22 AREBUR Pcs Sorters ELECTRIC CABINET AND CONTROLS __ 2.2.1. Electric Cabinet with PolytronICA Control P2 = Optional equipment on certain models © = Optional equipment 1 Ejector plate safety, on ALLROUNDER® 305 connected to Electric Cabinet, on all models ALLROUNDER® 221 connected to the switch housing on the left front side of the Clamping Unit Control unit see Fig. 1 cycle Coumer Alarm lights Q. for lubrication, oi! filter and oil level (see 2.8) Start-Stop push-butt for pump motor Receptacle for low pressure mould protection Main switch Opening of cabinet door ‘only possible if main switch is turned to ” Connection for the blow mould equipment 1m Connection for ejector plate safety or rec jumper plug! Connection for the photoslectric chute © Receptacte for limit switch “core out position” Insort key here for opening of © Connection for conwol box ‘cabinet door pneumatic safety gate Receptacle Schuko for 220 Receptacle for I “eore in in” position” Wire harness for Receptacte Perilex. directional valves ae (B-phase current) Connecting Pls for Clamping Unit | | Injection Unit allow. reen Pushbutton Timer Settings on Selector Switches soe 2.2.2 Digital Switches see 2.2.3, ‘Manual Pushbutton @ core in-out 1 Screw a4 Rotation Diode b23 Forward — Rectract ti bas 2) Injection Unit " Forward — Retract ‘Clamping Unit Closing — Opening f : : © Ejector forward 2] (Retracts when pushbutton Control Unit P2 is released) © Pnoumatic Safety Gate s00 2.5.3 (Controlbox) switched on, 2) Injotion unit can only be advanced, when toggles aro in locked position (iode B23 Is bright). E 050 083/0000 06/¢2 8003 M7] RREURG i 2.2.2 PolytroniCA Control P2, Des ‘The PolytronlCA is a sequence control, meaning the cycle must proceed from step to | Never set timers to 00.0, step or the machine will stop. setting must be at least 0.1 The LED lights in schamatic on face plate of the control unit and below the digital | “An automatic eycle wil be switches for time adjustments indicate the progression of the cycle: initiated only if the LED's ‘The electrical state of limit switches, selector switches, solenoids and timers can surrounded by 2 thin ring are lit bbe observed. (620, b31, b44 and auto.). The LED's with a wide ring must be dark (27, b34). “The LED lights for the directional valves Indicate when a control impuls is initiated by the contro! unit. “The solenoids itso! are energized through power transistors. Each trensistor Is fused separately [inside the door of the control panel, on the control cabinets with two doors: inside left door! Main Cycle Program Selector | Position switch @ [at ‘vanoa cond Trot elector wal peJand) in “Autornatic. The recycling mode must be selected in are depressed, switcht ition lector priority (automat reveling with Serene wien @or@) photo-electric recycling chute}. out Semi-automatic, every cycle must be initiated by ‘pening and closing of the safety gate, in | Fully automatic at the time-out of die open timer 14 oe oO [a = Ta | Fully @itomatic with photo recycling electric chute, @ [oun Tyg ejector lected Thro var. cesar i required, in| Hiya ejector not selected. Mechanical readvence selector switch Z) must be ee epresies TET aastor rab | Amount of eestor resets or hyd ctor repeat Gore Pall Sequences @® Lox = Tfboth selector switches Band in| Core in with open mould. The mould cannot be re depressed, switch Gnas closed unles the core isin priority @ out if no core pull sequencing is desea neither switch or trust be deoresea. Otis, the machine wil ot oper on automat. © pan = TGV ot Gaerne Te aac in| @hrmvst be depressed in addition wo @or if an Unit will otate until the signal Tnscrew Unit is used cote retract is energizes Ti | Core in with closed mould. The core cannot be ‘moved in before the mould is closed. Program Selector Switches The control units contain all the pushbottons and selector avitches forthe optional equiament, oven ft the electronics necessary for this DD®] OO @ sss _|eerorel sateen sere snot iid he vet nt care hom Bottors donot have any electri functions Time Adjustenent 5, 2.23 Pushbutton for manual oper- ations s.2.2.1 ‘Schematic Screw RPM ‘050 029/000 01/01 7711/7803 Mra ELT React Songer 2.23. PolytronICA Control P2, Adjustment of Timers ‘The timers are set by digital switches (steps 0.1 seconds) 223 6 Injection delay tim ‘A longer delay time on t8 can be 0.9.5 This isthe vime delay between the initiation ofthe used to prewarmn metal insert parts {forward movement ofthe injection unit andthe “inject” signal. The timer starts winen switch 623 mould is closed) ‘energized. Important, when working with open nozzles {0 avoid extrusion of material before the nozzle has reached the mould, Initially set 5 to 0.6 ~ 1s 0 Injection time, starts with time out of 16. On machine without holding presure 090.95 control 1) or when holding pressure 1 should be the same as injection pressure, 2 | Holding time, starts with 1 can be used to time injection and 0.99.95 |. tine out oft if 626 was reached before t1 had timed | holding pressure siultaneously out (timed switchover to holding pressure or fn that cose set 12 t0 0.1 | - tripping of imit switch b26 i tt had timed out frst IMPORTANT: | switened holding pressured before time out of tH b26 must be i wipped “12 must be st 0 a minimum of 00.18 8 | Cooting time, starts with time out of 12. If 13 has timed out before switch b2B 0.99.9 Time out of 13 stars clamp opening fat that time the | is tripped, the mould opens whenever injection unit has retracted to switch 628. 