Professional Documents
Culture Documents
Operaciones Basicas Maquinas ENGEL PDF
Operaciones Basicas Maquinas ENGEL PDF
Tel.: +43.50.620.0
Fax: +43.50.620.16062
Version: G/11/25/15/5
Printing date: 19.4.2010
Language Englisch
endproduktprüfer (epp)
PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1 ENGEL - COMPANY GROUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2 ENGEL - COMPANY HISTORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1 TEXT FORMATTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.1 SCREEN LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2 PROPER USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3 MACHINE OVERVIEW VICTORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.1 MACHINE OVERVIEW VICTORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4 INJECTION MOLDING IN GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.1 MOLDING CYCLE OF AN INJECTION MOLDING MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.2 IMPORTANT PRINCIPLES AND NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
SAFETY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1 PICTOGRAPHS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2 OVERVIEW OF SAFETY EQUIPMENT VICTORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3 SAFETY EQUIPMENT FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.1 EMERGENCY STOP BUTTONS FOR PLANT SHUTDOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.2 FUNCTIONING OF THE SAFETY GATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4 EDDITIONAL EQUIPEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5 MOUNTING AID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6 BEHAVIOR IN CASE OF FIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7 RESCUE ACTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1 COMPONENTS OF THE CONTROL UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.1 SWITCH PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1.2 CONFIGURABLE KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2 SCREEN STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.1 HEADER WITH INFO PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.2 SCREEN PAGE SELECTION AND FUNCTION KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.3 STATUS DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.4 PROGRAM KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.5 INPUT KEYBOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3 USER ACCESSS AUTHORIZATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.1 USER ACCESS CARD LOGIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.2 PASSWORD LOGIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4 SETUP SCREEN PAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
4.1 USER ADMINISTRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4.1.1 CREATING NEW USER ACCESS AUTHORIZATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
4.1.2 CHANGING USER ACCESS AUTHORIZATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4.1.3 DELETING USER ACCESS AUTHORIZATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4.1.4 SAVING USER ACCESS AUTHORIZATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4.1.5 IMPORTING/EXPORTING USER DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4.2 USER LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
5 OPERATION OF AN INJECTION MOLDING MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5.1 START UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5.2 MODES OF OPERATION OF THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
5.3 PUTTING OUT OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
6 HELP SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
7 ERROR SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
7.1 DELETING AND ACKNOWLEDGEMENT OF ALARMS AND MESSAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
7.2 INTERACTIVE MESSAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
8 SET VALUE GRAPHICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
8.1 QUICK SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
8.2 SETTING THE SPEED AND FORCE PROFILE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
CLAMPING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
1 MOUNT MOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
1.1 PREPARATIONS FOR MOUNTING THE MOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
1.2 MOUNT MOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
2 MOLD HEIGHT SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
3 EJECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
3.1 SET THE EJECTOR MOVEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
3.2 SETTING PART REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
3.3 EJECTOR START/STOP SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
3.4 SPRUE EJECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
4 MOLD CLOSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
3
4.1 CLOSING MOVEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
4.2 CLAMP FORCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
4.3 MOLD PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
4.4 EXTERNAL CLOSING INTERLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
4.5 SEQUENCE PROGRAMMING POSITIONS MOLD CLOSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
5 MOLD OPENING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
5.1 OPENING MOVEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
5.2 SEQUENCE SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
5.3 SEQUENCE PROGRAMMING POSITIONS MOLD OPENING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
HEAT ZONES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
1 BARREL HEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
1.1 MONITORING OF THE BARREL TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
1.2 STANDBY HEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
1.3 COMPACT REPRESENTATION OF THE HEATING ZONES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
1.4 SOAKING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
2 MOLD HEATINGS (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
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6 ENGEL operator basics (EOB) | Version G/11/25/15/5
Preface
Preface
Our task does not only deal with the production of injection molding machines alone. Being
one of the leading businesses for plastic manufacturing in the world, we offer all technological
modules such as injection molding machines, tools and automation systems from one source.
Our technologies enable our partners to act competitively and successfully.
Individual responsibility and the willingness of the employees to embrace innovation are the
foundation of our success. Our products are the result of their commitment. By making the
business segments independent, we ensure a flexible handling with regard to the require-
ments of our customers.
Our leading market position is built upon 2 corner stones. On the one side, the hi-technology
business that initiates continuous further development and on the other side, the production of
larger batches that makes our developments financially affordable. Our production locations in
Europe and North America are a guarantee for the constant quality of our products.
One of our basic business objectives, the production of high quality products of continual qual-
ity and reliability are only emphasized by the degree of satisfaction of our customers over lon-
ger periods of utilization.
We aim to strengthen the confidence in our products by carrying out a series of seminars that
should offer our customers and their employees the possibility of targeted purposeful training
knowledge and requisite know-how for handling our products. The intensive training contrib-
utes to helping avoid production downtimes and increases the operating lives of our products.
7
Preface
Automotive
Bumper
Packaging
Foodstuffs container
Medical
Implants
Teletronics
Technical moulding
Pipe fitting
Organizational chart:
9
Preface
In 1965, the company founder, Mr. Ludwig Engel deceased. His wife Mrs. Irene Schwarz
(maiden name being Engel) and Mr. Georg Schwarz took over the management of the com-
pany. In those days, a turnover of 120 million ATS (Austrian Schilling) was achieved with 438
employees.
In the course of reinforced foreign activities a worldwide marketing network was built up in the
middle of the 60ies. Today the export share is more than 90 % of the turnover whereby about
56 % are achieved in the EU region. ENGEL is represented in more than 70 countries, of them
with 20 own marketing subsidiaries. The first foreign production plant was established in
Guelph, Canada in 1977,.
After introducing robots and automation equipment to the production in our own factory in
Steyr in 1986, an important and successful step was initiated in a new production segment. In
January 1998, the production of the ENGEL robots relocated to a newer and larger factory in
Dietbach near to Steyr.
Large machines have been produced in the factory St. Valentin (approx. 20 km away from the
main factory Schwertberg) since 1988. Fully automated production systems and logistical sys-
tems enable the modern and economical production of large machines. In 1994, ENGEL intro-
duced the innovative 2 plate large machine technology to the market and in 1997, 1998 and
1999, being the first manufacturer of injection molding machines world wide, were com-
mended with the „Supplier of the Year - Award” by General Motors. In business year 1999 /
2000, ENGEL was the only manufacturer of injection molding machines that was commended
with the highest quality prize by Ford, the „Q1 Award”.
The market position was strengthened even more in the region of North and Central America
with the construction of the new large capacity machine factory in York, Pennsylvania, USA, in
1989 - especially in the automobile sector. In 1994, the extension of the factory was carried out
by doubling the production area. In 1995 a new factory was also built in Guelph, Canada in
North America for the sector of automating technologies.
At the end of 1997, Georg and Irene Schwarz transferred the management of the operative
businesses in Austria to 4 managing directors who's spokesperson is Dr. Peter Neumann. In
the same year, Engel founded the „ENGEL Machinery Korea Ltd.”, with the intention of build-
ing a production factory. With the opening of the production factory in October 2000, Engel had
developed itself to the first manufacturer in the branch with a global production concept and
productions on three continents. At the trade fair „K 2001”, Engel presented itself as the market
leader for injection molding systems.
Today ENGEL is the largest Austrian enterprise of its branch and is as individual mark the
worldwide largest manufacturer of injection molding machines.
11
Preface
1989 Opening of the factory for large machines ENGEL Machinery Inc. in York,
Pennsylvania, USA
1993 Enlargement of the production plant ENGEL Canada Inc., Guelph
1994 Doubling of the production area of the ENGEL Machinery Inc., York, USA
1995 Transfer of the production of robots for North America into newly acquired fac-
tory premises of the ENGEL Canada Inc.
1997 Extension of the machine assembly hall and of the administration building in the
headquarters Schwertberg
1997 Foundation of ENGEL Machinery Korea Limited as marketing and service cor-
poration with the intention to begin the planning work for a production factory in
Korea
1997 Family Schwarz entrusts the management of the operative corporations in Aus-
tria to a management team of four persons, with Mr. Dr. Neumann as spokes-
man.
1998 Opening of the new factory for Automatisierungstechnik Gesellschaft m.b.H. in
Dietach near Steyr. The existing production site of the Engel Automatisierung-
stechnik in Steyr is used for the installation of a new production site for special
metal technology under the product name ENGEL MARATHON. The ENGEL
Werkstofftechnik GmbH is founded. With this step ENGEL possesses 4 produc-
tion sites in Austria.
1999 Completion of the second expansion stage of the ENGEL large capacity
machine factory in St. Valentin. The assembly surface was more than doubled
with this expansion stage. ENGEL becomes market leader with large capacity
machines that have a closing force of more than 1000 t.
Laying of the foundation stone and building beginning for the first production
factory in the Far East (factory for small and medium-sized machines in Pyung-
taek-City in South Korea). With this step Engel as the only manufacturer of
injection molding machines possesses production sites in thee contintents.
2000 Opening of the production factory in Korea. Start of the machine assembly.
2002 Extension of the network factory subsidiaries in Europe by the foundation of
„ENGEL Finland” and „ENGEL Poland”. The capacity of ENGEL Hungary is
extended by moving into an enlarged operation building. The production factory
in Canada was extended.
In August the parent company in Schwertberg is severely hit by two tidal waves
after heavy rainfall. All the production equipment is destroyed. But already after
two months the production can be resumed. The catastrophy is taken as occa-
sion to start the project „Phoenix” and to understand the reconstruction as
chance for a new structuring of the production equipment and to convert a
future-oriented production concept.
2003 New construction of the parent company Schwertberg and erection of a flood
control. In the factory of large machines St. Valentin the extension stage III
starts with three hall ships with a total area of approx. 6500 m 2.
In Germany, the long-time branch in Cologne is closed and replaced by a new
building in Hagen. Combined with the new branch in Hagen, the production
location for the „ENGEL Automatisierungstechnik Deutschland GmbH” is estab-
lished, where the projects for automation plants are processed directly within
the German market.
With the beginning of the business year 2002 / 2003, the Austrian manufactur-
ing companies trade under the same name and are merged to „ENGEL AUS-
TRIA GmbH”.
2004 Introduction of the SPEED machine series.
2007 Opening of the large capacity machine factory in Shanghai / China
General
You have decided on an ENGEL product which is produced and supplied under strictest qua-
lity controls.
This instruction manual is an important part of the injection molding machine and intended for
any staff who work with or on the machine. Keep the instruction manual throughout the service
life of the machine, and pass it on to any subsequent owners or users. It is important to inte-
grate any amendments you receive with the instruction manual.
The documentation for the injection molding machine is divided into 3 manuals:
WARNING!
Improper use of the machine can lead to severe injury to persons and
damage to equipment!
Before operating the plant or performing any maintenance, you must
read this instruction manual carefully, and familiarize yourself with the
safety equipment.
Do not use the plant without appropriate training.
Participation at an ENGEL training center is highly recommended.
The main aim of this book is to impart the operation and all program functions of the injection
molding machine. The book provides the necessary information for setting a production pro-
cess.
