Moog DigiPack III J141-215 Maintance Manual

MRJ06301 Rev. Orig.

DigiPack

Ⅲ

Parison Wall Thickness Controller

J141-215

INSTALLATION,

MAINTENANCE

AND

USER’S MANUAL

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RECORD OF CHANGES

Rev.

Page

Description

Prepared

Checked

Approved

Orig.

New Model Release(EOJ20210)

T. Kouda
15, Mar’19

T.Shimizu
15, Mar ‘19

K.Mashino
29,Mar’19

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MOOG INTELLECTUAL AND PROPRIETARY INFORMATION LEGEND

This technical Document contains information that is proprietary to, and is the express property of Moog Inc., or Moog Inc. subsidiaries
except as expressly granted by contract or by operation of law and is restricted to use by only Moog employees and other persons
authorized in writing by Moog or as expressly granted by contract or by operation of law. No portion of this Data/Drawing/Document
shall be reproduced or disclosed or copied or furnished in whole or in part to others or used by others for any purpose whatsoever
except as specifically authorized in writing by Moog Inc.

NOTES TO USERS

(1) Description in this manual is subject to change without any obligation on the part of the Manufac-

turer.
(2) Notice would be appreciated if you find any question, omission or error in this manual.
(3) Disassembly, maintenance or repair, other than in accordance with the instruction herein or other

specific written instruction from MOOG will invalidate MOOG’s obligations under its warranty.
Refer to MOOG warranty for complete previsions thereof.

SAFETY INSTRUCTION

Description in this manual is essential to the safety of life and property, therefore, before operating
this equipment, you should first thoroughly read this manual, and this manual should be kept in ac­cessible for when you have any questions.

WARNING

This symbol with the word “WARNING” is used to call attention to safety instructions

concerning a potential hazard to people. Failure to comply with these safety instructions
can result in serious damage to health and can even prove fatal in extreme cases.

CAUTION

This symbol with the word “CAUTION” is used to call attention to instructions concerning

potential damage to the equipment or to the system as a whole.

NOTE

Notes contain useful information to the operator when starting up and operating the equip­ment or system.

MOOG JAPAN LTD.

1-8-37 NishiShindo, Hiratsuka, Japan 254-0019

Tel:[phone] Fax:[phone]

© MOOG 2019

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EN 61000-6-2:2005
IEC61000-4-2~6

Electromagnetic compatibility (EMC) - Part 6-2: Generic standards

- Immunity for industrial environments

EN61000-6-4:2007+A1:2011

Industrial, scientific and medical equipment - Radio-frequency dis­turbance characteristics - Limits and methods of measurement

About EMC Standard

1. Safety standard

Notes to certified of EC directive

J141-215 DigiPackⅢ is a device incorporated in customer's equipment (blow molding machine) and we
are conducting EMC test against EC Directive within the scope of embedded equipment, but the J141-215
DigiPackⅢ use by itself is not compatible with the EC Directive.

When customer completes the equipment with J141-215 and use it within Europe or shipment to the area
within European region as the final product, please be sure to check certified of EC Directive by customer
self.

Applicable directive and relative standard.

J141-215 is conducting the EMC test conforming to the EC directive below. It shows directives and related
standards.

EC Directive: EMC Directive 2014/30/EU
Relative Standard:

2. Measures EMC

In order to applicable EMC directive, please takes suitable measure against EMC with a customer's blow
molding machine.

And also, when include J141-215 in apparatus and it is used, please consider wire connection and ground­ing.

The cable used for each wire connection recommends use of a shielded cable.
A shielded cable should be connected to the terminal of J141-215, and the length of skin wire processing

should be less than 100 mm.

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TABLE OF CONTENTS

1. DigiPackⅢ Manual, Installation and Maintenance .............................................................................. 1

1-1. CHANGES FROM J141-214A ......................................................................................................... 1

1-2. INTRODUCTION .............................................................................................................................. 2

1-2-1. GENERAL DESCRIPTION.............................................................................................. 2

1-2-2. WHO CAN INSTALL THE DigiPackⅢ ............................................................................. 5

1-2-3. INSTALLATION TIME ..................................................................................................... 6

1-2-4. SOFTWARE UPDATE .................................................................................................... 6

1-2-5. BACKUP BATTERY ........................................................................................................ 7

1-2-6. SCREEN DISPLAY PROTECTION (password) ............................................................... 7

1-2-7. DATA TRANSFER FROM DigiPackⅡ ............................................................................. 7

1-3. DigiPackⅢ SPECIFICATION .......................................................................................................... 8

1-4. CHECK LIST .................................................................................................................................... 9

1-4-1. INSTALLATION CHECK LIST ......................................................................................... 9

1-5. MECHANICAL INSTALLATION ..................................................................................................... 10

1-5-1. GENERAL .....................................................................................................................10

1-5-2. TOOLING ADJUSTMENT .............................................................................................. 11

1-5-3. MOOG DIE GAP TOOLING ACTUATORS .....................................................................12

1-5-4. CYLINDER INSTALLATION ...........................................................................................12

1-5-5. CUSTOMER SUPPLIED CYLINDER REQUIREMENTS ................................................13

1-5-6. TOOLING ADJUSTMENT ..............................................................................................14

1-5-7. ACCUMULATOR POSITION MEASUREMENT .............................................................14

1-5-8. THE IMPORTANCE OF FILTRATION ............................................................................15

1-5-9. FILTER INSTALLATION .................................................................................................15

1-5-10. HYDRAULIC POWER SUPPLY ...................................................................................16

1-5-11. HYDRAULIC POWER SUPPLY START UP INSTRUCTIONS ......................................16

1-5-12. CONTAMINATION CONTROL ..................................................................................... 17

1-6. ELECTRICAL INSTALLATION ....................................................................................................... 18

1-6-1. GENERAL .....................................................................................................................18

1-6-2. REAR CONNECTOR .....................................................................................................18

1-6-3. TB-1, TB-2 WIRING .......................................................................................................19

