r4 Vert Tavrot Ing Ts 2009

INSTRUCTION MANUAL Rev 4

BABYPLAST 6/10VP 6/25VP

Touch screen

rotary table


I N S T R U C T I O N M A N U A L

Thank you for the trust you have placed in CRONOPLAST. Please read this manual carefully before operating our machinery.The manufacturer is not responsible for and does not provide

warranty for machines used for any purpose other than that for which themanufacturer has specified.

The manufacturer reserves the right to modify their product data orfeatures without prior notice.

CRONOPLAST sl

WARNINGBefore starting up the machine or carrying out any maintenance work,

read this instruction manual carefully

Last mod. 17/11/2009

TECHNICAL ASSISTANCE

CRONOPLAST S.L. C/Francesc Layret, 12-14 nave 23 - Pol. Ind. Sant Ermengol II - 08630 Abrera ( Barcelona) EspañaTel. 93 770 50 78 Fax 93 770 19 54

www.babyplast.com

VP


CE CONFORMITY STATEMENT

We hereby declare that the product type refered to is is a:BABYPLAST MODEL 6/10VP (6/25P), WITH SERIAL NUMBER: .................MANUFACTURER : CRONOPLAST S.L. -TO BE USED SOLELY FOR THE INJECTION MOULDING OF THERMOPOLYMERS: EXCLUDINGINFLAMMABLE AND OR EXPLOSIVE POLYMERS.

(according to delivery note nr. .............................dated...........................)

Babyplast 6/10P conforms to the following European standards:

- 98/37/CEE and subsequent modifications- 89/336/CEE and subsequent modifications (electromagnetic compliance directives)- 73/23/CEE and subsequent modifications (low voltage directives)

AUTHORISED STANDARDS APPLIED FOR THE CONFORMITY DECLARATION

For machine directives 98/37/CE :UNI EN 292-1UNI EN 292-2UNI EN 201

For electromagnetic compliance directives (89/336/CEE) :CEI EN 61000-6-2:2001CEI EN 61000-6-4:2001

For low voltage directives (73/23/CEE) :CEI EN 60204-1

Conformity to the declared standards carried out by:

- UNI EN 292-1, UNI EN 292-2, UNI EN 201 : Quadra report RP001- CEI EN 61000-6-2, CEI EN 61000-6-4 : Eletech report 50261EMC01.00- CEI EN 60204-1 : Eletech report 50261LVD01.00


CONTENTS

A/ General conditions and characteristics of BABYPLAST 6/10VP (6/25VP)............. A-0010B/ How to install a BABYPLAST 6/10VP (6/25VP)..........................................................B-0010C/ Start up...........................................................................................................................C-0010D/ How to operate a BABYPLAST 6/10VP (6/25VP)....................................................... D-0010E/ Alarms............................................................................................................................ E-0010F/ Maintenance & technical drawings............................................................................. F-0010

A/ General conditions and characteristics of BABYPLAST 6/10VP (6/25VP).A.1/General conditions......................................................................................................... A-0010A.2/What is a BABYPLAST 6/10VP (6/25VP) and what can it do?......................................A-0010A.3/Technical data................................................................................................................A-0020

A.3.1/ General dimensions of BABYPLAST 6/10VP (6/25VP).............................. A-0020A.3.2/ BABYPLAST 6/10VP (6/25VP), Basic parts list............................................ A-0030A.3.3/ Technical data............................................................................................... A-0040A.3.4/ Machine platens............................................................................................ A-0050A 3.5/ Main mould parts...................................................................................... ... A-0060

A.3.5a/ Mould MOULD HEIGHTS.................................................................. A-0070A.3.5b/ Mould: exampl BASE PLATE............................................................. A-0080A.3.5c/ Mould: exampl FIXED HALF.............................................................. A-0090A.3.5d/ Mould: exampl MOVING HALF.......................................................... A-0100

