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EOB

Engel Operator Basics


CC200
(Basic skills for operating
ENGEL injection moulding
machines)

Manufacturer: ENGEL AUSTRIA GmbH


A-4311 Schwertberg

Tel.: +43.50.620.0
Fax: +43.50.620.16062

e-mail: training.austria@engel.at www.engelglobal.com

Version: G/11/25/15/5
Printing date: 19.4.2010
Language Englisch

This manual has been established for information and/or trainings.


It is no component of the instruction manual.
The contents of these documents remains our intellectual property and must not be copied or distributed electronically or mechanically, changed, trans-
mitted, translated into another language nor be used otherwise without our written consent in no manner of what kind ever. Furthermore, the contents
may neither be made known to third parties nor be used for non-approved purposes. These documents only serve the company-internal benefit and use.
Each violation will be prosecuted under criminal and civil law (§12 and §13 UWG).
In the wake of the technical development we reserve the right to make changes without previous notice.
© Copyright by ENGEL Austria Ges.m.b.H.
Version: 3.0 2

endproduktprüfer (epp)
PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1 ENGEL - COMPANY GROUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2 ENGEL - COMPANY HISTORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1 TEXT FORMATTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.1 SCREEN LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2 PROPER USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3 MACHINE OVERVIEW VICTORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.1 MACHINE OVERVIEW VICTORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4 INJECTION MOLDING IN GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.1 MOLDING CYCLE OF AN INJECTION MOLDING MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.2 IMPORTANT PRINCIPLES AND NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

SAFETY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1 PICTOGRAPHS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2 OVERVIEW OF SAFETY EQUIPMENT VICTORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3 SAFETY EQUIPMENT FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.1 EMERGENCY STOP BUTTONS FOR PLANT SHUTDOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.2 FUNCTIONING OF THE SAFETY GATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4 EDDITIONAL EQUIPEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5 MOUNTING AID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6 BEHAVIOR IN CASE OF FIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7 RESCUE ACTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1 COMPONENTS OF THE CONTROL UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.1 SWITCH PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1.2 CONFIGURABLE KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2 SCREEN STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.1 HEADER WITH INFO PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.2 SCREEN PAGE SELECTION AND FUNCTION KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.3 STATUS DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.4 PROGRAM KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.5 INPUT KEYBOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3 USER ACCESSS AUTHORIZATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.1 USER ACCESS CARD LOGIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.2 PASSWORD LOGIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4 SETUP SCREEN PAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
4.1 USER ADMINISTRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4.1.1 CREATING NEW USER ACCESS AUTHORIZATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
4.1.2 CHANGING USER ACCESS AUTHORIZATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4.1.3 DELETING USER ACCESS AUTHORIZATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4.1.4 SAVING USER ACCESS AUTHORIZATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4.1.5 IMPORTING/EXPORTING USER DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4.2 USER LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
5 OPERATION OF AN INJECTION MOLDING MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5.1 START UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5.2 MODES OF OPERATION OF THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
5.3 PUTTING OUT OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
6 HELP SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
7 ERROR SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
7.1 DELETING AND ACKNOWLEDGEMENT OF ALARMS AND MESSAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
7.2 INTERACTIVE MESSAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
8 SET VALUE GRAPHICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
8.1 QUICK SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
8.2 SETTING THE SPEED AND FORCE PROFILE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

CLAMPING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
1 MOUNT MOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
1.1 PREPARATIONS FOR MOUNTING THE MOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
1.2 MOUNT MOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
2 MOLD HEIGHT SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
3 EJECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
3.1 SET THE EJECTOR MOVEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
3.2 SETTING PART REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
3.3 EJECTOR START/STOP SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
3.4 SPRUE EJECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
4 MOLD CLOSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

3
4.1 CLOSING MOVEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
4.2 CLAMP FORCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
4.3 MOLD PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
4.4 EXTERNAL CLOSING INTERLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
4.5 SEQUENCE PROGRAMMING POSITIONS MOLD CLOSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
5 MOLD OPENING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
5.1 OPENING MOVEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
5.2 SEQUENCE SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
5.3 SEQUENCE PROGRAMMING POSITIONS MOLD OPENING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

HEAT ZONES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
1 BARREL HEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
1.1 MONITORING OF THE BARREL TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
1.2 STANDBY HEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
1.3 COMPACT REPRESENTATION OF THE HEATING ZONES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
1.4 SOAKING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
2 MOLD HEATINGS (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

INJECTION UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101


1 NOZZLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
1.1 SPEED PROFILE AND STROKE POSITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
2 INJECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
2.1 INJECTION SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
2.2 SPECIFIC INJECTION PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
2.3 INJECTION TIME MONITORING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
2.4 INTRUSION PROGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
2.5 SWITCHOVER TO HOLD PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
3 HOLDING PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
3.1 HOLDING PRESSURE PROFILE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
3.2 COOLING TIME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
3.3 CUSHION MONITORING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
3.4 SCREW DIAMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
4 PLASTICIZING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
4.1 SPEED PROFILE AND BACK PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
4.2 PLASTICIZING TIME MONITORING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
4.3 PLASTICIZING MAINTAINED INSTRUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
4.4 DECOMPRESSION BEFORE AND AFTER PLASTICIZING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
4.5 BACK PRESSURE IN MANUAL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
4.6 TORQUES DURING PLASTICIZING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

PRODUCTION PROGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119


1 CYCLE TIME ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
2 MONITORING SYSTEMS FOR THE INJECTION MOLDING PROCESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
3 PRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
3.1 START-UP CYCLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
3.2 REJECTS IN SUCCESSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
4 MOLD PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
5 DATA DIALOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
5.1 STORAGE MEDIA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
5.2 SEQUENCE PREVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
5.3 READ DATA SET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
5.4 WRITE A PARTS DATA SET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
5.5 COPY PARTS DATA SET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
5.6 COPYING ALL PARTS DATA SETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
5.7 DELETE DATA SET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
5.8 EXPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
6 NOTEPAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
7 PRINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

MACHINE SEQUENCE AND MASK EDITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145


1 MACHINE SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
1.1 REPRESENTATION OF THE MACHINE SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
1.2 SEQUENCE STEP FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
1.3 STANDARD SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
1.4 LOADING A SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
1.5 STORING THE SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
1.6 PROGRAMMING A SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
1.6.1 INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
1.6.2 INSERT AN INSTRUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
1.6.3 CHANGING AN INSTRUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
1.6.4 REMOVING AN INSTRUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

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OPTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
1 CORE (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
1.1 ACTIVATE CORE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
1.2 START POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
1.3 SPEED AND PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
1.4 SWITCHING-OFF TYPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
1.5 SHAKE CORE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
1.6 CORE WITH EXTERNAL ENERGY SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
1.7 CORE SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
2 AIR VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
3 VIRTMOLD PROGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
3.1 SYSTEM REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
3.2 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
3.3 CREATING A MACHINE SIMULATION FROM A REAL MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
3.4 VIRTMOLD MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
3.5 VIRTMOLD VERSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
3.6 START AND SCREEN STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
3.7 EDIT DATA SET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

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Preface

Preface

Our task does not only deal with the production of injection molding machines alone. Being
one of the leading businesses for plastic manufacturing in the world, we offer all technological
modules such as injection molding machines, tools and automation systems from one source.
Our technologies enable our partners to act competitively and successfully.
Individual responsibility and the willingness of the employees to embrace innovation are the
foundation of our success. Our products are the result of their commitment. By making the
business segments independent, we ensure a flexible handling with regard to the require-
ments of our customers.
Our leading market position is built upon 2 corner stones. On the one side, the hi-technology
business that initiates continuous further development and on the other side, the production of
larger batches that makes our developments financially affordable. Our production locations in
Europe and North America are a guarantee for the constant quality of our products.
One of our basic business objectives, the production of high quality products of continual qual-
ity and reliability are only emphasized by the degree of satisfaction of our customers over lon-
ger periods of utilization.
We aim to strengthen the confidence in our products by carrying out a series of seminars that
should offer our customers and their employees the possibility of targeted purposeful training
knowledge and requisite know-how for handling our products. The intensive training contrib-
utes to helping avoid production downtimes and increases the operating lives of our products.

1 ENGEL - COMPANY GROUP

Company founder Ludwig Engel

Foundation: 1945 by Mr. Ludwig Engel

Legal position concerning The company is owned by the family to 100 %.


property:

Turnover (Business year 2005/ Austria group: 431,5 million EUR. .


2006): ENGEL-Worldwide: 545,9 million EUR.

Employees (Business year Austria group: 2.118


2001/2002): ENGEL worldwide: 3.389

Export rate: Approx. 93 %

7
Preface

Market position: ENGEL is the largest Austrian enterprise of its industry


and belongs to the worldwide leading manufacturers of
injection molding machines.
Market share in Europe is approx. 23 %.

Production plants at home: OÖ: ENGEL AUSTRIA GmbH, Schwertberg


OÖ: ENGEL AUSTRIA GmbH, Dietach
NÖ: ENGEL AUSTRIA GmbH, St. Valentin

Production locations in foreign Germany: ENGEL Automatisierungstechnik GmbH


countries: (Hagen)
Canada: ENGEL Canada Inc. (Guelph, Ontario, )
USA: ENGEL Machinery Inc. (York, Pennsylvania)
Korea: ENGEL Machinery Korea Ltd. (Pyongtaek-City)
Czech Republic: ENGEL Strojienska spol s.r.o.
(Kaplice) China: ENGEL Shanghai
Product range
„ Injection molding machines for the processing of thermoplastics and thermosets
„ 2-6 Aggregate injection molding machines for producing multi-colored or multi-material
combined injection molded parts
„ Horizontal and vertical elastomer injection molding machines
„ Horizontal and vertical low pressure injection molding units for the production of com-
pound parts with special surfaces (textile surfaces, painted films,foam films)
„ Turnkey injection molding production cells including automation equipment
„ Multi-axial linear robots
„ Injection molds for sandwich molded parts
„ Special metal components with the focal point being wear resistance

The responsibilities are divided into 5 business fields:

„ Automotive

Bumper

„ Packaging

Foodstuffs container

„ Medical

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Preface

Implants

„ Teletronics

Enclosure for mobile phones

„ Technical moulding

Pipe fitting

Engel marketing corporations and sales offices:


Germany (Hannover, Hagen, Nuremberg), Denmark, Finland, France, Great Britain, Ireland,
Italy, Holland, Norway, Austria, Poland, Russia, Sweden, Switzerland, Czech Republic,
Ukraine, Hungary, Belgium, Bulgaria, Greece, Kazakhstan, Croatia, Portugal, Rumania, Ser-
bia, Slovakia, Spain, Turkey, Cyprus, Canada, Mexico, USA, Argentina, Brazil, Chile, Ecuador,
Colombia, Peru, Uruguay, Venezuela, China, India, Korea, Singapore, Japan, Pakistan, Phil-
ippines, Taiwan, Thailand, Vietnam, South Africa, Egypt, Algeria, Tunisia, Iran, Israel, Leba-
non.

Organizational chart:

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Preface

2 ENGEL - COMPANY HISTORY


The company ENGEL was founded in 1945 by Ludwig Engel in Schwertberg, Upper Austria
(Oberösterreich) where the main office is still located. After producing machine components
and cable car accessories in the beginning years, the first manually operated Bakelite press
was added to the production program in 1948. This grounded the foundation for the production
of plastic molding machines. The serial production of injection molding machines for proces-
sing plastics began in 1955. The export activities were started at the same time.

The first injection molding machine from

In 1965, the company founder, Mr. Ludwig Engel deceased. His wife Mrs. Irene Schwarz
(maiden name being Engel) and Mr. Georg Schwarz took over the management of the com-
pany. In those days, a turnover of 120 million ATS (Austrian Schilling) was achieved with 438
employees.

In the course of reinforced foreign activities a worldwide marketing network was built up in the
middle of the 60ies. Today the export share is more than 90 % of the turnover whereby about
56 % are achieved in the EU region. ENGEL is represented in more than 70 countries, of them
with 20 own marketing subsidiaries. The first foreign production plant was established in
Guelph, Canada in 1977,.

After introducing robots and automation equipment to the production in our own factory in
Steyr in 1986, an important and successful step was initiated in a new production segment. In
January 1998, the production of the ENGEL robots relocated to a newer and larger factory in
Dietbach near to Steyr.

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Large machines have been produced in the factory St. Valentin (approx. 20 km away from the
main factory Schwertberg) since 1988. Fully automated production systems and logistical sys-
tems enable the modern and economical production of large machines. In 1994, ENGEL intro-
duced the innovative 2 plate large machine technology to the market and in 1997, 1998 and
1999, being the first manufacturer of injection molding machines world wide, were com-
mended with the „Supplier of the Year - Award” by General Motors. In business year 1999 /
2000, ENGEL was the only manufacturer of injection molding machines that was commended
with the highest quality prize by Ford, the „Q1 Award”.

The market position was strengthened even more in the region of North and Central America
with the construction of the new large capacity machine factory in York, Pennsylvania, USA, in
1989 - especially in the automobile sector. In 1994, the extension of the factory was carried out
by doubling the production area. In 1995 a new factory was also built in Guelph, Canada in
North America for the sector of automating technologies.

At the end of 1997, Georg and Irene Schwarz transferred the management of the operative
businesses in Austria to 4 managing directors who's spokesperson is Dr. Peter Neumann. In
the same year, Engel founded the „ENGEL Machinery Korea Ltd.”, with the intention of build-
ing a production factory. With the opening of the production factory in October 2000, Engel had
developed itself to the first manufacturer in the branch with a global production concept and
productions on three continents. At the trade fair „K 2001”, Engel presented itself as the market
leader for injection molding systems.

Today ENGEL is the largest Austrian enterprise of its branch and is as individual mark the
worldwide largest manufacturer of injection molding machines.

ENGEL - MILESTONES IN THE COMPANY HISTORY

1945 Foundation of the enterprise by Mr. Ludwig Engel


1948 Expansion of the production to the construction of cable railways and hoisting
plants
Manufacture of the first mechanical toggle lever presses
1950 Manufacture of the first hand operated injection molding machines and concen-
tration of the production on this field
1955 Reorganization of the production to the serial production of plastic processing
machines
1965 After the death of the founder of the firm: Takeover of the management by Mr.
Georg Schwarz and Mrs. Irene Schwarz (née Engel)
1966-1970 Extension of the foreign marketing activities by expansion to 40 foreign repre-
sentatives
1968 Standard equipment of the machines with electronic control system
1972 Foundation of ENGEL Danmark A/S in Copenhagen as first marketing and ser-
vice corporation outside Austria
1974 Foundation of ENGEL Canada Inc. in Guelph, Ontario, as marketing and ser-
vice corporation for the North American market
1977-1979 Expansion of ENGEL Canada Inc. to the production factory
1980 Development and production of high performance handling and robot systems
1983 The opening of the new ENGEL Technical Centre in Schwertberg, Austria, with
training centre and tool manufacturing, electrical engineering, electronics and
training workshops. Expansion of the in-house software department for the
ENGEL microcomputer technology.
1986 Foundation of ENGEL Machinery HK Ltd. in Hong Kong as first step into the
Far East market (China and South East Asia)
1986 Start of the production of robots and automation equipment in the separate fac-
tory Steyr/Münichholz
1988 Opening of the large capacity machine factory in St. Valentin, Lower Austria
(Niederösterreich), of the ENGEL-Maschinenbau Gesellschaft m.b.H.

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Preface

1989 Opening of the factory for large machines ENGEL Machinery Inc. in York,
Pennsylvania, USA
1993 Enlargement of the production plant ENGEL Canada Inc., Guelph
1994 Doubling of the production area of the ENGEL Machinery Inc., York, USA
1995 Transfer of the production of robots for North America into newly acquired fac-
tory premises of the ENGEL Canada Inc.
1997 Extension of the machine assembly hall and of the administration building in the
headquarters Schwertberg
1997 Foundation of ENGEL Machinery Korea Limited as marketing and service cor-
poration with the intention to begin the planning work for a production factory in
Korea
1997 Family Schwarz entrusts the management of the operative corporations in Aus-
tria to a management team of four persons, with Mr. Dr. Neumann as spokes-
man.
1998 Opening of the new factory for Automatisierungstechnik Gesellschaft m.b.H. in
Dietach near Steyr. The existing production site of the Engel Automatisierung-
stechnik in Steyr is used for the installation of a new production site for special
metal technology under the product name ENGEL MARATHON. The ENGEL
Werkstofftechnik GmbH is founded. With this step ENGEL possesses 4 produc-
tion sites in Austria.
1999 Completion of the second expansion stage of the ENGEL large capacity
machine factory in St. Valentin. The assembly surface was more than doubled
with this expansion stage. ENGEL becomes market leader with large capacity
machines that have a closing force of more than 1000 t.
Laying of the foundation stone and building beginning for the first production
factory in the Far East (factory for small and medium-sized machines in Pyung-
taek-City in South Korea). With this step Engel as the only manufacturer of
injection molding machines possesses production sites in thee contintents.
2000 Opening of the production factory in Korea. Start of the machine assembly.
2002 Extension of the network factory subsidiaries in Europe by the foundation of
„ENGEL Finland” and „ENGEL Poland”. The capacity of ENGEL Hungary is
extended by moving into an enlarged operation building. The production factory
in Canada was extended.
In August the parent company in Schwertberg is severely hit by two tidal waves
after heavy rainfall. All the production equipment is destroyed. But already after
two months the production can be resumed. The catastrophy is taken as occa-
sion to start the project „Phoenix” and to understand the reconstruction as
chance for a new structuring of the production equipment and to convert a
future-oriented production concept.
2003 New construction of the parent company Schwertberg and erection of a flood
control. In the factory of large machines St. Valentin the extension stage III
starts with three hall ships with a total area of approx. 6500 m 2.
In Germany, the long-time branch in Cologne is closed and replaced by a new
building in Hagen. Combined with the new branch in Hagen, the production
location for the „ENGEL Automatisierungstechnik Deutschland GmbH” is estab-
lished, where the projects for automation plants are processed directly within
the German market.
With the beginning of the business year 2002 / 2003, the Austrian manufactur-
ing companies trade under the same name and are merged to „ENGEL AUS-
TRIA GmbH”.
2004 Introduction of the SPEED machine series.
2007 Opening of the large capacity machine factory in Shanghai / China

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General

General

You have decided on an ENGEL product which is produced and supplied under strictest qua-
lity controls.
This instruction manual is an important part of the injection molding machine and intended for
any staff who work with or on the machine. Keep the instruction manual throughout the service
life of the machine, and pass it on to any subsequent owners or users. It is important to inte-
grate any amendments you receive with the instruction manual.

The documentation for the injection molding machine is divided into 3 manuals:

Operator manual (Operations)

Service manual (Commissioning, Maintenance, Spares)

Technical manual (Troubleshooting)

The instruction manual is available in the following forms:


„ printed (except Technical manual). A plan of the electric system is located in the switch
cabinet.
„ as integrated help on the control unit (except for spare parts and schematics).
„ On CD in PDF format.

ENGEL reserves the right to update the documentation.

WARNING!

Improper use of the machine can lead to severe injury to persons and
damage to equipment!
Before operating the plant or performing any maintenance, you must
read this instruction manual carefully, and familiarize yourself with the
safety equipment.
Do not use the plant without appropriate training.
Participation at an ENGEL training center is highly recommended.

The main aim of this book is to impart the operation and all program functions of the injection
molding machine. The book provides the necessary information for setting a production pro-
cess.
The manual is also designed help eliminate production failures as rapidly as possible.

Information on accessories is available in the Special Programs chapter.

Note!
The index contains a list of alarms.

13
General

1 Text formatting
The following text formatting is used to provide a clear manual layout and to emphasize parti-
cularly important information:

DANGER!

Information marked with this symbol points out immediate danger which
can lead to death or serious physical injury!

WARNING!

Information marked with this symbol warns of possible danger which


can lead to death or serious physical injury!

CAUTION!

Information marked with this pictogram warns of possible danger which


can cause injury to persons and damage to equipment!

CAUTION!

Information marked with this signal word warns of danger which can
cause damage to equipment!

Note!
Information provided with this symbol offers application tips and useful information.

Example:
Information provided with this symbol offers practical examples.

Bullet
„ Bullet (emphasis).
„ The operator does not need to maintain a fixed sequence or order.
„

Numbered sequence
1. Fixes procedure way after the numbers

14 ENGEL operator basics (EOB) | Version G/11/25/15/5


General

2. The operator must adhere absolute to the fixed operational sequence.


3.

Reference to a text at the screen or control panel.

Alarms and Messages are listed throughout the manual in table format, indicated by a symbol
for the alarm class, and including a description of the cause, effect, and troubleshooting infor-
mation.

Example of error message:

Error message text

Cause

Effect

Remedy

See the index of all manuals for an alarm list.

15
General

1.1 Screen layout


Depending on the machine configuration, the screen lengths can differ. Some screens support
scrolling. The screens are divided into functional areas.

Screens

CAUTION!

The parameters in the figures are purely incidental and should not be
used as a guide for machine set up.

2 Proper Use
ENGEL products are built to the current state-of-the-art, and comply with accepted safety stan-
dards.

Note that ENGEL injection molding machines must be used for manufacturing of injection
molded parts made of thermoplastics, thermosets and elastomers only, in accordance with the
instruction manual.
To this end, make sure you follow the processing instructions given by the material manufac-
turer!
(Improper processing could lead to injury or damage to equipment!)

Installation, operations, and maintenance of this machine must be performed by staff trained
for this purpose on ENGEL machines.

For damage from improper or not as agreed use, non-observation of the specifications in the
instruction manual as well as faulty operation ENGEL GmbH is not liable.

Modifying the machine invalidates its EC conformity; you are not permitted to put the machine
into operation in this case!

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General

3 Machine overview Victory

3.1 Machine overview Victory


Example: VC 650/150 POWER
Clamping unit side Injection unit side

1 2 3 4 5 6 7 8 9

15 14 13 12 11 10
14
13
12
11

[1] Hydraulic oil tank


[2] Clamping cylinder
[3] Hydraulic ejector
[4] Moving platen
[5] Stationary platen
[6] Barrel with nozzle
[7] Material container
[8] Injection unit
[9] Screw drive for plasticizing
[10] Main switch
[11] Mains connection
[12] Switch cabinet
[13] Control panel with screen
[14] Operator workplace
[15] Moving safety gate clamping unit side

17
General

4 Injection molding in general


Injection molding is the most important technique for producing molded parts. Originally deve-
loped for thermoplastics, today it can be used for more or less any kind of plastics, including
„ thermosets (PF molding compounds),
„ elastomers (e.g. rubber compounds),
„ foaming (e.g. on polystyrene basis),
„ filled and unfilled molding compounds.

The injection molding process, in one single work step, leads from the molding compound to
the finished formed part. The raw material is available to the processor as a powder or gran-
ules. The machine injects a liquid or at least a viscous material into a mold under high pres-
sure. Parts with high dimensional accuracy are produced.

