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BABYPLAST 6/10VP 6/25VP rotary table

Touch screen

INSTRUCTION MANUAL
Rev 4

BABYPLAST 6/10VP 6/25VP

VP

INSTRUCTION MANUAL
Thank you for the trust you have placed in CRONOPLAST. Please read this manual carefully before operating our machinery. The manufacturer is not responsible for and does not provide warranty for machines used for any purpose other than that for which the manufacturer has specified. The manufacturer reserves the right to modify their product data or features without prior notice.

WARNING
Before starting up the machine or carrying out any maintenance work, read this instruction manual carefully

TECHNICAL ASSISTANCE

CRONOPLAST sl

CRONOPLAST S.L. C/Francesc Layret, 12-14 nave 23 - Pol. Ind. Sant Ermengol II - 08630 Abrera ( Barcelona) Espaa Tel. 93 770 50 78 Fax 93 770 19 54

www.babyplast.com
Last mod. 17/11/2009

BABYPLAST 6/10VP 6/25VP

CE CONFORMITY STATEMENT
We hereby declare that the product type refered to is is a: BABYPLAST MODEL 6/10VP (6/25P), WITH SERIAL NUMBER: ................. MANUFACTURER : CRONOPLAST S.L. TO BE USED SOLELY FOR THE INJECTION MOULDING OF THERMOPOLYMERS: EXCLUDING INFLAMMABLE AND OR EXPLOSIVE POLYMERS.

(according to delivery note nr. .............................dated...........................)

Babyplast 6/10P conforms to the following European standards: - 98/37/CEE and subsequent modifications - 89/336/CEE and subsequent modifications (electromagnetic compliance directives) - 73/23/CEE and subsequent modifications (low voltage directives)

AUTHORISED STANDARDS APPLIED FOR THE CONFORMITY DECLARATION

For machine directives 98/37/CE : UNI EN 292-1 UNI EN 292-2 UNI EN 201 For electromagnetic compliance directives (89/336/CEE) : CEI EN 61000-6-2:2001 CEI EN 61000-6-4:2001 For low voltage directives (73/23/CEE) : CEI EN 60204-1

Conformity to the declared standards carried out by: - UNI EN 292-1, UNI EN 292-2, UNI EN 201 : - CEI EN 61000-6-2, CEI EN 61000-6-4 : - CEI EN 60204-1 : Quadra report RP001 Eletech report 50261EMC01.00 Eletech report 50261LVD01.00

BABYPLAST 6/10VP 6/25VP

GENERAL INDEX CONTENTS


A/ B/ C/ D/ E/ F/ General conditions and characteristics of BABYPLAST 6/10VP (6/25VP)............. A-0010 How to install a BABYPLAST 6/10VP (6/25VP)..........................................................B-0010 Start up........................................................................................................................... C-0010 How to operate a BABYPLAST 6/10VP (6/25VP)....................................................... D-0010 Alarms............................................................................................................................ E-0010 Maintenance & technical drawings............................................................................. F-0010

A/ General conditions and characteristics of BABYPLAST 6/10VP (6/25VP).


A.1/General conditions......................................................................................................... A-0010 A.2/What is a BABYPLAST 6/10VP (6/25VP) and what can it do?......................................A-0010 A.3/Technical data................................................................................................................A-0020 A.3.1/ General dimensions of BABYPLAST 6/10VP (6/25VP).............................. A-0020 A.3.2/ BABYPLAST 6/10VP (6/25VP), Basic parts list............................................ A-0030 A.3.3/ Technical data............................................................................................... A-0040 A.3.4/ Machine platens............................................................................................ A-0050 A 3.5/ Main mould parts...................................................................................... ... A-0060 A.3.5a/ Mould MOULD HEIGHTS.................................................................. A-0070 A.3.5b/ Mould: exampl BASE PLATE............................................................. A-0080 A.3.5c/ Mould: exampl FIXED HALF.............................................................. A-0090 A.3.5d/ Mould: exampl MOVING HALF.......................................................... A-0100 A.3.6/ How to move the injection point off centre.....................................................A-0110 A.3.7/ Connections for mould temperature control.................................................. A-0120 A.3.8/ Diagramme to show injection pressures........................................................A-0140 A.3.9/ Diagramme to show injection pressuresAugmented version........................ A-0140 A.4/ Warranty....................................................................................................................... A-0150

B/ How to install a BABYPLAST 6/10P (6/25VP)................................................................ B-0010


B.1/ Unpacking and parts check...........................................................................................B-0010 B.2/Electrical connections 400V 3 phase + N + earth........................................................ B-0020 B.3/Electrical connections 230V 3 phase + earth.................................................................B-0020 B.4/Cooling system...............................................................................................................B-0030 B.5/Hydraulic oil specifications............................................................................................. B-0040

C/ Start up.............................................................................................................................C-0010
C.1/ Safety devices...............................................................................................................C-0010 C.1.1/ Main switch................................................................................................... C-0020 C.1.2/ Emergency stop.............................................................................................C-0020 C.1.3/ Hydraulic system safety device..................................................................... C-0030 C.1.4/ Safety devices for guards.............................................................................. C-0040 C.2/Installing a mould........................................................................................................... C-0050 C2a/ Removing the mould........................................................................................C-0055 C.3/ Display panel.................................................................................................................C-0060 C.4/Pressure guages............................................................................................................C-0060 C.5/Cooling system - water manifold....................................................................................C-0070 C.6/Pneumatic pressure reduction unit for guard................................................................ C-0080 C.7/Display - Synoptic diagramme....................................................................................... C-0090 C.8/Starting the machine...................................................................................................... C-0100

BABYPLAST 6/10VP 6/25VP

D/ How to use a BABYPLAST 6/10P (6/25VP).................................................................... D-0010


D.1/ Menu................................................................................................................................... D-0010 D.1.1/ Display....................................................................................................................D-0010 D.1.2/ Icons - description of functions............................................................................. D-0020 D.1.3/ Start up - gate check.............................................................................................. D-0030 D.1.4/ Main menu............................................................................................................. D-0040 D.1.5/ Manual menu......................................................................................................... D-0050 D.1.5a/ Manual menu CLAMP................................................................................ D-0060 D.1.6/Setting the MOULD CLOSED position................................................................... D-0070 D.1.7/Semi automatic menu............................................................................................. D-0080 D.1.7a/ Temperature settings................................................................................. D-0090 D.1.7b/ Times and settings.................................................................................... D-0100 D-1.7b1/INJECTION CARRIAGE settings................................................. D-0110 D-1.7b2/ PLASTIFICATION settings.......................................................... D-0120 D-1.7b3/ EJECTION settings......................................................................D-0130 D-1.7b4/ INJECTION settings....................................................................D-0140 D-1.7b5/ CLAMP settings........................................................................... D-0150 D-1.7b6.QUALITY CONTROL settings..................................................... D-0160 D-1.7b6a/QUALITY CONTROL Log file........................................ D-0180 D.2/Starting a cycle................................................................................................................... D-0190 D.2.1/ Starting a semi automatic cycle..............................................................................D-0190 D.2.2/ Starting a purge cycle.............................................................................................D-0210 D.2.3/Setting up the PART COUNTER.............................................................................D-0230 D.3/ Mould setting programmes..................................................................................................D-0240 D.3.1/ Loading a mould setting programme......................................................................D-0240 D.3.2/ Create or modify a mould setting programme........................................................D-0250 D.3.2a/Mould setting programmes - times and settings......................................... D-0260 D.3.2a.1/ INJECTION CARRIAGE............................................................. D-0260 D.3.2a.2/ PLASTIFICATION.............................. ....................................... D-0270 D.3.2a.3 / EJECTION................................................................................. D-0280 D.3.2a.4/ INJECTION.................................................................................D-0290 D.3.2a.5/ CLAMP........................................................................................D-0300 D.3.2b/ Mould setting programmes TEMPERATURES......................................... D-0310 D.3.2c/ CORE PULL............................................................................................... D-0320 D.3.3/ Mould setting programmes - COPY A PROGRAMME............................................. D-0330 D.4/Machine configuration.......................................................................................................... D-0350 D.4.1/Machine configuration - Change language - Celsius/Farenheit.............................. D-0360 D.4.2/Machine configuration - Temperatures.................................................................. D-0370 D.4.3/Machine configuration - Times and settings............................................................D-0380 D.4.4/Software Upgrade.............................................................................................D-0390 D.5/ USB memory stick - Saving/retrieving mould settings.................................................. D-0410 D.5.1/Printing/Elaborating mould setting data on a PC...................................................D-0430 E/ ALARMS..................................................................................................................................E-0010 F/ Maintenance........................................................................................................................... F-0010 F/2 Electrical and hydraulic drawings......................................................................................... F-0020 ......................................................................................................... F- 0210

BABYPLAST 6/10VP 6/25VP

GENERAL SAFETY REGULATIONS


To be studied carefully before using the machine The Babyplast 6/10VP (6/25VP) injection moulding machine, for thermoplastic materials, has been constructed to meet most safety regulations actually in force. Failure to respect the following instructions, may cause injury to the user or damage to the machine. 1) Do not remove the warning labels from the machine. These labels must always be clearly visible. 2) Before using a thermoplastic material, always consult the manufacturer about possible health risks and the precautions that must be taken in order to avoid accidents. 3) To avoid the risk of electric shock, never use the machine unless it has been properly earthed. 4) All the safety guards on the machine must be positioned correctly and maintained in good working order. 5) The protective covers over the electrical and electronical compartments, must remain closed and screwed down. The removal of the protective covers, may expose the operator to the risk of electric shock. 6) Safety devices, covers and protections, should not be deactivated or tampered with. 7) When working near the injection area, always wear protective gloves and suitable eye protections. 8) The various components of the mould must be correctly positioned and well secured before starting the injection phase. 9) Before carrying out any maintenance, the machine must by disconnected from the mains and the main switch must be turned off and blocked by a qualified technician. 10) The system that limits the hydraulic pressure, must always be regulated so that the pressure does not exceed the maximum pressure of 130 bar. 11) Never place hands or other objects inside the protective guards while the machine is functioning. 12) Maintenance on the machine should be carried out by qualified personnel only. 13) The machine is supplied with a power supply cable but without a plug. The plug used should comply to standard EN 60309-1 and 16A power rating. 14) The machine must be connected to the power supply via a mains switch with a rating of of at least 4500A at 230V / 400V. The power supply socket and switch must be installed in visable position for easy access and must have an identification sign or label. IT IS THE RESPONSIBILITY OF THE OWNER TO ENSURE THAT THE MACHINE MEETS MAXIMUM SAFETY LEVELS AT ALL TIMES, AND THAT THE OPERATOR ALWAYS RESPECTS THE SAFETY AND MAINTENANCE INSTRUCTIONS FOUND IN THIS MANUAL AND ON THE LABELS ATTACHED TO THE MACHINE. IN CASE OF DOUBT AND OR FOR ANY FURTHER CLARIFICATIONS, PLEASE CONTACT YOUR NEAREST DEALER.

BABYPLAST 6/10VP 6/25VP

A
A.1/ GENERAL CONDITIONS

This technical documentation is intended for all those responsible for using and handling the BABYPLAST 6/10VP (6/25VP) injection moulding machine. We wish to emphasise that this injection moulding machine can only be used according to the instructions set out in this manual. Failure to follow this instruction manual correctly, may cause injuries to people and animals or damage to materials and things. In the event of any problems, please contact our technical staff. In its continued endeavour to improve its products, CRONOPLAST reserves the right to vary or modify such products without prior notice. It is strictly forbidden to reproduce or copy this manual without written prior consent from CRONOPLAST S.L., or to use said manual for unauthorised purposes. BABYPLAST 6/10VP (6/25VP)is a PATENTED model. BABYPLAST 6/10VP (6/25VP)has been designed and built according to EN 201, EN 60204-1-1992, EN 292-1, EN 292-2. The above include DIN 5310, DIN 5318T2, DIN 54635T48, according to the 89 / 392 / EEC and 93 / 44 / EEC Directives on machinery. The machine is certified as complying with the European standard "CE". ATTENTION! It is forbidden to sell or transfer this machine to the U.S.A., Canada and Mexico, unless the mechanical safety device kit has been installed. The manufacturer and distributor will not accept responsibility for accidents caused due to failure to observe this warning. The technical documentation for the machine, if within the European Economic Community, is provided in the language of the country of destination. For multi-lingual countries or those outside the European Community, the required language should be specified in the customers order.

A.2/ WHAT IS A BABYPLAST 6/10VP (6/25VP) AND WHAT CAN IT DO?


The BABYPLAST 6/10VP (6/25VP) injection moulding machine is the result of thirty years experience working in specific fields of plastic injection moulding, mould design and construction. Research and development, on the machine, began more than ten years ago, in response to an important area of demand: - FULL PRODUCTION OF MICRO PARTS - SMALL SERIES PRODUCTION. - PROTOTYPE DEVELOPMENT. - LOW COST OF MOULDS.. - LABORATORY TESTS. - TECHNICAL TRAINING. BABYPLAST 6/10VP (6/25VP) is the ideal solution for producing small plastic-moulded parts, without using multiple cavity moulds. This is particularly useful when developing prototypes or producing small series of parts. Owing to the low cost of the moulds used in our machines, in-depth experiments can be carried out before the final mould for large series production is built. As a result, both small and medium series can be produced easily, and COMPLETELY AUTONOMOUSLY. Thank you for the trust you have placed in Babyplast. We are confident that your BABYPLAST 6/10VP (6/25VP) machine, will help fulfil your application expectations. When handling and processing any injection moulding materials, customers must follow the material manufacturer's instructions with great care.

A-0010

A
A.3./ TECHNICAL DATA A.3.1/ General Dimensions

BABYPLAST 6/10VP 6/25VP

1600

830

1.370

670

All dimensions are in mm.

A-0020

BABYPLAST 6/10VP 6/25VP

A
A.3.2/ Babyplast 6/10VP (6/25VP) - BASIC PARTS LIST

10

11 12 13 14 15 16 17 18 19 20 21

18

22 23

6 5 4

3 2 1

27 28 29

24 25 26

1-Oil tank 2-Safety valve anti-drop 3-Micro switch - mould guard 4-EMERGENCY stop 5-Double start buttons - rotating table 6-Rotating table 7-Micro switch - hydraulic safety 8-Mould guard 9-Clamp transducer 10-Clamp piston 11-Heat guard 12-Hopper 13-Injection guard 14-Hydraulic manifold

15-Hydraulic safety valve 16-Hydraulic - maximum pressure regulator 17-Main switch 18-Photo cells 19-Clamp pressure gauge 20-Fixed mould guard 21-Injection pressure gauge 22-Display touch-screen 23-Alarm warning light 24-Data setting dial 25-Water manifold 26-Anti vibration pads. 27-Power cable 28-Electrical cabinet 29-Water inlet-oulet

A-0030

A
A.3.3/ TECHNICAL DATA
STANDARD INJECTION UNIT Piston diameter (mm.): Volume (cm3): Injection pressure (Kg/cm2.) : Injection capacity (cm3/ / sec): Plastification capacity (g/sec): Clamp force : Opening stroke : Ejection force: Ejection stroke : Hydraulic pressure : Oil tank capacity : Dry cycle : Rated power : Noise level : Power supply: 10 4 2.650 3,98 12 6, 5 1.830 5,74 14 9 1.340 7,81 1,8 6.250 Kg/cm2 110 mm 920 Kg 50 mm 130 Kg./cm2. 12 l. (a ppro x.) 2,4 s. 3 Kw < 70 db 16 12 1.030 10,2 18 15 815 12,9

BABYPLAST 6/10VP 6/25VP

AUGMENTED INJECTION UNIT 16 16 1535 6,84 20 25 980 10,7 3,1 62,5 KN 24 36 680 15,4

9,2 KN

3 ~ 230V. 50/60 Hz. + Earth 3 ~ 400V. 50/60 Hz. +Neutral + Earth

A circuit breaker must be used at the mains connection.

