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2 - Application ====

V68 Y4000

RUBBER INJECTION MOULDING

Technical Manual
Document: V684_2Aa
Edition: 16/06/2000 Std/A
Technical Manual V68 Y4000
Volume 2 - Application
Table of Contents
RUBBER INJECTION MOULDING

Table of Contents

Document: V684_2Aa
Edition: 16/06/2000

Chapter I - Safety ......................................................................................................................... 1

1. General safety instructions ................................................................................................. 1


1.1. Field of application .......................................................................................................... 1
1.2. Restrictions of the products used .................................................................................... 1
1.3. Main safety rules ............................................................................................................. 1
2. Personal safety devices ....................................................................................................... 3
2.1. Safety device SE ............................................................................................................. 3
2.2. Safety device S1 ............................................................................................................. 3
3. Electrical safety .................................................................................................................... 5
3.1. Main switch ..................................................................................................................... 5
3.2. Opening the cabinet door ................................................................................................ 5
3.3. Fault indicator .................................................................................................................. 5
3.4. STOP Punch button ...................................................................................................... 5
3.5. Fume extractor device ..................................................................................................... 6
3.6. Switch box ....................................................................................................................... 6
4. Hydraulic safety .................................................................................................................... 8
4.1. General ........................................................................................................................... 8
4.2. Hydraulic safety electrovalve .......................................................................................... 8
5. Closing unit safety ............................................................................................................... 9
5.1. Standard cage ................................................................................................................. 9
5.1.1. Opening of the cage elements ............................................................................. 9
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5.1.2. Front ..................................................................................................................... 9


5.1.3. Front guard ........................................................................................................... 9
5.1.4. Rear door ........................................................................................................... 10
5.1.5. Rear guard ......................................................................................................... 10
6. Safety on injection unit ...................................................................................................... 11
6.1. Hot surfaces .................................................................................................................. 11

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Edition: 16/06/2000 page i
Technical Manual V68 Y4000
Volume 2 - Application
Table of Contents
RUBBER INJECTION MOULDING

6.2. Compound inlet chute ................................................................................................... 11


6.3. Ladder placements ....................................................................................................... 11
7. Tooling safety ..................................................................................................................... 12
7.1. General ......................................................................................................................... 12
7.2. Hot surfaces .................................................................................................................. 12

Chapter II - Operating the machine ...................................................................................... 13

1. Powerisation ....................................................................................................................... 13
2. Selection of an existing mould ......................................................................................... 16
2.1. Mould selection ............................................................................................................. 16
2.2. Machines connected to the network ............................................................................. 16
3. Mould start-up programming ............................................................................................ 17
4. Installation of a new tooling .............................................................................................. 18
5. Machine initialisation ......................................................................................................... 24
6. Heating the machine .......................................................................................................... 26
6.1. Mould identification ....................................................................................................... 26
7. Changing the nozzle .......................................................................................................... 27
7.1. Access from below the fixed traverse heating platen .................................................... 27
7.2. Access from above the fixed traverse ........................................................................... 27
7.3. Adjusting injection unit microcontacts ........................................................................... 30
7.4. Beardown microcontact (S48) adjustment .................................................................... 30
7.5. Auto lift microcontact (S72) adjustment ........................................................................ 31
8. Compound loading ............................................................................................................. 34
8.1. Standard use ................................................................................................................ 34
8.1.1. Compound batch conditioning ........................................................................... 34
8.1.2. Rubber strip loading ........................................................................................... 34
8.1.3. Compound monitoring ....................................................................................... 34
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8.2. How to use a silicone stuffer ......................................................................................... 35


9. Starting production ............................................................................................................ 36
9.1. Preliminary conditions ................................................................................................... 36
9.2. Compound preparation ................................................................................................. 36
9.2.1. Standard use ..................................................................................................... 36
9.2.2. Using a CRB ...................................................................................................... 37

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page ii Edition: 16/06/2000
Technical Manual V68 Y4000
Volume 2 - Application
Table of Contents
RUBBER INJECTION MOULDING

9.3. Cycle in semi-automatic mode ...................................................................................... 37


9.3.1. Preliminary conditions ........................................................................................ 37
9.3.2. Machine fitted with S1 safety ............................................................................. 37
9.3.3. Machine fitted with SE safety ............................................................................. 38
9.4. Cycle in automatic mode ............................................................................................... 38
9.4.1. Preliminary conditions ........................................................................................ 38
9.4.2. Cycle start .......................................................................................................... 38
10.Production stop .................................................................................................................. 39
10.1.Procedure for purging in case of production stop ......................................................... 39
10.1.1.Standard use ...................................................................................................... 39
10.1.2.Using a CRB ...................................................................................................... 39
10.2.Procedure for restarting cycle. ...................................................................................... 39
10.2.1.After opening protector ....................................................................................... 39
10.2.2.After pressing P.B. STOP .................................................................................. 40
10.2.3.After an hydraulic pump unit stop. ...................................................................... 40
11.Opening the front ............................................................................................................... 42
11.1.Cleaning the guard ....................................................................................................... 42

Chapter III - Control station .................................................................................................... 45

1. Introduction ......................................................................................................................... 45
2. Operator interface .............................................................................................................. 46
2.1. The display system ....................................................................................................... 46
2.1.1. Hardware ............................................................................................................ 46
2.1.2. Display mechanism ............................................................................................ 46
2.2. The keyboard ................................................................................................................ 47
2.2.1. The associated optimisation function keys ......................................................... 48
2.2.2. The preset function keys .................................................................................... 48
2.2.3. The interface utility keys .................................................................................... 50
2.2.4. The directional keys ........................................................................................... 50
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2.2.5. The utility keys of the machine ........................................................................... 51


2.2.6. The numeric keypad ........................................................................................... 51
2.2.7. The standard keyboard socket outlet ................................................................. 52
3. Control front panels ........................................................................................................... 53
3.1. The main control front panel ......................................................................................... 53
3.1.1. Powerization ...................................................................................................... 54

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Volume 2 - Application
Table of Contents
RUBBER INJECTION MOULDING

3.1.2. Indicator lamps ................................................................................................. 55


3.1.3. Press operation selections ................................................................................. 55
3.1.4. Keyboard selections ......................................................................................... 58
3.1.5. Counters ........................................................................................................... 58
3.1.6. Operating mode selection ................................................................................. 60
3.1.7. Standard movement controls ............................................................................. 61
3.1.8. Optional movement controls .............................................................................. 63
3.1.9. Dual-hand control ........................................................................................... 65
3.2. The auxiliary control front panel .................................................................................... 66
3.2.1. The printer socket outlet .................................................................................... 66
3.3. Kit control buttons ......................................................................................................... 67
3.4. Ancillary cylinder control buttons .................................................................................. 68
3.5. Silicone stuffer control buttons ...................................................................................... 68

Chapter IV - Reading and programming of data ............................................................... 69

1. Screen ergonomics ............................................................................................................ 69


1.1. Introduction ................................................................................................................... 69
1.2. Heading line .................................................................................................................. 70
1.3. Message lines ............................................................................................................... 70
1.3.1. Active messages ................................................................................................ 70
1.3.2. Level of the fault messages ............................................................................... 71
1.3.3. Message display rules ....................................................................................... 72
1.3.4. Details of the alarm message line ..................................................................... 72
1.3.5. Details of the information message line ............................................................ 74
1.4. Active page ................................................................................................................... 74
1.4.1. Heading of the active page ................................................................................ 75
1.4.2. Structure of an active page ................................................................................ 75
1.5. Optimisation function .................................................................................................... 76
1.5.1. Colour code of the text keypads ........................................................................ 77
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2. Programming rules ............................................................................................................ 78


2.1. Active zones ................................................................................................................. 78
2.2. Bounding box ................................................................................................................ 78
2.2.1. Bounding box shift rules .................................................................................... 78
2.3. Data input validation and deletion ................................................................................. 79
2.3.1. Validation rules for numeric settings .................................................................. 79

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Volume 2 - Application
Table of Contents
RUBBER INJECTION MOULDING

2.3.2. Validation rules for a binary choice .................................................................... 79


2.3.3. Validation rules for an exclusive choice (radio buttons) ..................................... 79
2.3.4. Validation rules for a multiple choice (checkboxes) ........................................... 80
2.3.5. Validation rules of a pulldown menu item ........................................................... 80
2.4. Automatic programming ................................................................................................ 80
2.4.1. Selection rules for an optimisation function ........................................................ 80
2.4.2. Selection rules for the tolerance check .............................................................. 80
3. Use of the tables ................................................................................................................. 81
3.1. Introduction to the tables ............................................................................................... 81
3.1.1. Focus and active cells ........................................................................................ 81
3.1.2. Colour coding of the table cells .......................................................................... 81
3.2. Sequence sorting .......................................................................................................... 81
3.3. Data Screening ............................................................................................................. 82
4. Programming of the moulding parameters ...................................................................... 83
4.1. Page background design .............................................................................................. 83
4.2. Parameter display windows .......................................................................................... 84
4.2.1. Inquiry window ................................................................................................... 84
4.2.2. Programming window ......................................................................................... 84
4.2.3. Tolerance window .............................................................................................. 86
4.2.4. Colour code of the parameter windows .............................................................. 87
4.3. Activating an optimisation function ................................................................................ 87
4.3.1. Colour code of the optimisation function selection diamond. ............................. 88
5. Instructions for how to change parameters ..................................................................... 89
5.1. How to change a parameter set value .......................................................................... 89
5.2. How to change the tolerances of a parameter .............................................................. 89

Chapter V - Moulding parameters ......................................................................................... 91

1. Principle of the distribution of functions ......................................................................... 91


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2. Synoptic diagrams of the parameters .............................................................................. 93


2.1. Introduction ................................................................................................................... 93
2.2. Shot size setting ............................................................................................................ 94
2.3. Different types of injection piston retraction .................................................................. 95
2.4. Mould closing ................................................................................................................ 96
2.5. Injection (dynamic phase) ............................................................................................. 97

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Volume 2 - Application
Table of Contents
RUBBER INJECTION MOULDING

2.6. Injection (static phase) .................................................................................................. 98


2.7. Injection-transfer ........................................................................................................... 99
2.8. Initiation of the different time-delays ........................................................................... 100
2.9. Degassing ................................................................................................................... 101
2.10.Mould opening ............................................................................................................ 102
2.11.Ejection on the movable traverse ............................................................................... 103
2.12.Ejection on the fixed traverse ..................................................................................... 104
3. Function Compound preparation ................................................................................ 105
3.1. Base page Compound preparation ......................................................................... 105
3.1.1. Associated graphic page ................................................................................. 105
3.1.2. Main sub-functions ........................................................................................... 106
3.1.3. Parameters ...................................................................................................... 106
3.2. Optimisation page Back-pressure ........................................................................... 109
3.2.1. Associated graphic page ................................................................................. 109
3.2.2. Optimisation sub-function ................................................................................ 109
3.2.3. Parameters ...................................................................................................... 110
3.3. Optimisation page Extruder time-delay ................................................................... 111
3.3.1. Optimisation sub-function ................................................................................ 111
3.3.2. Parameters ...................................................................................................... 112
3.4. Optimisation page Extruder feed strip rupture ......................................................... 113
3.4.1. Associated graphic page ................................................................................. 113
3.4.2. Optimisation sub-function ................................................................................ 113
3.4.3. Parameters ...................................................................................................... 114
3.5. Optimisation page Shot size accuracy .................................................................... 115
3.5.1. Associated graphic page ................................................................................. 115
3.5.2. Optimisation sub-function ................................................................................ 115
3.5.3. Parameters ...................................................................................................... 116
3.6. Optimisation page Compound decompression ........................................................ 117
3.6.1. Optimisation sub-functions .............................................................................. 117
3.6.2. Parameters ...................................................................................................... 118
3.7. Optimisation page Silicone stuffer ........................................................................... 119
3.7.1. Optimisation sub-function ................................................................................ 119
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3.7.2. Parameters ...................................................................................................... 120


4. Function Mould closing ............................................................................................... 121
4.1. Base page Mould closing ........................................................................................ 121
4.1.1. Associated graphic page ................................................................................. 121
4.1.2. Main sub-functions ........................................................................................... 122
4.1.3. Parameters ...................................................................................................... 122

Document: V684_2Aa
page vi Edition: 16/06/2000
Technical Manual V68 Y4000
Volume 2 - Application
Table of Contents
RUBBER INJECTION MOULDING

4.2. Optimisation page Plate approach ........................................................................... 125


4.2.1. Optimisation sub-function ................................................................................. 125
4.2.2. Parameters ....................................................................................................... 126
4.3. Optimisation page Mould height adjustment screw ................................................. 127
4.3.1. Optimisation sub-function ................................................................................. 127
4.3.2. Parameters ....................................................................................................... 128
5. Function Filling ............................................................................................................. 129
5.1. Base page Filling ..................................................................................................... 129
5.1.1. Associated graphic page .................................................................................. 129
5.1.2. Main sub-functions ........................................................................................... 130
5.1.3. Parameters ....................................................................................................... 131
5.2. Optimisation page Injection profile ........................................................................... 136
5.2.1. Associated graphic page .................................................................................. 136
5.2.2. Optimisation sub-functions .............................................................................. 137
5.2.3. Parameters ....................................................................................................... 138
5.3. Optimisation page Degassing .................................................................................. 140
5.3.1. Optimisation sub-functions ............................................................................... 141
5.3.2. Parameters ....................................................................................................... 142
5.4. Optimisation page Cold runner block ....................................................................... 144
5.4.1. Optimisation sub-function ................................................................................. 144
5.4.2. Parameters ....................................................................................................... 145
5.5. Optimisation Page Beardown after injection ............................................................ 146
5.5.1. Optimisation sub-function ................................................................................. 146
5.5.2. Parameters ....................................................................................................... 147
5.6. Optimisation page Vacuum ...................................................................................... 148
5.6.1. Optimisation sub-function ................................................................................. 148
5.6.2. Parameters ....................................................................................................... 149
5.7. Optimisation page Automatic injection unit lift ......................................................... 150
5.7.1. Optimisation sub-function ................................................................................. 150
5.7.2. Parameters ....................................................................................................... 151
5.8. Optimisation page 2nd transfer ................................................................................ 152
5.8.1. Optimisation sub-function ................................................................................. 152
5.8.2. Parameters ....................................................................................................... 153
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5.9. Optimisation page Compound pressure .................................................................. 154


5.9.1. Optimisation sub-function ................................................................................. 154
5.9.2. Parameters ....................................................................................................... 155
6. Function Curing ............................................................................................................ 156
6.1. Base page Curing .................................................................................................... 156
6.1.1. Associated graphic page .................................................................................. 156

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Edition: 16/06/2000 page vii
Technical Manual V68 Y4000
Volume 2 - Application
Table of Contents
RUBBER INJECTION MOULDING

6.1.2. Main sub-functions ........................................................................................... 156


6.1.3. Parameters ...................................................................................................... 157
6.2. Optimisation page Curetrac Corrections ................................................................. 158
6.3. Optimisation page Curetrac communication ............................................................ 159
6.4. Optimisation page Network Link .............................................................................. 160
6.5. Optimisation page Ancillary areas ........................................................................... 161
6.5.1. Optimisation sub-functions .............................................................................. 161
6.5.2. Parameters ...................................................................................................... 162
7. Function Stripping and loading of inserts ................................................................. 163
7.1. Base page Stripping and loading of inserts ............................................................. 163
7.1.1. Main sub-functions ........................................................................................... 163
7.1.2. Parameters ...................................................................................................... 164
7.2. Optimisation Movable traverse ejectors ................................................................... 165
7.3. Optimisation page Movable traverse ejectors ......................................................... 166
7.3.1. Optimisation sub-functions .............................................................................. 166
7.3.2. Parameters ...................................................................................................... 167
7.4. Optimisation page Movable traverse ejectors with encoder .................................... 168
7.4.1. Optimisation sub-functions .............................................................................. 168
7.4.2. Parameters ...................................................................................................... 169
7.5. Optimisation page Mechanical ejectors ................................................................... 170
7.5.1. Optimisation sub-functions .............................................................................. 171
7.5.2. Parameters ...................................................................................................... 171
7.6. Optimisations Fixed traverse ejectors ...................................................................... 172
7.7. Optimisation page Fixed traverse ejectors .............................................................. 173
7.7.1. Optimisation sub-functions .............................................................................. 173
7.7.2. Parameters ...................................................................................................... 174
7.8. Optimisation page Fixed traverse ejectors with encoder ......................................... 175
7.8.1. Optimisation sub-functions .............................................................................. 175
7.8.2. Parameters ...................................................................................................... 176
7.9. Optimisation page Stripping kits .............................................................................. 178
7.9.1. Optimisation sub-functions .............................................................................. 178
7.9.2. Parameters ...................................................................................................... 179
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7.10.Optimisation page Plate approach .......................................................................... 180


7.10.1.Optimisation sub-function ................................................................................ 180
7.10.2.Parameters ...................................................................................................... 181
7.11.Optimisation page Sliding platen ............................................................................ 182
7.11.1.Optimisation sub-function ................................................................................ 182
7.11.2.Parameters ...................................................................................................... 183

Document: V684_2Aa
page viii Edition: 16/06/2000
Technical Manual V68 Y4000
Volume 2 - Application
Table of Contents
RUBBER INJECTION MOULDING

7.12.Optimisation page Ancillary cylinders ..................................................................... 184


7.12.1.Optimisation sub-functions ............................................................................... 184
7.12.2.Parameters ....................................................................................................... 185
7.13.Optimisation page Limits ......................................................................................... 186
7.13.1.Optimisation sub-functions ............................................................................... 186
7.13.2.Parameters ....................................................................................................... 187

Chapter VI - Thermotrac ...................................................................................................... 189

1. Temperature control and Thermotrac function ........................................................... 189


1.1. Introduction ................................................................................................................. 189
1.1.1. Controls and control coefficients ...................................................................... 189
1.1.2. Software Thermotrac ..................................................................................... 189
1.2. Active Thermotrac pages .......................................................................................... 190
1.2.1. Access to the different active pages of Thermotrac ....................................... 190
1.2.2. Colour code of the output states ...................................................................... 190
2. Function Thermotrac ...................................................................................................... 191
2.1. Base page Thermotrac ............................................................................................ 191
2.1.1. Ambient temperature and cold junction measured values ............................... 192
2.1.2. Characteristics of the heating and cooling areas ............................................. 192
2.1.3. Maximum temperatures ................................................................................... 192
2.1.4. Additional characteristics of the heating and cooling areas ............................. 193
2.2. Optimisation page Identification .............................................................................. 195
2.2.1. Identification control ......................................................................................... 195
2.2.2. Referencing columns ....................................................................................... 196
2.2.3. Identification course information frame ............................................................ 196
2.2.4. Frames of the control coefficients .................................................................... 196
2.3. Optimisation page Temperature control supervision .............................................. 198
2.4. Optimisation page Identification control .................................................................. 199
3. Identification through Thermotrac ................................................................................ 200
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3.1. Initiation of the identification process .......................................................................... 200


3.1.1. Identifiable areas .............................................................................................. 200
3.1.2. Starting conditions ............................................................................................ 200
3.1.3. How to start the identification cycle .................................................................. 200
3.2. Identification phases ................................................................................................... 202
4. Use of the PIDT coefficients ............................................................................................ 204

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Edition: 16/06/2000 page ix
Technical Manual V68 Y4000
Volume 2 - Application
Table of Contents
RUBBER INJECTION MOULDING

4.1. Heating-up conditions of a tooling .............................................................................. 204


4.2. Manual programming of the PIDT coefficients ............................................................ 204
5. Error messages Thermotrac ......................................................................................... 205

Chapter VII - Mastertrac ...................................................................................................... 207

1. Introduction ...................................................................................................................... 207


1.1. Movements compatible with Mastertrac ................................................................... 207
1.2. Controls reserved for the application of Mastertrac .................................................. 209
1.3. Cycle Mastertrac ....................................................................................................... 210
2. Function Mastertrac ....................................................................................................... 211
2.1. Access to the different active pages of Mastertrac ................................................... 211
2.2. Selections associated to Mastertrac ......................................................................... 211
2.2.1. Selection of the Mastertrac cycle (cycle 31) .................................................. 211
2.2.2. Selection of the optimisation functions used in the Mastertrac cycle (cycle 31) 211
2.3. Base page Mastertrac ............................................................................................. 212
2.3.1. Movement authorization .................................................................................. 212
2.3.2. Tables of the saved sequence ......................................................................... 213
2.4. Optimisation page Learning of the sequence .......................................................... 214
2.4.1. Activation of the learning mode ....................................................................... 214
2.4.2. Tables of the saved sequence ......................................................................... 215
2.4.3. Frame of the particular operations ................................................................... 215
2.5. Optimisation page Selections .................................................................................. 216
2.6. Optimisation page Cycle selection .......................................................................... 217
3. Application Mastertrac .................................................................................................. 218
3.1. Selections prior to the application of Mastertrac ....................................................... 218
3.1.1. How to select cycle 31 ..................................................................................... 218
3.1.2. How to select the optimisation functions to integrate into the Mastertrac sequence
218
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3.2. Application of the Learning function ......................................................................... 219


3.2.1. How to activate or deactivate the Learning Mode ......................................... 219
3.2.2. How to make a Mastertrac sequence ............................................................ 219
3.2.3. How to integrate a particular operation into a Mastertrac sequence ............. 220
3.2.4. How to save the last sequence executed in the learning mode ...................... 220
3.2.5. How to cancel the last step entered to a Mastertrac sequence ..................... 220
3.2.6. How to delete a Mastertrac sequence ........................................................... 221

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Volume 2 - Application
Table of Contents
RUBBER INJECTION MOULDING

3.3. Use of cycle 31 ............................................................................................................ 222


3.3.1. How to test the Mastertrac sequence ............................................................ 222
3.3.2. How to work in the Automatic mode with the last Mastertrac sequence ..... 222

Chapter VIII - Preset functions ............................................................................................. 223

1. Introduction ....................................................................................................................... 223


2. Function Maintenance .................................................................................................. 225
2.1. Base page Sequential Diagnostic ............................................................................ 225
2.1.1. Presentation and application ............................................................................ 225
2.1.2. Information on the course of the sequential program ....................................... 226
2.1.3. Comparison of cycles ....................................................................................... 226
2.1.4. Information on the difference found ................................................................. 226
2.1.5. How to compare the course of the current cycle with that of the previous cycle 226
2.2. Optimisation page Digital inputs .............................................................................. 228
2.2.1. How to read the status of a digital input ........................................................... 228
2.3. Optimisation page Other inputs/outputs .................................................................. 230
2.3.1. Associated graphic page .................................................................................. 230
2.3.2. Presentation and application ............................................................................ 230
2.3.3. Digital outputs .................................................................................................. 231
2.3.4. Analogue outputs ............................................................................................. 231
2.3.5. Pressure channels ........................................................................................... 231
2.3.6. Encoder channels ............................................................................................ 231
2.3.7. How to read the status of a digital output ......................................................... 232
2.3.8. How to read the value of an analogue output .................................................. 232
2.3.9. How to read the value of an analogue input ..................................................... 232
2.3.10.How to read the value of a counting channel ................................................... 232
2.4. Optimisation page Retrace inputs/outputs ............................................................... 233
2.4.1. Presentation and application ............................................................................ 233
2.4.2. Internal variables .............................................................................................. 234
2.4.3. Curve operating tools ....................................................................................... 234
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2.4.4. Visualization of plotting curves ......................................................................... 234


2.4.5. How to display the curve of an internal variable ............................................... 234
2.4.6. How to analyse an internal variable curve ....................................................... 235
2.5. Optimisation page Preventive maintenance ............................................................ 236
2.5.1. Presentation and application ............................................................................ 236
2.5.2. Description of the preventive maintenance table ............................................. 237

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Edition: 16/06/2000 page xi
Technical Manual V68 Y4000
Volume 2 - Application
Table of Contents
RUBBER INJECTION MOULDING

2.5.3. How to select/deselect a preventive maintenance operation ........................... 238


2.5.4. How to change a preventive maintenance operation ....................................... 238
2.5.5. How to reinitialize the counter triggering a preventive maintenance operation 239
2.6. Optimisation page Retrace faults ............................................................................ 240
2.6.1. Presentation and application ........................................................................... 240
2.6.2. Message filtration ............................................................................................. 240
2.6.3. Table retracing the faults encountered, ........................................................... 241
2.6.4. Process sorting ................................................................................................ 241
2.6.5. How to filter faults in the archive ...................................................................... 242
2.6.6. How to sort faults in the archive ....................................................................... 242
2.6.7. How to change the level of seriousness of a fault ........................................... 242
2.7. Optimisation page Setting software ......................................................................... 244
2.7.1. Presentation and application ........................................................................... 244
3. Function Production configuration ............................................................................. 245
3.1. Base page Production check ................................................................................... 245
3.1.1. Presentation and application ........................................................................... 245
3.1.2. Compatible parameters ................................................................................... 247
3.1.3. How to bring up a parameter window on the page Production check ........... 248
3.1.4. How to clear a parameter from the display zone ............................................. 248
3.1.5. How to modify a parameter set point using the + and - slopes ........................ 248
3.2. Optimisation page Production selection .................................................................. 250
3.3. Optimisation page Mould selection ......................................................................... 251
3.3.1. Presentation and application ........................................................................... 251
3.3.2. Table of stored moulds .................................................................................... 252
3.3.3. Mould duplication tool ...................................................................................... 252
3.3.4. How to select a mould ..................................................................................... 252
3.3.5. How to duplicate or create a mould ................................................................. 253
3.3.6. Using the page Mould selection with option OP227: Machine workstation RepNet-
win 253
3.4. Optimisation page Machine time ............................................................................. 254
3.4.1. Presentation and application ........................................................................... 254
3.4.2. Base sub-functions .......................................................................................... 255
3.4.3. Parameter ........................................................................................................ 255
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3.5. Optimisation page Cycle counter ............................................................................ 257


3.5.1. Presentation and application ........................................................................... 257
3.5.2. Press counter ................................................................................................... 258
3.5.3. Counter RepNet-win ...................................................................................... 258
3.6. Optimisation page Cycle selection .......................................................................... 259
3.6.1. Presentation and application ........................................................................... 259
3.6.2. Basic cycle ....................................................................................................... 260

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Table of Contents
RUBBER INJECTION MOULDING

3.6.3. Preset cycles .................................................................................................... 260


3.6.4. Specific cycles .................................................................................................. 264
3.6.5. How to select a cycle ....................................................................................... 264
3.7. Optimisation page Selections .................................................................................. 265
3.7.1. Presentation and application ............................................................................ 265
3.7.2. Optimisation functions Ejectors on fixed and movable traverses .................. 266
3.7.3. Optimisation functions Vacuum pump ........................................................... 266
3.7.4. Shortcuts .......................................................................................................... 266
3.7.5. How to select or to deselect an optimisation function ..................................... 266
3.7.6. How to use hot keys ...................................................................................... 267
3.8. Optimisation page Heating clock ............................................................................. 268
3.8.1. Presentation and application ............................................................................ 268
3.8.2. Stand-by temperature ...................................................................................... 268
3.8.3. Table of time ranges ........................................................................................ 269
3.8.4. the programming window for the stand-by temperature set value. .................. 269
3.8.5. Control window for the heating authorisation ................................................... 269
3.8.6. How to start up the heating clock ..................................................................... 269
3.8.7. How to reduce the temperature of areas of the mould during slack periods .... 270
4. Function Machine configuration ................................................................................. 271
4.1. Base page Machine configuration ........................................................................... 271
4.1.1. How to change the date on the machine .......................................................... 271
4.2. Optimisation page Language ................................................................................... 272
4.2.1. How to select a language ................................................................................. 272
4.3. Optimisation page Printer ........................................................................................ 274
4.4. Optimisation page Version ....................................................................................... 275
4.5. Optimisation page System ....................................................................................... 276
4.6. Optimisation page Press options ............................................................................. 277

Chapter IX - Graphic functions ............................................................................................ 279


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1. Introduction to the graphic pages .................................................................................. 279


1.1. General ....................................................................................................................... 279
1.2. Using a graphic page .................................................................................................. 279
1.2.1. Display on the screen ....................................................................................... 279
1.2.2. Clearing the screen .......................................................................................... 279
1.2.3. Printing ............................................................................................................. 279

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Table of Contents
RUBBER INJECTION MOULDING

1.3. Structure of a graphic page ........................................................................................ 280


1.3.1. Heading of the graphic page ............................................................................ 280
1.3.2. Different features of the graphic page ............................................................. 280
1.3.3. Plot axes .......................................................................................................... 281
1.4. Graph types ................................................................................................................ 283
1.5. Using the zoom ........................................................................................................... 283
1.5.1. General rules ................................................................................................... 283
1.5.2. Plot freezing ..................................................................................................... 285
1.6. Application procedures of the graphic pages .............................................................. 285
1.6.1. How to access a graphic page ......................................................................... 285
1.6.2. How to plot a graph .......................................................................................... 285
1.6.3. How to delimit the graph part to zoom? ........................................................... 285
1.6.4. How to control the zoom .................................................................................. 286
1.6.5. How to freeze a graph ..................................................................................... 286
1.6.6. How to exit the zoom ....................................................................................... 286
1.6.7. How to return to the dynamic plot .................................................................... 286
1.6.8. How to measure a point on the graph .............................................................. 287
1.7. List of the graphic pages ............................................................................................. 288
2. Graphic page Injection unit temperatures ............................................................... 289
3. Graphic page Back pressure ................................................................................... 290
4. Graphic page Extruding ............................................................................................ 291
5. Graphic page Clamping ........................................................................................... 292
6. Graphic page Injection (Time) .................................................................................. 293
6.1. Direct injection variant ................................................................................................ 293
6.2. Injection transfer variant ............................................................................................. 293
7. Graphic page Injection (Stroke) .............................................................................. 295
8. Graphic page Mould temperatures .......................................................................... 296
9. Graphic page Hydraulics .......................................................................................... 297
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Index ......................................................................................................................................... 299

Previous versions 315

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Table of Contents
RUBBER INJECTION MOULDING

1. Technical progresses ....................................................................................................... 315


1.1. Single documentation .................................................................................................. 315
1.2. Year of manufacture of the machine ........................................................................... 315
2. One-piece front side ......................................................................................................... 316
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Document: V684_2Aa
page xvi Edition: 16/06/2000
Technical Manual V68 Y4000
Volume 2 - Application
Chapter I - Safety
RUBBER INJECTION MOULDING

Chapter I - Safety

1. General safety instructions

1.1. Field of application


Rep presses are designed for rubber injection moulding.

WARNING: The use of the press in any other field of application is strictly forbidden.

1.2. Restrictions of the products used


Rep presses have been designed to transform, without any risk, a wide range
of elastomers except:
products that produce harmful gases,
abrasive products.

1.3. Main safety rules


REP machines are supplied with a specific safety configuration in compliance
with the safety standards in force in the user's country. Under no circum-
stances should modifications be carried out to the press inherent safety devic-
es described below without consulting the manufacturer or the official safety
bodies.

WARNING: REP will not accept liability in the event of an accident following unauthorized
modifications of the machine, its electric, hydraulic or pneumatic circuits or its
kinematic or regulating programs. Indeed, such modifications may endanger
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the operator's safety and are therefore strictly prohibited.


REP will not accept liability for use of the machine other than normal use as
described in the technical manual or for use outside the scope of its specific
safety configuration.

General safety instructions


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Volume 2 - Application
Chapter I - Safety
RUBBER INJECTION MOULDING

In order to ensure his own safety, the safety of the staff working in his vicinity
as well as the safety of the tooling, and so as not to divert the machine inher-
ent safety function, the user must respect the basic safety rules given below,
and instruct his staff accordingly:
1. the machine must be installed properly and the safety devices checked regu-
larly:
2. the machine must only be used respecting the instructions and characteristics
of application;
3. only skilled persons who have followed a special training are allowed to use
the machine;
4. no-one except the operator must approach the machine when it is in use. Be-
fore making any movement, he must make sure that no other person is in the
immediate vicinity of the machine;
5. the whole machine must be maintained and checked regularly by competent
staff.

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General safety instructions


Document: V684_2Aa
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Technical Manual V68 Y4000
Volume 2 - Application
Chapter I - Safety
RUBBER INJECTION MOULDING

2. Personal safety devices


Depending on the safety regulations and standards in force in the user's coun-
try, the REP press can be fitted with an SE or S1 safety device.
Please refer to the regulations and standards in force

WARNING: SE is the sole safety device compliant with the European safety directives
and having received the EC type-examination certificate .

2.1. Safety device SE


REP machines fitted with SE safety devices are protected by a cage shroud to
stop people entering into the closing unit and injection unit movement area
during the machine operating cycle.
The SE safety device requires the user to work with the cage doors and the
safety guard closed.
REMARK: Despite this, the user can operate the options installed on the closing unit (hy-
draulic ejectors on press: OP139 and OP141), when the guard is open, if he
has turned selector S12 beforehand (Select. open guard dual-hand ejectors)
to 1 and controlled the movements dual-handed, in other words by pushing si-
multaneously on the movement control button and on S93 (P.B. dual hand)
and by maintaining the dual control during the whole movement.
refer to section 3.1.3. Press operation selections, page 55
REP machines are fitted with the SE safety device including a hydraulic safety
electrovalve on the hydraulic approach network for closing and opening
movements. This Y69 electrovalve (E.V. Hydraulic safety) is pilot controlled
directly by the closed guard end of stroke microcontact reserved for this.
REMARK: The slide position of this electrovalve is continually controlled by the machine
process-control.

2.2. Safety device S1


REMARK: This section does not concern users in European countries.
REP machines fitted with the safety device S1 allow the operator to work ei-
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ther with or without the safety guard which usually prohibits access to the
closing unit movement area.

Personal safety devices


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Volume 2 - Application
Chapter I - Safety
RUBBER INJECTION MOULDING

The operating mode of the safety guard is selected via the key-operated
switch S4: (S4: selection of guard operation) which allows the following func-
tions:

Positions Operations
The press closing movements and movements of op-
0
without tions OP137a, OP139b and OP141c are authorized with
guard the guard open but they must be dual-handed-control-
led.
All movements of the press and its options can only be
1 with screen
carried out if the screen has been closed beforehand.
a. OP137: Sliding platen
b. OP139: Hydraulic ejectors of the movable traverse
c. OP141: Hydraulic ejectors of the fixed traverse

REMARK: When operating without guard, the cycle can be carried out in Manual or
Semi-automatic operating modes, but in this case the press can only be
closed with the a synchronised and continued S93 dual-handed control.
When operating with screen, the user can operate the options installed on the
hydraulic ejectors on press closing unit (OP139 and OP141), if he has turned
selector S12 beforehand (Select. open guard dual-hand ejectors) to 1 and con-
trolled the movements dual-handed, in other words by pushing simultaneously
on the movement control button and on S93 (B.P. dual hand) and by maintain-
ing the dual control during the whole movement.
refer to section 3.1.3. Press operation selections, page 55

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Personal safety devices


Document: V684_2Aa
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Volume 2 - Application
Chapter I - Safety
RUBBER INJECTION MOULDING

3. Electrical safety

3.1. Main switch


The handle of the main circuit breaker is located on the door of the switch cab-
inet. It enables the operator to switch off the electric current on the entire ma-
chine.
refer to section 3.1.1. Powerization, page 54

WARNING: The main isolating switch must be locked in position OFF prior to any electri-
cal intervention on the machine.
This type of intervention is prohibited to anyone other than authorized electri-
cal maintenance staff.

