Instruction Manual Automatic Injection Moulding Machine

Transcription

1 Englisch Instruction Manual Automatic Injection Moulding Machine BOY 22AVV-VH 22A VH 22A VV Dr. Boy GmbH & Co. KG Spritzgiessautomaten Neschener Straße 6 D Neustadt / Fernthal Telefon: / 3070 Telefax: / Mach.-No. Year of manufacture / 2002 We reserve the right to make technical modifications without prior notification 03 / AV

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3 Note: Read the operating instructions before taking the injection moulding machine into service and observe them. They should always be available within easy reach of the machine. + Pay particular attention to information enclosed in boxes. They contain information on operating the injection moulding machine and are often important to personal safety. Copyright, industrial property rights: We reserve all rights to this documentation. It must not be duplicated or made available to third parties without our consent. Important Note: The safety technology incorporated in the design and engineering of this injection moulding machine complies with the criteria specified in European Standard EN 201. Should this machine be resold and relocated into an area outside of Europe, the safety codes applicable to the new location of use must be observed. Responsibility for compliance with the latter standards no longer lies with the manufacturer. The machine's electrical equipment conforms with European Standard EN This symbol indicates that the manufacturer has been awarded a test certificate, issued by the accident prevention and occupational safety laboratory of the workmen s disability compensation insurance society. This certifies that the machine satisfies currently applicable requirements with regards to safety technology in the Federal Republic of Germany and thus complies with the Industrial Equipment statutes (Equipment Safety Act). This symbol indicates that the machine complies with regulations specified in the manufacturer s declaration. 01 / M / A M / A MV / AV D M/A/A-2C D M / A M / A

4 + The machine must only be connected to an electrical circuit which corresponds to current type, voltage and frequency as specified on the rating plate. The local regulations for grounding phasing and protection circuits must be observed when connecting. To maintain operating safety, changes to electrical, electronic or hydraulic components must only be made by authorized Boy service personnel. Compliance with application This injection moulding machine has been engineered to process standard thermoplastic materials (see Chapter 4) as well as PVC, elastomere, thermoset plastics and liquid silicones. The moulds used must be correct for machine operation for processing of these plastics. The manufacturer can accept no liability in case of the use of other materials or moulds which, as a result of their type or design, cause wear or damage to the machine or safety equipment; the manufacturer accepts no liability for consequential damage. This machine shall not be used for other applications of whatever nature, as this could lead to irreparable machine damage or to personal injury. Location of operation: Ensure adequate lighting and ventilation at the machine location during operation of the machine. The temperature range at the machine location should be between 10 and 45 C and air humidity should not exceed 70 %. Operating staff qualification Staff should have experience in the field of plastics processing; handling and use of plastics and injection molding machines must not cause danger to the operator. The operator should previously have received instruction on the machine to be operated from an authorized person. The safety instructions in this documentation should be known to the operator M / A M / A MV / AV D M/A/A-2C D M / A M / A 01 / 2002

5 Ban on employment of young people Employment of young people is only permitted if they are over the age of 16 and working under the supervision of a qualified expert, provided that such employment is necessary for the purposes of vocational training (in accordance with Section 5, Para. 1, VBG 7ac = regulations of the employers liability insurance associations, in Germany). The applicable national regulations must be observed in other countries. Supplementary equipment: A hazard assessment 1) must be undertaken in order to establish whether the conversion or attachment could result in additional risks (the machine s owner must discharge the duties of the manufacturer in this case). All resultant hazard areas in the supplementary equipment and injection moulding machine must be covered or enclosed within a locked fence. The standard of such protective mechanisms must not diminish the specified safety standard of the injection moulding machine with regard to the defined hazard areas and the protective measures required in this context (refer also to Section 5.4.3, DIN EN , edition 1997). Moulds: Only use moulds, the dimensions of which, such as alignment system, nozzles radius and sprue channel accord with the fitting dimensions of the machine (see Section 1.1.2). Additional guards must be fitted if moulds, the dimensions of which project beyond the mould-clamping surfaces of the machine plate, are used1. The safety distances from danger points (the closing mould in this case) relate to the external dimensions of the mould plates; guards which restore assurance of the original safety distances must be fitted if these dimension are exceeded. + Because of continuous technical refinement of our machines, differences between detail machine features and this operating manual may occur. 1) Note the specific national regulations. 2) The protective hood on the Boy 90 is open at the top. 01 / M / A M / A MV / AV D M/A/A-2C D M / A M / A

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7 TABLE OF CONTENTS 1 Description 2 Shipping and installation 3 Operating notes 4 Processing notes 5 Maintenance notes 6 Troubleshooting and repair 7 Hydraulic sequence charts, diagrams and equipment lists 8 Spare part information 9 Auxiliary equipments 10 Appendix You will find a detailed table of contents at the beginning of each chapter. 01 / M / A M / A MV / AV D M/A/A-2C D M / A M / A

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9 1 Description 1.1 Technical data Space requirement Mould clamp and ejector measures Ejector rod dimensions Nozzle dimensions Hopper flange connection dimensions Clamping force diagram Injection pressure diagram Back pressure diagram 1.2 Nozzle and screw arrangements 1.3 Barrel and nozzle heaters Heater controls Temperatures of the heater bands 1.4 Safety devices Safety devices of the clamping unit Electrical safety device Hydraulic safety device Mechanical safety device Safety devices of the injection unit Nozzle guard flap, VH machine Granulate hopper, VV machine Splash guard, VH machine Plasticizing barrels, screws and nozzles Additional safety notes Lower hopper section, VH machine Hoses Hydraulic system Ejector movement with open safety gate General safety notes 1.5 Description of Procan MD (M) Procan CT (A) 12 / MV / AV

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11 1.1 Technical data Machine model International size Clamping unit Clamping force Mould closing force Mould opening force Mould opening stroke, max. Maximum plate distance Minimum plate distance Clear width between tie bars Diameter Ejector force pushing / pulling Ejector stroke 22 M, 22 MV, 22 A, 22 AV, 22 D kn 220 kn 17,6 kn 40 mm 200 mm 400 mm 200 mm 254 mm 40 kn 18,1 / 12,0 mm 80 Injection unit Screw diameter Screw-L/D ratio Flight depth ratio Spec. injection pressure Theor. stroke volume Injection weight with polystyrene Injection capacity Plasticising capacity mm , ,5 12 2,4 2,18 2,00 2,05 2,25 2,20 bar ccm g g/s 25,45 33,35 48,46 57,39 75,82 98,44 g/s 1,0 1,8 3,7 5,4 6,6 7,1 Screw torque Motor Screw speed Motor Nm 50 cm 3 /U cm 3 /U cm 3 /U cm 3 /U U/min 50 cm 3 /U cm 3 /U cm 3 /U cm 3 /U Injection force Screw stroke Screw retraction force Nozzle pressure force Nozzle stroke Heating capacity (1) Hopper capacity kn 65,82 mm 80 kn 22,8 kn 48 mm 180 W 2 x = 3615 (22 M/A/V) = 4065 (22 D) L 13 (1) Standard barrel 11 / M / A MV / AV D 1.1 / 1

12 Technical data Spritzgiessautomaten Safety gate clamping unit (VV/VH) Hose diameter Opening force with 5 bar Closing force with 5 bar mm 4 N 491 N 412 General Number of drycycles (Euromap) Installed driving power Installed total power (1) Hydraulic system pressure High pressure Oil tank capacity 1,58 s mm kw 5,5 kw 9,11 (22 M/A/V) 9,56 (22 D) bar 160 bar 215 L (2) Dimensions and weights Length of machine min. Length of machine max. Width of machine Height of machine Floor area Total weight net (without oil) Total weight gross (without oil) Water manifold (NW hose) Main inlet/outlet Mould and feed-zone cooling system Sound pressure level 22 M/A/D M/A VV M/A VH mm mm mm mm (3) m 2 2,1 1,6 1,6 kg kg R 1/2" R 1/2" db (A) 74,5 (4) (1) Standard barrel (2) VV and VH-Machine (3) with open safety gate (4) DIN / 2 M / A MV / AV D 02 / 2002

13 Ejector rod dimensions When using special ejector rods, adjust them according to the following drawing / 2002 M / A M / A MV / AV M / A M / A M / A / 1

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15 1.1.3 Nozzle dimensions Adaptor bore for nozzles 27 M24 x 1,5 21 ø14 +0,025 ø22 H8 Open nozzle radius 35 mm Open nozzle radius R 1/2" 11 / M / A MV / AV D / 1

16 Nozzle dimensions Spritzgiessautomaten Open nozzle for various nozzle inserts This nozzle is used for individual inserts application, such as copperberyllium tips, or hardened steel nozzle inserts, which are designed and machined by the customer. Plunger nozzle for silicon rubber M 16 x 1,5 ø1,5 ø16 SW19 Ø65 Ø30 Ø95 ø 2 ø 6 R Part No cupper-beryllium steel Open nozzles with screen or different radius can be offered / 2 M / A MV / AV D 11 / 2001

17 1.1.4 Hopper flange connection dimensions For special hoppers, dryers or colour mixing equipment use below flange dimensions of barrel. ê Nozzle Screw diameter Standard Increased wear resist. Ø Y Y Note: To protect against accidents, the hopperbase is fastened with self locking screws. If using other hoppers, the owner of the machine will be responsible, that all safety arrangements are heeded. 11 / M / A MV / AV D / 1

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19 1.1.5 Clamping force diagram Clamping force Clamp pressure System pressure Injection pressure diagram Screw 11 / M / A MV / AV D / 1

20 1.1.7 Back pressure diagram Screw specific back pressure / 1 M / A MV / AV D 11 / 2001

21 1.2 Nozzle and screw arrangements Type: Equipped with radius shut-off nozzle for thermoplastics. suitable for: For all standard thermoplastics, except trigid PVC and FEP, PIFE Processing of glass fiber filled materials possible. However increased wear! The open nozzle is used for high viscous thermoplastics or for materials sensitive to friction heat, also for hot runner moulds in connection with the screw decompression. For hot runner moulds and thermoplastics in connection with decompression. Glass fiber reinforced materials FEP, PIFE The AC nozzle is used for shut off of injection at the mould`s parting line. PS, SB, SAN, ABS, PE, PP, PA, PC, POM only limited The noozle is guided by a centering plate on the mould side and is closed trough the shut off pin. The BC nozzle is used to inject thermoplastics directly without any sprue ê Mould gate nozzle with shut off mechanism PS, SB, SAN, ABS, PE, PP, PC, POM only limited 11 / M / A MV / AV D M / A D 1.2 / 1

22 Nozzle and screw arrangements Spritzgiessautomaten Type: The PVC nozzle is an open nozzle made of corrosion resistant steel. PVC suitable for: Rigid PVC The thermoset nozzle is a modified version of open nozzle Thermoset The rubber nozzle is a modified version of open nozzle Elastomer (Rubber) Hydr. shut off nozzle with cooling connection Liquid silicon rubber / 2 M / A MV / AV D M / A D 11 / 2001

23 1.3 Barrel and nozzle heaters Temperature control zones In the barrel area the temperatures are sensed by bayonet-type plug-in thermocouples. 22 D D The machine is fitted as standard equipment with three temperature control zones. Two (or optionally three) electrical heaters tapes regulated with temperature controllers are used to regulate the temperature of the screw barrel. The nozzle temperature is adjustable by its own temperature controller. Refer to chapter 3.2 for a description of the temperature controllers. M/A M/A/MV/AV/D The nozzle adaptor heater bands works synchronous to its neighbour barrel heater bands. The standard machine assembly consists of four temperature control zones. All heater bands are pluggable their replacement is possible without an electrician. Location of heater zones 22 D Standard equipment with 3 temperature control zones (Mica) (Ceramic) Zone 4 Zone 3 Zone 1 M/A/MV/AV/D Standard equipment with 4 temperature control zones D Zone 4 Zone 3 Zone 2 Zone 1 (Mica) (Mica) (Ceramic) (option) (22 D) Zone 4 Zone 3 Zone 2 Zone 1 M/A/MV/AV 12 / M / A M / A MV / AV D M / A D 1.3 / 1

24 Barrel and nozzle heaters Spritzgiessautomaten Changing the heating strip Before starting the changing operation, switch off the heating and allow the heating strips to cool down. Dismantle the old heating strips after they have cooled down. Assembly of the new heating strips: Pre-assemble nozzles and base heating strip and heat to 200 C. Then tighten again with a torque wrench (5 Nm). Pre-assemble cylinder heating strips, ceramic, and tighten again with a torque wrench (4 Nm) from the central clamping element, item 1, to the outer element, item 2. À Á Pre-assemble cylinder heating strips, mica, and pre-tighten with a torque wrench (8 Nm). Heat to 200 C and then tighten again with a torque wrench (9 Nm) from the central clamping element, item 1, to the outer element, item 2. Mount heat protection jacket with battery-operated screwdriver Heater controls Control panel at the electrical control enclosure Figure 1 shows the control panel at the top of the electrical control enclosure with its operator buttons to switch the heating circuits on and off. D M / A S80E S80 Heating ready for immediate operation Heating OFF / Stand-by ON Figure 1: Control panel at the electrical control enclosure + Caution! After maintenance work (software updates/change in hardware), check the setting of the temperature limiting value on the screen page / 2 M / A M / A MV / AV D M / A D 12 / 2001

25 Barrel and nozzle heaters Heater controls Main control of the plasticizing cylinder and nozzle heating circuits (or for mould heating when processing thermosetting plastics and elastomers) is the switch (S80) with its two positions Heating OFF (0) and Stand-by ON (I) as well as the illuminated push button (S80E), Heating ready for immediate operation. Switching off the heaters To switch off the heaters entirely, set the switch (S80) in its 0 position. In this state all the barrel heating zones are switched off, regardless of the setpoint values of the individual heater control zones and regardless of the preset mode of operation. It is consequently impossible for the heaters to be switched on automatically. Readying the heaters for immediate operation Put the switch (S80) in position I ; press the illuminated push button (S80E). The indicator lamp built into this push button shows that heaters are ready for operation Temperatures of the heater bands Operating temperatures The permitted operating temperatures are: For Mica heater bands 280 C For Ceramic heater bands 450 C 12 / M / A M / A MV / AV D M / A D 1.3 / 3

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27 1.4 Safety devices Safety devices of the clamping unit The safety gate of the clamping unit is a movable, lockable, and seperate protection device (type III according to EN 201) with two independently working interlocking systems. One system is affecting to the electrical circuit and the other the hydraulical circuit. Vertical clamping units require two mutually independent supporting devices. 1. The first supporting device for vertical clamping units comprises a pilotoperated check valve (RVG10). The switching status of the RVG10 is monitored by switch B23. M/A-machines Type M and A machines additionally feature a limit-value monitor for the rate of lowering in the event of a valve fault or cylinder leakage. 2. The second supporting device comprises the mechanical safety mechanism described in section which fulfills two functions: 1. Mould safety mechanism 2. Supporting mechanism This device is monitored by two proximity switches. They monitor the position of the locking element which must engage the toothed rack when the guard door is open. + Important! Since faults and defects in these devices will jeopardize the safety of the operating personnel, the manufacturer s customer service engineer should always be called in to remedy the fault. 08 / MV / AV 1.4 / 1

28 Safety devices Spritzgiessautomaten B22 B Electrical safety devices Limit switches -B20, -B22 With the safety gate open, the limit switch -B22 is actuated and the control circuit of the valves is interrupted by opening the electrical contact. The following valves are blocked in this situation: Y10 ê Y11 ê Y30 ê Y60 ê Y61 ê Y70 ê Y71 ê Y72 ê Y73 ê Mould closing mould opening Clamping force generation Ejector forward 1) Ejector retract 1) Core pull or unscrewing Core pull or unscrewing Core pull Core pull The limit switch -B20 is interupting the control circuit of the valves as well, indicating that the safety gate is open. 1) Y60 and Y61 are activated by "Hydr. ejector with open gate" 1.4 / 2 22 MV / AV 11 / 2001

29 Safety devices Limit switches -B28, -B28.1 In the interest of protecting the operator, the safety cage will open automatically when limit switches -B28 and -B28.1 are activated by the contact strip. Safety plug-in device -B27 The safety cage keeps personnel from reaching into the mould space and can be removed after separating the polarized safety connector, -B27. Locked function: pump Safety cage on type VH machines B27 Limit switches and safety cage on type VV machines B28 B28.1 Contact strip B27 11 / MV / AV 1.4 / 3

30 Safety devices Spritzgiessautomaten Hydraulic safety device The opened safety gate actuates valve 1SH7, which indirectly through valve LG26 blocks the oil supply to the hydraulic clamp circuit. Locked functions: closing and opening movement core pulls unscrewing devices Roller lever valve 1SH7 -B25 Manifold LG26 -B26 The position of the valves is signalled to control by pressure monitoring switches -B25 and -B26 which also indicate mechanical defects. In case of failure the drive motor -M01 is switched off. 1.4 / 4 22 MV / AV 11 / 2001

31 Safety devices Non-return check valve RVG10 The check valve RVG10 serves as a hydraulic support for the moving platen. Guide cylinders of the clamping unit A Y B X B23 RVG10 The locked position of the non-return check valve RVG10 is monitored via monitoring switch B23 when the guard door is open. The pump cuts out immediately if switch B23 is not tripped. The machine can only be restarted via the master switch (OFF/ON). MV / AV Drop monitor for the clamping unit The machine must run through at least one cycle in order to activate the monitor. When the machine is in the open position in semi-automatic or allautomatic mode, the pump cuts out immediately if the clamping unit (guard door open) drops by more than 5 mm/min. Error message: The message Hydraulic mould safety mechanism appears on the screen if the rate of lowering exceeds the above limit value. If the drop monitor is tripped: Correct functioning of the RVG10 must be checked immediately (see chapter 5.1) and the valve replaced if necessary. The seals of the two plunger cylinders connected to port "B" of the RVG10 must be examined for leaks. The machine can only be restarted via the master switch (OFF/ON). + Important: Before starting any repair work on the RVG10, the moving platen must be advanced to the position Mould closed or suitable spacers must be present when in the position Mould open in order to prevent the moving platen dropping slowly. 11 / MV / AV 1.4 / 5

32 Safety devices Spritzgiessautomaten Mechanical safety device When the safety gate is open, a compression spring causes a locking pawl to engage with a toothed rack attached to the moving mould platen, thus preventing any unintended movements. The position of the locking pawl and the compressing spring is checked by a proximity switch. Rack proximity switch Locking pawl In the case of a malfunction of the stopper: Locked function: pump M and A machines signalling alarm + Important! Before putting the machine into service, check the mechanical safety device. 1.4 / 6 22 MV / AV 11 / 2001

33 Safety devices Safety devices of the injection unit Nozzle guard flap, VH machine The nozzle flap protects against spurting molten plastic and danger of pinching caused by the forward movement of the nozzle. With nozzle flap open (switch -B42) the following functions are inhibited: nozzle advance injection plasticising Closing of the nozzle flap does not restart these movements automatically but a reset in manual mode is required for safety reasons. B Granulate hopper, VV machine B24.1 The feed tube at the granulate hopper can be removed only after separating the polarized safety connector -B24.1. Locked function: pump 11 / MV / AV 1.4 / 7

34 ê Safety devices Spritzgiessautomaten Splash guard, VH machine The purpose of the splash guard option is to protect the operator against burns caused by moulding compound escaping at the nozzle. When the nozzle is moved away from the mould, a pneumatic cylinder pushes the protective plate in front of the nozzle and thus excludes any hazard. The protective door and the mould cannot be opened until the protective plate is covering the nozzle. Refer to Chapter for a description of functions and the function diagram. Splash guard at the VH machine Pneumatic cylinder Guard plate + ATTENTION! With liquid silicone rubber processing units installed the splash guard can be removed. It must however, be reinstalled for the operation of thermoplast processing units. 1.4 / 8 22 MV / AV 11 / 2001