A-0040

BABYPLAST 6/10VP 6/25VP

A
MACHINE PLATENS

A.3.4/

Sez. B-B

B A

B A

Sez. A-A
Max. nozzle forward pos.

Mould locating pins All dimensions are in mm A-0050

A
A.3.5/ MAIN PARTS - MOULD AREA.

BABYPLAST 6/10VP 6/25VP

1 2 3 4

5 6 7 8 9 10 11
1. CHASSIS 2. SCREWS FOR FIXING MOVING MOULD HALF 3. MOVING PLATEN 4. MOVING MOULD HALF 5. INJECTION UNIT POSITION 6. FIXED MOULD HALF 7. EJECTOR PLATE 8. SCREWS FOR FIXING FIXED MOULD HALF 9. MOULD LOCATING PINS 10. FIXED PLATEN 11. EJECTORS

A-0060

BABYPLAST 6/10VP 6/25VP

A
A.3.5.a/ MOULD: Mould heights

Holes for fixing to moving platen. Moving mould half.

Injection unit position.

L
Fixed mould half Ejector plate Locating pins Slots for fixing to fixed platen
Dimension A (position = of injection unit)

B
70 - 95 mm
Minimum mould height A+B Dimension C

= =

120mm 229mm (Max. opening stroke) C - (A+B)

Mould open gap L =

C
A-0070

A
A.3.5b/ MOULD: example BASE PLATE 1

BABYPLAST 6/10VP 6/25VP

3 2 1

All dimensions are in mm A-0080

Sez. A-A

BABYPLAST 6/10VP 6/25VP

A
A.3.5c/ MOULD: example FIXED HALF 2

3 2
MAXIMUM NOZZLE MOVEMENT

95 70 10 45

1 45

1,5

R 1,5

All dimensions are in mm

ATTENTION
DO NOT MOVE THE NOZZLE FORWARD WITH MOULD OPEN
A-0090 A-0090

A
A.3.5d/ MOULD: example MOVING HALF 3

BABYPLAST 6/10VP 6/25VP

3 2 1

10

75

47.5

47.5

47.5

47.5

All dimensions are in mm A-0100

BABYPLAST 6/10VP 6/25VP

A
......../ MOULD: MOVING HALF 3

ATTENTION:

Construct the mould, moving half, so as to leave at least 10mm between the mould and the transparent guard wich rotates with the rotating table.

3 2 1

N.B. : The height of the rotating table can be modified according to the mould.

Moving platten Moving mould half Locating pins Gap Transparent guard

min 10

ca 140

ca 140

A-0110

A
A.3.5f ATTENTION: MOULD: ejection

BABYPLAST 6/10VP 6/25VP

Construct the mould, considering that the maximum ejector stroke is 30mm, so that the ejector plate does not touch the mould. (Leave approx. 2mm of gap), so that the force of the ejector piston does not push on the mould and hence rotating table.

Ejectors Gap Cavity plate Ejector return springs Ejector plate Max. ejector stroke Ejector piston
min 2 30

All dimensions are in mm.

A-0120

BABYPLAST 6/10VP 6/25VP

A
A.3.6/ Changing injection unit position

Babyplast 6/10VP (6/25VP), has three injection unit positions, at 70, 95 and 45 from the surface of the fixed platen.

TO CHANGE THE INJECTION ASSEMBLY POSITION, PROCEED AS FOLLOWS: Unscrew and remove the fixing screwsfrom position 1. Slide the complete injection unit 2 out and insert it into the new position. Screw in and tighten the two fixing screws in the new position. ATTENTION: THE MACHINE MUST BE DISCONNECTED FROM THE POWER SUPPLY BEFORE CARRYING OUT THIS OPERATION.
A-0110

A
kg/cm2 3.000

BABYPLAST 6/10VP 6/25VP

A.3.8/ DIAGRAMME TO SHOW INJECTION PRESSURES 6/10 VP

2.500
Specific pressure on material

Injection piston

2.000

10mm* 12mm

1.500 14mm 1.000 16mm 18mm 500

10

20

30

40

50

60

70

80

90

100

110

120 kg/cm2

Hydraulic pressure
* IMPORTANT NOTE: The maximum hydraulic pressure for the 10mm piston must be limited to 100 bar. This is done automatically by setting the value of 10mm for the piston size under TIMES AND SETTINGS in the MACHINE PARAMETERS menu see section D.4.3, page D-0400.

A.3.9/ DIAGRAMME TO SHOW INJECTION PRESSURES 6/25VP


kg/cm2 3.000

2.500
Specific pressure on material

Injection piston

2.000 16mm

1.500

1.000

20mm 24mm

500

10

20

30

40

50

60

70

80

90

100

110

120 kg/cm2

Hydraulic pressure

A-0140

BABYPLAST 6/10VP 6/25VP

A
A.4/ WARRANTY

The vendor guarantees that the material is to be supplied against all manufacturing faults, and accepts replacing any faulty part or repairing any faulty operation free-of-charge, providing the buyer notifies the vendor of said fault within a maximum period of TWELVE MONTHS from the date the machine is received at its destination. It is clearly stated that this warranty does not include: heating elements, paint, oil and optional accessories; wear caused through improper use and handling; knocks, in the case of damaged / broken seals on the hydraulic unit, If the maximum authorised pressure levels have been exceeded, troubles caused by faulty connections in the electrical system, the use of un-authorised lubricants, accidents and damage or any failure to observe the application and installation instructions detailed in this manual. Furthermore. the travelling expenses of a technician (hours and kilometres) as well as transport costs for replacement parts are also excluded. Once the TWELVE MONTH warranty period has expired, the vendor will not accept any claims or returned parts. However, faults that the buyer issues claims for, may be checked by the vendor, using any technical means considered necessary, on condition that the buyer does not obstruct the work of those who the vendor has nominated responsible for carrying out the revision. WARNING: In its continual endeavour to improve its products, CRONOPLAST reserves the right to modify or vary its products features or specifications without prior notification.

A-150

B
B/ INSTALLATION OF THE BABYPLAST 6/10VP (6/25VP) B.1/ UNPACKING AND PARTS CHECK.

BABYPLAST 6/10VP 6/25VP

ATTENTION: THE MACHINE IS TOP HEAVY, PAY GREAT ATTENTION WHEN MOVING THE MACHINE PARTICULARLY WITH A FORKLIFT TRUCK OR TROLLEY.

Babyplast is supplied in a wooden crate and weighs approx. 340 Kg. - see fig. a. First of all remove the srews that secure the front panel and remove it. (fig.b) Remove the screws that secure the other panels around the machine and remove them fig. c). Check the machine for signs of damage or any other faults and, if found, contact your nearest ditributor immediately. Remove the internal packing parts that secure the machine inside the wooden crate and using the two lifting rings on the top of the machine, lift the machine off the wooden base (fig.d). B.2/ INSTALLATION Screw the anti-vibration pads into the base of the machine and place it in a dry well lit place that is sheltered from atmosheric conditions and where the temperature does not exceed 40C (fig.e). Before lowering to the ground, check that the ground is level and if necessary make as near level as possible. (fig.f). Once the machine has been lowered to the ground, check that it is level and if necessary adjust the anti vibration pads. VERY IMPORTANT - ATTENTION, HANDLE WITH EXTREME CARE. Inside the packing you will find: a/ 1 BABYPLAST 6/10VP (6/25VP). b/ 1 instruction manual c/ 1 hopper. d/ 1 bag containing special tools. e/ 1 Set of accessories as requested by the customer.

Fig. a

Fig. b

Fig. c

Fig. d B-0010

Fig. e

Fig. f

BABYPLAST 6/10VP 6/25VP

B.2/ ELECTRICAL CONNECTIONS for 400V power supply

3 phase + neutral + earth - 400V - 50/60Hz


The mains power supply fuses inside Babyplast have a blow rating of 3.500 A at 400V. The machine must be connected to the mains via a 16A thermo / 0,030A differential circuit breaker, that is suitable for the power supply used. Attention! For power supplies with the neutral isolated from earth, a relay for permanent isolation must be installed. BABYPLAST 6/10VP (6/25VP) will be prepared for connecting to a power supply as specified in the customers order. WARNING: CHECK THAT POWER SUPPLY AND MACHINE ARE COMPATIBLE BEFORE CONNECTING TO MAINS POWER SUPPLY!!

B.3/ ELECTRICAL CONNECTIONS for 230V power supply

3 phase +earth - 230v - 50/60Hz


The mains power supply fuses inside BABYPLAST 6/10VP have a blow rating of 10.000 A at 230V. The machine must be connected to the mains via a 16A thermo / 0,030A differential circuit breaker, that is suitable for the power supply used. BABYPLAST 6/10VP (6/25VP) will be prepared for connecting to a power supply as specified in the customers order. WARNING: CHECK THAT POWER SUPPLY AND MACHINE ARE COMPATIBLE BEFORE CONNECTING TO MAINS POWER SUPPLY!! Current: Max 7,5A - average 3,5A FUSES INSTALLED ON THE fm542 BOARD Fuse pos. number F501 F502 F503 F504 Technical specifications 10A - 500V - rapid blow 10A - 500V - rapid blow 10A - 500V - rapid blow 8A - 250V - rapid blow Dimensions Power rating FUNCTION

6,3X32 F 6,3X32 F 6,3X32 F 6,3X32 F

500V/ 1.500A - 250V/10.000A 500V/ 1.500A - 250V/10.000A 500V/ 1.500A - 250V/10.000A

PHASE R PHASE S PHASE T

F505 F506 F507 F508 F509

8A - 500V -extra rapid 3,15A - 500V - extra rapid 3,15A - 500V - extra rapid 6,3A - 500V - extra rapid 3,15A - 500V - extra rapid

6,3X32 FF 6,3X32 FF 6,3X32 FF 6,3X32 FF 6,3X32 FF

500V/ 1.500A - 250V/10.000A 500V/ 1.500A - 250V/10.000A 500V/ 1.500A - 250V/10.000A 500V/ 1.500A - 250V/10.000A 500V/ 1.500A - 250V/10.000A

Plast. heater Chamber heater Nozzle heater F. mould heater M. mould heater

B-0020

B
B.4/ COOLING SYSTEM

BABYPLAST 6/10VP 6/25VP

This is needed to: Cool the hydraulic oil. Cool other parts of the machine. For connecting the cooling water supply to the BABYPLAST machine, the inlet and outlet hose must be of a flexible type. Connect the inlet hose to the water supply (see diagramme), the outlet hose to the return circiuit and open the shut-off valve. The temperature of the incoming water must be between 12C (min.) and 18C (max.). However, the minimum and maximum temperatures are indicative only and depend on the machine settings and working conditions. The water must be clean, otherwise a filter must be used and the calcium content controlled. The water hardness must be between 6 grd-9grd dH, and the pressure between 3-4bar (max.) with a difference between the inlet and outlet of 1.5 bar.

INLET TUBE diam. 8 mm approx. OUTLET TUBE diam. 11 mm approx.

B-0030

BABYPLAST 6/10VP 6/25VP

B
B.5/ HYDRAULIC OIL SPECIFICATIONS

BABYPLAST is not supplied with hydraulic oil unless requested as an accessory. Only an oil with the following properties can be used in the machine. OIL PROPERTIES: RANGE: -15C +80C 2 VISCOSITY: 12 100 mm /SEC.(CST) FILTRATION: 25 30 um. MINIMUM AGIP-OSO45 CASTROL-HISPIN AWS46 CHEVRON-EPHIDRAULIC OIL 11 ESSO -NUTOH48 IP-IPHYDRUS OIL 46 MACH -BP ENERGOL HLP80 MOBIL-DTE MEDIUM FIAT- RZA 40 TOTAL- AZOLLA 30 VERY IMPORTANT The guarantee on the machine will be void if any oils other than those listed above are used in the machine. CRONOPLAST does not accept any responsibility in such cases. How to fill the machine with hydraulic oil. Remove the oil cap and fill the tank until the level reaches the mark on the dipstick. attached to the oil cap. ATTENTION: THERE IS A SENSOR WITH A FLOAT, INSIDE THE OIL TANK, WHICH CAUSES THE MACHINE TO GO INTO ALARM (ALARM 023) IF THE OIL LEVEL IS TOO LOW. OPERATING TEMPERATURE: 45C MAXIMUM TEMPERATURE : 60C (ALARM 020) MINIMUM TEMPERATURE : 20C (ALARM 029).Below the minimum temperature, it will only be possible to switch on the motor, heaters and consult the various menus and settings. No machine movements will be possible.

Oil return filter Hydraulic system- max. pressure regulator Oil fill cap

B-0040

C
C./ SAFETY DEVICES C.1 SAFETY DEVICES Position of safety equipment devices. Safety for the user. Mould safety. Safety standards. EN 60204 T1/1985

BABYPLAST 6/10VP 6/25VP

DIN VDE 0113 T1/02.B6.

10

11

12 13

14 15

1. Emergency stop button 2. Clamp safety valve 3. injection guard 4. Double switch injection guard 5. Hydraulic safety valve 6. Main switch 7.Photo cells 8. Mould guard - rotating table 9. Mould guard 10. Alarm warning light 11. Double start button- cycle / rotation of table 12. Hydraulic safety switch - L/H mould guard 13. Double switch L/H mould guard 14. Hydraulic safety switch - R/H mould guard 15. Double switch R/H mould guard

C-0010

BABYPLAST 6/10VP 6/25VP

C
C.1.1/ MAIN SWITCH

Switches the machine ON and OFF and is found on the side of the machine (figura 1c). Has two positions (0 off - 1 on). When i n position 0 it is possible to insert a padlock to block it for safety reasons.

fig. 1c

C.1.2/ EMERGENCY STOP


Switches off the motor, all the electro-valves (thus stopping all the machines movements) all the heater elements, and activates alarm 031 EMERGENCY STOP. To restart the machine, once the emergency stop button has been pushed, rotate the button anti-clockwise and reset the alarm on the display.

C-0020

C
C.1.3/ HYDRAULIC SYSTEM SAFETY DEVICE

BABYPLAST 6/10VP 6/25VP

When one of the two, sideMOULD GUARD are opened, all the hydraulic fluid in the system is diverted to the oil tank, the power supply to the valves is cut, thus stopping all the machines movements. A micro switch is mounted on the safety valve (paragraph F hydraulic diagramme) to monitors it and ensure it functions correctly. If the transparent guard is closed and the hydraulic safety device does not return to its working position, alarm 002 GATE OPEN is activated.

