Manual Arburg

BAM_207185_000_EN_10

Operating manual for machine no. 207185

Thermofisher Scientific FSP BioLife Sciences Group

570 C 2000 - 800

27.11.2007

ARBURG GmbH + Co KG Postfach 11 09 72286 Lossburg Tel.: +49 (0) 74 46 33-0 Fax: +49 (0) 74 46 33 33 65 http://www.arburg.com e-mail: [email protected]

BAM_207185_000_EN_10

BAM_207185_000_EN_10

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Preface / Safety Instructions

11

Preface

13

Additional information for USA, Canada

15

Safety instructions

17

Personal protective equipment

25

Transport and operating conditions

27

1 Introduction

29

1.1 Getting to know your ALLROUNDER

31

1.1.1 Technical data ALLROUNDER 570 C

32

1.1.2 Dimensions for mould installation / ejector connections

33

1.1.3 Mould weights

39

1.1.4 Machine transport

41

1.1.5 Machine installation

43

1.1.6 Cooling water and pneumatic connections

49

1.1.7 Electrical connections

55

1.1.8 Filling the hydraulic oil

67

1.1.9 Checking the direction of rotation of the pump motor

71

1.1.10 Setting the nozzle centre

73

1.1.11 Noise emission

77

1.2 Inspecting the safety devices

79

1.2.1 Overview of the safety devices on the ALLROUNDER 470 C, 570 C

80

1.2.2 Inspecting the safety devices on the clamping unit

81

1.2.3 Inspecting the safety devices on the injection unit

85

1.2.4 Overview of the switch designations of safety devices ALLROUNDER 470 C, 570 C

89

1.2.5 Inspecting the hoses

91

1.2.6 Replacement of parts after natural ageing

93

1.2.7 Safety markings

95

1.2.8 Position of the safety markings - ALLROUNDER CENTEX

97


99

1.2.11 Inspection of screw-in fixing points for hoisting gear

101

1.3 General information on the SELOGICA controller

103

1.3.1 Modular structure of the SELOGICA controller

104

1.3.2 Software packages

105

1.3.3 Introduction to the screen layout

109

1.3.4 The status lines

111

1.3.5 Navigation mode and navigation level

115

1.3.6 The direct access keys

117

1.3.7 The special keys

119

1.3.8 The editing box

123

1.3.9 The parameter panel

129

1.3.10 The navigation levels

131

1.4 Overview of the operating elements

137

1.4.1 The most important operating elements and their functions

138

1.4.5 The operating panels

141

1.5 Accessories and machine sizes

155

1.5.1 Available accessories and optional equipment

156

1.6.3 Cycle time diagram

157

2 Production sequence, production / order control

165

2.1 Basic information on the production sequence

167

2.3 Extended production sequences

173

2.3.1 Basic sequence

174

2.3.2 Inserting symbols in the sequence

177

2.3.3 Erasing symbols

181

2.3.4 Moving symbols

185

2.3.5 Changing the start condition, switching over the drive

189

2.3.6 Programming examples of various production cycles

195

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1.2.9 Inspecting the viewing panels

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2.4 Markings in the sequence

197

2.4.1 Dry cycle / automatic cycle

198

2.5 Data input

203

2.5.1 Inputting production data

204

2.5.2 Inputting mould data

209

2.5.3 Changing the units

211

2.6 Order control, production control

213

2.6.1 Inputting order data

214

2.6.2 Operating mode selection

215

2.6.3 Automatic switch-on/off

221

2.6.4 Sequences for start-up and shut-down

225

2.6.5 Order change

235

3 Machine movements

239

3.1 Machine movements

241

3.1.1 Parameter input and colour codes

242

3.1.2 Direction of movement in the graphical displays

243

3.2 Parameter input for machine movements

245

3.2.1 Options for selecting parameter panels

246

3.2.2 Basic information on parameter panels

249

3.2.3 Parameters for mould movements

251

3.2.4 Parameters for ejector movements

263

3.2.5 Parameters for nozzle movements

273

4 Temperatures, plasticizing process and part formation

279

4.1 Temperature settings for the injection unit

281

4.1.1 Recommended values for nozzle and cylinder temperatures

282

4.1.2 Temperature settings for the nozzle and cylinder heating

283

4.1.3 Cylinder cooling, programmable

291

4.2 Mould temperature control settings

295

4.2.1 Mould cooling, manually adjustable

296

4.3 Nominal value control of cylinder and mould temperature

297

4.5 Plasticizing process

301

4.5.1 Dosage

302

4.5.3 Diagram: stroke volume / screw stroke injection unit 800 (15.3 oz

305

4.5.4 Decompression

307

4.6 Moulded part formation

309

4.6.1 Options for moulded part formation

310

4.6.2 Injection

313

4.6.3 Holding pressure

317

4.6.4 Remaining cooling time

321

5 Production control

323

5.1 Quality assurance

325

5.1.1 General information on quality assurance

326

5.1.2 Configuration of the monitoring graphics

327

5.1.3 Displaying the monitoring charts

331

5.1.4 Quality control and quality monitoring

343

5.3.2 Freely configurable pages

349

5.4 Monitoring functions

357

5.4.1 “Monitoring off in set-up operating mode”

358

5.4.2 Monitoring functions of machine, mould and injection unit

359

5.4.3 Monitoring functions

365

5.4.4 Mould position monitoring

367

5.4.5 End position monitoring via stroke marker

373

5.5 Printer

379

5.5.1 Types of printer

380

5.5.2 Printer connection

381

5.5.3 Printer configuration

383

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5.5.5 Configuration of documentation (printing or saving data

385

5.5.6 Archiving parameter panels and sequences, printing hard copies

387

6 Data set handling

391

6.1 Editing level and program designations

393

6.2 Program administration

395

6.2.1 Data memory

396

6.2.2 Program administration

399

7 Working with the machine

405

7.1 Setting into Operation

407

7.1.1 Inspections when installing the machine and during initial setting into operation

408

7.1.2 Switching on the machine

411

7.1.3 Mould installation ALLROUNDER 470/520/570 C

415

7.1.4 Zeroing the stroke measuring systems

421

7.1.5 Starting up the machine

425

7.2 Change of material, end of production

429

7.2.1 Important information on various plastics

430

7.2.2 Adjustment values and processing information for injection moulding materials

431

7.2.4 End of production, stopping the machine

433

7.4.3 User authorisation with transponder cards

435

7.5.6 Safety instructions for horizontal parting line injection

445

8 What to do in the case of malfunctions

447

8.1 Diagnosis

449

8.1.1 Valves / switches

450

8.2 Alarm functions

453

8.2.1 “Alarms” parameter panels and alarm functions

454

8.2.2 Alarm sequence

455

9 Cleaning and maintenance work

459

9.1 Cleaning the plasticizing cylinder, screw and nozzle

461

9.1.1 Removing the injection unit

462

9.1.2 Swivelling the injection unit

463

9.1.3 Cleaning the plasticizing cylinder and screw with a cleaning agent

465

9.1.4 Nozzle removal, cleaning and installation injection unit 800 (15.3 oz

467

9.1.5 Removing, cleaning and reinstalling the screw, injection unit 800 (15.3 oz

471

9.2 Changing the screw tips

473

9.2.1 Screw tips

474

9.2.2 Tools necessary for changing the nozzle tips

475

9.2.3 Installing / removing the screw tips

477

9.4 Changing the plasticizing cylinder

479

9.4.1 Changing the cylinder, injection unit 800 (15.3 oz

480

9.4.3 Reinstalling the cylinder after it has been dismantled

485

9.5 Installing the thermocouples

487

9.5.1 Replacing the thermocouples on the plasticizing cylinder, injection unit 800 (15.3 oz

488

9.5.2 Exchanging the thermocouples on the nozzle, injection unit 800 (15.3 oz

489

9.6 Changing the heating elements

491

9.6.1 Changing the heating elements, injection unit 800 (15.3 oz

492

9.6.2 Changing the nozzle heating band, injection unit 800 (15.3 oz

493

9.7 External heating-up of the cylinder module

495

9.8 Maintenance and inspection work

497

9.8.1 Maintenance schedule

498

9.8.2 Oil change, inspection of toothed ring

501

9.8.3 Maintenance of the oil filter / oil cooler

503

9.8.4 Venting the hydraulic system

505

9.8.6 Maintenance and repair work on the hydraulic system

507

9.8.9 Pressure settings

511

9.9 Hydraulic oils and lubricants

513

9.10 Environmental protection measures

521

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9.10.2 Gaseous materials / vapours

522

9.10.3 Disposal of used oils and lubricants

523

10 Graphical recording and measuring systems

525

10.1 Graphics - nominal/actual values

527

10.1.1 Configuration of graphics

528

10.1.2 Recording the starting point

531

10.1.3 Setting the graphics

533

10.1.4 Graphics display

535

10.2 Measuring systems

541

10.2.1 Measuring systems of the SELOGICA ’direct’ controller

542

10.2.2 Connecting and configurating the measuring system

543

10.2.3 Measuring the mould cavity pressure

549

10.2.4 External switch-over devices

555

10.2.5 Measuring system for thermocouples

557

10.2.6 General measuring system

559

11 In/outputs

561

11.2 Programmable outputs

563

11.2.1 Function of the programmable outputs

564

11.2.2 Start and end conditions for programmable outputs

567

11.2.3 Linking and repeating outputs

571

11.2.4 Movement stages and output active in end position

577

11.2.5 Outputs non-cyclic, alternating

581

11.2.6 Starting outputs as a stroke-dependent function

587

11.2.7 Additional functions for outputs

589

11.2.8 Parameters for programmable outputs

591

11.2.9 Monitoring

595

14 Part removal

597

14.2 EUROMAP 67 interface for robot system

599

14.2.1 General information on the interface

600

14.2.2 Connection between injection moulding machine and robot system

601

14.2.3 Pin assignment

603

14.2.4 Activating the robot system

609

14.2.5 Selecting the operating mode of the robot system

611

14.2.6 Inputting parameters for the robot system

613

14.2.7 Connecting a robot system, function check

615

14.2.8 Signal transfer, EUROMAP 67 interface

617

14.2.9 EUROMAP 12 adapter

619

14.3.3 Mould blow device

621

17 Software options / process technology

625

17.8 Production protocol

627

17.8.1 Parameter selection for the production protocol

628

17.8.2 Protocol (logging

629

17.8.3 Random sample selection

637

17.8.4 Production protocol

639

17.8.5 Protocol graphics

641

Important information

647

ARBURG subsidiaries and agencies

649

Important ARBURG addresses

651

Tell us your opinion…

653

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PREFACE

Preface The purpose of this document

This document serves as an introduction to the operation of your ALLROUNDER machine.

BAM_207185_000_EN_10

It is designed to simplify the process of getting to know the machine and allow you to fully benefit from its possibilities of application. This operating manual contains important information to ensure safe, efficient and economic operation of the machine. Observing this information helps to avoid any dangers of personal injury, reduce repair costs and machine down-time and to increase the reliability and lifespan of the machine. This operating manual is to be supplemented by any additional safety regulations for the prevention of accidents and for environmental protection valid in your particular country. The operating manual must always be at hand at the place where the machine is operating. The operating manual must be read and the information contained in it applied by every person engaged in the following kind of work with or on the machine e.g. ⽧ operation including set-up, troubleshooting in the course of operation, removal of production waste, cleaning and the disposal of operating and processing aids. ⽧ maintenance (servicing, inspection, repair work) and/or ⽧ transport

\\ALLG\EN00_B_00_306_001.FM 01 2006.12.06

In addition to the operating instructions and mandatory rules and regulations for the prevention of accidents and environmental pollution valid in the country and place of application of the machine, the generally recognized regulations for safe and correct operation particular to this field of technology are also to be observed.

© 2006 ARBURG GmbH + Co KG, Technical Documentation, D-72290 Lossburg, Tel. +49 (0)7446 / 33-0 -1-

PREFACE

Contents of the document

The machine is briefly introduced and its operating elements explained. Connection and installation of the machine is also shown. The possible functions are clarified with the aid of parameter panels. Application examples and data suggestions are not included. One cannot learn the processes of injection moulding with this document.

The last page of this document has been reserved for you. Please complete these few lines with “Your Comments”. Some chapters are compiled as an autonomous document and are only included if the machine comprises the respective equipment.

Layout of the operating manual

This operating manual has a “loose leaf system” layout which is comprised of individual chapters. Any sections or even entire chapters which are not relevant to this machine type are therefore omitted.

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The optimal application of the machine can be learned by following the respective machine set-up course.

On the other hand, some options, accessories and parameters may be described in the operating manual which are not standard equipment. The pages are numbered within each section in order to speed up cross referencing. All ARBURG registered trade marks are written in capital letters, e.g. ALLROUNDER.

Diagrams, dimensions, weights

All diagrams, dimensions, weights and descriptions in this document are solely related to a possible combination of equipment features for this machine type. The appearance, function, dimensions and weights of your individually configured machine may well differ from these specifications.

The technical data correspond to the level at the time of going to print. In the interest of continual further development, we reserve the right to make modifications.

© 2006 ARBURG GmbH + Co KG, Technical Documentation, D-72290 Lossburg, Tel. +49 (0)7446 / 33-0 -2-

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Before starting any work for which you depend on precise specifications, please contact us at ARBURG and ask for the data/drawings relating to your particular machine type.


( GB1678A )

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SAFETY INSTRUCTIONS

The working space in front of the control cabinet of the machine must be at least 750 mm (2 1/2 ft) or more. (See illustration above). The specified working space is to be kept free at all times and is not to be used e.g. as storage space.

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The working space in front of the control cabinet must be freely accessible from at least one side. When normally enclosed live parts are exposed for inspection or servicing purposes, the working space must be suitably safeguarded if it is in a passageway or general open space. The regulations of NFPA 79 also apply.

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Locks on the control cabinet doors The doors of the control cabinets are locked.

● Switch off the main switch ● Open the locks at the top and bottom of the control cabinet doors by inserting a two-way key (1) into the lock (2) and turning it 1/4 revolution to the right or left, depending on the locking position. ● Open the door. 䡩 The locking plate (3) is moved out and releases the rod (5) which is turned by a tension spring (4) 䡩 All other control cabinet doors can be opened.

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Opening the control cabinet doors

( GC1678ZA )

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Opening the doors is only possible when the main switch has been switched off and the door in which the main switch is integrated has been opened. When the door with the main switch is closed, all other doors lock automatically on closing.

SAFETY INSTRUCTIONS

Safety instructions Warnings and symbols

In this operating manual the following headings and symbols are used for particularly important information:

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IMPORTANT

The text in these boxes contains instructions regarding the efficient operation of the machine, in particular precautionary measures to prevent damage to the machine.

SAFETY INSTRUCTIONS

Three further symbols are also frequently used in this operating manual. Symbol Explanation ⽧ enumeration: identifies a list of items ● action: requires the machine operator to act reaction: identifies the reaction of the machine/controller to 䡩 an action

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( TB00497B )

Other symbols

The text in these boxes contains information relating to your personal safety or the prevention of machine damage. Observe these instructions and proceed very carefully.

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SAFETY INSTRUCTIONS

⽧ The machine has been built in accordance with state of the art standards and recognized safety regulations. Nevertheless, its use may constitute a risk to life and limb of the user or third parties, or cause damage to the handling device/machine or other material property.

⽧ The machine is designed exclusively for the processing of injection-mouldable materials in accordance with the data provided by the material supplier. Using the machine for purposes other than those specified e.g. using the machine as a press or for processing non-injection-mouldable materials or disassembling the machine and using the component parts for other purposes is considered contrary to its designated use. ARBURG cannot be held liable for any damage resulting from such misuse. The risk of such misuse lies entirely with the user.

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⽧ The machine must only be used in technically perfect condition and in accordance with its designated use and the instructions specified in the operating manual, by persons aware of its potential dangers and the safety regulations. Any functional disorders, especially those affecting the safety of the machine, must be rectified immediately.

Operating the machine within the limits of its designated use also involves complying with the instructions specified in the operating manual and the inspection and maintenance instructions.

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General principles; designated use of the machine

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SAFETY INSTRUCTIONS

Organisational measures

⽧ The operating manual and the short operating manual(s) must always be at hand at the place of work of the machine.

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⽧ In addition to the operating instructions, the user must observe all other generally applicable legal regulations relevant to accident prevention and environmental protection and instruct other persons involved accordingly. Such obligations also apply for example to the handling of hazardous substances and to the issuing and/or wearing of personal protective equipment. ⽧ The operating instructions must be supplemented by additional instructions from the employer (including supervisory and reporting duties) covering the company’s own particular facilities, e.g. in regard to work organization, work sequences or the personnel entrusted with the work. ⽧ Personnel entrusted with work on the machine must have read the operating instructions and in particular the safety instructions before beginning work. Reading the instructions after work has begun is too late. This applies especially to persons working only occasionally on the machine e.g. for setting-up, conversion or maintenance work. ⽧ Check - from time to time - whether the personnel is carrying out the work in compliance with the operating instructions and paying attention to the risks and safety factors involved. ⽧ Use personal protective equipment/clothing wherever required by the circumstances or by law, especially when working with hot injection moulding materials. ⽧ Observe all safety instructions and warnings attached to the machine. ⽧ Ensure that safety instructions and warnings on the machine are complete and perfectly legible. ⽧ In the event that safety-relevant changes are noticed on the machine or in its operational behaviour, stop the machine immediately and report the malfunction to the competent authority/ person. ⽧ Never make modifications, additions or conversions to the handling device which might affect its safety without ARBURG’s written approval. This applies also to the installation and adjustment of safety devices and valves as well as to welding or other work on load-bearing elements.

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⽧ If additional devices approved by ARBURG are subsequently removed, the original protective safety panels/devices must be reinstalled. ⽧ Spare parts must comply with the technical requirements specified by ARBURG. This is always guaranteed with original spare parts.

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SAFETY INSTRUCTIONS

⽧ Do not carry out program changes (software) to the programmable control systems, unless specifically permitted. ⽧ Replace hydraulic hoses within stipulated or adequate intervals even if no safety-relevant defects are apparent. ⽧ Adhere to the prescribed schedule and intervals specified in the operating manual for routine checks and inspections.

⽧ Screws and nuts which are sealed with red sealing lacquer must not be re-adjusted or removed. The safety-relevant functioning or setting of the part could no longer be guaranteed.

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⽧ For material refilling and all other overhead work on the machine, a suitable climbing aid is necessary: e.g. platform lift, safe ladder.

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⽧ For the execution of maintenance work, it is essential to use only workshop equipment especially adapted to the task on hand.

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SAFETY INSTRUCTIONS

Selection and qualification of personnel - fundamental responsibilities

⽧ All work on the machine must be executed by reliable personnel only. ⽧ Engage only trained or instructed staff; clearly define the individual responsibilities of the personnel for operation, set-up, maintenance and repair. ⽧ Do not allow persons under training / instruction or persons taking part in a general training course to work on or with the device/ machine without permanent supervision by an experienced person.

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⽧ Work on electrical equipment of the machine must only be carried out by a skilled electrician or by instructed persons under the supervision and guidance of a skilled electrician and in accordance with electrical engineering rules and regulations. ⽧ Work on gas-engineered equipment (pressure accumulators) is only to be carried out by especially trained personnel. ⽧ Work on hydraulic devices is only to be carried out by personnel with skilled knowledge and experience:

Safety instructions for specific operational phases standard operation

⽧ Refrain from carrying out any operations that might be prejudicial to safety. ⽧ Take all necessary precautions to ensure that the machine is operated only in a safe and correctly functioning state! Only operate the machine if all protective and safety-orientated devices, such as removable safety panels/switches/stops and emergencystop equipment are in place, fully functional and activated. ⽧ Inspect the machine regularly for visible damage and defects. Report any changes (including changes in its operational behaviour) to the competent authority/person immediately. If necessary, stop the machine and inhibit all functions. ⽧ In the event of a malfunction, stop the device/machine immediately and inhibit all functions. Have any defects rectified immediately. ⽧ Observe start-up and shut-down procedures, inspection and monitoring displays in accordance with the operating manual.

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⽧ Before starting up / actuating the machine, ensure that nobody is at risk by its functions or movements. ⽧ For the overhead task of refilling the material hopper suitable climbing aids must be used that comply with safety regulations. The same applies when connecting and disconnecting supply lines or pipes of conveyer appliances. Switch off machine before refilling the hopper. ⽧ For all work to be carried out on the machine, in particular work inside the protective safeguards or work on the plasticizing unit, always switch off the main switch first and secure it against reactivation.

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SAFETY INSTRUCTIONS

⽧ Observe the adjusting, maintenance and inspection duties and schedule stipulated in the operating manual, including information on the replacement of parts and equipment. This work must be executed by skilled personnel only. ⽧ Use a suitable hoisting device (crane) for the removal and installation of the mould. ⽧ Use a suitable hoisting device when changing the working position of the injection unit.

⽧ Always inform operating personnel before beginning non-routine operations and maintenance work. ⽧ Ensure that a sufficiently wide area is cordoned off around the maintenance work being carried out. ⽧ When the machine is completely shut down for maintenance and repair work, it must be secured against inadvertent restart-up: secure the main switch with a lock and remove the key and/or attach a warning sign to the main switch.

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⽧ Use a suitable climbing aid which complies with the safety regulations when suspending the injection on the crane hook.

⽧ When carrying out overhead assembly, maintenance or other work always use specially designed or otherwise safety-orientated climbing aids and platforms. Never use machine parts as a climbing aid. Keep the machine operating-area free of any dirt, granulate and cleaning agents. ⽧ Before carrying out any maintenance or repair work, clean the machine, in particular connection terminals and threaded connections, so that they are free of oil, fuel or cleaning agents. Do not use aggressive detergents. Use lint-free cleaning cloths only. ⽧ After cleaning, examine all hydraulic hoses and pipes for leaks, loose connections, chafe-marks and damage. Rectify any faults immediately. ⽧ Always tighten any screwed connections that have been loosened during maintenance and repair to the required torque. ⽧ If safety devices need to be removed for set-up, maintenance or repair purposes, they must be refitted and checked immediately upon completion of the maintenance and repair work. ⽧ Ensure that all replaced parts and materials are disposed of safely and with the minimum of environmental impact. Observe the instructions of the material manufacturer. ⽧ On the electric machine ALLDRIVE the locking switch on the safety door can be mechanically deactivated (see chapter 8.6 in the ALLDRIVE operating manual).

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Non-routine work in conjunction with the utilization of the machine, maintenance and repair work and trouble shooting in the course of operation, disposal of materials.

SAFETY INSTRUCTIONS

Warnings of particular sources of danger electrical energy

⽧ Use only original fuses with the specified current rating. Switch off the machine immediately if trouble occurs in the electrical supply system. ⽧ When inspection, maintenance, and repair work is being carried out on the control cabinet or other live parts, the machine parts must be de-energized, if specified. Before starting any work check these parts for the presence of power and ground or short circuit them in addition to insulating adjacent live parts and elements.

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⽧ The electrical equipment of the machine is to be inspected and checked regularly. Defects such as loose connections or scorched wires must be replaced immediately. ⽧ In the vicinity of the control cabinets for frequency converters (on machines with electric drives), electro-magnetic fields can be generated in a range of up to approx. 30 cm from the control cabinet surface. These electro-magnetic fields may slightly exceed the limit values specified in the DIN VDE 0848 (1995-07) regulations for exposure range 2 and may be hazardous for persons carrying implanted electronic health-supportive equipment.

Gas, dust, steam and smoke

⽧ Before carrying out welding, flame cutting and grinding work, clean the machine and its surroundings so that it is free of dust, granulate, oil and other flammable materials. Cover the hoses and provide adequate ventilation (risk of fire or explosion). ⽧ When processing different types of plastic materials, gases can be emitted that may be aggressive and/or detrimental to health. Ensure that adequate ventilation and exhaustion is provided. Do not simply let gases escape into the atmosphere. They must be collected and neutralised. ⽧ Suitable fire-extinguishing facilities, in particular for the types of materials being processed on the machine, as well as personal protective equipment to protect against possible gas formation, must be made readily available.

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Hydraulic and pneumatic equipment

⽧ Work on hydraulic equipment must only be carried out by persons with specialized knowledge and experience of hydraulic systems. ⽧ Check all cables, pipes, hoses and screwed connections regularly for leaks and visible damage. Repair any damage immediately. ⽧ Depressurize all system sections and pressure pipes (pressure accumulator, hydraulics, compressed air) in accordance with the specific instructions for these assembly groups, before carrying out any repair work involving them. ⽧ Adhere to the inspection and maintenance schedules of the hydraulic bladder-type accumulator. Observe the separate instructions of the manufacturer. ⽧ Hydraulic and pneumatic hoses must be laid and fitted correctly. Do not interchange the connections. The fittings, lengths and quality of the hoses must comply with the technical specifications.

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SAFETY INSTRUCTIONS

Oil, grease, plastics and other chemical substances

⽧ Observe the product-related safety regulations when handling oil, grease, plastic and other chemical substances. ⽧ Extreme care must be taken when handling hot operating materials and processing aids, in particular hot plastic materials (danger of burning or scalding)!

⽧ Appoint a person with the relevant specialized knowledge to assist in lifting operations. ⽧ Lift machines properly with lifting gear in accordance with the instructions in the operating manual (observe fixing points for lifting gear etc.) ⽧ Use only suitable means of transport of adequate load capacity.

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⽧ Use only appropriate lifting gear and load-bearing equipment of adequate capacity during transport and loading operations.

⽧ Fasten the load safely using suitable fixing points. ⽧ Before loading, apply devices provided for securing machine and injection unit against unintentional position change. Attach appropriate warning signs. ⽧ Carefully refit and fasten all parts which have been removed for transport purposes before re-commissioning the machine. ⽧ Cut off the external power supply even if only minor changes in location are carried out. Reconnect the machine to the mains supply properly before recommissioning. ⽧ When recommissioning, proceed only in accordance with the operating instructions.

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Transport of the machine

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Personal protective equipment As a protection against possible dangers during conversion, maintenance or repair work the machine operator must wear personal protective equipment. If required by the production procedure this protective equipment must also be worn during machine operation.

BAM_207185_000_EN_10

The following personal protective equipment is stipulated: Heat-resistant protective gloves, acc. to DIN EN 420/EN 407 For all work with hot objects such as the plasticizing cylinder, screw and nozzle. Eye protection / face mask according to DIN EN 166 For all work on the heated plasticizing unit and work that presents a risk for eyes and face.

..\ALLG\EN00_CC_00_306_000.FM 01 2003.11.21

( GC1469Z GD1469Z GB1469Z GE1469Z )

Safety shoes, category S2 according to DIN EN 345 For work where there is a risk of injury to the feet due to falling objects. Particle-filtering face mask, category FFP3, acc. to DIN EN 149 For all work where there is a possibility of air impurities.

IMPORTANT

Before deciding on the choice and application of personal protective equipment, the operating authority of the injection moulding machines has to carry out an inidiviual assessment of the degree of risk involved, in accordance with the law of safety precautions at the place of work, which takes into consideration in particular the type and extent as well as duration and probability of the risk involved for the operating personnel. This assessment is to be directive in the choice of suitable personal protective equipment. The personal protective equipment must be inspected regularly and kept in correct working order.

-1-

..\ALLG\EN00_CC_00_306_000.FM 01 2003.11.21

BAM_207185_000_EN_10


-2-


Transport and operating conditions Transport conditions

During transport of the machine the following environmental-specific values for temperature and humidity must be fulfilled (EN 60204-1 : 1997 pt. 4):

BAM_207185_000_EN_10

⽧ permissible temperature range: -25 °C to 55 °C -13 °F to 130 °F ⽧ permissible relative air humidity: min. 20 % max. 80 %

Operating conditions

During operation of the machine the following environmental-specific values must be fulfilled (EN 60204-1 : 1997 pt. 4): ⽧ voltage supply 0.9 ... 1.1 of the nominal voltage ⽧ frequency 0.99 ... 1.01 of the nominal frequency, when permanently on 0.98 ... 1.02 when briefly on ⽧ electro-magnetic compatibility (EMC) in accordance with EEC guideline (EMC 89/336) ⽧ permissible temperature range: 5 °C to 40 °C 40 °F to 105 °F ⽧ minimum hydraulic oil temperature: 15°C, 60 °F ⽧ permissible relative air humidity: max. 50 % at a max. temperature of 40°C (104°F)

..\ALLG\EN00_CD_00_306_003.FM 01 2007.06.19

⽧ the temperature of the cooling water supply must be above the temperature at which condensation takes place. Condensation could otherwise damage machine components. ⽧ maximum installation height: max. 2000 m above sea level max. 6600 ft above sea level ⽧ Ambient light intensity, in particular around the clamping unit: min. 500 Lux following EN1837/1999; in accordance with German operational safety standard (BetrSichV), App. II, section 2.4

-1-

..\ALLG\EN00_CD_00_306_003.FM 01 2007.06.19

BAM_207185_000_EN_10


-2-


BAM_207185_000_EN_10

Introduction

1 Introduction

-1-


BAM_207185_000_EN_10

Introduction

-2-

..\TECH-DAT\CG570\EN01AA_28_5404_000.FM 01 2007.11.05

BAM_207185_000_EN_10

Technical data ALLROUNDER 570 C

1.1

Getting to know your ALLROUNDER

1.1.1


Technical data 570 C - Europe Machine model 570 C 2000-800 EUROMAP size 1) Clamping unit Clamping force max. kN 2000 Closing force max. kN 70 Opening force / increased max. kN 50 / 520 Opening stroke max. mm 650 Mould height min. mm 300 Daylight between platens max. mm 950 Tie-bar clearance mm 570 x 570 Mould platen size (hor x vert) mm 795 x 795 Weight of mov. mould half max. kg 1500 Ejector force max. kN 66 Ejector stroke max. mm 225 Hydraulics, drive, general Drive power of hydraulic pump kW 22 Total connected load 2) kW 38.3 Colour: plastic coated, structure light grey / mint green / canary yellow Control cabinet Safety standard DIN EN 60204 Socket combination (1 single phase, 1 three-phase) 1 x 16 A Injection unit 800 Screw diameter mm 45 / 50 / 55 Effective screw length L/D 22 / 20 / 18 Screw stroke max. mm 200 Calculated injection volume max. cm³ 318 / 392 / 474 Shot capacity max. g/PS 291 / 359 / 434 max. kg/h PS 46 / 53 / 59 Material throughput 4) max. kg/h PA 6.6 23 / 27 / 30 Injection pressure3) max. bar 2470 / 2000 / 1650 max. cm³/s 174 / 214 / 260 Injection flow 3) Back pressure positive/negative max. bar 350 / 190 Circumferential screw speed max. m/min. 56 / 62 / 69 Screw torque max. Nm 880 Nozzle contact force max. kN 70 Nozzle retraction stroke max. mm 400 Installed cylinder heating power kW 13.2 / 6 Installed nozzle heating power kW 0.6 Material hopper capacity l 50 Machine dimensions and weights of basic machine Oil capacity l 290 Net weight ca. kg 7450 Electrical connection (pre-fused) 2) A 100

1 2) 3) 4)

1st figure: clamping force (kN) 2nd figure: max. dosage volume (cm3 ) x max. injection pressure (kbar) Values apply to 400 V/50 Hz. The load is symmetrically distributed over the 3 phases (observe when adding machine equipment). A combination of max. injection pressure and max. injection flow (max. injection capacity) can be mutually exclusive. Deviations are possible, depending on process settings and type of material used.

The technical data correspond to the current level when going to print. We reserve the right to modify specifications in the interest of further development. .

-1-

1.1.1


Technical data 570 C - USA 570 C 220 tons 15.3 oz

1) 2) 3) 4)

BAM_207185_000_EN_10

Clamping unit Clamping force max. US tons 220 Closing force max. US tons 7.7 Opening force / increased max. US tons 5.5 / 57.2 Opening stroke max. inch 25.59 Mold height min. inch 11.81 Daylight between platens max. inch 37.4 Tie-bar clearance inch 22.44 x 22.44 Mold platen size (hor x vert) inch 31.3 x 31.3 Weight of mov. mold half max. lbs 3300 Ejector force max. US tons 7.26 Ejector stroke max. inch 8.86 Hydraulics, drive, general Drive power of hydraulic pump kW 22 Dry cycle time for opening stroke 5) s-inch 2.6 - 15.71 Total connected load 1)2) kW 38.3 Colour: plastic coated, structure light grey / mint green / canary yellow Control cabinet Safety standard ANSI Injection unit 15.3 oz Screw diameter inch 1.77 / 1.97 / 2.17 mm 45 / 50 / 55 Effective screw length L/D 22 / 20 / 18 Screw stroke max. inch 7.87 Calculated injection volume max. inch³ 19.4 / 23.9 / 28.9 Shot weight max oz PS 10.3 / 12.7 / 15.3 Material throughput 4) max. lbs/h PS 101.2 / 116.6 / 129.8 max lbs/z PA 6.6 50.6/ 59.4 / 66 Injection pressure 3) max psi 35800 / 29000 / 23900 max in³/s 10.6 / 13. 1 / 15.9 Injection flow 3) Back pressure positive/negative max. psi 5080 / 2760 Circumferential screw speed max. ft./min. 184 / 203 / 226 Screw torque max. ft lbs 650 Nozzle contact force max. US-tons 7.7 Nozzle retraction stroke max. inch 15.75 Installed cylinder heating power kW 13.2/ 6 Installed nozzle heating power kW 0.6 Material hopper capacity lbs 80 Machine dimensions and weights of basic machine Oil capacity US-gall. 76.62 Net weight (without oil) lbs. 16390 Electrical connection (pre-fused) 1) A 125 Electrical connection (pre-fused) Motor 2) A 50 Heat A 40

Values apply to 230 V/60 cycles. The load is evenly distributed over three phases. Values apply to 460 V/60 cycles for motor and control resp. 230 V/60 cycles for heating. The load is evenl distributed over three phases (depending on optional equipment ordered). A combination of max. injection pressure and max. injection flow (max. injection capacity) can be mutually exclusive, depending on the equipmentrelated motor output. Deviations are possible depending on process settings and material type.

The technical data correspond to the current level when going to print. We reserve the right to modify specifications in the interest of further development.

-2-

1.1.1

..\TECH-DAT\CG570\EN01AA_28_5404_000.FM 01 2007.11.05

Machine model

Dimensions for mould installation / ejector connections

1.1.2

Dimensions for mould installation / ejector connections The technical data specifications refer to those at the time of going to print. We reserve the right of modification in the interest of continuous further development.

..\TECH-DAT\CG570\EN01AB_28_5404_000.FM 01 2007.11.05

( GI1712E )

BAM_207185_000_EN_10

Mould dimensions 570 C Part 1 - Europe

-1-

1.1.2


( GJ1712E )

BAM_207185_000_EN_10

The technical data specifications refer to those at the time of going to print. We reserve the right of modification in the interest of continuous further development.


Mould dimensions 570 C Part 2 - Europe

-2-

1.1.2




( 000245_US_000 )

BAM_207185_000_EN_10

Moud dimensions 570 C Part 1 - USA

-3-

1.1.2


(000246_US_000 )

BAM_207185_000_EN_10



Mold dimensions 570 C Part 2 - USA

-4-

1.1.2


Ejector coupling

The two following illustrations each show a different method for the connection of an ejector:

BAM_207185_000_EN_10

⽧ With compulsory ejector retraction. The bolts of the hydraulic ejector and the mould are connected firmly together.

1 2 3

coupling element fixed connection mould ejector bolt


( GA0950ZA GB0950ZA )

⽧ With thrust pad. There is no fixed connection between the hydraulic ejector bolt and the mould. The ejector bolts are only hydraulically actuated during advancement. Springs in the mould push them back into place.

1 2 3

Ejector length

coupling element no connection mould ejector bolt

⽧ 570 C

= max. 358 mm / 14.1”

IMPORTANT

Select the ejector length to be at least 1-2 mm shorter than the maximum dimension, so that the ejector system is not under pressure when the mould is closed.

-5-

1.1.2


( GA0881ZB )

BAM_207185_000_EN_10

⽧ 570 C = Part no. 95518.

1 2 3 4 5 6

Compulsory retraction

Blunt ejection

Coupling with connection element as an adjustable ejector bolt

Coupling with adjustment screw as an adjustable thrust pad

mould mould ejector bolt connection piece adjustment screw lock nut coupling piece

-6-

1.1.2


Dimensions of the coupling element

Mould weights

1.1.3

Mould weights

Maximum permitted mould weights (mould mass)

The maximum allowed mould weights for the moving mould half can be viewed in the following table. Do not exceed these values for any reason. This could lead to production problems and premature wear.

BAM_207185_000_EN_10

Maximum mould weights

kg / lbs 320 A

320 / 705

300 / 661

480 / 1058

370 A

360 / 793

360 / 793

540 / 1190

420 A

600 / 1323

450 / 992

900 / 1984

470 A

760 / 1675

450 / 992

1140 / 2513

Machine model

Maximum weight of mould (kg)

520 A 1500

1000 / 2205

750 / 1653

1500 / 3307

520 A

1100 / 2425

750 / 1653

1600 / 3527

570 A

1300 / 2866

750 / 1653

2000 / 4409

270/320 C

180/270 / 397/595 1)

400 / 882

370/420 C

600 / 1323

400 / 882

900 / 1984

420 C 1300

650 / 1433

400 / 882

1000 / 2205

470 C 1500

800 / 1764

600 / 1323

520 C 1500

1000 / 2205

1200 / 2646 1500 / 3307

470/520 C

1250 / 2756

750 / 1653

1800 / 3968

570 C

1500 / 3307

750 / 1653

2200 / 4850

221 K

75 / 165

150 / 331

170 S

36/55 / 79/1211)

85 / 187

270 S 370 S ..\TECH-DAT\ALLG\EN01AC_00_306_010.FM 01 2007.11.12

Max. weight of moving mould half on rotary table (kg)

Maximum weight of moving mould half on index unit (multi-comp. machine) kg / lbs

Maximum weight of moving mould half

135/200 /

297/4411)

360 / 793

300 / 661 360 / 793

540 / 1190

470 S

760 / 1675

600 / 1323

1140 / 2513

520 S

1050 / 2315

600 / 1323

1600 / 3527

570 S

1400 / 3086

750 / 1653

2100 / 4630

630 S

2500 / 5511

1000 / 2205

3800 / 8377

720 S

3600 / 7936

2000 / 4410

5300 / 11684

820 S

5000 / 11023

2000 / 4410

7500 / 16535

920 S Golden Edition

6000 / 13228

9000 / 19841

920 S

8000 / 17637

12000 / 26455

1200 T

400 / 882

750 / 1653

175 V

18 / 40 2)

60 / 132

55 / 121

275 V

2)

120 / 264

200 / 441

1 2

65 / 143

With optional support of moving mould mounting platen upper mould half

-1-

1.1.3

Mould weights

Without support

BAM_207185_000_EN_10

Support of the moving mould platen

( 000196_00_000 000197_00_000 000304_00_000 )

Support of the moving mould platen

(Support for the vertically acting forces e.g. mould weight)

..\TECH-DAT\ALLG\EN01AC_00_306_010.FM 01 2007.11.12

Mould carrier

-2-

1.1.3

Machine transport

1.1.4

Machine transport

Transporting the machine

A crane is required to transport the machine. The machine weight without oil is as follows: Machine model 570 C 2000-800

Machine weight 7750 kg / 17,086 lbs

BAM_207185_000_EN_10

The machine weight can be significantly higher depending on the machine equipment. The machine’s centre of gravity is located in the machine base near the fixed mounting platen. The centre of gravity is indicated on the operating side of the machine base. The position of the centre of gravity can vary depending on the machine equipment.

Transport jig 570 C

Für den Transport sollte auf jeden Fall die im Maschinenwerkzeug enthaltene Transportvorrichtung verwendet werden. ⽧ Transport jig 570 C: Transport jig metric: Transport jig USA: Transport jig Japan:

Transport with a crane 570 C

Part no. 242702, Part no. 244844, Part no. 244702.

● Attach the support brackets (4) of the transport jig to the fixed mould platen (see illustration). ● Tighten the head screws (2) to a torque of 710 Nm (523.6 ft lbs). ● Place the transport belts through the support brackets as shown in the illustration.

..\TECH-DAT\CG570\EN01AD_24_5404_000.FM 01 2006.03.06

● Loop one end of the transport belt (1) around the upper tie-bar of the clamping unit. ● Place the other end of the belt through the loop and pull it to a knot. ● Guide each free end of the two transport belts through the support brackets (see illustration) and suspend the end onto the crane hook. ● Attach the 2 head screws (3) with nuts to both support brackets directly in front of and behind the transport belt. ● Unscrew the nuts or screws on the machine feet and remove the transport pallets. ● If it is not possible to transport the machine to the site of installation with a crane, we recommend the use of a heavy-duty roller system with hoist.

-1-

1.1.4

Machine transport

SAFETY INSTRUCTIONS

For transport purposes, the movable platen of the machine must be opened to the maximum stroke. When transporting the machine without delivery pallet, and when applying hoisting equipment, the welts provided for this purpose in the floor of the machine base must be used to avoid slipping.

1 2 3 4

..\TECH-DAT\CG570\EN01AD_24_5404_000.FM 01 2006.03.06

( PA0581ZA GN1690ZA )

BAM_207185_000_EN_10

Use the transport belts supplied when suspending the machine on a crane.

Transport belts Head screws Head screws with nuts Support bracket

-2-

1.1.4

Machine installation

1.1.5 Explanation

Machine installation The machine requires neither foundation nor bracing. Remember to leave enough free space for conversion and maintenance work, see floor plan. To install the machine, proceed as follows for best results:

● Place the machine feet (3) with the centring bores exactly under the set screws (1).

..\TECH-DAT\C570\EN01AE_26_5404_001.FM 01 2007.11.08

( GB1702ZA GP1744ZA )

BAM_207185_000_EN_10

● Transport the machine to the place of installation, but do not set it down yet.

x: max. 10 mm!

● Lower the machine slowly to the floor. ● Adjust the set screws (1) so that the machine stands horizontal. ● Place an industrial spirit level in longitidunal and transverse directions on the lower tie-bars of the clamping unit.

-1-

1.1.5


BAM_207185_000_EN_10

● Check the alignment in longitidunal and transverse directions in two positions.

● Secure the set screws with the lock nuts provided. ● Tighten first the upper and then the lower lock nuts (2). There is only one lock nut (top) on the middle machine feet.

IMPORTANT

If your machine is equipped with a hydraulic pressure accumulator, please refer to chapter 15.4 also. For transport by air or sea the pressure accumulator is discharged and must be re-charged with nitrogen before setting into operation. If your ALLROUNDER is equipped with a swivel crane and electro hoist chain, the installation instructions in chapter 13.4 must be observed. Pressure accumulator and swivel crane are not available for the ALLROUNDER C GOLDEN EDITION.

-2-

1.1.5

..\TECH-DAT\C570\EN01AE_26_5404_001.FM 01 2007.11.08

● Check the setting again after several hours of operation.

( GJ1430Z )

The machine must be aligned so that the error in both directions does not exceed 0.1 mm/m (as far as possible).


The monitor housing is firmly screwed onto the machine with clamping elements (1) for transport purposes, so that the monitor housing can not move.

BAM_207185_000_EN_10

Transport protection on the monitor housing

● Unscrew the head screws (2) at the top and bottom by approx. ¼ revolution. 䡩 The monitor housing must now swivel easily.

( GK1678ZA )

IMPORTANT

● Tighten the head screws for clamping the transport device of the monitor housing before transporting the machine again. If your ALLROUNDER is equipped with a swivel crane and electrical hoist chain, the installation instructions in chapter 13.4 must be observed!

..\TECH-DAT\C570\EN01AE_26_5404_001.FM 01 2007.11.08

Pressure accumulator and swivel crane are not available for the ALLROUNDER C GOLDEN EDITION.

-3-

1.1.5


SAFETY INSTRUCTIONS

Clearance zone according to EN349 (at least 500 mm / 20”) must be observed. Otherwise there is a risk of the operator being squashed between the machine and other objects by moving aggregates!

-4-

1.1.5

..\TECH-DAT\C570\EN01AE_26_5404_001.FM 01 2007.11.08

( GT1702E GE1404Z )

BAM_207185_000_EN_10

Floor plan ALLROUNDER 570 C - Europe


..\TECH-DAT\C570\EN01AE_26_5404_001.FM 01 2007.11.08

( 000292_US_000 GE1404Z )

BAM_207185_000_EN_10

Floor plan ALLROUNDER 570 C - USA

SAFETY INSTRUCTIONS

Clearance zone according to EN349 (at least 500 mm / 20”) must be observed. Otherwise there is a risk of the operator being squashed between the machine and other objects by moving aggregates!

-5-

1.1.5

..\TECH-DAT\C570\EN01AE_26_5404_001.FM 01 2007.11.08

BAM_207185_000_EN_10


-6-

1.1.5

Cooling water and pneumatic connections

1.1.6


Water quality

Your injection moulding machine is equipped with high-quality aggregates and components which become hot during operation and must therefore be cooled. In order to ensure a problem-free operation, the quality of the water must fulfil the following requirements:

BAM_207185_000_EN_10

Hydrological data Overall hardness Carbonate hardness when using hardness stabilisers pH-value Conductivity Chloride Cl Grain size 1

max. < 15

unit °dH

< 5.6

°dH

6.5-8.5 < 50 < 100 < 0.1

LCE 1 mS/m mg/l mm

LCE = lime-carbon equilibrium

The cooling water must be free from contaminations such as floating or sinking particles or algae.

Using cooling water which does not fulfil the above criteria, can lead to malfunctions and damage (e.g. corrosion, lime formation). In this case we cannot accept any obligation of warranty. If in doubt, have your water analysed or consult a firm specialised in circulating cooling systems.

IMPORTANT

..\TECH-DAT\C-ALLG\DE01AF_05_307_003.FM 01 2005.04.04

Inspect the flow volume and return temperatures of your cooling water at regular intervals. Significant changes usually point to a narrowing of the cross-section of the cooling circuits. We recommend decalcifying the cooling circuits from time to time. Use a commercially available decalcifier for this purpose. Cooling water additives such as anti-frost, anti-alga, decalcifiers etc. must not contain substances which react with the plastic fittings or with copper and aluminium elements. Appropriate cautionary measures to protect the environment are also to be taken.

-1-

1.1.6


Compressed air connection

If your machine is equipped with a pneumatic system, the machine must be connected to the compressed air network. The connection is made through the pneumatic maintenance unit which is to be found on the machine base (see illustration).

The highest pressure level from the compressed air network must not exceed 10 bar.

Connection for compressed air Pressure adjustment valve

( PI0496ZA )

1 2

BAM_207185_000_EN_10

The compressed air which is fed to the maintenance unit must be free of oil and contaminations. Any condensation is collected in the water separator on the maintenance unit. The condensation must be discharged via the outlet cock before the maximum level is reached.

● Connect a compressed air supply line DN 9 to the pneumatic maintenance unit.

● Check that the output pressure complies with the value stipulated on the designation label near the maintenance unit and adjust it if necessary, proceeding as described in chapter 9.8.9.

IMPORTANT

The pneumatic system must only be operated via the pneumatic maintenance unit. Compressed air which has not ben processed by the maintenance unit can cause malfunctions or a total failure of the pneumatic components.

-2-

1.1.6


● Connect the supply line to the connection pieces (1) and tighten it with a hose clip.


Cooling water connection

Supply and return connections for the machine cooling system are located on the rear side of the machine on the fluid distributors (see illustration).1 For the cooling water supply line (inlet) you must use a filter.

Connection dimensions

Supply temperature °C / °F Supply: DN 25 max. 25 / 77 Return: DN 25 max. 80 / 176 Pressure difference between supply and return min. 4 bar / 60 psi.

Supply pressure Supply pressure static dynamic bar / psi bar / psi max. 8 / 120 min. 4 / 60


( TB00263A GA1435ZB )

BAM_207185_000_EN_10

Hose

1 2

cooling water supply DN 25 cooling water return DN 25

IMPORTANT

Do not use pipes for connection, use hoses only. Remove connection nipples which are not required from the cooling water manifold. This interrupts the flow. If a value is available in the data set for this cooling circuit, water may jet out if the nipple remains inserted.

1

depending on the machine equipment -3-

1.1.6


BAM_207185_000_EN_10

Connection assignment of an optional cooling water manifold

( GB1435ZA )

power supply (on rear side) insert thermocouple connector here (observe x-designation) knob for manual adjustment feed zone oil temperature control cabinet supply shut-off valve return water processor


1 2 3 4 5 6 7 8 9 10

-4-

1.1.6


BAM_207185_000_EN_10

Connection assignment of an optional cooling water manifold

Connection for power supply 5 V (on rear side) insert thermocouple connector here (observe x-designation) feed zone oil temperature control cabinet supply switch-off valve return water processor


( GC1435ZA )

1 2 3 4 5 6 7 8 9

-5-

1.1.6


Cover of the cooling water manifold

BAM_207185_000_EN_10

In order to connect the thermocouples 1 to the respective sockets on the cooling water manifold, the cover of the cooling water manifold must be swivelled open.

To open the cover

cover screw screw (do not unscrew)

● Unscrew the two upper screws (2) at the front and the back of the cover (the screws (3) must not be unscrewed).

( GE1308ZA )

1 2 3

● Connect the thermocouples.

To close the cover

● Swivel the cover back again. ● Attach the fixing screws (2) and tighten them.

SAFETY INSTRUCTIONS

1

Never operate the machine when the cover is open or not correctly fastened.

not standard -6-

1.1.6


● Swivel the cover to the front.

Electrical connections

1.1.7


BAM_207185_000_EN_10

Connection values

( GE1754Z )

SAFETY INSTRUCTIONS

IMPORTANT

The electrical connections of the machine must be carried out by a suitably qualified specialist in accordance with VDE (for USA, Canada: NFPA 79) as well as any other regulations applicable to your country. All safety regulations must be strictly observed.

A serial label with technical data is located on the control cabinet of the machine.

Your supply voltage must correspond to the working voltage indicated on the machine ratings label or mains connection label on the machine.

..\TECH-DAT\ALLG\EN01AG_00_306_005.FM 01 2007.11.14

The connection values for USA and Canada are described at the end of this chapter.

Faulty-current circuit breaker

If your machine is equipped with a frequency converter and is protected by a faulty-current circuit breaker, a universal-current type faulty-current circuit breaker with the following features must be used: ⽧ Type B in accordance with IEC 60755 A2, ⽧ Universal-current type (in acc. with EN 50178 chapter 5.2.11.2), ⽧ Pick-up current => 300 mA (no operator safety), ⽧ Reaction time => 300 ms.

-1-

1.1.7

The machine is driven by a three-phase motor which was connected to the control cabinet before leaving the factory.

Power connection cable(s)

The machine may have one or two connection cables, depending on the size and equipment of the machine. Two cables are required if the machine is to be operated with the type of connection "Separate power for heating and motor". Otherwise 2 cables are also needed when the total amount of power needed is so great that it cannot be connected together with the bridges. Which type of connection is stipulated for your machine is to be taken from the information label on the inside of the control cabinet door (see illustration).

⽧ The values for the back-up fuse are entered in the boxes "a", "c" and "e". ⽧ The stipulated voltage is entered in the boxes "b", "d", "f", as on the serial label.

( GU1553Z )

Motor

BAM_207185_000_EN_10


Example: Box a = 63 A Box c = 16 A Box e = 50 A

Back-up fuse for total nom. power Back-up fuse for heating Back-up fuse for motor

With this specification the power for the heating and motor can either be connected together or separately. If however only boxes "c" and "e" are marked, the power for the heating and the motor must be connected separately. The connectable conductor cross sections must be determined in accordance with the cable length and fusing.

-2-

1.1.7


The connections must only be carried out in accordance with this information.


Removing the cover

To connect the mains cable, the cover of the control cabinet must be removed. Proceed as follows: ● First you must ascertain which variation of fixture is applicable to your machine:

BAM_207185_000_EN_10

Cover with 4 outer screws on top

Cover with straight front edge, and 2 inner screws


( 000083_00_000 000086_00_000 000090_00_000 )

Cover with oblique front edge, and 2 inner screws

-3-

1.1.7


Removing the cover

● Unscrew the 4 screws located on the top of the cover and remove them.

Lifting off the cover

● Lift off the cover.

( 000083_00_000 000084_00_000 000085_00_000 )

Removing the screws

BAM_207185_000_EN_10

Cover with outer 4 screws on top


● Place the mains cable through the opening provided in the control cabinet.

-4-

1.1.7



( 000086_00_000 000087_00_000 000088_00_000 000089_00_000 )

BAM_207185_000_EN_10

Cover with oblique front edge, and 2 inner screws

Removing the screws

● Open the doors of the control cabinet. ● Look for the two screws. (They are each located 20 cm away from the outer wall). ● Unscrew the two screws and remove them.

Pushing back the cover

● Push the cover back approx. 5 mm.



● Insert the mains cable through the opening provided in the control cabinet.

-5-

1.1.7


Removing the screws

● Open the doors of the control cabinet ● Look for the two screws. (They are each located 20 cm away from the outer wall).

● Lift the front edge of the cover slightly.

Pulling the cover to the front

● Pull the cover approx. 1 cm to the front.





( 000090_00_000 000087_00_000 000092_00_000 000093_00_000 000089_00_000 )

● Unscrew the two screws and remove them.

● Place the mains cable in the opening provided in the control cabinet.

-6-

BAM_207185_000_EN_10

Cover with straight front edge, and 2 inner screws

1.1.7


Power connection

● Guide the mains cable through the opening provided in the high current control cabinet. ● Connect the yellow/green protective earth cable to the yellow/ green earthing terminal and connect N to the N-terminal. ● Connect the L1, L2, L3 conductors to the L1, L2 and L3 terminals, see illustration. ● Tighten the terminals.

BAM_207185_000_EN_10

● Check whether all screw terminals are well tightened. They may have become loose during transport.

Mains connection with separate heating current

● Connect the green/yellow protective earth cable to the PE-terminal and N1 to the N1 terminal. ● Remove the bridge between terminals L1 and L4, L2 and L5, L3 and L6, N and N1. ● Connect the heating current cable to L4, L5 and L6. ● Tighten the terminals.

Mounting the cover

● Mount the cover onto the control cabinet. ● Proceed in reverse order, as described for demounting.


( GB1392ZA )

Mains connection terminals

1 2 3 4 5 6

PE terminal N1terminal L4, L5, L6 terminal L1, L2, L3 terminal N terminal Main switch

If the machine requires high connection values it will be equipped with an additional high-current cabinet. The mains connection for this version is shown in the following illustration:

-7-

1.1.7


(depending on the machine equipment)

BAM_207185_000_EN_10

Mains connection for additional cabinet

● The machine must only be connected to the mains by a qualified specialist. ● Tighten all screw terminals in the control cabinet. If the terminals are not tightened the main switch and other components may suffer irreparable damage.

● When working on the electric or hydraulic system, always switch off the main switch and lock it to prevent it being inadvertently switched on again.

-8-

( PG0481ZA GL1343Z )

SAFETY INSTRUCTIONS

PE terminal N terminal L1, L2, L3 terminal N1 terminal L4, L5, L6 terminal main switch


1 2 3 4 5 6

1.1.7


Inspecting / adapting low voltage

In order to guarantee a disturbance-free function of the controller and the control elements, the low voltage of the machine must be 24 V (26-28 V in unloaded condition). The low voltage is dependent on which mains voltage the machine is connected to.

BAM_207185_000_EN_10

The low voltage can be changed by varying the connection to the taps on the terminal strip (1) connected to the transformer (see illustration).

( PF0481ZA )

Please ensure that the cables L1, L2 and L3 and the bridges (2) are connected in accordance with the available mains voltage in your area by referring to the table on the transformer or in the circuit diagrams. Reconnection must only be carried out by a suitably qualified electrician under observance of the safety regulations.

IMPORTANT ..\TECH-DAT\ALLG\EN01AG_00_306_005.FM 01 2007.11.14

Refer to the group 2 circuit diagram (low voltage supply). The circuit diagrams are supplied in the machine control cabinet.

-9-

1.1.7

The following information applies only to machines in the USA and Canada.

Motor

The machine is driven by a three-phase A.C. motor which is connected to the control cabinet before leaving the factory.

