Keba User Manual (4030) - 27march2006

Chapter 9 Controller Operation Manual
KEBA 4030 SYSTEM USER MANUAL
Table of Contents
KEBA 4030 SYSTEM USER MANUAL.....................................................................................1

1 Operations Manual.........................................................................................................3
1.1 Clamping Unit Setup...............................................................................................3
1.1.1 Mold Height Adjustment...............................................................................3
1.1.2 Mold Closing and Mold Protection...............................................................4
1.1.3 Mold Opening................................................................................................5
1.1.4 Ejector............................................................................................................6
1.1.5 Air Blast.........................................................................................................7
1.1.6 Core(s)...........................................................................................................8
1.2 Injection Unit Setup................................................................................................9
1.2.1 Nozzle/Injection Unit.....................................................................................9
1.2.2 Injection and Hold Pressure.........................................................................10
1.2.3 Charge (Plasticizing) and SuckBack...........................................................11
1.2.4 Heating.........................................................................................................12
2 Reference Manual........................................................................................................13
2.1 Control Panel (HMI).............................................................................................13
2.1.1 Control Panel and Buttons...........................................................................14
2.1.2 Machine Control Panel Buttons...................................................................14
2.1.3 Data Entry Keys...........................................................................................21
2.2 HMI Display..........................................................................................................23
2.2.1 Overview......................................................................................................23
2.2.2 Mold Settings...............................................................................................24
2.2.3 Injection.......................................................................................................28
2.2.4 Charge & Suckback Settings.......................................................................34
2.2.5 Ejection........................................................................................................37
2.2.6 Cores............................................................................................................40
2.2.7 Nozzle and Mold Adjustment Settings........................................................43
2.2.8 Temperature Control....................................................................................47
2.2.9 Hot Runner Control (optional).....................................................................51
2.2.10 Alarm and Message Display Screen............................................................54
2.2.11 I/O Channel Monitor....................................................................................55
2.2.12 Mold Data Settings......................................................................................61
2.2.13 Manager Settings.........................................................................................62
2.2.14 Process Data Protocol (Part Supervision)....................................................63
2.2.15 Quality monitoring.......................................................................................66
2.2.16 System Settings............................................................................................67
2.2.17 Analog Input Calibration Mask...................................................................71
2.2.18 Analog Output Calibration Mask-1.............................................................72
2.2.19 Analog Output Calibration Mask-2.............................................................73
2.2.20 Machine Settings Mask................................................................................74
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2.2.21 Machine Settings Mask-2............................................................................76

2.2.22 Machine Settings Mask-3............................................................................77
2.2.23 Machine Settings Mask 4.............................................................................78
2.2.24 Close Loop PID Parameters Settings Mask.................................................79
2.2.25 Temperature PID Parameters Settings Mask...............................................81
2.2.26 HotRunner Temperature PID Parameter Setting Mask (*Optional*)..........82
2.2.27 Engineer screen............................................................................................83
2.2.28 Servo Valve Calibration..............................................................................84
2.2.29 Engineers Prop.valve Connection screen....................................................85
2.2.30 Engineers Ramp Setting Mask.....................................................................86
2.2.31 Print Function..............................................................................................87
2.2.32 System Alarm and Message.........................................................................88
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1 Operations Manual
The instructions within the Operations Manual assume that you are familiar with the HMI panel keys and
the various HMI display screens. If you are not or you are looking for more information on any of the keys
or display screens please refer to the appropriate section within the Reference Manual.
1.1 Clamping Unit Setup

When changing the mold follow the machine manufacturer’s instructions at all times to avoid the
possibility of serious injuries to the machine operators.
After changing the mold you have to ensure that the mold and the nozzle/injection unit are properly
aligned to avoid damage to the machine. In addition, you need to make sure all necessary hose connections
to the mold have been properly established and the mold has been mounted securely.
1.1.1 Mold Height Adjustment

Before installing the mold use the Mold Adjustment buttons to adjust the mold thickness. Be sure to
disable the cores before adjusting the mold height.
First switch to Setup mode, and press the Mold Height Adjustment Forward button to roughly adjust for a
reduced mold height (reduced distance between moving and static platen) or the Mold Height Adjustment
Backward button to roughly adjust for an increased mold height (increased distance between moving and
static platen).
For continuous platen movement press and hold the
Adjust the mold height. key. The platen will move slightly and stop. Keep the
key pressed will start to move continuously. Release
the key to stop platen movement. If you press the key
and release it immediately, the platen will move
Turn the machine off. slightly and stop, allowing for micro adjustments.
You can repeat this operation until the moving platen
has reached the desired position.
Install the new mold. Turn the machine off and install the new mold.
Once you have finished the installation of the new
mold, close the safety gate, turn on the machine and
Turn the Machine on. press Setup Button once to activate Setup mode.
Switch the HMI display to the Nozzle screen by
pressing Nozzle Button. This screen allows you to
change the speed and pressure settings for mold
Switch to Setup operation mode adjust movement. You also can change the pressure
and, if necessary, change the speed and speed settings of the platen movement for setup
and pressure settings or load the mode: First press the mold button, then change to the
mold set data. "Param" screen. You can adjust the settings in the
const setup window. These settings are used for the
platen movement during Auto Mold Height
Adjustment.
Press Setup Button and then Mold After adjusting the settings press the Setup key again.
Close Button to execute the The controller will display: "Please close the door and
Autom.Mold Height. Adjustment. press the mold close button". After pressing the
button, the controller will execute an automatic mold
height adjustment until the new settings are reached.
Switch to normal operation mode. Once the automatic adjustment has finished all
machine operations will stop, the controller will give
a message, switch to Manual mode and the alarm will
sound.
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If you encounter any problems during the mold height adjustment press the Manual button for an
emergency reset to stop the operation.
1.1.2 Mold Closing and Mold Protection

Mold closing is executed in three to five phases: one to three High Speed closing stages, Protect- and High
Pressure closing. For optimum productivity mold closing should be executed as fast as possible. However,
to avoid damage to the mold and/or machine it is important to use correct settings to ensure appropriate
mold protection. For this reason pay particular attention to the Protect phase.
The number of the Mold closing stages can be set in the Mold Parameters screen.
Press the Manual button to activate the Manual

mode. Switch the HMI display to the mold settings
mask by pressing mold button on the main screen. Switch into Manual Mode.
Set the Mold Opening Stroke ("Open End"). The
Mold Opening Stroke is measured from the closed
mold. Therefore the Mold Opening Stroke position is Set the Mold Opening Stroke.
“0” when the mold is in its closed position.
Next enter the desired hydraulic speed and pressure

settings for the mold closing phases. You have to Set the hydraulic speed and pressure
ensure that the settings allow a smooth, jerk-free for the Hi.speed mold closing phases.
movement of the mold.
Set the hydraulic speed for the Protect phase low

enough to avoid damage to the mold in case a Set the transition position for
jammed part has remained in the mold. For the same switching from the High Speed phase
reason set the lowest hydraulic pressure possible. to the Protect phase.
The mold protection time can bet set on the Mold
Functions screen.
To avoid damage to the mold the transition point for Set the transition position for
switching between High Speed and Protect phase switching from the Protect phase to
should be set before the position where the mold the High Pressure phase.
could come into possible contact with a jammed
part.
The transition point for switching from the Protect Execute mold closing in Manual
to the High Pressure phase should be set at the Mode to verify the settings and to
position where both parts of the mold are starting to check for optimum performance.
touch to initiate the high pressure mold lock-up.
To accelerate mold closing you can activate the

differential high-speed mold closing option for the
High Speed closing phase.
The delay time of the high-speed mold closing valve
can be adjusted on the Mold Functions screen.
After setting all mold closing parameters execute mold closing in Manual Mode to check for optimum
machine performance. If you encounter any problems during the mold closing adjustment release the Mold
close button for an emergency reset to stop the operation.
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1.1.3 Mold Opening

Mold opening is divided into one to five phases. The initial Slow Speed opening, zero to three intermediate
High Speed phases and a final Low Speed phase to slow down the mold before the opening end position is
reached. The number of the Mold opening stages can be set in the Mold Parameters screen.

Switch into Manual Mode. mode. Switch the HMI display to the Mold Settings
mask by pressing the mold button on the main screen.
Verify the Mold Opening Stroke and adjust if

Verify the Mold Opening Stroke and
necessary. The Mold Opening Stroke is measured
adjust if necessary.
from the closed mold. Therefore the Mold Opening
Stroke position is “0” when the mold is in its closed
position.
Set the hydraulic speed and pressure
for the three mold opening phases. Next, enter the desired hydraulic speed and pressure
settings for the mold opening phases. You have to
ensure that the settings allow for a smooth, jerk-free
movement of the mold.
Set the transition position for
switching from the first Low Speed Set the hydraulic speed for the initial Low Speed
phase to the High Speed phase. phase low enough to allow for a smooth separation of
the part from the mold.
Adjust the transition point for switching from the

initial Low Speed phase to the intermediate High
Set the transition position for Speed phase accordingly.
switching from the High Speed phase
to the final Low Speed phase.
The transition point setting for switching from the
intermediate High Speed phases to the second Low
Speed phase should allow the mold to slow down
sufficiently before reaching the end position of the
Execute mold opening in Manual Mold Opening Stroke. This is necessary to avoid
Mode to verify the settings and to possible damage to the machine.
check for optimum performance.
After setting all mold opening parameters execute mold opening in Manual Mode to check for optimum
machine performance. If you encounter any problems during the mold opening adjustment release the
Mold open button for an emergency reset to stop the operation.
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1.1.4 Ejector
The ejector can be operated in three different modes to knock the finished product out of the mold at the
end of mold opening. You can choose between the Hold, Continous and the Vibration modes.
The Hold mode is used during half-automatic operation. The ejector moves forward according to the
ejector settings and the product is dropped or taken out. After the next cycle is started, the ejector will
move backward according to the backward settings.
In Continous mode the ejector is activated according to the Ejector and Ejector Count settings. The ejector
moves from backward position to Ejector forward End and back to Ejector backward End. This movement
is repeatet according to the Ejector Count setting.
If you use the Vibration mode the ejector movement is controlled by the Ejector and Ejector Count
Settings with the ejector vibrating (move from Ejector fwd. End to Ejector bwd.#2) at the end of the
forward movement according to the Ejector Count setting before retracting again.

mode. Switch the HMI display to the Eject Air Switch into Manual Mode.
Settings mask by pressing Eject Button on the main
screen.
First, set the Ejection Mode and Count. Please note, Set the Ejection Mode and Count.
if you want to deactivate the ejector you can do so
by setting the Ejection mode to “No”.
The initial ejection is divided into two phases that Set the Forward Pressure and Speed
can be controlled separately. Set the pressure, speed for both phases.
and transition position individually for each phase.
Next, set the pressure and speed for the backward

Set the Forward End Position
movement.
In addition, set the backward end position for the

ejector retraction between repeated activation (in
case of multiple ejector activation). Please note, the Set the transition point for switching
backward end position is relative to the absolute between first and second phase.
retraction end position that is used after final ejector
activation and determined by the transducer zero
point setting.
Set the Backward pressure and speed
and delay time (if necessary).
Set the Backward end position.
Set the Ejector Activation Delay

Times if necessary.
Activate the ejector in Manual Mode

to verify the settings and to check for
optimum performance.
After setting all ejection parameters activate the ejector in Manual Mode by pressing the Ejector forward
button to check for optimum machine performance. If you encounter any problems during the ejector
settings release the Ejector button for an emergency reset to stop the operation.
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1.1.5 Air Blast

The machine provides an air blast ejection option for the moving platen as well as for the stationary platen.
Depending on the machine type, two to six air blast outputs are available.

Switch into Manual Mode.
mode. Switch the HMI display to the Eject Air
Settings mask by pressing Eject button on the main
screen.
Set the air blast Activation Time. Note: If your machine has more than two air blasts,
the settings for air1 and air2 are on the Eject Air
Settings screen and the additional air blast settings
are on the Air Settings2 screen.
Set the air blast Activation Position.
First, set the Activation Time (duration of air blast)
for each platen. A setting of 0.0 will disable this air
blast.
Set the air blast Delay Time.
Set then the corresponding Activation Position at
which you want to activate the air blast. The
Activation Position refers to the mold position
Activate the air blast in Manual (reached during mold opening) at which the air blast
Mode to verify the settings and to is activated.
check for optimum performance.
If necessary, set the Delay Time for activating the air
blast (after the Activation Position has been reached)
according to your preferences.
In case you require additional cooling of the mold

product after mold opening, set the Delay Time for
the air blast activation accordingly.
After setting all air blast parameters activate the air blast in Manual Mode to check for optimum machine
performance. If you encounter any problems during the air blast setup release the Air button for an
Note: If your machine has more than two air blasts, in Manual mode Air1 button will activate air blast 1,
air blast 3 and air blast 5 if available. Air2 button will activate air blast 2, air blast 4 and air blast 6 if
available.
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1.1.6 Core(s)
Depending on your setup your machine may be equipped with up to 6 cores (A - F). Each core is
controlled separately. When setting up the core(s), you need pay close attention to make sure the settings
will not cause damage to the core(s) and/or the mold. Since the cores are freely programmable it is
impossible for the controller to prevent all possible settings errors.