Mould safety guards

Actuators hydraulic safety

C-0030

BABYPLAST 6/10VP 6/25VP

C
C.1.4/ SAFETY DEVICES FOR GUARDS 1 2

1-2/ Photo electric barrier If, during the rotation of the table, the photo electric barrier detects an intrusion, the power supply to the motor is cut and rotation stops immediately.

3/ Injection guard sensor When the injection guard sensor is activated, The power supply to all the valves (except the safety valves), which control the machine movements, is cut. The machine goes into alarm 003, the warning light comes on and an acoustic warning is given.

4-5-6-7/ Mould guard switches.

4
When the mould guard switches are activated, The power supply to all the valves (except the safety valves), which control the machine movements, is cut. The machine goes into alarm 002, the warning light comes on and an acoustic warning is given.

4 6

5 7

6 7
C-0040

C
C.2/ INSTALLING A MOULD
ATTENTION:

BABYPLAST 6/10VP 6/25VP

a. Before installing the mould, check that the rotating table turns clockwise, otherwise invert a fase in the power supply plug. b. The injection unit has 3 different injection positions (heights), check that the one selected is compatible with the mould to be used.

To install the mould, proceed as follows: A-/ Place the mould on the fixed platen making sure that it is correctly positioned on the two 10mm diam. locating pins B-/ Fix the lower mould half to the rotating table using four screws M10 x 25 . C-/ Press the two START buttons to rotate the table and release the buttons, when the table is approximately 130 from the initial position, so that the mould is near the left mould guard ( if the position is not correct, repeat the procedure).

D-/ Open the left mould guard and, via the open guard, position the upper mould half on top of the lower mould half. E-/ Press the two start buttons and keep them pressed till the mould assembly is in the correct position under the clamp piston. F-/ In MANUAL, lower the moving platen down onto the mould assembly. G-/ Fix the upper mould half to the moving mould platen using 4 screws M8 x 20. H-/ Fix the lower mould half to the rotating table. I-/ Connect the water cooling tubes and check for the correct movements of clamp and ejector pistons

L-/ Close the mould and check that the nozzle is in the correct position with respect to the mould. (CRONOPLAST S.L. and RAMBALDI Srl are highly experienced in the design and construction of moulds, and are therefore, in a position to be able to offer their customers the possibilty of collaboration for all aspects of mould construction in order to find the best technical solutions that suit the customers needs). C-0050

BABYPLAST 6/10VP 6/25VP

C.2a/ REMOVING THE MOULD


ATTENTION: Before removing the mould, check that the rotating table turns clockwise, otherwise invert a fase in the power supply plug.

To remove the mould proceed as follows: A-/ In MANUALclose the clamp till the mould is closed completely. B-/ Remove the M8 x20 screws which fix the upper mould half to the moving platen. C-/ Open the clamp completely so that the upper mould half remains on the lower mould half and thus both remain on the rotary table. D-/ While in the page MANUAL CLAMP press key F5
Fig.1
MANUAL: CLAMP

Fig.2
MANUAL: CLAMP

000.0 00.0mm

000.0 00.0mm

F1

F2

F3

F4

F5

F1

F2

F3

F4

F5

E-/ Once in the page as per Fig. 2, press the two start buttons and keep them pressed, The rotating table will rotate approximately 35 and stop near the right hand mould guard. remove the upper mould half

ATTENTION: While in this page, for safety reasons, ( the complete mould cannot pass under the transparent guard) it will not be possible to make the rotating table move again. The upper half of the mould MUST be removed, exit from this page and then it will be possible to rotate the table.
F-/ ONLY ONCE THE UPPER MOULD HALF HAS BEEN REMOVED return to the pageas per Fig. 1, rotate the table to the operator side and remove the lower mould half of the mould.
C-0055

BABYPLAST 6/10VP 6/25VP

BABYPLAST 6/10VP 6/25VP

C
C.3/ DISPLAY PANEL

Tool settings are set and saved via the multi-function touch-screen display. It is also possible to control the various functions of the machine and handle and activate the various phases of the cycle. A. TOUCH-SCREEN DISPLAY Visualise all data and functions of the machine as well as the synoptic diagramme of the machine. Allows machine parameters to be varied or saved, by touching the various icons or fields of data. B. References for icons The following refences are used (F1F2 etc..) to simplify the explanations of the functions of the various icons referred to in this manual on the touchscreen display. C. ALARM WARNING LIGHT Lights up when an alarm is activated. At the same time a description of the alarm/fault appears on the display. D. DIAL Allows a more rapid input/change of data.

MENU PRINCIPALE

C.4/ PRESSURE GAUGES


These are situated on the lower left-hand side of the machine.

CLAMP PRESSURE GAUGE Indicates the CLAMP PRESSURE which corresponds to the maximum working pressure of the machine. (system pressure 130bar).

INJECTION PRESSURE GAUGE Indicates the INJECTION PRESSURE (1st Pressure 2nd Pressure)

C-0060

C
C.5/ COOLING SYSTEM - WATER MANIFOLD
Situated on the left-hand side of the machine.

BABYPLAST 6/10VP 6/25VP

25 20 15 10

25 20 15 10

25 20 15 10

Icons : indicate the cooling zone. Sphere : Indicates the actual water flow rate. Control knobs: adjust the water flow rate to each zone

Regulates the water flow required for cooling:

1 2 3 4

mould half 1. mould half 2. Fixed platen. Hopper area.

The zones should be regulated so as to obtain a minimum amount of water consumption, in relation to the temperatures needed for each zone for the production cycle. The water flow, for cooling the hydraulic oil, is regulated automatically by an electro-valve. If the oil temperature exceeds 60C, alarm 020 OIL OVER HEATED is activated or 108 INVERTER OVER HEATED. C-0070

BABYPLAST 6/10VP 6/25VP

C.6/ SENSORE SICUREZZA CARRO INIEZIONE ARRETRATO

ATTENTION: It will only be possible to rotate the rotating table if sensor B, fitted to the injection carriage, is activated. Adjust the position of metal plate A so that sensor B is only activated when the injection carriage is fully back and adjust injection carriage time settings as per ( Parag. D.1.7.b1 page D-0110) to a value which is enough to activate the sensor.

C-0080

C
C.6/ Display - Synoptic diagram

BABYPLAST 6/10VP 6/25VP

The touch-screen display, other than allowing access to the various functions and parameters of the machine, also indicates the activation of hydraulic movements, the acivation of the motor and the heaters, the opening of guards and gate and the opening and closing of the mould.

1 2 3 R1 200

MENU PRINCIPALE R2 200 R3 200 R4 OFF 23 22 21 20 19

4 5 6 7 8 Ingranaggio cod 2345 9 10


000.0mm 00.0mm

11
1. 2. 3. 4.

12

13

14

15

16

17

18

Page visualised. Actual temperatures - H1 plastif. - H2 Chamber - H3 Nozzle - H4 Mould. If present, indicates that the motor is ON. This group of three arrows indicates that the mould is closing in HIGH PRESSURE and that the hydraulic valve has been activated. 5. Mould position. 6. Two black squares indicate that the mould is closed. 7. Indicates that the left guard is open. 8. Indicates that the right hand guard is open. 9. Indicates the name of the tool setting programme in use. 10. Icons: touch to activate corresponding function. 11. Mould heater active: Red -temperature within tolerance band, Yellow - temperature in stand-by. 12. Indicates activation of ejectors and that the hydraulic valve has been activated. 13. Nozzle heater active - Red -temperature within tolerance band, Yellow - temperature in stand-by 14. Indicates the injection carriage forward movement and that the hydraulic valve has been activated. 15. Indicates injection in progress and that the hydraulic valve has been activated 16. Indicates decompression in progress and that the hydraulic valve has been activated. 17. Indicates injection carriage backward movement and that the hydraulic valve has been activated. 18. Injection piston position 19. Indicates activation of plastification and that the hydraulic valve has been activated. 20. Plastification heater active: - Red -temperature within tolerance band, Yellow - temperature in stand-by 21 Chamber heater active: - Red -temperature within tolerance band, Yellow - temperature in stand-by 22. Indicates that the injection guard is open. 23. Indicates the closing or opening of the mould and that the corresponding hydraulic valve has been activated. C-0090

BABYPLAST 6/10VP 6/25VP

C
C.7/ STARTING THE MACHINE

The machine is now ready to be started. Check that it has been filled with oil to the correct level, and that it is connected to the mains correctly.After switching on at the main switch, the SAFETY GUARD CHECK must be carried out In order to continue. Before being able to start the motor, the safety guards must be opened and closed. If a fault is detected with any of the guard switches, it will not be possible to start the machine. Carry out the following procedures before starting the injection process: FIRST: Install the mould and set the mould closed position, following the instructions in section 2/C NSTALLING A MOULD (page C-050) and D1.6/ SETTING THE MOULD CLOSED POSITION.(page D-070) SECOND: Set the plastification temperature according to the specifications indicated by the manufacturer of the material to be injected. Set the injection chamber temperature to approximately 5/10 C below the plastification temperature parag. D.1.7a TEMPERATURE SETTINGS (page D0090) WARNING: Plastic material, which was used for tests during the manufacturing process, will be found in the INJECTION UNIT. MAKE SURE that this material is compatible with the temperatures at which the machine is to be programmed. If the user is not experienced in the transformation of thermoplastic materials, it is advisable to begin with a material with a wide temperature range, such as POLYPROPYLENE, POLYSTYRENE, POLYETHYLENE ABS,etc.so as to obtain best results right from the start. THIRD: Set the shot size based on the volume of the part, the cooling time between 2 and 4 seconds, the 1st injection pressure at approx. 50/60 bar and a time for the 1st injection pressure depending on the volume of the part to produce and the density of the material used (start with 1.5 - 3 seconds for example). Decompression should be set between 1 and 2 mm Parag. D.1.7b4 INJECTION SETTINGS (page D-0140) FOURTH: Set sprue break time from 0.5 to 0.8mm see INJECTION CARRIAGE TIME parag. D1.7b1 (page D0110). Set the opening stroke depending on the size of the part, see parag. D1.7b5 (page D-0150) and finally, set the ejection time from 0.2 to 0.7 secs. with 2 or 3 ejector strokes. parag. D.1.7b3 (page D-0130). FIFTH Close the material chute on the hopper and load the hopper with material as required. When the various, previously set, temperatures have been reached, open the material chute on the hopper and purge the machine according to section D.2.3 PURGE page D-0240). The machine is now ready to produce parts. SIXTH Put the machine in semi-automatic mode and make sure that the transparent guard and covers are closed. Place an insert in the first lower mould half and press the two START buttons till the mould rotates to the correct position under the clamp. If the mould is in the correct position, the machine will proceed to complete one cycle. In the meantime, the operator should load another insert in the other lower mould half. At the end of the cycle, press the the two start buttons again to complete the rotation of the table and until the ejection cycle has finished. The nozzle may cool slightly, during the first shots, as it comes into contact with the cold mould. If so, for the first shots only, increase the nozzle temperature by approximately 5 or 10%. If good results have been achieved, repeat this process several times , adjusting the different machine parameters such as times, temperatures, pressures and material load etc. Once stabilized, make sure that, at the end of the injection cycle, the injection piston reaches a point less than 3 mm (cushion) within 8 cycles (page D-0400), otherwise the machine will go into alarm injection incomplete (page D-0400) . To modify settings see parag. D.4.1 ADVANCED SETTINGS The parameters quoted in this section are only a guide line, because the various parameters and settings always depend on the material used, the mould construction and the volume of the part etc. WARNING: Some plastic materials maybe inflammable and/or explosive. C-0100

BABYPLAST 6/10VP

BABYPLAST 6/10VP

D
D.1/ MENU D.1.1/ Display Touch-screen

BABYPLAST 6/10VP

Menu open Motor status Clamp position Synoptic diagram


000.0mm

MAIN MENU

F8

00.0mm

F7

Injection position moviment Indicators Tool setting programme in use Function key icons

F6
PROGRAMME IN USE

F1

F2

F3

F4

F5

D-0010

BABYPLAST 6/10VP

D
Information/upgrade software upgrade software Display/CPU Mould closed position Save mould setting data Overwrite or change mould Access to mould settings Access to mould setting files Save data on USB memory stick Retreive data from USB memory stick Part counter Activate temp. in Stand-by Deactivate Temp. in Standby Quality control password 1212 Log file: Cycle time -cushion Save average cycle time Exit without saving Mould opening and inj. carr. in semi-automatic Start automatic or semiautomatic cycle Stop automatic or semiautomatic cycle Purge Purge to start cycle Purge to end cycle Core pull Setting times Activate airblow in manual if present Activate venturi loader

D.1.2/ ICONS - Description of functions


Switch ON the motor. Switch OFF the motor Timer for starting motor Access to tool settings Access to machine configurations Access to machine config. - password 1212 Access to manufacturer settings. Switch heaters ON Switch heaters OFF Access to temperatures page Atomatic menu Semi-automatic menu Manual menu Visualise alarm messages Confirm - return to previous page Clamp in manual or access to clamp data Inj. carriage in manual or access to inj. carriage data Plastification inmanual or access to plast. data Ejection in manual or access to ejection data Injection in maual or access to injection data Times and settings Manual movements clamp open Manual movements clamp closed
Pressed before F1/ F3 close and open as per programme

Access to keyboard Manual movements to the right Manual movements to the left

D-0020

D
D.1.3/ START UP - GATE CHECK

BABYPLAST 6/10VP

After turning the main switch to the 1 (ON) position, the BABYPLAST logo will appear for a few seconds followed by the following display:

Indicates right guard open

Indicates left guard open

000.0 00.0mm

Indicates injection guard open.

CHECK GUARDS

The clamp and injection guards should be in the closed position. At this point the user should follow the following procedure: 1. Open the left guard and then close it again. 2. Open the right guard and then close it again. 3. Open the ijection unit guard and then close it again The above procdure is necessary to gain access to the next menu and thus start the machine. If a fault is detected in the gate swiches, during the functional or sequence checks, the machine will go into alarm and start up will be prevented. If the gate check is successful, the MAIN MENU will appear on the screen (see next page). ATTENTION! If the machine goes into alarm FAULTY GATE or GUARD SWITCH (n 06, 07 or 08) during the gate check at start up, switch the machine off and then on again. If the machine goes into the same alarm while the machine is running, reset the alarm and carryout the gate check again but without switching off the machine.This procedure may be repeated three times after which the machine will go into alarm REPEATED FAULTY GATE SWITCH. At this point the machine must be switched off and then on again to reset the the gate check function.

1
D-0030

BABYPLAST 6/10VP

D
D.1.4/ MAIN MENU

MAIN MENU

F8

000.0mm 00.0mm

F7

Motor ON/OFF

F6

Machine configuration
Go to stored tool settings Timer for starting the motor and heaters

F1

F2

F3

F4

F5

Press F7 to switch on the motor. The motor symbol, in the top left hand corner of the display, will appear as long as the motor is running. press the same key again to switch off the motor. Keys F1, F2 & F3 are activated when the motor is switched on.
ATTENTION! If the oil temperature is below the minimum value set by the manufacturer (20C), no movements will be possible. In order that the oil reaches the correct temperature rapidly, the motor will turn at full speed.