Supply cables for the power connection

The machine is connected to the mains via one or two power supply cables, depending on the equipment installed. Two supply lines are required if the machine is to be operated with “separate heating and motor current”. Two supply lines will also be necessary if the total rating of the machine is so high that it cannot be connected together with the bridges. Which connection type is specified for your machine can be taken from the label on the inside of the control cabinet door (see illustration).

( GQ1596A )

Power connections for USA, Canada

BAM_207185_000_EN_10


⽧ The pre-fusing values are entered at “a”, “c” and “e”.

⽧ The power rating of the motor (in kW and hp) is entered at “g” and “i”. The stated power rating applies to the drive of the hydraulic pump, any connected electrically driven auxiliary axes are not included. ⽧ The fields “h” and “j” contain the values for the -

“full-load current” in accordance with CSA 22.2 no. 14, table 18 and

-

“locked - rotor current” in accordance with CSA 22.2 no. 14, pos. 5.7 (the locked rotor current is six times the current indicated in table 18).

- 10 -

1.1.7


⽧ The voltage specified on the machine rating plate is entered at “b”, “d” and “f”.


⽧ The temperature values given in °C and °F are the max. temperatures permissible for the connection line. ⽧ The values entered at Class J / AJT* are provided to help select the correct mains fuse. * (Fuse type by Ferraz Shawmut Inc, Newburyport, MA 01950 USA. Other fuse types may be used if they have the same characteristic values.).

BAM_207185_000_EN_10

The connections must have this form of identification. Example: Field “a” = 63 A Field “c” = 16 A Field “e” = 50 A

Pre-fusing of total nominal current Pre-fusing of heating Pre-fusing of motor

These specifications mean that the power for the heating and for the motor can be connected either together or separately. If however only the fields “c” and “e” are marked, the current for the heating and motor must be connected separately. The connectable conductor cross sections must be determined in accordance with the cable length and fusing.


● Now proceed with the power connections, as described in the previous pages of this chapter.

- 11 -

1.1.7


BAM_207185_000_EN_10


- 12 -

1.1.7

Filling the hydraulic oil

1.1.8


Oil quantities

You need hydraulic oil in accordance with DIN 51524 part 2 HLP46, DIN 51519 (see chapter 9.9 for selection of permissible oil types). Alternative hydraulic fluids must not be used without our explicit written consent - otherwise no guarantee! Please take the required oil quantities from the following table:

BAM_207185_000_EN_10

Machine 270 C 320 C 420 C 470 C 570 C

Calling up the oil level display

Oil quantity 165 litres / 43.6 US gall. 165 litres / 43.6 gall. 235 litres / 62 US gall. 235 litres / 62 US gall. 290 litres / 84.5 US gall.

The machine must have been previously connected as described in chapter 1.1.7. ● Put main switch to “I“ (red/yellow switch on control cabinet). ● When the request to “press controller start key” is displayed, press the controller start button under the screen of the monitor. 䡩 The alarm message “Alarm S925 oil level” “Oil level below min.” is displayed on the monitor.

..\TECH-DAT\S630\EN01AH_09_5404_001.FM 01 2007.06.26

( GB1306ZB )

䡩 The pump motor cannot be switched on.

1 2 3 4 5

Controller start key Emergency stop button Reading device for transponder cards (user access rights) Reading device for CompactFlash (memory medium) USB interface for PC keyboard

-1-

1.1.8


Call up the main group “Production control” with this key.

Call up the parameter panel “Valves/switches control circuit” with this function key.

BAM_207185_000_EN_10

Call up the superior group “Valves/switches” with this key.

..\TECH-DAT\S630\EN01AH_09_5404_001.FM 01 2007.06.26

Panel selection

-2-

1.1.8


Filling in the oil

● Unscrew the oil tank lid with air filter at the front of the machine base (to the left).

BAM_207185_000_EN_10

● Pour in the oil. Observe the handling and storing recommendations of the fluid manufacturer. Use a special filter unit for hydraulic fluid systems when filling the tank. Contaminations in the oil can lead to malfunctions! A suitable filter unit can be ordered from ARBURG (Part no. 529475, spare filter PN 529476). ● While filling in the oil, watch the positions S923, S924 and S925 in the parameter panel “Valves/switches control circuits”. You will find an explanation of the valve and switch displays in chapter 8.1.

Switch display on machine without oil filling: ⽧ S923 = marked, ⽧ S924 = not marked, ⽧ S925 = not marked. ● Keep filling with oil until S925 is marked. ● Now fill more slowly until S924 is also marked.

( GM1677Z GN1677Z GO1677Z GP1677Z )

● Pour in another 10 litres approx. 䡩 S923 must remain marked! 䡩 If you pour in too much oil, the marking at S923 is erased. The motor can not be switched on.

Switch display with oil filled to correct level: ⽧ S923 = marked, ⽧ S924 = marked,

..\TECH-DAT\S630\EN01AH_09_5404_001.FM 01 2007.06.26

⽧ S925 = marked.

no or too little oil

correct oil level

Motor can not be switched on

overfilled

Motor can not be switched on

-3-

1.1.8


1 2

BAM_207185_000_EN_10

● Replace oil tank cover with air filter and turn to right to close.

open close

IMPORTANT

Before setting into operation, the direction of rotation of the motor must be checked (see chapter 1.1.9). Input low speeds and pressure values for the first axis movements. This allows any air that is trapped in the hydraulic system to escape gently. Then load the start programme from the Compact-Flash system and vent the whole hydraulic system as described in chapter 9.8.4.

..\TECH-DAT\S630\EN01AH_09_5404_001.FM 01 2007.06.26

( GA0229ZA )

It can be necessary to top up the oil level after a few axis movements have been carried out.

-4-

1.1.8

Checking the direction of rotation of the pump motor

1.1.9


Switching on the motor

You cannot switch on the motor if there is no oil in the tank! The tank is already filled with hydraulic oil (acc. to 1.1.8). The direction of motor rotation must now be checked.

BAM_207185_000_EN_10

To do that turn on the machine (read section 1.4.1 “Switches and their functions” beforehand). ● Turn the main switch to “I” (red/yellow switch on front door of control cabinet). ● When the prompt “press start key” appears on the monitor, press the start key underneath the monitor, see illustration. Switch on the motor very briefly and immediately off again with the “motor on/off” keys on the manual control panel (see illustration). ● Observe the direction of motor rotation when the motor is activated (a second person can do this).

Does it rotate in the direction indicated by the arrow on the motor housing? ⽧ YES Your machine is now ready for the test run. You may skip the following points. ⽧ NO You cannot operate the machine in this manner. Please go on to the next point.

..\TECH-DAT\SDALLG\EN01AI_00_5404_000.FM 01 2006.02.09

● Switch the machine off. ● Cut off the power supply (pull power plug). ● Interchange two of three wires L1, L2, L3 on the power cable on the terminal strip inside the control cabinet (see 1.1.7 “Electrical Connections”). ● Inspect the direction of motor rotation again (as outlined above).

-1-

1.1.9


Work on the high current section must only be undertaken by suitably qualified specialists. When work is being undertaken on the high current system, the mains supply to the machine must be disconnected and protected against unintentional reconnection.

( GB1674ZB )

SAFETY INSTRUCTIONS

motor on/off controller start key

..\TECH-DAT\SDALLG\EN01AI_00_5404_000.FM 01 2006.02.09

1 2

BAM_207185_000_EN_10

Control panel

-2-

1.1.9

Setting the nozzle centre

1.1.10 Setting the nozzle centre When the machine bases under the clamping unit and under the injection unit are correctly aligned, the nozzle centre will also be correct. An inspection and/or adjustment of the nozzle centre becomes necessary when:

BAM_207185_000_EN_10

⽧ repair or maintenance work has been carried out on the injection unit

Vertical setting of the nozzle centre

● Remove the injection mould. ● Advance the nozzle into the centring bore of the fixed mould platen until it is flush with the mounting surface of the mould. ● Place the industrial spirit level (tolerance 0.1 mm/m) across the two support bars under the injection unit (using a plane-parallel bar as an aid, if necessary).

..\SPR-ZYL\Z800\EN01AJ_08_307_001.FM 01 2004.06.17

( GI1338ZA )

● Measure the vertical distance “A“ and “B“ between the bore of the nozzle tip and centring bore (see drawing).

1 2 A B

centring bore of fixed mould platen nozzle bore dimension A dimension B

-1-

1.1.10


BAM_207185_000_EN_10

Setting the nozzle centre on injection unit 800/15.3 oz

1 2 3 4 5

injection unit support bearing with securing bracket injection unit support bearing head screw bearing adjusting screw

● Loosen the head screws (3) in the rear support bearing (2).

● Ensure that all 4 screws are adjusted evenly. The horizontal adjustment (level) must not be allowed to change (check using spirit level). ● Insert the head screws (3) again and tighten them.

..\SPR-ZYL\Z800\EN01AJ_08_307_001.FM 01 2004.06.17

● Adjust the front bearing (1) so that the roller makes contact with the the guide rail of the injection unit.

( GF1625ZA )

● If there is a difference between dimension “A“ and “B” adjust the adjusting screws (5) in the bearing (4), until dimension “A” = “B”.

-2-

1.1.10


Horizontal adjustment of nozzle centre

The horizontal setting of the nozzle centre must also be inspected and if necessary adjusted. ● Advance the nozzle into the centring bore of the fixed mould platen.

1 2 C D

Centring bore of fixed mould platen Nozzle bore Dimension C Dimension D

..\SPR-ZYL\Z800\EN01AJ_08_307_001.FM 01 2004.06.17

( GS1338ZA )

BAM_207185_000_EN_10

● Measure the horizontal distance “C” and “D” with callipers between the bore of the nozzle tip and centring bore (see illustration).

-3-

1.1.10


If there is a difference between dimension “C” and “D”, adjust the eccentric bolts of the horizontal guide rollers, until “C” = “D”. ● Loosen hexagonal screw (1). ● Adjust eccentric bolt (2) and tighten the hexagonal screw (1).

hexagonal screw eccentric bolt guide roller

● Check all the adjustments on the clamping unit and injection unit again and correct them if necessary. ● Secure all threaded pins and adjustment screws with the nuts provided.

-4-

1.1.10

..\SPR-ZYL\Z800\EN01AJ_08_307_001.FM 01 2004.06.17

1 2 3

( GG1625ZA )

BAM_207185_000_EN_10

The eccentric bolt on the other side must be adjusted in the opposite direction.

Noise emission

1.1.11 Noise emission General information

The ALLROUNDER CENTEX machines have been constructed and manufactured using state-of-the-art technology.

BAM_207185_000_EN_10

Noise emission (airborne sound) has been reduced to a minimum due to the usage of low noise drive components. Dampening elements on the machine base and in the hydraulic system as well as guide and roller bearing technology on the moving parts of the machine, cater for noise reduction. The noise level may vary slightly depending the machine set-up and other factors which cannot be influenced. For this reason, a permissible range has been specified. The noise emission measurements were undertaken in accordance with DIN EN ISO 3744 and DIN EN SIO 3746. Measurements before the year 2003 were carried out in accordance with DIN 45636 part 1 and 37. The measurements were undertaken on identical machines..

Noise levels Machine type

570 C 2000-800 (220 tons 15.3 oz)

acoustic pressure level per 1 m meas. area in dB (A)

Work station related emission value in dB (A)

69…72

69…72

IMPORTANT

..\TECH-DAT\CG570\EN01AK_20_5404_000.FM 01 2006.04.28

⽧ The noise emission level may increase considerably if machine components become defective or worn. ⽧ Correct the defects immediately by replacing the parts in question. ⽧ Avoid machine adjustments which generate an increased noise emission level (e.g. hard closing movements). ⽧ Precautionary measures to prevent hearing damage should also be undertaken.

-1-

1.1.11

..\TECH-DAT\CG570\EN01AK_20_5404_000.FM 01 2006.04.28

BAM_207185_000_EN_10

Noise emission

-2-

1.1.11

Overview of the safety devices ALLROUNDER 470 C, 570 C

Inspecting the safety devices

1.2.1

Overview of the safety devices on the ALLROUNDER 470 C, 570 C

BAM_207185_000_EN_10

1.2

..\TECH-DAT\CG470570\EN01BA_17_5404_000.FM 01 2006.03.07

( GD1702ZA )

1

safety switch, safety interlock, see 1.2.2.

2

guard, clamping unit

3

safety switch, clamping unit, see 1.2.2.

4

safety switch, clamping unit, see 1.2.2.

5

safety switch, contact rail, see 1.2.2 (only when hydr. safety gate equipped, does not apply to ALLROUNDER GOLDEN EDITION)

6

safety switch, injection unit, see 1.2.3.

7

safety switch, screw safety cover, see 1.2.3.

For safety devices on machine base, see chapter 7.1.1.

-1-

1.2.1

Overview of the safety devices ALLROUNDER 470 C, 570 C

● Inspect the safety devices: ⽧ after every mould change, ⽧ at the start of each shift (with interrupted operation), ⽧ once a week (with continuous operation)! ● Hereby ensure that : BAM_207185_000_EN_10

⽧ the state of the safety devices is as specified, ⽧ the safety devices are in their specified position, ⽧ securely fastened, ⽧ and function correctly. ● Use the check lists on the following pages for inspection. ● Malfunctions must be corrected before the machine is put into operation. ● The machine must be switched off immediately if malfunctions occur during operation. ● Malfunctions are to be repaired by qualified personnel only. ● Do not change or remove any safety devices. Do not remove the effect of a safety device by modification to the machine! ● If peripheral devices and additional equipment are attached to the machine, the applicable safety devices must be inspected separately (see respective chapter on additional equipment / peripheral equipment) or manufacturer’s manual for peripheral devices).

..\TECH-DAT\CG470570\EN01BA_17_5404_000.FM 01 2006.03.07

SAFETY INSTRUCTIONS

-2-

1.2.1

Inspecting the safety devices on the clamping unit

1.2.2


Check list

BAM_207185_000_EN_10

Panel selection

Use the following pages as a check list when inspecting the safety devices. Photocopy them for use with the regular inspections. Tick off each point when it is in order.

Call up the main group “production control” with this key.


Call up the parameter panel “Valves/switches Safety Gate” with this key.

䡩 Here the status of each switch is displayed.

..\TECH-DAT\CG470570\EN01BB_17_5404_000.FM 01 2006.03.07

You will find a detailed explanation of the valve and switch displays in chapter 8.1.

-1-

1.2.2


( GF1702ZA )

BAM_207185_000_EN_10


-2-

1.2.2

BAM_207185_000_EN_10


1.

Safety gate 1 (clamping unit front); must be securely attached and move freely on the guide rails. The guide elements for the safety gate must be fully attached.

2.

Safety gate 2 (clamping unit rear); must be securely attached and move freely on the guide rails. The guide elements for the safety gate must be fully attached.

3.

Viewing panels on the safety gate must be securely attached.

4.

The guide rails of the safety gate must be securely attached.

5.

Safety switch for safety gate 1: Monitor display when safety gate open: ⽧ S151A = “marked”, ⽧ S151B = “marked”, ⽧ S171A = “marked”. Monitor display when safety gate closed: ⽧ S151A = “not marked”, ⽧ S151B = “not marked”, ⽧ S171A = “not marked”.

6.

Safety switch for safety gate 2: Monitor display when safety gate open: ⽧ S153A = “marked”, ⽧ S153B = “marked” ⽧ S171A = “marked”. Monitor display when safety gate closed: ⽧ S153A = “not marked”, ⽧ S153B = “not marked”,


⽧ S171A = “not marked”. 7.

Safety valve; is in correct working order.

8.

Safety switch for actuating safety valve: Monitor display when safety gates not completely closed: ⽧ S175 = “marked”, ⽧ S176 = “marked”. Monitor display when safety gates completely closed: ⽧ S175 = “not marked”, ⽧ S176 = “not marked.

-3-

1.2.2


9.

Safety rails (only with hydraulic safety gate, not standard, not on ALLROUNDER C GOLDEN EDITION). Safety gate 1 or 2 must stop and open a short stroke when the safety rail is actuated during the closing movement. Monitor display during closing movement of safety gate 1 or 2:

10.

The clamping unit safety cover must be fully installed. The protective cover panels on the machine base (to prevent injury) must be correctly mounted (see section 7.1.1).

11.

The panels must be complete and securely attached. The machine must only be set into operation when all 4 panels are installed.

Machine model:

___________________ Machine no.:

_______________

_______________


( EN_TB00497A )

Date of Inspector inspection: ___________________ (signature):

BAM_207185_000_EN_10

⽧ S161 or S162 = “marked”.

-4-

1.2.2

Inspecting the safety devices on the injection unit

1.2.3


Check list

BAM_207185_000_EN_10

Panel selection

Use the following pages as a check list when inspecting the safety devices. Photocopy them for use with the regular inspections. Tick off each point when it is in order.

Call up the main group “production control” with this key.


Call up the parameter panel “Valves/switches Safety Gate” with this key.

䡩 Here the status of each switch is displayed.

..\TECH-DAT\Z400800\EN01BC_15_5404_000.FM 01 2006.02.17

You will find a detailed explanation of the valve and switch displays in chapter 8.1.

-1-

1.2.3

1.

Switch located on the support (nozzle side on the fixed clamping platen); it must be securely mounted.

2.

Actuation element (2) on the nozzle cover; it must lock into the switch (1) on the support of the injection unit.

3.

Upper nozzle cover; must be completely closed during operation.

( GK1702ZA )

BAM_207185_000_EN_10


Monitor display when nozzle cover open: ..\TECH-DAT\Z400800\EN01BC_15_5404_000.FM 01 2006.02.17

⽧ S202 = “marked”. Monitor display when nozzle cover closed: ⽧ S202 = “not marked”. 4.

Lower nozzle cover; must be securely mounted.

5.

Upper cover of plasticizing cylinder; must be installed.

6.

Lower cover of plasticizing cylinder; must be installed.

-2-

1.2.3


7.

Screw cover; must be fully installed and closed during operation. Monitor display when screw cover open: ⽧ S204 = “marked”. Monitor display when screw cover closed:

BAM_207185_000_EN_10

⽧ S204 = “not marked”.

Prescribed function:

8.

Actuation element on moving panel; must lock into the safety switch when the screw cover is completely closed.

9.

Panels on screw cover; are complete and securely mounted.

10.

Groove nut which secures cylinder; must be tightened and secured.

● Machine movements are only possible when: ⽧ the injection unit is inserted in “production” position and secured, ⽧ the nozzle cover is completely closed, ⽧ the screw cover is completely installed and closed.

( EN_TB00497C )

● Screw movements are only permitted when the injection unit is inserted and secured.

Inspector ________________ (signature)

________________

..\TECH-DAT\Z400800\EN01BC_15_5404_000.FM 01 2006.02.17

Date of inspection:

-3-

1.2.3

..\TECH-DAT\Z400800\EN01BC_15_5404_000.FM 01 2006.02.17

BAM_207185_000_EN_10


-4-

1.2.3

Overview of the switch designations of safety devices ALLROUNDER 470 C, 570 C


1 2 3 4 5 6 7

Safety gate 2, S153A, S153B and S176 Nozzle cover, S202A Screw cover, S204 Safety valve, S171A and S171B = 1 switch Safety gate 1, S151A, S151B and S175 Safety rail, S161 or S162 (not standard, not on ALLROUNDER C GOLDEN EDITION) Guard, complete

..\TECH-DAT\CG470570\EN01BD_16_5404_000.FM 01 2006.03.07

( GM1702ZA )

BAM_207185_000_EN_10

1.2.4

-1-

1.2.4

..\TECH-DAT\CG470570\EN01BD_16_5404_000.FM 01 2006.03.07

BAM_207185_000_EN_10


-2-

1.2.4

Inspecting the hoses

1.2.5


BAM_207185_000_EN_10

Hydraulic hoses

All hoses on your injection moulding machine are to be inspected at least once every three months with regard to their operating condition. This inspection must be undertaken by an expert. An expert is someone qualified with an appropriate specialized training and experience in the field of hydraulic hoses. He should be totally familiar with all state-prescribed regulations of safety and accident prevention as well as with all guidelines and generally recognized rules applying to this technology, so that he is in a position to judge the safe working condition of the hydraulic hoses.

Possible defects

The following examples illustrate the most important defects which require an immediate replacement of the hoses. ⽧ The outer layer of the hose is damaged up to the lining (chafed sections, cuts or cracks). ⽧ The outer layer is brittle (cracks in the hose material). ⽧ The hose is deformed or deforms in a pressurized or pressureless state or when bent, e.g. layer separation, formation of blisters, pinched or crimped. ⽧ The hose leaks. ⽧ The hose drifts out of its fitting.

..\TECH-DAT\ALLG\EN01BE_00_306_001.FM 01 2005.05.09

( GA1052ZA )

⽧ The fitting is damaged or deformed (stability of the fitting or the connection of the hose/fitting is impaired). ⽧ The fitting is corroded and the function and stability impaired. ⽧ The duration of use is slightly exceeded (see date of manufacture on the hose fitting).

1 2 3 4

outer layer inner layer lining hose fitting

-1-

1.2.5


Water hoses

In the same way as the hydraulic hoses, the water hoses on the injection moulding machine must also be inspected regularly (at least once every three months). As some water hoses can convey very hot water, there is a considerable danger of scalding injuries being suffered by operating personnel if the hoses are in any way damaged or incorrectly connected.

Possible defects

The following examples show the most common defects which can make it urgently necessary to replace the water hoses or the connection fixtures. ⽧ The outer layer is damaged (chafe markes, cuts or cracks).

BAM_207185_000_EN_10

By regularly inspecting your water hoses you can help to prevent potential dangers and leakages and their consequences.

⽧ The hose is deformed or has kinks. ⽧ The hose is not water tight. ⽧ The seat on the connection fitting is defective. ⽧ The connection fixture is damaged.

Water hoses must be inspected at least every three months. This can prevent scalding injuries and flooding resulting from defective hoses and fittings.

..\TECH-DAT\ALLG\EN01BE_00_306_001.FM 01 2005.05.09

SAFETY INSTRUCTIONS

-2-

1.2.5

Replacement of parts after natural ageing

1.2.6


Hydraulic hoses

Hydraulic hoses are subject to a natural ageing process. This limits the duration of usage. The user of the injection moulding machine is responsible for ensuring that the hoses are replaced within the prescribed time period, even if there is no indication of a technical defect or malfunction.

BAM_207185_000_EN_10

The duration of use should not exceed 6 years from the date of manufacture.

Replacing the hoses

The following is to be observed when replacing the hoses: ⽧ Use only original spare parts. This ensures that the hoses are adequately rated for the required loads and the lengths and the fittings are correct. ⽧ Install in the original position of installation and do not change the access positions or bend angles.

SAFETY INSTRUCTIONS

Hoses must not come in contact with substances which could lead to hose damage, e.g. acids, alkaline solutions, solvents. Do not use illumination elements which form ozone or devices which create sparks in the immediate area. Avoid re-using the hoses. The initial use of the hose may have changed the characteristics in such a way as to present an increased risk if re-used.

..\TECH-DAT\ALLG\EN01BF_00_306_002.FM 01 2006.04.25

Water hoses

Due to their natural ageing and thermal stress, water hoses are subject to a certain level of material fatigue. In order to guarantee safe and problem-free operation of your injection moulding machine, we recommend replacing all water hoses at the latest every three years or at the first signs of damage in any individual hoses. Use only water hoses and fittings which are rated to withstand the required loads (thermal and pressure). This is guaranteed with original spare parts.

-1-

1.2.6


Also due to time deterioration, the toothed ring (2) in the drive coupling must be replaced after approx. 6 years. The drive coupling is installed between the motor and the hydraulic pump.

Viewing panels

Viewing panels (windows) of polycarbonate must be replaced every 6 years. For more information see chapter 1.2.9.

..\TECH-DAT\ALLG\EN01BF_00_306_002.FM 01 2006.04.25

( GV1707Z )

BAM_207185_000_EN_10

Drive coupling

-2-

1.2.6

Safety markings

1.2.7

Safety markings

Area of application: USA

According to “SPI” ANSI Z535, injection molding machines and peripheral devices operated in the USA have to be equipped with safety markings.

BAM_207185_000_EN_10

These safety markings consist of adhesive labels that are to be fixed in the immediate vicinity of danger zones. Due to the symbolic representation of objects and facts, the attention of the operator is quickly and easily drawn to the potential dangers. In addition to the symbols, the safety markings are explained by text. Inspection of safety markings

The completeness of the safety markings is to be inspected regularly, at least every 3 months. Missing or defective safety markings are to be replaced immediately. Where and which safety markings are to be fixed on the machine can be seen in the following chart.

IM

PORTANT

Do not clean safety markings with cleaning agents containing solvents.

..\TECH-DAT\ALLG\EN01BG_00_306_001.FM 01 2005.07.04

( TB00451A )

Order overview Part No. 10.101 10.102 10.103 10.104 10.105 10.106 10.107 10.108 10.109 237.985

Designation Label: “Danger: high voltage” Label: “Danger: high speed moving parts” Label: “Danger: hot surface” Label: “Warning: high pressure molten material” Label: “Warning: rotating screw” Label: “Caution: vapors and fumes” Label: “Caution: high speed moving operator gate” Label: “Danger: high speed moving parts inside clamping area” Label: Caution: danger of crushing injury from core and ejector” Label: “Caution: door is locked”

-1-

1.2.7

..\TECH-DAT\ALLG\EN01BG_00_306_001.FM 01 2005.07.04

( GK1376Z )

BAM_207185_000_EN_10

Safety markings

Safety markings

-2-

1.2.7

Position of the safety markings

Position of the safety markings ALLROUNDER CENTEX

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( GY1702ZA )

BAM_207185_000_EN_10

1.2.8

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1.2.8

\\TECH-DAT\CG-ALLG\EN01BH_11_5404_000.FM 01 2006.12.19

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Position of the safety markings

-2-

1.2.8

Inspecting the viewing panels

1.2.9


Viewing panels

The safety guards on your machine are sometimes equipped with viewing panels which enable the machine movements to be observed. Due to external influences such as heat, vapours or unsuitable cleaning detergents, these viewing panels can in time lose some of their shock resistance and become brittle (ageing process).

BAM_207185_000_EN_10

The ageing process of the viewing panels can occur sooner or later, depending on the intensity and concentration of the detrimental influences.

If it is already known before the machine leaves the factory that increased heat or vapours are likely to occur (e.g. if duromer, elastomer, or liquid silicone are to be processed on this machine) viewing panels of polycarbonate (PC) are installed. These viewing panels are extremely resistant to shock and breakage. Furthermore, all ALLROUNDERs on which it is possible to work with the injection unit in a position which faces the viewing panel are also equipped with viewing panels of polycarbonate. If a machine is later retrofitted to a production method which affects the viewing panels, the standard viewing panels of Plexiglas are to be replaced with ones of polycarbonate.

In order to guarantee the protective characteristics of the viewing panels, they must undergo regular inspections.

Possible faults

The following examples show the most common faults which can make an immediate replacement necessary: ⽧ plastic deformation (buckling or dents),

..\TECH-DAT\ALLG\EN01BI_00_306_000.FM 01 2004.02.06

⽧ cracks, ⽧ cloudiness

IMPORTANT

Never clean the viewing panels with alcohol or detergents containing solvents. Use commercially available window cleaning products

-1-

1.2.9


Replacing the viewing panels

In order to ensure their protective function, we recommend renewing the polycarbonate viewing panels every 6 years. This applies even if no apparent faults are visible on the viewing panels.

SAFETY INSTRUCTIONS

Viewing panels of polycarbonate are to be renewed at the latest every 6 years. When converting production to duromer, elastomer or liquid silicone processing, viewing panels of polycarbonate are to be installed. Viewing panels of polycarbonate must also be used when the injection unit is operated in a position facing the viewing panels. When working with hot plastic melt, combustion can occur which can cause serious burns!

Removing the viewing panel

BAM_207185_000_EN_10

No changes are visible e.g. when the viewing panels become brittle.

The viewing panels are attached on the inside of the safety gate and secured by profiled rails. A strip of neoprene between the rail and viewing panel serves as a cushioning element. ● Remove the attachment screws from the profiled rail. ● Remove the profiled rail complete with strip of neoprene. ● Now you can remove the viewing panel. ● Remove the protective foil from the viewing panel. ● Insert the new viewing panel in the safety gate. ● Ensure that the viewing panel contacts the protective panel evenly all round. ● Attach the profiled rail with neoprene strip and tighten the screws. ● Use only viewing panels of the specified quality and thickness. This is always guaranteed with original spare parts.

..\TECH-DAT\ALLG\EN01BI_00_306_000.FM 01 2004.02.06

Installing the viewing panel

-2-

1.2.9

Inspection of bolted fixing points for lifting gear

1.2.11 Inspection of bolted fixing points for lifting gear If there are bolted load fixing points attached to your machine or accessories, these must be inspected by a specialist at least once a year. With frequent use, the fixing points must be inspected more often.

BAM_207185_000_EN_10

Rotating load ring, with bolt, type VLBG

The following points must be checked: ⽧ Screws must fit tightly (check torque in accordance with table below), ⽧ Signs of corrosion, ⽧ Signs of wear, ⽧ Signs of deformation, ⽧ Cracks on load-bearing parts, ⽧ Body must rotate freely.

..\TECH-DAT\ALLG\EN01BK_00_306_000.FM 01 2007.10.30

( GN1744Z )

Load ring with bolt Nom. load capacity VLBG 1.5 t (M16) VLBG 2.5 t (M20

SAFETY INSTRUCTIONS

ARBURG Part no. 140753 148190

Torque value Nm / lbs ft 150 / 110.6 250 / 184.4

If the load ring bolt threads show signs of damage, they must not be used and are to be replaced immediately. ● Adjust to the direction of pull before applying the sling. The ring bolt must move freely and not be jammed in one corner. ● The thread of the bolt must not turn when under load. ● Use only original fixing screws which comply with the specified EN (DIN) standard and quality grades. If this is not observed there is a danger of serious or fatal injury! Threaded ring bolts which are used regularly (e.g. for machine conversion) must be additionally glued down with Loctite screw glue 243.

-1-

1.2.11

Inspection of bolted fixing points for lifting gear

Eye bolt type VRS M10 (0.4 t) M12 (0.75 t) M16 (1.5 t) M20 (2.3 t)

ARBURG Part no. 215210 245836 188653 193730

Torque Nm / lbs ft 10 / 7.4 25 / 18.4 60 / 44.25 115 / 84.8

BAM_207185_000_EN_10

Rotating eye bolt type VRS

The following points must be checked: ⽧ Screws must fit tightly (check torque in accordance with table below), ⽧ Signs of corrosion, ⽧ Signs of wear, ⽧ Signs of deformation, ( GO1744Z )

⽧ Cracks on load-bearing parts, ⽧ Body must rotate freely.

If the eye bolt threads show signs of damage, they must not be used and are to be replaced immediately. ● Adjust to the direction of pull before applying the sling. The eye bolt must move freely and not be jammed in one corner. ● The thread of the eye bolt must not turn when under load. ● Use only original fixing screws which comply with the specified EN (DIN) standard and quality grades. If this is not observed there is a danger of serious or fatal injury! Threaded eye bolts which are used regularly (e.g. for machine conversion) must be additionally glued down with Loctite screw glue 243.

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1.2.11

..\TECH-DAT\ALLG\EN01BK_00_306_000.FM 01 2007.10.30

SAFETY INSTRUCTIONS

Modular structure of the SELOGICA controller

1.3

General information on the SELOGICA controller

1.3.1


BAM_207185_000_EN_10

Optimal process guidance with regard to high quality of the injection moulded parts and economical production require a variety of function and set-up parameters. The SELOGICA controller on ARBURG ALLROUNDER machines makes all this available. One of the outstanding features of the SELOGICA 32 bit multiprocessor controller is the fact that it makes complex machine technology very simple and reliable to operate. This goal is achieved by: Logical, selective user guidance

⽧ In the individual parameter panels only those parameters are displayed that are actually required, depending on the machine equipment, the mould and order data and the cycle sequence. This guarantees the greatest possible transparency.

Plausibility check

⽧ The SELOGICA controller checks whether the inputs made by the user are plausible. Thus wrong inputs are ruled out.

Graphical sequence programming of the SELOGICA controller

⽧ The machine cycle is graphically programmed using symbols. Each machine function to be carried out, in particular simultaneous machine sequences, can be recognized at one glance.

\\STRG-SW\S-SW306X\01CA_00_306_000.FM 01 2004.02.09

Parameter panels can be selected direct from the sequence programming and the respective data input. Quality assurance

⽧ Extensive possible quality control programmes and optional graphical evaluations ensure the specified quality directly during production.

Modular design

⽧ Due to the modular structure of the software and corresponding hardware, your ALLROUNDER can be upgraded at any time with special applications such as core pull control, intrusion or programmable outputs etc. and can thus be adapted to your requirements without any problems.

Integration abilities

⽧ Temperature control devices, dryers, robotic handling devices etc. can be integrated in the SELOGICA controller at any time.

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1.3.1

\\STRG-SW\S-SW306X\01CA_00_306_000.FM 01 2004.02.09

BAM_207185_000_EN_10


-2-

1.3.1

Software packages

1.3.2

Software packages The function scope of the basic standard version of the SELOGICA controller can be considerably increased by optional modules (software packages). Each software package consists of a multitude of individual functions which are combined under the general term of package 1, package 2 and package 3.

BAM_207185_000_EN_10

The individual packages can be combined with each other, depending on the machine equipment. This provides many possibilities of gearing the controller to individual requirements.

Package 1 (extended monitoring functions) ⽧ Mould position monitoring: All processes in the sequence editor, for which the position of the mould is to be monitored, can be individually marked by the operator. The traditional ejector platen protection is included as standard equipment.

IMPORTANT

Without package 1 the mould position monitoring is predefined and cannot be switched off.

\\STRG-SW\S-SW306X\EN01CB_00_306_000.FM 01 2004.02.09

If you want to work without mould position monitoring you must use the short-circuit plug S141. ⽧ Stroke monitoring with simultaneous movements (only in connection with package 2): This function monitors whether core pulls, which are moved simultaneously with mould, ejector or injection movements, have reached their end position before the reference axis reaches a predefined stroke position. ⽧ Injection pressure monitoring The input maximum pressures for each stage are monitored during injection. If the maximum pressure is reached, several follow-on reactions are possible: the machine either switches off immediately or switch-over from injection pressure to holding pressure is immediately carried out and the machine switches off at the end of the cycle, or immediate switch-over to holding pressure is undertaken and the error evaluation rejects the part. ⽧ Monitoring functions in “Set-up” operating mode: In “set-up” operation the monitoring functions for each individual axis (e.g. clamping unit, ejector, core pull) can be deactivated by the operator.

-1-

1.3.2

Software packages

Package 2 (additional movements) ⽧ Ejector: Intermediate stop during ejector advancement and retraction, multiple short strokes (shaking) at intermediate stop position.

⽧ Extended clamping program (as from T2: controlled): Up to two clamping forces for injection, holding pressure and cooling. Second high-pressure build-up (e.g. after core pull insertion in closed mould with low clamping force). Programmable enable force (the high-pressure pump takes over the clamping function before it ends at a programmable force threshold). The main pump is thus free and the follow-on process can start earlier.

BAM_207185_000_EN_10

⽧ Core pull (for existing core pulls): Intermediate stop during insertion and retraction, core pull short strokes (shaking), extended holding pressure program (T2).


⽧ Extended sequence editor: Moving the logical AND conditions, switching over processes to another drive (pump, accumulator). Creating an individual drycycle sequence by marking certain processes which are not to be carried out in “dry-cycle” operation. Switching off processes during the fully automatic production cycle. Programming strokedependent start conditions for simultaneous movements.

-2-

1.3.2

Software packages

Package 3 (production control):

BAM_207185_000_EN_10

This package makes it possible to switch the machine on and off independently in order to carry out temperature reduction and preheating as well as to carry out start-up and shut-down cycles at the beginning/end of automatic production. ⽧ Automatic nominal temperature value control: Display of all heating, cooling and temperature control systems currently active on the machine, including the interface devices, such as temperature control devices and THERMOLIFT. Display of the current nominal temperature value level (nominal value, enable temperature, reduced temperature, off) for each operating status (manual, preparation, stand-by) and each unit. ⽧ Programmable alarm cycle: For the last cycle before switch-down of the machine, processes after end of cooling time can be marked for switch-off. ⽧ Start-up cycles: When the machine is started or restarted it must be assumed that the thermal conditions have not all been fulfilled in the first few cycles so that the quality of the parts cannot be guaranteed. The required number of “start-up” cycles can be programmed so that the parts are automatically treated as “rejects” without having to register a production error. ⽧ Programmable start-up and switch-down sequences: The “start-up”, “switch-down” and “production change” sequences are graphically displayed in a sequence diagram. Here all functions to be carried out, from the “stand by” operating mode to automatic processing and back, are programmed.


⽧ Time-controlled automatic switch on/off. ⽧ Second programming level: The level administration permits work on two different levels in the program. For example a new order can be programmed while the old order is still being processed.

-3-

1.3.2


BAM_207185_000_EN_10

Software packages

-4-

1.3.2

Introduction to the screen layout

1.3.3


BAM_207185_000_EN_10

The following illustration gives you an overview of the various sections on the SELOGICA ’direct’ screen

Temperatures, injection unit 1

Operating status

( PA0550DA )

Cylinder heating zone 1

1 2 3 4 5 6 7

Status lines Type of navigation Direct access keys Special keys Editing box Graphical inputs and table Navigation levels

..\STRG-SW\SDSW404X\EN01CC_00_5404_001.FM 01 2007.03.23

The individual areas are described in more detail in the following chapters.

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1.3.3


BAM_207185_000_EN_10


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1.3.3

The status lines

1.3.4

The status lines

BAM_207185_000_EN_10

The status lines are divided into three sections:

1 2 3

..\STRG-SW\SDSW404X\EN01CD_00_5404_000.FM 01 2006.02.13

( PB0550ZA PC0550D )

Alarm line

Alarm line Status display Actual values line

In the alarm line information, warnings, alarms and system errors are displayed. (Text in this illustration: Data error: invalid value at f9155)

Press this key to gain direct access to the parameter panel with the erroneous parameters.

The parameter designations are explained in more detail in the section “Input of production data”.

-1-

1.3.4

The status lines

IMPORTANT

If several messages are currently output, only the “most important” one is shown in the alarm line. A list of all active messages is to be found in the panels “Alarm messages“, “Warnings“ and “Information“. These can be called up via the green main group. Alarms in “manual” operating mode are not all output acoustically or visually.

In the status display the operator authorisation and the programming level is displayed.

User authorisation Programming level

( PD0550ZA )

1 2


Status display

BAM_207185_000_EN_10

In “dry cycle” mode or when the quality assurance function is switched off the yellow lamp lights up and any warnings are displayed on the screen.

-2-

1.3.4

The status lines

User authorisation: The user authorisation protects the controller from inputs by unauthorised persons. If the symbol has a green background, changes can be made in parameter panels or in the cycle sequence (depending on the level of authorisation).

BAM_207185_000_EN_10

Programming level: If this symbol has a green background, you are in the production level.

Preparation level: If this symbol has a yellow background, you are in the preparation level. In this level you can look at data and change it while the machine continues working with data from the production level.

In the actual values line the current actual values are displayed independent of the currently selected parameter panel.


( PE0550ZA )

Actual values line

1 2 3 4 5

Material volume Material cushion Maximum injection pressure Cycle time Part counter

-3-

1.3.4


BAM_207185_000_EN_10

The status lines

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1.3.4

Navigation mode and navigation level

1.3.5


BAM_207185_000_EN_10

On the SELOGICA ’direct’ you can switch over between theme navigation and sequence navigation at the press of a button.

1 2

When you press this key, symbols representing the individual themes are displayed in the navigation level.

..\STRG-SW\SDSW404X\EN01CE_00_5404_002.FM 01 2007.03.23

( PG0550ZA PI0597ZA )

Theme navigation

Theme navigation Sequence navigation

1 2 3

Main groups Superior groups Parameter panels

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1.3.5


In this display mode the navigation levels are divided into: ⽧ main groups (colour-coded), ⽧ superior groups (colours matching main group),

-

in green parameter panels you make a selection,

-

in grey parameter panels you find process parameters and,

-

in yellow parameter panels the monitoring parameters.

Due to the optical effects and the colour coding in all three levels you can easily recognise which parameter panel is currently displayed.

By pressing this key the superior group and parameter panel display changes into a symbolic representation of the sequence.

( PH0550DA )

Sequence navigation

BAM_207185_000_EN_10

⽧ parameter panels:

Main groups Sequence

In this type of representation the navigation levels are divided into ⽧ main groups ⽧ sequence. The individual parameter panels can be called up simply by pressing the respective sequence symbol.

-2-

1.3.5


1 2

The direct access keys

1.3.6


BAM_207185_000_EN_10

The direct access keys increase the ease of operation. Each of the four direct access keys automatically remembers the last parameter panel you selected in this sector.

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( PI0550ZA )

1 2 3 4

Parameter panels Measuring charts Monitoring charts Protocolling

Parameter panels

When you touch this key, the display changes to the last parameter page you selected in the grey main group.

Measuring charts

When you touch this key the display changes to the last parameter panel you selected in the “measuring charts” sector.

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1.3.6


When you touch this key the display changes to the last parameter panel you selected in the monitoring charts sector.

Protocolling

When you touch this key the display changes to the last parameter panel you selected in the protocolling sector.


BAM_207185_000_EN_10

Monitoring charts

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1.3.6

The special keys

The special keys

BAM_207185_000_EN_10

1.3.7

1 2 3 4

page forwards page backwards error search / parameter search Information / Help

Press this key if you want to go back to the previously called up parameter panel.

Page forwards

Press this key if you want to go return again to the first parameter panel.

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( PK0550ZA )

Page backwards

Error search

If the controller issues an alarm message which contains one or more faulty parameters, you must call up this parameter panel in order to rectify the cause of error. By pressing this key, the controller immediately calls up the parameter panel containing the first faulty parameter and displays it in the respective colour.

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1.3.7

The special keys

Parameter search

If there are no messages in the alarm line, you call up the parameter search with this key.

1 2

( PJ0550DA )

BAM_207185_000_EN_10

● A keyboard is displayed on the screen with which you first input the required parameter and then press the “Y” key to start the search.

Start search Cancel inputs

All functions of this displayed keyboard are carried out in the same way as on a conventional PC keyboard. You will find more details in the following chapter.

-2-

1.3.7


By pressing the “N” key you can cancel your input.

The special keys

Information / Help

By pressing this key you call up information on the currently marked parameter.

BAM_207185_000_EN_10

If the parameter is not dependent on another one, the following window is displayed:

Help - Input restrictions

no restricting parameters

go to parameter search

2

the parameter is not dependent on another one

3

with these symbols you can move the window to the left or right side of the touch screen (in case this window is covering the part of the screen you currently want to work in).


( PL0550DA )

1

-3-

1.3.7

The special keys

If the selected parameter is dependent on or limited by another parameter, the following window appears

BAM_207185_000_EN_10

Help - Input restrictions

1

by pressing this field you access the parameter panel of the dependent parameter.

Explanations: […] ← s101 = the upper limit of the selected parameter is determined in this example by s101.

The selected parameter is dependent on another one. Press this symbol to return to the previous display.


…] =

( PY0552ZA )

→ […] s101 = the lower limit of the selected parameter is determined in this example by s101.

-4-

1.3.7

The editing box

1.3.8

The editing box

Parameter selected

When a parameter has been selected, the following is displayed in the editing box ⽧ the designation (1), (2), ⽧ input possibilities or limit values (3)

BAM_207185_000_EN_10

⽧ the current value (4) of the respective parameter.

1 2 3 4 5 6

Process selected

When a process has been selected, the following are displayed ⽧ the designation and

( PN0550DA PC0551D ) ..\STRG-SW\SDSW404X\EN01CH_00_5404_001.FM 01 2007.02.07

designation in full (here: cylinder heating zone 1) parameter input range / limit values current value function-input / function keys edit / text input

⽧ the drive of the respective process.

Process: basic mould closing program Drive: control circuit 1

IMPORTANT

In sequence navigation mode you have two markings (one for the selected process in the sequence and one in the parameter panel). The contents of the editing box refer to the currently active parameter or process (i.e. the one you last touched on the screen).

-1-

1.3.8

The editing box

Function keys (5) The function keys displayed here vary. They always relate to the parameter panel currently in the display.

Selection Take over in protocol (log)

BAM_207185_000_EN_10

With this key you can select certain functions. When you touch it a window opens in which possible functions (related to the currently active parameter) are displayed for selection:

Depending on the currently selected parameter, the parameter can be ⽧ taken over in the protocol, ⽧ used as a start-up parameter,

( PX0551D )

⽧ taken over in the freely configurable parameter panels.

..\STRG-SW\SDSW404X\EN01CH_00_5404_001.FM 01 2007.02.07

Function input (5)

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1.3.8

The editing box

Magnifier

With this key you can “zoom in” or “zoom out” (enlarge or reduce certain sections of) a graphical display.

Flag

With this key you can select certain markings.

BAM_207185_000_EN_10

.

Visible marking

no markings omit in dry cycle omit in alarm omit in auto mould position monitoring


( PR0550D )

End position monitoring

Confirm

This key is used generally to activate actions and confirm inputs.

Delete

This key is used generally to deactivate actions and delete inputs.

-3-

1.3.8

The editing box

Edit / text input (6)

With this key you activate the currently possible input mode:

⽧ numeric keypad, ⽧ on-screen keyboard, ⽧ selection options).

erase the character last entered confirm input and transfer to parameter panel cancel input


1 2 3

( PO0550DA )

BAM_207185_000_EN_10

Numeric keypad:

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1.3.8

The editing box

BAM_207185_000_EN_10

On-screen keyboard:

( PP0550DA PM0551D )

1 2 3 4 5 6 7

erase input erase character last entered upper case (capital letters) confirm input and transfer to parameter panel erase input special characters lock upper case

All functions of this on-screen keyboard are carried out in the same way as on a conventional PC keyboard. Selection options: Sequence editor


Set marking Insert symbol Move symbol Delete symbol Change start condition Switch over drive Move branch end

-5-

1.3.8


BAM_207185_000_EN_10

The editing box

-6-

1.3.8

The parameter panel

1.3.9

The parameter panel

BAM_207185_000_EN_10

The parameter panel is divided into the input chart and the input table. For easier understanding, all processes are displayed in symbols so that very little text is necessary.

( PS0550DA )

1 2 3

Designation of the parameter panel (here: Injection Unit 1 Temperatures) Input chart Input table

..\STRG-SW\SDSW404X\EN01CI_00_5404_000.FM 01 2007.02.27

IMPORTANT

All movements are displayed in the direction (as seen from the view of the operator) in which they actually take place, i.e. for example: ⽧ mould closing from left to right ⽧ mould opening from right to left ⽧ injection from right to left ⽧ chronological order always from left to right If this display seems unfamiliar to you at first, you can refer to the arrows which always point in the direction of movement.

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1.3.9

..\STRG-SW\SDSW404X\EN01CI_00_5404_000.FM 01 2007.02.27

BAM_207185_000_EN_10

The parameter panel

-2-

1.3.9

The navigation levels

1.3.10 The navigation levels

BAM_207185_000_EN_10

Main group: machine settings

1 2 3


Assigned to this grey main group key you will find all parameter panels for the machine set-up parameters.

These are (depending on the configuration of your machine): ⽧ machine characteristic parameters ⽧ operating modes ( PY0550DA )

⽧ order data ⽧ switch-on/off ⽧ start-up / switch-off ⽧ production sequences,

..\STRG-SW\SDSW404X\EN01CJ_00_5404_002.FM 01 2007.02.28

⽧ mould, ⽧ ejector, ⽧ nozzle, ⽧ injection/holding pressure, ⽧ dosage, ⽧ cylinder temperature, ⽧ core pulls, ⽧ mould temperature, ⽧ conveyor belt / sorter unit, ⽧ programmable outputs, ⽧ robot system, ⽧ rotary table.

-1-

1.3.10


The keys for the parameter panels have different colours so that you can see at a glance which type of parameter panel is concerned. ⽧ in green parameter panels you make a selection, ⽧ in grey parameter panels you will find the process parameters and, ⽧ in yellow parameter panels the monitoring parameters.


Due to the optical effects and the colour coding you can easily recognise which type of parameter panel is currently displayed.

BAM_207185_000_EN_10

The symbols used are standardised and self-explanatory and in most cases already familiar from use with the conventional SELOGICA controller.

-2-

1.3.10


BAM_207185_000_EN_10

Main group: QS and documentation

1 2 3


Assigned to this yellow main group key you will find all parameter panels for quality assurance and documentation.

These are (depending on the configuration of your machine): ⽧ measuring systems, ⽧ measuring charts, ⽧ monitoring charts, ⽧ printer / archive ( PV0597DA )

⽧ protocol (logging), ⽧ SPC charts, ⽧ archiving, ⽧ quality control / quality monitoring,


⽧ monitoring, ⽧ cycle time diagram, ⽧ AQC.

-3-

1.3.10


The keys for the parameter panels have different colours so that you can see at a glance which type of parameter panel is concerned. ⽧ in green parameter panels you make a selection, ⽧ in yellow parameter panels you find the monitoring parameters.


Due to the optical effects and the colour coding you can easily recognise which type of parameter panel is currently displayed.

BAM_207185_000_EN_10

The symbols used are standardised and self-explanatory and in most cases already familiar from use with the conventional SELOGICA controller.

-4-

1.3.10


BAM_207185_000_EN_10

Main group: production control

1 2 3


Assigned to this green main group key you will find all parameter panels for the production control.

These are (depending on the configuration of your machine): ⽧ program administration, ⽧ host computer, ⽧ machine characteristic parameters,

( PW0597DA )

⽧ units ⽧ order data, ⽧ order control, ⽧ machine data, ⽧ user authorisation, ..\STRG-SW\SDSW404X\EN01CJ_00_5404_002.FM 01 2007.02.28

⽧ service functions ⽧ alarms / warnings / messages, ⽧ valves / switches.

The symbols used are standardised and self-explanatory and in most cases already familiar from use with the conventional SELOGICA controller. Due to the optical effects and the colour coding you can easily recognise which type of parameter panel is currently displayed.

-5-

1.3.10


BAM_207185_000_EN_10


-6-

1.3.10

The most imporant operating elements and their functions

1.4

Overview of the operating elements

1.4.1

The most important operating elements and their functions The main switch is located on the control cabinet. With this you switch the power supply for the whole machine on and off.

BAM_207185_000_EN_10

Main switch

⽧ Position “0” = OFF ⽧ Position “I” = ON.

IMPORTANT

..\STRG-SW\SDSW404X\EN01DA_00_5404_000.FM 01 2007.03.23

( GF1392D GB1674ZA )

Before you switch the machine off at the main switch, switch the heating and motor off first.

1 2 3 4 5

Controller start key Emergency stop switch Reading device for transponder cards (user authorisation) Reading device for compact flash (storage medium) USB interface for PC keyboard

-1-

1.4.1


Controller start button (1)

When you set the machine into operation, you must first start the SELOGICA controller. The controller start button (1) is located on the right under the touch screen.

䡩 When these tests are completed, the message “Press controller start key, release emergency stop” appears at the top of the screen in the alarm line. ● Press the controller start key.

Emergency stop switch (2)

With the emergency stop switch (2) you can cut off the power supply to the machine in an emergency.

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After switching on the main switch, the controller and various machine systems are tested.

All machine movements are stopped immediately and the heating is switched off. ● Press the red button to activate the emergency-stop switch. 䡩 The machine stops all movements. 䡩 All machine functions are inhibited. 䡩 The switch locks into (the locked) position when activated. ● Rectify the malfunction or cause of danger immediately! Before you can resume operation, the emergency stop switch must be released (unlocked). ● In order to do this, pull the red button out a little way.


䡩 The switch snaps back into (the released) position and the emergency-off switch is then unlocked.

IMPORTANT

If your ALLROUNDER is equipped with external safety devices (optional), the acknowledgement key must be pressed.

● Press the controller start key. (1) 䡩 The machine is ready to start again.

-2-

1.4.1

User authorisation via transponder card (3)

The personal transponder card authorises access to the controller in order to protect it from unauthorised inputs. Without the transponder card it is only possible to switch on the machine and work with it but not to make any changes to the data.

Compact flash reading device (4)

With the SELOGICA ’direct’ you can save your data on a compact flash card. The diskette drive is also available as a further option.

USB interface (5)

You can connect your PC keyboard to the controller via a USB interface. The USB interface for printers is located on the control cabinet.


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-3-

1.4.1


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-4-

1.4.1

The operating panels

1.4.5


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Operating panel 1

1 2 3

Operating panel 1 Operating panel 2 Operating panel 3

The keys in the first operating panel are used to switch various functions on and off. An LED is incorporated in each key.

( GL1464ZA )

Some keys have a switch function, others a push-button function. When the keys with a switch function are pressed, a function is either activated or deactivated. When it is activated, the LED in the key lights up continuously. When the key is pressed again to deactivate the function, the LED goes out. When the keys with a push-button function are pressed, the function is activated and the LED lit for as long as the key is pressed. When you release it, the function is deactivated and the LED goes out.

..\STRG-SW\S-SW307X\EN01DE_00_307_004.FM 01 2007.03.01

The keys have the following functions:

Motor

With this key you switch the pump motor on and off.

● Press this key briefly to switch on the motor. 䡩 The LED in the key lights up, the motor is switched on. ● Press the key again to switch off the motor. 䡩 The LED in the key goes out, the motor is switched off.

-1-

1.4.5

Heating

With this key you switch the heating of the machine on and off.

Alarm reset

With the alarm reset button you erase alarm messages on the screen. If an alarm occurs on the machine, all machine functions are stopped.

The alarm messages must be erased before the cycle can be continued. 䡩 The LED in the key flashes as long as the alarm is displayed. ● Rectify the cause of the alarm message.

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● Press the alarm reset key. The LED lights up as long as you keep the key suppressed. 䡩 The alarm message on the screen is erased. The cycle can now be restarted.

With this key on the operating panel you switch between manual and automatic control.

Various operating modes are effective in manual or automatic control. The selected operating mode is displayed in the status display as a symbol. ● Press the key briefly to switch over to “automatic” mode. 䡩 The LED in the key lights up, the “automatic” operating mode is active. ● Press the key again to switch over to “manual” operating mode. 䡩 The LED in the key goes out, “manual” mode is active.

With this key you can determine which further operating modes are to be effective in manual or automatic operation (see section 2.6.2).

-2-

1.4.5


Manual / automatic


Set-up

With this key you have the possibility of switching the machine to the “set-up” operating mode directly from the operating panel.

In this operating mode you can purposely switch off certain monitoring functions. Machine movements can be carried out using the keys on the second operating panel.

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The machine moves with fixed, pre-defined values for pressure, speed, mould, screw, nozzle and ejector (not for core pull and programmable outputs). ● Press this key briefly to switch over to “set-up” operating mode. 䡩 The LED in the key lights up, the “set-up” operating mode is active. ● Press the key again to switch off the “set-up” operating mode. 䡩 The LED in the key goes out, the “set-up” operating mode is switched off.

SAFETY INSTRUCTIONS

In the “set-up” operating mode, monitoring functions and stroke limitations can be switched off, depending on the programming in the “Monitoring off in set-up mode” parameter panel. This means that damage can be caused to the mould or machine if care is not taken when operating the machine in set-up mode! When returning to another operating mode, all values input in the parameter panel “Monitoring off in set-up mode” are reset.


All monitoring functions are thus reactivated.

-3-

1.4.5


With this key the machine can be set into a “switch-off” state.

● Press this key briefly to set the machine into the switch-off state. 䡩 The LED in the key is lit, the switch-off state is active. ● Press the key again to end the switch-off state.

Switch-off in “automatic” operating mode: ● Press the “switch-off” key. 䡩 The shut-down cycle is started at the end of the current cycle and the motor switched off. If automatic switch-on is activated, the machine will start again with the start-up cycle at the end of the programmed time.

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䡩 The LED in the key is dark, the switch-off state is ended.

Switch-off in “manual” operating mode: ● Press the “switch-off” key. 䡩 The cylinder and mould heating are set to the state which was programmed for each unit in the nominal value control. The motor remains on.