35 Safety devices Plasticizing barrels, screws and nozzles The following must always be observed when working on the plasticizing unit: An unintended discharge through the nozzle may occur due to of insufficient cooling (solidification) or decomposition of certain plastic compounds. To eliminate hazard potential, wear suitable protective clothing, goggles and gloves. In all cases only the nozzles, barrels, screws, backflow valves and mounting screws specified by the manufacturer are to be used. Temperatures at the barrel heaters: ê ê Units with mica insulation max. 280 C Units with ceramic insulation max. 450 C + Note: The controls monitor for temperature sensor failure, short circuit and unacceptably high temperatures; the entire heating system will be shut down if such a fault is detected. Some plastic compounds may, during processing, release gases, vapors or dusts which are hazardous to health and will require extraction units for their removal. The owner is responsible for providing such equipment. Extractors can be mounted on the fixed platen,see drawing of platen and ejector dimensions in Capter The holes are marked there as "Mounting holes for handling equipment". Please consult the manufacturer if a different mounting is required. The data sheets provided by the plastic manufacturers will indicate which plastics generate hazardous gases during processing. Only plastics, elastomers, silicones (liquid), thermoset plastics or PVC are to be processed. No other compounds are approved for use; they may result in damage to the machine. 11 / MV / AV 1.4 / 9

36 Safety devices Spritzgiessautomaten Additional safety notes Lower hopper section The lower hopper section is affixed with bolts which cannot be loosened with conventional tools; to prevent insuries to fingers by the rotating screw Hoses Hoses are to be inspected yearly and replaced if there are signs of damage or if the service life expiration date has been exceeded (see Section 5.12) Hydraulic system Contact with hydraulic fluid can cause skin irritation and other health problems. Avoid extended contact with the skin and otherwise wear suitable plastic gloves. Wash affected areas thoroughly following contact with the skin; flush copiously with water in case of contact with the eyes. Disposal The disposal of hydraulic fluids is regulated by law. Take spent fluids to an authorized collection or disposal point. Machinery components particulary those containing oil or hydraulic fluids must be disposed of in accordance with the local legal regulations. Hazardous fluid management or industrial disposal services can provide detailed information. 1.4 / MV / AV 11 / 2001

37 Safety devices Ejector movement with open safety gate If ejector movement is required with open safety gate the operator has to ensure that all apertures in the mould area are to be covered with appropriate safety devices in order to prevent undue manipulation. X Mould aperture (Danger zone) Ejector platen 11 / MV / AV 1.4 / 11

38 Safety devices Spritzgiessautomaten General safety notes All safety equipment and systems should be checked for correct functioning at regular intervals. The machine must be stopped immediately and the responsible operator informed if any defects or deficiencies are ascertained. Repair work must be performed, followed by re-checking of the safety equipment and systems. Any safety devices removed for set-up, maintenance or repair purposes must be refitted and checked immediately upon completion of the maintenance and repair work. Do not remove safety signs from machine. Replacement signs are available from the factory. Mounting screws for the microswitches of safety equipment (e.g.covers, guards) are sealed with seal wax; this seal may not be damaged nor may the switches be tampered with. Following repairs the switches must be checked for proper functioning (see Chapter 5.1) and the seal must then be restored. if optional features are being removed the originally provided safety features must be reinstalled. The machine must be restored to a safe condition. Never use water for fire-fighting on or around these machines - use only foam or extinguishing powder. Notes on safety to avoid damage to the mould! It is recommended in general to move the mould safety area at a speed of about 5%. 1.4 / MV / AV 02 / 2002

39 Procan CT V General description The Procan CT has a touch-sensitive colour display on which input fields can be selected directly by touching them. Numerical values are entered via a keypad on a console below the monitor. Every input must be confirmed by pressing ENTER. A KEYCARD must be inserted in order to enter setpoints. Other screens are selected by touching the icon displayed on the monitor. Selections are made by tapping the required selection field. When the field is tapped again, a list of possible functions pops up and the required function is once again selected by tapping the corresponding item. The selection must be confirmed by pressing ENTER. The screens in the Procan CT control system are largely self-explanatory on account of their texts. The following description is intended to provide the operator with an overview of the various areas of the control system and explain the basic philosophy underyling its operation. Operating areas There are three operating areas. a) Monitor (2.) The pivotable monitor is mounted on the fixed platen in the machine with ergono mically arranged keys on the right and left of the display for controlling individual machine movements, as well as a keypad for operation of the monitor. The monitor can be pivoted more than 90 about its vertical axis, thus allowing both the operator working on the machine and other supervisory personnel on an automatic production line to position the monitor exactly as they require. It can also be swivelled horizontally to adjust the position of the monitor in line with the operator s height. Dazzling reflections are eliminated by swivelling the monitor out of range of the interfering light source. b) Control panel (3.) The control panel on the top of the control cabinet (by 55/90 in the center console) includes the general switches for drive motor and heating, as well as the operating hours counter and Emergency OFF switch. c) A 3 ½ floppy disk drive is located on the front of the control cabinet (by 55/90 at the left-hand side). It is protected against dust and splashwater by a sliding cover and mounted on shock absorbers. The 25-pin socket for connecting a printer with parallel port is located on the outer left-hand panel of the control cabinet. The 9-pin socket on the outer left-hand panel of the control cabinet is used to connect peripheral devices with serial port (RS232). 02 / A A AV A A A 1.5 / 1

40 2. Monitor Spritzgiessautomaten Á À Â C M A H C F Ä Ã Figure 1: The monitor and its main parts (1) Touch-sensitive colour display (2) Computer indicators and movement keys for controlling the clamping unit (3) Mode selector, movement keys and indicators for controlling the injection unit (4) Slot for (K E Y C A R D) (5) Function keys, numerical keypad and screen selection keys 1.5 / A A AV A A A 02 / 2002

41 2.1 Touch-sensitive colour display À The following information can always be viewed at the top of the monitor, regardless of the screen momentarily selected: Information bar Date Setup value Cycle time Oil temperature Time Actual value Previous cycle time Name of data record Oil pressure Input screen Direct selection buttons À Á Â Ã Ä Å Æ Ç È É Figure 2: À Æ Ç È É Touch-sensitive colour display Direct selection buttons for selecting screen pages (the choices vary, depending on the screen page concerned) Screen selection via its number (only in main menu) Scroll back through the last 16 screen pages used Scroll forwards through the last 16 screen pages used The corresponding screens can be selected directly from any position via keys 11 15, since they appear on every screen Screen 8310 Change time / date Screen 7100 Setup value Screen 6200 Cycle time Screen 6100 Data record Screen 8320 Oil preheating Indication of the minimum KEYCARD required for input or selection of the field concerned The screen is saved as a PCX file when this field is pressed. Title of screen (help) 02 / A A AV A A A 1.5 / 3

42 2.2 Computer indicators and movement keys for the clamping unit Á The keys to the left and right of the display are used to operate the machine functions. The computer indicators form a group without associated buttons. Activation of the directional control valve responsible for a particular movement is indicated by the yellow indicator in the button. The indicators to the left of the buttons show that the corresponding limit position has been reached Computer indicators H8R1 Computer power indicator (flashes during the ramp-up phase). The LED does notlight up during normal operation. Failure of the process computer (RPS) can be indicated by the IPC computer: the LED lights up. Failure of the IPC computer cannot be indicated. H01G Speed, pump 1 H02G Speed, pump 2 (if installed) H01D Pressure, pump Movement keys Movement keys, cores / screwing: When one of the keys is pressed in manual and setup modes, the core / screwing movement continues in the corresponding direction until the key is released. In manual mode, the core can only be moved when the clamping unit is correctly positioned. Key: Insert cores / unscrewing with Indicator, directional control valves Y71/Y73 Indicator B71 limit position, core / screwing A inserted Indicator B73 limit position, core B inserted Key: Retract cores / screwing with Indicator, directional control valves Y70/Y72 Indicator B70 limit position, core / screwing A retracted Indicator B72 limit position, core B retracted 1.5 / A A AV A A A 02 / 2002

43 Movement keys, ejector: When one of the keys is pressed in manual and setup modes, the ejector continues to move in the corresponding direction until the key is released. In manual mode, the mould must be open before the ejector can advance. Key: Retract ejector with Indicator, directional control valve Y61 Indicator, ejector rear limit position Key: Advance ejector with Indicator, directional control valve Y60 Indicator, ejector front limit position Movement keys, clamping unit: When one of the keys is pressed in manual and setup modes, the clamping unit continues to move in the corresponding direction until the key is released. In manual mode, the ejector must be fully retracted for the movement Close clamping unit. Key: Open clamping unit with Indicator, directional control valve Y11 Indicator, limit position, mould open Key: Close clamping unit with Indicator, directional control valve Y10 Indicator, limit position, mould closed Key: Start The cycle is started when this key is pressed, provided that automatic or semiautomatic operation has been selected and all starting conditions have been met. 02 / A A AV A A A 1.5 / 5

44 2.3 Mode selectors and movement keys for the injection unit  The momentarily selected operating mode is indicated by the yellow LED in the mode selector. Activation of the directional control valve responsible for a particular movement is indicated in the keys for the individual movements. The indicators to the right of the keys show whether the corresponding limit position has been reached Mode selectors Mode selector STOP with STOP indicator When this key is pressed, the machine immediately switches all valves off and the pump is brought to a halt. In other words, even in automatic mode, the machine immediately stops regardless of the point reached in the cycle and even during the injection phase if necessary. No traverse movements whatsoever can be executed when the STOP key has been pressed. Mode selector Manual with Manual indicator When this key is pressed, the machine immediately switches all valves off and the pump is brought to a halt. In other words, even in automatic mode, the machine immediately stops regardless of the point reached in the cycle and even during the injection phase if necessary. All traverse movements can be executed via the machine operating keys when the Manual key has been pressed. However, the corresponding machine operating key must continue to be pressed until the movement is complete. The movement will stop immediately if the machine operating key is released earlier (jog mode). Setup + The machine switches to setup mode if the Manual key is pressed until the corresponding LED flashes (approx. 2 seconds). All machine movements are executed at low speed and with low pressure in setup mode. All profile settings and all limit positions are ignored. Setup mode can only be activated when Keycard 2 or 3 is inserted. Movements can only be executed in setup mode if the Manual mode button is pressed simultaneously. STOP mode is immediately activated as soon as the button is released. IMPORTANT: All interlocks are cancelled. Core pulls, for example, can be operated regardless of the mould position. Responsibility for all movements rests exclusively with the operator. Mode selector Semi-automatic with Semi-automatic indicator Semi-automatic operation is prepared when this key is pressed. A complete cycle is executed when the Start key is pressed, provided that all starting conditions have been met. At the end of the cycle, the machine waits for the Start key to be pressed again. Semiautomatic mode is used to remove a part by hand or to insert a part that is to be integrally moulded. If the Semi-automatic button is pressed during automatic operation, the machine will stop at the end of the complete cycle and then switch over to Stop mode. 1.5 / A A AV A A A 02 / 2002

45 Starting conditions: Mould open in limit position Ejector retracted in rear limit position Core pulls in correct position (if selected) Cylinder temperature reached Injection plunger in position for end of plasticizing Handling or brush in home position (if installed) Mode selector All-automatic with All-automatic indicator Automatic operation is prepared when this key is pressed. The cycle starts when the Start key is pressed, provided that all starting conditions have been met. The cycles are repeated until the set number of cycles has been reached or a fault occurs Movement keys Movement keys, plasticizing unit: When one of the keys is pressed in manual and setup modes, the plasticizing unit continues to move in the corresponding direction until the key is released. In manual mode, the mould must already be closed. Key: Plasticizing unit advance with Indicator, directional control valve Y40 Indicator, plasticizing unit in front limit position Key: Plasticizing unit retract with Indicator, directional control valve Y41 Indicator, plasticizing unit in rear limit position Movement keys, screw: When one of the keys is pressed in manual and setup modes, the injection plunger continues to move in the corresponding direction until the key is released. In manual mode, the cylinder temperature must have been reached for injection. Key: Injection with Indicator, directional control valve Y50 Indicator, commencement of hold pressure Key: Plasticizing with Indicator, directional control valve Y53 Indicator, end of plasticizing When this key is pressed in manual and setup modes, the injection plunger continues to rotate until the key is released. In manual and setup modes, the cylinder temperature must have been reached first. If a decompression stroke is programmed to follow after plasticizing, it is executed automatically in manual mode. Key: Decompression with Indicator, directional control valve Y51 Indicator, end of decompression When this key is pressed in manual and setup modes, the injection plunger continues to move back until the key is released. In manual and setup modes, the cylinder temperature must have been reached first. 02 / A A AV A A A 1.5 / 7

46 2.4 K E Y C A R D (K E Y C A R D) controlled access for data integrity A slot for the KEYCARD is provided on the right-hand side of the monitor. Various data records can be accessed, depending on the type of card inserted. The KEYCARD required for the selected input field is shown by the key icon in the top right-hand corner of the display. 1st level: without K E Y C A R D All setpoints and actual values can be viewed. Setpoints cannot be changed. The machine s response in the event of a fault can be selected in screens 5200 (with KEYCARD 1), 7220 and 7300 (with KEYCARD 2). Selector France (S6AB2) on screen 8310 can be set in order to prevent automatic commencement of a cycle following a fault or change of operating mode when working without KEYCARD. The cycle can only be restarted with a KEYCARD (at least level 1). This is required by a national safety regulation, e.g. in France. 2nd level: K E Y C A R D 1 All setpoints in the current operating data record can be changed. A data record saved with the same name remains unchanged and cannot be overwritten by saving the changes. 3rd level: K E Y C A R D 2 Data can be freely accessed with KEYCARD 2. In other words, all operating functions relating to data storage on screen 6100 can be executed with this card. 4th level: K E Y C A R D 3 All setpoints in the technician range can be changed with KEYCARD 3. Since these data have a far-reaching effect on control of the machine, KEYCARD 3 may only be used by specially trained personnel. KEYCARD 3 is normally used by the customer service technicians from Dr. Boy GmbH & Co.KG. + IMPORTANT! In extreme cases, the machine or mould may be damaged if setpoints are changed in the technician range by untrained personnel. This will also result in loss of all warranty rights. Liability for consequential damage or losses due to the use of KEYCARD 3 by untrained personnel is explicitly excluded. 1.5 / A A AV A A A 02 / 2002

47 2.5 Function keys, numerical keypad and screen selection keys C M A H C F À 0 Â À Function keys Á M A Menu* Selects the main menu A* Selects the alarm list When a new alarm occurs, it is indicated in a window regardless of the momentarily active screen. The alarm is acknowledged by closing the window, when the fault is no longer present. However, the alarm list can also be invoked directly from this window. All momentarily active alarms are listed here. From the alarm list, the operator can proceed to the alarm history, in which all alarms are listed in chronological order with indication of the time at which the alarm occurred and when it was remedied. Printer* Hardcopy output of the momentary screen page H C Help Activates the context-based Help function Á Numerical keypad Digits 0-9 For entering setpoints Period For entering setpoints with decimal places Plus For activating and deactivating profile points Minus For entering setpoints with negative sign ENTER Must always be used to conclude input of a setpoint or selection C For correcting incorrect inputs in setpoint fields. If a list box has been opened but no selection is to be made, the list box can be closed by pressing C. Â Screen selection keys* C F These four keys are used to select screen pages for the following areas directly: Clamping unit Injection unit Temperatures Setup data records * Selection via the keys is disabled when windows and list boxes have been opened on the screen. 02 / A A AV A A A 1.5 / 9

48 3. Control panel Spritzgiessautomaten 12, 22, 30 55, 90 -S80E -S80 Emergency OFF S80E Heating operational S80 Heating OFF / preparation ON -S01E -S01A S01E Motor ON S01A Motor OFF -P01 H -S20 -S21 -S55 V Selector Horizontal or vertical injection unit (only 30 A 2C) P01 Operating hours counter (by 55/90 at the right side of the switchgear cabinet) Figure 3:Control panel Motor ON/OFF The drive motor is switched on via the illuminated push-button (S01E) and off via the red push-button (S01A). If automatic activation of the machine by means of the seven-day timer has been selected, the motor will be switched on automatically at the programmed time. Further details can be found in the description of the seven-day timer (screen 7300). Heating control The switch (S80) with the two positions Heating OFF (0) and Heating prepared (1) and the illuminated push-button (S80E) Heating operational are used for general control of the plasticizing cylinder and nozzle heating (or of the mould heating for thermoset / elastomer materials). Switching off the heating Switch (S80) is set to position 0 in order to switch off the heating. In this case, all cylinder heating zones are switched off regardless of the setpoints for the individual control zones, regardless of the interference modes selected in the heating menu and regardless of the settings for the seven-day timer. It is impossible for the heating to switch on automatically. Heating ready for immediate operation Set switch (S80) to position I and press illuminated push-button (S80E). The indicator installed in the push-button lights up to show that the heating is ready for operation. Prepare heating for activation by the seven-day timer Set switch (S80) to position I; do not press push-button (S80E). If automatic activation of the machine by the seven-day timer has been selected, the heating will be switched on automatically at the programmed time. Operational readiness is then signalled by the indicator integrated in the push-button. Further details can be found in the description of the seven-day timer (screen 7300). + Note: If one of the modes Adjust to setpoint in case of fault or Adjust to reduced temperature in case of fault has been selected in the heating menu, these functions will also be ensured even if the indicator in push-button (S80E) does not light up. Switch (S80) must, however, be set to position I. 1.5 / A A AV A A A 02 / 2002

49 Structure of the user interface The term user interface is used to refer to all available screen pages. Rapid and specific location of the required setpoint inputs and actual value displays is ensured by the appropriate layout of data inputs on the screen pages, by functionally related grouping of screens to be opened via the yellow function keys and screen selection keys, and through the use of graphic symbols for the variable and invariable direct selection keys. Further possibilities are provided by the keys for scrolling backwards and forwards through the screen pages. Screen pages are identified not only by the caption in the distinctly coloured headline, but also by a 4-digit code number. The individual digits refer the screen page to individual groups. A screen page is located at the end of each branch, thus yielding the following structure: Invoking screens Screen page Designation 1000 Clamping unit Close Close options Open Open options Ejector Ejector options Air blast valves Core pull A Core pull A with pulse sensor Core pull B Core pull B with pulse sensor Close additional functions Brush control 2000 Plasticizing unit Plasticizing unit Plasticizing unit options 3000 Injection cycle Filling phase Filling phase Hold phase Hold phase options Oscilloscope channel 1 Oscilloscope channel 2 Trend display Envelope 4000 Plasticizing Plasticizing Plasticizing options 02 / A A AV A A A 1.5 / 11

50 Screen page Temperatures Setup data Designation Display of heating zones Display of plots Settings and tolerances Temperature control units Data records Times Notepad display Quick-Setup Data transfer Data transfer options Freely programmable outputs and inputs 7000 Production overview Production data Process data Process data tolerances Production overview 7-day timer / cycle conclusion Production overview operating data Production overview operating data forever SPC Control chart 1 SPC Control chart 1 Settings SPC Control chart 1 Gaussian distribution SPC Control chart 2 SPC Control chart 2 Settings SPC Control chart 2 Gaussian distribution M Technician Pressure gauge 9000 Memo Pad 9998 Main menu Control step indicator Input/output indicator Machine data Default setup Equipment Machine limit values Injection unit Clamping unit Service Zero point adjustment (1) Zero point adjustment (2) Temperature parameters Temperature calibration Copy temperature parameters Pressure gauge Memo pad 1.5 / A A AV A A A 02 / 2002