Motor status ON
MAIN MENU

F8
Motor OFF

000.0mm 00.0mm

F7

F6
Mould setting programme in use
Gear - art. 2345

Machine configuration
Access to stored mould settings

F1

F2

F3
Automatic menu

F4

F5

Manual menu

Switch heaters ON

ATTENTION! The heating elements are switched on by pressing key F3. The setting values will be taken from those stored in the tool setting programme indicated in the synoptic diagram.

D-0040

D
D.1.5/ MANUAL MENU
While in the MAIN menu, press F1 The following display will appear: to enter the MANUAL menu.

BABYPLAST 6/10VP

ATTENTION! when in any page in the MANUAL MENU except Ejectionit will be possible to rotate the table, by pressing the two start buttons simultaneously, under the following conditions:
1. sensor for injectio carriage back, must be activated. 2. sensor for ejectors back, must be activated. 3. Mould must have reached fully open position. If the above condions have not been met, at the moment the table should be rotated, then a red indicator will appear in the position in the synoptic diagramme where the consensus is missing.
MANUAL MENU

F8
Back to previous display

000.0mm 00.0mm

F7

F6

Temperatures

F1
Clamp

F2

F3

F4
Plastification

F5
Injection Ejection

Injection carriage

To activate the various movements in manual, press one of the keys to select the function required. Having entered the function required, press one of the two keys for backward or forward movements, or the two keys up and down movements.

For the menu MANUAL: CLAMP see following page. For the menu MANUAL: EJECTION F3 will activate the optional valve for AIR BLOW if installed. ATTENTION! For plastification and injection, piston movement will only be possible when the set temperatures have been reached. ( See tolerance band - user data input ). WARNING: WHEN CHANGING FROM ONE MATERIAL TO ANOTHER, LOADING A DIFFERENT MOULD SETTING PROGRAMME OR IN CASE OF RESIDUE MATERIAL LEFT IN THE SYSTEM FROM PREVIOUS PRODUCTION, GREAT CARE MUST BE TAKEN TO SET THE CORRECT PROCESSING TEMPERATURES ACCORDING TO THE MATERIAL MANUFATURERS DATA SHEET. FAILURE TO DO SO MAY CAUSE DAMAGE, BLOCKAGE, OR GAS; PARTICULARLY DURING PURGING. D-0050

BABYPLAST 6/10VP

D
D.1.5a/ MANUAL MENU : CLAMP
MANUAL: CLAMP

F1 F2

MANUAL CLAMP OPEN Speed set by manufacturer (30%)

Pressed before keys F1or F3 allows the opening and closing of the clamp at the speed set in the tool setting programme in use (see diagramme at bottom of page D1).

F8

F7

F3 F4 F5

MANUAL CLAMP CLOSE Speed set by manufacturer (30%) CLAMP DATA - please see below Set MOULD CLOSED POSITION - please see following page

F6

F1

F2

F3

F4

F5

ATTENTION! CLAMP CLOSED prohibited if the table is not in position (consensus from
sensor) MOULD OPEN PROHIBITED if injection carriage is forward (consensus from sensor)
When in the menu MANUAL CLAMP press F4 SETTINGS:
To vary values, touch window and rotate dial

to gain access to the menu for CLAMP TIMES AND

The maximum value depends on the thickness of the mould Maximum pressure for the low pressure clamp piston. Maximum pressure allowed for the low pressure clamp piston inside the mould safety control range (next line). If too high 034 mould safety alarm Mould safety control range:from the distance set in mm to the 0 mould closed position.

CLAMP TIMES AND SETTINGS Opening stroke Clamp pressure Mould safety Mould safety range Closing speed 1 Closing speed 2 Change closing speed Opening speed 1 055.0 050 035 2.0 070 020 030 075 mm bar bar mm % % mm %

F8

F7

See following diagramme where: V1: Closing speed 1 V2: Closing speed 2 P : Closing speed changing point 0 : Mould closed position

V100% 50%

V1 V2

F8

Save values in mould setting programme in use Confirm and exit

F7

D1

0 mm
D-0053

D
While in the MAIN menu, press F1

BABYPLAST 6/10VP

D.1.5.b/ MANUAL MENU: INJECTION CARRIAGE


to enter the MANUAL menu. The following display will appear:

ATTENTION! when in any page in the MANUAL MENU except Ejectionit will be possible to rotate the table, by pressing the two start buttons simultaneously, under the following conditions:
1. sensor for injectio carriage back, must be activated. 2. sensor for ejectors back, must be activated. 3. Mould must have reached fully open position.

MANUAL MENU

F8

000.0 00.0mm

F7
If the above condions have not been met, at the moment the table should be rotated, then a red indicator will appear in the position in the synoptic diagramme where the consensus is missing.

F6

F1

F2

F3

F4

F5
to gain access to the following menu:

From the MANUAL MENU, press key F2


MANUAL: INJECTION CARRIAGE

F8

000.0 00.0mm

F7

F6

F1

F2

F3

F4

F5

ATTENTION : to avoid damage to the mould and nozzle,the injection carriage can only be moved forward when the clamp is closed (in the synoptic diag. the indicators are activated). by first pressing key F6 and then pressing key F1. ATTENTION: Take care when using this function because the mould is not closed in high pressure
D-0055

BABYPLAST 6/10VP

D
D.1.5.c/ MANUAL MENU: EJECTION
to enter the MANUAL menu. The following display will appear:

While in the MAIN menu, press F1


MANUAL MENU

F8

000.0 00.0mm

F7

F6

F1

F2

F3

F4

F5
to gain access to the following menu:

While in the manual menu, press key F5


MANUAL: EJECTION

F8

000.0 00.0mm

F7

F6

F1

F2

F3

F4

F5

While in the EJECTION menu it is NOT possible to rotate the table. By presssing simulaneously the two START buttons, the ejectors will move forward as long as the buttons are pressed. By pressing the strat bouttons a second time, the ejectors will move backwards ATTENTION : ejector movements will only be possible if the table in position sensors are activated.
D-0060

ATTENTION!

BABYPLAST 6/10VP

D.1.6/ SETTING THE MOULD CLOSED POSITION

Install the mould, making sure that it is positioned correctly (follow pag.C-050). While in the MAIN menu, press F1 to enter the menu for mould closure in manual. Press F3 to close the mould till it is completely closed Press F5 to confirm the mould closed position. Touch the icon so that the numeric keypad appears, digit the password 1212 and confirm.

Mould closed

MANUAL: CLAMP

F8

F7
000.0 00.0mm

F6
Back to previous display

F1

F2

F3

F4

F5

Confirm mould closed position

ATTENTION! Ensure that both the symbols on the synoptic diagram, which indicate the mould closed status, turn black only when the mould is fully closed. The point at which the two symbols turn black, is the point at which the consensus is given for mould CLOSURE IN HIGH PRESSURE. If the two symbols do not turn black, when the mould has reached the mould closed position, the machine will go into alarm 034 MOULD SAFETY. N.B. It is possible to vary the mould safety settings and sensitivity range etc. See page D. 0300 paragraph D.3.3e.

D-0070

BABYPLAST 6/10VP

D
D.1.7/ SEMI AUTOMATIC MENU
MAIN MENU

F8
000.0 00.0mm

F7

Motor OFF

F6
Mould setting programme in use
Gear - art. 2345

Machine configuration Access to stored mould settings

F1

F2

F3

F4

F5

Manual menu

Automatic menu

Switch heaters ON

ATTENTION! By pressing F3 the heaters will be switched ON and the active zones will be shown in yellow during pre-heating and red when the respective tolerance bands have been reached; The settings will be taken from those saved in the mould setting programme highlighted in the synoptic diagramme.

While in the MAIN menu, press F2 will appear:


H1 AUTOMATIC MENU 200 H2 200 H3 200 H4

to gain access to the AUTOMATIC menu.The following display Actual temperatures


OFF

F8
Return to previous display Temperatures

000.0 00.0mm

F7

F6
Gear - art. 2345

Times and other settings

F1

F2

F3

F4

F5

Automatic cycle Semi-auto. cycle Purge Part counter icon present only if active in the AUTOMATIC function see pare :D-0380
ATTENTION! Plastification and injection piston movements will only be possible when the set temperatures have been reached. ( See tolerance band - users menu, data input ). If an Automatic, Semi-automatic or purge cycle is selected, and the machine has not reached the the set temperatures, the machine will go in alarm. D-0080

D
D.1.7a/ SETTING TEMPERATURES

BABYPLAST 6/10VP

H1

200

AUTOMATIC MENU H2 200 H3 200

Yellow : indicates that the heaters in the relative zones are in pre-heat mode or standby Red that the heaters in the relative tones are within the tolerance bands
H4 OFF

F8

000.0 00.0mm

F7

F6
Gear - art. 2345

F1

F2

F3

F4

F5
to gain access to the TEMPERATURES menu:
Save values in the mould settings programme in use

While in the AUTOMATIC menu press F6

Oil - reading only

Values set

Actual values

TEMPERATURES Oil H1 H2 H3 H4 045 200 200 195 0 C C C C 200 199 195 C Plastific. C Chamber C Nozzle

F8

514 C Mould

F7
M

F6
Confirm and exit without saving values set. STAND-BY Temperature. It is possible to activate or deactivate stand-by. If active, the zones will be shown in yellow on the synoptic diagramme in the main menu.

F1

F2

F3

F4

F5

It is only possible to activate or deactivate the zones from the pages of the mould setting programme.see page D-310

SETTING: Touch zone, which needs to be changed, in the field Values set. Rotate the dial M to set the value required. Press F7 to return to the previous page. The modified values are changed but not saved in the mould setting programme in use The modified values can be saved in the mould setting programme by pressing F8 . D-0090

BABYPLAST 6/10VP

D
D.1.7b/TIMES AND SETTINGS

H1

200

H2

AUTOMATIC MENU 200 H3 200

H4

OFF

F8

000.0 00.0mm

F7
M

F6
Gear - art. 2345

F1

F2

F3

F4

F5

While in the automatic menu press F5 to gain access to the menu for TIMES and SETTINGS, the following display shows readings only and cannot be modified:

TIMES AND SETTINGS Actual cycle time Actual cushion Average actual time Average time saved Quality control Cycle time error Cushion error 12.0 1.2 12.0 12.0 NO 05 1.0 % mm sec mm sec sec

F8

F7
M

F6
Return to previous display

F1

F2

F3

F4

F5

D-0100

D
D.1.7b1/ INJECTION CARRIAGE SETTINGS
TIMES AND SETTINGS Actual cycle time Actual cushion Average actual time Average time saved Quality control Cycle time error Cushion error 12.0 1.2 12.0 12.0 NO 05 1.0 % mm sec mm sec sec

BABYPLAST 6/10VP

F8

F7
M

F6
Return to previous display

F1

F2

F3

F4

F5

From the MAIN TIMES AND SETTINGS menu, press F1 INJECTION CARRIAGE TIMES AND SETTINGS :

to gain access to

Set a value GREATER than 0 ( from 0.5 to 0.8), the injection carriage moves back and away from the mould at each cycle and activates the sensor for injection carriage in the fully back position ( Par. C.6 page C-080). Please note: If the setting is 0 sec or the sensor is not activated, the machine will go into alarm 118CONSENSUS INJECTION CARRIAGE Varies the speed of the injection carriage.

INJECTION CARRIAGE TIMES AND SETTINGS Injection carr. time Inj. carriage seed 0.0 100 sec %

F8

F7

F6

ATTENTION : With rotating table, injection carriage time must be sufficient to activate the injection carriage fully back sensor, which must be set so as to allow the table to rotate with the nozzle fully back. ( see par. C.6 - page. C-0080)

Touch the field to be modified, vary the values by rotating the dial. Press F8 to save the changes in the mould setting programme in use. By pressing F7 the values will be changed but not saved in the mould setting programme.

D-0110

BABYPLAST 6/10VP

D
D.1.7b2/ SETTINGS - PLASTIFICATION

TIMES AND SETTINGS Actual cycle time Actual cushion Average actual time Average time saved Quality control Cycle time error Cushion error 12.0 1.2 12.0 12.0 NO 05 1.0 % mm sec mm sec sec

F8

F7
M

F6
Return to previous display

F1

F2

F3

F4

F5

From the MAIN TIMES AND SETTINGS menu press F2 PLASTIFICATION TIMES AND SETTINGS :

to gain access to

To use with 16/18mm diam. injection pistons. Serves for activating a double plastification so as to fill completely the above mentioned pistonsi.Setting a value, e.g. 5 sec, the plastification is activated for this time and then reactivated for a second time so as to reach the material load set. Varies the plastification piston speed.

PLASTIFICATION TIMES AND SETTINGS 2nd shot load time Plastification speed 0.0 100 sec %

F8

F7

Suction time

0.5

sec

F6

OPZIONAL : If present, the VENTURI LOADER can be activated or deactivated by pressing F6. If the suction time is 0, suction will stop when the sensor, installed in the hopper, detects the presence of material. Otherwise, if a value is set which is higher than 0, suction will continue after the sensor has detected material, for the time set. After 3 cycles of loading without activating the sensor, (no material present) the function deactvates. Press F6 to reactivate. ATTENTION: for a correct function use dried air. Touch the field to be modified, vary the values by rotating the dial. Press F8 to save the changes in the mould setting programme in use. By pressing F7 the values will be changed but not saved in the mould setting programme.

D-0120

D
D.1.7b3/ SETTINGS - EJECTION

BABYPLAST 6/10VP

TIMES AND SETTINGS Actual cycle time Actual cushion Average actual time Average time saved Quality control Cycle time error Cushion error 12.0 1.2 12.0 12.0 NO 05 1.0 % mm sec mm sec sec

F8

F7
M

F6
Return to previous display

F1

F2

F3

F4

F5

From the MAIN TIMES AND SETTINGS MENU pressF3 EJECTION TIMES AND SETTINGS:

to gain access to

EJECTION TIMES AND SETTINGS

Varies the ejection piston speed


Ejection speed 100 2 80 0,20 0,25 0,0 0,0 0,0 bar sec sec sec sec sec %

F8

N of ejector strokes ( max 10) Reducing this value reduces the distance the ejector piston moves.

Number of strokes Ejection pressure Ejection time Ejection return time Air blow time Ejection pause Pause end of cycle

F7

F6

Touch the field to be modified, vary the values by rotating the dial. Press F8 to save the changes in the mould setting programme in use. By pressing F7 the values will be changed but not saved in the mould setting programme.

