Service Manual

4.4 PROCAN-Control

4.4.1 DESIGN OF THE CONTROL SYSTEM 4.4.1

4.4.2 FUNCTIONAL DESCRIPTION OF THE COMPONENTS 4.4.2
4.4.3 POWER SUPPLY 4.4.5
4.4.4 CONTROL COMPONENTS - CONFIGURATION AND REPLACEMENT 4.4.7
4.4.5 INITIALIZATION OF THE PROCAN-CONTROL 4.4.13
4.4.6 BASIC MACHINE SETTING - SERVICE SCREENS 4.4.19
4.4.7 MESSAGES AND ALARM- MESSAGES 4.4.88
4.4.8 SERIAL INTERFACES 4.4.122
4.4.9 IMPORTANT SPARE- PARTS 4.4.126
4.4.10 TOOLS 4.4.127

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4.4.1 DESIGN OF THE CONTROL SYSTEM

PROCAN Control is a modular microprocessor system. The functional components can be subdi-
vided into operational and control elements. They are accommodated on standard European size
circuit boards and connected via two bus systems. Control and operation are linked via the serial
CAN bus. The various components of the control section are linked via the 8-bit wide parallel sys-
tem bus. Operation and interface communicate via a 16-bit system bus. The three data bus sys-
tems linking the computer components are located on the backplane of the subrack, via which the
supply voltages from the power pack and backup battery are also fed in. The external connections
are fed in via the front connectors of the individual circuit boards.

Screen/ 16-Bit Floppy-

I/O-Matrix Operating System Interface
Operating Drive
screen CPU Card
Unit serial REDIS REDIS
31B1 31B2
4 x Serial I/O

CAN - Bus

Digital Control
Input CPU
DE100 RC100/101
RC100/
101

System - Bus 8- bit

Temp.- Control. Digital Digital

Card Card Input ... Output ...
TK100 RK100 DE100 DA110 electrical
RC100/ RC100/ RC100/ RC100/ RC100/ RC100/ isolation
101 101 101 101 101 101

Figure 1: System structure of the PROCAN Control

The operating CPU, control CPU, temperature board and control board each have their own micro-
processor, thus permitting parallel processing of the open and closed-loop control tasks specific to
the machine on the independent single boards.
If required, the system can be equipped with up to two digital input boards with 32 channels each
and four digital output boards with 16 channels each. These boards are addressed by the control
CPU via the board addresses set on coding switches. The data are transmitted via the system bus.

08/12 4.4.1
 Service Manual

The subrack also accommodates the power pack board and coupling board for the backup batter-
ies. The data in the working memory are protected via the batteries in the event of a power failure.
The pump control board is also plugged into the subrack in order to simplify the overall structure.
However, this board does not constitute a PROCAN Control module.

4.4.2 FUNCTIONAL DESCRIPTION OF THE COMPONENTS

4.4.2.1 MONITOR AND OPERATING SECTION

A backlit LCD monitor is used to present the process parameters. The monitor is purely for display
and is controlled by the REDIS CPU. Data are keyed in via the folding touch-sensitive keypad and
selection menu. The inputs are forwarded to the REDIS CPU where their plausibility is checked.
The data output on the monitor are similarly supplied by the REDIS CPU, including the status LEDs
in the monitor housing. These data are transmitted via an I/O data bus.
The keycard reader for determining the authorization level is located at the side of the housing. The
reader uses an infrared decoder. One side of the keycard is irradiated by the IR diodes. The diodes
on the other side receive the IR light passing through the permeable parts of the card and are
switched through. These signals are forwarded to the REDIS and evaluated by the program.
The command keys for the machine functions are located on the right and left-hand sides of the
housing front. The signals from these keys are read as 24 V signals by a digital input board.

4.4.2.2 OPERATING CPU REDIS 31B1

The REDIS CPU A1B is equipped with a type 80C186 processor. It has a program memory of 1 MB
on four EPROMs, 64 kB long-term storage on a serial EEPROM, 256 kB battery-backed working
memory (RAM) and 64 kB video RAM.
In addition to the operating system and program functions, the program memory also contains the
lists of constants and the configuration files for all machine types, as well three complete language
versions for the screen display. When the system has been booted normally, the working memory
contains all the machine data relating to the equipment (machine status), the current setup data
record and the temporary data used by the CPU. Up to 30 setup data records and a copy of the
machine status can be permanently saved in the EEPROM, which does not require a backup bat-
tery.
All inputs from the operating unit are evaluated by the REDIS CPU. Set point inputs or changes in
the cycle are forwarded to the control CPU (RECON) via the CAN bus after being checked for plau-
sibility. When a new screen is called up, the REDIS requests current data, e.g. actual values, from
the RECON for the display if required. The operating system also ensures that the screen data are
refreshed regularly. Other tasks, such as conversions following changes in the system of values,
are executed solely in the working memory of the REDIS board before the results are transmitted to
the monitor. The CPU also processes and monitors the transfer of all data between RAM and
EEPROM, EEPROM and floppy disk or serial interfaces.

4.4.2.3 CONTROL CPU RECON RC100/101

The RECON RC100 A1D is equipped with a type 80C537 micro-controller. It controls the sequence
of machine functions and acts as intermediary in the exchange of data between CAN bus and 8-bit
system bus. The set points received from the REDIS are forwarded to the control boards, while
actual values are forwarded to the REDIS on request.
The program memory comprising one or two EPROMs essentially contains the instructions for the
sequential program. At the beginning of each program run, all the digital inputs are read by the in-
put boards and buffer-stored. The input data are evaluated logically in the actual sequencing pro-
gram. The output data are then stored in a second buffer memory. At the end of the program cycle,
the entire output data are mapped to the digital output boards and the output amplifiers switch on or
off accordingly.
4.4.2 08/12
 Service Manual

The analogue inputs are only processed directly by the RECON in special cases. The sequencing
program only evaluates those flags set by the control boards which reflect the status of a set point.
The flags indicate whether or not a set point has been reached and the corresponding outputs are
switched by the sequencing program accordingly.

4.4.2.4 CONTROL BOARD RK100/101

The control board A1E has eight analogue inputs (12-bit A/D converter via MUX), two analogue out-
puts (10-bit D/A converter) and two high-speed binary counter inputs. The board is divided into pro-
cess side and bus side and the two sides are electrically isolated to exclude external interference.
The process side contains a micro-controller with program EPROM which drives and evaluates the
D/A and A/D converters and which executes the control algorithms of the position controllers. Opto-
coupler (electrically isolated) connect this process controller to another controller with corresponding
program EPROM on the bus side. The latter communicates with the RECON CPU via a dual-ported
RAM (DPR, RAM can be read and written by both sides simultaneously) and is only used to transfer
data between the DPR and process controller via the optocoupler. The analogue section draws its
power supply via separate DC/DC converters.
The control board operates independently. In other words, when the set points have been trans-
ferred to the process controller and the RECON has signalled that a traverse movement has com-
menced, the pressure and speed profiles are adjusted independently as a function of the stroke po-
sitions. As soon as a position mark is reached, this event is reported to the RECON by a flag in the
DPR. The DPR is read and evaluated by the RECON in the same way as a normal digital input.
The RECON then switches the relevant digital outputs.
The PROCAN Control can be equipped with one or two control boards.

4.4.2.5 TEMPERATURE CONTROL BOARD TK110/100

The temperature control board A1H has eleven analogue inputs (12-bit A/D converters via MUX).
The basic mechanical design with process side, electrical isolation and bus side is identical with that
of the control board A1E. The functional sequences when transferring data to and from the temper-
ature control board are also the same.
The analogue inputs can in some cases be configured for different measuring ranges via the soft-
ware. This means that the temperature can be measured with thermocouples as well as KTY.
This control board also operates independently after receiving the set points. The actual values of
all heater zones are evaluated by the temperature software, while the duty cycle of the switch ele-
ments is calculated by the control algorithms. These switching operations are only executed but not
calculated by the RECON. The procedure is illustrated by the following simplified example:
Set point temperature for zone 1 is 210 °C.
Temperature control board A1H initially records an actual value of 20 °C. The temperature control
board software decides that the zone must be heated up and sets the flag "Heating zone 1 ON" in
the DPR. This flag is read by the RECON at the beginning of its program cycle. Depending on this
flag, the output for heating contactor K81 is prepared in the output map by the sequencing program
and the output on the output board is set at the end of the cycle.
The actual value reaches 210 °C during the heating-up process and the temperature software de-
cides that the heating zone must be switched off. The flag "Heating zone 1 ON" is reset. The flag is
read by the RECON and the output for K81 is deactivated.
The PROCAN Control can be equipped with one or two temperature control boards.

4.4.2.6 DIGITAL INPUT BOARD DE100

The digital input boards A1K and A1L provide 32 inputs each for 24 V signals. Each input is electri-
cally isolated from the BUS by optocoupler. The 24 V supply for the process side is supplied exter-
nally via plug connectors.

08/12 4.4.3
 Service Manual

4.4.2.7 DIGITAL OUTPUT BOARD DA110/120/121

The output boards A1M, A1N, A1P and A1Q have 16 digital outputs each. They are also electrically
isolated from the bus side by optocoupler. Each output channel is externally supplied with 24 V.
DA110: The type 412B output transistors have an internal logic circuit which reports any shorts, ex-
cessive temperatures and idle states (wire breaks). This signal is mapped into a register via a sta-
tus line of the transistor and can then be read via the BUS. The sequencing program can react to
defective output states in this way. Since an idle state also results in an error message, unused
outputs must be terminated to ground with a 27 KOhm resistor. Breaks in the transistor supply lines
must be bridged with 15 KOhm parallel to the interruption in order to suppress the error message.
DA120 / DA121: This newer version of the output cards was developed since the amplifier transis-
tors of the old board were not produced anymore. The new output amplifier transistor has no wire
breakage or over temperature sensing anymore. That means that this card will not produce the
alarm messages anymore.

4.4.2.8 INTERFACE BOARD REDIS 31B2

The interface board A1C1 is connected to the REDIS CPU via a 16-bit system bus. The board has
a controller and the power supply for the disk drive, as well as providing up to four serial interfaces,
two RS232 and two RS485 interfaces. The serial interfaces are used to connect such external pe-
ripheral devices as printers, temperature control units or scales and a host computer. A detailed
description of the interfaces can be found in section 4.4.7.

4.4.2.9 COUPLING BOARD KK110

The coupling board A1A2 supplies the power pack board A1A1 with 24 V DC from the machine con-
trol. The 5 V / 5 A and 12 V / 1.5 A output voltages of power pack A1A1 are fed into the bus board
via the coupling board to power the PROCAN components.
The coupling board accommodates a relay which is driven directly by the RECON watchdog circuit
and which deactivates the control system in the event of a fault.
The board also contains the holder for the backup batteries (2 x 1.5 V RR baby cells).

4.4.2.10 POWER PACK NK100 / NK101

NK100: The switched-mode power pack A1A1 draws its 24 V DC supply from the machine control
via the coupling board. The supply voltages of 5.0 V / 5 A and 12 V / 1.5 A for the PROCAN com-
ponents are generated from this DC supply. The output voltages are electrically isolated from the
machine control.
NK101: The new designed power pack A1A1 provides the same voltages as the NK100. Additionally
it also carries the back-up batteries. The coupling board KK110 is not required anymore. This
NK101 can not replace the NK100. It can only be used in connection with the newer subracks.

4.4.4 08/12
 Service Manual

4.4.3 POWER SUPPLY

4.4.3.1 OLD CONFIGURATION WITH NEW POWER PACK NK100

Drehstrom-Trafo-Netzgerät
+ + 24V
three phase
transformer 1 1 1 1
-F03 -F031 -F032 -F033
C03 C031 R03 R031
+ + 6A 2 1,6A 2 10A 2 10A 2
_ _ 4L+
L1H1 L3H1 4700uF 0.15uF
N 5L+
PE L2H1 3L+
-X2 6 1L+
U X1
X2
X1A2
X3
3 2 5 b3 b2 b2 b1
V Y1 0 b2 6 b2 2 b2 8 b1
-A1A1 -A1A2 -A1C2 -A1C1 -A1B 8 4 0 6
Y2
-A1K
Y3
BUS
W Z1 CPU
Z2
b4 b8 b1 b3
Z3 1 4 6 b2 b6 b1 2 b1 2
0 4
X1A2 AZ. X1K
5 POL 36 POL
Netzteil
Power E-
pack KARTE
-
A A4D
2 X2 PE
-K8R
DISKETTENLAUFWE
- A RK
1
0V
-X2 0 Betrieb Rechner -X2 0 -X2 0
Processor operation

-X2 0
A
U0A
1L+ -X2 6

AZ. AZ. AZ. AZ.

X1L X1A2
b3 b2 b2 b1 5
0 b2 6 b22 b2 8 b1
8 4 0 6 -A1M -A1N -A1P -A1Q -A1D -A1H -A1E -A1J -A1G -A1A2
-A1L
BUS CPU °C/°K REGLER °C/°K REGLER BUS

b4 b8 b1 b3
b2 b6 b1 2 b1 2 b2 b3 b2 b3 b2 b3 b2 b3 d3
0 4 2 2 2 2 2
X1L X1M X1 X1 X1 X1E
N P Q

0V 0
X2 0 X2 0 X2 0 X2 0 X2 0 X2 0 X2 0 V

E- A- Temperaturerfassung
Karte
Input Karte
Output card Temp. registration
card

Figure 2: Power supply of the PROCAN Control with A1A2 card

08/12 4.4.5
 Service Manual

4.4.3.2 NEW CONFIGURATION WITH NEW POWER PACK NK101

1L+ -X2 6

AZ. AZ. AZ. AZ.

X1L X1A2
b3 b2 b2 b1 5
0 b2 6 b22 b2 8 b1
8 4 0 6 -A1M -A1N -A1P -A1Q -A1D -A1H -A1E -A1J -A1G -A1A2
-A1L
BUS CPU °C/°K REGLER °C/°K REGLER BUS

b4 b8 b1 b3
b2 b6 b1 2 b1 2 b2 b3 b2 b3 b2 b3 b2 b3 d3
0 4 2 2 2 2 2
X1L X1M X1 X1 X1 X1E
N P Q

0V 0
X2 0 X2 0 X2 0 X2 0 X2 0 X2 0 X2 0 V

E- A- Temperaturerfassung
Karte
Input Karte
Output card Temp. registration
card

Figure 3: Power supply of the PROCAN Control without A1A2 card

4.4.6 08/12
 Service Manual

4.4.4 CONTROL COMPONENTS - CONFIGURATION AND REPLACEMENT

4.4.4.1 INTRODUCTION
The usual precautions must be taken to protect electronic components when replacing control com-
ponents (disconnection and isolation of the control system, protection against static charges, etc.).
If replacement boards are fitted, they must in some cases be configured so that they can operate
correctly with the control system. Before installing a replacement board, the position of jumpers,
address switches and the software versions of EPROMs on the old and new boards must be com-
pared and adjusted on the new board if necessary. This section describes the boards which must
be configured in this way.

In the time between the first release of the Procan Control and today the development has never
stopped. There is a permanent process of improvements which results in modifications in hardware
and software. The most significant steps in the development are visible in the software version
numbers. Most of the main software versions are at the same time an indicator for a bigger hard-
ware modification. That means that a software can only run on a certain hardware version. The main
differences are listed below:
Procan 1: Version 1.xx
Earliest software for the first Procan Control machines
Procan 2: Version 2.xx
Supports the new controller hardware with limit comparators on the RK101 and the Con-
troller card RC101 with bigger EPROM memory.
Procan 3: Version 3.xx
Supports the new Boy 30/55/90 and is also available with D-Visualisation (4.xx; Procan
MD). Assignment of inputs and outputs has changed (wiring).
Procan 4: Version 4.xx
Same wiring as Procan 3, but with D-Visualisation.
Procan 5: Version 5.xx
Supports the new Boy 35 and is also available with D-Visualisation (4.xx; Procan MD).
Assignment of inputs and outputs has again changed (wiring) against Procan 3.

08/12 4.4.7
 Service Manual

4.4.4.2 REDIS CPU

The REDIS CPU has a sandwich board with CPU voltage 5,10 – 5,15V
Screen -
four base-mounted EPROMs. The software Plug can be measured here !!!!
version is burned into the EPROMs. When
fitting a new board, care must be taken to en- U4
1

sure that the program version is compatible 1

with that of the RECON and control boards. If U3
in doubt, the complete sandwich board with the 1
U2 V
installed software status of the former REDIS
1
should be transferred to the new board. U1
If the EPROMs themselves are to be replaced,
e.g. following a change of software, care must
be taken to ensure that the EPROMs are Socket for sandwich Sandwich-board
board With EPROMs
plugged into the base correctly. The position
of the mark on the EPROM housing must line
up with the mark on the base. The direction
of the label on the EPROM is irrelevant. BUS-Plug
The EPROMs and bases are marked U1 to U4
so that the correct slot can be identified. Figure 4: REDIS with sandwich board

Important: This board may only be plugged into the slot provided for it on the subrack (A1B),
otherwise electronic components may be destroyed.

4.4.4.3 RECON CPU

The software version must also be compared on the REDIS CPU when replacing boards. Several
versions may be found on the RECON CPU:
RC100 Standard: The board has two EPROM bases for EPROM type 27C512, but only base U3
can be used. The part No. is 9626466.
In case that this card is used in a machine, then the relay K8R, which is installed
in every machine, must be removed from its socket and the contacts 11 to 14
must be bridged with an extra wire. The relay can cause malfunction if plugged.
RC100 for Brush: Both bases can be equipped. This is necessary, since two EPROMs are used for
large special programs, such as the brush control. This board is a modified ver-
sion of RC 100 Standard. The board can also be operated with only one EPROM
on U3 like an RC 100 Standard. The part No. is 9626508.
RC101 Standard: The newer version of the RC 100 as from software Procan 2 has only one
EPROM socket, but it permits use of either EPROM type 27C512 (28-pin) or type
27C020 (32-pin). The EPROM must be aligned in accordance with the markings
on the housing and base. Since the type 27C512 is shorter, the two left-hand
pins in each row remain unused, as Figure 4 shows. Jumper J1 must be set in
accordance with the type of EPROM. Type 27C020 has four times the storage
capacity (256 kB) of type 27C512 (64 kB) so that more complex special programs
can also be stored. The part No. is 9626530. This board can replace both RC
100 versions. If a brush control is installed, the sequencing program must be
copied from the original two 27C512 EPROMs to one 27C020 EPROM (can only
be done by the manufacturer).
The relay K8R can be plugged with this card (compare RC100).

4.4.8 08/12
 Service Manual

J1 1 1-2: 27C512
2
3 2-3: 27C020

1 1
U3

1 1

RC101
RC100
U3 U4
Figure 5: RC100 Figure 6: RC101
This board can be plugged into all slots to the left of board A1B for test purposes.

4.4.4.4 CONTROL BOARD RK100/101

The control board has two EPROMs 27C512 with posi- S1
tion labels U6 and U19. RK100 Address coding
The setting of address coding switch S1 must be set to RK101
0 whenever this board must be replaced.
1. RK A1E Address coding switch 0 U19
1
2. RK A1G Address coding switch 1
(see schedule 1).
Two versions of the control board are available. The RK
100 (part No. 9626468) uses conventional A/D conver- 1

U6
sion of the measured values via multiplexer when de-
termining the position. The more recent version RK101
(part No. 9626535) has an additional compensator cir- Figure 7: RK100/101
cuit permitting more rapid detection of critical stroke
positions. The RK101 can replace the RK100, but each
requires its own software version. In general the RK100
is used in Procan 1 systems, the RK101 is used as from
version Procan 2.
The board can be plugged into all slots to the left of
board A1B for test purposes.

08/12 4.4.9
 Service Manual

4.4.4.5 TEMPERATURE CONTROL BOARD TK100/110

Temperature control board TK100 is basically of the
same mechanical design as control board RK100. The S1
Adresskodierung
same instructions consequently also apply when replac- TK100
ing this board. The address coding switch 2 must be set
to 2.
1. TK A1H Address coding switch 0 X1H U19
1
2. TK A1J Address coding switch 1

Two versions of the TK100 are available. The older

board (part No. 9626467, TK110) contains the KTY re- 1

U6
sistor for temperature compensation of the measuring
inputs on the board. In the case of the newer board
(part No. 9626534, TK100), the compensating resistor
has been transferred to the heater terminal box and is Figure 8: TK100
connected externally via wires to pins X1H/z22-z26 and
X1H/d22-d26. This means that the new board cannot
be used as a replacement for the old board without ret-
rofitting the external resistor.
The board can be plugged into all slots to the left of
board A1B for test purposes.

4.4.4.6 DIGITAL INPUT BOARD DE100

Two digital input boards may be installed. DE100

1. DE A1K Address coding switch 0

2. DE A1L Address coding switch 1

The board can be plugged into all slots to the left of

board A1B for test purposes.
S1
Address coding

Figure 9: DE100

4.4.4.7 DIGITAL OUTPUT BOARD DA110/DA120/DA121

Up to four digital output boards may be installed. S1
DA110 Address coding

1. DA A1M Address coding switch 2

2. DA A1N Address coding switch 3
3. DA A1P Address coding switch 4
4. DA A1Q Address coding switch 5

The board can be plugged into all slots to the left of

board A1B for test purposes.

Figure 10: DA110

4.4.10 08/12
 Service Manual

4.4.4.8 COUPLING BOARD KK100/KK110

The coupling board contains the two backup batter-
ies and the coupling relay of the watchdog function. KK100
KK110
Two versions are available:
KK100: Watchdog function not operational. Relay
K8R is consequently not plugged in the
X1A2 (X3)
control cabinet and its contacts are
bridged. Part No. 9626462.

KK110: The coupling relay on this board has a

different protective circuit to eliminate
faults due to de-energization of the coil. Figure 11: KK100/110
This change as compared with the KK100
is associated with the watchdog modification on the RECON RC101 (see 4.4.4.3 RECON
CPU). The watchdog function is consequently fully operational. Relay K8R is activated
correctly and its contacts are connected. However, the watchdog function only operates
correctly in combination with the right software, RECON board and wiring in the control
cabinet. In other words, these changes must be retrofitted in older machines in which these
conditions are not met. If the changes are not made, the KK110 operates in the same way
as the KK100 and is therefore a full replacement for the later. The part No. is 9626531.
Important: This board must only be plugged into the slot provided for it on the subrack
(A1A2), otherwise electronic components may be destroyed.

4.4.4.9 POWER PACK NK100/NK101

Two different version are in use. Both are not compatible to each other.
NK100: The older version can only work in combination with the coupling board KK100/110. On
top of this card there are two potentiometers for the adjustment of the CPU voltage
(rear potentiometer: 5,10 – 5,15V) and the 12V (front potentiometer) for the back-
ground light. Part No. 9626461. When replacing this card the CPU voltage should be
measured on the small capacitors on the Eprom sandwich board (see 4.4.4.2). In case
that the voltage is out of tolerance it must be corrected by the related potentiometer.

NK101: The newer version of the power pack. This card contains the battery holder for the back-up
batteries. Machines with this card do not require the coupling board KK100/110. In case
that this new card must be used as a replacement for the old NK100 then the coupling
board KK100/101 must be removed and replaced by the adaptor card 9626574.
The NK101 also has an adjustment potentiometer for the CPU voltage (5,10 – 5,15V).
The part No. for NK101 is 9626573.

4.4.4.10 DISK DRIVE

The 1.44 MB 3.5" disk drive is supplied by a variety of manufacturers. The direction in which the
wide ribbon cable is plugged in may consequently vary. Plugging the cable in incorrectly does not
have any harmful effects. If a newly installed drive does not run when the cable is plugged in the
former direction, then the connector must be turned round. In some cases, the connector must be
machined to remove the coding notches.
Basically two different versions of floppy drive are in use:
Early floppy drive (NEC, Sony, …) with part number 9626479. This drive requires the data cable
9631243.

08/12 4.4.11
 Service Manual

Later floppy drive (TEAC, …) with part number 9626536. This drive requires the data cable
9631257. This cable has a pair of crossed wires. The floppy drive will not work with the not crossed
data cable.

4.4.4.11 SUBRACK

A01D A1J A1H A1Q A1N A1L A1B

A1E A1D A1P A1M A1K A1C1 A1C2 A1A2 A1A1
G A1G

X6

Figure 12: Subrack for PROCAN Control

4.4.4.12 ADDRESSING THE PROCAN COMPONENTS

Boy Designation Type Option Address
Code switch
A01DG Rexroth pump control board VT5041
A1E Control board, 8 analog inputs, 2 analog outputs, 2 RK 100/101 0
counter inputs
A1H Temperature board (10 measuring inputs) TK 100/110 2
A1D Control CPU (with PLC program) RC 100/101
A1Q 4th digital output board (16 outputs) DA 110 x 5
A1P 3rd digital output board (16 outputs) DA 110 x 4
A1N 2nd digital output board (16 outputs) DA 110 3
A1M 1st digital output board (16 outputs) DA 110 2
A1L 2nd digital input board (32 inputs) DE 100 x 1
A1K 1st digital input board (32 inputs) DE 100 0
A1B CPU board REDIS (communication) with EPROM REDIS 31B1
sandwich board REDIS 31E with user program
(language)
A1C1 1st interface board, 4-fold serial with floppy control- REDIS 31B2
ler
A1C2 spare REDIS 31B2 x
A1A2 Coupling board (with battery holder) KK 100/110
A1A1 Power pack, Input 24 V DC (18-36 V DC), Output NK 100/101
5V/5A and 12V/1.5A
Scedule 1: Components and addresses

4.4.12 08/12
 Service Manual

4.4.5 INITIALIZATION OF THE PROCAN-CONTROL

4.4.5.1 INTRODUCTION

The initialisation of the Procan control is always then required when the working memory of the RE-
DIS-CPU contains no one or incorrect data. This is the case when putting in operation in the works,
after exchange of the REDIS-board, after battery change, after software change or after system
collapse caused by external disturbances.
Depend on the situation the initialisation can be started on different stages. For this it is required to
know which data to which time are available in which memory.
When switching on the machine the CPU checks out at first whether all data according to chapter
4.4.5.3 are situated in the RAM. Is this not the case e.g. after battery change, exchange of a board,
pulling the board for software modification, installation of a new board or similar interventions, then
the program indicates the message "188 no system data! Load configuration data (8310)". The a.m.
message and the required procedure are described in detail in 4.4.7.2. The cases described there
assume on 3 basing situations A, B and C which could be caused by service measures or disturb-
ances.

The start point for the initialisation are always the questions:
1. Which data's are available respectively lost?
2. Where does one get the missing data's from?

An analysis of the kind of storage and the belonging data basis makes here clarity.

4.4.5.2 THE MEMORIES OF THE PROCAN CONTROL

The PROCAN control has 4 different memories:

RAM working memory on the REDIS-board, volatile memory battery buffered. It contains the
actual machine status, the loaded configuration, data files and the actual set up data
record. Data are lost when the REDIS board is pulled or the battery have been re-
placed.

E-PROM non volatile- read only memory on the REDIS-board. It contains the operating pro-
grams, screen data, the configuration data files for all machine types and the three
language versions. The data are burned in and can be erased only by UV-light.

E-EPROM non volatile memory on the REDIS-board. It contains the stored machine status and up
to 30 set up data records. The data only are lost by formatting or at intended deletion.

DISK non volatile memory on 1.44 MB diskette (on older machines optional but now stand-
ard). It contains the safety copy of the machine status from the E-Eprom and up to 150
set up data records. The data only are lost by formatting or at intended deletion.

08/12 4.4.13
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4.4.5.3 PROCAN CONTROL DATABASE

Following data are required for a correct operation:

Machine status: It provides all machine specific set up data like serial no., machine type,
zero points, calibration values of the pressure sensors, equipment options
screw diameter and control parameter.

Configuration data files: Contains all machine type related data which the program needs to convert
the pressure and speed set values. This are mainly information about pump
pressure and flow volume, diameter and strokes of the hydraulic cylinder,
absorption volume of the screw motor and basic set values of the control
parameters.

Set up data record: Provides the set values for the particular moulds, strokes, speeds, pres-
sures, temperatures and time set values are stored at "unit measure 3" as
mould specific values. Injection pressure and speeds are stored as specific
values at bar resp. ccm/sec. and the closing volume at ccm. This sort of
storage allows a certain independence of the screw diameter in the limit of
the physical possibilities. The set up data record stores also the condition of
all machines and setting options (e.g. core pull, shut off nozzle, outturn
monitoring etc.).

