Operator Manual:

 

Injection molding machine

SIJECT OP37/CPU614

Release: 2001-11-09

 

Chapter 1 : Basic Operation……………………………………………...2

1.1  How to call screens?…………………………………………………………2

1.2  How to set the parameters in screens?……………………………………….3

1.3  How to get the information from the permanent window?………………….5

Chapter 2 : Process Operation……………………………………………7

2.1 How to set the process for clamp?…………………………………………..7

2.2  How to set the process for ejector?…………………………………….…..12

2.3 How to set the process for carriage?……………………………………….18

2.4 How to set the process for inject/holding?…………………………………21

2.5 How to set the process for charging?………………………………………26

2.6 How to set the process for air blast?……………………………………….30

2.7 How to set the process for mold adjustment?………………………...……32

2.8 How to set the process for barrel heating?………………………..………..40

2.9 How to set the process for core?………………………………………...…43

2.10 How to start fully auto cycle?…………………………………………….46

2.11 How to start purge cycle?…………………………………………………50

Chapter 3 : Function Operation…………………………………………52

3.1 How to use oil pre heating function?………………………………………52

3.2 How to use the functions relative to heating?………………………………...

3.3 How to use the diagnosis function?…………………………………………..

3.4 How to use the part counter?…………………………………………………

3.5 How to set the proportional valve curve?…………………………………….

3.6 How to set the clock and date?……………………………………………….

3.7 How to change the language?……………………………………………….

3.8 How to change the measure unit……………………………………………...

3.9 How to get to the service password…………………………………………..

3.10 How to monitor the quality data…………………………………………..

3.11 How to monitor curve?…………………………………………………….

3.12 How to operate the mold data? ……………………………………………

3.13 How to calibrate the transducer?…………………………………………..

3.14 How to start up the power………………………………………………….

Chapter 4 : Alarm and message

           (unavailable)

 

 

Chapter 3 : Function Operation

3.1 How to enable the Oil pre heat function?

Step 1: Call screen No.2010 “Heater Functions”, ref. to “How to call the screens”;

 

Step 2: Notice the status of the box for “Pre selection oil pre heat mode”, if the box is blacken, that means the function already enabled. Otherwise Press F3 to active this function. If you want to disable this function, Press F3 to whiten the status box.

 

 

 

 

 

 



Step 3:If the Oil pre heat function is active, the safety gates must be closed, otherwise, the function can not be executed.

Rounded Rectangular Callout: The symbol must not be flash
 

 


    After switch on the machine, if the actual oil temperature below 36, the machine will come into the oil pre heat mode automatically.

At this time, the system will output the high pressure and flow which set in screen No.5311 “Miscellaneous parameter 1/9” and open all the pumps. When the actual oil temperature reaches 36°C, the system returns to manual mode automatically.

If during normal operation oil temperature drops below 30°C, machine mode will switch over to oil pre heating mode again.

Attention: the temperature 36°C and 30°C are recommend and could be modified in Screen No.5313 “Miscellaneous parameter 3/9” .

 

 

 

3.2 How to use the functions relative to heating?

Function 1 : Temperature keeping;

Function description : This function allows the barrel temperature keeping on the set value when the normal product stops and it can avoid damaging the material in the barrel by the too high or too low temperature.

Step 1: Setting the keeping temperature for each barrel zone in screen No. 2000 “Heater” ;

Step 2: Call screen No.2010 “Functions heater”, ref. to “How to call the screens?”;

Step 3: Push button F2 toggles between standard and keeping mode, the actual keeping function status can be monitored by the status box;

    Hint: After the keeping is active, the screw movement is disable.

Rounded Rectangular Callout: Status for keeping function

 

Function 2 : Alarm reaction;

Function description : This function allows setting the reaction of the heating if any alarm happens in the auto mode.

Step 1: Call screen No.2010 “Heater functions”, ref. to “How to call the screens?”;

Step 2: Moving the cursor to the setting section for “Alarm reaction”;

Setting the reaction delay time and enable the function.

 The reactions are selected in the “Heater off version”:

Shut off : when the alarm happens and the delay time runs out, the heating will shut off automatically.

Keeping : when the alarm happens and the delay time runs out, the heating will come into the keeping mode automatically.

 

 

Function 3 : Heating zone pre setting;

Function description : This function allows setting the zone number, control type and graphic according the actual barrel configuration. Normally this function is set by the manufacturer.

Step 1: Call screen No.2010 “Heater functions”, ref. to “How to call the screens?”;

Step 2: Setting the actual zone as “ON” below the “Function”. If the zone is active, the according setting values, for example, setting temperature, +tol etc, will displayed in screen No. 2000 “Heater”;

Step 3: Setting the control type for each active zone, for HaiTian machine, the standard setting should be close loop which means the thermocouple is installed, so set the “Open Loop” as “Off”;

The open loop can be used in some conditions, for example, if the thermocouple for this zone is destroyed and one spare part can be found in time, so the open loop can be selected for continuing the producing. For this use, the manual heating percentage should be set in screen No.2000 “Heater”.

