:

EC100 / CC100-A03
CONTROLLER-OPERATOR
6750 772 1502M
30 to 500 TON
EV9.01C40

Revision date: 2002-10-08

These documents remain the property of ENGEL (Canada) Inc. And must
not be copied without the written consent of ENGEL (Canada) Inc.
The contents of this manual may neither be made known to third parties or
be used for non-approved purposes.

DANGER
Complex machine with personal injury hazards.
Do not operate machine unless you are properly trained.
Read and understand the hazards outlined in chapter 7 of
this Controller Operator manual. Before start-up, check
safety devices as per chapter 7 - Machine safety checklist.
Do not operate machine unless all interlocks/safety devices
are in place and function properly.
Consult your supervisor, if in doubt about machine safety .
Failure to follow instructions could result in injury.

© 2001 Copyright by ENGEL CANADA INC.

Guelph, Ontario, Canada
 EC100 / CC100 - A03 OPERATOR:

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INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III
1. EC100 / CC100 A03 CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1. CONTROLLER FRONT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1. MANUAL SWITCHES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2. INDICATION LAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.3. PROGRAM INTERRUPTION KEY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.4. FACEPLATE SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.5. PROCEDURE FOR DATA ENTRY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.6. IBM KEYBOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.7. ON SCREEN HELP TEXT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.7.1. F1 - Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.7.2. F2 - Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.8. KEYSWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.9. CC100 DISKETTE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.10. SCREEN DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.11. SCREEN MESSAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.12. SCREEN MARKS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.13. SCREEN MARK COLORS / CC100. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.14. SPECIAL SCREEN FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.14.1. CURSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2. START - UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1. STARTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3. SET - UP TO RUN PRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1. GENERAL CONSIDERATIONS - MOLD / MATERIAL CHANGE . . . . . . . . . . . . . . . . . . 25
2. INSTALLING MOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3. SETTING MOLD PROTECTION PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.1. TOGGLE LEVER MACHINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.2. DIRECT HYDRAULIC MACHINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.3. DIRECT HYDRAULIC MACHINES (30 AND 55 TONS) - ZEROING SFX. . . . . . . . 30
4. SETTING CLAMP FORCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.1. TOGGLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.2. TOGGLE WITHOUT CLAMPFORCE TRANSDUCER. . . . . . . . . . . . . . . . . . . . . . . 31
4.3. DIRECT HYDRAULIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5. ADJUSTMENT OF INJECTION STROKE AND PRESSURE . . . . . . . . . . . . . . . . . . . . . 32
6. ADJUSTMENT OF CLAMP AND EJECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
7. ADJUSTMENT OF NOZZLE STROKE AND PRESSURE . . . . . . . . . . . . . . . . . . . . . . . 34
8. MANUAL TO AUTOMATIC CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4. SHUT DOWN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1. MACHINE SHUT-DOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5. SCREEN PAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
1. MAIN MACHINE FUNCTION KEYPADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2. MOLD CLOSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.1. MOLD CLOSING (SV2.00 OR GREATER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
2.2. SET VALUE GRAPHICS (SYSTEM VERSIONS LESS THAN SV2.00) . . . . . . . . . 46
2.3. SET VALUE GRAPHICS (SYSTEM VERSIONS SV2.00 OR GREATER). . . . . . . . 48
2.4. AUTO PROTECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

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2.5. CLAMPFORCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
2.6. MOLD HEIGHT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
2.7. INJECTION COMPRESSION / COINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
3. MOLD OPENING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
3.1. SET VALUE GRAPHICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
3.2. AIR VALVES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
3.3. CENTRAL LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
3.4. SAFETY GATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
3.5. MOLD GATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
4. EJECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
4.1. PRODUCTION DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
4.2. MOLD EJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
4.3. AUXILIARY POWER SOURCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
5. INJECTION BOOST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
5.1. BOOST TO HOLD CUT OFF MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
5.2. SET VALUE GRAPHICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
6. INJECTION HOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
6.1. SET VALUE GRAPHICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
7. SCREW FEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
7.1. SET VALUE GRAPHICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
8. QUALITY DATA PROGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
8.1. PROCESS DATA REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
8.2. PROCESS DATA GRAPHICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
8.3. PROCESS DATA MONITORING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
9. QUALITY DATA STATISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
9.1. NORMAL DISTRIBUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
9.1.1. Variation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
9.1.2. BELL CURVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
9.1.3. Process capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
9.2. MANUALLY INPUT QUALITY CONTROL CHARTS . . . . . . . . . . . . . . . . . . . . . . . 168
10. MAIN MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
10.1. PRINTER (SYSTEM VERSION LESS THAN 2.00) . . . . . . . . . . . . . . . . . . . . . . . 176
10.1.1. Preliminary Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
10.2. PRINTER (SYSTEM VERSION GREATER THAN SV2.00) . . . . . . . . . . . . . . . . 179
10.2.1. f1 - “PRINT TEXT PAGE” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
10.2.2. F2 - PARAMETER PRINTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
10.2.3. F3 - DISTR. REC. MENU (SYSTEM DATA REPORT) . . . . . . . . . . . . . . . . 182
10.2.4. F4 - PRINT STAT. REP (STATUS REPORT) . . . . . . . . . . . . . . . . . . . . . . . 184
10.2.5. F5 - DEVICES SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
10.2.6. F6 - SET UP GENERAL PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
10.2.7. F7 - STOP PRINTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
10.3. DISKETTE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
10.3.1. Diskette - Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
10.3.2. Diskette Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
10.3.3. To write to a blank disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
10.3.4. To write a mold disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
10.3.5. To read from a machine disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
10.3.6. To write to an existing machine disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
10.3.7. To read from a mold disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
10.3.8. To write to an existing mold disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195

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10.4. COMPARISON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
10.5. ADMINISTRATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
10.5.1. To change the working device; . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
10.5.2. To view the directory of files on a floppy disk or ram disk . . . . . . . . . . . . . . 200
10.5.3. To delete from the device selected. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
10.5.4. To copy between devices: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
10.5.5. To format a 3.5” floppy disk. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
10.5.6. To delete a directory or file from a device . . . . . . . . . . . . . . . . . . . . . . . . . . 203
10.6. TEXT PAGES (NOTES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
11. CORES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
11.1. CORE IN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
11.2. CORE OUT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
12. MOLD PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
12.1. CYCLE TIME ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
12.2. PRODUCTION INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
12.3. SELECTABLE TEXT PAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
12.3.1. SETTING ALPHA NUMERICAL CHARACTERS . . . . . . . . . . . . . . . . . . . . 237
12.4. PROCESS ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
12.5. EHV CARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
13. QUICK SET UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
14. SPRUE BREAK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
14.1. GHOST SHIFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
15. BARREL HEAT & OIL TEMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
15.1. AUXILIARY HEAT ZONES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
15.2. AUXILIARY HEAT ZONES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
16. MICROGRAPH PLUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
16.1. MICROGRAPH PLUS FUNCTIONAL CHARACTERISTICS: . . . . . . . . . . . . . . . 262
16.2. MICROGRAPH SET UP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
16.2.1. QUICK SET UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
16.3. SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
16.3.1. CURVE SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
16.3.2. MICROGRAPH ANALYZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
16.3.3. TRIGGER - Start point for recording. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
16.4. SECTION FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
16.5. SCALE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
16.6. MONITORING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
16.6.1. MONITORING WINDOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
16.7. MICROGRAPH PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
16.8. ACTIVATE SELECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
16.9. ACTIVATE SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
16.10. ACTUAL VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
16.11. IDEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
16.12. PRINT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
16.13. CURVE GROUPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
16.14. FLOW NUMBER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
16.15. FUNCTION KEY NAVIGATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
17. MICROPLAST/MICROFLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
18. SPECIAL FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
18.1. CHARGE AMPLIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
18.2. WEEKLY SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299

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18.3. HOST COMPUTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
18.4. MOLD TEMERATURE CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
18.5. DRYER CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
18.6. CHILLER CONTROLLER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
18.7. MULTIZONE TEMPERATURE CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . 311
18.8. LOADER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
18.9. ADDITIVE FEEDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
18.10. MELT PUMP CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
18.11. WEIGH SCALE PROGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
18.12. HYDRAULIC ACCUMULATOR PROGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
18.13. INSTANT TEXT CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
6. ERRORS AND MESSAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
1. ERROR OR MESSAGE ACKNOWLEDGMENT AND RESET . . . . . . . . . . . . . . . . . . . 329
2. ERROR PAGE - SAMPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
3. ON SCREEN ERROR MESSAGE HELP TEXT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
4. ERROR LISTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
5. WAITING POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371
6. HARDWARE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
6.1. HW - CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
6.2. HARDWARE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375
6.3. HW - INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376
6.4. SW - VERSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 377
6.5. SYSTEM INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 378
7. SYSTEM DATA REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379
8. VALUES OUT OF RANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383
7. SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385
1. MATERIAL HANDLING AND STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385
2. MATERIAL PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386
3. MOLD PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386
4. MOLD INSTALLATION AND REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387
5. MOLDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 388
5.1. "CORE AND EJECTOR MOTION" KEYSWITCH . . . . . . . . . . . . . . . . . . . . . . . . . 391
5.2. ENGEL MACHINE SAFETY FEATURES (TL100 TIEBARLESS). . . . . . . . . . . . . 392
5.3. ENGEL MACHINE SAFETY FEATURES (ES200 TOGGLE) . . . . . . . . . . . . . . . . 393
5.4. MECHANICAL SAFETY DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396
5.4.1. MECHANICAL SAFETY TYPE 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396
5.4.2. MECHANICAL SAFETY DEVICE TYPE 2 . . . . . . . . . . . . . . . . . . . . . . . . . . 397
5.5. SAMPLE MACHINE SAFETY CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 398
5.6. ENGEL ROTARY TABLE SAFETY FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . 399
5.6.1. ROTARY TABLE SAFETY FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400
5.6.2. Sample Rotary Machine Safety Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
5.7. ENGEL SHUTTLE TABLE SAFETY FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . 403
5.7.1. ENGEL SHUTTLE TABLE SAFETY FEATURES . . . . . . . . . . . . . . . . . . . . . 404
5.7.2. SAMPLE SHUTTLE MACHINE SAFETY CHECKLIST . . . . . . . . . . . . . . . . . 406
5.8. SAFETY INSTRUCTION PLATES AND LABELS . . . . . . . . . . . . . . . . . . . . . . . . . 407
5.9. SAFETY INSTRUCTION PLATES AND LABELS . . . . . . . . . . . . . . . . . . . . . . . . . 408
5.10. MOLDING SAFETY RULES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
5.11. PARTS HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416

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5.12. CHEMICAL HAZARDS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
8. APPENDIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
1. ENGEL ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
1.1. VELOCITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
1.2. PRESSURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
1.3. TIMERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421
1.4. POSITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
1.5. POSITIONS (CONTINUED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423
1.6. MISC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424
2. MOLDING TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425

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10/10/02 f
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INTRODUCTION

This manual is Part 1 of a 2 part manual.

Part 2 is the Controller Maintenance Manual.

Part 1 is designed to provide the operator with sufficient information for the day to day running of
the machine. It includes a safety section, an introduction to the controller faceplate and controls
and a line by line description of most screen pages. (Special screens not contained in this manual
will usually be described in the program description supplied with the machine manual).

A listing and description of error messages, along with corrective measures, is also contained in
this Operator Manual and should be the first point of reference should a problem occur.

THE SAFETY SECTION OF THIS MANUAL SHOULD BE READ AND UNDERSTOOD BEFORE
OPERATION OF THE MACHINE IS ATTEMPTED.

Part 2, the Controller Maintenance Manual, contains the controller screen pages relevant to
maintenance and troubleshooting. These include the "Service Menu", "Heat P.I.D.", "P & V
Control Parameters" and "Waiting Points". The Controller Maintenance Manual also contains
other information designed to be used only by trained maintenance personnel.

WARNING!

Some procedures described in these manuals, i.e. a

change in variable set values, may affect the safe opera-
tion of the machine. Therefore only suitably trained per-
sonnel should attempt these procedures. If any doubt
exists, as to whether machine safety would be compro-
mised, then the ENGEL SERVICE department must be
consulted.

2/3/01 INTRODUCTION i
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ii INTRODUCTION 2/3/01
 EC100 / CC100 - A03 OPERATOR:

1. EC100 / CC100 A03 CONTROLLER

1 CONTROLLER FRONT PANEL

ON
TEMP

ESC F1 F2 F3 F4 F5 F6 F7 F8

7 8 9 + ENTER
_
4 5 6
E
1 2 3 N
T
E
+/- 0 R CLEAR

Q
S

A ?

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1.1 MANUAL SWITCHES

All machines are equipped with manual function switches. The majority of manual function
switches will be of the two position variety. A sample configuration is shown below.

MOTOR CORES & SAFETY GATE

EJECTORS
OVERLOAD ACTIVATION OPEN CLOSE

AIR BLOW MOLD CLAMPING ALARM BELL AUX. HEAT

ON SECURE RELEASE SILENCE OFF AUTO.

MODE SELECT MOLD HEIGHT PART CHUTE BARREL HEAT CONTROL VOLTAGE
MANUAL AUTO INCREASE DECREASE STORE REJECT OFF AUTO OFF ON

CYCLE CORES & MOLD GATE MOTOR EMERGENCY

EJECTORS
START NO MOTION MOTION OPEN STOP START STOP

ON

OFF PR

Switching the "Cores & Ejectors" keyswitch to the MOTION

position will allow the mold to continue opening, the cores to
NOTE ! pull and the ejectors to come forward when the operator gate is
opened during a semi-automatic cycle. Appropriate
precautions must be taken before turning to the MOTION
position. Refer also to "Cores & Ejectors" keyswitch page in the
SAFETY section of this manual.

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1.2 INDICATION LAMPS

Located on the manual switchboard will be a configuration of lamps to indicate the current
operating state of the control voltage, the electric motor, the heats, the "cores & ejectors" special
program and if a motor overload conditions exists. If a lamp is lit, that specific condition exists. A
sample configuration is shown below.

CONTROL MOTOR HEAT CORES & EJECTORS MOTOR

VOLTAGE ON ON ACTIVATION OVERLOAD

1.3 PROGRAM INTERRUPTION KEY

Two important tasks:

A. Whenever the manual/automatic (Mode/Select) switch is switched from automatic to

manual, the current cycle is stopped immediately.

All machine movements can be effected in the manual mode. When this switch is switched
into the manual mode, the message "PROGRAM INTERRUPTION" will appear.

To restart the machine, the mold must be at its mold open position, the ejector must be at
its ejector back position and the screw must be at its screw feed position. Switch the Mode/
Select switch to automatic and re-close the front safety gate or, if so equipped, press the
“Cycle Start” push-button.

B. The Mode/Select switch is also used to reset and acknowledge all existing error
messages. If the error condition still remains, the error message will not be reset and the
message will remain on the screen.

In order to re-cycle the machine, the controls should be reset by switching the Mode/
Select switch from automatic to manual and back.

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1.4 FACEPLATE SYMBOLS

Function Keys

ESC F1 F2 F3 F4 F5 F6 F7 F8
The keys F1 - F8 allow for easy access to function related pages. If the operator is working on any
page, there will be a display at the bottom of the page outlining any related functions. The operator
only has to press the F-key related to the function desired and that page will appear. For example,
if the operator is viewing the mold close text page, he can change the display to the set value
graphics page by pressing key F2.

The “ESC” Escape key, when pressed will quit the help text program. See page for description of
help text feature

The double arrow key is not used as of 21-1-97.

Figure input keys and leafing keys

The operator will use these keys to enter the machine set val-
ues into the data input field.
7 8 9 + The “Increase/Decrease” keys are used to increase or
_ decrease the value within the cursor by one increment, e.g.
4 5 6 87.5 is increased to 87.6 by pressing the “+” increase key or to
87.4 by pressing the “-” decrease key.
E
1 2 3 N
T The +/- key is used to set the sign of the input value either +
E or -.
+/- 0 . R
The ENTER key has the same function as the “storage” key
which is describe later in the chapter.

The operator can move the cursor to the left, right, up or down
by pressing the respective arrow keys.
The scroll keys at the top of this display allow the operator to
move forward or backward within a specific page function. For
example, between parameter pages on the QDS, or within the
System Data Report function.

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Storage key

When the operator presses this key, whatever appears within the data entry
ENTER field will be entered into wherever the cursor is placed.

Repeat keyr

The operator can use this key to enter the same value a number of times.
For example, if 10 equal injection speeds were to be entered, move the cursor
to the first injection speed. Enter the first speed, move the cursor to the sec-
ond injection speed and press the duplicate key for each of the remaining 9
speeds. The remaining 9 speeds will be duplicates of the first injection speed.

Error acknowledgment keyt

The operator can individually check through the errors which appear on the

! error page with this key. With each press of this key the first error on the error
page is scanned to see if it still exists. If it does still exists the error message
will re-appear at the bottom of the error page and the second error on the list
will move up to the first position for examination.

The error messages also appear on most other pages in the bottom right
hand corner of the video display monitor. There you will see the first error that
would be on the main error message page. Also, just to the right of the single
error message would be a number which indicates how many error messages
are listed on the main error message page.si

If you are on the mold closing page, for example, you can individually scan
through the error message listing in the same manner as described above. If
the error condition does not still exist, the error message will be removed from
the display and the numerical total will decrease.

The operator can acknowledge all error messages simultaneously by switch-

ing the manual/automatic switch from automatic to manual and back.

Input clearing key

The operator can clear out the data entry field by pressing this key.

CLEAR

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1.5 PROCEDURE FOR DATA ENTRY

Step1. Move the cursor to the set value field.

Step2. Use the numerical keys to choose the value to be entered into the data entry field.

Step3. Press 'ENTER'. Whatever value was in the data input field will be entered into the set
value field.

NOTE!

Some functions require the operator to switch the program

'ON' or 'OFF'.

• ON : Enter a '1' into the data entry field and press 'ENTER'.
The program will switch from 'OFF' to 'ON'.

• OFF : Enter a '0' into the data entry field and press 'ENTER'.
The program will switch from 'ON' to 'OFF'.

• YES : Same as "ON"

• NO : Same as "OFF"

By pressing the keys below, the screen image belonging to that particular function will appear on
the monitor.

Quality
Mold Mold Screw Data Main Print
Ejector Injection Injection Out
Close Open Hold Refill Programs Menu

Q
S
Cores Quick Carriage Heats Robot Special Error
Setup Function Message s
Mold Micrograph/
Parameters Microplast

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Any screen image that appears can be printed out by pressing this key. Of
course, the printer must be connected according to the instructions given in this
manual.

To assist the operator in diagnosing machine problems, a numerically indexed

error message display will appear when this key is pressed. See 'ERROR
MESSAGES'.

Pressing this key will put the controller into manual mode

To run in semi-automatic mode, press this key.

To run in automatic mode, press this key.

Pressing this key puts the controller into the set-up mode. In effect, the mold
open/close speed and pressure will be reduced. This program is particularly
useful when installing or removing molds. In addition, to assist in purging and
refilling the screw with the carriage in the retracted position, zero back pressure
will be applied when in the set-up mode.

This key is used on machines equipped with metric/imperial conversion options.

Each time this key is pressed the controller will switch the monitor display
between available options. This option is configured by parameters 36269 and
36278. Parameter 36278 sets the password access level to changes units and
parameter 36269 configures the machine with either imperial or metric units.

If the machine is supplied with a disk drive and a “Help Disk”, or a RAM card, this
key gives the operator access to the help text on the RAM card or Help disk

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1.6 IBM KEYBOARD

An IBM style keyboard can be connected to the controller faceplate. The keyboard will give the
operator the facility to select screen pages and enter values for parameters.
The list below gives the keys strokes required to select the main screen pages, pressing those
keys again will toggle through the various screen pages available or the appropriate “F” key can
be pressed to select the screen page.
The “F” keys on the keyboard correspond to the “F” keys on the faceplate.
The keyboard “arrow” keys, left, right, down and up, move the cursor in that direction.

KEYS SCREEN PAGE

Alt S MOLD CLOSE
O MOLD OPEN
A EJECTORS
K CORES
W MOLD PARAMETERS
V QUICK SET UP
E INJECTION
N BOOST TO HOLD
D SCREW FEED
P CARRIAGE
T HEAT
G MICROGRAPH PLUS
Q QUALITY PROGRAMS
M MAIN MENU
F1 PRINT
H ROBOT
X SPECIAL PROGRAMS
F ERROR PAGE
Ctrl A CHANGE UNITS METRIC - IMPERIAL
C HELP
R AUTO REPEAT
F8 ESCAPE HELP
F9 BACK TO PREVIOUS SCREEN PAGE
F10 CLEAR ERRORS
The “back space”, “page up” and “page down” keys provide the same function on the controller
screen.

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1.7 ON SCREEN HELP TEXT

Help text is available via a RAM card or from a Help floppy disk. At any screen page , press the
QUESTION MARK

General Help
General information on, and the operation of the injection molding machine.

• Help with the help text.

• Operation of an injection molding machine.
• Putting into and taking out of operation of the machine.
• Molding cycle of an injection molding machine.
• Text input.
• Modes of operation; MANUAL, SET-UP, SEMI- AUTOMATIC and FULLY AUTOMATIC.
• Preparation for, and mold mounting.
• Machine operation setting sequences.

This screen is displayed when no specific item is selected and the HELP key is pressed, or the
information requested does not exist within the help function.

Help for Variables

Help information is provided on the selected variable. On any screen page, select a variable with
the cursor and press the HELP key. Text related to that variable will be displayed, the text is also
available in the Controller Operator or Controller Maintenance manuals.

Error help
Help information is provided on the selected error message. If the machine error screen page is
selected and an error number highlighted with the cursor, text related to that error will be
displayed. The text is also available in the Controller Operator manual.

When the help key is pressed a text box will be displayed. Initially the box will display the message
while the Help Disk or RAM card is being accessed.

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If the Help Disk or RAM card is present the text box will display a title related to the type of
information requested. In the example, help has been requested on the variables A mold open
position.

In the right hand corner of the text box a symbol of a disk drive or a RAM disk will be displayed,
confirming the source of the help text.

If no RAM disk or help disk is present the text box will display the message
“ Insert disk”. Press escape to exit the help function, insert the help disk and press the help key.

If a disk other than a help disk has been inserted, the text box will display the message
“Help-file not found”.

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1.7.1 F1 - INDEX

Pressing F1 Index will display the table of content of the “General Help” on-line manual. Using the
up/down keys on the controller faceplate, move the cursor to the required item and press ENTER
to display the text on the that selection. Further headings within the text can be selected and
pressing ENTER will display that information. A FORWARD or BACKWARD function key will be
displayed to enable the operator to move forwards or backwards through the selections made.

Disk Drive RAM Disk

1.7.2 F2 - PAGE

Press F2 Page will display the description of the selected screen page.

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1.8 KEYSWITCH

The keyswitch is located at the bottom of the switch panel on the controller cabinet.

ON
OFF PR

The key can be withdrawn from the keyswitch in all three positions.

• Position OFF: The following functions are blocked:

• Set value input
• Debugger/change of constants
• Diskette Read/Write

If you are concerned about maintaining consistent production,

serious consideration should be given to leaving the keyswitch in
this position and storing the key with a fully competent person. This
is one way of keeping track of program changes, while still allowing
viewing access to the more important screen pages.

• Position ON: The following functions are blocked:

• Service Menu access
• Diskette Read/Write

• Position PR:All functions are possible in the program (PR) key position.

The printer function is possible in all key positions.

1.9 CC100 DISKETTE

On the EC100/CC100-A03, the disk drive is mounted on the side of the controller cabinet. This is
where the diskette is inserted for reading in or writing out machine programs. Refer to the diskette
section in chapter five of this manual for a complete description of this function and how to use it.

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1.10 SCREEN DISPLAY

When the control voltage switch is turned on, a screen display similar to the one shown below will
appear.

The controller will first carry out a hardware and software test to determine if any malfunctions
currently exist. During the test, this symbol will be displayed:

The hour glass is displayed, indicating that the test is still active. While the test is active, no screen
pages are accessible and the motor will not start. When the test has been successfully completed,
the MANUAL symbol will be displayed:

The manual symbol is displayed, indicating that all pages are now accessible and that the motor
can now be started.

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The semi automatic symbol is displayed, indicating that the machine is running in the semi
automatic mode.

The automatic symbol is displayed indicating that the machine is running in the automatic mode.

This automatic symbol indicates that the machine was running in the automatic mode but an error
has occurred that has stopped the cycle.

This symbol indicates that an error or errors have occurred within the machine system.

These symbols indicates that the main motor is running and the barrel heating function is working.
The symbols are not displayed if that function is NOT working. If the “motor” symbol is displayed
and not the “heat” symbol, this then indicates, that the heats are not switched on but the motor is
running. If the motor symbol is not displayed, then the motor is not running.

If the software or hardware test has identified a malfunction, a specific System error number or
Ebias error number will appear at the bottom of the screen. Refer to the maintenance manual for
more information on these types of errors.

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1.11 SCREEN MESSAGES

A. Dialog area

The text appearing here informs the operator of the maximum and minimum range of the set
values as the cursor is scrolled down through the variables. Entering a value out of range will
result in the dialog area being highlighted in red, and the value entered will not be taken over.

B. Data input field

Move the cursor to the desired set value position, enter the new set value via numerical input keys
and press the “Enter” key for the new value to be taken over. The blue data entry box that appears
as the cursor is moved, indicates approximately the number of digits that can be entered as an
input value.

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C. Sequence error message

Running messages, warnings and errors which arise during operation are indicated here. The
figure next to the message indicates the total number of occurred errors. A star next to the
message indicates that more than nine errors are active.

All error messages are visible at the same time on the error listing page, key

D. Operating condition

Here the present mode of operation can be seen:

MANUAL

In MANUAL mode all functions are controlled by manually operating

= the control keys. The movement lasts as long as the key is actuated
and/or a certain end position is reached. All movements occur at the
set speeds and pressures

SEMI AUTOMATIC

If all the conditions for running the machine are satisfied, the machine
= will complete one cycle when the operator gate is opened and closed
or the green start button is pressed. Refer to chapter 2 of this manual
for the START UP PROCEDURE

AUTOMATIC

If all the conditions for running the machine are satisfied, the machine
= will continue to repeat the cycle automatically when the operator gate
is opened and closed or the green start button is pressed. Refer to
chapter 2 of this manual for the START UP PROCEDURE

SET UP

= In the SET UP mode the machine movements are controlled manu-

ally, but at reduced speeds and pressures. SET UP can only be
selected from MANUAL mode.

E. Date and Time display

This line displays the current date and time as set on the DATE/TIME page found under the
SERVICE menu. The colon in the time display will flash once a second, indicating that the
program is running.

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1.12 SCREEN MARKS

As an indication of outputs, inputs and profile points, so-called "marks" appear on the screen as
lighted rectangular boxes. These marks light up when the relevant output, input, profile point,
temperature range, switch-over point or time sequence is active or completed.

For example, on the mold closing page, the mark for 'V2' lights up when the mold is moving at the
second closing speed.

When the mold is opened to point 'A', the mark beside the opening stroke position A= 20.00 in.
will light up.

The operator can use these screen indications to watch the sequencing of the machine functions
during operation. As well, the operator can monitor these marks to determine a possible problem
area if these marks are not lighted. If a problem is suspected, the marks can be monitored while
operating the machine in manual mode.

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1.13 SCREEN MARK COLORS / CC100

Generally, screen mark colors indicate a different function.

Light Blue - inputs from limit switches
Red - means by which the boost to hold transition was effected.
This could also indicate certain special functions.
Yellow - heat within tolerance or a certain speed is in effect
Pink or Mauve - stroke position reached
Green - specific pressure that is in effect
Dark Blue - timer is timing

Running Display

During the normal operation of the machine, the colon of the time display in the upper right hand
corner of the monitor will continue to flash off and on approximately once every second.

If the colon continues to flash on and off, this indicates that the sequence program is running
correctly.

If the colon disappears or does not flash, this indicates a software problem and the machine will
stop.

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1.14 SPECIAL SCREEN FEATURES

NOTE!

For “System Versions” less than SV 2.00.

The following 'function frame' will be displayed with CUSTOMER password entry.

SYSTEM SERVICE
SETUP MENU

PRESS
F3 SYSTEM SET UP

The customer CAN access this page.

The settings shown on the screen page example are factory default setting. Unless there is a
problem with the printer output, Engel suggests that the settings remain unaltered. Refer to the
manual provided with your printer for alternative settings.

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1.14.1 CURSOR

entering “zero”

By default when the ENTER key is pressed without entering a value into the “Data input field” a
zero is entered where ever the cursor is placed. The option on this line is to have either:

0 = “entering a zero without preselection”

1 = “entering a zero with preselection”

If “with preselection” is selected a zero must be entered into the “Data input field” before the
controller will accept that value. This feature safeguards against inadvertently entering a zero.

Screensaver

The screen blanking feature can be adjusted to suit the customer’s requirements; the default is
screen blanking after ten minutes (600 seconds) of inactivity. Move the cursor down to the screen
save time, enter the required delay time in seconds and press the ENTER key to change the
setting.

PRINTER

Destination device

This line area allows the customer to choose the hard copy destination device, the choices are:
0 = No device
1 = Printer
2 = Floppy

The normal setting would be 1 = Printer, as the output device most often required.

If the floppy drive is chosen as a destination device and the “print screen” key is pressed, the
screen image will be saved to disk in a PCX format. The first file name will be HCOPY000.PCX
and subsequent file names will be incremented by one.

Type
This line gives the option of choosing different types of printers.
0 = 9 pin dot matrix
1 = 24 pin dot matrix
2 = not available
3 = HP DeskJet 800 series

The HP DeskJet will require a serial to parallel converter, such as the “Extended Systems ESI-
2634 SerialLink”. The SerialLink is introduced between the printer cable and the printer connector.
All print functions and features will operate as normal.

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Timeout graphic printer

In some cases the printer buffer may overflow causing a “PRINTER TIMEOUT” error. This
problem may be resolved by increasing the “graphic printer timeout” time.

HARDCOPY

without softkey 0 off

Enter a 0 on this line to turn this function OFF, a hard copy of a screen page to a printer or a soft
copy to a floppy disk WILL display the soft key function frame.

without soft key 1 on

Enter a 1 on this line to turn this function ON, a hard copy of a screen page to a printer or a soft
copy to a floppy disk WILL NOT display the soft key function frame.

A “hard copy abort” function key will be displayed, to enable the operator to end the hard copy
function, if required.

NOTE!

For “System Version” greater than SV2.00, only these

settings shown below are displayed.

NOTE!

Printer, Destination device and Hard copy settings are

found under Main Menu + F1 Printer function key.

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2. START - UP

1 STARTING PROCEDURE
The following instructions assume that all connections that allow for the machine to operate
correctly have been completed.

Circuit breakers must be in the ON position and water and air (if equipped) hoses must be
properly connected.

Step 1: Turn on the control voltage.

There is a control voltage switch on the CC100 machine switch panel.
If the emergency stop button is engaged then it should be disengaged by turning to the
right until it springs out. Additional emergency stops must also be disengaged.

Step 2: Ensure all safety gates and safety covers are closed.
The motors will not start if the operator safety gate is open but, once started, will
continue to run if the safety gate is opened.
The switches on the non-operator (back) safety gate and on safety guarding around a
robot work area, function in the same way as the emergency stops - the motor will not
start or run if the gates are open.

Step 3: Turn on the cooling water supply.

Ensure that the water supply inlet and water supply outlet have been properly
connected to allow for cooling water flow (i.e. heat exchanger, feed throat, platens,
mold, etc.)

Step 4: Check the ERROR page to ensure that there are no errors that will interfere with the
operation of the machine, certain error messages will not prevent the machine start up.
Check the error listing in the Controller Operator manual for more detailed information.

Step 5: Reset the controls by switching the program interruption button "PU" (manual/
automatic) from manual to auto and back to manual. The motor will start only when this
switch is in the manual position.

Step 6: Turn on the heat selector switch.

The heat selector switch has an OFF position and an AUTO position. Turn this selector
switch to AUTO. It will usually take 15 to 20 minutes for the screw and barrel to heat
up to operating temperature.

Step 7: Activate the motor START switch.

This will start the electric motor(s) that drives the pump system.

Step 8: Monitor the hydraulic oil temperature and the barrel temperatures.

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24 2. START - UP 8/10/02
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3. SET - UP TO RUN PRODUCTION

1 GENERAL CONSIDERATIONS - MOLD / MATERIAL CHANGE
If the type of plastic material or the mold in the machine is changed, consideration must be given
to the capability of that machine to perform the required molding operation.

The method of determination is to consider the following parameters:

• Specific gravity of the plastic material as specified by material manufacturer.
• Tons per square inch needed to mold material as specified by material manufacturer.
• Area of the molding
• Volume of molding, either in cubic inches, cubic centimetres or weight.

Check the Engel specification sheet for the machine in question:

• Clamp force
• Shot size
• Screw diameter
• Screw stroke
• Platen size

Consider the example of an ES85 injection molding machine with:

• Clamp force = 85 Ton
• Injection unit = 330
• Screw = 1.378"
• Screw stroke = 6.3"
• Injection capacity = 9.4 cubic inches
• Shot size for material with SG of 1 = 4.97 ounces
• Platen size = 21.73" x 20.08"

Engel specifications always give the shot size of an injection unit as it relates to a material with a
specific gravity of 1.
Consider a plastic material which has a specific gravity of 1.3, if it is used with the machine given
as an example above, the shot size will be 6.461 ounces (4.97 x 1.3 = 6.461).
If the molded part is 6" x 2" then the area is 12 square inches.
The material being considered is specified by the manufacturer as requiring between 3 to 5 Tons
per square inch for molding. Therefore this part requires between 36 (12 x 3) Tons to 60 (12 x 5)
Tons of clamp force to mold the part with the specified material.
The size of the mold must be taken in to consideration, because a part may only require 60 tons
of clampforce but the mold may be too big to fit on the platen of an ES85 and will therefore require
a bigger machine just to be able to mount the mold.
Wall thickness must be taken into consideration when determining the machine required. If the
ratio of injection flow length to wall thickness is greater than 200, then higher injection speed and
greater specific injection pressure will be required. Flow length is determined from the point of
entry into the mold to the furthest point from the point of entry.

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2 INSTALLING MOLD

NOTE!

It is the customers responsibility to ensure that the mold

is safely and securely installed.

Step 1. Set velocity and pressure to a minimum by activating the set-up mode on the program
selection panel.

Step 2. Make sure that the ejector rods are not in the way.

Step 3. Open the clamp to allow plenty of room to install the mold.

Step 4. Before lifting the mold, ensure that the two mold halves are safely clamped together.
Lower the mold into position and insert the location ring, located on the mold, into the
insertion ring (female end), located on the stationary platen.

NOTE!

Even in set-up mode damage may occur if the clamp is

closed on a mold that is misaligned. If at any time, during
the following steps, the mold shifts then it must be
realigned before allowing the clamp to close.

Step 5. (Toggle machines only) Still in the set-up mode, switch to the mold closing page and turn
the automatic mold height adjustment program on.
Turn the manual clamp switch to the close position and hold the switch in the close
position until the automatic mold height adjustment program switches off. At this point the
toggle should be locked and the mold held between the two platens.

Step 5. (Direct hydraulic machines only) Still in the set-up mode, switch to the mold closing page
and turn the manual clamp switch to the close position. Hold the switch in the close
position until the moving platen touches the back of the mold and the actual mold
position SFx = 0 (at least 5 seconds). At this point the mold should be held between the
two platens.

Step 6. Turn the motor(s) and control voltage off and use an approved lockout procedure to
ensure the machine is disabled. Check that clamp controls are disabled.

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Step 7. Using the proper bolts and clamps, fasten the mold to the platens. The mold bolts should
be screwed into the platens to a depth of at least one and a half times their diameter.
For example, a 0.75 inch bolt should be screwed into the platen at least 1.125 inches.
(i.e. 0.75 x 1.5 = 1.125).

Step 8. Any additional equipment, such as water lines, should be connected at this time.

Step 9. When the mold installation is secure and complete, remove the straps or tie-plate
securing the mold halves together.
Remove the machine lockout and restart the machine.

The mold height is set, but the clampforce must still be adjusted. See section "Setting
Clamp Force" in this chapter.

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3 SETTING MOLD PROTECTION PRESSURE

The purpose of mold protection pressure is to protect the mold, from anything trapped between
the two mold halves during mold closing. The pressure in the mold protection zone is set to a level
which should not be high enough to allow damage to occur to the mold.

NOTE!

You are responsible for setting this pressure correctly.

The most critical point to keep in mind is that 'P1' (high clamping pressure) must not come into
effect until the mold halves just touch. If 'P1' does come into effect before the mold halves touch,
the repeated "banging" will eventually damage the mold.

3.1 TOGGLE LEVER MACHINES

Before setting the parameters of mold protection pressure, it is important to understand how those
parameters interrelate on the toggle machines.

In order to make the mold closing function, and the mold protection pressure in particular, as
sensitive as possible, the control system monitors both the position of the platen and the position
of the toggle lever. During the initial start up of the machine, the non-linear movement of the platen
was recorded and combined with the linear movement of the toggle crosshead to come up with a
relationship between the two movements. That relationship will be shown by the ACTUAL MOLD
POSITION, SFx, on the mold closing page, and the ACTUAL TOGGLE POSITION, SKx, on the
clamp force page.

RELATIONSHIP BETWEEN TOGGLE LEVER AND MOLD STROKE

100%
23.62

MOLD
STROKE

100%
0% TOGGLE LEVER STROKE 26.97

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Mold protection starts with pressure P2a at mold position G1.

Mold protection pressure ends with pressure P2e at mold position G2f which is equivalent to
toggle lever position G2.

It is important to note that at mold position 0.0 inches., the toggle lever is still some distance from
the toggle locked up position B. In other words, the mold might be at position SFx = 0.0 inches,
and the corresponding toggle lever position might be SKx = 1.48 inches.

Step 1. Close the mold in SET UP, until the mold halves touch, and make a note of the SKx
value.

Step 2. Enter the value observed in SKx into variable G2. This will be the termination point of
mold protection pressure and the beginning of clamping pressure P1, equivalent G2f
mold position will be set at the same time. At this point, if you decrease the mold height,
G2 must also be increased.

Step 3. Determine the distance of the mold protection zone. Specifically, the starting point of the
mold protection zone, G1, depends on the design of the part and of the mold.

Step 4. Set the mold protection pressures, P2a to P2e to 50%.

Step 5. Set the mold protection time ZF to 99 seconds.

Step 6. Open and close the mold several times in the manual mode, and monitor the actual mold
protection time, ZFx. Set ZF to .5 seconds higher than ZFx.

Step 7. As you open and close the mold, start reducing the value of the P2a to P2e pressures
until you see a significant increase in the mold protection time ZFx.

For most applications these settings will be quite suitable. At this point the pressures are only just
enough to get the clamp through the mold protection zone and therefore should have little
available pressure to cause damage in case of an obstruction between the mold halves. Any
further reduction in pressures will make the mold protection more sensitive but at the expense of
cycle time.

There are five, totally independent, mold protection range, pressure and speed settings available.
The correct settings for mold protection will depend upon the application and will be at the
discretion of the individual setting up the machine

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3.2 DIRECT HYDRAULIC MACHINES

Step 1. Set G2 or G2f to 0.01 in. This will be the termination point of mold protection pressure
and the beginning of clamping pressure.

Step 2. Determine the distance of the mold protection zone. Specifically, the starting point of the
mold protection zone, G1, depends on the design of the part and of the mold.

Step 3. Set the mold protection pressure to 50%. P2a to P2e pressures should be set to the
same value unless you have some reason for a graduated mold protection pressure.

Step 4. Set the mold protection time to 99 seconds.

Step 5. Open and close the mold several times in the manual mode, and monitor the actual mold
protection time, ZFx. Set ZF to .5 seconds higher than ZFx.

Step 6. As you open and close the mold, start reducing the value of P2a to P2e pressures until
you see a significant increase in the mold protection time ZFx.

For most applications these settings will be quite suitable. At this point the pressures are only just
enough to get the clamp through the mold protection zone and therefore should have little
available pressure to cause damage in case of an obstruction between the mold halves. Any
further reduction in pressures will make the mold protection more sensitive but at the expense of
cycle time.

There are five, totally independent, mold protection range, pressure and speed settings available.
The correct settings for mold protection will depend upon the application and will be at the
discretion of the individual setting up the machine

3.3 DIRECT HYDRAULIC MACHINES (30 AND 55 TONS) - ZEROING SFX

When the mold stroke is calibrated initially, there is no mold installed in the machine. In this way,
we can calibrate the total stroke and "teach" the machine to recognize a certain voltage as
representing a specific position.

When the mold is installed, we use the same calibration data to reflect the stroke position, but now
a new zero position must be identified without interfering with the calibration data. Whenever you
install a different mold size in a direct hydraulic machine, you must re-zero SFx.

Step 1. Mount mold.

Step 2. Put the controls into the Set-up mode.

Step 3. Activate the mold close button.

Step 4. Hold the mold close button until SFx on the mold close page resets to 0.0 inches.

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4 SETTING CLAMP FORCE

4.1 TOGGLE

NOTE!

If the START CLAMPING PRESSURE variable G2 has

been set correctly prior to adjusting the tonnage, G2
must be increased at each decrease of the mold height.
Adjust G2 so that CLAMPING PRESSURE variable P1
activates just as the two mold halves touch.

Step 1. Set the program selection to the manual mode

Step 2. On the mold close page set 'P1' to 100%.

On the clamp force page, enter the required clamping force in the "Set Value" data field.

Step 3. Open and close the mold so that an "Actual" value of clamping force appears on the
screen. The actual value will be compared with the set value and the automatic clamp
force adjustment program will cause an adjustment by the mold height motor until the
actual value of the clamping force is within the allowed tolerance range as set by
SW35312. Within this tolerance range there is no clamping force adjustment.

4.2 TOGGLE WITHOUT CLAMPFORCE TRANSDUCER

Step 1. Set the program selection to the manual mode.

Step 2. Set clamping pressure (P1) to 100%

Step 3. Use the mold height key switch to manually adjust the mold height increase or decrease.

Step 4. Decrease the mold height until the toggle just barely locks in. This is the maximum clamp
force for the machine.

Step 5. If the machine is not equipped with a clampforce transducer, a reduction in tonnage can
be accomplished by reducing 'P1' and following steps (3) and (4). For example, a 300
Ton machine can be adjusted to approximately 150 Tons by reducing P1 to 50%.

4.3 DIRECT HYDRAULIC

Step 1. Set the amount of tonnage desired in the CLAMPFORCE SET datafield. The machine
clamping pressure will be automatically adjusted according to the tonnage desired.

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5 ADJUSTMENT OF INJECTION STROKE AND PRESSURE

Step 1. Stroke is set by 'C1'. Generally, it is a matter of trial and error until the correct stroke is
found. Knowing the shot size capacity of the machine and the required size of the part
provides a reasonable target for initial settings. It is always better to start with short shot
conditions and build up to a full mold cavity.

Step 2. P6', injection boost pressure should be set high enough so that there is enough pressure
available to maintain control of injection speed. Initially set 'P6' high but be certain to
switch into hold pressure before the mold cavities are full. Start to lower 'P6' until 'ZSx',
actual injection time, starts to increase. This is the point where you have just lost control
of the injection speed. Now increase 'P6' approximately 200-300 psi.

Step 3. Holding pressure should be set to the same level as the actual hydraulic pressure, 'PHx',
which was required to fill and pack the mold cavities. The holding pressure is used to
maintain pressure in the mold cavities until the gates freeze, and to "dress up" the
outside appearance of the molded part. Use the 10 step profiling to reduce over-packing
and stress on the molded part.

Step 4. It is extremely important to the finished part to switch into hold pressure before the mold
cavities reach too high of a peak pressure. If mold cavity pressure reaches a very high
value, part release could become a problem. The CC100 machine has five methods of
switching from first stage injection to hold pressure:
• Time dependent (Z1)
• Stroke dependent (C3)
• Hydraulic pressure dependent (PH)
• Mold cavity pressure dependent (PF)
• Externally via digital input (C3E)

Step 5. Holding pressure is set by pressures 'P7-P16' and will continue until timer 'Z2' times out.
As mentioned in step 3, try to set the first hold pressure to the pressure existing at boost
to hold transfer and then profile the pressures down.

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6 ADJUSTMENT OF CLAMP AND EJECTOR

A - wide enough to allow part to drop out or be removed.

W1 - mold closing slowdown should be set to allow for "soft" touching of mold.

W2 - mold opening slowdown should be set to allow clamp to slow down before reaching 'A'
(cushion opening).

W3 - mold closing slow down

W4 - first mold open position, to allow for slow demolding.

G1 - start of mold protection pressure. 'P2' in. Also start 'ZFx' timer.

G2f- end of mold protection pressure. P2 out, P1 in.

KS - position for corepull to move in. Clamp will stop until corepull-in limit switch is activated.

K0 - position for corepull to move out. Clamp will stop until corepull-out limit switch is activated.

L - position which indicates that the ejector is back. If possible, do not use 0.0 inches as the
'L' position.

L1 - position which indicates that the ejector has achieved its full set stroke

L2 - position for ejector shake if desired. Ejector will "shake" between 'L1' and 'L2' for counter
'AZ' number of times.

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7 ADJUSTMENT OF NOZZLE STROKE AND PRESSURE

Step 1: Make sure that the nozzle opening is aligned with the sprue bushing opening. In
general, it is best to have a slightly smaller nozzle opening. As well, make sure that
the nozzle and sprue bushing radii match.

Step 2: If sprue break is to be used set 'K' to the required sprue break position. Often sprue
break is used if the cooler mold contributes to a "freezing off" of the nozzle.

Step 3: Set the nozzle back speed and the two nozzle forward speeds to allow smooth
operation of the sprue break function and a "soft" touching of the nozzle against the
sprue bushing.

Step 4: The nozzle forward pressure should be set to keep the nozzle pressed against the
sprue bushing during injection. The exact pressure depends on the specific injection
pressure. In other words, if the nozzle is being pushed back during injection, 'P5' is set
too low. 'P5b' pressure should set to lower the pressure, therefore force, against the
stationary platen when the mold opens. Of course, 'P5b' is effective only when sprue
break is not employed in the machine cycle

Step 5: Set timer 'Z5a' long enough so that nozzle forward pressure has time to build up to the
desired level before the nozzle forward solenoid, 'S5' is deactivated. Check the
manual gauge to verify the desired pressure.

Step 6: To re-zero the nozzle, SDx, close the mold and activate the 'B' input. In manual, move
the nozzle forward and hold until SDx switches to zero.

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8 MANUAL TO AUTOMATIC CYCLE

The following instructions assume that the oil temperature is within the set operating range, the
barrel temperatures are within their specific tolerances, and that all safety devices have been
checked and verified by the maintenance department as being fully operational and correctly
adjusted.

Step 1. In manual, make sure that:

• the mold is at position 'A'.
• the ejector is at position 'L'.
• the screw is at position 'C1'. (and 'C2' if decompression before or after screw refill
used).

Step 2. Switch the selector switch on the pushbutton panel to automatic

Step 3. Press the automatic mode button on the control unit (or semi-automatic).

Step 4. Open and close the front safety gate, or press “Cycle Start” pushbutton(if so equipped).

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4. SHUT DOWN PROCEDURE

1 MACHINE SHUT-DOWN
The following general shut-down procedures apply when you are molding with common plastic
materials such as polyethylene (PE), polypropylene (PP), polystyrene (PS), etc.

Step 7 Slide the raw material hopper back and away from the feed throat so that no further
material drops through to the plasticizing screw.

Step 8 Switch the heat selector switch to the OFF position.

Step 9 Engage the manual or semi-automatic mode of operation.

Step 10 Move the carriage unit back and away from the carriage forward position.

Step 11 Reduce injection pressures and "purge" out the barrel by injecting and screw feeding
until most of the material has been removed from the barrel.
Clear away and dispose of the contaminated purged material.

Step 12 Examine the mold cavity and clean if necessary.

Afterwards, close the mold until the two mold halves are just touching but no clamp
force is being applied. This keeps the mold cavities contamination free during the
shutdown period.

Step 13 Switch off the control voltage selector switch.

Step 14 Switch off the main breaker on the power-supply cabinet.

Step 15 Turn off the cooling water supply.

NOTE!

A. If there is any possibility of the temperature falling

below freezing make sure that all water has been
removed from mold cavities, heat exchangers, water
towers, etc.

B. If the machine is equipped with an accumulator,

ensure that the accumulator has been relieved of any
pressure. Monitor the manual gauge to ensure that this
important step has been carried out.

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38 4. SHUT DOWN PROCEDURE 8/10/02

 EC100 / CC100 - A03 OPERATOR:

5. SCREEN PAGES

1 MAIN MACHINE FUNCTION KEYPADS

Q
S
When the operator presses any of the above keypads, the associated screen images and
functions will appear. Access into any sub-directories or functions can be conducted through the
use of the function frame display keys F1 - F8, as shown below.

ESC F1 F2 F3 F4 F5 F6 F7 F8

10/10/02 5. SCREEN PAGES 39

 EC100 / CC100 - A03 OPERATOR:

2 MOLD CLOSING
This screen page is typical of a machine with:
SYSTEM VERSION LESS THAN SV 2.00
NOTE OR
SYSTEM VERSION SV 2.00 OR GREATER, BUT WITHOUT
THE “AUTOPROTECT” MOLD PROTECTION PROGRAM.

PRESS

This screen page is typical of a Toggle lever machine.

Refer to the line numbers on the following pages for the description of each variable.

F1 MOLD CLOSING
F2 SET VALUE GRAPHICS
F3 AUTOPROTECT
F4 CLAMPFORCE
F5 MOLD HEIGHT
F6 INJECTION COMPRESION/COINING

40 5. SCREEN PAGES 10/10/02

 EC100 / CC100 - A03 OPERATOR:
1 .. . A C T U A L M O L D P O S I T I O N SFx = 20.00 in

This is the actual value of the mold position at any time during the cycle. Since it is an actual
value the operator cannot move the cursor to this position and cannot change the value that
appears on this line.

2 .. . M O L D O P E N IN G P O S IT I O N A = 20.00 in n

This is a value that the operator sets and indicates how far the mold will open during the
mold opening function. Of course, it also represents how far the mold will close during the
mold close function.

3 .. . 1 . C L O S I N G S P E E D A - W3 V1 = 60 %

This is the percentage speed at which the moving platen travels between point 'A', mold
open, and point 'W3', the start of the second closing speed. The percentage speed is set by
the operator at his discretion.

4 .. . 2 . C L O S I N G S P E E D W3 - W1 V2 = 40 %

This is the percentage speed at which the moving platen travels between point 'W3', the
start of the second closing speed, and point 'W1', the start of the third closing speed. The
percentage speed is set at the discretion of the operator.

5 .. . 3 . C L O S I N G S P E E D W1 - G1 V3 = 15 %

This is the percentage at which the moving platen travels between point 'W1', the start of the
third closing speed, and point 'G1' the start of mold protection pressure. This speed is
employed most effectively when it is used as a slow-down before entering the mold
protection zone.

6 .. . S TA R T 2 N D S P E E D V2 V3 = 2 .0 0 i n

This is a value that the operator sets and represents the point during the mold close function
where the first closing speed ends and the second closing speed begins.

7 .. . S TA R T 3 R D S P E E D V3 W1 = 1 .0 0 i n

This is a value that the operator sets and represents the point during the mold close function
where the second closing speed ends and the third closing speed begins. Try to set this
position before stroke position G1.

8 .. . S TA R T M O L D P R O T E C T I O N G1 = 0 .7 0 i n

This is a value that the operator sets and represents the actual mold position during mold
closing and where mold protection pressure begins. It is important to note that 'G1' is related
to the mold position, 'SFx'.

10/10/02 5. SCREEN PAGES 41

 EC100 / CC100 - A03 OPERATOR:
* These lines do not appear with “Autoprotect” or on SV2.00 or greater screen page.

These are values that the operator sets and are the percentage pressures that will be
applied to the clamping cylinder during the mold protection pressure function. The mold
protection pressure function begins at mold position "G1" and ends at toggle position "G2".
The stroke range of each pressure setting can be set on the set value graphics page. The
5 mold protection pressures P2A-P2E are completely independent and each can be set
higher or lower than the others to make this pressure setting extremely flexible.

These are values that the operator sets and are the percentage speeds of the mold during
the mold protection pressure function. The mold protection speed function begins at mold
position "G1" and ends at toggle position "G2". The stroke range of each speed setting can
be set on the set value graphics page. The 5 mold protection speeds V4A-V4E are
completely independent and each can be set higher or lower than the others to make this
speed setting extremely flexible.

* 11 .. S TO P M O L D P R O T E C T I O N G2f = 0.00 in

This is the mold position, during the mold close function, where mold protection pressure
ends and full clamping pressure begins. For toggle machines, this position should not be set
on this page. Instead, set the G2 toggle position on the Clamping force page, so that the
mold halves just touch before the machine goes into high clamping pressure. 'G2' must be
set greater than zero in order to engage full clamping pressure.

1 2 . .. M O L D P R O T. T I M E : ZFx = 0.00 ZF = 0.00 s

This is the actual time measurement of time that the mold protection function was in effect,
that is the amount of time for the mold to travel between mold position G1 and toggle
position G2.
ZF is a value that the operator sets as a limit to the time during which the mold protection
function is in effect. After reaching mold position G1, the start of mold protection, the mold
protection time ZFx will start timing. If there is an obstruction between the two mold halves,
the machine will still try to close under mold protection pressure P2a - P2e for the time ZF.
If the mold has not reached toggle position G2 by the end of time ZF, the clamp will open to
point A and go into alarm condition.

1 3 . . S TO P M O L D A F T E R M O L D P R O T. A L A R M NO

If the operator enters a 1 for yes the mold will stop as soon as the controller sees a mold
protection alarm. This line overrides the settings on line 14.
If the operator enters a 0 for No, and the controller sees a mold protection alarm, the mold
will try and close for as many times that are set on line 14.

42 5. SCREEN PAGES 10/10/02

 EC100 / CC100 - A03 OPERATOR:
1 4 . . T RY A G A IN C O U N T E R Max = 0

If the mold protection alarm is activated, and this counter is set higher than zero, the control
will open the mold, eject, and try to close again for the number of times set for this counter.
In effect the machine will try to clear itself of the obstruction, up to a maximum of 9 times,
before actually stopping due to a mold protection alarm.

This screen portion of the screen page is typical of a Direct Hydraulic machine.

S TO P M O L D P R O T E C T I O N G2f = 0.001 in

This is the mold position, for direct hydraulic machines, where mold protection pressure
ends and full clamping pressure begins.

The resolution of G2 “Stop Mold Protection” is enhanced for better control of the mold
protection function. This value is operator set and should be as close to 0.000 as possible.

NOTE!

If G2 is set too high, the mold faces will “bang” together,

eventually causing damage.

ACTUAL MOLD POS. <HI - RES> KSFx = 20.000 in

This line shows the mold position at high resolution, and is an actual value and cannot be
accessed by the operator. The mold transducer output is processed to give greater
accuracy on the actual mold position. This enables the machine to have tighter control of the
mold protection function and the mold position before high clamping pressure is exerted.

10/10/02 5. SCREEN PAGES 43

 EC100 / CC100 - A03 OPERATOR:
2.1 MOLD CLOSING (SV2.00 OR GREATER)

NOTE!

This screen page is typical of a machine with System

Version 2.00 or greater and the “Autoprotection” mold
protection program option enabled.

The majority of screen lines on this page are explained for the previous mold closing page.
The ones that are different are explained below.

The main settings for mold protection are on the “Autoprotect” screen page.

1 .. . 3 . C L O S I N G S P E E D W1 - G2hr V3 = 8 %

This is V3 the percentage speed at which the moving platen travels between point 'W1', the
start of the third closing speed, and “G2hr” the end of mold protection. This speed is
employed at a level that is just enough to ensure that the mold goes through the mold
protection zone.

2 .. . S TA R T 2 N D M . P R O T.P R E S S U R E G3 = 0.25 in

A second mold protection pressure may be required to finally close the mold against spring
tension, for example. Conversely, the operator may be require to initially enter the mold
protection area at one pressure and then reduce that pressure for final closing. This feature
gives the operator some flexibility over mold protection pressure settings.

44 5. SCREEN PAGES 10/10/02

 EC100 / CC100 - A03 OPERATOR:
This feature is enabled on the Autoprotect page. When line 12 “2nd mold prot press” on the
“Autoprotect” page is set to YES, lines 2 and 3 are displayed on the mold closing page as
shown in the figure.
The operator would set where the second mold protection pressure would start. That is, at
what position before the G2 position would the second pressure be employed.

3 .. . M O L D P R O T E C T I O N P R E S S . P 2 a = 15 % P2e = 8 %

On this line the operator would set the two mold protection pressures required. A flag next
to each pressure setting will light when that pressure is active. Mold protection pressure P2a
is active from G1 to G3 and mold protection pressure is active from G3 to G2. The mold
protection monitoring time is monitored from G1 to G2, whether or not the second mold
protection pressure is employed.

MOLD PROTECTION PRESSURE P2a = 100 %

If the second mold protection pressure is not used, only one setting for pressure is required.
The Mold closing page does not display any reference to the second mold protection
pressure and this line is displayed.
The mold protection pressure can be set a 100%, “Autoprotect” feature is monitoring the
pressure against a known good curve. Any deviation outside the tolerance set on the
“Autoprotect” page, will cause the machine to go in the mold protection alarm. Utilizing a
high pressure ensures that if there is no obstruction, mold protection will be completed in the
shortest time possible. The speed, of course, can be set to a value that is just fast enough
for the clamp and mold to make it though the mold protection zone. Set the speed V3 to a
level just sufficient to move the clamp through the mold protection zone without unduly
affecting the “mold protection time” ZFx.

4 .. . S TO P M O L D P R O T E C T I O N G2hr = 0.004 in

For Tiebarless machines, this is the mold position, during the mold close function, where
mold protection pressure ends and full clamping pressure begins.
The mold position now can be determined to three decimal places, this fact now makes the
mold protection function more sensitive. The “hr” in G2hr stands for “high resolution”

S TO P M O L D P R O T E C T I O N G2f = 0.00 in

For toggle machines, the line is as shown G2f mold position and is displayed in green. This
position can not be set on this page.
Instead, set the G2hr toggle position on the “Clamping force” screen page, so that the mold
halves just touch before the machine goes into high clamping pressure. “G2hr” must be set
greater than zero in order to engage full clamping pressure.

10/10/02 5. SCREEN PAGES 45

 EC100 / CC100 - A03 OPERATOR:
2.2 SET VALUE GRAPHICS (SYSTEM VERSIONS LESS THAN SV2.00)

PRESS

CLOSING PROFILE 99-10-07 12:00

100 %

0%
SFx 20.00 in G1a
23.00 in
A W3 W1 G1 G2f

A W3 W1 G1 G1a G1b G1c G1d G2f

1.... Position in 20.00 2.00 1.00 0.70 0.80 0.60 0.40 0.20 0.01
2.... Speed % 60 40 15 15 15 15 15 15 15
3.... Pressure % 100 100 100 25 25 25 25 25 65

The closing profile page displays a graphic representation of the set stroke positions, closing
speeds and closing pressures.

The red line indicates percentage pressure, while the green line indicates percentage speed.

F1 MOLD CLOSING
F2 SET VALUE GRAPHICS
F3 AUTOPROTECT
F4 CLAMPFORCE
F5 MOLD HEIGHT
F6 INJECTION COMPRESION/COINING

46 5. SCREEN PAGES 10/10/02

 EC100 / CC100 - A03 OPERATOR:
The set stroke positions, where the speed and pressure changes take effect, can be determined
by referring to the horizontal scale. Since the screen display is not large enough to show all stroke
positions at once, move the cursor to the right continuously to access the remaining stroke
positions.

Mold Protection Stroke Positions:

A five step mold protection profile has been provided on the mold closing variables page.

Entering a value into G1 will cause G1a through G2 to be set into five equal steps. Any new
settings for G1 will reset G1a through G2. Once G1 has been set the other positions can still be
adjusted manually.
- G1 > G1a > G1b > G1c > G1d > G2.

The intermediate stroke positions for mold protection pressure can be adjusted on the set value
graphics page. When the mold reaches the G1 position during mold closing, the hydraulic system
will follow the speed and pressure profile for each range as set out on the mold closing variables
page.

The set percentage of speed or pressure can be determined by referring to the vertical scale on
the left, 0% to 100%.

While the machine is cycling, the vertical blue line indicates the actual stroke position at any point
in time. This would equal the value of 'SFx'.

The hatched markings on the bottom right-hand corner of the graph indicate the position of the
stationary platen.

1 Position in inches - The operator can move the cursor to highlight a particular position and
enter a new value to change where specific speed or pressure zones take
effect.

2 Speed - The operator can move the cursor to highlight a particular

speed and enter a new value to change the speed during clamp closing.

3 Pressure - The operator can change only the mold protection pressure by moving the
cursor to highlight a mold protection pressure and entering a new value.

NOTE!

If any values are changed on the profile page, the values will
also be changed on the parameter page and will immediately
influence the machine performance.
Any values that appear in white represent software set values
and cannot be changed.

10/10/02 5. SCREEN PAGES 47

 EC100 / CC100 - A03 OPERATOR:
2.3 SET VALUE GRAPHICS (SYSTEM VERSIONS SV2.00 OR GREATER)

PRESS

The closing profile page displays a graphic representation of the set stroke positions, closing
speeds and closing pressures.

The red line indicates percentage pressure, while the green line indicates percentage speed.

F1 MOLD CLOSING
F2 SET VALUE GRAPHICS
F3 AUTOPROTECT
F4 CLAMPFORCE
F5 MOLD HEIGHT
F6 INJECTION COMPRESION/COINING

48 5. SCREEN PAGES 10/10/02

 EC100 / CC100 - A03 OPERATOR:
The set stroke positions, where the speed and pressure changes take effect, can be determined
by referring to the horizontal scale. Since the screen display is not large enough to show all stroke
positions at once, move the cursor to the right continuously to access the remaining stroke
positions.

Mold Protection Stroke Positions:

Mold protection, via “Autoprotect” has been set up to detect any variation in speed or pressure
compared to an ideal curve.

The mold pressure entered at P2a will be in effect from G1 and until G2hr is reached.
The closing speed set into V3 will be in effect from position W1 until G2hr is reached.

An intermediate stroke position, G3, for mold protection pressure can be set on the Autoprotect
screen page. The G3 position will be displayed on the Set Value Graphics screen page between
G1 and G2hr. When the mold reaches the G3 position during mold closing, the hydraulic system
will follow the pressure set into P2e on the Mold Closing screen page. Screen flags will indicate
which pressure is active P2a or P2e.

The set percentage of speed or pressure can be determined by referring to the vertical scale on
the left, 0% to 100%.

While the machine is cycling, the vertical blue line indicates the actual stroke position at any point
in time. This would equal the value of 'SFx'.

The hatched markings on the bottom right-hand corner of the graph indicate the position of the
stationary platen.