Insert machine
The Insert machine series was specially designed for manufacturing of metal/plastic compos-
ites. This technique involves manually or automatically placing metal inserts into the mold, and
then injecting plastic to cover them.

4.1 Molding cycle of an injection molding machine


In order to create one or more molded parts, the injection molding machine executes a series
of steps that are attuned to one another. In this regard, professionals speak of a molding cycle.
The molding cycle is judged on the time required (cycle time) or after a number of cycles set
on the production counter screen page (e.g. injection shot counter). Individual machine move-
ments can overlap each other in time.

Example of an injection molding machine sequence


Mold close
Nozzle contact
Inject
Holding pressure
cooling time
Plasticizing
Retract nozzle
Mold opening
Take-off

Time

First step: Mold closing


The injection cycle starts when the two mold halves close. A configurable speed and force pro-
file serves to protect the mold against damage. In case of mold parts with mold cavities, the
cores also move in After closing the mold, the machine builds up great clamping force.

Second step: Nozzle contact


The injection unit nozzle is moved up to the mold, and the operator set contact pressure is built
against the sprue bushing.

Third step: Injection and hold pressure

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General

The screw injects the melt from the screw antechamber into the mold cavity under high pres-
sure using a set speed profile. The pressure can be between 300 and 2500 bar depending on
mold and molding compound. A mechanical non-return valve prevents the backflow of the melt
into the screw channels.
The cooling time begins with the entry of the molten plastic into the mold. To prevent sink
marks or voids in the part, the machine switches over to hold pressure after the mold has been
filled. The hold pressure packs out the mold to compensate for material lost due to cooling until
the sprue freezes off (gate sealing). A hold pressure profile and time can be set by the opera-
tor. After the hold pressure, the operator set cooling time begins.

Fourth step: Plasticizing


The plastic granules fall from the material hopper through the feed throat of the injection barrel
into the feed section of the plasticizing screw. The screw turns and conveys the material for-
ward towards the nozzle through the externally heated barrel. As the screw turns, the shear
forces exerted on the material combined with the heat from the barrel cause the material to be
melted and conveyed to the front of the screw. The accumulation of melted mater.
Afterwards, for relieving the melt compressed in the screw antechamber the machine retracts
the screw (decompression). If necessary, a shut-off nozzle can ensure that no melt flows out
from the nozzle.

Fifth step: Nozzle retraction


The nozzle must sometimes be retracted from the mold in order that
„ the sprue shears off,
„ to prevent too much heat transfer from the nozzle to the sprue bushing,
„ to prevent the heated nozzle from being cooled down by the colder sprue bushing.

Sixth step: Ejection


At the end of cooling time, the mold opens with an operator set speed profile and the molded
part is ejected. When the moving mold half reaches the set open position, the molded part is
ejected. Ejector pins are moved through the moving mold half and push out the molded part.
The cycle is finished with the expiry of the recycle time and the machine is now ready for a new
cycle.

4.2 Important principles and notes


Several important prerequistes must be created to ensure optimal process control:
„ The part and mold must be designed to suit the mechanical, thermal and flow properties
of the plastic material used.
„ Standardized checks on incoming material.
„ Efficient machinery.
„ Well designed machine sequence.
„ Sequential quality test of the injection molding machine.
„ Systematic mold proving trials.
„ Optimization aids.

19
General

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Safety

Safety

Injection molding machines are powerful machines that create high PRESSURES - FORCES
- TEMPERATURES that can be dangerous to persons.
To protect persons against danger of accidents, ENGEL injection molding machines are fitted
with safety equipment.
Before operating a machine perform a visual check to ensure that the safety equipment is in
good working order. Also, manually check the locking systems by opening and closing all mov-
ing safety equipment.

[See Safety equipment functions on page 28.]

If you notice that safety equipment is defective,:


1. Switch off the machine immediately at the control panel and at the main switch.
2. Carry out no further activity on the equipment.
3. Immediately contact the member of staff responsible for the safety of the machine.
4. Do not resume operations until all safety equipment is working properly.

Note!
Always keep the whole plant clean. This improves its functionality and enhances operator
safety!

„ The floor around the plant as well as the specified access points and working places are
to be kept free of oil and pellets.
„ Only use marked locations as access points or workplaces.
„ Protect hoses against harmful influences such as acids and mechanical damage!
„ If you notice leakages, damage, or breaks in media lines, switch off the machine imme-
diately!
„ Never use plant surfaces as work surfaces. Do not use the plant as a mounting aid.
„ Comply with and never remove warning signs, notices or labels from machines!
„ Observe the safety instructions in the manual!
„ No access for unauthorized persons.

WARNING!

Danger of burns in the vicinity of hot components such as the barrel and
injection mold; danger of injury due to high pressure injection!
Insufficient pre-drying or decomposition of certain plastics can cause
the material to exit the nozzle or infeed opening in an uncontrolled way.
When working on the machine, use suitable protective clothing (safety
shoes, protective gloves, face protection, ...). Observe local safety regu-
lations for operating injection molding machines!
When working in the injection mold area, make sure the nozzle is
retracted! Make sure the barrel nozzle is not touching the mold!
Observe processing and safety instructions by the material manufac-

21
Safety

turer!
In case of injection steps where clamping force is not fully built up,
install additional, fixed, separating safeguards in the injection molding
machine mold area, or attach directly to the mold!

WARNING!

Danger from gases hazardous to health!


Observe processing and safety instructions by the material manufac-
turer. When processing materials that can cause a health risk, always
use extraction equipment.
The user is responsible for procuring and installing the extraction equip-
ment (e.g. above the injection mold, nozzle areas, material feed open-
ing).
When using nitrogen in processes, always check the oxygen content
first before all work in the pit.

WARNING!

Danger of crushing due to moving components on the machine!


During operations never reach into, or enter, component work areas,
except at positions designed for this purpose.
Never manipulate, disable, or remove safety equipment.
Do not use any molds that protrude over the mold area of the machine.
When connecting and disconnecting media lines in case of retooling
work, make sure that the system is depressurized and switch off the
motors.
Do not work or stand below moving components, even if the plant is
switched off.

CAUTION!

Danger of damage to equipment due to improper settings!


When operating the machine, use settings that precisely match the
requirements for safe operations of the machine, molds, and peripheral
units.
ENGEL is not liable for operator errors.

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Safety

WARNING!

Danger of fatal injury in case of improper maintenance!


Maintenance work and repairs to the machine must be performed by
trained and skilled staff only.
You must have comprehensive knowledge of safety precautions and
controls.
Always perform the maintenance tasks described in the instruction manual at the specified
intervals.
Additionally, keep to maintenance intervals and perform maintenance tasks on all safety
devices for the protection of staff and equipment to comply with your national and/or local
safety regulations.

Any work on the machine, beyond the described activities, must be carried out by ENGEL ser-
vice engineers.

WARNING!

Danger of falling and crushing in case of failure to use fixed mounting


aids!
Use suitable mounting aids for work at heights above 1.0 m (39.4 in).
Mounting aids must be provided by owner/operator if not included in
scope of order.
Unauthorized, non-permanent mounting aids can allow staff to reach
into dangerous areas of the machine.
Before you use non-permanent mounting aids, always switch off the
injection molding machine.
If you need to use a mounting aid, use equipment that complies with
local safety regulations and prevents from falling, tripping or slipping.
Never lean ladders against the machine.
Observe the additional safety instructions found throughout this man-
ual!

23
Safety

1 Pictographs
Description of the pictograms that may be affixed to the machine to indicate dangerous areas
or situations. Failure to observe safety signs can lead to severe injury.

Prohibitory signs

Symbol Description and examples of labels

Admittance for authorized persons only!


Standard labels on protection doors for safety guarding

Keep off the area!


Standard labels in the area of the injection unit and robot control cabinet

No admittance for persons with cardiac pacemaker!


Labels for magnetic holding plates in the clamping unit area

Working or standing below moving components and suspended loads is prohib-


ited!
Labels for machines with robots on protection doors, clamping unit and safety
guarding

No fork lift trucks!


Use of fork lifts or manual lifts for lifting the plant at this position is prohibited.

Do not use any credit cards, watches or small metal parts in the proximity!
Labels for magnetic holding plates in the clamping unit area

Mandatory Signs

Symbol Description and examples of labels

Read documentation!
On the control panel of the machine control

Use protection equipment!


In the barrel area

Use face protection!


In the barrel and injection mold area

Use lifting point for transport!


At lifting points

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Safety

Danger signs

Symbol Description and examples of labels

Warning against hot surface!


In the barrel area

Warning against mains voltage!


On control cabinets and distribution boxes

Warning against hand injuries!

Warning against floating loads!

Warning against pinching or squeezing!


In the clamping unit area

Warning against pressurized molten material!


In the barrel area

Warning against strong magnetic field!

25
Safety

Safety hints

Symbol Description

GUIDELINES FOR WORKING ON INJECTION MOLDING MACHINES:


Labels for the machine control

1. Always observe the local safety regulations for the operating safty of injection
moulding machines and robot systems (handling systems, mould change).
Read the instruction manual.
2. Keep safety equipment in good working condition. Never remove, deactivate
or disable safety equipment.
3. Do not remove any danger or information signs and markings from the
machine or from the additional equipment.
4. Control all the safety equipment on the machine and on the additional equip-
ment for correct function and check it at regular intervals.
5. Control all high-pressure pipelines at regular intervals for their worksafe
state.
6. Pay attention to that no hard objects get into the vent as well as into the feed
opening.
7. Entering the area of the injection unit is not allowed during the machine oper-
ation.
8. If a mounting aid is required for filling the processing material container, use
such which corresponds to the local safety regulations.
9. Do not enter the ejection area and/or do not reach into it during operation.
10. Caution in the area of the heated-up material cylinder ready for operation
(danger of combustion).
11. Always observe the processing guidelines and safety hints indicated by the
material manufacturer.
12. Use extractor fans when working with a vented cylinder and when process-
ing toxic types of material; wear the prescribed protective clothing.
13. Only use shut-off nozzles allowed by the legislator.
14. Never switch the main switch under load (e. g. when heatings are switched
on).
15. Switch off the motors for all maintenance and repair work in the machine's
work areas with moving parts. Make sure that the complete hydraulics system
is depressurized. Exercise special care if you use pressure accumulators.
16. Set the machine currentless by all means in case of repairs and modifica-
tion work. Switch off main switch and secure it and control for voltage freedom.
17. Make sure that the material in the material cylinder is not under pressure
and/or is not cooled down before you dismount the nozzle and/or the material
cylinder flange.
18. Mount and check the whole safety equipment after machine repairs.
19. No admittance to the machine for unauthorized persons.

Entering the injection unit when in operation not allowed, otherwise attach suit-
able covers, which prevent reaching into the danger area of the clamping unit.
Labels for the injection unit

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Safety

2 Overview of safety equipment Victory


Example: VC 650/160 Tech
Clamping unit side Injection unit side

1 2 3

10 9 8 7 6 5 4

[1] Clamping unit side rear sliding safety gate


[2] Alarm lamp (flashes in case of alarm)
[3] Injection unit side rear safety gate
[4] Main switch and machine type plate
[5] Rating plate on inside of control cabinet door
[6] Injection unit side - front safety gate
[7] Guidelines for working on injection molding machines
[8] EMERGENCY STOP button - red
[9] Clamping unit side front sliding safety gate
[10] Injection molded parts delivery chute cover

27
Safety

3 Safety equipment functions


To protect persons against danger of accidents, ENGEL injection molding machines are fitted
with safety equipment.

3.1 EMERGENCY STOP buttons for plant shutdown


The EMERGENCY STOP buttons are located on the control panel of the injection molding
machine and - depending on the machine type - in the following areas:
„ on the rear side of the injection molding machine
„ on the robot manual control unit
„ at the safety gate of a safeguard
„ inside a safeguard

When an EMERGENCY STOP button is activated, the injection molding machine motors
immediately switch OFF. Message:

Emergency-off

Cause An EMERGENCY STOP function is active, e.g. EMERGENCY STOP


button pressed, rear safety gate open

Effect The cycle, motors and movements stop immediately.


The alarm lamp flashes.

Restarting after an EMERGENCY STOP


1. Make sure no dangerous situations exist.
2. Release the EMERGENCY STOP button by turning it clockwise.
3. Activate the Program Interruption switch to acknowledge the alarm.
4. Switch on the motors.

Note!
The EMERGENCY STOP function is active in each mode of operation!

3.2 Functioning of the safety gates


Opening a safety gate blocks all hazardous movements and a corresponding message is dis-
played on screen.

Clamping unit safety gate x open

Effect All machine movements are blocked

Remedy Close the safety gate.

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Safety

Clamp unit safety gate interrupts cycle

Cause Safety gate has been opened in the automatic mode

Effect Cycle interruption, motor standstill, heating reduced, alarm lamp

Remedy Close the safety gates, move the machine into the start position and
start the cycle again.

Depending on the protection type, opening the rear safety gate on the clamping unit causes an
EMERGENCY STOP switch-off, or executes the same function as the operator side safety
gate.

When a safety gate on the injection unit is opened, the following message appears:

Nozzle safety gate open

Effect Blocks all injection unit movements cycle stop.

Remedy Close the nozzle side safety gate

4 edditional equipements
The installation of additional equipment is only permitted with the permission of ENGEL.
If additional equipment is attached to the machine without ground support, a new evaluation of
the risk of tipping must be implemented.
ENGEL is only responsible for the cooperation of the machine with additional equipment if the
interfaces have been designed by ENGEL.
Sockets on the injection molding machine may only be used for the specified additional or
peripheral equipment.

Robot interface / Automation to Euromap 67 or 12


Before connecting and using an interface, risk assessment must be performed by ROBOT
vendor!

WARNING!

Danger due to missing safety gates!


If safety gates are removed to support machine operations with periph-
eral equipment (e.g. conveyor-belts, stacking devices, etc.), the user
company must implement safety measures that do not impact on safety
levels!
If the machine is then operated again without peripheral equipment,
ensure the original safety gates are restored to their original state.
The installation of additional equipment must not reduce the view into dangerous machine
areas, not must it hinder access to workplaces specified in the operating manual.

29
Safety

In a case of damage, ENGEL does not assume liability of any kind!

5 Mounting aid
Machines with material hopper must be equipped as per EN 201 with secure access means or
the user must provide mobile, secure access means for the machine. We recommend that a
mounting aid offered by ENGEL be used.

Proper Use:
The mounting aid is only suitable for manual filling of the material hopper in horizontal standard
injection molding machines without a robot and without additional equipment. Free usage is
prohibited!

WARNING!

Danger of crushing due to moving components!


Unauthorized, non-permanent mounting aids can allow staff to reach
into dangerous areas of the machine.
Only position the mounting aid up to the position marked on the injec-
tion molding machine by a sign. It must be impossible to reach into any
danger areas of the machine.
Maintain safety distances as per EN ISO 13857.
Check the safety distances as per EN ISO 13857 of the mounting aid and respective machine
before use and mark the correct position with the sign.

Example: ENGEL mounting aid for manual material feed

The mounting aid on the front side of the machine


must be moved to the position marked by a sign and
fixed in place by locking the wheels.
The mounting aid must be present at the site prior to
start of production.

WARNING!

Danger of falling due to oil and spilt granulate!


Keep mounting aid clean and do not use if contaminated.

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Safety

6 Behavior in case of fire

1. Keep calm
2. Alert the fire department
3. Switch off the machine at the main switch
4. Alert all persons in the danger zone
5. If possible, close all fire doors
6. Switch of any venting and/or air conditioning units
7. As soon as possible, contain the fire with an approved fire extinguisher
8. Provide assistance and direction to anyone actively involved in fighting the fire

Use an abc class fire extinguisher


„ This is most suitable due to its versatility compared with other extinguishing agents.
„ Be familiar with the instruction label attached to the fire extinguisher.
„ Be aware that the fire extinguisher powder can cause an obstruction to view and will
leave a heavy residue which then must be removed from the machine.

DANGER!

Danger of fatal injury due to electric shock!


Use of water, foam or D class fire extinguishers is prohibited.
When using ABC powder fire extinguishers keep a distance of at least
one meter to electrical equipment.

Note!
If a fire has occurred on an ENGEL molding machine, it must not be put back into operation
until it has been inspected by an ENGEL Service Representative:

„ at your local ENGEL dealer/subsidiary, or


„ contact the nearest ENGEL works

31
Safety

7 Rescue actions
Perform the following rescue actions to release trapped persons from the mold area; note that
accidents of this kind can only occur in case of gross misuse or if you disable vital safety
devices!

1. 2 persons are required to provide first-aid (both must be skilled in the use of the injection
or compression molding system).
2. One of the two rescuers must mechanically secure the machine against motions, such
as lowering or clamping, that would further endanger the victim or rescuers (moving
mold mounting plate, core-pull, ejector).
3. The second rescuer must manually move the machine to a position where the victim
can be freed.
4. Leave the danger area (mold area) with the person you have rescued.
5. Give first aid.
6. Call a paramedic.

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Operation

Operation

The control unit has a Windows-style GUI with a color touch screen. Users need to log in to
access settings and parameters.
The data storage occurs on an USB memory stick.
Text and graphics editors support fast and easy customization of the machine to match your
injection molding process and free programming of the program sequence.
A help system with graphics supports operations and maintenance of the injection molding
machine.
You can install the optional VirtMold software to run the original machine visualization on a
PC. This gives you the ability to change settings independently of the injection molding
machine, and to store your changes on a Compact Flash card or USB memory stick to transfer
them to the machine.

33
Operation

1 Components of the control unit


Control voltage switch
Machine motor switch
Robot motor switch

Mold heating switch


Barrel heating switch

Sensor for the user authorization card (CC 200)

Emergency stop button


2 USB interfaces.
To connect to external devices (e.g.: memory
stick, printer, keyboard, etc..)

Color touch screen display

Configurable foil keys for the manual control of


the individual system motions.

Touch keys for manual control of the individual


machine movements.
(Optional swivel keys)

Start key
Program interruption
Safety button key

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Operation

Color touch screen display


The control unit is operated by tapping the desired menu items. Virtual input keyboards and
dialog windows open so that you can edit parameters.

CAUTION!
Do not use pointed, sharp, or metal objects, including ballpoint pens or pencils, on the touch
screen. This can lead to damage.
It is recommended that the touch screen be operated with either your hand or a suitable
marker.

Control voltage switch


After the control voltage has been switched on, it takes approx. 3 minutes until the machine is
ready for operation.

Note!
After switching off the control voltage, always wait at least 1 second until switching it back on.
The electronics modules must first be able to discharge.

USB interface
To write and read machine and parts data as well as production data. If possible, use Engel-
recommended USB memory sticks.
[See Storage media on page 129.]

Key-operated safety keyswitch


Certain machine interlocks can be circumvented by the simultaneous operation of the safety
key switch and the movement switch.
[See Mode of operation Manual or Program interruption on page 52.]

Program interruption
The program interruption switch is used to interrupt the automatic cycle and to acknowledge
the messages. In the switched-on state the following message is displayed:

Program interruption key

Effect The automatic cycle stops, current messages are acknowledged, you
can run the machine as in manual mode.

Remedy Turn the program interruption switch to Automatic.

Start key
You only need the Start key to start an automatic cycle. The machine's functional units must all
be at the starting position for this. The following message appears when switching over to
automatic mode:

Press start key

Cause The machine is ready to start an automatic cycle.

35
Operation

1.1 Switch panel


The switch panel can have a membrane keyboard or toggle switches. The switch panel has a
different design depending on the machine type or version.
A manual control of the machine's movement is possible by pressing the respective key.

The function of the keys is represented by symbols.

Machine-specific key symbols

Key symbol Key explanation

SP2-0734: Unbe-
kannter Befehl ab
"where k.hb..." - restli-
che Zeile ignoriert.
SP2-0042: Unbe-
kannter Befehl "*" - rest-
liche Zeile wurde
ignoriert.
SP2-0734: Unknown
instruction from
"ERROR in ..." -
remaining line ignored.
SP2-0734: Unbe-
kannter Befehl ab
"ORA-00933:..." - restli-
che Zeile ignoriert.
SP2-0044: Zum Auflis-
ten bekannter Befehle
HELP
und zum Verlassen
EXIT eingeben.

1.2 Configurable keys


The control panel has 8 foil keys that the user can individually assign functions. The configured
functions of the keys appear as symbols on the screen above the foil keys.

1 2

[1] Unassigned symbol fields


[2] Assigned symbol fields with a function
[3] Foil keys for calling up functions

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Operation

Example:
Procedure for assigning a function to a foil key.

1. Press the symbol field of a configurable foil key.


A key menu with the functions that can be selected appears on the screen and the
selected field turns red.

2. Press the desired symbol in the key menu to place it on the red field.

3. Activate the associated function by pressing the foil key below it.
4. To close the key menu, press the red field.

Note!
Symbol pairs such as: Turn mold swiveling device left and right or Move in or out core can be
inserted at the same time by selecting the symbol field on the left.

To delete a function or to replace it by a different one, either press an empty field or the
desired symbol.

37
Operation

2 Screen structure
The clearly designed touch screen of the control unit permits simple and fast programming.

2.1 Header with Info Panel


1 Data dialog 3 4 5 6
Info Panel - injection molding machine actual values
2 Mold position actual value Cooling time actual value
Clamping force actual Shot volume
Specific injection pres- Shot counter actual value

[1] Machine number


[2] Switches the Info Panel to Injection molding machine or Robot
[3] Page title
[4] User name
[5] User accesss authorization
[6] Date/time

2.2 Screen page selection and function keys


For user-friendly operation, the following screen page selections and function keys are availa-
ble:
Production, machine Setup, safety Back to a previous selection
Gate, ...
Mold closing, mold height Cycle time analysis, Weekly time
switch
Mold opening. Mold parameters, notepad

Ejector Data dialog

Core Print

Inject Mask editor

Holding pressure, switchover type Machine sequence

Plasticizing Setup

Nozzle Help

Heating, heating configuration Alarms

Micrograph, quality assurance pro-


Scroll keys (faded if not required).
grams
Switchover of the keys on robot or
machine

2.3 Status display


The first line shows current messages, warnings and alarms during operation. The number to
the right of the message indicates the total number of current messages. All the messages are
also displayed on the alarms screen.
The second line shows possible operating states. Colored symbols are active, dimmed ones
are inactive.

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Operation

Program
1 interruption key

2 3 4 5 6 7 8 9

[1] Line for messages and alarms


[2] Machine motor status symbol
[3] Robot motor status symbol
[4] Heater status symbol
[5] Data set active; read data set
[6] Final backup (not active)
[7] Printer (inactive)
[8] Network access (inactive)
[9] Program keys

2.4 Program keys

Setup Teach or Semi- Fully-


Manual Automatic Automatic

Colored highlighting indicates the current mode of operation. Depending on your user level,
you can click a field to display other modes of operation.

