English Manual - QMC 122 - RV2600602A

Instructions for assembly and use
Type QMC 122
RV2600602A – 17/09/2016
QMC 122 - English (Original manual)
© STÄUBLI 2016
2 / 133 © STÄUBLI 2016 - RV2600602A QMC 122
CONTENTS
1 - FOREWORD ................................................................................................................. 5
1.1 - Warranty.............................................................................................................................. 5
1.2 - Pictograms/terminology....................................................................................................... 5
2 - DESCRIPTION .............................................................................................................. 9
2.1 - Functions of the "QMC 122" magnetic system.................................................................... 9
2.2 - Description of the system .................................................................................................... 9
2.3 - Intellectual property ........................................................................................................... 11
2.4 - Identification ...................................................................................................................... 11
2.5 - Compliance with regulations ............................................................................................. 12
2.6 - Limits of use ...................................................................................................................... 14
2.7 - Operating modes............................................................................................................... 20
2.8 - Indicative dimensions and weights.................................................................................... 22
3 - SAFETY....................................................................................................................... 27
3.1 - General safety instructions................................................................................................ 27
3.2 - Installation safety instructions ........................................................................................... 28
3.3 - Operating safety instructions............................................................................................. 28
3.4 - Maintenance safety instructions ........................................................................................ 29
4 - PRESENTATION......................................................................................................... 31
4.1 - Magnetic plates ................................................................................................................. 31
4.2 - Controller........................................................................................................................... 34
4.3 - Control terminal ................................................................................................................. 42
5 - INSTALLATION .......................................................................................................... 43
5.1 - Storage instructions .......................................................................................................... 43
5.2 - Handling instructions ......................................................................................................... 43
5.3 - Installation ......................................................................................................................... 43
6 - USE ............................................................................................................................. 69
6.1 - First use ............................................................................................................................ 69
6.2 - Powering up ...................................................................................................................... 69
6.3 - Changing a mold ("Operator" mode) ................................................................................. 74
6.4 - Advanced functions ("Supervisor" mode)........................................................................ 105
6.5 - Setting functions.............................................................................................................. 109
6.6 - Molds management......................................................................................................... 117
6.7 - System calibration ........................................................................................................... 124
6.8 - System Information ......................................................................................................... 129
7 - MAINTENANCE ........................................................................................................ 131
7.1 - Scheduled maintenance.................................................................................................. 131
7.2 - Spare parts...................................................................................................................... 131
7.3 - Replacing the controller fuses ......................................................................................... 132
7.4 - Replacing the lithium battery ........................................................................................... 133
7.5 - Waste recycling ............................................................................................................... 133
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4 / 133 © STÄUBLI 2016 - RV2600602A QMC 122
1 - FOREWORD
You have recently purchased a new "QMC 122" magnetic clamping system developed by
STÄUBLI, and we would like to thank you for the trust you have put in our brand.
This "QMC 122" magnetic clamping system has been made with great care, and we hope that
it will give you full satisfaction.
IMPERATIVE
Read this manual carefully.
Comply with the instructions given in the manual.
Provide all the information in the manual to the concerned users and operators.
1.1 - WARRANTY
The conditions of application of the warranty are set out in our general conditions of sale.
See our general sales conditions dealing with warranty exclusions.
WARNING
Throughout the product service life, use of parts other than original STÄUBLI parts is
prohibited. This could cause severe damage to the products or shorten their service life.
Our guarantee is only applicable if our products:
- Contain only original STÄUBLI parts.
- Are used and serviced under conditions that comply strictly with our specifications.
The present manual is not contractual and the STÄUBLI company reserves the right to modify
it without notice.
STÄUBLI cannot be held liable for omissions of a technical or editorial nature or for accidental
damage or damage resulting from erroneous interpretation of the contents of this manual.
1.2 - PICTOGRAMS/TERMINOLOGY
1.2.1 - PICTOGRAMS USED IN THE MANUAL
Imperative
An instruction which informs the reader of the possible risks of injury or death faced by the
user. This instruction is applicable in terms of industrial safety.
Imperative
Instructions linked to an electrical hazard.
Attention
An instruction which informs the reader of risks which may result in equipment damage.
This instruction is applicable to the quality of the work.
QMC 122 © STÄUBLI 2016 - RV2600602A 5 / 133

1.2.2 - PICTOGRAMS OF THE QMC 122 CONTROLLER
Electrical hazard inside the box.
Important information. Refer to the device manual.
Read the manual.
Compliant with European Union directives.
6 / 133 © STÄUBLI 2016 - RV2600602A QMC 122

1.2.3 - TERMINOLOGY
Clamping:
Fixing the mold magnetically.
Releasing:
Releasing the magnetic fixing system from the mold.
PPE:
Personal Protective Equipment.
MPL:
Magnetic plate fitted on the mobile plate of the press.
FPL:
Magnetic plate fitted on the fixed plate of the press.
IMM:
Injection Molding Machine.
MCS:
Magnetic Clamping System (Magnetic Clamping System).
MCM:
Mold Change Mode (Mold Change Mode).
E70:
Interface, EUROMAP 70.
CAN:
Controller Area Network - Standard two-way communication bus as per ISO 11898.
RS485:
Serial communication link with the injection molding machine.
CALIB:
Denotes the calibration button.
HAND PENDANT:
Serial communication link with the control terminal.
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8 / 133 © STÄUBLI 2016 - RV2600602A QMC 122
2 - DESCRIPTION
2.1 - FUNCTIONS OF THE "QMC 122" MAGNETIC SYSTEM
The "QMC 122" magnetic clamping system is designed solely for electromagnetic clamping of
molds and tooling.
The "QMC 122" magnetic clamping system provides permanent magnetic clamping. It only
uses electrical energy while the mold is being clamped or released. Its design makes it
possible to display the clamping force.
The clamping force displayed is accurate, and it is based on measurement of the flux through
each pole.
Nonetheless, STÄUBLI cannot be held liable for any measurement errors resulting from
misuse or errors made when selecting a mold or incorrect information concerning mold size.
2.2 - DESCRIPTION OF THE SYSTEM

The assembly that you have purchased consists of the following elements:
- Two "QMC 122" magnetic plates in one or more parts (1) and (2), with or without a centering
ring.
- A controller (5).
- A control terminal (6) and its associated cable (7). In certain cases, these 2 components may
not be supplied.
- An interface cable (8).
- Plate/controller measurement cables (3).
- Plate/controller power cables (4).
QMC 122 © STÄUBLI 2016 - RV2600602A 9 / 133

1 2
4
5
Figure 2-1
10 / 133 © STÄUBLI 2016 - RV2600602A QMC 122

2.3 - INTELLECTUAL PROPERTY
The "QMC 122" magnetic clamping systems, together with the optional products supplied with
these systems, are protected by registered designs, patents and patent applications.
STÄUBLI is a registered trademark.
All counterfeiters will be prosecuted.
US PATENT : 6.489.871/6.636.153/7.782.164
CHINESE PATENT : ZL 02815976.4/ZL 200710106737.1
2.4 - IDENTIFICATION
For all information requests, orders for spare parts, or requests for servicing or repair work,
please quote the information shown on the manufacturer's plates.
Controller:
1: List number of the complete assembly

2: Cabinet file reference
1 2 3 3: Serial number
5 6 4: Controller reference
4 7 8
9 IP 54 IK 10 5: Year / Week of manufacture
6: Supply voltage in Volt
7: Frequency of the supply voltage in Hertz
8: Current levels in Amps
9: Switching capacity of the internal
protection device in Ampere
Magnetic plate (fixed on the side of the plate)

1: List number of the complete assembly
2: Reference of the magnetic plate assembly
fitted
1 2 3: Supply Voltage
4: Frequency in Hz
3 4 5 6
5: Weight of the magnetic plate
7 8 6: Year / Week of manufacture
7: Serial number
8: Maximum operating temperature
QMC 122 © STÄUBLI 2016 - RV2600602A 11 / 133

2.5 - COMPLIANCE WITH REGULATIONS
2.5.1 - GENERAL RECOMMENDATIONS
Concerning the "QMC 122" magnetic clamping system covered by the present manual:
- Is intended to be incorporated into a machine and cannot operate independently.
- Must not be put into service until the machine into which it is incorporated has been declared
compliant with the provisions of the machinery, occupational safety and health regulations in
force in the country of use.
As stated in the Foreword, it is the responsibility of the purchaser of the clamping system to
hand over this manual to the end user, or failing this, to take responsibility for integrating the
information into his own manual. The end user should read this manual carefully and keep it
for future reference.
2.5.2 - MACHINE DIRECTIVE 2006/42/CE

Within the framework of the machinery directive 2006/42/CE applicable in the European
Union, the magnetic clamping system "QMC 122" covered by this manual:
- It lies outside the scope of directive 2006/42/CE, because it contains no mobile parts or
elements.
- It is designed for incorporation in a machine for which directive 2006/42/CE is applicable and
it cannot operate independently.
- It must not be put into service until the machine in which it is to be incorporated has been
declared to comply with the provisions set out in directive 2006/42/CE.
The magnetic clamping system "QMC 122" complies with the provisions of chapters 5.10.2.2
and 7.1.21 of standard EN201:2009 which apply under the following conditions:
- The clamping system is integrated into an injection molding machine, the closing unit of
which is horizontal.
- Access to the mold area is prevented by guards.
- The magnetic clamping system is supplied by the manufacturer of the injection molding
machine at the same time as the machine.
If these conditions are not met, it is the responsibility of the purchaser to comply with the
provisions of the machine directive in force in the country where the machine is installed.
12 / 133 © STÄUBLI 2016 - RV2600602A QMC 122

2.5.3 - DECLARATION OF CONFORMITY
Référence : RR 2010 007 B
DÉCLARATION DE CONFORMITE
DECLARATION OF CONFORMITY
(Directives 2014/35/UE & 2014/30/UE)
Nous / We STÄUBLI FAVERGES

CS 30070
74210 FAVERGES FRANCE
Déclarons par le présent document que l’équipement :

Declare by this document that the equipment:
Description / Description Système de bridage magnétique /

Magnetic clamping system
Type / Type: QMC 122
Est conforme aux dispositions des directives suivantes :

Is in accordance with the provisions of the following directives:
2014/35/UE (matériel électrique destiné à être employé dans certaines

limites de tension)
2014/35/EU (Electrical equipment designed for use within certain voltage limits)
2014/30/UE (Compatibilité électromagnétique)
2014/30/EU (Electromagnetic compatibility)
Normes appliquées / Applied standards:

EN 61000 6-4
EN 61000 6-2
EN 60950-1
EN 60204-1
Faverges, 26.04.2016
C. MAYEUR A.C. TIBERGHIEN

Responsable Qualité Produit Responsable R & D Raccord
Stäubli Faverges SCA - Place Robert Stäubli - BP 70 - 74210 FAVERGES France ISO 9001:2000
QMC 122 © STÄUBLI 2016 - RV2600602A 13 / 133

2.5.4 - MEASUREMENT OF MAGNETIC FIELDS
The information below is based on the Directive 2013/35/UE. It is given for guidance only as it
is the responsibility of the purchaser to comply with the regulations applicable in the country to
meet the safety and health requirements of workers exposed to the risks due to
electromagnetic fields.
The safety zone that ensures that the magnetic field is less than the threshold of 1 mT at a
frequency of 50 Hz is located at least 30 cm from the surface of the magnetic plate "QMC 122".
The safety zone that ensures that the magnetic field is less than the threshold of 200 mT in
static condition is located at least 10 cm from the surface of the plate.
In the case of workers with particular risks (with active or passive medical devices, implanted
or on the body), the threshold is reduced to 0.5 mT in static condition. The safety zone that
ensures that the static magnetic field is less than this threshold is located at least 50 cm from
the surface of the plate.
A safety distance of 50 cm from the magnetic plate "QMC 122" makes it possible to respect
the three thresholds mentioned above.
See also chapter 3.1 for other precautions related to magnetic fields.
2.6 - LIMITS OF USE

2.6.1 - WORKING ENVIRONMENT
- Ambient operating temperature: +5°C to +40°C (32°F to 104°F).
- Ambient storage temperature: -25°C to +55°C (-13°F to 131°F).
- Humidity: 90% maximum without condensation.
- Maximum altitude: 2000 m.
- Installation of the cabinet: Vertical mounting.
- Ingress protection rating of the controller (according to IEC 60529): IP54(1).
- Ingress protection rating of the control terminal (according to IEC 60529): IP54(2).
- Considerations according to standard EN 60950-1:
. Overvoltage category: II.
. Pollution degree: 3 (macro-environment outside the cabinet).
. Pollution degree: 2 (macro-environment inside the cabinet).
. Comparative Tracking Index: IIIb.
(1)
: Installed according to recommendations and door closed.
(2): With memory card door closed.
14 / 133 © STÄUBLI 2016 - RV2600602A QMC 122

2.6.2 - PRECAUTIONS FOR USE
IMPERATIVE
THE MOLD MUST BE SUPPORTED BY A HOIST OR ANOTHER LIFTING DEVICE
THROUGHOUT THE MAGNETIZATION OR DEMAGNETIZATION TIME. The lifting
device can only be removed when the lights are green and the ERROR light is not active.
ATTENTION
This magnetic clamping system is designed to operate in a dry environment. Any
contamination by a fluid may shorten the system's service life and result in production
stoppages.
The STÄUBLI "QMC 122" magnetic clamping system has been designed to provide a
maximum density of magnetic flux at the polar surface to create strong clamping forces.
However, certain conditions likely to diminish its effectiveness must absolutely be taken into
account by the user:
- The size of the surface contact area with the mold.
- The quality of the materials used for the mold.
- The thickness of the mold base.
- The surface state between the mold and the magnetic clamping system.
- The temperature.
In addition, one must check to ensure that the characteristics of each half-mold (particularly
the weight and the length) are compatible with the magnetic clamping force so that there is no
slippage or tipping.
These precautions for use are described in detail in the following chapters.
2.6.3 - CONTACT SURFACE

As the "QMC 122" magnetic clamping system uses the full saturation principle, the clamping
force is proportional to the surface area. It is thus clear that any reduction in the contact
surface area with the mold leads to a proportional reduction in the clamping force.
Each magnetic pole develops a clamping force of 6.25 kN provided that it is fully covered and
that the limits of use are complied with.
Check the minimum dimensions recommended by the press manufacturer and/or given for the
clamping system.
The operator must take care when using molds with deep cavities: e.g. buckets. A large
molding surface increases the opening force, and this is not compatible with a mold base plate
surface area that is disproportionately small (clamping force too weak).
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2.6.4 - QUALITY OF THE MATERIALS
All the information concerning the clamping force set out in the STÄUBLI technical and
commercial documentation is based on construction type steel (with a low carbon content),
which is the type most commonly found. The standard reference is C22E or C45E (Europe)
and/or AISI1020 (USA).
As a general rule, it should be noted that an increase in the levels of alloy compounds in the
material reduces its permeability (i.e. its magnetic conductibility). Some types of molded steel
have lower permeability levels than construction type steel.
In the light of the wide range of materials, each of which can have widely differing magnetic
characteristics, STÄUBLI advises testing your materials to determine their clamping
capacities. If in doubt, don't hesitate to contact us.
2.6.5 - THICKNESS
All the magnetic flux generated by the magnets must be fully absorbed by the steel. f this is not
the case, there is magnetic loss; the flux density at the contact surface between the pole and
the mold will be reduced, and the bonding force could well be reduced considerably.
This means that it may be necessary to modify the mold base plate.
The STÄUBLI "QMC 122" magnetic clamping system requires mold base plates at least
20 mm thick.
20 mm
S N N S
S N N S
Figure 2-2
Remark: The thicker the back plate, the more rigid the mold, with correspondingly reduced risk
of "peeling".
2.6.6 - SURFACE STATE

It is important to make sure that the contact surfaces between the mold and the "QMC 122"
magnetic clamping system are free of impurities, residue or rust. Even a tiny air gap leads to a
reduction in the magnetic force. The surface finish, ground or milled, is of relatively minor
importance, but the operator must check for the absence of air gaps.
An air gap can also be created if the mold is not flat. The level of flatness required for the
contact surfaces is 0.1 mm/m².
16 / 133 © STÄUBLI 2016 - RV2600602A QMC 122

2.6.7 - TEMPERATURE
The "QMC 122" magnetic clamping system is designed to operate at temperatures of up to
100°C (212°F). If that temperature is exceeded, some magnets suffer irreparable damage.
In the range between 90°C (194°F) and 100°C (212°F), the clamping force must be reduced by
10 to 15% of the force obtained at ambient temperature (but without any permanent damage to
the magnets). The force displayed takes this temperature-related decrease into account.
Note:
The reduction also depends on the quality of the contact with the mold.
In conventional thermoplastic molding, the temperature rise transmitted to the magnetic plate
should not reach levels higher than 100°C (212°F). In some cases, however, it is necessary to
fit thermal insulation.
This insulation may be achieved by placing an insulating plate between the mold base and a
heat source. Each insulating plate must not be placed between the mold base plate and the
magnetic plate.
ATTENTION
Any damage caused to magnets by high temperatures is irreversible, and it cancels all
warranty rights!
2.6.8 - VERIFICATION OF MOLD ANTI-SLIPPAGE

In the case a half-mold which does not have a centering ring is clamped, make sure that it
does not exceed 1/8 of the clamping force displayed. If this instruction is not complied with,
there is a risk of mold slippage.
If the "Check cantilever and sliding" option is active (see chapter 6.5.7, page 116) and the
weights of the half-molds and the absence of a centering ring have been correctly entered (as
detailed in the second part of chapter 6.3.3, page 76), the controller "QMC 122" verifies that
the clamping force obtained is sufficient so that there is no risk of slippage.
The system emits a warning if the clamping force is less than 8 times the weight of the mold. In
this case, check that the conditions detailed in the previous chapters do not diminish the
effectiveness of the magnetic clamping.
The system issues an alarm if the clamping force is less than 5 times the weight of the mold. It
is advisable to replace the rear plates of the mold if they do not cover all the magnetic modules
and to make all possible modifications to avoid any slippage.
The "Check cantilever and sliding" function can be deactivated in the Supervisor / Options
menu. In this case, the user must take all necessary precautions to prevent the mold from
slipping.
QMC 122 © STÄUBLI 2016 - RV2600602A 17 / 133

2.6.9 - MOLD ANTI-TILTING VERIFICATION
Preliminary reminder:
Fm l
h
MFm W
Mw
Figure 2-3
MFm: Anti-tilt torque
Mw: Tilting torque
Fm: Magnetic clamping force
W: Weight
L: Half-mold length
l: Position of the half-mold's center of gravity
h: Clamping force lever arm
The mechanical laws give:

- MFm = Fm x h
- Mw = W x l
This calculation applies to each half-mold.
Mold anti-tilting verification:

When the "Check cantilever and sliding" option is active (see chapter 6.5.7, page 116) and the
data (weight and lengths) of the half-molds are correctly entered (as detailed in the second
part of chapter 6.3.3, page 76), the controller "QMC 122" automatically compares MFm and
Mw to ensure that the resulting clamping force is sufficient so that there is no risk of tilting.
The system emits a warning if the anti-tilt torque is less than 10 times the tilting torque. In this
case, check that the conditions detailed in the previous chapters do not diminish the
effectiveness of the magnetic clamping.
The system emits an alarm if the anti-tilt torque is less than 7 times the tilting torque. In this
case, this mold may not be adapted to this clamping system. We recommend that the rear
plates of the mold be replaced if they do not fully cover the magnetic modules and to make all
modifications possible to prevent tilting.
18 / 133 © STÄUBLI 2016 - RV2600602A QMC 122

2.6.10 - OPERATING CYCLE
A maximum of 6 cycles (magnetization or demagnetization) per minute is allowed.When this
limit is reached, the control terminal displays a "no entry" symbol for the plate concerned by
this limitation. This symbol is accompanied by a countdown, in seconds, of the remaining time
(17 seconds in the example below).
This limitation is managed by the controller software.
Figure 2-4
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2.7 - OPERATING MODES
2.7.1 - STANDARD MODE
In this mode, the user uses the control terminal to enter the necessary parameters and read
the information displayed by the "QMC 122" system. This is the recommended configuration,
which allows you to use all the functions described in this operating manual. This is also the
default configuration.
The operating authorizations between the "QMC 122" system and the injection molding
machine (IMM) are managed by a EUROMAP 70.0 interface (see page 5.3.8, chapter 58).
2.7.2 - FULLY INTEGRATED MODE

For fully integrated systems, the STÄUBLI control terminal is only required for configuration
and diagnosis. For normal operation, the system is controlled through the control panel of the
IMM.
In this operating mode, the user must refer to the user manual of the press which replaces this
manual for all operations concerning the use of the system.
The operating authorizations between the "QMC 122" system and the injection molding
machine (IMM) are managed by a EUROMAP 70.1 interface (see page 5.3.8, chapter 58).
To operate in this mode, a communication cable (provided by the manufacturer of the
machine) connecting the "QMC 122" controller with the IMM controller is required.
To configure the "QMC 122" system in fully integrated mode see chapters 6.5.6.2, page 114
and 6.5.7, page 116.
2.7.3 - PARTIALLY INTEGRATED MODE

When the user chooses to operate the "QMC 122" system without using the control terminal
and the communication link between the "QMC 122" controller and the IMM controller, it is not
possible to give the "QMC 122" controller a definition of the dimensions of the mold used.
In this case, the interface EUROMAP 70.1 makes it possible to actuate the magnetic clamping
system, but the clamping force values cannot be estimated. Other system functions are not
available and this operating mode is not recommended for the reasons set out below.
As stated in chapter 2.5.2, the "QMC 122" clamping system complies with the safety
requirements set out in chapters 5.10.2.2 and 7.1.21 of standard EN 201:2009. Among other
requirements, chapter 5.10.2.2 of this standard requires verification of the correct saturation of
the magnets before it is possible to start the production with a safety level PLr = b according to
the standard EN ISO 13849-1:2008. Verification of this saturation makes it possible to
maintain the mold with the force specified in the application.
The electromagnetic laws verified by tests under real conditions make it possible to confirm
that the magnets of a module can only be saturated if this module is covered by the mold.
Accordingly, and in order to satisfy this requirement of the standard with certainty, the measure
adopted by STÄUBLI is to verify that all the magnets covered by the mold are saturated.
To do this, the system must know the geometry of the mold used. This geometry can be
entered by the user in the standard mode via the STÄUBLI control terminal (chapter 6.5.7,
page 116) or in the fully integrated mode via a communication link between "QMC 122"
controller and the IMM controller. From this geometry, the controller will calculate the
proportion of modules covered and then deduce from it a minimum expected value of magnetic
flux.
This value is then compared with the magnetic flux measurement carried out on all the
modules to determine whether saturation can be considered satisfactory or not.
20 / 133 © STÄUBLI 2016 - RV2600602A QMC 122

In the case where the user does not enter the dimensions of the mold used - for example, in
the case of a EUROMAP 70.1 interface used alone - then the saturation of the magnets can
only be verified on a small number of modules and the "QMC 122" system will not be able to
calculate the clamping force.
IMPERATIVE
STÄUBLI recommends against using this operating mode and will make it possible only
when expressly requestly by the customer. Moreover, in this case, STÄUBLI recommends
installing appropriate means to prevent the mold from falling, for example a loading table
or the permanent securing of the mold.
QMC 122 © STÄUBLI 2016 - RV2600602A 21 / 133

2.8 - INDICATIVE DIMENSIONS AND WEIGHTS
2.8.1 - CONTROLLER DIMENSIONS AND WEIGHTS
C500/C1000:
B C
Figure 2-5
Note:
Depending on the version of the controller, the cables may exit from underneath or on
the side.
Type of controller
C500 C1000
A (mm) 400 400
B (mm) 400 400
C (mm) 200 200
D (mm) 200 200
Weight (kg) 15 16
Note:
The weights are given for informational purposes only, and they may vary according to
the installation.
22 / 133 © STÄUBLI 2016 - RV2600602A QMC 122

C2000/C4000:
B C
Figure 2-6
Note:
Depending on the version of the controller, the cables may exit from underneath or on
the side.
Type of controller
C2000 C4000
A (mm) 600 600

B (mm) 600 600
C (mm) 200 200
D (mm) 200 200
Weight (kg) 30 32
Note:
the installation.
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2.8.2 - PLATE SIZES AND WEIGHTS (FOR INFORMATION PURPOSES)
1-part plate:
52 1000 < x < 2000 (mm)

(mm)
500 < y < 1000

(mm)
Figure 2-7
3-part plate:
52 1000 < x < 2000 (mm)

(mm)
1000 < y < 1500

(mm)
Figure 2-8
24 / 133 © STÄUBLI 2016 - RV2600602A QMC 122

4-part plate:
52 1500 < x < 2000 (mm)
(mm)
1500 < y < 2000

(mm)
Figure 2-9
8-part plate:
52 1800 < x < 4000 (mm)

(mm)
2000 < y < 3500

(mm)
Figure 2-10
Type of plate
1 part 3 parts 4 parts 8 parts
Machine closing force (in
50  300 300  800 800  1300 1300  4000
Tonnes)
Approximate weight (kg) 100  300 300  600 500  1500 1300  4000
Note:
the installation.
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26 / 133 © STÄUBLI 2016 - RV2600602A QMC 122
3 - SAFETY
3.1 - GENERAL SAFETY INSTRUCTIONS
All work carried out on the "QMC 122" magnetic clamping system must comply strictly with the
safety rules in force in the country concerned.
Safety instructions:
A label similar to the one shown below is riveted on each plate. Never remove this label.
Strong magnetic field: Certain magnetic areas may be accessible during

work while the plate is in a magnetized state.
Prohibited for persons fitted with a pacemaker: Pacemakers, hearing aids

and other medical devices may be damaged or affected by the magnetic
clamping system.
The area prohibited to individuals with pacemakers includes:
- The area located between the 2 magnetic plates when they are
installed in the machine.
- A 50 cm area around each magnetic plate (regardless of their
status/position, particularly outside the machine).
The No Pacemakers labels must be posted on the outside of the machine so
as to be clearly visible by the operators.
Prohibited for elements sensitive to magnetic fields:

- The magnetic field exerts a strong force of attraction on ferrous
objects placed close to the active surfaces, which may cause risks
of pinching.
- Keep all sensitive devices that could be damaged or affected well
away.
A set of relevant safety labels is provided with the printed copy of this manual. During the
installation of the clamping system, these labels must be affixed outside the machine so as to
be clearly visible by those likely to approach system.
IMPERATIVE
Only authorised and qualified persons must be able to carry out the procedures described
in chapters 2, 3, 4, 5, 6 and 7.
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3.2 - INSTALLATION SAFETY INSTRUCTIONS
When lifting and handling the "QMC 122" magnetic clamping system and its various parts,
attach the slings correctly to avoid accidents or risk of damage.
The hoist must handled by a person authorised by the head of the installation site.
All the lifting equipment used (lifting rings, straps, slings, forklift trucks) must be in good
working order and correspond to the load to be moved.
The STÄUBLI company cannot be held liable for any incidents occurring during handling of the
"QMC 122" magnetic clamping system or its various parts.
The magnetic plates making up the "QMC 122" magnetic clamping system are fitted with
threaded holes on the upper surface for use of lifting rings.
These holes feature metric size threads (e.g. for systems designed for the European market)
or UNC threads (e.g. for systems designed for the North American market).
3.3 - OPERATING SAFETY INSTRUCTIONS

IMPERATIVE
Always check that the clamping force is sufficient for the weight of the mold
(chapter 2.6.8, page 17 and 2.6.9, page 18).
Check and make sure that the machine forces tending to pull the mold away are
always lower than the clamping force.
If this is not so, modify the machine parameters to ensure that the work can be done
in full safety.
Adjust the ejectors in adjustment mode with the forces and speeds set very low during the first
tests.
The main risks are the direct contact with the ejector with the rear plate of the mold and full
contact of the ejector pins in the case they are too long. Both situations must be avoided at all
costs.
During installation of the mold, check and correct its alignment as required, so that the ejectors
are perfectly lined up with the holes provided.
Check the temperature of the plates before touching them. This verification is possible using
the display provided by the system (see page 69, chapter 6.2). Wear gloves as required.
See the safety instructions given by the constructor of the injection press.
28 / 133 © STÄUBLI 2016 - RV2600602A QMC 122

3.4 - MAINTENANCE SAFETY INSTRUCTIONS
IMPERATIVE
Maintenance must be performed by technically proficient and certified personnel.
Wear all PPE, required by the applicable regulations regarding operator protection
(gloves, goggles and other protective equipment), to perform maintenance
operations.
IMPERATIVE
Disconnect the electrical power supply to prevent any untimely start-up.
Also disconnect the second power supply to the controller via the Euromap
connector linking the controller to the injection press.
All the adjustment, inspection and maintenance operations mentioned in this manual must be
carried out while the injection molding machine is shut down, if possible, with the magnetic
plates demagnetized.
IMPERATIVE
Maintenance of the electronic boards must be performed by qualified personnel who apply
recognized trade practices regarding electrostatic discharges.
QMC 122 © STÄUBLI 2016 - RV2600602A 29 / 133

30 / 133 © STÄUBLI 2016 - RV2600602A QMC 122
4 - PRESENTATION
4.1 - MAGNETIC PLATES
4.1.1 - DIFFERENT TYPES OF MAGNETIC PLATES
Each magnetic clamping system is made up of two magnetic plates:
- One fixed magnetic plate (FPL).
- One mobile magnetic plate (MPL).
Each magnetic plate, whether mobile or fixed, is made up of one or more sections.
The size of the plate on the plastic injection press determines the number of sections making
up the magnetic plates.
An application drawing is used to determine:
- The numbering system for the plate sections:
. F1, F2, F3, ... Fn for the sections of the fixed plate (FPL).
. M1, M2, M3, ... Mn for the sections of the mobile plate (MPL).
- The positions of the various sections to be installed on the plates of the injection press.
The figures below give some examples of plate configuration. The configuration is adapted in
the light of the specifications of each system.
"One-piece" plate - 1 magnetic plate:
FPL MPL
Figure 4-1
QMC 122 © STÄUBLI 2016 - RV2600602A 31 / 133

"Three-part" plate - 1 magnetic plate + 2 distance pieces:
FPL MPL
Figure 4-2
"Four-part" plate - 2 magnetic plates + 2 distance pieces:

FPL MPL
Figure 4-3
"Eight-part" plate - 4 magnetic plates + 4 distance pieces:

FPL MPL
Figure 4-4
32 / 133 © STÄUBLI 2016 - RV2600602A QMC 122

4.1.2 - ELEMENTS MAKING UP A MAGNETIC PLATE
Each magnetic plate is fixed on the plates of the injection press (IMM):
- A centering ring (3) ensures that the fixed magnetic plate is correctly fixed.
- A centering ring is not systematically used for the mobile magnetic plate.
The spaces left in the mobile plate for the ejectors must be determined at the time of order.
Each magnetic plate is made up of a certain number of circular magnetic modules (1). The
total number of magnetic modules on each plate depends on the press closing and opening
force levels. Four of the magnetic modules on each plate are used as reference points in the
"Flux measurement" safety control system and for "Movement Detection".
All the magnetic modules are used in the safety control system.
Each section of the magnetic plate is fitted with one or more connecting pockets (2). The
plates are connected to the controller via two types of cable: a power cable and a
measurement cable (see also figure 2-1).
Figure 4-5
QMC 122 © STÄUBLI 2016 - RV2600602A 33 / 133

4.2 - CONTROLLER
The type of controller depends on the size of the injection press and the number of magnetic
modules on each plate.
There are 4 controller versions:
- C500
- C1000
- C2000
- C4000
The controller is used to magnetise or demagnetise the magnetic modules fixed on the plates.
34 / 133 © STÄUBLI 2016 - RV2600602A QMC 122

4.2.1 - C500 CONTROLLER
A C500 controller is used to power plates fixed on an injection press with a closing capacity of
up to 500 tons.
12 11 10 9 4 3 2 1
5
6
7
8
13 14 15 16
17
Figure 4-6
Reference Description
1 Power modules (chapter 4.2.7)
2 Backplane
3 Mother board (chapter 4.2.5)
4 Power supply board (chapter 4.2.6)
5 Fuses F3, F4 (power supply board protection)
6 Contactor K1M
7 Fuses F1, F2 (mains supply protection)
8 Disconnector Q1
9 Cable gland signal connections of magnetic plates
10 Control terminal connector
11 Calibration button
12 RS485 link connector (SUB-D female)
13 Power supply cable cable gland
14 CAN link connector (SUB-D male)
15 EUROMAP 70 connector, interfaced with the injection press
16 Connectors power connections of magnetic plates
17 Protective cover for power connectors
Note:
As stated in chapter 2.8.1, the cable outlets may be on the underside or on the side of
the controller.
QMC 122 © STÄUBLI 2016 - RV2600602A 35 / 133

up to 1000 tons.
12 11 10 9 4 3 2 1
5
6
7
8
13 14 15 16
17
Figure 4-7
2 Backplane
6 Contactor K1M
8 Disconnector Q1
Note:
the controller.
36 / 133 © STÄUBLI 2016 - RV2600602A QMC 122

up to 2000 tons.
4 3 2 1
12 11 10 9
5
6
7
8
13 14 15 16
17
Figure 4-8
2 Backplane
6 Contactor K1M
8 Disconnector Q1
Note:
the controller.
QMC 122 © STÄUBLI 2016 - RV2600602A 37 / 133

up to 4000 tons.
4 3 2 1
12 11 10 9
5
6
7
8
13 14 15 16
17
Figure 4-9
2 Backplane
6 Contactor K1M
8 Disconnector Q1
Note:
the controller.
38 / 133 © STÄUBLI 2016 - RV2600602A QMC 122

4.2.5 - MOTHER BOARD
The mother board is fitted with several indicator lights providing information necessary for
after-sales services.
8 7 6 5 4 3 2
9
10
1
11
12
13
14 15 16
Figure 4-10
1 Microprocessor status
2 K1M contactor status
3 Presence voltage 3.3 V CAN bus
4 Presence voltage 5 V series link RS232
5 Status of relays REL1 and REL2
6 Backup lithium battery 3 V type BR2032
7 Fuses F1, F2 for protection of signals EUROMAP 70
8 Presence voltages 24 V, 5 V and 3.3 V internal
9 Presence voltage 5 V series link RS485
10 Presence voltage 24 V EUROMAP 70
11 Input signals EUROMAP 70
12 Auxiliary input signals EUROMAP 70
13 Output signals EUROMAP 70
14 Safety Magnetization / Demagnetization button status
15 System status signals
16 Proximity detectors for the fixed and mobile plates
QMC 122 © STÄUBLI 2016 - RV2600602A 39 / 133

4.2.6 - POWER SUPPLY BOARD
The power supply board (Figure 4-11) is equipped with a configurable transformer that accepts
several mains voltages (200 V AC to 480 V AC).
1 Protection fuse F1 at the transformer's secondary winding
2 Configurable terminal block J1
Configuration of the transformer
The table below shows the connections to be made on the terminal block J1 (2) according to
the mains voltage used.
Mains Connections on J1
voltage Wire ref. 5 Wire ref. 6
200 J1-4 J1-3 2 1

220 J1-4 J1-2
240 J1-4 J1-1
380 J1-5 J1-3
400 J1-5 J1-2
420 J1-5 J1-1
440 J1-6 J1-3
460 J1-6 J1-2
480 J1-6 J1-1
Figure 4-11
IMPERATIVE
This operation is to be carried out at the time of installation technically proficient
and certified personnel.
40 / 133 © STÄUBLI 2016 - RV2600602A QMC 122

Wiring of the terminal block J1
- Insert the reference wires 5 and 6 into the terminal block J1. The configuration depends on
the voltage used.
- Tighten the 2 screws of the terminal with a tightening torque between 0.5 Nm and 0.6 Nm.
- Clamp the 2 conductors and the protective sleeve (1) with a plastic collar (2) as shown below
(figure 4-12).
1 2
Figure 4-12
4.2.7 - POWER MODULE BOARD

The power module board controls the power supply to power circuit of the magnetic plates.
Figure 4-13
1, 2, 3, 4 Fuse for protection of power elements
QMC 122 © STÄUBLI 2016 - RV2600602A 41 / 133

4.3 - CONTROL TERMINAL
The control terminal is equipped with:
- An LCD unit (1).
- An "ERROR" alarm indicator light (2).
- An SD card slot (3).
- A safety Magnetization / Demagnetization button (4).
- A keyboard (5).
- A disconnectable cable (6).
2
1
Figure 4-14
42 / 133 © STÄUBLI 2016 - RV2600602A QMC 122

5 - INSTALLATION
5.1 - STORAGE INSTRUCTIONS
5.1.1 - FOR THE "QMC 122" MAGNETIC CLAMPING SYSTEM
The "QMC 122" magnetic clamping system must be stored in its original packaging, in a
sheltered area.
If the "QMC 122" magnetic clamping system is transported without its original packaging, the
sender must take all due precautions to ensure its protection.
If the "QMC 122" magnetic clamping system is transported on the injection press, the sender
must take all due precautions to ensure its protection.
5.1.2 - FOR STÄUBLI PARTS

STÄUBLI spare parts must be stored in a location free of pollution, impacts and humidity.
ATTENTION
Handle all parts carefully.
5.2 - HANDLING INSTRUCTIONS

The magnetic clamping system "QMC 122" must be handled with care in accordance with the
instructions in chapter 3.2.
5.3 - INSTALLATION
IMPERATIVE
The magnetic clamping system cannot be moved, reinstalled or transferred from one
machine to another, without consulting STÄUBLI and the IMM manufacturer beforehand.
We reiterate that the "QMC 122" system is not an interchangeable piece of equipment and
that it is intended to be permanently mounted in a previously determined machine.
The installation of the "QMC 122" magnetic clamping system on the injection press must
comply in full with the application drawing and the electrical diagrams.
The application drawing is forwarded with conformation of receipt of order for the plates.
The electrical diagrams are available inside the controller.
QMC 122 © STÄUBLI 2016 - RV2600602A 43 / 133

5.3.1 - PREPARATION OF THE MAGNETIC PLATES PRIOR TO INSTALLATION
Reminder:
This magnetic clamping system is designed to operate in a dry environment. All fluid
contamination reduces system service life, resulting in production stoppages and therefore
increased costs for the user company.
Tools:
- LOCTITE 518 plane sealant.

- LOCTITE 7063/7070 cleaner or equivalent.
Preparation:
Before installing the plates on the press, it is recommended to make a continuous bead of
plane sealant to insulate the electrical connectors from any possible fluid infiltration:
- Leakage directly from the machine plate.
Or
- Infiltration between the machine plate and the magnetic plate:
. From the outside.
. Via mounting points.
. Via the ejector holes, or any other through opening in the magnetic plate.
Procedure:
- Degrease and clean the areas of the magnetic plate where the sealing bead is to be applied.
- Place a 2 mm mm bead of LOCTITE 518 plane sealant along the periphery of the area
containing the electrical connectors and around all areas susceptible to fluid infiltrations.
- Degrease and clean the area of machine plates that will come into contact with the sealing
bead.
- Continue the plate installation procedure.
Sealing cord (Ø = 2 mm)
Figure 5-1
44 / 133 © STÄUBLI 2016 - RV2600602A QMC 122

5.3.2 - FITTING THE MAGNETIC PLATES
Tools:
- Torque wrench, spirit level.
Procedure:
ATTENTION
Comply with the positioning of the various sections (chapter 4.1.1, page 31).
For one-piece magnetic plates, start with the fixed side: (figure 5-2)
- Adjust the centering ring (4) on the fixed plate (3).
Note:
It is advisable to raise the magnetic plate on stand-offs to leave enough room to insert
the centering ring.
- Position the fixed magnetic plate between the tie-bars.
- Center the fixed magnetic plate on the machine plate (1) using the centering ring. Guide the
centering ring carefully into the reamed hole in the machine plate.
- Check the horizontality of the magnetic plate using a spirit level.
- Tighten the CHc screws (5) and (2) to the necessary torque level (chapter 5.3.2.1, page 48).
- Repeat the operations to fix the mobile magnetic plate on the mobile press plate (If the
mobile plate is not fitted with a centering ring, make sure there is no interference between the
mobile parts of the machine and the magnetic plate).
4
5
Figure 5-2
QMC 122 © STÄUBLI 2016 - RV2600602A 45 / 133

For plates in several sections, start with the fixed side:
- Comply with the positioning of the various sections. Each section is identified by a number
marked on the front (Mx for the sections on the mobile plate side and Fx for the sections on
the fixed plate side).
- Check the positioning of the various sections in the application drawing.
- Fix the lower section(s) of the fixed plate, without tightening the fixing screws.
- Fit and adjust the upper section(s).
- Insert the centering ring carefully.
- Position the plates carefully on the centering ring.
- Tighten the screws to the necessary torque level (chapter 5.3.2.1, page 48).
- Repeat the operations to fix the mobile magnetic plate on the mobile press plate (If the
mobile plate is not fitted with a centering ring, make sure there is no interference between the
mobile parts of the machine and the magnetic plate).
46 / 133 © STÄUBLI 2016 - RV2600602A QMC 122

For plates in several sections with a collar type fixing ring, start with the fixed side:
(figure 5-3)
- Position the centering ring (2) carefully in the reamed hole in the machine plate (1).
- Comply with the positioning of the various sections. Each section is identified by a number
marked on the front (Mx for the sections on the mobile plate side and Fx for the sections on
the fixed plate side).
- Check the positioning of the various sections in the application drawing.
- Fit and adjust the lower section(s) of the magnetic plate (3), without tightening the fixing
screws.
- Fit and adjust the upper section(s).
- Tighten the screws (4) to the necessary torque level (chapter 5.3.2.1, page 48).
- Repeat the operations to fix the mobile magnetic plate on the mobile press plate.
2
3
Figure 5-3
QMC 122 © STÄUBLI 2016 - RV2600602A 47 / 133

5.3.2.1-Screw tightening torques
Screw tightness and the efficiency of the tightening torques can only be guaranteed for 12.9
class screws, other than in specific cases of particular tightening torque levels as set out in the
manual.
CHc fixing screws
(Tolerance ± 7%)
Metric D M8 M10 M12 M16 M20 M24 M30 M36

CHc N.m 40 70 90 170 360 670 1350 2000
screws
12.9 black
steel lbf.ft 30 52 66 125 265 495 995 1475
screws
UNC
D 3/8" 5/8" 3/4" 1" 1"1/4
threads
CHc screws N.m 35 190 310 760 1600
12.9 black
steel lbf.ft 26 140 230 560 1180
screws
Characteristic parts
Figure 5-4
Reference Part Torque in Nm Wrench (a: across flats)

1 Connection pocket screw 9 a=3 Allen key
2 Connector socket screw 1.15 a=2 Allen key
3 Proximity detector 1 a=7 pipe/box wrench
48 / 133 © STÄUBLI 2016 - RV2600602A QMC 122

5.3.3 - FIXING THE CONTROLLER
ATTENTION
The controller is designed to be mounted vertically on the injection molding machine (the
support and fasteners must be able to withstand four times the weight of the controller). It
must be placed well away from any sources of excessive heat or moisture.
Once installed, the controller must be located at least 150 mm above the floor. Moreover,
the disconnector handle must be easily accessible and located between 0.6 m and 1.9 m
above the floor.
Tools:
- Drill, tap, fixing screw M8x30 (min.), spirit level, meter.
Procedure:
- Mark the positions of the fixing holes on the injection press.

- Drill and tap 4 holes in the frame of the injection press to fix the controller.
- Fix the controller in place.
C500/C1000 C2000/C4000
Figure 5-5
IMPERATIVE
When fastened to any other support than the injection molding machine, a fixing device
adapted to this structure must be used. The support and fasteners must be able to
withstand 4 times the weight of the controller.
QMC 122 © STÄUBLI 2016 - RV2600602A 49 / 133

5.3.4 - INSTALLATION OF CABLES
The various cables of the controller must run in the structure of the press while respecting the
bending radii defined in the table below.
Cable Max outer diameter (mm) Min bending radius (mm)

EUROMAP 16.0 65 (s) / 200 (d)
Power plates 11.3 45 (s) / 85 (d)
Signal plates 2 pairs 6.6 65 (s) / 100 (d)
Signal plates 5 pairs 8.3 80 (s) / 120 (d)
Control terminal 7.6 80 (s) / 120 (d)
Note:
(s): Bending radius for static installation.
(d): Bending radius for dynamic installation.
5.3.5 - CONNECTION OF THE CONTROL TERMINAL ON THE CONTROLLER

- Define the location of the control terminal on the injection molding machine.
- The control terminal must be placed in a suitable location and position for the operator. The
hook on the back of the control terminal is equipped with a magnet. This magnet is used to
fix the control terminal next to the control station of the press.
- Pass the cable from the control terminal to the controller.
ATTENTION
To avoid the risk of damage to the cable, it is advisable to pass the cable from the control
terminal through the inside of the press frame.
- Insert the SUB-D jack (2) on the connector (1).

- Fully tighten the 2 screws on the sides of the SUB-D connector.
Figure 5-6
50 / 133 © STÄUBLI 2016 - RV2600602A QMC 122

5.3.6 - POWER CONNECTIONS BETWEEN THE CONTROLLER AND THE "QMC 122"
MAGNETIC PLATES
The system is supplied with the multicore power cable harnesses 5 x 2.5 mm² and the modular
power plugs to be wired 4 pole + ground.
Measure the length necessary for each cable between the magnetic plates and the controller.
Cut off the excess length on the controller side while keeping a margin of 30 cm.
Connection on the magnetic plate side:
- Connect the 5-pole plug to the base of the connecting pocket according to the alignment of
the references (1).
- Put the cable in through to the controller via the locations provided. Make sure that the cable
cannot be damaged by the machine movements.
- Repeat the operations until all the connecting pockets on the fixed and mobile plates have
been linked to the controller.
Figure 5-7
ATTENTION
The plug is tightened on the base of the connector by hand or with a tool without
exceeding a torque of 7.5 Nm.
QMC 122 © STÄUBLI 2016 - RV2600602A 51 / 133

Connection on the controller side:
- Connect the free end of the power cable to the insert of the 4-pole + ground modular
connector as described below (figure 5-8). Use a flat screwdriver 0.5 x 3 mm or
0.4 x 2.5 mm.
Conductor reference Insert terminal

1 N° 1
2 N° 2
3 N° 3
4 N° 4
Green/Yellow
40 mm
10 mm
1- Pass the cable through the 2- Strip the cable

cable gland and cover
3- Insert the screwdriver blade 4- Insert the wire into the

to open the contact contact
5- Remove the screwdriver to 6- Connect the 5 wires by

close the contact repeating the 3, 4 and 5
operations
Figure 5-8
52 / 133 © STÄUBLI 2016 - RV2600602A QMC 122

- Assemble the insert (1) and the cover (2) of the connector with the screw (3) and the plastic
washer (4) with a tightening torque of 0.5 Nm. Then screw the cable gland (5) with a
tightening torque of 3 Nm (figure 5-8).
Note:
The plastic washer (4) ensures the sealing of the fixing screw (3).
5 3
2 1
Figure 5-9
- Remove the protective metal cover (1) by unscrewing (2) from the inside of the cabinet
(figure 5-10).
1 2 3
Figure 5-10
- Insert and lock the connectors (3) on their respective sockets (MPLx for the mobile plate and
FPLx for the fixed plate) (figure 5-10).
- Replace the protective metal cover (1) by screwing it (2) from the inside of the cabinet (figure
5-10).
QMC 122 © STÄUBLI 2016 - RV2600602A 53 / 133

5.3.7 - MEASUREMENT CONNECTIONS BETWEEN THE CONTROLLER AND THE "QMC 122"
MAGNETIC PLATES
The system is supplied with the multi-pair "measurement" cable harnesses.
IMPERATIVE
The connection must be made in accordance with the wiring diagrams supplied with the
controller "QMC 122".
ATTENTION
On systems with only one connecting pocket, there is only one kind of multicore cable (5
pair cable):
- 2 pairs are used for the flux measurement circuits.
- 3 pairs are used for the proximity sensor and the temperature sensor.
On systems with more than one connecting pocket per plate, a 5-pair cable is used on the
connecting pockets FPL1 and MPL1 and 2-pair cables are used on connecting pockets
FPL2 to FPL8 and MPL2 to MPL8.
Measure the length necessary for each cable between the magnetic plates and the controller.
Cut off the excess length on the controller side while keeping a margin of 60 cm.
54 / 133 © STÄUBLI 2016 - RV2600602A QMC 122

Connection on the magnetic plate side:
- Connect the 10-pole plug to the base of the connecting pocket according to the alignment of
the references (1).
- Put the cable in through to the controller via the locations provided. Make sure that the cable
cannot be damaged by the machine movements.
- Repeat the operations until all the connecting pockets on the fixed and mobile plates have
been linked to the controller.
Figure 5-11
ATTENTION
The plug is tightened on the base of the connector by hand or with a tool without
exceeding a torque of 7.5 Nm.
QMC 122 © STÄUBLI 2016 - RV2600602A 55 / 133

Connection on the controller side:
- Unscrew the screws (1) and remove the flange (2) from the cable gland plate (figure 5-12).
- Pass the end of the cable through the cable gland (3). Use the cable gland suitable for cable
diameter. The size (4) of the gland is indicated on each part:
. Cable gland size 7 for 2-pair cable.
. Cable gland size 8 for 5-pair cable.
Figure 5-12
- Route the cable inside the controller cabinet and prepare the cable as shown below
(Figures 5-13 and 5-14). The lengths are indicated in millimeters.
- Strip the cable end. The length "L1" must be adapted according to the type of controller.
15
L1
8
130
Figure 5-13
56 / 133 © STÄUBLI 2016 - RV2600602A QMC 122

- To connect the shield, cut the outer sheath of the cable (1) at both ends of the area (2).
Score the piece of sheath lengthwise and remove it. Be careful not to damage the shielding
under the sheath.
2
1
Figure 5-14
- Inside the controller, clip the stripped area of the cable onto the shielding plate (1) and then
clamp the cable to the attachment lug with a plastic collar (2) (figure 5-15).
- Route the free end of the cable into the upper duct (3) provided for this purpose up to the
terminal block (4) in connection with the connecting pocket to be connected.
- Connect the conductors to the spring terminal (4). Hold the different conductors as close as
possible to the terminal block, with a plastic collar (5).
4 3
Figure 5-15
- Repeat until all connecting pockets of the fixed and mobile plates are connected to the
controller.
- Replace the flange (2) and tighten the screws (1) of the cable gland plate with a tightening
torque between 1.5 Nm and 2 Nm (figure 5-12).
QMC 122 © STÄUBLI 2016 - RV2600602A 57 / 133

5.3.8 - CONNECTING THE ELECTRICAL INTERFACE BETWEEN THE CONTROLLER AND THE
PRESS
The controller "QMC 122" is equipped with an interface according to the recommendation
EUROMAP 70 (or SPI AN-145) which determines the signals necessary for interfacing the
magnetic clamping system with the injection molding machine (IMM).
The complete description of this interface is available free on the website www.euromap.org.
To ensure maximum security, it is strongly recommended to equip the IMM with an interface of
this type. Due to the wide variety of electrical designs in the different press control systems, it
is not guaranteed that all necessary inputs and outputs are available originally. However, it is
always possible to create an interface EUROMAP 70 subsequently (contact the manufacturer
of the injection press).
This interface provides a simple solution that ensures the safety and convenient operation of
the "QMC 122" system. In addition, it offers several configuration options. The interface
configuration EUROMAP 70.0 describes the standard interface, while EUROMAP 70.1
describes the extended interface that allows operation in fully integrated or partially integrated
mode.
For details on the different operating modes, see chapter 2.7.
The interface is connected via the modular connector (2) in Figure 5-16 located on the side or
bottom of the controller.
5.3.8.1-Description of the interface connections
1 2 3
Figure 5-16
(1): Connection cable between the plastic injection machine and the "QMC 122"
magnetic clamping system supplied with each system.
(2): Modular socket for the "QMC 122" controller end.
(3): Connector for the injection press end.
58 / 133 © STÄUBLI 2016 - RV2600602A QMC 122

IMPERATIVE
In accordance with standard EN 60950-1, the electrical circuits of the injection press
connected to the QMC 122 controller such as the EUROMAP interface, the RS485
connection or the CAN bus must be SELV (Very Low Voltage Safety) circuits in order to
ensure protection against electric shock.
The voltages present on these circuits must be less than 50 V DC or 30 V AC.
Characteristics of the contacts:

Enable injection press, magnetic clamping system OK (Terminals a1/a7; a6/a12):
- Maximum voltage: 50 V DC or 30 V AC.
- A current of at least 6 mA must be maintained during the signaling period.
- Maximum current: 6 A.
Enable magnetic clamping system (Terminals d1/d7; d6/d12):
- Maximum voltage: 50 V DC.
- A current of at least 6 mA must be maintained during the signaling period.
Logic signals:
- These signals must be in accordance with clause 3.3.1 of the standard EN 61131-2, Table 9,
Type 2 or clause 3.3.3 of EN 61131-2, Table 11, 0.1 A max.
Reference voltage (Table 1: Terminal a2 and Table 2:Terminal d2):
- Voltage: 18-36 V DC.
- Maximum voltage spike: 2.5 Vpp.
- Resistance to overvoltage: up to 60 V, 10 ms.
QMC 122 © STÄUBLI 2016 - RV2600602A 59 / 133

5.3.8.2-Contacts used by EUROMAP 70
Connector on the injection press (male) - Signals from the injection press to the
magnetic clamping system:
Male contact
N° (see (3) Signal name Description
figure 5-16)
d1 Enabling magnetic clamping (MCS Allow

d7 Enable) magnetization/demagnetization;
normally open
d2 Power supply from the magnetic Reference voltage of the magnetic

clamping system clamping system (24 V DC)
d5 Mold Change Mode The "Mold Change Mode" signal must
be independent from pins a1/a7 and
a6/a12. Injection press in "Mold
Change Mode"; normally open
d6 Enabling magnetic clamping (MCS Allow

d12 Enable) magnetization/demagnetization;
normally open
The injection press must provide 3 dry contacts.

Contacts to enable the magnetic clamping system (d1-d7, d6-d12)
The contacts to enable the magnetic clamping system must only be closed if the press
provides suitable safety conditions for clamping / releasing the molds. The exact conditions
are determined by the manufacturer of the injection press. However, it is important for the
contacts to close only when the press is in "Mold Change Mode" (when the force and speed of
the mobile parts on the injection press are limited) and when the safety doors are closed.
The 2 contacts to enable the magnetic clamping system must be closed before any attempts
are made to magnetize or demagnetize one of the plates.
During the switching cycle, the switchinc cycle is interrupted if one of the signals is lost. In this
case, the magnetic plate(s) will be in an undefined state. To return to a steady state, follow the
procedure in chapter 6.3.9.
Contact for the "Mold Change Mode" (d2-d5)
The "Mold Change Mode" contact must be closed before any attempts are made to magnetize
or demagnetize one of the plates. It must remain closed until the molds have been changed
and clamped on both sides. If the "Mold Change Mode" contact opens before the molds have
been clamped on both sides, an alarm is triggered and the magnetic clamping system opens
the contacts that enable the injection press (a1-a7 and a6-a12) to prevent any movements on
the injection press.
ATTENTION
It is important to be able to select the "Mold Change Mode" on the injection press, and for
contact d2-d5 to be closed, even while contacts a1-a7 and a6-a12 have been opened by
the alarm on the magnetic clamping system. If this is not so, the alarm on the magnetic
clamping system cannot be switched off. It is thus impossible to restart the injection press.
60 / 133 © STÄUBLI 2016 - RV2600602A QMC 122

Connector on the injection press (female) - Signals from the magnetic clamping system
to the injection press
Female
contact N°
Signal name Description
(see (3) in
figure 5-16)
a1 Enabling IMM movements (IMM Enabling injection press movements ;

a7 Enable) normally open
a6 Enabling IMM movements (IMM Enabling injection press movements ;
a12 Enable) normally open
The magnetic clamping system provides 2 dry contacts.

Contacts to enable the injection press (a1-a7, a6-a12)
If an error is detected by the magnetic clamping system, contacts a1-a7 and a6-a12 open. All
the movements on the injection press must stop immediately if one of these contacts opens.
The error can be reset by selecting "Mold Change Mode" on the injection press and, entering
the "Operator" mode of the magnetic clamping system, pressing the yellow "ALARM RESET"
key light on the control terminal. Once contacts a1-a7 and a6-a12 have been closed again, the
injection press can be restarted manually by the operator.
For fully-integrated systems using EUROMAP 70.1 the alarm is reset automatically after
selecting "Mold Chande Mode" on the IMM.
5.3.8.3-Contacts used by EUROMAP 70.1

In the case of a fully or partially integrated interface, the EUROMAP 70.1 interface is used.
This interface uses the contacts of the 70.0 interface along with additional contacts.
Connector on the injection press (male) - Signals from the injection press to the
magnetic clamping system:
Male contact N° (see (3)

figure 5-16)
d1 Enabling magnetic clamping Allow
d7 (MCS Enable) magnetization/demagnetizati
on; normally open
d2 Power supply from the Reference voltage of the

magnetic clamping system magnetic clamping system
(24 V DC)
d3 Magnetize MPL Normally open, momentary

signal > 1s
d4 Demagnetize MPL Normally open, momentary

signal > 1s
d5 Mold Change Mode The "Mold Change Mode"
signal must be independent
from pins a1/a7 and a6/a12.
Injection press in "Mold
Change Mode"; normally
open
QMC 122 © STÄUBLI 2016 - RV2600602A 61 / 133

figure 5-16)
d6 Enabling magnetic clamping Allow

d12 (MCS Enable) magnetization/demagnetizati
on; normally open
d9 Magnetize FPL Normally open, momentary

signal > 1s
d10 Demagnetize FPL Normally open, momentary
signal > 1s
Connector on the injection press (female) - Signals from the magnetic clamping system
to the injection press

figure 5-16)
a1 Enabling IMM movements Enabling injection press

a7 (IMM Enable) movements ; normally open
a2 Supply from IMM IMM reference potential

24 VDC
a3 MPL Magnetized Normally open, closed when
magnetized
a4 MPL Demagnetized Normally open, closed when

demagnetized
a6 Enabling IMM movements Enabling injection press

a12 (IMM Enable) movements ; normally open
a9 FPL Magnetized Normally open, closed when
magnetized
a10 FPL Demagnetized Normally open, closed when

demagnetized
62 / 133 © STÄUBLI 2016 - RV2600602A QMC 122

5.3.9 - CONNECTING THE CONTROLLER TO THE ELECTRICAL SUPPLY
5.3.9.1-Electrical characteristics
- Input voltage: 200/220/240/380/400/420/440/460/480 V AC, 50-60 Hz.
- Input current (permanent): 100 mA.
- Input current (during magnetization or demagnetization):
RMS current at the controller

Type of machine
input
C500 controller for injection press of under 20 A for 0.5 s per plate
125 tons
250 tons
500 tons
C1000 controller for injection press of under 80 A for 1 s per plate
1000 tons
2000 tons
4000 tons
Note:
The standard magnetic plates are designed to operate on a 380-415 V 50 Hz power
supply (e.g. for Europe) and a 440-480 V 60 Hz power supply (e.g. for the USA). If the
power supply voltage is different from the range shown for the magnetic plate, contact
STÄUBLI. Other voltages (200, 220, 240 V) can be used on request, but the magnetic
plates have to be specially designed. It should be noted that the maximum size for a
plate operating with a given controller is reduced in proportion to the power supply
voltage: for example, for a 220 V power supply, a C500 controller would only be
suitable for presses with a capacity of 250 tons.
IMPERATIVE
The power supply voltage must correspond to the voltage of the magnetic plates.
IMPERATIVE
When the controller disconnector is in the OFF position, some parts of the "QMC 122"
magnetic clamping system can remain energized.
After the operation of one of the two fuses, internal parts of the equipment may still have
dangerous voltage. Risk of electric shock
QMC 122 © STÄUBLI 2016 - RV2600602A 63 / 133

5.3.9.2-Power supply, cables and fuses
The "QMC 122" controller must be connected to the mains supply by means of a 3-conductor
cable with protective earth (not supplied), the characteristics of which are defined below:
- Rubber sheathed flexible cable compliant with standard IEC 60245 (designation
60245 IEC 53) or PVC sheathed flexible cable compliant with standard IEC 60227
(designation 60227 IEC 53).
- Green/yellow ground protective conductor with the same cross-section as the other
conductors.
- Cross-section of conductors: Maximum 16 mm2. The minimum cross-section of conductors
depends on the type of conductor (see table below).
- Outer cable diameter for the cable gland M25*: Min 12 mm - Max 18 mm.
- Outer cable diameter for the cable gland M32*: Min 17 mm - Max 25 mm.
*: The cable gland M32 is mounted originally on the cabinet. The M25 model is supplied in the
controller's spare parts package.
The power supply cable must be protected (see table below):
- Either by 2 fuses (1 per conductor) with gG characteristic (according to standards
IEC 60269-1 and 2) or CC/CD class for installations according to UL specifications.
- Either by a bipolar circuit-breaker curve D (compliant with standard IEC 60947-2).
In addition, a category-III omnipolar disconnecting system (compliant with standard
IEC 60947-3) external to the equipment and easy accessible must be installed upstream to
completely shut off power to the controller.
Fuse or Min
circuit cross-section Power supply
Type of machine
breaker of the rating
rating conductors
C500 controller for injection press of
under 125 tons 16 A 6 mm2 7 kVA





IMPERATIVE
In all cases, the cable cross-section must be checked and adapted according to the
installation conditions and the regulations in force in the country concerned.
It is recommended to obtain the mains supply from inside the injection press so that when the
power to the injection press is turned off the magnetic clamping system is turned off also.
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5.3.9.3-Connection
IMPERATIVE
The controller must be connected to the protective ground. Risk of electric shock inside the
cabinet.
The installation must be carried out by an authorized person in accordance with the
regulations in force in the country concerned.
IMPERATIVE
Before connecting to the mains, check that the EUROMAP interface cable is connected to
the injection press.
The power supply board of the controller must be configured according to the supply
voltage of the network. The configuration is described in chapter 4.2.6, page 40.
The "QMC 122" controller is connected to the mains supply:

- Either between 2 phases for voltages between 380 V and 480 V.
- Or between a phase and the neutral for voltages between 200 V and 240 V.
See the wiring diagram supplied with the "QMC 122" magnetic clamping system.
Procedure
- Strip the power supply cable as shown below (lengths in mm).
100
1 conductor
2 conductor
140* Protective earth
18 (Green/Yellow)
Figure 5-17
*: According to standard EN 60950-1, chapter 3.2, the earth conductor must be longer than the
other conductors.
- Crimp a cable ferrule with overmolded collar to the two supply conductors in accordance with
standards NF C 63-023 or DIN 46228.
- Leave the end of the earth conductor bare (without cable ferrule).
QMC 122 © STÄUBLI 2016 - RV2600602A 65 / 133

- Remove the protective cover from the contacts (1) from the disconnector Q1 (2)
(figure 5-18).
1
3
Figure 5-18
- Connect the power supply cable to the disconnector through the cable gland (3)
(figure 5-18). The earthing conductor must be connected as a priority. Observe the tightening
torques given below.
Element Tightening torque

Power terminal of the disconnector Q1 4 N.m
M25 cable gland 4 N.m
M32 cable gland 4 N.m
- Clamp the two supply conductors and the protective earth conductor, as close as possible to
the disconnector, with a plastic collar (1) (figure 5-19).
Protective earth
N L2
L L1
Power supply
1 between 2 phases
Phase-neutral power supply
Figure 5-19
- Replace the protective cover of the contacts (1) on the disconnector Q1 (2) (figure 5-18).
66 / 133 © STÄUBLI 2016 - RV2600602A QMC 122

5.3.10 - SYSTEM CALIBRATION
IMPERATIVE
The system must be calibrated in the final operating conditions (on the final customer's
premises).
Refer to section 6.7 on page 124 to carry out the calibration sequence.
5.3.11 - CHECKS AND TESTS
Action Result obtained
Preparation of the magnetic plates prior to installation

(chapter 5.3.1)
Installation of the magnetic plates and tightening of the
screws at the recommended torques (chapter 5.3.2)
Installation of the controller
Control terminal connected
Power cables connected
Measurement cables connected
Electrical interface connected
Power supply connected
Functional tests of the system and of the interface with

Result obtained
the IMM
The control terminal display shows the status of the system

when the power is turned on
The system is calibrated
The animated icon is displayed when the IMM is set to

"Mold Change Mode" and only in this mode
The icon is displayed when the safety conditions

allowing the magnetization or demagnetization of the mold
are met and only in this case
Proximity sensors are functional
The temperature sensors are functional
Try to start a magnetization without a mold. It must not be

possible to do this.
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Functional tests of the system and of the interface with
Result obtained
the IMM
Try to start a magnetization by covering only the proximity

sensors with a metal part. The system must detect that the
magnetic flux is not acceptable.
Carry out a magnetization test with a small mold. The 4

reference modules must be covered and the mold
dimensions must be entered. The system must accept the
magnetization and display the clamping force obtained.
Change the opening force setting (chapter 6.5.5) so that the

opening force is greater than the clamping force previously
obtained. Check that Force comparison option is enabled
(chapter 6.5.7). Magnetize the small mold again.
The system must display an alert message indicating that the
clamping force is less than the opening force.
Then set the opening force to its original value.
Carry out a magnetization test with a large mold. The 4

reference modules must be covered and the mold
dimensions must be entered. The system must accept the
magnetization and display the clamping force obtained.
Check that disconnecting the interface cable immediately

stops the machine.
Check that it is impossible to put the machine into production

mode if the mold is not properly magnetized on both sides.
Training Result obtained
Operator and Supervisor trained to use
5.3.12 - AFFIXING SAFETY LABELS

A set of relevant safety labels is provided with the printed copy of this manual. During the
installation of the clamping system, these labels must be affixed outside the machine so as to
be clearly visible by those likely to approach system.
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6 - USE
6.1 - FIRST USE
Carry out all the checks indicated in chapter 5.3.11 before starting the system for the first time.
In addition, it is imperative to read chapter 2.6 and chapter 3 before using the system.
After performing these checks, operate the disconnector on the front of the controller to turn on
the "QMC 122" system.
6.2 - POWERING UP
When the controller is turned on, the control terminal screen displays:
- Initially: The STÄUBLI logo.
- Then the system information (chapter 6.8, page 129).
- And lastly, the system status (figure 6-1).
Note:
When starting the system for the first time, set the time as described in chapter 6.5.1.
14 1 2 3 4
13
5
12
6
11
7
10 9 8
Figure 6-1
1 Controller identifier (displayed if other than 0)
2 "Mold Change Mode" signal (animated)
3 System Enable Signal (MCS Enable)
4 Safety system locked
5 Interface used
6 FPL clamping force
7 FPL temperature
8 FPL status
9 Mold identification
10 MPL status
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11 MPL temperature
12 MPL clamping force
13 Date (DD/MM/YY)
14 Time
Note:
The "System status" display (Figure 6-1) is the default display of the control terminal. If
the control terminal is not used for the set time, the display returns to the default
display.
70 / 133 © STÄUBLI 2016 - RV2600602A QMC 122

Meanings of the icons (*: animated icons)
MPL Magnetized FPL Magnetized
MPL Demagnetized FPL Demagnetized
No mold on MPL No mold on FPL
MPL movement FPL movement
MPL status unknown FPL status unknown
MPL disconnected! FPL disconnected!
Press not in MCM mode Press in MCM mode
Availability of the magnetic clamping system on the press (MCS Enable)
Safety system locked Safety system unlocked
Steady: Calibration button pushed

Data Log
Flashing: Maintenance request
70.0 EUROMAP 70.0 70.1 EUROMAP 70.1
Controller identifier (not displayed if identifier equal to 0)
Magnetization, demagnetization and calibration are disabled during the time

indicated (in seconds) (Fully integrated system code: 1511)
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Key functions on the keyboard:
Key Description
Magnetize the mobile plate (MPL)
Magnetize the fixed plate (FPL)
Demagnetize the mobile plate (MPL)
Demagnetize the fixed plate(FPL)
Reset the alarm
Menu or Return
1 or YES
2 or ABC or Scroll up through a menu
3 or DEF
4 or GHI
5 or JKL
6 or MNO
7 or PQRS
8 or TUV
9 or WXYZ
Delete an incorrect entry
0 or NO or Scroll down through a menu
Validate
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Selecting a menu:
- The selected menu is highlighted.

- To move the arrow up or down, press the following keys:
. to move up.
. to move down.
Entering text:
Text can be entered using the alphanumeric keys, in the same way as on a cell phone keypad.
For example: For "A", press twice in quick succession.
- Press in the event of an error to delete the last character entered.
- Press to validate the entry.
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6.3 - CHANGING A MOLD ("OPERATOR" MODE)
- Activate the "Mold Change Mode" (MCM) on the press.
- Check that the icon is displayed on the control terminal.
- Check that the icon is displayed on the control terminal.
- Press to return to the Main Menu.
- Select "Operator".
- Press to validate.
Note:
The blue safety button only operates if the "Operator" or "Supervisor" mode and mold
change have been selected. The "Stäubli-Service" mode is reserved for Stäubli
technian use.
6.3.1 - PIN CODE

- Enter the 4 figures of the PIN code. The default PIN code is 1234, but it is possible to change
it via the "Supervisor" Settings menu.
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6.3.2 - SAFETY MESSAGES
Answer the questions by pressing for YES or for NO.
"MPL mold mechanically clamped?"

In the case where the mobile plate is deactivated, ensure that the half-plate is mechanically
clamped.
- Validate that the half-mold, mobile side, is mechanically clamped by pressing for YES.
"FPL mold mechanically clamped?"

In the case where the fixed plate is deactivated, ensure that the half-mold, fixed side, is
mechanically clamped.
- Validate that the half-mold, fixed side, is mechanically clamped by pressing for YES.
"Mold straps fitted?"

Both halves of the mold must be assembled when changing a mold.
- Validate that both halves of the mold are locked together by pressing for YES.
"Crane attached?"
The mold must be held securely by a crane or another item of lifting equipment.
- Validate that both halves of the mold are correctly held by pressing for YES.
Note:
Activation/Disabling of the safety messages, "Safety Prompts" option (chapter 6.5.7,
page 116).
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6.3.3 - MOLD IDENTIFICATION AND DESCRIPTIVE DATA
A mold must be identified by a name.
Its height and width must be entered to obtain a display of the clamping force.
Note:
The name of a mold can only contain 20 characters at most (letters and figures only).
If no module is clamped, the message "Mold ID?" appears on the control terminal display.
Identification: Creating a new mold
- Enter the name of the mold.
If the mold has already been entered beforehand, it can be selected in the list of molds
available:
- Press to display the Mold menu.

- Select the mold.
- Press to validate. If the mold is selected from the list or if it has already been entered
beforehand, its measurements are displayed for checking.
- If the measurements comply with the mold, press to validate. The system is
operational. Go to chapter 6.3.6.2, page 89.
- If the measurements do not comply with the mold, there must be a mistake in the name
selected for the mold. Press to abandon. The system returns to the previous menu
and requests a fresh mold identification.
Mold measurements:
Once the mold has been entered, the mold measurement menu is displayed.
- Select the mold shape.
For a rectangular mold:
- Press to select "Width (mm)".

- Enter the mold width in millimetres.
- Press " for move the cursor to "Height(mm)".
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- Press to select "Height(mm)".
- Enter the height of the mold in millimetres.
- Press to exit the mold measurements menu.
Note:
If the mold identification and measurements have not been recorded, the system
operates, but the magnetic clamping force is not displayed.
For an offset rectangular mold:
Coordinates defined as seen facing the fixed plate on the machine.
- Press to select "X1(mm)".

- Enter the X coordinate (as compared with the center of the plate) from point 1 (left and
downwards).
- Enter the Y coordinate as compared with point 1 in the same way.
- Repeat the operation for the two coordinates of point 2 (right and upwards).
Note:
X2
Y2
Y1
1
X1
Figure 6-2
(looking at the fixed plate of the machine)
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For a round mold:
- Press to select "Diameter(mm)".

- Enter the mold diameter in millimetres.
Note:
For a mold with special dimensions:
ATTENTION
This type of dimension must be used whenever one of the rear plates of the mold has a
particular shape not matching any of the previously described shapes or whenever there is
a large recessed surface at the rear of the plate.
Before using this menu, contact STÄUBLI to obtain the values to be entered.
- Press to select "MPL An".

- Enter the value given by STÄUBLI.
- Press to select "MPL As".

- Press to select "FPL An".

- Press to select "FPL As".

Note:
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If the mold tilting and slippage check is active (chapter 6.5.7, page 116), 2 additional
screens appear (one for each half-mold).
Enter the information concerning the half-mold, mobile side:
- Press to select "Thickness (mm)".

- Enter the thickness of the half-mold, mobile side, in millimeters.
- Press to select "Weight (kg)".

- Enter the weight of the half-mold, mobile side, in kilograms.
- Press to select "Gravity center position (mm)".

- Enter the position of the half-mold's center of gravity, mobile side, in millimeters.
Note:
If the position of the half-mold's center of gravity is not specified (equal to 0), the value
used will be the thickness of the half-mold divided by 2.
For molds with special dimensions, an additional parameter must be entered.
- Press to select "Clamp. force position (mm)".
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- Enter the position of the clamping force of the half-mold, mobile side, in millimeters
(information provided by STÄUBLI).
- Press to change the status of the "Center ring mounted" option.
- If the half-mold, MPL side, is equipped with a centering ring, select , otherwise select
.
- Press to confirm and continue to the next screen. Or press to cancel and
return to the previous screen.
Enter the information concerning the half-mold, fixed side:
- Follow the same procedure as before, but this time providing the information concerning the
half-mold, fixed side.
- Press to confirm and terminate the operation. Or press to cancel and return to
the previous screen.
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6.3.4 - DIFFERENT MOLD DIMENSIONS AT FIXED END AND MOBILE END
This section describes how to enter the mold dimensions when the "Mold dimensions
FPL≠MPL" option is enabled.
The information concerning the mold is distributed on 2 screens. One for the half-mold at the
fixed end and one for the half-mold at the mobile end.
If all of the information does not fit on the screen, a scroll bar appears. Use and
to switch from one parameter to another.
6.3.4.1-Shape of the half-mold
- Press to select "Half mold shape".
- Use and to select the shape of the mold-half used.
Note:
For the MPL side, it is possible to select a different shape from the FPL side except in
the case of a special mold. In this particular case when the FPL side is set as special,
then the MPL is automatically set as special.
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6.3.4.2-Rectangular half-mold
FPL plate, front view MPL plate, front view
FPL side MPL side
- Press " for move the cursor to "Width (mm)".
- Press to select "Width (mm)".

- Enter the width of the half-mold in millimeters.
- Press " for move the cursor to "Height(mm)".
- Press to select "Height(mm)".

- Enter the height of the half-mold in millimeters.
Note:
See 6.3.4.6 to enter the other parameters.
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6.3.4.3-Offset rectangular mold
FPL side MPL side
- Press " for move the cursor to "X1(mm)".
- Press to select "X1(mm)".

- Enter the X coordinate (as compared with the center of the plate) from point 1 (left and
downwards).
- Enter the Y coordinate as compared with point 1 in the same way.
- Repeat the operation for the two coordinates of point 2 (right and upwards).
Note:
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6.3.4.4-Round half-mold
FPL side MPL side
- Press " for move the cursor to "Diameter(mm)".
- Press to select "Diameter(mm)".

- Enter the mold diameter in millimetres.
Note:
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6.3.4.5-Half-mold with special dimensions
ATTENTION
Before using this menu, contact STÄUBLI to obtain the values to be entered.
FPL side MPL side
- Press " for move the cursor to "FPL An (cm2)".
- Press to select "FPL An (cm2)".

- Press " for move the cursor to "FPL As (cm2)".
- Press to select "FPL As (cm2)".

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Note:
When the shape of the FPL half-mold has been set as special, the shape of the MPL
half-mold is automatically set as special.
Note:
6.3.4.6-Additional dimensions for anti-tilt / anti-slippage check
ATTENTION
The following parameters exist only if the tilting and slippage checks are enabled.
- Press " for move the cursor to "Thickness (mm)".
- Press to select "Thickness (mm)".

- Enter the thickness of half-mold in millimeters.
- Press " for move the cursor to "Weight (kg)".
- Press to select "Weight (kg)".

- Enter the weight of the half-mold in kilograms.
- Press " for move the cursor to "Gravity center position (mm)".
- Press to select "Gravity center position (mm)".

- Enter the position of the half-mold's center of gravity, mobile side, in millimeters.
Note:
If the position of the half-mold's center of gravity is not specified (equal to 0), the value
used will be the thickness of the half-mold divided by 2.
Only for molds with special dimensions:
- Press " for move the cursor to "Clamp. force position (mm)".
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- Press to select "Clamp. force position (mm)".
- Enter the position of the clamping force of the half-mold in millimeters (information provided
by STÄUBLI).
- Press " for move the cursor to "Center ring mounted".
- Press to change the status of the "Center ring mounted" option.
- If the half-mold is equipped with a centering ring, choose , otherwise choose .
6.3.4.7-Confirm or cancel the changes
- Press to confirm the information.
- To cancel the changes, press .
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6.3.5 - FITTING THE MOLD
- Adjust the press opening to suit the mold thickness.
- Lower the mold, with both halves attached together.
- Position the mold on the fixed plate side, using the centering ring.
- Close the safety doors.
- Put the magnetic plates in contact with the mold.
ATTENTION
Do not apply any clamping force with the press.
6.3.6 - CLAMPING/RELEASING A MOLD
6.3.6.1-Initial conditions
To magnetize or demagnetize the plate, the following conditions must be met:
Press in "Mold Change Mode" (the icon is animated when the signal is sent).
Enable signal for the magnetic clamping system from the press (the icon is displayed
when the signal is sent).
Safety system unlocked (press the blue safety button on the side of the control
terminal).
The enable signals for the magnetic clamping system may depend on one or more conditions
regarding the press (such as "Safety doors closed", "nozzle retracted", "ejectors retracted", or
"Plates closed").
If a mold is correctly clamped on the 2 plates, the two green lights on the control terminal are
lit, and the two white lights are off. Injection can be started by setting the press to automatic
mode.
If the press is in automatic mode, the yellow "ERROR" light is off, and only the green lights
stay on. The system is ready and injection can start.
If the press is in automatic mode and the yellow "ERROR" light is flashing, this means that the
automatic mode is not authorized because the mold has not been correctly magnetized on
both plates. The emergency stop circuit is opened on the press connected to the "QMC 122"
controller, causing the press to stop. In this case, set the press to "Mold Changing Mode" to
reset the error on the "QMC 122" magnetic clamping system (to do so, it is necessary to be in
operator mode for the clamping system). The alarm on the press may then be reset.
ATTENTION
Before attempting to clamp a mold, make sure it is in good contact with the magnetic plate.
Once the presence of the mold has been detected by the proximity sensors, the mold is
displayed on the unit.
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6.3.6.2-Clamping/releasing
Figure 6-3
- Keep the blue locking/unlocking safety button pressed down and press the corresponding
key to magnetize or demagnetize:
Magnetize the mobile plate Magnetize the fixed plate
Demagnetize the mobile plate Demagnetize the fixed plate
- Once the operation has been carried out correctly, a message is displayed and the
corresponding indicator light comes on. Example: "MPL Magnetized", the indicator
light comes on.
- When the two parts of the mold are correctly clamped, remove the lifting means and detach
the two half parts of the mold.
- If the mold identifier and dimensions have been entered, the system displays the clamping
forces.
- Start production.
6.3.6.3-Comparison with IMM forces

The magnetic clamping force is compared with the press forces. A message may be displayed
(chapter 6.3.8, page 91).
ATTENTION
If the clamping force is less than 50% of the opening force, less than the ejector force or
less than the nozzle force, the system displays a message and requests validation. The
green light flashes.
- The green light flashes. Answer YES or NO.

If the operator replies YES, the system assumes that the machine force levels have been
reduced to take the warning into account.
- The green light comes on steadily.
However, the message remains visible.
If the operator replies NO, the system assumes that the machine force levels have not been
reduced.
QMC 122 © STÄUBLI 2016 - RV2600602A 89 / 133

- The green light continues to flash.
The machine cannot be put into production mode. It is necessary to release the mold, reduce
the machine force levels, and re-clamp the mold to enable production to be carried out in full
safety.
6.3.6.4-"Mold rejected" message

During the magnetization of the mold, the "QMC 122" system measures the magnetic flux on
all the modules and this measurement makes it possible to determine whether the mold is
acceptable or not.
If the mold dimensions have been entered, the controller checks that there is a minimum of
magnetic flux on the reference modules (about 10%) and that the flux on the rest of the
modules, averaged with respect to the mold size entered, is acceptable (approximately ±20%).
If the mold dimensions have not been entered, the controller only checks the magnetic flux on
the reference modules and this flow must be close to the maximum attainable (about 80%).
If the mold is not accepted, the "MPL mold rejected" or "FPL mold rejected" message will be
displayed and the yellow ERROR light will blink.
Moreover, several other reasons may explain why the mold is rejected:
- The dimensions entered do not match the actual dimensions of the mold.
- A non-magnetic air gap due to impurities, dust, paint, etc.
- A fault in the rear plate, such as a shock, an uneven surface, or an unsuitable material.
- Large holes or recesses in the rear plates of the molds.
For more details, see chapter 2.6, page 14.
Once the problem has been identified and dealt with, make a fresh attempt to magnetize the
molds. If the problem persists, contact STÄUBLI.
90 / 133 © STÄUBLI 2016 - RV2600602A QMC 122

6.3.6.5-Detection of mold movement during production
If a mold movement is detected, all the movements of the press are stopped immediately:
- The yellow "ERROR" light flashes.
- A message is displayed to indicate on which plate the mold movement has been detected
and that the plate is still magnetized despite the movement.
It is necessary to switch back to "Mold Change Mode" and acknowledge the error on the
control terminal, from the "Operator" or "Supervisor" menu before resetting the press alarm.
If a movement is detected, the mold must be removed before trying to re-clamp it. Check the
installation and the mold to make sure that:
- The ejector travel and alignment settings are correct.
- The mold is functioning correctly. Mold seizing or packing increases the force necessary to
open it and may lead to mold movement.
6.3.7 - REMOVING A MOLD

- Stop the press with the platens closed.
- Fix the 2 mold halves together using mechanical fastenings.
- Lock the mold and attach the lifting hook.
- Demagnetize the plates.
If the demagnetization procedure has been carried out correctly the and
indicator lights come on.
- Open the press and remove the mold.
6.3.8 - CLEAR AN ERROR

In the event of a problem, an error message is displayed and the yellow "ERROR" light
flashes.
- Enter the Operator menu or the Supervisor menu.
- If the "Safety Prompts" option is enabled (chapter 6.5.7, page 116), answer the safety
messages (chapter 6.3.2, page 75).
- Press to clear the alarm.
The alarm disappears unless the fault is still present. For example, the temperature alarm
cannot be cleared until the temperature has dropped to an acceptable level.
QMC 122 © STÄUBLI 2016 - RV2600602A 91 / 133

6.3.9 - RETURN TO A STABLE STATE
Following an operating malfunction, it is possible that the "QMC 122" controller is unable to
determine the magnetic state of the plates. The control terminal then displays:
Figure 6-4
Perform the following actions to return to a known state:
- Close the press so that both parts of the mold are in contact.
- Attach the hoist.
- Fit the clamp.
- Stop the press with the platens closed.
- Fix the 2 mold halves together using mechanical fastenings.
- Lock the mold and attach the lifting hook.
- Demagnetize the plates.
Now the system status is known, the 2 plates are demagnetized, the control terminal displays:
Figure 6-5
It is then again possible to clamp a mold (chapter 6.3.6, page 88).
92 / 133 © STÄUBLI 2016 - RV2600602A QMC 122

6.3.10 - INFORMATION AND WARNING MESSAGES
Information messages
(Fully integrated system Description Action
code)
Enter PIN Enter the PIN code for the Enter the 4-figure PIN code.
level selected.
PIN Accepted Code OK. No action required.
Incorrect PIN Wrong code. Enter the 4-figure code again.
Enter New PIN Enter the new PIN code. Enter the 4-figure PIN code.
Confirm New PIN Confirm the new PIN code. Enter the 4-figure code again.
PIN Changed The code has been changed. No action required.
PIN Not Changed The code has not been Restart the procedure.
changed.
Put IMM in MCM (2505) Switch to "Mold Change Setting the machine to "Mold
Mode" on the machine. Change Mode".
Demag first It is necessary to Start demagnetization.
demagnetize the plate before
magnetizing it.
Mold not detected The mold is not detected by Put the mold in contact with
the proximity detector. the machine plate.
Mold detected Calibration is requested on a Remove the mold before

plate in contact with the mold. initiating the calibration.
Calibration button pushed Magnetization or Release the calibration

(1510) demagnetization is requested button before magnetization
while the calibration button is or demagnetization.
pressed.
Login required The user attempted to clear Go to the operator menu or in

the alarm in the status the supervisor's mold change
screen. menu to clear the alarm.
No enable from IMM The MCS enable signals Check that the machine is
(door closed, press sending the expected
mechanism set back, etc.) signals.
have not been received by
the controller.
Press Safety Button Press the side button and the Press the side button and the
Magnetize /Demagnetize Magnetize /Demagnetize
button at the same time. button at the same time.
Mold ID? The system is waiting for the Enter the name of the mold to
mold identifier. be clamped or select it in the
list.
Saving Mold Data Saving the mold information. No action required.
QMC 122 © STÄUBLI 2016 - RV2600602A 93 / 133

code)
Loading Mold Data Loading the mold No action required.

information.
No Force Calculation The system cannot display No action required.

the force because some of
the information is missing.
New Mold The system shows that the Then enter the mold
name has not been entered in dimensions (chapter 6.3.3,
the database beforehand. page 76)
Mold memory full The space available to store Contact STÄUBLI

mold information is full.
Mold straps fitted? Are the two halves of the Check the fastenings holding
mold held together with the the two parts of the mold
locking straps? together.
Fit the straps! Attach both parts of the mold Lock both parts of the mold
together. together.
Crane attached? Is the mold supported by the Check that the mold has been
crane? supported correctly.
Attach the crane! Attach the mold to the crane. Attach the mold.
MPL mold mechanically The plate, mobile side, was Check that the half-mold,
clamped? disconnected and the mobile side, is mechanically
half-mold must thus be clamped.
Clamp mechanically MPL The plate, mobile side, was Mechanically clamp the
mold! disconnected and the half-mold, mobile side.
half-mold must thus be
FPL mold mechanically The plate, fixed side, was Check that the half-mold,
clamped? disconnected and the fixed side, is mechanically
half-mold must thus be clamped.
Clamp mechanically FPL The plate, fixed side, was Mechanically clamp the
mold! disconnected and the half-mold, fixed side.
half-mold must thus be
FPL calibrated (0007) The fixed plate is calibrated. No action required.

The configuration has taken
the electricity supply voltage
into account to ensure
optimum system
performance levels.
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code)
MPL calibrated (0006) The mobile plate is No action required.

calibrated. The configuration
has taken the electricity
supply voltage into account to
ensure optimum system
performance levels.
Not Calibrated The system is not calibrated. Calibrate the system (chapter
6.7, page 124)
Save Data Log Save the records of Carry out the procedure
operations. described in chapter 6.4.3,
page 107.
Saving Data Log Saving in progress. No action required.
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Menu messages Description Action
Operator Menu reserved for operators. (chapter 6.3, page 74)
Supervisor Menu reserved for (chapter 6.4, page 105)

supervisors.
Stäubli-Service Menu reserved for Stäubli None

technicians.
Data Log Used to view the last 700 (chapter 6.4.3, page 107)
operations or occurrences
recorded.
Settings Used to adjust the machine (chapter 6.5, page 109)
parameter settings.
Options Used to manage options. (chapter 6.5.7, page 116)
Display Log The log will be displayed. Press enter to validate.
Set Time Used to set the time and the (chapter 6.5.1, page 109)
date.
Change OperatorPIN Used to modify the operator (chapter 6.5.2, page 110)
PIN code.
Change SupervisorPIN Used to modify the supervisor (chapter 6.5.3, page 111)
PIN code.
Change Language Used to change the language (chapter 6.5.4, page 112)
used.
Description Action
(Machine forces)
Closing(kN) Machine closing force. Enter the machine closing

force.
Opening(kN) Machine opening force. Enter the machine opening

force.
Nozzle (kN) Nozzle force. Enter the nozzle force.

Ejector(kN) Ejector force. Enter the ejector force.
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Mold information
Description Action
messages
For all the data to be entered concerning the mold, take a view facing the fixed plate
into account
Thickness (mm) Half-mold thickness. Enter the thickness of

half-mold in millimeters.
Weight (kg) Weight of the half-mold. Enter the weight of the

half-mold in kilograms.
Gravity center position (mm) Position of the half-mold's Enter the center of gravity of
center of gravity. If 0, the the half-mold.
length of the mold divided by
2 is used.
Center ring mounted Defines if the half-mold is Check the box if the half-mold
equipped with a centering is equipped with a centering
ring. ring, otherwise uncheck the
box.
Rectangular The mold is rectangular and No action required.

centered.
Offset The mold is rectangular but No action required.

offset.
Round The mold is round. No action required.
Width (mm) Mold width. Enter the width of the back

plate in millimeters.
Height(mm) Mold height. Enter the height of the back
plate in millimeters.
X1(mm) X coordinate of the lower Enter the distance along the

(figure 6-2) left-hand point of an offset X axis of the lower left-hand
rectangular mold (always point of the mold back plate,
positive). in millimeters.
Y1(mm) Y coordinate of the lower Enter the distance along the

(figure 6-2) left-hand point of an offset Y axis of the lower left-hand
X2(mm) X coordinate of the upper Enter the distance along the
(figure 6-2) right-hand point of an offset X axis of the upper right-hand
Y2(mm) Y coordinate of the upper Enter the distance along the

(figure 6-2) right-hand point of an offset Y axis of the upper right-hand
QMC 122 © STÄUBLI 2016 - RV2600602A 97 / 133

Mold information
Description Action
messages
For all the data to be entered concerning the mold, take a view facing the fixed plate
into account
Diameter(mm) Diameter of the mold back Enter the diameter of the
plate. mold back plate in
millimeters.
MPL An (cm2) North surface area covered Enter the surface area value
by the mold on the mobile provided by STÄUBLI in cm2.
plate.
MPL As (cm2) South surface area covered Enter the surface area value
by the mold on the mobile provided by STÄUBLI in cm2.
plate.
FPL An (cm2) North surface area covered Enter the surface area value
by the mold on the fixed plate. provided by STÄUBLI in cm2.
FPL As (cm2) South surface area covered Enter the surface area value
by the mold on the fixed plate. provided by STÄUBLI in cm2.
Warning messages
code)
MPL temp. sensor fault! The temperature sensor, Replace the temperature
(2008) mobile side, is defective. sensor.
FPL temp. sensor fault! The temperature sensor, Replace the temperature
(2009) fixed side, is defective. sensor.
Hardware fault! (2516) A hardware component of the Contact STÄUBLI.

controller is malfunctioning.
MPL hardware fault! (2516) A hardware component of the Contact STÄUBLI.

controller has a malfunction
on the MPL part.
FPL hardware fault! (2516) A hardware component of the Contact STÄUBLI.

controller has a malfunction
on the FPL part.
MPL SC broken! {n} (2502) The measurement circuits {n} Contact STÄUBLI (Check the
of the mobile plate are faulty. connections on the control
cables between the controller
and the mobile plate).
FPL SC broken! {n} (2503) The measurement circuits {n} Contact STÄUBLI (Check the
of the fixed plate are faulty. connections on the control
cable between the controller
and the fixed plate).
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Warning messages
code)
MPL RSC broken! (2502) The reference measurement Contact STÄUBLI (Check the
circuit is faulty on the mobile connections on the control
plate. cables between the controller
and the mobile plate).
FPL RSC broken! (2503) The reference measurement Contact STÄUBLI (Check the
circuit is faulty on the fixed connections on the control
plate. cable between the controller
and the fixed plate).
MPL current too high! {n} The Contact STÄUBLI.

magnetization/demagnetizati
on current is too strong in the
{n} part of the mobile plate.
FPL current too high! {n} The Contact STÄUBLI.

magnetization/demagnetizati
on current is too strong in the
{n} part of the fixed plate.
MPL disconnected! The mobile plate is Connect the control cables

disconnected from the between the controller and
controller although it is not the mobile plate.
demagnetized.
FPL disconnected! The fixed plate is Connect the control cables

controller although it is not the fixed plate.
demagnetized.
Both platens disconnected! The 2 plates are Connect the control cables
controller. the plates.
MPL Magnetized (0000) The mold half on the mobile No action required.
side is clamped.
MPL Demagnetized (0002) The mold half on the mobile No action required.
side has been released.
MPL Movement(sc) (2000) A mold movement has been Secure the mold.
detected by the movement Demagnetize. Check the
detector coils on the mobile installation and the mold.
side.
MPL Movement(prox.) (2000) A mold movement has been Secure the mold.
detected by the proximity Demagnetize. Check the
detector on the mobile side. installation and the mold.
QMC 122 © STÄUBLI 2016 - RV2600602A 99 / 133

Warning messages
code)
MPL mold rejected (1000) The magnetic flux level Enter the mold dimensions if
measured during clamping of they have not already been
the half-mold on the mobile entered and try another
plate is insufficient. clamping sequence.
Check the mold back plate
and the magnetic plate to
ensure they are in correct
contact with one another.
materials.
MPL F<Forig.! (1500) The mold clamping force on Check the mold back plate.
the mobile side is lower than
the force originally recorded.
MPL F<Feject.! (1502) The mold clamping force on WARNING, reduce the
the mobile side is lower than ejector force to avoid mold
the ejector force. movement.
MPL F<50%Fopen! (1504) The mold clamping force on WARNING, reduce the
the mobile side is lower than opening force to avoid mold
50% of the opening force. movement.
MPL T° Warning (1002) Warning, the temperature on WARNING, check that the
the mobile side has reached temperature does not reach
90° C. 100° C.
MPL T° Alarm! (2002) Alarm, the temperature on Do all you can to prevent the
the mobile side has reached temperature from rising any
100° C. This temperature further and get it to drop.
must not be exceeded!
MPL T° OK (0004) The temperature of the No action required. The

mobile plate has fallen below system is operational again.
80° C again.
FPL Magnetized (0001) The mold half on the fixed No action required.
side is clamped.
FPL Demagnetized (0003) The mold half on the fixed No action required.
side has been released.
FPL Movement(sc) (2001) A mold movement has been Secure the mold.
detected by the detector coils Demagnetize. Check the
on the fixed side. installation and the mold.
FPL Movement(prox.) (2001) A mold movement has been Secure the mold.
detected by the proximity Demagnetize. Check the
detector on the fixed side. installation and the mold.
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Warning messages
code)
FPL mold rejected (1001) The magnetic flux level Enter the mold dimensions if
measured during clamping of they have not already been
the half-mold on the fixed entered and try another
plate is insufficient. clamping sequence.
and the magnetic plate to
ensure they are in correct
contact with one another.
Also check that there are not
too many holes or cavities in
the mold back plate.
materials.
FPL F<Forig.! (1501) The mold clamping force on Check the mold back plate.
the fixed side is lower than
the force originally recorded.
FPL F<Fnozzle! (1503) The clamping force of the WARNING, reduce the
mold on the fixed side is less pressure level for the injector
than the nozzle force. nozzle to avoid mold
movement.
FPL F<50%Fopen! (1505) The mold clamping force on WARNING, reduce the
the fixed side is lower than opening force to avoid mold
50% of the opening force. movement.
FPL T° Warning (1003) Warning, the temperature on WARNING, check that the
the fixed side has reached temperature does not reach
90° C. 100° C.
FPL T° Alarm! (2003) Alarm, the temperature on Do all you can to prevent the
the fixed side has reached temperature from rising any
100° C. This temperature further and get it to drop.
must not be exceeded!
FPL T° OK (0005) The temperature of the fixed No action required. The

plate has fallen below 80° C system is operational again.
again.
Contactor Fault! (2506) The contactor is faulty. Contact STÄUBLI

(It is impossible to use the
controller until the problem
has been detected and dealt
with by a qualified person).
Relay Fault! RL2 (2509) Safety relay RL2 is faulty. Contact STÄUBLI (It is
impossible to use the
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Warning messages
code)
Relay Fault! RL1 (2508) Safety relay RL1 is faulty. Contact STÄUBLI (It is
impossible to use the
MSC FAULT {n} (2511) No magnetic flux is measured Contact STÄUBLI

by the measurement coils in (Check the continuity and the
part {n} of the mobile plate. insulation resistance as
measured on part {n} of the
plate concerned).
FSC FAULT {n} (2514) No magnetic flux is measured Contact STÄUBLI

by the measurement coils in (Check the continuity and the
part {n} of the fixed plate. insulation resistance as
measured on part {n} of the
plate concerned).
MRSC FAULT {n} (2510) No magnetic flux is measured Contact STÄUBLI

by the reference coils in part (Check the continuity and the
{n} of the mobile plate. insulation resistance as
measured on the reference
circuit for part {n} of the plate
concerned).
FRSC FAULT {n} (2513) No magnetic flux is measured Contact STÄUBLI

by the reference coils in part (Check the continuity and the
{n} of the fixed plate. insulation resistance as
measured on the reference
concerned).
MPC FAULT {n} (2010) The magnetization/ Contact STÄUBLI

demagnetization current (Check the continuity and the
measured is zero in the {n} insulation resistance as
part of the mobile plate. measured on the power
concerned.
Also check the fuses for part
{n}).
FPC FAULT {n} (2011) The magnetization/ Contact STÄUBLI

demagnetization current (Check the continuity and the
measured is zero in the {n} insulation resistance as
part of the fixed plate. measured on the power
concerned.
Also check the fuses for part
{n}).
102 / 133 © STÄUBLI 2016 - RV2600602A QMC 122

Warning messages
code)
MRSC coverage! (1506) The reference magnetic Check that the mold
modules of the mobile plate dimensions cover the
are not covered by the mold. reference modules.
Check that there are no holes
or cavities located in the mold
back plate.
FRSC coverage! (1507) The reference magnetic Check that the mold
modules of the fixed plate are dimensions cover the
not covered by the mold. reference modules.
Check that there are no holes
or cavities located in the mold
back plate.
MRSC error! (2512) The flux measured by the Contact STÄUBLI.

reference magnetic modules
of the mobile plate lies
outside the normal range.
FRSC error! (2515) The flux measured by the Contact STÄUBLI.

reference magnetic modules
of the fixed plate lies outside
the normal range.
MSC Fcalc error! (1508) The clamping force cannot be Check that the mold identifier
calculated because the mean and dimensions entered
flux measured by the correspond to the mold
magnetic modules on the clamped.
mobile plate lies outside the If this is not the case, enter
normal range. the correct information and
re-clamp the mold.
If the problem persists,
contact STÄUBLI.
FSC Fcalc error! (1509) The clamping force cannot be Check that the mold identifier
calculated because the mean and dimensions entered
flux measured by the correspond to the mold
magnetic modules on the clamped.
fixed plate lies outside the If this is not the case, enter
normal range. the correct information and
re-clamp the mold.
If the problem persists,
contact STÄUBLI.
MPL current too low! {n} The Contact STÄUBLI.

(2500) magnetization/demagnetizati (Check the power supply
on current as measured in voltage of the "QMC 122"
part {n} of the mobile plate is controller).
insufficient.
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Warning messages
code)
FPL current too low! {n} The magnetization/ Contact STÄUBLI.

(2501) demagnetization current as (Check the power supply
measured in part {n} of the voltage of the "QMC 122"
fixed plate is insufficient. controller).
MPL cantilever warning The magnetization force, Check all the parameters that
(1006) mobile side, is near the may reduce the magnetic
minimum force to counter clamping force (chapter 2.6,
mold tilting. page 14)
FPL cantilever warning The magnetization force, Check all the parameters that
(1007) fixed side, is near the may reduce the magnetic
mold tilting. page 14)
MPL cantilever alarm! (2006) The magnetization force, (chapter 2.6.9, page 18)
mobile side, is too low to
counter mold tilting.
FPL cantilever alarm! (2007) The magnetization force, (chapter 2.6.9, page 18)
fixed side, is too low to
counter mold tilting.
MPL sliding warning (1004) The magnetization force, Check all the parameters that
mobile side, is near the may reduce the magnetic
mold slippage. page 14)
FPL sliding warning (1005) The magnetization force, Check all the parameters that
fixed side, is near the may reduce the magnetic
mold slippage. page 14)
MPL sliding alarm! (2004) The magnetization force, (chapter 2.6.8, page 17)
mobile side, is too low to
counter mold slippage.
FPL sliding alarm! (2005) The magnetization force, (chapter 2.6.8, page 17)
fixed side, is too low to
counter mold slippage.
ATTENTION
In the event a mold movement is detected, it is imperative that the mold be secured to
prevent it from falling. The injection press must then be repositioned in "Mold Change
Mode" and the alarm must be cleared.
After identifying the problem causing the movement, it is also necessary to demagnetize
the mold before re-magnetizing it. It is recommended that a procedure be clearly defined
for the securing of equipment and operators.
Note:
In the tables above, the number in parentheses corresponds to the codified message
number for the fully-integrated interface.
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6.4 - ADVANCED FUNCTIONS ("SUPERVISOR" MODE)
- Select "Supervisor".
Note:
Access to the "Stäubli-Service" menu is reserved for use by the Stäubli After-Sales
staff.
QMC 122 © STÄUBLI 2016 - RV2600602A 105 / 133

6.4.1 - PIN CODE
It is preferable to replace the default PIN code as soon as the magnetic clamping
system is put into service.
- Enter the 4 figures of the PIN code. The default PIN code is 9876, but it can be changed via
the "Settings" menu of the "Supervisor"
The "Supervisor" menu is displayed.
- Select the desired option.
6.4.2 - CHANGING A MOLD

See chapter 6.3 page 74.
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6.4.3 - DATA LOG
During the operations, the log records all the information and messages displayed by the
magnetic clamping system.
- Select the desired option.
The last item recorded is displayed:
- Press to scroll back through the log.
- Press to scroll forward through the log.
QMC 122 © STÄUBLI 2016 - RV2600602A 107 / 133

- Press to exit the menu.
To save the history, insert an SD card in the location of the control terminal provided for this
purpose.
- Press to confirm, the wait for the operation to end.
The backed up data is saved in the SD card at the following location:

QMC122\N0XXXXXXX_XXXXXX
- N0XXXXXX corresponds to the list number of the complete assembly (chapter 6.8,
page 129).
- XXXXXX corresponds to the serial number of the complete assembly (chapter 6.8,
page 129).
In order to facilitate the diagnosis of a possible failure, STÄUBLI may ask you to send it an
archive of this folder (zip, rar, etc.) by e-mail.
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6.5 - SETTING FUNCTIONS
The Settings menu allows the Supervisor to modify the time, date, PIN codes, and language
and to save the various force values of the machine on which the QMC 122 is installed.
6.5.1 - SETTING THE DATE AND TIME
- Enter the TIME with the numeric keypad.
- Enter the MINUTES with the numeric keypad.
- Enter the SECONDS with the numeric keypad.
- Enter the DAY with the numeric keypad.
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- Enter the MONTH with the numeric keypad.
- Enter the YEAR with the numeric keypad.
6.5.2 - CHANGING THE OPERATOR PIN CODE
- If an operator PIN code is already set, a sub-menu appears.
To change the PIN code:
- Press to select "Edit".

- Enter the new 4-character PIN code in the "Enter New PIN" field.
- Reenter the 4-character PIN code in the "Confirm New PIN" field.
To delete the PIN code:
- Press .
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- Press to select "Delete".
- Press to confirm the deletion.

- Now the "Operator" menu is no longer protected by a PIN.
6.5.3 - CHANGING THE "SUPERVISOR" PIN CODE
- Enter the new 4-character PIN code in the "Enter New PIN" field.
- Reenter the 4-character PIN code in the "Confirm New PIN" field.
QMC 122 © STÄUBLI 2016 - RV2600602A 111 / 133

6.5.4 - CHANGING THE LANGUAGE
- Press or to select a language.
6.5.5 - RECORDING FORCES FOR THE INJECTION PRESS
ATTENTION
It is important that values entered correspond with the machine's actual force values.
These values are pre-entered at the factory, but it is up to the user to cross-check them.
As specified in chapter 6.3.6.2, these values are used in a function to trigger alerts and to
request user confirmation in the case the clamping force is below a certain percentage.
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- Press or to select the force to be entered.
- Enter the value.
- When all the forces have been entered, press to exit the menu.
6.5.6 - MODIFICATION OF THE CONTROLLER PARAMETERS
6.5.6.1-Adjusting the keyboard locking parameters

The "Time-out(mins)" setting is used to adjust the time after which the keyboard locks
automatically after the last action. It is then necessary to enter the PIN code to reactivate the
keyboard.
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- Enter the value.
6.5.6.2-Setting the controller identifier

The "ID" setting is used to assign the "QMC 122" controller an identifier. The value must be
between 0 and 4. When the parameter is greater than 0, an icon indicating this value appears
in the status bar on the main screen (chapter 6.2, page 69). When the parameter is 0, no icon
is displayed; the controller is not assigned an identifier.
ATTENTION
It is imperative to assign the "QMC 122" controller an identifier in order to operate in fully
integrated mode. Furthermore, for machines using several "QMC 122" several systems, the
controllers must be assigned different identifiers.
- Press to select "ID".
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- Enter the value.
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6.5.7 - OPTIONS
The options menu can be used to activate or disable certain functions:
Function Description
Safety Prompts Do the safety questions have to be put prior to all
magnetization or demagnetization actions?
Force Prompts Does the clamping force have to be compared with the
machine forces?
Metric Units Use of metric or American units.
Diagnostics Displays information to help diagnose faults. Contact

STÄUBLI.
Euromap 70.1 Selection of the 70.1 interface (Euromap 70.0 by default)
Check cantilever and sliding If active, the system checks if the clamping force is sufficient
to prevent the mold from slipping and tipping.
Mold dimensions FPL≠MPL Enables or not the option entering different dimensions for the
mold parts on the fixed and mobile side.
- Activating an option:
. Select the option.
. Press to validate. The empty box becomes when the option is active.
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6.6 - MOLDS MANAGEMENT
6.6.1 - ENTER / EDIT / DELETE A MOLD

- Select "Enter/Edit Mold".
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New Mold:
- Enter the name of the new mold and follow the instructions in chapter 6.3.3, page 76.
Mold edition:
- Enter the name of the mold and press to access the list of molds.
- Modify the parameters.
- Press to save the changes or to cancel.
Delete Mold:
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Cancel mold force:
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120 / 133 © STÄUBLI 2016 - RV2600602A QMC 122

6.6.2 - SAVE A MOLD FILE
This function is used to save all the mold definitions present in the QMC 122 controller to the
SD/SDHC card on the control terminal.
- Insert an SD/SDHC card into the control terminal.
- Select "Save Mold file".
- Choose a location on the SD/SDHC card where you want to save the file.
- Press to confirm.
- Enter a file name. The system serial number is shown by default.
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Note:
The extension ".mlx" will be added to the end of the file name.
- Wait for the operation to complete.
WARNING
The SD/SDHC card must not be removed before the end of the operation to avoid
corrupting the mold file and making it unusable.
6.6.3 - LOAD A MOLDS FILE

This function is used to transfer the mold definitions contained in a mold file to a QMC 122
controller.
The file can be either from another QMC 122 controller (see chapter 2) or from the mold editor
PC software.
WARNING
Molds defined as special (see chapter 6.3.3) are specific to a model of magnetic plates.
They can not be used on systems with a different plate model. Therefore, when loading the
mold file to a controller whose N-system number does not match, all special molds will be
ignored.
- Place the file to be loaded onto an SD/SDHC card.

- Insert the card into the control terminal.
- Select "Load Mold file".
- Select the file to be transferred.
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- Press to confirm.
- Wait for the operation to complete.
ATTENTION
The SD/SDHC card must not be removed before the end of the operation.
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6.7 - SYSTEM CALIBRATION
ATTENTION
There must not be any molds on the magnetic plates when starting calibration. The
calibration button located on the controller must be pressed.
- Select "Supervisor".
- Select "Calibrate".
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FPL calibration:
- Press the safety button then press the FPL Demagnetization button .
1
2
- 1 : Phase-angle firing times.
- 2 : Number of magnetic modules.
Demagnetization current
FPL1
FPL2
FPL3
FPL4
1 2
- 1 : Circuit A. Demagnetization current, number of electric pulses higher than the minimum
current threshold.
- 2 : Circuit B. Demagnetization current, number of electric pulses higher than the

minimum current threshold.
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Magnetization current
FPL1
FPL2
FPL3
FPL4
1 2
- 1 : Circuit A. Magnetization current, number of electric pulses higher than the minimum
current threshold.
- 2 : Circuit B. Magnetization current, number of electric pulses higher than the minimum
current threshold.
Flux display
FPL1
FPL2
FPL3
FPL4
1 2
- 1 : Flux for the reference magnetic modules.
- 2 : Flux for the other magnetic modules.
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MPL calibration:
- Press the safety button, then press the MPL Demagnetization button .
1
2
- 1 : Phase-angle firing times.
- 2 : Number of magnetic modules.
Demagnetization current
MPL1
MPL2
MPL3
MPL4
1 2
- 1 : Circuit A. Demagnetization current, number of electric pulses higher than the minimum
current threshold.
- 2 : Circuit B. Demagnetization current, number of electric pulses higher than the minimum
current threshold.
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Magnetization current
MPL1
MPL2
MPL3
MPL4
1 2
- 1 : Circuit A. Magnetization current, number of electric pulses higher than the minimum
current threshold.
- 2 : Circuit B. Magnetization current, number of electric pulses higher than the minimum
current threshold.
Flux display
MPL1
MPL2
MPL3
MPL4
1 2
- 1 : Flux for the reference magnetic modules.
- 2 : Flux for the other magnetic modules.
- Deactivate the calibration button (must no longer be pressed) to exit the Calibration mode.
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6.8 - SYSTEM INFORMATION
On powering up the controller, the control terminal displays the STÄUBLI logo, followed by the
system information:
3
4
7 5 6
Figure 6-6
1 Version of the application software and bootloader
2 Version of the terminal software and bootloader
3 List number of the complete assembly
4 Type of controller
5 Operating voltage
6 Type of coils contained in the plates
7 System serial number
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130 / 133 © STÄUBLI 2016 - RV2600602A QMC 122
7 - MAINTENANCE
7.1 - SCHEDULED MAINTENANCE
7.1.1 - AT EACH MOLD CHANGE
- Use a detergent (Quicksolv N2 and Neutrafilm H55 or equivalent) to clean the back plate of
each half-mold, and wipe with a clean cloth.
- Check that the magnetic plates are clean.
- Check the installation for contamination by a liquid.
- Repair all leaks of liquids.
7.1.2 - CLEANING THE MAGNETIC PLATES

The plates must be checked and cleaned whenever the error message "MPL F<Forig.!" or
"FPL F<Forig.!" appears during magnetisation, or at least every six months.
- Troubleshooting: Check the rear plates and see chapter 2.6, page 14.
- Use a detergent (Quicksolv N2 and Neutrafilm H55 or equivalent) to clean the magnetic
plates, and wipe with a clean cloth.
7.1.3 - 2 TIMES A YEAR (RECOMMENDED)

Check the tightening torque of the magnetic plate fixing screws.
7.1.4 - ONCE A YEAR (RECOMMENDED)

Arrange for work by a STÄUBLI technician to inspect the system, update the software and
hardware, and provide further training for your staff. This is a service that is provided and
invoiced at an attractive price. Contact the STÄUBLI after-sales service for an estimate.
Note:
The "QMC 122" magnetic clamping system is a high-technology electronic system. It is
essential to comply with the maintenance schedule set out above to ensure correct
operation of your product.
This magnetic clamping system is designed to operate in a dry environment. Any
contamination by a fluid may shorten the system's service life and result in production
stoppages.
7.2 - SPARE PARTS

All the repair work must be carried out by qualified personnel.
Consult STÄUBLI to obtain the references of the spare parts available.
Note:
For all information requests, orders for spare parts, or requests for servicing or repair
work, please quote the information shown on the manufacturer's plates (chapter 11,
page 2.4):
. List number of the complete assembly.
. Serial number.
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7.3 - REPLACING THE CONTROLLER FUSES
Refer to chapter 4.2 for the description and location of the individual fuses of the QMC 122
controller.
Refer to the "SPARE PARTS LIST" table of the wiring file supplied inside the controller cabinet
for the complete reference of each fuse.
Imperative
A defective fuse must be replaced only with a fuse having the same characteristics. Failure
to do so may result in overheating or fire hazard.
Specific features of the C500 controller
According to the reference of the C500 controller, the rating of the fuses positioned on the
power modules varies:
C500 controller
Fuse characteristics
reference
N541 27X X1 * 6.3 x 32 mm (1/4" x 1 1/4"), T 6.3 A, 500 VAC, Ir = 1500 A
N541 27X X2 * 6.3 x 32 mm (1/4" x 1 1/4"), T 10 A, 500 VAC, Ir = 1500 A
N541 27X X4 * 6.3 x 32 mm (1/4" x 1 1/4"), T 16 A, 500 VAC, Ir = 1500 A
(*): See chapter 2.4 page 11.
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7.4 - REPLACING THE LITHIUM BATTERY
The motherboard of the QMC 122 controller is equipped with a lithium battery for the backup of
certain information (chapter 4.2.5, page 39). This battery is not accessible to the operator.
Only an authorized person can work on this component.
Imperative
Observe the polarity when replacing the lithium battery (figure 7-1). Incorrect installation
may cause the battery to explode.
Never try to recharge the lithium battery. Explosion hazard.
For replacement, use only a BR2032 type 3V lithium battery with a minimum capacity
of 190 mAh.
The used battery must be disposed of in accordance with local regulations.
Figure 7-1
7.5 - WASTE RECYCLING

The QMC 122 controller incorporates subassemblies and components for which it is your
responsibility to comply with the applicable national regulations for waste treatment
(appropriate collection channels).
In particular for Europe, electronic components must follow the collection and recycling system
in accordance with Directive 2012/19/UE (Directive DEEE).
Under no circumstances should these components be disposed of with household waste.
QMC 122 © STÄUBLI 2016 - RV2600602A 133 / 133

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Instructions for assembly and use

Type QMC 122

QMC 122 © STÄUBLI 2016 - RV2600602A 3 / 133

QMC 122 © STÄUBLI 2016 - RV2600602A 5 / 133

Electrical hazard inside the box.

Important information. Refer to the device manual.

Read the manual.

Compliant with European Union directives.

6 / 133 © STÄUBLI 2016 - RV2600602A QMC 122

QMC 122 © STÄUBLI 2016 - RV2600602A 7 / 133

2.2 - DESCRIPTION OF THE SYSTEM

QMC 122 © STÄUBLI 2016 - RV2600602A 9 / 133

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1: List number of the complete assembly

Magnetic plate (fixed on the side of the plate)

QMC 122 © STÄUBLI 2016 - RV2600602A 11 / 133

2.5.2 - MACHINE DIRECTIVE 2006/42/CE

12 / 133 © STÄUBLI 2016 - RV2600602A QMC 122

Référence : RR 2010 007 B

Nous / We STÄUBLI FAVERGES

Déclarons par le présent document que l’équipement :

Description / Description Système de bridage magnétique /

Type / Type: QMC 122

Est conforme aux dispositions des directives suivantes :

2014/35/UE (matériel électrique destiné à être employé dans certaines

Normes appliquées / Applied standards:

C. MAYEUR A.C. TIBERGHIEN

QMC 122 © STÄUBLI 2016 - RV2600602A 13 / 133

2.6 - LIMITS OF USE

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2.6.3 - CONTACT SURFACE

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2.6.6 - SURFACE STATE

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2.6.8 - VERIFICATION OF MOLD ANTI-SLIPPAGE

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The mechanical laws give:

Mold anti-tilting verification:

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2.7.2 - FULLY INTEGRATED MODE

2.7.3 - PARTIALLY INTEGRATED MODE

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A (mm) 400 400

B (mm) 400 400

C (mm) 200 200

D (mm) 200 200

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A (mm) 600 600

C (mm) 200 200

D (mm) 200 200

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52 1000 < x < 2000 (mm)

500 < y < 1000

52 1000 < x < 2000 (mm)

1000 < y < 1500

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1500 < y < 2000

52 1800 < x < 4000 (mm)