Operator CC100

MICROCOMPUTER
CC100
TYPE: A01
Version 8.04
OPERATOR'S MANUAL
This manual has been established for training and information purposes.
It is no component of the instruction manual.
This document remains our property and must not be copied

without our written agreement. Its contents may neither be made
known to third parties nor be used for non-approved purposes.
It only serves for internal benefit and use. Each violation will be
sued according to §§ 12 and 13 UWG.
C Copyright by Engel Maschinenbau Gesellschaft m.b.H.

A - 4311 Schwertberg
Microcomputer CC100 - A01
Operator's manual
WARNING:
This instruction manual shows all setting
possibilities on the electronic control unit. At the
set-up and operation of the machine with diffe-
rent tools, moulds and peripheral equipment it
must most urgently be paid attention to the fact
that wrong settings can lead to defects on the
whole plant.
Exclusion of liability:
ENGEL does not take over any guarantees regarding

this manual. For mistakes included in it, consequential
damage or damage in causal relation due to the
information included in this manual ENGEL cannot be
made liable.
Further hint:
Technical alterations are reserved for the producer and flow into the
product without previous notice so that respective parts of this
documentation can be outdated.
Please pay attention to next page by all means
Index: 8.04-0 / 1995-01-05 Table of contents In 1

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Changes:
When you take this manual please first read up in appendix

1. There possibly innovations and/or changes which concern
the standard of the machine control system are included.
Special programs, customer-specific applications:
All deviations from the control standard equipment, which have been made according to
customer request, are summarized in the GENERAL INSTRUCTION MANUAL - chapter
7 - and exist as copy also in a special compartment in the control cabinet or electric cabinet.
Special executions and expanded plants, such as:
Multicolour plants
Multicomponent plants
Gasmelt
Mould changer
Rubber machines
ERC couplings
Downstream equipment
ENGEL - NET
PC connections
Direct-closing large machines
etc.
are recorded in separate documentations and are then laid out in the
"GENERAL INSTRUCTION MANUAL" (there chapter 7).
2 In Table of contents Index: 8.04-0 / 1995-01-05

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To this OPERATOR'S MANUAL:
This operator's manual shall give a rapid survey of the set-up and operation of the machine. You will
find under:
Chapter 1 Components and operation of the control unit

Modes of operation of an injection moulding machine
Chapter 2 Diskette operation, printer operation, text input
Chapter 3 Setting of the clamping unit
Chapter 4 Setting of the injection unit
Chapter 5 Error messages
Chapter 6 General special programs, also optional ones
Chapter MP Micrograph plus
Chapter QP Quality documentation package
Appendix 1 Change hints
Appendix 2 Index
Basically this manual is valid for all machine sizes. Differences are mentioned at respective points.
We designate the sizes ES25 - ES80 as SMALL MACHINES

ES100 - ES420 as MEDIUM-SIZED MACHINES
ES500 - ES3200 as LARGE MACHINES
Small and medium-sized machines include the same standards, large machines essentially differ
in the following items:
Starting from ES1000: Clamping force measurement on 4 tie-bars

Starting from ES800: 2-range central lubrication
Starting from ES650: Closed loop servo valve control standard
Starting from ES500: 4 closing and opening speeds
Starting from ES500: separate screen page Hydraulic survey
Starting from ES650: electric safety gate standard

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Operator's manual
Table of contents
Chapter 1 COMPONENTS AND OPERATION OF CC100 1-1
1. EQUIPMENT OF THE MICROCOMPUTER CONTROL UNITS ........................ 1-1

1.1 STANDARD EQUIPMENT 1-1
1.2 SPECIAL EQUIPMENT 1-2
2. COMPONENTS OF THE MICROCOMPUTER CONTROL UNITS .................... 1-4

2.1 INPUT KEYBOARD 1-5
2.1.1 Cursor keys and leafing keys 1-5
2.1.2 Figure input field 1-5
2.1.3 Storage key 1-5
2.1.4 Input clearing key 1-5
2.1.5 Copying key 1-6
2.1.6 Error acknowledgement key 1-6
2.2 IMAGE SELECTION KEYS AND FUNCTION KEYS 1-7
2.3 PROGRAM KEYS 1-9
2.4 SCREEN 1-9
2.4.1 Input field 1-10
2.4.2 Interactive error messages 1-10
2.4.3 State of operation 1-10
2.4.4 Error message 1-10
2.4.5 Screen tags 1-10
2.4.6 Function key inscription fields (soft keys) 1-10
2.4.7 Dimming 1-11
2.4.8 Temperature limit 1-11
2.4.9 Alarm display 1-11
2.4.10 User level 1-11
2.5 DISKETTE DEVICE 1-11
2.6 KEY-OPERATED SWITCH 1-11
2.7 SERIAL INTERFACES 1-12
2.8 TEXT INPUT KEYBOARD 1-12
2.9 MANUAL CONTROL KEYS 1-12
2.10 MAGNETIC CARD READER (OPTIONAL) 1-13
3. OPERATION OF THE MICROCOMPUTER CONTROL UNITS ...................... 1-14

3.1 TYPING-IN PROCESS 1-14
3.2 MOULD PARAMETERS 1-15
3.3 CYCLE TIME ANALYSIS 1-16
3.3.1 Part-time monitoring 1-17
3.4 PRODUCTION DATA COLLECTION 1-18
3.5 FREELY COMPILEABLE SCREEN PAGE 1-19

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4. OPERATION OF AN INJECTION MOULDING MACHINE ............................... 1-20

4.1 GENERAL 1-20
4.2 MODES OF OPERATION OF AN INJECTION MOULDING MACHINE 1-20
4.2.1 Mode of operation "Manual" 1-20
4.2.2 Mode of operation "Set-up" 1-21
4.2.3 Mode of operation "Semiautomatic" 1-22
4.2.4 Mode of operation "Fully automatic" 1-22
4.3 MOULDING CYCLE OF A SCREW INJECTION MOULDING MACHINE 1-23
4.3.1 Definition: MOULDING CYCLE 1-23
4.3.2 First work step: MOULD CLOSING 1-24
4.3.3 Second work step: INJECTION UNIT CARRIAGE 1-24
4.3.4 Third work step: INJECTION AND HOLDING PRESSURE 1-24
4.3.5 Fourth work step: PLASTICIZING 1-24
4.3.6 Fifth work step: INJECTION UNIT RETRACTION 1-25
4.3.7 Sixth work step: DEMOULDING 1-25
4.3.8 Important principles and hints 1-25
Chapter 2 MEMORY DEVICES AND TEXT INPUT 2-1
1. DISKETTE DEVICE ........................................................................................... 2-1

1.1 DISKETTE CONTENTS 2-1
1.2 READ DISKETTE 2-2
1.2.1 Change screen language 2-3
1.3 WRITE DISKETTE 2-4
1.4 FORMAT DISKETTE 2-4
1.5 ERASE DATA SET 2-5
1.6 DISPLAYS AND ERROR MESSAGES REGARDING DISK OPERATIONS 2-5
2. PRINTING ........................................................................................................... 2-6

2.1 PREPARATIONS 2-7
2.2 PRINTING SINGLE PAGES 2-8
2.3 PRINTING ALL PAGES 2-8
2.4 HARDCOPY 2-8
2.5 PRINTING MALFUNCTION MESSAGE RECORD 2-8
2.6 PRINTING CONSTANTS (SERVICE FUNCTION) 2-8
3. TEXT INPUT ....................................................................................................... 2-9

3.1 AUXILIARY FUNCTIONS OF THE INPUT KEYBOARD 2-9

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Chapter 3 SETTING OF THE CLAMPING UNIT 3-1
1. MOULD HEIGHT SETTING ................................................................................ 3-3

1.1 SETTING THE MOULD HEIGHT AT TOGGLE LEVER MACHINES 3-3
1.1.1 Automatic mould height setting program 3-3
1.1.2 Automatic mould height setting program without mould height stroke transducer 3-4
1.2 SETTING THE MOULD HEIGHT AT DIRECT-CLOSING MACHINES 3-5
2. CLAMPING FORCE ........................................................................................... 3-6

2.1 SETTING THE CLAMPING FORCE AT TOGGLE LEVER MACHINES 3-6
2.2 SETTING THE CLAMPING FORCE AT DIRECT-CLOSING MACHINES 3-8
3. CLOSING SPEED AND MOULD PROTECTION ............................................... 3-9
4. MOULD OPENING ........................................................................................... 3-11
4.1 MOULD OPENING WITH INCREASED OPENING FORCE ............................ 3-12
5. CYCLE MONITORING TIME ............................................................................ 3-13
6. CENTRAL LUBRICATION (TOGGLE LEVER MACHINES ONLY) ............... 3-13
7. SAFETY GATE SAFETY MONITORING .......................................................... 3-15

7.1 SPECIAL REGULATIONS FOR SWITZERLAND, ENGLAND, FRANCE, DENMARK3-16
7.2 AUTOMATIC SAFETY GATE 3-16
8. AIR VALVE (SPECIAL EQUIPMENT) ........................................................... 3-18
9. EJECTOR ......................................................................................................... 3-20

9.1 EJECTOR PROGRAM 3-21
9.2 EJECTION MONITORING (SPECIAL EQUIPMENT) 3-21
10. PRODUCTION DATA ....................................................................................... 3-22

10.1 REJECTS RECOGNITION 3-22
10.2 PRODUCTION COUNTER 3-23
10.3 START-UP CYCLES 3-23
11. CORE-PULL (SPECIAL EQUIPMENT) ........................................................... 3-24

11.1 CORE MOVING IN 3-26
11.1.1 Start 3-26
11.1.2 Mode of operation 3-26
11.1.3 Switching-off type 3-26
11.1.4 Pressure switching-off after moving in 3-26
11.1.5 In parallel to the mould movement 3-26

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11.1.6 Time monitoring 3-27

11.1.7 Position monitoring 3-27
11.1.8 Moving-in priority 3-27
11.2 CORE MOVING OUT 3-27
11.2.1 Start during mould opening 3-27
11.2.2 During cooling time 3-27
11.2.3 Mode of operation 3-28
11.2.4 Switching-off type 3-28
11.2.5 In parallel to the mould movement 3-28
11.2.6 Time monitoring 3-28
11.2.7 Position monitoring 3-28
11.2.8 Moving-out priority 3-29
11.3 CENTRAL EJECTOR AS CORE 3-29
11.4 CORE AS EJECTOR 3-29
11.5 CORE SAFETY 3-29
Chapter 4 SETTING OF THE INJECTION UNIT 4-1
1. CARRIAGE UNIT ................................................................................................ 4-1

1.1 AUTOMATIC DETERMINATION OF THE NOZZLE CONTACT POINT 4-3
1.2 RETRACTION OF THE INJECTION UNIT 4-3
2. HEATINGS ......................................................................................................... 4-4

2.1 GENERAL 4-4
2.2 CHARACTERISTICS 4-4
2.3 OPERATION 4-5
2.3.1 Activate temperature zone controller 4-5
2.3.2 Settings and displays 4-6
2.3.3 Display field 4-6
2.3.4 Soaking 4-6
2.3.5 Lowering 4-6
2.3.6 Oil temperature control 4-7
2.3.7 Traverse temperature control 4-7
2.3.8 Start-up circuit 4-7
2.4 ERROR MESSAGES 4-8
2.5 CONTROL PARAMETERS AND FURTHER FUNCTIONALITY 4-9
2.5.1 Regulator mode (% controller) 4-9
2.5.2 Emergency mode 4-10
2.5.3 Self-optimization 4-10
2.5.4 Compatibility of part diskettes 4-12
2.5.5 Storage of the temperature data 4-13
2.6 TEMPERATURE CONTROL UNITS WITH SERIAL CONNECTION (OPTION) 4-14

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3. INJECTION AND HOLDING PRESSURE ....................................................... 4-16

3.1 INCREASED SPECIFIC INJECTION PRESSURE 4-17
3.2 SETTING THE INJECTION SPEED 4-18
3.3 INJECTION TIME MONITORING 4-19
3.4 SWITCHOVER TO HOLDING PRESSURE 4-20
3.5 HOLDING PRESSURE 4-23
3.6 COOLING TIME 4-24
3.7 INTRUSION 4-25
3.8 CUSHION MONITORING 4-25
4. PLASTICIZING ................................................................................................. 4-26

4.1 PLASTICIZING TIME MONITORING 4-27
4.2 DECOMPRESSION 4-27
Chapter 5 ERROR MESSAGES 5-1
1. ERROR HELP (ERROR HELP FUNCTION) .................................................. 5-2

1.1 ERROR TEXT ORGANISATION 5-3
2. ERROR MESSAGE ACKNOWLEDGEMENT AND ERROR RESETTING ....... 5-3
3. LISTING OF THE ERROR MESSAGES ............................................................ 5-4

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Chapter 6 SPECIAL PROGRAMS 6-1
1. MICROPLAST / MICROFLOW ........................................................................... 6-1

1.1 MICROPLAST (VISCOSITY MEASUREMENT) 6-1
1.1.1 Selfpresetting, Auto Setup for Microplast 6-3
1.2 MICROFLOW 6-4
2. MICROTEMP - MOULD COOLING (OPTION) .................................................... 6-5

2.1 PROGRAM SEQUENCE 6-6
2.1.1 Monitoring of the advance temperature 6-7
2.1.2 Mode of operation without mould temperature couple (open loop) 6-7
2.1.3 Mode of operation with mould temperature couple (closed loop) 6-7
2.1.4 Flow monitoring 6-7
3. WEEK SWITCH CLOCK .................................................................................... 6-8
4. ABSOLUTE VALUE INPUT (OPTION) ............................................................ 6-10

4.1 GENERAL 6-10
4.2 STORAGE 6-10
4.3 CALCULATION ALGORISMS 6-11
5. CHARGE AMPLIFIER (OPTION) ..................................................................... 6-12
6. CENTRAL COMPUTER (OPTION) .................................................................. 6-14
7. PROGRAM QUICK SETUP .............................................................................. 6-16

7.1 PURPOSE 6-16
7.2 GENERAL 6-16
7.3 ACTUAL VALUE DISPLAY 6-16
7.4 CALL-UP 6-17
7.5 SETTING MODES 6-18
7.6 CALCULATIONS AFTER ENTERING QUICK SETUP PARAMETERS 6-18

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Chapter MP MICROGRAPH PLUS MP-1
1. PERFORMANCE CHARACTERISTICS ......................................................... MP-1
2. SIMPLE SETTING (FOR THOSE IN A HURRY) ............................................. MP-2

2.1 AUTOSETUP - SIMPLE SETTING AUTOMATICALLY MP-2
2.2 SIMPLE SETTING MANUALLY MP-3
2.2.1 Simple setting - parameter and scale selection MP-3
2.2.2 Simple setting - monitoring MP-3
2.2.3 Simple setting - partial images MP-4
3. MICROGRAPH PLUS HAS MORE FUNCTIONS ........................................... MP-5

3.1 SELECTIONS (=CURVE GROUPS) MP-5
3.1.1 Compilation of selections MP-5
3.1.2 Activation of selections MP-7
3.2 SECTIONS MP-8
3.2.1 Define and program sections MP-8
3.2.2 Activate sections MP-9
3.3 ACTUAL VALUES MP-10
3.3.1 Fade in, fade out actual values MP-11
3.4 MONITORING MP-12
3.4.1 Ideal curve - selection MP-13
3.4.2 Monitoring windows MP-14
3.4.3 Rejects evaluation and error messages MP-15
3.5 SCALES MP-15
3.5.1 X-axis MP-15
3.5.2 Y-axis MP-16
3.5.3 Select and change scales MP-17
3.6 GROUPS OF CURVES MP-18
3.7 GENERAL MP-20
3.7.1 Printing the graphics MP-20
3.7.2 Flow number and switchover point display MP-21
3.7.3 Storing MP-21
3.7.4 Fingerpost: Function keys and images MP-22

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Chapter QP QUALITY DOCUMENTATION PACKAGE (QDP) QP-1
1. PROCESS DATA RECORD ............................................................................ QP-1

1.1 OUTPUT OF THE RECORD QP-4
1.2 SHORT SIGNS IN THE TABLE OF VARIABLES QP-6
2. PROCESS DATA GRAPHICS ........................................................................ QP-7
3. PROCESS DATA MONITORING .................................................................. QP-11
Chapter QS QUALITY DATA STATISTICS (QDS) QS-1
1. QDS ................................................................................................................. QS-1

1.1 TERM NORMAL DISTRIBUTION QS-1
1.1.1 Test for normal distribution (histogram) QS-3
1.2 MACHINE CAPABILITY QS-4
1.3 CONTROL LIMITS QS-6
1.3.1 Calculation of the control limits according to the measured value distribution QS-6
1.3.2 Calculation of the control limits according to set specific limits QS-8
1.4 PROCESS CAPABILITY QS-11
1.5 QUALITY DATA STATISTICS PROGRAM (QDS) QS-14
1.5.1 Selection and setting of the parameters for the control cards QS-14
1.5.2 Initialization QS-17
1.5.3 Starting the quality data statistics QS-22
1.5.4 Error messages and manual setting of the control limits QS-25
1.5.5 Print, calculate and interrupt the statistic recording QS-26
Appendix 1 CHANGE HINTS A1-1
Appendix 2 INDEX A2-1

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Chapter 1 COMPONENTS AND OPERATION OF CC100
1. EQUIPMENT OF THE MICROCOMPUTER CONTROL UNITS

The ENGEL microcomputer control systems are modularly constructed multiprocessor systems with simple
operation philosophy. Highly integrated components guarantee the largest possible intelligence and operation
safety. The microcomputer control systems enable a clear programming of all functions of the injection moulding
machine. All set values decisive for the machine sequence, such as times, strokes, pressures, speeds,
temperatures, counters and switchover points can be preselected via the screen.
Due to the display of corresponding error texts an immediate recognition of operation or function errors is possible.
An automatic test of the electronic modules facilitates troubleshooting in a case of disturbance.
1.1 STANDARD EQUIPMENT
- Multimicroprocessor system 32-bit and 16-bit architecture with distributed intelligence

- Analog signal and control unit in RISC technology
- Touch-sensitive keyboard with function keys
- Soft keys for variable function selection
- Printer connection serial via V 24
- Program Quick Setup for the clear one-page simple setting of the machine
- 3 closing speeds, 4 starting from ES500
- 3 opening speeds, 4 starting from ES500
- 10-stage injection speed
- 10-stage holding pressure profile
- 5-stage back pressure profile
- alternative setting of clamping and injection unit with set value graphics
- Set value graphics for setting
- Digital software control of the functions on the injection unit
- Digital display of the screw speed
- Digital injection monitoring
- Automatic cushion monitoring
- Plasticizing time monitoring
- Cycle monitoring, cycle part-time monitoring
- Cycle time analysis
- Switchover criteria: time, stroke, hydraulic pressure, external 24V signal, parallel
- Display of the current switchover point
- Program air valve
- 8 heating control circuits
- Heating of the heating zones in steps
- Alternative sparing heating-up, start-up circuit
Index: 8.04-0 / 1995-01-05 Components and operation 1 1

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- Regulator and emergency mode for heatings

- Self-optimizing controllers for temperature control zones
- Automatic central lubrication control
- Screen text in all languages (Latin letters)
- Automatic screen disconnection
- Hardcopy of the opened screen page
- Digital display of all actual values
- Current action display
- Date and clock
- 3 text pages on which can be written freely (without keyboard)
- 1 freely composable screen page with 21 parameters
- Production data collection page
- Monitoring and alarm system
- Patented linearization progr.with compensation graphics for all proportional and servo valves
- Malfunction message record
- Colour flat screen in Thin Film Transistor technology (TFT)
- Error help texts (help function)
- Micrograph plus
- Automatic mould height setting via screen (starting from ES 65)
- Mould height stroke transducer starting from ES100
- Proportional valve on the clamping unit (starting from ES 100)
- Speed proportional valve for ejector and core-pull (starting from ES 100)
- Diskette drive built in
- increased extention possibility
- Micrograph
- Microplast
- Program multiple closing
starting from ES650: Electrically actuated safety gate
1.2 SPECIAL EQUIPMENT
- Data printer
- Mould cavity pressure switchover device with pressure transducer
- Absolute value input
- Text input keyboard
- Microflow
- Microtemp
- Quality documentation package, consisting of:
Trend graphics for 200 shots for freely selectable process parameters,
PD record (on printer or diskette),
graphic printout, also automatically,
process monitoring
- Quality data statistics QDS (according to Ford Q101) for establishing process/quality control
cards
- Program energy measurement
- Program core-pull, freely programmable
- Program injection-compression
- Program Gasmelt
- Program venting
2 1 Components and operation Index: 8.04-0 / 1995-01-05

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- Program parallel movements

- Additional 56 heating control zones
- Interfaces for integrating external temperature control units, scales, digital sliding caliper, ERC
robots, peripheral equipment, central computer
- FHK interface (Euromap 12)
- Interface record Euromap 15 for host connection
- Interface record Euromap 17 for temperature control units
- Screw return speed-dependent control of a pigment mixing unit
- Program mould changer
- Program screw position control
- Program automatic tie-bar retraction / tie-bar installation
- Program week switch clock extended --> Switch on motor, switch on/off peripheral equipment
- Energy saving in the holding pressure by means of motor cut-off
- Cooling water disconnection
- Magnetic card reading device for the user authority distinction
- Operating point finding OPF (in connection with a PC program)
- starting from ES500: Material cylinder fast mounting
Material cylinder coding
- up to ES600: Electric safety gate
and much more

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2. COMPONENTS OF THE MICROCOMPUTER CONTROL UNITS
The clearly constructed front panels of the microcomputer control unit enable an easy and fast
programming of the control systems.
QUALITÄTSDATENSTATISTIK 18.04.1993 20:37

Hydr.Umschaltw. Fließzahl Polsterlänge
n: 5n: m:
5 m:1010 Abstand:
Abstand: 100 SZx:
SZx: 200
200
SW: 64.0 OSG: 70.0 USG: 58.0 IW: 61.1 bar
SZx: 305 725
Zeit: 9:10 10:14
70.0
_ 64.0
x
58.0
2.00 Screen
s
1.00
Messungen: 2525
Messungen: unter spez:
unter 0 00.0%0,0%
spez: über spez: 0 0.0%
über spez: 0
UEGx:
0,0% 61.0 OEGx: 67.0 UEGs: 0.00 OEGs: 1.60
=
x: 64.00 : 1.51 s: 1.40 Cp: 1.33 Cpk: 1.22
VOLLAUTOMATIK
TEMP QUALITÄTS- SOLLWERTE EINGRIFFS- MASZ- QDS-FEHLER HAUPTMENÜ etc.
DATENSTAT. SPEZ.GRENZ. GRENZEN STÄBE LÖSCHEN --->
ON
Function
ESC F1 F2 F3 F4 F5 F6 F7 F8 >> keys
7 8 9 + ENTER
-
4 5 6 Input
E keyboard
1 2 3 N
!
T
E
+/- 0 . R CLEAR
Q Image
selection
C
S ! keys
Program
ENGEL A ! keys
B100DE80 (+B101DE80)

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2.1 INPUT KEYBOARD
2.1.1 Cursor keys and leafing keys
By means of the cursor keys (arrow keys) on the front panel a cursor, marked by
a bright field with inverse contents, can be moved on the screen and thus the
requested parameter can be selected.
The cursor appears immediately after selecting a screen page on the setting value
on which it stood at the last leaving of the screen page and can only be moved when
the key-operated switch is in position "ON" or "PR".
With the leafing keys one can leaf forwards and backwards if a page is longer than
the screen (e.g. malfunction message record).
B102DE80
2.1.2 Figure input field
With the figure input keys numerical values are typed in. By typing in the figure "1"
7 8 9 + programs can be switched on or a question can be answered with "YES".
- Sometimes it is also necessary, if several screen pages are allocated to one function
4 5 6 key, to press a figure in addition.
E The increment-decrement keys increase/decrease the value occupied with the
1 2 3 N
cursor by one step each, e.g.: 87.5 --> increment key --> 87.6.
T
+/- 0 . E The +/- key is used to determine the algebraic sign of an input value. The ENTER
R
key possesses the same function as the storage key.
B104DE80
2.1.3 Storage key
By pressing the key "ENTER" the value on the screen in the input field is stored. The
sole pressing of the key "ENTER" without previous number input leads to the input
ENTER "0", to answering a question with "NO" or to switching off a program, but this function
can also be determined so that for an input of the value '0' this must be selected
B104DE80
before actuating the ENTER key by means of input keyboard. See technical manual,
chapter 2, item 8.3.3, system setup.
2.1.4 Input clearing key
Already typed-in data are cleared from the input field. Further, this CLEAR key is
CLEAR provided for clearing conversational errors, which arise by typing in a too high or too
low value.
B104DE80

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2.1.5 Copying key
When a value has been handed over into the computer with "ENTER", it can be taken
over into the next cursor position without typing in this value once again. For this
purpose at first the cursor must be moved to the next value with the cursor keys and
B104DE80
then the copying key must be pressed.
2.1.6 Error acknowledgement key
When actuating this key, the error message is cleared from the error display field.
Thus the next error, if appeared, appears immediately in the field.
! ATTENTION: Only the messages are acknowledged, not the errors themselves.The
alarm lamp is also erased when no error exists any more which activates this.
B104DE80

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Mould Mould Holding Quality Main Hard-

closing opening Ejector Injection pressure Plasticizing progr. menu copy
Q
C
S !
B104DE80
Cores Mould-Quicksetup Injection Tempe- Micrograph Handling Special Error
parameters unit ratures Microplast system program page
FULLY AUTOMATIC
CONTROL SPECIFIC CONTROL CON- ERASE ERASE QUAL.DATA eetc.
tc
CARD LIMITS LIMITS FIGURATION QDS ERROR QDS ERROR PROGRAMS --->
ESC F1 F2 F3 F4 F5 F6 F7 F8 >>
B109DE80
Escape key. Close image window, control function exit. Switch-on key
(Not used for the present) (not used)
Function keys
variable inscription of function keys on the screen depending on further access possibilities per
screen page

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Survey of image selection and function keys:
F1 F2 F3 F4 F5 F6 F7 F8
MOULD SET VALUE CLAMPING MOULD

MOULD CLOSING CLOSING GRAPHICS FORCE HEIGHT
MOULD SET VALUE AIR CENTRAL

MOULD OPENING OPENING GRAPHICS VALVES LUBRICATION
SWITCHOVER SET VALUE CONTROL INJECTION SWITCHOVER S.V.GRAPHICS

INJECTION INJECTION MODE GRAPHICS PARAMETERS ABSOLUTE MODE ABSOL. ABSOLUTE
HOLDING HOLD.PRES. SET VALUE

HOLDING PRESSURE PRESSURE ABSOLUTE GRAPHICS
PLASTICIZING SET VALUE PLASTICIZING S.V.GRAPHICS

PLASTICIZING GRAPHICS ABSOLUTE ABSOLUTE
INJECTION UNIT
EJECTOR EJECTOR PRODUCTION
CORE CORE
CORES MOVING IN MOVING OUT
-
MOULD CYCLE TIME PRODUC.DATA SELECTABLE PROCESS HYDRAULIC e t c.
MOULD PARAM. PARAMETERS COLLECTION TEXT PAGE ANALYSIS´ SURVEY -->
HEATING HEATING HEATING CONTROL PAR. CONTROL PAR. TEMP.CONTR. MICROTEMP

TEMPERATURES ZONE 1-7 ZONE 8-15 ZONE 16-23 ZONE 0-15 ZONE 16-23 UNITS
QUICK SETUP
PRINTING DISKETTE TEXT PAGES SERVICE SERVICE

MAIN MENU MENU END
MICROGRAPH MICROPLAST
GRAPHICS MICROFLOW
HANDLING SYSTEM
CHARGE WEEK SWITCH CENTRAL

SPECIAL PROGRAM AMPLIFIER CLOCK COMPUTER
PROC.DATA PROC.DATA QUALITY OPERATING

Q RECORD GRAPHICS DATA STAT. POINT FINDING
BOLD Standard
NORMAL Special
CURSIVE Large machines

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Operator's manual
2.3 PROGRAM KEYS
Semi- Fully Special Error

Manual autom. automatic Set-up program page
ENGEL A !
B110DE80
2.4 SCREEN
The screen integrated into the control panel represents the communication element of the control unit. On the
screen pages certain fields are reserved for different displays, independently of the selected image. The CC100
is equipped with a colour flat display in TFT technology
Date Time
Page title User level Cursor
MOULD OPENING 4 95 01 10 16:30
1ST OPENING SPEED G2-W4 V6 = ... %

2ND OPENING SPEED W4-W2 V7 = ... %
3RD OPENING SPEED W2-A V8 = ... %
START 2ND SPEED V7 W4 = ..... mm

START 3RD SPEED V8 W2 = ..... mm
OPENING STROKE A = ..... mm

MOULD POSITION ACTUAL VALUE SFX = . . . . . mm
CYCLE MONITORING TIME NO

MAX = ..... ZUs = . . . . . ZUx = ..... s
SAFETY GATE:
E1 E2 E8 E8.1
TEMP RELEASE CLAMPING UNIT IN AUTOMATIC MODE NO
ON
MOTOR STOP 4
MOULD SET VALUE AIR
OPENING GRAPHICS VALVES
Input field Inscription of function keys State of operation Alarm display

Interactive error message Screen tags
Error message with error number
green lamp on front panel: 'Control unit in operation'
red lamp on front panel: 'Temperature alarm for screen'

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Operator's manual
2.4.1 Input field
After selecting a set value by means of cursor the newly typed-in value appears in this field. The max. digit number
of the set value to be entered is limited in each case.
2.4.2 Interactive error messages
This message informs if a plausibility limit was exceeded when entering a value: e.g. “MAX.VALUE = 100”. The
parameters adjustable via the screen are limited by machine-determined conditions; e.g. stroke positions can only
be set so large as is given by the mechanical construction of the machine; speed switchover positions cannot be
exchanged among each other. The timers must also be set limited. A part of the pressures and speeds is also
limited by machine-determined conditions so that 100 % does not correspond to the maximum system pressure.
Information and current measured values, which are displayed on the screen by the control system, cannot be
changed.
2.4.3 State of operation
In this field the current state of operation is displayed:
Manual Semiautomatic Fully automatic
Set-up (switching to 'Set-up' only possible 'manually')
Program interruption (simulates 'Manual mode',

switch on button panel of the machine)
2.4.4 Error message
Current messages, warnings and errors during operation are displayed here. The figure right beside the message
indicates the total number of the appeared errors. A star right beside the message indicates the pending of more
than 9 errors. All error messages are visible on the error image at the same time.
2.4.5 Screen tags
As active display of set set values and limit switches so-called screen tags are defined on the screen. These tags
light up when the corresponding set value or limit switch is active.
2.4.6 Function key inscription fields (soft keys)
These fields vary their inscription depending on the opened screen image and/or selected program
and inform about the current effect of the function keys (soft keys).

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2.4.7 Dimming
In order to spare the luminous electronics of the TFT screen, the microcomputer switches the screen dark if no
operation occurs for approx. 10 min. By pressing an image selection key the screen switches to bright again.
The time until the dimming can be changed. See to it 'Technical manual', chapter 2, item 8.3.3.
2.4.8 Temperature limit
The light-emitting diode 'TEMP' on the front panel signals excess temperature starting from 50 °C in the screen
console. The perfect function of the TFT display is no longer given.
2.4.9 Alarm display
For the identification of an appeared error or of an existing error message a warning triangle appears in this field.
2.4.10 User level
The first line on each screen page also shows the just valid user and/or authorization level, dependent on key-
operated switch position (item 2.6), password input and (optionally) magnetic card (item 2.10).
2.5 DISKETTE DEVICE
The diskette device serves to store and charge data, settings and programs. It is accommodated laterally on the
screen console together with key-operated switch and printer interface.
Charge = Read-in: already optimized and filed mould data from the 'part diskette';
fixed values, calibrations, error texts and sequence program from the
'machine diskette'
Store = Write: optimized mould data, program settings on 'part diskettes',

recording of process data on 'record diskette'.
In the phase of putting into operation fixed values, calibrations, ...
on 'machine diskette'
2.6 KEY-OPERATED SWITCH
Laterally on the screen console there is a key-operated switch with a key which can be withdrawn in all three
positions. Different operation functions are only possible in certain key-operated switch positions.In the first line
of each screen page the user level is displayed.
User level Switch position Access right
2, 3, 4, 5 “PR” All functions are possible
1 “ON” Locked is the service menu, the diskette functions as well as the unique
storage of a graphic curve (see program Micrograph)
0 “OFF” Only the image selection, printer function and program key function are
not locked.

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2.7 SERIAL INTERFACES
In series on the control console of the CC100 a 25-pole bush (V24 interface) is provided for the connection of a
printer. On special request further interfaces are available:
e.g. central computer Euromap 15, ENGEL-NET, temperature control units, hot runner controllers,
balances, sliding calipers
2.8 TEXT INPUT KEYBOARD
A connection possibility is provided for an IBM (or IBM-compatible) PC keyboard laterally on the control console.
For the operation see chapter 2, item 3.
2.9 MANUAL CONTROL KEYS
Control panel (Example: ES100)
START PROGRAM INTERRUPTION

AUTOMATIC MANUAL
MOULD MOULD HEIGHT INJECTION UNIT

OPENING CLOSING LARGER SMALLER FORWARD RETURN
EJECTOR INJECTION PLASTICIZING

RETURN FORWARD
CORE
FORWARD RETURN
CONTROL VOLTAGE MOTOR CYLINDER HEATING

SAFETY KEY
0 1 0 1 0 1 EMERGENCY-OFF
B112DE80

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With the push-buttons the function units can be moved into the corresponding direction when the control unit is
switched to the mode of operation "MANUAL" or the program interruption key is switched to manual.Certain locking
conditions between the individual function units must be observed, however.
With the simultaneous pressing of the safety key to the push-button certain locking conditions can be
circumvented.
The start key serves to start a semi or fully automatic cycle.
When pressing the EMERGENCY-OFF key the whole machine with the exception of the control unit and the
heatings is switched off immediately.
The program interruption key is used for interrupting the automatic cycle and for resetting the alarms.
Depending on machine execution or machine size the panel design can vary.
2.10 MAGNETIC CARD READER (OPTIONAL)
Instead of the key-operated switch and of the authorization system by means of password a magnetic card reader
can be employed optionally. On a magnetic card in form of a cheque card personnel number and the kind of
authorization are stored. When inserting the card the corresponding authorization is given immediately, which
appears on each screen page in the uppermost display line as number between 0 and 5 (access level).
Authorization Access level Correspondence Personnel number

(standard)
Choose pages ......................... 0 ....... Key "OFF"
---- " ---- ......................... 1 ....... Key "ON" 111, 112

+ Set value input
+ Diskette reading
---- " ---- ......................... 2 ....... Key "PR" 11, 12

+ (password input)
and thus service function,
debugger, calibration
Debugger, date, time, ................. 3 ....... Password "SM0"

optimization parameters
Calibrations, linearizations, ........... 4 ....... Password "SM1" 1, 2

control parameters injection unit
Machine size data, ........................ 5 ...... Passwort "SM2"

"dangerous values"
When pulling the card level '0' gets active.
On request by ENGEL the personnel numbers and the appertaining authorizations can be programmed on the cards
or be made by the customer himself with a corresponding programming device.
See also 'Technical manual', chapter 2.

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3. OPERATION OF THE MICROCOMPUTER CONTROL UNITS
After switching on the control unit, the microcomputer begins with the “hardware check” being controlled whether
all electronic cards as well as all in and outputs of the control system are okay.
The screen displays the control type (CC100) and in the last line of the switch-on image appears
***** please wait *****
After properly run down hardware check
***** ready *****
appears. The motor can be switched on and the machine made ready to start.
3.1 TYPING-IN PROCESS
- Switch key-operated switch to position “ON”

- Select the corresponding screen page with the image selection keys or function keys
- Move the cursor with the cursor keys to the set value to be changed
- Type in the value with the numerical keyboard or change it with the '+/-' keys step by step, thus the
value appears in the input field
- In case of a typing error actuate the key “CLEAR” and repeat the input
- Store the typed-in value with the key “ENTER”. The input field is erased and the new value is in the set
value field. If the typed-in value is too high or too low, an interactive error (e.g. MAX.VALUE = 100) is
displayed. By pressing the key “CLEAR” this message can be cleared again and the whole typing-in
process can be repeated.
- If one wants to copy the value, one can move the cursor to the next set value and store the value once
again or still several times by pressing the copying key.
- By keeping a key of the touch-sensitive keyboard pressed a repeat function comes into effect. Repeat
period and repeat frequency can be adjusted in the system setup ('technical manual'). The ENTER key
is excepted from the repeat function.

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3.2 MOULD PARAMETERS
Image selection key + F1
MOULD PARAMETERS 2 95-01-08 14:15
MOULD NUMBER W K N= .. . . . . . . . . . . . . . .
INJ.MOULDED PART NUMBER SPN = .. . . . . . . . . . . . . . .
MATERIAL NUMBER MTN = .. . . . . . . . . . . . . . .
MACHINE NUMBER MCN = .. . . . . . . . . . . . . . .
ORDER NUMBER ANR = .. . . . . . . . . . . . . . .
TEMPERATURE CONTROL UNIT 1 TCU1 = ... °C

MATERIAL DRYING UNIT . . . °C

MATERIAL CONVEYOR NO
SENSITIVITY PF TRANSDUCER .... pC/bar
MOTOR STOP 4
MOULD CYCLE TIME PROD. DATA SELECTABLE etc.
PARAMETERS COLLECTION TEXT PAGE --->
HYDRAULIC starting from ES 500

SURVEY
This screen page serves to store mould-specific data. In order to be able to use all alphanumerical characters, one
uses either an IBM PC keyboard (or a compatible one), which is connected laterally to the control console, or the
alphanumerical row of function keys, selectable with F8 ('etc'). See also chapter 2, item 3.

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3.3 CYCLE TIME ANALYSIS
For a better survey of the composition of the whole cycle time the time for the individual movement sequences of
the running and of the last cycle is displayed separated in seconds. For the last cycle automatically the per cent
share of the function referred to the total cycle time is calculated. The program enables the optimization of the cycle
time by time optimization of the individual functions.
Image selection key + F2 (Example: ES100)
CYCLE TIME ANALYSIS 4 94-01-08 14:15

C U R R E N T C Y C L E
- Mould closing 0.88 s
- Carriage 0.20 s - Actual value
- Injection 1.22 s 2.48 s
- Holding pressure 0.00 s
- Cooling time 0.00 s - Plasticizing
- Mould opening 0.00 s 0.00 s
- Ejection 0.00 s
- Demoulding
L A S T C Y C L E
- Mould closing 0.90 s 8.9 %
- Carriage 0.20 s 1.8 %
- Injection 1.22 s 12.0 %
- Holding pressure 2.00 s 19.8 %
- Cooling time 4.00 s 39.6 %
- Mould opening 0.98 s 9.7 %
- Ejection 0.40 s 3.9 %
- Demoulding 0.40 s 3.9 %
- Total time 10.10 s 100.0 %
- Plasticizing 2.22 s
MOTOR STOP 4
CYCLE TIME PART-TIME MAIN MENU
ANALYSIS MONITORING
After expired cycle the individual collected part-times ('CURRENT CYCLE') are transmitted on the memory ('LAST
CYCLE'). The screen tags display the just active part-time. The part-times can be controlled by means of the 'PART-
TIME MONITORING' ---> item 2.3.1.

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3.3.1 Part-time monitoring
If required, the individual part-times of the total cycle can be occupied with lower and upper limit and thus be
monitored. After expired cycle the evaluation occurs. A luminous mark signals an exceeding and/or not-reaching
per part-time, the next cycle start being prevented and the error message 142, "DEVIATION PART-TIME",
appears. The alarm lamp lights up.
Image selection key + F2 + F2 (Example: ES100)
PART-TIME MONITORING 3 94-12-22 14:15
DEVIATION
SET VALUE STORED
TOLERANCE +/-
ACTUAL VALUE LAST CYCLE
- Mould closing 0.84 0.60 0.82 s

- Carriage 0.22 0.60 0.22 s
- Injection 0.76 1.00 0.74 s
- Holding pressure 1.02 1.60 1.04 s
- Cooling time 3.00 3.60 3.00 s
- Mould opening 0.80 0.40 0.80 s
- Ejection 0.40 0.40 0.38 s
- Demoulding 0.30 0.30 0.30 s
- Total time 7.34 9.00 7.32 s
Transmit actual values on SET VALUES NO
MOTOR STOP 4
CYCLE TIME PART-TIME MAIN MENU
ANALYSIS MONITORING
By means of a switch the actual values of the preceding cycle can be transmitted on the set values. Afterwards
the accepted limits (tolerances +/-) must be entered. If individual part-times shall not be monitored, one sets the
corresponding tolerance to 0. The first automatic cycle and also the start-up cycles (see start-up cycles, chapter
3, item 10.3) are excepted from the monitoring.
Set values and tolerances are stored on the part diskette with the other mould parameters.

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3.4 PRODUCTION DATA COLLECTION
On a separate screen page the production remaining time as well as the cycle time deviation is calculated by the
input of the set cycle time, the number of cavities and the piece set value. By the input of the part weight the
remaining material demand is calculated.
PRODUCTION DATA COLLECTION 3 94-12-22 14:15
PRODUCTION REMAINING TIME CALCULATION

CYCLE TIME SET VALUE 22.5 s
CYCLE TIME ACTUAL VALUE 0.0 s
CYCLE TIME DEVIATION 0 %
NUMBER OF CAVITIES FA = 1
PIECE SET VALUE StZ = 10000 pcs
PIECE ACTUAL VALUE StZx = 0 pc
PRODUCTION REMAINING TIME 0 h 00 min 00 s
MATERIAL DEMAND CALCULATION

PART WEIGHT 200.0 g
REMAINING MATERIAL DEMAND 0 kg 000 g
MOTOR STOP 4
MOULD CYCLE TIME PROD.DATA MICROTEMP SELECTABLE
PARAMETERS COLLECTION TEXT PAGE
HYDRAULIC
SURVEY starting from ES 500

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3.5 FREELY COMPILEABLE SCREEN PAGE
On one screen page (freely composeable text page) individual lines can be copied together from other screen
pages. Thus it is possible to read off and/or to print out the parameters important for a certain production on one
page.
Procedure at copying:
- Select screen page
SELECTABLE TEXT PAGE 93-04-19 14:35
MIN = 0.00 MAX = 500.0 ZSx = 0.00 s
- Switch on selection mode
INSERT ERASE INSERT EXIT etc.

LINE LINE EMPTY LINE --->
- Move the cursor to the desired line and select "INSERT LINE"
- Select the screen page, of which one line shall be copied, move the cursor to the line, press "SELECT
LINE" and afterwards go back to the "SELECTABLE TEXT PAGE" again. Now the selected line is faded
in on the previously determined cursor position. By means of the commands on the command line a line
can also be erased and/or an empty line can be inserted.