39
Operation

2.5 Input keyboard


Users need to log in to select parameters. The following input keyboard appears for inputting
numerical parameters:
Set value
Input field (current value)
Display of possible input values (plausibility)
Previous value entered
intermediate deposit

Cancel key

Increment key (increase value)


Decrement key (reduce value)
Copy key, copies the value from the previous entry to the
input field
Enter key

interruption Help button for the selected parameter

The Enter key saves the value of the input field if it lies within the range of possible entries. If
this is not the case, the input field is highlighted in red and yellow.

A virtual keyboard is displayed when parameters are selected that require alphanumeric input.
Mold number

Se-

Special keys

Se-
Highlights the entire text

Highlights a portion of the text by activating this key and moving the cursor with the
arrow keys
Copies the selected text

Pastes the copied text

Parameter input process


1. Log in to the control unit with your user level.
2. Select the desired screen.
3. Press the set value to be changed.

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4. Type the value using the input keyboard; the value is displayed in the input field. Check
whether your entry is plausible.
Position

Indicates the plausible range of values.


In this example, the range of values lies between
intermediate deposit 0.0 and 100,0.

5. If you made an error while typing, press the Delete key. You can then enter the correct
value.
6. To store the value press the enter key.
If the entered value is nevertheless too high or too low, the colors of the plausibility dis-
play in the input field change to yellow/red (see the figure below). The control unit dis-
cards the value. You need to enter a correct value.

Position

intermediate deposit

7. To copy an existing value:


„ Select the next set value.
„ Press the copy key in the input dialogue (takes over the previously typed value from
the previous entry).
„ Press the enter key to store the value.

Switching programs and function units on and off


Mold height Function is not
Determine mold height activated.
Mold height
Minimum mountable mold height

The following input field appears when you click a program switch:
Determine mold height
Preview

When you press the Enter key, the control takes on the switch position shown in the preview.
A field with a checkmark is active, while an empty one is inactive.

41
Operation

Selection window (example: Monitoring type)


Production stop An input box appears for certain entries. The selected
Warning only setting is activated by selecting the item and then con-
firming your choice. The selected setting has a colored
Production stop
background.

Dialog window (example: Write data)


Separate dialog boxes are available to interact with menu functions that require additional que-
ries or entries. The content of the dialog box depends on the menu function and can require
various entries; on the other hand, their setup is standardized.
Write active parts data on
Available drives

Name Standard

Description

Free memory
Required memory

Cancel Help Write

Collapsible screen strip


Mold height
Determine mold height
Mold height
Minimum mountable mold height

Mold height

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3 User accesss authorization


To be able to enter or change parameters and settings to the plant, you must first log in to the
device using your user level. The language, user name, user level and type of units are assig-
ned to each user. The higher your user level, the more access privileges you have. Any
change to the plant is recorded automatically by the control unit with the date and time.
If you have a sufficient user level, you can also create, manage or delete your own user
names.

3.1 User access card login


The user data are stored on the user access authorization card.

Logging in and out with the user authorization card on the plant
A sensor for logging in with the authorization card is integrated into the control panel. If you
hold your authorization card in front of the sensor, you will be logged in. After a time that is set
in the control unit, the user is automatically logged out if the control unit is not put into opera-
tion.
There is also a slot for inserting the authorization card to the left of the transponder. The user
is then logged in until the authorization card is removed.

[1] User access authorization card slot


[2] Sensor

3.2 Password login


(EC200 Standard; CC200 Option)

To login from the machine using a password:

43
Operation

1. Access the Setup screen page.


User login
User 2
Password
3
Logout Logout

2. Select the user from the User drop-down menu.


3. Enter the correct password in the Password field.
4. You are successfully logged in when your user name and number appear in the screen
header.
5. You can log out from the device using the Logout key.

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On delivery of the device, the following users are created by default:

User name User level Pass-


word

Optimization L1 5 p

Optimization L2 6 p

Teach_L1 7 p

Teach_L2 9 p

Service_Customer 11 p

You can modify these users and add new ones. Whether you are capable of doing this
depends on your user level and the associated privileges. [See User level on page 50.]

Logout
For logout press the Logout key from the Setup screen page.

45
Operation

4 Setup screen page


Basic settings for the plant are made on the Setup screen. You can specify the language, date
and time, and can select the display mode of the units. You can also find the user login here,
with which you can register yourself on the device. You can call up the Setup screen using the
Setup check box (see figure).

Setup
Info Panel - injection molding machine actual value
Settings

Language German Unit

Date/time 18.07.2007 15:32:15 ISO Imperial

Absolute Relative

User login

User

Password

Logout Logout

Settings
In the settings, you can specify your desired language, change the date and time, and select
the display mode of the units.
„ Language
A few other languages are available in addition to the set one. Select your desired lan-
guage in the menu. The selected language receives a colored highlight. After you have
selected a language, a bar appears informing you of the progress of the language
change.
„ Date/time
To set the date and time, press the appropriate field. Please use the + or - button to set
or change the date and time. The selected field always receives a colored highlight. The
setting is saved by pressing the Enter key.

Day: 25 Month 6 Year 2005

Hour: 11 Minute 0 Second: 5

„ Units
You can change the display format of the units in the Setup menu item. Place a check-
mark next to your preferred setting.
„ ISO
Displays units in metric system
„ Imperial
Displays units in imperial system
„ Absolute
Displays absolute values

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„ Relative
Displays relative values (percent)

Simple conversion examples

Category ISO unit Imperial unit Conversion factors

Stroke 100 mm 3,94 in 100 mm x 0.0394 = 3.94 in

Absolute tempera- 100 °C 212 °F 100 °C x 1.8 + 32 = 212 °F


ture

Pressure 100 bar 1450.3 psi 100 bar x 14.503 = 1450.3 psi

Weight 100 g 3.53 oz 100 g x 0.0353 = 3.53 oz

Weight 100 kg 220.5 lb 100 kg x 2.205 = 220.5 lb

Force 100 kN 11.24 tf 100 kN x 0.1124 = 11.24 tf

Volume 100 cm³ 6.10 in³ 100 cm³ x 0.061 = 6.10 in³

Volume 100 l 26.42 gal/US 100 l x 0.264 = 26.42 gal/US

Torque 100 Nm 73.756 lbf ft 100 Nm x 0.7375 = 73.75 lbf ft

User login
To login enter the correct user and password

4.1 User administration


Engel supplies the plant with predefined user authorizations. You can create additional user
authorizations and modify existing ones.
For creating and changing user access authorizations an user access with administrator rights
is required.

47
Operation

4.1.1 Creating new user access authorization


You can create user access authorization only with the same or a lower access authorization
level than your own.
1. Access the Setupscreen page?
2. Press the Userbutton. A dialog box appears.
3. Select the Administrationtab
User login

User login Logged on Administra-

User Local Remote Language Unit

German ISO abso-

German ISO absolute

German ISO absolute

German ISO absolute

German ISO abso-

German ISO absolute

New Delete Change

Cancel Help Ok

4. Press the Newtouch key to access the dialogue window below.


New

User Name

Password Password

Confirmation Confirmation

Local Access level on the machine

Remote Access level from network to machine

Language German Language selection

Unit ISO absolute Unit of measurement selection

Administrator Authorization for new user to create addi-


tional accounts

Cancel Help Ok

5. Enter the settings for the new user in this dialog box. Enter the selected password again
in the Confirmation line.
6. Press Ok to load the new settings.
7. The new user is stored in the control unit.

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4.1.2 Changing user access authorizations


Only user access authorizations that have the same or a lower level than the current user
access can be changed.
1. Access the Setupscreen page.
2. Press the Usertouch-key to open another dialogue window.
3. In the new dialogue window select the Administrationtab.
4. Press the user authorization that you want to change. This user authorization now has
a blue highlight.
5. Press the Changekey. Another dialogue window appears.
6. You can enter the settings for the user authorization in this dialog box. You must confirm
the password for the settings to go into effect.
7. Press the Ok button to accept the modified settings.

4.1.3 Deleting user access authorization


Only user access authorizations that have the same or a lower level than the current user
access can be deleted.
1. Access the Setupscreen page.
2. Press the Usertouch-key to open another dialogue window.
3. In the new dialogue window select the Administrationtab.
4. Press the user access authorization that you want to delete. This user access authori-
zation now has a blue highlight.
5. Press the Deletekey.
6. The following dialog window appears.
Optimization L2

Delete?

Cancel Ok

7. Press the Ok button to delete the user access authorization.

4.1.4 Saving user access authorization


In the case of machines with a CC200 control unit, you must save new user access authoriza-
tions on user access authorization cards in order to be able to use them.
1. Access the Setupscreen page.
2. Press the Usertouch-key to open another dialogue window.
3. In the new dialogue window select the Administrationtab.
4. Press the user access authorization that you want to save to the card. This user access
authorization now has a blue highlight.
5. Press [Save]. Select [OK] from the dialogue window that appears to confirm.
6. Using the new card, touch the sensor with which programming is to take place.

4.1.5 Importing/exporting user data


The ’Data - dialog’ screen can be used to export the data of the generated user to an input
medium and to import them for another plant.

49
Operation

To do this, select the Setup, Export user data instruction menu button to export the data and
the Import user data to import them. The plant must be restarted after the data have been
imported.
As a result, the operator does not have to create the users for each plant from scratch.

4.2 User level

User levels and applications

Level Target group Applications

1 Start-up personnel Commissioning and decommissioning a


preset machine without the possibility of
editing the parameters.

2 Production staff (Option) Reserved for customer-specific require-


ments.

3 Setup personnel Additional parameter modifications for stan-


dard programs, reading and writing parts
data.

4 Reserved

5 Supervisor Additional parameters and programs for


optimization, Micrograph, process data
package, set value graphics (profile config-
uration), data dialog, heating optimization.

6 Reserved Additional customer-specific configuration.

7 Advanced setup personnel Additional sequence programming, heating


configuration.

8 Reserved

9 Reserved

10 Customer service techni- Additional parameters for maintenance pur-


cian poses and service tools for troubleshooting

11 Customer service techni- Additional calibration programs, variables


cian changes, loading and saving machine data,
saving the USB stick, software update

From 12 ENGEL service technician Additional functions and settings

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5 Operation of an injection molding machine

CAUTION!

Incorrect settings can lead to problems with or damage to the equip-


ment, so care must be taken during the setup and operation of the
machine.
Settings must be compatible to the function of the machine, mold, mate-
rial and peripheral units.

5.1 Start up
1. Switch on the machine main electrical isolator.
2. Switch the control voltage switch to ON (1).
The control unit starts and afterwards the data dialog screen is displayed.

Data dialog
Info Panel - injection molding machine actual value
Mold position actual val- Cooling time actual value
Clamping force actual Shot volume actual value
Specific injection pres- Shot counter actual value

Active parts data set

Data set attributes


Name
Author

Production date
Change author

Change date

Description

3. Log in with your user authorization.


The control unit is now in manual mode, and displays your user authorization level in the
top right of the screen.
The control unit also displays the following messages:

Barrel heaters are switched off;


Machine motor switched off

Cause The cylinder heaters and the machine motor are not yet switched on
or have been switched off by the appearance of an alarm (see alarms
on the screen).

Effect Prevents switchover to automatic mode

51
Operation

4. Switch on the heating for the barrel, and set the required temperature for the plastic type
you will be processing.
CAUTION!
Always enable monitoring for barrel heating to prevent screw movement and/or damage
to the screw tip due to low material temperature.
5. Switch on the machine motor. If an EMERGENCY STOP button is pressed, you must
relieve it by clockwise rotation. The safety gates on the clamping unit must be closed.
Observe the messages on the screen.
„ If the oil temperature is below the set minimum when the pump motor is started, the
oil preheating program switches on automatically. Ideal operating temperature 45 °C
(113 °F).
6. Open the shut-off valve for the cooling water.

5.2 Modes of operation of the machine


Mode of operation Manual or Program interruption
Control of the functions with the manual keys. Each movement lasts as long as you actuate
the respective manual key or a certain end position is reached. The safety gates must be
closed.

Other conditions that block movements:


„ Mold closing when ejector is retracted only. Note additional requirements for special
equipment such as cores, robots, and high speed mounting systems.
„ Mold opening: Check the additional conditions as with mold closing.
„ Ejector stroke at preset mold position only. Note additional requirements for special
equipment such as cores and robots.
„ Injection only when the barrel has been heated up, the mold is closed with the clamping
force built up and the nozzle has been applied.
Reduced injection pressure with an open mold or retracted injection unit is not possible
unless the safety key and the injection key are actuated simultaneously.
„ Plasticizing and decompression only for heated barrel. Plasticizing without back pres-
sure only when safety key is actuated at the same time.

Mode of operation Set-up

Selection of the set-up mode only possible from the manual mode. Functions such as mode
of operation ”MANUAL”, only the following additional items must be observed:

„ Mold protection monitoring is switched off.


„ The clamping force is not built up.
„ The closing and opening speeds are limited.
„ Ejector speed and ejector force are reduced.

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Mode of operation Teach


Teach mode can only be selected from manual mode. Functions such as Setup mode. Addi-
tionally, the machine sequence can be set up.

Mode of operation Semi and fully automatic mode


When working in semiautomatic mode, actuating the green Start key activates a work cycle
that repeats only if the key is pressed again. In fully automatic mode, the cycle repeats on its
own. The duration of the individual functions is determined by the adjustable or preset speeds
and timing relays.

The automatic mode can only be chosen if:


„ The motor is switched on
„ No alarms that would switch to manual mode exist.
„ The oil temperature is within the set tolerance.
„ The program interruption key is set to Automatic.

An automatic cycle start only occurs if


„ The mold is open
„ Plasticized and decompressed in the first cycle
„ The ejector being in retracted position stops.
„ The safety gates are closed
„ The set barrel temperatures are within the set tolerance.

Sample messages when the machine is not in the Start position:

Do not open the mold, ejector not retracted, plasticizing,


Alarm with cycle stop appeared, ... ,

Effect No automatic start, the alarm lamp flashes

Remedy Produce the start conditions.

Push-button actuated

Cause A pushbutton is actuated on operating state change.

Effect Semi-automatic, automatic mode not started, alarm lamp flashing.

53
Operation

5.3 Putting out of operation


The following shut down procedure relates to an injection molding machine using some of the
more commonly used plastic materials, such as polyethylene PE, polypropylene PP, polysty-
rene PS etc.
1. Close the material hopper shut-off solenoid to barrel.
2. Move the injection unit back sufficiently.
3. Relieve the clamping unit using ”Open mold” and then ”Close mold” until a gap of
approx. 2-3 mm forms between the two mold halves.
4. ”Purge” the barrel. Alternatively ”Plasticizing and Injection” until no more material is
forced from the nozzle.
5. Switch off the plasticization barrel and nozzle heating.
6. Switch off the control voltage.
7. Switch off the main electrical isolator.
8. Shut off the cooling water supply main valve to the injection molding machine.
9. Shut off the compressed air stop valve.

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6 Help system
The integrated Help provides you with specific support during commissioning, operation,
maintenance and the elimination of errors.
The Help system distinguishes between help for screens, parameters, sequence instructions
and alarms:
„ Screens
For each screen, the associated description can be called up using the button.
„ Parameters
For each parameter, the description can be called up in the associated dialog box using
the button.
„ Sequence instructions
For each selected sequence command, the associated description can be called up
using the button.
„ Alarms and messages
Highlighting a message on the ’Alarms’ screen and selecting the ’Help’ command menu
button opens the description of the alarm's cause and its elimination.

If you cannot find the desired information in this manner, a content and index directory is also
available.
Core moving platen
Help
1 2 3 4 5

5 Core (Option)

Cores are movable elements in the mold which are usually inserted into the cavity before the injec-
tion procedure and are then extracted afterwards.

Molded part, e.g.


pipe fitting

Cores

Close Back Next Contents


8 7 1

[1] Home/Contents: opens the plant table of contents.


[2] Table of contents of the current manual.
[3] Go to the previous chapter in the current manual.
[4] Go to the following chapter in the current manual.

55
Operation

[5] Go to the table of contents and the list of alarms in the current manual.
[6] Scroll buttons (the Help text can also be moved directly using your finger).
[7] Return and advance to previously opened chapters.
[8] Closing the Help.

Example: plant table of contents for injection molding machine and robot

Help

Close Back Next Contents

Press the machine or robot symbol to open the overview of the corresponding manual. In the
manuals and the control panel - with the explanation of the manual buttons - the following is
available:.

Help

1 2
operator manual - machine(en)

service manual - machine(en)

technical manual - machine(en)

operator panel
3

[1] Book symbol opens the table of contents of the corresponding manual.

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[2] Index symbol opens the table of keywords of the corresponding manual.
[3] Opens the Help for the control panel.

57
Operation

7 Error signals
Alarms and messages that have occurred are displayed by the control unit in text format
onscreen in 2 ways:
„ The control unit displays the last alarm that has occurred in the red message field in the
lower left.
„ The ’Alarms’ screen shows all current alarms from the top down in chronological order
of their appearance.
„ Waiting points (class 7) are located on a separate tab on this screen.

Alarms
Info Panel

time Class Description

Acknowledge safety gate 2

Clamping unit safety gate 2 open

Mold mounting crane not locked

Machine motor switched off

Acknowledge Settings Help

Acknowledge safety gate 2

An alarm-specific Help appears when you press the corresponding alarm and then instruction
menu button Help.

Note!
The index contains a list of alarms.

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The symbols beside the alarm texts specifies the alarm level/type:

Class Cause Effect

Control unit system errors Immediate system stop

Electrical system fault Immediate system stop

System fault Cycle stop

Process malfunction Cycle stop

Process malfunction Cycle not stopped

Information Alarm light turns ON or screen message


displayed

Waiting points Waiting points displayed on second tab

For some process monitoring tasks, you can switch off the alarms, e.g. cycle stop, rejects sort-
ing, switch on alarm lamp or ignore.

WARNING!

Danger of fatal injury!


Only trained service personnel are authorized to troubleshoot class 1-3
alarms.

7.1 Deleting and acknowledgement of alarms and messages


Depending on the alarm class, messages are deleted in the following manner:
„ After restoring the conditions.
„ At each cycle start, error messages from the previous cycle are deleted.
„ Certain alarms also require a manual acknowledgement. To do this either toggle the
Program Interruption switch OFF and ON, or select the message and press the
Acknowledgment key.

Naturally, any other alarms that exist once again cause your messages and reactions.

59
Operation

7.2 Interactive messages


In addition to the generated error messages, interactive symbols are also used in the program
to convey particular information. The following section describes the functionality of each sym-
bol:

Wait Wait message for executing an operational step

Information The message is purely informative without consequences.

Warning The message represents a warning, which must be acknowl-


edged to execute an action.

Error Alarm that can be eliminated at the operator level.

Fatal error Fatal software and/or system error.

At the end of the text, messages can still have another function or link:

The message is backed with a link. By touching the message the target is called
up and displayed.

The help has even more information. Press a message to open help.

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8 Set value graphics


The set value graphics are used to easily display and set speed, pressure or force profiles for
the individual functional units.

8.1 Quick setting


For quick settings, a small graphic is provided with numerical display of the current values and
graph adjustment keys for the respective movement.
Mold close
Info Panel
Closing profile

1 2 3
5

4
Mold stroke posi-

[1] Adjustment keys for the speed profile (green) and numerical display of the current value
[2] Graphic field for speed and force or pressure profile
[3] Adjustment keys for force or pressure profile (red) and numerical display of the current
value
[4] Current position marker (dark-blue) and numerical display
[5] Mold protection monitoring window (yellow)

Parallel adjustment of a curve


1. Press the corresponding Arrow key for force or speed.
„ A preview of the curve appears on the graphics.
2. Release the Arrow key.

Closing speed
Accept change

Cancel Help Execute

3. Press Execute.

Equalization of all graphical values


1. Press the chosen curve = key.
„ Numerical input field is displayed.
2. Type in the value.
3. Press the Enter key.

61
Operation

8.2 Setting the speed and force profile


Touching the graphic field opens a larger graphic window. The individual points on the graph
can be adjusted either by touching the screen and moving them with the finger or by typing in
values. The number of profile stages and mold protection monitoring (Autoprotect) can also be
set within this window.

Mold closing - set value graphics


Info Panel
1

3
2

Closing speed

Force during mold closing 4

Back Profile Edit Autoprotect View 5

[1] Status line


„ Digital display for position, speed and force of the component
„ Symbol for Line mode or Point mode active
„ Autoprotect mode active
„ Zoom mode active
„ X, Y actual value display of the selected point at the graphic setting

[2] Graphic window for speed and force profile


[3] Actual value bar (dark blue); can be switched on and off in the View menu.

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[4] Digital setting values for speed and force with corresponding switching positions; this
table can be switched on and off in the View menu.
[5] Menu keys for further functions

63
Operation

Changing a profile by dragging with your finger


1. Touch the graphic window.
„ A larger graphic window is displayed.
2. Touch the required profile (if necessary, press Change profile ).
„ The selected profile appears with points that you can move. The background of the
graphics field changes to the light color of the selected profile.
3. Touch the chosen profile points and drag them to the required new setting.
„ The chosen point is always colored and a preview (dotted line) is displayed.
4. Press Accept.
„ If you want to cancel the process, press Edit and Undo

Mold closing - set value graphics


Info Panel - injection molding machine actual value

2 3

Closing speed

Force during mold closing

4 5
Cancel Dot -> Line Change profile Accept

[1] Numerical display of the chosen point coordinates


[2] Chosen point
[3] Preview profile
[4] Switchover to line displacement mode (parallel displacement of one line between two
points)
[5] Switchover to the other profile

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Set push grid for graphical profile adjustment


1. Press Edit and Grid
2. Enter the number of desired grid lines (0 = off)
3. Press Accept

Equal division of the stroke points for the current screw stroke
1. Press Profile.
2. Press Space equally.

Set number of profile items


1. Choose the set value graphics.
2. Press Edit and Number of profile points.
Set the number of profile points

Number of points Speed points

Number of points Force points

Cancel Help Accept

3. Enter the number of the points for the required profile.


4. Press Accept.

Set zoom function


1. Press View and Zoom.
Zoom

Zoom type Switched off

Zoom start point

Zoom end point

Cancel Help Accept

2. Choose the zoom type from the selection box:


„ Switched off: Display of the set stroke of the function unit.
„ Maximum range: Display of the maximum possible stroke of the function unit.
„ Defined range: The zoom start and end points are adjustable.
„ Autoprotect: Display of the mold protection monitored area.

3. Press Accept.

Menu key Autoprotect

Autoprotect, mold protection monitoring can be activated on the set value graphics to protect
the mold during closing. Normally, mold protection monitoring is set on the mold closing screen
page.
[See Mold protection on page 79.]

65
Operation

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Clamping unit

Clamping unit

The clamping unit has the following tasks:


„ To close the mold quickly and to lock the mold ready to receive the shot.
„ To hold the mold closed against the injection pressure.
„ When the molded part has cooled, to initially separate the mold halves slowly and to
open quickly.
„ To eject the molded part.

Main structural units of a tie-barless clamping unit:


1 2 3 4

6 5

[1] Ejector
[2] Moving mold fixing platen
[3] Injection mould
[4] Stationary platen
[5] Frame
[6] Clamping cylinder

67
Clamping unit

1 Mount mold

WARNING!