Step 4: Selecting the graphic symbol for each zone;

You can select a graphic for each zone from the following choices:

Barrel, Nozzle/Big/End, Nozzle/Big/Middle, Nozzle/Small;

 

Function 4 : Calendar heating;

Function description : This function allows the heater switch to ON automatically by the pre set date and time.

Condition: the power for control system should be on and heater switch is off.

Step 1: Call screen No.2011 “Heater timer”, ref. to “How to call the screens?”;

Step 2: Moving the cursor to the week data setting line;

Setting the heating on time and enable the calendar as “ON”;

 

33 How to use the diagnosis function ?

Description: This function is used to monitor the actual data for all Digital input, Digital output, Analog input and Analog output;

 

331 How to monitor the digital input ?

Step 1 : Call screen No.1411 “Digital In”, ref. to “How to call the screens?”;

 

Step 2 : Monitor the actual status for each digital input.

Status Box: Indication of input status. If the status box is black, it indicates the according digital input signal is effective.

Hint: Input number consists of Byte number and bit number 0 to 7. The number is used for programming.

 

332 How to monitor the digital output ?

Step 1 : Call screen No.1421 “Digital Out”, ref. to “How to call the screens?”;

 

Step 2 : Monitor the actual status for each digital output.

Status Box: Indication of input status. If the status box is black, it indicates the according digital output signal is effective.

Rounded Rectangular Callout: Press F6 to active the outputRounded Rectangular Callout: Input the address Rounded Rectangular Callout: Set On

 

Output forcing function:

Function description: This function is useful for service. The service engineer can check the hardware circuit problem such as wire break, short connect etc by forcing effective the digital output.

Step 1: Push the emergency button;

Hint: For safety, the emergency button should be pushed and the motor is shut off.

Attention: During the function is working, the emergency button should be kept! All movement will be disable under this condition!

Step 2: Set the “Output forcing function” as “On”;

Step 3: Input the address of the favorite output;

The address includes two parts: the first is the Byte number, and the next is the bit number, the dot is between the two numbers.

The byte and bit number are easy gotten from the screen.

status for each digital input.

Status Box: Indication of input status. If the status box is black, it indicates the according digital input signal is effective.

Hint: Input number consists of Byte number and bit number 0 to 7. The number is used for programming.

Step 4: Push F6 to active the output, the according status box will be black. 

Step 5: Press F7 to stop the outputting after the circuit checking finished. The according status box will be white.

Hint: It is impossible to outputs two valves at the same time!

Step 6: If the next output is necessary to check, start from Step 3;

If the next output the near the actual output, the following softkeys are useful:

Using the soft-key “UP” (F2) or “DOWN”(F3) can increase or decrease the byte number automatically. So it is easy to check the next output wiring circuit after this circuit is finish.

Using the soft-key “UP” (F4) or “DOWN”(F5) can increase or decrease the bit number automatically.

Step 7: After all outputs checked, set the “Output forcing function” as “Off” ;then release the emergency button.

 

 

333 How to monitor the analog input for transducer?

 

Step 1 : Call screen No.1432 “Analog input”, ref. to “How to call the screens?”;

 

Step 2 : Monitor the actual position for each transducer.

 

 

 

 

334 How to monitor the analog output?

 

Step 1 : Call screen No.1441 “Analog output”, ref. to “How to call the screens?”;

 

Step 2 : Monitor the actual voltage output for each proportional valves.

 

34 How to set the part counter?

Description: This function is used to count the products. In the auto mode, the actual counter increases one after the holding phase finishes. If the set counter expires, the auto mode finishes after the actual cycle and a message pops up.

Step 1 : Call screen No.1101 “Part counter”, ref. to “How to call the screens?”;

Step 2 : Enable the part counter function;

      In case pre selection PART COUNTER SHUT OFF is ON machine will stop if the number of actual parts is reaching the part counter preset value. An alarm will show up accordingly.

Rounded Rectangular Callout: Set ON

Step 3 : Set the relative parameters;

     “Part count pre set” is used for the value of product number;

Number of produced moldings is been collected. The number of moldings per mold is taken into account.