1-6-4. COMMUNICATION AND SSI SNSOR WIRING..............................................................19

1-6-5. TB-2 I/O CIRCUITRY ................................................................................................ .....25

1-6-6. TB-3: POWER SUPPLY .................................................................................................26

1-6-7. NOISE AND GROUND ISOLATION ...............................................................................26

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1-7. CALIBRATION OF TOUCH SCREEN ........................................................................................... 29

1-8. DigiPackⅢ front panel .................................................................................................................. 30

1-9. TOOLING SYSTEM SETUP .......................................................................................................... 32

1-9-1. GENERAL OF SETUP ................................................................................................ ...32

1-9-2. MACHINE SETTING ......................................................................................................32

1-9-3. SET UP PROCEDURE ..................................................................................................35

2. DigiPackⅢ Manual, User operation .................................................................................................. 43

2-1. INTRODUCTION ............................................................................................................................ 43

2-2. PARISON CONTROL..................................................................................................................... 44

2-2-1. HISTORY .......................................................................................................................44

2-2-2. PARISON PROGRAMMING BENEFITS ........................................................................44

2-2-3. CONTINUOUS EXTRUSION MACHINES .....................................................................44

2-2-4. ACCUMULATOR MACHINES ........................................................................................44

2-2-5. PARISON PROGRAMMING BENEFITS ........................................................................45

2-2-6. WITH ACCUMULATOR BLOW MOLDING MACHINES .................................................46

2-2-7. WITH CONTINUOUS BLOW MOLDING MACHINES ....................................................46

2-2-8. PARISON MOLD ALIGNMENT ......................................................................................47

2-3. MAN MACHINE INTERFACE ........................................................................................................ 48

2-3-1. OPERATOR CONTROL .................................................................................................48

2-3-2. INPUT FUNCTION .........................................................................................................48

2-3-3. FUNCTIONS ..................................................................................................................51

2-3-4. STATE MONITORING AREA .........................................................................................51

2-3-5. EDIT AREA ....................................................................................................................52

2-4. SCREENS OF EDIT AREA ............................................................................................................ 53

2-4-1. EDITING METHOD ........................................................................................................53

2-4-2. F1: Profile Mode ............................................................................................................54

2-4-3. F2: Marker Mode ...........................................................................................................59

2-4-4. F3: File Mode .................................................................................................................61

2-4-5. F4: Monitor Mode ...........................................................................................................65

2-4-6. F5: Data Display Mode ..................................................................................................66

2-4-7. SHIFT→F1: Set Up Mode ..............................................................................................67

2-4-8. SHIFT→F2: Analog monitor ...........................................................................................67

2-4-9. SHIFT→F3: File delete and Backup/Restore .................................................................68

2-4-10. SHIFT→F4: Machine Setup .........................................................................................69

2-4-11. SHIFT→F5: Communication Mode ...............................................................................70

2-5. COMMUNICATION PROTOCOL ................................................................................................... 71

2-5-1. EtherNET COMMUNICATION SPECIFICATION ............................................................71

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2-5-2. PROFILE .......................................................................................................................71

2-5-3. WAVE ............................................................................................................................73

2-5-4. MONITOR ......................................................................................................................73

2-5-5. INFORMATION DATA ....................................................................................................73

2-5-6. INTERFACE CONTROL ................................................................................................74

2-5-7. OTHER ..........................................................................................................................76

2-5-8. ERROR CODE ..............................................................................................................76

2-5-9. ADC/DAC CHANNEL ................................................................................................ .....76

2-6. PROFILE DATA LIST ..................................................................................................................... 77

2-7. SETTING UP .................................................................................................................................. 78

2-7-1. OBJECTIVE ................................ ................................................................ ...................78

2-7-2. DIE GAP TOOLING SETUP ...........................................................................................78

2-7-3. PRELIMINARY SET UP .................................................................................................79

2-7-4. INITIAL TRIALS .............................................................................................................80

Reference Drawings

CC70353 ---------- Installation
CC70355---------- Customer Wiring

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Table of Figure

Figure 1-1 DigiPackⅢ appearance - - - - - - Page 2
Figure 1-2 Basic Continuous Blow Molding Machine Control Diagram- - - Page 3
Figure 1-3 Basic Accumulator Machine Control Diagram- - - - Page 4
Figure 1-4 Start up Display - - - - - - - Page 6
Figure 1-5 Die Gap Tooling Actuator Installation - - - - Page 10
Figure 1-6 Die Gap Tooling Actuator - - - - - - Page 10
Figure 1-7 Actuator – Die Gap Tooling Mechanical Adjustment - - - Page 11
Figure 1-8 Tooling Adjustment Mechanism - - - - - Page 11
Figure 1-9 Typical Cylinder Installation - - - - - Page 12
Figure 1-10 G631-XXX Servovalve - - - - - - Page 13
Figure 1-11 Typical Linear Potentiometer - - - - - Page 14
Figure 1-12 LWHxxx Potentiometer Installation- - - - - Page 14
Figure 1-13 High Pressure Filter - - - - - - Page 15
Figure 1-14 Hydraulic Power Supply - - - - - Page 16
Figure 1-15 Flow Pressure Filter - - - - - - Page 17
Figure 1-16 REAR CONNECTOR - - - - - - Page 18
Figure 1-17 DigiPackⅢ Installation Drawing - - - - - Page 20
Figure 1-18 ServoValve and Transducer Phasing- - - - - Page 21
Figure 1-19 TB-1 Connections - - - - - - Page 21
Figure 1-20 TB-1 Functions - - - - - - Page 22
Figure 1-21 TB-2 Connection - - - - - - Page 23
Figure 1-22 TB-2 Connection - - - - - - Page 23
Figure 1-23 TB-2 Functions - - - - - - Page 24
Figure 1-24 Input use external Power supply - - - - - Page 25
Figure 1-25 Input use internal Power supply - - - - - Page 25
Figure 1-26 Output use external Power supply - - - - Page 25
Figure 1-27 Output use internal Power supply- - - - - Page 25
Figure 1-28 Power supply Connections - - - - - Page 26
Figure 1-29 Accumulator Machine Timing chart - - - - Page 27
Figure 1-30 Continuous Machine Timing chart - - - - Page 28
Figure 1-31 Touch screen Calibration - - - - - Page 29
Figure 1-32 Touch screen calibration display - - - - - Page 29
Figure 1-33 DigiPackⅢ Flont panel - - - - - - Page 30
Figure 1-34 Machine setup display (SHIFT→F4) - - - - Page 33
Figure 1-35 Machine setting Functions - - - - - Page 33
Figure 1-36 Example of profile points change - - - - - Page 34
Figure 1-37 Setup screen - - - - - - - Page 35
Figure 1-38 Die Converge/Diverge Setup- - - - - - Page 35
Figure 1-39 Die Gap Setup - - - - - - - Page 36
Figure 1-40 DCDT Noise Filter - - - - - - Page 36
Figure 1-41 Die Gap Span Setting - - - - - - Page 37
Figure 1-42 Back - - - - - - - - Page 38
Figure 1-43 Gain select - - - - - - - Page 39
Figure 1-44 Gain setting - - - - - - - Page 39
Figure 1-45 Accumulator Setup - - - - - - Page 40
Figure 1-46 EMPTY Accumulator Set Up - - - - - Page 40
Figure 1-47 FULL Accumulator Set Up - - - - - Page 41
Figure 1-48 Extrusion Fixed- - - - - - - Page 41
Figure 1-49 Filling Fixed - - - - - - - Page 41
Figure 1-50 Accumulator setting (Back) - - - - - Page 42