4.4.5.4 START UP OF PROCAN CONTROL

When the REDIS board has been removed, that means separated from supply voltage and buffer
battery, only the data's of the RAM are lost. But the non volatile memory data (EEPROM) are still
available and can be reloaded. In case that the EEPROM of the original board have been formatted
or a new board were installed also the data of the EEPROM are lost. Now we have only the disk
data available which can be used for the initialisation procedure if in regular intervals secured by the
user. If also the data of the disc are not available then it is required to enter the machine status
manual as during the start up procedure in the works. For this the equipment options and the zero
point values should be known or it must be ascertained. This information are attached to the ma-
chine in the form of hardcopies of pages 8310, 9330 and 8510. If there is no copy available then the
data must be printed out or transcribed from the screen pages. When this also is not possible, then
it is required to establish all relevant data for the machine status corresponding to the machine
equipment. For this all technician pages (8310, 8330, 8340, 8350, 8380, 8410, 8420, 8510, 8520,
8530, 8560) must be checked on correctness and corrected if required.

The initialisation and also the start up procedure rundown in four steps.

A) Identification of the machine type, the assembled clamp-and injection unit.

This can be done by loading of the available machine status from the EEPROM or through entering
the corresponding code of the selector-switches S1AB1 to S2AB2 on screen 8330. (See descrip-
tion in chapter 4.4.6.)

B) Loading of the configuration-data files.

On screen page 8310, line 12 (see description at chapter 4.4.6) will be reloaded from the EPROM.
All control-parameter for temperature and movements will be entered with basic setting values.

4.4.14 08/12
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C) Entering machine specific- and equipment data

If a machine status is available in the EEPROM, the same will be loaded again. When there is no
status available or a reloading is unwanted because of the fact that the loaded basic setting data
will be replaced by data which are stored in the machine status, a check and correction of all
screen pages mentioned above so is carried-out.

D) Loading the data record

On screen page 6100 a set up data record is loaded from the EEPROM or a new data record is
made. If the EEPROM does not contain any mould setting data this can be transferred from the
disc.

08/12 4.4.15
 Service Manual

4.4.5.5 FLOW CHART FOR INITIALIZATION OF PROCAN CONTROL

New initialisation after disconnecting of REDIS-CPU, Software change or malfunctions

Alarm " 188 Keine Systemdaten! Konfig.- Daten laden (8310)“

Is the original machine-status available?

Yes, in the EEPROM Yes, on floppy-disk No

Screen 8330: Screen 8310:

Selector switch S5AB1 (Floppy format the non-volatile RAM
drive) set to 1.
Screen 8330:
Screen 6100: Set selector switches S1AB1 ...
Transfer machine status from S2AB2.
floppy to EEPROM

Screen 8310:
Load machine status.

Screen 8310: Load configuration files.

Set system clock.

Should the old machine status be reinstalled?

In case that the old status was still available it In case no status-file was available or the old
should be reinstalled usually. one should not be used because of soft-
warechange or other reasons
Yes No

Screen 8310: Screen 8310:

Load machine status. Set screw diameter.
Insert machine S/N number.
Set decompression pressure.

Screen 8330:
Set all required equipment selector switches

Screen 8340:
Set the configuration data for printer and
host.

Screens 8350 and 8380:

If existing, set the parameters for the data
interfaces of heating devices or scale.

A B
4.4.16 08/12
 Service Manual

A B
Screen 8410:
Set calibration values for injection-pressure sensor.
Set number of pulses of the rotation counter.
If necessary set calibration values for mould internal pres-
sure sensor.

Screen 8420:
Set calibration values for system-pressure sensor.
Set calibration values clamp-pressure sensor.

Screen 8510:
Make a zero point adjustment with the known old values or
in the conventional way by taking the mechanical values.
If necessary enter pseudo values and correct them after
the initialisation has been finished.

Screen 8520:
If necessary enter optimised temperature parameters.
Set the temperature limit (e.g. 300°C)

Screen 8530:
If necessary enter the optimised control parameters.

Screen 8560:
Enter the time for the screensaver.

Screen 8310:
Store the machine status

Switch main switch off and on.

Screen 6100:
Mould dataset existing?
In the non-volatile EEPROM On Floppy disk No

Screen 6100: Screen 6100:

Transfer mould-data from floppy into Create a new mould pro-
EEPROM. gram.

Screen 6100:
Load mould data-set.

Machine is ready for operation.

08/12 4.4.17
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4.4.18 08/12
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4.4.6 BASIC MACHINE SETTING - SERVICE SCREENS

All service screens are listed in this section. Screen pages 8510, 8520 and 8530 include detailed
instructions on the procedure to be followed for special service settings.

Screen 8100 "Technician Control step indicator" 4.4.20

Screen 8200 "Technician Input/output indicator" 4.4.22
Screen 8310 "Technician Machine data default setup" 4.4.25
Screen 8320 "Technician Machine data Equipment" 4.4.29
Screen 8330 "Technician Machine data Selector switches" 4.4.34
Equipment selector switches listed by software version 4.4.40
Screen 8340 "Technician Machine data Printer/host" 4.4.44
Screen 8350 "Technician Machine data Tempering control units" 4.4.47
Screen 8380 "Technician Machine data Product scale" 4.4.49
Screen 8410 "Technician Machine limit values Injection unit" 4.4.51
Screen 8420 "Technician Machine limit values Clamping unit" 4.4.54
Screen 8510 "Technician Service Zero-point adjustment" 4.4.57
Screen 8520 "Technician Service Temperature control parameters" 4.4.61
Screen 8530 "Technician Service Motion control parameters" 4.4.70
Screen 8540 "Technician Service Optimization Temperature board" 4.4.77
Screen 8550 "Technician Service TDMA" 4.4.82
Screen 8560 "Technician Service DEBREDIS" 4.4.86

08/12 4.4.19
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SCREEN 8100 "TECHNICIAN CONTROL STEP INDICATOR"

1
2
3
4
5
6
7
8
9

10
11
12
13
14

The "Technician Control step indicator" screen displays the program status. Shown here are the cur-
rent step in the program and the phase in which the machine control program is running.

1 Program step and phase

The summary of possible program steps:

0 Retract ejector before closing mould

1 Core movements before closing mould
2 Close mould, core movements at intermediate stop
3 Core movements before generating clamping force
4 Generating clamping force
5 Core movements after generating clamping force
6 Advance nozzle, generate nozzle force
7 Injection delay (screen 3700)
8 Start injection, nozzle shut-off valve
Phases 1 - 5: Stroke positions during injection
Phase 6: Holding pressure phase
9 Start nozzle return before plasticizing
10 Decompression before plasticizing, plasticizing, nozzle shut-off action
Phases 1 - 4: Stroke positions during plasticizing
Phase 5: Decompression
11 Spare
12 Start nozzle return after plasticizing
13 Spare
14 Wait for end of cooling period
15 Core movements before releasing clamping force, start air blast valves
16 Release clamping force
17 Core movements after releasing clamping force

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18 Open mould, core movements at intermediate stop

19 Advance ejector, pneumatic safety gate
20 Retract ejector, number of ejector strokes, pneumatic safety gate
21 Spare
22 Pause period to end of cycle
23 Spare
24 Outturn monitoring, outturn scale

If the machine stoppes during the cycle and the cause of stop is not clear, the operator writes down program step
and phase with actual time and other error messages to inform the service department.

Shown in clear text are the status for the

2,3 Mould
4,5 Ejector
6.7 Plasticizing unit
8.9 Screw.

10,11 Physical and electrical magnitudes are shown as the active set-point values at pump 1 for

12 Pressure
13 Back pressure
14 Speed.

These are the values which the control circuits output to the pump controller card.

08/12 4.4.21
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SCREEN 8200 "TECHNICIAN INPUT/OUTPUT INDICATOR"

1
2
3
4
5
6
7
8
9

10
11
12
13
14
15
16

The screen entitled "Technician Input/output indicator" is a status display for selected digital inputs and
outputs which are processed by the machine controls.
Since the display screen is refreshed every 400 ms, very fast modifications cannot be always represented
unobjectionably.

Shown in the upper section of the screen are the switching states of valves and outputs which are not indicated
using LEDs at the operating elements adjacent to the screen. The switching status for the output can be read
at the circle in front of the designation. If the circle is blank, then the output is not energized. If the circle is
filled, the output is energized.

Column 1 Output card

4 -Y80 - Feed zone valve A1N

5 -K81 - Heating zone 1 A1M
6 -K82 - Heating zone 2 A1M
7 -K83 - Heating zone 3 A1Q
8 -K84 - Heating zone 4 A1M
9 -K85 - Heating zone 5 (nozzle) A1M

Column 2 Output card

1 -Y02 - Pressure control pump 2 A1Q

2 -Y09 - System separation A1Q
3 -Y111 - Open mould slowly A1N
4 -Y14 - Mould protection A1M
5 -Y19 - Cooling circuit A1N
6 -Y20 - Close safety gate A1P
7 -Y21 - Open safety gate A1P
8 -Y24 - Nozzle protection (VH) A1P

4.4.22 08/12
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Column 3 Output card

1 -Y30 - Clamping force application A1M

2 -Y31 - Pressure converter at lower position A1P
3 -Y33 - Mould breathing A1P
4 -Y35 - Clamping force release A1P
5 -Y43 - Nozzle force release A1P
6 -Y48 - Evacuation A1Q
7 -Y49 - Open nozzle A1M
8 -Y58 - Injection with accumulator A1Q

Column 4 Output card

1 -Y64 - Air blast ejector 1 A1N

2 -Y66 - Air blast ejector 2 A1P
3 -Y72 - Insert core B A1P
4 -Y73 - Retract core B A1P
5 -Y760 - Brush down A1Q
6 -Y761 - Brush up A1Q
7 -Y762 - Brush rotate A1Q
8 -Y05T - Oil pre-heating A1N
9 -Y06T - Oil cooling controled A1N

Column 5 Output card

1 -K010 - Safety circuit A1M

2 -K01M - Switch on motor and heating A1N
3 -K10W - Mould closed (handling device interface) A1N
4 -K11W - Mould open (handling device interface) A1N
5 -K60W - Ejector in front position (handling device interface) A1N
6 -K61W - Ejector in rear position (handling device interface) A1N
7 -K7QA - Core pull retracted (handling device interface) A1P
8 -K7QE - Core pull inserted (handling device interface) A1P
9 -K8S - Reject shunt A1N

Column 6 Output card

1 -K54DK - Resolution/measurement range selection, cavity pressure A54 A1P

2 -K54F - Cavity pressure mould enable A1P
3 -B56W - Melt cushion position reached A1Q
4 -K8KW - Change carton A1Q
5 -K8W - Clear scales A1P
6 -RESO1 - Spare 1 A1Q
7 -RESO2 - Spare 2 A1Q
8 -RESO3 - Spare 3 A1Q
9 -RESO4 - Spare 4 A1Q

Shown in the lower section of the screen are the switching states of inputs and safety switches which are not
indicated using LEDs at the operating elements adjacent to the screen. The switching status for the input can
be read at the circle in front of the designation. If the circle is blank, then the input switch is not actuated (no
voltage at the input). If the circle is filled, the input switch has been actuated (voltage at the input).

08/12 4.4.23
 Service Manual

Column 1 Input card

13 -B05D - Oil filter A1K

14 -B05N - Minimal oil level A1K
15 -B42 - Nozzle guard A1K
16 -B43 - Nozzle swung into position A1K

Column 2 Input card

10 -B18 - Outturn monitoring A1K

11 -B20 - Safety gate monitoring switch at the front A1K
12 -B22 - Safety gate monitoring switch at the back A1K
13 -B25 - Monitoring roll lever valve A1K
14 -B26 - Hydraulic safety monitoring A1K
15 -B28 - Safety strip at safety gate A1L

Column 3 Input card

10 -K010E - Motor interlock ON A1K

11 -K01ME - Motor contactor K01 ON A1K
12 -F01B - Motor protection tripped A1K
13 -Z00 - Enable proportional valve A1K
14 -X28A - Alarm control system fault A5DG A1L
15 -B950 - Nozzle protection on top A1L
16 -B951 - Nozzle protection below A1L

Column 4 Input card

10 -B61W - Safety switch ejector A1L

11 -B760 - Brush below A1L
12 -B761 - Brush on top A1L
13 -B8WF - Product scale plate free A1L
14 -B8WW - Product scale plate in position A1L
15 -K29 - Mould clamped A1L
16 -K2DG - Pressure/oil volume clamping device A1L

Column 5 Input card

10 -K201 - Operating with handling devices A1L

11 -K210 - Release mould close A1L
12 -K260 - Release advance ejector A1L
13 -K261 - Release retract ejector A1L
14 -K270 - Release insert core A1L
15 -K271 - Release retract core A1L
16 -K65 - Ejector connected A1L

Column 6 Input card

10 -B530 - Screw diameter (bit 0) A1L

11 -B531 - Screw diameter (bit 1) A1L
12 -B532 - Screw diameter (bit 2) A1L
13 -RESI1 - Spare 1 A1K
14 -RESI2 - Spare 2 A1L
15 -RESI3 - Spare 3 A1L
16 -RESI4 - Spare 4 A1L

4.4.24 08/12
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SCREEN 8310 "TECHNICIAN MACHINE DATA DEFAULT SETUP"

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

The basic initialization and configuration parameters are entered in the screen entitled "Technician Machine
data default setup"

1 Screw diameter

The index for the screw size is entered here, corresponding to the particular machine configuration.

Screw diameters in mm:

Machine type
Index 22M 25M 50M 80M
1 16 16 28 36
2 18 18 32 42
3 22 22 38 48
4 24 24 42 -
5 28 28 - -
6 32 32 - -

All the values which depend on screw diameter, such as the plasticizing stroke, are calculated in accord-
ance with any change in screw diameter entered here.

08/12 4.4.25
 Service Manual

2 Unit of measure

The following settings are provided to specify the units of measure:

1: %
2: mm/s
3: ccm/s

Note: After switches over the unit of measure, input with "enter" and wait for activating of the new input will
be changed the machine should switched OFF and ON to guarantee a sure initialization of the graphics on
the screens 3300 and 3400.

3 Machine No.

The machine number must correspond to the range of serial numbers associated with the particular
model.

4-6 Software version

Display of the used Software version for Screen data, Operating system and User program.

Left column:

7,8 Enter date

The current date is entered here in the prescribed format.

The date and time will be entered in the machine when the last digit for the minutes is entered. The date
also must be entered once more at modification of the the time (e.g. summer-time / winter time).

9 Date format

The "format" function is used to adapt the way in which the date is represented to correspond with local
conventions:

1: DD.MM.YY (Day Month Year)

2: MM.DD.YY (Month Day Year)
3: YY.MM.DD (Year Month Day)

Right column:

7,8 Enter time of day

Entry for the current time of day. The date and time will be entered in the machine when the last digit for
the minutes is entered.

9 Time format

The "format" function is used to adapt the way in which the time of day is shown, to correspond with local
conventions:

0: 24-hour system
1: 12-hour system, am/pm

4.4.26 08/12
 Service Manual

10 Language

Selection of the local language, depending on which language module has been included. Every lan-
guage group includes 3 languages. A language is selected by the input of the number 0, 1 or 2. The lan-
guage switchover can be executed with KEYCARD 1.

11 Store/load machine status

Storing or loading the machine parameters.

Machine status can be loaded only when the "Machine No." in the data record corresponds with the cur-
rent machine number or if the current machine number is "0".

12 Load clamping unit configuration record

After selecting "Load clamping unit configuration" ("-" in the left-hand column) by entering "1", a window
will be inserted showing the available data records. Move the cursor to select; the file will be read with
the ENTER key is pressed. The selected data record must correspond to the machine status (selector
switch setting). To achieve this correspondence, the machine status must be loaded or the selector
switch setting must be entered manually in screen 8330. The key for the configuration file for the clamp-
ing unit is interpreted as follows:

Mnn = Machine model

Annn = Ejector model

Special machine types (e.g. other platen spacing) take another letter instead of A and a short explanation in
column "Material".

If the data record does not match the machine status, the routine will be aborted and an error message
will be output.

12 Load injection unit configuration record

After selecting "Load injection unit configuration ("-" in the right-hand column) by entering "1" a window
will be inserted showing the available data records. The cursor keys are used to make the selection; the
data will be read in when the ENTER key is pressed. The data record selected must correspond to the
machine status (selector switch setting). To achieve this corres-pondence, either the machine status
must be loaded or the selector switch setting will have to be entered manually in screen 8330. The key
for the injection unit configuration file is interpreted as follows:

Snnn = Injection unit model (international sizes)

Annn = Hydraulic motor type, displacement volume in ccm

Special machine types (e.g. other combinations) take another letter instead of A and a short explanation in
column "Material".

If the data record does not match the machine status, the routine will be aborted and an error message
will be output.

13 Formatting the non-volatile memory (EEPROM)

Formats the internal memory used for data and machine status (EEPROM). Warning! All the data rec-
ords and the machine status information stored in the memory will be permanently lost when the memory
is formatted!

14 Decompression before plasticizing

08/12 4.4.27
 Service Manual

Selector switch to activate the "decompression before plasticizing" item. If the selector switch is turned
on by entering "1", a set-point value for the "decompression before plasticizing" item can be entered at
plasticizing position 0 in screen 4000. If this switch is set to "-", then the stroke set-point value for plasti-
cizing position 0 will be set to zero. When entering a set-point value a minimum and maximum plausibil-
ity of 0 mm will be displayed, effectively precluding the entry of any other value.

15 Pressure limiting

Entry and display of the set-point for pressure during the screw retraction movement in the decompres-
sion phase, before and after plasticizing. Pressure is entered in bar or psi; where "ccm/s" is selected as
the unit of measure, it will be entered as a specific pressure value in bar or psi, taking into account the
ratio of the injection piston return surface to the screw piston surface.

16 Delay time

The delay time is applicable to the "decompression after plasticizing" function and runs from the end of
plasticizing to the start of decompression.

4.4.28 08/12
 Service Manual

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21

SCREEN 8320 "TECHNICIAN MACHINE DATA EQUIPMENT"

The screen entitled "Technician Machine data Equipment" is used to configure the machine with the
equipment options; these options are available in clear text form. The abbreviated forms for the selector switch
designations follow the clear-text entry. An overview of all the selector switches for the machine is provided in
screen 8330. The configuration is normally set up at the factory when the options are installed and can be
modified by persons with authorization level 3.

Left column:

1 Core pull A (S2AB3)

Activating this selector switch enables screen 1500. During the "read setup data from memory
(EEPROM)" routine a check is made to determine whether core pull function A is used in the data rec-
ord. If this is the case and if the corresponding selector switch (at the machine) governing core pull
function A is inactive, the reading routine will be terminated and the base data set will be loaded. The
operator will be notified with error message 159 (see also chapter 6.2) that the data record requires a
function for which the machine is not equipped. If core pull A is selected, the "screw A" routine will au-
tomatically be disabled and vice versa. The machine can only be equipped with either a core pull A or
a screw unit A. Core pull A may be operated in conjunction with core pull B.

2 Unscrewing A (S2AB4)

Activating this selector switch enables screen 1700. During the "read setup data from memory
(EEPROM)" routine a check is made to determine whether screw function A is switched on in the data
record. If this is the case and if the corresponding selector switch (at the machine) governing screw
function A is inactive, then the reading routine will be terminated and the base data set will be loaded.

08/12 4.4.29
 Service Manual

The operator will be notified with error message 159 (see also chapter 6.2) that the data record requires
a function for which the machine is not equipped. If screw function A is selected, then core pull A will
automatically be disabled and vice versa. The machine can only be equipped with either a screw A or
a core pull A. Screw unit A can be operated in conjunction with core pull B.

3 Thread counter 10 pulses per revolution (S2AB6)

4 Thread counter 100 pulses per revolution (S2AB7)

When using the screw A function the resolution for the thread counter can be set here, at 10 or 100
pulses per revolution.

5 Core pull B (S2AB5)

Activating this selector switch enables screen 1700. During the "read setup data from memory
(EEPROM)" routine a check is made to determine whether core pull function B is activated in the data
record. If this is the case and if the corresponding switch (at the machine) governing screw function B
is inactive, then the reading routine will be terminated and the base data set will be loaded. The opera-
tor will be notified with error message 159 (see also chapter 6.2) that the data record requires a function
for which the machine is not equipped. Core pull B can be operated in conjunction with core pull A.

6 Air blast valve (S2AB8)

Activating this selector switch enables screen 1400. During the "read setup data from memory
(EEPROM)" routine a check is made to determine whether the air blast function is activated in the data
record. If this is the case and if the corresponding selector switch (at the machine) is inactive, then the
reading routine will be terminated and the base data set will be loaded. The operator will be notified with
error message 159 (see also chapter 6.2) that the data record requires a function for which the machine
is not equipped.

8 Hydraulic nozzle shut-off needle (S6AB7)

Activating this selector switch enables the "nozzle shut-off needle" line in screen 2000. During the
"read setup data from memory (EEPROM)" routine a check is made to determine whether a hydraulic
control for the nozzle shut-off needle is switched on in the data record. If this is the case and if the cor-
responding selector switch at the machine is inactive, then the reading routine will be terminated and
the base data set will be loaded. The operator will be notified with error message 159 (see also chapter
6.2) that the data record requires a function for which the machine is not equipped.

9 Heating zone 3(S3AB6)

If this selector switch is activated, the set-point and actual values for heating zone 3 will be visible in
screens 5100 and 5200. In addition, the temperature required to maintain tolerances for heating zone
3 (screen 7220) can be selected in screen 7230. If "heating zone 3" is switched on, the "elasto-
mer/thermosetting plastic" function will be switched off and vice versa. Only those functions should be
selected which are actually installed at the machine.

10 Elastomer/thermoset plastic (S3AB7)

If this selector switch is activated, the arrangement of the heating zones in the mould will be visible in
screen 5100. If the "Elastomer/thermosetting plastic" function is switched on, the "heating zone 3"
function will automatically be switched off and vice versa. Only those functions should be selected
which are actually installed at the machine. The screw isn't closed at selector switch ON, if the tempera-
ture is too low.

11 Temperature control, feed zone (S3AB4)

4.4.30 08/12
 Service Manual

If this selector switch is activated, the set-point and actual values for the feed zone will be visible in
screens 5100 and 5200. In addition, the temperature at the feed zone can be specified in screen 7230
for use as a parameter in tolerance monitoring (screen 7220).

13,14 Hydraulic pressure sensor in injection cylinder (S4AB2, standard equipment)

If this selector switch is activated, the actual values and bar charts for injection pressure and back
pressure will be shown. In addition, the actual values for hydraulic and back pressure can be specified
in screen 7240 for use as a parameter in tolerance monitoring (screen 7220). The hydraulic pressure
sensor at the injection cylinder is standard equipment. Therefore the selector switch should always be
switched on.

15 Melt pressure sensor (S4AB4) (not implemented at present)

If this selector switch is activated, the actual values from the melt pressure sensor will be registered.
These can be utilized, by selecting a function in screen 3200, to control the change to hold pressure
and can be displayed with the appropriate selection in screen 3300. In addition, the actual values for
melt pressure can be specified in screen 7240 for use as a parameter in tolerance monitoring (screen
7220).

16 Mould internal pressure sensor (S4AB6)

If this selector switch is activated, the actual values for mould internal pressure will be registered. The-
se can be utilized, by selecting a function in screen 3200, to control the change to hold pressure and
can be displayed with the appropriate selection in screen 3300. In addition, the actual values for mould
internal pressure can be specified in screen 7240 for use as a parameter in tolerance monitoring
(screen 7220).

17,18 Mould / melt temperature sensor (S4AB5)

If this selector switch is activated, two mould temperature values and one melt temperature value will
be registered (provided that the required sensors are installed). These are then shown as actual and
reference value in screens 5100 and 5200. In addition, the actual values for melt pressure can be
specified in screen 7230 for use as a parameter in tolerance monitoring (screen 7220).

19,20 Cooling circuit with solenoid valve (S3AB3)

This selector switch activates the control for the solenoid valve in the cooling circuit.

21 American units (S4AB8, no option required)

This selector is used to switch between bar/ °C and psi/ °F. When the setup data is being read, a
check will be made to determine whether the units in storage correspond to the selector switch setting.
If this is not the case the reading routine will be terminated and error message 155 will be output.

08/12 4.4.31
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Right column:

1 Floppy disk drive (S5AB1)

Where the injection moulding machine is equipped with a floppy disk drive, this selector switch enables
the diskette functions. The functions of the printer port then also become available.

2 Image copy to disk (S9AB8)

If this selector is activated, the entry field for the graphics file prefix is enabled in screen 7250. Once
the prefix for the file name has been entered there and graphic output has been specified in screen
8340, every screen can be stored on diskette as a PCX file. Output of a screen is initiated by pressing
the printer key in the cursor control block. A floppy disk drive is required for this purpose. Refer to
screen 7250 for more information.

3 Printer port (S5AB2)

Where the injection moulding machine is equipped with a printer this selector enables the printer func-
tion. The machine must be equipped with the interface card for the diskette drive, as this is where the
printer interface is located.

4 Host computer connection (S5AB3)

Where the injection moulding machine is set up for use with a host computer, the function is enabled
with this selector switch. The machine must be equipped with the interface card for the diskette drive,
as this is where the host computer interface is located.

5 Data interface for product scale (S7AB1)

Where the injection moulding machine is equipped with a product scale, this selector switch enables
screen 8380, used to configure the scale. In addition, the part weight to be used for tolerance monitor-
ing purposes (screen 7220) can be selected in screen 7230.
Note: The data interface "product scale" has to do nothing with the outturn scale, with which the ejection of
a part is monitored by the input B18.

6 Data interface for temperature control devices (S7AB2)

Where the injection moulding machine is equipped with temperature control devices, this selector
switch enables screen 8350, used to configure these devices and screen 5400 for their operation.

7 Data interface for hot runner units (S7AB3, not implemented at present)

Where the injection moulding machine is equipped with hot runner units, this selector switch enables
screen 8360 for configuring these devices and screen 5300 for operation of the hot runner units.

8 Data interface for handling devices (S7AB4, not implemented at present)

Where the injection moulding machine is equipped with handling units, this selector switch enables
screen 8370, used to configure the handling units.
Note: The data interface for "handling devices" has to do nothing with the general EUROMAP handling
device interface, at this one the handling device is controlled by a relay board

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9 Data interface for hopper devices (S7AB5, not implemented at present)

11,12 Interlock for safety gate and ejector control (S3AB2)

If this selector switch is activated, a function selector switch in screen 1300 is enabled. The "safety
gate start" selector switch is locked out with the "interlock for safety gate and ejector control" selector
switch.

13 Safety gate start (S6AB2)

If this selector switch is activated, the cycle will be started when the safety gate closes.

15 Outturn monitoring / outturn scale (S6AB8)

This selector switch enables the corresponding selection option in screen 1800. When the setup data
are read, a check will be made to determine whether the function is switched on in the data record. If
this is the case and the corresponding selector switch at the machine is inactive, the reading routine
will be terminated and the base data set will be loaded. The operator will be notified with error message
159 (see also chapter 6.2) that the data record requires a function for which the machine is not
equipped.
Note: The outturn monitoring / outturn scale monitors with input B18, if the part is ejected correctly.
The outturn scale has to do nothing with the data interface "product scale", with which a part can be
weighed.

16 Brush control (S3AB8)

Note: The brush control requires a special program (REDIS and RECON), to activate the functions of the
brush. Switching on the selector switch in standard program is only displaying the functions in screen
1800.

Activating this selector switch will enable functions in screen 1800. When the setup data are read, a
check will be made to determine whether a brush is switched on in the data record. If this is the case
and the corresponding selector switch at the machine is inactive, the reading routine will be terminated
and error message 159 (see also chapter 6.2) will be output.

17 Evacuation during clamping (S0AB1)

This selector switch activates evacuation of the mould while clamping pressure is being built up. If the
selector switch is deactivated, the mould will be evacuated after clamping pressure has been generat-
ed, provided that the evacuation function has been activated in screen 1800.

19 Hot runner control zones 1-4 (S8AB1)

20 Hot runner control zones 5-8 (S8AB2)

(not implemented at present)

Where the injection moulding machine is fitted with hot runner control units, these selector switches are
used to enable screen 8350 for their configuration and screen 5300 for the operation of the hot runner
control units.

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 Service Manual

SCREEN 8330 "TECHNICIAN MACHINE DATA SELECTOR SWITCHES"

In the screen entitled "Technician Machine data Selector switches" the machine is configured to take pos-
sible equipment options into account. The setting for the selector switches is stored in the machine status. All
the selector switches for the machine are included in this table; the clear text description is in screen 8320.
The following description includes only those selector switches which are not described in screen 8320.