51 Input screens Main menu Input screens Cycle time appears after cycle start Space for supplementary functions 1 2 Space for special pages Cooling time 3 Figure 4: Main menu When the machine is switched on, it first runs through a number of self-tests before the main menu is displayed. The main menu lies at the heart of the entire operator guidance. All other screens can be invoked from here. The standard machine functions are represented by pictograms arranged around the Boy logo in a circle corresponding to the machine cycle. The corresponding screen is immediately displayed when a pictogram is selected. During the automatic cycle, the pictograms corresponding to the momentary part of the cycle are highlighted by a green background. If the cycle stops for any reason whatsoever, the operator can immediately see which function is responsible. For instance, if the changeover to hold pressure is not reached, the pictogram for INJECTION will continue to be highlighted by a green background and the operator knows where to look for the fault. Throughout the entire cycle time, a bar graph indicating the elapsed cycle time is displayed above the Boy logo. During the cooling time, a bar graph showing the elapsed cooling time is displayed below the Boy logo. Pictograms for supplementary functions, such as core pulls, brushing and breathing, are located on the left-hand side. These functions are selected in the same way as those represented by the ring of pictograms in the middle, except that they only appear when the corresponding function has been activated by entering a 1 on screen The pictograms for special pages are located on the right-hand side. 1 Contents of the screens (see overleaf) 2 Alphabetical index of Help texts 3 Notepad 02 / A A AV A A A 1.5 / 13

52 Contents of the control system Spritzgiessautomaten Screen pages Table of contents When the Boy logo is selected, a screen page appears with the tree structure for all available pages. This makes it very much easier to locate functions or pages. To the left of the page captions there are pictograms leading directly to the wanted page. Selection can also be made via the numerical keys 1 to 7. Scrolling backwards and forwards in the table of contents Figure 5: Table of contents for the control system 1.5 / A A AV A A A 02 / 2002

53 9998 Memo pad Screen 9998 Memo pad Figure 6: 9998 Memo pad Short texts can be entered on this screen and saved as text files (TXT). Operation is based on that of a standard text editor. 1 Menu line with standard editing functions 2 Text field 3 Typewriter keyboard The changeover between upper and lower-case letters is selective, i.e. shift first, then write. A line feed in the text is made by pressing the Enter/Return key or in the numerical keypad. The screen can be exited via the key Scroll up or one of the direct selection keys after saving the text input. 02 / A A AV A A A 1.5 / 15

54 Text input Spritzgiessautomaten Input screen, text input 1 2 Figure 7: Text input Wherever text has to be entered, it is keyed in via the keyboard displayed on the monitor. These screen pages cannot be selected directly and change in accordance with the input prompt concerned. 1 Text field 2 Typewriter keyboard Text inputs and setpoint inputs are concluded by pressing Enter or on the numerical keypad so that they can be adopted by the controller. 1.5 / A A AV A A A 02 / 2002

55 1100 CLAMPING UNIT CLOSE Screen 1100 CLAMPING UNIT CLOSE Figure 8: 1100 CLAMPING UNIT CLOSE All the setpoint and actual values needed for programming the closing movement are contained on this screen. Profile selection and the corresponding setpoint graph form the main elements of this screen. The bar graph below the setpoint graph shows the actual stroke by the clamping unit. 1 Clamping force Clamping force entered in kn. The application of high pressure ends automatically when the selected clamping force has been reached. Profile selection Profile selection is the same for all machine movements. A maximum of six profile points are available so that core retraction positions, for example, can be approached specifically. Each profile point is made up of the following elements: Control field As of position (set stroke) Speed (set speed) Pressure limit (set pressure, combined for several profile points) 02 / A A AV A A A 1.5 / 17

56 Screen 1100 CLAMPING UNIT CLOSE Spritzgiessautomaten SET key Example 1 Example 2 2 Control field The control fields have a number of special functions. When one of the control fields for a profile point is selected, it is highlighted by a yellow background. Function 1: Arrows now appear beside and below the graph; these arrows are used to change setpoints in the graph directly. The set stroke is changed with the aid of the arrows below the graph. The values change accordingly in the associated input field. The speed of the profile point is changed with the aid of the arrows to the left of the graph. The pressure of the profile point is changed with the aid of the arrows to the right of the graph. Function 2: The input fields associated with this profile point disappear when the plus key is pressed. The setpoints for the profile point reappear when the plus key is pressed again. In this way, each user can select as many or as few profile points as are needed to set the closing profile. Two profile points will suffice in the simplest case, namely points 0 (open) and 6 (mould protection). These profile points cannot be cancelled. 3 As of position - Set stroke The positions in the clamping stroke at which the respective values for speed and travel pressure are to be applied are set here. The set stroke for profile point 0 Mould open is coupled with that of profile point 5 on screen 1200 (Clamping unit Open) and cannot be set to a value smaller than that of the other profile points. The set speed values follow a ramp between the set strokes (see examples 1 and 2). To obtain a constant speed, the same speed must be entered for two consecutive profile points. The entered setpoints appear directly in the graph below. 1.5 / A A AV A A A 02 / 2002

57 Screen 1100 CLAMPING UNIT CLOSE SET ON? SET key: The key SET ON? appears at the top right after selecting the input field Position when entering profiles for the traverse movements for the clamping unit and values for the nozzle and ejector positions. Function 1: (Teach-in) The current actual position is adopted as the new setpoint when the key SET ON? is pressed. Function 2: (Zero adjustment) The key SET ON? similarly appears when the field Mould closed is selected. If this key is now pressed, the current actual value will be adopted as the new zero point. However, this is only possible in setup mode (zero adjustment for new mould). 4 Speed Set speed The speeds entered here are those at which the clamping movement is continued when the corresponding set strokes are reached. + Notes on safety to avoid damage to the mould! It is recommended in general to move the mould safety area at a speed of about 5%. 5 Pressure limit 1 / 2 Set pressure The pressure limit for the clamping movement between profile points 0-2 Mould open and 3-5 are set here. The pressure limit for profile point 6 Mould protection is entered separately in order to protect the mould (reduced mould clamping pressure). The system switches to mould clamping pressure when the position Mould closed is reached. 6 Coining, coining gap See Screen 1800 for coining. If coining is activated on screen 1800 and a coining gap is entered, it will be represented by a magenta-coloured line. The setpoint for the coining gap (max. 25 mm) can be changed in the input field. 7 Protection period The corresponding actual time starts at position 6 (mould protection). If the mould has not closed completely within this time, the clamping unit will reopen automatically and the ejector activated. 8 Repetition attempts Number of attempts made after expiry of the protection period. 02 / A A AV A A A 1.5 / 19

58 1110 CLAMPING UNIT CLOSE options Spritzgiessautomaten Screen 1110CLAMPING UNIT CLOSE options Figure 9: 1110 CLAMPING UNIT CLOSE options 1 Clamping force application time (monitoring time) If the clamping force is not reached within this time, the cycle will continue without application of the full clamping force. However, this should only be done in an emergency. This situation is normally due to defective seals in the pressure booster. 2 Offset clamping force start position This value should normally remain unchanged. It represents the distance from the zero point at which application of the high pressure is to start. Normally mm. 3 Profile selection The number of available profile points on screen 1100 is defined here. Profile points are activated and deactivated by tapping them. All profile points can be activated or deactivated simultaneously by tapping the line below. The control field for a profile point disappears when that point is deactivated. The screen must not be changed when the light is red. 4 Mould closing test Mould closing test in automatic mode: Only the mould closing side is operated in automatic mode when this function is active. The mould closing test can also be performed when the heating is switched off. 1.5 / A A AV A A A 02 / 2002

59 1200 CLAMPING UNIT OPEN Screen 1200 CLAMPING UNIT OPEN 1 Figure 10: 1200 CLAMPING UNIT OPEN All input fields and data required to compile the opening movement are contained on this screen page. Profile input is the same as on screen 1100 (CLOSE). 1 Ejector start position If the option Ejector start with mould open is selected on screen 1310 and a position is entered, it will be represented by a magenta-coloured line. The setpoint for the position can be changed in the input field. 02 / A A AV A A A 1.5 / 21

60 1210 CLAMPING UNIT OPEN options Spritzgiessautomaten 1210 CLAMPING UNIT OPEN options 1 2 Figure 11: 1210 CLAMPING UNIT OPEN options 1 Profile selection Profile selection is the same as on screen 1110 (CLOSE). 2 Mould open fast mode The system switches to fast mode from profile point 1 onwards when a 1 is entered (higher speed for Boy 50/80). 1.5 / A A AV A A A 02 / 2002

61 1300 CLAMPING UNIT EJECTOR Screen 1300 CLAMPING UNIT EJECTOR Figure 12: 1300 CLAMPING UNIT EJECTOR All the data and input fields needed to program the ejector are contained on this screen page. 1 Actual value display 2 Ejector program Ejector position Mould opening path Off Standard procedure Intermediate position for Ejector advance Intermediate position for Ejector retract Vibratory ejector Ejector via limit switch Off The ejector is not used in the machine cycle. All input fields are deactivated. 02 / A A AV A A A 1.5 / 23

62 Screen 1300 CLAMPING UNIT EJECTOR Spritzgiessautomaten Standard procedure The number of repeated ejector movements is entered in the field Number of strokes. The position, speed, ejector pressure and time dwelt in the forward position must be entered for the movement Advance ejector. The position to which the ejector must return, the speed and the ejector pressure must be entered for the movement Retract ejector. Intermediate position for Ejector advance The ejector stops for a preset time upon advancing to the set intermediate position. In addition to the standard program, a position, speed, ejector pressure and dwell time in the intermediate position must be entered here for the intermediate position. Intermediate position for Ejector retract The ejector stops for a preset time upon retracting to the set intermediate position. In addition to the standard program, the location of the intermediate position, the speed, ejector pressure and dwell time in the intermediate position must also be defined for retraction of the ejector. Vibratory ejector The ejector advances to the foremost position, is then retracted to an intermediate position, advances to the forward position and back to the intermediateposition in accordance with the set number of strokes. The ejector is retracted to its limit position when the set number of strokes has been executed. The intermediate position, set stroke, speed, ejector pressure and dwell time in the intermediate position must be programmed. Ejector via limit switch In contrast to the standard procedure, the set strokes are not required here. The advance and retract positions are detected by limit switches. All other setpoints must be entered as for the standard procedure. The pause time is entered in the last line (see Screen 6200). Ejector time-dependent The ejector advances at a preset time. The retract position is detected by limit switches. 3 4 Ejector advance / retract Setpoint inputs for advancing and retracting the ejector. Different input fields appear, depending on the set ejector program (line 2). Delayed ejector start: This time must elapse after Open mould before the set ejector program can start. 1.5 / A A AV A A A 02 / 2002

63 1310 CLAMPING UNIT EJECTOR options Screen 1310 CLAMPING UNIT EJECTOR options Figure 13: 1310 CLAMPING UNIT EJECTOR options 1 Ejector start during Switched on mould opening Switched off Switched on A position on the mould opening stroke can be entered when this option has been selected. The ejector begins to advance when this position is reached (graphically represented by the magenta-coloured line on screen 1200). However, this depends on the load on the mould opening movement and on the ejector load, since the hydraulic flows are divided for mould opening and closing movements and for the ejector. 2 Selector switch The equipment key which is additionally included on this screen can be used to proceed directly to the Selector screen (8320) in which the pneumatic safety gate or vertical machine can be selected, for example, both of which affect the ejector functions. 3 Optimization of ejector movement If the machine is equipped with a pneumatic safety gate and if the selector switch on screen 8320 has been activated by entering 1, the following inputs can be made with regard to the sequence for opening the safety cage: 1. Switched off 2. Safety cage opens when ejector retracted 3. Safety cage opens before ejector retracted 4. Ejector retracted when safety cage is open Option 4. is only available for vertical machines (screen 8320). Permits more accurate assumption of the required positions. 02 / A A AV A A A 1.5 / 25

64 1400 CLAMPING UNIT Air blast valves Spritzgiessautomaten Screen 1400 CLAMPING UNIT Air blast valves 1 Figure 14: 1400 CLAMPING UNIT Air blast valves These settings only appear when the selector switch Air blast valve has been activated on screen Program The following programs can be selected separately for blow valves 1 and 2: Switched off As of clamping force application As of mould position Parallel to ejector Switched off No further inputs required. As of clamping force application The air blast time must be entered in seconds. The air blast time commences upon application of the clamping force. As of mould position The set stroke must be entered. When this position is reached during the mould opening movement, the blow valve begins to blow for the set air blast time. Parallel to ejector No further inputs required. When ejector advanced The air blast valve is started in the position Ejector advanced. Air blast delay Commencement of the air blast is delayed by the time entered here. 1.5 / A A AV A A A 02 / 2002

65 1500/1600 CLAMPING UNIT CORE PULL A/B Screen 1500/1600 CLAMPING UNIT CORE PULL A/B Figure 15: 1500 CLAMPING UNIT CORE PULL A These settings only appear when the selector switch Core pull A or Core pull B has been activated on screen The setpoints can be entered on screen 1600 CORE PULL B in the same way as on screen 1500 CORE PULL A. 1 Signal Time Limit switch Pulse sensor (changes automatically to screen page 1510/1610 screwing function ) 2 Core program The following programs can be selected for Retraction: Switched off Before mould closes At intermediate stop With mould closed After clamping force application The following programs can be selected for Insertion: Switched off Before reduction of clamping force With mould closed At intermediate stop With mould open 02 / A A AV A A A 1.5 / 27

66 Screen 1500/1600 CLAMPING UNIT CORE PULL A/B Spritzgiessautomaten Speeds are specified as a percentage of the maximum flow rate. Retraction: Before mould closes The speed, pressure and travel time must be entered. The travel time serves as monitoring time for signalling by limit switch. At intermediate stop The speed and pressure must be entered, as well as the travel time serving as monitoring time for signalling by limit switch and the position at which the core is to be retracted when closing the mould. The position is entered in profile point 3 on screen With mould closed The speed, pressure and travel time must be entered. The travel time serves as monitoring time for signalling by limit switch. After clamping force application The speed, pressure and travel time must be entered. The travel time serves as monitoring time for signalling by limit switch. Insertion: Before reduction of clamping force The speed, pressure and travel time must be entered. The travel time serves as monitoring time for signalling by limit switch. With mould closed The speed, pressure and travel time must be entered. The travel time serves as monitoring time for signalling by limit switch. At intermediate stop The speed and pressure must be entered, as well as the travel time serving as monitoring time for signalling by limit switch and the position at which the core is to be started or inserted when closing the mould. The position is entered in profile point 3 on screen With mould open The speed, pressure and travel time must be entered. The travel time serves as monitoring time for signalling by limit switch. 3 Core after movement For each core program, it must also be specified whether the core is to be with or without pressure after movement. 4 Core sequence If the same core programs have been selected for core pull A and core pull B, the system also requires specification of the core sequence. This sequence determines whether core pull A or B is to move first or whether both are to move together. 1.5 / A A AV A A A 02 / 2002

67 1510/1610 CLAMPING UNIT CORE PULL A/B with pulse sensor Screen 1510/1610 CLAMPING UNIT CORE PULL A/B with pulse sensor Figure 16: 1510 CLAMPING UNIT core pull A with pulse sensor (screwing function) 1 Signal If the signal has been set to Pulse sensor on screen 1500/1600, screen 1510/1610 will appear automatically. Pulse sensor can only be selected if the thread counter used has been activated on screen The display reverts to screen 1500/1600 when the signal is set back to Time or Limit switch. The same setpoint inputs can be made on screen page 1610 CORE PULL B as on screen page 1510 CORE PULL A. 2 Core program The following programs can be selected for Retraction: Switched off Before mould closes At intermediate stop With mould closed After clamping force application The following programs can be selected for Insertion: Switched off Before reduction of clamping force With mould closed At intermediate stop With mould open 02 / A A AV A A A 1.5 / 29

68 Screen 1510/1610 CLAMPING UNIT CORE PULL A/B with pulse sensor Spritzgiessautomaten Retraction: Before mould closes The speed, pressure and monitoring time must be entered. At intermediate stop The speed and pressure must be entered, as well as the monitoring time and the position at which the core is to be retracted when closing the mould. The position must be entered in profile point 3 on screen With mould closed The speed, pressure and monitoring time must be entered. After clamping force application The speed, pressure and monitoring time must be entered. Insertion: Before reduction of clamping force The speed, pressure and monitoring time must be entered. With mould closed The speed, pressure and monitoring time must be entered. At intermediate stop The speed and pressure must be entered, as well as the monitoring time and the position at which the core is to be started or inserted when closing the mould. The position must be entered in profile point 3 on screen With mould open The speed, pressure and monitoring time must be entered. 3 Core after movement For each core program, it must also be specified whether the core is to be with or without pressure after movement. 4 Core sequence If the same core programs have been selected for core pull A and core pull B, the system also requires specification of the core sequence. This sequence determines whether core pull A or B is to move first or whether both are to move together. 5 Direction The direction of rotation must be entered. Input is coupled with the corresponding function for the opposite direction. 6 Speed The speeds for core movement are specified as a percentage of the maximum flow rate. 7 Monitoring time The counter must have reached the limit position before expiry of the monitoring time otherwise an error message will be output. 1.5 / A A AV A A A 02 / 2002

69 Screen 1510/1610 CLAMPING UNIT CORE PULL A/B with pulse sensor 8 Total number of revolutions Input is made in 0.01 revolutions. The actual number of pulses counted is shown to the right of the input field during the screwing procedure. The second decimal place will be ignored if Thread counter with 10 pulses per revolution has been selected on screen Portion of start revolution Number of revolutions performed at starting speed in order to break loose. 10Starting speed Speed at which the initial revolutions are performed. 11Brake pressure In order to ensure precise positioning, the system switches over to braking pressure 0.6 revolutions before reaching the limit position (i.e. 6 pulses in the case of a thread counter with 10 pulses per revolution or 60 pulses in the case of a thread counter with 100 pulses per revolution). The braking pressure must be set so that it is slightly higher than the counterpressure. The counterpressure (generated by a counterpressure valve) lies between 20 and 30 bar ( psi). The braking pressure is set when the oil is cold so that the screw still turns during the braking process. The oil quantity (braking speed) is set at 100% by a constant. 02 / A A AV A A A 1.5 / 31

70 1800 CLAMPING UNIT Close Additional functions Spritzgiessautomaten Screen 1800 CLAMPING UNIT Close Additional functions Figure 17: Screen 1800CLAMPING UNIT Close Additional functions This screen contains the supplementary functions Coining, Breathing, Evacuation and Outturn monitor. 1 Coining When coining has been activated, the coining gap, coining speed, locking position / pressure, correction position and locking value can be entered here. (The coining gap is represented graphically by a magenta-coloured line on screen 1100.) The coining sequence is as follows: Mould closes without application of high pressure until clamping pressure start position is reached (screen 1100) Injection until hold pressure begins Coining = Close mould with application of high pressure with the hold pressure profile and time set on screen 3200 and the coining speed set in the next line. Plasticizing, etc. 1.5 / A A AV A A A 02 / 2002

71 Screen 1800 CLAMPING UNIT Close Additional functions 2 Breathing When breathing is switched on, breathing start at screw position, breathing time, breathing mould opening stroke, mould open speed at breathing and mould open pressure at breathing can be entered here. The actual screw position is shown to the right of the input field. The breathing process is as follows: Mould closes with application of high pressure Injection until the position Breathing start at screw position is reached Breathing time starts Mould opens until position Breathing mould opening stroke is reached The mould closes again with application of high pressure when the breathing time has expired Injection continues. If breathing is started in the hold phase, the hold time will run again. 3 Evacuate If evacuation is switched on, the evacuation time can be entered here in the standard procedure. A delay time can additionally be entered if the procedure with clamping force has been selected. Evacuation time Delay time which commences when the mould closed position is reached. Application of the clamping pressure commences when this delay time has expired. Delay time The procedure is as follows for a set delay time: Mould closes without application of clamping force Advance nozzle Application of nozzle force Delay time starts with simultaneous commencement of evacuation The clamping force is applied when the set delay time has expired 4 Outturn monitor The outturn monitor can be switched on and off on this screen. It must also be activated by entering 1 on screen 8320 if it is to be switched on here. This monitor permits an additional protection function via outturn scales (flap, rocker or internal limit switch in the mould). The outturn monitor is activated before opening the mould and must have switched at least once at the end of the cycle if the part has been ejected correctly. The machine will stop if the outturn monitor signal is output during the mould closing movement, for instance because someone has reached into the chute (safety regulation in Great Britain). 02 / A A AV A A A 1.5 / 33