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Figure 2-1 DigiPackⅢ appearance - - - - - - Page 43
Figure 2-2 Section of an Un-programmed Parison and the Resulting Container Walls Page 45
Figure 2-3 Section of a Programmed Parison and the Resulting Container Walls - Page 45
Figure 2-4 Poor Vertical Alignment Between the Parison and the Mold - - Page 47
Figure 2-5 Good Vertical Alignment Between the Parison and the Mold. - - Page 47
Figure 2-6 DigiPackⅢ Front panel - - - - - - Page 48
Figure 2-7 Ten key on the screen (1) - - - - - Page 49
Figure 2-8 Ten key on the screen (2) - - - - - Page 49
Figure 2-9 Status indicator - - - - - - - Page 52
Figure 2-10 F1: Profile mode Screen - - - - - Page 53
Figure 2-11 Profile Mode Screen - - - - - - Page 54
Figure 2-12 0%Weight Change - - - - - - Page 56
Figure 2-13 (-)23.3% Weight Change - - - - - Page 56
Figure 2-14 0% Range H - - - - - - - Page 57
Figure 2-15 (+)25.0% Range H Change - - - - - Page 57
Figure 2-16 0% Range L - - - - - - - Page 58
Figure 2-17 (-)20.0% Range L - - - - - - Page 58
Figure 2-18 Marker Mode Screen - - - - - - Page 59
Figure 2-19 Slope Timing - - - - - - - Page 60
Figure 2-20 File Mode Selection Screen - - - - - Page 61
Figure 2-21 Select SAVE - - - - - - - Page 61
Figure 2-22 File Description Data-Page 1 - - - - - Page 62
Figure 2-23 File Description Data-Page 2 - - - - - Page 62
Figure 2-24 File Description Data-Page 3 - - - - - Page 62
Figure 2-25 Edit File name - - - - - - - Page 63
Figure 2-26 Change File Number - - - - - - Page 63
Figure 2-27 Initial Load Screen - - - - - - Page 64
Figure 2-28 File Load - - - - - - - Page 64
Figure 2-29 F4: Monito screen - - - - - - Page 65
Figure 2-30 Data Display Screen A - - - - - - Page 66
Figure 2-31 Data Display Screen B - - - - - - Page 66
Figure 2-32 Data Display Screen C - - - - - - Page 66
Figure 2-33 [SHIFT]→[F1]: Setup Screen - - - - - Page 67
Figure 2-34 [SHIFT]→[F2]: Analog Monitor Screen- - - - - Page 67
Figure 2-35 [SHIFT]→[F3]: File delete and Backup - - - - Page 68
Figure 2-36 File Delete - - - - - - - Page 69
Figure 2-37 [SHIFT]→[F4]: Machine Setup Screen - - - - Page 69
Figure 2-38 [SHIFT]→[F5]: Communication Mode Screen - - - Page 70

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1. DigiPackⅢ Manual, Installation and Maintenance

1-1. CHANGES FROM J141-214A

The basic specifications of DigiPackⅢ (J141-215) are equivalent to conventional J141-214A.

There are the following major differences.



Changed from currnt VGA (480 x 640) to WXGA (1200 x 800) size
In addition, with touch screen conversion, operation by the conventional push button switch and
display by the LED are abolished, and it is changed to operation/display on the screen. (Excluding
rotary knob and power supply confirmation LED)



Considering availability, change the external storage device to USB memory. (It is not attached to
controller)
The following USB memory has been tested for operation. The operation can not be guaranteed
with USB memory other than these model numbers. We recommend that you select the same
model number as below when purchasing.


 -HTU3A 16GBK

In addition, other than the above, you can refer to the list of USB memories being used without
problems by customers at the following URL:

https://www.moog.co.jp/products/controllers-software/blow-molding-controllers/digipack3.html

 -tightened, and the terminal block was made detachable.

Mounting screw size is M3.5. Please use crimp terminal matching it.
Also, since the terminal block is removable, rewiring is unnecessary when replacing the controller.



 Name change: DI 10 Servo OFF → Emergency. This signal is normally(under control) OFF, and

if input is ON, turns OFF the servo output. For details, refer to Figure 1-23 TB-2 Functions .