- S1AB1, S1AB2, S1AB3 = Selecting the clamping unit

Depending on software version. See lists below.

The selection of the clamping unit is checked when the clamping unit configuration data are loaded. If
the machine configuration does not correspond with these data, the loading routine will be terminated
and an error message will be output.

- S1AB4, S1AB5, S1AB6 = Selecting the injection unit

Depending on software version. See lists below.

The selection of the injection unit is checked when the injection unit configuration data are loaded. If
the machine configuration does not correspond with these data, the loading routine will be terminated
and an error message will be output.

Note: If a 25M is combined with an injection unit SP52, all pressures of injection unit and core pulls are
limited automatically to 160 bar, even if the screen input is possible up to maximum system pressure of
180 bar

- S1AB7, S1AB8 = Selecting the hydraulic motor (up to software 1.12 only)

Must both be set to 0.

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 Service Manual

The selection of the hydraulic motor is checked (but not used) when the injection unit configuration da-
ta are loaded. If the machine configuration does not correspond with these data, the loading routine
will be terminated and an error message will be output.

- S1AB7 (as from version 2.00)

All injection units with reduced rotation speed SP11, SP18, SP75 on 50M, SP185 on 80M

- S1AB8 (as from version 2.00)

Differential circuit at injection side on 50M/80M

- S2AB1, S2AB2 = Ejector stroke

Hub 80 130 150

mm mm mm
--------------------------------------
S2AB1 1 0 1
S2AB2 0 1 1

The length of the ejector stroke will be examined when the injection unit configuration data are loaded.
If the machine configuration does not correspond with these data, the loading routine will be terminated
and an error message will be output.

- S2AB3 = Core pull A

- S2AB4 = Unscrewing A
- S2AB5 = Core pull B
- S2AB6 = Thread counter 10 pulses/revolution
- S2AB7 = Thread counter 100 pulses/revolution
- S2AB8 = Air blast valve

- S3AB1 = Pneumatic safety gate

If the injection moulding machine is equipped with a pneumatically operated safety gate, this selector
switch enables this function.

- S3AB2 = Interlock safety gate and ejector control

- S3AB3 = Cooling circuit with solenoid valve
- S3AB4 = Temperature control, feed zone

- S3AB5 = Heating with semiconductor relay

If this selector switch is activated, the switching time for the heating controllers is shortened on 1/10.

- S3AB6 = Heating zone 3

- S3AB7 = Elastomer / thermosetting plastics
- S3AB8 = Brush control

- S4AB1 = spare
- S4AB2 = Hydraulic pressure sensor in the injection cylinder
- S4AB3 = spare
- S4AB4 = spare
- S4AB5 = Mould / melt temperature sensor
- S4AB6 = Mould internal pressure sensor
- S4AB7 = Central hydraulic pressure sensor
The selector switch is always switched on; the central hydraulic pressure sensor is standard equip-
ment.
- S4AB8 = American units

- S5AB1 = Floppy disk drive

- S5AB2 = Printer port

08/12 4.4.35
 Service Manual

- S5AB3 = Host computer interface

- S5AB4 = 2nd input card A1L

For differentiation from functions which are realized on the second input card, e.g. handling equipment
control.

- S5AB5 = High pressure (Clamp pressure) transducer (only up to software 2.xx)

The high pressure transducer is switched on with this selector switch if it is available in the machine. It
replaces the previous piston manometer. The high pressure actual value is displayed on screen 1100 as
number in bar or psi. The high pressure actual value as bar chart is represented on the screen 6300. The
sensor values are entered on the screen 8420 and can be saved in the machine status.
As from software version 3.00 this is a spare selector.

- S5AB6 = Machine type 25/30M with valve Y31

The first machines of the 25M series still are equipped with the valve Y31. The selector switch must at
these machines be switched on, else the clamping unit don't open.

- S5AB7 = Machine type 50M-80M without valve Y35

Up to software 2.xx:
The selector switch is switched on at machines with new pressure converter without valve Y35 (clamping
force release) of the type 50M and 80M. The selector switch suppresses the error message for output of
Y35.
As from Software 5.00:
Selector for spring loaded moulds

- S5AB8 = Valve Y111 switch on at clamping force release (only 30M-80M)

Up to software 2.xx:
The valve Y10 switched on during clamping force release at all machine types to prevent an opening
jump after clamping force release. The valve Y111 also must be switched on in addition to the valve
Y10 so that the logic valve LG10 closes and the oil cannot flow back to the tank at machines with new
pressure converter, at which the valve Y35 (clamping force release) is no longer available and the
clamping force release is switched from the valve Y31. It isn't absolutely required at machines with old
pressure converter and Y35 to switch the valve Y111 on. If you want to have same conditions as be-
fore, switch S5AB8 = 0. At S5AB8 = 1 the machine is some tenths of seconds cycle time faster, de-
pending on opening speed of the step 1. Therefore be valid:
Machine with new pressure converter S5AB8 = 1
Machine with old pressure converter and Y35: S5AB8 = 0 oder 1

S5AB8 doesn't play any roll at machine type 22M and 25M.

As from Software 3.00:

Spare selector

- S6AB1 = Characteristic curve linearization OFF (only for machine type 30M)

- S6AB2 = Safety gate start

- S6AB3 = French version

Take settings for French safety standards into account in controls.

- S6AB4 = Mould opening with change to fast mode

The mould opening fast mode is only effectively at the machine types 50M and 80M. If a setup data record
got stored with switched on selector switch, it only can be loaded dependently by the refined speed if the
selector switch is switched on. If the error message 154 was reported with the supplement "F133" or
"F134", the selector switch must switched on and the loading operation must be repeated.

4.4.36 08/12
 Service Manual

- S6AB5 = EUROMAP dry run circuit

The selector switch can be switched on and off in screen 8530. Refer to that screen for details.

- S6AB6 = Spare
- S6AB7 = Hydraulic nozzle shut-off
- S6AB8 = Outturn monitoring / outturn scale

- S7AB1 = Data interface for product scale

- S7AB2 = Data interface for tempering control units
- S7AB3 = Data interface for hot runner units
- S7AB4 = spare
- S7AB5 = spare
- S7AB6 = automatic highpressure generation-time (from version 2.00)
- S7AB7 = automatic highpressure release-time (from version 2.00)
- S7AB8
Up to version 1.30 = Y111 at highpressure release (only 30-80M)
As from version 2.00 = tap mode with Y14 (in manual mode only)

- S8AB1 = Hot runner control zones 1-4

- S8AB2 = Hot runner control zones 5-8
- S8AB3 = K01PV only in full automatic mode
- S8AB4 = spare
- S8AB5 = spare
- S8AB6 = spare
- S8AB7 = spare
- S8AB8 = pumpmotor softstart

- S9AB1 = Nozzle protection with Y24 (only VH-machines)

The selector switch must be switched on if the nozzle protection Y24 is installed. The function is possible
only with pneumatic safety gate at nozzle retraction. The nozzle protection is in the nonvoltage state in
front of the nozzle. If the safety gate is closed with key S20, the nozzle protection drives up at closed
safety gate. The nozzle can drive to the front only at driven up nozzle protection. About 105 mm (referred
to the zero point) the nozzle must carry away before the nozzle protection can drive down.

- S9AB2 = Oil cooling with Danfoss

If the oil cooling of the machine is controlled with a Danfoss regulating valve, the selector switch must be
switched on. If the oil cooling is controlled by the machine with valve Y06T, the selector switch must be
turned off.

- S9AB3 = Plasticizing without back pressure (0 bar) in manual mode

If the selector switch is switched on, the plasticizing is working without back pressure in the manual mode.
In automatic mode the plasticizing is working with the back pressure value set on screen 4000.

- S9AB4 = Reserved for special programs

Special programs are switched on or off with this selector switch, if the standard program shall also
alternatively be driven.

- S9AB5 = B61W, terminal X2-80 is available and wired

08/12 4.4.37
 Service Manual

The user program queries the input B61W only if the selector switch is switched on. Then mould closing is
interrupted as long as the ejector isn't in the position "ejector rear" and the switch B61W is closed.

- S9AB6 = Nozzle force generation simultaneous with clamping force generation

If the following conditions are true:

if selector switch S9AB6 = 1
and nozzle in contact
and not 25M with 52er injection unit
and not evacuating switched on
then the nozzle force generation time is started with an evaluated delay time (clamping force genera-
tion time minus nozzle force generation time, if 0 or negative immediately) and switched on Y40, but
with pressure and speed of the clamping force. This special sequence is locked in the manual mode. If
the nozzle force generation time is greater than the clamping force generation time, valve Y40 is
switched off at the end of clamping force generation time. This sequence saves cycle time by simulta-
neous running of nozzle force generation and clamping force generation.

Y30 clamping force generation

> T19 <

Y40 nozzle force generation

- S9AB7 = Switch for faster running (saves 200 ms/cycle)

Before "advance nozzle" and "injection start" a delay time of each 100 ms is scheduled per default, which
is been used as settle time for the hydraulic. If this time is not needed, switch off with selector switch
S9AB7 = 1 and save 200 ms per cycle. There is no delay of 100 ms, if the machine runs with nozzle in
contact. If an injection delay is set on screen 3700 (unequal 0.0 sec), so this time is decisive.

- S9AB8 = Copy image to disk

- S0AB1 = Evacuation during clamping

- S0AB2 = Vertical machine

If this selector switch is activated, the "eject with safety gate open" function on screen 1300 can be se-
lected.

- S0AB3 = Machine without decompression

This selector switch is turned on to suppress the error message 141 at valve Y51 if the decompression
feature is not implemented.

- S0AB4 = Reject shunt

If a reject shunt is installed in the machine, switch on this selector switch. The function of the reject shunt
is activated, when a tolerance is exceeded during the cycle. This are the conditions:
1. Choice of at least one process value in screen 7230 or 7240
2. Choose screen 7220
3. Switch on the tolerance monitoring in the column of chosen process value
4. Input of tolerance values in the columns -Tol and +Tol
5. Input of a reference value manually or with the automatic reference value determination (line 16 in
screen 7220, after point 7)
6. Input of #2 (reject signal and alarm message) or #3 (same as #2 with machine stop at end of cycle) in
column R (Reaction) near the process value.

4.4.38 08/12
 Service Manual

7. Switch on selector switch "Tolerance monitoring" in line 15

Note: The process values "Shot weight" by using of a product scale and "Mould internal pressure at end of
cooling time" are recorded with a cycle offset. So they are not suitable for separation with the reject shunt.

- S0AB5 = Pneumatic safety gate with valve Y21

To suppress the error message 165 for valve Y21 switch on the selector switch, if no pneumatic safety
gate is installed on the machine.

- S0AB6 = Injection with accumulator

Switch on the selector switch, if an accumulator is installed on the machine.

- S0AB7 = Oil pre-heating with Y05T / hand lever

If an oil pre-heating is installed in the machine which controls valve Y05T, switch on the selector switch
S0AB7. Also switch on the selector switch, if the oil pre-heating is activated with a hand lever on older
machines. The selector switch is switched off, when the new oil pre-heating is installed in the machine (a
relay controls output Y05T).

- S0AB8 = Ejector start during mould opening

If the selector switch is switched on, line 4 of screen 1300 is displayed for the input of an ejector start
position.

08/12 4.4.39
 Service Manual

EQUIPMENT SELECTOR SWITCHES LISTED BY SOFTWARE VERSION

Equipment selector switches as from version 1.15 up to 1.30 Page 8330
Selection of clamping unit
Selector 80M 50M 30M (old) 25M 22M
S1AB1 1 1 1 0 0
S1AB2 1 0 0 1 1
S1AB3 0 1 0 1 0
Selection of injection unit
Selector SP305 SP185 SP105 SP75 SP63 SP52
S1AB4 1 1 1 0 0 0
S1AB5 1 0 0 1 1 0
S1AB6 0 1 0 1 0 1
Selection of hydraulic oil motor (checked, but not used)
Selector slow fast 1 fast 2 fast 3
S1AB7 0 0 1 1
S1AB8 0 1 0 1
Selection of ejector stroke length
Selector 80 mm 130 mm 150 mm Unscrewing with ejector control
S2AB1 1 0 1 0
S2AB2 0 1 1 0
S2AB3 Core pull A
S2AB4 Unscrewing A
S2AB5 Core pull B
S2AB6 Thread counter 10 pulses/revolution
S2AB7 Thread counter 100 pulses/revolution
S2AB8 Air blast valve
S3AB1 Pneumatic safety cage S4AB1 spare
S3AB2 Interlock safety cage and ejector control S4AB2 Hydr. press. sensor in injection cylinder (1)
S3AB3 Cooling circuit with solenoid valve S4AB3 Control with P/Q valve
S3AB4 Temperature control of feed zone S4AB4 spare
S3AB5 Heating with semiconductor relay S4AB5 Mould / melt temperature sensor
S3AB6 3rd heating control zone S4AB6 Mould internal pressure sensor
S3AB7 Elastomer / thermosetting plastics S4AB7 Central hydraulic pressure sensor (always 1)
S3AB8 Brush control S4AB8 American units
S5AB1 Floppy disk drive S6AB1 Characteristic curve linearization OFF
S5AB2 Printer port S6AB2 Enable safety cage start
S5AB3 Host computer interface S6AB3 French version
S5AB4 2nd input card A1L S6AB4 Mould opening with fast mode (Y10)
S5AB5 Highpressure sensor S6AB5 EUROMAP- dry run circuit
S5AB6 25M with valve Y31 S6AB6 Two-pump machine
S5AB7 machines without Y35 (only 30-80M) S6AB7 Hydraulic nozzle shut-off
S5AB8 activates Y111 during clamp force release (only 30-80) S6AB8 Outturn monitoring / outturn scale
S7AB1 Data interface for product scale S8AB1 Hot runner control zones 1 - 4
S7AB2 Data interface for tempering control units S8AB2 Hot runner control zones 5 - 8
S7AB3 spare S8AB3 spare
S7AB4 spare S8AB4 spare
S7AB5 spare S8AB5 spare
S7AB6 spare S8AB6 spare
S7AB7 spare S8AB7 spare
S7AB8 spare S8AB8 spare
S9AB1 Nozzle safety gate with Y24 (only VH-machines) S0AB1 Evacuation during clamping
S9AB2 Oil cooling with DANFOSS (old) S0AB2 Vertical machines
S9AB3 Plasticizing without backpressure in manual mode S0AB3 Machine without decompression
S9AB4 Reserve for special program S0AB4 Reject shunt (Bad part separation)
S9AB5 B61W, terminal X2/80 available and connected S0AB5 Safety cage with Y21
S9AB6 Simultaneous clamp- and nozzle force generation S0AB6 Injection with accumulator
S9AB7 Switch for faster running (saves 200 ms/cycle) S0AB7 Oil preheating with valve Y05T / Handle
S9AB8 Copy image to floppy disk S0AB8 Ejector start during mould opening

4.4.40 08/12
 Service Manual

Equipment selector switches for version 2.xx Page 8330

Selection of clamping unit
Selector switch 80M 50M 30M old 25M / 30M 22M 12M
S1AB1 1 1 1 0 0 1
S1AB2 1 0 0 1 1 1
S1AB3 0 1 0 1 0 1
Selection of injection unit
Selector switch SP305 SP185 SP105 SP75 SP52 SP18 & SP11
S1AB4 1 1 1 0 0 1
S1AB5 1 0 0 1 0 1
S1AB6 0 1 0 1 1 1
Special selector switches
Selector switch The operator is not allowed to switch off this selector switches
S1AB7 All injection units with reduced rotation speed SP11, SP18, SP75 on 50M, SP185 on 80M
S1AB8 Injection fast mode (differential mode) 50M / 80M
Selection of ejector stroke length
Selector 80 mm (12M 30 mm) 130 mm (12M 80 mm) 150 mm (without function)
S2AB1 1 0 1 0
S2AB2 0 1 1 0
S2AB3 Core pull A
S2AB4 Unscrewing A
S2AB5 Core pull B
S2AB6 Thread counter 10 pulses/revolution
S2AB7 Thread counter 100 pulses/revolution
S2AB8 Air blast valve
S3AB1 Pneumatic safety cage S4AB1 spare
S3AB2 Interlock safety cage and ejector control S4AB2 Hydr. press. sensor in injection cylinder (1)
S3AB3 Cooling circuit with solenoid valve S4AB3 Control with P/Q valve
S3AB4 Temperature control of feed zone S4AB4 spare
S3AB5 Heating with semiconductor relay S4AB5 Mould / melt temperature sensor
S3AB6 3rd heating control zone S4AB6 Mould internal pressure sensor
S3AB7 Elastomer / thermosetting plastics S4AB7 Central hydraulic pressure sensor (always 1)
S3AB8 Brush control S4AB8 American units
S5AB1 Floppy disk drive S6AB1 Characteristic curve linearization OFF
S5AB2 Printer port S6AB2 Enable safety cage start
S5AB3 Host computer interface S6AB3 French version
S5AB4 2nd input card A1L S6AB4 Mould opening with fast mode (Y10)
S5AB5 Highpressure sensor S6AB5 EUROMAP- dry run circuit
S5AB6 30M with Y14 during opening and closing S6AB6 Two-pump machine
S5AB7 machines without Y35 (only 30-80M) S6AB7 Hydraulic nozzle shut-off
S5AB8 activates Y111 during clamp force release (only 30-80) S6AB8 Outturn monitoring / outturn scale
S7AB1 Data interface for product scale S8AB1 Hot runner control zones 1 - 4
S7AB2 Data interface for tempering control units S8AB2 Hot runner control zones 5 - 8
S7AB3 spare S8AB3 K01PV only in fully automatic mode
S7AB4 spare S8AB4 Heating switch control level 1°C (1,8°F)
S7AB5 spare S8AB5 Fast heating switched off
S7AB6 Automatic clamping force generation S8AB6 Decompression without shut off nozzle
S7AB7 Automatic clamping force release S8AB7 spare
S7AB8 Tap mode with Y14 (in manual mode) S8AB8 Soft start module
S9AB1 Nozzle safety gate with Y24 (only VH-machines) S0AB1 Evacuation during clamping
S9AB2 Oil cooling with DANFOSS (old) S0AB2 Vertical machines
S9AB3 Plasticizing without backpressure in manual mode S0AB3 Machine without decompression
S9AB4 Reserve for special program S0AB4 Reject shunt (Bad part separation)
S9AB5 B61W, terminal X2/80 available and connected S0AB5 Safety cage with Y21
S9AB6 Simultaneous clamp- and nozzle force generation S0AB6 Injection with accumulator
S9AB7 Switch for faster running (saves 200 ms/cycle) S0AB7 Oil preheating with valve Y05T / Handle
S9AB8 Copy image to floppy disk S0AB8 Ejector start during mould opening

08/12 4.4.41
 Service Manual

Equipment selector switches for version 3.xx Page 8330

Selection of clamping unit
Selector 90M 55M 30M new 22M 12M
S1AB1 1 1 0 0 1
S1AB2 1 0 1 1 1
S1AB3 0 1 1 0 1
Selection of injection unit
Selector SP346 SP205 SP79 SP52 SP18 & SP11
S1AB4 1 1 0 0 1
S1AB5 1 0 1 0 1
S1AB6 0 1 1 1 1
Special selector switches
Selector The operator is not allowed to switch off this selector switches
S1AB7 All injection units with reduced rotation speed SP11, SP18, SP79 on 55M, SP205 on 90M
S1AB8 Injection fast mode (differential mode) 55M / 90M
Selection of ejector stroke length
Selector 80 mm (12M 30 mm) 130 mm (12M 80 mm) 150 mm (without function)
S2AB1 1 0 1 0
S2AB2 0 1 1 0
S2AB3 Core pull A
S2AB4 Unscrewing A
S2AB5 Core pull B
S2AB6 Thread counter 10 pulses/revolution
S2AB7 Thread counter 100 pulses/revolution
S2AB8 Air blast valve
S3AB1 Pneumatic safety cage S4AB1 spare
S3AB2 Interlock safety cage and ejector control S4AB2 Hydr. press. sensor in injection cylinder (1)
S3AB3 Cooling circuit with solenoid valve S4AB3 spare
S3AB4 Temperature control of feed zone S4AB4 spare
S3AB5 Heating with semiconductor relay S4AB5 Mould / melt temperature sensor
S3AB6 3rd heating control zone S4AB6 Mould internal pressure sensor
S3AB7 Elastomer / thermosetting plastics S4AB7 Central hydraulic pressure sensor (always 1)
S3AB8 Brush control S4AB8 American units
S5AB1 Floppy disk drive S6AB1 Characteristic curve linearization OFF
S5AB2 Printer port S6AB2 Enable safety cage start
S5AB3 Host computer interface S6AB3 French version
S5AB4 2nd input card A1L S6AB4 spare
S5AB5 spare S6AB5 EUROMAP- dry run circuit
S5AB6 30M with valve Y14 during opening and closing (<15%) S6AB6 spare
S5AB7 spare S6AB7 Hydraulic nozzle shut-off
S5AB8 spare S6AB8 Outturn monitoring / outturn scale
S7AB1 Data interface for product scale S8AB1 decompression in manual mode to stroke
limit
S7AB2 Data interface for tempering control units S8AB2 switch off motor with temperature reduction
S7AB3 spare S8AB3 K01PV only in fully automatic mode
S7AB4 spare S8AB4 Heating switch control level 1°C (1,8°F)
S7AB5 “thermocouple short circuit detection” off S8AB5 Fast heating switched off
S7AB6 Automatic clamping force generation S8AB6 Decompression without shut off nozzle
S7AB7 Automatic clamping force release S8AB7 oil filter switch normally open
S7AB8 Tap mode with Y14 (in manual mode) S8AB8 Soft start module
S9AB1 Nozzle safety gate with Y24 (only VH-machines) S0AB1 Evacuation during clamping
S9AB2 Oil cooling with DANFOSS (old) S0AB2 Vertical machines
S9AB3 Plasticizing without backpressure in manual mode S0AB3 Machine without decompression
S9AB4 Reserve for special program S0AB4 Reject shunt (Bad part separation)
S9AB5 ejector with limit switch(only D visualisation S0AB5 Safety cage with Y21
S9AB6 Simultaneous clamp- and nozzle force generation S0AB6 Injection with accumulator
S9AB7 Switch for faster running (saves 200 ms/cycle) S0AB7 Oil preheating with valve Y05T / Handle
S9AB8 Copy image to floppy disk S0AB8 Ejector start during mould opening

4.4.42 08/12
 Service Manual

Equipment selector switches for version 5.xx Page 8330

Selection of clamping unit
Selector 90M 55M 35M 22M 12M
S1AB1 1 1 1 0 1
S1AB2 1 0 0 1 1
S1AB3 0 1 0 0 1
Selection of injection unit
Selector SP346 SP205 SP92 SP11&15 SP79 SP52 SP18
S1AB4 1 1 1 0 0 0 1
S1AB5 1 0 0 1 1 0 1
S1AB6 0 1 0 0 1 1 1
Special selector switches
Selector The operator is not allowed to switch off this selector switches
S1AB7 All injection units with reduced rotation speed SP11, SP18, SP79 on 55M, SP205 on 90M
S1AB8 Injection fast mode (differential mode) 55M / 90M
Selection of ejector stroke length
Selector 80 mm (12M 30 mm) 130 mm (12M 80 mm) 150 mm (without function)
S2AB1 1 0 1 0
S2AB2 0 1 1 0
S2AB3 Core pull A
S2AB4 Unscrewing A
S2AB5 Core pull B
S2AB6 Thread counter 10 pulses/revolution
S2AB7 Thread counter 100 pulses/revolution
S2AB8 Air blast valve
S3AB1 Pneumatic safety cage S4AB1 Spare
S3AB2 Interlock safety cage and ejector control S4AB2 Hydr. press. sensor in injection cylinder (1)
S3AB3 Cooling circuit with solenoid valve S4AB3 Spare
S3AB4 Temperature control of feed zone S4AB4 Melt pressure sensor
S3AB5 Heating with semiconductor relay S4AB5 Mould / melt temperature sensor
S3AB6 3rd heating control zone S4AB6 Mould internal pressure sensor
S3AB7 Elastomer / thermosetting plastics S4AB7 Central hydraulic pressure sensor (always 1)
S3AB8 Brush control S4AB8 American units
S5AB1 Floppy disk drive S6AB1 Characteristic curve linearization OFF
S5AB2 Printer port S6AB2 Enable safety cage start
S5AB3 Host computer interface S6AB3 French version
S5AB4 2nd input card A1L S6AB4 spare
S5AB5 Spare S6AB5 EUROMAP- dry run circuit
S5AB6 30M with valve Y14 during opening and closing (<15%) S6AB6 spare
S5AB7 Spring loaded mould 55/90M S6AB7 Hydraulic nozzle shut-off
S5AB8 Spare S6AB8 Outturn monitoring / outturn scale
S7AB1 Data interface for product scale S8AB1 decompression in manual mode to stroke limit
S7AB2 Data interface for tempering control units S8AB2 switch off motor with temperature reduction
S7AB3 Spare S8AB3 K01PV only in fully automatic mode
S7AB4 Data interface for handling devices S8AB4 Heating switch control level 1°C (1,8°F)
S7AB5 “thermocouple short circuit detection” off S8AB5 Fast heating switched off
S7AB6 Automatic clamping force generation S8AB6 Decompression without shut off nozzle
S7AB7 Automatic clamping force release S8AB7 oil filter switch normally open
S7AB8 Tap mode with Y14 (in manual mode) S8AB8 Soft start module
S9AB1 Nozzle safety gate with Y24 (only VH-machines) S0AB1 Evacuation during clamping
S9AB2 Oil cooling with DANFOSS (old) S0AB2 Vertical machines
S9AB3 Plasticizing without backpressure in manual mode S0AB3 Machine without decompression
S9AB4 Reserve for special program S0AB4 Reject shunt (Bad part separation)
S9AB5 ejector with limit switch(only D visualisation) S0AB5 Safety cage with Y21
S9AB6 Simultaneous clamp- and nozzle force generation S0AB6 Injection with accumulator
S9AB7 Switch for faster running (saves 200 ms/cycle) S0AB7 Oil preheating with valve Y05T / Handle
S9AB8 Copy image to floppy disk S0AB8 Ejector start during mould opening

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SCREEN 8340 "TECHNICIAN MACHINE DATA PRINTER/HOST"

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

Entered in the screen entitled "Technician Machine data Printer/host" are the interface parameters used to
drive the printer and for communications with the host computer. The following specifications are logical for
use as interface numbers for the printer:

Notes to the interface numbers: It has to be respected that same interface numbers (also those belonging to
one channel) aren't used twice. If the selector switches "Tempering control units" or "Product scale" switched on in
screen 8320, the interface numbers on screen 8350 ("Tempering control units") or screen 8380 ("product scale")
must have each another interface number.

7 The following specifications are logical for use as the interface numbers for the printer:

- Channel A RS232 4 Connector X232A (Standard)

- Channel B RS232 9 or 10 Connector X232B

The machine per default is equipped with the interface to output on a printer. The default entry must be 4
since the printer cable works at interface number 4. The 4-channel interface cable is available optionally.
Then all 4 interface channels are connected on the cabinet wall.

7 The following specifications are logical for use as the interface numbers for the host computer:

- Channel A RS422/485 7 or 8 Connector X485A

- Channel B RS422/485 11 or 12 Connector X485B

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Interface parameters must be specified in preparation for data transmission to printers and host comput-
ers. It is important to insure that the unit being served is set up with the same parameters. The following
parameters can be entered:

1 Baud rate

The range of transmission rates is 150, 300, 600, 1200, 2400, 4800, 9600 and 19200 Baud.

2 Parity check

The parity check can be switched on by entering "1", off by entering "0". The parity check for the host is
always "ON" and cannot be switched off.

3 Parity type

When the parity check function is activated, enter "1" for "odd" parity, "0" for even parity. The parity type
for the host is always "Even" and cannot be changed.

4 Data bits

Either 7 or 8 data bits may be specified. Graphic output always requires 8 bits. The number of data bits
for the host is always "8" and cannot be changed.

5 Stop bits

The number of stop bits may be either 1 or 2. "1" is set as the default value. The number of stop bits for
the host is always "2" and cannot be changed.

6 Timeout (in seconds)

Entry of maximum time to wait for a response by the unit. Entries from 5 s to 99 s are possible. If the
unit at the other end does not respond within this time, it is deemed to be out of service and an error
message will be generated.

8 Multidrop number

This is the address (0 to 15) assigned to the machine when it is used in a host computer network.

