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TMC TMC 1000E Operation Manual Download Page 105

Injection Molding Machine Chapter 5

V3.0

5-0

Chapter 5: Trouble Shooting

1. Mechanical Part…………………………. 5-1

1.1  Motor can not be started .................... 5-1
1.2  No clamp close .................................. 5-1
1.3  No clamp open................................... 5-2
1.4  No ejector forward............................. 5-2
1.5 No

ejector

retract ............................... 5-2

1.6 No

injection ....................................... 5-3

1.7 No suck back ..................................... 5-3
1.8 No

charge........................................... 5-4

1.9  No carriage advance & retract ........... 5-4
1.10  No mold thickness adjustment........... 5-5
1.11  No automatic clamping force .............. 5-5
1.12 Corepull failure.................................... 5-6
1.13 Temperature control abnormal ............ 5-6

2. Electrical part ........................................... 5-7

2.1 Warning screen description

5-7

2.2 Warning contents and maintenance

message indication...............................

5-8

2.3 System message and description ......... 5-14

3. Hydraulic part .......................................... 5-15

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Summary of Contents for TMC 1000E

Page 1: ...lding Machine Operation Manual V3 0 For System TM11 TMC Technology Corp No 726 Jieh Shou Road Sec 2 Pa Teh Taoyuan Taiwan Tel 866 3 3688127 Fax 886 3 3684959 E mail tmcinc ms29 hinet net Website Http www tmcint com ...

Page 2: ... 3 Safety labels and alarm devices 1 6 3 1 Definition of labels 1 6 3 2 Adhering position 1 6 3 3 Alarm light and buzzer 1 8 3 4 Escape when trapped in machine 1 8 4 Machine maintenance warranty 1 8 Chapter 2 Machine specifications 1 Machine specifications 2 1 2 Machine dimensions 2 4 3 Operating position 2 5 4 Safety devices layouts 2 6 5 Position of signs and labels 2 7 Chapter 3 Preparation of ...

Page 3: ... 1 1 1 Screen function selection key 4 1 1 2 Number alphabet key 4 1 1 3 Direction screen operation instruction key 4 1 1 4 Manual operation switch 4 1 2 Screen layout and operation 4 3 2 0 Main page of operation screen 4 5 2 1 Main page of operation screen 4 7 2 2 Machine monitoring screen 4 8 2 3 Clamp open close setting 4 9 2 4 Clamping parameters 4 11 2 5 Ejector setting 4 13 2 6 Ejector param...

Page 4: ...ic operation 4 56 4 3 Fully automatic operation 4 57 4 4 Emergency stop 4 57 4 5 Alarm clearance 4 57 4 6 Re start after safety interlock devices were tripped 4 58 5 Molding operation 4 58 5 1 Preparation before molding operation 4 58 5 2 Check before molding operation 4 58 5 3 Molding condition setting 4 59 5 4 Start molding 4 60 5 5 Change material or color change 4 60 5 6 Store read molding con...

Page 5: ...ection items 6 2 2 2 Monthly inspection items 6 2 2 3 Halt year inspection items 6 2 2 4 Maintenance and check chart 6 3 3 Cleaning 6 5 3 1 Screw removal installation and cleaning 6 5 3 2 Barrel removal installation and cleaning 6 6 3 3 Cooler removal installation and cleaning 6 7 3 4 Hopper window glass replacement 6 7 3 5 Filter removal installation and cleaning 6 7 3 6 Water distributor removal...

Page 6: ...on motion no motion B 1 Appendix C Robot Connection C 0 Appendix D USB file operation D 0 Chapter 8 Drawings 1 Description of major component parts and their positions installed on the machine 1 1 View from operational side 1 2 View from rear operation side 2 Appearance dimension drawing 3 Screw Barrel unit assembling drawing 4 Hydraulic circuit drawing 5 Hydraulic manifold drawing 5 1 Injection m...

Page 7: ...fe operation of machine 1 4 2 1 Operation environment 1 4 2 2 Disposal of scrap products or waste 1 4 2 3 Clamping unit 1 4 2 4 Injection unit 1 4 2 5 Hydraulic unit 1 5 2 6 Electrical unit 1 5 3 Safety labels and alarm devices 1 6 3 1 Definition of labels 1 6 3 2 Adhering position 1 6 3 3 Alarm light and buzzer 1 8 3 4 Escape when trapped in machine 1 8 4 Machine maintenance warranty 1 8 ...

Page 8: ...NANCE F2 F1 F3 F4 F5 F6 F7 F8 MENU 17 MAINTEN SUPPORT I O MAINT LIST 1 PUSH EMERGENCY BUTTON TO CHECK PUMP STOP 3 CK SAFETY DROP BAR MOVES SMOOTH 4 CK BARREL COVER IS FIXED 5 CK LUB OF MOVING PARETS ARE OK 10 CK HYD LUB OIL ARE ENOUGH NO RECYCLE OIL 7 CK COLD START PROTECT TIME AND DANGER 8 CK TEMP SET OF HYD OIL COLLAR ARE OK 9 CK IF PUMP HAS ANY NOISE 6 CK NO PARTS IS LOOSENED OR ABNORMAL 11 CK ...

Page 9: ...ghting disappears opening rear safety door or other side doors I O 103 must be OFF Close front door to have I O 101 I O109 on close rear door to have I O 103 on 1 1 3 Mold height limit switch Upon pressing the minimum mold thickness limit switch or actuate the proximity switch I O 111 must be OFF upon actuate the maximum mold thickness switch I O 112 must be OFF 1 2 Hydraulic safety device Inspect...

Page 10: ...V3 0 1 3 Mechanical safety device A Open close the front operation door and check the action of drop bar plate for smoothness B Barrel guard check barrel cover injection nozzle guard fixing screws Drop bar Barrel cover Injection nozzle guard ...

Page 11: ...horized and qualified personnel are allowed to operate the machine Prior to starting the machine please confirm all the safety guards are at normal positions After starting the machine please confirm the normal operation of the safety gate Please check if the mold is fixed tightly on the platens 2 4 Injection unit Do not touch the barrel to avoid electrical shock or get burned Do not step on the b...

Page 12: ...5 is allowed however when the temperature is below 20 please perform oil pre heat process to heat up the temperature oil temperature less than 20 will make the system very unstable When the hydraulic hose or valve is found loose please tighten them up immediately thus preventing oil leakage or other problems 2 6 Electrical unit Turn the power off before opening the control cabinet to prevent elect...

Page 13: ...Y HYDRAULIC OIL 3 CHECK IF EACH HYDRAULIC PRESSURE IS ACCURATE 4 CHECK IF THERE IS ANY ABNORMAL NOISE ON HYD SYSTEM 5 CHECK IF BOLTS AND NUTS OF TIE ROD ARE LOOSEN 6 CHECK THE COOLING SYSTEM 7 CHECK IF THE EMERGENCY STOP BUTTON FUNCTION NORMALLY 8 CHECK IF BARREL HEATING ELEMENTS AND TEMPERATURE CONTROLLER ARE NORMAL WEEKLY CHECK AND MAINTENANCE 1 REMOVE HYDRAULIC OIL FILTER FOR CLEANING 2 CHANGE ...

Page 14: ... WHEN OPENING ANY SAFETY GATE DANGER High Voltage High Temperature WARNING 1 Personnel who do not understand the machine shall not be assigned to operate the machine 2 Please check and confirm normal operation of the mechanical hydraulic electrical safety devices 3 Please confirm that when the safety door is open the mold shall not be clamped SPEC SCEW DEPTH INTO PLATEN ATTENTION MOLD FIXING SCREW...

Page 15: ...gh the sales department agents distributors of TMC one year warranty for parts is provided under normal operating conditions However the one year warranty shall not include the following conditions Machine has been modified without the written approval of TMC Machine components have been removed without the written approval of TMC Machine has been re sold without the written approval of TMC e g Th...

Page 16: ... Molding Machine Chapter 2 2 0 V3 0 Chapter 2 Machine specifications 1 Machine specifications 2 1 2 Machine dimensions 2 4 3 Operating position 2 5 4 Safety devices layouts 2 6 4 Position of signs and labels 2 7 ...

Page 17: ...LS HT kg hr x x x 17 26 30 32 45 59 41 53 76 HS LT kg hr 15 19 27 21 32 36 39 54 71 57 74 106 10 Injection rate 70kg cm2 cm3 sec 59 71 92 55 79 90 88 105 137 97 127 161 11 Screw speed torque LS HT rpm Nm 220 550 240 640 217 950 HS LT rpm Nm 350 310 275 450 288 550 303 670 12 Nozzle force kN 35 60 60 60 13 Heating input power kW 4 0 5 5 6 3 8 2 14 Barrel heating zones no 3 2 3 2 3 2 3 2 B Clamping ...

Page 18: ...0 196 237 283 242 288 338 292 336 382 11 Screw speed torque LS HT rpm Nm 233 1090 205 1760 212 2280 164 3640 HS LT rpm Nm 271 950 273 1330 265 1760 205 2650 12 Nozzle force kN 60 60 60 96 13 Heating input power kW 9 3 15 19 2 32 14 Barrel heating zones no 3 2 3 2 3 2 4 2 B Clamping Unit Code 1500 2000 2500 3500 15 Clamping force kN 1500 2000 2500 3500 16 Mold opening stroke mm 380 430 510 640 17 O...