Danger due to hot barrel and pressurized molten material.


Danger of serious eye injury and burns to skin!
Wear suitable protective clothing and face protector.
Make sure the barrel is depressurized by purging until empty.

1.1 Preparations for mounting the mold


„ Check that there is enough space on the machine to mount the mold.
„ Standard nozzle radius must be smaller than the radius of the sprue bushing or nozzle
contact position of the mold.
„ Mold centering must be approx. 0.1 mm (0.004 in) smaller than the centering bore on
the mold fixing platens.
„ Sufficient clamping force (approx. 3 kN per cm² projected mold area or ca. 2 tn per in²
projected mold area).
„ Check the mold height.
„ Sufficient opening stroke for ejecting the part.
„ Sufficient injection volume and specific injection pressure.
„ Ejector stroke (possibly air valve).
„ Special equipment (cores, mold heating etc.).
„ Maximum allowed mold weight for the moving platen (see the machine instruction man-
ual).
„ Clean the mounting surfaces of the mold fixing platens and mold, and whet them with
an oil stone if needed. The contact areas must be clean and free of grease, to enable
good friction contact Do not use grease paper; possibly lubricate lightly to pre-
vent corrosion (possibly with anti-corrosive spray ).
„ The lifting eye must be exactly above the center of gravity of the mold to allow the crane
to lift it as vertically as possible.
„ Use sufficient fastenings (taking the required opening forces into consideration). The
opening force is considerable for long cores (e.g. buckets, fittings). The best approach
is to screw down the mold directly to avoid spring travel. The formula for minimum reach
of screws is: Screw diameter x 1.5. The property class of the screws should be 8.8 or
10.9.
„ Match the ejector bolts to the machine (bolt length, ejector lock).
„ Prepare the hoses for cooling or temperature control, also any required temperature
control units or special equipment.

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Clamping unit

1.2 Mount mold

WARNING!

Danger to life and limb, and danger of crushing due to floating loads!
Floating load hazard.
Molds must be mounted only by skilled staff who are familiar with trans-
portation of injection molds.

Example:
Procedure for mounting an injection mold with connected mold halves.

1. Switch to ”Setup” mode of operation. Pay attention to low closing and opening speed.
2. Open the moving platen wide with Mold opening.
3. Use a bridge to join the mold halves and insert them into the machine. Align with the
mold fixing platen where the (more exact) centering lug of the mold is located; this is
normally the nozzle side.
4. Fix mold on the right mold fixing platen.
If you have a quick mounting system, press the Mount mold on stationary platen-
pushbutton to do this. The safety gate on the clamping unit must be closed.
5. Set mold height: Close the clamping unit safety gate and switch to ”Setup” mode, with
the Mold closing key, bring the moving platen cautiously to the mold .
TOGGLE LEVER MACHINES and FULLY ELECTRIC MACHINES: Measure and enter
mold height, then switch on mold height setting.
DUO MACHINES: Before mold closing switch on the program switch Determine mold
height .
6. ATTENTION! Ejector fully back. When using an hydraulic ejector, an ejector rod which
maybe integrated into the mold, must be introduced centrally into the ejector lock. After-
wards with applied mold fixing platen keep the key pressed shortly until the mold posi-
tion actual value displays ”0” on the screen. For checking whether the new mold height
has been stored, by a minimum opening the distance of the mold fixing platen to the
mold can be compared with the display of the actual mold stroke position.
7. Set the clamping force, and actuate up, down and up a few times in manual mode.
8. Fix mold on the left mold fixing platen.
If you have a quick mounting system, press the Mount mold on moving platenpush-
button to do this. The safety gate on the clamping unit must be closed.
9. Remove the connecting elements between the mold halves.
10. Cautiously open the mold, paying attention to the function of the mold as well as any
additional equipment (cores, solenoids etc.).
11. Move the ejector with low pressure and speed to the ejector rod and attach this into the
ejector lock. Set the ejector back position on the screen.
12. Provide the mold with the required connections and any additional equipment (such as
heating/cooling temperature control circuits, pay attention to the return flow restrictor).

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Clamping unit

2 Mold height setting


Mold height
Info Panel
+ Mold height
Determine mold height
Mold height
Minimum mountable mold height

Note!
The mold height must be redetermined, after mounting a new mold or after reading in a new
data set.

Actuating the Mold closing pushbutton, when the mold height is not determined, will display
this message:

Determine mold height

Cause The actual mold position has reached a value less than the calibrated
zero position or the mold height has not been set after reading in new
parts data.

Effect Mold closing and ejector advance is not possible.

Remedy Set the mold height.

Procedure:
1. Before mounting a mold on the machine, the clamping unit is at an undetermined mold
height. In Setup mode, open the moving platen until there is enough space to install the
new mold.
2. Mount the mold on the stationary platen.
3. Close the safety gates.
4. Completely retract the ejector.
ATTENTION to the ejector rod, ensure that it is not held forward during mold height
determination!
5. Switch on Determine mold height.
The machine will now move at setup speed and with setup force. The message Auto-
matic mold height determination enabledappears.
6. Press the start button or move the platen to the mold and keep the pushbutton actuated
until the screen flag lights up. The control unit takes over the current value on Mold
height.

Value Minimum mountable mold height indicates the smallest possible mold height for this
machine.
When the moving mold fixing platen reaches this position, the following message appears:

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Mold clamping mechanism on stop

Cause The clamp, on the direct-closing machine is at the mechanical stop


(e.g. the mold is too small).

Effect No clamping force build-up

Remedy Mount a spacer plate.

3 Ejector
The ejector takes the molded part from the injection mold.
1 2 3 4 5

[1] Ejector drive


[2] Ejector coupling
[3] Ejector connection rod
[4] Ejector plate of injection mold
[5] Ejector pins

CAUTION!

Danger of damaging the injection mold by the force of the ejector drive!
The injection mold can also fall down if the fastening is insufficient or in
the case of magnetic holding plates!
Set the ejector force as low as possible.
Set the ejector advanced and ejector retracted positions precisely.
Observe the braking paths when changing speed.
Release conditions for ejector movement:
„ Safety gates closed
„ Ejector start position reached
„ Any additional equipment (e.g. cores, robot) in release position

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Clamping unit

3.1 Set the ejector movement


Ejector

Advance profile

retract profile

Ejector stroke position


Ejector retracted position Ejector advanced position

Advance profile and retract profile


Multi-stage force and speed profiles, with switchover positions, can be set on the set value
graphics, for ejector advance and return.
[See Set value graphics on page 61.]
Forces and speeds are limited in setup mode.

Ejector stroke position


Measurement is carried out from the rear mechanical position of the machine ejector. The con-
trol unit displays the current value onscreen as vertical lines in graphical and digital form.
1 2 3 4 5

[1] Rear mechanical position


[2] Ejector retracted position
[3] Ejector stroke
[4] Ejector advanced position
[5] Front mechanical position

„ Ejector retracted position and Ejector advanced position


The ejector stroke is the difference of the ejector position retracted and the ejector
advanced position.

For example, if the ejector is not retracted during mold closing, the following message appears
in the standard case:

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Ejector not back

Effect Depending on the sequence setting, blocks e.g. mold closing, core
moving-in, etc..

Remedy Retract the ejector, check ejector plate and ejector pins.

Example:
Procedure for coupling and setting the ejector:

CAUTION!

Danger of crushing when coupling the ejector!


Spring-loaded mold ejectors can cause uncontrolled movements of the
ejector components.
Insert the ejector rod centrally into the ejector coupling.
1. Switch on operating mode Set-up.
2. If you are using an ejector coupling, move the machine ejector to the ejector rod and
couple it.
3. For trouble-free part removal, move the ejector accordingly far forwards.
4. Set the displayed ejector position as Ejector advanced position.
5. Move to the rear position. The ejector pins are not permitted to protrude outside of the
mold cavity.
6. Set the displayed ejector position as Ejector retracted position.
7. Switch to manual mode and check the set position again.

3.2 Setting part removal


Ejector shaking is used for molded parts that are difficult to remove.
When the Shake ejector instruction is inserted in the machine sequence, the associated set-
ting parameters appear on the screen.

Example: Machine sequence with Shake ejector

Open mold
200,0 mm

Ejector - shaking
2 times

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Clamping unit

Part removal
Ejector shake counter times

Ejector shake position

Ejector advance delay

Ejector retract delay

Mold pause time

Ejection control

Position at cycle end retracted

No ejection at mold protection

„ Ejector shake counter


To shake, set the value to 1 + the desired number of shaking movements.

Example with ejector shake counter, 2 times


1 2 3 4 5

[1] Rear mechanical position


[2] Ejector retracted position
[3] Ejector shake position
[4] Ejector advanced position
[5] Front mechanical position
[6] Shaking stroke

„ Ejector shake position


The shaking stroke results from the ejector advanced position and the ejector shaking
position.
„ Ejector advance delay
Has an effect the first time that the ejector is advanced.
„ Ejector retract delay
Has an effect each time that the ejector is retracted.
„ Position at cycle end
„ retracted
The ejector retracts after shaking.
„ advanced
The ejector remains advanced until the start of the next cycle (e.g. to remove molded
parts).

„ Mold pause time


Starts at the end of ejector movement and delays the next cycle start (e.g. so that the
molded parts can fall out).
„ Ejection control
Starting at mold opening until the end of the mold pause time, additional equipment, e.g.
light beam guard, scales or video camera, monitors the part removal procedure. If the
ejection control does not issue a signal, the following message appears:

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Ejection control

Cause A molded part was not removed - ejection control was activated.

Effect The alarm lamp flashes, new cycle will not start.

Remedy Eject the injection molded part.

„ No ejection at mold protection


In the case of a mold protection alarm, the mold is opened without ejector movement.

„ Robot take off on


In the case of machines with a robot, the setting parameter appears on the screen when
the Shake ejector instruction is inserted in the machine sequence.

Robot take off on first ejector stroke

„ first ejector stroke


Activation of the robot vacuum/compressed air circuits on the first ejector stroke.
„ last ejector stroke
Activation of the robot vacuum/compressed air circuits on the last ejector stroke.

3.3 Ejector start/stop settings


Start, stop settings
Opening stroke

Ejector advance start position

Ejector check position

„ Ejector advance start position


In the case of machines without parallel movement, the start position must always be
set so that it is the same as the opening stroke. As a result, the ejector starts after the
mold is completely open.
In the case of machines with several pumps, you can set simultaneous movement of the
ejector for mold movement in the machine sequence. During opening, simultaneous
movement then occurs when the start position is reached.

Note!

A reduction of the maximum speed during parallel movements can result as the second pump
is not available for the mold movement.

„ Ejector check position


If the ejector moves simultaneously as mold closing, it must be at the rear at the preset
check position (mold position).
Include corresponding braking stroke when setting the control position!
Message:

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Clamping unit

Ejector not back

Effect Mold closing stops. In automatic mode, movement waits until the
ejector is retracted and then continues.

Remedy Retract ejector.

3.4 Sprue ejector


The program is used for the separate sprue removal with the ejector, usually with a shorter
ejector stroke.
Certain instructions for the sprue removal in the machine procedure activate the settings on
the Sprue ejector screen. This parameter functions in the same way as for the standard ejec-
tor. [See Set the ejector movement on page 72.]

Example: Machine sequence with sprue ejection

Mold opening up to position 1


200,0 mm
Ejector - shake sprue ejector
2 times
Open mold
400,0 mm
Advance ejector
80,0 mm
Retract ejector
20,0 mm

Sprue ejector
Info Panel
Advance profile
+
retract profile
Ejector stroke position
Sprue ejector end position

Part removal
Sprue shake counter times

Sprue shake position

Sprue ejector advance delay

Sprue ejector retraction delay

In case of rejects, move to ejector advanced position


Start, stop settings
Opening stroke

Start sprue ejector advance

Ejector check position

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The ejector check position is identical to that for the standard ejector.

Additional setting parameter:


„ In case of rejects, move to ejector advanced position
When switched on, the ejector immediately advances all the way if there are rejects and
thus ejects the sprue together with the molded part, for example.

4 Mold closing
Mold closing should ideally occur as quickly as possible, but with regard to mold protection
requirements for speed and pressure reductions. When the mold is safely closed, clamp force
can be built up.

The closing movement is enabled when


„ the safety gates are closed,
„ the ejector is retracted
„ Start conditions fulfilled for any additional equipment used (e.g. cores).

4.1 Closing movement


Mold close
Info Panel
Closing profile

Mold stroke posi-


Opening stroke Mold close position

For mold closing, a multi-stage speed and force profile can be set with the set value graphics.
[See Set value graphics on page 61.]

Note!
Set the speed and force with consideration to the mold protection requirements.
Use ramps with fast movements to achieve smooth stops and starts.

In the mode of operation Setup closing speed and clamping force are limited.

The adjustable strokes are measured from the closed mold. The current Mold stroke position
is displayed on the screen by a vertical line and also as a value.

Set the Opening stroke large enough so that the part can be safely ejected.
Set Mold close position to the value which the machine displays when the mold is closed
without clamping force.

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Clamping unit

Note!
The machine switches to high clamping force when the Mold close position is reached
(except in setup mode)).

For injection and nozzle advance the mold must be closed, otherwise the following message
is displayed:

Mold not closed

Effect Injection and nozzle advance only possible with reduced pressure,
the alarm lamp flashes.

Remedy Close the mold in manual mode.

4.2 Clamp force


The clamping force is that force which is required to keep the mold closed against the injection
pressure.

The machine switches to the set clamping force after the mold closing when
„ the Mold close position is reached and
„ Operating mode ’Setup’ is switched off.

Clamp force
Clamp force

Note!
Set clamping force as high as needed for the injection process. Unnecessarily high clamping
force leads to increased energy consumption, causes wear and tear, and even damage of the
mold and mold fixing platen.

The set clamping force must be built up completely before injection can take place.
If the clampforce is too low, the following message is displayed:

Clamping force too low

Effect No injection process; the cycle finishes, the alarm lamp flashes, shot,
piece and rejects counter do not count.

Remedy Use the push-button to open and close the mold several times until
the clamping force is reached.

When the maximum clamping force is exceeded, e.g. by too high injection pressure in the cav-
ity, the following message is displayed:

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Clamping force exceeded

Effect Mold closing and the injection process stop, no new cycle start, the
alarm lamp flashes.

Remedy If the error appears during injection, change the molding settings
(mean cavity pressure too high).

4.3 Mold protection


Mold protection is the means by which the mold is protected against damage when a part is
trapped in the mold during closing.
Mold protection is sensitive enough to react to the smallest obstacles that prevent mold clos-
ing.
Mold protection monitoring
Mold protection monitoring time
Mold protection monitoring start

Mold stop after mold protection alarm


Multiple closings

Mold protection monitoring

„ Mold protection monitoring time


At the mold closing the machine measures the needed time between the positions Mold
protection monitoring start and Mold close position. If the machine needs longer
than the set Mold protection monitoring time, the mold protection alarm reacts.
„ Mold protection monitoring start
From this position the mold protection area begins. This area is represented in the clo-
sing profile backed yellow.
„ Mold stop after mold protection alarm
If you have activated this selection field, the mold no longer opens, but stops on the
position on which the mold protection alarm has appeared.
„ Multiple closings
When the counter is set bigger than zero, the mold opens and starts a new closing pro-
cess. When at the renewed closing process no mold protection alarm appears, the
machine continues the cycle.

Note!
Observe the following hints for setting the mold protection

„ Set for a good effective mold protection the speed against end of the closing process as
slowly as possible.
„ Choose just enough force, towards the end of mold closing, to close the mold without
affecting cycletime.
„ Set Mold protection monitoring start on the position from which damage of the mold
can arise when an injection molded part is trapped (e.g. part height + sprue).

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Clamping unit

„ The end of the mold protection monitoring is always the Mold close position. Set the
positon so that it is only reached when the two mold halves are applied.
„ Choose the Mold protection monitoring time greater than the time actually needed
for running through the monitoring area (pay attention to the actual value display).

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When a mold protection alarm is triggered off, the following message appears:

Mold protection

Cause The mold protection has reacted, e.g. by an injection molded part
which got stuck between the mold halves.

Effect If multiple closing is set to zero, the message Multiple closing end
appears at the same time, otherwise the set multiple closing pro-
cesses start.

Remedy Check the mold, maybe set the opening stroke greater, demolding
time longer, ejector stroke and/or ejector shake counter greater.

After the expiry of the counter Multiple closings the message appears:

Multiple closing end

Cause The mold protection has reacted and Multiple closings has reached
the set number.

Effect Switchover to manual mode, motor stops delayed and heatings


reduce delayed.

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Clamping unit

4.4 External closing interlock


It is possible to prevent the mold closing with a separate limit switch on the injection mold (e.g.
for the ejector plate). When the limit switch is not actuated the following message is displayed:

External closing interlock

Cause The enabling signal for mold closing is missing

Effect Mold closing stops.

Remedy Check the injection mold and the actuation of the safety switch.

4.5 Sequence programming positions mold closing


For the sequence programming, freely adjustable positions are provided such as mold inter-
mediate stop for move in cores, start position for parallel movements, etc. The positions used
in the closing sequence appear on the screen page Mold close.
Sequence programming positions
Closing position 1

Closing position 2

Closing position 3

Mold not closed on position

Cause The mold is for the requested movement not on the position pro-
grammed in the sequence.

Effect The requested movement cannot be executed.

5 Mold opening
At the end of cooling time and reduction of clamp force, the mold opens at an operator set
speed profile, the injection molded part being ejected from the moving mold half.

The opening movement is enabled if:


„ The safety gates are closed
„ Interlock conditions fulfilled for any additional equipment used (e.g. cores)

Message examples depending on the setting of the safety conditions when the movement is
not enabled:

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Ejector not back


Core 1 moving platen not moved in

Effect Opening movement is blocked

Remedy In manual mode, move the corresponding functional unit into the correct
position; Check the safety conditions;

5.1 Opening movement


Mold opening
Info Panel
Opening profile

Mold stroke position


Opening stroke

A multi-stage speed profile can be set for mold opening with the set value graphics. [See Set
value graphics on page 61.]

Note!
Coordinate the speed with ejection
Use ramps with fast movements to achieve smooth stops and starts

Opening speed and opening force are limited in ”Setup” mode.

The adjustable strokes are measured from the closed mold. The current Mold stroke position
is displayed on the screen by a vertical line and also as a value.

Set the Opening stroke large enough so that the part can be safely ejected.
The mold must be open at the start of an automatic cycle, if not, the following message is dis-
played:

Mold not open

Effect No cycle start possible, the alarm lamp flashes.

Remedy Move the mold to the start position in manual mode.

5.2 Sequence settings

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Clamping unit

Cancel mold safety


In set-up mode you can cancel the safety conditions calculated in sequence programming for
mold, ejector and core movements.
Sequence settings
Cancel mold safety

CAUTION!
Danger of mold damage!

Procedure
1. Switch to Set-up operating mode.
2. Activate the Cancel mold safetyscreen switch.

The Setup symbol changes:

3. Actuate the pushbutton for the required movement and the safety key at the same time.

The screen switch automatically deactivates when you switch to Manual mode.

Movement to Home position


The Movement to home position function gives you the ability to move the machine to the start
position by pressing the preset Movement to home position pushbutton.
Hold the button down until cycle start position has been reached.

Movement to home position carries out the following movements in the programmed order:
„ Screw - plasticize
„ Open mold
„ Core movements

Allow movement to home position

Pushbutton Movement to home position Mold opening

Allow movement to home position in automatic mode

„ Allow movement to home position


If the program switch is activated, you can use the preset pushbutton to move the
machine to the cycle start position.
„ Pushbutton Movement to home position
Options for the movement to home position pushbutton:
„ mold opening + safety key +

„ Machine movement to home position + safety key +

„ Robot movement to home position + safety key +

„ Mold opening

„ Allow movement to home position in automatic mode


If the program switch is activated, the machine automatically moves to the cycle start
position after the start key is pressed.

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5.3 Sequence programming positions mold opening


For the sequence programming freely adjustable positions are provided such as mold interme-
diate stop for move in cores, start position for parallel movements, etc. The positions used in
the opening sequence appear on the screen page Mold open.
Sequence programming positions
Opening position 1

Opening position 2

Opening position 3

Mold not open on position

Cause The mold is for the requested movement not on the position pro-
grammed in the sequence.

Effect The requested movement cannot be executed.

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Heat Zones

1 Barrel heating
Precisely controlled barrel heaters are required for producing a thermally uniform melt. The
shear forces, during plasticizing, produce 60 to 85% of the energy required for melting the
material. The melt temperature is affected by the barrel temperature, depending on the resi-
dence time in the barrel.

1 2 3 4 5 6

8 7

[1] Nozzle [4] Thermosensor [7] Feed throat with cooling


[2] Flange [5] Screw [8] Heater bands
[3] Material barrel [6] Feed opening for material

An increase of the melt temperature:


„ decreases the visibility of weld lines
„ increases the crystallinity
„ decreases the viscosity
„ decreases the orientation
„ decreases the pressure losses in the mold
„ increases the thermal stress in the melt and promotes gas production (thermal decom-
position)
„ decreases the mechanical loading (shear) of the melt caused by tearing the molecule
chains in the nozzle - gating system, as well as by numerous narrow cross-sections in
the mold
„ reinforces the shrinkage of the molded part
„ increases the cooling time slightly

WARNING!

Danger of burns in the vicinity of hot components such as the barrel and
injection mold; danger of injury due to high pressure injection!
Insufficient preliminary drying or the decomposition of certain plastics
can lead to accidental purging out of the nozzle of the feed opening.
When working on the machine, use suitable protective clothing (safety
shoes, protective gloves, face protection, ...). Observe local safety regu-
lations for operating injection molding machines!
When working in the injection mold area, make sure the nozzle is
retracted! Make sure the barrel nozzle is not touching the mold!
Observe processing and safety instructions by the material manufac-

87
Heat Zones

turer! When processing materials that can cause a health risk, always
use extraction equipment!
Maximum permitted barrel operating temperature:
+ 350 °C (662 °F)
Switch for barrel heating on control panel
Before switching on, the following message appears:

Barrel heaters are switched off

Cause The barrel heaters are not yet switched on or have been switched off
by the appearance of another alarm (see alarms on the screen).

Effect No cycle start possible

Remedy Switch on the main switch for barrel heaters on the control panel.
Eliminate the primary error.

All zone groups are automatically heated up to reach the set point at approximately the same
time..
If all barrel heaters have dropped below the lower tolerance limit, two minutes of heat soaking
starts, to protect the screw tip. The following message is displayed:

Barrel heat soaking is active

Effect All screw movements are blocked, no cycle start possible, when actu-
ating the start button the warning light flashes

The set values for the individual heating and cooling zones, and the tolerances can be set on
screen. Click the icon in question to view a descriptive text for the zone.