72 1810 Brush control Spritzgiessautomaten 1810 Brush control Figure 18: 1810 CLAMPING UNIT Brush control Brush control must be activated by entering 1 on screen Stroke count 2 Brush program 3 Spray 4 Setpoint input for the required number of brush strokes. Brush control switched off Advance ejector, brush cycle, retract ejector Advance ejector, retract ejector, brush cycle Brush on, advance / retract ejector, brush off Advance ejector, brush on, retract ejector, brush up Brush on to intermediate stop, advance ejector, brush down, retract ejector, brush off (can only be used with special brush) Can be switched on or off. Interval, delay and time can be set as required. In manual mode, a single brush cycle can be started by touching the arrow down button, provided that all other conditions have been met. The brush cycle continues until the button is released or when the brush cycle is complete (inserted or retracted, depending on the set program). The brush can be raised directly to its home position without passing the lower limit switch by touching the arrow up button button and stops when the button is released. 5 Spraying can be performed in manual mode by touching the spray button. 1.5 / A A AV A A A 02 / 2002

73 2000 PLASTICIZING UNIT Screen 2000 PLASTICIZING UNIT Figure 19: 2000 PLASTICIZING UNIT 1 Nozzle The following programs can be selected for the plasticizing unit: In contact Retraction after plasticizing Retraction before plasticizing 2 Nozzle stroke distance Indicates the actual nozzle position The following setpoint inputs can be made, depending on the program selected for the plasticizing unit: 3 Position nozzle in contact Enter the position for nozzle in contact with mould. The setpoint is referred to the adjusted zero point position. The key SET ON? appears at the top right when this field is selected. The current actual nozzle position is adopted as the new zero point if this key is now pressed. 02 / A A AV A A A 1.5 / 35

74 Screen 2000 PLASTICIZING UNIT Spritzgiessautomaten 4 Nozzle in contact force Enter the setpoint force for nozzle in contact in order to prevent material emerging between nozzle and mould. The nozzle in contact force simultaneously limits the travel pressure of the plasticizing unit. The pressure set here applies when the nozzle in contact position is reached. 5 Nozzle retract delay Delay time for delayed retraction of the nozzle before or after plasticizing. This input appears when a corresponding function with nozzle retraction has been selected. 6 Nozzle rear limit (in mm) Enter the position for Nozzle at rear when working with nozzle retraction. This position is ignored in manual mode and the operator can retract the nozzle to the rear limit stop. The actual nozzle position can be adopted as the new setpoint by pressing the key SET ON?. 7 Hydraulic nozzle shut-off If the hydraulic nozzle shut-off has been activated by entering 1 on screen 8320, it can be switched on and off here. Options for travel movements and setpoint inputs are entered on screen / A A AV A A A 02 / 2002

75 2010 PLASTICIZING UNIT Options Screen 2010 PLASTICIZING UNIT Options Figure 20: Screen 2010PLASTICIZING UNIT Options 1 Nozzle stroke distance 2 Current nozzle position Indicates the set nozzle stroke distance (screen 2000) Indicates the actual nozzle position 3 Nozzle position Input field for the setpoint position 4 Nozzle in contact pressure Input field (coupled with screen 2000) 5 Nozzle retract delay Input field (coupled with screen 2000) 6 Position contact pressure application Input field for the advanced position at which contact pressure is to be applied. 02 / A A AV A A A 1.5 / 37

76 Screen 2010 PLASTICIZING UNIT Options Spritzgiessautomaten 7 Nozzle travel speed advance / return Input field for setpoint speed 8 Travel pressure limit advance / return Input field for setpoint speed 9 Braking path, nozzle forward / return Input field for the braking path before reaching the nozzle in contact position and mechanical limit stop when retracting the plasticizing unit in manual mode. The travel speed is reduced to the set braking speed before reaching the corresponding position. 10Speed in braking path Input speed for the reduced travel speed in the braking path. 11Contact pressure application time Input field for the delay after starting application of contact pressure. The application time should lie between 0.1 and 0.8 seconds. Valve Y40 remains energized at the end of the application time if the contact pressure has been set to the system pressure. Valve Y40 is deenergized if a lower contact pressure has been set. The speed (volume) for the nozzle in contact pressure is the same as the Nozzle travel speed advance / return set above. 12 Minimum nozzle retraction for VH machines 13Delay times Input fields for the delay times for the hydraulic nozzle shut-off. The times entered run before or after closing the nozzle shut-off, thus isolating the hydraulic processes before and after opening and closing the nozzle. These fields only appear if the function Hydraulic nozzle shut-off has been activated by entering 1 on screen / A A AV A A A 02 / 2002

77 3100 INJECTION CYCLE FILLING PHASE Screen 3100 INJECTION CYCLE FILLING PHASE Figure 21: 3100 INJECTION CYCLE FILLING PHASE 1 Actual value display Current screw position Maximum injection pressure 2 Injection time reference value / actual value 3 Profile input The actual injection time is shown on the right. If the function Injection time monitoring has been activated on screen 3110, the injection monitoring time or injection time reference value for tolerance monitoring must be entered here. Profile input is the same as on screen 1100 (CLOSE). A special feature here, however, is that a ramp-like or abrupt transition can also be realized for the pressure limit with positions 3 and 4. An abrupt transition is obtained when the same positions are entered for points 3 and 4. The profile point before point 0 (end of plasticizing) is coupled with profile point 5 on screen 4000 (PLASTICIZING). Since this position is normally passed when plasticizing (e.g. by the decompression stroke), it marks the distance over which injection proceeds at the first injection speed up to position 0. If this profile point is changed, all profile points (except point 5) also change proportionally at the same time. Position 5 serves as the stroke monitor if the hold pressure is started as a function of time. If this position is reached before the set time has expired, the error message Injection time monitoring tripped is output and the machine cycle ended as set on screen / A A AV A A A 1.5 / 39

78 Screen 3100 INJECTION CYCLE FILLING PHASE 3110 INJECTION CYCLE FILLING PHASE Options Spritzgiessautomaten If the hold pressure changeover has been set to stroke-dependent on screen 3200, the system will switch to hold pressure when profile point 5 is reached. 4 Start hold pressure 5 The type of changeover to hold pressure set on screen 3200 is shown on this screen. The indicated setpoint for changing to hold pressure is coupled with screen 3200 and can be changed here. Bar graph display of the melt cushion The start of hold pressure is indicated by a vertical cyan-coloured line in the graph INJECTION CYCLE FILLING PHASE Options Figure 22: 3110 INJECTION CYCLE FILLING PHASE Options 1 Profile selection Profile points are entered in the same way as on screen 1110 (CLOSE). 2 Injection time monitoring 3 Injection delay Can be activated or deactivated. Influences the potential settings in line 2 of screen The entire line disappears if time-dependent changeover to hold pressure has been selected on screen Specification of the time-lag 4 Intrusion Can be activated and deactivated. The intrusion time is entered in seconds. 1.5 / A A AV A A A 02 / 2002

79 Screen 3100 INJECTION CYCLE FILLING PHASE 3110 INJECTION CYCLE FILLING PHASE Options 5 Injection with open mould in manual mode, can be activated and deactivated. 6 Injection work Indicates the injection work in Nm. 7 Auto. profile adjustment For injection and plasticizing. Automatic profile adjustment is activated as the default setting. The selected status, i.e. activated or deactivated, can be saved by the operator in the machine status. The profile is adjusted proportionally by the automatic profile adjustment function whenever the maximum profile value is changed. 02 / A A AV A A A 1.5 / 41

80 3200 INJECTION CYCLE HOLD PHASE Spritzgiessautomaten Screen 3200 INJECTION CYCLE HOLD PHASE Figure 23: 3200 INJECTION CYCLE HOLD PHASE 1 Actual value display Current screw position Maximum injection pressure when hold pressure starts 2 Melt cushion reference value / actual value 3 Hold pressure change The actual value for the melt cushion is shown on the right. The reference value for the melt cushion must be entered for monitoring of tolerances. The following programs can be selected for changing to hold pressure: Time-dependent Stroke-dependent Dependent on hydraulic pressure Dependent on cavity pressure By external signal 4 Profile input Profile input is the same as on screen 1100 (CLOSE), but refers to a time axis. If the total time (interval 5) is changed, all other time intervals change proportionally at the same time. 5 Start hold pressure The corresponding initial value for hold pressure must be entered here, depending on the changeover to hold pressure selected in line 3. It can likewise be changed on screen 3100 if necessary. No input is required if the changeover to hold pressure is triggered by an external signal. 1.5 / A A AV A A A 02 / 2002

81 3210 INJECTION CYCLE HOLD PHASE Options Screen 3210 INJECTION CYCLE HOLD PHASE Options Figure 24: 3210 INJECTION CYCLE HOLD PHASE Options 1 Hold pressure preselection Operation with hold phase Operation without hold phase 2 Profile selection Profile selection is the same as on screen 1100 (CLOSE). 3 Speed limit Entered as a percentage of the maximum flow rate. 4 Automatic profile adjustment For hold phase. The automatic profile adjustment function is comparable with that on screen 3110 (Injection cycle Injection phase Options). 02 / A A AV A A A 1.5 / 43

82 3300 OSCILLOSCOPE CHANNEL 1 Spritzgiessautomaten Screen 3300 OSCILLOSCOPE CHANNEL Figure 25: 3300 OSCILLOSCOPE CHANNEL 1 The process parameters are plotted over time on this screen. The display corresponds with that of a storage oscilloscope. 1 Value 1 Selection of the first process parameter to be plotted 01: Injection pressure B5D 02: Cavity pressure A54D 03: System pressure B01D 04: High pressure B30D 05: Setpoint pump pressure UAD 06: Setpoint pump delivery UAD 07: Setpoint back pressure Y55D 08: Screw rotation B53G 09: Clamping unit stroke B1W 10: Ejector stroke B6W 11: Screw stroke B5W 12: Stroke of unit B4W 13: Temp. heating zone 1 B81T 14: Temp. heating zone 2 B82T 15: Temp. heating zone 3 B83T 16: Temp. heating zone 4 (nozzle) B84T 17: Oil temperature B05T 18: Close clamping unit Y10 19: Open clamping unit Y11 20: Mould protection Y14 21: Clamping force application Y30 22: Open mould slowly Y111 23: Nozzle advance Y40 24: Nozzle retract Y41 25: Nozzle force application Y43 26: Hydraulic nozzle shut-off Y49 27: Injection Y50 28: Decompression Y51 29: Plasticizing Y53 30: Ejector advance Y60 31: Ejector retract Y61 32: Air blast valve Y / A A AV A A A 02 / 2002

83 Screen 3300 OSCILLOSCOPE CHANNEL 1 2 Value 2 Selection of the second process parameter to be plotted. This selection only appears if direct selection button 2 for displaying two measured values has been activated in line 6. The selections available are the same as for value 1. Value 2 is coupled with value Y on screen The beginning and the course of measurement are indicated in the status field. Data are transferred when measurement is complete. This is indicated in the status field and takes a few seconds. 3 Automatic start Selection of the starting point These selections only appear when direct selection button 3 (manual start) has been deactivated in line 6. Injection Hold phase Plasticizing Mould closing Mould opening 4 Graphic display of the set values. The display range of the y-axis can be set on the right and left of the graphic area for the measured value concerned. 5 Set measuring time The shortest time is one second. Since 100 values are always recorded, the maximum resolution is 10 ms = 100 Hz. 6 Direct selection button 1 - Changeover from channel 1 to channel 2 (screen 3310) 2 - Changeover, display value 1 or value Value Y from screen 3310 is also displayed when this button is activated. 3 - Changeover between automatic and manual start 4 - Start button for manual commencement of measurement (only appears if changeover button 3 manual start has been activated) 5 - Zoom function 5-fold for the time axis Shift time axis for 5-fold zoom 8 - Direct selection button for screen 9000 (pressure gauge) 02 / A A AV A A A 1.5 / 45

84 3310 OSCILLOSCOPE CHANNEL 2 Spritzgiessautomaten Screen 3310 OSCILLOSCOPE CHANNEL Figure 26: 3310 OSCILLOSCOPE CHANNEL 2 The process parameters are plotted here as a function of time or as a function of the screw stroke / clamping unit stroke. 1 Value Y Coupled with value 2 on screen Value X Definition of the x-axis - B5W: Screw stroke - B1W: Clamping unit stroke These selections only appear if button 2 has been activated in line 5 (x-axis changeover time / stroke). 3 Graphic display of the measured value with possibility of setting the y-axis range. 4 5 X-axis = time Measuring time (changeover button 2 in line 5 inactive) X-axis = stroke Measuring range set to the travel stroke (changeover button 2 in line 5 active) Direct selection buttons 1 Changeover from channel 2 to channel 1 (screen 3300) 2 Changeover x-axis time / stroke As on screen / A A AV A A A 02 / 2002

85 3500 Trend display Screen 3500 Trend display 1 2 Figure 27: 3500 Trend display Any two process parameters can be displayed as a trend on this screen. The data for the last 64 cycles are displayed. The setpoint or reference value shown on screen 7210 is used as the reference. If a reference value has not yet been entered for this value, the last actual value will automatically be used instead. The absolute values and relative values in relation to the reference values are indicated as standard. 1 2 Selection of the process parameters to be displayed 02 / A A AV A A A 1.5 / 47

86 3600 MEASURED VALUES Envelope curve Stroke-dependent graphics Spritzgiessautomaten Screen 3600 MEASURED VALUES Envelope curve Stroke-dependent graphics Figure 28 : 3600 MEASURED VALUES Envelope curve Stroke-dependent graphics The trace for a selected variable is displayed on this screen for each cycle. All actualvalue traces can consequently be viewed together and the reproducibility of the measured variable observed. 1 Measured variable The following envelope curves can be selected: 01 : Injection pressure over stroke 02 : Back pressure over screw stroke 03 : Speed over screw stroke 04 : Mould cavity pressure over stroke 2 Reference curve A reference curve (actual value, setpoint or manual input) can be defined with tolerance band. 1. Selection of the reference curve Home position, no response when selected. 2. Last actual-value trace as reference curve The last actual-value trace is presented as the reference curve. 3. Setpoint trace as reference curve The setpoint trace for the selected profile is displayed. No stroke-dependent setpoint trace available is displayed in the selection field for the mould cavity pressure. 1.5 / A A AV A A A 02 / 2002

87 Screen 3600 MEASURED VALUES Envelope curve Stroke-dependent graphics + 4. Manual input of setpoint trace... Manual input of coordinates is started. The operator selects a coordinate point on a theoretical reference curve by touching a point on (or outside) the diagram. The selected point is represented by a yellow arrow. The precise coordinates of the point are shown to the right of the diagram. The point is adopted by pressing Enter. Further points are added in the same way. At least two points should be selected in order to obtain a line. However, the reference curve is not plotted until option 5... and use as reference curve is selected and confirmed by pressing Enter. Important: Reference curve input (Enter after selection 4) should only be started when a measuring time is not running (status field green) and adopt as reference curve The reference curve entered in option 4, above, is displayed. The reference curve is not displayed if one of the other options 1, 2 or 3 is selected and confirmed by pressing Enter. A new reference curve can be entered when option 4 is selected again. 3 Automatic start 4 Measuring time The measuring time starts automatically as soon as the measurement has been enabled. This is indicated in the line Automatic start at and depends on the selected variable (1). The measuring time for recording a cycle is entered here in seconds. The measuring time should always be set so that it is slightly longer (up to the next full second) than the actual time of the selected cycle. Example: Injection time 1.83 seconds, measuring time 2 seconds. The shortest possible measuring time equals one second. 100 measurements are always performed during the measuring time (i.e. every 10 ms for 1 second measuring time, every 200 ms for 20 seconds). The values between the individual stroke positions are interpolated. If the selected measuring time is too short, only corresponding part of the distance travelled in this time can actually be presented. If the selected measuring time is too long, the values on the traces can no longer be correlated with the actual sequence. All actual-value traces except the last one are lost when the value changes. 5 Number of traces The number of traces which are to appear together on the graph is entered here (max. 9999). The actual value is displayed on the right, beside the setpoint. When the setpoint is exceeded, the counter is reset to 1 and the part counters for display inside the reference curve (green) and outside the reference curve (red) are similarly reset. The actual values are always zeroed when the display commences. When the set number of traces is reached, a file M3600nnn.PCX is generated in which nnn counts from 1 to 999. The file is stored in the background and is only generated if screen 3600 is visible at this time. 02 / A A AV A A A 1.5 / 49

88 Screen 3600 MEASURED VALUES Envelope curve Stroke-dependent graphics Spritzgiessautomaten 6 Counter Each trace within the tolerance band is documented by the green counter and each trace outside the tolerance band by the red counter. 7 Tolerance The positive and negative tolerance values for the reference curve are entered here as positive numerical values. The value is adopted when Enter is pressed and the traces are redrawn. All actual-value traces except the last one are lost in the process. 8 Minimum / maximum value The minimum and maximum setpoints for presentation of the y-axis are entered here in the selected unit of measure. The graph is erased when Enter is pressed and redrawn to the new scale. All actualvalue traces except the last one are lost in the process. Negative values can be entered for the minimum value in order to obtain an optimum presentation. 9 Changeover to Screen 3310 Measured values Channel 2. 10Disable measurement A new trace is not plotted when this key is pressed. Measurement is only enabled when the key is inactive. Measurement starts as described for Automatic start at. 11Redraw Redraw the last actual-value trace The last actual-value trace is redrawn; all other traces are retained. If the actual-value trace was covered by the reference curve, it now becomes visible again. Redraw the reference curve The last reference curve is redrawn; all other traces are retained. If the reference curve was covered by actual-value traces, it now becomes visible again. 12RESTORE Envelope curve Completely redraw the envelope curve The last actual-value trace and the current reference curve are redrawn. All measurement trace are retained. The last actual-value trace and the current reference curve are displayed if the diagram was erased beforehand by pressing RESET Envelope curve. 13RESET Envelope curve Erase the envelope curve The diagram is erased completely and the counters zeroed when RESET Envelope curve is pressed. The last actual-value trace and the current reference curve can subsequently be redrawn by pressing RESTORE Envelope curve. 1.5 / A A AV A A A 02 / 2002

89 4000 PLASTICIZING Screen 4000 PLASTICIZING Figure 29: 4000 PLASTICIZING 1 Actual value display Actual screw position 2 Plasticizing time 3 Decompression Indication of the actual plasticizing time Input of the maximum permissible plasticizing time (only possible if monitoring of the plasticizing time has been activated on screen 4010). If plasticizing is not ended within this time, the machine will output an alarm Plasticizing time monitor tripped and switches off at the end of the cycle (cycle conclusion as set on screen 7300). Setpoint input for screw retraction after plasticizing. Decompression stroke Decompression speed The difference between the maximum screw stroke and the setpoint end of plasticizing (profile point 5) can be entered here as the maximum stroke value. If the end of plasticizing is increased, the decompression stroke will decrease automatically if this would mean exceeding the maximum screw stroke. If position 5 (end of plasticizing) is changed, all other positions are changed proportionally at the same time. 4 5 Profile input is the same as on screen 1110 (CLOSE). Bar graph (as on screen 3100, without hold pressure line) 02 / A A AV A A A 1.5 / 51

90 4010 PLASTICIZING Options Spritzgiessautomaten Screen 4010 PLASTICIZING Options Figure 30: 4010 PLASTICIZING Options 1 Decompression before plasticizing 2-5 Off Active Setpoint inputs for: Pressure limit at decompression Delay before decompression after plasticizing Max. plasticizing pressure Plasticizing delay 6 Plasticizing time monitoring Off Active The maximum time can be set in line 2 on screen 4000 when plasticizing time monitoring has been activated here. 7 Back pressure 0 in manual mode 8 Profile selection Metering is performed with back pressure 0 in manual mode, regardless of the back pressure profile. Profile selection is the same as on screen 1110 (CLOSE). 1.5 / A A AV A A A 02 / 2002