Mode. Switch the HMI display to the Core Settings
mask by pressing Core button on the main screen.
If available, cores D – F can be modified on the
Core D-F Settings screen.
First, for each core choose either the Core type if
you want to use a regular core that is moved in and
out hydraulically or the Unscrew type if your mold
requires threads created by unscrewing the inserted Set the Core type (Function) and
core. If the core is not needed set the type to “off”. Control Mode for each core.
Next, select the desired Control type to control the
core movement. In Core type you can use either
limit Control or Time Control. In Unscrew Mode Set the hydraulic Pressure and Speed
you can use Time Control or Count Control. for each core.
Using limit Control allows you to control the core

movements by limit switches for end-position
control (for insertion and retraction). At the pre-set Set the Position values for moving in
point during the production cycle the core(s) will and out each core and enter the
move in/out until the limit switch controlled end- Activation Time or Unscrew Count (if
position is reached. Please make sure the limit used).
switches are activated since deactivated switches
will cause the machine to stop (if limit Control is
selected).
Activate the cores in Manual Mode
Time Control uses time settings for core insertion to verify the settings and to check for
and retraction. At the pre-set position during the optimum performance.
production cycle the core(s) are moved in/out for the
set period of time. Therefore core movement (travel)
is not controlled by end-position but by time. As a
result you will not be able to rely on the protection
of limit switches.
Accordingly, in Unscrew Mode the Time Control is used to set the time core unscrewing is activated (e.g.
for creating threads).
Count Control uses the pre-set number of revolutions to control the unscrewing of the core at the set
position during mold opening. To use Count Control you have to make sure a photo sensor for counting
the revolutions is installed on the core driving gear.
Please note that Count Control allows for higher precision than Time Control.
Set the Pressure, Speed, Activation Time, Unscrew Count (if used) and Position values for moving in and
retracting each core according to your needs.
After setting all core parameters activate the core(s) in Manual Mode to check for optimum machine
performance. If you encounter any problems during the core set-up release the Core button for an
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1.2 Injection Unit Setup

1.2.1 Nozzle/Injection Unit
Depending on your requirements you can set up the nozzle/injection unit to retract after injection has
finished. The controller offers you 3 different modes to choose if nozzle/injection unit retraction is needed.

mode. Switch the HMI display to the MoldAdjust
Nozzle Settings mask by pressing Nozzle button on
the main screen.
First, set the Retraction Mode (NozB). The After
Charge mode (AftChr) retracts the nozzle/injection
unit after charging (plasticizing) is finished. The
Set the Retraction Mode. Before Opening mode (BefMOp) initiates nozzle/
injection unit retraction before mold opening starts. If
you want to retract the nozzle/injection unit after
injection has finished choose the After Injection mode
Set the hydraulic pressure for (AftInj). Setting the mode to “No” will cause the
nozzle/injection unit Advance. nozzle and injection unit to stay in place (no
retraction).
Then set the hydraulic pressure for nozzle/injection

Set the hydraulic speed settings for unit Advance. Enter the hydraulic speed settings for
the High and Low Speed phases of the corresponding High and Low Speed phases of the
the nozzle/injection unit Advance. nozzle/injection unit Advance. During the forward
movement the High-Speed settings are used until the
set End Position is reached (transducer controlled
nozzle) or until the limit switch is reached (limit
Set the transition point between High switch control).
and Low-Speed phases by entering Thereafter in transducer mode, the nozzle/injection
the EndPos. or adjust the limit sw. unit will move forward using the Low-Speed settings,
for nozzle/injection unit Advance. until it has reached the final injection position and
continue output until the Move forward time has
passed.
In limit switch mode, the machine will do the Low-
Activate the nozzle/injection unit in Speed output for the preset time after reaching the
Manual Mode to verify the settings limit switch.
and to check for optimum
performance. Enter the End Position for the Advance movement to
set the transition point between High and Low-Speed.
It is important to allow for a safety margin of at least
20mm between the set End Position and the actual
contact point of nozzle and mold (at which the nozzle
stops its forward movement and the injection begins).
If the End Position is set too close to the contact point
of nozzle and mold the nozzle might not slow down
enough before touching the mold. The result could be
damage to mold and/or nozzle.
Finally, set the hydraulic pressure and speed settings for nozzle/injection unit Return. Enter the desired
Positions for retraction (transducer mode, 2 phases) or, in limit switch mode, set the Activation Time
setting for duration of nozzle/injection unit retraction.
After setting all nozzle/injection unit parameters activate the nozzle/injection unit in Manual Mode to
check for optimum machine performance. If you encounter any problems during the nozzle/injection unit
setup release the Nozzle button for an emergency reset to stop the operation.
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1.2.2 Injection and Hold Pressure

The Injection process is divided into 1-6 phases and Hold Pressure into 1-5 phases.
The number of the Inject and Hold Pressure stages
can be set in the Inject Parameters screen.
Activate the Manual Mode by pressing the Manual
button. Switch the HMI display to the Inject
Settings mask by pressing Inj Button on the main Switch into Manual Mode.
screen.
First, choose the Hold Pressure Switch Mode.

If the Time mode is used the controller will switch to Set the Hold Pressure Switch Mode.
Hold Pressure after the set injection time has
elapsed.
In case the Position mode has been selected the
controller will switch to Hold Pressure after the last
set injection position has been reached. Set the hydraulic Pressure and Speed
If your machine supports Injection Pressure- and/or for each of the Injection and Hold
Cavity Pressure sensors, this data can also be used as Pressure phases.
switch mode.
Depending on your selection, you can use one or
more of the above mentioned conditions for
switching from Injection to Holding. However, it is Set the Position settings for each of
recommended to always additionally use the time the Injection phases.
mode as a backup to initiate the Hold Pressure phase
if for some reason the set transition position and/or
pressure values cannot be reached.
Activation Pos. defines the screw position where the Set the Time settings for each of the
switch monitoring is started. Hold Pressure phases.
Please note that you should always set the time limit
higher than the usually required injection time. This
avoids poor molding results due to possible resign Set the Cooling Time before Charge
fluidity variations (poor fluidity could require a value (if needed).
longer than usual injection time). The transition
between each Hold Pressure phase is controlled by
the corresponding time settings and is not affected
by the Hold Pressure Transition Mode settings. Activate Injection and Hold Pressure
in Manual Mode to check for
Next, set the hydraulic pressure and speed for each optimum machine performance.
of the Injection and Hold Pressure phases.
Enter the Position settings for each of the Injection phases and the Time settings for each of the Hold
Pressure phases.
After setting all Injection/Hold Pressure parameters activate Injection and Hold Pressure in Manual Mode
to check for optimum machine performance. If you encounter any problems during the Injection/Hold
Pressure setup release the Inject button for an emergency reset to stop the operation.
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1.2.3 Charge (Plasticizing) and SuckBack

Charge (Plasticizing) is divided into 1-4 phases. You can set the Pressure, Speed (and Backpressure if
adjust function is available on your machine) for each phase individually.
The number of the Charge stages can be set in the Charge Parameters screen.
Suck-back is initiated before and/or after Charge (Plasticizing) if required.
Switch into Manual Mode. Press the Manual button to activate the Manual
mode. Switch the HMI display to the Charge
Suckback Setting mask by pressing Chrg Button on
the main screen.
Set the Charge (Plasticizing) values
for Pressure, Speed (and First, set the Charge (Plasticizing) values for
Backpressure) for each phase. Pressure, Speed (and Backpressure) individually for
every phase.
Next, enter the individual Positions for the transition

Set the Positions for the transition between the Charge (Plasticizing) phases.
between the Charge (Plasticizing)
phases. Choose the desired Suckback modes. Depending on
the selected mode, Suckback will be controlled by
using the Position or the Time. Choose the desired
mode for either Position control or Time control.
Set the Suck-Back modes and Speed
and Position/Time values. In addition, enter the Suck-back flow and pressure as
well as the desired Position or Time value.
Settings for Suckback after Charging are available on
the Charge Suckback Setting screen, for Suckback
If needed set the Cooling Time before before Charging on the Charge Suckback Function
Charge and/or Cooling Time. screen.
Note: Position settings for Suckback are absolute.
Set the Suck-back mode to “NO” if no Suck-back is

Activate Charge (Plasticizing)/Suck- required.
Back in Manual Mode to verify the
settings and to check for optimum If cooling is needed at the end of Injection/Hold
performance. Pressure and before Charge (Plasticizing)/Suck-Back
is initiated set the desired Cooling Time before
Charge value accordingly.
After setting all Charge (Plasticizing)/Suck-Back parameters activate Charge (Plasticizing) and Suck-Back
in Manual Mode to check for optimum machine performance. If you encounter any problems during the
Charge (Plasticizing)/Suck-Back setup press the Manual Button for an emergency reset to stop the
operation.
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1.2.4 Heating
Depending on your machine setup the barrel heating of the injection unit is equipped with up to 12 barrel
heating zones. The temperature, cushion and timer are controlled separately for each of the barrels’s
heating bands. The right hand graph shows the current (actual) and set temperature for each barrel heating
zone.
Activate the Manual Mode by pressing the Manual

Button. Switch the HMI display to the Temperature
Settings mask by pressing Temp Button on the main
screen. Switch into Manual Mode.
First, set the Temperature Mode (Keep Warm).

Choose “No” if you want to keep the temperature Set the Temperature Mode (Keep
always in the pre-set range regardless of the machine Warm).
operation. If set to “Use” the heater will keep the
barrel temperature at the KeepWarm-setting
temperature which can be set on the Temperature
Functions screen. Set the temperature for the different
barrel heating zones.
Next, set the temperature for the different barrel
heating zones. The field below (Act. State) gives you
a quick indication on the current heater status for the
corresponding barrel heating zone. Set the Temperature Cushion for each
Blue color indicates that heating is off. barrel heating zone.
Green color indicates that heating is on.
Yellow color indicates a problem with the
temperature sensor on this zone.
Set the Timer Mode and program the
Please note that the heater will be turned off timer for each barrel heating zone (if
immediately once the current temperature exceeds needed).
more than the set Temperature tolerance up to the set
value. For current temperatures below the set value
heater activation depends on the set Temperature
tolerance. Run the machine in Manual Mode to
check for optimum machine
To adjust the Temperature tolerance please presses performance.
Para Button to go to the Temperature Parameters
mask. Adjust the corresponding values for High
Tolerance and Low Tolerance. A tolerance value of
“20”, "10" for example will give an alarm and lock
all screw movements if the zone temperature is more
than 20°C higher or more than 10°C lower of the set
value.
The controller supports heating by PID control or

Set value which can be chosen separately for each
zone on the Temperature Functions screen.
If you want to use the Timer for barrel pre-heating on the Temperature Functions screen, select the days
and start times by checking "Act" and setting the times.
After setting all heating parameters run the machine in Manual Mode to check for optimum machine
performance. If you encounter any problems during the Heater setup press the Heating off button for an
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2 Reference Manual
2.1 Control Panel (HMI)
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9-14
2.1.1 Control Panel and Buttons

