressure should be
Close Slow Set #2: Used primarily the desired length of set high enough to prevent any parting line
with spring loaded tooling. When time. flash. The speed setting is used to ensure
enabled, an additional setting will the valve is opened enough to supply the
appear next to the first close slow set proper amount of oil to the cylinder(s) to
Tip: Enable the Tip ensure quick lockup.
point. This setting will allow you to button to partially
use a higher pressure to overcome retract the ejectors
For toggle machines, the position set point
the springs and reach the lockup when using multiple should be set .02 - .03 higher than the
position. ejector strokes. actual mold touch position.

Close Slow: This is the mold protection setting. Pressure is the

Ejector Retract/Forward: The retract position should key set point. Set the pressure just high enough to maintain
be slightly higher than zero, while the forward position clamp motion until the mold halves touch. Suggestion: While
should stop the ejector plate before it bottoms out. manually closing the clamp, reduce the pressure until the clamp
The pressure is normally 300 - 500 psi. Only use a stops. Then increase the pressure in small increments until the
higher pressure when running tools that require over clamp resumes motion. This method will ensure a safe setting
packing of the part. An overpacked mold may require a for the mold.
higher pressure to break the vacuum of the part from
the core.

5
 Screen 13 Injection Setup

Injection Setup Screen

Injection graph: Use this
graph to compare actual
Cutoff Select: Use the list box (field with the corner arrow) to select the values to set point values
preferred mode of transfer (position, time, or pressure). The timer is during the first stage of
active regardless of the mode of cutoff. The pressure set point is only injection phase.
active if pressure is selected as the mode of transfer. The values to the left of
Note: The terms cutoff and transfer have the same meaning. These the graph and below can
terms define the moment when control of the injection function switches be adjusted to resize the
Pressure Cutoff Enable: If graph. This allows you to
from speed to pressure.
cutting off by pressure, the zoom in and out, if
screw must travel past the desired. See next page.
position entered in this field
before the logic starts
looking for the cutoff
pressure set point. Actual values: The first two
boxes, starting on the left,
are values from the previous
shot. The last box is
Injection Unit: On/Off realtime information on the
current state of position,
speed and pressure.
See below for explanation.

Response: Is normally
enabled to achieve the Pack Volume: Allows
quickest response during independent control of the
injection. Disabled, the flow control valve for the
pump will only deliver the amount of time entered in
amount of oil necessary to the “SEC” field. If zero is
See below for explanation.
move the screw at the entered as a setting, then
desired speed. The trade the Hold Speed setting is
off is energy savings at the used throughout the hold
expense of machine phase function. See
responsiveness. diagram in the glossary
section.

Boost Profiling: There are many variables that determine the type of Hold Profiling: For most hold conditions, one pressure for the entire
profile used for the boost phase of injection. Among them are the type hold phase is used. However, for parts with a large wall thickness which
of material, runner system, wall thickness, gate size, flow length and require extended periods of hold time >10, reducing the pressure over
cycle time. Many processing conditions need only one injection speed time may be desirable. This profiling of pressure can greatly reduce
to make parts within specifications, while others need to be profiled with energy usage over extended periods of time. Hold profiling can also be
a reduction in injection speed, or vice versa. The number of steps that used to maintain a higher pressure while completing the packing of the
are used is entirely dependant on the processing conditions. part before dropping down to a lower holding pressure.

One injection speed = one

step. One hold pressure = one
step.

Two injection speeds = Two hold pressures = three

three steps. steps.

See next page for additional profiling information.

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Screens 130-131 Boost and Hold Profile Screens

Boost and Hold Profile Screens

Graph cursor:
On - The Zoom
Boost graph and profile settings: button and Arrow
buttons are
displayed. The
cursor can be
moved anywhere
along the x-axis.
The values at the
cursor position
2 1 will be displayed
Cursor
left
Cursor
right
in the top left
4 3 hand corner of
the screen.

Use the arrows or the zoom

Cursor and Zoom field to place the cursor at the
buttons hidden desired position. If the zoom
field is used, after entering a
value press the Enter key.

PID Values - See glossary

3 2 1

Boost Profile Settings: X-axis zoom: To zoom in and out, adjust the
1) - Start injecting at 4.00 in/s. fields on the left and right of the graph screen.
2) - Remain at 4.00 in/s until the 1.50 in position is reached. For example: to view the transition section of
3) - By the time the 1.00 position is reached, be at 3.00 in/s. Graph cursor: boost, set the left field value at a position slightly
4) - Remain at 3.00 in/s until the cutoff position is reached. Off - The Zoom lower than the end of the transition and set the
Boost Peak represents the highest speed used during injection. button and Arrow right field value slightly higher than the
Boost Pressure represents the highest pressure allowed during buttons are hidden.
beginning of the transition (see the above
injection. The cursor also is
hidden. graphic).
Hold graph and profile settings:

1
3 2

Cursor and Zoom

buttons hidden

Edit Profile: Press the Edit Profile soft key to

adjust the profile. After pressing the soft key, the
editing buttons (below) will be displayed. Use these
3 2 1 keys to adjust the profile to the desired settings.

Hold Profile Settings:

1) - For the first .5 seconds, be at 1400 psi.
2) - Take .10 seconds to drop down to 800 psi.
3) - Stay at 800 psi for 2.40 seconds.
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Screens 130-131 Boost and Hold Profile Screens

Saving Traces

“Saved Trace Menu” key not enabled

Enable the “Saved Trace Menu” by touching the key. The key will then appear highlighted and
the “Show Saved” keys will appear.

Press the desired “Show Saved ****” keys to show the saved trace(s).

Show Saved Show Saved Show

HOLD
Saved Saved Trace
Save Traces
Speed Pressure Spd
GRAPH
Control Menu

“Show Saved” keys displayed “Saved Trace Menu” key enabled

Current actual
speed trace
Saved pressure
trace

Saved speed
trace Current actual
pressure trace

Show Saved Show Saved Show

HOLD
Saved Saved Trace
Save Traces
Speed Pressure Spd
GRAPH
Control Menu

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 Screen 14 Recovery Screens

Basic Setup of Screw Recovery

Profiling: As with boost and hold, the recovery and back pressure of the screw
Rotate Speed: This setting is in can be profiled to enable the use of more than one speed or pressure. After
RPM and is used to determine the entering the desired “steps”, individual settings for each step will be displayed.
shear rate of the material in the For further information on setting up a profile, see the boost and hold profile
barrel. This is an important variable screen.
in the proper preparation of the
melt for the subsequent shot.

Rotate Delay: The amount of time

the screw remains forward before the
recovery phase (screw rotate) is
initiated.
The rotate delay timer is triggered by
the completion of the hold time. The
screw remains forward, with no
pressure being applied, for the
amount of time entered in the Rotate
Delay field.

Recovery Graph: Use this button to access the

recovery profile settings. Use the recovery graph to get
a graphical view of both screw RPMs and back
pressure. Profile and closed loop adjustments can be
made on the graph screen.
Back Pressure: One pressure is normally
used for this function. However, more than
one pressure may be used if desired.
Most manufacturer recommendations for
back pressure is between 50 - 175. Auto Purge: Can also
be accessed from the
Injection Setup
screen. Auto Purge is
normally used for
Decompress: Can be used before screw recovery, after color and material
screw recovery, or both before and after recovery. Open changes.
the list box field to select the mode of decompression The number of cycles
desired. Notice the current mode being used and the is counted by either
corresponding field (DECOMP AFTER) in which to set the amount of times
the decompression distance. the screw injects
The DECOMP position fields will remain hidden (notice forward, or the
the decompression setting for “before” is not shown) number of times the Cycle timer times out. Keep in mind that the
unless they have been selected. See the glossary screw will not always rotate back to the shot size when purging. This
section for an explanation of decompression. is the reason for the cycle timer setting.

9
Screen 15 Temperatures

Temperature Setup Screen

Start Preheat: Press this button to start the oil
preheat function. Oil preheating should be
done with start up.
Heat list box: Select heating mode from the drop down box. Note: The pumps must be on before the Preheat
command button appears on the screen.
Selections include auto, standby and off. The Tune selection
is used for maintenance purposes; and is not normally used
by the molding technicians.

Status: Displays the current

mode, temperature and duty
percentage being used.

Below Within Above

Tolerance Tolerance Tolerance

Zone Setup: Enter the desired temperature

setting for each zone here. The +/- settings are Zone Configuration: Touch the
the allowable deviations from the set point desired Zone button to open the
before an alarm is activated. The Standby Zone Setup window. Make the
setting is used to reduce the barrel desired selections. Then touch the ‘X’
Oil: Recommended oil temperatures while the machine is down. This
temperature setting is 110 to close the window.
reduces damage to the screw due to material
degrees. The plus and minus degradation.
deviation should be no more than
10 degrees. A small plus deviation
setting enables the machine to Temperature Zone Manual Override: To switch
continue running while the to manual control of a zone, enable the Manual
overheating condition is analyzed. Override button, then press the Set Manual button
on the warning
Note: To access oil set points, box that pops up.
setup level (2) is required. Note: Access level
4 or higher is
needed to enable
this function.

10
Screen 61 File Manager

Saving, Copying, and Deleting Files Show CfgIO Files: Press this button to show the configurable I/O
files saved to storage.
Show Mold Files: Show all the mold files that are in storage.
Show Cal Files: Show the calibration files currently stored.
Use the Screen List to navigate to this screen, or View Data Errors: If the status bar displays the “Data Error”
from the Setup Overview screen, press the “SETUP message, press this button to view the type of error that occurred.
FILE MANAGER” softkey.

Current files in
active memory

Job Information

External file storage list box.

Internal file storage list box. (flash drive - USB stick)
Status Bar

Load Active Setup: Use this button to load a file from the internal/external list box to active memory.
Highlight the desired file by touching it on the screen, or use the cursor keys. The actively highlighted file
is now ready to be loaded to active memory. Now touch the Load Active Setup button.
Save Active Setup: The parameters that are currently in active memory (parameters the control logic is
using while the machine is running) are saved by touching the Save Active Setup button. There are two
methods available to save a file:
1. Existing mold - simply highlight the corresponding job name in the internal/external box. Then
press the Save Active Setup button.
2. New mold - use the Save Active Setup As command.
Save Active Setup As: This command is used to store a new job that has not been previously saved.
When this button is pressed, a sub-window will pop up prompting the user to enter a file name. Enter the
file name using the virtual keyboard that will appear when the “SAVE FILE AS” field is touched. Then
press the Enter key. The file will now be stored to the drive that was selected.
Copy File External: Using this command will store a copy of the highlighted file to the external drive.
Copy File Internal: Using this command will store a copy of the highlighted file to the internal drive.
Delete File: Highlight the desired file and touch the Delete File button. A message box will pop up
confirming the deletion of the file. Pressing Enter will permanently delete the file.
Drive: Use this button to select the drive in which the USB stick is inserted.

11
 Glossary Terms, Definitions, Nomenclature

Screen 11 - Clamp Setup

Clamp Closed - Occasionally, there is some confusion regarding this set point. This timer is used to set the cure time
of the part being molded. Therefore, this setting is initiated at the end of the hold function. When this timer reaches zero,
the clamp will open and the part will then be ejected from the mold.

Clamp Lockup - Also known as the tonnage setting. On an HT machine, the psi setting will determine the pressure
used to toggle over the linkage. This, in turn, will determine the mechanical lock up force that is generated on the mold
halves. On an HP machine, this pressure setting is applied throughout the injection phase because it generates the actual
direct tonnage being applied to the clamp.

Try Again - This feature can help or hurt the machine process. It is normally used to alleviate the time an operator
spends un-jamming parts from a mold. Normally, if a part fails to come out of the mold, then the clamp will fail to reach the
lockup position on the subsequent cycle. This will cause an alarm condition. If Try Again is enabled, then the clamp will
open to the stop position, cycle the ejectors and try to close again. Many times this will clear the jammed part out of the
mold. Note: This feature should be used only if the part is cleared from the mold every time Try Again is initiated.

Screen 13 - Injection Setup - See the diagram on the next page for a graphical representation of the injection
and recovery stages.

Boost - A term used to describe first stage injection. Also known as the velocity stage. 90 to 98 percent of the part is
normally filled during this stage. Fill speed is the priority variable during this stage. The closed loop function reacts to the
speed signal feedback during this stage.

Closed Loop - Definition: The control logic adjusts the actual injection speed to match the set point speed. Similar to
closed loop control on an injection molding machine is the cruise control on a car. With cruise control turned on, the on-
board logic will adjust the gas pedal to match the speed (set point) the car was going when cruise control was turned on.