D-0130

BABYPLAST 6/10VP

D
D.1.7b4/ SETTINGS - INJECTION

TIMES AND SETTINGS Actual cycle time Actual cushion Average actual time Average time saved Quality control Cycle time error Cushion error 12.0 1.2 12.0 12.0 NO 05 1.0 % mm sec mm sec sec

F8

F7
M

F6
Return to previous display

F1

F2

F3

F4

F5

From the MAIN TIMES AND SETTINGS MENU press F4 AND SETTINGS: Set the shot size in order to obtain a cushion value less than 3 mm (pre-set parameter). Maximum value 60mm - The shot size depends on the pison size installed. When the set time has been reached the mould opens but except in the case that plastification has not finished. ATTENTION: To obtain a constant cycle time, set a value greater than the max. time needed to load the injection piston. Injection time, in which the value of the 1st injection pressure. must be reached otherwise the machine will go into alarm 107 PEAK NOT REACHED. If the second pressure is activated at a point set in mm (see page D-0290) the line 2nd pressure setting : 00.0mm will be seen. When the injection piston reaches the point set, the second injection speed is activated.

to gain access to INJECTION TIMES

INJECTION TIMES AND SETTINGS Shot size Cooling time 1st injection pressure 1st pressure time 2nd injection pressure 2nd pressure time Decompression Injection speed 2nd injection speed Second speed point 29.0 4.5 90 2.0 30 1.0 0,0 075 50 2,0 mm sec bar sec bar sec mm % % mm

ATTENTION: to see all the lines, move the cursor

Touch the field to be modified, vary the values by rotating the dial. Press F8 to save the changes in the mould setting programme in use. By pressing F7 the values will be changed but not saved in the mould setting programme.

D-0140

D
D.1.7b5/ SETTINGS - CLAMP

BABYPLAST 6/10VP

D
TIMES AND SETTINGS Actual cycle time Actual cushion Average actual time Average time saved Quality control Cycle time error Cushion error 12.0 1.2 12.0 12.0 NO 05 1.0 % mm sec mm sec sec

F8

F7
M

F6
Return to previous display

F1

F2

F3

F4

F5

From the MAIN TIMES AND SETTINGS MENU press F5 SETTINGS : The maximum value depends on the thickness of the mould Maximum pressure for the low pressure clamp piston. Maximum pressure allowed for the low pressure clamp piston inside the mould safety control range (next line). If too high 034 mould safety alarm Mould safety control range:from the distance set in mm to the 0 mould closed position.

to gain access to CLAMP TIMES AND

CLAMP TIMES AND SETTINGS Opening stroke Clamp pressure Mould safety Mould safety range Closing speed 1 Closing speed 2 Change closing speed Opening speed 1 055.0 050 035 2.0 070 020 030 075 mm bar bar mm % % mm %

F8

F7

See the following diag. where: V1: Closing speed 1 V2: Closing speed 2 P : Closing speed changing point 0 : Mould closed position

V100% 50%

V1 V2

F8 Save values in mould setting programme in use F7 Confirm and exit

D1

0 mm

Touch the field to be modified, vary the values by rotating the dial. Press F8 to save the changes in the mould setting programme in use. By pressing F7 the values will be changed but not saved in the mould setting programme.

D-0150

BABYPLAST 6/10VP

D
D.1.7b6/ SETTINGS - QUALITY CONTROL

By setting a tolerance band, it is possible to monitor two parameters on the machine: The CYCLE TIME and CUSHION, for which it is possible to see the last 20 cycles.
TIMES AND SETTINGS Actual cycle time Actual cushion Average actual time Average time saved Quality control Cycle time error Cushion error 12.0 1.2 12.0 12.0 NO 05 1.0 % mm sec mm sec sec

F8

F7
M

F6
Return to previous display

F1

F2

F3

F4

F5

From the MAIN TIMES AND SETTINGS menu, press F6 to gain access to QUALITY CONTROL . The following display shows readings only and cannot be modified:

QUALITY CONTROL Quality control Cycle time error Cushin error N of initial cycles N cycles for alarm Actual cycle time Actual avarage time Avarage time saved Actual cushion NO 10 1,0 10 % mm

F8

F7
20 15,0 15,0 15,0 0,0 sec sec sec mm

F6
Confirm and exit

F1

F2

F3

F4

F5

Data log CYCLE TIME and CUSHION

To modify the quality control parameters press F6 1212 to gain access to the following menu:

and then in the next display enter the passcode

D-0160

D
continued....../ SETTINGS - QUALITY CONTROL

BABYPLAST 6/10VP

QUALITY CONTROL Quality control NO Cycle time error Cushin error N of initial cycles N cycles for alarm Actual cycle time Actual avarage time Avarage time saved Actual cushin 10 1,0 10 % mm

F8

Confirm and save data in the mould settings programme.

F7
20 15,0 15,0 15,0 0,0 sec sec sec mm

Confirm and exit without saving data in the mould settings programme.

F6

F1

F2

F3

F4

F5

Touch the field to be modified, vary the values by rotating the dial. Press F8 to save the changes in the mould setting programme in use. By pressing F7 the values will be changed but not saved in the mould setting programme.

The Quality control function can be activated or deactivated by selecting YES or NO in the first line. press F8 to save and activate the required error value in the programme in use. Press F4 to save the t average cycle time in the programme in use. The quality control function will not be activated until the number of cycles, set in N of initial cycles, has been reached. The first cycle, after these initial cycles, will be used for reference by the quality control function. If the machine detects a percentage of variation which is more than that allowed, compared to the reference cycle, for a number of cycles greater than that set in line - N of cycles for alarm, the machine activates alarm 048 cycle time out of tolerance. OPTIONAL: On request it is possible to have an output which is activated each time a cycle is out of tolerance, and which can be used to activate a PART REJECT device. The machine, in this case, will be able to reject parts produced which are out of tolerance and will stop, in alarm, when the value of N CYCLES FOR ALARM has been reached. ATTENTION! Each time the settings are modified, a new set of initial cycles is run and hence a new reference cycle is obtained.

D-0170

BABYPLAST 6/10VP

D
D.1.7b6a/ QUALITY CONTROL - Log File

QUALITY CONTROL Quality control Cycle time error Cushin error N of initial cycles N cycles for alarm Actual cycle time Actual avarage time Avarage time saved Actual cushion NO 10 1,0 10 % mm

F8

F7
20 15,0 15,0 15,0 0,0 sec sec sec mm

F6

F1

F2

F3

F4

F5

To see the last 20 CYCLE TIMES and CUSHION values, press F3 display:

to see the following

Last cycle registered


n 1 2 3 4 5 6 7 8 9 Cycle 25 25 25 25 25 25 25 25 25

LOG FILE Cushion 0.12 0.12 0.12 0.12 0.12 0.12 0.12 0.12 0.12

F8

F7

F6

ATTENTION: to see all the lines, move the cursor

D-0180

D
D.2./START A CYCLE
R1 200 SEMIAUTOMATIC MENU R2 200 R3 200 R4 OFF

BABYPLAST 6/10VP

D.2.1/ Start a SEMI AUTOMATIC cycle

F8

000.0 00.0mm

F7
M

F6
Gear - art. 2345

F1

F2

F3

F4

F5

ATTENTION! In order to operate the rotating table, the sensors for: ejectors back, injection carriage back and mould open, must be activated.

From the AUTOMATIC MENU press key F2


SEMIAUTOMATIC R2 200 R3 200

to gain access to the SEMI AUTOMATIC CYCLE menu:

R1

200

R4

OFF

F8

000.0 00.0mm

F7

F6
Gear - art. 2345

F1

F2

F3

F4

F5

TO START A CYCLE: 1. Load and isert in the lower mould half on the operator side of the rotating table. 2. Press the two START buttons simultaneously and keep them pressed till the table reaches the CLAMP position, once this position has been reached, the clamp will close and the injection cycle will start automatically. 3. Load another insert and wait for the mould to open again. 4. Press the two START buttons simultaneously and keep them pressed till the ejection cylce (if set) has been completed. (ejector forward and back again). 5. Repeat from point 2

Press F3

: The mould opens completely and the injection carriage and nozzle move away from the mould.

ATTENTION! If the temperatures have not reached the tolerance bands, it will not be possible to start the automatic cycle and the machine indicate this with an alarm message without, however, switching off the motors and heaters.The alarm will deactivate when the operating temperatures have been reached. D-0190

BABYPLAST 6/10VP

When the machine is in a SEMI AUTOMATIC CYCLE, the following display will be seen:

R1

200

SEMIAUTOMATIC R2 200 R3 200

R4

OFF

F8

000.0 00.0mm

F7
M

F6
Gear - art. 2345

F1

F2

F3

F4

F5

While the machine is in operation, the following fuctions will be available:

Press F2

:The machine finishes the cycle in course and then stops.

Press F4

:To see the number set in the part counter and also check and reset the number reached. :To see and modify times and other settings.

Press F5

Press F6

:To see and modify temperatures.

D-0200

D
D.2.3/ Starting a PURGE CYCLE
From the AUTOMATIC MENU press key F2
SEMIAUTOMATIC MENU 200 H2 200 H3 200

BABYPLAST 6/10VP

to gain access to the SEMI AUTOMATIC CYCLE menu:

H1

H4

OFF

F8

000.0 00.0mm

F7

F6
Gear - art. 2345

F1

F2

F3

F4

F5

From the SEMIAUTOMATIC MENU press F3

to gain access to the PURGE CYCLE menu:

H1

200

SEMIAUTAUTOMATIC MENU H2 200 H3 200 H4

OFF

F8

000.0 00.0mm

F7

F6
Gear - art. 2345

F1
Press F1 Press F2

F2

F3

F4

F5

To start PURGE AT END OF CYCLE. At the end of this cycle the injection piston will stop in the fully forward position hence the cylinder will be empty. To start PURGE AT BEGINNING OF CYCLE. At the end of this cycle the injection cylinder will be loaded with the quantity of material set in the programme.

ATTENTION! If the temperatures have not reached the tolerance bands, it will not be possible to start the automatic cycle and the machine indicates this with an alarm message without, however, switching off the motors and heaters.The alarm will deactivate when the operating temperatures have been reached
WARNING:
WHEN CHANGING FROM ONE MATERIAL TO ANOTHER, LOADING A DIFFERENT MOULD SETTING PROGRAMME OR IN CASE OF RESIDUE MATERIAL LEFT IN THE SYSTEM FROM PREVIOUS PRODUCTION, GREAT CARE MUST BE TAKEN TO SET THE CORRECT PROCESSING TEMPERATURES ACCORDING TO THE MATERIAL MANUFATURERS DATA SHEET. FAILURE TO DO SO MAY CAUSE DAMAGE, BLOCKAGE, OR GAS; PARTICULARLY DURING PURGING.

D-0210

BABYPLAST 6/10VP

D
D

When the machine is running in the PURGE CYCLE, the following display will be seen:

H1

200

H2

PURGE 200 H3

200

H4

OFF

F8

000.0 00.0mm

F7
M

F6
Gear - art. 2345

F1

F2

F3

F4

F5

While the machine is running the following options will be available: Press F3 : The machine will finish the cycle in course and then stop.

Press F6 :

To visualise and modify temperatures.

At the end of 6 purge cycles, the machine will stop automatically and remain in idle until either another purge cycle is started (see previous page) or another function is selected.

D-0220

D
D.2.4/ SETTING UP THE PART COUNTER
AUTOMATIC MENU H2 200 H3 200

BABYPLAST 6/10VP

H1

200

H4

OFF

F8

000.0 00.0mm

F7

F6
Gear art. 2345

F1

F2

F3

F4

F5

From the AUTOMATIC MENU press F4


Settings
PART COUNTER Parts to produce 0

to gain access to the PART COUNTER menu:


To set the number of part to produce, touch the icon keypad and the following display will be shown:

Exit without saving

F8
0 1 2 5 8 0 3 6 9

Parts produced Nunber of cavities

000000 2

F7

4 7

Reset

F6

set the required value and confirm with

Confirm and exit Reset part counter (line - parts produced).

ATTENTION! Ensure that the number of cavities shown corresponds to the actual number of cavities in the mould.The number of cavities shown, corresponds to the number of cavities set in the mould settings programme in use. To modify, return to the MAIN MENU and press key F5 to enter the mould settings programme. By setting the value of parts to produce to 000000 the part counter is excluded and the machine will produce continuously. To zero the part counter rapidly, select the first digit on the left and change to zero. All the other digits will change to zero automatically. D-0230

BABYPLAST 6/10VP

D
D.3/ MOULD SETTING PROGRAMMES
D.3.1/ LOADING A MOULD SETTING PROGRAMME
MAIN MENU

F8
000.0 00.0mm

F7

F6
Gear - art. 2345

F1
When in the MAIN MENU press F5

F2

F3

F4

F5

to gain access to the following display:

PROGRAMMES

Exit without saving

F8
Programme selected

Confirm mould setting programme selected

F7
Gear - art. 2345

Retrieve programmes from a USB memory stick Save programmes onto a USB memory stick Access to mould setting programme selected.

F6

F1

F2

F3

F4

F5

Access to the mould setting programme folder

To select a new mould setting programme, go to the mould setting programme folder by pressing F1 The following display will be seen (see the following page):

D-0240

BABYPLAST 6/10VP

Go back a directory level


/home/root/Fm607/progs

Return to the programmes page


Gear - art. 2345
Plug - art. 4459

Gear - art. 1111 Gear - art. 422 Plug - art. 2222

Programme selected

Keypad to change name Exit and confirma programme selected


file filter

Plug - art. 4459

Exit without confirming

Eliminate programme selected

Touch the file to be selected, the name will be seen in the field file. touch the icon

to exit and confirm.

WARNING:

WHEN CHANGING FROM ONE MATERIAL TO ANOTHER, LOADING A DIFFERENT MOULD SETTING PROGRAMME OR IN CASE OF RESIDUE MATERIAL LEFT IN THE SYSTEM FROM PREVIOUS PRODUCTION, GREAT CARE MUST BE TAKEN TO SET THE CORRECT PROCESSING TEMPERATURES ACCORDING TO THE MATERIAL MANUFATURERS DATA SHEET. FAILURE TO DO SO MAY CAUSE DAMAGE, BLOCKAGE, OR GAS; PARTICULARLY DURING PURGING.

D-0245

BABYPLAST 6/10VP

D
From the MAIN MENU press F5
PROGRAMMES

BABYPLAST 6/10VP

D.3.2/ Create or modify mould setting programmes

to gain access to the following display:


Exit without saving

F8
Confirm and exit
Programme selected

F7
Plug - art. 4459

Retrieve mould setting programmes from a USB memory stick Save mould setting programmes onto a USB memory stick To gain access to a mould settings programme.

F6

F1

F2

F3

F4

F5

Access to mould setting programme folder

Press F2

to enter the mould setting programme selected.

PROGRAMME: Plug - art 4459 Customer Material Part weight Shot weight Mould number Average time saved Last modification01.01.2008 xxx POM 0,0 0,0 000 10.4 sec gr gr

Programme selected

F8
Exit without saving

F7

Save /Copy cycle programme Setup core pulls

F6

Set temperatures

F1

F2

F3

F4

F5

General settings

Touch the field to be modified, to vary the alphanumerical values, touch the icon keypad for the other values rotate the dial. Press F7 to save the changes in the mould setting programme in use or to copy the changes into a new mould setting programme. The value Average time saved can only be saved in the QUALITY CONTROL function. While the date in Last modification , is saved automatically the moment the last modification is made. Press F1 to gain access to the following display:

D-0250

BABYPLAST 6/10VP

D
D.3.2a/ Mould setting programmes - TIMES AND SETTINGS D.3.2a1 / INJECTION CARRIAGE
MAIN TIMES AND SETTINGS

F8

F7

F6

F1

F2

F3

F4

F5

Press F1

to gain access to INJECTION CARR. TIMES & SETTINGS :

By setting a value other than 0 (from 0.3 to 0.6), the injection carriage moves back and away from the mould at each cycle. If the setting is 0 sec the injection carriage will remain against the mould during each cycle Varies the speed of the injection carriage.

INJECTION CARR. TIMES & SETTINGS Injection carr. time Inj. carriage speed 0.3 100 sec %

F8

F7

F6

Touch the field to be modified, vary the values by rotating the dial. Press F6 to return to the previous page without saving. Press F7 to save changes in the mould setting programme in use or to copy the mould setting programme by changing the name. Press F8 to exit without saving.

D-0260

D
MAIN TIMES AND SETTINGS

BABYPLAST 6/10VP

D.3.3b/ Mould setting programmes - PLASTIFICATION TIMES AND SETTINGS

F8

F7

F6

F1

F2

F3

F4

F5

Press F2

to gain access to PLASTIFICATION TIMES AND SETTINGS :


PLASTIFICATION TIMES AND SETTINGS 2nd shot load time Plastification speed 0.0 100 sec %

To use with 16/18mm diam. injection pistons. Serves for activating a double plastification so as to fill completely the above mentioned pistonsi.Setting a value, e.g. 5 sec, the plastification is activated for this time and then reactivated for a second time so as to reach the material load set. Varies the plastification piston speed.

F8

F7

Suction time

0.5

sec

F6

OPZIONAL : If present, the VENTURI LOADER can be activated or deactivated by pressing F6. If the suction time is 0, suction will stop when the sensor, installed in the hopper, detects the presence of material. Otherwise, if a value is set which is higher than 0, suction will continue after the sensor has detected material, for the time set. After 3 cycles of loading without activating the sensor, (no material present) the function deactvates. Press F6 to reactivate. ATTENTION: for a correct function use dried air.

Touch the field to be modified, vary the values by rotating the dial. Press F6 to return to the previous page without saving. Press F7 to save changes in the mould setting programme in use or to copy the mould setting programme by changing the name. Press F8 to exit without saving.

D-0270

BABYPLAST 6/10VP

D
D.3.3c/ Mould setting programmes - EJECTION TIMES AND SETTINGS
MAIN TIMES AND SETTINGS

F8

F7

F6

F1
Press F3

F2

F3

F4

F5

to gain access to EJECTION TIMES AND SETTINGS :


EJECTION TIMES AND SETTINGS Ejection speed Number of strokes Ejection pressure Ejection time Ejection retur time Air blow time Ejection pause Pause end of cycle Ejection sensor Out at end of cycle 00 2 80 0,20 0,25 0,0 0,0 0,0 NO NO bar sec sec sec sec sec %

Varies the ejection piston speed N of ejector strokes ( max 10) Reducing this value reduces the distance the ejector piston moves. This function may be activated after installing the ejector sensor onto the moving platten. The sensor is supplied in the accessory pack with the machine. Activate this function by selecting YES. The sensor will detect whether the ejectors have fired or re-entered. In case of fault, the machine will go into alarm 039 EJECTORS DID NOT FIRE or 040 EJECTORS DID NOT RE-ENTER. Only in SEMIAUTOMATIC cycle. If active, at end of SEMIAUTOMATIC cycle. The ejectors remain out and re-enter only when the start key is pressed for start cycle.

F8

F7

F6

Touch the grey fields to change the values. The lines in bold print can only be changed in the MOULD SETTING PROGRAMME pages.

The values in the white fields can be changed, both in the MOULD SETTING PROGRAMME pages and in TIMES AND SETTINGS pages while the machine is running.

Touch the field to be modified, vary the values by rotating the dial. Press F6 to return to the previous page without saving. Press F7 to save changes in the mould setting programme in use or to copy the mould setting programme by changing the name. Press F8 to exit without saving.

D-0280

D
MAIN TIMES AND SETTINGS

BABYPLAST 6/10VP

D.3.3d/ Mould setting programmes - INJECTION TIMES AND SETTINGS

F8

F7

F6

F1
Press F3

F2

F3

F4

F5

to gain access to the following display: ATTENTION: to see all the lines, move the cursor.

Set the shot size in order to obtain a cushion value less than 3 mm (pre-set parameter). Maximum value 60mm - The shot size depends on the pison size installed. When the set time has been reached the mould opens but except in the case that plastification has not finished. ATTENTION: To obtain a constant cycle time, set a value greater than the max. time needed to load the injection piston. Injection time, in which the value of the 1st injection pressure. must be reached otherwise the machine will go into alarm 107 PEAK NOT REACHED. If the Injection Mode is activated POSITION the line 2nd pressure setting : 00.0mm will be seen. When the injection piston reaches the point set, the second injection speed is activated.

INJECTION TIMES AND SETTINGS Shot size Cooling time 1st injection pressure 1st pressure time 2nd injection pressure 2nd pressure time Decompression Injection speed 2nd injection speed Seconnd speed point Injection mode Accumulator 29.0 4.5 90 2.0 30 1.0 0,0 075 50 0.0 Peak OFF mm sec bar sec bar sec mm % % mm

Optional: Activates the output which controls the hydraulic accumulator (if installed) during the injection phase.

PEAK: (de-fault) - At the end of injection time and on condition that the 1st injection pressure has been reached, the machine will change over to the 2nd injection pressure. POSITION (Pos.) : The 1st injection pressure will be maintained till the position, previously set in the injection menu, has been reached. At this point, the machine will change over to the 2nd injection pressure Touch the field to be modified, vary the values by rotating the dial. Press F6 to return to the previous page without saving. Press F7 to save changes in the mould setting programme in use or to copy the mould setting programme by changing the name. Press F8 to exit without saving. D-0290

BABYPLAST 6/10VP

D
D.3.3e/ Mould setting programmes - CLAMP TIMES AND SETTINGS
MAIN TIMES AND SETTINGS

F8

F7

F6

F1
Press F5

F2

F3

F4

F5

to gain access to the following display:

The number of cavities set, conditions the part counter Depends on the mould height. With minimum mould h. 120 the maximum possible is 110mm Pressure setting for clamp piston N.B. the larger piston for high pressure (6,25 t.) is activated only when the mould is in the fully closed position. The maximum pressure allowed for the clamp piston in low pressure. If reached the machine goes in alarm 034 Mould safety The alarm in mould closing will be active starting from the position of the mould safetyr setting to the position of the mould safety exclusion setting N.B.Outside this range (mould safety and mould safety exclusion) the maximum pressure allowed is the pressure set in clamp pressure. his function is used to regulate the sensitivity of the MOULD CLOSED position. The range can be set between approx. 0,03 to 0,3 mm. Change the value to modify the setting.

TEMPI E QUOTE CHIUSURA Number of cavities Opening stroke Clamp pressure Mould safety Mould safety setting Mould safety excl. pos. Closing speed 1 Closing speed 2 Change closing speed Mould safety range Opening speed 1 Open guard Guard mov. in alarm N of moulds on table 2 055.0 050 035 2.0 0.10 070 020 030 0.10 075 NO NO 2 mm bar bar mm mm % % mm mm %

F8

F7

F6

A2

Present only if YES is set in the line AUTOMATIC (D-0380) Open guard: NO if the guard remains closed at end of cycle. YES if the guard remains open at end of cycle Guard mov. in alarm: NO machine in alarm guard closed YES machine in alarm guard open

Mould position

A1

2 set: TWO mould halves are present: the sensor, situated on the rotating protection, needs to be activated every half turn (two screws need to be fitted A1-A2 to the protection). 1 set: one mould half is present: the sensor, situated on the rotating protection, needs to be activated every complete turn (remove screw A2 which activates the sensor fitted behind the mould in respect to the rotation of the table).
D-0300

D
D.3.2b/ Mould setting programmes - TEMPERATURES
PROGRAMME: Plug art. 4459 Customer Material Part weight Shot weight Mould number Average time saved Last modification xxx POM 0,0 0,0 000 10.4 sec gr gr

BABYPLAST 6/10VP

Programme selected

F8
Exit without saving

F7

Save /Copy cycle programme Setup core pulls

01.01.2008

F6

Set temperatures

F1

F2

F3

F4

F5

General settings

Touch the field to be modified, to vary the alphanumerical values, touch the icon keypad for the other values rotate the dial. Press F7 to save the changes in the mould setting programme in use or to copy the changes into a new mould setting programme. The value Average time saved can only be saved in the QUALITY CONTROL function. While the date in Last modification , is saved automatically the moment the last modification is made. Press F2 to gain access to the following display:
ACTIVE zone NON ACTIVE zone

TEMPERATURES H1 Heater plastif. H2 Heater inj. chamber H3 Heater nozzle H4 Heater mould V1 Cooling fixed platen V2 Cooling hopper V3 Cooling fixed mould Hotrunner 215 215 215 215 0 0 0 0 C C C C C C C C % % % % % % % % X X X X X X X X

F8

F7
M

F6

V4 Cooling moving mould 0

to activate a zone, press directly on the symbol C (% only in case of emergency), then on the corresponding value field and rotate the dial to set the value required. press X to deactivate the zone completely.

N.B. : The valves, EV 1-2-3-4 (water manifold) are optional. However, in any case the values can be set as a reminder using the same values as the water manifold ( 5-10-15-20-25).

D-0310

BABYPLAST 6/10VP

D
D.3.5/ Mould setting programmes - core pull
Programme selected
xxx POM 0,0 0,0 000 10.4 sec gr gr

PROGRAMME: Plug - art. 4459 Customer Material Part weight Shot weight Mould number Average time saved Last modification

F8
Exit without saving

F7

Save /Copy cycle programme Setup core pulls

01.01.2008

F6

Set temperatures

F1

F2

F3

F4

F5

General settings

Press F3

to gain access to the following display:

Indication of the page, core pull A or B, being visualised

Digit the words activate or deactivate to activate or deactivate the core pull function in the respective page A or B.

Mould closed Injection

5 1 2 3 4

PROGRAMME Core pull A Pos 1 2 3 4 5 Core pull B Disabled Status OFF OFF OFF OFF OFF Time 0.0 0.0 0.0 0.0 0.0 Cons. OFF OFF OFF OFF OFF
Sch 1

F8
Cooling

F7

Mould open Ejection

F6

On request, a socket can be fitted for 24V output (output A - J708) (output B - J709) and the two respective PNP input sockets for cycle consensus (A J306 - BJ307). The two outputs A or B can be activated for an indefinite length of time when ON is set (status column), and 00s set (time column). The same outputs can also be activated for specific length of time by setting ON (status column) and a specfic time (time column). When ON is selected in the cons. column (consensus), the cycle will not start without the input (for consensus to continue) from an external source. Positions 1,2,3,4 & 5 represent the positons during the cycle when the outputs A or B will be activated (see following diagram). This function can also be used to activate a valve for air blow for example. To activate or deactivate the output A or B, select by touching the relative heading (Core pull A or Core pull B). D-0320

BABYPLAST 6/10VP

D.3.3/ TOOL SETTING PROGRAMMES - How to copy a programme.


If a new programme has to be created, which is similar to an existing programme, it is possible to copy the existing programme and make modifications if necessary. Do as follows: Example: Programme to copy New pragramme : Gear A : Gear B to gain access to the following display:
Exit without saving

From the main menu press F5


PROGRAMMES

F8
Programme selected

Confirm and exit

F7
Gear A

Retrieve mould seting programmes from USB memory stick Save mould setting programmes on a USB memory stick To gain access to a mould settings programme.

F6

F1

F2

F3

F4

F5
Access to the mould setting programmes folder

Check that the mould setting programme selected is the one to be copied, (to select another programme see page D-0240) press F2 to enter the programme

PROGRAMME: Gear A Customer Material Part weight Shot weight Mould number Average time saved Last modification xxx POM 0,0 0,0 000 10.4 sec gr gr

Programme selected

F8
Exit without saving

F7

Save /Copy cycle programme

01.01.2008

F6

F1
Press F7

F2

F3

F4

F5

to gain access to the following display: (see following page):

D-0330

BABYPLAST 6/10VP

D
PROGRAMME: Gear A Customer Material Part weight Peso stampata Numero stampo POM 0,0 gr SAVE PROGRAMME 0,0 gr A Gear 000 xxx

F8

F7

Save changes in the mould setting programme in use Change programme name by creating a new programme Exit without saving

Change 10.4 Cancel Yes Tempo m YESdio salvato sec

Last modification01.01.2008

F6

F1

F2

F3

F4

F5

Press Change :

/home/root/Fm607/progs

Gear 1111 Gear 4422 Plug 2222 Gear A

Gear 2345 Gear A

Programme selected

Key to change name Confirm and exit programme selected


file filter

Gear A

Exit without confirming

Eliminate programme selected

digit the new programme name (eg: Gear B) Press the icon keypad . The new programme created will be seen in the field file confirm and exit from keypad by pressing to confirm and exit. ( E.g. gear B) press the icon

D-0340

D
D.4/MACHINE CONFIGURATION
MAIN MENU

BABYPLAST 6/10VP

F8
000.0 00.0mm

F7

F6
Gear part. n 2345

Advanced settings

F1

F2

F3

F4

F5

From the main menu press F6

to gain access to the following display:

SET UP 15:25:33
February Sun 1 8 15 22 Mon 2 9 16 23 Tue 3 10 17 24 Wes 4 11 18 25 Thu 5 12 19 26 Fri 6 13 20 27 2008 Sat 7 14 21 28

F8

F7

F6
Manufacturer

F1

F2

F3

Advanced settings User

F4

F5

Press F4

and enter PASSCODE 1212

to gain access to ADVANCED USER SETTINGS:

D-0350

BABYPLAST 6/10VP

D
D.4a/ MACHINE CONFIGURATION - ADVANCED SETTINGS Change language - Celsius/Farenheit
and enter the pass code1212 (see previous page) to gain access

From DISPLAY SET UP press F4 to the following display :

Change language
Language

MACHINE PARAMETERS English Celsius 1 000045 000045 001555 reset

Change to Celsius/Farenheit Machine identification number - ( see page D-0410) Meter - hours . every 1500 hours there will be a reminder to change the oil return filter. Press the word reset to reset. Total hours counter. Cannot be reset. Total cycles counter. Cannot be reset. If is selected, the settings can only be modified by digiting the user password 1212

F8

Degrees Machine ID number Meter - Hrs Total hours Total cycles

F7

F6

Modification with password

F1

F2

F3

F4

F5

Press F3

to see the software versions installed in the 4 microprocessors mounted in the machine.

INFO

F8

F7
Software version display Software version CPU Software version - prop. valve Software version INVERTER Upgrade software: The icon is only active if the USB memory stick is inserted in the USB port on the machine. ( see page. D-0390) D-0360
FMP266 FM607 Sw. Ver.: 1.10 FMP266 FM542 Sw. Ver.: 2.00 FMP266 FM542DSPSw. Ver.: 1.60 FMP000 FM549 Sw. Ver.: 1.01AV

F6

D
From DISPLAY SET UP press F4 to the following display:
Change language
Language

BABYPLAST 6/10VP

D.4b/ MACHINE CONFIGURATION - ADVANCED SETTINGS TEMPERATURES


and enter the pass code 1212 (see previous page) to gain access
MACHINE PARAMETERS English Celsius 1 000045 000045 001555 reset

Change to Celsius/Farenheit Machine identification number (see page D-0410) Meter - hours . every 1500 hours there will be a reminder to change the oil return filter. Press the word reset to reset.

