07.02 small one in English op2228 new user manue bytiml
Contents
1. eee eee eee Page 37 17 1 3 If you can not increase it up to 110 bar Dy 1 Page 3 72 Speed adjustment UE Page 38 17 21 Group DECSSUEe aeaea aaia Page 38 17 2 2 Make temperatures are ready eese en teta eee eV ea Eee ease Ee Vae EHE euo ee EN NER ES Page 38 17 2 3 Inform us alter adjustment what Is oerte pte ra eae ee eterne ues Page 38 18 CC3500 0P2228 CONNECTION PLAN e ierra rh thv uoa Deua raa ve paa Prae aes Page 39 19 6400010P2228 ONNRCTION Page 50 20 IMPORTANT DIMENSION FOR MECHANICAL INSTALLATION Page 62 20 T installation of P2228 icai e ey Ene Page 62 20 2 Istallation 3500 aiii i it FERE NC ER PER ERE REESE PIE FERRE OE ODER ENSE IEEE EMI Page 63 20 5 Installation or CC 4000 iioi b e S ev PARE be eo SS erede Page 64 20 0 c Page 65 2 5 Installation of Relay GI Page 65 IV lt SRN REN ON SS INJECTION MOULDING MACHINE CONTROL SYSTEM BY OP2228 OP2228 is a man machine interface to use with controller CC3500 or CC4000 P2. I Ejector forward DO 14 Ejector backward DO 1 5 Feeding DO 1 6 Injection DO 1 7 Suck back DO 2 0 forward DO 2 1 ay 1 backward DO 2 2 1 dts n Jf 2 core forward DO23 2 5 45 Bil 2 core backward nO 2 4 n Alarm lamp DO 2 5 SERA Mould high adjust forward DO 2 6 high adjust backward DO 2 7 FEE S Digital outputs of CC3500 5 L CC3300 0P2228b connection Tm 24 EN Eas ADEA MEN 2 ALARM LAMP Max2A Itc1 rr HE weber 4 ee eee ERR LS Bevasion Ur ay L N N N N E 1 Relay 220 C de L Heater lor Contactor ELI C ct ni 2 Heater DO Fa AoA 12 Be ku RES ESTNE LITRO C X Heater DO X27 5 4 Heater DO 3 3 14 04 Fa 5 Andes Focal 15 lt po Do o Fa 3 lj L6 x IX 15 Eg T Pump Motor Delti amp Normal DO 3
3. H x 7 33 Clamp locked Clamp Locked SW installed on toggle mechanism uc ERIT TUSCE DI 3 44 height adjustment Height adjustment position pulses Ses en 2 C C a pi es Me UR FLY s eh HE Hydraulic Filter is dirty Ld DI Hydraulic Filter dirty switch sl Hes ABS SE A 4 BTE GERE SIP KR RJ DI36 product fallen down Photocell instelled under mould on the way product go oul PEE E T3 DI 3 7 Screw RPM counter oe Proximity switch on screw ART TT p CC4000 op2228 connection dida 8 ds LS Revision lt 4000 Digital Inputs CC400035 fr ke Mg itle Pagei D2ifthis connection is done 75 T JE SE XJ e 24 Another switch for input 15 not necessity a 014 0 Front gate back switch is free BET TIG TES s HE E S 2 page 1 23 n 41 2 Emergency Stop P2 2 42 Beserve erictical position for hydraulic clamp qaum 2143 Reservel Auxiliary piston out S Re cive Api piston in g TS DI4 5 Motor temperature is high idit PE Thermic switch on motor Lies 1 1146 Lubricati
4. aded reed dee Page 34 T H 35 16 External PD3300 Proportional valve adjustmennt eee ecce eee eee e eee eene Page 36 Pressure Page 36 16 1 1 Choose Machine parameters page from Page 25 16 1 2 Speed ad justme eoe EE Page 36 16 1 5 FIRE Ev EUR Page 36 16 2 Spect adus inen estesse et E Ion rb cii hen sni Page 37 16 2 Set Group pEGCSSUEE ioo e eror e el aser vende p a didici Page 37 16 2 2 Make temperatilres are Page 37 16 2 3 Inform us after adjustment what is eee e LLL ee eee eee eee e eese eee es eee Page 37 I6 5 Mechanical adq stimielit R Page 37 17 CC4000PD Proportional valve adjustment eee e eere eee ee e eee ee eee e eee eeons Page 37 I7 LPressure ad ustmehl oido eie eve iie eto EQ eee eve aiite ii ee tob e eode Page 37 17 1 1 Choose Machine parameters page from 1 Page 37 17 1 2 Usually first channel on CC4000PD is for pressure
5. 1 Cuonmswyor lobor NW Hk Tak ii 2228 cone Ken page Viie om LL 61 20 IMPORTANT DIMENSION FOR MECHANICAL INSTALLATION 20 1 Installation of OP2228 mo fF Front view and installation screw position _ ERMA 177mm EE siu Neccesity deepness em behind of operator interface 62 20 2 Installation of CC3500 Up view installation screw position ti p Pe zou 49mm 120mm Neccesity space of cable installation 28 E Ei 63 20 3 Installation of CC4000 292 Up view and installation screw position IE rip I SEDE 3mm 435mm Neccesity space of cable installation f 28 5c SE EI ARE 64 20 4 Installation of PD3000 214mm 38mm Up vi d installati i Side view p view Installation screw position Suo BE EXE E 20 5 Installation of Relay card 150mm LET TIT ili dd 855843 md 1 m z unugg I EI 65
6. d ul z FAPROTEDCCISDU Supply voltage coming from controller Page 2 D3 JC FEL HAs EH AS Injection 23 38 Screw literally forward is mechanically zero pomt kt zh Hr LSS 0 E Carriage jjs Carriage literally backward is mechanically zero point BS DER UE Ejector Ejector backward is mechanically zero point CLS BUS BL Clamp fij Clamp toggle locked ts mechanically zero point FE BET DT LB SE xx lt Amd H AIN 1 Injection AIN 4 Clamp CC3500 OP2228b connection plan Eu Hh EE AIN 2 Carriage Bedllim2 5 Ejector Fe AIN 5 Reserve HS PH H Analog Inputs of CC3500 CC35004 itil 98 KE E ER em Pr pf ECT Enable inputs active when While ert MEC odd pressure uy I by min Eg ri Current Liza ix PHETE 88 Vk kr ele lo shows D Sei I mix porri PD3300 UN Proportional Valve Driver T 3300 VERS CET oh p
7. ALS M Ist Core IN SW AT st Core is forward ME 3 DI 2 1 oa lst Core is backward Ist Core OUT SW s BEA 531 Tid Core is forward 2nd Core IN SW 255 flot ATE 27 23 7 2nd Core ts backward 2nd Core OUT SW 2 jl HU T iE BER Inl ni 0124 _ Ejector is forward Ejector forward SW TEE 25 In HITS SER RR fi C Ejector 15 backward Ejector backward SW HESH E F 4 Ae 15 Carriage is forward Carriage forward W Pis 7 In RET lel hs Carriage is backward Carriage backward SW If machine 15 equipped with x ju iG FRE position transducer those sw C4000 Digital Inputs are not in use T Fei ae f CCADOO HOP2223 connection plan CSAS tci 0878 eee de Lii Wy bh 4A ERR Revisioni L1 DI 3 0 Gates art open TRI I Sensor inside the rubber cushion of 3utematic door fee uere Bai TIRES T Ky DI i Automatic Door Safety protecct operator Hl CHO Bere er se iT TH Ry A Eu DI 32 Nozzle Safety Nozzle Cover Switch Ir dk b
8. 8 Nuzzle Do ips 16 Lubrication DO 3 5 7 07 Pump Moor Delta amp Normal Do 3 6 l 2 1 EDI Pump Motor Star Do 3 7 dr pL ad CCA4000 Digital Outputs CC400017 las 1 3I DELTA amp NORMAL 03 6 yap N LJ i oniacbors x deb um CL UR TEM mc e ce ea E rs HOTT LEY 9 r Page 12 DT NORMAL Lubrication Motor 421 TEES HO TEN SC EE RC ae Hie she ACHR DELTA Fi ma NORMAL ETE i Hg BL WER Ul ERIS E STAR Lo edi d CM TENN 41 Page 12 Jg N DELTA AE LEER TEE CCADUASOPT228b ecancetion plats 5 2 60 M 5 Heater Sy hn ds ay 6 Heater rae he EIEN 6 nda ss 7 Heater 12 03 3 03 Heater Active DO 41 04 Conveyor DO 4 4 15 05 Air Ejector DO 4 5 m 16 06 1 17 Air Ejector 2 DO 4 6 2 5 hit Regeneration DO 47 7 Relay Card 2 ots Digital outputs CCA000 EV
9. back 100 adjustment D ae adjustment by trp lok and while pressing hark Fill ge li LA TEL Hi A Ip copo HM pfo 1 Current Lim ser ES par ju Saeed Ag o EXE Hop n Speed AC n 7 is Pressure AO Ej mE w dues Current Lim E Uv DETTA VEIL eT KP PD3300 UN QV T Proportional Valve Diver 1 Agri SES Back Pressure Analog Output of CC3500 CC350042 8 edi NT UNE Yuken block need 12V supply this ease system needs another er Mm t d re a Power supply case using such a valve ask revision of this page Tile ee3sno OP2228b connection Sa VE aka HI Yulen EE P BA EE MON ioco ed Hui b Bot as IIE _______ ______ 3 46 eae DO 1 0 te tie Clamp torward DO 1 1 Carrige forward DO 1 2 In Bl Carriage backward DO 1 3