Automatic switch-on: ● Press the “automatic” key. 䡩 The start key flashes, but do not press it. ● Press the “switch-off” key. 䡩 The motor is switched off (without shut-down cycle) and the heating is set to the state programmed for each zone in the nominal value control. 䡩 If automatic switch-on is activated, the controller automatically starts with the start-up cycle after the programmed time.

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1.4.5


Switch-off


Stop at cycle end

With this key you can stop the machine at the end of the current cycle.

With “stop at cycle end” a new cycle is not automatically started at the end of the cycle; the next cycle is not started until the start key is pressed. ● Press the key briefly to activate “stop at cycle end”. BAM_207185_000_EN_10

䡩 The LED in the key lights up, the machine stops at the end of the current cycle. ● Press the key again to deactivate “stop at cycle end”. 䡩 The LED in the key goes out, and the next cycle begins automatically at the end of the current cycle.

IMPORTANT

This function must not be confused with “semi-automatic” and is not suitable for production.

Start

With the start key you start a new production sequence in automatic operation. Each automatic programme is started with this key. ● Press the start key and release it again. 䡩 The LED lights up as long as you press and hold the start key.


䡩 The LED flashes when the controller prompts you to press the start key. The LED also lights up as long as the machine is operating in automatic mode.

-5-

1.4.5


Zeroing key

The zeroing key is used in the “set-up” or “manual” mode to determine the machine zero points for stroke measurement. ● When you have moved to the end point, press this key simultaneously with the movement key and keep it suppressed. 䡩 The zero point for the respective machine movement is determined.

Conversion

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䡩 The LED in the key lights up as long as the zeroing key is suppressed.

With this key you switch the machine over to the “conversion” operating mode. 1

● Press the key and release it again. 䡩 In this operating mode special conversion sequences of the machine can be carried out.

Dry cycle

With this key you switch the machine to the “dry cycle” mode.

● Press this key and release it again. 䡩 The programmed dry cycle is carried out in the “dry cycle” operating mode, whereby the marked processes are omitted. ● Press the “automatic” key. 䡩 The machine carries out the programmed dry cycle sequence (see chapter 2.4)

IMPORTANT

In “dry cycle” make sure that the correct processes are marked in the sequence. Otherwise damage to the mould and machine can be caused!

1

not standard -6-

1.4.5


● Press the start key.


Purging

With this key you start the purging process.

Depending on the current nozzle and mould position, two different functions are carried out: ⽧ purging the hot runner, or

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⽧ purging the plasticizing cylinder.

Use the first function to clear the hot runner in the mould of moulding material. Requirement: ⽧ the nozzle must contact the mould, ⽧ the mould is opened and ⽧ f425 =”yes” (purge hot runner). ● Press the “Purging” key on the operating panel. 䡩 The hot runner is now purged. The parameters and values input in the “Purging” parameter panel are now active.

Use the second “Purging” function to remove thermally damaged plastic material from the plasticizing cylinder. Requirement: ⽧ The nozzle must be lifted off the mould. ● Press the “Purging” key on the operating panel.


䡩 The injection unit now moves back to the nozzle end position. 䡩 The purging program is carried out, whereby the parameters and values input in the “Purging” parameter panel become active.

-7-

1.4.5


Robot system on/off

Press this key to switch on the robot system.

䡩 The LED in the key lights up, the robot system is switched on. ● Press the key again to switch the robot system off again.1 䡩 The LED in the key does not light up. Press this key to deactivate the robot system1.

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Robot system active/inactive

䡩 The LED in the key does not light up. The drive of the robot system is switched on but remains inactive in the cycle. ● Press the key again to reactivate the robot system. The LED in the key lights up, the robot system is active.

Home position sequence

The home position sequence 1 serves the purpose of moving the robot system to the correct position for the start of the production sequence. ● Switch the machine to the “conversion” operating mode.1 ● Press the “home position sequence” key. 䡩 The LED lights up and the LED in the start key flashes. ● Press the start key.


䡩 The home position sequence is carried out once, as programmed.

1

not standard -8-

1.4.5


Partial sequence 1

With the partial sequence (not standard) you can carry out selected sections of the production sequence via this key. In this way whole sequences, for example interdependent core pulls can be moved with only one key. ● Switch the machine to the “conversion” or “manual” operating mode (not standard). “Manual” mode:

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● Press the “Partial sequence 1” key. 䡩 In the “manual” operating mode the “Partial sequence 1” is carried out as programmed for as long as the key remains pressed (LED is lit). As soon as the key is released the sequence stops. When it is pressed again the sequence is continued. “Conversion” mode: ● If the machine is in the “conversion” operating mode, the LED lights up and the LED in the start key flashes. ● Press the start key.


䡩 The partial sequence is carried out once, as programmed.

-9-

1.4.5


Start-up

Activating the start-up key

The start-up key (not standard) is used to switch over between bad part production and for quality evaluation.

● To activate the start-up key, input one of the following at parameter f053 ⽧ 0 = “automatically active“, if you want the start-up key to be automatically activated every time the operating mode is changed to “automatic”.

● Change to “automatic” operating mode. ● As soon as the start key is now activated the machine starts production. 䡩 The LED in the start-up key lights up to indicate that the machine is in bad-part production, i.e. all parts are graded as bad parts. ● Press the start-up again to inform the controller that the parts now produced are to be rated as good parts. 䡩 The LED in the key goes out.

( GL1464ZA )

● During the production now running you can switch over between good part production (LED off) and bad part production (LED on) as often as required.


Start-up key for switching over bad part / quality monitoring

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⽧ 1 = “active only when pressed“ if the start-up key is to be manually switched on when pressed.

- 10 -

1.4.5


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Operating panel 2

1 2 3


With the keys of the second operating panel you operate the machine in manual mode (manual/automatic key not activated = LED is off). The respective function is carried out for as long as you keep the key pressed. The movement stops when you release the key or reach the end marking or mechanical end limit.


The key for “conveyor belt” and “sorter unit” can also be used in automatic operation.

Mould opening

The mould opens with the values input in the “Mould opening” parameter panel.

Mould closing

The mould closes with the values input in the “Mould closing” parameter panel.

Plasticizing unit advancement

The plasticizing unit moves forward with the values input for “Nozzle movements” (fixed pre-defined values with contacting nozzle).

Plasticizing unit retraction

The plasticizing unit moves back with the values input for “Nozzle movements” (fixed pre-defined values with contacting nozzle).

- 11 -

1.4.5

The ejector retracts with the values input for “Ejector movements”.

Ejector advancement

The ejector advances with the values input for “Ejector movements”.

Screw advancement

The screw advances with the programmed values for purging speed and purging pressure. In the “set-up” operating mode it moves with fixed, pre-defined values.

Screw retraction

The screw retracts with the programmed values for speed and pressure.

Sorter unit

The flap position of the sorter unit1 is switched over (single sample). It is also possible to take random samples in the “automatic” operating mode.

Conveyor belt

The conveyor belt 1 starts to run. The movement ends when you release the key.

Dosage

The screw rotates and doses material. In the “Set-up” operating mode you can turn the screw to a certain position when the screw cover is open.

Air blast

The air blast device 1 demoulds the moulded part for as long as the key remains pressed.

1

not standard - 12 -

1.4.5


Ejector retraction

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Core insertion

A hydraulically (or non-hydraulically) operated core 1 is inserted into the mould with the programmed values, for as long as the key is pressed.

Core retraction

A hydraulically (or non-hydraulically) operated core 1 is retracted out of the mould with the programmed values for as long as the key is pressed.

Safety gate opening

The power-actuated safety gate 1 is opened.

Safety gate closing

The power-actuated safety gate 1 is closed.


( GL1464ZA )

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1

not standard - 13 -

1.4.5


1 2 3

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Operating panel 3


In the third operating panel you will find manual control keys for additional functions, for example:

Programmable outputs I - VIII

With the keys of the programmable outputs 1 the functions of the outputs can be activated at the programmed position in the cycle in manual mode.

Mould height adjustment

Mould height adjustment advancement (dependent on type of machine)


Mould height adjustment retraction (dependent on type of machine)

You will find a detailed description of the mould height adjusting function in chapter 7.1.

1

not standard - 14 -

1.4.5

Available accessories and optional equipment

1.5

Accessories and machine sizes

1.5.1

Available accessories and optional equipment A variety of accessories and optional equipment is available for the ARBURG ALLROUNDER machines.

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Please pay special attention to the following: ⽧ Not every accessory or optional piece of equipment is available for every machine. Various accessories and options can be used with a machine depending on the basic machine configuration. Some accessories and options require a specific basic configuration, which however is not available with every machine, meaning that not every machine can be supplemented with every option. ⽧ Some accessories and options cannot be combined with one another or are even mutually exclusive.

IMPORTANT

In this operating manual, you may therefore find options and accessories described which are not included in your machine or may not be available at all for your machine. Accessories and optional equipment are not always identified as such in this operating manual.

..\ZUBEHOER\S-ALLG\EN01EA_00_306_000.FM 01 2004.02.09

Please request exact technical details relating to options, accessories and extension possibilities of your machine from your ARBURG salesman.

-1-

1.5.1

..\ZUBEHOER\S-ALLG\EN01EA_00_306_000.FM 01 2004.02.09

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Available accessories and optional equipment

-2-

1.5.1

Cycle time diagram

1.6.3

Cycle time diagram In the cycle time diagram every single cycle step of the machine sequence is graphically recorded in a bar diagram and compared with a previously determined reference value 1. Any changes in the times can be immediately recognised.

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Besides the graphical display, the actual values are also displayed in a table as numerical values giving detailed information on the starting time, waiting time and running time of each cycle step. Here you can analyse and optimise the complete cycle.

..\STRG-SW\SDSW405X\EN01FC_00_5405_000.FM 01 2007.03.07

During the running production, the continuity of the injection moulding process can be checked by comparing the actual times with the reference values. Any deviations can be immediately located without individual parameter pages having to be called up.

1

if available -1-

1.6.3

Cycle time diagram

cycle time diagram started or stopped start or stop cycle time diagram symbols/processes in sequence (the active process is marked grey) scroll bar functions

IMPORTANT

Using key no. (2) the running display in the cycle time diagram can be stopped and continued as required.

-2-

1.6.3


1 2 3 4 5

( GI1704Z PL0599DA )

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Panel selection

Cycle time diagram

Time recording

For the production sequence, times are recorded in relation to the process and displayed in the cycle time diagram. There are three time modes for each process. These are displayed in a bar diagram and in table form: ⽧ Starting time (1): Starting time of process.

BAM_207185_000_EN_10

⽧ Waiting time (2): Although the process is active, no action is carried out because e.g. a delay time is programmed or a certain starting condition must be waited for (stroke start, external input, etc.). ⽧ Running time (3): Total running time of process including waiting time.


( PK0599DA )

The recorded times are displayed in seconds at a resolution of 1/100 sec. and an accuracy of +/- 0.01 sec.

1 2 3 4 5 6

Starting time Waiting time Running time Purple colour: reference value (see page 7) Green colour: actual value from present cycle Grey colour: actual value from previous cycle

IMPORTANT

Values from the previous cycle remain visible in grey colour until they are overwritten by the current values in green. Thus the values of a complete cycle are always visible. In addition to the marked symbol you see at a glance which process is currently active.

-3-

1.6.3

Cycle time diagram

Changing the view

You can change the view as required: ⽧ make bigger (zoom, in), ⽧ make smaller (zoom, out).

1

Zoom, out Every time you touch this key the display is made smaller. When you have reached the minimum size, this key is faded out.

2

Zoom, in Every time you touch this key the display is made larger. With the aid of the horizontal and vertical scroll bars you can move to each required section of the full picture. When you have reached the maximum size, this key is faded out.

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The programmed symbols of the sequence and the related times are displayed in a bar diagram in each view. The scale of the view depends on the total running time and is automatically adapted.

IMPORTANT

Measuring cursor

When you switch on the measuring cursor a movable vertical time line appears with which you can display any required time in the cycle sequence.

-4-

1.6.3


In order to display it again, keep pressing the “Zoom, out” key (1) until the standard view is reached.

( PM0599DA PX0598D )

When you use the “Zoom, in” function the values table is faded out.

( GB1575Z PI0599D PH0599DA GB1575Z PJ0599D )

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Cycle time diagram

1 2 3

Measuring cursor Move measuring cursor one step to left (fine adjustment) Move measuring cursor one step to right (fine adjustment)

IMPORTANT

You can touch the measuring cursor (1) directly, then drag it to the required position and drop it .


With this function greater movements of the measuring cursor can be undertaken with ease. If required, you can undertake a fine adjustment of the measuring cursor by pressing the keys (2) or (3) once to move the cursor one small step to the left or right. When you press and hold the keys (2) or (3) the measuring cursor is moved along until you release the key again.

Switching off the measuring cursor

Press this key to switch off the measuring cursor.

-5-

1.6.3

Cycle time diagram

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Sorting the symbols

Acc. to starting time

The symbols are sorted according to their starting time in ascending order.

Acc. to sequence

The symbols are sorted in lines according to their position in the sequence, i.e. simultaneously programmed symbols are arranged directly under each other.

Move symbol upwards/downwards

With the “Move symbol upwards” or “Move symbol downwards” key, individual symbols can be moved to any required position. This can be useful when you want to make a direct comparison of two symbols which are not placed together by the automatic sorting function.

( PY0598D )

The sequence symbols can be sorted in the following way:

The arrangement of the symbols in the cycle time diagram is saved together with the data set and is available again when the data set is next called up, providing the data set was saved.

-6-

1.6.3


IMPORTANT

Cycle time diagram

In order to be able to compare the current actual time values, you have the possibility of saving the times of any cycle as reference values. The reference values are displayed both in the bar diagram and in the table, so that you have information of the changes of the time behaviour at one glance.

BAM_207185_000_EN_10

Accepting reference values

The reference times are stored together with the data set and are available again the next time the data set is downloaded, providing the data was saved.


( PZ0598D )

IMPORTANT

-7-

1.6.3


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Cycle time diagram

-8-

1.6.3

Production sequence, production / order control



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2

-1-


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-2-

Basic information on the production sequence

2.1

Basic information on the production sequence The following diagram shows the procedure on the machine when creating a complete production sequence.

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User philosophy and cycle creation

Configuration of machine and controller

⽧ Outfit of the machine including additional equipment and software options (this configuration is determined when purchasing the machine and cannot be changed by the user)

Machine production cycle

⽧ Creation of required production cycle for the next production by means of the graphical sequence programming.

Input of physical process parameters

⽧ Input of strokes, pressures, speeds and other parameters for the machine movements.

Order control, production control

⽧ Selection of operating modes, control of peripheral devices and determination of order-related data.

Production

⽧ Activation of production control functions such as measuring and monitoring functions, documentation, program support.

ARBURG

..\STRG-SW\SDSW404X\EN02A_00_5404_001.FM 01 2006.04.19

( GB1757Z GB1757Z GB1757Z )

User

control

It is very important that you keep to the above order when setting up the machine. The production cycle data entered by the user are saved together with the data record.

-1-

2.1


The programming of the production cycle and the activation of the corresponding functions are undertaken in the theme or sequence navigation on the “SELOGICA direct” touch screen. The cycle sequence of the machine is displayed in symbols. Each symbol stands for a certain process in the cycle. The machine cycle starts on the left of the panel with the “Cycle start“ symbol. The order of the symbols corresponds to their order in the machine cycle.

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The process which is currently active is represented by a symbol with a dark background.

( PN0552D )

Production


Process: Injection Drive: control circuit 1

-2-

2.1


Injection flow, injection unit 1

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Delay time

Injection flow

( PW0550D PC0551D )

In this screen-shot the respective parameter panel is displayed together with the selected process.

Frame colour

The symbols in the production sequence are displayed in black on a white background. The frame colour of the symbol indicates which type of drive is used for this process: ⽧ A thin red frame means control circuit 1 or 2 (main pump), a thick frame symbolises the hydraulic accumulator (option) or control circuits 1 and 2.


⽧ Blue stands for control circuit 3 (high pressure pump, option). ⽧ Green stands for a non-hydraulic drive type (manual, electric, pneumatic, etc.). In addition, information on the drive of the selected panel is indicated in text in the editing box

(Process: basic mould closing program) (Drive: control circuit 1)

-3-

2.1


Consecutively arranged symbols mean that these machine functions are carried out in series, one after the other. I.e. one function must have ended before the next is started:

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Symbols arranged over one another mean that these machine functions are carried out simultaneously (e.g. cooling and dosage):

( GJ1458Z GK1458Z )

Process “C” does not begin until “A“ and “B“ are both completed.


Serial / parallel sequences

-4-

2.1


In the sequence navigation the monitor is divided into the following sections:

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Division of monitor display

(PX0550DA )

1 2 3 4 5 6 7 8

status lines navigation type direct access keys special keys editing box (here: Injection flow) input chart and table cycle main groups

IMPORTANT

In the sequence navigation you have two markings : one for the selected process in the sequence and one in the parameter panel.


The contents of the editing box relate to the currently active parameter or process (i.e. the one you last touched on the screen).

For more information on the individual sections, see chapter 1.3.3 “Introduction to the screen layout”.

-5-

2.1


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-6-

2.1

Basic sequence

2.3

Extended production sequences

2.3.1

Basic sequence

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The basic sequence is the most simple form of machine production sequence. The symbols represent are the minimum set of processes required for a production sequence.

Basic sequence

The controller offers the following basic cycles (see next page) which are compiled of the following processes: ⽧ cycle start, ⽧ mould closing, ⽧ nozzle advancement, ⽧ injection, ⽧ holding pressure, ⽧ cooling, simultaneous dosage, ⽧ decompression, ⽧ nozzle retraction, ⽧ mould opening, ⽧ ejector advancement, ⽧ ejector short-strokes, ⽧ ejector retraction,

..\STRG-SW\SDSW404X\EN02CA_00_5404_000.FM 01 2006.02.14

⽧ cycle end.

-1-

2.3.1

Basic sequence

1/3: Production with nozzle and ejector

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2/3: Production with ejector

3/3: Production


( GI1525Z GB1639Z GA1639Z )

You can also program an extended cycle, see following chapter.

-2-

2.3.1

Basic sequence

In the SELOGICA controller the required production sequence can be compiled individually. i.e. mould or machine related for optimum efficiency, using the basic sequence as a basis.

BAM_207185_000_EN_10

If your ALLROUNDER is equipped with MULTILIFT, the basic sequence will be as follows:

Calling up the basic sequence

● Touch one of the symbols in the sequence. Then touch this key.

䡩 The following window appears: Sequence editor Insert symbol

( GL1560Z PQ0550D )

Move symbol Delete symbol Change start condition Switch over drive


Move branch end Basic sequence

-3-

2.3.1

Basic sequence

● Touch the “Basic sequence” field.

1 2 3 4 5

page back one basic sequence basic sequence in display page forwards one basic sequence cancel select basic sequence and confirm

You can page through the three basic sequences with the arrow keys (1 and 3).

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䡩 The window is faded out and the following (Basic sequence selection) is displayed in the editing box:

䡩 The respective basic sequence is displayed. When you touch this key (5) you confirm and take over the selected basic sequence as the new production sequence.

With the “N” key (4) you can cancel all inputs and return to the previous production sequence.


( PZ0550DA )

How to insert, move and delete symbols is described in the chapter “Extended production sequences”.

-4-

2.3.1

Inserting symbols in the sequence

2.3.2

Inserting symbols in the sequence ● Touch any one of the symbols in the sequence.

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Then touch this key.

The following window appears: Sequence editor Insert symbol Move symbol Delete symbol Change start condition Switch over drive Move branch end

● Touch the “Insert symbol” field”.

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( PQ0550D )

Basic sequence

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2.3.2


䡩 The following window appears:

Selecting a symbol Selecting new symbol

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Core pull group

= Core pull 1 insertion

1 2 3 4 5 6

groups symbols designation of the selected symbol confirm all symbols (without group assignment; as with SELOGICA) cancel

IMPORTANT

● Touch the respective group (1) and then the required symbol (2). 䡩 The designation of the symbol is displayed in text (3).

You want to insert the symbol “Insert core pull 1” into the sequence: ● Touch the “Core pull” group and then the “Core 1 insertion” symbol.

Positioning the symbol

Press this key (4) to confirm your selection.

䡩 The window is faded out of the display. 䡩 The controller carries out a plausibility check in the background and indicates all possible insertion positions with green arrows:

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2.3.2


Example

( PJ0597DA )

Symbols with a green frame can be inserted in the sequence; symbols with a grey frame cannot be inserted e.g. because they are already programmed in the sequence.

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1

A green arrow pointing to the left means that the selected process can be inserted on the left of the marked symbol.

2

The green arrow pointing to the right means that the selected process can be inserted on the right of the marked symbol.

3

The green arrow pointing downwards means that the selected process can be inserted as a simultaneous process to the marked one.

The following display appears:


( GL1525ZA PB0551DA )

Production

Process: Basic mould closing program Drive: control circuit 1

1 2 3 4 5 6

all permissible insertion positions in the sequence are shown symbol to be inserted insert as a preceding symbol insert as a simultaneously processed symbol insert as a succeeding symbol cancel (you return to the original production sequence).

● Touch the required insertion position in the sequence (1) and then touch the required arrow symbol (3, 4 or 5) in the editing box. 䡩 The symbol is inserted into the sequence.

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2.3.2


Partner symbols

If you have selected a symbol which has a partner symbol (e.g. “Core insertion” - “Core retraction”), the sequence is incomplete after insertion of the first symbol. 䡩 A window appears which points out that the partner symbol is missing.

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Selecting new symbol

Missing symbols in sequence

= Core 1 retraction

● To insert the missing symbol, proceed in the same way as described above.

If you do not insert the partner symbol immediately into the sequence, you will be prompted to do so every time you touch the field “Insert symbol”. This will continue until the missing partner symbol is inserted. Furthermore, the partner symbol is displayed in colour as an optical indication.

( PK0597D )

IMPORTANT


As long as a partner symbol is missing, the sequence is incomplete and production cannot be started.

-4-

2.3.2

Erasing symbols

2.3.3

Erasing symbols ● Touch the symbol in the cycle that you want to delete. Then touch this key.

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䡩 The following window appears: Sequence editor Insert symbol Move symbol Delete symbol Change start condition Switch over drive Move branch end

● Touch the “Delete symbol” field.


( PQ055D )

Basic cycle

-1-

2.3.3

Erasing symbols

䡩 If you have selected a symbol that does not have a partner symbol the following window appears:

Symbols without partner symbols

Confirm selection

designation of the symbol confirm cancel

Confirm your selection with this key.

( PE0551DA )

䡩 The symbol is deleted from the cycle.


1 2 3

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= Ejector short strokes

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2.3.3

Erasing symbols

䡩 If you have selected a symbol which has a partner symbol, the following window appears

Symbols with a partner symbol

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Confirm selection

= Core 1 insertion

1 2 3 4 5

partner symbols designation of the selected symbol only the selected symbol is deleted, the partner symbol remains in the cycle. both symbols are deleted cancel

● If you only want to delete one of the partner symbols, touch the required symbol (1) and then confirm your selection with the “Y selected” key (3). 䡩 The symbol is deleted from the cycle.

( PF0551DA )

䡩 The partner symbol in the cycle is marked red as a reminder that the cycle is now incomplete.

IMPORTANT

Every time you touch the field “Insert symbol“ you will be reminded of the missing symbol. This occurs until you either insert the missing symbol again or have deleted both partner symbols.


As long as partner symbols are missing the cycle is incomplete and you cannot start production. ● If you want to delete both partner symbols, confirm with the “Y all” key (4). 䡩 Both partner symbols are deleted from the cycle.

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2.3.3


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Erasing symbols

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2.3.3

Moving symbols

2.3.4

Moving symbols

Moving symbols

● Touch the symbol in the cycle that you want to move. Then touch this key.

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( PQ0550D GL1525ZA )

Basic sequence

● Touch the “Move symbol” field. 䡩 The window is faded out.

䡩 The controller carries out a plausibility check in the background and indicates all permissible insertion positions with green arrows:

Positioning the symbol

1

A green arrow pointing to the left means that the selected process can be inserted on the left of the marked symbol.

2

The green arrow pointing to the right means that the selected process can be inserted on the right of the marked symbol.

3

The green arrow pointing downwards means that the selected process can be inserted as a simultaneous process to the marked one.

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2.3.4

Moving symbols


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Production

Process: basic mould opening program Drive: control circuit 1

1 2 3 4 5 6

All permissible insertion positions in the sequence are shown Symbol you want to move Insert as a preceding symbol insert as a simultaneously processed symbol insert as a succeeding symbol cancel (you return to the original production cycle).)

● Touch the required insertion position in the cycle (1) and then touch the required arrow symbol (3, 4 or 5) in the editing box.


( PG0551DA )

䡩 The symbol is moved to the required position in the cycle.

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2.3.4

Moving symbols

Moving a branch end

When inserting a simultaneous process in the production cycle, the controller always selects the shortest possible duration for the simultaneous process. This means the end condition of the process is set at the earliest possible point by the branch end.

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Example

1

branch end

Process “C” does not begin until both “A” and “B” are completed.

Moving a branch end

If you want to set a different end condition for the simultaneous process, you can move the branch end. ● Touch the simultaneously programmed symbol in the production sequence, the branch end of which you want to move. Then touch this key.


( GQ1525ZA PQ0550D )

Sequence editor Insert symbol Move symbol Delete symbol


Change start condition Switch over drive Move branch end Basic cycle

● Touch the “Move branch end” field. The window is faded out.

-3-

2.3.4

Moving symbols

䡩 The controller carries out a plausibility check in the background and indicates all possible positions to which the branch end can be moved.

Positioning the branch end


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Production

Process: ejector short strokes Drive: control circuit 1

1 2 3

all permissible insertion positions are displayed cancel (you return to original production cycle) confirm

● Touch the required insertion position in the sequence (1) and then the “Y” key (3) in the editing box. 䡩 The branch end is moved within the sequence.


䡩 If the branch end cannot be moved, a message is displayed in the input area to indicate this.

IMPORTANT

The branch end is moved to a position in front of the selected symbol.

SAFETY INSTRUCTIONS

The mould or machine can suffer serious damage if the branch end is not correctly inserted.

-4-

2.3.4

Changing the start condition, switching over the drive

2.3.5


Changing the start condition

You have the possibility of programming some simultaneous processes as a stroke-dependent function of mould, nozzle/injection or ejector movements or as a cavity pressure-dependent function (not standard).

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Symbols which have been programmed stroke-dependently are not started until the mould, nozzle, screw or ejector have reached a certain stroke position.

IMPORTANT

When you activate a stroke-start, the controller always takes over the maximal value for safety reasons. This can lead to a data error.


For this reason you must always reprogram the correct value after activating a stroke-start.

-1-

2.3.5


● Touch the simultaneously programmed symbol in the sequence, which you want to start stroke-dependently. Then touch this key.


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Sequence editor Insert symbol Move symbol Delete symbol Change start condition Switch over drive Move branch end Basic cycle

䡩 The controller determines the affiliated process for the strokedependent start. 䡩 If the start condition cannot be changed, a message is displayed to indicate this.

( PQ0550D )

● Touch the “Change start condition” field“.


Activating a stroke start

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2.3.5


䡩 The following window appears: Select new start option

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= Stroke-dependent start (Basic mould opening program)

Confirm with this key.

䡩 The start condition is changed.


( PI0551D PJ0551Z GZ1525Z GA1533Z )

Marking

䡩 In the sequence both symbols are marked:

The symbol of the process triggering the stroke-dependent start is marked with a marking pointing downwards:

The symbol of the process which is to be started stroke-dependently is marked with a marking pointing upwards:

Stroke position

● Enter the stroke position, at which the stroke-dependent process is to start, in the parameter panel of the simultaneous process.

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2.3.5


With some processes you have the possibility of switching over the type of drive assigned for this process by the controller (not possible with machines of the K series). ● Touch the symbol in the sequence, the drive of which you want to change.

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( PQ0550D )

Basic sequence

● Touch the “Switch over drive” field. 䡩 The controller now determines all possible drive alternatives. 䡩 If the drive cannot be changed, a message to indicate this is displayed. 䡩 A window appears to select a new drive.

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2.3.5


Switching over the drive


Selecting a new drive: Select new drive

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= High pressure pump

1 2 3 4

drive symbols designation confirm cancel

Drives which are already assigned are displayed grey. The “Y” key (3) is faded out when you touch the symbol of such a drive and the message “Drive already assigned” appears under the designation (2). ● Touch the symbol of the new drive (1) and confirm this with the “Y” key (3). 䡩 The drive is switched over.


( PK0551DA )

䡩 The frame colour of the symbol is adapted to the new drive type.

-5-

2.3.5


Frame colour

⽧ A thin red frame stands for control circuit 1 or 2 (main pump); a thick red frame symbolises the hydraulic accumulator (not standard) or control circuits 1 and 2. ⽧ Blue stands for control circuit 3 (high-pressure pump, not standard) ⽧ Green stands for a non-hydraulic drive (manual, electric, pneumatic etc.).

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The respective drive of the selected process also appears in text in the editing box.

(Process: basic mould closing program) (Drive: control circuit 1)

IMPORTANT


( PC0551D )

For movements via control circuit 3 the speed can be reduced with the aid of an optional hydraulic flow regulating valve.

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2.3.5

Programming examples of various production cycles

2.3.6



( GB1533ZB GB1338ZB GE1533ZA )

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Clamping program with intermediate stop

1 2

closing to intermediate stop mould closing

1 2

core insertion in closed mould core retraction from closed mould

1 2 3

safety gate opening after ejector advancement safety gate closing before ejector retraction Run time You can enter the necessary run time in the respective parameter panel. This run time must always be adhered to. This ensures that every cycle is the same length and that the thermal balance is maintained.

Program with core pull

Program with safety gate

-1-

2.3.6


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2.3.6

Dry cycle / automatic cycle

2.4

Markings in the sequence

2.4.1


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With the SELOGICA controller it is possible to create a separate production sequence for the “Dry cycle” or “Automatic” modes. You thus determine which processes of the production sequence are to be omitted in “Dry cycle” or “Automatic”. ● Touch any symbol in the sequence. Then touch this key.

䡩 The following window appears Visible marking

no markings omit in dry cycle omit in alarm

( PR0550D )

omit in auto mould position monitoring



-1-

2.4.1


Activating a dry cycle Omit process in dry cycle

● Touch the “omit in dry cycle” field.

If you want to add further markings, touch the respective symbol first and then this symbol.

䡩 The following window appears: Sequence editor Set marking Insert symbol ( PL0551Z PM0551D )

Move symbol Erase symbol Change start condition Switch over drive Move branch end

● Touch the “Set marking” field. 䡩 The window is faded out and the selected symbol is marked.

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2.4.1


Adding markings

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䡩 The window is faded out and the controller marks those symbols which are usually omitted in the dry cycle with a red rhombus.


Removing the marking

If you want to remove a single marking or all markings, touch the respective symbol and then this key.

䡩 The following window appears: Sequence editor

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Delete marking Insert symbol Move symbol Erase symbol Change start condition Switch over drive Move branch end

● Touch the “Delete marking” field.


( PN0551D )

䡩 The window is faded out and the marking removed from the selected symbol.

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2.4.1


If you want to remove the dry cycle from the display, first touch any symbol in the sequence and then the flag key.

䡩 The following window appears Visible marking

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no markings omit in dry cycle omit in alarm omit in auto mould position monitoring End position monitoring

● Touch the “no markings” field.

( PR0550D )

䡩 The window and all markings are faded out of the display.


Fading out the dry cycle

-4-

2.4.1


Activating the automatic cycle Omitting processes in automatic

If you want to exclude certain processes from the automatic sequence, proceed as described for dry cycle: ● Touch the flag symbol and then the “omit in automatic” field.

Adding and removing markings is carried out in the same way as for “dry cycle” as described at the beginning of this chapter.


( P00551Z )

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䡩 The window is faded out. Press the “pencil” symbol (“set markings”) to set a marking on the required processes.

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2.4.1


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2.4.1

Inputting production data

2.5

Data input

2.5.1


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After you have created the required machine cycle in the production sequence, parameters must be input for each process.

The parameter panel colour coding

1 2 3


( PI0597ZA )

The keys for calling up the parameter panels have different colours so that you can see at a glance what type of parameter panel they are: ⽧ green parameter panels: here you make a selection, ⽧ grey parameter panels: here you find process parameters,

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⽧ yellow parameter panels: here you find the monitoring parameters.

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2.5.1


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The parameter colour coding

⽧ black:

parameters which can be changed by the user,

⽧ green:

actual values

⽧ white:

editable touch key,

⽧ grey:

non-editable touch key,

⽧ yellow:

tolerances,

⽧ red:

parameter has caused alarm,

⽧ blue:

cursor position.

( PS0550D )

Background colours of parameters / text

In the parameter panel itself the meaning and function of each parameter are indicated by the respective colour or background colour of the parameter.

In addition, a 3D effect indicates which touch key is currently pressed.

IMPORTANT

During the development stage of the “SELOGICA direct” great importance was paid to ensure that all touch keys are recognisable as such. There are no so-called “hidden” functions; all touch keys have a defined minimum size and a frame.

-2-

2.5.1


Parameter colour coding


Calling up parameter panels

Proceed as follows to call up parameter panels: ⽧ In theme navigation: first touch the symbol of the respective main group, then of the superior group and then of the required parameter panel.

Or:

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⽧ In sequence navigation: touch the respective symbol in the sequence. The division of parameter panels into main and superior groups is described in chapter 1.3.10 “Navigation levels“.

Inputting parameters / text

Parameters are always input using the Edit key. When you press this the currently possible input mode (numeric keypad, on-screen keyboard, selection options) is activated.


( PO0550DA )

Numeric keypad:

1 2 3

erase the character last entered confirm input and transfer to parameter panel cancel input

-3-

2.5.1


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On-screen keyboard:

1 2 3 4 5 6 7

erase input erase character last entered upper case (capital letters) confirm input and transfer to parameter panel erase input special characters lock upper case


( PP0550DA )

All functions of this on-screen keyboard are carried out in the same way as on a conventional PC keyboard.

-4-

2.5.1


In the parameter panels each parameter has an individual designation. They are however all comprised of one letter and one number. Each letter and number have a specific meaning. Letters describe the type of parameter: C= comments d= diameter, in mm e= sensitivity, in pC/bar, mV/V f= function, yes/no or quantity F= force, in kN K= relays m= material (shot weight) in g n= revolutions (rpm) p= pressure, in bar Q= flow, in cm³/s, l/min s= stroke position, in mm S= switch/input (display value only) t= time, in s, min T= temperature, in °C / °F U= voltage v= speed, in mm/s V= volume, in cm³ Y= valve (display of actual status only) SK = scale graduations St = variable


BAM_207185_000_EN_10

Parameter designations

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2.5.1


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2.5.1

Inputting mould data

2.5.2

Inputting mould data The input of mould data such as the mould height, ejector length and screw diameter are of particular importance.

BAM_207185_000_EN_10

SAFETY INSTRUCTIONS

It is very important to ensure that correct values are input otherwise damage can be caused to the mould end ejector system.

● Call up the parameter panel “Mould and cylinder parameters”.

Mould and cylinder parameters Mould height

Screw diam, progr.

Ejector length

Screw diam. available

Mould

Nozzle zero point

( PQ0551D )

Cylinder

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Mould height

Mould height s9100

Mould height = distance between mounting platens of closed mould. ⽧ The opening stroke is measured from here. ⽧ When zeroing the mould the mould height is taken from here and entered at s9100 ⽧ The min. mould height is input here when installing a new mould.

-1-

2.5.2

Inputting mould data

Ejector length s9103

The actual length of the mould ejector bolt. ⽧ The value at s9103 is used for zeroing the ejector stroke measuring system ⽧ The value at s9103 also determines the zero point for the ejector movements ⽧ The ejector movements are measured from here.

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⽧ When a new mould is installed the max. ejector length is input here.

Mould f9100

Designation of mould (up to 15 characters are possible).

Screw diameter, programmed d9104

Screw diameter in created or downloaded program.

Screw diameter, available d9105

This is a machine-related input and is not changed when a new data diskette is read into the machine.

IMPORTANT

A correct data input at d9105 is of vital importance because this is used to calculate other parameter values.

Zero point for nozzle movements. All input values for the nozzle movements and positions are based on this zero point. After zeroing the nozzle you should check the entered value. The set value should be greater than 0.0 mm otherwise the nozzle may not contact the mould correctly.

Cylinder f9106

Designation of the cylinders (up to 15 characters are possible).

-2-

2.5.2


Nozzle zero point s9101

Changing the units

2.5.3

Changing the units Depending on the equipment installed on your machine, the option is available of switching over the measuring units of some parameters. For example: ⽧ Metric or US units, ⽧ Temperatures in °C or °F,

BAM_207185_000_EN_10

⽧ All parameters of screw advancement/retraction can be input in units of volume or stroke length. ⽧ All parameters of screw circumferential speed can be input in units of m/min or mm/s.

( PK0623D )

⽧ All pressure values can be input as hydraulic or specific pressure.

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IMPORTANT

Loading a new data set does not influence the units you have selected.

Changing the language

In addition to your standard language you have the option of loading a further language (not standard). This language must be stored on the Compact-Flash card. For more details please consult your ARBURG sales advisor.

-1-

2.5.3


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Changing the units

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2.5.3

Inputting order data

2.6

Order control, production control

2.6.1

Inputting order data After the mould data, the order data are entered next.

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This data is used by the controller to calculate other important data for the order control. ● Call up the “Order data” parameter panel.

Order data Order

Time left, order

Cavity count

Time left, order

Machine: Machine cycle counter

Order quantity Good parts Bad parts Random samples

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( PW0551D )

Cavity count

Order f075A

● Here you enter a designation for the current order (up to 16 characters are possible).

Cavity count f9103

● Here you specify how many cavities the mould has.

Order part quantity f076

● Here you specify the number of parts you want to produce in this order. 䡩 To calculate the number of parts produced, the controller counts the cycles and multiplies this number by the cavity count entered at f9103.

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2.6.1

Inputting order data

Actual good parts value f077

Actual value of good parts produced. The controller computes the number of good parts already produced by multiplying the number of good cycles by the number of mould cavities.

Actual bad parts value f087

Here the count of parts recognised by the controller as bad parts is displayed. If the machine is equipped with a sorter unit (not standard), and if this is activated, these parts can be sorted out. ● To reset this value to “0”, first touch the parameter and then the “Edit” function key (pencil). Enter “0” via the numeric keypad and confirm your input with the “Y” key.

Actual random sample value f095

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● To reset this value to “0”, first touch the parameter and then the “Edit” function key (pencil). Enter “0” via the numeric keypad and confirm your input with the “Y” key.

Here the number of parts is displayed that have been removed with the random sample function of the sorter unit (not standard). ● To reset this value to “0”, first touch the parameter and then the “Edit” function key (pencil). Enter “0” via the numeric keypad and confirm your input with the “Y” key“.

Remaining time t080 / t081

The controller estimates the time needed to complete the current order, based on the calculated number of parts already produced and the time taken to produce them.

Machine cycle counter f071

The controller displays the total number of machine cycles here. This counter cannot be reset.

-2-

2.6.1


䡩 The controller displays the estimated time needed to complete the order in days, hours and minutes at parameters t080 and t081.

Operating mode selection

2.6.2


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In the “Operating mode” parameter panel you input which operating modes are to be effective in manual and automatic operation.

Operating modes Automatic mode Op. mode change after stop at cycle end Simult. movements in manual Autom. switch over after standby

Manual mode no no no

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( PP0597D GD1674E )

Automatic mode f041 = automatic

-1-

2.6.2


“Automatic” mode ● Touch the “Automatic” key (next to “Automatic operating mode) and then press the “Edit” key (pencil). 䡩 The following window appears in which you can select the required operating mode in the usual way. Selection

Dry cycle

Automatic

At the end of each cycle a new cycle is started automatically.

Dry Cycle

The next cycle starts automatically at the end of each cycle, in the same way as with automatic.

As the dry cycle mode is usually required for test purposes, one or more processes in the production sequence e.g. injection unit movements, can be deactivated.

IMPORTANT

The “dry cycle” mode does not have production status (yellow warning light is on). Check whether the markings are correctly set in dry cycle.

-2-

2.6.2


Automatic

( PA0552D )

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Automatic


“Manual” operating mode ● Touch the field next to “Manual operating mode” and then the “Edit” key (pencil). 䡩 The following window appears in which you can make your selections in the usual way. Selection

BAM_207185_000_EN_10

Hand Manual Set-up


( PZ0551D )

Conversion

Manual

Here you operate the machine movements using the keys on the operating keypad. The speeds and pressures which are programmed for each process become effective.

Set-up

Here you operate the machine movements using the keys on the operating keypad. The machine moves with fixed, pre-defined values for speed and pressure.

SAFETY INSTRUCTIONS

In “Set-up” operating mode, monitoring functions can be partially switched off, depending on the programming in the “Monitoring off in Set-up mode” parameter panel. Work in this operating mode must therefore be carried out with the utmost care to prevent damage to the mould and machine.

-3-

2.6.2


Conversion

All conversion and changing sequences are carried out in this operating mode.

When this function is activated the controller changes to “manual” mode after stop at cycle end. Pre-requirement: the machine must be in “automatic” mode. ● Input “yes” at f046 by touching the “Y” key. Press this key (stop at cycle end) on the operating keypad.

䡩 The LED lights up. 䡩 The current cycle is completed, the machine stops at the end of the cycle and changes to “Manual” mode. ● To start the next cycle the start key must be pressed.


Operating mode change to manual after stop at cycle end f046

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Other settings

-4-

2.6.2


Simultaneous movements in manual mode f9430

If this function is active (f9430 = yes) other movements can be carried out simultaneously with “mould closing” and “mould opening”. Pre-requirement: You have programmed simultaneous movements to run parallel with the mould movements in the production sequence. ● Set f9430 to “yes”. ● Press the “mould closing” or “mould opening” key.

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䡩 The movements are carried out simultaneously.

SAFETY INSTRUCTIONS

Automatic switch-over after standby f9163

If parameter f9430 is set to “no”, simultaneously programmed movements are omitted. This can mean for example that the mould closes and the ejectors are still advanced.

If this function is active (f9163 = yes), the parameter “Standstill until switch-over to standby“ (t961) is displayed.


● Enter the standstill duration here after which the machine is to switch over to standby.

-5-

2.6.2


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-6-

2.6.2

Automatic switch-on/off

2.6.3


Function

The automatic switch-on/off program switches the pump motor and the heating on or off at a pre-set time. With switch-on the hydraulic oil is preheated. The switch-on/off program can be used for the following functions: ⽧ Preheating the hydraulic oil, ⽧ Controlling the cooling system (depending on equipment),

BAM_207185_000_EN_10

⽧ Switching off mould and cylinder heater zones or reducing the temperatures to nominal value, or heating up to enable temperature, ⽧ Purging the cylinder before switch-off, ⽧ Closing the mould before switch-off. The controller programs the heating and cooling systems or other processing functions to switch on at an earlier, pre-set time so that the machine is ready for operation at the programmed starting time.

Autom. switch-on/off

( PQ0597DA )

Aut on/off

ON

yes

Time

Production

Day, month

Monday

Year

Tuesday

Weekday

Wednesday Thursday Friday Saturday


Sunday

Autom. switch-on/off f011 (no/yes) = yes

1 2

Switch-on times Switch-off times

IMPORTANT

The automatic switch-on/off program can only be utilised to its full extent when the machine is equipped with the automatically controlled water distributor.

-1-

2.6.3


Procedure for programming Setting the system clock

The SELOGICA controller has an internal clock with date and time display.

Time t007

● Here you input the current time. For example “8.16“ for 8:16 a.m.

Day, month t008

● Here you input the current day and month. For example “17.05“ for May 17th.

Year t009

● Input the current year here.

Weekday t010

● Input the current weekday here. For example “3” for Wednesday.

BAM_207185_000_EN_10

As the switch-on/off times are programmed via this clock, the clock must first be set to the correct time (if this has not already been done).

IMPORTANT

The SELOGICA clock continues to run when the machine is switched to “0”. The clock is powered by an accumulator. The date and time only need to be set once. The values only need to be reset if the diagnosis board is removed from the controller or the accumulator discharged.


The machine can only switch on automatically at the pre-set times, e.g. for preheating, when the SELOGICA clock is correctly set.

-2-

2.6.3



( PR0597DA )

BAM_207185_000_EN_10

Setting the switch-on/off times Switch-on times t011 to t017

● In this column you enter the time of the daily production start.

Switch-off times t021 to t027

● In this column you enter the time of the daily production end.

Activate

When you have input the switch-on and off times, the new program has to be activated. ● Touch the field next to the time and press the “Y” key. 䡩 A tick indicates that the time is active

1 2 3

Switch-on time active Switch-off time active Activate/deactivate complete automatic switch-on/off.

Example: If you want the machine to produce continually from Monday morning through to Friday evening, set a tick at the switch-on time on Monday morning (1) and one at the switch-off time on Friday evening (2). If you want to stop production overnight, set a tick for switch-on and one for switch-off on each day. You can of course only program automatic switch-on and switch the machine off manually, (or vice versa) if required. ● When your times are activated (with corresponding ticks) touch the Automatic switch/off field (3) and set the parameter f011 to “yes”.

-3-

2.6.3


Set the manual/automatic key on the operating panel to “Auto“.

䡩 The LED lights up.

䡩 The LED lights up. 䡩 The automatic switch-on/off program is now activated. 䡩 The controller switches the machine on in accordance with the respective pre-warming times and heats the cylinder and mould to the programmed temperatures. The machine is then ready for production at the times programmed at t011 to t017.

BAM_207185_000_EN_10

Press the standby key on the operating keypad.


䡩 When the switch-off times t021 to t027 are reached the machine switches off or reduces the temperatures of the mould and cylinder.

-4-

2.6.3

Sequences for start-up and shut-down

2.6.4


Creating a start-up/shut-down sequence

With the SELOGICA controller it is possible to create special sequences for the start-up and shut-down processes.

BAM_207185_000_EN_10

These processes are carried out when the machine is operated via automatic switch-on/off or via the part counter.

Start-up sequence ● Call up the parameter panel “Start-up sequence”.

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( PL0597DA )

Start-up sequence

Process: standby omit

1 2 3 4 5 6 7 8

Standby Switch-on Nozzle in end position Purge cylinder Pre-dosage and decompression Waiting for start key Reference sequence Production

The individual processes for the start-up sequences can be activated/ deactivated in this panel. The processes are carried out consecutively in the order in which they appear in the sequence.

-1-

2.6.4


Deactivating processes

Proceed as follows to deactivate certain process in the start-up sequence: ● Touch the symbol in the start-up sequence which you want to deactivate.

BAM_207185_000_EN_10

Touch this key.


Set marking

● Touch the “Set marking” field.

When you deactivate the “Waiting for start key” symbol (6), i.e. there is a marking in the top right corner, the controller does not wait for the start key to be pressed. In this case hot injected material could cause damage to the mould and heater band.

-2-


SAFETY INSTRUCTIONS

( PT0551D PS0551Z )

䡩 The window is faded out, the symbol in the sequence is displayed grey and has a marking in the top right corner.

2.6.4


Reactivating deactivated processes

Proceed as follows to reactivate previously deactivated processes in the sequence: ● Touch the symbol in the start-up sequence that you want to reactivate.

BAM_207185_000_EN_10



Delete marking

● Touch the “Delete marking” field. 䡩 The window is faded out and the marking is removed from the symbol.


( PU0551D )

Inputting data for the start-up sequence

For some processes in the start-up sequence parameter values must be input. Touch the sequence navigation.

䡩 The parameter panel related to the selected symbol in the startup sequence is displayed. The input of data is described in the following pages.

-3-

2.6.4


Switch-off sequence ● Call up the “Switch-off sequence“ parameter panel.

BAM_207185_000_EN_10

Switch-off sequence

Process: production omit

1 2 3 4 5

Production Mould closing before switch-off Nozzle in end position Purge cylinder Standby


The processes are carried out consecutively, in the order in which they appear in the sequence.

( PM0597DA )

You can activate and deactivate individual processes for the switchoff sequence in this panel.

-4-

2.6.4



Proceed as follows to deactivate certain processes in the switch-off sequence: ● Touch the symbol in the start-up sequence which you want to deactivate.

BAM_207185_000_EN_10



Set marking

● Touch the “Set marking” field. 䡩 The window is faded out, the symbol in the sequence is displayed grey and has a marking in the top right corner.


To reactivate previously deactivated processes in the switch-off sequence, proceed as described for the start-up sequence, on page 3.


( PT0551D )

The markings in the switch-off sequence are identical to those in the “start-up” sequence on page 2.

-5-

2.6.4


For some processes in the switch-off sequence, parameter values must be input. Touch the sequence navigation.

BAM_207185_000_EN_10

䡩 The parameter panel related to the selected symbol in the switch-off sequence is displayed. The input of data is described in the following pages.


Data input the for switch-off sequence

-6-

2.6.4


Inputting data for the start-up / switch-off sequences

If you have created a start-up / switch-off sequence certain data must be input in the respective parameter panel.

BAM_207185_000_EN_10

Start-up sequence

Start-up Start-up cycles after heating out of tolerance Start-up cycles after heating in tolerance Standstill time monitoring with start -up cycles Standstill time Wait for start key

Start-up cycle count after heating not in tolerance

● Here you enter the required number of start-up cycles.

Actual no. of start-up cycles f090I

The actual value of start-up cycles, (i.e. the number completed out of the total number entered at f090), is displayed here.

No. of start-up cycles after heating in tolerance f090A

● Here you enter the required number of start-up cycles.


( PN0597D )

No. of start-up cycles after heating out of tolerance f090

䡩 If the automatic operating mode was quit and then restarted, causing the heating to be out of tolerance, the count of start-up cycles input here is carried out before the normal production is restarted.

䡩 If the automatic operating mode was only temporarily inactive and is now restarted, whereby the heating remained in tolerance, the count of start-up cycles input here is carried out before the normal production is started.

-7-

2.6.4


Start-up cycles, actual f090I

The actual value of completed start-up cycles (out of those input at f090A) is displayed here.

Monitoring of standstill time f070

Here you can select one of three options: ⽧ not active,

When the standstill time is exceeded the number of start-up cycles entered at f090 (heating not in tolerance) is carried out before continuing production. ⽧ with start-up sequence via key When the standstill time is exceeded the programmed start-up sequence is carried out and the machine starts with the specified number of start-up cycles before continuing production.

Standstill time t070

BAM_207185_000_EN_10

⽧ with start-up cycles

This parameter is displayed when you have activated “Monitoring of standstill time” (f070). ● Here you enter the required time. 䡩 When the standstill time is exceeded, the controller reacts as programmed at “Monitoring of standstill time”(f070).

When this parameter is set to “yes” the machine waits for the start key to be pressed before starting production. ● Input the required time here. 䡩 If this time is exceeded, the controller goes on alarm.


Wait for start key t031

-8-

2.6.4


Switch-off sequence

Switch-off

BAM_207185_000_EN_10

Cooling water main valve Switch off motor in manual/standby

Motor switch-off delay

( PO0597D )

Cooling water main valve

Cooling water main valve t944

● Here you enter the time after which the cooling water main valve is to close.

Motor switch-off in manual/ standby f061

● Here you enter whether the motor is to switch off in “Manual/ standby” mode.

Motor switch-off delay t061

This parameter is displayed when you have set the parameter “Motor switch-off in manual/standby“ (f061) to “yes”.


● Enter the delay time here, after which the motor is to switch off.

-9-

2.6.4


BAM_207185_000_EN_10


- 10 -

2.6.4

Order change

2.6.5

Order change With the “Order change” function the SELOGICA controller is able to start the next order autonomously with a different data set.

BAM_207185_000_EN_10

Pre-requirement: The data set for the following order is located on level 2 (preparation level) and the same mould is used.

● Call up the “Order change” parameter panel.

Order change sequence

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( PH0552DA )

Order change sequence

Process: switch-on omit

1 2 3 4 5 6 7 8 9 10 11 12

Change levels Switch on Nozzle to end position Purge cylinder Predosage and decompression Wait for start button Reference sequence Production Mould closing before switch-off Nozzle to end position Purge cylinder Change levels

Individual processes for the start-up sequence can be activated and deactivated in this panel. The processes are carried out consecutively one after the other.

-1-

2.6.5

Order change

Proceed as follows to deactivate processes in the order change sequence: ● Touch the symbol in the sequence which you want to deactivate. Then touch this key.

BAM_207185_000_EN_10

䡩 The following window appears. Edit sequence

Set marking


( PT0551D )

䡩 The window is faded out, the symbol in the sequence is displayed in grey and marked.



-2-

2.6.5

Order change


Proceed as follows to reactivate deactivated processes: ● Touch the symbol in the sequence that you want to reactivate. Press this key.

BAM_207185_000_EN_10

䡩 The following window appears Edit sequence

Delete marking

● Touch the “Delete marking” field. 䡩 The window is faded out and the marking in the symbol is removed.

Data input for the order change sequence

Touch the sequence navigation.

( PU0551D ) ..\STRG-SW\SDSW404X\EN02FE_00_5404_001.FM 01 2006.04.20

Parameter values must be entered for some processes in the order change sequence.

䡩 The parameter panel corresponding to the selected symbol in the start-up sequence appears.

IMPORTANT

All data in the “Order data” parameter panel must be checked to ensure that they are complete and correctly entered.

-3-

2.6.5

Order change

Activating the order change

When all data has been input, you can activate the “Order change” function.

Order change

Continual order change

activated no

BAM_207185_000_EN_10

Order change

Dosage for follow-on order in last cycle no Wait for start key after change Pre-heat dryer

1 no


( PS0597D )

Order change f080 = activated

-4-

2.6.5


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Machine movements

3 Machine movements

-1-


BAM_207185_000_EN_10

Machine movements

-2-

Parameter input and colour codes

3.1

Machine movements

3.1.1


BAM_207185_000_EN_10

With the SELOGICA “direct” control system the parameters relating to machine movements are entered into tables.

Mould closing Delay time

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( PI0586D )

End of stage

IMPORTANT

In addition to the input table, a chart is available for every machine movement which has a measuring system installed on its axis. This displays your inputs in graphic form. Any changes made to the input values are displayed accordingly in the chart.

-1-

3.1.1


BAM_207185_000_EN_10

In the SELOGICA direct, individual parameters and their touch field background areas are colour coded according to their meaning and functions:

Text colour “green”: Text colour “black”: Field “white”: Field “yellow” Field “blue”: Colour “grey”:

Actual value Nominal value Nominal values Tolerance values Selected field Actual values

( PJ0586DA )

1 2 3 4 5 6


Colour of text / field

-2-

3.1.1

Direction of movement in the graphical displays

3.1.2


BAM_207185_000_EN_10

All movements are displayed in the direction in which they actually take place (as seen from the view of the machine operator). This is made clear in the input table by arrows and the numbers which ascend in the direction of movement of the stages.

Example: Mould closing

1

Direction of movement for mould closing

For “mould closing” the table and its respective chart indicate the direction of left to right, because the mould also closes in this direction, as seen from the operator side.

( PK0586DA PL0586DA )

Mould opening

..\STRG-SW\SDSW404X\EN03AB_02_5404_000.FM 01 2006.03.08

1

Direction of movement for mould opening

Accordingly, the direction of movement of the “Mould opening” process is displayed from right to left, because the mould opens in this direction.

Chronological sequences

Chronological sequences are always displayed from left to right.

-1-

3.1.2


BAM_207185_000_EN_10


-2-

3.1.2

Options for selecting parameter panels

3.2

Parameter input for machine movements

3.2.1

Options for selecting parameter panels Parameter inputs can be undertaken either in the sequence or theme navigation mode.

BAM_207185_000_EN_10

The parameter panels are displayed in the same way in both navigation modes.

..\STRG-SW\SDSW404X\EN03BA_02_5404_001.FM 01 2006.04.19

( PG0550ZA PH0550D )

1 2

Selecting panels in sequence navigation mode

Theme navigation mode Sequence navigation mode

When you touch this key, a symbolic representation of the sequence is displayed in the navigation level.

Holding pressure injection unit 1

-1-

3.2.1


Parameter panels are displayed simply by touching the respective process in the sequence. For the currently selected process ⽧ the designation and ⽧ the drive.

BAM_207185_000_EN_10

are displayed in the editing box.