3.2. Opening the cabinet door


The door of the switch cabinet is equipped with 2 safety latches. It must be
closed and locked when the machine is being used for production or settings.

WARNING: Access inside the cabinet is prohibited to anyone other than authorized elec-
trical maintenance staff.

3.3. Fault indicator


A press fault indicator (H40) shows any anomaly that could be a potential
safety hazard.
refer to section 3.1.2. Indicator lamps, page 55

3.4. STOP Punch button


The machine is fitted out in standard version with a self-locking emergency
stop switch in the form of a punch-button which will stop the machine im-
mediately.
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refer to section 3.1.1. Powerization, page 54


When the Punch button is activated, the KA1 relay contacts cut all supply
inside the electrical cabinet except 220VAC which supplies the PC UPS and the
24VDC supply.

Electrical safety
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Technical Manual V68 Y4000
Volume 2 - Application
Chapter I - Safety
RUBBER INJECTION MOULDING

When the Punch button has been activated, the press cannot move. Turn
and pull out the button head to reconnect the a.m. circuits to the main power
supply.

WARNING: Pushing S201 will not insulate the whole switch cabinet from its supply net-
work: the mains supply must be cut off by means of the main switch isolator
Q1 prior to any electrical intervention on the machine.
When the mains power is cut, the 220VAC voltage saved by the UPS power-
ing the machine PC is maintained for 2 minutes.

REMARK: When the machine is fitted with the option OP071: Simplified rear cage exten-
sion, a second STOP push button(S200) is installed inside the cage.

3.5. Fume extractor device


Some materials injected can give off harmful fumes.
In order to reduce the contamination caused by these fumes, a fume extrac-
tion system must be installed and connected to the REP press.

WARNING: If the user of the machine installs this kind of smoke extractor in case of emis-
sions of harmful gas, dust or fumes, he does so under his own responsibility.

However, the option OPV072: Prearrangement for fume extraction is pro-


vided to configure the REP press so that:
it can only be used when the above extraction system is in operation.
it is automatically stopped if the extraction system stops.

3.6. Switch box


Warning labels are affixed to all the machine switch boxes in order to alert the
operator to the danger of electric shock when opening these boxes. These la-
bels are rectangular, they are red on a yellow background and they show the
following symbol:
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Electrical safety
Document: V684_2Aa
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Technical Manual V68 Y4000
Volume 2 - Application
Chapter I - Safety
RUBBER INJECTION MOULDING

WARNING: Persons unauthorised to carry out electrical maintenance work are prohibited
from opening these switch cabinets.
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Electrical safety
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Edition: 16/06/2000 page 7
Technical Manual V68 Y4000
Volume 2 - Application
Chapter I - Safety
RUBBER INJECTION MOULDING

4. Hydraulic safety

4.1. General
The hydraulic hoses are grouped together, to ensure that even if one hose
breaks, no dangerous movement is caused.
The control electrovalves are three-position type, so that any movement is
stopped in the event of a power cut-off.
In addition to the pressure limiter, an overflow valve mounted on the hydrau-
lic circuit at the pump outlet which prevents the pressure from exceeding the
285-bar maximum value.

WARNING: It is strictly prohibited to modify the hydraulic circuit or to replace equipment


with inappropriate equipment.
Flanges and flexible holding chains must be refitted correctly and the tighten-
ing torques for the different connection supports and hydraulic equipment re-
spected.

4.2. Hydraulic safety electrovalve


REMEMBER: The hydraulic safety electrovalve is part of the SE safety device which com-
plies with European safety directives and which has been granted the EC type-
examination certificate.
The hydraulic safety electrovalve (Y69) is an electrovalve installed upstream
from the hydraulic circuit of the closing unit.
This electrovalve is directly piloted by the microcontact cascade reserved for
this and mounted on each machine cage guard and door.
Furthermore, movement of the electrovalve spool is monitored by a position
sensor (S59: L.S. control E.V. hydraulic safety).
The closing movement is only possible if Y69 is pilot controlled.
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Hydraulic safety
Document: V684_2Aa
page 8 Edition: 16/06/2000
Technical Manual V68 Y4000
Volume 2 - Application
Chapter I - Safety
RUBBER INJECTION MOULDING

5. Closing unit safety

5.1. Standard cage


The standard cage of a press is made up of a swivelling front, 2 fixed side pan-
els and a door on the rear of the unit. All the movable elements of the cage are
controlled by microcontacts.

5.1.1. Opening of the cage elements


If a movable cage element fails to close or opens during a press cycle, it will
inhibit any movement of the press.

WARNING: If a cage element should open during a cycle, the operator will have to turn
to the setting mode, to open the press to the maximum before he can restart
a production cycle.
The automatic or semi-automatic cycle is not interrupted if the safety guard
is open during the curing phase and closed before the end of this phase.

5.1.2. Front
The front of a press swivels. When open, this permits access to inside the cage
and therefore facilitates tool mounting and maintenance operations and clos-
ing unit and machine guard maintenance and cleaning operations.
When open, it also gives easy access to the injection unit and therefore facili-
tates adjusting, maintenance and cleaning operations.
These movements are controlled and secured by a microcontact.

WARNING: The front face must be kept closed with the screws supplied for this.
refer to section 11. Opening the front, page 42

5.1.3. Front guard


The front guard is a pneumatic control guard which is mounted in the front
structure.
These movements are controlled and secured by microcontacts.
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REMARK: The SE safety requires the operator to close the guard before controlling any
press movement.
refer to section 2. Personal safety devices, page 3

Closing unit safety


Document: V684_2Aa
Edition: 16/06/2000 page 9
Technical Manual V68 Y4000
Volume 2 - Application
Chapter I - Safety
RUBBER INJECTION MOULDING

5.1.4. Rear door

WARNING: The rear door is fitted with 2 safety latches. Before closing the rear door,
make sure no-one is inside the cage.

5.1.5. Rear guard


The rear door can be replaced with a screen when the machine is equipped
with special option OPV037: Automated rear guard
The rear guard movements are all controlled and secured by microcontacts.
REMARK: The SE safety requires the operator to close the guards before controlling any
press movement.
refer to section 2. Personal safety devices, page 3

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Closing unit safety


Document: V684_2Aa
page 10 Edition: 16/06/2000
Technical Manual V68 Y4000
Volume 2 - Application
Chapter I - Safety
RUBBER INJECTION MOULDING

6. Safety on injection unit

6.1. Hot surfaces

WARNING: As some parts of the injection unit reach relatively high temperatures, it is rec-
ommended to guard against burns by wearing safety gloves for any work car-
ried out around the injection unit.

Warning labels are affixed to the machine, near to the heating areas to alert the
operator to the danger of burns. These labels are triangular, black on a yellow
background and carry the following symbol:

6.2. Compound inlet chute


The extruder inlet is protected by a chute which is secured to the extruder bar-
rel, in front of the extruder barrel inlet hole. The length of this chute has been
designed to make it impossible for the operator to touch the extruder screw
with his fingers.

WARNING: The extruder inlet chute should in no case be removed when the machine is
in production.
The shape of the screw and of the extruder barrel has been specially de-
signed to ensure maximum efficiency of the rubber strip intake. Do not try to
help feed rubber strip into the extruder hole with any metal object.

6.3. Ladder placements


If any work is required on the upper parts of the injection unit, set a ladder up
using the locating supports provided.
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see illustration Fig. 7. Ladder placements, page 29

Safety on injection unit


Document: V684_2Aa
Edition: 16/06/2000 page 11
Technical Manual V68 Y4000
Volume 2 - Application
Chapter I - Safety
RUBBER INJECTION MOULDING

7. Tooling safety

7.1. General
Any tool entailing risks which are not covered by the machine protection sys-
tems must feature its own protection devices.
As moulds are naturally heavy, appropriate handling equipment must be
used.

WARNING: In any case, attention must be paid to ensuring that the moulds or accesso-
ries are secured properly.
As all parts of an elastomer injection mould reach very high temperatures, it
is recommended to guard against burns by wearing safety gloves for any
work carried out around the mould.

7.2. Hot surfaces


Warning labels are affixed to the machine close to the heating areas to alert the
operator to the danger of burns. These labels are triangular, black on a yellow
background and carry the following symbol:

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Tooling safety
Document: V684_2Aa
page 12 Edition: 16/06/2000
Technical Manual V68 Y4000
Volume 2 - Application
Chapter II - Operating the machine
RUBBER INJECTION MOULDING

Chapter II - Operating the machine

1. Powerisation
 Switching on electrical cabinet and starting up PC.
1. Position main circuit breaker Q1 to ON.
see section Main switch, page 54
2. Check that the Punch button S201 is released.
see section 3.4. STOP Punch button, page 5
REMARK: The PC is switched on the same time as the whole of the electrical cabinet. The
power-on page is displayed while the operating system Windows NT and
REP machine control software are loading; this may take a few minutes.
see also illustration Fig. 1., page 13
 Switching process-control on
3. Press the green push button S203; the green lamp of the button lights up.
see section Push button Process control voltage on, page 54
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Fig. 1. power-on page

Powerisation
Document: V684_2Aa
Edition: 16/06/2000 page 13
Technical Manual V68 Y4000
Volume 2 - Application
Chapter II - Operating the machine
RUBBER INJECTION MOULDING

Q1

Key Init

H40 S4* S100 P1 P2 S0

S32** S17 P3

S203 S204 S18 S38 S35 S75 S43

S201 S212 S11 S108 S33 S41 S66

S202 S213 S19 S37 S36 S76 S44

S211 S12 S107 S34 S42 S65


S93

S112 S176
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S124

S175

S123

Fig. 2. Control station of a G8 press

Powerisation
Document: V684_2Aa
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Volume 2 - Application
Chapter II - Operating the machine
RUBBER INJECTION MOULDING

 Switching process-control off


4. Press the red push button S202; the green lamp of the button S203 goes out.
see section Push button Process control stop, page 54
 Switching hydraulic pump unit on
5. Press the yellow push button S212; the yellow lamp of the button lights up.
see section Push button Hydraulic pump unit power on, page 55
 Switching hydraulic pump unit off
6. Press the red push button S211; the yellow lamp of the button S212 goes out.
see section Push button Hydraulic pump unit stop, page 55
 Switching electrical cabinet off
7. Press Punch button S201.
see section 3.4. STOP Punch button, page 5
 Total insulation of electrical cabinet
8. Position main circuit breaker Q1 to OFF.
see section Main switch, page 54
REMARK: The 220VAC saved by the UPS which feeds the PC is maintained for 2 minutes
after the cabinet power supply is cut.
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Powerisation
Document: V684_2Aa
Edition: 16/06/2000 page 15
Technical Manual V68 Y4000
Volume 2 - Application
Chapter II - Operating the machine
RUBBER INJECTION MOULDING

2. Selection of an existing mould


For the operator, a mould consists of all the machine management and
moulding parameters programmed for a given tooling and stored under one
label.
You must choose a mould number before starting a new production.This op-
eration enables you to associate one group of parameters to a given tooling.

2.1. Mould selection


1. Select a mould number.
see section 3.3.4. How to select a mould, page 252
2. Program the mould with only the parameters needed to start up production.
see section 3. Mould start-up programming, page 17
REMARK: The mould will be stored locally on the machine hard disk.

2.2. Machines connected to the network


When a machine is connected to the network RepNet-win, all the moulds as-
sociated with all tooling previously used in the workshop are in general
stored on the hard disk central terminal RepNet-win.
Despite this, each press can also store 100 moulds.
Mould selection can therefore be made according to the following methods:
locally: by selecting a mould among those stored on the press,
see section 2.1. Mould selection, page 16
across the network: by the following procedure:
1. Select a mould number.
see section 3.3.4. How to select a mould, page 252
2. Program the mould with the parameters stored on the central terminal.
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Selection of an existing mould


Document: V684_2Aa
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Technical Manual V68 Y4000
Volume 2 - Application
Chapter II - Operating the machine
RUBBER INJECTION MOULDING

3. Mould start-up programming


Start-up programming is to program a minimum number of moulding pa-
rameters enabling you to start up a new production with new tooling. These
parameters are the main parameters displayed on the 5 main function screens
corresponding to simple mould programming.
Start-up programming can then be supplemented by parameter program-
ming for the different optimisation functions chosen for the tooling during
use.

1. Press key . Program the main screen parametersCompound prepara-


tion.

2. Press the key . Program the main screen parametersMould closing.

3. Press the key . Program the main screen parametersFilling.

4. Press the key . Program the main screen parametersCuring.

5. Press the key . Program the main screen parametersStripping and


loading of inserts.

refer to section 5. Instructions for how to change parameters, page 89

REMARK: Some optimisation functions are needed depending on the tooling used: for ex-
ample, Cold runner blocks.
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Mould start-up programming


Document: V684_2Aa
Edition: 16/06/2000 page 17
Technical Manual V68 Y4000
Volume 2 - Application
Chapter II - Operating the machine
RUBBER INJECTION MOULDING

4. Installation of a new tooling


 Checking programming for the appropriate mould parameters

1. Press key . Check that the parameters displayed are programmed; if


not program them.
see section 4.1. Base page Mould closing, page 121

2. Press key . Check that the parameters displayed are programmed; if


not program them.
see section 6.1. Base page Curing, page 156
3. If the machine is equipped with the option OP137 Sliding platen, successive-

ly press the keys and , set the displayed parameters and select
the optimisation function.
see section 7.11. Optimisation page Sliding platen, page 182
4. If the machine is equipped with the option OP139 Movable traverse ejectors,

successively press the keys and , set the displayed parameters


and select the optimisation function.
see section 7.2. Optimisation Movable traverse ejectors, page 165
5. If the machine is equipped with the option OP141 Fixed traverse ejectors,

successively press the keys and , set the displayed parameters


and select the optimisation function.
see section 7.7. Optimisation page Fixed traverse ejectors, page 173
 Opening the front
REMARK: It is possible to open the front to facilitate access to inside the cage.
In this case, the front must always be closed and kept closed with the screws
provided whenever the machine is in operation.
see section 11. Opening the front, page 42
 Loading and fastening the mould

6. Turn selector S0 to .
7. Open the press by pressing S34 up to the opening limit position.
see section Push button Press opening, page 62
8. If the machine is equipped with the option OP137 Sliding platen, control the
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sliding platen out by pressing S44 and the dual-hand control simultaneously.
S93
see section Push button "Sliding platen in", page 64
9. Handle the new tooling with a handling H and a lift truck to position it on
the heating platen of the movable traverse.
refer to volume 9 - Tooling

Installation of a new tooling


Document: V684_2Aa
page 18 Edition: 16/06/2000
Technical Manual V68 Y4000
Volume 2 - Application
Chapter II - Operating the machine
RUBBER INJECTION MOULDING

10. If the machine is equipped with the option OP137 Sliding platen, control the
sliding platen in by pressing S43 and the dual-hand control
simultaneouslyS93.
see section Push buttone Sliding platen out, page 64
 If the press is equipped with standard heating platens:
11. Centre the mould and put the fastening screws near the mould without block-
ing them.
 If the press is fitted with quick latch heating platens:
12. Place the stops on the heating platen of the movable traverse.
 The mould is now prefastened on the movable traverse heating platen.
13. Close the press by pressing S33 until being about 20 mm away from the ap-
proach.
Check that the centring cone is aligned with the fixed traverse heating platen
hole. Close the press completely
see section Push button Press closing, page 62
 If the press is equipped with standard heating platens:
14. Screw and tighten the fastening screws of the half-mould on the fixed traverse
side.
Screw and tighten the fastening screws of the half-mould on the movable
traverse side.
 If the press is fitted with quick latch heating platens:
15. Tighten the half-mould vices on the fixed traverse side.
Finish tightening the stop screws on the half-mould on the movable traverse
side.
 The half-moulds are now completely fastened to the heating platens.
16. Remove the retaining flanges from the different parts of the mould which stop
it opening.

WARNING: The retaining flanges which stop the mould opening must be removed before
the press opening control otherwise it and the tooling may be seriously dam-
aged.

 Fastening the plate on the fixed traverse ejector bars


17. If the machine is equipped with the option OP141 Fixed traverse ejectors
and if a plate has to be fixed to the ejector bars, control the fixed traverse ejec-
tors out by pressing S76a until touching the plate.
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see section Push buttonb "Fixed traverse ejectors out", page 63


18. Position the insulating studs and screw the fastening shouldered screws.
Refer to the indications of Volume 9 - Tooling

a. If the guard is open, dual-hand controls must be used.


see section 2. Personal safety devices, page 3

Installation of a new tooling


Document: V684_2Aa
Edition: 16/06/2000 page 19
Technical Manual V68 Y4000
Volume 2 - Application
Chapter II - Operating the machine
RUBBER INJECTION MOULDING

 Fastening the plate onto the movable traverse ejector bars


19. If the machine is equipped with the option OP139 Movable traverse ejectors
and if a plate has to be fixed to the ejector bars, control the movable traverse
ejectors out by pressing S66a. until touching the plate.
see section Push buttonb Movable traverse ejectors out, page 64
20. Position the insulating studs and screw the shouldered fastening screws.
Refer to the indications of Volume 9 - Tooling
 Heat-up of the mould
 Connect the different plugs for heating the CRB and the ancillary heaters.
Position the different thermocouples in their respective receivers.
see illustration Fig. 3., page 21

WARNING: Thermocouples used on G8 presses are insulated thermocouples. Under


no circumstances may other types of thermocouples be used on these ma-
chines.

21. Heat the mould and its ancillary areas.


see section 6. Heating the machine, page 26
 It is better to wait until the different mould areas are at the right temperature
before continuing to install the mould.
 Initialisation of the closing unit
22. Adjust S51 microcontact activation rod: Mould closing L.S.
see illustration Fig. 4., page 22
REMARK: The rod end is fitted with an adjustable micro metric nut to precisely adjust
the activation of microcontact S51 and status change of the associated input I
006.
refer to section 2.2.1. How to read the status of a digital input, page 228
23. Initialise closing unit.
refer to points 2. to 4. of section 5. Machine initialisation, page 24
 Adjustment of the clamping stroke
24. Check that there is enough space between the bottom of the movable traverse
and the top of the mould height adjustment nut to insert the clamping block.If
not, screw the mould height adjustment nut onto its screw to gain enough
space.
see illustration Fig. 5., page 23
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25. Move clamping block in by pressing S35.


see section Push button Clamping-block in - Clamping, page 62

Installation of a new tooling


Document: V684_2Aa
page 20 Edition: 16/06/2000
Technical Manual V68 Y4000
Volume 2 - Application
Chapter II - Operating the machine
RUBBER INJECTION MOULDING

Refer- Function Refer- Function


ence ence
B4 Cold runner block nozzle thermocouple B10 Ancillary zone 2 thermocouple

B6 Fixed traverse platen thermocouple CRB CRB fixed connector

B7 Movable traverse platen thermocouple CH1 Ancillary zone 1 fixed connector

B8 Ancillary zone 1 thermocouple CH2 Ancillary zone 2 fixed connector

B9 Cold runner block body thermocouple

B6 CH1

B10

B9

B4

CRB B7

CH2 B8
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Fig. 3. Thermocouple and heater plug connections

Installation of a new tooling


Document: V684_2Aa
Edition: 16/06/2000 page 21
Technical Manual V68 Y4000
Volume 2 - Application
Chapter II - Operating the machine
RUBBER INJECTION MOULDING

26. Adjust the clearance between the bottom of the movable traverse and the top
of the mould height adjustment nut by tightening or untightening the mould
height adjustment nut on its screw.
REMARK: The clearance determines the clamping cylinder stroke. REP recommends the
following clearance :

= Clearance
(mm)

direct injection 6

injection-transfer 15a

a. the clearance must be adapted to the tooling used.

27. Tighten the 4 nut locking screws.

WARNING: Clamping is to be done diagonally by respecting the clamping torque (T = 6 m


daN) on the screws

S51: L.S. Mould closing Micrometric adjustment pin

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Adjustable rod

Counternut

Fig. 4. Adjustment of the S51 microcontact actuating rod c

Installation of a new tooling


Document: V684_2Aa
page 22 Edition: 16/06/2000
Technical Manual V68 Y4000
Volume 2 - Application
Chapter II - Operating the machine
RUBBER INJECTION MOULDING

 End of the mould installation


28. Open the press by pressing S34 up to the opening limit position.
see section Push button Press opening, page 62
29. Make sure that the front is kept closed with the screws provided.
see section 11. Opening the front, page 42

Nut screwing
=
larger clearance ()

Movable traverse

Clamping block

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Mould height adjustment nut

Mould height adjust-


ment screw Nut unscrewing
=
smaller clearance ()

Fig. 5. Clearance adjustment

Installation of a new tooling


Document: V684_2Aa
Edition: 16/06/2000 page 23
Technical Manual V68 Y4000
Volume 2 - Application
Chapter II - Operating the machine
RUBBER INJECTION MOULDING

5. Machine initialisation
 Checking programming for the appropriate mould parameters
1. Check that the start-up parameters are programmed; if not, program them.
see section 3. Mould start-up programming, page 17
 Heat-up of the mould
see section 6. Heating the machine, page 26
REMARK: It is better to wait until the different mould areas are at the right temperature
before initialising the closing unit.
 Heating the injection unit
see section 6. Heating the machine, page 26
REMARK: It is better to wait until the different injection unit areas are at the right temper-
ature before initialising.
 Closing unit stroke initialisation

2. Turn selector S0 to .
see section Selector Operating modes, page 60
3. Close the press by pressing S33a until the different mould parts mechanically
touch.
see section Push button Press closing, page 62

4. Continue controlling the press closing and press the key simultaneously
to initialise the counter linked to the closing unit encoder.
see section Key Initialisation, page 51
Closing unit is initialised.
5. Open the press by pressing S34 up to the opening limit position.
see section Push button Press opening, page 62
 Injection unit stroke initialisation
REMARK: The injection unit can only be initialised when the press is completely open or
when the injection unit is lifted.
6. Totally purge the injection unit by pressing S19.
see section Push button Purge-Injection, page 61
7. When the machine pressure increases while the injection piston is at its lowest

stroke, continue to control the purge and press the key simultaneously
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to initialise the injection unit encoder counter.


see section Key Initialisation, page 51
The injection unit is initialised.

a. In S1 safety, if the guard is open, dual-hand controls must be used.


see section 2.2. Safety device S1, page 3

Machine initialisation
Document: V684_2Aa
page 24 Edition: 16/06/2000
Technical Manual V68 Y4000
Volume 2 - Application
Chapter II - Operating the machine
RUBBER INJECTION MOULDING

 Initialisation of ejector strokes


When the machine is fitted with one or several OPV040 Movable traverse
ejector encoder or OPV041 fixed traverse ejector encoder options, the oper-
ator must also initialise their strokes.
8. Control ejectors in by pressing S75a or S65a..
see sections Push button "Movable traverse ejectors in", page 63 and Push buttonb
"Movable traverse ejectors in", page 64
9. When the machine pressure rises while the ejectors are entirely in, continue to

control their run-in and press the key simultaneously to initialise the
counters linked to their encoders.
see section Key Initialisation, page 51
 The press is fully initialised
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a. If the guard is open, dual-hand controls must be used.


see section 2. Personal safety devices, page 3

Machine initialisation
Document: V684_2Aa
Edition: 16/06/2000 page 25
Technical Manual V68 Y4000
Volume 2 - Application
Chapter II - Operating the machine
RUBBER INJECTION MOULDING

6. Heating the machine


 Checking programming for the appropriate mould parameters
1. Check that all the temperature parameters are programmed; if not, program
them.
see section 3. Mould start-up programming, page 17
 Heating the mould and its ancillary areas

2. Press key then , check that coefficients P, I, D and T were cal-


culated at the last mould identification.
see section 2.2. Optimisation page Identification, page 195
REMARK: If there are no coefficients, you must start the mould identification process be-
fore adjusting the mould temperature.
refer to section 6.1. Mould identification, page 26
3. Turn selector S213 to 1.
see section Selector Closing unit heating, page 56
 Heating the injection unit
4. Turn selector S204 to 1.
see section Selector Injection unit controller, page 55

6.1. Mould identification


The temperatures of the mould and ancillary heating areas are regulated by
digital controllers built into the machine software. These controllers use PIDT
control coefficients:
P is the coefficient for proportional action.
I is the coefficient for integral action.
D is the coefficient for derived action.
T is the sampling period.
The PIDT coefficients have to be adapted to the different tooling areas to be
controlled. They are obtained via the Thermotrac software and its mould
identification process.
REMARK: Identification is recommended for every time you control the mould and ancil-
lary zone heating areas.
refer to section 3. Identification through Thermotrac, page 200
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Heating the machine


Document: V684_2Aa
page 26 Edition: 16/06/2000
Technical Manual V68 Y4000
Volume 2 - Application
Chapter II - Operating the machine
RUBBER INJECTION MOULDING

7. Changing the nozzle


On a REP press, there are 2 different ways of dismounting and changing the
nozzle, each using a different access:
access from below the fixed traverse heating platen,
access from above the fixed traverse.

WARNING: Even when the controller is stopped, the nozzle may remain hot.
Before intervening, it is important to protect against burns by wearing high
temperature protective gloves.
It is better to wait until the nozzle cools down before dismounting it to avoid
the risk of jamming.

7.1. Access from below the fixed traverse heating platen


REMARK: The nozzle may only be changed from below the fixed traverse when:
the press is fully open,
the mould is dismounted,
the press is switched off.

WARNING: Even when the different heaters have been stopped, the heating plates and
the actual nozzle may remain hot.
Before intervening, it is important to protect against burns by wearing high
temperature protective gloves.

1. Control the injection unit beardown by pressing S42 until the nozzle sticks out
below the fixed traverse heating platen.
see section Push button Injection unit beardown, page 63
2. Get to the 6 sides of the nozzle from inside of the press.
Untighten and remove the old nozzle.
3. Mount the new nozzle.

7.2. Access from above the fixed traverse


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WARNING: The first version of V68 presses is equipped with a front side without shutter.
In this case, it is not possible to have access to the injection unit front side in
the way described below because the front side has to be wide open and a
step-ladder is necessary.
refer to Fig. 117., page 316

Changing the nozzle


Document: V684_2Aa
Edition: 16/06/2000 page 27
Technical Manual V68 Y4000
Volume 2 - Application
Chapter II - Operating the machine
RUBBER INJECTION MOULDING

1. Stop the injection unit controller by turning selector S204 to position 0.


2. Lift completely the injection unit by pressing S41.
see section Push button Injection unit lift, page 63
3. Position safety pins.
4. Stop hydraulic pump unit by pressing S211.
5. Open shutter above front guard.
6. Set a ladder up using the locating supports provided
see illustration Fig. 7., page 29

WARNING: The safety pins must always be put into place before any intervention on the
nozzle.
see picture Fig. 6., page 28

7. Get to the 6 sides of the nozzle.


Untighten and remove the old nozzle.

Safety pins

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Fig. 6. Safety pin positioning on the injection unit

Changing the nozzle


Document: V684_2Aa
page 28 Edition: 16/06/2000
Technical Manual V68 Y4000
Volume 2 - Application
Chapter II - Operating the machine
RUBBER INJECTION MOULDING

Injection unit access shutter


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Fig. 7. Ladder placements

Changing the nozzle


Document: V684_2Aa
Edition: 16/06/2000 page 29
Technical Manual V68 Y4000
Volume 2 - Application
Chapter II - Operating the machine
RUBBER INJECTION MOULDING

8. Mount the new nozzle.


9. Close and lock shutter above front guard.

7.3. Adjusting injection unit microcontacts

WARNING: The first version of V68 presses is equipped with a front side without shutter.
In this case, it is not possible to have access to the injection unit front side in
the way described below because the front side has to be wide open and a
step-ladder is necessary.
refer to Fig. 117., page 316

There are 2 adjustable microcontacts at the bottom of the injection unit column
on the front side:
S48: Injection unit beardown L.S.,
S72: Injection unit automatic lift L.S.
REMARK: Microcontact S72 is only installed on the press when the latter is fitted with op-
tion OP120: unit injection automatic lift or option OP155: CRB prearrangement

7.4. Beardown microcontact (S48) adjustment


REMARK: It is very important to check the S48 setting at each mould change.
This is because during a cycle, the injection phase cannot start if S48 is not
activated.
However, purging outside the mould is possible when S48 is not activated.
Purging is also possible when the press is open, whatever the status of S48.
 A new tooling has been mounted. A new correct nozzle for the tooling has
been installed.
1. Close the mould by pressing S33.
see section Push button Press closing, page 62
2. Control the injection unit beardown by pressing S42 until the nozzle touches
the mould.
see section Push button Injection unit beardown, page 63
3. Stop hydraulic pump unit by pressing S211.
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see section Push button Hydraulic pump unit stop, page 55


4. Open shutter above front guard.
5. Set a ladder up using the locating supports provided.
see illustration Fig. 7., page 29,
6. Adjust main cam to activate S48.

Changing the nozzle


Document: V684_2Aa
page 30 Edition: 16/06/2000
Technical Manual V68 Y4000
Volume 2 - Application
Chapter II - Operating the machine
RUBBER INJECTION MOULDING

7. Check corresponding input status (I 005 = 1).


se reporter la section 2.2.1. How to read the status of a digital input, page 228
REMARK: When microcontact S72 is installed and used, the main cam must activate S48
even when the injection unit is in Automatic lift position.
see illustration Fig. 8., page 32
8. Close and lock shutter above front guard.

7.5. Auto lift microcontact (S72) adjustment


REMARK: It is important to check the S72 setting at each mould change.
This adjustment allows the injection unit lift on a limited stroke, allowing only
compound decompression in the injection canals or in the CRB body. when the
latter is installed.
 A new tooling has been mounted. A new correct nozzle for the tooling has
been installed.
1. Close mould by pressing S33a.
see section Push button Press closing, page 62

2. Turn selector S0 to .
see section Selector Operating modes, page 60
3. Control the injection unit beardown by pressing S42 until the nozzle touches
the mould.
see section Push button Injection unit beardown, page 63
4. Lift the injection unit on the desired stroke by pressing S41.
see section Push button Injection unit lift, page 63
5. Stop hydraulic pump unit by pressing S211.
see section Push button Hydraulic pump unit stop, page 55
6. Open shutter above front guard.
7. Set a ladder up using the locating supports provided.
see illustration Fig. 7., page 29,
8. Adjust main cam to activate S48.
9. Check corresponding input status (I 005 = 1).
refer to section 2.2.1. How to read the status of a digital input, page 228
10. Adjust additional cam just above S72 microcontact activator.
11. Check corresponding input status (I 050 = 0).
refer to section 2.2.1. How to read the status of a digital input, page 228 and to illus-
tration Fig. 8., page 32.
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12. Close and lock shutter above front guard.

a. In S1 safety, if the guard is open, dual-hand controls must be used.


see section 2.2. Safety device S1, page 3

Changing the nozzle


Document: V684_2Aa
Edition: 16/06/2000 page 31
Technical Manual V68 Y4000
Volume 2 - Application
Chapter II - Operating the machine
RUBBER INJECTION MOULDING

Injection unit in position Total lift:

L.S. status Input status


S72 released I 050 = 0
S48 released I 005 = 0
S72

S48

Main cam (S48 activated)

Additional cam (S72 activated)

Injection unit in position Automatic lift:

L.S. status Input status


S72
S72 released I 050 = 0
S48
S48 activated I 005 = 1

Injection unit in position Beardown:

L.S. status Input status


S72 activated I 050 = 1
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S72
S48 activated I 005 = 1

S48

Fig. 8. Activation of the injection unit microcontacts

Changing the nozzle


Document: V684_2Aa
page 32 Edition: 16/06/2000
Technical Manual V68 Y4000
Volume 2 - Application
Chapter II - Operating the machine
RUBBER INJECTION MOULDING

WARNING: The length of the additional S72 activation cam must not be modified. It ena-
bles the injection unit automatic lift stroke to be limited.
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Changing the nozzle


Document: V684_2Aa
Edition: 16/06/2000 page 33
Technical Manual V68 Y4000
Volume 2 - Application
Chapter II - Operating the machine
RUBBER INJECTION MOULDING

8. Compound loading

8.1. Standard use

8.1.1. Compound batch conditioning


The rubber compound batches must be prepared in rectangular strips with
the nominal dimensions as in volume 9 - Tooling and any length
refer to volume 9 - Tooling

8.1.2. Rubber strip loading


In order to avoid rubber strip intake and rupture problems, it is essential to
respect the following procedure before loading the strip into the extruder:
1. Heat up the injection unit
see section 6. Heating the machine, page 26
REMARK: It is better to wait until the different injection unit areas are at the right temper-
ature before proceeding to load the compound.
2. Turn extruder selector S11 to 1.
see section Selector Extruder, page 56
3. Introduce the strip into the compound inlet chute and help the intake by push-
ing on the first few centimetres.
REMARK: The rubber strip should be introduced into the extruder loading hole called
compound inlet chute.
The compound inlet chute round profile avoids the rubber strip from being torn.
The rubber strip can therefore be pulled by the extruder screw with a box
placed on the floor or with a detachable unrolling system.

WARNING: The extruder inlet chute should in no case be removed when the machine is
in production.
The outlines of the screw and of the extruder barrel have been specially de-
signed for ensuring the best possible intake of the rubber strip and we strong-
ly advise you against helping the rubber strip into the extruder hole with your
fingers or any metal object.
The nearness of the extruder heating area can increase the compound inlet
chute temperature, therefore we strongly advise you to wear heat-protective
gloves when manually loading the compound.
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8.1.3. Compound monitoring


The press process-control can detect the end or rupture of the rubber strip and
trigger an alarm.
refer to section 3.4. Optimisation page Extruder feed strip rupture, page 113

Compound loading
Document: V684_2Aa
page 34 Edition: 16/06/2000
Technical Manual V68 Y4000
Volume 2 - Application
Chapter II - Operating the machine
RUBBER INJECTION MOULDING

8.2. How to use a silicone stuffer


refer to the Silicone stuffer manual (Volume 5 - Option OP064: Silicone stuffer)
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Compound loading
Document: V684_2Aa
Edition: 16/06/2000 page 35
Technical Manual V68 Y4000
Volume 2 - Application
Chapter II - Operating the machine
RUBBER INJECTION MOULDING

9. Starting production

9.1. Preliminary conditions


 The machine has been switched on.
see section 1. Powerisation, page 13
 The machine has a cooling water supply and compressed air supply.
refer to volume 1 - Installation.
 A mould has been selected.
see section 2. Selection of an existing mould, page 16
 The main parameters have been programmed.
see section 3. Mould start-up programming, page 17
 A mould has been installed on the press.The mould height adjustment nut has
been adjusted.
see section 4. Installation of a new tooling, page 18
 A nozzle adapted to the tooling has been installed.
see section 7. Changing the nozzle, page 27
 The injection unit microcontacts have been adjusted.
see section 7.3. Adjusting injection unit microcontacts, page 30
 The machine has been heated.
see section 6. Heating the machine, page 26
 The machine has been initialised.
see section 5. Machine initialisation, page 24
 A rubber strip is inserted in the compound inlet chute.
see section 8. Compound loading, page 34

9.2. Compound preparation

9.2.1. Standard use


It is always advisable to purge several times before starting up a production
cycle.These successive purges are to clean the injection chamber of any cured
residues.
 The extruder selector S11 is in position 1. The injection piston is in the position
defined by shot size setting parameter 30.
1. Open the press by pressing S34 or lift the injection unit by pressing S41.
see section Push button Press opening, page 62
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see also section Push button Injection unit lift, page 63


REMEMBER: It is possible to purge outside the mould when S48 is not activated. Purging is
also possible when the press is open, whatever the status of S48.
2. Control purging by pressing S19.
see section Push button Purge-Injection, page 61
 By releasing S19, the extruder starts rotating. The injection piston lifts to the
position defined by shot size setting parameter 30.
3. Control several purges by pressing S19.

