PX255Standard
HMI Controller & Software Manual
Standard Version
Techmation Co., Ltd.
9F, No.529 Chung Cheng Road Hsin-Tien City, Taipei Hsien
Taiwan, R.O.C.
M8A HMI Controller & Software Manual, Standard Version
Preface
This Controller & Software Manual for the Techmation M10C HMI Series (Standard Version) consists of two parts, the Operations Manual and the Reference Manual.
Please refer to the Operations Manual for exact instructions on how to set up and program the machine?s clamping unit, injection unit, production monitor and the printing and networking functions.
For a detailed explanation of the HMI panel and panel keys as well as for the various HMI display screens please use the Reference Manual.
Warning: For safety precautions and general machine operation and maintenance you must refer to the machine manufacturer?s manual. This is essential to avoid serious injury to the machine operator and to prevent damage to the machine. Changing the machine setup and settings without proper care and knowledge can lead to damage to the machine.
Liability: Techmation assumes no liability in any form for machine operation in connection with the use of this manual. It is your responsibility to ensure safe machine operations. Never operate the machine without proper training and instructions. Read both manuals first (the machine manufacturer?s manual and Techmations?s Controller & Software manual) before attempting any operation of the machine.
Please note that the information in this manual is subject to change without notice.
For any further information, spare parts & services, documentation & product updates, general inquiries etc., please contact us at the following address:
Techmation Co., Ltd.
9F, No. 529, Chung Cheng Road Hsin-Tien City, Taipei Taiwan, R.O.C.
Phone: +886-2-2218 1686 Fax: +886-2-2218 1766
E-mail: techtp@techmation.com.tw
We hope you will find this manual helpful for your machine operations. In order to help us improve our products and documentation we encourage you to provide us with any feedback and suggestions for improvement you might have.
This document remains our property and must not be copied without our written consent. Its contents may neither be made known to third parties nor be used for non-approved purposes. This manual is for internal use only.
Copyright ? 2000 by Techmation Co., Ltd., Taipei, Taiwan, R.O.C 2 Techmation Co., Ltd.
M10C HMI Controller & Software Manual, Standard Version
Table of Contents Preface ................................................................................................................................ 2 1. Operations Manual ........................................................................................................ 5 1.1 Clamping Unit Setup .............................................................................................. 5 1.1.1 Mould Height Adjustment ............................................................................ 5 1.1.2 Mold Closing and Mold Protection ............................................................... 6 1.1.3 Mold Opening ............................................................................................... 7 1.1.4 Ejector ........................................................................................................... 8 1.1.5 Air Blast ........................................................................................................ 9 1.1.6 Core(s) ......................................................................................................... 10 1.2 Injection Unit Setup .............................................................................................. 11 1.2.1 Nozzle/Injection Unit .................................................................................. 11 1.2.2 Injection and Hold Pressure ........................................................................ 12 1.2.3 Charge (Plasticizing) and Suck-Back ......................................................... 13 1.2.4 Heater .......................................................................................................... 14 1.3 Production Monitor Setup .................................................................................... 15 1.4 Other Functions and Settings ................................................................................ 17 2. Control Panel (HMI) .................................................................................................... 18 2.1 Control Panel and Keys ........................................................................................ 19 2.1.1 Machine Control Panel Keys ...................................................................... 19 2.1.2 Machine Operating Mode Keys .................................................................. 20 2.1.3 Mold Height Adjustment ............................................................................ 20 2.1.4 Manual Operation Mode Keys .................................................................... 21 2.1.5 Mold Adjustment Keys ............................................................................... 25 2.1.6 Data Entry Keys .......................................................................................... 26 2.1.7 Numerical Keys........................................................................................... 26 2.1.8 Text Input Keys ........................................................................................... 26 2.1.9 Input Dialog Box Confirm/Cancel Keys ..................................................... 27 2.1.10 Screen Selection Keys ................................................................................. 28 2.2 HMI Display ......................................................................................................... 28 2.2.1 Screen Selection .......................................................................................... 29 2.3 Control Panel ........................................................................................................ 29 2.4 Clamp Settings ...................................................................................................... 31 2.4.1 Clamp open/close setting ............................................................................ 31 2.4.2 Clamp set..................................................................................................... 32 2.4.3 Clamp PAR1 ............................................................................................... 33 2.5 Injectio .................................................................................................................. 34 2.5.1 Injection Settings......................................................................................... 34 2.5.2 Inject Set ..................................................................................................... 35 2.5.3 Injection Settings Profile ............................................................................. 36 2.5.4 Injection Settings Profile ............................................................................. 38 2.6 Ejection ................................................................................................................. 39 2.6.1 Ejector Settings ........................................................................................... 39 2.6.2 Air Blast Settings ........................................................................................ 40 2.7 Core Settings ........................................................................................................ 40 2.7.1 Core A/B ..................................................................................................... 41 2.7.2 Core C/D .................................................................................................... 42 2.7.3 Core FUNC ................................................................................................ 41 2.7.4 Core PARA ................................................................................................ 43 2.8 Nozzle Settings ..................................................................................................... 42