The following parameters are specified for the print-out:

9 Hard copy form

Either text or graphic mode will be used for the print-out; enter 0 or 1 to specify. In the text mode only
those portions of screen content made up of ASCII characters will be output to the printer. In the
graphic mode the screen will be output to the printer pixel by pixel. When writing a PCX file to diskette
the graphic mode must always be selected here.

10 Color printing

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Enter 0 or 1 to select B/W or color. 0 is the default setting. A printer for monochrome output is normal-
ly connected; there is no selection screen for customizing the colors.

11 Number of pins

Enter 9 or 24 pins.

12 Boldface

Enter 0 or 1 to specify normal or boldface printing.

13 Print density

Normal density or double density; enter 0 or 1 respectively. In the double-density mode all the charac-
ters will be struck twice to create a darker image on the page.

14 Printer model

 -1 = Standard printer, e.g. EPSON LQ-870

 0 = NEC P6
 1 = EPSON LX

ASCII or text-mode print-out can be effected with (nearly) all standard printers, which have a serial inter-
face RS232, a memory of 8 kbyte (9-pin printer) or 32 kbyte (24-pin printer or inkjet printer) and which are
working with "hardware-handshake". The difference is the graphic printout. EPSON LX is chosen, if a 9-
pin printer is used, which do not understand the graphic commands "print head on position".

15 Accept parameters

Changes in parameters will become effective only when you have accepted them by entering "1".

16 Accept error message print parameters

If you specified that error messages be sent to the printer (in screen 7250), changes in parameters
must also be activated by entering "1", since the error print-out uses its own printer driver. The error
messages will nonetheless be printed on the same printer as all other printer output.

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SCREEN 8350 "TECHNICIAN MACHINE DATA TEMPERING CONTROL UNITS"

1
2
3

This screen can only be chosen, when the selector switch "Tempering control units" (S7AB2) in screen 8320 is
switched on. The data transmission of set-point values and actual values are set in screen 5400.
As from software version 2.00 this page is no more available. The settings must be done on page 5400
instead.
Entered in the screen entitled "Technician Machine data Tempering control units" are the interface
parameters used to drive and for communications with the tempering control units.

The transmission parameters of the serial interface are fixed and have the following format:

 Transmission: asynchronous
 Bit sequence: 1 start bit, 8 Data bits, 1 parity bit, 1 stop bit
 Parity: even
 Baud rate: 4800

The protocol of tempering control unit is developed by Messrs. Grossenbacher Apparatebau AG for the tempering
control units type "HB-Therm". The protocol also is used by other manufacturers of tempering control units (GWK,
Regloplast, Single, Tool-Temp), for whose correct function we cannot take any guarantee.

1 Interface number

Input of the interface number. In RS232 mode the use of interface number 9 (10) is recommended. See
also the "Notes to the interface numbers" in screen description 8340.

2 Interface timeout

Won't receive any actual values within this time, the data communication will reported faultily. The default
value is 5 sec. The value should be approx. 5 times greater than the cycle of measurement in the next line.

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3 Cycle of measurement

The cycle of measurement is the intervall, in which actual values are demanded from the tempering control
unit. The default value is 1 sec. The value should be always shorter than the interface timeout.

4 Accept parameters

Changes in parameters will become effective only when you have accepted them by entering "1" (ON).

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SCREEN 8380 "TECHNICIAN MACHINE DATA PRODUCT SCALE"

4
5
6
7

10
11
12

This screen can only be chosen, when the selector switch "Product scale" (S7AB1) in screen 8320 is switched on.

Entered in the screen entitled "Technician Machine data Product scale" are the interface parameters used
to drive and for communications with the product scale.

The protocol is developed by Messrs. Mettler for the product scale type "PM2000" with serial interface RS232.

1 Data transmission

The data transmission to the product scale is switched on when a "1" is entered here. The product scale
must be connected with the machine with a special interface cable. The interface parameters to product
scale and machine must correctly be oriented and agree. The function of the data transmission is
recognized by the version number of the product scale software displayed on the right side.

2 Weight setpoint value (in gram)

The set-point weight of the part is entered here. If the weight is determined by the automatic reference value
determination (choice: "Shot weight" in screen 7230, "Reference value determination" in screen 7220), this
is the reference value.

3 Weight actual value (in gram)

The current actual weight of the last weighed part (or the last weighing) is displayed here.

4-7 Operation mode

The different operation modes are set in this frame. The following operation modes can be chosen:

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5 1 - Automatic scale operation

In the automatic scale operation a weighing per cycle is done in the scale operation mode set in
line 7.

2 - Manual scale operation

In manual scale operation line 6 appears, in which the following 2 inputs are possible to adjust
product scale and machine.

6 1 - Actual values per cycle

2 - Cont. display actual value
At the continous display of actual values the weight is permanently transferred with the repeating
clock of the product scale, independent of whether the product scale is in neutral position or not.

7 Scale operation mode

There are three scale operation modes available. Normally adjustment 1 is used.

1 - S Transmit the next possible result after standstill of product scale.

2 - SR Transmit the next possible result after standstill of product scale, later on a valid
dynamic result at each weighing, then the first result after standstill of product scale.
3 - SNR Transmit the next possible result after standstill of product scale, also after each load
and unload a further result automatically.

8 Tare

The tare command is transmitted to the product scale when a "1" is entered here. The actual weight is set
to zero. After the tare command the switch is reset to "0" automatically. The manual taring is only useful in
the manual scale operation mode. In the automatic scale operation mode the taring is made automatically
before each weighing.

9 Weighing delay

The weighing delay starts after the signal "Product scale plate clear" (B8WF). The next weighing command
is transmitted to the product scale after the end of weighing delay (default 1 sec).

10,11 Set of interface parameters

See also the "Notes to the interface numbers" in screen description 8340.

Recommended values are:

 Interface number: 9
 Baud rate: 9600
 Parity: ON
 Parity type: Even
 Timeout: 2

12 Accept parameters

Changes in parameters will become effective only when you have accepted them by entering "1" (ON).

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SCREEN 8410 "TECHNICIAN MACHINE LIMIT VALUES INJECTION UNIT"

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19

Set-point values of the injection unit depending on the machine itself are shown in the screen entitled "Techni-
cian Machine limit values Injection unit". Some values are unchangeable and fixed.

1 Nozzle travel speed advance/return

Entry for set-point value and display of nozzle travel speed when the nozzle is not being braked; this
value is normally entered in % of the maximum value shown in the next line.

2 Travel speed, maximum value

Fixed value specifying the maximum possible nozzle travel speed in mm/s.

3 Braking path, nozzle forward (in mm)

4 Braking path, nozzle return (in mm)

Set-point entry and display of the braking paths along the forward and rearward strokes, within which
the nozzle will travel at reduced speed. This reduced speed is entered in screen 2000 in the field des-
ignated "Speed at braking path".

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5 Nozzle closing time

6 Nozzle opening time

Set-point entry and display of a time, during which a hydraulic nozzle shut-off device will be sure to be
able to complete its action. During this time the nozzle shut-off needle is working with system pressure
and a volume speed of 60%. The time for needle valve nozzle advance and retract can now be varied.
The value programmed for the nozzle opening time should only be greater than zero if the nozzle does
not open with the injection pressure and speed. (only important for rubber and special materials).

7 Pressure transducer, injection pressure (in bar)

Set-point value used to scale the measurement range for the pressure transducer which measures in-
jection pressure (the maximum value can be read at the data plate for the pressure sensor).

8 0 - max. signal (in volts)

Measurement range for the electrical characteristic values for the injection pressure transducer (0 to 10
V). When using pressure transducers with electrical measurement ranges deviating from these values,
both the starting value and the final value can be entered as set-point values.

9 Melt pressure (in bar)

Measurement range scale determination for the melt pressure transducer (the maximum value can be
read from the data plate for this sensor).

Scale determination for the mould internal pressure transducer:

10 Mould internal pressure (in bar)

Measurement range scale determination for the mould internal pressure transducer (the maximum val-
ue can be read from the data plate for this sensor).

11 Measurement range 1
12 Measurement range 2

Set-point value for the measurement range scaling factor used with a piezo measurement transducer,
or the amplification factor for a strain gauge transformer. (Please refer to the specifications for the
pressure and measurement transducers for information on the adjustment range and functioning.) The
selection in screen 3200 determines which measurement range will be entered for which sensor if the
start of the hold phase is to be dependent on cavity pressure. The set-point value for the normal range
is entered as measurement range 1; the value for the more sensitive range is entered as measurement
range 2, where the transducer is designed to operate with two ranges. If the transducer has only one
measurement range, this is to be entered at range 1; measurement range 2 can be set to the same
set-point value or zero.

13 Maximum back pressure (in bar)

Fixed value limiting the upper range of entries for back pressure values.

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14 Rated screw speed (in RPM)

Fixed value for nominal screw speed using the hydraulic motor selected.

15 Pulses per revolution (default = 2)

Set-point value of the pulse sensor to messure the screw rotation speed. The input is prepared for pulse
sensors from 2-100 pulses per revolution.

16 Maximum screw advancing speed (in mm/s)

Fixed value limiting the upper range of speed entries for screw advancing.

17 Emptying speed (in mm/s)

Fixed value for the reduced volumetric flow when emptying the barrel. The fixed value is activated, if
switch B43 is opened.

18 Emptying pressure (in bar or psi)

Set-point value for limiting pressure while emptying the barrel. The set-point value is activated, if switch
B43 is opened.

19 Nozzle shut-off needle delay

The needle valve nozzle responds as before if "0.00" is entered. If a time is entered, a corresponding
delay is actively inserted before and after switching on or off the needle valve nozzle in order to sup-
press the effect of pressure (160 bar) and rate (60%) of the needle valve nozzle on the processes
"Start injection", "End injection", "Begin decompression" and "End decompression". The associated
time-lag is not triggered if decompression or a decompression stroke has not been selected, or if the
opening and closing time for the needle valve has been set to zero.

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SCREEN 8420 "TECHNICIAN MACHINE LIMIT VALUES CLAMPING UNIT"

1
2
3

4
5
6
7
8
9
10

11
12
13

With the exception of pressure transducer calibration values for the hydraulic pressure and high pressure, also
coining pre-switching, only unchangeable, fixed values depending on the machine itself are shown in the
screen entitled "Technician Machine limit values Clamping unit".

1 Minimum mould installation depth (in mm)

This fixed value specifies the minimum installation depth of a mould for the injection moulding ma-
chine.

2 Hydraulic pressure transducer (in bar)

Set-point value specifying the measurement range scale for the hydraulic pressure transducer. (The
maximum value can be read from the data plate on the pressure sensor.)

3 0 - max. signal (in volts)

Measurement range for the electrical characteristic values for the hydraulic pressure transducer (0 to 10 V).
When using pressure transducers with different electrical measurement ranges, both the starting value and the
final value can be entered as set-point values.

The following limit values are also fixed.

5 System pressure (in bar or psi)

Specification of maximum system pressure.

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7 Clamping unit travel speed (in mm/s)

Maximum clamping unit travel speed in the closing direction.

8 Travel speed, ejector advance (in mm/s)

9 Travel speed, ejector return (in mm/s)

Maximum ejector travel speeds.

10 Rated motor power (in kW)

This fixed value indicates the rated motor power.

Set-point value for the calibration of the high pressure transducer. The actual value is displayed on screen 1100, if
selector switch S5AB5 = 1.

11 High pressure transducer (in bar or psi)

Set-point value specifying the measurement range scale for the high pressure transducer. (The maxi-
mum value can be read from the data plate on the high pressure sensor.)

12 0 - max. signal (in volts)

Measurement range for the electrical characteristic values for the high pressure transducer (0 to 10 V).
When using pressure transducers with different electrical measurement ranges, both the starting value
and the final value can be entered as set-point values.

13 Coining, Y10 = 0, Y30 = 1 (value in mm)

The set-point value can changed in conjunction with the coining mode (screen 1800). To close the
clamping cylinder for small coining gaps a pre-switch off point is defined for "Mould close" (Y10). The pre-
switch off point is between 0.5 mm (22M) and 0.8 mm (80M).

It follows a summery of informations about coining:

The coining sequence has been changed so that the coining gap can be approached more accurately:
Coining is activated by entering "1" on screen 1800. A coining speed up to 100% can be entered there
in next line 2. The coining pressure is entered as a hold pressure at the four input positions on screen
3200 as before (e.g. 160 bar). In order to lock the clamping cylinder for small coining gaps, a prelimi-
nary cutout point is defined for "Close mould" (Y10) which can be entered on screen 8420. It is prede-
fined at 0.5 mm. The coining gap is set as follows:
During the normal closing procedure, the "Clamping pressure build-up" is set on screen 1100 so that
the moving platen continues approx. 0.6 - 1.0 mm beyond this point when the clamping pressure has
been built up. The value is shown as the negative closing stroke (Sclosed). The required coining gap is
entered as the "Clamping pressure build-up" and calculated as follows:
Coining gap position = Clamping pressure build-up position + Sclosed + coining gap

Example: Clamping pressure build-up = 235.5 mm

Sclosed = -0.7 mm
Coining gap = 2.0 mm

Input: Coining gap = 235.5 mm + (-0.7 mm) + 2.0 mm = 236.8 mm

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The function of the closing movement during the coining procedure is then tested in manual mode.
The "Mould protection" is set to a value of not less than approx. 10 mm; the last traverse speed (2) is
set so low that the clamping unit moves slowly when closing in the protection area. The mould protec-
tion pressure is set to approx. 22 - 24 bar and the protection speed to approx. 15%. If hand button
"Close mould" is still depressed even after LED Y10 in the push-button has gone out, the moving platen
will slowly move into its "coining gap" position and proceed up to 0.3 mm beyond it when valve Y30
(clamping pressure build-up) is subsequently energized (the extent to which the coining gap position is
exceeded differs, depending on the setting and type of mould). The clamping unit is locked in its conic-
ity by retraction of the pressure transducer as it moves into the coining gap position. Gaps up to 3 mm
wide are coined with the maximum clamping force in the 50M, for example, and gaps up to 5 mm wide
are still coined at two-thirds of the maximum clamping pressure. The coining gaps of the 22M and 25M
are correspondingly smaller.

If larger gap widths are required, valve Y30 can be prevented from switching by increasing the mould
protection pressure or decreasing the preliminary cutout point on screen 8420. Although this means
that the clamping unit is not locked during injection, the wide coining gap ensures that it cannot simply
be forced open. Due to the hydraulic system, it is more difficult to predict the response of machine
types 22M and 25M when working with gap widths without interlock.

The coining sequence is as follows:

 Mould closes without building up high pressure until the coining gap position is reached.
 Injection until start of hold phase.
 Coining = Mould closes with high pressure built up from the hold profile over the hold time.
 Plasticizing, etc.

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 Service Manual

1
2
3
4
5

6
7
8
9
10

11
12
13
14
15

SCREEN 8510 "TECHNICIAN SERVICE ZERO-POINT ADJUSTMENT"

1-10 The zero-point adjustments for the linear displacement transducers at the clamping unit, ejector, plasti-
cizing unit and screw are carried out at the screen entitled "Technician Service Zero-point adjust-
ment". Two routines are provided for zero point adjustment:

1. The machine component affected is put into its mechanical "home" position, i.e. moved to the stop. If
the mechanical limit position cannot be reached, either the position value for the axis being adjusted is
to be modified to suit (in the appropriate screen) or a value is entered as the correction value. Experi-
ence indicates values around the minimal installation depth minus 20 mm for the clamping unit and -10
for the other axes. In so far as the actual value for voltage when at the mechanical limit position lies
within the zeroing window, the correction value will be calculated on the basis of the absolute path val-
ue currently measured; this is done by entering and accepting the reference path, which is zero for the
ejector, plasticizing unit and screw. Since the mould mounting platens in the clamping unit cannot be
closed to zero, the reference path value to be entered is the actual platen spacing (measured without a
mould mounted), when the set-point for voltage is within the zeroing window. In case of doubt the min-
imum mould mounting depth as shown in screen 8420 will be entered here. If the voltage value is not
within the zeroing window, the path potentiometer is to be adjusted so that the zero point lies within the
zeroing window.

2. In so far as the correction values for the individual paths are known, these can be entered direct, with-
out checking the zeroing window.

The machine status is to be saved once the zero point adjustment is complete. The momentary correction
values can, in addition, be printed out at a printer.

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The screw stroke position is subject to the selection of the unit of measure. Where "%" or "mm/s" is selected
as the unit of measure, the stroke lengths will be displayed in mm. Where "ccm/s" is selected, the stroke
lengths are displayed in ccm.

Interrelationships among the three values:

1-5 When the reference value is accepted with the ENTER key, the following applies to the ejector, plas-
ticizing unit and screw:

Reference value + absolute path + correction value = 0

This means that the correction value is always negative. It is the value by which the reference zero
point must be undershot to arrive at the potentiometer's absolute zero point.

When accepting the reference value, the following applies to the clamping end:

Reference value + absolute path + correction value = minimum platen spacing.

Thus the correction value is always smaller than the minimum platen spacing.

Shown in the lower table are the constants for the zeroing window and the current absolute actual
values for the potentiometer setting, in volts.

11-15 Adjustment of electrical transducer stroke

IMPORTANT! The electrical transducer stroke may only be adjusted

by specially trained personnel.

Note: It is not essential to adjust the electrical stroke retroactively when upgrading the software of ma-
chines with position transducer potentiometers supplied by Messrs. SFERNICE, since the lengths used
are identical with those saved as constants in the configuration file.

The use of position transducer potentiometers made by different manufacturers has made it necessary
to make the electrical stroke of the potentiometer variable. This now also makes it possible to correct
the existing tolerances of the potentiometers used, such as in those cases in which the customer wished
to utilize an ejector stroke or screw stroke of 80 mm, but was unable to do so because the tolerances on-
ly permitted an actual value of 79 mm (reading on display).

The new adjustment capability can be found on screen 8510 "Zero point adjustment". Adjustment of the
electrical stroke is only meaningful and can only be done correctly if the zero point has been correctly ad-
justed to date. Proceed as follows to adjust the electrical stroke retroactively:
a) Set "Unit of measure" (8310 line 2) to 1.
b) The mould must be removed as a safety precaution when adjusting transducer 1 (mould).
c) Load basic data set (6100, last line). Pressures and speeds should be adjusted if necessary so that
all limit positions can be assumed.
d) The distances of the individual axes must be measured mechanically and the values noted: meas-
ure the maximum distance between the mould platens, the distance between front and rear limit on
the ejector, distance between front and rear limit on injection- unit (remove mould), distance be-
tween front and rear positions of screw (or read value on the scale).
All measured values should at least be equal to the typical set points of the machine. In other words,
a 130 mm ejector must be able to travel this distance; the distance of 400 mm between platens on a
22M must be reached, etc. All mechanical values should normally be several tenths of a millimetre
higher in practice.
e) Open mould to maximum extent, advance ejector to maximum, retract unit as far as possible to rear
and retract screw to maximum extent.

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f) Important! Note all correction values in the first box at the top right. Also note the values for nozzle
brake path forward and return on screen 8410.
g) Activate correction function (third box). The motor is automatically switched off for safety reasons
and cannot be switched on again until the correction function is deactivated.
h) The stroke value can now be reached with the cursor. The stroke value is now modified until the
actual value on the right coincides with the set point measured mechanically (d).
i) The correction value in the first box may change as a result of the new inputs. In this case, the cor-
rection value noted in step f) must be entered again for the axis concerned.
j) Steps h) and i) may have to be repeated several times if the stroke value changes significantly.
k) IMPORTANT! The setpoints of the corresponding axis change when stroke values are entered.
For this reason:
The mould data record must be reloaded on screen 6100 whenever the electrical stroke has
been adjusted.
l) Save status (screen 6100) on non volatile memory (EEPROM) and floppy disk.
m) Deactivate correction function in third box on screen 8510. The motor can then be switched on
again.
n) Since the reference value of the clamp unit may change during the electrical adjustment, a zero
point adjustment with the real actual value at mould closed position (1. line in 3. box top right value)
can be carried out finally. But this is not absolutely necessary since the reference value has no func-
tion other than while the normal zero point adjustment.
o) Enter the values again on screen 8410 which were noted in step f) for the nozzle brake path forward
and backward. Standard values are 10mm (15mm for 80M).
p) Load the configuration file for the injection unit on screen 8310.
q) Load the machine status on screen 8310.

Revision of window values in case of zero adjustment

Through new stroke transducers and the introduction of rubber couplings at some transducers, the ad-
justment values applicable to version 1.12 and above were revised again. It is pointed out that the opti-
mum set value listed in the table is only the theoretical optimum value. The zero point may be within the
whole window, however, make sure that you don’t get too close to the lower adjustment limit which is
simultaneously used as inquiry point „inaccessible area“ and if over travelled, would output the error
"stroke transducer defective". The adjustment windows of the position encoders do not consider any
mechanical conditions of the machine but only the relation of mechanical piston stroke to the required
electric stroke with a safety reserve.

Piston stroke
possible electric stroke

 

lower adjustment limit upper adjustment limit

optimum set value
adjustment
window

 Inaccessible area, position encoder failure identification

The following page shows the new table:

08/12 4.4.59
 Service Manual

80M position encoder adjustment values

Axis Stroke Piston Stroke pot. Stroke ad- Adjustment optimum Adjustment Adjustment
transducer stroke electr. justment limit set value limit window
mm mm value mm Jvmin V V JVmax V JF mm
B1W 114 L18 430 457.2 13.6 0.060 0.30 0.513 20.7
B6W 114 L6 130 152.4 11.2 0.100 0.73 1.304 18.4
B6W 114 L7 150 177.8 13.9 0.100 0.78 1.407 23.2
B4W 114 L14 250 355.6 52.8 0.100 1.48 2.842 97.5
B5W 114 L6 145 152.4 3.7 0.075 0.24 0.378 4.6
50M position encoder adjustment values
Axis Stroke Piston Stroke pot. Stroke ad- Adjustment optimum Adjustment Adjustment
transducer stroke electr. justment limit set value limit window
mm mm value mm Jvmin V V JVmax V JF mm
B1W 114 L18 350 457.2 53.6 0.060 1.17 2.263 100.7
B6W 114 L4 80 101.6 10.8 0.100 1.06 1.928 18.6
B6W 114 L6 130 152.4 11.2 0.100 0.73 1.304 18.4
B6W 114 L7 150 177.8 13.9 0.100 0.78 1.407 23.2
B4W 114 L9 210 228.6 9.3 0.100 0.41 0.670 13.0
B5W 114 L6 120 152.4 16.2 0.100 1.06 1.960 28.4
30M position encoder adjustment values
Axis Stroke Piston Stroke pot. Stroke ad- Adjustment optimum Adjustment Adjustment
transducer stroke electr. justment limit set value limit window
mm mm value mm Jvmin V V JVmax V JF mm
B1W 114 L14 300 355.6 27.8 0.100 0.78 1.435 47.5
B6W 114 L4 80 101.6 10.8 0.100 1.06 1.928 18.6
B6W 114 L6 130 152.4 11.2 0.100 0.73 1.304 18.4
B4W 114 L8 180 203.2 11.6 0.100 0.57 0.993 18.1
B5W 114 L4 95 101.6 3.3 0.100 0.32 0.500 4.1
25M position encoder adjustment values
Axis Stroke Piston Stroke pot. Stroke ad- Adjustment optimum Adjustment Adjustment
transducer stroke electr. justment limit set value limit window
mm mm value mm Jvmin V V JVmax V JF mm
B1W 114 L9 200 228.6 14.3 0.100 0.63 1.107 23.0
B6W 114 L4 80 101.6 10.8 0.100 1.06 1.928 18.6
B4W 114 L8 180 203.2 11.6 0.100 0.57 0.993 18.1
B5W 114 L4 80 101.6 10.8 0.100 1.06 1.928 18.6
B5W 114 L4 90 101.6 5.8 0.100 0.57 0.993 9.1
22M position encoder adjustment values
Axis Stroke Piston Stroke pot. Stroke ad- Adjustment optimum Adjustment Adjustment
transducer stroke electr. justment limit set value limit window
mm mm value mm Jvmin V V JVmax V JF mm
B1W 114 L9 200 228.6 14.3 0.100 0.63 1.107 23.0
B6W 114 L4 80 101.6 10.8 0.100 1.06 1.928 18.6
B4W 114 L8 180 203.2 11.6 0.100 0.57 0.993 18.1
B5W 114 L4 80 101.6 10.8 0.100 1.06 1.928 18.6
Special ejector
Axis Stroke Piston Stroke pot. Stroke ad- Adjustment optimum Adjustment Adjustment
transducer stroke electr. justment limit set value limit window
mm mm value mm Jvmin V V JVmax V JF mm
B6W 114 L7 150 177.8 13.9 0.100 0.78 1.407 23.2
B6W 114 L8 180 203.2 11.6 0.100 0.57 0.993 18.1

4.4.60 08/12
 Service Manual

SCREEN 8520 "TECHNICIAN SERVICE TEMPERATURE CONTROL PARAMETERS"

1
2
3
4
5
6
7
8
9
10
11
12
13
14 Start-up damped heating

The adjustment parameters for the heating control zones are set in the screen entitled "Technician Service
Temperature control parameters".
The first entry is the controller number, which causes the parameters for the selected controller to be displayed.

1 Controller number

1 - Heating zone 1
2 - Heating zone 2
3 - Heating zone 3
4 - Heating zone 4
5 - Heating zone 5 (nozzle)
6 - Heating zone, stationary mould half
7 - Heating zone, movable mould half
8 - Melt temperature
9 - Oil temperature control (Type KTY)
10 - Feed zone control (Type KTY)

The parameters for the particular heating zone will be shown and entered beneath the controller number.

The functions of the individual control parameters for the temperature control card are described in the docu-
mentation for the temperature control card.

08/12 4.4.61
 Service Manual

The following parameters can be entered:

2-4 Type of thermocouple

Select 1 for "on"; the other two types of thermocouples will automatically be switched "off".

Fe-Cu-Ni On/Off (iron-constantan, type L)

KTY On/Off
0 to 10 V On/Off (not used)

5 Integral action time

Integral action time Tn in units of 10 ms (2000.0 = 20 seconds) in old temperature software

Integral action time Tn in units of 10 ms (250.0 = 25 seconds) in new temperature software

6 Rate time

Rate time (delay time) Tr in seconds

7 Type of control

0: 3-point control (heating and cooling)

1: 2-point control (heating only)

9 Proportional range

Xp for heating and cooling.

10 Switching period

For heating and cooling, in seconds.

Parameters are assigned to these values during initial loading of the configuration data records.

11 Variable temperature limit

This effectively prevents any overheating of sensitive materials and destruction of the screw or plasticizing unit.
Numerical values between 122 and 932 can be entered; this is the equivalent of a temperature from 50
to 500 °C when American units are set. The default value equals 470 °C (878 °F) as before. The mo-
tor and heating are deactivated by the control system regardless of relay K8R when the temperature
exceeds the preset limit. The error message "30 Temperature exceeded / K8R" is output. All actual
values continue to be refreshed on the screen, but the motor remains disabled and the heaters are no
longer switched on by the control system. The machine must be switched off and on again at the mas-
ter switch. The machine is then operational again if the actual temperature has not exceeded the limit
although a thermocouple has broken. The temperature limit is saved in the machine status.

12,13 Hysteresis of bar chart (screen 5100)

The last two entries affect the hysteresis of the bar chart representation in screen 5100, "Temperatures
Heating zones display", and are applicable to all the bar graphs shown. The range of scaling is set
which is visible additionally under and over the bar chart set-point values and actual values of tempera-
tures. Changes here are displayed on screen 5100, if the machine is switched off and on.

14 Start-up sequence for heating (as from version 2.00)

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 Service Manual

The heating control is equipped with a start-up sequence which will minimise the overswing when the heaters
are started from the cold condition up to the set-up value. With the following parameters the operator has influ-
ence on the start-up characteristic of the control:

Damped Amplification range

The proportional range Xp (screen 8520), which was calculated for each zone by the self optimising, can be
damped by an input in the range of 1 - 100% in the last row on screen 8520. The default setting is 50%. This
damping will become effective 50°C (90°F) before the set point is reached. This setting relates to the individual
Xp- value of each zone. The function will be switched off when the difference between actual temperature and
setpoint is less than 5°C (9°F). ( With selector switch S8AB5 = 1 this switch off point can be altered to 1°C
(1,8°F) for test purpose. The setting will become active after machine was switched off and on.)