1 Position in inches - The operator can move the cursor to highlight a particular position
and enter a new value to change where specific speed or pressure
zones take effect.
S45 is the mold closing stroke position where the mold slows down
until switch bGV position.

2 Speed - The operator can move the cursor to highlight a particular speed and
enter a new value to change the speed during clamp closing.

3 Pressure - The operator can change only the mold protection pressure by
moving the cursor to highlight a mold protection pressure and
entering a new value.

If any values are changed on the profile page, the values will also be changed on the parameter
page and will immediately influence the machine performance.
Any values that appear in white represent software set values and cannot be changed.

10/10/02 5. SCREEN PAGES 49

 EC100 / CC100 - A03 OPERATOR:
2.4 AUTO PROTECT

NOTE!

Autoprotect is only available from System Version SV2.00 or greater

PRESS

SPEED MONITORING

Refer to the line numbers on the following pages for the description of each variable.

F1 MOLD CLOSING
F2 SET VALUE GRAPHICS
F3 AUTO PROTECT
F4 CLAMPFORCE
F5 MOLD HEIGHT
F6 INJECTION COMPRESION/COINING

50 5. SCREEN PAGES 10/10/02

 EC100 / CC100 - A03 OPERATOR:
FORCE OR HYDRAULIC PRESSURE MONITORING

Autoprotect - precision mold protection - is achieved either by force (pressure) or speed

monitoring. Any variation in the current speed or pressure outside a set tolerance compared to a
predetermined monitoring curve, activates the mold protection.

The monitoring curve is recorded during the first cycle and all other curves are compared with the
monitoring curve. Alternatively the monitoring curve can be re-initialized after each successful
mold closing sequence.

If the control voltage is switched off or any of the mold closing parameters are changed, the
monitoring curve is automatically erased and initialized on the next successful mold closing
sequence.

NOTE!

The first closing function or first closing after a parameter change will
not be monitored by Autoprotect curve.
During these times mold protection will only rely on the setting in “max
force / min speed” and the time set in ZF

Autoprotect requires one successful closing function to generate a monitoring curve. The initial
closing function relies on the protection afforded by the mold closing screen page. It is
recommended to set the last closing speed to a low value (i.e. 10 -15%)

10/10/02 5. SCREEN PAGES 51

 EC100 / CC100 - A03 OPERATOR:

NOTE!

When changing the following parameters the mold protection

monitoring is re-initialized during the next cycle and the
Autoprotect monitoring curve is not active during this cycle.

Mold protection monitoring relies on the setting in “Max force /

Min speed” and the time set in ZF during this time.

Closing strokes: A,W3,W1,G1,G3,G2

Closing speeds: V1,V2,V3
35043 Speed on G2
35068 Speed on position mold closed
Mold protection pressures: P2,P2e
Ramps: 35131 Speed braking after W3
35139 Speed braking to W1
35132 Speed braking before or after G2
35155 Speed braking on position mold closed
35171 Speed start acceleration mold closing
35147 Pressure braking on position G3
35148 Pressure braking on position G1
Minimum speed 24353 Minimum speed at speed measurement
Maximum force 24208 Maximum force at force measurement
Stroke tolerance 28174 Stroke tolerance for strongly dynamic curves
Switch on of the mold protection monitoring.
Switchover from pressure to speed monitoring and vice versa.

52 5. SCREEN PAGES 10/10/02

 EC100 / CC100 - A03 OPERATOR:

NOTE!

The maximum time for recording a monitoring curve is 8 seconds,

mold protection must not exceed this time.

1 .. . M o n i t o r in g SPEED / FORCE
The type of monitoring required is selected here by entering a 0 for SPEED monitoring or a
1 for FORCE monitoring. Toggle machines can only use speed monitoring.
Speed monitoring:
The speed of the mold closing is monitored during the mold protection phase between G1
and G2. The actual speed curve is displayed and compared with a monitoring curve
recorded earlier. When the mold closing function encounters an obstacle, preventing mold
closing, the speed profile will change. If the speed changes are outside the curve
tolerances, mold protection is activated.
The mold protection monitoring time is also active in parallel with the speed monitoring.
Force monitoring
Force monitored mold protection requires an additional pressure transducer on the high
speed closing cylinder for Tiebarless machines. The additional pressure transducer must be
enabled on the machine set up page of the service menu.
The pressure in the “high speed” cylinder is monitored during the mold protection phase
between G1 and G2. The pressure values are displayed as a curve on the screen page and
compared with a curve recorded earlier. If the actual pressure values exceed the monitoring
curve tolerance, mold protection is activated.
The mold protection monitoring time is also active in parallel with the force monitoring.

2 .. . P r o g r a m ON / OFF
Enter 1 on this line to turn the program on, or 0 to turn the program off. If the program is
turned off the normal mold protection set up on the “Mold Closing” page is still effect.

3 .. . In it ia l i z e c y c le NO / YES
When the “Initialize cycle” is set to NO, the monitoring curve is recorded during the first
successful mold closing sequence and the current actual curve is compared to that initial
monitoring curve.
When the “initialization cycle" is switched to YES the monitoring curve is freshly recorded
from each successful closing sequence and the current actual curve is effectively compared
with the last successful curve. A new monitoring curve is drawn on the previous actual
curve.
This setting effectively compensates for variations in the machine or mold, until optimum
operating temperature has been reached. Engel recommends that during the start up of a
process that the line “Initialize cycle” be set to YES until a stable process has been
established. Once the process is stable and the machine is producing the parts required,
switch “Initialize cycle” to NO.

10/10/02 5. SCREEN PAGES 53

 EC100 / CC100 - A03 OPERATOR:
4 .. . S p e e d / F o r c e t o l. = 1.00 in /s
If SPEED is selected as the monitoring choice, the speed tolerance setting is displayed.
Conversely if the FORCE is selected the force tolerance setting is displayed.
The tolerance is the amount that the monitoring curve is vertically displaced from the actual
curve. The displaced monitoring curve is above the actual curve when force is used and
below the actual curve when speed is used.

5 .. . St r o k e to l. = 0.000 in
This is a tolerance set on the horizontal plane of the monitoring curve. The tolerance can
allow for horizontal variation of the actual curve during the mold protection phase, between
G1 and G2, without going into mold protection alarm.
In most situations, this tolerance can be set to zero. A stroke tolerance may be required
when a process demands a high speed to G1 and a fast braking ramp to G2. This situation
would result in a curve with a steep gradient to G2.
Due to the way the controller samples the values of the “actual curve”, sampling of the start
position of the curve may begin a little earlier or later than the “monitoring curve”. This
situation could result in the two curves being slightly displaced in the horizontal direction.
This only becomes a problem when part of the curves have a steep gradient.
Stroke tolerance allows for horizontal variations in curve position, by the amount entered on
the "Stroke Tolerance" line. The curve may be out of tolerance as far as force or speed is
concerned but as long as it is only out of tolerance for the distance set in the stroke
tolerance, there will be no mold protection alarm. When the curve is out of tolerance for
more than the distance set stroke tolerance the machine goes into a mold protection alarm.
A good starting point for stroke tolerance would be approximately 0.008 of a inch (0.2 mm).
Mold protection will become less sensitive if too large a tolerance is set.

6 .. . M i n S p e e d / M a x F o r c e = 0.002 i n /s

NOTE!

A value must be entered into the minimum speed or maximum force to ensure
that basic mold protection is available during any initialization phase.

This line is set depending upon the type of mold protection chosen. The maximum force or
minimum speed is a safety limit that is only in operation during intialization of the curve. A
mold protection alarm will result, if this set variable is exceeded during initialization.
A typical value for minimum speed is 0.004 in/s (0.1 mm/s)
A typical value for maximum force is 80% of the mold protection pressure set in P2a.

7 .. . S c a l e = 15.0 i n /s
This line sets the scale of the Y axis of the monitoring curve. This should be set greater than
the expected maximum to ensure that the monitoring and actual curves are displayed to
their best resolution.
If no value is set here, the scale is automatically set so that the maximum values for the
curve lie in the upper portion of the graph.

54 5. SCREEN PAGES 10/10/02

 EC100 / CC100 - A03 OPERATOR:
8 .. . . _ _ _ A c t . v a l u e c u rv e
This line represents the actual speed or force of the mold protection function in real time.
This curve is redrawn during each cycle.

9 .. . -- - -- M o n it o r in g c u r v e
This line represents the monitoring curve. This curve is used as an ideal to compare the
actual curve to during mold protection.

1 0 . . M o l d p r o t. e r r o r a t P o s it i o n = 0 . 0 0 0 in
This is the actual position at which the mold protection was activated. The value is not
erased during multiple closing attempts so that the error can be more easily identified.

11 . . M o l d p r o t. e r r o r a t S p e e d = 0 . 0 0 0 in /s
This is the actual speed at which the mold protection was activated. The value is not erased
during multiple closing attempts so that the error can be more easily identified.

1 2 . . 2 n d M o l d P r o t. P r e s s N O / Y E S
Enter 1 on this line to activate the second mold protection pressure.
G3 the start of the second mold protection pressure will be displayed on the graph and
under the “Stroke” column.
This feature is used where a higher pressure is required for the last part of mold closing. For
example; with a mold that has a spring loaded section that would require extra force to close
the mold against the spring pressure.

1 3 . . Sta tu s
This line displays the current status of the mold protection monitoring.
The following messages are displayed:
Monitoring switched off.
Initialization active.
Monitoring active.
Monitoring and Initialization active.
Initialization finished.
Monitoring complete.
Measuring time error.
Mold protection error.
Graphic evaluation completed.
Mold protection evaluated.
No graphic data existing.
14.. FSZ = 2
If the mold protection alarm is activated, and this counter is set higher than zero, the control
will open the mold, eject, and try to close again for the number of times set for this counter.
In effect the machine will try to clear itself of the obstruction, up to a maximum of 9 times,
before actually stopping due to a mold protection alarm.

1 5 . . B r ie f d e s c r i p ti o n o f s c r e e n pa g e l i n e s
Where ever the cursor is placed, a brief description of that line is given.

10/10/02 5. SCREEN PAGES 55

 EC100 / CC100 - A03 OPERATOR:
1 6 . . St r o k e

G1, G2 and G3 are set to suit the mold and process. Larger parts will require a larger value
for G1. Special molds may require a second, higher pressure (P2e) at position G3 to reach
G2 in a reasonable time. When screen line 12 is set to YES, G3 will appear on the Mold
closing screen page and here on line 16 on the Autoprotect screen page.

G1 = Start of mold protection

G3 = Start of second mold protection pressure P2e (G3 is displayed when the “second
mold protection pressure” is enabled on line 12).
G2 = End of mold protection
FSZ = The number of mold closing attempts when mold protection occurs.

17.. Force

Mold protection pressure should be set at least high enough so that the mold goes through
mold protection successfully. Ideally the mold protection pressure should be set so the mold
protection phase is completed as consistently and quickly as possible. The mold protection
curve should be nearly identical to the monitoring curve.

P2a = Mold protection pressure from position G1.

P2e = Mold protection pressure from position G3 (P2e is displayed when the second mold
protection pressure is enabled on line 12).
max = This is the actual maximum force required to successfully move through mold
protection.

18.. Speed

The speeds through mold protection should be set to suit the type of mold and to achieve a
reasonable cycle time. For example, a heavy mold with a short mold protection stroke would
require a slower speed to prevent the inertia of the moving components from carrying the
mold through mold protection stroke without any protection.

V2 = Second closing speed from position W3 to position W1.

V3 = Third closing speed from position W1 to position G2

1 9 . . Ti m e

Initially set ZF to a large value until the process is stable and running good parts, then set
the time down to a value close to, but slightly greater than, the actual time.

ZF = Maximum mold protection monitoring time.

act = Actual mold protection time.

56 5. SCREEN PAGES 10/10/02

 EC100 / CC100 - A03 OPERATOR:
2.5 CLAMPFORCE

PRESS

NOTE!

The lines marked with an asterisk are for Toggle Lever machines only
Refer to the line numbers on the following pages for the description of each variable.

F1 MOLD CLOSING
F2 SET VALUE GRAPHICS
F3 AUTO PROTECT
F4 CLAMPFORCE
F5 MOLD HEIGHT
F6 INJECTION COMPRESION/COINING

10/10/02 5. SCREEN PAGES 57

 EC100 / CC100 - A03 OPERATOR:
1 .. . S E T VA L U E SK = 250.0 ton

The operator sets the set value to whatever clamp force is desired up to the limits of the
machine design.

2 .. . C O N T R O L TO L E R A N C E 5.0 ton

This is the clampforce control tolerance limit. Within this plus/minus tolerance, no
clampforce adjustments will be made.

If the machine is equipped with a clamp force transducer and a sensor to monitor
revolutions of the mold height motor. The clamp force of each cycle can be monitored and
adjusted, if the actual clamp force exceeds the limits of positive and negative tolerance
when compared to the set value.

This is a value that the operator sets and indicates how far the mold will open during the
mold opening function. Of course, it also represents how far the mold will close during the
mold close function.

5 .. . A C T U A L M O L D P O S I T I O N SFx = 2 0 . 0 0 in

This is the actual value of the mold position at any time during the cycle. Since it is an actual
value, the operator cannot move the cursor to this position and cannot change the value that
appears on this line.

This is a value that the operator sets and represents the toggle lever position where mold
protection pressure ends and clamping pressure 'P1' begins. It is important to note that 'G2'
is related to toggle lever position 'SKx'.

This is a value that the operator sets and is the percentage pressure that is applied to the
clamp cylinder in order to achieve toggle lock-up. This pressure comes into effect at point
'G2' and is maintained until the control unit receives an indication that toggle lever position
'B' has been reached. If the machine has a clampforce transducer, P1 must be set at 100%.

When the box beside 'B' is illuminated, it is an indication that the toggle is locked and is also
the signal to initiate the next function in the cycle, i.e. nozzle forward.
The operator can move the cursor to this position and select where the toggle lever locked
position will be recognized by the machine. If it is set too high the toggle lever will not be
mechanically locked up and 'flashing' could occur during injection.

58 5. SCREEN PAGES 10/10/02

 EC100 / CC100 - A03 OPERATOR:
9 .. . A C T U A L TO G G L E P O S I T I O N S K x = 2 3 . 0 0 in

This is a value that represents the linear distance from the mechanical toggle locked
position at any time during the cycle. Since it is an actual value, the operator cannot move
the cursor to this position and therefore cannot change the value that appears on this line.

10.. SPEED (G 2 - B ) = 65 %

This is an operator set value, and represents the speed at which the toggle straightens out.
That is, as the mold moves from position G2, the start of clamping pressure to position B,
toggle lever locked.

11 . . S P E E D (A F T E R B ) = 10 %

The machine has reached full clampforce at position B, but the toggle still has a small
amount of travel to complete. The speed set here is the speed of the final straightening out
of the toggle, from position B.

10/10/02 5. SCREEN PAGES 59

 EC100 / CC100 - A03 OPERATOR:
2.6 MOLD HEIGHT

PRESS +

NOTE!

The lines marked with an asterisk are only displayed when a

mold height transducer is fitted.

F1 MOLD CLOSING
F2 SET VALUE GRAPHICS
F3 MOLD VENTING
F4 CLAMPFORCE
F5 MOLD HEIGHT
F6 INJECTION COMPRESION/COINING

60 5. SCREEN PAGES 10/10/02

 EC100 / CC100 - A03 OPERATOR:
1 . A U T. M O L D H E IG H T A D J U S T M E N T. . O F F

The operator can turn on or off the “automatic mold height adjustment” by entering either a
1 or 0 in the data entry field, when the cursor is positioned on this line.

This is a program designed to speed up mold installation. When this program is switched
'ON' and the set-up mode of operation is in effect, the set-up person can automatically set
the correct mold height so that the two mold halves just touch when the clamp is fully
toggled. The mold is positioned, with the two mold halves locked together, so that the
location ring (on the mold) is inserted in the insertion ring (on the platen).The mold close
selector switch is activated until the program decides that the mold height is set. When the
proper mold height is achieved the automatic mold height adjustment program will
automatically turn itself 'OFF'.

At this point the machine should be switched off and locked out so that the mold clamps can
be installed.

Also the clamp force will now require setting.

NOTE!

Automatic mold height adjustment is off during processing

and is not involved with closed loop clampforce control.

2. A C T U A L P O S IT I O N FHx = 20.00 in

This is the actual mold height as indicated by the mold height transducer (if so equipped)
this value cannot be selected or changed by the operator.

This is the mold height required for a particular mold. This is the value to which the mold
height is adjusted when the AUTOMATIC PROGRAM is ON, if the machine is equipped with
a mold height transducer.

This is the minimum mold height for the machine, (a variable setvalue).

This is the maximum mold height for the machine, (a variable setvalue).

This line indicates by means of a lighted flag, whether the mold height is increasing or
decreasing.

10/10/02 5. SCREEN PAGES 61

 EC100 / CC100 - A03 OPERATOR:
2.7 INJECTION COMPRESSION / COINING

PRESS +

Hydraulic machine:- Injection compression / coining via pressure transducer

F1 MOLD CLOSING
F2 SET VALUE GRAPHICS
F3 AUTO PROTECT
F4 CLAMPFORCE
F5 MOLD HEIGHT
F6 INJECTION COMPRESION/COINING

62 5. SCREEN PAGES 10/10/02

 EC100 / CC100 - A03 OPERATOR:
Injection compression and coining are very similar in function, both requiring two clamping stages.
The mold is closed to the first position or clamp pressure and injection takes place.
With "Injection Compression" the injection stops while the second stage clampforce is applied,
Injection starts again when the set clampforce is reached.
With "Coining" on the other hand, injection continues throughout both clamping stages. Switch
over to the second stage clamping happens during injection hold after injection boost.

NOTE!

If no auxiliary hydraulic power source is available, “Coining”

must be done after the “Injection hold” time has expired.

Injection compression or injection coining for toggle machines can be initiated by clampforce or
clamp position.
Injection compression or injection coining for fully hydraulic machines can be initiated by hydraulic
pressure during clamping or clamp position.

Injection Compression
1. Clamp closes to a position or tonnage.
2. Injection begins.
3. At a preselected injection position.
a. Clamp closes to full set value tonnage, compressing the material.
b. After compression, Injection will resume and the cycle will be completed.

Coining
1. Clamp closes to a position or tonnage.
2. Injection begins.
3. At the end of injection boost.
a. Clamp is allowed to close to full set value tonnage, coining the material.
b. Injection has not been interrupted.

To reference clamp closing by tonnage:

• A fully hydraulic machine must have a pressure transducer.
• A toggle machine must have a clampforce transducer.

1 … 1 s t S TA G E C O M P R E S S I O N SKC = 0.0 t

The operator sets the first clamp force tonnage. When the actual tonnage equals the first
stage set tonnage, the injection unit advances to the "J" position and injection is started.

10/10/02 5. SCREEN PAGES 63

 EC100 / CC100 - A03 OPERATOR:
2 … 2 n d S TA G E C O M P R E S S IO N SKP = 0.0 t

The operator sets the second clamp force tonnage.

Injection Compression: When the operator set "Screw pos. to compress" position is
reached during injection (line 5) and the "Compression delay time"
expires (line 7), the second stage clamp force tonnage is applied.
Once clamping is completed, injection will resume and finish the
cycle.

Coining: When the injection boost cycle switches into hold the "Compression delay time"
will run, upon expiry of the delay time the clamp is allowed to close under the
second stage clamp force tonnage.

NOTE!

If an auxiliary hydraulic power source is not employed, coining

must be done after the injection hold time has expired.

3 … A C T U A L VA L U E SKx = 0.0 t

This is the actual value of the mold position at any time during the cycle. Since it is an actual
value, the operator cannot move the cursor to this position and cannot change the value that
appears on this line.

4 … A C T U A L M O L D P O S . ( H I -R E S ) K S F x = 0.00 mm

This line shows the mold position at high resolution, and is an actual value and cannot be
accessed by the operator. The mold transducer output is processed to give greater
accuracy on the actual mold position. This enables the machine to have tighter control of the
mold protection function and the mold position before high clamping pressure is exerted.

64 5. SCREEN PAGES 10/10/02

 EC100 / CC100 - A03 OPERATOR:
* 5 … S C R E W P O S . TO C O M P R E S S = 0.00 in

NOTE!

This line is only displayed for injection compression.

When the 1st stage compression tonnage has been reached, the nozzle advances to the "J"
point, injection is started and continues until the "SCREW POSITION TO COMPRESS" is
reached. After the "Compression Delay Timer" expires the 2nd stage compression begins.
Once clamping has been completed, injection will resume and finishes the function.

NOTE!

The injection cycle is not interrupted for coining.

6 … A C T U A L S C R E W P O S IT IO N SSx = 0.00 in

This is the actual value of the screw position at any time during the cycle. Since it is an
actual value, the operator cannot move the cursor to this position and cannot change the
value that appears on this line.

7 … C O M P R E S S I O N D E L AY T I M E ZLC = 0.0 s

The "COMPRESSION DELAY TIMER" is started by either "SCREW POSITION TO

COMPRESS" being reached in the case of "Injection compression" or by the switch over
from Injection Boost to Injection Hold in the case of "Coining". The flag, when lit, indicates
that the delay time is in effect.

8 … IN J E C T I O N C O M P R E S S IO N = OFF

The operator can turn on or off the “Injection compression” by entering either a 1 or 0 in the
data entry field, when the cursor is positioned on this line.

10/10/02 5. SCREEN PAGES 65

 EC100 / CC100 - A03 OPERATOR:
Hydraulic machine :- Injection compression / coining via clamp position

1 … S TO P M O L D P R O T E C T I O N G2f = 0.00 in

This is the mold position, during the mold close function, where mold protection pressure
ends and clamping pressure begins.

2… END COMPRESSION POSITION = 0.0 in

At mold position G2f, the nozzle advances to the "J" point and injection begins until the
"SCREW POSITION TO COMPRESS" is reached and injection is halted. The
"COMPRESSION DELAY TIME" runs and upon expiry, the clamp closes using the "CLAMP
COMPRESSION SPEED" and "CLAMP COMPRESSION PRESSURE" set on the screen
page. When the clamp reaches the "END COMPRESSION POSITION", full clamp pressure
is exerted until the clamp completes the closing cycle. Injection resumes and continues
through injection hold pressure.
or
2 … E N D C O IN IN G P O S IT I O N = 0.0 in

At mold position G2f, the nozzle advances to the "J" point and injection begins. The
switchover from injection boost to injection hold triggers the "COMPRESSION TIME
DELAY". The "COMPRESSION DELAY TIME" runs and upon expiry, the clamp closes
using the "CLAMP COMPRESSION SPEED" and "CLAMP COMPRESSION PRESSURE"
set on the screen page. When the clamp reaches the "END COMPRESSION POSITION",
full clamp pressure is exerted until the clamp completes the closing cycle.

66 5. SCREEN PAGES 10/10/02

 EC100 / CC100 - A03 OPERATOR:
3 … A C T U A L M O L D P O S . ( H I -R E S ) K S F x = 0.00 mm

This line shows the mold position at high resolution, and is an actual value and cannot be
accessed by the operator. The mold transducer output is processed to give greater
accuracy on the actual mold position. This enables the machine to have tighter control of the
mold protection function and the mold position before high clamping pressure is exerted.

4 … A C T U A L C L A M P TO N N A G E SKx = 0.0 t

This line displays the actual clamp tonnage at any time during the cycle and cannot be
accessed or changed by the operator.

5… CLAMP COMPRESSION SPEED = 0 %

This the operator set speed that the clamp closes at, from the end of mold protection until
the "End of compression" position.

6… CLAMP COMPRESSION PRESSURE = 0 %

This the operator set pressure that the clamp closes with, from the end of mold protection
until the "End of compression" position.

* 7 … S C R E W P O S .TO C O M P R E S S = 0.00 in

NOTE!

This line is only displayed for injection compression.

When the 1st stage compression tonnage has been reached, the nozzle advances to the "J"
point, injection is started and continues until the "SCREW POSITION TO COMPRESS" is
reached. After the "COMPRESSION DELAY TIMER" expires the 2nd stage compression
begins. Once clamping has been completed, injection will resume and finishes the function.

NOTE!

The injection cycle is not interrupted for coining.

8 … A C T U A L S C R E W P O S IT IO N SSX = 0.00 in

This is the actual value of the screw position at any time during the cycle. Since it is an
actual value, the operator cannot move the cursor to this position and therefore cannot
change the value that appears on this line.

10/10/02 5. SCREEN PAGES 67

 EC100 / CC100 - A03 OPERATOR:
9 … C O M P R E S S I O N D E L AY T I M E Z L C = 0.0 s

The "COMPRESSION DELAY TIMER" is started by either "SCREW POSITION TO

COMPRESS" being reached in the case of "Injection compression" or by the switch over
from Injection Boost to Injection Hold in the case of "Coining". The flag, when lit, indicates
that the delay time is in effect.

1 0 . . IN J E C T I O N C O M P R E S S IO N = OFF

The operator can turn on or off the “Injection compression” by entering either a 1 or 0 in the
data entry field, when the cursor is positioned on this line.

68 5. SCREEN PAGES 10/10/02

 EC100 / CC100 - A03 OPERATOR:
Toggle machine: Injection compression/coining via clampforce transducer

1 … C L A M P F O R C E S E T VA L U E SK = 0.0 t

The operator sets the set value to whatever clamp force is desired up to the limits of the
machine design.

2 … IN IT I A L C O IN IN G F O R C E SKC = 0.0 t
or
2 … IN IT I A L C O M P R E S S . F O R C E SKC = 0.0 t

The operator sets the first clamp force tonnage. When the "ACTUAL CLAMPFORCE"
equals the "INITIAL COINING or COMPRESSION FORCE", the injection unit advances to
the "J" position and injection is started.

3… ACTUAL CLAMP FORCE = 0.0 t

This line displays the actual clamp tonnage at any time during the cycle and cannot be
accessed or changed by the operator.

4… ACTUAL MOLD POSITION SFx = 0.00 in

This is the actual value of the mold position at any time during the cycle. Since it is an actual
value, the operator cannot move the cursor to this position and cannot change the value that
appears on this line.

10/10/02 5. SCREEN PAGES 69

 EC100 / CC100 - A03 OPERATOR:
5 .. A C T U A L TO G G L E P O S I T I O N SKx = 0.00 in
This is a value that represents the linear distance from the mechanical toggle locked
position at any time during the cycle. Since it is an actual value, the operator cannot move
the cursor to this position and therefore cannot change the value that appears on this line.

6… CLAMP COMPRESSION SPEED = 0 %

After the "COMPRESSION DELAY TIMER" expires the clamp resumes closing under the
screen page set "Clamp Compression" speed.

7… CLAMP COMPRESSION PRESSURE = 0 %

After the "COMPRESSION DELAY TIMER" expires the clamp resumes closing under the
screen page set "Clamp Compression" pressure.

8 … S C R E W P O S .TO C O M P R E S S = 0.00 in

NOTE!

This line is only displayed for injection compression.

When the "INITIAL COMPRESSION FORCE" tonnage has been reached, the nozzle
advances to the "J" point, injection is started and continues until the "SCREW POSITION
TO COMPRESS" is reached. After the "COMPRESSION DELAY TIMER" expires the clamp
closes under the screen page set "Clamp Compression" speed and pressure. Once
clamping has been completed, injection will resume and finishes the function.

NOTE!

The injection cycle is not interrupted for coining.

9 … A C T U A L S C R E W P O S IT IO N SSX = 0.00 in
This is the actual value of the screw position at any time during the cycle. Since it is an
actual value, the operator cannot move the cursor to this position and therefore cannot
change the value that appears on this line.

1 0 . . C O M P R E S S I O N D E L AY T I M E ZLC = 0.0 s
The "COMPRESSION DELAY TIMER" is started by either "SCREW POSITION TO
COMPRESS" being reached in the case of "Injection compression" or by the switch over
from Injection Boost to Injection Hold in the case of "Coining". The flag, when lit, indicates
that the delay time is in effect.

11 . . IN J E C T I O N C O M P R E S S IO N = OFF
The operator can turn on or off the “Injection compression” by entering either a 1 or 0 in the
data entry field, when the cursor is positioned on this line.

70 5. SCREEN PAGES 10/10/02

 EC100 / CC100 - A03 OPERATOR:
Toggle machine: Injection compression/coining via clamp position

1 … S TA R T C L A M P I N G P R E S S U R E G 2 = 0.00 in

This is a value that the operator sets and represents the toggle lever position where mold
protection pressure ends and clamping pressure 'P1' begins. It is important to note that 'G2'
is related to toggle lever position 'SKx'.

2 … C O M P R E S S I O N P O S IT IO N = 0.00 in
or
2 … C O I N I N G P O S I T IO N = 0.00 in

The clamp reaches the G2 position under mold protect speeds and pressures. At G2 the
clamp continues to advance at the screen page set values for "COMPRESSION SPEED"
and "COMPRESSION PRESSURE". The forward movement continues until the clamp
reaches the "COMPRESSION POSITION" and stops. The carriage moves to the J position
and injection starts.

3… ACTUAL MOLD POSITION SFx = 0.00 in

This is the actual value of the mold position at any time during the cycle. Since it is an actual
value, the operator cannot move the cursor to this position and cannot change the value that
appears on this line.

10/10/02 5. SCREEN PAGES 71

 EC100 / CC100 - A03 OPERATOR:
4 .. A C T U A L TO G G L E P O S I T I O N SKx = 0.00 in

This is a value that represents the linear distance from the mechanical toggle locked
position at any time during the cycle. Since it is an actual value, the operator cannot move
the cursor to this position and therefore cannot change the value that appears on this line.

5… ACTUAL CLAMP FORCE = 0.0 t

This line displays the actual clamp tonnage at any time during the cycle and cannot be
accessed or changed by the operator.

6… CLAMP COMPRESSION SPEED = 0 %

This is the operator set speed that the clamp closes at, from the "Compression" position
until the toggle is locked at the "B" position.

7… CLAMP COMPRESSION PRESSURE = 0 %

This is the operator set pressure that the clamp closes at, from the "Compression" position
until the toggle is locked at the "B" position.

8 … S C R E W P O S .TO C O M P R E S S = 0.00 in

NOTE!

This line is only displayed for injection compression.

When the "COMPRESSION POSITION" has been reached, the nozzle advances to the "J"
point, injection is started and continues until the "SCREW POSITION TO COMPRESS" is
reached. After the "COMPRESSION DELAY TIMER" expires the clamp closes “CLAMP
COMPRESSION” pressure and speed. Once clamping has been completed, injection will
resume and finishes the function.

NOTE!

The injection cycle is not interrupted for coining.

9 … A C T U A L S C R E W P O S IT IO N SSX = 0.00 in

This is the actual value of the screw position at any time during the cycle. Since it is an
actual value, the operator cannot move the cursor to this position and therefore cannot
change the value that appears on this line.

72 5. SCREEN PAGES 10/10/02

 EC100 / CC100 - A03 OPERATOR:
1 0 . . C O M P R E S S I O N D E L AY T I M E ZLC = 0 .0 s

The "COMPRESSION DELAY TIMER" is started by either "SCREW POSITION TO

COMPRESS" being reached in the case of "Injection compression" or by the switch over
from Injection Boost to Injection Hold in the case of "Coining". The flag, when lit, indicates
that the delay time is in effect.

11 . . IN J E C T I O N C O M P R E S S IO N = OFF

The operator can turn on or off the “Injection compression” by entering either a 1 or 0 in the
data entry field, when the cursor is positioned on this line.

10/10/02 5. SCREEN PAGES 73

 EC100 / CC100 - A03 OPERATOR:

3 MOLD OPENING

PRESS

Refer to the line number on the following pages for the description of each variable

F1 MOLD OPENING
F2 SET VALUE GRAPHICS
F3 AIR VALVES
F4 CENTRAL LUBRICATION
F5 SAFETY GATE
F6 MOLD GATES

74 5. SCREEN PAGES 10/10/02

 EC100 / CC100 - A03 OPERATOR:
1 .. . 1 S T O P E N I N G S P E E D (G 2 - W 4 ) V6 = 20 %

This is the percentage speed of the first mold opening speed range. For toggle machines,
this speed can be used to fight against the tendency of the toggle to snap open. “G2”
represents the toggle position where the mold is closed, or “SFx”=0. “W4” represents the
mold stroke position where the first opening speed ends, and the second opening speeds
begins.

2 .. . 2 N D O P E N I N G S P E E D (W 4 - W 2 ) V7 = 75 %

This is the percentage speed at which the moving platen travels between point “W4”, the
start of the second opening speed, and point “W2”, the start of the third opening speed. The
percentage speed is set by the operator at his discretion.

3 .. . . 3 R D O P E N I N G S P E E D (W 2 - A ) V8 = 30 %

This is the percentage speed at which the moving platen travels between point “W2”. The
start of the third opening speed, and point 'A', the mold open position. This speed should be
set lower to allow the mold to stop as close as possible to the mold open position “A”.

* 4 *. . I N C R .O P E N I N G P R E S S U R E N O /Y E S WA K = 0 . 0 0 in

This line is only displayed if the machine is a Direct Hydraulic with an EHV pump where
regenerative clamp circuit is used for clamp opening. Set value parameter 35491 must be
set to a 1 for regenerative clamp opening.

To increase clamp opening force, the regenerative clamp valve S12a is held off until an
operator specified clamp position WAK is reached.

At WAK, the regenerative clamp valve will be released for normal clamp speed.

5 .. . S TA R T 2 N D S P E E D (V 7 ) W4 = 0 .2 0 i n

This is a value that the operator sets and represents the point during the mold open function
where the first opening speed ends and the second opening speed begins.

6 .. . S TA R T 3 R D S P E E D (V 8 ) W2 = 1 8 . 0 0 in

This is a value that the operator sets and represents the point during the mold open function
where the second opening speed ends and the third opening speed begins.

7 .. . M O L D O P E N P O S I T I O N A = 2 0 . 0 0 in

This is a value that the operator sets and indicates how far the mold will open during the
mold opening function. Of course, it also represents how far the mold will close during the
mold close function.

10/10/02 5. SCREEN PAGES 75

 EC100 / CC100 - A03 OPERATOR:
8 .. . A C T U A L M O L D P O S I T I O N SFx = 2 0 . 0 0 in

This is the actual value of the mold position at any time during the cycle. Since it is an actual
value, the operator cannot move the cursor to this position and cannot change the value that
appears on this line.

9 .. . C Y C L E T IM E M O N ITO R I N G NO/YES

This program can be turned on or off at the discretion of the operator. If the program is
turned on (i.e. YES), the controller will monitor the actual cycle time 'ZUx'. If 'ZUx' exceeds
the maximum allowed cycle time 'MAX', error 38 - "CYCLE TIME EXPIRED" will appear and
the machine will stop cycling. If the program is turned off (i.e. NO), the cycle time 'ZUx' will
not be monitored.

To turn the program on, move the cursor to the 'NO' position, press '1', then press 'ENTER'.

To turn the program off, move the cursor to the 'YES' position and press 'ENTER'.

10.. MAX = 0 .0 ZUs= 0 .0 ZUx = 0.0 s

'MAX' is the maximum allowed cycle time before the press will stop cycling and exhibit an
alarm condition.

'ZUs' is the previous cycle's cycle time.

'ZUx' is the current, real time cycle time. The 'ZUx' timer begins at the start of mold closing.

11 . . S A F E T Y G AT E : G AT E K I C K E R CHOICE 2
A U T. O P E N IN G A F T E R : E N D O F F E E D C 2 *

MANUAL OPERATION:
GATE OPEN:
To open the safety gate, the GATE OPEN manual selector switch must be operator to the
OPEN position.
GATE CLOSE:
The safety gate must be closed manually.
SEMI AUTOMATIC
Option 1
The safety gate can be selected to open at various points in the semi-automatic cycle
depending on the selection made at the gate kicker option choice.

There are three choices of gate operation when running in semi-automatic:

0 = off.
1 = end of cycle.
2 = end of feed C2*.

76 5. SCREEN PAGES 10/10/02

 EC100 / CC100 - A03 OPERATOR:
Option 2

Option 2 allows ejector retraction or core functions to operate with the gate open.These
functions are only available if the SPI keyswitch is enabled.

Set parameter 36005 to 1 and enable the Core + Ejector SPI keyswitch for ejector retraction
with an open safety gate.

Set parameter 36133 to 1 and enable the Core + Ejector SPI safety switch for core function
with the safety gate open.

If the parameters are set to a 1 when the Core + Ejector SPI keyswitch is not active, the
controller will switch to option 1 automatically and display the error message “SPI SWITCH
REQUIRED”.

If the parameters have been set to a 1, but the Core + Ejector SPI keyswitch was then
disabled, the option would default back to option 1.

NOTE!

Before activating the Cores and Ejector keyswitch read the

precautions in the safety section of the operator manual
regarding this switch.

AUTOMATIC OPERATION:

Only option 1 is available for automatic mode. The gate will only open when the required
part count has been reached.

If the machine has option 2 selected in semi-automatic mode and then the machine is
switched to fully automatic, the kicker program will automatically default to option 1.

12.. O P E N I N G D E L AY T I M E Z V O = 0 .0 s

The operator can set a delay time for the opening of the safety gates. If the time is set to
zero, then the gate will open at the choice set on line 11.

The blue flags give the operator a visual indication of the inputs relevant to the safety gate .

The red flags give a visual indication of the output relevant to the safety gate.
• SGN = powered safety gate air supply
• SGA = powered safety gate open
• SGZ = powered safety gate closed.

10/10/02 5. SCREEN PAGES 77

 EC100 / CC100 - A03 OPERATOR:
If the software mark beside 'E1' is lit and the area beside 'E2' is blank, this indicates that the
door is closed and the mold will be allowed to close.
If the software mark beside 'E1' is blank and the area beside 'E2' is lit, this indicates that the
door is open and the mold will be prevented from closing.

13.. OPENING AFTER FEED N O /Y E S

To turn the program on, move the cursor to the 'NO' position, press '1', then press 'ENTER'.

To turn the program off, move the cursor to the 'YES' position and press 'ENTER'.

If the operator answers NO, the clamp will open to the “A” position (when the cooling time
expires) during the feed time. Feeding will be suspended until the clamp reaches the “A”
position and then it will resume.

If the operator answers YES the mold will wait until feeding has finished before the clamp
opens to the “A” position.

NOTE!

This line is only displayed when a robot handling system is fitted and enabled.

M I N . O P E N .S T R H A N D L . S Y S T A H = 0.00 in

This line sets the minimum opening stroke of the mold before the robot handling system is
allowed to move into the mold area

78 5. SCREEN PAGES 10/10/02

 EC100 / CC100 - A03 OPERATOR:
3.1 SET VALUE GRAPHICS

PRESS

OPENING PROFILE 96-10-07 12:00

100 %

0%
23.00 in A W2 SFx 20.00 in W4 G2

A W2 W4 G2 B
1.... P o s i t i o n in 20.00 18.00 0.20 3.00 0.10
2.... S p e e d % 0.0 30 75 20 25
3.... P r e s s u r e % 0.0 75 75 75 75

The opening profile page displays a graphic representation of the set stroke positions, opening
speeds and opening pressures.

The red line indicates percentage pressure, while the green line indicates percentage speed.

F1 MOLD OPENING
F2 SET VALUE GRAPHICS
F3 AIR VALVES
F4 CENTRAL LUBRICATION
F5 SAFETY GATE
F6 MOLD GATES

10/10/02 5. SCREEN PAGES 79

 EC100 / CC100 - A03 OPERATOR:
The set percentage of speed or pressure can be determined by referring to the vertical scale on
the left, 0% to 100%.

While the machine is in cycling, the vertical blue line indicates the actual stroke position at any
point in time. This would equal the value of 'SFx'.

The hatched markings on the bottom right-hand corner of the graph indicates the position of the
stationary platen.

1. Position in inches: The operator can move the cursor to adjust where the specific
speed or pressure zones take effect.

2. Speed: The operator can move the cursor to adjust the speed during
clamp opening by shifting the cursor and entering a new value.

3. Pressure: The mold opening pressure cannot be adjusted with the cursor.

NOTE!

A. If any values are changed on the profile page, the values

will also be changed on the parameter page and will
immediately influence the machine performance.

B. Any values that appear in white represent software set

values and cannot be changed.

80 5. SCREEN PAGES 10/10/02

 EC100 / CC100 - A03 OPERATOR:
3.2 AIR VALVES

PRESS

If the optional air flow function is equipped on the machine, this program can be employed to
assist in part ejection.

Refer to the line number on the following pages for the description of each variable.

F1 MOLD OPENING
F2 SET VALUE GRAPHICS
F3 AIR VALVES
F4 CENTRAL LUBRICATION
F5 SAFETY GATE
F6 MOLD GATES

10/10/02 5. SCREEN PAGES 81

 EC100 / CC100 - A03 OPERATOR:
1 .. . S E L E C T I O N F O R S TA R T O F A I R B L O W I N G

This area provides information as to the choices of when the air blow program should begin
during the cycle. The operator would choose from this list and enter the number
representing his choice in the area labelled 'FUNCTION'. If two air blow programs are
active, the choice must be made for each program.

2 .. . S TA R T A I R B L O W IN G 1 A2 = 0.00 in

This is a mold stroke position that the operator sets and indicates the starting position of the
air-blow program when either function 1 or 4 is chosen.

3 .. . A I R B L O W I N G D E L AY T I M E Z LV 1 = 0.0 s

Once the program begins, 'ZLV1' represents the amount of delay time before the blowing
function actually starts. If 'ZLV1' equals zero, there is no delay time.

4 .. . A I R B L O W I N G T I M E ZL1 = 0.0 s

This is a time that the operator would set and represents the amount of time that a
pneumatic air blower would blow on the molded part to aid in part ejection.

5 .. . S TA R T A I R B L O W IN G 2 A3 = 0.00 in

see 2 above

6 .. . A I R B L O W I N G D E L AY T I M E Z LV 2 = 0.0 s

see 3 above

7 .. . A I R B L O W I N G T I M E ZL2 = 0.0 s

see 4 above

8 .. . A C T U A L M O L D P O S I T I O N SFx = 20.00 in

This is the actual value of the mold position at any time during the cycle. Since it is an actual
value, the operator cannot move the cursor to this position and cannot change the value that
appears on this line.

82 5. SCREEN PAGES 10/10/02

 EC100 / CC100 - A03 OPERATOR:
3.3 CENTRAL LUBRICATION

PRESS

Refer to the line number on the following pages for the description of each variable.

F1 MOLD OPENING
F2 SET VALUE GRAPHICS
F3 AIR VALVES
F4 CENTRAL LUBRICATION
F5 SAFETY GATE
F6 MOLD GATES

NOTE!

This screen page is for toggle machines only.

10/10/02 5. SCREEN PAGES 83

 EC100 / CC100 - A03 OPERATOR:
1 .. . L U B R IC AT I O N AT E V E RY ZSZ = 10 Cyc

The toggle lubrication function will be activated based on the number of cycles set on this
line.

2 .. . L U B R IC AT I O N O I L L E V E L BZ2

If the flag next to BZ2 is not lit, the lubrication oil reservoir is almost empty. The machine will
stop cycling and error message 37 - LUBE OIL LEVEL LOW will be displayed on the error
page.

3 .. . L U B R IC AT I O N P R E S S U R E BZ1

This line indicates that the lubrication pressure has been reached, when the flag is lit.

4 .. . L U B R IC AT I O N A C T IV E

This line indicates if the lubrication system is functioning, the flag will be lit when the
lubrication function is active.

84 5. SCREEN PAGES 10/10/02

 EC100 / CC100 - A03 OPERATOR:
3.4 SAFETY GATES

PRESS

F1 MOLD OPENING
F2 SET VALUE GRAPHICS
F3 AIR VALVES
F4 CENTRAL LUBRICATION
F5 SAFETY GATE
F6 MOLD GATES

10/10/02 5. SCREEN PAGES 85

 EC100 / CC100 - A03 OPERATOR:
This screen page monitors the hydraulic interlock and shows an overview of all the inputs
associated with the front safety gate which are monitored by the controller .

The controller will monitor the inputs listed below in the following manner:

Each pair of inputs will be checked that they are in opposite states within a set time period if a
change of state on one of the inputs has occurred. Any pair of inputs must never be in the same
state at the same time.

Pair #1 E1 & E2 Parameter 35254 (sec)

(Digin 1) (Digin 2)

Pair #2 E1 & E7 Parameter 35254 (sec)

(Digin 1) (Digin 4)

Pair #3 E1 & XE8Q Parameter 35266 (sec)

(Digin 1) (Digin 29)

If either pair #1 or #2 are in error then the error message “ GATE SWITCH FAULT “ will be
displayed. If this error occurs check for proper operation of the associated inputs.

If pair #3 is in error then the error message “ HYD.CLOSING SAFETY “ will be displayed. If this
error occurs check for proper operation of the associated inputs.

All the flags will be active on the same line on the screen at one time, as the gate opens or closes.
This is a quick check to see if everything is functioning correctly.

86 5. SCREEN PAGES 10/10/02

 EC100 / CC100 - A03 OPERATOR:
3.5 MOLD GATES

PRESS

F1 MOLD OPENING
F2 SET VALUE GRAPHICS
F3 AIR VALVES
F4 CENTRAL LUBRICATION
F5 SAFETY GATE
F6 MOLD GATES

10/10/02 5. SCREEN PAGES 87

 EC100 / CC100 - A03 OPERATOR:
A mold gate is a hydraulically or pneumatically activated gate within the mold, used to control the
flow of plastic into the mold.

This program consists of five different selections for activating the opening of the mold gate and
three different selections for activating the closing of the mold gate. The screen page shows all
selections turned off, that is, set to “0”, with four opening selections available. The fifth opening
selection is not included in the standard mold gate, the fifth selection must be requested as a
special mold gate addition.

MANUAL OPERATION

Manual operation can be achieved by activating a manual switch on the control panel
designated for the mold gate.

The switch may be one of two types:

1. A two position spring return (returns to center), the center position will shut off the
solenoid for opening ,which will close the mold gate. The left side of the switch is the
mold gate #1 open function and the right side of the switch is used for a second mold
gate if this was purchased.
2. A three position switch with the center being neutral, the left side of the switch opens
the mold gate and the right side of the switch closes the mold gate.

NOTE!

All mold gate movements are blocked if the safety gate is

opened.

AUTOMATIC OPERATION
The automatic operation of the mold gate is achieved via five selections for mold gate
opening and three selections for mold gate closing. The machine must be in automatic
mode.

Mold Gate Opening Selection : 1

The mold gate is held open.
The closing selections are not needed for this opening selection.

Mold Gate Opening Selection : 2

The mold gate opens with the beginning of nozzle forward.
One of the closing selections is needed in conjunction with this opening selection. The mold
gate will open with the beginning of the nozzle forward and close depending on the closing
selection.

88 5. SCREEN PAGES 10/10/02

 EC100 / CC100 - A03 OPERATOR:
Mold Gate Opening Selection : 3
The mold gate opens with the beginning of the injection.
One of the closing selections is needed in conjunction with this opening selection. The mold
gate will open with the beginning of injection and close depending on the closing selection.

Mold Gate Opening Selection : 4

The mold gate opens at a set position within the clamp closing stroke.
One of the closing selections is needed in conjunction with this opening selection. The mold
gate will open on an operator set position within the clamp stroke (from “0” to “A”). This set
position appears on the screen when this selection is chosen.

Mold Gate Opening Selection : 5

(Only available if the requested as an addition)
The mold gate opens at a set position within the injection stroke.
One of the closing selections is needed for this opening selection. This selection is only
accessible via a designated variable for this selection, otherwise the page will show only the
four previous selections. The mold gate will open on a operator set position within the
injection stroke. This set position will appear when this selection is chosen.
The mold gate opening can be delayed by the setting of “the mold gate opening delay time”
(swmoldel)

WARNING!

THE MOLD GATE OPENING SET POSITION SHOULD BE SET AS

CLOSE TO THE INJECTION “C1” POSITION AS POSSIBLE TO
PREVENT THE UNIT FROM INJECTING BEFORE THE MOLD
GATE OPENS.

Mold Gate Closing Selection : 1

The mold gate will close X seconds before the hold time expires.
When this selection is chosen, the mold gate timer will appear, and the operator can set the
desired time. The mold gate will close at the set time before the hold pressure time expires,
that is, if 1 second is set the mold gate will close 1 second before the end of the hold time.

Mold Gate Closing Selection : 2

The mold gate closes at the end of hold.
When this selection is chosen the hold timer flag and a “delay after hold” timer will appear.
The mold gate will wait until, after the hold time times out, and the “delay after hold” timer
has expired before the mold gate will close. To setup the injection hold timer, the operator
must go to the “injection hold” page.

Mold Gate Closing Selection : 3

The mold gate will close at the end of cooling.
When this selection is chosen the cooling timer flag will appear. The mold gate will wait for
the cooling timer to time out and then the mold gate will close. To setup the cooling timer,
the operator must go to the “injection hold” page.

10/10/02 5. SCREEN PAGES 89

 EC100 / CC100 - A03 OPERATOR:

4 EJECTOR

PRESS

Refer to the line numbers on the following pages for the description of each variable.

The ejector page will only display the settings for pressure and speed if
the machine is equipped with a proportional valve and depending on
the current auxiliary pump setting. A machine with manual pressure
and speed control for ejectors on the fly with an independent auxiliary
pump turned on, will not display the speed and pressure settings. If the
auxiliary pump was turned off, then the pressure & speed settings
would be present.

F1 EJECTOR
F2 PRODUCTION DATA
F3 IN MOLD EJECTOR (optional)
F4 AUXILIARY PUMP (optional)

90 5. SCREEN PAGES 10/10/02

 EC100 / CC100 - A03 OPERATOR:
1 .. . . A C T U A L M O L D P O S IT I O N SFx = 2 0 . 0 0 in

This is the actual value of the mold position at any time during the cycle. Since it is an actual
value the operator cannot move the cursor to this position and cannot change the value that
appears on this line.

2 .. . .. M O L D O P E N P O S I T IO N A = 20.00 in

This is a value that the operator sets and indicates how far the mold will open during the
mold opening function. Of course, it also represents how far the mold will close during the
mold close function.

3 .. . .. S TA R T E J E C TO R F O RWA R D A1 = 20.00 in

If the machine is equipped with an accumulator or an extra pump, specifically dedicated to

ejecting on-the-fly, this function can be initiated during the mold opening stroke. If the
machine does not have the extra power source, start ejector forward position 'A1' must be
set equal to the mold open stroke position 'A'.

CAUTION!

If you decrease the mold open position A, A1 will be

automatically decreased.
If you then increase A, A1 will remain at the lower valve
causing the ejector forward function at that position. Make
sure cores are clear!

4 .. . .. R E T R A C T P O S IT I O N L = 1.00 in

This is a value that the operator sets and represents the required rear position of the ejector.
Since the operator can set the rear position, the ejector does not necessarily have to return
to its mechanical zero point. This helps the operator cut time from the total cycle.
If possible, try not to set the 'L' position to 0.0 inches.

5 .. . . S TA R T 2 N D S P E E D F W D . V 2 7 L3 = 2.50 in

This is a value that the operator sets and represents the position where the second ejector
forward speed, V27, begins. If not required, set equal to L or L1.

6 .. . .. E J E C TO R F O RWA R D P O S I T IO N L1 = 3.00 in

This is a value that the operator sets and represents the required ejection stroke. The
ejector will move from its rear position 'L' to the distance away from zero indicated by 'L1'.
Given an 'L' position of 1.00 inch and an 'L1' position of 3.00 inches., respectively, this
ejector will move 2.00 inches forward and then 2.00 inches back. 'L1' cannot be set greater
than the mold open stroke position 'A'.

10/10/02 5. SCREEN PAGES 91

 EC100 / CC100 - A03 OPERATOR:
7 .. . .. E J E C TO R S H A K E P O S IT IO N L2 = 2.50 in

This variable is used to allow the operation of the ejector between the full ejector stroke
position, 'L1', and an intermediate stroke position, 'L2'. To achieve this function, 'L2' must be
set higher than 'L'. The ejector will move forward to position 'L1' and "shake" between 'L1'
and 'L2', once less than the number set at 'AZ' - Ejector Counter, then retract to position 'L'.
For example, if 3 shakes are desired then 'AZ' should be set to 4.

8 .. . . E J E C TO R P O S . A C T. VA L . SAx = 1.00 in

This is the actual value of the ejector position at any time during the cycle. Since it is an
actual value the operator cannot move the cursor to this position and cannot change the
value that appears on this line.

9 .. . .. 1 S T E J E C TO R F O RWA R D S P E E D V25 = 40 %

This is a value that the operator sets and represents the percentage speed required for the
first ejector forward speed movement.

1 0 . .. 2 N D E J E C TO R F O RWA R D S P E E D V27 = 40 %

This is a value that the operator sets and represents the percentage speed required for the
second ejector forward speed movement, if required.

11 . .. E J E C TO R R E T R A C T S P E E D V26 = 40 %

This is a value that the operator sets and represents the percentage speed required for the
backward ejection movement.

1 2 . .. E J E C TO R F O RWA R D P R E S S U R E P25 = 30 %

This is a value that the operator sets and represents the percentage pressure required for
the forward ejection movement.

1 3 . .. E J E C TO R R E T R A C T P R E S S U R E P26 = 30 %

This is a value that the operator sets and represents the percentage pressure required for
the backward ejection movement.

1 4 . .. .. E J E C TO R F O RWA R D D E L AY Z AV = 0.0 s

This is a value that the operator sets that will delay the ejector forward function. The time
'ZAV' begins at point 'A1 - START EJECTOR FORWARD'. When 'ZAV' expires, the ejector
forward function will start. The delay will occur only on the first ejection of a multiple ejection
cycle.

92 5. SCREEN PAGES 10/10/02

 EC100 / CC100 - A03 OPERATOR:
1 5 . .. .. E J E C TO R R E T R A C T D E L AY ZA = 0.0 s

This is a value that the operator sets to cause the ejector to dwell in its forward position for
'ZA' length of time before the ejector backward movement occurs. For example, if 'ZA' was
set to 2 seconds, the ejector would move forward the length of its stroke and after 2 seconds
the ejector would move back to its rear position. The dwell in the forward position will occur
for each ejection of a multiple ejection cycle.

1 6 . .. R E - C Y C L E T I M E Z5 = 0.0 s

This is a value that the operator sets and represents the amount of time that the mold will
stay in the open position, after the ejection function, but before a new cycle start. This is
generally used to guarantee enough time for the ejected part to fall clear of the two mold
halves before the next automatic cycle start.

1 7 . .. E J E C TO R C O U N T E R AZ = 2 t im

This is a value that the operator sets for the number of times the ejector is required to cycle,
forwards and back and is used for multiple ejections.
If 'AZ' is set to zero, the ejector will not operate (in any mode of operation). If ‘AZ" = 1, then
the ejector will move from ‘L" retract position to ‘L1" forward position and return to ‘L".
If AZ is set to any value greater than one then the ejector will “shake" between ‘L1" and ‘L2"
one less than the number set at "AZ".

1 8 . .. C Y C L E E N D S W I T H E J E C TO R . .. B A C K /F O RWA R D

If the machine is running in semi-automatic, the operator can choose to have the cycle end
with the ejector forward or back. If the operator chose to have the cycle end with the ejector
forward, the following cycle would start with the ejector retracting.
To have the cycle end with the ejector in the forward position, move the cursor to this line,
press 1, and then press 'ENTER'.
To have the cycle end with the ejector in the retracted position, move the cursor to this line,
then press 'ENTER'.

1 9 . .. E J E C T I O N M O N I TO R I N G Y E S /N O

This is an option that is used to detect whether or not a molded part has been ejected and
is clear of the mold. Ejection scales or a photocell determine if the molded part has fallen
clear of the mold and, if so, signals the next cycle to begin.

If the signal (LS) is received during mold opening indicating that the part has dropped out,
there will be no ejection, but the cycle will continue. If the mold has opened without seeing
the signal (LS), the ejection function will operate but the controller must see the signal (LS)
indicating that the part has dropped out within the re-cycle time, 'Z5' to continue the cycle.

For example, if the operator is employing an airblow to eject the part during mold open, the
ejector can be employed as a back-up ejection system. The ejection control function can
eliminate the need for hydraulic ejection and lead to significant cycle time savings.

10/10/02 5. SCREEN PAGES 93

 EC100 / CC100 - A03 OPERATOR:
4.1 PRODUCTION DATA

PRESS

Refer to the line numbers on the following pages for the description of each variable.

F1 EJECTOR
F2 PRODUCTION DATA
F3 IN MOLD EJECTOR (optional)
F4 AUXILIARY PUMP (optional)

94 5. SCREEN PAGES 10/10/02

 EC100 / CC100 - A03 OPERATOR:
Rejects Program

A reject is recognized and the reject counters will increment based on the following programs:
1. Injection Time Monitoring (see injection page)
2. Cushion Size Monitoring (see hold pressure page)
3. Micrograph 'a' to 'c' curve Comparison (see Micrograph Parameters page)
4. Microplast Flownumber Monitoring (see Microplast)
5. Microflow Correction Tolerance Monitoring (see Microflow)
6. Quality Data Statistics - Specification Limit Monitoring (see QDS Control Limits page)
7. Process Data Monitoring (as an error evaluation).

NOTE!

When you are first setting up a mold consideration should be

given to the deactivation of these programs until you are ready
to run production.

1 .. . .. . .S TA R T- U P C Y C L E S : A C T = 0 SET = 5 Cyc

When the operator starts the machine in an automatic cycle, it often occurs that the first few
shots will be of poor quality. Usually, this can be attributed to the screw and barrel not being
completely heated up, yesterday's purging material showing up in today's melt, hydraulic oil
not being up to temperature, and so on.

If the operator enters a value in 'SET', that number of cycles after starting will automatically
be rejected without incrementing the shot or parts counters, or the rejects counters.

On the cycle after 'ACT' (actual) equals 'SET', the shot and parts counters will start
incrementing as normal.

For every incrementation of 'ACT', and for any reject identified thereafter, the digital output
'AA' is energized. If the machine is equipped with optional equipment to recognize that a
reject part has been produced, the reject parts can be separated from the good parts.

To set 'ACT' to zero, move the cursor to either SHOT ACTUAL VALUE - SZx or PIECE
ACTUAL VALUE - StZx and press ENTER.
The message "ARE YOU SURE?, (Enter) = Yes" will appear. Press ENTER again to confirm
your action. This action will set 'SZx', 'StZx' and 'ACT' to zero.

10/10/02 5. SCREEN PAGES 95

 EC100 / CC100 - A03 OPERATOR:
2 .. . . R E S TA R T AT M A N U A L M O D E A F T E R 0 s

If the machine has been switched into manual or semi-automatic mode and restarted in
automatic within the time set on this line, the counter will continue to count shots and
rejects.
If the machine has been in manual for longer than the time set here, the “Start-up cycles:
ACT” will be set to zero. When the machine is restarted in automatic, the controller will reject
all the parts produced until the cycle after, 'ACT' (actual) equals 'SET' as set on line 1.
From this point on the shot and parts counters will start incrementing as normal.

3 .. . . R E J E C T S M A X 4 Sht / 50 min

ACT .= 0 Cyc

If the operator sets REJECTS MAX. 4 SHOTS in every 50 minutes on this line, the machine
will be allowed to produce up to 4 rejects for every separate period of 50 minutes. If the
machine produces 5 rejects in any period of 50 minutes, the machine will go into an alarm
condition and will stop cycling.
The actual number of rejects and the accumulated time will be reset to zero when each
period of 50 minutes expires. As well, if the machine stops cycling due to too many rejects
being produced, both the actual rejects accumulated and the accumulated time will reset to
zero after approximately 15 seconds.

4 .. . . R E J . S E Q U E N C E A C T. = 0 MAX = 3 Cyc

The operator can choose to have the machine stop cycling and go into an alarm state if a
certain number of consecutive rejects are identified.
This function is not in effect if this line is set to zero. If a number greater than zero is entered
on this line, the control will continue to "look" for consecutive rejects.

5 .. . . R E J E C T S TO TA L = 0 Cyc

This line displays the total number of rejects identified over a number of time periods, or
consecutively.
To reset this counter, move the cursor to this line and press 'ENTER'. The following prompt
will appear:
'ARE YOU SURE ?, enter> = YES'
The prompt is asking the operator if it is safe to delete the rejects count. In other words,
should the operator record the total before deletion?
If it is safe to delete the counter, press 'ENTER' once more. The counter will reset to zero.

6 .. . . S H O T S E T VA L U E SZ = 900Cyc

This area allows the operator to set the machine in automatic or semi-automatic and the
machine will continue to cycle until 'SZx' equals 'SZ'. When 'SZx' equals 'SZ' the machine
will stop cycling, the motor will shut off and the barrel heat will lower according to the heat
page programmed levels.
A change in this variable will cause an adjustment to 'Good Parts Required', StZ.

96 5. SCREEN PAGES 10/10/02

 EC100 / CC100 - A03 OPERATOR:
7 .. . . S H O T A C T. VA L U E SZx = 0Cyc

This line displays the total number of cycles since the machine was put into semi-automatic
or automatic, including rejects and parts produced during the “start-up cycle”.
To reset this counter, move the cursor to this line and press 'ENTER'. The following prompt
will appear:
'ARE YOU SURE ?, enter> = YES'
This prompt is asking the operator if it is safe to delete the shot count. In other words, should
the operator record the total before deletion ?
If it is safe to delete the counter, press 'ENTER' once more. The counter will reset to zero.

8 .. . . C AV IT Y N U M B E R FA = 4

This line allows the operator to indicate that a multiple cavity mold is being employed. This
line also acts as the multiplier, in order to assist in keeping track of total production.
The minimum valve for 'FA' is 1. The maximum value for 'FA' is 999.

9 .. . . P I E C E S E T VA L U E StZ = 3600 Pcs

This area allows the operator to set the machine in automatic or semi-automatic and the
machine will continue to cycle until 'StZx' equals 'StZ'. When 'StZx' equals 'StZ', the
machine will stop cycling, the motor will shut off and the barrel heat will lower according to
the heat page programmed levels.
A change in this variable will cause an adjustment to 'Total Cycles Required', SZ.

1 0 . . P I E C E A C T. VA L U E StZ x = 0 Pcs

This line displays the total number of parts produced. 'StZx' is the product of the number of
cycles 'SZx' times the number of cavities 'FA'. It will not increment if a reject is produced or
during the “Start - up cycles” function.
To reset this counter, move the cursor to this line and press 'ENTER'. The following prompt
will appear:
'ARE YOU SURE ?, enter> = YES'
This prompt is asking the operator if it is safe to delete the parts count. In other words,
should the operator record the total before deletion ?
If it is safe to delete the counter, press 'ENTER' once more. The counter will reset to zero.

10/10/02 5. SCREEN PAGES 97

 EC100 / CC100 - A03 OPERATOR:
4.2 MOLD EJECTORS

PRESS

CONTROLLED BY THE MAIN PUMP

Refer to the line numbers on the following pages for the description of each variable.