10. can be there is chose Open contact of the button In this project rE is relay contact in machine parametre rE not button contact look Pagel B3 and C3 RJDIL2 Emergency Stop rU pb NS es E E RESTO AM Bi E PIC qe FLA Se Tor FA T Ll fee 3E a Ws ee H1 NC Ft Pe A D 0 EE d R Tesco E101 TE EE e mE ea f EF BER SC E B3 RCI e n 1 3 External start Auto start button ad EL zd e zs Tz 81d uris 2 1 4 Clamp mechanically locked Clamp um a SW x C PL B PE HiH TRHA LJ Mould height is Min Mould oo a minimum Law EE HE STE o C DI 1 Mould height is Max Mould Height maximum SW HESS LN CJ DLL Mould height adjustment position pulses ERE SHE Digital Input of CC3500 Mould high adjustment gear proximity SW Fe EE a Ber FP OK CC3535004 CC3500 OP2228b connection plan lt aS ie ale he fe Tee ERR 1 evasion 24V 2 0 Ist Core IN SW S dip E C DI 2 1 Ist Core OUT SW T o 22 C DI 2 2 2nd Core SW FES FA DI 2 3 2nd Core OUT SW ER PT ER m i
11. i T 50 All Programme Changing o ie mee m iH oo gt a 45 j 1 p 1 8 The cable should be min 6 1 5mm M RET Pris oe 1 Hi X ZEE zs i Pit 24V 5 Front Dod AV ud j d is 7j d g DILO Front Door closed i PI Fr e Front Door Back sw Front Door Closed Hr prj p BUT Test WEA DI 4 0 page D2 LJ LI Back Door closed Back door closed hit 1H hr X E S pagel C2 sy 1 2 Emergency Stop 1 BETH O 13 Extemal Auto Start Button c at HS dictt a 2 14 Hydraulic pump M motor overload tar over current protection x HERESY ER 3 1 5 hight Mould min sw adjustment MIN position ti s ddl pu du HEURES POT EE RE Shi Se i Mr d H 5 ni L hight Mould MN adjustment max sw adjustment position Fe AE Ra SL 9 1 7 Hydraulic oil level low a Haa fir EE Hydraulic tank level switch i HE ICT S CC4000 Digital Input A Sin a cc4000 0p2228 connection plan FAS It a 0E 8 he
12. OP2228 USER MANUAL FOR MACHINE MANUFACTURERS OP2228 I DESCRIPTION OE KEYS ertt beri e E Vb ree Page 2 I T Prosranmmlle cose testas eb Ed VR OR Pee Eee UY Page 2 1 2 Mode cuui ec Page 3 INE IPOD t t Page 4 2 DESCRIPTION OE MAIN una eso Eo cop Eua Page 6 DiC ipse T Page 8 SEEDECTOR itin Pagel0 d INJECTION AND Page 12 dle GROUP N EEEE 13 T 14 STU PN oet S Page 15 3 2 DA TE Page 16 Oe niii bib Dt MNT Page 16 c Page 18 y E UI C M HR Page 18 CUN qu Rc Page 20 7 3 Get rid of core precautions while fixing mould ecce eee e eere eee eue Page 20 S WEA CLINT CLEGG qc SE E c d Page21 I MACHINE PARAMETERS Page 22 EIE 24 TION o
13. Tank level SW iff EE E CT an DI 2 5 0 04 Lubrication pressure SW DI 2 6 Lubrication pressure SW d e oN 127 Hydraulic filter dirty SW Lubrication pressure 15 OK on latest point Digital Input of cc3500 CC3500 st Core is IN Ist Core is OUT 2nd 15 TN 2 2 bes 2n IE MUT Hydraulic tank level is low afl 1 Librication oil level 15 low Filter is dirty 3500 2228 connection plan duis WEL XR dd da Revision 24V e 30 HER DEDERE Hydraulic pump motor overload protection machine equipped by position 0131 transducers these inputs are empty dr HAE FU cei arp SOBRE 4 M wir These 4 switches can be NO or There are chose for them in machine NUNC can be parametre 013 2 TT 2 Carriage is forward EI CV xou Carnage forward SW 1 MI In um IDL 3 23334 3 5413 REHE p TE II n n JT Xe i f Jo EU Po NO NC can be C P 33 m Carriage backward SW Carriage is backward
14. e I LI a bota ae nd mum mm FI 1 t it TI TT Ce er x ova P poads 0131007 21165214 Jg 01 02 2115891 58 Clamp backward 10 d oN Clamp forward 5 EC Carrige forward DO12 amp BE Al BY Fan Carriage backward DO13 amp BES IH Ejector forward 014 amp Til ra SZ Ejector backward 1 5 E TH Et Js Feeding 2016 Le Injection 001 7 5 ma i suck back DO 2 0 Re iB l core forward DO21 ET core backward 022 n 2 core forward DO23 5 2 5 4 Bj 2 core backward DO 2 4 2 ND ALARM LAMP SJ Alarm lamp DO 2 5 RIB KY 2 high adjust forward DO 2 6 high adjust backward DO 27 FRE N CC4000 digital outputs FAPROTEL OP2228 IAL LSCH 3 E Eu EMV Relay iL RTE Hemer Miar m 11 o1 8 2 025 3 Heater 3 2 E 1 4 Heater 14 045 45r and 89 15
15. 6 Aer on i NUS oie its Is On G NORMAI lubrication Pump Motor Star DO X7 dus alil silii eral Fa THEM AE iR VE Mesh ca D DELTA t ic Hc Rlta 5 NORMAL Sen i pump robar N d a 5 Digital Output of CC3500 _ _ CC3500 d totis HH T vi 8 1 Wo l T j E DELTA amp NORMAL a 03 6 1 ata 81 48 5 Heater 5 o d These outputs can ix Ure Hw LT np EJ be used for heaters J F TE tb ok or any other extra er Ath function 6 Heater 6g 7 Heater 753 Jr Bs ress dM Heaters active Reserve Air Ejector Air Eyector2 Regenration Digitalo output of CC3500 CC3500 7C r4 0 3500 0 2224 connection plan 3 Jul A i Revizii 49 19 4000 2228 ONNRCTION PLAN Bate 2 dA JA m f 29 fom at ATE ee i rE E 5 front Ln Hii pecia e E 5 nz Door THAI pipid Emergacv stop mlay 24 VDC coil zT EUR sober m oria ae ore Lia da a E T 3 775 eS 7 ALT ELA TRETAT
16. Page 24 91 2 CLAMP BACK PRESSURE iae quud cE euo Page 24 CLAMP AG ETVA NA dee eiteviva coi Page 25 914 GROUP AC TEVA DION i iiie Page 25 9 1 5 GROUP amp RJECTOR POSITIONING Page 25 9S L0 PRS SENSOR aiite Pee esq d erae Page 25 POWERON 25 9 2 5 55 En tus desides Page 26 9 2 1 Clamp Ruler 220 0 Page 26 9 2 2 Injection transducer zero 5 4 Page 27 9 2 3 Group at carriage transducer zero adjustmennt e eee eee e ee eee e eere eese eee eee uus Page 27 9 2 4 Ejector transducer zero adjustment e eee eee eee e eee eee eee e eee ee eee eee eate esee soe ane Page 27 27 IT Pniax 30 PA DETTE 1 A Page 30 13 CHANGING and COPPING MOULD Page 31
17. TEMP 6 TEMP 7 TEMP FOR TEMP PRESS F4 SS SSS SS SSS E NOSE Pu 1 Set value deltal resistance active 2 Set value delta2 resistance active in scale resistance active in RATIO2 scale resistance passive must be greater than DELTA2 RATIO must be greater than RATIO2 Controller 1s calibrated according to J type FE Constant thermocouple characteristics D1 describes wide band and border of it is SET TEMPRATURE D1 while temperature is comings up from cold to the set value till the border of D1 band heater get continue energy but when temperature goes in DI band temperature gets energy by PWM with ratiol R1 D2 describes narrow band and border of it is SET TEMPRATURE D2 when temperature is in D2 band heater gets energy by PWM with ratio2 R2 It must be DI2D2 and RI gt R2 Usually D1 10 or 15 D2 1 or 3 R1 3 5 R2 1 5 Ratios and bands can be adjusted separately for each zone after watching after a while temperature fluctuation these parameters are set precisely If F4 key is pressed it can pass HEATER page 7 CORES FOR PRESS 7 1 CORES is choose on SELECTION page here is only displayed CORE 1 by pressing ENTER key is selected by pressing Cl key it became disable CORE 2 by pressing ENTER key is selected by pressing CI key it became disable CORE IN FIRST if there are 2 cores and these cores movement are same which core will be go
18. control system amp hydraulic system are working together well or not 9 MACHINE PARAMETERS MAX SYSTEM PRESSURE LUBRICATION TIHE LUBRICATION ON LUBRICATION OFF CLAMP OPEN CLOSE REDUCTOR PRESS REDUCTOR SPEED PS OFSET PS GAIN RPM PARAMETER FOR SELECT PRESS MACH PRM On the main page below parameters appears MAX SYSTEM PRESSURE is for scaling of analog output refers to pressure reference if this value is set 140 bar 1 pressure ref analog output reaches when any pressure value 15 set 140 bar As for speed this one is not necessity because speed settings are percentage 22 LUBRICATION TIME is defined how long the lubrication will work ON OFF LUBRICATION ON is defined the lubrication ON time LUBRICATION OFF is defined the lubrication OFF time CLAMP OPEN CLOSE NO Define how often lubrication occur For example this number is 50 means each 50 close open of clamp unit starts lubrication this counter 15 incremental let s say 3 close open occurred in Manuel mode 2 close open occurred in half automatic in this case in automatic mode end of 45th close open a 50 counter is over amp Lubrication happens automatically as long as lubrication time amp although there is pressure switch if there 15 no signal coming from this switch in oiling time controller warns us Whatever the value of lubrication counter end of the first automatic cycle after power on controller makes lubrication and clear