The Control Panel is made from stainless steel to make the panel water, dirt and abrasion resistant. All
keys are operated through type a mechanical contact switches to provide for reliability and a long service
life (the lifetime of the control panel is only limit by the number of actuations).
2.1.2 Machine Control Panel Buttons
The machine control panel keys allow you to switch between different machine operating modes and to
manually control the operation of the machine. Nevertheless, even most manual commands will be
executed using the stored machine settings. It is therefore important that you verify the settings first to
ensure safe machine operation.
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9-16
Machine Operating Mode Buttons
Manual Key: This key has various functions. It is used to change from Auto Operation mode
to Manual Operation mode as well as a reset key for movements and alarms.
Half-Auto Key: Press this key to run the machine in Half-Auto Operation mode. After each
cycle you have to open and close the safety gate (or push the Cycle start button at closed safety gate if your
machine has this option installed) to start the next cycle.
Full Auto Key: Press this key to run the machine in Auto Operation mode. Use this operation
mode to let the machine execute each cycle automatically. The controller will stop the machine and the
alarm will sound if the shotcounter reaches the set value (-> refer to Manager screen) or in case of an
error.
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Mold Adjustment and Lubrication Keys
Setup Button: Press this key once to activate the Manual Mold Height Adjustment mode.
Switch the control unit display to the MoldAdjust Nozzle Settings mask by pressing Nozzle Button on the
main screen. This screen allows you to adjust the speed and pressure settings after the mold has been
changed.
Use the Mold Adjustment Buttons described in this section to roughly adjust for mold thickness and to
advance or retract core(s) if necessary.
Once you have finished the installation of the new mold, close the safety gate and adjust the pressure,
speed and position settings (using the MoldAdjust Nozzle Settings mask) for the new mold. After adjusting
the settings press the Setup Button again followed by the Mold close Button to close the mold. While
closing the mold the controller will execute an automatic mold height adjustment until the new settings are
reached. Once the automatic adjustment is finished all machine operations will stop, change to Manual
mode and the alarm will sound.
If you encounter any problems during mold height adjustment press the Manual Button for an emergency
reset to stop the operation.
Mold Height Adjustment Backward Button: While in Manual Mold Height Adjustment
mode use this key to roughly adjust for an increased mold height (increased distance between moving and
static platen). For continuous platen movement press and hold the button. The platen will move slightly
and stop. Keep the key pressed the platen will start to move continuously. Release the key to stop platen
movement. If you press the key and release it immediately, the platen will move slightly and stop, allowing
for micro adjustments. If you want to move it more slightly, you can select the “One Gear Adj”(--> Nozzle
Function Mask). This will make the machine move one gear every time you press the button. You can
repeat this operation until the moving platen has reached the desired position. A limit switch may stop
backward movement of the platen to prevent damage to the machine. Please make sure the limit switch
(located on the machine) is activated.
Please note that you can use this key in Manual Mold Height Adjustment mode only.
Mold Height Adjustment Forward Key: While in Manual Mold Height Adjustment mode
press this key to roughly adjust for a reduced mold height (reduced distance between moving and static
platen). For continuous platen movement press and hold the key. The platen will move slightly and stop.
Keep the key pressed the platen will start to move continuously. Release the key to stop platen movement.
If you press the key and release it immediately, the platen will move slightly and stop, allowing for micro
adjustments. If you want to move it more slightly, you can select the “One Gear Adj”(--> Nozzle Function
Mask). This will make the machine move one gear every time you press the button. You can repeat this
operation until the moving platen has reached the desired position.
Please note that you can use this key in Manual Mold Height Adjustment mode only.
Lubrication Button: While in any mode press this key and then release the button, the
controller will lubricate the machine one time, at the same time, reset the lubrication counter.
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Manual Operation Mode Keys (Left)
Open Mold button: While in Manual Operation mode, close the safety gate and press and
hold this key to open the mold. Once you release the key mold opening will stop. If core(s) and/or air
blows are used they will be activated according to the settings. Press Core Button on the main screen to
view the core settings and Ejector Button to view the air blow settings. Please note that you can use the
Open Mold button in Manual Operation mode and Manual Mold Height Adjustment mode.
Close Mold button: While in Manual Operation mode, close the safety gate and press and
hold this key to close the mold. If core(s) are used they will be moved according to the settings. Press Core
Button on the main screen to view the core settings. In case a robot is installed it must be reset. If the
ejector is in knockout position, it must be retracted before the mold can close. Once you release the Close
Mold key mold closing will stop. Please note that you can use this key in Manual Operation mode and
Manual Mold Height Adjustment mode.
Ejector Backward button: Use this button in Manual Operation mode to retract the ejector.
Ejector movement will stop once the button has been released or the back limit has been reached. Please
note that you can use this key in Manual Operation mode and Manual Mold Height Adjustment mode.
Ejector Forward Button: Use this key in Manual Operation mode to activate the ejector.
Before the ejector can be activated the mold has to be opened completely and all cores have to be retracted.
The ejector will be activated according to the Ejector settings. Press Eject button on the main screen to
view the settings. Please note that you can use Ejector Activation key in Manual Operation mode and
Note that this button has no function if Ejector mode is set to "No"!
9-19
Core A In Core A Out buttons: Press the Core A In button to move in core A or
use the Core A Out button to pull core A. Any core movement will be executed according to the current
settings. Press Core Button on the main screen to view the core settings.
Please note that you can use this button only in Manual mode or in Manual Mold Height Adjustment
mode.
Core B In Core B Out buttons: Press the Core B In button to move in core B or
use the Core B Out button to pull core B. Any core movement will be executed according to the current
mode.
Core C In Core C Out buttons: Press the Core C In button to move in core C or
use the Core C Out button to pull core C. Any core movement will be executed according to the current
mode.
Also note that the platen position and the core sequence must match if you press these buttons. Otherwise
the cores can’t move.
Cores D – F can only operate by using the mold close/open – buttons.
Air Blast Moving Platen button: Use this button in Manual Operation mode to activate the
air blast for the moving platen. The current air blast settings will be used. Press Eject Button on the main
screen to view the settings. Please note that you can use this key in Manual Operation mode and Manual
Mold Height Adjustment mode.
Air Blast Static Platen Key: Use this button in Manual Operation mode to activate the air
blast for the static platen. The current air blast settings will be used. Press Eject Button on the main screen
to view the settings. Please note that you can use this button in Manual Operation mode and Manual
Mold Height Adjustment mode.
Please note that air blast can only be activated when the platen position is bigger than the air blast
activation position. Otherwise it can’t do any movement if you press the two buttons.
9-20
Manual Operation Mode Keys (Right)
Nozzle Forward Button: Press and hold this button in Manual Operation mode to move the
nozzle and injection unit forward. Release the button to stop the movement. Please make sure the nozzle
advance limit is set correctly (limit switch located on the machine or transducer profile endpos. setting) to
prevent damage as a result of the nozzle colliding with the mold.
Please note that you can use this key in Manual Operation mode and Manual Mold Height Adjustment
mode.
Nozzle Backward Button: Press and hold this button in Manual Operation mode to retract
the nozzle and injection unit. Release the button to stop movement.
mode.
Injection Button: To use this button the controller has to be in Manual Operation mode or
Manual Mold Height Adjustment mode with the Heating activated. After the pre-set Barrel Temperature
has been reached press and hold this button to inject resin as desired. The injection will stop as soon as the
key is released or the Inject- and Hold Pressure sequence has finished. The injection will be executed
according to the injection settings. Press Inj Button on the main screen to view the settings.
Charge Button: Use this button in Manual Operation mode or Manual Mold Height
Adjustment mode to charge the injection unit. Press and release this key to start charging. The operation is
automatically stopped once charging has been completed. If necessary, press and release the Charge
button again to stop charging immediately. Press Charge Button on the main screen to view the settings.
mode.
This button has another function: start the Auto Purge, while in manual mode, press the Inj Button on the
main screen, then press the Func Button on the second screen, check the Auto Purge to “Use”, now press
the Charge Button. The controller will activate the Auto Purge movement.
Suck-Back Key: While in Manual Operation mode, press this key after resin injection to
initiate suck-back. The operation will stop once the key has been released, the set time has passed or the set
endposition has been reached. Suck-back will be executed according to the suck-back settings. Press
Charge Button to view the settings. Please note that you can use this key in Manual Operation mode and
9-21
Manual Operation Mode Keys (Bottom)
Hydraulic Pump Motor On/Off Button: Press this Motor On button in

Manual Operation mode to start the hydraulic pump motor (customer installed). And press the Motor Off
button in Manual Operation mode to stop the hydraulic pump.
Heating On/Off Button: Press this Heating On button in Manual Operation

mode to start heating the barrel, press this Heating Off button to stop heating the barrel. The heating will
use the current barrel heating settings. Press Temp button on the main screen to view the settings
9-22
2.1.3 Data Entry Keys
The keys described in this section are used for numerical input.
When you touch any Number Field on the screen, this keyboard will appear and let you input the number
you want to. The computer control unit has a pre-set minimum/maximum for most values that cannot be
exceeded. This values are displayed above the keyboard, in this case: Input from 20.1 to 599.9 is possible
If you try to enter a value that exceeds the pre-set minimum/maximum you will not be able to leave the
current entry field until a correct value has been entered.
Ok button: The input will be checked according to the limits. If the input is
valid, the controller will confirm the input. If it's out of tolerance, the controller will ask for a valid input.
Cancel button: Press this button to cancel your changes and to close the dialogue box. If
this button is used during numeric value input no changes will be made and the currently selected
parameter will be reset to its original value.
Help Button: Press this button to get help from the controller.
Delete Button: Deletes wrong number inputs.
Increase Button: Press this button once to increase the value.
Decrease Button: Press this button once to decrease the value.
Re-Input Button: by pressing this button; the number you have input last time will be
copied to the number field.
Important: In order to avoid any loss of data and/or settings make sure you have saved the current mold
set again before loading a new mold. If you fail to do so any settings changes you may have made will be
lost.
If you are unsure if the current settings have been saved always save the current mold set into the mold set
database.
2.2 HMI Display
2.2.1 Overview
Operation Mode Barrel Temperature Shot Count Cycle Time
Nozzle
Move display Position (opt)
Pressure,
Flow,
optional: Charge RPM
Clamp tons
Inj.pressure
Screw
2nd prop. Position
valve (opt)
Ejector
Position Oil
Temperature
Mold
Position
Date
Time
An arrow right of the

Screen Menu Movement Status / motor will appear here if
Alarmdisplay the hydraulic motor is
turned on.
2.2.2 Mold Settings
Mold Settings
Hi.Close: Differential high-speed mold closing option.

Set Clamp Force (Set Clamp For): Set clamping pressure in tons. (if machine is equipped with a clamp
force sensor)
Mld-Open-Stroke (Open Str): displays the distance the mold will travel between mold closed and mold
open positions
Clamp Position (Clamp pos.): Current clamp (mold) position.
Mold Opening and Closing Settings: Mold Closing and Mold Opening are divided into 3 phases each.
Pressure and speed settings can be adjusted separately for each phase. The transition between each phase is
controlled by the corresponding position settings.
Mold Functions
Mold Protection Time (Mld Prot.Time): Set the mold protection time, if the setting time has elapsed and
the mold didn’t finish the mold protection, an alarm will be appeared and the controller will stop mold
movement immediately.
Actual Mold Protection Time (Act Mold Prot.Time): actual mold protection time
Hi Close Delay Time (Hi.Close Time): Set the delay time for the High close valve to reduce the shock.
Mold Parameters
Mold Close (Mld Close): Set the mold close pressure and flow at the setup mode.
Mold Open (Mld Open): Set the mold open pressure and flow at the setup mode.
Stage: Adjust the phases for the mold open and the mold close movement.
Mold Settings Profile (ClProf and OpProf)
The corresponding Mold Closing and Mold Opening profiles are displayed in the Pressure/Flow-Position
Graphs on the right hand side (top: Pressure-Positon, bottom: Flow-Position).
The Pressure – Position graph and the Flow– Position graph show the current mold settings.
2.2.3 Injection
Injection Settings
Switch Mode:
If the Time mode is used the controller will switch to Hold Pressure after the set injection time has
elapsed.
In case the Position mode has been selected the controller will switch to Hold Pressure after the last set
injection position has been reached.
If your machine supports Injection Pressure- and/or Cavity Pressure sensors, this data can also be used as
switch mode.
Depending on your selection, you can use one or more of the above mentioned conditions for switching
from Injection to Holding. However, it is recommended to always additionally use the time mode as a
backup to initiate the Hold Pressure phase if for some reason the set transition position and/or pressure
values cannot be reached.
Please note that you should always set the pre-set time limit higher than the usually required injection
time. This avoids poor molding results due to possible resign fluidity variations (poor fluidity could
require a longer than usual injection time).
Hold Pressure (Hold Pres.): Current screw pressure.
Injection Time (Time Threshold): Set the time for switch to hold movement.
Screw Stroke (Screw Str): Sets the distance the Injection will travel.
Screw Pos (Screw Pos): Current screw position.
Pressure Hold and Injection Settings: The Injection process is divided into 4 - 6 phases, Pressure Hold
into 3 - 4 phases (depending on customer setup). Pressure and speed settings can be adjusted separately for
each phase. For the Injection process the transition between each phase (including the transition from
Injection to Hold Pressure) can be controlled by time or position settings. Which settings (either time or
position) are used depends on the Hold Pressure Transition Mode settings. Please refer to the Hold
Pressure Transition Mode section in this paragraph for a more detailed explanation on how to use the
different transition modes.
The transition between each Hold Pressure phase is controlled by the corresponding time settings and is
not affected by the Hold Pressure Transition Mode settings.
The corresponding Injection and Hold Pressure profiles are displayed in the Pressure-Position Graph on
the right hand side (Injection right, Hold Pressure left).
Please note that it is possible to use a combination of pressure and time settings to control the injection
process by setting the position value for the transition from Injection to Pressure Hold to zero. In this case
the final position will never be reached and the pre-set injection time will be used as a backup (please refer
to the Hold Pressure Transition Mode section in this paragraph for more details).
Injection Functions
Inject Switch: see Injection Settings screen
Activation Position (Activation Pos): defines the screw position where the switch monitoring is started.
Note: just set the position to the maximum screw stroke if you don’t need this function.
Hold Decompression Function (HoldDecom Func): It is a special function for big machines. When the
machine changes from injection to hold, a special valve will be opened at the same time to reduce the
shock.
Auto Purge Settings
Auto Purge: In Manual or Setup Operation mode, AutoPurge can be used by setting this Radio Button to
“Use”, and afterwards pressing the Charge button on the key panel.
Pressure and Flow Settings for Auto Purge: The Auto Purge movement is divided to three movements,
Injection, Charge, and Suck-Back. Pressure and speed settings can be adjusted separately for each
movement. Note: It is not possible to set a position for the charge movement; it's time controlled. When the
set time is elapsed, the charge movement will stop and continue with Suck-Back.
Purge Count: Set the number of auto purge cycles you want to execute.
Purge Time: The auto purge movement can be limited by setting this time (in seconds).
Additional Injection Functions
Cold Drop: Cold drop can be used in half auto and auto cycle mode by setting this Radio Button to “Use”.
This movement can be activated after the clamp closed and the nozzle doesn’t be forward with the setting
pressure and flow to inject the clod material out of the screw. The movement will be stopped when the
actual screw position is less than the setting position.
Intrusion: Intrusion can be used in the half and auto cycle mode by setting this Radio Button to “Use”.
This charge movement can be activated before injection with the setting pressure and flow. It also can set
the backpressure value. This movement will be stopped if the setting time has elapsed.
Gas Injection: setting the Radio Button to “Use” can use Gas Injection if the machine is equipped with the
gas device. This function will be activated after the actual position is less than the setting position and stop
after the setting time has elapsed.
Injection Valve Gate Settings
Valve Gate Settings

Valve Gate: Valve gate can be controlled by the time and position separated.
Use Valve Gate: The valve gate can be used when this checkbox is selected.
No Of Gates: How many valve gate you want to use.
Injection Parameters
Const Output: Setting for the injection movement in setup mode.