F1 EJECTOR
F2 PRODUCTION DATA
F3 IN MOLD EJECTOR (optional)
F4 AUXILIARY PUMP (optional)

98 5. SCREEN PAGES 10/10/02

 EC100 / CC100 - A03 OPERATOR:
1 .. . . A C T U A L M O L D P O S I T I O N SFx = 2 0 . 0 0 in

This is the actual value of the mold position at any time during the cycle. Since it is an actual
value the operator cannot move the cursor to this position and cannot change the value that
appears on this line.

2 .. . . M O L D O P E N P O S I T I O N A = 20.00 in

This is a value that the operator sets and indicates how far the mold will open during the
mold opening function. Of course, it also represents how far the mold will close during the
mold close function.

3 .. . . S TA R T E J E C TO R F O RWA R D 3A1= 20.00 in

If the machine is equipped with an accumulator or an extra pump, specifically dedicated to

ejecting on-the-fly, this function can be initiated during the mold opening stroke. If the
machine does not have the extra power source, start ejector forward position 'A1' should be
set equal to the mold open stroke position 'A'.

CAUTION!

If you decrease the mold open position A, 3A1 will be automati-

cally decreased. If you then increase A, 3A1 will remain at the
lower value causing the ejector forward function to operate at that
position. Ensure cores are clear before ejectors operate!

4 .. . . R E T R A C T P O S IT IO N 3L

This flag, when illuminated, indicates that the mold ejector is in the retracted position.

5 .. . . E J E C TO R F O RWA R D P O S I T I O N 3L1

This flag, when illuminated, indicates that the mold ejector is in the forward position.

6 .. . . E J E C TO R F O RWA R D S P E E D 3V25 = 40 %

This operator set value represents the percentage forward speed for the mold ejector
movement.

7 .. . . E J E C TO R R E T R A C T S P E E D 3V26 = 40 %

This operator set value represents the percentage return speed for the mold ejector
movement.

8 .. . . E J E C TO R F O RWA R D P R E S S U R E 3P25 = 30 %

This is a value that the operator sets and represents the percentage pressure required for
the forward mold ejection movement.

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 EC100 / CC100 - A03 OPERATOR:
9 .. . . E J E C TO R R E T R A C T P R E S S U R E 3P26 = 30 %

This is a value that the operator sets and represents the percentage pressure required for
the backward ejection movement.

1 0 . . E J E C TO R F O RWA R D D E L AY 3 Z AV = 0.0 s

This is a value that the operator sets that will delay the mold ejector forward function. The
time '3ZAV' begins at point '3A1 - START EJECTOR FORWARD'. When '3ZAV' expires, the
mold ejector forward function will start. The delay will occur only on the first ejection of a
multiple mold ejection cycle.

11 . . E J E C TO R R E T R A C T D E L AY 3ZA = 0.0 s

This is a value that the operator sets to cause the ejector to dwell in its forward position for
'3ZA' length of time before the ejector backward movement occurs. For example, if '3ZA'
was set to 2 seconds, the ejector would move forward the length of its stroke and after 2
seconds the ejector would move back to its rear position. The dwell in the forward position
will occur for each mold ejection of a multiple mold ejection cycle.

1 2 . . R E - C Y C L E T IM E Z5 = 0.0 s

This is a value that the operator sets and represents the amount of time that the mold will
stay in the open position, after the ejection function, but before a new cycle start. This is
generally used to guarantee enough time for the ejected part to fall clear of the two mold
halves before the next automatic cycle start.

1 3 . . E J E C TO R C O U N T E R 3AZ = 2 t im

This is a value that the operator sets for the number of times the mold ejector is required to
cycle, forwards and back and is used for multiple mold ejections.
If '3AZ' is set to zero, the mold ejector will not operate (in any mode of operation). If ‘3AZ" =
1, then the mold ejector will move from ‘L" retract position to ‘L1" forward position and return
to ‘L".

1 4 . . C Y C L E E N D S W IT H E J E C TO R . . . B A C K / F O RWA R D

If the machine is running in semi-automatic, the operator can choose to have the cycle end
with the mold ejector forward or back. If the operator chose to have the cycle end with the
mold ejector forward, the following cycle would start with the mold ejector retracting.

To have the cycle end with the mold ejector in the forward position, move the cursor to this
line, press 1, and then press 'ENTER'.

To have the cycle end with the mold ejector in the retracted position, move the cursor to this
line, and then press 'ENTER'.

100 5. SCREEN PAGES 10/10/02

 EC100 / CC100 - A03 OPERATOR:
CONTROLLED WITH SECOND PUMP AND PROPORTIONAL SPEED CONTROL

If a second pump with an additional proportional speed control valve has been purchased
for independent ejection functions the mold ejector will operate in the same manner as
described previously. With exception that the screen settings for pressure will not be
available and that now the 3A1 position can be set smaller than the A position.

Using standard ejector solenoids or independent solenoids

If the requirement for using the main machine ejectors with only limit switches is required
then this is possible by using the mold ejector option and by setting a parameter within the
control.

Parameter 36287 is used to control which solenoids will be used with the mold ejector
program.

0 – The mold ejector program will utilize the ejector 3 / mold ejector inputs and outputs.

1 – The mold ejector program will utilize the ejector 3 / mold ejector inputs but will use the
main machine ejector outputs. In this case the main machine ejector program will be
turned off and will not be allowed to be turned on, unless parameter 36287 is set to a
zero.

If the main machine ejector solenoids are utilized with the mold ejector program then mold
ejector program will function exactly as described above with exception that the main
machine ejector solenoids will be utilized.

10/10/02 5. SCREEN PAGES 101

 EC100 / CC100 - A03 OPERATOR:
4.3 AUXILIARY POWER SOURCE

PRESS

Refer to the line numbers on the following pages for the description of each variable.

F1 EJECTOR
F2 PRODUCTION DATA
F3 IN MOLD EJECTOR (optional)
F4 AUXILIARY PUMP (optional)

102 5. SCREEN PAGES 10/10/02

 EC100 / CC100 - A03 OPERATOR:
The independent pump for cores & ejectors option is used when the machine operation requires
the ejectors to operate with “ejectors on the fly”. The option has been set to support a manual
isolation valve or an automatic isolation valve ( SPT ). It will also support proportional speed
control for both cores & ejectors.

1 .. . IN D E P.S E C . P U M P F O R C O R E S & E J E C . Y E S / N O

If the operator moves the cursor to this line and presses 1 and ENTER then the YES will
appear and the output from the optional independent additional pump will be used for the
cores and ejectors.
If the operator moves the cursor to this line and presses 0 and ENTER then the NO will
appear and the optional independent additional pump will not be active.

2 .. . IN D E P.S E C . P U M P S TAT U S

When the independent additional pump is active, then the box at the end of this line will be
illuminated.

If the option has configured for a manual isolation valve then the screen will appear as shown . If
a automatic isolation valve has been configured then the SPT valve status will also appear on the
auxiliary pump screen page.

When selecting the machine ejectors / cores to run from the main pump or the second pump the
operator has to manually open/close the isolation valve. The following are the parameter that
affect the independent pump setup.

Parameter Description
35760 0 = Automatic SPT valve is installed.
> 0 The manual isolation valve message display time in seconds. This is the amount
of time that the message will be displayed.

35757 Manual isolation valve message display selection.

0 = Message A:
Whenever the independent pump is turner on the message will read:
PLEASE DO NOT FORGET TO TURN THE MANUAL ISOLATION VALVE TO
or THE CLOSED POSITION
Whenever the independent pump is turner off the message will read:
PLEASE DO NOT FORGET TO TURN THE MANUAL ISOLATION VALVE TO
THE OPEN POSITION

1 = Message B:
Whenever the independent pump is turner on the message will read:
PLEASE DO NOT FORGET TO TURN THE MANUAL ISOLATION VALVE TO
or THE OPEN POSITION
Whenever the independent pump is turner off the message will read:
PLEASE DO NOT FORGET TO TURN THE MANUAL ISOLATION VALVE TO
THE CLOSED POSITION

10/10/02 5. SCREEN PAGES 103

 EC100 / CC100 - A03 OPERATOR:

5 INJECTION BOOST

PRESS

Refer to the line numbers on the following pages for the description of each variable.

F1 INJECTION BOOST
F2 BOOST CUT - OFF MODE
F3 SET VALUE GRAPHICS
F4 P & V CONTROL PARAMETERS (see Controller - Maintenance)

104 5. SCREEN PAGES 10/10/02

 EC100 / CC100 - A03 OPERATOR:
1 .. . . IN C R . S P E C I F I C IN J E C T I O N P R E S S U R E Y E S / N O

Normally, the increased injection pressure function is switched to 'No' and the injection
process occurs with a regenerative hydraulic circuit. This has the effect of an increased
injection speed, but a proportional reduction in the specific injection pressure. When the
increased injection pressure function is switched to 'YES', the regenerative hydraulic circuit
drops out and the injection process occurs with a lower maximum speed but with a
proportional increase in specific injection pressure. When the operator switches this
program from 'NO' to 'YES', a lower maximum injection speed will appear on line 2.

2 .. . . M A X I N J E C T I O N S P E E D 4.4 i n /s

This is where the maximum injection speed possible for the particular machine is shown and
should be used as a reference when profiling the 10 injection speeds. When increased
injection pressure is selected on line 1, a lower maximum injection speed will be
automatically entered into this data field.

3 .. . . P U R G I N G S P E E D L IM IT 0.5 I n /s

When manual injection is performed and either the nozzle is not forward (position J not
reached) or the mold is not closed (position G2 not reached) the purge speed limit is in
effect. Any injection speed profile steps that are higher than the speed limit will be
temporarily reduced to the value of the speed limit and restored to their original value after
manual injection is completed.

The flag will illuminate to indicate that purging speed limit is in operation.

4 .. . . P E A K A C T U A L I N J E C T I O N S P E E D : = 3 .3 i n /s

This is the actual value of injection speed during the injection function. Since it is an actual
value the cursor cannot be moved to this position.

The operator has the ability to profile the speed of injection based on the 10 velocity settings
V12 - V21 shown above. The operator has the choice of setting each of the 10 separate
injection speeds between .1 in/s and the maximum injection speed that appears on line 2.
The operator can choose a length or distance for each of the 10 separate speed zones on
the set value graphics page. For example, 'V12' can be maintained for half of the stroke with
'V13' through 'V21' being distributed throughout the last half of the injection stroke.

6 .. . . IN J . B O O S T P R E S S U R E L IM IT P6 = 1 4 5 0 ps i

Injection pressure, 'P6', should be viewed as the upper limit of injection pressure. Normally,
the operator should set this pressure 300-400 psi higher than the hydraulic pressure
actually needed to fill the mold. If this level of pressure is reached during injection, the
control would lose its capacity to manage injection speed. Specifically, if this pressure is
reached during injection, speed will decrease.

10/10/02 5. SCREEN PAGES 105

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7 .. . . A C T U A L H Y D R A U L I C P R E S S . PHx = 0 ps i

The actual value of hydraulic pressure during injection or hold pressure is displayed in
variable 'PHx'.

8 .. . . A C T U A L S C R E W P O S IT IO N SSx = 4.2 in

This is the actual value of the screw position at any time during the cycle. Since it is an
actual value, the operator cannot move the cursor to this position and cannot change the
value that appears on this line.

9 .. . . IN J E C T I O N T I M E M O N I TO R I N G
MIN 0.00 MAX 0.00 ZSx = 0 .0 0 s

A minimum and/or maximum injection time can be set in this area. During the injection
function, if the actual injection time 'ZSx', falls outside of the minimum/maximum time
boundaries, the cycle will terminate.
Specifically, if the maximum boundary is exceeded, the injection will immediately stop, the
screw will reload and the mold will open. If the minimum boundary is exceeded, injection is
completed, the screw will reload and the mold will open.
ZSx is the variable monitors the actual time of injection. This timer starts at the beginning of
injection and ends at the transfer point of injection boost to hold pressure.

The intrusion function allows the operator to prefill some of the mold cavity before the start
of injection. The program can be used in cases where the barrel does not have the capacity
to fill the mold.
If the program is employed, the screw will turn for 'ZIN' amount of time before injection
starts. An intrusion speed must also be set.

If the intrusion program is employed, the operator must also set the intrusion speed, 'V23'.
This will dictate the screw RPM rate while the intrusion function is active.

106 5. SCREEN PAGES 10/10/02

 EC100 / CC100 - A03 OPERATOR:

This line allows the operator to choose from 3 separate shut-off nozzle functions.
0 - held closed
This is used on machines equipped with the shut-off nozzle option, but the shut-off nozzle
is not mounted on the barrel. This prevents the digital output for this function from being
activated and prevents the cylinder and linkage from moving when not necessary.
1 - held open
This is used on machines that have the shut-off nozzle mounted but is not required. The
digital output for this function will always be active and the shut-off nozzle will always be
open.
2 - automatic
This choice will cause the shut-off nozzle to open at the start of injection subject to the delay
time as outlined below.

If the machine is equipped with an appropriate nozzle shut-off valve, this timer can be
employed to control the time at which the valve opens. For example, if this timer was set to
0.14 s, the injection function would start and after 0.14 s, the shut-off nozzle would open up
allowing plastic to travel into the mold. If the time was set to zero, the shut-off nozzle would
open up immediately at the start of injection.

10/10/02 5. SCREEN PAGES 107

 EC100 / CC100 - A03 OPERATOR:
5.1 BOOST TO HOLD CUT OFF MODE

PRESS

Refer to the line numbers on the following pages for the description of each variable.

F1 INJECTION BOOST
F2 BOOST CUT - OFF MODE
F3 SET VALUE GRAPHICS
F4 P & V CONTROL PARAMETERS (see Controller - Maintenance)

NOTE!

Whichever of the five different methods of boost to hold trans-

fer has been chosen by the controller will be indicated by a
flag appearing beside the triggering variable. This flag will
remain lit until the next cycle.

108 5. SCREEN PAGES 10/10/02

 EC100 / CC100 - A03 OPERATOR:
1 .. . . S C R E W S T R O K E D E P E N D E N T YES

If the operator chooses to transfer into hold pressure based upon reaching a specific screw
position, then this program must be activated.

Move the cursor to this line, press '1', then 'ENTER'. To turn this program off, press '0', then
'ENTER'.

2 .. . . S T R O K E C U T-O F F S E T P O I N T C3 = 0.3 in

The linear screw stroke transducer monitors the axial position of the screw. Therefore, if this
program is turned on, and if 'C3' is set to a value above 0 inches, the control will "watch" for
the screw position to equal 'C3'. When the two values are equal, the control will switch into
the hold pressure function, pressures P7-P16.

3 .. . . A C T. S C R E W P O S . AT C U T-O F F C3u = 0.0 in

The actual position of the screw at the moment of boost to hold transition is reflected in
variable 'C3u'. The screw position at the hold pressure transfer point will be shown
regardless of which method of boost to hold transfer is employed.

4 .. . . A C T U A L S C R E W P O S IT IO N SSx = 4.2 in

This is the actual value of the screw position at any time during the cycle. Since it is an
actual value, the operator cannot move the cursor to this position and cannot change the
value that appears on this line.

5 .. . . T I M E D E P E N D E N T Y E S /N O

If the operator chooses to transfer into hold pressure after a certain period of injection time,
then this program must be activated.

Move the cursor to this line, press '1', then 'ENTER'. To turn this program off, press '0', then
'ENTER'.

6 .. . . IN J E C T I O N B O O S T T I M E Z1 = 3.00 s

The controller monitors the amount of time during the injection function. Therefore, if this
program is turned on, and if 'Z1' is set to a value, the control will watch for the actual time to
equal 'Z1'. When the two values are equal, the control will switch into the hold pressure
function, pressures P7-P16.

7 .. . . A C T U A L IN J . B O O S T T I M E ZSx = 0.00 s

This variable monitors the actual time of injection. This timer starts at the beginning of
injection and ends at the transfer point of injection boost to hold pressure. The elapsed
injection time will be displayed regardless of which method of boost to hold transfer is
employed.

10/10/02 5. SCREEN PAGES 109

 EC100 / CC100 - A03 OPERATOR:
8 .. . . H Y D R A U L I C P R E S S U R E D E P E N D E N T Y E S /N O

If the operator chooses to transfer into hold pressure based upon reaching a specific
hydraulic injection pressure, then this program must be activated.

Move the cursor to this line, press '1', then 'ENTER'. To turn this program off, press '0', then
'ENTER'.

9 .. . . H Y D R . P R E S S . C U T-O F F P O I N T PH = 0 ps i

The hydraulic pressure transducer monitors the hydraulic pressure during injection.
Therefore, if this program is turned on, and if 'PH' is set to a value greater than 0 psi, the
control will "watch" for the hydraulic pressure to equal 'PH'. When the two values are equal,
the control will switch into the hold pressure function, pressures P7-P16.

1 0 . .. H Y D . P R E S S . AT C U T- O F F PHu = 0 ps i

The actual value of hydraulic pressure at the moment of boost to hold transition is reflected
in variable 'PHu'. The hydraulic pressure at the hold pressure transfer point will be displayed
regardless of which method of boost to hold transfer is employed.

11 . .. H Y D . P R E S S . C U T- O F F W IN D O W C3b = 0.00 in
To guarantee that the boost to hold transition occurs at the correct position, a cut-off window
can be set.
C3b is set to a particular screw position, and until that screw position is reached the
controller will ingore any boost-to-hold transfer settings. Once the set screw position C3b
has been reached, the controller will transfer from boost to hold when the desired transfer
setting is reached.
For example, if hydraulic pressure transfer is required, a pressure spike at the beginning of
injection, as in the case of some hot runner molds, could cause a premature transfer into
hold pressure.
If 'C3b' is set to a value after the known pressure spike area the control will ignore the
pressure spike and only "look" for the value 'PH' after screw position 'C3b'. Refer to the
variable 'C3u' for an indication of the screw position at which 'PH' was identified.

1 2 . .. P E A K VA L .PV s = 0 A C T. PHx = 0 ps i

The peak value of hydraulic injection pressure is displayed in variable 'PVs'. The actual
value of hydraulic pressure during injection or hold pressure is displayed in variable 'phx'.

1 3 . .. C AV I T Y P R E S S . D E P E N D E N T Y E S /N O

If the operator chooses to transfer into hold pressure based upon reaching a specific mold
cavity pressure, then this program must be activated. Of course, the machine must have a
cavity pressure transducer in order to use this program.

Move the cursor to this line, press '1' then 'ENTER'. To turn this program off, press '0', then
'ENTER'.

110 5. SCREEN PAGES 10/10/02

 EC100 / CC100 - A03 OPERATOR:
1 4 . .. C AV. P R E S S .C U T- O F F P O IN T PF = 0 ps i

The cavity pressure transducer monitors the mold cavity pressure during injection.
Therefore, if this program is turned on, and if 'PF' is set to a value greater than 0 psi, the
control will "watch" for the cavity pressure to equal 'PF'. When the two values are equal, the
control will switch into the hold pressure function, pressures P7-P16.

1 5 . .. C AV. P R E S S .AT C U T- O F F PFu = 0 ps i

The actual value of mold cavity pressure at the moment of boost to hold transition is
reflected in variable 'PFu'. The mold cavity pressure at the hold pressure transfer point will
be displayed regardless of which method of boost to hold transfer is employed.

1 6 . .. P E A K VA L .P F s = 0 A C T. PFx = 0 ps i

The peak value of mold cavity pressure is displayed in variable 'PFs'. The actual value of
mold cavity pressure during injection or hold pressure is displayed in variable 'PFx'.

1 7 . .. E X T E R N A L C U T- O F F C3E Y E S /N O

The operator could have the option of supplying an external digital signal to the control to
initiate the transfer from boost to hold pressure. For example, the mold could be equipped
with a device to monitor the mold parting line during injection. When the parting line
separates to a certain extent, a digital signal would be supplied to the controller causing the
boost to hold pressure transfer.

Move the cursor to this line, press '1', then 'ENTER'. To turn this program off, press '0', then
'ENTER'.

1 8 . .. PA R A L L E L C U T- O F F Y E S /N O

The operator can use the parallel cut-off program to set up a "first come-first served" boost
to hold transfer condition. For example, if two or more cut-off programs have been activated,
whichever condition is met first will cause the boost to hold pressure transfer. Until this
program has been turned on, only one boost to hold cut-off can be activated at any one
time. If this program does not appear on your boost to hold cut-off page, the program can
be activated by setting the variable set value 35482 equal to 1. User level 1 password must
be entered in order to activate the program.

1 9 . .. PA R A L L E L C U T- O F F W I N D O W C3d = 0.0 in

If the operator has employed the parallel cut-off program in order to use two or more
possible cut-offs, an additional cut-off window can be set using variable 'C3d'.

In other words, even though one or more of the parallel cut-off conditions have been met, it
can be further dictated that screw stroke position 'C3d' must also be met before the transfer
from boost to hold will be effected. Please note that if time is being employed as one of the
cut-off conditions, the time Z1 will begin at 'C3d', if 'C3d' is set greater than 0.0 inches. If
'C3d' equals 0.0 inches, the time Z1 begins at the beginning of injection as it does normally.

10/10/02 5. SCREEN PAGES 111

 EC100 / CC100 - A03 OPERATOR:
5.2 SET VALUE GRAPHICS

PRESS

IN J E C T I O N P R O F I L E 96-10-07 12:00

100 %

0%
Sp = 0.00 in SSx 4.20 in
6.30 in
C2J C2I C2H C2G C2F C2E C2D C2C C2B C2A C1

C2J C2I C2H C2G C2F C2E C2D

0.40 0.79 1.19 1.59 2.07 2.40 2.87
1..... Injection stroke 0.00
2..... Injection speed 0.5 0.7 1.0 1.5 1.5 1.5 1.5 1.5
3..... Injection pressure 1001 1450 1450 1450 1450 1450 1450 1450

The injection profile page displays a graphic representation of the set stroke positions, injection
speeds and injection boost pressure.

The red line indicates injection boost pressure ,'P6', while the green line indicates percentage
speed.

F1 INJECTION BOOST
F2 BOOST CUT - OFF MODE
F3 SET VALUE GRAPHICS
F4 P & V CONTROL PARAMETERS (see Controller - Maintenance)

112 5. SCREEN PAGES 10/10/02

 EC100 / CC100 - A03 OPERATOR:
The set stroke positions, where the separate injection speed zones change, can be determined
by referring to the horizontal scale. Since the screen display is not large enough to show all stroke
positions at once, move the cursor to the right continuously to access the remaining stroke
positions.

The set percentage of speed or pressure can be determined by referring to the vertical scale on
the left 0% - 100%.

While the machine is cycling, the vertical blue line indicates the actual screw position at any point
in time. This would equal 'SSx'.

The variable Sp and the red vertical line represent the actual screw position where speed control
was lost (PHx = P6). Ideally PHx should never reach the pressure limit P6.

The hatched markings on the bottom left-hand corner of the graph indicate the position of the
stationary platen.

1. Injection stroke: The operator can move the cursor to adjust where the specific injec-
tion speed zones take effect. In other words, the operator does not
necessarily have to accept the automatic division of the injection
stroke into 10 equal speed zones. However, it is important to note
that if the speed zones are adjusted, the same proportions will be
maintained if the screw refill stroke value 'C1' is changed.
The 10 injection speed zone stroke positions will be, once more,
automatically divided into 10 equal speed zones if the screw refill
stroke value 'C1' is entered twice. This will also automatically divide
the screw refill stroke into 5 equal back pressure and screw refill
speed zones.

2. Injection speed The operator can move the cursor to adjust the injection speed for
each specific speed zone by shifting the cursor and entering a new
value.

3. Injection pressure: The operator cannot change the pressure for each injection zone.
The values that appear for zones 'C2A' to 'C2J' represent 'Injection
boost' pressure, 'P6'. The actual injection pressure, PHx should
always be lower than 'P6'. The pressure to the left of 'C2J' is the first
injection hold pressure 'P7'.

NOTES
A. If any values are changed on the profile page, the values will also be
changed on the parameter page and will immediately influence the
machine performance.
B. Any values that appear in white represent software set values and
cannot be changed.

10/10/02 5. SCREEN PAGES 113

 EC100 / CC100 - A03 OPERATOR:

6 INJECTION HOLD

PRESS

* REFER TO NOTE
Refer to the line numbers on the following pages for the description of each variable.

NOTE!

If you change barrels and the screw diameter size, enter the
new screw diameter size on line 12 and refer to the outline
regarding this program change.
Refer to notes 1 and 2 concerning screw diameter changes.

F1 INJECTION HOLD
F2 SET VALUE GRAPHICS

114 5. SCREEN PAGES 10/10/02

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The operator has the option of profiling the post injection pressure (hold pressure) based on
the 10 pressure settings P7 - P16 shown above. The operator has the choice of setting each
of the 10 separate hold pressures between 0 psi and the maximum system pressure. Each
of the hold pressures is maintained for 1/10 of the injection hold pressure time 'Z2'.

Specifically, the hold pressure time, 'Z2', is divided by 10, and each separate hold pressure
is maintained for its respective portion of the time.

2 .. . . I N J E C T I O N H O L D T IM E Z2 = 3.0 s

This is a value that the operator sets and is the length of time that hold pressure is
maintained. Each of the ten hold pressures is maintained for 1/10 of 'Z2' time. This variable
should be timed to end when the gates in the mold cavity "freeze".

If the screw bounces back at the beginning of hold pressure, the first hold pressure, 'P7'
may not be high enough.

If the screw moves back at the end of hold time 'Z2', the time is not long enough.

3 .. . . C O O L IN G T IM E A C T = 0 .0 Z4 = 7.0 s

The 'Z4' variable is a time that the operator sets and represents the intended amount of time
allowed for the molded part to cool.

The 'ACT' variable represents that actual cooling time as the machine is running. This time
begins when the hold pressure time, 'Z2', ends.

Normally, when the actual value equals the set value, 'Z4', the cooling time has been
completed and the mold open function will begin. If the actual value exceeds 'Z4' time,
check the screw refill function for correct operation.

4 .. . . C U S H IO N M O N ITO R IN G P R O G R A M : ON/OFF

The operator can choose to monitor the cushion value, 'CPx' and its relationship to the
minimum ('MIN') or maximum ('MAX') cushion allowed. Specifically, at the end of hold
pressure the control would examine 'CPx'. If 'CPx' is less than 'MIN' or greater than 'MAX',
an error message would appear, the rejects count would increment by one, and the digital
output 'AA' would activate to separate this "bad" part from all the good parts. Optional
equipment is required to employ the good part/bad part separation.

To turn the program on, move the cursor to the 'ON/OFF' position, press '1', then press
'ENTER'.

To turn the program off, move the cursor to the 'ON/OFF' position, and press 'ENTER'.

10/10/02 5. SCREEN PAGES 115

 EC100 / CC100 - A03 OPERATOR:
5 .. . . M I N = 0 .0 0 MAX= 1.0 CPx = 0.00 ins

The operator can monitor minimum allowed cushion length by setting 'MIN' to some value.
If 'MIN' is set to zero, this becomes the minimum allowed cushion length. At the end of hold
pressure time, 'Z2', the actual length of the cushion, 'CPx', is calculated and compared to
the value entered in 'MIN'.

The operator can monitor maximum allowed cushion length by setting 'MAX' to some value
greater than zero. At the end of the hold pressure time, 'Z2', the actual length of the cushion,
'CPx', is calculated and compared to the value entered in 'MAX'.

If 'CPx' is less than 'MIN', or greater than 'MAX', a reject message increments the rejects
counter by one and the digital output 'AA' is activated. The digital output 'AA' can be used to
separate good parts from bad parts if the machine is equipped with a mechanical parts
separator (i.e. robot arm, bad parts chute, etc.).

The variable 'CPx' is an actual value and cannot be set by the operator. Specifically, at the
end of the hold pressure time, 'Z2', the actual value of the cushion is calculated and that
value appears as 'CPx'.

6 .. . . C U S H IO N C O R R E C T IO N CP 0.0 ins

This is a value that the operator can set if a particular cushion length is desired. If 'CP' is set
to a value greater than zero, the program is activated. At the end of the hold pressure time,
'Z2', the actual length of the cushion, 'CPx', is calculated and compared to the value that is
entered in 'CP'. If there is a difference between 'CP' and 'CPx' the next screw refill stroke will
be adjusted accordingly. If there is a cushion correction, the new corrected screw refill
stroke will appear as corrected feed stroke 'C1*'.

This program should only be activated to compensate for a known mechanical deficiency,
such as a defective check ring, and is normally set to 0.00. As well, this variable must be set
to 0.00 (i.e. OFF) when MICROPLAST/MICROFLOW is employed.

7 .. . . S E T S C R E W F E E D S T R O K E C1 = 4.0 ins

This is a value that the operator sets and represents the distance that the screw travels
backwards axially during the screw refill function. Specifically, as the value of 'C1' is
increased, a greater amount of plastic is "loaded" in front of the screw in preparation for the
next injection.

8 .. . . C O R R E C T E D F E E D S T R O K E C1 *= 4.0 ins

The variable 'C1*' is a calculated value and cannot be set by the operator. Specifically, if the
cushion correction program, 'CP', has been activated and a new screw refill stroke has been
calculated, the corrected screw feed stroke will appear on this line.

9 .. . . A C T U A L S C R E W P O S IT IO N SSx = 4.2 ins

This is the actual value of the screw position at any time during the cycle. Since it is an
actual value, the operator cannot move the cursor to this position and cannot change the
value that appears on this line.

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10.. ACTUAL HYDRAUL.PRESSURE PHx = 0 ps i

If the machine is equipped with a hydraulic pressure transducer, the transducer will send a
signal that reflects the hydraulic pressure, back to the control. The specific value of the
hydraulic pressure at any time will be reflected in the variable, 'PHx'.

11 . . IN J .H O L D P E A K P R E S S U R E PNS = 0 ps i

If the machine is equipped with a hydraulic pressure transducer, the transducer will send a
signal that reflects the peak hydraulic hold pressure. This allows the operator to more
closely monitor his molding process.

12.. SCREW DIAMETER SDM = 40.0 mm

This program line allows the operator to limit specific injection pressure by associating a
maximum allowed hydraulic pressure with a specific screw diameter.

Certain screw diameters (SW35459 - SW35462) are assigned certain maximum hydraulic
injection pressures (SW35110 - SW35113 for regenerative injection; SW35116 - SW35119
for increased injection pressure). If the operator indicates that a new screw diameter is
being used, the controller will automatically limit the maximum pressure allowed for
pressures P6 - P16. Note that this includes injection boost pressure P6 and the hold
pressures, P7 - P16.

NOTE!

If you change barrels, pay special attention to the above

program changes. If you are not absolutely clear on this
point, contact ENGEL before you initiate the program
change, and especially before you cycle the machine.

NOTE!

Before reloading software confirm and note the screw

diameter. After reloading the software, the screw diameter
will be flashing at 0.0. The noted value will have to be
entered manually. The customer service password will give
access to this variable. The range of values are be
displayed in the lower lefthand dialog box. Enter the value
for the screw diameter into blue data entry box and press
the enter key.
The message “ARE YOU SURE? PRESS ENTER FOR YES”
will be displayed; press ENTER again to confirm the
setting.

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6.1 SET VALUE GRAPHICS

PRESS

Refer to the line numbers on the following pages for the description of each variable.

The Hold Pressure profile page displays a graphic representation of the injection hold pressure
times, injection hold speeds and injection hold pressure.

The yellow line indicates the injection hold time profile, the red line indicates injection hold
pressure and the white line indicates percentage speed.

F1 INJECTION HOLD
F2 SET VALUE GRAPHICS

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The horizontal scale represents the Injection hold time, split into ten time zones, the speed and
pressure for each time zone can be seen and adjusted as required. Since the screen display is
not large enough to show all injection hold pressure times at once, move the cursor to the right
continuously to access the remaining time zones.

The set percentage of speed or pressure can be determined by referring to the vertical scale on
the left 0% - 100%.

While the machine is cycling, the vertical blue line indicates the actual hold pressure time.
This would equal 'Z2x'.

The hatched markings on the bottom left-hand corner of the graph indicate the position of the
stationary platen.

1. Inj. hold press. time: The operator can adjust the overall time of the injection hold and
the time period will automatically divide into 10 equal time zones.

2. Injection speed The speed for each time zone is the same. If user level 1 pass-
word has been entered, the operator can adjust the overall injec-
tion hold speed. The operator can move the cursor to any speed
and enter a new value, up to 100%. The speed for each time zone
will change to the new value.

3. Injection pressure: The operator can move the cursor to adjust the injection hold
pressure for each specific time zone by moving the cursor to that
particular pressure and entering a new value.

NOTE!

A. If any values are changed on the profile page, the values

will also be changed on the parameter page and will
immediately influence the machine performance.

NOTE!

B. Any values that appear in white represent software set

values and cannot be changed.

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7 SCREW FEEDING

PRESS

Refer to the line numbers on the following pages for the description of each variable.

F1 SCREW FEEDING
F2 SET VALUE GRAPHICS

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1 .. . . S E T S C R E W F E E D S T R O K E C1 = 4.00 in
This is a value that the operator sets and represents the linear distance that the screw will
move back during the screw refill function. If the operator enters the stroke value twice, the
injection stroke will be divided into 10 equal length. This process will also divide the screw
refill stroke into 5 equal lengths. On the profile page for each of these functions, the operator
can re-adjust these speed and pressure ranges.

2 .. . . C O R R E C T E D F E E D S T R O K E C1* = 4.00 in
The variable 'C1*' is a calculated value and cannot be set by the operator. Specifically, if the
cushion correction program, 'CP', has been activated and a new screw refill stroke has been
calculated, the corrected screw feed stroke will appear on this line.

This is a value that the operator sets and represents the percentage speed of the maximum
screw RPM required during the screw refill function. The five separate speeds are initially
divided equally over the screw refill stroke, 'C1'. If the operator wishes to adjust the screw
refill stroke divisions, this can be done on the set value graphics page.

4 .. . . M A X IM U M S C R E W F E E D S P E E D DZm = 0 rpm
This is the maximum rpm rate identified, and stored, during the screw refill function.

5 .. . . A C T U A L S C R E W F E E D S P E E D DZx = 0 rpm
This is the actual value of the screw RPM rate during the screw refill function.

6 .. . . B A C K P R E S S U R E P E A K VA L . PSs = 0 ps i
This is the highest level of back pressure monitored during the screw refill function.

7 .. . . A C T U A L B A C K P R E S S U R E PSx = 0 ps i
During the screw refill function, 'PSx' will exhibit the actual back pressure existing at any
moment throughout the total screw refill function. This actual reading from the hydraulic
pressure transducer and the set value as chosen by the operator can be compared and
action can be taken if there are any significant differences noticed.

These five values represent the amount of pressure being applied to the back of the
injection cylinder piston. In other words, this represents the amount of pressure that the
screw must overcome in order to move back during the screw refill function. Of course, this
also causes pressure to be exerted on the plastic ahead of the screw during the screw refill
function. The maximum possible back pressure is 580 psi and the length or distance of each
zone can be set by the operator on the set value graphics page. If the set -up mode of
operation is activated, the above back pressure settings will be ignored and 0 psi back
pressure will result. This is useful in purging and in filling the screw cavity when the carriage
is in a retracted position.

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9 .. . . S C R E W F E E D M O N ITO R I N G T I M E R : O N /O F F

The operator can choose to monitor the feeding time, 'ZDx', and its relationship to the
minimum ('MIN') or maximum ('MAX') screw feeding time allowed. Specifically, during screw
refill the control would monitor 'ZDx'. If 'ZDx' is less than 'MIN' or greater than 'MAX', the
current cycle would be completed but the machine would then go into an alarm condition.

To turn the program on, move the cursor to the 'ON/OFF' position, press '1', then press
'ENTER'.

To turn the program off, move the cursor to the 'ON/OFF' position, and press 'ENTER'.

10.. MIN= 0.0 MAX. 7.0 ZDx = 0.0 s

If the operator chooses to monitor the screw refill function with regard to a set minimum refill
time ('MIN') or a set maximum refill time ('MAX'), the time values would be entered on this
line.
'MIN' - minimum allowed screw refill time.
'MAX' - maximum allowed screw refill time.
'ZDx' - actual screw refill time.
If 'ZDx' falls outside of the MIN/MAX time window, the machine will complete the current
cycle, but the machine would then go into an alarm condition. The 'SCREW FEED
MONITORING TIMER' program must be turned on for the time limits to be monitored.

11 . . L A S T C Y C L E ZDs = 0.0 s

This line shows the actual screw refill time on the last cycle. This value can be compared
with the actual screw refill time ZDx.

1 2 . . S C R E W F E E D D E L AY T I M E Z3 = 0.0 s

This is a value that the operator sets and represents the amount of time delay before
starting the screw refill function. This timer starts at the end of decompression before screw
refill, 'C4', or at the end of hold pressure if 'C4' equals zero.

This function can be used where especially long cooling times lead to plastic degeneration.
In other words, it can be employed to move the screw refill function later along within the
cooling time 'Z4'.

13.. DECOMPRESS. BEFORE FEED C4 = 0.0 in

This is a value that the operator sets to make the screw pull back a particular distance
before the screw refill function. For example, if 'C4' was set to .25 inches, the screw would
“suck back" .25 inches and then start refilling the barrel cavity.

14.. DECOMPRESS. AFTER FEED C2 = 0.20 in

This is a value that the operator sets to make the screw pull back a particular distance after
the screw refill function. For example, if 'C2' was set to .20 inches, the screw would refill the
barrel cavity and then "suck back" .20 inches.

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15.. D E C O M P R E S S I O N S TO P C2* = 4.20 in

The variable 'C2*' is a calculated value and cannot be set by the operator. Specifically, if the
decompression function after screw refill has been used, this variable represents the sum of
the screw stroke and the decompression stroke after screw refill. (i.e. C2* = C1* + C2).

16.. DECOMPRESSION SPEED V24 = 40 %

This is a value that the operator sets and represents the percentage speed at which
decompression, or "suck back" occurs. This velocity is in effect during decompression
before or after the screw refill function.

1 7 . . A C T U A L S C R E W P O S IT IO N SSx = 4.20 in

This is the actual value of the screw position at any time during the cycle. Since it is an
actual value the operator cannot move the cursor to this position and cannot change the
value that appears on this line.

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7.1 SET VALUE GRAPHICS

PRESS

SCREW FEED PROFI LE 96-10-07 12:00

100 %

0%
SSx 4.20 in
6.30 in
C4 C4B C4C C4D C4E C1

C4 C4B C4C C4D C4E C1

1..... Plasticizing stroke 0.00 0.81 1.62 2.43 3.24 4.00
2..... Screw rotat. in PCT. 25 25 25 25 25 0
3..... Back Press. in bar 44 44 44 44 44 0

The feeding profile page displays a graphic representation of the set stroke positions, refill speeds
and backpressures.

The red line indicates percentage pressure, while the green line indicates percentage screw RPM.

F1 SCREW FEEDING
F2 SET VALUE GRAPHICS

The set stroke positions, where the screw RPM and pressure changes take effect, can be
determined by referring to the horizontal scale.

The set percentage of screw RPM or pressure can be determined by referring to the vertical scale
on the left, 0% to 100%.

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While the machine is cycling, the vertical blue line indicates the actual stroke position at any point
in time. This would equal the value of SSx.

The hatched markings on the bottom left-hand corner of the graph indicates the position of the
stationary platen.

1. Plasticizing stroke: The operator can move the cursor to adjust where the specific
screw refill speed and back pressure zones take effect. In other
words, the operator does not necessarily have to accept the
automatic division of the screw refill stroke into 5 equal refill
zones. However, it is important to note that if the zones are
adjusted, the same proportions will be maintained if the screw
refill stroke value 'C1' is changed.
The 5 screw refill zones will be, once more, automatically
divided into 5 equal refill zones if the screw refill stroke value
'C1' is entered twice.
This will also automatically divide the injection speeds into 10
equal speed zones.

2. Screw rotat. in PCT: The operator can move the cursor to adjust the specific screw
rotation speed as a percentage of the maximum set speed.

3. Back pressure in bar: The operator can move the cursor to adjust the specific back-
pressure for each screw refill zone.

NOTE!

A. If any values are changed on the profile page, the valves will
also be changed on the parameter page and will immediately
influence the machine performance.

NOTE!

B. Any values that appear in white represent software set values

and cannot be changed

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 EC100 / CC100 - A03 OPERATOR:

8 QUALITY DATA PROGRAMS

PRESS

F1 PROCESS DATA REPORT

F2 PROCESS DATA GRAPHICS

F3 QUALITY DATA STATISTICS

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8.1 PROCESS DATA REPORT

PRESS

F1 PROCESS DATA REPORT

F2 PROCESS DATA GRAPHICS

F3 QUALITY DATA STATISTICS

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If the operator chooses Process Data Reports function, a page similar to the one above will
appear. This program will allow the operator to monitor up to 20 variables concerning the machine
or the molding process. As well as appearing on the screen, this information can also be
periodically printed out based on a specific number of cycles or after a certain amount of time.

A- This area of the Process Data page displays the selected variables. A cursor will appear so
that the operator can choose the variables to be monitored.

B- This area displays the first 11 variables which will be monitored, and which will also appear
on the screen. If more than 11 variables are chosen, the 12th through to the 20th will not
appear on the screen, however, they will be printed out.

C- This is the main display area for the monitored variables. The display area will also exhibit
the starting or stopping time of the program. This is also the area where the variable list will
appear, from which, the operator would choose the variables of interest.

D- This section of the Process Data page, is where the program is set up, with regard to:

1. When will the recording start, based on time or cycles.

2. How often will the event be recorded, based on time or cycles.

3. How many recordings will be made. (i.e. When will they end?)

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Function Frame Display

To activate the Process Data Report programs, you must:

Press “etc. -->”

This will cause the program's specific function frame display to appear.

Process Data Report

The function frame displays, relevant to the Process Data Report program, appear below.

F1 If the operator presses 'START/STOP', the Process Data Report program will start or stop.

F2 The operator would press 'PARAMETERS' to choose when the recording would start, how
often the event will be recorded, and when the recordings will end.

F3 The operator would press 'SET-UP' to choose the desired variables from the list of variables
which would appear in the main display area.

F4 The operator would press ‘OUTPUT UNIT" to select either: the “Printer”, “Floppy Normal”,
“Floppy Lotus”, “Floppy Excel” or “Screen Only” as an output device.

F8 The operator would press 'etc. --->' to return to the main Process Data menu.

When the operator presses F3 - SET-UP the following function from will appear.

F1 The operator would press 'INSERT' to choose a variable which would appear to the left of
the position of the cursor.

F2 The operator would press 'DELETE' to delete the variable located at the cursor position.

F3 The operator would press 'MODIFY' to choose a variable to monitor.

F4 The operator would press SELECT EVERYTHING to choose all the variables.

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F5 The operator would press EXIT to return to the previous function frame display.

F1 After choosing 'MODIFY' or 'INSERT' the operator would then press 'SELECT' to finalize
and enter the chosen variable.

F8 The operator would press 'EXIT' to return to the previous function frame display.

When the operator selects F4 - OUTPUT UNIT from the first function frame the following function
frame will appear

F1 If the operator presses “PRINTER”, the data will be transmitted to the RS232 serial data
port. The message "Output on printer" will also appear.

F2 If the operator presses the “FLOPPY" function key the following function frame will be
displayed and the data can be saved to the floppy disk.

F1 If the operator presses “FORMAT NORMAL”, the data will be transmitted to the
diskette or RAMDISK in an ASCII format. The message "Output on floppy (normal
format)" will also appear.

When a floppy output is selected the alphanumeric function frame will appear. A file
name must be entered, of up to 8 characters, into the data entry field. Refer to the
Mold Parameter page section, of this chapter entitled, "Setting Alphanumeric
Characters". When the file name has been entered, the message "Please wait" will
appear while the control checks the diskette and diskette drive cables.

NOTE!

The printer output file will have a PD file name extension.

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F2 If the operator presses “FORMAT LOTUS”, the data will be transmitted to the floppy
disk or RAMDISK in a PARSED (spreadsheet) format. The message "Output on
floppy (Lotus format)" will also appear.

When floppy disk or RAMDISK output is selected the alphanumeric function frame will
appear. A file name must be entered, of up to 8 characters, into the data entry field.
Refer to the Mold Parameter page section, of this chapter entitled, "Setting
Alphanumeric Characters". When the file name has been entered, the message
"Please wait" will appear while the control checks the diskette and diskette drive
cables.

NOTE!

The Lotus file will have a PRM file name extension.

F3 If the operator presses “FORMAT EXCEL”, the data will be transmitted to the diskette
or RAMDISK in a PARSED (spreadsheet) format. The message "Output on floppy
(Excel format)" will also appear.

When floppy disk or RAMDISK output is selected the alphanumeric function frame will
appear. A file name must be entered in the same manner as for format LOTUS.

NOTE!

The Excel file will have a XLE file name extension.

F3 If the operator presses “NO OUTPUT”, no data will be transmitted to an output device, but
the data could still be viewed on the screen as it is generated. The message "No output
device selected" will also appear.

F4 If the operator presses the “RAMDISK" function key the following function frame will be
displayed and the data can be saved to the RAMDISK. The RAMDISK is re-writeable
memory on-board the CPU card that can be used as a storage medium.

The functions are the same as for the Floppy as described on the previous page.

F8 The operator would press 'EXIT' to return to the previous function frame display.

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 EC100 / CC100 - A03 OPERATOR:
8.2 PROCESS DATA GRAPHICS

PRESS

F1 PROCESS DATA REPORT

F2 PROCESS DATA GRAPHICS

F3 QUALITY DATA STATISTICS

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If the operator chooses Process Data Graphics function, a page similar to the one above will
appear. This program will allow the operator to select up to eight variables and monitor up to three
variables concerning the machine or molding process. As well as appearing on the screen, this
information can be automatically printed out on a graphic printer after a certain cycle count, or
after a certain period of time.

A -This area of the Process Data page displays the selected variables and the operator can set a
separate resolution for each monitored variable by adjusting for 0% and 100%, an upper and
lower limit. An actual value for each variable also appears in this section.

B -This is the main display area for the monitored variables. The vertical scale shows the variable
recorded with 0% equaling the lower limit and 100% equaling the upper limit. The horizontal
scale displays the last 200 event recordings. For the operator's added benefit, the horizontal
scale also displays a time and cycle number related to each 1/5 portion of the graphic. This is
also the area where the variable list will appear, from which, the operator would choose the
variables of interest.

C -This section of the Process Data page is where the program is set up, with regard to:

1. When will the recording start, based on time or cycles.

2. How often will the event be recorded, based on time or cycles.

3. How many recordings will be made. (i.e. When will they end?)

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Variables List
SZx. . . . . . .Shot Counter Actual Value
DZx . . . . . Screw Rotation
PHu . . . . . Hydraulic Pressure Dependent Cut-off Point
PFu . . . . . Cavity Pressure Dependent Cut-off Point
PFs. . . . . . Cavity Pressure Peak Value
C3u . . . . . Screw Position at Cut-off
PVS . . . . . Hydraulic Pressure Peak Value Injection Boost
PNs . . . . . Hydraulic Pressure Peak Value Injection Hold
PSs . . . . . Back Pressure Peak Value
ZFx. . . . . . Mold Protection Time Actual Value
ZDx . . . . . Elapsed Feeding Time
ZSx. . . . . . Elapsed Injection Time
ZUs . . . . . Elapsed Cycle Time
Z4x . . . . . . Elapsed Cooling Time
CPx . . . . . Cushion Length
ASZ . . . . . Reject Total
OelTx . . . . Oil Temperature Actual Value
H1x. . . . . . Temperature - Heat Zone 1
up to
H20x. . . . . Temperature - Heat Zone 20
VSchx. . . . Mold Closing Speed
SKs . . . . . Clamping Force Stored
FZx. . . . . . Flow Number
SKx1 . . . . Clamping Force Current (Tie bar 1)
SKx2 . . . . Clamping Force Current (Tie bar 2)
SKx3 . . . . Clamping Force Current (Tie bar 3)
SKx4 . . . . Clamping Force Current (Tie bar 4)
SKs1 . . . . Clamping Force Stored (Tie bar 1)
SKs2 . . . . Clamping Force Stored (Tie bar 2)
SKs3 . . . . Clamping Force Stored (Tie bar 3)
SKs4 . . . . Clamping Force Stored (Tie bar 4)
Std . . . . . . Time (Hours)
Min . . . . . . Time (Minutes)
SSx . . . . . Screw Metering Stroke
SFs. . . . . . Mold Opening Stroke Stored
StZx . . . . . Part Counter Actual Value

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Function Frame Display

To activate the Process Data Graphic programs, you must:

Press “etc. -->”

This will cause the program's specific function frame display to appear.

Process Data Graphics

The function frame displays, relevant to the Process Data Graphics program, appear below.

F1 If the operator presses 'START/STOP' the Process Data Graphics program will start / stop.

F2 The operator would press 'PARAMETERS' to choose when the recording would start how
often the event will be recorded, and when the recordings will end.

F3 The operator would press 'SET-UP' to allow the cursor to be moved to one of the three
variables monitoring positions. Move the cursor to the chosen line and press 'SET' or
'RESET'.

F4 The operator would press 'CLEAR' to clear out the current screen graphic display. The
graphic display would start once more from the extreme left hand side.

F5 The operator would press 'PRINT' to print out the current graphic display. The graphic
printer must be set up according to the instructions in this manual.

F6 The operator would press 'AUTO.PRINT ON/OFF' to turn the automatic printout function on
or off. If the automatic printout function is active, the graphic display will be printed out
automatically after every 200 recordings. As well, if the automatic printout function is active
the indication 'AUTOHC' will appear in the “END” box at lower right hand corner of the
screen.
This “AUTOPRINT” runs independently from the AUTOPRINT on the “Process Data
Monitoring” screen page. But if both “AUTOPRINTS” are selected, both selected screens
will be printed.

F7 The operator would press “STATISTIC MONITORING” to enter the process data monitoring
program.

F8 The operator would press “etc.-->” to return to the main Process Data menu.

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F1 The operator would move the cursor to one of the three variable monitoring positions and
press 'SET'. This action will cause the main variable list to appear, and will "fix" the variable
monitoring position.
F2 The operator would move the cursor to one of the three variable monitoring positions and
press 'RESET'. This action will delete the variable at that position.
F8 The operator would press 'EXIT' to return to the previous function frame display.

F1 The operator will move the cursor to the location of the variable desired and press
'SELECT'. The chosen variable will be entered into the previously "fixed" variable
monitoring position. As the cursor is moved from one variable to another, the variable and
an explanation of what the variable represents, will appear directly above the function frame
display.
F8 The operator would press 'EXIT' to return to the previous function frame display.

F1 See 'SET' above.

F2 See 'RESET' above.
F3 The operator would press 'LOWER LIMIT' to set the minimum variable value for the graphic
display. For example, the operator may want to monitor a temperature range between
200 oC and 300 oC. The 200 oC temperature represents the lower limit or 0% on the vertical
axis of the graph.
F4 The operator would press 'UPPER LIMIT' to set the maximum variable value for the graphic
display. For example, the operator may want to monitor a temperature range between
200 oC and 300 oC The 300 oC temperature represents the upper limit or 100% on the
vertical axis of the graph.
F5 The operator would move the cursor onto one of the eight variable. Pressing this key will
have that variable represented by the color red on the graph.
F6 The operator would move the cursor onto one of the eight variable. Pressing this key will
have that variable represented by the color blue on the graph.
F7 The operator would move the cursor onto one of the eight variable. Pressing this key will
have that variable represented by the color green on the graph.
F8 The operator would press 'EXIT' to return to the previous function frame display

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 EC100 / CC100 - A03 OPERATOR:
8.3 PROCESS DATA MONITORING

PRESS

The Process Data Monitoring is part of the Process Data Graphic program. It is capable of
monitoring eight selected process parameters. One of the parameters can be displayed
graphically, showing the average values, tolerances, warning limits and actual values.
Process Data Monitoring offers expanded functionality over the Process Data Graphics.
The mean, x bar, and average of the mean,x bar bar, of up 8 process parameters are
calculated, plus monitoring tolerances are set up
The scale of the graph is taken from the PROCESS DATA GRAPHICS.
The xqsoll (set average value - x bar set value) is displayed with a white line.
The xqist (actual average value - x bar actual value) is displayed with a green line.
The xqq (total average value - x bar bar) is displayed with a blue line.
The plus and minus tolerances are displayed with a red line.

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Max This the maximum parameter of the graph i.e. 100%. This value should be set to a
level that is close but higher than the maximum value that is anticipated.

Min This the minimum parameter of the graph i.e. 0%. This value should be set to a level
that is close but lower than the minimum value that is anticipated.

xqset This is the average set value of the measurements taken over the initialization run.
This represented on the graph by a white line.

xqact This is the average actual value which is taken over the latest 160 - 200 measured
values, and corresponds to the values on the graph. This is represented on the graph
by a green line.

xqq This is the total average value of all the measurements taken. This is represented on
the graph by a blue line.

+Tol This is the maximum tolerance allowed on the measured value. This can be set by the
operator or can be set up automatically by the controller during the initialization run.
The controller selects the highest measured value during the initialization run and
employs this as the maximum tolerance. This function can be disabled by entering a
zero. This is represented on the graph by a red line.

-Tol This is the minimum tolerance allowed on the measured value. This can be set by the
operator or can be set up automatically by the controller during the initialization run.
The controller selects the lowest measured value during the initialization run and
employs this as the minimum tolerance. This function can be disabled by entering a
zero. This is represented on the graph by a red line.

WG+- This is a setting that will warn the operator when the measured values are starting to
go out of tolerance. This value can be input manually by the operator and ideally
should be a value within the maximum and minimum tolerance ranges. This value can
also be calculated automatically by the controller during an initialization run. The
controller compares the set average value (xqset) with the plus and minus tolerance
settings. The difference between the set average value and the closest tolerance
value is divided by two and entered as the Warning Tolerance (WG+-) value. This is
represented on the graph by yellow lines.

+TolCnt This is the total number of times that the measured value has gone over the
maximum tolerance.

-TolCnt This is the total number of times that the measured value has gone below the
minimum tolerance.

InitCnt This is the number of measurements taken over the initialization.

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F1 The “SELECTION LIST” key will display a screen page with up to eight parameters that
were selected.

F2 If the machine is in automatic, the process monitoring graphics has been stopped and the
machine process is running smoothly. The “INITIALIZATION” key will initialize the selected
parameter and take between 30 to 200 measurements (200 recommended) to generate the
average values, tolerance ranges, warning limits and error counter.

F3 The “ERROR RECORD” key will display all the parameters that were out of tolerance.

F4 The “ERROR EVALUATION” key will display a screen where the operator has a choice of
actions in the event of a parameter out of tolerance.

F5 The “PRINTING” key will output a hardcopy of the selected page a printer.

F6 The “AUTOPRINT ON” key, when pressed will turn the automatic printout function ON or
OFF. If this function is active, the graphical display will be automatically printed out after 200
recordings. When the function is active, the text AUTOHC will be displayed in the “END” box
at the lower right-hand corner of the screen.
This “AUTOPRINT” runs independently from the AUTOPRINT on the “Process Data
Graphics” screen page. But if both “AUTOPRINTS” are selected, both selected screens will
be printed.

F7 The “ERASE ALARM LAMP” key will clear any current alarm condition from the display and
will not disturb the automatic cycle.

F8 The “EXIT” key will return the screen to the previous Process data page.

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F1 - Selection list

From the main Process Data Monitoring menu press F1

The process parameters selected from the parameter pool in PROCESS DATA GRAPHICS
are displayed in this selection list.

This screen page displays the eight preselected process parameters. The average values,
tolerances ranges, warning limits and error counter can be seen for each parameter. These
values can be manually entered or set up automatically in an initialization run and then
manually adjusted.

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F2 - Initialization
From the main Process Data Monitoring menu, press F2.
The initialization key is not displayed if the PROCESS DATA GRAPHICS is running.
To stop PROCESS DATA GRAPHICS running, press F1 at the PROCESS DATA
GRAPHICS screen page.
When F2 “Initialization” key is pressed the following function frame will be displayed:

The F1 function key returns the screen to the graphic display.

Use the up/down cursor to select the parameters to be monitored. Move the cursor to the
parameter required and press F2 Set, that parameter will be highlighted in green. Continue
to select the required parameters in this way until all required parameters are selected.
To set up a parameter to be displayed on the PROCESS DATA MONITORING graph, use
the up/down cursor, select the parameter for initialization and press F2 Set. Unless you
deliberately select a parameter for graphical display, the last parameter selected will be
displayed.
To start the intialization, press F4 Start.
The display will change from the “Selection list” to the graphic display and the name of the
parameter being displayed will appear at the top left corner of the screen.

After the initialization run of 30 to 200 measurements of the chosen parameters, the
controller determines the mean value from the recorded values and inserts that value into
xqset (x bar set value).

The largest value becomes the “+ tol.” and the smallest becomes the “- tol”.

The warning limits are calculated from the differance between the closest tolerance to the
mean and the mean value divided by two.

For example, the minimum tolerance equals 6.4 and maximum equals 7.3 and the mean is
6.8. The minimum tolerance is closer to the mean than the maximum and the differance
between the two is 0.4. This vaue is divided by 2 to give warning limits of +/- 0.2.

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F3 - Error record

From the main Process Data Monitoring menu, press F3

This screen displays the process data monitoring error record. The error record displays:

1. Parameter name

2. The date the error occurred

3. The time the error occurred

4. The shot counter count

5. The type of error; Warning limit or Tolerance.

The error record can be printed out by pressing the function key F1 “PRINTING”.

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F4 - Error Evaluation

From the main Process Data Monitoring menu, press F4

A series of “error” actions can be preselected by the operator. The operator can decide to
execute one of the following actions for an error that is out of the plus or minus tolerance:
1. No action
2. Alarm lamp on
3. Reject signal without alarm lamp
4. Reject signal with alarm lamp
5. Stop the cycle
The operator can decide to execute one of the following actions for an error that is out of the
“warning tolerance”:
1. No action
2. Alarm lamp on
3. Stop the cycle
Move the white cursor through the selections until the desired action is reached. The action
is enabled by pressing F1 “TAKEOVER”. The action text is then highlighted in red indicating
that it has been chosen.

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9 QUALITY DATA STATISTICS

PRESS

QUALITY DATA STATISTICS 98-09-06 06:49

This page will be blank until the program is activated by selecting machine or molding parameters
to monitor.

The box in the upper left hand corner will contain the part number SPN, as chosen by the operator
on the mold parameter page and will appear on any printouts.

Refer to the following pages for a complete description of the QDS program.

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F1 Press 'F1' - CONTROL CHARTS, to view the QDS graphic display.

Up to three machine or molding parameters can be monitored, but only one at a time will
appear on the screen. To move back and forth between the three monitored parameters,
press the forward or back scroll keys on the numerical key pad.

F2 If the operator chooses 'F2' - SPEC. LIMITS, the following page will appear.

QDS-SPECIFIC. LIMITS 92-07-06 06:49

1... Stop after spec.limits exceeded NO

2... Rejects after spec. Limits exceeded NO

3... SPECIFICATION LIMITS: LOWER UPPER

SET VAL. (USG) (OSG)
Flownumber 0.0 0.0 0.0
Cav.switchovr.pr. 0 0 0 psi
Hydr.switchov pr. 0 0 0 psi
Switchover posit. 0.00 0.00 0.00 in
Injection time 0.0 0.0 0.0 s
Plasticizing time 0 0 0 psi
Cavity press.max 0.00 0.00 0.00 in
Cushion length 0 0 0 psi
Holding press.max 0 0 0 psi
Back press. Max 0 0 0 psi

1...... Stop after spec. Limits exceeded ? NO

If this question is answered 'Yes', then the machine cycling would stop if any of the
monitored parameters' upper or lower specification limits were exceeded.

2...... Rejects after spec. Limits exceeded.? NO

If this question is answered 'Yes', then the part produced on that particular cycle would be
rejected if any of the monitored parameters' upper or lower specification limits were
exceeded. The digital output 'AA' would activate and the rejects counters would increment
by one.

3...... Specification Limits

Indicates the area where the operator would enter the upper and lower specification limits
for the monitored parameter. The operator must also enter the set value which must be a
reasonable estimate of the sample average value in order to give the program a realistic
starting point.

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F3 If the operator chooses 'F3' - QDS - CONTROL LIMITS, the following page will appear.

QDS-CONTROL. LIMITS 92-07-06 06:49

1... Stop after control limit exceeded NO

2... CONT. LIMITS: UEGX OEGX UEGs OEGs
Flownumber 0.00 0.00 0.000 0.0
Cav.sw.ov.pr. 0.0 0 0.0 0.00 0.00
Hydr.sw.ov.pr. 0.0 0 0.0 0.00 0.00
Switchov. pos. 0.00 0 0.00 0.000 0.000
Inject. time 0.00 0 0.00 0.000 0.000
Plasti. time 0.00 0 0.00 0.000 0.000
Cav. pres.max 0.0 0 0.0 0.00 0.00
Cush. length 0.00 0 0..0 0.000 0.000
Hold. pres.max 0.0 0 0 0.00 0.00
Back pres. max 0.0 0 0 0.00 0.00

1...... Stop after control limit exceeded ? NO

If this question is answered 'Yes', then the machine cycling would stop if any of the
monitored parameters' upper or lower control limits were exceeded.

2...... CONTROL LIMITS:

Even though the control limits are calculated during the calibration cycle, they can also be
adjusted manually in this area. The process must be stopped and started again after
making any manual changes!

QDS Abbreviation description

AV Actual Value FZx Actual Flow Number
SV Set Value PFu Cavity Pressure at Boost Cut-off
USG Lower Specification Limit PHu Hydraulic Pressure at Boost Cut-off
OSG Upper Specification Limit C3u Screw Stroke at Boost Cut-off
UEGx Lower Control Limit (xbar) ZSx Actual Injection Boost Time
OEGx Upper Control Limit (xbar) ZDx Actual Screw Feed Time
UEGs Lower Control Limit (Sigma) PFs Peak Value of Cavity Pressure
OEGs Upper Control Limit (Sigma) CPx Actual Cushion Length
PNs Peak Value of Injection Hold Pressure
PSs Peak Value of Back Pressure

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F4 If the operator chooses 'F4'- QDS-SCALE ADJUSTMENT, the following page will appear.

QDS-CONFIGURATION 92-07-06 06:49

1... shot sample n= 10 Cyc

2... Number of samples m= 10 Cyc
3... Distance between samples 0 Cyc
4... Number of classes for histogram 10
5... Print also time NO
6... Print also shot counter NO

7... SCALES Auto/ XQUER s

Setting (max) (max)
Flownumber AUTO 0.00 0.000
Cav.switchovr.press. AUTO 0.0 0.00
Hydr.sw.ov pressure. AUTO 0.0 0.00
Switchover position AUTO 0.00 0.000
Injection time AUTO 0.00 0.000
Plasticizing time AUTO 0.00 0.000
Cavity press.max AUTO 0.0 0.00
Cushion length AUTO 0.00 0.000
Holding press.max AUTO 0.0 0.00
Back press. Max AUTO 0.0 0.00

1......shot sample n= 10 Cyc

indicates how many individual samples are included within a single subgroup

2......Number of samples m= 10
indicates how many samples will be taken and how many subgroups will appear on the
graphic page.