The manual is also designed help eliminate production failures as rapidly as possible.
Note!
The index contains a list of alarms.
13
General
1 Text formatting
The following text formatting is used to provide a clear manual layout and to emphasize parti-
cularly important information:
DANGER!
Information marked with this symbol points out immediate danger which
can lead to death or serious physical injury!
WARNING!
CAUTION!
CAUTION!
Information marked with this signal word warns of danger which can
cause damage to equipment!
Note!
Information provided with this symbol offers application tips and useful information.
Example:
Information provided with this symbol offers practical examples.
Bullet
Bullet (emphasis).
The operator does not need to maintain a fixed sequence or order.
Numbered sequence
1. Fixes procedure way after the numbers
Alarms and Messages are listed throughout the manual in table format, indicated by a symbol
for the alarm class, and including a description of the cause, effect, and troubleshooting infor-
mation.
Cause
Effect
Remedy
15
General
Screens
CAUTION!
The parameters in the figures are purely incidental and should not be
used as a guide for machine set up.
2 Proper Use
ENGEL products are built to the current state-of-the-art, and comply with accepted safety stan-
dards.
Note that ENGEL injection molding machines must be used for manufacturing of injection
molded parts made of thermoplastics, thermosets and elastomers only, in accordance with the
instruction manual.
To this end, make sure you follow the processing instructions given by the material manufac-
turer!
(Improper processing could lead to injury or damage to equipment!)
Installation, operations, and maintenance of this machine must be performed by staff trained
for this purpose on ENGEL machines.
For damage from improper or not as agreed use, non-observation of the specifications in the
instruction manual as well as faulty operation ENGEL GmbH is not liable.
Modifying the machine invalidates its EC conformity; you are not permitted to put the machine
into operation in this case!
1 2 3 4 5 6 7 8 9
15 14 13 12 11 10
14
13
12
11
17
General
The injection molding process, in one single work step, leads from the molding compound to
the finished formed part. The raw material is available to the processor as a powder or gran-
ules. The machine injects a liquid or at least a viscous material into a mold under high pres-
sure. Parts with high dimensional accuracy are produced.
Insert machine
The Insert machine series was specially designed for manufacturing of metal/plastic compos-
ites. This technique involves manually or automatically placing metal inserts into the mold, and
then injecting plastic to cover them.
Time
The screw injects the melt from the screw antechamber into the mold cavity under high pres-
sure using a set speed profile. The pressure can be between 300 and 2500 bar depending on
mold and molding compound. A mechanical non-return valve prevents the backflow of the melt
into the screw channels.
The cooling time begins with the entry of the molten plastic into the mold. To prevent sink
marks or voids in the part, the machine switches over to hold pressure after the mold has been
filled. The hold pressure packs out the mold to compensate for material lost due to cooling until
the sprue freezes off (gate sealing). A hold pressure profile and time can be set by the opera-
tor. After the hold pressure, the operator set cooling time begins.
19
General
Safety
Injection molding machines are powerful machines that create high PRESSURES - FORCES
- TEMPERATURES that can be dangerous to persons.
To protect persons against danger of accidents, ENGEL injection molding machines are fitted
with safety equipment.
Before operating a machine perform a visual check to ensure that the safety equipment is in
good working order. Also, manually check the locking systems by opening and closing all mov-
ing safety equipment.
Note!
Always keep the whole plant clean. This improves its functionality and enhances operator
safety!
The floor around the plant as well as the specified access points and working places are
to be kept free of oil and pellets.
Only use marked locations as access points or workplaces.
Protect hoses against harmful influences such as acids and mechanical damage!
If you notice leakages, damage, or breaks in media lines, switch off the machine imme-
diately!
Never use plant surfaces as work surfaces. Do not use the plant as a mounting aid.
Comply with and never remove warning signs, notices or labels from machines!
Observe the safety instructions in the manual!
No access for unauthorized persons.
WARNING!
Danger of burns in the vicinity of hot components such as the barrel and
injection mold; danger of injury due to high pressure injection!
Insufficient pre-drying or decomposition of certain plastics can cause
the material to exit the nozzle or infeed opening in an uncontrolled way.
When working on the machine, use suitable protective clothing (safety
shoes, protective gloves, face protection, ...). Observe local safety regu-
lations for operating injection molding machines!
When working in the injection mold area, make sure the nozzle is
retracted! Make sure the barrel nozzle is not touching the mold!
Observe processing and safety instructions by the material manufac-
21
Safety
turer!
In case of injection steps where clamping force is not fully built up,
install additional, fixed, separating safeguards in the injection molding
machine mold area, or attach directly to the mold!
WARNING!
WARNING!
CAUTION!
WARNING!
Any work on the machine, beyond the described activities, must be carried out by ENGEL ser-
vice engineers.
WARNING!
23
Safety
1 Pictographs
Description of the pictograms that may be affixed to the machine to indicate dangerous areas
or situations. Failure to observe safety signs can lead to severe injury.
Prohibitory signs
Do not use any credit cards, watches or small metal parts in the proximity!
Labels for magnetic holding plates in the clamping unit area
Mandatory Signs
Read documentation!
On the control panel of the machine control
Danger signs
25
Safety
Safety hints
Symbol Description
1. Always observe the local safety regulations for the operating safty of injection
moulding machines and robot systems (handling systems, mould change).
Read the instruction manual.
2. Keep safety equipment in good working condition. Never remove, deactivate
or disable safety equipment.
3. Do not remove any danger or information signs and markings from the
machine or from the additional equipment.
4. Control all the safety equipment on the machine and on the additional equip-
ment for correct function and check it at regular intervals.
5. Control all high-pressure pipelines at regular intervals for their worksafe
state.
6. Pay attention to that no hard objects get into the vent as well as into the feed
opening.
7. Entering the area of the injection unit is not allowed during the machine oper-
ation.
8. If a mounting aid is required for filling the processing material container, use
such which corresponds to the local safety regulations.
9. Do not enter the ejection area and/or do not reach into it during operation.
10. Caution in the area of the heated-up material cylinder ready for operation
(danger of combustion).
11. Always observe the processing guidelines and safety hints indicated by the
material manufacturer.
12. Use extractor fans when working with a vented cylinder and when process-
ing toxic types of material; wear the prescribed protective clothing.
13. Only use shut-off nozzles allowed by the legislator.
14. Never switch the main switch under load (e. g. when heatings are switched
on).
15. Switch off the motors for all maintenance and repair work in the machine's
work areas with moving parts. Make sure that the complete hydraulics system
is depressurized. Exercise special care if you use pressure accumulators.
16. Set the machine currentless by all means in case of repairs and modifica-
tion work. Switch off main switch and secure it and control for voltage freedom.
17. Make sure that the material in the material cylinder is not under pressure
and/or is not cooled down before you dismount the nozzle and/or the material
cylinder flange.
18. Mount and check the whole safety equipment after machine repairs.
19. No admittance to the machine for unauthorized persons.
Entering the injection unit when in operation not allowed, otherwise attach suit-
able covers, which prevent reaching into the danger area of the clamping unit.
Labels for the injection unit
1 2 3
10 9 8 7 6 5 4
27
Safety
When an EMERGENCY STOP button is activated, the injection molding machine motors
immediately switch OFF. Message:
Emergency-off
Note!
The EMERGENCY STOP function is active in each mode of operation!
Remedy Close the safety gates, move the machine into the start position and
start the cycle again.
Depending on the protection type, opening the rear safety gate on the clamping unit causes an
EMERGENCY STOP switch-off, or executes the same function as the operator side safety
gate.
When a safety gate on the injection unit is opened, the following message appears:
4 edditional equipements
The installation of additional equipment is only permitted with the permission of ENGEL.
If additional equipment is attached to the machine without ground support, a new evaluation of
the risk of tipping must be implemented.
ENGEL is only responsible for the cooperation of the machine with additional equipment if the
interfaces have been designed by ENGEL.
Sockets on the injection molding machine may only be used for the specified additional or
peripheral equipment.
WARNING!
29
Safety
5 Mounting aid
Machines with material hopper must be equipped as per EN 201 with secure access means or
the user must provide mobile, secure access means for the machine. We recommend that a
mounting aid offered by ENGEL be used.
Proper Use:
The mounting aid is only suitable for manual filling of the material hopper in horizontal standard
injection molding machines without a robot and without additional equipment. Free usage is
prohibited!
WARNING!
WARNING!
1. Keep calm
2. Alert the fire department
3. Switch off the machine at the main switch
4. Alert all persons in the danger zone
5. If possible, close all fire doors
6. Switch of any venting and/or air conditioning units
7. As soon as possible, contain the fire with an approved fire extinguisher
8. Provide assistance and direction to anyone actively involved in fighting the fire
DANGER!
Note!
If a fire has occurred on an ENGEL molding machine, it must not be put back into operation
until it has been inspected by an ENGEL Service Representative:
31
Safety
7 Rescue actions
Perform the following rescue actions to release trapped persons from the mold area; note that
accidents of this kind can only occur in case of gross misuse or if you disable vital safety
devices!
1. 2 persons are required to provide first-aid (both must be skilled in the use of the injection
or compression molding system).
2. One of the two rescuers must mechanically secure the machine against motions, such
as lowering or clamping, that would further endanger the victim or rescuers (moving
mold mounting plate, core-pull, ejector).
3. The second rescuer must manually move the machine to a position where the victim
can be freed.
4. Leave the danger area (mold area) with the person you have rescued.
5. Give first aid.
6. Call a paramedic.
Operation
The control unit has a Windows-style GUI with a color touch screen. Users need to log in to
access settings and parameters.
The data storage occurs on an USB memory stick.
Text and graphics editors support fast and easy customization of the machine to match your
injection molding process and free programming of the program sequence.
A help system with graphics supports operations and maintenance of the injection molding
machine.
You can install the optional VirtMold software to run the original machine visualization on a
PC. This gives you the ability to change settings independently of the injection molding
machine, and to store your changes on a Compact Flash card or USB memory stick to transfer
them to the machine.
33
Operation
Start key
Program interruption
Safety button key
CAUTION!
Do not use pointed, sharp, or metal objects, including ballpoint pens or pencils, on the touch
screen. This can lead to damage.
It is recommended that the touch screen be operated with either your hand or a suitable
marker.
Note!
After switching off the control voltage, always wait at least 1 second until switching it back on.
The electronics modules must first be able to discharge.
USB interface
To write and read machine and parts data as well as production data. If possible, use Engel-
recommended USB memory sticks.
[See Storage media on page 129.]
Program interruption
The program interruption switch is used to interrupt the automatic cycle and to acknowledge
the messages. In the switched-on state the following message is displayed:
Effect The automatic cycle stops, current messages are acknowledged, you
can run the machine as in manual mode.
Start key
You only need the Start key to start an automatic cycle. The machine's functional units must all
be at the starting position for this. The following message appears when switching over to
automatic mode:
35
Operation
SP2-0734: Unbe-
kannter Befehl ab
"where k.hb..." - restli-
che Zeile ignoriert.