91 Screen 4010 PLASTICIZING Options 9 Machine cycle without material Is only activated during final acceptance testing of the machine by Dr. Boy GmbH & Co.KG. The machine is set so that the screw only retracts without plasticizing. 10Cleaning control Cleaning control of the injection unit is activated via this switch. All functions except decompression remain available even when cleaning control is active. Cleaning control OFF Deactivation of the cleaning control while it is running automatically causes the system to switch to Stop. The switch is deactivated automatically when cleaning control expires. Cleaning without nozzle in contact Press decompression button. The nozzle is first of all retracted in setup mode (see page 1.5/6). This is then followed by injection and metering (up to the set stroke length) until the set cleaning time has expired. + Cleaning with nozzle in contact Advance the nozzle and apply the nozzle contact pressure. Important: The nozzle contact pressure must not be set too high, otherwise the stationary mould half will be overstressed when the mould is open or could even tear off in extreme cases. Press decompression button. Injection and metering (up to the set stroke length) continue in setup mode (see page 1.5/6) by pressing the Metering button until the set cleaning time has expired. 02 / A A AV A A A 1.5 / 53

92 5100 TEMPERATURES DISPLAY OF HEATING ZONES Spritzgiessautomaten Screen 5100 TEMPERATURES DISPLAY OF HEATING ZONES Figure 31: 5100 TEMPERATURES DISPLAY OF HEATING ZONES 1 Setup temperature Setpoint input for the heating zones. If feed control has been mounted on the machine and activated by entering 1 on screen 8320, the setpoint for the feed is also entered here and the actual value displayed. The corresponding heating zone is switched off when 0 C (32 F) is entered. 2 Actual temperature 3 Duty cycle Indication of the actual temperature in the heating zones. Indication of the duty cycles of the heating zones. 4 Graphic display of setpoint and actual values. Yellow = setpoint Blue = Actual value below setpoint, -15 C, screw disabled Green = Actual value in working range, setpoint + 15 C Red = Actual value above setpoint (+15 C) 5 Mould temperature If the option Mould temperature sensor has been installed on the machine and activated by entering 1 on screen 8320, the temperature of the mould walls on the moving and stationary platens will be indicated here. Two additional temperature zones can be controlled here if desired and if installed on the machine. 1.5 / A A AV A A A 02 / 2002

93 5110 TEMPERATURES DISPLAY OF PLOTS Screen 5110 TEMPERATURES DISPLAY OF PLOTS Figure 32: 5110 TEMPERATURES DISPLAY OF PLOTS 1 Setpoint input for the heating zones, coupled with screen Indication of actual values as on screen Plots Graphic display of the actual values over a variable time axis. Values are scaled automatically. 5 Adjustment of the measuring time seconds at 100 second intervals. Since 100 measurements are recorded, one value is recorded every second when 100 sec is set and one value every six seconds when 600 sec is set. 02 / A A AV A A A 1.5 / 55

94 5200 Temperatures Settings and tolerances Spritzgiessautomaten Screen 5200 Temperatures Settings and tolerances Figure 33: 5200 Temperatures Settings and tolerances 1 Heating status Status indicator: Heating switched off Heating switched on Reduced heating 2 Heating zone Input of setpoints and tolerances for each cylinder heating zone. Presentation of actual values. 3 Mould temperatures Input of setpoints and tolerances for each mould temperature zone. Presentation of actual values. 4 Reactions Definition of the reaction to violation of the tolerances in a temperature zone. Definitions can be entered separately for overheating and underheating, as well as for heating zones and mould temperature zones. No reaction (off) Stored reaction If tolerance monitoring for a parameter has been deactivated by touching No reaction (off), the previously set reaction can be reactivated by touching Stored reaction. The reaction active before switching off is reactivated by pressing ENTER. Alarm 1.5 / A A AV A A A 02 / 2002

95 Screen 5200 Temperatures Settings and tolerances Reject signal Filter signal and alarm message Machine off at end of cycle Filter signal and alarm message. Machine stops with the cycle conclusion selected on screen Heating zones when machine stops Definition of the heating status reaction when the machine stops following a tolerance violation or an alarm. Heating switched off Heating remains on Heating reduced 6 Reduced temperature Input of the reduction value. The temperature of each heating zone is reduced by this amount. This maintains the profile structure. 02 / A A AV A A A 1.5 / 57

96 5400 Temperatures Temperature control units Spritzgiessautomaten Screen 5400 Temperatures Temperature control units (optional) Figure 34: 5400 Temperatures Temperature control units 1 Switch on data link to the temperature control units. 2 The following inputs can be made and the following actual values are displayed for each of the four temperature control units: Setpoint: Actual value: Duty cycle: Operating status: Input of the required temperature Indication of the actual temperature Indication of the actual heating or cooling output of the temperature control unit in percent (cooling output is shown with a negative sign). Current operating mode of the temperature control unit 3 Mode:Can be selected for each temperature control unit 0 =Temperature control unit off 1 =Temperature control unit in controlled mode (normal) 2 =Cool mould and temperature control unit off 3 =Empty mould then switch temperature control unit off 4 =Cool and empty mould, then switch temperature control unit off 5 =Optimize control parameters Not all these modes may be available, depending on the type and make of temperature control unit used. 1.5 / A A AV A A A 02 / 2002

97 6100 SETUP DATA Data records Screen 6100 SETUP DATA Data records Figure 35: 6100 SETUP DATA Data records Management of the setup data records has been realized on this screen. Setup data records can be saved on hard disk and loaded from hard disk or copied to floppy disks. 1 Load setup data record The field Load setup data record from hard disk must be touched for this purpose. A list box appears to the right of the field. The box opens when tapped twice and one of the listed setup data records can then be selected by tapping it. The data record is transferred to the machine storage when confirmed via Enter. File name Indication of the actual file name To enter the file name, tap the field File name (automatically change to screen 9999). The file name must not exceed 8 characters, since an MS- DOS operating system is used for manage ment of the setup data records. Press Enter to conclude input of the file name. Description A description of the selected file is displayed (if available) The description can be entered in the same way as the file name. Up to 28 characters can be entered for this purpose. 02 / A A AV A A A 1.5 / 59

98 Screen 6100 SETUP DATA Data records Spritzgiessautomaten 2 Store setup data record on hard disk Before a setup data record can be stored on hard disk, a file name and a description (if desired) must be entered for that data record as described above. Once the file name has been defined, the setup data record is stored by tapping the field Store setup data record on hard disk. 3 Copy setup data record from hard disk to floppy disk A list box with all available setup data records is displayed when this field is tapped. A setup data record must be selected and is then copied to the floppy disk when Enter is pressed. 4 Copy setup data record from floppy disk to hard disk A floppy disk containing setup data records must be inserted in the disk drive before selecting this function, otherwise the message No files will be output. A list box with all the setup data records available on the floppy disk will be displayed when this field is tapped. A setup data record must then be selected and is copied to the hard disk when Enter is pressed. 5 Delete setup data record on hard disk A list box with all the setup data records available will be displayed when this field is tapped. A file must be selected and is then deleted from the hard disk when Enter is pressed. 6 Move process data from hard disk to floppy disk A list box with all the available process data files will be displayed when this field is tapped. A file must be selected and is then copied to the floppy disk when Enter is pressed. 7 Delete process data record on hard disk A list box with all the available process data files will be displayed when this field is tapped. A file must be selected and is deleted from the hard disk when Enter is pressed. 8 Machine status Load Save The machine status with important information specific to the machine can be loaded or saved by tapping the corresponding field. Notepad file for setup data record Notes can be written to the setup data record with the aid of the notepad (screen 9998). If the name of the notepad file is identical with that of the setup data record, the text file will be appended to the setup data file, thus becoming a part of the file, when the setup data record is saved. The original text file is retained and not deleted. Example: Setup data record yyy.r06 Compile and save notepad file yyy.txt Save setup data record yyy.r06 + yyy.txt The text thus becomes part of the setup data record and is automatically transported, copied and displayed together with the setup data record when loaded. 1.5 / A A AV A A A 02 / 2002

99 6200 SETUP DATA TIMES Screen 6200 SETUP DATA TIMES Figure 36: 6200 SETUP DATA TIMES 1 Cycle time monitoring Cycle time monitoring should be set so that it is longer than the actual cycle time. The machine will then be switched off if the actual cycle time exceeds the cycle time monitoring for any reason whatsoever.(cycle conclusion as set on screen 7300) 2 Cooling time The cooling time follows the hold phase. The mould opens at the end of the cooling time. 3 Pause time The pause time starts upon conclusion of a complete cycle. This is normally when the part has been ejected. In all-automatic operation, the next cycle starts upon expiry of the pause time. 4 Clamping force application time (monitoring time) The clamping force is normally applied until the set clamping force has been reached. This can take between 0.5 and 0.8 seconds, depending on the model in question. If the monitoring time set here is reached when applying the clamping force, for instance on account of defective seals in the pressure booster, application of the clamping force will be aborted and the normal cycle continues. A clamping force application time longer than the cycle monitoring time in line 1 can be set if this is not wanted (maximum value ). In this case, the machine will be switched off upon expiry of the cycle monitoring time. This interrupts the automatic cycle and prevents the mould being overpacked. 02 / A A AV A A A 1.5 / 61

100 Screen 6200 SETUP DATA TIMES Spritzgiessautomaten 5 Protection period Mould protection time This time starts when the mould protection position is reached and ends at the mould closed position (clamping force application). If the time has expired before the mould closed position is reached, a corresponding error message will be output, the clamping side reopens completely, the ejector is actuated and a new closing movement will start, if a number of repetition attempts has been set on screen This may happen, for example, if the last part has not been ejected. When the set number of repetition attempts has proved unsuccessful, an error message is output and the cycle is concluded as set on screen Injection time / Hold time / Plasticizing time The respective actual times can be monitored on this screen. Since these times are made up of several profile points, they must be entered on the corresponding screens. The required profile can be called up directly by pressing the appropriate symbol at the side. 1.5 / A A AV A A A 02 / 2002

101 6400 Notepad display Screen 6400 Notepad display Figure 37: 6400 Notepad display The texts compiled with the notepad function (screen 9998) can be viewed here. Operation is based on that of a conventional text editor Menu bar with standard editor functions (display only) Text field Navigation buttons Display: Line (L) Row (X) File name (F) Mode (M) 02 / A A AV A A A 1.5 / 63

102 6600 SETUP DATA Quick-Setup Spritzgiessautomaten Screen 6600 SETUP DATA Quick-Setup Figure 38: 6600 SETUP DATA Quick-Setup 1. Setup data Setpoints All the main setup parameters are contained in this screen and provide a rapid overview of the machine settings. The setpoints can be changed directly. For many setup jobs, this makes it unnecessary to change back and forth between different screens. 2. Set up mould The key Set up mould must be pressed when a new setup is to be entered for a mould. The operator is now interactively prompted: to close the mould and set the zero point. This is only possible in setup mode (see page 1.5/6). to move the nozzle to the contact position and set the zero point. A basic data record containing all the basic settings is then loaded. A simple mould could be operated immediately with these settings. However, the inputs must now be checked and supplementary functions programmed. Quick setup mode is only ended when the setup data have been saved. 1.5 / A A AV A A A 02 / 2002

103 6700 Data transfer Screen 6700 Data transfer Figure 39: Data transfer Data can always be output to a printer and saved in a file (in print format). Graphic output to the printer is performed in the background. While the print data are being processed, a bargraph is displayed at the top of the screen and indicates the progress made in printing. If the bargraph does not turn yellow for some time, the selected printer driver (screen 6710) is not compatible with the on-line printer. If the yellow phase is not followed by a green phase, the printer has not been connected or is not ready. + Printouts can optionally be triggered without printer by actuating the key icon in the top right-hand corner of the headline. A.pcx file is generated in this case and can be copied to a floppy disk in screen The data can then be processed with an image processing program (e.g. MS-Paint). 1 Process data, alarm messages and the current setup data record can be printed. When the corresponding key is pressed, the process or alarm data are logged continuously until the key is deactivated (activated key is highlighted by a different colour). The current setup data record is saved or printed in the form of a list spread over three pages. 02 / A A AV A A A 1.5 / 65

104 6700 Data transfer Spritzgiessautomaten The selector switch Printer connected informs the control system that a printer has been connected. Printer icons appear beside the aforementioned switches when this selector is set to 1. The corresponding data are output to the printer when these switches (with green background) are activated DIR A: 10DIR C: The respective data can be copied from hard disk to floppy disk for visualization and further processing on a standard personal computer. Displays the contents of the floppy disk in the drive. Displays the contents of the directory \Runtime\Data on the hard disk storage. 11 Select the screen Data transfer Options for printer configuration. 1.5 / A A AV A A A 02 / 2002

105 6710 Data transfer Options Screen 6710 Data transfer Options Figure 40 : 6710 Data transfer Options 1 A window with the available printer drivers appears when this key is pressed. Enter must be pressed after selecting the required driver (or that of a compatible printer). A printer driver need only be selected in order to output graphic data. 2 3 A selection window with the possible country settings for the keyboard appears when this key is pressed. The selection is made in the same way as selection of the printer driver. The log file is displayed when this key is pressed. The log file can be displayed on the alarm history screen. 02 / A A AV A A A 1.5 / 67

106 6800 Freely programmable outputs and inputs Spritzgiessautomaten Screen 6800 Freely programmable outputs and inputs Figure 41: 6800 Freely programmable outputs and inputs 1 Scope of function: Switched off Freely programmable inputs Freely programmable outputs Freely programmable inputs and outputs 2 Outputs The following can be programmed for each of the four outputs: Switch-on signal: Defines the event setting the output. Possible events are listed by tapping the field. An event is adopted by tapping the required event and then pressing Enter. Delay: Actuation of the output is delayed by this length of time following occurrence of the event. Duration: The output is set for the time specified here following occurrence of the event and expiry of the delay. The symbol at the end of the line indicates when an output has been set. 1.5 / A A AV A A A 02 / 2002

107 Screen 6800 Freely programmable outputs and inputs 3 Inputs The following can be programmed for each of the four inputs: Enable: The machine cycle can be halted at certain points in the cycle and does not continue until a defined enable signal is received at the corresponding input. The possible points available in the cycle are listed by tapping the field. The required point must be selected and confirmed by pressing Enter. Enabled with: The input in this field determines whether the halted cycle is to be restarted with a 0 V or 24 V signal at the corresponding input. Manual enable: The halted cycle can be restarted for test purposes by tappping this field. The symbol at the end of the line indicates when the input has been set by a 24 V signal. 02 / A A AV A A A 1.5 / 69

108 7100 Production overview Production data Spritzgiessautomaten Screen 7100 Production overview Production data Figure 42: 7100 Production overview Production data Job and mould-related data are entered, calculated and displayed on this screen A job name, mould name and material name can be entered here. The display switches to screen 9999 when the corresponding field is tapped. Each name may contain up to 28 characters. Cavity number The cavity number is entered here. It is multiplied by the number of cycles to yield the number of units. Interval signal Subsequent handling systems, etc. can be controlled via the interval signal, thus providing a signal for palletization, for example. Reset number of units The number of units is reset by tapping the Reset button and pressing Enter to confirm the function. Start cycles (bad parts) The set number of pieces are counted as bad parts when production starts and the reject flap is activated, if installed. The parts produced are included in the required number of pieces when these starting cycles have been completed. 6 Indication of the actual number of good parts Indication of the actual number of decremented units Input of the setpoint number of units 1.5 / A A AV A A A 02 / 2002

109 Screen 7100 Production overview Production data Screen 7200 Production overview Process data 7 8 Screen 7200 Indication of the actual total good parts bad parts effectiveness, calculated as a percentage of total parts and bad parts expected production time, calculated from the remaining number of units and mean cycle time Input of the shot weight of the part in grams Indication of the actual mean cycle time, calculated from the sum of the cycle times and number of cycles Indication of the actual material throughput, calculated from the entered shot weight, unit of weight as desired Production overview Process data Figure 43: 7200 Production overview Process data Figure 43: 7200 Process data Selection Ten selectable process data can be displayed on this screen with the currently stored values for each cycle. The last 64 shots are saved in the memory and can be scrolled with the buttons arrow up and arrow down (2 and 3). The display immediately returns to the last cycle recorded when the button actual cycle (1) is touched. When selection (4) is touched, a window appears in which the process data can be selected. One process parameter can be selected for each of the ten columns and is then recorded until the next change is made on screen A list box containing all process parameters altogether appears when the field corresponding to the column number is tapped. One of these process parameters can then be selected and set aside for logging. The display reverts to screen 7200 when Close is tapped after making the selection. All parameters are always recorded in the background. If the choice of process parameters is changed, the parameters for the last 64 cycles can still be viewed retroactively even if they were hitherto not defined. All process parameters are saved on a daily basis as *.PDD files and can be copied onto floppy disk with screen / A A AV A A A 1.5 / 71

110 7210 Production overview Process data Tolerances Spritzgiessautomaten Screen 7210 Production overview Process data Tolerances Figure 44: 7210 Production overview Process data Tolerances 1 Tolerance monitoring Tolerance monitoring can be switched on or off completely here. The set tolerance values remain unchanged. 2 Automatic reference value determination When this function is activated, the machine determines the arithmetic mean from the last ten cycles, or from the next ten cycles if desired, and uses this mean as the reference value for each process value that does not exist in the form of a setpoint. 3 Parameter The process parameters selected by the operator on screen 7200 are listed here according to classification numbers. Setpoint The reference value for the process parameter is shown here. This may be the entered setpoint or a mean calculated from the process. Values can be entered by hand or determined automatically. Tolerance +/- Tolerances are entered here. Inputs are made in the physical units for the setpoint or reference value and referred to that value. 1.5 / A A AV A A A 02 / 2002

111 Screen 7210 Production overview Process data Tolerances Reaction on infringement The reaction to infringement of a tolerance is set in this column by tapping the required reaction. No reaction (off) Stored reaction If tolerance monitoring for a parameter has been deactivated by touching No reaction (off), the previously set reaction can be reactivated by touching Stored reaction. The reaction active before switching off is reactivated by pressing ENTER. Alarm Reject signal Filter signal and alarm message Machine off at end of cycle Filter signal and alarm message. Machine stops with the cycle conclusion selected on screen Screen 5200 Since a reaction cannot be selected for temperatures, the text Screen 5200 is invariably displayed here. The required reaction can be set separately for cylinder heating zones and mould zones on screen Screen 5200 can be selected directly via the direct selection buttons at the bottom of the monitor. 4 The machine is only switched off if the set number of tolerance violations (e.g. 10) is reached within the reference value to be entered here (e.g. 100 cycles). 02 / A A AV A A A 1.5 / 73

112 7300 Production overview 7-day timer / Cycle conclusion Spritzgiessautomaten Screen 7300 Production overview 7-day timer / Cycle conclusion Figure 45: 7300 Production overview 7-day timer / Cycle conclusion 1 7-day timer On Off 2 Day of week A starting (switch-on) time and a stop (switch-off) time can be programmed for every day of the week. The time only becomes effective when the On switch is tapped and the background colour changes to green, i.e. the time is activated. Important: The start or stop time must be reached, otherwise a reaction cannot take place. The 7-day timer is like a cam controller in which the cam must be tripped. If the heating is to be switched on by the 7-day controller, the tommy switch on the heating must be set to 1 (see chapters 1.3 and 1.5, page 10). 3 Pre-heating temperature When the pre-heating temperature function is selected, the cylinder heating zones are preheated to the specified temperature. The temperature is only increased to the process temperature set on screen 5100 when the operating mode is changed. 4 Time limiting If the heating is switched on by the 7-day timer, the operating mode must be changed within the set time limit, otherwise the heating will be switched off again. 1.5 / A A AV A A A 02 / 2002

113 Screen 7300 Production overview 7-day timer / Cycle conclusion 5 Cycle conclusion If a fault occurs or if the machine is switched off by the 7-day timer, the machine will not stop until the end of the cycle is reached. Possible settings for the cycle conclusion: 1: Mould opens, ejection, stop 2: Mould opens, ejection, nozzle retracts, stop 3: Mould opens, ejection, nozzle retracts, inject slowly, stop 4: Mould opens, no ejection, stop 5: Mould opens, no ejection, nozzle retracts, stop 6: Mould opens, no ejection, nozzle retracts, inject slowly, stop 7: Mould remains closed, stop 8: Mould remains closed, nozzle retracts, stop 9: Mould remains closed, nozzle retracts, inject slowly, stop Machines with pneumatic safety door Cycle conclusion is always performed without Nozzle retraction and without Inject slowly in these machines, even if these options do appear in the selected cycle conclusion. 02 / A A AV A A A 1.5 / 75