Process: Basic mould closing program Drive:

When you touch this key, a symbolic representation of the individual theme areas is displayed in the navigation level.

( PC0551D PI0597ZA )

Selecting panels in theme navigation mode

Control circuit 1

Temperature injection unit 1


-2-


1 2 3

3.2.1


BAM_207185_000_EN_10

The parameters for the machine movements are undertaken in the main group “Set-up parameters”.

1 2 3 4 5

Superior group “mould” Superior group “ejector” Superior group “nozzle” Superior group “injection axis” Superior group “dosage”

All available parameter panels are listed under each superior group. When you touch the superior group “mould” for example, the parameter panels for the “Mould closing” and “Mould opening” processes are displayed. The keys for the parameter panels are colour-coded so that you can see at a glace which type of parameter panel it is : ⽧ in green parameter panels you make a selection, ⽧ in yellow parameter panels the monitoring parameters.


( GG1693ZB )

⽧ in grey parameter panels you find the process parameters and

-3-

3.2.1


BAM_207185_000_EN_10


-4-

3.2.1

Basic information on parameter panels

3.2.2

Basic information on parameter panels The parameter panel is divided into 2 areas: one for the input chart and one for the input table. For easier understanding, all processes are displayed graphically using as little text as possible. Mould closing

BAM_207185_000_EN_10

Delay time

Designation of the parameter panel Input chart Input table

Each field in the input table stands for a parameter. When you touch one of these fields exact details on this parameter are displayed in the editing box. Furthermore, the area relating to this parameter is marked in blue in the chart above.

..\STRG-SW\SDSW404X\EN03BB_02_5404_000.FM 01 2006.03.09

( PQ0593DA )

1 2 3

-1-

3.2.2

Basic information on parameter panels

Parameter designation in the editing box

The following information appears in the editing box when a parameter is selected: ⽧ designation, ⽧ input options or limit values ⽧ and the current value.

Operating status

1 2 3 4 5 6

BAM_207185_000_EN_10

Cylinder heating zone 1

Designation in text Parameter Input range / limit values Current value Function input / function keys Edit / text input

The key “Function input” (5) refers to parameters and therefore only appears when a parameter field has been selected. If however you last touched a process in the sequence, the key “visible marking” appears in this position (see chapter 1.3.8).

( PN0550DA )

You will find a more detailed explanation on the editing box in chapter 1.3.8 “Editing box“.

IMPORTANT

The contents of the editing box is dependent on the parameter or process which is currently active (i.e. the one you last touched).

-2-

3.2.2


In the sequence navigation you have two markings: one for the process selected in the sequence and one in the parameter panel.

Parameters for mould movements

3.2.3


BAM_207185_000_EN_10

The information in this chapter refers to the use of the maximum number of stages for mould movements. The parameter panels in your control system can vary from those pictured here, depending on the equipment installed on your machine.

Mould closing / opening Panel selection

Mould ( GJ1693Z PP0586DA )

closing The mould closing movement can be carried out in several stages. Each stage is characterised by its own closing speed, a closing force and a stroke position.

opening The mould opening movement can be carried out in several stages. Each stage is characterised by its own closing speed, a closing force and a stroke position. Mould opening

Mould closing

Delay time

..\STRG-SW\SDSW404X\EN03BC_00_5404_000.FM 01 2007.02.09

Delay time

-1-

3.2.3

1

Delay time [in s] With this parameter you can delay the start of the mould movement to intermediate stop by up to 99.9 s.

2

Stage count The movements can be carried out in up to four stages.

2a

Mould clamping

3

Closing / opening speed [in mm/s] The last speed of “Mould closing” is the positioning speed. This is effective during the last movement stage until switch-over to clamping force occurs.

4

Closing / opening force [in kN]

5

Stroke positions / end of stage [in mm] Stroke positions are required to switch the various speeds on and over. These stroke positions indicate the distance from the zero point of the mould stroke (zero point = mould closed).

BAM_207185_000_EN_10


A stage of the mould movement ends at each of the stroke positions. Switch-over to the next values occurs via a ramp. From this position the mould movement then continues with the data of the next stage. The stroke from the next to last to the last stage is the mould protection stroke (see mould protection) on the next page. Position “Clamping force on” [in mm] Switch-over to clamping force occurs at this position.

7

Position “Mould open” [in mm]

8

Tolerance “Mould open” [in mm] Here you can input a tolerance for the “Mould open” position. When the mould stops at a position which deviates from the last stroke position by more that this tolerance, the controller goes on alarm.

9

Actual values

10

Physical designation of the parameters v = speed F = force s = stroke

-2-


6

3.2.3


Mould protection During the closing movement the mould must travel the mould protection stroke within a certain time with a low force. If foreign particles or moulded parts from the cycle before hinder the mould closing movement, the time calculated for travelling the monitored path is exceeded. The controller stops the closing process and issues an alarm.

BAM_207185_000_EN_10

The mould protection path is the stroke distance from the next to last to the last stage of the mould closing movement.

Input the “Monitoring time of the mould protection stroke” in the “Monitoring” parameter panel under the “Mould” superior group. Here you can also specify how the machine is to react in case of alarm.

( GL1693Z PR0586D )

Panel selection

Monitoring

Monitoring time of mould protection phase Protection alarm No

2nd attempt after protection alarm

Immediate machine stop


Follow-on function after protection alarm Further mould monitoring functions: Position monitoring

Yes

-3-

3.2.3


Mould closing / opening to intermediate stop Pre-requirement

The respective process must be programmed in the production sequence.

BAM_207185_000_EN_10

Panel selection

Mould opening to intermediate stop

This operation is always processed before “Mould closing”. The mould can stop at any position during the closing movement. At this position inserts can be placed in the mould, for example, or cores inserted.

This operation is always processed before “Mould opening”. The mould can stop at any position during the opening movement. At this position parts can able removed for example, or cores retracted. ( GJ1693Z PQ0586DA )

closing to intermediate stop

Mould opening to intermediate stop

Mould closing to intermediate stop

Delay time


Delay time

-4-

3.2.3

1

Delay time [in s] With this parameter you can delay the start of the mould movement to intermediate stop by up to 99.9 s.

2

Stage count The movement to intermediate stop can be divided into up to two stages. Each stage has its own force, a speed and a stroke position.

3

Closing / opening speed [in mm/s]

4

Closing / opening force [in kN]

5

End of stage [in mm] End of the first stage of the mould movement to intermediate stop.

6

Intermediate stop position [in mm] The mould stops at this position and the process programmed next in the production sequence follows.

7

Tolerance of intermediate stop [in mm] Here you can input a tolerance for the last stroke position. If the mould stops at a position which deviates by more than this tolerance, the controller goes on alarm.

8

Actual values

9

Physical designation of the parameters v = speed F =force s = stroke


BAM_207185_000_EN_10


-5-

3.2.3


Mould clamping As soon as the mould is closed, the clamping force becomes effective. The clamping force holds the two mould halves together during the following processes and remains effective until the end of the remaining cooling time.

BAM_207185_000_EN_10

Panel selection

Mould clamping

( GI1693Z PS0586DA )

Enable force

1 2 3 4 5


Monitoring of mould closed

Actual values Clamping force from mould closed onwards [in kN] Monitoring of mould closed [in mm] Tolerance for monitoring of mould closed [in mm] Enable force [in kN]

-6-

3.2.3

BAM_207185_000_EN_10


1

Actual values

2

Clamping force starting from mould closed [in kN] The mould is clamped together with this force after it has completely closed.

3

Monitoring of mould closed [in mm] When you input the position here at which the mould is to have closed, this is monitored.

4

Tolerance of mould closed monitoring [in mm] If the position input at (3) for ”Mould closed” is exceeded by more than this tolerance, the controller goes on alarm.

5

Enable force [in kN] This parameter only appears when you have set parameter f131 = “Enable force reached” to “yes” in the “Mould selection” parameter panel (see next section). Here you input the force starting from which the main pump is to be switched off (enabled). After this the pressure build-up until the final clamping force is reached is undertaken by this pump alone.

Activating the enable force

After switching over the clamping force the main pump and highpressure pump build up the clamping force together. In order to release the main pump earlier for other tasks, you can input a threshold value (enable force) at which the main pump is switched off from the clamping force.

IMPORTANT


If the main pump is switched off too early, the build-up of the full locking force can be delayed.

-7-

3.2.3


BAM_207185_000_EN_10

Panel selection

Selezione stampo Mould selection Enable force reached

Y

Clamping program

● To activate switch-over via the enable force, set parameter f131 = “Enable force reached” to yes.


( GM1693Z PT0586D )

䡩 In the “Mould closing / mould clamping” parameter panel, the parameter F131 “Enable force” is displayed (see above).

-8-

3.2.3


Extended clamping program In the extended clamping program (not standard) you have the option of inputting up to two clamping stages for the injection, holding pressure and cooling processes.

BAM_207185_000_EN_10

Panel selection

Mould selection Enable force reached

Yes

Clamping program Extended clamping program


( GM1693Z PV0586D )

● In order to activate the extended clamping program set parameter f132 “Clamping program” to “extended clamping program”.

-9-

3.2.3


䡩 A new parameter panel “Extended clamping” appears. .

Extended clamping program

BAM_207185_000_EN_10

Enable force

Monitoring of mould closed during injection/holding pressure Monitoring of mould closed

6

( PU0586DA )

2 3 4 5

Enable force [in kN] (see above, section “Mould clamping” Stage count Clamping forces [in kN] of the individual processes Run times (duration of effectiveness) [in s] of the last clamping force “Mould closed” monitoring [in mm] (see above, section “Mould clamping“) Actual value


1

- 10 -

3.2.3


Clamping program with 2nd high pressure build-up The clamping program with 2nd high-pressure build-up is used when a core is to be inserted into the closed mould. This gives you the possibililty of programming two different clamping forces.

BAM_207185_000_EN_10

The first clamping force (during core insertion) is effective from “Mould closed” to the end of “core insertion” and is usually selected fairly low. For the subsequent processes a high clamping force can be selected.

The respective symbol must be inserted in the sequence diagram in order to be able to operate with the 2nd high pressure build-up.

䡩 The parameters F139 “Clamping force after mould closed” and F132 “2nd clamping force” now appear in the “Mould closing / mould clamping” parameter panel.


( GN1693E GP1331Z GA1575Z GA1575Z )

Requirement

- 11 -

3.2.3


BAM_207185_000_EN_10

Panel selection

Mould clamping Enable force

2 3 4 5

Enable force [in kN] (see above, section “Mould clamping“) Actual value of closing force [in kN] F139 is the clamping force which becomes effective from “mould closed” to “high-pressure build-up” [in kN] F132 is the 2nd (maximum required) clamping force [in kN] Monitoring of mould closed [in mm] (see above, section “Mould clamping”)

- 12 -

3.2.3


1

( GI1693Z PW0586DA )

Monitoring of mould closed

Parameters for ejector movements

3.2.4


BAM_207185_000_EN_10

The information in this chapter refers to the use of the maximum number of stages for ejector movements. The parameter panels in your ALLROUNDER can vary from those pictured here, depending on the equipment installed on your machine. The representation and input of parameters on the screen is carried out in the same way for all movements. For this reason, only those parameters for ejector movements are described in the following sections. You will find more detailed information on input options in chapters 3.1 to 3.2.2.

Programmable ejector movements (via control circuit 1 or 2) The ejector movements can be programmed in one or more stages (depending on the equipment of your machine). Up to three stages are programmable for the processes “Ejector advancement / retraction”. One or two stages are available for the processes “Ejector advancement or retraction to intermediate stop”.

..\STRG-SW\SDSW404X\EN03BD_00_5404_000.FM 01 2007.07.04

Each stage is hereby marked with its own speed, a force and a stroke position.

-1-

3.2.4


Requirement


BAM_207185_000_EN_10

Panel selection

Ejector retraction


( GO1693Z PX0586DA )

advancement

-2-

3.2.4


Ejector retraction to intermediate stop

This operation is always processed before “Ejector advancement”. The ejector can stop at any position during the advancement movement. This can be used for example to remove parts.

This operation is always processed before “Ejector retraction. The ejector can stop at any position during the retraction movement. This can be used for example to remove parts.

Ejector short strokes


( PE0592DA PY0586DA )

BAM_207185_000_EN_10

advancement to intermediate stop

-3-

3.2.4

Advancement / retraction speed [in mm/s]

2

Advancement / retraction force [in kN]

3

Stroke positions / end of stage [in mm] Stroke positions are required to switch the various speeds on and over. These stroke positions indicate the distance from the zero point of the mould stroke (Zero point = ejector completely retracted in mould). A stage of the ejector movement ends at each of the stroke positions. Switch-over to the next values occurs via a ramp. From this position the mould movement then continues with the data of the next stage.

4

“Ejector advanced” position [in mm] Input here the position at which the ejector is to have reached its foremost end position.

5

Tolerance of “Ejector advanced” [in mm] Here you can input a tolerance for the “Ejector advanced” position. When the mould stops at a position which deviates from the last stroke position by more that this tolerance, the controller goes on alarm.

6

“Ejector retracted” position [in mm] Input here the position at which the ejector is to have reached its rearmost end position.

7

Minus tolerance of “Ejector retracted” [in mm] Here you can input the minus tolerance for the zero position of the ejector. When the ejector stops at a position which deviates from the ejector zero position by more that this tolerance, the controller goes on alarm.

8

Plus tolerance of “Ejector retracted” [in mm] Here you can input the plus tolerance for the zero position of the ejector. When the ejector stops at a position which deviates from the ejector zero position by more that this tolerance, the controller goes on alarm.

9

Intermediate stop position of advancement/retraction movement [in mm] The ejector stops at this position. The ejector movement is then continued with the values of the following process (ejector advancement/retraction).

10

Tolerance of intermediate stop [in mm] Here you can input a tolerance for the intermediate stop position. When the ejector stops at a position which deviates from the intermediate stop position by more than this tolerance, the controller issues an alarm.

11

Interval count (number of short strokes)

12

Retraction position of short stroke [in mm] In order to reduce the time requirement for the short stroke process, the ejector can be retracted to this position instead of of completely.

-4-

3.2.4


1

BAM_207185_000_EN_10



BAM_207185_000_EN_10

Manually adjusted ejector movements (via control circuit 3) Manually adjusted ejector force

If the ejector movement is carried out via control circuit 3 (depending on the machine equipment), the speed and force of the movements are not programmed in stages, but adjusted manually.

Requirement


Panel selection

advancement

retraction


( GO1693Z PG0592DA )

Ejector

-5-

3.2.4


Ejector retraction to intermediate stop

This operation is always processed before “Ejector advancement”. The ejector can stop at any position during the advancement movement. This can be used for example to remove parts.

This operation is always processed before “Ejector retraction. The ejector can stop at any position during the retraction movement. This can be used for example to remove parts.

( PF0592DA PZ0586DA )

BAM_207185_000_EN_10

advancement to intermediate stop


Ejector short strokes

-6-

3.2.4


BAM_207185_000_EN_10


1

Position of “Ejector advanced“ [in mm] (see above, section “Ejector movements via control circuit 1 or 2“)

2

Tolerance of “Ejector advanced“ [in mm] (see above, section “Ejector movements via control circuit 1 or 2“)

3

Position of “Ejector retracted” [in mm] (see above, section “Ejector movements via control circuit 1 or 2“)

4

Minus tolerance of “Ejector retracted” [in mm] (see above, section “Ejector movements via control circuit 1 or 2“)

5

Plus tolerance of “Ejector retracted” [in mm] (see above, section “Ejector movements via control circuit 1 or 2“)

6

Force [in kN]

7

Pressure [in bar] (is calculated by the controller after input of the force)

8

Intermediate stop position during advancement/retraction movement [in mm] The ejector stops at this position. The movement is then continued with the values of the next process (ejector advancement or retraction).

9

Tolerance of intermediate stop [in mm] Here you can input a tolerance for the intermediate stop position. When the ejector stops at a position which deviates from the intermediate stop position by more than this tolerance, the controller issues an alarm.

10

Interval count (number of short strokes)

11

Retraction position of short stroke [in mm] In order to reduce the time requirement for the short stroke process, the ejector can be retracted to this position instead of of completely.

● Input the required advancement or retraction force at “Force (6). 䡩 The controller calculates the hydraulic pressure required for this force and displays the calculated value (7).

-7-

3.2.4


BAM_207185_000_EN_10

Manual adjustment of pressure and speed

1 2 3

Pressure reduction valve Meas. nipple for manometer Flow regulator

● Set the displayed pressure value on the pressure reduction valve (1) of the ejector on the closing manifold. ● Check the pressure with the manometer from the machine tool kit, see illustration. Connect the manometer to the measuring nipple (2). ( GX1702ZA )

䡩 The adjusted pressure value and thus the input force now become effected as maximum in the ejector movement.


● Set the speed on the flow regulator (3).

-8-

3.2.4


Ejector movements simultaneous to mould movements

BAM_207185_000_EN_10

When you program an ejector movement in the sequence simultaneous to ⽧ “Mould closing/opening” or ⽧ “Mould closing/opening to intermediate stop” the parameter panel “Ejector monitoring” appears under the “ejector” superior group .


( GR1335Z PA0592D )

● Activate the “Monitoring of distance between mould and ejector”. 䡩 Depending on the programmed sequence, a new parameter “minimum distance” appears for the respective ejector movement. ● Input the safety distance between ejector and mould at “minimum distance”. 䡩 This distance is monitored by the controller. If the actual distance falls short of the minimum value, the controller issues an alarm.

SAFETY INSTRUCTIONS

As there is a great risk of the mould and ejector colliding when these processes are carried out simultaneously, it is very important that the monitoring of this minimum distance is activated. Otherwise, if a collision takes place, the ejector and mould can suffer considerable damage. Select the safety distance sufficiently large in order to avoid a collision of the ejector with the fixed mould platen half even at low speeds.

-9-

3.2.4


When you program an ejector movement in the sequence as a mould stroke-related movement, the parameter “Start with mould stroke” appears in the “Ejector advancement/retraction” or “Ejector advancement/retraction to intermediate stop” parameter panels.

1

BAM_207185_000_EN_10

Ejector movements initiated in relation to mould movements

Start with mould stroke


( GD1331Z PB0592DA )

● Input here the stroke which is to have been travelled before the ejector movement starts.

- 10 -

3.2.4

Parameters for nozzle movements

3.2.5

Parameters for nozzle movements The information in this chapter refers to the use of the maximum number of stages for nozzle movements. The parameter panels on your machine can vary from those illustrated here, depending on the equipment installed.

BAM_207185_000_EN_10

The representation and input of parameters on the screen is carried out in the same way for all movements. For this reason, only those particular parameters for nozzle movements are described in the following sections. You will find more detailed information on input options in chapters 3.1 to 3.2.2.

Nozzle advancement / retraction The nozzle movement can be carried out in up to two stages. Each stage is hereby identified by its own speed, a force and a stroke position. The respective process must be programmed in the production sequence.

..\STRG-SW\SDSW404X\EN03BE_00_5404_001.FM 01 2006.03.23

Requirement

-1-

3.2.5


BAM_207185_000_EN_10

Panel selection

Nozzle retraction

1

Position of “Nozzle retracted” [in mm] Here you input the position at which the nozzle is to have reached its rear end position.

2

Tolerance of “Nozzle retracted” [in mm] Here you can input a tolerance for the retracted end position of the nozzle. If the nozzle stops at a position which deviates from the retracted end position by more than this tolerance, the controller goes on alarm.

3

Tolerance of “Nozzle advanced” [in mm] Here you can input a tolerance for the advanced nozzle position (mechanical end position, i.e. the nozzle contacts the mould). If the nozzle stops at a position which deviates from the advanced end position by more than this tolerance, the controller goes on alarm.

-2-

3.2.5


( GH1704Z PH0592DA )

advancement


Nozzle contact force With the nozzle contact force you determine the force with which the nozzle contacts the mould during the part formation process.

BAM_207185_000_EN_10

This force can be programmed or adjusted on the pressure reducing valve on the injection manifold (depending on the machine equipment).

Programmable nozzle contact force (control circuit 1 or 2) Requirement



( GQ1693Z PD0592DA )

Panel selection

Nozzle contact force:

1 Nozzle contact force starting from dosage [in kN] 2 Nozzle contact force starting from injection [in kN]

-3-

3.2.5


Manually adjustable nozzle contact force (control circuit 3) Requirement


BAM_207185_000_EN_10

Panel selection

( GQ1693Z PC0592DA )

Nozzle contact force:

1 Force, manual adjustment [in kN]

● Input the required nozzle contact force at “Force, manual adjustment“ (1). 䡩 The controller now computes the hydraulic pressure required for this force and displays the value at “Contact pressure, manual adjustment” (2).

-4-

3.2.5


2 Contact pressure, manual adjustment [in bar] (is calculated by the controller after inputting the force)


BAM_207185_000_EN_10

Manual pressure adjustment

1 Pressure reducing valve 2 Manometer ● Set the displayed value for the contact pressure on the pressure reducing valve (1). 䡩 The adjusted pressure value and thus the force value input at “Force, manual adjustment” now become effective for the nozzle contact.


( GF1564ZA )

● Check the pressure on the manometer (2).

-5-

3.2.5


BAM_207185_000_EN_10


-6-

3.2.5

Temperatures, plasticizing process and part formation



BAM_207185_000_EN_10

4

-1-


BAM_207185_000_EN_10


-2-

Recommended values for nozzle and cylinder temperatures

4.1

Temperature settings for the injection unit

4.1.1


BAM_207185_000_EN_10

The following recommendations are non-binding values. The manufacturer’s recommendations are to be given priority.

Nozzle temperature

● Set the nozzle-end cylinder temperature first (see table).

Cylinder temperature

● Working towards the feed side, set the temperature of each following heating zone approx. 5 - 10 °C lower. ⽧ The difference between the first and last heating zone should not exceed 20 °C. ⽧ When processing PA (with the exception of amorphous PA) better feeding results are achieved when the temperatures remain the same or are slightly higher towards the feed end.


⽧ When processing thermally sensitive materials, the upper temperature values are only to be used with higher shot capacities.

-1-

4.1.1


Polyphenylene oxide Polyvinyl chloride Cellulose acetates Polymethyl methacrylate Polycarbonate Polysulphone Polyether sulphone Polyethylene

LDPE HDPE Polypropylene PP PA 6.6 PA 6 PA 6.10 Polyamide PA 11 PA 12 PA amorph Polyoximethylene POM Polyethylene terephthalate PET Polybutylene terephthalate PBT Polyphenylene sulfide PPS FEP Polyfluorolefine ETFE

160-230°C/320-446°F 160-250°C/320-482°F 200-260°C/392-500°F 180-260°C/356-500F 245-290°C/473-554°F 160-180°C/320-356°F 150-190°C/302-374°F 185-225°C/365-437°F 160-190°C/320-374°F 220-250°C/428-482°F 275-320°C/527-608°F 320-390°C/608-734°F 320-390°C/608-734°F 175-250°C/347-482°F 220-300°C/428-572°F 220-290°C/428-554°F 270-295°C/518-563°F 240-265°C/464-509°F 220-260°C/428-500°F 200-250°C/392-482°F 200-250°C/392-482°F 260-300°C/500-572°F 185-215°C/365-419°F 260-280°C/500-536°F 230-270°C/446-518°F 300-360°C/572-680°F 320-370°C/608-698°F 315-365°C/599-689°F

Inject with open nozzle only

X X X X X X

BAM_207185_000_EN_10

Polystyrene heteropolymerisates

PS SB SAN ABS PPO PVC rigid PVC soft CA CAB, CP PMMA PC PSU PES

Process only after drying

X X X X X X X

X X X X X X X X X

( EN_TB00038A )

Polystyrene

Nozzle-side cylinder Thermally temperatures sensitive

X X X X X


Injection moulding material

-2-

4.1.1

Temperature settings for the nozzle and cylinder heating

4.1.2


Nozzle and cylinder heating zone

For heating the plasticizing cylinder, the controller supplies up to eight heating zones - depending on the model of machine and equipment installed. ⽧ Zone 1: for the feed zone

BAM_207185_000_EN_10

⽧ Zone 2 - 4: (injection unit 30, 60, 70) for the cylinder heating, including nozzle ⽧ Zone 2 - 5: (injection unit 100, 150, 170, 250 and 290) for the cylinder heating, including nozzle ⽧ Zone 2 - 6: (injection unit 350 + 400) for the cylinder heating, including nozzle ⽧ Zone 2 - 7: (injection unit 675 + 800) for the cylinder heating, including nozzle ⽧ Zone 2 - 8: (injection unit 1300, 2100 + 3200) for the cylinder heating, including nozzle


( GK1693Z PD0593DA )

The number of cylinder heating zones is pre-defined for each machine and cannot be changed. The number of heating zones on your machine can be seen in the parameter panel “Cylinder temperature control selections” under the superior group “Injection unit temperatures”:

Cylinder temp. control selections Cylinder water channels Cylinder heating zones Cylinder heating zones, tested

1 Cylinder water channel (see chapter 4.1.3) 2 Cylinder heating zones Here you can see the (pre-defined) number of cylinder heating zones on your machine

-1-

4.1.2


Cylinder and nozzle heating

You can switch the cylinder and nozzle heating on and off with the following function key on the operating pad.

BAM_207185_000_EN_10

Cylinder and nozzle heating switch-on/off

1 Nozzle heating 2 Cylinder heating

IMPORTANT

T801 to T804,

⽧ Injection unit 100, 150, 170, 250 and 290:

T801 to T805,

⽧ Injection unit 350, 400:

T801 to T806,

⽧ Injection unit 675, 800:

T801 to T807,

⽧ Injection unit 1300, 2100 + 3200:

T801 to T808.


⽧ Injection unit 30, 60 and 70:

( GF0018ZA )

The cylinder heating zones are numbered as follows:

-2-

4.1.2


BAM_207185_000_EN_10

Panel selection, temperatures

Temperatures, inj. unit 1

Nozzle

Feed

2 Cylinder heating zone, designation Here you can input a description text, or name, for each zone (max. 16 characters).


( GR1693Z PC0593DA )

1 Operating mode of cylinder heating zone In this example all zones are OFF

-3-

4.1.2


Assigning operating modes to cylinder heating zones ● Input the required operating mode for each heating zone. The following inputs are possible Selection Measurement BAM_207185_000_EN_10

OFF Regulation Measurement with QS

OFF

The cylinder heating zone is switched off.

Regulation

In “Regulation” the sensor measures the actual temperature in the heating zone and compares it with the nominal temperature. If the actual temperature is too low, the heating is switched on, if it is too high, the heating is turned down. For the “Regulation” operating mode, two additional tolerances are displayed:

( PZ0592D )

Measurement

⽧ the lower enable tolerance, and


⽧ the upper switch-off tolerance.

-4-

4.1.2

BAM_207185_000_EN_10


Preparation / switch-off cylinder 1 Lower enable tolerance

Upper switch-off tolerance

1 Lower enable tolerance All regulated heating zones must have reached at least their nominal temperatures minus the tolerance, in order for the machine movements to be carried out.

( GT1693Z PV0592DA )

To ensure that the heat is evenly distributed in the cylinder, a predefined time (in relation to injection unit) must also elapse during every initial heating up phase after switching on the machine, or if the enable temperature falls too long under tolerance, before the screw movements are enabled. This can prevent screw breakage due to not properly molten material. 2 Upper switch-off tolerance If one or more of the regulated heating zones exceeds the nominal temperature by more than this tolerance, the controller issues a warning. If the temperature continues to climb, the cylinder heating is switched off.


● Input the required tolerance values.

Measurement

The actual temperature is measured via a sensor and compared with the input nominal value. If the temperatures deviate from each other by more than the input tolerance, the controller issues an alarm. No energy is supplied here.

-5-

4.1.2


In addition to this temperature measurement, the actual temperature can be measured at a certain point in the cycle (start of injection, start of cooling or end of cooling) and be used for quality assurance purposes.

BAM_207185_000_EN_10

The values for the quality assurance are entered in the “Quality monitoring - measured temperatures” parameter panel“:

( GS1693Z PX0592DA )

Quality monitoring of meas. temperatures

1

Number of the cylinder heating zone used for the quality monitoring.

2

Actual temperature of cylinder heating zone.

3

Nominal temperature of cylinder heating zone

4

Plus/minus tolerance of cylinder heating zone Here you input the max. permitted deviation from the nominal temperature. If this temperature exceeds or falls short of this tolerance, the controller issues an alarm (Condition: “Monitoring of meas. zone (6) is set to “yes”. )

5

Time at which measurement is to be taken: Possible inputs:

6

⽧ At start of injection, ⽧ At start of cooling, ⽧ At end of cooling Monitoring of measuring zone If you select “no” here, the temperature is not used for the quality-related monitoring. If your machine has been producing for a sufficiently long period, and has reached a stable production status, you can switch the monitoring to “yes”. The temperature is then included in the monitoring functions. -6-

4.1.2


Measurements for QA


Inputting the nominal temperatures and tolerances After you have assigned the suitable operating modes to the heating circuits, a chart appears in which you can enter the temperatures and tolerances:

BAM_207185_000_EN_10

Temperatures of injection unit 1

1 2 3 4 5

Actual temperature of cylinder heating zone Nominal temperature of cylinder heating zone Plus/minus tolerance of cylinder heating zone Lower enable tolerance Actual operating status of cylinder heating zone


( PT0592DA )

Operat. status

-7-

4.1.2


If your machine is equipped with the option “Machine-related cooling circuits, programmable, regulated” the following parameter panel appears for the regulated cooling of the support yoke:

BAM_207185_000_EN_10

Temperatures, injection unit 1

Operat. status

( PR0592DA )

1 Support yoke cooling


Support yoke cooling

-8-

4.1.2

Cylinder cooling, programmable

BAM_207185_000_EN_10

4.1.3


Pre-requirement

Your machine is equipped with the option “Machine-related cooling circuits, programmable, regulated”.

Water channels in cylinder

For the cooling of the plasticizing cylinder the controller provides a certain number of water channels, depending on the machine model and equipment installed

Assignment of water channels

● Input the respective number of cooling channels in the parameter panel “Cylinder temperature control selection” (dependent on machine equipment).

Cylinder temperature control selections ( GK1693Z PD0593DA )

Water channels in cylinder Cylinder heating zones Cylinder heating zones tested

1

Cylinder wter channels

..\STRG-SW\SDSW404X\EN04AC_02_5404_001.FM 01 2006.04.19

Here you can input how many water channels your machine has. 2

Cylinder heating zones (pre-defined)

-1-

4.1.3


Cylinder water channels


1 Operating mode of cylinder cooling channels In this example all cooling channels are “off”. 2 Description of the cylinder cooling channels Here you can enter a designation for each cooling zone (max. 16 characters).

( GY1693Z PP0592DA )

BAM_207185_000_EN_10

䡩 As soon as you have input the number of water channels, the parameter panel for the mould cooling “Mould cooling channels“ is displayed:

-2-

4.1.3


Assignment of operating modes for cooling channels ● Input the required operating mode for each cooling channel. The following inputs are possible: Selections Regulation BAM_207185_000_EN_10

“Off” Regulation

Set-value independent of machine operating status Set value, dependent on cylinder heating

Set-value, cylinder cooling

The cooling channel is switched off.

Automatic control (regulation)

In automatic control (regulation) the sensor measures the actual temperature and compares it with the nominal temperature. If the actual temperature is too high, the cooling is switched on, if it is too low, the cooling is turned down or switched off.

( PN0592D )

Off


The automatic control is independent of the machine operating mode.

IMPORTANT

The following three operating modes are mere setting functions, therefore no thermocouple is necessary. The inputs are always given as a set value (in %) and thus have an influence on the opening area of each cooling channel. You can input values between “0” and “100”, whereby ⽧ 0

= completely closed,

⽧ 100 = completely open.

-3-

4.1.3

Set-value control, independent of operating status of machine

Here you can enter an opening range for the respective cooling channel which is always the same, independent of the operating status of the machine.

Set-value control dependent on cylinder heating

Here you can enter an opening range for the respective cooling channel. This is linked with the cylinder heating and opens in relation to this i.e. if the cylinder heating is active the respective cooling channel is opened. 䡩 In the nominal temperature control system (see chapter 4.3) the cooling channels are dependent on the nominal value control of the cylinder heating

Set-value control, cylinder cooling

In this operating mode you input an opening range for the cylinder cooling.

BAM_207185_000_EN_10


䡩 Under the nominal temperature control a line is displayed for each group (see chapter 4.3). Here you can select whether the cooling channel is to be open or closed for each operating status.

After you have assigned the appropriate operating modes to the cooling channels, a chart is displayed in which you input the temperatures, tolerances and set-values, depending on the selections made:

( PL0592DA )

Cylinder water channels

1 2 3


Inputting nominal temperatures, tolerances and set-values

Actual temperature of the cooling channel Nominal temperature or setting variable of the cooling channel Plus/minus tolerance of the regulated cooling channel

-4-

4.1.3

BAM_207185_000_EN_10

Mould cooling, manually adjustable

4.2

Mould temperature control settings

4.2.1


Precondition

Your machine is equipped with a manually adjustable cooling water manifold.

Water channels in mould

For the mould cooling, the controller provides a certain number of water channels, depending on the machine model and equipment installed.


( GZ1693Z PJ0592DA )

Panel selection

1

Mould cooling channels Here you can input the flow in manually adjustable scale gradients for each channel.

2

Description of mould cooling channel Here you can enter a description text for each cooling channel (max. 16 characters).

-1-

4.2.1


BAM_207185_000_EN_10


-2-

4.2.1

Nominal value control of cylinder and mould temperature

4.3


You can see all available and activated devices at one glance and centrally control your temperature behaviour.

Panel selection

Precondition: Your machine is equipped with a cavity or hot runner heating or a temperature control device.

..\STRG-SW\SDSW404X\EN04C_01_5404_000.FM 01 2006.03.02

( GB1704ZZ GB1575Z GB1575Z PF0593DA )

BAM_207185_000_EN_10

In the nominal value control you can input how the heating and cooling devices (not standard) are to behave in the various operating statuses of the machine.

-1-

4.3


1

Operating status of the machine The operating statuses are displayed by the following symbols: automatic mode

BAM_207185_000_EN_10

manual mode

in preparation

in stand-by

2

Connected and activated heating or cooling device and its operating status as an actual value (off, nom./on, enable temperature or sink temperature).

3

Operating mode / operating status (actual value) Here the current operating mode or operating status of the machine is displayed (automatic, manual, preparation or standby).

4

If several devices are connected, the area to which the devices below apply, are listed.

5

Connected and activated device, e.g. hot runner device. The operating status of any external devices is displayed here. The controller displays dedicated parameter panels under the “mould” or “cylinder temperature control” superior group for programming the external devices.

6

Temperature behaviour of the device in each operating status. The following inputs are possible (depending on the selected operating mode):

-2-

4.3


Each of these symbols is the column header of the devices displayed underneath.


Selection Off Off

( PE0593Z )

BAM_207185_000_EN_10

Nom./on Enable Sink

Off

Device is switched off

Nom. /on

Device is switched on, brought to nominal temperature and held constant.

Enable temperature

Device is brought to enable temperature and held constant.

Sink temperature

Device is brought to sink temperature and held constant. ● Input the required behaviour for the four operating modes / operating statuses of the machine.


䡩 The selected temperature behaviour is displayed by a symbol. 䡩 When changing to the respective operating mode, the device reacts as programmed.

-3-

4.3


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-4-

4.3

Dosage

4.5

Plasticizing process

4.5.1

Dosage

BAM_207185_000_EN_10

The information in this chapter is based on a dosage process using the maximum number of stages. The parameter panels in your ALLROUNDER may vary from those illustrated here, depending on the equipment installed on your machine. The screen display and the input of parameters is carried out in the same way for all processes. Therefore only the special parameters for the dosage process are described in this chapter. You will find more details on input options in chapters 3.1 to 3.2.2.

In the dosage process the programmed amount of material is predosed for the following cycle. The dosage process can be carried out in up to three stages. Each stage is characterised by its own screw circumferential speed, a back pressure and a dosage volume.

The “Dosage” process must be programmed in the production sequence.


Pre-requirement

-1-

4.5.1


( GD1704Z PH0593DA )

BAM_207185_000_EN_10

Dosage

Panel selection

-2-

4.5.1

Dosage

1

Remaining cooling time [in s] With this time you determine the cooling duration of the moulded part which continues after the last holding pressure stage. ● Input the required cooling time here. 䡩 The remaining cooling time starts at the end of the last holding pressure stage.

BAM_207185_000_EN_10

䡩 The mould can not be opened before the remaining cooling time has expired. 2

Circumferential speed of the screw (in mm/s or m/min) The screw can be rotated in up to three speed stages, in order to dose material for the next cycle.

3

Back pressure [in bar] During dosage, the back pressure values of each stage become effective. The intensity of the back pressure depends on the viscosity of the material being processed. You can also input a negative back pressure. For this purpose press the “-” key before inputting the value. Negative back pressures can be of an advantage when processing materials in powder form such as ceramic or metal powder, or pastes or soft rubbers.

4

“End of stage“ and “Dosage volume“ [in ccm for volume or in mm for screw stroke]. Stroke positions are required to switch the various speeds on and over to the next one. At the “end of stage” position the screw rotates with the data of the following stage.


The parameter “Dosage volume“ shows how much dosage volume is to be achieved and thus the end of the dosage process.

-3-

4.5.1

Dosage

Dosage options Additional adjustments can be undertaken in the “Dosage selection” parameter panel.

BAM_207185_000_EN_10

Panel selection

( GC1704Z PG0593DA )

Back pressure in manual With this function you can determine an individual back pressure for “Manual” mode”. ● Input “Y” here. 䡩 A new parameter “Back pressure” is displayed.

2

Back pressure [in bar] Input the back pressure here which is to be effective in “Manual” mode. You can also input a negative back pressure. For this purpose press the “-” key before inputting the value.

3

Material cushion control (not standard) The material cushion control serves the purpose of keeping the material cushion in front of the screw constant. ● Input "Y" here to activate the material cushion control. 䡩 A new parameter "material cushion control, nominal" is displayed.

4

Material cushion, actual value [in ccm] Here the actual value of the material cushion is displayed.

5

Material cushion control, nominal value [in ccm] ● Input here the required material cushion. 䡩 Each deviation from the material cushion nominal value is corrected in the next cycle.

-4-

4.5.1


1

Diagram: stroke volume / screw stroke injection unit 800 (15.3 oz)

4.5.3


Screw diameter mm / inch 45 / 1.77 50 / 1.97 55 / 2.16

1 mm/0.039” equals ccm / cu in 1.59 / 1.10 1.96 / 1.12 2.37 / 0.14

max. screw stroke mm / inch 200 / 7.87 200 / 7.87 200 / 7.87

max. dosage vol. ccm / cu in 318 / 19.41 392 / 23.92 474 / 28.92

..\SPR-ZYL\Z800\EN04EC_12_307_000.FM 01 2006.02.22

( GY1608E )

BAM_207185_000_EN_10

Injection unit 800 (15.3 oz)

-1-

4.5.3

..\SPR-ZYL\Z800\EN04EC_12_307_000.FM 01 2006.02.22

BAM_207185_000_EN_10


-2-

4.5.3

Decompression

4.5.4

Decompression The screen displays and the input of parameters is carried out in the same way for all processes. Therefore only the special parameters for the decompression process are described in this chapter.

BAM_207185_000_EN_10

You will find more details on input options in chapters 3.1 to 3.2.2.

..\STRG-SW\SDSW404X\EN04ED_00_5404_000.FM 01 2006.03.02

( GP1326Z GA1575Z GA1575Z )

When the processes “Decompressure before dosage” or “Decompression after dosage” have been programmed in the production sequence, further parameters are displayed in the “Dosage/decompression” parameter panel.

-1-

4.5.4

Decompression

BAM_207185_000_EN_10

Panel selection

3 4

( GD1704Z PI0593DA )

2

Decompression before dosage Delay time Decompression flow Decompression volume Dekompression after dosage Delay time Decompression flow Decompression volume Decompression flow [in ccm/s] Decompression volume [in ccm]

● Input the required values for flow and volume. 䡩 The decompression volume is decompressed with the decompression flow either before the dosage process is started or after dosage.

-2-

4.5.4

..\STRG-SW\SDSW404X\EN04ED_00_5404_000.FM 01 2006.03.02

1

Options for moulded part formation

4.6

Moulded part formation

4.6.1

Options for moulded part formation In the parameter panel “Injection and holding pressure selections” you select which option is to end the injection process.

BAM_207185_000_EN_10

Panel selection

a) b) c)


( GE1704Z PN0593DA )

d) e) a) Injection and holding pressure selections b) Screw diameter, programmed c) End of injection via d) Enable volume yes e) Pressure ramp at switch over yes

1

End of injection via (here injection pressure) With this parameter you determine the end condition of the injection process and switch-over to holding pressure (see “End of injection via” on following page.

2a

Enable volume (yes/no), (not standard) Here you can activate an enable volume. When you set this parameter to “yes” a further parameter (2b) is displayed.

2b

Enable volume [in ccm] (see “Enable volume” on page 3.)

3

Pressure ramp at switch-over (yes /no) (see “Pressure ramp at switch-over” on page 3).

-1-

4.6.1


䡩 Depending on the equipment of your machine, the following options are available: Selection Injection pressure Volume

BAM_207185_000_EN_10

Injection pressure Measuring system 1 Time

⽧ End of injection via volume / stroke Here switch-over occurs when a certain volume or switch-over point is reached. ⽧ End of injection via injection pressure (not standard) Switch-over to holding pressure occurs when the injection pressure input in the “Injection” parameter panel is reached. ⽧ End of injection via measuring system 1-4 (not standard) Depending on the measuring system selected, switch-over to holding pressure occurs when a certain pressure is reached, e.g. mould cavity pressure. ⽧ End of injection via time In this case the injection process is ended when a programmed time elapses. ● Select the end condition most suitable for your application. 䡩 The respective parameters are displayed in the “Injection” parameter panel (see chapter 4.6.2).

-2-


End of injection via

4.6.1


Enable volume

By inputting an enable volume (not standard) you have the possibility of excluding any pressure peaks. The enable volume has hereby priority over the pressure query.

BAM_207185_000_EN_10

Switch-over to holding pressure without enable volume with enable volume

1 2

Switch-over to holding pressure Pressure peak (disturbing factor)

1 2

Switch-over to holding pressure Pressure peak (is ignored)


( GB1496DA GC1496DA )

● Set the enable volume option to “yes”. ● Input the enable volume which must have been reached before switch-over to holding pressure can occur.

Pressure ramp at switch-over

Great differences in pressure between injection and holding pressure can lead to quality deficiencies in the moulded part, because the switch-over to holding pressure is carried out too abruptly. In order to avoid such pressure jerks, i.e. to “smooth out the course of the curve” you have the possibility of activating the function “Pressure ramp at switch-over”. When this function is activated, the controller adapts the holding pressure to the last injection pressure in order to achieve an even pressure course (ramp). ● Set the option “Pressure ramp at switch-over” to “yes”. ● Input the ramp time at parameter t311 during which the controller is to have achieved the holding pressure (see chapter 4.6.3 “holding pressure”).

-3-

4.6.1


BAM_207185_000_EN_10


-4-

4.6.1

Injection

4.6.2

Injection The information in this chapter is based on an injection process using the maximum number of stages. The parameter panels in your ALLROUNDER may vary from those illustrated here, depending on the equipment installed on your machine.

BAM_207185_000_EN_10

The screen displays and the input of parameters is carried out in the same way for all processes. Therefore only the special parameters for the injection process are described in this chapter. You will find more details on input options in the chapters 3.1 to 3.2.2. The injection process can be carried out in up to five stages. each stage is characterised by its own injection flow, an injection pressure and a stroke position.


( GF1704Z )

Panel selection

-1-

4.6.2

Injection

End of injection via volume Injection, injection unit 1

Injection flow [in ccm/s]

2

Injection pressure [in bar] During injection the input injection pressure values become effective as a maximum for each individual stage. These pressure values are maximum values, not nominal values.

3

Stroke positions / end of stage [in ccm] Stroke positions are required to switch the various speeds on and over. These stroke positions indicate the material volume still to be injected. Switch-over to the next values is carried out at the correct time via a ramp. After this position the injection process is continued with the data of the following stage. The value of the last stage is the point at which switch-over to holding pressure occurs. 䡩 When this material volume is reached, the last injection stage is ended and the first holding pressure stage begins.

4

Switch-over value for injection pressure, actual value [in bar] Here the actual value of the switch-over pressure at the time of switch-over to holding pressure is displayed.

5

Switch-over volume, actual value [in ccm] Here the material volume at the time of switch-over to holding pressure is displayed.

-2-

4.6.2


1

( PJ0593DA )

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Delay time

Injection

End of injection via injection pressure, meas. system or time Depending on the equipment of your machine, you can also end the injection process when ⽧ a certain injection pressure, ⽧ a value of the measuring system or ⽧ a certain time

BAM_207185_000_EN_10

is reached (see chapter 4.6.1 “Moulded part formation selection“).

In this case a slightly different input table is displayed in which the parameter of the last stroke position is replaced by a symbol “Switchover to holding pressure”. Directly underneath this a further input box appears in which you can enter the value at which switch-over to holding pressure is to occur.


( PL0593DA PK0593DA )

End of injection via injection pressure

1

Switch-over pressure [in bar] Switch-over to holding pressure occurs which this injection pressure is reached.

1

Switch-over value / switch-over pressure Switch-over to holding pressure occurs which this value is measured.

End of injection via measuring system

-3-

4.6.2

Injection

( PM0593DA )

Switch-over time [in s] Switch over to holding pressure occurs which this time expires.


1

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End of injection via time

-4-

4.6.2

Holding pressure

4.6.3

Holding pressure The information in this chapter is based on a holding pressure process using the maximum number of stages. The parameter panels in your ALLROUNDER may vary from those illustrated here, depending on the equipment installed on your machine.

BAM_207185_000_EN_10

The screen displays and the input of parameters is carried out in the same way for all processes. Therefore only the special parameters for the holding pressure process are described in this chapter. You will find more details on input options in the chapters 3.1 to 3.2.2. The course of the holding pressure can be programmed in up to ten stages. Each stage is marked by two plotting points and a time.


( GG1704Z )

Panel selection

-1-

4.6.3

Holding pressure

1

Holding pressure flow [in ccm/s] This value determines the volume flow during the individual holding pressure times. The holding pressure flow must be selected high enough in order for the adjusted pressure values to be reached.

2

Plotting points [in bar] ● Input the required pressure for each plotting point here.


The plotting points for each pressure stage determine the course of the whole holding pressure process:

( PP0593DA GM1156D )

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Holding pressure, injection unit 1

-2-

4.6.3

Holding pressure

3

Ramp time up to next plotting point [in s] With these inputs you determine the duration of the pressure ramp from one plotting point to the next.

IMPORTANT

In order to maintain a pressure level for a certain length of time, input the same pressure value for two consecutive plotting points and determine the duration of effectiveness with the respective time.

4

Total of all holding pressure times [in s] Here the total of all ramp times from 3) are added and displayed. You can thus see at a glance how much time the complete course of holding pressure takes.

5

Ramp time, actual value [in s] Here you can see the current actual value for each ramp time during the holding pressure phase.


BAM_207185_000_EN_10

The holding pressure time does not specify the duration of effectiveness of the holding pressure. It is the time taken to complete the pressure change from one plotting point to the next.

-3-

4.6.3


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Holding pressure

-4-

4.6.3

Remaining cooling time

4.6.4

Remaining cooling time With the remaining cooling time you determine the duration of the cooling time which overlaps the last holding pressure time.

BAM_207185_000_EN_10

Panel selection

Dosage Remaining cooling time


( GD1704Z PH0593DB )

Delay time

1

Remaining cooling time [in s]

● Input the required cooling time here. 䡩 The remaining cooling time starts at the end of the last holding pressure stage. 䡩 The mould cannot be opened before the remaining cooling time has expired.

-1-

4.6.4


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Remaining cooling time

-2-

4.6.4


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Production control

5 Production control

-1-


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Production control

-2-

General information on quality assurance

5.1

Quality assurance

5.1.1

General information on quality assurance With the SELOGICA direct there are four different functions available for quality assurance (optional equipment which may not be installed on your machine).

BAM_207185_000_EN_10

Monitoring functions for : ⽧ monitoring charts (chapters 5.1.2 and 5.1.3), ⽧ quality-relevant parameters (chapter 5.1.4), ⽧ machine-related monitoring functions (chapter 5.4.2, ff.).

Graphical monitoring

The SELOGICA controller offers four possibilities of graphical monitoring ⽧ monitoring of curves ⽧ monitoring of peak values ⽧ integral monitoring (with pressure signals only), alternatively monitoring of temperature mean value (if a thermocouple is connected), ⽧ monitoring of peak time value. You can either: ⽧ activate only one of the above mentioned monitoring options,


⽧ or combine several options.

Procedure

The following three steps must be adhered to when setting up the quality monitoring: step 1:

configuration of the monitoring charts (chapter 5.1.2).

step 2:

display of the monitoring charts (chapter 5.1.3).

step 3:

set parameter “f4001 = quality monitoring” to “yes” and, if required, activate the error assessment (chapter 5.1.4).

-1-

5.1.1


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General information on quality assurance

-2-

5.1.1

Configuration of the monitoring graphics

5.1.2


Graphical recording

With the SELOGICA direct controller you have the possibility of graphically recording the chronological progress of several actual values and of monitoring them on-screen. With the aid of the additionally displayable reference curve (see chapter 5.1.3) you can carry out a precise comparison of the nominal values with the recorded actual values.

BAM_207185_000_EN_10

The curves recorded by the controller are displayed in up to eight charts and monitored. In each monitoring chart a curve and the respective monitoring settings are displayed. With standard equipment the following actual values can be recorded and monitored: ⽧ injection pressure, ⽧ injection flow, ⽧ pressure, control circuit 1, ⽧ screw volume.

Before you can record the actual values, you must first configure the monitoring chart and enter the data you require.

( PX0619DA )

Configuration

Count of monitoring charts

Recording condition 1


Count of recording conditions

Recording condition 2

1 2

Recording signal Recording condition

-1-

5.1.2


Count of monitoring charts f3003

● Input here the number of monitoring charts you require (max. 8 charts).

Count of recording conditions f3001

With this parameter you can define up to two recording conditions.

Recording conditions 1 and 2

The recording conditions are comprised of various parameters (start, delay, duration, threshold). The start condition can later be assigned to the monitoring signal. You can choose between the following possibilities: ⽧ Start with injection Recording starts with injection.

BAM_207185_000_EN_10

䡩 After inputting a number greater than ’0’, further parameters are displayed.

⽧ Start with holding pressure Recording starts at switch-over to holding pressure ⽧ Screw volume for injection Here you must input the screw volume at which the recording is to start. ⽧ Pressure threshold, injection pressure Input a threshold value here, at which the recording is to start, e.g. 700 bar. In addition you can also input a delay, if required, or an enable volume.

⽧ Start via sequence marking. 1 Here you can individually define the starting and stopping points of the monitoring chart by a marking in the production sequence. Delay time for recording conditions 1 and 2. This time starts when the recording condition is fulfilled and thus offers you the possibility of starting with a delay:

1 2 3 4 5 6

1


Delay

( GA1496ZA )

⽧ Pressure threshold, meas. system 1 - 8 1 Input the threshold value here (at which recording is to start).

start condition fulfilled delay start of recording recording duration end of recording time axis

not standard -2-

5.1.2


Duration

● Enter the duration of recording here. 䡩 During the time entered here the monitoring signal is recorded and monitored. The recording ends at the latest at the end of the remaining cooling time (t400), in order to make it possible to evaluate good or bad parts. (Exception: stop via sequence marking).

BAM_207185_000_EN_10

Threshold

This parameter is only displayed when “pressure threshold” is selected at “Start 1” or “Start 2”. ● Input the required pressure value here at which the recording is to start.

Enable volume

By inputting an enable volume (e.g. 10 cm3) pressure peaks can be excluded, whereby the enable volume has priority over the pressure enquiry:

( GB1496EA GC1496EA )

Start of recording without enable volume

1 2

Recording starts Pressure peak (disturbance factor)

1 2

Recording starts Pressure peak (is not recorded)


Start of recording with enable volume:

-3-

5.1.2


Selecting the recording signal (1)

Here you enter which actual values you want to record: ⽧ Injection pressure, ⽧ Injection flow, ⽧ Meas. system 1-8, 1 ⽧ Mould stroke, actual, 1 ⽧ Clamping force, actual, 1 ⽧ Pressure, control circuit 1, BAM_207185_000_EN_10

⽧ Pressure, control circuit 2, 2 ⽧ Screw volume, ⽧ Gas cavity pressure 1, 1 2, 1 ⽧ Ejector stroke, 1 ⽧ Ejector force. 1

If you have configured two recording conditions, you can assign the required condition here for each chart: 1=

Recording condition 1 is effective

2=

Recording condition 2 is effective.


Assigning a recording condition (2)

1 2

not standard depending on equipment installed on machine -4-

5.1.2

Displaying the monitoring charts

5.1.3

Displaying the monitoring charts The SELOGICA direct controller offers you three options for graphical monitoring: ⽧ peak value (pressure / time),


( GC1729Z PY0619DA )

BAM_207185_000_EN_10

⽧ envelope curve, ⽧ integral monitoring (only with pressure signals), alternatively temperature mean value monitoring (if a thermocouple is connected). You can either activate only one of the above mentioned monitoring functions, or of combining several together.

Calling up the parameter panels for the monitoring charts


1 2 3 4 5 6 7 8 9

Recording condition Start/stop display of chart Display limits (min. / max.) Display area time axis (min. / max.) Position of meas. cursor on time axis Display of the progress of cycle Monitored area Recorded signal Measuring cursor

-1-

5.1.3


Starting/stopping the recording (2)

During production, the selected measured values are continually recorded and displayed as a coloured curve in the chart window. At the top right next to the chart the green start symbol indicates that the recording is running.

Press the stop symbol in the editing box, in order to stop the display.

䡩 At the top right next to the chart the red stop symbol indicates that the recording is frozen.

BAM_207185_000_EN_10

In order to precisely measure individual values in the curve, the display must be stopped (frozen).

You can now undertake individual measurements with the measuring cursor.

IMPORTANT

When the recording is stopped, the curves in the chart are not updated.

In order to continue the recording the display must be restarted.

Display range (3)

Here you can enter the minimum and the maximum display value. In order to achieve as detailed a curve as possible, the range should be selected only as large as necessary.

-2-

5.1.3


Press the start symbol in the editing box to restart the display.


Display of cycle progress (6)

Here the cycle progress is displayed in a continuous bar. ⽧ yellow = injection, ⽧ dark blue = holding pressure, ⽧ red = decompression, ⽧ green = dosage,

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⽧ grey = other.

Meas. cursor (9)

The measuring cursor is displayed as a vertical line in the chart window. Individual measuring points of the monitoring chart can be selected and the respective value read off (5). The measuring cursor can be moved to the left or right with these keys.

Grid (8)

For a better overview, a background grid can be displayed in the chart window.

( PN0605D 9

Press this key.


䡩 The following selection window appears. Functions Grid on/off Adjust chart

● Touch the “Grid on” or “Grid off” key. 䡩 The grid is faded in/out. 䡩 The display of the grid is adapted by the controller to the required size.

-3-

5.1.3


Adjusting the chart

With the SELOGICA direct controller it is possible to let the controller make a suggestion for the chart adjustments. A chart with the specified curves is drawn up, reference values for these parameters calculated and the display of the curves optimised. ● Touch the “Adjust chart” key. 䡩 The controller carries out the following functions: ⽧ displays the recorded values,

The upper and lower limits of each curve are adapted automatically to the display on the screen.

The chart thus drawn up serves only as an adjustment aid and can be used as an indication for the further mould-specific settings.

BAM_207185_000_EN_10

⽧ optimises the display range of the curves.

IMPORTANT

Any manual adjustments previously made to the chart are automatically overruled by the “Adjust chart” function key.


Only the display range of the curves is optimised.

-4-

5.1.3


IMPORTANT

The special keys for the graphical recording are only displayed when you touch the screen inside the chart area.

BAM_207185_000_EN_10

Zoom in/out function

With this key you can increase the size of the graphical display (zoom in).