 Signal addition: DI 11 temperature up completion. This signal is normally(under control) OFF, and

if input is ON, turns OFF the servo output. (Please turn ON when the resin is sufficiently warmed
up and it becomes operable.) Please refer to Figure 1-23 TB-2 Functions for details.



 serial communication function




For other details, please check this manual in detail.

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1-2. INTRODUCTION

288.00 mm

LCD Touch screen 10.1 (WVGA)

青色画面時 (RGB: 183.221.232)

DigiPackⅢ

Parison Controller

MOOG

0% 25% 50% 75% 100%

100

90

80

70

60

50

40

30

20

10

1

File Name:1234567890123456

Point No.

Die gap

Delay

Auto cycle

72

5.0

1.5

ON

%

sec

Data

Weight

Range H

Range L

* 79.0

0.0

0.0

0.0

%

%

%

%

5

6

Start

Die gap

Continuous

Accumulator

Divergent

Convergent

End of filling

Point out
End of

extrusion

F1 : Profile

F2 : Marker

F3 : File

F4 : Monitor

F5 : Data

Cursor

DEL S hift

X10 Set

2018/1/23 13:35:45

Cycle time 10.0 100% = 25.40

m

m

sec

Figure 1-1 DigiPackⅢ appearance

1-2-1. GENERAL DESCRIPTION

The J141-215 DigiPackⅢ is a user friendly, high performance 200 Point Digital Blow Molding Parison
Wall Thickness controller producing lighter, stronger containers at increased production rates.

A properly installed and intelligently used system will deliver higher operating efficiency from your blow
molding machine as a result of faster molding cycles, shorter change over times and reduced scrap.

The DigiPackⅢ adjusts the parison wall thickness by controlling the core position with the core actuator.
The core position can be finely set up to 200 points maximum.

For an accumulator type blow molding machine, set the target core position with reference to the accumu­lator position. For a continuous blow molding machine, set the target core position based on time.

The core position control system with the above setting consists of four main components: DigiPackⅢ
controller, servo valve, actuator for core and feedback detector for accumulator. The function of each
component is as follows.

 Operator using DigiPackⅢ to set the core position (core die gap opening / closing amount) required

 DigiPackⅢ also functions as a digital interface with the PLC controller of the blow molding machine

 The servo valve adjusts the flow rate to the core actuator according to the flow (spool position) com-

 The actuator for the core, the core is fixed to the rod, and the rod (core) moves according to the flow

to obtain a product with the desired wall thickness (usually constant wall thickness). In addition, it
outputs a flow (spool position) command to the servo valve so that the core follows the set core
position.

and provides information such as the end of the program and the point status of sequential programs.

mand from DigiPackⅢ.

rate adjusted by the servo valve. Moving the core changes the gap through which the parison passes
and controls the wall thickness of the parison.

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Hydraulics

Die Gap

PLC Controller

Servovalve

Actuator

DCDT

Core Position

Parison Cutoff Knife

 Accumulator feedback detector is used for accumulator type blow molding machine. The DigiPackⅢ

changes the target core position while monitoring the signal from this detector.

1.2.1.1. Continuous blow molding machines

Tooling

Figure 1-2 Basic Continuous Blow Molding Machine Control Diagram

When used with continuous blow molding machines, the DigiPackⅢ controls the parison wall thickness
relative to the machine cycle time. The machine cycle starts when the start signal is input (when the parison
cutting knife disconnects the parison). The cycle time can be determined by the following.

a) Fixed cycle time set by the operator (when [Auto cycle] is OFF)
b) Automatic cycle time set by repeatedly measuring the time between start signals (when [AUTO CY-

CLE] is ON)

When using the fixed cycle time of a), it is necessary for the machine operation time to be negligible for
reasons such as multiple die interlocking, or It is a premise that it is a machine that performs machine
functions such as closing and moving molds within the cycle time

The shape of the parison wall profile is set digitally by the operator. The size of the die gap, measured by
a die gap position transducer, is compared with the operators commanded position as set on the DigiPack

Ⅲ display.
The error between the operators set position and the actual position causes the servovalve to flow oil to

the actuator to reduce the position error to a very small value. This feedback process ensures that the
actual die gap follows the commanded die gap very accurately.

With a continuous blow molding machine, DigiPackⅢ operates / processes as follows.
① The operator sets the core position (core die gap opening / closing amount) necessary to obtain the

desired wall thickness (usually constant wall thickness) product on the DigiPackⅢ controller panel.

② When the start signal switches from OFF to ON, DigiPackⅢ controls the servo valve so that the core

follows the set position according to the cycle time.

③ The servo valve adjusts the flow rate to the core actuator according to the (flow rate) command from

DigiPackⅢ.

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Hydraulics

Die Gap
Actuator

PLC Controller

Servovalve

Actuator

DCDT

Position

Accumulator Push Cylinder

Accumulator

Position

④ By controlling the actuator for the core, control the thickness of the parison at the core die gap portion.
⑤ During ② to ④, DigiPackⅢ functions as a digital interface with the PLC of the blow molding machine

and provides information such as the end of the program and the point status of the program sequen­tially.

1.2.1.2. Accumurator type molding machines

When used with accumulator machines, the DigiPackⅢ controls the parison wall thickness relative to the
accumulator position as the plastic is being extruded.

As the total quantity or volume of plastic extruded is proportional to the accumulator position, then it follows
that the resulting parison wall thickness at any given point on the length of the container must be related
to the accumulator position. Given that the physical properties of the plastic and its temperature are con­stant from container to container, then each container’s weight and strength will be consistent.

Tooling

Figure 1-3 Basic Accumulator Machine Control Diagram

A potentiometer measures the accumulator position and controls the vertical axis of the program display.
The operator can also set the accumulator operating stroke, shot size, and accumulator injection comple-

tion position (cushion). In addition, DigiPackⅢ also provides interface signals to the machine's PLC for
these functions. After that, the operation of the accumulator is controlled by the PLC.