114 7400 Production overview Operating data Spritzgiessautomaten Screen 7400 Production overview Operating data 1 2 Figure 46: 7400 Production overview Operating data 1 Accumulated downtimes can be correlated with various causes on this screen. The following causes for standstills are possible: Start time (i.e. tooling before the first automatic operation) Maintenance No job Cause 1, 2, 3, 4, 5 (user-defined text changed on screen 7410) The downtime is added cumulatively whenever the machine is not in automatic or semiautomatic operation. The accumulated downtime can be correlated with one of the possible causes by pressing the corresponding arrow key. The momentary downtime is then zeroed. 2 The production time is also shown on this screen. The machine s effectiveness is calculated from the downtime and production time and displayed here. All downtimes are zeroed when the Reset button is touched. Every change, correlation of downtimes and resetting of the complete downtimes can be cancelled via the UNDO button at the bottom edge of the display. 1.5 / A A AV A A A 02 / 2002

115 7410 Production data Operating data forever Screen 7410 Production data Operating data forever 1 2 Figure 47: 7410 Production data Operating data forever 1 This screen lists the same causes of downtimes as screen 7400, except that they are cumulatively added forever here. These data are not deleted, even when the Reset button is pressed on screen The user can define own texts for causes 1 5 by touching the switch for user defined text changes. A field appears beside the causes when this switch is tapped. Screen 9999 appears when the field is tapped and a text with up to 28 characters can then be entered for the cause. Input must be concluded by pressing Enter. The changed text for causes 1 5 subsequently also appear on screen / A A AV A A A 1.5 / 77

116 7500/7600 Production overview SPC Control chart 1/2 Spritzgiessautomaten Screen 7500/7600 Production overview SPC Control chart 1/2 1 2 Figure 48: 7500 Production overview SPC Control chart 1 The statistical data for the selected process parameter are displayed on this screen. 1 Change over between the standard deviation S and the range R. 2 Xqq is shown as a line in the mean-value chart when switch Xqq is actuated. 1.5 / A A AV A A A 02 / 2002

117 7510/7610 Production data SPC Control chart 1/2 Setup Screen 7510/7610 Production data SPC Control chart 1/2 Setup Figure 49: 7510 Production data SPC Control chart 1 Setup The settings required for operation of the SPC control chart are made on this screen. The process parameter to be statistically presented and evaluated must have been selected in position 1 when selecting the process data on screen The depiction range for the mean-value graph is defined by entering the +/- tolerance values for this parameter on screen The number of random samples required and the number of consecutive cycles (scope of sampling) for a sample must have been defined before starting the SPC. The number of pre-samples may be either 50 or 100 cycles. The number of pre-sample cycles is consequently: scope of sampling x number of pre-samples. There are no pause cycles during the pre-samples. The values for cp, cpk, cm and cmk are determined during this time. 3 The number of cycles until the next sample is defined as the number of pause cycles. 4-6 The depiction range for the standard deviation s and for the range r can be selected here in order to obtain optimum presentation of the values. 02 / A A AV A A A 1.5 / 79

118 7520/7620 Production overview SPC Control chart 1/2 Gaussian distribution Spritzgiessautomaten Screen 7520/7620 Production overview SPC Control chart 1/2 Gaussian distribution 1 Figure 50: 7520 Production overview SPC Control chart 1 Gaussian distribution The Gaussian distribution for the selected process parameter is presented as a bar chart on this screen. 1 If required, the Gauss curve can be built up again via this switch. 1.5 / A A AV A A A 02 / 2002

119 8100 Technician Control step indicator Screen 8100 Technician Control step indicator Figure 51: 8100 Technician Control step indicator 1 This screen page displays the program status. The momentary program step is displayed, together with the current phase of the machine control program. In the event of a standstill during the machine cycle and if unclear fault states arise, the operator should note the step number and phase, as well as the time and other observations and report these to the customer service department. 2 The status of mould, ejector, unit (plasticizing unit) and screw is output in plain text Active setpoints for pump 1: Pressure Back pressure Speed (volume) These are shown as physical and electrical parameters and represent the values delivered to the pump control card by the controller. 02 / A A AV A A A 1.5 / 81

120 8200 Technician Input/Output indicator Spritzgiessautomaten Screen 8200 Technician Input/Output indicator 1 Figure 52: 8200 Technician Input/Output indicator The screen Technician Input/Output indicator is a status indicator for the selected digital inputs and outputs processed by the machine control. 1 The switching state of the valves and inputs/outputs is indicated in the corresponding column for each input or output card. IP 161 A Y10 - Close clamping unit -Y11 - Open clamping unit -Y14 - Mould protection - Not used -Y51 - Injection plunger, decompression -Y53 - Injection plunger, metering - Not used - Not used - Not used -B54 - Hold pressure start 24 V -B53G - Counter input 1, screw speed -B7DI - Counter input 2, screwing device 1.5 / A A AV A A A 02 / 2002

121 Screen 8200 Technician Input/Output indicator A Y33 - Vent mould -Y40 - Advance nozzle -Y41 - Retract nozzle -Y43 - Nozzle force application -Y49 - Hydraulic shut-off nozzle -Y50 - Injection -PRA1 - Programmable output 1 -PRA2 - Programmable output 2 -K010 - Prepare motor ON -K01M - Switch on motor and heating -K01A - Energy-optimized motor control -K8AS - Reject flap, tolerance exceeded -K81 - Heating zone 1 = Infeed -K82 - Heating zone 2 -K83 - Heating zone 3 -K84 - Heating zone 4 = Nozzle A Y60 - Advance ejector -Y61 - Retract ejector - Not used -Y30 - Clamping force application -PRA3 - Programmable output 3 -PRA4 - Programmable output 4 -Y111 - Open mould slowly - Not used -Y05T - Oil preheating -Y06T - Oil cooling controlled -Y19 - Coolant circulation -Y31 - Hold pressure booster down -Y35 - Clamping force reduction -Y80 - Water valve for temp. of feed opening -H00 - Fault indicator -K8R - Heater fault A B18 - Outturn monitor / outturn scales -K201 - Operation with handling units -K210 - Enable mould closing -PRE1 - Programmable input 1 -PRE2 - Programmable input 2 -PRE3 - Programmable input 3 -PRE4 - Programmable input 4 -B61W - Ejector safety switch 02 / A A AV A A A 1.5 / 83

122 Screen 8200 Technician Input/Output indicator Spritzgiessautomaten Not used - Not used - Not used -S02W - Changeover setup keys 30A-2C -B52 - Screw (Micro) -B21 - Interlock rack -K8E - Heating ON -Z00 - Enable proportional valve -K010E - Safety circuit -K01ME - Motor contactor K01 ON -F01B - Motor protection for pump motor tripped -B05N - Minimum oil level -B05D - Negative pressure, filter -B42 - Nozzle protection flap -B26 - Hydraulic protection of clamping unit -B25 - Monitoring of roller lever valve -B22 - Rear safety hood switches -B20 - Front safety hood switches -B950 - Nozzle protection top -B951 - Nozzle protection bottom -B43 - Injection unit slewed outwards -S20 - Push-button, close safety door -S21 - Push-button, open safety door -B28 - Safety bar, safety hood A B70 - Core A inserted -B71 - Core A pulled -B72 - Core B inserted -B73 - Core B pulled -B762 - Brush in home position -B761 - Brush raised -B760 - Brush lowered -B75 - Cylinder mould unlocked (30A-2C) -B76 - Cylinder mould locked (30A-2C) -B77 - Turn mould forwards (30A-2C) -B78 - Turn mould backwards (30A-2C) - Not used -S75 - Turn mould (30A-2C) -K260 - Enable ejector forwards -K261 - Enable ejector backwards -K270 - Enable core insertion -K271 - Enable core pulling -K65 - Ejector connected -B60 - Ejector advanced (limit switch) -B61 - Ejector retracted (limit switch) - Not used - Not used 1.5 / A A AV A A A 02 / 2002

123 Screen 8200 Technician Input/Output indicator A Y21 - Open safety fence -Y24 - Nozzle protection VH -Y48 - Evacuate -K54DK - Range selection, mould internal pressure -K54F - Enable mould internal pressure -X541 - Hold pressure start -B56W - Position of melt cushion reached -Y20 - Close safety fence - Not used -Y72 - Mould insert core B -Y73 - Mould pull core B -Y70 - Mould insert core A -Y71 - Mould pull core A - Not used - Not used - Not used A K10W - Mould closed -K11W - Mould open -K60W - Ejector at front -K61W - Ejector at rear -K01PV - All-automatic -K7QA - Core pullers advanced -K7QE - Core pullers retracted -K01PE - Setup mode -Y75 - Cylinder mould unlocked (30A-2C) -Y76 - Cylinder mould locked (30A-2C) -Y77 - Turn mould forwards (30A-2C) -Y78 - Turn mould backwards (30A-2C) - Not used - Not used -K8KW - Change box - Not used A Y64 - Air blast device 1 -Y66 - Air blast device 2 -Y760 - Brush down -Y761 - Brush up -Y762 - Turn brush -Y763 - Spraying (brush control) - Not used - Not used 02 / A A AV A A A 1.5 / 85

124 8310 TECHNICIAN MACHINE DATA DEFAULT SETUP Spritzgiessautomaten Screen 8310 TECHNICIAN MACHINE DATA DEFAULT SETUP Figure 53: 8310 TECHNICIAN MACHINE DATA DEFAULT SETUP 1 Language Choice of display language (basic languages: German / English / French / Spanish) Unit of measure Changeover between %, mm/s and ccm/s. Setpoints and actual values are entered or displayed in mm or ccm, depending on the unit of measure set here. 2 3 So-called constant lists are the most important element on this screen. These constant lists are normally set once in the factory during commissioning and need not subsequently be corrected. The constant lists define the machine-based constants according to clamping unit, ejector, injection and plasticizing unit, temperatures and others. The selected constant lists should not normally be changed. Any changes that may be required should only be made in consultation with the customer service department. The screw diameter and machine number can be entered on this screen for information. If the screw diameter is changed, all related injection unit data will be converted and any infringements displayed. 4 The software versions for screen data and visualizing firmware, as well as for the operating system are important items of information. If faults develop in the machine, these version numbers must be reported to the customer service department in addition to the fault description. 1.5 / A A AV A A A 02 / 2002

125 8320 TECHNICIAN MACHINE DATA Equipment Screen 8320 TECHNICIAN MACHINE DATA Equipment Figure 54: 8320 TECHNICIAN MACHINE DATA Equipment This screen is normally set once during commissioning in the factory, since it contains the machine configuration. If additional functions are retrofitted on the machine, the retrofitted configuration must be activated by entering a 1 on this screen. Inputs must be confirmed by pressing Enter. Depending on the activated equipment, additional direct selection buttons for additional screen pages appear or disappear at the sides of the main menu. The possibilities for entering values and displays of actual values on the various screen pages similarly change in line with the machine equipment. Oil preheating Oil preheating can be activated or deactivated and the setpoint (40 C) entered. The oil temperature is now adjusted to the setpoint for oil preheating. Alarm indicator, continuous light When this function is activated, the alarm indicator lights up continuously in the event of a fault instead of flashing. Optimization of mould movement When this function is activated, the mould automatically moves to the set open position and to the mould protection position, regardless of the set profile. 02 / A A AV A A A 1.5 / 87

126 8410 TECHNICIAN MACHINE LIMIT VALUES Injection unit Spritzgiessautomaten Screen 8410 TECHNICIAN MACHINE LIMIT VALUES Injection unit Figure 55: 8410 TECHNICIAN MACHINE LIMIT VALUES Injection unit 1 The injection pressure sensor and back pressure valve are calibrated on this screen. A voltage is assigned to each pressure (depending on machine type). Defaults: 0 bar 210 bar (180bar) 1 V 10 V 2 3 Every pressure value can be used for calibration. The pressure reading on a reference instrument is entered for this purpose and the actual pressure matched with the setpoint by varying the setpoint voltages. To set the proportional valve back pressure, corresponding setopints are set for the back pressure on screen 4000 Plasticizing. The actual pressure must then be matched with the setpoint pressure by varying the setpoint voltages. Defaults: 0 bar 50 bar 0,3 V 8 V The injection pressure transducer must in all cases have been calibrated beforehand. Information displayed: Max. screw speed Emptying speed The following inputs must be made on this screen: Pulses per revolution (= twice the number of teeth) Emptying pressure (active when injection unit is slewed out) 4 If the cavity pressure sensor has been activated on screen 8320, corresponding input fields will appear here. 1.5 / A A AV A A A 02 / 2002

127 8420 TECHNICIAN MACHINE LIMIT VALUES Clamping unit Screen 8420 TECHNICIAN MACHINE LIMIT VALUES Clamping unit Figure 56: 8420 TECHNICIAN MACHINE LIMIT VALUES Clamping unit The pressure transducers of the clamping unit are calibrated on this screen. A voltage is assigned to each pressure value for this purpose. Defaults (depending on machine type). 1 2 Hydraulic pressure transducer 0 bar 210 bar (180 bar) system pressure 1 V 10 V High-pressure transducer 0 bar 350 bar (high pressure) 1 V 10 V Every pressure value can be used for calibration. The pressure reading on a reference instrument is entered for this purpose and the actual pressure matched with the setpoint by varying the setpoint voltages. 3 Information displayed: System pressure Speed Mould closing Mould opening / open fast mode Ejector advance / retract 02 / A A AV A A A 1.5 / 89

128 8510 TECHNICIAN SERVICE Zero point adjustment (1) Spritzgiessautomaten Screen 8510 TECHNICIAN SERVICE Zero point adjustment (1) 1 2 Figure 57: 8510 TECHNICIAN SERVICE Zero point adjustment (1) Electrical adjustment of the position transducers for the clamping unit and ejector can be carried out on this screen. The adjustment is normally made once in the factory and need only be repeated when a defective position transducer has to be replaced. The machine must be in setup mode for adjustment of the zero point. 1 Clamping unit 2 Ejector The mould need not be removed for this purpose, although the best results are obtained if the mould is removed first. 1. Close the clamping unit as far as possible in setup mode. 2. Measure the platen distance and enter the value in the field marked PD on the right. 3. Open the clamping unit as far as it will go mechanically. 4. Measure the platen distance and enter the value in the second field on the lefthand side of the display. All the values required will be calculated from these two inputs by the controller. The zero point correction value is similarly calculated and displayed. The correction value represents the difference between the absolute zero point of the transducer and the value specified in step 2. Note the two input values and the correction value: these three values precisely define the installed position of the transducer. The ejector must be moved to the rear position when decoupled, without mould and in setup mode. The value zero must then be entered in the left-hand field and confirmed by pressing Enter, as for all other inputs. The ejector is then advanced as far as it will go mechanically in setup mode. The distance measured from the zero point in mm is now entered in the right-hand field. All other required values are calculated from this by the controller. 1.5 / A A AV A A A 02 / 2002

129 8511 TECHNICIAN SERVICE Zero point adjustment (2) Screen 8511 TECHNICIAN SERVICE Zero point adjustment (2) 1 2 Figure 58: 8511 TECHNICIAN SERVICE Zero point adjustment (2) Zero point adjustment for the plasticizing unit and screw is carried out on this screen. 1 Plasticizing unit The plasticizing unit must be advanced to the mechanical stop in setup mode. A zero is entered in the left-hand field. The plasticizing unit must then be moved back as far as possible to the mechanical stop. The distance measured from the zero point is then entered in the right-hand field. All other required values are calculated from these two values. 2 Screw The screw is advanced to the stop in setup mode. A zero is entered in the left-hand field marked Zero point. The screw must then be moved back to the mechanical stop in setup mode and the distance measured from the zero point is entered in the right-hand field (Maximum value). All other values are calculated from these two values. 02 / A A AV A A A 1.5 / 91

130 8520 Technician Service Temperature parameters Spritzgiessautomaten Screen 8520 Technician Service Temperature parameters /6 8 5/7 9 Figure 59: 8520 Technician Service Temperature parameters The temperature controller of the Procan CT includes a self-optimization function. Temperature control should normally function perfectly with the control parameters contained in the lists of constants, so that optimization should only be required in exceptional cases. 1 Heating zone 2 Control parameters 3 Factors Indication of the heating zones Max. rise time (speed) 0,1 C/s Delay time sec. Amplitude %/ C Period sec. Adjustment of amplification Adjustment of integral action time Adjustment of rate time Adjustment of curve rate-of-rise 1. Manual optimization 1.1 Parameter adjustment by hand (2): This option should normally not be used, since it requires detailed, in-depth knowledge of control systems. 1.5 / A A AV A A A 02 / 2002

131 Screen 8520 Technician Service Temperature parameters 1.2 Adjustment of factors (3): This is the recommended method for optimizing controlled zones by hand. Value zero is impermissible. If zero or an excessively large value is entered, a value greater than 30,000 will appear in the optimization status. See Adjustment of amplification: The degree of control is incremented or decremented in line with the deviation between setpoint and actual value. Response Actual temperature fluctuates. Excessive overshooting, despite small adjustments in setpoint (incremented in 5 steps). Excessive drop in temperature when starting because 100% duty cycle is reached too slowly. Remedy Reduce value (0,9 0,8 0,7...) Increase value (1,1 1,2 1,3 1,4...) Adjustment of integral action time: Change in degree of control depends on deviation between setpoint and actual value, as well as on time. Compensation of permanent deviation. Response Actual value takes very long to reach the setpoint or does not reach the setpoint at all (always remains a few degrees below the setpoint). Actual temperature fluctuates. Excessive overshooting, despite small adjustments in setpoint (incremented in 5 steps). Remedy Reduce value (0,9 0,8 0,7...) Increase value (1,1 1,2 1,3 1,4...) Adjustment of rate time: Brakes the controller. The degree of control is decreased before reaching the setpoint when heating up. When the setpoint is reduced, a degree of control is built up before the actual value reaches the setpoint. Response Actual temperature fluctuates. Setpoint is no longer or barely reached even when the setpoint is adjusted in small steps (incremented in 5 steps). Heating up in steps. Undershooting when setpoint is reduced or when starting up. Degree of control is only established after a delay. Excessive overshooting even when setpoint is increased in small steps. Remedy Reduce value (0,9 0,8 0,7...) Increase value (1,1 1,2 1,3 1,4...) Adjustment of curve rate-of-rise: Determines the rate of temperature increase. The heating-up process can be specifically slowed in this way if necessary. Response Heating-up phase too slow Excessive overshooting when heating up Remedy Increase value (1,1 1,2 1,3 1,4...) Reduce value (0,9 0,8 0,7...) 02 / A A AV A A A 1.5 / 93

132 Screen 8520 Technician Service Temperature parameters Spritzgiessautomaten 2. Self-optimization (4/5) 4 Optimization 2.1 Optimization This basic optimization should normally not be used, not even after changing plasticizing units. Basic optimization is only appropriate in machines in which zones 1,2,3,4 are used to heat the mould. Optimization can take up to 90 minutes. Basic optimization can be interrupted by hand at any time via the switch Optimization switched off (stop). Requirements: Optimization temperature must be greater than 150 C. The actual temperature of all zones concerned must be less than 100 C. Optimization is only performed for those zones for which a setpoint other than zero has been set. 5 Optimization temperature + Procedure: Enter the temperature in the field Optimization temperature. When working with materials which are susceptible to high temperatures, note that heating zone 4 heats up to 20 above the optimization temperature. Switch on the heating and then immediately start via the switch Optimization start Optimization process: Zones 2 and 3 heat up to the optimization temperature. Zone 1 (feed zone) to 10 less than the optimization temperature and zone 4 (nozzle) to 20 above the optimization temperature. The values for the delay time and maximum rise time are determined when heating up to the optimization temperature. The amplitude and period of oscillation are then determined in an oscillation test with four oscillations altogether. When the four oscillations have been completed by all zones, optimization is deactivated and adjusted to the preset setpoint. The corresponding parameters are recalculated after the optimization. The parameters are saved when the machine status is saved on screen / A A AV A A A 02 / 2002