SP2-0042: Unbe-
kannter Befehl "*" - rest-
liche Zeile wurde
ignoriert.
SP2-0734: Unknown
instruction from
"ERROR in ..." -
remaining line ignored.
SP2-0734: Unbe-
kannter Befehl ab
"ORA-00933:..." - restli-
che Zeile ignoriert.
SP2-0044: Zum Auflis-
ten bekannter Befehle
HELP
und zum Verlassen
EXIT eingeben.
1 2
Example:
Procedure for assigning a function to a foil key.
2. Press the desired symbol in the key menu to place it on the red field.
3. Activate the associated function by pressing the foil key below it.
4. To close the key menu, press the red field.
Note!
Symbol pairs such as: Turn mold swiveling device left and right or Move in or out core can be
inserted at the same time by selecting the symbol field on the left.
To delete a function or to replace it by a different one, either press an empty field or the
desired symbol.
37
Operation
2 Screen structure
The clearly designed touch screen of the control unit permits simple and fast programming.
Core Print
Plasticizing Setup
Nozzle Help
Program
1 interruption key
2 3 4 5 6 7 8 9
Colored highlighting indicates the current mode of operation. Depending on your user level,
you can click a field to display other modes of operation.
39
Operation
Cancel key
The Enter key saves the value of the input field if it lies within the range of possible entries. If
this is not the case, the input field is highlighted in red and yellow.
A virtual keyboard is displayed when parameters are selected that require alphanumeric input.
Mold number
Se-
Special keys
Se-
Highlights the entire text
Highlights a portion of the text by activating this key and moving the cursor with the
arrow keys
Copies the selected text
4. Type the value using the input keyboard; the value is displayed in the input field. Check
whether your entry is plausible.
Position
5. If you made an error while typing, press the Delete key. You can then enter the correct
value.
6. To store the value press the enter key.
If the entered value is nevertheless too high or too low, the colors of the plausibility dis-
play in the input field change to yellow/red (see the figure below). The control unit dis-
cards the value. You need to enter a correct value.
Position
intermediate deposit
The following input field appears when you click a program switch:
Determine mold height
Preview
When you press the Enter key, the control takes on the switch position shown in the preview.
A field with a checkmark is active, while an empty one is inactive.
41
Operation
Name Standard
Description
Free memory
Required memory
Mold height
Logging in and out with the user authorization card on the plant
A sensor for logging in with the authorization card is integrated into the control panel. If you
hold your authorization card in front of the sensor, you will be logged in. After a time that is set
in the control unit, the user is automatically logged out if the control unit is not put into opera-
tion.
There is also a slot for inserting the authorization card to the left of the transponder. The user
is then logged in until the authorization card is removed.
43
Operation
Optimization L1 5 p
Optimization L2 6 p
Teach_L1 7 p
Teach_L2 9 p
Service_Customer 11 p
You can modify these users and add new ones. Whether you are capable of doing this
depends on your user level and the associated privileges. [See User level on page 50.]
Logout
For logout press the Logout key from the Setup screen page.
45
Operation
Setup
Info Panel - injection molding machine actual value
Settings
Absolute Relative
User login
User
Password
Logout Logout
Settings
In the settings, you can specify your desired language, change the date and time, and select
the display mode of the units.
Language
A few other languages are available in addition to the set one. Select your desired lan-
guage in the menu. The selected language receives a colored highlight. After you have
selected a language, a bar appears informing you of the progress of the language
change.
Date/time
To set the date and time, press the appropriate field. Please use the + or - button to set
or change the date and time. The selected field always receives a colored highlight. The
setting is saved by pressing the Enter key.
Units
You can change the display format of the units in the Setup menu item. Place a check-
mark next to your preferred setting.
ISO
Displays units in metric system
Imperial
Displays units in imperial system
Absolute
Displays absolute values
Relative
Displays relative values (percent)
Pressure 100 bar 1450.3 psi 100 bar x 14.503 = 1450.3 psi
Volume 100 cm³ 6.10 in³ 100 cm³ x 0.061 = 6.10 in³
User login
To login enter the correct user and password
47
Operation
Cancel Help Ok
User Name
Password Password
Confirmation Confirmation
Cancel Help Ok
5. Enter the settings for the new user in this dialog box. Enter the selected password again
in the Confirmation line.
6. Press Ok to load the new settings.
7. The new user is stored in the control unit.
Delete?
Cancel Ok
49
Operation
To do this, select the Setup, Export user data instruction menu button to export the data and
the Import user data to import them. The plant must be restarted after the data have been
imported.
As a result, the operator does not have to create the users for each plant from scratch.
4 Reserved
8 Reserved
9 Reserved
CAUTION!
5.1 Start up
1. Switch on the machine main electrical isolator.
2. Switch the control voltage switch to ON (1).
The control unit starts and afterwards the data dialog screen is displayed.
Data dialog
Info Panel - injection molding machine actual value
Mold position actual val- Cooling time actual value
Clamping force actual Shot volume actual value
Specific injection pres- Shot counter actual value
Production date
Change author
Change date
Description
Cause The cylinder heaters and the machine motor are not yet switched on
or have been switched off by the appearance of an alarm (see alarms
on the screen).
51
Operation
4. Switch on the heating for the barrel, and set the required temperature for the plastic type
you will be processing.
CAUTION!
Always enable monitoring for barrel heating to prevent screw movement and/or damage
to the screw tip due to low material temperature.
5. Switch on the machine motor. If an EMERGENCY STOP button is pressed, you must
relieve it by clockwise rotation. The safety gates on the clamping unit must be closed.
Observe the messages on the screen.
If the oil temperature is below the set minimum when the pump motor is started, the
oil preheating program switches on automatically. Ideal operating temperature 45 °C
(113 °F).
6. Open the shut-off valve for the cooling water.
Selection of the set-up mode only possible from the manual mode. Functions such as mode
of operation ”MANUAL”, only the following additional items must be observed:
Push-button actuated
53
Operation
6 Help system
The integrated Help provides you with specific support during commissioning, operation,
maintenance and the elimination of errors.
The Help system distinguishes between help for screens, parameters, sequence instructions
and alarms:
Screens
For each screen, the associated description can be called up using the button.
Parameters
For each parameter, the description can be called up in the associated dialog box using
the button.
Sequence instructions
For each selected sequence command, the associated description can be called up
using the button.
Alarms and messages
Highlighting a message on the ’Alarms’ screen and selecting the ’Help’ command menu
button opens the description of the alarm's cause and its elimination.
If you cannot find the desired information in this manner, a content and index directory is also
available.
Core moving platen
Help
1 2 3 4 5
5 Core (Option)
Cores are movable elements in the mold which are usually inserted into the cavity before the injec-
tion procedure and are then extracted afterwards.
Cores
55
Operation
[5] Go to the table of contents and the list of alarms in the current manual.
[6] Scroll buttons (the Help text can also be moved directly using your finger).
[7] Return and advance to previously opened chapters.
[8] Closing the Help.
Example: plant table of contents for injection molding machine and robot
Help
Press the machine or robot symbol to open the overview of the corresponding manual. In the
manuals and the control panel - with the explanation of the manual buttons - the following is
available:.
Help
1 2
operator manual - machine(en)
operator panel
3
[1] Book symbol opens the table of contents of the corresponding manual.
[2] Index symbol opens the table of keywords of the corresponding manual.
[3] Opens the Help for the control panel.
57
Operation
7 Error signals
Alarms and messages that have occurred are displayed by the control unit in text format
onscreen in 2 ways:
The control unit displays the last alarm that has occurred in the red message field in the
lower left.
The ’Alarms’ screen shows all current alarms from the top down in chronological order
of their appearance.
Waiting points (class 7) are located on a separate tab on this screen.
Alarms
Info Panel
An alarm-specific Help appears when you press the corresponding alarm and then instruction
menu button Help.
Note!
The index contains a list of alarms.
The symbols beside the alarm texts specifies the alarm level/type:
For some process monitoring tasks, you can switch off the alarms, e.g. cycle stop, rejects sort-
ing, switch on alarm lamp or ignore.
WARNING!
Naturally, any other alarms that exist once again cause your messages and reactions.
59
Operation
At the end of the text, messages can still have another function or link:
The message is backed with a link. By touching the message the target is called
up and displayed.
The help has even more information. Press a message to open help.
1 2 3
5
4
Mold stroke posi-
[1] Adjustment keys for the speed profile (green) and numerical display of the current value
[2] Graphic field for speed and force or pressure profile
[3] Adjustment keys for force or pressure profile (red) and numerical display of the current
value
[4] Current position marker (dark-blue) and numerical display
[5] Mold protection monitoring window (yellow)
Closing speed
Accept change
3. Press Execute.
61
Operation
3
2
Closing speed
[4] Digital setting values for speed and force with corresponding switching positions; this
table can be switched on and off in the View menu.
[5] Menu keys for further functions
63
Operation
2 3
Closing speed
4 5
Cancel Dot -> Line Change profile Accept
Equal division of the stroke points for the current screw stroke
1. Press Profile.
2. Press Space equally.
3. Press Accept.
Autoprotect, mold protection monitoring can be activated on the set value graphics to protect
the mold during closing. Normally, mold protection monitoring is set on the mold closing screen
page.
[See Mold protection on page 79.]
65
Operation
Clamping unit
6 5
[1] Ejector
[2] Moving mold fixing platen
[3] Injection mould
[4] Stationary platen
[5] Frame
[6] Clamping cylinder
67
Clamping unit
1 Mount mold
WARNING!
WARNING!
Danger to life and limb, and danger of crushing due to floating loads!
Floating load hazard.
Molds must be mounted only by skilled staff who are familiar with trans-
portation of injection molds.
Example:
Procedure for mounting an injection mold with connected mold halves.
1. Switch to ”Setup” mode of operation. Pay attention to low closing and opening speed.
2. Open the moving platen wide with Mold opening.
3. Use a bridge to join the mold halves and insert them into the machine. Align with the
mold fixing platen where the (more exact) centering lug of the mold is located; this is
normally the nozzle side.
4. Fix mold on the right mold fixing platen.
If you have a quick mounting system, press the Mount mold on stationary platen-
pushbutton to do this. The safety gate on the clamping unit must be closed.
5. Set mold height: Close the clamping unit safety gate and switch to ”Setup” mode, with
the Mold closing key, bring the moving platen cautiously to the mold .
TOGGLE LEVER MACHINES and FULLY ELECTRIC MACHINES: Measure and enter
mold height, then switch on mold height setting.
DUO MACHINES: Before mold closing switch on the program switch Determine mold
height .
6. ATTENTION! Ejector fully back. When using an hydraulic ejector, an ejector rod which
maybe integrated into the mold, must be introduced centrally into the ejector lock. After-
wards with applied mold fixing platen keep the key pressed shortly until the mold posi-
tion actual value displays ”0” on the screen. For checking whether the new mold height
has been stored, by a minimum opening the distance of the mold fixing platen to the
mold can be compared with the display of the actual mold stroke position.
7. Set the clamping force, and actuate up, down and up a few times in manual mode.
8. Fix mold on the left mold fixing platen.
If you have a quick mounting system, press the Mount mold on moving platenpush-
button to do this. The safety gate on the clamping unit must be closed.