With an accumulator type blow molding machine, DigiPackⅢ operates / processes as follows.
① The operator sets the core position (core die gap opening / closing amount) necessary to obtain the

desired wall thickness (usually constant wall thickness) product on the DigiPackⅢ controller panel.

② When the start signal switches from OFF to ON, the DigiPackⅢ controls the servo valve so that the

core follows the set position according to the position of the accumulator.

③ The servo valve adjusts the flow rate to the core actuator according to the (flow rate) command from

DigiPackⅢ.

④ By controlling the actuator for the core, control the thickness of the parison at the core die gap portion.

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⑤ During ② to ④, DigiPackⅢ functions as a digital interface with the PLC of the blow molding machine

and provides information such as the end of the program and the point status of the program se­quentially.

Successful performance of the DigiPackⅢ depends a great deal upon how well it is installed on the
machine. By following the instructions contained idatan this manual it will be possible to easily install this
system and obtain many years of trouble free operation.

1-2-2. WHO CAN INSTALL THE DigiPackⅢ

The installation of the DigiPackⅢ control system requires the installer to be familiar with electrical wiring,
hydraulic plumbing and basic metal working. The calibration and start up of the finished system requires
some understanding of the blow molding process and use of test instruments such as a digital voltmeter.
The plumbing, wiring and bracketry should not be difficult. Most molding shop maintenance men who are
familiar with blow molding machines will have little difficulty with the help of this manual.

The system can be satisfactorily calibrated to the machine and started up without assistance or special
equipment by following the instructions in this manual.

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USB memory

Save

DIGIPK3.FMW

Software version

1-2-3. INSTALLATION TIME

The time to install a DigiPackⅢ varies with the type and size of machine, mechanical constraints such
as the location of water lines and auxiliary equipment and the ability of the mechanic doing the installation.

Our experience has shown that typical maintenance men will require about 20 to 30 man hours. Smaller
machines will require less time.

Of this time, the actual machine shut down time can be held to 6 hours or less.

1-2-4. SOFTWARE UPDATE

The software of this controller may be updated if a bug is found or the function is improved. Please check
the software update status (latest version) from the MOOG website below. Also you can download the
update file "DIGIPK3.FMW" from the website. How to update Please refer to the following description.

Update Process

1. Prepare the USB memory and turn off the power of DigiPackⅢ.

2. Save the "DIGIPK3.FWM" file to the USB memory using the computer.

3. Insert the USB memory into the DigiPackⅢ and turn ON the DigiPackⅢ.

4. Turn the rotary knob clockwise while turning on the power.

5. When "Updating firmware ..." appears on the display, the update process is in progress.
※ It takes about 30 seconds to update. If "Failed" is displayed on the screen, or if nothing happens

and screen changed to the startup screen, the upgrade fails. Please try again from process 1. If
"Failed" is inevitably displayed and the upgrade is not successful, there is a possibility that the file
is broken. Please download "DIGIPK3.FWM" again and try update again.

6. Then check the software version in the startup display (Figure 1-4).

7. Turn off the power and remove the USB memory.

Figure 1-4 Start up Display

USB memory is not included with DigiPackⅢ. Refer to section 1-1. for recommended USB.
"DIGIPK3.FWM" can download the latest version from the MOOG website

https://www.moog.co.jp/products/controllers-software/blow-molding-controllers/digipack3.html

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1-2-5. BACKUP BATTERY

Since backup of an internal clock is using the ultra capacitor, there is no necessity for exchange.
Backup time is about three weeks.
A time display may be [----.--.-- --:--] when not turning on electricity the time of the power activation after
purchase, and for a long period of time.
In such a case, please set up the right time on F2 screen. (Reference 2-4-3. )

1-2-6. SCREEN DISPLAY PROTECTION (password)

The DigiPackⅢ has two types of screen configurations that the normal operation screen (F1 to F5) and
the setting screen (SHIFT → F1 to F5) for making various settings. Each screen can be distinguished by
the color of the background. The background color of the normal operation screen is light blue " "
The background color of the setting screen is yellow " ". In this controller, the transition to the setting
screen is limited by the password. When entering the setting screen, entering a password enables you to
migrate.

* Once you enter the password, it is not necessary to enter the password until you restart the controller.
Also, if password function is unnecessary, it is possible to invalidate password from SHIFT → F4 screen.
See 1.9.2.1

Password: 6009 (Password is fixed and can not be changed)

Password input

After activating the controller, the password entry screen will be displayed when entering to the setup
screen by first pressing “SHIFT” and then pressed Fx key. Once you enter 4-digit password, you will be
able to switch to the setup screen without entering again the password. This will be retained until you
restart DigiPackⅢ.

In addition, this password can be enabled / disabled on the machine setting screen (SHIFT→ F4) . Refer
to Section 1.9.2.1 Machine Settings for details.

This level change does not indicate any notice on display. Please check the level is correctly
changes or not by press SHIFT→F1, if the level “Low” should not goes to setup display

1-2-7. DATA TRANSFER FROM DigiPackⅡ

The saving data of DigiPackⅡcan be transferred to DigiPackⅢ due to following process.
With the DIgiPackⅡsave the parameters file to SD Card and copy it to USB by using PC. Then, load

parameter file from USB to DigiPackⅢ. (Refer to 2-4-4. for save/load description)
NOTE: New parameter like PURGE/TOOLING is not include.

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1-3. DigiPackⅢ SPECIFICATION

Model Number:

J141-215 DigiPackⅢ.

Function:

Max 200 points Single head blow molding Parison programmer

Application:

Accumulator Based or Continuous Extrusion Blow Molding Machines
can be selected.

Profile Points:

10 to 200，Custom points. And Straight or Spline interpolation can be
selected.

Tooling Type:

Divergent or convergent die gap tooling types can be selected.

Tooling Position Control:

Digital closed loop servo system with a 1m sec update time.

Tooling Position Monitor:

From Tooling Position Actuator’s DCDT  10 VDC.

Accumulator Position Monitor:

From Accumulator Potentiometer 0 to 10 VDC FS.