Max Injection Time: Time setting for the maximum injection time. The controller will alarm if the time
has elapsed and the movement still isn’t finished.
Stage: Adjust the phases for the injection and the hold movement.
2.2.4 Charge & Suckback Settings
Charge & Suckback Settings
Suck-Back Mode (SB Mode): Depending on the selected mode, Suck-back will be controlled using the
stroke or time setting. Choose Position for stroke control and Time for time control. Set the suck-back
mode to “No” if no suck-back is needed.
Screw Stroke (Screw Str): the max injection stroke of the machine.
Screw Position (Screw Pos): Current screw position.
Charge (Plasticizing) Settings: The Charge (Plasticizing) process is divided into three phases. You can
set the values for pressure, backpressure (optional), speed and end position individually for each phase.
Suck-Back Settings: Allows you to set the values for suck-back pressure, speed and stroke/time. Suck-
back will be executed according to the mode selected. Please refer to the Suck-Back Mode section of this
paragraph for further explanation. Note: In Manual mode, the settings for Suckback after charging
("SB aft.") are used.
Charge & Suckback Functions
Max Plasticizing Time: The set plasticizing time is the maximum plasticizing time for the charging
movement. If the set time is elapsed, the charge movement will stop and the controller will give an alarm.
Suck-Back Settings: Allows you to set the values for suck-back pressure, speed and stroke/time. Suck-
back will be executed according to the mode selected. Please refer to the Suck-Back Mode section of this
paragraph for further explanation. Note: In Manual mode, the settings for Suckback after charging
("SB aft.") are used.
Charge & Suckback Parameters
Charge stages (ChrgStages): Adjust the stages for charge movement.

Const Settings
Charge: set the flow and the pressure for the charge movement in setup mode.
Suck-Back: set the flow and pressure for the suck-back movement in setup mode.
2.2.5 Ejection
Ejection Settings
Eject Stroke. (Ejector Str): the max ejector stroke of the machine.
Eject Position (Eject Pos): Current ejector position.
Ejector Count (EjeCount): The number of times the ejector will be activated.
Delay: set the delay time before Eject forward and backward.
Ejector Settings:
The Ejector is activated automatically after Mold Opening has finished. The initial ejection is divided into
two phases that can be controlled separately. You can set pressure, speed and end position individually for
each phase.
Ejector Mode (EjeMode):
The Hold Mode (Hold) is used during half-automatic operation. The ejector moves forward according to
the ejector settings and the product is dropped or taken out. After the safety gate has been opened and
closed the next cycle will start and the ejector with move back. Because of this condition, this mode is not
allowed in full automatic operation mode.
In Continuous Mode (Cont) the ejector is activated according to the Ejector and Ejector Count settings.
This mode is usually used for automatic machine operation.
If you use the Vibration (Vib) Mode the ejector will be activated according to the Ejector and Ejection
count settings. But the difference between count mode and vibrate mode is that after reaching the forward
end position ("EjeF.End"), the ejector only moves back to the second backward-phase ("EjeB.#2") and
then to forward end again. The last time the ejector will be back to the end position.
Please note that if you want to deactivate the ejector you can set the ejector mode to “No”.
Air Ejector Settings:
The machine provides up to 6 air blast ejection valves; for the moving plate as well as for the stationary
plate. Set the start position, activation time and delay time (if necessary) according to your preferences.
Note: If you want to disable this function, set the Act.Time to 0.0!
Ejection Functions
Use Ejector Backward Function (Use EjeBwd Func) & Ejector Backward time (Eje.bwd.time):
If you use this function, the ejector backward valve will be opened according to the Ejector Backward time
(unit is seconds) when mold close movement is activated. It is used to ensure that the ejector keeps in
backward position while the mold is closing.
Ejector Link (Link): when this function is selected, the ejector movement will be started while mold is
opening according to the Link Activation Pos. (optional function).
Link Activation Pos: If Ejector Link function is active at the mold reaches this position during mold
opening, the ejector movement is started.
Ejection Parameters
Const out Settings:

Ejector Forward (Eje Fwd): the flow and pressure for the ejector forward in the setup mode.
Ejector Backward (Eje Bwd): the flow and pressure for the ejector backward in the setup mode.
2.2.6 Cores
Core Settings
Core Settings:
Depending on the setup of your machine, it may be equipped with up to 6 cores (A, B, C, D, E, F). Each
core is controlled separately.
Set the Pressure, Speed, Activation Time, Unscrew Count (if used) and Position values for moving in and
retracting each core according to your needs.
Type: Choose the Core mode if you want to use a regular core that is moved in and retracted
hydraulically. The Unscrew mode should be used if your mold requires threads created by unscrewing the
inserted core. If you don’t need Core, just check the radio button to “off”.
Control: In Core mode you can either use Limit control or Time control. In Unscrew mode you can either
use Time control or Count control.
Using Limit control allows you to control the core movements by limit switches for end-position control
(for insertion and retraction). At the pre-set point during the production cycle the core(s) will move in/out
until the limit switch controlled end-position is reached. Please make sure the limit switches are activated
since deactivated switches will cause the machine to stop (if Limit control is selected).
Act.Time control uses time settings for core insertion and retraction. At the pre-set position during the
production cycle the core(s) are moved in/out for the set period of time. Therefore core movement (travel)
is not controlled by end-position but by time. As a result you will not be able to rely on the protection of
limit switches.
Accordingly, in Unscrew mode the Time control is used to set the time core unscrewing is activated (e.g.
for creating threads).
Val.Del.T allowes you to set a delay time for the direction valve. The machine builds up pressure and flow
and opens the direction valve after this delay time.
Count control uses the pre-set number of revolutions to control the unscrewing of the core at the set
position during mold opening. To use Count Control you have to make sure a photo sensor for counting the
revolutions is installed on the core driving gear.
Please note that Count Control allows for higher precision than Time control.
Core Functions
Hold: By activating this function, the core valve will be opened while injection is active. So the force of
the hydraulic oil will make sure that the core keeps at the in position.
Link: If this function is used, the core will be activated parallel to the mold open movement according to
your settings. Please note that only one core can use the link function at the same time.
Core conn. To E12 Robot: Selector to define which core signals (CoreIn, CoreOut) are connected to the
Euromap12 robot core signals.
Core Parameters
Special Core Usage: special core sequences can be activated here. make sure that the setting is 0 if you
operate standard molds.
A manual book for these special core sequences is available on request.
Max Core move Time (Max Core Move): the monitor time for the core movement.
Const out Settings

Core A…F In (CoreA…FIn): set the flow and pressure for the core A to F In movement in the setup
mode. Each core can use a separate setting.
Core A…F Out (CoreA…FOut): set the flow and pressure for the cores A to F Out movement in the
setup mode. Each core can use a separate setting.
2.2.7 Nozzle and Mold Adjustment Settings
Nozzle and Mold Adjust Settings
If your machine is equipped with Nozzle limit switch:
If your machine is equipped with Nozzle transducer:

Pressure: Set the hydraulic pressure for Nozzle advance and retraction.
Flow: Set the hydraulic flow for Nozzle advance and retraction.
Nozzle Forward Fast (NozF.Fst.): Set the speed for the corresponding high speed movements of the
nozzle (injection unit). During advance movement the high-speed settings are used according to the
position (if your machine is equipped with a nozzle transducer) or until the limit switch (if equipped with
nozzle limit switch) is reached. Thereafter the nozzle will advance using the low-speed settings until it has
reached the final injection position. Please refer to the end-position settings for more information on how
to set the end-position to avoid damage to the nozzle/mold.
Nozzle Forward Slow (NozF.Slow.): Set the speed for the corresponding low speed movements of the
nozzle (injection unit) during the final advance movement before contact with the mold is made.
Please refer to the end-position settings for more information on how to set the end-position to avoid
damage to the nozzle/mold.
Act. Time (Duration of Nozzle Retraction): Use this feature to control nozzle retraction using a time
setting if your machine is equipped with a nozzle limit switch. If using a nozzle transducer, nozzle
retraction is controlled by position.
Nozzle Back Mode (NozB): Set the mode for the nozzle backward movement. In after charge (AftChr)
mode, the nozzle will move back after the charge movement finished. In Before Mold Open (BefMOp)
mode, the nozzle will move back before the mold opens. In the After Injection (AftInj) mode, the nozzle
will be back after the injection movement has been finished. If you doesn’t need the nozzle backward
movement, just set the mode to “No”.
Mold Height Adjustment Settings

Mold Forward (Mld.F.): Set the hydraulic pressure and flow for mold height advance adjustment. Please
refer to the Mold Adjustment Button section for more information on the mold height adjustment process.
Mold Backward (Mld.B.): Set the hydraulic pressure and flow for mold height retract adjustment. Please
refer to the Mold Adjustment Keys section for more information on the mold height adjustment process.
Nozzle Functions
Nozzle Hold Function (Hold Nozzle): this function keeps the nozzle forward valve
open during injection and charging to keep the nozzle touch the mold tightly.
Nozzle Delay Time (Delay NozBk): This delay time is used in the After Injection mode of the nozzle.
After injection has finished and this delay time has elapsed, the nozzle starts to move backward.
One Gear Adjust Function (One Gear Adj): If this function is used, the mold height adjust (advance and
retraction) will move forward or backward only one gear. It is used for the micro mold height adjust. If
you don’t need this function, switch this mode to “No”.
Nozzle Parameters
Const out Settings

Nozzle Forward (Noz Fwd): Set the pressure and flow for the nozzle forward movement in the setup
mode.
Nozzle Backward (Noz Bwd): Set the pressure and flow for the nozzle backward movement in the setup
mode.
Nozzle Valve Delay Time (Noz Val Delay T): delay time of direction valve at nozzle backward
movement stop
Mold Height Adjust Automatic, Mold Open Position (MldAdj.Auto OpenPos): in automatic mold
height adjustment mode, the mold open to this set position before it readjusts the gears.
Mold Height Adjust Automatic, Back Gears (MldAdj.Auto BackGears): in automatic mold height
adjustment mode, the mold adjusts this number of gears backward if it couldn't close the mold.
Use Dynamic Clamp Force Adjustment (Use Dyn.Cl.Force Adj.): If your machine is equipped with a
clamp force sensor, this selector is displayed. Set it to "Use" if you want to adjust the clamp force
dynamically in Automatic Mode.
Clamp Force Deviation (Clamp Force Dev.): tolerance setting in percent where no adjustment is done.
Clamp Force per Impulse (Cl.Force per Imp.): determine the change of the clamp force per impulse by
using the One Gear Adjust function. The setting's unit is tons per Impulse.
Note that improper setting of this parameter can lead to malfunction of the dynamic clamp force
adjustment.
2.2.8 Temperature Control
Temperature Settings
Use this screen to set the temperature for the different barrel heating zones (up to 16 depending on your
setup) and to monitor the current status.
In case of temperature related malfunctions this screen enables you to analyze possible causes. If the color
of barrel is yellow, this means you have either a disconnected corresponding Temperature sensor or a
malfunctioning Temperature Card. If the color of the barrel is green, this means the heating is activated. If
the color of the barrel is blue, this means the heating is deactivated now.
Keep Warm: Set this mode to “Use” if you want to keep the temperature at a reduced Keep Warm value.
Press the Func Button on the Temperature settings mask to set the temperature for keep warm. If
production should continue, make sure to disable this function again by setting the selector to "No". Note:
make sure to use PID or PVC function, otherwise this function cannot keep the set value.
Cool Prevent: additional time setting after the barrel heating reaches the set value. if time has not elapsed,
all screw (injection, charge, suck-back) movements are disabled. after the set time has elapsed, the
controller allows the screw movements. By using this function, you can make sure that all material in the
screw has reached the set temperature.
Act Value: The current temperature for the corresponding barrel heating zone.
Set Value.: Set your desired temperature value for the corresponding barrel heating zone.
Temperature Functions
This screen allows you also to program barrel heating activation using day and time settings.
Temperature Mode (Mode): Set the Temperature mode on the Temperature function mask on the
second screen of temperature. You can set the mode for each barrel separately. In PID mode, the
temperature will be controlled by PID, which is used to control the temperature more precisely. In Set
mode, the temperature will be controlled by the percent rate which is set by the user. For example, if the
user sets the rate is 50%, the heating will be on e.g. one second and then be off one second. If you don’t
need this barrel heating, set this barrel’s mode to “off”.
If your machine is equipped with a PVC cooling function, by selecting this mode you can activate
additional cooling outputs for each zone. Both heating and cooling are PID-controlled.
Keep Warm: These settings are used for the Keep warm function ("Use") on the Temperature Settings
mask on the main screen. Each barrel temperature can be set separately. The machine will keep the
temperature on the value you have set (if PID or PVC mode is selected).
Heater Presetting:
Set the time and day you want the barrel heater to be turned on to pre-heat the machine before operation. If
you want to use the heating presetting, activate the checkbox and set the time and day you want pre-heat
the machine. Otherwise disable it by deactivating the checkbox.
Temperature Parameters
Temperature High Tolerance (High Tol.): Set the upper tolerance for each barrel separately.
Temperature Low Tolerance (Low Tol.): Set the lower tolerance for each barrel separately.
Oil Temperature Setting:

Oil Temperature (Oil Temp.): Hydraulic Oil temperature indicator.
Oil Set: set temperature for the oil cooling. If the oil temperature is higher than this set value, the
controller will activate the oil cooler.
Alarm AutoStop: the setting temperature for stopping auto movement. If the oil temperature is higher
than this setting value, the controller will stop the auto movement after finishing the actual cycle, switch to
the manual mode and display an alarm to show the oil temperature is too high and the automatic mode has
been stopped.
Alarm Motor Off: the setting temperature for turning off the motor. If the oil temperature is higher than
this setting value, the controller will switch off the motor and display an alarm for the oil temperature.
Group Heating: by activating this checkbox, the barrels will heat up together keeping a small tolerance
(Tol.betw.Zones setting).
Note: If the Group Heationg is used, expect a longer heat up time, because the zones will sometimes
reduce it's outputs to keep the tolerance to other zones.
Tolerance between Zones (Tol.betw.Zones): the controller will keep all zones in this tolerance during
heating up.
Heating Ramp: The ramp for the group heating function. It is set in °C per second. Make sure to set it
equal or lower than the capability of the barrel heating. Otherwise the result of the Group Heating may not
be good.
Error Mode: If this function is activated, the machine automatically reacts on temperature sensor breaks
by switching to "Set" mode. Also a message is given to inform the operator. After the sensor is repaired it
switches back to the original heating mode.
Cool on Hold: in case your machine is equipped with water cooling channels, this checkbox, if activated,
also does cooling in Manual operation mode. If it's unchecked, it will stop cooling in Manual op.mode.
Expected minimum temperature change (exp.min.temp.ch.):
This function is used to detect malfunctions on temperature inputs, e.g. wrong wiring or short circuit.
While the controller does full heating (100% output), the reaction on the corresponding temperature inputs
in monitored. The temperature must rise at more than this set value. In case the temperature doesn't
increase, an alarm will be given and the heating for the related zone will be stopped.
For example you set 4.0, this means the heating, if switched on, must increase at least 4°C per minute
while doing 100% heating.
2.2.9 Hot Runner Control (optional)
Hot Runner Settings
Use this screen to set the temperature for the different mold heating zones (up to 32 depending on your
setup) and to monitor the current status. This screen allows you also to program hot runner heating
activation using day and time settings.
In case of temperature related malfunctions this screen enables you to analyze possible causes. If the color
of the hot runner display is yellow, this means you have either a disconnected corresponding Temperature
sensor or a malfunctioning Temperature Card. If the color of the hot runner display is green, this means the
heating is activated now. If the color of the hot runner display is blue, this means the heating is deactivated
as you can see above.
HRS Cool Prevent: additional time setting after the mold heating reaches the set value. if time has not
elapsed, all screw (injection, charge, suck-back) movements are disabled. after the set time has elapsed, the
controller allows the screw movements. By using this function, you can make sure that all material in the
screw has reached the set temperature.
Act Value: The current temperature for the corresponding hot runner-heating zone.
Set Val.: Set your desired temperature value for the corresponding hot runner-heating zone.
Hot Runner Functions
Hot Runner Temperature Mode (Mode): Set the HotRunner mode. You can set the mode for each hot
runner separately. In PID mode, the temperature will be controlled by PID, which is used to control the
temperature more precisely. In Set mode, the temperature will be controlled by the rate which is set by the
user. For example, if the user set the rate is 50%, the heating will be on one second and then be off one
second. If you don’t need this hot runner heat, set this barrel’s mode to “off”.
Heater Presetting
Set the time and day you want the mold heater to be turned on to pre-heat the machine before operation. If
you want to use the heating presetting, activate the checkbox and set the time and day you want pre-heat
the machine. Otherwise disable it by deactivating the checkbox.
Hot Runner Parameters
Temperature High Tolerance (High Tol.): Set the upper tolerance for each mold heating zone
separately.
Temperature Low Tolerance (Low Tol.): Set the lower tolerance for each mold heating zone separately.
Group Heating: by activating this checkbox, the HotRunners will heat up together keeping a small
tolerance (Tol.betw.Zones setting).
Note: If the Group Heationg is used, expect a longer heat up time, because the zones will sometimes
reduce it's outputs to keep the tolerance to other zones.
Tolerance between Zones (Tol.betw.Zones): the controller will keep all zones in this tolerance during
heating up.
Heating Ramp: The ramp for the group heating function. It is set in °C per second. Make sure to set it
equal or lower than the capability of the mold heating. Otherwise the result of the Group Heating may not
be good.
Error Mode: If this function is activated, the machine automatically reacts on temperature sensor breaks
by switching to "Set" mode. Also a message is given to inform the operator. After the sensor is repaired it
switches back to the original heating mode.
Expected minimum temperature change (exp.min.temp.ch.):

This function is used to detect malfunctions on temperature inputs, e.g. wrong wiring or short circuit.
While the controller does full heating (100% output), the reaction on the corresponding temperature inputs
in monitored. The temperature must rise at more than this set value. In case the temperature doesn't
increase, an alarm will be given and the heating for the related zone will be stopped.
For example you set 4.0, this means the heating, if switched on, must increase at least 4°C per minute
while doing 100% heating.
2.2.10Alarm and Message Display Screen
[Alarm]/[Message]: All alarms are displayed on the [Alarm] screen. By pressing the [Message] label, the
view can be changed to messages.
State: the stateof the alarm/message: can be active or inactive
Time: the time the alarm/message occurred.
Class: is used to separate alarms which are Class 1 and messages which are Class 2. Alarms of Class 3
work as message in Manual mode and as alarm in Automatic mode.
Description: Brief explanation of the alarm/message that has occurred on the machine.
Help ID: the system name of the alarm.
Confirm Button: This button can be used to confirm the alarm/message instead of using the Manual
button.
Setup Button: the columns that should be displayed can be setup here.
Help Button: opens a detailed help page for the corresponding alarm. If no information is available, the
main page of the help is displayed.
2.2.11 I/O Channel Monitor
Selection Mask
DIs: Selector to display the states of the digital inputs of the controller
Keys: Selector to display the states of the panel keys (not available on all systems)
DOs: Selector to display states of the digital outputs of the controller
LEDs: Selector to display the states of the panel LED (not available on all systems)
AIs: Selector to display the states of the analog Inputs
AOs: Selector to display the states of the analog output
TOs: Selector to display the temperature output (not available on all systems)
Digital Input Channel Monitor
This screen allows you to verify if the controller is receiving an input signal from the relevant
sensor/switch. In case you encounter possible input related hardware problems during machine operation
switch to this screen and verify. Inputs with HIGH level are marked with a green circle.
Digital Output Channel Monitor
This screen allows you to verify if the controller output signal is reaching the connected hardware. In case
you encounter possible output related hardware problems during machine operation switch to this screen
and verify.
You can identify an output signal by the label displayed next to the corresponding output channel. If the
circle color is changed to red, this indicates that the output channel currently outputs a signal. If the circle
color is white, this indicates that the output channel isn’t output a signal.
Force Function for Digital Output signal:

Technicians and System Administrators can use the Force function to force outputs to output HIGH level.
Please keep in mind that if a digital output is forced, all other digital outputs are switched off for safety
reasons!
Touch the area of the digital output that you want to force. After this, a dialog will open:
Confirm Button: By pressing this button, the selected digital output will be switched
to HIGH level and all other digital outputs will be switched off.
Cancel Button: Press this button to cancel your changes and to close the dialogue box.
If this button is used no changes will be made and the current settings will be kept in it's original status.
To reset the force of the digital outputs, touch any area on the screen or change to a different screen or tab.
Analog Input Channel Monitor
This screen allows you to verify if the controller is receiving an analog input signal from the relevant
sensor. In case you encounter possible analog input related hardware problems during machine operation
switch to this screen and verify.
Analog Output Channel Monitor
Force Function for Analog Output Signal

Technicians and System Administrators can use the Force function to force outputs to any voltage or
physical unit depending on the connected valve.
Touch the area of the analog output that you want to force. E.g. for the Pressure proportional valve, you
can choose if you want to input a pressure or a voltage value. After this, a dialog will open:
Temperature Output Channel Monitor (not available on all systems)
Force Function for Temperature Input/Output Signal:

Technicians and System Administrators can use the Force function to force outputs to defined PWM ratio
to the corresponding temperature outputs.
The dialog described in this section is used to force the temperature output signals:
2.2.12Mold Data Settings
Active mold data: The current mold data in use.
Drive: destination where the mold data is saved, options:

CF: the mold data is saved into the controller's CF card memory
USB: if a memory stick is connected to the USB port of the controller, select this option
Name: The name of the mold data.
Data: The creation time of the mold data.
Size: The size of the file (in bytes).
Load: Select a mold data file and then push this button to load it.
Save: Saves the actual mold data setting to the Active mold data.
Save As: Saves the actual mold data to a new file.
Delete: Deletes the selected mold data.
Rename: Changes the filename of the selected mold data.

2.2.13Manager Settings
Auto Delay: The delay time before Automatic Cycle starts.

In Full Automatic mode, this delay time is executed once after the machine is switched to this mode and
the automatic cycle is started.
In Half Automatic mode, the delay time is executed every time after starting the cycle.
Maximum Cycle Time (Max Cyc.Time): The maximum cycle time. If this time is exceeded, the
controller will give an alarm and stop the cycle.
Part Drop Time: Set the monitor time for the part drop sensor in Full Automatic mode here. If this time
is exceeded and no part drop has been detected, the controller will give an alarm and stop the cycle.
Shots: The number below Set label indicates the setting product counts. The number field below Now
label indicates the current product counts. The Button below Reset label is used to reset the product
counter.
If the Set value is reached, the controller will stop the Automatic cycle and give a message. After
confirming this message, the shotcounter will be reset to 0 automatically.
Use Photosensor: Selector if the photosensor is used to detect parts drops in Full Automatic mode.
2.2.14Process Data Protocol (Part Supervision)
output to printer output to file
This screen can be used to monitor relevant production parameters.

The monitored values are represented in a table.
Start and Stop: enables or disables the part supervision.

Setup: opens a setup dialog for the part supervision
View:
Hold List: Pauses the display of the parameters. The parameters are still recording in the background and
the display continues normally (without missing any data) by pressing the button Release List.
Delete: clears the data of the table
Details Off: hides the status headline for displaying the interval and the output. It can be switched on again
by pressing Details On.
By pressing the Setup button, a dialog like this will open:
Measure Parameter: is used for the basic setup of the data recording.
Kind of measure: you can choose Time measure or Cycle measure.

Cycle measure: records data at the end of an automatic cycle.
Start Delay: delays the start of the data recording by the setting.
Interval: determines which part datas are recorded. "1 Shot" means the part data of all parts is recorded,
e.g. a setting of 5 means only the data of every 5th .part is recorded.
Events: not used
Time measure records data depending on the time setting, e.g. every 10 seconds. Usually this setting is
not used.
Protocol: allows to record the data (additionally to the display on the screen) to file or to printer (if
available).
Unit System: the unit system (ISO or Imperial) for the data recording can be selected here.
Parameter Selection: is used to setup the parameters that should be monitored.
This dialog is separated into Available Parameter and Selected Parameter.

The Available Parameters are arranged in several groups. Please choose the relevant parameters for the
part supervision from the group "Quality" by using the arrows in the middle. All Selected Parameters will
be recorded.
Properties: can be used to set a arbitrary color for each column.

2.2.15Quality monitoring
This screen can be used to supervise the production quality.

Parameter:
Bad Count: number of parts classified as "Bad" according to the settings below.
Good Count: number of parts classified as "Good" according to the settings below.
Bad Rate: percentage of bad part of the production.
Interval defines which parts are supervised. A setting of 1 means all parts are supervised. A setting of e.g.
5 means only every 5th part is supervised.
Settings:
All parameters relevant for the part quality are displayed in this table by Actual-, Set- and Tolerance-value.
The selector on the right side (No / Use) is used to enable/disable the supervision of the corresponding
parameter.
A part is classified as "Bad" if any Actual value is lower than the corresponding Set – Tolerance value or
bigger than Set + Tolerance value and the corresponding selector is set to Use.
.
2.2.16System Settings
This screen is used to login users with higher access rights.
It also displays the used language, the date, the unit, the current user and the device IP address.
Language: Press this item menu to display the Language switch mask. Then the user can choose the
demanded language.
Note: Usually the machine will be delivered with your local language and English language. Other
languages are available at your machine manufacturer on request.
Date: modify and display the current date and time.