Starting production
Document: V684_2Aa
page 36 Edition: 16/06/2000
Technical Manual V68 Y4000
Volume 2 - Application
Chapter II - Operating the machine
RUBBER INJECTION MOULDING

4. Do not forget to retrieve the purged compound.

9.2.2. Using a CRB


refer to Volume 5 - Option OP155: Cold runner block prearrangement

9.3. Cycle in semi-automatic mode


A cycle production can be done according to 2 different operating methods:
Semi-automatic,
Automatic.
see section Selector Operating modes, page 60

9.3.1. Preliminary conditions


 The press is open
 The extruder selector S11 is on position 1. The injection piston is in the position
defined by shot size setting parameter 30.
 An operating cycle has been chosen.
see section 3.6. Optimisation page Cycle selection, page 259

9.3.2. Machine fitted with S1 safety

1. Turn selector S0 to .

2. Choose the guard operation using S4*.


see section Selector Guard operation, page 57
see also section 2.2. Safety device S1, page 3
REMEMBER: When operating without guard, the press can only be closed by pressing the
dual-handed control S93 simultaneously and continually.
When the machine runs without guard, the operator can operate the options
installed on the closing unit (hydraulic ejectors inside press: OP139 and
OP141), but first, he must turn the selector key S12 (Selection of dual-hand
controlled ejectors with guard open) to position 1 and control the movements
with the dual-hand, i.e. he must press the movement control button and S93
(P.B. dual hand) simultaneously and not release them during the whole move-
ment.
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Starting production
Document: V684_2Aa
Edition: 16/06/2000 page 37
Technical Manual V68 Y4000
Volume 2 - Application
Chapter II - Operating the machine
RUBBER INJECTION MOULDING

3. Control ejectors in by pressing S75a or S65a..


see sections Push button "Movable traverse ejectors in", page 63 and Push buttonb
"Movable traverse ejectors in", page 64
4. Control press closing by pressing S33a..
5. Control clamping block in by pressing S35a..
 The rest of the cycle is automatic.

9.3.3. Machine fitted with SE safety


see section 2.1. Safety device SE, page 3

1. Turn selector S0 to .
see section Selector Operating modes, page 60
2. Close the guard by pressing the green button S37.
see section Push button Front guard closing, page 62
3. Control ejectors in by pressing S75 or S65.
see sections Push button "Movable traverse ejectors in", page 63 and Push buttonb
"Movable traverse ejectors in", page 64
4. Control the press closing by pressing S33.
5. Control clamping block in by pressing S35.
 The rest of the cycle is automatic.

9.4. Cycle in automatic mode

9.4.1. Preliminary conditions


 The press is open
 The extruder selector is in position 1. The injection piston is in the position de-
fined by shot size setting parameter 30.
 An operating cycle has been chosen.
see section 3.6. Optimisation page Cycle selection, page 259

9.4.2. Cycle start


1. Make sure that all the optimisation functions are in place before starting the
first cycle.
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2. Turn selector S0 to .
see section Selector Operating modes, page 60
3. Close the guard by pressing the green button S37.
see section Push button Front guard closing, page 62
 The rest of the cycle is automatic.

a. In S1 safety, if the guard is open, dual-hand controls must be used.


see section 2.2. Safety device S1, page 3

Starting production
Document: V684_2Aa
page 38 Edition: 16/06/2000
Technical Manual V68 Y4000
Volume 2 - Application
Chapter II - Operating the machine
RUBBER INJECTION MOULDING

10. Production stop

10.1. Procedure for purging in case of production stop


To avoid all risk of the compound staying in the curing injection unit, it is ad-
visable to purge the injection unit before stopping the machine and switching
it off.

10.1.1. Standard use


1. Break the rubber strip.

WARNING: Purging does not only mean emptying the injection chamber but also means
finishing extrusion of the production compound already taken in by the ex-
truder screw and possibly replacing it with an non-curing purge compound.
In this case, it is necessary to leave the injection unit extruder and heating
rotation selectors in position 1 until the injection unit is completely purged.

2. Purge by pressing S19 several times until there is no more compound left in
the extruder.
see section Push button Purge-Injection, page 61
3. Lift injection unit by pressing S41.
see section Push button Injection unit lift, page 63
4. Deselect the extruder rotation by turning selector S11 to 0.
see section Selector Extruder, page 56
5. Stop hydraulic pump unit by pressing S211.
see section Push button front panel STOP, page 54
6. Cut off the heaters by turning selector S204 to 0.
see section Selector Closing unit heating, page 56
7. Leave the injection unit in automatic cooling.
8. When the temperature measured at parameters 61 and 62 has reached the min-
imum 43 C, switch the process-control off.
9. Isolate the machine by placing isolating switch Q1 to O.

10.1.2. Using a CRB


refer to Cold runner block manual (Volume 5 - Option OP155: CRB prearrangement)
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10.2. Procedure for restarting cycle.

10.2.1. After opening protector


The voluntary opening of the safety guard or a cage door during an automatic
or semi-automatic cycle interrupts the cycle in process.
REMARK: The automatic or semi-automatic cycle is not interrupted if the guard is open
during the curing phase and closed before the end of this phase.

Production stop
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Technical Manual V68 Y4000
Volume 2 - Application
Chapter II - Operating the machine
RUBBER INJECTION MOULDING

1. Close all protectors remaining open.

2. Turn selector S0 to .
see section Selector Operating modes, page 60
3. Open the press by pressing S34 up to the maximum opening position.
see section Push button Press opening, page 62
4. Reposition optimisation functions (ejectors on press, sliding platen etc.) in
their cycle start conditions.
5. Open safety guard by pressing S38.
see section Push button Front guard opening, page 62
6. Restart cycle.
see section 9. Starting production, page 36

10.2.2. After pressing P.B. STOP


Activating the STOP P.B. immediately stops the cycle in process, but does not
stop the machine control system supply.
1. Pull on Punch button S201 to deactivate.
2. Switch process-control and hydraulic pump unit off.
see section 1. Powerisation, page 13

3. Turn selector S0 to .
see section Selector Operating modes, page 60
4. Open the press by pressing S34 up to the maximum opening position.
see section Push button Press opening, page 62
5. Reposition optimisation functions (ejectors on press, sliding platen etc.) in
their cycle start conditions.
6. Open safety guard by pressing S38.
see section Push button Front guard opening, page 62
7. Restart cycle.
see section 9. Starting production, page 36

10.2.3. After an hydraulic pump unit stop.


In the event of a voluntary or accidental stop of the hydraulic pump unit (e.g.
following an electrical motor overload), the operator must solve the problem
which caused the pump unit stop and start a new cycle following the proce-
dure listed below:
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1. Switch hydraulic pump unit on and check rotation.


see section 1. Powerisation, page 13

2. Turn selector S0 to .
see section Selector Operating modes, page 60
3. Open the press by pressing S34 up to the maximum opening position.
see section Push button Press opening, page 62

Production stop
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Volume 2 - Application
Chapter II - Operating the machine
RUBBER INJECTION MOULDING

4. Reposition optimisation functions (ejectors on press, sliding platen etc.) in


their cycle start conditions.
5. Open safety guard by pressing S38.
see section Push button Front guard opening, page 62
6. Restart cycle.
see section 9. Starting production, page 36
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Production stop
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Technical Manual V68 Y4000
Volume 2 - Application
Chapter II - Operating the machine
RUBBER INJECTION MOULDING

11. Opening the front


The front of a press can be opened to facilitate machine and tooling mainte-
nance and cleaning operations.
1. Open the front guard by pressing S38.
see section Push button Front guard opening, page 62
2. Press Punch button S201
see section 3.4. STOP Punch button, page 5
3. Undo the front locking screws.
refer to illustration Fig. 9., page 43
4. Open the front.
5. Perform work required inside the cage.
6. Close the front when finished.

WARNING: The front of the machine must always be closed and kept closed with the
screws provided whenever the machine is in operation.

7. Switch process-control and hydraulic pump unit on.


refer to section 1. Powerisation, page 13

11.1. Cleaning the guard


The front locking system consists of screws and springs. The springs release
the front closing control microcontacts while the locking screws are not tight-
ened. In this case, it is not possible to close the guard.
Nevertheless, there is a procedure to close the guard to clean its inside:
1. Open the guard,
2. Undo the front locking screws,
3. Keep the front closed manually,
4. Close the guard by pressing the green button S37.
see section Push button Front guard closing, page 62
5. Let the front open with the locking system springs,
6. Clean inside the guard.
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Opening the front


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Volume 2 - Application
Chapter II - Operating the machine
RUBBER INJECTION MOULDING

6 mm
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Fig. 9. Position of the front locking screws

Opening the front


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Edition: 16/06/2000 page 43
Technical Manual V68 Y4000
Volume 2 - Application
Chapter II - Operating the machine
RUBBER INJECTION MOULDING

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Opening the front


Document: V684_2Aa
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Technical Manual V68 Y4000
Volume 2 - Application
Chapter III - Control station
RUBBER INJECTION MOULDING

Chapter III - Control station

1. Introduction
The control station of a G8 press is located on the door of the switch cabinet,
it combines the following elements:
the operator interface,
the main control front panel,
the auxiliary control front panel.
see illustration Fig. 10., page 45

Operator interface
(see page 46)

Main control front panel


(see page 53)

Dual hand
(see page 65)
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Auxiliary control front panel


(see page 66)

Fig. 10. Control station of a G8 press

Introduction
Document: V684_2Aa
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Technical Manual V68 Y4000
Volume 2 - Application
Chapter III - Control station
RUBBER INJECTION MOULDING

2. Operator interface
The operator interface includes a PC with integral display system and a key-
board.

2.1. The display system


The display system is used to set the moulding parameters by means of the
keyboard and to read the information given by the process-control to the op-
erator during machine operation.

2.1.1. Hardware
Physically, the display system is a 10 inch LCD colour screen with a resolution
of 640 x 480 pixels.

2.1.2. Display mechanism


The display mechanism is controlled by the keyboard.
Refer to section 2.2., page 47
Every preset function key refers to a different main function page.
Each main function page can have up to 7 associated pages. The associated
pages or pages of associated optimisation functions are displayed using the
function keys F1 to F7 assigned to the 7 text keypads at the bottom of the
screens.
see illustration Fig. 11., page 46

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Fig. 11. Example of main page: Mould closing function

Operator interface
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Technical Manual V68 Y4000
Volume 2 - Application
Chapter III - Control station
RUBBER INJECTION MOULDING

For further information concerning the operation of the display mechanism


and the ergonomics of the screens, please refer to Chapter IV - Reading and
programming of data, page 69.

2.2. The keyboard


see illustration Fig. 12., page 47
The keyboard is a specific Rep press keyboard. It includes 54 keys distributed
over the 6 different keypads listed below:
1. the associated optimisation function keys keypad, (see page 48)
2. the preset functions keypad, (see page 48)
3. the interface utilities keypad, (see page 50)
4. the directional keypad, (see page 50)
5. the machine utilities keypad, (see page 51)
6. the numeric keypad (see page 51)
7. a standard keyboard socket outlet is provided on the front side of the machine.
(see page 52)

2 6
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3 4 5

Fig. 12. Operator interface keyboard

Operator interface
Document: V684_2Aa
Edition: 16/06/2000 page 47
Technical Manual V68 Y4000
Volume 2 - Application
Chapter III - Control station
RUBBER INJECTION MOULDING

2.2.1. The associated optimisation function keys

Key Function
Associated optimisation function keys
Every function key F1 to F7 is associated with one of the 7
blue keypads available at the bottom of the screen once the
F
to process-control is on.
1
These keys make the optimisation screens of each of the pre-
set functions accessible. The optimisation is described in the
text specified in the associated text keypad.

2.2.2. The preset function keys


These keys make the main screen of the corresponding function available.

Key Function

Key Compound preparation


a
see section 3.1. Base page Compound preparation, page 105

Key Mould closing


b
see section 4.1. Base page Mould closing, page 121

Key Filling
c
see section 5.1. Base page Filling, page 129

Key Curing
d
see section 6.1. Base page Curing, page 156

Key Stripping and loading of the inserts


e see section 7.1. Base page Stripping and loading of inserts,
page 163

Key Thermotrac
f
see section 2.1. Base page Thermotrac, page 191
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Key Mastertrac
g
see section 2.3. Base page Mastertrac, page 212

Key Network
h refer to volume 5 - Option OP183: RepNet-win machine compu-
ter

Key Maintenance
i
see section 2.1. Base page Sequential Diagnostic, page 225

Operator interface
Document: V684_2Aa
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Technical Manual V68 Y4000
Volume 2 - Application
Chapter III - Control station
RUBBER INJECTION MOULDING

Key Function

Key Production configuration


j
see section 3.1. Base page Production check, page 245

Key Machine configuration


k
see section 4.1. Base page Machine configuration, page 271
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Operator interface
Document: V684_2Aa
Edition: 16/06/2000 page 49
Technical Manual V68 Y4000
Volume 2 - Application
Chapter III - Control station
RUBBER INJECTION MOULDING

2.2.3. The interface utility keys


These keys control the operator interface utilities.

Key Function
Key Escape
l This key enables to exit the Graph or Tolerance functions
in process.

Key Online Help


m
This key controls the display of the Online Help screen.

Key Tolerances
This key controls the display of the window containing the
n
tolerances associated with the active parameter
Refer to section 4.2.3. Tolerance window, page 86

Key Print
o
This key controls the printout of the active screen

Key Graphics
This key controls the display of the graphic window associat-
p
ed with the active parameter.
Refer to section 1.2. Using a graphic page, page 279
Key Short-circuit
This key is used to move between the interdependent
q
screens.
Refer to section 3.7.4. Shortcuts, page 266

2.2.4. The directional keys


These keys control the movements between the different programming areas
of the current screen.

Key Function

Key Right arrow


r
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This key makes the next active area on the same line available

Key Left arrow


s This key makes the previous active area on the same line
available
Key Up arrow
t This key makes the nearest active area on the previous line
available

Operator interface
Document: V684_2Aa
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Technical Manual V68 Y4000
Volume 2 - Application
Chapter III - Control station
RUBBER INJECTION MOULDING

Key Function
Key Down arrow
u This key makes the nearest active area on the next line avail-
able

2.2.5. The utility keys of the machine


These keys control the press utilities.

Key Function
Key Display of the active alarm messages

v Only one active alarm message can be viewed at the same


time, but the others can be successively viewed by pressing
this key.
Key Initialisation
This key is used to reset to zero the counters used on the dis-

placement axes on the machine (movable traverse, injection,
I
options) after a mains power cut.
n
it REMARK: The Init key is used according to the proce-
dure specific to stroke initialisation.
see section 5. Machine initialisation,
page 24

2.2.6. The numeric keypad


The numeric keypad comprises the following keys:

Key Function

0 Numeric keys 0 to 9.
to

Key Minus
- This key is used to diminish the selected value by successive
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decrements.
Key Plus
+ This key is used to increase the selected value by successive
increments.

Key Delete
x
This key deletes the last value or function entered.

Operator interface
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Technical Manual V68 Y4000
Volume 2 - Application
Chapter III - Control station
RUBBER INJECTION MOULDING

Key Function

Key Validation
y
This key validates the last value or function entered.

2.2.7. The standard keyboard socket outlet

Socket
Function
outlet
Standard keyboard socket outlet
This DIN format socket outlet (5 socket contacts) makes pos-
sible the connection of a standard PC keyboard.
i Connection and disconnection are possible with power on
m
p REMARK: The standard keyboard is configured in AZ-
ERTY mode. This configuration can be
modified with the Control panel of
Windows NT.

WARNING: When an external keyboard is used, make sure that the numeric keypad is
activated (Num Lock = ON) before disconnecting the keyboard and reusing
the keyboard built into the machine control station.
Otherwise, the operator will not be able to type in numerical values with ma-
chine keys 0 to 9.

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Operator interface
Document: V684_2Aa
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Volume 2 - Application
Chapter III - Control station
RUBBER INJECTION MOULDING

3. Control front panels


The machine controls are distributed over the 2 following front panels:
The main control front panel which is always mounted on the machine, is
equipped with the basic (standard) control equipment and the control
equipment of the most frequently installed options,
The auxiliary control front panel, which is only mounted when the machine
is equipped with one or several additional options, is fitted with the control
equipment of these options.

3.1. The main control front panel


The main control panel comprises different control equipment distributed
over the 8 following separate keypads:
1. the powerization,
2. the fault display,
3. the press operation selections,
4. the keyboard selections,
5. the counters,
6. the operating mode selection,
7. the standard movement controls,
8. the optional movement controls,
9. the dual-hand control.
see illustration Fig. 10., page 45

2 3 4 5 6
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1 7 8

Fig. 13. Main control front panel


9

Control front panels


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Technical Manual V68 Y4000
Volume 2 - Application
Chapter III - Control station
RUBBER INJECTION MOULDING

3.1.1. Powerization

Position
number on
Unit electrical
Function
diagram

Main switch
Q1 allows the manual powerization and de-powerization of the switch cab-
inet.
Q1 is also used to separate the whole electrical circuit from the machine after
an incident of electrical concern (overcurrent or short-circuit).
Q1

WARNING: Never work on the electrical circuits of the machine un-


less the handle of the main switch Q1 is locked into the
OFF position by a padlock.

Push button front panel STOP


S201 controls the de-powerization of all electrical circuits of the switch cab-
inet, except the PC, the sequential software management board and the en-
S201 coders.
IMPORTANT: S201 is part of the SE safety device which is certified to be
compliant with the European guidelines and which has
been granted the type-examination certificate.
Push button Process control voltage on
S203 S203 controls the powerization of the process control circuits.
The powerization of the process control circuits is checked through H60.

H60 Power-On indicator Process control

Push button Process control stop


S202
S203 controls the de-powerization of the process control circuits.
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Document: V684_2Aa
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Technical Manual V68 Y4000
Volume 2 - Application
Chapter III - Control station
RUBBER INJECTION MOULDING

Position
number on
Unit electrical
Function
diagram

Push button Hydraulic pump unit power on


S212 S212 controls the powerization of the hydraulic pump unit motor.
The powerization of the hydraulic pump unit is checked through H61.

H61 Power-On indicator Hydraulic pump unit

Push button Hydraulic pump unit stop


S211
S211 controls the de-powerization of the hydraulic pump unit motor.

3.1.2. Indicator lamps

Position
number on
Unit electrical
Function
diagram

H40 Indicator Press fault

Push button Indicator test


S32 is only available when the machine is equipped with the OP302 option
S32
(European safety).
S32 allows to check the lighting of all control panel indicator lamps.

3.1.3. Press operation selections


Each control panel selector becomes active when its lever (or key) is turned to
position 1.
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Position
number on
Unit electrical
Function
diagram

Selector Injection unit controller


S204
S204 controls the start of the injection unit temperature controller.

Control front panels


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Technical Manual V68 Y4000
Volume 2 - Application
Chapter III - Control station
RUBBER INJECTION MOULDING

Position
number on
Unit electrical
Function
diagram

Selector Closing unit heating


S213 S213 controls the initiation of the heating and the regulation of the different
mould heating zones.

Selector Extruder
S11 authorises the extruder operation.
The extruder rotation only becomes effective when all the following condi-
tions are fulfilled simultaneously:
S11 the shot size stroke defined by parameter 30 is not reached,
the injection unit temperature controller selector is on position 1 (see S204,
page 55),
the extruder delay-time defined by parameter 50 has elapsed or is disa-
bled.The last condition is not to be fulfilled when the press is in the Ad-
justment mode or when it is open and in the manual operating mode.
Selector dual-hand controlled ejectors with open guard
S12 is a key selector which is only available when the machine is equipped
with the option OP139 (Movable traverse ejectors) or the option OP141
S12 (Fixed traverse ejectors).
S12 authorises the operation of the ejectors with the guard open. In this case,
the control must be bi-manual.
refer to dual-hand control S93, page 65

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Technical Manual V68 Y4000
Volume 2 - Application
Chapter III - Control station
RUBBER INJECTION MOULDING

Position
number on
Unit electrical
Function
diagram

Selector Full-force beardown


S17 is a key selector which is only available when the machine is equipped
with the option OP119 (Full-force beardown).
S17 controls the hydraulic fluid distribution over the full section of the injec-
tion unit beardown cylinder in order to increase the beardown force of the
nozzle on the mould during the injection or purge.
Full-force beardown is recommended when injecting through a cold runner
block (C.R.B.)

WARNING: Before making any use of the full-force beardown it is


S17 essential to inspect and check the fastening of the fixed
traverse half-mould, as the beardown forces present
during a purge when the mould is open are very high:
F
(daN)
V68 Y4000 19,635

Selector Guard operation


S4 is a key selector which is only available when the machine is equipped
with the option OP301 (S1 level safety).
S4 selects the machine operation:
position 0: Without guard (safety guard open)
position 1: With guard (safety guard closed)
S4

WARNING: It is highly recommended to remove the key from selec-


tor S4 when it is positioned on 1 (with guard).
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Technical Manual V68 Y4000
Volume 2 - Application
Chapter III - Control station
RUBBER INJECTION MOULDING

3.1.4. Keyboard selections

Position
number on
Unit electrical
Function
diagram

Selector Keyboard
S100-S101 is a 3-position key selector. Each position authorises a specific
keyboard function:

: Keyboard access
the position Keyboard access (S101) authorises the reading and program-
ming of the parameters set points; it prohibits all press movements.

: Slopes + and -
the position Slopes authorises the reading and the modification of the pa-
rameters set points by successive increments or decrements.

: Keyboard inhibition
S100-S101 the Keyboard inhibition (S100) position authorises the reading of all pa-
rameters, but prohibits any modification.

WARNING: It is highly recommended to remove the key from selec-


tor S100-S101 when it is in position Keyboard inhibi-
tion.

3.1.5. Counters

Position
number on
Unit electrical
Function
diagram

Total cycle counter


P1
P1 is incremented at each cycle during the injection. It can't be reset to zero.
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Cycle counter with reset to zero


P2 is only available when the machine is equipped with the option OP205
P2 (Cycle counter with reset to zero).
P2 is incremented at each cycle during the injection. P2 can be reset to zero
when pressing the push button on the front panel.

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Technical Manual V68 Y4000
Volume 2 - Application
Chapter III - Control station
RUBBER INJECTION MOULDING

Position
number on
Unit electrical
Function
diagram

Hour counter
P3 is only available when the machine is equipped with the option OP122
P3 (Hour counter).
P3 displays the number of operation hours performed by the hydraulic
pump unit.
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Volume 2 - Application
Chapter III - Control station
RUBBER INJECTION MOULDING

3.1.6. Operating mode selection

Position
number on
Unit electrical
Function
diagram

Selector Operating modes


S0-S1 is a 4-position key selector. Each position authorises a specific operat-
ing mode:

: Adjustment
the Adjustment operating mode authorises the operator to control all
press movements manually, except the clamping and injection. The press
opening and closing only take place at low speed.

WARNING: The Adjustment operating mode is used for the adjust-


ment of the mould peripherals, that is why it is essential
to take particular care when controlling the option
movements inside the press, for they are not checked
by their respective microcontacts.

: Manual
S0 the Manual operating mode authorises the operator to control all press
S1 movements manually, including the clamping and injection. The operator
can run a comprehensive manually controlled cycle.

: Semi-automatic
the Semi-automatic operating mode authorises the operator to control the
press movements manually until reaching the movement clamping-block
in. The remaining cycle stages are completed automatically.

: Automatic
the Automatic operating mode authorises the operator to control the
guard closing manually (button S37) to launch the cycle which is completed
automatically.
This operating mode is the current production mode.
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Volume 2 - Application
Chapter III - Control station
RUBBER INJECTION MOULDING

3.1.7. Standard movement controls


A standard press movement is generally controlled by pressing the corre-
sponding push button and maintaining it pressed down during the desired
stroke.
When the push button is released, the movement stops automatically.
NOTE: The opening and closing movements of the guard are executed by pressing
once on their respective controls.
As with the Manual operating mode, clamping block in, clamping block out,
clamping, unclamping and injection are controlled by pressing once on their re-
spective controls.

Position
number on
Unit electrical
Function
diagram

Push button Injection piston retraction


S18
S18 controls the retraction of the injection piston.

Push button Purge-Injection


S19 controls the purge regardless of the selected operating mode.
S19 also controls the injection in the Manual operating mode.
REMARK: In the Adjustment mode, S19 is used for the initialisation
S19 of the injection unit strokes. The initialisation is carried out

by simultaneously pressing S19 and the key Init on


the keyboard while the press is open and the injection pis-
ton is in the mechanical stop position end of injection
stroke.

Push button Forward step-by-step learning cycle


S108
refer to section 1.2., page 209.
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Push-button Reverse step-by-step learning cycle


S107
refer to section 1.2., page 209.

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Technical Manual V68 Y4000
Volume 2 - Application
Chapter III - Control station
RUBBER INJECTION MOULDING

Position
number on
Unit electrical
Function
diagram

Push button Front guard opening


S38 controls the immediate opening of the front guard and stops the execu-
tion of the current cycle.
S38
REMARK: The cycle is not interrupted if the guard opening is initiated
during the curing phase and the closing of the guard before
the end of the curing time (parameter 56).
Push button Front guard closing
S37 controls the closing of the front guard.
S37 also controls the cycle start in the Automatic operating mode.
S37
REMARK: Because the guard movements are controlled automatical-
ly, it is essential to check the opening and the closing of the
guard each time a new cycle is launched in the Manual,
Semi-automatic and Automatic operating modes.
Push button Press closing

S33a controls the press closing in the Adjustment, Manual and Semi-auto-
matic operating modes.

S33 REMARK: In the Adjustment mode, S33 is used for the initialisation
of the closing unit strokes. The initialisation takes place

when simultaneously pressing S33 and the key Init on


the keyboard while the press is closed, that is while the
parting lines of the different mould parts are in contact.

Push button Press opening


S34 S34a controls the press opening in the Adjustment and Manual operating
modes.

Push button Clamping-block in - Clamping


S35a controls the clamping-block in movement of the press in the Adjust-
S35 ment operating mode.
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S35a controls the clamping-block in and clamping movement in the Manu-


al and Semi-automatic operating modes.
Push button Unclamping-Clamping-block out
S35a controls the clamping-block out movement of the press in the Adjust-
S36 ment operating mode.
S35 controls the unclamping and clamping-block out movement of the press
in the Manual operating mode.

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Volume 2 - Application
Chapter III - Control station
RUBBER INJECTION MOULDING

Position
number on
Unit electrical
Function
diagram

Push button Injection unit lift


S41
S41 controls the injection unit lift regardless of the operating mode.

Push button Injection unit beardown


S42 controls the beardown of the injection unit regardless of the operating
mode.
S42
IMPORTANT: In the Semi-automatic and Automatic operating modes,
the injection phase is not completed, if the injection unit is
not forced down; in order to cause the injection phase to be
completed, the microcontact S48 must be enabled.
a. If the press is equipped with the selector key S4 and if the latter is set to 0 (with no guard), the dual-handed control
must be used. Refer to the indications relating to S93.

3.1.8. Optional movement controls


Optional movements are controlled by pressing the corresponding push but-
ton and by keeping it pressed down during the desired stroke.When the push
button is released, the movement stops automatically.

Position
number on
Unit electrical
Function
diagram

OP141a

S75 Push buttonb "Movable traverse ejectors in"

S76 Push buttonb "Fixed traverse ejectors out"


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Volume 2 - Application
Chapter III - Control station
RUBBER INJECTION MOULDING

Position
number on
Unit electrical
Function
diagram

OP139c

S66 Push buttonb Movable traverse ejectors out

S65 Push buttonb "Movable traverse ejectors in"

OP137d

S43 Push buttone "Sliding platen in"

S44 Push buttone Sliding platen out

a. These push-buttons are only available when the machine is equipped with the option OP141: Fixed traverse ejectors.
They are only active when one of the cycles implying the option is selected.
b. If the press is equipped with the selector key S12 and if the latter is set to 1, the dual-handed control must be used.
Refer to the indications relating to S93.
c. These push-buttons are only available when the machine is equipped with the option OP139: Movable traverse ejec-
tors. They are only active when one of the cycles implying the option is selected.
d. These push-buttons are only available when the machine is equipped with the option OP137: Sliding platen
e. The movements of the sliding platen must always be operated with the dual-handed controls. Refer to the indications
relating to S93.

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Chapter III - Control station
RUBBER INJECTION MOULDING

3.1.9. Dual-hand control

Position
number on
Unit electrical
Function
diagram

Push button Dual-hand


S93 is the push button located on the left side of the switch cabinet.
To guarantee the operator's safety during movements outside the area pro-
tected by the cage of the machine and regardless of the operating mode cho-
sen, certain movements are initiated only if S93 is activated
simultaneously with the corresponding push buttons.
1 When the press is equipped with the S1 safety level and the selector S4
(Selector Guard operation) is in position 0 (without guard), S93 must be
activated with the following push buttons:
S33 for the press closing,
S35 for the clamping-block in movement and the clamping.
2 When the machine is equipped with option OP141 (Fixed traverse ejec-
tors) and the selector S12 (Selector dual-hand controlled ejectors with
S93 open guard) is in position 1, S93 must be activated simultaneously with
the following push buttons:
S75 for the run-in of the fixed traverse ejectors,
S76 for the run-out of the fixed traverse ejectors.
3 When the machine is equipped with the option OP139 (Movable traverse
ejectors) and the selector S12 (Selector dual-hand controlled ejectors
with open guard) is in position 1, S93 must be activated simultaneously
with the following push buttons:
S66 for the run-out of the movable traverse ejectors,
S65 for the run-in of the movable traverse ejectors.
4 When the machine is equipped with the option OP137 (Sliding platen),
S93 must be activated simultaneously with the following push-buttons:
S44 for the run-out of the sliding platen,
S43 for the run-in of the sliding platen.
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Volume 2 - Application
Chapter III - Control station
RUBBER INJECTION MOULDING

3.2. The auxiliary control front panel


The auxiliary control front panel includes different selection and control ele-
ments distributed over the 4 keypads listed below:
1. the different selector keys and controls,
2. the additional option selector keys,
3. the optional printer socket outlet,
4. the additional option movement controls,
see illustration Fig. 14., page 66

CELLS
RESET

1 2 4

Fig. 14. Auxiliary control front panel

The legends (logic diagrams) correspond to the additional selections and op-
tions on the press.

3.2.1. The printer socket outlet


The printer socket [format HE5 (subD), 25 female contacts] allows the connec-
tion of any printer to the parallel port.
REMARK: The printer driver is to be installed on the PC operating system.
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Volume 2 - Application
Chapter III - Control station
RUBBER INJECTION MOULDING

3.3. Kit control buttons


The kit movement control buttons are located on the auxiliary control front
panel when the machine is configured with one of the following options:
OP146: Top rear stripping kit
OP147: Bottom front stripping kit.

Position
number on
Unit electrical
Function
diagram

S123 Push button Plate in

S124 Push button Plate out

S175 Push button Kit ejector in

S176 Push button Kit ejector out

S112 Selector Continuous cycle

CELLS
RESET
S310 Push button Front cell resetting
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H310 Indicator Front cell resetting

For further information concerning the operation and the controls of the kits, please
refer to volume 5 - Option: Stripping kits.

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Technical Manual V68 Y4000
Volume 2 - Application
Chapter III - Control station
RUBBER INJECTION MOULDING

3.4. Ancillary cylinder control buttons


The ancillary cylinder movement control buttons are located on the auxiliary
control front panel when the machine is prearranged for them.

Position
number on
Unit electrical
Function
diagram

S401 Push button Ancillary cylinder 1 out

S400 Push button Ancillary cylinder 1 in

S403 Push button Ancillary cylinder 2 out

S402 Push button Ancillary cylinder 2 in

For further information concerning the operation and the controls of the ancillary cyl-
inders, please refer to the machine customization manual, volume 10 - Specials.

3.5. Silicone stuffer control buttons


The ancillary cylinder movement control buttons are located on the control
box of the silicone stuffer when the machine is configured with the option
OP050: prearrangement for silicone stuffer.
For further information concerning the operation and the controls of the silicone
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stuffer, please refer to volume 5 - Option: OP064-Silicone stuffer.

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Volume 2 - Application
Chapter IV - Reading and programming of data
RUBBER INJECTION MOULDING

Chapter IV - Reading and programming of data

1. Screen ergonomics

1.1. Introduction
The G8 screen is divided into 5 distinct areas:
1. the line for the heading,
2. the line for the alarm messages,
3. the line for the information messages,
4. the active page,
5. the keypads of the associated optimisation functions.

4
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Fig. 15. Details of a G8 screen page

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Volume 2 - Application
Chapter IV - Reading and programming of data
RUBBER INJECTION MOULDING

1.2. Heading line

The heading line displays the following information:

Back-
Position on Name of the
Function ground col-
Fig. 16. zone
our
A Date Displays the current date
B Time Displays current time
Grey
Digital manom- Display of the measured service pressure value
C
eter (expressed in bars)

(a)
D Heading Displays base function heading Light blue or
Dark blue
E Mould Displays current mould number Grey
a. See section 1.4.1. Heading of the active page, page 75

1.3. Message lines

1.3.1. Active messages


 Alarm messages
When a fault is detected on the machine, it is declared to be active, until be-
ing cleared; the corresponding message is stored and can be displayed on the
alarm message line.

A B C D E
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05/12/00 10:01:25 0 bar Mould closing Mould: V58Y20


Self-check door A disabled 05/12/00 09:56:12
Open and close door A Phase 0

Fig. 16. Details of the heading line

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Volume 2 - Application
Chapter IV - Reading and programming of data
RUBBER INJECTION MOULDING

 Information messages
The machine process-control automatically generates information messages
intended for the operator. Generally, an information message is part of a contex-
tual machine use advice (example: please close the safety guard).
An information message remains active until being effectively cleared by the
operator as a response to the message. It may be overlapped by a new mes-
sage. Information messages are not stored.