F8

Degrees Machine ID number Meter - Hrs Total hours Total cycles

F7

F6

Modification with password

F1
Press F4 to

F2

F3

F4

F5

gain access to Machine parameters TEMPERATURES:


TEMPERATURES Tol. band max. error Temperature in stand-by Timeout for alarm Pre-heating time 25 80 3 180 C % min sec

The value set, will be the toleranceband for the temperature in use. If the operating temperature increases or decreases by a value greater than this set temperature, (i.e. goes out of the tolerance band) the machine goes into alarm Tol. band max error. Manual operation of the injection piston and plastification will not be possible nor will it be possible to enter an automatic cycle until the operating temperatures are within this tolerance band.

The stand-by temperature always depends on the temperatures set in each of the mould setting programmes and when active, the heater zones will be seen in yellow. The stand-by temp. activates in the following cases: 1.When the heaters are switched on in automatic. 2.When the machine is in alarm for a greater length of time than the time out alarm. 3.When the heaters are switched on manually. If the machine is in alarm for a time greater than that set fo time out alarm, the heaters will go into the stand-by mode. After double the length of time, the heaters and motor will be switched off.

When the heaters are switched on, they will remain at the stand-by temperature for the length of time set for pre-heating time

Touch the field to be modifed, change the value by rotating the dial.
ATTENTION: If the actual temperatures exceed by more than double the value set in Tol. band max. error, the machine will go in alarm 112..116 OVER TEMPERATURE.. - Motor and heaters will be switched off.

D-0370

BABYPLAST 6/10VP

D
D.4c/ MACHINE CONFIGURATION - ADVANCED SETTINGS TIMES AND SETTINGS
and enter the pass code 1212 (see previous page) to gain access to
MACHINE PARAMETERS Language English Celsius 1 000045 000045 001555 reset

From display set up press F4 the following display:


Change language Change to Celsius/Farenheit Machine identification number (see page D-0410) Meter - hours . every 1500 hours there will be a reminder to change the oil return filter. Press the word reset to reset.

F8

Degrees Machine ID number Meter - Hrs Total hours Total cycles

F7

F6

Modification with password

F1
Press F5

F2

F3

F4

F5

to gain access to MACHINE PARAMETERS - TIMES AND SETTINGS:


TIMES AND SETTINGS Piston diameter Injection pressure Cushion Injection incomplete Timeout clamp close Closing speed in manual Opening speed 2 Intrusion programme Automatic mode 14 60 3,0 8 4,0 30 NO NO NO sec % mm bar mm

ATTENTION: The value of 10mm MUST be set if a 10mm injection piston is installed on the machine. This setting will limit the maximum injection pressure to 100 bar. Maximum injection pressure in manual and purge. Maximum cushion. If the cushion is more, than the value set, for a number of cycles greater than that set in the line Injection incomplete (next line), the machine will go into alarm 036 INJECTION INCOMPLETE If the cushion is more, than the value set in the previous line (Cushion), for a number of cycles greater than that set in this line (Injection incomplete), the machine will go into alarm 036 INJECTION INCOMPLETE If the clamp does not reach the 0 mould position (mould closed) within the set time, The machine will go into alarm 042 TIMEout mould closed Clamp speed in manual mode Activate / deactivate the second opening speed. When active, it will be possible to set the point at which the speed changes, in the CLAMP TIMES AND SETTINGS menu.

Set date and time Select NO (default): Cycle only in semi-automatic Select YES : cycle in automatic/semiautomatic with possiblity of guard open or not at end of cycle in case of alarm ( see manual page D-300) If NO is set (default): Standard cycle. If YES is set:Produces a pre-injection. and a line will appear, in the INJECTION menu, where it will be possible to set a time to activate plastification before the injection phase.

Touch the field to be modifed, change the value by rotating the dial.
D-0380

D
D.4.4/ UPGRADE SOFTWARE
From the page DISPLAY SETTINGS press F4 gain access to the following screen :

BABYPLAST 6/10VP

and insert the assword 1212 (see previous page) to

Change language
Language

MACHINE PARAMETERS English Celsius 1 000045 000045 001555 reset

Change Celsius/Farenheit Machine identification number(see page.D-0410) Meter - hours . every 1500 hours there will be a reminder to change the oil return filter. Press the word reset to reset. Total hours counter. Cannot be reset.
Total cycles counter. Cannot be reset.

F8

Degrees Machine ID number Meter Total hours Total cycles Modify with password

F7

F6

F1

F2

F3

F4

F5

If is selected, the settings can only be modified by digiting the user password 1212
Peress F3 ATTENTION: to see the software versions loaded on the 4 microprocessors fitted to the machine Upgrade diplay: The folder FM607, suppplied by the manufacturer, should be loaded onto a USB memory key Upgrade CPU: The fileFMP282_FM542Appl_V......mot should be present

Remove the cover found on the bottom side the display, and insert the USB memory stick into one of the two USB ports as indicated.

D-0390

BABYPLAST 6/10VP

Press F3 to see the software versions loaded onto the 4 micrprocessors fitted to the machine : ATTENTION: It is only possible to gain access to the following pages with the motor OFF
INFO

F8

F7
Software version of the Display Software version of the CPU Software version of the Prop. valve Software version of the INVERTER Software upgrade icon is only active when the USB memory key is inserted. Press F7 to gain access to the following display:
SOFTWARE UPGRADE FMP282 FM607 Sw. Ver.: 1.10 FMP282 FM542 Sw. Ver.: 2.00 FMP282 FM542DSPSw. Ver.: 1.60 FMP000 FM549 Sw. Ver.: 1.01AV

F6

F8
Key FM607 (display) to load upgrade file for the display from the USB memory key Key FM542 (CPU) to load upgrade file for the CPU from the USB memory key
FM607 (Display) Upgrade

F7
FM542 (CPU) Upgrade

F6

To upgrade software do as follows: FM607 Display: press the corresponding key, the numeric key pad will apear, digit the password 1122 and confirm. At the end press F7, remove the USB key switch off the machine at the main switch and then switch it on again. FM542 CPU: press the corresponding key, the numeric key pad will apear, digit the password 1122 and confirm the main directory of the USB key will appear, select the file: FMP282_FM542Appl_V..... and confirm. At the end press F7, remove the USB key switch off the machine at the main switch and then switch it on again. When upgrading the CPU and Display together, it is possible to swith the machine OFF and on again at the end of both operations. D-0400

ATTENTION:

D
D.5/ USB MEMORY STICK - Saving/downloading

BABYPLAST 6/10VP

Remove the cover found on the bottom side the display, and insert the USB memory stick into one of the two USB ports as indicated.

MENU PRINCIPALE

F8

000.0 00.0mm

F7

F6
Ingranaggio cod 2345

F1

F2

F3

F4

F5

From the MAIN MENU press F5

to gain access to the following display:

D-0410

BABYPLAST 6/10VP

ATTENTION:

the icons F4 and F5 are only activeif the USB memory stick is inserted into one of the USB ports.

PROGRAMMES

F8
Programme selected

F7
Gear - art. 2345

F6

F1

F2

F3

F4

F5

By pressing the icon F4, a folder will be created in the USB memory stick called: BabyFMP282_ID001 this folder will contain ALL the mould setting programme files found in the machine. ATTENTION :If the folder already exists, any files, contained inside this folder, with the same name will be overwritten By pressing F5 all mould setting programmes in the folder BabyFMP282_ID001 will be loaded onto the machine. ATTENTION the files with the same name will be overwritten. ATTENTION: do NOT change the name of the folder created , the names of the files inside can be changed, but not that of the folder otherwise it will not be possible to load the files (mould setting programmes) not the machine

If more than one Babyplast are owned and in the case that each machine should have its own mould setting programmes, it is possible to give each Babyplast a different ID number (machine Identification number ( eg: 01 - 02 - 03 ecc.) on the MACHINE PARAMETERS ( see page D-0360). In this case, even if only one USB memory stick is used, different folders will be created with different names based on the machine ID number For example: BabyFMP282_ID001 BabyFMP282_ID002 BabyFMP282_ID003....ecc. It will be possible to modify the position of files (mould setting programmes) and change their names inside the various folders via a PC.

D-0420

D
1. Copy the folder 2.Open the programme BP_Program_Viewer_v100 into a directory on a PC BP_Program_Viewer_v100 found inside.

BABYPLAST 6/10VP

D.5.1/ PRINT AND ELEBORATE MOULD SETTING DATA ON A PC

3.Select Open

4. using browse select the folder BabyFMP66_ID001 where the mould setting programmes (files) have been previously saved. (see paragraph D.5 page D-0410)

D-0430

BABYPLAST 6/10VP

5. Select the folder Progs and then the mould setting programme (file) required

6. Open

7. Once the mould setting programme (file) has been opened, it will be possible to print it, copy and past it into another programme (such as Microsoft Word / exel etc) save it in a different format.

D-0440

E
E.9/ ALARMS
N

BABYPLAST 6/10VP 6/25VP

MESSAGE

CAUSE
Mould guard open Injection guard open The motor has over heated Thermocouple analog inputs faulty Faulty guard / gate switch or switches are not synchronised with the hydraulic safety valve. Fault eeprom on CPU Inconsistency in the gate check proceedure

ACTION
Close guard and ensure that the corresponding indicator, on the synoptic diag., goes out. Check the power supply to the motor. Alarm is only present durng testing by manufacturer Swich off at the main switch. Check the position of the switches in the guards.Repeat gate check. Switch machine OFF and then ON again. If persists contact a technician. Swich off at the main switch. Check the position of the switches in the guards.Repeat gate check.

001 LEFT GUARD OPEN 002 RIGHT GUARD OPEN 003 INJ. GUARD OPEN 004 MOTOR OVER HEATED 005 OFFSET ANALOG INPUT FAULTY 006 FAULT SWITCH - LEFT GUARD 007FAULT SWITCH - RIGHT GUARD 008 FAULTY SWITCH INJ. GUARD 010 EEPROM FM542 ERROR 011 INCONSISTENT GATE CHECK

012 FAULTY THERMOCOUPLE PLATEN 013 FAULTY THERMOCOUPLE HOPPER 014 FAULTY THERMOCOUP. PLASTIF. 015 FAULTY THERMOCOUP. INJ. CHAM. 016 FAULTY THERMOCOUPLE NOZZLE 017 FAULTY THERMO. FIXED MOULD 018 FAULTY THERMO. MOVING MOULD 019 HOPPER OVER HEATED

Thermocouple faulty

Check thermocouple, wires and connections. Change if necessary.

020 OIL OVER HEATED 021 FAULTY INTERN. COMPENS. T/C 022 FAULTY EXTERN. COMPENS. T/C 023 OIL LEVEL LOW

Insufficient cooling at base of hopper. If more than 70C, machine goes into alarm Insufficient cooling. Temperaturover 60C Faulty thermocouple cold joint compensator on circuit board. Faulty thermocouple cold joint compensator in socket. Oil level is too low

Check water flow and the temperature of the cooling system. Check water flow and the temperature of the cooling system. Contact a technician Check wires and contacts change NTC component. Check for leaks, check oil level float and connections. Fill tank to correct level.

024 NEUTRAL PHASE MISSING 026 PHASE MISSING 027 CURRENT FAULT 028 INVERTER ALARM 029 OIL COLD

030 FAULTY OIL COMPENS. T/C 031 EMERGENCY 032 CHANGE FILTER 033 EJECTORS OUT

Check power supply connections Check power supply connections Check power supply voltage Contact a technician Inverter faulty Oil temperature less than 20C Switch on the motor and / or wait for the oil temperature to go above the minimum temperature allowed. Check wires and connectioins or Oil thermocouple cold joint change NTC component compensator faulty Emergency stop button activated Reset button or check external alarm source. or input from external alarm. Change return filter and and reset hour The machine has worked for metre 1500 hrs. Make ejectors return in manual mode. Trying to start a cycle with Check the M4 x 20 screw which ejectors out and ejector return connects the ejector pin in mould to the sensor active. ejector piston on machine Neutral phase not connected Phase not connected

E-0010

BABYPLAST 6/10VP 6/25VP

E
CAUSE
1. Object trapped between two the mould halves 2.Mould safety set too sensitive. 3.Mould safety range too low

MESSAGE

ACTION
Remove the object which is stopping the mould from closing. Increase Mould safety (page D-0150) Enter the mould setting programme in use , clamp page (D-320) line mould safety range increase the value set. Switch the machine OFF and then ON again. 1. Incomplete or no injection due to a part stuck in the mould cavity or a blocked nozzle. 2.Material load set too high. Reduce until cushion is under 3mm. 1.No material in hopper 2.Hopper chute blocked Check hopper or plastification valve Check mould or min mould open setting. 1.Check mould 2.Check position of ejector sensor. 3.If sensor is not present, deactivate function. Check screw in eject. pist. Check at which point in the cycle, the machine stopped. 1.Increase closing speed / pressure. 2.Increase mould safety pressure. 3.Check for the mould closed indicators on the synoptic diag.

034 MOULD SAFETY ALARM

035 RECURENT FAULTY SWITCH

036 INJECTION INCOMPLETE

037 TIMEOUT MATERIAL LOAD

038 TIMEOUT MOULD OPENING 039 EJECTORS DID NOT FIRE 040 EJECTORS DID NOT RE-ENTER 041 MAX CYCLE TIME EXCEEDED 042 TIMEOUT MOULD CLOSURE

1.Incorrect gate switch sequence. 2.Switch not in correct position The injection piston has not reached the correct cushion positon (less than 3mm) for 8 consecutive cycles see pag.D-380 Activates if material does not load within 23 Sec. from the start of plastification Mould does not open or wrong setting for min. mould opening The ejector sensor is active and did not detect ejectors fired. The ejector sensor is active and did not detect ejectors re-entered Cycle has not been completed within 90 sec. The mould does not close within 3 sec.

No impulse from injection pressure 1.Check the setting of the injection pressure switch and that it functions switch within 3 sec correctly. (page F-140 pos. 11) from the start of high pressure. 044 TIMEOUT DECOMPRESSION Decompression point not reached Check the injection valve. within 3 sec. Reset counter / start a new batch. 045 END OF PRODUCTION BATCH End of production batch. Contact a technician. 046 DSP COMMUNICATION PROBLEM Faulty proportional valve Contact a technician. 047 PROBLEM WITH CIRCUIT BREAKER Faulty circuit breaker Check the cause 048 CYCLE TIME OUT OF TOLERANCE The quality control function is activated and the cycle time has Increase the % set for tolerance band. gone out of tolerance Check connections 050 FAULTY MOULD TRANSDUCER Faulty transducer readings 051 FAULTY INJECTION TRANSDUCER Check the cause / cycle parameters. 052 CUSHION OUT OF TOLLERANCE The quality control function is activated and the cushion value is Increase the % set for tolerance band. out of tolerance check mould and connection of sensors 054 TIME-OUT CORE PULL A No consensus for core pull 055 TIME-OUT CORE PULL B 056 CHECK GUARDS AND GATE Guard / gate check not completed. Open guards, wait for at least 2 secs and then close again. 043 TIMEOUT HIGH PRESSURE

E-0020

E
N MESSAGE 064 TIME-OUT PLASTIF. HEATER 065 TIME-OUT INJ. CHAMBER HEATER 066 TIME-OUT NOZZLE HEATER 067 TIME-OUT MOULD HEATER 068 TIME-OUT MOV. MOULD HEATER 069 TIME-OUT MACHINE STOPPED

BABYPLAST 6/10VP 6/25VP

CAUSE ACTION Reset the alarm, switch the machine Activates when the heaters do OFF and check heaters and not reach the set temperature connections. within 30mins. (manufacturer setting by default)

Activates when machine remains Reset the alarm and switch ON the motor and heaters. with heaters and motor ON, but without running a cycle, for more than 30 mins. (manufacturer setting by default) 070 AUTO-OFF FOR MACHINE STOPPED Activates after the machine has Reset the alarm and switch ON the motor and heaters. been in alarm for more than 6 mins. (user setting page D-0370). - Motor and heaters are switched OFF. Switch machine OFF and then ON Faulty CPU 071 CONNECTION PROBLEM FM542 again. If persists contact a technician. Activates if the heaters have not Exit from Automatic/Semiautomatic/ 072 NOT REACHED PLASTIFIC. TEMP. 073 NOT REACHED INJ. CHAMBER TEMP yet entered within the tolerance Purge and wait for the temperatures to bands and the operator attempts enter within the respective tolerance 074 NOT REACHED NOZZLE TEMP. to use plastification or injection bands 075 NOT REACHED MOULD TEMP. 076 NOT REACHED MOV. MOULD TEMP. functions. Reset alarm and close guard / gate Guard / gate open 078 GATE OPEN DURING CYCLE 079 INJ. GUARD OPEN DURING CYCLE Check thermocouples and connections. Temperatures out of tolerance 080 ERROR PLASTIFICATION TEMP. (+ 0 -) band during cycle. 081 ERROR INJ. CHAMBER TEMP. 082 ERROR NOZZLE TEMP. 083 ERROR MOULD TEMP. 084 ERROR MOVING MOULD TEMP. Switch the machine OFF and ON again Faulty proportional valve 106 SHORT CIRCUIT PROP. VALVE If persists contact a technician. Increase injection time. Set injection pressure not 107 PEAK NOT REACHED Check injection pressure transducer reached connections. Check cooling circuit , valve and Inverter temperature has gone 108 INVERTER OVER HEATED over the operating temperature thermocouple which control the temperature. allowed. Check hydraulic line pressure and that Clamp piston does not reach 111 TIMEOUT HIGH PRESS. MOULD clamp high pressure valve activates. high pressure 130b The actual temperature has 112 OVER TEMPERATURE PLAST. gone out of tolerance by double 1. Set a higher temperature setting that 113 OVER TEMPERATURE CHAMBER is within the tolerance band or wait for the max imum tol. temp .set 114 OVER TEMPERATURE NOZZLE the machine to cool to a suitable 115 OVER TEMPERATURE FIXED MOULD (page D-0390) because: temperature. 116 OVER TEMPERATURE MOV. MOULD 1. A temperature has been changed while the machine is still 2. Contact a technician. hotand the new value is out of the tolerance band by double. 2. A faulty triac or optoisolator has caused a short circuit in the heater. Data load failure while starting 128 DATA LOAD FM542 KO Switch machine OFF and then ON machine 129 DATA LOAD INVERTER KO again. If persists contact a technician. 130 COMUNICATION FM542 KO 131 COMUNICATION INVERTER KO

E-0030

BABYPLAST 6/10VP 6/25VP

E
CAUSE Timeout activation of rotating table sensor Injection carriage sensor not activated ACTION Check sensors and rotation of table.

MESSAGE

117 TIMEOUT ROTAZIONE TAVOLA 118 CONSENSO CARRO INIEZIONE

119 CONSENSUS MOULD OPEN 120 CONSENSUS MOULD POSITION 121 INTERVENTION PHOTOCELL

Check sensor functions correctly and its position. Check injection carriage moves fully back Mould open setting not Check setting and movement for mould reached. open. Mould position sensor not Check position of sensor (par. D.3.2a5 activated pag. D-0320) During the rotation of the table, 1. Check that nothing is in front of the the photocells have detected an guard photocells, reset and return table to correct position. intrusion. 2.Check cable and contacts. Switch machine OFF and then ON again. If persists contact a technician.

128 DATA LOAD FM542 KO 129 DATA LOAD INVERTER KO 130 COMUNICATION FM542 KO 131 COMUNICATION INVERTER KO 132 PROBLEM WITH CAN-BUS 133 CAN-BUS IN ERROR 144 EXCESS VOLTAGE - INVERTER 145 INSUF. VOLTAGE - INVERTER 146 INVERTER OVER HEATED

Data load failure while starting machine

Bad connection CPU - Euromap Check and/ or replace cable CPU/ Euromap. Check power supply voltage or contact Inverter voltage too high technician. Inverter voltage too low Check valve and water flow. Inverter heat exchanger Check heat exchanger thermocouple temperauture too high Mtor temperature too high Faulty inverter board Inverter current too high Inverter current too high Current to motor too high Inverter data load KO Error with inverter parameters Power supply voltage too high Current to motor too high Check phases, power supply cables to motor and thermocouple. Re-set adn switch on motor. Contact technician. Contact technician. Contact technician. Switch machine of and on again if problem repeats, contact technician. Switch machine of and on again if problem repeats, contact technician. Check power supply Check connections to motor/ oil viscosity/ contact technician.

147 MOTOR OVERHEATED 148 POWER FAULT - INVERTER 149 EXCESS CURRENT - INVERTER 150 PROTECTION IXT INVERTER 151 PROTECTION I2T MOTOR 152 INVERTER PARAMETERS KO 153 OFFSET CURRENT OUT OF RANGE 154 POWER SUP. VOLTAGE TOO HIGH 155 MOTOR OVER LOAD

F
F/ MAINTENANCE
OIL:

BABYPLAST 6/10VP 6/25VP

All the materials used in the construction of BABYPLAST have been studied so that they require minimum maintenance and are easy to replace.

The oil and filters must be kept clean and must be replaced within the recommended periods so that the hydraulic equipment does not wear prematurely. RECOMMENDED PERIODS FOR OIL CHANGE: = 2000 to 5000 HOURS ( acc. to oil type) FILTER: = 1500 HOURS REFRIGERATION UNIT: If treated water is used, so as to avoid calcium deposits from forming, no maintenance is required. If treated water is not used, the system will have to be cleaned depending on calcium level in the water. MOVEABLE PARTS: Injection piston and cylinder: periodically check the area behind the injection piston and cylinder and remove any residue plastic material which may have accumulated during normal function. Hydraulic parts : periodically check for oil leaks and, if necessary replace any damaged seals. (Complete sets of seals are available for each assembly). Moving platen: The moving platen is fitted with STD bushes lined with TEFLON, which allow movement. Rotating table: keep the space between the rotating table and fixed platen well lubricated. GASKETS: All the gaskets are fitted with bronze reinforced PTFE friction strips, and O-ring seal. Check the that the surfaces correspond before joining. ELECTRICAL EQUIPMENT. Inspect the ventilator in the electrnics compartment, particularly in hot weather, keep the unit dry and clean, and make sure the connections are well-maintained. Do not use used parts when replacing elements, especially where FUSES AND TRIACS are concerned. Electrical maintenance should be carried out by qualified personel only. HEATING EQUIPMENT: Seeing as all the heating elements are standard and the thermocouples are independent, they are easy to maintain. If other thermocouples are used,they should be a ground isolated "J"-type to avoid disturbances from electrical noise. The Nozzle has an armoured heating element which is fixed in place by a cup shaped protecive cover. Keep this assembly as clean as possible and check the condition of wiring regularly for damage etc. NOZZLE The Nozzle has an armoured spiral heating element which is fixed in place by a cup shaped protecive cover. Keep this assembly as clean as possible and check the condition of wiring regularly for damage etc. INJECTION CHAMBER has two 8 x 80 diameter bulb type 200 W heating elements which need to be checked regularly. Keep this assembly as clean as possible and check the condition of wiring regularly for damage etc. PLASTIFICATION CHAMBER The plastification chamber is heated by a - 230V 1000W 37mm diam. heater band (diam. 60 x 120mm 230V 1100W for augmented version) which guarantees an optimal and uniform heat distribution which is essential for technical polymers. Keep this assembly as clean as possible and check the condition of wiring regularly for damage etc.

F-0010

BABYPLAST 6/10VP 6/25VP

F
F.1/ Machine out of service

When the machine is out of service, we recommend that is is removed from the production area and that a suitable suitable label, indicating the machine status, is placed on the machine in a visible area. Once the machine is out of service, we recommend that the various parts are divided and grouped by the various material types for recycling or disposal. All materials used in the machine construction ar non toxic and do not present a health hazard and so can be handled without taking any particular precautions. ATTENTION! The hydraulic oil must be disposed of according to local laws in force at the time and must not be dispersed in the atmosphere. ATTENTION! At the end of the working life of the machine, it must be dismantled and disposed of by qualified personel only. Only suitable lifting and moving equipment must be used according to local laws in force at the time.

F-0015

F
F/ Electrical drawings - Electro-mechanical diagramme

BABYPLAST 6/10VP 6/25VP

F-0020

BABYPLAST 6/10VP 6/25VP

F
F/ Electrical drawings - 400V - 3Ph Power connections

F-0030

BABYPLAST 6/10VP 6/25VP

F/ Electrical drawings - 230V -3Ph Power connections

F-0035

F
F/ Electrical drawings - Gate switch connections

BABYPLAST 6/10VP 6/25VP

F-0040

BABYPLAST 6/10VP 6/25VP

F
F/ Electrical drawings -Outputs

F-0050

F
F/ Electrical drawings -Inputs

BABYPLAST 6/10VP 6/25VP

F-0060

BABYPLAST 6/10VP 6/25VP

F/ Electrical drawings -Inverter,CPU & Display connections

F-0070

BABYPLAST 6/10VP 6/25VP

F/ Electrical drawings - ROTARY TABLE Inputs

F-0075

in2+

BABYPLAST 6/10VP 6/25VP

F/ Electrical drawings -Euromap 67.1 connections (optional)

F-0080

BABYPLAST 6/10VP 6/25VP

F/ Electrical drawings board CPU board layout (FM542-1) part n C30903100

F-0090

BABYPLAST 6/10VP 6/25VP

F/ Electrical drawings Power board layout (FM542-2) part n C30902000

F-0100

BABYPLAST 6/10VP 6/25VP

F/ Electrical drawings Display layout (FM607A) part n 0903200

F-0110

BABYPLAST 6/10VP 6/25VP

F/ Electrical drawings inverter (FM549BP) part n C30902300

ATTENTION: When removing this board, do not separate the board from the aluminium base. Failure to do so may cause serious damage.
F-0120

BABYPLAST 6/10VP 6/25VP

F/ LAYOUT HEATER THERMOCOUPLE CONNECTIONS

THERMOCOUPLE HOPPER 302.6651400 ZONE H1: PLASTICATION Heater 30301400 Thermocouple 30201400 ZONE H2: CHAMBER Heater 30300800 Thermocouple 30201000 ZONE H3: NOZZLE Heater 30300400 Thermocouple 302.6651200

Detail A

CRONOPLAST s.l.

F-0130

F
F/ HYDRAULIC SYSTEM

BABYPLAST 6/10VP 6/25VP

OIL TANK

OIL TANK

15

19

16

18

17

8 7 5 2-3 1-4-6

043306105600000 C40203700 C40203600 ES-OD02 402.2001101 ES-OD02 402.2001102 ES-OD02 402.2001100

Valve VSON.08A Solenoid S5L35HRL 12VDC 23W Cl.H Prop. valve VEP5A2R10.77K0604NA Solenoid S8.356HRL.24DC 20W Cl.F Valve VED8I4306.58K34.44NCD215 Solenoid S8.356HRL.24DC 20W Cl.F Valve VED8I4206.58K40.30NCC215 Solenoid S8.356HRL.24DC 20W Cl.F Valve VED8I4306.58K32.44NCD215

1 1 1 2 1 2 2 6 3

Hydraulic diagramme

OFEO7806RL0001

BABYPLAST 6/10PV
cronoplast sl

24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9

10000800 40202300 40201600 40203400 10000500 407.2001134 402.6252710 407.6801200 40202900 C30400300 C10006500 402.6950200 30706800 40203900 OC9001003 OC9001053

Safety valve No return valve vuz 18BSP 5 PSI 1/8 Primer valve Safety Valve assembly Radiator assembly Suction filter Maximum pressure reg. DBDS Return filter Pump 3,5l Motor 3 phase - 330V - 50hz AFT valve Pressure gauge 160 bar Pressure transducer 250 bar - 10v Pressure switch 110/107bar (160bar) Screw M8x8 with diam.0,5mm hole Screw M6x6 with diam. 0,6mm hole

F-0140

20

1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1

BABYPLAST 6/10VP 6/25VP

I
2 10 2 12 3 T 4A 4B 3

1A

1B

1A : INJECTION 1B: DECOMPRESSION

2 :PLASTIFICATION 3 : EJECTION 4A : CLAMP H. P. 4B : CLAMP L. P. 5A : MOULD OPEN 5B: PRES. RELEASE


6A : NOZZLE BACK 6B: NOZZLE FORWARD

12

P
5 5A 5B 7

11 6 6A 6B 11

9 8

F/ Hydraulic manifold

12 11 10 9 8 7 5 2-3

Connections A-B-C-D-E-F-G-H-I-J-K-L--PRS1-: G1/8 Connections P-T-TRS: G1/4

1-4-6

30706800 40203900 OC9001003 OC9001053 043306105600000 C40203700 C40203600 ES-OD02 402.2001101 ES-OD02 402.2001102 ES-OD02 402.2001100

Pressure transducer 250 bar - 10v Pressure switch 110/107 bar (160bar) Screw M8x8 with diam.0,5mm hole Screw M6x6 with diam. 0,6mm hole Valve VSON.08A Solenoid S5L35HRL 12VDC 23W Cl.H Prop. valve VEP5A2R10.77K0604NA Solenoid S8.356HRL.24DC 20W Cl.F Valve VED8I4306.58K34.44NCD215 Solenoid S8.356HRL.24DC 20W Cl.F Valve VED8I4206.58K40.30NCC215 Solenoid S8.356HRL.24DC 20W Cl.F Valve VED8I4306.58K32.44NCD215

1 1 1 1 1 1 1 2 1 2 2 6 3
OFEO7806RL0001 Hydraulic block

BABYPLAST 6/10PV
cronoplast sl

F-0150

BABYPLAST 6/10VP 6/25VP

F-0160

BABYPLAST 6/10VP 6/25VP

F/ Motor - pump assembly

B A

Part number

DESCRIPTION

Motor - pump assembly Heat exchanger assembly

A 10003000 B 10000500
Part n

F-0170

Description

F
F/ Standard injection unit 6/10VP

BABYPLAST 6/10VP 6/25VP

DESCRIPTION

Q.ty

Note

F-0180

CRONOPLAST s.l.

Part number

BABYPLAST 6/10VP 6/25VP

F
F/ Augmented injection unit 6/25VP
Qty Note DESCRIPTION

F-0190

CRONOPLAST s.l.

Part number