A.3.6/ How to move the injection point off centre.....................................................A-0110A.3.7/ Connections for mould temperature control.................................................. A-0120A.3.8/ Diagramme to show injection pressures........................................................A-0140A.3.9/ Diagramme to show injection pressuresAugmented version........................ A-0140

A.4/ Warranty....................................................................................................................... A-0150

B/ How to install a BABYPLAST 6/10P (6/25VP)................................................................ B-0010

B.1/ Unpacking and parts check...........................................................................................B-0010B.2/Electrical connections 400V 3 phase + N + earth........................................................ B-0020B.3/Electrical connections 230V 3 phase + earth.................................................................B-0020B.4/Cooling system...............................................................................................................B-0030B.5/Hydraulic oil specifications............................................................................................. B-0040

C/ Start up.............................................................................................................................C-0010

C.1/ Safety devices...............................................................................................................C-0010C.1.1/ Main switch................................................................................................... C-0020C.1.2/ Emergency stop.............................................................................................C-0020C.1.3/ Hydraulic system safety device..................................................................... C-0030C.1.4/ Safety devices for guards..............................................................................C-0040

C.2/Installing a mould........................................................................................................... C-0050C2a/ Removing the mould........................................................................................C-0055

C.3/ Display panel.................................................................................................................C-0060C.4/Pressure guages............................................................................................................C-0060C.5/Cooling system - water manifold....................................................................................C-0070C.6/Pneumatic pressure reduction unit for guard................................................................ C-0080C.7/Display - Synoptic diagramme....................................................................................... C-0090C.8/Starting the machine......................................................................................................C-0100

GENERAL INDEX


D/ How to use a BABYPLAST 6/10P (6/25VP).................................................................... D-0010

D.1/ Menu................................................................................................................................... D-0010D.1.1/ Display....................................................................................................................D-0010D.1.2/ Icons - description of functions............................................................................. D-0020D.1.3/ Start up - gate check.............................................................................................. D-0030D.1.4/ Main menu............................................................................................................. D-0040D.1.5/ Manual menu......................................................................................................... D-0050

D.1.5a/ Manual menu CLAMP................................................................................ D-0060D.1.6/Setting the MOULD CLOSED position................................................................... D-0070D.1.7/Semi automatic menu............................................................................................. D-0080

D.1.7a/ Temperature settings................................................................................. D-0090D.1.7b/ Times and settings.................................................................................... D-0100

D-1.7b1/INJECTION CARRIAGE settings................................................. D-0110D-1.7b2/ PLASTIFICATION settings..........................................................D-0120D-1.7b3/ EJECTION settings......................................................................D-0130D-1.7b4/ INJECTION settings....................................................................D-0140D-1.7b5/ CLAMP settings........................................................................... D-0150 D-1.7b6.QUALITY CONTROL settings..................................................... D-0160 D-1.7b6a/QUALITY CONTROL Log file........................................ D-0180

D.2/Starting a cycle................................................................................................................... D-0190D.2.1/ Starting a semi automatic cycle..............................................................................D-0190D.2.2/ Starting a purge cycle.............................................................................................D-0210D.2.3/Setting up the PART COUNTER.............................................................................D-0230

D.3/ Mould setting programmes..................................................................................................D-0240D.3.1/ Loading a mould setting programme......................................................................D-0240D.3.2/ Create or modify a mould setting programme........................................................D-0250

D.3.2a/Mould setting programmes - times and settings......................................... D-0260D.3.2a.1/ INJECTION CARRIAGE.............................................................D-0260D.3.2a.2/ PLASTIFICATION.............................. ....................................... D-0270D.3.2a.3 / EJECTION................................................................................. D-0280D.3.2a.4/ INJECTION.................................................................................D-0290D.3.2a.5/ CLAMP........................................................................................D-0300

D.3.2b/ Mould setting programmes TEMPERATURES.........................................D-0310D.3.2c/ CORE PULL............................................................................................... D-0320