1.3.2. Level of the fault messages


 Alarm messages
Alarm messages are classified according to the 3 following levels:

Fault level Line


Action upon the back-
Signalling
No Descriptiona cycle run ground
colour
Alarm message display
4 Cycle lock Immediate stop + blinkerb + flashing lampc Red
+ klaxond
Alarm message display
Production stop at + blinkerb + flashing lampc
the end of the clamp-
3 Production stop Klaxond when Orange
ing phase of the next
cycle the press
stops
Alarm message display
2 Flashing light blank Yellow
+ blinkerb + flashing lampc
a. Refer to section 2.6. Optimisation page Retrace faults, page 240
b. see H40, page 55
c. only if the machine is equipped with option OP190 Flashing alarm
d. In case of specific outfit.

REMARK: The user can change the initial fault levels of the alarm messages 3, 2 or 1 by
eventually assigning a higher or lower level between 1 and 3 to the message
concerned. An alarm message downgraded to 1 becomes an information mes-
sage; it is displayed on the line available for this purpose, but unlike the other
current information messages, it is stored.
 Information messages
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Information messages are classified according to the following levels:


0 = current messages
1 = alarm messages downgraded to 1 by the operator

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Volume 2 - Application
Chapter IV - Reading and programming of data
RUBBER INJECTION MOULDING

Fault level Line


Action upon the Type of mes- back-
Signalling
No Descriptiona cycle run sage ground
colour
1 stored Information
Information blank message dis- Grey
0 not stored play
a. Refer to section 2.6. Optimisation page Retrace faults, page 240

1.3.3. Message display rules


 Alarm messages
Only one fault message can be displayed at the same time on the alarm mes-
sage line.
If several faults are active simultaneously, the following rule is to be applied:
1. the message of higher level is displayed first,
2. between 2 messages of the same level, the more recent message is displayed
first.

3. the operator can scroll all messages when pressing the key .
(see page 51).
REMARK: If one or several messages are generated during the scrolling asked for by the
operator, they come first and are governed by the above mentioned rule.

 Information messages
The information message line always displays the latest information generat-
ed by the machine process-control.

1.3.4. Details of the alarm message line


This line displays the following information:

F G H
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05/12/00 10:01:25 0 bar Mould closing Mould: V58Y20


Self-check door A disabled 05/12/00 09:56:12
Open and close door A Phase 0

Fig. 17. Details of the alarm message line

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Volume 2 - Application
Chapter IV - Reading and programming of data
RUBBER INJECTION MOULDING

Line back-
Position on
Name of the zone Function ground
Fig. 17.
colour
F Alarm Displays active fault message (a)
G Fault date Displays the date the fault occurred on the press Grey or
Yellow or
Displays the time the fault occurred on the Orange or
H Fault time
press Red
a. See section 1.3.2. Level of the fault messages, page 71
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Volume 2 - Application
Chapter IV - Reading and programming of data
RUBBER INJECTION MOULDING

1.3.5. Details of the information message line


This line displays the following information:

Line back-
Position on
Name of the zone Function ground
Fig. 18.
colour
J Information message Displays active information message
Displays the name of the active sequential Grey
K Sequential phase
phasea
a. The indication of the current sequential phase is very helpful for servicing operations completed on phone by the
Technical Assistance Department of REP. Don't forget to indicate it.

1.4. Active page


The active page is the area displayed in the middle part of the screen.
Its content differs according to the function selected on the keyboard.
The active page is depending on the case:
a base page called by one of the preset function keys,
(refer to section 2.2.2., page 48),

05/12/00 10:01:25 0 bar Mould closing Mould: V58Y20


Self-check door A disabled 05/12/00 09:56:12
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Open and close door A Phase 0

J K

Fig. 18. Details of the information message line

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Volume 2 - Application
Chapter IV - Reading and programming of data
RUBBER INJECTION MOULDING

an optimisation page called by one of the 7 optimisation function keys


(refer to section 2.2.1., page 48).
REMARK: When powerizing the machine, the active page displayed is the base page
Production check.

1.4.1. Heading of the active page


 Heading of the base page
The base page heading is always displayed on the screen heading line. (refer
to position D section 1.2., page 70).
The base page heading is displayed on a background which may be different:
light blue background if the base page is active,
dark blue background if the base page has an optimisation page and if this
page is active.
 Optimisation page headings
The optimisation page headings are displayed in the text keypads associated
with the optimisation function keys.
The text keypads associated to the optimisation function keys are displayed
in a changing background colour:
the one of the active optimisation page is displayed on a light blue back-
ground,
the ones of the other accessible pages are displayed on a dark blue back-
ground,
those of the other inaccessible pages are displayed on a light grey back-
ground.
also see section 1.5. Optimisation function, page 76

1.4.2. Structure of an active page


An active page can contain information relating to:
the machine configuration,
the production configuration
the moulding parameters,
the maintenance,
the online help.
The active page can combine the following areas:
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a page background design,


display areas,

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Volume 2 - Application
Chapter IV - Reading and programming of data
RUBBER INJECTION MOULDING

active zones.
either arranged in different points of the active page,

or arranged in tables with several lines and columns


refer to section 3. Use of the tables, page 81

either arranged in multiple-choice lists with checkboxes

choice 1 (not validated)


 choice 2 (validated)
choice 3 (not validated)
 choice 4 (validated)

Fig. 19. Example of a multiple-choice list

either arranged in exclusive-choice lists with radio buttons

choice 1 (not validated)


choice 2 (validated)
choice 3 (not validated)
choice 4 (not validated)

Fig. 20. Example of an exclusive-choice list

or presented as a pulldown menu (exclusive choice)

choice x (validated)
choice 1 (not validated)
choice 2 (not validated)
choice 3 (not validated)

Fig. 21. Example of a pull-down menu


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1.5. Optimisation function


A base page may have up to 7 optimisation functions represented by the key-
pads at the bottom of the screen.
REMARK: Depending on the optional equipment available on the machine, the 7 optimi-
sation functions may not all be accessible.
The description of every optimisation function is given in the text keypad as-
sociated with one of the 7 optimisation function keys.

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Chapter IV - Reading and programming of data
RUBBER INJECTION MOULDING

1.5.1. Colour code of the text keypads


Every optimisation function keypad can be displayed according to a particu-
lar colour code.

Keypad Keypad out-


Texts Status of the function
background line
Light grey without without No optimisation function
Light grey Dark grey without No access to the function on the machine
without Function accessible and disabled

Dark blue White Function accessible and enabled


Orange One of the parameters of the optimisation page is ac-
tive.
without Disabled function displayed on the active page.
Light blue a White
Orange Enabled function displayed on the active page.
a. Only 1 of the 7 keypads can be light blue.

see illustration Fig. 22., page 77


see also 4.3. Activating an optimisation function, page 87
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Page can be accessed


Active page but function not active

Page can be ac-


Page cannot be ac- cessed, function active
cessed

Fig. 22. Example of colours of the optimisation functions' keypads

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Technical Manual V68 Y4000
Volume 2 - Application
Chapter IV - Reading and programming of data
RUBBER INJECTION MOULDING

2. Programming rules

2.1. Active zones


Active areas are data input fields enabling the operator to:
enter or modify a numeric value,
make a choice,
Active areas can also be interaction areas allowing the operator to directly get
to another page (shortcuts).

2.2. Bounding box


The bounding box makes it possible to localise the active area among those dis-
played on the page.
REMARK: Generally, the focus is a black-shaded bounding box delimiting the zone.
Only one area can be activated at the same time.
refer to section 2.2.1. Bounding box shift rules, page 78

2.2.1. Bounding box shift rules


When powerizing the machine and displaying an active page for the first
time, the focus is positioned on the active zone located at the top left of the
active page.
Then, when displaying the same page again, the active zone is the zone which
was last active during the previous display.
 The bounding box shift rules are listed below:
Use the arrow keys to move the focus from one active area to another (see
page 50).
Access by moving to the area nearest the initial active area.
The shifts are limited to the margins of the active page (example: no shift to
the right at the end of a line).
The key Validation performs the same move as the key Right arrow.
If one window combines several active areas, the above mentioned shift
rules are applicable inside the window.
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Programming rules
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Chapter IV - Reading and programming of data
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If one page contains several active area windows, the above mentioned shift
rules are applicable to pass from one window to the other.

WARNING:
The data input into an active area can be validated only by the key
(Validation key).
In the same way, the data input into one or several active zones combined in

the same window can only be validated by the key before shifting the
focus to another window.

2.3. Data input validation and deletion

2.3.1. Validation rules for numeric settings


When activating the area, the previous value is deleted. Only separating
characters are displayed (double point, decimal point).
All numbers are to be entered in order to complete the whole area from left
to right.
REMARK: The quantity of numbers to program depends on the active area.

The last value entered is validated only by using the key .


The last value entered whether complete or not is deleted by using the key

.
If the operator shifts the bounding box by using one of the arrows before
validating the last value entered, the previous value is restored.
If the operator validates or tries to shift the cursor when the last value en-
tered is outside the limits, the display area is deleted and an information
message displayed.

2.3.2. Validation rules for a binary choice

The last value selected is validated only by using the key .


The last selected value is deleted by using either the key Deletion or by
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pressing the key once more.

2.3.3. Validation rules for an exclusive choice (radio buttons)

The radio button on which the focus is set is validated by the key .
The radio button which has been validated last is disabled by the validation
of another radio button.

Programming rules
Document: V684_2Aa
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Technical Manual V68 Y4000
Volume 2 - Application
Chapter IV - Reading and programming of data
RUBBER INJECTION MOULDING

2.3.4. Validation rules for a multiple choice (checkboxes)

The checkbox on which the focus is set is validated by the key .

The latest checkbox validated is disabled by the key .

2.3.5. Validation rules of a pulldown menu item

The key opens the pulldown menu.


The bounding box can be shifted to the required menu item by using the

keys and .

The menu item activated the latest is validated by the key .

2.4. Automatic programming

2.4.1. Selection rules for an optimisation function


An optimisation function can be used only if all the parameters relating to this
function are set.
To simplify its selection, the following rules are established:
The input and validation of all set values of all parameters relating to an op-
timisation function automatically validate its selection.
When entering a zero value to a set value of one of the parameters relating
to an optimisation function its selection is automatically cancelled.

2.4.2. Selection rules for the tolerance check


The parameter tolerance check can't be used if no tolerance is set.
To simplify its selection, the following rules are established:
The tolerance check status must be forced to ON,
The input and validation of a value which is not equal to zero within the
limits set for one of the tolerances associated with a parameter automatical-
ly force the other tolerance to the same value, if it is zero.
The reset to zero of the 2 tolerances associated with a parameter deactivates
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the tolerance check of this parameter.

Programming rules
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Volume 2 - Application
Chapter IV - Reading and programming of data
RUBBER INJECTION MOULDING

3. Use of the tables

3.1. Introduction to the tables


The tables display lists of data arranged in cells. Each cell shows one of the
data characteristics.
Each item of data is split over one line of several cells.
Each column of the table groups the cells of features common to different
items of data.
The title of each column shows the feature displayed in the column.

3.1.1. Focus and active cells


Some cells can be active and others not, depending on the type of data pre-
sented in the table.
The focus can be moved from one active cell to another either by moving be-
tween the headings or between data cells.
When the bounding box is positioned on a data cell, the operator can change
any cell content whatsoever following the rules described in section 2.3. Data
input validation and deletion, page 79

3.1.2. Colour coding of the table cells


Each cell is displayed with a particular colour code.

Bounding Cell back- Cell bound-


Type of cell
box ground ing box
deactivated Dark blue without
Heading cell
activated Light blue Orange
deactivated Light grey without
Data cell
activated Light grey Black

3.2. Sequence sorting


When the bounding box reaches a table heading cell, the operator can order a
sequence sorting over the whole table by validating the position of the bound-

ing box with the key .


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Sort and sequence is an intuitive sort which arranges the data as a function of
the type of information presented in the column from which the sort begins :
if the information is numerical, sorting is in ascending numerical order,
if the information is textual, sorting is in ascending alphanumerical order,
if the information is chronological (date, time), sorting is in ascending
chronological order.

Use of the tables


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Volume 2 - Application
Chapter IV - Reading and programming of data
RUBBER INJECTION MOULDING

3.3. Data Screening


Some tables permit the data in them to be screened as a function of criteria
specifically included in an exclusive choice list.
refer to section 2.3.3., page 79

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Use of the tables


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Volume 2 - Application
Chapter IV - Reading and programming of data
RUBBER INJECTION MOULDING

4. Programming of the moulding parameters


The moulding parameters are distributed over the different base pages relat-
ing to the preset functions and their optimisation pages.
REMINDER: A moulding parameter can be inquired, programmed or modified on the same
page.
The position of the keyboard selector key (see S100-S101, page 58) is the
only element to define the authorization regarding the programming and mod-
ification of the parameter set values.

4.1. Page background design


Every base or optimisation function has a background design.
REMARK: The same function may have several background designs. In such a case, the
only design displayed is determined by the press configuration.
The page background design represents the following elements:
the simplified design of the mechanical press elements involved in the cur-
rent function. This graphic representation is deliberately different from a
particular mechanical configuration (horizontal or vertical presses).
the 5 axes of the physical events each materialised by a white, horizontal
line and a symbol representative of the event:

Physical
Symbol Units used
events

minutes and seconds (mm. ss)


Time
or 1/10 second (0.1 s)

temperatures degrees Celsius (C)

Strokes 1/10 millimetre (0.1 mm).


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millimetre per second (mm/s)


Speeds or 1/10 millimetre per second(0.1 mm/s)
or percentage of a maximum value (%).

Pressures bar (bar)

Programming of the moulding parameters


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Technical Manual V68 Y4000
Volume 2 - Application
Chapter IV - Reading and programming of data
RUBBER INJECTION MOULDING

4.2. Parameter display windows


The information of each moulding parameter of an active page is displayed in
a window aligned with one of the white screen background lines representing
the physical event of the parameter.
The design and content of the window are different according to the position
of the keyboard selector key (see S100-S101, page 58) :
selector key positioned on Keyboard inhibition or Modification by
slopes + and -, the window is an inquiry type window.
selector key positioned on Keyboard access, the window is a programming
type window.
There is a third type of window (tolerance window) allowing to display or
program the information regarding the parameter associated tolerances.
The number and positioning of the windows displayed on a given page de-
pend on the press configuration.

4.2.1. Inquiry window


The parameter inquiry window is made up of 3 areas at the maximum (see il-
lustration Fig. 23., page 84.):
the parameter set value displayed on a white background,
the parameter number displayed on a yellow background,
the measured parameter value displayed in bold characters on a variable
colour background
(refer to section 4.2.4. Colour code of the parameter windows, page 87).
REMARK: The inquiry window of a parameter has no measure area, if there is no meas-
ured value for this parameter.
Moreover, on the Filling base and optimisation pages, only the inquiry win-
dow of parameter 30 has a measure area among the inquiry windows of the
injection unit stroke parameters.
The inquiry window is active when showing the black-shaded bounding box
(the focus).

4.2.2. Programming window


When an inquiry window is active, it changes into a programming window
when positioning the keyboard selector key to Keyboard access.

parameter number
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set value measured value

1545 00 1289 4630 30 4630

window not activated window activated

Fig. 23. Details of the inquiry windows

Programming of the moulding parameters


Document: V684_2Aa
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Technical Manual V68 Y4000
Volume 2 - Application
Chapter IV - Reading and programming of data
RUBBER INJECTION MOULDING

A programming window has a more important size than a display window;


it consists of the following areas (see picture Fig. 24., page 85):
the heading of the parameter on a yellow background,
the min. and max. programming values,
the reminder of the symbol and measuring unit of the physical event of the
parameter,
the parameter set value displayed on a white background,
the parameter number displayed on a yellow background,
the parameter measure displayed in bold characters on a variable colour
background
(refer to section 4.2.4. Colour code of the parameter windows, page 87).
the status box of the parameter associated tolerance check, if the parameter
allows tolerances. The check box is activated if the tolerances have been ac-
tivated in the tolerance window.
REMARK: A programming window is systematically active when being displayed. The in-
itial active zone is the set value input zone framed with a bounding box (the
focus).

symbol for the physical


event
heading
max. program-
ming value
Fixed platen heating
min. programming
value 0 250 C measuring unit

195 65 195 
status box of the associ-
ated tolerance
set value

parameter number measured value

Fig. 24. Details of a programming window


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Programming of the moulding parameters


Document: V684_2Aa
Edition: 16/06/2000 page 85
Technical Manual V68 Y4000
Volume 2 - Application
Chapter IV - Reading and programming of data
RUBBER INJECTION MOULDING

4.2.3. Tolerance window


Only the parameters allowing tolerances have an associated tolerance win-
dow.
The tolerance window is displayed when the operator presses the key Toler-
ance on the keyboard (see page 50).
REMARK: The information of the tolerance window can be changed only when position-
ing the keyboard selector to Keyboard access.
There are 2 separately programmable tolerances :

Tolerances Application
Triggers an alarm if the parameter measure exceeds the set
value by a value at least equal to (+)
(+)
Alarm if Measure [Set value + (+)]
Triggers an alarm if the parameter measure is below the set
value by a value at least equal to ()
()
Alarm if Measure [Set value - ()]

The tolerance window displays the following information (see picture Fig. 25.,
page 86):
the heading of the window and the measuring unit of the physical event of
the parameter,
the tolerance value (+),
the tolerance value (),
the tolerance check status (ON or OFF),

measuring unit tolerance check condi-


tion
tolerance value (+)

Tolerance C
(+)
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15 ON

() 5

function cycle lock :


tolerance value () status ENABLED

Fig. 25. Details of a tolerance window

Programming of the moulding parameters


Document: V684_2Aa
page 86 Edition: 16/06/2000
Technical Manual V68 Y4000
Volume 2 - Application
Chapter IV - Reading and programming of data
RUBBER INJECTION MOULDING

the status of the cycle lock function:

= disabled, i.e. no cycle lock at the cycle end,

= enabled, i.e. cycle lock at the cycle end when stating measured val-
ues outside the tolerances,
REMARK: If the keyboard selector is positioned on Keyboard access, a tolerance win-
dow is systematically active when being displayed. The initial active zone is the
input zone of the tolerance (+), it is framed with a bounding box (the focus).

4.2.4. Colour code of the parameter windows


 Set value
The parameter set value zone always has a white background.
 Parameter number
The parameter number zone always has a yellow background.
 Measured value
If the tolerance check selection is active, the area giving the measured value of
the parameter has a variable colour background depending on the measured
deviation [Set value - Measure] and the tolerances linked to the parameter.

Measured devia- Area Measure


Tolerances
tion Background colour Example

Disabled Any White 195 65 150

Below the toler- 195 65 195


Green
ance
Enabled
Above the toler- 195 65 150
Red
ance
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4.3. Activating an optimisation function


The following conditions must be satisfied for an optimisation function to be
active:
all the set values of the parameters associated with it must be valid,

Programming of the moulding parameters


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Edition: 16/06/2000 page 87
Technical Manual V68 Y4000
Volume 2 - Application
Chapter IV - Reading and programming of data
RUBBER INJECTION MOULDING

the function must be selected.


REMARK: An optimisation function is selected :
when its checkbox displayed on the page Selections is ticked,
refer to section 3.7.5., page 266.
or when the associated diamond-shaped box is blue
refer to section 4.3.1., page 88.

4.3.1. Colour code of the optimisation function selection diamond.

State of the opti- Diamond-shaped box


misation func-
tion Background colour Example

activated Blue

Deactivated White

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Programming of the moulding parameters


Document: V684_2Aa
page 88 Edition: 16/06/2000
Technical Manual V68 Y4000
Volume 2 - Application
Chapter IV - Reading and programming of data
RUBBER INJECTION MOULDING

5. Instructions for how to change parameters

5.1. How to change a parameter set value


1. Move the bounding box to the inquiry window of the parameter to change by

using the keys , , and .

2. Set the keyboard selector S100-S101 to the position .


3. As the inquiry window is active, it changes into a programming window.
refer to section 4.2.2. Programming window, page 84
4. Enter the new set value, making sure that it is within the maximum value pro-
grammed.

5. Validate the new set value entered with the key .

REMARK: If a set value greater than the maximum is entered, it will be cut off at the max-
imum programmed value.
 To change the set value of another parameter:
6. Repeat steps 1. to 5.
 To stop changes :

7. Exit the position .

5.2. How to change the tolerances of a parameter


1. Move the bounding box to the inquiry window of the parameter to change by

using the keys , , and .

2. Set the keyboard selector S100-S101 to the position .


 As the inquiry window is active, it changes into a programming window.
refer to section 4.2.2. Programming window, page 84

3. Press the key .



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The tolerances window opens.


refer to section 4.2.3. Tolerance window, page 86
4. Enter the new set value for the tolerance (+).
5. Validate the tolerance entered (+) and move the bounding box to the 2nd tol-

erance by using the key .

6. Enter the new set value for the tolerance (+).

Instructions for how to change parameters


Document: V684_2Aa
Edition: 16/06/2000 page 89
Technical Manual V68 Y4000
Volume 2 - Application
Chapter IV - Reading and programming of data
RUBBER INJECTION MOULDING

7. Validate the new tolerance entered () by using the key .

8. Press the key to close the tolerances window.

9. Exit the position .

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Instructions for how to change parameters


Document: V684_2Aa
page 90 Edition: 16/06/2000
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

Chapter V - Moulding parameters

1. Principle of the distribution of functions


A Rep press is expected to produce parts through rubber injection mould-
ing.
To do so, the press must successively execute the particular actions described
here-below:
1. prepare the compound,
2. close the mould,
3. fill the mould with the compound,
4. cure the compound inside the mould,
5. strip the parts and load the inserts, if available.
The process-control of the G8 type press has been developed with the aim of
simplifying the inquiry and programming of the moulding parameters for the
operator. The operator interface presents the production cycle split into the
main functions equivalent to the actions listed above.
The moulding parameters of a G8 type Rep press are distributed over the dif-
ferent active pagesa relating to each of the 5 preset functions and their associ-
ated optimisation functions, available by means of the keyboard keys.
see illustration Fig. 26., page 91 and table Tab. 1., page 92

Access keys to the preset


functions
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Fig. 26. Operator interface keyboard

a. An active page is a screen displayed on the terminal operator.

Document: V684_2Aa
Edition: 16/06/2000 page 91
page

Chapter V - Moulding parameters


92

Access keys

Base pages Optimisation pages

Compound Back-pres- Extruder feed Shot size ac- Compound


preparation sure Extruder strip rupture curacy Silicone
decompres-
time-delay stuffer
page 105 page 109 page 113 page 115 sion
page 111 page 119
: page 289 : page 290 : page 291 : page 291 page 117

Mould closing Mould height


Plate ap-
adjustment
page 121 proach
screw
: page 292 page 125
page 127

Technical Manual V68 Y4000


Injection pro- Automatic in- 2nd transfer
Filling Cold runner Beardown af-
file Degassing Vacuum jection unit
block ter injection Compound
page 129 lift
page 136 page 140 page 148 pressure
page 293) page 144 page 146

Volume 2 - Application
: page 295 page 150 page 152

Curing Curetrac
Curetrac Cor- Network Ancillary are-
communica-
page 156 rections Link as
tion
: page 296 page 158 page 160 page 161
page 159
Document:
Edition:

Stripping and Movable Fixed


Plate ap- Ancillary cyl-
loading of in- traverse ejec- traverse ejec- Stripping kits Sliding platen Limits
proach inders
serts tors tors
page 178 page 182 page 186

RUBBER INJECTION MOULDING


page 180 page 184
page 163 page 165 page 173
16/06/2000
V684_2Aa

Tab. 1.Functions, function keys and associated active pages

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Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

2. Synoptic diagrams of the parameters

2.1. Introduction
The synoptic diagrams of the following pages allow to rapidly visualise the
interdependence of the parameters involved in the press movements and be-
longing to different physical events.
Every synoptic diagram represents several vertical axes, each symbolising
one of the parametrizable physical events, the parameters involved for eve-
ry function or sub-function.
The base function and their parameters are represented in grey-shaded boxes.
The optimisation functions and their associated parameters appear in white
background boxes.

displacement limit
Direction of movement given by the arrows

XX

Optimisation function
Optimisation VV
parameter

YY
Base function Base parame-
ters

WW PP
Optimisation Function
TT

displacement limit

Strokes Speeds Pressures Times


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Physical events

Fig. 27. Symbolisation of the synoptic diagrams

Synoptic diagrams of the parameters


Document: V684_2Aa
Edition: 16/06/2000 page 93
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

2.2. Shot size setting

Max.shot size

30

Shot size setting


2A (see page 115)

3A

Back pressure
40 (see page 109)

Proportioning Feed strip rupture detec-


(see page 105) 20 4C tion
(see page 113)

Injection unit heater


57 safety
(see page 105)

0.75 s 20 Progressive start-up


5C
(see page 113)
0 t
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point zero

Strokes Speeds Pressures Times

Fig. 28. Synoptic diagram of shot size

Synoptic diagrams of the parameters


Document: V684_2Aa
page 94 Edition: 16/06/2000
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

2.3. Different types of injection piston retraction

Max.shot size

3C

Piston retraction after


2B 4B extruding
(see page 117)

30

Proportioning
20
(see page 105)

3B

Piston retraction before


2B 4B extruding
(see page 117)
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point zero

Strokes Speeds Pressures

Fig. 29. Synoptic diagram of the injection piston retractions

Synoptic diagrams of the parameters


Document: V684_2Aa
Edition: 16/06/2000 page 95
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

2.4. Mould closing

Injection-transfer
(see Fig. 33., page 99)
point zero

Adjustment of the clear-


Clamping ance under the clamping
43
(see page 121) block

05

Low speed approach 0B


stage 12 44
(see page 121)

04

13

09
High speed closing Intermediate low speed
stage 13 12 44 stage
(see page 121) (see page 125)

08

13

03

Low speed closing stage


02 12
(see page 121) Insert lift
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12
(see page 170)

L.S. mould open


Strokes Speeds Pressures

Fig. 30. Synoptic diagram of the mould closing

Synoptic diagrams of the parameters


Document: V684_2Aa
page 96 Edition: 16/06/2000
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

2.5. Injection (dynamic phase)

Max.shot size

1st volumetric degas- 2nd volumetric degas-


sing sing
(see page 140) (see page 140)

30

Injection pressure limita-


21 48 tion
36 (see page 136)

31

37

1st speed level during


the dynamic injection 2nd speed level during
phase 21 the dynamic injection
(see page 129) phase
(see page 136)

22

35
Static injection
(see Fig. 32., page 98)
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point zero

Strokes Speeds Pressures

Fig. 31. Synoptic diagram of the dynamic injection phase


(example shown with 2 speed levels)

Synoptic diagrams of the parameters


Document: V684_2Aa
Edition: 16/06/2000 page 97
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

2.6. Injection (static phase)

Max.shot size

30

Injection (dynamic phase)


(see Fig. 31., page 97)

35

Initiation of the different


time-delays
(see Fig. 34., page 100)

41 51

1st pressure holding


stage of the static injec- 41 51
tion phase
(see page 129)

2nd pressure holding


stage of the static injec-
42 52 tion phase
(see page 136)
point zero
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Strokes Pressures Times

Fig. 32. Synoptic diagram of the static injection phase

Synoptic diagrams of the parameters


Document: V684_2Aa
page 98 Edition: 16/06/2000
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

2.7. Injection-transfer

point zero

Clamping
43 51
(see page 121)
-1-
Clamping
05 block in 05
2nd transfer stage
1E 4E (see page 152)

0E

-2-
Opening 1st transfer stage
1D 4D (see page 129)

Mould closing
(see Fig. 30., Injection (dynamic phase)
page 96) (see Fig. 31., page 97)

0D 0D

-3- -4-
Excess Slight 43
clamping

0D +
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Strokes Speeds Pressures Times


L.S. mould open

Fig. 33. Synoptic diagram of the injection transfer

Synoptic diagrams of the parameters


Document: V684_2Aa
Edition: 16/06/2000 page 99
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

2.8. Initiation of the different time-delays

Injection unit heater


57 safety
(see page 105)
Curing time
(see page 156) 56

Extruder time-delay
50 (see page 111)

Automatic lift after injec-


54 58 tion
(see page 150)

Kinematics of a degas-
sing process
(see Fig. 35., page 101) Beardown holding after
5A injection
2nd delayed degassing (see page 146)
(see page 140) 55

2nd pressure holding


52 stage of the static injec-
54 tion phase
Injection
(dynamic phase)
Kinematics of a degas- (see Fig. 31.,
sing process page 97)
(see Fig. 35., page 101)
1st pressure holding
1st delayed degassing 51 stage of the static injec-
(see page 140) 53 tion phase
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35

Times Strokes Times

Fig. 34. Time diagram

Synoptic diagrams of the parameters


Document: V684_2Aa
page 100 Edition: 16/06/2000
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

2.9. Degassing

point zero

-1- Extraction pressure limi-


Unclamping 1A 46 tation
Opening (see page 186)

0A

Kinematics of a degas-
sing process
(see page 140)

-2-
54 Opening time

point zero

-3-
Clamping 43
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0A

Strokes Speeds Pressures Times

Fig. 35. Kinematics of degassing processes

Synoptic diagrams of the parameters


Document: V684_2Aa
Edition: 16/06/2000 page 101
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

2.10. Mould opening

point zero

Low speed extraction Extraction pressure limi-


stage 10 46 tation
(see page 163) (see page 186)

00

11

06
High speed opening Low intermediate speed
stage 11 10 86 stage
(see page 163) (see page 180)

07

11 Opening stroke limita-


tion
(see page 186)

01
Low speed ejection Ejection pressure limita-
stage 10 86 tion
0F
(see page 163) (see page 165)
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L.S. mould open


Strokes Speeds Pressures

Fig. 36. Synoptic diagram of the mould opening

Synoptic diagrams of the parameters


Document: V684_2Aa
page 102 Edition: 16/06/2000
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

2.11. Ejection on the movable traverse

Max.stroke

9C

7C

9B

In-stroke of the movable


traverse ejectors with
encoder 71 81
(see page 168)

Out-stroke of the mova-


ble traverse ejectors with 71
encoder
(see page 168)

9A
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point zero
Strokes Speeds Pressures

Fig. 37. Synoptic diagram of the movable traverse ejectors in/out

Synoptic diagrams of the parameters


Document: V684_2Aa
Edition: 16/06/2000 page 103
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

2.12. Ejection on the fixed traverse

point zero

9D

Out-stroke of the fixed


traverse ejectors with
encoder
(see page 173) 72

In-stroke of the fixed


traverse ejectors with
encoder
72 82
(see page 173)

9E

7F

9F
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Max. stroke
Strokes Speeds Pressures

Fig. 38. Synoptic diagram of the fixed traverse ejectors in/out

Synoptic diagrams of the parameters


Document: V684_2Aa
page 104 Edition: 16/06/2000
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

3. Function Compound preparation

3.1. Base page Compound preparation


see illustration Fig. 40., page 105

3.1.1. Associated graphic page


see section2. Graphic page Injection unit temperatures, page 289
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Fig. 40. Base page Compound preparation

Function Compound preparation


Document: V684_2Aa
Edition: 16/06/2000 page 105
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

3.1.2. Main sub-functions

Associated param-
Base sub-functions
eters

Proportioning 20 30
(page 94) (page 108) (page 108)

61
Extruder heating
(page 107)

62
Heating of the injection chamber
(page 107)

60
Compound temperature indicator
(page 107)

Injection unit heater safety 57


(page 94) (page 106)

Tab. 2.Sub-functions available on the base page Compound preparation

3.1.3. Parameters

Default
N Description
value

Times

57  Safety time of the injection unit


Parameter 57 is a delay-time initiated at the beginning of the extrusion phase
expressed and defining the rated time the compound is allowed to stay in the injection
in minutes chamber without any risk of pre-curing.
and seconds When elapsed, the delay-time 57 stops the heaters in the injection unit areas
and cools the whole injection unit safely until the temperature 62 of the injec-
tion chamber is stabilized below 43C. The cycle is interrupted. 9959
REMARK: During the safety cooling, the temperature controller of the in-
jection unit continues to run in order to favour the evacuation
of the calories carried over by the thermal oil with the water
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flow circulating through the exchangers.


The delay-time 57 is reset to zero with a new injection, a manual purge control
or a controller stop.

Tab. 3.Parameters of the base page Compound preparation

Function Compound preparation


Document: V684_2Aa
page 106 Edition: 16/06/2000
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

Default
N Description
value

Temperatures

60  Temperature indicator at the extruder outlet


Parameter 60 indicates the temperature of the material at the outlet of the ex-
expressed truder.
in Celsius
REMARK: Parameter 60 is not an active parameter of the machine, as
there is no resulting effect on the machine; however it can be parameter
used by the peripheral software programs Curetrac and set value
62
RepNet-win .
This value is processed by the software Curetrac to evaluate the heat of the
compound during each shot size setting.

This value can be used by RepNet-win to monitor the above mentioned heat-
ing.

61  Extruder temperature
Parameter 61 defines the temperature of the extruder barrel.
expressed
REMARK: The control of the heating area 61 takes place in a closed
in Celsius
loop; the temperature measurement is done by the thermo-
couple B2.
The mechanical pressure of the extruder screw exerted on without
the compound rapidly results in a temperature increase of the
extruder barrel. Consequently, the extruder circuit is cooled
down immediately whenever an excessive value of the 61 set
value is detected. The said cooling lasts proportionally to the
difference between the measured value and the temperature
set value.

62  Injection chamber temperature


Parameter 62 defines the temperature of the injection chamber.
expressed
REMARK: The control of the heating area 62 takes place in a closed
in Celsius
loop; the temperature is measured by the thermocouple B3, without
and when the set value is exceeded, there is no cooling.
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The only possible cooling for the injection chamber circuit is


the safety cooling controlled by the delay-time 57 or by the
manual stop of the temperature controller.

Tab. 3.Parameters of the base page Compound preparation(cont.)

Function Compound preparation


Document: V684_2Aa
Edition: 16/06/2000 page 107
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

Default
N Description
value

Strokes

30  Shot size setting stroke


Parameter 30 is a point on the injection piston axis defining:
expressed
the end of the shot size setting stroke executed at the rotation speed 20
in 0.1 mm
the beginning of the first stage of the dynamic injection phase executed at without
the injection speed 21.
Parameter 30 is also present on the base page Filling (refer to section 5.1.,
page 129) and on the optimisation page Injection profile (refer to section
5.2., page 136).

Speeds

20  Rotation speed of the extruder screw


Parameter 20 defines the rotation speed of the extruder screw stabilised after
expressed the progressive starting stages, optionally set in 5C.
without
in rpm Extruding starts once the time 50, if set, has elapsed and lasts until the injection
piston, pushed by the compound, reaches point 3A, if set, or otherwise point
30.