Programming Inputs:

By Rotaly knob and touch panel switches.

Display:

Color Display (LCD). 10.1 inch(WXGA) touch screen.
English/Japanese/Chinese language selected by Parameter at Setup

screen.

Memory:

100 program profile patterns can be stored in a Flash RAM. And can
be stored in USB memory.

※ Supports standard USB memory, up to 32G. (Refer to 1-1. )
※ Data format: FAT32

Point Marker:

A marker output signal can be set maximum 10 program point.

Other Functions:

Shot Size, Delay, Cushion (for accumulator machines only), die gap,
data saving, profile curve adjustment (Weight and Range H/L), adjust­ment of the tooling actuator stroke and the accumulator position trans­ducer, backup for the system timer(by capacitor).

Output to Servovalve:

MFB type: ± 10, 20, 50, 100 mA or EFB type: ± 10 VDC

Servovalve Monitor:

± 100% Spool Stroke equals 4-20mA

I/O for Accumulator:

0 to 10 VDC transducer output and 10 V DC transducer excitation.

I/O for Tooling Position:

± 10 VDC DCDT output and ± 10 V DC DCDT excitation.

Common External Input:

Photo Coupler Isolated
Customer Supplied 15 to 24 Vdc @ 10 mA /Channel

24 VDC External Outputs:

Photo MOS Relay
Customer Supplied 15 to 24 Vdc @
100mA /Channel Max.
Accumulator type: End of Extrusion/Filling Relay Contacts:
250Vac @ 1 A/channel MAX.

Communication:

Data transfer with host computer by RS422 and Ethernet

Power Requirements:

24 VDC 0.5A min (MAX 3.0A depend on Servovalve Power required)
No ripple requirement : Max +-10 %

Temperature/Humidity:

0 to 45ºC within 85% relative humidity

IP rating

Front side = IP20, Rear side = IP30

Dimensions:

288 (W) x 240 (H) x 55 (D) mm (not include terminal)

Weight:

3.6 kg

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1-4. CHECK LIST

*The instructions in this section are general installation procedures.

1-4-1. INSTALLATION CHECK LIST

Order parts for installation
Identify component mounting locations and procure the necessary mounting brackets
Install the DigiPackⅢ unit in the blow molding machine or optional enclosure
Mount tooling servoactuator to machine
or Mount servovalve manifold and
or Mount DCDT to tooling actuator
Mount servo actuator pressure filter
Install hydraulic power supply
Install main system filter
Make hydraulic pressure and return connections and flush the hydraulic system,
Mount accumulator position transducer, if required
Install conduit and pull cables for the tooling servoactuator, transducers, filter differential pressure switch

and interface between the DigiPackⅢ control panel and the machine PLC
Check the wiring
Calibrate transducers
Set up the control loop
Connect the actuator to the die gap tooling and adjust the die gap end points.

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Figure 1-5 Die Gap Tooling Actuator Installa-

tion

Figure 1-6 Die Gap Tooling Actuator

Filter

Servovalve

DCDT

Tooling Actuator

1-5. MECHANICAL INSTALLATION

*The instructions in this section are general installation procedures.

1-5-1. GENERAL

Mounting provisions for the tooling servoactuator
should include a stable mounting platform for the
tooling actuator, a filter location which allows the filter
element to be readily replaced and mechanical pro­visions allowing simple adjustment of the mechanical
relationship between the actuator and the die gap.
Figure 1-5 shows such as a well planned installation.

A tooling servoactuator provides a long lived solution
to the problems caused by high temperatures and
force levels. Low friction seals and strong bearings
insure long term and good tooling die gap positioning
performance. A built in position transducer provides
mechanical isolation from shocks and climbing feet.
A directly manifold servovalve is tightly coupled to the
actuator. Figure 1-6 illustrates a packaged tooling ac­tuator with provisions for pre-blow air.

Figure 1-5 shows a typical tooling actuator installa­tion. A servovalve (upper right) is directly mounted on
a manifold, which in turn is attached to a tooling ac­tuator. Directly below is a DCDT position transducer
measuring the actuator rod and die gap tooling mo­tion. In addition, a high pressure filter mounted di­rectly on the manifold provides clean oil to the servo­valve. Tooling adjustment provisions are also shown.

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Figure 1-8 Tooling Adjustment Mechanism

Die Gap

Adjust-

ment

Lock

Figure 1-7 Actuator – Die Gap Tooling Mechanical Adjustment

1-5-2. TOOLING ADJUSTMENT

When a mold change is made, it is often necessary to
change the die gap tooling assembly. Therefore the actu­ator installation must provide for simple adjustment of the
die gap tooling position relative to the actuator position.
Figure 1-7 shows two possible methods of adjusting the
positional relationship between the tooling actuator and
the die gap tooling’s closed position. Tooling motion stops
may be required to limit the forces on the die gap tooling
when the die and mandrel touch. Figure 1-8 is a typical
installation.

Some actuators with an anti-rotation fea­ture require the nut torque loads on the
anti-rotation device to be limited by ab­sorbing the tightening torque with a
wrench on the actuator rod flats

Tooling stops are required to insure a die gap that cannot close on a continuous molding machine. An
inadvertent closure of the die gap could cause very high pressures in the extruder barrel and extrusion
head and result in their damage and/or failure.

The above comments must be considered for the proper installation of either a Moog supplied die gap
tooling actuator or a customer supplied actuator.

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Core control Actuator (example: J085-139)

Servo Valve(G631-3004B)

DCDT Sensor

The actuator rod extends when the cur­rents of the servo valve pins A, C are pos­itive with respect to the currents of the pins
B, D

Pin A

Pin B
Pin C
Pin D
Pin E

+10V

-10V

+OUT

-OUT
N/A

Pin C becomes positive with respect to pin D
when retracting the actuator

Connector compatible with
MS3106-14S-5S

Servovalve

DCDT Toolong Posi­tion Transducer

Tooling Acutuator

The extruder barrel and/or screw can be severely damaged if the die gap closes when the
extruder is running. A mechanical motion stop must be installed which will not allow the die gap
to close.