1626 is reached (injection unit is retracted). 4 Die open time: 099% starts with the end of the ejector sequence {hydr. ejector strokes or mechanical ejector reset strokes finished). f the machine is on fully automatic, the time out of 14 starts the naxt cycle 1) The injection unit does not have the directional valve s 13. ead ees ‘050 38/0000 01/01 7711/7804 Mfa cane wit 23 Manual Operation _see Electric Cat T Mould Size see Leaflet, Front Page of this Manual Important Mould Height” | Adjust by moving the adjustable platen along the tebars {with} Adjust clamping pressure and hhand crank in (113). ‘according to Table 4.3.1. The Clamp Pressure | Lock in place with wedge plates (112), ‘wedge plates can be loosened while clamping unit is in open (closed position ‘Closing and With adjustment knobs on front of machine base, independant Opening Speed _| from aach other Ejector “Adjusted with threaded sleave (167) on Frontside of clamping | The damping may influence Damping Cylinder. Damping (reduction of opening speed) starts when the | the opening stroke, As, ‘center toggle pin begins to depress the bushing (167). The higher the bushing is moved up, the earlier the damping starts, [Limit Switches on the Adjustable Platen bad (115) First switch cam from front, Turning cam in (towards right) ‘Mould Open Stop | reduces the opening stroke. b25 (116) ‘Switch cam in the middle. Turning cam in increases the reset Ejector Reset stroke. Amount of resets is adjustable with selector knob BSB Stroke 1)| on the control unit. Reset stroke active only after limit switch bad is tripped. b23 (117) Fear (short) switch cam. b23 is pressed when toggle is in Injection Start | locked position. Active only in automatic operation. Cam is factory adjusted, ba With core pull sequences, if the core must be retracted after Intermediate ‘mould is partially open. If the mould should open without Mould Stop intermediate stop or if the core should be retracted with mould closed: turn switch cam in all the way. Receptacles on Switch Housing of Adjustable Platen eed betes B64 “The receptacle on the Switch housing permits the connection | if not required, insert red Ejector Piate of alimit switch located on the mould. Required if mechanical | jumper plug into B64, Safety side cores of the ejector plate must be in a defined position before the mould is allowed to close. A microswitch on the ‘mould will confirm the proper position of these components before closing 30 631 Receptacle on bottom side of ewitch housing (hycr. ejector see | If no hyd. ejector is used, Hydraulic 26.1). insert red jumper plug or cycle Ejector will not start Electric Safety Gate Switches (witch housing on hdr. safety valve) __Bafety Switch] Clamping unit will not close, 1520 and B27 20,021 ~ the safety gate is not completely closed. in ewitch housing on hye. for safety gate safety vale. 80 The safety arid on top of the safety for safety grid gate is not completely moved forward. 200 = The safety cage is not mounted when for working with vertical clamp. safety hood ~The injection unit is not festened in the vertical adapters (on left front side of safety while they are mounted on the machine, hood. Tow Pressure mould protection, ‘Switches on Low Pressure Mould Protection Plate ‘also active in manuel position ‘B60 (744) ‘Dpersted by the long cam rod (143) sorewed into the moveable | During mouid closing &60 must platen. Adjust the cam rod to trip B60 when mould is com- tbe depressed before b61 other- pletely closed and before b61 is ‘ripped. wise mould will reopen. ‘eT (164) ‘Operated by the short cam rod (163) mounted on the st a wr 190 tionary mould platen. The short cam is factory adjusted. Do not readjust! 