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2.8.1 Nozzle/Mold Adjustmen ............................................................................. 42 2.8.2 Nozzle/Mold FUNC .................................................................................... 43 2.8.3 Nozzle/Mold PARA .................................................................................... 43 2.9 Temperature Control ............................................................................................ 44 2.9.1 Temperature set ........................................................................................... 44 2.9.2 Temperature Settings .................................................................................. 44 2.9.3 Temperature func ........................................................................................ 45 2.9.4 Temperature para ........................................................................................ 46 2.9.5 Heater Presetting ......................................................................................... 46 2.10 Fast set .................................................................................................................. 46 2.11 Alarm/Error Message Display Screen .................................................................. 48 2.12 Monitoring Settings (Automatic Alarm) ............................................................. 49 2.12.1 Monitoring Settings 1.................................................................................. 49 2.12.2 Monitoring Settings 2/3 (Production Parameter Comparison) ................... 51 2.13 Transducer Zero Point Reset ................................................................................ 53 2.14 I/O Channel Diagnostics ....................................................................................... 54 2.14.1 Input Channel Diagnostics (PB) ................................................................. 54 2.14.2 Output Channel Diagnostics (PC) ............................................................... 55 2.14.3 I/O Channel Reassignment.......................................................................... 56 2.14.4 Mold Set Database ...................................................................................... 57 2.14.5 Mold Save ................................................................................................... 58 2.14.6 Mold Read ................................................................................................... 59 2.14.7 Mold Delete................................................................................................. 60 2.14.8 System Settings ........................................................................................... 61 2.15 Version ................................................................................................................. 61 2.16 System Parameter ................................................................................................. 62 2.16.1 System set ................................................................................................... 62 2.16.2 Data Base .................................................................................................... 63 2.16.3 System Reset ................................................................................................ 63 2.16.4 Other set ...................................................................................................... 64 2.16.5 DA Adjutment ............................................................................................. 65 3. I/O Channel Index ....................................................................................................... 65 3.1 Input Channels ...................................................................................................... 66 3.2 Output Channels ................................................................................................... 66 3.3 Parameter Index .................................................................................................... 67 3.3.1 Parameter 1 ................................................................................................. 67 3.3.2 Parameter 2 ................................................................................................. 71 4. Alarm/Error Message Index ........................................................................................ 74 5. Robot Installation (Optional) ....................................................................................... 77
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1. Operations Manual
The instructions within the Operations Manual assume that you are familiar with the HMI panel keys and the various HMI display screens. If you are not or you are looking for more information on any of the keys or display screens please refer to the appropriate section within the Reference Manual.
1.1 Clamping Unit Setup
When changing the mold follow the machine manufacturer?s instructions at all times to avoid the possibility of serious injuries to the machine operators.
After changing the mold you have to ensure that the mold and the nozzle/injection unit are properly aligned to avoid damage to the machine. In addition, you need to make sure all necessary hose connections to the mold have been properly established and the mold has been mounted securely.
1.1.1Mould Height Adjustment
Before installing the mold use the Mold Adjustment keys to adjust for mold thickness and to advance or retract core(s) if necessary.
Press the Reduced Mold Height Adjustment Key to roughly adjust for a reduced mold height (reduced distance between moving and static platen) or the Increased Mold Height Adjustment Key to roughly adjust for an increased mold height (increased distance between moving and static platen).
Adjust the mold height. For continues platen movement press and hold the key. The platen will move slightly and stop. Keep the key pressed and after a one-second delay the platen will start to move continuously. Release the key to stop platen movement. If you press the key and release it immediately, the platen will move slightly and stop, allowing for micro adjustments. You can repeat this operation until the moving platen has reached the desired position.
Turn the machine off and install the new mold. Once you have finished the installation of the new mold, close the safety gate, turn on the machine and press the Manual Mold Height Adjustment On/Off Key once to activate the Manual Mold Height Adjustment mode. Switch the HMI display to the Other Settings screen by pressing F7 (Other 1). This screen allows you to change the speed and pressure settings after the mold has been changed. If necessary, adjust the pressure, speed and position settings for the new mold or load the mold set data.
After adjusting the settings press the Manual Mold Height Adjustment On/Off key again to close the mold. While closing the mold the controller will execute an automatic mold height adjustment until the new settings are reached. Once the automatic adjustment has finished all machine operations will stop and the alarm will sound. This indicates that you can now switch back to manual or automatic operation modes.
Turn the machine off. Install the new mold. Turn the Machine on. Switch to Manual Mold Height Adjustment mode and, if necessary, change the speed and pressure settings or load the mold set data. Execute the Automatic Mold Height Adjustment. Switch to normal operation mode. Please note that for safety reasons you have to switch to Manual mode first by pressing either the Manual Mold Height Adjustment On/Off key or the Manual key. If you wish to use any other mode, please change to the desired mode after you have switched to Manual mode.