Page 19: ...ec 352 397 496 517 573 693 779 927 1088 11 Screw speed torque LS HT rpm Nm 100 6650 111 8060 138 9580 HS LT rpm Nm 143 4550 158 5600 173 8060 12 Nozzle force kN 96 125 125 13 Heating input power kW 41 50 82 14 Barrel heating zones no 4 2 4 2 4 2 B Clamping Unit Code 5000 7500 10000 15 Clamping force kN 5000 7500 10000 16 Mold opening stroke mm 820 1000 1150 17 Open daylight mm 1720 2000 2350 18 Di...

Page 20: ...Injection Molding Machine Chapter 2 2 4 V3 0 2 Machine dimensions ...

Page 21: ...Injection Molding Machine Chapter 2 2 5 V3 0 3 Operating position ...

Page 22: ...Injection Molding Machine Chapter 2 2 6 V3 0 4 Safety devices layouts ...

Page 23: ...Injection Molding Machine Chapter 2 2 7 V3 0 5 Position of signs and labels ...

Page 24: ... Molding Machine Chapter 2 2 8 V3 0 1 Front emergency stop 3 Cycle start 2 Rear emergency stop 4 Daily check and maintenance 5 Weekly check and maintenance 6 Lifting indication 7 Danger 8 Warning 9 Safety valve ...

Page 25: ...Injection Molding Machine Chapter 2 2 9 V3 0 10 Lubrication 11 Warning 12 Danger 13 Shock Warning 14 Turn off power 15 Name plate ...

Page 26: ...g 3 6 5 Adjusting of mounting pad 3 7 6 Ventilation 3 8 7 Preparation before operation 3 9 7 1 Power supply 3 9 7 2 Cooling water 3 10 7 3 Main power water connection position 3 10 7 4 Material 3 10 7 5 Hydraulic oil lubrication oil and grease 3 11 7 6 Operating temperature and humidity 3 11 8 Pre operation checkpoints 3 12 8 1 Check before power ON 3 12 8 2 Check before motor starting 3 12 8 3 Mo...

Page 27: ...00 1000 1200 1200 1500 E60 3900 1000 1000 1150 1200 1200 1850 E90 4100 1000 1000 1250 1200 1200 1900 E120 4400 1200 1200 1300 1200 1200 1950 E150 4600 1200 1200 1350 1200 1200 2000 E200 5500 1500 1500 1400 1500 1500 2200 E250 5850 1500 1500 1500 1500 1500 2250 E350 7400 2000 2000 1800 2000 2000 2400 E500 8700 2500 2500 2000 2200 2200 2550 E750 10700 2500 2500 2150 2500 2500 2850 E1000 12000 2700 2...

Page 28: ...iner according to machine dimensions and weights E series Weight kg Dimension L W H mm 30 1500 2500 1000 1500 60 3100 3900 1150 1850 90 3800 4100 1250 1900 120 5200 4400 1300 1950 150 5800 4600 1350 2000 200 8000 5500 1400 2200 250 10000 5850 1500 2250 350 16000 7400 1800 2400 500 25000 8700 2000 2550 750 40000 10700 2150 2850 1000 60000 12000 2450 3050 3 2 Process of transportation 3 2 1 Lift too...

Page 29: ...168 M16 used in 30E 150E 3 2 2 Machine lift support position a 30E 250E Method 1 1Wire rope 2Eye bolt 3H beam machine frame 4U bolt on machine H beam 5Steel pipe D 76 3mm t 7mm be used to lift at both side 6Shackle JIS B2801 SD 12 Method 2 Put skates beneath machine bottom use 10 tons forklift to push it ...

Page 30: ...e rope 2Machine frame 3H beam machine frame 4 Steel pipe D 76 3mm t 7mm be used to lift at both side 5Movable crane 20 tons use two at the same time c 750E 1000E Machine of this model is disassembled to three main parts for shipment C1 Machine frame clamping side ...

Page 31: ...5 1Wire rope 2Machine frame 3H beam machine frame 4 Steel pipe D 76 3mm t 7mm be used to lift at both side 5Movable crane 20 tons use two at the same time C2 Machine frame injection side Lifting device and method are same as C1 C3 Clamping unit ...

Page 32: ...ure s and or agent qualified personnel 4 Leveling Machine must be leveled after installation unleveled machine has potential risks and can cause damages both to operator and machine itself a Adjust horizontal level at front side Check level on tie bars in horizontal direction by level gauge precision 0 05mm M and adjust mounting pads to have level within 0 2mm M b Adjust horizontal level at back s...

Page 33: ... checking level 2 Clean tie bars surface 3 Use auxiliary gauge when check level in front back direction 5 Adjusting of mounting pads Adjust mounting pads to have a good machine level Adjust pads height by swivel 1 and fix it by tightening 2 Different mounting pads may have different structure refer to manufacture s instruction manual ...

Page 34: ...g Machine Chapter 3 V3 0 3 8 6 Ventilation If ventilation is necessary when processing some specific plastic resin according to resin supplier recommendation suggestion on ventilation apparatus position is shown below ...

Page 35: ...m to the specification as shown in the table below C Confirm that the voltage conforms to the operation voltage of the machine D N G must be connected independently Caution E Size of N G should be at least half size of R S T same size is preferred Model Motor kW Heating kW Breaker NFB Wire section area mm2 60E 11 2 5 5 75A 50A 20 14 90E 15 6 3 75A 50A 20 14 120E 18 75 8 2 100A 60A 30 14 150E 22 5 ...

Page 36: ...ns are shown in the photos below Model 60E 90E 120E 150E 200E 250E 350E 500E 750E 1000E Pipe Diameter 3 4 1 1 1 4 Water volume 40L min 60L min 70L min 80L min 120L min 7 3 Main power water connection position 7 4 Material The standard barrel unit of this machine is B type general screw which can produce most of the plastic materials However material with glass fiber rigid PVC Nylon PC etc special ...

Page 37: ...chine will stop Specification of oil product Hydraulic oil viscosity 46 68cSt 40 anti wear oil shall be used such as SHELL TELLUS S46 68 Recommends use viscosity 46 for cold temperature 68 for tropical temperature climate Grease common grease No 0 or 1 shall be accepted Lubrication oil viscosity 150 220cSt 40 high pressure resist gear oil shall be used such as SHELL OMALA 150 7 6 Operating tempera...

Page 38: ...l cabinet to the ON position B Power for the main control cabinet shall be turned on in the same manner 60E 250Emodel has only one control cabinet 8 2 Check before motor starting Check the hydraulic oil in the oil tank Check the cooling water pipe for proper connection and water supply Check the hydraulic pipes for being tightened up without any damage After the checkpoints mentioned above are con...

Page 39: ...FILTER 3 CK AND CLEAN OIL COOLER 4 CK NO MOVING PARTS ARE LOOSENED 5 CK AND CLEAN ELECTRIC CABINET 6 TIGHT ALL WIRING TERMALS 8 TEST PRESS AND SPEED LINEARILITY 7 CLEAN AND ADJUST ALL 9 CLEAN WASTE OIL HALF YEARLY CHECK AND MAINTENANCE 1 CK PALTEN S PARALLELISM 2 CHANGE HYD SYSTEM OIL 3 CK SCREW BARREL FUNCTION WELL 4 MACHINE LEVELING ADJUST MONTHLY CHECK MAINTENANCE LOG MOLD EXTERN TEMP SET OK TH...

Page 40: ...IS Locating ring φP EURO Nozzle radius Rm 60E 190 190 100 320 320 320 500 500 100 125 R15 90E 220 220 150 360 400 400 590 590 100 125 R15 120E 240 240 150 425 425 425 640 640 100 125 R15 150E 250 250 150 500 460 460 670 670 100 125 R15 200E 280 280 200 550 510 510 760 760 150 160 R15 250E 320 320 200 600 580 580 850 850 150 160 R15 350E 380 380 300 750 710 710 1050 1050 150 160 R15 500E 450 450 35...

Page 41: ...5 4 Start molding 4 60 2 5 Ejector setting 4 13 5 5 Change material or color change 4 60 2 6 Ejector parameters 4 15 5 6 Store read molding condition by memory card 4 60 2 7 Corepull setting 4 17 2 8 Core parameters 4 19 6 Machine shutdown procedures 4 61 2 9 Injection setting 4 20 2 10 Injection parameters 4 22 2 11 Injection closed loop control 4 24 2 12 Charge Carriage setting 4 26 2 13 Charge ...

Page 42: ...t on MEMORY screen 1 3 Direction Help key To provide the function for cursor moving direction the HELP key in the center is operation description key press once to display operation description on the current screen press again to return to the original operation screen 1 4 Manual switch Prior to operation of manual movement corresponding function must be selected in the function setting screen ot...

Page 43: ...Injection Molding Machine Chapter 4 V3 0 4 2 SCREEN DISPLAY AREA FUNCTION KEY HOT KEY MOTOR ON OFF HEATER ON OFF ALARM RESET EMERGENCY STOP MANUAL KEYS MOTION KEY USA ONLY CYCLE START DATA LOCK ...