19. delay T is a timer for each core movement If timer value is zero core operates with switches if it 1s not Zero core activation time 15 defined by this timer to complete its action CORE IN PRESS SPEED AT __ i CORE OUT EE ES FOR CORE PRESS Fo 7 3 Get_rid of core precautions while fixing mould with core One of the major headache is fixing a mould on the machine with the core especially if mould has 2 core functioning with sequent In such a case unless all switch and core valve solenoids connections are done 100 correct controller does not permit operator to check core motion in manual mode because of precautions in the program This program is so user friendly on this aspect In manual mode when manual mode selection key and core key are pressed together controller activate the core without noticing precautions Same precautions are in effect for clamp motions as well and same facility is in effect for clamp manual motions too if mould has cores when operator press manual key and clamp backward or forward button clamp moves without any limitation comes from core switch position 20 SUR ABACK Tum GN 20 BLOWING BLOWING These feature brings operators easiness and also think twice because they should use two finger together at the same time before manual core or clamp motions without precautions in order to be able to fix the mould with core on machine If F5
20. feeding speed Q 100 Press feeding button look screw turning speed till you reach max speed or till you see decreasing on the speed adjust G2 and measure valve 2 voltage and write it down 16 2 3 Inform us after adjustment what is 0 bar valvel voltage valvel voltage Q 5 valve2 voltage Q 100 valve2 voltage 16 3 Mechanical adjustment 2 screw you should see on the P Q valve One of them is big and has contra nut This one is mechanical max pressure adjustment After electronic adjustment set group max system pressure in ADJPQ page Press group back look indicator and adjust mechanically pressure till you see decreasing from maximum pressure When you see it increase little bit mechanical adjustment and fix it by contra nut Other small screw should be loosen out to take air out from hydraulic system If there is an air in the hydraulic system pump run very noisy If air always coming check vacuum pipe between tank amp pump Advise Beter to fix pressure indicator on output of P Q block before adjustments 17 CC4000PD Proportional valve adjustment AO2 AO A03 404 OFSET OFSET Z4 22 bie G4 CURRENT CG2 E JCURRENT CG4 CURRENT CGI ny CURRENT CG3 2 Gl G3 OFSET 71 JOFSET 73 17 1 Pressure adjustment 17 1 1 Choose Machine parameters page from OP Set MAXIMUM SYSTEM PRESSURE minumum 100 bar maximum 140 bar Second page in Machine Parameters you wil
21. is main page below key it will work 29 11 Pmax and Qmax PRESS SPEED Hees SA 56 MAY CLAMP CLOSING 190 090 EROUP FORY 090 070 INJECTION 120 100 FEEDING 100 100 SUCKBACK 070 100 GROUP BACK 070 090 CLAMP OPENING 120 100 EJECTOR FORY 090 090 EJECTOR BACK 080 100 1 070 070 2 CORE 070 070 TU Each movement maximum pressure and maximum speed are defined here amp these max value appear on the each adjustment page For example Clamp Close max 100 bar Clamp Close max 100 were set here When we go clamp close page we will see these value in right up window next to date window If operator want to set any value bigger than those a question mark appear next to this parameter to warn you that this set value 15 not acceptable because exceeding maximum value 12 Language When the system 1s at main page if it 1s pressing the key can be Chinese or English or Turkish After controller initialize itself if Operator Interface program is English English Language is chosen by controller automatically To select language numerical key 15 pressed 30 P EIE ss p n H Hi H 1 H i To select language related key is pressed To escape this section is pressed MAIN PAGE key 13 CHANGING and COPPING MOULD NUMBER In order to be able to change moul
22. lubrication counter REDUCTOR PRESS while the mould hight adjustment is making this unit will work with this pressure REDUCTOR SPEED while the mould hight adjustment is making this unit will work with this speed PS OFSET If machine has pressure transducer on accumulator output or pump output this parameter must be set as below When OP2228 is used with CC4000 OFFSET Measured value on analog input as Milivolt x 4095 10000 PS GAIN is a value as bar that usually pressure tranceducer manufacturer describe what 1s maximum sensor output against max pressure which sensor can measure For example sensor gives 10 bar at 250 bar Anolog input of CC4000 is maximum 10V therefore clamp sensor gain is 250 bar RPM coefficient 15 a divider to divide the number of counted pulses coming from screw while it s turning If MACH PRM key is pressed it will pass SELECTION page 79 9 1 Selection aREGENERASYON CLAMP BACK P NO CLAMP rn PAS GROUP IN IHJ ATI PASIV GROUP IN FEED LLY PASIV GROUP LET EJECTOR SWITCH PRS SENSOR POWER QN Mf FOTOCELL FOR RULER PRESS MACH PRH 9 1 1 REGENERATION is a feature on the clamp hydraulic section Sometimes clamp unit get oil from pressure line amp front of clamp cylinder while clamp is going forward Usually oil in the front of cylinder goes to tank if there is no regeneration This feature brings us less oil consumption amp high speed closing If regene
23. OINTS OP2228 CC3500 OP2228 CC4000 TO COMPARE with PD3300 Digital outputs 32 outputs Basic 32 Expandable up to 48 Analog inputs 5 inputs Basic 4 4 more can be added and configured due to analog signal Analog output 3 outputs Basic 4 outputs expendable up to 8 and additional 4 can be configured PWM output None it need external 4 channel pwm driver build in proportional valve driver controller PD3300 Power supply Need at least 5Amp 24VDC Need at least 5Amp 24VDC standard SMPS Operator standard SMPS Operator Interface and controller can Interface and controller can run operate stand alone stand alone Electronic GND Semi isolated 100 isolated from outside and analog inputs and analog outputs Short circuit protection None All digital outputs and pwm outputs has overload protection if current exceed 3A output shut off automatically Proper for Small and medium size Medium and big size machine machine especially equipped with complicated closed loop hydraulic Points to underline Independent memory locations in Operator Interface and Controller to initialize system with cross check Controller goes running without Operator Interface after initializing upon power System need standard power supply which easy to find in the market everywhere 3 levels password to do soft lock on keyboard Automatic wrong set value detection Real machine simulation with the ratio of set position Manuel keys with LED indicator to sim
24. OR INJECTION lel uni Ar Qt lt a Im LCORE OUT 2 CORE 2 CORE OUT Biel it 2 BLOWING Clamp Backward ii Clamp Forward CLAMP FORW Ejector In Ejector Out EJECTOR BACK Group Forward Group Backward G ROUP BACK Suckback mE A SUCKBACK INJECTION Feedin DOOR FEEDING DOOR ADT tfl lt 4 Core 1 In 1 1 CORE IN LOORE OUT 2 4 H Core 2 In aH Core 2 Out ZS EOS 2 CORE DUI ejector 2 2 BLOWING 1 LBLOWING Mould hight adjustment backward Mould hight adjustment forward Every manual key has LED light when the key is pressed the LED will light on 2 Description of main page 4 99 SET 18 REAL 148 152 15 2 204 00290m TUE Os t 001 09 C 000 05 SE ESTA BERI cH 0006 0049 004C E wheather protection key 15 unlocked that depend on its level allowed 2 3 4 5 6 e paremeters can be set shows the position of end of feeding base on position trancedure lenght set in machine paremeters is filled up on the begining of holding During automatic working when lubrication unit run oil figure appear in this area shows clamp opening position base clamp position trancedure lenght set in ma