104 Preumatic ‘See Speciel Equipment 2.5.3 Gu Safety Gate Closing of gate see 2.7.4 163 1) For using as intermediate stop during closing s¢¢ 2.5.2 (core pull sequence) aha 144 (D601 © 050 008/cu00 06/02 8003 M[a ‘Manuel Operation of Injection Unit, sae Electric Cabinet 2.2.1 (© -= Not Standard INJECTION UNIT onal Machines) Moving Spod of | Adjustment with presure reducing valve (228. Injection Unit | Change ony if necessary (se 45) (Nozzle) 0 Factory adjusted to medium speed. ‘Nozzle Pressure © | This pressure is factory adjusted and ahould not be changed un. less unavoidable. Adjustment with pressure reducing valve (422) (ogo 4 Resiction of nozzle pressure may be necessary if Jpental nozzle tips are used, fr exemple: Berylium copper tis. injection Speed | Adjvatment knob on front of machine bese Injection ‘just with adjustment knabs on front of mathe bas. Pressure Feod out on pressure gauge located on machine ave. Adjust ee mame | Sock resue olowen pone ores potezng ime), | aww nr tao pad Back Presure_|_ but athigh as necesary (uniform plsticizing). Serew Speed “Agjut with adjuting knob on injection unit. Tow FP ie derable para Aliso indicated on FPM gauge on injaction unit or control | larly with temperature sensitive Froinec just stron speed to fini plstilzing just before the | melts (or example: PVC, POM) machine ls ready for clamp opening. fre lair ied materia. Swoke Lime” Do not aajust cams 027, b28, b29 too closely together! Swtehes Minimum distonoe = sencing heed diameter ofthe proximity switches. Otherwise, the proximity Jitches maybe wigpred falsely (for exemple: the sew decompression may not occu) iw Determines he plestcizing stoke, fe. svoke ofthe plasticzing | Asiong asthe screw rotates Plasticiing row (te further te com is moved tothe right the freer will | (627 depressed) the nozzle Ec the plestctzing stoke ond, thoraforetheamount of melt | remains gaint the mould scounulated) i" and the clamp steys closed ‘Tne soke aio determines the size of the remaining materi | heer timeout of t3 (628 must cushion (the further the cam is moved to the rght the more | be rached before clamp material wil be left efter filing the mould, ee snsin automatic operation). bao Determines the screw retraction for melt decompression. Screw ‘On materials with low melt viscos- ‘Screw Retract Retraction = Distance between b27-b29 (see Figure below) ty screw decompression works best Average srake: 2.8 mm (depending on material nd nozzle | It the material cushion is very small configuration) (23mm). Sate Secompression reduces drooling when working with | Wet material increase the drooting open nozzle. problem. In that case predry . Some special materials are sensitive to decompresion, creating | material or use hopoer cris. laminations or fish oye, In euch cases shutoff nozzles must be sed without sew decompression. wae TTo We right of 625) fs imitng the noezl revraction rox, | The edges of the came ar a de- Injection Unit Nozzle retraction = Distance between cam edges b29 and b28. ‘fining factor (see Fig. below). Feurect, ‘average valve 5-10 rm (depending on material end mould. stop 26 26 must be tripped during injection or t2 will not start even For optimal injection Holding pressure | - if machine is not equipped with holding pressure (not slarm adjust cam t0, and complete ‘standard on all machines) trip b26 just at the injection point when mould Is i «if timed holding pressure I oectec TE a ia supervision b26 switches to holding pressure (stroke controlied holding y ai pressure) Itt has timed out before B26 is tripped (set &1 t0 0.1 sec.). = Advones sre (advan elinga nd raw compietay? 827 Screw Motor B29 screw Retract Stop 128 Injection retract stop 226 Holding Pressure Injection pressure Holding pressure 050 32/0000 08/02 8001 MtARBURG 28 25.4 Special Equipment Hydraulic Ejector 28 284 Important Hf no hydr. ejector is used program selector switch @ must be in depressed position Electric Hard wired into switch housing located on adjustable platen. Connecti Hydraulic | Permanent: Connections | On hyd. manifold under safety gate, ‘Switch On _| Release selector push buttes @ on control unit “Amounts of | Selactor switch B38 on control unit. Strokes Speeds Forward ‘Adjustment knob in front of machine base Retract, ‘Adjustment knob in front of machine base Working pressure _s02 4.3.2 ad = st $90 Loamn lock serow “Adjustment | With pressure reducing valve on hydr. manifold behind wo adjune B30 directional valve. Energize hydraulic ejector forward. Readout | Pressure gauge on hydr. manifold opposite of the pressure reducing valve Limit Switehes 30 Stroke adjustment, Removing b31 increases Ejector ‘the stroke, forward stop | Important: Ejector stroke is influenced by the forward speed, B34 ‘DO NOT change setting. Factory adjusted. If B31 Is not depressed, clamping Ejector Do not use to adjust retraction of the ejector. Required only | unit will not close. Retract stop | for electric signal. Adjust retraction stroke of ejector by ‘mechanical means in the mould. Manual Pushbutton “ejector forward” (symbol). Ejector moves operation | forward while pressing the pushbutton, retraction is auto- matic when any other directional valve is energized.) ‘Mounting of | Adjust speed “ejector forward to “1” and adjust ejector ‘Moulds ‘stroke to minimum (position long cam rad to just extinguish ‘with Hyde, } pilot light 630). When using split coupling (s9e data sheet 4.12),| The ejector bar of the mould must Elector the mould can be mounted the usual way hecause the piston of | be adjustable. Preadjust the length the hydraulic ejector cylinder can be connected with the mould after it is mounted, Ifa slipin connection is to be used, each mould haif must be mounted separately. Before mounting the ‘movable mould half, the ejector bor of the mould must be hitched into the piston rod of the hyd. ejector. Proceed as follows: Set speed adjustment “ejector retract” to “0”, press pushbutton "ejector forward (the Piston rod of the hydr. ejector will stay forwards it not, turn off pump motor). When piston is forward, slip the ejector bar of the mould into the hyd. ejector. Slowly open the speed adjustment for ejector retract until the piston retracts slowly. Fasten mould mounting screw loosely, close mould and tighten mounting screws securely. Adjust length of ejector bar so that the maximum retraction of the ejector plete is not limited by mould components but the full retraction of the hyd. ejector piston. To adjust ejector stroke: First adjust the desired moving speed and then {if necessary) adjust the long cam rod {for 630} to the stroke desired. Of the ejector bar according to data Page 9.8. ‘Aajust mould opening speed to "0" to avoid reopening of the ‘mould if the low pressure mould protection would react (in case it is not yet adjusted properly). Otherwise, the loosely fastened ‘mould could be knocked off the platen by the unexpected ‘moutd opening 7) fast retraction by pressing pusibutton “Injection unit forward” 060 90/0000 02 7812 Mno ‘Tau onegrtmecnen 25.2 Core Pull Equipment Electric Connections 252 |_tmoortant 32 ‘electric cabinet ' prong receptacle on the left side of Cores 1a” __| for connecting the limit awiteh 832 located on mould 38 3 prong receptacle on lef side of elacvic cabinet for Core is wetractes”| connecting te limit switch 833 located on mould Hyreulie_ Connections | Quick cisconnects on yr. manlfoldbshing the hyar. directional valve. Working Pressure Adjustment | Wh pressure reducing valve on hyd. manifold next to Girectional valve. Readout ‘On pressure gauge loceted on hydr. manifold opposite cof the pressure reducing valve Sree For core in and retract with adjustment knob on Front OF Adjustment machine bese Core pall (elector switches on control uni, imit saith on sequences clamping unit). Core in with * open mould Core out with * closed mould * partilly closed mould + partaly oben mould + dlosed mould * completely open mould @ ‘Depress core should move wn with ‘open mould, The mould cannot be closed unless the core is in. Tio core sequence & required: selector switches @ or @) must ‘not be depressed or machine will not eycle in automatic. 1f both selector switches © and ‘are depressed, selector switch has priority. bas 7 Mould Crack only active if sequence 4 is selected "To move core ini partially closed mould: As Tong 28 B25 16 tripped the core cannot move in. As soon as the cam moves away from switch b25 the mould closing stops and the core moves into the mould, The mould closing continues when the limit switch ,core isin" is confirmed. Core in with open mould: Reo! com for 825 comalataly (L.ED 625 dark when mould is open) ‘When mechanical elector re advance is selected (J in depressed position) b38 must be set to .0". © Depress if corein with mould closed is to be selected. The ‘core cannot be moved in unless the mould is closed. a5 v Mould Crack “To retract the core with partially or totally open mould. ‘As long as b45 is not tripped the core retraction is inter rupted. ‘When-b46 is tripped, the mould opening stops and the core is retracted, The mould continues to open when the signal (core is retracted) is initiated To retract core with closed mout Move cam for b4S all the way to the right LED ba5 must be dark with mould in closed position. Core pull retraction with open mould: Retract cam so that LED bd5 extinguishes with mould in ‘open position. Required if core cannot be retracted under pressure (with mould closed) © Depress when working with an unserewing mould. @ must be pressed together with © and © or core rotation will not stop before the signal core retract” is initiated, Manual Pushbuttons on control unit Do not energize ejector when core Controt Selector switch @ must not be depressed. is in mould. Testing Even when ,core in” motion with closed mould is selected Core is it possible to test the core action while the mould is open Movements (unless mould would be damaged by this test) For this depress selector switch @ ; after the test retract core, release selector switch @ and press selector switch © . 1) On switch housing on adjustable mould platen. (080 09/0000 0101 7712/7804