9. Remove the connecting elements between the mold halves.
10. Cautiously open the mold, paying attention to the function of the mold as well as any
additional equipment (cores, solenoids etc.).
11. Move the ejector with low pressure and speed to the ejector rod and attach this into the
ejector lock. Set the ejector back position on the screen.
12. Provide the mold with the required connections and any additional equipment (such as
heating/cooling temperature control circuits, pay attention to the return flow restrictor).
69
Clamping unit
Note!
The mold height must be redetermined, after mounting a new mold or after reading in a new
data set.
Actuating the Mold closing pushbutton, when the mold height is not determined, will display
this message:
Cause The actual mold position has reached a value less than the calibrated
zero position or the mold height has not been set after reading in new
parts data.
Procedure:
1. Before mounting a mold on the machine, the clamping unit is at an undetermined mold
height. In Setup mode, open the moving platen until there is enough space to install the
new mold.
2. Mount the mold on the stationary platen.
3. Close the safety gates.
4. Completely retract the ejector.
ATTENTION to the ejector rod, ensure that it is not held forward during mold height
determination!
5. Switch on Determine mold height.
The machine will now move at setup speed and with setup force. The message Auto-
matic mold height determination enabledappears.
6. Press the start button or move the platen to the mold and keep the pushbutton actuated
until the screen flag lights up. The control unit takes over the current value on Mold
height.
Value Minimum mountable mold height indicates the smallest possible mold height for this
machine.
When the moving mold fixing platen reaches this position, the following message appears:
3 Ejector
The ejector takes the molded part from the injection mold.
1 2 3 4 5
CAUTION!
Danger of damaging the injection mold by the force of the ejector drive!
The injection mold can also fall down if the fastening is insufficient or in
the case of magnetic holding plates!
Set the ejector force as low as possible.
Set the ejector advanced and ejector retracted positions precisely.
Observe the braking paths when changing speed.
Release conditions for ejector movement:
Safety gates closed
Ejector start position reached
Any additional equipment (e.g. cores, robot) in release position
71
Clamping unit
Advance profile
retract profile
For example, if the ejector is not retracted during mold closing, the following message appears
in the standard case:
Effect Depending on the sequence setting, blocks e.g. mold closing, core
moving-in, etc..
Remedy Retract the ejector, check ejector plate and ejector pins.
Example:
Procedure for coupling and setting the ejector:
CAUTION!
Open mold
200,0 mm
Ejector - shaking
2 times
73
Clamping unit
Part removal
Ejector shake counter times
Ejection control
Ejection control
Cause A molded part was not removed - ejection control was activated.
Effect The alarm lamp flashes, new cycle will not start.
Note!
A reduction of the maximum speed during parallel movements can result as the second pump
is not available for the mold movement.
75
Clamping unit
Effect Mold closing stops. In automatic mode, movement waits until the
ejector is retracted and then continues.
Sprue ejector
Info Panel
Advance profile
+
retract profile
Ejector stroke position
Sprue ejector end position
Part removal
Sprue shake counter times
The ejector check position is identical to that for the standard ejector.
4 Mold closing
Mold closing should ideally occur as quickly as possible, but with regard to mold protection
requirements for speed and pressure reductions. When the mold is safely closed, clamp force
can be built up.
For mold closing, a multi-stage speed and force profile can be set with the set value graphics.
[See Set value graphics on page 61.]
Note!
Set the speed and force with consideration to the mold protection requirements.
Use ramps with fast movements to achieve smooth stops and starts.
In the mode of operation Setup closing speed and clamping force are limited.
The adjustable strokes are measured from the closed mold. The current Mold stroke position
is displayed on the screen by a vertical line and also as a value.
Set the Opening stroke large enough so that the part can be safely ejected.
Set Mold close position to the value which the machine displays when the mold is closed
without clamping force.
77
Clamping unit
Note!
The machine switches to high clamping force when the Mold close position is reached
(except in setup mode)).
For injection and nozzle advance the mold must be closed, otherwise the following message
is displayed:
Effect Injection and nozzle advance only possible with reduced pressure,
the alarm lamp flashes.
The machine switches to the set clamping force after the mold closing when
the Mold close position is reached and
Operating mode ’Setup’ is switched off.
Clamp force
Clamp force
Note!
Set clamping force as high as needed for the injection process. Unnecessarily high clamping
force leads to increased energy consumption, causes wear and tear, and even damage of the
mold and mold fixing platen.
The set clamping force must be built up completely before injection can take place.
If the clampforce is too low, the following message is displayed:
Effect No injection process; the cycle finishes, the alarm lamp flashes, shot,
piece and rejects counter do not count.
Remedy Use the push-button to open and close the mold several times until
the clamping force is reached.
When the maximum clamping force is exceeded, e.g. by too high injection pressure in the cav-
ity, the following message is displayed:
Effect Mold closing and the injection process stop, no new cycle start, the
alarm lamp flashes.
Remedy If the error appears during injection, change the molding settings
(mean cavity pressure too high).
Note!
Observe the following hints for setting the mold protection
Set for a good effective mold protection the speed against end of the closing process as
slowly as possible.
Choose just enough force, towards the end of mold closing, to close the mold without
affecting cycletime.
Set Mold protection monitoring start on the position from which damage of the mold
can arise when an injection molded part is trapped (e.g. part height + sprue).
79
Clamping unit
The end of the mold protection monitoring is always the Mold close position. Set the
positon so that it is only reached when the two mold halves are applied.
Choose the Mold protection monitoring time greater than the time actually needed
for running through the monitoring area (pay attention to the actual value display).
When a mold protection alarm is triggered off, the following message appears:
Mold protection
Cause The mold protection has reacted, e.g. by an injection molded part
which got stuck between the mold halves.
Effect If multiple closing is set to zero, the message Multiple closing end
appears at the same time, otherwise the set multiple closing pro-
cesses start.
Remedy Check the mold, maybe set the opening stroke greater, demolding
time longer, ejector stroke and/or ejector shake counter greater.
After the expiry of the counter Multiple closings the message appears:
Cause The mold protection has reacted and Multiple closings has reached
the set number.
81
Clamping unit
Remedy Check the injection mold and the actuation of the safety switch.
Closing position 2
Closing position 3
Cause The mold is for the requested movement not on the position pro-
grammed in the sequence.
5 Mold opening
At the end of cooling time and reduction of clamp force, the mold opens at an operator set
speed profile, the injection molded part being ejected from the moving mold half.
Message examples depending on the setting of the safety conditions when the movement is
not enabled:
Remedy In manual mode, move the corresponding functional unit into the correct
position; Check the safety conditions;
A multi-stage speed profile can be set for mold opening with the set value graphics. [See Set
value graphics on page 61.]
Note!
Coordinate the speed with ejection
Use ramps with fast movements to achieve smooth stops and starts
The adjustable strokes are measured from the closed mold. The current Mold stroke position
is displayed on the screen by a vertical line and also as a value.
Set the Opening stroke large enough so that the part can be safely ejected.
The mold must be open at the start of an automatic cycle, if not, the following message is dis-
played:
83
Clamping unit
CAUTION!
Danger of mold damage!
Procedure
1. Switch to Set-up operating mode.
2. Activate the Cancel mold safetyscreen switch.
3. Actuate the pushbutton for the required movement and the safety key at the same time.
The screen switch automatically deactivates when you switch to Manual mode.
Movement to home position carries out the following movements in the programmed order:
Screw - plasticize
Open mold
Core movements
Mold opening
Opening position 2
Opening position 3
Cause The mold is for the requested movement not on the position pro-
grammed in the sequence.
85
Clamping unit
Heat Zones
1 Barrel heating
Precisely controlled barrel heaters are required for producing a thermally uniform melt. The
shear forces, during plasticizing, produce 60 to 85% of the energy required for melting the
material. The melt temperature is affected by the barrel temperature, depending on the resi-
dence time in the barrel.
1 2 3 4 5 6
8 7
WARNING!
Danger of burns in the vicinity of hot components such as the barrel and
injection mold; danger of injury due to high pressure injection!
Insufficient preliminary drying or the decomposition of certain plastics
can lead to accidental purging out of the nozzle of the feed opening.
When working on the machine, use suitable protective clothing (safety
shoes, protective gloves, face protection, ...). Observe local safety regu-
lations for operating injection molding machines!
When working in the injection mold area, make sure the nozzle is
retracted! Make sure the barrel nozzle is not touching the mold!
Observe processing and safety instructions by the material manufac-
87
Heat Zones
turer! When processing materials that can cause a health risk, always
use extraction equipment!
Maximum permitted barrel operating temperature:
+ 350 °C (662 °F)
Switch for barrel heating on control panel
Before switching on, the following message appears:
Cause The barrel heaters are not yet switched on or have been switched off
by the appearance of another alarm (see alarms on the screen).
Remedy Switch on the main switch for barrel heaters on the control panel.
Eliminate the primary error.
All zone groups are automatically heated up to reach the set point at approximately the same
time..
If all barrel heaters have dropped below the lower tolerance limit, two minutes of heat soaking
starts, to protect the screw tip. The following message is displayed:
Effect All screw movements are blocked, no cycle start possible, when actu-
ating the start button the warning light flashes
The set values for the individual heating and cooling zones, and the tolerances can be set on
screen. Click the icon in question to view a descriptive text for the zone.
Barrel heating
Info Panel
Set value
pos. tolerance
neg. tolerance
Minimum monitoring
A graphic field with symbol is displayed for each temperature zone with the following settings:
Set value (dark line)
Actual value (red and/or blue bar with digital display)
Tolerance band (green field)
Status display for:
89
Heat Zones
Heating soaking
The set values and tolerances can be set individually. Set them equal with [=] all zones of a
group or displace them proportionally with the arrow keys. Observe the given tolerances from
the material manufacturer.
The feed throat temperature (material feed opening) is closed loop controlled with water cool-
ing. Temperature control is important for feed performance and flow capability of the material
(no lump formation, uniform plasticizing time).
A temperature profile that increases towards the nozzle is often required with a standard
screw. Machines that use barrier screws would use a decreasing temperature profile.
The screw type in the barrel heating group parameters can be set as of user level 13.
Screw Standard
Standard
Barrier
Barrier screw
Barrier screws can be used for semi-crystalline and amorphous thermoplastics. Excellent plas-
ticizing performance and improved homogeneousness of the molten material can be expected
due to the modified screw geometry.
To allow for sufficient surface fusing and melting upstream of the barrier area, you need to set
far higher temperatures for the inlet area than for the 3-zone screw.
A temperature profile that drops towards the nozzle is also recommended.
Setting too low a temperature at the inlet leads to a drop in plasticizing performance and to
undissolved particles being transported towards the screw tip, and thus to far higher wear and
tear.
If the machine has a barrier screw, and you set a rising profile, the following message appears:
Setting too low a temperature at the inlet leads to a drop in plasticizing performance and
to undissolved particles being transported towards the screw tip, and thus to far higher
wear and tear.