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Barrel heating
Info Panel

Zones Group Control parame-

Set value

pos. tolerance

neg. tolerance

Minimum monitoring

Reduce to standby temperature

Set value pos. tolerance neg. tolerance


Compact

Heating switched on (Switch on the control panel)

A graphic field with symbol is displayed for each temperature zone with the following settings:
„ Set value (dark line)
„ Actual value (red and/or blue bar with digital display)
„ Tolerance band (green field)
„ Status display for:

89
Heat Zones

Zone switched off

Zone not within the tolerance

Heating active (red), cooling active (blue)

Heats are reducing to standby temperature

Optimization: active (yellow), error (red), completed (green)

Heating defective, thermocouple break

Heating soaking

The set values and tolerances can be set individually. Set them equal with [=] all zones of a
group or displace them proportionally with the arrow keys. Observe the given tolerances from
the material manufacturer.
The feed throat temperature (material feed opening) is closed loop controlled with water cool-
ing. Temperature control is important for feed performance and flow capability of the material
(no lump formation, uniform plasticizing time).

A temperature profile that increases towards the nozzle is often required with a standard
screw. Machines that use barrier screws would use a decreasing temperature profile.

The screw type in the barrel heating group parameters can be set as of user level 13.
Screw Standard

Standard

Barrier

Barrier screw
Barrier screws can be used for semi-crystalline and amorphous thermoplastics. Excellent plas-
ticizing performance and improved homogeneousness of the molten material can be expected
due to the modified screw geometry.
To allow for sufficient surface fusing and melting upstream of the barrier area, you need to set
far higher temperatures for the inlet area than for the 3-zone screw.
A temperature profile that drops towards the nozzle is also recommended.
Setting too low a temperature at the inlet leads to a drop in plasticizing performance and to
undissolved particles being transported towards the screw tip, and thus to far higher wear and
tear.
If the machine has a barrier screw, and you set a rising profile, the following message appears:

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Values out of range

Caution: barrier screw!


Due to the modified screw geometry of barrier screws, the temperature characteristic for
the barrel must be set differently from that of a 3-zone screw.
To allow for sufficient surface fusing and melting upstream of the barrier area, you need
to set far higher temperatures for the inlet area than for the 3-zone screw.

A temperature profile that drops towards the nozzle is also recommended.

Setting too low a temperature at the inlet leads to a drop in plasticizing performance and
to undissolved particles being transported towards the screw tip, and thus to far higher
wear and tear.

Cases of wear and tear due to incorrect temperature settings are not covered by warran-
ty!

Read and understood?

Cancel Help Execute

The control unit will not apply the values you have entered until you press Execute.

Recommended procedure when optimizing the cylinder temperature profile:


1. Based on the required material temperature you can set a constant temperature profile
from the nozzle to the inlet.
2. If this setting leads to reproducible and constant plasticizing performance, you can
increase the inlet temperature gradually.
The plasticizing time should decrease as infeed temperatures increase. Recommended
temperature vector between the inlet zone and the metering zone: 20 to 40 °C (36 °F to
72 °F).
3. The inverse temperature profile results in a more consistent temperature distribution
and thus in improved quality of molten material.
Higher inlet temperatures will only increase the material temperature slightly.
If infeed problems occur, reduce the temperature at the start of the inlet area by approx.
10 °C (18 °F).
4. Set the hydraulic back pressure in this area between 2 to 5 bar (29 to 72 psi). As back
pressure rises, plasticizing performance falls more than proportionally.
5. Due to the low shear stress of the melt an average higher screw speed can be set than
when using a 3-zone screw.

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Heat Zones

1.1 Monitoring of the barrel temperature


A maximum positive and negative tolerance can be set for the safety of the material and screw.
Set value

pos. tolerance

neg. tolerance

Minimum monitoring

If the positive tolerance is exceeded, the following message is displayed:

Barrel heating zone x too hot Mold heating zone x too hot

Cause The actual value of at least one zone is above the set positive toler-
ance.

Effect At barrel heaters: Alarm lamp flashes, current cycle is finished, motor
switches off delayed, heatings switch off immediately.
In mold heaters, the error reaction can be set in the ’Heating configu-
ration’.

Remedy Possibly change the heating settings (set temperature differences


between individual zones too great, a hotter zone heats up a neigh-
bouring zone), possibly reduce the plasticizing speed (shear forces
too great), turn on the cooling for feed throat temperature.

If the negative tolerance is not reached, the following message is displayed:

Barrel heating zone x too cold Mold heating zone x too cold

Cause The actual value of at least one monitored zone lies below the set
negative tolerance.

Effect At barrel heaters: All screw movements are blocked, current cycle is
finished, no cycle start possible.
In mold heaters, the error reaction can be set in the ’Heating configu-
ration’.

Remedy Wait until the temperatures are within the tolerance limits.

Note!
Switching off Minimum monitoring is possible only with a certain access authorization level.
Danger of the screw tip breaking (see Technical Manual -)!

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1.2 Standby heats


All barrel heater groups are lowered to standby temperature in order to avoid thermal damage
to the polymer melt.
Reduce to standby temperature

Set value pos. tolerance neg. tolerance


Compact
A standby temperature set to 0 causes the heat zones to be switched off. If the standby tem-
perature is set equal to or greater than the highest zone value, the temperature is not reduced.

Standby is active:
„ when switching the program on manually with the screen switch for the group
„ when an alarm appears which brings the machine to a standstill for all zones

Message:

Barrel heating reduced, Mold heating reduced

Effect Message only

Remedy After eliminating the main error and switching off the screen switch,
the group heats up to the set value.

93
Heat Zones

1.3 Compact representation of the heating zones


In order to improve clarity if there is a large number of barrel or mold heating zones, the heat-
ing screens can be switched to a compact representation.
Mold heating
Info Panel
+ Zones Group Control parame-

Reduce to standby temperature

Set value pos. tolerance neg. tolerance


Normal

„ Compact/normal
Screen switch for switching between the compact and the normal representation of the
heating zones.
To change the settings, tap the bar graph of a zone:

The dialog window for changing the zone settings and control parameters opens:

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Heat Zones

Hot runner 1

Zone Control parame-

Values
Set value
pos.tolerance

neg.tolerance

Minimum monitoring

Accept for all zones of this type


Values Accept
Set value
pos.tolerance
neg.tolerance
Minimum monitoring

Cancel Help Accept

Changes can be made for the selected zone in the line Values . In the line Accept for all
zones of this type , you can use the screen switches to accept the changed values for zones
of the same type.

1.4 Soaking inspection


The soaking inspection provides additional protection function to the screw and non-return
valve in addition to the soaking time.
For initial plasticizing after heating up, the screw rotates for the first 5 s at a maximum periph-
eral velocity of 0.100 m/s (0.328 ft/s). In case of hydraulic injection units, additionally without
back pressure. Message:

Soaking inspection active

Cause The soaking inspection is active.

Effect Screw rotates at max. 0.100 m/s, no back pressure for hydraulic
injection units

Remedy Soaking inspection run through successfully.

If the maximum value is exceeded on testing the torque, the screw stops turning and post-
soaking is performed.

95
Heat Zones

Soaking inspection: Maximum torque reached

Cause The material is not yet fully plasticized and the maximum torque was
exceeded.

Effect Post-soaking time starts, plasticizing stops

Remedy If the error occurs multiple times in succession, the barrel tempera-
tures may be set too low.

Postsoaking active - no screw movement possible!

Effect No screw movement possible.

Remedy Wait for postsoaking time.

Soaking inspection restarts the next time the screw rotates. If soaking inspection is performed
without exceeding torque limits, plasticizing occurs with the set values.

Soaking inspection was active

Cause Soaking inspection active on plasticizing.

Effect The produced part is recognized as rejects.

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Heat Zones

2 Mold heatings (Option)


Mold heating
Info Panel

+ Zones Group Control parame-

Set value

pos. tolerance

neg. tolerance

Minimum monitoring

Set value

pos. tolerance

neg. tolerance

Minimum monitoring

Reduce to standby temperature

Set value pos. tolerance neg. tolerance


Compact

You must switch on the mold heatings with a separate switch on the control panel. The follow-
ing message is displayed before switching on:

Mold heating is switched off

Cause The mold heatings are not yet switched on or have been switched off
by the appearance of an alarm (see Alarm page on the screen).

Effect Message only

Remedy Switch on the mold heating at the control panel or eliminate the main
error.

97
Heat Zones

For mold heating controls, see barrel heating. [See Barrel heating on page 87.]
The zones available on the machine can be displayed or hidden as needed. It is also possible
to enable monitoring of individual error reactions.

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Heat Zones

99
Heat Zones

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Injection unit

Injection unit

The injection unit has the following tasks:


„ To melt and uniformly mix the material.
„ To move the nozzle to the mold and hold the nozzle against the mold under injection
pressure.
„ To inject the material into the mold cavity with high pressure.

WARNING!

Danger due to hot barrel and pressurized molten material!


Exiting material can cause serious eye injury and burns to skin.
Wear suitable protective clothing and face protector.

Main structural unit of an injection unit:

1 2 3 4 5

8 7 6

[1] Electrically heated nozzle


[2] Electrically heated barrel
[3] Connection between piston rod and machine frame
[4] Material hopper
[5] Cooled feed section (feed throat) with thermometer
[6] Hydraulic motor for screw drive
[7] Hydraulic injection cylinder
[8] Position display for screw

101
Injection unit

1 Nozzle
The injection unit moves with the nozzle to the sprue bushing of the mold and builds up an
adjustable contact force. To prevent the nozzle from cooling off too much, or to tear off the
sprue, cyclic retraction can be set, if necessary.

Locking conditions:
„ Nozzle advance is released when the safety gates on the clamping and injection unit
are closed.
„ Nozzle return is released when the safety gates on the injection unit are closed. In the
manual mode you can always return up to the maximum stroke.

1.1 Speed profile and stroke positions


Nozzle
Info Panel
Advance profile

retract profile

Multi-stage speed profiles can be set, for the advance and return of the nozzle, with the set
value graphics.
[See Set value graphics on page 61.]

Note!
When setting, ensure that the nozzle makes smooth contact with the mold.

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Injection unit

Nozzle contact position


Nozzle contact position

Nozzle stroke position


Nozzle stroke position
Nozzle contact position reached
Nozzle stroke

Force build-up time

Contact force

Contact force during part removal

Delay time retraction


Nozzle safety position

„ Nozzle contact position reached


The nozzle contact position is redetermined each time in manual mode or during the first
automatic cycle.
„ The nozzle moves forward with decreased speed and reduced force until the contact
point is reached.
„ After approx. 2 s standstill recognition on the contact point the screen flag lights up
(zero point for the stroke measurement).

„ Nozzle stroke
If a value greater than 0 is set for the nozzle stroke, the nozzle retracts in automatic
mode.
„ Force build-up time
A force buildup time of approximately 0.2 to 0.3 s is required to permit a contact force to
build up.
„ Contact force
The Contact force is the force which presses the nozzle against the mold at the injection
and plasticizing process.
Set the force high enough so that no material escapes between nozzle and mold.
„ Contact force during part removal
Effective force for contacting nozzle without built up clamping force.
Observe the load bearing ability of the right mold half in case of open mold!
„ Delay time retraction
The nozzle retracts, depending on the set sequence program, at the end of plasticizing
or at the end of hold pressure, after the Delay time retraction.
„ Nozzle safety position
To prevent squeezing and shearing points in the nozzle area, the nozzle stroke is limited
in automatic and manual mode. In manual mode, you need to actuate the safety button
to fully advance and return the nozzle.
If the nozzle is not within the limited nozzle stroke, the following message is displayed:

103
Injection unit

Nozzle position out of area

Cause Nozzle contact position not yet ascertained

Effect No automatic start

Remedy Press the safety key again to move the nozzle into the permitted noz-
zle stroke range.

The nozzle contact position must be ascertained before switching over to automatic mode;
otherwise the following message is displayed:

Determine nozzle contact position

Cause Nozzle contact position not yet ascertained

Effect No automatic start

Remedy Ascertain nozzle contact position in manual mode

The nozzle must make contact to inject; otherwise the following message is displayed:

Nozzle contact position not reached

Effect Injection only possible with reduced pressure, the warning light
flashes.

Remedy In manual mode, move the nozzle up to the mold.

Start nozzle in parallel


In the standard case the nozzle moves forward after the mold closing.
Start nozzle in parallel
Start position nozzle advance

On machines with parallel movements the advancing starts parallel with mold closing. The set
Start position nozzle advance refers to the mold stroke.

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Injection unit

2 Inject

1 2 3 4

[1] Cavity pressure


[2] Specific injection pressure
[3] Non-return valve
[4] Hydraulic injection pressure

During injection, the screw, with a non-return valve, becomes a piston. The molten material is
injected into the mold, under high pressure at a set speed profile, by the forward movement of
the screw. The melt freezes quickly in layers closed to the walls of the mold. The mold filling
phase is specially critical for the surface appearance, orientation, crystallinity of the part.

Locking conditions:
„ All safety gates closed
„ Barrel temperature within the tolerance
„ When the mold is closed, for purging the preselected clamp force must be reached.
„ Reduced injection occurs with an open mold or unapplied nozzle when the safety button
is not actuated at the same time;

105
Injection unit

2.1 Injection speed


To visualize the injection process as well as possible, the different areas in the set value
graphic use different colors.
Inject
Info Panel - injection molding machine ac-
Injection unit

Injection profile

1 2 3

Shot volume

[1] Material cushion set value


[2] Switchover point to holding pressure
[3] Decompression after plasticizing

A multi-stage speed profile can be set for the injection process with the "set value graphics".
[See Set value graphics on page 61.]
The speed peak value (green field) and the current speed display are available as additional
process information on the screen.

Essential influences of the injection speed on the molded part:


„ Burning, entrapped air (air cannot escape rapidly enough)
„ Jetting, injection speed too high (incorrect mold gate position)
„ Incompletely filled parts (material cools off before the cavity is filled)
„ Record effect (the melt freezes too early, through which the frontal/laminar flow is dis-
turbed)

2.2 Specific injection pressure


The injection pressure required at injection depends upon:
„ the viscosity of the material
„ the temperature of mold and material
„ the injection speed
„ the mechanical design of the mold (Sprue cross-sections, wall thickness of the injection
molded part, length of the melt flow path).

Injection pressure
Specific injection pressure limit
Specific injection pressure peak value
Stop injection at pressure limit
Increased specific injection pressure

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Injection unit

The set Injection pressure limit can be considered as a safety setting for the mold. The injec-
tion resistance changes due to variations in viscosity of the material or fluctuations in temper-
ature during production. For consistant quality the machine must closed loop control the set
speed exactly until reaching the switchover point. This is only possible then when the injection
pressure limit is set higher than the actual injection pressure. Ensuring tha).

Example:
Injection process

6
2

3 4 5

s
t

Inject Holding pressure

[1] Set injection pressure limit (e.g. 10% higher than injection pressure peak value)
[2] Required injection pressure for overcoming the injection resistance
[3] Set injection speed
[4] Set switchover point
[5] Mechanical end position of the screw
[6] Holding pressure

Increased specific injection pressure


It is possible to switch to increased specific injection pressure, if the maximum pressure is not
sufficient. A lower maximum injection speed is the trade off, for higher injection pressure.

Stop injection at pressure limit


The molding stops when reaching the pressure limit (e.g. with blocked cavity, ...) when the
screen switch is switched on.

Pressure limit at x ccm exceeded

Effect The set injection speed cannot be reached. Cycle continues to run
with injection hold pressure time (without pressure), shot is consid-
ered as rejects, no new cycle start.

Remedy Possibilities: Check cavities, increase pressure limit, switch over to


increased injection pressure, set injection speeds lower

107
Injection unit

2.3 Injection time monitoring


Injection time monitoring
Minimum injection time Max. injection time

Switchable monitoring for the injection procedure.


Injection stops when the minimum/maximum monitoring time responds. Message:

Injection time exceeded

Cause Possibilities: Switchover position to hold pressure not reached, sprue


frozen-in, cavity not demolded, incorrect temperatures.

Effect The automatic cycle stops, the rejects and shot counter are incre-
mented, the piece counter is not.

Remedy Check the feed channels, cavity(ies) and temperatures.

Injection time not reached

Cause Changeover pressure to hold pressure reached too early due to:
Sprue frozen-in and/or sprue channels blocked, cavity not demolded,
temperatures not correct.

Effect The automatic cycle stops, the rejects and shot counter are incre-
mented, the piece counter is not.

Remedy Check the feed channels, cavity(ies) and temperatures.

2.4 Intrusion program


Intrusion
Intrusion time

Intrusion speed

An increase of the maximum shot volume is possible in special cases by the intrusion, but it
must be plasticized up to the mechanical stop before in order that the screw can be supported.
By setting the intrusion time higher than 0 the screw turns before the injection and intrudes
material into the mold with the set speed.

2.5 Switchover to hold pressure


After the injection phase, the control switches over to hold pressure to reduce shrinkage. For
the production of consistant quality parts, the mold must always be completely filled before
switching over. To compensate for possible variations in the process, other switchover possi-
bilities are available:
„ Volume-dependent switchover
„ Time-dependent switchover

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Injection unit

„ Injection pressure-dependent switchover


„ Switchover as a function of mold cavity pressure
„ External switchover via additional device

Choose the method of switchover that produces the greatest repeatability of part quality. Only
one method of switchover to hold pressure is possible. When one method is selected the pre-
vious is automatically switched off.
If the ’move in cycles with mold safety’ program switch is activated in the move in cycles tab
on the production screen when you select ’Volume-dependent switchover’ , the following dia-
log box appears.
Startup cycles mold safety active
Start-up cycles check switchover volume!
Switchover volume

Start-up cycles switchover volume

Cancel Help Execute

The chosen method of switchover, indicated by a flag, along with the current switchover value
is available as important processing information.

Volume-dependent switch over


Switchover type
Info Panel

+ Volume-dependent switch over


Switchover volume
Start-up cycles switchover volume
Switchover volume actual value

This switchover method has generally proved successful if there are fluctuations in viscosity
and temperature.
A different switchover value may be needed on starting up production. The start-up cycle
switchover volume applies for the number of start-up cycles set. [See Production on
page 122.]

Time-dependent switch over


Time-dependent switch over
Switchover time

When time dependent switchover method is used, hold pressure is initiated after the set swi-
tchover time.

Injection pressure-dependent switch over


Injection pressure-dependent swi-
Specific switchover pressure

Switchover range
Specific pressure at switch over
Specific injection pressure peak value

This switchover method has mainly proved successful when volume variations are the main
problem. Some reasons for volume variations are e.g.:

109
Injection unit

„ Addition of re-grinded material


„ Low back pressure
„ Irregular closing of the non-return valve e.g. due to slow acceleration on injection, or fail-
ure to set decompression
„ With unbalanced multi-cavity molds (gate problems)

The injection pressure - less the injection resistance - is always proportional to the cavity pres-
sure.
The pressure increase, which arises when the cavities are filled, will cause switchover. There-
fore, always choose a switchover pressure lower than the injection pressure limit.
Injection pressure-dependent switchover also provides good mold safety as the machine
always switches to hold pressure immediately at a certain pressure setting.
A pressure spike at the beginning of injection will cause a premature switchover, a Switchover
window must be set so that the machine switches to hold pressure within that window.
P
possible pressure peak
Switchover pressure

Switchover range

INJECTION HOLD PRESSURE

t
The injection pressure peak value and the current pressure display also provide important
process information on screen.

External switchover
External switchover
???

A signal from an external device enables the switchover to hold pressure, when "External swi-
tchover" is selected.

Parallel switchover (option)


This is sometimes used as an additional safety setting.
Parallel switch over
Switchover range

On parallel switchover the activated switchover type whose criteria are fulfilled first triggers the
switchover process after reaching the switchover area.

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Injection unit

3 Holding pressure
The screw still presses on material via the fluid center of the molded part during the first coo-
ling phase in order to compensate for the shrinkage of the material. The injection hold pres-
sure compresses the melt and therefore produces those quality characteristics which depend
on part density.

3.1 Holding pressure profile


Holding pressure
Info Panel
Holding pressure profile

Holding pressure time

Holding pressure time

For the hold pressure phase for the different optimization aims a multi-stage hold pressure pro-
file can be set with the set value graphics. [See Set value graphics on page 61.]
The hold pressure peak value (green field) and the current pressure display are available in
addition as important process information on the screen.

Too low hold pressure causes: Too high hold pressure causes:

Sink marks and voids Tensions near the sprue

Greater shrinkage Flash formation

Smaller molded-part dimensions Tensile stresses in the outer layers

Greater dimensional variations Demolding difficulties

Internal orientation due to melt back-flow

Holding pressure time


The injection hold pressure time should last until the gate freezes. Too short injection hold
pressure time causes:
„ Sink marks and voids
„ Internal orientation due to melt back-flow
„ Greater warpage, especially of partially crystalline materials
„ Underweight and smaller dimensions
„ Greater dimensional variations
„ Greater shrinkage

111
Injection unit

An increase of the melt temperature, of the mold wall temperature and of the holding pressure
delays the gate freezing off.

3.2 cooling time


cooling time
cooling time

As the mold has a different temperature to the melt, the cooling time begins with the entry of
the melt into the mold.
With the end of hold pressure, the set cooling time starts. Upon expiry the mold opens. The
cooling time essentially depends on the plasticizing process and on the demoldability of the
molded part.

Too short cooling time has the following impact:


„ Increases the warpage.
„ Increases the mechanical deformations during demolding.
„ On thick-walled molded parts, this leads to the re-melting of cooled part layers at the
surface because of the high heat capacity of the fluid center.

3.3 Cushion monitoring


Cushion monitoring
Minimum cushion Maximum cushion

cooling time
cooling time

Shot volume
Shot volume

The control unit displays on the screen the material cushion, which still remains in the screw
antechamber of the barrel until the end of hold pressure. The remaining melt cushion should
be approx. 5 to 10 % of the shot volume.
Monitoring is also provided. When monitoring is switched on, the following impact is seen,
when the measured value lies outside the set tolerances:
Message:

Cushion too small

Cause The melt cushion is under the set limit, e.g. due to volume variations
of the material, escape of material between nozzle and sprue bush,
leaks on the non-return valve,

Effect Message only, the rejects and shot counter increment, the piece
counter does not. The automatic mode only stops when exceeding
the allowed rejects.

Remedy Increase the metering stroke, back pressure, contact pressure of the
nozzle, replace the non-return valve on the screw

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Injection unit

Cushion too large

Cause The melt cushion is over the set limit. Possibilities: Sprue frozen-in or
blocked, one cavity has not been demolded, temperatures incorrect.

Effect Message only, the rejects and shot counter increment, the piece
counter does not. The automatic mode only stops when exceeding
the allowed rejects.

Remedy Check the feed channels, cavity(ies) and temperatures.

3.4 Screw diameter


Screw diameter
Screw diameter

After the installation of a barrel with another screw diameter for calculating the specific injec-
tion pressure the correct screw diameter must be set. Message:

Set screw diameter

Cause No screw diameter corresponding to the injection unit is set

Effect Calculation of the specific injection pressure is wrong

113
Injection unit

4 Plasticizing

1 2 3 4

[1] Filled cavities


[2] Screw antechamber for melt (specific back pressure)
[3] Feed throat for the material
[4] Hydraulic back pressure

During plasticizing the nozzle often remains applied and is closed by the cavities filled previ-
ously. The screw conveys the material plasticized by the shear forces and hot barrel liner into
the screw antechamber. This accumulation of material in the antechamber moves the screw
backwards, against an operator set back pressure to ensure good and uniform plasticizing.