With this key you can reset the graphical display to its original size (zoom out).

Reference values

In order to be able to interpret the actual value curves and to compare them, you require a reference curve. The controller offers you two ways of creating a reference curve:

If the “Quality monitoring” parameter (f4001) is set to “no” and the machine is operating in automatic mode, the “Take over reference values” function key (1) is displayed.


( PN0621DA )

Possibility 1

When you touch this key the controller takes over the current actual value curve as a reference curve and all quality-relevant actual values as reference values.

-5-

5.1.3


If the “Quality monitoring” parameter (f4001) is set to “no”, the parameter “Reference value calculation” (f4004) appears. The following inputs are possible: ⽧ no calculation, ⽧ normal calculation, ⽧ fine calculation,

After selecting one of these options, the parameter “Cycle count for reference calculation” appears. At the same time the respective tolerances are set. ● Select the number of cycles from which a reference curve is to be calculated.

BAM_207185_000_EN_10

⽧ calculation without tolerance.

( PD0621D )

Additionally, the actual values of all quality-relevant parameters are also calculated and taken over as respective reference values.


Possibility 2

-6-

5.1.3


Peak value monitoring With peak value monitoring the highest point of the curve is calculated and monitored in the range of the specified tolerance. You can monitor either the highest point of the curve or the time at which the highest point must be reached.

Peak value monitoring is important for checking the density of the melt and for protecting the mould. Peak value monitoring f3151

Peak value monitoring (time) f3161

yes

no

no

yes

yes

yes

no

no

What is monitored: Occurrence of the peak value within a tolerance range Occurrence of the peak value within a certain time Occurrence of the peak value within a monitoring window Monitoring inactive


( PA0621DA )

BAM_207185_000_EN_10

We recommend a combination of both possibilities.

1 2 3 4 5 6

Recorded actual value Peak value monitoring Peak value monitoring (time) Tolerance in relation to reference value (+/-) Reference value Actual values

-7-

5.1.3


Recorded actual value (1)

The displayed actual value curve is freshly recorded with each cycle. The monitoring range is displayed by the broken lines (vertical / horizontal) (4).

IMPORTANT

Tolerance (4)

Maximum permissible deviation of the peak value (in general 5 %). If the actual value deviates from the reference value by more that the tolerance specified here, a corrective measure is carried out, as programmed.

Reference value (5)

Here the value is displayed which was determined and taken over as a reference value.

Actual value (6)

Display of the current actual values.

Peak value monitoring (2, 3)

● Set parameter f3x51 to “yes” if you want to monitor the peak value.

BAM_207185_000_EN_10

A monitoring curve is only possible when a reference curve has been created. This can be compared with all following curves (see section “Determining reference values”.

● Set parameter f3x61 to “yes” if you want to monitor the peak value (time).


䡩 The monitoring function is now activated.

-8-

5.1.3


Envelope curve monitoring

BAM_207185_000_EN_10

With envelope curve monitoring a certain section of the curve (specified by you) is monitored with the aid of a tolerance range.

1 2 3 4


Recorded actual value Envelope curve monitoring Deviation tolerance in relation to reference value (+/-) Start, end of monitoring

The displayed actual value curve is recorded for each cycle.

( PB0621DA )

The monitoring area (start, end) is indicated by the two vertical pink lines (4). The deviation tolerance (3) is indicated by the two red curve sections which lie parallel to the pink reference curve.


The complete monitoring range has a grey background.

IMPORTANT

A monitoring curve is only possible when a reference curve has been created. This can be compared with all following curves (see section “Determining reference values”.

-9-

5.1.3


Deviation tolerance (3)

Maximum permissible deviation of the actual value from the reference curve (in general 5 %).

Start, end (4)

● Input the range to be monitored.

Envelope curve monitoring (2)

● Set parameter f3x31 to “yes” if you want to monitor the peak value.


䡩 The monitoring function is now activated.

BAM_207185_000_EN_10

If the actual value deviates from the reference value by more that the tolerance specified here, a corrective measure is carried out, as programmed.

- 10 -

5.1.3


Integral monitoring (only for pressure signals) With the aid of the integral monitoring you can monitor a pressure integral for a pressure curve. The pressure integral is the sum of the currently effective pressures. In “integral monitoring via time/stroke” it is displayed below the graph as an area with a grey background.

BAM_207185_000_EN_10

This area is monitored by the controller.


( PC0621DA )

1 2 3 4 5 6

Recorded actual value Integral monitoring Start, end of monitoring Reference value Tolerance in relation to reference value Actual value


The displayed actual value curve is recorded again for each cycle.

Start, end (3)

● Enter the range here that you want to monitor.

- 11 -

5.1.3


Here the value is displayed which was determined and taken over as a reference value.

Tolerance (5)

● Enter the permissible tolerance in bar · s (in general 5 %). If the actual value deviates from the reference value by more that the tolerance specified here, a corrective measure is carried out, as programmed

Actual value (6)

This parameter shows the current actual value.

Integral monitoring (2)

● Input the required integral monitoring here.

BAM_207185_000_EN_10

Reference value (4)

䡩 The monitoring is activated. The following options are available: ⽧ no integral monitoring. ⽧ integral monitoring via time. The time of the start and end of the monitoring must be entered here, together with the tolerance of the range. ⽧ integral monitoring to pressure peak. In this case you only have to input the tolerance because the controller automatically determines the integral up to the maximum pressure from the start of injection.


⽧ Integral monitoring up to switch-over point. The controller computes the integral up to the switch-over point to holding pressure. You only have to input the permissible tolerance.

- 12 -

5.1.3

Quality control and quality monitoring


..\STRG-SW\SDSW406X\EN05AD_00_5406_000.FM 01 2007.02.05

( PD0621D DE_TB00478C )

BAM_207185_000_EN_10

5.1.4

f4001 Quality control

f4121 Error evaluation

yes yes no no

yes no no no

Quality monitoring f4001

f4131 Good part evaluation when quality monitoring is switchd off yes no

Behaviour of machine all tolerance deviations lead to errors all tolerance deviations lead to alarms good/bad parts, no alarms all bad parts, no alarms

With this parameter you activate/deactivate the quality monitoring. The quality monitoring should not be switched on until the machine has produced several cycles in succession with constant part quality, as otherwise the controller will keep issuing an alarm. If, when the quality monitoring is switched on, the tolerance of a programmed monitoring function is exceeded or not achieved, an alarm is issued or the error evaluation started (when error evaluation is set to "yes").

-1-

5.1.4


Good part evaluation with deactivated quality monitoring f4131

If, with activated quality monitoring, the tolerance of a programmed monitoring is exceeded or not reached, an alarm is issued or the error evaluation started. If the machine is equipped with a sorter unit 1 or robotic handling device 1, these parts are rejected as bad parts.

The parameter "Good part evaluation with deactivated quality monitoring" offers you the possibility of counting these cycles as good parts even if the quality monitoring is switched off, and, if the machine has the respective equipment, of sorting them as good parts too. ● Input "yes" at f4131 (Quality monitoring = "no").

BAM_207185_000_EN_10

However, if you have only switched off the quality monitoring to optimise reference values or tolerances, these parts may well actually be good parts.

䡩 If a defective cycle occurs only a warning is displayed but is not evaluated as an error. 䡩 All produced parts are sorted as good parts, providing the machine is equipped accordingly.

Reference value determination f4004

When parameter "Quality monitoring" is set to "no", the parameter "Reference value determination" appears. Here the following inputs are possible: ⽧ off, ⽧ normal (greater tolerances), ⽧ fine (smaller tolerance),

After selecting one of the options for reference value determination, the parameter “No. of cycles for reference value determination” appears. At the same time the respective tolerances are set. ● Select the required number of cycles from which a reference curve is to be determined. Furthermore, the mean value is taken of all actual values of the quality relevant parameters and taken over as the respective reference values.

1

not standard -2-

5.1.4


⽧ determination of reference value without tolerance.

BAM_207185_000_EN_10


Error evaluation f4121

● Input "yes" here to activate the error evaluation.

Shot count per evaluation f4124

● Input the number of cycles (lot size) at this parameter, which you periodically want to monitor, e.g. 100.

Evaluated cycles f4125

Here the number of cycles is displayed which have already been evaluated. When this actual value reaches the specified lot size it is reset to “0” and starts counting again. ● To reset this actual value to “0”, enter “0” here and confirm your entry.

Errors per evaluation f4122

Per lot size you can permit a certain number of errors, e.g. 5. As soon as the maximum error count per lot size is exceeded, the controller goes on alarm (in this case after the 6th error).

Errors per evaluation f4123

Display of all errors which have occurred up till now during the current evaluation. This value is also reset to “0” when the counter is reset. Setting this actual value to “0” is only possible when the counter of the actual value cycles is also reset to “0”.

Max. count of successive errors f4126

In order to quickly recognize possible malfunctions in the injection moulding process, you have the further possibility of specifying at this parameter after how many errors in succession the controller is to go on alarm.


If, for example, you have input "max. 2 errors" the controller will issue an alarm after the third error in succession.

Actual count of successive errors f4127

Display of successive errors. This value is reset to “0” as soon as one correct cycle is produced. Setting this actual value to “0” is only possible when the counter of the actual value cycles is also reset to “0”.

Total count of erroneous cycles f4128

Here all erroneous cycles produced up till now, are displayed. ● To reset this actual value to “0”, enter “0” here and confirm your entry.

Bad part cycles after error f4133

At this parameter you can input how many cycles are to be counted as bad parts after an error.

-3-

5.1.4


Quality monitoring

Included in the parameter panels for quality monitoring you will also find all relevant parameters for quality assurance. Changes to the parameters can be undertaken either in the respective parameter panels or here. The reference values and any tolerance values are automatically set by the controller.

BAM_207185_000_EN_10

Stroke-volume-pressure values

Quality monitoring for stroke/volume/pressure Monitoring of switch-over volume Monitoring of maximum injection pressure Monitoring of switch-over injection pressure Monitoring of material cushion

Monitoring of stroke position, at which switch-over from “Injection” to “Holding pressure” occurs.

Max. injection pressure f4054

Monitoring of maximum injection pressure.

Switch-over injection pressure f4071

Monitoring of switch-over pressure at which switch-over from “injection pressure” to “holding pressure” occurs.

Material cushion f4061

Monitoring of material cushion at the front of the screw.

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( PE0621D )

Switch-over volume f4064

5.1.4

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Switch over pressure/value meas. system 1-8

Only with activated cavity pressure recording (not standard) or general meas. system. Monitoring of switch-over pressure at which switchover from “injection” to “holding pressure” occurs.

Monitoring of injection start f4068

Monitoring of the screw position at the start of injection (depending on equipment installed).

Activation

● To activate the monitoring, input "yes" here. 䡩 If the actual value deviates from the reference value by more than the tolerance, a programmed corrective measure is carried out, in accordance with the respective erroneous behaviour.

Times and functions

Quality monitoring of times and functions Monitoring of cycle time Monitoring of dosage time Monitoring of injection time Variable injection time measurement


( PF0621D )

Start of injection time measurement

Cycle time f4011

Monitoring of the total cycle time from "cycle start" to "cycle end".

Dosing time f4014

Monitoring of the required dosing time from "Dosage start" to "Dosage end".

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5.1.4


Injection time f4017

Monitoring of the required injection time from "Injection start" to "Injection end" or "Holding pressure start".

IMPORTANT

It is not possible to monitor the injection time when switch-over is time-controlled.

䡩 If the actual value deviates from the reference value by more than the tolerance, a programmed reaction is triggered in accordance with the respective erroneous behaviour.

Monitoring of the required injection time between two measuring points. The following inputs are possible: ⽧ No monitoring ⽧ Fixed start of injection (injection stop variable) ⽧ Variable meas. condition (start and stop variable). ● Input the screw position at “Start of injection time measurement” at which the measurement is to begin (only possible with “variable meas. condition”). ● Input the screw position at "End of injection time measurement“ at which the measurement is to stop. 䡩 If the actual value deviates from the reference value by more than the tolerance, a programmed reaction is triggered in accordance with the respective erroneous behaviour.


Variable injection time measurement f4021

BAM_207185_000_EN_10

● To activate the monitoring, input "yes" here.

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5.1.4

Freely configurable pages

5.3.2

Freely configurable pages With the SELOGICA controller you have the possibility of compiling three controller parameter pages according to your own requirements. This reduces the need to call up various parameter panels.

Through the user authorization function you have the further possibility of enabling changes to be made only in the parameters of the freely configurable panels and inhibiting all other parameter panels.

Panel selection


( PS0605DA )

BAM_207185_000_EN_10

This also simplifies the optimisation of the machine adjustment and the monitoring of the various parameters.

1 2 3

Freely configurable page 1 Freely configurable page 2 Freely configurable page 3

The freely configurable pages can be “filled” with parameters as required (for the procedure: see following sections).

-1-

5.3.2


In order to structure the freely configurable pages clearly you can define a field as the “title”. A text of up to 28 characters can be entered in these fields. ● Touch a field that you want to use as the “title”.

BAM_207185_000_EN_10

Touch this key.

䡩 The following window appears: Selection

Title

● Touch the “title” button. 䡩 The window is faded out again.

( PO0605D )

䡩 The respective field has a blue background and a further key (edit/text input) is displayed.


Defining the titles of the pages

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5.3.2


Touch the “edit / text input” key.

䡩 An on-screen keyboard is displayed.

BAM_207185_000_EN_10

● Enter the required title and confirm your input with the “Y” key.

IMPORTANT


( PP0605D )

The “edit / text input” key is only displayed when you touch a field to which the feature of “title” is assigned.

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5.3.2


In each freely configurable page you can insert up to 30 parameters and titles. To select and insert parameters in the freely configurable pages, proceed as follows: ● Quit the freely configurable pages. ● Select a parameter that you want to take over to a freely configurable page, by touching it. BAM_207185_000_EN_10

Touch this key.

䡩 The following window is displayed: Selection Freely configurable page 1 Freely configurable page 2

● Touch one of these keys, depending on in which freely configurable page you want to put the parameter.

( PR0605D )

Freely configurable page 3

䡩 The parameter is taken over into the respective page and the window is faded out again. 䡩 The designation of the parameter appears in the freely configurable page together with its current value.

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5.3.2


Selecting and inserting parameters


Deleting a parameter or title

● If you want to delete a parameter or a title, touch the respective field. Then touch this key.

䡩 The following window appears

BAM_207185_000_EN_10

Selection

Delete line Title

● Touch the key “Delete line”.


( PQ0605D )

䡩 The respective parameter or title is deleted and the window is faded out again.

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5.3.2


In order to compile the freely configurable pages individually according to your requirements, you can move each field upwards or downwards. With this key the previously selected field is moved one position downwards.

1 2 3 4

( PT0605DA )

BAM_207185_000_EN_10

With this key the previously selected field is moved one position upwards.

Move field downwards Move field upwards Delete title / line Enter


Moving fields

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5.3.2


User tip

If you want to insert a parameter directly in a certain place in the freely configurable page, you can touch the respective field and then select the required parameter in the usual way. The next parameter you have taken over then appears in the freely configurable page at the previously selected position. Further parameters are taken over consecutively.

BAM_207185_000_EN_10

Editing parameters

All parameters which have been taken over in the freely configurable page can be edited in the usual way. All changes made to parameters in the freely configurable pages are automatically also changed in the original parameter panel. This means that parameters can be managed centrally from the freely configurable pages.

IMPORTANT

Parameters which you have entered in the freely configurable pages are saved in the data set together with their respective values.


The configuration of the freely configurable parameter pages can also be undertaken via a data set (see chapter 9.3 “Program administration”.

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5.3.2


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5.3.2

“Monitoring off in set-up operating mode”

5.4

Monitoring functions

5.4.1


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With the SELOGICA controller, it is possible to switch off various monitoring functions and stroke limitations for the “Set Up” operating mode. 1 ● Select the “Set-up” operating mode. Panel selection

( PT0619D )

Monitoring off in “Set-up” operating mode.

● Here you activate or deactivate various monitoring functions. ⽧ To switch off monitoring: enter “yes”.


⽧ To activate monitoring: enter “no”.

1


5.4.1


Axis end points exceedable f180

● Enter “yes” here if you want to move beyond the axis end points during machine movements. 䡩 When you now undertake machine movements via the manual keypad, the machine will not stop at the axis end points. 䡩 The movements end only when the key is released or when the machine has reached the mechanical end limit.

In “Set-up” mode, monitoring and stroke limitation can be partially switched off, depending on the programming in the “Monitoring Off in Set Up Operating Mode” parameter panel. Incorrect operation can lead to damage to the mould or other machine parts. ● Great care must therefore be taken when carrying out machine movements in set-up mode. In “Set-up” operating mode the ejector can be moved when the clamping system is in any position except s504 “Mould open”. Danger of damage to the mould!


SAFETY INSTRUCTIONS

BAM_207185_000_EN_10

The monitoring functions are reactivated when you change over from “Set-up” to another mode.

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5.4.1

Monitoring functions of machine, mould and injection unit

5.4.2

Monitoring functions of machine, mould and injection unit In the monitoring parameter panels you can set the monitoring times and follow-on functions for various processes.

Machine monitoring Cycle time

Cycle time t902

● Input the maximum time for a complete machine cycle here.

Cycle time, actual value t4012

Here the actual cycle time of the last machine cycle is displayed.

䡩 If this time is exceeded an alarm is displayed and the machine immediately stopped. We recommend: actual value t4012 + 3…5 s

..\STRG-SW\SDSW406X\EN05DB_00_5406_000.FM 01 2007.02.06

( PS0619D )

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Machine monitoring

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5.4.2


Mould monitoring

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Mould monitoring

Monitoring time of mould protection t105

● Enter the maximum time for the mould protection stroke here. 䡩 The mould protection stroke (s103 to s105) which is part of the closing process must be completed during the time set at t105.

Actual mould protection time t4052

The time actually taken to complete the mould protection stroke is measured and displayed at t4052 "Actual value".

2nd attempt after protection alarm f105

This function enables you to undertake a second attempt to close the mould after a mould protection alarm has occurred.

Follow-on function after protection alarm f102


● Enter “yes” at f105 “2nd attempt after protection alarm”.

With this function you select how the machine is to react after an alarm occurs at t105 . The following options are available: ⽧ immediate machine stop, ⽧ mould opening, ⽧ opening as an alarm cycle.

-2-

( PQ0619D )

䡩 If the time set at t105 is exceeded, an alarm is displayed. We recommend: actual value t4052 + 0.1…0.2 s

5.4.2


( PU0619D )

BAM_207185_000_EN_10


Optical barrier for mould f550

As an option, the mould can be monitored by an optical barrier. Then a new cycle only begins when moulded parts have been ejected from the clamping unit or e.g. the ejector pins have completely retracted again and are no longer detected by the optical barrier. If the mould area is not free at the start of the clamping process, an alarm is issued and the machine stops.

Position monitoring f128

Here you enter whether you want to work with or without mould position monitoring (see also chapter “Mould position monitoring“).

Monitoring of injection unit

Monitoring of maximum dosage time t402

● Enter the maximum time for the dosage process.

Dosage time, actual value t4015

Here the actual dosage time of the last machine cycle is displayed.

Follow-on function after t402 f402

● Select here which function is to be carried out after the maximum injection time t402 has been exceeded.

䡩 If this time is exceeded an alarm is displayed and the machine stops. We recommend: actual value t4015 + 3…5 s, depending on the remaining cooling time.

Possible inputs: ⽧ immediate machine stop ⽧ stop at cycle end.

-3-

5.4.2


f4111 Maximum torque

Monitoring of the maximum torque value of the screw during the dosage process. ● Enter “yes” here to activate the monitoring function.

Monitoring of maximum injection time t309

● Enter the maximum time for the injection process here.

Actual injection value t4018

Here the actual injection time of the last machine cycle is displayed.

Follow-on function after t309 f309

● Here you select when the machine is to be stopped after the maximum injection time t309 has been exceeded.

䡩 If this time is exceeded, an alarm is displayed and the machine stopped or the error evaluation is started. We recommended: Actual value of t4018 + 0.05…0.1 s

BAM_207185_000_EN_10

䡩 If the maximum permitted torque is reached during the dosage process, the machine carries out a follow-on function as programmed.

Possible inputs: ⽧ immediate machine stop, ⽧ stop at cycle end, ⽧ error evaluation.

IMPORTANT

From this position you can easily start a new cycle after the cause of error has been rectified.

If the machine is equipped with a sorter unit (not standard) and if error evaluation is activated (f309 = error evaluation), the part can be sorted out as a reject.

-4-

5.4.2


By selecting the “stop at cycle end” function, you have the advantage that the machine sequence is not abruptly interrupted but carried out to the end.The machine has then dosed material for the next cycle.


Monitoring of injection pressure f4112

With this function (not standard) you monitor the maximum permissible injection pressure (p301 to p305). If during the injection process one of these maximum pressure values is reached, the selected function is carried out. Possible inputs are: ⽧ no monitoring, ⽧ stop at cycle end with switch-over to holding pressure, ⽧ immediate machine stop.


BAM_207185_000_EN_10

⽧ error evaluation with switch-over to holding pressure,

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5.4.2


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5.4.2


5.4.3


BAM_207185_000_EN_10

Here you activate/deactivate various monitoring functions.

Various parameters are displayed here, depending on the equipment supplied with the machine.

Weighing scales for the ejected part f9144

As an option the machine can be equipped with weighing scales for the ejected part. A new cycle is then only started when the moulded part has fallen out of the clamping unit and the correct weight has been registered by the scales and signalled to the controller.

..\STRG-SW\SDSW406X\EN05DC_00_5406_000.FM 01 2007.02.05

( PR0619D )

● Input “Yes” at the respective parameter to activate the monitoring functions.

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5.4.3


BAM_207185_000_EN_10


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5.4.3

Mould position monitoring

5.4.4

Mould position monitoring With the SELOGICA controller it is possible to activate position monitoring directly in the production cycle you have created.

BAM_207185_000_EN_10

When position monitoring is switched on, the correct position of the mould or the ejector platen is monitored by a switch during the execution of the selected process:

1

Before you activate position monitoring you must first check whether the connections for the signals are correctly installed.

..\STRG-SW\SDSW404X\EN05DD_00_5404_000.FM 01 2007.03.21

( GP1461ZA GO1662ZA )

Signal connections

Switch S141

1 2 3

X333 for “core retracted” signal X332 for “core inserted” signal X331 for position monitoring

IMPORTANT

If the mould has position monitoring, the S141 switch must be connected to socket X331 and activated.

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5.4.4


● Touch any symbol in the sequence. Then touch this key.


BAM_207185_000_EN_10

Visible marking

no markings omit in dry-cycle omit in alarm omit in automatic mould position monitoring

( PR0550D )

end position monitoring


Activating position monitoring

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5.4.4


● Touch the “Mould position monitoring” field.

BAM_207185_000_EN_10

䡩 The window is faded out and the controller marks the symbol related to the activated position monitoring (mould closing) with a marking (red mould in small square).

䡩 The position of the ejector plate is now monitored when the selected process is carried out in automatic or manual mode. 䡩 If the switch is not activated during a position-monitored process (i.e. the position is not correct) the machine is stopped and an alarm is displayed. 䡩 The status of the switch is displayed at S141 = “Mould position monitoring” in the “Valves/switches for mould” parameter panel.

Adding markings

If you want to add more markings, touch the respective symbol first and then this key.



( PP0551Z )

䡩 The window is faded out and the selected symbol is displayed with a marking.

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5.4.4


Removing markings

If you want to remove a single marking or all markings, first touch the respective symbol and then this key.


When you want to remove the position monitoring from the display, touch any symbol in the sequence first and then touch this key. 䡩 The following window appears: Visible marking

no markings omit in dry-cycle omit in alarm

mould position monitoring end position monitoring

● Touch the “no markings” field. 䡩 The window and all markings are removed from the display.

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5.4.4

( PR0550D )

omit in automatic


Removing position monitoring from the display

BAM_207185_000_EN_10

䡩 The window is faded out and the marking is removed from the selected symbol.


User tip

In order to ascertain whether the S141 switch is mechanically defect we recommend installing an additional function check of this switch (not standard).

BAM_207185_000_EN_10

Program this symbol in the sequence with (between “Ejector advancement” and “Ejector retraction”).

The switch S141 must be entered in the respective parameter panel. The status of this switch (active/inactive) can be queried.


( GO1546ZA )

In this application the inactive state of S141 must be queried.

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5.4.4


BAM_207185_000_EN_10


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5.4.4

End position monitoring via stroke marker

5.4.5

End position monitoring via stroke marker With the SELOGICA controller you have the possibility of activating end position monitoring (not standard) for core pulls programmed simultaneously with mould or ejector movements, directly in the production sequence you have compiled. ● Touch any symbol in the sequence.

BAM_207185_000_EN_10


䡩 The following window appears: Visible markings selection

no markings

omit in dry cycle

omit in alarm

omit in automatic

..\STRG-SW\SDSW406X\EN05DE_00_5406_000.FM 01 2007.02.01

( PR0550D )

mould position monitoring


Activating end position monitoring

● Touch the field “end position monitoring”. 䡩 The window is faded out again.

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5.4.5


Setting a marking

Touch first the core pull symbol, the end positions of which you want to monitor, and then this key.

䡩 The following window appears: Visible markings selection Set marking BAM_207185_000_EN_10

Insert symbol Move symbol Delete symbol Change start condition Switch over drive Move branch end


( PZ0605D GH1644DA )

䡩 The selected symbol is marked with a yellow marking and the window is faded out again.

Stroke marking for end position End position monitoring ..\STRG-SW\SDSW406X\EN05DE_00_5406_000.FM 01 2007.02.01

1 2

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5.4.5


Removing the marking

If you want to remove a marking again, touch first the respective symbol and then this key.

䡩 The following window appears: Visible marking selection Set marking BAM_207185_000_EN_10

Insert symbol Move symbol Delete symbol Change start condition Switch over drive Move branch end



( PA0618D )

䡩 The marking on the selected symbol is removed and the window faded out again.

-3-

5.4.5


If you want to remove the markings for the end position monitoring, touch first any symbol in the sequence and then this key.


BAM_207185_000_EN_10

Visible marking selection

no markings

omit in dry cycle

omit in alarm

omit in automatic

mould position monitoring


● Touch the “no markings” field. ( PR0550D )

䡩 All the markings are removed and the window faded out.


Removing all markings

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5.4.5


Setting a stroke marker

For correct end position monitoring you now set a stroke marker.

BAM_207185_000_EN_10

● Call up the “Core pull monitoring” parameter panel.

1

Either “mould stroke” or “ejector stroke” is displayed at parameter s172, depending on which the marker for end positioning is set.

● Enter the mould or ejector stroke at s172, by which the core pull movement is to have reached its end position at the latest.

( PD0618DA )

䡩 In automatic mode, the core pull must have reached its end position at the latest by the time the ejector or mould reaches the value input at s172. 䡩 If this is not the case an alarm is issued and the machine stopped. 䡩 In automatic operation the core pull end position is now monitored in relation to the mould or ejector stroke.


⽧ The core pull process is thereby an “end position monitored process”. ⽧ The mould or ejector process determines the stroke marker for the monitoring.

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5.4.5


BAM_207185_000_EN_10


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5.4.5

Types of printer

5.5

Printer

5.5.1

Types of printer

BAM_207185_000_EN_10

Depending on the equipment level of the SELOGICA controller, you can connect up to two printers to the machine via an USB interface. Older printer models which do not have an USB interface, can be connected via a serial interface, as an option. For more details, please consult your ARBURG sales consultant.

IMPORTANT

Only the following printer is permitted to be connected to the SELOGICA ’direct’ controller: ⽧ HP DeskJet® 5940, This printer can be obtained from ARBURG stating Part No. 239198 bezogen werden.


A correct printing function is not possible on other printers. In the worst case, the connection of a non 100 % compatible printer can cause damage to the interfaces or parts of the controller or printer.

-1-

5.5.1


BAM_207185_000_EN_10

Types of printer

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5.5.1

Printer connection

5.5.2

Printer connection The data link between the SELOGICA controller and the printer is made with the respective interface cable.

IMPORTANT

Ensure you use a high-quality interface cable. BAM_207185_000_EN_10

Please note that the transmission quality deteriorates the longer the cable is. This can lead to transmission errors. The length of the interface cable should therefore only be as long as necessary.

The cable is connected to the printer interface on the controller side of the machine. The printer interface is located on the side of the control cabinet:


( PZ0619ZA )

Connecting the printer

1

USB-interface for printer

If required an additional USB interface is available to connect a second printer (option).

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5.5.2

Printer connection

If your machine is additionally equipped with a serial interface (not standard) you can also connect older printer models which do not have an USB interface. The following printers can be connected: ⽧ HP DeskJet® 550C, ⽧ HP DeskJet® 560C, ⽧ HP DeskJet® 660C, ⽧ HP DeskJet® 690C, BAM_207185_000_EN_10

⽧ HP DeskJet® 695C, ⽧ HP DeskJet® 697C, ⽧ HP DeskJet® 610C, ⽧ HP PaintJet®, ⽧ Canon BubbleJet® 4400, ⽧ Epson Stylus Color® 440. However, only production protocols can be printed out on these printers. To print out parameter panels and graphical diagrams, you require a printer with a USB interface.

Printer with serial interface

To connect a printer with a serial interface, use the following interface cable: ⽧ Interface cable for printers with serial interface OKI-Microline-Series: part no. 188.271 Standard ASCII printers (IBM compatible)

To connect a printer with a parallel interface, use the following interface cable and the following adapter: ..\STRG-SW\SDSW406X\EN05EB_00_5406_000.FM 01 2007.02.06

Printer with parallel interface

⽧ Plug connector part no. : 141.214 ⽧ Adapter part no. : 141.215.

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5.5.2

Printer configuration

5.5.3


BAM_207185_000_EN_10

In order to print the selected protocols and panels correctly you must first activate the connected printer in the parameter panel “Printer selection“.

Activating the printer

● Enter “via USB interface” at “Printer 1” ● Enter “automatic recognition” at “Printer type”. 䡩 The printer is now activated.

( PQ0621D )

● If you have connected a second printer (not standard) activate this one in the same way.


Pre-requirements

The following points must be observed in order to obtain a correct print-out of your data: ⽧ The controller must be equipped with the respective printer interface. ⽧ The correct interface cable must be used. ⽧ The DIP switches on the printer must be set correctly (this does not apply to printers with USB interface). ⽧ The printer must be correctly connected, supplied with paper and ready for operation.

-1-

5.5.3


BAM_207185_000_EN_10


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5.5.3

Configuration of documentation (printing or saving data)

5.5.5

Configuration of documentation (printing or saving data) Before the controller can print out any documentation records, you must first specify which functions the connected printer is to carry out. You can print out or save data of the following events in a file: ⽧ all occurring alarms and operating mode changes, ⽧ set-up protocols and production protocols,

BAM_207185_000_EN_10

⽧ panels and sequences When you archive (document) such data files, you can process them further or print them out on a PC, e.g. with a text processing program or a table calculation program. For how to import the files into the program on your PC and process them please refer to the operating manual of your respective PC program. ● Ensure that a printer is connected to the selected interface and that it is ready for operation.

Archiving selection Archiving alarms and operating mode change

Archiving production protocol

..\STRG-SW\SDSW406X\EN05EE_00_5406_000.FM 01 2007.02.06

( PR0621D )

Archiving set-up protocol

Archiving panels and sequences

IMPORTANT

Many current printers only start to print out when the first page in in the printer memory is completely full.

-1-

5.5.5

Configuration of documentation (printing or saving data)

Alarms and operating mode change protocols Panels and sequences

● With these parameters you select whether you want to print out the data on the printer or save in a file. Possible inputs: ⽧ no archiving of data (no output device selected), ⽧ print out on printer 1, ⽧ print out on printer 2 (not standard),

Archiving data in a file

● If you want to save the data in a file, enter a file name for each archiving category (mode).

Archiving the set-up protocol

If you have activated the set-up protocol function, the following changes are immediately printed out or saved in a file:

BAM_207185_000_EN_10

⽧ save data in a file.

⽧ all correct value and parameter changes, ⽧ all yes/no changes, ⽧ all changes make in the sequences, ⽧ all password inputs.

Archiving the production protocol Archiving mode

The following options are available: ⽧ no archiving (deactivated), ⽧ archiving of actual values,

Machine stop, if output device not ready

● Enter “yes” here if the machine is to stop if the printer is not ready to print.

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5.5.5

..\STRG-SW\SDSW406X\EN05EE_00_5406_000.FM 01 2007.02.06

⽧ archiving of nominal and actual values.

Archiving parameter panels and sequences, printing hard copies

5.5.6

Archiving parameter panels and sequences, printing hard copies If you require an archive or printed copy of parameter panels and/ or sequences for your production documentation, proceed as follows:

..\STRG-SW\SDSW406X\EN05EF_00_5406_000.FM 01 2007.02.06

( PO0621DA PP0621DA )

BAM_207185_000_EN_10

Archiving parameter panels

1 2 3

Panel list Pre-assign panel list Archive panel list

1 2 3

Sequence list Pre-assign sequence list Archive sequence list

Archiving sequences

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5.5.6


● Touch a button in the panel list or sequence list (1). Press this key.

䡩 A selection of parameter panels / sequences is displayed.

䡩 The selected parameter panel / sequence is taken over. To remove individual parameter panels / sequences again, press the “no selection” key.

Pre-assigning the panel list / sequence list (2)

BAM_207185_000_EN_10

● Select the required parameter panel /sequence and confirm your selection with the “Y” key.

● Alternatively you can press this key (2) and then the “Y” key. 䡩 The keys of the panel list / sequence list are pre-assigned with a standard selection. Non-active parameter panels / sequences are displayed in grey lettering. To remove individual parameter panels / sequences again, touch first the “pencil” key and then “no selection”.

IMPORTANT

Check in the parameter panel whether the correct mode of archiving (file, print-out) is entered and whether the printer is connected and ready for operation.

● To archive the panel list, press this key and then the “Y” key. 䡩 Depending on the configuration the parameter panels / sequences are printed out or saved in a file.

IMPORTANT

When archiving sequences the whole programmed sequence is printed out or saved (not just the area visible in the screen).

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5.5.6


Archiving the panel list / sequences (3)


Printing hard copies (single panels)

Single parameter panels or screen shots can be printed using the key “print hard copy” (1).

BAM_207185_000_EN_10

● Display the required panel on the monitor.

1

Hard copy button

● Press the button (1). 䡩 The area visible on the screen is printed out.

IMPORTANT


( PS0621ZA )

The “Hard copy” button is only displayed when the required mode of archiving (file/printer) is entered and the printer connected and ready for operation.

-3-

5.5.6


BAM_207185_000_EN_10


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5.5.6


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Data set handling

6 Data set handling

-1-


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Data set handling

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Editing level and program designations

6.1


BAM_207185_000_EN_10

In the “program administration” parameter panel you give a designation to the program you have created, the mould and the material.

( PV0621DA )

1 2 3 4 5

Editing level

Level currently displayed Program designations Copy level, production level Copy level, preparation level Exchange levels

---> preparation level ---> production level

The controller has the following two levels:


The machine works in automatic mode with the data in the production level.

In the preparation level you can look at and edit data while the machine is operating with the data from the production level.

You can see from the “Editing level” key in the status line (1) which level is currently displayed.

-1-

6.1


With the “Editing level” key (1) you can switch over between the display of the production level and the preparation level.

Program designations (2)

● Input a designation for the current program, the mould used and the material (max. 15 characters for each) in the respective key spaces.

Copying and exchanging levels

To copy or exchange the data sets of the two levels, you have the following options:

BAM_207185_000_EN_10

Changing levels

⽧ Copy production level into preparation level (3). The data set which was previously in the preparation level will hereby be overwritten. ⽧ Copy preparation level into the production level (4). The data set which was previously in the production level will hereby be overwritten. ⽧ Exchange production level with preparation level (5). ● Select the required function and confirm this with the “Y” key.

IMPORTANT

When copying data from one level into another, you overwrite the data previously on that level. Save any important data sets beforehand!


Copying and exchanging data in the production level is only possible when the machine is in standstill and no follow-on order is programmed.

-2-

6.1

Data memory

6.2

Program administration

6.2.1

Data memory Machines with SELOGICA ’direct’ controller are equipped with an interface for CompactFlash memory cards (CF-I). The interface is located on the user console next to the controller start key.

BAM_207185_000_EN_10

CompactFlash

Controller start key Emergency stop button Reading device for transponder cards (user authorisation) Reading device for CompactFlash (memory medium USB-interface for PC keyboard


( GB1674ZA )

1 2 3 4 5

-1-

6.2.1

Data memory

Machines with SELOGICA ’direct’ controller can be optionally equipped with a diskette drive as a data memory. The diskette drive is located on the side of the control cabinet.

BAM_207185_000_EN_10

Diskette drive

1

Only pre-formatted diskettes can used on the machine (1.44 MByte). It is not possible to format them on the machine.

( GJ1582ZA )

The diskette drive operates with 3.5 inch high density diskettes. Only diskettes with the designation 3.5" 2HD (100 % error free) may be used, to ensure error-free operation.


Diskettes

Diskette drive

-2-

6.2.1

Data memory

An overwrite protection (metal slide) which prevents unintentional reformatting and overwriting the diskette is located on the left hand side of the diskette. Overwrite-protected diskettes can only be read and not overwritten.

BAM_207185_000_EN_10

Read-only diskettes

1

Overwrite protection slide on the rear side

⽧ Overwrite protection slide open = overwrite-protected (only reading possible) ⽧ Overwrite protection slide closed = not overwrite-protected (reading, writing (saving) and formatting possible)

● Insert the diskette into the diskette drive with the metal slide pointing towards the drive. The label on the diskette must point in the direction of the control cabinet. ● The diskette must click into the drive (to remove the diskette from the drive gently press the ejector button on the diskette drive).


( GD0420ZA )

Inserting a diskette

-3-

6.2.1


BAM_207185_000_EN_10

Data memory

-4-

6.2.1


6.2.2


Saving a program

You can save your programs on a compact flash card or a diskette (not standard).

BAM_207185_000_EN_10

● Call up the “Data administration” parameter panel.

Data administration ARBURG prog. file Order 1.arb

Location Diskette

Program

Compact flash

Machine model Machine size Mould Material Screw diameter Date created Time created Read only no

Order 1 Order 2

Program file Order 1.arb

File Stored program Information on selected program

● Touch the file (1) “Compact Flash“ or “Diskette“.


( PK0552DA )

1 2 3

-1-

6.2.2


Touch this key.


BAM_207185_000_EN_10

Selection

Save program here Save system here Update display

● Touch the “Save program here” field if you want to save mould/ related data sets and programmed settings (e.g. sequences). ● Touch the “Save system here” field if you want to save machine/ related data sets (e.g. calibrations).


When you touch a program, further information on this is displayed on the right side of the screen (3) (see illustration on previous page).

( PM0552D )

䡩 The program is saved in the selected file and appears in the tree structure (2).

-2-

6.2.2


Loading a program Proceed as follows to load a program onto the machine: ● Insert a data diskette into the drive or connect a compact flash card with the required program.

BAM_207185_000_EN_10

● Call up the “Data administration” parameter panel.


Location Diskette Compact Flash

Program Machine model Machine size Mould Material Screw diameter Date created Time created Read only

Order 1 Order 2

no

1 2 3

File Program Information on selected program

● Open the “Diskette” or “Compact Flash” file (1) and touch the program you want to download.


( PK0552DA )


-3-

6.2.2


Touch this key.


Load program

Rename program Delete program

BAM_207185_000_EN_10

Selection

Update display

● Touch the “Load program” field. 䡩 A safety check will ask you if you really want to overwrite the program which is currently on the machine.


( PL0552D )

● Answer “yes” by touching the “Y” key if you want to overwrite the current program, or cancel the process with the “N” key.

-4-

6.2.2


Renaming/deleting a program Pre-requirement

The correct data diskette or Compact Flash card is installed.

BAM_207185_000_EN_10


Location Diskette Compact Flash

Program Machine model Machine size Mould Material Screw diameter Date created Time created Read only

Order 1 Order 2

no


File Program Information on selected program

● Open the “Diskette” or “Compact Flash” file (1) and touch the program you want to rename or delete.


( PK0552DA )

1 2 3

-5-

6.2.2


Touch this key.


Load program

Rename program Delete program

BAM_207185_000_EN_10

Selection

Update display

Renaming a program

● Touch the “Rename Program” field 䡩 The on-screen keyboard is displayed with which you can enter the new program name.

( PL0552D )

● Confirm your input with the “Y” key or cancel the process with the “N” key.

● Touch the “Delete program” field. 䡩 A safety check will ask you if you really want to overwrite the program which is currently on the machine. ● Answer “yes” by touching the “Y” key if you want to overwrite the current program, or cancel the process with the “N” key.

-6-

6.2.2


Deleting a program


BAM_207185_000_EN_10

Working with the machine

7 Working with the machine

-1-


BAM_207185_000_EN_10

Working with the machine

-2-

Inspections when installing the machine and during initial setting into operation

7.1

Setting into Operation

7.1.1


BAM_207185_000_EN_10

Daily inspections, mould change

Inspect the following points before daily set-up and after a mould change: ● Are all safety devices functioning as stipulated? ● Is sufficient hydraulic oil filled? Never switch on the pump without oil, even briefly! ● Are the doors on the control cabinet completely closed? Dust penetration can lead to damage. ● Are the safety panels (protection against reaching into the danger area) correctly installed on the machine base (see page 4 of this chapter. ● Is an oversized mould installed, that requires additional cover? (Refer to page 3 of this chapter). ● Is the cooling water supply open? ● Does the charge pressure of the hydraulic accumulator for pilot oil correspond with the regulations? See chapter 1.1.14 (depending on machine equipment)! ● Does the charge pressure of the hydraulic accumulator for injection correspond with the regulations? Check in accordance with the enclosed manual of manufacturer (not standard). ● The maintenance schedule must be observed - see chapter 9.8! ● The first replacement filter is included in the accessories kit.

..\TECH-DAT\ALLG\EN07AA_00_306_000.FM 01 2004.02.27

● Carry out first oil change after 20,000 hours of operation.

-1-

7.1.1


⽧ Never climb on top of a machine in operation! ⽧ Always cordon off adequate space around the machine when carrying out maintenance or conversion work. Ensure that no persons other than the operator are in the vicinity of the machine.

⽧ Ensure cylinder and nozzle temperatures are correct. Incorrect temperatures can lead to combustion and explosions! ⽧ Never mix two materials that may chemically react with one another or if their processing temperatures do not correspond! ⽧ The operator must have a tool (e.g. compressed air, vacuum cleaner) available, to remove any granulate spillage.

BAM_207185_000_EN_10

⽧ Always wear protective gloves and a safety mask when carrying out maintenance work on a heated cylinder!


SAFETY INSTRUCTIONS

-2-

7.1.1


SAFETY INSTRUCTIONS

If the mould or parts attached to it protrude beyond the upper or lower half of the movable clamping platen during operation, which could present a danger of shearing or crushing, the safety clearance r1 and r2 should be inspected. In this case, the safety clearance is to be re-established by a fixed installed additional protection panel. Refer here also to the European standard EN294.

BAM_207185_000_EN_10

On machines which are open at the top, side protection panels with increased height must be provided.


( GL1046ZA )

The operating authority of the machine is responsible for ensuring that these measures are undertaken.

1

Mould (protruding)

-3-

7.1.1


BAM_207185_000_EN_10

If the openings on the machine base are not filled (closed) with additonal devices such as conveyer belt etc., the openings must be sealed off by protection panels (1) or (2) to prevent any dangerous access.

Protection panel at front end of machine base

2

Protection panel operator side/valve side of machine base

( GE1561ZA GF1561ZA )

1

-4-


Protection panels on machine base

7.1.1

Switching on the machine

7.1.2


Inspections

● Carry out the inspections as described in section 7.1.1.


The main switch is located in the control cabinet. With this you switch the power supply of the whole machine on and off.

BAM_207185_000_EN_10

● Turn the main switch to “I”.

⽧ Position “0” = OFF ⽧ Position “I” = ON. 䡩 After switching on the main switch the controller and various machine functions are tested. When these tests are completed after approx. 2 mins. the message “Press controller start key (unlock emergency stop)” appears.

..\TECH-DAT\SDALLG\EN07AB_00_5404_000.FM 01 2007.02.06

( GF1392D GB1674ZA )

● Press the controller start key (1).

1 2 3 4 5

Controller start key Emergency stop switch Reading device for transponder cards (user authorisation) Reading device for Compact Flash (memory medium) USB interface for PC keyboard

IMPORTANT

When the “automatic switch-on” function (not standard) is set to “yes” the heating becomes active when the main switch is switched on.

-1-

7.1.2


Switching on the machine cooling

● Open the cooling water supply (if it is manually closed).

Preheating the hydraulic oil

A uniform part quality can be achieved more quickly by preheating the hydraulic oil up to 40 - 45 °C (104-113°F). ● Close the safety gates.

䡩 The machine starts preheating the oil. 䡩 All automatic movements are prevented as long as the oil temperature has not reached at least 30 °C (86°F), or is not within the tolerance range T941 ± T941T.

BAM_207185_000_EN_10

Press this key to switch on the pump motor.

䡩 Pre-heating is automatically interrupted when the tolerance area is reached. The set temperature and the tolerance for the oil temperature are to be found in the “Machine cooling system” parameter panel (superior group “Valves/Switches).

IMPORTANT

In order to protect the machine, these values can only be changed by Service personnel.

-2-

7.1.2


( PH0618D )

Machine cooling system


Switching on mould temperature control

● Switch on the mould temperature control devices (if available) and check the following settings: ⽧ temperatures, ⽧ operating mode of each zone,

BAM_207185_000_EN_10

⽧ programmed procedures in the temperature nominal value control.

Switching on the heating

Press this key in the first operating panel to switch on the heating.

䡩 All movements of the screw are prevented as long as the heating zones have not reached at least the enable temperatures. 䡩 In order to ensure that the cylinder is completely heated through to the correct temperature, a further pre-defined screw enable time is waited for, after the cylinder enable time has been reached (in accordance with the size of the injection unit). All screw movements remain inhibited during this time.

IMPORTANT

While the machine is heating up to the nominal temperature the controller calculates the regulation parameters (adaptation). To ensure that these parameters are calculated correctly, the machine should be left to heat up undisturbed.


When saving a data set the determined control parameters are also saved on the diskette. When the heating has adapted and afterwards a new data set is imported, the newly imported control parameters and not the previously determined ones become valid after switching the heating briefly off and on again. Exception: if the temperature difference between switching the heating off and on is so great, a new adaptation will be carried out.

-3-

7.1.2


BAM_207185_000_EN_10


-4-

7.1.2

Mould installation ALLROUNDER 470/570 C

7.1.3


Requirements

⽧ The mould and ejector system must correspond to the installation dimensions and the ejector connection dimensions in section 1.1.2. Measure carefully before installation!

( GC1736ZA )

BAM_207185_000_EN_10

⽧ Set the operating mode to “Set Up”.

Installing the mould from the rear of the machine

When only limited space is available for the mould installation you can remove the middle console of the safety device on the rear of the machine and push back the guide rail.

1 2

guide rail threaded pin

..\TECH-DAT\CG470570\EN07AC_05_5404_000.FM 01 2007.03.21

● Slide the safety gate completely to the right. ● Remove the threaded pin for the guide rail on the support. ● Slide the guide rail to the right as far as the mechanical limit. ● When the mould installation is successfully completed, replace the middle console and the guide rail with safety gate in their original position. ● Check the function of the safety gate before setting the machine into operation.

-1-

7.1.3


Checking the mould

● Before installation the mould halves must be firmly connected together, e.g. with a bridge.

Installing the mould

● Carefully clean the clamping surfaces of the mould and machine and coat with oil or an anti-corrosion agent. ● Place an insulating plate between the mould and platen.

BAM_207185_000_EN_10

● Carry out the inspections according to section 7.1.1 and turn the machine on according to section 7.1.2. Retract the injection unit fully.

Retract the ejector fully.

● Lift the mould into the clamping unit. Centre it with the aid of the centring hole on the fixed platen and fasten it. ● If you are working with a mechanical or hydraulic quick clamping device refer to chapter 13.1 on accessories. ● Close the safety gates. ● Set the operating mode to “Set-up”.

IMPORTANT

Centre the mould only on one of the two mould platens (preferably the fixed platen). Centring on both sides could possibly lead to increased mould wear.

-2-

7.1.3


Move the movable platen carefully towards the mould until it makes contact with the mould.


Clamping the mould

● Tighten all screws. ● Remove the connections between the mould halves, e.g. bridges. ● Zero the mould as follows. ● Open the mould (s504).

BAM_207185_000_EN_10

● Ensure that the ejector coupling is opened.

IMPORTANT

With heavy moulds or with mould parts which are difficult to move, the force for mould closing in set-up mode might be insufficient. In this case, switch over briefly to manual mode, increase the clamping force and repeat the zeroing process. Set the operating mode back to “Set-up” again after completion. Ensure that all screws fixing the mould are correctly tightened! Otherwise the mould may fall out on opening! Do not open the mould before all the data for mould opening and closing have been tested and if necessary corrected!


Incorrect data can lead to mould damage!

-3-

7.1.3


Connecting the ejector without fixed coupling element

The hydraulic ejector is connected with the aid of a split coupling. Proceed as follows if you are operating with a coupling element without a fixed connection (see chapter 1.1.2):

BAM_207185_000_EN_10

● Attach the coupling element with the adjustment screw to the piston rod of the hydraulic ejector (clamp using the split coupling).

A play of 1 mm must remain between the mould ejector rod and the adjustment screw of the coupling (the rod heats up and expands during operation). ● Tighten the lock nuts again on the adjustment screw and inspect the play.

Connecting the ejector with fixed coupling element

If you are operating with a coupling element which has a fixed connection to the mould ejector rod, proceed as follows: ● Attach the coupling with the connection element to the mould ejector rod, before the mould is installed. Observe the maximum length according to chapter 1.1.2. ● Tighten the lock nuts on both sides. Install the mould and attach it as described in this chapter. ● Attach the coupling element to the piston rod of the hydraulic ejector with the aid of the split coupling. ● Retract the ejector completely and zero it (see chapter 7.1.4).

-4-

7.1.3

( GW1268ZB )

ejector piston rod coupling element split coupling


1 2 3


Coupling the ejector

● Input the maximum ejector length (s610) in the “Operating Data” function panel. Advance the ejector of the machine until the seat of the ejector bolt (coupling device) locks into the ejector coupling. ● Open the safety gate and lock the ejector coupling.

BAM_207185_000_EN_10

● Close the safety gate. ● Fully retract the ejector with the connected mould ejector rod. ● Zero the ejector as follows: You are working with the coupling as described in chapter 1.1.2. If there is no fixed connection between the coupling and the ejector, proceed as follows: ● Place the coupling adaptor with adjusting screw into the coupling and close the lock. A play of 0.6 mm must remain between the mould ejector bolt and the adjusting screw in the coupling element (the screw heats up and expands during operation).


( GA1099ZA )

● Tighten the lock nut on the adjustment screw and re-check the play.

1 2

open ejector coupling close ejector coupling

-5-

7.1.3


If you are operating with a coupling element which is fixed to the mould ejector bolt, proceed as follows:


● Tighten the lock nut on both sides, install the mould and tighten as described. Open the mould. Advance the ejector in set-up mode with a low force and slow speed until the coupling element locks into the coupling. Close the ejector coupling. Retract the ejector and zero it.

BAM_207185_000_EN_10

● Open the ejector coupling and retract the ejector completely. Before installing the mould, screw the coupling element onto the connection element of the mould ejector. Observe the maximum length (see chapter 1.1.2).

-6-

7.1.3

Zeroing the stroke measuring systems

7.1.4



The stroke measuring systems of the machine always take measurement from fixed points which cannot be changed (machinerelated zero points). You can however input all data for machine movements as absolute values.

BAM_207185_000_EN_10

To make this possible, zero points must be determined for each mould for the stroke measurement systems (mould-related zero points). This occurs in a simple manner by “zeroing” the stroke measurement system. The machine must be in “Set-up” or “manual” operating mode. The following stroke measuring systems must be zeroed:

Zeroing the mould

⽧ Mould movements

zero position = mould closed

⽧ Ejector movements

zero position = ejector retracted

⽧ Nozzle movements

zero position = nozzle on mould.

By zeroing the mould you inform the machine of the mould height and determine a starting point for the mould movement.

..\STRG-SW\SDSW404X\EN07AD_00_5404_001.FM 2007.11.08

Call up the parameter panel “Mould and cylinder parameters” with this key.

● Enter the exact mould height at s9100, if not already entered. If this is not known, enter the minimum possible mould height. Ensure that the operating mode is on “set-up”. Press this key to close the mould.

-1-

7.1.4


When the mould is closed you can zero it.

䡩 The value “0.0 mm” now appears at “Mould stroke actual value” on the monitor. This value may increase up to 0.2 mm as soon as you release the keys. This does not matter, the mould springs back a little as soon as the clamping force is released.


䡩 In addition, the exact mould height is automatically calculated and appears at s9100 in the “Mould and cylinder parameters” function panel.

BAM_207185_000_EN_10

Press and hold this key and then press the “<0>” key also. Press both keys down for approx. 2 seconds.

-2-

7.1.4


Zeroing the ejector

Press this key to open the mould.

● Call up the “Ejector retraction” parameter panel with this key.

BAM_207185_000_EN_10

Press this key to retract the ejector.

● Check whether the ejector has reached the mechanical end limit. Press and hold this key and then press the “<0>” key also. Press and hold both keys for approx. 2 seconds.

Zeroing the nozzle

Press this key to close the mould.

● Call up the “Nozzle advancement” parameter panel.


Press this key to advance the nozzle. Hold this key down and press the “<0>” key also. Press and hold both keys for approx. 2 seconds.

䡩 The value “0.0 mm” now appears on the monitor at “nozzle stroke actual value”. This value can increase up to 0.2 mm as soon as the keys are released. This does not matter, the nozzle springs back a little as soon as the nozzle contact force is removed.

IMPORTANT

Zero the nozzle at cylinder nominal temperature as far as possible.

-3-

7.1.4


BAM_207185_000_EN_10


-4-

7.1.4

Starting up the machine

7.1.5


Checking the data

You have inspected the machine according to section 7.1.1 and have switched it on according to section 7.1.2.

BAM_207185_000_EN_10

● Check all the settings for the stroke control again! This is especially important when you are working with a program which has been loaded from a diskette! Set the machine to the “Set-up” operating mode.

Checking the temperatures

● Ensure that the nominal temperatures for cylinder and nozzle heating have been reached. All movements of the screw are inhibited in automatic mode as long as the temperatures are not within tolerance. ● Ensure that the mould temperature corresponds with the nominal value (inspect temperature control devices if available).

IMPORTANT

When the machine is put into operation for the first time or when the nozzle has been changed, the nozzle and nozzle tip must be tightened after the nominal temperature is reached. The sealed parts may leak if this is not observed! Furthermore, the clamping screws on the nozzle heating system must be tightened after the first heating up. Badly fitting heating elements lead to higher energy consumption and the heating-up period is prolonged.

..\STRG-SW\SDSW404X\EN07AE_00_5404_000.FM 01 2007.02.06

Material supply

SAFETY INSTRUCTIONS

● Fill the material hopper and slide it over the feed opening.

Use a suitable climbing aid or a conveyer for the overhead refilling of the material hopper. When connecting and disconnecting the conveyor supply lines, always use suitable climbing aids. Always switch off the machine before refilling the material hopper and before carrying out assembly work on the machine!

-1-

7.1.5


Measuring the melt temperature

After the cylinder has heated up you can measure the material temperature with a dip thermometer. ● Switch over to manual control.

Press this key. The machine doses material. Keep the key suppressed until material emerges from the nozzle. Caution, hot plastic!

SAFETY INSTRUCTIONS

BAM_207185_000_EN_10

Press this key to retract the injection unit completely.

For all work on the heated plasticizing cylinder a face mask and safety gloves must be worn. If this is not observed the high temperatures of the hot plastic melt could cause serious burns!

Open the mould fully (paying attention to the supply lines attached to the mould).

Retract the plasticizing unit. Press this key again until the plasticizing unit is retracted to the mechanical limit.