If you encounter any problems during the mold height adjustment press the Manual key for an emergency reset to stop the operation.
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1.1.2Mold Closing and Mold Protection
Mold closing is executed in three phases: High Speed closing, Low Speed closing and High Pressure closing. For optimum productivity mold closing should be executed as fast as possible. However, to avoid damage to the mold and/or machine it is important to use correct settings to ensure appropriate mold protection. For this reason pay particular attention to the Slow Speed phase.
Press the Manual key to activate the Manual mode. Switch the HMI display to the Clamp Settings screen by pressing F2 (Clamp). Switch into Manual Mode.
Set the Mold Opening Stroke. The Mold Opening Stroke is measured from the closed mold. Therefore the Mold Opening Stroke position is “0” when the Set the Mold Opening Stroke. mold is in its closed position.
Next enter the desired hydraulic speed and pressure
Set the hydraulic speed and pressure settings for the three mold closing phases. You have
for the three mold closing phases. to ensure that the settings allow for a smooth, jerk-free movement of the mold.
Set the hydraulic speed for the Low Speed phase low
Set the transition position for enough to avoid damage to the mold in case a
switching from the High Speed phase jammed part has remained in the mold. For the same
to the Low Speed phase. reason set the lowest hydraulic pressure possible.
To avoid damage to the mold the transition point for switching between High Speed and Low Speed phase should be set before the position where the mold Set the transition position for could come into possible contact with a jammed part. switching from the Low Speed phase to the High Pressure phase. The transition point for switching from the Low Speed to the High Pressure phase should be set at the position where both parts of the mold are starting to touch to initiate the high pressure mold lock-up.
Execute mold closing in Manual
Mode to verify the settings and to To accelerate mold closing you can activate the
check for optimum performance. differential high-speed mold closing option for the High Speed closing phase.
After setting all mold closing parameters execute mold closing in Manual Mode to check for optimum machine performance. If you encounter any problems during the mold closing adjustment press the Manual key for an emergency reset to stop the operation.
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1.1.3Mold Opening
Mold opening is divided into three phases. The initial Slow Speed opening, an intermediate High Speed phase and a final Low Speed phase to slow down the mold before the opening end position is reached.
Press the Manual key to activate the Manual mode.
Switch into Manual Mode. Switch the HMI display to the Clamp Settings screen
by pressing F2 (Clamp).
Verify the Mold Opening Stroke and adjust if
Verify the Mold Opening Stroke and necessary. The Mold Opening Stroke is measured
adjust if necessary. from the closed mold. Therefore the Mold Opening
Stroke position is “0” when the mold is in its closed position. Set the hydraulic speed and pressure Next, enter the desired hydraulic speed and pressure for the three mold opening phases. settings for the three mold opening phases. You have to ensure that the settings allow for a smooth, jerk-free movement of the mold.
Set the transition position for Set the hydraulic speed for the initial Low Speed
switching from the first Low Speed phase low enough to allow for a smooth separation of
phase to the High Speed phase. the part from the mold.
Adjust the transition point for switching from the initial Low Speed phase to the intermediate High
Set the transition position for Speed phase accordingly. switching from the High Speed phase
to the final Low Speed phase. The transition point setting for switching from the
intermediate High Speed phase to the second Low Speed phase should allow the mold to slow down sufficiently before reaching the end position of the
Set Auto Cycle Delay Time for robot Mold Opening Stroke. This is necessary to avoid
use if necessary. possible damage to the machine.
In case you want to use a robot to retrieve the mold product at the end of the mold opening/production
Execute mold opening in Manual cycle you need to set the Auto Cycle Delay Time. Mode to verify the settings and to Enter the time to elapse between the end of mold check for optimum performance. opening and the beginning of mold closing
(indicating the start of the next production cycle).
After setting all mold opening parameters execute mold opening in Manual Mode to check for optimum machine performance. If you encounter any problems during the mold opening adjustment press the Manual key for an emergency reset to stop the operation.
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1.1.4Ejector
The ejector can be operated in three different modes to knock the finished product out of the mold at the end of mold opening. You can choose between the Hold, Count Number and the Vibration modes.
The Hold mode is used during semi-automatic operation. The ejector moves forward according to the ejector settings and the product is dropped or taken out. After the safety gate has been opened and closed the next cycle will start.
In Count Number mode the ejector is activated according to the Ejector and Ejection Count settings. This mode is usually used for automatic machine operation. It does not require the opening and closing of the safety door to continue the production cycle.
If you use the Vibration mode the ejector movement is controlled by the Ejector and Ejection Count settings with the ejector vibrating at the end of the forward movement according to the Vibration setting set in the Parameter 2 screen (setting No. 6) before retracting again.
Press the Manual key to activate the Manual mode. Switch the HMI display to the Ejection Settings Switch into Manual Mode. screen by pressing F5 (Eject).
First, set the Ejection Mode and Count. Please note,
Set the Ejection Mode and Count. if you want to deactivate the ejector you can do so
by setting the Ejection Count to “0”.
The Eject Try Again function is used for the Photo
Set the Forward Pressure and Speed Sensor auto operation mode. If the mold product
for both phases. cannot be knocked out completely, the alarm will
sound and the ejector will be activated again. If the mold product is then successfully knocked out the machine will resume normal operation; otherwise it
Set the Forward End Position and will stop for trouble shooting.
Vibration time (if necessary).
If the mold product has not been knocked out successfully while in Photo Sensor auto operation mode and the Eject Try Again function is not Set the transition point for switching activated, the alarm will sound and the machine will
between first and second phase. stop for ejection trouble shooting.
The initial ejection is divided into two phases that can be controlled separately. Set the pressure, speed Set the Backward pressure and and transition position individually for each phase. speed and delay time (if necessary).
Next, set the pressure and speed for the backward movement. The Backward Delay time allows you to set the time the ejector will stay in the forward end Set the Backward end position. position before it is retracted.
In addition, set the Backward end position for the ejector retraction between repeated activation (in Set the Ejector Activation Delay case of multiple ejector activation). Please note, the
Time if necessary. Backward end position is relative to the absolute retraction end position that is used after final ejector activation and determined by the transducer zero point setting.
Activate the ejector in Manual Mode
to verify the settings and to check for If you require additional cooling of the mold product
optimum performance. after mold opening, set the Ejector Activation Delay Time accordingly.
After setting all ejection parameters activate the ejector in Manual Mode to check for optimum machine performance. If you encounter any problems during the ejection set-up press the Manual key for an emergency reset to stop the operation. 8 Techmation Co., Ltd.
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1.1.5Air Blast
The machine provides an air blast ejection option for the moving platen as well as for the stationary platen.
Press the Manual key to activate the Manual mode.
Switch into Manual Mode. Switch the HMI display to the Ejection Settings
screen by pressing F5 (Eject).
First, set the Activation Time (duration of air blast) Set the air blast Activation Time. for each platen.
Set then the corresponding Activation Position at which you want to activate the air blast. The Set the air blast Activation Position. Activation Position refers to the mold position (reached during mold opening) at which the air blast is activated.
Set the air blast Delay Time.
If necessary, set the Delay Time for activating the air blast (after the Activation Position has been reached) according to your preferences.
Activate the air blast in Manual
Mode to verify the settings and to In case you require additional cooling of the mold check for optimum performance. product after mold opening, set the Delay Time for
the air blast activation accordingly.
After setting all air blast parameters activate the air blast in Manual Mode to check for optimum machine performance. If you encounter any problems during the air blast set-up press the Manual key for an emergency reset to stop the operation.
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1.1.6Core(s)
Depending on your setup your machine may be equipped with up to 3 cores (A, B and C). Each core is controlled separately. When setting up the core(s), you need pay close attention to make sure the settings will not cause damage to the core(s) and/or the mold. Since the cores are freely programmable it is impossible for the controller to prevent all possible settings errors.
The two graphs on the right side of the Core Settings screen indicate the core movement in relation to mold closing (top) and opening (bottom).
Press the Manual key to activate the Manual Mode. Switch the HMI display to the Core Settings screen by pressing F6 (Cores).
Switch into Manual Mode. First, choose for each core either the Core Mode if
you want to use a regular core that is moved in and retracted hydraulically or the Unscrew Mode if your mold requires threads created by unscrewing the Set the Core Mode (Function) and inserted core. If the core is not needed set the Control Mode for each core. Function value to “0”.
Next, select the desired Control Mode to control the core movement. In Core Mode you can use either Set the hydraulic Pressure and Speed Cycle Control or Time Control. In Unscrew Mode for each core. you can use Time Control or Count Control.
Using Cycle Control allows you to control the core movements by limit switches for end-position Set the Position values for moving in control (for insertion and retraction). At the pre-set and retracting each core and enter the point during the production cycle the core(s) will Activation Time or Unscrew Count move in/out until the limit switch controlled end-(if used). position is reached. Please make sure the limit switches are activated since deactivated switches will cause the machine to stop (if Cycle Control is selected).
Activate the cores in Manual Mode
to verify the settings and to check for Time Control uses time settings for core insertion
optimum performance. and retraction. At the pre-set position during the production cycle the core(s) are moved in/out for the set period of time. Therefore core movement (travel) is not controlled by end-position but by time. As a result you will not be able to rely on the protection of limit switches.
Accordingly, in Unscrew Mode the Time Control is used to set the time core unscrewing is activated (e.g. for creating threads).
Count Control uses the pre-set number of revolutions to control the unscrewing of the core at the set position during mold opening. To use Count Control you have to make sure a photo sensor for counting the revolutions is installed on the core driving gear.
Please note that Count Control allows for higher precision than Time Control.
Set the Pressure, Speed, Activation Time, Unscrew Count (if used) and Position values for moving in and retracting each core according to your needs.
Unique to Core A is the possibility to activate Core Unscrewing a second time (2nd Uns.) at the end of the mold opening cycle. Please note that the second unscrewing can only use Count Control.
After setting all core parameters activate the core(s) in Manual Mode to check for optimum machine performance. If you encounter any problems during the core set-up press the Manual key for an emergency reset to stop the operation.
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1.2 Injection Unit Setup
1.2.1Nozzle/Injection Unit
Depending your requirements you can set up the nozzle/injection unit to retract after injection has finished. The controller offers you 3 different modes to choose from if nozzle/injection unit retraction is needed.
Press the Manual key to activate the Manual mode. Switch the HMI display to the Other Settings screen by pressing F7 (Other 1).
Switch into Manual Mode.
First, set the Retraction Mode (Sprue Back). The After Charge mode (A. Chg.) retracts the nozzle/injection unit after charging (plasticizing) is Set the Retraction Mode. finished. The Before Opening mode (B. Opn.) initiates nozzle/ injection unit retraction before mold opening starts. If you want to retract the nozzle/injection unit after injection has finished Set the hydraulic pressure for choose the After Injection mode (A. Inj.). Setting the nozzle/injection unit Advance. value to “0” will cause the nozzle and injection unit to stay in place (no retraction).
Next, set the hydraulic pressure for nozzle/injection Set the hydraulic speed settings for unit Advance. Enter the hydraulic speed settings for the High and Low Speed phases of the corresponding High and Low Speed phases of the the nozzle/injection unit Advance. nozzle/injection unit Advance. During the forward movement the High-Speed settings are used until the set End Position is reached. Thereafter the nozzle/injection unit will move forward using the Set the transition point between High Low-Speed settings, until it has reached the final and Low-Speed phases by entering injection position. the End Position for nozzle/injection unit Advance. Enter the End Position for the Advance movement to set the transition point between High and Low-Speed. It is important to allow for a safety margin of at least 20mm between the set End Position and the actual Activate the nozzle/injection unit in contact point of nozzle and mold (at which the nozzle Manual Mode to verify the settings stops its forward movement and the injection begins). and to check for optimum If the End Position is set too close to the contact point performance. of nozzle and mold the nozzle might not slow down enough before touching the mold. The result could be damage to mold and/or nozzle.
Please note that a position setting of “0” refers to the position reached at the end of maximum nozzle/injection unit retraction. As a result the Advance End Position is always greater than “0”.
After setting all nozzle/injection unit parameters activate the nozzle/injection unit in Manual Mode to check for optimum machine performance. If you encounter any problems during the nozzle/injection unit set-up press the Manual key for an emergency reset to stop the operation.
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1.2.2 Injection and Hold Pressure
Depending on your machine set-up the Injection process is divided into 1 - 4 phases and Hold Pressure into 1 - 3 phases. The corresponding pressure - position graph of the current injection settings and the real-time values achieved during the current Injection/Hold Pressure cycle are display in the Injection Settings Profile. Press F4 (Profile) to access the Injection Settings Profile screen for a review of your settings.
Activate the Manual Mode by pressing the Manual key. Switch the HMI display to the Injection Settings screen by pressing F3 (Inject). Switch into Manual Mode.
First, choose the Hold Pressure Transition Mode. If the Time mode is used the controller will switch to
Set the Hold Pressure Transition Hold Pressure after the set injection time has
elapsed. In case the Position mode has been selected Mode. the controller will switch to Hold Pressure after the last set injection position has been reached. However, the set time is used as a backup to initiate the Hold Pressure phase if for some reason the set transition Set the hydraulic Pressure and Speed position cannot be reached. for each of the Injection and Hold Pressure phases. Please note that you should always set the time limit higher than the usually required injection time. This avoids poor molding results due to possible resign fluidity variations (poor fluidity could require a Set the Position settings for each of longer than usual injection time). The transition the Injection phases. between each Hold Pressure phase is controlled by the corresponding time settings and is not affected by the Hold Pressure Transition Mode settings. Set the Time settings for each of the It is possible to use a combination of pressure and Hold Pressure phases. time settings to control the injection process by setting the position value for the transition from Injection to Pressure Hold to zero. In this case the final position will never be reached and the pre-set Set the Delay Time before Charge injection time will be used as a backup. However, value (if needed). doing so will disable the monitoring of the current injection data and as a result you will not be able to use the injection cushion for monitoring the injection process. Please refer to the Monitor Settings 1
Activate Injection and Hold Pressure section of the reference manual for more information
in Manual Mode to check for on monitoring options.
optimum machine performance.
Next, set the hydraulic pressure and speed for each of the Injection and Hold Pressure phases.
Enter the Position settings for each of the Injection phases and the Time settings for each of the Hold Pressure phases.
If cooling is needed at the end of Injection/Hold Pressure and before Charge (Plasticizing)/Suck-Back is initiated set the desired Delay Time before Charge value accordingly.