133 Screen 8520 Technician Service Temperature parameters 6 Post-optimization 2.2 Post-optimization Post-optimization should always be performed whenever an acceptable controlled result cannot be obtained with the basic parameters and manual adjustment. The post-optimization process can be interrupted by hand at any time via the switch Post-optimization switched off (stop). Requirements: The actual value must be as close as possible to the setpoint, i.e. balanced out. The maximum deviation between actual value and setpoint must not exceed 20. Post-optimization is only performed for one zone at a time. Procedure: 7 Heating zone Enter the zone to be optimized. Start via the switch Post-optimization start. Optimization process: The zone is made to oscillate around the preset setpoint. Three oscillations are performed. The amplitude and period are determined. The oscillation can reach up to approx. 15, but is usually smaller. Post-optimization can also be performed while automatic operation is in progress. However, tolerance monitoring should be deactivated first. The corresponding parameters are recalculated after post-optimization. The parameters are saved when the machine status is saved on screen Status Optimization status: =No error =Parameterization aborted because setpoint has been changed or optimization interrupted =Parameterization aborted by timeout =Invalid value for amplitude measured in oscillation test =Invalid value for period measured in oscillation test =Invalid value calculated for amplification =Invalid value calculated for integral action time =Invalid value calculated for rate time Post-optimization status not equal to 0 = Parameterization limit reached 9 Temperature limit value If the temperature limit value set here is exceeded by any of the actual values in the cylinder heating zones, the main heating contactor will be de-energized directly. This ensures that a defective semiconductor relay cannot lead to an uncontrolled rise in temperature. 02 / A A AV A A A 1.5 / 95

134 8521 Technician Service Temperature calibration Spritzgiessautomaten Screen 8521 Technician Service Temperature calibration Figure 61: 8521 Technician Service Temperature calibration The four cylinder heating zones can be calibrated on this screen. However, the temperature should only be adjusted by a few degrees. Sensors, sensor installation, wiring and hardware should be checked first if a larger deviation is found. Sensor temperature Calibrated temperature Calibration The actually measured temperature is shown here. This value only appears on this screen. The calibrated temperature is displayed here. This value also appears on all other screens and is used for logging. Each of the four zones should be calibrated at low temperature (room temperature) and at high temperature (over 200 C). The reference value and the raw value must be entered for each minimum and maximum. Important: temperature measurement will not work if values are not entered on this screen. The defaults are shown above. Raw value Reference value The value in the Sensor temperature field must be entered here. The value shown on a reference instrument must be entered here. 1.5 / A A AV A A A 02 / 2002

135 8530 Technician Service Copy temperature parameters Screen 8530 Technician Service Copy temperature parameters Figure 60: 8530 Technician Service Copy temperature parameters Save and load temperature parameters: The heating parameters are saved in the machine status and in the setup data record. When loading the machine status, the loaded parameters are immediately adopted as the current parameters. The heating parameters are not adopted automatically when loading the setup data record. The parameters loaded from the setup data record are shown in the second line in each case. If the parameters differ, the advisory message Different temperature parameters for machine and setup data is output after loading the setup data record. The selector to Copy the temperature parameters must be set to Copy if these parameters are to be adopted as the current parameters. For mould heating purposes, heating parameters specific to the mould concerned can be loaded in this way. It is often undesirable to load specific heating parameters for cylinder heating purposes. 02 / A A AV A A A 1.5 / 97

136 9000 PRESSURE GAUGE Spritzgiessautomaten Screen 9000 PRESSURE GAUGE Figure 62: 9000 PRESSURE GAUGE An analog pressure gauge appears on this screen so that the pressure can also be read off at a distance during setup work. Direct selection buttons 1 Change to screen 3300 OSCILLOSCOPE CHANNEL 1 2 Change to screen 3310 OSCILLOSCOPE CHANNEL 2 3 Filter 4 Scroll back through the last 16 screen pages used 5 Scroll forwards through the last 16 screen pages used 1.5 / A A AV A A A 02 / 2002

137 2 Shipping and installation 2.1 Shipping, storage and installation Safety precautions for shipping and storage Shipping unpacked Shipping the packed machine Storage Installation, working place of operational staff Floor load Levelling Cleaning and assembly 2.2 Hyraulic fluid fill Hydraulic fluid types Quantities Installing the hydraulic fluid 2.3 Water supply connection, water consumption Water supply connection Cooling circuit for the fluid tank Mould cooling circuit Water consumption Hydraulic fluid cooling Mould cooling Water quality Water hardness 2.4 Electrical connections Feed lines Connecting the control voltage transformers 11 / M / A M / A MV / AV D M / A D

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139 2.1 Shipping, storage and installation Safety precautions for shipping and storage Shipping unpacked Boards are attached underneath the machine frame to provide sufficient clearance for lifting forks. Fork-lift trucks are to be used for moving the units inside the plant and when loading them on trucks. When loading on vehicles, the following shall be observed: Center of gravity (marked at the machine frame) Keep the machine level Avoid jerks when starting. Use ropes to lash the machine on the truck bed. Cover with plastic sheeting to protect against moisture. (only for open-bed vehicles) The machine is always to be transported without hydraulic fluid (hazard of fluid escaping in case of an accident) 11 / MV / AV 2.1 / 1

140 Shipping, storage and installation Spritzgiessautomaten Shipping the packed machine Larger machines are crated, smaller ones are packed in cardboard. The base plate is bolted to the machine and provides sufficient clearance for transportation using a fork-lift or lifting truck. L B H X Crate dimensions: Crate length Crate width Crate height Clearance 22M/A VV 22M/A VH L 2050 mm 2130 mm B 1030 mm 1050 mm H 2780 mm 2030 mm X 100 mm 100 mm The precautionary measures mentioned in Section are also to be observed when moving the machine in its packaging Storage Machines which are packed are protected against moisture by a sealed plastic envelope. Condensate can form if there are extreme temperature fluctuations and this could result in corrosion damage. Regardless of whether packaged or not packaged, machines should be stored only in dry areas. Storage conditions: Relative humidity Room temperature ê max. 70 % ê 5 40 C / 2 MV / AV 11 / 2001

141 Shipping, storage and installation Installation, working place of operational staff Space requirements Dimensions for installation and connection: refer to the space requirement plan in Section max. height max. height VH = 1897 VV = 2946 VH = 1980 VV = Attention: Do not use step-ladders etc. to operate the machine. Only separate, stable, non-slip ladders or plinths are to be used for hopper changing, discharge and re-filling Working place of set-up personell Maximum footprint (m 2 ) Working place of operator / MV / AV 2.1 / 3

142 Shipping, storage and installation Spritzgiessautomaten Floor load Floor load Machine weight + Mould weight [kg] [kg/m 2 ] = Max. footprint [m 2 ] Machine Machine weight Mould weight Max. footprint Floor load VV VH [kg] [kg] [m 2 ] 1,6 1,6 [kg/m 2 ] Levelling The included levelling pads are to be mounted before setting the machine down on the floor. Á À Levelling: Loosen the lock nut, Item 1. Rotate the threaded spindle, Item 2, to adjust machine height. Height adjustment max. = 10 mm. Set the levelling pads so that all pads are in full contact with the floor and that the machine is level. Once the adjustment has been made, re-tighten the lock nut, Item 1. The levelling pads can be adjusted in the vertical direction only Cleaning and assembly Remove the machine protection compound. Mount the included parts, such as the hopper, etc / 4 MV / AV 11 / 2001

143 2.2 Hydraulic fluid fill Hydraulic fluid types Only mineral oil based hydraulic fluids with highly active additives may be used which do not affect lead containing bearing materials. The requirements of VDMA and DIN 51524, part 2 for HLP hydraulic oils must be met or essential properties exceeded. The following oil grades can be used for the automatic injection moulding machine: Supplier Oil grade Aral GF 46 BP HLP 46 Castrol Hyspin SP 46 S Hyspin AWS 46 Chevron EP 46 Esso NUTO-H 46 Total Fina Elf Total Azolla ZS 46 Elf Elfona DS 46 Fuchs Renolin B 15 Mobil Mobil DTE 25 Shell Tellus 46 Texaco HDC 46 Wintershall Wiolan HS 46 Refer to the safety notes in Section Quantities Machine typ Quantities 12 M / A 115 L 22 M / A, D 115 L 22 M / A, VV-VH 105 L 30 M / A, D 115 L 55 M / A 200 L 90 M / A 200 L HLPD oils may be used provided they conform with the requirements of DIN 51524, Part 2 and VDMA Please consult the manufacturer before using! 01 / M / A M / A MV / AV D M / A D M / A M / A 2.2 / 1

144 Oil filling Spritzgiessautomaten Filling the hydraulic fluid Before filling hydraulic fluid remove the cap at the tank and inspect the inside of the tank for cleanliness. Re-install the tank cap and tighten. Fill the pump with hydraulic fluid: To do so, detach the leaked fluid line, fill until fluid escapes, and then reattach the leak line. Leaked fluid line Open the filler pipe (bayonet catch). Pour the fluid through a fine-mesh strainer0 to keep any foreign particles which may be present in the container from entering the tank. Fill the tank, until the level, show on the sight glass has been reached. Close the filler pipe once again. Fluid filler pipe Sight glass / 2 M / A M / A MV / AV D M / A D 01 / 2002

145 2.3 Water supply connection, water consumption Water supply connection Cooling circuit for the fluid tank M Temperature control valve M/A Coolant valve Y06T Stop cock Return, (drain) ø21feed, (inlet) ø21 Return, (drain) ø21feed, (inlet) ø21 Connection Connect the feed and return lines as shown. When making the connections, pay attention to the arrow on the valve indicating the direction of flow. Max. water pressure is 10 bar. M The temperature control valve is set at the factory for 40 C (fluid tank temperature). Re-adjust only if the fluid temperature deviates from 40 C. (see Chapter for adjustment instructions) M/A The Y06T coolant valve (solenoid) in the return line of the coolant circuit opens to allow water to flow if the temperature exceeds 40 C. The valve is closed at temperatures below 40 C. The factory setting for the flow control valve may be changed only by a customer service technician. Hydraulic fluid temperature indicator The fluid temperature is shown at the screen. M-Machine A-Machine ê + Note: Excessive fluid temperature will increase the leak rate and reduce the service life of hydraulic components, seals and gaskets. ê 01 / M / A M / A MV / AV M / A 2.3 / 1

146 Water connection, water consumption Spritzgiessautomaten Mould cooling circuit Mould cooling To keep the mould temperature constant, the mould cooling circuit is installed seperately from the cooling circuit of the hydraulic fluid. The connection of the water supply for the mould temperature at the coolant manifold s inlet and outlet (see illustration). Front row - Feed Back row - Return Coolant manifold Return Mould connections Feed section Feed Return Feed Operating parameters Coolant temperatures max. pressure 40 C 8 bar 60 C 6 bar 80 C 4 bar + Caution: These parameters must be observed. Any non-observance may result in damage to the equipment and for injuries to operators. Cooling at the feed section The first circuit has already been set up at the factory to serve the feed section for the plasticizing unit / 2 M / A M / A MV / AV D M / A D 11 / 2001

147 Water connection, water consumption Water consumption The diagram below shows the water consumption as a function of the temperature difference between cooler inlet and outlet and as a function of the cycle time Hydraulic fluid cooling Example: 30M/A/D Example: 22 M/A/D Example: 12M/A known: Cycle time 1,5 sec Temp. difference 7,5 C known: Cycle time 6 sec Temp. difference 20 C known: Cycle time 6 sec Temp. difference 11 C Shown in the graph - at 340 litres/hour Shown in the graph - at 58 litres/hour Shown in the graph - 43 litres/hour Power consumption 12,5 4 (kw) 10 30A-2C 3 7,5 30M/A/D 22M/A/D 2 5 Temperature difference 1 12M/A ( C) Water consumption (l / h) Cycle time (sec.) / M / A M / A MV / AV D M / A D 2.3 / 3

148 Water connection, water consumption Spritzgiessautomaten Mould cooling Flow diagramm Float position l/min The machine is fitted as standard with a water manifold which supports four cooling circuits. Maximum flow per circuit is 10 l/min if the larger water manifold option with more than four cooling circuits is installed Water quality The following analytical parameters should remain within the limits specified if water is used as the circulating medium in heat transfer systems: Hardness ph value at 20 C Chloride ions Total chlorides and sulphates 5-25 d 6,5-8,5 max. 150 mg/l max. 250 mg/l Drinking water frequently meets the requirements imposed. Excessively soft water (water which has been excessively demineralized, distilled water and rainwater) can have a corrosive effect. Corrosion is expedited in particular by the concentration of chlorides. Excessively hard water expedites the formation of boiler scale and sludge Water hardness mval/l d e f US 1 mval alkaline earth ions 1,00 2,80 3,51 5,00 50,0 1 German degree d 0,357 1,00 1,25 1,78 17,8 1 English degree e 0,285 0,798 1,00 1,43 14,3 1 French degree f 0,200 0,560 0,702 1,00 10,0 1 American degree* US 0,020 0,056 0,070 0,10 1,0 * Values in ppm, assuming that 1 litre water has a mass of 1 kg / 4 M / A M / A MV / AV D M / A D M / A M / A 01 / 2002

149 2.4 Electrical connection 22 M / A / MV / AV 5,5 kw Pump motor Standard Plasticising unit Total apparent power Total rated current Customers fuse Feeder wire size Rated drive current Customers fuse Feeder wire size Rated heating current Customers fuse Feeder wire size 22 D 5,5 kw Pump motor Standard Plasticising unit Total apparent power Total rated current Customers fuse Feeder wire size Rated drive current Customers fuse Feeder wire size Rated heating current Customers fuse Feeder wire size Operating voltage 1) 5) 4) 460 V 415 V 400 V 400 V 230 V 230 V 200V 60 Hz 50 / 60 Hz 50 / 60 Hz 50 / 60 Hz 50 / 60 Hz 50 / 60 Hz 50 / 60 Hz (kva) 12,4 15,5 15,1 26,1 15,3 15,3 14,5 I 1 (A) 15,6 21,5 21,9 37,8 38,5 38,5 41,9 F 1 (A) Q 1 (mm 2 ) 2,5 2,5 2, (AWG) I A (A) 9,5 10,5 10,9 26,9 22,7 22,7 26,1 F A (A) 2) Q A (mm 2 ) 2) 1,5 1, (AWG) I H (A) 6,6 11,9 11,8 11,8 17,2 17,2 17,2 F H (A) 2) Q H (mm 2 ) 2) 1,5 1,5 1,5 2,5 2,5 2,5 (AWG) Operating voltage 1) 5) 4) 460 V 415 V 400 V 400 V 230 V 230 V 200V 60 Hz 50 / 60 Hz 50 / 60 Hz 50 / 60 Hz 50 / 60 Hz 50 / 60 Hz 50 / 60 Hz (kva) 14,4 14,6 14,3 25,4 15,6 15,6 14,7 I 1 (A) 18,1 20,4 20,7 36,7 39,3 39,3 42,6 F 1 (A) Q 1 (mm 2 ) 2,5 2,5 2, (AWG) I A (A) 9,5 10,5 10,9 26,9 22,7 22,7 26,1 F A (A) 2) Q A (mm 2 ) 2) 1,5 1, (AWG) I H (A) 9,4 10,7 10,6 10, F H (A) 2) Q H (mm 2 ) 2) 1,5 1,5 1,5 2,5 2,5 2,5 (AWG) ) With 1 additional DS- socket 400 V / 16 A in the driving circuit 2) Only for common feeder cable 4) Direct start 5) Star-delta start + ATTENTION! The electrical equipment of machines is to be inspected and checked at regular intervals. Defects such as loose connections or scorched cables must be rectified immediately. 11 / M / A MV / AV D 2.4 / 1

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151 Electrical connection Feed lines Common feeder cables for drive and heating Drive Heating Separate feeder cables for drive and heating Drive Heating + ATTENTION! Put safety covers on terminals after connection of power supply cable. 11 / M / A M / A MV / AV D M / A D M / A M / A 2.4 / 3

152 Electrical connection Spritzgiessautomaten Connection the control voltage transformers See terminal plan or voltage data on the electrical parts. + ATTENTION! Prior to starting up the machine please check for the correct connection of control transformers. This check must be made by qualified personnel / 4 M / A M / A MV / AV D M / A D M / A M / A 11 / 2001

153 3 Operating notes 3.3 Pressure measuring instruments 3.7 Oil preheating and cooling Oil preheating Oil cooling 3.9 Mould installation 3.11 Nozzle alignment 3.12 Adjustment of nozzle needle 3.13 Changing out the hopper 3.14 Screw and barrel change Barrel change Change of screw tip 01 / M / A M / A MV / AV M / A

154 + Daily safety check! 1. Have all installation tools been removed from the machine after set-up? 2. Access to the mould excluded on all sides? (Visual check - Pay attention to accessories) 3. Limit switches/contact strip on safety hood functioning correctly? 4. Stops and guides for safety hoods functioning correctly? 5. Potential points of crushing and/or shearing danger on the plasticizer unit guarded? 6. Heating system correctly set for the plastic to be processed? 7. Discharge opening shielded? 8. Injection molding machine free of oil and water leakage? 9. Working area free of potential stumbling points, granulate and other fouling? M / A M / A MV / AV D M/A/A-2C D M / A M / A 01 / 2002

155 3.3 Pressure measuring instruments Pressure reading: All pressure readings are displayed or available on the screen. (see chapter 1.5) M-Machine Pressures of clamping unit and system pressure (pump pressure) on screen page Pressures of injection unit on screen page A-Machine Pressures of injection unit on screen page Pressures of clamping unit on screen page System pressure displayed (pump pressure) on screen page Pump unit with pressure sensor B01D B01D 11 / M / A MV / AV M / A 3.3 / 1

156 Pressure measuring instruments Spritzgiessautomaten Clamping unit with pressure sensor B30D B30D Injection unit with pressure sensor B5D B5D / 2 M / A MV / AV M / A 11 / 2001

157 3.7 Oil preheating and oil cooling By starting production with warm hydraulic fluid, rejects are prevented and the start-up times are reduced Oil preheating If the oil preheating function has been activated on screen 8320, it can be switched on with the heating via the 7-day timer (screen 7300). Automatic oil pre-heating is possible only with the machine in the stop operating mode. (see description in chapter 1.5) A temperature can additionally be entered at which preheating of the oil is to stop automatically. Screen 8320 ê Oil cooling The oil temperature can be entered here and this temperature is regulated using a switching valve for the water supply. The oil pre-heating unit also regulates to the value entered. If the set-point value is zero, a temperature of 40 C is set. Switching valve / 2002 A A AV A/A-2C A A 3.7 / 1

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159 3.9 Mould installation Closing plate Mounting plate Mounting dimensions: The attachment dimensions applicable when mounting the mould are given in chapter in the table specifying the mould mounting and ejector dimensions. Before installing mould check: Nozzle radius Nozzle depth Nozzle bore Temperature control connections Corepulling system Unscrewing device system Hotrunner Insulating plates Special programs Other peripheral equipment Take care of lubrication points 11 / AV 3.9 / 1

160 Mould installation Spritzgiessautomaten Mould installation: 1. Before installation reduce opening and closing speed to a minimum. 2. Place moving to the open end position. 3. Injection unit back. ATTENTION! Switch off main switch. 4. Lift mould in and bolt to the fixed platen. 5. Recheck ejector position. ATTENTION! Switch on main switch and pumpmotor. 6. Advance the moveable mould platen toward the mould (not at high pressure). Set the clamping pressure application position, Mould closed limit, for the minimum value (Screen 1100). 22A: 200,0 Screen Open gate and bolt on the moving mould half. 8. Set the opening stroke, mould protection stroke and clamping pressure application position for mm. 9. Connect mould cooling - or heating equipment. + ATTENTION: The total weight of the mould must not exceed 250 kg A AV 3.9 / 2 09 / 2000