2C  Rotation speed of the extruder screw


Parameter 2C defines the average rotation speed of the extruder screw on the
expressed whole shot size setting stroke.
in rpm parameter
REMARK: Parameter 2C is not an active parameter of the machine, as set value
there is no resulting effect on the machine; however it can be 20
used by the peripheral software program RepNet-win.

Tab. 3.Parameters of the base page Compound preparation(cont.)


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Function Compound preparation


Document: V684_2Aa
page 108 Edition: 16/06/2000
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

3.2. Optimisation page Back-pressure


The optimisation page Back-pressure is always accessible.
see illustration Fig. 41., page 109

3.2.1. Associated graphic page


see section 3. Graphic page Back pressure, page 290

3.2.2. Optimisation sub-function

Associated
Optimisation sub-function
parameters

Back pressure 40
(page 94) (page 110)

Tab. 4. Sub-function available on the optimisation page Back-pressure


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Fig. 41. Optimisation page Back-pressure

Function Compound preparation


Document: V684_2Aa
Edition: 16/06/2000 page 109
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

3.2.3. Parameters

Default
N Description
value

Pressures

40  Back pressure
Parameter 40 defines the back-pressure captured in the rear of the injection without
expressed piston during extruding.
in bars

Tab. 5. Back-pressure optimisation page parameters

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Function Compound preparation


Document: V684_2Aa
page 110 Edition: 16/06/2000
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

3.3. Optimisation page Extruder time-delay


The optimisation page Extruder time-delay is always accessible.
see illustration Fig. 42., page 111

3.3.1. Optimisation sub-function

Associated
Optimisation sub-function
parameters

Extruder time-delay 50
(page 100) (page 112)

Tab. 6. Sub-function available on the optimisation page Extruder time-delay


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Fig. 42. Optimisation page Extruder time-delay

Function Compound preparation


Document: V684_2Aa
Edition: 16/06/2000 page 111
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

3.3.2. Parameters

Default
N Description
value

Time

50  Delayed extruder start


REMARK: Parameter 50 is not used in the setting and manual oper-
expressed ating modes.
in minutes During direct injection, parameter 50 is a delay-time initiated at the end of the
and seconds static injection phase, i.e. once 52 has elapsed, if set, otherwise when 51 has
elapsed.
without
During injection-transfer, parameter 50 is a delay-time initiated at the end of
the pressure holding time, i.e. when 51 has elapsed.
Parameter 50 defines the delay between the end of the last injection and the ex-
truder start.
When elapsed, the time-delay 50 controls the rotational movement of the ex-
truder screw, if selector S204 is positioned on 1. (refer to S204, page 55)

Tab. 7. Extruder time-delay optimisation page parameters

V:\G8\Vol2\A\A_utilisation_parametres.fm

Function Compound preparation


Document: V684_2Aa
page 112 Edition: 16/06/2000
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

3.4. Optimisation page Extruder feed strip rupture


The optimisation page Extruder feed strip rupture is always accessible.
see illustration Fig. 43., page 113

3.4.1. Associated graphic page


see section 4. Graphic page Extruding, page 291

3.4.2. Optimisation sub-function

Associated
Optimisation sub-function
parameters

Progressive start-up 5C
(page 94) (page 114)

Feed strip rupture detection 4C


(page 94) (page 114)

Tab. 8. Sub-function available on the optimisation page Extruder feed strip rupture
V:\G8\Vol2\A\A_utilisation_parametres.fm

Fig. 43. Optimisation page Extruder feed strip rupture

Function Compound preparation


Document: V684_2Aa
Edition: 16/06/2000 page 113
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

3.4.3. Parameters

Default
N Description
value

Time

5C  Progressive extruder start


Parameter 5C is a time-delay defining the duration of the increase in speed.
expressed speed
in minutes
and seconds
20
4 seconds

times
0 5C

Pressures

4C  Extruding average (Extruder feed strip rupture) (recom-


mended
Parameter 4C defines the limit value of the pressure used during shot size set-
default
expressed ting after the starting stages of the extruder set in 5C.
value) av-
in bars
Parameter 4C is used to detect a sudden drop in extruder service pressure erage ex-
caused by a rubber feed strip rupture. truding
pressure
over 3 cy-
cles

Tab. 9. Extruder feed strip rupture optimisation page parameters V:\G8\Vol2\A\A_utilisation_parametres.fm

Function Compound preparation


Document: V684_2Aa
page 114 Edition: 16/06/2000
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

3.5. Optimisation page Shot size accuracy


The optimisation page Shot size accuracy is always accessible.
see illustration Fig. 44., page 115

3.5.1. Associated graphic page


see section 4. Graphic page Extruding, page 291

3.5.2. Optimisation sub-function

Associated param-
Optimisation sub-function
eters

Shot size setting 2A 3A


(page 94) (page 116) (page 116)

Tab. 10. Sub-function available on the optimisation page Shot size accuracy
V:\G8\Vol2\A\A_utilisation_parametres.fm

Fig. 44. Optimisation page Shot size accuracy

Function Compound preparation


Document: V684_2Aa
Edition: 16/06/2000 page 115
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

3.5.3. Parameters

Default
N Description
value

Strokes

3A  Stroke of the extruder screw at low rotation speed


(recom-
Parameter 3A defines the low-speed rotation transition point of the extruder mended
expressed screw 2A on the axis of the injection piston. Slowing-down is used to obtain adefault
in 0.1 mm more accurate shot size setting. value)
Stroke 30 -
REMARK: The low speed 2A becomes only effective when the value 3A
10 mm
is below the value 30.

Speeds

2A  Low rotation speed of the extruder screw ((recom-


mended
Parameter 2A defines a low-speed rotation of the extruder screw to be used at
default
expressed the end of the shot size setting, in order to obtain a more accurate shot size set-
value)
in rpm ting.
Speed 20
divided by
2

Tab. 11. Shot size accuracy optimisation page parameters

V:\G8\Vol2\A\A_utilisation_parametres.fm

Function Compound preparation


Document: V684_2Aa
page 116 Edition: 16/06/2000
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

3.6. Optimisation page Compound decompression


The optimisation page Compound decompression is always accessible.
see illustration Fig. 45., page 117

3.6.1. Optimisation sub-functions

Optimisation sub-functions Associated parameters

Piston retraction before extruding 3B


(page 95) 2B (page 118) 4B
Piston retraction after extruding (page 118) 3C (page 118)
(page 95) (page 118)

Tab. 12. Sub-functions available on the optimisation page Compound decompression


V:\G8\Vol2\A\A_utilisation_parametres.fm

Fig. 45. Optimisation page Compound decompression

Function Compound preparation


Document: V684_2Aa
Edition: 16/06/2000 page 117
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

3.6.2. Parameters

Default
N Description
value

Strokes

3B  Piston retraction before extruding


Parameter 3B is a point on the injection piston axis defining:
expressed the limit point of the injection piston with automatic piston retraction,
in 0.1 mm without
the beginning of the shot size setting stroke.
The piston retraction before extruding starts when the time 50, if set, has
elapsed and is used to decompress the injection circuit before the extruder
starts.

3C  Piston retraction after extruding


Parameter 3C defines the limit point of the injection piston with automatic pis-
expressed ton retraction. without
in 0.1 mm
The piston retraction after extruding is used to relieve the compound stored
in the injection chamber from any back-pressure.

Speeds

2B  Piston retraction
Parameter 2B defines the retraction speed of the injection piston: (manual-
expressed when being controlled manually, ly control-
in 0.1 mm/ led)
sec when being controlled automatically before shot size setting on the stroke
delimited by the points 35 and 3B or after shot size setting on the stroke de- 200
limited by the points 30 and 3C.

Pressures

4B  Piston retraction
Parameter 4B defines the retraction pressure of the injection piston: (manual-
V:\G8\Vol2\A\A_utilisation_parametres.fm

expressed ly control-
when being controlled manually, led)
in bars
when being controlled automatically before shot size setting on the stroke
delimited by the points 35 and 3B or after shot size setting on the stroke de- 80
limited by the points 30 and 3C.

Tab. 13. Compound decompression optimisation page parameters

Function Compound preparation


Document: V684_2Aa
page 118 Edition: 16/06/2000
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

3.7. Optimisation page Silicone stuffer


REMARK: The optimisation page Silicone stuffer is only accessible when the machine
is configured with the option OP122: Silicone stuffer.
see illustration Fig. 46., page 119

3.7.1. Optimisation sub-function

Associated param-
Optimisation sub-function
eters

77 87
Silicone stuffer
(page 120) (page 120)

Tab. 14. Sub-function available on the optimisation page Silicone stuffer


V:\G8\Vol2\A\A_utilisation_parametres.fm

Fig. 46. Optimisation page Silicone stuffer

Function Compound preparation


Document: V684_2Aa
Edition: 16/06/2000 page 119
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

3.7.2. Parameters

Default
N Description
value

Speeds

77  Silicone stuffer movement speed


Parameter 77 defines the speed of the silicone stuffer movements. without
expressed
in%

Pressures

87  Service pressure of the silicone stuffer


Parameter 87 defines the service pressure of the silicone stuffer. without
expressed
in bars

Tab. 15. Silicone stuffer optimisation page parameters

V:\G8\Vol2\A\A_utilisation_parametres.fm

Function Compound preparation


Document: V684_2Aa
page 120 Edition: 16/06/2000
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

4. Function Mould closing

4.1. Base page Mould closing


see illustration Fig. 47., page 121

4.1.1. Associated graphic page


see section 5. Graphic page Clamping, page 292
V:\G8\Vol2\A\A_utilisation_parametres.fm

Fig. 47. Base page Mould closing

Function Mould closing


Document: V684_2Aa
Edition: 16/06/2000 page 121
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

4.1.2. Main sub-functions

Base sub-functions Associated parameters

Low speed closing stage 03 12


(page 96) (page 122) (page 123)

High speed closing stage 03 04 13


(page 96) (page 122) (page 122) (page 123)

Low speed approach stage 04 05 12 44


(page 96) (page 122) (page 123) (page 123) (page 124)

Clamping 43
(page 96) (page 124)

Tab. 16. Sub-functions available on the base page Mould closing

4.1.3. Parameters

Default
N Description
value

Strokes

03  Beginning of high speed closing


Parameter 03 is a point on the closing unit axis defining:
without
expressed the end of the low speed closing stroke (12),
in 0.1 mm
the beginning of the high speed closing stroke (13).

04  End of high speed closing


Parameter 04 is a point on the closing unit axis defining:
expressed without
the end of the high speed closing stroke (13),
in 0.1 mm
the beginning of the approach stroke executed at low speed (12) and safety
pressure (44),

Tab. 17. Parameters of the base page Mould closing


V:\G8\Vol2\A\A_utilisation_parametres.fm

Function Mould closing


Document: V684_2Aa
page 122 Edition: 16/06/2000
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

Default
N Description
value

05  Mould safety
Parameter 05 is a point on the closing unit axis used as the tolerance of the ZE-
expressed RO point of the closing stroke and defining:
in 0.1 mm
the end of the approach stroke executed at low speed (12) and safety pres-
sure (44),
the beginning of the clamping-block-in phase (for the machines with 3-
stroke type closing).
the end of the 30-second time-out for the closing phase. without
To protect the tooling, the information mould closed given by the parameter
05 is coupled to the information of microcontact S51 (L.S. mould closing).

REMARK: The microcontact S51 does not exist on the vertical V48 type
machines.
Parameter 05 is also used for the Filling function when the press operates in
the injection-transfer mode.
see section 5.1. Base page Filling, page 129

Speeds

12  Low speed closing


Parameter 12 defines:
expressed
in mm/s the closing speed which is always used in the setting mode,
without
the closing speed used in other operating modes than the setting mode,
outside the stroke limited by the points 03 and 04,
the closing speed used by the optimisation function Plate approach.
refer to section 4.2. Optimisation page Plate approach, page 125.

13  High speed closing


Parameter 13 defines the closing speed used in the operating modes other than
expressed the setting mode on the stroke limited by the points 03 and 04 outside the without
in mm/s areas defined by the optimisation function Plate approach.
refer to section 4.2. Optimisation page Plate approach, page 125.
V:\G8\Vol2\A\A_utilisation_parametres.fm

Tab. 17. Parameters of the base page Mould closing(cont.)

Function Mould closing


Document: V684_2Aa
Edition: 16/06/2000 page 123
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

Default
N Description
value

Pressures

43  Clamping
Parameter 43 defines during direct injection the clamping pressure applied to
expressed the mould once the clamping block is in,
in bars
Parameter 43 can also be used for the injection transfer moulding
refer to section 5.1. Base page Filling, page 129.
without

WARNING: Never clamp the press without a mould in place or with


a mould thinner than the mini mould.
refer to volume 9 - Tooling

44  Approach
Parameter 44 defines:
expressed
in bars the safety pressure applied to the closing cylinders on the low speed ap-
proach stroke 12 delimited by the points 04 and 05, without
the safety pressure applied to the closing cylinders when the function Plate
approach is used.
refer to section 4.2. Optimisation page Plate approach, page 125.

Tab. 17. Parameters of the base page Mould closing(cont.)

V:\G8\Vol2\A\A_utilisation_parametres.fm

Function Mould closing


Document: V684_2Aa
page 124 Edition: 16/06/2000
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

4.2. Optimisation page Plate approach


REMARK: The optimisation page Plate approach is only accessible when the machine
is configured with one of the following options:
OP133: Mechanical ejectors,
OP139: Hydraulic ejectors of the movable traverse,
OP141: Hydraulic ejectors of the fixed traverse.
see illustration Fig. 48., page 125

4.2.1. Optimisation sub-function

Optimisation sub-function Associated parameters

Intermediate low speed stage 08 09 12 44


(page 96) (page 126) (page 126) (page 126) (page 126)

Tab. 18. Sub-function available on the optimisation page Plate approach


V:\G8\Vol2\A\A_utilisation_parametres.fm

Fig. 48. Optimisation page Plate approach

Function Mould closing


Document: V684_2Aa
Edition: 16/06/2000 page 125
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

4.2.2. Parameters

Default
N Description
value

Strokes

08  Beginning of the low intermediate closing speed


Parameter 08 is a point on the closing unit axis defining:
expressed the end of the first closing stroke completed at high speed (13), without
in 0.1 mm
the beginning of the intermediate closing stroke completed at low speed (12)
and safety pressure (44),

09  End of the low intermediate closing speed


Parameter 09 is a point on the closing unit axis defining:
expressed without
the end of the intermediate closing stroke completed at low speed (12) and
in 0.1 mm
safety pressure (44),
the beginning of the second high speed closing stroke (13),

Speeds

12  Low speed closinga


without
expressed Parameter 12 defines the closing speed over the stroke delimited by the points
in mm/s 08 and 09.

Pressures

44  Approach a
Parameter 44 defines the safety pressure applied to the closing cylinders for
without
the low speed intermediate stroke 12 delimited by the points 08 and 09.
expressed
in bars

Tab. 19. Plate approach optimisation page parameters


V:\G8\Vol2\A\A_utilisation_parametres.fm

a. The parameters 12 and 44 are also used for the base function Mould closing. (refer to section 4.1., page 121).

Function Mould closing


Document: V684_2Aa
page 126 Edition: 16/06/2000
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

4.3. Optimisation page Mould height adjustment screw


The optimisation page Mould height adjustment screw is always accessible.
see illustration Fig. 49., page 127

4.3.1. Optimisation sub-function

Associated
Optimisation sub-function
parameters

Adjustment of the clearance under the clamping block 0B


(page 96) (page 128)

Tab. 20. Sub-function available on the optimisation page Mould height adjustment screw
V:\G8\Vol2\A\A_utilisation_parametres.fm

Fig. 49. Optimisation page Mould height adjustment screw

Function Mould closing


Document: V684_2Aa
Edition: 16/06/2000 page 127
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

4.3.2. Parameters

Default
N Description
value

Strokes

0B  Adjustment of the clamping stroke


Parameter 0B is a point on the closing unit axis defining a precise stop during
expressed the mould opening, to allow the adjustment of the clamping stroke, i.e. the ad-
in 0.1 mm justment of the clearance between the mould height adjustment nut and the
clamping block of the 3-stroke closing machines.
It is only useful in the setting mode after having selected cycle 30 and by fol-
lowing the procedure described below:
1 Closing,
without
2 Loosen the mould height adjustment nut to leave sufficient space for the
clamping block,
3 Clamping block in,
4 Reopening with forced stop at point 0B,
5 Fasten the mould height adjustment nut until touching the clamping block,
6 Closing,
7 Clamping block out,
8 Opening.

Tab. 21. Mould height adjustment screw optimisation page parameters

V:\G8\Vol2\A\A_utilisation_parametres.fm

Function Mould closing


Document: V684_2Aa
page 128 Edition: 16/06/2000
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

5. Function Filling

5.1. Base page Filling


REMARK: The base page Filling is a page configured by selecting the type of injections
which can be:
either direct injection,
or injection-transfer.
see illustration Fig. 50., page 129

5.1.1. Associated graphic page


see section 6. Graphic page Injection (Time), page 293
V:\G8\Vol2\A\A_utilisation_parametres.fm

Fig. 50. Base page Filling with direct injection

Function Filling
Document: V684_2Aa
Edition: 16/06/2000 page 129
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

5.1.2. Main sub-functions

Base sub-functions Associated parameters

62
Heating of the injection chamber
(page 131)

1st speed level during the dynamic injection phase 21 30 35


(page 97) (page 133) (page 132) (page 133)

with injection-transfer : 1st transfer stage 05 0D 1D 4D


(page 99) (page 132) (page 132) (page 133) (page 134)

with direct injection : 1st pressure holding stage of the static


35 41 51
injection phase
(page 133) (page 133) (page 131)
(page 98)

35 43 51
Transfer holding pressure (with injection-transfer)
(page 133) (page 134) (page 131)

47
Average injection pressure (with direct injection)
(page 134)

4F
Average transfer pressure ( (with injection-transfer))
(page 135)

Tab. 22.Sub-functions available on the base page Filling

V:\G8\Vol2\A\A_utilisation_parametres.fm

Fig. 51. Base page Filling with injection-transfer

Function Filling
Document: V684_2Aa
page 130 Edition: 16/06/2000
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

5.1.3. Parameters

Injection Default
N Description
type value

Times

51  Duration of the 1st injection holding pressure


Parameter 51 is a delay-time used with direct injection, and it is
Direct injection

expressed launched at the end of the dynamic injection phase when reaching
in minutes the point 35.
and seconds It defines the application time of pressure 41 during the first stage without
of the static injection phase.
When elapsed, the time-delay 51 controls the initiation of the time-
delay 52, if set, otherwise it controls the initiation of the time-de-
lays 50, 56, 58 and 5A.

 Duration of the clamping pressure holding time


Injection-transfer

Parameter 51 is a delay-time used with injection-transfer, where it


is launched after the transfer at the transition to point 05.
It defines the application time of pressure 43 during pressure without
holding.
When elapsed, the time-delay 51 controls the initiation of the time-
delays 50, 56, 58 and 5A.

Temperatures

62  Injection chamber temperature


Parameter 62 defines the temperature of the injection chamber.
expressed
REMARK: The control of the heating area 62 takes place in a
in Celsius
closed loop; the temperature is measured by the
thermocouple B3, and when the set value is ex-
ceeded, there is no cooling. The only possible without
cooling for the injection chamber circuit is the
safety cooling controlled by the delay-time 57 or
by the manual stop of the temperature controller.
Parameter 62 is also present on the base page Compound prepa-
V:\G8\Vol2\A\A_utilisation_parametres.fm

ration (refer to section 3.1., page 105)

Tab. 23.Parameters of the base page Filling

Function Filling
Document: V684_2Aa
Edition: 16/06/2000 page 131
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

Injection Default
N Description
type value

Strokes


Injection-transfer

05 Mould safety
Parameter 05 is a point on the closing unit axis defining the end of
expressed the transfer stages begun at point 0D. without
in 0.1 mm
Parameter 05 is also used for the base function Mould closing
(refer to section 4.1., page 121).

0D  Mould opening during injection-transfer


Parameter 0D is a point on the closing unit axis defining the accu-
expressed rate mould opening stroke at the end of the slight clamping re-
in 0.1 mm leasing the injection,
Parameter 0D is also the starting point of the first transfer stage ex-
Injection-transfer

ecuted at speed 1D and pressure 4D,


REMARK: The value 0D must always be above the value 05.
without

WARNING: The value 0D must be 3 mm below the clear-


ance under the clamping block, to ensure an
oil cushion under the clamping piston pre-
venting mechanical locking in the event of an
incident, such as double injection.

30  Shot size setting stroke


Parameter 30 is a point on the injection piston axis defining:
expressed
the end of the shot size setting stroke executed at the rotation
in 0.1 mm speed 20
without
the beginning of the first stage of the dynamic injection phase
executed at the injection speed 21.
Parameter 30 is also present on the base pages Compound prep-
aration (refer to section 3.1., page 105) and Injection profile (re-
V:\G8\Vol2\A\A_utilisation_parametres.fm

fer to section 5.2., page 136).

Tab. 23.Parameters of the base page Filling(cont.)

Function Filling
Document: V684_2Aa
page 132 Edition: 16/06/2000
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

Injection Default
N Description
type value

35  Transition to holding pressure


Direct injection

Parameter 35 is a point on the injection piston axis defining:


expressed the end of the last stage of the dynamic injection phase executed without
in 0.1 mm
at one of the injection speeds 21 to 25,
the transition to the static injection phase with the initiation of
delay-time 51.

 Transition to the transfer phase


Injection-transfer

Parameter 35 is a point on the injection piston defining:


the end of the last stage of the dynamic injection phase executed without
at one of the injection speeds 21 to 25,
the transition to the first transfer stage by applying pressure 4D
and speed 1D.

Speeds

1D  Transfer speed during the first stage


Injection-transfer

Parameter 1D defines the transfer speed applied:


expressed either to the stroke delimited by the points 0D and 05,
in% without
or only to the stroke delimited by the points 0D and 0E when the
optimisation function 2nd transfer is active.
see section 5.8. Optimisation page 2nd transfer, page 152
Parameter 1D is associated with pressure 4D.


Injection-transfer

21 Injection speed during the first stage


Direct injection

Parameter 21 defines the injection piston speed during the first


expressed stage of the dynamic injection phase for the stroke starting at without
in 0.1 mm/s point 3C, if set, or otherwise at point 30 and delimited by the point
31, if set, or otherwise by point 35.

Pressures
V:\G8\Vol2\A\A_utilisation_parametres.fm

41  1st holding pressure after injection


Direct injection

Parameter 41 only used with direct injection, defines the pressure


expressed applied to the injection piston during the first stage of the static in-
in bars without
jection phase, i.e. during the time 51.
REMARK: The speed, during the pressure stage, is only lim-
ited by the maximum pump displacement value.

Tab. 23.Parameters of the base page Filling(cont.)

Function Filling
Document: V684_2Aa
Edition: 16/06/2000 page 133
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

Injection Default
N Description
type value

43 Injection-transfer  Holding pressure after transfer


Parameter 43 used with injection-transfer defines the holding
expressed pressure applied to the mould after the transfer(s) at the transition
in bars without
to point 05.
Parameter 43 can also be used with direct injection.
refer to section 4.1. Base page Mould closing, page 121.

47  Average injection pressure


REMARK: Parameter 47 is not an active parameter of the
expressed machine, as there is no resulting effect on the ma-
in bars chine; however it can be used by the peripheral
software programs Curetrac and RepNet-win.
Direct injection

Parameter 47 defines the average pressure value during the injec-


tion, i.e. as long as the injection piston is moving. without

This value is used by the software Curetrac to assess the viscosity
of the compound during every injection by calculating how much
energy is needed for its injection.

This value can be used by the RepNet-win software to monitor


this viscosity and to check that every injection is progressing sat-
isfactorily.

4D  Transfer pressure during the first stage


Injection-transfer

Parameter 4D defines the transfer pressure applied:


expressed
in bars either to the stroke delimited by the points 0D and 05,
without
or only to the stroke delimited by the points 0D and 0E when the
optimisation function 2nd transfer is active.
refer to section 5.8. Optimisation page 2nd transfer, page 152.
Parameter 4D is associated with speed 1D.

Tab. 23.Parameters of the base page Filling(cont.)


V:\G8\Vol2\A\A_utilisation_parametres.fm

Function Filling
Document: V684_2Aa
page 134 Edition: 16/06/2000
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

Injection Default
N Description
type value

4F  Average transfer pressure


expressed
REMARK: Parameter 4F is not an active parameter of the
in bars
machine, as there is no resulting effect on the ma-
chine; however it can be used by the peripheral
software programs Curetrac and RepNet-win.
Injection-transfer

Parameter 4F defines the average value of the closing pressure


during the transfer phase, i.e. on the stroke delimited by the
points 0D and 05. without

This value is used by the Curetrac software to assess the viscosity


of the compound during every transfer by calculating how much
energy is needed for its transfer.

This value can be used by the RepNet-win software to monitor


this viscosity and to check that every transfer is progressing satis-
factorily.

Tab. 23.Parameters of the base page Filling(cont.)


V:\G8\Vol2\A\A_utilisation_parametres.fm

Function Filling
Document: V684_2Aa
Edition: 16/06/2000 page 135
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

5.2. Optimisation page Injection profile


The optimisation page Injection profile is always accessible.
see illustration Fig. 52., page 137

5.2.1. Associated graphic page


see section 7. Graphic page Injection (Stroke), page 295

V:\G8\Vol2\A\A_utilisation_parametres.fm

Function Filling
Document: V684_2Aa
page 136 Edition: 16/06/2000
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

5.2.2. Optimisation sub-functions

Optimisation sub-functions Associated parameters

Proportioning 30
(page 94) (page 138)

2nd speed level during the dynamic injection phase 22 31


(page 97) (page 139) (page 138)

23 32
3rd speed level during the dynamic injection phase
(page 140) (page 138)
35
(page 139)
24 33
4th speed level during the dynamic injection phase
(page 140) (page 139)

25 34
5th speed level during the dynamic injection phase
(page 140) (page 139)

Injection pressure limitation 48


(page 97) (page 140)

2nd pressure holding stage of the static injection phase 42 52


(page 98) (page 140) (page 138)

Tab. 24.Sub-functions available on the optimisation page Injection profile


V:\G8\Vol2\A\A_utilisation_parametres.fm

Fig. 52. Optimisation page Injection profile

Function Filling
Document: V684_2Aa
Edition: 16/06/2000 page 137
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

5.2.3. Parameters

Injection Default
N Description
type value

Times


Direct injection

52 Duration of the 2nd injection pressure holding time


Parameter 52 is a delay-time used with direct injection, initiated
expressed when 51 has elapsed; it determines the application time of pres- without
in minutes sure 42 during the second stage of the static injection phase.
and seconds

Strokes

30  Shot size setting stroke


Parameter 30 is a point on the injection piston axis defining:
expressed
the end of the shot size setting stroke executed at the rotation
in 0.1 mm
speed 20
without
the beginning of the first stage of the dynamic injection phase
executed at the injection speed 21.
Parameter 30 also features on the base page Compound prepa-
ration (refer to section 3.1., page 105) and on the base page Fill-
ing (refer to section 5.1., page 129).

31  Beginning of the 2nd stage of the dynamic injection phase


Parameter 31 is a point on the injection piston axis defining:
expressed
the end of the first stage of the dynamic injection phase executed without
in 0.1 mm
at the injection speed 21.
the beginning of the second stage of the dynamic injection phase
executed at the injection speed 22.

32  Beginning of the 3rd stage of the dynamic injection phase


Parameter 32 is a point on the injection piston axis defining:
expressed
the end of the second stage of the dynamic injection phase exe- without
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in 0.1 mm
cuted at the injection speed 22.
the beginning of the third stage of the dynamic injection phase
executed at the injection speed 23.

Tab. 25.Injection profile optimisation page parameters

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Document: V684_2Aa
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Technical Manual V68 Y4000
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Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

Injection Default
N Description
type value

33  Beginning of the 4th stage of the dynamic injection phase


Parameter 33 is a point on the injection piston axis defining:
expressed the end of the third stage of the dynamic injection phase execut- without
in 0.1 mm
ed at the injection speed 23.
the beginning of the fourth stage of the dynamic injection phase
executed at the injection speed 24.

34  Beginning of the 5th stage of the dynamic injection phase


Parameter 34 is a point on the injection piston axis defining:
expressed
the end of the fourth stage of the dynamic injection phase exe- without
in 0.1 mm
cuted at the injection speed 24.
the beginning of the 5th stage of the dynamic injection phase ex-
ecuted at the injection speed 25.

35  Transition to holding pressure


Parameter 35 is a point on the injection piston axis defining:
Direct injection

expressed
the end of the last stage of the dynamic injection phase executed without
in 0.1 mm at one of the injection speeds 21 to 25,
the transition to the static injection phase with the initiation of
delay-time 51.

The same parameter 35 also features on the base page Filling (re-
fer to section 5.1., page 129).
Injection-transfer

 Transition to the transfer phase


Parameter 35 is a point on the injection piston defining:
the end of the last stage of the dynamic injection phase executed without
at one of the injection speeds 21 to 25,
the transition to the first transfer stage by applying pressure 4D
and speed 1D.

Speeds
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22  Injection speed during the 2nd stage


Parameter 22 defines the speed of the injection piston during the
expressed second stage of the dynamic injection phase for the stroke starting without
in 0.1 mm/s at point 31 and delimited by point 32, if set, or otherwise delimited
by point 35.

Tab. 25.Injection profile(cont.) optimisation page parameters

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Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

Injection Default
N Description
type value

23  Injection speed during the 3rd stage


Parameter 23 defines the speed of the injection piston during the
expressed second stage of the dynamic injection phase for the stroke starting without
in 0.1 mm/s at point 32 and delimited by point 33, if set, or otherwise delimited
by point 35.

24  Injection speed during the 4th stage


Parameter 24 defines the speed of the injection piston during the
expressed fourth stage of the dynamic injection phase for the stroke starting without
in 0.1 mm/s at point 33 and delimited by point 34, if set, or otherwise delimited
by point 35.

25  Injection speed during the 5th stage


Parameter 25 defines the speed of the injection piston during the without
expressed fifth stage of the dynamic injection phase for the stroke starting at
in 0.1 mm/s point 34 and delimited by point 35.

Pressures

42  2nd holding pressure after injection


Direct injection

Parameter 42 only used with direct injection, defines the pressure


expressed applied to the injection piston during the second stage of the static
in bars without
injection phase, i.e. during the time 52.
REMARK: The speed, during the pressure stage, is only lim-
ited by the maximum pump displacement value.


Direct injection

48 Injection pressure limitation


Parameter 48 defines the maximum pressure value possible to use
expressed during the dynamic injection phase, i.e. from the beginning of the 250 bar
in bars injection to point 35.

Tab. 25.Injection profile(cont.) optimisation page parameters


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5.3. Optimisation page Degassing


The optimisation page Degassing is always accessible.

Function Filling
Document: V684_2Aa
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Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

see illustration Fig. 53., page 141

5.3.1. Optimisation sub-functions

Optimisation sub-functions Associated parameters

1st volumetric degassing 36


(page 97) (page 143)

2nd volumetric degassing 37


(page 97) 0A 1A 54 (page 143)

1st delayed degassing (page 143) (page 143) (page 142) 53


(page 100) (page 142)

2nd delayed degassing 55


(page 100) (page 142)

Tab. 26.Sub-functions available on the optimisation page Degassing


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Fig. 53. Optimisation page Degassing

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Edition: 16/06/2000 page 141
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

5.3.2. Parameters

Default
N Description
value

Times

53  Postponement of the first time-delayed degassing


Parameter 53 is a delay-time initiated at the end of the dynamic injection phase
expressed when reaching point 35 and determining the postponement of the first de-
in minutes layed degassing relative to the end of the dynamic injection phase.
and seconds
When elapsed, the delay-time 53 controls the release of the first delayed degas-
sing according to the procedure listed below: without

1 pressure relief on the clamping cylinder,


2 opening on the stroke delimited by point 0A,
3 initiation of the degassing time-delay 54,
4 clamping at the end of time-delay 54.

54  Opening time during degassing


Parameter 54 is a delay-time initiated during degassing when starting the
expressed opening at point 0A and defining:
in 0.1 s without
the mould opening time during degassing and before its clamping,
the initiation of time-delay 55 of the second time-delayed degassing.
When elapsed, time-delay 54 controls the mould clamping.

55  Postponement of the 2nd delayed degassing


Parameter 55 is a delay-time initiated at the end of the opening time 54 during
expressed the first delayed degassing, determining the postponement of the second de-
in minutes layed degassing versus the first.
and seconds
When elapsed, the delay-time 55 controls the release of the second delayed de-
gassing according to the procedure listed below: without

1 pressure relief on the clamping cylinder,


2 opening on the stroke delimited by point 0A,
3 initiation of the degassing time-delay 54,
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4 clamping at the end of time-delay 54.

Tab. 27.Degassing optimisation page parameters

Function Filling
Document: V684_2Aa
page 142 Edition: 16/06/2000
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

Default
N Description
value

Strokes

0A  Opening stroke during degassing


Parameter 0A is a point on the closing unit axis defining the end of the mould without
expressed opening stroke during degassing.
in 0.1 mm

36  Initiation of the 1st volumetric degassing


Parameter 36 defines, on the injection piston axis, the release point of the first
expressed volumetric degassing which takes place according to the following proce-
in 0.1 mm dure:
1 injection stop, without
2 pressure relief on the clamping cylinder,
3 opening on the stroke delimited by point 0A,
4 initiation of the degassing time-delay 54,
5 clamping at the end of time-delay 54.

37  Initiation of the 2nd volumetric degassing


Parameter 37 defines, on the injection piston axis, the release point of the sec-
expressed ond volumetric degassing which takes place according to the following pro-
in 0.1 mm cedure:
1 injection stop, without
2 pressure relief on the clamping cylinder,
3 opening on the stroke delimited by point 0A,
4 initiation of the degassing time-delay 54,
5 clamping at the end of time-delay 54.

Speeds

1A  Opening speed during degassing


Set value
Parameter 1A defines the mould opening speed during degassing on the
V:\G8\Vol2\A\A_utilisation_parametres.fm

of parame-
expressed stroke delimited by point 0A. ter 10
in mm/s

Tab. 27.Degassing(cont.) optimisation page parameters

Function Filling
Document: V684_2Aa
Edition: 16/06/2000 page 143
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

5.4. Optimisation page Cold runner block


REMARK: The optimisation page Cold runner block is only accessible when the ma-
chine is configured with the option OP155: Pre-arrangement for Cold Runner
Block,
see illustration Fig. 54., page 144.

5.4.1. Optimisation sub-function

Associated param-
Optimisation sub-function
eters

63 64
Injection with cold runner block
(page 145) (page 145)

Tab. 28.Sub-function available on the optimisation page Cold runner block

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Fig. 54. Optimisation page Cold runner block

Function Filling
Document: V684_2Aa
page 144 Edition: 16/06/2000
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

5.4.2. Parameters

Default
N Description
value

Temperatures

63  Nozzle(s)
Parameter 63 defines the thermal oil temperature of the control circuit of the
expressed secondary nozzles of a Cold Runner Block (C.R.B.).
in Celsius
REMARK: The control of the heating area 63 takes place in a closed
loop; the temperature measurement is done by the thermo-
without
couple B4.
The throttling work of the compound during the injection rap-
idly leads to a temperature increase of the secondary noz-
zles. Consequently, the secondary nozzle circuit is cooled
down immediately whenever an excessive temperature value
of the 63 set value is detected.