3......Distance between samples = 0 Cyc

indicates how many cycles will run between each subgroup

4......Number of classes for histogram 10

indicates the number of divisions on the histogram. Two accepted methods are available
to determine the number of intervals:
Method 1: Take the square root of the total number of data points and round to the nearest
whole number.
k = √125 = 11.18 = 11 intervals
Method 2: Use the table below to provide a guideline for dividing your sample into a
reasonable number of classes.

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Number of data points Number of classes

Under 50 5-7

50 - 100 6 - 10

100 - 250 7 -12

over 250 10 -20

5...... Print also time? NO

If this question is answered 'YES', and if the automatic printing function is active, then the
control charts printed out will also include the time of each sample calculation.

6...... Print also shot count? NO

If this question is answered 'Yes', and if the automatic printing function is active, then the
control charts printed out will also include the cycle number of each sample calculation.

7...... SCALES:
If the specification limits are very wide and the process exhibits a very low standard
deviation, then the calculated control limits may be difficult to see on the graphic page.
The operator can adjust the scale of the display on the graphic page by moving the cursor
to the monitored parameter and turning the scale adjustment to manual. The operator can
then manually adjust the scale of the graphic display by entering various numbers for
'XBAR' (max) or SIGMA (max). The process must be stopped and started again after
making any manual changes!
Only the graphic display is adjusted. Changing the scale of the graphic display does not
change the set specification limits of the process.

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F5 If the operator chooses 'F5' - CONTROL CHART TYPE, the following page will appear.

The standard QDS program calculates the control limits, OEG and UEG, based on
the following calculations:

UEG = =
X - A3( s- ) OEG = =
X + A3( s- )
These calculations however, produce extremely tight control limits which often
leads to rejecting "out of control" cycles that still fall within the product's specifica-
tion limits.

In order to still employ statistical process control, the operator can choose to
calculate the control limits based on specification limits. With the selection of an
exceeding share 'P' and a control probability '1- Pa', the control limits will be
calculated as a distance away from the specification limits, not as a distance from
X-bar. In effect we are calculating “acceptance control limits”.

If you decide to employ this program, the 'GIVEN LIMITS' function must be
switched to 'YES', the 'EXCEEDING SHARE' must be selected, and the
'CONTROL PROBABILITY' must be selected. All variables function independently.

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We use the following formula for 'K' to produce the upper and lower control limits.

k = U1-p + U1-Pa
√n

∧
OEG = OSG + (k . σ)
UEG = USG – (k . ∧
σ)

Starting from the specification limits, the control limits are calculated as the
distance 'K' times sigma.

Control Exceeding
probability share

95% Pa = 95% p = 1%
1%

k.o Distribution of the k.o

individual values

o USL
LSL LCL UCL

s4
s3
s2
s1 Initialize

In the example above, we have used an exceeding share of 1% and a control

probability of 95%. From the table below, this would produce a 'K'- value of 3.06.

e.g.

k = U1 - p + U1-Pa = 2.326 + 1.645 = 3.06

n √5

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This leads to the calculation of acceptance control limits such that up to 5% of the
time we will accept product that could be as much as 1% defective.

The operator should recognize that as the exceeding share becomes smaller and
the control probability becomes larger, the calculated distance away from the
specification limits will become greater.

In other words, as 'K' becomes larger, the upper and lower control limits come
closer together, increasing the chances of exceeding either control limit.

Factors for calculating the control limits with an exceeding 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

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F8 If the operator presses 'F8' - etc. -->, the QDS function frame display as shown below will
appear. This feature is described in the section “Manual Control Charts”.

F8 If the operator presses 'F8' - etc. --> again, the QDS function frame display as shown below
will appear.

F1 To start or stop the QDS program, press 'F1' - STOP/START.

NOTE!

The 'F1' function frame display must read 'START' in order to

select any variables to monitor (i.e. 'F2' - SET-UP)

When 'F1' displays 'START', the QDS program is NOT operating.

When 'F1' displays 'STOP', the QDS program is operating.
When 'START' is pressed, the function frame, as shown below, will be displayed.

'F1'- PROCESS RUN would be pressed only if your parameters are normally dis-
tributed and if a capable process exists.

'F2'-INITIALIZE is pressed after you have chosen your parameters, and have set
specification limits and an expected average set value for each parameter.

A subgroup size and number of subgroups must also be set to initialize the process.
Refer to the section entitled "Setting the QDS Program".

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F2 The operator must press 'F2'-SET-UP in order to choose the parameters to monitor.
A sample listing appears below.

Flow number Quality values 1

Cavity sw. ov. pr. max Quality values 2
Hydr. sw. ov. pr. max. Quality values 3
Switchover position
Injection time
Plasticizing time
Cavity press. max.
Cushion length
Holding press. max
Back press. max

Remember, in order to access this selection 'F1' must read 'START'. Refer to the section entitled
"Selecting Variables".

F3 At any time, a summary of the screen information to date can be printed out by
selecting 'F3'-PRINT.

As well, remember that any page that appears on the screen can be
printed out with a graphic printer by pressing function key".

F4 Press F4 for the Histogram. Whenever statistical data are used to predict a quality level, the
statistical data must have been derived from a normally distributed sample and population.
As a first step, the operator should run a single sample of perhaps 100 cycles to determine
if the chosen variable can be used to statistically predict a quality level.
After the test run (initialization) has been completed, the operator would call up the
histogram page to determine if the test run exhibited a normal distribution.
For example, after the initialization has been completed, the operator would press 'F4'-
HISTOGRAM, and a graphic similar to the one below would appear.
Example of a histogram with 100 measurements of the hydraulic switchover pressure (PHu)
with distribution “normal” (a<=c).

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9.1 NORMAL DISTRIBUTION
During production it is impossible to produce identical parts, there will always be a slight degree
of variation. It is the degree of variation that is important, if the variation is too great then the parts
will fall outside the quality specification set by the customer.

9.1.1 VARIATION
Variation can be divided into two catergories: common and special cause. An understanding of
these is important when interpreting the data displayed on the control charts.
Common cause variation
• Plasticizing time
• Injection time
• Cushion size
• Shot size
These variables should only varying slightly from cycle to cycle.
Special cause variation
• Material batch type
• Contaminated material
• Faulty hydraulics
The variation seen here will cause substantial change in the process data.

9.1.2 BELL CURVE

If only common cause variations are present, then the distribution will be normally distributed in
form of a symetrical bell shaped curve about a mean-value (x-bar). The mean-value (x bar) equals
the most common value. The curve is also characterised by S the standard deviation, this
indicates the variation within the process around the average, this equals the distance from the
mean-value (x bar) to the turning point of the curve.
This information is shown graphically as a bar chart and a display on the screen will indicate
whether the curve is “normal” or “not normal”.
The process parameter which could show normal distribution are:
• Flow number.
• Plasticizing time.
• Cushion size, if no cushion correction is used.
• Injection time.
• Switch -over values which not being used for switch -over to hold pressure.
• Peak values of Cavity and Hydraulic pressures.
Any variables that are self correcting, for example, PID control on heater bands will compensate
for any variation measured to maintain the required temperature. In short, any variable that is
closed looped controlled will not give a normal distribution.

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Example of a histogram with 100 measurements of the hydraulic switchover pressure (PHu)
with distribution “not normal” (a>c).

Along with other statistical information, the histogram page will indicate in the bottom right
hand corner:
DISTRIBUTION NORMAL
or
DISTRIBUTION NOT NORMAL

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If the test run does not have a normal distribution, then that machine parameter cannot be
used to predict any statistically significant level of quality. Another parameter must be
chosen.
The program compares the absolute value difference between a cumulative normal
distribution function and the sample cumulative distribution function to arrive at the value “a
max”. If “a max” is greater than a certain critical value based on the sample size, then you
would reject the hypothesis that the sample is representative of a normal population.
To summarize:
If “a max” is less than or equal to “c”, the distribution is normal.
If “a max” is greater than “c”, the distribution is not normal.

NOTE!

The histogram is only accessible after the test run has been
completed.

F5 Press 'F5'-ERROR REPORT and a QDS-error page, similar to the one shown over the
page, will be displayed.
This will show the limit exceeded, cycle number, date and time, process parameter and the
actual measured value.
The errors could result from the upper or lower specification limits being exceeded, the
upper or lower control limits being exceeded, or the upper or lower standard deviation
control limits being exceeded.

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QUALITY DATA STATISTICS

ERROR

USPECLIM 1225 96-07-30 08:19 CUSHION LENGTH 0.54

OEG XB 1225 96-07-30 08:19 CUSHION LENGTH 0.50
OEG XB 1227 96-07-30 08:21 CUSHION LENGTH 0.44
UEG XB 1434 96-07-30 10:17 FLOW NUMBER 63.5
UEG S 1449 96-07-30 10:26 HYDRAULIC PRESS. CUT-OFF 0.5
UEG XB 1454 96-07-30 10:29 FLOW NUMBER 63.5
UEG XB 1459 96-07-30 10:32 FLOW NUMBER 63.6
UEG S 1459 96-07-30 10:32 HYDRAULIC PRESS.CUT-OFF 0.5
UEG XB 1467 96-07-30 10:36 FLOW NUMBER 63.6
UEG S 1467 96-07-30 10:36 HYDRAULIC PRESS.CUT-OFF 0.5
OEG XB 1567 96-07-30 11:33 CUSHION LENGTH 0.47

Limit Cycle Date Time Process Measured

Exceeded Number Parameter Value

F6 Press 'F6'-CALCULATE, and the function keys as described below will appear.

F1- CONTROL LIMITS will re-calculate the process control limits based on the last
recorded sample subgroup.

F2- SPECIFICATION LIMITS will adjust the upper and lower specification limits to 3
standard deviations from the sample mean value. The adjusted specification limits
will appear on the page as yellow lines while the old specification limits will remain
as green lines until the next sample group update.(CC100 only)

Press 'F2', then 'F7'-EXECUTE COMMAND.

F3- SPECIFICATION LIMITS will adjust the upper and lower specification limits to 4
standard deviations from the sample mean value. The adjusted specification limits
will appear on the page as yellow lines while the old specification limits will remain
as green lines until the next sample group update. (CC100 only)

Press 'F3', then 'F7', EXECUTE COMMAND.

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CAUTION!

If the control limits are re-calculated, the values calcu-

lated during the initialization process will be erased.

F7 Press 'F7'-AUTOPRINT ON, and the control system will automatically print out the graphics
related to each monitored parameter. If the autoprint function is on, the designation 'AUTO-
PRT' will appear in the upper right hand corner of the QDS page.
The autoprint function will cause the graphics to be printed out based on the product of the
number of samples, times the sample size. For example, if 10 samples are requested and
the sample size is 10, the graphic printout for each monitored parameter will represent 100
monitored cycles. To deactivate the autoprint, press 'F7' again.

F8 Press 'F8'-etc. --> to return to the main QDS function frame display.

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SELECTING VARIABLES

Step 1: Press F2 - SELECT

Step 2:

The operator must move the cursor to one of the three cursor positions using
the left/right cursor keys before pressing 'F1'-SET. 'F2'-RESET will eliminate the
parameter at the cursor position.
Step 3: If the cursor is in the position where the operator wishes to enter a parameter,
press 'F1'-SET. The cursor will now appear in a highlighted state at the first
parameter-Flownumber. The function frame display will change to that as
shown below.

Step 4: Move the cursor, using the up/down cursor keys, to the parameter you wish to
monitor, and press 'F1'-SELECT.
The parameter will now appear in the cursor position decided upon in step 2.
Repeat steps 2 - 4, to enter other parameters for the QDS program.

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SETTING THE QDS PROGRAM

The main objective of this program is to provide statistical information so that specific predictions
can be made concerning the molded part quality. However, if this program is to be employed
effectively, three conditions must exist:
1. The operator must have a basic understanding of production statistics.
2. The machine must be producing "good parts" that fall within the accepted
specification limits.
3. A determination has been made as to which process parameters are directly
related to specific part quality parameters.

Step 1: Test for normal distribution and determine if the process is capable and within
specification limits.

1. From the function frame display as shown above, press 'F4'- SCALE
ADJUSTMENT.
2. For initialization purposes and to calculate control limits enter

SUBGROUP SIZE n = 10 Cyc

NUMBER OF SUBGROUPS m= 10
SAMPLE FREQUENCY = 0 Cyc

Also, beside the chosen variables enter:

(SV) (USG) (OSG)

SV - Expected average set value

USG - Lower specification limit
OSG - Upper specification limit

3. Adjust the 'CONTROL CHART TYPE' page if you wish to calculate the control
limits according to set specification limits rather than standard statistical
procedures. If you wish to employ this program, it must be activated to
'Initialize'. Otherwise, make sure the monitored variables are switched to 'No'
before the 'Initialization'.

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Step 2: Start the test run

1. From the function frame as shown above, press F1 “START”

2. From the function frame as shown above, press F2 “INITIALIZE”. This will start
the calculation of the control limits.

At the end of the initialization, the program will stop. The page will be similar to
the one shown below.

QUALITY DATA STATISTICS 99 –09 –15 12:00

‚Stroke cut-off Flownumber Cavity press.(peak-val)

n: 10 m: 10 FREQUENCY 0 SZx 8760 INIT
1
SV: 0.24 USG: 0.28 OSG: 0.21 AV: 0.24in
SZx:
SZx : 8764
8764 8789
8769 8814
8774 8779
8839 8784
8864
2 TIME
TIME: 16:09
16:09 16:21
16:10 16:33
16:11 16:46
16:12 16:59
16:13
0.28

- 0.26
X
3 0.24
0.22

0.016
s 0.012
4 0.008
0.004
Sample#:#:100
Sample 25 Under Spec: 0 0.0% Over Spec: 0 0.0%
5
UEGx: 0.247 OEGx: 0.228 UEGs: 0.014 OEGs:0.000
--
X: 0.238 o: 0.007 s: 0.007 cm: 1.8 cmk : 1.6

10/10/02 5. SCREEN PAGES 161

 EC100 / CC100 - A03 OPERATOR:
Screen Variables:
1. n - Subgroup size
m - Number of subgroups
FREQUENCY - Sample frequency (cycles between samples)
SZx - Cycle number at process start
INIT - Indicates that the initialization mode is running, or has been
completed.
Autoprt - Indicates that the autoprint function is active
SV - Expected set value (i.e. expected average)
When the process runs, this will be the calculated average
determined during initialization
OSG - Upper specification limit of X
USG - Lower specification limit of X
AV - Actual value of x in the current cycle

2. SZx - The cycle number of the sample calculation

Time - The time of the sample calculation

3. X bar - Graph of the average value

Red lines: control limits
Yellow lines: specification limits
Blue line: X bar bar average of the averages
Green line: X bar average
4. S: - Graph of the standard deviation
Red lines: control limits
Blue line: S bar average
Green line: S

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 EC100 / CC100 - A03 OPERATOR:
5. Sample # : - Number of actual measurements (i.e. cycles) since the start of the
program, not including the cycles between samples.
under spec - The number of samples that fell below the lower specification limit
and in percentage terms.
over spec : - The number of samples that fell above the upper
specification limit and in percentage terms.
OEGx: - The calculated upper control limit of X bar.
UEGx: - The calculated lower control limit of X bar.
OEGs : - The calculated upper control limit of s.
UEGs : - The calculated lower control limit of s.
(For sample sizes less than 6, this will always be zero).
X bar bar - The average value of all sample averages. This is the digital display
of the straight blue line on the graph.
^ σ - The estimated standard deviation.
S bar - The average value of all sample standard deviations.
Cm : - The measured process capability index, which is the ratio of the
difference between the specification limits to the measured process
σ
variability.( 6 ^ s )
When the program runs "in production", the Cm will automatically
change to Cp, but still represents the same variable. The Cm
designation appears only as the result of initialization.
Cmk : - The measured location of the distribution of values relative to the
specification limits. The maximum value of Cmk is equal to Cm and
indicates that the process is centered. When the program runs "in
production", the Cmk will automatically change to Cpk, but still
represents the same variable. The Cmk designation appears only
as the result of initialization.

9.1.3 PROCESS CAPABILITY

Process capability is defined as the allowable spread of measurements divided by the actual
spread. The allowable spread is the differance between the upper and lower specification limit.
The actual spread is determined by the process data collected and is calculated by multiplying the
standard deviation “S” by 6.
As the standard deviation increases in a process, Cp decreases in value. As the standard
deviation decreases, the process become less variable, Cp increases in value.
Convention states that when a process has a Cp less than 1 it is considered potentially incapable
of meeting specification requirements. When Cp is greater or equal to 1, the process has the
potential of being capable, that is nearly all the measurements taken fall within the specifications.
Ideally Cp should be as high as possible. the higher Cp, the lower the variability with respect to
the specification limits.

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 EC100 / CC100 - A03 OPERATOR:
Cp looks at the variation only, but Cpk considers the variation and position of the average in
relation to the specification limits
When the initialization phase is complete and the process is running, Cp and Cpk will be
calculated and displayed on the screen.
It is important to monitor the values of Cp and Cpk to identify changes in process capability. If the
values improve, find out why and try to enhance that condition.

1. Decide whether or not the process is capable, and if the monitored parameters
have normal distributions.
After the initialization process has been completed, look for Cm and Cmk values of at
least 1.33 to be assured that the process is capable. If Cmk is significantly less than Cm,
it is an indication the process is not centered.
If Cmk= 1.00, then 99.735% of the production will be within specification.
If Cmk= 1.33, then 99.994% of the production will be within specification.
From the function frame display as shown below, F4 “HISTOGRAM”.

The bottom right hand corner will indicate either distribution normal or distribution not
normal.
If the distribution is not normal, try the initialization again using a different sample size.
Increase or decrease the total initialization run by units of 10. For example, instead of
using a subgroup size of 10, try using 11. This would give an initialization run of 110
instead of the suggested 100.
If the distribution is still not normal, another parameter must be used for the quality data
statistics and initialization must be repeated.liz

NOTE!

If the parameter is normally distributed and Cm and Cmk exhibit

acceptable values, then set up the QDS for production process control.

CAUTION!

Do not change any machine process values after the QDS initialization. If
any changes are made, the current initialization would become invalid.

164 5. SCREEN PAGES 10/10/02

 EC100 / CC100 - A03 OPERATOR:
Step 2: Set up the QDS program to run process control.

1. From the function frame above, press F2 “SPEC LIMITS”.

2. Set the number of sub-groups required for the process.

3. Set the sample frequency required for the process. Remember, this refers to the
number of cycles between samples.

4. DO NOT adjust the sub-group size from that used during the initialization.

1. From the function frame display, as shown above, press F1 “START”.

1. From the function frame display, as shown above, press F1 “PROCESS RUN”

2. The QDS starts with the sample frequency, so no process data will be measured until
after this number of cycles has be completed.

3. To have the graphic information on each monitored parameter printed out

automatically after every n x m samples, select F7 “AUTOPRINT ON” on the
secondary QDS function frame display.

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 EC100 / CC100 - A03 OPERATOR:
SUMMARY OF SYMBOLS AND FORMULAE
Symbols
Xi - A single sample measurement.
X bar - A sample subgroup average.
X bar bar - The average of the subgroup averages.
s - Standard deviation (sigma).
s bar - The average of all standard deviations.
^σ - Estimated standard deviation of the population - sigma hat.
∑ - The summation of ....
n - Subgroup size
Cp - Process capability
Cpk - Process capability index
UEG - Lower control limit (LCL)
OEG - Upper control limit (UCL)
OSG - Upper specification limit (USL)
USG - Lower specification limit (LSL)
A3, B3, B4 and C4 Conversion factor as a function of the sample size

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 EC100 / CC100 - A03 OPERATOR:
Constants - Conversion factors

The Constants or “conversion factors” are used for calculating the “Sigma hat” - standard
deviation and control limits. The constants are stored in the controller, up to a sample size of 25
measured values.

SAMPLE SIZE A3 C4 B3 B4 C
n ________________________________________________________________

2 2.659 0.7979 -------- 3.267 --

3 1.954 0.8862 -------- 2.568 --
4 1.628 0.9213 -------- 2.266 0.381
5 1.427 0.9400 -------- 2.089 0.343

6 1.287 0.9515 0.030 1.970 0.319

7 1.128 0.9594 0.118 1.882 0.299
8 1.099 0.9650 0.185 1.815 0.283
9 1.032 0.9693 0.239 1.761 0.271
10 0.975 0.9727 0.284 1.716 0.260

11 0.927 0.9754 0.321 1.679 0.249

12 0.886 0.9776 0.354 1.646 0.240
13 0.850 0.9794 0.382 1.618 0.233
14 0.817 0.9810 0.406 1.594 0.225
15 0.789 0.9823 0.428 1.572 0.218

16 0.763 0.9835 0.448 1.552 0.213

17 0.739 0.9845 0.466 1.534 0.206
18 0.718 0.9854 0.482 1.518 0.200
19 0.698 0.9862 0.497 1.503 0.195
20 0.680 0.9869 0.510 1.490 0.190

21 0.663 0.9876 0.523 1.477 0.187

22 0.647 0.9882 0.534 1.466 0.184
23 0.633 0.9887 0.545 1.455 0.180
24 0.619 0.9892 0.555 1.445 0.177
25 0.606 0.9896 0.565 1.435 0.174

26
27
28
29
30

>30
0.886
√ n

10/10/02 5. SCREEN PAGES 167

 EC100 / CC100 - A03 OPERATOR:
9.2 MANUALLY INPUT QUALITY CONTROL CHARTS

Press

The following function frame is displayed:

F8 If the operator presses F8 “etc. -->”, the QDS function frame display as shown below will
appear.

It is possible to manually enter individual parameters, and in so doing, create control charts from
the machine using information not generated by the machine e.g. Molded part dimension or
molded part weight.

The recording of these parameters occurs in parallel with any selected automatic parameters.

The operator can input up to three different quality parameters and as with the automatic
generation of control charts, the manual control charts must be set up with limit values, sample
sizes etc.

Screen pages designated with the letter Q are for manual input of data.

When one of the function keys (F2 to F6) has been selected the quality control function frame will
change to the one shown below.

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 EC100 / CC100 - A03 OPERATOR:
Press F1 “CONTROL CHARTS” to view the QDS graphic display.

Press F2 “SPEC. LIMITS”, the following screen page will be displayed.

QDS-SPECIFIC. LIMITS Q 98-08-06 06:49

1.... Stop after spec.limits exceeded NO

2..... Rejects after spec.limits exceeded NO

3..... SPECIFICATION LIMITS: LOWER UPPER

SET VAL. (USG) (OSG)
Quality value 1 1.00 1.00 1.00
Quality value 2 1.00 1.00 1.00
Quality value 3 1.00 1.00 1.00

1......Stop after spec. Limits exceeded? NO

If this question is answered 'Yes', then the machine cycling would stop if any of the monitored
parameters' upper or lower specification limits were exceeded.

2......Rejects after spec. Limits exceeded.? NO

If this question is answered 'Yes', then the part produced on that particular cycle would be rejected
if any of the monitored parameters' upper or lower specification limits were exceeded.

3......Specification Limits

indicates the area where the operator would enter the upper and lower specification limits for the
monitored parameter. The operator must enter the set value which must be a reasonable estimate
of the sample average value in order to give the program a realistic starting point.

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 EC100 / CC100 - A03 OPERATOR:
Press F3 “QDS - CONTROL LIMITS Q”, and the following screen page will be displayed.

QDS-CONTROL. LIMITS Q 92-07-06 06:49

1..... Stop after control limit exceeded NO

2...... CONT. LIMITS: UEGX OEGX UEGs OEGs

Qual.val.1 1.00 1.00 0.100 0.100
Qual.val.2 1.00 1.00 0.100 0.100
Qual.val.3 1.00 1.00 0.100 0.100

1......Stop after control limit exceeded? NO

If this question is answered 'Yes', then the machine cycling would stop if any of the monitored
parameters' upper or lower control limits were exceeded.

2......CONTROL LIMITS:

Even though the control limits are calculated during the calibration cycle, they can also be
adjusted manually in this area. The process must be stopped and started again after making any
manual changes!

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Press F4 “QDS - SCALE ADJUSTMENT Q”, and the following page will be displayed.

QDS-CONFIGURATION Q 92-07-06 06:49

1...... shot sample n= 10 Cyc

2...... Number of samples m= 10 Cyc
3.......Distance between samples 0 Cyc
4...... Number of classes for histogram 10
5...... Print also time NO
6...... Print also shot counter NO

7...... SCALES Auto/ XQUER s

Setting (max) (max)
Quality value 1 AUTO 1.00 1.000
Quality value 2 AUTO 1.00 1.000
Quality value 3 AUTO 1.00 1.000

1.... shot sample n = 10 Cyc

indicates how many individual samples are included within a single subgroup

2.... Number of samples m = 10

indicates how many samples will be taken and how many subgroups will appear on the
graphic page.

3.... Distance between samples = 0 Cyc

indicates how many cycles will run between each subgroup

4.... Number of classes for histogram 10

indicates the number of divisions on the histogram.

5.... Print also time? NO

If this question is answered 'YES', and if the automatic printing function is active, then the
control charts printed out will also include the time of each sample calculation.

6.... Print also shot count? NO

If this question is answered 'Yes', and if the automatic printing function is active, then the
control charts printed out will also include the cycle number of each sample calculation.

10/10/02 5. SCREEN PAGES 171

 EC100 / CC100 - A03 OPERATOR:
7...... SCALES:
If the specification limits are very wide and the process exhibits a very low standard
deviation, then the calculated control limits may be difficult to see on the graphic page.
The operator can adjust the scale of the display on the graphic page by moving the cursor
to the monitored parameter and turning the scale adjustment to manual. The operator can
then manually adjust the scale of the graphic display by entering various numbers for
'XBAR' (max) or SIGMA (max). The process must be stopped and started again after
making any manual changes!
Only the graphic display is adjusted. Changing the scale of the graphic display does not
change the set specification limits of the process.

172 5. SCREEN PAGES 10/10/02

 EC100 / CC100 - A03 OPERATOR:
Press F5 “CONTROL CHART TYPE Q”, and the following screen page will be displayed.

NOTE!

Ensure that some values are entered into the “Control Proba-
bility” and “Exceeding Share” for “quality value 1, 2 and 3. If
these values are set to zero, the system will show the error
“Value out of range”.

Please refer to the section on “Control Chart Type” earlier in this chapter.

10/10/02 5. SCREEN PAGES 173

 EC100 / CC100 - A03 OPERATOR:
Press F6 “QUALITY VALUES” and the following screen page will be displayed.

QUALITY VALUES 92-07-06 06:49

1...... QP-Shot counter 0 Cyc

Qualit.measval.1 0.00
Qualit.measval.2 0.00
Qualit.measval.3 0.00

2....... shot / sample n= 1 Cyc

3....... Number of samples m= 1 Cyc
4....... Number of the input measurements = 0 Cyc

1.... QP - Shot counter 0 Cyc

The QP shot counter is related only to the manual quality control chart and has no
connection with the production shot counter.

2.... shot sample n= 0 Cyc

This line indicates how many individual samples are included within a single subgroup

3.... Number of samples m= 0

This line indicates how many samples will be taken and how many subgroups will appear
on the graphic page.

4.... Number of input measurements = 0 Cyc

This line the total number of input measurements. When the “shot sample” times “Number
of sample” (n x m) equals this number, no more inputs are expected.

174 5. SCREEN PAGES 10/10/02

 EC100 / CC100 - A03 OPERATOR:

10 MAIN MENU

Press

F1 PRINTER

F2 DISKETTE

F3 TEXT PAGES (NOTES)

F4 NOT USED (See Controller Maintenance manual)

F5 ACCESS RIGHTS (See Controller Maintenance manual)

10/10/02 5. SCREEN PAGES 175

 EC100 / CC100 - A03 OPERATOR:
10.1 PRINTER (SYSTEM VERSION LESS THAN 2.00)

Press

Refer to the following pages for the description of each function.

10.1.1 PRELIMINARY STEPS

Step 1. Plug the printer into 120 volts A.C. and turn on the ON/OFF switch.

Step 2. Connect the data cable between the RS-232 serial interface plug on the front of the
control panel and the other end to the serial interface on the printer

Step 3. Feed paper into the printer. Make sure the paper does not bind.

Step 4. Briefly press the “ON LINE" key on the printer to initialize the recording head.

176 5. SCREEN PAGES 10/10/02

 EC100 / CC100 - A03 OPERATOR:

F1 If the operator presses “PRINT ALL PAGES" all of the pages with the asterisk (*) will be
printed out. There may additional pages listed on a second page which can be accessed
by moving the cursor down or pressing the scroll forward button.

F2 If the operator presses “PRINT PARAMETERS” the software variable parameters and their
current values will be printed out.

F3 If the operator presses “TOP OF PAGE”, a new page top location will be initialized at the
current paper position.

F4 If the operator presses “STOP PRINTING”, the printing function will terminate as soon as
the last page, within the printer's memory, has been printed out.

F5 If the operator presses “PRINT SYSTEM DATA REPORT”, the last 60 operator set value
changes will be printed out. As well, this function will print out the last 60 machine errors
that have occurred and the last 60 dates and times that the machine has been turned “ON”
or “OFF”.

F6 If the operator presses “TEXT PRINTER”, a display indicating this mode will appear in the
bottom left hand corner of the monitor. The printing function must be in this mode in order
to use a specifically dedicated text printer.

F7 If the operator presses “GRAPHIC PRINTER”, a display indicating this mode will appear in
the bottom left hand corner of the monitor. If the machine is connected to a graphics capa-
ble printer, the controller printing function must be in this mode to print out graphics. It is not
necessary to switch into text printing to print text with a graphics printer.

F8 If the operator presses “etc. -->" the function frame display will change to one similar to that
shown below. To change back to the main printing function frames, press “etc. -->" once
more.

F1 If the operator presses “SELECTION ON”, an asterisk (*) will appear beside
the variable at the cursor location. When the “PRINT ALL PAGES” function is
chosen, only the pages indicated with an asterisk will be printed out.

F2 If the operator presses “SELECTION OFF”, the asterisk (*) at the cursor loca-
tion will be deleted. When the “PRINT ALL PAGES” function is chosen, only the
pages indicated with an asterisk will be printed out.

F3 When the operator presses “PRINT”, the page at the cursor location will be
printed out. The asterisk is irrelevant for this function.

10/10/02 5. SCREEN PAGES 177

 EC100 / CC100 - A03 OPERATOR:

F4 To copy a page on to floppy disk or to the RAM disk, press “PRINT TO

FLOPPY”. The function frame as shown below will be displayed.
Press “FLOPPY” or “RAM disk” to select the required medium.
Press EXIT to return to the previous function frame. In the lower left hand corner
of the screen the message “FLOPPY” or “RAM disk” is displayed instead of
“GRAPHIC PRINTER" or “TEXT PRINTER”.
Move the cursor to the required page and press F3 “Print One Page”. The text
from the page is saved onto the disk as plain text and can be viewed on a PC in
“Windows” with “Notepad”.

Special Printing Note

If the printer preliminary steps have been completed and this key is pressed, any
page that appears on the screen monitor will be printed out. This function is only
possible with a graphics printer.

Printing a screen page in this way takes longer than using the printer menu
described above.

Two to three screen pages can be printed by in series. Select the page and press
the print key, then select the next page and press the print key again. This should
work for two or three pages, depending upon the system memory and the size of
the page.

178 5. SCREEN PAGES 10/10/02

 EC100 / CC100 - A03 OPERATOR:
10.2 PRINTER (SYSTEM VERSION GREATER THAN SV2.00)

Press

10.2.1 F1 - “PRINT TEXT PAGE”

Select F1 to print the text from a screen page or many screen pages onto a recording medium.

Over the page is a listing of all the screen pages available for printing, select the page or pages
required and initiate the printing from the function frame.

F5 “Devices selection” enables the operator to choose between various type s of printers, floppy
disk or RAMdisk as a recording medium.

These selections are explained on the following pages in this section.

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 EC100 / CC100 - A03 OPERATOR:

10.2.1.1 PRELIMINARY STEPS

Step 1. Plug the printer into 120 volts A.C. and turn on the ON/OFF switch.

Step 2. Connect the data cable between the RS-232 serial interface plug on the front of the
control panel and the other end to the serial interface on the printer

Step 3. Feed paper into the printer. Make sure the paper does not bind.

Step 4. Briefly press the 'ON LINE' key on the printer to initialize the recording head.

F1 If the operator presses “SELECT ALL” all of the pages will be marked with an asterisk (*).
There may additional pages listed on a second page which can be accessed by moving the
cursor down or pressing the “page down” button.

F2 If the operator presses “DESELECT ALL” all the asterisks will be removed.

F3 If the operator presses 'SELECTION ON', an asterisk (*) will appear beside the variable at
the cursor location. When the “F6 PRINT SELECTION” function is chosen, only the pages
indicated with an asterisk will be printed out.

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 EC100 / CC100 - A03 OPERATOR:

F4 If the operator presses “SELECTION OFF”, the asterisk (*) at the cursor location will be
deleted. When the “F6 PRINT SELECTION” function is chosen, only the pages indicated
with an asterisk will be printed out.

F5 When the operator presses “PRINT SINGLE PAGE”', the page at the cursor location will be
printed out. The asterisk is irrelevant for this function.

F6 If the operator presses 'TOP OF PAGE ', a new page top location will be initialized at the
current paper position.

F7 If the operator presses 'STOP PRINTING', the printing function will terminate as soon as
the last page, within the printer's memory, has been printed out.

F8 If the operator presses “EXIT”, the screen will return to the previous page.

10.2.2 F2 - PARAMETER PRINTING

“Parameters Printing” prints out the software variable parameters and their current values.

Press F2 to select “Parameters Printing” and press F6 to start the printing of the report.

The status report can be printed to a floppy disk or a printer to be viewed by an Engel
service or software engineer to resolve a problem with the machine.

Printing the report to a floppy disk is recommended, ensure that the floppy device has been
selected as the current device. Refer to “F5 - Device selection” for information on how to
select the floppy drive as an output device.

10/10/02 5. SCREEN PAGES 181

 EC100 / CC100 - A03 OPERATOR:
10.2.3 F3 - DISTR. REC. MENU (SYSTEM DATA REPORT)

The whole or part of the “System Data Report” can be printed out, the system data report
comprises the following components:
• System displays the last 60 system errors.
• Error displays the last 60 machine errors.
• Input displays the last 60 “Set Value” changes.
• State displays the last 60 program mode changes (manual, semi-auto, auto
etc.) or service password entries.
• User displays what the machine controller was waiting for when the machine
went into alarm state.

F1 The “Select all” key will mark all the items with an asterisk, when F6 “Print Selection” is
pressed all items marked with an asterisk will be printed out.

F2 The “Deselect all” key will remove all the asterisk previously placed.

182 5. SCREEN PAGES 10/10/02

 EC100 / CC100 - A03 OPERATOR:
F3 The “Selection On” key will place an asterisk at the cursor location.

F4 The “Selection Off” key will delete an asterisk at the cursor location.

F5 The entire “System Data Report” can be printed out with this key.

F6 The “Print Selection” key prints out all the selected items.

F7 The “Stop Printing” key will terminate the printing function as soon as the printer memory

F8 The “Exit” key will return the screen to the previous page.

10/10/02 5. SCREEN PAGES 183

 EC100 / CC100 - A03 OPERATOR:
10.2.4 F4 - PRINT STAT. REP (STATUS REPORT)

The ‘Status Report” is a snapshot of the status of the machine at a moment in time and is
useful as a troubleshooting aid.

Press F4 to select “Print Stat. Rep.” and press F6 to start the printing of the report.

The status report can be printed to a floppy disk or a printer to be viewed by an Engel
service or software engineer to resolve a problem with the machine.

Printing the report to a floppy disk is recommended, ensure that the floppy device has been
selected as the current device. Refer to “F5 - Device selection” for information on how to
select the floppy drive as an output device.

184 5. SCREEN PAGES 10/10/02

 EC100 / CC100 - A03 OPERATOR:
10.2.5 F5 - DEVICES SELECTION

The current output device is displayed at the bottom of the “Printing” screen pages. The output
device can be selected on this screen page.

Pressing F5 will display the screen page shown below.

10.2.5.1 DEVICE PARAMETERS

PRINTERS

All the printer selections require these parameters to be set

10/10/02 5. SCREEN PAGES 185

 EC100 / CC100 - A03 OPERATOR:
ELECTRONIC STORAGE MEDIA

ASCII = Normal plain text

UNICODE = Symbolic characters

The choices here are between FLOPPY DISK or RAM DISK. If FLOPPY is selected the data will
be saved to a floppy disk. If the RAMDISK is selected the data will be saved internally in memory
on the CPU card. Machine and process disk information can be saved to the RAMDISK. The
contents of the RAMDISK can be browsed from the “DISKETTE” functions screen page.

10.2.6 F6 - SETUP GENERAL PARAMETERS

with/without softkey 0 NO
Enter a 0 on this line to turn this function to NO, a hardcopy of a screen page to a printer or a
softcopy to a floppy disk WILL display the softkey function frame.

with/without softkey 1 YES

Enter a 1 on this line to turn this function to YES, a hardcopy of a screen page to a printer or a
softcopy to a floppy disk WILL NOT display the softkey function frame.

10.2.7 F7 - STOP PRINTING

If the operator presses 'STOP PRINTING', the printing function will terminate as soon as the last
page, within the printer's memory, has been printed out.

186 5. SCREEN PAGES 10/10/02

 EC100 / CC100 - A03 OPERATOR:
10.3 DISKETTE

PRESS

Refer to the following pages for the description of this function.

10/10/02 5. SCREEN PAGES 187

 EC100 / CC100 - A03 OPERATOR:
10.3.1 DISKETTE - MEMORY

The software incorporates a diskette function to store and retrieve various programs.
A complete machine diskette includes:
AR161_1.e - First Analog card sequence program
AR161_2.e - Second Analog card sequence program
EBIAS32.BIN - Sequence program
LINTAB.BIN - Linearization tables, calibrations
PARAM.BIN - Machine Dependent Heat P.I.D.
A complete process diskette includes:
SGM \ CMPTXT.CFG - Selectable text page configuration
SGM \ GRAFIK.BIN - Graphic data (ideal curve)
SGM \ MICTMP.BIN - MicroTemp data
SGM \ PARAM.BIN - Set values
SGM \ PDGRAF.CFG - Quality data graphics configuration
SGM \ PDPROT.CFG - Process data report configuration
SGM \ SPC.CFG - Quality data statistics configuration
SGM \ TEXT.BIN - Content of text pages

NOTE!

Included with the set values are the Mold Dependent Heat
P.I.D. control parameters. If a servo valve is installed on
the machine, the P & V control parameters and all the
variables on that particular page, except for P6, are
stored on the machine disk in the PARAM.BIN file. P6 is
stored on the mold disk.

The diskette function follows normal DOS rules regarding data storage in directories and retrieval
from those directories DIR>. A backslash included in the file name indicates subdirectories.
In the table of contents, the files are indicated by the file name, length in bytes and the date of the
file creation.

e.g. PARAM.BIN 2048 98-10-04 8:59

II I I
File Name Length Date/Time

It is possible to store up to 100 different mold set-ups on a diskette, but only 40 mold set-ups if the
robot program (ERC) is included.

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 EC100 / CC100 - A03 OPERATOR:
The machine diskette can store only one set of machine information and this information can only
be read by that specific machine. In other words, when a machine diskette is created, the machine
number is automatically copied onto the diskette to prevent the wrong machine diskette being
used.

Diskette

INSERTION
ARROW

WRITING
OPEN/CLOSE WINDOW
PROTECTION ON OTHER SIDE
WINDOW OF DISKETTE
A7630243

1. The diskette is inserted with the insertion arrow at the top and facing away from the operator,
i.e. with the underside of the disk facing the operator.

2. If the writing protection window is open, no new information can be written on to the diskette.

To disable the overwrite protection feature, close the protection window. With the window closed,
new information can be written on to the diskette.

Diskette Technical Information

- 3.5 inch diskette
- Double Sided/ High Density (DS/HD)
- Unformatted = 2.0 Megabytes
- Formatted = 1.44 Megabytes
- Tracks/In. = 135 TPI
- Tracks/Surface = 80
- 3M # 12513
- Can be formatted on an IBM compatible PC, MS-DOS system 3.00 or greater.

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10.3.2 DISKETTE INTERFACE

The CC100 has the diskette device incorporated into the display cabinet.

Preliminary Steps

Step 1. The keyswitch must be in position 'PR'.

Step 2. Insert the diskette into the diskette device on the side of the display cabinet with the
insertion arrow at the top and facing away from the operator, i.e. with the underside of the
disk facing the operator.

Ensure the disk "clicks" into place.

Step 3. PRESS - Diskette

Step 4. The disk drive symbol at the bottom of the screen page will turn from grey
to red to indicate that the diskette function is active.

Step 5. If the disk is not recognized, the message “Unknown disk type” will be displayed and
the following function frames will appear:

If the disk is recognized as a “Machine Data” or “Mold Data” disk the following function
frames will appear:

The disk type will appear at the top left-hand corner of the screen page, either:
MACHINE DISK
or
MOLD DISK

If the machine disk is inserted and recognized as belonging to the machine the serial number will
be displayed under “Machine data”.

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10.3.3 TO WRITE TO A BLANK DISK

Press F2

The following function frame choices are available to the operator:

To write to a Machine Disk

Press F2

The words “Write Machine Disk” appears in the top left hand corner of the screen page, and the
following function frame choices are available.

F1 Enables the operator to enter a new file name via the Alpha numeric key. When the F1 key
is pressed, F8 is enabled as ETC--->. Pressing F8 will display the Alpha numeric function
keys, for a description of how to use these keys, refer to the “Selectable Text Page”
description in this chapter.

F5 Writes all the machine data on to the diskette. At the bottom left of the screen, the name
of the file being copied appears (e.g. a: \ ebias32.bin). On the bottom right of the screen
an advancing white bar indicates the progress of the file copying. When the data has been
written to the disk, the message “All Data Write OK” is displayed indicating that the files
have been successfully written.

The files copied to the diskette will appear on the right hand side of the screen page.

F6 Starts the write function when only one file of the machine data is selected. Select the file
or files required for copying and press F6. At the bottom left of the screen, the name of the
file being copied appears (e.g. a: \ ebias32.bin). On the bottom right of the screen an
advancing white bar indicates the progress of the file copying. When the data has been
written to the disk, the message “Data Write OK” is displayed indicating that the file(s)
have been successfully written.

F7 Enables the operator to escape the write function and return to a previous menu.

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10.3.4 TO WRITE A MOLD DISK

Press F3

The message “Input Directory Name” is displayed along with the Alpha numeric function keys.
Enter a directory name and press “Enter”. The new file name will appear on the left hand side of
the screen. The Mold diskette can hold up to 100 different mold setups, so it is important to give
the mold setup directory a name that relates to the machine from which the mold set up is taken.

The words “Write Mold Disk” appears in the top left hand corner of the screen page, and the
following function frame choices are available.

F1 Enables the operator to enter a new directory name via the Alpha numeric key. When the
F1 key is pressed, F8 is enabled as ETC--->. Pressing F8 will display the Alpha numeric
function keys, for a description of how to us these keys, refer to the “Selectable Text Page”
description in this chapter.

F6 Starts the write function. Select the file or files required for copying and press F6. At the
bottom left of the screen, the name of the file being copied appears (e.g. A: \ mach1 \ sgm
\ grafix.bin). On the bottom right of the screen an advancing blue bar indicates the
progress of the file copying. When the data has been written to the disk, the message
“Data Write OK” is displayed indicating that the file(s) have been successfully written.

F7 Enables the operator to escape the write function and return to a previous menu.

10.3.5 TO READ FROM A MACHINE DISK

Press F1

NOTE!

The machine must be in MANUAL, to read from a disk

When the disk is inserted for “reading - in”, the control
system checks that the disk belongs to the machine by
comparing the machine number with the number on the
disk.

If the disk and machine are compatible, the contents of the diskette will appear on the left-hand
side of the screen. The cursor appears at the top of the file listing and the following function
frame will appear:

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Highlight the file to be read with the cursor and press F6 to start the “read” function. The name of
the file being read will appear below the left-hand side of the screen. The progress bar on the
right-hand side of the screen will advance to indicate the progress of the “read” function. When the
data has been read from the disk, the message “Data Read OK” is displayed indicating that the
file(s) have been successfully read.

To read all the file from the disk, press F5 “Read all Data”, all the files on the disk will be read into
the controller memory with the exception of the EBIAS32.BIN file.

NOTE!

The “Ebias.bin” portion of the machine disk cannot be

read-in using this procedure. The reading-in of the Ebias
should be performed by a trained service technician.
Refer to the Controller Maintenance manual, chapter 2,
“Loading the software”.

To escape from the “Read” function press F7 Exit and the previous function frame appears.

Press F8 etc.--> to gain access to the Alphanumeric function frame and enter the file name to be
read, manually.

When the program is completed, the main function frame display will reappear.

10.3.6 TO WRITE TO AN EXISTING MACHINE DISK

Press F2
The words “Write Machine Disk” appears in the top left hand corner of the screen page, and the
following function frame choices are available.

Use the cursor to highlight the file(s) to be overwritten

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F1 Enables the operator to enter a new file name via the Alpha numeric key. When the F1 key
is pressed, F8 is enabled as ETC--->. Pressing F8 will display the Alpha numeric function
keys, for a description of how to us these keys, refer to the “Selectable Text Page”
description in this chapter.

F5 Writes all the machine data on to the diskette. At the bottom left of the screen, the name
of the file being copied appears (e.g. a: \ ebias32.bin). On the bottom right of the screen
an advancing white bar indicates the progress of the file copying. When the data has been
written to the disk, the message “All Data Write OK” is displayed indicating that the files
have been successfully written.

The files copied to the diskette will appear on the right hand side of the screen page.

F6 Starts the write function when only one file of the machine data is selected. Select the file
or files required for copying and press F6. At the bottom left of the screen, the name of the
file being copied appears (e.g. a: \ ebias32.bin). On the bottom right of the screen an
advancing white bar indicates the progress of the file copying. When the data has been
written to the disk, the message “Data Write OK” is displayed indicating that the file(s)
have been successfully written.

F7 Enables the operator to escape the write function and return to a previous menu.

10.3.7 TO READ FROM A MOLD DISK

Press F1

NOTE!

The machine must be in MANUAL mode.

The contents of the diskette will appear on the left-hand side of the screen. Move the cursor to the
directory required and press F6 Start Read. The name of the file being read will appear below the
left-hand side of the screen. The progress bar on the right-hand side of the screen will advance to
indicate the progress of the “read” function. When the data has been read from the disk, the
message “Data Read OK” is displayed indicating that the file(s) have been successfully read.

To escape from the “Read” function press F7 Exit and the previous function frame appears.

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Press F8 etc.--> to gain access to the Alphanumeric function frame and enter the file name to be
read, manually.

When the program is completed, the main function frame display will reappear.

Press F7 “Exit” to escape the Read function and return to the main menu.

10.3.8 TO WRITE TO AN EXISTING MOLD DISK

Press F2

The message “Write Mold Disk” appears in the top left hand corner of the screen page, and the
following function frame choices are available.

The message “Warning! The whole data set will be deleted” is display. All the data on the disk will
be overwritten by the new data from the controller. If the operator wishes to keep the data already
on the disk, a new directory name must be created.

Press F1 “New Directory”, the alphanumeric function frame will appear and a new name can be
entered. The new name will appear on the left-hand side of the screen as a directory tree. Use the
cursor to highlight the name of the directory to which the data will be written.

To write the process data, press F6 “Start Write”, as each file is being written the file name will
appear on the left-hand side of the screen and the progress bar on the right-hand side will
advance to indicate the progress of the write function. The message “Write OK” will be displayed
when the directory has been successfully written.

The mold disk can hold up to 100 process data sets.

Press F7 “Exit” to escape the Write function and return to the main menu.

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10.4 COMPARISON

Press F3 to compare parameters values on the floppy or RAM disk with the parameter values in
the machine software.

Depending upon the “Working Device” selected, Floppy or RAM disk, the directories and files will
be listed on the right-hand side of the screen.

Move the cursor to the right-hand side of the screen and select the file to be compared, e.g. the
param.bin file.

Press F6 “Start Comparison”. If the parameter values are all identical, no information will be
displayed.

The message “Comparison OK” will be displayed to confirm that the comparison function has
finished.

If any parameter values are different, the information will be displayed as shown over the page.

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The message comparison OK is displayed to confirm the end of the comparison function. If there
are no difference between the two files the screens will be blank apart from the headers.

The display shows:

P = parameter number

INT = internal machine value

EXT = value on external device i.e. floppy or RAM disk

[] = units

If many changes have been made, the display will be filled with parameter values that have been
changed. The operator may need to scroll down to see all the information.

To further identify the parameters, press F6 “Screenlines”

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SCREENLINES

To further aid the operator to locate the changed variable:

• The screen page that parameter is on is displayed.
• the relevant line that contains the parameter
• the parameter number.

If the variable that has changed does not appear on a screen page the line will say “No picture
found”.

Press “Exit” to return to the previous menu.

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Printer / Floppy

A record of the comparison can be saved:

Press F1 for a hardcopy to a printer.

or
Press F2 for a copy onto a floppy disk.

The information contains:

• Disk type
• Serial number of the machine
• File location
• Changed parameter values

Sample page

Comparison MOLD DATA # 8435

A:\123456\SGM\PARAM.BIN

P INT EXT [] P INT EXT []

8036 18.00 19.00 s;

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10.5 ADMINISTRATION

To utilize the other features of the diskette function:

Press F6 Administration

Pressing F6 “Administration” will enable the following function frame. Press F7 “Exit" at any time
to escape to the main menu.

Press F7 “Exit” escape to the main menu.

10.5.1 TO CHANGE THE WORKING DEVICE;

Press F1 Working Device

A function frame will be displayed giving the options for the working device.

Press F1 to select the floppy disk as the working device or press F2 to select the RAM disk as the
working device.

Press F7 “Exit” to escape the “Working Device” function and return to the main menu.

10.5.2 TO VIEW THE DIRECTORY OF FILES ON A FLOPPY DISK OR RAM DISK

Press F2 “View Directory”

The message “please wait” appears, followed by “View OK”. The directory tree appears on the
left-hand side of the screen and the list of files appears on the right-hand side.

Press F1 to choose between the devices available:

Floppy

Ram disk

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Pressing either floppy or RAM disk will cause that device’s directories and files to be displayed on
the left-hand side of the screen and the symbol over that part of the screen will be either a floppy
drive symbol or a RAM disk symbol, as shown above.

10.5.3 TO DELETE FROM THE DEVICE SELECTED.

Press F4

The following function frame will be displayed and the cursor will appear on the first file. Move the
cursor to the file to be deleted and press F6”Execute” to confirm the delete function.

The other option is to press F8 “etc. -->” to select the file name via the alphanumeric function
frame. Enter the file name manually and the cursor will move to that filename. Only enough of the
file name has to be entered to distinguish it from the other filenames.

The file name being deleted will appear on the bottom left of the screen page and on the right the
advancing white bar will show the progress of the function.

10.5.4 TO COPY BETWEEN DEVICES:

Press F3 Copy

The RAM disk can provide the option for language and unit changes at the push of a button. The
screen pages could be switched from English to Spanish and from Imperial units to Metric unit via
a front panel softkey function.

The RAM disk enables files to be copied from it, to a floppy disk or from a floppy disk to the RAM
disk. This function allows files to be copied between the two devices.

Press F1 “Copy from device” to choose the device from which the files are copied, the following
function frame will be displayed.

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Press F1 to choose “Floppy” or F2 to choose “RAM disk”.

Pressing either “Floppy” or “RAM disk” will cause that device’s directories and files to be displayed
on the left-hand side of the screen and the symbol over that part of the screen will be either a
floppy drive symbol or a RAM disk symbol.

Press F7 Exit to return to the previous screen page.

Press F2 “Copy to Device” to choose the device to which the files will be copied, the above
function frame will be displayed again. Choose either F1 “Floppy” or F2 “RAM disk”, obviously the
choice would be the opposite from the “Copy from Device” choice.

The “Copy from” directory will be displayed on the left-hand side of the screen with the appropriate
symbol above that half, either a floppy or RAM disk symbol.

The “Copy to” directory will be displayed on the right-hand side of the screen with the appropriate
symbol above that half, either a floppy or RAM disk symbol.

Press F7 Exit to display this function frame.

The cursor can only select from the “Copy from” side of the screen, move the cursor using the up/
down arrow keys to select the required file.

The other option is to press F8 etc. --> to select the file name via the alphanumeric function frame.
Enter the file name manually and the cursor will move to that filename. Only enough of the file
name has to be entered to distinguish it from the other filenames.

Press F6 “Start copy” to copy the selected file.

or
Press F5 “Copy all data” to copy all files from the device.

The file names being copied will appear on the bottom left of the screen page and on the bottom
right the advancing white bar will show the percentage progress of the function.

The words “Copy OK” wil be displayed at the bottom left corner of the screen, when the copy
function has been successfully completed.

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10.5.5 TO FORMAT A 3.5” FLOPPY DISK.

Press F4 Format. The message “Warning!. All data will be deleted” is displayed, and the following
function frame is displayed.

Press F1 to select the device to be formatted.

Press F1 to select floppy.

Press F7 to exit to the previous menu.

Press F6 to format the diskette. The advancing bar on the bottom right of the screen, indicates
the progress of the format function. The format process will take less than two minutes, the
diskette can be formatted on an IBM compatible PC that is running DOS 3.0 or better.

The space available on the diskette is indicated underneath the progress bar. When the formatting
is complete the message “Format OK” will be displayed.

Press F7 “Exit” to escape the format function and return to the main menu.

10.5.6 TO DELETE A DIRECTORY OR FILE FROM A DEVICE

Press F5 Delete

Use the Delete function in conjunction with the View Directory function key to display the
directories and files on the disk.

Move the cursor to the directory or file to be deleted, or press etc.--> to gain access to the
Alphanumeric function frame and enter the file name to be deleted manually.

Press F6 “Execute” to delete the directory or file.

Press F7 “Exit” to escape the delete function and return to the main menu.

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DISKETTE ERRORS & MESSAGES

“OK” Program is working correctly.

“Write Protection" A write protected diskette has been inserted. If you wish to write
over the current information, close the write protection window.
“Disk Unformatted” Diskette must be formatted before it can be used.
“No Disk” The read/write diskette function was started, but no disk was
inserted in the disk drive. Ensure diskette is fully inserted into the
disk drive.
‘Unknown Disk Type” Diskette has not been identified as either a machine or mold
diskette. This message appears after formatting if a read function is
chosen.
“MACHINE DATA’’ The inserted diskette is a machine parameter diskette.
“MOLD DATA” The inserted diskette is a mold set-up diskette.
‘'Report Diskette” Not yet installed (optional)
“Interface Diskette” Not yet installed (optional)
“Read Error” Data set name not according to DOS convention. Name can only
start with numbers or letters. The name cannot contain periods,
commas, etc.
“Write Error” This message is displayed when a problem writing to the disk has
arisen
“Unallowed Disk Change” The diskette function has been disengaged during a read/write
function.
“Directory Already Exists” The chosen mold file name already exists. Choose another file
name.
‘File Not Found” The chosen file does not exist. Check the file name. Is this the
correct disk? Is the disk defective?
“Disk Full” This diskette is full. Another new formatted diskette is required to
store more information.
“Path Does Not Exist” The chosen file does not exist. Check the file name. Is this the
correct diskette? Is the diskette defective?
“Error” An operation or consideration error exists.
“Machine Number The machine number (serial number) on the inserted diskette is not
Does Not Match” identical to the one stored in the CPU.
“Input Directory Name” Enter the name of the file. This prompt arises when new mold
setups are stored.
“All Data Read OK” This message is displayed after the “Read All Data” function key
has been pressed and all the data has been successfully read in
from the disk.

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“Read OK” This message is displayed after the “Start Read” function key has
been pressed and the file has been successfully read in from the
disk.
“All Data Write” This message is displayed after the “Write All Data” function key
has been pressed and all the data has been successfully written to
the disk.
“Write OK” This message is displayed after the “Start Write” function key has
been pressed and the file has been successfully written to the disk.
“Please wait.......” This message is displayed while the controller is performing the
task assigned.
“View OK” This message is displayed after the “View Directory” function key
has been pressed and the directory displayed
“Delete OK” This message is displayed after the “Delete” function key has been
pressed and the directory of file successfully deleted.
“Copy all OK” This message is displayed after the “Copy All” function key has
been pressed and all the copy all function has been successfully
completed.
“Copy OK” This message is displayed after the “Copy” function key has been
pressed and the copy function has been successfully completed.
“Format OK” This message is displayed after the “Format” function key has been
pressed and the format function has been successfully completed.
“Floppy Operation locked” The operation requested is not possible. For example, reading from
an empty, formatted diskette. Make sure that the keyswitch is in
position 'PR'.

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10.6 TEXT PAGES (NOTES)

PRESS

This area of the control system allows the operator to store up to three pages of informational
messages. To access the three pages, press '0' for the first page, '1' for the second page, and '2'
for the third page. The messages are also stored on the diskette when using the diskette "write"
function, and, can also be printed out.

TEXT INPUT

An IBM compatible keyboard can be connected to the front panel. This feature provides the facility
to input text:
• The three text screen pages
• Instead of using the front panel keypad to input values, the keyboard can be used
to enter values where ever the cursor can be placed.

IBM
keyboard
connector
The text pages can be reached as follows:
• Select the “Menu” function key.
• Select F3 for the text pages.
• Page one appears first, the other pages are selected using the F2 or F3 function
keys.
• Function key F7 selects the color of the text. The color of the function key
corresponds to the color of the text. The colors are available sequentially as
follows,
Red, Green, Yellow, Blue, Magenta, Cyan, and White.

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Auxiliary functions of the keyboard.

PC Key Insert Switch over between:

• Overwrite mode (cursor static)
• Inserting mode (cursor flashing)

Backspace Deletes the character to the left of the cursor.

Delete Deletes the character at the cursor position.

Ctrl Delete Deletes the line that the cursor is on, and leaves the line empty.

Alt Delete Deletes the whole page.

Ctrl Insert Inserts a line before the line that the cursor is on.

Enter Ends the line the cursor is on and moves the cursor to the next
line down.

Page Down Selects the next page.

Page Up Selects the preceding page.

Home The cursor is move to the top left hand corner of the page.

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11 CORES

11.1 CORE IN

PRESS

F1 CORE IN
F2 CORE OUT

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1 .. . O P E R AT IO N B Y: CORE CORE CORE

The operator has the option of using the central hydraulic ejector as a core. This can be very
useful in situations where 3 cores are required.
If this program is turned on, the main ejector program will be turned off by the controls by
setting the ejector counter 'AZ' to zero.
When this program is turned on, the ejector is still controlled by the relevant ejector valves,
'S25' and 'S26', however the stroke transducer does not control position. The ejector
function would be controlled by limit switches “E18” and “E19”.
To summarize, when this program is activated, the ejector page variables are deactivated.
The core page variables come into effect to control the "ejector as a core”, both in and out.
To turn this program on, move the cursor to the “CORE 3” position and press “1”, then
'ENTER'. The following prompt will appear:
'ARE YOU SURE ?, YES = 1 ENTER>'
This prompt is asking you to be certain that you want this program activated. Will your
activation of this program cause any mechanical difficulties ?
If you are certain that this program can be safely activated, press “1”, then press “ENTER”,
once more.

2... MOVING IN OFF OFF OFF

The operator must activate the required core functions on this line before they will operate.
To turn the program on, move the cursor to the 'ON/OFF' position, press “1”, then press
“ENTER”.
To turn the program off, move the cursor to the “ON/OFF” position and press “ENTER”.

This variable has 3 specific functions:

1. In general, variable “KS1” allows the operator to choose at which point, between the mold
open position 'A' and the toggle locked position 'B', that the core will move in, or start
moving in.
2. If the operator sets “KS1” equal to 0.04 inch, the core will begin moving in at position “B8”.
See line 16 below.
3. If the operator sets “KS1” equal to 0.0 inch., the core will begin moving in at position “B”,
toggle lever locked.

NOTE!

The mold position for “core - in” is recognized by the software as

the KS1 value plus 0.2mm, while the mold is moving and KS1 plus
0.5mm when the mold has stopped. The “core - in” movement is
also allowed at any point less than the mentioned positions.

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If the operator sets 'KE1' to a value less than 'KS1', the 'core-in' limit switch signal must be
received by the time the mold reaches monitoring position 'KE1' or the machine will
immediately stop cycling and go into a 'core not in' alarm.
This function will be switched off if 'KE1' is set to 0.0 in.

5... MOVING IN PRIORITY KP1E = 0 KP2E = 0 KP3E = 0

The operator can choose the priority in which the cores will move in by entering a value from
0-2 on this line. This is independent of the moving out priority.
If multiple cores are in operation, the core program with the lower number will operate first.
If multiple cores are in operation and if all core programs have the same priority number,
then all cores will move in at the same time.

6... WHILE MOLD IS MOVING KZ1E = NO KZ2E = NO KZ3E = NO

This variable must be switched to 'yes' to allow the core to move in as the mold is closing.
If this variable is switched to 'NO', the core must be in before the mold will continue to close.
In other words, the closing will stop at the designated position and wait for the signal
indicating that the core is in before continuing the mold close function.
This program can be extremely useful if electric or pneumatic core functions are being
employed.
If the machine is equipped with a hydraulic core function, the machine must also be
equipped with an accumulator or an extra pump, specifically dedicated to the core function,
in order to use the core-in on-the-fly procedure.
To turn the program on, move, the cursor to the 'YES/NO' position, press '1', then press
'ENTER'.
To turn the program off, move the cursor to the 'YES/NO' position and press 'ENTER'.

7... WITH AUX.POWER SOURCE KH1E = NO KH2E = NO KH3E = NO

If the machine is equipped with electric or pneumatically operated cores, this line must be
switched to 'YES'. The core function will then be controlled with specific digital outputs.
To turn the program on, move the cursor to the 'YES/NO' position, press '1', then press
'ENTER'.
To turn the program off, move the cursor or the 'YES/NO' position and press 'ENTER'.

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8... VALVE OFF AFTER MOVINGKD1E = NO KD2E = NO KD3E = NO

The operator can choose to deactivate the controller outputs after the core-in position has
been reached. The effect will be the same regardless if time or limit switch inputs are used
to indicate the core-in position being reached.
To turn the program on, move the cursor to the 'YES/NO' position, press 1, then press
'ENTER'.
To turn the program off, move the cursor to the 'YES/NO' position and press 'ENTER'.

9... TIME - DEPENDENT KT1E = NO KT2E = NO KT3E = NO

The operator has the choice of operating the core programs based on time or upon reaching
a certain limit switch position.

If the time dependent mode is chosen, the limit switch inputs relevant to the core program
chosen, must be jumpered to 24 volts (VE).

To turn the program on, move the cursor to the 'YES/NO' position, press 1, then press
'ENTER'.

To turn the program off, move the cursor to the 'YES/NO' position and press 'ENTER'.

If the operator chooses to employ time dependent core functions, variable 'ZE1' must also
be set.