Unit System: Select the system unit for the controller. Possible selections are ISO or Imperial unit.
If you press the User button on this screen to login a user with higher acces rights, the screen below will
appear.
Note: If the keyswitch on the machine is off, it's not possible to login users. The User button is disabled in
this case.
User: choose the user name of the operator.
Password: the password for the corresponding user.

Force Write Permission: not used
Read Only: If you enable this selection, the user will be logged in using the "Read Only" mode. This
means you cannot change any variables. Usually it's not used.
Logout: This button is only displayed if a user is logged in and can be used to logout. By pressing this
button, the machine will switch back to the lowest user level.
Online: This tab is only displayed if a user is logged in. It displayes all users currently connected to the
controller.
Note: This can be more than one if your machine is equipped with a remote control function by telephone
line or network.
Confirm Button: The selection you have chosen will be activated.
Cancel Button: Press this button to cancel your changes and to close the dialogue boxes. If this
button is used before pressing the confirm button no changes will be made and the current settings will be
kept in its original status.
Display: press this button to set the Brightness and the Contrast of the display.
Note: depending on your system, this function may not be available.
By pressing the System Button on the setting mask, a dialog as pictured below will be displayed:
Restart HMI: this function is not available now.

By pressing the Details button on the setting mask, a dialog as pictured below will be displayed:
This screen contains internal information and is therefore usually not needed by the user.
Spooler: this function is not available now.
By pressing the Version button on the setting mask, a dialog as pictured below will be displayed:
If you have any questions and need to contact the machine manufacturer, please also provide all this
version information.
Network: this button is not available until now.
Lock: this function is not available.
Report: by pressing this button, the controller will open a directory chooser and afterwards create the
system status report. This is internal information and therefore not necessary for the user. Use this button
only if the machine manufacturer asks you to do so.
Masks Button: The masks button on the settings mask includes special screens, e.g. if your machine is
equipped with a remote control using the telephone line.
2.2.17Analog Input Calibration Mask
After the transducer has been changed or certain machine parts have been modified (e.g. the mold
transducer) you have to reset the corresponding transducer's zero point (in setup operation mode):
1. Press the Setup Button on the key-panel; change the operation mode to setup mode.
2. Move the corresponding transducer to the two end position. One is the forward end position, then record
the minimum voltage. The other is the backward end position, then record the maximum voltage. Input all
this values to the corresponding number-fields.
Mold Transducer (Mold Transd): The transducer for the Clamp (Mold) position.
Screw Transducer (Screw Transd): The transducer for the Injection Screw position.
Ejector Transducer (Ejector Transd): The transducer for the Ejector position.
Nozzle Transducer (Nozzle Transd): The transducer for the Nozzle (Injection Unit) position. Note that
this function is optional.
Screw RPM: Sensor for charge RPM. This settings are only available if your machine is equipped with an
electric charge motor.
Injection Pressure Sensor (Pressure Sensor): Sensor for Injection Pressure (depending on machine
setup).
Clamp Force Sensor (Clamp Force): Sensor for Clamp Force (depending on machine setup)
Note that this screen is compiled according to your machine setup. So the display can slightly vary to the
screen displayed above.
2.2.18Analog Output Calibration Mask-1
Pump Pressure Calibration:

Pressure: Input the pressure and the corresponding voltage for the system pressure.
Points: Input the maximum number of points used for the system pressure calibration
Pump velocity calibration:
Velocity: Input the velocity and the corresponding voltage.
Points: Input the maximum number of points used for the system velocity calibration
2.2.19Analog Output Calibration Mask-2
Do the calibration after the electrical motor for charge movement and/or the servo valve for the
backpressure control has been changed or certain machine parts have been modified. You have to reset the
Charge and Backpressure’s zero point (in setup operation mode):
Charge Calibration:
1: Input the minimum RPM and the corresponding minimum voltage.
2: Input the maximum RPM and the corresponding maximum voltage.
Backpressure calibration:
Backpressure Calibration:
1: Input the minimum Bar and the corresponding minimum voltage.
2: Input the maximum Bar and the corresponding maximum voltage.
2.2.20Machine Settings Mask
The Machine Settings screen is used to set the machine data which have effect on the machine movements
and the machine functions.
Note: this screen only can be accessed by high level users. Wrong settings can lead to machine
malfunction.
The Machine Settings screen is used to set the machine data which have effect on the machine movements
and the machine functions.
malfunction.
Number of Cores (Num.of cores): Set the core number.

Minimum Pressure Voltage (MinPres.Voltage): Set the minimum voltage for the pump pressure.
Core Cushion: It is a special function for the core. If you want a more precise core activation position,
activate this checkbox. On the other hand this function can extend the cycle time.
EjectEnd Limit: the upper limit of eject end position
Extra Protect: if the function is used , the mold fast close valve will be closed till the last phase of
moldclose movement, otherwise the mold fast close valve will be closed after reaching the mold protect
position.
Hydraulic Mold Adjust Motor (Hydr.MldAdj.Motor): if hydraulic motor is used to adjust the mold
height adjust, activate this checkbox. Otherwise disable this selection.
Velocity Output Ramp (Vel Output Ramp): Set the maximum ramp for the pump flow.
Maximum Pressure Voltage (Max.Pres.Voltage): Set the maximum voltage for the pump pressure.
Pressure Output Ramp (Pres Output Ramp): Set the maximum ramp for the pump Pressure.
Maximum Velocity Voltage (Max.Vel.Voltage): Set the maximum voltage for the pump flow.
Minimum Velocity Voltage (Min.Vel.Voltage): Set the minimum voltage for the pump flow.
Invert Door Signal: Invert the signal for the rear door.
Monitor Time: monitor time for the mold adjust gear. if the controller detects no impulses at active mold
adjust movement during the set time, it will give an alarm.
Auto Mold Adjust Limit Time (MldAdj Auto Limit T): The maximum time for the mold auto adjust. If
the setting time elapsed and the auto mold adjust is still not finished, the controller will give the user an
alarm and stop the auto mold adjust.
Maximum Clamp Tons (Max.Cl.Tons): Set the maximum clamp tons for this machine. This is required
if your machine is equipped with a clamp force sensor.
Hydraulic Safety Gate Select (Hydr Check): if hydraulic safety gate is mounted on this machine,
activate this checkbox.
Screw Sensor Mode (ScrSenMo): Set the sensor type for the charge RPM.
Mold Protection Pressure Limit (Mld.Prot.Pres.Limit): Set the maximum pressure for the mold
protection pressure in the mold close movement.
Use E Chrg:if the electric charge motor is installed on the machine, activate this checkbox
Supervis. Oil Filter: the monitor time for the oil filter.
Calibration Time (Cali Time): the set time for the controller to estimate if the movement stop or not.
Oil Level Error R-Edge trigger: Set the R-Edge trigger or not for the oil level error.
Maximum Position Difference (Max.Pos.Diff): The allowed position tolerance for the position precise.
Supervis. Oil Level: Set the monitor time for the oil level error.
Use Photo Sensor: in full automatic mode, use the photo sensor or not.
Oil Filter Error R-Edge trigger: Set the R-Edge trigger or not for the oil filter error
Motor Idle Time: If there is no movement on the machine, the motor will switch off to save power and to
protect the machine. The setting is in minutes.
Motor Cool Water Time (Mot.Cool.W.Time): The delay time for the motor cool water. If the delay time
elapsed and the motor still doesn’t have the cool water, the controller will give the user an alarm to connect
the cool water.
Pump1 Idle Time: Delay time for pump Idle Output.
Pump Velocity Idle: Velocity Output during Idle.
Pump Pressure Idle: Pressure Output during Idle.
Maximum Flow: Set the maximum flow for the machine.
Maximum Flow Ramp: Set the maximum ramp for the pump flow.
Maximum Pressure: Set the maximum pressure for the machine.
Maximum Flow Ramp: Set the maximum ramp for the pump pressure.
Motor Protection Time (Mot.Prot.Time): At motor start, the ON relais outputs for this set time.
Motor Tri Delay Time: not used.
Supervise Front Safety Gate Time (supervise.Fr.SG): the monitor time for the front safety gate. if the
safety gate uses more than 1 digital input, it will ignore different states of the inputs due to mechanical
tolerances.
Supervise Nozzle Safety Gate Time (supervise.Noz.SG): the monitor time for the nozzle safety gate.
Supervise Rear Safety Gate Time (supervise.Rear SG): the monitor time for the rear safety gate.
Hydr Alarm T: set the time of hydraulic alarm time
Mold Auto Adjust Delay Time (MldAdjDelayTime): The delay time for auto mold adjust movement
start.
2.2.21Machine Settings Mask-2
Machine Settings mask -2 is used to set the machine data that has effect on the machine’s movements.
malfunction.
Const Output:
The unit of the ramp settings is difference per second: e.g. a flow ramp setting of 200 will cause the
controller to ramp from 0 to 99% flow in 0.5seconds
Pressure: Set the pressure ramp for all setup movements.
Flow: Set the flow ramp for all setup movements.
Profile Output:
Maximum Pressure Ramp (MaxPress Ramp): Set the profile pressure ramp for all movements.
Minimum Pressure Output (MinPres Out): Set the minimum pressure output for all movements.
Maximum Flow Ramp (MaxFlow Ramp): Set the profile flow ramp for all movements.
Minimum Flow Output (MinFlow Out): Set the minimum flow output for all movements.
StopPres Ramp: Set the Pressure ramp when the movement is stopped.
StopFlow Ramp: Set the Flow ramp when the movement is stopped
2.2.22Machine Settings Mask-3
Machine Settings mask -3 is used to set the machine data which have effect on the machine’s movements.
malfunction.
save Machine Data (save Mach.Data): by pressing this button, all setup data of the machine is stored to
the location selected at Drive
load Machine Data (load Mach.Data): by pressing this button, all setup data of the machine is loaded
from the location selected at Drive
Drive: selector for the location to load/save the machine data.
possible selections are:
Compact Flash: The data is saved to/loaded from the controller's compact flash memory card
USB: If a USB memory stick is connected to the controller, choose this selector to save to/load from the
USB memory stick.
Maximum Inject speed (max.Inj.speed): Set the maximum speed of the injection movement here. Unit is
millimeters per second (mm/s). This setting is used for the closed loop control of the injection movement.
Flow Pump2 On: set the threshold flow value for additional pumps
Number of Pumps (No. of Pumps): Set the number of pumps used in this machine
Mold Open Stroke (Open Str.): Set the mold open stroke
Ejector Stroke (Ejector Str.): Set the Ejector stroke
Nozzle Stroke (NozMaxStr): Set the Nozzle stroke (if your machine is equipped with this option)
Screw Stroke (Screw Str.): Set the Screw stroke
Screw Gain: used for the correct calculation of the charge RPM. The number defines how many bolts are
mounted in your screw and depends on the machine type.
Use Accumulator: enable this selector if your machine is equipped with an accumulator to support the
injection
High speed machine: enable this selector if your machine is equipped with an accumulator and an electric
charge motor to support parallel movements.
2.2.23Machine Settings Mask 4
Number of Lubrication Units: set this number of lubrication units according to your machine type. The
display will vary if your machine if this setting is changed.
Lubrication Pressure Reached (Lubr.Pressure Reached): An indication device if the lubrication
pressure has been reached.
Shot Interval: the interval counter between two times of lubrication.
Lubrication Time (Lubr.Time): the total time for one lubrication process.
On Time: the “on” time for the lubrication pump.
Off Time: the “off” time for the lubrication pump.
Note: The lubrication pump is activated during On Time and switched off during Off Time. This is
continued cyclically until the Lubr.Time has elapsed.
2.2.24Close Loop PID Parameters Settings Mask
Injection Speed Close Loop: If the machine should use the close loop control for the injection movement,
activate this checkbox and set the corresponding PID parameters.
Make sure that the Maximum Inject speed setting on MachineData3 screen is correct to avoid possible
malfunction.
Hold Close Loop: If the machine should use the close loop control for the Hold movement, activate this
checkbox and set the corresponding PID parameters.
Make sure that your machine is equipped with an Injection pressure sensor if you want to use this function.
Charge Revolution Close Loop: If the machine should use the close loop control for the charge
movement, activate this checkbox and set the corresponding PID parameters.
Please not that the machine's screw should be equipped with at least 2 bolts to supply the required
accuracy.
Note: The availability of the closed loop control depends on the machine type and is therefore not available
for all machines.
2.2.25Temperature PID Parameters Settings Mask
Note that the display of the screen varies depending on the number of barrel heating zones on your
machine.
Zone 1 – Zone 12: The user can view (and set) the corresponding PID parameters for the temperature
control here. Anyway setting the PID parameters manually is usually not necessary because the Optimize
function provides the PID parameters.
Optimize: This function is used to get the PID parameters for all barrel heating zones. Before activating
the Optimize function, make sure that the temperature of all zones is lower than 50° to avoid malfunction.
In Setup or Manual mode, activate this checkbox and then press the Heating On button on the key- panel.
Then the machine will perform the analysis of the correct PID parameter for the temperature controlling.
Note: The PID parameters are set by the machine manufacturer; the user should not use this function to
avoid malfunction of the machine.
Maximum Temperature (Maximum Temp): Set the maximum temperature the machine can support. For
safety reasons the heating is automatically switched off if any of the barrel heating zones reaches this
value.
Note: this value is set by the machine manufacturer; the user should not modify this setting to avoid
malfunction of the machine.
2.2.26HotRunner Temperature PID Parameter Setting Mask
(*Optional*)
Note that the display of the screen varies depending on the number of hot runner heating zones on your
machine.
Zone 1 – Zone 12: The user can view (and set) the corresponding PID parameters for the temperature
control here. Anyway setting the PID parameters manually is usually not necessary because the Optimize
function provides the PID parameters.
Optimize: This function is used to get the PID parameters for all hot runner heating zones. Before
activating the Optimize function, make sure that the temperature of all zones is lower than 50° to avoid
malfunction.
In Setup or Manual mode, activate this checkbox and then press the Hot runner Heating On button on the
key- panel. Then the machine will perform the analysis of the correct PID parameter for the temperature
controlling. Note: The machine manufacturer sets The PID parameters; the user should not use this
function to avoid malfunction of the machine.
Maximum Temperature (Maximum Temp): Set the maximum temperature the machine can support. For
safety reasons the heating is automatically switched off if any of the barrel heating zones reaches this
value.
Note: The machine manufacturer sets this value; the user should not modify this setting to avoid
malfunction of the machine.
2.2.27Engineer screen
Mold Servo Valve (Use Mold Servo V.): if the mold servo valve is installed on this machine, activate this
checkbox.
Inj Proportional Valve(Use Inj Proportional V): if the injection servo valve is installed on this
machine,activate this checkbox
Use Cl.Force Sensor: if the clamp force sensor is installed on this machine, activate this checkbox
Use BackPr Valve: if the backpressure servo valve is installed on this machine, activate this checkbox
Nozzle Mode (NozMode): Set the nozzle controller mode to Postion or Limitswitch control
Machine Size: Select the machine size, big or small. If the clamp tons of this machine is bigger than 450
tons, the setting is “Big”, otherwise it's “Small”.
Safety Standard: Two safety standards are available: CE and Chinese. The correct setting was already
done by the machine manufacturer.
Use HotRunners: if the hotrunners are installed, activate this checkbox
Inj Core Check: if you want to check that all cores are in while the injection movement is activate,
activate this checkbox
Use Robot: if a Robot is installed on the machine, activate this checkbox
Use Inj Pr Sensor: If the injection pressure sensor is installed on the machine, activate this check box.
MinPuls T: Minimum pulse time of the PWM signal. If the calculated PWM output would be shorter than
the set value, the controller adds it to the next cycle to protect the heating relais.
Note that this setting may have no effect depending on the used controller type.
Cycle T: the cycle time of the PWM signal. Make sure this setting is correct to avoid possible damage to
the heating relais.
Note that this setting may have no effect depending on the used controller type.
Nozzle1 – Nozzle12: The user can select all kinds of temperature sensor for the temperature input signal
Depending on the used controller type, J-, K- and L-Type or J- and K-Type are supported.
2.2.28Servo Valve Calibration
Use this screen after replacing any of the servo valves installed on the machine.
Make sure to set the data according to the data provided by the manufacturer of the corresponding valve.
It's possible to set up to 10 points for each movements.
No .of Lintab Points Inject: Set the available points for the injection movement.
No .of Lintab Points Backpressure: Set the available points for the backpressure movement.
No .of Lintab Points Hold: Set the available points for the hold pressure movement.
No .of Lintab Points Mold Open: Set the available points for the mold open movement.
No .of Lintab Points Mold Close: Set the available points for the mold close movement.
2.2.29Engineers Prop.valve Connection screen
This setting is used to adjust the controller's proportional valve output according to the hydraulic scheme.
The correct settings are done by the machine manufacturer.
Note that improper changes can lead to machine malfunction.
Use Eje.bk.LS:Use the ejector back limit switch or not.
Chin:Use Cyc.Start Btn:Use Chinese cycle start button.
2.2.30Engineers Ramp Setting Mask
Abs.Pump Flow: Set the absolute flow of the machine.