Cases of wear and tear due to incorrect temperature settings are not covered by warran-
ty!
The control unit will not apply the values you have entered until you press Execute.
91
Heat Zones
pos. tolerance
neg. tolerance
Minimum monitoring
Barrel heating zone x too hot Mold heating zone x too hot
Cause The actual value of at least one zone is above the set positive toler-
ance.
Effect At barrel heaters: Alarm lamp flashes, current cycle is finished, motor
switches off delayed, heatings switch off immediately.
In mold heaters, the error reaction can be set in the ’Heating configu-
ration’.
Barrel heating zone x too cold Mold heating zone x too cold
Cause The actual value of at least one monitored zone lies below the set
negative tolerance.
Effect At barrel heaters: All screw movements are blocked, current cycle is
finished, no cycle start possible.
In mold heaters, the error reaction can be set in the ’Heating configu-
ration’.
Remedy Wait until the temperatures are within the tolerance limits.
Note!
Switching off Minimum monitoring is possible only with a certain access authorization level.
Danger of the screw tip breaking (see Technical Manual -)!
Standby is active:
when switching the program on manually with the screen switch for the group
when an alarm appears which brings the machine to a standstill for all zones
Message:
Remedy After eliminating the main error and switching off the screen switch,
the group heats up to the set value.
93
Heat Zones
Compact/normal
Screen switch for switching between the compact and the normal representation of the
heating zones.
To change the settings, tap the bar graph of a zone:
The dialog window for changing the zone settings and control parameters opens:
Hot runner 1
Values
Set value
pos.tolerance
neg.tolerance
Minimum monitoring
Changes can be made for the selected zone in the line Values . In the line Accept for all
zones of this type , you can use the screen switches to accept the changed values for zones
of the same type.
Effect Screw rotates at max. 0.100 m/s, no back pressure for hydraulic
injection units
If the maximum value is exceeded on testing the torque, the screw stops turning and post-
soaking is performed.
95
Heat Zones
Cause The material is not yet fully plasticized and the maximum torque was
exceeded.
Remedy If the error occurs multiple times in succession, the barrel tempera-
tures may be set too low.
Soaking inspection restarts the next time the screw rotates. If soaking inspection is performed
without exceeding torque limits, plasticizing occurs with the set values.
Set value
pos. tolerance
neg. tolerance
Minimum monitoring
Set value
pos. tolerance
neg. tolerance
Minimum monitoring
You must switch on the mold heatings with a separate switch on the control panel. The follow-
ing message is displayed before switching on:
Cause The mold heatings are not yet switched on or have been switched off
by the appearance of an alarm (see Alarm page on the screen).
Remedy Switch on the mold heating at the control panel or eliminate the main
error.
97
Heat Zones
For mold heating controls, see barrel heating. [See Barrel heating on page 87.]
The zones available on the machine can be displayed or hidden as needed. It is also possible
to enable monitoring of individual error reactions.
99
Heat Zones
Injection unit
WARNING!
1 2 3 4 5
8 7 6
101
Injection unit
1 Nozzle
The injection unit moves with the nozzle to the sprue bushing of the mold and builds up an
adjustable contact force. To prevent the nozzle from cooling off too much, or to tear off the
sprue, cyclic retraction can be set, if necessary.
Locking conditions:
Nozzle advance is released when the safety gates on the clamping and injection unit
are closed.
Nozzle return is released when the safety gates on the injection unit are closed. In the
manual mode you can always return up to the maximum stroke.
retract profile
Multi-stage speed profiles can be set, for the advance and return of the nozzle, with the set
value graphics.
[See Set value graphics on page 61.]
Note!
When setting, ensure that the nozzle makes smooth contact with the mold.
Contact force
Nozzle stroke
If a value greater than 0 is set for the nozzle stroke, the nozzle retracts in automatic
mode.
Force build-up time
A force buildup time of approximately 0.2 to 0.3 s is required to permit a contact force to
build up.
Contact force
The Contact force is the force which presses the nozzle against the mold at the injection
and plasticizing process.
Set the force high enough so that no material escapes between nozzle and mold.
Contact force during part removal
Effective force for contacting nozzle without built up clamping force.
Observe the load bearing ability of the right mold half in case of open mold!
Delay time retraction
The nozzle retracts, depending on the set sequence program, at the end of plasticizing
or at the end of hold pressure, after the Delay time retraction.
Nozzle safety position
To prevent squeezing and shearing points in the nozzle area, the nozzle stroke is limited
in automatic and manual mode. In manual mode, you need to actuate the safety button
to fully advance and return the nozzle.
If the nozzle is not within the limited nozzle stroke, the following message is displayed:
103
Injection unit
Remedy Press the safety key again to move the nozzle into the permitted noz-
zle stroke range.
The nozzle contact position must be ascertained before switching over to automatic mode;
otherwise the following message is displayed:
The nozzle must make contact to inject; otherwise the following message is displayed:
Effect Injection only possible with reduced pressure, the warning light
flashes.
On machines with parallel movements the advancing starts parallel with mold closing. The set
Start position nozzle advance refers to the mold stroke.
2 Inject
1 2 3 4
During injection, the screw, with a non-return valve, becomes a piston. The molten material is
injected into the mold, under high pressure at a set speed profile, by the forward movement of
the screw. The melt freezes quickly in layers closed to the walls of the mold. The mold filling
phase is specially critical for the surface appearance, orientation, crystallinity of the part.
Locking conditions:
All safety gates closed
Barrel temperature within the tolerance
When the mold is closed, for purging the preselected clamp force must be reached.
Reduced injection occurs with an open mold or unapplied nozzle when the safety button
is not actuated at the same time;
105
Injection unit
Injection profile
1 2 3
Shot volume
A multi-stage speed profile can be set for the injection process with the "set value graphics".
[See Set value graphics on page 61.]
The speed peak value (green field) and the current speed display are available as additional
process information on the screen.
Injection pressure
Specific injection pressure limit
Specific injection pressure peak value
Stop injection at pressure limit
Increased specific injection pressure
The set Injection pressure limit can be considered as a safety setting for the mold. The injec-
tion resistance changes due to variations in viscosity of the material or fluctuations in temper-
ature during production. For consistant quality the machine must closed loop control the set
speed exactly until reaching the switchover point. This is only possible then when the injection
pressure limit is set higher than the actual injection pressure. Ensuring tha).
Example:
Injection process
6
2
3 4 5
s
t
[1] Set injection pressure limit (e.g. 10% higher than injection pressure peak value)
[2] Required injection pressure for overcoming the injection resistance
[3] Set injection speed
[4] Set switchover point
[5] Mechanical end position of the screw
[6] Holding pressure
Effect The set injection speed cannot be reached. Cycle continues to run
with injection hold pressure time (without pressure), shot is consid-
ered as rejects, no new cycle start.
107
Injection unit
Effect The automatic cycle stops, the rejects and shot counter are incre-
mented, the piece counter is not.
Cause Changeover pressure to hold pressure reached too early due to:
Sprue frozen-in and/or sprue channels blocked, cavity not demolded,
temperatures not correct.
Effect The automatic cycle stops, the rejects and shot counter are incre-
mented, the piece counter is not.
Intrusion speed
An increase of the maximum shot volume is possible in special cases by the intrusion, but it
must be plasticized up to the mechanical stop before in order that the screw can be supported.
By setting the intrusion time higher than 0 the screw turns before the injection and intrudes
material into the mold with the set speed.
Choose the method of switchover that produces the greatest repeatability of part quality. Only
one method of switchover to hold pressure is possible. When one method is selected the pre-
vious is automatically switched off.
If the ’move in cycles with mold safety’ program switch is activated in the move in cycles tab
on the production screen when you select ’Volume-dependent switchover’ , the following dia-
log box appears.
Startup cycles mold safety active
Start-up cycles check switchover volume!
Switchover volume
The chosen method of switchover, indicated by a flag, along with the current switchover value
is available as important processing information.
This switchover method has generally proved successful if there are fluctuations in viscosity
and temperature.
A different switchover value may be needed on starting up production. The start-up cycle
switchover volume applies for the number of start-up cycles set. [See Production on
page 122.]
When time dependent switchover method is used, hold pressure is initiated after the set swi-
tchover time.
Switchover range
Specific pressure at switch over
Specific injection pressure peak value
This switchover method has mainly proved successful when volume variations are the main
problem. Some reasons for volume variations are e.g.:
109
Injection unit
The injection pressure - less the injection resistance - is always proportional to the cavity pres-
sure.
The pressure increase, which arises when the cavities are filled, will cause switchover. There-
fore, always choose a switchover pressure lower than the injection pressure limit.
Injection pressure-dependent switchover also provides good mold safety as the machine
always switches to hold pressure immediately at a certain pressure setting.
A pressure spike at the beginning of injection will cause a premature switchover, a Switchover
window must be set so that the machine switches to hold pressure within that window.
P
possible pressure peak
Switchover pressure
Switchover range
t
The injection pressure peak value and the current pressure display also provide important
process information on screen.
External switchover
External switchover
???
A signal from an external device enables the switchover to hold pressure, when "External swi-
tchover" is selected.
On parallel switchover the activated switchover type whose criteria are fulfilled first triggers the
switchover process after reaching the switchover area.
3 Holding pressure
The screw still presses on material via the fluid center of the molded part during the first coo-
ling phase in order to compensate for the shrinkage of the material. The injection hold pres-
sure compresses the melt and therefore produces those quality characteristics which depend
on part density.
For the hold pressure phase for the different optimization aims a multi-stage hold pressure pro-
file can be set with the set value graphics. [See Set value graphics on page 61.]
The hold pressure peak value (green field) and the current pressure display are available in
addition as important process information on the screen.
Too low hold pressure causes: Too high hold pressure causes:
111
Injection unit
An increase of the melt temperature, of the mold wall temperature and of the holding pressure
delays the gate freezing off.
As the mold has a different temperature to the melt, the cooling time begins with the entry of
the melt into the mold.
With the end of hold pressure, the set cooling time starts. Upon expiry the mold opens. The
cooling time essentially depends on the plasticizing process and on the demoldability of the
molded part.
cooling time
cooling time
Shot volume
Shot volume
The control unit displays on the screen the material cushion, which still remains in the screw
antechamber of the barrel until the end of hold pressure. The remaining melt cushion should
be approx. 5 to 10 % of the shot volume.
Monitoring is also provided. When monitoring is switched on, the following impact is seen,
when the measured value lies outside the set tolerances:
Message:
Cause The melt cushion is under the set limit, e.g. due to volume variations
of the material, escape of material between nozzle and sprue bush,
leaks on the non-return valve,
Effect Message only, the rejects and shot counter increment, the piece
counter does not. The automatic mode only stops when exceeding
the allowed rejects.
Remedy Increase the metering stroke, back pressure, contact pressure of the
nozzle, replace the non-return valve on the screw
Cause The melt cushion is over the set limit. Possibilities: Sprue frozen-in or
blocked, one cavity has not been demolded, temperatures incorrect.
Effect Message only, the rejects and shot counter increment, the piece
counter does not. The automatic mode only stops when exceeding
the allowed rejects.