As soon as the mold reaches the position for starting the core-in function, the core will move
in for 'ZE1' period of time.

If the core is not in by the time 'ZU1' period of time has expired, the machine will immediately
stop cycling and go into a 'core not in' alarm. When the core is in, a limit switch input will be
activated which indicates that position.
This function can be used in addition to, or in place of, variable 'KE1', monitoring position
for core-in. Setting 'ZU1' to 0.0 s, turns the monitoring time off.

If the core program is being employed, this variable controls the hydraulic speed with which
the core moves in.

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 EC100 / CC100 - A03 OPERATOR:

If the core program is being employed, this variable controls the hydraulic pressure with
which the core moves in.

The operator is encouraged to use only the amount of pressure required to move the core
efficiently into position.

The operator should also recognize that after the mold heats up (and expands), more
pressure could be required to complete the core movement.

This line displays software markers indicating either digital inputs being received, or digital
outputs being activated for each separate core function.

Digital Inputs: ( light blue marker indicates input received)

E14 - Core 1 is out

E16 - Core 2 is out

E18 - Core 3 is out

SAW - Ejector plate is back. This is a core safety.

E15 - Core 1 is in

E17 - Core 2 is in

E19 - Core 3 is in

Digital Outputs: (red marker indicates that the digital output is active)

S14 - Send core 1 out

S16 - Send core 2 out

S18 - Send core 3 out

S15 - Send core 1 in

S17 - Send core 2 in

S19 - Send core 3 in

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 EC100 / CC100 - A03 OPERATOR:
15.. ACTUAL MOLD POSITION SFx = 20.00 in

This is the actual value of the mold position at any time during the cycle. Since it is an actual
value, the operator cannot move the cursor to this position and cannot change the value that
appears on this line.

This is a value that represents the linear distance from the mechanical toggle lever locked
position. It is important to recognize that when the two mold halves just touch, the toggle
crosshead still has some distance to travel before the locked position. Therefore, it is normal
to see an actual mold position (SFx) of 0.0 inches and an actual toggle lever position (SKx)
of 1.48 inches if the mold is closed but the toggle is not locked.

1 6 . . M O V E IN B E F O R E TO N N A G E B8 = 0.0 in

This toggle lever position is used in conjunction with variable 'KS1'. See line 3 above.

The operator can set a toggle lever position in variable 'B8'. When that toggle lever position
is reached, the core will start moving in.

1 7 . . IN T H E S E T- U P M O D E E L I M I N AT E C O R E I N T E R L O C K S YES/NO

CAUTION!

Eliminating core interlocks can result in serious damage

to the mold.

This feature can only be selected in the SET-UP mode.

If NO is selected all the interlock conditions apply, even though the machine is in SET-UP.

If YES is selected the mold core interlocks are overridden and the mold can be opened and
closed regardless of core position.

This feature must only be employed by a competent set - up person who is aware of the
damage that could result from closing the mold with the cores in an unsafe position. The set
- up person must be aware of the core safe positions

10/10/02 5. SCREEN PAGES 213

 EC100 / CC100 - A03 OPERATOR:
1 8 . . S P I S TA N D A R D C O R E P U L L S E T U P 0

The ‘SPI standard core pull set up” automatically sets the machine to run one of seven
standard SPI sequences. An eighth special sequence may be added as an option.

NOTE!

The sequences can only be changed in the “Set up mode”.

The sequences are:

1. Core IN on “A” position. Core OUT at intermediate position.
2. Core IN and OUT on “B” position.
3. Core IN and OUT on “A” position then back IN after ejection.
4. Core IN parallel to mold closing. Core OUT parallel to mold opening.
5. Core IN at intermediate position. Core OUT at intermediate position.
6. Core IN and OUT on “A” position.
7. Core OUT on mold open via unscrewing timer. (Parallel during opening is selectable)
8. Ejector forward, Core IN, Core OUT (count), Ejector back. (Engel special)

To set up a standard SPI sequence, switch the machine into “Set up” mode, move the cursor
to the “SPI STANDARD CORE PULL SET UP” line at the bottom of the screen page. Enter
the number of the SPI sequence required, refer to the following sequence details for more
information. Entering a zero will turn off the sequence program.

When an SPI sequence is selected, default values are entered in the relevant variable
parameters, for example any intermediate position will be set to half of position A, mold
open. The variable can be adjusted as required by the operator, to suit the application. To
return to the default value, the operator would re-enter the sequence number.

A dialog box will be displayed, if the operator changes the value of position A, mold open,
after a sequence has been set. The dialog box will request confirmation of the core settings.
Dialog boxes will also be displayed when there is an intermediate position or timer in the
sequence after position A has been changed.

214 5. SCREEN PAGES 10/10/02

 EC100 / CC100 - A03 OPERATOR:
Sequence Details:

Set Sequence “1” Pull Sequence “1”

Gate is closed Clamp partially opens
Ejector Returns* Core Pulls
Core Sets Clamp finishes opening
Clamp closes Ejector Forward
Inject Gate is opened
Set Sequence “2” Pull Sequence “2”
Gate is closed Cores pull
Clamp closes Clamp Opens
Core Sets Ejector Forward
Inject Ejector Returns
Gate is opened
Set Sequence “3” Pull Sequence “3”
Core Sets Clamp opens
Gate is opened Core Pulls
Gate is closed Ejector Forward
Clamp closes Ejector Returns
Inject
Set Sequence “4” Pull Sequence “4”
Gate is closed Clamp Open / Core Pulls
Clamp closes / Core Sets Ejector Forward
Inject Ejector Returns*
Gate is opened
Set Sequence “5” Pull Sequence “5”
Gate is closed Clamp partially opens
Clamp partially opens Core Pulls
Core Sets Clamp finishes opening
Clamp finishes closing Ejector Forward
Inject Ejector Returns*
Set Sequence “6” Pull Sequence “6”
Core Sets Clamp opens
Clamp closes Core Pulls
Inject Ejector Forward
Ejector Returns
Set Sequence “7”
Mold opens after injection
During mold opening, unwind timer is started
Cores rotate, ejecting part
Mold opening continues
Special ENGEL Sequence “8”
Mold opens
Ejector Forward
Core 1 Sets
Core in and out will repeat the amount of times set in COUNT.
Ejector retracts*

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Special ENGEL “EJECTOR / CORE” sequence (selection 8)

The Special ejector / core sequence is provided to allow core movement with the machine ejector
on the forward “L1” position.
The program switch is accessible on both core in and core out pages.
Only the first core is operational for the special sequence. The second and third cores are
automatically disabled and can not be accessed once the program is activated.
Putting the machine control into “setup” mode will give access to "SPI STANDARD CORE 1
SETUP (0-8)" at the bottom of the screen page.
Move the cursor down to the "SPI STANDARD CORE 1 SETUP (0-8)" line and enter an 8 will
cause the screen to display “SPECIAL ON” and “COUNT” under “CORE 1”.
Count is how many times the core will move in and out before the ejector can be retracted. If the
core count is set to zero, a 1 will be automatically entered into the field.
The start ejector forward A1 position and the core in and out positions are set equal to the mold
open ”A” position.
If the mold open “A” position is altered, the special ejector /core sequence will update
automatically to the new position.
The ejector counter is automatically set to 1.
The ejector start position must not be changed once the program is enabled.
The ejection-monitoring program is disabled due to the fact that the sequence must fully
complete.

216 5. SCREEN PAGES 10/10/02

 EC100 / CC100 - A03 OPERATOR:
11.2 CORE OUT

PRESS

F1 CORE IN
F2 CORE OUT

10/10/02 5. SCREEN PAGES 217

 EC100 / CC100 - A03 OPERATOR:
1 .. . O P E R AT E B Y: CORE CORE CORE

The operator has the option of using the central hydraulic ejector as a core. This can be very
useful in situations where 3 cores are required.

If this program is turned on, the main ejector program will be turned off by the controls by
setting the ejector counter 'AZ' to zero.

When this program is turned on, the ejector is still controlled by the relevant ejector valves,
'S25' and 'S26', however the stroke transducer does not control position. The ejector
function would be controlled by limit switches 'E18' and 'E19'.

To summarize, when this program is activated, the ejector page variables are deactivated.
The core page variables come into effect to control the “ejector as a core', both in and out.

To turn this program on, move the cursor to the 'core/ejector' position and press '1', then
'ENTER'. The following prompt will appear:

'ARE YOU SURE ?, YES = 1 ENTER>'

This prompt is asking you to be certain that you want this program activated. Will your
activation of this program cause any mechanical difficulties ?

If you are certain that this program can be safely activated, press '1', then press 'ENTER',
once more.

2... MOVING OUT OFF OFF OFF

The operator must activate the core function on this line before it will operate.

To turn the program on, move the cursor to the 'ON/OFF' position, press '1', then press
'ENTER'.

To turn the program off, move the cursor to the 'ON/OFF' position and press 'ENTER'.

This variable has 3 specific functions.

1. Variable 'K01' allows the operator to choose the point, between the mold open
position 'A' and the toggle locked position 'B', that the core will move out, or start
moving out.
2. If the operator sets 'K01' equal to 1mm (0.04 in.), the core will begin moving out at
position 'B8'. See line 18 below.
3. If the operator sets 'K01' equal to 0.00 in. the core will begin moving out at position
'B', toggle lever locked, but before mold opening. See line 9 and 11 below.

218 5. SCREEN PAGES 10/10/02

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NOTE!

The mold position for core - out is recognized by the

software as the KO1 value minus 0.2mm, while the mold
is moving and KO1 minus 0.5mm when the mold has
stopped. The core - out movement is also allowed at any
point greater than the above mentioned positions.

If the operator sets 'KA1' to a value greater than 'K01', the 'core-out' limit switch signal must
be received by the time the mold reaches monitoring position 'KA1' or the machine will
immediately stop cycling and go into a 'core not out' alarm.

This function will be switched off if 'KA1' is set to 0.00 in.

5... PRIORITY FOR MOVING OUTKP1A =0 KP2A =0 KP3A = 0

The operator can choose the priority in which the cores will move out by entering a value
from 0-2 on this line. This is independent of the moving in priority.

If multiple cores are in operation, the core program with the lower number will operate first.

If multiple cores are in operation and if all core programs have the same priority number,
then all cores will move out at the same time.

6... WHILE MOLD IS MOVINGKZ1A =NO KZ2A =NO KZ3A = NO

This variable must be switched to 'YES' to allow the core to move out as the mold is
opening.

If this variable is switched to 'NO', the core must be out before the mold will continue to
open. In other words, the opening will stop at the designated position and wait for the signal
indicating that the core is out before continuing the mold open function.

This program can be extremely useful if electric or pneumatic core functions are being
employed.

If the machine is equipped with a hydraulic core function, the machine must also be
equipped with an accumulator or an extra pump, specifically dedicated to the core function,
in order to use the core-out on-the-fly procedure.

To turn the program on, move the cursor to the 'YES/NO' position, press '1', then press
'ENTER'.

To turn the program off, move the cursor to the 'YES/NO' position and press 'ENTER'.

10/10/02 5. SCREEN PAGES 219

 EC100 / CC100 - A03 OPERATOR:
7... WITH AUX. POWER SOURCEKH1A =NO KH2A =NO KH3A = NO

If the machine is equipped with electric or pneumatically operated cores, this line must be
switched to 'YES'. The core function will then be controlled with specific digital outputs.

To turn, the program on, move the cursor to the 'YES/NO' position, press '1', then press
'ENTER'.

To turn the program off, move the cursor to the 'YES/NO' position and press 'ENTER'.

8... TIME DEPENDENT KT1A =NO KT2A =NO KT3A = NO

The operator has the choice of operating the core program based on time or upon reaching
a certain limit switch position.

If the time dependent mode is chosen, the limit switch inputs relevant to the core program
chosen, must be jumpered to 24 volts (VE).

To turn the program on, move the cursor to the 'YES/NO' position, press '1', then press
'ENTER'.

To turn the program off, move the cursor to the 'YES/NO' position and press 'ENTER'.

9... DURING COOLING TIME KV1A =NO KV2A =NO KV3A = NO

This program allows the operator to activate the core out function at any time after cooling
begins.

If this function is switched to 'YES', a core-out delay time begins as soon as cooling begins.
As soon as a delay time equal to 'ZV1' has expired, the core will begin to move out. See line
11 below.

To turn the program on, move the cursor to the 'YES/NO' position, press '1', then press
'ENTER'.

To turn the program off, move the cursor to the 'YES/NO' position and press 'ENTER'.

If the operator chooses to employ time dependent core functions, variable 'ZA1' must also
be set.

As soon as the mold reaches the position for starting the core-out function, the core will
move out for 'ZA1' period of time.

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 EC100 / CC100 - A03 OPERATOR:

If the program 'BEFORE MOLD OPENING' is being employed, 'ZV1' represents the amount
of time, after cooling has started, until the core will begin to move out.

By setting 'ZV1' to a certain value, the operator can cause the core-out function to activate
during cooling.

If 'ZV1' is too long, the mold open function will not be delayed. Instead, the cores will move
out based on variable 'K01', 'MOLD POSITION FOR CORE OUT'.

If the core is not out by the time 'ZUa1' period of time has expired, the machine will
immediately stop cycling and go into a 'core not out' alarm. When the core is out, a limit
switch input will be activated which indicates that position.

This function can be used in addition to, or in place of, variable 'KA1', monitoring position for
core-out. Setting 'ZUa1' to 0.0 s, turns the monitoring time off.

13.. SHAKE AS EJECTOR KRZ1 =0 KRZ2 =0 KRZ3 = 0 X

Core 1 or Core 2 can be used to complete the ejector function, but only one at a time. If this
function is employed, the main ejector will be turned off by the controls by setting the ejector
counter 'AZ' to zero.

Using the core as an ejector can be conducted with or without hydraulics and can be
monitored by time or limit switches.

The core would move out as an ejector when the mold opened up to position 'K01', mold
position for core out.

The core/ejection function would occur 'KRZ' number of times. If 'KRZ' is set to zero, this
function is deactivated.

To summarize, when 'KRZ' is set to a number greater than zero, the ejector and all its page
variables are deactivated. The core page variables come into effect to control the "core as
an ejector", both in and out.

If the core program is being employed, this variable controls the hydraulic speed with which
the core moves out.

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 EC100 / CC100 - A03 OPERATOR:

If the core program is being employed, this variable controls the hydraulic pressure with
which the core moves out.

The operator is encouraged to use only the amount of pressure required to move the core
efficiently into position.

The operator should also recognize that after the mold heats up (and expands), more
pressure could be required to complete the core movement.

This line displays software markers indicating either digital inputs being received, or digital
outputs being activated for each separate core function.

Digital Inputs: ( light blue marker indicates input received)

E14 - Core 1 is out
E16 - Core 2 is out
E18 - Core 3 is out

SAW - Ejector plate is back. This is a core safety.

E15 - Core 1 is in
E17 - Core 2 is in
E19 - Core 3 is in

Digital Outputs: (red marker indicates that the digital output is active)
S14 - Send core 1 out
S16 - Send core 2 out
S18 - Send core 3 out
S15 - Send core 1 in
S17 - Send core 2 in
S19 - Send core 3 in

17.. ACTUAL MOLD POSITION SFx = 0.00in TOGGLE LEVER POSITION SKx = 0.00in

SFx is the actual value of the mold position at any time during the cycle. Since it is an actual
value, the operator cannot move the cursor to this position and cannot change the value that
appears on this line.

SKx is a value that represents the linear distance from the mechanical toggle lever locked
position. It is important to recognize that when the two mold halves just touch, the toggle
crosshead still has some distance to travel before the locked position. Therefore, it is normal
to see an actual mold position (SFx) of 0.00 inches and an actual toggle lever position (SKx)
of 1.48 inches if the mold is closed but the toggle is not locked.

222 5. SCREEN PAGES 10/10/02

 EC100 / CC100 - A03 OPERATOR:

This toggle lever position is used in conjunction with variable 'K01'. See line 3 above.

The operator can set a toggle lever position in variable 'B8'. When that toggle lever position
is reached, the core will start moving out.

19.. IN THE SET-UP MODE ELIMINATE CORE INTERLOCKS YES/NO

CAUTION!

Eliminating core interlocks can result in serious damage

to the mold.

This feature can only be selected in the SET-UP mode.

If NO is selected all the interlock conditions apply, even though the machine is in SET-UP.

If YES is selected the mold core interlocks are overridden and the mold can be opened and
closed regardless of core position.

This feature must only be employed by a competent set - up person who is aware of the
damage that could result from closing the mold with the cores in an unsafe position. The set
- up person must be aware of the core safe positions

20.. S P I S TA N D A R D C O R E P U L L S E T U P 0

Refer to the description for “Cores in”, this feature can be set up from either screen page.

10/10/02 5. SCREEN PAGES 223

 EC100 / CC100 - A03 OPERATOR:

12 MOLD PARAMETERS

PRESS

A7600377

F1 MOLD PARAMETER
F2 CYCLE TIME ANALYSIS
F3 PRODUCTION FORECAST
F4 SELECTABLE TEXT PAGE
F5 PROCESS ANALYSIS
F6 EHV CARD
F8 etc.

224 5. SCREEN PAGES 10/10/02

 EC100 / CC100 - A03 OPERATOR:

CAUTION!

Ensure that the mold halves are together, but not under
tonnage, when the machine is shut down. This will help
maintain the mold halve alignment.

The Quick Mold Change (QMC) system is constantly

under system pressure when the machine is cycling. This
ensures that the mold security and alignment are main-
tained. If the machine is shut down with the mold halves
open and no hydraulic system pressure is available,
there exists the possibility that the weight of the mold
halves will cause them to “slip” out of alignment. Closing
the mold with the mold halves misaligned could cause
serious damage to the mold.

There are 4 program selections:

0 : PROGRAM IS OFF
1 : MOVING PLATEN ONLY
2 : STATIONARY PLATEN ONLY
3 : BOTH PLATENS

The software flags beside SECURED, when lit, indicates if the mold half is secured. An unlit flag
indicates that the mold half is released.

The software flags beside S29 (moving platen) and S30 (stationary platen) will be active to
indicate that the hydraulic release function is in effect.

In order to operate the QMM program, the following conditions must exist.
1. The program must be in 'Set-up' mode.
2. The nozzle must be fully retracted.
3. The front safety gate must be closed.
4. The program selector must be set to choices 1, 2, or 3.
5. The keyswitch for mold release or mold secure must be activated.

10/10/02 5. SCREEN PAGES 225

 EC100 / CC100 - A03 OPERATOR:
2 .. . . M O L D N U M B E R WKN = ENGEL 1 !

This variable provides information on the mold that this particular set-up has used in the
past.

3 .. . . IT E M N U M B E R SPN = ENGEL 2 !

This variable provides information on molded parts that this particular set-up has produced
in the past. This name or number will also appear on the QDS program to help identify any
QDS printouts.

4 .. . . M AT E R I A L N U M B E R M T N = ENGEL 3 !

This variable provides information on the type of material that this particular set-up has used
in the past.

5 .. . . M A C H I N E N U M B E R MCN= ENGEL 4 !

This variable provides information about which particular machine this set-up has been
carried out on in the past.

6 .. . . O R D E R N U M B E R ANR = * * * * ** * 7 !

This variable provides information on the order number related to this particular set-up.

7 .. . . M O L D WAT E R H E AT E R 1 T G 1 = 0°F
M O L D WAT E R H E AT E R 2 T G 2 = 0°F
M O L D WAT E R H E AT E R 3 T G 3 = 0°F

These variables provide information about the mold temperature settings when this mold
was used in the past.

8 .. . . M AT E R I A L D RY E R 0°F

If a material dyer was used in this process previously, the temperature of the dryer would be
entered in this variable.

9 .. . M AT E R I A L C O N V E Y O R B E LT NO

If this process used a conveyor belt in the past, it could be indicated in this area, either yes
or no.

1 0 . . S E N S IT I V I T Y P F - T R A N S D U C E R 0 . 0 0 0 p C / ps i

If this process used a mold cavity pressure transducer, the sensitivity of the transducer in
Pico coulombs per psi can be entered for future reference.

226 5. SCREEN PAGES 10/10/02

 EC100 / CC100 - A03 OPERATOR:
12.1 CYCLE TIME ANALYSIS

PRESS

A7600377

This program allows the operator to monitor the cycle time and all its component parts. As the
machine cycle progresses, each cycle component time interval is recorded and displayed under
the heading 'Current Cycle'. As each cycle component is being monitored, a software marker will
appear to the right of the monitored component as additional information for the operator.
As each cycle ends, the stored time intervals will appear below the heading 'Last Cycle'. The left
column displays the actual time intervals in hundredths of seconds, while the right column
displays the time intervals as a percentage of the total cycle.

F1 MOLD PARAMETER
F2 CYCLE TIME ANALYSIS
F3 PRODUCTION FORECAST
F4 SELECTABLE TEXT PAGE
F5 PROCESS ANALYSIS
F6 EHV CARD
F8 etc.

10/10/02 5. SCREEN PAGES 227

 EC100 / CC100 - A03 OPERATOR:
SEQUENCE TIME MONITORING

PRESS

A7600377

This program screen allows the operator to monitor and/or stop the machine cycle if any or all
portions of the machine cycle are greater than the allowed tolerances.

F1 MOLD PARAMETER
F2 CYCLE TIME ANALYSIS
F3 PRODUCTION FORECAST
F4 SELECTABLE TEXT PAGE
F5 PROCESS ANALYSIS
F6 EHV CARD
F8 etc.

228 5. SCREEN PAGES 10/10/02

 EC100 / CC100 - A03 OPERATOR:
Step 1. Monitor the actual value times as the machine is cycling.

Step 2. Choose and enter a plus/minus tolerance for all the machine cycle components that you
are interested in monitoring. The program will have no effect on the machine operation if
the tolerances are set to zero.

Step 3. To transfer the last cycle actual values to the set value data field, move the cursor to the
NO position at the bottom of the page, press 1, then ENTER.

The program will now monitor the set and actual values with regard to the plus/minus tolerances.
If any component of the machine cycle exceeds the allowed tolerances, error 145 - CYCLE
DEVIATION will appear on the error page and the machine will stop cycling. The portion of the
cycle that is out of tolerance will be indicated by the software flag on the right hand side of the
page.

10/10/02 5. SCREEN PAGES 229

 EC100 / CC100 - A03 OPERATOR:
12.2 PRODUCTION INFORMATION

PRESS

A7600377

This program allows the operator to enter known information about the process.
The Control System will take the information and calculate the amount of time and material that is
required for this production run.

F1 MOLD PARAMETER
F2 CYCLE TIME ANALYSIS
F3 PRODUCTION FORECAST
F4 SELECTABLE TEXT PAGE
F5 PROCESS ANALYSIS
F6 EHV CARD
F8 etc.

230 5. SCREEN PAGES 10/10/02

 EC100 / CC100 - A03 OPERATOR:
1.... CYCLE TIME SET VALUE15.0s

The operator will enter the estimated time for each cycle on this line.

2.... CYCLE TIME ACTUAL VALUE0.0s

The actual cycle time will be displayed on this line at the end of each cycle.

3.... CYCLE TIME DEVIATION0 %

This line displays the positive or negative deviation, in percentage terms, between the set
value cycle time and the actual value cycle time.

If this deviation becomes too large, the calculated 'REMAINING PRODUCTION TIME'
would become meaningless. Monitor this variable for the first few cycles and consider
adjusting the cycle set value if the deviation will disrupt the calculated production time.

Remember that the first cycle of an automatic cycle run is always approximately 3 seconds
longer than subsequent cycles, since the controller always re-zeroes the carriage on the
first cycle.

4.... CAVITY FA = 4

This line allows the operator to indicate that a multiple cavity mold is being employed. This
line also acts as the multiplier, in order to assist in keeping track of total production. In other
words, every cycle, 'FA' number of parts are produced.

5.... PIECE SET VALUE StZ = 3600 Pcs

This area allows the operator to set the machine in automatic or semi-automatic and the
machine will continue to cycle until 'StZx' equals 'StZ'. When 'StZx' equals 'StZ', the
machine will stop cycling, the motor will shut off and the barrel heat will lower according to
the heat page programmed levels. A change in this variable will cause an adjustment to
‘Total Cycles Required', SZ.

6.... PIECE ACTUAL VALUE StZx = 0 Pcs

This line displays the total number of parts produced. 'StZx' is the product of the number of
cycles, 'SZx', times the number of cavities, 'FA'. It will not increment if a reject is produced.

To reset this counter, move the cursor to this line and press 'ENTER'. The following prompt
will appear:

'ARE YOU SURE ?,enter> = YES'

This prompt is asking the operator if it is safe to delete the parts count. In other words,
should the operator record the total before deletion?

If it is safe to delete the counter, press 'ENTER' once more. The counter will reset to zero.

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 EC100 / CC100 - A03 OPERATOR:
7.... PROD. REMAIN. TIME 3 h 45 min 00 s

When the operator enters the cycle time set value, the control system will calculate the time
required for the total production run and enter that value on this line in hours, minutes and
seconds.

The example on this page shows that 900 cycles are required to produce 3600 parts using
a 4 cavity mold.

i.e. 900 cycles x 15 seconds/cycle = 3 hours 45 minutes

During the production run, this line will decrement every cycle, a value equal to the cycle
time set value.

Please note: A reject cycle, as defined in the “Production Data” screen page (Ejector + F2)
description in this chapter, will not reduce the remaining production time.

Therefore, this line will display the estimated time before the production run is completed.

8.... PART WEIGHT 10.0 g

The operator can enter the known part weight on this line for the calculation of the total
weight of plastic required to complete this production run. This is the part weight per cavity
and can also be configured in pounds and ounces.

9.... REMAINING MATERIAL 36 kg 000 g

When the operator enters the part weight, the control system will calculate the amount of
material required for the total production run and enter that value on this line in kilograms
and grams. This variable can also be configured in pounds and ounces.

The example on this page shows that 3600 parts are required and each part weighs 10.0
grams.

i.e. 3600 parts x 10.0 grams/part = 36 kilograms

During the production run, this line will decrement every cycle, a value equal to the number
of cavities times the part weight (i.e. 4 x 10 = 40 grams).

Please note: A reject cycle, as defined in the “Production Data” screen page (Ejector + F2)
description in this chapter, will not reduce the amount of the “Remaining
material”

Therefore, this line will display the estimated amount of material still required before the
production run is completed.

232 5. SCREEN PAGES 10/10/02

 EC100 / CC100 - A03 OPERATOR:
12.3 SELECTABLE TEXT PAGE

PRESS

A7600377

This program will allow the operator to create a page to include frequently chosen variables.

The function frame as shown below will be displayed.

Press F1, F2 or F3 for text pages 1,2 or 3.

Press F8 - 'etc.' to display the function frame as shown below

F1 “SELECTION MODE ON” will activate the selectable text page.

F8 etc. will return the function frame display to the previous function frame.
To activate this program press, F1. The function frame as shown below will be displayed.

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INSERT LINE The chosen line will appear in the position of the cursor as it is
placed on the selectable text page. If there is an existing line on
the page, the chosen line will be inserted above the line position of
the cursor.

DELETE LINE The line in the position of the cursor will be deleted if 'F2' is
pressed.

INSERT A blank line will be inserted between the position of the cursor and
BLANKLINE the text lines which appear below the cursor when 'F3' is pressed.

REPLACE LINE The text line which currently exists in the position of the cursor will
be replaced with a new chosen text line when 'F4' is pressed and
the selection procedure as outlined below, is followed.

EXIT If the operator presses 'F8', the selectable text page program will
terminate and return the operator to the mold parameter page
function frame display.

etc. If pressed, this will return the function frame display to that of the
mold parameter function frame display and back again.
It also allows movement between various function frame displays
and the function frame display of the selectable text page.
Suppose the operator wanted to design a single page displaying
only 3 lines of text. Specifically, the operator wanted to monitor at
glance, the screw position at cut-off, 'C3u', the hydraulic pressure
at cut-off, 'PHu', and the actual cushion value, 'CPx'.

234 5. SCREEN PAGES 10/10/02

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The operator would press “SELECTION MODE ON” and carry out the following procedure.

Step 1 Press F1 “INSERT LINE”

This will highlight the F1 function frame in bright yellow

Step 2 Press “INJECTION”

The main injection page will appear with the selectable page cursor at the top of the page. The
function frame will appear as shown below.

Step 3 Press F8 etc.--->

This step is required to access the required page. The injection function frames as
shown below will appear.

Step 4 Press F2 “BOOST - HOLD CUTOFF MODE”

Step 5 Press F8 “etc.---->”
This will return the selection function frame as shown below.

Step 6 Move the cursor down to the line required.

“SCREW POS. AT CUT-OFF C3u = 0.00in”

Step 7 Press F1 “SELECT LINE”

This will highlight the F1 function frame in bright yellow.

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NOTE!

To select multiple lines of text from a screen page at

once, move the cursor down to each line required and
press F1 - “SELECT LINE” at each line, before
proceeding with step 8.

Step 8 Move the selectable text page cursor down to “HYDRAULIC PRESSURE AT
CUTOFF PHu”

Step 9 Press F1 “SELECT LINE”

Step 10 Press F2 “SELECTABLE TEXT PAGE”
This will return the display to the selectable text page and install the selected lines
of text on that page.

Step 11 If the lines have been successfully entered, move the selectable text page cursor
down to an empty line and proceed to the next step.

Step 12 Press F1 “INSERT LINE”.

Step 13 Press “HOLD PRESSURE”

Step 14 Move the cursor down to the line required.

MIN = 0.00 MAX = 0.00 CPx = 0.00 in

Step 15 Press F1 “SELECT LINE”

This will highlight the F1 function frame in bright green.

Step 16 Press F2 “SELECTABLE TEXT PAGE”

This will return the display to the selectable text page and install the required line
of the text on that page.
If this exercise has been completed successfully, the “SELECTABLE TEXT PAGE”
should appear as shown below.
SCREW POS. AT CUTOFF C3u = 0.00 in
HYDR.PRESS. AT CUTOFF PHu = 0 psi
MIN = 0.00 MAX = 0.00 CPx = 0.00 in

Step 17 Press F5 “EXIT”

This will terminate the selectable text program.

236 5. SCREEN PAGES 10/10/02

 EC100 / CC100 - A03 OPERATOR:
12.3.1 SETTING ALPHA NUMERICAL CHARACTERS

In recognition of the fact that our customers may want to identify the mold parameters using
numbers, letters or even some symbols, ENGEL has programmed into the Control System, an
alphanumeric capability.

For example, the mold number on line number 1, on the mold parameter page, is 'ENGEL 1 !'

To practice using this function, follow the steps below.

Step 1 Press + F8 etc.-->

A7600377

A display similar to the one below will appear in the function frame display.

The data entry field directly above the left side of the display is where the chosen characters will
appear.

The top row of numbers indicate which numerical entry key must be pressed for the
corresponding symbol which appears directly below each number.

The function keypads F1 - F6 must be used to move the operational cursor to the frame containing
the desired symbol.

If function keypad 'F7' is pressed, the display will change from upper case to lower case letters.

If function keypad 'F8' is pressed, the mold parameter page functions will return to the display
area.

If a mistake is made entering the symbols, the last symbol entered can be removed by pressing
the 'CLEAR' keypad.

10/10/02 5. SCREEN PAGES 237

 EC100 / CC100 - A03 OPERATOR:
Step 2 -To enter ENGEL 1!, press:

1.....
F2 + 4 = E
2.....
F3 + 3 = N
3.....
F3 + 6 = G
4.....
4 + = E
5.....
F3 + 1 = L
6.....
F5 + 1 = SPACE

7.....
F1 + 1 = 1
8.....
F5 + 2 = !
9.....
ENTER
“ENGEL 1!” will be entered on to the mold parameter page where ever the cursor is placed.

238 5. SCREEN PAGES 10/10/02

 EC100 / CC100 - A03 OPERATOR:
12.4 PROCESS ANALYSIS

PRESS

A7600377

F1 MOLD PARAMETER
F2 CYCLE TIME ANALYSIS
F3 PRODUCTION FORECAST
F4 SELECTABLE TEXT PAGE
F5 PROCESS ANALYSIS
F6 EHV CARD
F8 etc.

10/10/02 5. SCREEN PAGES 239

 EC100 / CC100 - A03 OPERATOR:
12.5 EHV CARD

PRESS

A7600377

F1 MOLD PARAMETER
F2 CYCLE TIME ANALYSIS
F3 PRODUCTION FORECAST
F4 SELECTABLE TEXT PAGE
F5 PROCESS ANALYSIS
F6 EHV CARD
F8 etc.

The Bosch control parameters, Kp, Ki and Kd can be viewed on the “EHV card” screen page
along with the DIL switch positions for each pump fitted. The “EHV card” screen page can be
accessed via the Mold Parameters function key. This page is for viewing only and no changes
can be made here. Any changes to the control parameters or DIL switches must be made at the
Bosch card.
The control parameter and DIL switch settings of a newly installed card can be checked on this
screen page.
The control parameter are in the “Document chapter on the “machine specification page.
The DIL switch settings are in the “Electrical chapter” on the “Amp card - pump page.

240 5. SCREEN PAGES 10/10/02

 EC100 / CC100 - A03 OPERATOR:

13 QUICK SET UP

PRESS

The cursor can be moved to any of the settings and a new value entered via the data entry field.

As each setting is highlighted with the cursor, the description of that setting will be displayed on
the lower left corner of the screen.

The flags under the main functions of the machine, light when that function is active.

10/10/02 5. SCREEN PAGES 241

 EC100 / CC100 - A03 OPERATOR:
SETTING MODES

The Quick set up feature has two modes, “Normal” and “Parameter new setting”.

Normal Mode

Normal mode is used for correction of settings after the machine has been set up. This mode is
entered by default when the Quick Set Up key is pressed. These settings will be referred to in the
following table as “New Parameter Settings NO”, that is the new parameter settings mode has not
been selected.

Parameter New Setting Mode

NOTE!

When the parameter new setting mode is entered, any

settings optimizations already on the machine will be
overwritten.

At the lower right of the machine representation is the line “Parameter new setting” YES/NO.
Select this line with the cursor and enter a 1 for YES. The prompt ARE YOU SURE will appear,
answer YES to use the quick set up calculations. These settings will be referred to in the following
table as “New Parameter Settings YES”, that is the new parameter settings mode has been
selected.

EJECTOR
Ejector position, retracted - L and forward - L1
New Parameter Settings NO New Parameter Settings YES
Positions L and L1 are operator selected. The times: ZAV and ZA are set to zero.
Shake position (L2) and start of 2nd forward Positions L and L1 are operator selected, but
position (L3) are set the same as retract posi- the position L2 is placed half way between the
tion L. retract position L and the forward position L1.

Ejector pressure P
New Parameter Settings NO New Parameter Settings YES
The hydraulic pressure setting for ejector The value for ejector forward hydraulic pres-
forward entered at P appears as P25 on the sure P25 is imposed on ejector retract hydrau-
ejector page. lic pressure P26

242 5. SCREEN PAGES 10/10/02

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Ejector speed V

New Parameter Settings NO New Parameter Settings YES

The speed setting entered at V becomes the The speed setting entered at V becomes V25,
V25 and V27 setting on the ejector page. V26 and V27.

Ejector shake counter AZ

New Parameter Settings NO New Parameter Settings YES

No special calculations

Re-cycle time Z5

New Parameter Settings NO New Parameter Settings YES

No special calculations

CLAMP (opening)

First opening speed V6

New Parameter Settings NO New Parameter Settings YES

No special calculations

Second opening speed V7

New Parameter Settings NO New Parameter Settings YES

Adjusting V7, changes V8 proportionally Sets V8 equal to V7

Start second opening speed position W4

New Parameter Settings NO New Parameter Settings YES

If W4 is set equal to or less than W2, W2 Changing W4 sets W2 to equal A.

remains unchanged. If W4 is set greater than
W2, W2 is changed to equal W4.

Mold opening stroke position A

New Parameter Settings NO New Parameter Settings YES

Changing A, sets W2, W3 and A1 to the same Changing A, sets A1, W3 and W2 to the same
value as A and changes W4 proportionally. value as A.

10/10/02 5. SCREEN PAGES 243

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CLAMP (closing)

Clamping force SK

New Parameter Settings NO New Parameter Settings YES

Operator set G2 is changed as a function of clamping force.

From a table of ten possible G2 settings a
value is selected whose table index
corresponds to 1/10th of the percentage
clamping force. Position B is corrected as
necessary, so B is equal to or less than G2.

Start mold protection G1

New Parameter Settings NO New Parameter Settings YES

Operator set Position W1 is set equal to position G1

Closing speed V1

New Parameter Settings NO New Parameter Settings YES

Adjusting V1 changes V2 proportionally. Sets V2 equal to V1

Third closing speed V3

New Parameter Settings NO New Parameter Settings YES

No special calculations

Mold protection pressure P2

New Parameter Settings NO New Parameter Settings YES

Setting P2 changes P2a directly and P2b thru Setting P2 changes P2a thru P2e to be equal
P2e proportionally. to the P2 setting.

Mold protection time ZF

New Parameter Settings NO New Parameter Settings YES

No special calculations

HEATS
New Parameter Settings NO New Parameter Settings YES

No special calculations. The values shown are the actual temperatures.

244 5. SCREEN PAGES 10/10/02

 EC100 / CC100 - A03 OPERATOR:

INJECTION

Injection profile VS

New Parameter Settings NO New Parameter Settings YES

The injection profile values, V12 to V21 are All injection profile values, V12 to V21, are set
changed proportionally. The value VS to equal V.
corresponding to the highest value in the
series V12 to V21.

Injection boost pressure P6

New Parameter Settings NO New Parameter Settings YES

The hydraulic pressure P6 for injection is calculated.

Specific hold pressure PN

New Parameter Settings NO New Parameter Settings YES

The holding pressure profile values, P7 to P16 All holding pressure profile values, P7 to P16,
are changed proportionally. The value PN are set to equal PN.
corresponding to the highest value in the
series P7 to P16.

Stroke cut off point C3

New Parameter Settings NO New Parameter Settings YES

Stroke dependent switch over is enabled

All other switch-overs are disabled.

Injection time monitoring ZS

New Parameter Settings NO New Parameter Settings YES

ZS is set to equal the maximum injection ZS is set to equal the maximum injection mon-
monitoring time ZS1. The minimum injection itoring time ZS1. The minimum injection moni-
monitoring time ZS0 is adjusted to maintain a toring time ZS0, the intrusion time, ZIN, and
proportional difference to ZS1 intrusion speed, V23, are all set to zero.

Plasticizing screw stroke C1

New Parameter Settings NO New Parameter Settings YES

No special calculations

10/10/02 5. SCREEN PAGES 245

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Specific back pressure PS

New Parameter Settings NO New Parameter Settings YES

Adjusting PS changes the holding pressure The holding pressure profile values, P17 to
profile values, P17 to P21 proportionally. The P21 are set to be equal, and this value is dis-
value PS corresponding to the highest value in played as PS.
the series P17 to P21.

Screw speed V

New Parameter Settings NO New Parameter Settings YES

The screw speed values, DZV1 to DZV5 are Screw speed values in the series, DZV1 to
changed proportionally. The Quick set up DZV5, are set to be equal, and this value is
value V corresponding to the highest value in displayed as V.
the series DZV1 to DZV5.

Decompression before feed C2

New Parameter Settings NO New Parameter Settings YES

Operator set. Screw retraction speed V24 is set to 10%

Decompression after feed C4

New Parameter Settings NO New Parameter Settings YES

Operator set. Screw retraction speed V24 is set to 10%

Holding pressure time Z2

New Parameter Settings NO New Parameter Settings YES

No calculation

Cooling time Z4
New Parameter Settings NO New Parameter Settings YES

No calculation

Screw diameter SDM

New Parameter Settings NO New Parameter Settings YES

No calculation

246 5. SCREEN PAGES 10/10/02

 EC100 / CC100 - A03 OPERATOR:

CARRIAGE

Sprue break stroke K

New Parameter Settings NO New Parameter Settings YES

K = 0 = Sprue break OFF and position J is also As in the normal mode, but additional parame-
set to zero. ters are influenced:
V9 = 40%
K = >0, sprue break program 2 is switched ON
and position J is set to a value of 1/10 of K, J1 V10 = 10%
is also changed proportionally. V11 = 20%
P5a = 10%
Z6 = 0

Nozzle forward pressure P5

New Parameter Settings NO New Parameter Settings YES

Operator set. Nozzle pressure build up time Z5a is set to

0.2s.

Nozzle forward speed V9

New Parameter Settings NO New Parameter Settings YES

Adjustment of V9 changes the speed V10 The speed V10 is changed to a quarter of the
proportionally. value of V9.

Cycle time monitoring ZU

New Parameter Settings NO New Parameter Settings YES

By default the cycle monitoring is ON, entering a zero switches the cycle monitoring OFF.

The following is a list of the abbreviations used in the quick set function, with their description.

EJECTOR
P Ejector pressure
V Ejector speed
L Ejector position, retract
L1 Ejector position, forward
AZ Ejector, shake counter
Z5 Re-cycle time

10/10/02 5. SCREEN PAGES 247

 EC100 / CC100 - A03 OPERATOR:
CLAMP OPENING
V6 Clamp opening, 1st speed G2 to W4
V7 Clamp opening, 2nd speed W4 to W2
W4 Start 2nd mold opening speed
A Clamp open position
ZU Cycle monitoring time
ZUx Actual cycle time

CLAMP CLOSING
SK Clamping force
V1 Mold closing, 1st speed A to W3
V3 Mold closing, 3rd speed W1 to G2
G1 Start of mold protection
P2 Mold protection pressure (1st)
ZF Mold protection time, set value

CARRIAGE
K Sprue break stroke
P5 Nozzle forward pressure
V9 Nozzle forward speed

INJECTION
VS Injection speed
P6 Injection boost pressure
C3 Stroke cut-off point
PN Specific hold pressure
Z2 Injection hold time
Z4 Cooling time
ZS Injection time monitoring
SDM Screw diameter

FEEDING
C1 set screw feed stroke
V Screw speed
PS Specific back pressure
C2 Decompression after feed
C4 Decompression before speed

INJECTION UNIT
SZ Shot counter set value

248 5. SCREEN PAGES 10/10/02

 EC100 / CC100 - A03 OPERATOR:

14 SPRUE BREAK

PRESS

Refer to the line numbers on the following pages for the description of each variable

F1 NOZZLE

F3 GHOST SHIFT

10/10/02 5. SCREEN PAGES 249

 EC100 / CC100 - A03 OPERATOR:
1 .. . . A U TO . S P R U E B R E A K = 0 : N O

The operator has three choices regarding the sprue break function.
If the operator moves the cursor to this line and enters:
0 - NO
The sprue break function will be de-activated regardless of the other screen entries on this
page. See P5b pressure, line 8.

1 - after time Z6
The sprue break function will be initiated after time Z6. But on single pump machines the
following points must be taken into consideration.
• If “Screw break delay” (Z3), “Screw refill”, “Decompression” and “Sprue break delay”
(Z6) happen within the “Cooling time” (Z4), Sprue break will occur after the Z6 delay
time and before the mold opens.
• If “Screw break delay” (Z3), “Screw refill”, “Decompression” and “Sprue break delay”
take longer than the “Cooling time” (Z4), Sprue break will occur after the delay time (Z6)
and after the mold opens.
• If the combined delays and functions happen in a time close to, but less than the
“Cooling time”, the “Sprue break” will start and will be interrupted by the mold opening.
Once the mold has opened the sprue break will finish
• If the combined delays and functions take too long, Sprue break will not occur at all.

2 - bef. mold open.

The sprue break function will be initiated before the mold is allowed to open.
The mold will not open until:
• the screw has refilled.
• the screw has decompressed (suck back).
• the carriage has moved back to the K position (sprue break).
Note: Sometimes these actions may take longer than the required set cooling time. This
effectively increases your cooling time, which may be undesirable.

2 .. . . 1 .N O Z Z L E F O RWA R D S P E E D V9 = 20 %

This is the operator set percentage of maximum speed at which the nozzle will travel from
stroke position 'K' to stroke position 'J1'. This speed will only be employed when sprue break
is used and only after the first cycle. The first cycle and manual forward movements employ
speed SW35054.

3 .. . . 2 .N O Z Z L E F O RWA R D S P E E D V10 = 10 %

This is the operator set percentage of maximum speed at which the nozzle will travel from
stroke position 'J1' to stroke position 'J'. This speed should be set low to avoid "crashing"
the nozzle tip into the sprue bushing. Similar to V9, this speed will only be employed when
sprue break is used and only after the first cycle. The first cycle and manual forward
movements employ speed SW35054.

250 5. SCREEN PAGES 10/10/02

 EC100 / CC100 - A03 OPERATOR:
4 .. . . S TA R T 2 .N O Z Z L E S P E E D P O S . J1 = 0.20 in

This is a value that the operator sets and indicates the point, as the carriage unit moves
forward, where the "nozzle slow down" speed comes into effect.

5 .. . . N O Z Z L E C O N TA C T P O S I T IO N J

This is used to indicate when the nozzle is fully forward against the sprue bushing. When
this position is attained by the carriage unit, a rectangular box to the right of the letter 'J' will
light up. This position (i.e. box lighted) must be attained before injection will start.

6 .. . . N O Z Z L E C O N TA C T P R E S S U R E P5 = 80 %

This is a value that the operator sets and is the percentage pressure that is applied to the
carriage cylinder in order to force the nozzle against the sprue bushing during injection.

7 .. . . N O Z Z L E P R E S S . B U IL D U P T IM E Z5a = 0.20 s

When the nozzle moves forward and reaches position 'J', timer 'Z5a' will start timing. After
timer 'Z5a' times out, injection will start. This period of time allows the machine hydraulic
system time to build up nozzle forward pressure so that when injection starts the nozzle will
remain firmly pressed against the sprue bushing and will not be pushed back due to
injection pressures. This time will be present during each cycle so try to avoid setting Z5a
too long. This time is not in effect for the first cycle or in manual (see SW35029).

8 .. . . N O Z Z .F W D . P R E S S . A F T E R F E E D . P5b = 30 %

This reduced nozzle forward pressure function is standard on 30 to 100 Ton machines and
550 to 3500 Ton machines. It is optionally available on 150 to 450 Ton machines.

After the screw has been refilled and decompression has been completed, the operator can
choose to reduce the nozzle forward pressure before the mold opens. In this way nozzle
forward pressure, acting on the stationary platen half of the mold, can be reduced. Of
course, this can only function using sprue break option 0.

9 .. . . S P R U E B R E A K S T R O K E K = 0.80 in

This is a value that the operator sets and indicates the distance that the carriage unit will
move backwards for the sprue break function.

1 0 . . S P R U E B R E A K D E L AY T I M E Z6 = 0.0 s

This is a value that the operator sets and indicates the amount of delay after hold pressure
(i.e. Z2 timed out) before the carriage unit will move backwards for the sprue break function.

11 . . S P R U E B R E A K S P E E D V 11 = 30 %

This is the operator set percentage of maximum speed at which the carriage unit travels
backward. This speed will be in effect for manual, semi-automatic or automatic mode of
operation.

10/10/02 5. SCREEN PAGES 251

 EC100 / CC100 - A03 OPERATOR:
12.. ACTUAL NOZZLE POSITION SDx = 0.80 in

This is the actual value of the carriage unit position at any time during the cycle. Since it is
an actual value, the operator cannot move the cursor to this position and cannot change the
value that appears on this line.

13.. NOZZLE GUARD E9

The 'E9' refers to the purge guard that covers the nozzle and front portion of the barrel. If
the purge guard is in position, the rectangular box to the right of 'E9' will be lighted and the
injection and nozzle forward functions will be allowed to occur. If the rectangular box is not
lighted, the injection and nozzle forward functions will not be allowed to occur.

1 4 . . N O Z Z L E F U L LY R E T R A C T E D P O S I T I O N

When the carriage unit moves to the rear position, a light blue flag will light up beside
variable K1.

Position K1 actually represents the maximum stroke of the carriage minus SW35010
distance. This position has been added to the program, to avoid "crashing" the carriage into
the mechanical maximum stroke position while in the manual mode.

252 5. SCREEN PAGES 10/10/02

 EC100 / CC100 - A03 OPERATOR:
14.1 GHOST SHIFT

PRESS

Refer to the line numbers on the following pages for the description of each variable.

F1 NOZZLE

F3 GHOST SHIFT

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Ghost shift, when enabled, will only be invoked when:
• The current production run has finished.
• An error has occurred that prevents the machine from continuing the automatic cycle, but
will allow the machine to be cycled and operated safety in manual mode. All condition for
the machine to be cycled in manual mode must be met.
Errors or conditions that cause the pump motor to be switched off immediately will
obviously prevent the ghost shift from being executed.

1 .. . .. . .G H O S T S H IF T P R O G R A M S E L E C T I O N : 0
The operator has four choices regarding the ghost shift program.
If the operator moves the cursor to this line and enters:0
for PROGRAM SWITCHED OFF
• the ghost shift program will be de-activated.
If the operator moves the cursor to this line and enters: 1
for PULL NOZZLE BACK ONLY.
When the machine stops cycling in the automatic mode the ghost shift program will:
• pull the nozzle back to the fully retract position.
If the operator moves the cursor to this line and enters: 2
for PULL NOZZLE BACK AND PURGE BARREL.
When the machine stops cycling in the automatic mode the ghost shift program will:
• pull the nozzle back to the fully retract position
• purge material from the barrel by moving the screw forward.
If the operator moves the cursor to this line and enters 3
for PULL NOZZLE BACK - PURGE BARREL & EMPTY RUNNER USING SCREW SUCK
BACK.
When the machine stops cycling in the automatic mode the ghost shift program will:
• pull the nozzle back to the fully retract position
• purge material from the barrel by moving the screw forward.
• move the nozzle forward to meet with the sprue bushing
• clear out the runner system by sucking back with the screw
• pull the nozzle back to the fully retract position
• purge material from the barrel by moving the screw forward.
• the machine shuts down and the heats are reduced.

2 .. . .. . S H U T D O W N S E Q U E N C E T I M E L I M IT: 1 0 . 0 s
The operator may set a maximum time on this line for the completion of the ghost shift
shutdown sequence. If the set time limit is reached the ghost shift program will terminate
and the error message "GHOST SHIFT TIME" will appear.

254 5. SCREEN PAGES 10/10/02

 EC100 / CC100 - A03 OPERATOR:

15 BARREL HEAT & OIL TEMP.

O
F

PRESS

Refer to the line number on the following pages for the description of each variable

F1 BARREL HEAT & OIL TEMP

F2 AUXILIARY HEAT ZONES (8 - 15)
F3 AUXILIARY HEAT ZONES (16 - 23)
F4 HEAT P.I.D. ZONES 0 - 15 see Controller
F5 HEAT P.I.D. ZONES 16 - 23 Maintenance manual

NOTE!

Refer to screen line 8:

Bosch pumps must be run with the oil temperature set to 104o F (40 oC)
Rexroth pumps must be run with the oil temperature set to 120o F (45 oC)

10/10/02 5. SCREEN PAGES 255

 EC100 / CC100 - A03 OPERATOR:
1 .. . H E AT S O A K IN G
The marker located just to the right of the HEAT SOAKING text, on each heat page, will
flash off and on to indicate that the screw movement delay time is still running.
While this marker is flashing, no screw movement will be allowed and the error message
131-HEAT SOAK ACTIVE will be displayed. This function helps to guarantee a better heat
transfer along the length of the screw and barrel.
If any heat zones fall below the minus tolerance, the screw movement delay time will begin
as soon as the minus tolerance is reached once more.

This is the area where the operator would set and monitor the heat conditions for the
injection cylinder and other heat zones. Zones 1-6 allow the operator to identify each
specific heating zone. Generally, the nozzle section of the barrel is represented by number
1, with the barrel zones following sequentially.
SETV °F - In this column the operator would set the desired temperature for the
nozzle and barrel zones. If you are not using a zone, it must be set to 0
(OFF). Move the cursor to the set value position and press 'ENTER'.
ACT °F - The actual value temperature for each zone appears in this column.
The actual temperature is "read" by an iron-constantan thermocouple.
STATUS - T = The zone temperature is within tolerance.
H = The zone is in the heating phase
C = The zone is in the cooling phase
E = Zone error: Temperature too high
Thermocouple break
Heating defective
Short circuit on output

CAUTION!

Misuse of the MONITOR variable can lead to serious and

expensive screw or barrel damage.
MONITOR - If the operator turns off the MONITOR for any zone, that particular zone's
minus tolerance will not be monitored. Even though the minus tolerance
condition has not been met, the screw movement will still be allowed. If the
barrel is cold and screw movement is attempted, solidified plastic in the
barrel could damage the screw.

256 5. SCREEN PAGES 10/10/02

 EC100 / CC100 - A03 OPERATOR:
Turning the MONITOR off for the nozzle zone might be useful in situations where a tight
minus tolerance is required for a particular molding situation. Since the nozzle presses
against the sprue bushing during injection there can be a great deal of heat transfer from the
nozzle to the mold. Even though the temperature might fall lower than the minus tolerance,
screw movement will still be allowed. Since there are no moving parts in the nozzle area
generally, no damage would result.

Heat zone 6 can be used for Melt Temperature Monitoring or Mold Temperature monitoring.
In both cases, the zone performs a monitor function only and will operate effectively with the
set value set to 0.0 (i.e. off) and the monitor function turned 'OFF'. However, if your desire
is to also control the machine cycle or alarm activation states, then the set value must be
set to the correct melt temperature range and the monitor function turned 'ON'.

The relevant error message would then appear, "MELT/MOLD TEMPERATURE HIGH

3 .. . T E M P E R AT U R E TO L E R A N C E + 3 0 .0 o F - 3 0 .0 o F

The operator would set the maximum plus or minus tolerance allowed for zones 1-6 in this
area. If the actual value temperature falls above or below the set value by more than the
allowed plus or minus tolerance limit, the machine cycle will terminate. The relevant error
message would then appear, "SCREW TEMPERATURE HIGH" or "SCREW
TEMPERATURE LOW".
The MONITOR function has no effect on the plus tolerance. The MONITOR can be ON or
OFF, but if the plus tolerance is exceeded, the cycle will terminate. The MONITOR function
overrides only the minus tolerance setting. In other words, if the MONITOR function is
turned OFF, the minus tolerance will not be monitored. Be careful!

4 .. . S TA N D B Y T E M P. S E T P O I N T 250.0 oF
5 .. . M A N U A L S TA N D B Y T E M P E R AT U R E : OFF/ON

NOTE!

If you turn this program on, do not forget to turn it off again
when restarting the machine.

These lines refers to the level of temperature that each of these heat zones will be lowered
to if the machine goes into an alarm during an automatic or semi-automatic cycle. For
example, if the machine goes into an alarm condition that stops the machine cycle, zones 1
through 6 will reduce their temperature to 250 degrees Fahrenheit automatically. This
program is to guard against material degradation during periods when the machine is not
cycling but material is sitting in the barrel subjected to heat from the heater bands
The operator can manually turn on the heat lowering program on this line. To turn the
program on, move the cursor to the 'OFF' position, enter a '1' in the data entry field and
press the 'ENTER' key.

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This line displays the set value and actual value temperatures for the material feed throat.
If the actual temperature rises above the allowed plus tolerance, the machine will stop
cycling and go into an alarm.

7 .. . T E M P E R AT U R E TO L E R A N C E 50.0o F
This is where the operator would set the maximum allowed temperature plus tolerance.
There is no negative tolerance associated with this function.

Zone 0 is reserved for the oil temperature. The set value (on the left) is the oil temperature
that the machine will maintain during operation. The actual value of the oil temperature
appears to the right of the set value. This temperature reading is electrically transmitted to
the control system by a thermocouple located within the oil tank.
Initially, when the machine is switched on and the pump motor started the oil temperature is
below the set value. The controller will employ an oil preheating program to raise the oil
temperature. The oil preheating will stay on until the oil temperature reaches the set value.
If the control voltage is switched off for any reason and then switched on again, the oil
temperature will have dropped below the set value. When the pump motor is started, the oil
preheating program will be employed to bring the oil temperature to the set value.
Once the oil is at the set value and preheat is switched off, the oil is monitored for maximum
and minimum temperature limits only.
If the actual temperature rises above the set value, the controller will send a signal to the
water valve on the heat exchanger, opening a valve to allow water to flow through the heat
exchanger. The heat is transferred from the oil to the water, the flow of cooling water around
the heat exchanger continues until the actual oil temperature is reduced to the set value
temperature.
The flag to the right of the set and actual values will be active when the actual temperature
falls between the set minimum and maximum limits

9 .. . M I N I M U M T E M P E R AT U R E L I M I T 104.0 o F
"MIN TEMPERATURE" represents the minimum allowed oil temperature for cycling in the
automatic or semi-automatic mode. Below this temperature all hydraulic functions are still
possible in the manual mode. When the actual oil temperature is below the set minimum
temperature, the oil preheating program is employed. Oil is forced over a hydraulic cartridge
valve under pressure, in order to heat the oil up more quickly. The preheat program
switches off when the actual value temperature equals or exceeds the set minimum.

1 0 . . M A X IM U M T E M P E R AT U R E L IM IT 140.0 o F
"MAX TEMPERATURE" represents the maximum allowed oil temperature before the
machine automatically goes into an alarm condition. If the temperature reaches this level,
the machine will stop cycling but the electric motor will continue to run for two minutes. After
this programmed time delay the electric motor will shut down.

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15.1 AUXILIARY HEAT ZONES

O
F

PRESS

When this page is called up, the operator will have access to the zones that are designated for
auxiliary heat control. In effect, these variables behave in the same manner as those variables
that appear on the barrel heat page.

Refer to the line number on the following pages for the description of each variable

F1 BARREL HEAT & OIL TEMP

F2 AUXILIARY HEAT ZONES (8 - 15)
F3 AUXILIARY HEAT ZONES (16 - 23)
F4 HEAT P.I.D. ZONES 0 - 15 see Controller
F5 HEAT P.I.D. ZONES 16 - 23 Maintenance manual

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1 .. . . H E AT S O F T S TA R T OFF/ON a c t iv e :
fo r z o n e s : 8 - 15 li m it = 80 %

In order to protect heaters or a heat sensitive material, the heating capacity of the machine
can be reduced using the soft start feature.

The soft start feature can be turned on by entering a one on the line “heat soft start yes/no”.

The active flag will remain lit during soft start heating and until the zone or zones have
reached the percentage limit setting.

The operator can chose the zones for soft start heating, 9 to 23. To heat up one zone slowly,
enter that zone number twice.

The limit setting is for how far the zone is heated up before full power heating is applied. If
the set temperature limit is 440 oF and the limit is set to 80%, the soft start will heat the zone
or zones to 352 oF slowly under half power and then switch to full power until the zone
reaches 440 oF.

0% is equal to full power, the zone or zones are quickly heated up using full power, until they
reach the set temperature.

100% is equal to half power, the zone or zones are slowly heated up using half power until
they reach the set temperature.

Any percentage setting in between 100% and 0% will heat the zones to that percentage of
the set temperature. When the percentage set temperature has been reached the zone will
be heated up under full power until the zone reaches the set temperature.

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15.2 AUXILIARY HEAT ZONES

O
F

PRESS

When this page is called up, the operator will have access to the zones that are designated
for auxiliary heat control. In effect, these variables behave in the same manner as those
variables that appear on the barrel heat page. For a description of the function of the above
variables, refer to the section labelled BARREL HEAT & OIL TEMP.

F1 BARREL HEAT & OIL TEMP

F2 AUXILIARY HEAT ZONES (8 - 15)
F3 AUXILIARY HEAT ZONES (16 - 23)
F4 HEAT P.I.D. ZONES 0 - 15 see Controller
F5 HEAT P.I.D. ZONES 16 - 23 Maintenance manual

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16 MICROGRAPH PLUS

PRESS

16.1 MICROGRAPH PLUS FUNCTIONAL CHARACTERISTICS:

1. Allows up to seven actual values, including one ideal curve, to be plotted on a graphic
display. Each variable has a distinctive color for maximum clarity.

2. Has the facility to display the actual value parameters, such as:
• Screw Stroke
• Hydraulic Pressure
• Injection Speed
• Mold Cavity Pressure
for each Injection unit in any combination and in up to four curve groups.

3. The curve groups can be viewed more closely in two ways:

• With a zoom capability of once, twice or four times magnification.
• With three freely selectable viewing sections. The three sections can be set up to view
specific areas of the curves for each of the four curve selections.

4. A small graphic representation of the complete graph is shown with the zoomed area
referenced within a white dotted box.

5. The scale of the main graph can be altered to make maximum use of the dimensions of
the graph.

6. Ideal curves can be assigned from good production settings and subsequent curves can
be compared with the ideal for quality control or reject monitoring.

7. The actual values can be viewed on any part of the graph, using the sliding cursor.

8. All curve selections are recorded simultaneously.

9. Flow number measuring window and flow number display are available.

10. Parameters and set ups can be stored on floppy disk for each mold set up.

11. Switch over point is displayed.

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16.2 MICROGRAPH SET UP
16.2.1 QUICK SET UP

The operator now has the option for automatic set-up

F1 Auto Setup

If the machine is running in automatic and producing good parts, the control system temporarily
stores the parameters which are required for automatic adjustment.

When the operator presses the function key F1 “Auto setup” the following calculations are made
from the stored parameters.

The injection time is rounded off to produce the measurement time.

The measurement time delay is set to zero.

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The scales for:
Screw position
Hydraulic pressure
Injection speed
Mold cavity pressure

are derived from a table for the peak/actual values.

If not otherwise specified, the hydraulic pressure curve 1 (line 5) and the injection speed 3 (line 7)
are automatically selected. As an ideal curve the last hydraulic pressure curve is taken with a
tolerance of 10%.

The micrograph display consists of three separate channels: a, b, and c

Channel a: green curve
Channel b: blue curve
Channel c: red curve

Channels 'a' and 'b' can be assigned to represent:

0- screw position,
1- hydraulic pressure,
2- cavity pressure, or
3- injection speed.

The operator must decide which function will be placed in Channel 'a' and which function will be
placed in Channel 'b'. It is not necessary to choose both Channels 'a' and 'b', however only
Channel 'a' has the ability to select reject parts. Channel 'b' can only monitor.

If the operator chooses curves to be monitored, the chosen one for channel “a" is assumed to be
the one which is transferred for the ideal curve.

Channel 'c' represents an ideal curve which is used to compare with either channels 'a' or 'b'. After
an ideal injection process is set-up, the operator could choose to store curve a or curve b into
channel 'c' as an ideal comparison. The following injections would be compared to the ideal 'c'
curve.

The operator can choose which variables to monitor. The choice must be made between:
0 .... SCREW POSITION 4.70 in
1 .... HYDRAULIC PRESSURE 2900 psi
2 .... MOLD CAVITY PRESSURE 11600 psi
3 .... INJECTION SPEED 5.90 in/s

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Each of the four variables can be adjusted so that the resulting curve has a resolution which better
reflects the maximum deviation allowed. For example, even though maximum hydraulic pressure
is 2900 psi (variable 1 above), the operator could choose to have this variable set at 1450 psi to
represent 100% on the graph. Simply move the cursor to the data field '2900' and change the
value to 1450 psi.

The operator can also choose the time base for the recording period and if required the time that
the recording shall be delayed for at the start of injection.

Maximum / Minimum Deviation

The operator can decide the maximum and minimum deviation allowed. This can only be
determined by looking at and/or testing the molded parts to determine which are defective and
which are not.

It is also important to note that the scale of the curve must be taken into account since it will be
reflected in the maximum deviation allowed.

Ideal Curve

To select an ideal curve for quality or reject control, press F6 “Ideal” from the Quick set up function
key strip.

The function key strip shown below will be displayed.

Choose channel A (F2) or channel B (F3) to transfer into the ideal curve.

The curve chosen will be displayed, surrounded with a red tube (channel C). The tube represents
the tolerance zone and if the tolerance zone is exceeded, an error message DEVIATION will be
displayed. The part produced on this cycle will be deemed a reject.

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16.3 SETUP

To set up the monitoring of the Injection unit variables, press the function key F2 SETUP.

The function keys shown below will be displayed.i

The functions available are described in the following sub-paragraphs.

• Curve Selection.
• Section Function.
• Scale.
• Monitoring Window.
• Micrograph Parameters.

Pressing function key F8 EXIT returns to the previous function key strip.

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16.3.1 CURVE SELECTION

1 Press Function key F1 CURVE CHOICE.

The screen now displays two of the four curve selection boxes, the other two curve
selection boxes are off the screen to the right. The Cursor keys are used to scroll
between four selections.
In a desired selection move the highlight down to a colored line where a curve selection
is to be added or changed.
2 Press SET.
The highlight will also now appear in Injection Unit box 1.
If there are more than one injection unit, the other Injection Unit boxes can be selected
with the left and right cursor keys cursor keys.
Position the highlight on the required variable.
The name and function of that variable will appear in the bottom lefthand corner of the
screen page.
3 Press the function key F1 TAKE OVER.
That variable will appear in the highlighted area against the colored line selected.

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NOTE!

The same variable cannot be selected twice.

Pressing the function key F2 DELETE will erase any highlighted variable from any of the
colored lines. A new variable can now be entered against that colored line.
Pressing function key F8 EXIT will return the screen to the previous set of function keys.

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16.3.2 MICROGRAPH ANALYZER

Micrograph Analyzer can graph digital and analog signals along with the normal curve selections.
Any parameters, digital inputs, digital outputs and markers can be selected. If the customer
service password has been entered the default parameters available are displayed. When the
cursor is scrolled down to the next available curve choice and the SET function key is pressed the
cursor now appears in injection unit 1 box. When this cursor is moved to the default parameter
selection, the analyzer function frame is displayed. The choices are:
F3 - MF Numbers = Variable parameter
F4 - DI Numbers = Digital input number
F5 - DO Numbers = Digital output number
F6 - MK Numbers = Marker number
F7 - Default parameters = Resets the displayed parameter numbers to the default settings
P4502 - Mold closing speed
P4503 - Ejector speed
P15200 - Temperature zone 1
P15201 - Temperature zone 2
P15202 - Temperature zone 3
P15203 - Temperature zone 4
P15204 - Temperature zone 5
F8 - EXIT = Returns to the Quick Setup / Setup function frame.

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The default parameters can be chosen by pressing F1 TAKE OVER or, alternatively, the function
keys F3 through F7 can be selected.

If “MF Number” is selected, the blue data “entry box” is displayed and any parameter number, that
is valid to the machine being used, can be entered.

Any parameter can be selected, but the “actual value” parameters are more useful than the “set
value” parameters. An alphanumeric list of all the “actual value” parameter numbers is provided
in chapter 8 - Appendix of this manual.

Press the enter key to bring that parameter number to the “default parameter area” of the screen
and then press F1 TAKE OVER to select that parameter for a curve choice. Press F1 - SET to
accept that choice or F2 - DELETE to clear the choice.

The same actions are used when selecting digital inputs, digital outputs or markers. When the
input function is pressed and a number entered, where ever the cursor is placed in the “default
parameter area” that number will appear in place of the default number.

To change a specially selected variable back to the default, select that special variable with the
cursor and press F7 - DEFAULT PARAMETER.

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16.3.3 TRIGGER - START POINT FOR RECORDING.

NOTE!

If no trigger is selected the default, 0 - Standard, will be used.

Select F1 “Micrograph” + F8 etc. + F2 “Setup” + F5 “Micrograph Parameters” screen page to

access the trigger settings. Press F1 “Trigger” to select the required start point of the recording.
Any trigger point can be selected, enter the corresponding number into the blue “data entry” box
and press the “Enter” key. An asterisk will indicate the trigger chosen.
The trigger will default to the 0 setting, “Standard” the start of injection, once the control voltage
has been turned OFF and ON again.

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16.4 SECTION FUNCTION

Three sections of each of the four graphical displays can be viewed in more detail using the
SECTION FUNCTION.

To set up the three SECTIONS:

Press the function key F1 'Setup'
Press function key F2 'Section Function'.

Pressing SECTION FUNCTION displays the following keys:

Press F1 to edit 'section 1'

Press F2 to edit 'section 2'
Press F3 to edit 'section 3'

Pressing the 'Section Change' function keys will display the function keys for setting the margins
or boundaries of that section.

The small graphic display, to the right of the main display, will show a white dotted box and a
number to the right of the display.

The white dotted box is the section to be adjusted and the number displayed is the number of the
section.

Initially the left margin key is highlighted and the left margin can be moved to the desired position
using the cursor key. Pressing F2, F3 or F4 will highlight the other margin keys and those margins
can be adjusted using the cursor keys to create the required sectional view of the main graph.

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16.5 SCALE

X-AXIS

Y-AXIS

The Y axis is displayed as a percentage scale and is always divided into five equal parts, even
when a portion of the graph is viewed.

Pressing the function key F3 SCALE, will open the blue data entry field. The first parameters at
the top right of the display are highlighted. The parameters are selected using the up/down cursor
keys, they are highlighted in the color of the related curve.

Entering a new number for the upper limit of the Y axis of the parameter selected, will cause that
scale to change. It may be advantageous to bring the scale of the graph down to close to the
maximum value of the largest curve in order to display the largest image possible.

Note that when changing the scale of a particular parameter that the small graphical
representation will change its scale accordingly. Any monitoring sections set up must be checked
to ensure that they still cover the desired area of the graph.

The various scales are displayed using the function key F1 SHOW SCALE or hidden from view
with the function key F2 HIDE SCALE.

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16.6 MONITORING

The recording and display of actual values permits the comparison of curves or parts of curves
with a selected ideal curve. In this way the quality of manufactured parts can be monitored.

16.6.1 MONITORING WINDOW

The two monitoring windows can only be set if an ideal curve is selected when setting up the
CURVE SELECTION variables. If no ideal curve is selected the function key F4 MONITORING
WINDOW will not appear.

The monitoring windows can be freely set anywhere on the graph, as long as they do not overlap
(see the figure over the page).

The MONITORING WINDOWS are set from function key F4 MONITORING WINDOWS, which in
turn activates another set of function keys, namely window 1 or 2, left or right margin.

Pressing any of the margin adjustment keys, highlights that key in green. The margin is then
adjusted with the left or right cursor keys, which moves the bars under the graph.

These portion of the curves are the portions compared between ideal and current curves.

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C FLOWNR.INJ.UNIT 10.0 CUT-OFF INJ.UNIT 1 D

A....Large Graphic Display.

B....Partial Curve Monitoring Windows.

C....Flownumber.

D....Active Section.

E....Small Graphic.

F....Actual values, which are displayed when the function key 'Cursor Actual Values'.

G....Active Curve Selection.

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16.7 MICROGRAPH PARAMETERS

The Micrograph Parameter page is reached through the SETUP function. Once in setup, select
function key F5 MICROGRAPH PARAMETERS.

A...X Axis time base 0 to 255 seconds

B...X Axis time base delay, 0 to 99.9 seconds
C...Ideal curve selection 1
D...Ideal curve selection 2

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The time period of the actual value recording is set from 0 to 255 seconds.

The recording can be delayed from the start of injection for up to 99.9 seconds.

On this page the tolerances for the four possible ideal curves are set as a percentage deviation
from the ideal. The percentage value tolerance is chosen by the operator.
If 0% is entered then the deviation monitoring is inactivated.

A deviation is detected if the actual value in at least one monitoring window has not reached or
has exceeded the curve of the tolerance band.

If a deviation has been recognized, then the message DEVIATION, white letters on a red
background, is displayed at the bottom left-hand corner of the screen.

If the deviation message is displayed as yellow letters on a red background, then the start delay
or time bases are not identical, or the wrong curve is being compared with the ideal (i.e. psi versus
in/sec).

On the error page, an error message REJECTS GRAPHICS is displayed and the reject counter is
incremented by one.

The shot counter is also incremented by one, but the piece counter is not. When the maximum
value of the shot counter is reached the cycle stops.

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16.8 ACTIVATE SELECTION

The Curve Selections are set up to record the actual values from each injection unit. To display
each curve selection on the screen, that selection must be 'activated'.

Press the function key F3 ACTIVATE SELECTION.

The blue data entry box will appear.

Enter, from the numeric key pad either 1, 2, 3 or 4 for the required selection.

When the number is entered that curve selection will appear.

The small graphic in the bottom left-hand corner shows that complete graph and also a white
dotted box which is the area of the curve displayed on the large graphic.

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16.9 ACTIVATE SECTION

Three sections can be set up to view various parts of each of the four curve selection in greater
detail.

To activate one of the three sections, press function key F4 ACTIVATE SECTION.

The blue data entry box will appear.

Enter, from the numeric key pad either 1, 2 or 3 for the required section.

When that number is entered the large graphic changes to show that pre-selected area of the
curve, and the small graphic displays the number of the section.

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16.10 ACTUAL VALUES

The actual values of the variables can be monitored at any point on the graph.

When function key F5 'Cursor Act. Vas'. is pressed, a vertical white dotted cursor will appear on
the main graph. The line can be moved across the graph using the left and right cursor keys.

The actual values of all the selected variables can be seen on the display under the heading of
'ACTUALS :'.

Before this facility is activated, the actual values are only shown as asterisks.

Press the function key F8 'Etc.' to escape from the 'Cursor Actual Values' function.

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16.11 IDEAL

The Ideal function key will only be active if in the curve selection set up an ideal curve is selected.

Before selecting an ideal curve from the recorded curves, ensure that the desired curve selection
is displayed, see paragraph 4 'Activate Selection'.

When the desired curve selection is displayed, an ideal curve can be selected by pressing the
function key F6 IDEAL.

The recorded variables are listed on the top right-hand side of the display, use the cursor keys to
scroll the highlight down through the list. The highlight changes color to match the color of the line
representing that curve.

Press the function key F1 TRANSFER so that variable becomes the ideal curve.

A tube appears around the curve, in the color selected for the 'Ideal Curve' on the Curve Selection
page, defining the tolerance zone as set up on the Micrograph Parameters page (see the figure
over the page).

Pressing function keys F2 CHANNEL a TRANSFER or F3 CHANNEL b TRANSFER will transfer

channel a or b to become the ideal curve.

If the percentage values for deviation are changed, pressing F4 ADAPT SCALES will adapt the
new values to the existing scale. This is only required when a single ideal curve is used in several
selections. Otherwise, the scale adaptation occurs automatically when F1 TRANSFER is
pressed.

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16.12 PRINT

To print out a hard copy of the graph displayed.

1 Connect the printer to an 120 Volt a.c. electrical outlet and turn the printer on/off
switch to ON.

2 Connect the data cable between the RS-232 serial interface plug on the front of the
machine control panel and the serial interface connector on the printer.

3 Feed the paper into the printer.

4 Briefly press the ON LINE key on the printer to initialize the printing head.

5 On the machine control panel press the function key F6 'Print'.

Press the print key F7 to print out a hard copy of any graph.

If the hardcopy print key on the front faceplate is used, a function key 'Hardcopy Abort' will appear.
To escape from the print function press the hardcopy abort key.

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16.13 CURVE GROUPS

The Curve Groups function is activated from, the graph symbol key plus Etc. (F8) plus Etc. (F8)
plus Curve Groups (F1). Any previously recorded curves will appear on the screen.

Start

Press key F1 to start the “Curve Groups” recording. The recording will start with the next
shot and will display up to 40 curves and save them in memory. On recording the 41st
curve the oldest curve will be overwritten and erased from the screen. When the group of
curves recording is started, a message will be displayed, CURVE GROUPS START, under
the graphics. The recording will remain active, despite any screen changes, until F1 STOP
is pressed again.

Stop

When the “Curve Groups” recording has been selected by pressing F1 and the key
changed from START to STOP, the function key F1 must be pressed again to stop the
recording.

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Delete

To erase the group of curves from memory, press F2 and answer yes to the prompt
“Are you sure Yes/No”.

Delete Last Shot

To erase the group of curves for the last cycle, press F3.

Store on Disk

To store the Curve Groups on to diskette, insert disk into disk drive and press F4.

Ideal Curve

The current group of curves can be transferred into an ideal curve by pressing F5 followed
by F1. This ideal curve range is comprised of the area of the envelope produced by the
recorded curves, plus the tolerance tube around that envelope. The tolerance tube is
defined on the Micrograph Parameters page by the tolerance limits “Max. pos. dev” and
“Max. neg. dev.”

Exit

To leave the Curve Groups screen, F8. Unless STOP (F1) has been pressed the group of
curves will continue to be stored into memory.

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16.14 FLOW NUMBER

The Flownumber measuring start and stop points are displayed on the graph as two vertical blue
lines. The operator is able to see which part of the injection stroke curve is being used

In order to display the Flownumber measuring start and stop points on the Micrograph display, it
is necessary to set up those points on the Microplast/Microflow page or pages. The number of
Microplast/Microflow pages is dependent upon the number of fitted injection units.

The MICROPLAST program uses the FLOW NUMBER as a basis for accepting or rejecting the
part. This depends on the deviation between the REQUIRED FLOW NUMBER and the ACTUAL
FLOW NUMBER.

The MICROFLOW program uses the FLOW NUMBER as a basis for adjusting the hold pressure
profile and/or the boost cut-off point within the specific tolerance zone. This depends on the
deviation between the REQUIRED FLOW NUMBER and the ACTUAL FLOW NUMBER.

A REQUIRED FLOW NUMBER must be entered in order to start the program. This is any random
number to start with, but must changed to the number, which, on average, occurs most often as
the ACTUAL FLOW NUMBER.

The actual value of the FLOW NUMBER is displayed on the Micrograph page and represents the
injection energy required for a selected portion of the filling stroke. The number actually
represents the average load-induced hydraulic injection pressure, within the operator assigned
stroke measurement limits.

An increase in the FLOW NUMBER value indicates an increase in energy required for the
selected portion of the filling stroke. Normally, it can be interpreted as an increase in viscosity of
the material injected into the cavity.

A decrease in the FLOW NUMBER value indicates a decrease in energy required for the selected
portion of the filling stroke. Normally, it can be interpreted as a decrease in viscosity of the material
injected into the cavity.

The FLOW NUMBER TOLERANCE is used to set a plus/minus tolerance zone around the
REQUIRED FLOW NUMBER and is compared to the ACTUAL FLOW NUMBER. Any FLOW

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The MEASURING START position indicates the starting point of the FLOW NUMBER
measurement and is a stroke position after the start of injection. The measurement should begin
at some point after the screw has started the injection. This is in order to prevent any pressure
spikes or inconsistencies from adversely affecting the FLOW NUMBER calculation.

The MEASURING STOP position indicates the stopping point of the FLOW NUMBER
measurement and is a stroke position after the start of injection. The measurement should stop at
some point before the screw starts to slow down due to the effect of filling and packing the mold
cavity.

The MEASURING STOP position should be set so that there is at least 100 ms left before the
transfer from boost to hold pressure. This allows time for the controller to calculate the FLOW
NUMBER and to make adjustments to the hold pressure profile and/or the hydraulic cut-off point.

NOTE!

See page 287 for a description of “Microplast/Microflow”.

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The figure below the Micrograph Plus screen page has the start and stop positions for the flow
number measurement which will be shown as two blue vertical lines on the screen page.

The switchover point position is displayed as a broken vertical line on the screen page.

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 EC100 / CC100 - A03 OPERATOR:
16.15 FUNCTION KEY NAVIGATION CHART

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 EC100 / CC100 - A03 OPERATOR:

17 MICROPLAST/MICROFLOW

PRESS

NOTE!

The optional cushion correction program 'CP', on the Hold Pressure

page, must be set to 0.00 (i.e. OFF) in order to effectively employ
the MICROPLAST/MICROFLOW program.

Refer to the line numbers on the following pages for the description of each variable.

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The MICROPLAST program will use the FLOW NUMBER as a basis and, depending on the
deviation between the REQUIRED FLOW NUMBER and the ACTUAL FLOW NUMBER, the part
will be accepted or rejected.

The MICROFLOW program will use the FLOW NUMBER as a basis, and depending on the
deviation between the REQUIRED FLOW NUMBER and the ACTUAL FLOW NUMBER, an
adjustment of the hold pressure profile and/or the boost cut-off point can be effected within the
specific tolerance zone (line 14).

An increase in FLOW NUMBER indicates: - increase in material viscosity

- less filling and packing of the part(s)
- less part weight
- problem with critical parts dimensions

A decrease in FLOW NUMBER indicates:- - decrease in material viscosity

- overfilling and overpacking of the part(s)
- more part weight
- problem with critical parts dimensions

1.. REQUIRED FLOW NUMBER = 100.0

A REQUIRED FLOW NUMBER must be entered in order to start the program. This can be
any random number to start with, but you must change it to the number, which, on average,
keeps occurring as the ACTUAL FLOW NUMBER on line 2.

In other words, after you have set up a relatively stable process, and you are satisfied with
the part quality, the average actual flow number should be entered as the process
REQUIRED FLOW NUMBER.

2.. ACTUAL FLOW NUMBER = 102.0

The actual value of the FLOW NUMBER will be displayed on this line and represents the
injection energy required for a selected portion of the filling stroke.

The number actually represents the average load-induced hydraulic injection pressure,
within the operator assigned stroke measurement limits.

An increase in the FLOW NUMBER value indicates an increase in energy required for the
selected portion of the filling stroke. Normally, it can be interpreted as an increase in
viscosity of the material injected into the cavity.

A decrease in the FLOW NUMBER value indicates a decrease in energy required for the
selected portion of the filling stroke. Normally, it can be interpreted as a decrease in
viscosity of the material injected into the cavity.

This number is a measured actual value. The operator cannot select this datafield.

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3... FLOW NUMBER TOLERANCE+/- = 4.0

This datafield is used to set a plus/minus tolerance zone around the REQUIRED FLOW
NUMBER as compared to the ACTUAL FLOW NUMBER. Any FLOW NUMBER
measurement falling outside this tolerance zone will cause that part to be rejected.
The reject counter will be incremented by one and the reject output will be activated.
If the correction program is employed (see line 8), corrections will be made if the flow
number varies from the required value. Corrections are only made if the flow number is still
inside the tolerance zone.

4.. MEASUREMENT START = 1.50 in ■

This variable indicates the starting point of the FLOW NUMBER measurement and is a
stroke position after the start of injection. The measurement should begin at some point
after the screw has started the injection in order to prevent any pressure spikes or
inconsistencies from adversely affecting the FLOW NUMBER calculation.

5.. MEASUREMENT STOP = 0.50 in ■

This variable indicates the stopping point of the FLOW NUMBER measurement and is a
stroke position after the start of injection. The measurement should stop at some point
before the screw starts to slow down due to the effect of filling and packing the mold cavity.
Ideally, the measurement stop position should be set so that there is at least 100 ms left
before the transfer from boost to hold pressure. This allows the A02 enough time to actually
calculate the FLOW NUMBER and to make the adjustment to the hold pressure profile and/
or the hydraulic cut-off point. If this is not the case, the error "MPLAST MEAS. ERROR" will
be displayed.

6.. AUT. SETUP OF PARAMETERS OFF/ON ■

The automatic set-up of microplast parameters determines the “Required flownumber”,

“Tolerance zone”, and the measurement start/stop positions.
To use the auto set-up program, the machine must be running a stable process producing
good parts. To turn the program ON, position the cursor on this line, press 1 followed by
ENTER or press 0 and ENTER to turn the program OFF.
The program requires two cycles to determine the microplast parameters. The measuring
range is determined on the first cycle, and on the next cycle the flownumber is measured.
At the end of the cycle the measured flownumber becomes the “Required flownumber” with
a 10% “Tolerance zone”.

7.. MICROFLOW

The MICROFLOW section provides the corrective component of this program. If the
operator moves the cursor to the datafield labelled as "MODE >>" (line 8), any of the 4
program choices can be selected. The choice shown is mode 0 = NO CORRECTION. If the
operator chooses any of the other three choices, the listing 0-3 will "scroll" to that choice and
automatically re-arrange the order of the listing.

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8.. MODE OF CORR. 0

On this line the operator enters the “mode of correction” from the choices shown below:

9... 0 = NO CORRECTION

If the operator chooses this program, no hold pressure or cut-off pressure correction will be
attempted. Reject parts can still be selected using the FLOW NUMBER tolerance on line 3.

10. 1 = SWITCHOVER PR.+HOLD PR.

This program would be employed when hydraulic boost pressure is used as a means to
transfer from boost to hold pressure. Note that two separate corrections will be initiated. If
there is a calculated pressure correction (plus or minus), the correction will be applied to
adjust both the boost cut-off point and the hold pressure.

11. 2 = ONLY SWITCHOVER PRESSURE

This program would be employed when hydraulic boost pressure is used as a means to
transfer from boost to hold pressure. Only the boost pressure transfer point would be
adjusted; no adjustment would be attempted on the hold pressure profile.

If there is a calculated pressure correction (plus or minus), the correction will be applied to
adjust the boost cut-off point.

12.. 3 = HOLD PRESSURE ONLY

This program can be employed when using any of the five separated means of transferring
from boost to hold pressure. Only the hold pressure profile would be adjusted.

If there is a calculated pressure correction (plus or minus), the correction will be applied to
the hold pressure profile.

13.. CORRECTION (psi/digit) = 0.00

This datafield is for the entry of the amount of correction or adjustment, per digit of FLOW
NUMBER deviation, applied to the boost cut-off point and/or the hold pressure profile. The
correction factor units are psi/digit of FLOW NUMBER deviation.
CONTROL PRINCIPLE:
Actual FLOW NUMBER minus FLOW NUMBER set value = +/- (some deviation)
The result of this calculation is then multiplied with the value shown in item 11 and
represents the pressure correction in "psi". The formula for the correction is:
(line 2) minus (line 1) multiplied by (line 13) equals (line 14) or (line 15) psi
If Positive - Hold pressure profile and/or the boost cut-off point are increased by this
amount.
If Negative - Hold pressure profile and/or the boost cut-off point are decreased by this
amount.

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14..PLUS CORRECTION = 0.0 psi
Step 1: line (2) 102
line (1) -100
Deviation +2
Step 2. Deviation +2
line (13) x 20
Plus Correction 40.0 psi

15.. MINUS CORRECTION = 0.0 psi

The same principal as shown in item 14 applies. If it results in a minus correction, the
amount of correction will be displayed in this line.

16.. TOL.ZONE PRESSURE CORRECT.+/- = ± 0.0 psi

As long as the calculated pressure correction stays within this variable tolerance,
corrections to the hold pressure and/or boost injection pressure will be made.
If the calculated pressure correction plus or minus, exceeds the value of this variable, the
shot will be rejected and no hold pressure and/or boost injection pressure adjustment will be
attempted.
If the flownumber tolerance from line 3 is reached before this tolerance, then the part will be
rejected as described above.
The reject counter will be incremented by one and the reject output will be activated.

17.. HYDR. PRESSURE ACT.VAL. PHx = 1450.0 psi

This variable shows the operator the actual value of hydraulic pressure at any time during
injection boost or injection hold.

18..REJECTS FLOW NUMBER ■

The rectangular box to the right of this line will be lighted whenever the FLOW NUMBER
tolerance (line 3) has been exceeded, or whenever a calculated pressure correction (line 14
or 15) has exceeded its tolerance limits (line 16). This area remain blank as long as the
process is within the allowed tolerance windows.

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18 SPECIAL FUNCTIONS

PRESS

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 EC100 / CC100 - A03 OPERATOR:
18.1 CHARGE AMPLIFIER

PRESS

Refer to the line numbers on the following pages for the description of each variable.

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1... TRANSDUCER TYPE: PRESSURETRANSDUCER

The operator would move the cursor to this line to adjust the program according to the type
of cavity pressure transducer employed.

Move the cursor to this line and enter:

0 - PRESSURE TRANSDUCER

1 - FORCE TRANSDUCER

2.. FORCE TRANDUCER SENSITIVITY5.00 pC/N

If the force transducer is employed, the sensitivity can be set on this line. The sensitivity of
the force transducer lies in the range of 3.00 to 5.00 pC/N.

3... PIN DIAMETER 0.00 in

If the force transducer is employed, the pin diameter must be set on this line for the force to
pressure conversion calculation.

4... MEASURING RANGE 5000 pC

The measurement range of 5000 pC and 20000 pC is set for each transducer separately.
Switching of the charge amplifier to the measurement range 20000 pC is accomplished via
a digital signal supplied by the controller.

+24V on Digital Output S63 5000 pC

0V on Digital Output S63 20000 pC

5.. PRESSURE TRANDUCER SENS 9.00 pC/bar

If the pressure transducer is employed, the sensitivity can be set on this line. The sensitivity
of the pressure transducer lies in the range of 2.50 to 9.00 pC/bar.

6... MEASURING RANGE 20000 pC

The measurement range of 5000 pC and 20000 pC is set for each transducer separately.
Switching of the charge amplifier to the measurement range 20000 pC is accomplished via
a digital signal supplied by the controller.

+24V on Digital Output S63 5000 pC

0V on Digital Output S63 20000 pC

7... CAVITY PRESSURE ACT. VAL. PFx =0 psi

This is the actual value of the pressure in the mold cavity and can not be accessed by the
operator.

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CHARGE AMPLIFIER KISTLER 5039 A221

The model 5039A 221 from Kistler is a charge amplifier which converts the electrical charge
produced by the pressure transducer and outputs a measurement signal (mold cavity pressure)
in two voltage ranges to the controller. The ranges can be switched via the controller if required.

The Cavity Pressure Transducer is calibrated via the Input Calibration page under the Service
Menu screen pages.

If the measurement voltage does not lie within the range set on the “Input Calibration” page, the
error message 29 "CHARGE AMPLIFIER" will appear.

Resolution of the measuring signal:

DO 45 (S62) Digital output for reset or operate activation

DO 63 (S63) Digital output for measurement range change-over

AI 5 Q+ Analog input of pressure measurement signal

AI 5 Q-

Device supplies: 0 to +10 V

12-bit resolution of the control system: 0 to 4095 V

Range 5 000 pC: 10V corresponds to 5000 pC

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

Range 20 000 pC: 10V corresponds to 20000 pC

10V corresponds to 4095 bits
e.g.: sensitivity = 2.5 pC/bar:
so max. 20000/2.5 = 8 000 bar measurable
10V / 8000bar = 1.25mV / bar

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 EC100 / CC100 - A03 OPERATOR:
18.2 WEEKLY SCHEDULE

PRESS

Refer to the numbers on the following pages for the description of each subject area.

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1.... ******TIMER****** ON/OFF

In order to use the weekly scheduling program, you must first turn the program on.

Move the cursor to the ON/OFF datafield, press numerical key '1', then press 'ENTER'.

The day will automatically appear directly above. This will always be correct if the correct
year, month and day have been entered in the service menu area.

2.... SWITCH-OFF MANUAL YES/NO

When the weekly schedule program is active, the operator can choose to turn off devices,
the motor, or the heat, via this program.

The operator can also choose to override the time program and manually start the 'OFF'
sequence. The switching 'OFF' would still be subject to any programmed delays.

Move the cursor to the 'YES/NO' datafield, press numerical key '1', then press 'ENTER'.

This is the area where the operator would choose the exact day and time to turn the heats
and devices on or off. As a precaution, the current software program only allows the motor
to be turned off.

The lighted software marker just to the right of the 'DAY' column indicates the current day
based on the 'WEEKDAY' setting.

Move the cursor to the start or stop area for the day that you wish to program. Enter the
desired start or stop time based on military time and press 'ENTER'.

For example, 11:00 p.m. would be entered as 23:00.

THE CLOCK SWITCHES

DEVICES ON OFF
MOTOR NO NO
HEATING NO NO
DEVICE1 NO NO
DEVICE2 NO NO

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In order to use the clock to switch an apparatus on or off, you must set the above switches
accordingly. For example, if you want to switch the heat both on and off, you must change
both switches to 'YES'.

Move the cursor to the on or off switch area of the apparatus you wish to control. Enter '1'
for 'YES' or '0' for 'NO' and press 'ENTER'.

ON - DELAY OFF - DELAY

4... DEVICE ON SET ACT SET ACT
MOTOR 0.0 0.0 0.0 0.0 min
HEATING 0.0 0.0 0.0 0.0 min
DEVICE1 0.0 0.0 0.0 0.0 min
DEVICE2 0.0 0.0 0.0 0.0 min

In order to avoid starting or stopping all the apparatus at the same time, an 'ON - DELAY'
and 'OFF - DELAY' is provided.

The lighted software marker which would appear under the 'ON' designation, indicates
whether or not a particular apparatus has been activated by the switch clock. The heating
marker will remain lighted if a 'STANDBY TEMPERATURE SET POINT' has been chosen
on the heat page. It is important to note that if the 'HEAT STANDBY' program has been
activated, the operator must go to the heat page and turn 'OFF' the program 'MANUAL
STANDBY TEMPERATURE'. Otherwise, the heat will not increase again to the set value
temperatures. If you want the heats to turn off completely, the 'STANDBY TEMPERATURE
SET POINT' must be set to 32'F or 0'C.

Move the cursor to the 'ON' or 'OFF' Delay set value location of the apparatus you want to
control. Enter the delay times and press 'ENTER'.

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5... DEVICE1 OFF DEVICE2 OFF

This area is used as an ON/OFF switch for any devices that are controlled by the switch
clock. They must first be turned on to be controlled by the program. If these variables are
turned on, specific digital outputs will be activated. If the 'DELAYED MOTOR STOP' function
causes the motor to shut down, these two devices will be turned 'OFF' as well. The operator
must return to this switch clock page and turn the devices 'ON' once more.

Move the cursor to the 'OFF' position, press numerical key '1', then press 'ENTER'.

NOTE!

If the switch-off time is reached in mid-cycle, the current cycle

will be completed, but the next cycle will be prevented.
The switch-off program will start switching off the apparatus,
subject to any set delay times.

NOTE!

The time setting 00:00 (i.e. 24:00) will not cause a switch-on or
switch-off.

Digital Outputs: Motor - M1

Heating - HZA (if standby temperature 0)
Device1 - S46
Device2 - S47

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 EC100 / CC100 - A03 OPERATOR:
18.3 HOST COMPUTER

PRESS

Refer to the numbers on the following pages for the description of each subject area.

This is an example of the host computer interface page which is optionally available.
Please refer to the following pages for more information on the host computer function. For
a complete description of the wiring connections, group and channel numbers and the host
computer protocol, please refer to the maintenance manual.

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1.... ORDER NUMBER ANR=

This variable provides information on the order number related to this particular set-up.

2.... ITEM NUMBER SPN=

This variable provides information on molded parts that this particular set-up has produced
in the past. This name or number will also appear on the QDS program to help identify any
QDS printouts.

3.... MOLD NUMBER WKN=

This variable provides information on the mold that this set-up has used in the past.

4.... MATERIAL NUMBER MTN=

This variable provides information on the type of material that this set-up has used in the
past.

5.... DATA SET NUMBER = 00000000

The mold parameter data set coding actual and set value numbers appear on this line.

6.... ORDER TRANSMISSION NO

To start the data transmission, the operator must switch this function to 'YES'.
To start the data transmission, move the cursor to this line, press '1', then press 'ENTER'.
To stop the data transmission, move the cursor to this line, and press 'ENTER'.

This line shows data transmission information. The software markers beside each of the variables
will be lit, to indicate that:
1) the transmission has been started,
2) there is an error, or fault, in the transmission,
3) a status code has been entered,
4) the data transmission is complete.

8.... STANDSTILL INPUT

If the machine is taken out of production, the operator would enter a code number from this
listing. The computer can then track the reasons for non-production and periodically supply
a printout on machine performance.

9..... Code 07

When the machine is taken out of production, the operator would enter the code number
from the list above related to the reason for non-production. For example, this code number
means that the machine is out of production due to a lack of material.

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 EC100 / CC100 - A03 OPERATOR:
18.4 MOLD TEMERATURE CONTROLLER

PRESS

Refer to the line numbers on the following pages for the description of each variable.
Although SPI has set standards, for these device interfaces, variations in units of measurement
will occur. Also the inputs and outputs shown on the ENGEL screen pages are those required by
SPI. Additional information may be shown on a screen page if such is specified.

For any particular application it is recommended, that in addition to this manual, reference is made
to the Controller-Maintenance Manual and the device manufacturer's literature.

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1.... DEVICE CONTROL: ON/OFF

The operator must turn the device control program 'ON' before the ENGEL controller can
communicate with the device.

To turn the program on, move the cursor to the 'ON/OFF' position, press 1, then press
'ENTER'.

To turn the program off, move the cursor to the 'ON/OFF' position and press 'ENTER'.

2.... DEVICE ACTIVE

When the box on this line is illuminated it is an indication that the ENGEL controller is
communicating with the device.

Since communication with a device is intermittent this box will not be illuminated
continuously.

3.... TEMPERATURE SET POINT 0°F

This is the operator set value for the desired dryer temperature.

4.... HIGH TEMP TOLERANCE 0°F

This is the operator set value for the number of degrees by which the temperature set point
may be exceeded.

5.... LOW TEMP TOLERANCE 0°F

This is the operator set value for the maximum number of degrees permitted below
temperature set point.

6.... PROCESS DELIVERY TEMP. 0°F

This is the actual value of the temperature going to the mold.

7.... PROCESS ALARMS: 0

The number displayed on this line relates to an SPI defined process alarm. Some device
controllers will cause a value of one to appear here which means the device is processing.

When an alarm occurs then the corresponding box on these two lines is illuminated.

10... COMMUNICATION ALARM: 0

The number displayed on this line indicates an alarm, as defined in the section on SPI
device interfaces in the Controller Maintenance manual.

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 EC100 / CC100 - A03 OPERATOR:
18.5 DRYER CONTROLLER

PRESS

1.....
2.....

3.....
4.....
5.....
6.....

7.....
8.....
9.....
10....

Refer to the line numbers on the following pages for the description of each variable.

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 EC100 / CC100 - A03 OPERATOR:
1.... DEVICE ACTIVE:

When the box on this line is illuminated it is an indication that the ENGEL controller is
communicating with the device.
Since communication with a device is intermittent this box will not be illuminated
continuously.

2.... DEVICE CONTROL: ON/OFF

The operator must turn the device control program 'ON' before the ENGEL controller can
communicate with the device.
To turn the program on, move the cursor to the 'ON/OFF' position, press 1, then press
'ENTER'.
To turn the program off, move the cursor to the 'ON/OFF' position and press 'ENTER'.

3.... TEMPERATURE SET POINT0°F

This is the operator set value for the desired dryer temperature.

4.... HIGH TEMP TOLERANCE0°F

This is the operator set value for the number of degrees by which the temperature set point
may be exceeded.

5... LOW TEMP TOLERANCE 0°F

This is the operator set value for the maximum number of degrees permitted below
temperature set point.

6.... PROCESS DELIVERY TEMP0°F

This is the actual value of the temperature going to the dryer.

7.... PROCESS ALARMS: 0

The number displayed on this line relates to an SPI defined process alarm. Some device
controllers will cause a value of one to appear here which means the device is processing.

When an alarm occurs then the corresponding box on these two lines is illuminated.

10... COMMUNICATION ALARM: 0

The number displayed on this line indicates an alarm, as defined in the section on SPI
device interfaces in the Controller Maintenance manual.

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 EC100 / CC100 - A03 OPERATOR:
18.6 CHILLER CONTROLLER

PRESS

1.....
2.....

3.....
4.....
5.....
6.....

7.....
8.....
9.....
10...

Refer to the following pages for the description of each variable.

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 EC100 / CC100 - A03 OPERATOR:
1.... DEVICE ACTIVE:

When the box on this line is illuminated it is an indication that the ENGEL controller is
communicating with the device.

Since communication with a device is intermittent this box will not be illuminated
continuously.

2.... DEVICE CONTROL: ON/OFF

The operator must turn the device control program 'ON' before the ENGEL controller can
communicate with the device.

To turn the program on, move the cursor to the 'ON/OFF' position, press 1, then press
'ENTER'.

To turn the program off, move the cursor to the 'ON/OFF' position and press 'ENTER'.

3.... TEMPERATURE SET POINT 0°F

This is the operator set value for the desired dryer temperature.

4.... HIGH TEMP TOLERANCE 0°F

This is the operator set value for the number of degrees by which the temperature set point
may be exceeded.

5.... LOW TEMP TOLERANCE 0°F

This is the operator set value for the maximum number of degrees permitted below
temperature set point.

6.... PROCESS DELIVERY TEMP. 0°F

This is the actual value of the temperature going to the process.

7.... PROCESS ALARMS: 0

The number displayed on this line relates to an SPI defined process alarm. Some device
controllers will cause a value of one to appear here which means the device is processing.

When an alarm occurs then the corresponding box on these two lines is illuminated.

10.... COMMUNICATION ALARM: 0

The number displayed on this line indicates an alarm, as defined in the section on SPI
device interfaces in the Controller Maintenance manual.

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 EC100 / CC100 - A03 OPERATOR:
18.7 MULTIZONE TEMPERATURE CONTROLLER

PRESS

1.....
2.....
3.....

4....
5....
6....
7....
8....

Refer to the line numbers on the following pages for the description of each variable.

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 EC100 / CC100 - A03 OPERATOR:
1.... DEVICE ACTIVE:

When the box on this line is illuminated it is an indication that the ENGEL controller is
communicating with the device.

Since communication with a device is intermittent this box will not be illuminated
continuously.

2.... DEVICE CONTROL: ON/OFF

The operator must turn the device control program 'ON' before the ENGEL controller can
communicate with the device.

To turn the program on, move the cursor to the 'ON/OFF' position, press 1, then press
'ENTER'.

To turn the program off, move the cursor to the 'ON/OFF' position and press 'ENTER'.

3... ZONE SET ACT ZONE SET ACT ZONE SET ACT
o o o o o o
F F F F F F
1 0 0 11. 0 0 21. 0 0
2. 0 0 12. 0 0 22. 0 0
3. 0 0 13. 0 0 23. 0 0
4. 0 0 14. 0 0 24. 0 0
5. 0 0 15. 0 0 25. 0 0
6. 0 0 16. 0 0 26. 0 0
7. 0 0 17. 0 0 27. 0 0
8. 0 0 18. 0 0 28. 0 0
9. 0 0 19. 0 0 29. 0 0
10. 0 0 20. 0 0 30. 0 0

On these lines the operator can set up the required temperature of each hot runner. There
is the facility for up to 30 hot runners to be monitored. The set temperature can be seen and
the actual temperature can be monitored.

4.... NUMBER OF ZONES TO MONITOR 1

On this line the operator will set up the number of zones to be monitored.

5.... HIGH TEMPERATURE TOLERANCE 0

The operator can set the upper temperature tolerance on this line.

6.... LOW TEMPERATURE TOLERANCE 0

The operator can set the lower temperature tolerance on this line.

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 EC100 / CC100 - A03 OPERATOR:
7 .. . . P R O C E S S A L A R M S : 0 COMMUNIC. ALARM: 0

The number displayed on this line relates to an SPI defined process alarm. Some device
controllers will cause a value of one to appear here which means the device is processing.

The number displayed on this line indicates an alarm, as defined in the section on SPI
device interfaces in the Controller Maintenance manual.

When an alarm occurs this box is illuminated.

10/10/02 5. SCREEN PAGES 313

 EC100 / CC100 - A03 OPERATOR:
18.8 LOADER

PRESS

Refer to the line numbers on the following pages for the description of each variable.

314 5. SCREEN PAGES 10/10/02

 EC100 / CC100 - A03 OPERATOR:
1 .. . . D E V IC E A C T I V E :

When the box on this line is illuminated it is an indication that the ENGEL controller is
communicating with the device.

Since communication with a device is intermittent this box will not be illuminated
continuously.

2 .. . . D E V IC E C O N T R O L : O N /O F F

The operator must turn the device control program 'ON' before the ENGEL controller can
communicate with the device.

To turn the program on, move the cursor to the 'ON/OFF' position, press 1,and then press
'ENTER'.

To turn the program off, move the cursor to the 'ON/OFF' position and press 'ENTER'.

3 .. . . L O A D T IM E A S E T P O I N T 0 s e c

This is the operator set value for the amount of time to load from bin A.

4 .. . . L O A D T IM E B S E T P O I N T 0 s e c

This is the operator set value for the amount of time to load from bin B. If the loader is not a
proportioning type then "LOAD TIME B" is ignored.

5 .. . . P R O C E S S A L A R M S : 0

The number displayed on this line relates to an SPI defined process alarm. Some device
controllers will cause a value of one to appear here which means the device is processing.

When an alarm occurs then the corresponding box on these two lines is illuminated.

8 .. . . C O M M U N IC AT I O N A L A R M : 0

The number displayed on this line indicates an alarm, as defined in the section on SPI
device interfaces in the Controller Maintenance manual.

10/10/02 5. SCREEN PAGES 315

 EC100 / CC100 - A03 OPERATOR:
18.9 ADDITIVE FEEDER

PRESS

Refer to the line numbers on the following pages for the description of each variable.

316 5. SCREEN PAGES 10/10/02

 EC100 / CC100 - A03 OPERATOR:
1 .. . . D E V IC E A C T I V E :

When the box on this line is illuminated it is an indication that the ENGEL controller is
communicating with the device.

Since communication with a device is intermittent this box will not be illuminated
continuously.

2 .. . . D E V I C E C O N T R O L : ON/OFF

The operator must turn the device control program 'ON' before the ENGEL controller can
communicate with the device.

To turn the program on, move the cursor to the 'ON/OFF' position, press 1, then press
'ENTER'.

To turn the program off, move the cursor to the 'ON/OFF' position and press 'ENTER'.

3 .. . . A D D I T I V E F E E D R AT E . . .. 0 gpm

This line is set by the operator for the rate of additive feed in grams per minute.

4 .. . . A D D I T I V E F E E D / T IM E U N I T 0 gpm

This line is set by the operator for the amount of time that the feeder is active.

5 .. . . A D D I T I V E F E E D R AT E A D J . 0 gpm

6 .. . . M AT E R I A L U S A G E R AT E 0 gpm

This is the actual value of material usage. This line cannot be accessed.

7 .. . . P R O C E S S A L A R M S : 0

The number displayed on this line relates to an SPI defined process alarm. Some device
controllers will cause a value of one to appear here which means the device is processing.

When an alarm occurs then the corresponding box on these two lines is illuminated.

1 0 . . C O M M U N IC AT I O N A L A R M : 0

The number displayed on this line indicates an alarm, as defined in the section on SPI
device interfaces in the Controller Maintenance manual.

10/10/02 5. SCREEN PAGES 317

 EC100 / CC100 - A03 OPERATOR:
18.10 MELT PUMP CONTROLLER

PRESS

1....
2....

3....
4....
5....
6....

7....
8....
9....
10...
11...

12...
13...
14...
15...

Refer to the line numbers on the following pages for the description of each variable.

318 5. SCREEN PAGES 10/10/02

 EC100 / CC100 - A03 OPERATOR:
1.... DEVICE ACTIVE:

When the box on this line is illuminated it is an indication that the ENGEL controller is
communicating with the device.

Since communication with a device is intermittent this box will not be illuminated
continuously.

2.... DEVICE CONTROL: ON/OFF

The operator must turn the device control program 'ON' before the ENGEL controller can
communicate with the device.

To turn the program on, move the cursor to the 'ON/OFF' position, press 1, then press
'ENTER'.

To turn the program off, move the cursor to the 'ON/OFF' position and press 'ENTER'.

3.... SPEED SET POINT.... 0 rpm

This is the operator set value for the desired pump speed.

4.... HIGH SPEED TOLERANCE 0 rpm

This is the operator set value for the maximum by which the speed setpoint may be
exceeded.

5.... LOW SPEED TOLERANCE 0 rpm

This is the operator set value for the maximum rpm permitted below the speed setpoint.

6.... SPEED...................... 0 rpm

This is the operator set value for the desired pump speed.

7.... INLET PRESSURE SET POINT 0 psi

This is the operator set value for the desired inlet pressure.

8.... HIGH INLET PRESSURE TOLERANCE 0 psi

This is the operator set value for the maximum by which the inlet pressure may be
exceeded.

9.... LOW INLET PRESSURE TOLERANCE 0 psi

This is the operator set value for the maximum number of psi permitted below inlet pressure
setpoint.

10/10/02 5. SCREEN PAGES 319

 EC100 / CC100 - A03 OPERATOR:
10.... INLET PRESSURE....... 0 psi

This is the actual value of inlet pressure.

11.... OUTLET PRESSURE..... 0 psi

This is the actual value of outlet pressure.

12.... PROCESS ALARMS 0

The number displayed on this line relates to an SPI defined process alarm. Some device
controllers will cause a value of one to appear here which means the device is processing.

When an alarm occurs then the corresponding box on these two lines is illuminated.

15.... COMMUNICATION ALARM: 0

The number displayed on this line indicates an alarm, as defined in the section on SPI
device interfaces in the Controller Maintenance manual.

320 5. SCREEN PAGES 10/10/02

 EC100 / CC100 - A03 OPERATOR:
18.11 WEIGH SCALE PROGRAM

PRESS

The weigh scale program is implemented when critical part weight must be maintained. The scale
is an addition to part quality recognition and will determine if the part is acceptable or must be
rejected.

This program has been developed for weigh scales manufactured by Sartorious or Mettler.

Parameter 36812 is used to select the type of weigh scale used,

0 = Mettler or 1 = Sartorious

The part weight may be monitored via the Quality Data Statistic program and / or the
Process Data Reports program.

10/10/02 5. SCREEN PAGES 321

 EC100 / CC100 - A03 OPERATOR:
1 .. . . W E IG H S C A L E P R O G R A M OFF

This is where the "Weigh Scale" program is turned on or off by the operator.
If the program is off then it may be turned on by moving the cursor to this position and
pressing "1" and then "ENTER".
If the program is on then it may be turned off by moving the cursor to this position and
pressing "0" and then "ENTER".

2 .. . . M E A S U R I N G D E L AY T IM E ZMV 0.00 s

When the mold has reached A position or the conformation signal from the robot has been
received, the controller will determine if the scale is a zero. If any weight is detected, the
error message 238 (SCALE NOT A ZERO) will be displayed. If the scale is at zero, the
"Measuring time delay" will run. This time must be long enough for the part to removed from
the mold and be placed on the weigh scale. The flag, when lit, indicates that the delay time
is in effect.

3 .. . . W E IG H T M O N ITO R I N G T I M E ZMU 0.00 s

When the "Measuring delay time" has expired, the "Weight monitoring time" will run. The
flag, when lit, indicates that the monitoring time is in effect. If the "Weight threshold /
recognition" has not been reached within the "Weight monitoring time", the error message
239 (THRESH NOT REACHED) will be displayed.

4 .. . . S P E C IF I E D PA R T W E IG H T 0.00 oz

The target part weight is entered on this line. This information could be derived from either
running many good parts and finding an average weight, or calculating the weight from the
volume of the part

5 .. . . A C T U A L PA R T W E IG H T 0.00 oz

This is the actual part weight as measured by the scale. This is an actual value and cannot
be accessed or changed by the operator.

6 .. . . W E IG H T T H R E S H O L D / R E C O G N I T I O N 0.00 oz

This is an operator set weight that the scale must register during the "Weight monitoring
time" to recognize that a part has been placed on the scale. If "Weight threshold /
recognition" has not been reached within the "Weight monitoring time", the error message
239 (THRESH NOT REACHED) will be displayed.

7 .. . . P R E V IO U S C Y C L E W E I G H T 0.00 oz

This is the stored value of the last part weighed.

322 5. SCREEN PAGES 10/10/02

 EC100 / CC100 - A03 OPERATOR:
8 .. . . W E IG H T + TO L E R A N C E 0.00 oz

This is an upper weight tolerance set by the operator. If the part is too heavy and exceeds
the upper weight tolerance, the part will be rejected, the reject counter will increment by one,
and the error message 240 (WEIGHT PLUS TOL.) will be displayed.

9 .. . . W E IG H T - TO L E R A N C E 0.00 oz

This is an lower weight tolerance set by the operator. If the part is too light and exceeds the
lower weight tolerance, the part will be rejected, the reject counter will increment by one,
and the error message 241 (WEIGHT MINUS TOL.) will be displayed.

1 0 . .. W E IG H T S C A L E R E J E C T / S TAT U S

This flag will light to indicate a reject part.

11 . .. M A X IM U M C O N S E C U T I V E R E J E C T S : 0 0 CYC

The operator can set the number of rejects acceptable in a predetermined number of cycles.
If this number is exceeded the machine will stop cycling and the error message 243
(MAXI.REJECTS SCALE) will be displayed.

1 2 . .. W E IG H I N G S TA R T S B Y: 0 MOLD REACHING A

The weighing function can be initiated by one of two methods:

0 = MOLD REACHING A

1 = ROBOT SIGNAL

AUTOMATIC OPERATION

Depending on which trigger selection is chosen, the scale monitoring program will wait until the
mold has reached the “A” position or the confirmation signal from the robot.

At this point, control will determine if the scale is zeroed. If weight is acknowledged, the error
message "SCALE NOT AT ZERO" will be displayed.

The measuring delay time will begin and time out. Immediately succeeding will be the weight
monitor timer. If the weight threshold / recognition value has not been reached within the monitor
time, the error message "THRESH.NOT REACHED" will be displayed.

If the part is light or too heavy and out of tolerance specs, respective error messages will be
displayed.

All rejects will be acknowledged. If consecutive rejects are produced, the machine will stop cycling
and display the error message "MAXI.REJECTS SCALE".

10/10/02 5. SCREEN PAGES 323

 EC100 / CC100 - A03 OPERATOR:
18.12 HYDRAULIC ACCUMULATOR PROGRAM

PRESS

Accumulators can store hydraulic energy during times of low demand and supply the volume
necessary to increase the actuation speed for injection, cores and ejector.

There are two types of charging circuits available.

1. Non-independent charging.
This type uses the same Y and K proportional valves and pump that provide other
machine functions.
Charging of the accumulator(s) usually takes place during injection hold, cooling or before
injection (injection will begin when the accumulator has reached P43 maximum pressure.
The accumulator(s) are not allowed to charge during machine preheating, or when a
manual machine function is demanded. When a manual function is demanded the
accumulator stops charging, and a delay time runs before the movement is permitted.
In automatic mode the charging will stop when cores or ejector functions are demanded or
with double EHV pumps, charging will stop during carriage or screw movement.

2. Independent charging circuit.

This type has a dedicated pump to supply the hydraulic demands required to charge the
accumulator.
The accumulator charging will not interrupt the machine cycle.

324 5. SCREEN PAGES 10/10/02

 EC100 / CC100 - A03 OPERATOR:
1 .. . . A C C U M U L ATO R P R O G R A M : 0

The accumulator program selection choices may be limited by parameter 36917, the
machine may only have choices 0 and 1.
When a selection has been made a flashing message across the center of the screen will
be displayed, refer to line 6 for a description.
0 = Accumulator program is disabled.
1 = Is active for injection.
2 = Is active for ejector and cores.
3 = Is active for injection, ejector and cores.

When the program 1 or 3 is selected, the injection speed calibration with accumulator may
be activated. During speed calibration, the control will always confirm that maximum P43
pressure is attained before initiating measurement. An accumulator speed calibration is not
possible if the program is set to 0 or 2. If attempted, the calibration program will stop and the
error message 247 HYDR.ACCU.DISABLED will be displayed.

When using the accumulator for injection, independent velocity control parameters are
available and can be adjusted on the P & V Control parameter page.

The closed loop injection will always automatically enable. The increased injection pressure
switch will also automatically default to YES.
When the accumulator selection is set equal to 2 or greater, the digital output (SPT) isolation
valve for cores and ejector will automatically enable.

2 .. . . M I N I M U M P R E S S U R E P42 = 0 ps i

The minimum pressure for the accumulator is operator set. The value must be chosen to
suit the application. The range of settings for minimum pressure is from zero to the value on
P43 maximum pressure line.

3 .. . . M A X IM U M P R E S S U R E P43 = 0 ps i

The maximum pressure for the accumulator is operator set. The value must be chosen to
suit the application. The lowest value for the maximum pressure setting is related to P6
(Injection pressure) plus a "headroom" value of approximately 145 to 290 psi (10 to 20 bar).
The range of settings for P43 will be from P6 plus the headroom up to maximum system
pressure

4 .. . . A C T U A L P R E S S U R E PHX2 = 0 ps i

This is an actual value and therefore cannot be selected or changed by the operator. This
displays the actual value of the pressure in the accumulator.

5 .. . . D R A IN C L O S E D F I L L IN G A C T I V E

These flags, when illuminated, indicate that the function is active, i.e.the "Drain is closed" or
the accumulator "Filling is active".

10/10/02 5. SCREEN PAGES 325

 EC100 / CC100 - A03 OPERATOR:
6 .. . . C H E C K P O S IT I O N O F M A N U A L IS O L AT IO N VA LV E

After an accumulator selection has been entered or when reading in a mold parameter disk
that changes the accumulator selection, this line will flash across the center of the screen.
The black and yellow text field directs the operator to "check position of manual isolation
valve". The operator should ensure that the accumulator is ON or OFF according to the
application required. The message will remain flashing until the valve has been checked
and the operator selects another screen page.

7 .. . . A C C U . C H A R G E S E T T I N G S : SPEED: 80 %
PRESS.: 75 %

If the accumulator charging circuit is of the "non-independent" type and a customer password is
entered, these lines will be displayed. Speed and pressure can be set to regulate the K and Y
proportional valves for charging.

326 5. SCREEN PAGES 10/10/02

 EC100 / CC100 - A03 OPERATOR:
18.13 INSTANT TEXT CHANGE

PRESS

To change all the screen pages into the required language, press:
F1 ENGLISH
F2 SPANISH
F3 FRENCH
F4 GERMAN
Wait for five seconds and all the screen page will be displayed in the selected language.
The screen page shows the language change screen as if all four language options were
purchased.

NOTE!

Only the purchased options will be available.

10/10/02 5. SCREEN PAGES 327

 EC100 / CC100 - A03 OPERATOR:

328 5. SCREEN PAGES 10/10/02

 EC100 / CC100 - A03 OPERATOR:

6. ERRORS AND MESSAGES

Sequence errors and messages are displayed in text in two locations.

1. All pages, except the 'Test and Parameters' area of the main menu, have the sequence
error message field at the bottom right-hand side of the page. In this area, the first error or
message which appears on the actual error page is listed. To the right of the error or
message that appears, will be a number indicating the total number of occurred errors or
messages.

2. The operator can elect to view all the errors or messages by selecting the key ! .
On this page the errors or message will appear in chronological order according to their
occurrence.

1 ERROR OR MESSAGE ACKNOWLEDGMENT AND RESET

There are two methods of eliminating errors or messages from the screen in order to reset the
controls for a cycle re-start.

The operator can individually check through the list of messages by using the error
acknowledgment key. With each press of this key, the first error or message is scanned to see if
it still exists. If it does still exist, the error message will re-appear at the bottom of the list and the
second error or message will move up to the first position for examination. Now, if the operator has
taken steps to remove the error or message condition, by pressing the error acknowledgment key,
the error or message will be eliminated from the screen.

The operator can scan all the errors or messages simultaneously by switching the manual/
automatic switch from automatic to manual and back.

Most errors or messages that appear on the error page will remain listed even when the error
condition has been removed. The operator must physically take steps to clear the messages with
either of the two procedures outlined above.

Some messages only appear during a particular cycle and will not remain listed on the error
message page. For example, messages can appear indicating that a reject part is being
produced. This is based on various tolerances set by the operator (e.g. cushion too large). This
type of message will not remain and appears as a message only.

NOTE!

In order to re-cycle the machine the controls should be

reset by switching the manual/automatic selector switch
from automatic to manual and back.

8/10/02 6. ERRORS AND MESSAGES 329

 EC100 / CC100 - A03 OPERATOR:

2 ERROR PAGE - SAMPLE

PRESS
!
ERROR LISTING 99-07-06 06:49

39 MOTOR STOPPED
55 FRONT GATE IS OPEN
107 CLAMP COVER OPEN
64 NOZZLE NOT ALIGNED
56 NOZZLE GUARD OPEN
40 OIL LEVEL LOW
41 OIL FILTER - F1
62 EMERGENCY STOP
37 LUBE OIL LEVEL LOW
84 GATE SWITCH FAULT

Refer to the following pages for a numerical listing of errors and procedures to reset.

The sample error listing above, could appear if the breaker for VE voltage tripped.

NOTE!

If your machine has special options or functions, please refer

to the software description of that special option or function
for any error messages that are not listed in the following
pages.
The software description can be found in section two of the
Machine manual.

330 6. ERRORS AND MESSAGES 8/10/02

 EC100 / CC100 - A03 OPERATOR:

3 ON SCREEN ERROR MESSAGE HELP TEXT.

The error message information found in this chapter, is also available on a built in memory card
or on a floppy help disk. To utilize either of these facilities, proceed with the following steps:

Press the ERROR PAGE symbol

! on the controller faceplate

The following display will appear:

MACHINE WAITING HARDWARE SYST. DATA VALUES OUT

ERROR POINTS CHECK REPORT OF RANGE

Press F1, to display the current machine errors.

Move the cursor to select the error number requiring further explanation.

Press the QUESTION MARK symbol on the controller faceplate

If a RAM card has been fitted, a text box will be displayed with the description of the machine
error. A symbol of the RAM chip will be displayed in the top righthand corner of the text box,
confirming that a RAM card has been fitted.

If the onboard “Help Memory” is not available, the message “Insert disk “ will be displayed.

Insert the Help Text disk into the floppy drive and press the “Question Mark’ symbol.

The message “please wait....” will be displayed, while the files on disk are accessed.

The text box will be displayed with the description of the machine error. A symbol of the Disk Drive
will be displayed in the top righthand corner of the text box, confirming that correct help disk has
been inserted.

The text displayed can also be found in the ‘ERROR LISTING’.

If the Help function is run with no disk inserted, the message “insert disk” will be displayed

If the “Help” program is run with the wrong diskette inserted, the error message
"Help - File not found" will be displayed.

Press the ESC (Escape) at any time to exit the help function.

8/10/02 6. ERRORS AND MESSAGES 331

 EC100 / CC100 - A03 OPERATOR:

4 ERROR LISTING
0 EBIAS-ERROR-STOP

A sequence system error has occurred.

Using the Ebias error number which occurs to the right of this error message.
Refer to the numerical listing of Ebias errors supplied on a floppy disk attached to the inside
front cover of the Controller Maintenance Manual that accompanies this manual.
Refer to chapter 6 section 3 of the Controller Maintenance manual for instructions of how to
install the “System and Ebias” error help file on to a computer.

Make a note of the Ebias error number. Use the search function within the “System and
Ebias” error help file for information on that error.

Reset: When you have corrected the problem, reset the Ebias error message by switching
off/on the control voltage.

1 (RESERVED)

2 CPU- BATTERY IS LOW

The CPU battery power is too low.

WARNING!

This card contains Electrostatic Sensitive Devices. Use safe

handling procedures when removing the card from the rack.

This message will appear whenever the back-up battery on the CPU card is in danger of
becoming defective.

Reset: Change the battery on the CPU card and read in the machine diskette. See the
instructions in the maintenance manual on "Loading the Ebias Software".

3 VALUE OUT OF RANGE

An operator programmed set value is out of the programmed range.

This message will appear if a value resulting from the read in of cassette or diskette
information is beyond normal machine parameters.

Reset: Check to see if the correct diskette was used. The value or values in question will
flash on the screen.

332 6. ERRORS AND MESSAGES 8/10/02

 EC100 / CC100 - A03 OPERATOR:
4 FLOPPY ERROR

During the writing of a data record on diskette a floppy error has occurred. (Disk drive not
connected, diskette full, diskette "write protected" etc.)

Reset: Reconnect disk drive or try a new diskette. Attempt to write to the diskette again.

5 PRINTER NOT READY

An instruction for printing out a screen page has been given, but there is a problem with the
printer. This error message will appear after a one minute time-delay.

Reset: Connect printer and / or control cable, or set up the printer. Press error
acknowledgment key. Press print-out key again.

6 HARDCOPY

The control system does not have enough memory to complete this task.

The hardcopy function will be interrupted.

Reset: Turn the mode selection switch off and on again to reset the message.

13 RC100-HANDLING

Collective error message for problems on RC100. The error messages produced by the
RC100 are listed on the handling system error message page. Go to the Handling system
error message menu, open error page and press + F4)

Reset: Depends upon the RC100 message(s).

14 AR161- ANALOG CARD

The main CPU cannot start the AR161 analog card(s) after switching on the machine. The
machine will not run.

Reset: Check the AR161 analog card for: hardware / bus problem, incorrect software
version, incorrect card coding or second AR161 is missing.

20 REJECT-MICROGRAPH

A reject has been identified based on the Micrograph curve tolerances.

This message will appear when the actual micrograph injection curve differs from the ideal
injection curve by more than the set tolerance allowed.

Reset: Determine the reason for the rejects if the problem persists. Check to see if the
material is contaminated.

8/10/02 6. ERRORS AND MESSAGES 333

 EC100 / CC100 - A03 OPERATOR:
21 REJECT-MICROPLAST

A reject has been identified based on the Microplast flownumber tolerances.

This message will appear when either of the 2 microplast/microflow tolerances are
exceeded. The rejects counter will increment by one and the digital output 'AA' (DO 11) will
be activated until the next cycle start.

Reset: Determine the reason for the rejects if the problem persists. Check to see if the
material is contaminated.

23 MOLD TRANSDUCER

The mold stroke or toggle stroke (on a toggle machine) transducer wiring is defective.

The mold/toggle stroke transducer signals are checked for a wire break. If the actual voltage
is less than or greater than the "signal stored at minimum/maximum", as defined on the
stroke calibration page, this message will be displayed and the mold function will be
prevented.

Reset: Determine if the wiring to the transducer is broken or loose. Check the mold/toggle
transducer for the correct signals and function. Check stroke calibration.

24 NOZZLE TRANSDUCER

The nozzle stroke transducer wiring is defective.

The nozzle stroke transducer signals are checked for a wire break. If the actual voltage is
less than or greater than the "signal stored at minimum/maximum", as defined on the stroke
calibration page, this message will be displayed and the nozzle function will be prevented.

Reset: Determine if the wiring to the transducer is broken or loose. Check the nozzle
transducer for the correct signals and function. Check stroke calibration.