1-5-3. MOOG DIE GAP TOOLING ACTUATORS

The Die Gap Tooling Actuator is designed specifically to control the die gap motion in blow molding extru­sion heads. Their design specification includes: Low friction, Long life piston and rod seals. Graphite flake
cast iron rod bearings to absorb potential side loads and high temperatures. Provision for blow air through
the piston rod, and pre adjusted position feedback transducer.

The mounting provisions for a die gap tooling actuator must include: a strong mounting structure, provi­sions for axial and parallel alignment of the tooling actuation rod (mandrel) with the die gap actuators rod,

provisions to allow the actuator stroke center and the tooling’s effective stroke center to coincide, tooling

motion stops to protect the tooling and/or extruder. Figure 1-6 illustrates a packaged tooling actuator.

1-5-4. CYLINDER INSTALLATION

Figure 1-9 shows an installation example of Moog's die gap core control actuator.

Figure 1-9 Typical Cylinder Installation

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Figure 1-10 G631-XXX Servo-

1-5-5. CUSTOMER SUPPLIED CYLINDER REQUIREMENTS

The customer supplied cylinder is required to control the die gap motion in blow molding extrusion heads.
As such their purchase specification must include: Low friction, long life piston and rod seals; Robust rod
bearings capable of absorbing large potential side loads and high temperatures. A quality cylinder must
be purchased to meet these requirements.

The mounting provisions for the tooling actuator shall include: a strong mounting structure, provisions for
axial and parallel alignment of the tooling actuation rod (mandrel) with the die gap actuators rod, provisions

to allow the actuator stroke center and the tooling’s effective stroke center to coincide, tooling motion stops

to protect the tooling and/or extruder.

Some actuators with an anti-rotation feature require the nut torque loads on the anti-rotation
device to be limited by absorbing the tightening torque with a wrench on the actuator rod flats.

1.5.5.1. MANIFOLD

The manifold must be mounted using as close as possible to the cylinder. Ideal methods are to mount the
manifold directly on the cylinder, sealing the ports with “O” rings or to use tubing between the cylinder and
manifold.

The pressure and return connections should be straight thread fittings using an “O” ring as a seal. Tapered

thread fittings are not encouraged as they tend to leak and when they are torqued up to stop the leak, the
servovalve mounting surface is distorted, causing leakage at the servovalve-manifold seal. Straight thread
fittings using “O” rings do not leak or cause mounting surface distortion.

Should tapered thread fittings be used, ONLY Teflon tape can be used on the tapered threads as a sealant.
The Teflon tape must not cover the last two threads at the smaller diameter portion of the thread. Any other
material will cause eventual contamination problems.

Figure 1-7 shows two possible methods of adjusting the positional relationship between the tooling actu­ator and the tooling die gap closed position. Tooling motion stops may be required to limit the forces on
the die gap tooling when the die and mandrel touch. “Figure 1-9” is a typical installation.

Tooling motion stops may also be required to insure a die gap opening on a continuous molding machine.
An inadvertent closure of the die gap could cause very high pressures in the extruder barrel and extrusion
head and result in their damage and/or failure. The above comments must be considered for the proper
installation of either a Moog supplied die gap tooling actuator or a customer supplied actuator.

1.5.5.2. SERVOVALE MOUNTING

The servovalve is mounted to a manifold with four mounting

screws and using four “O” rings to seal the Pressure, Return

(Tank), and the two Cylinder hydraulic connections.
The “O” ring seal between the servovalve and manifold depends

upon the servovalve mounting manifold surface flatness to insure
that there are no oil leaks. This surface must be flat within

0.025mm and have a √32 RMS finish.
Two servovalves mounting patterns are available: a Cetop 5, NG

10 or a Ø22,2mm, Moog 76 port circle.

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LWH

300

500

750

900

Electrical Data

Rated Stroke

mm

300

500

750

900

Nominal Resistance

Kohm

5 5 10

10

Independent Linearity

%

0.07

0.05

0.05

0.05

Mechanical Data

mm

Mechanical Stroke

B

312

515

769

922

Body Length

A

375

579

833

985

Mounting Feet Spacing

X

280.5

484.5

738.5

890.5

1-5-6. TOOLING ADJUSTMENT

When a mold change is made, it is often necessary to change the die gap tooling assembly. Therefore the
actuator installation must provide for simple adjustment of the die gap tooling position relative to the actu­ator position.

The extruder barrel and/or screw can be severely damaged if the tooling die gap closes when
the extruder is running. A mechanical motion stop must be installed which will not allow the die
gap to close.

1-5-7. ACCUMULATOR POSITION MEASUREMENT

If the DigiPackⅢ is being installed on a continuous extrusion machine please go to the next section.
Accumulator type blow molding machines require a position transducer to indicate the accumulator posi-

tion. The parison wall thickness pattern can then be programmed with direct reference to the accumulator
stroke of Shot Size.

1.5.7.1. INSTALLATION REQUIREMENTS

The position transducer is required to operate in a high temperature and vibration environment. In addition
the transducer must accommodate some mechanical miss-alignment without reduction of life and linearity.

The part of position sensor allows adjustment for interlocking the movable part of the potentiometer with
the moving of the accumulator. and also has the following functions:

1) An accumulator driven bearing guided structure for the potentiometer drive arm

2) Mounting provisions for the potentiometer on the same bearing guided structure, provisions for
adjustment to insure parallel motion of the potentiometer guide arm and potentiometer drive rod

3) And a rod end bearing between the potentiometer drive rod and the potentiometer guide arm

Figure 1-11 Typical Linear Potentiometer Figure 1-12 LWHxxx Potentiometer Installation

Installation Information

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1-5-8. THE IMPORTANCE OF FILTRATION

Figure 1-13 High Pressure Fil-

ter

Adequate contamination control in any hydraulic system is the key to a
highly reliable system. Proper filter placement and selection insures
long term trouble free operation of every hydraulic system component.
There are three essentials:

1) a high pressure filter mounted directly at the tooling actu­ator

2) a re-circulating circuit providing continuous filtration and
heat removal

3) proper control of the tank breathing and filling operations
to prevent the ingression of contaminant

High pressure filter (β15»75, 15µ absolute) mounted directly with tubing
at the tooling actuator provides protection against particles created by
component failures.