D.3.3/ Mould setting programmes - COPY A PROGRAMME............................................. D-0330

D.4/Machine configuration.......................................................................................................... D-0350D.4.1/Machine configuration - Change language - Celsius/Farenheit.............................. D-0360D.4.2/Machine configuration - Temperatures.................................................................. D-0370D.4.3/Machine configuration - Times and settings............................................................D-0380

D.4.4/Software Upgrade.............................................................................................D-0390

D.5/ USB memory stick - Saving/retrieving mould settings.................................................. D-0410 D.5.1/Printing/Elaborating mould setting data on a PC...................................................D-0430

E/ ALARMS..................................................................................................................................E-0010

F/ Maintenance........................................................................................................................... F-0010F/2 Electrical and hydraulic drawings......................................................................................... F-0020

......................................................................................................... F-0210


GENERAL SAFETY REGULATIONS

To be studied carefully before using the machine

The Babyplast 6/10VP (6/25VP) injection moulding machine, for thermoplastic materials, has beenconstructed to meet most safety regulations actually in force. Failure to respect the following instructions, maycause injury to the user or damage to the machine.

1) Do not remove the warning labels from the machine. These labels must always be clearly visible.

2) Before using a thermoplastic material, always consult the manufacturer about possible health risks and theprecautions that must be taken in order to avoid accidents.

3) To avoid the risk of electric shock, never use the machine unless it has been properly earthed.

4) All the safety guards on the machine must be positioned correctly and maintained in good working order.

5) The protective covers over the electrical and electronical compartments, must remain closed and screweddown. The removal of the protective covers, may expose the operator to the risk of electric shock.

6) Safety devices, covers and protections, should not be deactivated or tampered with.

7) When working near the injection area, always wear protective gloves and suitable eye protections.

8) The various components of the mould must be correctly positioned and well secured before starting theinjection phase.

9) Before carrying out any maintenance, the machine must by disconnected from the mains and the mainswitch must be turned off and blocked by a qualified technician.

10) The system that limits the hydraulic pressure, must always be regulated so that the pressure does notexceed the maximum pressure of 130 bar.

11) Never place hands or other objects inside the protective guards while the machine is functioning.

12) Maintenance on the machine should be carried out by qualified personnel only.

13) The machine is supplied with a power supply cable but without a plug. The plug used should comply tostandard EN 60309-1 and 16A power rating.

14) The machine must be connected to the power supply via a mains switch with a rating of of at least 4500A at 230V / 400V. The power supply socket and switch must be installed in visable positionfor easy access and must have an identification sign or label.

IT IS THE RESPONSIBILITY OF THE OWNER TO ENSURE THAT THE MACHINE MEETS MAXIMUMSAFETY LEVELS AT ALL TIMES, AND THAT THE OPERATOR ALWAYS RESPECTS THE SAFETY ANDMAINTENANCE INSTRUCTIONS FOUND IN THIS MANUAL AND ON THE LABELS ATTACHED TO THEMACHINE. IN CASE OF DOUBT AND OR FOR ANY FURTHER CLARIFICATIONS, PLEASE CONTACTYOUR NEAREST DEALER.


This technical documentation is intended for all those responsible for using and handling the BABYPLAST 6/10VP(6/25VP) injection moulding machine.We wish to emphasise that this injection moulding machine can only be used according to the instructions set outin this manual.Failure to follow this instruction manual correctly, may cause injuries to people and animals or damage tomaterials and things.In the event of any problems, please contact our technical staff.In its continued endeavour to improve its products, CRONOPLAST reserves the right to vary or modify suchproducts without prior notice.It is strictly forbidden to reproduce or copy this manual without written prior consent from CRONOPLAST S.L.,or to use said manual for unauthorised purposes.

BABYPLAST 6/10VP (6/25VP)is a PATENTED model.