Advance screw fully. ..\STRG-SW\SDSW404X\EN07AE_00_5404_000.FM 01 2007.02.06

Dosage

● Remove the material which has emerged from the nozzle. Dose manually.

You can input a special value for back pressure when dosing in manual mode with a retracted nozzle. This will prevent material emergence from the nozzle: ● Input “yes” at f404.

-2-

7.1.5


Determining the number of start-up cycles

During the start-up cycles, quality-related errors do not lead to a machine alarm. Furthermore, the parts produced are sorted out and counted as “bad parts” if you are using a sorter unit (not standard).

BAM_207185_000_EN_10

● Input the number of required start-up cycles after “heating off” at f090. Input the number of required start-up cycles to be carried out after “auto interruption” at f090A.

Start-up order of injection units 1

On two-component machines you can define at which production stage the respective injection unit is to become active at parameters f9426 and f9427. (On three- and four-component machines parameters f9428 and f9429 are additionally available, see chapter 20.2.1). ● If you do not want an order of sequence, input the following values: f9426 = 1 injection unit 1, f9427 = 1 injection unit 2. 䡩 Both injection units become active in the first production stage. ● If you are producing a part which consists of a pre-form and a finished part (i.e. produced in two production stages), define the order of sequence as follows: f9426 = 1 injection unit 1, f9427 = 2 injection unit 2. 䡩 Injection unit 1 is active in the first stage and produces the preform. Injection unit 2 becomes active in the second stage and completes the moulded part. (For more information see chapters 20.1.15 and 20.1.16).


Opening the mould

Open the mould completely (to s504).

Retract the ejector completely (to s613).

Starting automatic operation

● Select the required operating mode. ● Press manual/auto in order to switch on automatic (LED lights up). ● The LED on the start key flashes. ● Press the start key. The first cycle starts.

1

only on multi-component machines -3-

7.1.5


BAM_207185_000_EN_10


-4-

7.1.5

Important information on various plastics

7.2

Change of material, end of production

7.2.1


BAM_207185_000_EN_10

Compatibility

When changing the material, never mix two materials that may react with one another or of which the processing temperatures are not compatible! This could lead to residue formation, combustion and explosions. Always observe the correct cylinder and nozzle temperatures! The information supplied by the material supplier must be complied with! Incorrect temperatures can lead to combustion or explosion! If the processing temperatures of the old and new materials are not the same, the plasticizing cylinder must first be cleaned. Inject a relatively insensitive material for this purpose (PE, PP or PMMA - see table in 7.2.2. page 1). Only then should you inject the new material.

Peculiarities with POM or PC

Before or after processing with POM or PC the plasticizing cylinder must be cleaned with an insensitive material. Inject with PE, PP or PMMA (see table). Better still: purge with a cleaning material (see chapter 9.1.3) The nozzle must be cleaned before or after the processing of PC! It is advisable to have an additional nozzle for the processing of PC.

..\TECH-DAT\ALLG\EN07BA_00_306_000.FM 01 2004.03.01

PC must not be allowed to cool in the plasticizing cylinder as it will create a strong bond with the surface of the screw and cylinder wall. The material must be completely removed from the cylinder at the end of production (see above). The cylinder temperature should not sink below 150 - 170 °C (302 - 338°F) during interruptions in production or machine down time.

Peculiarities of PVC

SAFETY INSTRUCTIONS

After processing with PVC, the entire plasticizing unit must be cleaned. Remove the plasticizing screw for this purpose (see 9.1.3 for instructions).

Cleaning and maintenance work on a heated cylinder as well as changing of colour or material must only be undertaken when a face mask and safety gloves are worn.

-1-

7.2.1


Peculiarities with PVDF

The melt of PVDF must not come in contact with products containing Boron (screw, cylinder, nozzle, certain types of fibre glass) or MoS2, because spontaneous degradation of the melt occurs which can lead to fire or the formation of gas. It is also important to use only colouring agents, fillers and reinforced materials which are recommended by the manufacturer.

ARBURG plasticizing cylinders and screws are stamped with a number on the rear of the shaft. If you are in doubt, please contact ARBURG and state these numbers to ensure that your components are suitable for the processing of PVDF.

PVDF must not be processed with plasticizing units that have been hardened with Boron (ARBID version). A high pressure build-up in the plasticizing cylinder can result from the chemical reaction. Danger of explosion! It is absolutely essential to observe the processing instructions stipulated by the material manufacturer.

..\TECH-DAT\ALLG\EN07BA_00_306_000.FM 01 2004.03.01

SAFETY INSTRUCTIONS

BAM_207185_000_EN_10

ARBID plasticizing components (cylinder, screw, check valve) have a layer containing Boron and must not be used for the processing of PVDF.

-2-

7.2.1

Adjustment values and processing information for injection moulding materials

7.2.2


Europe

..\TECH-DAT\ALLG\EN07BB_00_306_000.FM 01 2004.05.05

( TB00039C )

BAM_207185_000_EN_10

Moulding material

Nozzle-end cylinder temp.

PS

°C 160-230

SB SAN

Mould temperature

1

Injection pressure bar

°C

Holding pressure bar

Back pressure bar

Remarks (see footnotes)

20-80

650-1550

350-900

40-80

160-250 200-260

50-80 40-80

650-1550 650-1550

350-900 350-900

40-80 40-80

2

ABS PPO mod.

180-260 245-290

50-85 75-95

650-1550 1000-1600

350-900 600-1250

40-80 60-90

2 3

PVC - rigid PVC - soft

160-180 150-170

20-60 20-60

1000-1550 400-1550

400-900 300-600

40-80 40-80

3

5 6 7

3

5

2

2 3 4

7

CA CAB

185-225 160-190

60-80 60-80

650-1350 650-1350

400-1000 400-1000

40-80 40-80

2 3

CP PMMA

160-190 220-250

60-80 20-90

650-1350 1000-1400

400-1000 500-1150

40-80 80-120

2

PC PSU, PES

290-320 320-390

85-120 100-160

1000-1600 900-1400

600-1300 500-1100

80-120 80-120

2

7

2

7

PE-LD

210-250

20-40

600-1350

300-800

40-80

PE-HD PP

250-300 220-290

20-60 20-60

600-1350 800-1400

300-800 500-1000

60-90 60-90

2 3

2

4

PA 6.6 PA 6

270-295 230-260

20-120 40-120

450-1550 450-1550

350-1050 350-1050

40-80 40-80

2 4

PA 6.10 PA 11

220-260 200-250

20-100 20-100

450-1550 450-1550

350-1050 350-1050

40-80 40-80

2 4

60-90 60-90

2 4

3 4

PA 12 PA amorph

200-250 260-300

20-100 70-100

450-1550 900-1300

350-1050 300-600

POM PETP

185-215 260-280

80-120 20-140

700-2000 800-1500

500-1200 500-1200

40-80 80-120

PBTP PPS

230-270 300-360

20-60 20-200

800-1500 750-1500

500-1200 350-750

80-120 40-80

FEP ETFE

340-370 315-365

150-180 80-120

1

2 4

4

2

7

2 3 4 2 3 4 2

7 5

8

5

8

If no other empirical values are available: Nozzle temperature = adjust to nozzle-end cylinder temperature. Reduce the cylinder temperature by 5-10°C for each heater zone approaching the feed zone: max. temperature difference between the nozzle-end and feed zone 20°C. Set the nozzle heater band and the following heater band to the same temperature if more than 2 heater zones are available

2

Process granulate only when dry!

3

Thermally sensitive! Set upper temperature value only with a high shot count (short dwell time in cylinder)..

4

Highly wear resistant cylinder assembly recommended for processing reinforced materials.

5

Do not use shut-off nozzle, work with open nozzle only

6

Injection recommended without check valve.

7

Highly wear resistant cylinder assembly recommended (bi-metal cylinder and PK screw)

8

Anti-corrosion cylinder assembly required (BMK cylinder and screw of Ni alloy)

-1-

7.2.2


USA Injection pressure psi

Holding pressure psi

Back pressure

Remarks (see footnotes)

PS

°F 1 320 - 446

°F 68 - 176

9427 - 22480

5076 - 13053

580 - 1160

SB SAN

320 - 482 392 - 500

122 - 176 104 - 176

9427 - 22480 9427 - 22480

5076 - 13053 5076 - 13053

580 - 1160 580 - 1160

2

ABS PPO mod.

356 - 500 473 - 554

122 - 185 167 - 203

9427 - 22480 14503-23206

5076 - 13053 8702 - 18129

580 - 1160 870 - 1305

2 3

PVC - rigid PVC - soft

320 - 356 302 - 338

68 - 140 68 - 140

14503-22480 5801 - 22480

5801 - 13053 4351 - 8702

580 - 1160 580 - 1160

3

5 6 7

3

5

psi

2

2 3 4

7

CA CAB

365 - 437 320 - 374

140 - 176 140 - 176

9427 - 19580 9427 - 19580

5801 - 14503 5801 - 14503

580 - 1160 580 - 1160

2 3

CP PMMA

320 - 374 428 - 482

140 - 176 68 - 194

9427 - 19580 14503-20305

5801 - 14503 7251 - 16679

580 - 1160 1160 - 1740

2

PC PSU, PES

554 - 608 608 - 734

185-248 212 - 320

14503-23206 13053-20305

8702 - 18854 7251 - 15954

1160 - 1740 1160 - 1740

2

7

2

7

PE-LD

410 - 482

68 - 104

8702 - 19580

4351 - 11603

580 - 1160

PE-HD PP

482 - 572 428 - 554

68 - 140 68 - 140

8702 - 19580 11603-20305

4351 - 11603 7251 - 14503

870 - 1305 870 - 1305

2 3

2

4

PA 6.6 PA 6

518 - 563 446 - 500

68 - 248 104 - 248

6526-22480 6526-22480

5076 - 15228 5076 - 15228

580 - 1160 580 - 1160

2 4

PA 6.10 PA 11

428 - 500 392 - 482

68 - 212 68 - 212

6526-22480 6526-22480

5076 - 15228 5076 - 15228

580 - 1160 580 - 1160

2 4

870 - 1305 870 - 1305

2 4

3 4

PA 12 PA amorph

392 - 482 428 - 572

68 - 212 158 - 212

6526-22480 13053-18854

5076 - 15228 4351 - 8702

POM PETP

365 - 419 500 - 536

176 - 248 68 - 284

10152-29007 11603-21755

7251 - 17404 7251 - 17404

580 - 1160 1160 - 1740

PBTP PPS

446 - 518 572 - 680

68 - 140 68 - 392

11603-21755 10877-21755

7251 - 17404 5076- 10877

1160 - 1740 580 - 1160

FEP ETFE

644 - 698 599 - 689

302 - 356 176 - 248

2 4

4

2

7

2 3 4 2 3 4 2

7 5

8

5

8

1

If no other empirical values are available: Nozzle temperature = adjust to nozzle-end cylinder temperature. Reduce the cylinder temperature by 5-10°C for each heater zone approaching the feed zone: max. temperature difference between the nozzle-end and feed zone 20°C. Set the nozzle heater band and the following heater band to the same temperature if more than 2 heater zones are available.

2

Process granulate only when dry!

3

Thermally sensitive! Set upper temperature value only with a high shot count (short dwell time in cylinder).

4

Highly wear resistant cylinder assembly recommended for processing reinforced materials.

5

Do not use shut-off nozzle, work with open nozzle only!

6

Injection recommended without check valve.

7

Highly wear resistant cylinder assembly recommended (bi-metal cylinder and PK screw)

8

Anti-corrosion cylinder assembly required (BMK cylinder and screw of Ni alloy)

-2-

BAM_207185_000_EN_10

Mould temperature

( TB00039C )

Nozzle-end cylinder temp.

7.2.2

..\TECH-DAT\ALLG\EN07BB_00_306_000.FM 01 2004.05.05

Moulding material

End of production, stopping the machine

BAM_207185_000_EN_10

7.2.4



Observe the important information contained in section 7.2.1 at the end of production!

Stopping the material supply

● Slide the feed hopper to the blocked position. ● Allow the machine to continue processing until the dosage volume cannot be achieved due to lack of material. The controller goes on alarm.

Ejection of last part

● Set to “manual” operating mode. Press the alarm reset key (erase alarm).

Press this key. The nozzle retracts and stops. Press the key again until the nozzle is retracted to the mechanical end limit.

Open the mould.

Press these keys alternately to eject the part.

..\STRG-SW\S-SW306X\EN07BD_00_306_000.FM 01 2004.03.02

Purging the cylinder

● Set the operating mode to “Set Up”. Press these keys alternately until material stops emerging from the nozzle.

SAFETY INSTRUCTIONS

If the material feed is located overhead, always use a suitable climbing aid to reach the material hopper. Always switch off the machine before carrying out any work on a climbing aid.

-1-

7.2.4


Cleaning the mould

● Clean the mould. Apply an anti-corrosion agent if necessary.

IMPORTANT

The movable mould platen must only sink by a maximum of 1 mm/ min. If it sinks more than 1mm/min., the clamping unit must be checked and if necessary the seals renewed. Always move the peripheral devices out of the mould clamping area before interrupting the production or switching off the machine. Collisions or movement problems due to stroke monitoring could otherwise occur.

● Switch off the pump motor. ● Switch off the heating. ● Shut off the supply of cooling water. The individual cooling circuits can remain open. You do not need to adjust them again when you restart operation. ● Switch off the main switch. The main switch must remain at position “1” if you are operating with automatic switch on.

..\STRG-SW\S-SW306X\EN07BD_00_306_000.FM 01 2004.03.02

Switching off the machine

BAM_207185_000_EN_10

With machines with vertically arranged clamping unit there is a tendency for the movable mould platen to sink slowly downwards when the production is interrupted or the machine is switched off. This sinking tendency is caused by very slight oil leaks that can occur in spite of flawless seals.

-2-

7.2.4

User authorisation with transponder cards

7.4.3

User authorisation with transponder cards The SELOGICA DIRECT controller is fitted with a reading device for transponder cards. The transponder reader supports the EUROMAP65 card format (see www.euromap.org) We recommend using transponder cards when particular importance is placed on user identification and access control.

BAM_207185_000_EN_10

If the transponder reading device is activated on your machine, this symbol is displayed in red in the status display on your screen.

After you have inserted your transponder card in the reading device, the contents of your card are displayed in the parameter panel “User authorisation”.

( PS0552Z PT0552Z )

Authorisation levels User name

Authorisation levels

User number

Authorisation level selection

active superuser

Authorisation stage Safety key (code) Group identification of machine

**** ARBURG


Group identification card Language Country Valid until

Safety key f1208 (*-*****) = ****

-1-

7.4.3

User name

Here the name of the user on the transponder card is displayed (maximum 16 ASCII characters, figures and letters). This field can also be empty.

User number

The the user number is displayed. This field can also be empty.

Authorisation stage

Here the authorisation stage of the user, in accordance with EUROMAP65 is displayed. The authorisation is always valid for the configuration stipulated by the superuser. This field can also be empty for the Superuser. Possible levels 1, 2, 3. EUROMAP recommends using 1 as the lowest and 3 as the highest level.

BAM_207185_000_EN_10


The respective symbol is also displayed in the status line on the screen. Symbol for authorisation level 1

Symbol for authorisation level 2

Symbol for authorisation level 3


Authorisation levels disabled

Symbol for superuser

The superuser can: ⽧ carry out all controller functions, ⽧ define new authorisations and group identifications.

-2-

7.4.3

BAM_207185_000_EN_10


Machine group ID

Here the group ID of the machine is displayed.

Card group ID

Group ID on the transponder card. Only when this matches the group ID of the machine will you receive the access rights to the defined authorisation group.

Language

Language ID (3-letter code acc. to ISO 639-2). This field can also be empty.

Country

Country ID (2-letter code acc. to ISO 3166-1). This field can also be empty.

Valid until

End of validity. If the expiry date lies in the past, the controller ignores the card. If no validity date is entered, the transponder card is valid indefinitely.

IMPORTANT

The transponder card is your personal access authorisation to the controller and thus protects against unauthorised inputs. ● Never give your card to an unauthorised person. This applies in particular to the superuser. ARBURG includes 5 transponder cards with each transponder reader on delivery. Each card has the highest user authorisation. More cards can be ordered under the part no. 237676.


If you want to modify the cards and create a superuser card for yourself, you require the programming device for transponder cards together with the necessary SAFELOG PC software and an operating manual. To program the transponder cards you further require a PC with USB connector and MICROSOFT® WINDOWS® operating system ME/2000/XP. The superuser transponder card is required to access the changing functions and to define the individual authorisation levels. ● Treat your transponder card therefore with as much care as you would your personal bank card!

-3-

7.4.3


Undertaking changes

The superuser can undertake changes in the parameter panel “Authorisation levels”.

IMPORTANT

Determine as quickly as possible which person is to hold the function of superuser.

BAM_207185_000_EN_10

The superuser should then define the authorisation levels of the other users as quickly as possible.

1

2

3

Machine selections

no

nos

yes

Physical parameters/optimisation

yes

no

yes

Machine cycle

yes

yes

yes

Automatic control

yes

yes

yes

Monitoring

no

yes

yes

Quality assurance

no

yes

yes

Meas. data acquisition/charts

no

no

yes

Data records administration

no

yes

yes

Robot programming

no

yes

yes

Freely programmable parameter panel

no

yes

yes

Protocols/printing functions

no

yes

yes


Authorisation level:

( PS0552Z PT0552Z )


Machine selections f1121 (no / yes) = yes

-4-

7.4.3


Call up the “Authorisation levels” parameter panel with this symbol key.

● Select the required authorisations for all users of this level. Use the “Y” key to activate authorisations and the “N” key to deactivate them.

BAM_207185_000_EN_10

⽧ The authorisations are newly defined for all users of this stage. ⽧ Each user only has access to the controller functions which are set to “yes” in this authorisation level for his personal user ID. ⽧ The authorisation levels can be defined differently on each machine by the superuser.

IMPORTANT


Only the superuser can change authorisation levels.

-5-

7.4.3


Key switch option

Machines equipped with the “Key switch” option permit access to most controller functions, without using a transponder card. ⽧ Key switch “ON” Permits access to all controller functions with the exception of those which are reserved for the superuser only. An inserted transponder card of authorisation levels 1 to 3 has no influence.

Safety key (code)

The safety key (code) is used to check the validity of the card. The machine accepts only cards which have the same safety key as set on the machine.

BAM_207185_000_EN_10

⽧ Key switch “OFF”: The machine behaves in the same way as a machine without the “key switch” option and answers only to cards.

On delivery, all machines and cards have the same safety key. In order to prevent unauthorised persons from operating your machine, you can assign an individual safety key valid only for your factory.

CAUTION

Only alter the safety key on your machine after you have created new cards which are programmed with the new safety key (code). As soon as the safety key is changed on the machine the old card IMMEDIATELY loses its validity. It is then impossible to input data.

If you want to change your safety key: ● First create new cards with a new individual safety key using the programming kit.

EUROMAP65 stipulates that all machines, no matter from which manufacturer, are given the same safety key. This key is then valid for all machines which conform with EUROMAP65. In order to differentiate between individual user and machine groups, you should use the group ID (see following page).

-6-

7.4.3


● Then you can input a new individual safety key on your machine. Your old card then immediately becomes invalid. Use one of the new, previously programmed cards to operate the machine.


Machine group ID

The group ID provides a further possibility of denying access to your machines to unauthorised persons, in addition to the safety key. While the safety code is intended to primarily prevent outsiders from gaining access to your machines, the group ID serves the purpose of limiting the authorisation of individual employees to certain machines only.

BAM_207185_000_EN_10

Example

In a machine hall there are two groups of machines. The employees operating the machines of group 1 are only to have access to machines of their group (independent of authorisation level). The same applies to group 2. The superuser allocates the group ID, e.g.“Dept. 1” to all machines of group 1 and “Dept. 2” to all machines of group 2. The safety key is the same for all machines. The head of this department, who oversees both groups, requires access to all machines. For this purpose, so-called “wildcards” are required. Wildcards contain retainers for one or more characters in the code or ID. For example a “?” stands for one character and “*” stands for any number of characters. The head of department is therefore given the group code “Dept. ?”. The head of the whole firm who requires access to all machines in the factory will be given the group ID “*”. If he were given the code “B*” he would only have access to machines with a code starting with the letter “B”.

CAUTION


Even a superuser card is only valid for machines which match the group ID. A superuser can exclude himself from the operation of a machine by inputting a group ID which does not match his own card. A superuser card with the group ID “*” (asterisk) matches all machines, no matter which group ID it has.

-7-

7.4.3


With this option you can activate or deactivate authorisation levels. ⽧ “Active” means : The rules stipulated in the selection panel “Authorisation levels” apply for permission to access the controller functions.

⽧ “Inactive“ means: The “Authorisation levels” selection panel is not available. Each user has general user authorisation without transponder card. A superuser card must be used only for parameters reserved for the superuser only. (If your machine is equipped with the “key switch” option, the user authorisation is now only determined by the key switch. )

BAM_207185_000_EN_10

(If your machine is equipped with the “key switch” option, this only applies when the key switch is set to “OFF”, because when the key switch is set to “ON” access to controller functions is granted anyway.



-8-

7.4.3


BAM_207185_000_EN_10

Access denied

I have changed the safety code or group ID of the machine and now have no access to correct this.

Service functions Special functions code Machine equipment display

Boot controller with next switch-on no

Save machine status Service code:


( PS0552Z PU0552Z )

ID for generating service code

Boot controller with next switch-on f9999 (no / yes) = no

● Change to the “Service functions” function panel. Note the number for the “ID for creating reset code“. Please consult ARBURG stating this and your machine number. Transponder card reader is defective

The transponder card reader appears to be defective and I need access to a machine. ● Proceed as described above under “Access denied”. 䡩 After your transponder card reader has been repaired, as superuser you can reactivate the authorisation levels as required.

-9-

7.4.3


BAM_207185_000_EN_10


- 10 -

7.4.3

Safety instructions for horizontal parting line injection

7.5.6


BAM_207185_000_EN_10

If your machine is being operated in L-position or in working position 4 or 5 (vertical clamping unit and horizontal injection unit - this depends on the equipment of the machine), the nozzle points directly towards the operating area of the user.

Explosive combustion

Some plastics can ignite or are subject to an explosive combustion when exposed to high temperatures too long.

Caution!

Combustion can also occur when the safety gate is open. Operating the machine in the above mentioned working positions can thus lead to a higher risk of burns.

SAFETY INSTRUCTIONS

All work in the nozzle and mould area may only be carried out when a face mask and protective safety gloves are worn. Set lower values of speed and pressure before purging or dosing the cylinder until empty. During this process of purging and dosing until empty, do not stay in the area where the material is being ejected. Ensure the correct temperature settings and drying regulations are observed, as prescribed by the material manufacturer (danger of combustion).

Attach a deflection plate to the mould when possible which covers the material ejection zone during opening of the mould (see construction suggestion on the following page).

..\TECH-DAT\ALLG\EN07EF_00_306_001.FM 01 2006.05.17

( GF1716Z )

The operating personnel (e.g. for insertion or removal work) must also wear protective clothes and a face mask.

-1-

7.5.6


In order to increase safety in the parting line during horizontal injection, we recommend attaching a deflection plate to the mould, which covers the material ejection zone during opening of the mould. In this way, you prevent hot plastic entering the mould or spraying out into the open during purging or dosing the cylinder until empty or in the case of combustion. The deflection plate must be manufactured individually for each mould and is not available for this reason from ARBURG.

( GI1309ZA )

BAM_207185_000_EN_10

The following illustration indicates a possible variation as to the arrangement of the deflection plate..

1 2 3 4 5

..\TECH-DAT\ALLG\EN07EF_00_306_001.FM 01 2006.05.17

Deflection plate for horizontal parting line

support pressure spring deflection plate stop nozzle

-2-

7.5.6

What to do in the case of malfunctions



BAM_207185_000_EN_10

8

-1-


BAM_207185_000_EN_10


-2-

Valves / switches

8.1

Diagnosis

8.1.1

Valves / switches

BAM_207185_000_EN_10

In the parameter panels of the superior group “Valves/switches” you will find all displays of the valves and switches and the current actual values. ● Select the parameter panels of the valves/switches group.

( PV0552DA )

1

Select another group

The parameter panels can be grouped in two or more sections, depending on the equipment installed on the machine.


The blue key (1) on the right next to the parameter panel keys tells you that more parameter panels are available than can be displayed.

-1-

8.1.1

Valves / switches

Changing the group

● Touch the blue key (1) to change the group. 䡩 The following window appears:

Select group

● Touch the key of the required group. 䡩 The small window is faded out and the parameter panels of the selected group are displayed.

BAM_207185_000_EN_10

Valves/switches part 2

IMPORTANT


( PX0552Z )

All parameter panels of the “Valves/switches” group have only a display function i.e. they cannot be edited here.

-2-

8.1.1

Valves / switches

Parameter panels

A variety of parameter panels can appear here, depending on the equipment of the machine. The following are a few examples: ⽧ Valves/switches of control circuits, ⽧ Valves/switches of electric main pump, ⽧ Valves/switches of heating and motor, ⽧ Cooling system of machine,

BAM_207185_000_EN_10

⽧ Valves/switches of safety gate, ⽧ Valves/switches of monitoring, ⽧ Valves/switches of programmable outputs, ⽧ Valves/switches of mould, ⽧ Valves/switches of ejector, ⽧ Valves/switches of corn pulls, ⽧ Valves/switches of nozzle, ⽧ Valves/switches of screw, ⽧ Valves/switches of cylinder, ⽧ Valves/switches of moulded parts, ⽧ Valves/switches of robot system, ⽧ Valves/switches of external protective enclosure, ⽧ Valves/switches of lubrication, ⽧ Valves/switches of configurable in/outputs, ⽧ Valves/switches of special signals.


The following illustration shows an example of the lay-out of a parameter panel.

-3-

8.1.1

Valves / switches

BAM_207185_000_EN_10

Valves/switches of safety gate

1 2 3 4

Switch display : “marked” Switch display : “not marked” Selected (touched) valve/switch Switch designation explained in text

The status of a valve/switch is displayed by a filled circle (1), or empty circle (2). ⽧ The filled circle means: “Switch display marked” or “Switch is set” (logic 1).

( PW0552DB )

⽧ The empty circle means: “Switch display not marked“ or “Switch is not set“ (logic 0).


A worded description of the selected (touched) valve/switch is displayed in the editing box (4).

-4-

8.1.1

“Alarms” parameter panels and alarm functions

8.2

Alarm functions

8.2.1


BAM_207185_000_EN_10

Alarms, warnings, information

1 2 3 4 5

Alarms Warnings Information Alarm functions Alarm protocol

You will find all active error messages in the parameter panels of “alarms”, “warnings” and “information”.

When the error has been rectified, the respective error message is deleted from the parameter panel.


( PT0597DA )

Should more than one error occur at a time, the most important alarm message is displayed in the alarm line. All others are saved in these parameter panels in the order of their occurrence and displayed.

-1-

8.2.1


Alarm functions.

Alarm functions Alarm time Alarm message

via time

BAM_207185_000_EN_10

Duration of alarm message

Text for external alarm input S932

Alarm time

Alarm time t951

● Input the required alarm time here. We recommend: ⽧ 5 - 10 minutes for thermally non-sensitive plastics 䡩 If an alarm occurs on the machine, the programmed switch-off function is carried out after the time entered here has expired and the machine switches off.

● Enter the required type of alarm message here. ⽧ When “via time” is selected, the alarm functions are switched off again after a specified length of time. ⽧ When “continually on” is selected the alarm functions are not switched off until the “Alarm reset” button on the operating pad is pressed.

Alarm message duration t952

This parameter is displayed when “via time” has been selected at f956 “alarm message”. ● Enter the required duration of the alarm message here. 䡩 Should an alarm occur on the machine, the alarm functions are started and the respective alarm message appears on the screen. The alarm functions are switched off again after the length of time entered here has elapsed.

-2-

8.2.1


Alarm message f956

( PJ0552D )

⽧ 1 - 3 minutes for thermally sensitive plastics

Alarm sequence

8.2.2

Alarm sequence With the SELOGICA controller it is possible to create a separate sequence for the case of an alarm. In this sequence you determine which processes in the production cycle are not to be carried out when an alarm has occurred. ● Touch any symbol in the sequence.

BAM_207185_000_EN_10


䡩 The following window appears: Visible marking

No markings Omit in dry-cycle Omit in alarm Omit in automatic Mould position monitoring


( PR0550D )


-1-

8.2.2

Alarm sequence

Activating an alarm sequence

● Touch the “omit in alarm” field.

Removing the markings

If you want to remove individual markings, touch first the respective symbol and then this key.

BAM_207185_000_EN_10

䡩 The window is faded out and the controller marks the symbols which are usually not carried out in the alarm sequence with a red exclamation mark.

● Touch the “Delete marking” field. 䡩 The window is faded out and the marking removed from the selected symbol.

If you want to add markings to other symbols, touch the respective symbol and then this key.

䡩 The window is faded out and the selected symbol is marked accordingly.

( PF0552Z )



Adding further markings

-2-

8.2.2

Alarm sequence

Removing the alarm sequence from the display

If you want to remove the alarm sequence from the display, first touch any symbol in the sequence and then this key. 䡩 The following window appears: Visible marking

BAM_207185_000_EN_10

No markings Omit in dry-cycle Omit in alarm Omit in automatic Mould position monitoringg End position monitoring

● Touch the “No markings” field.


( PR0550D )

䡩 The window and all markings are removed from the display.

-3-

8.2.2


BAM_207185_000_EN_10

Alarm sequence

-4-

8.2.2


BAM_207185_000_EN_10

Cleaning and maintenance work

9 Cleaning and maintenance work

-1-


BAM_207185_000_EN_10

Cleaning and maintenance work

-2-

Removing the injection unit

9.1

Cleaning the plasticizing cylinder, screw and nozzle

9.1.1


BAM_207185_000_EN_10

The injection unit must be removed in order to carry out maintenance work on the screw or check valve. . ● Before removing the injection unit it must be secured by a suitable crane or stabilizing device on the machine. ● Loosen the lock nuts on the injection unit support. ● Unscrew the threaded pins fully, see illustration.

..\SPR-ZYL\Z400800\EN09AA_07_306_000.FM 01 2006.02.17

( GN1702ZA )

● Pull the injection unit back on its supports.

1 2

SAFETY INSTRUCTIONS

lock nut threaded pin

Maintenance work on a heated cylinder must only be carried out when a face mask and protective gloves are worn. Before removing the injection unit it must be secured by a suitable crane or a securing device! Danger! Injection unit can fall if not stabilizied and cause considerable injury!

-1-

9.1.1

..\SPR-ZYL\Z400800\EN09AA_07_306_000.FM 01 2006.02.17

BAM_207185_000_EN_10


-2-

9.1.1

Swivelling the injection unit

9.1.2

Swivelling the injection unit For maintenance and cleaning work in the nozzle or non-return valve region, the injection unit can be swivelled diagonally to the front (see illustration). ● Remove the injection unit as described in section 9.1. ● Retract the injection unit on its support rails to the mechanical end limit (1).

( GP1702ZA )

BAM_207185_000_EN_10

● Swivel the injection unit to the front on the operating side (2).

..\SPR-ZYL\Z400800\EN09AB_09_401_000.FM 01 2006.06.12

SAFETY INSTRUCTIONS

Before swivelling the injection unit it must be secured with a suitable crane or a securing device on the machine. Danger! Injection unit can fall if not stabilized! Considerable damage or injury can be caused! When swivelling the injection unit, ensure that the hydraulic hoses do not become caught or twisted (danger of damage). It is not possible to change the cylinder when it is in the swivelled position.

-1-

9.1.2

..\SPR-ZYL\Z400800\EN09AB_09_401_000.FM 01 2006.06.12

BAM_207185_000_EN_10

Swivelling the injection unit

-2-

9.1.2

Cleaning the plasticizing cylinder and screw with a cleaning agent

9.1.3


SAFETY INSTRUCTIONS

For all maintenance work on the heated cylinder, always use a face guard and safety gloves!

BAM_207185_000_EN_10

Shut-off nozzles must be removed before cleaning the plasticizing cylinder (danger of blockage). Open nozzles can remain installed.

Cleaning

● Push the feed hopper into the locked position. ● If the material hopper is located overhead, use a suitable climbing aid to reach the material hopper. Always switch off the respective machine before carrying out any work on a climbing aid. ● Retract the injection unit fully and purge and dose the cylinder until empty. ● Adjust the cylinder temperatures to the upper values for the respective type of material (see 4.4.3). A higher temperature ensures a better cleaning performance. ● Set a high back pressure and medium screw rotation speed. ● Pour cleaning agent into the feed opening using a beaker. Do not insert hard tools into the feed opening. Do not let dirt fall the feed opening. ● Allow the screw to rotate until the cleaning agent has fully displaced the old material in the plasticizing cylinder and the cleaning agent emerges clean. 䡩 If this is not the case, see “Problems during cleaning” on the next page. ● Set the cylinder temperatures to the required value.

\\SPR-ZYL\ALLG\EN09AC_00_306_001.FM 01 2007.11.06

● Push the feed hopper (with new material) back over the feed opening. ● Allow the screw to rotate until the new material has fully displaced the cleaning agent from the plasticizing cylinder. ● Install the nozzle, if it was removed, as follows: ⽧ Thoroughly clean thread and fit of the nozzle and apply a little heat-proof grease. ⽧ Tighten the nozzle according to 9.1.4. ● Reset the desired screw rotation speed and back pressure.

-1-

9.1.3


Problems during cleaning

1. The plasticizing screw does not rotate or it does not supply material. ● Increase the screw rotational speed. If this does not help, increase the cylinder temperature too. 2. No material emerges from the nozzle. Nozzle is blocked.

⽧ “Rozylit”, Alfred Engelmann, D-30900 Wedemark, in particular when working with high processing temperatures, e.g. with PC. ⽧ “NCR cleaning granules”, Normann Rassmann GmbH & Co., D20459 Hamburg.

\\SPR-ZYL\ALLG\EN09AC_00_306_001.FM 01 2007.11.06

Recomended cleaning agents (German manufacturers)

BAM_207185_000_EN_10

● Unscrew the nozzle tip (right hand thread). If this does not help, remove the nozzle and if necessary remove the screw and clean the non-return valve (see 9.1.5).

-2-

9.1.3

Nozzle removal, cleaning and installation injection unit 800 (15.3 oz]

9.1.4

Nozzle removal, cleaning and installation injection unit 800 (15.3 oz) The following information applies to the cylinder module for thermoplastic processing.

Removing the nozzle

● Unscrew the nozzle tip.

BAM_207185_000_EN_10

● Remove protective cover. ● Unscrew head screws and remove them. ● Remove sensor from the nozzle. ● Remove nozzle heater band. ● Remove the nozzle. Cleaning the nozzle

● Clean the nozzle and head screws thoroughly and apply a light coating of heat-proof grease to the thread and fit of the nozzle and to the screws.

..\SPR-ZYL\Z800\EN09AD_14_307_001.FM 01 2004.06.18

( GM1582ZA )

We recommend: assembly paste PBC PolyButylCuprysil (available from ARBURG in 1kg container under PN 101064).

1 2 3 4

lock nut head screw cone nozzle

IMPORTANT

The diameter on the cone of the nozzle must correspond to the screw diameter.

-1-

9.1.4


Installing the nozzle

● Insert the nozzle into the cylinder. ● Screw the lock nut onto the cylinder. Do not tighten it (it should only make light contact)! Do not attach the nozzle heating band just yet. ● Ensure that the lock nut is correctly positioned (see illustration). ● Position the lock nut so that each bolt makes contact with a bore on the nozzle.

BAM_207185_000_EN_10

● Insert one of the bolts into the lock nut and retract the lock nut slightly in order to find the correct position relative to the nozzle. ● Tighten the bolt manually. ● Attach the remaining bolts and tighten them manually. ● Screw the sensor back into the nozzle.

( GM1120ZA )

● Ensure that the sensor contacts the nozzle.

lock nut open nozzle positioning pin

IMPORTANT

Ensure lock nut is positioned correctly (see illustration). The bolts must be positioned in the bores on the nozzle. Otherwise the positioning pin for the nozzle could be damaged. ● Ensure that the sensor contacts the nozzle (see chapter 9.5.2)

-2-

9.1.4

..\SPR-ZYL\Z800\EN09AD_14_307_001.FM 01 2004.06.18

1 2 3


● Tighten the six bolts with a torque wrench to the value listed under A in the table below, working crosswise. The sequence from 1 to 6 must be observed (see illustration).

( GL1120ZA )

BAM_207185_000_EN_10

● Repeat the process and increase the torque to the value listed under B in the table below. Injection unit

Screw size

800 / 15.3 oz

M16 1 / 0.6”

800 / 15.3 oz

M 20 / 0.8”

1

Torque A B 100 Nm 200 Nm / 73.75 ft lbs 147.5 ft lbs 100 Nm 300 Nm / 73.75 ft lbs 221.3 ft lbs

not standard

IMPORTANT

The temperature sensor on the nozzle tip must be unscrewed before the open nozzle is removed.

..\SPR-ZYL\Z800\EN09AD_14_307_001.FM 01 2004.06.18

It is not absolutely necessary to remove the lock nut when removing the nozzle. The nozzle can be removed when the six bolts are removed. All parts must be heated up to the same temperature before the screws are tightened.

-3-

9.1.4

..\SPR-ZYL\Z800\EN09AD_14_307_001.FM 01 2004.06.18

BAM_207185_000_EN_10


-4-

9.1.4

Removing, cleaning and reinstalling the screw, injection unit 800 (15.3 oz)

9.1.5

Removing, cleaning and reinstalling the screw, injection unit 800 (15.3 oz) The following information applies to the cylinder module for thermoplastic processing.

BAM_207185_000_EN_10

SAFETY INSTRUCTIONS

⽧ When carrying out maintenance work on the heated cylinder always wear a face mask and protective gloves. ⽧ Do not use hard tools when cleaning. A cleaning brush can be found in your spare parts kit. ⽧ Avoid burning off plastic remnants with a blow torch (loss of hardness or distortion may be the result). ⽧ Use a solvent only when it is absolutely necessary (flammable, vapours are often harmful).

Removing the screw

● Heat up the cylinder module and inject until empty. ● Unscrew the nozzle tip. ● Remove the nozzle safety cover. ● Unscrew the nozzle temperature sensor (switch off the nozzle heating via the controller. ● Loosen head screws of nozzle fastening.

( GA1182Z )

● Loosen the lock nut of the nozzle and remove it while the cylinder module is still installed, see chapter 9.1.4. ● Remove the nozzle. ● Open the screw cover on the support housing. ● Remove the cylinder module. Proceed as described in chapter 9.4.

..\SPR-ZYL\Z800\EN09AE_12_307_000.FM 01 2004.06.17

● Remove the screw manually from the front of the cylinder.

-1-

9.1.5

Removing, cleaning and reinstalling the screw, injection unit 800 (15.3 oz)

Cleaning the screw

● Clean all parts thoroughly. All surfaces that make contact with the plastic must be free from plastic residues. ● Check the cleanliness of the feed zone. Do not remove plastic residue with hard tools; use a heat gun to melt it down.

Installing the screw

● Slide the screw into the cylinder when it is cold. The non-return valve should insert easily.

● Re-insert the nozzle with lock nut (as described in chapter 9.1.4) and tighten it. ● Reinstall the cylinder module, see chapter 9.4. ● Reattach the nozzle heating band (tighten the attachment screws evenly).

BAM_207185_000_EN_10

● Apply a light coating of heat-resistant grease ( e.g. Molykote paste U) to the threads on the lock nut and nozzle tip as well as the fit on the nozzle body and nozzle tip.

● Screw in the thermocouple tightly (Is the bore clean?). ● Ensure that the sensor contacts the nozzle. ● Reattach the nozzle safety cover.

IMPORTANT

All parts must be heated up to the same temperature before the screws are tightened.

-2-

9.1.5

..\SPR-ZYL\Z800\EN09AE_12_307_000.FM 01 2004.06.17

( GN1582Z )

● Screw on the nozzle tip and tighten it. Torque value for nozzle tip: 300 Nm / 221.3 ft lbs.

Screw tips

9.2

Changing the screw tips

9.2.1

Screw tips

BAM_207185_000_EN_10

The screw is normally equipped with one of the following two screw tips: Ribbed tip with non-return valve and seat ring

ribbed screw tip non-return valve seat ring screw

..\SPR-ZYL\Z060-13X\EN09BA_00_306_000.FM 01 2004.04.08

( GU1362ZA )

1 2 3 4

-1-

9.2.1

Screw tips

● Avoid impact stress and knocks on ARBID cylinder units and check valves made of sintered materials! ● When carrying out maintenance work on a heated cylinder (heating switched on), always wear a face mask and protective gloves.

( GV1362ZA )

SAFETY INSTRUCTIONS

smooth screw tip without non-return valve screw

..\SPR-ZYL\Z060-13X\EN09BA_00_306_000.FM 01 2004.04.08

1 2

BAM_207185_000_EN_10

Smooth tip without non-return valve

-2-

9.2.1

Tools necessary for changing the nozzle tips

9.2.2

Tools necessary for changing the nozzle tips ⽧ Key for ribbed tip (the correct key for the ribbed tip is to be found in your spare parts kit). ⽧ Clamping jaws for smooth screw tip.

BAM_207185_000_EN_10

⽧ Wrench for rotating the screw at the drive end.

Key for ribbed tip with nonreturn valve

(depending on the machine equipment)

\\SPR-ZYL\ALLG\EN09BB_00_306_002.FM 01 2004.04.26

( GB1063Z GT1552Z )

Key for ribbed tip with nonreturn valve (highly wear resistant version)

-1-

9.2.2

Tools necessary for changing the nozzle tips

Construction suggestion for clamping jaws for dismantling screw tips without non-return valve.

BAM_207185_000_EN_10

Clamping jaws

⽧ Clamping jaws dimension D = d + 0.1 mm, ⽧ d = screw diameter d (see illustration below), ⽧ Dimensions in brackets apply to screw diameter 65 to 80.

( GK1552Z GW1362ZA )

Screw tip without non-return valve d + 0.1mm

1 2

smooth screw tip without non-return valve screw \\SPR-ZYL\ALLG\EN09BB_00_306_002.FM 01 2004.04.26

Screw tip without non-return valve

-2-

9.2.2

Installing / removing the screw tips

9.2.3


Removing the screw

● Clamp the ribbed tip with the correct key; clamp the smooth tip with the clamping jaws in a vice. ● Unscrew the screw tip (right hand thread).

● Carefully clean the head of the screw, the fits of the screw tip and the seat ring. ● Grease the thread of the ribbed screw tip or smooth screw tip evenly with a thin coating of heat-resistant grease (e.g. molycote paste U). ● Push the non-return valve (bushing) and the seat ring onto the ribbed tip (observe the direction of mounting of the seat ring and the non-return valve, see illustration).

( GB0815Z )

BAM_207185_000_EN_10

Installing the screw

..\SPR-ZYL\Z030-13X\EN09BC_00_307_003.FM 01 2005.11.04

● Manually turn the ribbed tip or the smooth screw tip firmly into the screw. ● Clamp the ribbed tip with the correct key, the smooth screw tip with the correct clamping jaws in a vice.

-1-

9.2.3


● Tighten the screw at the drive end with a torque wrench. See table below for the correct torque values.

BAM_207185_000_EN_10

Torque values

15 / 0.59

20 / 14.64

18 / 0.71

25 / 18.45

7.388

20 / 0.79

25 / 18.45

99.481

190.883

22 / 0.87

30 / 22.15

7.389

190.880

25 / 0.98

30 / 22.15

7.390

190.838

30 / 1.18

35 / 25.84

55.302

187.859

35 / 1.38

40 / 29.53

7.392

183.408

40 / 1.47 45 / 1.77 50 / 1.97 55 / 2.17 60 / 2.36 65 / 2.56 70 / 2.76 80 / 3.15

50 / 36.91 65 / 47.98 65 / 47.98 80 / 59.06 80 / 59.06 80 / 59.06 90 / 63.38 100 / 73.75

7.393 7.394 42.480 103.607 107.909 164.691 141.804 -

182.728 171.259 172.580 176.536 180.026

190.886

Injection unit size Euromap/

US oz

30 + 70 60 100 150 / 170 250 / 290 350 / 400 675 / 800 1300

0.6 + 1.4 1.3 2.3 3.4 / 3.7 6.1 7.4 / 8.2 13.8 / 15.3 29.1

Wrench (3) part no 223546 154681 109618 120676 109619 118507 107931 189503

180.027 206.380

IMPORTANT

Ensure that all parts have heated up to the same temperature before tightening the thread.

-2-

9.2.3

( GU1552ZA )

Key for ribbed tip highly wearwear-resistant resistant version (1) version (2) part no. part no. 111.959

..\SPR-ZYL\Z030-13X\EN09BC_00_307_003.FM 01 2005.11.04

Ø mm/inch

Torque value Nm / ft lbs

Changing the cylinder, injection unit 800 (15.3 oz)

9.4

Changing the plasticizing cylinder

9.4.1


Removing the plasticizing cylinder (thermoplastics)

● Set low injection pressure and speed values. ● Inject and purge the cylinder until empty.

BAM_207185_000_EN_10

● Advance the screw fully and then retract it by 10-20 mm. ● Advance the injection unit to the foremost end position. ● Pull the screw cover back onto the support housing. ● Open the screw coupling. 䡩 If your machine is equipped with a position-regulated screw, observe page 5 in this chapter.

( GP1112ZA )

Screw coupling, injection unit 800

1 2

open closed

● Remove the circlip on the groove nut. ..\SPR-ZYL\Z800\EN09DA_12_307_000.FM 01 2004.06.17

● Remove the groove nut (with a sickle spanner).

-1-

9.4.1


1 2

circlip groove nut

( GE1227ZA GM1625ZB )

● Attach the clamp to the guide rail of the cylinder module so that it contacts the front of the support stirrup (see illustration).

1 2

Support rail on plasticizing cylinder Attach clamp here

● Retract the injection unit fully by pressing the “nozzle retraction” key. 䡩 The cylinder module is retained in place during retraction by the clamp and thus pulled out of the support housing. ● Remove the injection unit as described in chapter 9.1 and pull it back onto the support rails. ● Suspend the cylinder module on the two suspension rings and remove it with the crane.

-2-

9.4.1

..\SPR-ZYL\Z800\EN09DA_12_307_000.FM 01 2004.06.17

Attaching the clamp

BAM_207185_000_EN_10

Groove nut and circlip


..\SPR-ZYL\Z800\EN09DA_12_307_000.FM 01 2004.06.17

( GC1226Z )

BAM_207185_000_EN_10

Suspension of thermoplastics cylinder, injection unit 800

-3-

9.4.1


Installing the cylinder

Pre-requirement: The injection unit is fully retracted and pulled back onto the support rails. ● Lift the cylinder module with a crane into the support stirrups of the injection unit.

Attaching the clamp

● Attach the clamp to the guide rail of the cylinder module so that it contacts the rear of the support stirrup (see illustration). ● Push the injection unit into the support elements and secure it with the threaded pins and the lock nuts.

Support rail on plasticizing cylinder Attach clamp here

( GM1625ZA )

1 2

BAM_207185_000_EN_10

● Push the cylinder module into the support housing.

● Open the screw cover. ● Attach the groove nut and tighten it. ● Secure the groove nut with the circlip. ● Close the screw coupling.

Adapting the control parameters

● Load the data set for the next production with the new cylinder module. ● Heat up the cylinder until the actual temperatures concur with the nominal values. ● Save the data set again.

-4-

9.4.1

..\SPR-ZYL\Z800\EN09DA_12_307_000.FM 01 2004.06.17

● Push the screw manually into the screw coupling.


Screw coupling with position regulation 1

On machines with a position-regulated screw or pressure accumulator, the injection unit coupling is equipped with a cover with which the screw can be clamped in the screw coupling without play.

BAM_207185_000_EN_10

This ensures that even the slightest inaccuracies in the control are eliminated, which might otherwise occur when a certain play is present in the screw coupling.

Head screw Coupling cover Locking element Coupling segment Pressure spring Coupling housing

..\SPR-ZYL\Z800\EN09DA_12_307_000.FM 01 2004.06.17

( GC1425ZA )

1 2 3 4 5 6

1


9.4.1


Opening the screw coupling

On machines which are equipped with a no-play coupling cover, the screw cover cannot be opened until the coupling cover is unclamped. ● Unscrew the four clamping screws at the front of the screw coupling by a few turns.

● Loosen the four clamping screws at the front of the screw coupling, if they are tightened. ● Push the screw into the coupling and close the locking element. ● Tighten the screw coupling according to the following table.

Coupling cover Clamping screws in coupling cover

Coupling cover for position regulation Part no. Torque

( GP1112ZC )

1 2

Injection unit 800 135598 145 Nm / 107 ft lbs

..\SPR-ZYL\Z800\EN09DA_12_307_000.FM 01 2004.06.17

Closing the screw coupling

BAM_207185_000_EN_10

● Turn the locking element and remove the screw.

-6-

9.4.1

Reinstalling the cylinder after it has been dismantled

9.4.3

Reinstalling the cylinder after it has been dismantled If you have completely dismantled the cylinder module, e.g. in order to clean the cylinder, proceed as follows to reinstall it: ● Install the cylinder model as described in chapter 9.4.1. ● Screw on the groove nut (3) manually until it makes contact with the support housing.

BAM_207185_000_EN_10

● Open the clamping screw (1) on the clamping element (2). ● Switch on the cylinder heating and heat up the cylinder to the nominal temperature. ● Move the nozzle up to the installed mould and allow the nozzle contact pressure to build up. ● Tighten the clamping screw (1) while the nozzle contact pressure is built up. ● Retract the nozzle.

..\SPR-ZYL\Z60-13X\EN09DC_00_306_000.FM 01 2004.04.19

( GV1609ZA )

● Tighten the groove nut (3).

IMPORTANT

Proceed in the same way if you want to install a new cylinder module or one which has been repaired. This assembly step does not need to be carried out with cylinder modules which were installed in the machine before leaving the factory. If the clamping screw (1) is not tightened under nozzle contact pressure, the clamping element (2) can move during operation. As a result the cylinder module will become loose even if the groove nut is tightened and secured with a circlip.

-1-

9.4.3

..\SPR-ZYL\Z60-13X\EN09DC_00_306_000.FM 01 2004.04.19

BAM_207185_000_EN_10

Reinstalling the cylinder after it has been dismantled

-2-

9.4.3

Replacing the thermocouples on the plasticizing cylinder, injection unit 800 (15.3 oz)

9.5

Installing the thermocouples

9.5.1


BAM_207185_000_EN_10

Removal

● Switch off the machine at the main switch, for safety reasons. ● Remove the two suspension rings (ring bolts) at the top of the cylinder module. ● Remove the upper protective cover on the cylinder module. ● Pull off the insulator pads (push-button fastening) of the respective heating zone. ● Unscrew the screw-in tab on the thermocouple and pull it out of the bore. ● Remove the front side cover on the operator side of the cylinder module. 䡩 The heating distribution channel with the supply connections is now freely accessible. ● Unclamp the thermocouple to be replaced from the plug connection. Observe the designation (B11-B16). ● Unscrew the spiral spring out of the cover panel on the heating distribution channel.

..\SPR-ZYL\Z800\EN09EA_14_307_000.FM 01 2004.06.17

( GB1226ZA )

● Pull out the thermocouple with the connection leads.

1 2 3 4

thermocouple plug connector, connection for thermocouples connection diagram heating distribution channel in cylinder module

-1-

9.5.1


● Push the connection leads of the thermocouple from the top through the respective bore in the cover panel of the heating distribution channel. ● Screw the spiral spring 4-5 rotations into the bore in the cover panel. ● Place the connection wire of the thermocouple into the terminal in the heating distribution channel.

● Reattach the front side cover on the cylinder module. ● Clean the bore of the thermocouple, if necessary (otherwise you may get an inaccurate measurement!) ● Unscrew the screw-in connection tab of the thermocouple far enough back onto the spiral spring to ensure an unhindered insertion of the thermocouple into the bore.

BAM_207185_000_EN_10

● Clamp the wires into the plug connectors. Observe the designations (B11-B16).

● Push the thermocouple into the bore until the tip touches the bottom. ● Screw the connection tab in until the clearance from the screw-in thread is 5 mm. ● Squeeze the spiral spring together and screw in the tab as far as the end limit. 䡩 The spiral spring now presses the thermocouple against the bottom of the bore.

( GA1378ZA )

● Reattach the top protection panel on the cylinder module and secure it with the suspension rings (ring bolts).

1 2 3 4

Screw-in tab Thermocouple Bore for thermocouple Plasticizing cylinder

䡩 When the heating is switched on, any false polarity of the thermocouples or a cable rupture is recognized and indicated on the screen in an error message.

-2-

9.5.1

..\SPR-ZYL\Z800\EN09EA_14_307_000.FM 01 2004.06.17

Installation

Exchanging the thermocouples on the nozzle, injection unit 800 (15.3 oz)

9.5.2

Exchanging the thermocouples on the nozzle, injection unit 800 (15.3 oz) The following information applies to cylinder modules for thermoplastic processing.

Removal

● Switch the machine off at the main switch for safety reasons.

BAM_207185_000_EN_10

● Remove the plug connector from the thermocouple on the front side of the cylinder module. ● Remove the screw-on muff from the thermocouple. ● Remove the thermocouple from the bore.

Installation

● Clean the bore of the thermocouple thoroughly (otherwise you may get an inexact measurement). ● Unscrew the muff on the thermocouple far enough back onto the spiral spring so that an unhindered insertion of the thermocouple into the bore is possible (see table for dimensions). ● Insert the thermocouple into the bore until the tip makes contact with the base of the bore. ● Screw the screw-in muff onto the spiral spring until the clearance to the end of the bore is approx. 5mm. ● Squeeze the spiral spring together and screw the muff on as far as it will go. 䡩 The spiral spring now pushes the thermocouple against the base of the bore.

..\SPR-ZYL\Z800\EN09EB_14_307_000.FM 01 2004.06.17

● Insert the plug connector of the thermocouple into the plug coupling on the front side of the cylinder module.

-1-

9.5.2

Exchanging the thermocouples on the nozzle, injection unit 800 (15.3 oz)

Installation length X 175 mm / 6.9”

BAM_207185_000_EN_10

Machine Injection unit 800 (15.3 oz)

IMPORTANT

..\SPR-ZYL\Z800\EN09EB_14_307_000.FM 01 2004.06.17

( GX1112Z )

Ensure that the sensor makes contact with the nozzle.

-2-

9.5.2

Changing the heating elements, injection unit 800 (15.3 oz)

9.6

Changing the heating elements

9.6.1


BAM_207185_000_EN_10

The following information applies to the cylinder module for thermoplastic processing.

Removal

● Remove the cylinder module as described. Leave it sitting on the supports. ● Remove the screws on the upper safety cover of the cylinder module. ● Remove the top upper safety cover on the cylinder module. ● Open the push-on cover on the insulator pads of the respective heating zone. ● Unscrew the screw-in tabs from the thermocouples. Remove the thermocouple from the bore. ● Remove the side cover panels on the cylinder module. 䡩 The heating distribution channel with the supply connections is now freely accessible. ● Open the two clamping elements surrounding the heating shells and remove them. ● Remove the connection cables of the heating shells on the terminal strip in the heating distribution channel (open the contact on the terminal strip by pushing it with a screwdriver from below). ● Mark the thermocouple connections and their respective heating zones. ● Pull out the connection of the heating shell to be changed.

..\SPR-ZYL\Z800\EN09FA_14_307_000.FM 01 2004.06.17

● Remove the heating shell with its connection cables.

-1-

9.6.1

BAM_207185_000_EN_10


Installation

upper heating shell lower heating shell heating shell clamping element insulator pad

Proceed in reverse order. Lay the cable in the heating distribution channel in the brackets provided.

( GD1182ZA )

1 2 3 4

IMPORTANT ..\SPR-ZYL\Z800\EN09FA_14_307_000.FM 01 2004.06.17

After heating up the heating elements for the first time, the clamping screws must be tightened again. Incorrectly fitting heating elements can cause a higher energy consumption and prolong the heating-up period.