161 3.11 Nozzle alignment Nozzle bore Through unfavourable addition of tolerances, the nozzle bore may be offset in relation to the mould casting bushing, in which case over-injection occurs. Procedure for series VV machines Move the nozzle into position for measurement: The tip of the nozzle should be aligned (in a single plane) with the mould mounting surface. Removing the cover eliminates the need to execute any potentially hazardous movements of the injection unit. Loosen the flange mounting screws, item 1. Adjust in the fashion described below. When adjustment is complete, tighten down the mounting screws and reattach the covers at the injection unit. À 1 Mould centring Nozzle 3 R R à Measure with the calipers and correct the deviation. 5 Adjustment: front/back 1. Loosen set screws 1 and 3 by about 2 turns. 2. Loosen set screw 4 slightly, by about 1/2 turn. 3. Tighten set screws 2 and In reverse order for the opposite direction. Adjustment: left/right 1. Loosen set screws 4, 1 and Tighten set screw In reverse order for the opposite direction. The threads on the pins have a pitch of 1,5 mm. 11 / MV / AV 3.11 / 1

162 Nozzle alignment Spritzgiessautomaten Procedure for series VH machines Loosen the mounting screws, item 1, at the boom. Loosen the adjustment screws, item 3, together with the lock nuts. Loosen the screws, item 2, at the rear injection unit mount. Height adjustment: The height is adjusted by rotating the threaded spindle, item 4. Adjustment range = 70 mm Pitch of the threaded spindle = 1.5 mm Lateral adjustment: The lateral is adjusted by rotating the threaded pins, item 5. Pitch of the threaded pins = 1.5 mm À Â Á Ä Ã Ä Once the adjustment has been made, tighten down the mounting screws, items 1 and 2. Turn the adjustment screw, item 3, down to the stop and tighten the lock nuts / 2 MV / AV 11 / 2001

163 3.12 Adjustment of nozzle needle Nozzle needle To ensure that the surface of the sprue point is in a plane with that of the mould, the stroke range for the height of the nozzle needle is adjustable where using hydraulically actuated shut-off nozzles. Procedure: The pump must be switched on. Loosen the lock nuts, Item 1. Adjust the nozzle needle by rotating the turnbuckle, Item 2, until the face of the needle is flush with the surface of the nozzle. Re-tighten the lock nuts, Item 1, after the adjustment has been made. When dealing with nozzles AC and BC (Chapter 1.1.3) the needles are adjusted so that the forward face is aligned with the plane represented by the injection surface of the moulded part. Incorrect Incorrect Correct Needle too low Needle too high À Á À 11 / MV / AV 3.12 / 1

164 3.13 Changing the hopper Spritzgiessautomaten + Attention: Separate, stable non-slip ladders or plinths must be used for hopper changing, discharge and re-filling. Do not use step-ladders etc. to operate the machine. Procedure: 1. Push in the slider, Item 1, at the hopper outlet. 2. Rotate the knob, Item 2, to release the hopper. 3. Lift the hopper out of the locating pins. VH VV ê Á À ê ê Á + + Important! Maximum hopper weight of 35 kg must not be exceeded. Important! The hopper must be grounded (to avoid static charges) if material is fed to the plasticizing unit automatically / 1 MV / AV 02 / 2002

165 3.14 Screw and barrel change Barrel change + Note: Always wear safety gloves and a face guard when working on nozzles, barrels and screws when the unit is in a heated state! See safety references chapter 1.4. Procedure: 1. Heat plasticizing unit. Attempting to retract a cold screw can cause damage to the coupling. 2. Retract the complete injection unit to endposition. 3. Continue injection until the plasticizing unit is empty. 4. Use the decompression key to retract the screw to minimum 30 mm. VH-Maschine 5. Remove the forward, center and rear covers from the injection unit. 6. Remove the hopper (see Chapter 3.13), and the heater band cover. 7. Loosen the clamping ring, Item 1, and slide it to the rear. 8. Rotate the screw at which the pin, Item 2, can be removed from underneath. 9. Switch off the pump and knock the pin Item 2 out with a mandrel. 10. Open the nozzle guard and remove the hopper nipple. VV-Maschine 5. Remove the safety cover and heater band cover from the injection unit. 6. Remove the hopper. (see Chapter 3.13) 7. Loosen the clamping ring, Item 1, and slide it to the top. 8. Rotate the screw at which the pin, Item 2, can be removed from rear. 9. Switch off the pump and knock the pin Item 2 out with a mandrel. 10. Detach the polarized safety connector unit B24.1, and remove the feed tube. Ä ê Center cover B24.1 ê Front cover 01 / MV / AV 3.14 / 1

166 Screw and barrel change Spritzgiessautomaten Procedure: 11. Remove the cable clamp at the rear of the machine used to fix the cables for the nozzle and barrel heating tapes and thermocouples. 12. Detach plugs X81 to X85 at the terminal box. 13. Remove the thermocouples from the barrel heating tapes. 14. Detach the water hoses at the cooling ring, Item 5. Caution: the cooling water may be hot! 15. Where the hydraulic nozzle shut-off is installed, loosen the attachment at the nozzle lever. 16. Unscrew the cap screws, Item 3, and remove the ring halves, Item 4. Â Á ê Ã Safety pin À 17. Pull out the plasticizing unit toward the clamping end; lift it out and lay it aside, behind the machine, on wooden blocks. 18. To heat the screw attach plus X81 to X85 and reattach the thermocouples. 19. When heated, pull the screw out toward the rear. 20. The reassembling is to be done in invested sequence. 21. Ensure that the safety pin is securely fitted when reassembling parts. 22. Lightly grease the contact surfaces between barrel and housing with Paste ME31-52 in order to prevent fretting corrosion. + Important note: Be sure to attach all the covers after reinstalling thew barrel / 2 MV / AV 03 / 2002

167 Screw and barrel change Change of screw tip To change the nonreturn valve, unscrew screw tip by means of this tip key. A tip key belongs to the tool kit. Procedure: Clamp the screw in a vice with soft jaw inserts. Position the special wrench mating with the tip. ê Left-hand threads Loosen the tip by turning to the right. With reinstalling of new screw tip lay on high-temperature paste (UNIMOLY HTC METALLIC) on thread. 01 / M / A M / A MV / AV D M / A M / A 3.14 / 3

168 Screw and barrel change Spritzgiessautomaten Classification of tip key dependent on screw diameter: Thermoplast / silicon units Ø Part-No. Width across flats BOY 12/22/ SW SW SW SW SW SW SW SW41 BOY 55/ SW SW SW SW SW55 Elastomere units Ø Part-No. Width across flats BOY SW SW SW41 BOY 22/30/ SW SW SW SW55 BOY / 4 M / A M / A MV / AV D M / A M / A 01 / 2002

169 4 Processing notes 4.1 Maximum shot weight 4.2 Recommended processing data Additional recommendations 4.3 Wear on plasticising units 4.4 Set-up data sheet (M/D) 01 / M / A M / A MV / AV D M/A/A-2C D M / A M / A

170

171 4.1 Maximum shot weight BOY 12 BOY 22 BOY 30 BOY 55 BOY 90 Short Designation Factor Screw Screw Screw Screw symbol ø (mm) ø (mm) ø (mm) ø (mm) ø (mm) DIN,ASTM F M weight weight weight weight (g) (g) (g) (g) (g) PS SAN ABS LDPE HDPE PP PA POM PPO PC PPSU PMMA CA CAB PVCW PVCH PBTP PES PUR PPS LSR Polystyrene Acrylnitril-butadiene-styrenecopolymer High-pressure polyethylene Low-pressure polyethylene Polypropylene Polyamide Polyacetal Polyphenyleneoxide (Noryl) Polycarbonate Polysulfone Polymethylmethacrylate Cellulose acetate Cellulose acetobutyrate Soft polyvinylchloride Rigid polyvinylchloride Polybutylenterephthalat Polyethersulfon Polyhrethan Polyphenylensulfid Liquid-Silicone-Rubber 0, , , , , , , , , , , , , , , , , , , , , These values are guiding values and may change as per different grades of raw materials used. Formula to calculate the (max.) shot weight: max. shot weight = factor F M x theor. stroke volume (cm 3 ) (Chapter. 1.1 technical data) 01 / M / A M / A MV / AV D M/A/A-2C D M / A M / A 4.1 / 1

172

173 4.2 Recommended processing data Chemical Short Trade names, Predrying Mould Temp. Nozzle Front Center Rear Nozzle type Fluidity Back pressure designation symbol examples h at C C x - GF C C C C x - Gf (specific) 1. Polystyrene PS Vestyron not C NV, AC, good 100 bar Polystyrol required BC, O, VK Hostyren 2. Styrene-acryl-nitril- SAN Luran 3h/80 C C O, (NV) good bar copolymerisate medium 3. Styrene-butadiene- SB Polystyrol 3h/80 C C O, (NV) good bar copolymerisate 400/500 Types medium 4. Acrylnitril-butadien ABS Novodur W 3h/85 C C NV, AC, medium 200 bar styrene-copolymerisat Terluran O 5. Soft polyethylene LDPE Baylon not C NV, AC, BC, good 100 bar (high-pressure PE) Hostalen required O, VK Lupolen Vestolen 6. Hard polyethylene HDPE Hostalen not C NV, AC, BC, good 100 bar (low-pressure PE) Lupolen required O, VK Vestolen 7. Polypropylene PP Hostalen PP not C NVx, AC, good 100 bar Novolen required BC, Ox, VK BC, Ox, VK Vestolen P 8. Polyvinylchloride PVC Vestolit not C PVC bad none (Hard-PVC) Hostalit required 9. Polyvinylchloride PVC Vinoflex not C O, (NV) medium 50 bar with plasticiser Vestolit required Solvic 10. Polymethyl- PMMA Plexiglas 6h/100 C C (NV, AC) bad 200 bar methacrylate Resarit O, (VK) NV,AC,BC 01 / M / A M / A MV / AV D M/A/A-2C D M / A M / A 4.2 / 1

174 Recommended processing data Spritzgiessautomaten Chemical Short Trade names, Predrying Mould Temp. Nozzle Front Center Rear Nozzle type Fluidity Dynamic designation symbol examples h at C C x - GF C C C C x - Gf pressure 11. Polycarbonate PC Makralon 1h/10 C C O, (NV) bad 200 bar Lexan In case of mach.-stop continue heating at 160 C. 12. Polyamide PA Ultramid 16h/100 C 40-80(120) C NVx, Ox, medium 100 bar Durethan AC 13. Polyacetal POM Hostaform C 4h/100 C C (NV, AC) medium 100 bar Ultraform O Develin 14. Polybutylene- PBTP Pocan 4h/120 C C NV, AC, good 100 bar therephthalat Ultradur O 15. Polyphenylen- PETP Ultradur 4h/120 C C NV, AC, good 100 bar therephthalat Rynite O 16.Polyphenylen- PPO Noryl 2h/110 C C NV, O good 100 bar oxid (modified types) 17. Polyphenylen- PPS Ryton 6h/150 C C O good 100 bar sulfid 18. Polyphenylen- PPE Vestoran 4h/100 C C O good 100 bar ether x = () = NV = AC = BC = O = VK = glass-fiber reinforced conditionally recommended shut off nozzle AC nozzle BC nozzle open nozzle prechamber nozzle + Note: Long cycle time and large wall thickness low cylinder temperatures short cycle time and small wall thickness high cylinder temperatures These are just approximations, please note the recommendations by the raw material manufacturers. The processing temperatures can vary ± 20 C from the temperatures indicated herein / 2 M / A M / A MV / AV D M/A/A-2C D M / A M / A 01 / 2002

175 4.2.1 Additional recommendations Conditioning of moulds Unfortunately, even today there is not enough attention being given to the condition of injection moulds. The exact temperature of the injection mould is critical to the quality and dimensional accuracy and/or the dispersion range of any production. For this reason, the recommended temperatures of the raw material manufacturers must be observed. Compliance with the mould temperature required for the material to be processed of course is connected with some expenditure which, however, will pay off very quickly specifically in the case of technical items. Listed below are some of the most common conditioning systems. Circulating cooling This type of cooling or better conditioning of moulds is the oldest form still common today. Compliance with a certain optimum processing temperature is not readily possible as there may be pressure and feeder temperature variations in the water system. Therefore, this procedure cannot be recommended for quality parts having close dimensional tolerances. Conditioning units Conditioning through the use of conditioning units is an optimum in terms of temperature consistency, mainly when the mould temperature is controlled through a thermal sensor and an appropiate controller. This type of conditioning is particularly recommended for thermoplastic material requiring a high mould temperature, such as polycarbonate, polyamide and polyacetal. (In case of M/A machines use screen number 5400) Extractors Please consult the manufacturer if extractors have to be mounted directly on the machine. Temperature control of feed throat When operating the 14 mm screw unit (12M/A) the application of the optional fealure "Cooling water distributor with electr. shut-off valve for feed throat" is recommended, ass. group no A temperature probe monitors and controls the temperature in the feed throat area of the screw thus guarantying a uniform feeding. Predrying Irrespective of a temperature control in the feed throat and in order to prevent a possible blocking of material within the throat, we recommend to process hard-to-feed raw materials only predried. 01 / M / A M / A MV / AV D M/A/A-2C D M / A M / A 4.2 / 3

176 Identification characteristics for thermoplastics Main group Polyolefines Styrenes Acetals Vinylchloride Designation PE PP PS SAN ABS SB CA POM PVCw PVCh PA PPO PMMA PC Optical: opaque (milky) transparent Can be marred by fingernail Cannot be marred by fingernail Breakage behaviour no fracture white fracture brittle fracture Burning behaviour sooting cleat flame self-extinguishing Vapour smell candle wax horn - like stryrene pungent fruity phenole tarry Soluble in carbon tetrachloride Melting point C Ropines of melt Identification Identification not always present / 4 M / A M / A MV / AV D M/A/A-2C D M / A M / A 01 / 2002

177 4.3 Wear on plasticising units Wear Wear is defined as the erosion of a material surface as a result of friction. Wear is therefore neither a material nor a surface property of the screw and barrel but a system property. Type of wear Abrasive wear Flushing wear Erosion Corrosion Pitting corrosion Causes Type and chemical composition of the raw material Raw material blends Property of the raw material during its processing Occuring pressures in the melt Style and quantity of filler Colour pigmentation Temperature control Dwell times Throughput rate Flow velocity Decomposition and fission products Media such as atmospheric oxygen, carbon dioxide, water and steam + Note: As a preventative measure and a means of protection against premature wear and in turn failure of the plasticising units, we recommend the use of High wear resistant plasticising units. High wear resistant plasticising units The following applies in general: The more frequent the mould change, and in turn material and colour change, the more practical is the use of high wear resistant plasticising units. 01 / M / A M / A MV / AV D M/A/A-2C D M / A M / A 4.3 / 1

178 Wear on plasticising units Spritzgiessautomaten Thermoplastics Standard thermoplastics Polyethylene Polypropylene Polystyrene Polyvinylchloride Transition thermoplastics Styrene acrylnitril copolymers Acrylnitril butadiene styrene copolymers Acrylates Styrene maleic anhydride copolymers and terpolymers Technical thermoplaste Polyphenylene oxide blends Polycarbonates Polyacetal Polyester Polyamide Heavy-duty thermoplastics Polyarylate Polysulfone Polyethersulfone Polyetherimide Polyamideimide Polyphenylene sulphide Crystalline suphide polymers Polyetherketone Fluorthermoplastics + Note: For the processing of so-called "transition thermoplastics" and "technical thermoplastics", the use of high wear resistant plasticising units is urgently recommended. For the processing of "heavy-duty thermoplastics", the use of high wear resistant plasticising units is essential! These wear-resistant units are not included in the standard scope of supply and must be ordered separately / 2 M / A M / A MV / AV D M/A/A-2C D M / A M / A 01 / 2002

179 5 Maintenance notes 5.1 Inspection of safety devices Hydraulic safety Electrical safety Mechanical safety Control console 1) 5.2 Filter Pressure filter Suction filter Bleeding 5.3 Oil change 5.4 Lubrication points Grease brand table 5.5 Maintenance of plasticising unit Screw and cylinder Nozzles general Thermoset nozzle 2) 5.6 Maintenance of pump unit 5.7 Maintenance of injection unit 5.8 Maintenance of clamping unit 5.9 Control of safety equipments 5.10 Cleaning the screen 5.11 Cleaning the water distributor 5.12 Inspecting and replacing hose assemblies 5.13 Stroke transmitters 1) not for : 22V/30 2) not for : 12M / A 01 / M / A M / A MV / AV M/A/A-2C D

180 + Note: Work on the hydraulic system may only be carried out by duly authorized personnel. Before starting any work on the hydraulic system, care must be taken to ensure that the system has been depressurized and that the platens are open. Malfunctions caused by using of spare parts which have not been procured from the manufacturer could result in a breakdown of the machine. Service diagnosis will be rendered more difficult because our service technician will spend much more time to investigate the cause of trouble. In these cases no claims towards the manufacturer within the warranty will be accepted M / A M / A MV / AV D M/A/A-2C D M / A M / A 01 / 2002

181 B A Y X Spritzgiessautomaten 5.1 Inspection of safety devices + ATTENTION! During maintenance and repair activities pump motor and main switch must be switched off Hydraulic safety No closing movement may occur while the safety gate is open. Check: The switching status of B26 is shown in screen With the safety gate opened and pump motor ON a DC voltage of about 24 V must be present between terminals X2/12 (+) and X2/0 (-). This voltage shows that B26 limit switch, which operates LG26 safety cartridge valve, is closed. (see chapter 1.4) Monitoring the RVG10 Guide cylinders of the clamping unit B23 RVG10 If the machine is in semi or all-automatic mode (guard door closed), the pump will switch off immediately when: the mould safety position is approached and a DC voltage is not applied to terminal x2/481(+) and x2/0(-) by B23 when pressure is applied. If the drop monitor is tripped: Correct functioning of the RVG10 must be checked immediately and the valve replaced if necessary. The seals of the two plunger cylinders connected to port "B" of the RVG10 must be examined for leaks. The machine can only be restarted via the master switch (OFF/ON). + Important: Before starting any repair work on the RVG10, the moving platen must be advanced to the position Mould closed or suitable spacers must be present when in the position Mould open in order to prevent the moving platen dropping slowly. 05 / MV / AV 5.1 / 1

182 Inspection of safety devices Spritzgiessautomaten Electrical safety Both safety limit switches B20 and B22 must be set in a manner, that during the opening of the gate B20 is released first and then B22 is activated. The pump motor will automatically switch OFF, if: Screen 8200 limit switch B20 is bridged with safety gate in closed position. Wire bridge from terminal X2/17 to terminal X2/ 1. limit switch B20 is interrupted with safety gate in open position. Remove wire from terminal X2/17. limit switch B22 is interrupted with safety gate in closed position. Remove wire from terminal X2/18. limit switch B22 is bridged with safety gate in open position. Wire bridge from terminal X2/18 to terminal X2/ 1. limit switch B25 is bridged with safety gate in closed position. Wire bridge from connection socket XA32/d32 to terminal X2/1. limit switch B25 is interrupted with safety gate in open position. Remove wire from connection socket XA32/d32. limit switch B26 is interrupted with safety gate in open position. Remove wire from connection socket XA32/d30. Check: The switching status of B20 and B22 are shown in screen With safety gate open the DC voltage between terminals X2/18 (+) and X2/0 (-) as well as between X2/19 (+) and X2/0 (-) must be lower than 1 V. With gate closed voltage must be about 24 V. Monitoring switch B23 The DC voltage measured between terminals X2/48(+) and X2/0(-) must be approx. 24 V when the hood is open. A DC voltage of approx. 24 V must be present between terminals x2/481(+) and x2/0(-) when the shroud is closed and pressure is applied / 2 AV 08 / 2000