 

How to reset the counter:

Shot counter detects the total number of automatic cycles and it is not to be reset. The reset sequence is as following:

Step 1: Push F2 Reset Start (Password level 2 required);

Step 2: Push F3 Reset C1 to zero or push F4 reset C2 to zero;

 

 

 

 

 

 

35 How to set the proportional valve curve:

 

Before setting the proportional valve curve, the curve type should be set first;

Step 1: call screen 5200;

    In this screen, we recommend setting as following:

    Line 1 for valve curve type set “4 point 1”, Enable set “ON”; this means the analog output channel 1 (normally used for system pressure output, refer to screen 5250 for detailed setting”)

    Line 2 for valve curve type set “4 point 2”, Enable set “ON”; this means the analog output channel 2 (normally used for system flow output, refer to screen 5250 for detailed setting”)

Step 2: if the proportional valve for back pressure controlling is installed, then:

    Line 3 for valve curve type set “Standard linear”, Enable set “ON”;

    Otherwise, jump to step 3.

Step 3: set the other lines for Enable as “OFF”, and don’t care about the valve curve type for other lines because they are disable.

 

Background:

      There are 4 kinds of valve curve type can be selected: offset and gain,4 point curve, standard linear, free programmable, refer to “proportional valve curve type” for more detail. Here, we just want to say the 4 point curve for pressure and flow valve, standard linear for back pressure are enough according our experience.

Step 4: call screen 5220 to set the analog output channel 1&2;

       According the HaiTian hydraulic circuit design, normally the machine only install one pressure proportional valve for all pressure control and one flow proportional valve for all flow control. Usually an additional pressure proportional valve installed for back pressure control, but it is not standard for all machine. So we always use analog output channel 1 as system pressure control, channel 2 as system flow control and channel 3 as back pressure control.

Step 5~Step 9: set 4-point curve 1 for system pressure control;

Step 5: decide the 4 pressure points, these 4 points will decide the curve as following drawing:

               Pressure

 

                                                 4

                P4

 

 


                                         3

                P3

                             2

                P2

 

                P1    1

                   Act1  Act2     Act3       Act4       Analog output (V)

For example:

To setting the curve, we select 4 points in this curve: 100% pressure, 70%, 40% and 0.So we set CONT for 4-point curve 1 from up to down( from 4 to 1) as 1000, 700, 400 and 0.

 

Attenetion:1000  represents 100% of pressure.

 

the max system pressure is 140 Bar which set in screen 5200 Norm for channel 1, so the pressure points, so the according 4 point pressure are 140bar, 98bar(equal to 140*0.7), 56bar(equal to 140*0.4) and 0bar. From the drawing, we can see P1 is 0, P2 is 56, P3 is 98 and P4 is 140.

 

Step 6: adjusting the point 4 to find the Act 4 value;

          Sub step A: Set 1000 which represents 10V output in Act 4( Line 4 under ACT of 4-point curve 1). Then set 140 bar and 10s for holding step1 in screen 400, that means we will use holding pressure to set the curve.

          Recommend: holding step had better set only one step so that avoiding mistake.

          Background: we can use other movement, for instance, core etc to setting the curve too. We think the best way is using holding because it is good for holding pressure close-loop control.

 

Rounded Rectangular Callout: Set 10.0sRounded Rectangular Callout: Set 140bar

 

Sub step B: If the barrel temperature is OK, press the inject key K55. Look the identify of system pressure gauge.

 

Sub step C: If the real pressure is more than 140 bar, for example, 150bar, then you should reduce the value Act 4, for instance, from 1000 to 950…until the real pressure is just 140 bar;

 

Sub step D: If the real pressure is less than 140 bar, for example, 130bar, you should adjust the pressure max volume in the proportional amplify board until the real pressure is just 140 bar. You should avoid over-adjusting the max volume, otherwise a “dead zone”(in this zone, the current output from the amplify board not change even the input voltage from PLC changed) maybe occurs. Refer to “how to adjust proportional amplify board”.

Attention: at this time, you must confirm that the min volume in the proportional amplify board is minimum, otherwise the 0 bar maybe not accuracy.

 

Step 7: adjusting the point 3 to find the Act 3 value;

          Set 98 bar and 10s for holding step1 in screen 400, then:

If the barrel temperature is OK, press the inject key K55. Look the identify of system pressure gauge.

If the real pressure is more than 98 bar, for example, 110bar, then you should reduce the value Act 3, for instance, from 700 to 650…until the real pressure is just 98 bar;

If the real pressure is less than 98 bar, for example, 90bar, you should increase the value Act 3, for instance, form 700 to 720… until the real pressure is just 98 bar;

 

Step 8: adjusting the point 2 to find the Act 2 value;

       Like step 7, get the Act 2 value by the holding pressure 56bar;

 

Step 9: adjusting the point 1 to find the Act 1 value;

       Normally the CONT 1 is 0 bar, so the Act 1 can set a very small voltage.

 

Step 10~Step 14: set the 4-point curve 2 for flow proportional valve;

Step 10: decide the 4 flow points, these 4 points will decide the curve as following drawing:

 


               Flow

 

                                                 4

                F4

 

                                      

                                      3

                F3

                            2

                F2

 

                F1    1

                    Act1 Act2     Act3        Act4        Analog output (V)

 

 

 

For example:

To setting the curve, we select 4 points in this curve: 100% flow, 70%, 40% and 0.So we set CONT for 4-point curve 2 from up to down( from 4 to 1) as 1000, 700, 400 and 0.