After the installation of a barrel with another screw diameter for calculating the specific injec-
tion pressure the correct screw diameter must be set. Message:
113
Injection unit
4 Plasticizing
1 2 3 4
During plasticizing the nozzle often remains applied and is closed by the cavities filled previ-
ously. The screw conveys the material plasticized by the shear forces and hot barrel liner into
the screw antechamber. This accumulation of material in the antechamber moves the screw
backwards, against an operator set back pressure to ensure good and uniform plasticizing.
Locking conditions:
All safety gates closed
Barrel temperature within the tolerance
Shot volume
Shot volume
The whole cooling time can be used for plasticizing, without sacrificing cycle time. The setting
of a multi-stage profile for the peripheral speed and the back pressure is possible on the set
value graphics. [See Set value graphics on page 61.]
The current peripheral velocity of the screw ’’V’’ as well as the back pressure peak value
(green field) and back pressure actual value are available as information on the screen.
Shot volume
Sufficient shot volume must be set, for filling the mold. The required residual melt cushion at
the end of hold pressure should be approximately 5 to 10% of the plasticizing stroke. For a
mold filling study at start-up, a short shot must be set initially and then must be increased grad-
ually. In the ideal case the plasticizing stroke shall lie in the range between 1 and 3 screw
diameters. Otherwise especially thermal problems, surface marks and volume variations can
arise.
If plasticizing time monitoring is activated, and if the measured value is outside the preset
tolerance, plasticizing stops.
Cause The set plasticizing monitoring time has been exceeded e.g. by feed
problems or insufficient material.
Effect The alarm lamp flashes and the plasticizing stops, the current cycle is
finished, delayed motor stop and delayed switch to standby tempera-
ture.
Remedy Refill material, check material feed chute and feed throat tempera-
ture.
115
Injection unit
Cause The set plasticizing monitoring time has not been reached. Previous
cycle screw stroke was too short.
Effect The alarm lamp flashes and the plasticizing stops, the current cycle is
finished, delayed motor stop and delayed switch to standby tempera-
ture.
In addition, the plasticizing time Last cycle and the current time are displayed on the screen,
as important process information.
Effect The machine automatically plasticizes until the preset shot volume
has been reached.
Note!
This program can be activated in the Variables Monitor, in the ’Plasticizing’variables list by
setting the variable Release separate back pressure in manual mode.
In this context, we need to mention the plastifying count which is available in the process data
package. This shows the mean hydraulic pressure in bar (psi) during plastifying for the whole
metering area.
117
Injection unit
Production programs
last current
Mold close
Nozzle
Inject
Holding pressure
cooling time
Plasticizing
Mold opening
Ejector
Cores
Part removal
Total time
View
1 2 3 4
[1] Scroll window to the left
[2] Set to full cycle time
[3] Magnify and minimize
[4] Scroll window to the right
The current and the last cycle are displayed separately in seconds, and on two-line bar graph-
ics. The top bar shows the current cycle, the lower bar the last one. Dark points on the bars
indicate force/pressure build-up and reduction as well as movement direction changes.
Screen flags mark the function that is currently active.
119
Production programs
+ Monitorings
Activation
Switch the monitoring systems back on
Switch off all monitoring systems
Cushion monitoring
Minimum cushion Maximum cushion
Activation
Switch for switching on/off all monitoring systems.
Monitorings
[See Injection time monitoring on page 108.]
[See Cushion monitoring on page 112.]
[See Plasticizing time monitoring on page 115.]
Effect The machine stops cycling immediately and switches into ’MANUAL’
mode. A delayed motor stop and delayed switch to standby heats is
initiated, the alarm lamp flashes.
Remedy Check at which movement the machine stopped. You can refer to the
alarm screen to determine which error caused the malfunction. You
should also check the waiting points. Then move the machine to the
start position.
121
Production programs
3 Production
Production data is displayed on a dedicated screen page.
Production
Info Panel
Production counter
Piece counter Shot counter
Number of cavities pc
Good parts - set value pc Sht
Production counter
Number of cavities
The piece counters always count with the set cavity number.
Good parts - set value
After the desired production amount is input, the corresponding shot and piece counters
count in the automatic cycle.
Good parts total
If the piece counter reaches the set value, the machine finishes production.
Reject - startup cycles
Rejects counter for set start-up cycles at start of production or when the cycle is inter-
rupted.
Production rejects
Rejects during production occur when monitoring systems are triggered, such as the
injection cycle, Micrograph, quality programs, mold temperature.
Total rejects
Start-up cycles rejects + production rejects.
Production total
If the shot counter reaches the set value, the machine finishes production.
A green pie diagram shows the ratio of good parts produced to the set good parts
value.
A red pie diagram shows the reject rate related to total production.
Message when the piece counter for good parts or the total rejects counter elapses:
Effect The alarm lamp flashes, the cycle finishes, a delayed motor stop and
heat reduction to standby is initiated.
Remedy To continue production, use the [R] key to reset the actual shot or
piece value back to 0.
Shot weight
Input for calculating the remaining material requirement.
Remaining material requirement
Display of the remaining material requirement for the remaining number of pieces.
When inputting the available amount of material, the set piece value can be calculated.
123
Production programs
Start-up settings
Start-up cycles set value Sht
Start-up settings
Start-up cycles set value
Adjustable total amount of start-up cycles with rejects sorting and post injection pres-
sure in percent of production parameter.
Start-up cycles actual value
Display of the start-up cycles with the reset key
Start-up cycles after automatic interruption of at least
The machine starts again with the start-up cycles after an interruption to the cycle that
lasts longer than the preset time .
Start-up cycles with own switchover volume - set value
Adjustable number of parts of the start-up cycles set value with a separate Start-up
cycles switchover volume.
Cause Production is currently in the start-up phase with the set start-up
cycles.
If the start-up cycles are set with their own switchover volume, a switchover volume must be
set; otherwise, the following message appears:
Remedy Set the start-up cycle switchover volume to a volume that just about
fills the mold.
125
Production programs
Rejects
Rejects signal
Maximum rejects per time Sht
Actual rejects Sht
Time period for rejects min
Rejects
2 rejects counters are available to control production, they can be activated by a set value set-
ting larger than 0.
Maximum rejects per time
Resetting the rejects counter actual value after Time period for rejectshas elapsed.
Max. rejects sequence
Adjustable rejects directly in succession. Automatic reset for good part production.
Action for sequence max. rejects/max. rejects in succession
Optional actions Warning or Production stop when reject counter elapses.
Remedy Determining the cause of rejects with the help of additional alarm
messages.
Switch the program interruption key on/off.
4 Mold parameters
This screen is used to save mold-specific information.
You can use the screen editor to add strips and variables, e.g. for additional units to this
screen.
Mold parameters
Info Panel
+ Mold data
Mold number Recorder housing
Material number
Machine number
127
Production programs
5 Data dialog
The data dialog box is used to save and load data sets on the machine or on external storage
media (Compact Flash, USB stick, network).
The screen page appears after switching on the control unit and/or after pressing the screen
page selection key.
Data dialog
Info Panel
Change date
Description
Machine number
Mold image
6
Parts data Edit Setup View 7
Note!
Problems may occur if you use other USB devices that have not been tested.
If you select a data carrier with insufficient free storage space, the program will cancel the save
operation and display a message. The message shows which data carrier is full, along with the
last file that was completely stored on the data carrier.
129
Production programs
Remedy Select a data carrier with more free space and try to save again.
Example:
Procedure for opening a sequence preview.
Parts data
2. Press the instruction menu key parts data and sequence preview.
3. A window with the sequence preview appears:
Sequence preview
Retract ejector
20,0 mm
Mold closing up to position 1
200,0 mm
Move in core stationary platen
Mold - close
0,0 kN
Nozzle - build up contact force
20,0 kN
Screw injection
Screw - plasticize
Help OK
Note!
The sequence preview is stored as a parts data element. To make sure the preview is up to
date, always save your parts data after changing the machine sequence.
A preview of the robot sequence is not possible.
If a preview is not available for a parts data set, the following message is displayed:
131
Production programs
Sequence preview
OK
Sequence data
Machine settings
Robot
Sequence data
Machine settings
Sequence data
In the sequence data only the machine or robot sequence is stored. When you only read in the
sequence data, only the sequence changes. Parameters such as speeds, pressures, posi-
tions,... do not change.
Machine settings
In the setting data all parameters such as speeds, pressures, positions,... are stored. When
you only read in the setting data, only these parameters change. The sequence does not
change.
Example:
Procedure when loading an existing parts data set from a data carrier.
Values corrected
Remedy On the screen page Plausibility check open the window corrected
values and check which parameters have been corrected.
Acknowledge the message in this window.
Note!
If you read a parts data set from another plant, the following message is displayed:
EMOTION_TEST
The data set has not been created with this machine
Continue anyway?
Example:
Procedure for saving an active parts data set on a storage medium.
1. Select the active parts data set with the key at the top right of the screen.
2. Enter name and information in the Data set attributes window.
3. Select the storage medium. usbmassstorage.0.0.0\ is a USB memory stick,
harddisk0\ is the control unit's internal memory.
4. Press ’Parts data’ and ’Write’.
The following window is displayed
Write active parts data on
Available drives
Description
5. Change the set attributes, when necessary, and confirm with Write.
The control unit stores the parts data set on the selected drive.
6. If a data set with the same name already exists on the data carrier, the dialog window
’Overwrite ??’is displayed. If YES, press Execute.
133
Production programs
Available drives
2. Select the Source drive and the Aim drive to which you will be copying the data sets.
3. Press Execute to start the copying process.
4. The dialog box disappears once the copying process has been completed.
If you attempt to copy a data set from the source drive that has the same name as an existing
data set on the aim drive, the following message appears:
Overwrite?
.Standard sequence
Cancel
This data set will not be copied to the aim drive. Continuing copying other data sets.
Execute
The data set on the aim drive will be overwritten by the data set on the source disk.
135
Production programs
5.8 Export
The export function gives you the ability to export the settings data and machine and robot
sequences in various file formats.
Exporting machine and robot sequences is only possible in HTML file format The sequences
are additionally saved as PNG images.
Example:
Follow these steps to export the settings data for the machine.
1. Press the Parts data and Injection protocol keys. The following dialog box appears:
Export
0 of 34 selected
Production
Mold close
Compression
Mold height
Mold opening
Venting
Air valve
Ejector
Machine sequence
3. Select the screens for the protocol, and press OK to continue. The following dialog box
appears.
Save
Selection:
File name:
File type:
4. Select the drive you wish to export to, as well as the file name and the file type.
If you selected the machine or robot sequence, you can only select HTML as a file type.
The sequences are additionally stored as PNG images with the file name and extension
’_imm_xxx’ or ’_erc_xxx ’.
5. Press Save to start exporting. The following dialog box appears.
Export
Cancel
6. A progress indicator appears for the Export process. The dialog is closed after success-
fully completing the export.
137
Production programs
6 Notepad
The note screen page is used to store special production information.
Notepad
Info Panel
+ Notes
Training (se-
The left column shows, for selection, all message with titles and author's user name.
New
Creates a new note; you can enter your own title and content.
Edit
Lets you edit the selected note.
Save
Saves the new/changed note.
Delete
Deletes the highlighted note.
7 Print
The control system offers printing processes from different programs as well as the printing-
out of screen pages. The CC200 control system supports printers which are PCL-3-capable
and whose manufacturers observe this specification exactly. For printing on the spot at the
machine you must connect one printer to a USB interface on the front panel.
When the machine is connected to a LAN network, printing to the networked printers is possi-
ble.
The following printer types are tested for the CC200 control unit:
Local printers with USB connection
Manufacturer Type
Manufacturer Type
The control unit offers the following printing possibilities of screen pages (masks):
a hard copy of the current screen page with screen page selection keys
a graphic printout of the current screen page
several graphic printouts of a selection of screen pages
textual printout of the current screen page
textual printout of a selection of screen pages
A hard copy as PNG picture and graphic printouts of individual or several screen pages can be
stored in Postscript format as file.
139
Production programs
An export function in the Data dialog permits text output in file format.
Example:
Graphic or textual printout of screen pages on a local printer:
1. Connect a printer with USB cable and switch the printer on.
Text printing
3. Press Setup
Settings for screen page output
Printer settings
Output on printer
Compress PS
Settings for printing to file
Print to file
Type
Directory
File name
Cancel Help OK
4. Switch on Output on printer . In addition, the selection possibility print to file is still
available. [See Output of the current screen page as hard copy in file format: on
page 141.]
5. When switching over to ’Output on printer’ the printer dialog appears of the currently set
printer. Select the local printer and press OK.
6. When you want to have a text printing, switch on Text printing.
Production
Freely programmable in/outputs
Shut-off nozzles
Minicam
Mold close
Mold height
Mold opening
Printer settings
Output on printer
Compress PS
Settings for printing to file
Print to file
Type
Directory
File name
Cancel Help OK
141
Production programs
Selection:
143
Production programs
1 Machine sequence
The machine sequence serves the graphic representation, change and creation of program
sequences. The representation of the sequence is possible in each mode of operation and in
each user level. For creating or changing a sequence you need the user level 7 or higher.
Moreover, the machine must be in the mode of operation Teach .
Into these sequences you can program the different machine movements and instructions.
Machine sequence
Info Panel
Machine sequence 2
Instructions: 1
Mold 3
Nozzle
Retract ejector
Screw
20 mm
Ejector Mold - close
200,0 kN
Core moving platen Nozzle - build up contact force
All cores 23,5 kN
Freely programmable
Time
Wait until
4 5 6 7 8
Standard Times Program Edit View
145
Machine sequence and Mask Editor
For a better overview, the sequence is subdivided into three sequences. These sequences
contain individual program steps.
Click the + Icon to the left of the sequence to open the sequence. This displays all the program
steps programmed for the sequence.
Retract ejector
20,0 mm
Mold - close
200,0 kN
Nozzle - build up contact force
23,5 kN
Next to the program steps is a short text which describes the step.
You can fade the text in and out with the menu key View + display text.
Select a step by tapping the symbol. The selected step is now shown with a red border.
Retract ejector
20,0 mm
When you touch the symbol once again, a dialog window is displayed
The dialog box is used to configure the selected step in the sequence.
Depending on the selected movement set and actual values may be available.
The set value in the dialog box is the same set value as shown on the screen for the current
movement.
The dialog box may also contain programming notes for the display e.g. Attention - already
programmed.
In fully or semi-automatic mode, the control unit will display a green arrow to indicate the cur-
rent step if you have enabled the Step indicator . Steps that have been successfully com-
pleted are marked with a green checkmark.
In a parallel closed branch, all movements must be completed before the next movement can
start.
In a parallel open branch, the next step in the main branch starts without waiting for the step in
the parallel open loop to complete.
147
Machine sequence and Mask Editor
Inactive steps are indicated by a red strike-through. These steps are ignored when the
sequence runs.
Depending on your machine configuration, various data sets with sequence templates may
exist.
Screw
inject
Screw - plasticize
Nozzle - retract
Note!
Save the current parts data set before loading a sequence in order to save the changes you
made.
Data dialog
Info Panel
2. Press the + symbol for the data set you wish to load.
3. Touch the + Symbol in front of injection molding machine.
149
Machine sequence and Mask Editor
Cancel
Cancels the parts data reading
Execute
Starts the parts data reading. Changes you made which were not saved are lost
7. When the parts data reading starts, a window appears. When this window disappears,
the parts data reading is completed
Read
Sequential sequence
Compression sequence
When you load a sequence with components unavailable on the machine, the following mes-
sage is displayed:
A note appears on the machine sequence screen telling you which movement is not available.
Component not available: Mold swivelling device 1 does not exist
Component not available: Nozzle 2 does not exist
Component not available: Screw 2 does not exist
If you press the blue arrow, the indicator will jump to the position in the sequence where the
missing movement is programmed.
These movements are tagged with a caution icon in the machine sequence.
Cancel
Cancels exiting Teach mode. The sequence is not saved.
151
Machine sequence and Mask Editor
Undo
Teach mode is exited. No sequence changes are saved.
Execute
Teach mode is exited, the changes to the sequences are saved.
When an incorrect setting is detected during the calculation of the safeties an error appears
and the following message is displayed:
The machine sequence message window displays a note on the step in the sequence that is
causing the error. Press the blue arrow at the end of the message to jump to the position in the
sequence.
Movement as single movement not allowed: Mold closing 500.0 kN
Note!
The sequence is saved in the parts data. Therefore rewrite the parts data after saving the
sequence.
CAUTION!
When you switch to Teach mode, the machine sequence background switches from gray to
white.
Effect Movements with the pushbuttons like in setup mode. Writing and
reading of data sets is not possible
153
Machine sequence and Mask Editor
Instructions
Mold
Nozzle
Retract ejector
Screw
20 mm
Ejector Mold - close
200,0 kN
Core moving platen
Nozzle - build up contact force
Core stationary platen 23,5 kN
All cores
Air valve
Venting
Freely programmable
Delivery chute
Vacuum equipment
Time
Wait until
You program the machine sequence by inserting or removing instructions from the sequences.
Thus you can adapt the machine sequence to your demands. Engel delivers the machine with
a standard sequence.
Note!
Write the parts data before programming a sequence in order to store the parameter changes
you made.
If you change the sequence, you must save the change in order that the machine can calculate
the safeties. Only after saving machine movements are possible.
When an incorrect setting is detected during the calculation of the safeties an error appears
and the following message is displayed:
The machine sequence message window displays a note on the step in the sequence that is
causing the error. Press the blue arrow at the end of the message to jump to the position in the
sequence.
Movement as single movement not allowed: Mold closing 500.0 kN
1.6.1 Instructions
Movement and structure instructions are available for programming the machine sequence.
The number of available instructions depends on the machine equipment. The most common
instructions are listed here.
Movement instructions
Core moving platen Move in or move out cores on the moving mold fixing
platen
155
Machine sequence and Mask Editor
Core stationary Move in, move out cores on the stationary mold fixing
platen platen
Air valve
cooling time
structure instructions
Time Waits until the set time has expired, only afterwards the
sequence continues. 6 adjustable times are available
Parallel open Inserts a parallel branch, but does not wait for the end of
branch the parallel sequence.
Example:
Inserting the Air valve - blowing instruction after mold opening in the opening sequence
2. Click the position in the machine sequence where you wish to insert the air valve. In this
case Mold - opening.
3. A dialog window is displayed. In this window you can set the necessary parameters for
the instruction.
Air valve
Number
Action Blowing
Blowing time
Blowng time actual value
4. Press Execute. You have now added the instruction to the machine sequence!
Example:
Change the blowing time of an air valve to 2 seconds.
1. In the machine sequence, double click the instruction you wish to modify. A dialog box
appears.
Air valve
Number
Action Blowing
Blowing time
Blowng time actual value
2. In the dialog window you can change the parameters of the instruction. Change the
blowing time from 1 to 2s.
3. Press Execute. The changed parameters are taken over and the dialog window closes.
157
Machine sequence and Mask Editor
Example:
Removing the Air valve - blowing instruction from the opening sequence.
1. Highlight the Air valve - blowing instruction in the machine sequence by tapping it. The
instruction is now outlined in red, and is thus selected.
Open mold
350,0 mm
Air valve - blowing
1s
Advance ejector
20,0 mm
Retract ejector
20,0 mm
2. Press the menu keys Edit and Remove. The instruction is now erased from the
machine sequence.
You can undo the removal by pressing the keys Edit + Undo.
Options
1 Core (Option)
Cores are movable elements inside the mold, which generally move into the mold before the
injection process and move out afterwards.
Injection molded
part:
Cores
In addition, depending on the equipment of the machine and setting of the program sequence,
certain safety conditions must be fulfilled. Message examples:
Remedy In manual mode, move the corresponding functional unit into the correct
position; Check the safety conditions;
Each core is equipped with a separate pushbutton for moving in and out. The same locking
conditions as in Automatic are valid (mold position, situation of the core positions, etc.).
When a core moves out of position (limit switch deactuated) during the mold movement, the
movement stops immediately - message:
159
Options
Effect Mold, ejector, other core movements are blocked, also injection if the
mold is not open. In automatic mode cycle stop.
Remedy Move the core in/out in manual mode, check the limit switch.
CAUTION!
The program checks the chosen core setting in connection with the end position jumper.
In case of error, message:
Cause Core limit switches are defective or actuated at the same time.
Effect The core movement as well as the closing and opening are blocked.
Effect The core movement as well as the closing and opening are blocked.
Effect The core movement as well as the closing and opening are blocked.
Effect The core movement as well as the closing and opening are blocked.
Effect The core movement as well as the closing and opening are blocked.
161
Options
at mold open
at mold closed with clamp force
at a mold intermediate position
parallel to the mold movement
Example: Move core in and out with open mold
Closing sequence Opening sequence
Closing sequence
3. Remove the jumper plug and connect the limit switches and safety switches.
4. Choose the screen page Core moving platen. The switch Activated must be switched
on.
Two green round flags beside move in and move out display that the core is built into
the sequence.
Time-dependent
Core actuation time
Monitoring time
Speed output
Pressure output
Core actuation
Core in end position
Core end position status
The respective flag for Core actuation lights during a core movement dark-red.
A dark-green flag for Core in end position position displays the respective end position for
moved in or moved out.
The flag for Core end position status indicates whether the core is retracted or advanced
(this is valuable information especially in time-dependent operation).
The two flags of the safety switches saw must be active for each core movement. When not -
message:
Remedy Check the position of the ejector plate and ejector pins
163
Options
With the switch Deactivated in the sequence on the screen it is possible to deactivate the
core in the sequence. The machine then runs the cycle sequence without core movements.
If you actuate with deactivated core with the pushbuttons a core movement, for the respective
core a message appears:
Cause The core has been actuated with the pushbutton although it is not
used in the sequence or is deactivated in the sequence.
Note!
Take into consideration the amount of the braking stroke when setting the monitoring point
Pressure output
You can configure a separate speed and pressure in each direction of movement for each
core. The holding pressure and speed outputs only take effect if the cores are not switched off
at final limit position and the machine is equipped with a 2 pump hydraulic system.
Manometer
Monitoring time
Cause The core has not reached the limit switch for the stop position within
the set monitoring time.
Effect Mold, ejector, core movements and the automatic cycle are stopped.
Remedy Move the core in and out in manual mode to check the limit switch.
Also, in manual mode maintain the timing of the set core sequence.
Switched on time-dependent:
The core continues to move until the actuation time has expired.
Note!
Bridge the unused limit switches with the jumper plug
Activate core shaking by programming a Shake core step at the required position in the
sequence.
After programming core shaking, the setup parameters are displayed on the screens in ques-
tion.
165
Options
Delay time
You can set delays for moving in and out for core shaking. The move in delay is only
effective for the first move in.
Core shake counter
Number of shaking strokes the core performs.
If you set the shaking counter to 0 the core shaking step is not active in the sequence.
Position at cycle end
If you need to move the core in, for example to take off a molded part, select moved in.
The core will not move out until before the start of the next cycle in this case.
Finish core shaking on ejection control
Core shaking stops immediately when the ejection control monitor triggers, and the
sequence continues.
Program for pneumatically or electrically operated cores. Activation of the 24V outputs without
hydraulic pressure and speed actuation.
2 Air valve
A solenoid air valve offers the possibility to switch on compressed air for certain mold or
machine functions. The valve is mounted near to the stationary platen.
Air valve
Info Panel
+ Air valve
Blowing time 1,00
Air valve 1 actuation DO021
For activating the air valve switch on the screen swich and insert in the machine sequence the
instructon ’Air valve - start’ for the air valve on the corresponding position. The air valve
switches off after the set ’Blowing time’ , only afterwards the sequence continues.
The instruction ’Air valve - stop’enables the stopping of the air valve before the expiry of the
blowing time.
167
Options
Example:
Air-supported demolding of a molded part.
Actuate air valve as of opening position 1 and stop after blowing time has elapsed or at end of
ejector movement.
Note!
Air valve actions are blocked according to the regulations EN201 with an open safety gate, as
movements operated by compressed air can produce dangerous situations.
WARNING!
Although an open safety gate interrupts the electrical actuation of the air
valves, a dangerous movement could occur. Movrements due to the fail-
ure of the compressed air supply or by a loose hose - CANNOT be
ignored.
The machine operator has to ensure that, when opening a gate, no dan-
gerous movement can occur. This can be achieved with suitable safety
gates.
3 VirtMold Program
The VirtMold program is used to simulate ENGEL injection molding machines and robots with
CC/EC200 control units. It permits parts data sets to be created, edited and tested on a PC
without interrupting the production process. The data sets can be exchanged at any time
between a real machine and VirtMold.
Note!
Before installing VirtMold, close all other applications.
3.2 Installation
VirtMold consists of the VirtMold basic simulation plus one or more machine simulations.
Note!
The installation of additional machine simulations does not require reinstallation of the Virt-
Mold basic simulation.
The ’Install Virtual Machines’ window appears automatically after completing the installation,
or can be selected in the Start menu - Programs/ENGEL VirtMold/Copy machines.
169
Options
Select the desired machine in selection box Virtual Machines to be installed (check the field
in front of the machine number or name ) and click Install.
Files are now copied to your computer, and then displayed in the Virtual Machines already
installedfield.
In order to remove a machine from the PC, select the machine in selection box Virtual
Machines already installed and click the Removebutton.
Finish the installation process by pressing Exit.
D:\C2K
VM_314563 VM_314560
VM_315550
VM_324561
To create a machine simulation, you need either an empty USB stick (CC/EC200) or an empty
Compact Flash memory card (CC200 only) with a capacity of at least 256 MB.
2. Switch to the Data dialog screen and press Setup - System Flashcard
Data dialog
System name
Author
Production date
Change author System flash card
Change date
Software update
3. The Save Flashcarddialog box appears. Select the drive with the storage medium to
which you want to copy the system flashcard. Press Save to start copying.
Save flash card
/hard disk1//
Cancel
171
Options
314563 VM_314560
VM_315550
VM_324561
5. In Select location of Virtual Machines folder , select the storage medium with the
copy of the system flashcard. To do this, use Select Folder to open a search window
and select the drive with the storage medium from it. Now the machine number of the
machine from which you have created the system flashcard appears in selection field
Virtual Machines to be installed.
E:\
314563 VM_314560
VM_315550
VM_324561
6. Select the field in front of the machine number and click Install. A DOS box appears,
and the installation procedure starts.
7. The DOS box is closed when the installation procedure is completed. The machine
number is displayed in field Virtual Machines already installed . Exit the Install Virtual
Machines program by clicking the button Exit.
8. Before removing the storage medium from the PC, select ’Remove or eject hardware’.
Failure to do so could damage the data on the storage medium.
After successfully installing the machine simulation, launch VirtMold and select the desired
machine in the selection window.
Menu items
Configuration
This window displays all the links and settings for the simulation. These settings cannot
be changed after the installation.
Windows
This selection opens an additional menu where you can enable/disable all windows in
the machine simulation. You can use the mouse to arrange the open windows and to
scale the windows.
Example of a simulation window selection menu:
The view can become cluttered if several simulation windows are in use. To avoid this,
as many windows as you like can be gathered together into a collective window with a
selection bar. Drag a window over another one and use the selection bar to select the
active window.
active window
Selection bar
To split up a collective window, select a window in the selection bar and drag it out by
holding the left mouse button down.
Load/Save windows cfg
You can use these functions to store the window layout for the simulation, and open the
same layout at any time later. This function is useful if several people work with a
machine simulation, but prefer different window layouts.
Select Machine
You can change the machine simulation with this function. The function can be selected
after stopping the current simulation (menu item Stop Machine). The same dialog box
as during launching of the simulation appears. [See Start and screen structure on
page 174.]
173
Options
ENGEL VirtMold
The program can also be started by selecting Start menu - Program Files/ENGEL VirtMold/
ENGEL VirtMold.
When the program loads, it displays a dialog box where you can select the machine. This is
mandatory for using multiple machines. Select the machine you need, and press Start to con-
tinue.
Selection window
Note!
With some PCs, it takes a few minutes until the simulation has started completely. Do not start
VirtMold again in this time!
When the simulation is up and running, at least 3 windows are visible. VirtMold controls are
identical to those for the actual machine. Use the PC mouse to navigate the screen.
Sample view:
1 2
You can arrange the windows to suit your own preferences, and select windows with additional
functions. These settings are performed in the VirtMold menu.
175
Options
Example:
Data dialog
Production date
1. Store the parts data set for the machine on a Compact Flash memory card or USB stick.
2. Connect the storage medium to the PC.
3. Select the storage medium drive in the VirtMold Data dialog.
4. Upload data set to VirtMold and then run the simulation with it.
5. To back up the data set, select any drive in the Data dialog and save. Save the data set
on your PC on a Compact Flash memory card or USB stick; select ’Remove or eject
hardware’. Failure to do so could damage the data on the storage medium.
6. Reading a parts data set into the machine.
Note!
To simplify managing the data sets of several machine simulations, it is possible to save
directly in the machine directory. To do this, select the simulation drive (normally drive O:) as
the storage drive in the Data dialog box. The simulation drive is visible in the selection window
when the machine simulation is started.
177
Options
179
Inject . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Screen layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Injection molding in general . . . . . . . . . . . . . . . . . . . . . . . . 18 Screen page selection and function keys . . . . . . . . . . . . . . 38
Injection molding machine cycle . . . . . . . . . . . . . . . . . . . . . 18 Screen structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Injection speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Screw diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Injection time monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . 108 Sequence preview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
InjectionUnit1.er_InjTime.1000 . . . . . . . . . . . . . . . . . . . . . 108 Sequence programming positions mold closing . . . . . . . . . 82
Input keyboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Sequence programming positions mold opening . . . . . . . . 85
Installation of VirtMold . . . . . . . . . . . . . . . . . . . . . . . . . . . 169 Sequence settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Interactive messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Set value graphics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Intrusion program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 Setting the number of profile items . . . . . . . . . . . . . . . . . . 65
Setting the speed and force profile . . . . . . . . . . . . . . . . . . 62
L Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Loading machine sequence . . . . . . . . . . . . . . . . . . . . . . . 149 Shake core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Shake ejector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
M Soaking inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Sprue ejector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Machine sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Start and screen structure of VirtMold . . . . . . . . . . . . . . . 174
Machine sequence - Changing an instruction . . . . . . . . . 157
Machine sequence - Inserting an instruction . . . . . . . . . . 156 Start up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Start-up cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Machine sequence - Removing an instruction . . . . . . . . . 158
Status display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Machine sequence - standard sequence . . . . . . . . . . . . . 148
Machine sequence - visualization of machine sequence . 146 Storage media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Switch panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Machine sequence and Mask Editor . . . . . . . . . . . . . . . . 145
Switchover to hold pressure . . . . . . . . . . . . . . . . . . . . . . . 108
Machine-specific key symbols . . . . . . . . . . . . . . . . . . . . . . 36
Mandatory Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Mold closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 T
Mold heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Text formatting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Mold height adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Torques during plasticizing . . . . . . . . . . . . . . . . . . . . . . . 117
Mold opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Mold parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 U
Monitoring of the barrel temperature . . . . . . . . . . . . . . . . . 92 USB storage media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Monitoring systems for the injection molding process . . . 120 User access authorization - login with card . . . . . . . . . . . . 43
Mount mold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 User access authorization - password login . . . . . . . . . . . . 43
Mounting aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 User administration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Movement to Home position . . . . . . . . . . . . . . . . . . . . . . . . 84 User level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
N V
Notepad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 VirtMold menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 VirtMold Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Nozzle contact position . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 VirtMold system requirements . . . . . . . . . . . . . . . . . . . . . 169
Nozzle speed profile and stroke positions . . . . . . . . . . . . 102 VirtMold Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Nozzle stroke position . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
W
P Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Part removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Write a parts data set . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Pictographs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Plasticizing maintained instruction . . . . . . . . . . . . . . . . . . 116
Plasticizing number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Plasticizing speed profile . . . . . . . . . . . . . . . . . . . . . . . . . 114
Plasticizing time monitoring . . . . . . . . . . . . . . . . . . . . . . . 115
Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Printing textually and graphically . . . . . . . . . . . . . . . . . . . 140
Production counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Production programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Programming machine sequence . . . . . . . . . . . . . . . . . . . 153
Prohibitory signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Proper Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Putting out of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
R
Read parts data set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
rejects in succession . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Rescue actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
S
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Safety equipment - overview . . . . . . . . . . . . . . . . . . . . . . . 27
Safety equipment function . . . . . . . . . . . . . . . . . . . . . . . . . 28
Safety hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14, 24
Save machine sequence . . . . . . . . . . . . . . . . . . . . . . . . . 151
Save sequence - safeties not current . . . . . . . . . . . . . . . . 151
Saving user access authorization . . . . . . . . . . . . . . . . . . . . 49