Locking conditions:
„ All safety gates closed
„ Barrel temperature within the tolerance

4.1 Speed profile and back pressure


Plasticizing
Info Panel
Plasticizing profile

Shot volume
Shot volume

Plasticizing delay time

The whole cooling time can be used for plasticizing, without sacrificing cycle time. The setting
of a multi-stage profile for the peripheral speed and the back pressure is possible on the set
value graphics. [See Set value graphics on page 61.]

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Injection unit

The current peripheral velocity of the screw ’’V’’ as well as the back pressure peak value
(green field) and back pressure actual value are available as information on the screen.

A too low value causes: A too high value causes:


Unplasticized material Thermal degradation of the melt
Insufficient mixing of additves increased wear of cylinder and screw
Shortening of glass fibers

Shot volume
Sufficient shot volume must be set, for filling the mold. The required residual melt cushion at
the end of hold pressure should be approximately 5 to 10% of the plasticizing stroke. For a
mold filling study at start-up, a short shot must be set initially and then must be increased grad-
ually. In the ideal case the plasticizing stroke shall lie in the range between 1 and 3 screw
diameters. Otherwise especially thermal problems, surface marks and volume variations can
arise.

Plasticizing delay time


A plasticizing delay time is provided for thermally sensitive materials during long cooling times.
This allows the dwell time of the melt in front of the screw to be shortened. The time starts after
decompression before plasticizing.

4.2 Plasticizing time monitoring


Plasticizing time monitoring
Minimum plasticizing time Maximum plasticizing time
Plasticizing time most recent cycle

If plasticizing time monitoring is activated, and if the measured value is outside the preset
tolerance, plasticizing stops.

Plasticizing time exceeded

Cause The set plasticizing monitoring time has been exceeded e.g. by feed
problems or insufficient material.

Effect The alarm lamp flashes and the plasticizing stops, the current cycle is
finished, delayed motor stop and delayed switch to standby tempera-
ture.

Remedy Refill material, check material feed chute and feed throat tempera-
ture.

115
Injection unit

Plasticizing time not reached

Cause The set plasticizing monitoring time has not been reached. Previous
cycle screw stroke was too short.

Effect The alarm lamp flashes and the plasticizing stops, the current cycle is
finished, delayed motor stop and delayed switch to standby tempera-
ture.

Remedy Check feed channels, cavity(ies), temperatures, back pressure and


screw speed.

In addition, the plasticizing time Last cycle and the current time are displayed on the screen,
as important process information.

4.3 Plasticizing maintained instruction


If you hold down the plasticize pushbutton for a longer period in manual mode, the machine
will automatically plasticize until the preset shot volume has been reached, even if you release
the pushbutton.

The following criteria stop automatic plasticizing:


„ Plasticizing stroke performed
„ Plasticize button re-pressed
„ Program interruption button pressed
„ Sequence for max. plasticizing time with plasticizing time monitoring activated
„ Switchover to automatic mode
„ Opening a safety gate

Plasticizing time monitor-


Minimum plasticizing time 11,0 Maximum plasticizing time 15,0

Max. plasticizing time manual mode 15,0


Last cycle

Max. plasticizing time manual mode (option)


Max. plasticizing time manual mode is always active in manual mode, even if plasticizing time
monitoring is switched off.
You can set the value to 0 s to disable the maintained instruction.

Automatic plasticizing active

Cause Plasticizing with maintained instruction is active.

Effect The machine automatically plasticizes until the preset shot volume
has been reached.

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Injection unit

4.4 Decompression before and after plasticizing


Decompression (screw retraction) before plasticizing serves to relieve the pressure of the mol-
ten material in the hot runner and barrel. Decompression after plasticizing serves to relieve the
pressure of the molten material in the barrel and guarantees a more even clamping behavior
of the non-return lock on injection (e.g. decompression volume 5-10% of shot volume).
Decompression
Decomp. before plasticiz- Decomp. after plasticizing
Decompression end
Decompression speed before plasticizing
Decompression speed after plasticizing

Normally the decompression speed must be coordinated approximately to the retraction


speed of the screw during plasticizing.
Relief end is composed of shot volume and relief volume after plasticizing. This position of the
screw is also a start condition for the 1st automatic cycle.

4.5 Back pressure in manual pressure


When Back pressure in manual mode is activated a separate back pressure output for the
plasticizing process is produced.
Application example: At the start of production, plasticizing followed by purging with the nozzle
retracted often occurs to remove old material from the barrel. A low back pressure is required
to support plasticizing with the nozzle retracted.
Back pressure in manual pressure
Back pressure output in manual mode

Note!
This program can be activated in the Variables Monitor, in the ’Plasticizing’variables list by
setting the variable Release separate back pressure in manual mode.

4.6 Torques during plasticizing


These values help in optimizing the plasticizing process. Any changes during a fixed set-up
production are related to melt temperature, batch variations and feed problems:
Torque
last current
Torque peak value
Torque mean value
Torque
Max. torque

In this context, we need to mention the plastifying count which is available in the process data
package. This shows the mean hydraulic pressure in bar (psi) during plastifying for the whole
metering area.

117
Injection unit

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Production programs

Production programs

1 Cycle time analysis


This overview shows the individual time components of the complete cycle time of the func-
tions. It helps in the optimization of the cycle time by time-optimizing the individual functions.
Cycle time analysis
Info Panel

Cycle time analysis

last current
Mold close
Nozzle
Inject
Holding pressure
cooling time
Plasticizing
Mold opening
Ejector
Cores
Part removal

Total time

View
1 2 3 4
[1] Scroll window to the left
[2] Set to full cycle time
[3] Magnify and minimize
[4] Scroll window to the right

The current and the last cycle are displayed separately in seconds, and on two-line bar graph-
ics. The top bar shows the current cycle, the lower bar the last one. Dark points on the bars
indicate force/pressure build-up and reduction as well as movement direction changes.
Screen flags mark the function that is currently active.

119
Production programs

Separate display of the total time.


Adjustable times for a zoom section and keys for making changes.

Start time display


Instead of the movement duration, the Start time display measures the time from the start of
the injection cycle to the start of the movement in question.
After startup, the text Start times is located above the bar graph under menu key View.

2 Monitoring systems for the injection molding process


Clear display of all process monitoring systems so that they can be switched on/off and set
together.
Monitorings
Info Panel

+ Monitorings

Activation
Switch the monitoring systems back on
Switch off all monitoring systems

Injection time monitoring


Minimum injection time Max. injection time

Cushion monitoring
Minimum cushion Maximum cushion

Plasticizing time monitoring


Minimum plasticizing time Maximum plasticizing time
Plasticizing time most recent cycle

Cycle monitoring time

Max. cycle monitoring time

Cycle time until start button


Autoprotect injection
Ideal curve evaluation active
Micrograph
Ideal curve evaluation active

Activation
Switch for switching on/off all monitoring systems.

Monitorings
[See Injection time monitoring on page 108.]
[See Cushion monitoring on page 112.]
[See Plasticizing time monitoring on page 115.]

Cycle monitoring time


After optimizing the injection molding process, the cycle monitoring time serves to safeguard
fully automatic production. The control unit always stores the previous cycle time at the end of
the mold pause time.
To activate this, set the Max. cycle monitoring time to a slightly longer value than the Last
cycle time and switch on monitoring.

In case of an error, the following message appears:

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Production programs

Cycle time overrun and delayed motor stop

Effect The machine stops cycling immediately and switches into ’MANUAL’
mode. A delayed motor stop and delayed switch to standby heats is
initiated, the alarm lamp flashes.

Remedy Check at which movement the machine stopped. You can refer to the
alarm screen to determine which error caused the malfunction. You
should also check the waiting points. Then move the machine to the
start position.

121
Production programs

3 Production
Production data is displayed on a dedicated screen page.
Production
Info Panel

Production Start-up cycles rejects in succes- Batch size

Production counter
Piece counter Shot counter
Number of cavities pc
Good parts - set value pc Sht

Good parts total pc Sht

Reject - startup cycles pc Sht


Production rejects pc Sht

Total rejects pc Sht

Production total pc Sht

Good parts Rejects rate

Do not plasticize after the shot/piece counter has elapsed

Production counter
„ Number of cavities
The piece counters always count with the set cavity number.
„ Good parts - set value
After the desired production amount is input, the corresponding shot and piece counters
count in the automatic cycle.
„ Good parts total
If the piece counter reaches the set value, the machine finishes production.
„ Reject - startup cycles
Rejects counter for set start-up cycles at start of production or when the cycle is inter-
rupted.
„ Production rejects
Rejects during production occur when monitoring systems are triggered, such as the
injection cycle, Micrograph, quality programs, mold temperature.
„ Total rejects
Start-up cycles rejects + production rejects.
„ Production total
If the shot counter reaches the set value, the machine finishes production.
„ A green pie diagram shows the ratio of good parts produced to the set good parts
value.
„ A red pie diagram shows the reject rate related to total production.

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„ Do not plasticize after the shot/piece counter has elapsed


Due to the switching-on, the machine no longer plasticizes in the last cycle.

Message when the piece counter for good parts or the total rejects counter elapses:

Shot counter expired, or Parts counter expired

Effect The alarm lamp flashes, the cycle finishes, a delayed motor stop and
heat reduction to standby is initiated.

Remedy To continue production, use the [R] key to reset the actual shot or
piece value back to 0.

Calculation of remaining production time


Calculation of remaining production time
Cycle time set value
Cycle time actual value
Cycle time deviation

Remaining production time

„ Cycle time set value


Input for calculating the cycle time deviation from the cycle time actual value and the
remaining production time.
„ Remaining production time
Calculation with the remaining number of pieces and the cycle time set value.

Material demand calculation


Material demand calculation
Shot weight
Remaining material requirement

„ Shot weight
Input for calculating the remaining material requirement.
„ Remaining material requirement
Display of the remaining material requirement for the remaining number of pieces.
When inputting the available amount of material, the set piece value can be calculated.

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3.1 Start-up cycles


Two adjustable counters permit automatic rejects sorting at the start of production or the start
of an automatic cycle with adjustable mold safety.
Production
Info Panel

Production Start-up cycles rejects in succes- Batch size

Start-up settings
Start-up cycles set value Sht

Start-up cycles actual value Sht

Start-up cycles after automatic interruption of at least


Post injection pressure in percent of production parameters

Start-up cycles with own switchover volume - set value Sht

Start-up cycles with own switchover volume - actual value Sht

Start-up cycles switchover volume


Switchover volume actual value

Start-up settings
„ Start-up cycles set value
Adjustable total amount of start-up cycles with rejects sorting and post injection pres-
sure in percent of production parameter.
„ Start-up cycles actual value
Display of the start-up cycles with the reset key
„ Start-up cycles after automatic interruption of at least
The machine starts again with the start-up cycles after an interruption to the cycle that
lasts longer than the preset time .
„ Start-up cycles with own switchover volume - set value
Adjustable number of parts of the start-up cycles set value with a separate Start-up
cycles switchover volume.

Additional start-up settings (option)


„ Injection pressure limit in percent of production parameters
„ Back pressure in percent of production parameters
„ In manual mode with run-in parameters
Switch for activating the start-up parameters in manual mode.

During the start-up cycles the following message is displayed:

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Start-up phase active

Cause Production is currently in the start-up phase with the set start-up
cycles.

Effect The minimum plasticizing and injection time monitoring, as well as


the Microplast, Microflow and Micrograph monitors, are not active.
Rejects is active.

Remedy Automatically after the completion of the start-up cycles.

If the start-up cycles are set with their own switchover volume, a switchover volume must be
set; otherwise, the following message appears:

Adjust moving-in switchover point

Effect Automatic cycle start not possible. Alarm lamp lit.

Remedy Set the start-up cycle switchover volume to a volume that just about
fills the mold.

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3.2 rejects in succession


Rejects during production occur when monitoring systems are triggered, such as the injection
cycle, Micrograph, quality programs, mold temperature.
A reject signal serves to sort manufactured parts with a follow-on unit (robot, delivery flap,
conveyor-belt), or stop production after a number of reject moldings.
Production
Info Panel

Production Start-up cycles rejects in succes- Batch size

Rejects
Rejects signal
Maximum rejects per time Sht
Actual rejects Sht
Time period for rejects min

Maximum rejects in succession Sht


Actual rejects in succession Sht

Action for sequence max. rejects/max. rejects in succession Production stop

Good part production possible from operation mode Fully automatic

Rejects
2 rejects counters are available to control production, they can be activated by a set value set-
ting larger than 0.
„ Maximum rejects per time
Resetting the rejects counter actual value after Time period for rejectshas elapsed.
„ Max. rejects sequence
Adjustable rejects directly in succession. Automatic reset for good part production.
„ Action for sequence max. rejects/max. rejects in succession
Optional actions Warning or Production stop when reject counter elapses.

The message rejects counter lapsed or maximum rejects in succession:

Rejects counter expired

Effect Depending on the action you selected warning only or production


stop

Remedy Determining the cause of rejects with the help of additional alarm
messages.
Switch the program interruption key on/off.

„ Good part production possible from operation mode


Option to enable good part production in semi-automatic or only in fully automatic
mode. If you select fully automatic , the control unit will assume all moldings in semi-
automatic mode to be rejects.

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4 Mold parameters
This screen is used to save mold-specific information.
You can use the screen editor to add strips and variables, e.g. for additional units to this
screen.
Mold parameters
Info Panel

+ Mold data
Mold number Recorder housing

Molded part number

Material number

Machine number

Order number Order number

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5 Data dialog
The data dialog box is used to save and load data sets on the machine or on external storage
media (Compact Flash, USB stick, network).
The screen page appears after switching on the control unit and/or after pressing the screen
page selection key.

Data dialog
Info Panel

\hard disk\0 1 Active parts data set: Standard sequence 2

\hard disk\0 3 Data set attributes 4


STANDARD+CORE- Name SIDE_WALL_01

STANDARD INJ.RED. Author

STANDARD_PARALL Production date

STANDARD_SEQUEN Change author

Change date

Description

Machine number

Mold image

6
Parts data Edit Setup View 7

[1] Selecting a medium


Press the down arrow key to access all possible drive selections.
„ hard disk0 System Flash card
„ usbmassstorage plugged-in USB stick
„ harddisknet Network drive connection

[2] Status information


Displays status (symbol) and the name of the active set (selection key to display the
attributes and the mold image).
[3] Dialog box with settings data sets (project selection)
Touch the required selection to display the data attributes on the right side of the screen.

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[4] Data set attributes


Shows all data in the selection window of the selected project. Can be modified depend-
ing on user privileges.
„ Name Selectable project file name = file name in selection list
„ Author Name of the creator
„ Production date
„ Change date, author Date and name of the user making the latest changes.
„ Description user defined descriptive text

[5] Mold image


The image that was saved along with the parts data set is displayed here. Using instruc-
tion menu buttons Edit and Mold image , you can load an image with the format *.jpg
or *.png and then save it along with the parts data set.
[6] Message window shows dialogs for completed actions, error messages, information
and so on. Can be hidden and displayed in the Viewmenu. Appears when an action is
being carried out.
[7] Instruction menu keys
„ Parts data using the instructions: Sequence preview, Read, Write, Copy, Copy all,
Delete and Injection protocol.
„ Edit using the instructions Delete message and Load mold image.
„ Setup using the instructions: Export user data, Import user data, System flashcard,
Software update, License update, Read machine data, Write machine data and Dis-
play active machine data.
„ View with the instructiions: Selection window on/off, message window on/off, maxi-
mizing/minimizing.

5.1 Storage media


The following USB devices have been tested by Engel - their functioning is thus ensured.

Device Manufacturer Type

floppy drive Mitsumi D353GUE

Memory stick SanDisk Cruzer Mini USB 2.0 256 MB,


Cruzer Micro USB 2.0 512 MB,
Cruzer crossfire 1 GB, 2 GB

Memory stick Memory Corp Memory Corp MC512USB9

Flash Drive PNY Technologies PNY USB 2.0 1 GB

Note!
Problems may occur if you use other USB devices that have not been tested.

If you select a data carrier with insufficient free storage space, the program will cancel the save
operation and display a message. The message shows which data carrier is full, along with the
last file that was completely stored on the data carrier.

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Flash card full X

Effect Cancelling save to data carrier.

Remedy Select a data carrier with more free space and try to save again.

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5.2 Sequence preview


When you save a parts data set, a sequence preview of the machine sequence is automati-
cally created. This is useful to check the sequence settings before loading a parts data set.

Example:
Procedure for opening a sequence preview.

1. Select parts data and then injection molding machine.

Parts data

Injection molding ma-

2. Press the instruction menu key parts data and sequence preview.
3. A window with the sequence preview appears:
Sequence preview

Retract ejector
20,0 mm
Mold closing up to position 1
200,0 mm
Move in core stationary platen

Mold - close
0,0 kN
Nozzle - build up contact force
20,0 kN

Screw injection

Screw - plasticize

Help OK

4. Press OK to close the window.

Note!
The sequence preview is stored as a parts data element. To make sure the preview is up to
date, always save your parts data after changing the machine sequence.
A preview of the robot sequence is not possible.

If a preview is not available for a parts data set, the following message is displayed:

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Production programs

Sequence preview

Preview could not be loaded!

OK

5.3 Read data set


A parts data set consists of the sequence and setting data of machine and robot. You can eit-
her read in the whole parts data set or only certain data. When you only read in a certain part
of the parts data, only these change. The other data are preserved.
Parts data
Injection molding ma-

Sequence data
Machine settings

Robot

Sequence data
Machine settings

Sequence data
In the sequence data only the machine or robot sequence is stored. When you only read in the
sequence data, only the sequence changes. Parameters such as speeds, pressures, posi-
tions,... do not change.

Machine settings
In the setting data all parameters such as speeds, pressures, positions,... are stored. When
you only read in the setting data, only these parameters change. The sequence does not
change.

Example:
Procedure when loading an existing parts data set from a data carrier.

1. Switch the machine to manual mode.


2. Select the storage medium. usbmassstorage.0.0.0\ is a USB memory stick,
harddisk0\ is the control unit's internal memory.
3. Select the setting data set from the list.
Display of the information in the window Data set attributes
4. Press ’Parts data’ and ’Read’.
A window with a clock is displayed. The control unit loads the chosen parts data set and
overwrites the current machine setting. The manual control keys of the machine are not
active during loading.
If the read values cannot be set (plausible), the following message appears:

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Values corrected

Effect Message only

Remedy On the screen page Plausibility check open the window corrected
values and check which parameters have been corrected.
Acknowledge the message in this window.

Note!
If you read a parts data set from another plant, the following message is displayed:

EMOTION_TEST
The data set has not been created with this machine

Continue anyway?

Cancel Help Execute

5.4 Write a parts data set

Example:
Procedure for saving an active parts data set on a storage medium.

1. Select the active parts data set with the key at the top right of the screen.
2. Enter name and information in the Data set attributes window.
3. Select the storage medium. usbmassstorage.0.0.0\ is a USB memory stick,
harddisk0\ is the control unit's internal memory.
4. Press ’Parts data’ and ’Write’.
The following window is displayed
Write active parts data on

Available drives

Name Parts data

Description

Free memory C:\5632

Required memory C:\231

Cancel Help Write

5. Change the set attributes, when necessary, and confirm with Write.
The control unit stores the parts data set on the selected drive.
6. If a data set with the same name already exists on the data carrier, the dialog window
’Overwrite ??’is displayed. If YES, press Execute.

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5.5 Copy parts data set


Procedure when copying a parts data set to another data carrier.
1. Select the storage medium (usbmassstorage.0.0.0\ is a USB memory stick).
2. Press to select a Settings data set from the list.
3. Press the ’Parts data’ and ’Copy’menu key.
A window is displayed, with drive option, name proposal and description.
Copy chosen parts data on

Available drives

Name Copy 1 of training 4

Parts data set for training


Description

Free memory C:\5632

Cancel Help Copy

4. Choose a drive and enter requested changes.


5. Press Copy.

5.6 Copying all parts data sets


Procedure for copying all data sets on a storage medium to another storage medium
1. Press the ’Parts data’ and ’Copy all’menu buttons The following dialog box appears.
Copy all data sets
Source drive hard disk0

Aim drive usbmassstorage.0.0.0

Cancel Help Execute

2. Select the Source drive and the Aim drive to which you will be copying the data sets.
3. Press Execute to start the copying process.
4. The dialog box disappears once the copying process has been completed.

If you attempt to copy a data set from the source drive that has the same name as an existing
data set on the aim drive, the following message appears:
Overwrite?
.Standard sequence

Cancel Help Execute

„ Cancel
This data set will not be copied to the aim drive. Continuing copying other data sets.
„ Execute
The data set on the aim drive will be overwritten by the data set on the source disk.

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5.7 Delete data set


Procedure when deleting a data set
(As of user privilege level 5):
1. From the selection window, choose the drive that contains the data set.
2. From the directory list, select the data set.
3. Press Parts data and Delete.
The following data dialog box is displayed ’Really delete data set?’ with the name of the
selected data set.
4. By confirming with the Execute key, the data set is deleted.

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5.8 Export
The export function gives you the ability to export the settings data and machine and robot
sequences in various file formats.

You can export to the following file formats:


„ CSV for e.g. Excel
„ TXT for e.g. Word
„ HTML for e.g. Internet Explorer

Exporting machine and robot sequences is only possible in HTML file format The sequences
are additionally saved as PNG images.

Example:
Follow these steps to export the settings data for the machine.

1. Press the Parts data and Injection protocol keys. The following dialog box appears:
Export
0 of 34 selected

Production
Mold close

Compression

Mold height

Mold opening

Venting
Air valve
Ejector

Machine sequence

Cancel Help Delete Select all OK

2. In the dialog box, select the screens you wish to export.


To select all screens, press Select all.
To remove the selection, press Delete.
To export the machine and robot sequence, activate the matching screen switches.

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3. Select the screens for the protocol, and press OK to continue. The following dialog box
appears.
Save

Selection:

File name:

File type:

Cancel Help Save

4. Select the drive you wish to export to, as well as the file name and the file type.
If you selected the machine or robot sequence, you can only select HTML as a file type.
The sequences are additionally stored as PNG images with the file name and extension
’_imm_xxx’ or ’_erc_xxx ’.
5. Press Save to start exporting. The following dialog box appears.
Export

Cancel

6. A progress indicator appears for the Export process. The dialog is closed after success-
fully completing the export.

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6 Notepad
The note screen page is used to store special production information.
Notepad
Info Panel

+ Notes
Training (se-

Pre-drying of the material 3 hours


Training (se-
5 Start-up cycles set with rejects

New Edit Save Delete Cancel

The left column shows, for selection, all message with titles and author's user name.
„ New
Creates a new note; you can enter your own title and content.
„ Edit
Lets you edit the selected note.
„ Save
Saves the new/changed note.
„ Delete
Deletes the highlighted note.