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4. OPERATION OF AN INJECTION MOULDING MACHINE
4.1 GENERAL
The injection moulding process is the most important process of the production engineering for moulded parts. It
was originally developed for thermoplastics and can be applied today to almost all plastics, also to heat-
thermosetting (PF moulding compounds), crosslinking (e.g. rubber compounds), foaming (e.g. on polystyrene
basis) as well as to unfilled and filled moulding compounds. Which meaning has the term "Injection moulding
process" and what is an "Injection moulding machine". The word injection moulding points to it that at this process
a liquid or at least plastic viscous compound is injected into a mould under high pressure, so here it concerns the
thermoforming of a plastic material, namely not the conversion of semi-finished products, but the shaping of the
base material itself, which is available to the processor as powder and/or granules. So the injection moulding
process is a forming, which leads in one single work step executed by the machine from the moulding compound
to the finished moulded part using machine- and mould-technical conditions. By injection moulding thermoplastics
parts of different dimensions and shape can be manufactured with high dimensional accuracy in relatively short
time, virtually without finishing.
For the manufacture of one or several moulded parts the injection moulding machine carries out a series of work
steps tuned to each other, which repeat themselves in the same order when manufacturing each part. In this
connection the expert speaks of a moulding cycle.
4.2 MODES OF OPERATION OF AN INJECTION MOULDING MACHINE
Injection moulding machines enable an operation in four function steps:
- Manual
- Set-up
- Semiautomatic
- Fully automatic
4.2.1 Mode of operation "Manual"
In case of manual actuation all functions are controlled by hand. Each movement lasts as long as the respective
manual control key is actuated and/or a certain end position is reached.The speed and pressure profiles are passed
like in the automatic mode.
For most movements certain locking conditions must be met:
- Mould closing can only occur at closed safety gate, closed plexiglass protection and rear ejector
position. Further, at special equipment, such as core-pull, handling systems and high speed mounting devices
it must be paid attention to special conditions.

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- Mould opening is only allowed at closed plexiglass protection and closed safety gate. The condition "Closed
safety gate" can be cancelled by pressing the safety key in addition. For special equipment it must also be
paid attention to special conditions like at mould closing.
- At the ejector advance the plexiglass protection and the safety gate must be closed as well as the ejector
forward position of the mould must be reached. The condition "Closed safety gate" can again be cancelled
in the manual mode by pressing the safety key in addition. Due to handling systems again special conditions
can be given.
- The return of the ejector is only possible at closed safety gate and closed plexiglass protection, but with the
safety key it can also be returned again at open safety gate.
- Injection can only occur at closed safety gate, closed nozzle protection, cylinder temperature within the set
tolerance and not swivelled-out injection unit. With swivelled-out injection unit it can be moulded with max.
20 % speed together with the safety key. This serves as extension aid for the material cylinder.
- Plasticizing and decompression are only allowed when the cylinder temperature is within the set tolerance.
- At the injection unit advance the nozzle guard must be closed.
- The mould height adjustment at toggle lever machines is only possible at closed safety gate,
closed plexiglass protection and only in connection with the safety key. Mould height larger can also be
adjusted at open safety gate.
4.2.2 Mode of operation "Set-up"
Like mode of operation "MANUAL", only the following additional items must be observed:
- Select 'Set-up' only possible from the manual mode
- the mould protection monitoring is switched off
- the clamping pressure and the clamping force of the machine are limited
- the closing speed is limited with 20 % and the opening speed with 50 %
- the closed loop clamping force control is switched off
- the automatic mould height setting program for toggle lever machines only functions in the
mode of operation "SET-UP"
- at direct-closing machines the mould height must be set in this mode of operation.

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4.2.3 Mode of operation "Semiautomatic"
In the semiautomatic mode one work cycle is introduced by actuating the green start key on the control panel.
The period of the individual functions is determined by adjustable or given speeds and time function elements.
The (semi)automatic mode can only be selected when:
- the motor is switched on
- no errors exist which would switch to manual mode
- program oil preheating does not run
- program interruption key is at automatic mode.
For a (semi)automatic cycle certain starting conditions must be fulfilled:
- the mould must be open
- it must be plasticized and the decompression must be carried out
- the hydraulic ejector must stand in the rear position
- the safety gates must be closed
- the set cylinder temperatures must lie within the set tolerance.
4.2.4 Mode of operation "Fully automatic"
At fully automatic operation the actuation of the green start key introduces a work cycle, which repeats itself
automatically.
The process-conditioned difficulties at the production of moulded parts on injection moulding machines partly lie
in the constancy of all processing parameters. Each measure of change releases a complete change of the whole
system. From this can be seen which importance is attached to the constant operation of the machine in case
of manual operation and how advantageous the possibilities of the fully automatic production sequence are. On
top of it, with the automation the production costs can be reduced so that it is considered as a matter of course
today to employ fully automatically controlled machines where this is possible technically.
For practical injection moulding a large number of machine types is available, which differ less by process-
conditioned basic conceptions than by variants in the construction form of their construction elements, the drive
or control systems. Injection moulding machines are characterized by two constructive main components, the
clamping unit and the injection unit. The most frequent type of construction of the injection moulding machines is
the horizontal one. At this method of construction injection and clamping unit work horizontally in axial direction
to each other.

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4.3 MOULDING CYCLE OF A SCREW INJECTION MOULDING MACHINE
The moulding cycle has a direct influence on the two main aims of most plastics processors.
These aims are:
- To produce as many parts as possible per day with the machines.
- To ensure that these parts correspond to the requests of the customer.
Therefore it is at first important to define what it is about at the cycle.
4.3.1 Definition: MOULDING CYCLE
At the processing of plastics in discontinuous processes, for example at injection moulding etc., one designates
with cycle the well-timed succession of machine movements, which correspond to certain processing operations,
which comprise all operations required for manufacturing a moulded part.
The cycle is judged according to the time which it takes (cycle time) or according to the number of cycles in the
time unit (e.g. number of shots at injection moulding). Individual machine movements can overlap in time.

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4.3.2 First work step: MOULD CLOSING
The moulding cycle begins with the closing of the mould, the platen on the clamping unit moving with a set speed
and pressure profile in direction platen on the injection unit. The processing of the profiles and the stroke course
can be watched on the control unit. On reaching the mould protection stroke it is switched to low mould protection
pressure in order to protect the mould from damage if an injection moulded part was not ejected. When the mould
is closed, it is switched to high pressure again and/or the toggle lever is locked. At moulded parts with large
undercuts like e.g. at a fitting together with the closing and/or on certain positions of the mould the cores are moved
in (a core is a mould part, which is moved into the mould cavity from outside).
4.3.3 Second work step: INJECTION UNIT CARRIAGE
After occurred closing movement of the mould the injection unit moves the nozzle in contact position with the mould
sprue bush. At modern injection moulding machines this contact position is determined at the first automatic cycle
automatically.
4.3.4 Third work step: INJECTION AND HOLDING PRESSURE
The work piston of the hydraulic injection cylinder is pressurized with an adjustable speed profile and a hydraulic
pressure necessary for it and presses the screw plunger forwards, the melt in the space in front of the screw plunger
being injected into the mould cavity under high pressure via nozzle and mould sprue runners. The pressure in the
plasticizing cylinder (material cylinder) can be between 300 and 2500 bar depending on machine and moulding
compound. As the mould has another temperature than the melt, the cure time begins when the melt enters the
mould. In order that no sink marks or voids arise and the moulded part gets unusable, it must be switched to holding
pressure after filling the cavity in order to push on the volume lost by curing until the sprue cures (gate sealing point).
The holding pressure is determined by a holding pressure time and a pressure profile. Afterwards the cooling time
starts.
4.3.5 Fourth work step: PLASTICIZING
In the feed section of the screw plunger the granules fall out of the material hopper through the opening of the material
cylinder and are transported in the wake of the screw rotation within the screw channels in nozzle direction through
the cylinder heated from outside, the material particles being in contact with the hot cylinder liner being sheared
off and changed off permanently by the flights of the screw plunger so that a homogeneous melt flows in front of
the screw tip. This accumulation of the broken down material causes an axial return movement of the screw plunger,
overcoming an adjustable counter pressure (back pressure) of the hydraulic injection cylinder. On reaching the melt
volume (plasticizing stroke) required for mould filling the screw is retracted in order to relieve the melt compressed
in the space in front of the screw (decompression). If necessary, a shut-off nozzle sees to it that no melt flows out
of the nozzle.

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4.3.6 Fifth work step: INJECTION UNIT RETRACTION
After the expiry of the retraction delay time the injection unit is returned from the sprue bush. This is sometimes
important in order that the sprue is torn off, the cooled sprue bush does not heat too strongly and the heated nozzle
does not cool too strongly.
4.3.7 Sixth work step: DEMOULDING
With the end of the cooling time the mould opens with a set speed profile. After reaching the start position the ejector
moves forward, the moulded part being ejected by means of ejector pins. Afterwards the ejector returns and a pause
time (demoulding time Z5) starts. After its expiry the cycle is finished and a new cycle can be started.
4.3.8 Important principles and hints
In order to get good parts with a short processing cycle, the setting of the injection moulding machine should occur
according to a fixed plan. Without such a plan the manufactured parts are often not fabricated optimally, or the
processing cycle is longer than necessary. In order to reach an optimization of the injection moulding process,
so to fabricate moulded parts of the same good quality under the lowest possible time, material and energy
expenditure, the processor should know the employment purpose of the part exactly. For this purpose it is found
out by the buyer of the moulded parts or by the quality control in the own plant which deviations of quality
characteristics can lead to the refusal of the article. So among others the tolerances, the strength and the
appearance of the injection moulded parts have an influence on the employment of the finished moulded parts. It
is up to the processor to take the suitable measures in order to guarantee an injection moulding process of perfect
quality. If the existing known values are not sufficient, a procedure in steps is indicated. In no case an adjustment
without plan of the technological parameters will lead to satisfactory results.
It should not be tried to already control the quality of parts when it is not ensured that the mould is run in correctly.
The principle that quality cannot be achieved by controlling, but must be produced shall be pointed out. Therefore
it must also be ensured that the correct material is processed, that it is dried if necessary and is available in
sufficient quantity. Further, it must be controlled whether the machine and the injection mould function perfectly.
Some hours which are spent for eliminating an error of mould or machine can pay for themselves rapidly by faster
cycles and fewer disturbances.

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Chapter 2 MEMORY DEVICES AND TEXT INPUT
Index: 8.04-0 / 1995-01-05 Memory, text input 2 1

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- Select the desired directory with the cursor

- the function keys 'DISPLAY DIRECTORY', 'SELECT DIRECTORY' and 'EXECUTE COMMAND'
appear.
- Start the read-in with function key "EXECUTE COMMAND" or truncate with "EXIT".
2 2 Memory, text input Index: 8.04-0 / 1995-01-05

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DISKETTE 4 95-01-22 14:15
Cursor /
NYLON <DIR> 92-12-03 READ FROM DISK

TRAINING <DIR> 93-01-26
KELTEST <DIR> 94-02-10
MOTOR STOP 4
READ FROM WRITE ON FORMAT ERASE DATA SET EXIT
DISK DISK DISKETTE
Optionally by means of a memory extension card (RAM card) a more rapid switchover between 3 different languages
can be built in. The texts are selected with function keys on the screen page 'Special' ("S"). With the following
selection of a screen image the switchover has been made.

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2.1 PREPARATIONS

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- Switch the printer to the power supply
- Insert enough paper and pay attention to unhindered paper feeding
- Switch the printer to “ON LINE”
- Adjust the paper to sheet beginning with the handwheel
- Select the printer menu (press MENU KEY + F1)
- Select text or graphic printer on the screen (F6 and/or F7)
Message depending on selection: GRAPHIC PRINTER or TEXT PRINTER
- With the function key “F3” the control unit is informed about the page beginning on the printer in order
not to print over the page perforation.
PRINTING 3 95-01-09 14:35
* TEXTPAGES * SELECTABLE TEXT PAGE * MOULDPARAMETERS

* QUICK SETUP * MOULD CLOSING * MOULD OPENING
* CLAMPING FORCE * INJECTION * MOULD HEIGHT
* CENTRAL LUBRICATION * INJECTIN ABSOLUTE * SWITCHOVER MODE
* SWITCHOVER MODE ABS. * HOLDING PRESSURE * HOLDING PRES.ABSOLUTE
* MICROPLAST * MICROGRAPH * PLASTICIZING
* PLASTICIZING ABSOLUTE * CARRIAGE UNIT * EJECTOR
* AIR VALVES * PRODUCTION * MOVE IN CORE
* MOVE OUT CORE * HEATINGS 1 - 7 * HEATINGS 8 - 15
* HEATINGS 16 - 23 * CONTROL PARAMETERS 0 - 15 * CONT.PARAMETERS 16 - 23
* CYCLE TIME ANALYSIS * PROD.DATA COLLECTION * ERROR IMAGE
* MICROTEMP * WEEK SWITCH CLOCK * CENTRAL COMPUTER
* CHARGE AMPLIFIER * QDS-SPECIFIC LIMITS * QDS-CONTROL LIMITS
* QDS CONFIGURATION * QDS-CONTROL CARDS TYPE * TEMP.CONTROL UNITS
MOTOR STOP 4
PRINT ALL PRINT SET PAGE STOP MALFUNCTION TEXT GRAPHIC etc.
PAGES CONSTANTS BEGINNING PRINTING MES.RECORD PRINTER PRINTER --->
it appears next
line
SELECTION SELECTION PRINT SINGLE etc.

ON OFF PAGE --->

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2.6 PRINTING CONSTANTS (SERVICE FUNCTION)
Internal fixed values are printed out with function key F2. (see Technical Manual)

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3. TEXT INPUT
Laterally on the CC100 control console a connection for an IBM PC (or compatible) text input keyboard is provided.
With this keyboard:
a) 3 screen pages can be written on. The entered text is also stored onto the part diskette and can be
printed out.
b) instead of the front panel input keyboard all values which can be reached with the cursor can be
entered numerically as well as alphanumerically.
Procedure for a)
- Connect keyboard to the interface on the front panel.

- Print image selection key 'MENU'.
- Print function key F3 'TEXT PAGES'.
- It appears the first empty one of the 3 screen pages, which can now be written on at will by means of the
connected keyboard.
- With the function keys F2 and/or F3 one opens the further pages, which can be written on freely.
- With F7 one switches to the next colour. The colour of the function key corresponds to the set input
colour. Red -> green -> yellow -> blue -> magenta -> cyanogen -> white -> ...
F1 F2 F3 F4 F5 F6 F7 F8
1 2 3 COLOR etc.
--->
Page 1 Page 2 Page 3 Switch over

color
3.1 AUXILIARY FUNCTIONS OF THE TEXT INPUT KEYBOARD
The cursor (= writing position) can be positioned on the image at will with the arrow keys
PC key: "Insert" ( Éinfg´ ) ... Switchover between

- Overwriting mode (cursor is static)
- Inserting mode (cursor flashes)
"Backspace" ( <--- ) ... deletes the character left beside the cursor
in the inserting mode the rest of the line is displaced to the
left by one character
"Delete" ( Éntf´ ) ... deletes the character on the cursor position, the rest of the
line is displaced to the left by one character
"Ctrl-Delete" ( ´Strg´ + Éntf´ ) ... deletes the line in which the cursor stands, then
inserts an empty line
"Alt-Delete" ( Ált´ + Éntf´ ) ... deletes whole page
"Ctrl-Insert" ( ´Strg´ + Éinf´ ) ... inserts an empty line before each line in which the
cursor stands
"Enter" ( <---| ) ... the cursor is positioned on the next line in the first
column
"Page Down" ( ´Bild ^ ) ... Selection of the next page
"Page Up" ( ´Bild v ) ... Selection of the preceding page
"Home" ( ´Pos1´ ) ... the cursor is positioned on page beginning

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Chapter 3 SETTING OF THE CLAMPING UNIT
Index: 8.04-0 / 1995-01-05 Clamping unit 3 1

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Image selection key (Example for ES100)

Setting
limitations
MOULD CLOSING 2 95-01-10 16:30
MOULD POSITION ACTUAL VALUE SFX = . . . . . Display
mm L1 + 5 mm - max
OPENING STROKE A = .....
mm 0 - 100
0 - 100
1ST CLOSING SPEED A - W3 V1 = ... % 0 - 100
2ND CLOSING SPEED W3 - W1 V2 = ... % W1 - A
G1 - W3
3RD CLOSING SPEED W1 - G2 V3 = ... %
0 - W1
0 - P2a
START 2ND SPEED V2 W3 = ..... 0 - 999.9
mm
START 3RD SPEED V3 W1 = ..... Display
mm 0 - G1 (mould)
0 - 100
MOULD PROTECTION STROKE G1 = ..... 0 - 10
mm
MOULD PROTECTION PRESSURE P2a = . . . P2e = ... 0-9
%
MOULD PROTECTION TIME ACT. = . . . . . ZF = ... s
PROG.INTERRUPTION
TOGGLE LEVER POSITION ACTUAL 4 VALUE SKx = .....
mm
MOULD SET VALUE CLAMPING MOULD
MOULD
CLOSING PROTECTION
GRAPHICS ENDFORCE
TOGGLE LEVER
HEIGHT G2 = .....
mm
CLAMPING PRESSURE P1 = ... %
TOGGLE LEVER LOCKED B = ..... mm
Image selection key (starting from ES550) Setting

MULTIPLE CLOSING Max = . times
limitations
MOULD CLOSING 2 95-01-10 16:30
MOULD POSITION ACTUAL VALUE SFX = . . . . . mm Display
OPENING STROKE A = ..... mm L1 + 5 mm - max
1ST CLOSING SPEED A - W3 V1 = ... % 0 - 100
2ND CLOSING SPEED W3 - W1 V2 = ... % 0 - 100
3RD CLOSING SPEED W1 - G2 V3 = ... % 0 - 100
START 2ND SPEED V2 W3 = ..... mm W1 - A
START 3RD SPEED V3 W1 = ..... mm G1 - W3
MOULD PROTECTION STROKE G1 = ..... mm 0 - W1
MOULD PROTECTION PRESSURE P2a = . . . P2e = ... % 0 - P2a
MOULD PROTECTION TIME ACT. = . . . . . ZF = ... s 0 - 999.9
TOGGLE LEVER POSITION ACTUAL VALUE SKx = . . . . . mm Display
MOULD PROTECTION END TOGGLE LEVER G2 = . . . . . mm 0 - G1 (mould)
0 - 100
CLAMPING PRESSURE P1 = ... % Display
CLAMPING PRESSURE ACTUAL VALUE . . . bar 0 - 10
TOGGLE LEVER LOCKED B = . . . . . mm
0-9
MULTIPLE CLOSING Max = . times
PROG.INTERRUPTION 4
MOULD S.V.GRAPHICS CLAMPING MOULD
CLOSING MOULD STROKE FORCE HEIGHT
2 3 Clamping unit Index: 8.04-0 / 1995-01-05

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1. MOULD HEIGHT SETTING

1.1 SETTING THE MOULD HEIGHT AT TOGGLE LEVER MACHINES
At the toggle lever machines the mould height is adjusted by an electric motor, which drives the tie-bar nuts over
a gear rim.
With the push-button and simultaneous actuation of the safety key (key-operated switch) the mould height can
be set larger/smaller in the operation mode “MANUAL” or “SET-UP” at closed safety gate. In the operation mode
“SET-UP” the closing and opening speeds as well as the hydraulic pressure are limited.
At large machines the mould height adjustment is only possible when the lubrication of the mould height adjustment
has run off without error and when the mould is in an allowed range (otherwise error "Mould not in position").
The message “ADJUSTING MOTOR” indicates that the motor does not rotate although it has been actuated (e.g.
end position reached).
In order to improve the comfort for the mould height setting, in the operation mode “SET-UP” an automatic mould
height setting program can be switched on.
1.1.1 Automatic mould height setting program

Setting
limitations
MOULD HEIGHT 2 95-01-19
14:35
On/Off
AUT. MOULD HEIGHT ADJUSTMENT OFF
0 - 9999.9
ACTUAL VALUE FHx = ..... mm 0 - 9999.9
0 - 9999.9
SET VALUE FH = ..... 0 - 9999.9
mm
MINIMUM FHmin = ..... mm
MAXIMUM FHmax = ..... mm
MOULD HEIGHT LARGER SMALLER
PROG.INTERRUPTION 4

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2. CLAMPING FORCE
The clamping force which a machine must bring up in order to close the mould against the injection pressure, is
approx. one third up to half a ton per square centimeter of projected moulding surface for normal-flowing moulded
parts.
A too small clamping force setting leads to a flash formation on the injection moulded part, a too high setting can
lead to a damage of the mould and/or of the mould plates.
2.1 SETTING THE CLAMPING FORCE AT TOGGLE LEVER MACHINES
At toggle lever machines the closed loop clamping force control is made by the mould height adjustment motor,
which can be actuated with the push-button “Mould height larger/smaller”. An automatic closed loop control is
necessary at toggle lever machines because the mould size changes by temperature variations and thus the
clamping force also changes. The motor corrects at open mould if a larger deviation than approx. 3 % of the set
value appears.
Independently of it, the tie-bar extension is constantly monitored at injection and if the maximum extension limit
is reached (maximum clamping force of the machine + 10 %), injection is interrupted immediately (alarm display:
“CLAMPING FORCE TOO HIGH”). The mould opens after the cooling time.
If the set clamping force at beginning injection is not reached (message: CLAMPING FORCE LOW), the automatic
cycle terminates without injection and holding pressure and does not start again.
Tie-bar extension diagram

ES600/100
Tie-bar extension (mm)
Clamping force in %
Mould height

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Procedure for presetting the clamping force:

Setting
limitations
CLAMPING FORCE 2 95 01 10 16:30
SET VALUE SK = ..... KN 0 - nominal value

BAND WIDTH FOR CLOSED LOOP CONTROL ..... KN Display
ACTUAL VALUE SKx = . . . . . KN Display
Closed loop clamping force control: - + Display
OPENING STROKE A = ..... mm L1+5mm - max.
MOULD POSITION ACTUAL VALUE SFx = . . . . . mm Display
LOCKING POSITION B = ..... mm 0 - 10.0

TOGGLE LEVER POSITION ACTUAL VALUE SKx = . . . . . mm Display
PROG.INTERRUPTION 4
- Select mode of operation “MANUAL”
- The set value is set to the required clamping force
- Set the clamping pressure “P1” at least so high that the clamping force can be reached.
- By closing and opening the mould several times the closed loop control occurs automatically to the set value,
the position mould protection end “G2” having to be reached in order that the machine can switch to high pressure.
Starting from machine size ES1000 the screen page for clamping force settings is extended:

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Setting
limitations
CLAMPING FORCE 4 95 03 10 16:30
SET VALUE SK = ..... KN 0 - nominal value

LIMIT MAXIMUM SKmax = .. ... KN SKmin - nominal value +10%
LIMIT MINIMUM SKmin = .. ... KN 0 - SKmax
BAND WIDTH FOR CLOSED LOOP CONTROL = ..... KN Display
ACTUAL VALUES
Tie-bar 1 Tie-bar 2 Display
. . . . . KN . . . . . KN
Tie-bar 3 Tie-bar 4 Display

. . . . . KN . . . . . KN
Selection for closed loop control: TIE-BAR NUMBER 1 1-4

Closed loop clamping force control: - +
OPENING STROKE A = .. ... mm L1+5mm - max.

MOULD POSITION ACTUAL VALUE SFx = ..... mm Display
LOCKING POSITION B = .. ... mm 0 - 999.9
TOGGLE LEVER POSITION ACTUAL VALUE SKx = ..... mm Display
PROG.INTERRUPTION 4
Starting from the ES1000 a 4-tie-bar measurement is installed. The individual tie-bar charges can be read off on
the screen, but the closed loop clamping force control only occurs via one tie-bar which must be selected. The
monitoring regarding error "CLAMPING FORCE LOW" and "CLAMPING FORCE HIGH" runs on all tie-bars.
2.2 SETTING THE CLAMPING FORCE AT DIRECT-CLOSING MACHINES
At the direct-closing machines the clamping force is determined with the input of the set value. The position mould
protection end “G2” must be reached in order that the machine switches to high pressure.
For the injection the clamping pressure must be built up completely. This is time-controlled at machines without
build-in clamping pressure transducer. At too low clamping force the error message 28, "Clamping force too low"
appears.

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3. CLOSING SPEED AND MOULD PROTECTION
In order to reach an as fast and exact as possible closing and opening movement and a corresponding mould
protection, one can fulfill these requirements with different settings on the screen.
Mould protection means low hydraulic clamping pressure and slow closing speed shortly before the mould is
completely closed in order to protect it against damage if a part of the injection moulded part is still in the mould.
Image selection key + F2 (Example ES100HL)
CLOSING PROFILE 2 95 01 10 16:30
100% Set value graphics

for the whole
closing stroke
0%
330.0 mm SFx 330.5 mm
A W3 W1 G1 B
G2
A W3 W1 G1 G2 B
Closing stroke 310.0 280.0 70.0 35.0 0.4 0.0
Speed 40 90 50 50 100 5
Pressure 100 100 100 22 100 100
PROG.INTERRUPTION 4
MOULD SET VALUE
CLOSING GRAPHICS
The adjustable strokes are measured from the closed mould. The closing movement is allowed when the safety
gates are closed and the ejector is at the rear. The locking conditions of possibly used additional equipment
(e. g. core-pulls, handling devices) must also be observed.

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Setting procedure:
- Select mode of operation “MANUAL”
- Set the opening stroke “A” so that a perfect demoulding of the part is possible.
- Set the closing speeds and corresponding switchover positions as fast and without jerks as possible
considering a corresponding mould protection. In particular the third closing speed must be tuned to the
mould protection so that no damage of the mould arises if an injection moulded part is jammed between
the two mould halves.
- Set the mould protection stroke “G1” to the position, starting from which a damage of the mould can
arise if an injection moulded part is jammed.
- Set the mould protection pressure as low as possible
- Set the position mould protection end “G2” so that it is only reached when the two mould halves are
applied.
- Set the mould protection time “ZF” somewhat larger than the measured actual value. The mould
protection time starts from the position “G1” and is reset on reaching the position “G2”. If this time expires
before the position “G2” is reached, the closing movement stops immediately and an alarm is displayed.
As a function of a screen switch on the page for mould closing the machine opens the mould or does not
make a movement any more:
MOULD STOP AFTER MOULD PROTECTION ALARM YES/NO
This screen line can be activated by the machine setter. See technical manual,
chapter 3, 'Mould protection'.
Program MULTIPLE CLOSING
If the mould cannot be closed completely in the mould protection phase, say by a not entirely ejected part,
the mould protection time ZF runs off. The mould opens, the ejector, if switched on, advances and returns. A
new mould closing attempt begins.The maximum number of closing attempts can be determined on the
screen page "MOULD CLOSING" in the line "MULTIPLE CLOSING" from 1 to 9. On reaching the maximum
number the mould protection finally reacts. The mould opens, the alarm lamp lights up. After a delay time
(approx. 5 minutes) the motor switches off and the heatings lower.

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4. MOULD OPENING
Image selection key up to ES420

Setting
limitations
1ST OPENING SPEED G2-W4 V6 = ... % 0 - 100

2ND OPENING SPEED W4-W2 V7 = ... % 0 - 100
3RD OPENING SPEED W2-A V8 = ... % 0 - 100
0 - W2
START 2ND SPEED V7 W4 = ..... mm W4 - A
START 3RD SPEED V8 W2 = ..... mm L1 + 5mm - max.

Display
OPENING STROKE A = ..... mm Yes/No
0 - 6553.5
MOULD POSITION ACTUAL VALUE SFX = . . . . .
mm
Display
CYCLE MONITORING TIME NO Yes/No
MAX = ..... ZUs = . . . . . ZUx = . . . . . s
SAFETY GATE:
E1 E2 E8 E8.1
RELEASE CLAMPING UNIT IN AUTOMATIC MODE NO
PROG.INTERRUPTION 4
OPENING GRAPHICS VALVES LUBRICATION
Image selection key starting from ES500

Setting
limitations
1ST OPENING SPEED B-W6 V5 = ... %

0 - 100
2ND OPENING SPEED W6-W4 V6 = ... % 0 - 100
3RD OPENING SPEED W4-W2 V7 = ... % 0 - 100
4TH OPENING SPEED W2-A V8 = ... % 0 - 100
START 2ND SPEED V6 W6 = .. ... mm 0 - W6
W4 - W2
START 3RD SPEED V7 W4 = ..... mm W2 - A
L1 + 5mm - max.
START 4TH SPEED V8 W2 = ..... mm Display
OPENING STROKE A = ..... mm

Yes/No
MOULD POSITION ACTUAL VALUE SFX = . . . . . 0 - 6553.5
mm
1-5
*) Display
CYCLE MONITORING TIME NO *) Displays
MAX = ..... ZUs = . . . . . ZUx = ..... s *) 0 - 65.5
*) Yes/No
SAFETY GATE: ele ctric CHOICE: 1

automat. opening PROG.INTERRUPTION
after: 4 End holding pressure *) from ES650 std.
E1
MOULD
E2
SET VALUE
bSGZB
AIR
bSGAB
CENTRAL SGA SGZ SGN
OPENINGGRAPHICS
OPENING DELAY VALVES LUBRICATION Zog = ... s
RELEASE CLAMPING UNIT IN AUTOMATIC MODE NO

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The adjustable strokes are measured from the closed mould. The opening movement is allowed when the safety
gates are closed. When the safety gate on the operator side is open, opening can be actuated by the simultaneous
pressing of the manual control key and the safety key if a mechanical stop for the safety gate is present on the
moving mould fixing platen. Moreover, the mechanical stop allows in the automatic mode mould opening and ejector
forward at open safety gate, the switch 'RELEASE CLAMPING UNIT IN AUTOMATIC MODE' having to be set to
'YES'. The locking conditions of possibly used additional equipment (e.g. core-pulls) must also be observed.
For opening 3 (4 starting from ES500) adjustable speeds are provided. In the mode of operation “SET-UP” the
opening speed is limited.
OPENING PROFILE 4 95 01 10 16:30 Set value graphics
100% for the whole

opening stroke
0%
420.0 mm SFx 356.1 mm
A W2 W4 B
G2
A W2 W4 G2 B
Opening stroke 355.0 300.0 40.0 0.0 0.0
Speed 0 40 80 25 25
Pressure 0.0 100 100 100 10
PROG.INTERRUPTION 4
4.1 MOULD OPENING WITH INCREASED OPENING FORCE
At machines of the size ES250HL and ES350HL the program "OPENING FORCE INCREASED" can be chosen.
Up to the adjustable stroke position A4 the mould opens slowly in order to reach more force for separating the mould
surfaces.
Screen line on page 'Mould opening':
OPENING FORCE INCREASED YES WA4 = 12.0 mm

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5. CYCLE MONITORING TIME
Screen lines: CYCLE MONITORING TIME ON

MAX = ..... ZUs = ..... ZUx = ..... s
When a machine is optimized according to the mounted mould and shall continue to run automatically, a cycle
monitoring is set in order to switch off the motor in case of a disturbance and possibly also reduce and/or switch
off the heatings.
When the cycle monitoring time is switched on, the monitoring time begins to run with the cycle start (ZUx) and
is reset automatically with the beginning of the next cycle. The actual value of the preceding cycle is stored on
the screen (ZUs). Usually the cycle monitoring time (maximum value) is set some seconds larger than the actual
cycle time of the machine. If the monitoring time expires, the cycle is interrupted immediately and the switchover
to the operation mode “MANUAL” occurs (message: “CYCLE TIME EXCEEDED” and “MOTOR STOP DELAYED”).
After 2 minutes the motor switches off and the heating reduces to the possibly set reduction temperature (message:
“MOTOR STOP” and “HEATING LOWERS”). The cycle monitoring time also runs in the semiautomatic mode in
order to introduce the disconnections in case of reaction. The cycle time ZUs is stored at the end of the cycle (end
ejection).
6. CENTRAL LUBRICATION (TOGGLE LEVER MACHINES ONLY)

At toggle lever machines the toggle levers must be lubricated constantly according to an adjustable cycle number
depending on machine type and load.
Image selection key + F4 Setting

limitations
CENTRAL LUBRICATION 4 95 01 10 16:30
CENTRAL LUBRICATION COUNTER ZSZ = ... SCH 0 - 500
OIL LEVEL BZ2 Display

LUBRICATION PRESSURE BZ1 Display
LUBRICATION ACTIVE Display
PROG.INTERRUPTION 4

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at large machines, starting from ES500 a 2-range lubrication is built in in order to correspond to the lubrication
requirements of large machines:
Range 1: Toggle levers
Lubrication process cycle- and time-dependent
Range 2: 4 - tie-bar adjustment (starting from ES800)
Lubrication process cycle-, time- and adjusting impulse-dependent
The greasing criteria (set values) are set at the factory and run simultaneously. The one reached first releases
Setting the
limitations
CENTRAL LUBRICATION 3 95 01 10 16:30
CYCLES TIME
RANGE 1:
ZZ1 Z1
SET VALUE ... ... min Display
ZZ1x Z1x
ACTUAL VALUE ... ... min Display
LAST LUBRICATION IMPULSE:

ZZ1 Z1 Display
OIL LEVEL: BZ2 BZ6 Display

LUBRICATION PRESSURE RANGE 1 MIN MAX Display
LUBRICATION ACTIVE Display
PROG.INTERRUPTION 4
lubrication process.
The display "LAST LUBRICATION IMPULSE" shows the criterion which released the lubricationprocess last. Each
range is equipped with minimum (2 bar) and maximum (20 bar) pressure switches in order to monitor a correct
lubrication process. Also the lubrication oil level in the oil container is monitored. In a case of error an alarm is
released, the cycle is stopped and the hydraulic motors are switched off after approx. 2 minutes. Error messages:
129, 'CL PRESSURE REDUCTION', 36, 'LUBRICATION PRESSURE LACK' or 37, 'LUBRICATION OIL LEVEL'.
The display 'System separation' signals with luminous mark that it is switched over to lubrication range 2.
8. AIR VALVE (SPECIAL EQUIPMENT)

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7. SAFETY GATE SAFETY MONITORING
Basically the safety monitorings are dependent on whether on the machines for the safety gate on the operator
side a mechanical stop is mounted on the moving mould carrier platen. At machines with mechanical platen stop
on the moving mould fixing platen the safety gate can always only be opened so far as the left mould fixing platen
is opened. If it is necessary to open the safety gate further, a mechanical interlock must be shifted. By further
opening the motor and the supply voltage are switched off like at the pressing of the EMERGENCY-OFF key or
like at the opening of the rear safety gate (message: "EMERGENCY-OFF").
At machines without mechanical platen stop all movements on the clamping unit are locked at open safety gate
(message: SAFETY GATE OPEN) even if the safety key is pressed at the same time.
At machines with mechanical platen stop the movements "Mould closing" and "Mould height adjustment" are
always locked at open safety gate in the mode of operation "MANUAL", but all other movements on the clamping
unit are released by pressing the safety key in addition.
In the semi or fully automatic mode the safety gate can only be opened before the end of the cycle (from end holding
pressure) when the release of the movements on the clamping unit is switched on on the screen.
Screen line: RELEASE CLAMPING UNIT IN AUTOMATIC MODE YES
With simultaneous actuation of the safety key and input of the figure 1 this program can be set to “YES” on the
screen.
The opening of the safety gate in the automatic mode before the end of the holding pressure causes a cycle
interruption (message: “SAFETY GATE INTERRUPTS CYCLE”), at opening after the end of the holding pressure
the machine terminates the cycle and a new cycle must be introduced by actuating the start key.
The monitoring of the safety gate on the operator side occurs by the limit switches “E1” and “E2” whose actuation
is displayed by a screen tag.
SAFETY GATE : E1 E2
At closed safety gate “E1” must be actuated and “E2” deactuated, at open safety gate “E1” must be de-actuated
and “E2” actuated. If this is not the case, this means both are actuated or both are de-actuated, an alarm is released
after 1 sec. (message: “SAFETY GATE LIMIT SWITCH DEFECTIVE”).
On closing and opening the safety gate both limit switches are actuated on a certain position for a short time. If
now the safety gate is moved too slowly or left standing exactly on this position, this alarm also arises. The
acknowledgement of this alarm and the release of the locked movements can occur with the program
interruption key only after eliminating the error and perfect switching sequence (opening and closing of the gate)
of the limit switches.
At opening the safety gate still actuates a hydraulic valve in addition, which blocks the closing movement
independently of the electric monitoring.
(At large machines on opening the safety gate an electrically actuated pilot valve is deactivated. Thus a seat valve
installed into the clamping cylinder lines is closed, by which the closing movement is locked.)
This valve is monitored by further switches, E8 and occasionally E8.1. If it does not close within 0.4 seconds after
opening the safety gate, the motor stops and the alarm “HYDR.CLOSING SAFETY” is displayed. The
acknowledgement of this alarm and the release of the locked movements can occur with the program
interruption key only after eliminating the error and perfect switching sequence (opening and closing of the gate)
of the limit switches.

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Lines on screen page 'Mould opening':

SAFETY GATE: e l e c t r i c S e l e c t i o n: 2
automat. opening after: End cooling time
OPENING DELAY TIME ZVO = 2.2 s
E1 E2 E8 bSGN bSGZB bSGAB bSGN SGA SGZ

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With the screen switch “FUNCTION” different function sequences for the respective air valve can be selected.
In the manual mode the corresponding air valve can be actuated at any time with the manual control key with function
Setting
limitations
AIR VALVES 4 95 01 10 16:30
FUNCTION 0 = SWITCHED OFF

FUNCTION 1 = MOULD CLOSING AFTER A2/A3 Legend
FUNCTION 2 = BEGINNING INJECTION
FUNCTION 3 = BEGINNING COOLING TIME
FUNCTION 4 = MOULD OPENING STARTING FROM A2/A3
FUNCTION 5 = HANDLING SYSTEM RELEASE AWV
VALVE 1 FUNCTION . . .
0-5
START AIR BLOWING 1 A2 = . . ... mm
0-A
AIR BLOWING DELAY TIME 1 ZLV1 = . . . s
0 - 999.9
AIR BLOWING TIME 1 ZL1 = . . . s
0 - 999.9
VALVE 2 FUNCTION . . .
START AIR BLOWING 2 A3 = . . ... mm 0-5
0-A
AIR BLOWING DELAY TIME 2 ZLV2 = . . . s
0 - 999.9
AIR BLOWING TIME 2 ZL2 = . . . s
0 - 999.9
MOULD POSITION ACTUAL VALUE SFx = . . . . . mm
Display
PROG.INTERRUPTION 4
MOULD SET VALUE AIR
OPENING GRAPHICS VALVES
switch unequal to zero.
FUNCTION 0:
The air valve 1 is switched off. It cannot be activated in the manual mode either.
FUNCTION 1:
As soon as at mould closing the position A2 gets free, the delay time ZLV1 starts and after its expiry the air valve
SL1 is active as long as the air blowing time ZL1 is set.
FUNCTION 2:

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With beginning injection the delay time ZLV1 starts and after its expiry the air valve SL1 is active as long as the
air blowing time ZL1 is set.
FUNCTION 3:
With beginning cooling time the delay time ZLV1 starts and after its expiry the air valve SL1 is active as long as
the air blowing time ZL1 is set.
FUNCTION 4:
As soon as at mould opening the position A2 is reached, the delay time ZLV1 starts and after its expiry the air
valve SL1 is active as long as the air blowing time ZL1 is set.
FUNCTION 5:
The air valve can also be activated externally:

After opening the mould upto position “A” the actuation of the handling system input AWV is waited for. As soon
as the input is active, the delay time ZLV1 starts and after its expiry the air valve SL1isactive as long as the air
blowing time ZL1 is set.
For air valve 2 the same functions are possible. Only at function “0” the air valve 2 is actuated during the injection
process.
It can only be switched off if a function of 1 - 5 is selected and the “AIR BLOWING TIME” is set to "0".
9. EJECTOR

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Image selection key
For the advance of the ejector one pressure (P25) and 2 speeds (V25, V27) can be set. For the retraction of the
ejector one pressure (P26) and one speed (V26) are available. The desired positions for the ejectorSetting
stroke must
limitations
EJECTOR 4 95 01 10 16:30
MOULD POSITION ACTUAL VALUE SFx = . . . . . mm Display
OPENING STROKE A = ..... mm L1 + 5mm - max.
START EJECTOR FORWARD A1 = ..... L1 + 5mm - A
mm
0 - L3
EJECTOR AT THE BACK L = ..... mm L - L1
START 2ND SPEED FORWARD V27 L3 = ..... mm L - max.stroke
EJECTOR STROKE L1 = ..... mm L - L1
EJECTOR SHAKING POSITION L2 = ..... mm Display
0 - 100
EJECTOR POSITION ACTUAL VALUE SAx = . . . . . mm 0 - 100
1ST EJECTOR SPEED FORWARD V25 = ... % 0 - 100
2ND EJECTOR SPEED FORWARD V27 = ... % 0 - 100
EJECTOR SPEED RETURN V26 = ... % 0 - 100
EJECTOR PRESSURE FORWARD P25 = ... % 0 - 99.9
EJECTOR PRESSURE RETURN P26 = ... % 0 - 99.9
EJECTOR FORWARD DELAY ZAV = ... s 0 - 999.9
EJECTOR RETURN DELAY ZA = .... s 0-9
DEMOULDING TIME Z5 = ..... s in front/rear
EJECTOR COUNTER AZ = . . times
POSITION AFTER CYCLE END : REAR yes/no
EJECTION MONITORING NO
PROG.INTERRUPTION 4
EJECTOR PRODUCTION
be set with respect to the rear mechanical zero point. If shaking shall occur several times, an additional shake
position is provided for it.
10. PRODUCTION DATA
mech. ´0´ L L3 L2 L1 mech.max
Ejector forward
Shaking
Ejector return

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The ejector movement is allowed when the mould has reached the start position “A1” and the safety gates on the
clamping unit are closed. At open safety gate on the operator side in the operation mode “MANUAL” the ejector
can be moved with the push-button by pressing the safety key in addition if a platen stop for the safety gate is
mounted.
Locking conditions for possibly mounted additional equipment (e.g. cores, handling system) must also be
observed.
9.1 EJECTOR PROGRAM
The switch-on of the ejector program occurs by setting the ejector shake counter larger than “0”.
If in the automatic program the position “START EJECTOR FORWARD A1” is reached during mould opening, the
ejector advances up to position 'L3' with speed V25, starting from 'L3' with V27 up to pos. 'L1'. Afterwards the ejector
returns up to the shake position “L2”. It moves to and fro between L1 and L2 the number of times set on the shake
counter “AZ”. At the last time it returns to position “L”. Shake counter = 1 means 'no shaking, so retraction to "L"
after reaching "L1".
With the time “ZAV” the ejector advance and with “ZA” the ejector return can be delayed.
The demoulding time Z5 starts after the ejector has reached the rear end position and the shake counter has
expired. It must be set so large that the injection moulded part has enough time to fall out between the mould halves.
After the expiry of the time the next cycle starts.
If the safety gate is opened while the ejector is in front position, it stops and only returns again when the safety
gate is closed again.
If the ejector at mould closing or at core moving-in is not on the rear position “L”, these movements are locked
(message: “EJECTOR NOT AT THE REAR”).
9.2 EJECTION MONITORING (SPECIAL EQUIPMENT)
An ejection monitoring can occur e.g. by an ejection balance, ejection plate, a light barrier or a video system. Thus
possibly a better mould protection can be reached or perhaps cycle time can be saved by an earlier and/or faster
mould closing movement.
Screen line: EJECTION MONITORING YES/NO
If this program is switched on (typing in the figure “1”), in the automatic mode a new cycle only starts when the
ejection monitoring unit recognizes that the injection moulded part(s) is(are) demoulded. The new cycle starts
immediately after the ejection monitoring has given a signal and the ejector is in rear position.
If the unit does not give any signal until the expiry of the demoulding time “Z5”, the alarm “EJECTION MONITORING”
is displayed.

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Setting
limitations
PRODUCTION 4 95 01 10 16:30
START-UP CYCLES ACT. = 0 SET = ... Sch 0 - 999
0 - 999
REJECTS MAX ... Sch / . . . min Display
ACT. = 0 Sch 0-9
Display
REJECTS SEQUENCE ACT. = 0 MAX = . Sch
REJECTS TOTAL = 0 Sch
0 - 999999999
Display
SHOT SET VALUE SZ = .. . . . . . . Sch
SHOT ACTUAL VALUE SZx = 0 Sch 1 - 999
0 - 999999999
NUMBER OF CAVITIES FA = ... Display
PIECE SET VALUE Stz = . . . . . . . . Pcs
PIECE ACTUAL VALUE Stzx = 0 Pc
PROG.INTERRUPTION 4
EJECTOR PRODUCTION

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10.3 START-UP CYCLES
At production beginning - start of the automatic cycle - a start-up circuit becomes effective. The machine
produces the set set number of start-up cycles without increasing the piece counter. The shot counter is
increased. The rejects message is active. From reaching that set number the actual production begins.
Setting the set value to 0 bridges this circuit.
When switching over from automatic to manual mode and/or when interrupting the production with the program
interruption key an adjustable delay time (typ. 60sec) starts, after whose expiry the start-up cycle counter is
set to 0 in order to be able to begin the following production with the start-up circuit again.

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11. CORE-PULL (SPECIAL EQUIPMENT)
The core-pull program is executed as triple core-pull matrix. Whereas for the function of the cores 1 and 2 “real”
cores are used, for the function of the third core also the central ejector can be used. If a triple core-pull equipment
is mounted on the machine, the central ejector is not needed for the function of the third core. On the other hand
each core (max. one) can also be programmed as ejector.
Image selection key
Setting
CORE MOVING IN 1 95-01-01 16:18 limitations
CORE1 CORE2 CORE 3
MOVING IN OFF OFF OFF ON/OFF
OPERATION BY: Core Core Core 3: Core/ejector
START MOULD POSITION KS1 =..... KS2 =..... KS3 =..... mm 0 - max.mould
CONTROL POINT MOULD KE1 =..... KE2 =..... KE3 =..... mm stroke
MOVING-IN PRIORITY KP1E = 0 KP2E = 0 KP3E = 0 0 - max.mould
IN PARALLEL TO THE MOLD MOVEM.KZ1E =NO KZ2E = NO KZ3E = NO stroke
PNEUMATIC/ELECTRIC KH1E =NO KH2E = NO KH3E = NO 0-2
PRESSURELESS AFTER MOVING IN KT1E =NO KT2E = NO KT3E = NO yes/no
TIME-DEPENDENT KV1E =NO KV2E = NO KV3E = NO yes/no
MOVING-IN TIME ZE1 =..... ZE2 =..... ZE3 =..... s yes/no
MONITORING TIME ZU1 =..... ZU2 =..... ZU3 =..... s yes/no
SPEED V31 = ... V33 = ... V35 = ... % 0 - 999.9
PRESSURE P31 = ... P33 = ... P35 = ... % 0 - 999.9
MOVED OUT E14 S14 E16 S16 E18 S18 0 - 100
MOVED IN E15 S15 E17 S17 E19 S19 SAW 0 - 100
Displays
Displays
MOULD POSITION ACTUAL VALUE SFx = . . . . . mm TOGGLE LEVER POS.ACT.VALUE =. . . . . mm
IN WITHOUT CLAMPING PRES. B8 =. . . . . mm

Display
0 - max.mould
PROG.INTERRUPTION 4 stroke
CORE CORE
MOVING IN MOVING OUT

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Operator's manual
Image selection key
Setting
CORE MOVING OUT 1 95-02-01 16:18limitations
CORE 1 CORE 2 CORE 3 ON/OFF

MOVING OUT OFF OFF OFF 3: Core/ejector
OPERATION BY: Core Core Core 0 - max.mould stroke
START MOULD POSITION KO1 =..... KO2 =..... KO3 =..... mm 0 - max.mould stroke
CONTROL POINT MOULD KA1 =..... KA2 =..... KA3 =..... mm 0-2
MOVING-OUT PRIORITY KP1A = 0 KP2A = 0 KP3A = 0 yes/no
IN PARALLEL TO THE MOULD MOVEMENT KZ1A =NO KZ2A =NO KZ3A =NO yes/no
PNEUMATIC/ELECTRIC KH1A =NO KH2A =NO KH3A =NO yes/no
TIME-DEPENDENT KT1A =NO KT2A =NO KT3A =NO yes/no
DURING COOLING TIME KV1A =NO KV2A =NO KV3A =NO 0 - 999.9
MOVING-OUT TIME ZA1 =..... ZA2 =..... ZA3 =..... s 0 - 999.9
DELAY FROM BEGININING COOLING TIME ZV1 =..... ZV2 =..... ZV3 =..... s 0 - 999.9
MONITORING TIME ZUa1 = . . . . . ZUa2 = . . . . . ZUa3 = . . . . . s 0-9
SHAKING AS EJECTOR KRZ1 = 0 KRZ2 = 0 timesl 0 - 100
SPEED V31 = ... V33 = ... V35 = ... % 0 - 100
PRESSURE P31 = ... P33 = ... P35 = ... % Displays
MOVED OUT E14 S14 E16 S16 E18 S18 Displays
MOVED IN E15 S15 E17 S17 E19 S19 SAW
Display
MOULD POSITION ACTUAL VALUE SFx = . . . . . mmTOGGLE LEVER POS.ACT.VALUE SKx = . . . . . mm 0 - max.mould stroke
OUT WITHOUT CLAMPING PRES. B8 = . . . . . mm
PROG.INTERRUPTION
CORE CORE 4
MOVING IN MOVING OUT
The core-pull movement is allowed when the start position is reached and the safety gates on the clamping unit
are closed. In the operation mode "MANUAL", with open safety gate on the operator side, the cores can be run
by pressing the safety key in addition.
For each core a separate speed and one pressure for each movement direction can be set.

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11.1 CORE MOVING IN
11.1.1 Start
To each core a moving-in position is allocated (KSx). When the mould reaches this position, the moving-in starts.
Exceptions are the settings 0.0 mm and 1.0 mm. At 1.0 mm the moving-in starts with reaching the position bB8
(before clamping pressure build-up), at 0.0 mm with reaching the position bB (after clamping pressure build-up).
11.1.2 Mode of operation
Via the screen switch “PNEUMATIC / ELECTRIC" it can be selected if pressure and volume are supplied by the
hydraulic plant during the core-pull movement. When it is a pneumatically or electrically operated core, this switch
is set to “YES” so that the core-pull movement is only introduced via the 24 Volt outputs.
11.1.3 Switch-off mode
The cores can move in time- or limit switch-controlled. If the screen switch “TIME-DEPENDENT” is set to “YES”,
the core moves in until the moving-in time (ZEx) has expired. This time starts at the same time with the beginning
of the moving-in movement. If this switch is set to “NO”, the core is considered as moved in as soon as the respective
end position limit switch (bE15, bE17 or bE19) is reached. At time-dependent operation the not used end position
limit switch input must be bridged with +24V (blind plug).
11.1.4 Pressure cut-off after moving in
If the screen switch “PRESSURELESS AFTER MOVING IN” is switched on, the core is switched off with reaching
the moving-in criterion (time or limit switch). The cut-off concerns in each case the valves, at hydraulic core also
the pressure and volume actuation.
11.1.5 In parallel to the mould movement
With switched on screen switch “IN PARALLEL TO THE MOULD MOVEMENT” the core-pull movement starts as
soon as the mould passes the moving-in position. From this point both movements run off in parallel. At machines
with standard hydraulic system this program is only possible with electric or pneumatic core-pull. If it shall be
operated with hydraulic core-pull, the necessary prerequisites must be created on the hydraulic plant (at large
machines standard).
With switched off program the mould movement stops on the core moving-in position until the core is moved in.

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11.1.6 Time monitoring
With the beginning of the moving-in movement also a monitoring time starts in each case. If this time expires before
the core is moved in, the core-pull movement and the current automatic cycle are interrupted as well as an error
message is output. By setting the monitoring time to the value = 0 this function is switched off.
11.1.7 Position monitoring
This function is only relevant for the program “IN PARALLEL TO THE MOULD MOVEMENT”. On the position
“CONTROL POINT MOULD” it can be set up to which stroke point (clamping unit) the core must be moved in. When
the mould reaches this point without that the core has reached its end position, mould movement and automatic
cycle stop and an error message is output. By setting the control position to the value = 0 this function can be
switched off.
11.1.8 Moving-in priority
In order to regulate the order of the moving-in of the cores at the same moving-in positions, to each core a moving-
in priority can be allocated. It is valid that the core with the lower priority number (e.g. 0) moves in before the core
with higher priority number (e. g. 1). If two cores have the same priority number as well as the same moving-in
positions, they move in at the same time.
11.2 CORE MOVING OUT
11.2.1 Start during mould opening
To each core a moving-out position is allocated (KOx). When the mould reaches this position, the moving-out starts.
Exceptions are the settings 0.0 mm and 1.0 mm. At 0.0 mm the moving-out still starts before beginning mould
opening (under (high) clamping pressure), at 1.0 mm with releasing the position bB8, i. e. after reducing the
clamping pressure.
Starting from ES100 ND with proportional valve on the clamping unit the mould opens with fixed, low speed at 'B8'
program until B8 gets free.
11.2.2 During cooling time
If the program "DURING COOLING TIME" is switched on and the moving-out position of the core is set = 0, the
core moving-out delay ZVx starts with end holding pressure. After the expiry of this time core moving-out starts.
Thus the core can be moved out from beginning cooling time. If the moving-out delay time should not yet have expired
at beginning mould opening possibly due to a setting error, it is stopped and the core moves out according to the
set moving-out position.

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11.2.3 Mode of operation
Via the screen switch “PNEUMATIC / ELECTRIC" it can be selected whether pressure and volume are supplied
by the hydraulic plant during the core-pull movement. If it is a pneumatically or electrically operated core, this switch
is set to “YES” so that the core-pull movement is only introduced via 24 V outputs.
11.2.4 Switch-off mode
The cores can move out time- or limit switch-controlled. If the screen switch “TIME-DEPENDENT” is set to “YES”,
the core moves out until the moving-out time (ZAx) has expired. This time starts at the same time with the beginning
of the moving-out movement. If this switch is set to “NO”, the core is considered as moved out as soon as the
respective end position limit switch (bE14, bE16 or bE18) is reached.
11.2.5 In parallel to the mould movement
With switched on screen switch “IN PARALLEL TO THE MOULD MOVEMENT” the core-pull movement starts as
soon as the mould passes the moving-out position. From this point both movements run off in parallel. At machines
with standard hydraulic system this program is only possible with electric or pneumatic core-pull. If it shall be
operated with hydraulic core-pull, the necessary prerequisites must be created on the hydraulic plant (at large
machines standard).
With switched off program the mould movement stops on the core moving-out position until the core is moved out.
11.2.6 Time monitoring
With the beginning of the moving-out movement also a monitoring time starts in each case. If this time expires before
the core is moved out, the core-pull movement and the current automatic cycle are interrupted as well as an error
message is output. By setting the monitoring time to the value = 0 this function is switched off.
11.2.7 Position monitoring
This function is only relevant for the program “IN PARALLEL TO THE MOULD MOVEMENT”. On the position
“CONTROL POINT MOULD” it can be set up to which stroke point (clamping unit) the core must be moved out.
When the mould reaches this point without that the core has reached its end position, mould movement and
automatic cycle stop and an error message is output. By setting the control position to the value = 0 this function
can be switched off.

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11.2.8 Moving-out priority
In order to regulate the order of the moving-out of the cores at the same moving-out positions, to each core a moving-
out priority can be allocated. It is valid that the core with the lower priority number (e.g. 0) moves out before the
core with higher priority number (e. g. 1). If two cores have the same priority number as well as the same moving-
out positions, they move out at the same time.
11.3 CENTRAL EJECTOR AS CORE
The third core can be realized in two ways. Either by using a triple core-pull equipment or by the hydraulic and
electric equipment of the central ejector (S25, S26). In this case the ejector can of course not be used for ejection
functions. Also, the movement of the ejector is not controlled via long stroke transducers, but via mechanical limit
switches.
On the screen, page “Core 3”, it can be selected in the first line whether a core or the ejector is used.
11.4 CORE AS EJECTOR
Each core can also be used as ejector. Prerequisite is, however that the central ejector is switched off (ejector
counter = 0).
As start position for ejection the start position for core moving out is valid. The core as ejector can be operated with/
without hydraulics as well as time- or limit switch-dependent. As monitoring only the monitoring time is effective.
The remaining sequence corresponds to that of the standard ejector program.
By setting the core-pull shake counter to the value = 0 this function is switched off.
11.5 CORE SAFETY
In each closing and/or opening position of the mould the position of the cores is checked. If a core leaves its
position during the mould movement (limit switch de-actuated), it stops immediately - error message "CORE
NOT MOVED IN" and/or "CORE NOT MOVED OUT" appears.
ATTENTION: As the core-pulls are largely considered as freely

programmable, the more easily setting errors arise,
which can cause defects on the mould and machine.
Hence the control program contains safety routines,
but which can certainly not prevent all wrong settings.
Therefore approach the setting of the core programs with the highest caution.

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Additional safety offers the deliberate "blind plugging" of the not used end position switches. So each
individual, not used switch on the mould must be bridged in order to produce a smooth sequence.
e-g: Double core-pull mounted on the machine.

Customer uses simple core-pull,
moving in time-dependent (without limit switch),
moving out with end position switch.
--> Limit switch E14 ... in action
Limit switch E15 ... bridge
The program checks the selected core setting in connection with the end position bridges. In case of error:
message: "CORE LIMIT SWITCH DEFECTIVE", no closing/opening movement possible.
With simultaneous actuation of both end positions of one core (e.g. E14 and E15) the error message "CORE
x LIMIT SWITCH DEF." appears. Core movement and the following movements are stopped.
When moving in/out priorities are selected, the next core can only move when the preceding one has already
reached the end position.
If during a core movement one end position of one of the cores standing still gets free, the core movement is
stopped. Error message: "CORE x NOT MOVED IN/OUT".
In the automatic mode the cycle monitoring time should be used generally in order to be able to switch off the
machine in error cases.
When a core end position gets free during injection, injection is interrupted, the cycle is terminated, cycle new
start is prevented. Error message: "CORE x NOT MOVED IN".

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Chapter 4 SETTING OF THE INJECTION UNIT
1. CARRIAGE UNIT
Screen page as example of ES100HL:
Image selection key
Setting
limitations
CARRIAGE UNIT 4 95 01 10 16:30
NOZZLE RETRACTION 0 NO 0 - 2 / yes/no

1ST NOZZLE SPEED FORWARD V9 = ... % 0 - 100
2ND NOZZLE SPEED FORWARD V10 = ... % 0 - 100
START 2ND NOZZLE SPEED J1 = ..... mm 0 - K
Display
NOZZLE IN FRONT J
0 - 100
CONTACT PRESSURE P5 = ... % 0 - 655.35
CONTACT PRESSURE BUILD-UP TIME Z5a = . . . . . . s
0 - P5
HOLDING PRESSURE AT DEMOULDING P5b = ... %
J1 - max.stroke
NOZZLE STROKE K = ..... mm 0 - 6553.5
NOZZLE RETRACTION DELAY TIME Z6 = ..... s 0 - 100
NOZZLE SPEED RETURN V11 = ... % Display
NOZZLE POSITION ACTUAL VALUE SDx = ..... mm
Display
NOZZLE GUARD E9Q E9
PROG.INTERRUPTION 4
The movement of the injection unit is allowed at closed nozzle guard (screen tag "E9" active). For the advance
of the injection unit 2 speeds and one pressure (P5) are provided, which is limited to a minimum value for
safety reasons in the operation mode "Set-up" and/or at not closed mould. In order to facilitate the
disassembly of the screw and/or of the material cylinder the unit can be swivelled out. In this position the
movement of the injection unit is only possible together with the safety key.
Index: 8.04-0 / 1995-01-05 Injection unit 4 1

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P5 (limited at open mould and

in the set-up program)
V9
V10
Z5a
J J1 K SDx
P fix in manual mode
V11
J K SDx
B407DE73
2 4 Injection unit Index: 8.04-0 / 1995-01-05

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2. HEATINGS
2.1 GENERAL
The card slide-in module E-8-THERMO is provided for the measurement and closed loop control of temperatures
on ENGEL. It works as intelligent peripheral unit with self-optimizing closed loop control, by which the time-
consuming empirical determination of the optimum control parameters is omitted.
In order to guarantee an optimum closed loop control, at the first putting into operation of a heating circuit (e.g. mould
heating) a control parameter data set must be determined and stored on the mould diskette together with the setting
parameters of the machine. By switching on the optimization program on the page of control parameters the
processor calculates new control parameters automatically within a calibration cycle (see item 2.5.3).
Per card 8 heating circuits with one input each for a thermocouple and one 24V/500mA output each for heating
and/or cooling are available. The outputs switch in positive logic,
i.e. output = +24V ... Heating and/or cooling on
= 0V ... off
The original state is displayed by means of light emitting diodes.
2.2 CHARACTERISTICS
The control characteristic line corresponds to a P-I-D behaviour.

The resolution of the measuring inputs is 14bits.
Minimum controller clock time (t0) = 200ms
Couple types: FE-KO Standard
NiCr-Ni optional software (on HCPU)
PT100optional hard and software (card E-8-PT100)
Self-optimizing controller
alternatively per zone automatic setting for scanning time (t0)
Proportional factor (xph),
Integral factor (tn),
Differential factor (tv).
Controller types: 0 : only display of the zone temperature
1 : Regulator mode (% control)
2 : 2-point controller (heating on/off or cooling on/off)
3 : 3-point controller (heating/cooling)
Emergency mode (= alternative switchover to % control after thermocouple break)

Start-up circuit (= Heating-up with half the capacity up to threshold value)
Capacity display (in %)
Application: The most inert temperature distances up to hot runners with increase times of 10°C / sec,
temp.control units without installed controller, feed zone cooling, oil cooling...

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2.3 OPERATION
Image selection key 'HEATINGS'
Display field:
T ... in tolerance
Display ready for production,
H ... Heating phase
Variable zone designation texts soaking finished
K ... Cooling lphase
F ... Error Setting
limitations
HEATINGS 1-7 4 95-01-14 15:34
ZONE SET
ACTUAL STATUS MONIT-
(°C) T H K F ORING 0 - 500.0
Nozzle............... 1. 200.0 °C 200.3 ON 0 - 500.0
Cylinder............ 2. 210.0 °C 209.2 ON 0 - 500.0
Cylinder............ 3. 210.0 °C 209.7 ON 0 - 500.0
Cylinder............ 4. 210.0 °C 210.4 ON 0 - 500.0
Mould 2P.......... 5. 16.0% ***.* OFF 0 - 500.0
Mould 3P.......... 6. -19.0% ***.* OFF 0 - 50.0
MAX.POS.TEMPERATURE DEVIATION 20.0 °C 0 - 50.0
MAX.NEG.TEMPERATURE DEVIATION 30.0 °C
0 - 500.0
LOWERING TO 120.0°C OFF on / off
0 - 500.0
Traverse........... 7. 8.0 °C 49.5 0 - 50.0
MAX.POS.TEMPERATURE DEVIATION 10.0 °C
min - 60.0
OIL TEMPERATURE: 40.0 °C 39.8 0 - max
MINIMUM TEMPERATURE 37.0 °C min - 60.0
MAXIMUM TEMPERATURE 60.0 °C
PROG.INTERRUPTION 4
HEATINGS HEATINGS HEATINGS CONTR.PAR. CONTR.PAR. TEMP.CONTR.
1-7 8 - 15 16 - 23 0 - 15 16 - 23 UNITS
2.3.1 Activate temperature zone controller
Mould heatings (group 1) and cylinder heatings (group 0) are switched on with separate switches on the keyboard
panel. A digital signal of these switches activates the corresponding zones. The main contactors energize. Only
after the input of a set value larger than 0 the corresponding zone controller begins to work and the corresponding
tolerance zones regarding alarm messages act. The control parameters must have certain basic settings. See to
it section 'Control parameters'.
An automatic heating-up causes that all zones of one group reach the set set value at the same time if possible
(the faster zones wait for the slower ones).

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2.3.2 Settings and displays
For each heating zone on the screen a temperature setting (set value), a temperature display (actual value), a
display field and a switch, with which the negative monitoring can be switched on/off, is provided. Each zone is
superscribed individually corresponding to its purpose.
For the traverse temperature (material feed chute) only one positive monitoring value is available.
The oil cooling control zone (always zone 0) is provided with a separate tolerance zone besides set value
preselection, actual value display and display field.
2.3.3 Display field
Per zone lighting-up screen tags show the current state of the controller.
T H K F
Error display in general, zone produces alarm for:

temperature too high,
thermocouple break,
heating defective,
short circuit on output.
Error text appears in the error message field
right below on the screen
in cooling phase
in heating phase
Temperature is in the tolerance range
2.3.4 Soaking
After switching on the machine and heating up the material cylinder, with switched-on monitoring (at least one
monitoring switch is at 'ON') after exceeding the negative deviation value the screw movement is still locked for
approx. 2 minutes. Thus a better soaking of the material is guaranteed and a mechanical damage of the screw tip
is prevented. The screen tag 'Ready for production' in the 2nd image line flashes for the display of the soaking phase.
For zone 2 always the monitoring shall remain switched on (danger of break of the screw tip).
2.3.5 Lowering
Screen lines:
LOWERING TO ...... °C ON/OFF
if the cycle monitoring or an alarm, which brings the machine to a standstill, react, all active heatings are regulated
down to the set lowering temperature value automatically in order to prevent a possible thermal damage of the
plastic melt (message 'HEATING LOWERS'). If the lowering temperature is set as large as or larger than the highest
value of a zone on a screen page, lowering does not occur. The value "0" as lowering temperature causes the
switching-off of all heating zones via main contactors. Further, by switching on the lowering program it can be
lowered to the set value manually. The adjustable lowering value is always valid for all zones together on one screen
page; exception: the traverse cooling does not lower.

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Operator's manual
Lowering of the heatings is also activated automatically when the control voltage is switched off and on again in
order to avoid a possible overheating after a short power failure during the production. For this purpose before the
power failure the machine in automatic mode or heating lowering must already be active or the error 'Motor stop
delayed' must exist.
2.3.6 Oil temperature control
Screen lines:
THKF
OIL TEMPERATURE: 40.0 °C 39.8
MINIMUM TEMPERATURE 37.0 °C
MAXIMUM TEMPERATURE 60.0 °C
The oil temperature is controlled by means of water cooling. During the production it should always be approx. 40
- 45°C. The cooling water valve is connected to the cooling output of the zone 0. If the oil temperature is below
the set minimum value, after switching on the motor an oil preheating program starts (message: OIL
TEMPERATURE TOO LOW). An automatic cycle start is not possible. Manual and set-up operation are further
possible, the oil heating process is interrupted when introducing a movement and it is continued again time-delayed
after this has been terminated in order to avoid shocks in the hydraulic system.
During the oil heating the increase of the temperature is checked. Within a space of time of approx. 5 min the
temperature must rise by 2 °C. Otherwise the error 'ERROR OIL PREHEATING' arises, the alarm lamp is set and
the motor switches off.
If the maximum value is exceeded, the cycle is interrupted and alarm is displayed (message OIL TEMPERATURE
TOO HIGH).
If the minimum temperature is not reached by approx. 10 °C *) in the automatic mode, the cycle stops, the alarm
lamp is set.
*) Settings of constants can be seen in the 'technical manual', chapter 4, item 7.
2.3.7 Traverse temperature control
Screen lines:
TKF
Traverse....... 7. 48.0 °C 49.5
MAX.POS.TEMPERATURE DEVIATION 10.0 °C
The feed zone (traverse) is temperature-controlled by means of water cooling. A water valve, connected to the
cooling output KÜx takes over the control. Up to the ES420 zone 7 and/or KÜ7 is used; starting from ES500 zone
7 or 8 and/or KÜ7 or KÜ8. The lowering program has no effect on the traverse temperature control. The feed zone
is not allocated to any group, but belongs to the cylinder heatings as regards error messages.
2.3.8 Start-up circuit
Also 'Half-wave circuit'.
Screen line from heating page 2:
e.g.: START-UP CIRCUIT ON active:

FOR ZONES 8 - 13 THRESHOLD = 80 %

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In order to protect sensitive heating cartridges or media to be heated in the heating-up phase against too rapid
temperature increases, the heating capacity can be reduced to the half with so-called half-wave circuit. The zones
which shall offer this possibility are defined by the operator on the screen: in the example above the range from
zone 8 up to zone 13 is set to start-up. The start-up can be switched on/off via screen switch.
Function: Up to a percentage (threshold) which can be given of the respective zone set value or
after it has not been reached, the zones heat with half the capacity.
e.g.: Zone set value = 150 °C

Threshold = 80 % (correspond to 120 °C)
Threshold value = 120 °C
---> Up to reaching the 120 °C the zone is heated with half the capacity.
Threshold = 0% ---> always full capacity

Threshold = 100 % ---> always half the capacity
By lighting up the tag 'ACTIVE' displays the active start-up circuit. It goes out on reaching the threshold value of
all zones.
2.4 ERROR MESSAGES
In the sequence error message field right below on the screen global hints, alarms and error messages appear.
By means of the actual temperature displays and display fields the zone which has released the alarm can be
determined. The error effects, eliminations and resettings are described in the chapter 5. The following messages
are possible:
(53) CYLINDER TEMP. LOW and (125) MOULD TEMP. LOW

(65) CYLINDER TEMP.HIGH and (126) MOULD TEMP. HIGH
(67) CYL.COUPLE BREAK and (168) MOULD COUPLE BREAK
(169) OIL COUPLE BREAK
(70) CYL.HEATING DEFECTIVE and (127) MOULD HEATING DEFECTIVE
(131) SOAKING
(132) CYLINDER HEATING OFF and/or (133) MOULD HEATING OFF
(167) SHORT CIRCUIT TEMP.CARD
(101) HEATING SWITCHED OFF
(74) CHECK CONTROL PARAM.
(66) HEATING LOWERS
(42) OIL TEMP.TOO LOW
(43) OIL TEMP.TOO HIGH
(117) ERROR OIL PREHEATING

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2.5 CONTROL PARAMETERS AND FURTHER FUNCTIONALITY
Image selection key ‘CONTROL PARAMETERS 0 - 15´ + F4
CONTROL PARAMETERS 0-15 3 95-01-09 16:17
Z o n eXph T n Tv T0 HKV C b h Pact Emerg.% contr.Optim.

°C sec sec sec sec °C % mode Mode Interlock
0. 1.0 0.0 0.0 10.0 1.00 1.0 0 NO 2 OFF
1. 61.6 115.2 23.0 3.2 1.00 57.0 35 YES NO 2 OFF
2. 219.1 716.8 143.4 25.6 1.00 192.0 14 NO NO 2 OFF
3. 217.6 716.8 143.4 25.6 1.00 189.0 6 NO NO 2 OFF
4. 162.4 614.4 122.8 25.6 1.00 154.0 10 NO NO 2 OFF
5. 50.0 700.0 120.0 15.0 1.00 40.0 18 NO NO 2 OFF
6. 50.0 700.0 120.0 5.0 1.00 40.0 4 NO NO 3 OFF
7. 50.0 400.0 100.0 0.2 1.00 40.0 2 NO NO 3 OFF
8. 10.0 0.0 10.0 5.0 1.00 0.0 0 NO NO 3 OFF

9. 10.0 0.0 10.0 5.0 1.00 0.0 0 NO NO 3 OFF
10. 10.0 0.0 10.0 5.0 1.00 0.0 0 NO NO 3 OFF
11. 10.0 0.0 10.0 5.0 1.00 0.0 0 NO NO 3 OFF
12. 10.0 0.0 10.0 5.0 1.00 0.0 0 NO NO 3 OFF
13. 10.0 0.0 10.0 5.0 1.00 0.0 0 NO NO 3 OFF
14. 10.0 0.0 10.0 5.0 1.00 0.0 0 NO NO 3 OFF
15. 10.0 0.0 10.0 5.0 1.00 0.0 0 NO NO 3 OFF
PROG.INTERRUPTION 4
HEATING HEATING HEATING CON.PARAM. CON.PARAM.
ZONE 1-7 ZONE 8-15 ZONE 16-23 ZONE 1-15 ZONE 16-23
TEMP.CONTR:
UNITS
The meaning and/or the setting of the parameters on this screen page are described in the 'Technical manual',
chapter 4.
For the operator on the machine primarily the switches '% controller', 'Emergency mode' and 'Optimization' are
interesting and described in the following.
2.5.1 Regulator mode (% controller)
The regulator mode can be selected individually for each zone. It is needed to temperature control zones which
are equipped without returning thermocouple, a constant temperature control capacity, adjustable in per cent,
being raised on the controller output. Due to the lack of the couple and thus of the actual temperature, from the
computer, except for the short circuit recognition, no monitoring can occur. If despite existing actual temperature
the zone is switched to regulator mode, the monitorings remain ineffective also in this case.
On the control parameter screen page a switch (% controller) is provided for the choice between regulator

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mode and 'normal' controller mode. When setting the switch to 'REGULATOR' the mode is automatically set
to '1' and on the screen page for heatings instead of the zone set value [ °C] the regulator set value is displayed
with the unit [%] and an input range of [-100 ... 100]. By switching off the switch the backtakeover of the zone set
value set before the switching-on and resetting of the mode on the value which corresponds to the determination
of the zone occurs:
(Text constant) Text Controller determination Mode

-------------------------------------------------------------------------------------------------------
0 (not used) Measuring channel (0)
1 Nozzle 2-point controller (2)
2 Cylinder 2-point controller (2)
3 Cylinder 3P 3-point controller (3)
4 Mould 2-point 2-point controller (2)
5 Mould 3-point 3-point controller (3)
6 Traverse 2-point controller (2)
7 Material Measuring channel (0)
8 Res.for Microtemp Measuring channel (0)
9 Flange Measuring channel (0)
10 Temp.control unit Measuring channel (0)
11 Hot runner 2-point controller (2)
2.5.2 Emergency mode
For each zone a selector switch for 'Emergency mode' exists on the control parameter page. If in the switched-
on state ('YES') on this zone a thermocouple break appears, the message 'THERMOCOUPLE BREAK' is output,
but the production continues to run undisturbed. In this case it is automatically switched over from controller to
regulator mode, the temperature control capacity raised last being used as new regulator set value. The conversion
to regulator mode does not occur when the temperature control capacity was 100% (possibly heating-up phase)
in order to ensure that the conversion to emergency mode only occurs when the zone is in swung-in state and no
fatal overheating can take place.
2.5.3 Self-optimization
The determination of the parameters (identification of the controlled members) for an optimum control behaviour
of the different zones can turn out to be tedious and sometimes not satisfactory in manual, empirical method of
working. On the E-8-Thermo card exists the possibility to call on an automatic finding of the control parameters
alternatively per zone.
In general a single heating-up optimization is enough, i.e. the control parameters function for the heating-up of the
zones as well as in the control state in the operating point. If it appears necessary to improve the oscillation
behaviour of the zones around the operating point, an 'operating point optimization' can be connected at the outlet
side zone per zone.
Heating-up optimization, prerequisites and procedure:
- Because of mutual strong influence all zones should be identified at the same time.
- Bring zone(s) to room temperature.
- Set heating switch on the control panel to 'OFF', the tag 'INTERLOCK' lights up.
- Set set values at least 50 °C above the actual temperature, best to the later operating
temperature, 30 °C deviation from the actual zone set value.

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- Do not set the pos. and neg. temperature deviation too small (to 50 °C) as in the following, not
controlled heating-up phase the monitoring functions could react.
- The cooling controlled members used in the operation (e.g. traverse cooling) should be switched on by
all means as also such influence the determination of parameters.
- Switch off half-wave circuit (start-up circuit).
- Set controller mode to '2' (2-point controller)
- Make basic setting of control parameters in order to prevent extreme settings:
Xph Tn Tv T0 HKV Cbh

Nozzle 40.0 100.0 25.0 5.0 1.00 0.0
Cylinder 100.0 600.0 200.0 10.0 1.00 0.0
Mould heatings 100.0 600.0 200.0 10.0 1.00 0.0
Hot runners 20.0 50.0 15.0 0.5 1.00 0.0
- Switch on screen switch 'OPTIMIZATION' for the corresponding zones. The values for T0 are
automatically set to 0.2 sec.
It is switched off automatically when the set-actual temperature difference is less than 50 °C or the
determination is completed.
- Switch on heating switch on the control panel.
------> The self-determination, heating-up attempt, begins.

Duration: for 'fast' zones approx. 1 - 2 minutes
for 'slow' zones up to 2 hours
The machine heats with 100% heating capacity up to a certain value and afterwards switches off the
heating. After a defined cooling-off phase the calculation of the optimum control parameters begins.
During the determination phase the set set values need not necessarily be reached.
After completing the determination process the parameters:
Xph = reciprocal value of the amplification

Tn = integral share
Tv = differential share
T0 = cycle time
Cb = Cut-Back, proportional factor for heating-up
are overwritten, the machine switches over to control operation and begins with the heating-up to the
set set values.
By switching off the optimization switch the self-determination can be stopped manually.
A manual resetting of the self-optimized control parameters after completing the automatic determination
is possible.
Hints:The set zone set temperature can be exceeded at the heating-up attempt.
Therefore the heating-up attempt should be made without material. Thus arising errors in the
determination are minimal and can be neglected.
In case of need the value for HKV must be set manually:
° Heating-cooling ratio HKV only for 3-point controllers, basic value = 1.00
° For 2-point controllers (only heating or only cooling) HKV is not needed.
For the oil cooling (always zone 0) the parameters represented in the above screen image of control parameters
function well. Here a self-determination is not exactly necessary.

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Also for the traverse temperature control the parameters, like set for the oil cooling, are considered as good.
If a couple break appears during the determination, this is interrupted. The 'optimization' switch is set to 'OFF'.
The heating-up monitoring is not active during the self-determination.
Operating point optimization
If necessary - also during the automatic mode - the parameters of individual zones found at the heating-up
optimization occurred before can be reoptimized for better oscillation behaviour in the operating point.
Procedure
- current optimizations must be completed (= all optimization switches are 'OFF').
- all temperatures must be swung in in their operating points. Actual values ~ set values.
- half-wave circuit must not be active.
- the maximum negative temperature deviation shall not be set too small (approx. 30°C)
- do not switch on neighbouring zones simultaneously to the operating point optimization.
- switch on the optimization switches zone per zone, e.g. individually or not neighbouring ones at
the same time, 1 + 3 (+ 5) ..., then, after completion 2 + 4 ...
Reoptimize mould heating zones individually, especially if the mutual influence of the heatings
is not known exactly.
The optimization undertakes a cooling phase by 8 °C. ATTENTION in the automatic mode !
After reaching the difference of 8°C from the actual value in the start moment the reoptimization is
completed, the set value is regulated again. The optimization switch goes on 'OFF'.
- Switch on the reoptimization only when the current optimization(s) is (are) switched off and the
temperatures are swung in again.
2.5.4 Compatibility of part diskettes
Compatibility of the part sets (mould data) between the E-8-Thermo and the older temperature card E-7-TEMP7
basically exists. Taken over are zone set values, tolerance limits, lowering values and switches. The conversion
from total to tenth temperature values and vice versa occurs when reading in a diskette. Nevertheless after the read-
in it is recommended to see through the heating pages since say the zone allocation on a machine, equipped with
E-8-Thermo, is a different one due to the presence of 8 instead of 7 zones per card (traverse cooling). Between the
card types the heating control parameters are not of the same meaning and are therefore not taken over from the
diskette.

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2.5.5 Storage of the temperature data
The storage of the machine settings of the temperature zones is made separately depending on zone function on
machine and/or parts data diskette.
On parts diskette are stored by all means:
Heating set values

% set values (for regulator mode)
Monitoring switches
Tolerances
Reduction values
Half-wave settings
Stored on machine and/or parts data diskette dependent on use:
Control parameters (xph, tv, tn, HKV, t0, cb)

Controller mode (mode)
Regulator mode switch (% controller)
By means of the setting of the zone designation text (preset, see page 5 of this chapter) the allocation of the storage
on parts and/or machine diskette is determined. In case of need (e.g. attachment of further mould heatings) the
setting of this text can be changed with constants. The procedure of the change is described in the 'Technical
manual'.
The zone designators set the storage course:

stored on
(Text constant) Text Controller determination parts disk machine disk
-----------------------------------------------------------------------------------------------------------------------------
0 (not used) Measuring channel x
1 Nozzle 2-point controller x
2 Cylinder 2-point controller x
3 Cylinder 3P 3-point controller x
4 Mould 2-point 2-point controller x
5 Mould 3-point 3-point controller x
6 Traverse 2-point controller x
7 Material Measuring channel x
8 Res.for Microtemp Measuring channel x
9 Flange Measuring channel x
10 Temp.control unit Measuring channel x
11 Hot runner 2-point controller x
After changing zone designation texts or new optimizations of heatings the corresponding diskette must be
updated.
The parameters of undesignated, free, not used zones (text constant = 0) are stored with the parts data set without
restriction.

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2.6 TEMPERATURE CONTROL UNITS WITH SERIAL CONNECTION (OPTION)
By means of a serial interface a communication with external temperature control units can be built up. The external
unit controls the medium to be temperature controlled automatically, gets temperature set value, maximum
deviations and lowering value from the machine control unit and supplies to this actual value, heating and cooling
capacity, mode of operation and error messages.
Image selection key ´HEATINGS´ + function key F6
TEMPERATURE CONTROL UNITS 4 95-01-08 23:23
COMMUNICATION CONTROL UNIT <==> TEMP.CONTROL UNITON
Z O N E S 1 2 3 4
COMMUNICATION ON ON ON OFF
SET VALUE °C 88.0 88.0 92.0 0.0
ACTUAL VALUE °C 86.0 87.0 92.0 0.0
POS.TOLERANCE °C 10.0 10.0 10.0 0.0
NEG.TOLERANCE °C 6.0 6.0 6.0 0.0
LOWERING VALUE °C 35.0 35.0 35.0 0.0
LOWERING OFF OFF OFF OFF
CAPACITY % +20 +10 -2 0
IN TOLERANCE
PROG.INTERRUPTION 4
HEATING HEATING HEATING CONTR.PARAM. CONTR.PARAM. TEMP.CONTR.
ZONE 1-7 ZONE 8-15 ZONE 16-23 ZONE 0-15 ZONE 16-23 UNITS
For the transmission of the data a record runs, which is capable of communication for the following manufacturers
of temperature control units:
HB-THERM, REGLOPLAS, BOE-THERM, TOOLTEMP, GWK,

WITTMANN, PIOVAN.
Up to 16 zones can be connected per interface depending on the technical specification.

Each zone can be activated / deactivated via screen switch. At 'OFF' the external controller continues to run with
set value set last.
If an actual value falls outside the set tolerances, the next automatic cycle is locked, the alarm lamp lights and
the errors 143 'TCU-TEMP.TOO HIGH' and/or 144 'TCU-TEMP.TOO LOW' appear on the screen.

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The temperature control unit signals further errors, which switch off the unit and lock the next automatic cycle:
134 “TCU-SET VALUE OUT OF RANGE" ....if not plausible set value
135 “TCU-COUPLE BREAK" ....if thermocouple broken
136 “TCU-HEATING DEFECTIVE" ....if HB heating broken
137 “TCU-COOLING DEFECTIVE" ....if HB cooling defective
138 “TCU-LEVEL LOW" ....if cooling fluid under minimum
139 “TCU-FLOW TOO SMALL" ....if required flow is not reached
140 “TCU-LIMIT TEMP.EXCEEDED" ....if temperature limit exceeded
141 “TCU-PUMP DEFECTIVE" ....if HB-Therm pump defective
142 “TCU-COMMUN.TIMEOUT" ....RS232 interface communication interrupted
Settings on the temperature control unit:
Under "CONTROLLER/COOLER OPERATION MODE" there are the following possibilities:
Controller operation mode Cooler operation mode
Mode 0 ....... MACHINE ______________ EXTERNAL

Mode 1 ....... UNIT ______________ EXTERNAL
Mode 2 ....... MACHINE ______________ INTERNAL
Mode 3 ....... UNIT ______________ INTERNAL

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3. INJECTION AND HOLDING PRESSURE
Image selection key

Setting
limitations
INJECTION 2 95 01 10 16:30
INCREASED SPECIFIC INJECTION PRESSURE YES yes/no

MAX. INJECTION SPEED: ... mm Display
INJECTION SPEED: ACT. = . .. mm/s SET: Displays
... ... ... . .. ... 0 - max.speed
... ... ... . .. ... 0 - max.speed
INJECTION PRESSURE LIMIT P6 = ..... bar 0 - max.pressure
HYDRAULIC PRESSURE ACTUAL VALUE PHx = ..... bar Display
SCREW POSITION SSx = ..... mm Display
INJECTION TIME MONITORING:
MIN = ... MAX = ... ZSx = ... s 0-max, min-999.9, display
INTRUSION TIME ZIN = ..... s 0 - 6553.5
INTRUSION SPEED V23 = ... % 0 - 100
INJECTION DELAY ZSV = . . . . . s *) 0 - 99.99
PROG.INTERRUPTION 4
INJECTION SWITCHOVER SET VALUE CONTROL
MODE GRAPHICS PARAMETERS
*) from ES500
The injection movement is allowed at closed safety gate, closed nozzle guard and when the material cylinder
temperature is within the set tolerance band. With swivelled-out injection unit the safety key must be pressed in
addition, the injection speed being limited to approx. 20 %.

