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CY-600GII
OPERATION MANUAL CYS-600GII
CY-800GII
CYS-800GII
GⅡ
INTRODUCTION
Thank you for purchase of the Star Traverse Automatic Unloader. When linked to a molding machine,
the unloader will automatically remove products from the mold and transport them to a conveyor belt to
other designated location. This manual describes the unloader's functions and presents important
information about operating methods and precautions. Please read through this manual carefully so that
you will be able to use the unloader safely and effectively. Keep this manual in a place of easy access.
* This manual describes the standard model. For optional specifications, refer to corresponding separate
manuals.
Contents
MACHINE SECTION
z Point
Important points for operation procedures are displayed with mark in this manual.
-1-
1-3. Safety Precautions
DANGER
z Do not enter the operation range.
Do not enter the operation range of the machine. You may be caught or lodged in the
machine resulting in injury.
Do not maintain the machine while it is in operation. Shut down the air supply and turn off the
power switch on the operation panel and the power circuit breaker before maintenance.
WARNING
z Clothing must be proper for working.
Wear proper clothes for working. To avoid injury from trapping, do not wear too large
clothes or costume jewelry/accessories.
Do not modify the machine. STAR assumes no responsibility for accidents or failures
caused by modifications to the machine by users.
To avoid electric shock, ground the machine in accordance with the relevant regulation
in your country. When a routine inspection is made or the conveyor is relocated, check
that the machine is grounded appropriately.
To prevent fire resulting from overcurrent, use a non-fuse circuit breaker for wiring to
the power source.
A high voltage is applied in the electric box. Opening it may result in electric shock or injury.
-2-
z Do not touch the machine during operation.
To prevent trapping accidents, do not insert your hand in the machine while it is running.
The machinery should be shut down during times when power supply is frequently
going off due to thunderstorm or other such external event. Operating with an irregular
power supply may lead to equipment damage.
CAUTION
z Determine the supervisor for performing operation.
Determine the supervisor when teaming up with two or more operators for making
machine adjustments, etc.
z Pneumatic source
To protect pneumatic components from damage, supply dry air using a dryer. After-
coolers and air dryers are available from STAR. Contact your local distributor when
necessary.
Read and follow the operational procedures and precautionary remarks provided in this
manual.
Provide a 1-m-wide or larger maintenance room around the machine for safe operation.
Keep obstacles clear of the room.
Tidy up the area around the machine, and keep the area well illuminated.
-3-
z Perform maintenance daily.
Perform maintenance daily and check that the machine is in normal conditions. Contact
your local distributor in the event of failure.
If an abnormality or failure is found during operation, stop the machine and follow the
directions from your local distributor.
When carrying out inspection, repair, adjustment, cleaning, or lubrication work within the
unloader's movement range, be sure to lock the POWER switch. Post an appropriate sign on the
operation Panel to ensure that no one switches on the machinery while work is in progress.
Some inspection, repair, adjustment, cleaning, and lubrication work must be carried out while
standing on a platform or scaffold. Be sure that the stand is securely set up, and wear a safety belt.
Before carrying out inspection, repair, adjustment, cleaning, or lubrication work within
the unloader's movement range, you must shut down not only the unloader itself but also
all devices that are linked to it (such as the molding machine and conveyor).
-4-
Types of warning labels
-5-
z Warning label for high voltage
Be sure to turn off the circuit breaker in the
control box during maintenance.
In particular, disconnect the cable to the
molding machine before performing
maintenance on the control box, and turn off
the primary power of the plant.
-6-
z Precautions for travel adjustment
Refer to the operation manual for travel
adjustment of movable parts. Make
adjustments in a safe way.
Even if the power and the air pressure are
turned off, some pressure may remain in the air
cylinder. The cylinder may move abruptly. Be
sure to wear protective equipment for
adjustment. Avoid adjustment within the
movable range.
-7-
z Warning for being caught
Do not inadvertently touch the parts such as
motor, spindle, gear, pulley or belt, that may
catch, within the movable range for
maintenance or any other reason.
Turn off the power and the air pressure before
accessing the machine.
-8-
List of hexagon wrench size and min. tightening torque
<Caution>
z Tighten bolts at least with the standard torque specified above.
z After tightening a bolt, be sure to check that it is secured on the tightening surface.
Shallow tightening tap or clogged chips inside the tap may prevent a bolt from being
tightened even when it's been tightened with the specified torque.
z Use values of the tightening force F and the point of application of force L3 as
guides.
z Check bolts for looseness every month.
-9-
1-4. Locations of Warning Labels
The following diagram shows the location and content of caution plates affixed to the unloader.
- 10 -
1-5. Mechanical Specifications
Model CY-600GII CYS-600GII CY-800GII CYS-800GII
0.49MPa [5 kgf/cm2]
Normal air pressure
(No water content or dust allowed in air)
Product-side 150
Crosswise
Stroke (mm)
Runner-side 100 100
- 11 -
2. NAMES OF THE PARTS AND THEIR FUNCTIONS
2-1. Configuration Diagram
Valve unit
Crosswise unit
- 12 -
2-3. Product-Side Vertical/Crosswise Unit
⃝
1 Vertical stroke adjustment stopper
This bracket sets crosswise standby position and crosswise stroke by adjusting the position.
⃝ Shock absorber for advance end
6
- 13 -
①
⑪ ⑩
⑧
③ ⑦
④
⑥
② ⑨
⃝
1 Crosswise LM guide ⃝
8 Ascent end proximity switch (LS-3)
This guide holds crosswise straightness. This switch is used to confirm that the vertical arm
⃝
2 Chuck mounting plate (link bracket) completed ascending.
The chuck plate is mounted here. ⃝
9 Connection terminal for wiring of product-in-
POINT
This connector can be connected only to the
⃝
3 Posture action speed controller
machine-type limit switch.
This controller controls the posture action speed.
⃝
4 Posture cylinder
⃝
10 Release prevention vertical lock cylinder
This cylinder turns the posture section 90° in
The release prevention cylinder activates and
reverse.
⃝
5 Posture return speed controller
prevents the posture section from being released
when the air pressure is reduced with the pressure
This controller controls the posture return speed. relief cock, etc.
⃝
6 Ascent end proximity switch dog (for LS-3)
⃝
11 Posture action end auto-switch (LS-9)
This dog is used to activate the ascent end This switch is used to confirm that the posture side
proximity switch completed action.
⃝
7 Posture return limit automatic switch (LS-8)
- 14 -
2-4. Runner-Side Vertical/Crosswise Unit (CYS model)
② ③ ④
⑤ ⑥
⃝
1 Vertical stroke adjustment stopper plate
- 15 -
②
④
⑦
⃝
1 Crosswise LM guide ⑥
The release prevention cylinder activates and prevents the runner chuck section from being
released when the air pressure is reduced with the pressure relief cock, etc.
⃝
5 Runner confirmation sensor in the chuck (LS-4S)
- 16 -
2-5. Traverse Rail Unit
② ① ④ ⑤ ⑧ ⑨ ⑥ ⑦
⃝
1 Pressure reducing valve with filter ⃝
6 Traverse home position proximity switch
Be sure to keep this residual pressure This switch is activated when the carriage unit is
releasing cock closed when using the positioned in the area where products can be
unloader. extracted.
⃝
9 Extract-side area proximity switch dog
⃝
3 AC servo motor
(for LS-10)
This dog turns on the extract-side area proximity
⃝
4 Release-side area proximity switch (LS-12)
switch (LS-10).
This switch is activated when the carriage unit is
not positioned above the molding machine.
⃝
5 Traverse over run proximity switch (LS-2)
- 17 -
① ②
③ ⑤ ⑥
⃝
1 Toothed belt for traverse (iron rubber AT belt)
⃝
2 Transverse LM guide
- 18 -
2-6. Valve Unit
CAUTION
• Never attempt to adjust the air cylinder while automatic operation
is in progress, as this can be dangerous. Switch operation to
MANUAL mode before making the adjustment.
• Do not set the air cylinder speed too high, as this may result in
equipment damage. Begin adjustment at slow speed, and
increase the speed gradually to the appropriate level.
• Note that the solenoid valve may become hot during operation,
and may remain hot for some time after power is shut off. Don't
touch the solenoid until you are sure it has cooled off.
POINT
Be sure to set the controller POWER switch to OFF before using the manual operation
button on the solenoid.
Note that forward and return operation may not be available.
- 19 -
③ ② ①
⑬ ⑥
⑪
⑮
⑩
⑨
⑯
⑧
⑰ ⑭
⑦
- 20 -
⃝
1 Unload-side descending high speed control
⃝
2 Produce-side descending speed control
⃝
3 Runner-side descending speed control
⃝
4 Product-side ascending speed control
⃝
5 Runner-side ascending speed control
⃝
6 Manual operation button for the product side high speed descent
If pressed concurrently with 16, the product side vertical arm descends with high speed.
⃝
7 Posture action manual operation button
Pressing this button starts the posture of the product chuck section.
⃝
8 Produce-side advancement manual operation button
Pressing this button advances the product-side vertical arm and releasing the button returns the
arm.
⃝
9 Runner-side advancement manual operation button
Pressing this button advances the runner-side vertical arm and releasing the button returns the arm.
⃝
10 Runner-side chuck opening manual operation button
Pressing this button opens the runner chuck and releasing the button closes the chuck.
⃝
11 Product-side chuck opening manual operation button
Pressing this button opens the produce-side chuck and releasing the button closes the chuck.
⃝
12 Sprue chuck opening manual operation button
Pressing this button opens the sprue chuck and releasing the button closes the chuck.
⃝
13 Absorption manual operation button
Pressing the button when the power is off releases absorption and releasing the button starts
absorption.
⃝
14 Vacuum generator
Pressing this button moves down the runner side vertical arm and releasing the button moves up
the arm.
⃝
16 Product-side descending manual operation button
Pressing this button moves down the product side vertical arm and releasing the button moves up
the arm.
⃝
17 Posture return manual operation button
Pressing this button returns the posture of the product chuck section.
- 21 -
2-7. Locations of Limit Switches
③
⑥ ④ ⑤
- 22 -
① ② ③ ④
- 23 -
3. AUTOMATIC UNLOADER SETTINGS
POINT
For full information about how to set the unloader, refer also to <Operation section>.
CAUTION
Before making settings of the unloader or manually checking its
operation, lower the speed of each cylinder with the speed controller.
Wiring
Connect the molding machine to the control box of the unloader, and use the control box to verify the
signals between the molding machine and unloader.
WARNING
• If you are going to operate the molding machine independently
(unlinked), you should first move the carriage unit to the release
side (outside of the molding machine).
• If jumper is plugged into the relay metal connector box, the
molding machine will remain able to execute mold open/close
even while the unloader's vertical arm is in lowered position within
the mold. This can result in damage to the mold and/or the arm.
Interlock
metal connector
Jumper plug
- 24 -
2. Checking the signals in the control box
Turn on the power switch on the pendant unit. The
power lamp lights up on the pendant unit.
The following screen appears on the LCD and initial
check starts.
When initial check has been completed normally, the initial screen is displayed.
When the input signals from the molding machine indicated on the screen are under normal
conditions, wiring is completed.
ON ........... In reverse video
OFF ......... In normal video (characters in black)
- 25 -
Piping
Connect the primary-side air hose you have prepared to
the <IN> of the filter regulator.
Primary-
side hose
Residual
pressure
POINT
releasing
cock Be sure to keep the residual pressure releasing cock
completely closed when operating the unloader.
- 26 -
Unloading and Release Positions
z Unloading position
When operating the unloader for the first time after
installing it, be sure to input a point (value) within the
extract side area so that the center of the unloader
2025 carriage unit comes at the center of the mold.
POINT
POINT
- 27 -
3-2. Setting Procedure
POINT
• When descending, turn on the release side descent mode (MD2) in advance.
• When replacing the product chuck in a state of posture returned, turn off the release-side
posture mode (MDSS).
After chuck plate replacement, turn on the release-side posture mode (MDSS) at the arm
ascent end and adjust the speeds of posture action and return (refer to "2-3").
Press OPERAT key and key concurrently and return the unloader to the home position.
- 28 -
2. Product-Side Crosswise Standby Position Setting
1021
- 29 -
3. Product-Side Crosswise Stroke
1023 d Loosen the fixation bolt of the rod clamp with the
hexagonal wrench.
POINT
1024
Adjust the stroke after completely pulling out the
cylinder rod of the crosswise cylinder because the
setting position may be misaligned when supplying
air.
1025
- 30 -
4. Product-Side Vertical Stroke Setting
c Measure a distance A from the center of the nozzle of the
chuck plate to the center of the nozzle of the molding
machine.
Please note that the center position of the chuck
1027 plate may not match with height of the center of
A
the nozzle of the molding machine due to structure
of the chuck plate.
CAUTION
• Never adjust the stroke when the vertical arm is lowered. It is
very dangerous because the stopper is loaded.
• Adjust the stroke when the vertical arm is at the ascent end. The vertical
arm may descend and it is very dangerous if it is not at the ascent end.
CAUTION
Be sure to additionally tighten the fixation bolt
after adjustment.
- 31 -
5. Runner-Side Crosswise Standby Position Setting (CYS model)
POINT
1031 Adjust the stroke after completely puling out the cylinder
rod of the crosswise cylinder because the setting position
may be misaligned when supplying air.
1032
1033
- 32 -
6. Runner-Side Crosswise Stroke Setting (CYS model)
1036
CAUTION
Be sure to additionally tighten the
stopper bolt after adjustment.
- 33 -
7. Runner-Side Vertical Stroke Setting (CYS model)
CAUTION
Never adjust the stroke when the vertical arm is lowered. It is very
dangerous because the stopper is loaded.
1037 POINT
The runner may be caught at the position other than
center of the nozzle of the molding machine
according to the shape of the runner.
1039
CAUTION
Be sure to additionally tighten the bolt after adjustment.
- 34 -
8. Selection and Checking of Product Confirmation Limit Switch
Check the product manually and verify that this is shown on the control box's I/O display screen.
c For product-side vertical unit
The confirmation limit switch depends on the product extracting method, so select the
corresponding mode first.
POINT
For detail on how to set these modes, see the operation manual for the controller.
2057
- 35 -
c. Suction-confirmation sensor (LS-4V)
POINT
- 36 -
z Setting the detection area
Observe the lamp to find the position at which
detection is made with the runner chucked.
POINT
- 37 -
9. Position while Travelling Setting
1044 POINT
Release-side area proximity switch d Set the release-side area proximity switch dog with
the release-side area proximity switch (LS-12).
POINT
Release-side area
proximity switch dog
Set the mode and the timer referring to the operation section of the manual after the above
mechanical setting is completed.
CAUTION
• Be sure to additionally tighten each bolt adjusted when setting before starting
the automatic operation.
• Check to see that the tools used for mechanical adjustment are not left on the
unloader or inspection table again before starting manual or automatic
operation after adjusting the machine. If something drops, workers may be
injured or machines may be damaged.
POINT
The next preparation time can be reduced by recording the set dimension for each mold.
- 38 -
4. MAINTENANCE AND INSPECTION
To prolong the service life of the unloader and to prevent accidents, inspect the unloader regularly (once
a month).
- 39 -
Maintenance and Inspection Table
Inspection
Work No.
Half-yearly
Every three
Every two
Monthly
years
Daily
Pressure
1 { Air pressure Visual
gauge(0.49MPa)
* If you gave any questions regarding inspection methods, items and actions, contact the technical
service staff at our sales office.
** General diagnosis will be provided at your company's expense. Please consult the sales staff at our
sales office.
- 40 -
Lubrication diagram
② ①
② ①
- 41 -
Oiling
z LM guide
1. Feed grease by the grease pump from the grease
nipple.
Grease
* Supply grease from the grease nipple periodically (refer to "Lubrication Diagram").
* Use lithium grease #0.
- 42 -
5. PARTS LIST
- 43 -
6. EXPENDABLE PARTS LIST
z Product-side vertical unit
Manufact Replacement
No. Code No. Product Name Type Qty Remarks
urer interval
1 Vertical cylinder
1 Packing set ARDB32- 610- R3118 TANHAY 3000 km
SET (600GII)
1 Vertical cylinder
2 Packing set ARDB32 –810-R3118 TANHAY 3000 km
SET (800GII)
ARDBA32-150-C73KS- 1
3 Packing set TANHAY 3000 km Crosswise cylinder
R3110 SET
1
4 Packing set ARDB32-65-C73KS-R3112 TANHAY 3000 km Posture cylinder
SET
1 Drop prevention
5 Packing set ACQ2B25-10T-R3123 TANHAY 3000 km
SET cylinder
6 120484 DU bush DUB0808 DAIDO 2 1 year Posture
7 220031 DU thrust washer DUT06 DAIDO 2 1 year Posture
2 million
8 Shock absorbor KBM10-50-11-SCMK2 KYB 1 Ascent end
times
2 million
9 100858 Shock absorbor KBM10-50-12C KYB 1 Descent end
times
2 million
10 100854 Shock absorbor KBMT12-20-7 KYB 1 Advance end
times
- 44 -
z Valve unit
Manufact Replacement
No. Code No. Product Name Type Qty Remarks
urer interval
Product side
crosswise
Runner side
20 million
1 182837 Solenoid valve SY3140-5MO SMC 5 crosswise
times
Runner chuck
Product chuck
Sprue chuck
20million Runner side
2 182841 Solenoid valve SY7120-5MO-02 SMC 1
times vertical
20 million Posture action
3 182838 Solenoid valve SY3240-5MO SMC 1
times return
20million Product side
4 182836 Solenoid valve SY9120-5MO-03 SMC 1
times vertical
20million Product side
5 210675 Solenoid valve VP542R-5G-03A SMC 1
times descent low speed
6 001877 Silencer AN110-01 SMC 2 1 year Manifold
7 Suction filter ZM-SF SMC 1 1 year Vacuum generator
8 Silencer Ass’y ZM-SA SMC 1 1 year Vacuum generator
9 Filter element AF30P-060S SMC 1 1 year Filter regulator
- 45 -
7. AIR CIRCUIT DIAGRAM
CY-600GII
CY-800GII
- 46 -
20 Taper plug with hexagon hole 1/8-8 7
19 Union Y KQ2U06-00 SMC 1
18 Speed controller AS2201F-01-06S SMC 4
17 Speed controller AS2201F-01-04S SMC 2
16 Ace ball 1/4 2
15 Check valve AKB02A-02S SMC 1
14 Vacuum pressure GZ46-K-01 SMC 1
13 Vacuum generation unit ZM101M-A5G-E15-X247 SMC 1
12 Valve for removing residual air pressure IN-289-731 (6*6) SMC 1
11 Silencer AN110-01 SMC 2
10 Valve with silencer ASN2-04 SMC 5
9 Blanking plate ass'y SY3000-26-9A SMC 1
8 Solenoid valve SY3140-5MO SMC 5
7 Solenoid valve SY3240-5MO SMC 1
6 Manifold SS5Y3-42-07-01 SMC 1
5-3 Screw M4*31 (For SY7000) SMC 2
5-2 Gasket SY7000-11-9 SMC 1
5-1 Solenoid valve SY7120-5MO-02 SMC 1
4 Three-port solenoid valve VP542R-5G-03A SMC 1
3-2 Gasket (bis) SY9000-11-3A SMC 1
3-1 Solenoid valve SY9120-5MO-03 SMC 1
2 Manifold 302384-101-0 STARTECHNO 1
1 Filter regulator AW30-03BDE SMC 1
No. Name Type Manufacturer Qty Remarks
This diagram shows a type with S side vertical unit.
CYS-600GII
CYS-800GII
- 47 -
8. GENERAL DRAWING
CY-600GII
CY-800GII
- 48 -
Dimension within ( ) indicates dimension for 600st.
Dimension within < > indicates dimension for 1000TR.
Dimension within { } indicates dimension for 1200TR.
Dimension within [ ] indicates dimension for 1600TR.
1400TR regular operation
CYS-600GII
CYS-800GII
- 49 -
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