-2-

9.6.1

Changing the nozzle heating band, injection unit 800 (15.3 oz)

9.6.2

Changing the nozzle heating band, injection unit 800 (15.3 oz) The following information applies to the cylinder module for thermoplastic processing. ● Switch off the main switch on the machine for safety reasons.

BAM_207185_000_EN_10

● Unscrew the nozzle tip (1). ● Remove the protective cover (2) on the nozzle. ● Disconnect the plug for the nozzle heating band (4) (plug-coupling at the front end of the cylinder module). ● Open the clamping screws (3) on the nozzle heating band. ● Remove the nozzle heating band. ● Attach the new heating band to the nozzle. The screws on the nozzle heating band must be located at the top. ● Tighten the screws on the nozzle heating band. ● Reattach the protective nozzle cover. ● Screw the nozzle tip back in. ● Tighten the nozzle tip (torque value = 300 Nm / 221.5 ft lbs).

..\SPR-ZYL\Z800\EN09FB_14_307_000.FM 01 2004.06.17

( GM1582ZB )

● After the first heating up, the clamping screws (3) must be retightened.

1 2 3 4 5

nozzle tip protective cover clamping screws nozzle heating band nozzle

-1-

9.6.2

..\SPR-ZYL\Z800\EN09FB_14_307_000.FM 01 2004.06.17

BAM_207185_000_EN_10

Changing the nozzle heating band, injection unit 800 (15.3 oz)

-2-

9.6.2

External heating-up of the cylinder module

9.7


BAM_207185_000_EN_10

Explanation

SAFETY INSTRUCTIONS

A plug connector is available as optional equipment for your machine in order to heat up the cylinder module outside the machine (e.g. for cleaning purposes). The plug connector serves as an extension cable between the cylinder module and the machine.

● For all work on the heated cylinder a face mask and safety gloves are to be worn. Never stand in front of the nozzle when the cylinder has not completely cooled down or is not completely empty. Discharging material or escaping gas explosions could cause serious burns! The plug connector must only be connected or disconnected when the cylinder heating is switched off!

The temperature regulation of the individual heating zones is carried out via the machine controller.

..\SPR-ZYL\ALLG\EN09G_00_306_003.FM 01 2005.12.05

The plug connectors for the external cylinder heating: Thermoplastic cylinder

Part no.

30, 60, 70, 100, 170, 250, 290 150, 350, 400 675, 800 1300, 2100, 3200

157109 130331 110806 184324

Requirement

In order for the plug connector to be connected on the machine side, there must be no cylinder module installed on the machine.

Making the connection

● Switch the cylinder heating off. ● Plug the plug connector for the external cylinder heating into the plug socket on the cylinder support housing of the injection unit. ● Plug the socket side of the plug connector into the cylinder module. ● Check the values for the temperature adjustment and adjust if necessary. ● Switch on the heating. 䡩 The cylinder module will be heated up to the pre-selected temperature.

-1-

9.7


Plug connectors for cylinder heating Injection unit 30, 60, 70, 100, 170, 250, 290

BAM_207185_000_EN_10

Injection unit 150, 350, 400

Injection unit 675, 800

..\SPR-ZYL\ALLG\EN09G_00_306_003.FM 01 2005.12.05

( GW1613Z GX1613Z GY1613Z GZ1613Z )

Injection unit 1300, 2100, 3200

-2-

9.7

Maintenance schedule

9.8

Maintenance and inspection work

9.8.1

Maintenance schedule Observe the schedules stated here. This will help to prevent unnecessary malfunctions and repairs and extend the lifetime of your machine. See chapter 9.9 for suitable lubricants.

..\TECH-DAT\CG400800\EN09HA_18_5404_003.FM 01 2007.06.05

( GA1516Z GB1516Z GC1516Z GD1516Z GE1516Z GF1516Z GI1516Z )

BAM_207185_000_EN_10

The plastic coating of the machine must not be treated with cleaning agents that contain ketones e.g. acetone, methanol, ethanol, glycol, PER, trichloroethane.

All plastic parts on the machine, including the viewing panels on the safety guards, must not be cleaned with alcohol or detergents containing solvents.

SAFETY INSTRUCTIONS

The safety devices must be inspected regularly: ⽧ after each mould change, ⽧ at the beginning of each work shift, ⽧ once a week in continual operation.

The operating hours already completed are displayed in the “Machine parameter display“ parameter panel. Stipulated maintenance work

Location:

oil/grease

01-xx

machine base

clean

02-xx

clamping unit

spray

03-xx

safety guards

filter change

04-xx

injection unit

oil change

05-xx

plasticizing unit

pressure accumulator

06-xx

hydraulic system

inspect/replace

07-xx

cooling water distributor

08-xx

-

09-xx

robot system

10-xx

electric system

The position numbers in the following tables correspond to those in the picture on the following page.

-1-

9.8.1


Location

Remarks

Regularly

Check safety guards/cover panels after each mould change and at the beginning of each work shift; once a week in continual operation.

-

Regularly

Check condensation in the pneumatic system.

-

If necessary, drain off condensation

every 3 months

Check hydraulic hoses.

-

See 1.2.5

every 3 months

Check machine installation; if necessary readjust alignment

-

See 1.1.5

every 3 months

Visual check of hydraulic system for leakages

every 6 months

Water cooled control cabinets: check water cooler in the control cabinet for leakages; check water flow of control cabinet cooler; if necessary clean nozzle on the return flow.

10-10

every 12 months Air-cooled control cabinet only: clean fleece filter of ventilator, replace if necessary. as required

Top up gear lubricant oil of unscrewing unit (only if necessary). Fill up to the oil inlet screw or when lid open, the cog wheels must be not quite covered with oil (CLP320).

visible on exterior ventilation grid -

Depending on machine equipment

every 200 hours Clean columns of injection unit and apply a light coating of oil. More frequently if required.

03-01

every 200 hours Clean tie-bars of clamping unit and apply a light coating of oil (only in those areas where no movements take place). More frequently if required.

04-01

every 200 hours Clean running surfaces of support rails and apply a light coating of oil (CLP220). Grease rollers (KP2K).

04-00

every 500 hours Grease sliding blocks of movable mould platen (KP2K grease).

04-02

every 500 hours Clean guide columns of the safety gate on clamping unit and apply a light coating of oil (CLP220 oil).

03-01

every 500 hours Clean guide columns of the sliding panels of the injection unit and apply a light coating of oil (CLP220 oil).

04-01

every 500 hours Oil guide bushing of hydraulic ejector.

02-07

every 500 hours Oil guide bushing of coupling bolt on hydraulic ejector (CLP220 oil).

02-07

only with quickclamping system

every 500 hours Grease movable mould platen (CLP220 oil); Do not overfill lubrication bowls! Check more often when operating with high mould temperatures. At least every 3 months.

02-02

8 lubricating nipples

every 2000 hours Grease bearings on injection bridge (3) with Norplex LKR2 from Rhenus (400 g cartridge = Part No. 529524). Remove sealing screw (1) on vertical injection unit. Top up with grease using grease gun (2) until grease emerges from the sealing screw bore (1). Screw in sealing screw again on vertical injection unit. (Sealing screw (1) must not be mounted on horizontal injection unit.)

04-00

see illustration

every 2000 hours Grease rollers on injection unit support with KP2K. Apply a light coating of oil (CLP220) to running surfaces of support rails.

04-00

-2-

BAM_207185_000_EN_10

WHAT and WHERE?

Depending on machine equipment

9.8.1


When / No. operating hours


WHAT and WHERE?

Location

Remarks

every 5000 hours Replace oil filter set. At least every 12 months.

01-35

See chapter 9.8.3

every 5000 hours Clean part of oil cooler through which water flows and decalcify.

01-35

See chapter 9.8.3

every 5000 hours Check air filter in tank lid and replace if necessary. To do this remove id, unscrew black housing, change filter insert, close housing, replace lid.

01-35

every 5000 hours The state of hydraulic hoses is to be checked by a suitably qualified person for their operational safety.

-

See chapter 1.2.5

every 20,000 hours

Change hydraulic oil (HLP46); clean oil tank. Have the oil checked by an oil company after 12 months at the latest. Top up with oil when the message “Oil level under nominal value” appears at S925 (=nominal value).

01-35

See chapter 9.8.2 and 9.8.4

every 20,000 hours

Always check the condition of the toothed ring in the drive coupling when changing the oil.

06-48

every 20,000 hours

Change the oil filter set with each oil change. (Fine filter part no. 115.311), clean the oil cooler thoroughly and decalcify it.

01-35

See chapter 9.8.3

every 6 years

Check hydraulic hoses and replace them if required. (Maximum duration of usage 6 years).

06-50

See chapter 1.2.5 and 1.2.6

See 9.8.2


( GD1621ZA )

BAM_207185_000_EN_10

When / No. operating hours

1 2 3

Sealing screw (only on vertical injection unit) Lubricating nipple Injection bridge

-3-

9.8.1

-4-

02-07

02-07

02-02

01-35

01-35

01-35

06-48

06-50

04-00


04-02

03-01 ( GF1705ZA )

Every 6 years:

Every 20,000 hours:

Every 5,000 hours:

Every 2,000 hours:

Every 500 hours:

Every 200 hours:

As required:

Every 12 months:

Every 6 months:

Every 3 months:

Regularly:

Location:

Number:

BAM_207185_000_EN_10


Reference numbers:

10-10

03-01

04-01

04-01

04-00

9.8.1

Oil change, inspection of toothed ring

9.8.2


Schedule

Change the hydraulic oil after every 20,000 operating hours. Carefully observe the oil changing schedule noting the date of each change (see 9.8.1).

BAM_207185_000_EN_10

Procedure

For the oil change, the oil should have a temperature of between 45 °C and 50 °C (thin bodied). ● Open the tank cap and pump out the oil. ● Remove the tank cover (underneath the injection unit). ● Remove oil residue. ● Clean the tank thoroughly. Do not use fibrous cloths or cleaning wool! ● Pour in new oil according to section 1.1.8. ● Vent the hydraulic system according to section 9.8.4.


⽧ With each oil change also replace the oil filters (see 9.8.3) and the air filter insert in the tank cover. ⽧ Cater for absolute cleanliness during the oil change. Contamination will shorten the machine’s lifetime. ⽧ Use only oil brands and types listed in section 9.9 (DIN 51524 version 2/H-LP46/DIN 51519/ISO VG46). ⽧ Get your oil supplier to test the oil quality at least once a year, independently of the service intervals.

..\TECH-DAT\ALLG\EN09HB_00_306_001.FM 01 2006.04.25

⽧ Do not mix oil brands. Do not change the oil brand without good reason. Otherwise foam and sludge could result.

IMPORTANT

The warranty for the hydraulic system will cease to apply, if the above maintenance instructions are not complied with!

-1-

9.8.2


The drive motor and the hydraulic pump unit are connected by a claw coupling. Between the steel hubs (1 and 3) there is a plastic toothed ring (2) which serves as a dampening element.

BAM_207185_000_EN_10

Inspection of toothed ring

● Inspect this toothed ring visually for: ⽧ any damage, cracks or signs of wear, ⽧ signs of porosity. ● Replace the toothed ring (2) if necessary.

IMPORTANT

..\TECH-DAT\ALLG\EN09HB_00_306_001.FM 01 2006.04.25

( GV1707ZA )

If the steel hubs (1 and 3) also show signs of wear, the whole coupling must be replaced.

-2-

9.8.2

Maintenance of the oil filter / oil cooler

9.8.3

Maintenance of the oil filter / oil cooler An oil filter is installed on the rear of the machine base.

Replacing the oil filter

● Switch off the main switch, for reasons of personal safety. ● Pull out the filter insert and insert a new one. For the first replacement a filter insert is included in your machine tool kit. ● Screw on the lid again tightly. ● Make sure the filter is inserted the correct way up, see illustration.

..\TECH-DAT\C_S_ALLG\EN09HC_00_306_001.FM 01 2004.05.04

( GS1561ZA )

BAM_207185_000_EN_10

● Unscrew the cover of the filter housing.

1 2

Cover Filter insert

-1-

9.8.3

Maintenance of the oil filter / oil cooler

Maintenance of the oil cooler

The oil cooler must be cleaned and decalcified at least once a year. ● Switch the machine off and let it cool down. ● Close off the water supply to the machine. ● Remove the supply and return hoses from the water distributor to the oil cooler.

● Connect a commercially available decalcifying unit. The operating pressure must not exceed 16 bar.

IMPORTANT

Carefully observe the maintenance schedule and note the date of each replacement (see 9.8.1):

BAM_207185_000_EN_10

The cooler is decalcified fully assembled:

The filter must be replaced every 5,000 hours. The machine monitors the condition of the filter. When the monitor displays the following message: “Tip 4 Oil filter dirty, (replace)”, replace the filter immediately. The warranty for the hydraulic system will become void if the above maintenance instructions are not complied with!

When undertaking maintenance work on the cooler/filter system, always switch off the machine and let it cool down first. Hot machine surfaces can cause serious burns! De-pressurize all hoses before disconnecting them. ..\TECH-DAT\C_S_ALLG\EN09HC_00_306_001.FM 01 2004.05.04

SAFETY INSTRUCTIONS

Danger of injury through liquids spurting out!

-2-

9.8.3

Venting the hydraulic system

9.8.4


When is it necessary?

Venting of the hydraulic system is always necessary if it is possible that large amounts of air have penetrated the system. The system should be vented after one of the following circumstances:

BAM_207185_000_EN_10

⽧ after filling the oil tank for the first time ⽧ after an oil change or other work on the hydraulic system ⽧ after a long machine standstill.

Air in the hydraulic system?

Air in the hydraulic system can be recognized by: ⽧ foaming of the oil ⽧ sudden, jerky injection and clamping unit movements ⽧ abnormal noises.

How to vent

● Set low speeds and pressures for the initial axis movements. 1. Open and close the clamping unit 8 - 10 times in manual control (total stroke). 2. Advance and retract the nozzle 8 - 10 times (total stroke). 3. Advance and retract the screw 8 - 10 times (total stroke). If there is still material in the cylinder, the cylinder and nozzle heating must be switched on beforehand and the nominal temperatures must be reached. 4. Inspect the oil level after venting and top up if necessary (see 1.1.8).

\\TECH-DAT\ALLG\EN09HD_00_306_000.FM 01 2004.04.27

● Load the start program from the system diskette and repeat steps 1 - 4 several times until the hydraulic system is completely vented.

IMPORTANT

● Remove the mould before venting the hydraulic system. Sudden, jerky machine movements can cause damage to the mould!

-1-

9.8.4

\\TECH-DAT\ALLG\EN09HD_00_306_000.FM 01 2004.04.27

BAM_207185_000_EN_10


-2-

9.8.4

Maintenance and repair work on the hydraulic system

9.8.6


SAFETY INSTRUCTIONS

BAM_207185_000_EN_10

All remaining pressure must be relieved before work commencement. The main switch of the machine must be switched off and secured (with a padlock) against unintentional switch-on. ● Attention: System under pressure! Before commencing work relieve remaining oil pressure (see manometer). Not observing these instructions can lead to risk of (fatal) injury!

Pressure level inspection

( GW1338Z )

Maintenance and repair works on the hydraulic system of the machine must only be undertaken by personnel with special knowledge and experience in hydraulics.

Before you undertake any work on the hydraulic system, you must ensure that all remaining pressure has been discharged. This should be inspected with the aid of a manometer from the machine spare parts kit (see illustration).

● Provide a mechanical support for all movements which may cause risk of injury. ● Screw the coupling of the manometer onto the following measuring nipples successively:

\\TECH-DAT\ALLG\EN09HF_00_306_002.FM 01 2007.06.19

⽧ Measuring nipple M1.2 = clamping pressure ⽧ Measuring nipple M1.14 = mould closing ⽧ Measuring nipple M1.44 = mould opening ⽧ Measuring nipple M2.3 = nozzle contact pressure ⽧ Measuring nipple M3.1 = injection side pressure ⽧ Measuring nipple M6.5 = ejector pressure The nipples are designated accordingly on the hydraulic distribution manifold. ⽧ Measuring nipple M7.5 = core pull pressure

-1-

9.8.6


Reducing the remaining pressure

Any pressure remaining in the system should be discharged through the respective nipple. ● Slowly screw a measuring cable without a manometer attached onto the measuring nipple. 䡩 As soon as the quick coupling of the measurement nipple opens, the pressure is relieved as some hydraulic oil emerges. ● Collect the emerging oil in a container.

Support of vertical hydraulic units

Vertically positioned hydraulic units (clamping unit, injection unit) must be supported before commencing any maintenance or conversion work to prevent them from slipping. Do not remove any hydraulic connections before the support is effective. Not observing these points can lead to danger of very serious injury.

As a result of the forces of gravity acting on vertically positioned cylinders, the moving cylinder and consequently the entire unit can fall down when the hydraulic connections are opened. The hydraulic oil which is displaced by gravity will be discharged under the resulting pressure. ● For this reason, a support must be installed before any maintenance and repair work is carried out on the machine, to prevent the hydraulic unit slipping down.


SAFETY INSTRUCTIONS

BAM_207185_000_EN_10

● Inspect the remaining pressure once again.

-2-

9.8.6


Suggestion for the support of a vertical hydraulic unit Clamping unit:

⽧ Measure the clearance between the fixed and movable mould platen. ⽧ Cut 2 thick pieces of squared timber to this measurement.

BAM_207185_000_EN_10

⽧ Insert the squared pieces of timber vertically between the fixed and movable clamping platen and secure them to one of the columns. They should be arranged diagonally.

Injection unit

⽧ Measure the clearance between the support housing for the plasticizing cylinder and the fixed mould platen. ⽧ Cut a thick piece of squared timber to this measurement. ⽧ Insert the squared timber vertically between the support housing and the fixed mould clamping platen and secure it to one of the injection unit columns. ⽧ Also place a similar support between the machine base and drive housing when the drive housing is retracted.


Move the nozzle and the screw to the most advanced (lowest) position, if possible before repair work. A support of the injection unit is then not required. The injection unit can also be removed and repaired in the horizontal position.

-3-

9.8.6


BAM_207185_000_EN_10


-4-

9.8.6

Pressure settings

9.8.9

Pressure settings The system pressure of the machine is set before leaving the factory and must not be changed. The level of the system pressure is marked on a designation label as shown in the following illustration. The designation label is located near the hydraulic control manifold or, for the pneumatic system, near the maintenance unit.

BAM_207185_000_EN_10

System pressure

1 2 3 4 5

( GW1608ZA )

Example

number block 1 (units of 100) number block 2 (units of 10) number block 3 (units of 1) hydraulic system pressure pneumatic system pressure

On the label illustrated above the following squares have been punched: ⽧ punch on block 1

= 2 means 200,

⽧ punch on block 2

= 6 means 60,

⽧ punch on block 3

= 0 means 0,

⽧ punch on square 4

= hydraulics.

..\TECH-DAT\ALLG\EN09HI_00_307_000.FM 01 2004.04.27

In this case the hydraulic system pressure is set at 260 bar. No label is available for the settings of variable pressure values, such as the manually adjustable core pull or nozzle contact pressure. These pressure values must be adapted to the individual application.

SAFETY INSTRUCTIONS

Settings which have been sealed must only be adjusted by an ARBURG service technician. Accidents or damage can be caused if this is not observed!

-1-

9.8.9

Pressure settings

Adjusting the hydraulic pressure

To check and adjust the adjustable hydraulic pressure, there is either a manometer or a connection for a measuring instrument on the respective control manifold. The measuring connections are marked on the control manifold with a milled number, e.g. M2.3. The meaning of this designation can be taken from the hydraulics circuit plan of the machine. ● Connect the manometer with measuring tube (1) from your machine tool kit to the respective measuring connection (2).

The manometers on the control manifolds, as well as the manometer with measuring tube, have a display tolerance of 1,6 %. For very precise pressure settings, therefore, a precision manometer must be used.

Adjusting the pneumatic pressure

The pneumatic pressure is set on the pressure relief valve on the pneumatic maintenance unit. ● Pull the knob out, set the pressure and press the knob back in again to lock it.

-2-

9.8.9

..\TECH-DAT\ALLG\EN09HI_00_307_000.FM 01 2004.04.27

IMPORTANT

( GX1608ZA )

BAM_207185_000_EN_10

● Adjust the set screw until the required pressure is reached.

Hydraulic oils and lubricants

9.9


..\TECH-DAT\ALLG\EN09I_00_306_008.FM 01 2007.11.12

BAM_207185_000_EN_10

Correct lubricants and adequate lubrication are essential to ensure maximum performance, avoid operating malfunctions and prolong the life span of your machine. You may only use hydraulic oils and lubricants which conform to the standards listed in the following table. Grease for the nozzle threads and clamping screws correspond to the standard which applies to Molykote Paste U.

Designations of hydraulic fluids

The following overview explains the meaning of the hydraulic oil designations. H=

Hydraulic oil

V=

Active ingredients for improvement of viscosity/temperature behaviour

L=

Active ingredients for increasing the anti-corrosion and/or ageing protection

P=

Active ingredients for lowering the wear and/or for increasing the load capacity

D=

Active ingredients with detergent and dispersion characteristics (cleansing and suspending ageing and foreign particles). The service life of the filter element can be hereby reduced.

46 =

Kinemat. viscosity at 40 °C, this norm permits fluctuations of ±10 %.

ZA =

Zinc and ash-free

PAO=

Poly-Alpha-Olephin; synthetic mineral oil

HC =

Hydro-cracking; new-technology basic oil with high viscosity index,

EP =

Extreme pressure; active ingredients for high-performance oils requiring high pressure stability,

AW =

Anti-wear; active ingredients for improved adhesion and gliding properties,

LAV =

Air release property.

-1-

9.9


⽧ Mixing capabilities, compatibility Never mix different lubricants or lubricants of different manufacturers together. If this is unavoidable, e.g. when changing the oil on a machine, a compatibility test must be carried out by the lubricant manufacturer. ⽧ System rinse required (fluid, seals and hoses).

⽧ Zinc/ash-free hydraulic fluids These fluids are subject to approval by ARBURG, due to compatibility problems and counter reactions with the types of seals often installed in hydraulic systems. ⽧ Component safety The hydraulic fluid must be free of sodium and chlorine. The content of heavy metals in the hydraulic fluid must be limited to a minimum. The listed products are compatible with bearings and bearing media (radial-, axial bearings and hydrostatic bearings).

BAM_207185_000_EN_10

⽧ Viscosity category Only viscosity category VG46 (ISO VG46 DIN51519) is permitted due to the type of hydraulic pump installed.

⽧ Fluids for increased requirements or special fluids Hydraulic fluids of the category HVLP have multi-grade character and a naturally high viscosity index (energy-saving, long-life). For the high-performance mechanisms of the ALLROUNDER with AED and the ALLDRIVE, fluids must be used which are listed in the “high-performance machine oils” table. For ALLROUNDERs which are used in the food industry or which require an FDA USDA-H1 or NSF approval, fluids from the table “Special hydraulic oils” must be used. Hydraulic fluids which come under the “low-flammable” category cannot be approved for ARBURG machines because they would damage the special sealing systems and adapted hydraulic components. Here secondary measures with regard to fire prevention are more appropriate. Hydraulic fluids which are not based on mineral oil are not permitted. Hydraulic fluids which come under the category of “synthetic esters“ (HEE, HEES) must be tested and require ARBURG’s explicit approval. ⽧ Setting into operation/maintenance/repairs Observe the guidelines for handling and storage stipulated by the fluid manufacturer and fill the system with pre-filtered hydraulic fluid only (ISO 4406: 1999 - ≤ grade 18/15/12). Adhere to the maintenance and oil-changing schedules and specifications stipulated in the operating manual.

-2-

9.9


Lubricants in general


Purity grades for hydraulic oils Neutral institutes have ascertained that failures of hydraulic systems are caused in 80 % of cases by contamination of the hydraulic fluid. For this reason, besides such basic characteristics such as viscosity, temperature stability and anti-wear properties, the purity of the hydraulic fluid plays a particularly decisive role in ensuring a fault-free operation of your injection moulding machine.

BAM_207185_000_EN_10

Oil is usually contaminated by hard particles such as dust and abraded material or soft particles which arise during the ageing process. The soft particles can stick to the hydraulic components or deposit in the filters and impair their function. In order to measure and assess the degree of contamination, socalled “purity grades” have been introduced. Here the quantity and size of the particles per 100 ml oil are ascertained. The method for determining the purity of the oil and the classification of the purity grades are defined in ISO standard 4406:1999. ISO 4406: 1999 (International Standard Organisation) The classification is determined in accordance with the size of the particles > 4 µm, > 6 µm and > 14 µm. The particle count is ascertained cumulatively and specified in ordinal numbers, which are specified in turn in ISO standards. Example: purity grade 18/15/12 means: ⽧ 18 indicates particles sized > 4 µm ⽧ 15 indicates particles sized > 6 µm ⽧ 12 indicates particles sized > 14 µm. In respect of components such as pumps and valves installed in the hydraulic circuit of your injection moulding machine, the following purity levels apply as maximum values.


Standard ISO 4406: 1999

max. 18/15/12

If an additional filter system is used for increasing the life span of the machine components, the purity classification ISO 4406:1999 - 15/12/ 09 must be achieved permanently (see section on fluid management, page 4).

IMPORTANT

Have the hydraulic fluid of your injection moulding machine checked (analysed) by an oil specialist at least once a year. All additional methods of filtration do not substitute the oil change prescribed in the maintenance schedule. Acidic components in very old oils can corrode the hoses and seals.

-3-

9.9


The specified purity grades already correspond to the demands on a high-speed hydraulic system with control valves in an injection moulding machine. A further increase in machine availability can be achieved by improving the purity grades and ensuring the upkeep of the required oil quality. For this purpose, an overall concept, i.e. a so-called fluid management is required, which is based on the following aspects:

-

Only selected lubricants (see lubricants table, footnote 1) with increased performance reserves (LAV, AW, EP, wear codes) must be used.

⽧ Handling / avoidance, -

Lubricants are to be handled in a way which is not detrimental to the environment or to production. Do not change or mix different types of lubricants.

-

Storage in production ambience in suitable storage tanks with integrated filter station.

-

Purity grade in the storage tank: ISO4406: 1999 - 15/12/09.

-

Filling / refilling of hydraulic system only with suitable transport containers through filter system.

BAM_207185_000_EN_10

⽧ High-performance lubricants,

⽧ Realisation -

Machine filter concept with circulation or bypass filter using 3 µm absolute filters.

-

Connections for external filtering system for dedusting and dewatering.

⽧ Monitoring -

Regular lubricant analyses at intervals of 3- 6 months (trend analysis).

-

Figures:

Viscosity, Acid content, Oxidation, Water content, Soiling Purity grade ISO 4406 : 1999 - 15/12/09

⽧ Extended monitoring or fluid condition monitoring -


Fluid management and fluid condition monitoring

Monitoring system with sensors integrated in the hydraulic system (purity grades and oil condition).

-4-

9.9

1 Hyspin AW S22 Rando Oil HD-22

Castrol LMX Starplex EP2

Alpha SP320 Meropa 320

Alpha SP220 Meropa 220

-5-

Tellus Oil 46 Tellus Oil DO 46 1 Albida EP 2 Omala Oil 320 Omala Oil 220 Cassida Fluid HF 46 1 FOOD-LUBE ISO46 1 Vulcolub HLP ISO 46 Vulcogear EP ISO 220 Volcogear EP ISO 320 Unversal grease 1910 EP2

HLP HLP-D-ZA PAO PAO HLP

-

Wh Wiolan HS46 DIVINOL HLP46

Zeller + Gmelin HLP

-

-

Lubr. oil CLP320

Hydraulic oil HLP 46 Lubr. oil CLP220

HLP

Voitländer

H&R Lube HLP Blending GmbH

CARTER EP320

CARTER EP220

Azolla ZS46

HLP

Total

-

-

HEM Hydro HLP46

HLP

-

Tamoil

Strub

Shell Oil

-

Q8 Haydn 46

HLP

Azolla ZS 22 Multis EP2

Wh-Wiolan HS22 -

Wh-Wiolub LFP 2 -

Long term grease E-EP NLGI 2 Hydraulic oil HL22

-

FOOD_LUBE ISO22 Vulcolub HLP ISO22

Morlina Oil 22 Cassida Fluid HF 22

-

Renolin B5

-

-

Renolit Duraplex EP2

Q8

Renolin CLP EP 320

Renolin CLP EP 220

Renolin B15 Renolin MR46MC 1

HLP HVLP

Fuchs Petrolub

Esso NUTO H22 Mobil DTE 22

Esso Beacon EP2 Mobilgrease XHP222

Esso Spartan EP320 Mobilgear 632

Esso Spartan EP220 Mobilgear 630

Esso NUTO H46 Mobil DTE 25 Mobil Excel 46 1

HLP HLP HVLP-ZA

exxonmobil

-

-

-

-

Enak HLP46

HLP

EVVA

Rando Oil HD-46

Table of lubricants

Chevron Texaco HLP

Hyspin AWS46

HLP

CASTROL

Energol HLP-HM22

Energrease LC2

Energol GR-XP 320

Energol GR-XP 220

Energol HLP-HM46

HLP

BP

Avilub-RSL 22

Avilub Special grease EP

Avilub-RSX 320

Avilub-RSX 220

Avilub-RSL 46

HLP

AVIA

VITAM GX22

Aralub MKL 2

Degol PAS 320

Degol PAS 220

VITAM GX46

HLP

ARAL

AGER 22

GR MU EP2

Blasia 320

Blasia 220

OSO 46

HLP

AGIP

Lubr. oil C22

-

Gear oil CLP320

Gear oil CLP220

Hydraulic oil HLP46

HLP

ADDINOL

ISO VG22 DIN51519 DIN 51517-1 C22

ISO VG46 DIN51519 DIN 51517-3 CLP220 DIN 51524-2

Hydraulic

Standard

DIN51825 KP2 P/N

Central hydraulic DIN51517-3 CLP320

Hydraulic oil Pneumatic oil spray lubrication

Lubricating grease Central lubrication Manual lubr. points

Lubricating oil

BAM_207185_000_EN_10

Unit gear oil (not for ALLDRIVEs)

Central lubrication Manual lubr. points

Lubricating oil

Hydraulic

Type of oil Hydraulic oil

Application

Fluid



The hydraulic oils and lubricants listed below are a selection of suitable sorts, according to the information given by the oil manufacturers/hydraulic component suppliers.

Hydraulic fluid fulfils the requirements of improved wear resistance values: VKA value (four-ball tester for luboils) > 1600 N, gear rig test by the FZG method > 12, Brugger value: b > 30 N/qmm

IMPORTANT

Different types of lubricants must not be mixed!

9.9


Heavy-duty gear oil and special hydraulic oils with special requirements Heavy-duty gear oils

Use Standard

ARAL BP Chevron Texaco exxonmobil Fuchs Petrolub PANOLIN Shell Oil TotalFinaElf

Type of oil Gear Gear PAO PAO PAO PAO PAO PAO PAO PAO

Gear oil Heavy duty gears AED and ALLDRIVE DIN 51517-3 CLP220-HC DEGOL PAS 220 Enersyn EP-XF 220 Texaco PINNACLE WM 220 Mobilgear SHC XMP 220 Renolin Unisyn CLP220 Tecsynth 220 Shell Omala HD 220 TOTAL Carter SH 220

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Fluid

Special hydraulic oils Fluid Use

Type of oil Foodstuff industries

Standard

ISO VG 46 DIN 51519 DIN 51524-2

Bell-Ray

PAO

Shell Oil Strub

PAO PAO

1

Gear oil FDA USDA-H1 / NSF approval

Bell-Ray No-Tox SYNTHETIC HYD-OIL 46 Cassida Fluid HF 46 1 FOOD-LUBE- ISO 46 1

Hydraulic fluid fulfils the requirements of improved wear resistance values: VKA value (four-ball tester for luboils) > 1600 N, gear rig test by the FZG method > 12, Brugger value: b > 30 N/qmm

Grease OKS 422 PBC (PolyButylCuprysil) Molykote P 40 Molykote U-N, grey

Use Index unit Mould height adjustment Mould height adjustment system Nozzle thread, Nozzle fit, Ribbed screw tip

Part no. 224151 101064 526403 259998

Container size Cartridge, 400 g Tin, 1000 g Tin, 500 g Tin, 1000 g

14894

Tube, 50 g

-6-


Auxiliary lubricants

9.9


Initial filling of grease and oil

When a new machine is delivered the lubrication points are completely lubricated and any grease containers e.g. for central lubrication are filled. The hydraulic oil is emptied before transport so that only a small amount is left in the hydraulic circulation.

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Which oils and greases are included in the machine on delivery or in the machine accessories are listed in the following table: Grease lubricants contained in ALLROUNDER machines on delivery Central hydraulics Shell Tellus Oil DO 46 ARBURG Electric Dosage (AED) Wittenstein / alpha (life prolongation lubrication) Fuchs Renolin PG 220 MOOG Klueberplex BEM 34-132 ALLDRIVE gear mechanisms ARAL Degol PAS 220 Unscrewing unit ARAL Degol PAS 320 Central lubrication grease 221 K ARAL Aralub MKL 2 Central lubrication - oil 320 K ARAL Degol PAS 220 Central lubrication - ALLDRIVE ARAL Degol PAS 220 Tie-bar lubrication felts ARAL Degol BG 220 Tie-bar adjustment - grease MolyPaul PBC Tie-bar adjustment - grease Molykote P-40 Machine feet 630-820 S OKS OKS 200 Machine feet ARAL Aralub MKL 2 Index unit hydraulic/mechanic OKS OKS 422 Index unit electric/mechanic OKS OKS 422

oil grease oil oil grease oil oil oil grease grease paste grease grease grease

ARAL VITAM GX46 Remaining oil Hydraulic oil from the central hydraulic system Klüber Tribo Start HT2 grease Temperature control oil oil from the mould circuit ARAL

Aralub MKL 2

grease


Rotary table Central hydraulics Rotary bearing/rotary table Rotary transmission leadthrough, low-temperature < 120 °C Rotary transmission leadthrough, high-temperature > 120 °C Other lubrication points (grease)

Remaining oil

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9.9


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9.9

Gaseous materials / vapours

9.10 Environmental protection measures 9.10.2 Gaseous materials / vapours Exhausting gases

Gases and vapours are given off during the plastification of plastic materials. The gases often contain harmful and poisonous substances.

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The gases can emerge at the following locations: ⽧ at the vent opening (only with vented cylinders), ⽧ at the nozzle ⽧ at the mould. ● For this reason, an effective device for the collection and exhaustion of the gas should be placed in the immediate vicinity. ● Do not simply exhaust the gas unfiltered into the open air. ● Ensure that the exhausted gases are suitably processed (filter, neutralised etc.).

SAFETY INSTRUCTIONS

⽧ Before commencing production consult your plastics manufacturer about possible detrimental effects on the environment and suitable protection measures.

( PA0386ZA )

⽧ Gases and dust can be harmful depending on their composition. ⽧ Do not inhale the gas or dust.

\\TECH-DAT\ALLG\EN09JB_00_306_000.FM 01 2004.04.28

Attachment of a gas or dust filter is exclusively the responsibility of the machine operating authority.

Extraction unit (example)

1

mobile extraction unit

A list of suppliers and installation suggestions is available from ARBURG on request. -1-

9.10.2

Gaseous materials / vapours

Dust emission

Just as gases, the dust from some plastics can also contain harmful substances. For this reason, sealed granulate feed systems should be used for materials containing dust.

( GV1180ZA )

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Granulate feed with dust extraction

dust collection bell bracket filter bag

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1 2 3

9.10.2

Disposal of used oils and lubricants

9.10.3 Disposal of used oils and lubricants Used oils and lubricants are substances detrimental to water and the environment that must be taken to a special disposal facility after use.

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Improper storage or disposal of used oils and lubricants endangers the environment. Mixing with other materials such as solvents, brake and cooling fluids is strictly forbidden.

Used oils

Used oils are all mineral lubricating or industrial oils that have become unsuitable for the use for which they were originally intended. Related to your injection moulding machines, this applies in particular to the hydraulic and gear lubricating oils. (EAK-no. 130201, 130202), (LAGA 54114), (OECD AC030)

Separate disposal

Hydraulic oils must be stored, collected or transported separately from other used oils and disposed of in a special facility.

Mixing ban

It is strictly forbidden to mix used oils with other used oils or waste products, in particular with those that are used for recycling.

Verification

The verification of the disposal of used oils is compulsory. Every company or workshop that produces, collects and/or disposes of more than one amount of used oil (depending on country) is obliged to keep a record of the exact amount, consistency, origin, place of storage, delivery and acceptance , whereby in particular the date of delivery and acceptance is to be recorded. Information and proof is to be presented on demand to the respective authority.

\\TECH-DAT\ALLG\EN09JC_00_306_000.FM 01 2004.04.28

IMPORTANT

The above mentioned information and instructions are only extracts from the Regulation for the Disposal of Used Oil BGBI no. 49 dated 31.10.1987 and from the guide line RL 75/439/EEC: Disposal of Used Oils. This information is not to be deemed as complete! Further information is therefore to be taken directly from the respective laws or guide lines. Laws and guide lines that are effective in your country are to be observed additionally, even if they are not explicitly mentioned here.

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9.10.3

\\TECH-DAT\ALLG\EN09JC_00_306_000.FM 01 2004.04.28

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Disposal of used oils and lubricants

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9.10.3

Graphical recording and measuring systems



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10

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Configuration of graphics

10.1 Graphics - nominal/actual values 10.1.1 Configuration of graphics

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Recording values for graphics

With the SELOGICA ’direct’ controller, it is possible to record the time-dependant or stroke-dependant progression of several nominal and/or actual values, and to display them in a graphical diagram on the monitor. With this function, external pressure, stroke and speed transducers record the values which are subsequently output on a very precise X/ Y plotter It is thus possible to display an exact comparison of the nominal values with the actual values recorded.

The curves recorded by the controller are displayed in the “Graphics 1” and “Graphics 2” diagrams. Up to 4 curves can be displayed in each diagram.

The following data can be recorded: ⽧ Injection pressure, nominal value ⽧ Injection flow, nominal value ⽧ Screw stroke ⽧ Injection pressure, actual value ⽧ Injection flow, actual value


⽧ Cavity pressure (not standard).

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10.1.1



Before you can record the nominal and actual values, you must first configure the graphics and select which data you require. Press this key

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䡩 The following parameter panel appears.

Selection of signals for meas. graphs 1

Count of meas. graphs

4

Count of curves in graph 1 Signal 2

Injection pressure, act.

Signal 3

Injection flow nom.

Signal 4

Injection flow, Ist

Recording delay

5.00 s

Recording duration

1,00 s

( PI0605Z PU0552Z )

Signal 1

Injection pressure, nom.

● Select the “Count of measurement graphs” field. f3002 Count of measurement graphics

● Input the number of diagrams required here. Possible inputs are: ⽧ 0 = no recording, ⽧ 1 = one diagram (up to 4 curves possible), ⽧ 2 = two diagrams (up to 8 curves possible). The input of parameters is identical for both diagrams. Therefore, only the parameters and functions of graphic 1 are described in the following.

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10.1.1


Signal 2 f3214 = screw volume, act.


f3112 Number of curves in graphic 1

● Select the number of curves required for graphic 1 here. ● Input which values are required for recording at parameters f3113 to f3116. Possible inputs are: ⽧ injection pressure, nominal value, ⽧ injection flow, nominal value ⽧ screw volume, actual

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⽧ injection pressure, actual value ⽧ injection flow, actual value, ⽧ control circuit 1.

t3112 Recording delay

● Input the required delay time here.

t3113 Recording duration

● Input the recording time here.

䡩 The controller does not begin with the recording of the selected values until this time has expired.

䡩 The selected values are recorded during this time and their progression is displayed in a diagram on the monitor.


The duration of recording can be selected up to 999 seconds long. This means that several consecutive cycles can be recorded.

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10.1.1


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10.1.1

Recording the starting point

10.1.2 Recording the starting point After you have configured the graphic panels, you select the starting point of the recording.

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Press this key.

䡩 The production sequence of the machine appears. ● Select the process at which the recording is to be started (e.g. injection).

Press this key.

䡩 The following selection window appears. Visible marking selection no markings omit in dry cycle ( PJ0605D )

omit in alarm omit in automatic


graphics tripper point 1 graphics tripper point 2

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10.1.2

Recording the starting point

The process is identified with a symbol in the production sequence.


( PK0605Z )

The controller starts with the recording of the selected values when this process is started in the automatic sequence.

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The selected process is marked as a starting point for the recording of the values input at f3113 to f3116.

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10.1.2

Setting the graphics

10.1.3 Setting the graphics With the SELOGICA ’direct’ it is possible to call up a suggestion for the graphics settings. A graphics panel with predefined curves is created, reference values for these parameters are determined and the display of the curves is optimized. ● Call up the measurement graphics.

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Press this key.

䡩 The following selection window appears: Functions

Grid OFF Set graphics

● Touch the “Set graphics” field. 䡩 The controller carries out the following functions: ( PL0605D )

⽧ selects parameters, ⽧ records a reference cycle ⽧ displays recorded values,


⽧ optimizes the display area of the curves.

Recording is carried out from start of injection to end of holding pressure. The upper and lower limits of each curve are automatically adapted to the screen size by the controller. The recorded curves are thus always displayed as large as possible on the screen. The monitoring graphics created in this way simply serve as an adjustment aid and can also serve as a guide for further mouldspecific adjustments.

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10.1.3


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Setting the graphics

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10.1.3

Graphics display

10.1.4 Graphics display The curves you have configured acc. to 10.1.1 and 10.1.2 are displayed in the function panels “Graphics 1” and “Graphics 2”.


( PM0605DA )

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Calling up the graphics panel

1 2 3 4 5 6 7 8 9

parameter value measured with measuring cursor position of cursor on time axis display of time axis/stroke axis display of cycle progression measuring cursor recorded values grid graphics display started/stopped

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10.1.4

Graphics display

The screen displays have the following meanings: 1. Recorded value: (parameters 1-4, or 5-8) ⽧ value designation ⽧ value unit

2. Values measured at measuring cursor Here the values are displayed in accordance with the measuring cursor adjustment. 3. Position of cursor on time axis Here you see the position of the cursor on the time axis. 4. X-axis display:

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⽧ display range.

⽧ stroke axis/time axis ⽧ unit ⽧ display range. 5. Display of the cycle progression The progression of the cycle is represented by a continuous bar here. ⽧ yellow

= injection

⽧ dark blue

= holding pressure

⽧ red

= decompression

⽧ green

= dosage

⽧ grey

= others

6. Measuring cursor You can measure individual recorded values with the measuring cursor more exactly, either with running or frozen display. 7. Recorded values The values selected and recorded in the parameter panel “Graphic Panel Configuration” are graphically displayed here. 8. Grid Background grid (can be faded in/out). 9. Graphics display can be started or stopped with the start/stop symbol.

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10.1.4


Screen displays

Graphics display

Starting/stopping the display

The selected measured values are continuously recorded and displayed as coloured graphs in the graphics window during production. 䡩 The start symbol at the top right next to the graphic indicates: “Graphics 1 display running”. The display can be stopped to measure individually values in the curve more exactly.

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● Press the stop symbol in the editing box to stop the display. 䡩 The display is stopped, i.e. the screen display is frozen. 䡩 The stop symbol at the top right next to the graphic indicates: “Graphics 1 display stopped”. The measurement cursor can be used to measure values when the display is running or frozen. While the display is stopped, the curves in the graphics panel are not updated. The recording must be restarted to continue displaying the recorded values. ● Press the start symbol in the editing box to restart the display of the recorded values. 䡩 The display is started.


䡩 When the recording is restarted the new recorded values are displayed in the graphics window.

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10.1.4

Graphics display

The measuring cursor appears as a vertical line in the graphics window. Individual measuring points of the displayed recording curve can be selected and the respective values read off.

The measuring cursor is moved to the left or the right with the cursor keys. The values of the measuring points which have been selected with the measuring cursor are displayed on the right next to the graphics window: 1st field:

selected measuring value for curve 1

2nd field:


3rd field:


4th field:


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Measuring cursor

The time/stroke position of the measuring cursor is displayed underneath the graphics panel.

( PN0605D )

In order to simplify the overview, a background grid can be called up on the graphics window. Functions Grid ON Set graphics

● Touch the “Grid ON” or “Grid OFF” field. 䡩 The grid in the graphics panel is faded in or out. 䡩 The display of the grid is optimised by the controller according to the current requirements.

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10.1.4


Grid

Graphics display

Zoom in/out

With this key you can make the graphics display larger (zoom in).

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With this key you can return the graphics display to its original size (zoom out).

Graphics 2

䡩 If you have selected “2” at f3002 = “Graphics panel count” a second graphics panel will appear. With this key you change to graphics panel 2.


Graphics display 2 is identical in function and layout to graphic display 1.

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10.1.4


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Graphics display

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10.1.4

Measuring systems of the SELOGICA ’direct’ controller

10.2 Measuring systems 10.2.1 Measuring systems of the SELOGICA ’direct’ controller Possible types of measuring system

The measuring program (not standard) of the SELOGICA ’direct’ controller permits the use of various types of measuring systems:

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1. Measurement of the mould cavity pressure ⽧ Piezo system (direct or indirect), ⽧ DMS system (direct or indirect), ⽧ Piezo system with automatic pressure switch-over (direct or indirect), ⽧ Piezo system, manually switchable (direct or indirect). 2. External switching devices 3. Thermocouples, 4. General measuring system 5. General measuring system with automatic switch-over.

For the actual measurement the following equipment is also necessary : ⽧ analog I/O board, ⽧ amplifier for DMS systems or ⽧ amplifier for thermocouples, or ⽧ general measuring system,


⽧ charge amplifier for Piezo systems. We further recommend our special measuring interface for the connection of plotters etc.

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10.2.1


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Measuring systems of the SELOGICA ’direct’ controller

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10.2.1

Connecting and configurating the measuring system

10.2.2 Connecting and configurating the measuring system


( GG1180ZB )

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The measuring systems are usually attached to the movable mould platen:

1 2 3 4

Connecting the measuring system

amplifier for pressure transducer movable mould platen amplifier for pressure transducer measuring sensor cable

● Plug the transducer connector into the respective socket. You can connect up to 8 systems simultaneously. However you must have a separate amplifier for each system and the controller must be equipped accordingly.

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10.2.2


Selecting the measuring system

Press this key.

䡩 The superior group for measuring systems appears.

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Press this key.

䡩 The following panel appears:

Meas system 1

Meas system 2

available meas. system meas. system switched off


Piezo-System

meas. system switched off

direct measurem. 1.10 pC/bar

meas. range

9091 bar

actual value

0

( PY0599Z PU0552Z )

sensitivity

bar


Meas. method

selected meas. system f9411 = Piezo system

● Select “Measuring system switched off” in the 2nd line of Measuring System 1. Press this key

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10.2.2


䡩 The following window appears: Selection Piezo system Meas. system switched off

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Piezo system DMS system Piezo w. automatic pressure switch-over Piezo, with switch-over External switch-over devices Thermocouples

● Select the required measuring system and press the “Y” key.


( PZ0599D )

䡩 Further parameters appear.

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10.2.2


Meas system 1

Meas system 2



Piezo-System


Meas. method

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● Next, you input the required method of measurement:

direct measurem.

Sensitivity

1,10 pC/bar

Meas. range

9091 bar

Actual value

0

bar

( PY0599Z PU0552Z )

Selected meas. system f9411 = Piezo system

● Select the “Meas. method” field. Press this key.

● Select “direct measurement” or “indirect measurement” depending on the requirement, and press the “Y” key.

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10.2.2


Measuring method


1 2

Mould cavity Pressure transducer

1 2 3

Mould cavity Transmission element Force transducer (meas. tongue)

Indirect measurement with force transducer


( GA1403ZA GB1403ZA )

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Direct measurement with pressure transducer

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10.2.2


Whether a direct or indirect measuring method is to be used can be ascertained for the various Piezo systems from the serial label of the pressure transducer :

⽧ pC/bar

= direct measurement,

⽧ pC/N

= indirect measurement.

When you select the measuring system and the measuring method the controller activates the pressure measuring channel. The respective parameters of the measuring system selected are displayed in the lower half of the parameter panel.

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This depends on the unit of sensitivity, as follows:


Measuring method for various Piezo systems

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10.2.2

Measuring the mould cavity pressure

10.2.3 Measuring the mould cavity pressure Piezo system and DMS system

You have connected and configured your pressure measuring system as described in chapter 10.2.2. The controller now requires a few parameter inputs.

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Direct measurement

Meas. system 1

Meas. system 2 available measuring system

available measuring system meas. system switched off


Piezo system


Method of measurem.

direct measurem.

Sensitivity

1,10 pC/bar

Meas. range

9091 bar

Actual value

0


( PY0599Z PU0552Z )

bar

Meas. method f9412 = direct measurement

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10.2.3


● Input the sensitivity of your pressure transducer at parameter e9414 or e9424 (see serial label or operating instructions of transducer). ⽧ With the Piezo system the input is in pC/bar, ⽧ with the DMS system it is in mV/V.

You can now measure the cavity pressure which is built up during the plasticizing cycle. In the “Actual value” field you can read off the values measured at parameters p4515/p4525. With these values you can subsequently optimise the adjustments of your machine.

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䡩 The controller calculates the measuring range p9414 or 9424 (in bar) from the sensitivity input.

IMPORTANT

The measuring range (p9414 / p9424) must be greater than the maximum pressure that you are expecting, as any pressure above this value would destroy your pressure transducer.

Meas. system 1

Meas system 2



Piezo system


Meas method Diam. of pin Sensitivity


( PY0599Z PU0552Z )

Indirect measurement

indirect measurem. 0.5 mm 1.10 pC/bar

Meas. range

462996 bar

Meas. range

9.09 kN

Actual value

0 bar

Meas. method f9412 = Indirect measurement

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10.2.3


● Input the diameter of the measuring pin at d9414 or d9424 in mm. ● Input the sensitivity of your pressure transducer at parameter e9416 or e9426 (to be seen on the serial label or in the operating instructions of your transducer). ⽧ With the Piezo system the input is in pC/N, ⽧ with the DMS system it is in mV/V.

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䡩 The controller calculates the measuring range p9417 or p9427 (in bar) from the inputs of the pin diameter and the sensitivity. 䡩 The measuring range f9414 or f9424 is also calculated by the controller You can now measure the cavity pressure which is built up during the plasticizing cycle. In the “Actual value” field you can read off the values measured at parameters p4515/p4525. With these values you can subsequently optimise the adjustments of your machine.

IMPORTANT


The measuring range (p9414 / p9424) must be greater than the maximum pressure that you are expecting, as any pressure above this value would destroy your pressure transducer.

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10.2.3


Piezo system w. switch-over

You have connected your pressure measuring system as described in chapter 10.2.2 and configured it for “Piezo systems with automatic pressure switch-over. The controller now requires a few parameter inputs.

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Direct measurement

Meas system 1

Meas system 2

available measuring system Meas. system switched off

available meas. system Meas. system switched off

Piezo, umschaltbar

Meas. system switched off

Meas method

direct measurem.

Charge amplifier range

5000

Sensitivity

1.10 pC/bar

Meas. range

4545 bar 0 bar

( PY0599Z PU0552Z )

Actual value

● Input the range of the connected charge amplifier at parameter p9414 or f9424 in pC. The following inputs are possible: ⽧ Stage 1: 5000 pC, or ⽧ Stage 2: 20000 pC. 䡩 The controller calculates the measuring range p9416 or p9426 from this input and the sensitivity.

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10.2.3


selected measuring system f9411 = Piezo, with switch-over


IMPORTANT

The range of the charge amplifier must be selected so that the expected highest cavity pressure does not exceed the measuring range ( p9416 or p9426), otherwise the pressure transducer could become damaged!

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We recommend that you input the higher value first (stage 2) and then watch how high the mould cavity pressure actually becomes during the process. If necessary the range of the charge amplifier can be corrected downwards (to stage 1).

● Input the sensitivity of your pressure transducer at parameter e9414 or e9424 in pC/bar (see serial label or operating instructions of your pressure transducer). ● You can now measure the cavity pressure which is built up during the plasticizing cycle.


䡩 In the “Actual value” field you can read off the values measured at parameters p4515/p4525. With these values you can subsequently optimise the adjustments of your machine.

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10.2.3


Indirect measurement

● Input the range of the connected charge amplifier at parameter p9414 or f9424 in pC. Possible inputs are: ⽧ Stage 1: 5000 pC or ⽧ Stage 2: 20000 pC

IMPORTANT

The range of the charge amplifier must be selected so that the highest mould cavity pressure expected does not exceed the measuring range (p9419 or p9429), otherwise the pressure transducer could suffer considerable damage!

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䡩 The controller calculates the measuring range p9419 or p9429 and F9416 and F9426 from this input, the sensitivity and the pin diameter.

We recommend inputting the higher value (stage 2) first and then watching to see how high the mould cavity pressure actually becomes. If necessary the range of the charge amplifier can be corrected downwards.

● Input the diameter of the measuring pin in mm at parameter d9414 or d9424. ● Input the sensitivity of your pressure transducer at parameter e9416 or e9426 (see serial label or operating instructions of your pressure transducer).

Piezo system with automatic pressure switch-over

Compared to the Piezo system with manual switch-over, the Piezo system with automatic pressure switch-over offers you the additional possibility of letting the controller calculate the ideal switch-over point for you without having to determine it yourself in stages.

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10.2.3


You can now measure the cavity pressure which is built up during the plasticizing cycle. In the “Actual value” field you can read off the values measured at parameters p4515/p4525. With these values you can subsequently optimise the adjustments of your machine.

External switch-over devices

10.2.4 External switch-over devices The SELOGICA ’direct’ offers you the possibility of connecting an external switch-over device via an interface.

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The external switch-over device determines the switch-over point to holding pressure and sends this in the form of an electronic signal to the controller.

Meas system 2



external switch-over devices



( PY0599Z PU0552Z )

Meas system 1

Selected measuring system f9411 = external switch-over devices

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10.2.4


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External switch-over devices

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10.2.4

Measuring system for thermocouples

10.2.5 Measuring system for thermocouples

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You have connected and configured your measuring system as described in chapter 10.2.2. The controller now requires a few parameter inputs.

Meas system 1

Meas system 2



Thermofühler


Type of thermocouple


( PY0599Z PU0552Z )

Actual value

Type L 0 pC/bar

Type of thermocouple f8016 = Type L

Type of sensor

● Input the type of sensor you are using at parameter f8016 or f8018, see following examples: ⽧ “0“ = Type J, and ⽧ “1“ = Type L. You can now measure the cavity pressure which is built up during the plasticizing cycle (parameters p4515/p4525 each show the current actual value). With these values you can subsequently optimise the adjustments of your machine.

IMPORTANT

The actual values T8019 or T8029 only show a valid measurement during the plasticising cycle.

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10.2.5


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Measuring system for thermocouples

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10.2.5

General measuring system

10.2.6 General measuring system With the “general measuring system” you have the possibility of also checking quality characteristics that are not directly connected to pressure or temperature, for example weight or length.

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You have connected and configured your measuring system as described in chapter 10.2.2. The controller now requires a few parameter inputs.

Meas system 1

Meas system 2

available meas. system Meas system switched off

available meas. system Meas system switched off

General meas. system

Meas system switched off

zero point

0.000

unit 0.000

actual value

0.000

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( PY0599Z PU0552Z )

conversion factor

selected meas. system f9411 = general meas. system

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10.2.6

General measuring system

Zero point

If you do not want 0 volt to correspond to 0 parts of your selected unit you can input a zero point at parameter f4512 or f4522, e.g. 10 units.

Unit

● At parameter f4513 or f4523 you input the unit you are using in text form, e.g. “kg“ for kilogram or “mm“ for millimetre.

Conversion factor

The amplifier generally has an operating range of 0 to 10 volt. You must therefore input a suitable conversion factor at parameter U4511 or U4521, e.g. 0.5 kg corresponds to 1 volt. Ideally the value you expect should be around 5 volt, so that enough capacity is available.

You can now read off the current actual value in the parameter panel and optimize the adjustments of your machine.

General measuring system with automatic switch-over

Compared to the conventional general system, the general measuring system with automatic switch-over gives you the additional possibility of having the ideal switch-over point calculated for you by the controller and you do not need to determine this yourself in steps.


Actual value

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With a signal of 0 volt the corresponding zero point is output (in this case 10 kg).