25 EJECTOR TRANSDUCER

The ejector stroke transducer wiring is defective.

Before the mold is closed, the ejector stroke transducer signals are checked for a wire
break. If the actual voltage is less than or greater than the "signal stored at minimum /
maximum", as defined on the stroke calibration page, this message will be displayed and
the ejector function will be prevented.

Reset: Determine if the wiring to the transducer is broken or loose. Check the ejector
transducer for the correct signals and function. Check stroke calibration.

334 6. ERRORS AND MESSAGES 8/10/02

 EC100 / CC100 - A03 OPERATOR:
26 SCREW TRANSDUCER

The screw stroke transducer wiring is defective.

The screw stroke transducer signals are checked for a wire break. If the actual voltage is
less than or greater than the "signal stored at minimum/maximum", as defined on the stroke
calibration page, this message will be displayed and the screw function will be prevented.

Reset: Determine if the wiring to the transducer is broken or loose. Check the screw
transducer for the correct signals and function. Check stroke calibration.

27 MOLD HEIGHT TRANSD.

The mold height stroke transducer circuit is defective.

The machine mold height circuit must operate within a definite minimum and maximum limit.
This message indicates that the limit has been exceeded. This message also appears when
there has been an interruption to the control system.

Reset: Check the stroke transducer for the mold height, the actual voltage feedback and
the minimum and maximum limits.

28 CLAMPFORCE TOO LOW

The actual clamping force is lower than allowed for injection.

To prevent injection from occurring at a low clampforce, set value 35312 is set to guarantee
a minimum clamp tonnage before injection is allowed. This will help to prevent flashing of
the mold during start-up when the mold could be cooler and the tonnage lower.

In manual mode, open and close the mold until the machine is within the plus/minus
tolerance set value 35312 is set in tenths of tons.

29 CHARGE AMPLIFIER

The cavity pressure transducer charge amplifier may be defective.

During a test of the charge amplifier immediately after start-up, a measured voltage falls
outside of the set minimum and the set maximum tolerances. These parameters represent
bit values with 4095 equaling 10 volts. This will not impair the machine functions and will
only appear as a message.

Reset: Determine if the charge amplifier is defective. Monitor mold cavity pressure actual
value, 'PFx'.

8/10/02 6. ERRORS AND MESSAGES 335

 EC100 / CC100 - A03 OPERATOR:
30 INJ.TIME TOO LONG

The maximum injection time has been exceeded.

This will stop injection immediately, stop the cycle, increment the rejects total by one and
output the digital signal 'AA' (DO 11).

Reset: Determine why the injection "time window" has been exceeded. Perhaps there
has been a change in material due to mechanical failure (i.e. heater band, check
ring, etc.). Is the boost to hold pressure transfer operating correctly?

31 INJ.TIME TOO SHORT

The minimum injection time has not been reached.

The screw will refill, but the machine will stop cycling. The rejects counter will increment by
one and the digital output signal 'AA' (DO11) will be activated.

Reset: Determine why the injection "time window" has been exceeded. Perhaps there
has been a change in material due to mechanical failure (i.e. heater band, check
ring, etc.).

32 CUSHION TOO SMALL

The minimum cushion condition has not been met.

This does not stop the cycle, but initiates the reject signal 'AA' (DO11) and increments the
rejects total by one.

Reset: The digital output 'AA' (DO 11) is reset automatically at the next mold close. Check
cushion limits on the hold pressure page.

33 CUSHION TOO LARGE

The maximum cushion length has been exceeded.

This does not stop the cycle but initiates the reject signal 'AA' (DO 11) and increments the
rejects total by one.

Reset: The digital output 'AA' is reset automatically at the next mold close. Check cushion
limits on the hold pressure page.

336 6. ERRORS AND MESSAGES 8/10/02

 EC100 / CC100 - A03 OPERATOR:
34 MOLD PROTECTION

The mold protection function has been initiated.

This function measures the time of mold protection. Specifically, the time between mold
protection start, 'G1', and mold closed 'G2f'. If the actual mold protection time , 'ZFx'
exceeds the maximum time allowed, 'ZF', the mold will open up and the machine will stop
cycling. On toggle machines, refer to the "Clamp Force" page and set variable 'G2' - START
CLAMPING PRESSURE so that the ACTUAL TOGGLE POSITION 'SKx' can reach 'G2'.

Reset: Remove obstruction or determine other cause of mold protection alarm. Restart
machine.

35 CLOSING SYSTEM G6

High clamping pressure is not switched on.

If the clamp cylinder on a direct hydraulic machine extends to its mechanical limit, high
clamping pressure will not be switched on. This protects the clamp cylinder.

Reset: If this alarm comes up, the mold currently in the machine may be too small.

36 NO LUBE PRESSURE

The toggle lubrication system is defective.

The pressure switch input 'Z1' (DI 22) must become active during the toggle lubrication
function.

Reset: This alarm could indicate defective pressure switch, broken lube line, lubrication
motor not turning on, etc.

37 LUBE OIL LEVEL LOW

The toggle lubrication oil reservoir level is too low.

This alarm will stop all toggle movements. The oil level switch input 'Z2' (DI 23) must always
be active.

Reset: Fill reservoir or check the oil level switch.

8/10/02 6. ERRORS AND MESSAGES 337

 EC100 / CC100 - A03 OPERATOR:
38 CYCLE TIME EXPIRED

The maximum cycle time was exceeded. The maximum cycle time is either set on the “Mold
open” screen page as “Cycle time monitoring - max” or on the “Quick set up” screen page
as “Zu” in the Mold open column.

This runs in automatic and semi-automatic. For example, if the operator takes too long
removing the part and re-starting the next cycle, this alarm will be active. Not active when
the program is turned off on the “Mold open” screen page (Cycle time monitoring - NO.

Reset: Determine why cycle time is being exceeded and re-start machine. The first
automatic cycle is always longer than subsequent cycles due to the programmed
re-zeroing of the nozzle 'J' position. Check all machine timers.

39 MOTOR STOPPED

The motor has stopped or has not yet been switched on.

Digital input 'TD' (Digin 19) will be active (+24V) when the motor is running on the delta
windings.

Reset: Determine if motor is running on delta windings for 'TD' input.

40 OIL LEVEL LOW

The hydraulic oil level is too low.

This alarm will cause the motor to switch off immediately.

Reset: Fill tank to proper level. Digital input 'OEN' (DI20) must be active.

41 OIL FILTER - F1

The suction oil filter pressure switch reacted.

This alarm usually indicates that the filter is dirty and will switch the motor off immediately.

Reset: Check filter. Clean and/or replace if necessary. Digital input 'F1' (DI21) must be
active.

42 OIL TEMP.TOO LOW

The actual oil temperature is below the operator set minimum oil temperature. Although all
functions are possible in manual mode, semi-automatic and automatic modes are blocked.
During this time, the preheating program is in effect.

Reset: Wait for the temperature to rise to the set minimum or choose a lower set
minimum on the heat page.

338 6. ERRORS AND MESSAGES 8/10/02

 EC100 / CC100 - A03 OPERATOR:
43 OIL TEMP TOO HIGH

The actual oil temperature is above the operator set maximum oil temperature.

The machine will complete the current cycle and then stop in the mold open position. The
electric motor will continue to run for two minutes so that oil will continue to flow through the
heat exchanger for additional cooling.

Reset: Check heat exchanger operation, water supply, etc. Heating card, cooling output 0
activates 'SFTH' which opens up the water valve on the heat exchanger.

44 HYDR.CLOSNG.SAFETY

The hydraulic interlock safety E8 or E8.1 has reacted indicating an unsafe condition.

E8 (di 4) monitors the up/down position of the hydraulic interlock cartridge valve. If the
safety gate is open and the valve is not in the correct position (di 4 at 24 volts), the motor
will shut off and this error message will appear. In addition, E8.1 (di 29) monitors the position
of the hydraulic interlock lever. If the mold is closing and the lever is not in the correct
position (di 29 at 0 volts), the motor will shut off and this error message will appear.

Reset: Check the wiring and status of E8 (DI 4) and E8.1 (DI 29).

45 FEED TIME EXPIRED

The screw refill time, 'MAX', was exceeded.

The screw refill function has tried to refill the barrel, but has not been able to within the 'MAX'
time allowed. This usually indicates that the hopper is empty. This error message is not
active when the 'SCREW FEED TIME LIMIT MONITORING' program is switched to NO.

Reset: Check the hopper for plastic or check the feed throat for bridging.

46 FEED TIME SHORT

The screw refill time, 'MIN', was not reached.

If the actual screw refill is less than the "MIN' value, this message will appear. This can
occur when the machine has been running well but a mold cavity has been blocked. Under
this condition, it would take less time than normal to refill the barrel. This error message is
not active when the 'SCREW FEED TIME LIMIT MONITORING' program is switched to
'NO'.

Reset: Check the screw refill function regarding speed (RPM). Check the setting of the
'MIN' time. Monitor the screw refill function as well as the injection function.

8/10/02 6. ERRORS AND MESSAGES 339

 EC100 / CC100 - A03 OPERATOR:
47 CYCLE COUNT REACHED

The machine cycles equal the shot set value, 'SZ'.

The machine will count "good part" cycles until the actual machine cycles, 'SZx', equals the
set value cycles, 'SZ'. When the two are equal, the machine will stop.

Reset: Set the shot counter to a new value. If you do not wish to use this function, set
'SZ' to 9999999, or to zero.

48 PART COUNT REACHED

The set "Good Parts Required" count 'StZ' has been reached.

When the counter for "Good Parts Produced" 'StZx' equals the set value "Good Parts
Required" 'StZ' the machine will stop. The motor will turn off and the heats will lower
according to the heat standby program settings. This program is only in effect when the set
value parts counter is greater than zero.

Reset: Set the "Good Parts Required" to a new value. This counter may be accessed by
pressing Ejection page then pressing Production Data. Set 'StZ' to zero if you do
not wish to use this function.

49 TOO MANY REJECTS

The rejects counter has recorded the maximum number of rejects allowed.

Rejects will be counted if the cushion tolerances have been exceeded, if the injection time
tolerances have been exceeded, if the microplast flownumber tolerances have been
exceeded, if the micrograph tolerances have been exceeded, or if the mold close try again
program has been activated.

Reset: Clear out the rejects counter and determine why the rejects are being counted.
Check consecutive rejects counter.

50 EJECTOR NOT BACK

The ejector is not at position 'L'.

This message will appear if the ejector is not at position 'L' when the clamp begins to close.

Reset: In manual mode, move the ejector back until the rectangular box beside 'L' is lit.
Try not to use 0.0 as an ejector back position.

340 6. ERRORS AND MESSAGES 8/10/02

 EC100 / CC100 - A03 OPERATOR:
51 MOLD NOT SECURED

The mold is not properly secured.

This message will appear when any mold function is attempted when either, or both, mold
halves are not indicated as being secured. Digital input 'BWGB' (DI 30) must be active to
indicate that the moving half of the mold is secured. Digital input 'BWGF' (DI 31) must be
active to indicate that the stationary half of the mold is secured.

Reset: Check the activated state of digital input 30- 'BWGB' and digital input 31-
'BWGF'. Check all wiring and proximity switches.

52 NO MOLD CLOSE-SPI

The digital input for 'SPI' interlock is not active.

If the 'SPI' input is not at 24 VE, the mold close function will be blocked.

Reset: Determine why this input is not at 24 VE. It could be a broken 24 VE jumper.

53 BARREL TEMPER. LOW

At least one monitored temperature has fallen below the negative tolerance.

The injection and screw refill functions are blocked to protect the screw and barrel.

Reset: Determine if the heat zone is defective (i.e. triac, heater band, etc.). Check heat
zone tolerances.

54 MOLD NOT IN POSIT.

The mold is not at position 'A'.

This message is displayed, if machine cycling is attempted when the mold is not at 'A'.

Reset: In manual mode, move the mold back until the rectangular box beside 'A' is lit.

55 FRONT GATE IS OPEN

The front safety gate has been opened.

This message will appear whenever you open the front safety gate. When the safety gate
is open, the rectangular box beside 'E2' (DI 2) will be lit while the box beside 'E1' (DI 1) will
not be lit. When the gate is closed, the rectangular box beside 'E1' (DI 1) will be lit while the
box beside 'E2' (DI 2) will not be lit.

Reset: Close the front safety gate.

8/10/02 6. ERRORS AND MESSAGES 341

 EC100 / CC100 - A03 OPERATOR:
56 NOZZLE GUARD OPEN

The nozzle protection has been opened.

This message is displayed when the nozzle protection guard is open. The cycle will stop.

Reset: Digital input 'E9' (DI 5) must be active. The input switch could be defective or out
of adjustment. This input is in series with limit switches E9.1, E9.2 and E9.3.

57 EJECTION CONTROL

The part has not dropped out of the mold.

This program is designed to be used with a photo electric eye or weigh scale located
beneath the mold to detect a part falling through after ejection. The control will wait for the
signal before a new cycle will start.

Reset: Check mold for stuck part or check detection device. Check the ejection control
program on the ejector page.

58 CYCLE START READY

The machine is ready to start an automatic cycle.

This is a message only which appears when switching over from manual to automatic.

Reset: Press cycle start button.

59 GATE INTRUPT. CYCLE

The safety gate has been opened. This message will appear when the safety gate is
opened during an automatic or semi-automatic cycle. If the core/ejector keyswitch override
is active the gate can be opened after the end of hold pressure.

Reset: If the gate has not been opened, check limit switches 'E1' (DI 1) and 'E2' (DI 2).

60 FEEDING, NOT AT C1

The screw is not at position 'C1'.

This message will appear if a cycle start is initiated but the screw is not at position 'C1'
which would indicate that the screw has not completely refilled.

Reset: In manual mode, move the screw back until the rectangular box beside 'C1' is lit.

342 6. ERRORS AND MESSAGES 8/10/02

 EC100 / CC100 - A03 OPERATOR:
61 DECOMPR. NOT AT C2

The screw is not at position 'C2'.

This message will appear if a cycle start is initiated but the screw is not at position 'C2'. This
position must be achieved if decompression is used.

Reset: In manual mode, move the screw back until the rectangular box beside 'C2' is lit.

62 EMERGENCY STOP

An emergency stop condition has occurred on the machine.

This message appears when the emergency stop button is pressed.

On some machines, this message will appear due to a continuity break in the 'E3', 'E4' and
'E10' series of limit switches.

Reset: Release emergency stop button. Ensure that digital input 'NOT' (DI 0) is active.
See the electric drive diagram.

63 PROG.INTERRUPTION

The machine has been switched to manual mode of operation.

This message will appear every time the manual/automatic selector switch is turned to
manual mode. The manual/automatic selector switch is used to simultaneously clear all
non- current error messages and to reset the controls.

Reset: Switch manual/automatic key from automatic to manual and back to clear error
messages and to reset controls.

64 NOZZLE NOT ALIGNED

The injection unit is swiveled.

This message will appear when the injection unit is swiveled in order to remove the screw.
Injection and carriage functions are blocked.

Reset: Digital input 'E52' (DI 10) must be active. Check limit switch E52.

8/10/02 6. ERRORS AND MESSAGES 343

 EC100 / CC100 - A03 OPERATOR:
65 TEMP.TOO HIGH Z.xx

At least one monitored temperature zone has increased above the positive tolerance.

The "xx" in the error message indicates the effected zone.(E8 thermo card only)

Digital output 'HZA' is de-activated. The current cycle is completed and all of the heat zones
are turned off.

Reset: Determine if the heat zone is defective (i.e. shorted triac, wrong heat zone settings,
high friction heat, etc.).

66 HEAT IS AT STANDBY

All heats will reduce to the heat lowering set value.

This message appears when a machine alarm stops the running cycle. The heat zones
lower to a set value temperature designed to prevent material degradation due to long
exposure to heat as would be the case if the machine stopped in mid-cycle. This message
also appears if the heat standby program has been activated manually. If the program has
been activated manually it must also be de-activated manually.

Reset: Remove machine alarm, wait for heats to increase again to within the set tolerance
levels and re-cycle the machine.

67 THERMOCPL. BRK Z.xx

There is a break in the thermocouple circuit which reads the actual temperature.

The "xx" in the error message indicates the effected zone.(E8 thermo card only)

This message appears when an actual value temperature falls suddenly to ambient room
temperature indicating a break in the thermocouple. The current cycle would stop.

Reset: Replace thermocouple, wait for heats to increase again to within the set tolerance
levels and re-cycle the machine.

68 CUSHION CORRECTION

The cushion correction from one cycle to the next was larger than a set maximum (set value
35006, typically 25mm).

This message will appear if 'CP' is set larger than zero and if the cushion correction was
larger than 25 mm. The current cycle would stop.

Reset: This problem is usually associated with injection (i.e. sprue bushing blocked, mold
gate blocked, etc.). Clear problem and re-cycle the machine.

344 6. ERRORS AND MESSAGES 8/10/02

 EC100 / CC100 - A03 OPERATOR:
69 CALIBR.INTERRUPT

A pressure or speed calibration has been interrupted.

This message will appear during the calibration function if the stroke calibration has been
left on, or if something interrupts the cycle. For example, during calibration, if the purge
guard was raised, this message would appear and the calibration function would be
switched off.

Reset: Determine what stopped, or prevented, the calibration function and then initiate the
calibration function again.

70 HEAT DEFECTIVE

The heat zones have not increased in temperature as expected.

The "xx" in the error message indicates the effected zone.(E8 thermo card only)

This message will appear if at least one heat zone is not increasing in temperature within a
constant period of time. The digital output 'HZA' will be de-activated and all heat zones will
be switched off.

Reset: Determine if any heat zones are defective (open triac, defective heater band, etc.).
Make sure that no heat zone set values have been entered by mistake.

71 DELAYED MOTOR STOP

The motor will switch off in approximately two minutes.

This message will appear whenever a particular machine alarm condition is present and
the cycle is stopped. If the alarm condition is not cleared within two minutes, the motor will
switch off.

Reset: Determine and remove the machine alarm condition and re-cycle the machine.

72 WRONG MOLD HEIGHT

The actual mold position value, 'SFx' has reached a position less than zero, or for toggle
machines, the set and actual mold height positions are beyond the allowed tolerance.

On a direct hydraulic machine, the actual mold position value, "SFx" has reached a position
less than the calibrated zero position. If a mold height transducer is installed, as in a toggle
machine, the actual mold height is beyond the allowed tolerance when compared to the set
mold height position.

Reset: For direct hydraulic machines, turn on the 'Set-up' mode of operation and hold the
mold close selector switch until 'SFx' equals zero.
For toggle machines check and adjust the mold height position.

8/10/02 6. ERRORS AND MESSAGES 345

 EC100 / CC100 - A03 OPERATOR:
73 NOT IN SET-UP MODE

The set-up mode has not been activated.

The controller must be switched into set-up mode before the mold height adjustment
function will operate.

Reset: Switch into the set-up mode and continue adjusting the mold height.

74 CHECK CNTRL.PARAM

At least one heating control parameter is missing.

This message will appear if the heats are turned on and the P.I.D. heat control parameters
are not complete.

Reset: Check and/or set the heat control parameters.

75 MOLD HEIGHT MOTOR

The mold height motor is not turning.

This message appears if a mold height correction is being tried, but no revolutions of the
mold height motor are being recorded.

Reset: The problem could be a defective 'bIE' proximity switch or the mold height motor
breaker has been tripped.

76 CLAMPFRCE.TOO HIGH

A clamp force has been measured which is higher than the allowed limit.

This message will appear if a measured clamp force exceeds a set value maximum.

Reset: Determine if the clampforce transducer is defective before recycling the machine.
Check the actual value tonnage, set value tonnage and the tonnage tolerances.

77 CORE 1 PROGRAM ?

The core-pull program is not switched on.

This message will appear if the core in selector switch is activated and the program has not
been switched on. The core movement will be blocked.

Reset: On the core-pull page move the cursor to the 'OFF' position, enter '1' in the data
entry field and press 'ENTER'. Check the jumpers for 'E14' (DI 6) and 'E15' (DI 7)
if you are not using this program.

346 6. ERRORS AND MESSAGES 8/10/02

 EC100 / CC100 - A03 OPERATOR:
78 CORE SAFETY-SAW

The core-pull safety limit switch has not been activated.

This message will appear if the core-pull safety limit switch, which monitors whether or not
the ejector plate is back, has been activated. The digital input 'SAW' (DI 17) must be active
or the core-pull function will be blocked.

Reset: The digital input 'SAW' must be active. If not, check the 'SAW' limit switch.

79 NO MOVEM.SPEED CAL.

The speed calibration is defective.

This message will appear during the speed calibration if no movement is being detected at
the screw but maximum output signal is being sent to the Y-valve.

Reset: Check all wiring to and from the PA89 card and to and from the Y-valve. Determine
if the output signals are present.

80 QDS-XBAR LIMIT

The calculated control limits for the average 'X' have been exceeded.

One of the parameters being monitored using the quality data statistics program have
exceeded the calculated control limits.

Reset: Determine if there is a problem with the machine, material, or any other possible
cause. Keep in mind however, that it is statistically possible to exceed these limits
and still have the process in control.

81 HOST STOPPED CYCLE

The host computer has initiated a cycle termination.

The current cycle will be completed and the controller will switch to manual mode.

Reset: Determine the reason for the host computer activated cycle stop.

82 B- BEFORE -G2

The toggle locked signal 'B' was received before the end of mold protection signal 'G2'.

This message will appear if the signal indicating that the toggle is locked is received, or is
still active from the last cycle, before the toggle locked signal.

Reset: Check the operation of the mold stroke transducer. Check all transducer wiring.
Check the analog card for correct operation.

8/10/02 6. ERRORS AND MESSAGES 347

 EC100 / CC100 - A03 OPERATOR:
83 MPLAST RANGE ERROR

A flownumber measurement has fallen outside the tolerance zone.

The part will be rejected and the reject counter incremented by one.

Reset: Investigate what caused the flow number tolerance to be exceeded or increase
the flow number tolerance.

84 GATE SWITCH FAULT

Front safety gate limit switches are defective.

This message will appear when the safety gate is being opened or closed and the limit
switches 'E1' (DI 1) and 'E2' (DI 2) are not operating correctly. 'E1' active and 'E2' not
active indicates that the gate is closed. 'E1' not active and 'E2' active indicates that the gate
is open.

Reset: Check both limit switches, 'E1' and 'E2', for correct operation. These digital inputs
are displayed on the mold opening page.

85 A1 NOT REACHED

The mold is not at position 'A1'.

The ejector will not move forward until position 'A1', as set out on the ejector page, has
been reached.

Reset: Check the mold stroke transducer for correct function. Check the setting of 'A1' in
relation to 'A' on the ejector page.

86 CLAMP FORCE 0-POINT

The offset voltage from the clamp force stroke transducer is outside of its correct range.

This message will appear if the mold opens up to point 'A' and the offset voltage from the
clamp force transducer is outside of its correct range. Normally, the offset voltage, with
the mold at position 'A', is approximately 70 m Volts DC.

Reset: Re-adjust the clamp force stroke transducer. This error could indicate a
mechanical problem with the clampforce transducer rod (i.e. broken disc springs).

348 6. ERRORS AND MESSAGES 8/10/02

 EC100 / CC100 - A03 OPERATOR:
87 MPLAST MEAS.ERROR

The microplast flownumber measurement was interrupted by the switchover to holding

pressure.

This message will appear if the microplast flownumber is still being calculated when the
machine switches over to hold pressure. The flownumber calculation must end at least 0.1
seconds before the switchover to hold pressure. Also, stroke position C3 (also C3b or C3d)
must not be reached before the measurement stop position.

Reset: Check the setting of the "measurement stop position" on the microplast page. If it
is set too close to the end of injection boost, the above message will appear.
Check the stroke position setting C3 (also C3b or C3d).

88 PRESS. CORRECTION

The maximum hold pressure or back pressure correction tolerance was reached.

This message will appear if there was a hold pressure or back pressure correction up to this
maximum tolerance level. This is only a message and the machine continues to cycle.

Reset: Determine the correct setting.

89 QDS - STD.DEV.LIMIT

The calculated control limits for the standard deviation, 'S', have been exceeded.

One of the parameters being monitored using the quality data statistics program, have
exceeded the calculated control limits. The operator has the option of stopping the machine
cycling if the question, 'IF CTRL. LIMITS EXCEEDED - STOP CYC ?' is answered as YES.

Reset: Determine if there is a problem with the machine, material, or any other reason.

90 NO PRESSURE P-CAL

The pressure calibration is defective.

This message will appear during the pressure calibration if no pressure increase is
identified despite an increase in output voltage steps.

Reset: Check all wiring from the analog card to the PA89 card and from the PA89 card
to the K-valve. Check the K-valve to determine whether or not it is defective.

8/10/02 6. ERRORS AND MESSAGES 349

 EC100 / CC100 - A03 OPERATOR:
91 MOLD MOUNT ERROR

There is a problem with the mold mounting monitoring switches.

If the controller receives an indication that the mold halves are both secured and released
at the same time, the quick mold change function, or the machine cycle, will be ended.

Reset: Check the proximity switches indicating that the mold is secure, 'BWGB' (DI 30)
and 'BWGF' (DI 31) , and the proximity switches indicating that the mold is
released, 'BWEB' and 'BWEF'. Check all wiring related to the quick mold change
program.

93 NO TURNS, RPM-CAL

The screw rotation calibration is defective.

This message will appear during the screw rotation calibration if no rotation of the screw is
detected but maximum output signal is being sent to the Y-valve.

Reset: Check all wiring to and from the PA89 card and to and from the Y-valve. Determine
if the output signals are present. Check digital input 'DZx' on analog card.

94 QDS - SPEC. LIMIT

The specification limits for a monitored parameter have been exceeded.

The operator can choose to have the machine stop cycling if this condition occurs.
Specifically, by responding in the affirmative to the question 'IF SPEC. LIMITS EXCEEDED
- STOP CYC ?', the machine will stop cycling at the end of the current cycle. The operator
also has the option of rejecting an out of specification part if he responds in the affirmative
to the question 'IF SPEC. LIMITS EXCEEDED - REJ. PART ?'.

95 ROBOT NOT READY

A robot interlock has stopped the mold closing function.

This message is displayed if digital input 'HSP' is not active and mold closing is attempted.

Reset: Determine why digital input 'HSP' (DI 55) is not at 24VE.

350 6. ERRORS AND MESSAGES 8/10/02

 EC100 / CC100 - A03 OPERATOR:
97 OIL FILTER F2/F2.2

A pressure filter is defective.

A pressure switch on the pressure filter, or the servo valve filter if installed, has reacted
indicating a clogged filter. Pressure switches F2 and F2.2 are connected in series into digital
input port 'F2'. Digital input 'F2' (DI 13) must be at 24 VE to permit machine operation.

Reset: Change the pressure filter or the Moog valve filter. If the alarm persists, check the
interface diagram for wiring connections.

98 CORE 1 NOT IN

Core 1 has not been moved in.

This message will appear if the core-in limit switch 'E15' is not active when a clamp or
ejector movement is attempted.

Reset: Determine why digital input 'E15' (DI 7) , is inactive. Possible defective limit switch.

99 CORE 1 NOT OUT

Core 1 has not been moved out.

This message will appear if the core-out limit switch 'E14' (DI 6) is not active when a clamp
or ejector movement is attempted.

Reset: Determine why the digital input 'E14' is inactive. It could be a defective limit switch.

100 MOLDHGHT.END STOP

The minimum or maximum mold height position has been reached.

The minimum or maximum mold height position has reached 35014 (max) or 35013 (min).
This message will appear whenever the values have been reached.

Reset: Check the operation of the mold height transducer and it’s position feedback
voltage.

101 HEATING DISABLED

The controller program has turned off the heat.

This message will appear when the controller turns off the digital output 'HZA'. This output
is required to activate the contactor for all barrel heats.

Reset: Check all heating program tolerances and standby heat settings.

8/10/02 6. ERRORS AND MESSAGES 351

 EC100 / CC100 - A03 OPERATOR:
102 SCHEDULED SHUTDOWN

The weekly time switch has switched off a device.

This message will appear to indicate that the timer clock has switched off a motor, a
peripheral device, or the heats.

Reset: This message can be eliminated by switching the manual/automatic mode select
key. If the machine re-starts using the weekly time switch, this error message will
be erased.

103 CLAMP PROP. VALVE

The clamping unit proportional valve circuit is defective.

This message will appear when a particular defect is identified in the clamping unit
proportional valve circuit.

Reset: Digital input 'M1S' (DI56) must be active.

104 MTEMP WATER IN

The inlet water temperature is out of tolerance.

This message will appear whenever the inlet water temperature is outside of the minimum/
maximum deviation allowed as set out on the Microtemp page.

Reset: Correct the incoming water temperature problem. Check for correct thermocouple
operation. Check allowed deviation on microtemp page.

105 MTEMP COOLING

The cooling function cannot be controlled.

During a Microtemp calibration it was determined that cooling cannot be controlled using
this Microtemp calibration.

Reset: The microtemp program can only be employed using open loop adjustable cooling
times on the program page.

106 MTEMP. HEATING ERR

The heating function cannot be controlled.

During a microtemp calibration procedure (i.e. 10 cycles), a rise of at least two degrees
Celsius was not detected.

Reset: The microtemp program can only be employed using open loop adjustable heating
times (i.e. valve closed) on the program page. Otherwise, a separate temperature
controller is required.

352 6. ERRORS AND MESSAGES 8/10/02

 EC100 / CC100 - A03 OPERATOR:
107 INJECT. COVER OPEN

The front cover plate protection is open.

This message will appear when the front cover plate is opened or removed on the ES 30,
55 or 85 Ton.

Reset: Reset:Digital Input 'E52' (DI 10) must be active.

108 CLAMP COVER OPEN

The Plexiglas protection covers on the clamp unit are not closed.

The Plexiglas covers must be closed or all clamp movements will be stopped.

Reset: Digital input 'AS' (DI 11) must be active.

109 MICROTEMP VALVE 1

There is no flow, or not enough flow, in this microtemp cooling circuit.

Digital output 'S89' activates microtemp circuit 1. Digital input 'b95' monitors whether or not
flow exists in microtemp circuit 1.

Reset: Check digital output 'S89' and digital input 'b95'. Check all wiring.

110 MICROTEMP VALVE 2

There is no flow, or not enough flow, in this microtemp cooling circuit.

Digital output 'S88' activates microtemp circuit 2. Digital input 'b94' monitors whether or not
flow exists in microtemp circuit 2.

Reset: Check digital output 'S88' and digital input 'b94'. Check all wiring.

111 MICROTEMP VALVE 3

There is no flow, or not enough flow in this microtemp cooling circuit.

Digital output 'S87' activates microtemp circuit 3. Digital input 'b93' monitors whether or not
flow exists in microtemp circuit 3.

Reset: Check digital output 'S87' and digital input 'b93'. Check all wiring.

8/10/02 6. ERRORS AND MESSAGES 353

 EC100 / CC100 - A03 OPERATOR:
112 MICROTEMP VALVE 4

There is no flow, or not enough flow, in this microtemp cooling circuit.

Digital output 'S86' activates microtemp circuit 4. Digital input 'b92' monitors whether or not
flow exists in microtemp circuit 4.

Reset: Check digital output 'S86' and digital input 'b92'. Check all wiring.

113 MICROTEMP VALVE 5

There is no flow, or not enough flow, in this microtemp cooling circuit.

Digital output 'S85' activates microtemp circuit 5. Digital input 'b91' monitors whether or not
flow exists in microtemp circuit 5.

Reset: Check digital output 'S85' and digital input 'b91'. Check all wiring.

114 MICROTEMP VALVE 6

There is no flow, or not enough flow, in this microtemp cooling circuit.

Digital output 'S84' activates microtemp circuit 6. Digital input 'b90' monitors whether or not
flow exists in microtemp circuit 6.

Reset: Check digital output 'S84' and digital input 'b90'. Check all wiring.

115 MICROTEMP VALVE 7

There is no flow, or not enough flow, in this microtemp cooling circuit.

Digital output 'S83' activates microtemp circuit 7. Digital input 'b89' monitors whether or not
flow exists in microtemp circuit 7.

Reset: Check digital output 'S83' and digital input 'b89'. Check all wiring.

116 MICROTEMP VALVE 8

There is no flow, or not enough flow, in this microtemp cooling circuit.

Digital output 'S82' activates microtemp circuit 8. Digital input 'b88' monitors whether or not
flow exists in microtemp circuit 8.

Reset: Check digital output 'S82' and digital input 'b88'. Check all wiring.

354 6. ERRORS AND MESSAGES 8/10/02

 EC100 / CC100 - A03 OPERATOR:
117 OIL PREHEAT ERROR

The machine control has detected a defect in the oil temperature monitoring circuit.

This message will appear when the oil preheat program is active but no rise in oil
temperature is detected in a given period of time. The motor will be stopped to preventover
heating.

Reset: Check the oil temperature thermocouple.

119 CORE 2 NOT IN

Core 2 has not been moved in.

This message will appear if the core-in limit switch 'E17' (DI 9) is not active when a clamp
or ejector movement is attempted.

Reset: Determine why the digital input 'E17' is not active. Possible defective limit switch.

120 CORE 2 NOT OUT

Core 2 has not been moved out.

This message will appear if the core-out limit switch 'E16' (DI 8) is not active when a clamp
or ejector movement is attempted.

Reset: Determine why the digital input 'E16' is not active. Possible defective limit switch.

121 CORE 3 NOT IN

Core 3 has not been moved in.

This message will appear if the core-in limit switch 'E19' (DI 58) is not active when a clamp
or ejector movement is attempted.

Reset: Determine why the digital input 'E19' is not active. Possible defective limit switch.

122 CORE 3 NOT OUT

Core 3 has not been moved out.

This message will appear if the core-out limit switch 'E18' (DI 57) is not active when a clamp
or ejector movement is attempted.

Reset: Determine why the digital input 'E18' is not active. Possible defective limit switch.

8/10/02 6. ERRORS AND MESSAGES 355

 EC100 / CC100 - A03 OPERATOR:
123 CORE 2 PROGRAM ?

The core-pull program is not switched on.

This message will appear if the core in selector switch is activated and the program has not
been switched on. The core movement will be blocked.

Reset: On the core-pull page move the cursor to the 'OFF' position, enter '1' in the data
entry field and press 'ENTER'. Check the jumpers for 'E16' (DI 8) and 'E17' (DI 9)
if you are not using this program.

124 CORE 3 PROGRAM ?

The core-pull program is not switched on.

This message will appear if the core in selector switch is activated and the program has not
been switched on. The core movement will be blocked.

Reset: On the core-pull page move the cursor to the 'OFF' position, enter '1' in the data
entry field and press 'ENTER'. Check the jumpers for 'E18' (DI 57) and 'E19'
(DI 58) if you are not using this program.

125 MOLD TEMPERAT. LOW

The mold temperature actual value is too low.

This message will appear, and the machine will stop cycling, when the actual mold
temperature falls below the mold temperature lower limit. This condition will not be
monitored if the zone's monitor is turned OFF.

Reset: Check the heat page settings for the mold.

126 MOLD TEMPERA. HIGH

The mold temperature actual value is too high.

This message will appear, and the machine will stop cycling, when the actual mold
temperature rises above the mold temperature upper limit.

Reset: Check the heat page settings for the mold.

356 6. ERRORS AND MESSAGES 8/10/02

 EC100 / CC100 - A03 OPERATOR:
127 MOLD HEAT DEFECTV

The mold heat function is defective.

This message will appear when the heat does not increase, in a given period of time, as one
would normally expect. The controller is "looking" for the heat to increase, but does not
"see" it.

Reset: Is the heater switch turned on? Is a heat zone set value entered where no
equipment is installed ?

128 RECLOSE FRONT GATE

To start a new cycle, reclose the safety gate.

This appears as a message to inform the operator that a new cycle will start when he
recloses the front safety gate.

Reset: This message will be eliminated upon a new cycle start.

131 HEAT SOAK

The heat soak delay program is operating.

A specific period of time must expire before the screw will be allowed to move. This period
of time helps to ensure that heat is equally distributed throughout the screw and barrel
before screw movement is allowed.

Reset: Wait for the heat soak delay time to expire (typically 2 minutes) before attempting
screw movement. Refer to the heat page for a full description of this program.

132 BARREL HEATING IS OFF

The barrel heat is switched off at the control panel

This message does not appear when the heat zones are set to zero.

Reset: Switch the barrel heats on at the control panel.

133 MOLD HEAT IS OFF

The mold heat is switched off at the control panel.

This message does not appear when the set values of the corresponding zones are set to 0.

Reset: Switch the mold heat on at the control panel.

8/10/02 6. ERRORS AND MESSAGES 357

 EC100 / CC100 - A03 OPERATOR:
138 GATE SAFETY STRIP

The safety strip on the front gate has been activated.

One of the digital inputs DWR (DI 45) or DWV (DI 62) have been deactivated causing the
safety gate outputs SGA (DO 30), SGZ (DO 38) and SGN (DO 40) to deactivate.

Reset: Switch the Manual/Automatic mode select switch to reset the safety strip error.

145 CYC TIME DEVIATION

One or several "part-times" of the cycle lie outside the set tolerance limit.

The deviated time or times can be determined on the screen page "Part-time monitoring"
(select "Mold parameters" + F2 + F2) in the "Deviation" column. The next cycle will not start
and the alarm is set.

Reset: Adjust incorrectly set tolerances and values or set tolerances to zero to disable the
monitoring.

146 MOLD NOT IN POS.

Mold or Toggle stroke position has changed without change being requested

This message will occur when the mold or toggle position changes when it should not
change. i.e. the controller or operator has not deliberately actuated the movement.

The alarm limit for the amount of movement permitted is set in set value 35022 .

Reset: Check that set value 35022 is set to a realistic value. Check the reason for the
position change (Is there a hydraulic problem ?)

147 EJECTOR NOT IN POS.

Ejector stroke position has changed without change being requested

This message will occur when the ejector position changes when it should not change. i.e.
the controller or operator has not deliberately actuated the movement.

The alarm limit for the amount of movement permitted is set in set value 35020.

Reset: Check that set value 35020 is set to a realistic value. Check the reason for the
position change (Is there a hydraulic problem ?)

358 6. ERRORS AND MESSAGES 8/10/02

 EC100 / CC100 - A03 OPERATOR:
152 TANK SHUT-OFF FLAP

One of the pump suction line shut-off valves is closed.

On the regulated pump machine design Digital input F1 (DI 21) should be high to indicate
the shut-off valves are open to provide oil to the pump.

Reset: Open the shut-off valve and check that the switch is operating correctly.

161 OIL FILTRATION ON

The oil filtration program is switched on.

The oil filtration program is located on the Hydraulic Status page. If the program is active,
the main motors will not start and the error message will appear.

Reset: Check the Hydraulic status page and de-activate the filtration program if not
required.

167 SHORT CIRCUIT. E8

A temperature card output has been short-circuited.

Current measured at the digital outputs of an E-8-Thermo card was too high indicating a
possible short-circuit. The cards are protected against continuous short-circuits.

Reset: Examine connections between temp. card(s) and triac(s). Replace components if
necessary

168 MOLD COUPLE BREAK

Mold Thermocouple Break. The Mold Thermocouple is defective or the thermocouple

connections to the temperature card are broken. On the Heat screen page the mold
temperature zone field shows: '***.*'

Without the 'Emergency mode' program, the machine finishes the cycle and stops. The
alarm lamp is set, delayed motor switch off and the heats switch off.

With the 'Emergency mode' program the machine continues to run with the last known
heating capacity. In the event of a thermocouple break, the machine is automatically
switched over from controller mode to regulator mode. In the regulator mode no
temperature monitoring takes place.

'EMERGENCY MODE' is selected on the Control Parameter page. Under the column
"Emerg. Mode" and against the zone(s), required to be in emergency mode, enter YES.

Reset: Investigate thermocouple and/or thermocouple lines/contact points.

8/10/02 6. ERRORS AND MESSAGES 359

 EC100 / CC100 - A03 OPERATOR:
169 OIL COUPLE BREAK

Oil Thermocouple Break. The Oil Thermocouple is defective or the thermocouple

connections to the temperature card are broken. On the Heat screen page the oil
temperature zone field shows: '***.*'

The machine stops cycling, the alarm lamp is set, delayed motor switch off and the heats
switch off. When the motor switches off, the cooling water valve also switches off. No
emergency operation possible.

Reset: Investigate thermocouple and/or thermocouple lines/contact points.

173 EBIAS 999

F A T A L error, call ENGEL service !!

The machine will no longer run in AUTOMATIC.

Reset: ***** Call ENGEL service****** Can only be serviced by ENGEL technician.

174 DATE / TIME ERROR

Date and/or time has been set wrongly.

Exact dates and times which are read off by the control unit are not correct, e.g. recordings
with QDP or QDS or printouts of screen pages are dated wrongly.

Reset: Switch on service mode and correct date/time.

175 SAFETY KEY SWITCH ON

The SUVA safety switch is in position 'Safety'.

Only for machines with Swiss safety equipment.

Only serves as display. Digital input 'bSICH' must be at +24V.

Reset: Switch off safety switch.

176 NOZZLE GUARD DEF.

The nozzle guard limit switches (E9 and E9Q) have not been actuated within 1 second of
each other. The motor stops and the alarm is set.

Reset: Nozzle guard limit switches E9 (DI 5) and E9Q (DI 3) must be checked and the
fault rectified for an error-free movement cycle.

360 6. ERRORS AND MESSAGES 8/10/02

 EC100 / CC100 - A03 OPERATOR:
177 F2 RETURN FILTER

A pressure filter is defective.

A pressure switch on the pressure filter has reacted indicating a clogged filter.

Pressure switch F2 (DI 13) is connected to digital input port 'F2'. Digital input 'F2' must be
at 24 VE to permit machine operation.

Reset: Change the pressure filter. If the alarm persists, check the interface diagram for
wiring connections.

178 REJECTS ADD. CURVE

The micrograph "rejects evaluation" has detected a deviation e.g. by batch variation,
temperature variation, compared to the additional curve.

Message only displayed, the rejects counter is incremented.

See criteria for the deviation in the "MICROGRAPH" program.

Reset: Automatically resets at the beginning of each cycle.

179 PD GRAPHICS-MONIT.

The Process Data Monitoring program, upper or lower limits have been exceeded.

Depending on the variables being evaluated the error message may involve:

- error message and alarm lamp only.

- cycle stop and alarm lamp.

- error message, rejects message and selection

- without alarm lamp

- error message, rejects message and selection

- with alarm lamp

- cycle stop and alarm lamp

Reset: Determine the reason for the variable exceeding the set tolerance and correct the
error i.e. (new initialization, correction of the tolerance etc.).

8/10/02 6. ERRORS AND MESSAGES 361

 EC100 / CC100 - A03 OPERATOR:
180 PD GRAPHICS ALARM

The PD Graphics program, upper or lower limits have been exceeded.

Depending on the variables being evaluated the error message may involve:

-no consequence.

-message and alarm lamp only.

-cycle stop and alarm lamp.

Reset: Determine the reason for the variable exceeding the set tolerance and correct the
error i.e. (new initialization, correction of the tolerance etc.).

181 MOLD HEAT LOWERS

All heats will reduce to the heat lowering set value.

This message appears when a machine alarm stops the running cycle. The heat zones
lower to a set value temperature designed to prevent material degradation due to long
exposure to heat as would be the case if the machine stopped in mid-cycle. This message
also appears if the heat standby program has been activated manually. If the program has
been activated manually it must also be de-activated manually.

Reset: Remove machine alarm, wait for heats to increase to within set tolerance levels
and re-cycle the machine.

182 SG MONITORING RELAY (Safety Gate Monitoring Relay)

The signal from the safety gate monitoring relay did not coincide with the signal from E2
and/or E1 after 0.5 seconds. The motor stops and the alarm is set. The error state is
maintained until the error is acknowledged.

Reset: Check that the actuation of the safety gate limit switches E1 (DI 1) and E2 (DI 2)
coincides with the actuation of the safety gate monitoring relay.

183 SG SAFETY STRIP

The safety strip on the safety gate has been activated.

The safety gate can not be opened or closed automatically.

Reset: Remove the obstruction from the safety gate, switch the machine into manual and
close the safety gate. Turn the mode selection switch off and on again to reset the
message

362 6. ERRORS AND MESSAGES 8/10/02

 EC100 / CC100 - A03 OPERATOR:
200 ROB. INTRLK - EJ. FWD

A robot interlock has stopped the ejector forward function.

This message will appear if digital input 'AWV' (DI 53) is not active and the ejector forward
movement is attempted.

Reset: Determine why digital input 'AWV' is not at 24 VE.

201 ROB. INTRLK - EJ. RET.

A robot interlock has stopped the ejector return function.

This message will appear if digital input 'AWZ' (DI 54) is not active and the ejector return
function is attempted.

Reset: Determine why digital input 'AWZ' is not at 24 VE.

202 ROB. INTRLK-OPENING

A robot interlock has stopped the mold opening function.

This message will appear if digital input 'HSP' is not active and the mold opening function
is attempted.

Reset: Determine why digital input 'HSP (DI55)' is not at 24 VE.

203 ROB. INTRLK-CLOSING

A robot interlock has stopped the mold closing function.

This message will appear if digital input 'b63' is not active and the mold closing function is
attempted.

Reset: Determine why digital input 'b63' (DI63) is not at 24VE.

204 ROB. INTRLK-CORE OUT

A robot interlock has stopped the core out function.

This message will appear if digital input 'KEA' is not active and the core out function is
attempted

Reset: Determine why digital input 'KEA' (DI52) is not at 24VE.

8/10/02 6. ERRORS AND MESSAGES 363

 EC100 / CC100 - A03 OPERATOR:
205 ROB. INTRLK-CORE IN

A robot interlock has stopped the core in function.

This message will appear if digital input 'KEE' is not active and the core in function is
attempted

Reset: Determine why digital input 'KEE' (DI56) is not at 24VE.

206 ROB. INTRLK - INDXING

A robot interlock has stopped the indexing function.

This message will appear if digital input 'b75' (DI 75) is not active and the indexing function
is attempted.

Reset: Determine why digital input b75 is not at 24VE.

207 MECHANICAL INTRLK.

The mechanical interlock monitoring and/or function is defective.

If mold closing is attempted and the mechanical interlock has not been released, mold
closing will be prevented and this message will appear. Also, if this mechanical interlock is
supposed to be engaged, but is not, the motor will shut off and this message will appear.
This will be the case if digital output S45 (DO 27) has been deactivated but the digital input
E21 (DI 28) has not been deactivated within the supervision time. If the supervision time is
set to 0, the monitoring of the mechanical interlock out switch input E21 is disabled.

Reset: Check the digital output S45, the digital input E21 and the supervision time.

208 NOZZLE NOT BACK

The nozzle must be moved back to operate the quick mold change program.

In order to avoid contacting the nozzle when operating the quick mold change program, the
nozzle must be moved back until the 'NOZZLE FULLY RETRACTED' flag 'K1', on the sprue
break page, is activated.

Reset: In the manual mode, activate the nozzle back selector switch.

209 ROB. INTRLK - OPEN INT

A robot interlock has stopped the mold opening at an intermediate robot position.

This message will be displayed if digital input 'fof' (DI 61) is not active and the mold opening
at intermediate robot position function was attempted.

Reset: Determine why digital input ‘fof’ is not at 24VE.

364 6. ERRORS AND MESSAGES 8/10/02

 EC100 / CC100 - A03 OPERATOR:
224 P6 – PRESSURE LIMIT

The injection pressure has exceeded the operator set P6 limit.

This is just an error message, the machine continues to function. If this level of pressure is
reached during injection, the control would lose its capacity to manage injection speed. If
this pressure is reached during injection, speed will decrease.

Reset: Check actual injection pressure and determine why it is so close to the P6 limit.

226 REQUIRE SPI SWITCH

Gate kicker option 2 has been requested, but the SPI keyswitch is disabled. To allow ejector
and core movement with the safety gate open the SPI keyswitch must be enabled as well
as the relevant parameters.

Reset: To clear the error message, switch the program interrupt switch from automatic to
manual and back to automatic. Enable the SPI keyswitch and then option 2 can be
selected.

235 LOST G2 or J

Either the G2 clamp position or the J point nozzle position is no longer seen by the
controller. This error message is for “closed loop” machines and will only be displayed in the
automatic mode during the injection cycle.

The Injection cycle will continue, but the injection speed will drop to the purging level. The
purge speed is set by a voltage in parameter 36807.

There is no, or insufficient pressure on the clamp or injection carriage to maintain their
position during injection.

Reset: Determine why there is insufficient pressure on the clamp or injection carriage.

238 SCALE NOT AT ZERO

The controller has detected an output from the weigh scale when no output is expected.
When the mold reaches A position or an conformation signal from the robot is received the
controller is trigger to check the scale for a zero value. The controller checks the weigh
scale for an output, no output indicates that the scale is at zero, i.e. no weight is present on
the scale. If an output is detected, indicating that weight is present the error message is
displayed. If no weight is detected, the cycle is allowed to continue.

Reset: Check the weigh scale, is the weigh scale switched on? Is there a part still on the
weigh scale?. Rectify any problems and clear the error message.

8/10/02 6. ERRORS AND MESSAGES 365

 EC100 / CC100 - A03 OPERATOR:
239 THRESH. NOT REACHED

Weight has not been detected on the scale wihin the weight monitoring time ZMU. If the
scale is detected as being at zero, a measuring delay time ZMV is started. ZMV must be
enough time for the part to be removed from the mold and placed on the scale. When the
measuring time delay has expired a weight monitoring timer starts, if no weight is detected
within this time, the error message is displayed. The threshold weight is set on the weigh
scale screen page, this is the minimum weight that must be detected within the monitoring
time.

Reset: Is the monitoring time long enough for the part to reach the scale, is the part being
placed correctly on the scale?. Rectify any problems and clear the error message.

240 WEIGHT PLUS TOLER.

The part weight detected is too heavy. The weight of the part lies above the screen page set
"SPECIFIED PART WEIGHT" plus the "WEIGHT +TOLERANCE". The error message will
be displayed and the reject part will be acknowledged and counted on the screen page.

241 WEIGH MINUS TOLE.

The part weight detected is too light. The weight of the part lies below the screen page set
"SPECIFIED PART WEIGHT" minus the "WEIGHT – TOLERANCE".The error message will
be displayed and the reject part will be acknowledged and counted on the screen page.

243 MAXI.REJECTS SCALE

Too many rejects have been detected. The amount of rejects per cycle has exceeded the
value set on the WEIGH SCALE screen page. The error message will be displayed and
machine will stop at the end of the cycle.

Reset: Investigate why rejects are being produced. What has changed in the process?

245 ENCLOSURE ACKNOWL.

A servomotor start has been attempted but the enclosure safety gate has not been closed
or acknowledged as closed. The motors will not start until the enclosed safety area is secure
and confirmed as secure by operating the "Protected Area Acknowledgement Key to
position 1.

Reset: Close and acnowledge door as closed. Clear the error message.

247 HYDR.ACCU DISABLED

An accumulator speed calibration was attempted when accumulator program 0 or 2 was

selected. Injection was not selected as an option, therefore a speed calibration will not be
possible. Calibration is not necessary unless injection selected and therefore will be
stopped and the error message will be displayed.

Reset: Select program options 1 or 3 to perform a speed calibration

366 6. ERRORS AND MESSAGES 8/10/02

 EC100 / CC100 - A03 OPERATOR:
248 CHARGE TIME EXCEEDED

The maximum time allowed for the accumulator to charge to pressure P43 has been
exceeded. The accumulator has failed to reach the set value P43 in the time set in
parameter 36916. The pump motor will be switched into a delayed stop, the machine will be
switched into manual mode, the alarm lamp will flash and the error message will be
displayed.

Reset:

2000 MECH. CLOSE SAFETY

Clamp movement attempted but mechanical safety interlock released input not seen at
Digital Input 28.

Mold movement is locked.

Check mechanical safety mechanism and limit switch.

Reset: Switch the program interrupt switch from ON to OFF and back to ON.

2001 RETURN OIL FILTER

The return oil filter is contaminated.

The automatic cycle will stop and the alarm lamp will flash. Clean or change the oil filter.

Reset: Switch the program interrupt switch from ON to OFF and back to ON.

2002 PRESSURE TOO LOW

The idle pressure has been below the set minimum idle pressure for more than 4 minutes.

The pump motor will stop and the alarm lamp will flash.

Reset: Switch the program interrupt switch from ON to OFF and back to ON.

2003 EMERG. STOP FAULTY

The emergency stop monitoring circuit has reacted. The digital input bNOT (DI 0) and the
emergency stop input signal from the RC90/100 Robot System are different. The two inputs
must be the same within a set monitoring time.

The pump motor will stop and the alarm lamp will flash.

Check the emergency stop circuit.

Reset: Activated and reset the emergency stop button. Switch the program interrupt
switch from ON to OFF and back to ON.

8/10/02 6. ERRORS AND MESSAGES 367

 EC100 / CC100 - A03 OPERATOR:
2428 P - TRANSDUC. PH1 DEF.

The pressure transducer (Pump Pressure) voltage, measured by the control unit does not
lie within the defined tolerance range (+200mV to +10V).

The automatic cycle will stop and switches over to manual, the movements are locked, the
pump motor stops and the alarm lamp flashes.

Check the pressure transducer and cable for open or short circuits. Check the supply
voltages to the transducer. Check the “Input Calibrations” screen page, the actual value
must lie in between zero and max value.

Reset: Switch the program interrupt switch from ON to OFF and back to ON.

2429 P - TRANSDUC. PH2 DEF.

The pressure transducer (Clamp Pressure) voltage, measured by the control unit does not
lie within the defined tolerance range (+200mV to +10V).

The automatic cycle will stop and switches over to manual, the movements are locked, the
pump motor stops and the alarm lamp flashes.

Check the pressure transducer and cable for open or short circuits. Check the supply
voltages to the transducer. Check the “Input Calibrations” screen page, the actual value
must lie in between zero and max value.

Reset: Switch the program interrupt switch from ON to OFF and back to ON.

2430 P - TRANSDUC. PH3 DEF.

The pressure transducer (Injection Pressure) voltage, measured by the control unit does not
lie within the defined tolerance range (+200mV to +10V).

The automatic cycle will stop and switches over to manual, the movements are locked, the
pump motor stops and the alarm lamp flashes.

Check the pressure transducer and cable for open or short circuits. Check the supply
voltages to the transducer. Check the “Input Calibrations” screen page, the actual value
must lie in between zero and max value.

Reset: Switch the program interrupt switch from ON to OFF and back to ON.

368 6. ERRORS AND MESSAGES 8/10/02

 EC100 / CC100 - A03 OPERATOR:
2431 P - TRANSDUC. PH4 DEF.

The pressure transducer (Pump 2 Pressure) voltage, measured by the control unit does not
lie within the defined tolerance range (+200mV to +10V).

The automatic cycle will stop and switches over to manual, the movements are locked, the
pump motor stops and the alarm lamp flashes.

Check the pressure transducer and cable for open or short circuits. Check the supply
voltages to the transducer. Check the “Input Calibrations” screen page, the actual value
must lie in between zero and max value.

Reset: Switch the program interrupt switch from ON to OFF and back to ON.

2457 VT CARD 1 DEFECT

The EHV pump speed and pressure control card is defective or the 24Volt monitoring input
on the control unit is not present.

The alarm lamp flashes, the pump motor switches off and the heats are switched to standby.

Check the security of the card in the rack and the supply voltage to the card. Check the
connection from the control unit to the card. Exchange the card for a known working card,
transfer the settings from the suspect card to the working card.

Reset: Switch the program interrupt switch from ON to OFF and back to ON.

2458 VT CARD 2 DEFECT

The EHV pump speed and pressure control card is defective or the 24Volt monitoring input
on the control unit is not present.

The alarm lamp flashes, the pump motor switches off and the heats are switched to standby.

Check the security of the card in the rack and the supply voltage to the card. Check the
connection from the control unit to the card. Exchange the card for a known working card,
transfer the settings from the suspect card to the working card.

Reset: Switch the program interrupt switch from ON to OFF and back to ON.

8/10/02 6. ERRORS AND MESSAGES 369

 EC100 / CC100 - A03 OPERATOR:
2459 VT CARD 1 UNIT 2 DEFECT

The EHV pump speed and pressure control card is defective or the 24Volt monitoring input
on the control unit is not present.

The alarm lamp flashes, the pump motor switches off and the heats are switched to standby.

Check the security of the card in the rack and the supply voltage to the card. Check the
connection from the control unit to the card. Exchange the card for a known working card,
transfer the settings from the suspect card to the working card.

Reset: Switch the program interrupt switch from ON to OFF and back to ON.

370 6. ERRORS AND MESSAGES 8/10/02

 EC100 / CC100 - A03 OPERATOR:

5 WAITING POINTS

Press the ERROR page symbol

!
The following display will appear:

MACHINE WAITING HARDWARE SYST. DATA VALUES OUT

ERROR POINTS CHECK Etc.
REPORT OF RANGE

Press

To assist the technician in troubleshooting on the machine, there are waiting points which are
displayed when the machine stops. The waiting point indicates the next sequence point in the
cycle that has not been reached. Therefore, the cycle stopped in the sequence position
immediately before the waiting point listed.
This function only works in automatic or semi-automatic mode. Below are listed the waiting points.
0 TMS - START BUTTON 31 CLOSED LOOP CLAMPING FORCE CONTROL
1 MOLD CLOSING END 32 CORE 1 IN
2 CARRIAGE END 33 CORE 2 IN
3 INJECTION FINISHED 34 CORE 3 IN
4 COOLING TIME END 35 CORE 1 OUT
5 DEMOLDING TIME 36 CORE 2 OUT
6 EJECTION END 37 CORE 3 OUT
7 CLOSING SPEED - POS. W1 38 CORE 1 IN - POS. KS1
8 MOLD PROTECTION BEGINNING-POS. G1 39 CORE 2 IN - POS. KS2
9 MOLD PROTECTION END - POS. G2 40 CORE 3 IN - POS. KS3
10 BREAK POSITION - POS. B1 41 CORE 1 IN - POS. KO1
11 TOGGLE LEVER LOCKED - POS. B 42 CORE 2 OUT - POS. KO2
12 MOLD STANDSTILL 43 CORE 3 OUT - POS. KO3
13 MOLD OPEN - POS. A 44 CORE 1 IN - LIMIT SWITCH E15
14 DECOMPRESS. BEFORE PLAST.- POS. C4 45 CORE 1 IN - ZE1
15 PLASTICIZING END - POS. C1 46 CORE 2 IN - LIMIT SWITCH E17
16 DECOMPRESS. AFTER PLAST. - POS. C2 47 CORE 2 IN - ZE2
17 PLASTICIZING DELAY TIME - Z3 48 CORE 3 IN - LIMIT SWITCH E19
18 INTRUSION TIME - ZIN 49 ORE 3 IN - ZE3
19 J-DETERMINATION 50 CORE 1 OUT - LIMIT SWITCH E14
20 INJECTION UNIT FRONT - POS. J 51 CORE 1 OUT - ZA1
21 PRESSURE BUILD-UP TIME Z5A 52 CORE 2 OUT - LIMIT SWITCH E16
22 NOZZLE RETRACTION DELAY Z6 53 CORE 2 OUT - ZA2
23 INJECTION UNIT REAR - POS.K 54 CORE 3 OUT - LIMIT SWITCH E18
24 EJECTOR FRONT - POS.L1 55 CORE 3 OUT - ZA3
25 EJECTOR REAR - POS.L 56 CORE 1 OUT DELAY - ZKAV1
26 EJECTOR SHAKE - POS. L2 57 CORE 2 OUT DELAY - ZKAV2
27 START EJECTOR FORWARD - POS. A1 58 CORE 3 OUT DELAY - ZKAV3
28 EJECTOR FORWARD DELAY ZAV 59 START AIR BLOWING 1 - POS. A2
29 EJECTOR BACKWARD DELAY ZA 60 AIR BLOWING TIME 1 - ZL1
30 MOLD OPENING INTERMEDIATE STOP 61 AIR BLOWING TIME 2 - ZL2

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62 BLOWING DELAY TIME 1 - ZLV1 86 MOVE IN CORES FINISHED
63 BLOWING DELAY TIME 2 - ZLV2 87 MOVE OUT CORES FINISHED
64 EJECTION MONITORING - INPUT BLS 88 CLAMPING FORCE CHECK
65 CORE IN POSITION B8 89 SAFETY GATE CLOSING E1
66 CLAMPING PRESSURE REDUCTION 90 SAFETY GATE OPENING E1-FREE
67 CLAMPING PRESSURE BUILD-UP 91 INJECTION DELAY
68 MOLD HEIGHT - POS. FH 92 RELEASE MOLD CLOSING
69 HANDLING INTRLK - HSP 93 RELEASE MOLD OPENING
70 END INCREASED OPENING FORCE 94 RELEASE PLASTICIZING
71 BOOST TO HOLD CUT_OFF 95 RELEASE INJECTION
72 CONTACT PRESSURE REDUCTION 96 RELEASE CARRIAGE UNIT FORWARD
73 PROGRAM INTERRUPTION 97 RELEASE CARRIAGE UNIT RETURN
74 MOLD OPENING END 98 RELEASE EJECTOR FORWARD
75 STROKE CALIBRATION FINISHED 99 RELEASE EJECTOR RETURN
76 CLOSED LOOP CF CONTROL START POSITION 100 RELEASE MOLD MOUNTING MOVING PLATEN
77 MOLD MOUNTED MOVING PLATEN 101 REL MOLD DISMOUNTING MOVING PLATEN
78 MOLD DISMOUNTED MOVING PLATEN 102 RELEASE MOLD DISMOUNTING FIXED PLATEN
79 MOLD MOUNTED FIXED PLATEN 103 RELEASE MOLD MOUNTING FIXED PLATEN
80 MOLD DISMOUNTED FIXED PLATEN 104 RELEASE MOLD HEIGHT SMALLER
81 START INJECTION 105 RELEASE MOLD HEIGHT LARGER
82 START MOLD OPENING 106 RELEASE MOVE IN CORE
83 HANDLING SYSTEM RELEASE EJECTOR FWD 107 RELEASE MOVE OUT CORE
84 HANDLING SYSTEM DEPOSITING FINISHED 108 STARTING POSITION NOZZLE FORWARD
85 TAKE-OFF POSITION AFZ 109 SAFETY GATE OPENING DELAY

372 6. ERRORS AND MESSAGES 8/10/02

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6 HARDWARE CHECK

!
Press the ERROR page symbol:

The following function frame will be displayed

Press F3

The hardware check information is split into five screen pages which will display:
• Hardware configuration
• Hardware test
• Hardware information
• Software version
• System information

The information presented on these pages is used by Engel service and software engineers for
troubleshooting. Have a hardcopy of this information when calling the Engel service department
with a machine problem.

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6.1 HW - CONFIGURATION

This page indicates how the hardware package of each machine is configured. The sample page
above shows the:
CPU type and frequency,
the sub modules associated with the CPU card.

The number of:

Digital input cards;
Digital output cards;
Analog cards
Temperature cards

Refer to the Controller maintenance manual for a fuller description of all the possible cards used
in a machine configuration.