Fast heating range

The fast heating with 100% duty cycle between the starting temperature and a deviation of 50°C to the set point
can be switched off by setting selector S8AB4 = 1. Default setting is S8AB4 = 0, fast heating on. The fast heat-
ing with 100% DC will be active independent of the value which is calculated and displayed on screen 5100
while the function is active.

Example:

Set point 200°C

control area in production
Switch point 195°C

damped amplification area

Switch point 150°C

fast heating with 100% DC

cold machine 20°C

On screen 5100 an indicator in the shape of a circle is placed on the right side of the actual values. When this
circle is filled all heating zones have passed the switch point to the control area of production. Now the opti-
mised control characteristic is working. We recommend not to start the production before the indicator is acti-
vated, because in some cases the temperature can fall under the 15°C (27°F) protection-limit and the screw
rotation will be locked.

If the set point will be changed by more than 20°C (36°F) the damped or the fast mode can be activated de-
pending on the temperature difference.

08/12 4.4.63
 Service Manual

procan control temperature regulation

This description is applicable to both, the old and the new temperature control software.

Temperature software up to version

1009830B (T19) und 1009840C(T06), in the following named "Old",
and temperature software as from version
10098310 (T19) und 10098410(T06), in the following named "New".

The theory:

A software-based control concept is used for temperature regulation in the procan-control system. It
utilizes a PID regulation characteristic with a delayed D component.

The simplified representation of the temperature regulation algorithm looks like this:

n
DC = x p (Set - Act n ) +
x p  7.5
Tn  (Set - Act v ) + x p  T v  ( Act n-1 - Act n )
v=0

DC Duty cycle
xp Gain factor
Set Set-point value
Act(n) Actual value at the current scanning time
Act(n-1) Actual value at the previous scanning time
Old New
Tn Reset (integral) time divided by Tn Reset (integral) time gives the
7.5 gives the value in seconds value in seconds
Tv Derivative time (differential factor) in seconds

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 Service Manual

The design of the regulation is explained in the following examples:

In this example the effects of the derivative action are disregarded.

At automatic injection moulding machines the heating circuit breakers are switched off so that the
actual value does not change.

1. Operation with purely proportional control

xp =2
Tn =0
Set = 50
Act = 20

The duty cycle in this case is calculated as follows:

DC = x p  (Set - Act n )
DC = 2 * (50 - 20) = 2 * 30
DC = 60

The duty cycle thus amounts to 60%. In the real situation the actual temperature would now rise
and the duty cycle reduced proportionally. Any residual control deviation will not be corrected.

2. Operation as a PI controller

Old New
xp =2 xp =2
Tn = 2000 Tn = 200
Set = 50 Set = 50
Act = 20 Act = 20

In this case the duty cycle is calculated as is shown below:

n
DC = x p  (Set - Act n ) + x p  7.5
Tn
  (Set - Act
v=0
v )

Thanks to the proportional factor in the control concept, a duty cycle of 60% is set as soon as the
controller is actuated.
Due to the integral action, the duty cycle per second is increased as illustrated below:

Alt Neu
EDi = 2/2000 * 7,5 * (50 - 20) EDi = 2/200 * (50 - 20)
EDi = 0,0075 * 30 = 0,225% EDi = 0,1 * 30 = 0,3%

This means that once every second 0.225% is This means that once every second 0.3% is add-
added to the initial duty cycle specification of ed to the initial duty cycle specification of 60%.
60%. After 60 seconds the duty cycle will have After 60 seconds the duty cycle will have reached
reached a length of 73,5% (60 + 60 * 0.225). a length of 78% (60 + 60 * 0.3).

08/12 4.4.65
 Service Manual

Adjustment rules

Under normal circumstances the temperature controller will operate satisfactorily with the default
parameters. If, however, this should at some time prove not to be the case, the control parameters
can be adjusted so as to achieve better control characteristics. The heating curve is shown in each
case below along with the approach to the set-point value. The parameters should be increased or
decreased by steps of 10% in each case. The use of a chart recorder is ideal. Often, however, it
will be sufficient to follow the activity as the unit heats up, observing the actual temperature value.

1. Xp vergröß
1.decrease Xp ern

1. Xp verkleinern
1.increase Xp
2.2.Increase
Tn vergrößern
Tn

1. XpXvergröß
1.decrease ern und
p and Tn
Tn verkleinern
2. decrease Xp
2. Xp vergröß ern

1.1.
Decrease Tn
Tn verkleinern

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 Service Manual

1.1.
decrease
Xp X
vergröß
p ern
2.2.
decrease
Xp vergröß ern undTn
X p and increase
Tn vergröß ern

1.
1. Increase Tn
Tn vergrößern
2.
2. Decrease Xp and increase
Xp verkleinern und Tn
Tn vergrößern

1.1.Increase
Xp Xverkleinern
p and decreaseT
und n
2. decrease T
Tn verkleinern
n

2. Tn verkleinern

Ideale
Ideal Aufheizkurve
warm-up curve.
Don’t touch a thing!
bloß nichts verändern!

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 Service Manual

Determining the adjustment parameters if regulation with the standard parameters is not sat-
isfactory

The control parameters can be determined by making an oscillation test. The material to be pro-
cessed should be present in the injection cylinder. All other conditions -- the nozzle being in contact
and cooling zone water valve open -- are important to simulating real-world conditions for the values
determined.

1. Adjust the set-point values for all the zones to the specified processing temperature. Be careful
when dealing with temperature-sensitive materials; keep in mind that the temperature can over-
shoot the target by as much as 20°. In these cases the set-point values for the oscillation test
should be adjusted to values an appropriate distance below the processing temperature.

In screen 8529, set the amplification gain (Xp) for all the zones at 99.9.
Set Tn and Tv to zero.

The controller now operates as a pure switching controller.

2. Switch on the heating.

3. Note the maximum temperature (T1) at all the zones where the value exceeds the set-point val-
ue.

4. Note for all the zones the time (t1) at which the temperature drops to the set-point value.

5. Note the minimum temperature (T2) for all the zones which lie below the set-point value.

6. Note for all zones the time (t2) at which the actual temperature falls to the set-point value for the
second time.

7. Switch off the heating.

T1

Set-point value

T2

t1 t2
Oscillating period

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The parameters are then determined as follows:

Old New
Tn = oscillation period (t2 - t1) in seconds * 7.5 Tn = oscillation period (t2 - t1) in seconds
Tv = 0.05 * oscillation period in seconds (t2 - t1) Tv = 0.2 * oscillation period in seconds (t2 - t1)
100
x p = T1-T2 100
x p = T1-T2
Example: Example:

Zone 1: Oscillation period = 270 s Zone 1: Oscillation period = 270s

Feed zone T1 - T2 = 20° Feed zone T1 - T2 = 20°

Tn = 270 * 7.5 = 2025 Tn = 270

Tv = 0.05 * 270 = 13,5 Tv = 0,2 * 270 = 54
Xp = 100 / 20 = 5 Xp = 100 / 20 = 5

Zone 2: Oscillation period = 580s

Zone 2: Oscillation period = 580 s
T1 - T2 = 22°
T1 - T2 = 22°
Tn = 580
Tn = 580 * 7.5 = 4350;
Tv = 0,2 * 580 = 116
but entry 3276.7 Xp = 100/22 = 4,5
Tv = 0.05 * 580 = 29
Xp = 100 / 22 = 4,5; Zone 4: Oscillation period = 615s
entry 3.4 (4.5 * 3276.7 / 4350) T1 - T2 = 28°

Zone 4: Oscillation period = 615 s Tn = 615

T1 - T2 = 28 ° Tv = 0,2 * 515 = 103
Xp = 100/28 = 3,6
Tn = 615 * 7.5 = 4612.5;
but entry 3276.7 Nozzle: Oscillation period = 60s
Tv = 0.05 * 515 = 25,8 Zone 5 T1 - T2 = 7°
Xp = 100 / 28 = 3,6;
Tn = 60
but entry 2,6
Tv = 0,2 * 60 = 12
Xp = 100/7 = 14,3
Nozzle: Oscillation period = 60 s
Zone 5 T1 - T2 = 7°

Tn = 60 * 7.5 = 450
Tv = 0.05 * 60 = 3
Xp = 100 / 7 = 14,3

Important: As illustrated in this example, it is As from version 2.01 the influence of the startup
conceivable that the values determined for Tn circuit must be taken into consideration (startup
can in fact not be entered. In this case enter the Xp).
maximum value of 3267.6. The value for Xp is
then, however, to be reduced proportionally.

08/12 4.4.69
 Service Manual

SCREEN 8530 "TECHNICIAN SERVICE MOTION CONTROL PARAMETERS"

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19

The adjustment parameters for the controller card and the associated control circuits for the mould, ejector,
injection, hold phase and back pressure are entered in the screen entitled "Technician Service Motion con-
trol parameters".
Speed is controlled by the mould and ejector control circuits. A position-dependent speed control concept has
been implemented to govern the injection process. Back pressure is regulated via the controller card. All other
pressures are regulated via the pump.

The following operating statuses can be specified for running in the machine:

1 Set up machine (left side)

In this operating mode the machine will be operated with the fixed set-point values at reduced levels
(pressure and speed) for both the mould and the injection process. The selector switch is the same as in
screen 6100 line 13 "Set up machine (load basic data set)".

1 Dry run (right side)

This switches on the process for a dry run (without screw rotation). The travel values in the EUROMAP
standard for the dry run must be loaded using a suitable data record.

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 Service Manual

The set-point values indicated below are displayed in "counts" and may assume values from 0 to 4095 (corre-
sponding to 12-bit resolution). Parameters are assigned when the configuration data records are loaded and
can be saved in the machine status.

The following entries have the same meaning for all control circuits, if no other remarks.

4,14 Minimum adjustment step (Min. manipulated value)

(default 0, mould open and close 22M and 25M: 400)

Limitation of the manipulated value. This value is output as the minimum manipulated value as soon as
the controller is activated, even if the set setpoint demands a lower value. For instance, if 409 is entered
here, a minimum of 1 V is output as soon as "Mould closing" is actuated, even if the setpoint speed
equals 3%, which corresponds to an analog voltage of 0.3 V.

5,15 Max. regulation variable at 4095 (Max. controlled value at 4095)

(Defaults: clamping unit 1000, injection unit 4095)

This value is used to limit the control range of the controller. The value entered here in counts repre-
sents the maximum control exercised by the controller. In other words, a value of 4095 (corresponding
to 10 V) means that the controller can operate over the full range (0 - 10 V). This limitation of the control
range is V-shaped, i.e. the controller can intervene with +/- 409 counts (1 V) when the manipulated value
equals 10% (409 counts). If the controller is too choppy, its response can be improved by reducing this
value. The controller is deactivated if zero is entered and injection is controlled in an open loop.

Max. controlled value Control range at Control range at Control range at

at 4095 10 V 5V 1V
4095 (10 V) 0 - 10 V 0 - 10 V 0-2V
3685 (9 V) 1 - 10 V 0.5 - 9.5 V 0.1 - 1.9 V
3276 (8 V) 2 - 10 V 1-9V 0.2 - 1.8 V
2866 (7 V) 3 - 10 V 1.5 - 8.5 V 0.3 - 1.7 V
2457 (6 V) 4 - 10 V 2-8V 0.4 - 1.6 V
2047 (5 V) 5 - 10 V 2.5 - 7.5 V 0.5 - 1.5 V
1638 (4 V) 6 - 10 V 3-7V 0.6 - 1.4 V
1228 (3 V) 7 - 10 V 3.5 - 6.5 V 0.7 - 1.3 V
819 (2 V) 8 - 10 V 4-6V 0.8 - 1.2 V
409 (1 V) 9 - 10 V 4.5 - 5.5 V 0.9 - 1.1 V
0 (0 V) 10 V 5V 1V

6,17 Lower controller action limits (Lower limit control contact)

(Defaults: clamping unit 800, injection unit 0)

This value determines the point in counts below which the controller is deactivated completely and op-
eration continues with open-loop control. If the value 409 is entered, this means that only open-loop con-
trol prevails at less than 1 V (10% speed). This should be set if the controller tends to oscillate at low in-
jection speeds, for instance due to static friction. The controller is deactivated completely if 4095 is set.

08/12 4.4.71
 Service Manual

7,16 Gain (Amplification) (default depends on machine)

Defaults:
22M 25M 50M 80M
Mould close 20 20 10 5
Mould open 30 30 20 10
Mould open fast speed (S6AB4=1) - - 10 5
Ejector 50 50 50 50
Injection 20 20 40 70
Back pressure 100 100 100 100

That is the proportional amplification factor of the controller.

The higher the gain, the more aggressively the controller will respond to deviations between set point and
actual values. The controller may start to oscillate if too high a gain is set. This controller does not re-
quire high gain values, since set point jumps are immediately set as controlled values.

8,19 I-component, V controller (I-part, speed control)

(Defaults: Clamping unit 50 = 500 ms, injection unit 500 = 5000 ms)

I-component, i.e. the integral-action time of the controller in 10 ms increments. The higher this value, the
weaker the I-component becomes. Since a controller with purely proportional action has a lasting control
deviation, the residual difference between set point and actual values must be compensated via the I-
component. This value ensures accurate speed control in conjunction with long injection strokes and
times. The I-component is deactivated completely if zero is entered. Small values (less than 10) lead to
destabilization of the controller.

9 Time-lag for I-component (Deceleration I-part) (default 20 = 200 ms)

Time in 10 ms increments during which the controller remains deactivated and only the set component is
active following a set point jump. This ensures that the controller need only be dimensioned to respond
to set point changes.

10 Braking factor for Y14 (default depends on machine)

The following default values are commonly used: 22M = 70
25M = 55
50M = 90
80M = 100
This factor is decisive for calculating the braking point in order to protect the mould. The higher this val-
ue, the sooner the machine starts to brake. If it equals zero, as with the former control, braking does not
commence until the "Mould Protection" position is reached.
The braking factor can be optimally set as follows:
 Set the protection pressure on screen 1100 to 0 bar and note the current value.
 Invoke screen 8530. The set point for mould protection and the actual value of the clamping unit are
shown here under the braking factor for Y14 (line 11).
 Close the mould several times in manual mode. It always stops when reaching the actual switching
position for Y14 on the closing stroke. If the actual value at the holding point is greater than the set point,
the braking factor for Y14 can be carefully reduced until set point and actual value are more or less the
same (the mould must be re-closed several times and the actual and set point values compared when-
ever the braking factor is changed). The actual value should always be approx. 1-2 mm greater than the
set point in order to remain on the safe side. If the actual value is smaller than the set point, the mould
may still close with a bang if the protection travel is short.
 Reset the mould protection pressure on screen 1100 to the original value after optimisation.
 Save the machine status on screen 6100.

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 Service Manual

15 Maximum adjustment step (Holding pressure and back pressure)

The largest possible value at which the actuator can be driven.

The following parameter can be entered for the holding pressure control circuit:

17 Y1 for hold (holding pressure)

Minimum adjustment step for the stroke valve, to keep the injection unit under pressure during the hold
phase.

The following parameters can be entered for the back pressure control circuit:

17 Sensor offset
Matching the characteristic curves for the hydraulic pressure sensor actual value and for the stroke valve
set-point value.

18 Sensor slope
Matching the characteristic curves for the hydraulic pressure sensor actual value and for the stroke valve
set-point value.

19 Controller limiting
Bandwidth within which the control algorithm is effective. The value is entered relative to the set-point
value.

As from version 1.12 the following changes and new features are included:

1. Improved injection control

The dynamic response of this control, which is of great importance for the quality of the mouldings, has been
improved considerably. In other words, the full pump acceleration capacity is exploited for high-speed injection.

The upper diagram shows the response of the former injection control. The property typical of this
position controller, namely drag, is clearly evident in the diagram. The controller was active
throughout the entire range, resulting in a slow control response following Start Injection. Although
this control response could be accelerated with higher gain, this rapidly led to destabilization (hunt-
ing) of the controller.

The lower diagram shows the response of the revised injection control. It is very much more dy-
namic at the start and accurately follows the set point value. The most important difference, howev-
er, is that the controller no longer has to operate over the full range; a controlled value is now speci-
fied as the starting value. Only the resultant deviations from the actual value need now be compen-
sated by the controller which takes the form of a PI controller.

08/12 4.4.73
speed
Service Manual

injection stroke
speed

injection stroke

The above examples illustrate high-speed injection processes with short injection strokes.

2. Revised clamping unit control

The clamping unit control has been completely revised. The most important change concerns actu-
ation of the mould protection procedure. In the past, the point at which the mould protection proce-
dure was tripped had to be set by the operator so that the machine came to a stop soon enough to
prevent the mould closing with a bang. If this setting was ever changed (e.g. alteration of the Mould
Open point), the mould may close with a bang as a result of the change.

The new mould protection procedure prevents the mould closing with a bang when normal values
are set, regardless of which setting happens to be selected. The variable point "Mould protection"
now represents the actual distance from which the mould protection procedure is active and the ma-
chine operates with reduced pressure. Zero can be entered here if mould protection is not required.
The control now ensures that the machine is braked in good time and that it is actually braked at the
set Mould Protection point so that the mould is finally clamped at reduced pressure.
The braking point is calculated on the basis of the actual speed. This means that the speed can be
set to 100% at any point on the profile and is still automatically braked in good time. This naturally
4.4.74 08/12
 Service Manual

means that the set speed is not actually reached, since the machine must be braked while still ac-
celerating.

If the former setting is used by the customer, the machine will brake far too soon and noth-
ing can go wrong.
speed

set-point for
position "mould
protection"

clamping stroke

Open - 1 - 2 - 3
From position ... onwards mm 150 100 60 40
Speed % 100 80 30 10

Former setting of the clamping unit

closing speed in steps

calculated calculated
speed

point point

30% closing speed

speed set-value for

mould protection

clamping stroke

Setting 1: 30% closing speed

Open - 1 - 2 - 3
From position ... onwards mm 150 100 60 5
Speed % 30 30 30 10

Setting 2: Graduated closing speed

Open - 1 - 2 - 3
From position ... onwards mm 150 100 60 5
Speed % 100 80 30 10

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 Service Manual

Application example:

Setting 1 was used after setting-up the mould, thus ensuring an optimum setting for the entire injection pro-
cess. The mould protection stroke of 5 mm set in position 3 would have caused the mould to close at almost
full speed with the former control. The actual braking path required is now calculated and equals approx. 15
mm in this particular case. The clamping unit now closes more quickly in order to reduce the cycle time: the
operator need only increase the speed value to achieve this purpose. There is no longer any need to consider
the mould protection stroke. The braking path now equals 40 mm and is calculated automatically.

The mould protection stroke is the only thing to have changed when setting the clamping profile. A minimum
mould protection stroke of zero can now be entered, as compared with the minimum of 5 permitted in the past.

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SCREEN 8540 "TECHNICIAN SERVICE OPTIMIZATION TEMPERATURE BOARD"

Self-optimisation of temperature parameters (new screen 8540)

1. Concise description for operation

1. The heating must be switched off (S80 = OFF)

2. Optimisation condition: Actual value less than 50 °C (122 °F), cold machine ideal. Difference be-
tween actual value and setpoint on screen 5100 equals at least 120 °C (216 °F). The set points
should be set to the working range for the application in question. When working with nozzle contact,
the nozzle should also make contact during optimisation. The set point for heating zones to be ex-
cluded from the optimisation must be equal to zero.
3. All heating zones activated on screen 5100 are optimised (zones 1 - 4 and nozzle). The water-cooled
feed section cannot be optimised.
4. Move cursor to STOP in lower frame and enter 1 to start (START appears). Optimisation starts in
AUTOMATIC mode and the new parameters are automatically adopted as a parameter block. In
MANUAL mode, the parameters are optimised and must then be adopted by the operator manually
as prompted by the system. In this mode, only the parameters activated in line 2 are actually adopt-
ed.
5. Switch on heating. The heating set point must not be changed in any way and the machine cannot be
moved during the optimisation process.
6. When optimisation has been concluded successfully, the set-up data record must be saved in the
EEPROM and on floppy disk.

2. Detailed information on self-optimisation

2.1 General
Self-optimisation of the temperature board is a means of determining the most appropriate control parameters
for the respective heating zones. In other words, the parameters required for control are determined by the
process itself. This also makes it a simple matter to determine the parameters for heated moulds. The pro-
cess is not used for the water-cooled feed section and for controlling the oil temperature in our machines.
2.2 Starting conditions
All existing zones should be heated at the same time if possible, although the zones can also be optimised
individually. Certain conditions must be met in order to start the optimisation process. If these conditions are
not met, the optimisation process will be aborted in stage 1 or after the control phase (stage 6). If the condi-
tions are permissible but not ideal for determining parameters, a warning appears in the status line in the form
of a hexadecimal value.

The following conditions must be met in order to start the optimisation process:

 Heater master switch S80 must be off.

 The controllers for the heating zones to be optimised must be switched on, either by entering a set
point for the corresponding cylinder heating zone or via the connected mould heating.
 The machine should be cold. A warning appears if the actual value exceeds 50 °C (122 °F). Optimi-
sation is aborted if the actual temperature exceeds 120 °C (248 °F). The set point should lay within
the working range of the heating zone. The start-up test continues until this value is almost reached.
The first six stages are reserved for the control phase and the heating zones are not yet switched on
by the optimisation program during these six stages. The optimisation process can consequently be
halted at any time here. Each optimisation stage lasts 20 seconds.
 The difference between set point and actual value must exceed a specified minimum value when
starting the optimisation process so that a valid heating process is possible. A warning appears if the
difference is less than 120 °C (216 °F) and optimisation is aborted if it is less than 80 °C (144 °F).
 Before starting the optimisation process, the machine must have reached a stable temperature. Ma-
jor fluctuations in temperature (e.g. due to the effects of heating or cooling processes) would result in
incorrect parameters. The control phase during the first six stages is used to determine any such
fluctuations. A warning appears if the fluctuation during the first 2 minutes (= 6 stages) exceeds 1 °C
(1.8 °F) and the optimisation process is aborted if it exceeds 3 °C (5.4 °F).

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The following conditions must be noted without fail during the optimisation process:

 Temperature set points must not be changed.

 None of the controllers may be switched on or off.
 Temperature limits and control parameters must not be changed.
 The heating must not be switched on or off by the 7-day timer.
2.3 Starting the optimisation process
2.3.1 Self-optimisation with automatic adoption of parameters

Self-optimisation is started by switching the default STOP to START when the cursor is located in the field and
entering 1. The heating must then be switched on via the heater master switch S80 and push-button S80E.
The message "Self-optimisation active" appears when the process has started. The message remains on dis-
play until cancelled or until the optimisation process is complete and the fault-free parameters have been
adopted automatically. The prompt "Optimisation active" appears in the status line to draw attention to the
active optimisation process if the message has been cancelled.

The selection STOP/START is automatically reset to STOP when optimization is complete and the message
"Self-optimisation ended" appears on the monitor. "Optimisation inactive" appears in the status line.

If optimization is to be aborted, the selection can be reset to STOP by hand by entering a 0 (or "-" and Enter).

The message "Self-optimization aborted" appears. If the process is aborted during the first 6 stages, it can be
restarted since the heating has not yet been switched on. The heater master switch must be switched off be-
fore restarting.

The message "Self-optimization disabled" appears if the optimization process cannot be started, e.g. because
the heating has been switched on.

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2.3.2 Self-optimisation with manual adoption of parameters

The selection AUTOMATIC/MANUAL must be switched to MANUAL in order to activate optimisation with man-
ual adoption of the parameters. For this purpose, a "1" must be entered when the cursor is in the field AUTO-
MATIC.

The self-optimisation process is performed exactly as described for "Self-optimisation with automatic adoption
of parameters". Before the parameters are adopted, however, the process is interrupted and the operator
asked whether the parameters are to be adopted. The operator can then select the heating zones in line 2 to
determine the zones for which the optimised parameters are to be adopted. For this purpose, 1 or "-" must be
entered for each activated zone. The parameters are then adopted with the cursor in the line "Adopt parame-
ters".

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2.4 Status display

Every zone has a status word indicating the momentary operating status in hexadecimal notation.

0001 TEST Verification of conditions in progress (stages 1 - 6)

0002 ABORT Invalid configuration
0004 WARNING The configuration is not ideal
0008 CONFIG Optimisation in progress with heating (stage 7 onwards)

0010 ERROR Invalid parameters

0020 CONTROL Heating phase, closed-loop control (not in optimisation)
0040 FAULT Control phase, closed-loop control (not in optimisation)
0080 FINISHED Optimisation of zone complete (regardless of outcome)

0100 SETACTDIFF Difference between set point and actual value too small
0200 TEMPERATUR Starting temperature too high
0400 FLUCTUATION Actual value fluctuates too strongly
0800 Not used

1000 COOLMEAS Cooling curve is being or has been measured

2000 KTABERROR Bit used for internal fault localization
4000 PROBLEMZO Problem zone, heating values declining
8000 Not used

The following (theoretical) combinations are possible for a hexadecimal position:

Display Combined significance of display

0
1 1
2 2
3 1 + 2
4 4
5 1 + 4
6 2 + 4
7 1 + 2 + 4
8 8
9 1 + 8
A 2 + 8
B 1 + 2 + 8
C 4 + 8
D 1 + 4 + 8
E 2 + 4 + 8
F 1 + 2 + 4 + 8

The following status steps are displayed in succession when the optimisation is ideal (the three bits are mutual-
ly exclusive):
0001 TEST Verification of conditions in progress (stages 1 - 6)
0008 CONFIG Optimisation in progress with heating (stage 7 onwards)
0080 FINISHED Optimisation of the zone is complete

Warnings or abort during the optimisation process (the two bits are mutually exclusive):
0002 ABORT Invalid configuration
0004 WARNING The configuration is not ideal

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Reasons for Warning or Abort (the bits can appear in combinations and always refer to the cause of the bit set
for WARNING or ABORT. ERROR only occurs in conjunction with ABORT. PROBLEMZONE is intended for
internal information. A zone which is strongly affected by neighbouring zones delays completion of the optimi-
sation process, but does not constitute a direct fault):

0010 ERROR Invalid parameter

0100 SETACTDIFF Difference between set point and actual value too small
0200 TEMPERATUR Starting temperature too high
0400 FLUCTUATION Actual value fluctuates too strongly
4000 PROBLEMZO Problem zone, heating values declining

All other bits are of no significance to the user.

Invalid parameters or none at all have been determined when the abort bit is set. These parameters are not
saved when automatic optimisation is active. The cause of the fault can be seen from the combination of bits
listed in the table.

If the process is not aborted, but the parameters to be expected on account of the conditions are slightly dis-
torted and not ideal, the WARNING bit will be set together with the CONFIG bit (000C). The cause of the warn-
ing can be seen from the combination of bits listed in the table.

2.5 Special cases

The temperature profile in some zones may be strongly affected by neighbouring zones or the heating capacity
of these zones may be so low (e.g. mould heating) that they do not achieve their set point value when operated
alone or the time required to reach the set point may be intolerably long. The heating phase is interrupted after
a maximum period of 150 stages = 50 minutes. The bits for warning and problem zone appear in the status
word, the parameters are valid. In the unlikely event that the actual temperature of 80 °C (176 °F) has not yet
been reached when the heating process is aborted, the bits for abort and problem zone will be set in the status
word and there will be no control parameters determined.

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 Service Manual

1
2
3
4
5
6
7

8
9

10
11
12
13

SCREEN 8550 "TECHNICIAN SERVICE TDMA"

Input, output, marker and data statuses can be viewed and modified in the screen entitled "Technician Ser-
vice TDMA".

1-9 Module

Entry of a data module number in the control software.

1-9 Addr (address)

Entry of a data word address within the module.

Once the data module number and address have been entered, eight data words from the controls are shown,
beginning with the address indicated. The values are shown in decimal and hexadecimal format in the first
field.

The version numbers for the controller and temperature card are shown on screen 8550 as follows (example
from software version 1.14):
Controller card: Module 8 Address 235 Version number 110D (hex), (decimal: 4365)
Temperature card: Module 10 Address 235 Version number C0B (hex), (decimal: 3083)

For the service technician the following data words are important. They show the counter for wrong measure-
ments of the stroke transducers. In case this counters are showing a value > 0 the transducers must be
checked. Wrong measurements are usually caused by defect cables or worn transducers.
Module Address Module Address
Transducer B1W 1 21 Transducer B4W 1 23
Transducer B6W 1 22 Transducer B5W 1 24

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The value in module 4 under address 194 indicates the number of the keycard in use.

10-12 Type

The following entries are available for selection:

0: Input
1: Output
2: Marker

10-12 Addr. (address)

Entry of a data byte address from the control software.

Once the type has been selected and the address entered, two bytes, beginning with this address, are output in
binary format.