 

Attenetion:1000  represents 100% of pressure.

 

The max system flow is 99% which set in screen 5200 Norm for channel 2.

We recommend that you can use the screw speed to set the flow curve. The max screw speed is set in screen 1301 machine data. The easy way to know the max screw speed is input the a very big value, for example, 1000RPM in screen 500 charging, then a system message pop up, for example:

                     452 Value exceeds upper variable

                     limit.250

 

 So the max screw speed is 250 RPM, the according 4 point flow are 250RPM, 175RPM(equal to 250*0.7), 100RPM(equal to 250*0.4) and 0RPM. From the drawing, we can see F1 is 0, P2 is 100, P3 is 175 and P4 is 250.

     Background: we can use inject speed to setting the curve too. If you decide setting the curve by screw rotate, checking the screw sensor before the next step is required.

 

Step 11: adjusting the point 4 to find the Act 4 value;

          Sub step A: Set 1000 which represents 10V output in Act 4( Line 4 under ACT of 4-point curve 1). Then set 250 RMP and a long distance for charging step1 in screen 500.

 

         Attention: the material should exist in barrel while rotate the screw.

 

         Recommend: holding step had better set only one step so that avoiding mistake.

Rounded Rectangular Callout:    Real      
  RPM
Rounded Rectangular Callout: Set 250

 

     Sub step B: If the barrel temperature is OK, press the charge manual key K58. Look the real screw speed in the screen 500.

 

     Recommend: The best way is use a test measurer to get the real RPM, because the screen display RPM  has a difference comparing with the real RPM.

 

     Sub step C: If the real RPM is more than 250, for example, 260, then you should reduce the value Act 4, for instance, from 1000 to 950…until the real RPM is just 250;

 

     Sub step D: If the real pressure is less than 250, for example, 220, you should adjust the flow max volume in the proportional amplify board until the real RPM is just 220.

 

     You should avoid over-adjusting the max volume, otherwise a “dead zone”(in this zone, the current output from the amplify board not change even the input voltage from PLC changed) maybe occurs. Refer to “how to adjust proportional amplify board”. The method to check the dead zone is set a little low speed, for example, 240 in charging step 1, then charging in manual mode, if the real RPM display value is a little lower than 250, it identifies no dead zone exist; if the real RPM display value is as same as before, you must re-adjust the max flow volume to lower in  proportional amplify board.

 

Attention: at this time, you must confirm that the min volume in the proportional amplify board is minimum, otherwise the 0 bar maybe not accuracy.

 

Step 12: adjusting the point 3 to find the Act 3 value;

          Set  175 RPM for charging step1 in screen 500, then:

If the barrel temperature is OK, press the inject key K58. Look real RPM in screen.

If the real RPM is high than 175, for example, 190bar, then you should reduce the value Act 3, for instance, from 700 to 650…until the real pressure is around 175RPM;

If the real RPM is less than 175, for example, 150bar, you should increase the value Act 3, for instance, form 700 to 720… until the real RPM is around 175 RPM;

 

Step 13: adjusting the point 2 to find the Act 2 value;

       Like step 12, get the Act 2 value by the charging speed 100RPM;

 

Step 14: adjusting the point 1 to find the Act 1 value;

       The zero point for flow curve is different with pressure because it has a bottom voltage. You can do in this way to find the correct Act1:

      Sub step 1: set 0 in Act 1;

      Sub step 2: call screen 300;

      Sub step 3: set 100 bar in carriage forward pressure;

      Sub step 4: set 2% in carriage forward flow, as follow:

 

Rounded Rectangular Callout: Set 2Rounded Rectangular Callout: Set 100

 

     Sub step 5: press carriage forward manual key K45 to move the carriage;

     Sub step 6: if the carriage can’t move, then increase the Act 1 a little, for example, form 0 to 30, then try again…until the carriage can move a little; if the carriage can move, it is abnormal. The flow min volume in proportional amplify board maybe not in min position or some other hardware abnormal.

 

According our experience, the Act 1 normally is 100~300, and the current for flow proportional valve is 0.15~0.2A when 0% is outputted.

 

Step 15: set the standard linear for back pressure proportional valve;

The standard linear don’t need set any parameters, the max backpressure is 140 which set in screen 5200 Norm for channel 3

 

3.6 How to set the clock and date?

Step 1: Call screen No.5041 “Date and Time”, ref to “How to call the screens”;

Attention: Password level 0 is required;

Step 2: Set the date and time for PLC system;

      If the actual PLC time is correct, jump to Step 3

      Input the correct value in SET line as the format: Day-Month-Year Hour-Minute-Second, then press F4, the values in ACT line will change to the same value.

Rounded Rectangular Callout: 1) Set PLC systemOval Callout: Actual PLC time      Attention: Only 2 bits for Year setting, so the last 2 bit can be set, for example, 2002 should be set as 02;

Rounded Rectangular Callout: 2) Press F4

 

 

     This PLC system data and time will concerd with the function “Heater Timer” in screen No.2011;

 

Step 3: Set the date and time for operator panel;

      Input the correct value in SET line as the format: Day.Month.Year  Hour.Minute.Second, then press , the actual date and time in main window will change to the correct value.

 

 

 

 

Rounded Rectangular Callout: Actual panel date and time
 


Rounded Rectangular Callout: Set panel date & time

 

 

 

3.7 How to change the language?

 

Step 1: Call screen 5040;


Press K20, the press F4 in screen 5000; a message will be pop up to require the accordance password level, password “100” should be input;

 

 

Step 2: In screen 5040, press F3 “CHANGE LANGUAGE”, you can get English,German and Chinese by sequence.

 

 

 


 

 

3.8 How to change the measure Unit?

Step 1: Call screen No.5050 “Unit Selection”, ref to “How to call the screens”;

Attention: Password level 0 is required;

Step 2: Move to cursor to the line which you want to change, press , then all the selections appears in a pop up window, Move the  and Down cursor to the unit that you need, press  , then the selected unit will display in the position.

      All the selectable units are as following:

      Axis-Position: mm or Inch ;

      This unit will change all the positions for movement, for example, clamp,ejector,inject etc.

 

      Machine Dimensions: mm or Feet ;

      This unit will change the dimensions in screen No. 1301 “Machine Data”.

 

      Pressure: Bar or Psi ;

      This unit will change all the setting and display pressure except injection,holding and backpressure.

 

      Pressure Injection/Holding/Backpressure: Bar or Psi ;

      This unit will change all the setting and display pressure for injection,holding and backpressure.

 

      Injection Speed: mm/s or inch/s ;

      This unit will change the setting and display speed for injection.

 

      Temperature: °C or °F ;

      This unit will change all the setting and display temperature.

 

Hint: After the unit changed, the original value will be changed according the new unit automatically.

 

 

3.9 How to get the service password level

For customer level, if the setting protected by a higher password level, the system message will display :

                                Please enter password

                                Current level:

 

 

Then the operator can input the password, there are 2 password levels for customer, refer to “How to set the customer passwords”

 

For the service, you should do as the following steps:

Step 1: get the super customer level;

       When above motioned system message occurs, password “100” should be input;

 

Step 2: find the screen 5000 Service menu 1;

Rounded Rectangular Callout:    Input 5000        There are two ways: 1) In any screen, input 5000 in the screen select field of main window;

 

   

    

          2) Press K20, then screen 5000 called;

 

 

Step 3: Press F4 softkey, call screen 5040 system settings;

      If you  not get to the super customer level, when F4 in screen 5000 is pressed, the system message for password will pop up, then password “100” should be input;

Rounded Rectangular Callout: A setting field will appear for SCT, input 723                                                                                      

Step 4: Press F7 to call screen 5042 service code

Rounded Rectangular Callout: A setting field will appear for SCE, input SCE

 

Step 5: input password “723” in the SCT setting field;

       After setting that, SCT(service code technician) level valid. Under this level, Ramp setting, lubrication setting, etc. permit to achieve;

 

If further settings need be modified, SCE level is necessary:

Step 6: insert the floppy disk including SCE password, normally only the service engineer from manufacture hold this disk.

 

Step 7: input  password “SCE” in the SCE setting field;

          If you want to input alphabet characters, you first press the ALPHA-mode push button  , then the LED in the left side will on, it means you can input the left alphabet characters in the numeric key. Then press the numeric key “1”, the character “S” be input to the setting filed, continue to press the numeric key “7”, “8”, the character “C”, “E” be input. After input finish, press  ALPHA-mode stop key , then the LED of ALPHA-mode push key will turn off, it means the system returns back to the numeric input status.

 

Step 8: press the softkey F4, the system reads out the data from the password;

          If the disk is correct, the data in the floppy will appear in the screens, for example, in screen 100, screen 500, etc.

         Under SCE level, the proportional valve curve setting, auto tuning, etc, permit to achieve;

 

 

3. 10 How to monitor the quality data?

Description: This function is used to monitor the actual data that can be pre set by the operator since the last 50 cycles. The Min and Max value will be sampled and the average is calculated.

 

Step 1 : Call screen No.1335 “Quality data configuration”, ref. to “How to call the screens?”;

 

Step 2 : Select the favorite data from each field.