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6.2 HARDWARE TEST

When the control voltage is turned on, an automatic software test is conducted. Shortly
afterwards, relay 136 is energized which connects VK (solenoids) voltage to the controller.

At this time the controller will carry out a digital output failure test and will list the results of the test
on the hardware test page as shown above.

This area gives an indication of the digital outputs which are not normally connected or‚ if the
circuit has been found to be open during the hardware test. If the usual state of these outputs are
recorded, a new‚ problem could be easily identified when a comparison is made with this listing.
This area is strictly related to digital outputs.

DO321 #0 refers to the first digital output card, the list of outputs relate to the first card.

DO321 #0 refers to the second digital output card, the list of outputs relate to the second card.

NOTE!

If any Digital Output is short circuited during the machine cycle, the
short circuited channel will appear just below the "circuit breaks" area,
in yellow type on the CC100. Refer to the description of Ebias errors
for a listing of typical digital output assignments and also to your own
electrical interface diagram to identify and locate the short circuit.

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6.3 HW - INFORMATION

This screen page details all the electronic card information, the screen page shown is
representative of a standard machine, the information will be different for a customized machines.

component This column lists the electronic cards in the rack.

no. This column lists the card number, ie 0 = the first card,
1 = the second card etc.
print-no. This column lists the part number of the card.
ser-no. This column lists the serial number of the card.
rev. This column lists the revision state of the card.
var. This column lists the variant of the card.
bsz. This column lists the card information useful to Engel service and software
engineers.

376 6. ERRORS AND MESSAGES 8/10/02

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6.4 SW - VERSION

This screen page indicates the software versions of all the programmable devices within the
machine hardware.

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6.5 SYSTEM INFORMATION

The system information page indicates:

• The machine fabrication number or serial number.

• A listing of the system drives. If the system contains a Ramdisk card or an extra
memory card, the memory size will be listed in this area.
• The number of the serial interface ports and their specific use.

378 6. ERRORS AND MESSAGES 8/10/02

 EC100 / CC100 - A03 OPERATOR:

7 SYSTEM DATA REPORT

!
Press the ERROR page symbol:

The following function frame will be displayed

Press F4
This program can be extremely useful to the operator or the maintenance technician. In effect, a
record is kept of various machine conditions even after the controls have been switched off.

To access this program, press 'F8' - etc. --> and the following function frame display will appear.

F1 Press 'System' for a display of the last 60 system errors or 'RUN/STOP' conditions.

The screen page displays: Sequence number.

Date of occurrence.
Time of occurrence.
Cycle number.
Error text.
POWER - FAIL The electrical power was turned off.
STOP The control voltage was turned off.
RUN The control voltage was turned on.
TIME OLD The time was updated.
TIME NEW A new time and date has been entered.
SYSTEM-ERROR A system error has occurred. (e.g. software error, card fault)
Refer to SYS-errors in the error section of this manual
RESET The controller has been reset on the CPU card. This should
never be attempted by the customer.

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F2 Press 'Error' for a display of the last 60 machine errors. The last “error” is displayed
at the top of the list. In addition to the error in text and its reference number, the
date, time, cycle number and other information is shown to assist the operator or
maintenance technician.

ERROR Refer to the specific error number and the error listing in the
error section of this manual for a full description of each
message.

ERROR BEGIN... This series of errors begin with this error message.

QUIT OLD ERRORSThe errors have been validated and reset individually when
the “Error acknowledgment key was pressed.

QUIT-ALL-ERRORS The errors have been reset using the manual / automatic
selector switch.

CLEAR ERROR The error has been reset automatically after its elimination.

F3 Press 'Input' for a display of the last 60 set value changes. The last “Input” change
is displayed at the top of the list.

2170 99-01-24 10:57 3333 Input: User: 2 Pers#: 2

SW 4116 old: 50 new: 75

The above message indicates that on sequence number 2170, on January. 24,
1999 at 10:57 am, someone using the customer service password access
changed the set value 4116 from the old value 50 % to a new value of 75 %. This
occurred on cycle number 3333.

NOTE!

If a password access card was used, the “Per#” would

display the personnel number from that card. This would
identify the card user.

A complete list of all set values can be found in chapter 8 of the Controller
Maintenance manual.

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F4 Press 'State' for a display of the last 60 program mode changes or service
password entries. The last “State” change is displayed at the top of the list.

STATE ... The program has been changed form one state to another

0 MANUAL
1 PROGRAM INTERRRUPTION
2 SET-UP
3 SEMI-AUTOMATIC
4 AUTOMATIC
e.g. STATE : 1 <--- 3

In this example the program has been changed from program interruption mode to
semi-automatic mode

Whenever the manual keyswitch is switched from automatic to manual, the

program interruption mode will be activated. In addition to the information being
registered on this page of the program memory ,error message 63 -PROGRAM
INTERRUPTION will also appear on the memory message page.

A service password has been entered.

e.g. Password Input: :... <--- 8
6 ... Service password
8 ... Engel service password
10 ... Engel software password

F5 The “User” function indicates what the machine controller was waiting for when the
machine went into alarm. The page shows:
Date of event
Time of event
Program number running at the time
Step number of the program
Event waited for......

The information will be useful to determine why the machine has gone into alarm.

The program and step numbers can be used by the Engel service or software
personnel to troubleshoot the system.

The information is stored and can viewed at a later time. The information may be
displayed on two or more screen pages. The latest event is displayed at the top of
the first page. The earlier events can accessed by scrolling down the page or
pages.

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F6 The “Print” function enables the operator to print out each individual parts of the
System Data Report:
F1 - System errors, F2 - Machine errors,
F3 - Input changes and F4 - State changes.

NOTE!

The entire “System Data Report” can be printed out by

employing F5 - “PRINT SYSTEM DATA REPORT” on the
“PRINTER” screen page.

F7 The “Screen –Lines” function is used in conjunction with F3 “Input”. The function
key only appears when F3 “Input” function key is pressed. The changed Set
Values indicated on the “Input” page can be viewed in more detail on the “Screen-
Lines” page.

SCREW FEEDING SW4116

DECOMPRESSION SPEED V24 75 %

The Set Value number is displayed with the Screen Page and Line text. This
enables the operator to identify the Set Value without having to refer to the Set
Value listings in the Controller Maintenance manual.

382 6. ERRORS AND MESSAGES 8/10/02

 EC100 / CC100 - A03 OPERATOR:

8 VALUES OUT OF RANGE

!
Press the ERROR page symbol:

The following function frame will be displayed

Press F5
When an error message is displayed “Value out of range” , the offending variable or variables will
be displayed on the Values out of range” page. The “Values out of range” screen page will display
the name of the screen page and the variable number of the “value out of range”. The next line
will display the line from that screen page that contains the “value out of range”.

The screen page can be selected and the “value out of range” will be flashing. Highlight the
flashing variable with the cursor and on the lower left hand side of the screen page the actual
range of that variable will be displayed in brackets [0 - 100].

The maximum and minimum range provides the operator with the limits of the variable and
therefore the variable can be adjust back into tolerance so that it no longer generates an error
message.

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384 6. ERRORS AND MESSAGES 8/10/02

 EC100 / CC100 - A03 OPERATOR:

7. SAFETY
1 MATERIAL HANDLING AND STORAGE
Manual Handling
Whenever possible material should be handled by automated or mechanical lifting devices,
operated by well trained, competent persons. Where manual handling is required, protective
equipment (i.e. safety shoes and gloves) and the correct technique for lifting and moving a load
will help prevent injury to the worker.

Forklifts
These should be operated by competent, authorized persons only. They should be properly
equipped with a protective canopy, a backup warning device, a fire extinguisher (electrically
powered trucks), and other devices as required by local regulations. Appropriate safety
equipment (i.e. hard hat and safety shoes) should be worn by operators and persons in the vicinity
of fork trucks. Loads must not exceed the rated capacity of the truck. Riding as a passenger on
the truck, or its load, is prohibited. Standing on or under elevated forks is also prohibited. There
should be ample clearance in alleyways, preferably with a separate traffic lane. Correct
procedures for refueling, recharging, inspection, maintenance and testing of forklifts must be
written up and acted upon. Observation of these and other appropriate precautions will help to
prevent injury caused by falling material, collision, fire and explosion, battery acid burns, and
exposure to carbon monoxide.

Hand Carts
Carts should be equipped with hand guards and large diameter wheels. Operators should wear
appropriate protective equipment (i.e. gloves and safety shoes) and be trained in the correct
procedure for loading and moving carts.

Cranes
Cranes should be equipped with a safety catch on the hook and an audible beeper for horizontal
travel. They should be operated by trained competent persons only. As designated by local
regulations the crane and its auxiliary equipment must be inspected and tested regularly. Persons
working near cranes must stay clear of the load and wear appropriate protective equipment (i.e.
hard hat and safety shoes).
Rated load capacity of the crane must not be exceeded. Persons should not be raised or lowered
by a crane. Particular care must be taken to avoid pinching of hands or fingers between the chain
and the load.

Stacking
Material in bags or barrels should be stacked employing the correct techniques. This will help
prevent spilling from bags, collapsing bags and falling barrels.

Work Areas
Working areas and walking surfaces must be kept clean and tidy. Floors must be kept in good
condition and objects must not be allowed to clutter or obstruct aisles. Spilled liquid should be
mopped up immediately. Spilled dry material should ideally be vacuumed to avoid movement of
potentially harmful dust caused by dry sweeping.

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2 MATERIAL PREPARATION
Dryer

Care should be taken to avoid contact with hot surfaces of the dryer. Thermal degradation of
overheated pellets will produce gases and fumes which may be hazardous to health. Avoid
inhalation of these degradation products.

Blender

The rotating barrel of the blender should be suitably guarded to prevent persons from becoming
entangled. The emergency stop button should be well identified and accessible. Only trained
competent persons should operate the blender.

Bandsaw

This machine should be guarded so that the cutting edge of the blade required for the operation
is the only exposed moving part. The emergency stop button should be well identified and
accessible. The blade and the wheels must be inspected and adjusted for optimum safe
operation. Bandsaws should only be run by competent trained persons who are wearing suitable
protective equipment and no loose clothing or jewellery.

Grinder

The guarding on this machine and the design of the hopper should prevent the operator from
being able to contact the blades. The emergency stop button should be well identified and
accessible. The operator should be protected from particles flying from the grinder by a flexible
barrier covering the feed hopper opening. The operator must be competent and properly trained.
Dust from the grinder may be a hazard to workers nearby. The dust may be inhaled or it may form
an explosive mixture only requiring a source of ignition. Air filtration must be used to bring the
concentration of dust to an acceptable level. Grinders commonly emit high noise levels and
should be isolated by suitable barriers or have sound absorbing material applied to them to
reduce operator exposure to this noise. For this reason persons working with the grinder, or within
close proximity, should use hearing protection in addition to other appropriate protective
equipment (i.e. safety glasses). Cleaning, inspection and maintenance must only be performed
after the machine has been correctly locked out.

3 MOLD PREPARATION
Where work on the mold is performed in-house the use of various machines may be required.
These may include lathes, milling machines, drill presses and grinding tools etc. Each step of
these operations should only be performed by suitably trained and competent persons.
Appropriate protective equipment must be used and standard safe operating practices for the
machines must be followed. When chemicals, such as degreasing agents or paints, are used in
the mold preparation care should be taken to avoid skin contact with or inhalation of these
materials.

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4 MOLD INSTALLATION AND REMOVAL

Attention should be paid to the hazards involved in the movement of molds. To help prevent the
mold from swinging out of control and causing hand and finger injuries, it is recommended that
two people wearing gloves and safety shoes install and position the mold in the machine. See
sections under "MATERIAL HANDLING AND STORAGE" regarding use of cranes and forklifts.

MOLD INSTALLATION PROCEDURE

Step 1. Set velocity and pressure to a minimum by activating the set-up mode on the program
selection panel.

Step 2. Make sure that the ejector rods are not in the way.

Step 3. Open the clamp to allow plenty of room to install the mold.

Step 4. Lower the mold into position and insert the location ring, located on the mold, into the
insertion ring (female end), located on the stationary platen.

Step 5. (Toggle machines only) Still in the set-up mode, switch to the mold closing page and turn
the automatic mold height adjustment program on.
Turn the manual clamp switch to the close position and hold the switch in the close
position until the automatic mold height adjustment program switches off. At this point the
toggle should be locked and the mold held between the two platens.

Step 6. (Direct hydraulic machines only) Still in the set-up mode, switch to the mold closing page
and turn the manual clamp switch to the close position. Hold the switch in the close
position until the moving platen touches the back of the mold and the actual mold position
SFx = 0 (at least 5 seconds). At this point the mold should be held between the two
platens.

Step 7. Turn the motor(s) and control voltage off and use an approved lockout procedure to
ensure the machine is disabled. Check that clamp controls are disabled.

Step 8. Using the proper bolts and clamps, fasten the mold to the platens. The mold bolts should
be screwed into the platens to a depth of at least one and a half times their diameter.
For example, a 0.75 inch bolt should be screwed into the platen at least 1.125 inches.
(i.e. 0. 75 x 1.5 = 1.125).

Step 9. Any additional equipment, such as water lines, should be connected at this time.

Step 10. When the mold installation is secure and complete then the machine lockout may be
removed and the machine restarted.

The mold height is set, but the clampforce must still be adjusted.

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5 MOLDING
Various safety features have been designed and built into your ENGEL injection molding
machine. The machine is designed to meet the codes required by the original purchaser. If the
machine is re-located, responsibility for conformation to codes of the new area will not be
assumed by ENGEL.

It is the responsibility of the user to create safe operating conditions on and around the machine.
The following is presented to assist you in achieving this important goal.

General Precautions

Injection molding machines convert electrical energy into hydraulic energy. In the process
tremendous forces are developed. This is particularly evident in the clamping mechanism and in
the heated plastic. These machines are designed with safety in mind, however their potential for
inflicting injury, if safety precautions are not observed, should never be underestimated.

WARNING!

WHENEVER THIS MACHINE IS RUNNING, IT IS

ABSOLUTELY ESSENTIAL THAT ALL GUARDS ARE IN
THEIR PROPER PLACE.

Guards are provided on the machine to protect the body from contact with moving parts or areas
of high temperature.

WARNING!

NO PERSON SHOULD REACH OVER, UNDER OR

AROUND GUARDS WHILE MACHINE IS IN OPERATION.

The correct positioning of the guards should be checked before startup. Movable guards are
provided with switching devices to prevent operation of the machine with the guard removed.
These switches or interlocks must be regularly (at start of shift) checked for effectiveness. Any
problem with the operation of a switch must be corrected before the machine is run.

388 7. SAFETY 8/10/02

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WARNING!

SWITCHES AND INTERLOCKS MUST NEVER BE

INTENTIONALLY DEFEATED.

MELTED PLASTIC may be under extremely high pressure and is unbelievably hot. Blockages of
semi-cooled plastic may occur and when freed can violently release molten material with
considerable force. Careful attention should be paid to the correct procedure for removing frozen
plugs of plastic. Purging also releases hot plastic under some pressure. Purging of hot runner
molds is particularly hazardous. The purge guard must be in position and suitable protective
equipment must be worn by the operator.

The EMERGENCY STOP BUTTON or MOTOR STOP BUTTON is easily identifiable and
accessible. It is essential that the motor be stopped any time a person has to reach into the mold
space or toggle area for more than a few seconds. The motor should also be stopped for any work
that involves a persons hands in the area of the feed throat and the screw.

ELECTRICAL CIRCUITS carrying relatively high voltages are present on the machine,
particularly in the area of the plasticizing barrel. The heater band wiring is quite exposed and is
therefore more susceptible to damage. Care should be taken when working in close proximity to
these wires. Whenever damaged or broken wires or conduit, open electrical boxes and control
panels or any other apparent electrical hazard is detected the machine should be stopped and the
power shutoff at the main disconnect switch. Do not power up the machine until the problem has
been rectified by a suitably qualified person.

WARNING!

WHENEVER MAINTENANCE OR REPAIR WORK IS TO BE

CARRIED OUT, THE DISCONNECT SWITCHES MUST BE
TURNED TO THE "OFF" POSITION AND AN APPROVED
LOCKOUT PROCEDURE IMPLEMENTED.

SUGGESTED LOCKOUT PROCEDURE

Step1. Alert the operator and supervisor.

Step2. Identify all sources of residual energy.

Step3. Before starting work, place padlocks on the switch, lever, or valve, locking it in the "off"
position, installing tags at such locations to indicate maintenance in progress.

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Step4. Ensure that all power sources are off, and bleed off hydraulic or pneumatic pressure, or
bleed off any electrical current (capacitance), as required to prevent accidental
movement of machine components.

Step5. Test operator controls.

Step6. As an additional safeguard on vertical clamp machines, safety blocks should be placed so
as to mechanically prevent the clamp from closing under it's own weight, even though it
is electrically locked out.

Step7. After maintenance is completed, all machine safeguards that were removed should be
replaced, secured, and checked to be sure they are functioning properly.

Step8. Only after ascertaining that the machine is ready to perform safely should padlocks be
removed, and the machine cleared for operation.

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5.1 "CORE AND EJECTOR MOTION" KEYSWITCH

No Motion

Under normal operating conditions the "Core and Ejector Motion" keyswitch must be locked in the
"NO MOTION" position. This will prevent clamp, core and ejector motion when the operator's gate
is opened.

Motion

Under exceptional circumstances, where the employer of the operator determines it is necessary
to lift parts manually from the mold face, the machine may be operated with this switch in the
"MOTION" position.

Following the opening of the operator's gate, this will permit the clamp to continue its opening
stroke only, the cores to pull (but not set) and ejector to come forward (but not return). This
sequence will occur only in the semi-automatic mode of operation.

The machine will be operated with this switch in the "MOTION" position only after pinch points
created by cores and ejectors and pinch points created by the opening mold have been guarded.
It is the responsibility of the mold designer, mold maker and of the employer of the operator to
make sure that these pinch points are guarded.

When the employer determines there is no need to run the machine with the switch in the
"MOTION" position it is his responsibility to verify that the key switch is then turned and locked in
the "NO MOTION" position.

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5.2 ENGEL MACHINE SAFETY FEATURES (TL100 TIEBARLESS)

6 5 7
E21 3 E10 8
9
9

E9

E52

1
E4 E3
4
E2 E1
2

Legend Description
1- - - - - - - - - - Main Electrical Power Disconnect
2- - - - - - - - - - Emergency Stop button
3- - - - - - - - - - Mechanical Safety Device (Closing Protection)
4- - - - - - - - - - Hydraulic Interlock
5- - - - - - - - - - Barrel Heatshield
6- - - - - - - - - - Safety Gates (Operator and Non Operator)
7- - - - - - - - - - Injection Guard (sliding)
8- - - - - - - - - - Injection Guard (swinging)
9- - - - - - - - - - Hard Covers around Clamp and Injection unit
Switches
E1, E2, E3, E4 - - - Limit switch on Safety Gates
E9 - - - - - - - - - Limit switch on sliding injection guard (Nozzle Guard)
E10 - - - - - - - - Limit switch on Operator gate stop
E21 - - - - - - - - Limit switch on Moving Platen Dropbar mechanical interlock
E52 - - - - - - - - Limit switch on swinging injection guard

NOTE!

Do not operate machine unless all safety features are in place

and functioning properly. These safety features are typical of
an ENGEL machine but may vary with machine size and
options.

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5.3 ENGEL MACHINE SAFETY FEATURES (ES200 TOGGLE)

4
E10
8 8 6
E21 3 7 E9
E52

E4 E3
E2 1
2
E1
5

Legend - - -Description
1- - - - - - -Main Electrical Power Disconnect
2- - - - - - -Emergency Stop button
3- - - - - - -Mechanical Safety Device (Closing Protection)
4- - - - - - -Purge Guard
5- - - - - - -Hydraulic Interlock
6- - - - - - -Barrel Heatshield
7- - - - - - -Safety Gates (Operator and Non Operator)
8- - - - - - -Hard Covers around Clamp and Injection unit
Switches- - -
E1, E2,
E3, E4 - - - -Limit on Safety Gates
E9 - - - - - -Limit switch on sliding injection guard (Nozzle Guard)
E10 - - - - -Limit switch on Operator safety gate stop
E21 - - - - -Limit switch on Moving Platen Dropbar mechanical interlock
E52 - - - - -Limit switch on swinging injection guard

NOTE!

These safety features are typical of an ENGEL machine

but may vary with machine size and option.

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These protective features are built into the machine to protect personnel. The user is responsible
for each protective device being in good working order before the machine is placed in operation.
The user must maintain these safety features in working order.

Operational and maintenance personnel must be trained to recognize that variations in machine
configuration (i.e. vertical or horizontal clamp), machine size and age may result in changes to the
design and position of safety features and guards.

We very strongly recommend that the safety features are inspected at the beginning of each shift
and when a new mold is installed. A log should be kept detailing when and by whom the
inspections were performed.

MAIN DISCONNECT SWITCH

- Operation of this switch to open the electrical cabinet door, cuts power downstream of the main
disconnect switch.
- L1, L2, and L3 entering the cabinet may still be live.
- Check that operating the handle cuts power to machine.

EMERGENCY STOP BUTTON

- Pushing this switch in will cause a break in the electric motor circuit causing the motor to stop.
- Restart of the motor should not be possible until the button is released.
- Check that motor stops when button is pressed.

MECHANICAL SAFETY DEVICE

- Mechanically prevents clamp closure when operator side gate is open.
- Some designs require adjustment to suit various mold open strokes.
- Please refer to detailed directions elsewhere in this manual.
- Check that mechanism moves freely and is correctly adjusted.

PURGE GUARD
- Provides operator protection during purging.
- Activates limit switch E9 to prevent injection while guard is raised.
- Check that raised purge guard prevents carriage movement.
- ES 30/55 machines have a sliding guard which performs the duties of the purge guard. This
guard actuates E9 limit switch.

HYDRAULIC INTERLOCK
- Cuts the flow of hydraulic fluid to the clamp cylinder thereby preventing clamp closure.
- Check that hydraulic interlock arm pushed back stops clamp closure.

BARREL HEATSHIELD
- Provides operator protection from direct contact with heater bands.
- Check that shields are in place before operating.

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SAFETY GATE (OPERATOR SIDE)
- Provides protection from the moving clamp.
- Activates mechanical safety device, hydraulic interlock, limit switches E1 and E2.
- Check that opening gate activates appropriate devices and prevents clamp closure.

SAFETY GATE (NON-OPERATOR SIDE)

- Provides protection from the moving clamp.
- Activates limit switches E3 and E4 to stop motor.
- Check that opening this gate causes motor to stop.
- ES 30/55 with a single gate may not have switches E3 and E4.

COVER AROUND CLAMP ASSEMBLY

- Provides protection from the toggle mechanism while machine is in operation.
- Check that panels are securely fastened in position.

E10 LIMIT SWITCH ON

- Releasing the bar, to allow the operator side gate to be opened passed the moving platen for
access to the area behind the clamp, engages limit switch E10.
- The limit switch is in the Emergency stop circuit, when the limit switch is engaged the machine
is immobilized.

E21 LIMIT SWITCH ON MOVING PLATEN DROP-BAR MECHANICAL INTERLOCK

(This device is not installed on all machines)
- Check that clamp closure is prevented as soon as the bar is raised.
- Opening the operator safety gate will deactivate limit switch E21.
Digital input 28 will go low (0 Volts).
- Closing the operator safety gate will actuate limit switch E21.
Digital input 28 will go high (24Volts), indicating that the mechanical interlock has been
released.

E52 LIMIT SWITCH INDICATING INJECTION UNIT ALIGNMENT

(This switch is not installed on all machines)
- Rotation of the carriage, to permit barrel change, will actuate limit switch E52.
- On ES30/55 this switch is operated by movement of the swinging injection guard.
- Check that activation of E52 prevents injection.

8/10/02 7. SAFETY 395

 EC100 / CC100 - A03 OPERATOR:
5.4 MECHANICAL SAFETY DEVICES

NOTE!

There are two types of mechanical safety devices currently

used on ENGEL machines. Please make yourself aware of the
type used on your machine and of the adjustments required (if
any) for maximum protection.

5.4.1 MECHANICAL SAFETY TYPE 1

SAFETY ROD SAFETY ROD

MOVING
BASE
PLATE PLATEN

BRACKET
LATCH

LEVER

SHAFT ROLLER
A4600089

MECHANICAL SAFETY DEVICE AS VIEWED FROM ABOVE

1. When the front safety gate is opened the latch drops into a groove in the safety
rod thus preventing the clamp from closing.

2. As the front safety gate is closed the cam on the gate contacts the roller which
is attached through the lever and the shaft to the latch. This causes the latch to
be lifted away from the safety rod. The rod is then free to move through the base
plate and the clamp permitted to close.

3. This design requires no regular adjustment. However, it is essential to regularly

check that the latch moves freely as the safety gate is opened and closed. This
device must be kept clean and free from all debris.

396 7. SAFETY 8/10/02

 EC100 / CC100 - A03 OPERATOR:
5.4.2 MECHANICAL SAFETY DEVICE TYPE 2

This type of Mechanical Safety Bar is fixed to the toggle crosshead and moves through the
cylinder platen with each movement of the clamp. The latch and pneumatic actuator are mounted
on the back of the cylinder platen and are spring loaded into the latched position.

A failure of the compressed air supply will result in the Mechanical Safety Device being in the
locked position.

When the safety gate is opened, the cam mounted on the safety gate actuates the pneumatic
valve. These actions divert compressed air into the piston side of the pneumatic latch and closes
the latch onto the Mechanical Safety Device ratchet bar, preventing closure of the clamp.

Closing the safety gate de-activates the pneumatic valve that diverts air to the rod side of the
pneumatic latch and opens the latch, freeing the mechanical safety device and allowing the clamp
to close.

The Mechanical Safety Device can be overridden (mold opening only) with the keyswitch CORES
AND EJECTORS - MOTION / NO MOTION when switched into the MOTION position.

Solenoid S45 will energize and divert the flow of compressed air to the rod side of the pneumatic
actuator and also connect the piston side to atmosphere.

8/10/02 7. SAFETY 397

 EC100 / CC100 - A03 OPERATOR:
5.5 SAMPLE MACHINE SAFETY CHECKLIST

SAFETY CHECKLIST
YES NO
FUNCTION REMARKS
INIT. INIT.

1. DO LIMIT SWITCHES E3 & E4 ON

THE REAR DOOR STOP THE MOTOR ?

2. IS THE MECHANICAL SAFETY DEVICE

ADJUSTED CORRECTLY -DOES THE
STRIKE PLATE DROP FREELY ?

3. DOES THE HYDRAULIC INTERLOCK

STOP CLOSING OF THE PRESS ?

4. DO LIMIT SWITCHES E1 & E2 STOP

THE CLOSING OF THE CLAMP ?

5. DOES THE EMERGENCY STOP BUTTON

STOP THE MOTOR WHEN PRESSED ?

6. DOES AN OPEN GATE STOP CLAMP

FROM CLOSING ?

7. IS THE HEAT SHIELD OVER THE

BARREL INSTALLED ?

8. ARE THE HEAT CONTROL INSTRUMENTS

FUNCTIONING PROPERLY ?

9. ARE THERE ANY OIL OR WATER LEAKS ?

10. IS SAFETY GATE ALARM CIRCUIT

FUNCTIONAL ?

11. ARE ALL SAFETY WARNING LABELS

ATTACHED TO MACHINE ?

398 7. SAFETY 8/10/02

 EC100 / CC100 - A03 OPERATOR:
5.6 ENGEL ROTARY TABLE SAFETY FEATURES

EMERGENCY STOP

MECHANICAL HEAT SHIELD

CLOSING
SAFETY MAIN ELECTRICAL ISOLATOR

MFSI

LIGHT CURTAIN or PURGE SHIELD

PNEUMATIC
SAFETY PURGE GUARD
GATE

EMERGENCY STOP

NOTE!

These safety features are typical but may vary with

machine size and options.

8/10/02 7. SAFETY 399

 EC100 / CC100 - A03 OPERATOR:
5.6.1 ROTARY TABLE SAFETY FEATURES

These protective features are built into the machine to protect personnel. The user is responsible
for each protective device being in good working order before the machine is placed in operation.
The user must maintain these safety features in working order.

Operational and maintenance personnel must be trained to recognize that variations in machine
configuration (i.e. vertical or horizontal clamp), machine size and age may result in changes to the
design and position of safety features and guards.

We very strongly recommend that the safety features are inspected at the beginning of each shift
and when a new mold is installed. A log should be kept detailing when and by whom the
inspections were performed.

Main Disconnect Switch

• Operation of this switch to open the electrical cabinet door, cuts power downstream of
the main disconnect switch.
• L1, L2, and L3 entering the cabinet may still be live.
• Check that operating the handle cuts power to machine.

Emergency Stop Buttons

• Pushing any one of these switches in will cause a break in the electric motor circuit
causing the motor to stop.
• Restart of the motor should not be possible until the button is released.
• Check that motor stops when any one of these buttons is pressed.

Mechanical Safety Device

• Mechanically prevents clamp closure when the light curtain is interrupted.
• A spring causes the stop bar to be engaged when the light curtain is interrupted, when
the machine is in manual, or when pneumatic power is lost.
• A pneumatic cylinder disengages the stop bar when the clamp is being operated.
• A fault with the limit switch E21 (D128) monitoring this device would be indicated by a
"MECH.INTRLCK FAULT" error on the monitor.

Light Curtain
• Interruption of the light curtain will prevent clamp or ejector movements.
• In manual mode check that clamp and ejector movement are prevented when the light
curtain is being interrupted.
• Run a finger slowly down the edge of the light curtain and check that as each beam is
interrupted the "LIGHT CURTAIN HAZARD" warning light is illuminated.

400 7. SAFETY 8/10/02

 EC100 / CC100 - A03 OPERATOR:
Mold Flash Safety Interlock (MFSI)
• Provides operator protection during injection.
• Prevents injection if mold is not closed.
• Check that switch is made when mold halves are in contact and not before.
• With PDC (Purge Slide closed) input made and K (nozzle back) position reached to allow
for purging but with the Mold Flash Safety Interlock not made, check that manual
injection is prevented.

Purge Guard
• Provides operator protection during purging.
• De-activates limit switch E9 to prevent injection while guard is raised.
• Check that raised purge guard prevents carriage movement.

Purge Slide
• Provides operator protection during purging.
• Limit switch PDC (slide closed) must be made to allow purging.
• With slide out of position but Mold Flash Safety Interlock input made and position K
(nozzle back) reached check that manual injection is not possible.

Barrel Heatshield
• Provides operator protection from direct contact with heater bands.
• Check that shields are in place before operating.

Cover Around Clamp Assembly

• Provides protection from the toggle mechanism while machine is in operation.
• Check that opening either of the locking side panels stops the motor via limit switches E3
and E4.
• Check that the other fixed panels are securely fastened in position.

8/10/02 7. SAFETY 401

 EC100 / CC100 - A03 OPERATOR:
5.6.2 SAMPLE ROTARY MACHINE SAFETY CHECKLIST

ENGEL ROTARY SAFETY CHECKLIST

DATE: TIME: CHECKED BY: SIGNED:

FUNCTION YES NO REMARKS

1. DOES THE MAIN DISCONNECT SWITCH CUT

POWER TO THE MACHINE ?

2. DOES THE MOTOR STOP WHEN ANY ONE

OF THE EMERGENCY STOP BUTTONS IS
PRESSED ?

3. DOES AN INTERRUPTION OF THE LIGHT

CURTAIN PREVENT BOTH CLAMP AND
EJECTOR FUNCTIONS ?

4. IS INJECTION PREVENTED IF THE MOLD

IS NOT CLOSED ?

5. IS CARRIAGE MOVEMENT AND INJECTION

PREVENTED WITH RAISED PURGE GUARD ?

6. IS INJECTION PREVENTED IF THE PURGE

SLIDE IS NOT CLOSED ?

7. DOES THE MOTOR STOP WHEN EITHER OF

THE LOCKING CLAMP COVERS IS OPENED ?

8. ARE ALL COVERS SECURELY IN PLACE ?

9. IS THE BARREL HEATSHIELD IN PLACE ?

10. ARE THERE ANY OIL OR WATER LEAKS ?

11. ARE ANY WIRES DAMAGED OR ELECTRICAL

CONNECTIONS EXPOSED ?

12. ARE ALL SAFETY WARNING LABELS

ATTACHED TO MACHINE?

NOTE!

This is a sample checklist and intended as a guide only.

Certain machine options may require additions to, or

deletions from the list.

402 7. SAFETY 8/10/02

 EC100 / CC100 - A03 OPERATOR:
5.7 ENGEL SHUTTLE TABLE SAFETY FEATURES

B77 8

AS 5

E9
2
B77
AS
3

Legend - - -Description
1- - - - - - -Main Electrical Power Disconnect
2- - - - - - -Emergency Stop button
3- - - - - - -Mechanical Safety Device (Closing Protection)
4- - - - - - -Light Curtain
5- - - - - - -Front Safety Gate
6- - - - - - -Purge Guard
7- - - - - - -Heatshield over barrel
8- - - - - - -Hard Covers around Clamp and Injection unit
Switches- - -
E9 - - - - - -Limit switch on Purge Guard
B77 - - - - -Switch indicating mechanical safety engaged
AS - - - - - -Switch indicating front safety gate closed

NOTE!

These safety features are typical of an ENGEL machine

but may vary with machine size and option.

8/10/02 7. SAFETY 403

 EC100 / CC100 - A03 OPERATOR:
5.7.1 ENGEL SHUTTLE TABLE SAFETY FEATURES

These protective features are built into the machine to protect personnel. The user is responsible
for each protective device being in good working order before the machine is placed in operation.
The user must maintain these safety features in working order.
Operational and maintenance personnel must be trained to recognize that variations in machine
configuration (i.e. vertical or horizontal clamp), machine size and age may result in changes to the
design and position of safety features and guards.
We very strongly recommend that the safety features are inspected at the beginning of each shift
and when a new mold is installed. A log should be kept detailing when and by whom the
inspections were performed.

MAIN DISCONNECT SWITCH

• Operation of this switch to open the electrical cabinet door, cuts power downstream of
the 107 disconnect switch.
• L1, L2, and L3 entering the cabinet may still be live.
• Check that operating the handle cuts power to machine.

EMERGENCY STOP BUTTONS

• Pushing any one of these switches in will cause a break in the electric motor circuit
causing the motor to stop.
• Restart of the motor should not be possible until the button is released.
• Check that motor stops when any one of these buttons is pressed.

MECHANICAL SAFETY DEVICE

• Mechanically prevents clamp closure when the light curtain is interrupted.
• A spring causes the stop bar to be engaged when the light curtain is interrupted, when
the machine is in manual, and when pneumatic power is lost.
• A pneumatic cylinder disengages the stop bar when the clamp is being operated.
• A fault with the limit switch (B77) monitoring this device would be indicated by a
"MECH.INTRLCK FAULT" error on the monitor.

LIGHT CURTAIN
• Interruption of the light curtain will prevent clamp or ejector movements.
• In manual mode check that clamp and ejector movement are prevented when the light
curtain is being interrupted.
• Run a finger slowly down the edge of the light curtain and check that as each beam is
interrupted the "LIGHT CURTAIN HAZARD" warning light is illuminated.

FRONT SAFETY GATE

• Provides operator protection during injection.
• De-activates limit switch AS to prevent injection while gate is open.
• Check that injection is prevented when gate is opened. (For the purpose of this check the
gate must be open enough to release limit switch AS but not so far as to interrupt the light
curtain).

404 7. SAFETY 8/10/02

 EC100 / CC100 - A03 OPERATOR:
PURGE GUARD
• Provides operator protection during purging.
• De-activates limit switch E9 to prevent injection while guard is raised.
• Check that raised purge guard prevents carriage movement.

BARREL HEATSHIELD
• Provides operator protection from direct contact with heater bands.
• Check that shields are in place before operating.

COVER AROUND CLAMP ASSEMBLY

• Provides protection from the toggle mechanism while machine is in operation.
• Check that all fixed panels are securely fastened in position.

8/10/02 7. SAFETY 405

 EC100 / CC100 - A03 OPERATOR:
5.7.2 SAMPLE SHUTTLE MACHINE SAFETY CHECKLIST

ENGEL SHUTTLE SAFETY CHECKLIST

DATE: TIME: CHECKED BY: SIGNED:

FUNCTION YES NO REMARKS

1. DOES THE MAIN DISCONNECT SWITCH CUT

POWER TO THE MACHINE?

2. DOES THE MOTOR STOP WHEN ANY ONE

OF THE EMERGENCY STOP BUTTONS IS
PRESSED ?

3. DOES AN INTERRUPTION OF THE LIGHT

CURTAIN PREVENT BOTH CLAMP AND
EJECTOR FUNCTIONS ?

4. IS INJECTION PREVENTED IF THE FRONT

SAFETY GATE IS OPEN ?

5. IS CARRIAGE MOVEMENT AND INJECTION

PREVENTED WITH RAISED PURGE GUARD ?

6. IS INJECTION PREVENTED IF THE PURGE

SLIDE IS NOT CLOSED ?

7. ARE ALL COVERS SECURELY IN PLACE ?

8. IS THE BARREL HEATSHIELD IN PLACE ?

9. ARE THERE ANY OIL OR WATER LEAKS ?

10. ARE ANY WIRES DAMAGED OR

ELECTRICAL CONNECTIONS EXPOSED ?

11. ARE ALL SAFETY WARNING LABELS

ATTACHED TO MACHINE ?

NOTE!

This is a sample checklist and intended as a guide only.

Certain machine options may require additions to, or deletions

from the list.

406 7. SAFETY 8/10/02

 EC100 / CC100 - A03 OPERATOR:
5.8 SAFETY INSTRUCTION PLATES AND LABELS

Safety instruction plates are fastened to your machine at strategic locations. Under no
circumstances shall they be removed. They must be kept clean and readable. Operating and
maintenance personnel must understand each safety instruction before they are permitted to
work on the machine.

This section includes "DANGER", "WARNING" and "CAUTION" signs used on ENGEL
machines.

These signs are used to indicate a potential hazard caused by the improper use, adjustment,
maintenance, or removal of a safety device or guard.

The following pages show samples of the signs and the positions on the machine where they may
be found.

8/10/02 7. SAFETY 407

 EC100 / CC100 - A03 OPERATOR:
5.9 SAFETY INSTRUCTION PLATES AND LABELS

Safety instruction plates are fastened to your machine at strategic locations. Under no
circumstances will they be removed. They must be kept clean and readable. Operating and
maintenance personnel must understand each safety instruction before they are permitted to
work on the machine.
This section includes "DANGER", "WARNING" and "CAUTION" signs used on ENGEL machines.
These signs are used to indicate a potential hazard caused by the improper use, adjustment,
maintenance, or removal of a safety device or guard.
The following pages show samples of the signs and where on the machine they may be found.

8 5 7
2
9 6 3
1

4
3

F1 F2 F3 F4 F5 F6 F7 F8

7 8 9 ENT
4 5 6
1 2 3
. !
- 0 CLE

A !

ON
OFF PR

CONT MO BARREL MO
VOL O OMOLD O OVER

CORE S BARREL HEAT

MOLD
POWER
HEATHO PPER
O I OF OF
AU OP AU UNL

EJECTOR
MOLD CLA MPING INJECTION
RETR SEC FW RELE INJE FE

CLAM
MODE
P CONTROL
SEL ECT VO LTAGE CARRIAGE
OP CLO MAN MOTORO FW RETR

MOLD HEIGHT
MODECONTROL
SEL ECT VO LTAGE
MOTOR STO
EMERGENCY
P
INCR DECR MAN OF ST

1
2 11 1 10 12 9
2
FIND # DESCRIPTION DRAWING NUMBER
1 HIGH VOLTAGE C3401.0301
2 CRUSHING INJURY C3401.0307
3 HIGH SPEED MOVING PARTS C3401.0302
4 HIGH PRESSURE FLUID C3401.0306
5 MOLTEN MATERIAL C3401.0317
6 HOT AREA C3401.0312
7 ROTATING SCREW C3401.0318
8 COMPLEX MACHINE C3401.0315
9 FILTER CLEANING EC98.723.6354B
10 FILL PUMP-STARTUP EC98.723.6356B
11 STATIC SENSITIVE EC98.723.6370B
12 CSA DISCLAMER EC98.723.6355B

408 7. SAFETY 8/10/02

 EC100 / CC100 - A03 OPERATOR:

NOTE!

These warning labels are typical of an ENGEL machine but

may vary with machine size and options.
HIGH VOLTAGE

DANGER
High voltage.
Before servicing turn off, lock out/
tag out main power disconnect.
Do not modify electric or
hydraulic circuits unless
authorized by manufacturer.
Earth ground machine and electri-
cal cabinet before turning
on power. failure to comply can
cause shock, burns or death.

HIGH SPEED MOVING PARTS

DANGER
High speed moving parts.
Do not operate with gates /
guards removed or open.
DO NOT REACH AROUND,
UNDER, OVER OR THROUGH
GATE / GUARDS
while machine is operating.
can cause crushing injury
or death.

8/10/02 7. SAFETY 409

 EC100 / CC100 - A03 OPERATOR:
HOT AREA

DANGER
High voltage.
Hot surface.
Turn off and lock out
main power disconnect,
allow to cool before
servicing.
Can cause shock,
severe burns or death.

MOLTEN MATERIAL

WARNING
High pressure
molten material.
Stand clear and wear
protective gear when
purging and/or servicing
injection system.
Can cause severe burns.

WARNING
MOLTEN PLASTIC IS EXTREMELY HOT AND
WILL CAUSE SEVERE BURNS TO HUMAN FLESH.
ALWAYS WEAR A FACESHIELD AND PROTECTIVE CLOTHING WHEN REMOVING
BLOCKAGES IN INJECTION UNITS, THE MOLTEN PLASTIC MAY BE UNDER PRESSURE.
UNLESS YOU ARE WEARING PROTECTIVE CLOTHING AND A FACESHIELD,
NEVER LOOK DIRECTLY INTO AN ORIFICE (NOZZLE OR FEEDTHROAT)
THAT MAY DISCHARGE MOLTEN PLASTIC UNDER PRESSURE.

410 7. SAFETY 8/10/02

 EC100 / CC100 - A03 OPERATOR:
ROTATING SCREW

WARNING
Rotating screw.
Do not operate with
hopper removed or put
hands or feet into opening.
Serious bodily injury
can occur.

CRUSHING INJURY

CAUTION
Crushing injury.
High speed moving parts.
When operator gate is open and
keyswitch “Core and Ejector
Motion” is turned to motion, do not
reach into unguarded mold area
where pinch points are created.

Consult supervisor for instructions.

Failure to follow safety procedures
can cause injury.

8/10/02 7. SAFETY 411

 EC100 / CC100 - A03 OPERATOR:
COMPLEX MACHINE

CAUTION
Complex machine with hazards.
Do not operate machine unless trained,
read and understand the Maintenance/
Operator manual(s). Prior to start-up,
test safety devices per instruction man-
ual. Do not operate machine unless
interlocks/safety devices are in place and
function properly. Do not modify machine
unless authorized by manufacturer.
Failure to follow instructions could
result in injury.

412 7. SAFETY 8/10/02

 EC100 / CC100 - A03 OPERATOR:
FILTER CLEANING

FILL PUMP

8/10/02 7. SAFETY 413

 EC100 / CC100 - A03 OPERATOR:
CSA DISCLAIMER

414 7. SAFETY 8/10/02

 EC100 / CC100 - A03 OPERATOR:
5.10 MOLDING SAFETY RULES

5. Only competent persons with suitable training and a knowledge of its safety devices should
operate the machine.
6. A thorough check of all safety devices should be made before the machine is operated.
7. If any safety equipment is missing, damaged or inoperative the machine may not be
operated until the fault is rectified.
8. Any hazard, regardless of how minor, should be reported to the supervisor.
9. The floor and work area around the machine must be kept clean and clear of oil and water.
10. Exposed electrical connections, bare wires, oil or water leaks, excessive component wear
and other maintenance problems must be reported to the supervisor.
11. Only those persons trained and authorized should change machine settings or attempt to
repair the machine.
12. Use safety devices as provided and do not modify, bypass or make inoperative any such
safety device or equipment.
13. Do not engage in shouting or horseplay.
14. Do not climb on the machine.
15. Use proper ladders or gantries for manual loading of hoppers.
16. Be careful to not obstruct access to fire exits, fire extinguishers, or other emergency
equipment.
17. Do not wear loose clothing, jewellery, or any other article which may become entangled in
the machine. Keep long hair restrained.
18. Always wear the appropriate personal protective equipment for the job. Be aware that hot
plastic can melt through some safety shoes.
19. Set up and run the machine within manufacturers' recommended parameters.
20. Make sure that correct fluid levels and temperatures are maintained.
21. Stay alert while working with powerful molding machines.

8/10/02 7. SAFETY 415

 EC100 / CC100 - A03 OPERATOR:
5.11 PARTS HANDLING

Gluing

Gluing requires local ventilation to decrease the hazard of solvent inhalation. Suitable protective
equipment (i.e. gloves) should be used to minimize skin contact. Where possible this operation
should be isolated.

High Frequency Welding

The high frequency sound emitted during this operation may cause hearing loss. Personal
hearing protection should be worn and this area should be adequately soundproofed and isolated.

Robots

Robots are most commonly used for removal of the parts from molds and some assembly. In
these applications their range of movement may be quite limited. However, due to their speed and
power, care must be exercised when working in close proximity to these machines.

Do not assume that because the robot is stationary for a period of time that it is shut down and
therefore safe to approach. A section of the robot program requiring no activity may be followed,
without warning, by a section demanding rapid, wide ranging movements.

WARNING!

DO NOT ENTER THE WORK ENVELOPE OF A ROBOT

UNLESS IT IS SHUT DOWN.

Conveyors

The moving parts of the conveyor itself should be suitably guarded to exclude the danger of parts
of the body or clothes becoming trapped. Guards must also be placed along the length of the
conveyor to prevent objects from falling off it. When working near conveyors safety hats and
shoes should be worn. No person should ride on a conveyor. Emergency stop buttons should be
provided along the length of the conveyor.

416 7. SAFETY 8/10/02

 EC100 / CC100 - A03 OPERATOR:
5.12 CHEMICAL HAZARDS

A great many chemicals are used or produced as by-products in injection molding. Some of these
chemicals are considered to be toxic (can cause a harmful effect). However the toxic effects, and
associated health risks of these chemicals, depend upon exposure time, concentration, method
of entry into the body and an individuals' susceptibility.

Knowledge of the chemicals being used or produced is the key to avoiding harmful exposure. This
knowledge may be obtained from the "Material Safety Data Sheets", supplied by the
manufacturer, or it may have to be obtained from testing conducted within the plant. Once the
hazards are identified then suitable control measures to limit exposure must be implemented.

There are four main areas of concern regarding chemicals in injection molding.
2. THERMAL DEGRADATION is the incomplete combustion of materials
containing carbon. It may occur during machine cycle interruption, setup, or
barrel purges.
3. SOLVENTS which are commonly used in plastic welding compounds and as
degreasing agents.
4. RESIDUAL MONOMER is unreacted monomer produced during processing of
resins.
5. ADDITIVES are commonly found in resins. Of particular concern are the metals
in pigment additives.

In all cases exposure should be limited by engineering controls, industrial hygiene practices, work
practices and personal protective equipment.

8/10/02 7. SAFETY 417

 EC100 / CC100 - A03 OPERATOR:

418 7. SAFETY 8/10/02

 EC100 / CC100 - A03 OPERATOR:

8. APPENDIX

1 ENGEL ABBREVIATIONS

1.1 VELOCITIES
Variable Description

V1 Clamp closing speed A to W3

V2 Clamp closing speed W3 to W1
V3 Clamp closing speed W1 to G2
V4A-E 5 Mold Protection speeds
V6 Clamp opening speed G2 to W4
V7 Clamp opening speed W4 to W2
V8 Clamp opening speed W2 to A
V9 Nozzle forward speed K to J1
V10 Nozzle forward speed J1 to J
V11 Sprue break speed (J to K)
V12 1st injection speed
V13 2nd injection speed
V14 3rd injection speed
V15 4th injection speed
V16 5th injection speed
V17 6th injection speed
V18 7th injection speed
V19 8th injection speed
V20 9th injection speed
V21 10th injection speed
V23 Intrusion speed
V24 Decompression speed
V25 Ejector forward speed
V26 Ejector retract speed
V30 Speed (core 1 moving out)
V31 Speed (core 1 moving in)
V32 Speed (core 2 moving out)
V33 Speed (core 2 moving in)
V34 Speed (core 3 moving out)
V35 Speed (core 3 moving in)
VP2 1st mold protection speed
VP2A 2nd mold protection speed
DZx Actual screw feed speed (rpm)

10/10/02 8. APPENDIX 419

 EC100 / CC100 - A03 OPERATOR:
1.2 PRESSURES
Variable Description

P1 Clamping pressure
P2 1st mold protection pressure
P2A 2nd mold protection pressure
P2A-E 5 Mold protection pressures
P5 Nozzle forward pressure
P5b Holding (nozzle) pressure after injection
P6 Injection boost pressure
P7 1st injection hold pressure
P8 2nd injection hold pressure
P9 3rd injection hold pressure
P10 4th injection hold pressure,
P11 5th injection hold pressure
P12 6th injection hold pressure
P13 7th injection hold pressure
P14 8th injection hold pressure
P15 9th injection hold pressure
P16 10th injection hold pressure
P17 1st back pressure
P18 2nd back pressure
P19 3rd back pressure
P20 4th back pressure
P21 5th back pressure
P25 Ejector forward pressure
P26 Ejector retract pressure
P30 Pressure core 1 out
P31 Pressure core 1 in
P32 Pressure core 2 out
P33 Pressure core 2 in
P34 Pressure core 3 out
P35 Pressure core 3 in
PH Hydraulic pressure cut-off point (boost to hold)
PHu Hydraulic pressure at cut-off
PHs Peak value of injection pressure
PVs Peak value of injection pressure (this abbrev. sometimes used)
PH3a Actual melt pressure,(special equipment)
PH3x Peak melt pressure, (special equipment)
PHx Hydraulic pressure actual value
PF Cavity pressure cut-off point
PFu Cavity pressure at cut-off
PFs Peak value of cavity pressure
PVs Peak Value of cavity pressure (this abbrev. sometimes used)
PFx Cavity pressure actual value
PNs Injection hold peak pressure
PSs Back pressure peak value
PSx Back pressure actual value

420 8. APPENDIX 10/10/02

 EC100 / CC100 - A03 OPERATOR:
1.3 TIMERS
Variable Description

Z1 Injection boost time

Z2 Injection hold time
Z3 Screw feed delay time
Z4 Cooling time
Z4x Elapsed cooling time (also appears as 'ACT')
Z5 Recycle time (time mold is open after ejection)
Z5a Nozzle contact pressure time (delay before injection)
Z6 Sprue break delay tim
ZA Forward dwell (ejector)
ZA1 Moving out time (core 1)
ZA2 Moving out time (core 2)
ZA3 Moving out time (core 3)
ZAV Forward delay (ejector)
ZD Screw feed time limit (A01) (Max - Min on A02)
ZDx Elapsed feeding time (screw)
ZE1 Moving in time (core 1)
ZE2 Moving in time (core 2)
ZE3 Moving in time (core 3)
ZF Mold protection time set value
ZFx Mold protection time actual value
ZIN Intrusion time
ZKV Toggle lever lockup time (A01)
ZL1 Air blowing time (air valve 1)
ZLV1 Air blowing delay time (air valve 1)
ZL2 Air blowing time (air valve 2)
ZLV2 Air blowing delay time (air valve 2)
ZS0 Minimum injection time limit (A01) Minimum on A02
ZS1 Maximum injection time limit (A01) Maximum on Ao2
ZSx Elapsed injection boost time
ZU1 Monitoring time (core 1 in)
ZU2 Monitoring time (core 2 in)
ZU3 Monitoring time (core 3 in)
ZUa1 Monitoring time (core 1 out)
ZUa2 Monitoring time (core 2 out)
ZUa3 Monitoring time (core 3 out)
ZUs Time taken for previous cycle
ZUx Elapsed time of the current cycle (begins at start of mold close)

10/10/02 8. APPENDIX 421

 EC100 / CC100 - A03 OPERATOR:
1.4 POSITIONS

Variable Description

A Mold open position

A1 Mold position to start ejector
A2 Start air blowing 1
A3 Start air blowing 2
AH Minimum opening stroke robot
B Toggle lever locked
B1 Start toggle lock slowdown (A01)
B8 Move in before tonnage (cores)
BG2 End mold protection pressure (A01)
C1 Set screw feed stroke
C1* Corrected feed stroke (corrected by the cushion program)
C2 Decompress after feed
C2* Decompression stop (corrected feed stroke plus decompression)
C3 Stroke cut-off point
C3b Hydraulic pressure cut-off window
C3d Cut-off window (screw position before parallel cut-off)
C3u Screw position at cut-off
C4 Decompress before feed
CP Cushion length set value
CPx Actual cushion length
G1 Start of mold protection
G1A Start of 2nd mold protection (A01)
G2 Start clamping pressure (toggle lever position)
G2f Stop mold protection (mold position)
J Nozzle contact position
J1 Start 2nd nozzle forward speed
K Sprue break stroke
K1 Nozzle fully retracted
KA1 Monitor position for core out (1)
KA2 Monitor position for core out (2)
KA3 Monitor position for core out (3)
KD1E Valve off after movement (core 1)
KD2E Valve off after movement (core 2)
KD3E Valve off after movement (core 3)
KE1 Monitor position for core in (1)
KE2 Monitor position for core in (2)
KE3 Monitor position for core in (3)
KH1A Using auxiliary power source (core 1 out)
KH2A Using auxiliary power source (core 2 out)
KH3A Using auxiliary power source (core 3 out)

422 8. APPENDIX 10/10/02

 EC100 / CC100 - A03 OPERATOR:
1.5 POSITIONS (CONTINUED)
Variable Description

KH1E Using auxiliary power source (core 1 in)

KH2E Using auxiliary power source (core 2 in)
KH3E Using auxiliary power source (core 3 in)
KO1 Mold position for core out (1)
KO2 Mold position for core out (2)
KO3 Mold position for core out (3)
KP1A Priority for moving out (core 1)
KP2A Priority for moving out (core 2)
KP3A Priority for moving out (core 30
KP1E Priority for moving in (core 1)
KP2E Priority for moving in (core 2)
KP3E Priority for moving in (core 3)
KS1 Mold position for core in (1)
KS2 Mold position for core in (2)
KS3 Mold position for core in (3)
KT1A Time dependent (core 1 out)
KT2A Time dependent (core 2 out)
KT3A Time dependent (core 3 out)
KT1E Time dependent (core 1 in)
KT2E Time dependent (core 2 in)
KT3E Time dependent (core 3 in)
KV1A Before mold opening (core 1 out)
KV2A Before mold opening (core 2 out)
KV3A Before mold opening (core 3 out)
KZ1A While mold is moving (core 1 out)
KZ2A While mold is moving (core 2 out)
KZ3A While mold is moving (core 3 out)
KZ1E While mold is moving (core 1 in)
KZ2E While mold is moving (core 2 in)
KZ3E While mold is moving (core 3 in)
L Retract position (ejector)
L1 Forward position (ejector)
L2 Shake position (ejector)
SAx Actual ejector position
SDx Actual nozzle position
SFs Mold opening stroke (stored), see Program
SFx Actual mold position
SKx Actual toggle position
SSx Actual screw position
W1 Mold position at start of 3rd closing speed (between W3 and G1)
W2 Mold position at start of 3rd opening speed (between W4 and A)
W3 Mold position at start of 2nd closing speed (between A and W1)
W4 Mold position at start of 2nd opening speed (between A and W2)

10/10/02 8. APPENDIX 423

 EC100 / CC100 - A03 OPERATOR:
1.6 MISC.
Variable Description

AZ Ejector counter (number of times ejector comes forward)

FA Number of cavities
FZx Flow number (Microplast/Microflow)
H1x Temperature - heat zone 1
H2x Temperature - heat zone 2 ....etc.
KRZ Shake as ejector (cores - number of times)
Min Time (minutes)
OelTx Oil temperature actual value
SKs Clamping force stored
SKs1 Clamping force stored (tiebar 1)
SKs2 Clamping force stored (tiebar 2) .....up to 4
SKx1 Clamping force current (tiebar 1)
SKx2 Clamping force current (tiebar 2) .....up to 4
Std Time (hours)
StZ Good parts required (set value
StZx Good parts required (actual value)
SZ Total cycles required
SZx Total cycles produced (actual value - excluding rejects)
VSchx Mold closing speed (actual value)
ZSZ Number of cycles interval between toggle lubrications

424 8. APPENDIX 10/10/02

 EC100 / CC100 - A03 OPERATOR:

2 MOLDING TROUBLESHOOTING
Try the simplest procedure first.

A. No longer able to hold a material cushion or the shot size is increasing:

1. Check the check ring to see if it is cracked, broken or something is holding it open.
2. Check the barrel/cylinder and screw for "WEAR".

B. The nozzle is drooling:

4. Check nozzle pyrometer for overriding.
5. Reduce nozzle heat 10 degrees at a time.
6. Make sure that after the screw retracts there is time for decompression.

C. Material leakage between the nozzle and mold:

1. Check that the nozzle is flush against the sprue bushing.
2. Check that the radius of the nozzle tip is slightly less than the sprue bushing.
3. Check the nozzle and sprue bushing for chips or cracks.

D. The screw does not feed:

1. Check and make sure the nozzle is not clogged.
2. Check the hopper and feed throat to make sure that material has not bridged.
3. Check for plasticized material at the rear of the feed screw.
Make sure the watercooling is on. Lower the rear zone heat.
4. Decrease back pressure.

10/10/02 8. APPENDIX 425

 EC100 / CC100 - A03 OPERATOR:
E. Short shots:
1. Check for insufficient material feed.
2. Increase injection pressure.
3. Increase back pressure (especially when running regrind).
4. Increase melt temperature.
5. Increase nozzle temperature.
6. Increase injection speed.
7. Increase mold temperature.
8. Enlarge mold vents-check for clogging.
9. Enlarge gates.
10. Enlarge sprue.
11. Check runner system geometry.
12. Check the Check Ring.
13. Check barrel/cylinder and screw for "WEAR".

F Flashing:
1. Decrease injection pressure.
2. Decrease injection speed.
3. Check mold to make sure no molded material is on mold surface.
4. Increase clamp pressure
5. Decrease mold temperature.
6. Decrease melt temperature.
7. Check for worn mold parts or mismatched parting line.
8. Check runner and/or gate geometry.
9. Check for hydraulic leak or toggle wear in the clamp system.
10. Check projected area of part. The machine may not be large enough.

G Bubbles in the molded part:

1. Material not dried long enough.
2. Increase back pressure.

426 8. APPENDIX 10/10/02

 EC100 / CC100 - A03 OPERATOR:
H Splay or streak marks on the part:
1. Material not dried long enough.
2. Decrease melt temperature.
3. Decrease screw speed.
4. Decrease injection speed.
5. Lengthen cooling time.
6. Check for excessive regrind.
7. Check for contaminated material.
8. Check the barrel/cylinder heating system for dead or hot spots.
9. Check for excessive material holdup time, shot size versus capacity.
10. Check barrel/cylinder and screw for "WEAR".

I. Weld or flow lines in molded part:

1. Increase the mold temperature.
2. Increase injection speed.
3. Increase melt temperature.
4. Increase sprue.
5. Check for poor venting.
6. Vent the runner system.
7. Use fan type gate.
8. Change the location of the gate.

J. Sinks:
1. Check the material feed.
2. Increase holding pressure time.
3. Increase nozzle temperature.
4. Decrease mold temperature.
5. Increase injection speed.
6. Increase size of gates.
7. Check mold for balanced filling.
8. Check check ring.
9. Check barrel/cylinder and screw for "WEAR".

10/10/02 8. APPENDIX 427

 EC100 / CC100 - A03 OPERATOR:
K Smokey effect in clear parts:
1. Check nozzle temperature.
2. Check the barrel/cylinder heating system for dead or hot spots.
3. Check for material contamination.
4. Check barrel/cylinder and screw for "WEAR".

L. Parts stick in cavity:

1. Check for undercuts.
2. Decrease injection pressure.
3. Decrease injection holdtime.
4. Decrease injection speed.
5. Polish cavity.
6. Add undercut to core.
7. Raise temperature on back half of mold.
8. Use mold release.

M. Parts stick on core:

1. Check for undercuts.
2. Polish mold and break corners.
3. Decrease injection pressure.
4. Decrease injection holdtime.
5. Raise temperature on front half of mold.
6. Use mold release.

N. Parts burning:
1. Check for adequate venting.
2. Polish vents to make sure they are not clogging.
3. Decrease melt temperature.
4. Increase gate size.
5. Check barrel/cylinder and screw for "WEAR"/

428 8. APPENDIX 10/10/02

 EC100 / CC100 - A03 OPERATOR:
O. Laminations:
1. Check material for contamination.
2. Increase back pressure (especially if running regrind).
3. Increase melt temperature.
4. Increase screw speed.
5. Check material for dryness.
6. Increase size of gates.

P. Parts warped or distorted:

1. Increase injection hold time.
2. Increase overall cycle time.
3. Decrease melt temperature.

4. Decrease mold temperature.

5. Add rips to part of possible.
6. Check part geometry.
7. Use different mold temperature on each half of the mold.
8. Raise mold temperature.
9. Check ejector system for even removal.
10. Use cooling fixture.
11. Check barrel/cylinder and screw for "WEAR".

10/10/02 8. APPENDIX 429

 EC100 / CC100 - A03 OPERATOR:
REVISION LIST

DATE NATURE OF REVISION ORIGINAL REVISED

PAGE PAGE
00/3/01 ISSUE
00/8/23 Added information on E10 limit switch 386 - 389 386 - 389
00/9/28 Revise information on Autoprotect feature 48 - 53 48 - 54
00/11/29 Revised information on oil preheating 255 255
01/02/07 Added more detail on the “Ghost shift” feature 251 251
01/02/07 Added more information on C3b 108 108
01/04/10 Added note: A reject cycle does not affect the “remaining” data on 229 229
the ‘Production Information” screen page.
01/04/10 Added note: Oil temperature settings for Bosch and Rexroth pumps 252 252
01/05/24 Complex machine - personal injury hazard warning Front Front
01/05/24 Added warning concerning working in situations where hot plastic 406 406
material may be a hazard to personnel
01/06/11 Revised text regarding flownumber & pressure correction tolerances 289 - 291 289 - 291
01/08/24 Micrograph Analyzer - corrected info on trigger and actual values 266 - 268 266 - 268
01/08/24 Actual value parameter list added for use with Micrograph anayzer 426 - 438
01/08/24 QDS - Normal distribution and Process capability information 141 - 164 141 - 164
01/08/24 Revised “Ebias error stop” error message description 328 328
01/08/24 Revised the COPY function description for coping between devices 198 - 199 198 - 199
02/10/08 Added IBM style keyboard functions 8
02/10/08 Removed actual value listing from chapter 8 - not valid 426 - 438

430 8. APPENDIX 10/10/02