25. PRESSURE DELAY 00 5 T um rh FW IP n mE FOR INJECTION PRE In machine parameter selection page bring us chose to run group with ruler or switch When switch is chosen in selection page group page turn to simple as above Moreover it is possible to work only one switch on the way of group back to stop group back motion by switch and by connecting carriage is forward input direct to 24V without using a switch to stop forward motion pressure delay can be used as a duration of forward motion hence carriage can work only back positioning switch and forward motion works with timer If F2 key is pressed it can pas INJECTION page 5 TIMES m T3 4 WAITING TIHE m 0 g d EXTRUZYON TIME 000 0 5 BLOWING DELAY 001 0 3 1 BLOWING re 003 0 2 BLI Ne TIME lt 00 0 8 1 1 FOR DEL AY IESS F3 n COOLING TIME runs after holding when it is over clamp starts open WAITING TIME is an required interval between end of the cycle and beginning of coming cycle Automatic mode when cycle finish machine waits as long as this time automatically this one is for giving time to product leave the moulds if machine has fotocell on clamp section fotocell should give signal controller in this waiting time to be sure that product left mould Semi automatic or gate start mode this time is set as a required waiting time so that operator can accomplish his her job in
26. THEE can be 0134 Ejector is forward Ejector forward SW mE fel aT RET A can be Cy 135 Ejector backward SW Ejector 15 backward ________ De HC can be 113 6 rH Product fall down Photocell can be there is chose in machine parametre RT ELEC TE PNP 7 8 Photacell tm PU iE up dr Sd ER AER ii Ik Uit BE VER A Gs Jit zx Hydromotor RPM counter input f SHz DI 3 7 2 roximity SW Si ip RO Digital Input of CC3500 Tithe 500 22288 connection plan 7 5 1 a err snb 05878 ee die wis d GA KP WR RR LO UM evasion All thermocouples must be isolated and J type Bf A op AE HI pui dtp d a Heater pu Heater 2 The pui dtp d 3 Heater 3 The yl dut ie 4 The Nozzle heater works with duty 5 The cycle time if there is no thermocouple QH s A LLL d amp PENS T 7 The The thermocouple signal input of CC3500 EE TELE J type thermocouple Hydraulic Tank Hk Fs RT Tile CC3500 OP2228b connection plan C Itc
27. TPUT TEST is entered each digital out can be forced active and passive by choosing digital output with arrow keys then press active makes output active press passive makes output passive In the same page by arrow keys analog outputs can be choose and their values can be max and minimum by MIN and MAX keys or by using incrementing and decrementing buttons under left and right arrow keys successively analog output values can be changed step by step INCREASE PRESS PRESS Re OV PRESS MAX OV PRESS OR INPUT SELECT PRESS 1 0 When INPUT SELECT is entered Contacts position of defined digital inputs in this page can be opted to NORMALLY OPEN NO NORMALLY CLOSED NC 28 Er 3 E FORWARD NC GROUP BACKWARD EJECTOR FORWARD EJECTOR FOR WARD FOTOCELL NC EMERGENCY STOP IT NC FOR BUTTON TEST PRESS 17 If numeric and arrow keys are wanted to be tested come up to KEY line by arrow key then by pressing numeric and programming and arrow keys their values can be seen on the key line if you want to escape this section press key first then main page make you return previous page When cursor next to address function and manual keys can be tested by pressing them when any one of them pressed related led light on so both led and key were got tested FOR DIGITAL 10 PRESS 170 If the system
28. Y 00 5 DIST POSITION 0578 FOR INJECTION PRESS 2 But if itis choose movable FEEDING GROUP or GROUP FEEDING appear on the next line to determine when group move in automatic cycle Pressure delay is a timer to be sure that group pressed well to mould this time runs right after group reached end of the forward position by keeping 1 group pressure and speed as long as this delay by this way after reaching the position which determines where group touch clamp fixed part it is gone on being pressed to group towards fixed mould part all long PRESSURE DELAY time then injection starts Group forward and backward movements have 1 position pressure and 1 speed How to find last position of group forward What 15 the easy way Consider that zero of group position 1s mechanically end of back movement Take the machine manual mode close clamp then take group forward till nozzle touch fixed mould side Read the group position 358mm 1 set 357mm as last position of group forward In this case first position could be 353mm 1 Base on this example if group will run movable first position of back could be 353mm too and the last position of back movement could be 348mm Do not miss if clamp is not closed manual or automatic group cannot be taken to forward If group motion control is done by switch group pressure and speed only one for each direction as you can see below 21 wu 11 BGROUP THOYEMENT 90191
29. ___ If ejector is functioning with position transducer ejector forward and backward movements have 1 speed pressure and position but if 15 equipped by switch or working with timer by means of forward waiting timer as explained above just one speed and pressure enough for each direction If ejector has position transducer mechanically end of ejector back movement is zero point therefore forward position can be set depend on mould If clamp is not open 1 3 of total opening stroke ejector does not go forward If pushing number is more than 1 comes back till first back position not the last back position then push forward again 1t comes to end of the back position only end of last react to reduce ejecting time for several eject in order to be facilitate this feature obviously ejector should be equipped by position transducer If F1 key is pressed it can pass CLAMP page 4 INJECTION AND FEEDING POSITION 0241 mm FOR GROUP PRESS F2 There are 2 main section First 2 zone are for injection with high speed and high pressure to fill the mould then again 2 zones are for holding pressure Usually there 15 no movement or quite short movement in holding stages But in spite of that there are 2 speed reference in holding stages too besides pressure references It must not be omitted that as long as first 2 injection zones pressure references show us just upper limit of injection that injection pressure cannot be over this
30. and breaking position means that even if last position of clamp opening is set 500mm it never stop at 500 mm perhaps 510mm may be more as it was mentioned above depend on breaking position and speed and pressure and off course high speed before breaking zone Therefore usually last position of clamp opening and 1 position of clamp closing can set at same value i e if last position of clamp opening is 500 1 position of clamp closing be set 500mm as well Anyway this 17 zone of clamp closing is for starting of the movement against friction because of inertia of clamp and mould section and between arms or mechanical parts that s why this zone can be narrow with high pressure and low speed P1270bar and 01 50 FAST is for fast closing pressure is rather low than 1 zone and speed is high as much as operator need SLOW 15 for breaking right before mould protection Usually question is what is the way to adjust correct position for mould protection zone When new mould is fixed on the machine in mould height adjustment page clamp can be closed and opening by displaying actual position of clamp the correct position of beginning of mould protection zone 15 right before linking of clamp fixed part movable part Let it be 150mm which we read on the screen right before linking clamp parts in this case beginning of breaking zone before entering mould protection zone can be chose 250mm to reduce speed and pressure Ba
31. chine parameters fault line COIC 15 back pressure during feeding 05 7 is pressure set in mould paremeters for each motion A MAL is speed set in moul paremeters for each motion is system pressure if there 1s pressure sensor on the machine 0000mm 2210000 20029 is ejector position is clamp position is injection and feeding position is group carriage position injection time holding time cooling time shows how long one cycle with this mould paremeters mould number actual counter set counter 3 CLAMP UNIT CLAMP CLOSING CLAMP CLOSING WT 05077 040 T 030 1 PRESS 07 081 070 SPEED 030 B EE S SU 00 1 0070 0003 0530 gt 1 2 5 POSITION 0589 nm CLAMP OPENING STOP BRAKE BRAKE FAST START 020 030 040 DEO 10581 120450120400 FOR EJECTOR PRESS There are 5 zones START is between last position of opening and 1 position of clamp close for example last position of clamp opening is 500mm and 1 position of clamp close is 490mm 1 zone functioned from 500mm to 490 mm with and Q1 as 1 pressure and 1 speed successively set in 1 zone As a matter of fact clamp opening never ends up on the last position because of delays on response of hydraulic valves and inertia of clamp section with mould gravity that s why always clamp last position 15 exceeded depend on last pressure and speed
32. d number or copy present mould to any mould number system should be in MANUEL MODE This control system can keep parameters up to different 50 molds To recall any one of recorded mould parameter MOULD MOULD hd Aci 18 EN Ue pa jm n m So gems T i uua 00000 ms 27000000 no E ct 05 000 4514 000 15 03 027 25 see 00001 10000 MESS sii 1 31 Here mould number can be changed or copy in another number To change the mould number just entering new mould number is enough then press ENTER Then write the mould number to copy present mould parameter in 32 E Te ct mM et inn C0000 M FL Don 151 02022 75 4 1 8 To close setting of mould number press MAIN PAGE Without closing this option machine cannot move 33 14 Setting or erasing counter is just possible if system in MANUEL MODE Press key Set how many cycle you need and press ENTER When counter reach this amount machine will stop and give you warning that counter is full a ad i The H While window exist on counter set section pressing MAIN PAGE eras
33. e up to 350 C 8 zone belongs to thermocouple of tank temperature TMP Tolerance is plus minus tolerance band on set value if temperature goes out up or down from this band alarms occur Over up is not a reason to stop injection and filling over down makes stop the process to prevent screw and barrel Selection page regarding temperatures bring us adjustment of oil temperature Oil temperature offset is needed if thermocouple is not J type Fe Constant oil tank If it is FE Constant J type offset value is zero if it is another type offset value must be set base on difference between real tank temperature and indicated tank temperature on the screen Oil temperature alarm value 1s for just warning for operator Oil temperature stop value is for stopping pump motor If it is pressed F4 key screen will change shown below 6 1 PID PARAMETER NOZZLE CAN BE CONTROLLED BY PERCENTAGE there 15 2 parameter to adjust it one of them activation time is adjustable by percentage of duty other 1s duty cycle On time should be longer the OFF time when temperature need decreasing OFF time should be longer the ON time always notice proportion between these two timers because by this way the energy are given to heater can be controlled Small end medium size machine IO or 15 s duty cycle is proper for example we can enter 70 and 106 but for big size machine total cycle time 1s almost 20s 1 2 3 TEMP 4_ 5
34. es actual cycle counter SOET 150 0 15010201020 065 10301027102110201020 dear dif die RES ME dem 1 P 1 i i LE mL By pressing CL key actual counter can be made 0 Without closing option by MAIN PAGE machine can not move 34 15 Passwords Password cancelling press key password figure and level no will be flash press 0 key after password figure will be disappear In this case we can not change any parameter on the screen A 1 Jat password activation press f key password figure will be flash which level will be flash which level will be active we will press this number 1 2 or 3 after we will eater password related level after pressing ENTER this level will be active by pressing MAIN PAGE key flashing will be off press again key the figure will be appear on the screen which level password will be changed we will write this number after what will be password we will write this number and press enter by pressing MAIN PAGE key we can exit this section 35 m 30 00001 B J0000mn Sp E c 000 43 55 11 16 22100 T 0 15 m 00200 16 1 Pressure adjustment 16 1 1 Choose Machine param
35. eters page from OP Set MAXIMUM SYSTEM PRESSURE minumum 100 bar maximum 140 bar Second page Machine Parameters you will see ADJPQ enter this page Write P2000 for GROUP BACK pressure Q 050 GROUP BACK speed Start pump 16 1 2 Usually first channel on PD3300 is for pressure so if you connect like this When you pres group back button you see on REFI Look pressure indicator pressure indicator must show max 5 bar now If it is high or zero try to adjust it arround 5 bar by 21 Set Group pressure P 050 bar now Group back pressure pres group back button you must see a pressure if it is higher then or less then 50 bar adjust it by Gl Set Group back pressure 110 bar press group back button look indicator if it is less try to increase it by Gl again 36 16 1 3 If you can not increase it up to 110 bar by Gl try it by CGI If you use CG1 adjust indicatot more than 110 1 can be 130 bar then reduce it by you change adjustment you must check and adjust again zero adjustment by Z1 After zero adsjustment you must adjust again set pressure valve by Gl 16 2 Speed adjustment 16 2 1 Set Group pressure 050 bar set Group back speed Q 005 Press group back button look pressure indicator and reduce indicator by Z2 when pressure begin going down on the pressure indicator leave it and measure valve 2 voltage and write it down 16 2 2 Make temperatures are ready take group back and in ADJPQ page Set feeding pressure P 0070 bar
36. ic Ejector 1 3 di Ejector backward 15 mechanically zero point AIN BE EUER n Fr Bl x il Clamp SAIN 4 2 4 1 Locked clamp toggle locked is mechanically zero point Bb F a ap bn System Pressure ses transducer me a E AINS Sigii AING 10 10V a EL pr di ET IE ERAT Clamp Pressure transducer Injection Pressure transducer bh ae 7 22 A RED Sign EO V art 10 Simi AINS AIN amp 8 Carriage Pressure mransducer Beer sign Ota OV oF 10V CC4000 Analog Inputs A 25 CCADUUSOP222Rconnectien plas Leas Itc AWO 25 Parr har tine Ty 3 4 57 _____ sindino 000795 jur JUALIN Q A 4 C M p ag cov um B 198110 195110 Eg TEU HE HRT 5 juan yun juano 45 me WAT Cw zov 4 p HEE C 195050 5 e 1950 25 8 5 E gt 0 0 0 X T c lt 5 i ILE kn Jate t KT 1 5 A c
37. in first is selected by pressing ENTER at this line CLAMP CLOSE which core will work when the clamp closed 15 selected by pressing ENTER key of this line CLAMP OPEN which core will work when the clamp opened is selected by pressing ENTER key at this line AT INJ CORE ACT if the cores want to make action during injection process by pressing ENTER key it 1s selected CORE OUT FIRST if there are 2 cores and these cores movement are same which core will be go in first is selected by pressing ENTER at this line CLAMP CLOSE which core will work when the clamp closed 15 selected by pressing ENTER key of this line CLAMP OPEN which core will work when the clamp opened is selected by pressing ENTER key at this line AT INJ CORE ACT if the core want to make action during injection process by pressing ENTER key it 1s selected ON THE WAY if the core will go out when clamp medium position by pressing ENTER key this facility will be active And it will be entered In which position core will go out If this work 1s selected and there are two cores both core will work when the clamp reach this position Clamp will stop and first core will go out and then if there is second core will go out FOR PARAM PRESS Fo By pressing F5 key it is passed PARAMETER page 7 2 core movements have pressure and speed value here DELAY 15 for right before core movement if delay is not zero core starts movement after this
38. key is pressed it can pass CORE page 8 MACHINE CHECK These parameters can be changed only when first level password is unlocked 53 CLAMP 1 1 051 GROUP INJECTION FEEDING SUGKB ALK BAGK CLAMP OPENING EJECTOR FORN EJECTOR BACK 1 CORE 2 GURE GATE 21 This 1s section 15 only for starting up hydraulic section easy Without considering any position limitation on the movement you can give each piston movement by using manual buttons in this page while system is in MANUEL mode Only temperatures a limitation for injection filling and suck back if temperatures are set value there is no any other restriction to get the movement in this page Movements pressure amp speed can be set here independently When you push any manual button related pressure amp speed are applied on analog outputs with activation of the related digital output Hence only related value 1s active and analog outputs are assigned set values entered on this page Movement goes on unless you leave Manuel button without any position or switch or security and safety control except temperatures This 15 a very good advantage to start up machine hydraulic system or to find a trouble on the hydraulic system Position transducers are not affected here but actual position of the pistons can be watched while we are on this page on the right ACTUAL PARAMETER windows This feature helps us to consider
39. l see ADJPQ enter this page 27 Write P2000 for GROUP BACK pressure Q 050 GROUP BACK speed Start pump 17 1 2 Usually first channel on CC4000PD is for pressure so if you connect like this When you pres group back button you see on REFI Look pressure indicator pressure indicator must show max 5 bar now If it is high or zero try to adjust it arround 5 bar by Z1 Set Group pressure P2050 bar now Group back pressure press group back button you must see a it is higher then or less then 50 bar adjust it by Gl Set Group back pressure 110 bar press group back button look indicator if it 1s less try to increase it by Gl again 17 1 3 If you can not increase it up to 110 bar by Gl try it by CGI If you use adjust indicatot more than 110 1 can be 130 bar then reduce it by you change adjustment you must check and adjust again zero adjustment by Z1 After zero adsjustment you must adjust again set pressure valve by Gl 17 2 Speed adjustment 17 2 1 Set Group pressure 050 bar set Group back speed Q 005 Press group back button look pressure indicator and reduce indicator by Z2 when pressure begin going down on the pressure indicator leave it and measure valve 2 voltage and write it down 17 2 2 Make temperatures are ready take group back and in ADJPQ page Set feeding pressure P 0070 bar feeding speed Q 100 Press feeding button look screw turning speed till you reach max speed or till you see decrea
40. nism locked well after reaching last point on the clamp close way CLAMP OPENING There are 5 zones too START 15 for unlocking Here system need low speed high pressure and this distinct should be short first position is end of this zone can be 50 or 70mm therefore usually around zero is the beginning of this zone FAST is for fast opening usually it is longest zone in opening here pressure is moderate speed 15 high BRAKE is for slow down before breaking pressure and speed should be decreased in it BRAKE is for breaking before stopping pressure and speed should be lower than previous ones STOP is last zone before stop pressure and speed should be lower than in 34 4 and 5 zone length are depend one high speed and all length of opening but on conclusion these last 3 zones function like step down function hence speed and pressure had better been reduced step by step in each one and length of them cannot be more than 50 or 70 mm each By pressing F1 key it is passed EJECTOR page 3 EJECTOR eEJEGTOR YES 4 WAITING WITH NO REACT AME MIDWAY PUSHER NUMB 001 FORWRD WAITING T 00 0 5 EJECTOR BACKWARD SPEED WIRE POSITION 0000 FOR PRESS F1 Ejector Yes No 15 choose on first line WAITING WITH PQ YES define as long as forward waiting time ejector forward last pressure and speed are in effect NO in waiting just keep ejector forward valve active without pressu
41. on oil level is low Taboao en s Hat afi Level switch il Hs itt pr Lubrication pressure is OK on 5m 4 7 the lastest point CC4000 Digital Inputs CC400047 gt dtc irre ee ie ee oe ERR L5 Revision ec4000 op2228 connection plan 3 thermocouples can be J type K type unless customer reguire K type controller is adjustment for J type of UU LEE BK B E D p i Jr dup ds Heater p 1 4 iz 2 Heater 3 Heater 5 Heater 6 Heater JI e 55 7 heater CC4000 thermocouple inputs Nozzle heater works with duty CC40005 cycle time if there is no thermocouple pe Tog IES A E frs x A L TE top T TERI Hydraulic Tank Fs jn sl Title C4000 OP2228 connection plan SPAS IT i pmi io er ees Foe 2o TRI i AH FSPROTELOP2228 HEATER SCH 10V Injection i Bi E p n Screw literally forward 15 mechanically zero point a AIN peat REF LES 1 Bip SASL SE ERIL 1 Carriage 8 Fi AIN 2 CUM AIN 2 Carriage literally backward 15 mechanically zero point IE SE jd 2 ESES SU ps og We
42. parameter 15 pressed CL key L If it pressed on the main page this key is used for changing language MOULD CHANGE While the parameter is entering for cursor movement is used If it pressed on the main page this key 1s used for mould change and copy While the parameter is entering for cursor movement is used If it pressed on the main page this key 15 used for password While the parameter 15 entering for cursor movement is used If it pressed on the main page this key 15 used for product set and reset While the parameter 15 entering for cursor movement is used If it pressed on the main page this key is used for PQ Max page Machine check ALARM 15 used for entering ALARMLIST page Machine parameter page I O page 1 2 Mode selectors takes machine to manuel mode in order to use manuel keys MANUEL cycle starts when safety door is closed and it ends when the door is open If safety door is AUTOMATIC this mode doesn t operate L WITH DOOR in this mode can be started pressing CLAMP CLOSE button on the OP or external start button that it can be connected 2 6 Each cycle to start should be pressed start button In this mode the machine runs full automatic and between two cycle there is waiting time is used for starting the heaters is used for starting the pump mould hight adjustment mode 2 CLAMP FORW JB EJEC 5 E 4 CLAMP BACK J FEEDING DO
43. plify checking out real time motions Standard RS232 communication between Operator interface and Controller Huge selection facilities Machine Parameter Pages to simplify retrofitting applications Soft ramp adjustment for beginning and ending of each motion RK NN SN NS Soft position transducer span and offset adjustment Soft pressure transducer adjustment to measure injection or system pressure Adjustment page to make easy start up and check the reason of problems on machine Ejector and Carriage can operate with position transducer or switch or timer Effective mould protection Ejector can react on the way of clamp opening Programmable core configurations inclusive of operating on the way back of clamp Run cores manual without restriction Extrusion before injection to fill cavity in mould Programmable air ejector Programmable phonamatic or hydraulic actuated automatic door Programmable hydraulic accumulator Programmable input contact selection Controller diagnosis Real time alarm record 1 Description of keys 1 1 Programming key MOULD CHANGE F1 F2 F3 F4 F5 is used for entering parameter page When any paremeter is wrong question mark appear on this paremeter and cursor can not be shifted till operator correct it then cursor can be moved to another paremeter by arrow keys 0 1 2 3 4 5 6 7 8 9 niimerical keys ENTER to load written numerical value to memory While the parameter is entering for canceling the
44. ration is YES regeneration output get active from first position of clamp to slow down position of clamp closing 9 1 2 CLAMP BACK PRESSURE 15 a proportional pressure control value on the way to oil returning tank from tank output of clamp bidirectional valve Hence when the pressure is created on this way by this proportional valve during mould protection or breaking right before stoping back during opening clamp movement faces an extra force because of back pressure against the movement inertia Above diagram shows us a typical application regarding regeneration and back pressure Clamp cylinder P Hack pressure Lj If clamp back pressure is YES related anout of controller CC4000 gives a reference voltage depend on the set values of back pressures in the clamp parameter page look at section 1 3 9 1 3 CLAMP ACTIVATION Which parts of automatic cycle clamp piston forward valu selenoid 15 wanted to be active this 1s the selection Sometimes toggle system piston should be kept on under pressure during the injection 9 1 4 GROUP ACTIVATION In INJECTION in FEEDING in SUCKBACK till OPENING can be choose to make group carriage forward valve solenoid active so that nozzle will press fixed plated well Off course clamp or group or both of them are choose active during the other movement and if they do not have separated pressure and speed control value they will see same pressure amp speed value of the main movement But if
45. re and speed REACT CLAMP OPEN OR MIDWAY of clamp opening bring a choose to eject product while clamp opening when chosen midway that under that a line appear to set the position of clamp so that when clamp reaches that position while it 15 opening ejector get active to move forward Do not neglect that in order to be able to utilize this function ejector and clamp should be supplied from different hydraulic power source otherwise ejector motion effects clamp back speed PUSHER NUMBER is a number shows how many time ejector reacts FORWARD WAITING time runs when ejector reaches last forward position if timer value is not set Zero If this time is not zero when ejector reach forward position ejector forward valve keeps active as long as this timer By using this two features ejector can be run with timer To true this first ejector should be chosen with switch in machine parameter instead of position transducer and second ejector forward and backward switch inputs should be connected to 24V DC directly Now forward waiting time operate as ejector forward time and backward time It shouldn t be forgotten choosing waiting PQ YES neither On the other hand when ejector 15 chosen working with switch machine parameter page ejector page turn to simple as below EJECTOR YES ET WAITING WITH YES REACT MP PUSHER NUMB FORERO WAITING T 0 0 5 EJECTOR ____ Trao _
46. se on this example between 500mm to 250mm clamp moves with high speed and from 250mm to150mm breaking before mould protection and now M PRT 1s for mould protection Another question how can the correct point be found to finish mould protection zone Best point is where two parts of mould touch each other which can be read from screen while new mould 15 being fixed on the machine in mould height adjustment page This is M4 after M4 locking zone takes place till M5 In mould protection zone pressure and speed must be as low as possible 1 is 70mm clamp unit should cover the distance betweenl50mm to 70mm in mould protection time otherwise clamp goes back till last position of clamp opening with mould protection alarm In automatic mode as much as open close number clamp tries being closed again automatically if it has been opened because of mould protection MOULD PROTECTION TIME is a time over to pass mould protection zone in this time otherwise clamp goes back LOCK 15 locking zone between M4 and 5 5 15 zero or very near to zero position of clamp transducer look at zero adjustment of clamp transducer In the machine parameter there 15 a choosing concerning M5 it can be on or off for more explanation look machine parameter section In this section pressure must be high but speed 15 low to avoid the hydraulic chock in fact no clamp 1s no need speed just need pressure to lock clamp well LOCK TIME is used for being sure toggle mecha
47. siness that when power on heaters get on automatically without pressing heaters ON button on the operator interface but if it 1s off after power on heaters on button on the operator interface must be pressed to make heaters on If MACH PRM key is pressed it will pass RULER ADJUSTMENT page 25 9 2 Transducer adjustments Lam P Q CLAHP 040 040 FEEDING 0300 050 050 GROUP 0500 040 040 EJECTOR 0200 040 040 039g must be close TemP must set FOR PARAM PRESS HACH PRH On the transducer adj page when RULER OFSET key is pressed left right corner selected function box shows us ruler offset In this case zero adjustments of transducers can be done as follows But to get in ruler offset section OP2228 must be in MANUEL mode otherwise it give us warning so before pressing RULER OFSET key not forget to take OP2228 to MANUEL MODE 9 2 1 Clamp Ruler Offset Adjustment Press clamp forward button like manual mode clamp goes forward with P amp Q was set on the transducer adjustment page when movable mould part link fixed part up toggle mechanism must be locked position if it 1s not before zero adjustment take all clamp section to back by using mould height adjustment then do again clamp position transducer zero adjustment When toggle arms reaches locked position clamp position transducer reach its zero position release clamp forward button as soon as button 15 released 4000 get this position 1s zero posi
48. sing on the speed adjust G2 and measure valve 2 voltage and write it down 17 2 3 Inform us after adjustment what is 0 bar valvel voltage P max valvel voltage Q 5 valve2 voltage Q 100 valve2 voltagek 38 18 3500 2228 CONNECTION PLAN 220 FI 44 EE um P 24 E37 X rp I Ha Fim 2A Curie e E TEX er mor m Eg qu MV rcr qp ec 16 D sop ralas or contactar 39 sv Supply For the position transcucers DART ICON MOD A CC3500 e E ci 5 a g Pc JE G 2 Programme Changing 5 Windows 2 S OF RRA T z Communication cable V Tc CC3500 P3 pli 1 tci HER um NE LIU 7 _ it par 40 IP ie di Oo DI 1 0 Gates arc closed Zar o Back Door Closed Front Door Back Front Door Closed ETIK HEGTX MERENS T24V FEROJ E DILI Nozzle cover is closed Nozzle Cover Closed Ies Bs i Ke uera When emergency stop push this input must be active IF emergency stop button 15 connected direct here use Normally
49. they have independent pressure amp speed clamp amp group will see last pressure amp speed of their last step in their movement 9 1 5 GROUP amp RJECTOR POSITIONING FEATURES Depend on machine sometimes group and ejector can not be equipped by position transducer ruler and switch neither except eroup back switch So if there is no switch or position transducer 1 ejector forward ejector backward carriage forward motion can function by timer But to use timer here selection must be SWITCH and then instead of ejector forward ejector backward and carriage forward switch these 3 inputs should be connected to 24 Please read ejector and group paragraphs how to use them with timer Ruler here shows us functioning by transducer so if for example forward movement is choose by distance backward cannot be by sw or timer Sw shows us positioning by switch 9 1 6 PRS SENSOR is pressure switch on the lubrication pomp or on the last point to be lubrication on the system to measure lubrication oil pressure Some of lubrication system has this pressure switch but some of them doesn t have If system has it must be YES If it is YES in the OILING TIME this pressure switch must be active but it doesn t mean that when this switch 15 active lubrication is over no lubrication waits till end of the lubrication time so pressure switch only to be sure that lubrication executed proper 9 1 7 POWER ON Temperature on or off bring us an ea
50. this interval If operator late controller give OPERATOR warning that machine is WAITING FOR START EXTRUSION TIME is for turning screw before injection to fill mould cavities mould has big cavity without injection then when this timer 15 over injection starts fill the corners of mould up Hence by small size machine big cavity can be injected like pair of sole in the same mould BLOWING DELAYS start with cooling time then as much as blowing times air ejectors blow 5 1 DELAY TIME MOTION RISING FALING DELAY DELAY DELAY FAULI CLAMP CLOSING MMN 0 0 GROUP FORK INJECTION FEEDING SUCKBACK GROUP BACK CLAHP OPENING EJECTOR FORW EJECTOR BACK 2 CORE EN DATE gt 25 o c o It is pressing F3 key will be change this page MOTION DELAY is delay before any motion RISING DELAY 15 delay at the beginning of motion between directional hydraulic valve solenoid and building system pressure on DELAY is delay at the end of motion between going system pressure down and hydraulic directional valve solenoid FAULT is time over for each motion if it is over controller gives alarm 5 2 DATE TIME DATE 11 06 11 TIHE 13 05 FOR TIME PRESS F3 Itis pressing F3 key will be change this page 6 HEATERS MAX 180 180 180 180 180 050 050 I EUR PID PRESS Standard program has 7 temperature zone Each zone can control temperatur
51. tion of toggle clamp Clamp tranceducer length Adjustment pressure P speed Q clamp transducer position without subtracting offset value are on the table As an extra Reductor forward amp reductor backward pressure amp speed adjustments are available This reductor here means hydro motor actuated reductor for taking clamp section to back or forward base on mould height then after this first adjustment second adjustment 1 done for zero point of clamp transducer Hydraulic clamp systems clamp transducer zero point 15 accepted where the mould parts link up each other For zero adjustment the way below follows there is mould height adjustment first this one is done by hydro motor actuated reductor Here hydro motor use reductor forward and backward P amp Q on the clamp transducer adjustment table Then by pressing mould forward clamp close manual button movable part 15 linked fixed part up This point 1s the zero point of this mould therefore when clamp close button release CC4000 save this position for this mould as a zero point When mould change if hydraulic clamp 15 26 selected zero point change automatically If new mould zero point set before when mould number change the zero point of this mould automatically 1s going effect But 1f mould zero point did not set before each new mould need new zero adjustment for clamp if clamp 15 hydraulic system During clamp zero adjustment in the position column clamp transd
52. ucer position 1s shown 9 2 2 Injection transducer zero adj Notice heaters must be on and reached set value Press injection button till screw reach last position then release button last point of the screw on the injection way is zero point of injection transducer where button is released CC4000 get this point as a zero point of injection The position of injection cylinder 18 displayed on the position column of the table 9 2 3 Group at carriage transducer zero adjustment Press group backward manual button till group press back on it is mechanical construction Back position of group 1s zero of group transducer When group press back release group back button to make zero this point 9 2 4 Ejector transducer zero adjustment Press ejector back manual button when ejector completely back position this 1s the zero point of ejector release the button zero adjustment occurred automatically If group or ejector is selected by switch or timer operation their zero adjustment do not make sense 10 Extra 24 digital output card 8 channel 10 bit dac card cannot be used with 2228 When this section 15 entered all digital inputs and outputs appear on the screen to watch actual situation of the machine APUL FOR ANALOG 10 PRESS 170 When I O key is pressed all analog inputs and thermocouple inputs appear on the screen to follow actual all analog inputs 2 FOR OUTPUT TEST PRES S 170 When OU
53. values but it doesn t mean that actual injection pressure follows pressure reference Reference can 100 bar but actual pressure can be 70 bar on the pressure gage 1 but it can never be more than 100 bar if it is means that proportional valve adjustment is not correct HOLDING T D choosing of time or position is for determining of length of holding steps Holding starts with last position of first 2 injection steps then it goes on either base on time or positions of injection cylinder base on chose here INJECTION TIME is estimated or required or ideal injection time that does not include holding In this time first 2 injection speed must be over if it is not controller waits for 500ms more than gives warning that injection time 1s over without stopping machine but stopping injection process it pass to feeding and beginning of new cycle this warning is disappeared automatically FEEDING AND SUCKBACK are on same page Filling or feeding has 2 steps with back pressure suck back has only distance that is on effect after feeding For example feeding positions 55 and 60 and distance of suck back 1s 5mm Feeling 15 over at 60mm then 5mm suck back is occurred If suck back distance is zero means that there is no suck back By pressing F2 key it is passed GROUP page 4 1 GROUP Group movable or fixed is a choosing if it 1s fixed in automatic cycles group is always pressed to mould part on the fixed plates aGROUP H VEMENT PRESSURE DELA
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