BABYPLAST 6/10VP (6/25VP)has been designed and built according to EN 201, EN 60204-1-1992, EN 292-1,EN 292-2.The above include DIN 5310, DIN 5318T2, DIN 54635T48, according to the 89 / 392 / EEC and93 / 44 / EEC Directives on machinery.

The machine is certified as complying with the European standard "CE".ATTENTION! It is forbidden to sell or transfer this machine to the U.S.A., Canada and Mexico, unless the mechanical safety device kit has been installed. The manufacturer and distributor will not accept responsibility for accidents caused due to failure to observe this warning.

The technical documentation for the machine, if within the European Economic Community, is provided in thelanguage of the country of destination. For multi-lingual countries or those outside the European Community, therequired language should be specified in the customers order.

A.2/ WHAT IS A BABYPLAST 6/10VP (6/25VP) AND WHAT CAN IT DO?

The BABYPLAST 6/10VP (6/25VP) injection moulding machine is the result of thirty years experience workingin specific fields of plastic injection moulding, mould design and construction.Research and development, on the machine, began more than ten years ago, in response to an important areaof demand:

- FULL PRODUCTION OF MICRO PARTS- SMALL SERIES PRODUCTION.- PROTOTYPE DEVELOPMENT.- LOW COST OF MOULDS..- LABORATORY TESTS.- TECHNICAL TRAINING.

BABYPLAST 6/10VP (6/25VP) is the ideal solution for producing small plastic-moulded parts, without usingmultiple cavity moulds. This is particularly useful when developing prototypes or producing small series of parts.Owing to the low cost of the moulds used in our machines, in-depth experiments can be carried out before thefinal mould for large series production is built.As a result, both small and medium series can be produced easily, and COMPLETELY AUTONOMOUSLY.

Thank you for the trust you have placed in Babyplast. We are confident that your BABYPLAST 6/10VP (6/25VP)machine, will help fulfil your application expectations.When handling and processing any injection moulding materials, customers must follow the material manufacturer'sinstructions with great care.

A.1/ GENERAL CONDITIONS

A-0010

A


A-0020

All dimensions are in mm.

A.3./ TECHNICAL DATAA.3.1/ General Dimensions

A

1600 670

830

1.37

0


A-0030

A.3.2/ Babyplast 6/10VP (6/25VP) - BASIC PARTS LIST

A

1-Oil tank 2-Safety valve anti-drop 3-Micro switch - mould guard 4-EMERGENCY stop 5-Double start buttons - rotating table 6-Rotating table 7-Micro switch - hydraulic safety 8-Mould guard 9-Clamp transducer10-Clamp piston11-Heat guard12-Hopper13-Injection guard14-Hydraulic manifold

15-Hydraulic safety valve16-Hydraulic - maximum pressure regulator17-Main switch18-Photo cells19-Clamp pressure gauge20-Fixed mould guard21-Injection pressure gauge22-Display touch-screen23-Alarm warning light24-Data setting dial25-Water manifold26-Anti vibration pads.27-Power cable28-Electrical cabinet29-Water inlet-oulet

2

3

1

56

4

87 10 11 12 9 13 14 15 16 17 18 19 20 21 18 22 23

2526

242829

27


A.3.3/ TECHNICAL DATA

A-0040

A circuit breaker must be used at the mains connection.

3 ~ 230V. 50/60 Hz. + Earth3 ~ 400V. 50/60 Hz. +Neutral + Earth

STANDARDINJECTION UNIT

AUGMENTEDINJECTION UNIT

1 0 1 2 1 4 1 6 18 16 20 24

4 6, 5 9 1 2 1 5 16 25 36

2.650 1.830 1.340 1.030 815 1535 980 680

3,98 5,74 7,81 10,2 12,9 6,84 10,7 15,4

1,8 3,1

6.250 Kg/cm2 62,5 KN

110 mm

920 Kg 9,2 KN

50 mm

130 Kg./cm2.

12 l . (approx.)

2,4 s.

3 Kw

< 70 db

Piston diameter (mm.):

Volume (cm3):

Injection pressure (Kg/cm2.) :

Injection capacity (cm3/ / sec):

Plastification capacity (g/sec):

Clamp force :

Opening stroke :

Ejection force:

Ejection stroke :

Hydraulic pressure :

Oil tank capacity :

Dry cycle :

Rated power :

Noise level :

Power supply:

A


All dimensions are in mm

A-0050

A.3.4/ MACHINE PLATENS

Mould locating pins

Max. nozzleforward pos.

A

Sez. B-B

B

A

Sez. A-A

A

B


A-0060

2

3

4

5

6

7

8

9

1

10

11

A.3.5/ MAIN PARTS - MOULD AREA.

1. CHASSIS

2. SCREWS FOR FIXING MOVING MOULDHALF

3. MOVING PLATEN

4. MOVING MOULD HALF

5. INJECTION UNIT POSITION

6. FIXED MOULD HALF

7. EJECTOR PLATE

8. SCREWS FOR FIXING FIXED MOULD HALF

9. MOULD LOCATING PINS

10. FIXED PLATEN

11. EJECTORS

A


A-0070

Holes for fixing tomoving platen.

Moving mould half.

Injection unitposition.

Fixed mould half

Ejector plate

Locating pins

Slots for fixing tofixed platen

Dimension A (position of injection unit) = 70 - 95 mm

Minimum mouldheight A+B = 120mm

Dimension C = 229mm (Max. opening stroke)

Mould open gap L = C - (A+B)

A.3.5.a/ MOULD: Mould heights

AL

C

B

A


A.3.5b/ MOULD: example BASE PLATE 1

A-0080

1

2

3

Sez.

A-A


A


A-0090

A.3.5c/ MOULD: example FIXED HALF 2

A-0090

2

1

3

MAXIMUM NOZZLE MOVEMENT


ATTENTIONDO NOT MOVE THE NOZZLE FORWARD WITH MOULD OPEN

A

45

1 R 1,5

45°

1,5

9570

10


A-0100

A.3.5d/ MOULD: example MOVING HALF 3

3

1

2


A

75

47.5

47.5

47.547.5

10


A-0110

A......../ MOULD: MOVING HALF 3

Moving platten

Moving mould half

Locating pins

Gap

Transparent guard

ATTENTION: Construct the mould, moving half, so as to leave at least 10mm between the mould and the transparent guard wich rotates with the rotating table.

N.B. : The height of the rotating table can be modified according to the mould.

3

1

2

min

10

ca 1

40

ca 1

40


min

2

30

A.3.5f MOULD: ejection

A-0120

A

All dimensions are in mm.

Ejectors

Gap

Cavity plate

Ejector return springs

Ejector plate

Max. ejector stroke

Ejector piston

ATTENTION: Construct the mould, considering that the maximum ejector stroke is 30mm, so that the ejector plate does not touch the mould. (Leave approx. 2mm of gap), so that the force of the ejector piston does not push on the mould and hence rotating table.

BABYPLAST 6/10VP 6/25VP A

Babyplast 6/10VP (6/25VP), has three injection unit positions, at 70, 95 and 45 from the surface ofthe fixed platen.

TO CHANGE THE INJECTION ASSEMBLY POSITION, PROCEED AS FOLLOWS:

Unscrew and remove the fixing screwsfrom position 1. Slide the complete injection unit 2out and insert it into the new position. Screw in and tighten the two fixing screws in thenew position.

ATTENTION:

THE MACHINE MUST BE DISCONNECTED FROM THE POWER SUPPLY BEFORE CARRYING OUT THIS OPERATION.

A.3.6/ Changing injection unit position

A-0110

1 2


A.3.8/ DIAGRAMME TO SHOW INJECTION PRESSURES 6/10 VP

A-0140

* IMPORTANT NOTE: The maximum hydraulic pressure for the 10mm piston must be limited to 100 bar. This is done automatically bysetting the value of 10mm for the piston size under “TIMES AND SETTINGS in the “MACHINE PARAMETERS” menu see sectionD.4.3, page D-0400.

0 10 20 30 40 50 60 70 80 90 100 110 120 kg/cm2

Ø 10mm*

kg/cm2

3.000

2.500

2.000

1.500

1.000

500

Ø 18mm

Ø 12mm

Ø 14mm

Ø 16mm

Hydraulic pressure

Spe

cific

pre

ssur

e on

mat

eria

l Ø Injection piston

A.3.9/ DIAGRAMME TO SHOW INJECTION PRESSURES 6/25VP

0 10 20 30 40 50 60 70 80 90 100 110 120 kg/cm2

kg/cm2

3.000

2.500

2.000

1.500

1.000

500Ø 24mm

Ø 20mm

Ø 16mm

Hydraulic pressure

Spe

cific

pre

ssur

e on

mat

eria

l Ø Injection piston

A


A-150

The vendor guarantees that the material is to be supplied against all manufacturing faults, and accepts replacingany faulty part or repairing any faulty operation free-of-charge, providing the buyer notifies the vendor of said faultwithin a maximum period of TWELVE MONTHS from the date the machine is received at its destination.

It is clearly stated that this warranty does not include: heating elements, paint, oil and optional accessories; wearcaused through improper use and handling; knocks, in the case of damaged / broken seals on the hydraulic unit,If the maximum authorised pressure levels have been exceeded, troubles caused by faulty connections in theelectrical system, the use of un-authorised lubricants, accidents and damage or any failure to observe theapplication and installation instructions detailed in this manual.Furthermore. the travelling expenses of a technician (hours and kilometres) as well as transport costs forreplacement parts are also excluded.Once the TWELVE MONTH warranty period has expired, the vendor will not accept any claims or returned parts.However, faults that the buyer issues claims for, may be checked by the vendor, using any technical meansconsidered necessary, on condition that the buyer does not obstruct the work of those who the vendor hasnominated responsible for carrying out the revision.

WARNING:

In its continual endeavour to improve its products, CRONOPLAST reserves the right to modify or vary its productsfeatures or specifications without prior notification.

A.4/ WARRANTY

A


B/ INSTALLATION OF THE BABYPLAST 6/10VP (6/25VP)B.1/ UNPACKING AND PARTS CHECK.

ATTENTION: THE MACHINE IS TOP HEAVY, PAY GREAT ATTENTION WHEN MOVING THE MACHINE PARTICULARLY WITH A FORKLIFT TRUCK OR TROLLEY.

Babyplast is supplied in a wooden crate and weighs approx. 340 Kg. - see fig. a. First of all remove the srewsthat secure the front panel and remove it. (fig.b) Remove the screws that secure the other panels around themachine and remove them fig. c). Check the machine for signs of damage or any other faults and, if found,contact your nearest ditributor immediately.Remove the internal packing parts that secure the machine inside the wooden crate and using the two liftingrings on the top of the machine, lift the machine off the wooden base (fig.d).B.2/ INSTALLATIONScrew the anti-vibration pads into the base of the machine and place it in a dry well lit place that is shelteredfrom atmosheric conditions and where the temperature does not exceed 40°C (fig.e). Before lowering to theground, check that the ground is level and if necessary make as near level as possible. (fig.f). Once themachine has been lowered to the ground, check that it is level and if necessary adjust the anti vibration pads.VERY IMPORTANT - ATTENTION, HANDLE WITH EXTREME CARE.

Inside the packing you will find:a/ 1 BABYPLAST 6/10VP (6/25VP).b/ 1 instruction manualc/ 1 hopper.d/ 1 bag containing special tools.e/ 1 Set of accessories as requested by the customer.

B-0010

Fig. a Fig. b Fig. c

Fig. d Fig. e Fig. f

B


B-0020

3 phase + neutral + earth - 400V - 50/60Hz

The mains power supply fuses inside Babyplast have a blow rating of 3.500 A at 400V.The machine must be connected to the mains via a 16A thermo / 0,030A differential circuit breaker,that is suitable for the power supply used.

Attention! For power supplies with the neutral isolated from earth, a relay for permanent isolation mustbe installed.

BABYPLAST 6/10VP (6/25VP) will be prepared for connecting to a power supply as specified in thecustomer’s order.

WARNING: CHECK THAT POWER SUPPLY AND MACHINE ARE COMPATIBLE BEFORECONNECTING TO MAINS POWER SUPPLY!!

3 phase +earth - 230v - 50/60Hz

The mains power supply fuses inside BABYPLAST 6/10VP have a blow rating of 10.000 A at 230V.The machine must be connected to the mains via a 16A thermo / 0,030A differential circuit breaker,that is suitable for the power supply used.

BABYPLAST 6/10VP (6/25VP) will be prepared for connecting to a power supply as specified in thecustomer’s order.

WARNING: CHECK THAT POWER SUPPLY AND MACHINE ARE COMPATIBLE BEFORECONNECTING TO MAINS POWER SUPPLY!!

Current: Max 7,5A - average 3,5A

FUSES INSTALLED ON THE fm542 BOARD -

Fuse pos. Technical Dimensions Power rating FUNCTION number specifications

F501 10A - 500V - rapid blow 6,3X32 F 500V/ 1.500A - 250V/10.000A PHASE RF502 10A - 500V - rapid blow 6,3X32 F 500V/ 1.500A - 250V/10.000A PHASE SF503 10A - 500V - rapid blow 6,3X32 F 500V/ 1.500A - 250V/10.000A PHASE T

F504 8A - 250V - rapid blow 6,3X32 F

F505 8A - 500V -extra rapid 6,3X32 FF 500V/ 1.500A - 250V/10.000A Plast. heaterF506 3,15A - 500V - extra rapid 6,3X32 FF 500V/ 1.500A - 250V/10.000A Chamber heaterF507 3,15A - 500V - extra rapid 6,3X32 FF 500V/ 1.500A - 250V/10.000A Nozzle heaterF508 6,3A - 500V - extra rapid 6,3X32 FF 500V/ 1.500A - 250V/10.000A F. mould heaterF509 3,15A - 500V - extra rapid 6,3X32 FF 500V/ 1.500A - 250V/10.000A M. mould heater

B.2/ ELECTRICAL CONNECTIONS for 400V power supply

B.3/ ELECTRICAL CONNECTIONS for 230V power supply

B


B-0030

This is needed to:Cool the hydraulic oil.Cool other parts of the machine.

For connecting the cooling water supply to the BABYPLAST machine, the inlet and outlet hose must be of aflexible type. Connect the inlet hose to the water supply (see diagramme), the outlet hose to the return circiuitand open the shut-off valve.

The temperature of the incoming water must be between 12ºC (min.) and 18ºC (max.). However, theminimum and maximum temperatures are indicative only and depend on the machine settings and workingconditions.The water must be clean, otherwise a filter must be used and the calcium content controlled.The water hardness must be between 6 grd-9grd dH, and the pressure between 3-4bar (max.) with adifference between the inlet and outlet of 1.5 bar.

B.4/ COOLING SYSTEM

INLET TUBE diam. 8 mm approx.OUTLET TUBE diam. 11 mm approx.

B


Oil return filter

B-0040

BABYPLAST is not supplied with hydraulic oil unless requested as an accessory. Only an oil with thefollowing properties can be used in the machine.