After setting all Injection/Hold Pressure parameters activate Injection and Hold Pressure in Manual Mode to check for optimum machine performance. If you encounter any problems during the Injection/Hold Pressure set-up press the Manual key for an emergency reset to stop the operation.
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1.2.3Charge (Plasticizing) and Suck-Back
Charge (Plasticizing) is divided into three phases. You can set the Backpressure and Speed for each phase individually. Suck-back is initiated at the end of Charge (Plasticizing) if required.
Press the Manual key to activate the Manual mode. Switch the HMI display to the Injection Settings Switch into Manual Mode. screen by pressing F3 (Inject).
First, set the Charge (Plasticizing) values for Backpressure and Speed individually for each phase. Set the Charge (Plasticizing) values for Backpressure and Speed for each Next, enter the Positions for the transition between phase. the three Charge (Plasticizing) phases.
Choose the Suck-Back mode. Depending on the selected mode, Suck-Back will be controlled using the
Set the Positions for the transition Position or Time setting. Choose the value “0” for
between the three Charge Position control and the value “1” for Time control.
(Plasticizing) phases.
In addition, enter the Suck-back Speed and Position/Time values. The same input field (below the Suck-Back Pressure and Speed settings) is used for
Set the Suck-Back mode and Speed both, the Time and the Position settings. The field
and Position/Time values. label will change according to the selected mode to
indicate the required value.
Set the Suck-back Position/Time value to “0” if no
If needed set the Delay Time before Suck-back is needed.
Charge and/or Cooling Time values.
If cooling is needed at the end of Injection/Hold Pressure and before Charge (Plasticizing)/Suck-Back is initiated set the desired Delay Time before Charge
Activate Charge (Plasticizing)/Suck-value accordingly.
Back in Manual Mode to verify the settings and to check for optimum In case cooling is needed after the completion of
performance. Charge (Plasticizing)/Suck-Back and before the mold
is opened enter the desired Cooling Time.
After setting all Charge (Plasticizing)/Suck-Back parameters activate Charge (Plasticizing) and Suck-Back in Manual Mode to check for optimum machine performance. If you encounter any problems during the Charge (Plasticizing)/Suck-Back set-up press the Manual key for an emergency reset to stop the operation.
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1.2.4Heater
Depending on your machine set-up the barrel heater of the injection unit is equipped with up to 9 barrel heating zones. The temperature, cushion and timer is controlled separately for each of the barrel?s heater bands. The right hand graph shows the current (actual) and set temperature for each barrel heating zone.
Activate the Manual Mode by pressing the Manual key. Switch the HMI display to the Temperature Settings screen by pressing F8 (Temp).
Switch into Manual Mode.
First, set the Temperature Mode (Keep Warm). Choose “0” if you want to keep the temperature always in the pre-set range regardless of the machine
Set the Temperature Mode (Keep operation. If set to “1” the heater will keep the barrel
Warm). temperature at half the pre-set temperature during times of inactivity.
Next, set the temperature for the different barrel
Set the temperature for the different heating zones. The field below (Act. State) gives you
barrel heating zones. a quick indication on the current heater status for the corresponding barrel heating zone. The * indicates the current temperature is within the set range (cushion). The + indicates the current temperature is
Set the Temperature Cushion for below the set range (cushion) and the heater has
each barrel heating zone. been activated. The - indicates the current temperature is exceeding the set value and as a result the heater has been turned off.
Set the Timer Mode and program the Please note that the heater will be turned off
timer for each barrel heating zone (if immediately once the current temperature exceeds
needed). the set value. For current temperatures below the set value heater activation depends on the set Temperature Cushion. Run the machine in Manual Mode to To adjust the Temperature Cushion, please press F5 check for optimum machine (Para. 2) to go to the Parameter 2 screen. Adjust the performance. corresponding values within the second column. A cushion value of “20” for example would activate the heater once the current temperature has dropped more than 20o C below the set value.
If you want to use the Timer for barrel pre-heating set the Timer Mode to “1” otherwise disable it by entering “0”. To program the barrel heater band activation set the time and day individually for each barrel heating zone.
In case of temperature related malfunctions a “977”, ?988” or “999” will be displayed in the Real Value field. A “977” refers to either a disconnected or malfunctioning D/A Temperature Card. The value “988” identifies either a problem with the Thermal Wire Interface or the corresponding Temperature Sensor. In case the current temperature is exceeding the normal temperature range (the current temperature is above 450o C) the value “999” will be displayed.
After setting all Heater parameters run the machine in Manual Mode to check for optimum machine performance. If you encounter any problems during the Heater set-up press the Manual key for an emergency reset to stop the operation.
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1.3 Production Monitor Setup
The HMI and controller provide you with automatic production monitoring and alarm features. The system allows you to set a desired operating range with upper and lower limits (Delta Values) for each production parameter. Once the current parameter value is outside the set operating range the machine will stop operation and the alarm will sound. For later analysis the monitoring system will record the time and the type of error that caused the alarm. To access the Alarm/Error Message Display screen press F6 (Alarm).
At the beginning of each operation, the automatic alarm is turned off until the machine has finished the pre-set number of production cycles in Auto
Switch into Automatic Mode. Operation mode. After the number of pre-set
production cycles the automatic alarm will be activated and the achieved parameter values of the last production cycle will be used as reference points
Activate the Automatic Alarm Mode for the upper and lower limits (Delta Values) of each
by setting it to “1”. production parameter. Should any of the current production parameters during the next production cycle and thereafter be outside the set upper and lower limits (Delta Values) the alarm will sound and
Set the Delta Values (% and/or machine operation will stop for trouble shooting. absolute) for the production
parameter control. The activation of the automatic alarm function is
delayed to allow for a stabilization of the production cycles. At the start of machine operation it is normal that the current production parameters vary
Switch to the Parameter 2 screen considerably from one cycle to the next before they and set the Auto Alarm Unit Count. begin to stabilize. You should consider this when
setting the number of production cycles before automatic alarm activation to allow for a smooth operation without interruptions. Switch to the Product Data screen to Press the Time Auto key to activate the Automatic set the Target Shot Count and the mode. Switch the HMI display to the Monitor 1 Pack Count (if necessary). screen by pressing F1 (Moni 1).
First, activate the Automatic Alarm Mode by setting the Auto Alarm value to “1”. Run the machine in Automatic Mode.
Next, set the Delta Values (% and/or absolute) for the production parameter control. See below for a more
In case of improved production detailed explanation for the calculation of upper and results re-establish the Reference lower limits based on the Delta Values. Values by setting the Auto Alarm
To adjust the automatic alarm activation settings Mode to “2” if desired. switch to the Parameter 2 screen by pressing F5 (Para. 2) and enter the desired value into field No. 0 in the 4th column from the left.
Switch to the Product Data screen by pressing F9 (Prod). Set the Target Shot Count and the Pack Count (if necessary). Please note that the Pack Count feature is optional and requires the installation of a separate sensor for the Pack Count input. After setting the Target Shot Count and the Pack Count switch back to the Monitor 1 screen by pressing F1 (Moni 1).
Run the machine in Automatic Mode after setting all parameters until the activation of the Auto Alarm Mode to verify the settings and to check for optimum performance. In case of improved production results after the activation of the Auto Alarm Mode re-establish the Reference Values by setting the Auto Alarm Mode to “2” if desired.
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To set the upper and lower limits for current production parameters you can use % values and/or absolute values. These Delta Values are then used in connection with the established Reference Value to determine the upper and lower limits. In case you use a combination of % and absolute values the upper/lower limits will be calculated according to the following formula:
Upper Limit Where
RV + (RV * x/100) + y RV = Reference Value
x = Delta Percentage Value (e.g. 10 for 10%)
Lower Limit y = Delta Absolute Value
RV - (RV * x/100) - y
Since the Reference Values are not fixed and vary from one machine operation cycle to the next the values are lost once the machine is turned off. They will be re-established at the beginning of the next operation cycle by using the current parameter values to determine the new reference points for the upper and lower limits (Delta Values).
If at some point after establishing the Reference Value you want to replace them with the currently achieved parameter values (e.g. because of improved production results) you can set the Auto Alarm Mode at the top of the screen to “2”. The controller will then use the parameter values of the last production cycle as the new reference values.
In all other cases the displayed Auto Alarm mode indicates, if the Auto Alarm has already been activated (mode 1) or if the necessary number of production cycles for establishing the reference values has not yet been reached (mode 0).
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1.4 Other Functions and Settings
The use of optional features such as Power Doors, the Robot, the Solenoid Valve and the Accumulator is set within the Other Functions and Settings screen. Their availability is dependent on your machine set-up.
Press the Manual key to activate the Manual mode. Switch into Manual Mode. Switch the HMI display to the Other Settings screen by pressing F7 (Other 1).
Set the Power Door mode. If activated the Safety Set the Power Door mode. Door opens automatically (in semi-auto mode only) at the end of the cycle. The operating keys to close and open the door are activated. If this function is
Set the Robot Mode. disabled the Safety Doors will not open automatically
and any door opening and closing has to be done manually without the help of the power assisted operating keys.
Set the Inject Fast mode.
Please note that manual Safety Door operation might require considerable physical strength especially when operating large machines. Set the Accumulator mode.
Next, set the Robot Mode. Activate if a robot is used for retrieving the product from the mold. Run the machine in Manual Mode to Activating the Inject Fast mode allows the use of an verify the settings and to check for optional solenoid valve to achieve higher injection optimum performance. speeds.
The Accumulator should be activated if you need to achieve a higher injection pressure and with it the capability of higher injection speeds.
After setting all parameters run the machine in Manual Mode to check for optimum machine performance. If you encounter any problems during set-up press the Manual key for an emergency reset to stop the operation.