Mold Cyl.Diameter: Set the mold cylinder diameter.
Mold Rod Diameter: Set the mold rod diameter.
Eject Cyl.Diameter: Set the ejector cylinder diameter.
Eject Rod Diameter: Set theejector rod diameter.
Screw Cyl.Diameter: Set the screw cylinder diameter.
Screw Rod Diameter: Set the screw rod diameter.
Noz Cyl.Diameter: Set the nozzle cylinder diameter.
Noz Rod Diameter: Set the nozzle rod diameter.
2.2.31Print Function
Basically all printers with USB interface and supporting HPL4 and/or Postscript language can be
connected to the controller. However due to the variety of available printers it cannot be guaranteed that all
HPL4/Postscript printers can work. If you are not sure if your printer can work, contact the machine
manufacturer for detailed information.
Connect the printer to any of the USB ports available on your controller
Choose the screens you want to print by activating the corresponding checkboxes and press the Print
button.
Setup: Open this dialog to select which printer you want to use. Also use this dialog to choose if the
printer output should be sent to the printer or to a file.
Print Operation screens (Print Op.): use this button to print all operation screens.
Print all screens (Print All): use this button to print all HMI screens. Note that this will produce many
pages and therefore take some time.
Printer spooler (Spooler): open this dialog to check how many documents are in the printer's queue.
Another possibility for printing screens is to touch the headline. After this a message dialog for printing
will open.
2.2.32System Alarm and Message
Alarm List
Alarm Name: erCoreXNotBackward.
Content: Core X not backward.
Cause: Core X is not in the backward position. The coreX out’s limit switch is not “on” (in
limit switch mode, refer to the IO monitor mask) or the move out time has not
elapsed during core out movement
Effect: Stop the mold open and ejector movement.
Solution: Check the core X status and move the coreX backward, Press the “Manual Button” to
confirm the alarm after the fault is removed.
Alarm Name: erEjectorNotBackward.
Content: Ejector not in backward position.
Cause: Ejector is not in the backward position. The Ejector sensor for the ejector back is not
“on”, refer to the IO monitor mask and/or the profile end position has not been
reached.
Effect: Stop the mold close movement.
Solution: Check the ejector limit switch and the profile; Press the “Manual Button” to confirm
the alarm after the fault is removed.
Alarm Name: erOilFilterNotOk.
Content: Oil filter clogged up.
Cause: System will display this alarm if the sensor for the oil filter is triggered.
Effect: Stop all movements if the setting time elapsed.
Solution: Check the oil filter.
Alarm Name: erEmergencyStopFront.
Content: Emergency Stop Button Front pressed.
Cause: Emergency Stop Button is pressed.
Effect: Stop the motor.
Solution: Reset the Emergency stop button, Press the “Manual Button” to confirm the alarm
after removes the fault.
Alarm Name: erOilLevelLow.
Content: Oil level is too low.
Cause: System will display this alarm if the sensor for the oil level is triggered.
Effect: Stop all movements if the settings time elapsed.
Solution: Check the oil level.

Alarm Name: erChrgMotorTempHigh.
Content: Charge Motor Temperature Too High.
Cause: The digital input from the electrical charge motor is “on”.
Effect: Stop the charge movement.
Solution: Check digital input from the electrical charge motor, Press the “Manual Button” to
confirm the alarm after removes the fault.
Alarm Name: erCoreXInTimeout.
Content: Timeout during core X out.
Cause: The time for core X out movement is longer than the monitor time.
Effect: Stop the core X out movement.
Solution: Check the core X status; Press the “Manual Button” to confirm the alarm after
removes the fault.
Alarm Name: erOilTempHighAutoStop.
Content: Oil Temperature high! Automatic stopped.
Cause: The hydraulic oil temperature is higher than the setting value for the automatic stop.
Refer to the Temperature parameter mask.
Effect: Stop the automatic movement.
Solution: Check the oil temperature and check the system cool water; Press the “Manual
Button” to confirm the alarm after removes the fault.
Alarm Name: erOilTempHighMotorOff.
Content: Oil Temperature high! Motor stopped!
Cause: The hydraulic oil temperature is higher than the setting value for motor stop. Refer to
the Temperature parameter mask.
Solution: Check the oil temperature and check the system cool water; Press the “Manual
Button” to confirm the alarm after removes the fault.
Alarm Name: erCentralLubError.
Content: Central lubrication failed.
Cause: When the controller is in the automatic lubrication status and doesn’t get the signal
for the lubrication press is reached in the setting time. The alarm will display.
Effect: Stop the next automatic cycle after this cycle is finished.
Solution: 1. Check the lubrication oil level 2. Check the lubrication oil circuit 3. Check the
lubrication press relay. Press the “Manual Button” to confirm the alarm after removes
the fault.
Alarm Name: erCycleTimeExceeded.
Content: Cycle Time exceeded.
Cause: The actual cycle time is longer than the setting cycle time.
Effect: Stop the automatic cycle movement.
Solution: 1. Check automatic cycle time 2.check all the movements in manual mode. Press the
“Manual Button” to confirm the alarm after removes the fault.
Alarm Name: erPhotosensorTimeout.
Content: No dropped part detected in Full Automatic mode.
Cause: The sensor for checking part dropped is not triggered in setting time.
Solution: 1. Check the product on the machine 2.check the digital input on the IO monitor.
Press the “Manual Button” to confirm the alarm after removes the fault.
Alarm Name: erShotLimitReached.
Content: No. of Shots reached.
Cause: The set number of shots is reached.
Solution: Press the “Reset” button on the manager mask or the “Manual Button” to confirm the
alarm and to reset the shot counter.
Alarm Name: erMoldFwdTimeout.
Content: Timeout during mold forward.
Cause: The actual time for mold close is longer than the setting time.
Solution: 1. Check the mold close movement in manual mode 2. Check the pressure and flow
settings for mold close 3. Check the system hydraulic circuit 4. Check the monitor
time .Press the “Manual Button” to confirm the alarm after removes the fault.
Alarm Name: erMoldBwdTimeout.
Content: Timeout during mold backward.
Cause: The actual time for mold open is longer than the setting time.
Solution: 1. Check the mold open movement in manual mode 2. Check the pressure and flow
settings for mold open 3. Check the system hydraulic circuit 4. Check the monitor
Alarm Name: erMoldProtection.
Content: Mold protection!
Cause: The actual time for mold protection is longer than the setting time. the controller will
display this alarm
Effect: Stop the current automatic cycle movement.
Solution: 1. Check the mold 2. Check the pressure and flow settings for mold open 3. Check
the system hydraulic circuit 4. Check the monitor time .Press the “Manual Button” to
Alarm Name: erInject1Timeout.
Content: Timeout during injection!
Cause: The actual time for injection is longer than the setting time. the controller will display
this alarm
Solution: 1. Check the pour mouth of mold 2. Check the hold switch function 3. Check the
system hydraulic circuit 4. Check the monitor time .Press the “Manual Button” to
Alarm Name: erPlasticizing1Timeout.
Content: Timeout during plasticizing!
Cause: The actual time for plasticizing is longer than the setting time. the controller will
display this alarm
Solution: 1. Check the hopper if it has the material 2. Check the barrel temperature settings and
the pressure and flow settings for plasticizing 3. Check the system hydraulic circuit 4.
Check the monitor time .Press the “Manual Button” to confirm the alarm after
removes the fault.
Alarm Name: erNozzleFwdTimeout.
Content: Timeout during nozzle forward
Cause: The actual time for nozzle forward is longer than the setting time. the controller will
display this alarm
Solution: 1. Check the nozzle position settings 2. Check the pressure and flow settings for
nozzle forward 3. Check the system hydraulic circuit 4. Check the monitor time
.Press the “Manual Button” to confirm the alarm after removes the fault.
Alarm Name: erNozzleBwdTimeout.
Content: Timeout during nozzle backward.
Cause: The actual time for nozzle backward is longer than the setting time. the controller will
display this alarm
Solution: 1. Check the nozzle position settings 2. Check the pressure and flow settings for
nozzle backward 3. Check the system hydraulic circuit 4. Check the monitor time
.Press the “Manual Button” to confirm the alarm after removes the fault.
Alarm Name: erAutoPurgeFinished.
Content: Auto purge finished
Cause: Give the user a message after the auto purge is finished.
Effect: The alarm lamp flares.
Solution: Press the “Manual Button” to confirm the alarm.
Alarm Name: erMotorNoCoolWater.