64  Cold runner block


Parameter 64 defines the thermal oil temperature of the C.R.B. body control
expressed circuit, provided this option is available on the machine.
in Celsius
REMARK: The temperature control of the heating area 64 takes place in
a closed loop; the temperature measurement is done by the
thermocouple B9. without
Whenever an excessive temperature value versus set value
64 is detected, the block is cooled down immediately.
Safety cooling controlled by delay-time 57 or by the manual
stop of the circulator (simultaneous with the manual stop of
the injection unit controller) is also possible on the cold runner
block circuit.

Tab. 29.Cold runner block optimisation page parameters


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Function Filling
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Edition: 16/06/2000 page 145
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

5.5. Optimisation Page Beardown after injection


The optimisation page Beardown after injection is always accessible.
see illustration Fig. 55., page 146

5.5.1. Optimisation sub-function

Associated
Optimisation sub-function
parameters

Beardown holding after injection 5A


(page 100) (page 147)

Tab. 30.Sub-function available on the optimisation page Beardown after injection

V:\G8\Vol2\A\A_utilisation_parametres.fm

Fig. 55. Optimisation page Beardown after injection

Function Filling
Document: V684_2Aa
page 146 Edition: 16/06/2000
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

5.5.2. Parameters

Default
N Description
value

Times

5A  Injection unit beardown after injection


Parameter 5A is a delay-time initiated:
expressed
in minutes during direct injection, at the end of the static injection phase, i.e. once 52 has
and seconds elapsed, if set, otherwise when 51 has elapsed.
without
with injection-transfer, at the end of the transfer pressure holding time, i.e.
when 51 has elapsed.
Delay-time 5A defines the holding time of the injection unit beardown move-
ment after the injection; when elapsed, it controls the stop of the injection unit
beardown movement.

Tab. 31.Beardown after injection optimisation page parameters


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Function Filling
Document: V684_2Aa
Edition: 16/06/2000 page 147
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

5.6. Optimisation page Vacuum


REMARK: The optimisation page Vacuum is only accessible when the machine is con-
figured with the option OP111: Pre-arrangement for vacuum pump.
see illustration Fig. 56., page 148.

5.6.1. Optimisation sub-function

Associated
Optimisation sub-function
parameters

59
Vacuum before injection
(page 149)

Tab. 32.Sub-function available on the optimisation page Vacuum

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Fig. 56. Optimisation page Vacuum

Function Filling
Document: V684_2Aa
page 148 Edition: 16/06/2000
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

5.6.2. Parameters

Default
N Description
value

Times

59  Vacuum prior to injection


Parameter 59 is a time-delay initiated simultaneously with the mould clamp-
expressed ing.
in minutes Delay-time 59 defines the time for which the start of injection is postponed, al-
and seconds lowing the generation of a vacuum inside the clamped mould; when elapsed, without
it controls the injection.
REMARK: Vacuum may be used in two different modes.
see section 3.7.3. Optimisation functions Vacuum pump,
page 266

Tab. 33.Vacuum optimisation page parameters


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Function Filling
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Edition: 16/06/2000 page 149
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

5.7. Optimisation page Automatic injection unit lift


The optimisation page Automatic injection unit lift is always accessible.
see illustration Fig. 57., page 150

5.7.1. Optimisation sub-function

Associated
Optimisation sub-function
parameters

Automatic lift after injection 58


(page 100) (page 151)

Tab. 34.Sub-function available on the optimisation page Automatic injection unit lift

V:\G8\Vol2\A\A_utilisation_parametres.fm

Fig. 57. Optimisation page Automatic injection unit lift

Function Filling
Document: V684_2Aa
page 150 Edition: 16/06/2000
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

5.7.2. Parameters

Default
N Description
value

Times

58  Automatic injection unit lift after the injection


Parameter 58 is a delay-time initiated:
expressed
in minutes during direct injection, at the end of the static injection phase, i.e. once 52 has
and seconds elapsed, if set, otherwise when 51 has elapsed.
without
with injection-transfer, at the end of the pressure holding time, i.e. when 51
has elapsed.
Delay-time 58 defines the postponement of the injection unit lift movement af-
ter the end of the last injection; when elapsed, it controls the injection unit lift
movement.

Tab. 35.Automatic injection unit lift optimisation page parameters


V:\G8\Vol2\A\A_utilisation_parametres.fm

Function Filling
Document: V684_2Aa
Edition: 16/06/2000 page 151
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

5.8. Optimisation page 2nd transfer


REMARK: The optimisation page 2nd transfer is a page only accessible when the injec-
tion type chosen is injection-transfer.
see illustration Fig. 58., page 152

5.8.1. Optimisation sub-function

Optimisation sub-function Associated parameters

with injection-transfer: 2nd transfer stage 0E 1E 4E


(page 99) (page 153) (page 153) (page 153)

Tab. 36.Sub-function available on the optimisation page 2nd transfer

V:\G8\Vol2\A\A_utilisation_parametres.fm

Fig. 58. Optimisation page 2nd transfer

Function Filling
Document: V684_2Aa
page 152 Edition: 16/06/2000
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

5.8.2. Parameters

Injection Default
N Description
type value

Strokes


Injection-transfer

0E Stroke of the 2nd transfer stage


Parameter 0E is a point on the closing unit axis defining:
expressed the end of the first transfer stage which started at the point 0D, without
in 0.1 mm
the beginning of the second transfer stage executed at speed 1E
and pressure 4E and finishing once point 05 has been reached.

Speeds


Injection-transfer

1E Transfer speed during the second stage


Parameter 1E defines the transfer speed for the stroke delimited by
expressed points 0E and 05. without
in% Parameter 1E is associated with pressure 4E.

Pressures


Injection-transfer

4E Transfer pressure during the 2nd stage


Parameter 4E defines the transfer pressure for the stroke delimited
expressed by the points 0E and 05. without
in bars Parameter 4E is associated with speed 1E.

Tab. 37.2nd transfer optimisation page parameters


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Function Filling
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Edition: 16/06/2000 page 153
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

5.9. Optimisation page Compound pressure


REMARK: The optimisation page Compound pressure is a page only accessible when
the injection type chosen is direct injection and when the machine is configured
with the special option OPV073: Compound pressure,
see illustration Fig. 59., page 154.

5.9.1. Optimisation sub-function

Associated
Optimisation sub-function
parameters

45
Compound pressure check inside the mould
(page 155)

Tab. 38.Sub-function available on the optimisation page Compound pressure

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Fig. 59. Optimisation page Compound pressure

Function Filling
Document: V684_2Aa
page 154 Edition: 16/06/2000
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

5.9.2. Parameters

Injection Default
N Description
type value

Pressures


Direct injection

45 Compound pressure inside the mould


Parameter 45 defines the compound pressure measured inside the
expressed mould. without
in bars

Tab. 39.Compound pressure optimisation page parameters


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Function Filling
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Edition: 16/06/2000 page 155
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

6. Function Curing

6.1. Base page Curing


see illustration Fig. 60., page 156

6.1.1. Associated graphic page


see section 8. Graphic page Mould temperatures, page 296

6.1.2. Main sub-functions

Associated
Base sub-functions
parameters

Curing time 56
(page 100) (page 157)

65
Heating of the fixed traverse platen
(page 157)

67
Heating of the movable traverse platen
(page 157)

Tab. 40.Sub-functions available on the base page Curing

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Fig. 60. Base page Curing

Function Curing
Document: V684_2Aa
page 156 Edition: 16/06/2000
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

6.1.3. Parameters

Default
N Description
value

Times

56  Curing time
Parameter 56 is a delay-time initiated at the end of the static injection phase,
expressed i.e. once 52 has elapsed, if set, otherwise when 51 has elapsed.
in minutes without
Delay-time 56 defines the curing time of the last parts moulded; when elapsed,
and seconds
it controls the mould unclamping and opening.
REMARK: The rubber holding time inside the mould is equal to 51 + 52
+ 56.

Temperatures

65  Temperature of the heating platen of the fixed traverse


Parameter 65 defines the temperature of the mould part which is mounted on
expressed the heating platen of the fixed traverse.
without
in C
REMARK: The temperature control of the heating area 65 takes place in
a closed loop; the temperature measurement is done by the
thermocouple B6.

67  Temperature of the heating platen of the movable traverse


Parameter 67 defines the temperature of the mould part which is mounted on
expressed the movable traverse heating platen.
without
in C
REMARK: The temperature control of the heating area 67 takes place in
a closed loop; the temperature measurement is done by the
thermocouple B7.

Tab. 41.Parameters of the base page Curing


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Function Curing
Document: V684_2Aa
Edition: 16/06/2000 page 157
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

6.2. Optimisation page Curetrac Corrections


see illustration Fig. 61., page 158.

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Fig. 61. Optimisation page Curetrac Corrections

Function Curing
Document: V684_2Aa
page 158 Edition: 16/06/2000
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

6.3. Optimisation page Curetrac communication


see illustration Fig. 62., page 159.
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Fig. 62. Optimisation page Curetrac communication

Function Curing
Document: V684_2Aa
Edition: 16/06/2000 page 159
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

6.4. Optimisation page Network Link


see illustration Fig. 63., page 160.

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Fig. 63. Optimisation page Network Link

Function Curing
Document: V684_2Aa
page 160 Edition: 16/06/2000
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

6.5. Optimisation page Ancillary areas


REMARK: The optimisation page Ancillary areas is only made accessible when the ma-
chine is configured with one of the following options:
OP115: Heater ancillary area No 1,
OP116: Heater ancillary area No 2,
OPV117: OP117: Heating ancillary area N3,
see illustration Fig. 64., page 161.

6.5.1. Optimisation sub-functions

Associated
Optimisation sub-functions
parameters

66
Heating ancillary area No 1
(page 162)

68
Heating ancillary area No 2
(page 162)

69
Heating ancillary area No 3
(page 162)

Tab. 42.Sub-functions available on the base page Ancillary areas


V:\G8\Vol2\A\A_utilisation_parametres.fm

Fig. 64. >Optimisation page Ancillary areas

Function Curing
Document: V684_2Aa
Edition: 16/06/2000 page 161
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

6.5.2. Parameters

Default
N Description
value

Temperatures

66  Temperature of the ancillary area No 1


Parameter 66 defines the temperature of the mould part heated by the ancil-
expressed lary area N1.
without
in C
REMARK: The temperature control of the heating area 66 takes place in
a closed loop; the temperature measurement is done by the
thermocouple B8.

68  Temperature of the ancillary area No 2


Parameter 68 defines the temperature of the mould part heated by the ancil-
expressed lary area N2.
without
in C
REMARK: The temperature control of the heating area 68 takes place in
a closed loop; the temperature measurement is done by the
thermocouple B10.

69  Temperature of the ancillary area No 3


Parameter 69 defines the temperature of the mould part heated by the ancil-
expressed lary area N3. without
in C
REMARK: The control of the heating area 69 takes place in a closed
loop; the temperature is measured by the thermocouple B11.

Tab. 43.Ancillary areas optimisation page parameters

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Function Curing
Document: V684_2Aa
page 162 Edition: 16/06/2000
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

7. Function Stripping and loading of inserts

7.1. Base page Stripping and loading of inserts


see illustration Fig. 65., page 163

7.1.1. Main sub-functions

Base sub-functions Associated parameters

Low speed extraction stage 00 10


(page 102) (page 164) (page 164)

High speed opening stage 00 01 11


(page 102) (page 164) (page 164) (page 164)

Low speed ejection stage 01 10


(page 102) (page 164) (page 164)

Tab. 44.Sub-functions available on the base page Stripping and loading of inserts
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Fig. 65. Base page Stripping and loading of inserts

Function Stripping and loading of inserts


Document: V684_2Aa
Edition: 16/06/2000 page 163
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

7.1.2. Parameters

Default
N Description
value

Strokes

00  Beginning of high speed opening


Parameter 00 is a point on the closing unit axis defining:
without
expressed the end of the extraction stroke executed at low speed (10),
in 0.1 mm
the beginning of the opening stroke executed at high speed (11).

01  End of high speed opening


Parameter 01 is a point on the closing unit axis defining:
without
expressed
the end of the opening stroke executed at high speed (11);
in 0.1 mm
the beginning of the low speed ejection stroke (10).

Speeds

10  Low speed opening


Parameter 10 defines:
expressed
in mm/s the opening speed always used in the setting mode,
without
the opening speed used in operating modes other than the setting mode,
outside the stroke delimited by the points 00 and 01,
the opening speed used by the optimisation function Plate approach.
refer to section 7.10. Optimisation page Plate approach, page 180.

11  High speed opening


Parameter 11 defines the opening speed used in operating modes other than
expressed the setting mode on the stroke delimited by the points 00 and 01 outside the without
in mm/s areas defined by the optimisation function Plate approach.
refer to section 7.10. Optimisation page Plate approach, page 180.

Tab. 45.Parameters of the base page Stripping and loading of inserts


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Function Stripping and loading of inserts


Document: V684_2Aa
page 164 Edition: 16/06/2000
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

7.2. Optimisation Movable traverse ejectors


The optimisation page Movable traverse ejectors is specific to one of the 3
optimisation functions relating to the movable traverse ejection and which
can be installed on the machine:
movable traverse hydraulic ejectors
movable traverse hydraulic ejectors (with encoder)
mechanical ejectors.

Press options available on the machine


(refer to section 4.6., page 277).

Optimisation functions OP133 OP139 OPV040

Movable traverse hydraulic ejectors


X
(refer to section 7.3., page 166).

Movable traverse hydraulic ejectors with encoder


X X
(refer to section 7.4., page 168).

Mechanical ejectors
X
(refer to section 7.5., page 170).
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Function Stripping and loading of inserts


Document: V684_2Aa
Edition: 16/06/2000 page 165
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

7.3. Optimisation page Movable traverse ejectors


REMEMBER: The optimisation page Movable traverse ejectors is a page accessible only
when the machine is configured with the option OP139: Side hydraulic ejectors
on the movable traverse.
see illustration Fig. 66., page 166.

7.3.1. Optimisation sub-functions

Associated param-
Optimisation sub-functions
eters

71 81
Ejection on the movable traverse
(page 167) (page 167)

Tab. 46.Sub-functions available on the optimisation page Movable traverse ejectors

V:\G8\Vol2\A\A_utilisation_parametres.fm

Fig. 66. Optimisation pageMovable traverse ejectors

Function Stripping and loading of inserts


Document: V684_2Aa
page 166 Edition: 16/06/2000
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

7.3.2. Parameters

Default
N Description
value

Speeds

71  Speed of the movable traverse ejectors


Parameter 71 defines the speed of the movable traverse hydraulic ejectors without
expressed when not equipped with encoders.
in%

Pressures

81  Pressure of the movable traverse ejectors


Parameter 81 defines the maximum service pressure of the movable traverse without
expressed hydraulic ejectors on their full in-stroke and out-stroke.
in bars

Tab. 47.Movable traverse ejectors optimisation page parameters


V:\G8\Vol2\A\A_utilisation_parametres.fm

Function Stripping and loading of inserts


Document: V684_2Aa
Edition: 16/06/2000 page 167
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

7.4. Optimisation page Movable traverse ejectors with encoder


REMEMBER: The optimisation page Movable traverse ejectors is a page accessible only
when the machine is configured with the options OP139: Side hydraulic ejec-
tors on the movable traverse and OPV040: Encoder on movable traverse ejec-
tors.
see illustration Fig. 67., page 168.

7.4.1. Optimisation sub-functions

Optimisation sub-functions Associated parameters

Out-stroke of the movable traverse


7C 9B 9C DJ
ejectors with encoder
(page 169) (page 169) (page 169) (page 169)
(page 103) 71 81
In-stroke of the movable traverse ejec- (page 169) (page 170)
9A
tors with encoder
(page 169)
(page 103)

Tab. 48.Sub-functions available on the optimisation page Movable traverse ejectors

V:\G8\Vol2\A\A_utilisation_parametres.fm

Fig. 67. Optimisation page Movable traverse ejectors with encoder

Function Stripping and loading of inserts


Document: V684_2Aa
page 168 Edition: 16/06/2000
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

7.4.2. Parameters

Default
N Description
value

Strokes

9A  End of the in-stroke of the movable traverse ejectors


Parameter 9A is a point on the axis of the movable traverse ejectors defining without
expressed the end of their in-stroke executed at speed 71 and pressure 81.
in 0.1 mm

9B  Beginning of the low speed out-stroke of the movable traverse ejectors


Parameter 9B is a point on the axis of the movable traverse ejectors defining without
expressed the end of their out-stroke executed at high speed 71 and pressure 81 and the
in 0.1 mm beginning of their out-stroke executed at low speed 7C and pressure 81.

9C  End of the out-stroke of the movable traverse ejectors


Parameter 9C is a point on the axis of the movable traverse ejectors defining without
expressed the end of their out-stroke executed at low speed 7C and pressure 81.
in 0.1 mm

DJ  tolerance on the out-stroke of the movable traverse ejectors

10
expressed
in 0.1 mm

Speeds

71  Speed of the movable traverse ejectors


Parameter 71 defines the speed of the hydraulic ejectors of the movable without
expressed traverse on their full in-stroke and on their out-stroke delimited by the points
in mm/s 9A and 9B.

7C  Low out-stroke speed of the movable traverse ejectors


Parameter 7C defines the low speed of the out-stroke end of the hydraulic without
expressed
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ejectors of the movable traverse on the stroke delimited by the points 9B et 9C.
in mm/s

Pressures

Tab. 49.Parameters of the optimisation page Movable traverse ejectors with encoder

Function Stripping and loading of inserts


Document: V684_2Aa
Edition: 16/06/2000 page 169
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

Default
N Description
value

81  Pressure of the movable traverse ejectors


Parameter 81 defines the maximum service pressure of the movable traverse without
expressed hydraulic ejectors on their full in-stroke and out-stroke.
in bars

Tab. 49.Parameters of the optimisation page Movable traverse ejectors with encoder(cont.)

7.5. Optimisation page Mechanical ejectors


REMEMBER: The optimisation page is a page accessible only with the machine configu-
ration including the option OP133: Movable traverse mechanical ejectors
see illustration Fig. 68., page 170.

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Fig. 68. Optimisation page Mechanical ejectors

Function Stripping and loading of inserts


Document: V684_2Aa
page 170 Edition: 16/06/2000
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

7.5.1. Optimisation sub-functions

Associated param-
Optimisation sub-functions
eters

Insert lift 02 DG
(page 96) (page 171) (page 171)

Ejection pressure limitation 86


(page 102) (page 171)

Tab. 50.Sub-functions available on the optimisation page Movable traverse ejectors

7.5.2. Parameters

Default
N Description
value

Strokes

02  Insert lift
Parameter 02 is a point on the closing unit axis defining the mould opening at
expressed the end of the cycle. The Insert lift stroke can start after the full opening of
in 0.1 mm the machine and the automatic closing executed at the low closing speed (12) without
up to point 02.
The insert lift position is used to reload the inserts on the insert holder plate
once the latter has been emptied by the mechanical ejectors.

DG  Tolerance on the insert lift stroke

10
expressed
in 0.1 mm

Pressures

86  Ejection pressure limit


Parameter 86 defines the limit value of the pressure used at the low speed without
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expressed opening 10 on the mould opening stroke delimited by the point 01 and the end
in bars of the opening stroke defined in table or by parameter 0F.

Tab. 51.Mechanical ejectors optimisation page parameters

Function Stripping and loading of inserts


Document: V684_2Aa
Edition: 16/06/2000 page 171
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

7.6. Optimisations Fixed traverse ejectors


The optimisation page Fixed traverse ejectors is specific to one of the 2 op-
timisation functions relating to the fixed traverse ejection and which can be
installed on the machine:
fixed traverse hydraulic ejectors
fixed traverse hydraulic ejectors (with encoder)

Press options available on the


machine
(refer to section 4.6., page 277).

Optimisation functions OP141 OPV040

Fixed traverse hydraulic ejectors


X
(refer to section 7.3., page 166).

Fixed traverse hydraulic ejectors with encoder


X X
(refer to section 7.4., page 168).

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Function Stripping and loading of inserts


Document: V684_2Aa
page 172 Edition: 16/06/2000
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

7.7. Optimisation page Fixed traverse ejectors


REMEMBER: The optimisation page Fixed traverse ejectors is a page accessible only
when the machine is configured with the option OP141: Side hydraulic ejectors
of the fixed traverse.
see illustration Fig. 69., page 173.

7.7.1. Optimisation sub-functions

Associated param-
Optimisation sub-functions
eters

72 82
Ejection on the fixed traverse
(page 174) (page 174)

Tab. 52.Sub-functions available on the optimisation page Fixed traverse ejectors


V:\G8\Vol2\A\A_utilisation_parametres.fm

Fig. 69. Optimisation page Fixed traverse ejectors

Function Stripping and loading of inserts


Document: V684_2Aa
Edition: 16/06/2000 page 173
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

7.7.2. Parameters

Default
N Description
value

Speeds

72  Fixed traverse ejector speed


Parameter 72 defines the speed of the fixed traverse hydraulic ejectors when without
expressed not equipped with encoders.
in%

Pressures

82  Pressure of the fixed traverse ejectors


Parameter 82 defines the maximum service pressure of the fixed traverse hy- without
expressed draulic ejectors on their full in-stroke and out-stroke.
in bars

Tab. 53.Fixed traverse ejectors optimisation page parameters

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Function Stripping and loading of inserts


Document: V684_2Aa
page 174 Edition: 16/06/2000
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

7.8. Optimisation page Fixed traverse ejectors with encoder


REMEMBER: The optimisation page Fixed traverse ejectors is a page accessible only
when the machine is configured with the options OP141: Side hydraulic ejec-
tors of the fixed traverse and OPV040: Encoder on movable traverse ejectors.
see illustration Fig. 70., page 175.

7.8.1. Optimisation sub-functions

Optimisation sub-functions Associated parameters

Out-stroke of the fixed traverse ejectors with enco-


72 7F 82 9E 9F
der
(page 174) (page 176) (page 174) (page 176) (page 176)
(page 104)

In-stroke of the fixed traverse ejectors with enco-


9D
der
(page 176)
(page 104)

Tab. 54.Sub-functions available on the optimisation page Fixed traverse ejectors


V:\G8\Vol2\A\A_utilisation_parametres.fm

Fig. 70. Optimisation page Fixed traverse ejectors with encoder

Function Stripping and loading of inserts


Document: V684_2Aa
Edition: 16/06/2000 page 175
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

7.8.2. Parameters

Default
N Description
value

Strokes

9D  End of the in-stroke of the fixed traverse ejectors


Parameter 9D is a point on the axis of the fixed traverse ejectors defining the without
expressed end of their in-stroke executed at speed 72 and pressure 82.
in 0.1 mm

9E  Beginning of the low speed out-stroke of the fixed traverse ejectors


Parameter 9E is a point on the axis of the fixed traverse ejectors defining the without
expressed end of their out-stroke executed at speed 72 and pressure 82, and the begin-
in 0.1 mm ning of their out-stroke executed at low speed 7F and pressure 82.

9F  End of the out-stroke of the fixed traverse ejectors


Parameter 9F is a point on the axis of the fixed traverse ejectors defining the without
expressed end of their out-stroke executed at low speed 7F and pressure 82.
in 0.1 mm

Speeds

72  Fixed traverse ejector speed


Parameter 72 defines the speed of the fixed traverse hydraulic ejectors on their without
expressed full in-stroke and their out-stroke delimited by the points 9D and 9E when the
in mm/s ejectors are equipped with encoders.

7F  Low out-stroke speed of the fixed traverse ejectors


Parameter 7F defines the low speed of the out-stroke end of the hydraulic without
expressed ejectors of the fixed traverse on the stroke delimited by the points 9E et 9F.
in mm/s

Tab. 55.Parameters of the optimisation page Fixed traverse ejectors with encoder
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Function Stripping and loading of inserts


Document: V684_2Aa
page 176 Edition: 16/06/2000
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

Default
N Description
value

Pressures

82  Pressure of the fixed traverse ejectors


Parameter 82 defines the maximum service pressure of the fixed traverse hy- without
expressed draulic ejectors on their full in-stroke and out-stroke.
in bars

Tab. 55.Parameters of the optimisation page Fixed traverse ejectors with encoder(cont.)
V:\G8\Vol2\A\A_utilisation_parametres.fm

Function Stripping and loading of inserts


Document: V684_2Aa
Edition: 16/06/2000 page 177
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

7.9. Optimisation page Stripping kits


NB: The optimisation page Stripping kits is a page accessible only with the ma-
chine configuration including one of the following options:
OP146: Top rear stripping kit
OP147: Bottom front stripping kit
see illustration Fig. 71., page 178

7.9.1. Optimisation sub-functions

Associated param-
Optimisation sub-functions
eters

Single-plate translation 73 83
Double-plate translation (page 179) (page 179)

74 84
Ejection on stripping kit
(page 179) (page 179)

Tab. 56.Sub-functions available on the optimisation page Stripping kits

V:\G8\Vol2\A\A_utilisation_parametres.fm

Fig. 71. Optimisation page Stripping kits

Function Stripping and loading of inserts


Document: V684_2Aa
page 178 Edition: 16/06/2000
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

7.9.2. Parameters

Default
N Description
value

Speeds

73  Plate translation speed


Parameter 73 defines the plate-out speed outside the press and plate-in speed without
expressed inside the press.
in%

74  Kit ejector speed


Parameter 74 defines the in/out speed of the stripping kit ejector. without
expressed
in%

Pressures

83  Plate translation pressure


Parameter 83 defines the maximum service pressure during the plate moving without
expressed outside and inside the press.
in bars

84  Kit ejector pressure


Parameter 84 defines the maximum service pressure during the out-stroke and without
expressed in-stroke of the stripping kit ejector.
in bars

Tab. 57.Stripping kits optimisation page parameters


V:\G8\Vol2\A\A_utilisation_parametres.fm

Function Stripping and loading of inserts


Document: V684_2Aa
Edition: 16/06/2000 page 179
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

7.10. Optimisation page Plate approach


REMARK: The optimisation page Plate approach is a page accessible only when the
machine is configured with one of the following options:
OP133: Mechanical ejectors
OP139: Hydraulic ejectors of the movable traverse.
see illustration Fig. 72., page 180.

7.10.1. Optimisation sub-function

Optimisation sub-function Associated parameters

Low intermediate speed stage 06 07 10 86


(page 102) (page 181) (page 181) (page 181) (page 181)

Tab. 58.Sub-function available on the optimisation page Plate approach

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Fig. 72. Optimisation pagePlate approach

Function Stripping and loading of inserts


Document: V684_2Aa
page 180 Edition: 16/06/2000
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

7.10.2. Parameters

Default
N Description
value

Strokes

06  Beginning of the low intermediate opening speed


Parameter 06 is a point on the closing unit axis defining:
expressed the end of the first opening stroke executed at high speed (11), without
in 0.1 mm
the beginning of the intermediate opening stroke completed at low speed
(10) and safety pressure (86),

07  End of the low intermediate opening speed


Parameter 07 is a point on the closing unit axis defining:
expressed without
the end of the intermediate opening stroke completed at low speed (10) and
in 0.1 mm
safety pressure (86),
the beginning of the second opening stroke executed at high speed (11),

Speeds

10  Low speed openinga


without
expressed Parameter 10 defines the opening speed on the stroke delimited by the points
in mm/s 06 and 07.

Pressures

86  Approach a
Parameter 86 defines the maximum service pressure applied to the closing cyl- without
expressed
inders while opening on the intermediate stroke completed at low speed 10
in bars
delimited by the points 06 and 07.

Tab. 59.Plate approach optimisation page parameters


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a. The parameters 10 and 86 are also used for the base function Stripping and loading of inserts. (refer to section 7.1.,
page 163).

Function Stripping and loading of inserts


Document: V684_2Aa
Edition: 16/06/2000 page 181
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

7.11. Optimisation page Sliding platen


REMARK: The optimisation page Sliding platen is a page accessible only when the ma-
chine is configured with the option OP137: Sliding platen.
see illustration Fig. 73., page 182.

7.11.1. Optimisation sub-function

Optimisation sub-function Associated parameters

15 16 17
Sliding platen
(page 183) (page 183) (page 183)

Tab. 60.Sub-function available on the optimisation page Sliding platen

V:\G8\Vol2\A\A_utilisation_parametres.fm

Fig. 73. Optimisation page Sliding platen

Function Stripping and loading of inserts


Document: V684_2Aa
page 182 Edition: 16/06/2000
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

7.11.2. Parameters

Default
N Description
value

Speeds

15  Sliding platen out speed


Parameter 15 defines the sliding platen moving out speed until having without
expressed reached the microcontact S45 (L.S. sliding platen slow-down).
in%

16  Sliding platen out dampening speed


Parameter 16 defines the sliding platen moving out speed on the stroke delim-
expressed ited by the microcontacts S45 (L.S. sliding platen slow-down) and S55 (L.S. slid-
in% without
ing platen out).
Parameter 16 is used to dampen the stop of the sliding platen by absorbing its
kinetic energy.

17  Sliding platen in speed


Parameter 17 defines the sliding platen in speed until having reached the mi- without
expressed crocontact S54 (L.S. sliding platen in).
in%

Tab. 61.Sliding platen optimisation page parameters


V:\G8\Vol2\A\A_utilisation_parametres.fm

Function Stripping and loading of inserts


Document: V684_2Aa
Edition: 16/06/2000 page 183
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

7.12. Optimisation page Ancillary cylinders


REMARK: The optimisation page Ancillary cylinders is a page accessible only when the
machine is configured with one of the following options:
OPV066: Pre-arrangement for ancillary cylinder No 1,
OPV067: Pre-arrangement for ancillary cylinder No 2.
see illustration Fig. 74., page 184.

7.12.1. Optimisation sub-functions

Associated param-
Optimisation sub-functions
eters

70 80
1st ancillary cylinder
(page 185) (page 185)

75 85
2nd ancillary cylinder
(page 185) (page 185)

Tab. 62.Sub-functions available on the optimisation page Ancillary cylinders

V:\G8\Vol2\A\A_utilisation_parametres.fm

Fig. 74. Optimisation page Ancillary cylinders

Function Stripping and loading of inserts


Document: V684_2Aa
page 184 Edition: 16/06/2000
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

7.12.2. Parameters

Default
N Description
value

Speeds

70  Speed of ancillary cylinder No 1


Parameter 70 defines the speed of the movements of the 1st ancillary cylinder without
expressed system.
in%

75  Speed of ancillary cylinder No 2


Parameter 75 defines the speed of the movements of the 2nd ancillary cylinder without
expressed system.
in%

Pressures

80  Pressure of the ancillary cylinder No 1


Parameter 80 defines the maximum service pressure during the movements of without
expressed the 1st ancillary cylinder system.
in bars

85  Pressure of the ancillary cylinder No 2


Parameter 85 defines the maximum service pressure during the movements of without
expressed the 2nd ancillary cylinder system.
in bars

Tab. 63.Ancillary cylinders optimisation page parameters


V:\G8\Vol2\A\A_utilisation_parametres.fm

Function Stripping and loading of inserts


Document: V684_2Aa
Edition: 16/06/2000 page 185
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

7.13. Optimisation page Limits


The page Limits is always accessible.
see illustration Fig. 75., page 186

7.13.1. Optimisation sub-functions

Associated param-
Optimisation sub-functions
eters

Opening stroke limitation 0F DF


(page 102) (page 187) (page 187)

Extraction pressure limitation 46


(page 102) (page 187)

Tab. 64.Sub-functions available on the optimisation page Limits

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Fig. 75. Optimisation page Limits

Function Stripping and loading of inserts


Document: V684_2Aa
page 186 Edition: 16/06/2000
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

7.13.2. Parameters

Default
N Description
value

Strokes

0F  End of the opening stroke


Parameter 0F is a point on the closing unit axis defining the mould opening, in
expressed turn triggering the end of the cycle.
without
in 0.1 mm
REMARK: The precise stop position can only be obtained when the ma-
chine is equipped with the option OP171: Mould opening
stroke limit.

DF  Opening stroke tolerance

10
expressed
in 0.1 mm

Pressures

46  Extraction pressure limit


Parameter 46 defines the maximum pressure value which may be applied to
expressed the low speed extraction stroke 10 starting at point zero mould closed and
without
in bars delimited by the point 00.
The pressure force 46 controls the part extraction at the beginning of the mould
opening.

Tab. 65.Limits optimisation page parameters


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Function Stripping and loading of inserts


Document: V684_2Aa
Edition: 16/06/2000 page 187
Technical Manual V68 Y4000
Volume 2 - Application
Chapter V - Moulding parameters
RUBBER INJECTION MOULDING

V:\G8\Vol2\A\A_utilisation_parametres.fm

Function Stripping and loading of inserts


Document: V684_2Aa
page 188 Edition: 16/06/2000
Technical Manual V68 Y4000
Volume 2 - Application
Chapter VI - Thermotrac
RUBBER INJECTION MOULDING

Chapter VI - Thermotrac

1. Temperature control and Thermotrac function

1.1. Introduction

1.1.1. Controls and control coefficients


The temperatures of the heating and cooling areas of a G8 type REP press are
controlled by digital controllers integrated into the machine software, using
PIDT control coefficients matching the different areas to control.
REMINDER: P is the coefficient for proportional action.
I is the coefficient for integral action.
D is the coefficient for derived action.
T is the sampling period.

WARNING: There is no direct link between the control coefficients calculated by Thermo-
trac of previous generations (I and II) and those calculated by
Thermotrac III.

1.1.2. Software Thermotrac

The temperature control software Thermotrac III equipping the REP G8


presses consists of 2 parts:
the calculating software executing for each heating area a study to define
the PIDT control coefficients; the software afterwards takes the different pa-
rameters into account to ensure the thermal continuity of the tooling.
the temperature control software using the coefficients to stabilize the tem-
peratures and to ensure a quick and efficient temperature control.
V:\G8\Vol2\A\A_utilisation_Thermotrac.fm

The control software Thermotrac can operate in 3 different modes:


by using coefficients determined by the identification:
This mode is the best for precise control.
by using coefficients entered manually :
In this case, the precision of control will depend on the accuracy of the co-
efficients.
without initial coefficients:
In this case, the precision of control will depend on the time allowed for the
software to determine the most appropriate coefficients for the mould.