The main contamination protection is provided by oil taken from one
corner of the tank, flowing through the low pressure re-circulating filter
back to the opposite corner of the tank. The re-circulation filter is a low
pressure filter (β3»75, 3µ absolute) with an inexpensive replacement
filter element. The re-circulation also incorporates a heat exchanger to
maintain low oil temperature and insure adequate oil life.

Protection against ingression of contaminant during oil make up and normal breathing is provided with
breather rated at 10µ.

Currently, MOOG does not sell filters. Please purchase directly from the filter manufacturer.

1-5-9. FILTER INSTALLATION

High pressure filter or equivalent, β15>75 rated, high pressure filter must be mounted as close as possible
(50mm to 300mm) to the actuator or servovalve manifold. The location of the filter must allow an easy
access to make a replacement of filter element easy and safety.

Filter Installation Information

The hydraulic connection between the filter and actuator must be tubing. Under no circumstances can
hydraulic hose be used as the hose is a contaminant generator and this contaminant will go directly into
the servovalve, eventually causing contamination problems.

The hydraulic connections used will be a straight thread “O” ring sealed boss into the servoactuator and
high pressure filter with either flared or compression fittings used to connect the tubing to the straight
thread fittings.

The use of tapered thread fittings with pipe dope will cause both contamination and leakage problems.
Teflon tape may be used, but only if applied in such a manner as to keep the edge of the Teflon tape at
least two threads away from the end of the fitting.

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1-5-10. HYDRAULIC POWER SUPPLY

Figure 1-14 Hydraulic Power Supply

The Hydraulic Power Supply provides clean oil to the die gap
tooling actuator at a constant supply pressure. An accumulator
provides the peak flows that may be required. A water heat
exchanger ensures reasonable oil temperatures.

The Hydraulic Power Supply is normally used on first installa­tions when the cleanliness condition of the blow molding ma­chine’s hydraulic power supply is unknown or suspect.

A separate hydraulic power supply provides a reliable source
of clean oil for trouble free long term operation. A bypass filter
allows the oil to be continually cleaned and cooled.

The hydraulic power supply pressure output should be con­nected directly to the input port of the high pressure filter at
the die gap tooling actuator or the servovalve manifold. The
actuator or manifold return line goes to the hydraulic power
supply return port.

1-5-11. HYDRAULIC POWER SUPPLY START UP INSTRUCTIONS

1) Check for any damage to the hydraulic power supply and its parts.

2) Fill the tank through the breather filter with Shell/Tellus 68 or equivalent fluid.

3) Check the nitrogen gas pressure in the accumulator bladder. The pressure should be 35 bar or 66%
of the maximum system pressure, whichever is higher. Add nitrogen, if necessary.

4) Replace the filter elements with flushing elements. Store the original filter elements in a clean, very
clean plastic bag.

5) Connect the pressure and return lines to and from the tooling actuator assembly

6) Check the motor name plate for the correct line voltages and connect the motor to power. Start the
motor and check that it rotates in the proper direction.

7) Connect cooling water to the heat exchanger. The required water flow rate is 30 1/min at 2-3 bar.

8) Run the hydraulic power supply for at least 6 hours. Vary the flow rate and pressure to thoroughly
flush all chips and dirt into the filters. Monitor for leaks and repair.

9) Replace the flushing filter elements with the elements removed in step 4.

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1-5-12. CONTAMINATION CONTROL

Figure 1-15 Flow Pressure Filter

Long term trouble free operation with a minimum of unplanned
down time and adequate oil contamination control are linked very
closely. It is very important to maintain adequate oil cleanliness.
The addition of a system contamination control filter will control
oil contamination levels at minimum expense.

The filter should be located such that the flow through the filter is
relatively constant and at a low pressure. The junction of the re­turn lines from the tooling actuator and the system relief valve is
a suitable location.

Currently, MOOG does not sell filters. Please purchase
directly from the filter manufacturer.

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Lock lever
Please lock securely

when fixing the con­nector.

TB-3：Power connector
(Screw diameter 3.0 mm,

tightening torque 0.6 Nm)

Reference wiring
diagram

Ethernet Plug

TB-1：Base connector

Connector removal status
(Screw diameter 3.5 mm,

tightening torque 1.0 Nm)

Release

Lock

TB-2 ： Connector
installation state

Desorption

1-6. ELECTRICAL INSTALLATION

1-6-1. GENERAL

Electrical installation includes several phases of work:

A) mounting the DigiPackⅢ in a suitable location
B) determining the correct phasing so the servovalve, tooling position transducer and, possibly,

accumulator position transducer may be connected to the DigiPackⅢ

C) determining the blow molding machine interface interaction with the DigiPackⅡand then

wiring the machine-DigiPackⅢ interface

D) connect the DigiPackⅢ to electrical power supply from the stable 24VDC

DigiPackⅢ MOUNTING

The DigiPackⅢ must be mounted in a location free of vibration, with protection from the environment and
most important, located in a position allowing the operator and setup man easy visual and physical access.
It is recommended that the mounting be on a swing out panel allowing easy access to the front and back
sides of the DigiPack3.

Mounting information is shown in “Figure 1-17”. Brackets providing simple panel mounting are included.

All wiring from the DigiPackⅢ must be shielded. The shield is to be grounded to the DigiPackⅢ
ground at the DigiPackⅢ only Any other ground paths may cause damage.

1-6-2. REAR CONNECTOR

The rear connector of DigiPackⅢ can be detached. When installing the connector, secure with the lock
lever. See Figure 1-16.

Figure 1-16 REAR CONNECTOR