Closed Loop - Technical Description: Changes the output (command signal) to the valve when the actual value is
offset from the set point value. The controller is able to monitor the actual injection speed from feedback signals sent from a
sensor (position potentiometer for boost stage and pressure transducer for the hold stage). If the actual speed is not the
same as the set point value, then the controller will adjust the command signal out to the valve - this is the exact same
concept as cruise control is for an automobile. Closed loop, normally, should be enabled except for troubleshooting pur-
poses. Gain and reset are the major tuning values. If tuning has to be performed, adjust the gain and reset unless there are
consistent, large load disturbances, i.e., thick to thin wall transitions in the mold, a cold slug in the sprue. Adjust the rate to
overcome the load disturbance. There is normally a 2-3:1 ratio between the gain value and the reset value. Once these
values are established, further adjustment should not be necessary.

Hold - Pressure is the priority variable during this function. This function is used to transmit pressure
into the mold cavities until the mold gates solidify. This helps to prevent volumetric shrinkage of the parts.

Hold Speed % - Determines how much the flow control valve is open after the pack volume timer
elapses. The percentage is based on the percentage of valve opening. 0% = closed, 100% = wide open. A
25% setting will usually provide for all of the flow necessary to achieve the desired pressure setting.

Pack Volume - This setting determines the flow control valve opening for the amount of time specified.
The pack volume is used if independent control of the valve is desired for a certain amount of time during
the first phase of the hold function. Remember, pressure becomes the priority function once the cut-off
position is reached. The control logic is making adjustments to the relief valve based on the feedback of
the pressure transducer. The pack volume only determines the amount the flow control valve is opened. This will have little
effect on the pressure unless the valve is not opened enough to allow flow through it. Sometimes, leaving the valve (flow
control) opened a larger amount than normal will help to prevent ‘bounce-back’ during the transition to hold.

12
 Glossary Terms, Definitions, Nomenclature

Screen 14 - Recovery Setup

Residence Time - The amount of time the material spends in the barrel. This time is measured from the moment the
material enters the barrel from the feed throat to the time it is injected into the mold. Residence time is an often overlooked
factor in solving molding problems. Too much residence time can cause a decomposition of the plastic; and too little time
will result in non-uniform melt viscosity. Note: Keep in mind that residence time is just one of many factors affecting melt
viscosity. Plasticization rate, barrel temperatures and back pressure are other considerations.

Rotate Delay - Delay is used when the processing conditions have long cure times, combined with short rotate
times. By delaying the rotate phase of the cycle, the freshly prepared melt for the next shot will not be in a static state for a
long period of time. The delay will help to reduce the amount of non-uniformity of the melt. Non-uniform melt is a major
contributor to processing difficulties.

Decompression - is used to reduce the plastic pressure in front of the check valve and, sometimes, the runner
system in a hot runner mold. Many times, after screw rotate, an excess of plastic pressure has developed in front of the
check valve of the screw. This has the effect of, possibly, creating inconsistent shot sizes due to the inability of the check
valve to prevent plastic from leaking backwards. By using decompression, the plastic pressure in front of the check ring is
reduced, thereby allowing the valve to seat off easier. This will prevent backward leakage and force all of the molten plastic
forward and into the mold.

Injection and Recovery Sequence

Cushion
.125 to .250 Cut-off/Transfer Shot Size
Hold Time
and Pressure Boost Speed (in/sec)

Screw Position After Decompression

Fill Part 90 to 98%

Transfer from Closed Loop Speed Control

to Closed Loop Pressure Control

Screw Rotate/Back Pressure

Decompression Decompression
Before Rotate (if used) After Rotate

13
 Glossary Terms, Definitions, Nomenclature

Screen 15 - Temperature Setup

Duty % - The amount of power being used to heat the zone. The main screen will display the actual percentage
being used. If using the manual override, then a manual duty % must be specified in the
zone configuration window. To access the window, touch the desired zone button on the
main screen.

Manual Override - Warning: If using manual override with no thermocouple, be

aware that the zone may not heat up as quickly as the other zones. Screw damage could
occur during start up if you rotate the screw before it has come up to the operating temper-
ature. Use a temperature probe (or infrared) to check the zone before rotating.
Manual Override is used if a thermocouple goes bad and the machine needs to
keep running, or a larger (or smaller) nozzle is used with a particular mold. To access the
manual override switch, press the desired Zone button on the Temperature Setup screen to
access the Zone Setup window.

Standby - When the machine is down for short periods of time, it would be wise to set the barrel heats to the
Standby mode. The standby temperature set points should be set low enough to prevent material degradation and carbon
build-up on the screw. A ballpark setting would be at the softening (or melting) point of the material.

14