Content: No cooling water for motor
Cause: The motor don’t have the cool water.
Solution: 1. Check the cool water 2. Set the monitor longer. Press the “Manual Button” to
confirm the alarm.
Alarm Name: erSafetyGateRearNotClosed.
Content: Safety Gate Rear not closed
Cause: The safety gate rear is open.
Solution: 1. Check the safety gate rear 2. Close the safety gate rear. Press the “Manual Button”
to confirm the alarm.
Alarm Name: erCloseDoor.
Content: Please close door
Cause: Message for half automatic cycle.
Effect: Wait for the user to start the next cycle.
Solution: Close the door and start next automatic cycle.
Alarm Name: erOpenDoor.
Content: Please open door
Cause: Message for half automatic cycle.
Effect: Wait for the user to take the product out.
Solution: Open the door and take the part out.
Alarm Name: erHydrCloseSafety.
Content: Hydr. Close safety not open.
Cause: Hydraulic close safety is closed.
Effect: Can’t do any movement.
Solution: Check the hydraulic close safety. Press the “Manual Button” to confirm the alarm
Alarm Name: erMoldNotOpen.
Content: Mold not opens.
Cause: The mold doesn’t move back to the end position.
Effect: Stop the current automatic cycle movement, and can’t do ejector forward movement
Solution: 1. Check the mold end position 2. Check the pressure and flow settings for mold open
3. Check the system hydraulic circuit. Press the “Manual Button” to confirm the
alarm after removes the fault.
Alarm Name: erSensorProblem.
Content: Problem with sensor of zone %1n.
Cause: The temperature sensor failure.
Effect: The color for the temperature display will be changed to yellow.
Solution: Check the corresponding sensor connection. Press the “Manual Button” to confirm
the alarm after removes the fault.
Alarm Name: erInjPosSequence.
Content: Error in inject position sequence.
Cause: The position settings for injection are error.
Effect: Can’t do the injection movement.
Solution: Check the position settings for injection on the injection mask by press the inj button
on the main mask. Press the “Manual Button” to confirm the alarm after removes the
fault.
Alarm Name: erHoldTimeSequence.
Content: Error in hold time sequence.
Cause: The profile for the hold time is error.
Effect: Can’t do the hold movement.
Solution: Check the hold time profile settings for hold on the injection mask by press the inj
button on the main mask. Press the “Manual Button” to confirm the alarm after
removes the fault.
Alarm Name: erAutoAdjustFinished.
Content: automatic mold adjust finished
Cause: The controller will give the user this alarm after the auto mold-adjust is finished.
Effect: The alarm lamp flares.
Solution: Press the “Manual Button” to confirm the alarm.
Alarm Name: erTempTooLow.
Content: Temperature of Zone %1n too low.
Cause: The corresponding zone’s temperature is lower than low tolerance of the setting
temperature.
Effect: Stop the automatic cycle.
Solution: Check the corresponding zone’s temperature. Press the “Manual Button” to confirm
Alarm Name: erTempTooHigh.
Content: Temperature of Zone %1n too high.

Cause: The corresponding zone’s temperature is higher than up tolerance of the setting
temperature.
Effect: Stop the automatic cycle.
Alarm Name: erHeatingNotOk.
Content: Heating defect.
Cause: When the temperature is not reach the setting value and the user press the injection,
suck-back,charge,and automatic button on the key-panel, the controller will give the
user this alarm
Effect: Stop the automatic cycle and prohibit the movement which is correlative to the screw
part.
Alarm Name: erDecompAfterPlastTimeout.
Content: Timeout during suck back after plasticizing.
Cause: The actual time for suck back after plasticizing is longer than the setting time. the
controller will display this alarm
Solution: 1. Check the suck back movement in manual mode 2. Check the pressure and flow
settings for suck back 3. Check the system hydraulic circuit 4. Check the monitor
Alarm Name: erDecompBeforePlastTimeout.
Content: Timeout during suck back before plasticizing.
Cause: The actual time for suck back before plasticizing is longer than the setting time. the
Solution: 1. Check the suck back movement in manual mode 2. Check the pressure and flow
Alarm Name: erPlastBeforeInjTimeout.
Content: Timeout during plasticizing before injection.
Cause: The actual time for plasticizing before injection is longer than the setting time. the
Solution: 1. Check the plasticizing movement in manual mode 2. Check the pressure and flow
Alarm Name: erSafetyGateInjectionOpen.
Content: Safety Gate Injection not closed.
Cause: Safety gate for injection is open.

Solution: 1. Close the safety gate for injection 2.Check the digital input in the IO monitor. Press
the “Manual Button” to confirm the alarm after removes the fault.
Alarm Name: erNozzleMeasureError.
Content: Error %1n in nozzle measure block.
Cause: The measure block for nozzle sensor failure.
Solution: 1. Check nozzle sensor’s wire connection 2.Check the analogy input in the IO
monitor. Press the “Manual Button” to confirm the alarm after removes the fault.
Alarm Name: erEjeMeasureError.
Content: Error %1n in Ejector measure block.
Cause: The measure block for ejector sensor failure.
Solution: 1. Check ejector sensor’s wire connection 2.Check the analogy input in the IO
Alarm Name: erEjectorFwd.
Content: timeout during ejector fwd
Cause: The actual time for ejector forward is longer than the setting time. the controller will
display this alarm
Solution: 1. Check the ejector movement forward in manual mode 2. Check the pressure and
flow settings for ejector forward 3. Check the system hydraulic circuit 4. Check the
monitor time .Press the “Manual Button” to confirm the alarm after removes the fault.
Alarm Name: erEjectorBwd.
Content: timeout during ejector bwd
Cause: The actual time for ejector backward is longer than the setting time. the controller
will display this alarm
Solution: 1. Check the ejector back movement in manual mode 2. Check the pressure and flow
settings for ejector back 3. Check the system hydraulic circuit 4. Check the monitor
Alarm Name: erEjeFwdPosSequence.
Content: Error in ejector forward position sequence.
Cause: The profile for the ejector forward is error.
Effect: Can’t do the ejector forward movement.
Solution: Check the ejector forward profile settings for ejector on the ejector mask by press the
eje button on the main mask. Press the “Manual Button” to confirm the alarm after
removes the fault.
Alarm Name: erEjeBwdPosSequence.
Content: Error in ejector backward position sequence.
Cause: The profile for the ejector backward is error.
Effect: Can’t do the ejector backward movement.
Solution: Check the ejector backward profile settings for ejector on the ejector mask by press
the eje button on the main mask. Press the “Manual Button” to confirm the alarm
Alarm Name: erAirValveNotFinished.
Content: Air valve %1n not finished.
Cause: The corresponding air valve movement is not finished.
Effect: Can’t do the mold movement, stop the automatic movement
Solution: 1. Check Air valve settings on the ejector mask by press the eje button on the main
mask. 2. Check the air valve movement in manual mode. Press the “Manual Button”
to confirm the alarm after removes the fault.
Alarm Name: erEjectorHoldInFA.
Content: Ejector Mode "Hold" not allowed in Full Automatic Mode.
Cause: The ejector mode is “hold” in automatic operation mode.
Effect: Stop the automatic movement.
Solution: 1. Check ejector type settings on the ejector mask by press the eje button on the main
mask. Press the “Manual Button” to confirm the alarm after removes the fault.
Alarm Name: erAutoAdjustTimeout.
Content: Automatic mold adjust timeout.
Cause: The actual time for auto mold-adjust movement is longer than the setting time. the
Effect: Stop the current auto mold-adjust movement and change the operation mode to
manual.
Solution: 1. Check the mold adjust forward and mold adjust backward movement in setup
mode 2. Check the pressure and flow settings for mold adjust 3. Check the system
hydraulic circuit 4. Check the monitor time .Press the “Manual Button” to confirm
Alarm Name: erClampPressureMeasureError.
Content: Error %1n in clamp pressure measure block.
Cause: The measure block for pressure sensor failure.
Solution: 1. Check clamp pressure sensor’s wire connection 2.Check the analogy input in the
IO monitor. Press the “Manual Button” to confirm the alarm after removes the fault.
Alarm Name: erSafetyGateNozzleNotClosed.
Content: Safety Gate Carriage not closed.

Cause: Safety gate carriage is open.
Solution: 1. Close the safety gate carriage2.Check the digital input in the IO monitor. Press the
Alarm Name: erSafetyGateMoldNotClosed.
Content: Safety Gate Mold not closed.
Cause: Safety gate Mold is open.
Solution: 1. Close the safety gate mold 2.Check the digital input in the IO monitor. Press the
Alarm Name: erMoldMeasureError.
Content: Error %1n in mold measure block.
Cause: The measure block for mold sensor failure.
Solution: 1. Check mold pressure sensor’s wire connection 2.Check the analogy input in the IO
Alarm Name: erMoldFwdPosSequence.
Content: Error in mold forward position sequence.
Cause: The position settings for mold forward are error.
Effect: Can’t do the mold forward movement.
Solution: Check the position settings of the profile for mold forward on the mold mask by press
the mold button on the main mask. Press the “Manual Button” to confirm the alarm
Alarm Name: erMoldFwdPosSequence.
Content: Error in mold backward position sequence.
Cause: The position settings for mold backward are error.
Effect: Can’t do the mold backward movement.
Solution: Check the position settings of the profile for mold backward on the mold mask by
press the mold button on the main mask. Press the “Manual Button” to confirm the
alarm after removes the fault.
Alarm Name: erTempNozzleHeatingNotOk.
Content: Nozzle Heating Temp. Not Ok.
Cause: The heating temperature is not ok, and the user wants to start the movement or want
to change to automatic mode.
Effect: Stop the movement.
Solution: Check the heating temperature for corresponding barrel; Press the “Manual Button”
to confirm the alarm after removes the fault.
Alarm Name: erInjectionPreMeasureError.
Content: Error %1n in Injection pressure measure block.
Cause: The measure block for injection pressure sensor failure.
Solution: 1. Check injection pressure sensor’s wire connection 2.Check the analogy input in the
Alarm Name: erInjectionPosMeasureError.
Content: Error %1n in Injection position measure block.
Cause: The measure block for injection position sensor failure.
Solution: 1. Check injection position sensor’s wire connection 2.Check the analogy input in the
Alarm Name: erPlasticizingTimeout.
Content: Timeout during plasticizing.
Cause: The actual time for plasticizing movement is longer than the setting time. the
Effect: Stop the plasticizing movement.
Solution: 1. Check plasticizing movement in setup mode 2. Check the pressure and flow
settings for plasticizing movement 3. Check the system hydraulic circuit 4. Check the
monitor time .Press the “Manual Button” to confirm the alarm after removes the fault.
Alarm Name: erPushMoldBt
Content: Push Mold Close Button
Cause: During the manual mode, push the Setup button twice, then this alarm will be
displayed
Effect: Informs the user that pushing the mold close button will start automatic mold height
adjust.
Solution: 1. push the mold close button , the machine will start automatic mold adjust.
2. push the setup button, the machine will return to normal mold adjust status
3. push the manual button, the machine will return to manual mode.

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Chapter 9 Controller Operation Manual

KEBA 4030 SYSTEM USER MANUAL

KEBA 4030 SYSTEM USER MANUAL.....................................................................................1

2.2.21 Machine Settings Mask-2............................................................................76

1.1 Clamping Unit Setup

1.1.1 Mold Height Adjustment

1.1.2 Mold Closing and Mold Protection

Press the Manual button to activate the Manual

Next enter the desired hydraulic speed and pressure

Set the hydraulic speed for the Protect phase low

To accelerate mold closing you can activate the

1.1.3 Mold Opening

Press the Manual button to activate the Manual

Verify the Mold Opening Stroke and adjust if

Adjust the transition point for switching from the

Press the Manual button to activate the Manual

Next, set the pressure and speed for the backward

In addition, set the backward end position for the

Set the Backward end position.

Set the Ejector Activation Delay

Activate the ejector in Manual Mode

1.1.5 Air Blast

Press the Manual button to activate the Manual

In case you require additional cooling of the mold

Press the Manual button to activate the Manual

Using limit Control allows you to control the core

1.2 Injection Unit Setup

Press the Manual button to activate the Manual

Then set the hydraulic pressure for nozzle/injection

1.2.2 Injection and Hold Pressure

First, choose the Hold Pressure Switch Mode.

1.2.3 Charge (Plasticizing) and SuckBack

Next, enter the individual Positions for the transition

Set the Suck-back mode to “NO” if no Suck-back is

Activate the Manual Mode by pressing the Manual

First, set the Temperature Mode (Keep Warm).

The controller supports heating by PID control or

2.1.1 Control Panel and Buttons

2.1.2 Machine Control Panel Buttons

Machine Operating Mode Buttons

Mold Adjustment and Lubrication Keys

Manual Operation Mode Keys (Left)

Manual Operation Mode Keys (Right)

Manual Operation Mode Keys (Bottom)

Hydraulic Pump Motor On/Off Button: Press this Motor On button in

Heating On/Off Button: Press this Heating On button in Manual Operation

Delete Button: Deletes wrong number inputs.

Increase Button: Press this button once to increase the value.

Decrease Button: Press this button once to decrease the value.

Operation Mode Barrel Temperature Shot Count Cycle Time

An arrow right of the

Hi.Close: Differential high-speed mold closing option.

Inject Switch: see Injection Settings screen

Auto Purge Settings

Valve Gate Settings

Const Output: Setting for the injection movement in setup mode.

Charge stages (ChrgStages): Adjust the stages for charge movement.

Const out Settings: