Gilogic_GT-C Manual En

GILOGIC II/GT-C SYSTEMInjection Molding Machine Control

Operator Manual

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This pubblication is the property of GEFRAN spa. Any divulgation or reproduction of it as a whole or in part in forbidden unless

expressly authorised.

While every care has been taken during the preparation, the compilation and checking to ensure the accuracy of the information

contained in this manual, GEFRAN spa cannot assume any responsability for events caused by the use of the same.

The same statement is made on behalf of all persons and companies involved in the creation and the production of this manual.

GEFRAN spa reserves the right to make design or functional modifications, without prior notice and at any time.

© Copyright 2005 - Gefran S.p.A. - Tutti i diritti riservati

Injection moulding machine – Gefran system Gt-C + Gilogik2 Pag.2

1. Index page 1. Index page ......................................................................................................................................................... 3 2. Manual structure ................................................................................................................................................ 5

2.1. List of screen pages ................................................................................................................................... 5 2.2. Call the screen pages ................................................................................................................................. 6 2.3. Structur of screen pages............................................................................................................................. 6 2.4. Set the parameters...................................................................................................................................... 6

3. Screen Pages Description .................................................................................................................................. 7 3.1. Page “00 Logo” ......................................................................................................................................... 7

3.1.1. Data corrupted or losed...................................................................................................................... 8 3.2. Page “01 Main menu”................................................................................................................................ 9 3.3. Page “02 Heating” ................................................................................................................................... 10 3.4. Page “03 Hot runner” .............................................................................................................................. 12 3.5. Page “04 Schedule” ................................................................................................................................. 13 3.6. Page “05 Temperature graph” ................................................................................................................. 14 3.7. Page “06 Mold close” .............................................................................................................................. 16 3.8. Page “07 Mold open” .............................................................................................................................. 17 3.9. Page “08 Ejector” .................................................................................................................................... 18 3.10. Page “09 Cores”................................................................................................................................... 20

3.10.1. Page “Cores Options” ...................................................................................................................... 22 3.10.2. Page “Cores special cycles”............................................................................................................. 23

3.11. Page “10 Accessories”......................................................................................................................... 24 3.12. Page “11 Injection profiles” ................................................................................................................ 26 3.13. Page “12 Charge profiles” ................................................................................................................... 28 3.14. Page “13 Carriage/Purge”.................................................................................................................... 29

3.14.1. Page “Auto purge”........................................................................................................................... 30 3.15. Page “14 Injection graph”.................................................................................................................... 31 3.16. Page “15 Production data”................................................................................................................... 32 3.17. Page “16 Quality selection”................................................................................................................. 33 3.18. Page “17 Quality display” ................................................................................................................... 33 3.19. Page “18 Quality graph”...................................................................................................................... 35 3.20. Page “19 Mold data internal” .............................................................................................................. 36 3.21. Page “20 Mold data external”.............................................................................................................. 38 3.22. Page “21 Printer” ................................................................................................................................. 39 3.23. Page “22 Machine status”.................................................................................................................... 40 3.24. Page “23 Actual alarms”...................................................................................................................... 41 3.25. Page “24 Alarms history” .................................................................................................................... 42 3.26. Page “25 I/O Diagnostic” .................................................................................................................... 43

3.26.1. Page “Node diagnostic”................................................................................................................... 44 3.26.2. Page “25.A I/O digital output” ........................................................................................................ 45 3.26.3. Page “25.B I/O analog output” ........................................................................................................ 46 3.26.4. Page “25.C I/O digital input” .......................................................................................................... 47 3.26.5. Page “25.D I/O analog input”.......................................................................................................... 48

3.27. Page “26 Easy data setting”................................................................................................................. 49


3.28. Page “27 Settings history” ................................................................................................................... 50 3.29. Page “28 General setting”.................................................................................................................... 51 3.30. Page “29 Analog input setup” ............................................................................................................. 52 3.31. Page “30 Analog output setup” ........................................................................................................... 53 3.32. Page “31 PID Parameters”................................................................................................................... 54 3.33. Page “32.1 Limits/Ramp”.................................................................................................................... 55 3.34. Page “32.2 Limits/Ramps” .................................................................................................................. 56 3.35. Page “33 Close loop setting” ............................................................................................................... 57 3.36. Page “Service function”....................................................................................................................... 58

3.36.1. Page “Linearization”........................................................................................................................ 58 3.36.2. Page “Pumps setting” ...................................................................................................................... 59 3.36.3. Page “Keyboard diagnostic”............................................................................................................ 60 3.36.4. Page “Service function”................................................................................................................... 61 3.36.5. Page “Local net management”......................................................................................................... 62 3.36.6. Page “Machine configuration” ........................................................................................................ 63


2. Manual structure

2.1. List of screen pages

00 Logo page, called by system start-up 01 Main menus

02 Heating zones 03 Hotrunner 04 Schedule

Heat group

05 Temperature graph 06 Mold close 07 Mold open 08 Ejector 09 Cores

Mold group

10 Accessories 11 Injection profiles 12 Charge profiles 13 Carriage/purge

Injection group

14 Injection graph 15 Production data 16 Quality selection 17 Quality display

Production data

18 Quality graph 19 Mold data internal 20 Mold data external Mold data group

21 Printer 22 Machine status overview 23 Actual alarm 24 Alarm history 25 Diagnostic I/O 25A I/O digital output 25B I/O analog output 25C I/O digital input 25D I/O analog input 26 Easy data settino

Machine status

27 Settino history 28 General setting 29 Analog input calibrations 30 Analog output calibrations 31 PID parameter 32.1 Limits/ramps 32.2 Limits/ramps

Calibration group

33 Close loop setting


2.2. Call the screen pages

The system permits to select a page in following 3 ways:

1) In MAIN MENU, all pages are identified by a head title and by a number (can used for the print function), insert the number to search the page;

2) Press the F key in F2~F8 which represents the function group the searched pages belongs first. All the pages in this group are identified by graphic icons in the bottom-side horizontal-strip of the page. You have to press the F key to access at the right page.

3) Pressing the Fn key for this group once and once again until the right page displayed. But above 3 methods are not used for searching the pages with the identify number great than 28. The only way to access these pages is first come into page 28 in MAIN MENU and then select the relative icon.

2.3. Structur of screen pages

The main fields of this page including 7 parts: 1) Left-high: Actual Date and Time display; 2) Center-high: Page Title and Number; 3) Right-high: Showing the limits for settings (max,min);0/1 for selectors; multi-selectors; 4) Setting Zone: This zone is in the center page for setting, displaying graph; 5) Group Selection Zone: It’s in the lower side, bar graph with 8 icons for group-selection 6) Message Display Zone: Actual alarm display and password level indication. It locates

below the group Selection Zone.

2.4. Set the parameters

• Numerical parameter: data input by numeric keyboard; enter for conferm; insert

password if needed; number must be in limits; • Yes/No selectors: the setting method is first moving the cursor to the selecting area and

then press “ENTER”, the selection “YES” or “NO” will be showed; • Multiple selector: there are 2 or more selections possible in one setting area and it’s

displayed a selection description. The selecting method is as same as the “YES/NO selectors”.

• Alphanumeric data input : only provided in mold data storage or load, press ENTER in character input and select char with arrow key Up or Down


3. Screen Pages Description

3.1. Page “00 Logo”

This page contains: the Company Symbol, the Software Program Identification Code, the Firmware Version Identification Code either for PLC and for Control Panel. It also gives the message “ WAIT PLEASE……”. When the power on, the system first self-diagnose just like a personal computer ,checking all the hardware and if no problem this screen will be displayed .This page means the system is uploading the software and this process need about 10 seconds. When it finishes, page “01 MAIN MENU” will appear automatically.


3.1.1. Data corrupted or losed

If there is some problem with variables (variables corrupted or losed) the video page00 appear in this way. The operator has to restart the pc and after he has to load the variables recipe.


3.2. Page “01 Main menu”

This page will be displayed automatically after page 00. When in other pages, this page can be recalled by F1 key. Here a page can be selected freely in three ways: one is moving the cursor to the page which the operator wants and then press “ENTER”; another is inputting the page number in “SELECTION PAGE :”, then press “ENTER”; another is through the F key (F1-F8) If a new data will be input, the right password level should be efficient. This system supplies 3 password levels: level 1 is for setting the normal operation data; level 2 is for selecting the special function, such as output test, analog input calibration ; level 3 is the highest level and all settings are possible. Level 1 and level 2 can be changed in page 28, but level 3 is unchangeable. Every time that the system starts, the password should be inputted. Once a password inputted, the corresponding password level will keep efficient until the screen sleep works. If the required password level not efficient when you press “ENTER” to input a new data, at the left-down corner a message will appear. For example , “PASSWORD (Liv,1)… ”, this message means need password level 1, so the operator must input the password level 1 in page 01. In this page ,the screen brightness can be adjusted by F1 software key, after pressing F1, a red pane will display in the icon above F1, it means that the brightness can be adjusted .Then press the cursor “up” or “down” to adjust the screen brightness light or dark. On TFT color display this function is not active.


3.3. Page “02 Heating”

This page is made by 4 sections(besides the 2 bar-graphs with icons):

1) Temperature bar graphs for real and setting values of 7 zones; 2) Cylinder drawing is for displaying the real statues of every heaters (nozzle and 6 zones); 3) Temperature setting zone:

MODE-There are 3 modes for heating. (1) PID : automatically heating by PID regulation; (2) MANUAL : heating on continually with setting power (SET MAN) without check real temperature; (3) OFF: heating off.

SET [°C] -The set temperature value; MAX +[°C] -The set temperature upper limit, and this is a relative value; MIN - [°C] -The setting temperature lower limit, and this is a relative value; SET [%] -Only in MANUAL heating mode this setting is efficient. It is the heating

time ratio, its value equal: time for heater on in unit time / unit time. For example: set [%]=15,it means the heating

regulation is 15 seconds for heater on in 100 seconds. In fact, this value can be considered as heating power.

REAL [°C] -Display the real zone temperature; REAL [%] -Display the real heating power; ALARM-There are 5 kinds of heater alarms in the system. real temperature lower than the setting temperature; real temperature higher than the setting temperature; thermo couple wire broken; heater wire broken; heater wire short-connection ;


4) Function setting zone: “HISTOGRAM MAX SET POINT”- this value is the maximal temperature setting value,

it is as same as the “MAX VALUE” in page 30; “MAX CABINE TEMPERATURE”-this setting value is the maximal cabin temperature,

the thermocouple is inside the PLC. If the real cabin temperature is high than the setting value, a alarm will be display but not stop any movement.

“WAIT MODE” is a special function. This function is used for keeping the barrel temperature when the machine stops temporarily.

For example: The operator will leave to lunch at 11:00 and he wants stop the work during his lunch time. He does not want to turn off the heating because that will waste some time when he begins to work this afternoon. But if still turn on the heater ,the setting temperature (for example 200°C) is too high and it is not good for the material in the barrel. He only want 50°C to keep the temperature of barrel . He will come back at 12:00 and he hopes the system will begin to heating at 11:50 .So when he comes back this afternoon, he can work right now. To realize this requirement, when the operator leaves he first select “WAIT MODE” as “YES”, then set “PERCENTAGE OF SET” as “25%” (200°C ×25%=50°C ), finally set “WAIT TIME” as “50” minutes.


3.4. Page “03 Hot runner”

This page is for heating the hot-runners(option function). The using method is similar to the

page “HEATING”.


3.5. Page “04 Schedule”

This page is for the function of pre-heating barrel and hot-runners(option function) by internal clock and calendar. the operator can set each working day of beginning and stopping in a week, either for BARREL or for HOT-RUNNER in 2 different sections.


3.6. Page “05 Temperature graph”

This page is for displaying the temperature graph of each heating zone (including the oil temperature) in past 24 hours. The system will sample and store the temperature of each zone every 5 minutes. There are 2 coordinates in this page. On the Y axis of coordinate ,the upper value and the lower value can be set, so the graph can be enlarged or reduced. The “partial view” can display the temperatures freely by the function keys in the right icons bar. The “total view” can display the temperatures in past 24 hours. The section between the two coordinates is for selecting the displayed zones. At the same time, maximal value of displayed zones is 4. Move the cursor to the selecting part, press “ENTER” , one zone name will displayed, press “ENTER” continually until the required zone displayed. The temperature value will be shown at its right side. The low section is for function selecting. “Grids” is the function for selecting the grids in 2 coordinates or not. “Selection” is the function of displaying partial view. Here only displaying the selected tool and the tool is selected with the function selection keys “Func” in the bottom side icons bar. “--->” and “<---” are the assistant function keys. Move the cursor in the “Func” then press “ENTER” , the tool name will displayed in the right side of “Selection”. The tools in “Func” includes “Cursor 1”, “Cursor 2”, “Stop acquisition”, “Clear graphics”. “Cursor 1” is the left Y axis in the coordinate of “partial view”, after select “Cursor 1” then can move the left Y axis to left or right using the assistant function keys “<---” or “--->”. When the cursor 1 moved, the left displayed time will changed every 5 minutes. “Cursor 2” is the right Y axis in the coordinate of “partial view”, the use method is as same as the “Cursor 1”. When the cursor 2 moved, the right displayed time will changed. So by moving cursor


1 and cursor 2, the partial view display time can be changed, the operator can set the time zone that he interested . “Stop acquisition” is for freeze the graphics, in this way the operator can show always the situation in this moment. “Clear graphics” is for erase all data about graphics and restart.


3.7. Page “06 Mold close”

This page is for setting the data of mold close. There are 5 steps in closing mold. Setting the position, speed and pressure in sequential steps. The zero position for mold movement is the end position of closing mold. The setting position of each step is the change point, for example, like the above screen, the change point from step 1 to step 2 is 250.0mm, that means during closing mold the speed and pressure are 60% and 120 bar separately when the real position is great than 250.0mm. If the real mold position is between 250.0 and 50.0, the outputs of the speed and pressure will be 80% and 140 bar. Step 5 “mold clamping” has not the setting position because the end position of closing mold is not judged by position but by the limit switch “Finish close mold”. The section below the 5 steps is the graph for setting, from this graph, the operator can check his setting and read the real mold position. The lowest section is for function selection and time setting. The selection “High speed mode” is for selecting a valve named “High speed valve” will open during the high speed closing zone. The “Close time” is for setting the whole time of closing mold . If the real time exceeds the setting time, the alarm as “Close mold overtime” will displayed and the movement stops. The “Protection time” is for protecting the mold, the setting position is the position when the two parts of the mold begin to connect, the setting speed and pressure should be lower, so if something is in the mold, during step 4 “Mold slow”, this timer starts and it will exceed the setting time because the pressure and speed are low, then a alarm displayed and the mold could be protected.


3.8. Page “07 Mold open”

This page is for setting the data of mold open. The screen and setting method are similar to Page “MOLD CLOSE”. The only different is the “Stop position tolerance”. This tolerance is used to control the ejector forward. If the real mold position is between the upper tolerance and the lower tolerance , the ejector could forward, otherwise forbid. The upper tolerance = the setting position of step 5 + “tolerance +”; The lower tolerance = the setting position of step 5 - “tolerance -”; Attention: The system will output zero pressure and speed when the mold position of lower tolerance reached and the aim of working as such is to reduce the inertia.


3.9. Page “08 Ejector”

This page is for ejector . The up-left section is for ejector forward. It has the setting graph and setting zone. The “Delay time” is executed before the ejector forwards. The time is used to avoid the pressure influence of last movement. The up-right section is for ejector backward. It is similar to the Forward section. But please notice that the position for step 2. Here a small value not zero can be set, for example 2mm. By this, the mechanical strike can be avoided. The reason is the system will output zero for pressure and speed when this position (step 2) reached, the ejector could return to the back end with inertia. Notice: The position for step 2 must not set too great, otherwise the ejector can’t return to the end point by inertia and the switch named “BACK END” will not on, so the system forbids closing mold! The ejector action has three working modes: “Single” means :the ejector only forwards one time no concern with the ejector counter. In manual mode, press the “ejector for.” Key, the ejector forwards and then stops when it reaches the end position. In semiauto mode, the ejector only forward once, in next cycle, the ejector first backward when the cycle starts. This mode can’t used in Full-Auto mode. If this mode is selected in Full-Auto mode, the Full-Auto mode will be converted to Semi-Auto mode automatically. And if this mode is selected, the Full-Auto mode is inaccessible ,in this condition, press the “FULLAUTO” key, the light for “SEMIAUTO” will be on. “Normal” means: the ejector forwards to the setting point and then backwards to end point several times as the number set in “Ejector counter”. In manual mode, press the “EJECTOR


FORWARD” continually ,the ejector works as same as in Auto mode. “Vib” means vibration , the difference with “Normal” is the back movement, the ejector only backwards to the position of step 1 and then forward. Just in the last time, the ejector backwards to the position of step 2. “Ejector counter” is for setting the times of ejector movement. The system permits one working mode efficient in the same time. So if one working mode is selected as “YES” the others will be “NO” automatically. All for “NO” is permit in condition of only ejecting by air. The low-right section is for air ejecting. The setting position is the point that the air valve on. If the operator wants use this function , first set “SELECT” as “YES”.


3.10. Page “09 Cores”

This page is for cores. The software supplies 2 terms of cores and 2 terms of unscrews. The unscrew can be used as core. So 4 terms of cores can be used at most. Now we can use core 1 as an example to explain how to set the data: Only selecting the core 1 as “YES”, it can work. The selection column is in the first line. “POS mm” is for setting the position of core in and core out. If the setting position is just in the closing path when closing mold, the mold closes to the setting position and then stops, the core begins to move in, after core in finishes, the mold continues to close again. Core out works just like this. If the operator wants the core moves in before closing mold, he should set the position greater than the real open end position, so first core in and then close mold when the cycle starts. If the operator wants the core moves in after closing mold, he should set the position as “0”, the core will move in after closing mold. If the operator wants the core moves out before opening mold, he should set the position as “0”, so first core out and then open mold. If the operator wants the core moves out after opening mold, he should set the position as a value between the real open stop position and the open mold tolerance lower limit, because the position can’t reached if the setting is greater than the real final position, then the core will out after closing mold. If the setting core in and out positions of core 1 and core 2 are same, the move sequence is first core 1 in then core 2 in and first core 2 out then core 1 out. Speed and pressure of core only has one step. “TIME” has the different functions in mode SIGNAL and mode TIME (option page). In “SIGNAL” mode ,this time is the alarm time, if the real time exceeds the setting, a alarm will


appear and the movement stops. In “TIME” mode ,it is the moving time. “DELAY” is the delay time before core moves, its function is as same as the ejector delay time. The setting method for unscrew is similar to core. If the operator wants to use “unscrew 1” as “core 3”, move the cursor to “unscrew 1” then press “ENTER”, the “core 3” will displayed. The counter number should be set when used as unscrew. In the middle page it’s possible to select easier cores in sequence. If select 2 or more cores, by select “IN SEQUENCE” YES, by select cores IN or OUT at moold open position, cores IN before mold close and cores out after mold open end. This, without check mold IN/OUT position set. At same, if select cores IN or OUT at mold close position, cores IN when mold close END and cores OUT before mold open. If select at position, only by set common position, cores IN or OUT at same position. Don’t check each core IN / OUT position set. On “CORES OPTIONS” page, it’s possible select the sequence IN and the sequence OUT It’s possible select special cores functions in page “SPECIAL CYCLES”


3.10.1. Page “Cores Options”

Page for cores options. “MODE” has two selections: one is SIGNAL, the positions of core in and core out judged by two limit switches; another is TIME, the setting time controls the core in and core out. “HOLD” is selected as “YES”, for example, the valve for core in will on when injection. Otherwise, the valve not open. “D. MOLD” is the function that the core can work during mold movement. That is to say ,core in during closing mold and core out during opening mold. This function is unavailable in this machine. Set sequence if selected on page CORES. Set minimum speed and pression need to move mold for reatch cores IN/OUT position when is an intermediate mold position.


3.10.2. Page “Cores special cycles”

In this page the operator can set a special cycles for every cores and set the delay time.


3.11. Page “10 Accessories”

This page is for lubrication, mold adjustment and robot. 1) Lubrication:

Lubrication MODE : Number of cycles mean that every Nr machine cycles in auto or semiauto mode, set on Cicle Nr…., start lubrication. Interval Time mean that every Interval time seconds, set below, (timer start when machine work in auto or semiauto mode), start lubrication.

Lubrication at 1st cycle : when machine start at first auto or semiauto cycle, execute lubrication Lubrication type…: there are 3 types of lubrication Time : lubrication cycle consist in set digital output for lubrication for work time

set below. Pressure 1: lubrication cycle consist in set digital output for lubrication until read digital input signal from lubrication pressure switch. Work time is alarm time. If pressure switch not ON before end alarm time, lubrication alarm is set ON. Pressure 2: lubrication cycle consist in set digital output for lubrication for work time. During lubrication time, if pressure switch not ON, lubrication alarm is set ON.

2) Mold adjustment: Here the pressures and speeds for close mold, open mold, mold adjust forward and mold adjust backward can be set .The setting pressures and speeds should not be too high ,especially for mold adjustment. We comment 50bar and 40 % are the up limit. In manual mode, press the “AUTO MOLD ADJUST” key once, the light of “AUTO MOLD


ADJUST” becomes on and the light of MANUAL becomes off, it represents now is in the manual mold adjust mode. In this mode, close mold, open mold, carriage forward, carriage backwards, mold adjust forward and mold adjust backward can works by pressing the relative keys. This time, the movements use the special pressures and speeds not same as the normal movements in other working mode. The carriage movements will not limited by setting position, it only stopped by mechanical parts. Press the “AUTO MOLD ADJUST” key twice, the system comes into the auto mold adjust mode. In this mode, close the safety door and press the “MOLD ADJUST FORWARD” key once, the auto mold adjust starts. Press the “AUTO MOLD ADJUST” key again, the adjustment can be interrupted. When the adjustment finish or interrupted, the system converts to manual working mode automatically. 3)Robot (option function): Here select the robot as “YES” if the robot be used. And select the time when the robot starts. When the robot finishes, the next cycle starts. 4) “Photo detect” is the selection for using a photo sensor in full auto mode 5) “Auto door” is for use the doors in automatic mode; in this machine this function is not available.


3.12. Page “11 Injection profiles”

This page is for setting the data of injection. The up-right section is for injection including 6 steps. The up-left section is for holding pressure including 5 steps. The middle of the screen is the graph for setting data. Below the graph is the section for function selection. The zero point of the screw movement is the end position of injecting. So the setting position of step 1 is greatest and step 6 is the end point.

“Holding selection”: It is to select the type of converting from injection to holding pressure. In this system there are three types to select.

1) TIME: Set a whole injection time, when this time is exceeds, the injection changes to holding pressure automatically. In this mode, the outputs for pressure and speed depend on the setting position as same as in mode POSITION. Below the section for holding pressure, the whole injection time can be set in “Injection time”.

Attention: in other two modes, this time is used for alarm. In this setting time, if the end point of injection not reached, an alarm will occurs and the movement stops.

2) POSITION: The injection end position is the setting position of step 6, the injection converts to holding pressure automatically if this position reached.

3) PRESSURE: During injection, when the system pressure is higher than the setting, the injection stops and holding pressure starts. Below the up-left “Injection time”, a pressure of converting point can be set.

“Cushion check”: This function is for controlling the product quality by detecting the end position of holding pressure. “Cushion point” is for setting the standard end position. “Tolerance +” is a relative value for setting the cushion upper limit. “Tolerance -” is a relative value for setting the cushion lower limit.


Real upper limit = “standard cushion point” + “tolerance +”; Real lower limit = “standard cushion point” - “tolerance - ”.

In full auto mode, when this function selected, if the real end point out of the upper limit and lower limit, a alarm occurs and the next cycle stops after this cycle finished. In manual mode, press the “INJECT” key continually, the injection and holding pressure can be executed sequentially.


3.13. Page “12 Charge profiles”

This page is for charging and suck back. The upper section is for setting the charging, the “BACK-PRESS” is for setting the value of back pressure. In this machine, the system can’t control the back pressure, the back pressure can only adjusted by manual so setting the back pressure is no of use. In manual mode, press “CHARGE” key one time, the charge movement works continually even releasing the key. When the charge end position reached, the movement will stop automatically. During charging, press the “CHARGE” key again, the charging will be interrupted. The following section is for setting the suck back. “Suck back before charge” is able to select and this function only executed in auto mode. “Suck back after charge” is standard. In manual mode, pressing the “SUCK BACK” key, the setting data of “Suck back after charge” will be executed. The lower section is for setting timers. “Charge time”: it is for setting the maximal permitted charge time. When the real time exceeds the setting time, an alarm occurs and the charging stops. “Delay before charge” is for setting the delay time before charging. “Cooling time” is used for setting the time for cooling the product. This timer starts when the holding pressure finishes. If this timer not reach the setting time, the mold can’t open. During the cooling time, the machine can execute the other movements sequential except mold movement and cores. This time is only efficient in auto mode.


3.14. Page “13 Carriage/Purge”

This page is for carriage movement and auto purge. The left section is for carriage movement. The zero position of carriage is the end point for carriage backward. Carriage forward has two steps. In manual mode, carriage backward has two steps. But in auto mode, carriage backward only works step 1. “Carr. Safety time” is for setting the alarm time during carriage forward. If in this setting time the carriage can’t reach the final position, an alarm occurs and the movement stops. “Carriage back” has three selections: 1) BEFORE CHARGE is carriage backward before charging;

2) AFTER CHARGE is carriage backward after charging and suck back. 3) NO MOVE is carriage not backward so that decreasing the cycle time.

The right side section is for auto purge.


3.14.1. Page “Auto purge”

This function only can be executed in manual mode. First select the “Auto purge selection” as “YES”, then press the “AUTO PURGE” key once, purging starts. The working method is as same as lubrication. Press the “AUTO PURGE” key again, the movement interrupted. Attention: Before purge, move the carriage to the back point so that the nozzle can’t touch with the mold. “Purge time” is for setting alarm time. If in this time the movement not finish, an alarm occurs and the movement stops. “Counter repeat” is for setting the purge times. Because only one time, maybe the barrel can’t be cleaned.

Then the operator can set the two steps injection, two steps charge and one step suck back. The purge sequence is inject->charge->suck back.

The two steps charge is setting by time not by position.


3.15. Page “14 Injection graph”

This page is for displaying the injection curve. The range of Y axis in coordinate can be set. Y axis can display the injection speed and pressure. The lower section is for function selection. “Pressure” has three selections:

1) none: not display the pressure curve; 2) real: display the real pressure curve; 3) real+memo: display the real curve and the memorized curve, so the operator can compare

the two curves. “Speed” selection is as same as “Pressure”.

“Time setting” is for setting the display time. The injection real data during the period between the injection beginner and this setting time are memorized and displayed.

“Selection” includes: “cursor 1” is the left X axis in the coordinate, the operator can use the two keys “---->” and

“<----” to move the axis, so the displayed range can be changed. Like “cursor 1”, “cursor 2” is the right X axis in the coordinate. “memorized” is to store the current curve as the memo curve, and the original memo curve will

be erased. “Axis X” can select “Time” or “Position”, it will change the variable of X axis . “Grid” is for selecting the grids displayed or not in the coordinate.


3.16. Page “15 Production data”

This page is for production data. “Total production piece”: This is for setting the product quantity . In auto mode, the counter increases one piece every holding pressure end. A message will displayed if the real counter equal the setting and the next cycle stops automatically. “Bad pieces product”: This function is to count the bad product. “Remaining piece”: This is to count the remain product. “Production hours”: This is to display the real working time. “Production hours remaining”: This is to display the working hours for remaining product. “Production average pre hour”: This is to display the product number pre hour. “Today production”: This is to display the working hours for current day. “Yesterday production”: This is to display the working hours for last day. “Last cycle time”: This is to display the real time for last cycle. “Actual cycle time”: This is for setting the maximal cycle time and displaying the real cycle time. If the real cycle time exceeds the setting time, an alarm occurs and the next cycle stops in auto mode. “Interval time”: This is for setting the interval time between every two cycle in Full time auto mode.


3.17. Page “16 Quality selection”

This page is for quality control. There are 20 variables for quality control. The operator can select freely at maximal 6 variables to control quality at the same time. Each variable has two sections, “SELECT” is to select this variable or not; “MIN” is to set the minimal value for quality control; “MAX” is to the maximal value for quality control; “ALARM” is to select the alarm displaying or not when the real variable out of the setting. The priority of the variables is from up to down. Because at the same time only 6 variable can be selected, if the operator selects the 7th variable, the variable with the lowest priority will be discarded. Notice: The latest variable “CLAMPING FORCE” is not useful, because the force sensor is unavailable in this machine.

3.18. Page “17 Quality display”


This page is for displaying the quality variable. The upper section is for displaying the real selected quality variables of latched cycle. The maximal number is 200. The quality variables are selected in page 16. The middle section is for displaying the minimal value ,average value and maximal value among the latched values. In the lower section the operator can decide how many cycles to latch once. And can erase the latched values in one screen . With “Stop production” function the operator can choose to stop production if there are too much cycles off band. Here also supply the print function. At the bottom, the two keys is the scroll up key and scroll down key, using these two keys, the operator can look the variables in other cycles freely.


3.19. Page “18 Quality graph”

This page is for displaying the quality curve. Choose the variable with F6-F7 key, other selected variable will be displayed and the graph changes correspondingly. From this curve, the operator can know the quality trend clearly.


3.20. Page “19 Mold data internal”

This page is for mold recipe storage and load. The mold recipe is written in the internal memory zone. The F4 key is for storing the current mold data to EPROM, the F5 key is for loading the mold data from EPROM to the current mold data. “Selection NR. ID CODE”: It is the number of the mold recipe in EPROM, range is 0~29. “ID code”: It is the code of the mold recipe, the operator can define it freely, but here only the numerical key can be input. “TYPE(0=MOLD 1=SETUP)”: It is for selecting the type of the mold recipe. “0=MOLD” is the parameters in recipe only including the normal operate parameters, for example, injection pressure, etc. “1=SETUP” including the all parameters, for example, the calibration values of transducers. “Description”: It is for operator to write the description of the recipe, it is easy to understand. Here alphabetic characters can be input, move the cursor to the description and then press “ENTER”, the character will displayed from the head, using the up cursor to find the correct character, then move the right cursor to select the next character. The sequence of displaying the alphabetic characters is 1~9,A~Z. Example 1: The operator wants to store the current mold recipe in EPROM and the storage position is NR 3, the operate parameters storage is enough, then he can do as following: “Selection NR. ID CODE” here input “3”; “ID code” can defined freely, also “Description”; “TYPE(0=MOLD 1=SETUP)” here input “0”( if store all the parameters, here input “1”) After above setting, press F4 key, the process will executed.


Example 2: The operator wants to load the mold recipe NR 2 , then he can do as following: “Selection NR. ID CODE” here input “2”; “ID code” can defined freely, also “Description”; “TYPE(0=MOLD 1=SETUP)” here input “0” After above setting, press F5 key, the process will executed. When finish, the current recipe is replaced.


3.21. Page “20 Mold data external”

This page is for mold recipe storage and load and is operated with the floppy disk. The operate method is as same as page 19, here the icon “format” is used for format the floppy disk. Before a new floppy disk is used to storage, it must be formatted by this function first. The low section is for displaying the operate messages.


3.22. Page “21 Printer”

This page is for printer. The print function permits printing the selected pages, move the cursor to the head of the page and press “ENTER”, this page is selected. The operator has to press F5 key for printing all pages; F6 key for reset all print selections; F7 key for start printing. The system only support the serial printers.


3.23. Page “22 Machine status”

This page is the monitor screen. From upper section the operator can know the working mode, the setting pressure and setting speed, the real pressure, the temperatures for each zone and the heating status. From the machine picture the real values of 4 transducers, the oil temperature, the cabine temperature and the motor status can be displayed. The cores and unscrews status, the mold recipe, the setting and real times of movements also can reached from this screen.


3.24. Page “23 Actual alarms”

This page is for displaying the actual alarms. When an alarm occurs, the icon for F8 will flicker. Press the F8, the operator can read the concrete alarm.


3.25. Page “24 Alarms history”

This page is for displaying the history alarms. The operator can read the data, time of the past 200 alarms, also the happened time for last same alarm. This screen is useful to analyze the malfunction. The current alarm records can be erased or printed by selecting the function in the last two lines of this page.


3.26. Page “25 I/O Diagnostic”

This page is for selecting the board of PLC to watch. The layout of this picture is as same as the real PLC. Move the cursor to the appropriate board and the press “ENTER”, the current statues of this board will be displayed, for example, page 25.A, page 25.B, page 25.C, page 25.D.


3.26.1. Page “Node diagnostic”

If the operator press enter on the previus page at the ETH100 position he access to this page. In this page the operator can see if there is some problem with plc communication or if there is some card not configurated in right mode.


3.26.2. Page “25.A I/O digital output”

This page is the I/O sub-screen of Page 25. In page 25, move the cursor to the board named “U16” then “ENTER”, this page will be displayed. In this system ,there are 3 boards named “U16”, but for calling this page they are not different. Each “U16” board has a section, in the section, every output channel has its number, short name, and a circle for showing the current statues. When move the cursor to a channel, its full name will be showed in the yellow rectangle. The system has a special function named “output test” in this page. “Enable test” is for selecting this function. When the “Enable test” is “NO”, this page is for showing the real “on/off” statues of each output channel. When the “Enable test” is “YES”, the system comes into the “output test” mode and at the same time a red message line will occur in the bottom. This function is usually used to check the wires connecting with valves broken or not. In this mode, other pages are forbidden to call. Move the cursor the channel that will be tested and press “ENTER”, then the circle becomes yellow, it means the channel outputted. At the same time, only one channel can be tested.. So if the cursor moved to another channel and “ENTER”, the new channel will be outputted, at the same time, the original one is reset. “Set time” is for the whole test time, this timer starts once begins to test, if the time finishes, quit to this test mode automatically. Attention: For safety, this test function can be selected when the motor is on. The motor can’t start in test mode also.


3.26.3. Page “25.B I/O analog output”

This page is the D/A8 sub-screen of page 25. In page 25, move the cursor to the “D/A8” board and “ENTER”, this screen will appear. The usage is similar to “I/O output”. “Enable test” is for selecting the testing function. When the “Enable test” is “NO”, this page is for showing the real value of each output channel. When the “Enable test” is “YES”, the system comes into the “ D/A output test” mode and at the same time a red message line will occur in the bottom. This function is usually used to check the currency to the proportional valves . In this mode, other pages are forbidden to call. Move the cursor the channel that will be tested ,first input the value to test , then move the cursor to the small square and finally press “ENTER”, then the square has a yellow cross, it means the value for this channel outputted. The range for testing value is 0~4095. For example, when the operator tests the pressure, 4095 is the highest pressure (140 bar), 2047 is the medium (70 bar); when the speed is tested, 4095 is fastest speed (99%), 2047 is the medium (50%). At the same time, only one channel can be tested.. So if the cursor moved to another channel and “ENTER”, the new channel will be outputted, and at the same time, the original one is reset. “Set time” is as same as in “I/O test”, this timer starts once begins to test, if the time finishes, quit to this test mode automatically. Attention: For safety, this test function can be selected when the motor is on. The motor can’t start in test mode also.


3.26.4. Page “25.C I/O digital input”

This page is for showing the input channels statues. In page 25 , move the cursor to the “E16” board and “ENTER”, this screen will appear. From this screen the operator can know the input signals.


3.26.5. Page “25.D I/O analog input”

This page is for showing the values of analog input channels . In page 25 , move the cursor to the “TERMO” board or “A/D6” board and “ENTER”, this screen will appear. From this screen the operator can know the real values of the input channels.


3.27. Page “26 Easy data setting”

This page is for setting the data in one screen. Most of the operate parameters can be set here and setting those in one page can save the time.


3.28. Page “27 Settings history”

This page is for displaying the history setting. Past 200 setting parameters can be displayed with their data ,time, the original value and the new value. Clearing and printing the record of the selected page is possible.


3.29. Page “28 General setting”

This page is for general setting . You can show the page of calibration with F1-F8 key “Language selection”: English, Chinese and Italian can be selected. “Change password 1” and “Change password 2” are for changing the passwords. Move the cursor to here and select “YES”, the a input zone will appear following the words. The passwords should be 8 characters and can’t less. Changing passwords need password level 2. “Date(mm-dd-yy)” is for setting the date, the setting formation is month-day-year. The operator can move the cursor to set the new value separately . “Day of week”: here shows the day name of week according the date. “Time(hh-mm-ss)” is for setting the time, the setting formation is hour-minute-second. “Save screen” is the function of screen sleeping. It can enlarge the life of screen. When this function efficient, the operator can set a time in “Wait time”, the unit is minute. This means the screen will blank automatically if no any data setting occurs during this time. Attention : when the screen is sleeping, press the working key, the screen can’t be restore. This function is inefficient if selecting the “Save screen” as “NO” or “0” is set in “Wait time”. In this page there are also the information about the software and the firmware version of plc and screen with the date of last modify.


3.30. Page “29 Analog input setup”

This page is for setting the analog input. This page has set correctly in manufactory and it need not modified. If it is necessary to modify the settings, please connect with the manufacturer before changing. In this screen ,the four transducer and the pressure sensor can be set. “ two points decides a line”, The method is setting the minimal and maximal points. For transducers, first move the machine to the minimal position, read the real point from the left side and set it in “point” of “MIN” ,then set the displaying value in following, usually set “0” here. Second, move the machine to the maximal position, read the real point from the left side and set it in “point” of “MAX” ,then measure the real length from the minimal point and set it in following. For pressure sensor, read the value in the system pressure gauge, when it is “0”, set the real points in “point” of “MIN”, then set “0” in following. Outputting the maximal pressure (140 bar) , write down the real points when the value of gauge is 140bar, set this value in “point” of “MAX”, then set “140” in following. “FL” is a filter on real value. You have to increase this value if you have the Real value that change continuously. “Nr of pulse x round” is for setting the real holes in the screw speed detector.


3.31. Page “30 Analog output setup”

This page is for setting the range of analog output. This page has set correctly in manufactory and it need not modified. If it is necessary to modify the settings, please connect with the manufacturer before changing. The unit of the analog output is voltage. The voltage will be changed to current through the amplified board and it drives the proportional valve. “MIN” is for setting the minimal output voltage. “MAX” is for setting the maximal output voltage. “F.S’ is for setting the maximal displaying value, its unit is not voltage but “bar” or “%”. Usually, the “MIN” is set zero and the “MAX” is set “9.99”. The “motor START Y time” is the delay time for output about Y contactor of the pump.


3.32. Page “31 PID Parameters”

This page is for setting the heating PID parameters (heating and cooling) The customer should not change these parameters. The operator can set the two parameters below the screen: “Max set on injector”, “Max set on hot runner”. With the selection for “Copy 1st thermo param. In each” the operator can set only the 1st thermo param. and copy these parameters on the other zones.


3.33. Page “32.1 Limits/Ramp”

This page is for setting the ramps and up limit of each pressure. For each movement 3 parameters can be set: speed ramp, pressure ramp, pressure up limit. The ramp is to improve the performance of the machine. The hydraulic circuit will cause the strike if the output changes to a new value directly when the output changed. So the operator can use the ramp to decrease the strike. Using the ramp, the system will output some middle values between the original output and new output. The ramp range is 0~100, zero is no ramp, the new value will be outputted directly. “1” is minimal ramp, it means the changing process is very long , and the steps of the outputs are most. “100” is the maximal ramp, it means the changing process is very short, and the steps of the outputs are less.


3.34. Page “32.2 Limits/Ramps”

The left of this page is for setting ramps, and the right is for setting the delay times. “Carriage F. Adjust” in low-left side is for setting the pressure and speed of carriage forward in mold adjust mode. “Carriage B. Adjust” is for setting the pressure and speed of carriage backward in mold adjust mode. The delay times are mainly used for decreasing the influence of last movements. When a movement finishes, zero pressure and speed will be outputted. But the pressure can down to zero right now because of the inertia, if execute the next movement as soon as the last movement finished, a strike will be caused in the hydraulic circuit. The delay times of each movement are the waiting time before executing the movement.


3.35. Page “33 Close loop setting”

This page is for setting the close loop parameters. The customer should not change these parameters .


3.36. Page “Service function”

You can access at these page if you press in general setting group.

Attention !!! These pages are useful only in manufacturer. The customer need not use these pages.

3.36.1. Page “Linearization”

In this page the operator can set the linearization of all analog output. He can set 8 step of linearization. This page has set correctly in manufactory and it need not modified. If it is necessary to modify the settings, please connect with the manufacturer before changing.


3.36.2. Page “Pumps setting”

This page is for setting the working mode of pumps. This page has set correctly in manufactory and it need not modified. If it is necessary to modify the settings, please connect with the manufacturer before changing. The combination of the pumps can be set in this chart. The left side of the chart is for setting the flow points that the combination should change. The right side is for setting the pumps “ON/OFF”.


3.36.3. Page “Keyboard diagnostic”

This page is useful to check the keyboard and test if it work right.


3.36.4. Page “Service function”

This page is only for expert technician.


3.36.5. Page “Local net management”

This page is only for expert technician. In this page he can enable the network port through the right password


3.36.6. Page “Machine configuration”

This page is only for expert technician.


AUPROAUPRO-MECATRONICA, S.L.

Plaça Mil.lenari nº 9 local 2A08160 Montmeló (Barcelona) - Spain

Tel. +34 935 681 349Fax. +34 935 684 850

www.aupro-mecatronica.com

Documents

Gilogic_GT-C Manual En