For the service technician the following data markers are important

Marker 230 - 231 "motor off"

This marker (type 3) was created to trace down the reason for sporadic motor shut off in order to find out
whether the reason comes from the sequence program.
The meaning of the single bits are:
Marker 230.0 minimum oil level
230.1 hydraulic safety device
230.2 electrical safety device
230.3 oil temperature too high
230.4 shut down by weekly clock
230.5 shut down by cycle time monitoring
230.6 motor off by REDIS
230.7 Stroke transducer 1 malfunction (B1W)

231.0 Stroke transducer 4 malfunction (B4W)

231.1 Stroke transducer 5 malfunction (B5W)
231.2 Stroke transducer 6 malfunction (B6W)

As from software 2.00 additional:

Marker 231.3 B42 < 300ms open
231.4 interruption of Z00, which comes over
 F032 Fuse
 S00 emergency stop
 K200 emergency stop robot
 K220 emergency stop robot
 S01E direct start contactor
 K011 star-delta contactor
 K01M relay "preparation motor and heaters"
231.5 interruption of K010E, which comes over
 B24 cover clamp unit
 B27 cover injection unit VV
 B29 cover clamp platen
 B241 cover VV
 B242 cover VV
231.6 interruption of B43

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By using the type "Input" (0) and "output (1) the statuses of the I/O- channels can be read directly. The chart
on the following pages shows the addresses of all inputs and outputs.

Example:
Type 0 Input 0.0 The bits 0.0 to 3.7 show status 1 or 0 from input-board A1K
Type 1 Output 8.0 The bits 8.0 to 9.7 show status 1 or 0 from output-board A1M

In case the output-address is entered under type "Input" (0) the display will show the malfunction-bits of the
output transistors on the selected output-board. This bit will be activated by cable breakage or overload.
Example:
Type 0 Input 8.0 The bits 8.0 to 9.7 show status 1 or 0 from all output-transistors on board
A1M.

13 Set-point value

Entry of a decimal numerical value.

13 Address

Entry of a data word address from the control software.

13 Module

Entry of a module number.

The last three entries described make it possible to enter a numerical value directly in a data word for the con-
trols. Acceptance is by pressing the ENTER key at "module".

Entries made in this screen should be undertaken with the greatest possible care since this type of direct inter-
vention in the memory for the controls can cause the machine to assume unforeseeable statuses. Modification
is possible only with a special access authorization card in the development department.

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The I/O addresses

INPUT BOARD 1 (A1K) INPUT BOARD 2 (A1L)
0.0 S7Y6 Key- switch Screwing with Y60/61 4.0 B950 Nozzle guard top
0.1 RESI1 Reserve 1 4.1 B951 Nozzle guard bottom
0.2 B18 Outturn monitoring / ejection scale 4.2 B8WF Scales clear
0.3 B43 Injection unit swivelled out 4.3 B8WW Scales in position
0.4 B05D Negative pressure filter 4.4 K201 Operation with handling devices
0.5 B05N Minimum oil level 4.5 K210 Enable mould closing
0.6 B20 Front hood switch 4.6 K260 Enable ejector advance
0.7 B22 Rear hood switch 4.7 K261 Enable ejector retract
1.0 B25 Monitoring roller lever valve 5.0 K270 Enable core advance
1.1 B26 Hydraulic mould protection 5.1 K271 Enable core retract
1.2 B42 Nozzle guard 5.2 B70 Core A advanced
1.3 F01B Motor protection dropped 5.3 B71 Core A retracted
1.4 K01ME Motor contactor K01 ON 5.4 B72 Core B advanced
1.5 K010E Safety circuit 5.5 B73 Core B retracted
1.6 K8E Heater ON 5.6 S760 Start brushing by hand
1.7 Z00 Enable proportional valve 5.7 B761 Brush raised
2.0 S16 Push-button 16 (cycle start) 6.0 B760 Brush lowered
2.1 S4 Push-button Machine stop 6.1 RESI2 Reserve 2
2.2 S3 Push-button Manual mode 6.2 RESI3 Reserve 3
2.3 S2 Push-button Semi-automatic mode 6.3 B5310 Scanning screw diameter 0
2.4 S1 Push-button Fully automatic mode 6.4 B531 Scanning screw diameter 1
2.5 S11 Push-button Nozzle advance 6.5 B532 Scanning screw diameter 2
2.6 S12 Push-button Nozzle retract 6.6 B28 Safety rail on hood
2.7 S13 Push-button Injection 6.7 S20 Close guard door
3.0 S15 Push-button Plasticizing 7.0 S21 Open guard door
3.1 S14 Push-button Screw retraction 7.1 S55 Cleaning
3.2 S5 Push-button Close mould 7.2 B61W Safety switch, ejector
3.3 S6 Push-button Open mould 7.3 K65 Ejector connected
3.4 S7 Push-button Ejector advance 7.4 K29 Mould clamped
3.5 S8 Push-button Ejector retract 7.5 K2DG Pressure/speed clamping device
3.6 S9 Push-button Core advance (screwing) 7.6 X28A Alarm control loop fault A5DG
3.7 S10 Push-button Core retract (unscrewing) 7.7 RESI4 Reserve 4

OUTPUT BOARD 1 (A1M) OUTPUT BOARD 3 (A1P)

8.0 K010 Prepare motor ON 16.0 Y24 Nozzle guard VH
8.1 H00 Fault indicator 16.1 Y111 Open mould slowly
8.2 Y10 Close mould 16.2 Y20 Close fence
8.3 Y11 Open mould 16.3 Y21 Open fence
8.4 Y14 Mould protection 16.4 Y31 Holding pressure transducer down
8.5 Y30 Clamping force build-up 16.5 Y33 Bleed mould
8.6 Y40 Nozzle advance 16.6 Y35 Clamping force relieved
8.7 Y41 Nozzle retract 16.7 Y54 Nozzle force relieved
9.0 Y50 Injection 17.0 K01A Softstart module
9.1 Y53 Plasticizing 17.1 Y72 Advance mould part B
9.2 Y49 Hydraulic shut-off nozzle 17.2 Y73 Retract mould part B
9.3 Y51 Decompression 17.3 K54DK Range selection, cavity pressure
9.4 K81 Control zone 1 = heating zone 1 17.4 K7QA Core pulls retracted
9.5 K82 Control zone 2 = heating zone 2 17.5 K7QE Core pulls advanced
9.6 K84 Control zone 4 = heating zone 4 17.6 K8W Clear scales
9.7 K85 Control zone 5 = nozzle 17.7 K54F Enable cavity pressure

OUTPUT BOARD 2 (A1N) OUTPUT BOARD 4 (A1Q)

12.0 Y60 Ejector advance 20.0 K01PE Set-up mode
12.1 Y61 Ejector retract 20.1 Y02 Pressure control pump 2
12.2 K01M Switch on motor and heating 20.2 Y09 System isolation
12.3 Y05T Oil pre-heating 20.3 Y58 Inject. with accu or diff.- mode
12.4 Y19 Coolant circulation 20.4 K83 Control zone 3 = heating zone 3
12.5 Y64 Air blast valve 1 20.5 Y760 Brush down
12.6 Y70 Screw in mould parts A right 20.6 Y761 Brush up
12.7 Y71 Unscrew mould parts A left 20.7 Y762 Brush turn
13.0 Y80 Water valve for feed temperature 21.0 RESO1 Reserve 1
13.1 K8S Ejection filter, tolerance exceeded 21.1 RESO2 Reserve 2
13.2 K10W Mould closed 21.2 RESO3 Reserve 3
13.3 K11W Mould open 21.3 X541 Holding pressure start
13.4 K60W Ejector advanced 21.4 B56W Melt cushion position reached
13.5 K61W Ejector retracted 21.5 K8KW Box change
13.6 K01PV Fully automatic 21.6 Y48 Evacuate
13.7 Y06T Oil cooling regulated 21.7 Y66 Air blast valve 2

08/12 4.4.85
 Service Manual

SCREEN 8560 "TECHNICIAN SERVICE DEBREDIS"

1
2
3
4

5
6
7

8
9

Data from REDIS can be shown and modified in the screen entitled "Technician Service DEBREDIS".

1 Displaying a value

2-4 Type

The following entries for the type may be used:

D: Digital values (binary)

F: Floating point values

I: Integer values

L: Long integer values

Index

Measured value number within REDIS.

Once the type has been selected and the index entry made, the physical value, the electrical value in decimal
format and the electrical value in hexadecimal format will be shown.

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5 Entering an electrical value

6 Value

Entering a numerical value (integer).

6 Type

the following units can be used for type:

D: Digital values (binary)

F: Float point values

I: Integer values

L: Long integer values

6 Index

Measured value number within REDIS.

Modification is possible only with a special access authorization card in the development department.

7 Background illumination of the screen

(Screen background light switches off after 0 min)

Background illumination of the screen can now be deactivated after a period between 1 minute and 50
minutes. The illumination is not deactivated and remains on constantly if zero is entered. This value is
not stored in the status. To increase the life-time of the bulb this timer should be as short as pos-
sible (appr. 2 min.).

8,9 Reset system!

Restarts and resets the control system. A RESET will be executed when "warm is selected"; all the
current data will be retained in memory. When "cold" is selected a RESET with basic initialization will
be executed; all data present in the controls will be deleted.

Note: All entries exept of the background illumination of the screen can only be done with a special
keycard to protect the system against writing in the memory.

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4.4.7 MESSAGES AND ALARM- MESSAGES

4.4.7.1 INTRODUCTION
All messages and alarm reports will appear in a window. There are two groups of messages and
alarms:
1. Messages initiated by the REDIS system (visualization, input, control and communication). The-
se messages are shown in a window inserted at the upper left corner of the frame. The messag-
es are numbered and are not entered in the alarm list. They can be deleted with the DELETE key
(to the left of the ENTER key in the cursor control block) or when the correct entry is made and
concluded with the ENTER key, or when the content of the screen changes.
2. Messages initiated by the RECON system (sequence control). These messages appear in a win-
dow inserted at the upper left corner of the frame and are identified with a triangle. In front of the
text you will see the time at which the message was triggered. These messages, numbered at
the end, are entered in the alarm list. The message can be deleted from the normal screen at
any time by pressing the reset key (the second function for "L" in the arrow key block) but it will
remain in the alarm list and will be deleted there only after the cause of the message has been
eliminated. The alarm list is called up with the "A" key (second-level function for the "Y" key in
the direct access block). Press the delete key to return to the screen shown prior to the alarm
page (if you have not pressed any other key in the meantime).
If error messages are transmitted to a printer, the time at which the error occurred will also be print-
ed out. After the cause of the error has been rectified, the same error message will appear once
again. An arrow indicates whether the error appeared or was eliminated.
Example:
15:39  Screw temperature too low 21
15:43  Screw temperature too low 21

Details on printer output will be found in the description for screen 7250, "Production overview Pro-
cess Data Print-out", in Chapter 1.5.

3. Fault history and fault log

The alarm side includes the possibility of switching over to a "fault history" with which the last 50
messages and reports can be viewed. The error messages are listed in the same way as on a
printer. In other words, one line is displayed when the fault occurs and another when it disap-
pears. The changeover is effected by pressing the function key "A" under the corresponding
symbol. The fault history cannot be printed out as hardcopy. The arrow up and arrow down keys
can be used to leaf through the history. The last error message generated is always displayed
when the list contains 50 full lines.

All error messages can additionally be logged on a process data disk or separate blank floppy
disk. They are logged in plain English, together with the date and time at which they occurred
and subsequently disappeared.

"1" must be entered in the line "error messages" in the "floppy disk" field at the bottom of screen
7250. A file name conforming to DOS conventions (max. 8 characters or numerals; period and
extension with up to three characters or numerals can be entered if desired) must be entered in
the line below. The file name can be edited at any time. As with all text inputs, this input com-
mences and is concluded by pressing Enter.

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4.4.7.2 NUMBERED MESSAGES GENERATED BY THE REDIS SYSTEM:

1 Initialization in progress

This message appears about 20 seconds after the machine is switched on, remains visible for about
18 seconds and, if initialization is completed successfully, disappears and is replaced by message 2.

2 Initialization completed

This message appears once initialization has run to completion and remains visible until the opera-
tor calls the first screen or presses the delete key.

3 Too many set-point values on the page

This message indicates that more than 100 set-point values are defined in a screen. It should ap-
pear only during the program development phase.

4 Page not present

This message appears when a softkey is used to select an icon (the pictogram in the screen just
above the key) and either the corresponding screen does not exist or cannot be selected due to the
setting of the selector switches. Pressing a softkey for which no icon is shown in the screen will not
trigger an error message.

5 Illegal key

This message tells the operator that he has pressed a key which is not applicable to the particular
entry. If, for example, the instructions call for entering "1" or "0" (or "-") and key "2" is pressed by
mistake and confirmed with the ENTER key, then this message will appear. It will also appear if a
digit key is pressed at the beginning of a text entry which is supposed to be started with the ENTER
key.

6 Value too small Min:

If a set-point value is confirmed with the ENTER key but the value is smaller than the lower plausibil-
ity limit for the set-point value, then this message is displayed together with the minimum value.
Enter a plausible set-point value and conclude with ENTER; the error message will then be cleared
automatically. If this error message appears because the set-point value was changed inadvertent-
ly, then the previous status is restored by pressing a cursor control key.

7 Value too large Max:

If a set-point value is confirmed with the ENTER key but the value is greater than the upper plausi-
bility limit for the set-point value, then this message is displayed along with the maximum value.
Enter a plausible set-point value and conclude with ENTER; the error message will then be cleared
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 Service Manual

automatically. If this error message appears because the set-point value was changed inadvertent-
ly, then the previous status is restored by pressing a cursor control key.

9 No access authorization

This message appears if the operator attempts to make an entry without having established proper
authorization. Authorization access is granted with one of the three KEYCARDs, numbered 1, 2 or
3. The system will show which KEYCARD authorization level is required; this information appears at
the "operator authorization" entry when help key "H" is pressed twice.

10 Incorrect machine operating mode

This message appears when an entry is to be made with the machine in a certain operating mode,
e.g. "STOP" or "Manual mode", but the machine is in fact in another mode, e.g. "Semiautomatic" or
"Automatic". If the entry is possible only in the STOP mode and the machine is in automatic opera-
tion, then you may press the "semiautomatic" key, wait until the end of the cycle and repeat the en-
try.

11 Printer not switched on

This message appears if the machine transmits data to the printer but the printer does not issue a
"ready to receive signal" because, for example, it is out of paper, the printer is switched off or is not
in the "ON LINE" or "READY" status, or the cable is not connected at both the printer and the ma-
chine. The absence of an interface card or of the printer itself will trigger this message when the
printer option is activated. The message appears in each case after the "timeout" period, specified
in screen 8340, has elapsed. In so far as no overly large volume of data is output, all the data to be
printed will be placed in buffer storage and will not be lost. Where process data is printed for each
cycle, the buffer will accept additional data for up to 50 cycles if print-out is not possible when pro-
duction is interrupted. The following applies in general: If the contents of the buffer cannot be out-
put, no new data will be stored for later print-out and will be lost; this holds true until the contents of
the buffer have been printed. The operator should either return the printer to service as quickly as
possible or switch off the printer function in screen 7250.

20 Illegal data word / bit address at RECONC module

This message appears if the REDIS system attempts to write to memory areas which are not pre-
sent in the control system. This may be an indication that the REDIS and RECON program versions
in use do not match.

21 Illegal system number in transmission

This message appears when communications to the controls cannot be established using the sys-
tem number entered in the VISU data record. This may indicate that the REDIS and RECON pro-
gram versions in use do not match; check the program versions. If the REDIS is reset and restarted
internally (after a malfunction and intervention by the watchdog) it will no longer be synchronized
with RECON, which will also cause this error. The machine should be switched off and back on.

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22 Data medium procedure completed

This message appears when a data operation in internal, non-volatile memory (EEPROM) has been
successfully completed. Such operations include loading, storing, deleting and formatting. This
does not apply to data disk operations.

25 File reading error

This message appears when the selected file in the EEPROM cannot be read properly. Store the
mould data on a diskette (screen 6100, if this is not done regularly in any case) and reformat the
non-volatile memory (screen 8310). Then store on diskette the current machine status as shown in
screen 8310. The mould data can again be copied from the diskette and into the EEPROM (screen
6100).

29 Please wait.

This message appears whenever an activity initiated by the operator (such as storing a data record),
takes a longer period of time and it is necessary to wait until this operation is complete. No other
entries can be made in the screen during this time. The message will disappear automatically once
the waiting period has elapsed.

32 Incorrect hour/minute format

This message appears if, after changing from the 24-hour to the 12-hour system, a time of day is
entered which conflicts with the format. The operator must enter the hours and minutes again, us-
ing the correct format.

33 Incorrect format for baud rate

This message appears if an incorrect baud rate is entered. Baud rates of 150, 300, 600, 1200,
2400, 4800, 9600 and 19200 are permissible.

38 Floppy disk drive not ready

This message appears if the program attempts to access the floppy disk drive and the drive does
not respond to the desired function. Ensure that the diskette drive and the interface card are pre-
sent and ready for operation and that both the data and power supply cables are connected properly
at both the floppy disk drive and the interface card. Check that the interface card has been plugged
into the subrack properly and makes perfect contact. Check to insure that the diskette in the drive is
inserted completely; the green LED on the drive should light during the disk operation.

40 Diskette write error

This message appears when an error occurs while writing a file to disk. Check to see whether the
diskette is write-protected. The slider at the square opening at the left edge of the diskette should
cover this opening. Then repeat the write operation. If the error appears again, then try a new
diskette. The data already stored on the defective diskette can be recovered at an MS-DOS com-

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patible PC. The defective diskette should not be reused. In this context we would urgently recom-
mend using the PC to make backup copies of diskettes, to prevent data loss in case of a defective
diskette or drive failure.
This message will also be shown in case the REDIS-CPU can not write data to a defective EEPROM.
If this message comes up when data is transfered from the floppy to the EEPROM the fault is located
on the REDIS board. The board must be changed.

41 Diskette read error

This message appears when a file on the diskette cannot be read. The file may be corrupted. Try
to read it once again. If the error occurs again, then the file has been lost, although it may be possi-
ble to read it at a PC. The data already stored on the defective diskette can be recovered at an MS-
DOS compatible PC. The defective diskette should not be reused. In this context we would urgently
recommend using the PC to make backup copies of diskettes, to prevent data loss in case of a de-
fective diskette or drive failure.

42 Formatting error

This message appears when it is not possible to format correctly either a diskette or the non-volatile
memory (EEPROM). The reason for this error when might be that no diskette is mounted in the
floppy disk drive, that the diskette is damaged or that it is the wrong type (density). The diskette
might also be write-protected. In this case writing must be enabled by moving the slider at the left-
hand edge so as to cover the opening. Use 89mm (3 1/2"), 1.44 MB (high-density) diskettes. Pur-
chasing pre-formatted diskettes saves time-consuming formatting on the machine. The diskettes
can also be formatted on an MS-DOS PC when required. If there is a formatting error in the non-
volatile memory, then the REDIS CPU board will have to be replaced. After this is done, all the data
will either have to be loaded from a diskette or re-entered manually (see details at error message
188).

45 File not present

This message informs the operator that the file which is to be read is not in fact present on the disk-
ette or in the EEPROM. This error can occur if the diskette is removed from the floppy disk drive
after the diskette directory has been read. This error is also reported if, when selecting a data rec-
ord from a directory, the ENTER key is pressed while the cursor is on a blank line.

47 Data medium is full

This message appears when the non-volatile memory is full (with a capacity for 30 files), if there ar
50 files stored on a diskette or if a PCX data disk is full. If the EEPROM is full, clear space by delet-
ing a suitable data record. If a diskette is full, then insert a blank diskette. If the diskette has not
been formatted, then it will have to be formatted before use. Use only HD (high-density) diskettes
with a capacity of 1.44 MB.

53 The diskette is write-protected

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This message appears when an attempt is made to store or delete data on, or format, a write-
protected diskette. Remove the diskette from the drive, move the write-protect slider over the open-
ing, reinsert the diskette and restart the operation.

62 Data medium will be formatted

This message appears whenever a diskette or the non-volatile memory is to be formatted. Format-
ting a diskette takes about 5 minutes; any data which may be present on the diskette will be perma-
nently erased. Pre-formatted HD (high-density) diskettes with 1.44 MB capacity may be used; these
need not be formatted. The non-volatile memory (EEPROM) need be formatted only when a defect
is suspected in this area. All data will be lost when the EEPROM is formatted; the status, configura-
tion data records and mould data records will have to be loaded from a diskette or entered manually.
See the explanation at error message 188 for details.

65 Printer not graphic-capable

This message will appear if the wrong number of matrix needles has been selected in screen 8340
for graphic output. It also appears if a printer is used which is not supported by the machine. In this
case, text can be output, but graphics cannot. The machine manufacturer can, on request, provide
additional drivers for common printer models in later versions of the software.

66 Replace batteries !

This message appears if the voltage in the batteries on the KK100 coupler card (slot A1A) drops
below the value required for dependable storage of the data on the REDIS-31B1-CPU (slot A1B).
This message is also shown if no batteries are installed. The data in the volatile memory of the
REDIS-31B1-CPU will be lost when the batteries are replaced, but those in the EEPROM are re-
tained. The machine must be switched off when changing the batteries. Pull the KK100 coupler
card, insert the batteries in the proper orientation (polarity) and reinstall the coupler card. Install two
1.5 V batteries for electronic equipment (leak-proof alkali manganese cells, IEC size LR6 miniature,
BOY part number 9 621 003). Rechargeable NiCad batteries or lithium cells may not be used since
these will not deliver the required 1.5 V. The data are then to be restored, following the directions
given at error message 188.

70 Data medium not formatted

This message appears if an attempt is made to write to the EEPROM and the memory has not been
formatted. Formatting is carried out in screen 8310.

88 Logging printer too slow

This message appears if the printer has not completed printing the log or data record when data for
the next printing cycle becomes available. The problem may be that the printer is not ready (OFF
LINE) or that it is out of paper. This message will also be seen if the printer is very slow and the
printer buffer very small. Using the wrong printer cable (e.g. from the older machine generation
which utilized the X-ON/X-OFF protocol) may also trigger this error, since a hardware handshake is
used in procan control. This message will not appear if the log is written simultaneously to the disk-
ette, since in this case the data will not be lost.

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89 Illegal value in index/multiplex variable

This message appears if an index value for indexed texts or multiplexed set-point/actual values lie
outside the plausibility limits. This message may indicate that the program versions for REDIS and
RECON do not match or that the machine status in an old program version is no longer compatible
with a new program version. In this case the status should be stored in memory once again. If this
is not successful, then the EEPROM will have to be formatted (screen 8310).

90 Error in host computer communications

This message appears whenever there is a malfunction in communications with the host computer.

91 Host computer re-initialization

This message appears when the host computer orders an initialization of all the values in REDIS,
such as happens when reading from a data medium.

93 New initialization of host computer completed

This message appears once initialization under host computer command has been completed.

97 Tolerance monitoring:

This message appears if the tolerance monitoring function has been activated and a violation of
tolerances is detected during production. The designation for the tolerance parameter violated will
be appended. Depending on the response specified in screen 7220, the machine will either issue
the alarm message only, or it will activate a reject signal in addition to sort out the defective part, or
it will additionally stop the machine at the end of the cycle. The alarm message is cleared when the
machine is restarted manually after shutdown and otherwise when a moulding is produced which is
within the tolerance limits.

102 Autom. reference value determination in progress

This message appears if the automatic reference value determination feature was activated with an
entry in screen 7220. The number of cycles already registered is indicated. Automatic reference
value determination is not suspended when the machine is stopped but instead continues when pro-
duction is resumed. It is possible to terminate the function manually at any time, simply by resetting
the selector switch in the screen.

103 Reference value determination aborted

This message appears if the automatic reference value feature is switched off before ten cycles
have been completed or if the parameters being monitored are changed before the ten-cycle period
has been completed.

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104 Reference value determination concluded

This message appears after the reference values have been successfully determined, over a phase
ten cycles in length. The reference values are entered in the parameter selection table in screen
7220.

105 Communication error at CANBUS

This message appears to signal that CANBUS is overloaded. A hexadecimal identifier follows this
message; please note this number. The error can normally be reset by pressing the delete key and
the message will disappear from the screen. If the error occurs frequently, please contact customer
service to have the problem rectified.

107 Manual termination, hard copy printout

This message appears ...

 if the hard copy key is pressed before the previous printout was completed;
 during graphic output to diskette if the print quality was not set for graphics (screen 8340) or if no
file name was specified (screen 7250).

110 Procedure was aborted

This message appears whenever a diskette or memory operation is aborted with the delete key.
Intentional termination may make sense, for example, if you wish to view the contents of a diskette
or the EEPROM or if a yes/no choice is answered with "no".

114 Keyboard locked by host computer

This message appears when entries can be made only by the host computer after its being as-
signed exclusive control over the machine. In this situation it is not possible to make entries at the
machine keyboard.

115 Keyboard unlocked by host computer

This message appears to indicate that the host computer has again enabled the keyboard, making it
possible to effect entries there.

116 Set-up data transfer from host computer

This message appears when the transfer of a mould data record from the host computer to the ma-
chine has been initiated and is in progress. This particular data record will be loaded as the active
operating data record.

117 Set-up data transfer from host computer completed

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This message appears when the transmission of the mould data record from the host computer to
the machine has been completed.

118 Set-up data activation

This message appears when REDIS has received a data set and placed it in buffer storage but has
not activated the data record, i.e. has not loaded this record as the active data record in the operat-
ing data memory area. Once it has been activated, this data record will be available for use as the
operating data record.

119 Set-up data activation completed

This message appears after a data record has been activated.

126 Temperature too high

This message appears when a temperature has been exceeded during production by more than the
tolerance value entered in screen 5200. This message will not be seen if the monitoring function is
activated. If response level 1 or higher has been activated, then the process level will indicate at the
same time which heating zone reported the violation.

127 Temperature too low

This message appears when, during production, a temperature has fallen below specifications, by
more than the tolerance value entered in screen 5200. This message will not be seen if the monitor-
ing function is activated. If response level 1 or higher has been activated, then the process level will
indicate at the same time which heating zone reported the violation.

137 CANBUS Timeout

This message appears if a CANBUS object cannot be transmitted within one second. It draws the
operators attention to the fact that this case has occurred and remains on the monitor until cancelled
by pressing the Delete key. The CANBUS is initialised regardless of the message and communica-
tions are resumed. Regeneration is impossible if initialisation cannot be performed due to the per-
manent nature of the fault or because the fault buffer is overflowing. In this case, the CANBUS
must be initialised by switching the machine off and on again. However, this fault should only occur
in conjunction with hardware problems (e.g. short-circuiting in the CANBUS) and must then be rem-
edied.

147 Floppy not for PCX files!

148 Floppy not for set-up data records!
149 Floppy not for process data!

The appropriate message appears when a diskette set up for storing a certain type of data has been
inserted in the drive and an attempt is made to store a different type of data. The following applies:

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There are three types of files: mould data records (with machine status data), process data and im-
age copies (PCX files). They are stored on separate diskettes. The first time data is stored on any
given diskette an identifier file indicating the type of data will automatically be written to the disk.
Subsequently the machine will permit you to store only data of the same type on this particular disk-
ette.

151 Initial programming completed

This message appears when initial programming has been completed. If initial program is interrupt-
ed by switching off the machine, the current data record will automatically be re-loaded prior to initial
programming.

152 Initial programming in progress

This message appears as soon as initial programming commences. The message window can be
removed with the delete key but it will reappear each time a new screen is called up and at each
new set-point value.

153 Data record does not match machine configuration

This message appears if the configuration at the clamping unit does not correspond that in the data
record to be loaded. Check the setting of the selector switches for the clamping unit and the ejector
stroke (screen 8330). Check screen 8310 to see whether the configuration files have been loaded.
The data in the machine will not be affected; the previous set-up record is retained.

154 Value in data record fails plausibility check:

This message appears if a value in the data record violates its plausibility limits during calculation.
The identifier number for the measured value which was determined implausible is delayed. The
default data record is loaded; no data record name will appear in the screen header.
The message appears not only when loading a data record, but can also be triggered by changing
the screw diameter if the re-calculation of the set-point values on the injection end gives an implau-
sible value. In this case it is important to ensure that the old screw diameter is entered before the
current data record is loaded again.

155 Data record incompatible - Units:

This message appears if the data in the data record being read have been stored in the other units
of measure (bar/psi, °C/°F). The data record can be loaded only after the selector switch for "Amer-
ican units" in screen 8320 has been set to the opposite value (from "-" to "1" or from "1" to "-").