Page 44: ...N SUCKBACK CARRIAGE FORWARD CARRIAGE BACKWARD AIR BLAST 2 AIR BLAST 2 CHARGE LUBRICATION LOCK PIN IN LOCK PIN OUT GATE OPEN GATE CLOSE b Mold key yellow background MANUAL MODE PUMP ON OFF SEMI AUTO MODE HETER ON OFF FULL AUTO MODE ALARM ACKNOLEDGE c Page access key white background CLAMP SETUP EJECTION SETUP CORE SETUP INJECTION SETUP CHARGE SETUP TEMPERATURE SETUP DATA STORAGE SPC DATA d Function...

Page 45: ...Injection Molding Machine Chapter 4 V3 0 4 3 2 Screen layout and operation When the power is on TMC logo screen shown up as follows Screen 4 1 ...

Page 46: ...SE PIPE IS LOOSENED LEAKING 12 CK NO AIR IS BLENDED INTO HYD SYSTEM 13 CK ALL GROUDINGS ARE CONNECTED OK 14 CK MOLD CLAMP ARE TIGHT 15 CK MOLD PROTECTION DEVICE IS OK 2 CK NO LEAKING IN HYD SYSTEM 1 CK AND CLEAN HYD FILTER 3 CK AND CLEAN OIL COOLER 4 CK NO MOVING PARTS ARE LOOSENED 5 CK AND CLEAN ELECTRIC CABINET 6 TIGHT ALL WIRING TERMALS 8 TEST PRESS AND SPEED LINEARILITY 7 CLEAN AND ADJUST ALL ...

Page 47: ...0 SUCK B B V2 P2 0 0 A11 0 0 A10 0 0 A13 0 0 A12 A ACTION STATUS 03D05M07Y INJ PRESS ACTUAL Screen4 3 2 0 1 Machine status area black characters with white background Ａ１ It is an icon of present screen Ａ２ 03D05M07Y This position displays the date where D day M month Y year 03D05M07Y means 03 MAY 2007 Ａ３ 10h 25m 10s This position displays the time where h stands for hour m stands for minute s stand...

Page 48: ...ond set proportional pressure valve On the left side is the command number on the right side is the command value 2 0 2 Parameters setting area Ｂ Operator screen is with GREEN background while engineering screen is with BLUE background ITEM FORWORDGROUND BACKGROUND SPEED BLACK BLUE POSITION RED GREY PRESSURE RED LIGHT BLUE TIME BLACK FUNCTION DARK BLUE ACTUAL VALUE WHITE READ ONLY Use key to enter...

Page 49: ... allowed 10h25m10s 20 C CHARGE TEMPERATURE MEMORY MACHINE MONITOR SPC CLAMPING EJECTION INJECTION CORE PASSWORD 1 MAIN MENU 100 0mm 50 0mm TEMPERATURE PAR BACK PRESS GRAPH EXTERNAL I O CHANGE LOG ALARM LOG MAINTENANCE INJ GRAPH MOULD ADJ AUTO PURGE CHARGE PAR MOULD SUPPORT FUNCTION PROD MANAGEMENT CLAMPING PAR EJECTION PAR CORE PAR INJECTION PAR ACTION STATUS PASSWORD 1 M 1 0mm PASSWORD 2 110 0mm ...

Page 50: ...COUNT 000 0 000 0 000 0 000 0 000 0 000 0 COOLING T CHARGE END PT INJ END PT 000 0 000 0 000 0 000 0 000 0 SET CURR 10 0 PRE 000 0 000 0 000 0 000 0 000 0 000 0 000 0 000 0 000 0 000 0 INJ PRESS 0bar 140bar CLAMP P FORCE 250 Ton 210 GOOD PARTS 123456 INJ START PT 000 0 000 0 PROD INJ CHANGE MOLD EXTERN MAIN PRE CURR SET A C B D E CURVE Screen 4 5 Ａ It represents the transducer of clamp The left tr...

Page 51: ... MOLD EXTERN MAIN A B C D E F G H I K J ACTION STATUS Screen 4 6 V Speed setting in percentage 0 100 PT mm Position setting uses the on the panel to input decimal point P bar Pressure setting Ａ OPEN END Clamp open end position Ｂ If the contact force of male and female mold halves is too strong increase switching position set value of rapid to low speed for earlier speed slow down Ｃ Setting of clam...

Page 52: ...Ａ actual time Ｊ ROBOT SIGNAL PT T When the mold is opened to the set position or greater than mold open end set position computer will output a signal I O 196 to robot interface to trigger picking up of the finished parts The second set point is robot signal check timer robot must give a signal to allow mold close within interval time or robot signal check time Case 1 Interval timer robot signal t...

Page 53: ...OFF INTERVAL T COUNT OFF CHARGE ON FLY CLOSE RELEASE OFF OPEN CLOSE 2 2 SECTION SECTION RAMP DECOMPRESS PT 50 0 300 0 HR mm mm P V CHANGE MOLD EXTERN MAIN E H G B A D C F I J K M L N GREASE LUB T 1hr Screen 4 7 Ａ CLAMP DECOMPRESS After screw charge the mold open to DECOMPRESS PT position and stop waiting for the completion of cooling then open again to open end position Ｂ DECOMPRESS PT Clamp pre o...

Page 54: ...ened to this position ejector sequences start Ｊ LUBRICATION T It s the lubrication time for each lubrication process Please refer to Table 4 1 Ｋ LUB COUNT Total mold close cycle that to initiate lubrication process Ｌ CLOSE SECTION Mold close sections Ｍ OPEN SECTION Mold open sections Ｎ Reserved function Time The 1st week The 2nd week The 2nd month The 2nd year Model LUB TIME LUB COUNT LUB TIME LUB...

Page 55: ...ncrease finished parts reproducibility mold structures has to be suitable for compression sequences Set Ａ OFF Ｂ position to 0 0 when it is not used Ａ INJ END MOLD COMPRESS when set ON compression sequences start at transfer position mold lock pressure increases according to setup point hence clamping force also increases to compress molded parts Ｂ COMPRESS START INJ PT compression sequences start ...

Page 56: ...JECT RET MID PT 60 0 CHANGE MOLD EXTERN PROD MANAG C B A F 30 RET 1 50 10 0 0 2 DELAY COUNT 0 2 0 3 4 3 ROBOT CYCLE TIME G 60 0 D E Screen 4 8 Ａ EJECT FUNCTION Set on to run ejector process Ｂ EJECT SHAKING To run ejector shaking sequences set EJECT RET MID PT a little smaller than FWD END position ejector will move forward to FWD END and then move backward to EJECT RET MID PT until EJECT COUNT is ...

Page 57: ...to be used when machine runs with robot delay some time to let robot move into mold area to catch parts Forward delay time is only used for one time while backward delay is used in every backward movement Ｆ EJECT RET MID PT It is the retracted position for ejector forward 2 sequences ejector advances to forward position 2 then ejector retracts to EJECT RET MID PT 3 ejector advances to the FWD END ...

Page 58: ... 100 000 0 mm 0 0 0 0 0 0 0 00 OFF P1 0 00 P2 0 0 V1 V2 03D05M07Y ACTION STATUS M 0 2mm Screen 4 9 Ａ ALARM OFF EJECT When set on ejector doesn t move forward when alarm occurred to prevent mixing good parts and bad parts Ｂ POSITION when the mold is opened to this set position air blast blowing delay time will start timing upon completion of timing blow operation takes action Ｃ DELAY air blast dela...

Page 59: ...re Ｉ IN MOLD CUT When set on after charge IN MOLD CUT DELAY starts timing when time s up ejector advances to ejector advance position 1 then retracts to RET END position then do charging cooling mold open Ｊ IN MOLD CUT DELAY delay time after injection for ejector advance Ｋ CUT EJ BACK DELAY delay time for ejector retracts Remark this function MUST work with special designed mold ...

Page 60: ...m 140 000 0 000 0 332 100 250 0 100 IN OUT 0 0 0 0 0 0 CORE 3 OFF P1 P2 0 0 V1 V2 ACTION STATUS M OPN_E EJ_F CLO_E POSIT OPN_E CLO_E Screen 4 10 Ａ CORE MODE 1 OPN E Clamp open end Core in Clamp close Injection Clamp open end Core out 2 POSIT Core in and out at specified clamp position 3 CLS E Clamp close to end Core in Injection Core out Clamp open 4 EJ_F Clamp open end Ejector forward Core out Co...

Page 61: ...the user has to install limit switch at the corresponding I O point Take off bridges on terminal board 2 7 1 All timer counter limit switch must be made to complete core process When only limit switch is used the timer and counter shall be set to 0 When limit switch is not used I O 131 132 133 134 331 332 and C must be short circuited 2 7 2 Unscrewing If core is used as unscrewing COUNT value take...

Page 62: ... 100 0mm OFF OFF OFF 1 0mm 110 0mm 0 0 0 0 0 0 P1 P2 0 0 V1 V2 03D05M07Y ACTION STATUS M Screen 3 11 Ａ CORE ON FLY When set on core sequence is performed while mold is still opening Option feature Ｂ CORE PRESS HOLDING Energizes core valve during injection to prevent core is pushed out by cavity pressure Core 1 in pressure and speed settings are used as holding commands in E 2 model 2008 09 22 chan...