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7 Print
The control system offers printing processes from different programs as well as the printing-
out of screen pages. The CC200 control system supports printers which are PCL-3-capable
and whose manufacturers observe this specification exactly. For printing on the spot at the
machine you must connect one printer to a USB interface on the front panel.
When the machine is connected to a LAN network, printing to the networked printers is possi-
ble.

The following printer types are tested for the CC200 control unit:
Local printers with USB connection

Manufacturer Type

Hewlett Packard HP Deskjet 990 Cxi

Hewlett Packard HP Deskjet 995 C

Hewlett Packard HP Business Inkjet 1000

Hewlett Packard HP Business Inkjet 1100D

Hewlett Packard HP Deskjet 6840

Hewlett Packard HP Deskjet 6940

Hewlett Packard HP Officejet Pro K500

Hewlett Packard HP Officejet Pro K5400

Hewlett Packard HP Laserjet 2605DN

Brother Laserprinter HL-5270DN

Network printers (Postscript)

Manufacturer Type

Hewlett Packard HP Laserjet 4100dtn

Hewlett Packard HP Laserjet 4000 PS

Hewlett Packard HP Laserjet 2605DN

The control unit offers the following printing possibilities of screen pages (masks):
„ a hard copy of the current screen page with screen page selection keys
„ a graphic printout of the current screen page
„ several graphic printouts of a selection of screen pages
„ textual printout of the current screen page
„ textual printout of a selection of screen pages

A hard copy as PNG picture and graphic printouts of individual or several screen pages can be
stored in Postscript format as file.

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Production programs

An export function in the Data dialog permits text output in file format.

Example:
Graphic or textual printout of screen pages on a local printer:

1. Connect a printer with USB cable and switch the printer on.

2. Choose the printer menu.


Print

Screen page selection


Current screen page
Hardcopy

Text printing

Cancel Help Setup Ok

3. Press Setup
Settings for screen page output

Printer settings
Output on printer

Compress PS
Settings for printing to file
Print to file

Type

Directory

File name

Cancel Help OK

4. Switch on Output on printer . In addition, the selection possibility print to file is still
available. [See Output of the current screen page as hard copy in file format: on
page 141.]
5. When switching over to ’Output on printer’ the printer dialog appears of the currently set
printer. Select the local printer and press OK.
6. When you want to have a text printing, switch on Text printing.

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7. Select Selection of screens and confirm with Printing.


Screen page selection
0 of 65 selected

Production
Freely programmable in/outputs

Freely configurable screen

Shut-off nozzles
Minicam

Mold close

Set value graphics

Mold height
Mold opening

Cancel Help Delete Select all OK

8. Select the required screen pages from the selection of screens.


9. Press OK to start the printing process.

Output of the current screen page as hard copy in file format:


1. Choose the printer menu
2. Press Setup
Settings for screen page output

Printer settings
Output on printer

Compress PS
Settings for printing to file
Print to file

Type

Directory

File name

Cancel Help OK

3. Switch on Print to file.


4. Select the Type of the screen page (File format).

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5. In Directory the output file is fixed.


Save

Selection:

Cancel Help Save

6. The path is filed by save and the window is closed.


7. Enter in the mask Settings for the screen page output a designation in the line File
name.
8. With OK start the output process to file.

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Machine sequence and Mask Editor

Machine sequence and Mask Editor

1 Machine sequence
The machine sequence serves the graphic representation, change and creation of program
sequences. The representation of the sequence is possible in each mode of operation and in
each user level. For creating or changing a sequence you need the user level 7 or higher.
Moreover, the machine must be in the mode of operation Teach .

The machine sequence is divided into 3 sequences:


„ Closing sequence
„ Injection sequence
„ Opening sequence

Into these sequences you can program the different machine movements and instructions.

Machine sequence
Info Panel

Machine sequence 2
Instructions: 1
Mold 3
Nozzle
Retract ejector
Screw
20 mm
Ejector Mold - close
200,0 kN
Core moving platen Nozzle - build up contact force
All cores 23,5 kN

Freely programmable

Time

Wait until
4 5 6 7 8
Standard Times Program Edit View

[1] Selection window Instructions


This screen lists all the instructions you need to program your sequence. Select the
required instruction by clicking on it.
[2] Sequence selection
Switchover between machine sequence and additional sequence
[3] Sequence window
Graphical display of the selected program sequence with short description. The window
can be scrolled horizontally and vertically.
[4] Standard menu key
This function supports loading of sample sequences. Not selectable in Teach mode.
[5] Menu key Times
Overview of available delay times.

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Machine sequence and Mask Editor

[6] Menu key Program


Functions: Print sequence, save.
[7] Menu key Edit
Functions: Copy, Insert, Cut, Delete, Undo, Redo, Close sequences, Delete messages.
These functions serve the programming of the sequence.
[8] Menu key View
Place, Coupling, To Step Indicator, Step Indicator, Text view, Grid, Grid size, Selection
box, Message box, Full screen.
By pressing a function you fade it in or out.

1.1 Representation of the machine sequence


The machine sequence represents the individual movements of the machine, step by step,
from the top down.

For a better overview, the sequence is subdivided into three sequences. These sequences
contain individual program steps.
Click the + Icon to the left of the sequence to open the sequence. This displays all the program
steps programmed for the sequence.

Example closing sequence

Retract ejector
20,0 mm
Mold - close
200,0 kN
Nozzle - build up contact force
23,5 kN

Next to the program steps is a short text which describes the step.

Example: Ejector retract


Ejector - chosen machine movement

Retract ejector retract - the ejector executes this movement


20 mm

20.0 mm - the ejector retracts to this position

You can fade the text in and out with the menu key View + display text.

Select a step by tapping the symbol. The selected step is now shown with a red border.

Retract ejector
20,0 mm

When you touch the symbol once again, a dialog window is displayed

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Example dialog box Ejectors - Retract


Ejector
Movement retract
Ejector retracted position

Ejector position actual value


Attention - Already programmed

Cancel Help Execute

The dialog box is used to configure the selected step in the sequence.
Depending on the selected movement set and actual values may be available.
The set value in the dialog box is the same set value as shown on the screen for the current
movement.

The dialog box may also contain programming notes for the display e.g. Attention - already
programmed.

1.2 Sequence step functions


The machine sequence is processed step by step. The next step in the sequence does not
start until the previous step has been successfully completed.

In fully or semi-automatic mode, the control unit will display a green arrow to indicate the cur-
rent step if you have enabled the Step indicator . Steps that have been successfully com-
pleted are marked with a green checkmark.

Step successfully com- Advance ejector


pleted 20,0 mm
Mold - close
Step currently active
500,0 kN

In a parallel closed branch, all movements must be completed before the next movement can
start.

All parallel steps com-


pleted.
Mold - close Core moving platen
500,0 kN move in

Next step starting. Nozzle - build up


contact force

In a parallel open branch, the next step in the main branch starts without waiting for the step in
the parallel open loop to complete.

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Machine sequence and Mask Editor

Step in parallel open branch still active

Step in main branch com- Mold - close Air valve - blowing


pleted 500,0 kN 5,00 s
Step in main branch start- Nozzle - build up
ing contact force

Inactive steps are indicated by a red strike-through. These steps are ignored when the
sequence runs.

Step successfully com- Open mold


pleted 350,0 mm
Step inactive - will be Core moving platen
ignored. move out
Next step starting. Ejector - shaking
2 times

1.3 Standard sequence


Engel supplies the machine with predefined sequence templates. These sequences are sto-
red as parts data sets on harddisk0 . The parts data sets do not contain machine settings but
simply sequence data.
The icons in the data dialog show you which parts data sets contain sequence data and
machine settings, or simply sample sequences.

Parts data set icons in the data dialog


Parts data set with sequence and machine settings
Parts data set with sample sequence data (write-protected)

Depending on your machine configuration, various data sets with sequence templates may
exist.

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For example, standard sequence: STANDARD_SEQUENCE

Retract ejector Open mold

Mold - close Ejector - shaking


1 times
Nozzle - build up con-
tact force

Screw
inject
Screw - plasticize

Nozzle - retract

1.4 Loading a sequence


The sequence is stored as a parts data element. When you load a parts data set, you load the
sequence at the same time.
You can use the Data dialog and the machine sequence to load the sequence separately.
However, you can only load sample sequences in the machine sequence.

Note!
Save the current parts data set before loading a sequence in order to save the changes you
made.

Procedure for loading a sequence in the data dialog:


1. Change to the screen page Data dialog.

Data dialog
Info Panel

Active parts data set: NOTSTANDARD+COREFIX

Data set attributes


NOTSTANDARD+COR Name STANDARD+COREFIX
STANDARD+CORE- System name STANDARD+COREFIX

Injection molding ma- Author User 9


Sequence data Production date

Machine settings Change author User 9

2. Press the + symbol for the data set you wish to load.
3. Touch the + Symbol in front of injection molding machine.

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Machine sequence and Mask Editor

4. Select sequence data.


5. Press Parts data and Read.
6. If you have changed the current parts data set, a dialog window appears.
Changed data will be lost!
STANDARD+COREFIX

Cancel Help Execute

„ Cancel
Cancels the parts data reading
„ Execute
Starts the parts data reading. Changes you made which were not saved are lost

7. When the parts data reading starts, a window appears. When this window disappears,
the parts data reading is completed
Read

Process is running, please wait

Loading a sample sequence in the machine sequence:


1. Change to the ’Machine sequence’screen.
2. Select the ’Standard’ menu button.
3. The following dialog box appears.

Sequential sequence

Compression sequence

Cancel Display Help Execute

4. Select the required sequence.


„ Cancel
Cancels the parts data reading.
„ Display
Shows a preview of the sequence.
„ Execute
Loads the selected sequence into the machine sequence.

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Machine sequence and Mask Editor

When you load a sequence with components unavailable on the machine, the following mes-
sage is displayed:

Movement not available

Effect Machine motor stops, no movement possible

Remedy Finish setting state.

A note appears on the machine sequence screen telling you which movement is not available.
Component not available: Mold swivelling device 1 does not exist
Component not available: Nozzle 2 does not exist
Component not available: Screw 2 does not exist

Times Program Edit View

If you press the blue arrow, the indicator will jump to the position in the sequence where the
missing movement is programmed.
These movements are tagged with a caution icon in the machine sequence.

Mold swivelling device 1 does not exist

1.5 Storing the sequence


If you change the sequence, you must save the change in order that the machine can calculate
the safeties. Only after saving machine movements are possible.

Save sequence - safeties not current

Effect All movements are blocked.

Remedy Save sequence.

There are two ways to save the sequence.

1. Saving by pressing the keys Program + Save


You save the sequence. The machine remains in mode of operation Teach.
2. Saving by exiting Teach mode.
By pressing the Manual program key Teach mode is exited. The following dialog window
is displayed.
Save machine sequence
Do you want to store the sequence change?

Cancel Help Undo Execute

„ Cancel
Cancels exiting Teach mode. The sequence is not saved.

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Machine sequence and Mask Editor

„ Undo
Teach mode is exited. No sequence changes are saved.
„ Execute
Teach mode is exited, the changes to the sequences are saved.

When an incorrect setting is detected during the calculation of the safeties an error appears
and the following message is displayed:

Wrong setting in the sequence

Effect An incorrect setting is programmed into the sequence.

Remedy Eliminate the incorrect setting and save the sequence.

The machine sequence message window displays a note on the step in the sequence that is
causing the error. Press the blue arrow at the end of the message to jump to the position in the
sequence.
Movement as single movement not allowed: Mold closing 500.0 kN

Note!
The sequence is saved in the parts data. Therefore rewrite the parts data after saving the
sequence.

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1.6 Programming a sequence


The machine sequence visualizes the program sequence, step by step, top down. To program
the machine sequence, you need to add instructions in the sequence editor.

The following conditions must be fulfilled in order to program a sequence.


„ User access authorization 7 or higher
„ Teach mode of operation

CAUTION!

Due to the freely programmable nature of the sequence editor, it is very


easy to make setting mistakes. Pay close attention to the settings
because incorrect settings can lead to equipment damage.

How to switch into Teach mode of operation


1. Finish any automatic cycle that is running.
2. Press the Manual program key
3. Press the Teach program key

When you switch to Teach mode, the machine sequence background switches from gray to
white.

The following message is displayed:

Editing mode active

Effect Movements with the pushbuttons like in setup mode. Writing and
reading of data sets is not possible

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Machine sequence and Mask Editor

Example: Machine sequence in Teach mode of operation


Machine sequence
Info Panel
Machine sequence

Instructions

Mold

Nozzle
Retract ejector
Screw
20 mm
Ejector Mold - close
200,0 kN
Core moving platen
Nozzle - build up contact force
Core stationary platen 23,5 kN

All cores

Air valve

Purging into the screw

Venting

Freely programmable
Delivery chute

Vacuum equipment

Electric safety gate


Robot

Time

Wait until

Parallel closed branch

Parallel open branch

Times Program Edit View

You program the machine sequence by inserting or removing instructions from the sequences.
Thus you can adapt the machine sequence to your demands. Engel delivers the machine with
a standard sequence.

Note!
Write the parts data before programming a sequence in order to store the parameter changes
you made.

If you change the sequence, you must save the change in order that the machine can calculate
the safeties. Only after saving machine movements are possible.

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Save sequence - safeties not current

Effect All movements are blocked.

Remedy Save sequence.

When an incorrect setting is detected during the calculation of the safeties an error appears
and the following message is displayed:

Wrong setting in the sequence

Effect An incorrect setting is programmed into the sequence.

Remedy Eliminate the incorrect setting and save the sequence.

The machine sequence message window displays a note on the step in the sequence that is
causing the error. Press the blue arrow at the end of the message to jump to the position in the
sequence.
Movement as single movement not allowed: Mold closing 500.0 kN

1.6.1 Instructions
Movement and structure instructions are available for programming the machine sequence.
The number of available instructions depends on the machine equipment. The most common
instructions are listed here.

Movement instructions

Symbol Name Function description

Mold Mold opening, closing, to position. If you select Mold


opening/closing to position , the position appears
on screen after saving the sequence.

Nozzle Nozzle build up contact force, advance without con-


tact pressure, retract, relieve contact pressure

Screw Injection or plasticizing

Ejector Advance, retract, shaking

Core moving platen Move in or move out cores on the moving mold fixing
platen

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Machine sequence and Mask Editor

Symbol Name Function description

Core stationary Move in, move out cores on the stationary mold fixing
platen platen

All cores Stop all cores

Air valve

Freely programma- Activating and deactivating programmable inputs


ble in/outputs

cooling time

structure instructions

Symbol Name Function description

Additional Starts the additional sequence.


sequence

Acknowledgement Wait for acknowledgement. The next step in the


sequence does not start until the start button is pressed.

Time Waits until the set time has expired, only afterwards the
sequence continues. 6 adjustable times are available

Wait until Wait for preset condition to be fulfilled.

Parallel closed Adds a parallel branch; this must also be processed


branch before starting with the next step in the sequence.

Parallel open Inserts a parallel branch, but does not wait for the end of
branch the parallel sequence.

1.6.2 Insert an instruction


For activating a function it is sometimes necessary to insert an instruction into the sequence.

Example:
Inserting the Air valve - blowing instruction after mold opening in the opening sequence

1. Select the air valve in the instructions dialog.

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2. Click the position in the machine sequence where you wish to insert the air valve. In this
case Mold - opening.

Core stationary platen Opening sequence

All cores Open mold


350,0 mm
Air valve
Advance ejector
Time 65,0 mm
Retract ejector
Robot marker
20,0 mm
Wait until
Opening sequence

3. A dialog window is displayed. In this window you can set the necessary parameters for
the instruction.
Air valve
Number

Action Blowing

Blowing time
Blowng time actual value

Cancel Help Execute

4. Press Execute. You have now added the instruction to the machine sequence!

1.6.3 Changing an instruction


Changing the parameters of an instruction.

Example:
Change the blowing time of an air valve to 2 seconds.

1. In the machine sequence, double click the instruction you wish to modify. A dialog box
appears.
Air valve
Number

Action Blowing

Blowing time
Blowng time actual value

Cancel Help Execute

2. In the dialog window you can change the parameters of the instruction. Change the
blowing time from 1 to 2s.
3. Press Execute. The changed parameters are taken over and the dialog window closes.

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Machine sequence and Mask Editor

1.6.4 Removing an instruction


Remove one or several instructions from the machine sequence. You cannot remove
sequences.

Example:
Removing the Air valve - blowing instruction from the opening sequence.

1. Highlight the Air valve - blowing instruction in the machine sequence by tapping it. The
instruction is now outlined in red, and is thus selected.

Open mold
350,0 mm
Air valve - blowing
1s
Advance ejector
20,0 mm
Retract ejector
20,0 mm

2. Press the menu keys Edit and Remove. The instruction is now erased from the
machine sequence.

You can undo the removal by pressing the keys Edit + Undo.

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Options

1 Core (Option)
Cores are movable elements inside the mold, which generally move into the mold before the
injection process and move out afterwards.

Injection molded
part:

Cores

The core movement is enabled if:


„ the safety gates on the clamping unit are closed,
„ the 2 limit switches Core safety 1 and Core safety 2 have been actuated,
„ in France, in manual mode the push-buttons and the safety key must be pressed.

In addition, depending on the equipment of the machine and setting of the program sequence,
certain safety conditions must be fulfilled. Message examples:

Mold not open


Ejector not back
Core x moving platen not moved in
Core x moving platen not moved in on intermediate stop

Effect Core movement is blocked

Remedy In manual mode, move the corresponding functional unit into the correct
position; Check the safety conditions;

Each core is equipped with a separate pushbutton for moving in and out. The same locking
conditions as in Automatic are valid (mold position, situation of the core positions, etc.).
When a core moves out of position (limit switch deactuated) during the mold movement, the
movement stops immediately - message:

159
Options

Core x end position left

Effect Mold, ejector, other core movements are blocked, also injection if the
mold is not open. In automatic mode cycle stop.

Remedy Move the core in/out in manual mode, check the limit switch.

CAUTION!

Danger of damage to equipment due to improper settings!


When operating the machine, use settings for freely programmable
cores that precisely match the requirements for safe operations of the
machine and mold.
When you save the sequence, the control unit will perform calculations
to prevent some incorrect settings.
Additional safety is offered by deliberately ”bridging” of unused end position limit switches with
a jumper plug.

Core x jumper plug moved in/out is missing

Cause If a core is not activated or is time-dependent, normally the limit


switch signals must be activated by a jumper plug. See screen flags
at the core settings.

Effect All clamping unit movements are interlocked.

Remedy Attach the jumper plug or correct the programming.

The program checks the chosen core setting in connection with the end position jumper.
In case of error, message:

Core x limit switch defective

Cause Core limit switches are defective or actuated at the same time.

Effect The core movement as well as the closing and opening are blocked.

Remedy Check the limit switches

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Core x move in moving platen limit switch defective

Cause Time-driven core move out and simultaneous limit switch-driven


move in.

Effect The core movement as well as the closing and opening are blocked.

Remedy Check the limit switches

Core x move out moving platen limit switch defective

Cause Time-driven core move in and simultaneous limit switch-driven move


out.

Effect The core movement as well as the closing and opening are blocked.

Remedy Check the limit switches

Core x move in stationary platen limit switch defective

Cause Time-driven core move out and simultaneous limit switch-driven


move in.

Effect The core movement as well as the closing and opening are blocked.

Remedy Check the limit switches

Core x move out stationary platen limit switch defective

Cause Time-driven core move in and simultaneous limit switch-driven move


out.

Effect The core movement as well as the closing and opening are blocked.

Remedy Check the limit switches

1.1 Activate core


Procedure:
1. Insert in the sequence editor the core moving-in/-out symbols on the corresponding
position. [See Machine sequence on page 145.]
2. By the choice of the sequence you fix at the same time where the core shall move:

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Options

„ at mold open
„ at mold closed with clamp force
„ at a mold intermediate position
„ parallel to the mold movement
Example: Move core in and out with open mold
Closing sequence Opening sequence

Closing sequence Opening sequence

Retract ejector Open mold


25,0 mm 300,0 mm
Core moving platen Core moving platen
move in move out
Mold - close Ejector - shaking
100,0 kN 1 times
Nozzle - build up contact force
Opening sequence
47,0 kN

Closing sequence

3. Remove the jumper plug and connect the limit switches and safety switches.
4. Choose the screen page Core moving platen. The switch Activated must be switched
on.
Two green round flags beside move in and move out display that the core is built into
the sequence.

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Screen page Core moving platen

Core moving platen


Info Panel
Core moving platen 1
Mold position actual value
move in move out
Mold check position
With ext. energy supply
Switch off at end position

Time-dependent
Core actuation time

Monitoring time
Speed output

Pressure output

Hold pressure output

Ejector and core movements on pump

Core actuation
Core in end position
Core end position status

The respective flag for Core actuation lights during a core movement dark-red.
A dark-green flag for Core in end position position displays the respective end position for
moved in or moved out.
The flag for Core end position status indicates whether the core is retracted or advanced
(this is valuable information especially in time-dependent operation).
The two flags of the safety switches saw must be active for each core movement. When not -
message:

Core safety active

Cause Limit switch Core safety has not been actuated

Effect The core moving-in is blocked

Remedy Check the position of the ejector plate and ejector pins

163
Options

With the switch Deactivated in the sequence on the screen it is possible to deactivate the
core in the sequence. The machine then runs the cycle sequence without core movements.
If you actuate with deactivated core with the pushbuttons a core movement, for the respective
core a message appears:

Core x deactivated in the sequence

Cause The core has been actuated with the pushbutton although it is not
used in the sequence or is deactivated in the sequence.

Effect The core will not be actuated

Remedy Check the sequence; activate the core

1.2 Start position


When choosing a sequence, the mold position at which the core moves is already set in the
sequence editor. If a sequence is chosen with mold intermediate stop or parallel movement,
this position must be set on the Mold close or Mold open screen page.
On the Control point mold on the core page you can set up to which mold position the core
must be run. When the mold reaches this point without that the core has reached its final posi-
tion, the mold movement stops with an error message.
Switching off monitoring by setting the control position to the value = 0.

Note!
Take into consideration the amount of the braking stroke when setting the monitoring point

1.3 Speed and pressure


Speed output

Pressure output

Hold pressure output

You can configure a separate speed and pressure in each direction of movement for each
core. The holding pressure and speed outputs only take effect if the cores are not switched off
at final limit position and the machine is equipped with a 2 pump hydraulic system.

Screen switch ’’Switch-off at end position’’

The core switches off when the end position is reached.


When this screen switch is unchecked, after moving-in, the core only switches off at the end of
hold pressure. You may have to manually adjust a pressure relief valve to ensure that excess
pressure is not applied to the core cylinders during further machine movements. Check this
adjustment with the manometer!

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Pressure reduction valve


(turn counterclockwise to reduce pressure)

Manometer

1.4 Switching-off type


Time-dependent 1
Core actuation time 1

Monitoring time

The cores' movements are limit switch-controlled or time-dependent.

Switched off time-dependent :


„ The core continues to move until the respective limit switch is reached.
„ An adjustable Monitoring time is effective when the value is set greater than 0. The fol-
lowing message appears if the core needs longer:

Core x monitoring time moving in exceeded


Core x monitoring time moving out exceeded

Cause The core has not reached the limit switch for the stop position within
the set monitoring time.

Effect Mold, ejector, core movements and the automatic cycle are stopped.

Remedy Move the core in and out in manual mode to check the limit switch.
Also, in manual mode maintain the timing of the set core sequence.

Switched on time-dependent:
„ The core continues to move until the actuation time has expired.

Note!
Bridge the unused limit switches with the jumper plug

1.5 Shake core


Just like for the ejector you can demold molded parts by shaking the cores.

Activate core shaking by programming a Shake core step at the required position in the
sequence.
After programming core shaking, the setup parameters are displayed on the screens in ques-
tion.

165
Options

Screen page Core moving platen


Delay time

Core shake counter times


Position at cycle end moved out

Finish core shaking on ejection control

„ Delay time
You can set delays for moving in and out for core shaking. The move in delay is only
effective for the first move in.
„ Core shake counter
Number of shaking strokes the core performs.
If you set the shaking counter to 0 the core shaking step is not active in the sequence.
„ Position at cycle end
If you need to move the core in, for example to take off a molded part, select moved in.
The core will not move out until before the start of the next cycle in this case.
„ Finish core shaking on ejection control
Core shaking stops immediately when the ejection control monitor triggers, and the
sequence continues.

In manual mode core movements are controlled by pushbuttons.


If the shake counter is set to 0, the following message appears when the pushbuttons are
pressed in manual mode:

Core x shaking counter deactivated

Effect Shaking movement not possible.

Remedy Set core shaking counter.

1.6 Core with external energy supply


With ext. energy supply

Program for pneumatically or electrically operated cores. Activation of the 24V outputs without
hydraulic pressure and speed actuation.

1.7 Core signals


The core signals screen gives you an overview of the end position status of all cores for the
machine, along with core safety.

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Example screen page Core Signals


Core signals
Info Panel
Core(e) moving platen
move in move out
DO DI DO DI
1 2 3
DO DI DO DI
DI DI
DO DI DO DI
DO DI DO DI
Core stationary platen
move in move out
DO DI DO DI
DO DI DO DI
Core safety
Core safety 1 DI
DI
4
Core safety 2
Cores pressure relief
Cores pressure relief moving platen DO 5
[1] Core actuation
Lights up when the core is actuated.
[2] Core in end position
Lights up when the core has reached the corresponding limit switch.
[3] Core end position status
Lights up when the control unit has executed the corresponding core movement
depending on time or on the limit switch.
[4] Core safety
Lights up when the corresponding core safety switch is actuated.
[5] Cores pressure relief
Lights up when the pressure relief valve is actuated.

2 Air valve
A solenoid air valve offers the possibility to switch on compressed air for certain mold or
machine functions. The valve is mounted near to the stationary platen.

Air valve
Info Panel

+ Air valve
Blowing time 1,00
Air valve 1 actuation DO021

For activating the air valve switch on the screen swich and insert in the machine sequence the
instructon ’Air valve - start’ for the air valve on the corresponding position. The air valve
switches off after the set ’Blowing time’ , only afterwards the sequence continues.
The instruction ’Air valve - stop’enables the stopping of the air valve before the expiry of the
blowing time.

Push-button Air valve

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Options

Example:
Air-supported demolding of a molded part.
Actuate air valve as of opening position 1 and stop after blowing time has elapsed or at end of
ejector movement.

Open mold Wait until: Mold open on position 1

Ejector - shaking Air valve - start


1 times
Air valve
Stop

Note!
Air valve actions are blocked according to the regulations EN201 with an open safety gate, as
movements operated by compressed air can produce dangerous situations.

WARNING!

Although an open safety gate interrupts the electrical actuation of the air
valves, a dangerous movement could occur. Movrements due to the fail-
ure of the compressed air supply or by a loose hose - CANNOT be
ignored.

The machine operator has to ensure that, when opening a gate, no dan-
gerous movement can occur. This can be achieved with suitable safety
gates.

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3 VirtMold Program
The VirtMold program is used to simulate ENGEL injection molding machines and robots with
CC/EC200 control units. It permits parts data sets to be created, edited and tested on a PC
without interrupting the production process. The data sets can be exchanged at any time
between a real machine and VirtMold.

3.1 System requirements


„ Operating system Windows 2000 or Windows XP
„ Processor > 1,5 Ghz
„ Memory 1 GB RAM
„ Hard disk space for VirtMold - basic simulation approx. 80 MB, plus approx. 100 MB per
machine simulation
„ Monitor resolution 1280 x 1024 Pixel recommended
„ Compact Flash memory card reader or USB interface
„ CD-ROM drive

Note!
Before installing VirtMold, close all other applications.

3.2 Installation
VirtMold consists of the VirtMold basic simulation plus one or more machine simulations.

Note!
The installation of additional machine simulations does not require reinstallation of the Virt-
Mold basic simulation.

Installation of the VirtMold - Basic simulation


If you have already installed VirtMold or an eTrainer, first check the VirtMold version [See Virt-
Mold Version on page 174.]. If this is current (version 2.1.12.1 or higher), continue with the
installation of machine simulation.
If you have an old version of VirtMold (before 2.1.12.1), uninstall this version before you con-
tinue. Then install the current version of VirtMold.
If you have not yet installed the VirtMold program on your computer, install the VirtMold basic
simulation (Basic Components + VirtMold).
To do this, follow the instructions of the installation program on the installation CD
(README.htm).

Installation of machine simulation (Install Virtual Machines)


There are 2 standard machines on the installation CD. Their installation is described below. If
you want to create a machine simulation from a real machine, switch to: [See Creating a
machine simulation from a real machine on page 170.]

The ’Install Virtual Machines’ window appears automatically after completing the installation,
or can be selected in the Start menu - Programs/ENGEL VirtMold/Copy machines.

169
Options

Select the desired machine in selection box Virtual Machines to be installed (check the field
in front of the machine number or name ) and click Install.
Files are now copied to your computer, and then displayed in the Virtual Machines already
installedfield.
In order to remove a machine from the PC, select the machine in selection box Virtual
Machines already installed and click the Removebutton.
Finish the installation process by pressing Exit.

D:\C2K

VM_314563 VM_314560
VM_315550
VM_324561

3.3 Creating a machine simulation from a real machine


You can create a machine simulation for VirtMold from any real machine with a CC/EC200
control unit.

To create a machine simulation, you need either an empty USB stick (CC/EC200) or an empty
Compact Flash memory card (CC200 only) with a capacity of at least 256 MB.

Procedure for copying the system flashcard:


1. Insert the storage medium into the machine.

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2. Switch to the Data dialog screen and press Setup - System Flashcard

Data dialog

/hard disk1 Active parts data set STARTUP

/hard disk1 Data set attributes


Name

System name

Author

Production date
Change author System flash card

Change date
Software update

Description License update

Read machine data


Machine number
Write machine data

Display active machine data

Parts data Edit Setup View

3. The Save Flashcarddialog box appears. Select the drive with the storage medium to
which you want to copy the system flashcard. Press Save to start copying.
Save flash card

Available drives \hard disk\1


Directory

Cancel Help Save

4. The Save Flashdialog box appears.


Back-up Flash

/hard disk1//

Cancel

5. The dialog box disappears as soon as the copying process is completed.

Procedure for installing the machine simulation


1. Boot your PC.
2. Attach the storage medium with the copy of the system flashcard to your PC.
3. Launch the Copy machines program. To do so, select Programs/ENGEL VirtMold/Copy
machinesin your PC's Start menu.

171
Options

4. The Install Virtual Machineswindow appears

314563 VM_314560
VM_315550
VM_324561

5. In Select location of Virtual Machines folder , select the storage medium with the
copy of the system flashcard. To do this, use Select Folder to open a search window
and select the drive with the storage medium from it. Now the machine number of the
machine from which you have created the system flashcard appears in selection field
Virtual Machines to be installed.

E:\

314563 VM_314560
VM_315550
VM_324561

6. Select the field in front of the machine number and click Install. A DOS box appears,
and the installation procedure starts.
7. The DOS box is closed when the installation procedure is completed. The machine
number is displayed in field Virtual Machines already installed . Exit the Install Virtual
Machines program by clicking the button Exit.
8. Before removing the storage medium from the PC, select ’Remove or eject hardware’.
Failure to do so could damage the data on the storage medium.

After successfully installing the machine simulation, launch VirtMold and select the desired
machine in the selection window.

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3.4 VirtMold menu


The VirtMold menu icon appears on the right side of the toolbar to indicate that a machine sim-
ulation is running . Use the right mouse button to select.
This menu lets you select the basic settings for the simulation by left clicking.

Menu items

„ Configuration
This window displays all the links and settings for the simulation. These settings cannot
be changed after the installation.
„ Windows
This selection opens an additional menu where you can enable/disable all windows in
the machine simulation. You can use the mouse to arrange the open windows and to
scale the windows.
Example of a simulation window selection menu:

The view can become cluttered if several simulation windows are in use. To avoid this,
as many windows as you like can be gathered together into a collective window with a
selection bar. Drag a window over another one and use the selection bar to select the
active window.
active window

Selection bar

To split up a collective window, select a window in the selection bar and drag it out by
holding the left mouse button down.
„ Load/Save windows cfg
You can use these functions to store the window layout for the simulation, and open the
same layout at any time later. This function is useful if several people work with a
machine simulation, but prefer different window layouts.
„ Select Machine
You can change the machine simulation with this function. The function can be selected
after stopping the current simulation (menu item Stop Machine). The same dialog box
as during launching of the simulation appears. [See Start and screen structure on
page 174.]

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Options

„ Stop Machine/Start Machine


You can select ’Stop Machine’ to stop the current machine simulation. The selection tog-
gles to ’Start Machine’. This option lets you start the machine you stopped (e.g. to rem-
edy a malfunction in the simulation).
However, you can select another machine simulation by selecting ’Select Machine’.
„ Tutorial (Option)
Opens an interactive training session for the machine control unit.
„ Help (Option)
Only activates the online help on a machine simulation.
„ About
Provides information about the simulation variants. [See VirtMold Version on
page 174.]
„ Exit
This selection terminates VirtMold (complete simulation).

3.5 VirtMold Version


To do so, open the VirtMold menu and select About. A window with information about the
’Basic Components’ and ’VM_Loader’ versions appears. If both are higher than 2.1.12.1, you
do not need to reinstall VirtMold.
Press Ok to close the window.

3.6 Start and screen structure


After the installation, an icon with the name ENGEL VirtMold is created on your computer
desktop. Double-click the icon to start VirtMold.

ENGEL VirtMold

The program can also be started by selecting Start menu - Program Files/ENGEL VirtMold/
ENGEL VirtMold.
When the program loads, it displays a dialog box where you can select the machine. This is
mandatory for using multiple machines. Select the machine you need, and press Start to con-
tinue.

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Selection window

Note!
With some PCs, it takes a few minutes until the simulation has started completely. Do not start
VirtMold again in this time!

When the simulation is up and running, at least 3 windows are visible. VirtMold controls are
identical to those for the actual machine. Use the PC mouse to navigate the screen.

Sample view:

1 2

1. Control unit user interface


2. Switch panel
3. Safety gate overview
4. Machine simulation

You can arrange the windows to suit your own preferences, and select windows with additional
functions. These settings are performed in the VirtMold menu.

175
Options

3.7 Edit data set


In order to use a machine parts data set in the simulation, you need a Compact Flash memory
card reader or a USB port on the PC.
The Data Dialog on the VirtMold shows you all the PC drives (including network drives) that
are available as storage drives for managing or archiving parts data sets.
When saving data, VirtMold automatically creates a DATA folder in the root directory of the cur-
rent drive. To view the data sets later, make sure you do not move the folder to a subdirectory.

Example:

Data dialog

c:\ Active parts data set: Screw cap_small

c:\ Data set attributes


Screw cap_small Name Screw cap_small
Cup Author

Production date
1. Store the parts data set for the machine on a Compact Flash memory card or USB stick.
2. Connect the storage medium to the PC.
3. Select the storage medium drive in the VirtMold Data dialog.
4. Upload data set to VirtMold and then run the simulation with it.
5. To back up the data set, select any drive in the Data dialog and save. Save the data set
on your PC on a Compact Flash memory card or USB stick; select ’Remove or eject
hardware’. Failure to do so could damage the data on the storage medium.
6. Reading a parts data set into the machine.

Note!
To simplify managing the data sets of several machine simulations, it is possible to save
directly in the machine directory. To do this, select the simulation drive (normally drive O:) as
the storage drive in the Data dialog box. The simulation drive is visible in the selection window
when the machine simulation is started.

Simulation drive (Mounted to:)


This drive is automatically assigned
by VirtMold; normally, it is drive O:
If this is already occupied by another
application, an available drive is
assigned.

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Options

178 ENGEL operator basics (EOB) | Version G/11/25/15/5


Symbols *Start key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
*Start-up phase active . . . . . . . . . . . . . . . . . . . . . . . . . . . .125
*Adjust moving-in switchover point . . . . . . . . . . . . . . . . . 125
*Alarm with cycle stop appeared . . . . . . . . . . . . . . . . . . . . 53 *Value corrected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133
*Wrong setting in the sequence . . . . . . . . . . . . . . . . . . . . .155
*Automatic plasticizing active . . . . . . . . . . . . . . . . . . . . . . 116
*Barrel heat soaking is active . . . . . . . . . . . . . . . . . . . . . . . 88
*Barrel heater at standby . . . . . . . . . . . . . . . . . . . . . . . . . . 93 A
*Barrel heaters are switched off . . . . . . . . . . . . . . . . . . . . . 88 Activate core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .161
*Barrel heating x too cold . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Air valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .167
*Barrel heating x too hot . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
*Clamp unit safety gate interrupts cycle . . . . . . . . . . . . . . . 29 B
*Clamping force exceeded . . . . . . . . . . . . . . . . . . . . . . . . . 79 Back pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114
*Clamping force too low . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Back pressure in manual pressure . . . . . . . . . . . . . . . . . .117
*Clamping unit safety gate open . . . . . . . . . . . . . . . . . . . . 28 Barrel heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
*Core deactivated in the sequence . . . . . . . . . . . . . . . . . 164 Barrier screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
*Core end position left . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 Behavior in case of fire . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
*Core limit switch defective . . . . . . . . . . . . . . . . . . . . . . . 160
*Core monitoring time exceeded . . . . . . . . . . . . . . . . . . . 165 C
*Core not moved in/out . . . . . . . . . . . . . . . . . . . . . . . . . . 159 Cancel mold safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
*Core safety active . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163 Changing user access authorizations . . . . . . . . . . . . . . . . .49
*Core safety error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 Clamp force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
*Core x move in moving platen limit switch defective . . . 161 Clamping unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
*Core x move in stationary platen limit switch defective . 161 Compact representation of the heating zones . . . . . . . . . . .94
*Core x move out moving platen limit switch defective . . 161 Components of the control unit . . . . . . . . . . . . . . . . . . . . . .34
*Core x move out stationary platen limit switch defective 161 Configurable keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
*Cushion too large . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 cooling time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
*Cushion too small . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 Copy parts data set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134
*Cycle time exceeded . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 Copying all parts data sets . . . . . . . . . . . . . . . . . . . . . . . .134
*Delayed motor stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .159
*Determine mold height . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Core signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .166
*Determine nozzle contact position . . . . . . . . . . . . . . . . . 104 Core speed and pressure . . . . . . . . . . . . . . . . . . . . . . . . .164
*Editing mode active . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153 Core with external energy supply . . . . . . . . . . . . . . . . . . .166
*Ejection control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Creating a machine simulation from a real machine (VirtMold)
*Ejector not back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73, 76 170
*Emergency-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Creating new user access authorization . . . . . . . . . . . . . . .48
*External closing interlock . . . . . . . . . . . . . . . . . . . . . . . . . 82 Cushion monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
*Flash card full . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 Cycle monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120
*Injection time exceeded . . . . . . . . . . . . . . . . . . . . . . . . . 108 Cycle time analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
*Injection time not reached . . . . . . . . . . . . . . . . . . . . . . . . 108
*Jumper plug for core moved in/out is missing . . . . . . . . 160 D
*Mold clamping mechanism on stop . . . . . . . . . . . . . . . . . 71
Danger signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
*Mold heating is switched off . . . . . . . . . . . . . . . . . . . . . . . 97
Data dialog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128
*Mold heating reduces . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Data dialog - Copy all parts data sets . . . . . . . . . . . . . . . .134
*Mold heating x too cold . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Data dialog - Export . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136
*Mold heating x too hot . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Decompression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117
*Mold not closed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Delete data set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135
*Mold not closed on position . . . . . . . . . . . . . . . . . . . . . . . 82
Deleting user access authorization . . . . . . . . . . . . . . . . . . .49
*Mold not open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
*Mold not open at position . . . . . . . . . . . . . . . . . . . . . . . . . 85
*Mold protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
E
edditional equipements . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
*Movement not available . . . . . . . . . . . . . . . . . . . . . . . . . 151
Editing the data set (VirtMold) . . . . . . . . . . . . . . . . . . . . . .176
*Multiple closing end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
*Nozzle contact position not reached . . . . . . . . . . . . . . . . 104 e-Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Ejector movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
*Nozzle position out of area . . . . . . . . . . . . . . . . . . . . . . . 104
Ejector start/stop settings . . . . . . . . . . . . . . . . . . . . . . . . . .75
*Nozzle safety gate open . . . . . . . . . . . . . . . . . . . . . . . 15, 29
*Piece counter expired . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Ejector stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
EMERGENCY STOP function . . . . . . . . . . . . . . . . . . . . . . .28
*Plasticizing not reached . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Export injection protocol . . . . . . . . . . . . . . . . . . . . . . . . . .136
*Plasticizing time exceeded . . . . . . . . . . . . . . . . . . . . . . . 115
*Plasticizing time not reached . . . . . . . . . . . . . . . . . . . . . 116
*Postsoaking active - no screw movement possible . . . . . 96 G
*Pressure limit at x ccm exceeded . . . . . . . . . . . . . . . . . . 107 Guidelines for working on the injection molding machine . .24
*Program interruption key . . . . . . . . . . . . . . . . . . . . . . . . . 35
*Pump motor switched off . . . . . . . . . . . . . . . . . . . . . . . . . 51 H
*Push-button actuated . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Header with Info Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
*Rejects counter expired . . . . . . . . . . . . . . . . . . . . . . . . . 126 Help system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
*Save sequence - safeties not current . . . . . . . . . . . . . . . 155 Holding pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
*Set screw diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Holding pressure profile . . . . . . . . . . . . . . . . . . . . . . . . . . .111
*Shot counter expired . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
*Soaking inspection active . . . . . . . . . . . . . . . . . . . . . . . . . 95 I
*Soaking inspection Maximum torque reached . . . . . . . . . 96 Importing/exporting user data . . . . . . . . . . . . . . . . . . . . . . .49
*Soaking inspection was active . . . . . . . . . . . . . . . . . . . . . 96 Info Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

179
Inject . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Screen layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Injection molding in general . . . . . . . . . . . . . . . . . . . . . . . . 18 Screen page selection and function keys . . . . . . . . . . . . . . 38
Injection molding machine cycle . . . . . . . . . . . . . . . . . . . . . 18 Screen structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Injection speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Screw diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Injection time monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . 108 Sequence preview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
InjectionUnit1.er_InjTime.1000 . . . . . . . . . . . . . . . . . . . . . 108 Sequence programming positions mold closing . . . . . . . . . 82
Input keyboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Sequence programming positions mold opening . . . . . . . . 85
Installation of VirtMold . . . . . . . . . . . . . . . . . . . . . . . . . . . 169 Sequence settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Interactive messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Set value graphics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Intrusion program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 Setting the number of profile items . . . . . . . . . . . . . . . . . . 65
Setting the speed and force profile . . . . . . . . . . . . . . . . . . 62
L Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Loading machine sequence . . . . . . . . . . . . . . . . . . . . . . . 149 Shake core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Shake ejector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
M Soaking inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Sprue ejector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Machine sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Start and screen structure of VirtMold . . . . . . . . . . . . . . . 174
Machine sequence - Changing an instruction . . . . . . . . . 157
Machine sequence - Inserting an instruction . . . . . . . . . . 156 Start up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Start-up cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Machine sequence - Removing an instruction . . . . . . . . . 158
Status display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Machine sequence - standard sequence . . . . . . . . . . . . . 148
Machine sequence - visualization of machine sequence . 146 Storage media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Switch panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Machine sequence and Mask Editor . . . . . . . . . . . . . . . . 145
Switchover to hold pressure . . . . . . . . . . . . . . . . . . . . . . . 108
Machine-specific key symbols . . . . . . . . . . . . . . . . . . . . . . 36
Mandatory Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Mold closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 T
Mold heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Text formatting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Mold height adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Torques during plasticizing . . . . . . . . . . . . . . . . . . . . . . . 117
Mold opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Mold parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 U
Monitoring of the barrel temperature . . . . . . . . . . . . . . . . . 92 USB storage media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Monitoring systems for the injection molding process . . . 120 User access authorization - login with card . . . . . . . . . . . . 43
Mount mold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 User access authorization - password login . . . . . . . . . . . . 43
Mounting aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 User administration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Movement to Home position . . . . . . . . . . . . . . . . . . . . . . . . 84 User level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

N V
Notepad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 VirtMold menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 VirtMold Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Nozzle contact position . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 VirtMold system requirements . . . . . . . . . . . . . . . . . . . . . 169
Nozzle speed profile and stroke positions . . . . . . . . . . . . 102 VirtMold Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Nozzle stroke position . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
W
P Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Part removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Write a parts data set . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Pictographs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Plasticizing maintained instruction . . . . . . . . . . . . . . . . . . 116
Plasticizing number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Plasticizing speed profile . . . . . . . . . . . . . . . . . . . . . . . . . 114
Plasticizing time monitoring . . . . . . . . . . . . . . . . . . . . . . . 115
Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Printing textually and graphically . . . . . . . . . . . . . . . . . . . 140
Production counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Production programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Programming machine sequence . . . . . . . . . . . . . . . . . . . 153
Prohibitory signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Proper Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Putting out of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

R
Read parts data set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
rejects in succession . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Rescue actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

S
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Safety equipment - overview . . . . . . . . . . . . . . . . . . . . . . . 27
Safety equipment function . . . . . . . . . . . . . . . . . . . . . . . . . 28
Safety hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14, 24
Save machine sequence . . . . . . . . . . . . . . . . . . . . . . . . . 151
Save sequence - safeties not current . . . . . . . . . . . . . . . . 151
Saving user access authorization . . . . . . . . . . . . . . . . . . . . 49

180 ENGEL operator basics (EOB) | Version G/11/25/15/5