156 Voltage value not inside zeroing window

This message will appear if, during zero point adjustment, a reference value is entered and the cor-
responding device is not within the range of the specified zeroing window. When entering the refer-
ence values, the appropriate stroke potentiometer must be within the zeroing window to eliminate
the possibility of mechanical damage to the potentiometer when strokes are executed later. With

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the corresponding device in contact with the mechanical stop, adjust the potentiometer mechanically
so that the voltage value is within the zeroing window.

157 Selection not possible

This message appears if the operator selects functions which are mutually locked out. It is not pos-
sible to activate in screen 8320 the configuration switch for heating zone 3, for example, if pro-
cessing for elastomer/thermoset plastics has been specified, and vice versa. The other selector in
each case will have to be deactivated by selecting "0" or "-".

158 Copy screen to data record:

Following this message is the name of the file to which the contents of the screen will be written.
The name is made up as follows:

ddn_mmmm.PCX

Legend:
dd = 2 characters which the operator must enter in screen 7250 before he
can store screen files.
n = Sequential number between 0 and 9, assigned automatically, to diffe-
rentiate among screens which are stored one after the other.
_ = Delimiter.
mmmm = Screen number.
.PCX = File extension designating this as a pixel file. This file can be viewed
on any PC using, for example, "Paintbrush", running under "Windows".

159 Function indata record does not match machine configuration

The function in the data record (program selection) does not match the current setting for the con-
figuration switches. The default data record will be loaded, which will take a little time. The name
field is blank after loading. The configuration switch expected by the program is indicated by the
number of the measured value. The main configuration switches which may be involved are listed
below:

I 5 Air blast valve 1 S2AB8

I 6 Air blast valve 2 S2AB8
I 7 Insert core pull A S2AB3
I 7 Screwing A S2AB4
I 9 Insert core pull B S2AB5
I 91 Retract core pull A S2AB3
I 91 Unscrewing A S2AB4
I 98 Retract core pull B S2AB5
D 19 Needle shut-off valve S6AB7
D 25 Outturn monitoring S6AB8
D 389 Injection with accumulator S0AB6
D 401 Brush control S3AB8

170 Are you sure? Yes/No

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171 Delete file? Yes/No

172 Format data device? Yes/No
173 Overwrite existing file? Yes/No

The appropriate query appears for all critical operations in which data would be destroyed and lost
forever. Confirm the action by pressing "Y"; any other key will be interpreted as "no" and will abort
the operation.

187 Malfunction of screw diameter detection device

This message appears if the automatic sensing of the diameter detects an illegal combination of
bits. This also happens if the plug for automatic diameter sensing is not attached or if automatic
diameter detection was switched on erroneously.

188 No system data! Load configuration data (8310)

This message will always appear if, after the machine was switched on, initialization was conducted
and no data are present in the working memory (RAM) for proper running of the machine.

A: Normal case:

a) After removing the REDIS-CPU from the module rack (e.g. when changing the EEPROM without
actions as described below for the special cases)

b) After removing the KK100 coupler card (battery clips) from the module rack (to change the bat-
tery, for instance)

Once the appropriate card has been reinserted, the machine switched on and the error message
shown, the following steps must be carried out:

1. Select screen 8310 "Technician Machine data Default set-up". Entries can be made here only if
the KEYCARD providing level 3 authorization has been inserted.

2. Use the cursor control keys to select "Load machine status" (line 11) and press "1" to start. If
machine status data has already been stored in the EEPROM in the machine, message "29
Please wait" will appear. If this message is not shown, then the operator must assume that no
machine status information is present in the EEPROM; he then continues with the entries as de-
scribed in special case 1 or 2. The machine status data include the zero point adjustment value,
the screw diameter, the machine number, the interface parameters, the selector switches, the
current piece count, the sensor parameters and other important basic settings.

3. Select the minus sign at the left, one line down (under "Machine status") and press "1" to start. A
directory will be opened listing all the permissible configuration files for the clamping end. Exam-
ple: M022A080. Legend:
M022 = Machine model
A080 = Ejector type 80 mm
Other letters may be substituted for the letter "A" if there is further differentiation in the configuration
file. The desired file, which must correspond to the machine configuration, is to be selected with
the cursor control keys and loaded with the ENTER key.

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4. Select the minus sign at the right in the same line and press "1" to start. A directory will be
opened listing all the permissible configuration files for the injection end. Example: S052A160.
Legend:
S052 = Injection unit type (international sizes)
A160 = Hydraulic motor type, displacement volume in ccm
Other letters may be substituted for the letter "A" if there is further differentiation in the configuration
file. The desired file, which must correspond to the machine configuration, is to be selected with
the cursor control keys and loaded with the ENTER key.

5. Load the machine status in line 11 again so that calculations for the pressure sensors and for the
values dependent on the screw diameter can be made. Load the edited parameters for the elec-
tric zero point adjustment and the controller and temperature parameters.

6. Enter the date and time in line 8. The date and time will be accepted after the minutes have been
typed, and inserted in the header once the ENTER key is pressed.

7. Select screen 6100 "Set-up data Data records" and load a data record matching the mould, carry
out initial programming or load set-up data from a diskette.

B: Special case 1

If there is no machine status information stored in the EEPROM or if the EEPROM has been in-
advertently formatted in response to a command, or if a REDIS-CPU is installed which had been
run on another machine or delivered as a replacement part, then you may proceed as follows if
the machine status and set-up data records are stored on diskette:

1. Select screen 8320 "Technician Machine data Equipment" and switch on "Floppy disk drive"
(line 1 in the right-hand column) by entering "1". If no FDD is present, then you must continue
with the procedure described at special case 2.

2. If the REDIS-CPU was taken from another machine or supplied as a replacement part, then the
EEPROM will have to be formatted (screen 8310) before copying.

3. Select screen 6100 "Set-up data Data records". Enter "1" for machine status at the left in line 9
if "2" (set-up data) has been selected. Select (Disk ® EEPROM) in line 8 and start by pressing
"1". If there is a status file on the diskette, it will be shown with an entry in the disk directory
"M_STATUS.005". Copy this file into the EEPROM by pressing ENTER.

4. With the switch in line 9 set at "2" (set-up data), it is possible in line 8 (Diskette  EEPROM) to
copy all the desired set-up data records from the diskette to the EEPROM.

5. Continue initialisation as described at "A: Normal case", as of step 1.

C: Special case 2

If you cannot proceed as described for special case 1, then low-level, manual initialisation will be
necessary. The procedure is as follows:

1. Write down all the current zero point adjustment values (correction values) shown in screen 8510
or copy them later from the machine acceptance log, if they are still valid. If the zero point ad-

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justment values are no longer known, it will be necessary to adjust these reference values, with-
out a mould being installed, as is detailed in Chapter 1.5 at the description for screen 8510.

2. Write down all the selector switches in screen 8330 which are set for "1", if this is still possible. If
this information is no longer available, it can also be found in the machine information log.

3. If the instructions were to change out a program in accordance with special case 2, then switch
the machine off now and replace the EEPROMs. Then power up the machine and wait for initiali-
sation to run to completion.

4. If the instructions were to proceed as per special case 2 and the instructions indicate that the
EEPROM is to be formatted, then use screen 8310 to do so. All data (machine status and set-up
data) will be erased when the EEPROM is formatted. The EEPROM must always be formatted if
a REDIS-CPU was supplied as a replacement part or was taken from another machine.

5. Move the selector switches in screen 8330 to the following settings by entering "1":

Machine model see description of 8330

Injection unit see description of 8330
Ejector stroke see description of 8330

6. Make the following entries in screen 8310, if necessary:

Desired unit of measure
Machine number as shown on the data plate or machine acceptance log
Date and time formats
Current date and time of day
Select language
Always load a configuration record for the clamping end (see A: Normal case, step 3)
Always load a configuration record for the injection end (see A: Normal case, step 4)
Correct screw diameter, if necessary
Enter decompression pressure limit (e.g. 80 bar)
Enter delay period before start of decompression, if necessary (e.g. 0.3 s)

7. In screen 8320, set all machine equipment selector switches to correspond with the equipment
actually present.

8. In screen 8330 set all those selector switches which were not entered as plain text entries in
screen 8320 (e.g. S4AB7 is always "1"); the best method is to use the entries in the machine ac-
ceptance log.

9. In screen 8340 set all the parameters for the printer if the printer interface is present. Set all the
parameters for communications with the host computer if this option has been installed.

10.The following entries are made in screen 8410:

Nozzle travel speed advance/return
Braking path, nozzle forward and return

The entries for the transducer used to register injection pressure must always be made correctly.
Installed as standard equipment is a pressure sensor rated at 180 bar, delivering 1 to 10 V. In
case of doubt, check the machine acceptance log or read the values shown on the sensor itself.
If the melt pressure sensor or cavity pressure sensor option is used, the appropriate values are to
be entered in the screen.

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11.The entries for the hydraulic pressure sensor in screen 8420 must always be made correctly.
Installed as standard equipment is a pressure sensor rated at 180 bar, delivering 1 to 10 V. In
case of doubt, check the machine acceptance log or read the values shown on the sensor itself.

12.Screen 8510: If the zero point correction values are known, then enter these values for all four
axes in the appropriate column. If these values are not known, then it will be necessary to adjust
the reference values as described in Chapter 1.5 for screen 8510. In preparation for doing this it
will be necessary to load the set-up data record in screen 8530 (machine set-up) by entering "1".
If a set-up record is available on diskette, it can be copied and loaded in the EEPROM (screen
6100).

13.The machine status is stored in screen 8310 (this can also be done in screen 6100).

14.The initial generation of a set-up data record for a mould can be carried out in screen 6100.

189 Change process data diskette; almost full

This message appears if more than 195 process data files have been stored on the diskette. Since
the diskette can store a maximum of 200 process data records, it should be replaced as soon as the
green lamp on the drive goes out. The new diskette should be formatted and blank. If it has not
been formatted, this can be done while the injection moulding machine is running.

190 Process data disk is full; insert new disk!

This message appears when the process data diskette is full, i.e. after 200 process data files have
been stored. Since the current process data record has not been written to disk, the green indicator
lamp at the drive will remain on until the full diskette is removed and a blank, formatted diskette has
been inserted. Any new data records which the machine generates in the meantime will be lost. If
the process data is output to a printer, parallel to storage on the diskette, then the output at the
printer will be taken to be sufficient documentation and the machine will not wait to write the data to
a diskette.

191 Faulty data transmission to product scales

This message appears if the scales are not ready for operation or not connected or if the data cable
is defective. It may also happen that the parameters for the scales interface do not correspond to
the parameters set at the machine. The settings can be checked in screen 8380.

192 Product scales fault 1

Product scales fault 2
Product scales fault 3
Product scales fault 4

One of these messages will appear if the data communications between the machine and the scales
produce illogical results. The scales initiate the message and forward it to the machine.

1. A command which the machine has sent to the scales is incorrect (syntax error). This error can
occur only in the software development phase.

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2. A command which the machine has sent to the scales is in fact correct, but illogical. One exam-
ple would be a tare command sent when the scales are in the overload or insufficient load range;
the command can therefore not be executed.

3. The sequence of characters sent by the machine to the scales was not correct and does not
comply with the scales communications protocol.

4. The weight is greater than 327,67 g or less than minus 99.9 g.

All scale errors refer to the type PM2000 scales made by company Mettler.

193 Tempering control unit data transmission defective

This message appears if the tempering control unit are not ready for operation or not connected or if
the data cable is defective. It may also happen that the parameters for the tempering control unit
interface do not correspond to the parameters set at the machine. The settings can be checked in
screen 8350.

194 Invalid set-point value to tempering control units

The value sent to the tempering control unit is too high.

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4.4.7.3 MESSAGES ISSUED BY THE RECON SYSTEM (PROCESS SEQUENCE):

1 Cycle time monitoring tripped 1

The cycle time monitoring function is one which can be tripped by any of a number of causes during
production. The motor will be switched off; no further motions are possible. The heating will be
regulated as was previously specified by the operator in screen 5200 at "Response at heating zones
when machine is stopped".

The causes of the error could be:

 As described in further detail for the particular fault in the alarm window.
 The machine hopper is empty; no material is available for processing.
 The machine is running in the semiautomatic mode and the next cycle was not started within the
predetermined cycle monitoring time.
 A valve either does not respond to commands or is sticking.
 The A01DG pump control card has gone into the malfunction status.
 External equipment units have not given a ready-for-operation signal.
 The mould safety device has been tripped.
 Another electrical or mechanical malfunction has shut down the machine.
 The specified number of acceptable repetition attempts for "close mould" was not taken into con-
sideration when specifying the overall cycle time, so that the cycle monitoring time can elapse
while repetitions are being attempted.

To locate the source of a defect, first press the A key (alarm key) in the block of rapid-access keys.
If there is a message describing the fault which was detected, then the message will be shown. The
fault history can also be viewed by pressing the function key "A" below the symbol after opening the
alarm window; it may provide further information on the actual cause of the error. If this is not the
case, the operator can call up screen 8100 and examine the process step display to determine the
step and phase during which the error occurred.

Summary of the program steps:

0. Retract ejector before closing mould

1. Core movements before closing mould
2. Close mould, core movements at intermediate stop
3. Core movements before generating clamping force
4. Generating clamping force
5. Core movements after generating clamping force
6. Advance nozzle, generate nozzle force
7. Injection delay
8. Start injection, nozzle shut-off valve
Phases 1 - 5: Stroke positions during injection
Phase 6: Holding phase
9. Start nozzle return before plasticizing
10. Decompression before plasticizing, plasticizing, nozzle shut-off action
Phase 1-4: Positions along the stroke length during plasticizing
Phase 5: Decompression
11. Spare
12. Start nozzle return after plasticizing
13. Spare

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14. Wait for end of cooling period

15. Core movements before generating clamping force, start air blast valves
16. Release clamping force
17. Core movements after releasing clamping force
18. Open mould, core movements at intermediate stop
19. Advance ejector, pneumatic safety cage
20. Retract ejector, number of ejector strokes, pneumatic safety cage
21. Spare
22. Pause period to end of cycle
23. Spare
24. Outturn monitoring, outturn scale

Error reset:

The "cycle time monitoring tripped" error message is reset by pressing the manual mode key. If
other malfunctions are shown in the alarm list, these will have to be rectified first. The motor can
then be switched back on again and production can be resumed.

2 Outturn monitoring tripped 2

Causes of error:

Either the part is still in the mould or does not exhibit the correct weight, if outturn scales are in-
stalled. This will prevent starting the next cycle. The cycle will also be interrupted if the ejection flap
is opened during a movement at the clamping end or if the signal at the switching contact (B18) at
the ejection flap changes. The status of the input signal is shown in screen 8100.

Error reset:

This alarm will reset itself after the ejection flap or scale has been actuated and returned to its neu-
tral position, provided that there is no discontinuity in the electrical circuit to the switching contact
(B18).

3 Maximum oil temperature exceeded 3

Causes of error:

a) The temperature of the hydraulic fluid has exceeded 60°C (140°F). The current fluid temperature
can be read at the upper right in every screen.

b) There is a discontinuity at some point along the lead to the oil temperature sensor (B05T), the
temperature sensor is defective, or a connector plug is not seated correctly. In this case a tem-
perature of 158°C (316°F) will be shown in the screen.

Error reset:

a) The hydraulic fluid must cool down to below 60°C (140°F). If the supply of water to the oil cooling
unit has been closed, then open the feed valve.

b) Eliminate the reason for the discontinuity.

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4 Oil level below minimum 4

Causes of error:

a. The oil level has fallen below the minimum.

b. There is a discontinuity in the lead to the oil level switch (B05N) or a connector plug is not
seated properly.

c. The voltage supply via the safety circuit is interrupted. In this case RECON error message
23: "Safety circuit K010 interrupted" should appear in the alarm list.

Error reset:

a. Top up the hydraulic fluid tank.

b. Eliminate the discontinuity.

c. In this case, see the instructions at RECON error message 23.

6 Electrical locking guard 6

Causes of error:

 The limit switch (B22) is actuated or not released when the safety cage is closed.

 The limit switch (B20) is actuated or not released when the safety cage is open.

 There is a discontinuity in the lead to (B20) or (B22).

Effect:

Mould movement is suspended; the motor is switched off. The heating goes into the status to be
assumed when the machine is stopped, prescribed in screen 5200.

The status of input signals (B20) and (B22) is shown in screen 8100. Note: Since the limit switch
(B20) is fitted internally with both NO and NC contacts and since they do not always switch mechan-
ically at exactly the same time (within a period of 20 ms), this error message may appear briefly
when the safety cage is closed. This will not be noticeable at the screen but, if a printer is being
used to log errors, this message will be output twice (once when it occurs and once when it is elimi-
nated).

Error reset:

Open and close the safety cage after the cause of the error has been rectified. If the electrical safe-
ty interlock device is now functioning properly, then it will be possible to restart the motor.

7 Hydraulic locking guard 7

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Causes of error:

a) The limit switch (B26) used to monitor the valve (LG26) is not closed when the safety cage is
open. There may be a discontinuity in the lead to (B26).

b) The limit switch (B26) remains closed after the first movement of the mould following the closing
of the guard cage. The contacts at (B26) might be fused or there is a short in the lead.

c) The safety switch (B25) used to monitor the roller lever valve (B26) is not closed when the safety
cage is open. There may be a discontinuity in the lead to (B25).

d) The safety switch (B25) is not open when the safety cage is closed. The contacts at (B25) might
be fused or there may be a short in the lead.

Effect:

When in the automatic mode the cycle will be suspended and the motor switched off. The heating
goes into the status to be assumed when the machine is stopped, prescribed in screen 5200.

When in the manual mode, the following functions will be positively locked out:
 Closing and opening the mould
 Moving the ejector
 Moving cores or the screwing device

Error reset:

The following conditions must be met to restart the motor: the safety cage must be opened and
closed once again; the safety devices must switch properly while this is being done; the key for
manual mode must then be pressed.

8 Pump motor 1 bimetallic relay tripped 8

Causes of error:

a) Pump motor 1 is running hot.

b) The response current at the bimetallic relay (F01B) is set too low.

Error reset:

a) Let the pump motor cool down.

b) Adjust the response current at the bimetallic relay (F01B). The response current should be set to
match the rated current for motor 1.

Press the reset button at the bimetallic relay (F01B) once the motor has cooled down.

9 Mould protection tripped 9

Explanation of the interrelationships:

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The protection time and the number of repetition attempts are entered in screen 1100. If the time
which elapses from the commencement of mould safety monitoring (including switching of mould
protection valve Y14) to the clamping pressure application position exceeds this specified protection
time, then the mould opening and closing process will be repeated (with injector and the specified
core pull programs), up to the maximum count specified at "repetition attempts". If the mould fails to
reach the "apply clamping pressure" position, then the mould will be retracted to the open position
and the message will appear.

Causes of error:

Possible causes of error include:

 Part was not ejected or is stuck in the mould.

 Injection residues prevent closing.
 The setting for the protection time is too short.
 The position as of which clamping pressure is applied has been set for a value which is too scant
or the mould has changed shape as a result of heating.
 The mould does not move easily or the pressure and volume settings are too low.
 The ejector is sticking.

Error reset:

The error message will be cleared automatically as soon as the cause of the error is rectified and if
the mould protection device is not tripped during the next closing cycle.

10 Nozzle protection flap open 10

Causes of error:

The nozzle guard flap is not closed or there is a discontinuity in the lead to (B42).

Effect:

Automatic operation is generally suppressed when the nozzle protection flap opens. The mould
must be in its home position to restart automatic operation.

The following movements, which would not be hazardous if the nozzle guard flap were open, do not
suspend automatic operation and can be executed in the manual mode with the nozzle guard flap
open:
 Injection unit movements,
 Moving the injection unit away from the mould (retracting the injection unit),

Error reset:

Either the nozzle guard flap must be closed or the discontinuity must be repaired.

11 Close safety cage 11

Causes of error:

The safety cage was opened.

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Effect:

All movements at the clamping end, including the ejector and core pullers or screwing devices, are
suspended or locked out. The injection cycle is also locked out. The safety cage can only be
opened without interrupting the automatic cycle during a sequence with very long cooling time (vul-
canisation time) if there are no other movements active apart from the cooling time. However, the
safety cage must be re-closed before expiry of the cooling time in order to bring the cycle to its
proper conclusion.

Error reset:

Close the safety cage.

Note:

The error message "Close safety cage" is suppressed in semi-automatic and fully automatic opera-
tion if the selector for "pneumatic safety cage" is switched on. The error message no longer ap-
pears on the monitor or in the process data log and the red light remains off.
In semi-automatic operation without "pneumatic safety cage", the error message is not output at the
end of the cycle if the safety cage is opened. Parts can be removed and inserts fitted without ob-
struction in this way. If the safety cage is opened during the cycle, the error message appears as
usual and the cycle is aborted.
The safety feature of preventing all traverse movements when the safety cage is open is naturally
retained.

12 Pump control interrupted 12

Causes of error:

This error message will be shown whenever and as soon as the 24 V voltage ceases to be available
at input (Z00) [terminal X2/9, card input X1K/d16].

It is normal that pressing the S01E key (motor ON) for direct starting or opening relay contact K011
in the case of star-delta starting will cause this error message to be shown; it is of no significance in
this situation and will disappear as soon as the motor has reached speed.

The following malfunctions or operating sequences can trigger this error message:

a) Pressing the emergency stop button, if this option is installed.

b) When the circuit breaker trips or the F032 fuse blows (depending on the machine model), which
will interrupt the 24 V power supply.
c) Opening the K200 safety contacts (emergency stop button at the handling unit) or the K220 con-
tacts with built-in optional handling units.
d) When the circuit breaker trips or the F031 fuse blows (depending on the machine model) where
optional built-in handling units are present.
e) Discontinuity in the lead or lack of the 24 V supply voltage for other reasons.

Error reset:

a) Unlock the emergency stop button. The machine can be restarted if the hazardous situation is no
longer present.

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b) Reset the F032 circuit breaker or replace the F032 fuse. Ensure that the reason behind the cir-
cuit breaker or fuse failure has been located and rectified.
c) Rectify the cause for the interruption at the handling unit; unlock the emergency stop button at
the handling unit.
d) Reset the F031 circuit breaker or replace the F031 fuse. Ensure that the reason behind the cir-
cuit breaker or fuse failure has been located and rectified.
e) Locate and rectify the discontinuity in the lead.

13 Mould stroke potentiometer malfunction 13

14 Nozzle stroke potentiometer malfunction 14
15 Screw stroke potentiometer malfunction 15
16 Ejector stroke potentiometer malfunction 16

Causes of error:

 The stroke sensor for the indicated movement is defective.

 The connector plug for the indicated stroke sensor is not seated properly.
 There is a short or discontinuity in the lead to the indicated stroke sensor.
 The RK100 controller card may be defective if all four message appear and all other causes can
be eliminated as possibilities.

Effect:

The motor is switched off. The heating responds by going into the status specified when the ma-
chine is stopped, as prescribed in screen 5200.

Error reset:

The error message disappears automatically once the error has been rectified.

17 Nozzle swung out 17

Causes of error:

Models 22M and 25M:

The 24-V wire jumper at the input (B43) [terminal X2.21, card input X1K d4] is missing or has been
removed.

All other M series models:

The injection unit has been swung out of its normal position, thus opening the limit switch (B43), or
there is a discontinuity in the connecting wire to the input specified above.

In this position it is possible only to move the screw forward and backward for service purposes, in
the manual mode, at the emptying pressure and speed specified in screen 8410 (this being done to
remove the screw, for example).

Error reset:

Models 22M and 25M:

The error message is cleared as soon as the jumper at terminal X2.21 has been connected.

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All other M series models:

The error message disappears as soon as the injection unit has been returned to its normal position
or the discontinuity at the limit switch (B43) has been rectified.

18 Core in wrong position 18

Message without an alarm lamp

Causes of error:

a) A movement at the ejector or clamping unit has been initiated (manual or automatic mode) alt-
hough the core pull (or screwing unit) is not yet in the position prescribed in the programming for
the cores.
b) It may be that there is a short or open circuit in one or more of the limit switches or the leads to
the switches.
c) It may be that a screwing unit was programmed to rotate in a particular direction, monitored by a
limit switch, although the screwing unit is not equipped with a limit switch and will have to be con-
trolled by a timer.
d) It may be that a core pull or screwing movement was programmed but that no such device is pre-
sent. In this case an output error will be reported as well.

Error reset:

a) Operating in the manual mode, move the core into the correct position. The message will disap-
pear after a successful attempt to move the ejector or clamping unit and core puller into the cor-
rect position.
b) Rectify any defects in the lead cables.
c) Reset the switch in screen 1700 to respond to the timer signal.
d) Switch off core programming in screens 1500 to 1700.

19 Mould not in open position 19

Message without an alarm lamp

Causes of error:

A movement of the ejector, clamping unit or cores has been initiated although the movable platen is
not in the open position. If the ejector is not in its limit position at the start of the cycle it will auto-
matically be retracted; the error message does not appear.

Error reset:

Open the mould in the manual mode.

20 Temperature reduction active 20

Message without an alarm lamp

This message appears

if the "temperature reduction when machine is stopped" option was selected in screen 5200 and if
the machine has been shut down during production in response to an error and consequently
switched into the STOP mode.

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Reset:

Set the machine for "manual mode" so that the heating will again be regulated to the set-point val-
ues. Production can then be resumed.

21 Screw temperature too low 21

Causes of error:

This error message will be shown as long as the temperature at any barrel heating zone deviates by
more than 15 K (a difference of 15°C or 27°F) from the set-point value; in this situation the screw
cannot be moved, either for injection or plasticizing or decompression. Starting a cycle in the auto-
matic mode is disabled.

Error reset:

The error message will disappear automatically as soon as the temperatures at all the heating zones
rise to within 15 K of the set-point value; the screw is then cleared for operation.

22 Ejector not in start position 22

Message without alarm lamp

Message:

This message appears when a closing motion is initiated in the manual mode but the ejector is not
in its fully retracted position. If a switch for monitoring spring-loaded sheet moulds is installed and
activated (input B61W, selector S9AB5 = 1), this error message also appears when switch B61W is
not closed.

Error reset:

Operating in the manual mode, the ejector is retracted. The error message will be cleared automat-
ically in the next closing motion.

23 Safety circuit K010 interrupted 23

Causes of error:

The safety circuit comprising the monitoring switches and plugs at the covers and safety cage for
the clamping and injection units has been interrupted. This configuration normally includes the
B27, B29 and B24 switches and, in vertical machines, the B241 and B242 switches in addition. In-
put K010E is shown in the lower section of screen 8200.

a) If the circle in the K010E diagram is filled in, then all the input conditions for the safety circuit
have been satisfied. The computer will then prevent output K010 being activated, also shown in
screen 8200 (in the upper section). A second condition is that the K8R computer operating relay
is de-energized. K8R opens if the watchdog in the RECON-CPU has not been triggered for a pe-
riod of more than 400 ms or when the internal "voltage present" or "processor running" signals
are not present. Furthermore, the K8R relay cannot be pulled up if a lead at plug X1A2, pin 1 or
2, is defective.

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b) If both error messages (4 and 23) are included in the error list, then it may be assumed that there
is in fact an interruption in the input section of the safety circuit or that fuse F031 has been
tripped.

Error reset:

a) The cause behind the "K8R open" defect is to be rectified.

b) The interruption in the safety circuit (absence of a guard) is to be rectified. Reset the safety
switch F031 or replace fuse F031. Here it is necessary to ensure that the reason for the safety
component being tripped has been identified and rectified.

24 Oil pre-heater on - No traversing possible 24

Message:

This message is issued if the oil preheating option was selected in screen 7300 and the operating
mode selector switch is set for STOP. This message will also appear if, while the oil preheating fea-
ture is switched on, the 7-day timer switches on the machine.

Effect:

The oil preheating feature remains active until the hydraulic fluid has reached a temperature of 40°C
(104°F) or until the operating mode selector switch is changed out of the STOP mode and into an-
other operating mode. Refer to screen 7300 for further information on oil preheating.

25 Change oil filter 25

Message without alarm lamp

Causes of error:

a) The oil filter is clogged and must be replaced.

b) There is a discontinuity at some point in the lead to the low-pressure sensor switch (B05D) or the
switch itself is defective.

Error reset:

a) The error message is cleared automatically after the oil filter is replaced.

b) The discontinuity is to be rectified or the low-pressure switch (B05D) replaced.