Page 63: ...0 60 0 140 140 80 0 7 8 50 60 70 6 1 0mm 90 80 5 4 100 3 2 110 0mm 9 9 0 6 000 105 0 100 0 140 10 0 0 0 0 0 SUCK B 0 0 CH END 1 15 P1 P2 0 0 V1 V2 ACTION STATUS M Screen 4 12 2 9 1 Three major stage of injection V P V Injection speed control 1 INJ SPEED SECTION can be set on the INJECTION PAR screen 2 It is recommended to set low speed to 10 20 3 0 10 0 mm before P V TRANS POINT position 3 It is r...

Page 64: ...eal P V TRANS POINT P Holding pressure control 1 Pressure holding V is usually set at 10 20 and shall not set to 0 2 Set the pressure holding TIME to 0 can reduce the sections of holding pressure Or the holding pressure sections required can be directly set on the INJECTION PAR screen 3 To reduce the INJ HOLD PRESS SECTION according to the solidification process of the product thus reducing the st...

Page 65: ...IGNAL GAS ON DELAY T OFF 0 0 20 0 40 0 OFF 5 0 0 0 0 0 0 0 OFF OFF 0 0 G4 G G6 G5 SCREW DIA RESIN DENSITY UNIT WEIGHT GAS ON T G2 G3 G1 ACTION STATUS OFF OFF M F 1 0mm 210 0mm 0 00 mm 00 OFF 45 mm 12 0 mm 1 00 60 g 10 0 0 0 0 0 0 0 0 0 OFF 100 0 10 0 P1 mm 0 0 P2 0 0 V1 V2 03D05M07Y Screen 4 13 Ａ CUSHION MONITOR When set on injection end position must be in between low and high limit position if n...

Page 66: ...run gas assist injection sequences HOLDING INJECTION GAS ASSIST SIGNAL mm GAS ON DELAY T GAS ON T I O 54 ON Ｇ PARAMETER AUTO SET function key in A SCREW DIA and some other data of G1 G6 then move cursor to PARAMETER AUTO SET and set on computer will automatically set charge end position CH END and P V TRANS POINT Ｈ INJ SPEED SECTION set desired steps for injection phase Ｉ INJ HOLD PRESS SECTION se...

Page 67: ...10 10 50 0 10 10 6 5mm Screen 4 14 1 It is an optional device by means of a pressure transducer on the injection cylinder the actual pressure of the cylinder can be measured through the high speed closed loop control inside the control computer makes the molding process more accurate 2 CPM CPP CPI and CPD are closed loop control parameters which have been adjusted precisely before factory delivery...

Page 68: ...g pressure will be immediate feedback to perform closed loop control Ｃ Y coordinate on the left is the pressure Ｄ Y coordinate on the right is the speed Ｅ X coordinate is the time or position To the left X coordinate is time to the right X coordinate is position when X TIME is on the X coordinate is changed to time scale Ｆ X TIME When set on unit of x axis is changed to time scale ...

Page 69: ...10 0 50 0 0 0 0 0 0 SUCK B 40 P1 SUCK BACK P2 0 0 V1 V2 ACTION STATUS M Screen 4 15 V Speed setting in percentage 0 100 PT mm Position setting uses the on the panel to input decimal point P bar Charge pressure setting value Screw rotation pressure BP bar Charge backpressure setting valve Digital back pressure model 2 12 1 Charge setting Ａ INJ END It is the read value of injection end position whic...

Page 70: ... 0 and suck back setting at 3 0 the final position shall be at 53 0 If suck back before charge function is on screw will suck back at the setting distance before charge starts 2 12 3 Carriage setting Ｆ Speed 1 to speed 2 low speed position is usually set to the position of 20 0 50 0 before nozzle contacts with the mold Ｇ Carriage forward stop position F W END is usually set to the position plus 1 ...

Page 71: ...ECTION L K ACTION STATUS M OFF OFF 1 0mm SUCK BACK T I J 110 0mm 2 0 3 0 0 0 0 0 0 0 0 10 0 15 0 P1 0 0 0 0 P2 0 0 V1 V2 Screen 4 16 Ａ CHARGE MOVEMENT Set on to activate automatic carriage retract after charge and advance before injection during auto cycle Ｂ CHARGE ONE TOUCH Press the charge key once charge operates continuously Press again to stop charge Ｃ INTRUSION Refer to page 4 22 Ｄ INTRUSION...

Page 72: ...e movement monitor time When this time is up carriage movement stops no matter what carriage position is Ｋ CARRIAGE HOLD T The time for carriage been pressurized to hit against the mold before injection it is usually set at 0 5 1 0 second Ｌ CHARGE SECTION Charge steps setting ...

Page 73: ... OFF DANGER HEATER CUT OFF COLD START T min A B 1 0mm 10 0 400 10 0 110 0mm HYD OIL 45 45 OK OFF 0 0 0 0 0 0 P1 P2 0 0 V1 V2 ACTION STATUS M Screen 4 17 Ａ DANGER HEATER CUT OFF Usually set to maximum temperature 50 Ｂ COLD START T min Each time the heater is on after read temperature in every zones reaches to the set temperature within 5 cold start protection timer starts counting screw is only all...

Page 74: ... 18 Ａ ALARM OFF HEATER If this function is on in auto mode when the machine stop because of alarm Unless the alarm is resolved the heater will be shut off when unattended time is up Ｂ NOZZLE TEMP KEEP When set on temperature setting unit in H1 is changed to 100 or greater means H1 is always on 20 means heater is on for 20 heating cycle heater is off for 80 heating cycle Ｃ ON T OFF T Heater automat...

Page 75: ...Injection Molding Machine Chapter 4 V3 0 4 32 starts running to cool down barrel ...

Page 76: ...E DOWN A GATE COPY FROM 0 TO 0 TARGET 0 SAVE LOAD COPY B C D Screen 4 19 Ａ NO 1 100 are stored in internal memory on CPU board 101 200 are stored in memory card USB disk New USB file operations refer to Appendix D F4 CURSOR MODE Upon on cursor can be moved for input of mold name with letter key Upon OFF cursor can be moved to MOULD NO then press ENTER F5 MOULD SAVE Writing data into mould memory c...

Page 77: ...0 10 0 10 0 M D 0 0000 S D 0 0000 MAX 10 0 MIN 10 0 AVG 10 0 20 0 0 0 0 0 0 LAST MOULD STATISTICS 0 SAMPLE 1 C P1 P2 0 0 V1 V2 SPC Screen 4 20 Ａ Press to change items continuously check the selected sampling items at the message area press ENTER Sampling items 0 Injection front position 10 Charging time 20 H3 temperature 1 Injection time 11 Suck back stop position 21 H4 temperature 2 Injection 1 2...

Page 78: ... the band scale from 1 to 200 for easy reading F6 Press F6 can update curve display F4 Press F4 can clear the DATA on screen F3 Next page it is the statistics for main items 10h25m10s 20 C 03D05M07Y F2 F1 MENU 01 PAGE UP TEMP 5 TEMP 6 CYCLE T TEMP 3 TEMP 4 TEMP 1 TEMP 2 INJ START CHARGE T INJ P INJ T INJ END SAMPLE X 3W CLEAR F3 F4 DATA F5 F6 F7 F8 100 0mm 100 0mm MIN S D M D 1 0mm MAX 110 0mm 0 0...

Page 79: ...HI 1 ENG 2 OTR 0 0 C 1 F 0 0 Bar 1 PSI V1 0 0 0 V2 50 50 OFF 0 0 0 0 V1 V2 1 0 0 5 P1 0 0 P2 0 0 0 OFF 2 USB SUM_CHECK L_PASS S V RAM EEPROM 20070213 MT07021201 O O O 7611 318 318 V1 41 TMNOF04 20 2007 V1 00 TM11 US M98 SYS M98 TM11 PLC OS 04 30 2007 04 30 2007 V1 00 M98 TM11 SCREEN OS SYSTEM TYPE M98_TM11 26D 12M 07Y Screen 4 22 Ａ TEST P1 At TEST P1 key in testing pressure value at V1 the value i...

Page 80: ... different machines for identification when several machines issue alarms at the same time Ｈ COUNT RESET If it is set on the number of preset total and lot count would be reset on the PROD MANAGEMENT Ｉ BUZZER DISABLED Disable alarm buzzer when alarm is active but keep the alarm light flashing Ｊ SCREEN PRINT Set on in order to print present screen to usb disk in BMP format Ｋ SPC PRINT Set on in ord...

Page 81: ...150 10 10 10 1 999999 10000 10000 200 2 0 0 0 20 0 20 0 01M 21D 10h 00m 1000 01M 21D 09h 00m 01M 20D 10h 10m PROD END A B C D MODIFY DATE 2007 12 21 MODIFY ESTIMATE PRODUCT END T 0 E Screen 4 23 Ａ BAD PARTS When cushion monitor function is on and the continuous defective parts judged by cushion monitor is over BAD PARTS setting alarm is fired Ｂ PRESET TOTAL When total production parts counter is r...

Page 82: ... DO AUTO TONNAGE AFTER AUTO DIE HEIGHT AND MOLD FIT ON 3 MOLD SUPPORT DIE HEIGH 8 Screen 4 24 Ａ DIE HEIGHT ADJ Before adjust die height die height adjustment function has to be turn ON Ｂ DIE HEIGHT ADJ PRESS Die height adjusting pressure shall not be set higher than 50bar Ｃ DIE HEIGHT ADJ SPEED Die height adjusting speed shall not be set higher than10 Ｄ Make sure that there is no mold on the machi...

Page 83: ... HEIGHT ADJ function will be reset to off NOTES ON MOLD SETUP MODE in USA model USA machines ranging from 60E to 250E top guard with limit switch is fitted over mould area mould setup mode is activated by following conditions 1 When fitting mold if rear operator gate is opened pump will be shut off and alarm be fired by opening front operator gate can disable buzzer sound temporarily but alarm con...

Page 84: ...mm 0 0 0 0 0 0 P1 P2 0 0 V1 V2 ACTION STATUS M Screen 4 25 In the end of production or the operator wants to change material this function can be used to automatic purge residual material from screw barrel Ａ Set proper pressure and speed settings Ｂ PURGE ON OFF Set purge ON OFF switch to on press F3 purge processes start Ｃ Upon completion of all procedures machine will stop automatically and purge...

Page 85: ...03 109 110 111 1 0mm 113 121 122 131 110 0mm 196 385 183 184 187 188 0 0 0 0 137 0 0 133 134 P1 135 136 P2 0 0 V1 V2 ACTION STATUS M 201 202 251 252 253 254 255 261 266 267 271 272 291 292 293 294 295 297 236 235 234 233 232 231 222 221 214 213 212 211 204 203 301 302 303 304 305 306 307 308 311 312 313 314 315 316 331 332 351 352 353 354 355 356 358 359 362 363 364 365 386 389 011 012 013 014 015...

Page 86: ...017 018 016 R TYPE PANNEL EXTERN OUT T C INTER DIAGNO PROD CORE 5 IN CORE 5 OUT Screen 4 27 Pressing F2 key to display output definitions page as follows V1 0 0 0 0 V2 0 0 P1 0 0 P2 100 0mm 100 0mm 110 0mm 1 0mm ACTION STATUS M 29D08M07Y 10h25m10s 20 C 3W F2 F1 F3 F4 F5 F6 F7 F8 MENU 01 MONITOR STIC OUT FUNCTION MANAG I O MONITOR I O OUT1 1 OUT1 2 OUT2 1 OUT2 2 CORE 3 OUT CORE 3 IN GATES CLOSED CL...

Page 87: ...ore 2 out limit switch 184 Core 2 out 135 Motor contactor monitor 187 Air blast valve on stationary platen 136 Robot enable core action 188 Air blast valve on moving platen 137 R type panel 196 Robot start signal I O board 2 201 Injection front safety gate limit switch 251 Motor 1 205 Injection rear safety gate limit switch 252 Pump1 relief valve 209 Drop bar switch 253 Pump 2 relief valve 210 Noz...

Page 88: ...ate close stop 362 Pneumatic power gate close 313 Pneumatic power gate open stop 363 Pneumatic power gate open 314 Pneumatic power close low speed 364 Pneumatic power gate close low speed 315 Pneumatic power gate open low speed 365 Pneumatic power gate open low speed 316 Reserved 385 Core 3 in 331 Core 3 in limit 386 Core 3 out 332 Core 3 out limit 389 Air blast valve 3 Remarks Some of IO may be r...

Page 89: ...there is no existing information in the changing log memory therefore some contents might have random data This is a normal condition Later on when the change information is recorded one by one the random data will be overwritten automatically 2 Log data has 5 pages totally latest change records are stored on page 1 with the biggest serial number 3 Press F8 can clear recorded data and password 3 h...

Page 90: ...G or use direction key to move the cursor on main menu screen to ALARM LOG press ENTER to display this screen Screen 4 30 1 Log data has 4 pages with 60 data totally the latest alarm is stored on page 1 with the biggest serial number 2 Press F8 can clear recorded data and password 3 has to be entered ...

Page 91: ...in menu screen to MAINTENANCE press ENTER to display this screen Prior to operation of the machine user must check every item thus ensuring safety of personnel and machine operation V1 0 0 0 0 V2 0 0 P1 0 0 P2 100 0mm 100 0mm 110 0mm 1 0mm ACTION STATUS M 29D07M07Y 10h250m10s 20 C 3W DAILY CHECK MAINTENANCE F2 F1 F3 F4 F5 F6 F7 F8 MENU 17 MAINTEN SUPPORT I O MAINT LIST MONTHLY CHECK MAINTENANCE LO...

Page 92: ... F8 EXTERN I O 00 00 00 00 00 00 100 0mm 50 0mm 01 21 02 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 03 21 02 04 21 02 2 M 3 ACTION STATUS 1 0mm 02 21 02 4 ...

Page 93: ...G MANAG PROD F7 F8 FUNCTION 100 0mm 100 0mm PRESET CUSHION PRESET SUCK BACK HOLDING VOLUME TRANSFER POSITION 80 0 mm 4 250 0 mm 150 TON 150 mm AUTO SET PARTS WEIGHT MATERIAL 2004 08 10 ACTION STATUS DATE MODIFY M 14 20 30 SCREW DIM RESIN DENSITY 1 0mm 110 0mm 5 5 10 OFF 10 0 mm 200 g 2 5 mm 0 0 0 0 0 0 1 10 45 0 mm P1 P2 0 0 V1 V2 29D08M07Y Screen 4 33 This screen can assist the operator in settin...

Page 94: ...CORD SCREEN RECEIVE PLC RECEIVE SCREEN T RING MAX PLC T RING MAX OK 0 000 OK 512 18 OK 512 14 OK 0 000 OK 0 000 15 210 0 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 21717 1000 UP DOWN CVDW MO OSTIC PV 2 BOARD I O 2 BOARD HOUR NAL I O LOOP BLOCK MONITOR EXT I O 100 0 HOUR AUTO RUN METER T C INTER DIAGN 01 02 03 04 07 09 08 06 05 12 14 13 11 10 17 18 16 15 19 22 24 23 20 ...

Page 95: ...104 121 138 155 172 096 095 094 093 098 097 080 079 081 078 077 076 114 115 113 112 111 110 092 091 090 089 088 073 075 074 072 071 107 109 108 106 105 161 178 131 132 130 148 149 147 128 129 127 145 146 144 165 166 164 182 183 181 162 163 179 180 124 141 125 126 142 143 123 122 140 139 158 175 159 160 176 177 157 156 174 173 ACTION STATUS 085 086 069 068 M 103 102 1 0mm 120 119 137 136 154 153 17...

Page 96: ... 0 0 0 0 0 0 1 0 0 0 0 2 2 0 5 0 0 2 20 0 2 0 2 0 5 0 0 0 0 1 100 0 0 0 0 0 5 0 0 0 0 5 1 0 3 0 60 0 0 0 0 1 2 0 0 0 0 0 0 1 0 0 0 0 0 0 1 0 20 0 0 1 5 0 1 0 0 0 2 0 0 1 2 0 900 0 0 0 0 1 10 0 0 0 0 0 10 0 10 0 0 1 1 0 1 0 0 0 0 1 2 0 2 0 0 0 0 1 0 1 9999 0 0 0 0 0 0 1 0 0 0 1 1 0 0 2 2 0 0 1 10 0 0 0 200 0 0 0 0 1 2 0 0 0 0 0 0 1 0 0 0 5 0 1 5 0 0 5 0 1 0 1 0 0 0 0 0 2 0 1 10 0 2 0 0 0 0 1 2 3 4 ...

Page 97: ...6D 12M 01Y 17H 25M 00S 3W SPC PRINT SYSTEM S N SHIPPING DATE USER S ROM V PLC S ROM V SCREEN ROM V SYSTEM TYPE MACHINE No PRESSURE 0 5 10 0 FUNCT TEST CHANGE INTER NAL I O EXTERN NAL I O SHOT CNT RST HYD OIL HEAT SHOT CNT 1234 OFF TEMP REC TIME TEMP REC MODE OFF 20 BUZZER DISABLED OFF A TM11 US M98 SYS V1 41 TMNOF04 20 2007 04 19 2007 M98TM11 MT07021201 M98 TM11 2007 02 13 WR07102 PLC OS V1 00 S20...

Page 98: ...rt up Check all safety related items are ok according to maintenance screen P1 1 then release emergency push buttons turn on main power turn on heater power turn on pump motor power wait until temperature conditions are OK 4 1 Manual operation Clamp close Carriage Advance Injection Charge Suck back Carriage Retract Clamp open Ejector adv Ejector ret Ａ Press manual key to switch to manual mode clos...

Page 99: ...arge screen set CHA END position to 0 Refer to following figure Ｃ On charge screen set SUCK B position properly Refer to following figure Ｄ Press semi auto key Ｅ Close front operator gate press and manual clamp close key One Touch Ｆ Upon end of cycle open front operator gate then close it again and press and release manual clamp close key again One Touch machine will perform next cycle PTmm Pbar V...

Page 100: ...aged CAUTION When manual key is pressed auto operation will be stopped immediately and the machine is switched to manual mode CAUTION During clamp close operation opening safety gate will stop clamping close operation immediately 4 4 Emergency stop One emergency stop push button is located on operation panel and the other one is located at the rear operation side pressing any one can shut off moto...

Page 101: ...mi auto operation and auto operation molding operation can be performed 5 1 Preparation before molding operation After dry running before molding operation confirm the following items again Clamp open operation has been completed machine stays at clamp open stop position Charge operation has been completed Clamp open stroke is sufficient for taking out falling the product Charge stroke has met req...

Page 102: ...tic material into the mold usually low speed is required before holding transfer point then adjustment is depended on molding condition Ｄ Injection monitor time refer to page 4 204 of chapter 4 for setup It s the time required for the screw advances from starting position of injection to holding transfer position usually injection monitor time must be set longer than the actual injection time fail...

Page 103: ...mmended values shown in table below retract carriage to proper position ＢPress F3 barrel purge function to start this function CAUTION Please confirm once again that sufficient plastic material has been available in the hopper and material type is correct CAUTION Please confirm that operation mode is manual otherwise no actuation can be made Item Suck back time Charge time Delay time Injection tim...

Page 104: ...e retract key to retreat the carriage to retract nozzle away from the mold Ｆ Press charge key machine starts charging continuously until screw retracted to set position Ｇ Press injection key to purge out residual material from barrel Ｈ Repeat procedures F G until charge operation can not retract screw to set position then press charge key machine stops charge operation Ｉ Turn off the heater and mo...

Page 105: ...ct 5 2 1 6 No injection 5 3 1 7 No suck back 5 3 1 8 No charge 5 4 1 9 No carriage advance retract 5 4 1 10 No mold thickness adjustment 5 5 1 11 No automatic clamping force 5 5 1 12 Corepull failure 5 6 1 13 Temperature control abnormal 5 6 2 Electrical part 5 7 2 1 Warning screen description 5 7 2 2 Warning contents and maintenance message indication 5 8 2 3 System message and description 5 14 3...

Page 106: ... B Robot enable clamp close signal isn t on C I O W 6A fuse blown out D In manual mode core in not completed E Corepull operation not completed F Ejector retract not completed G Directional valve stuck H Directional valve signal wire failure I Decompression circuit failure J Clamp close pressure too low K Clamp close back pressure time too short A Check I O 101 103 109 110 must be on B Check robot...

Page 107: ...d I Increase speed setting J Increase pressure setting 1 4 Ejector advance failure A Clamp not fully opened B Eject pressure speed not being set properly C Eject has reached to set position D Mold stuck ejector plate can not move advance E Directional valve stuck F Directional valve signal wire failure G Ejector plate hole position not conform to the mold A Open clamp again or adjust clamp open st...

Page 108: ...in barrel A Check temperature setting page B Adjust parameter setting C Replace fuse D Adjust parameter setting E Check clamp close and carriage in operation F Clean L17 C16 V17 G Clean and repair R6 H Clean direction valveV11 V17 manually press SPOOL I Repair signal wire261 0 267 0 J Adjust injection parameter K Adjust temperature parameter L Repair injection cylinder M Remove nozzle or screw and...

Page 109: ...M Hydraulic motor torque insufficient N Quill damaged A Check temperature setting page B Adjust parameter setting C Check temperature control system D Adjust parameter setting E Revise function setting F Lower down back pressure setting G Check hopper barrel feeding port H Remove barrel for cleaning I Clean barrel J Replace screw tip assembly K Clean and repairV16 V16 1 L Repair signal wire 266 0 ...

Page 110: ...irectional valve stuck L Directional valve signal wire failure A Unload mold first B Release locking screw C Check mold adjusting braking device D Check and repair LS28 LS29 E Add grease for lubrication F Check distance circuit of proximity switch G Correct settings H Correct settings I Clear foreign matters J Tighten up K Clean V28 V29 manually press spool L Check and repair signal wires 178 0 17...

Page 111: ...hin 5 degree when starting machine first time D Heater band failure E Heater contactor M4 damaged F Temperature in control box indicates 17 degrees G Temperature unstable H Temperature board TMP LED light not flicker I Temperature keeping function is on J LO temperature too low K HI temperature too high L ABN heating circuit failure M DIS thermocouple broken N INV thermocouple polarity wrongly con...

Page 112: ... area If no action is taken for a period of time alarm screen will be displayed automatically The operator shall perform trouble shooting in accordance with the descriptions on the alarm page After remedy is made open and close front operation gate once or press button to reset alarm If button is pressed before malfunction is solved alarm sound can be stopped however alarm is not cleared and the m...

Page 113: ...sition set value 02 Lubrication oil shortage Please check lub oil input no 213 214 1 M S A I O 213 ON IO214 OFF 2 T C 361 I O 214 OFF when lubrication over 1 Open safety gate 2 Check lubrication oil level 3 Check lubrication piping and pressure switch 04 Cycle time over Please check full cycle status S A T C 321 exceeded 1 Open safety gate 2 Adjust T C 321set value 3 Check actual operation status ...

Page 114: ...sf press over Please check inj page S A Upon pressure holding switch pressure exceeded setting value 1 Check transfer point settings 2 Check mold and nozzle for blockage 12 Hyd oil temperature fault Please check temperature page M S A Oil temperature exceed high and low limit 1 Check oil temperature high and low setting value 2 Check cold water for availability 13 Hyd oil level low Please check hy...

Page 115: ...ck clamp setting S A T C 325 clamp open monitor time over 1 Open safety gate 2 Adjust T C 325 set value 3 Check clamp open close mechanism and hydraulic circuit 25 Core in out position abnormal Please check core position setting M manual corepull performed not in core in core out position S A during corepull operation T C 321 full cycle time over M S A eject operation performed not in corepull out...

Page 116: ...p open close position is not at end position before barrel cleaning 1 Open safety door 2 Clamp must be open before cleaning barrel 31 Purge cover be open Please check purge cover input no 210 M S A I O 210 OFF 1 Open safety gate 2 Close nozzle cover 3 Check limit switch 32 Parts not pass confirmation Please check parts input no 122 S A When T C 326 starts time counting I O 122 OFF 1 Open safety ga...

Page 117: ...actual condition 38 Auto mold adjustment finished M Auto mold adjustment completed 1 Open safety gate 39 Emergency circuit is opened Check emergency circuit M S A front or rear emergency stop button is pressed or side gate on clamp side or rear operation gate is opened 1 Open safety gate 2 Release emergency stop button 3 Close side door e g rear operation gate 41 Motor Ì not confirm IO 231 IO 232 ...

Page 118: ...safety gate not closed 1 Open safety gate 2 Close No 5 safety gate 89 Hyd Safety valve monitor device is opened M S A After operation door is closed I O 109 not ON 1 Open safety gate 2 Check safety valve monitor device 92 Core in not completed before clamp close M Core in operation not completed 1 Open safety gate 2 Perform manual core in 3 Check corepull device 93 Core out not completed before cl...

Page 119: ... in please wait 45 operator parameter being protected 14 Module memory being read please wait 46 if screen information is to be printed please depress ENTER button 15 Module memory transmission completed 47 if printing is to be terminated please depress ENTER button 16 Information being protected input code 1 48 please turn power off and remove memory card 17 Information being protected input code...

Page 120: ...too low or too high D Oil contaminated deteriorated A Expel air in proportion valve B Check according to 3 1 above C adjust oil temperature 20 50 D change hydraulic oil 3 4 Vibration during operation A Air in system line B lubrication not enough C Hyd cylinder damaged A Expel air in cylinder or system line B more lubrication C Check hydraulic cylinder 3 5 Machine inoperative A Pressure insufficien...

Page 121: ... and check chart 6 3 3 Cleaning 6 5 3 1 Screw removal installation and cleaning 6 5 3 2 Barrel removal installation and cleaning 6 6 3 3 Hopper window glass replacement 6 6 3 4 Cooler removal installation and cleaning 6 7 3 5 Filter removal installation and cleaning 6 7 3 6 Water distributor removal installation and cleaning 6 8 4 Lubrication 6 9 4 1 Toggle system lubrication 6 9 4 2 Grease lubric...

Page 122: ...ct I O 111 min mold thickness I O 112 max mold thickness on I O monitor screen when limit switch is depressed highlight of the corresponding I O disappeared C Open the clamp side gate emergency stop circuit will actuate highlight of I O 221 disappears D Press front or rear emergency stop button to activate emergency stop circuit highlight of I O 221 disappeared 1 2 Hydraulic safety The front rear ...

Page 123: ...on of various parts for any abnormality or looseness Check hydraulic hoses for looseness or oil leakage Expelling air in hydraulic system Check machine grounding wire for being proper Check mold fixing screw for security Check mold protection device for normality 2 2 Monthly inspection items Inspect and clean filters of hydraulic system Check of hydraulic system for oil leakage Inspect and clean t...

Page 124: ... the drawing E0001 LUB03 page 5 8 Hydraulic oil temperature control Checking made only by a skilled specialist Filling oil for centralized lubrication system 1 Refer to the TM3 operation manual s Visual control Cleaning Drain 2 2 I E0001 CHK01 inspection items on page 5 2 hydraulic oil use 46cSt 40 C 圖圖圖圖 ...

Page 125: ... TM3 operation manual s 2 Grease lubrication refer to the drawing E0001 LUB03 page 5 8 Checking made only by a skilled specialist Visual control Changing renewal regularity Changing of content tank Cooling water Cleaning E0001 CHK02 inspection items on page 5 2 ...

Page 126: ...he barrel with injection operation F Draw the screw away from the barrel from between fixed platen and movable platen Procedures for installing the screw back in the barrel after screw is cleaned are A Install the screw into the barrel from between fixed platen and moving platen B Use copper bar or non metal object to push the part between screw head and movable platen to hit the screw into the ba...

Page 127: ... the inj unit with injection operation Procedures for installing the barrel are A Use steel cable to hang the barrel use copper bar or non metal object to hit against the part between barrel end cap and movable platen to push the barrel into the injection unit by clamp close operation B Tighten barrel fixing nut C Install screw into coupling quill and fix the screw lock ring D Install all heater b...

Page 128: ...l rods E Use only soften agent to remove limescale ask agent supplier for usage F Install cooler piping cover and end cover luck up fixing screw G If limescale is too much replace a new cooler to avoid serious breakdown 3 4 Filter removal installation and cleaning It is very important that O ring on the oil filter cover shall maintain sealed condition Caution Upon installing the entire oil filter ...

Page 129: ...ull out water supply knob and rotate it clockwise to stop water supply B Rotate transparent tube fixing nut counter clockwise to remove it C Draw out the transparent tube and clean it with the attached plastic brush smearing with detergent D Install the transparent tube and rotate the fixing nut clockwise for tightening up Return water knob Transparent tubes Fixing nut Water supply knob ...

Page 130: ...il is Recommended For Toggle Lub 8 Descripation Lub Unit Distributor Nylon Tube Aluminum Tube Nylon Tube T Joint Nipple Elbow Nipple Elbow Distributor 5 11 10 9 8 7 6 Part No 4 3 1 2 PHD6 PA6 PB6 PHD4 PA4 PB4 PH4 PA4 PB4 PD6 PA6 PB6 PK6 RH3200 RH3300 LCB 4011B Specification 4 1 9 7 2 5 2 4 11 10 LUBRICATION SYSTEM 16 16 2 5 1 E0060 LUB01 E60 E150 4 2 1 6 3 ...

Page 131: ...The Table 1 The Lub Time Is 25sec The 250E Time Of Used Is 1 Year Clamp Is 200T 200T 250T 80 2 Depending On Clamp Tonnage And Cycle Time Of Each Case 1 cSt150 250 Oil Is Recommend For Toggle Lubrication 3 For Example Note Recommend Setting For Toggle Lub Counter Time The Lub Counter Is 118 80 148 a See The FIG 1 350day B Point D Point 118 C A ...

Page 132: ...Injection Molding Machine Chapter 6 V3 0 6 11 4 3 Lubrication points and timing ...

Page 133: ...height adjustment gear special extended grease nipple is needed for greasing the gear mechanism Fist screw in extended grease nipple into grease holes greasing as usual take it off after finishing greasing otherwise die height adjustment mechanism will be seriously damaged Extended grease nipple Grease hole for die height gear Screw in extended grease nipple into greasing hole ...

Page 134: ...V PCS 1 2 04421 23 1051051300 Heater band full circle ψ105 105 1300W 230V PCS 1 3 74230 01 16 Thermocouple 1 6M PCS 1 4 042161 11 8104 Limit switch MZ 8104 PCS 1 5 74433 01 04 Nylon pipe ψ4 m 2 6 74433 01 06 Nylon pipe ψ6 m 2 7 74342 02 04 Pipe sleeve PB 4 PCS 5 8 74342 02 04 Pipe sleeve PB 6 PCS 5 9 04406 11 22025 Solid state relay 25A 220V PCS 1 10 74411 01 16 Fuse 16A PCS 1 11 74411 01 06 Fuse ...

Page 135: ... PCS 4 20 74541 11 030 O ring G30 PCS 1 21 74541 11 075 O ring G75 PCS 2 22 74541 11 060 O ring G60 PCS 4 23 74541 21 016 O ring P16 PCS 1 24 74541 21 020 O ring P20 PCS 1 25 74551 13 050 Seal IDI 50 65 10 PCS 1 26 74551 15 030 Seal USI 30 40 6 PCS 2 27 74551 15 050 Seal USI 50 60 6 PCS 2 28 74935 01 01 Tool box Red PCS 1 29 74936 01 14 Hex wrench 14mm PCS 1 30 74936 03 09 Hex wrench 10 pcs SET 1 ...

Page 136: ...Injection Molding Machine Chapter 6 V3 0 6 15 32 061 120 3141 Nozzle head S45C PCS 1 ...

Page 137: ...hanism adjustments 7 1 1 1 Adjustment of carriage center height 7 1 1 2 Adjustment of moving mold plant slide shoes 7 2 2 System adjustments 7 3 2 1 Adjustment of electronic transducer 7 3 2 2 Adjustment of proportion valve 7 5 2 3 Adjustment of motor overload protector 7 6 ...

Page 138: ...hat secures carriage rod Ｂ Loosen the bolt that secures support Ｃ Adjusting of carriage support bolt Clockwise rotation increase the height Counter clockwise rotation decrease the height Ｄ After center is adjusted lock up the bolt that secures carriage support Ｅ Lock up the bolt that secures carriage rod Mold shall be installed with locating ring and shall align with the center of nozzle to facili...

Page 139: ... shoes The purpose of this adjustment is to make the four tie bar holes fixed platen and moving platen to be on the same central line Adjustment procedures are as follows Ａ Confirm that no mold is set between platens Ｂ Loosen the nut that secures 1251 pull the shoe out Ｃ Mount a dial gauge on moving platen measure the vertical displacement of tie bar Ｄ Pushes the shoe into mating slant slot by han...

Page 140: ...ust 7 variable resistors on the lower side of M93PT8 board to max value SCALE Clockwise rotation lower Counter clockwise rotation higher Ｄ If the mechanism to be adjusted is attempted to stop at the min position adjust to min value NULL Ｅ If the mechanism to be adjusted is attempted to stop at the max position adjust to max value SCALE Ｆ Make sure once again that whether min value max value is cor...

Page 141: ...n value NULL Ejector retract to the end 6 Clamp position min value NULL Clamp close to the end Upper row 7 Injection position min value NULL Injection to the end 1 Accumulator pressure max value Nil 2 Injection speed max value SCALE Nil 3 Injection pressure max value NULL Nil 4 Carriage position max value SCALE Carriage retract to the end 5 Ejector position max value SCALE Ejector forward to the e...

Page 142: ... correct and smooth operation Adjustment procedures are as follows Ａ Make sure that wire connection of proportional valve is good and the valve is still in normal operation Ｂ Open control box door Power is still ON Ｃ There is a total of 4 sets 3 per set variable resistors on theM95PV board 1 set of proportional pressure flow valve is controlled by 2 sets of variable resistors Ｄ There are 3 places ...

Page 143: ...al valve has been adjusted upon factory delivery unless it s output linearity is not comply with settings Do not make any adjustment arbitrarily CAUTION When the linearity isn t complying with settings please notify service department for help 2 3 Adjustment of motor overload protector thermal relay When motor load exceeds the set current motor overload protector will be tripped automatically to s...

Page 144: ...t make any adjustment arbitrarily Set current value of various machine models Operation Voltage 60E 90E 120E 150E 200E 250E 350E 500E 750E 1000E 220V 40A 54A 38A 38A 45A 65A 85A 105A 38 105A 105 105A 380V 26A 35A 22A 26A 33A 41A 51A 61A 22 61A 61 61A The values above may differ from your machine please contact TMC for details before you adjust overload protector ...

Page 145: ...Injection Molding Machine Appendix A A 0 V3 0 Appendix A 1 Hydraulic sequence A 1 2 How to re open clamp when it locked A 17 ...

Page 146: ...Injection Molding Machine Appendix A A 1 V3 0 1 Hydraulic Sequence 1 1 ALL GATES CLOSED INPUTS 101 103 109 110 111 112 201 205 209 210 211 212 212 213 221 222 231 233 ON OUTPUTS 251 295 ON ...

Page 147: ... A A 2 V3 0 1 2 CLAMP CLOSING V240 V241 V287 V246 P160 P207 P161 P162 PT37 PT46 PT30 PT31 PT32 IO156 IO157 TC322 IO252 IO253 V1 P1 PT47 PT48 V242 P230 V288 P208 Depend on CLOSE SECTION setting IO158 IF CLOSE RELEASE IO895 ON CLAMP CLOSE ...

Page 148: ...Injection Molding Machine Appendix A A 3 V3 0 1 3 CARRIAGE ADVANCE If CARRIAGE MOVEMENT ON then CARRIAGE ADVANCE ...

Page 149: ...Injection Molding Machine Appendix A A 4 V3 0 1 4 INJECTION INJECTION ...

Page 150: ...Injection Molding Machine Appendix A A 5 V3 0 ...

Page 151: ...Injection Molding Machine Appendix A A 6 V3 0 1 5 CHARGING ...

Page 152: ...Injection Molding Machine Appendix A A 7 V3 0 If CARRIAGE MOVEMENT ON then CARRIAGE RETRACT ...

Page 153: ...Injection Molding Machine Appendix A A 8 V3 0 1 6 CLAMP OPENING ...

Page 154: ...3W EJECT FUNCTION EJECT SHAKING IO891 IO867 EJECT B W DELAY T EJECT COUNT P187 PT27 V267 P185 PT25 V265 V266 PT26 P186 PARAMETER EJECT F2 F1 F3 F4 F5 F6 F7 F8 MOLD ADJ LOG SUPPORT MENU 02 I O RET END RET 1 IO926 PRODUCT SENSOR EJECT RET MID PT CHANGE MOLD EXTERN PROD MANAG ROBOT CYCLE TIME V300 P220 PT85 TC347 TC348 TC440 PT84 OFF TC852 EJECT F W DELAY T EJECTOR RETRACT 1 8 NEW CYCLE REPEATED ...

Page 155: ...d is at open end position CLS_E Start core movement when mold is at close end position POSIT Start core movement when mold is at specified mold position EJ_F Start core movement when ejector is at forward end position EJ_END Start core movement when ejector cycle is finished AS_EJ Core outputs is used as standard ejector ...

Page 156: ...ine Appendix A A 11 V3 0 1 9 1 1 CORE IN CORE 1 IN OPN_E POSIT CLS_E CORE MODE Core 1 Core 2 Core 3 Core In Delay TC359 TC344 TC390 Core In Time TC351 TC353 TC376 Core In L S IO131 IO133 IO331 Core In Valve 1O182 IO184 IO385 ...

Page 157: ... Appendix A A 12 V3 0 1 9 1 2 CORE OUT CORE 1 OUT OPN_E POSIT CLS_E CORE MODE Core 1 Core 2 Core 3 Core Out Delay TC360 TC345 TC391 Core Out Time TC352 TC354 TC377 Core Out L S IO132 IO134 IO332 Core Out Valve 1O181 IO183 IO386 ...

Page 158: ... EJECTOR BACKWARD FORWARD CORE OUT CORE IN CORE MODE EJ_F COLLAPSIBLE CORE MOLD OPEN END EJECTOR FORWARD CORE OUT CORE IN EJECTOR BACKWARD NEW CYCLE If ejector count 1 then sequence act as MOLD OPEN END EJECTOR FORWARD CORE OUT NEW CYCLE CORE IN EJECTOR BACKWARD MOLD CLOSE ...

Page 159: ...Injection Molding Machine Appendix A A 14 V3 0 1 9 2 GAS VENT SEQUENCE ...

Page 160: ...Injection Molding Machine Appendix A A 15 V3 0 1 9 3 INJECTION COMPRESSION SEQUENCE ...

Page 161: ...Injection Molding Machine Appendix A A 16 V3 0 1 9 4 GAS VENT INJECTION COMPRESSION ...

Page 162: ...tion Molding Machine Appendix A A 17 V3 0 1 9 5 VALVE GATE FUNCTION VALVE GATE If VALVE GATE function is ON core 1 and core 2 functions are change to valve gate function REGARDLESS of core s function ON OFF ...

Page 163: ... Appendix A A 18 V3 0 INJECTION DELAY CORE 1 IN INJECTION INJECTION CORE 1 IN DELAY CORE 1 IN TIME CORE 2 IN TIME CORE 2 IN CORE 2 IN DELAY CORE 2 OUT TIME CORE 2 OUT CORE 2 OUT DELAY CORE 1 OUT TIME CORE 1 OUT CORE 1 OUT DELAY ...

Page 164: ...procedures 2 1 Set clamp DECOMPRESS position to 0 1 S pressure to 140 speed to 99 2 2 Press manual clamp open close key intermittently to re open mold NACHI Proportional System 2 3 If the clamp still can t be opened tighten the knob in proportional pressure valve R1 fully C W in completely then press manual clamp open close key intermittently to re open it again ...

Page 165: ...Injection Molding Machine Appendix A A 20 V3 0 Attention 1 The knob in R1 must be loosened after the clamp is opened 2 Restore the original decompression position and pressure settings ...

Page 166: ...n t be opened turn max adjustable resistor in pressure control board PV60 fully C W in then press manual clamp open close key intermittently to re open it again Attention The adjustable resistor max must be restored after the clamp is opened CALL TMC OR TMC LOCAL AGENT IF MOLD STILL CAN T BE OPENED ...

Page 167: ...ECTOR COUNT must be set to 1 ONLY when motion on 4 Collapsible core mode is not allowed when motion on 5 Starting procedures 5 1 Open operator gate 5 2 Turn semi auto mode on 5 3 Turn motion key to OFF then to ON position again 5 4 Close operator gate 5 5 Push cycle start button to start cycle Remarks For anti tie down safety motion key must be turned OFF then turned ON in semi auto mode to activa...

Page 168: ...Injection Molding Machine Appendix C C 0 V3 0 Appendix C Robot Connection 1 Signal Definition C 1 2 Wiring Example C 2 ...

Page 169: ...hen IO222 is ON clamp close is allowed IO196 Signal for robot to come in when clamp opened to OPEN END position or clamp position is greater than ROBOT SIGNAL PT setting value IO196 is ON IO136 Robot enables core movement core movement is enabled only when IO136 is ON IO101 It is ON when operator gate is closed is OFF when gate is opened IO1020 Internal IO set on when machine has euromap or spi ro...

Page 170: ...HANGE LOG CYCLE T INTERVAL T TENANCE MAIN F7 F8 EXTERN I O PT58 TC TC326 TC321 100 0mm 50 0mm P163 V243 DECOMPRESS V245 P209 PT82 V289 3 S PT29 P165 2 S P207 PT47 P230 PT48 V244 PT36 P164 1 S PT35 PT30 P208 PT31 P161 ACTION STATUS 2 S V241 M 3 S V242 1 0mm LOW P V 4 S V288 V287 210 0mm PTmm V PT32 P162 0 0 0 0 0 0 CLOSE END LOCK V246 P1 P2 0 0 V1 V2 2 Wiring example 222 IN IO BOX CN IOL M90 IO1 IN...

Page 171: ...Injection Molding Machine Appendix D D 0 V1 0 Appendix D USB file operation 1 Program date D 1 3 Operation items D 1 4 Function descriptions and operations D 3 ...

Page 172: ...tems Press F2 to change operation item there are 10 function items 1 LOAD MEMO SET Load mold data from USB disk to machine 2 SAVE MEMO SET Save present molding data to USB disk 3 LOAD US USC Load user program in USB disk to machine Stop motor power and heater power first 4 LOAD OS OSC Load screen program in USB disk to machine 5 LOAD PLC PLC Load PLC program in USB disk to machine 6 SAVE US USC Ba...

Page 173: ...X SET This function is to load molding data in USB disk to machine current molding setup only molding data are loaded when using special engineer USB disk then machine related parameters will also be loaded Steps press F2 ITEM CHANGE UNTIL 1 LOAD MEMO SET is showed Æ user F3 F4 to select data Move cursor to desired item position press ENTER and data will be loaded to machine During loading process...

Page 174: ...F4 to select data press ENETR to overwrite selected data Press F5 will move cursor to SAVE AS position enter desired mold name without SET extensions filename then pressure ENTER to save mold data in a new created filename maximum filename length is 31 letters 3 LOAD US USC used to update user program file extension name can only be USC 96Kbyte Steps press F2 ITEM CHANGE UNTIL 1 LOAD US USC is sho...

Page 175: ...Injection Molding Machine Appendix D D 4 V1 0 4 LOAD OS OSC used to update screen program file extension name can only be OSC 1536Kbyte ...

Page 176: ... system messages show LOAD FILE 100 CHECK SUM OK UPDATE TO FLASH 100 OK THEN TURN OFF MAIN POWER AND TURN ON AGAIN 5 LOAD PLC PLC This function is to update PLC program the extension file name can only be PLC for example M98TM11 20100423 PLC 384Kbyte Steps press F2 ITEM CHANGE UNTIL 1 LOAD PLC PLC is showed Æ use F3 F4 to select screen program press ENTER to update PLC program Wait until system me...

Page 177: ...TIL 1 SAVE US USC is showed Æ use F3 F4 to select destination folder Press F5 will move cursor to SAVE AS position enter desired file name without extensions filename then pressure ENTER to save user program in a new created filename extension file name USC will be added automatically Filename must be different from existed files Wait until system messages show SAVE FILE COMPLETE 100 ...

Page 178: ...Injection Molding Machine Appendix D D 7 V1 0 7 SAVE OS OSC This function will save current machine screen program in USB disk ...

Page 179: ...me OSC will be added automatically Filename must be different from existed files Wait until system messages show SAVE FILE COMPLETE 100 8 SAVE PLC PLC This function will save current machine PLC program in USB disk Steps press F2 ITEM CHANGE UNTIL 1 SAVE PLC PLC is showed Æ use F3 F4 to select destination folder Press F5 will move cursor to SAVE AS position enter desired file name without extensio...

Page 180: ...overwrite existed mold data in internal memory Steps press F2 ITEM CHANGE UNTIL 9 MEMO COPY TO INSIDE is showed Æ use F3 F4 then enter to select mold file selected files are colored in purple repeat above steps to choose multiple files Press F5 will move cursor to INSIDE MEMORY NAME area enter to selected destination file position and repeat selection by using move enter keys Press F6 to start cop...

Page 181: ...d Æ use F3 F4 then enter to select mold file selected files are colored in purple repeat above steps to choose multiple files Press F5 will move cursor to INSIDE MEMORY NAME area enter to selected source file position and repeat selection by using move enter keys Press F6 to start copying processes if there is any mold file has the same file name as in source file system will automatically add 1 2...

Page 182: ... Chapter 8 Drawings 1 Appearance dimension drawing 2 Barrel assembling drawing 3 Hydraulic circuit drawing 4 Hydraulic manifold drawing 5 1 Injection manifold 5 2 Clamp manifold 5 3 Ejector manifold 5 Oil hoses drawing 6 Electrical wiring diagram ...

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