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2. Control Panel (HMI)
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2.1 Control Panel and Keys
The Control Panel is covered with a protective Mylar layer to make the panel water, dirt and abrasion resistant. All keys are operated through type A mechanical contact switches to provide for reliability and a long service life.
2.1.1Machine Control Panel Keys
The machine control panel keys allow you to switch between different machine operating modes and to manually control the operation of the machine. Nevertheless, even most manual commands will be executed using the stored machine settings. It is therefore important that you verify the settings first to ensure safe machine operation. Techmation Co., Ltd. 19
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2.1.2Machine Operating Mode Keys
Manual Key: This key has various functions. It is used to change from Auto Operation mode
to Manual Operation mode as well as a reset key for data and alarm settings.
Semi-Auto Key: Press this key to run the machine in Semi-Auto Operation mode. After each
cycle you have to open and close the safety gate to start the next cycle.
Photo Sensor Key: Press this key to run the machine in Auto Operation mode with the Photo
Sensor activated. At the end of each cycle, the photo sensor will verify whether the product has been properly ejected from the mold within 4 seconds. If the product is still in the mold the machine will automatically stop and the alarm will sound. The control display will show an ?Ejection Failure? error message.
Time Auto Key: Press this key to run the machine in Auto Operation mode. Use this
operation mode to let the machine execute each cycle automatically. The controller will stop the machine and the alarm will sound in case an error occurs. In this mode the photo sensor is not activated.
2.1.3Mold Height Adjustment
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2.9.3Temperature func
At this photo you could choose the time of heater
Act time: when you are setting the heating temperature, please choose the time and enter 1 to use, when it reach to the setting time the system will atomically start the heater switch.
Stand by time + Stand by temperature: when chose stand by temperature, and the temperature reaches, the system will start the stand by temperature.
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2.9.4Temperature para
This photo including temperature setting and all the other para (detail information please referral to the Para chart)
2.9.5Heater Presetting
Set here the time and day you want the barrel heater to be turned on to pre-heat the machine before operation. If you want to use the heater presetting set the mode to 1 otherwise disable it by entering “0”.
2.10 Fast set
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This photo can be fast set close mold, open mold, eject mold, inject mold pressing, charge, suck back, and also temperature
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2.11 Alarm/Error Message Display Screen
Total Error Count: The total number of errors recorded.
Display Start No: The screen displays 10 error messages a time. If you have more than 10 recorded errors you can enter here the error number for the first error to be displayed on the screen.
Example: If you have 49 recorded error messages and you want to view error 40 through 49 you would
enter 40 to display error 40 as the first error. Since the screen can display 10 errors at once you would see error 40 through 49.
Please note that the controller stores only the last 100 error messages error No. 1 being the first one recorded. The recorded errors will be kept even if the machine is turned off. For a list and explanation of all error/alarm messages please refer to the Alarm/Error Message Index section of this manual.
Reset: Set this value to “1” if you want to reset the error log. No: Error number.
Code: Error code to identify the type of error.
Total Cnt (Total Count): Total number of occurrences of this specific error. Alarm Description: Brief explanation of the error that caused the alarm. Str.Tim. (Start Time): The time the error occurred and the machine stopped. Reset Tim (Reset Time): The time the error was reset and the machine restarted.
Please note that errors are only recorded while in Auto Operation mode. In any other operation mode the error messages will only be displayed in the bottom left message field of the screen (just above the F1-F8 keys).
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2.12 Monitoring Settings (Automatic Alarm) 2.12.1Monitoring Settings 1
The HMI and controller provide you with an automatic monitoring and alarm system. The system allows you to set a desired operating range with upper and lower limits (Delta Values) for each production parameter. Once the current parameter value is outside the pre-set range the machine will stop operation and the alarm will sound. For later analysis the monitoring system will record the time and the type of error that caused the alarm.
At the beginning of each operation, the automatic alarm is turned off until the machine has finished the pre-set number of production cycles in Auto Operation mode. After the number of pre-set production cycles the automatic alarm will be activated and the achieved parameter values of the last production cycle will be used as reference points for the upper and lower limits (Delta Values) of each production parameter. Should any of the current production parameters during the next production cycle and thereafter be outside the pre-set upper and lower limits (Delta Values) the alarm will sound and machine operation will stop for trouble shooting.
The activation of the automatic alarm function is delayed to allow for a stabilization of the production cycles. At the start of machine operation it is normal that the current production parameters vary considerably from one cycle to the next before they begin to stabilize. You should consider this when setting the number of production cycles before automatic alarm activation to allow for a smooth operation without interruptions.
To adjust the automatic alarm settings use the Parameter 2 screen and enter the desired value into field No. 0 in the 4th column from the left.
To set the upper and lower limits for current production parameters you can use % values and/or absolute values. These Delta Values are then used in connection with the established Reference Value to determine the upper and lower limits. In case you use a combination of % and absolute values the upper/lower limits will be calculated according to the following formula:
Upper Limit Where
RV + (RV * x/100) + y RV = Reference Value
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