26 Brush not in start position 26

Message without alarm lamp

Causes of error:

a) The brush has dropped and left its limit switch

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b) The "brush raised" limit switch (B761) is defective, feed lines or plug connections are interrupted.

c) There is no shorting plug with wire strap for input B761 when the brush is removed.

d) Program sequence in screen 1800 has been set to 0 (brush control deactivated) although the
brush was not in the top position.

Error reset:

a) Raise brush in manual mode. The brush can be raised directly into the starting position by simul-
taneously pressing S760 "Start brush process by hand" and "Cycle start".

b) Check wires and plug connections, replace defective limit switch.

c) Fit shorting plug with wire strap.

d) Activate brush program and move brush to starting position.

30 Overheating / K8R 30

When this fault is signalled, the computer monitoring relay K8R drops, the motor switches off, the
alarm indicator lights up and operation of the machine is disabled. The computer monitoring relay
K8R only drops if installed. The machine must in all cases be switched off after remedying the fault
and should not be switched on again for at least 5 seconds.

Causes of error:

a) Temperature sensor broken

b) An actual temperature has exceeded the temperature limit in screen 8520. If a status data rec-
ord is loaded from versions which do not include the temperature limit in the status data record,
the temperature limit will be 0 °C (32 °F) and the motor cannot be switched on.

c) Computer fault. This only applies if the new RECON RC101 with new communications card
KK110 has been installed. Motor contactor and heating contactor will de-energize if the computer
monitoring relay K8R has additionally been installed and rewired.

Error reset:

a) Install new temperature sensor or repair the interruption.

b) Increase temperature limit in screen 8520 and save it in the status data record.

c) Identify REDIS or RECON as the source of the error and replace it.

31 Oil temperature too low 31

Message without alarm lamp

Message:

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This message is shown whenever the oil temperature is at 30°C (86°F) or below. When the oil tem-
perature is below 30°C, it is advisable to preheat the oil in order to produce faultless parts. (Oil pre-
heating is specified in screen 7300.)

Reset:

The error is reset automatically when the hydraulic fluid temperature rises above 30°C (86°F).

32 Oil temperature - Pre-warning 32

Message without alarm lamp

Causes of error:

This message appears if the hydraulic fluid temperature rises above 55°C (131°F) and serves as a
preliminary warning, before shut-down temperature of 60°C (140°F) is reached.

Error reset:

Take the measures required to ensure sufficient oil cooling. This message will disappear when the
temperature falls below the specified pre-warning level.

50 Injection monitoring tripped 50

Causes of error:

This message appears if

a) the machine has not gone into the holding pressure phase within the maximum injection period,
specified in screen 3100. For this to happen, the selector switch for "maximum injection period"
must be switched on in line 4 and a realistic monitoring period must be specified. The monitoring
period can be specified for all types of change to holding pressure with the exception of time-
dependent start or, naturally, "operation without holding pressure".

b) the "minimum injection stroke" has not been traversed within the specified injection period when
operating with time-dependent start of holding pressure. For this purpose the selector switch at
line 4 in screen 3100, "monitor minimum injection stroke", must be switched on and a realistic
position value must be entered at position 5, line 5 in screen 3200.

This message may appear in both the automatic and manual modes.

Effect:

When running in the automatic mode, injection will be suspended if the monitoring time is exceeded.
The cycle will then be continued normally through to its conclusion. The machine is shut down at
the end of the cycle, as per screen 7300. Then, after the cycle monitoring time has elapsed, the
machine goes into the status described there (see alarm message 1).

Error reset:

The error message is cleared when injection is started again and the injection time monitoring func-
tion is not tripped. If injection monitoring is not desired, then the selector switch should be turned

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off. If the injection time thus selected proves to be too short, then it should be extended. If the moni-
toring position is too small, it should be enlarged.

58 Plasticizing monitoring tripped 58

Causes of error:

This message appears if the maximum plasticizing time, set at line 4 in screen 4000, is exceeded.
To enable this function, the selector switch before "max. plasticizing time" must be switched on.

This message may appear in both the automatic and the manual modes.

Effect:

When running in the automatic mode, plasticizing will be terminated if the monitoring time is ex-
ceeded. The cycle will then be continued normally through to its completion. At the end of the cycle
the machine will be shut down in accordance with the selection made in screen 7300. Then, once
the cycle monitoring period has elapsed, the machine will then be shut down as described there
(see alarm message 1). When in the manual mode it will be necessary to continue plasticizing
through to completion, in order to reach the "end of plasticizing" position.

Error reset:

This error message is cleared when plasticizing is restarted and the plasticizing monitoring feature is
not tripped. If monitoring of plasticizing is not desired, then the selector switch should be turned off.
If the monitoring period selected proves to be too short, then it should be extended as appropriate.

60 Machine switched off by 7-day timer 60

Message without alarm lamp

Message:

The machine is switched off at the specified time, as programmed for the 7-day timer in screen
7300. Any cycle in progress will run to completion before the machine is shut down.

Reset:

The message is cleared automatically when the machine is switched on again and if the unit is
switched to the manual mode.

61 Defect, controller card 1 61

62 Defect, temperature card 1 62

Causes of error:

This error is reported in the following situations:

a) The corresponding card (controller card 1 = A1E, temperature card 1 = A1H) is not present in the
card rack when the machine is switched on. The machine cannot be operated in this situation.

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b) The monitoring period for the feedback signal from the card has expired (watchdog function).
This is the case if the card has not reported for a period exceeding 2 seconds. The card need
not of necessity be defective but the error should be observed. In case of doubt, i.e. where tem-
peratures or movements are not properly controlled, the machine should be switched off and
back on.

c) If the error message appears repeatedly, replace the corresponding card.

Error reset:

The error message disappears automatically if the cause of the error has been eliminated or the
monitoring once again functions correctly.

70 Time monitoring, core A tripped 70

71 Time monitoring, core B tripped 71

Causes of error:

The core affected or the screwing unit A did not reach the programmed limit position within the spec-
ified monitoring period. If the operator wishes to run the machine without the time monitoring fea-
ture, he should set the corresponding time monitoring value at maximum (99.9 s). The monitoring
period is activated when the "limit switch" or "counter" signal is selected.

Error reset:

The error message will be cleared automatically when the machine is restarted.

72 Core limit switch A not reached 72

73 Core limit switch B not reached 73

Causes of error:

This message will be shown when a core pull is run with the "limit switch" signal but is not in its pro-
grammed home position. The message will also appear if both limit switches report the "closed" or
"open" signal simultaneously or if the "open" signal is given simultaneously as long as the core is not
being moved.

Error reset:

In manual mode, move the core to its home position. If both limit switches are then closed (see the
LEDs for switch status B70 and B71 or B72 and B73 at the left edge of the screen), then either the
limit switches will have to be adjusted or there is a short circuit at the limit switches.

92 Heater relay K8E off - Push button S80E 92

Message without alarm lamp

Causes of error:

This message is shown when the operator powers up the machine, to remind him to switch on the
heating. When the machine is shut down due to an interruption in the line power supply the heating
will stay off after power has been restored; this message will appear in this instance, too. If starting

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under control of the 7-day timer has been activated, the heating will be switched on at the specified
time.

Error reset:

Press the S80E button. Switch S80 (Heating ON) must be switched on for this purpose.

100 Heating zone 1 below tolerance (1) 100

101 Heating zone 2 below tolerance (2) 101
102 Heating zone 3 below tolerance (3) 102
103 Heating zone 4 below tolerance (4) 103
104 Nozzle temperature below tolerance (5) 104
105 Stationary mould half temperature below tolerance (6) 105
106 Movable mould half temperature below tolerance (7) 106
107 Melt temperature below lower tolerance (8) 107
108 Oil temperature below lower tolerance (9) 108
109 Feed temperature below lower tolerance (10) 109

Causes of error:

A message indicating that the temperature in a particular temperature monitoring zone has fallen
below the prescribed level will be shown if "1" or higher has been selected in screen 5200 as the
"reaction to low temperature" and if the actual temperature is below the set-point temperature, less
the tolerance values entered in the "- tolerance" columns in each case.

Error reset:

The message disappears automatically once the actual value for temperature returns to a point with-
in the tolerance window.

110 Heating zone 1 tolerance exceeded (1) 110

111 Heating zone 2 tolerance exceeded (2) 111
112 Heating zone 3 tolerance exceeded 3) 112
113 Heating zone 4 tolerance exceeded (4) 113
114 Nozzle temperature tolerance exceeded (5) 114
115 Stat. mould half temperature tolerance exceeded (6) 115
116 Movable mould half temperature tolerance exceeded (7) 116
117 Melt temperature tolerance exceeded (8) 117
118 Oil temperature tolerance exceeded (9) 118
119 Feed temperature tolerance exceeded (10) 119

Causes of error:

A message indicating that the temperature in a particular temperature monitoring zone has risen
above the prescribed level will be shown if "1" or higher has been selected in screen 5200 as the
"reaction to high temperature" and if the actual temperature is above the set-point temperature, plus
the tolerance values entered in the "+ tolerance" columns in each case.

Error reset:

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The message disappears automatically once the actual value for temperature returns to a point with-
in the tolerance window.

120 Measurement point defect, heating zone 1 (1) 120

121 Measurement point defect, heating zone 2 (2) 121
122 Measurement point defect, heating zone 3 (3) 122
123 Measurement point defect, heating zone 4 (4) 123
124 Measurement point defect, nozzle (5) 124
125 Measurement point defect, stationary platen (6) 125
126 Measurement point defect, movable platen (7) 126
127 Measurement point defect, melt (8) 127
128 Measurement point defect, oil (9) 128
129 Measurement point defect, feed (10) 129

Causes of error:

This error is reported when a discontinuity in a sensor is detected at the corresponding measure-
ment signal input.

Error reset:

The error message disappears automatically once the discontinuity has been eliminated.

General information on output errors:

Output error messages are only generated by the DA110 output card. The later DA121
can not generate this alarms anymore. Software as from version 5.00 does not dis-
play this alarms anymore even if a older DA110 is plugged in the rack..

If an output error is reported, investigate the following possible causes:

a) The output is shorted.

b) There is a discontinuity at the output. A discontinuity will be detected even if the corresponding
output is not being driven at that moment.
c) The output is not being used. An option has been activated in the selector switch screen but this
option is not present in the machine.
d) The output is thermally overloaded.
e) The output connector for the corresponding card is not attached.

Listed below are the error messages together with the output card affected, the output pin in the
connector and the terminal. The connector pin and the terminal are listed for orientation; in case of
doubt the wiring diagram in the machines electrical cabinet is authoritative. A symbol indicates
where the status of the particular output is indicated at the machine:

 = shown in screen 8200

 = shown at an LED at the screen housing (LED in a key)
 = shown as a blinking red alarm lamp

08/12 4.4.119
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Card A1M, Connector X1M Pin Terminal

130 Motor preparation K010 ** Defect at output 130 z2 K010/A2 

131 Alarm lamp H00 ** Defect at output 131 z4 X2/68 
The alarm lamp may be burned out or loose.
132 Close mould Y10 ** Defect at output 132 z6 X2/51 
133 Open mould Y11 ** Defect at output 133 z8 X2/53 
134 Mould protection Y14 ** Defect at output 134 z 10 X2/54 
135 Clamping force applic. Y30 ** Defect at output 135 z 12 X2/52 
136 Advance nozzle Y40 ** Defect at output 136 z 14 X2/59 
137 Retract nozzle Y41 ** Defect at output 137 z 16 X2/62 
138 Injection Y50 ** Defect at output 138 z 18 X2/60 
139 Plasticizing Y53 ** Defect at output 139 z 20 X2/65 
140 Hydr. shut-off nozzle Y49 ** Defect at output 140 z 22 X2/66 
141 Decompression Y51 ** Defect at output 141 z 24 X2/64 
142 Heating zone 1 control K81 ** Defect at output 142 z 26 K81/A2 
143 Heating zone 2 control K82 ** Defect at output 143 z 28 K82/A2 
144 Heating zone 4 control K84 ** Defect at output 144 z 30 K84/A2 
145 Nozzle heating control K85 ** Defect at output 145 z 32 K85/A2 

Card A1N, Connector X1N Pin Terminal

146 Advance ejector Y60 ** Defect at output 146 z 2 X2/55 

147 Retract ejector Y61 ** Defect at output 147 z 4 X2/56 
148 Switch on motor/heating K01M ** Defect at output 148 z 6 K01M/A2 
149 Oil pre-heating Y05T ** Defect at output 149 z 8 X2/90 
150 Coolant circuit Y19 ** Defect at output 150 z 10 X2/67 
151 Air blast valve Y64 ** Defect at output 151 z 12 X2/63 
152 Screw-in, right Y70 ** Defect at output 152 z 14 X2/57 
153 Unscrewing, left Y71 ** Defect at output 153 z 16 X2/58 
154 Feed zone valve K80A ** Defect at output 154 z 18 X2/89 
155 Reject shunt K8S ** Defect at output 155 z 20 X10HG/d10 
156 Mould closed handling K10W ** Defect at output 156 z 22 X10HG/d18 
157 Mould open handling K11W ** Defect at output 157 z 24 X10HG/d20 
158 Ejector forward handling K60W ** Defect at output 158 z 26 X10HG/d24 
159 Ejector rearward handling K61W ** Defect at output 159 z 28 X10HG/d26 
160 Automatic handling K01PV ** Defect at output 160 z 30 X10HG/d16 
161 Oil cooling Y06T ** Defect at output 161 z 32 X2/75 

Card A1P, Connector X1P Pin Terminal

162 Nozzle protection (VH) Y24 ** Defect at output 162 z2 X2/73 

163 Slowly open mould Y111 ** Defect at output 163 z 4 X2/74 
164 Close safety cage Y20 ** Defect at output 164 z 6 X2/69 
165 Open safety cage Y21 ** Defect at output 165 z 8 X2/70 
166 Press. conv. at lower pos. Y31 ** Defect at output 166 z 10 X2/61 
167 Breathing mould Y33 ** Defect at output 167 z 12 X2/78 
168 Clamping force release Y35 ** Defect at output 168 z 14 X2/77 
169 Nozzle force release Y43 ** Defect at output 169 z 16 X2/76 
170 Air blast valve Y66 ** Defect at output 170 z 18 X2/92 
171 Set core B Y72 ** Defect at output 171 z 20 X2/71 
172 Pull core B Y73 ** Defect at output 172 z 22 X2/72 
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173 Cavity pressure range K54DK ** Defect at output 173 z 24 X2/91 

174 Core pull inserted K7QA ** Defect at output 174 z 26 X10HG/d30 
175 Core pull retracted K7QE ** Defect at output 175 z 28 X10HG/d28 
176 Clear scales K8W ** Defect at output 176 z 30 X10HG/d12 
177 Cavity pressure clear K54F ** Defect at output 177 z 32 X2/88 

Card A1Q, Connector X1Q Pin Terminal

178 Manual mode K01PE ** Defect at output 178 z 2 K01PE/A2 
179 Pump 2 pressure control Y02 ** Defect at output 179 z 4 
180 System separation Y09 ** Defect at output 180 z 6 
181 Injection with accumulator Y58 ** Defect at output 181 z 8 
182 Heating zone 3 control K83 ** Defect at output 182 z 10 K83/A2 
183 Brush down Y760 ** Defect at output 183 z 12 
184 Brush up Y761 ** Defect at output 184 z 14 
185 Bush rotate Y762 ** Defect at output 185 z 16 
186 A1Qz18 (bit 23.0) ** Defect at output 186 z 18 
187 A1Qz20 (bit 23.1) ** Defect at output 187 z 20 
188 A1Qz22 (bit 23.2) ** Defect at output 188 z 22 
189 Holding pressure start X541 ** Defect at output 189 z 24
190 Melt cushion position reached B56W ** Defect ... 190 z 26 
191 Change carton K8KW ** Defect at output 191 z 28 
192 Evacuation Y48 ** Defect at output 192 z 30 
193 A1Qz32 (bit 23.7) ** Defect at output 193 z 32 

The following error messages for temperature control units are transmitted to the machine from the
temperature control unit and refer to the type "HB-Therm" units made by company Grossenbacher.
We cannot guarantee that all error messages will also be generated by other manufacturers of tem-
perature control units or that the error numbers refer to the same causes. Always refer to the manu-
facturers manual in cases of doubt. Information on the action required to remedy the fault can also
be found there.
200 Temperature control unit: sensor break 200
201 Temperature control unit: overheating 201
202 Temperature control unit: level too low 202
203 Temperature control unit: temp. diff. infeed/return flow 203
204 Temperature control unit: overheating limit 204
205 Temperature control unit: motor protection 205
206 Temperature control unit: phase failure 206
207 Temperature control unit: system error 207
208 Temperature control unit controller 1 208
209 Temperature control unit controller 2 209
210 Temperature control unit controller 3 210
211 Temperature control unit controller 4 211
212 Temperature control unit controller 5 212
213 Temperature control unit controller 6 213
214 Temperature control unit controller 7 214
215 Temperature control unit controller 8 215

232 Target piece count achieved, reset (7100) 232

This message appears when the target piece count set in screen 7100 has been reached. Multiple
cavities will be taken into consideration. The machine will be stopped at the end of the cycle. The
machine cannot continue production until the piece counter in screen 7100 has been reset.

08/12 4.4.121
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4.4.8 SERIAL INTERFACES

4.4.8.1 INTRODUCTION
The PROCAN Control can provide up to four serial interfaces via the interface board A1C1. These
ports can be used to connect printers, temperature control units, scales and a host computer. One
or two interfaces are connected to 9-pin connectors on the left-hand wall of the control cabinet in the
standard version. All four interfaces can optionally be installed. Two RS232 and two RS485 are
available in this case.
The following combinations can be connected:

 1 process data printer to RS232

1 alarm printer to RS232
1 host computer to RS485
1 temperature control unit to RS485
 1 printer (process and/or alarm printer) to RS232
1 host computer to RS485
1 scales to RS232
1 temperature control unit to RS485
 1 printer (process and/or alarm printer) to RS232
1 temperature control unit to RS232

Note with regard to interface numbers: Care must be taken to ensure that the same interface
numbers (including those belonging to one channel) are not used more than once. If the selectors for
"temperature control units" or "product scales" on screen 8320 have been activated, the interface
numbers on screen 8350 ("temperature control units") or 8380 ("product scales") must not collide with
those for printers, host computers or one another. The correlation between connector and interface
numbers and their wiring is illustrated in Figure 11.

4.4.8.2 PRINTER PORT

Printers can only be connected to the RS232 interfaces. Since the data are transmitted with hard-
ware handshake protocol, it is essential to use the printer cable shown in Figure 12. Commercially
available V24 cables, etc. cannot be used. The configuration of the serial printer port must match
that of the port of the PROCAN Control. Depending on manufacturer, this is done either via DIP
switches on the printer housing or on the interface board or by entering the values in a menu. On
the PROCAN side, the appropriate inputs must be made on screen 8340 (see section 4.4.6). Incor-
rect setting of the transmission protocol at the printer port repeatedly gives rise to problems. The
term hardware handshake is not found very often in the printer manuals. Some only offer the
XON/XOFF protocol, which must then be deactivated for the hardware handshake to work. Others
do not require the XON/XOFF to be deactivated, but in these cases the CTS signal must additionally
be enabled (e.g. in the case of NEC). This information must be derived from the printer manuals.
The following printers have been tested by the manufacturer:
Printer type: EPSON LX400, EPSON LQ 870 or compatible types. The full EPSON character set
must be supported.
NEC P20 or compatible types.
IMPORTANT: The printers are often only equipped with a parallel interface. The RS232 interface
must be ordered separately.

4.4.122 08/12
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SCHNITTSTELLENKABEL: 4-FACH
(Leitrechner, Drucker, Waage, Temperiergerät...) Schnittstellen- Stecker-
25 pol.
Nummer Nummer
9 pol.(RS232)
Kanal A
1 7
RTS RTS
2 8
CTS CTS
3 2
TXD
3 oder 4 1
TXD
4 3
RXD RXD
5 5
GND GND
9 pol.(RS485)
Kanal
7 9
+TXD/RX
D
-TXD/RXD
8 4
A
+TXD/RXD
-TXD/RXD
4321
+ RXD
9 8
+ RXD 7 oder 8 2
10 3
- RXD - RXD
11 5
GND GND
9 pol.(RS232) 4231
Kanal
13 7
RTS B RTS

CTS
14 8
CTS Die Anordnung
TXD
15 2
TXD 9 oder 10 3 der Stecker
16 3
RXD RXD variirt mit dem
17 5
GND GND
9 pol.(RS485)
Herstell-
19 9
Kanal B ungsdatum der
+TXD/RXD +TXD/RX
-TXD/RXD 20 4
D
-TXD/RXD
Maschine
+ RXD
21 8
+ RXD 11 oder 12 4
22 3
- RXD - RXD
23 5
GND GND
25
SCHIRM
0.75 Meter
0.15 Meter
Kabel von Interface-Karte nach Schaltschrankwand
1-fach (nur Stecker 1) 9631244
Schnittstellenbelegung REDIS 31B2
2-fach (Stecker 1 und 2) 9631254
n.Z. 156799-4 4-fach(Stecker 1-4) 6004663 (1567994)
Baugruppe:4663

Figure 13: Interface lead and numbering

Druckerkabel DATENÜBERTRAGUNGSKABEL METTLER-WAAGE

MiniMETTLER connector
ÜBERTRAGUNGSKABEL ZUM DRUCKER (procan control) ME-33930
6
1 11

9 pol. 25 pol. 7
2 12
8 20 8 am Metallgehäuse anlöten
CTS CTS 3 13
2 3
TXD TXD 10

7 5 15
5
GND GND
1 1
SCHIRM SCHIRM D-SUB STECKER
15 pol. 9 pol.(RS232)
Schaltschrankseite Druckerseite Kanal B
2 2
RXD TXD
3 8
DTR CTS
12 3
TXD RXD
13 5
GND GND

15.0 Meter

2.5 METER

Parameter: Waage Maschine

Menue: I-FACE- Bildschirm 8380

S. = Stb Schnittstelle =9
b = 9600 Bautrate = 9600
P = -E- Parität = EIN
Teile-Nr.: 6014662 PAUSE = 1 Par Typ = Even
Au = OFF Time out = 2sec

Schnittstellenbelegung Mettler Waage

n.Z. 156855-4
Baugruppe:4607

Figure 14: Data lead between printer and Mettler scales

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4.4.8.3 INTERFACE FOR SCALES

When the injection moulding machine is equipped with product scales, screen 8380 can be called up
to configure the scales via selector S7AB1. The part weight for tolerance monitoring (screen 7220)
can also be selected on screen 7230.
Note: The product scales data interface has nothing to do with the turn-out scales which monitor the
turn out of a part via input B18.
Scales can only be connected to the RS232 interfaces. All tests carried out by the manufacturer
used the protocol of the Mettler PM2000. The pin assignment of the data lead can be seen in Fig-
ure 12.
Further information can be found in section 4.4.6, under the description of screen 8380.

4.4.8.4 INTERFACE FOR TEMPERATURE CONTROL UNITS

Temperature control units are available with both RS232 interfaces and RS485 interfaces. In many
cases, the temperature control units are sold with a standard current interface, but these are not
supported by our machines. The majority of temperature control units are optionally available with
RS232 interface. The RS485 is rarely offered. The transmission parameters are set after activating
selector S7AB2 on screen 8350 (see description in section 4.4.6).
The following units have been tested by the manufacturer:

Temperature control units: HB-Therm

GWK
Regloplast
Single

The pin assignment of the connecting leads is illustrated in Figure 13.

4.4.8.5 HOST COMPUTER INTERFACE

The host computer can only be connected to an RS485 interface. The transmission parameters are
set on screen 8340.

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Datenübertragungskabel Temperiergeräte

Parameter Temperiergerät Maschine

gwk Schnittstellenbelegung Dr. BOY
Bildschirm 8350
Übertragung Schnittstelle =9 D-Sub Stecker D-Sub Stecker
= asynchron
Baudrate = 4800 Schnittstellentimeout = 5sec. 9 pol.(RS232)
25 pol.
Parität = gerade/even Zyklische Istwerterfassung = 1 sec. 1
Kanal B
Schirm
Bit-Reihenfolge = 1 Startbit 2 3
TXD RXD
8 Datenbits 3 2
RXD TXD
1 Paritätsbit 7 5
1 Stoppbit GND GND
4 7
RTS RTS
5 8
CTS CTS
Schnittstellenbelegung EN GND
4

HB-Therm EN 3
5

Tool-Temp
Regloplas Dr. BOY
D-Sub Stecker D-Sub Stecker
Single Schnittstellenbelegung Dr. BOY
25 pol. 9 pol.(RS232)
Kanal B
1
Schirm D-Sub Stecker D-Sub Stecker
2 3
TXD RXD 9 pol.(RS232)
3 2 9 pol.
RXD TXD 1 Kanal B
7 5 Schirm
GND GND 3 3
RTS
4 7
RTS TXD RXD
2 2
5 8 RXD TXD
CTS CTS 5 5
GND GND
6 7
GND RTS
7 8
GND CTS
Brücke nur bei HB-Therm Best.-Nr.: 19903 (6m)
Regloplas Regloplas Best.-Nr.: E00405 (5m)

Figure 15: Data transfer lead for temperature control units

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4.4.9 IMPORTANT SPARE- PARTS

Code Description Type Part-No.

A1E 1. - 2. Control board, 8 Analog-Inputs2 Analogue-Outputs, 2 RK 100 9626468

A1G counter inputs
A1E 1. - 2. Control board, 8 Analog-Inputs2 Analogue-Outputs, 2 RK 101 9626535
A1G counter inputs. With comparator circuits (new version)
A1H 1. - 2. Temperature board (10 Inputs) TK 110 (older) 9626467
A1J with integrated compensation resistor
A1H 1. - 2. Temperature board (10 inputs) TK 100 (new- 9626534
A1J with external compensation resistor er)
A1D Control -CPU (with sequence program) RC 100 9626466
A1D Control -CPU (with sequence program) RC 100 9626508
for brush control (2 EPROMs)
A1D Control -CPU (with sequence program) new version with big RC 101 9626530
Eprom
A1M 1. - 4. Digital output board (16 Outputs) DA 110 9626465
A1N DA121 9626593
A1P
A1Q
A1K 1. - 2. Digital input board (32 Eingänge) DE 100 9626464
A1L
A1B CPU-board REDIS (Communication) carries EPROM-sandwich REDIS 31B1 9626463
board REDIS 31E with user- program (language)
A1C1 1. - 2. Interface-board 4-fold serial with floppy controller REDIS 31B2 9626472
A1C2
A1A2 Coupling- board with battery carrier, Battery 9621003 KK 100 9626462
A1A2 Coupling- board with battery carrier, Battery 9621003 KK 110 9626531
A1A1 Power supply Input 24 V DC (18-36 V DC), Output 5V/5A and NK 100 9626461
12V/1, 5A
A1A1 Power supply Input 24 V DC (18-36 V DC), Output 5V/5A and NK 1101 9626573
12V/1, 5A (with battery holder)
Card rack old as a single spare part 9636044
Card rack assembled with mit 9629013
Netzteil NK100 9626461
Koppelkarte KK100 9626462
REDIS 31 B1 9626463
DE100 9626464
DA110 2 Stück 9626465
RECON RC100 9626466
TK110 9626467
RK100 9626468
Card rack like above but with 9629025
Koppelkarte KK110 9626531
RECON RC101 9626530
TK100 9626534

Card rack as above but with 9629027

RK101 9626535

4.4.126 08/12
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Keycard 1 9629016
Keycard 2 9629017
Keycard 3 9629018
A21 Screen unit, complete old style with movable flap 9629014
A21 Screen unit, complete new style with not moving flap 9629051
Cable kit for screen unit 9631250
Cable kit for screen unit 4m long 9631272
A4D Floppy drive (replaced by 9626536) 9626479
A4D Cable for floppy drive 9626479 9631243
A4D Floppy drive new 9626536
A4D Cable for floppy drive 9626536 9631257
Screen background light Sharp (old) 9613032
Screen background light Hitachi(new) 9613030
keyboard foil operating keys right 9629019
keyboard foil operating keys left 9629020
keyboard foil functional keys (8 yellow keys) 9629021
keyboard foil keyboard flap 9629022
keyboard foil complete set 9629023
Keycard reader 9629026
Backplane for board carrier (bus-board) with socket for cou- 9626545
pling board KK101
Backplane for board carrier (bus-board) for new power pack 9626594
without socket for coupling board

4.4.10 TOOLS

Desciption Best.- Nr.

WZ 01

WZ 02

WZ 03

WZ 04

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4.4.128 08/12