Each field number provides selection out of up to 8 parameters. The detailed information is:

Field number 1: Actual temperature 1 to 8;

Field number 2: Maximum screw rotation speed, Injection work, Charging work;

Field number 3: Transfer to holding position, Mold open position, Start injection position, Cushion;

Field number 4: as same as Field number 3;

Field number 5: Maximum injection pressure, Transfer pressure;

Field number 6: as same as Field number 5;

Field number 7: Maximum injection speed;

Field number 8: Injection speed phase time, Total injection time, Charge time, Clamp close time, Clamp open time, Ejector advance time, Ejector retract time, Cycle time;

 

Short sign: This short-sign will be displayed on quality data table screen to identify the selected parameter.;

 

Alarm reaction: One can pre select at this point for each field separately whether or not an alarm reaction will be carried out, if limits are violated

 

Step 3 : Call screen No.1330 “Quality data”, ref. to “How to call the screens?”;

Softkey F3 to F7 select according tenfold block.

The information at this screen is :

Shot number;

Time stamp of pick up time as: hhmmss. hh=hours; mm= minutes; SS Seconds;

Below to tenfold block calculated parameter from last 50 shots are being displayed: Min and Max, Average, Standard deviation Sigma;

 

Alarm: If any alarm reaction is pre selected at Screen no. 1335, controller is responding as follows:

An alarm will show up if according warning limits (yellow) are violated.

An alarm will show up and machine mode will switch over to “Automatic stop”, if according alarm limits (Red) are violated.

 

How to reset the actual quality data:

Step 1 : Call screen No.1335 “Quality data configuration”, ref. to “How to call the screens?”;

Step 2 : Push button F2 will reset all table data to Zero. Calculated values will be updated as the second new data set will be picked up;

 

 

 

How to monitor curve?

Function escription: By this function, the operator can monitor the actual and setting curve.

 

How to monitor temperature curve?

Function description: The temperatures up to 8 channels( screen No. 1731~1738) can be monitored by curve. These screens provide history display of about last 4,5 hours actual temperature trend .The following example is for barrel zone 1.

 

Step 1 : Call screen No.1731 “Temperature trend 1”, ref. to “How to call the screens?”;

 

Step 2 : Set the Y-axis limit value to required solution;

     The value in X-axis is the time in last 4 or 5 hours.

 

How to monitor injection curve?

Function description: This screen can display injection speed actual and set value curve, and injection limit pressure actual and set curve.

 

Step 1 : Call screen No.1711 “Injection V-curve”, ref. to “How to call the screens?”;

 

Step 2 : Set the parameters to required solution;

These parameters includes:

Display ON/OFF selection;

y-axis scaling Max and Min, separately for pressure and speed.

 

 

 

How to monitor holding curve?

Function description: This screen can display holding actual and set value curve.

 

Step 1 : Call screen No.1710 “Holding P-curve”, ref. to “How to call the screens?”;

 

Step 2 : Set the parameters to required solution;

These parameters include:

Display ON/OFF selection;

y-axis scaling Max and Min.

 

How to monitor recovery curve?

Function description: This screen can display actual and set value curve for screw rotational speed and backpressure.

 

Step 1 : Call screen No.1712 “Recovery curve”, ref. to “How to call the screens?”;

 

Step 2 : Set the parameters to required solution;

These parameters include:

Display ON/OFF selection;

y-axis scaling Max and Min.

 

3.11 How to use trigger curve?

Function description: Trigger curve provides display of fast analog events that can be selected in the screen.

 

Step 1 : Call screen No.1781 “Trigger curve”, ref. to “How to call the screens?”;

 

Step 2 : Select the trigger event;

 

Step 3 : Select pick up value;

 

Step 4 : Set the time values;

The parameters include:

Sample time, Delay time;

 

3.12 How to operate the mold data?

   In our system, the mold data can be save in the flash memory of the panel or in the 3.5floppy disk. The mold data can be loaded from the flash memory or the floppy disk.

   Attention: Loading data need motor and heating OFF!

3.12.1 How to save the actual mold data to the flash memory?

Step 1 : Call screen No.1130 “data save + load”, ref. to “How to call the screens?”;

Step 2 : Set the “Select data medium” as “Flash”;

Step 3 : Be sure that the “Record type” as “Data”;

Hint : the other record types are for service use.

Step 4 : Input the mold data name under the “Name”;

Hint: the numeric and alpha characters are allowed to input.

Step 5 : Input the other information under the “Comment”, such as the product name, the date etc.

Rounded Rectangular Callout: Step 5Rounded Rectangular Callout: Step 4Rounded Rectangular Callout: Step 3Rounded Rectangular Callout: Step 2

Rounded Rectangular Callout: Step 6 

 


Step 6 : Press F2 to save the mold date;

Step 7 : If the mold data name is already exist in the flash memory, a message

                     

Overwrite it

0 Yes/ 1 No

pops up. Pressing 0 to overwrite the data. Then a message display:

Date Op< = > Plc

 

That indicates the mold data is saving. After the mold data is saved, a message occurs:

Transfer OK!

 

So, the mold data is saved in the flash memory successfully.

 

 

3.12.2 How to save the actual mold data to the floppy disk?

Step 1 : Call screen No.1130 “data save + load”, ref. to “How to call the screens?”;

Step 2 : Insert the 3.5floppy which has enough space to the disk. Format the floppy if necessary, ref to “How the format the floppy disk”

Step 3 : Set the “Select data medium” as “Floppy”;

Step 4 : Be sure that the “Record type” as “Data”;

Hint : the other record types are for service use.

Step 5 : Input the mold data name under the “Name”;

Hint: the numeric and alpha characters are allowed to input.

Step 6 : Input the other information under the “Comment”, such as the product name, the date etc.

Rounded Rectangular Callout: Step 6Rounded Rectangular Callout: Step 5Rounded Rectangular Callout: Step 4Rounded Rectangular Callout: Step 3

Rounded Rectangular Callout: Step 7 

 


Step 7 : Press F2 to save the mold date;

Step 8 : If the mold data name is already exist in the flash memory, a message

 

 

                    

Overwrite it

0 Yes/ 1 No

pops up. Pressing 0 to overwrite the data. Then a message display:

 

Date Op< = > Plc

 

That indicates the mold data is saving. After the mold data is saved, a message occurs:

Transfer OK!

 

So, the mold data is saved in the flash memory successfully.

 

 

3.12.3 How to upload the mold data from the flash memory?

Step 1 : Call screen No.1130 “data save + load”, ref. to “How to call the screens?”;

Step 2 : Set the “Select data medium” as “Flash”;

Step 3 : Be sure that the “Record type” as “Data”;

Hint : the other record types are for service use.

Step 4 : Press F6 to select the mold data from all exist mold data list;

A window which display the all exist mold data list will pop up after pressing F6. Move the cursor up or down to the name that you want, then press ENTER. The selected mold data name and comment will displayed in the column “Name”.

Rounded Rectangular Callout: Step 4Rounded Rectangular Callout: Step 3Rounded Rectangular Callout: Step 2

Rounded Rectangular Callout: Step 5 

 


Step 5 : Press F3 to load the mold date;

 

Step 6 : A message display:

Date Op< = > Plc

 

That indicates the mold data is loading. After the mold data is loaded, a message occurs:

Transfer OK!

 

So, the mold data is loaded to the actual mode successfully.

 

 

3.12.4 How to upload the mold data from the floppy disk?

Step 1 : Call screen No.1130 “data save + load”, ref. to “How to call the screens?”;

Step 2 : Insert the 3.5floppy which contains the mold data to the disk.

Step 3 : Set the “Select data medium” as “Floppy”;

Step 4 : Be sure that the “Record type” as “Data”;

Hint : the other record types are for service use.

Step 5 : Press F6 to select the mold data from all exist mold data list;

A window which display the all exist mold data list will pop up after pressing F6. Move the cursor up or down to the name that you want, then press ENTER. The selected mold data name and comment will displayed in the column “Name”.

Rounded Rectangular Callout: Step 5Rounded Rectangular Callout: Step 4Rounded Rectangular Callout: Step 3

Rounded Rectangular Callout: Step 6 

 


Step 6 : Press F3 to load the mold date;

 

Step 7 : A message display:

Date Op< = > Plc

 

That indicates the mold data is loading. After the mold data is loaded, a message occurs:

Transfer OK!

 

So, the mold data is loaded to the actual mode successfully.

 

How to format the floppy disk?

Step 1 : Call screen No.1130 “data save + load”, ref. to “How to call the screens?”;

Step 2 : Insert the 3.5floppy which need to be formatted to the disk.

Step 3 : Set the “Select data medium” as “Floppy”;

Step 4 : Set the “Format data medium” as “Format”;

Attention: Format will destroy all the data in the floppy disk!

 

3.12.5 How to erase the mold data?

Step 1 : Call screen No.1130 “data save + load”, ref. to “How to call the screens?”;

Step 2 : Set the “Select data medium” as “Floppy” or “ Flash”;

Step 3 : Press F6 to select the mold data that you want to erase;

Step 4 : Press F4 to erase the selected the mold data;

 

3.13 How to calibrate the transducers

 

Step1: Make sure the transducer installation is correct, including the wiring, the location etc. Measuring the 3 wires which connecting to the transducer, that should be fit for the electronical scheme.  The transducer location should avoiding the transducer damaged during movement.

 

Step 2: Move the machine to the minim position, read out the actual binary code and set this value to reference point 1, then set the position value in value 1, normally we set zero in value 1.