Document: V684_2Aa
Edition: 16/06/2000 page 189
Technical Manual V68 Y4000
Volume 2 - Application
Chapter VI - Thermotrac
RUBBER INJECTION MOULDING

1.2. Active Thermotrac pages

1.2.1. Access to the different active pages of Thermotrac

Information relating to the Thermotrac function is distributed over the dif-


ferent active pages of the Thermotrac preset function and the associated op-
timisation functions, accessible through the keyboard keys.
see table Tab. 66., page 190

Access keys

Main pages Optimisation pages

Temperature
Identification
Thermotrac Identification control super-
control
vision
page 191 page 195
page 199
page 198

Tab. 66.Functions, function keys and associated active pages

1.2.2. Colour code of the output states

On the different active pages of the Thermotrac function, the status of the
process control outputs relating to a heating or cooling command is repre-
sented through the following colours:

Keypad background Output status


Heating Cooling Heating Cooling
Heating running, the corresponding
Orange - -
output is controlled
Cooling running, the corresponding
- Green -
output is controlled
Heating stopped, the corresponding Cooling stopped, the corresponding
White
output is not controlled output is not controlled
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Heating impossible: the area has no Cooling impossible: the area has no
Greyish
assigned output assigned output

Document: V684_2Aa
page 190 Edition: 16/06/2000
Technical Manual V68 Y4000
Volume 2 - Application
Chapter VI - Thermotrac
RUBBER INJECTION MOULDING

2. Function Thermotrac

2.1. Base page Thermotrac


The base page Thermotrac controls the heatings of the different machine ar-
eas. The base page screen is divided into 4 different areas:
A - the display line of the ambient temperature and cold junction measured val-
ues,
B - the columns for the recap of the heating and cooling areas characteristics,
C - the columns for the maximum set values (cooling and heating),
D - the columns for the recap of the heating and cooling areas additional charac-
teristics,
refer to illustration Fig. 76., page 191

A a b

c d e g h i j k l n
f

B m D
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Fig. 76. Base page Thermotrac

Function Thermotrac
Document: V684_2Aa
Edition: 16/06/2000 page 191
Technical Manual V68 Y4000
Volume 2 - Application
Chapter VI - Thermotrac
RUBBER INJECTION MOULDING

2.1.1. Ambient temperature and cold junction measured values


a - The window ambient displays the workshop ambient temperature meas-
ured at the rear of the switch cabinet on top of the hydraulic tank.
b - The window switch cabinet displays the cold junction temperature
measured inside the switch cabinet on the Thermocouples card N1.

2.1.2. Characteristics of the heating and cooling areas


REMARK: None of the elements listed below can be modified on the page Thermotrac.
c - The column Channel indicates the order number of the temperature channel
(heating/cooling area).
d - The column Assignment displays the channel denomination.

e - The column indicates the statusa of the heating output associated with
the channel.

f - The column indicates the statusa of the cooling output associated with
the channel.
g - The column Set value displays the temperature set value programmed for
the channel.
h - The column Para. displays the moulding parameter number associated with
the temperature channel.
i - The column Measured value displays the channel temperature measured
value.

2.1.3. Maximum temperatures

j - The column makes it possible to enter the cooling threshold, i.e. the
cooling limitation set value. Cooling lasts as long as the thermocouple indi-
cates a value above the cooling limit value - 3 C.
The default cooling limitation set value is 45C.
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a. The status of the output is defined by the colour of the small window.
refer to section 1.2.2. Colour code of the output states, page 190

Function Thermotrac
Document: V684_2Aa
page 192 Edition: 16/06/2000
Technical Manual V68 Y4000
Volume 2 - Application
Chapter VI - Thermotrac
RUBBER INJECTION MOULDING

refer to illustration Fig. 77., page 193.


k - The column max displays the maximum temperature value during the
heating.

2.1.4. Additional characteristics of the heating and cooling areas


l - The 3 columns Heating and cooling type indicate the heating and cooling
configuration on the channel, which is defined by the REP sequential software:

= heating,

= cooling,

= safety cooling,
m - The column Pid displays the temperature channel identification character-

T (C)

Cooling limit (High limit)


Cooling stop (Low limit)
3C

t (s)

Temperature
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0
t (s)

Status of the cooling output

Fig. 77. Cooling range

Function Thermotrac
Document: V684_2Aa
Edition: 16/06/2000 page 193
Technical Manual V68 Y4000
Volume 2 - Application
Chapter VI - Thermotrac
RUBBER INJECTION MOULDING

istics that may be:

Select
the
Box Output status
check-
box

Greyish - Channel non-identifiable

deselected Channel identifiable, the PID coefficients have not


been defined
White
selected Channel identifiable, the PID coefficients have been
defined

n - The column Stand-by displays the temperature channel stand-by character-


istics that may be:

Select
the
Box Output status
check-
box

Greyish - Stand-by impossible

deselected Stand-by possible, but not actuated


White
selected Stand-by actuated

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Function Thermotrac
Document: V684_2Aa
page 194 Edition: 16/06/2000
Technical Manual V68 Y4000
Volume 2 - Application
Chapter VI - Thermotrac
RUBBER INJECTION MOULDING

2.2. Optimisation page Identification


The optimisation page Identification controls the identification process. Its
screen is divided into 5 different areas:
A - the identification control
B - the reference columns of the different areas,
C - the identification course information frame,
D - the frames of the control coefficients.
refer to illustration Fig. 78., page 195

2.2.1. Identification control


The identification of the temperature channels is actuated when the box
Identification is selected.
REMARK: The identification of a temperature channel is only possible if its heating selec-
tor has been positioned on 1 and its identification set value programmed.

A d

a b c e f g h i j k l m

B D
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Fig. 78. Optimisation page Identification

Function Thermotrac
Document: V684_2Aa
Edition: 16/06/2000 page 195
Technical Manual V68 Y4000
Volume 2 - Application
Chapter VI - Thermotrac
RUBBER INJECTION MOULDING

2.2.2. Referencing columns


a - The column Channel indicates the order number of the temperature channel
(heating/cooling area).
b - The column Assignment displays the channel denomination.
c - The column Para. displays the moulding parameter number associated with
the temperature channel.

2.2.3. Identification course information frame


d - The window Duration displays a timer which starts when the box Identifi-
cation ref. A is selected.
REMARK: The timer only stops when all identification areas have reached the end of the
identification cycle either successfully or unsuccessfully, in which case a de-
fault message is displayed.
e - The column Set value displays the temperature set value programmed for
the channel.
REMARK: There is a single identification set value for the different mould areas. Only the
identification set value for the mould areas can be programmed:

Identification
Injection unit areas Mould areas
set value
Type fixed programmable
Value 100C 220C > set value > 120Ca
a. default value = 120 C

f - The column Phase indicates the identification phase number when the iden-
tification process is running.

g - he column indicates the statusa of the heating output associated with the
channel.

2.2.4. Frames of the control coefficients


 The frame Cooling displays the cooling coefficients of the different channels
with a configuration including a cooling. It consists of the 2 following col-
umns:
h - The column P gives the value of the P coefficient for cooling,
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i - The column T gives the value of the T coefficient for cooling,


REMARK: P and T have default values of respectively 1 and 15.

a. The status of the output is defined by the colour of the small window.
refer to section 1.2.2. Colour code of the output states, page 190

Function Thermotrac
Document: V684_2Aa
page 196 Edition: 16/06/2000
Technical Manual V68 Y4000
Volume 2 - Application
Chapter VI - Thermotrac
RUBBER INJECTION MOULDING

 The frame Heating displays all the heating coefficients relating to the mould ar-
eas.
j - The column P gives the P coefficient value calculated during the last identi-
fication phase,
k - the column I gives the I coefficient value calculated during the last identifi-
cation phase,
l - the column D gives the D coefficient value calculated during the last identi-
fication phase,
m - the column T gives the T coefficient value calculated during the last identi-
fication phase,
REMARK: The coefficients of the heating channels can be modified manually.
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Function Thermotrac
Document: V684_2Aa
Edition: 16/06/2000 page 197
Technical Manual V68 Y4000
Volume 2 - Application
Chapter VI - Thermotrac
RUBBER INJECTION MOULDING

2.3. Optimisation page Temperature control supervision


REMARK: This page is only used for the display of the different data required for the cal-
culations of the temperature control in the different areas of the injection unit
and the mould.
This page is not very interesting for the machine operator. However, it is made
accessible to simplify the dialogue with the REP Technical Assistance Division
in the event of anomalies associated with the thermal control.
refer to illustration Fig. 79., page 198

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Fig. 79. Optimisation page Temperature control supervision

Function Thermotrac
Document: V684_2Aa
page 198 Edition: 16/06/2000
Technical Manual V68 Y4000
Volume 2 - Application
Chapter VI - Thermotrac
RUBBER INJECTION MOULDING

2.4. Optimisation page Identification control

REMARK: This page is only used for the display of the different data required for the cal-
culations during the identification of the injection unit and the mould different
areas.
This page is not very interesting for the machine operator. However, it is made
accessible to simplify the dialogue with the REP Technical Assistance Division
in the event of anomalies associated with the identification carried out by Ther-
motrac.
refer to illustration Fig. 80., page 199
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Fig. 80. Optimisation page Identification control

Function Thermotrac
Document: V684_2Aa
Edition: 16/06/2000 page 199
Technical Manual V68 Y4000
Volume 2 - Application
Chapter VI - Thermotrac
RUBBER INJECTION MOULDING

3. Identification through Thermotrac

3.1. Initiation of the identification process

3.1.1. Identifiable areas


All heating areas of the REP press can be identified, except the extruder and
injection chamber areas, for their correction coefficients have been defined
by the REP Technical Department and cannot be modified.

3.1.2. Starting conditions


Before launching the temperature channel identification phase through Ther-
motrac, make sure that:
the injection unit is in the lifted position (above all when using sensitive
compounds likely to vulcanize during the identification cycle),
the selector switches for the heating up of the areas to identify are posi-
tioned on 1.
REMARK: To initiate the identification of the mould heating areas it is not necessary to
close the mould. However, the coefficients obtained after an identification per-
formed with a mould could prove to be unsuitable once the mould being closed.
If the same mould is used on another press of identical type, the identification
process does not have to be repeated.

3.1.3. How to start the identification cycle

1. Go to the optimisation page Identification by pressing the keys and

successively.

2. Set the keyboard selector S100-S101 to the position .


3. Move the bounding box to one of the windows of column ref. e by using the

keys , , and .
4. Enter a reference value for the mould area identification between 120C and
220C.
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5. Move the bounding box to the checkbox Identification by using the keys

, , and .

6. Select the box by using the key .

7. Exit the position .

Identification through Thermotrac


Document: V684_2Aa
page 200 Edition: 16/06/2000
Technical Manual V68 Y4000
Volume 2 - Application
Chapter VI - Thermotrac
RUBBER INJECTION MOULDING

 The identification process is now launched.


REMARK: The values of the coefficients P, I, D and T cannot be changed during the iden-
tification cycle.Thermotrac.
The identification time depends on the mould inertia. The identification time is
therefore shorter on a smaller mould.
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Identification through Thermotrac


Document: V684_2Aa
Edition: 16/06/2000 page 201
Technical Manual V68 Y4000
Volume 2 - Application
Chapter VI - Thermotrac
RUBBER INJECTION MOULDING

3.2. Identification phases


The identification phases of each one of the heating areas are numbered from
0 to 11.

Phase Time Description


Preliminary phase
During this phase, all heating areas are set to 0 and the PID coef-
ficients are saved. Different tests are completed before starting
the identification cycle:
0 60 s testing of the identification reference values,
testing of the deviation between the set value and the meas-
ured value which should be above or equal to 60C.
During this phase, the machine also defines the sampling period
T.
Measuring phase of the initial temperatures
1 180 s
The initial temperatures of all areas to identify are measured.
Full power heating phase
In case there should be a CRB, if the reference value is below
variable 120C, heating takes place until reaching the value [Reference -
depend- 20C].
2
ing on the
mould As for a mould area, if the reference value is above 120C, heat-
ing takes place until reaching the value [Reference - 30C].
Once this value being reached, the system goes on to Phase 3.
Proportional phase
Heating is controlled according to the deviation between the set
value and the instantaneous measurement.
3 variable
REMARK: Heating is controlled according to the propor-
tional phase principle until the end of the identi-
fication.
4
5 Process analysis phase
variable
6 The heating curve is modelised by different internal calculations.
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Identification through Thermotrac


Document: V684_2Aa
page 202 Edition: 16/06/2000
Technical Manual V68 Y4000
Volume 2 - Application
Chapter VI - Thermotrac
RUBBER INJECTION MOULDING

Phase Time Description


8 variable Calculation phase of the P, I and D coefficients
Memorization phase of the P, I and D phases
9 variable The transfer takes place only if the identification has been suc-
cessful. If it has not, the previous coefficients are preserved.
10 variable Memorization phase of the identification conditions.
Holding phase of the heating
variable The heating of the areas where the identification is finished is
depend- maintained while the other areas are finishing their identifica-
11
ing on the tion process. As soon as all areas have been identified, the iden-
mould tification is de-activated and the control starts according to the
latest coefficients validated.
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Identification through Thermotrac


Document: V684_2Aa
Edition: 16/06/2000 page 203
Technical Manual V68 Y4000
Volume 2 - Application
Chapter VI - Thermotrac
RUBBER INJECTION MOULDING

4. Use of the PIDT coefficients

4.1. Heating-up conditions of a tooling


To heat up a tooling, the heating areas must have been programmed with a
temperature reference and the PIDT control coefficients of all areas must have
been memorized.
REMARK: If the identification has been completed in normal conditions, the coefficients
are memorized automatically.
When starting a production with the PID coefficients being zero, a self-adapt-
ing process replaces the identification; the calculated coefficients are likely to
be inaccurate.
Coefficients matched to a mould ensure the dependable stability of the area
temperature around the reference value. It is therefore possible to adjust the
temperature references of the different areas to their maximum value without
taking the risk of exceeding these values.

4.2. Manual programming of the PIDT coefficients


The machine adjuster can program the values of the PIDT coefficients when
he has no time to run an identification cycle.
The PIDT coefficients can also be changed at any time if the temperature con-
trol is insufficient. In this case it is recommended to try the following correc-
tions:
to correct a hunting effect, act upon the P coefficient by decrementing it
by 1.
for an energy relating correction, act upon the coefficient P in the following
way:
increment P by 1 if the temperature control is below the reference value,
decrement P by 1 if the temperature control is above the reference value.
for a long term correction, act upon the coefficient I:
increment I by 1 if the temperature control is above the reference,
decrement I by 1 if the temperature control is below the reference.
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CAUTION Don't misuse such an advice; better study your manufacturing process. REP
points out that the thermal processes are slow and that it is recommended to
allow the temperature to stabilize during the equivalent of 20T (which means
20 times the time set for the T coefficient of the area) before performing any
modification.

Use of the PIDT coefficients


Document: V684_2Aa
page 204 Edition: 16/06/2000
Technical Manual V68 Y4000
Volume 2 - Application
Chapter VI - Thermotrac
RUBBER INJECTION MOULDING

5. Error messages Thermotrac


Messages Causes Remedy
Temperature: The instantane- The measuring chain on the channel
ous measurement of one does not detect any temperature
channel of the injection unit is
increase.
fixed Check that the associated ther-
REMARK: the fact that there is no
mocouple is not faulty.
Temperature: The instantane- temperature increase is a means of
ous measurement of a mould detection limiting the risks of mate-
channel is fixed rial deterioration and fire.

The measured value is above 150C


Temperature: Excessive
whereas the set value can't exceed Check that the associated ther-
safety measurement on a
150C in an area of the injection mocouple is not faulty.
channel of the injection unit
unit. Check the heater contacts.
Temperature: Excessive The measurement is above 250C Check the condition of the ther-
safety measurement on a whereas the reference value can't mostats of heater plates.
mould channel exceed 250C in a mould area.
Temperature: The instantane-
ous measurement of a chan-
nel of the injection unit is The measurement indicates a tem-
zero. Check that the associated ther-
perature equal to zero whereas this
mocouple is not faulty.
Temperature: The instantane- is not possible.
ous measurement of a mould
channel is equal to zero
Temperature: Relay sticking The relay is not activated but it
alarm on a channel of the remains stuck.
injection unit This is like a permanent heating
Cut the press power supply off.
control, with a risk of deterioration of
Temperature: Relay sticking the heating components, the ther-
alarm on a mould channel mal oil and a risk of fire.
No heating area has been selected
Temperature: No channel before initiating the identification.
Select at least one area.
selected for Thermotrac REMARK: This message is dis-
played only after 60s.
The identification reference is not
Temperature : Thermotrac Change the reference value
compatible with the Thermotrac against a positive value.
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reference zero or below zero


operation.
Temperature: Measurement No remedy; wait until one of the
The area temperature is below or other channels arrives at phase
of the channel below or equal
equal to zero.
to zero 3 and de-activate Thermotrac
Temperature: Deviation Ref- For a dependable operation, the Increase the reference value
erence less Measurement deviation should be above or equal which should remain below
below 60C to 60C. 220C.

Error messages Thermotrac


Document: V684_2Aa
Edition: 16/06/2000 page 205
Technical Manual V68 Y4000
Volume 2 - Application
Chapter VI - Thermotrac
RUBBER INJECTION MOULDING

Messages Causes Remedy


Turn the heating selector switch
Temperature: Heating selec- The heating selector of the area to to 1 or wait until one of the other
tor switch not reset identify is not positioned on 1 channels passes to phase 3 to
de-activate Thermotrac
Check the circuit breakers and
contacts of the heating areas
Temperature: Measurement The thermocouple detects that the
concerned.
below Initial measurement + 3 heating is not quick enough. The
Check that the size of the tool-
after 30 minutes heating at installed heating power is insuffi-
ing is compatible with the heat-
100% cient.
ing power installed on the
machine.
Temperature: Incoherent The thermocouple in charge of the
A value equal to 20C will be
ambient temperature meas- ambient temperature finds an inco-
considered by default.
urement herent value
If possible, reduce the initial
Temperature: Initial tempera- The reference value asked for
temperature, but it would be
ture above the reference shows a value below the initial tem-
easier to change the reference
value perature of the area.
value.
Check the circuit breakers and
contacts of the heating areas
Temperature: Measurement The thermocouple detects that the
concerned.
below Initial measurement + heating is not quick enough. This
Check that the size of the tool-
10 after 1 hour of heating at means that the installed heating
ing is compatible with the heat-
100% power is insufficient.
ing power installed on the
machine.

V:\G8\Vol2\A\A_utilisation_Thermotrac.fm

Error messages Thermotrac


Document: V684_2Aa
page 206 Edition: 16/06/2000
Technical Manual V68 Y4000
Volume 2 - Application
Chapter VII - Mastertrac
RUBBER INJECTION MOULDING

Chapter VII - Mastertrac

1. Introduction
Mastertrac is a software enabling the user to program, store and reproduce
a sequence of movements in addition to the basic kinematics of the machine.
This sequence is generally used for the stripping of moulded parts by control-
ling the movements of the optimisation functions installed on the press in a
precise order depending on the tooling.
The full machine cycle composed of the basic cycle movements associated
with the sequence set by Mastertrac is called the Mastertrac cycle or cycle
31.
REMARK: Cycle 31 is linked to the mould number, i.e. that it is stored with the mould
parameters relating to a specific mould number.
see section 3.6. Optimisation page Cycle selection, page 259

The software Mastertrac includes the 2 following distinct functions:


the learning function during which the operator makes and stores the se-
quence of movements.
the application function of cycle 31.

1.1. Movements compatible with Mastertrac


The movements that can be integrated into the sequence made during the
Mastertrac learning phase are listed below:
Movements relating to the machine guard.
Movements relating to certain machine optimisation functions.
Particular operations outside the machine kinematics.
refer to table Tab. 67., page 208
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The Mastertrac software can be used only, if the optimisation functions re-
lating to the movements to execute have been:
installed on the press before,
refer to section 4.6. Optimisation page Press options, page 277
selected before,
refer to section 2.2.2. Selection of the optimisation functions used in the Master-
trac cycle (cycle 31), page 211

Introduction
Document: V684_2Aa
Edition: 16/06/2000 page 207
Technical Manual V68 Y4000
Volume 2 - Application
Chapter VII - Mastertrac
RUBBER INJECTION MOULDING

Movable traverse ejectors

Fixed traverse ejectors

Ancillary cylinder 1

Ancillary cylinder 1
Description

Bottom front kita


Sliding platen

External PLC
Top rear kita

Brushing

Brushing
option

OPV061

OPV066

OPV067
Phase

OP137

OP139

OP141

OP146

OP147

OP151

OP152
No
Movement
N

01 Guard(s) opening standard movement


02 Sliding platen in x
03 Guard(s) closing standard movement
12 Sliding platen out x
13 Fixed traverse ejectors out x
14 Fixed traverse ejectors in x
15 Movable traverse ejectors out x
16 Movable traverse ejectors in x
Plate out x x
17
Brushing while plate is moving out x x x x
Plate in x x
18
Brushing while plate is moving in x x x x
19 Kit ejector out x x
20 Kit ejector in x x
24 Ancillary cylinder 1 in x
25 Ancillary cylinder 1 out x
26 Ancillary cylinder 2 in x
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27 Ancillary cylinder 2 out x


30 Manual operation operated only by Mastertrac
31 External PLC operation x

Tab. 67.Movements compatible with Mastertrac


a. Mastertrac is only compatible with the single-plate kits.

Introduction
Document: V684_2Aa
page 208 Edition: 16/06/2000
Technical Manual V68 Y4000
Volume 2 - Application
Chapter VII - Mastertrac
RUBBER INJECTION MOULDING

1.2. Controls reserved for the application of Mastertrac

Position
number on
Unit electrical
Function
diagram

Push-button Forward step-by-step learning cycle

S108 When the selected operating mode is Adjustment or Manual, the S108
push-button controls the execution of each step of cycle 31 in ascending nu-
merical order.

Push button Step-by-step learning cycle (reverse)

S107 When the selected operating mode is Adjustment or Manual, the S107
push-button controls the execution of each step of cycle 31 in descending
numerical order.
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Introduction
Document: V684_2Aa
Edition: 16/06/2000 page 209
Technical Manual V68 Y4000
Volume 2 - Application
Chapter VII - Mastertrac
RUBBER INJECTION MOULDING

1.3. Cycle Mastertrac

Special case of Special case of


Phase N Step N Sequence description the safety device the safety device
SEa S1a

03 n +2 Guard closing Guard closingb

- n +3 (n + 3) th movement

Manual and dur-


- n +4 th ing setting :
(n + 4) movement Linking move-
Linking move- ments by pressing
ments by pressing simultaneously
- - S108 or S107. on S108 or S107
In automatic and and S93 (dual-
semi-automatic : handed com-
- - Automatic link- mands)
ing of movements

- m mth movement
< Cycle N31 >

Automatic linking see section 3.6.2.,


04 to 11 Basic cycle
of movements page 260

- 1 1st movement

Manual and dur-


- 2 2nd movement ing setting : Linking move-
Linking move- ments by pressing
ments by pressing simultaneously
- - - S108 or S107. on S108 or S107
In automatic and and S93 (dual-
semi-automatic : handed com-
- - - Automatic link- mands)
ing of movements
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- n nth movement

01 n +1 Guard opening Guard opening

a. see section 3.6.2., page 260


b. The guard opening and closing movements can be included in cycle 31. In this case, they must be programmed by
the function learning mode.

Introduction
Document: V684_2Aa
page 210 Edition: 16/06/2000
Technical Manual V68 Y4000
Volume 2 - Application
Chapter VII - Mastertrac
RUBBER INJECTION MOULDING

2. Function Mastertrac

2.1. Access to the different active pages of Mastertrac


Information relating to the Mastertrac function is distributed over the differ-
ent active pages of the Mastertrac preset function and the associated optimi-
sation functions, accessible through the keyboard keys.
see table Tab. 68., page 211

Access keys 

Main pages Optimisation pages

Learning of
Mastertrac Selections Cycle selection
the sequence
page 212 page 216 page 217
page 214

Tab. 68.Functions, function keys and associated active pages

2.2. Selections associated to Mastertrac

2.2.1. Selection of the Mastertrac cycle (cycle 31)


The user must select the cycle 31 - Mastertrac, to use the machine with the
Mastertrac cycle or to set a new sequence.
refer to section 2.6. Optimisation page Cycle selection, page 217

2.2.2. Selection of the optimisation functions used in the Mastertrac cycle (cycle 31)
Before setting a cycle 31 or using a previously stored cycle 31, the user must
select all machine optimisation functions involved in the cycle 31.
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refer to section 2.5. Optimisation page Selections, page 216.

Function Mastertrac
Document: V684_2Aa
Edition: 16/06/2000 page 211
Technical Manual V68 Y4000
Volume 2 - Application
Chapter VII - Mastertrac
RUBBER INJECTION MOULDING

2.3. Base page Mastertrac


The base page Mastertrac displays the latest movement sequence saved
through the optimisation page Learning of the sequence.
The base page Mastertrac is divided into 3 different areas:
A - the checkbox Movement authorization,
B - the table displaying the beginning of the saved sequence,
C - the table displaying the continuation of the saved sequence.
see illustration Fig. 81., page 212

2.3.1. Movement authorization


The checkbox Movements authorised allows the operator to leave the Mas-
tertrac sequence instantaneously, for example after a mechanical trouble.
REMARK: If no Mastertrac sequence is saved, the button Movements authorised is in-
operative.
If the operator selects the checkbox Movements authorised and the Set-
ting operating mode, he can execute all press movements by using the tradi-
tional push-buttons, and reset the press to the initial position.

a b c a b c

B C
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Fig. 81. Base page Mastertrac

Function Mastertrac
Document: V684_2Aa
page 212 Edition: 16/06/2000
Technical Manual V68 Y4000
Volume 2 - Application
Chapter VII - Mastertrac
RUBBER INJECTION MOULDING

2.3.2. Tables of the saved sequence


The 2 tables are consecutive (the 2nd table is completed only if the Master-
trac sequence includes mores than 14 steps). They show the sequence saved
during the learning phase.
REMARK: The sequence can include up to 28 successive steps or movements; a move-
ment can be repeated several times.
Both tables are composed of the 3 following columns:
a - the column Step No displays the order number of each movement of the saved
sequence.
REMARK: The column Step No looks different according to the selection of cycle 31:
if the step numbers are displayed, the cycle 31 is selected; otherwise another
cycle is selected.
b - the column Mastertrac sequence saved displays the wording of every movement
of the saved sequence.
c - the last column from the right specifies the execution mode of every move-
ment:

the symbol specifies that the corresponding movement has to be exe-


cuted with the 2-hand control, i.e. by pressing the push-button S107 or the
push-button S108 simultaneously with S93.
This is the case with a movement executed with the safety guard being
open.
the empty field means that the corresponding movement is executed either
in the automatic mode either when simply pressing the push-button S107 or
S108.
This is the case with a movement executed with the safety guard being
closed.
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Function Mastertrac
Document: V684_2Aa
Edition: 16/06/2000 page 213
Technical Manual V68 Y4000
Volume 2 - Application
Chapter VII - Mastertrac
RUBBER INJECTION MOULDING

2.4. Optimisation page Learning of the sequence


The optimisation page Learning of the sequence authorises the operator to
make the sequence of movements to be integrated into the Mastertrac cycle
The optimisation page Learning of the sequence is divided into 4 distinct ar-
eas:
A - the checkbox Activation of learning mode,
B - the table displaying the beginning of the stored sequence,
C - the table displaying the continuation of the stored sequence.
D - the frame containing the particular operations possible to integrate into the
Mastertrac cycle.
see illustration Fig. 82., page 214

2.4.1. Activation of the learning mode


The checkbox Enabling the learning mode is used for 2 different purposes:
when being selected, the checkbox allows the selection of the learning
mode, in order to make a sequence of movements.
when the operator de-selects the checkbox after having made a sequence of
movements, a final step Sequence End is made and the sequence stored

d e g
A D
f h

a b c a b c

B C
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Fig. 82. Optimisation pageLearning of the sequence

Function Mastertrac
Document: V684_2Aa
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Technical Manual V68 Y4000
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Chapter VII - Mastertrac
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2.4.2. Tables of the saved sequence


These 2 tables are exactly the same as those dealt with in the section 2.3.2.,
page 213.

2.4.3. Frame of the particular operations


The frame makes it possible to select one of the 5 radio buttons listed below:
d - The 1st radio button validates the latest movement controlled on the machine,
in order to add it to the sequence.
REMARK: The wording specified on the right of the 1st radio button literally indicates the
last movement. The bounding box automatically focuses on the said radio but-
ton once the checkbox Enabling the learning mode is selected; the wording
is then Phase 0.
e - the radio button Manual intervention allows a manual intervention to be inte-
grated to the Mastertrac cycle; this forces the operator to release the controls,
in order to complete an intervention on the tooling.
f - The radio button Deletion of the last movement allows the operator to delete the
last step of the sequence being saved.
g - The radio button External PLC-unit makes it possible to complement the se-
quence with the movements of a stripping PLC which are executed outside the
press, and to resume the stored sequence run after having received the state-
ment specifying the execution of the external movements.
REMARK: The output O 06 (press cycle end signal) controls the micro-relay KA84 send-
ing the signal electrically isolated contact to the external PLC unit.
The relay KAxx of the external PLC unit sends a signal electrically isolated
contact back, that supplies the input I 022 (Automatic cycle start signal).
The integration of this function into the Mastertrac sequence requires the
availability of the option Cycle end signal sending on the press.
h - The radio button Cycle deletion deletes the latest sequence displayed on the
screen, regardless of whether being stored or not. After deletion, the bounding
box goes back to step No 1 in order to save a new cycle.
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Chapter VII - Mastertrac
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2.5. Optimisation page Selections


The optimisation page Selections makes it possible to select the optimisa-
tion functions relating to the movements to be integrated into the Mastertrac
sequence.
see illustration Fig. 83., page 216
The optimisation page Selections displays as many lines as the press com-
prises optimisation functions likely to be integrated into a Mastertrac se-
quence. Such optimisation functions must have been configured on the
machine.
refer to section 4.6. Optimisation page Press options, page 277

REMARK: The selections made on the Selections page of Mastertrac are taken up on
the page Selections of the function Production configuration and vice versa.
This page can be used in the same way as page Selections of the function
Production configuration, especially the hot keys.
refer to section 3.7. Optimisation page Selections, page 265

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Fig. 83. Optimisation pageSelections

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Chapter VII - Mastertrac
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2.6. Optimisation page Cycle selection


The optimisation page Cycle selection is shared by the basic functions
Mastertrac and Production configuration.
It enables the Mastertrac operator to select the cycle 31 reserved for Master-
trac among the different cycles offered in the standard version.
REMARK: Its application is described more detailed in section 3.6. Optimisation page
Cycle selection, page 259.
see also illustration Fig. 84., page 217

Radio button for


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the cycle selection


Mastertrac

Fig. 84. Optimisation pageCycle selection

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3. Application Mastertrac

3.1. Selections prior to the application of Mastertrac

3.1.1. How to select cycle 31

1. Go to the page Cycle selection by successively pressing the keys and

.
2. Select cycle 31 by shifting the bounding box to the corresponding radio button

by means of the keys and .

3. Set the keyboard selector S100-S101 to the position .

4. Confirm the choice by means of the key .

5. Exit the position .

3.1.2. How to select the optimisation functions to integrate into the Mastertrac sequence

1. Go to the page Selections by successively pressing the keys and

.
2. Select the desired function by shifting the white line background by means of

the keys and .

3. Set the keyboard selector S100-S101 to the position .

4. Select the line associated checkbox by means of the key .


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REMARK: It is possible to set the parameters required for the application of the selected
optimisation function by using the hot keys.
refer to section 3.7.4. Shortcuts, page 266

5. Exit the position .

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3.2. Application of the Learning function

3.2.1. How to activate or deactivate the Learning Mode

1. Go to the page Learning of the sequence by pressing the keys and

successively.
2. Move the bounding box to the checkbox Enabling the Learning mode by us-

ing the keys , , and .

3. Set the keyboard selector S100-S101 to the position .


 To disable the Learning mode :

4. De-select the checkbox by using the key .


The step Sequence End is integrated into the sequence.

5. Exit the position .

 To enable the Learning mode :

6. Select the checkbox by using the key .

7. Exit the position .

3.2.2. How to make a Mastertrac sequence


1. Select cycle 31.
refer to section 3.1.1., page 218

2. Select the optimisation functions to integrate into the Mastertrac sequence.


refer to section 3.1.2., page 218
3. Go to the page Learning of the sequence by successively pressing the keys

and .
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4. Enabling the Learning mode


refer to section 3.2.1., page 219

5. Set the keyboard selector S0-S1 to the position .


6. Control the first movement to integrate into the sequence until actuating the
limit switch microcontact.

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 The wording of the executed movement is displayed beside the ref. d radio
button of the illustration Fig. 82., page 214.
7. Confirm the integration of the movement into the sequence by means of the

key .
8. Repeat the operation (points 6. to 7.) for the other movements.
9. Disabling the Learning mode by saving the sequence.
refer to section 3.2.4., page 220

3.2.3. How to integrate a particular operation into a Mastertrac sequence


1. Start making the sequence.
refer to section 3.2.2., page 219

2. Set the keyboard selector S100-S101 to the position .


3. Shift the bounding box to the radio button corresponding to the desired oper-
ation (ref. e or ref. g of the illustration Fig. 82., page 214) by using the keys

, , and .

4. Confirm the choice by means of the key .

5. Exit the position .

3.2.4. How to save the last sequence executed in the learning mode
The latest sequence is saved when the Learning mode is disabled.
refer to points 1. to 4. of section 3.2.1., page 219

3.2.5. How to cancel the last step entered to a Mastertrac sequence


 Sequence making has already started and the last step entered is a mistake.

1. Set the keyboard selector S0-S1 to the position .

2. Control the opposite movement of the movement to delete until actuating the
limit switch microcontact.
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 The wording of the executed movement is displayed beside the ref. d radio
button of the illustration Fig. 82., page 214.

3. Set the keyboard selector S100-S101 to the position .

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Chapter VII - Mastertrac
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 Shift the bounding box to the radio button Deletion (ref. f of the illustration

Fig. 82., page 214.) by using the keys , , and .

4. Confirm the choice by means of the key .


 The step is deleted.

3.2.6. How to delete a Mastertrac sequence


1. Go to the page Learning of the sequence by successively pressing the keys

and .
2. Enabling the Learning mode
refer to section 3.2.1., page 219

3. Set the keyboard selector S100-S101 to the position .


 Shift the bounding box to the radio button Sequence deletion (ref. h of the il-

lustration Fig. 82., page 214.) by using the keys , , and

4. Confirm the choice by means of the key .


 The sequence is deleted.
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Chapter VII - Mastertrac
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3.3. Use of cycle 31

3.3.1. How to test the Mastertrac sequence


1. Select cycle 31.
refer to section 3.1.1., page 218

2. Select the optimisation functions used in the Mastertrac sequence.


refer to section 3.1.2., page 218

3. Go to the page Mastertrac by pressing the key .

4. Set the keyboard selector S0-S1 to the position .


5. Press the push-button S108 by successive impulses. If the guard is open, press
the push button S93 (P.B. dual-handed control) simultaneously.
REMARK: Each time the operator presses S108, the movement is controlled step-by-step
in the ascending order of the step numbers. The movement of the next step
cannot be controlled as long as the microcontact of the current movement limit
switch is not actuated.
6. Press the push-button S107 to return to the previous step. If the guard is open,
press the push button S93 (P.B. dual-handed control) simultaneously.
REMARK: Each time the operator presses S107, the movement is controlled step-by-step
in the descending order of the step numbers. The movement of the previous
step cannot be controlled as long as the microcontact of the current movement
limit switch is not actuated.
7. Go on like this until reaching the sequence end.
REMARK: In case of a trouble, the operator should shift the bounding box to the checkbox

Movements authorised and select the checkbox by means of the key .