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3.1 INCREASED SPECIFIC INJECTION PRESSURE
The necessary injection pressure at an injection process essentially depends on the viscosity of the material, on
the temperature, the injection speed and the flow resistance of the mould (sprue cross-sections, wall thickness
of the injection moulded part, mould temperature etc.). Depending on the screw diameter the specific injection
pressure is in a certain ratio to the hydraulic pressure (see injection pressure diagram).
With switched-off program ( drawn-through line) the machine can operate with a higher injection speed, but
it needs a higher hydraulic pressure in order to reach a certain specific injection pressure. If the maximum hydraulic
system pressure is not sufficient, one switches the program “INCREASED INJECTION PRESSURE” to “YES” (-
------ broken line).
bar
specific injection pressure
2600
2400 2400 (40 )
2200
2000
1900 (45 )
1800 1800 (40 )
1600
1550 (50 )
1400 1400 (45 )
1200
1150 (50 )
1000
800
600
400
200
Hydraul. pressure
0 10 20 30 40 50 60 70 80 90 99.9 %
16 32 48 64 80 96 112 128 144 160 bar
B408DE72

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3.2 SETTING THE INJECTION SPEED
INJECTION PROFILE 4 95 01 10 16:30
100%
0%
SSx 100.3 mm 200.0 mm
C2J C2H C2F C2D C2B
C2I C2G C2E C2C C1
C2J C2I C2H C2G C2F C2E C2D

Injection stroke 0.0 10.0 20.0 30.0 40.0 45.0 60.0 70.0
V: 100% = 150mm/s 30 30 30 50 60 65 68 68
P: 100% = 160.0bar 70.0 80.0 80.0 80.0 80.0 80.0 80.0 80.0
PROG.INTERRUPTION 4
Each injection speed is effective a tenth of the plasticizing stroke and each holding pressure a tenth of the holding
pressure time. By means of the set value graphics the speed switchover points can be changed manually. An
automatic tenth part formation only occurs again with twice the same input of the plasticizing stroke “C1”.
If individual points have been changed manually, with the following input of the plasticizing stroke "C1" the whole
profile is adapted to the new C1 in per cent (compression/extension).

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At injection the machine shall be able to control the set speed exactly reproduceable until reaching the
switchover point, even if disturbing influences, such as e.g. viscosity changes or temperature variations of the
material, change the injection resistance. This is only possible when the set injection pressure “P6” is set higher
than the actually necessary injection pressure (approx. 20 bar higher). It must be made sure that neither the
maximum hydraulic system pressure nor the set injection pressure “P6” is reached at injection (see manometer
position “3” or screen display “PHx” and/or graphics). The set injection pressure limit may only be considered as
safety setting.
A machine with CC100 interpolates the speed and pressure profile. Start and ramps are set via adjustable constant.
Pressure and speed diagram “INJECTION and HOLDING PRESSURE”
3.3 INJECTION TIME MONITORING
necessary injection pressure
HOLDING PRESSURE INJECTION
Screen lines: INJECTION TIME MONITORING

MIN = ... MAX = ... ZSx = ... s
The injection time monitoring cannot be switched off. The maximum monitoring must always be set larger than
the actually needed injection time. At the reaction of the minimum and/or maximum monitoring the rejects counter
counts, injection is interrupted and the machine terminates the cycle. The piece counter does not count. A
downstream unit can be controlled with a signal.
3.4 SWITCHOVER TO HOLDING PRESSURE

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Operator's manual

After the mould filling process (injection) it shall be switched over from speed control to pressure control (holding
Setting
limitations
SWITCHOVER MODE 4 95 01 10 16:30
yes/no
STROKE-DEPENDENT SWITCHOVER YES 0 - max.stroke
SWITCHOVER SET VALUE C3 = ..... mm Display
Display
SCREW POSITION AT SWITCHOVER C3u = ..... mm yes/no
SCREW POSITION SSx = ..... mm 0 - 6553.5
INJECTION TIME SWITCHOVER NO Display
SWITCHOVER SET VALUE Z1 = ..... s yes/no
INJECTION TIME ACTUAL VALUE ZSx = . . ... s 0 - max.pressure
HYDRAULIC PRESSURE SWITCHOVER NO 0 - max.stroke
SWITCHOVER SET VALUE PH = ..... bar Display
SWITCHOVER RANGE C3b = . . ... mm Display
HYDRAULIC PRESSURE AT SWITCHOVER PHu = ..... bar yes/no
PEAK VALUE PVS = . . . . . ACTUAL PHx = ..... bar 0 - max.pressure
CAVITY PRESSURE SWITCHOVER NO Display
SWITCHOVER SET VALUE PF = ..... bar Display
yes/no
CAVITY PRESSURE AT SWITCHOVER PFu = . . . . . bar
PEAK VALUE PFs = . . . . . ACTUAL PFx = . . . . . bar
EXT. SWITCHOVER C3E NO
PROG.INTERRUPTION 4
pressure) in order to still press after material via the fluid centre during the first cooling phase. At this moment always
the same amount of material must be in the mould in order to produce the same parts quality. There are 5 different
switchover possibilities in order to influence possibly appearing disturbing influences (e. g. volume variations): time-
dependent, stroke-dependent, hydraulic pressure-dependent, mould cavity pressure-dependent, externally via an
additional device.
Generally that switchover mode shall be selected, which causes the largest precise reproducibility of the parts
quality. Always only one switchover mode setting is possible. At the selection of one possibility the other
switchover modes are switched off automatically.
The effective switchover mode is displayed on the screen by the lighting-up of a screen tag at PF, PH, C3, Z1 and
C3E.
3.5 HOLDING PRESSURE

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Operator's manual
Stroke-dependent switchover:
The machine switches to holding pressure on reaching the position "C3".
Setting example: STROKE-DEPENDENT SWITCHOVER YES

SWITCHOVER SET VALUE C3 = 10 mm
SCREW POS. AT SWITCHOVER C3u = ... mm
SCREW POSITION SSx = ... mm
Time-dependent switchover:
The machine switches to holding pressure after the expiry of the injection time “Z1”.
Setting example: INJECTION TIME SWITCHOVER YES

SWITCHOVER SET VALUE Z1 = 1.3 s
INJECTION TIME ACTUAL VALUE ZSx = ... s
Hydraulic pressure-dependent switchover:
The machine switches to holding pressure after reaching the switchover range and the set hydraulic pressure (PH).
Hydraulic pressure-dependent switchover is mainly used if at very slow injection speeds the inaccuracy of the screw
non-return valve and thus arising volume variations shall be compensated.
Setting example: HYDRAULIC PRESSURE SWITCHOVER YES

SWITCHOVER SET VALUE PH = 80 bar
SWITCHOVER RANGE C3b = 30 mm
HYDRAUL.PRESS.AT SWITCHOVER PHu = ... bar
PEAK VALUE PVs= ... ACT. PHx = ... bar
Mould cavity pressure-dependent switchover:
The machine switches to holding pressure (only possible with incorporated pressure and/or force transducer in the
mould) after reaching the set mould cavity pressure. In practice it has shown that mould cavity pressure-dependent
switchover yields a better reproducibility often at single-cavity moulds. (See also chapter 6/item 8 "Charge
amplifier")
Setting example: MOULD CAVITY PRESSURE SWITCHOVER YES

SWITCHOVER SET VALUE PF = ... bar
MOULD CAVITY PRESS.AT SWITCHOVER PFu = ... bar
PEAK VALUE PFs = ... ACT. PFx = ... bar

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Image selection key
MICROGRAPH 93-12-12 16:24

SCALES: SELECTION 1
AG-1 PHx 200.0 bar
AG-1 VSx 60 mm/s
IDK1
ACTUAL VALUES:
AG-1 PHx *.* bar
AG-1 VSx * mm/s
FLOW NUMBER UNIT 1: 98.4 Switchover point: UNIT 1
M A N U A L
MICROGRAPH MICROPLAST etc.
- FLOW 1 -->

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Operator's manual
Image selection key

Each holding pressure is in general effective one tenth of the holding pressure time “Z2”. The peak value of the
Setting
limitations
HOLDING PRESSURE 0 95 01 10 16:30
HOLDING PRESSURE: P7 UP TO P16 (bar)

... ... ... ... ... 0 - max.pressure
... ... ... ... ... 0 - max.pressure
HOLDING PRESSURE TIME Z2 = ..... s 0 - 6553.5

COOLING TIME ACTUAL = ..... Z4 = ..... s 0 - 6553.5
CUSHION MONITORING NO yes/no

MIN = . . . . . mm MAX = . . . . . CPx = . . . . . 0-max, min-25mm
mm
0 - max.stroke
METERING STROKE C1 = ..... mm Display
SCREW POSITION SSx = . . . . . mm Display

Display
HYDRAULIC PRESSURE ACTUAL VALUE PHx = . . . . . bar
HOLDING PRESSURE PEAK VALUE PNS = . . . . . bar 3 progr. values
SCREW DIAMETER SDM = . . mm
PROG.INTERRUPTION 4
HOLDING SET VALUE
PRESSURE GRAPHICS
hydraulic holding pressure often arises immediately after the switchover to holding pressure and is stored as “PNS”.
In standard 3 screw diameters can be set, which must only be considered as notice. With the special program
“Absolute value input” the screw diameter is however necessary for converting from the specific injection pressure
to the hydraulic pressure. At special screw diameter a pressure limitation can thus become effective.
With the set value graphics for holding pressure to each holding pressure stage period of time, pressure and
volume can be given:
At the input of the Z2 the individual time stages are also changed proportionally (compression / extension). A tenth
part formation results when entering the same value on Z2 twice.

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The processing of the holding pressure profile occurs interpolating (point to point with straight line connection) with
the exception of the start and end ramp. These can be given with constant values.
HOLDING PRESSURE PROFILE 4 95 01 05 16:30
100%
0%
Z2x 0.00 s 10.00 s
Z2a Z2b Z2c Z2d Z2e Z2f Z2g Z2h Z2i Z2
Z2a Z2b Z2c Z2d Z2e Z2f Z2g

Holding pressure time 0.00 1.00 2.00 3.00 4.00 5.00 6.00 7.00
V in % 20 20 20 20 20 20 20 20
P: 100% = 150.0 bar 100 90 85 80 70 60 50 30
PROG.INTERRUPTION 4
HOLDING SET VALUE
PRESSURE GRAPHICS

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4. PLASTICIZING
Image selection key

Setting
limitations
PLASTICIZING 4 95 01 10 16:30
METERING STROKE C1 = ..... mm 0 - max.stroke
PLASTICIZING SPEED: %
... ... ... ... ... 0 - max.stroke
SCREW SPEED MAX. DZm = . . . u/m Display
SCREW SPEED ACTUAL DZx = . . . u/m Display
BACK PRESSURE PEAK VALUE PSs = ... bar Display

BACK PRESSURE: (bar) PSx = ... bar Display
... ... ... ... ... 0 - 40 bar
PLASTICIZING TIME MONITORING NO yes/no

MIN = . . . MAX = . . . ZDx = . . . . . s Display
PLASTICIZING DELAY TIME Z3 = ..... s 0 - 6553.5
DECOMPRESSION BEFORE PLASTICIZING C4 = ..... 0 - max.stroke

mm 0 - max.stroke
DECOMPRESSION AFTER PLASTICIZING C2 = ..... mm Display
0 - 100
DECOMPRESSION END C2* = . . . . . mm Display
SCREW RETRACTION SPEED V24 = ... %
SCREW POSITION ACTUAL VALUE SSx = . . . . . mm
PROG.INTERRUPTION 4
PLASTICIZING SET VALUE
GRAPHICS
Plasticizing is allowed when the set cylinder temperature is reached. The position PLASTICIZING END is
calculated from plasticizing stroke + cushion correction, the position DECOMPRESSION END from plasticizing
end + decompression after plasticizing.
In the manual program the back pressure can be switched off by pressing the safety key and subsequent pressing
the plasticizing key. Thus plasticizing can occur with free-flow nozzle without changing the setting parameters.
For plasticizing a 5-stage speed and back pressure profile can be set. Each plasticizing speed and each back
pressure is effective one fifth of the plasticizing stroke. On the set value graphic image the pressure and speed
switchover points can be changed manually. An automatic fifth part formation only occurs again at twice the same
input of the plasticizing stroke “C1”.
If individual stroke points have been changed manually, at the subsequent input of a new plasticizing stroke C1
the whole profile is adjusted to the new C1 in per cent (compression/extension). The processing of the profile
occurs interpolating (point to point with straight line connection) with the exception of the start and end ramps.
These can be given with constant values.

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PLASTICIZING PROFILE 4 95 01 10 16:30
100%
0%
SSx 100.3 mm 200.0 mm
C4 C4B C4C C4D C4E C1
C4 C4B C4C C4D C4E C1

Metering stroke 8.0 20.0 40.0 60.0 80.0 100.0
Screw speed in PCT 50 60 70 80 80 0
Pressure in bar 7.0 7.0 6.0 5.0 4.0 0.0
PROG.INTERRUPTION 4
PLASTICIZING SET VALUE
GRAPHICS
4.1 PLASTICIZING TIME MONITORING
When the plasticizing monitoring time “ZD” is switched on, within the set time plasticizing and decompression must
be terminated. Otherwise the alarm “PLASTICIZING TIME EXCEEDED” reacts whereby plasticizing and the next
cycle stop.
4.2 DECOMPRESSION
Decompression before plasticizing is reached with setting the set value C4 larger than “0”. Immediately after holding
pressure end the screw is retracted with an adjustable speed and a fixed pressure. Afterwards plasticizing occurs
after the expiry of the plasticizing delay time.
Decompression after plasticizing is switched on with setting the set value C2 larger than “0”. C2 must be entered
as distance from the position C1. After end plasticizing the screw is retracted with an adjustable speed and a fixed
pressure. Both programs can also be used at the same time.

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Chapter 5 ERROR MESSAGES
Appearing ERRORS, MESSAGES AND WARNINGS are recorded on the screen in clear text in 2 ways:
- in the SEQUENCE ERROR MESSAGE FIELD

- on THE ERROR IMAGE
The SEQUENCE ERROR MESSAGE FIELD is defined on each screen image except graphics and service
functions right below on the screen and is occupied with the corresponding message after the appearance of an
error or warning.
If several errors have arisen, the message of the error appeared at first stands in this display line; right beside it
a figure informs about the total number of appeared errors.
All arisen errors become visible at the same time if the ERROR IMAGE is called up with the image selection key.
Press image selection key
ERROR IMAGE 1 95 01 2 16:30
38 CYCLE TIME EXCEEDED

71 MOTOR STOP DELAYED
PROG.INTERRUPTION 4
MALFUNCTION
MACHINE WAITING HARDWARE etc
MESSAGE
ERRORS POINTS CHECK --->
RECORD
On this image the errors stand from top to bottom chronologically according to their appearance. The number left
beside the error texts helps in rapidly finding the closer meaning in this chapter.
Index: 8.04-0 / 1995-01-05 Error messages 5 1

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1. ERROR HELP (ERROR HELP FUNCTION)
For the more exact error definition and easier error elimination in the control program there is a textual support,
which can be called up by means of function keys in case of need.
To each error message which appears in one line right below on the screen a text paragraph with error reason and
elimination hints can be brought on the screen from the machine diskette or, if built in, on a memory extension
card.
Opening a help text:
Starting from the opened error image one selects the function key F8 'etc.'
Two function keys appear:
HELP HELP etc.

FLOPPY MEMORY --->
F1 F2 ....... F8
With installed memory card (e.g. E-MU102) select F2, otherwise lay the machine diskette into the floppy drive and
press F1.
It appears a cursor field over the error number of the uppermost displayed error text and further function key
definitions:
ERROR IMAGE 1 95 01 2 16:30
38 CYCLE TIME EXCEEDED

71 MOTOR STOP DELAYED
PROG.INTERRUPTION 4
HELP HELP etc
OFF ON --->
Now one leads the cursor with the arrow keys on the requested error text and selects 'F2'.
If one needs information about errors, which are not listed on the screen at present, one moves the cursor
under the error entered right at the bottom and then enters the asked error number by means of numeral
keyboard and concluding 'ENTER'.
2 5 Error messages Index: 8.04-0 / 1995-01-05

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After occurred selection the corresponding help text is charged by the machine diskette or the memory card and
is listed on the screen.
If no help text exists, in the dialog error message field appears: 'No help function
error No. xx'
With the function key F1 'ERROR SELECTION' the help text is erased, the error list appears again for the renewed
selection possibility.
1.1 ERROR TEXT ORGANISATION
The error texts are stored on the machine diskette in small blocks. These files lie collected in a subdirectory:
'ERRGER' for German, 'ERRENG' for English, 'ERRFRE' for French error text,
e.g.
Text for error 124 lies on: \ERRGER\ERR0124.TXT
2. ERROR MESSAGE ACKNOWLEDGEMENT AND ERROR RESETTING
The clearing of errors can occur in different ways:

!
- The ERROR ACKNOWLEDGEMENT KEY clears the error messages from the
sequence error message field individually, without resetting the reactions occurred due to the errors,
such as cycle blockings, switching off the heating, etc. On actuating this key the next pending message
moves into the sequence error message field if several errors have appeared. If the acknowledged error
is still pending, it is again added to the end of the list as the one appeared last. The advantage of this key
is to “see through” the pending errors without having to select the error image and to clear MESSAGES,
such as “CYCLE TIME EXCEEDED”.
The error acknowledgement key also erases the alarm lamp when no error is outstanding any longer.
Another advantage of the acknowledgement key is to clear messages in the course of the automatic
cycle, so to make free the display line and/or the error image in order to immediately recognize the next
accruing message or the error arising at first without disturbing the cycle by the PU switch.
- The simultaneous RESETTING and CLEARING of the error messages and of its consequences occurs
with the program interruption switch (briefly switch ON and OFF). Furthermore pending errors cause of
course their messages and reactions again.
- At each cycle start (mould closing in the automatic mode) all messages of the preceding cycle are cleared
(e.g. rejects graphics, rejects flow number etc.)
- Some messages, such as "Motor stop" or "Safety gate open" are erased automatically after the
conditions have been restored.

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3. LISTING OF THE ERROR MESSAGES

In this list the error messages, their effects and reasons as well as their elimimination and resetting are explained.
The error messages which are marked with * are primarily intended for service.
Abbreviations in this list:
PU Program interruption switch

FS Alarm plant is activated
* EBIAS ERROR STOP
A sequence system error has appeared (short circuit on a digital output card, output card defective,
program error). On the error image to this error one can read off a number, which is helpful for the more
exact localization of the error reason above all if you make use of our telephonic after-sales service.
Effect: The machine stops immediately.
Elimination: Check relays and solenoid valves for short circuit; possibly exchange the digital output card
Resetting: Switch off - on the control voltage. The error number is on the hardware test image also after
switching on. After repeated switching off - on this number is cleared again.
2 CPU BATTERY
The storage battery on the CPU card gets empty and should be exchanged in order not to lose all
data when the control voltage is switched off.
(Battery normal voltage = 3.7V,
alarm message arises from 3.0V downwards, data safety is no longer given under 2.5V)
Effect: Message only
Elimination: Build in new battery on the CPU card, but store the data on a mould diskette before as all data
get lost. Afterwards read in the machine diskette which is in the control cabinet and the mould
diskette again.
Resetting: Switch on and off PU switch and/or press error acknowledgement key.
3 PARAM. OUTS. RANGE
Due to a diskette operation a not correct value has been stored in the control system. This value
flashes on the screen and must be set newly.

Elimination: Set value(s) newly.

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4 FLOPPY ERROR
During the recording of the quality data record on diskette a floppy error has appeared.
(Diskette device disconnected, diskette full, diskette broken and so on)
Effect: none
Elimination: Control diskette, control diskette drive
Resetting: Stop and start again recording of the quality data record.
5 PRINTER NOT READY
An instruction to print out a screen page, graphic curves or a record has been given although no
printer has been connected. This error appears approx. 1 minute time-delayed.
Effect: The data to be recorded get lost.

Elimination: Connect printer, control cable and/or printer settings.
If no PD record printout is requested, it must be switched to 'No output unit'.
Resetting: Press error acknowledgement key. Input printout instruction newly.
6 E-MEM (0) BATTERY

7 E-MEM (1) BATTERY
8 E-MEM (2) BATTERY
9 E-MEM (3) BATTERY
The capacity of the buffer battery of a memory expansion card E-MU102 (E-MU052) runs short. The
figure in parentheses indicates the card number.
Effect: None immediately. Only display that the memory contents is no longer protected
against data loss.
Elimination: Switch off machine, pull memory card and exchange the battery. After switching
on the machine, eliminate the writing protection on the card, i.e.bring the flip
switch in the left position and afterwards read in the machine diskette. When
reading in, the memory contents between main CPU and memory card are
divided up automatically. After reading in bring the writing protection switch in
right position again.
Resetting: none
10 HANDLING SYSTEM COMMUNICATION
With activated "handling system" no communication between the main CPU and the handling system
subsystem takes place.
Effect: Immediate stop of the automatic cycle, switchover to manual mode, alarm lamp
Elimination: Examine couple card, CPUs
Resetting: Control voltage off/on.

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11 SUBSYSTEM UNIT 3/4
At a multicolour injection moulding machine the 3rd or 4th injection unit cannot be addressed by the
machine control system (possibly switched off or defective).
Effect: Only display on the screen; but the injection moulding machine can possibly be
operated without the 3rd or 4th injection unit.
Elimination: Check power supply and BUS couple card.
12 SUBSYSTEM HEATING
Additional heating control circuits cannot be addressed by the machine control system.
Effect: Only display on the screen; but the injection moulding machine can possibly be
operated without additional heating control circuits.
Elimination: Check power supply of the additional heating control circuits and BUS couple card.
13 RC100 HANDLING SYSTEM
Collective error message for problem on RC100. In the handling system error message menu (open
error page and press + F4) the error messages produced by the RC100 are listed up.
Effect: Dependent on the existing RC100 message(s)

Elimination: ditto
Resetting: ditto
14 ANALOG CARD AR161
The main CPU cannot start up the AR161 analog card(s) after switching on the machine.
Effect: Machine ist not capable to run

Elimination: Check AR161, possibly hardware/bus problem, wrong software version, card coding
wrong or 2nd AR161 is missing.
Resetting: Control voltage off/on
20 REJECTS - GRAPHICS
The graphics rejects evaluation yielded a deviation e. g. due to batch variation, temperature variation,
change of the machine setting.
Effect: Only message, the rejects counter is going to add, the piece counter not.
Elimination: See criteria for the deviation in the program “MICROGRAPH”.
Resetting: Automatically at each cycle start

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21 REJECTS - FLOW NUMBER
The flow number monitoring yielded an exceeding of the tolerance zone e. g. due to batch variation,
temperature variation, change of the machine setting.
Effect: Only message, the rejects counter is going to add, the piece counter not.
Elimination: See criteria for the deviation in the program "MICROPLAST".
Resetting: Automatically at each cycle beginning
22 EXTERNAL ALARM (starting from ES500)
An additional device does not function. The limit switch input "E7" is a message input for additional
devices, such as e.g. handling devices, temperature control units.
Effect: The cycle is finished and the alarm lamp flashes.
Elimination: Check additional device
Resetting: Switch on and off PU switch
* 23 MOULD STROKE TRANSDUCER DEF(ECTIVE)

* 24 NOZZLE STROKE TRANSDUCER DEF(ECTIVE)
* 25 EJECTOR STROKE TRANSDUCER DEF(ECTIVE)
* 26 SCREW STROKE TRANSDUCER DEF(ECTIVE)
* 27 MOULD HEIGHT STROKE TRANSDUCER DEF(ECTIVE)
For the respective function unit the control system has measured a position which is not possible
according to the calibrated zero and maximum positions.
Possible error reasons: stroke transducer defective, cable break.
Effect: The automatic cycle stops and the respective movement is locked.
Elimination: Check stroke transducer and its fixing and possibly clean and/or exchange it; check
cable for wire break and/or short circuit.
Also check transducer voltage: Open screen image 'Stroke calibrations'.
'ISTU' must lie between 'UO' and 'UMAX'.
28 CLAMPING FORCE LOW
The minimum clamping force has not been reached (set value minus 10 % of max. clamping force, at large
machines separate set value).
Effect: The cycle is terminated without injection process and FS is actuated.

Shot, piece and rejects counter do not count.
Elimination: Toggle lever: Close and open several times with the push-button until the clamping
force is reached.
Direct closing: Wait for clamping pressure build-up with pressed push-button
'Closing'.

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* 29 CHARGE AMPLIFIER
The charge amplifier test for the cavity pressure measurement (additional equipment) was not okay.The
test voltage of the charge amplifier was outside the allowed range. The test always occurs when
switching over to mode of operation "MANUAL".
Effect: Only message

Elimination: Check the charge amplifier
30 INJ.TIME EXCEEDED
The max. injection time ZS1 from start injection until start holding pressure has been exceeded, e.g.:
switchover position to holding pressure not reached, sprue frozen-in, cavity not demoulded,
temperatures not correct.
Effect: The automatic cycle stops, the rejects and shot counter are counted up, the piece
counter not.
Elimination: Check sprue channels, cavity(ies) and temperatures.
31 INJ.TIME TOO SHORT
The min. injection time ZSO from start injection until start holding pressure has not been reached.
Possibilities: switchover pressure to holding pressure reached too early, sprue frozen-in and/or sprue
channels blocked, cavity not demoulded, temperatures not correct.
Effect: The automatic cycle stops, the rejects and shot counter are counted up, the piece
counter not
Resetting: Switch on and off PU key.
32 CUSHION TOO SMALL
The material cushion lies under the set limit, e. g. due to escape of material between nozzle and sprue
bush, leakages on the non-return valve, volume variations of the material.
Effect: Message only, the rejects and shot counter are counted up, the piece counter not.
The cycle is only finished after the allowed rejects are exceeded.
Elimination: Increase carriage pressure of the nozzle, renew non-return valve and/or increase
plasticizing stroke, increase back pressure.
Resetting: Automatically at each cycle start.
33 CUSHION TOO LARGE
The material cushion lies above the set limit. Possibilities: sprue frozen-in and/or blocked, one cavity has
not been demoulded, temperatures not correct.
Effect: Message only, the rejects and shot counter are counted up, the piece counter not.
The cycle is only finished after the allowed rejects are exceeded.
Resetting: Automatically at each cycle start.

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34 MOULD PROTECTION
The mould protection has reacted; at mould closing between the mould protection positions “G1” and “G2”
the machine has needed longer than the set monitoring time “ZF”, e. g. due to an injection moulded part
which got stuck between the mould halves.
Effect: In the mode of operation “MANUAL” closing stops and FS is set; in the automatic mode the
cycle continues immediately with mould opening and FS is set; no further cycle start.
Elimination:Set opening stroke larger and/or demoulding time longer; set ejector stroke and/or ejector
shake counter higher.
Resetting: In the mode of operation “MANUAL” by mould opening, in the automatic mode switch on and
off PU switch.
35 CLOSING SYST. STOP (CLOSING SYSTEM ON STOP)
The clamping system of a direct-closing machine has reached the mechanical stop (e. g. the built-in
mould is too small).
Effect: The high pressure will not be switched on.

Elimination:Mount intermediate plate.
Resetting: Switch on and off PU switch.
* 36 LUBR. PRESSURE LACK
Too little pressure is built up in the central lubrication system of a toggle lever machine (less than 25 bar
and/or 12 bar at 2-range lubrication of large machines). Possibilities: leakage or air in the lubricating
system, pump does not run or deliver, pressure switch defective.
Effect: No next cycle start, central lubrication pump stops, motor switches off delayed, closing stops,
FS is set.
Elimination: Eliminate leakage; air can possibly be pumped out by setting the central lubrication counter
to 1 and by repeated closing attempts. Check the fuses of the pump, check pump and pressure
switch.
Resetting: Switch on and off PU switch. Thus a new lubrication cycle starts. When the lubrication
runs ok now, the acknowledgement occurs automatically after lubrication end.
* 37 LUBR. OIL LEVEL
The lube oil level in the tank of the central lubrication of a toggle lever machine is too low (limit switch
bZ2).
Effect:Central lubrication pump and closing stop, motor switches off delayed, FS is set.
Elimination: Refill oil
Resetting: Switch on and off PU switch. Thus a new lubrication cycle starts. When the lubrication
runs ok now, the acknowledgement occurs automatically after lubrication end.

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38 CYCLE T. EXCEEDED
The set cycle monitoring time has been exceeded; in most cases due to another error (e.g. mould
protection, plasticizing time).
Effect: The machine stops immediately and switches to mode of operation "MANUAL". Motor
switches off delayed, heating lowers delayed, FS is set.
Elimination: Check in which position the machine is standing; on the error image it can be seen which error
has appeared at first. Afterwards move the machine in start position.
39 MOTOR STOP
Due to the appearance of an error the motor has fallen off (see error image on the screen) or is not yet
switched on.
Effect: Blocks switchover to automatic mode.

Elimination:Eliminate the error which has switched off the motor.
Resetting: Switch on motor.
* 40 OIL LEVEL LOW
The hydraulic oil level is too low.
Effect: Motor stops, heatings lower, FS is set.

Elimination:Refill oil, eliminate possible leakages.
* 41 CHECK SUCTION FILTER
A hydraulic suction filter is soiled.
Effect: Motor switches off, heatings lower, FS is set.

Elimination: Clean and/or change filter.
42 OIL TEMP. TOO LOW
The hydraulic oil temperature is too low.
Effect: Blocks switchover to automatic mode; if the motor runs and no manual control key is actuated,
the action oil preheating occurs, nevertheless the machine can be operated normally in the
manual program; oil temperature parameters must be set on heating image 1.
Elimination: Switch on motor and wait until the hydraulic oil temperature is reached; possibly set the lower
tolerance limit for the oil temperature lower on the screen page for the heatings.
43 OIL TEMP. TOO HIGH

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The hydraulic oil has exceeded the set maximum temperature.
Effect: Machine terminates the running cycle, no next cycle start, the oil cooling remains switched
on, FS is set. After a temperature of 70 °C is reached, the motor and the cooling water valve
switch off.
Elimination:Turn on cooling water, check cooling water inlet and cooling water valve; possibly clean oil
cooler.
44 HYDR. CLOS. SAFETY
The hydraulic closing safety valve, which shall prevent a mould closing movement at open safety gate,
has not switched in correct function. The safety function of the valve is monitored with limit switch E8 and
safety gate limit switch E1. When closing and opening the safety gate within a switching time of approx.
1 second E8 and E1 must occupy a counterequal contact position. At machines with pilot controlled seat
valve a further limit switch, E8.1, is mounted with analog function to E8.
Effect: The motor stops immediately and FS is set.

Elimination: Open and close several times with closed safety gate so that the oil in the lines of the clamping
unit gets warmer and thus the closing safety valve switches faster again. Check function E1
and E8 (and/or E8.1) for counterequality.
Resetting: Machines with E8: Open/close safety gate, then PU, then motor on.
Machines with E8 and E8.1: Close safety gate, motor on, mould closing and
mould opening, then PU,
i.e. at least one error-free switching function of the limit switches must occur.
45 PLASTIC. T. EXCEEDED
The set plasticizing monitoring time has been exceeded.
Effect: FS is set and plasticizing is stopped; the running cycle is terminated, the motor switches off
delayed and the heatings lower delayed.
Elimination: Refill material, check material feed shank and traverse temperature.
46 PLASTIC. T. T. SHORT
The set plasticizing monitoring time ZD has not been reached. Possibly it has been injected too little.
Effect: FS is set and plasticizing is stopped; the running cycle is terminated, the motor switches off
Elimination:Check sprue channels, cavity(ies), temperatures, back pressure and screw speed.

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47 SHOT COUNTER OFF
The shot counter has run off.
Effect: FS is set, the cycle is terminated, no new start, the motor switches off delayed, the heating
lowers delayed.
Elimination: Reset the shot counter
48 PIECE COUNTER OFF
The piece counter has run off.
Effect: FS is set, the cycle is terminated, no new start, the motor switches off delayed, the heating
lowers delayed.
Elimination: Reset the piece counter.
49 ALLOWED REJECTS EXCEEDED
The rejects counter and/or the rejects sequence counter has run off.
Effect: FS is set, the running cycle is terminated, the motor switches off delayed, the heating lowers
delayed.
Elimination: See by means of the error display which monitoring has counted up the rejects counter and
afterwards clear the rejects counter.
50 EJ.(ECTOR) NOT IN THE REAR
The ejector is not in rear position (pos. L not reached). Is only displayed when actuating the closing
function.
Effect: Closing is stopped immediately.

Elimination: Return ejector, check ejector plate and ejector pins.
Resetting: none
51 MOULD NOT MOUNTED
The mould is not mounted by means of high speed mounting device. The digital inputs DIBWGF and/
or DIBWGB do not lie on +24V.
Effect: Automatic start not possible

Elimination: Mount mould with push-buttons. Check limit switch WGB (moving platen) and/or
WGF (fixed platen) for actuation. Per platen the switches are connected in series.
Resetting: Switch on-off PU key.

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52 SP1 INTERLOCK ACTIVE
An additional equipment on the clamping unit (e. g. a handling system) does not give a release signal.
Effect: Mould closing is blocked.

Elimination: Move additional equipment to start position.
Resetting: none
53 CYLINDER TEMPERATURE LOW
The actual value of at least one monitored zone lies below the set tolerance (min.neg.temperature
deviation). This message is suppressed in the manual mode when the selector switch on the control
panel is switched off. It can be suppressed generally zone by zone when the respective screen
switch 'Monitoring' stands on 'OFF'.
Effect: The screw movements plasticizing, decompression and injection are locked. In the
automatic mode the cycle is finished nevertheless, no new cycle start possible. Alarm
lamp is set after switching over from manual to automatic mode and/or on actuating the
start key.
Elimination: Check whether heatings are switched on. Wait until the temperatures have exceeded
the negative tolerance limit (the yellow tags 'T' in the display fields light).
Resetting: Message goes out when all active zones have exceeded the neg. tolerance limit and the
soaking time has run down. Switch on-off PU switch when alarm lamp was set.
54 MOULD NOT IN POS.
The mould does not stand on the start position.

(At large machines also possible in connection with the mould height adjustment)
Effect: No cycle start (at large machines also no mould height adjustment) possible, FS is set.
Elimination: In the mode of operation “Manual” or "Program interruption" move the mould to start
position.
Resetting: Switch on/off PU switch
55 SAFETY GATE OPEN
The safety gate has been opened.
Effect: Mould height adjustment, closing, opening, ejector, injection and core movements stopped.
Pay attention to the function of the safety key! In different countries different safety regulations
are valid (see programm description "Safety gate safety monitoring").
Elimination: Close safety gate, screen tag E1 must be active and screen tag E2 must be deactive.
Resetting: none

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56 NOZZLE GUARD OPEN
The nozzle guard cover has been opened.
Effect: The injection and advance of the carriage unit is blocked; in the automatic mode the
cycle is stopped.
Elimination: Close nozzle guard cover, screen tag E9 must be active.
Resetting: none
57 EJECTION MONITORING
An injection moulded part has not been demoulded; the ejection monitoring (additional equipment) has
reacted.
Effect: FS is set, no next cycle start.

Elimination: Demould injection moulded part.
58 START BUTTON
The machine is ready to start an automatic cycle.
Effect: Message only; appears when switching over from manual to automatic mode.
Elimination: Press start key
Resetting: none
59 GATE INTERR. CYCLE (SAFETY GATE INTERRUPTS CYCLE)
In the automatic cycle the safety gate has been opened before end holding pressure.
Effect: Closing, ejector return and injection stopped, motor switches off delayed, heatings
lower delayed, FS is set.
Elimination: Move the machine to start position and start new cycle.
60 PLASTICIZ. C1 FREE
It is not plasticized completely.
Effect: No cycle start, FS is set.

Elimination: Plasticize in the manual mode.

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61 DECOMPR. 2, C2 FREE
It is not plasticized and/or decompression is not carried out.
Effect: No cycle start, FS is set.

Elimination: Plasticize in the manual mode and perform decompression.
62 EMERGENCY-OFF
An emergency-off function is active. An emergency-off function is released by pressing the emergency-

off key, by opening the rear safety gate and if the safety gate on the operator side is opened wider than
the moving mould fixing platen (at manual safety gate shift bolt on the moving mould fixing platen (E10
is free)).
Effect: FS is set, motor stops immediately.

Elimination: Unlock emergency-off key and/or close the corresponding safety gate.
63 PROG. INTERRUPTION
The program interruption switch PU has been switched on.
Effect: The automatic cycle is interrupted, the machine can be operated like in the manual
mode, all errors are reset at the same time.
Elimination: Switch off PU switch
Resetting: none
64 UNIT SWIVELLED OUT
The injection unit is swivelled out.
Effect: FS is set, no cycle start possible, unit movements stopped, injection as extension aid
for the screw and/or material cylinder is only possible with safety key and limited
speed.
Elimination: Swivel in injection unit.

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65 CYLINDER TEMPERATURE HIGH
The actual value of at least one zone lies above the set tolerance (max. pos. temperature deviation).
A current cycle is finished, all zones together are switched off and the alarm lamp is actuated. This
message is not suppressed, even if the cylinder heating switch on the control panel is switched off. It
appears delayed in time by approx. 1 min starting from tolerance band exceeding.
Effect: Alarm lamp is set, a running cycle is finished, motor(s) switch(es) off delayed, heatings switch
off immediately.
Elimination:Possibly change heating setting (maybe set temperature differences between individual
zones are too large, hotter zone heats the neighbour zone); possibly lower plasticizing speed
(shear forces too big), possibly check heating triacs for permanent passage.
66 CYL.HEATING LOWERS
The cylinder heating controllers lower the temperature to the set lowering value. This can be chosen
manually via screen switch or arise due to preceding errors, which lead to a machine standstill. If the
lowering value is set equal to 0, the heatings switch off generally (HZA de-energizes).
Heating lowering is also activated after power failure if before this the machine has run in auto-
matic mode, lowering was switched on or the error 'Motor stop delayed' has existed.

Elimination: If consecutive action, eliminate primary error. By switching off the screen switch chosen
lowering is interrupted manually and heated up to the set value again.
Resetting: Like primary error
* 67 CYL.(INDER) COUPLE BREAK
A thermocouple is defective or the connection of a couple to the temperature card is interrupted. The
field of the actual temperature of the corresponding zone shows on the screen: '***.*'.
Effect: Without program 'Emergency mode': The machine finishes cycle and stops then. The
alarm lamp is set, motor switches off delayed, heatings switch off immediately.
With program 'Emergency mode': The machine continues to run with the heating
capacity (regulator mode) with which the zone controller has worked before the couple
break. See further below: 'EMERGENCY MODE'
Elimination: Examine thermocouple and/or thermolines, contact points
Resetting: Without 'Emergency mode': Switch on-off PU switch
68 CUSHION ERROR
The cushion correction (special program) from one shot to another yielded a larger value than 25 mm.
Only at switched-on cushion correction program (CP set larger than 0).
Effect: FS is set, running cycle is terminated, the motor falls off delayed, the heatings lower delayed.
Elimination:Check non-return valve, possibly escape of material between nozzle and sprue bush.

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* 69 LINEARPROG. INTERR. (LINEARIZATION PROGRAM INTERRUPTED)
A pressure or speed linearization program has been interrupted.
Effect: The running linearization process is interrupted; in the respective cursor field for switching
on - off the linearization program you can read “OFF”.
Elimination: At the linearization for the corresponding movement the same safety regulations and/or
interlocks must be observed as in the manual program. It must be found out which condition
has broken off the linearization process.
Resetting: Switch on program newly.
70 CYL(INDER) HEATING DEFECTIVE
No temperature increase occurs despite actuation of a heating zone. This error case is recognized by
investigating a temperature difference of 2°C over an adjustable period of time. With switching off the
respective heating switches on the control panel this message is suppressed.
Effect: Running cycle finished, no new cycle start possible, alarm lamp set, motor
switches off delayed, heatings switch off immediately (HZA de-energizes).
Elimination: Check fuses, heater bands, connections, triacs.
71 MOTOR STOP DELAY
The motor will switch off delayed (after approx. 2 min); result of another error.
Effect: At first message only, then the motor switches off delayed and the heatings lower.
Elimination: Find out by means of the error display on the screen which error has stopped the machine.
72 WRONG MOULD HEIGHT
Direct-closing machine:
In the mode of operation “MANUAL” at mould closing the zero point of the mould height set last has
been passed; arises if the left mould fixing platen is moved up to the mould after mounting a mould
with smaller mould height.
Toggle lever machine:

The mould height actual value lies outside an adjustable tolerance around the mould height set
value.
Effect: Mould closing and ejector forward stop immediately.

Elimination: Switch over to mode of operation “SET-UP” and set mould height newly (see description:
Setting of the mould height at direct-closing machines).
Resetting: none

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73 SWITCH ON SET-UP
At a direct-closing machine in the mode of operation “MANUAL” at mould closing the zero point of the
mould height set last has been passed; arises in connection with error (WRONG MOULD HEIGHT)
after repeated actuation of mould closing as hint to switch over to “Set-up”.
Effect: Mould closing is stopped and can only occur in the mode of operation “SET-UP”.
Elimination: Switch over to mode of operation “SET-UP” and set mould height newly (see description:
Setting of the mould height at direct-closing machines).
Resetting: none
74 CHECK CONTR. PARAM.
A control parameter of the heating is set wrongly. Thus improper monitoring evaluations and damage
on the injection unit could arise.
Effect: Alarm lamp is set. All screw movements are locked. The heating insufficient
temperature monitoring switches (screen page 'Heatings') are set to 'ON'.
Elimination: Check the heating control parameters, possibly scanning times t0 (screen page 'Control
parameters') stand on 0. These shall be entered larger than/ equal to 0.1 sec.
75 ADJUST. MOTOR
The mould height adjusting motor at toggle lever machines does not rotate. It has possibly been moved
up with straightened toggle lever without switched-on automatic mould height setting program to the
mould up to the mechanical stop or the motor does not rotate.
Effect: The actuation for the adjusting motor is switched off, FS is set.
Elimination: Check motor, fuses, limit switch.
76 CLAMP. FORCE TOO HIGH
The alarm limit of the clamping force (maximum clamping force + 10 %, at large machines separate set
value) has been exceeded.
Effect: Mould closing and the injection process stop, the next cycle is locked, FS is set.
Elimination: If the error appears at injection, change the settings for injection (too high average mould cavity
pressure).

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77 CORE 1 LIMIT SW. DEF.
Blind plug is missing and/or core-pull limit switches E14 or E15 are defective.
Effect: The core-pull movement as well as closing and opening are locked.
Elimination: Connect blind plug, check limit switch
78 SAFETY LIMIT SWITCH SAW
The ejector safety switch “SAW” is not actuated.
Effect: Core moving-in is locked

Elimination: Check position of the ejector plate and ejector pins
* 79 NO MOVEM.SPEED CAL.
At speed calibration no movement has been reached at maximum actuation of the Y valve.
Effect: The calibration is interrupted.

Elimination: Check actuation of the Y valve and the valve itself, check control card and wiring to the valve
as well as stroke transducer of the valve; possibly hydraulic pump also defective.
Resetting: none
80 QDS CONT. LIMITS XQ(X BAR)
In the quality data statistics program the control limits of a sample mean value (x bar) have been
exceeded.
Effect: The machine stops in dependence of a screen switch on the screen image "Control
limits" of the quality data statistics program.
Elimination: Find out by means of the special error screen page of the QDS program which mean
value has been exceeded and counteract the disturbance according to the criteria for
the QDS program.
Resetting: With the command QDS-ERROR ERASING (Screen image "Control limits").
81 HOST STOPS CYCLE
The central computer has stopped the machine
Effect: The cycle is terminated and afterwards it is switched to operation mode

"MANUAL"
Elimination: Determine the reason at the central computer

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82 B REACHED BEF. G2
Position “B” (toggle lever locked) has been reached before mould protection end "G2".
Effect: Closing is locked and FS is set.

Elimination: Check setting of “G2” and "B".
83 RESERVE, NOT USED
84 GATE LIMIT SW. DEF. (SAFETY GATE LIMIT SWITCHES DEFECTIVE)
The safety gate limit switches (E1 and E2) have been actuated and/or not actuated at the same time
longer than 1 second. The error state is preserved via control voltage switching-off until purposive error
acknowledgement.
Effect: Motor stops immediately, FS is set

Elimination: The safety gate limit switches E1 and E2 and their counterequal switch position must be
checked
Resetting: At least one error-free switching function of E1 and E2 by safety gate closing/opening,
afterwards PU on/off.
85 A1 NOT REACHED
The mould does not reach the ejector start position “A1”.
Effect: Ejector does not move forward

Elimination: Set opening stroke and/or ejector start position correctly
Resetting: none
* 86 CLAMP FORCE ZERO P.
The clamping force zero point is not set correctly; the offset voltage of the clamping force stroke
transducer lies outside the range of +30 mV upto +200 mV
Effect: Possibly clamping force display not correct

Elimination: Readjust clamping force transducer
Resetting: none
87 FLOW NUMBER MEASURING TIME
The flow number measurement reached into the holding pressure phase or it remained too little time
between the termination of the measurement and the switchover to holding pressure in order to make
the flow number calculation (at least 0.2 sec. necessary).
Effect: No holding pressure correction
Elimination: Set flow number measuring positions correctly
Resetting: none

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* 88 P CORRECTION (PRESSURE CORRECTION)
Only at open loop controlled machines with E8 and/or E16 analog card.
The maximally allowed correction limit (K0175) for the holding pressure control has been reached.
Effect: The holding pressure control is switched off and the machine continues to operate without
holding pressure control.
Elimination: Possibly make pressure calibration, set constant KO175 larger.
Resetting: none
89 QDS CONT. LIMIT S
In the quality data statistics program the control limits of the standard deviation have been exceeded.
Effect: The machine stops in dependence of a screen switch on the screen image "Control
limits" of the quality data statistics program.
Elimination: Find out by means of the special error screen page of the QDS program which standard
deviation has been exceeded and counteract the disturbance according to the criteria
for the QDS program.
Resetting: With the command ERASE QDS ERROR (screen image "Control limits").
* 90 NO PRESS. P. CAL(IBRATION)
At pressure calibration no pressure increase has been reached at maximum actuation of the K valve.
Effect: The calibration is interrupted

Elimination: Check actuation of the K valve and the valve itself; check control card and wiring to the valve
as well as the stroke transducer of the valve; possibly hydraulic pump defective.
Resetting: none
91 FAST MOUNT(ING) DEF(ECTIVE)
The mould is not mounted and/or mounted and dismounted state was recognized at the same time and
it was attempted to start an automatic cycle.
Effect: No cycle start possible, FS is set

Elimination: Move in the mounting wedges in the manual mode, check limit switches
92 NOT USED

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* 93 NO SCREW SPEED CAL(IBRATION)
At screw speed calibration no screw speed is found out (no impulses on input bDZ on the analog card).
Effect: Screw speed calibration is stopped

Elimination: Check actuation of the Y valve and the valve itself; check control card and wiring to the valve
as well as stroke transducer of the valve; possibly hydraulic pump defective; check limit switch
“bDZ”.
Resetting: none
94 QDS SPEC.(IFIC) LIMITS
In the quality data statistics program the specific limits have been exceeded.
Effect: The machine stops, counts rejects or gives only one message as a function of a screen
switch on the screen image "Control limits" of the quality data statistics program.
Elimination: Find out by means of the special error screen page of the QDS program which mean
value has been exceeded and counteract the disturbance according to the criteria for
the QDS program.
Resetting: With the command QDS-ERROR ERASING (Screen image "Control limits").
95 HANDLING SYSTEM INTERLOCK
One of the inhibiting inputs of the handling system is not active.
Effect: The corresponding movement is locked
Input AWV ........ Ejector forward release

Input AWZ ........ Ejector return release
Input HSP ......... Closing - opening - injection release
Input b63 ...........Closing release (until mould closed)
Input KEE ..........Core in injection position release
Input KEA ..........Core in take-off position release
Elimination: Move the handling system on the correct release position
Resetting: none
96 PRESS. LIMIT EXCEEDED
At injection the set pressure limit P6 (screen image “Injection”) was reached at speed control.
Effect: The set injection speed cannot be reached.

Elimination: Increase pressure limit P6, switch over to increased injection pressure, set injection speeds
more slowly.
Resetting: none

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97 HIGH PRESS. FILTER
The high pressure filter and/or servo valve filter in the hydraulic system is soiled; digital input F2 is not
applied on +24 VE.
Effect: Machine terminates the running cycle and stops.

Elimination: Check filter and possibly exchange it.
98 CORE 1 NOT IN
One core is not in moved-in end position
Effect: Mould and ejector movement is locked

Elimination: Move in core, check limit switch (E15)
99 CORE 1 NOT OUT
Core 1 is not in moved-out end position

Elimination: Move out core, check limit switch (E14)
100 MH ADJ. END POS. (MOULD HEIGHT ADJUSTMENT END POSITION)
The minimum or maximum mould height is reached
Effect: Mould height adjustment is switched off

Elimination: If the minimum stroke limit is too big, mount an intermediate plate on the mould.
101 HEATING SWITCHED OFF (starting from ES500)
Consecutive message for all alarms, which switch off all heatings in common.

Elimination: Eliminate primary error

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102 SWITCH CLK. SW. OFF (SWITCH CLOCK SWITCHED OFF)
The week switch clock has switched off the machine.
Effect: Depending on the set program the motor, the heatings and possibly additional units are
switched off.
Elimination: Set week switch clock correctly
Resetting: none
* 103 NOT USED
104 ADVANCE TEMP. WRONG
Microtemp error message in the operation without thermocouple. The advance temperature for the mould
cooling has exceeded the set tolerance limit.
Effect: Cycle stops, FS

Elimination: Check the cooling circuit
105 COOLING TOO WEAK
Microtemp error message in case of operation with mould temperature couple. During calibration within
10 cycles and constantly open cooling water valves no minimum temperature decrease of 2°C has been
measured.
Effect: The mould can only be operated without closed loop control with adjustable cooling times
(open loop).
Elimination: Switch over to open loop control
106 TEMPERATURE CONTROL UNIT NECESSARY
Microtemp error message in case of operation with mould temperature couple. During calibration within
10 cycles and constantly closed cooling water valves no minimum temperatureincrease of 2°C has been
measured.
Effect: The mould can only be operated without closed loop control with adjustable
cooling times (open loop).
Elimination: Switch over to open loop control
107 COVER FRONT PLATE
The moving front plate cover on the clamping unit is open. Digital input bAS does not lie on +24V.
Effect: Mould height adjustment locked
Elimination: Close the cover
Resetting: none

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108 PLEXI PROTECT. OPEN
The plexiglass cover on the clamping unit is open. Digital input b52 does not lie on +24V.
Effect: All movements on the clamping unit are locked

Elimination: Close cover
Resetting: none
109 - 116 MICROTEMP VALVE 1 - 8
The minimum flow monitoring of one cooling circuit has reacted (possibly one circuit blocked).
Effect: Cycle is terminated and FS is set

Elimination: Check cooling circuit
117 ERROR OIL PREHEATING
The oil temperature has not risen despite switched-on oil preheating program.
Effect: Motor stops

Elimination: Check thermocouple and hydraulic system
118 not used
119 CORE 2 NOT MOVED IN
Core 2 is not in moved-in end position

Resetting: Switch on-off PU switch
120 CORE 2 NOT MOVED OUT

121 CORE 3 NOT MOVED IN
Core 3 is not in moved-in end position


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122 CORE 3 NOT MOVED OUT

123 CORE 2 LIMIT SWITCHES DEF.(ECTIVE)
Blind plug is missing and/or core-pull limit switch E16 or E17 is defective.
Elimination: Connect blind plug, check limit switches
124 CORE 3 LIMIT SWITCHES DEFECTIVE
Blind plug is missing and/or core-pull limit switch E18 or E19 is defective.
Elimination: Connect blind plug, check limit switches
125 MOULD TEMPERATURE LOW
At least one mould temperature has not reached the negative tolerance limit; this "start-up safety"
can be switched off for the individual heating zones on the screen image "Heatings". In the manual
mode this message is suppressed when the mould heatings on the key panel are switched off.
Effect: All screw movements are blocked, no cycle start, FS is set at the switchover from
manual to automatic mode.
Elimination: Switch on heating; wait until the temperature of the corresponding heating zone lies
within the set tolerance.
126 MOULD TEMPERATURE HIGH
The actual value of at least one zone lies above the set tolerance (max. pos. temperature deviation).
A current cycle is finished, all zones together are switched off and the alarm lamp is actuated. This
message is not suppressed, even if the mould heating switch on the control panel is switched off. It
appears time-delayed by approx. 1 min starting from tolerance band exceeding.
Effect: Alarm lamp is set, a running cycle is finished, motor(s) switch(es) off delayed, heatings
switch off immediately.
Elimination: Possibly change heating setting (maybe set temperature differences between individual
zones are too big, hotter zone heats neighbour zone), possibly lower plasticizing speed
(shear forces too big), possibly check heating triacs for permanent passage.

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127 MOULD HEATING DEFECTIVE
It occurs no temperature increase despite actuation of a heating zone. This error case is recognized
by investigating a temperature difference of 2°C over an adjustable period of time. With switching
off the mould heating switch on the control panel this message is suppressed.
Effect: Running cycle finished, no new cycle start possible, alarm lamp set, motor switches off
delayed, heatings switch off immediately (HZA de-energizes).
Elimination: Check fuses, heater bands, connections, triacs.
128 SK83 - TIE-BAR SELECTION (STARTING FROM ES500)
For the closed loop clamping force control no tie-bar has been selected. (Screen image
"CLAMPING FORCE")
Effect: No closed loop clamping force control

Elimination: Select tie-bar
129 CENTRAL LUBRICATION PRESSURE REDUCTION (STARTING FROM ES500)
At a lubrication process the max. pressure switch has not been relieved after lubrication stop and
monitoring time and/or the min. pressure switch has not been actuated. Min. pressure switch is
actuated at pressure larger than/equal to 2 bar.
Effect: Clamping unit locked

Elimination: Check switch
130 SAFETY GATE INTERLOCK (STARTING FROM ES1200)
Starting from machine size ES1200 the safety gate must be closed in two-hand operation. If the
interlock provided for this purpose is not moved out, this error is set. A simultaneous actuation of the
two end position switches also sets this error.
Effect: No safety gate movement, motor stop

Elimination: Check interlock and/or limit switch
131 SOAKING
If the minimum negative temperature deviation is exceeded at the heating-up of all active heating
zones, for the better heat penetration of the screw the releases for injection and screw rotation are
still delayed by a period of time of approx. 2 min. During this phase a green screen tag flashes in the
second line of the heating images. The message only appears if a screw movement shall be intro-
duced during this time.
Effect: All screw movements are blocked, no cycle start possible, the alarm lamp is set on
actuating the start key.
Elimination: Wait
Resetting: For erasing the error message switch on-off PU switch

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132 CYLINDER HEATING OFF
2 possibilities:
1)
Consecutive message for all alarms, which switch off all heatings generally.

2)
On the control panel the main switch for cylinder heatings is switched off. Does not appear
when the set values of the corresponding zones are set equal to 0.
Effect: Only message for operating personnel. The corresponding zone controllers are also
switched off in the software. It arises the consecutive error 'CYL.TEMP.LOW' when
the temperature(s) fall(s) under the lower deviation limit.
Elimination: Switch on main switch on the control panel or set all corresponding set values of the
cylinder heating group to 0.
Resetting: Switch on-off PU switch if consecutive errors have arisen.
133 MOULD HEATING OFF
2 possibilities:
1)
Consecutive message for all alarms, which switch off all heatings generally.

2)
On the control panel the main switch for mould heatings is switched off. Does not appear when the
set values of the corresponding zones are set equal to 0.
Effect: Only message for operating personnel. The corresponding zone controllers are also
switched off in the software. It arises the consecutive error 'MOULD TEMP.LOW'
when the temperature(s) fall(s) under the lower deviation limit.
Elimination: Switch on main switch on the control panel or set all corresponding set values of the
mould heating group to 0.
Resetting: Switch on-off PU switch if consecutive errors have arisen.
134 TEMPERATURE CONTROL UNIT-SET VALUE OUT OF RANGE
Error from the external temperature control unit that a not plausible set value has been entered.
Effect: Temperature control unit is switched off, no next cycle start, FS is set.
Elimination: Enter plausible value for temperature control unit and switch on temperature
control unit.

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135 TEMPERATURE CONTROL UNIT-COUPLE BREAK
Error from the external temperature control unit that a temperature couple is broken.
Elimination: Control temperature couple and switch on temperature control unit.
136 TEMPERATURE CONTROL UNIT-HEATING DEFECTIVE
Error message from the external temperature control unit that the heating is defective.
Elimination: Control and switch on temperature control unit.
137 TEMPERATURE CONTROL UNIT-COOLING DEFECTIVE
Error message from the external temperature control unit that the cooling is defective.
138 TEMPERATURE CONTROL UNIT-LEVEL LOW
Error from the external temperature control unit that the level of the filling state is too low.
Elimination: Control temperature control unit, check level and switch on temperature
control unit.
139 TEMPERATURE CONTROL UNIT-FLOW TOO SMALL
Error from the external temperature control unit that the flow is too small.
140 TEMPERATURE CONTROL UNIT-LIMIT TEMPERATURE EXCEEDED
Error from the external temperature control unit that the limit temperature has been exceeded.

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141 TEMPERATURE CONTROL UNIT-PUMP DEFECTIVE
Error from the external temperature control unit that the pump is defective.
142 TEMPERATURE CONTROL UNIT-COMMUNICATION TIMEOUT
Error in the communication between control unit and temperature control unit has been stated.
Effect: No next cycle start, FS is set.

Elimination: Control all plug connections, check connection cable, avoid possible
disturbing influences (for the service technician: check communication by
means of EBIAS debugger).
143 TEMPERATURE CONTROL UNIT-TEMPERATURE TOO HIGH
At least one temperature control unit temperature has exceeded the positive tolerance limit.
Effect: The injection is blocked, no cycle start, FS is set.

Elimination: Wait until the temperature of the corresponding temperature control zone lies
within the set tolerance. Control temperature control unit.
144 TEMPERATURE CONTROL UNIT-TEMPERATURE TOO LOW
At least one temperature control unit temperature has exceeded the negative tolerance limit.
Effect: The injection is blocked, no cycle start, FS is set.

Elimination: Wait until the temperature of the corresponding temperature control zone
lies within the set tolerance. Control temperature control unit.
145 DEVIATION CYCLE
One or several part-times of the cycle lie outside the set tolerance limit of the cycle time monitoring-
image selection key "Mould parameters" + F2 + F2. The time which has deviated can be determined
on the screen page "Part-time monitoring" in the column 'Deviation'.
Effect: no cycle start, FS is set.

Elimination: Correct wrongly set tolerances and set values, possibly set tolerances to zero, i.e.
switch off monitoring.

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146 MOULD STROKE POSITION
Position stroke monitoring has reacted because the mould stroke has changed by the set tolerance
stroke without deliberate actuation.
Effect: Motor stops immediately, FS is set.

Elimination: Control of the hydraulic clamping unit and of the solenoids for the clamping unit.
Check set tolerance stroke. Possibly write tolerance stroke on zero, i.e. switch off
the position stroke monitoring.
147 EJECTOR STROKE POSITION
Position stroke monitoring has reacted because the ejector stroke has changed by the set tolerance
stroke without deliberate actuation.
Effect: Motor stops immediately, FS is set.

Elimination: Control of the hydraulic ejector unit and of the solenoids for the ejector.
Check set tolerance stroke. Possibly write tolerance stroke on zero, i.e.
switch off the position stroke monitoring.
148 MAX.VOLTAGE SK1

149 MAX.VOLTAGE SK2
150 MAX.VOLTAGE SK3
151 MAX.VOLTAGE SK4
The voltage of clamping force transducer 1 (2,3,4) lies above the maximum resolution of
the analog card (1 volt). (Clamping force transducer defective, wrong settings)
Effect: Mould closing and the injection process stop, the next cycle is locked, FS
is set.
Elimination: Check clamping force transducer 1 (2,3,4).
152 TANK SHUTTING CLACKS (MACHINES WITH BY-PASS FILTERING)
One of the pump suction line shutting clacks is not open. Digital input F1 does not lie on +24VE.
Effect: Motor switches off, heatings lower, FS is set.

Elimination: Open shutting clacks, check limit switches
153 CHECK FILTER (STARTING FROM ES550)
Filter(s) of the own filter station is/are soiled. Digital input F2 does not lie on + 24VE.
Effect: Machine terminates the running cycle and stops, FS is set.

Elimination: Check and possibly exchange filter

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154 PRESSURE PUMP 1 (STARTING FROM ES550)

Pump pressure transducer test:

Pump pressure smaller than minimum pressure variable displacement pump.
Pump pressure larger than maximum pressure variable displacement pump.
Stand-by pressure not left.
Stand-by pressure not reached.
Stand-by pressure at oil preheating not reached.
Exact error can be seen on screen page "Pump states".
As pressure transducer defective, variable displacement pumps must be separated from each other.
Effect: FS is set, pump interconnection is dissolved, the motors switch off delayed and
the heatings lower delayed.
Elimination: Check pressure transducer, amplifier cards of the pumps.
159 SUPPLY MOOG V. (STARTING FROM ES550)
The supply voltage of the MOOG valve is not okay.
Effect: FS is set, injection and plasticizing are interrupted, the motors switch off and the
heatings lower.
Elimination: Check supply voltage of the MOOG valve.
160 UNIT NOT AT THE REAR (STARTING FROM ES550)
At mould dismounting the injection unit is not in its most rear position.
Effect: Mould dismounting not possible.

Elimination: Return unit entirely.
161 OIL FILTRATION ON (MACHINES WITH BY-PASS FILTERING)
The program switch "OIL FILTRATION" is switched on and the oil filtration is active.
Effect: Main motor does not start

Elimination: If necessary filtrate, switch off filtration.
Resetting: Automatically after switching off the filtration.

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162 INJ.PRES. HIGH (STARTING FROM ES550)
Pressure in the injection cylinder > maximum pressure.
Effect: FS is set, injection stopped, the running cycle is terminated, the motors switch off
Elimination: Check pressure transducer injection unit, check servo valve.
163 MOULD NOT CLOSED (PRESSURE PAD MACHINES)
For un/locking the rapid motion the machine is not closed, i.e. either mould stroke transducer not 0
and/or limit switch rapid motion closed (bGV) not actuated. In the set-up mode the rapid motion
unlocking is also possible at not closed machine, for retraction of the cylinders.
Effect: Rapid motion un/locking is locked.

Elimination: Check mould closing, limit switch (bGV) and stroke transducer SFx.
164 RAPID MOTION LOCKING (PRESSURE PAD MACHINES)
If rapid motion locking not in correct position, i.e. for mould closing/opening unlocked,
for pressure pad pressure build-up/pressure reduction locked.
Effect: Mould closing/opening and/or pressure pad movement locked.

Elimination: Un/lock rapid motion, possibly choose set-up. Check limit switch for
rapid motion locking.
165 PRESSURE BUILD-UP MONITORING (PRESSURE PAD MACHINES)
If after rapid motion closing and locking the pressure pad pressure build-up lasts longer than the
monitoring time. Serves to monitor the clamping pressure transducer (PHx3).
Effect: Pressure build-up is stopped, FS is set, it is switched over to mode of operation

"MANUAL", the motors switch off delayed and the heatings lower delayed.
Elimination: Check clamping pressure transducer (PHx3), check monitoring time (constant)
166 PRESSURE REDUCTION MONITORING (PRESSURE PAD MACHINES)
If the pressure pad pressure reduction before unlocking and rapid motion opening lasts longer than
the time measured at the 1st automatic cycle for pressure reduction + unlocking + force stroke.
Serves to monitor the clamping pressure transducer (PHx3).
Effect: Pressure reduction is stopped, FS is set, the machine terminates the running
cycle, no next cycle start, the motors switch off delayed and the heatings lower
delayed.
Elimination: Check clamping pressure transducer (PHx3).

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167 SHORT CIRCUIT TEMP.C.
On digital outputs of an E-8-Thermo card too high current was measured ---> short circuit possible.
The corresponding zone(s) is (are) shown via the display field(s).
Effect: The short circuit zone(s) is (are) switched off immediately, the remaining zones
are lowered delayed. The motor switches off delayed, the alarm lamp lights.
Elimination: Examine connections between temp. card(s) and triac(s). The cards themselves
are permanent short circuit stable and need only be exchanged in case of doubt.
Resetting: Switch off and on control unit again.
168 MOULD COUPLE BREAK
A thermocouple is defective or the connection of a couple to the temperature card is interrupted. The
field of the actual temperature of the corresponding zone shows on the screen: '***.*'
Effect: Without program 'Emergency mode': The machine finishes cycle and stops then.
The alarm lamp is set, motor switches off delayed, heatings switch off
immediately.
With program 'Emergency mode': The machine continues to run with the heating
capacity (regulator mode), with which the zone controller worked before the couple
break. See further below: 'EMERGENCY MODE'
Resetting: Without 'Emergency mode': Switch on-off PU switch
169 OIL COUPLE BREAK
The oil couple is defective or the connection of the couple to the temperature card is interrupted. The
field of the oil actual temperature zone shows on the screen: '***.*'
Effect: The machine finishes the cycle and stops then. The alarm lamp is set, motor and
cooling water valve switch off delayed, heatings switch off immediately.
170 VT CARDS ERROR (STARTING FROM ES500)
One of the VT cards is faulty.
Effect: FS is set, the motors switch off and the heatings lower. Renewed motor start is
prevented.
Elimination: Check supply voltage and seat of the VT cards in the holding devices.

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171 SAFETY GATE OPENING AND CLOSING (STARTING FROM ES500)
After switching on the main switch or after a voltage loss the electric closing safety must be initialized
newly.
Effect: Motors cannot be started.

Elimination: Open and close again safety gate.
172 STEP-ON SAFETY (STARTING FROM ES1000)
The step-on safety between the mould halves has been actuated.
Effect: Mould closing and safety gate closing is locked. Safety gate opening is only
possible electrically.
Elimination: Relieve step-on plates/light beam guards again. Possibly check limit switches/light
beam guards.
173 EBIAS 999
F A T A L error, call ENGEL service !!
Effect: Automatic mode no longer possible

Elimination: Call ENGEL service !
Resetting: Only by service technician
174 DATE/TIME WRONG
Date and/or time has been set wrongly.
Effect: Exact dates and times which are read off from the control unit are not
correct, e.g. recordings with QDP or QDS or printouts of screen pages are
dated wrongly.
Elimination: Switch on service mode and correct date/time.
Resetting: Switch on-off PU
175 SAFETY CIRCUIT
The SUVA safety switch is in position 'Safety'. Only for machines with Swiss safety equipment.
Only serves as display. On digital input 'bSICH' lie +24V.
Effect: The dangerous voltages for valves and motors are switched off, the control
unit is in normal function.
Elimination: Switch off safety switch.
Resetting: None

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176 NOZZLE GUARD DEFECTIVE
The nozzle guard safety circuit has reacted. The digital inputs bE9 and bE9Q have and/or have
not been actuated longer than 1 second. For proper function E9 and E9Q must always occupy
counterequal switch position.

Elimination: Nozzle guard circuit E9 and E9Q must be checked for counterequal
switching function:
Nozzle guard closed: E9 on +24V open: E9 on 0V
E9Q on 0V E9Q on +24V
Resetting: An error-free cycle of the nozzle guard circuit due to nozzle guard
opening/closing, afterwards switch on-off PU switch
177 NO OIL FILTRATION (only machines with by-pass filtering)
The digital input F2 does not lie on +24VE because either the induction current motor is switched
off or the oil filter is soiled.
Effect: Machine finishes the current cycle and stops, motor(s) is (are) switched off,
heatings lower, FS is set.
Elimination: Check and possibly exchange filter and/or switch on motors.
Resetting: Automatically with active input F2
178 REJECTS ADDITIONAL CURVE
The graphic rejects evaluation of the additional curve has yielded a deviation e.g. by batch
variation, temperature variation, change of the machine setting.
Effect: Only message, the rejects counter is counted up, the piece counter not.
Elimination: See criteria for the deviation in the program "MICROGRAPH".
Resetting: Automatically at each cycle beginning
179 PD GRAPHICS MONITORING
In the quality data monitoring program the tolerance ranges have been exceeded.
Effect: Depending on set error evaluation:

-no consequence
-message and only alarm lamp
-message, rejects message and selection without alarm lamp
-message, rejects message and selection with alarm lamp
-cycle stop and alarm lamp
Elimination: Find out on the basis of the error record of the process data monitoring
program which value has been exceeded and counteract the disturbance
correspondingly (new initialization, correction of the tolerance and the like).
Resetting: depends on the set error evaluation
-Automatically at each cycle beginning without cycle stop
-Switch on-off PU switch at cycle stop

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180 PD GRAPHICS ALARM
In the quality data monitoring program the warning limits have been exceeded.
Effect: Depending on set error evaluation:

-no consequence
-message and only alarm lamp
-cycle stop and alarm lamp
Elimination: Find out on the basis of the error record of the process data monitoring
program which value has been exceeded and counteract the disturbance
correspondingly (new initialization, correction of the tolerance and the like).
Resetting: depends on the set error evaluation
-Automatically at each cycle beginning without cycle stop
-Switch on-off PU switch at cycle stop
181 MOULD HEATING LOWERS
The mould heating controllers lower the temperature to the set lowering value. This can be chosen
manually via screen switch or arise due to preceding errors, which lead to a machine standstill. If the
lowering value is set equal to 0, the heatings switch off generally (HZA de-energizes).
Heating lowering is also activated after power failure if before this the machine has run in automatic mode,
lowering has been switched on or the error 'Motor stop delayed' has existed.

Elimination: If consecutive action, eliminate primary error. By switching off the screen switch chosen
lowering is interrupted manually and heated up to the set value again.
182 SG MONITORING RELAY (SAFETY GATE MONITORING RELAY)
The signal of the safety gate monitoring relay was not equivalent to E2 and/or antivalent to E1 after a
switching time of 0.5 seconds (SUVA-specifically).
The error state is preserved via control voltage switching-off until deliberate error acknowledgement.

Elimination: Safety gate limit switches E1 and E2 must be checked with the switch position of the
safety gate monitoring relay
Resetting: At least one error-free switch function of E1 and E2 and the signal of the safety gate
monitoring relay by safety gate closing/opening, afterwards PU on/off.
182 SG SAFETY STRIP
The safety strip on the safety gate has been actuated (input inactive).
Effect: The safety gate cannot be opened and/or closed automatically.

Elimination: Check pressure wave strip and/or wiring.

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184 PUSH-BUTTON ACTIVE
When switching over to manual mode (and/or when switching on the control voltage)
no push-button may be actuated as otherwise a movement could start automatically.
Effect: FS is set. No movement in manual mode can be started.

Elimination: Check whether all push-buttons are switched off.
Resetting: automatically when no push-button is actuated any longer.
185 INPUT FORCE STROKE
The parts set has been read in from a toggle lever machine into a pressure pad machine. Possibly a stroke
with increased opening force is requested.
Effect: The machine opens without force stroke.

Elimination: Program switch increased opening force and update stroke.
186 CONTROL CABINET TEMPERATURE
Via a zone the control cabinet temperature is measured, two limits being effective.
Effect: 1) Control cabinet temperature alarm limit:

If this value is exceeded, only this error message appears and the mould protection lamp
is set - the machine continues to produce.
2) Control cabinet temperature maximum value (alarm limit + 10,0Ö”C):

If the temperature exceeds the maximum value, the machine stops after the expiry of the
cycle, the alarm lamp is set and the motors switch off delayed.
Elimination: Check ventilators and filters on the control cabinet doors and in the control cabinet.
Exchange defective ventilators and soiled filters.
2000 MECHANICAL CLOSING SAFETY
The signal of the mechanical closing safety has not been active at a mould movement.
Effect: Mould movement is locked

Elimination: Check mechanical closing safety
Resetting: none
2001 RETURN FILTER
A return filter is soiled.
Effect: The automatic cycle stops, FS is set

Elimination: Clean and/or change filter

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2002 PRESSURE TOO LOW
Idling pressure examination: The idling pressure has been under the set idling pressure limit longer than
4 minutes. Too low idling pressure can lead to the overheating of the motor after longer time.
Effect: Motor stops, FS is set

Elimination: Check pressure transducer, idling outputs
2003 EMERGENCY-OFF CIRCUIT DEFECTIVE
The EMERGENCY-OFF circuit monitoring has reacted. The digital input DINOT is unequal to the
EMERGENCY-OFF signal of the RC90 and/or RC100 handling system from the bus communication. In
the normal case the digital input DINOT and the EMERGENCY-OFF signal from the handling system
must always be equal within an adjustable monitoring time.

Elimination: Check emergency-off circuit.
Resetting: An error-free EMERGENCY-OFF switching cycle by actuating the EMERGENCY-OFF
button, afterwards switch PU switch on-off.
2098 TIE-BAR PULLING ACTIVE!
Hint program switch tie-bar pulling is switched on.
Effect: Switchover to automatic mode is locked. Mould opening/closing with decreased speed.
Elimination: Switch off program switch tie-bar pulling
Resetting: Switch off program switch tie-bar pulling
2099 CLAMPING FORCE DIFFERENCE
The pressure transducers of the tie-bars have exceeded their allowed tolerance among each other.
Effect: The machine stops the pressure build-up.

Elimination: Check locking and actuation of the pressure pad manifold.
Possibly reduce pressure build-up quantity.
2100 HIGH SPEED END POSITION
The minimum or maximum high speed position has been reached.
Effect: Mould closing and/or mould opening is locked.

Elimination: If the minimum stroke limit is too big, mount an intermediate plate on the mould.

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2101 HIGH SPEED LOCKING LIMIT SWITCHES
The limit switches for locking the high speed have been left.
Effect: Locking of the high speed is locked.

Elimination: Check mould height and/or limit switch setting.
2102 PLATEN PARALLELISM
The difference of the two mould stroke transducers is bigger than the allowed tolerance.
Effect: Mould closing and/or mould opening is only allowed in set-up.

Elimination: Check both stroke transducers and/or platen parallelism.
2103 DEVIATION TIE-BAR POSITION SET-ACTUAL
The difference between set value and actual value of a tie-bar is too big.
Effect: Clamping force build-up and/or reduction is locked.

Elimination: Check mould height, calibrated positions and locking.
2104 UNEQUAL TIE-BAR POSITION
The difference of the tie-bar positions (set value minus actual value) of the tie-bars among each other
is too big.
Effect: Clamping force build-up and/or reduction is locked.

Elimination: Check mould height, calibrated positions and locking.
2105 MOULD HEIGHT STROKE TRANSDUCER 2 DEF

By the control unit for the respective function unit a position has been measured which is not possible
according to the calibrated zero and maximum positions. Possible error reasons: Stroke transducer
defective, cable break.
Effect: The automatic cycle stops and the respective movement is locked.
Elimination: Check and possibly clean and/or exchange stroke transducer,
check cable for wire break and/or short circuit.

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2109 REAR SAFETY GATE LIMIT SWITCHES DEFECTIVE
The safety gate limit switches (E1.2 and E2.2) have been actuated and/or not been actuated at the same
time longer than 1 second.

Elimination: Safety gate limit switches E1.2 and E2.2 must be checked
2110 LOCKING ON THE REAR SAFETY GATE
From machine size ES1200 the safety gate must be closed in two-hand operation. If the locking provided
for this purpose is not moved out, this error is set. A simultaneous actuation of the two end position
switches also sets this error.
Effect: no safety gate movement, motor stop

Elimination: Check locking and/or limit switches
2111 REAR SAFETY GATE OPENING AND CLOSING
After switching on the main switch or after a power failure the electric closing safety must be initialized
newly.
Effect: Motors cannot be started.

Elimination: Open and close rear safety gate again.
2112 SAFETY STRIP REAR SAFETY GATE
The safety strip on the rear safety gate has been actuated (input inactive).
Effect: The rear safety gate cannot be opened and/or closed automatically.
Elimination: Check pressure wave strip and/or wiring.

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Chapter 6 SPECIAL PROGRAMS
1. MICROPLAST / MICROFLOW
Setting
limitations
MICROPLAST 4 95-01-10 16:30
FLOW NUMBER SET VALUE = . . . . . 0 - 999.9

FLOW NUMBER ACTUAL VALUE = . . . . . Display
TOLERANCE ZONE FLOW NUMBER +/- . . . . . 0 - 999.9
MEASUREMENT START = . . . . . mm STOP - C1
MEASUREMENT STOP = . . . . . mm 0 - START
AUT. PARAMETER SETTING yes/no
MICROFLOW
CORRECTION MODE 0 0 ... NO CORRECTION
0-3
1 ... SWITCHOVER PRES. + HOLDING PRES.
2 ... ONLY SWITCHOVER PRESSURE
3 ... ONLY HOLDING PRESSURE
CORRECTION FACTOR (bar/digit) = . . . . .

0 - 99.99
CALCULATED CORRECTION PLUS = . . . . . bar
0 - Display
CALCULATED CORRECTION MINUS = . . . . . bar
0 - Display
TOLERANCE ZONE f.PRES.CORRECTION +/- . . . . bar
0 - 999
HYDRAULIC PRES.ACTUAL VALUE PHx = . . . . . bar
Display
REJECTS - FLOW NUMBER
Display
PROG.INTERRUPTION 4
MICROGRAPH MICROPLAST-
- FLOW 1
1.1 MICROPLAST (VISCOSITY MEASUREMENT)
At the program “Microplast”, during the dynamic mould filling phase, the flow number is determined as dimension
figure for the energy comsuption at the mould filling process. At a given mould filling resistance and unchanged
machine setting as well as with constant melt and mould temperature one obtains information about the changed
flowability of the plastics melt via this rheometrical on-line measurement on the injection moulding machine. In this
way different materials can be compared with each other with the same machine setting and the same mould.
Moreover, batch variations of the raw material as well as a changing filler content can be recorded by means of
comparative measurements so avoiding extensive incoming goods control. Furthermore,
Index: 8.04-0 / 1995-01-05 Special programs 6 1

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processing errors, such as insufficient pre-drying or different reclaimed fractions can be recognised. All these
changes often have an effect on the moulded part (e. g. dimensions, weight).
The required injection pressure for a given mould basically depends on the viscosity and on the temperature of the
material as well as on the injection speed. A prerequisite for this is however that the set pressure limit “P6” and/
or the maximum system pressure are not reached during the injection process.
Proceeding on the assumption that an injection moulding machine in the fully automatic mode can maintain the
temperature and reproduce the injection speed, one can infer the viscosity (flow behaviour) of the material from the
hydraulic injection pressure.
When the material gets more viscous, the injection pressure increases, when the material gets less viscous, the
injection pressure decreases.
As the level of the injection pressure at the beginning of the injection process basically depends on the acceleration
of the screw and at the end on the compression of the material, the injection pressure must be measured during
the average half of the injection process.
For this purpose two measuring positions must be set on the screen, which are also displayed after each injection
process if the control system is equipped with a screen graphics.
The measuring positions must be set so that the flow number measurement is finished approx. 0.2 seconds before
the switchover position to holding pressure is reached, as otherwise the alarm “FLOW NUMBER MEASURING
TIME” is displayed.
Graphic image with measuring position display for the flow number:
100%
80%
.
60%
40%
20%
0%
0.00 0.80 1.60 2.40 3.20 4.00s
Flow number
measurement window
The flow number measurement is switched on if a flow number set value is given on the screen. Then, from the mean
value of the hydraulic pressure between the measuring positions, a so-called flow number is determined. By setting
a tolerance in % a quality control and/or a rejects sorting can be made, since a change in the material (e. g. batch
change) or a variation in temperature (e. g. interruption of operation) has an effect on the flow number and thus on
the quality of the part.
If the flow number moves outside the set tolerance, the alarm “REJECTS FLOW NUMBER” is displayed, the piece
counter is not increased and the rejects counter is increased by 1. (The shot counter is increased). But the machine
only switches off after the set number of tolerated rejects/hour. By means of a signal to a down-stream unit rejects
can be sorted.
The flow number tolerance must be set so that only those parts which lie outside the fixed quality tolerance are
sorted out.
2 6 Special programs Index: 8.04-0 / 1995-01-05

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1.1.1 Self-presetting, Auto Setup for Microplast
Microplast set value, tolerance and the stroke values for the measuring window are preoccupied automatically.
Starting position:
The machine runs in automatic mode and produces good parts.
Setting procedure:
The operator switches the screen switch for the automatic parameter setting Microplast to "ON".
As long as the program is active, a screen tag is set.
Beginning with the following cycle now the following calculation is carried out:
delta s = (metering stroke C1 - C3u) * 0.2
C17 = C1 - delta s C18 = C3u + delta s
After the measuring range for the flow number measurement is determined automatically, the flow number is
measured at the following cycle (flow number set value on 99.9; tolerance on 99.9%). The measured actual value
is stored as set value at the cycle end and provided with a tolerance of 10%.

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1.2 MICROFLOW
If the part weight or the dimensions of a part lie outside the required quality tolerance because of a change in the
flow behaviour of the plastic melt, this can be corrected by manually changing the holding pressure and/or the
switchover pressure. The control system can correct this automatically with the program “Microflow” if a
corresponding correction factor and a correction type are determined.
Example:
For the production of a technical moulding of PP an average part weight of 33.50 g with an average flow number
of 44.9, a holding pressure of 30 bar, with a tolerance zone of +/- 5 Digit was fixed. After multi-shift production the
machine switched to disturbance after the flow number had been exceeded 3 times within the entered period of
10 min.
The process data (melt and mould temperatures at +/- 2 degrees centigrade constant) led one to suspect reduced
flowability of the raw material.
With 33.27 g at a flow number of 55.2 the moulded parts ejected last clearly lay outside the fixed tolerance zone.
Weight distribution at flow number change
Part weight (g) Flow number change
33.55
33.50 max. weight tolerance
33.45 35 bar
determined weight
33.27 distribution at
30 bar
different holding
25 bar pressures
35 45 55 Flow number
Production field without
Microflow program
Production field with
By manually increasing the holding pressure to 35 bar at the same stroke-dependent switchover one again obtained
moulded parts with the original initial weight. Now the correction factor could be determined:
k= Holding pressure change = 5

Flow number change 10.4
The production was continued with the originally optimized holding pressure and corresponding Microplast and
Microflow settings.
By entering a tolerance zone for the pressure correction, mould damage is avoided in the case of a correction factor
or flow number set value being set wrongly. The machine is operated with the set holding pressure if the calculated
correction is larger than the set tolerance, and rejects are counted.

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2. MICROTEMP - MOULD COOLING (OPTION)
Mostly one finds today still manually adjustable flow controllers for mould cooling. Thus a rapid and reproducible
resetting of the flow rate for the individual cooling circuits via data carrier cannot be reached. Further, appearing
disturbing influences (pressure variations, changes of the cooling water inlet temperature, longer-term deposits in
the cooling bores) influence the product properties (dimensional accuracy, warpage).
A new problem solution for the mould cooling offers the mould system “Microtemp” alternatively open loop or closed
loop controlled via process computers. For minimizing the tube lengths the connection units equipped with high
speed couplings sit on and/or in the area of the mould fixing platens.
System components
Solenoid valves
(Flow controller) Thermo-
couple
P
Flow monitor
Thermo-
couple
Injection
Process computer
moulded
part EC88/CC90
Cooling
circuit
Mould
For old, hardened-through moulds, at which a later temperature couple installation is difficult, as replacement for
the flow controllers the desired solenoid valve opening time per cycle can be set on the machine control system.
At the design of new injection moulds in the area between cooling bore and mould wall temperature couples for
measuring the mould wall temperature shall be provided. The couple lines are summarized on standardized multiple
connectors for a fast manual and/or automatic high speed coupling.

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For precision injection moulded parts each circuit in the mould shall be equipped with a representative temperature
couple in the mould wall. Thus the temperature conditions in the mould can be recorded completely and be kept
constant despite appearing disturbing influences. The surcharge for the temperature couple installation lies at
injection moulds for technical mouldings in most cases under 2 % of the total mould costs. Further, with a
deliberately set temperature couple also only one critical moulded part range can be recorded with high measure
requirements and/or warpage problems. At multi-cavity moulds one can infer the temperature conditions in the total
mould on the basis of individual measurements in one cavity.
2.1 PROGRAM SEQUENCE
MICROTEMP 4 95-01-22
14:15
CLOSED LOOP CONTROL - MOULD TEMPERATURE:
ZONE STATUS SET A C T .E F FLOW

(°C) (°C) (l/min) monitoring F
Man. A u t o
*1* 0 Valve closed 0 24 0.0 0.0 NO
*2* 1 open loop 0 *** 1.5 2.5 NO
*3* 2 closed loop 38 36 0.0 0.0 YES

*4* 3 Valve open 0 22 0.0 0.0 NO
*5* 0 Valve closed 0 24 0.0 0.0 NO
*6* 0 Valve closed 0 24 0.0 0.0 NO
*7* 0 Valve closed 0 24 0.0 0.0 NO
*8* 0 Valve closed 0 24 0.0 0.0 NO
MONITORING - ADVANCE TEMPERATURE: ( ° C )

SET VALUE 13 °C
ACTUAL VALUE 13 °C
MAX. DEVIATION 3 °C
PROG.INTERRUPTION 4
MOULD CYCLE TIME PROD. DATA MICROTEMP SELECTABLE etc.
PARAMETERS COLLECTION TEXT PAGE --->
MACHINE
PARAMETERS starting from ES 500
By entering a figure 0 - 3 the corresponding cooling circuit is switched to a certain operation status:
0 = Valve is always closed
1 = Operation mode without thermocouple in the mould (open loop)
2 = Operation mode with thermocouple in the mould (closed loop)
3 = Valve is always open

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Operator's manual
The program “Microtemp” closed loop or open loop controls, depending on whether a temperature couple is present
at the injection mould or not, the mould temperature by connecting and disconnecting cooling water via solenoid
valves. To each control circuit a mould temperature couple each, a solenoid valve and possibly a flow monitor is
allocated in a fixed way.
A temperature couple in the inlet monitors the cooling water temperature and supplies an error message if the limit
value is exceeded. If flow monitors are installed, each monitors a minimum flow per cooling circuit and supplies
an error message if the flow is not reached (FLOW MICROTEMP).
2.1.1 Monitoring of the advance temperature
For monitoring the advance temperature a set value and a maximum deviation for the actual value can be given.
If the actual value exceeds the set maximum deviation, the error “ADVANCE TEMPERATURE WRONG” is
displayed. The monitoring starts with an adjustable delay time when a valve is opened.
2.1.2 Mode of operation without mould temperature couple (open loop)
If no mould temperature couples are installed, on the screen STATUS 1 must be set and a flow be given in l/min.
With beginning injection the cooling water valves open for a calculated cooling time corresponding to the set flow.
For automatic and manual mode separate flows can be given. The temperature actual value is replaced by "***".
2.1.3 Mode of operation with mould temperature couple (closed loop)
On the screen the desired set value for the mould temperature must be given and the status “2” be set. In the
operation mode “MANUAL” the corresponding cooling water valve is opened when the set value temperature is
exceeded and closed when it is not reached.
In the automatic mode the control system determines itself the control parameters automatically in a first
calibration phase and/or when exceeding a fixed set control tolerance.
The cooling and/or temperature control system must be designed so that a mould temperature change of at least
2 degrees centigrade can be measured by the couples during 10*) consecutive cycles in the automatic mode at
full and/or at no actuation of the valves.
If this is not the case, a calibration error mark (EF) is set on the screen and the error "COOLING TOO WEAK"
or "TEMPERATURE CONTROL UNIT NECESSARY" is displayed. The cycle new start is prevented, the alarm lamp
lights up. Set corresponding measures and start the cycle newly. Afterwards the corresponding cooling water
valves are always actuated at beginning injection for a calculated time.
*) In the standard case the number of calibration cycles is set to 3, but can be changed according to
requirements. See Technical Manual, list of constants, KO446.
The calibration begins with 'NOT COOLING' if the temperature actual value is smaller than the set value.
'COOLING', that is flow on, is introduced from exceeding the set value.
2.1.4 Flow monitoring
If a valve opens in the cooling circuit and if the monitoring is switched on, a corresponding minimum flow is
monitored. The reaction of the monitoring displays a screen tag (F) on the screen image “MICROTEMP” and/or
the error message “MICROTEMP VALVE x”.
The activation of a cooling water valve and the signal of the monitoring switch of a cooling circuit displays one screen
tag each.

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3. WEEK SWITCH CLOCK
WEEK SWITCH CLOCK 4 95-01-10 16:30

** WEDNESDAY **
SWITCH CLOCK OFF
SWITCHING-OFF MANUAL NO
DAY START STOP VIA SWITCH CLOCK
MON 0 : 00 0 : 00 UNITS ON OFF
TUE 0 : 00 0 : 00
WED 0 : 00 0 : 00 MOTOR NO NO
THU 0 : 00 0 : 00 HEATING NO NO
FRI 0 : 00 0 : 00 UNIT 1 NO NO
SAT 0 : 00 0 : 00 UNIT 2 NO NO
SUN 0 : 00 0 : 00
S W I T C H - O N D .S W I T C H - O F F D E L A Y
UNIT ON SET A C T . SET ACT.
MOTOR 0.0 0.0 0.0 0.0 m i n
HEATING 0.0 0.0 0.0 0.0 m i n
UNIT 1 0.0 0.0 0.0 0.0 m i n
UNIT 2 0.0 0.0 0.0 0.0 m i n
UNIT 1 OFF UNIT 2 OFF

Main switch for
additional units
PROG.INTERRUPTION 4
WEEK SWITCH
CLOCK
The function of the 'week switch clock' serves the purposive switching-off and switching-on of the machine at freely
selectable moments within one week.
General:
The initialization of the switch clock occurs with setting the current date and the exact time.
Motor, heating and the two units can be switched on and off differently.
If the switch-off moment is reached during an automatic cycle, this cycle is still terminated, but the next is blocked
and the switch-off procedure (delay times etc.) is started. Also the cycle time monitoring is stopped by the switch-
off procedure.
The switch-off of the heatings via switch clock occurs by automatic switching-on of the screen switch "MANUAL
TEMPERATURE REDUCTION" , i. e. if a reduction temperature is set, the heating is not switched off, but only
reduced. If the reduction temperature is set to 0, the output HZA switches off in the hardware by the heatings getting
deactive. Also temperature control units coupled via serial interfaces are switched to lowering operation.

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Function:
If on the current weekday the time set under the title "START" and/or "STOP" is reached, the switching-on and/
or switching-off delay times of all preselected units start, by which it is possible to fix an optional switching-on and/
or switching-off sequence. After switching off the first unit the error message "SWITCH CLOCK OFF" appears,
which is erased again after switching on all units via switch clock.
After switching off the machine by the clock the control voltage can be switched off-on without disturbing a
switching-on of the machine programmed by the clock.
Outputs:
M1 .... ....... Switch off pump motor

HZA ............ Heatings off at lowering temperature = 0
DV1 .... ........ Switch off unit 1 (option)
DV2 .... ........ Switch off unit 2 (option)
MSI .... ........ Start motor (option)
The setting 00:00 causes no switching-on and switching-off, i. e. this time setting is ignored.
Premature stop of the machine:
If the machine shall be stopped before the switching-off time of the switch clock is reached, but the switching-
on function via the clock shall remain active, one selects the function:
"SWITCHING-OFF MANUAL YES"
Thus an immediate switching-off of the machine is introduced, but the switching-on moment of the clock is
still active. -------> Simulation of the function "Switch clock off".
Premature switching-on of the machine:
Switching on-off the program interruption key causes the interruption of the switch clock OFF function. The
units switch on, heatings heat up. The pump motor must be switched on manually (on the key panel).
If the heatings were lowered before the switching-off by the clock, the temperatures go on the operation set
value again after switching on by the clock. If the error which released the lowering still exists, however,
lowering occurs again.

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4. ABSOLUTE VALUE INPUT (OPTION)
4.1 GENERAL
On the injection unit this program block creates the possibility to give more specific moulded part data of the control
system. So in parallel to the screen pages with their relative values analogously constructed screen images exist,
which contain absolute set and actual values.
The following injection parameters are connected with each other as partners:
Hydraulic pressures (bar) <===> Specific injection pressures (bar)

Back pressures (bar) <===> Specific back pressures (bar)
Stroke positions (mm) <===> Stroke volumes (ccm)
Injection speeds (mm/s) <===> Injection rates (ccm/s)
Screw speeds (%) <===> Peripheral speed (m/min)
RELATIVE values ABSOLUTE values
Thus absolute values and relative values exist in parallel when changing one of the two values the respective partner
value being calculated newly. If the conversion for the partner value yields an unallowed result, the value of the
selected parameter is taken over, but the partner value is not updated. From this moment the not updated partner
value flashes until it is written on a plausible value. Further, new calculations occur when changing the screw
diameter as well as when switching over from increased injection pressure to not increased injection pressure (and
vice versa). Starting point of these new calculations are the absolute values in each case.
Screen pages:
INJECTION <==> INJECTION ABSOLUTE VALUES

SWITCHOVER MODE <==> SWITCHOVER MODE ABSOLUTE VALUES
HOLDING PRESSURE <==> HOLDING PRESSURE ABSOLUTE VALUES
PLASTICIZING <==> PLASTICIZING ABSOLUTE VALUES
SET VALUE GRAPHICS <==> SET VALUE GRAPHICS ABSOLUTE VALUES
4.2 STORAGE
The absolute values are stored on disk. If the control system reads in a disk which has stored no absolute values,
from the read-in relative values new absolute values are calculated.

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4.3 CALCULATION ALGORISMS
Pressure:
As Ak
Pr = Ps * —— Ps = Pr * ——
Ak As
Pr ... Hydraulic pressure (relative)

Ps ... Specific injection (back) pressure (absolute)
As ... Area screw
Ak ... Area injection piston
Volume:
V s ... Stroke
s = — As ... Area screw
As V ... Volume
Injection rate:
V V ... Injection rate

v = — v ... Injection speed
As As ... Area screw
Screw speed:
The screw speed (%) is converted in m/min.
nn
n0 = —— U ... Screw circumference [m]
U n0 ... Output speed [1/min]
nn ... Rotational speed [m/min]

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5. CHARGE AMPLIFIER (OPTION)
The test signal for the mould cavity pressure determination and/or mould cavity pressure switchover is supplied
by a "charge amplifier". The electric charge, which the transducer produces in the mould, is transformed in the
charge amplifier into an electric voltage and passed on to the control unit, which calculates the mould cavity
pressure by means of corresponding setting parameters.
In this way also all settings which concern the charge amplifier can be made on the control unit and stored on
diskette.
Image selection key S + F1
Setting
limitations
CHARGE AMPLIFIER 4 95 01 10 16:30
0 = Pres. transducer
TYPE OF TRANSDUCER FORCE TRANSDUCER 1 = Force transducer
FORCE TRANSDUCER 0 - 10.00
FORCE TRANSDUCER SENSITIVITY . . . . pC/N 0 - 10.0
PIN DIAMETER . . . mm 0 = 5000, 1 = 20000
MEASURING RANGE . . . . . pC
PRESSURE TRANSDUCER 0 - 100.00

PRESSURE TRANSDUCER SENSITIVITY . . . . pC/bar 0 = 5000, 1 = 20000
MEASURING RANGE . . . . . pC
CAVITY PRESSURE ACTUAL VALUE PFx = . . . . bar Display
PROG.INTERRUPTION 4
CHARGE WEEK SWITCH CENTRAL
AMPLIFIER CLOCK COMPUTER

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Type of transducer: After selecting the line TYPE OF TRANSDUCER with the cursor, it can be switched
to 'Force transducer' by entering "1" and to 'Pressure transducer' by entering "0".
Transducer sensitivity: For both types of transducer separate values can be set. The sensitivity of the force
transducers lies in the range of 3.00 to 5.00 pc/N, at pressure transducers in the range
of 2.50 to 9.00 pC/bar.
Measuring range: The measuring ranges of 5000 pC and 20000 pC can be set separately for both types
of transducer.
The switchover of the charge amplifier to the measuring range 20000 pC occurs by
means of a digital signal, which is prepared by the control system (+24V on output
S63).
Pin diameter: Only at force transducers also the pin diameter can be set in the range of 0.0
up to 10.0 mm.
ENGEL standard charge amplifiers are:
KISTLER Z13378: When the control unit is switched on and when switching over the mode of operation
from automatic in manual program a test of the charge amplifier is carried out. If this
test is not positive, the error message "CHARGE AMPLIFIER" appears. The
machine functions are not impaired by this.
KISTLER 5039 A221: Like Z13378, but without this test function.
Resolution of the test signal:
Device supplies: 0 to + 10 Volt

12-bit resolution of the control system: 0 to 4095 bits
Range 5000 pC: 10 V correponds to 5000 pC

10 V corresponds to 4095 bits
e.g.: Sensitivity = 9 pC / bar:

so max. 5000 / 9 = 556 bar measurable
10 V / 556 bar = 18 mV / bar
4095 bits / 556 bar = 7.3 bits / bar
Range 20000 pC: 10 V corresponds to 20000 pC

10 V corresponds to 4095 bits
e.g.: Sensitivity = 2.5 pC / bar

so max. 20000 / 2.5 = 8000 bar measurable
10 V / 8000 bar = 1.25 mV / bar
4095 bits / 8000 bar = 0.5 bits / bar

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6. CENTRAL COMPUTER (OPTION)
When connecting a central computer ( = host computer) the following screen page is available:
Image selection key S + F3
Setting
limitations
CENTRAL COMPUTER 4 95-01-10 16:30
ORDER NUMBER ANR = . . . . . . . . . . . . . . . . 16 digits alphanum.

MOULDED PART NUMBER SPN = . . . . . . . . . . . . . . . . 16 digits alphanum.
MOULD NUMBER WKN= . . . . . . . . . . . . . . . . 16 digits alphanum.
MATERIAL NUMBER MTN = . . . . . . . . . . . . . . . . 16 digits alphanum.
DATA SET NUMBER = . . . . . . . . 0 - 99999999
ORDER TRANSMISSION NO Yes/no
STATUS: START ERROR CODE FINISHED Displays
STANDSTILL INPUT Menu:
01 - Prepare machine 06 - No order 16 digits alphanum.
02 - Machine defective 07 - No material 16 digits alphanum.
03 - Mould defective 08 - No personnel 16 digits alphanum.
04 - Mould proving 09 - Overcapacity 16 digits alphanum.
05 - Clean machine 10 - No release 16 digits alphanum.
11 - Other reasons 98 - Out of order 16 digits alphanum.
Code . . Input 0 - 99
PROG.INTERRUPTION 4
etc
CHARGE WEEK SWITCH CENTRAL --->
AMPLIFIER CLOCK COMPUTER
Whole mould data sets (injection parameter sets), individual set or actual values, process data as well as standstill
reasons, error and operation states can be transmitted to the host (uploading).
From the host mould data sets or individual set values can be transferred into the control system (downloading).
For this purpose one selects the coding of the requested injection parameter set and sets "REQUEST
TRANSMISSION" to "YES" (1 + ENTER).
When the set is present in the host, the transmission starts.

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The screen tags inform about the state of the transmission:
START Transmission started

ERROR Transmission error, transmission interrupted
CODE Injection parameter set code (SET) not present on the host
FINISHED Transmission completed with success
The line "CODING ACTUAL" shows the mould code when the mounted mould is equipped with mould coding.
The input "CODE .." allows a communication to the host say for statistical purposes, which informs about the
standstill reason. Take the coding number from the indicated menu.
The user can change and/or enter newly the text of the standstill reasons by means of the front panel keyboard.
The text is stored on the machine diskette.

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7. PROGRAM QUICK SETUP
7.1 PURPOSE
Survey of the most important settings on one screen page.
Thus: Fast basic setting to the first cycle.
Fast access for optimization in the automatic cycle.
7.2 GENERAL
The program Quick Setup represents the most important machine settings in compressed form on one screen
page. Thus it enables the operator on the one hand to inform himself about the essential machine data on only one
page, on the other hand he can make the machine largely "ready for production" by setting only the Quick Setup
parameters.
7.3 ACTUAL VALUE DISPLAY
The following actual values are displayed on the page Quick Setup:
Mould stroke actual value SFx [mm]

Nozzle stroke actual value SDx [mm]
Ejector stroke actual value SAx [mm]
Screw stroke actual value SSx [mm]
Mould height actual value FHx [mm]
(At toggle lever machines without mould height stroke transducer: “*****”)
Hydraulic pressure actual value PHx [bar]
Screw speed DZx [1/min]
Cycle time ZUx [s]
Temperatures Hxx [“C]

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7.4 CALL-UP
With actuating the fast call key the Quick Setup appears.
QUICK SETUP 4 95-01-10 23:12
EJECTOR OPENING CLOSING CARRIAGE INJECTION PLASTICIZING
40
P 60 % V6 100 % SK 500 kN HEATING 46 VS 75 mm/s C1 80 mm
V 100 % V7 100 % V1 60 % SET ° C P6 120 bar V 75 %
L 0 mm W4 40 mm V3 40 % 190 200 210 210 200 C3 20.0 mm PS 12 bar
L1 20 mm A 100 mm G1 50 mm 191 200 220 210 201 PN 105 bar
AZ 1 mal ZÜ 26 s P2 40 % ACTUAL °C Z2 1.0 s
Z5 0.0 s ZUx 16 ZF 5.0 s INJECTION UNIT Z4 6 s C2 0 mm
K 50 mm ZS 99.0 s C4 0 mm
SZ 0 SZx 91 Sch P5 70 % V9 100% SDM 45 mm
Ejector Mould position Nozzle position Screw Screw

position SFx 100 mm SDx 50 mm position speed
SAx 0 mm Mould height FH 100 mm SSx 79 mm DZx 0 /min
FHx 0 mm Oil temperat. 10°C Injection pres. PHx 13 bar
Ejector pressure Parameter new setting NO
PROG.INTERRUPTION 4
Set the cursor with the arrow keys to the requested parameter and change in the usual way with entering the new
value and concluding 'ENTER'.
Left below in the image the clear text of the parameter appears, over which the cursor zone is.
Tags under the main functions (ejector, ...) indicate the activity in the cycle.

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7.5 SETTING MODES
Basically one distinguishes between normal and setting mode. While the normal mode is intended for the
recorrection of parameters, the setting mode serves for the first (basic) setting of the machine. After each selection
of the screen page "QUICK SETUP" the normal mode is valid. The setting mode is activated by switching on the
switch "Parameter new setting".
ATTENTION ---> At the same time with the switch-on of the switch "Parameter new settings"
("normal") machine settings from the current Quick Setup data are calculated;
thus also already occurred fine optimizations are overwritten !!
To guard against an unwanted actuation of the 'Parameter new setting' switch the
input is protected via an interrogation 'Are you sure?' and can only occur in manual
and/or set-up mode
7.6 CALCULATIONS AFTER ENTERING QUICK SETUP PARAMETERS
7.6.1 Clamping unit:
Clamping force [kN]:
As a function of the clamping force the position G2 is changed. From a table of ten possible G2 settings (constants)
that value is selected whose table index corresponds to one tenth of the per cent
clamping force value (SK[%]/10). The value "Pos.B" is recorrected if necessary (B<=G2).
Mould opening stroke pos. A [mm]:
Normal mode:
The positions A1 and {W1...W4} are also corrected proportionally. The mould protection start position G1 is
corrected if necessary (G1 <= W1).
Setting mode:
The positions A1, W3 and W2 are set equal to the pos. A. The position W4 is calculated with A/4. Position W1
is set equal to the pos. G1.
Mould protection beginning pos. G1 [mm]:
Setting mode:
Position W1 is set equal to pos. G1.
Start 2nd opening speed pos. W4 [mm]:
If necessary W2 is corrected (W4 <= W2).
Closing speed V1 [%]:
Normal mode:
changes V2 proportionally.
Setting mode:
Sets V2 equal to V1.

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3rd closing speed V3 [%]:
No special calculations.
1st opening speed V6 [%]:
2nd opening speed V7 [%]:
Normal mode:
Changes the 3rd opening speed V8 proportionally.
Setting mode:
Sets the 3rd opening speed V8 equal to V7.
Mould protection pressure P2 [%]:
Normal mode:
Changes the first mould protection pressure value P2a directly and the second one (P2e) proportionally.
Setting mode:
Sets the values P2 = P2a = P2e.
Mould protection time ZF [s]:
7.6.2 Ejector
Ejector rear, pos.L [mm]:
Setting mode:
The times "Ejector forward delayed (ZAVV)" and "Ejector front (ZA)" are set to 0. The position L2 is placed between
the positions L and L1 (L2 = L + (L1 - L) / 2).
Ejector front, pos. L1 [mm]:
Setting mode:
See ejector rear, pos. L
Ejector pressure [%]:
Normal mode:
Hydraulic pressure for ejector forward (P25) [%].
Setting mode:
Transmits the hydraulic pressure for ejector forward (P25) to ejector return (P26) [%].

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Operator's manual
Ejector speed V [%]:
Setting mode:
Sets V26 equal to V.
Ejector counter AZ:
Pause time Z5:
No special calculations
7.6.3 Heatings:
The values, represented in the symbol material hopper, show set and actual value of the traverse cooling.
The values, represented in the symbol material cylinder, show zone 1 to 5 (at large machines up to zone 7).
7.6.4 Injection unit:
Injection profile VS [mm/s]:
Normal mode:
The injection profile values {V12...V21} are changed proportionally, the value VS corresponding to the highest value
from the series {V12...V21}.
Setting mode:
All injection profile values {V12...V21} are set equal to the value V. As upper input limit that maximum speed is
valid which can be reached by the machine on the basis of the position of the switch "Increased injection pressure",
but if for the pressure values {P6...P16} settings are selected which could also be reached without operation mode
"Increased injection pressure", and when the operation mode "Increased injection pressure" is switched on, the
switch for this operation mode is switched off automatically if the speed preselection should lie outside these limits.
Hydraulic pre-injection pressure P6 [bar]:
Hydraulic holding pressure PN [bar]:
Normal mode:
The holding pressure profile values (hydraulic pressure) are changed proportionally, the value PN corresponding
to the highest value of the series {P7...P16}.
Setting mode:
The holding pressure values of the series {P7...P16} are set equal to the value PN.

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Operator's manual
Switchover position to holding pressure C3 [1/10 mm]:
Setting mode:
The switch for stroke-dependent switchover to holding pressure is switched on and the remaining switchover mode
switches (time, pressure etc.) are switched off.
Time monitoring injection ZS [1/10 s]:
Normal mode:
The max. injection time monitoring (ZS1) is set equal to the Quick Setup time ZS. The min. injection time monitoring
(ZS0) is recorrected by maintaining the difference to the max. injection time monitoring.
Setting mode:
Is set equal to the max. injection time monitoring ZS1. The minimum injection time monitoring ZS0 is set equal
to zero. Further, the parameters "Intrusion time" (ZIN) and intrusion speed (V23) are set equal to zero.
Plasticizing end C1 [mm]:
Hydraulic back pressure PS [bar]:
Normal mode:
The back pressure profile values (hydraulic pressure) are changed proportionally, the value PS corresponding to
the highest value of the series {P17...P21}.
Setting mode:
The back pressure values of the series {P17...P21} are set equal to the value PS.
Screw speed, V [%]:
Normal mode:
The screw speed values [%] are changed proportionally, the Quick Setup value V corresponding to the highest value
of the series {DZV1... DZV5}.
Setting mode:
The screw speed values of the series {DZV1...DZV5} are set equal to the Quick Setup value V.
Decompression before plasticizing, C4 [mm]:
Setting mode:
Screw retraction speed V24 is set to 10 %.
Decompression after plasticizing, C2 [mm]:
Setting mode:
Screw retraction speed V24 is set to 10 %.
Holding pressure time Z2:

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Operator's manual
Cooling time Z4:
Screw diameter SDM:
Setting mode:
No calculations
Normal mode:
No calculation.
With installed program 'Absolute value input' a new setting of the screw diameter causes:
hydr. holding pressures, hydr. back pressures, hydr. injection pressure are calculated corresponding to set specific
pressures on the Quicksetup.
The program 'INJECTION PRESSURE INCREASED' on the injection image calculates new specific pressures, the
hydraulic ones remain the same.
7.6.5 Carriage unit
Position carriage unit rear, K [mm]:
Normal mode:
When entering the value 0 the retraction program is switched off (=0) and the pos. J1 is set to 0.
If the pos. K is changed from the value 0 to a value > 0, the retraction program 2 is switched on and the pos. J is
set to the value K / 10.
When changing pos. K from a value > 0 to a value > 0, the pos. J1 is also changed proportionally.
Setting mode:
Like in the normal mode, but in addition the following parameters are influenced:
V9 = 40 %, V10 = 10 %, V11 = 20 %, P5a = 10 %, Z6 = 0.
Carriage pressure, P5 [%]:
Setting mode:
Carriage pressure build-up time Z5a is set to 0.2 s.
Carriage speed, V9 [%]:
Normal mode:
The braking speed V10 is also changed proportionally.
Setting mode:
The braking speed V10 is set to one fourth of the value of V9.
7.6.6 Various times:
Cycle monitoring time, ZU [s]:
When entering the value 0 the switch "Cycle monitoring" is switched off, otherwise switched on.

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Chapter MP MICROGRAPH PLUS
1. PERFORMANCE CHARACTERISTICS
- Representation of 7 curves at the same time (including ideal curve), distinction in colours
- free selection and compilation of the curves from the parameters of each existing unit:
Screw stroke Hydraulic pressure
Injection speed Mould cavity pressure (option)
further parameters as option (e.g. heatings, further hydraulic pressures...)
- per selection (=curve group) 1 ideal curve can be determined, but altogether only 2 different ideal curves in the
standard system. When coupling further subsystems (3-, 4-colour plants), from there curves can be transmitted
into the main system and be displayed.
For each subsystem 2 ideal curves can be defined.
- Representation of the ideal curve as tube; colour can be determined.
- 4 selections (curve groups) can be compiled at will separated from each other; one selection consists of up to
7 curves.
- Magnifier function: 3 sections per group of curves can be defined freely, separated from each other, and be called
up fast.
- fast call-up of full, half and quarter image with the figure keys, partial images can be displaced with cursor.
- constant display of the selected section in small full image.
- all set parameters and setups stored on floppy per mould data set.
- Scales can be faded in via function key and can be changed directly, also later.
- Ideal curve can be allocated to each selected parameter.
- Ideal curve can be derived from 'group of curves'.
- Groups of curves can be stored on diskette.
- 2 monitoring windows can be set freely separated from each other.
- digital, exact actual value display on optional curve position via function key and cursor.
- Display of the switchover point, of the flow number and of the flow number measurement window.
- simultaneous recording of the selected curves.
Index: M4-1 / 1995-01-05 Micrograph plus M+ 1

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2. SIMPLE SETTING (FOR THOSE IN A HURRY)
2.1 AUTOSETUP - SIMPLE SETTING AUTOMATICALLY
Starting position:
The machine runs in automatic mode and produces good parts. With cycle end the parameters which are
necessary for the automatic self-setting are stored temporarily.
Setting process:
The operator presses the function key "AUTOSETUP" in the submenu "QUICK SETUP MICROGRAPH". Thus the
following calculations are made from the parameters stored temporarily:
- The rounding-off of the injection time yields the measurement time.

- The measurement delay time is set to zero.
- The scales for the screw position, the hydraulic pressure, the injection speed and the mould cavity
pressure are derived from a table of the actual/peak values, always the next higher value from a fixed
table being used as setting value, e.g.: Current peak value of the injection speed = 0 (after switching on
the control unit) ---> Value 50 mm/s is preoccupied.
The calculation results are represented summarized on the screen on the page 'QUICK SETUP MICROGRAPH'
(--> item 2.2)
At the first setting (after resetting the data) in principle the hydraulic pressure curve (1) and the injection speed curve
(3) are selected and represented.
As ideal curve the last hydraulic pressure curve is taken, with a tolerance of 10%.
When curves are already selected, these selected ones are represented and those of channel A are assumed as
ideal curve.
Setting
QUICK SETUP MICROGRAPH 4 95-01-10 16:24limitations
CHANNEL a = 1 0-3
CHANNEL b = 3 0-3
CHANNEL c = ideal
0 . . . . SCREW POSITION 120 mm 0 - 6553,5

1 . . . . HYDRAULIC PRESSURE 200 bar 0 - 999,9
2 . . . . MOULD CAVITY PRESSURE 800 bar 0 - 9999,9
3 . . . . INJECTION SPEED 150 mm/s 0 - 999
TIME SETTINGS:
Time base 2 s 0 - 255
Start delay 0.0 s 0 - 99,9
IDEAL CURVE 1
Max.pos.tube deviation: 10 % Max.pos. i.deviation: 0 % 0- 100
Max.neg. tube deviation: 10 % Max.neg. i. deviation: 0 % 0 - 100
MOTOR STOP 4
MICROGRAPH MICROPLAST MICROPLAST AUSSTIEG
- FLOW 1 - FLOW 2
2 M+ Micrograph plus Index: M4-1 / 1995-01-05

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Operator's manual
2.2 SIMPLE SETTING MANUALLY
Select the screen page
and actuate:
F1 F2 F8
MICROGRAPH MICROPLAST e t c.
- FLOW 1 ..................... --->
F1
QUICK
SETUP .....................
It appears the page 'QUICK SETUP MICROGRAPH' for the input and survey of the simple settings.
2.2.1 Simple setting - parameter and scale selection
Select on the screen page 'QUICK SETUP MICROGRAPH' for channel a and/or b a parameter from the list (0 to
3) and set the scale correspondingly.
Further, select the time base for the recording period. If the graphic recording shall start delayed at injection
beginning, enter this start delay time.
Afterwards return to the graphic image again with function key F8 'etc.' and start the injection process. You will
find your basic setting confirmed.
2.2.2 Simple setting - monitoring
If you want to derive a quality and/or rejects criterion from an injection parameter which now appears as curve on
the screen, activate the monitoring function:
At first set on the 'QUICK SETUP MICROGRAPH' image a positive and negative deviation tolerance for ideal curve
1, select F8 and afterwards F6 "Ideal curve":
New row of function keys:

F1 F2 F3 F4 F8
TRANSFER CHANNEL a CHANNEL b ADAPT EXIT

TRANSFER TRANSFER SCALE

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Now determine with F2 and/or F3 which channel, a or b, shall be used for quality control.
After the selection you see the concerned curve surrounded with a red tube (channel c). This represents the set
tolerance zone. If it is exceeded and/or not reached, the error message "DEVIATION" arises, the produced part
is valued as rejects.
2.2.3 Simple setting - partial images
With the figure input keys 2 and 4 you can select partial images (magnifiers): 2 = Half image
4 = Quarter image
1 = return to the full image
In the small survey graphics right below on the screen you see the position of the current partial image. With the
cursor keys the partial images can be displaced.
Example: it has been selected:

Channel a = 1, hydraulic pressure, maximum swing = 200.0 bar
Channel b = 3, injection speed, maximum swing = 60 mm/s
Time base = 4s
MICROGRAPH 3 95-01-02 16:24

100%
SCALES: SELECTION 1 Display of the
AG-1 PHx 200,0 bar
c h o s e n
AG-1 VSx 60 mm/s
80% IDK1 AG-1 PHx parameters
60%
40%
ACTUAL VALUES: Survey graphics,
AG-1 PHx 94.0 bar here full image
AG-1 VSx 13 mm/
20%
s
0%
0.00 0.80 1.60 2.40 3.20 4.00s
*
PROGR.INTERRUPTION 4
!
- FLOW 1 -->
B700DE84

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3. MICROGRAPH PLUS HAS MORE FUNCTIONS
3.1 SELECTIONS (=CURVE GROUPS)
4 selections (groups) of up to 7 curves each and also flow number and switchover point display can be compiled
individually. 1 selection each is represented on the screen, but all are recorded in the background in order that one
has the possibility after occurred injection process to view all selected curves.
3.1.1 Compilation of selections
Image selection key

Entry into the "SETUP" of the
MICROGRAPH PLUS occurs from the
graphic image with the function key F8
F1 F2 F8
(etc) and F2 (Setup). Now here one selects
MICROPLAST etc.
MICROGRAPH - FLOW 1 --> the curve selection with F1.
.......
F1
QUICK SETUP
SETUP
F1
CURVE
SELECTION
.......
MICROGRAPH - CURVE SELECTION
SELECTION 1 SELECTION 2
green PHx Unit 1 PHx Unit 2
blue VSx Unit 1 VSx Unit 2
red IDK1
yellow PHx Unit 1
cyan
magenta Selection field,
white selected curves,
FLOW NUMBER UNIT 1
SWITCHOVER POINT UNIT 1
FLOW NUMBER UNIT 2
SWITCHOVER POINT UNIT 2
flow number and switchover
point
UNIT 1 UNIT 2
SSx PHx SSx PHx Parameter menu
PFx VSx PFx VSx
IDK1 IDK2 IDK3 IDK4 Ideal curve selection
Hydraulic pressure selected parameter

M A N U A L in plain language
SET ERASE EXIT

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2 selection fields can always be seen on this image.

After the first opening:
F1
SET
with cursor key one leafs on:
F2 and/or
ERASE
and further:
F1 F8
TAKE OVER EXIT
with cursor key one returns.
....
B704DE72
Setting a curve:
Now set the cursor field with the cursor keys into the requested selection field and with
on the requested colour line.
Press the function key F1 with the text "SET". The cursor field jumps into the parameter menu.
F1 shows "TAKE OVER".
Now select a parameter with the cursor keys. An explaining text to the current parameter appears left below on
the screen. With F1 "TAKE OVER" the parameter is transmitted into the selection field. The cursor jumps there.
Erasing and/or replacing a curve:
Set the cursor in the selection field on the curve to be erased and/or to be replaced. Function key F2 shows
"ERASE". So erase with F2 the entry and set a new curve if desired.
With function key F8 "EXIT" leave the setting mode.
In the set mode there is also the possibility to select one, altogether 4 different ideal curves per selection. The
process for this corresponds like described; one moves the cursor field over the terms IDK1 and/or IDK2 and takes
over. (IDK3 and/or IDK4 are exclusively valid for the 3rd and/or 4th unit.)
Selection of flow number and switchover point display:
Place the cursor over the field "Flow number unit 1" and/or "Switchover point unit". By entering the unit number
you can now produce the corresponding display.

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Operator's manual
3.1.2 Activation of selections
On the graphic image right above one reads off the

current curve group:
F1 F2 F8 SCALES: SELECTION 1
- FLOW 1 --> In order to get to the other selections, one presses F8
.......
(etc.) and then F3 (ACTIVATE SELECTION). Left below
F1 F2 F3 on the screen the blue input field appears. With pressing
QUICK SETUP ACTIVATE the numeric keys 1,2,3 or 4 select one of the 4 curve
SETUP SELECTION
....... groups (selections).
it appears:
> <
1 2 3

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Operator's manual
3.2 SECTIONS
Besides half and quarter image, which can be called up fast with the numeric input keyboard (2 and/or 4, return
to the full image with 1), there is the possibility to program 3 sections (magnifiers) separately from each other. In
a small survey graphics on the screen right below the position and the section number can be read off.
3.2.1 Define and program sections
Enter with key F8 (etc.), then F2 (Setup) into the

setting mode. Function key F2 brings a new key
line. Here one selects the section to be changed
F1 F2 F8
with F1, F2 and/or F3.
MICROPLAST etc.
MICROGRAPH --> Afterwards with F1, F2, F3 and F4 and the cursor
- FLOW 1
.......
keys the margins of the section can be set
observing the small survey graphics.
F1 F2
E.g. press F3 "TOP MARGIN" - F3 being represented
QUICK SETUP
SETUP
inversely - move with the cursor keys the top
....... margin of the section.
F1 F2 With F8 (EXIT) you leave this function.

SECTION
FUNCTION
F1 F2 F3
SECTION SECTION SECTION
*1* CHANGE *2* CHANGE *3* CHANGE
z.B.
F1 F2 F3 F4
LEFT RIGHT TOP BOTTOM
MARGIN MARGIN MARGIN MARGIN
moves
1 Section 1 is shown

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Operator's manual
3.2.2 Activate sections
After occurred setup the call-up of the set windows

can occur very fast.
F1 F2 F8 With F8 (etc) and then F4 (ACTIVATE SECTION)
MICROPLAST etc. the blue input field appears left below on the
MICROGRAPH -->
- FLOW 1
....... screen.
The figures 1, 2 or 3 bring the corresponding
F1 F2 F3 F4 section.
QUICK SETUP ACTIVATE ACTIVATE The selected section can be read off on the survey
SETUP SECTION SECTION graphics.
.......
A * in this display indicates half, quarter or full
image.
Half and quarter image can be displaced with the
it appears: cursor keys by half a .
> < e.g. quarter image:
1 2 3
1
Call-up of a full, half

or quarter image:
4 moves
<-- -->
1 2

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Operator's manual
3.3 ACTUAL VALUES
Right in the screen middle current actual values can be read off on determinable curve points. With not selected
functions the values show '*.*'. A pointer as vertical stroke can be faded into the graphics and be displaced with
the cursor keys . On current position the actual values display correspondingly.
displaceable bar
<--->
MICROGRAPH 3 94-10-02 16:24

100%
SCALES: SELECTION 1
AG-1 PHx 200.0 bar
AG-1 VSx 60 mm/s
80% IDK1 AG-1 PHx
displayed
actual values
60%
40%
ACTUAL VALUES:
AG-1 PHx 94.0 bar
AG-1 VSx 13 mm/
20%
s
0%
0.00 0.80 1.60 2.40 3.20 4.00s
*
PROGR.INTERRUPTION 4 !
- FLOW 1 -->
B700DE84

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Mikrocomputer CC100 - A01
Bedienerhandbuch
3.3.1 Fade in, fade out actual values
F1 F2 F8
MICROPLAST etc. Enter with key F8 (etc.), then with F2 (SETUP)
MICROGRAPH
- FLOW 1 -->
....... into the setting mode. Pressing the key F5 brings
the bar into the graphics. The actual values on
F1 F2 F3 F4 F5 the points of intersection with the curves are
QUICK SETUP CURVE ACTIVATE ACTUAL displayed digitally. The bar can be displaced with the
SETUP SELECTION SECTION VALUES
cursor keys .
moves and displays: ACTUAL VALUES:

AG-1 PHx 94.0 bar
<-- --> AG-1 VSx 13 mm/s
Index: M4-1 / 1994-01-05 Micrograf plus M+ 11

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Bedienerhandbuch
3.4 MONITORING
The graphic recording of actual values offers the possibility to make a tolerance evaluation by comparing curves
and/or the area under the curves (integral) or parts of them. So one determines an occurred curve path to the "ideal
curve" according to which each further shot in this parameter is compared with this ideal curve and is valued
corresponding to tolerance band.
Two types of monitoring are provided:

TUBE: Around the ideal curve a tolerance band in the form of a tube is drawn.
INTEGRAL: The area under the ideal curve is valued as ideal area.
The monitorings can be used at the same time and show the error messages "GRAPHICS-TUBE DEVIATION" and/
or "GRAPHICS-INT.DEVIATION" in case of reaction.
Before the evaluation the ideal curves and current recordings are synchronized in the switchover point, i.e. the new
curve path is displaced (in the computer internally) until the switchover points lie on top of each other. Two
parameters of free choice can be used as ideal curves, but only one per curve group (selection).
Also only parts of a curve can be monitored. For this purpose 2 different windows can be set at will, represented
optically by 2 bars under the graphics.
Screen page + F8 + F2 + F5 (MICROGRAPH PARAMETERS)
MICROGRAPH 3 94-10-02 16:24

TIME SETTING:
100%
TIME BASE: 3s
START DELAY: 0.0 s
80% IDEAL CURVE 1:

MAX.POS.T.DEV.: 10 %
MAX.NEG.T.DEV.: 10 %
60% MAX.POS.I.DEV.: 0 %
MAX.NEG.I.DEV.:0 %
Tolerance
IDEAL CURVE 2: settings
40% MAX.POS.T.DEV.: 5%
MAX.NEG.T.DEV.: 5%
MAX.POS.I.DEV.: 0%
20% MAX.NEG.I.DEV.:0 %
0%
0.00 0.80 1.60 2.40 3.20 4.00s
*
FLOW NUMBER UNIT1: 98.4 Switchover point: UNIT 1
!
- FLOW 1 -->
B700DE84
12 M+ Micrograf plus Index: M4-1 / 1995-01-05

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Bedienerhandbuch
You determine the 'thickness' of the tube around the ideal curve with 'Max.pos.(/neg.) t.dev.' and/or the +/- tolerance
of the area under the curve with 'Max.pos.(/neg.) i.dev.'. In vertical direction the inputs are valid as per cent values
of the respective parameter dimension, horizontally as per cent values of the selected time base. The input 0 %
switches the monitoring off, in each case separately for ideal curve 1 and/or 2, 3 or 4.
3.4.1 Ideal curve - selection
F1 F2 F8
MICROGRAPH MICROPLAST etc. At the compilation of curve groups (selections)

-->
- FLOW 1
....... --> see item 5.1.1 reserve one colour and one place
for the ideal curve. If you have utilized the simple
F1 F2 F6 setting before, the ideal curve 1 on channel c is
QUICK SETUP IDEAL occupied with 'red'.
SETUP
....... CURVE Now go back to the graphic image (F8, "EXIT").
With F8 (etc.) you get to the next function key line.
Now press F6 (IDEAL CURVE).
it appears cursor field: In the selection display right above on the screen
a cursor field appears. Move the cursor with
SCALES: SELECTION 1 to the curve which shall serve as ideal
AG-1 PHx 200.0 bar curve. With the function key F1 (TRANSFER)
AG-1 VSx 60 mm/s execute the command. Around the curve path a
IDK1 tube appears in selected colour and according to
the set tolerance indications. Right beside the
moves
cursor display IDK1 (2,3,4) the selected parameter stands.
IDK3 and IDK4 can only be used for the 3rd and/
or 4th unit.
F1 F2 F4 If per cent values for deviations are changed later,

TRANSFER SCALE with 'F4' 'SCALE ADAPTION' the new values are
ADAPTION
....... adapted to the existing scale. This is only required
when one and the same IDK is used in several
selections, otherwise the adaption with F1 'TRANS-
FER' occurs automatically.
Tube
positive tolerance field
Ideal curve
negative tolerance field
B708DE72

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Bedienerhandbuch
3.4.2 Monitoring windows
The two monitoring windows can only be set when an ideal curve is selected. Without ideal curve the function key
'MONITORING WINDOWS" is faded out.
The windows can be set separated from each other in their size and placing - without overlapping - in order to monitor
e.g. only certain curve parts. Under the graphic image a bar displays the window margins in the colour of the
selected ideal curve.
Set monitoring windows:
F1 F2 F8
MICROGRAPH MICROPLAST etc. With F8 (etc.) and afterwards F2 (SETUP) the
- FLOW 1 -->
....... setting soft key strip appears. F4 (MONITORING
WINDOWS) brings a new strip. One selects the
F1 F2 margin to be changed (e.g. window 1 left margin;
QUICK SETUP the active soft key is backed green) and displaces
SETUP
....... with the cursor keys left and/or right the limitation
to the requested point.
F1 F2 F3 F4
MONITORING
WINDOWS
F1 F2 F3 F4
WINDOW 1 WINDOW 1 WINDOW 2 WINDOW 2
LEFT MAR. RIGHT MAR. LEFT MAR. RIGHT MAR.
moves

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3.4.3 Rejects evaluation and error messages
Rejects are given if at switched-on monitoring, i.e. entered tolerance set values larger than 0%, in at least one
window the current curve has not reached and/or exceeded the tolerance band. Left below on the graphic screen
page appears the error message "DEVIATION" white on red ground. If it is displayed yellow on red, start delay time
or time base are not identical.
Even with not opened graphic page one recognizes a deviation message in the general error display line (or error
page): "REJECTS GRAPHICS 1" (and/or ...2, 3 or 4). At multi-unit machines it is found out from which injection
unit a deviation has occurred in order to be able to delay possible rejects messages (normally 1 cycle). The rejects
counter is counted up by 1 (screen page 'Production data') and with a rejects maximum value the max. rejects
number per hour can be determined. The shot counter is also counted up, the piece counter not. When the
maximum value is reached, the machine switches off.
3.5 SCALES
3.5.1 X-axis
On the abscissa (x-axis) it is recorded in time scale. The recording period (time base) can be set 1 sec to 255 sec:
Screen page + F8 + F2 + F5 (MICROGRAPH PARAMETERS)
TIME SETTINGS:
e.g. TIME BASE: 6 s (1 - 255 s)
e.g. START DELAY: 3.2 s (0 - 25.5 s)
A newly set time scale is shown on the X-axis immediately. The graphic recording remains unchanged until the
next start injection, however.
Attention to the selected deviation tolerance for the monitoring circuit. With changing the time base the width of
the ideal curve tube also changes (per cent values !).
Start delay
With beginning injection a graphic start delay runs, after whose expiry the actual graphic recording begins. This
delay time is considered in the time axis (x-axis):
e.g.: Start delay = 3.2 sec:
0%
3.20 4.40 5.60 6.80 8.00 9.20 s

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3.5.2 Y-axis
On the one hand the ordinate (y axis) constantly protracts a per cent scale, divided into 5 parts:
20%, 40%, 60%, 80%, 100%.
The maximum swings of the individual selected parameters (curves) are listed in the screen right above. These can
be changed, the concerned curve taking over the new scale immediately. On the right margin of the graphics the
scale to a requested curve can also be protracted.
Screen page
MICROGRAPH 3 94-10-02 16:24

100% 200 SCALES: SELECTION 1
AG-1 PHx 200.0 bar
AG-1 VSx 60 mm/s
80% 160 IDK1 AG-1 PHx
60% 120
Maximum swings for
100% in the graphics
40% 80
ACTUAL VALUES:
AG-1 PHx 94.0 bar
20% 40 AG-1 VSx 13 mm/s
0% 0
0.00 0.80 1.60 2.40 3.20 4.00s
*
FLOW NUMBER UNIT 1: 98.4Switchover point: UNIT 1
!
- FLOW 1 -->
B700DE84
Absolute scale of one curve can be faded

in
fixed per cent scale always time scale

BM1DE804..PM4
Bedienerhandbuch
3.5.3 Select and change scales
F1 F2 F8

- FLOW -->
....... With F8 (etc.) and afterwards F2 (SETUP) enter
F1 F2 into the setting soft key strip. When pressing the
QUICK SETUP F3 (SCALE) the blue input field appears left
SETUP
....... below on the screen and a cursor field in the
F1 F2 F3
selection table. Now select with the cursor keys
the parameters one after the other and enter the
SCALE
requested scales (in absolute values) with the
numeric input keys.
With the function key F1 (FADE IN SCALE) bring
> < appears:
the scale of the parameter right into the graphic
and image, which is occupied with the cursor field.
cursor field
With F2 (FADE OUT SCALE) erase the scale
display.
SCALES: SELECTION 1
AG-1 PHx 200.0 bar
AG-1 VSx 60 mm/s
ATTENTION: In the survey graphics the scales
IDK1 are also changed correspondingly, this also
means that the possibly preselected windows
(magnifiers) must be changed if required.
Select
> parameters
>
7 8 9
4 5 6
1 2 3
- 0 .
ENTER ---> selected curve appears

in the selected scale
Select scale display:
F1 F2 F8
FADE IN FADE OUT EXIT
SCALE SCALE
.....
or return to a new input
Scale appears right

Index: M4-1 / 1994-01-05 beside the graphics Micrograf plus M+ 17
BM1DE804.PM4
Bedienerhandbuch
3.6 GROUPS OF CURVES
Call-up:
F1 F2 F8
- FLOW -->
.......
F1 F2 F8
QUICK SETUP etc.
SETUP -->
.......
F1
GROUP OF
CURVES
F1 F2 F3 F4 F5 F8
START / ERASE ERASE STORE I D E A L etc.
STOP SHOT CURVE -->
.......
The function of groups of curves is activated by actuating the function key 'Group of curves'. The already recorded
curves appear.
The curves selected within an optional curve selection group are stored after each shot and displayed in the
graphics. When changing the curve selection group the recording for the curves selected in this group also runs.
When the curve memory is filled fully, the oldest curves are overwritten by a new shot. The total number of curves
which can be stored is fixed with 40.
Start
Start of the recording of the group of curves. The function key text changes to 'STOP'. The recording begins with
the next shot. Already recorded curves are not erased. When the curve memory is full, the oldest curves are
overwritten and erased from the screen. The active recording is signalled with the display of the text 'GROUP OF
CURVES START' under the graphics and remains active despite screen page change until F1 'STOP' is actuated.
Stop
Stopof the recording of the group of curves. The function key text of the key F1 changes to 'START'. The curve(s)
of the current cycle is (are) no longer taken over. By renewed actuation of the F1 the recording can be continued.
Erase

BM1DE804..PM4
Bedienerhandbuch
With F2 the whole memory of groups of curves is erased with safety interrogation.
Erase shot
With F3 the recorded curves of the cycle moved last are erased.
Ideal curve
A current group of curves can be transferred into an ideal curve with F5 (and afterwards F1). This ideal curve range
is composed of the area of the band produced by the recorded curves (envelope) plus a tube surrounding this area,
defined by the tube tolerance limits 'Max.pos.t.dev.' and 'Max.neg.t.dev.' and integral limits 'Max.pos.i.dev.' and
'Max.neg.i.dev.'. (See also item 'Monitoring').
Store on diskette
Tolerance band
Envelope from group
B710DE80
With actuating the function key F4 the data of the current group of curves are written on diskette once.
Exit
Leave the functions of groups of curves with F8. A started recording continues to run.

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Bedienerhandbuch
3.7 GENERAL
3.7.1 Printing the graphics
2 possibilities: 1) each opened screen image can be printed out with the 'HARD COPY' key
on a graphic printer, connected to the control unit front

panel interface.
2) one gets a larger, better resolved printout of the graphic image with the
function key F8 (etc.) and afterwards F7 (PRINT):
E.g.:
100%
80%
60%
40%
20%
0%
0.00 0.80 1.60 2.40 3.20 4.00s
FLOW NUMBER UNIT 1: 98:4 Switchover point: UNIT

1
SCALES: SELECTION 1
AG-1 PHx 200.0 bar
AG-1 VSx 60 mm/s

BM1DE804..PM4
Bedienerhandbuch
3.7.2 Flow number and switchover point display
100%
80%
60%
40%
20%
0%
0.00 0.80 1.60 2.40 3.20 4.00s
Flow number actual value display. The two stroke Switchover point display. The switchover point
points on the injection stroke, which represent the flow position is represented as broken vertical bar. Via the
number measuring window, can be recognized as 2 curve selection the switchover point of an optional unit
vertical bars (blue) with small flag in the graphic image. can be selected.
Flow numbers of further units, if existing, can be
displayed via the curve selection.
3.7.3 Storing
All machine settings, configurations and ideal curves are stored on the parts diskette together with the mould data.

BM1DE804.PM4
Bedienerhandbuch
3.7.4 Fingerpost: Function keys and images
MICROGRAPH MICROPLAST MICROPLAST etc

- FLOW 1 - FLOW 2 -->
*)
QUICK SETUP ACTIVATE ACTIVATE ACTUAL IDEAL CURVE PRINT etc

SETUP SELECTION SECTION VALUES -->
GROUP OF EXIT
***)
CURVES
START/ ERASE ERASE STORE IDEAL CURVE EXIT

STOP SHOT DISKETTE
AUTO EXIT
SETUP TRANSFER CHANNEL a CHANNEL b ADAPT EXIT
SCALE
EXIT
**)
CURVE SECTION SCALE MONITORING MICROGRAPH EXIT

SELECTION FUNCTION WINDOWS PARAMETERS
WINDOW 1 WINDOW 1 WINDOW 2 WINDOW 2 EXIT

LEFT MAR. RIGHT MAR. LEFT MAR. RIGHT MAR.
FADE IN FADE OUT EXIT

SET ERASE EXIT SCALE SCALE
TAKE OVER SECTION SECTION SECTION EXIT

*1* CHANGE *2* CHANGE *3* CHANGE
LEFT RIGHT TOP BOTTOM EXIT

MARGIN MARGIN MARGIN MARGIN
*) if further units exist

**) only comes with selected curve
***) only CC100

BM1DE804..PM4
Operator's manual
Chapter QP QUALITY DOCUMENTATION PACKAGE (QDP)
This program package enables a numerical and graphic recording of all the process data measured by the control
system. By means of this package process data which are in connection with the parts quality can be determined,
documented and monitored.
While at the "process data record" (PDR) all numerical values per shot can be recorded, printed out and stored
on diskette, the "process data graphics" (PDG) allows graphic recording and printing of 8 process parameters.
The recording of these values is either possible as a function of time or as a function of cycle. Into the process data
graphics a "process data monitoring" (PDM) with mean value formations is integrated.
Selection of the programs: Process data record: ´Q´ key + F1

Process data graphics: ´Q´ key + F2
Process data monitoring: ´Q´ key + F2 + F7
1. PROCESS DATA RECORD

PD RECORD 2 95 01 10 16:30
START EVENT END

TIME 0 SEC TIME 1.0 SEC 0 EVENTS
CYCLES 0 SHOT CYCLES 0 SHOT
PROG.INTERRUPTION 4
PROCESS PROCESS QUALITY DATA OPERATING
DATA RECORD DATA GRAPHICS STATISTICS POINT FINDING
Index: 8.04-0 / 1995-01-05 Quality documentation package QP 1

BQPEN804.PM4
Operator's manual
For compiling a record one goes on the next command line with the command "etc" (F8):
START / PARAMETERS SET OUTPUT etc.

STOP UNIT --->
F1 F2 F3 F4 F5 F6 F7 F8
B657DE73
Witch command "SET" (F3) the selection table appears in screen middle. It shows in short signs the list of the
selectable process parameters. See table in item 1.3 of this chapter.
The cursor stands in the entry list:
PD RECORD 3 94-01-10 14:26
Entry list
SZx DZx PHu PFu PFs C3u PVs PNs PSs ZFx ZDx ZSx ZUs
Z4s CPx ASZ ÖlTx H1x H2x H3x H4x H5x H6x H7x H8x H9x
Selection table H10x H11x H12x H13x H14x H15x H16x H17x H18x H19x H20x VSchx SKs
FZx SKx1 SKx2 SKx3 SKx4 SKs1 SKs2 SKs3 SKs4 Std Min SSx SFs
*) StZx DZl TG1x TG2x TG3x TG4x ASSx APNs APSs AC3u APHu APVs ACPx
**)
MPx MEx HPx HEx GPx GEx E/Kg Gew.
START EVENT END

Recording CYCLES 0 SHOT CYCLES 0 SHOT
parameters
PROG.INTERRUPTION 4
INSERT ERASE CHANGE SELECT EXIT
EVERYTHING
First entry: Press F1 "INSERT". The cursor jumps in the selection table.
A new row of function keys appears:
SELECT EXIT
F1 F2 F3 F4 F5 F6 F7 F8
B657DE73
Now move the cursor with the arrow keys on the parameter which shall appear in the entry list and effect the
entry by the input of the command 'SELECT' (F1). In the lower range of the screen image the selected
parameter is described more exactly in plain language in a display line.
*) The underlined values only at large machines

**) The parameters shown in italics are optional (external temperature control units, absolute value input)
2 QP Quality documentation package Index: 8.04-0 / 1995-01-05

BQPEN804.PM4
Operator's manual
For further entries move the cursor in the entry list to the right and repeat the described process starting from F1
"INSERT". Maximally 20 entries are possible.
Insert: Set the cursor in the entry list on the parameter in front of which a new one shall come.
Then perform selection process with F1 "INSERT".
Change: Set the cursor in the entry list on the parameter which shall be replaced.
Then perform selection process with F1 "INSERT".
Erase: Set the cursor in the entry list on the parameter which shall be erased.
Remove the entry with F2 "ERASE".
Select everything: All parameters of the selection table are preselected, i.e. all parameters are recorded on
diskette or printer depending on selection. On the screen the first 11 parameters are listed up.
After selecting the process parameters one sets the recording parameters:
START: After the set time and/or the set cycles the recording starts
EVENT: Measuring intervals, time- or cycle-dependent
EVENTS: Number of measurements (“0” = everlasting recording)
At cycle-dependent recording the selected parameters are recorded at the cycle end (after the rejects
evaluation).
Input the command “PARAMETERS” (F2) and input the corresponding values with the cursor and the input
keyboard.
Afterwards start the recording with the command “START” (F1), (EVENT is represented with background
—> EVENT). With "STOP" (F1) the recording can be finished.
PD RECORD 3 95-01-10 14:26
SZx Std Min PHu PNs ZSx CPx FZx
SZx Std Min PHu PNs ZSx CPx FZx
01:40 RECORDSTART
16 1 4 56,6 48 1,20 3.8,5 25,5
17 1 4 56,4 47 1,22 3.8,5 25,3
18 1 4 56,5 48 1,20 3.8,4 25,3
19 1 5 56,8 48 1,22 3.8,6 25,7
20 1 5 57,0 48 1,22 3.8,6 25,6
01:52 RECORD STOP
START EVENT END

PROG.INTERRUPTION 4
STOP UNIT --->

BQPEN804.PM4
Operator's manual
1.1 OUTPUT OF THE RECORD
By means of the row of function keys the output medium can be determined:
At first press "OUTPUT UNIT" (F4):

STOP UNIT --->
F1 F2 F3 F4 F5 F6 F7 F8
B657DE73
A new line appears, the PDR output selection menu:
PRINTER FLOPPY FLOPPY FLOPPY NO etc.

NORMAL LOTUS EXCEL OUTPUT --->
F1 F2 F3 F4 F5 F6 F7 F8
B657DE73
Output on screen: Press F4

On the screen the record always runs along, even if another means of operation is
selected. F4 switches off the output on printer and/or floppy.
Output on printer: Press F1

At a printer connected to the front panel after 'START' (F1) the record printout occurs. It
begins with a 'header', a legend:
e.g.: RECORD START 05-01-90 01:14
Stx.. PIECE COUNTER ACTUAL (Pc)

SZx . . SHOT COUNTER ACTUAL (Sh)
Std . . TIME (h)
Min . . TIME (Min)
PHu . . HYDRAUL. PRESS. SWITCHOVER VALUE (bar)
PNs . . HYDR. PRESS. PEAK VAL. HOLDING PR. (bar)
ZSx . . INJECTION TIME ACTUAL VALUE (s)
CPx . . CUSHION / ACTUAL VALUE (mm)
FZx . . FLOW NUMBER ()
Stx SZx Std Min PHu PNs ZSx CPx FZx

-------------------------------------------------------------------------------------------------------------------
103 103 01 14 63,1 67,1 1.34 4,2 53,0
104 104 01 14 63,0 67,3 1,33 4,1 53,5
* 104 105 01 15 63,5 68,1 1,34 1,4 54,1
REJECTS

BQPEN804.PM4
Operator's manual
-------------> Hint: The shot counter counts each machine cycle; the piece counter only
the "good parts". Hence pay attention, if used, to the allocation of these
counters in the record. In the PD record rejects are marked with a '*'.
Output on floppy: Press F2, F3 or F4.

At inserted, formatted diskette (for formatting see chapter 2, item 1.4) the output of
the record on diskette occurs after 'START' (F1). The arriving data are collected in
an ASCII file. 2 formats are possible: 'NORMAL' (F2) corresponds exactly to the
form which would also appear on the printer (ASCII format). 'LOTUS' (F3) works
strictly in tabular form. These data can be loaded in the data processing program
'LOTUS' on a personal computer and be reused. Format 'EXCEL' (F4) can be
treated on the PC with windows tool 'EXCEL'.
Before the recording, which is available later on diskette in file form, a file name
must be assigned. For this purpose the alphanumeric input possibility by means of
function keys or a PC keyboard, connected to the keyboard interface right on the
control console, can be utilized. Select a fitting name with a length of up to 8
characters. Further characters are added automatically with a point separated
from the system.
e.g.: LASCHE.PD 'NORMAL'

LASCH_3.PD 'NORMAL'
LASCH_2.PRN 'LOTUS'
etc.
When selecting the output on floppy this function has priority over all other floppy operations; e.g. Read / write
part diskette ... These functions are only allowed when in the PD output selection menu 'PRINTER' or 'NO
OUTPUT' has been selected again.
In case of not inserted diskette or drive problems the error 4 'FLOPPY ERROR' appears.

BQPEN804.PM4
Operator's manual
1.2 SHORT SIGNS IN THE TABLE OF VARIABLES
Short
desig-
nation Explanation Unit
______________________________________________________________
SZx Shot counter actual value Shot
DZx Screw speed on C1 rpm
PHu Hydraulic pressure switchover value bar
PFu Mould cavity pressure switchover value bar
PFs Mould cavity pressure peak value bar
C3u Screw position switchover value mm
PVs Hydraulic pressure peak value at injection bar
PNs Hydraulc pressure peak value at holding pressure bar
PSs Back pressure peak value bar
ZFx Mould protection time actual value sec
ZDx Plasticizing time actual value sec
ZSx Injection time actual value sec
ZUs Cycle time actual value sec
Z4x Cooling time actual value sec
CPx Cushion length mm
ASZ Total rejects counter Shot
ÖlTx Oil temperature actual value °C
H1x Heating 1 actual value °C
up to H20x Heating 20 actual value °C
VSchx Closing speed actual value mm/s
Sks Clamping force peak value kN
FZx Flow number actual value -
Skx(1-4) *) Clamping force running kN
Sks(1-4) *) Clamping force peak value kN
Min Time Minutes
Std Time Hours
SSx Plasticizing stroke mm
SFs Mould opening stroke mm
StZx Piece counter Pcs
DZl Screw speed running rpm
TG1x Temperature control unit actual value ZO1 °C
ASSx Swept volume absolute ccm
APNs Spec. holding pressure peak value bar
APSs Spec. back pressure peak value bar
AC3u Switchover volume ccm
APHu Switchover pressure specific bar
APVs Pre-injection peak value spec. bar
ACPx Cushion volume actual value ccm
MPx **) Motor power actual value KW
MEx **) Energy motor last cycle KWh
HPx **) Heating capacity actual value KW
HEx **) Energy heating last cycle KWh
GPx **) Total capacity actual value KW
GEx **) Energy total last cycle KWh
E/Kg **) Specific energy requirements total KWh/Kg
Gew. **) Shot weight (sprue+part) set value g
*) SKx1-SKx4 and/or SKs1-SKs4 starting from ES500 (4-tie-bar measurement)

**) MPx-Gew (special program energy measurement) starting from ES500

BQPEN804.PM4
Operator's manual
2. PROCESS DATA GRAPHICS
General:
The process data graphics (PDG) enables the simultaneous recording of 8 process parameters. 3 of these values
can be called up at the same time and at optional moments and be represented graphically distinguished in the
colours red, green and blue. The remaining 5 are recorded in the background. The recording of the values occurs
either as a function of time or shot-referred. At recording as a function of time an oscilloscope function arises
whereas at shot-referred recording production-dependent trend graphics arises. For each of the 8 curves the
measuring range (scale) can be set at will. For monitoring these process data warning and tolerance limits can
be defined and evaluated. The mean values x bar and x double bar are formed and displayed.
At cycle-dependent recording at the moment of the beginning 'Mould opening' the takeover of the selected process
parameters into the PDG occurs and for the tolerance evaluation into the PDM.
Call-up: Image selection with 'Q' key + F2:
PD GRAPHICS 4 95-01-10 14:26
0% 100% Actual values

SZx C3u PHu PNs 2 10 6,8 mm
.... .... .... .... 50 100 88,2 bar
30 200 76,3 bar
100 %
80 %
60 %
40 %
20 %
0%
0 SZx 40 80 120 160 200
START EVENT END

PROG.INTERRUPTION 4
PROC.DATA PROC:DATA etc.
RECORD GRAPHICS --->
Set parameters, select curves:
For setting the graphics switch to the next command line with the command "etc" (F8):
START / PARAMETERS SET ERASE PRINT AUTOPRINT MONITOR- etc.

STOP ON / OFF ING --->
F1 F2 F3 F4 F5 F6 F7 F8
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With command "SET" (F3) a selection table of the possible process parameters appears:
PD GRAPHICS 4 95-01-10 15:59

Line allocation .... .... .... ....
.... .... .... ....
SZx DZx PHu PFu PFs C3u PVs PNs PSs ZFx ZDx ZSx ZUs
Z4s CPx ASZ ÖlTx H1x H2x H3x H4x H5x H6x H7x H8x H9x
Selection table H10x H11x H12x H13x H14x H15x H16x H17x H18x H19x H20x VSchx SKs
FZx SKx1 SKx2 SKx3 SKx4 SKs1 SKs2 SKs3 SKs4 Std Min SSx SFs
*) StZx DZl TG1x TG2x TG3x TG4x ASSx APNs APSs AC3u APHu APVs ACPx
**)
MPx MEx HPx HEx GPx GEx E/Kg Gew.
START EVENT END

Recording TIME 0 SEC TIME 1.0 SEC 0 EVENTS
parameters CYCLES 0 SHOT CYCLES 0 SHOT
PROG.INTERRUPTION 4
SET R ESET EXIT
Select with the cursor a field in the line allocation and put the cursor in the selection table by the input of the
command "SET". A new function row appears:
SELECT EXIT
F1 F2 F3 F4 F5 F6 F7 F8
B657DE73
Move the cursor on the desired parameter in the selection table (the short sign is described in the screen middle)
and take over the value on the previously selected curve colour by the new command "SELECT" (F1). In item 1.3
of this chapter all selectable parameters are listed up.

BQPEN804.PM4
Operator's manual
Scale:
A value taken over newly into the line allocation appears in the line allocation field as short sign and with an input
possibility for the scale:
min = ... []
max = ... []
ist = ... []
On the command line appear the commands "LOWER LIMIT" and "UPPER LIMIT":
SET RESET LOWER UPPER GREEN RED BLUE EXIT

LIMIT LIMIT
F1 F2 F3 F4 F5 F6 F7 F8
B657DE73
For the respective measured value with the command "LOWER LIMIT" the 0 % line and "UPPER LIMIT" the 100
% line can be fixed in order to get an as good as possible resolution and to be able to represent the curves one
beside the other with the same measured values.
Colour allocation:
With the function keys F5, F6 and F7 the colour allocation is selected. Curves without colour allocation are not
displayed, but are recorded in the background unhindered. They can be taken over into the graphics by colour
allocation at optional moments.
Recording parameters:
After selecting the process parameters the recording parameters are set:
START: After the set time and/or the set cycles the recording starts
EVENT: Measuring intervals, time- or cycle-dependent
END: Number of measurements ("0" = everlasting recording)
Enter the command "PARAMETER", position the cursor and set the corresponding values with the input keyboard.

BQPEN804.PM4
Operator's manual
Starting and stopping the recording
Start the recording with the command "START" (F1) (the text 'EVENT' is represented with background). The
function key text changes to 'STOP'. With renewed actuation of F1 the recording can be stopped again. A fulll
graphic image shows 200 measured values. After 200 measurements (a full graphic image) the graphics is
displaced to the left by a fifth, the first 40 measurements fall out of the image
PD GRAPHICS 4 95-01-10 14:26
0% 100% Actual values

SZx C3u PHu PNs 2 10 6,8 mm
.... .... .... .... 50 100 88,2 bar
30 200 76,3 bar
100 %
80 %
60 %
40 %
20 %
0%
0 SZx 40 80 120 160 200
17:37:45 18:22:23 Exact time
245 SZx 285 Number of shots
START EVENT END
PROG.INTERRUPTION 4
START / PARAMETERS SET ERASE PRINT AUTOPRINT MONITOR- etc.
STOP ON/OFF ING --->
Erase:
The command "ERASE" erases all recorded curves.
Print:
With connected graphic printer the current recording state of the graphics is printed out with the command "PRINT".
With the command "AUTOPRINT ON" it is always printed out after 200 measurements (one full screen page each).

BQPEN804.PM4
Operator's manual
3. PROCESS DATA MONITORING
The program process data monitoring (PDM and/or CPC) is integrated into the program process data graphics
(PDG). It represents a 100% monitoring of 8 selectable process parameters (CPC, Continuous Process Control).
Function:
The PDM offers as expanded functionality as compared with the PDG the formation of the mean values x bar and
x double bar of maximally 8 selected process parameters as well as their monitoring. Alternatively one of the
parameters is displayed graphically with its tolerance limits, warning limits and mean values.
At cycle-dependent recording at the moment of the beginning 'Mould opening' the takeover of the selected
process parameters into the PDG occurs and for the tolerance evaluation into the PDM.
Call-up:
Image selection + F2 + F8 + F7
PROCESS DATA MONITORING 3 94 01 10 16:30

SREW POS.SWITCHOVER VALUE xqset = 0006.8 mm + tol = 0 0 0 7 . 2 m m + TolCnt = 0
max = 00008.0 mm xqact. = 0006.9 mm - tol = 0006.4 mm - TolCnt = 0
min = 00003.0 mm xqq = 0006.7 mm Wg+/- = 0000.2 mm InitCnt = 200
00008,0 mm
Act.value (green) xqq (blue) Warning limit +/- (yellow) xqset (white)
00007,5 mm
+ tol (red)
00007,0 mm
00006,5 mm
- tol (red)
00006,0 mm
00005,5 mm
15:45.12 16:05.10 16:25.15 16:45.09 17:05.10
SZx 105 145 185 225 265
START EVENT END

PROG.INTERRUPTION 4
SELECTION INITIALIZE ERROR ERROR PRINT AUTOPRINT DELETE EXIT
TABLE RECORD EVALUATION ON ALARM LAMP

BQPEN804.PM4
Operator's manual
Selection list:
The process parameters which are selected in the PDG from the parameter pool there appear in the selection list
(achievable with F1 in the PDM) of the PDM with their value preselection possibilities.
Image selection: + F2 + F8 + F7 + F1
PROCESS DATA MONITORING 4 95 01 10 16:30
Designation Mean value Tolerance Warning limit Error counter

Setl Act. total min max +/- min max
Cursor SCREW POS.SWITCHOVER 0006.8 0006.9 0006.7 0006.4 0007.2 0000.2 0 0

....
....
....
8 possible entries ....
....
....
....
START EVENT END

PROG.INTERRUPTION 4
SELECTION INITIALIZE ERROR ERROR PRINT AUTOPRINT EXIT
LIST RECORD EVALUATION ON
Graphically displayed is that parameter over which the cursor in the selection list is set. Here the operator can read
off mean values, tolerance ranges, warning limits and error counter per parameter. The setting of these values can
occur by set value preselection or also automatically in an initialization run.
The scale of the graphics is taken over from the PDG.
Initialize, (F2):
For each of the selected process parameters an initialization run can be started independently of each other in
the automatic state of operation of the machine. This comprises 30 - 200 measurements, 200 measurements being
suggested by the control system.
A possibly running measurement in the PDG must be stopped. The 'cycle' counter in the 'Event' field is set to '1'.
The moulding process should already run stably before the initialization is started with F2.
After the completion of the Init run the computer forms the mean value about the recorded measured values and
transfers it in the value x bar-set. The largest measured value is employed as plus tolerance and the smallest one
as minus tolerance. The warning limit is calculated from the smaller distance between x bar-set and the tolerance
limits, divided by 2, e.g.: min tol. = 6.4 mm, max tol. = 7.3 mm, x bar-set = 6.8 mm ---> Wl = +/- 0.2 mm.
All value takeovers are proposals and can be recorrected by the operator.

BQPEN804.PM4
Operator's manual
Regular measurement, (F1 in the PDG)
The regular measurement is started and/or stopped with function key F1 in the PDG. Each measurement also
causes a new calculation of x bar and x double bar. For calculating x bar the last 160 - 200 measured values are
used. If the calculation basis comprises 200 values, the 40 oldest measured values are eliminated and the following
measurement is made on the basis of the last 161 measured values. Further, at each measurement the
monitoring calculations are made.
Mean value formation:
The PDM forms a set-mean value (x bar-set), an actual-mean value (x bar) and a total mean value (x double bar).
The set-mean value is determined in an initialization run, but can also be entered manually and/or recorrected. The
actual-mean value refers to the 160 - 200 values measured last. This exactly corresponds to the values represented
graphically on the screen. The total mean value is determined via the entire measured values.
Tolerance limits, (F1, selection list)
For each selected process parameter a maximum and a minimum absolute tolerance value is determined
automatically in the initialization run or manually by set value preselection in the selection list. If a measured value
exceeds the given tolerance values, an error event is produced. By entering the value '0' on the tolerance limits the
monitoring can be switched off.
Warning limits, (F1, selection list)
The warning limit adjustable for each process parameter serves to monitor the mean value x bar. If the amount of
the difference from x bar-set and x bar exceeds the warning limit value, an error event is produced. The monitoring
of the warning limit can be switched off by entering the value '0'. The warning limit is a relative +/- value.
Error evaluation, (F4)
For the operator it is possible to select different actions for the error events. The selection occurs via a separate
menu, to be called up with the function key F4 in the PDM. The cursor is moved via the corresponding text field
and afterwards the error evaluation is activated with F1 'Takeover'.
Possibilities for tolerance ranges: no consequence
Message and only alarm lamp
Message, rejects message and selection without alarm lamp
Message, rejects message and selection and alarm lamp
Cycle stop and alarm lamp
Possibilities for warning limits: no consequence

Message and only alarm lamp
Cycle stop and alarm lamp
During the start-up phase (chapter 3, item 10.3) a possible rejects message is ignored.

BQPEN804.PM4
Operator's manual
Turn off alarm lamp, (F7)
The turning-off of the alarm lamp can be released with the function key F7 without disturbing the automatic mode.
Error record, (F3)
When actuating the F3 in the PDM an error record appears, in which all error events from the PDM are represented
collected. The entries comprise information about names of the process parameter, date/time ofthe
error appearance, shot counter count, kind of the event (warning limit or tolerance) and the measured value.
Two counters per process parameter sum up the recognized tolerance exceedings and display this in the selection
list.
PROCESS DATA MONITORING 4 95-01-25 16:52
Designation Date Time Shot counter Error Value

Screw pos.switchover 94-01-23 14:35.57 2035 Warning limit 12.3
Hydr.pres.switchover 94-01-24 03:20.20 2422 Warning limit 99.4
... ... ... ... ... ...
The error record can be printed out with actuating the function key F1.
Printing of the PDM, (F5 and/or F6):
With actuating the F5 the current graphic state can be output on a printer.
The 'AUTOPRINT' function (F6) (de)activates automatic printing after 200 measured values (full graphic image).

BQPEN804.PM4
Operator's manual
Chapter QS QUALITY DATA STATISTICS (QDS)
1. QDS
An economic manufacture of products can only be guaranteed by permanent monitoring and constant improvement
of the production processes. The quality data statistics program enables a quality control integrated into the
production by means of different types of quality control cards (process control cards) for the analysis of quality-
referred process data. Thus disturbing influences which act on the production process can be recognized in time
and corrective measures can be set. At the same time the production process gets more transparent and is thus
mastered better, which leads to a considerable increase in the quality and productivity. But in order to utilize this
program correspondingly, the selected machine parameters must be in tight connection with the parts quality and
shall lie normally distributed.
1.1 TERM NORMAL DISTRIBUTION
In a fabrication process as well as at the production of an injection moulded part, it is not possible to exactly
reproduce measures (dimensions, part weight). Different disturbing influences act on the process, such as e. g.
mould wear, material batch variations, filler and colour content changes, temperature variations, irregular closing
of the non-return valve, machine variations etc. From this results a more or less strongly varying part quality.
The measured values scatter around the set measure and form a frequency there, which decreases symmetrically
towards larger and smaller values. If these values are represented in a diagram, a theoretical curve will result
idealized, which is characterized by the mean value (x bar), equals the most frequent value, and the standard
deviation (s), equals the distance of the turning point of the curve from the mean value.
Turning point of the curve
Measured value x Measured value
_2
(x i - x) s = Standard deviation of a sample
s=
n-1 xi = individual measured value of a sample
x = Mean value of the measured values of a
B642DE72
sample
n = Number of the measured values of a sample
Index: 8.04-0 / 1995-01-05 Quality data statistics QS 1

BQSEN804.PM4
Operator's manual
At injection moulding at each machine cycle a series of process parameters is measured by the machine
control system, but which not all lie normally distributed.
Reasons:
A switch-off or switchover mechanism integrated into the control system with self-resetting yields not normal
distribution, e. g. opening stroke SFx, plasticizing stroke SSx or that switchover point actual value with which the
switchover to holding pressure occurs.
Products which are manufactured in several process steps or which stem from several similar machines cannot
be normally distributed even if the products of the individual machines are normally distributed.
A trend of the mean value, i. e. if the mean value is not stationary, for example caused by mould wear or increasing
moisture content of the material, can cause a not normal distribution.
All values which are controlled by a closed control loop show a not normal distribution, e. g. temperatures, clamping
force, holding pressure, effective switchover point to holding pressure etc.
Values which should lie normally distributed:

Flow number, mould cavity pressure peak value, all measured switchover point actual values with which it is not
switched over, plasticizing time and cushion.
Example of a calculation of the standard deviation for a sample with 5 measured values of the hydraulic
switchover pressure (PHu):
2
xi x xi x ( xi x )
63 0 0
65 2 4
x i 315
61 x= = = -2 4
n 5
64 1 1
62 63 -1 1
2
x i =315 (xi -x) = 10
2
(x i - x) 10
s= = = 2,5 = 1,58 bar
n-1 4
B643DE72
2 QS Quality data statistics Index: 8.04-0 / 1995-01-05

BQSEN804.PM4
Operator's manual
1.1.1 Test for normal distribution (histogram)
At the program “Initialization” a number of consecutive samples is considered as one single big sample and the
mean value and the standard deviation are calculated, the measured values being represented graphically in a bar
diagram (histogram) and checked for “normal distribution”.
Example of a histogram with 25 measurements of the hydraulic switchover pressure (PHu) with normal
distribution (a smaller than/equal to c)
Number of measured values
6
Curve form of a normal distribution
4
Characteristic values
60 65
x: 64.0 s: 1.3844 amax: 0.14 c: 0.174 normally distributed
Example of a historgram with 25 measurements of the hydraulic switchover pressure (PHu) with not
normal distribution (a larger than c)
Number of measured values
6
Curve form of a normal distribution
4
Characteristic values
60 65
x: 62.36 s: 1.4369 amax: 0.239 c: 0.174 not normally distributed
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1.2 MACHINE CAPABILITY
For reaching a controlled production it is required to make a machine capability examination for each product, only
the machine itself being judged as individual element of a production sequence. Usually after optimizing the
machine one single large sample (in the normal case a number of consecutive subsamples e. g. 5 x 5 pcs) is taken.
For this purpose
- the setting of the machine during the examination is not changed

- the parts are fabricated without interruption
- only material of one batch is taken.
Process data, which are in close connection with the part quality (weight, dimensional accuracy, surface) and
which lie normally distributed, are compared with the specification limits. If the result is negative, the process must
be reoptimized until the samples supply a satisfactory result. Thus the machine capability is reached. The machine
capability examination is taken up in the quality data statistics program (calibration cycle).
The determination of the machine capability occurs with the factors Cm and Cmk (C stems from 'Capability'.)
OSG - USG
Cm = >= 1.33
6s
Cm compares the upper and lower specification limit (OSG, USG) with the machine scattering 6s, the position of
the distribution to the specification limits being not observed. This is determined by calculating Cmk.
_ _
OSG - x x - USG
Cmk = or >= 1.33
3s 3s
The smaller of the two values is decisive for judging the instantaneous position of the distribution to the specification
limits.
At the machine capability it is expected that at least eight standard deviation units lie within the tolerance and/
or specification limits whereas at the process capability at least six standard deviation units are expected within
the specification limits, but it is always calculated with six. Therefore at the machine capability examination Cm
and Cmk shall always be >= 1.33.

BQSEN804.PM4
Operator's manual
Machine capability characteristic values
USG OSG c = 1,33

m
c
mk = 1,33
- 4s - 3s - 2s - 1s + 1s + 2s + 3s + 4s
c = 0,67
m
c = 0,33
mk
- 4s - 3s - 2s - 1s + 1s + 2s + 3s + 4s
B645DE72

BQSEN804.PM4
Operator's manual
1.3 CONTROL LIMITS
By means of control limits disturbing influences which act on the production process can be recognized early and
corrective measures can be set in time. The calculation of the control limits for the mean value and of the standard
deviation occurs at calibration. After passing the calibration cycle, which contains one single large sample
consisting of several subsamples, on the machine no settings may be changed any longer in order to avoid a
falsification of the following statistics.
1.3.1 Calculation of the control limits according to the measured value distribution
Quality control cards, which are developed due to the measured value distribution and the 3 sigma range is used
for producing the control limits, work with the tightest possible limits according to production-technical aspects.
The sigma hut range is the estimate rate of the standard deviation of the basic entirety (includes all values of the
total production) and is derived from the mean value of the standard deviation (s bar) of the individual samples. Sigma
hut is always somewhat larger than s bar.
For calculating sigma hut and the contact limits constants are required, which are in dependence of the number
of measurements per sample. These constants are stored in the control system up to a sample size of 25 measured
values. Therefore maximally only a number of 25 measurements per sample can be set.
Extract:
n A3 C4 B3 B4
--------------------------------------------------------------------------------------------
5 1.427 0.9400 - 2.089
10 0.975 0.9727 0.284 1.716
15 0.789 0.9823 0.428 1.572
20 0.680 0.9869 0.510 1.490
25 0.606 0.9896 0.565 1.435

BQSEN804.PM4
Operator's manual
Mean value distribution

of the samples ( x )
at calibration
=
x
OSG USG
A3 . s A3 . s
OEG UEG
s4
s5
s2
s3
s1
Calibration
cycle
B646DE72 x1
Turning point of the curve
s1 + s2 + s3 + s4 + s5 = x1 + x2 + x 3+ x 4+ x 5
s = x =
5 5
=
OEG x = x + A3 . s = (example) 64 + 1,427 . 1,4 = 66
=
UEG x = x - A3 . s = (example) 64 - 1,427 . 1,4 = 62
OEG s= B4 . s = (example) 2,089 . 1,4 = 2,9
UEG s= B3 . s = (example) 0 . 1,4 = 0
OEGx= Obere Eingriffsgrenze

upper control des Mittelwertes
limit of the mean der Stichprobe
value of the sample
UEGx = Untere Eingriffsgrenze
lower control des Mittelwertes
value of the sample
x = Mittelwert der Stichprobe
Mean value of the sample (x-bar)(x-quer)
= = Mittelwert
Mean valueder Stichprobenmittelwerte
of the (x-quer-quer)
sample mean values (x-double bar)
x
s = Standardabweichung
Standard deviation
s = Mittelwert
Mean valueder Standardabweichung
of the (s-quer)
standard deviation (s-bar)
A3, = Umrechnungsfaktoren in Abhängigkeit
Conversion factors as a function desofUmfanges
of the volume the individualder einzelnen
sample
B3, B4 Stichprobe
OEGs = Obere Eingriffsgrenze
upper control der Standardabweichung
limit of the standard deviation
UEGs = Untere Eingriffsgrenze der Standardabweichung
lower control limit of the standard deviation
s OSG = Obere spezifische Grenze
upper specific limit
USG = Untere spezifische
lower specific limit Grenze
B646DE72

BQSEN804.PM4
Operator's manual
1.3.2 Calculation of the control limits according to set specific limits
Where functional aspects speak for it to allow a larger tolerance range and thus larger limit distances, in the sense
of an economic production the tolerance range must be larger than the plus/minus 3 sigma hut range of the
instantaneous production distribution. As rule of thumb the demand has proven that the tolerance range should
be at least equal or larger than the 12-fold sigma hut range of the production. Only so systematic variations of the
process parameters, caused by temperature variations, batch variations and the control behaviour of the automatic
injection moulding machine, can be allowed during the production in required extent.
The difference to the previously described control card lies in the calculation of the control limits for the mean value
(x bar). Depending on the allocation selected according to economic criteria and thus given of error share (excess
share p) and control probability (1-Pa) the distance of the control limits to the specification limits is calculated. So
it can be set with which probability a control limit alarm is displayed at a certain excess share. Before this
calculation, which occurs at "Initialization", the specific limits must be known and set.
OEG OSG
The smaller the allowed excess share and the
Verteilung der larger the control probability, the larger gets
Distribution of the
Einzelwerte the distance of the control limits to the specific
individual values
(momentane limits.
(instantaneous For this example an excess share of 1% was
Gesamtheit!)
entirety!) u 1-p. assumed at a control probability of 95% and a
p = z.B. 1% sample size of 5 measurements.
Verteilung
Distribution der
of the
Mittelwerte n= z.B. 5
mean values n
1-Pa = z.B 95%
5%
.u 1-Pa
n
k.
.u 1-Pa u 1-Pa
k. = u 1-p. + k = u 1-p + = 2,326 + 1,645 = 3,06
n n 5

BQSEN804.PM4
Operator's manual
Starting from the limit values the control limits are drawn in the distance (k * sigma).
Distribution of
_ the Control Excess
mean values probability share
x
Pa = e.g. 95% p = e.g. 1%
1% 95%
k. Distribution of
k.
the individual
OSG OEG values (current UEG USG
entirety)
s4
s3
s2
s1 Initialize
_
x
_
s 1 + s 2+ s 3 + s 4 + s 5 s
s = =
5 C4
OEG = Obere
upper Eingriffsgrenze
control limit of the des
meanMittelwertes der Stichprobe
value of the sample
UEG = Untere Eingriffsgrenze
lower control des Mittelwertes
value of the sample
OSG = Obere
upper spezifische
specific limit Grenze
USG = Untere
lower specific limit Grenze
spezifische
= Standardabweichung
Standard deviation of the entirety
der at initialization
Gesamtheit beim Initialisieren
k = Errechneter
Calculated value,
Wert,which changes
der sich as a functionofdes
in Abhängigkeit the eingestellten
set excess share
Überschreitungs-
_ and of the control probability
anteiles und der Eingriffswahrscheinlichkeit ändert.
x = Mittelwert
Mean value of theStichprobe
einer sample
s = Mean value
Mittelwert of the
der standard deviation
Standardabweichung
B648DE72
So for this example it is valid that the control card displays a control limit message at 95% when an excess
share of 1% of the entirety is reached.

BQSEN804.PM4
Operator's manual
Factors for calculating the control limits with an error share p and a control probability 1-Pa.
p (%) u1-p 1-Pa (%) u1-Pa
0,1 3,090 99 2,326

0,5 2,576 95 1,645
1,0 2,326 90 1,282
1,5 2,171 85 1,036
2,0 2,054 80 0,842
2,5 1,960 75 0,675
3,0 1,881 70 0,524
3,5 1,812 65 0,385
4,0 1,751 60 0,253
4,5 1,696 55 0,126
5,0 1,645 50 0,000
6,0 1,555 40 - 0,253
7,0 1,476 30 - 0,524
8,0 1,405 20 - 0,842
9,0 1,341 10 - 1,282
10,0 1,282 5 - 1,645
15,0 1,036 1 - 2,326

BQSEN804.PM4
Operator's manual
1.4 PROCESS CAPABILITY
The process capability examination is a long-term examination. For this purpose equally large samples like at the
machine capability examination are taken from the current process over a longer production period. All disturbing
influences acting on the process are recorded (directly or indirectly).
In the ideal case all process-relevant actual values would have to flow into the sum frequency formation collected
and closed.
This expenditure can be circumvented, however by allocating the actual values to the corresponding classes after
each sample taking and by forming their sum frequency.
The following calculation of the process capability can only occur if there is normal distribution for the measured
actual values. For the calculation of the process capability usually a tolerance zone given by the designer of parts
is required for a measure or the weight.
At injection moulding there is now the problem that neither measure nor weight, but a series of process parameters,
which are in connection with these quality characteristics, are recorded automatically. From this results that the
process capability can be derived from those process parameters which
- lie normally distributed,
- show a connection to the quality of the product and
- which can be occupied with a tolerance zone.
From experience one knows that there is a certain connection between the mentioned, normally distributed lying
process parameters and the end product, but there are no mathematically defined algorisms for these connections.
So for the preselection of the tolerances only the way of empirical determination remains. Again under the
prerequisite that for a certain process parameter the upper and lower tolerance has been determined correctly, the
calculation of the process capability can occur.
The process capability is defined by the values Cp and Cpk.

The characteristic value Cp reflects the ratio between specific tolerance zone width and the 6-fold
estimate rate of the standard deviation (sigma hut).
The characteristic value Cpk indicates the position (mean value) of the process and the process scattering within
the specific tolerance limits.
For the process capability now the request is valid that at least all sample mean values x bar, which lie within the
+/- 3 sigma hut range, are also within the given tolerance. Thus the characteristic value Cpk shall always be larger
than/equal to one.

BQSEN804.PM4
Operator's manual
Hypothetical
population of all Turning point of the curve
measured values
of the samples (xi)
i
=
x
OSG USG
3x 3x
Minimum distance Maximum distance
OEG UEG
s3
x3
Distance between
s2 the samples
x2 Distance between
s1 the samples
x1
Distance between
the samples
Start
_
s = (Example) 1,4 = 1,5
=
C4 0,94
Cp = OSG - USG = (Example) 70 - 58 = 1,33

6 . 1,5
6.
Minimum distance
5,5
Cpk = = (Example) = 1,22
3. 3 . 1,5
_ = Schätzwert der of
Estimated value Standardabweichung
the standard deviation ofder
theGrundgesamtheit
population (sigma hut)(Sigma-Dach)
s = mittlere Standardabweichung
Mean standard deviation
C4 = Umrechnungsfaktor
Conversion factor as ain Abhängigkeit
function desvolume
of the sample Stichprobenumfanges
Cp = Faktor;
Factor; beschreibt
describes thedie Größe
size der Streuung
of scattering relativelyrelativ zur spezifischen
to the specific tolerance Toleranz
OSG = Obere spezifische Toleranz
Upper specific tolerance
USG = Untere spezifische
Lower specific Toleranz
tolerance
Cpk = Faktor;
Factor; beschreibt
describes thedie Streuung
scattering andund Lage
position to zur spezifischen
the specific toleranceToleranz
B649DE72

BQSEN804.PM4
Operator's manual
PROCESS CAPABILITY
Capable processes (practically all produced products within one specification limit)
Measure Measure
Not capable processes (products outside one or both specification limits are produced)
Measure Measure
Capable process with systematic deviation
mean change of the

mean value
Measure

BQSEN804.PM4
Operator's manual
1.5 QUALITY DATA STATISTICS PROGRAM (QDS)
In order to get a quality data statistics together with documentation so-called “quality control cards” must be
established and printed out. They serve the regular control and improvement of a process and shall help to find out
systematical errors in the process. 3 control cards can be represented in parallel. For those process parameters
which lie normally distributed and which are used for statistical calculation the following evaluations are made:
- Preselection of the intervals (measured values per sample, distance between the samples) and the
number of samples for all process parameters together.
- Calculation and graphic representation of the mean value per sample (x bar), of the mean value of the
mean values (x double bar) with upper control limit (OEG) and lower control limit (UEG). Calculation and
graphic representation of the standard deviation (s) per sample, of the mean value of the standard
deviation (s bar) with upper and lower control limit.
- After each sample, calculation and display of the estimate rate of the standard deviation of the parent
population (sigma hut), which supplies a statement about the scattering, calculation of the factor Cp,
which indicates the ratio of the scattering width of the parent population to the set specific tolerance and
Cpk, which still includes the position of the scattering to the specific tolerance in addition to Cp. Only the
values displayed on the control cards on the screen are used for these
calculations.
1.5.1 Selection and setting of the parameters for the control cards
At first the machine process must be set to “good parts” and be determined which process data are in direct
connection with the parts quality. If no connection can be found, the program cannot be applied. It should also
already be fixed within which tolerance limits the measured values must lie in order to be still able to produce “good
parts”.
Image selection key
QUALITY PROGRAMS 3 95 01 10 16:30
1 . . . . . PD RECORD
2 . . . . . PD GRAPHICS
3 . . . . . QUALITY DATA STATISTICS
4 . . . . . OPERATING POINT FINDING
PROG.INTERRUPTION 4
PROC.DATA PROC.DATA QUALITY OPERATING
RECORD GRAPHICS DATA STAT. POINT FIND.

BQSEN804.PM4
Operator's manual
- with F3 select "QUALITY DATA STATISTICS"
QUALITY DATA STATISTICS 4 95 01 10 16:30
n: 5 M : 5 Distance: . . SZx: . . . .
SW: . . . . OSG: . . . . USG: . . . . IW: o.o bar
SZx: . . . .
Zeit:
0.4
0.2
0.0
0.04
0.03
0.02
0.01
Measurements: 0 under spec: 0 0.0 % over spec: 0 0.0 %

UEGX: 0.00 OEGX: 0.00 UEGS: 0.00 OEGS: 0.00
: 0.00 : 0.00 s: 0.00 Cp: 0.00 Cpk: 0.00
PROG.INTERRUPTION 4
CONTROL SPECIFIC CONTROL CON- CONTROL DELETE QUALITY etc.
CARD LIMITS LIMITS FIGURATION CARD TYPE QDS ERROR PROGRAMS ---->
- With the command "etc" switch over to the 2nd command line. Three control cards can be operated in
parallel.
START SET PRINT HISTOGRAM ERROR CALCULATE AUTOPRINT etc.

RECORD ON ---->

BQSEN804.PM4
Operator's manual
- Select “SET”, by which the 10 parameters (actual values) which can be used for statistics appear on
the screen. 3 of them can be selected.
Flow number
Mould cavity pressure switchover value
Hydraulic pressure switchover value
Switchover position
Injection time
Plasticizing time
Mould cavity pressure peak value
Cushion length
Holding pressure peak value
Back pressure peak value
PROG.INTERRUPTION 4
SET RESET EXIT
- Select “SET”, move the green field to the corresponding parameter with the cursor keys and press
“SELECTION". The value appears on the upper screen margin. With the command “RESET” one can
erase a selection.
With "EXIT" the screen switches back to the graphic image.
With the "leafing keys" one selects between the 3 control cards.

BQSEN804.PM4
Operator's manual
1.5.2 Initialization
With the initialization at the same time the check for normal distribution, the examination for machine capability
and the calculation of the control limits occur. For the machine capability examination and if the control limits shall
occur after the specific limits, the specific limits must already be set before. The machine runs in the automatic
mode and produces good parts.
- Select screen page “SPECIFIC LIMITS”. For the previously selected parameters set the values accord-
ing to the quality criteria.
Setting
limitations
SPECIFIC LIMITS 4 95 01 10 16:30
Stop after 'specific limits exceeded' NO yes/no

Rejects after 'specific limits exceeded' yes/no
SPECIFIC LIMITS: LOWER UPPER

SET VALUE ( USG ) ( OSG )
Flow number . . . . . . . . . . . . . . . 0 - 999.9
Cavity pres.switchover . . . . . . . . . . . . . . . bar 0 - 6553.5
Hydr.pres.switchover . . . . . . . . . . . . . . . bar 0 - 999.9
Switchover position . . . . . . . . . . . . . . . mm 0 - 999.9
Injection time . . . . . . . . . . . . . . . s 0 - 6653.5
Plasticizing time . . . . . . . . . . . . . . . s 0 - 999.9
Cavity pressure max. . . . . . . . . . . . . . . . bar 0 - 6553.5
Cushion length . . . . . . . . . . . . . . . mm 0 - 6553.5
Holding pressure max. . . . . . . . . . . . . . . . bar 0 - 999.9
Back pressure max. . . . . . . . . . . . . . . . bar 0 - 999.9
PROG.INTERRUPTION 4

BQSEN804.PM4
Operator's manual
- Select screen page "CONFIGURATION" and set shot per sample, number of samples, distance between
the samples and the number of classes for the histogram.
If too many samples are set, the error message 'TOO MANY SAMPLES' appears in the interactive error
message field.
Setting
limitations
CONFIGURATION 4 95 01 10 16:30
Shot / sample n = 5 sh 2 - 25
Number of samples m = 10 sh 1 - 99
Distance between the samples 0 sh 0 - 999
Number of classes for histogram 10 10 - 20
Print also time YES yes/no
Print also shot counter YES yes/no
SCALES Auto / Manual XBAR S
Setting (max.) (max.) xbar s
Flow number AUTO 0.0 0.00 999.9 99.9
Cavity pres.switchover AUTO 0 0.00 6553.5 655.35
Hydr.pres.switchover AUTO 0 0.00 999.9 99.99
Switchover position AUTO 0.0 0.00 999.9 99.99
Injection time AUTO 0.00 0.000 655.35 65.535
Plasticizing time AUTO 0.0 0.00 999.9 99.99
Cavity pressure max. AUTO 0 0.00 6553.5 655.35
Cushion length AUTO 0.0 0.00 999.9 99.99
Holding pressure max. AUTO 0 0.00 999.9 99.99
Back pressure max. AUTO 0 0.00 999.9 99.99
PROG.INTERRUPTION 4
The distance between the samples must be set to "0" at initialization. If it is set to automatic scale, the graphic
recording of the control cards depends on the specific limits. The scale can be set for each control card individually
when it is switched to "MANUAL" by typing in the figure "1".

BQSEN804.PM4
Operator's manual
- If the control limits shall be calculated according to previously determined specific limits, select screen
page "CONTROL CARD TYPE", set "YES" and enter the excess share and the control probability in per
cent.
Setting
limitations
CONTROL CARD TYPE 4 95 01 10 16:30
CONTROL PROBABILITY
EXCESS SHARE
GIVEN LIMIT VALUES
for
Flow number NO 00.0 % 00 % 0.1 - 15.0 1 - 99
Cavity pressure switchover NO 00.0 % 00 % 0.1 - 15.0 1 - 99
Hydr.pressure switchover NO 00.0 % 00 % 0.1 - 15.0 1 - 99
Switchover position NO 00.0 % 00 % 0.1 - 15.0 1 - 99
Injection time NO 00.0 % 00 % 0.1 - 15.0 1 - 99
Plasticizing time NO 00.0 % 00 % 0.1 - 15.0 1 - 99
Cavity pressure max. NO 00.0 % 00 % 0.1 - 15.0 1 - 99
Cushion length NO 00.0 % 00 % 0.1 - 15.0 1 - 99
Holding pressure max. NO 00.0 % 00 % 0.1 - 15.0 1 - 99
Back pressure max. NO 00.0 % 00 % 0.1 - 15.0 1 - 99
yes/no
PROG.INTERRUPTION 4

BQSEN804.PM4
Operator's manual
- After reselection of the control card and of the second command line, start initialization
with the command “START”. After the selection of “START” a subcommand line appears
on the screen:
“PROCESS RUN” “INITIALIZATION”
PROCESS RUN: ...... Start the process data statistics (process capability)
INITIALIZATION: ...... Start the calibration cycle
- Here one selects 'Initialization'. Right above the control card “INITIAL.” appears.

Hydraulic pres.switchover value Flow number Cushion length
n: 5 m: 5 Distance: . . SZx: . . . . INITIAL.

SW: 64.0 OSG: 70.0 USG: 58.0 IW: 64.0 bar
SZx: 100 110 120
Time: 9:10 9:14 9:18
70.0
_
x 64.0
58.0
2.00
s
1.00

UEGX: 61.0 OEGX: 67.0 UEGS: 0.00 OEGS: 1.8
: 64.00 : 0.00 s: 1.4 Cm: 0.00 Cmk: 0.00
PROG.INTERRUPTION 4

BQSEN804.PM4
Operator's manual
After the expiry of the calibration cycle the values x bar and s are calculated for the large sample (consisting of
several subsamples) made at initialization and are displayed in the histogram. At the same time also the values
x double bar and s bar (calculated from the subsamples) are automatically taken over as set value for the process
data statistics, the control limits are calculated and stored.
- Select the histogram and check if the process parameter used for the statistics lies normally distributed

Hydr.pres.switchover value Flow number Cushion length
n: 5 m : 5 Distance: 0 SZx: 120 INITIAL.

SW: 64.0 OSG: 70.0 USG: 58.0 IW: 64.0 bar
60 65
x : 64.00 s : 1.3844 amax: 0.14 c: 0.174 normally distributed
PROG.INTERRUPTION 4
EXIT
ATTENTION! If the value does not lie normally distributed, another parameter must be used for the machine
capability examination and calculation of the control limits as the values Cm and Cmk as well
as control limits are calculated wrongly. But if the program shall only serve to record and
monitor a parameter, the control limits can be changed manually.

BQSEN804.PM4
Operator's manual
1.5.3 Starting the quality data statistics
Important: During the QDS run nothing may be changed at the settings of the machine, otherwise the QDS
must be started again with initialization as the control limits and the machine capability examination
are no longer valid.
After the expiry of the calibration cycle and automatic stop of the QDS control limits and set value are secured and
starting points for the actual “PROCESS RUN”. The settings for number of samples and distance between the
samples are selected. The value shot/sample must be the same as in the initialization mode as it was the basis
for the calculation of the control limits (A3 constant) and is used for its monitoring.
- Select the screen image "CONFIGURATION", set the number of samples and the distance between the
samples. Possibly change the scale of the graphic recording when the curve is represented very small.
Setting
limitations
CONFIGURATION 4 95 01 10 16:30
Shot / sample n = 5 sh 2 - 25
Number of samples m = 10 sh 1 - 99
Distance between the samples 0 sh 0 - 999
Number of classes for histogram 10 10 - 20
Print also time YES yes/no
Print also shot counter YES yes/no
SCALES Auto / ManuAL XBAR S
Setting (max.) (max.) xbar s
Flow number AUTO 0.0 0.00 999.9 99.9
Cavity pres.switchover AUTO 0 0.00 6553.5 655.35
Hydr.pres.switchover AUTO 0 0.00 999.9 99.99
Switchover position AUTO 0.0 0.00 999.9 99.99
Injection time AUTO 0.00 0.000 655.35 65.535
Plasticizing time AUTO 0.0 0.00 999.9 99.99
Cavity pressure max. AUTO 0 0.00 6553.5 655.35
Cushion length AUTO 0.0 0.00 999.9 99.99
Holding pressure max. AUTO 0 0.00 999.9 99.99
Back pressure max. AUTO 0 0.00 999.9 99.99
PROG.I NTERRUPTION 4

BQSEN804.PM4
Operator's manual
- Afterwards one starts the QDS with "START" and "PROCESS RUN".
---> This begins with the measuring distance!

Hydr.pressure switchover Flow number Cushion length 1)
n: 5 m : 10 Distance: 100 SZx: 200 INITIAL. 2)
SW: 64.0 OSG: 70.0 USG: 58.0 IW: 61.1 bar
SZx: 305 725 3)
Time: 9:10 10:14
70.0
_
x 64.0
4)
58.0
2.00
s
1.00 5)

UEGX: 61.0 OEGX: 67.0 UEGS: 0.00 OEGS: 1.60 6)
: 64.00 : 1.51 s: 1.4 Cp: 1.33 Cpk: 1.22
PROG.INTERRUPTION 4
After each sample the values x double bar, s bar, sigma hut, Cp and Cpk are calculated as well as s and x bar
are recorded graphically.

BQSEN804.PM4
Operator's manual
Description of the control card:
1) Indication of the selected parameters for the 3 control cards
2) n: .................. Indication of the shots per sample

m: ................. Indication of the number of samples
Distance: ...... Indication of the distance between the samples
ZSX: ............. Shot counter, is only updated when the statistics is started newly.
SW: .............. In the calibration cycle: selected set value, in the normal cycle: x-double bar
value transmitted from calibration cycle
OSG: ............ Upper specific limit of x
USG: ............ Lower specific limit of x
IW: ................ Current actual value of x
3) SZx: .............. The shot counter and the

Time: ............. time as additional information measured at the end of the respective sample
4) x bar: .......... Graph of the mean value

Red lines: control limits
Yellow lines: specific limits
Blue line: x double bar
Green line: x bar
5) s: ................ Graph of the standard deviation

Red lines: control limits
Yellow lines: specific limits
Blue line: s bar
Green line: s
6) Measurements: Number of measurements and/or cycles from the start of the statistic recording without
the distances between the samples.
under spec: .. Number of samples which lay below the spec. limit. Absolute and in per cent.
over spec: .... Number of samples which lay above the spec. limit. Absolute and in per cent.
OEGX: ......... Upper control limit of x bar
UEGX: ......... Lower control limit of x bar
OEGS: ......... Upper control limit of s
UEGS: ......... Lower control limit of s
x double bar: current mean value of the mean values. Digital display of the blue straight line in the x
bar graph.
Sigma hut: .. Estimate rate for the standard deviation
s bar: ........... Mean value of the standard deviation
Cp: ............... Process capability index, only contains the scattering
Cpk: ............. Process capability index, besides scattering also contains the position of the mean
value to the specification limits.

BQSEN804.PM4
Operator's manual
1.5.4 Error messages and manual setting of the control limits
During the process run the error message “QDS-CONTROL LIMIT XQ” arises when the control limits are
exceeded, “QDS-SPEC.LIMITS” when the specific limits are exceeded. The alarm lamp flashes and the error is
stored. With the command "ERROR RECORD" it can be read off on the screen which of the process parameters
has released the error and/or in which direction the limit has been exceeded.

Hydr.pres.switchover Flow number Cushion length
USPEZGR 118 93-01-24 08:11 Hydr.pres.switchover 57.3

UEG XQ 122 93-01-24 08:12 Hydr.pres.switchover 60.7
UEG S 123 93-01-24 08:12 Hydr.pres.switchover 1.81
OSPEZGR 124 93-01-24 08:12 Hydr.pres.switchover 71.2
OEG XQ 124 93-01-24 08:12 Hydr.pres.switchover 71.2
USPEZGR 135 93-01-24 08:15 Hydr.pres.switchover 0.00
Limit Date Time Process parameter Measured

Shot counter value
PROG.INTERRUPTION 4
EXIT
The error message and the alarm lamp can be erased with the instruction “DELETE QDS ERROR” during the
automatic operation.

BQSEN804.PM4
Operator's manual
If an error appears, the machine stops the cycle in dependence of the screen switches:
“CONTROL LIMITS” and "SPECIFIC LIMITS".
Setting
limitations
CONTROL LIMITS 4 95 01 10 16:30
Stop after 'control limits exceeded' NO yes/no
CONTROL LIMITS: UEGx OEGx UEGs

OEGs
0 - 655.35
Flow number . . . . . . . . . . . . . . . . . . . . 0 - 655.35
Cavity pres.switchover . . . . . . . . . . . . . . . . . . . . 0 - 655.35
Hydr.pres.switchover . . . . . . . . . . . . . . . . . . . . 0 - 655.35
Switchover position . . . . . . . . . . . . . . . . . . . . 0 - 65.535
Injection time . . . . . . . . . . . . . . . . . . . . 0 - 655.35
Plasticizing time . . . . . . . . . . . . . . . . . . . . 0 - 655.35
Cavity pressure max. . . . . . . . . . . . . . . . . . . . . 0 - 655.35
Cushion length . . . . . . . . . . . . . . . . . . . . 0 - 655.35
Holding pressure max. . . . . . . . . . . . . . . . . . . . . 0 - 655.35
Back pressure max. . . . . . . . . . . . . . . . . . . . .
M A N U A L
PROG.INTERRRUPTION 4
The control limits are calculated in the calibration cycle. A manual change is also possible on the screen
image "CONTROL LIMITS" when the process parameter does not lie normally distributed in order to be able
to utilize the program for quality control.
1.5.5 Print, calculate and interrupt the statistic recording
If a graphic printer is connected to the control unit, with the command “PRINT” the printing of the selected control
card starts. The printer should be set to a tighter type matter (about 15 cpi). The command “AUTOPRINT ON”
causes an automatic printing of the corresponding control card after each complete recording. If the shot counter
and the time shall also be printed, the switches on the screen image “CONFIGURATION" must be set to “YES”.
With the command “CALCULATE” for a control card the specific limits, with 3- or 4-fold sigma hut, or the control
limits can be calculated newly according to the last sample.
Attention! The values calculated at initialization and the graphic recording are erased.
With command “STOP” the statistic recording can be interrupted. After renewed start the graphics is erased and
the recording begins again.

BQSEN804.PM4
Operator's manual 10
Appendix 1 CHANGE HINTS
Display of the current state (index) of this manual:
CURRENT INDEXES:
Chapter: IN 1 2 3 4 5 6 MP QP QS
8.04- 0 0 0 0 0 0 0 M4-1 0 0
C = Change
D = Deletion
S = Supplement
Change index 1: Type

When What Chap./Item C D S
Index: 8.04-0 / 1995-01-05 Change hints A1 1

BA1EN804.PM4
Operator's manual
Change index 1: Type

When What Chapt./It. C D S
2 A1 Change hints Index: 8.04-0 / 1995-01-05

BA1EN804.PM4
Appendix 2 INDEX
For the easier finding of topics and terms in this book an alphabetic index register is added here. The numbers
standing after the entries indicate chapter and page (e.g. Hardcopy 2-8 ..... chapter 2, there page 8). Please also
leaf through the following one, two pages in order to possibly find the wanted term once again.
SYMBOLS
central lubrication 3-14
% control 4-4 Change QP-3
% controller 4-9 charge amplifier 6-12, 6-13
+/- key 1-5 Clamping force 6-18
2-point controller 4-4 clamping force 3-6, 3-7
3-point controller 4-4 clamping pressure 3-7
4 - tie-bar adjustment 3-14 Clamping unit 6-18
4-tie-bar measurement 3-8 clamping unit 3-1
classes QS-18
A CLEAR 1-5
closed loop 6-6
A 3-10 closed loop clamping force control 3-6, 3-8
A1 3-21 closing speed 3-9
A2 3-18 Cm QS-4, QS-21
ABSOLUTE VALUE INPUT 6-10 Cmk QS-4, QS-21
Absolute value input 4-23 coding 6-14
actual values 6-16, MP-10 coding number 6-15
actual-mean value QP-13 Colour allocation QP-9
ADJUSTING MOTOR 3-3 Compatibility of part diskettes 4-12
advance temperature 6-7 CONFIGURATION QS-18, QS-22, QS-26
air valve 3-18 Continuous Process Control QP-11
Alarm display 1-11 control card QS-9, QS-14, QS-18, QS-20, QS-24, QS-26
algebraic sign 1-5 CONTROL CARD TYPE QS-19
arrow keys 1-5 control cards QS-16
ASCII file QP-5 control characteristic line 4-4
Authorization 1-13 control limit QS-14
Auto Setup for Microplast 6-3 control limits QS-6, QS-8, QS-9, QS-10, QS-17, QS-19, QS-21, QS-
automatic heating-up 4-5 22, QS-24, QS-25, QS-26
AUTOPRINT QP-10, QS-26 Control panel 1-12
AUTOSETUP MP-2 CONTROL PARAMETERS 4-9
control parameters 4-5
B control probability QS-8, QS-10, QS-19
controller clock time 4-4
back pressure profile 4-25
Controller types 4-4
bar diagram QS-3
cooling 4-4
basic entirety QS-6
Cooling phase 4-5
Baud rate 2-6
cooling phase 4-20
beginning injection 3-6
Cooling time 6-22
BOE-THERM 4-14
cooling time 1-24, 4-24
C CORE SAFETY 3-29
CORE-PULL 3-24
C1 4-25 core-pull matrix 3-24
C2 4-26 correction factor 6-4
C3 4-20, 4-21 correction type 6-4
C3d 4-22 couple break 4-12
C3E 4-20, 4-22 Couple types 4-4
C3u 4-21 Cp QS-11, QS-14, QS-23, QS-24
C4 4-26 CPC QP-11
calibration cycle QS-4, QS-22, QS-24, QS-26 Cpk QS-11, QS-14, QS-23, QS-24
Capacity display 4-4 CPx 4-24
Carriage pressure 6-22 cursor 1-14
Carriage speed 6-22 Cursor keys 1-5
Carriage unit 6-22 curve group MP-12
central computer 6-14 cushion correction 4-25
central ejector 3-29
Index: 8.04-0 / 1995-01-05 Index A2 1

BA2EN804.PM4
Operator's manual
Cushion monitoring 4-24 estimate rate QS-6, QS-11, QS-14

cushion monitoring 3-22 EVENT QP-3, QP-9
cycle 1-22, 1-25 exact time 6-8
cycle interruption 3-15 EXCEL QP-5
cycle monitoring 3-13 excess share QS-8, QS-9, QS-19
Cycle monitoring time 6-22 excess temperature 1-11
Cycle time 6-16 External switchover 4-22
cycle time 1-16, 1-23
CYCLE TIME ANALYSIS 1-16 F
cycle time deviation 1-18
cycle time monitoring 6-8 FE-KO 4-4
cylinder heatings 4-5 feed zone 4-7
FHx 6-16
D filling phase 6-1
flash formation 3-6
data set name 2-6 floppy QP-5
Data word length 2-6 flow monitor 6-7
date 6-8 Flow monitoring 6-7
decompression 4-25, 4-26 flow number 3-22, 6-2
Decompression after plasticizing 6-21 Flow number actual value display MP-21
DEMOULDING 1-25 Flow number change 6-4
demoulding time 1-25, 3-21 flow number measurement 6-2
DEVIATION MP-15 flow number tolerance 6-2
Differential factor 4-4 flow rate 6-5
Dimming 1-11 flow resistance 4-17
Direct closing system 3-5 flowability 6-1
DIRECTORY 2-2 Force transducer 6-13
directory name 2-6 formatting 2-4
Diskette 2-1 freely composeable text page 1-19
diskette 4-12, QP-5 full image MP-4
Diskette contents 2-1 "Fully automatic" 1-22
diskette device 1-11 function keys 1-10
diskette drive 2-1
Display field 4-5, 4-6 G
Distance QS-24
disturbing influences 4-19, QS-6 G1 3-10
DZx 6-16 G2 3-7
G2 settings 6-18
E gear rim 3-3
good parts QS-14
E-8-PT100 4-4 graphic monitoring 3-22
E-8-THERMO 4-4 GRAPHIC PRINTER 2-7
E-8-Thermo 4-10, 4-12 Graphic printer 2-6
E-MU102 5-2 Group of curves MP-18
E1 3-15, 3-17 GWK 4-14
E2 3-15, 3-17
E9 4-1 H
ejection balance 3-21
ejection monitoring 3-21 Half image MP-4
ejection plate 3-21 Half-wave circuit 4-7
Ejector 6-19 Hardcopy 2-8
Ejector force 6-19 hardware check 1-14
ejector counter 3-29 HB-THERM 4-14
ejector shake counter 3-21 'header' QP-4
ejector stroke 3-20 Heating 4-4
Ejector stroke actual value 6-16 heating 6-8
Ejector volume 6-20 heating circuits 4-4
Emergency mode 4-4, 4-10 heating zone 4-6
ENTER key 1-5 heating-up attempt 4-11
entirety QS-9 heating-up monitoring 4-12
Entry list QP-2 Heating-up optimization 4-10
entry list QP-3 Heatings 6-20
Envelope MP-19 help text 5-2
Erase QP-3 high pressure 3-7
ERROR ACKNOWLEDGEMENT KEY 5-3 histogram QS-3, QS-18, QS-21
error counter QP-12 HKV 4-11
Error display 1-10 HOLDING PRESSURE 4-16
error elimination 5-2 holding pressure 1-24, 4-3, 4-20, 4-21, 4-23
Error evaluation QP-13 Holding pressure time 6-21
ERROR HELP 5-2 holding pressure time 4-18
ERROR HELP FUNCTION 5-2 holding pressure values 6-20
ERROR IMAGE 5-1 host computer 6-14
error messages 4-8 HYDR.CLOSING SAFETY 3-15
error record QP-14 Hydraulic pressure actual value 6-16
error share QS-10 Hydraulic pressure-dependent 4-21
errors 1-10 hydraulic pressure-dependent 4-20
Escape key 1-7 HZA 6-8, 6-9
2 A2 Index Index: 8.04-0 / 1995-01-05

BA2EN804.PM4
I magnetic card 1-13

magnetic card reader 1-13
IBM PC keyboard 1-15 malfunction message record 2-8
ideal curve 2-1, MP-2 "Manual" 1-20
Ideal curve selection MP-5 MANUAL 3-3, 3-10
ideal curves MP-6 MANUAL CONTROL KEYS 1-12
identification 4-10 MANUAL TEMPERATURE REDUCTION 6-8
IDK1 MP-6 material cylinder temperature 4-16
IDK2 MP-6 MAX.VALUE 1-10
image selection key 1-7 mean value QS-1, QS-3, QS-6, QS-8, QS-11
increase times 4-4 Mean value formation QP-13
"Increased injection pressure" 6-20 mean values QP-7, QP-12
INCREASED INJECTION PRESSURE 4-17 measured value distribution QS-6
increment-decrement keys 1-5 measuring distance QS-23
Initialization QS-3, QS-8, QS-17, QS-20 Measuring range 6-13
initialization QS-18, QS-26 MEMORY DEVICES 2-1
initialization run QP-12 memory card 5-2
INJECTION 4-16 memory extension card 2-3
injection 4-20 MESSAGES 5-1
injection cushion 4-24 MICROFLOW 6-1
injection pressure 4-19 Microflow 6-4
Injection profile 6-20 Micrograph 4-22
injection profile values 6-20 MICROGRAPH PLUS MP-1
Injection rate 6-11 MICROPLAST 6-1
injection speed 4-18 Microplast 6-1
Injection time 4-19 MICROTEMP 6-5, 6-7
Injection time monitoring 4-19 mode 4-10
injection time monitoring 6-21 Mode of operation 1-20
Injection unit 6-20 Monitoring windows MP-14
injection unit 4-1 Motor 6-8
Input field 1-10 mould cavity pressure 6-12
Insert QP-3 Mould cavity pressure-dependent 4-21
integral MP-12 mould cavity pressure-dependent 4-20
Integral factor 4-4 mould diskette 2-2
integral limits MP-19 mould filling process 4-20
Interactive error messages 1-10 Mould heatings 4-5
interface 4-14 MOULD HEIGHT 3-3
intrusion 4-24 Mould height actual value 6-16
MOULD HEIGHT ADJUSTMENT 3-4
J mould height adjustment motor 3-4, 3-6
MOULD OPENING 3-11
J 4-3 MOULD PARAMETERS 1-15
mould parameters 2-1
K mould protection 3-9
mould protection pressure 3-10
K 4-3
mould protection time 3-10
key-operated switch 1-5, 1-11, 1-14
Mould stroke actual value 6-16
KISTLER 5039 A221 6-13
mould temperature couple 6-7
KISTLER Z13378 6-13
MOULDING CYCLE 1-23
moulding cycle 1-24
L Moving-in priority 3-27
L 3-21 Moving-out priority 3-29
L2 3-21 multiprocessor 1-1
L3 3-21
languages 2-3 N
leafing keys 1-5
n QS-24
light barrier 3-21
new setting 6-18
limit switches 1-10
NiCr-Ni 4-4
line allocation QP-8
NORMAL QP-5
line allocation field QP-9
NORMAL DISTRIBUTION QS-1
long-term examination QS-11
normal distribution QS-3, QS-11, QS-17
LOTUS 2-1, QP-5
normal mode 6-18
LOWER LIMIT QP-9
nozzle contact point 4-3
Lowering 4-6
nozzle protection 4-1, 4-16
lowering program 4-7
nozzle retraction delay time 4-3
lowering temperature 4-6
Nozzle stroke actual value 6-16
lubrication oil level 3-14
number of cavities 1-18, 3-23
lubrication process 3-14
M O
OEG QS-14
m QS-24
OEGS QS-24
machine capability QS-4, QS-17, QS-21, QS-22
OEGX QS-24
'machine diskette' 1-11
oil cooling 4-11
machine number 2-6
oil cooling control zone 4-6
machine settings 6-16
Index: 8.04-0 / 1995-01-05 Index A2 3

BA2EN804.PM4
Operator's manual
oil preheating program 4-7 Q

Oil temperature control 4-7
open loop 6-7 QDP QP-1
OPENING FORCE INCREASED 3-12 QDS QS-22
Operating point optimization 4-12 quality control QS-1
oscilloscope function QP-7 Quality control cards QS-6
OSG QS-4, QS-24 quality control cards QS-1
OUTPUT UNIT QP-4 quality data statistics QS-1, QS-14
QUALITY DOCUMENTATION PACKAGE QP-1
P Quarter image MP-4
quarter image MP-9
P1 3-7 Quick Setup 6-16, 6-17
P5 4-1 QUICK SETUP MICROGRAPH MP-2
P5b 4-3
P6 4-19 R
Parallel switchover 4-22
Parameter menu MP-5 RAM card 2-3
Parity 2-6 read-in 4-12
'part diskette' 1-11 ready 1-14
part diskette 1-17, QP-5 'record diskette' 1-11
part weight 1-18 Record diskette 2-1
Part-time monitoring 1-17 Recording parameters QP-9
part-times 1-16 recording parameters QP-3
partial images MP-4 reduction temperature 6-8
partner value 6-10 REGLOPLAS 4-14
pause time 1-25 Regulator mode 4-4, 4-9
PC keyboard 1-12, 1-15 Rejects MP-15
PD GRAPHICS QP-7, QP-8, QP-10 rejects 3-22, 6-4, QP-5
PD RECORD QP-1, QP-2 rejects counter 3-22, 4-19
PDG QP-1, QP-7 REJECTS GRAPHICS 1 MP-15
PDM QP-1, QP-11 rejects recognition 3-22
PDR QP-1 rejects sequence 3-22
PF 4-20, 4-21 rejects sequence counter 3-22
PFu 4-21 rejects sorting 6-2
PH 4-20, 4-21 relative values 6-10
PHx 6-16 remaining material demand 1-18
piece counter 3-23 reproduceable 4-19
Pin diameter 6-13 retraction 4-3
PIOVAN 4-14 retraction program 6-22
PLASTICIZING 1-24 rheometrical 6-1
Plasticizing 4-25
Plasticizing end 6-21 S
plasticizing stroke 4-18
Plasticizing time monitoring 4-26 s QS-23, QS-24
platen stop 3-15 s bar QS-6, QS-14, QS-21, QS-23, QS-24
platens 3-1 safety gate 3-15, 3-16, 3-21, 4-16
plausibility limit 1-10 safety key 1-21, 3-3, 3-12, 3-15, 3-16
please wait 1-14 sample QS-2, QS-3, QS-4, QS-6, QS-11, QS-14, QS-18, QS-21, QS-
PNS 4-23 24, QS-26
PR 1-11 sample size QS-6
pressure build-up time 4-2 SAx 6-16
pressure correction 6-4 Scale QP-9
pressure profile 4-19 scale MP-15, MP-17, QP-12
Pressure transducer 6-13 scanning time 4-4
pressure wave switches 3-16 scattering QS-14
PRINT QP-10 screen language 2-3
PRINTER QP-5 Screen tags 1-10
Printing the graphics MP-20 screen texts 2-3
process capability QS-4, QS-11, QS-20 Screw speed 6-11
Process capability index QS-24 Screw diameter 6-22
process control cards QS-1 screw diameter 2-3, 4-17, 4-23
process data QP-1 Screw speed 6-16, 6-21
Process data collection 2-1 Screw stroke actual value 6-16
process data graphics QP-1, QP-7 SDx 4-3, 6-16
process data monitoring QP-1, QP-11 section MP-9
process data record QP-1 sections MP-8
process parameters QP-8 SELECTABLE TEXT PAGE 1-19
PROCESS RUN QS-20, QS-23 Selection list QP-12
process run QS-25 selection table QP-2, QP-3, QP-8
PRODUCTION DATA 3-22 selections MP-5
PRODUCTION DATA COLLECTION 1-18 self-determination 4-11
production documentation 2-6 Self-optimization 4-10
production remaining time 1-18 "Semiautomatic" 1-22
profile 4-18 Sensitivity 6-13
Proportional factor 4-4 SEQUENCE ERROR MESSAGE FIELD 5-1
servo valve control 4-19
4 A2 Index Index: 8.04-0 / 1995-01-05

BA2EN804.PM4
SET QP-2 time-dependent 4-20

Set value graphics 3-9, 3-12 tn 4-4
set value graphics 4-18, 4-23 toggle lever 3-1
set-mean value QP-13 toggle lever machines 3-3
"Set-up" 1-21, 4-1 toggle levers 3-13
SET-UP 3-3 tolerance band MP-12, MP-15
setting mode 6-18 Tolerance limits QP-13
SFx 3-5, 6-16 tolerance ranges QP-12
shake position 3-21 TOOLTEMP 4-14
shot counter 3-23 total mean value QP-13
shot/sample QS-22 Transducer sensitivity 6-13
Sigma hut QS-24 transmission 6-14
sigma hut QS-6, QS-8, QS-11, QS-23, QS-26 traverse cooling 4-6
Soaking 4-6 traverse temperature 4-6
soaking 4-5 traverse temperature control 4-7
soft keys 1-10 trend graphics QP-7
specific injection pressure 4-17 TUBE MP-12
specification limit QS-4 tube MP-4, MP-19
specification limits QS-8 turning point QS-1
SSx 6-16 tv 4-4
standard deviation QS-1, QS-2, QS-3, QS-6, QS-11, QS-14, QS-24 Type of transducer 6-13
standstill reason 6-15
Start delay MP-15 U
start key 1-22
Start-up circuit 4-4, 4-7 UEG QS-14
start-up circuit 3-23 UEGS QS-24
State of operation 1-10 UEGX QS-24
step sequence 1-23 UPPER LIMIT QP-9
straightening 3-1 User level 1-11
Stroke-dependent 4-21 USG QS-4, QS-24
stroke-dependent 4-20
sum frequency QS-11 V
survey graphics MP-8, MP-9, MP-17
V24 interface 1-12, 2-6
SUVA 5-35
V27 3-21
switch clock 6-8
VISCOSITY MEASUREMENT 6-1
switch-off moment 6-8
Volume 6-11
switch-off procedure 6-8
switch-on function 6-9
Switch-on key 1-7
W
switchover 4-20 Warning limits QP-13
switchover mode 4-20 warning limits QP-12
Switchover point display MP-21 water cooling 4-7
switchover point display MP-6 WEEK SWITCH CLOCK 6-8
Switchover position to holding pressure 6-21 weekday 6-9
swivelled-out 4-16 Weight distribution 6-4
System separation 3-14 whole cycle time 1-16
SZx QS-24 WITTMANN 4-14
work cycle 1-22
T Writing protection 2-5
t0 4-4
TABLE OF VARIABLES QP-6
X
TEMP 1-9, 1-11 X axis MP-15
Temperature alarm for screen 1-9 x bar QP-7, QP-11, QS-1, QS-8, QS-11, QS-23, QS-24
temperature control capacity 4-10 x bar-set QP-12
TEMPERATURE CONTROL UNITS 4-14 x double bar QP-11, QS-14, QS-21, QS-23, QS-24
temperature display 4-6 xph 4-4
temperature setting 4-6
Temperatures 6-16 Y
text input 2-9
TEXT INPUT KEYBOARD 2-9 Y axis MP-16
Text INPUT KEYBOARD 1-12
TEXT PAGES 2-9 Z
Text printer 2-6
TFT screen 1-11 Z1 4-20, 4-21
theoretical curve QS-1 Z4 4-24
thermocouple 4-4, 4-9 Z5 1-25, 3-21
thermocouple break 4-4 Z5a 4-2
threshold 4-8 Z6 4-3
threshold value 4-4 ZA 3-21
tie-bar extension 3-6 ZAV 3-21
Tie-bars 3-1 ZD 4-26
time 6-8 ZF 3-10
time base MP-15 ZIN 4-24
Time monitoring injection 6-21 ZL1 3-18
Time-dependent 4-21 ZLV1 3-18
Index: 8.04-0 / 1995-01-05 Index A2 5

BA2EN804.PM4
Operator's manual
zone designators 4-13

zone function 4-13
zone temperature 4-4
ZSx 4-21
ZUs 3-13
ZUx 3-13, 6-16
6 A2 Index Index: 8.04-0 / 1995-01-05

BA2EN804.PM4

Operator CC100

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MICROCOMPUTER

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C Copyright by Engel Maschinenbau Gesellschaft m.b.H.

ENGEL does not take over any guarantees regarding

Please pay attention to next page by all means

Index: 8.04-0 / 1995-01-05 Table of contents In 1

When you take this manual please first read up in appendix

Special programs, customer-specific applications:

Special executions and expanded plants, such as:

2 In Table of contents Index: 8.04-0 / 1995-01-05

To this OPERATOR'S MANUAL:

Chapter 1 Components and operation of the control unit

Chapter 2 Diskette operation, printer operation, text input

Chapter 3 Setting of the clamping unit

Chapter 4 Setting of the injection unit

Chapter 5 Error messages

Chapter 6 General special programs, also optional ones

Chapter MP Micrograph plus

Chapter QP Quality documentation package

Appendix 1 Change hints

We designate the sizes ES25 - ES80 as SMALL MACHINES

Starting from ES1000: Clamping force measurement on 4 tie-bars

Index: 8.04-0 / 1995-01-05 Table of contents In 3

Chapter 1 COMPONENTS AND OPERATION OF CC100 1-1

1. EQUIPMENT OF THE MICROCOMPUTER CONTROL UNITS ........................ 1-1

2. COMPONENTS OF THE MICROCOMPUTER CONTROL UNITS .................... 1-4

3. OPERATION OF THE MICROCOMPUTER CONTROL UNITS ...................... 1-14

4 In Table of contents Index: 8.04-0 / 1995-01-05

4. OPERATION OF AN INJECTION MOULDING MACHINE ............................... 1-20

Chapter 2 MEMORY DEVICES AND TEXT INPUT 2-1

1. DISKETTE DEVICE ........................................................................................... 2-1

2. PRINTING ........................................................................................................... 2-6

3. TEXT INPUT ....................................................................................................... 2-9

Index: 8.04-0 / 1995-01-05 Table of contents In 5

Chapter 3 SETTING OF THE CLAMPING UNIT 3-1

1. MOULD HEIGHT SETTING ................................................................................ 3-3

2. CLAMPING FORCE ........................................................................................... 3-6

3. CLOSING SPEED AND MOULD PROTECTION ............................................... 3-9

4. MOULD OPENING ........................................................................................... 3-11

4.1 MOULD OPENING WITH INCREASED OPENING FORCE ............................ 3-12

5. CYCLE MONITORING TIME ............................................................................ 3-13

6. CENTRAL LUBRICATION (TOGGLE LEVER MACHINES ONLY) ............... 3-13

7. SAFETY GATE SAFETY MONITORING .......................................................... 3-15

8. AIR VALVE (SPECIAL EQUIPMENT) ........................................................... 3-18

9. EJECTOR ......................................................................................................... 3-20

10. PRODUCTION DATA ....................................................................................... 3-22

11. CORE-PULL (SPECIAL EQUIPMENT) ........................................................... 3-24

6 In Table of contents Index: 8.04-0 / 1995-01-05

11.1.6 Time monitoring 3-27

Chapter 4 SETTING OF THE INJECTION UNIT 4-1

1. CARRIAGE UNIT ................................................................................................ 4-1

2. HEATINGS ......................................................................................................... 4-4

Index: 8.04-0 / 1995-01-05 Table of contents In 7

3. INJECTION AND HOLDING PRESSURE ....................................................... 4-16

4. PLASTICIZING ................................................................................................. 4-26

Chapter 5 ERROR MESSAGES 5-1

1. ERROR HELP (ERROR HELP FUNCTION) .................................................. 5-2

2. ERROR MESSAGE ACKNOWLEDGEMENT AND ERROR RESETTING ....... 5-3

3. LISTING OF THE ERROR MESSAGES ............................................................ 5-4

8 In Table of contents Index: 8.04-0 / 1995-01-05

Chapter 6 SPECIAL PROGRAMS 6-1

1. MICROPLAST / MICROFLOW ........................................................................... 6-1

2. MICROTEMP - MOULD COOLING (OPTION) .................................................... 6-5

3. WEEK SWITCH CLOCK .................................................................................... 6-8