 

        Recommend 1:

        The value set in reference point 1 should be less a little than the actual binary code, for example, 3 or 5 points, the reason is the system will display a very large value if the actual binary code less than the setting reference point 1. For this, when closing finish, the position not display 0.0mm, maybe 0.5mm, it is no problem because the clamping end is controlled by limit switch.

 

       Recommend 2:

       At the minim position, the actual binary code should not less than 50, you can adjust the transducer location to fitting for this requirement. If the actual binary code is too small, it identifies the contactor of the transducer very near to the physical limit and it is dangerous to the transducer! 

 

 

          Words explanation:

         REF. POINT 1: reference point 1; the actual binary code in min position is set here;

         IN VALUE 1: in value 1; the display position value in min position is set here;

         REF. POINT 2: reference point 2; the actual binary code in max position is set here;

         SACALE FACTOR: max value; the display position value in max position is set here;

         ACT BINARY CODE: actual binary code, this column only for display;

         ACTUAL: actual position value, this column only for display;

         OFFSET MEASURE: this column only for display;

         MOLD SPEC. RP 1: this column only for display;

         MOLD SPEC. RP 2: this column only for display;

         MIN. SPEC. RP1: set the value in reference point 1 to this column, this column is designed to full hydraulic machine but it is necessary to be set in toggle machine;

         MIN. SPEC. RP2: set the value in scale factor to this column, this column is designed to full hydraulic machine but it is necessary to be set in toggle machine;

 

Step 3: Move the machine to the maximum position, read out the actual binary code and set this value to reference point 2, then set the position value in scale factor, normally this value is measured because this way is accuracy.

 

Step 4: Move the machine to check the result.

 

 

 

 

Now two examples are given:

Example 1:Calibrating the mold transducer

Step 1: make sure the hardware circuit correct;

Step 2: closing the mold to the end. Look the actual binary code, for instance, now is 100, then set 95(a little smaller) to reference point 1 and set 95 to MIN. SPEC. RP1 also. When the closing finish, the position should display 0.0mm, so set 0.0mm to value 1.

Step 3: opening the mold to the max position, be sure, it is the mechanical max position! Look the actual code, for instance, now is 19880, then set 19888( a little bigger) to reference point 2 and set 19888 to NIN. SPEC. RP2 also. Measuring the real distance from zero position, for example, 580.0mm, then set 580.0 to scale factor.

Step 4: move the mold to the middle position and check. If any problem, return to step 1;

 

Example 2: Calibrating the inject pressure transducer

Step 1: make sure the hardware circuit correct;

Step 2: if the pressure gauge for system is zero and no any movement, we can think now the pressure is zero although maybe there is a very low pressure exist in the hydraulic circuit. Look the actual binary code, for instance, now is 100, then set 100 (for pressure transducer a smaller setting is not necessary) to reference point 1 and set 0 to value 1.

Step 3: set the holding pressure to Max, for example,140 bar and also a long holding time, for example, 5 seconds. To calibrating the pressure transducer, only one holding step is enough.

Step 4: in manual press the inject key to do holding phase. The system pressure gauge should display 140 bar because the linear for proportional value should be adjusted perfect before calibrating the pressure transducer. Look the actual binary code, for example , 23000, and then set 23000 to reference point 2 and set 140 to scale factor.

 

Step 5: check the middle pressure. If any problem, return to step 1;

 

 

 

 

Principle:

    The linear of the position is kept by the linear of the transducer.

    For system, two points decide one line, so if the max and min points are available, all the other points can be decided.

   The transducer only supplies the binary code to system, if the system knows the according position for min and max binary code, so any binary code is confirmed by one position display. Reference to the following chart:

 

 

 

 

                       Position(mm)

 


 

                           Scale factor

 

 

 

 

 

 

                                 Value 1

 


                       Ref point 1                Ref point2     Binary code                       

 

 

 

 

 

 

 

3.14 How to start up the power?

Step 1 : Confirm the power line from the factory is powered;

 

Step 2 : Turn on the main switch 1-DISC (Ref to electrical drawing No. 8) in the machine.

 

Step 3: The system starts to work.

First, all the key lights are on for 3 seconds and the LCD starts to display the process for self-diagnosis.

Then after 10 seconds the start screen displayed.

The system is still starting up until the message “Start up completely” occurs;

 

Step 4: Press  to reset all the alarms on the screen;

Press  to reset all the messages on the screen;

Hint: These alarms and messages are occurred by the system initialization and can be reset easily. 

 

Step 5: Confirm the motor and the heater are ready to run;

      The key lights can indicate the actual status:

Motor ON enabled: K1-LED flashes

Heater ON enabled: K2-LED flashes

Mold Heater ON enabled: K3-LED flashes

 

If the actual status is disable, push  to see the actual alarms and resolve them.

 

Step 6: Push K1 to turn on the motor;

Push K2 to start the barrel heater;

Push K3 to start the mold heater(Option);