He can now take over again the control of the machine and handle the usual
control push-buttons of the control panel, to reset the optimisation functions to
their initial positions

3.3.2. How to work in the Automatic mode with the last Mastertrac sequence
1. Select cycle 31.
refer to section 3.1.1., page 218

2. Select the optimisation functions used in the Mastertrac sequence.


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refer to section 3.1.2., page 218

1. Set the keyboard selector S0-S1 to the position .

2. Press the push-button S108 to start the cycle.

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Chapter VIII - Preset functions
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Chapter VIII - Preset functions

1. Introduction
The preset functions are the 3 following functions:
Maintenance,
Configuration of the production run,
Configuration of the machine
The 3 keyboard keys associated with these 3 functions give access to the main
screen of each function and to the screens of their respective sub-functions.
see illustration Fig. 85., page 223 and table Tab. 69., page 224

Access keys to the preset


functions
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Fig. 85. Operator interface keyboard

Introduction
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page

Introduction

Chapter VIII - Preset functions


224

Access keys

Main pages Optimisation pages

Other in-
Sequential Di- Retrace in- Preventive Setting soft-
Digital inputs puts/outputs Retrace faults
agnostic puts/outputs maintenance ware
page 228 page 230 page 240
Maintenance
page 225 page 233 page 236 page 244
: page 297

Production Production Mould selec- Cycle selec-


Machine time Cycle counter Selections Heating clock
check selection tion tion
page 254 page 257 page 265 page 268
Production page 245 page 250 page 251 page 259

Technical Manual V68 Y4000


configuration

Machine con-

Volume 2 - Application
Language Printer Version System Press options
figuration
page 272 page 274 page 275 page 274 page 277
page 271

Tab. 69.Preset functions and preset function keys


Document:
Edition:

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16/06/2000
V684_2Aa

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2. Function Maintenance
REMARK: The following information will allow the user to learn how to have access and
use the different screen pages dedicated to the maintenance of a machine.
However, you will find thorough maintenance information in volume 3 - Main-
tenance, section Trouble shooting aids.

2.1. Base page Sequential Diagnostic

2.1.1. Presentation and application


The page Sequential Diagnostic makes it possible to collect the information
necessary to understand the trouble occurred during a given cycle (current
cycle) by comparing the latter with the previous cycle.
REMARK: It can be interesting to consult this page before calling the maintenance staff
or the REP Technical Assistance Department.
The active area of the page is divided into 3 different areas:
A - the frame giving information on the progress of the sequential program,
B - the frame comparing the current automatic cycle with the previous cycle,
C - the frame giving information on the differences found in the cycle.
see illustration Fig. 86., page 225

A a b
c

B
d e
f

g i
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h j

Fig. 86. Base page Sequential Diagnostic

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2.1.2. Information on the course of the sequential program


The frame displays 3 text areas indicating:
a - the complete denomination of the actual sequential phase,
b - the actual sub-program,
c - the actual operating mode.

2.1.3. Comparison of cycles


The frame displays the following elements:
d - a green indicator lamp which only lights up when the Automatic operating
mode has been selected.
REMARK: The function Comparison of cycles can only be used when the operating
mode previously selected is the Automatic mode.
e - a red indicator lamp which lights up when the comparison of the latest cycle
(current cycle) with the cycle that has preceded it (previous cycle) shows a dif-
ference in the evolution of the logical status of a sequential variable.
REMARK: the result of the comparison is only given at the end of the current cycle
f - the windows of the texts Previous cycle and Current cycle.
REMARK: When the course of the current cycle is 100% identical to the course of the pre-
vious cycle, the elements of the frame Comparison of cycles remain the
same.

2.1.4. Information on the difference found


When a difference between the course of the previous cycle and the course of
the current cycle is detected, the red indicator lamp lights up and the text ar-
eas at the bottom of the screen give the following information:
g - the name of the variable which has changed from one cycle to the other,
h - its status during the current cycle,
i - the name of the phase during which the variable has changed,
j - the name of the sub-program during which the variable has changed.

2.1.5. How to compare the course of the current cycle with that of the previous cycle

1. Go to the page Sequential Diagnostic by pressing the key .


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2. Turn the operating mode selector key S0-S1 to position . The green indi-
cator lamp ref. d must light up.

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 If the red indicator lamp ref. e does not light up, the course of the current cycle
is identical to the course of the previous cycle.
 If the red indicator lamp ref. e lights up, the course of the current cycle is dif-
ferent from the course of the previous cycle.
In this case, the information concerning the difference detected is displayed by
the following windows:
ref. g : the name of the variable which has changed from one cycle to the oth-
er,
ref. h : its status during the current cycle,
ref. i: the name of the phase during which the variable has changed,
ref. j: the name of the sub-program during which the variable has changed.
REMARK: This information may be passed on to the REP Technical Assistance Depart-
ment for interpretation.
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2.2. Optimisation page Digital inputs


The active area of the optimisation page Digital inputs displays the status
of the system digital inputs in a 17-line table, each line displaying 8 inputs.
The writing format of a digital input is always I xyz where xyz is a number
between 001 and 136.
An input is supplied at 24VDC when the associated green indicator lamp on
the left of the input number is lit. Its logical status is then I xyz = 1.
REMARK: To make searching the electrical diagram easier, the screen gives the page
numbers of the diagram where the input circuits relating to the input numbers
and the name of the connector on which the inputs are installed can be looked
up.
see illustration Fig. 87., page 228

2.2.1. How to read the status of a digital input

1. Go to the page Digital inputs by pressing the keys and suc-


cessively.
2. Note the number of the desired input.

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Fig. 87. Optimisation page Digital inputs

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 If the green indicator lamp to the left of input number is lit, the electrical level
of the input is 24VDC and its logical level is 1.
 If the green indicator lamp to the left of input number is not lit, the electrical
level of the input is 0VDC and its logical level is 0.
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2.3. Optimisation page Other inputs/outputs

2.3.1. Associated graphic page


see section 9. Graphic page Hydraulics, page 297

2.3.2. Presentation and application


The optimisation page Other inputs/outputs makes it possible to read the
following values:
logical status upstream of each digital output,
conversion value of the analogue numerical converter upstream of each an-
alogue output,
value of the first analogue reading on the analogue inputs,
value of counters on the encoder channels
The active zone of the optimisation page Other inputs/outputs is divided
into 4 distinct areas:
A - the digital outputs table,
B - the analogue outputs,
C - the analogue pressure inputs,
D - the counting channels.
see illustration Fig. 88., page 230

B a b c
d d d
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e f g
C
h i i
j k l
D m m m

Fig. 88. Optimisation page Other inputs/outputs

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2.3.3. Digital outputs


The top of the active zone of the page shows the status of the system's digital
outputs grouped in a table of 10 lines with 8 inputs on each.
The writing format of a digital output is always O yz where yz is a number
between 001 and 080.
An output supplies a 24V signalDC when the associated red indicator lamp
left of the output number is lit. Its logical status is then O yz = 1.
REMARK: To make searching the electrical diagram easier, the screen gives the page
numbers of the diagram where the output circuits relating to the output num-
bers and the name of the connector on which the outputs are installed can be
looked up.

2.3.4. Analogue outputs


The lower part of the active zone of the optimisation page Other inputs/out-
puts shows the measurement of 6 analogue output channels of which only 3
are used in a standard configuration:
a - CNA1 = main pressure control analogue output
b - CNA2 = back-pressure control analogue output
c - CNA3 = flow rate control analogue output
d - Non allocated analogue outputs
REMARK: Measurements are displayed in tenths of millivolts (0,1 mV).

2.3.5. Pressure channels


The lower part of the active zone of the optimisation page Other inputs/out-
puts shows the measurement of 6 analogue pressure inputs of which only 4
are used in a standard configuration:
e - B30 = measured value of main pressure
f - B42 = clamping pressure measurement channel
g - B31 = back-pressure measurement channel
h - B43 = mould pressure measurement channel
i - None allocated pressure measurement channels
REMARK: The measured values are displayed in bars.

2.3.6. Encoder channels


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The lower part of the active zone of the optimisation page Other inputs/out-
puts shows the measured value of 6 displacement control channels of which
only 3 are used in a standard configuration:
j - B34-B35 = extruder rotation measurement channel
k - U32 = movable traverse stroke measurement channel
l - U33 = injection piston stroke measurement channel
m - Non allocated displacement control channels
REMARK: Measurements are displayed in tenths of millimetres (0,1 mm).

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2.3.7. How to read the status of a digital output

1. Go to the page Other inputs/outputs by pressing the keys and

successively.

2. Note the number of the desired output.


 If the red indicator lamp to the left of the output number is lit, the electrical lev-
el of the output is 24VDC and its logical level is 1.
 If the green indicator lamp to the left of the output number is not lit, the elec-
trical level of the output is 0VDC and its logical level is 0.

2.3.8. How to read the value of an analogue output

1. Go to the page Other inputs/outputs by pressing the keys and

successively.

2. Note the number of the desired output.


 The value is expressed in tenths of millivolts and may vary between 0 and
100000.

2.3.9. How to read the value of an analogue input

1. Go to the page Other inputs/outputs by pressing the keys and

successively.

2. Note the number of the desired input.


 The value is expressed in tenths of millivolts and may vary between 0 and
100000.

2.3.10. How to read the value of a counting channel

1. Go to the page Other inputs/outputs by pressing the keys and

successively.
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2. Note the number of the desired counting channel.


 The value is expressed in tenths of millivolts and may vary between 0 and
100000.

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2.4. Optimisation page Retrace inputs/outputs

2.4.1. Presentation and application


The page Retrace inputs/outputs allows the user of the machine to track the
plotted curves of the 6 internal variables which can be selected from all the
variables available.
The plotted lines of the 6 curves are synchronous, they can be likened to the
plotting lines on a 6 channel oscilloscope.
The page Retrace inputs/outputs is also used for:
diagnosis of complex breakdowns that may involve both the control part
and the sequential part of the machine.
diagnosis of breakdowns linked only to problems on the sequential inputs.
The active zone of the optimisation page Retrace inputs/outputs is divided
into 2 distinct areas:
A - the frame containing the plotting curve operating tools,
B - set of 6 graphics forming the plotting curve display element.
see illustration Fig. 89., page 233

a b
A

e
c d

B
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Fig. 89. Optimisation page Retrace inputs/outputs

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2.4.2. Internal variables


The page Retrace inputs/outputs allows the user of the machine to plot the
curves of 6 internal variables that he can select from the following different
families:
Bool : Boolean variable
Cons : set point value of a parameter
Cst : constant
Ent : sequential input
Mes : measured value of a parameter
Num : numeric variable
Sort : sequential output and analogue output set value
Stat : static variable

2.4.3. Curve operating tools


a - the luminous button permits selection of the plotting curve scrolling mode :
when the button indicator lamp is green the curves are scrolling continu-
ously.
when the indicator lamp is black, the curves are fixed but storage of them
continues.
b - when the indicator lamp of the luminous button ref. a is black although the
plotting curves are fixed, the shift arrows allow the curve to be scrolled in ei-
ther direction.

2.4.4. Visualization of plotting curves


 Selection of the variable to be tracked is done via the following pull-down help
menus :
c - Pulldown variable type selection menu :
The type of variable can be selected from the different types presented in the
section 2.4.2., page 234.
d - Selecting the variable :
the variable can be selected from all the variables of a given type.
 Once the variable has been selected, the curve is plotted in the next frame :
e - Selected variable plotting window :
The curve is plotted in blue between its 2 upper and lower limits which are cal-
culated automatically and configured as a function of the variable selected.
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2.4.5. How to display the curve of an internal variable

1. Go to the page Retrace inputs/outputs by pressing the keys and

successively.

2. Check that the indicator of the luminous button ref. a is green.


3. Select one of the plotting windows ref. e by positioning the focus on the varia-
ble type selection menu ref. c.

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4. Select a type of variable ref. c.


5. Select the variable to be checked ref. d
 The plotting scale is automatically configured and plotting starts.

2.4.6. How to analyse an internal variable curve

1. Go to the page Retrace inputs/outputs by pressing the keys and

successively.

2. Position the focus on the indicator of the luminous button ref. a.

3. Freeze the curves by means of the key .


 The indicator of the luminous buttonref. a changes to black.

 To analyse the earlier part of the plotted curve :

4. Position the focus on the key .

5. Scroll the plotted curve using the key .

 To return to the later part of the curve :

6. Position the focus on the key .

7. Scroll the plotted curve using the key .

 To reactivate scrolling of the curve :


8. Position the focus on the indicator of the luminous button ref. a.

9. Reactivate scrolling by means of the key .


 The indicator of the luminous buttonref. a changes to green.
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2.5. Optimisation page Preventive maintenance

2.5.1. Presentation and application


The page Preventive maintenance allows the machine maintenance staff to:
schedule requests for the various preventive maintenance operations.
to validate the requests for the various preventive maintenance operations
which have been scheduled and carried out on the machine,
The active zone of the optimisation page Preventive maintenance is ar-
ranged as a table with several columns.
see illustration Fig. 90., page 236

a b c d f
e

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Fig. 90. Optimisation page Preventive maintenance

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2.5.2. Description of the preventive maintenance table


a - The column Operation lists the preventive maintenance operations that the
operator can select by checking the box to the left of the line.
REMARK: There are 2 types of operation :
The first 7 operations are defined by REP;
The remaining 8 operations are not allocated, the user can program them
as he wishes.
You only have to enter the name of the operation to be carried out on the
line of your choice using a standard PC keyboard (102 keys) which can be
easily connected to the power supply.
b - The column Set value permits programming of the number of cycles or the
time expressed in hours before the preventive maintenance request.
The operator simply changes the set value to reset the counter to zero and clear
the request from view.
c - The column Counter indicates the number of cycles or the time in hours
elapsed since the last change of the preventive maintenance set value.
d - The column to the right of the column Counter gives Set value and
Counter programming type:

Number of cycles to be entered.

Units of time to be entered (unit = hour).

e - The next to last column indicates the status of the preventive maintenance
request :
The black indicator lamp means that the set value has not been
reached.
The red indicator lamp means that the set value has been reached
and that the request is been treated.

f - The last column permits the programming or reading of an event linked to a


preventive maintenance request.
Events may be evaluated as being of one of the following 3 levels of gravity :
Information :
a request for a maintenance operation is displayed on a white ground, like
a message on the information messages line.
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Blinking :
a request for a maintenance operation is displayed on a yellow ground like
a message on the alarm messages line and the fault indicator lamp H40 will
blink at the same time.
Production stop :
a request for a maintenance operation is displayed on an orange ground like
a message on the alarm messages line: the fault indicator lamp H40 blinks
at the same time and production is stopped at the end of the current cycle.

Function Maintenance
Document: V684_2Aa
Edition: 16/06/2000 page 237
Technical Manual V68 Y4000
Volume 2 - Application
Chapter VIII - Preset functions
RUBBER INJECTION MOULDING

2.5.3. How to select/deselect a preventive maintenance operation

1. Go to the page Preventive maintenance by pressing the keys and

successively.

2. Select the maintenance operation to be validated.


3. Move the bounding box to the checkbox corresponding to the operation re-

quired by using the keys and .

4. Set the keyboard selector S100-S101 to the position .

 Check the box to validate the operation with the key .

 Deselect the box to invalidate the operation with the key.

2.5.4. How to change a preventive maintenance operation


1. Go to the page Preventive maintenance by successively pressing the keys

and .
2. Select the maintenance operation to be validated.
3. Select the column in which the characteristic to be changed appears with the

and keys.

4. Set the keyboard selector S100-S101 to the position .


 To change the set value;
5. Move the bounding box on to the cell to be changed in the column ref. b using

the keys and .

6. Enter the new set value and validate with the key .

7. Exit the position .


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 To change the programming type;


8. Move the bounding box on to the cell to be changed in the column ref. d using

the keys and .

9. Select the input in number of cycles or in time using the key .

Function Maintenance
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Volume 2 - Application
Chapter VIII - Preset functions
RUBBER INJECTION MOULDING

10. Exit the position .

 To change the type of event on expiry of the counter;


11. Move the bounding box on to the cell to be changed in the column ref. f using

the keys and .

12. Open the pulldown menu using the key .

13. Select one of the lines using the keys and .

14. Confirm the choice by means of the key .

15. Exit the position .

2.5.5. How to reinitialize the counter triggering a preventive maintenance operation

1. Go to the page Preventive maintenance by pressing the keys and

successively.

2. Select the maintenance operation to be reinitialized.

3. Move the bounding box to the column ref. b using the keys and

4. Set the keyboard selector S100-S101 to the position .

5. Move the bounding box on to the cell to be changed using the keys and

.
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6. Validate by means of the key .


 The corresponding counter is reset to zero.

7. Exit the position .

Function Maintenance
Document: V684_2Aa
Edition: 16/06/2000 page 239
Technical Manual V68 Y4000
Volume 2 - Application
Chapter VIII - Preset functions
RUBBER INJECTION MOULDING

2.6. Optimisation page Retrace faults

2.6.1. Presentation and application


The page Retrace faults allows the user and the machine maintenance staff
to:
display all the different information or alarm messages appearing on the
machine,
sort the different messages according to their characteristics,
change the level of gravity of each of the events causing the fault,
filter the message display by level of gravity.
This page consists of 2 distinct zones :
A - the message filtration frame by level of seriousness,
B - the table recapping the faults encountered,
C - the seriousness level programming frame.
see illustration Fig. 91., page 240

2.6.2. Message filtration


The frame at the top of the active window allows the messages to be filtered
according to the level of seriousness.

A a b

c d e

B
f
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Fig. 91. Optimisation page Retrace faults

Function Maintenance
Document: V684_2Aa
page 240 Edition: 16/06/2000
Technical Manual V68 Y4000
Volume 2 - Application
Chapter VIII - Preset functions
RUBBER INJECTION MOULDING

When the operator selects a level of seriousness, the only elements that will be
displayed are this level of seriousness and the levels of seriousness greater
than the latter.
REMINDER: The levels of seriousness are classified in a descending order as follows:
Cycle blocking,
Production stop,
Signal lamp,
Information.
a - The 4 radio buttons make it possible to select the minimum level to display.
b - The checkbox System faults makes it possible to select the display of the
faults inherent to the PC.
refer to section 2.6.5., page 242

2.6.3. Table retracing the faults encountered,


Each message is listed in the table as a function of the following
characteristics :
c - The column Fault title shows the identification number and the description
of the message.
d - The column Status shows the status of the fault which may be :
either 1 when the event relating to the fault has not disappeared yet,
or 0 when the event relating to the event has disappeared.
The status of the fault is displayed on a coloured background which repre-
sents the message current level a of seriousness.
see section 1.3.2. Level of the fault messages, page 71
e - The column Date shows the day and the time the message appeared.
f - The table has a vertical scrollbar which gives access to all error messages
stored in memory.

REMARK: The scrollbar is always controlled by the keys and .


When the bounding box is on the scrollbar, it can only get out of it by means of

the keys and .

2.6.4. Process sorting


The table can be sorted over all columns.
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refer to section 2.6.6., page 242

a. The seriousness level of a message can be modified according to the rules set in section 1.3.2. Level of the fault messa-
ges, page 71

Function Maintenance
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Technical Manual V68 Y4000
Volume 2 - Application
Chapter VIII - Preset functions
RUBBER INJECTION MOULDING

2.6.5. How to filter faults in the archive

1. Go to the page Retrace faults by pressing the keys and suc-


cessively.

2. Move the bounding box using the keys and on to the mini-
mum seriousness level to be displayed in the table (position number ref. a)

3. Validate by means of the key .


 The table is now filtered.

2.6.6. How to sort faults in the archive

1. Go to the page Retrace faults by pressing the keys and suc-


cessively.
2. Move the bounding box to the caption of the column (position number ref. c to

ref. e) where the sorting is to be carried out by means of the keys and

3. Validate by means of the key .


 The table is sorted according to the ascending order of the data in the column
selected.

4. Validate once again by pressing the key .


 The table is sorted according to the descending order of the data in the column
selected.

2.6.7. How to change the level of seriousness of a fault

1. Go to the page Retrace faults by pressing the keys and suc-


cessively.
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2. Set the keyboard selector S100-S101 to the position .

3. Move the bounding box on to the scrollbar ref. f by means of the keys

and .
4. Select the fault for which the level of seriousness should be changed by means

of the keys and .

Function Maintenance
Document: V684_2Aa
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Volume 2 - Application
Chapter VIII - Preset functions
RUBBER INJECTION MOULDING

5. Move the bounding box out of the scrollbar by using the key . The fault
then appears on a grey background.
6. Move the bounding box on to the new level of seriousness by means of the

keys and .

7. Validate by means of the key .

REMARK: The colour of the memorised message level of seriousness is displayed in the
column ref. d and remains the same. The new level of seriousness will be tak-
en into account when the message reappears.
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Function Maintenance
Document: V684_2Aa
Edition: 16/06/2000 page 243
Technical Manual V68 Y4000
Volume 2 - Application
Chapter VIII - Preset functions
RUBBER INJECTION MOULDING

2.7. Optimisation page Setting software

2.7.1. Presentation and application


The page Setting software allows the machine maintenance staff to carry
out the various adjustments on:
the control card for variable displacement pumpsAY201,
the back pressure module,
the various hydraulic valves.
The active zone of the page is divided into 3 zones :
A - the pressure calibration frame,
B - the valve calibration frame,
C - the back pressure setting frame.
see illustration Fig. 92., page 244
REMARK: Because this page is a utility for the exclusive use of the machine maintenance
staff, all information relating to its use is given in volume 3 - Maintenance.

B
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Fig. 92. Optimisation page Setting software

Function Maintenance
Document: V684_2Aa
page 244 Edition: 16/06/2000
Technical Manual V68 Y4000
Volume 2 - Application
Chapter VIII - Preset functions
RUBBER INJECTION MOULDING

3. Function Production configuration

3.1. Base page Production check

3.1.1. Presentation and application


The page Production check can be personalized and it allows the user to:
select the parameters considered essential for the current production run,
display the same moulding parameters by splitting them between families,
change certain moulding parameters using + and - slopes.
REMARK: This page is the default page which appears when the machine is first
switched on.

see illustration Fig. 93., page 245

A
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Fig. 93. Base page Production check

Function Production configuration


Document: V684_2Aa
Edition: 16/06/2000 page 245
Technical Manual V68 Y4000
Volume 2 - Application
Chapter VIII - Preset functions
RUBBER INJECTION MOULDING

The active zone of the page Production check is divided into 2 different ar-
eas:
A - the parameter display zone is divided into 5 families:
injection unit speeds and strokes,
pressures,
times,
injection unit temperatures,
mould temperatures.
B - the combobox for the selection of parameters to be displayed or changed.

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Function Production configuration


Document: V684_2Aa
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Volume 2 - Application
Chapter VIII - Preset functions
RUBBER INJECTION MOULDING

3.1.2. Compatible parameters


Only the moulding parameters listed in the table can appear in the display
zone and only those followed by +/- can be changed.

Injection unit
Injection unit Mould tempera-
speeds and Pressures Times
temperatures tures
strokes

see see see see see


Mod

Mod

Mod

Mod

Mod
No No No No No
page page page page page

20 108 +/- 40 110 +/- 50 112 +/- 60 107 +/- 65 157 +/-

21 133 +/- 41 133 +/- 51 131 +/- 61 107 +/- 66 162 +/-

22 139 +/- 42 140 +/- 52 138 +/- 62 107 +/- 67 157 +/-

23 140 +/- 43 124 +/- 53 142 +/- 63 145 +/- 68 162 +/-

24 140 +/- 44 124 +/- 54 142 +/- 64 145 +/- 69 162 +/-

25 140 +/- 45 155 +/- 55 142 +/-

2A 116 +/- 46 187 +/- 56 157 +/-

2B 118 +/- 47 134 +/- 57 106 +/-

2C 108 +/- 48 140 +/- 58 151 +/-

30 108 no 4B 118 +/- 59 149 +/-

31 138 no 4C 114 +/- 5A 147 +/-

32 138 no 4D 134 +/- 5C 114 +/-

33 139 no 4E 153 +/-

34 139 no 4F 135 +/-

35 133 no

36 143 no

37 143 no

3A 116
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no

3B 118 no

3C 118 no

Tab. 70.Parameters compatible with the page Production check

Function Production configuration


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Volume 2 - Application
Chapter VIII - Preset functions
RUBBER INJECTION MOULDING

3.1.3. How to bring up a parameter window on the page Production check

1. Go to the page Production check by pressing the key .


2. Select the desired parameter from the combobox. The list can be scrolled using

the keys , , and .

3. Validate the selected parameter display by means of the key .


 The parameter is then displayed in the column reserved for it.

3.1.4. How to clear a parameter from the display zone

1. Go to the page Production check by pressing the key .


2. Select the desired parameter from the combobox. The list can be scrolled using

the keys , , and .

3. Validate the deletion of the selected parameter by means of the key .


 The parameter is then deleted.

3.1.5. How to modify a parameter set point using the + and - slopes

1. Go to the page Production check by pressing the key .


2. Select the desired parameter from the combobox. The list can be scrolled using

the keys , , and .


 If the parameter appears on the line of the combobox with a red box on its
right, its set value cannot be changed.
 If the parameter appears on the line of the combobox with a green check box
on its right, its set value may be changed.

3. Set the keyboard selector S100-S101 to the position .

4. Press the key to increase the set value by one unit. Repeat from the be-
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ginning as required.

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Volume 2 - Application
Chapter VIII - Preset functions
RUBBER INJECTION MOULDING

5. Press the key to decrease the set value by one unit. Repeat the operation
if necessary.

WARNING: The set value resulting from the last change using the + or - slopes is saved
automatically.
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Function Production configuration


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Technical Manual V68 Y4000
Volume 2 - Application
Chapter VIII - Preset functions
RUBBER INJECTION MOULDING

3.2. Optimisation page Production selection


The page Production selection is exclusively reserved for the use of Cure-
trac program machine module.
refer to Volume 5 : OP192 Curetrac Machine System

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Function Production configuration


Document: V684_2Aa
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Technical Manual V68 Y4000
Volume 2 - Application
Chapter VIII - Preset functions
RUBBER INJECTION MOULDING

3.3. Optimisation page Mould selection

3.3.1. Presentation and application


The page Mould selection allows the user of the machine to:
display all the different moulds programmed and stored on the machine
(max. 100 moulds),
select the current mould from the 100 moulds stored,
copy one mould on to another.
REMINDER: For the operator, a mould consists of all the machine management and
moulding parameters programmed for a given tooling and stored under one la-
bel.
The mould also stores the selected cycle.

The Mould selection consists of the following 2 elements:


A - the table presenting the moulds stored and consisting of 5 columns in the cen-
tre of the screen,
B - the mould duplication tool consisting of blue columns to the left and right of
the table A.
see illustration Fig. 94., page 251

a
f b c d e g

B
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Fig. 94. Optimisation page Mould selection

Function Production configuration


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Edition: 16/06/2000 page 251
Technical Manual V68 Y4000
Volume 2 - Application
Chapter VIII - Preset functions
RUBBER INJECTION MOULDING

3.3.2. Table of stored moulds


The table presenting the stored moulds consists of 5 columns on a grey back-
ground:
a - The radio buttons column permits selection of one of the moulds from the 100
available.
b - The column Numbera indicates the available mould numbers.
c - The 3rd column is used to identify the mould literallya (the wording is entered
via a keyboard external to the machine).
d - The column Start of last use gives the date on which the mould was last
used.
e - The column End of last use gives the date of the last cycle produced with the
mould before it was changed.

3.3.3. Mould duplication tool


The mould duplication tool consists of 2 columns outside the table presenting
the moulds:
f - The column Source permits definition of the mould to be copied.
g - The column Destination permits definition of the mould to be created or
modified.

3.3.4. How to select a mould

1. Go to page Mould selection by pressing the keys and succes-


sively.
2. Place the focus on the radio buttons column and move the pointer to the line

desired using the keys and .

3. Set the keyboard selector S100-S101 to the position .

4. Validate the selection by means of the key .


 After loading for a few seconds, the new mould number is displayed at the top
right of the screen

5. Exit the position .


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a. The mould number can be modified when the bounding box is positioned on the mould number cell.
The caption of the 3rd column can also be modified when the bounding box is positioned on the corresponding cell.
In both cases, you only have to enter the text to be modified using a standard PC keyboard (102 keys) which can be
easily connected to the power supply.

Function Production configuration


Document: V684_2Aa
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Volume 2 - Application
Chapter VIII - Preset functions
RUBBER INJECTION MOULDING

3.3.5. How to duplicate or create a mould

1. Go to page Mould selection by pressing the keys and succes-


sively.
2. Place the focus in the Source column and move the pointer over the blue
ground to the desired line.
3. Place the focus in the Destination column and move the pointer over the
blue ground to the desired line.

4. Set the keyboard selector S100-S101 to the position .

5. Control the duplication by means of the key .


6. Several situations may occur:
If the destination line is empty : a new mould is created by copying the
source mould.
If the destination line is not empty: the old mould is deleted by the copy of
the source mould.
If the mould line is empty: a new mould is created and all the set values of
the parameters are nil.

7. Exit the position .

3.3.6. Using the page Mould selection with option OP227: Machine workstation RepNet-win

WARNING: When option OP227: machine system RepNet-win is used, moulds are usu-
ally saved and stored on the central terminal.
They are transferred on request to the presses where they become inde-
pendent moulds of the central terminal.
In other words, the page Mould selection must be used with particular care,
for if a modification of the parameters of the mould used on the machine has
been validated for the running production, it must be transferred to the central
terminal to be stored, at the risk of being lost for good.
On the other hand, the mould number transferred from the central terminal
should not be changed on the machine. If this was the case, its transfer to the
central terminal runs the risk of erasing a mould with the same number or the
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data base supervisor would create a mould with an unknown RepNet-


winnumber.
In short, only one line on the table of page Mould selection is to be used and
the mould duplication functions must not be used when option OP227: Ma-
chine systemRepNet-win is used on the machine.
refer to volume 5 - Option OP227: Machine System RepNet-win

Function Production configuration


Document: V684_2Aa
Edition: 16/06/2000 page 253
Technical Manual V68 Y4000
Volume 2 - Application
Chapter VIII - Preset functions
RUBBER INJECTION MOULDING

3.4. Optimisation page Machine time

3.4.1. Presentation and application


The page Machine time programs the different time parameters used by the
software RepNet-win to monitor the production.
see illustration Fig. 95., page 254

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Fig. 95. Optimisation page Machine time

Function Production configuration


Document: V684_2Aa
page 254 Edition: 16/06/2000
Technical Manual V68 Y4000
Volume 2 - Application
Chapter VIII - Preset functions
RUBBER INJECTION MOULDING

3.4.2. Base sub-functions

Associated param-
Main sub-functions
eters

C0
Monitoring of sequential cycle time (out of curing)
(page 255)

C1
Stripping time monitoring
(page 255)

C2
Extruding time monitoring
(page 255)

C3
Injection time monitoring
(page 256)

C4
Total cycle time monitoring
(page 256)

Tab. 71.Sub-functions available on the base page Machine time

3.4.3. Parameter

Default
No Description
value

Times

C0  Machine time
Parameter C0C0 is a timer which starts when the press closing phase begins.
expressed It measures the cycle duration until the end of the opening stroke, once all
0
in seconds programmed option movements have been performed.
REMARK: The curing time 56 is not taken into account in time C0.

C1  Stripping time
Parameter C1 is a timer which starts at the end of the cycle once all pro-
expressed grammed sequential movements have been performed. It measures the dura- 0
in seconds tion of manual stripping operations from the guard closing to the beginning
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of the next press closing.

C2  Extruding time
Parameter C2 is a timer which starts together with the rotation of the extruder 0
expressed screw and which measures the duration of the extrusion phase.
in seconds

Tab. 72.Parameters of the base page Machine time

Function Production configuration


Document: V684_2Aa
Edition: 16/06/2000 page 255
Technical Manual V68 Y4000
Volume 2 - Application
Chapter VIII - Preset functions
RUBBER INJECTION MOULDING

Default
No Description
value

C3  Injection time
Parameter C3 is a timer which starts simultaneously to the injection and which 0
expressed times the dynamic injection phase up to point 35.
in seconds

C4  Cycle time
Parameter C4 is the sum of the Machine, Stripping and Extruding times:
expressed 0
C4 = C0 + C1 + 56.
in seconds
Parameter C4 represents the total duration of a cycle.

Tab. 72.Parameters of the base page Machine time(cont.)

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Function Production configuration


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Volume 2 - Application
Chapter VIII - Preset functions
RUBBER INJECTION MOULDING

3.5. Optimisation page Cycle counter

3.5.1. Presentation and application


The page Cycle counter allows the user of the machine to:
program the number of cycles to be performed,
to display the number of cycles programmed locally on the machine and the
number of cycles completed,
to display the number of cycles programmed on the central terminal Rep-
Net-win and the number of cycles completed.
see illustration Fig. 94., page 251

c
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Fig. 96. Optimisation page Cycle counter

Function Production configuration


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Edition: 16/06/2000 page 257
Technical Manual V68 Y4000
Volume 2 - Application
Chapter VIII - Preset functions
RUBBER INJECTION MOULDING

3.5.2. Press counter


a - The Number of cycles to be done window of the Local counter frame per-
mits local input of the number of cycles the press is to complete.
b - The Number of cycles done window of the Local counter frame displays
the number of cycles that the machine has already completed.

3.5.3. Counter RepNet-win

c - The Counter RepNet-win frame is displayed only when the option OP227
Machine terminal RepNet-win is installed on the machine. It makes it pos-
sible to display the set value and the status of the cycle counter programmed
from the central terminal.

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Function Production configuration


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Chapter VIII - Preset functions
RUBBER INJECTION MOULDING

3.6. Optimisation page Cycle selection

3.6.1. Presentation and application


see illustration Fig. 97., page 259
The page Cycle selection allows the user of the machine to select a machine
operating cycle among the different cycles presented in a standard version:
a - basic cycle,
b - preset cycles,
c - specific cycles.
Selection is completed by validating one of the lines on the screen. The kine-
matics corresponding to a cycle other than the standard cycle is then dis-
played in the white part of the active zone.
REMARK: Cycles 1 to 7 and cycle 31 are attached to the mould number, i.e. they are
stored with the moulding parameters relating to a mould number. The cycle
stored in a mould is automatically validated when the mould number is select-
ed and activated.
see section 3.3. Optimisation page Mould selection, page 251

b
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Fig. 97. Optimisation page Cycle selection

Function Production configuration


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Volume 2 - Application
Chapter VIII - Preset functions<