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10.2.6


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In/outputs

11 In/outputs

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In/outputs

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Function of the programmable outputs

11.2 Programmable outputs 11.2.1 Function of the programmable outputs The programmable outputs are used to start and end processes, in dependence on the machine’s cycle sequence.

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With the programmable outputs you can start and stop external devices or control mould functions. The programmable outputs can also be used to query signals from external devices or from the mould and, in relation to these, to start and stop machine functions.

Activating programmable outputs

You activate the programmable outputs by inserting the required output symbols in the sequence editor in the production sequence. As soon as the output symbols are inserted in the sequence editor, you can call up the respective parameter panels and select the start and end conditions. In the same way you can link outputs together and select whether the outputs are to be triggered in a cyclic manner, in a non-cyclic 1 manner or alternately 1. Using the following outputs 1 and 2 as an example, we want to show you how to proceed when programming the outputs. Outputs 3/4, 5/6, and 7/8 etc. are programmed in the same way and therefore need no separate instructions.


Assuming 2 outputs are to be programmed: output 1 to be started simultaneously with “mould closing“ and ended via a run time. Output 2 is to be started after “nozzle advance” and ended after “mould opening”.

1

not standard -1-

11.2.1


Select sequence navigation.

Touch this key.

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䡩 The “Edit sequence” window appears. ● Touch the “Insert symbol” field. 䡩 The window for selecting the symbols appears. Press this symbol.

䡩 The symbols of the “Outputs” group are displayed. Select new symbol

䡩 All the processes that can be programmed in the sequence editor appear in the input box. ● Select output 1 and insert the symbol as a process to operate simultaneously with “mould opening” in the production sequence. As output 1 is to be ended after a run time, no stop symbol need be programmed for this output. ● For output 2 you insert the start symbol after the process “nozzle advance”. As this process is to be stopped by an end symbol, insert the end symbol of output 2 after the process “mould closing”.

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11.2.1


( PA0599D )

Outputs group


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The production sequence could look like this:

As soon as you have inserted the outputs in the production sequence, the parameter panels of the outputs are displayed and further parameter panels for these outputs can be called up.

Description of outputs

Call up the theme navigation with this key.

With this key you call up the parameter panel “programmable output 1”.

For a better overview you can input an explanatory text for each output in this parameter panel. This text is displayed in the production sequence when the cursor is positioned on the respective symbol. It also appears in various alarm texts.


This comment is also displayed in the parameter panel of the respective output and can also be edited there.

f9351 Description text for output 1

● Input here the explanatory text for the function of output 1 (28 ASCII characters), e.g. “pneumatic cylinder insertion”.

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11.2.1


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11.2.1

Start and end conditions for programmable outputs

11.2.2 Start and end conditions for programmable outputs Call up theme navigation with this key.

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Touch this symbol.

● Place the cursor on “Start of output 1”. Press this key.

( PB0599D PC0599D )

䡩 The “Selection” window appears. Selection f9311 = immediate or delayed start immediate or delayed start after S2210 and delayed


after S2220 and delayed

You have several possibilities of starting or ending each output.

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11.2.2


Start conditions Start output

● Select “immediate or delayed start” at “Start of output“. 䡩 The output starts in accordance with the sequence programming immediately or after a delay.

● Select “after S2210 and delayed” at “Start of output”. 䡩 The output starts in accordance with the sequence programming as soon as S2210 has reacted and the programmed delay time has expired. ● Select “after S2220 and delayed” at “Start output” 䡩 The output starts in accordance with the sequence programming, as soon as the switch S2220 reacts and the programmed delay time has expired.

(Only when no start-stop-type is programmed in the sequence) ● Select the field “End of output 1”. Press this key.

䡩 The “Selection” window appears ( PE0599D )

Selection f9321 = via S2210 (level) via S2210 (positive edge) via S2220 (positive edge)


End condition of output

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Further possibilities

via run time via S2210 (level) via S2220 (level)

● Select the “via run time” condition for the end of the output. 䡩 The output is ended when this selectable run time ends.

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11.2.2


Further end conditions

Input “via S2210 (positive edge) for “End of output”. 䡩 The output is ended according to the sequence programming as soon as switch S2210 signalizes a positive edge. ● Input “via S2220 (positive edge) for “End of output”

Positive edge means that the status of the switch must change from “0” to “1” (see illustration). If the switch is already on ”1” at the start of the process, it must first become “0” and then “1” again, so that the output can be ended (see illustration).


( GC1456E )

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䡩 The output is ended according to the sequence programming as soon as switch S2220 signalizes a positive edge.

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11.2.2


● Select “Via S2210 (level)” for end of output. 䡩 The output is ended as soon as switch S2210 signalizes level 1 has been reached. ● Select “Via S2220 (level)” for end of output.

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䡩 The output is ended as soon as switch S2220 signalizes level 1 has been reached.

If you compare both switch diagrams you will see that example “a” is the same with positive edge as with “level”. Only example “b” leads to different results. The start and end of an output can not be linked with the same input. A message in the display draws attention to this invalid combination. The inputs to be linked with start and end conditions are pre-defined. 2 inputs are assigned to 2 programmable outputs. Output 1 and 2:

1st input S2210 2nd input S2220

Output 3 and 4:


Output 5 and 6:


Output 7 and 8:


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11.2.2

( GC1456E )

For the end of the process, only level “1” of the switch is relevant. If level “1” is already reached at the start of the process, the process is immediately ended again without triggering the valve (see example b).


End via S2210 (level)

Linking and repeating outputs

11.2.3 Linking and repeating outputs

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With the SELOGICA ’direct’ control system it is possible to link outputs with each other or to repeat outputs several times in a production sequence.

Output 1 and 2, linked as a common group

Linking outputs as a common group shows the control system that both outputs trigger the same “axis“. This has an effect e.g. on the monitoring of the end switch. In the above sequence for example, output 1 makes the advancement movement with pneumatic cylinder and output 2 makes the retraction movement with the same pneumatic cylinder. Call up the theme navigation.

( GT1443Z PD0599D )

With this key you call up the parameter panel “Programmable outputs selection 1/2”.

● Select the field “Link outputs 1 and 2”.


Press this key.

The “Selection” window appears. Selection f9351 = no link no link common group common output Y2210

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11.2.3


f9331 Linking outputs 1/2

It is possible to link 2 outputs with each other in 2 different ways. With the aid of this function advancement and retraction movements can be realised for example, or one output triggered several times. Possible inputs: ⽧ No link.

With a “common group” the outputs move the same axis and represent the counter movements to each other. Both outputs must be programmed in the sequence. Possible example of application: control of a pneumatic cylinder for ejecting the moulded parts. The first output advances the cylinder; the second output retracts it again.

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⽧ Common group: This value is only possible when the end condition is not a startstop-type with 2 symbols in the sequence.

⽧ Common output: With this link, the signal of the 2nd (4th, 6th, 8th) output is sent to the valve of the 1st (3rd, 5th, 7th) output. As each output can only be programmed once in a sequence, this option is only useful when a signal is required several times in a sequence. If for example output 1 and 2 are linked as a common output, then output 1 is always activated when one of them is triggered.

A repetition can be programmed for each output, providing no startstop-type has been programmed. The output can be carried out in the sequence several times, depending on the assigned inputs or the run time. Insert this symbol for repetitions.

The number of repetitions to be carried out after the respective symbol in the sequence must be input in the parameter panel of the programmable output. The functions for the input of the repetitions are as follows: f2213

repetition of output 1, to

f2283

repetition of output 8.

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11.2.3


Repetitions


As with “start” and “end” a requirement must be stated for the repetition too. These are input at parameters f9341 to f9348.

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Possible inputs: Press this key.

䡩 The “Selection” window appears.

The 1st input of the programmable output ends a repetition. Before the following repetition can be ended by the same input, it must become inactive once (= 0). Only after that will the active (= 1) input be accepted again.

Via S2220

The 2nd input of the programmable output ends a repetition process. Before the following repetition can be ended by the same input, it must become inactive (= 0) once. Only after that will the active (= 1) input be accepted again.

Via run time

Each repetition is active for the run time displayed in the parameter panel.


( PB0599D GU1443Z )

Via S2210

Programming example

Output 1 controls an ejector integrated in the mould. A shaking movement (short stroke) of the ejector is achieved by repeating the output which ensures correct demoulding of the part.

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11.2.3


This input is only possible with outputs 2, 4, 6 and 8 when a group repetition is programmed.

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In the following switch diagram you see an example for a common group with 2 end switches S2210 and S2220 and group repetition via end switch S2224. In this way a shorter stroke can be achieved for example for the shaking movement. .

If two outputs are combined as a common group only one repeat symbol “group repetition” can be programmed in the sequence for this group. For both outputs the end conditions for the respective repetition of each output must be indicated. During the repetitions the end condition of the second output is at the same the start condition for the first output and vice versa.

Output 1

Group repetition 2/1

Output 2

( GE1456E )

The following programming method is pre-defined in the production sequence:


Via S2224

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11.2.3


As with such a configuration both outputs move the same axis and output 1 is in end position before the group repetition starts, the group repetition begins with output 2 and ends with output 1. Afterwards output 1 is in end position and output 2 can be moved. With the aid of these settings an ejector for example can be controlled via the programmable outputs. The group repetition represents the short stroke (shaking) movements.

Programming example


( GC1458Z )

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The parameters for the group repetition are only to be found in the parameter panel of the 1st (3rd, 5th, 7th) output.

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11.2.3


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11.2.3

Movement stages and output active in end position

11.2.4 Movement stages and output active in end position If a programmable output is driven via control circuit 1 or 2 and if the machine is equipped with the “extended movements” function, two different movement stages are available. These can be moved with various pressure and speed parameters.

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Touch this key.

● Select the field “P/Q switch-over“. ● Activate the speed/pressure switch-over at parameters f9361 to f9368


( PB0599D )

● Activate “output active in end position” at parameters f9371 to f9378 for the respective output.

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11.2.4


The switch-over of these stages can be carried out either by a runtime or a special input. In the first case the run time must be entered in the parameter panel.

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If the switch-over is carried out via the input, a run-time is not displayed in the parameter panel. While the output is active you can switch over between the stages via the input as often as you like. The production sequence of the machine is stopped during this time.

A1 L2 L1 L0 S T

Trigger output 1 Output pressure stage 2 (S2214 to S22284 active) Output pressure stage 1 (S2214 to S2284 not active) Output with no pressure Switch-over signal (S2214 to S2284) Run time

This is of course only possible when the number of programmed stages is greater than 1. Otherwise only the first stage will be moved, independent of the switch-over input. The selection is made via the following parameters: ⽧ f9361 switch-over output 1 via S2214 ( GA1367Z )

⽧ f9362 switch-over output 2 via S2224 ⽧ f9363 switch-over output 3 via S2234 ⽧ f9364 switch-over output 4 via S2244 ⽧ f9365 switch-over output 5 via S2254 ⽧ f9366 switch-over output 6 via S2264


Movement stages

⽧ f9367 switch-over output 7 via S2274 ⽧ f9368 switch-over output 8 via S2284

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11.2.4


Output active in end position

Each output can be programmed so that it is active in the end position, i.e. with a hydraulic function the hydraulic pressure is held, with a non-hydraulic function the valve remains triggered although the process is ended.

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The production sequence of the machine can continue during this time. If this is the case, a pressure reduction symbol must be programmed in the sequence, to reduce the “ held” pressure or with the non-hydraulic functions to switch off the triggering of the valves.

Pressure reduction

When outputs are configured as a “common group” the pressure reduction symbol is not essential, because the counter movement automatically reduces the pressure previously held. There is however the possibility here of programming the pressure reduction symbol for output 1 (3,5,7): ⽧ after the standard symbol,


( GV1443Z GB1367Z )

⽧ after the group repetition.

In these positions in the sequence the output (1,3,5,7) is in end position.

A1 A2 EA1 EA2

Output 1 hold pressure Output 2 hold pressure End position of output 1 End position of output 2

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11.2.4


Output active in end position (leaving signal actuated) is possible for both hydraulic and non-hydraulic drives! Selectable options: ⽧ output not active in end position

⽧ output in end position is active in “automatic” and “manual” operating modes. In the “automatic” operating mode the function is as above. In the “manual” operating mode the output remains actuated after the manual sequence has ended - without further activation of the sequence key. This function can only be selected when two outputs are defined as a common group.

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⽧ output in end position is only active in the “automatic” operating mode. After the end condition for the output has been reached it is not switched off but remains actuated.

IMPORTANT

If the safety gate is opened during the production sequence all outputs and other pressures are switched off.


As soon as the safety gate is closed and the start button pressed the outputs that were previously active are automatically reactivated. The triggering remains active and the pressure is held although no function was activated beforehand.

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11.2.4

Outputs non-cyclic, alternating

11.2.5 Outputs non-cyclic, alternating

1

The functions “non-cyclic or alternating, fixed and selectable“ are non-standardized features of the programmed outputs. If your machine is equipped with the “extended movements” function you determine in the parameter panel “cycles output” after how many cycles an output is to be set. If this function is not activated the output is set in every cycle. BAM_207185_000_EN_10

With this function it is possible, for example, to carry out an output alternately with another output in every second cycle only, or to carry out an output only after a certain number of cycles (e.g. cleaning the mould every 5th cycle).

( PB0599D PQ0599D )

Call up the function panel “programmable outputs 1/2 selection” with this key.

● Select the field “Cycles, output 1 and 2”. Press this key.


䡩 The “Selection” window appears. Selection f9630 = cyclic, standard cyclic, standard non-cyclic alternating, fixed alternating, selectable

1

not standard -1-

11.2.5


● Enter the desired variant (cyclic, non-cyclic or alternating) at f9630. ● For the outputs 2/3 to 7/8 call up the respective selection panel and proceed in the same way. Selectable options:

⽧ Non-cyclic In the parameter panel you can select how many cycles should be carried out without activating the output. ⽧ Alternating fixed Can only be selected when two outputs are defined as a common group. In the production sequence the symbols are marked by a second frame. Only one process is undertaken per cycle, whereby the output programmed first in the sequence is carried out first. Thereafter each cycle is alternated between the linked processes.

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⽧ Standard carried out in every cycle.

After you have selected a non-cyclic sequence the function key “cycles output 1/2” is displayed. f2360 Nominal

Here you input after how many cycles the output is to be activated e.g. input = “3”: output 1 is activated in every third cycle, i.e. in cycle 3, 6, 9 etc.

f2361 Actual

Here is displayed how many of the cycles pre-selected at f2360 have already been carried out.

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11.2.5


( GW1443Z )

⽧ Alternating selectable Linking of outputs “1” and “2”. The outputs move alternately, whereby the number of cycles for each output is additionally selectable. The change to the linked output is not carried out until the predefined number of cycles of the currently active output has been completed. This is only possible when the outputs are linked as a “common group”.


Non-cyclic via limit switch

The non-cyclic outputs can also be started via 1 or 2 limit switches. Proceed as follows to program this: Press this key.

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䡩 The following parameter panel appears:

Cycles, programmable output 1/2

Output 1/2 non-cyclic

via counter 0

0

Cycles until output 1/2

0

0


( PN0599Z PT0552Z )

Cycles without output 1/2 after auto start

Output 1/2 non-cyclic f2364 = via counter

● Select the field “Output 1/2 non-cyclic”.

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11.2.5


Press this key.

䡩 The “Selection” window appears. Selection

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f2364 = via 2 limit switches via counter via limit switch via 2 limit switches

● Select, e.g. “via 2 limit switches” and confirm with the “Y” key.

( PO0599D PN0599Z PT0552Z )

䡩 Further parameters are displayed.

Cycles, programmable output

Output 1 active when Signal status Output 2 active when Signal status

via 2 limit switches not assigned 0


Output 1/2 non-cyclic

not assigned 0

Condition for activation of output 1(/2) f2365 = not (yet) assigned

● Select the field “Output 1 active when”.

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11.2.5


Press this key.

The “Selection” panel with all possible switches which can be inserted in this position, appears.

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Selection f2355 = S701 core pull 1 inserted S923 Oil level under maximum S924 Oil level nominal value S925 Oil level over minimum S932 External alarm input S951 Monitoring 24 V -F007 S952 Monitoring 24 V -F006 S953 Monitoring 24 V -F005

● Select e.g. “S701 core pull inserted“ and confirm with the “Y” key.

( PP0599D )

䡩 Now the output is activated only when switch S701 has “0” status when it is queried, not in every cycle. ● If you input “1” in the field “Signal status” the output is activated when switch S701 has the signal status of “1”.


Proceed in the same way when programming the second limit switch.

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11.2.5


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11.2.5

Starting outputs as a stroke-dependent function

11.2.6 Starting outputs as a stroke-dependent function If outputs are programmed simultaneously with axes equipped with stroke measurement, the output can be started as a stroke-dependent function. Example: You have programmed output 1 simultaneously with “mould closing” in the production sequence.

BAM_207185_000_EN_10

● Select the symbol for “Output 1” in the sequence editor. Press this key.

䡩 The “Edit sequence” window appears. Press this key.

䡩 The symbol for output 1 now has a stroke-start marker.

( GA1458Z )

● When you press this key again the stroke-start marker is removed.

Stroke-start is possible with the following movements:


⽧ mould opening / closing, ⽧ ejector advancement / retraction, ⽧ screw advancement / retraction (injection/dosage/decompression), ⽧ nozzle advancement / retraction.

Additionally on 2-component machines: ⽧ screw 2 advancement / retraction (injection 2, dosage 2, decompression 2) ⽧ nozzle 2 advancement / retraction When programming a stroke start, a stroke appears in the parameter panel of the respective output (with stroke start for screw 1/2: a volume). ● Input here a value at which the output can start.

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11.2.6

Starting outputs as a stroke-dependent function

Time start before end of cooling time

Outputs can be programmed simultaneously with the cooling symbol and assigned with a stroke start. Of course a true stroke start is not possible here; a time-dependent start before the end of the cooling time is what is symbolised.

In the “manual” operating mode outputs can only be moved when they are programmed in the sequence. Only then are the respective and necessary parameters available. In the “set-up” operating mode an output that has not been programmed can be moved. The output remains active for as long as the corresponding sequence key is pressed.


Sequences in “manual” and “set-up” mode

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In the parameter panel the times t2210 to t2280 are no longer shown as delay times but as “time before end of cooling time”. When the symbol is reached in the sequence this is the time to be waited until the end of the cooling time t2210 (to t2280) is reached.

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11.2.6

Additional functions for outputs

11.2.7 Additional functions for outputs Outputs with open safety gate

Depending on the equipment of the machine, outputs can be activated when the safety gate is open.

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As an additional safety measure machines with this facility have a key switch which must be switched to the “on“ position to use this function (input S2200 = 1). You can now start (activate) the outputs in the production sequence in the key-operating mode. What you have selected is displayed with a stop symbol under the respective process in the production sequence. The automatic sequence is interrupted in key operating mode. The movement can only be continued by pressing the key of the corresponding process. It can be interrupted as often as desired. When the end position is reached the automatic sequence is continued after “close safety gate”. As a further option it is also possible to start outputs automatically when the safety gate is open. For this option however certain safety precautions are necessary to ensure safe operation.

..\STRG-SW\SDSW405X\EN11BG_00_5405_000.FM 01 2006.05.02

In automatic mode a warning is displayed under the process in the production sequence.

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11.2.7

..\STRG-SW\SDSW405X\EN11BG_00_5405_000.FM 01 2006.05.02

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Additional functions for outputs

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11.2.7

Parameters for programmable outputs

11.2.8 Parameters for programmable outputs After you have inserted the outputs in the production sequence, the parameters for the individual outputs have to be defined in the respective parameter panels.

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Call up the theme navigation by pressing this key.

Select the symbol for output 1 in the sequence editor.

䡩 The respective parameter panel appears.

Text describing output

For a better overview you can enter a description text for each output at parameters f9351 to f9358 in the parameter panels. This text is shown in the production sequence when the cursor is positioned on the respective symbol.

..\STRG-SW\SDSW405X\EN11BH_00_5405_000.FM 01 2006.05.02

This text is also displayed in the parameter panel “Programmable output selection” and can be edited there. The text is further displayed in the alarm texts of the respective output.

-1-

11.2.8


Output run times

The run time is the time during which the output is actuated i.e. the length of time that the output is active and carries out its function. ● Input the required run time for the outputs at parameters t2211 to t2281 in the parameter panels of the individual outputs. The run times t2211 to t2281 can have different meanings depending on the configuration: ⽧ Run time of stage 1 (if multi stages apply) and switch-over via time. BAM_207185_000_EN_10

⽧ Total run time with stage switch-over via input and end via run time. ⽧ Total run time (end via run time) with drive via control circuit 3 or non-hydraulic drive. Stage switch-over is not possible.

Run times t2212 to t2282

Run time of stage 2 in all cases not mentioned above.

Run times t2214 to t2284

Run time of repetition (a stage switch-over is not possible within repetitions).

Start / end delay Start delay

The outputs and their repetitions can be started with a time delay. ● Input the required start delay at parameters t2210 to t2280 in the parameter panels of the outputs The start of the output is delayed by this freely determinable time. The output does not become active until this time has expired.

End delay

With start-stop types the output can be ended with a time delay. ● Input the required end delay at the parameters t2251 to t2258 in the parameter panels of the outputs. The end of the output is delayed by this freely determinable time. The output does not become inactive until this time has expired.

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11.2.8


● Input the start delays for the repetitions of the output at parameters t2213 to t2283 in the parameter panels of the outputs.


Number of stages

If your machine is equipped with the function “extended movements” and the output is hydraulically activated, you can use up to two stages with different speeds (volumes) and pressures. ● Input the required number of stages at parameters f2210 to f2280 in the parameter panels of the outputs.

BAM_207185_000_EN_10

Flow volume stage

For hydraulically activated outputs input the required flow volume for the respective stage here. ● Input the required oil flow volumes for each stage at parameters Q2211 to Q2281 (for stage 1) or at parameters Q2212 to Q2282 (for stage 2) in the parameter panels of the outputs.

Pressure stage

For hydraulically activated outputs input the required hydraulic pressure for the respective stage here. ● Input the required pressures for the stages at parameters p2211 to p2281 (for stage 1) or at parameters p2212 to p2282 (for stage 2) in the parameter panels of the outputs.

Manual adjustment of holding pressure

For hydraulically activated outputs with manual adjustment enter the set pressure here. ● Set the required pressure on the pressure setting cartridge of the pressure valve. ● Read off the pressure on the manometer.


● Enter the value you have read off here as a note book value.

-3-

11.2.8


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11.2.8

Monitoring

11.2.9 Monitoring

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Activating the monitoring

You can monitor the outputs with the aid of the functions: ⽧ f9382

Monitoring of output 1 to

⽧ f9388

Monitoring of output 8.

Touch the theme navigation key.

Call up the parameter panels for the programmable outputs with this symbol key.

Touch this symbol.

Press this key.

The “Selection” window appears. Selectable options:

..\STRG-SW\SDSW405X\EN11BI_00_5405_001.FM 01 2006.05.04

⽧ not active ⽧ in “manual” and “automatic” modes The monitoring is the same in both operating modes. ⽧ only in “automatic” mode The output can be operated without monitoring in “manual” mode. This is used for example when the output carries out a movement that extends beyond the mould and injection areas and can therefore be driven independently of the actual condition of these axes. In this case it is not necessary to change to the “set-up” operating mode and to switch off the monitoring there.

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11.2.9

Monitoring

“Monitoring off in set-up mode“

In “set-up” mode the monitoring can be switched off for each programmable output. At the start of the sequence the correct position of the remaining axes is no longer inspected. The output can therefore be moved independently of the position of the remaining axes.

BAM_207185_000_EN_10

Touch this symbol.

Call up the monitoring with this key.

Press this function key.

䡩 The panel “Monitoring “off” in set-up mode appears. Possible inputs: ⽧ f153

Monitoring “off” for output 1 to

⽧ f160

Monitoring “off” for output 8.

For safety reasons, when quitting the “set-up” operating mode all functions, even those for the other axes are re-set to “no”.

In the “set-up” mode the monitoring can be switched off for every programmable output. Incorrect operation of the machine and the outputs can cause damage to the mould and the machine, or even present danger to the operator.

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11.2.9

..\STRG-SW\SDSW405X\EN11BI_00_5405_001.FM 01 2006.05.04

SAFETY INSTRUCTIONS


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Part removal

14 Part removal

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Part removal

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General information on the interface

14.2 EUROMAP 67 interface for robot system 14.2.1 General information on the interface In order to be able to operate a robot system, the injection moulding machine must be equipped with an appropriate interface and the corresponding software (not standard). BAM_207185_000_EN_10

The interface for the robot system makes communication possible between the machine controller and the robot system. In order to make the controls of the various robot system manufacturers compatible with the interfaces of the machine manufacturers, a standard interface assignment has been developed and given the designation EUROMAP 67. A 50-pin plug-socket combination serves as plug connector (see chapter 14.2.2).

Type of interface

Not all available pins and sockets are always used on an interface as this depends on the particular application. Therefore the following distinguishing criteria have been additionally determined for the interfaces: ⽧ f9060 = 2: standard EUROMAP 67 interface basic equipment, this pin assignment is always available. ⽧ f 9264: extended interface Pin ZA8 (signal “mould opened to intermediate stop) is supported by the software.


⽧ f9605: mould opening when S681 = 0 extended interface and additional software variant.

SAFETY INSTRUCTIONS

The safety signals “Safety gates closed” and “Emergency stop” are transmitted via 2 circuits.

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14.2.1

General information on the interface

The required version is installed before the machine leaves the factory If your interface is not connected to an ARBURG robotic system (i.e. robotic system or integral picker), then “no robotic system” is displayed at f9602.


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The message “no robotic system” is only displayed on machine models without ARBURG robot system interface.

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14.2.1

Connection between injection moulding machine and robot system

14.2.2 Connection between injection moulding machine and robot system

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If your machine is equipped with an interface for a robot system, the connection socket is located on the console on the machine base.

25P + E HAN 50D

Part no. 223446 Part no. 18300 Part no. 202346

Socket (fem. conn.) Pin (male conn.) Socket housing

25P + E HAN 50D

Part no. 223375 Part no. 18299 Part no. 202446

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( GA1646EA )

Pin (male conn.) Socket (fem. conn.) Plug housing

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14.2.2

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Connection between injection moulding machine and robot system

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14.2.2

Pin assignment

14.2.3 Pin assignment The injection moulding machine (IMM) is connected to the robot system (RS) via a plug connector, type HAN 50 D.

⽧ Row A

1 to 9,

⽧ Row B

1 to 7,

⽧ Row C

1 to 9.

This results in a designation e.g. ZB3 (Z = pin side, B = row, pin = 3). 1. Pin assignment

a. from injection moulding machine (IMM) ZA1/ZC1 emergency stop (circuit 1) ZA2/ZC2 emergency stop (circuit 2) ZA7 mould opened (start of RS) ZA3/ZC3 protection for IMM closed (circuit 1) ZA4/ZC4 protection for IMM closed (circuit 2) ZB3 ejector “is retracted“ ZB4 ejector “is advanced” ZB5 core pulls 1 “are inserted” ZB6 core pulls 1 “are retracted” ZB7 core pulls 2 “are inserted” ZB8 core pulls 2 “are retracted” ZA5 reject part ZB2 automatic operation ZA6 mould closed ZC8 part moulded ZA8 mould opened to intermediate stop ZA9 +24 V ZC9 0V


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On the injection moulding machine the pin-side of the plug connection is marked with a “Z” (to correspond with the socket side of the RS):

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14.2.3

Pin assignment

On the robot system the pin-side plug connector is designated with ⽧ row A

1 to 9,

⽧ row B

1 to 7,

⽧ row C

1 to 9.

This results in a designation such as B3 (B = row, pin = 3). b. from robot system A6 enable for mould closing A3/C3 mould area free A1/C1 emergency stop (RS) A2/C2 emergency stop (RS) B2 operation without RS B3 enable for ejector retraction B4 enable for ejector advancement B5 enable for core pulls 1 insertion B6 enable for core pulls 1 retraction B7 enable for core pulls 2 insertion B8 enable for core pulls 2 retraction A7 enable for full mould opening C5 +24 V C9 0V

Voltage supply

The voltage for the RS is supplied by a separate lead and is conducted via the main switch of the RS.

Type of contact, load capacity

All contacts in the RS and in the IMM are potential-free contacts.

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1. Pin assignment

⽧ For the loading capacity of the robot system contacts: see information of RS manufacturer.


⽧ The contacts on the IMM can be loaded with: max. 60 V, 1 A.

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14.2.3

Pin assignment

Signals and pin assignments

You can also check the signals and the pin assignments of the EUROMAP 67 interface in the parameter panel “Robot systems. Call up the “Administration” main group with this key.

Call up the parameter panel “Valves/switches of robot system” with this key.


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Call up the “Valves/switches” superior group with this key.

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14.2.3

Pin assignment

4. Pin assignment:

Start of robot system (from IMM) Start of RS movement into mould K660

ZA3/ZC3 ZA4/ZC4 ZB3

ZB4

ZB5

ZB6

ZB7

ZB8

ZA5

ZB2 ZA6

ZC5 ZA8

1

Safety gates “are closed” (from IMM) Ejector “is retracted” K667 Ejector “is advanced” (from IMM) K666 Core pulls 1 free for robot to enter mould area (from IMM) K668 Core pulls 1 are in position for removal of moulded part (from IMM) K669 Core pulls 2 free for RS to enter mould (from IMM) K672 Core pulls 2 are in position for removal of moulded part (from IMM) K673 Reject part (from IMM) K662 Fully automatic IMM (from IMM) Mould closed (from IMM) K665 Part moulded K664 (from SM) Mould opened to intermediate stop ¹ (from IMM) K663

The contacts must be opened with the emergency stop signal from the IMM. The signal is sent by the IMM when the contact is closed. The signal impulse must be guarded in such a way that it is only sent when the minimum opening width required by the robot to enter the mould has been reached or exceeded. Inadvertent alteration to a mould opening stroke smaller than that required for the robot system to enter the mould must not be possible. The signal must remain active until the mould is opened and must not be deactivated by a change of operating mode or opening of the safety gate. Note: if the signal is sent too soon (incorrect or inadvertent alteration to stroke encoder signal s504) damage to the robot system can be caused. Safeguard of the movement of the RS in and out of the mould. The contacts are closed when the safety gates on the IMM are closed.

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Emergency stop (from IMM)

IMM sends signal to RS that the ejector is retracted, independent of the position (signal from IMM) of the movable mould platen (contact closed). IMM sends signal to RS that the ejector is advanced (can be an impulse) (contact closed)

IMM sends signal to RS that the core pulls 1 are in position for the RS to enter the mould, independent of the position of the mould platen (contact closed) 1 IMM sends signal to RS that the core pulls 1 are in position for part removal (can be an impulse) (contact closed).1

IMM sends signal to RS that the core pulls 2 are in position for the RS to enter the mould, independent of the position of the mould platen (contact closed) 1 IMM sends signal to RS that the core pulls 2 are in position for part removal (can be an impulse). (contact closed) 1 IMM sends signal to RS that the removed part is a reject. The signal must be set with “mould opened” and can be reset together with the start of “mould closing”. 1 (contact closed). IMM sends signal to RS that the operating mode switch is on “fully automatic” (contact closed). IMM sends signal to RS that mould closing is completed. The signal “Enable for mould closing” (S685) can be herewith deleted (contact closed). K664 is active in automatic, when injection is completed from the start of mould opening to “enable for mould closing”. K663 is active from intermediate stop position to “mould opened (K660 = “1”).

not standard, option only

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14.2.3


ZA1/ZC1 ZA2/ZC2 ZA7

Pin assignment

A6

Start of mould closing (from RS) S685

Enable signal for mould closure. The contact closes when the RS has retracted far enough for the mould to be closed and when other control devices of the RS have enabled mould closing. When the IMM is operated without RS this contact is automatically bridged.

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CAUTION: when RS is connected, mould closing must only be enabled when the contact is closed.

A3/C3

A1/C1 A2/C2

Emergency stop (from RS)

B2

Operation with robot system (from RS) S680

B3

Ejector “retracted” (from RS) S687 Ejector “advanced” (from RS) S686 Enable movement of core pulls 1 to position for RS to enter mould unhindered 1 S689 Core pulls 1 in position for part removal 1 S688 Core pulls 2 in position for RS to move unhindered into the mould area 1 S692 Core pulls 2 in position for part removal 1 S693 Enable Full mould opening (from RS)

B4

B6


Monitoring of “mould area free” (from RS) S681

B5

B7

B8

A7

C5 C9 1

The signal “Enable mould closing” itself must not be sent by the closing of a safety gate or a key in OR function, even in manual operation. The signal remains active for the duration of the mould closing process. When the signal is interrupted, the closing movement must also be stopped. Monitoring for mould opening and closing. The contact is sent from the limit switch directly on the insertion shuttle. The limit switch is opened when the insertion shuttle leaves its starting position in the area of the IMM (before it enters the mould area). If the contact is open, neither an opening or closing movement of the IMM must occur. The contact remains effective even without RS operation. Emergency stop. When the contact is opened the control system of the IMM is switched off. The contact is to be connected in series with the emergency stop function of the IMM. Operating mode selection. The open contact sends signal to IMM: operation with RS (= position 1). The closed contact sends signal to IMM: operation without RS (= position 0). Enable for “Ejector retraction. The closing of the contact permits the machine to retract the mould ejector (permanent signal until acknowledged). Enable for “Ejector advancement”. The closing of the contact permits the machine to advance the mould ejector (permanent signal until acknowledged). Enable signal from RS (S689) for core pull 1 retraction.

Enable signal from RS (S688) for core pull 1 insertion.

Enable signal from RS (S692) for core pull 2 retraction.

Enable signal from RS (S693) for core pull 2 insertion.

Enable signal from RS (S684) for full mould opening.

+24 V Ground

not standard, option only

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14.2.3


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Pin assignment

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14.2.3

Activating the robot system

14.2.4 Activating the robot system Before you can operate your external robot system via the robot system interface, you must first activate the robot system in your maching configuration.

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With this key you call up the main group “Set-up parameters”.

With this key you call up the superior group “Robot system”.

Call up the parameter panel “Standard robot system“ with this key.

● Input “yes” at f9148 robot interface (k661 output). 䡩 Thus in automatic operation the signal K661 = “1”.


When the signal K661 is queried by the robot system, the robot system can be activated and moved to the respective positions in the production sequence.

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14.2.4


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Activating the robot system

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14.2.4

Selecting the operating mode of the robot system

14.2.5 Selecting the operating mode of the robot system When the injection moulding machine is operated in manual mode, an external robot system is not normally actuated (K662 and K664 are not actuated).

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In order to enable the use of the robot system in manual mode of the machine, you must first activate the function f9480. Call up the main group “Set-up parameters” with this key.

Call up the superior group “Robot systems” with this key.

With this key you call up the parameter panel “Standard robot system“.

● Select “active” at f9480 = automatic signal (K661) in manual. 䡩 The signal K661 is thus set to “1”, even in manual operation.


The robot system can now also be operated in manual modes.

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14.2.5


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Selecting the operating mode of the robot system

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14.2.5

Inputting parameters for the robot system

14.2.6 Inputting parameters for the robot system The following functions are available, depending on the equipment and the configuration of the interface for the robot system. Some parameters are only displayed when the respective processes are programmed in the production sequence.

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Call up the main group “Set-up parameters” with this key.

Call up the superior group “Robot systems” with this key.

With this key you call up the parameter panel “Standard robot system“.

● Enter the required data at each parameter.

f9485 Stroke-start parallel to mould

● Input “Yes” here if the robot system is to be started with K663 and no intermediate stop is programmed. 䡩 K663 becomes active as soon as s567 is reached.

s567 Stroke start

● Input the stroke position in mm here, at which the robot system is to move into the mould.


䡩 K663 becomes active as son as s567 is reached.

s566 Minimum mould stroke for start

● Input the minimum mould stroke here which must be reached before the robot system is started. 䡩 If s566 is not reached the controller issues an alarm (not when f9072 = “yes”).

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14.2.6


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Inputting parameters for the robot system

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14.2.6

Connecting a robot system, function check

14.2.7 Connecting a robot system, function check

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Installation surfaces on top of the fixed mould clamping platen have been prepared for the installation of a robot system (refer also to chapter 1.1.2 “Mould installation dimensions”).

SAFETY INSTRUCTIONS

If you are operating your machine with a robot system, a certain element of danger results in the area of action of the robot system which must be appropriately safeguarded. For this reason, a suitable safeguard which corresponds to the accident prevention regulations must be installed! The machine must only be operated when the safeguard is installed.

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The operating authority of the machine is responsible for ensuring these safety measures are carried through.

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14.2.7

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Connecting a robot system, function check

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14.2.7

Signal transfer, EUROMAP 67 interface

14.2.8 Signal transfer, EUROMAP 67 interface

Injection unit machine - ejector

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( GV1561E GW1561E )

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Injection unit machine -clamping unit

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14.2.8

Signal transfer, EUROMAP 67 interface

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Injection unit machine - core pull

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( GX1561E )

The output of the end position signals for core pull group 2 and the monitoring of the enable signals are the same as for core pull group 1.

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14.2.8

EUROMAP 12 adapter

14.2.9 EUROMAP 12 adapter If your machine is equipped with a EUROMAP 67 interface, you can also connect robot systems based on EUROMAP 12 with the aid of the adapter cable, part no. 227023.

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All signals required for EUROMAP 12 are made available on a plug connector HAN32.

● Insert the 50-pin plug from the adapter cable into the plug connector +D02 -X134. ● Connect your robot system to the 32-pin plug connector on the adapter cable.

Machine operation without robot system

When no robot system is connected to the interface, the supplied bridging cable must be inserted in the interface. If no bridging cable is inserted, the machine cannot be operated.

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SAFETY INSTRUCTIONS

On account of the enactment of the robot interface, EUROMAP 67 (redundant safety signals for emergency stop and “safety gates closed”), the EUROMAP 12 robot interface is now only permissible for such robots which, according to the specifications by the robot manufacturer, fall in the EUROMAP 12 risk category. Analogously with the current technological developments, ARBURG therefore accepts no liability for non-compliance with EUROMAP specifications insofar as this may cause injury or damage to persons or machinery or for any other damages which may be incurred in the sphere of the buyer or third party due to the operation of a system not safe to operate. In such a case, the buyer shall hold ARBURG free from any complaints or damage claims.

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14.2.9

EUROMAP 12 adapter

EUROMAP 12 pin assignment

If you are working with the adapter cable for EUROMAP 12 the pin assignment corresponds to the following parameter panel: Handling Devices

Signals from handling device: pin: S680 operation without handling 20 S681 mould area free 18/26 S684 S685 S686 S687 S688 S689

enable enable enable enable enable enable

full mould opening mould closing ejector advancement ejector retraction core pull insertion core pull retraction

28 17 22 21 24 23

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Signals from the machine: pin: K660 mould open position 02 K661 automatic 10 K662 reject 08 K663 intermediate mld opening pos.14 K664 part injected 13 K665 mould closed 12 K666 ejector advanced 05 K667 ejector retracted 04 K668 core pulls inserted 06 K669 core pulls retracted 07 K680 order change is active K681 cycle before order change

BS0071UK.TXT

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This parameter panel is not displayed when a EUROMAP 67 interface is in operation, and serves in this case merely as a comparative overview.

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14.2.9

Mould blow device

14.3.3 Mould blow device The optional mould blow device can assist the demoulding of parts with a blast of compressed air.

( GS1716ZA )

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The mould blow device (3) is attached to the machine base and must be connected to the compressed air network at connector (4). The air blast nozzle (1) is mounted near the mould with the adjustable fixture (2).

Inserting the mould blow process in the production sequence

In order to activate the mould blow function, you determine the position in the production sequence at which the air blast is to be carried out. To do this, proceed as follows:


Call up the production sequence of the machine with this key.

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14.3.3

Mould blow device

Time controlled mould blow

䡩 The mould blow process starts when this symbol is reached. ● You input the duration of the mould blow process in the “Mould blow“ parameter panel.

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Insert this symbol for mould blow in the production sequence.

Insert these symbols at the start and stop positions of the mould blow process.

( GD1437Z GT1716Z )

Mould blow not time controlled (start-stop type)

䡩 The mould blow process ends as soon as the stop symbol is reached.

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14.3.3


䡩 The mould blow process starts when the start symbol is reached.

Mould blow device

Stroke-dependent mould blow

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● Program the “mould blow” process simultaneously with the process with which mould blow is to be started as a strokedependent function. ● Select the “Mould blow” process. Press this key.

䡩 The parameter panel “Sequence editor” appears. ● Select the function “Change start condition”. ● Input “stroke-dependent start”. Mould blow delay, duration, stroke start


( GU1716Z )

t551 Mould blow delay

● After inserting the mould blow process in the production sequence, you now enter the values for the delay, the duration and if applicable, the stroke start. 䡩 The mould blow process starts as soon as the symbol is reached and t551 has expired.

t552 Mould blow duration

The air blast is carried out for the duration input at t552.

t571 End delay

Is only displayed when the start-stop type of mould blow has been programmed. 䡩 The mould blow process ends when the time input at t571 expires.

s551 Start condition, stroke

Is only displayed when the start of mould blow has been programmed as a stroke-dependent function of another process. 䡩 The mould blow process starts as soon as the stroke of the process with which mould blow has been simultaneously programmed, (e.g. mould opening, ejector advancement) has been reached.

s551 Start condition, volume

Is only displayed when the start of mould blow has been programmed as a stroke-dependent function of another process. 䡩 The mould blow process starts as soon as the programmed screw stroke, or volume has been reached.

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14.3.3


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Mould blow device

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14.3.3

Software options / process technology



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17

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Parameter selection for the production protocol

17.8 Production protocol 17.8.1 Parameter selection for the production protocol With the production protocol function, it is possible to record and print a protocol during production with up to 16, partly quality-relevant parameters. BAM_207185_000_EN_10

This protocol can for example: ⽧ accompany completed parts as a certicate of quality or ⽧ be used as a shift protocol for error analysis.

Selecting parameters for the production protocol

Here you select the parameters, the data of which are to be stored in the production protocol.

Protocol parameter selection

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( PK0621D )

Protocol parameters 1-8

Touch this key to display a list of all parameters which can be included in the protocol.

● Select the required parameters and confirm this with the “Y” key. 䡩 In automatic sequence the values of these parameters are recorded and displayed in the production actual values.

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17.8.1

Parameter selection for the production protocol

It may be necessary to make several attempts in order to achieve the optimal parameter selection. It is advisable to gain an overview as to which parameters have an influence on the quality characteristics of the moulded part and how large this influence is.

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When the protocolling function is activated, the parameters selected here are recorded cycle for cycle in the “Production protocol” parameter panel, whereby the last cycles are displayed.

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17.8.1

Protocol (logging) function selections

17.8.2 Protocol (logging) function selections Here the various protocol modes, start conditions and protocolling range (duration) etc. are selected.

Protocol function selection

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( PJ0621D )

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These inputs influence the values recorded in the production protocol and consequently the printed and/or graphically displayed values.

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17.8.2


Protocolling good parts f1400

With the parameter f1400 “Good part protocolling” you determine the recording mode for the production protocol for good parts. Possible inputs are: ⽧ no protocolling ⽧ conditional protocolling ⽧ cyclic protocolling

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⽧ continuous protocolling.

The individual inputs have the following function: ⽧ No protocolling No data are protocolled for the good parts. ⽧ Conditional protocolling Up to 5 protocol starts are possible for each order. Start times / part counts can be selected as desired. The duration of the protocol is input either in number of cycles or time period. ⽧ Cyclic protocolling The protocols are started in relation to the cycle count, whereby the intervals between protocols are input in no. of cycles or in time. This means “protocolled” and “non-protocolled” cycles alternate until the nominal part count stipulated in the order is reached. ⽧ Continuous protocolling Every cycle producing good parts is protocolled

If deviations from the tolerances occur, the part is recognized as a “bad part” and the cycle will not be recorded.

Protocolling bad parts f1408

However, with the aid of the f1408 “protocol bad parts” parameter, these cycles can also be recorded. ● Input “Y” at f1408 “protocol bad parts”. 䡩 All cycles selected by the protocol functions are recorded, regardless of whether the parts are “good parts” or “bad parts”. In addition, all bad parts are protocolled. If the good part protocolling is switched off, only bad parts are protocolled.

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17.8.2


Only the cycles which are recognized by the controller as “good parts” are recorded in the production protocol.


Resetting the part counter

To reset the part counter to “0”, call up the “Order data” parameter panel:

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Order data

Good parts Bad parts

● Touch the “good parts” parameter (f077) or “bad parts” parameter (f078). ● Enter “0” as reset value and confirm your input. 䡩 The displayed value is deleted.


( PW0551D )

䡩 The machine starts counting from “0” again.

IMPORTANT

When you reset the parts counter to “0” the protocolling also starts from the beginning again. If these protocols are archived, the protocol starts with a new header.

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17.8.2


Conditional protocolling

Protocol functions selection Good part protocolling

Protocol start

Bad part protocolling

Protocol starts per order Part count for start 1

Protocolling BAM_207185_000_EN_10

Protocol range

Protocol cycle counter

With this parameter you determine whether you want protocolling to start after a certain number of cycles (cycle-related) or after a certain time interval (time-related). Possible inputs are: ⽧ cycle-related start of protocolling,

Further parameters for the determination of the protocol start are displayed, depending on the input at f1411.

( PI0621D )

⽧ time-related start of protocolling.

⽧ Input: f1411 = cycle-related: ● Enter the count of protocol starts (max. 5) at f1413 “protocol starts per order”. ● Enter the count of parts after which a protocol is to be started at f1431 to f1435. ⽧ Input: f1411 = time-related: ● Enter the number of protocol starts (max. 5) at f1413 “protocol starts per day”. ● Enter the times at which a protocol is to be started at parameters t1431 to t1435.

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17.8.2


Protocol start f1411


Protocolling f1412

With the “Protocolling” parameter f1412 you determine the range or duration of the protocolling function. Possible inputs are: ⽧ protocolling via cycle count ⽧ protocolling via time duration.

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Further parameters for the determination of the protocol duration are displayed, depending on the input at f1412. ⽧ Input f1412 = via cycle count: ● Enter the count of cycles, at which each protocol start is to be recorded, at f1414 “protocol range”. ⽧ Input: f1412 = via time duration: ● Input the duration of recording for each protocol at t1414 “protocol duration”. You can select any desired combination of these parameters for determining the recording mode and duration.

Example of conditional protocolling:

Input values: ⽧ Good part protocolling = conditional protocolling, ⽧ Protocolling = via cycle count, ⽧ Protocol starts per day = 5, ⽧ Protocol range = 3.


( GF1288Z )

⽧ Protocol starts = time-related,

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17.8.2


Cyclic protocolling

Protocol functions selection Good part protocolling

Protocol start

Bad part protocolling Protocolling BAM_207185_000_EN_10

Protocol range Protocol intervals

Protocol cycle counter

With this parameter you determine whether protocolling is to be started as a cycle-related or time-related function. Possible inputs are: ⽧ cycle-related start of protocolling,

Further parameters for the determination of the protocol start are displayed, relating on the input at f1411.

( PH0621D )

⽧ time-related start of protocolling.

⽧ Input: f1411 = cycle related: ● Enter the count of cycles to be carried out between two protocol starts at f1415 “protocol interval”. ⽧ Input: f1411 = time-related: ● Enter the time which is to lapse between two protocol starts at t1415 “protocol interval”.

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17.8.2


Protocolling start f1411


Protocolling f1412

● With parameter f1412 “Protocolling” you determine the duration of protocolling. Possible inputs are: ⽧ protocolling via cycle count ⽧ protocolling via time duration Further parameters for determining the protocol duration are displayed, relating on the input at f1412.

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⽧ Input: f1412 = via cycle count: ● Input the cycle count which is to be recorded with each protocol at f1414 “protocol range”. ⽧ Input: f1412 = via time duration: ● Input the recording duration for each protocol at t1414 “protocol duration”. You can select any combination of these parameters for the determination of the mode and duration of recording Example of cyclic protocolling:

Possible inputs: ⽧ Good part protocolling = cyclic protocolling, ⽧ Protocol starts = time-related, ⽧ Protocolling = via cycle count ⽧ Protocol range = 2,


( GA1580ZA )

⽧ Protocol interval = 5.

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17.8.2


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17.8.2

Random sample selection

17.8.3 Random sample selection During production, a certain number of protocolled cycles can be taken as random samples (depending on equipment installed on your machine).

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Such random samples can for example be enclosed with the printed production protocol or can be tested more rigorously for other quality aspects.

Activating random sample selection

Proceed as follows to activate random sample selection: ● Insert the process “Sort out part/sprue” at the required position in the production sequence. 䡩 The parameter “Random sample selection” is displayed in the parameter panel “Protocol functions selection” .

Protocol functions selection

( PG0621D )


● Enter “every protocol” at “Random sample selection”. 䡩 Parts are now sorted out with each protocol.

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To deactivate this function, enter “not active”.

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17.8.3


After you have activated random sample selection, you determine the number of cycles which are to be selected as random samples with each protocol. ● Input the required cycle count at “Random sample range, nom.” This input is dependent on the value you have entered at parameter f1414 = “protocol range” in the “Protocol Functions” parameter panel.

( GD1729Z )

These random samples are marked in the production protocol with a symbol and counted as “Random samples” in the “Order data” parameter panel.

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As a maximum, all cycles that are recorded in the production protocol can be selected as random samples.

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Determining the number of random samples f1406

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17.8.3

Production protocol

17.8.4 Production protocol

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The values recorded in the production protocol are displayed on the monitor (in relation to machine equipment).

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( PM0621DA )

1 2 3 4 5 6 7 8 9 10 11 12

Mean value (8)

parameters selected in “Protocol parameter selection” protocol cycle counter nominal values tolerances good parts bad parts largest protocolled value mean value (average) of protocolled values standard deviation smallest protocolled value change to parameter panel scroll bar (to scroll through list)

The mean value is determined as follows: Mean value = total of all values of a parameter divided by the number of protocolled cycles.

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17.8.4

Production protocol

Standard deviation (9)

The standard deviation is determined as follows:

s = standard deviation n = number of values x = protocolled values

The smaller the standard deviation, the smaller the dispersion of the values around the average value, which means that the recorded values have a small fluctuation. ⽧ If the standard deviation is small, the fluctuation of the protocolled values around the average value is small.

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The standard deviation is a measurement of the dispersion. It tells us how far the recorded measured values differ.

⽧ If the standard deviation is large, either the fluctuation of the protocolled values around the average value is relatively large or a few “freak values” have been recorded. Example

No. of cycles

Standard dev.

= n = Total of x = Total of x² = s no deviation in standard = no dispersion of values

Actual value parameter 2: 12 4 18 16 10 0 14 0 6 20 10 100 1000 0

= n = Total of x = Total x² = s large deviation in standard = large dispersion of values

( CA0114D DE_TB00086A )

1 2 3 4 5 6 7 8 9 10

Actual value parameter 1: 10 10 10 10 10 10 10 10 10 10

10 100 1472 7.24

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Cycle no.

Large fluctuations in part quality

No fluctuations in part quality

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17.8.4

Protocol graphics

17.8.5 Protocol graphics If your SELOGICA controller is equipped with a production protocol function, the protocol parameters that have been recorded can be graphically displayed on the monitor. The values protocolled by the controller are hereby displayed in the “Protocol Graphics 1” to “Protocol Graphics 4” parameter panels (depending on the number of protocolled parameters). BAM_207185_000_EN_10

The division of the parameters into 4 graphic panels is carried out according to the following rules: ⽧ Each graphic panel can contain a maximum of 4 curves. ⽧ First graph: parameters 1-4. ⽧ Second graph: parameters 5-8. ⽧ Third graph: parameters 9-12. ⽧ Fourth graph: parameters 13-16.

IMPORTANT

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Parameters with metering functions (part counters, protocol cycle counters, date, time) are not graphically displayed.

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17.8.5

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Protocol graphics

1 2 3 4 5 6

Start, date and time Stop, date and time Date and time meas. cursor position Bad part Good part Statistical evaluations

With the measuring cursor you can measure individual values and display them, when the display is currently running or frozen. The measuring cursor is displayed as a vertical line in the graphical window. The measuring cursor can be moved to the left or right with these keys.


Measuring cursor

( PL0621DA )

When you touch the graphical area, the usual graphic functions are available:

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17.8.5

Protocol graphics

Grid

In order to simplify the overview, a background grid can be made to appear in the graphics window. Press this key.

䡩 The following selection mask appears. BAM_207185_000_EN_10

Functions Grid ON (OFF) Adjust graph

● Touch the keys “Grid ON” or ”Grid OFF”. 䡩 The grid is faded in and out of the graph window. 䡩 The range of the grid is hereby optimised by the controller.

( PN0605D )

Adjusting the graph

The SELOGICA ’direct’ controller offers, if you request it, a suggestion for the graphical settings. A graph with a pre-defined curve is compiled, reference values determined for these parameters and the display of the curve optimised. ● Touch the “Adjust graph” key. 䡩 The controller carries out the following function:


⽧ Optimisation of the display area of the curves. The upper and lower margins of the curve are automatically adapted to the screen in order to display the recorded curves as large as possible on the screen.

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17.8.5

Protocol graphics

IMPORTANT

If you have manually adjusted the display area beforehand, this will be changed when you press the “Adjust graph” function key.

Recording start/stop

During production the selected measured values are continuously recorded and displayed as coloured curves in the graphics window. The green start symbol at the top right next to the graph indicates that the recording is running.

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Only the display area of the curves is optimised.

In order to precisely measure individual values the display must be stopped (frozen). Press the stop symbol in the editing box to stop the display.

䡩 The red stop symbol at the top right next to the graph indicates that the recording has been stopped. You can now measure individual values with the measuring cursors.

IMPORTANT

To continue the recording the display must be restarted. Press the start symbol in the editing box to restart the display.

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17.8.5


When the recording is stopped, the curves in the graphic window are not renewed.

Protocol graphics

Zoom in/out

With this key you can increase the size of the graphic display.

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With this key you can reset the graphic display to its original size.

IMPORTANT

The special keys for graphical recording are only displayed when you touch inside the graphic area.

The parameter panels “Protocol graphics 2, 3, 4“ are identical in layout and function to parameter panel “Protocol graphic 1“.


Protocol graphics 2/3/4

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17.8.5


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Protocol graphics

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17.8.5


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( PC0556Z ) BAM_207185_000_EN_10



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France: ARBURG S.A.S. Z.I. "Fosse à la Barbière" 1 Rue Louis Saillant 93605 Aulnay-sous-Bois Tél.: +33 (0) 1 48 65 15 07 Fax: +33 (0) 1 48 65 13 54 e-mail: [email protected]

ARBURG Head office:

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( CA0048Z )

Germany: ARBURG GmbH + Co KG Postfach 11 09 72286 Lossburg Tel.: +49 (0) 74 46 33-0 Fax: +49 (0) 74 46 33 33 65 http://www.arburg.com e-mail: [email protected]

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Shanghai: ARBURG (Shanghai) Co., Ltd. No. 58 Hu Qing Ping Highway Shanghai 201105 P.R. China Tel.: +86 (0)21 6268 2211 Fax: +86 (0)21 6268 9210 e-mail: [email protected]

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America:

ARBURG Machine & Trading (Shenzhen) Co., Ltd. 1D, 1st Floor, Block F3.8, Tianan Cyber Park Futian 518040 Shenzhen P.R. China Tel.: +86 (0)755 83433750 3753 Fax: +86 (0)755 83433748 e-mail: [email protected]

YOUR COMMENTS

Tell us your opinion… … concerning this operating manual!

BAM_207185_000_EN_10

As an operator you work daily with our injection moulding machine and use this operating manual. Therefore, you know best what proves its worth in actual practice. We endeavour to produce an operating manual which allows you to operate the machine in the most optimum, safe and efficient manner. You can assist us and others by undertaking the following: ⽧ Take this page, answer the following questions, ⽧ put it in a stamped envelope and send it to ARBURG. In anticipation, we would like to thank you for your co-operation!

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⽧ What is your occupation? ⽧ Is there anything we could change in this manual to make it more useful to you? 1. 2. 3.

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YOUR COMMENTS

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Manual Arburg

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