OIL PROPERTIES: RANGE: -15ºC +80ºCVISCOSITY: 12 100 mm /SEC.(CST)

FILTRATION: 25 30 um. MINIMUM

AGIP-OSO45CASTROL-HISPIN AWS46CHEVRON-EPHIDRAULIC OIL 11ESSO -NUTOH48IP-IPHYDRUS OIL 46MACH -BP ENERGOL HLP80MOBIL-DTE MEDIUMFIAT- RZA 40TOTAL- AZOLLA 30

VERY IMPORTANTThe guarantee on the machine will be void if any oils other than those listed above are used in the machine.CRONOPLAST does not accept any responsibility in such cases.

How to fill the machine with hydraulic oil.

Remove the oil cap and fill the tank until the level reaches the mark on the dipstick. attached to the oil cap.ATTENTION: THERE IS A SENSOR WITH A FLOAT, INSIDE THE OIL TANK, WHICH CAUSES THEMACHINE TO GO INTO ALARM (ALARM 023) IF THE OIL LEVEL IS TOO LOW.

OPERATING TEMPERATURE: 45°CMAXIMUM TEMPERATURE : 60°C (ALARM 020)MINIMUM TEMPERATURE : 20°C (ALARM 029).Below the minimum temperature, it will only be possibleto switch on the motor, heaters and consult the various menus and settings. No machine movements will bepossible.

B.5/ HYDRAULIC OIL SPECIFICATIONS

2

B

Hydraulic system- max.pressure regulator

Oil fill cap


C-0010

C./ SAFETY DEVICESC.1 SAFETY DEVICES

Position of safety equipment devices.Safety for the user.Mould safety.Safety standards. EN 60204 T1/1985 DIN VDE 0113 T1/02.B6.

C

11

109 78 11 763 42 5

1312

15141.Emergency stop button2. Clamp safety valve3. injection guard4. Double switch injection guard5. Hydraulic safety valve6. Main switch7.Photo cells8. Mould guard - rotating table9. Mould guard10. Alarm warning light11. Double start button- cycle / rotation of table12. Hydraulic safety switch - L/H mould guard13. Double switch L/H mould guard14. Hydraulic safety switch - R/H mould guard15. Double switch R/H mould guard


C.1.1/ MAIN SWITCH

Switches the machine ON and OFFand is found on the side of themachine (figura 1c).Has two positions (0 off - 1 on).When i n position 0 it is possible toinsert a padlock to block it for safetyreasons.

Switches off the motor, all the electro-valves (thus stopping all the machines movements) all the heaterelements, and activates alarm 031 EMERGENCY STOP.To restart the machine, once the emergency stop button has been pushed, rotate the button anti-clockwiseand reset the alarm on the display.

C.1.2/ EMERGENCY STOP

C-0020

C

fig. 1c


C.1.3/ HYDRAULIC SYSTEM SAFETY DEVICE

C-0030

When one of the two, sideMOULD GUARD are opened, all the hydraulic fluid in the system is diverted to theoil tank, the power supply to the valves is cut, thus stopping all the machines movements. A micro switch ismounted on the safety valve (paragraph F hydraulic diagramme) to monitors it and ensure it functionscorrectly.If the transparent guard is closed and the hydraulic safety device does not return to its working position, alarm002 GATE OPEN is activated.

C

Mould safety guards Actuators -hydraulic safety


C-0040

C.1.4/ SAFETY DEVICES FOR GUARDS

C

1-2/ Photo electric barrier

If, during the rotation of the table, the photo electric barrierdetects an intrusion, the power supply to the motor is cutand rotation stops immediately.

3/ Injection guard sensor

When the injection guard sensor is activated, The powersupply to all the valves (except the safety valves), whichcontrol the machine movements, is cut. The machine goesinto alarm 003, the warning light comes on and an acousticwarning is given.

4-5-6-7/ Mould guard switches.

When the mould guard switches are activated, The powersupply to all the valves (except the safety valves), whichcontrol the machine movements, is cut. The machine goesinto alarm 002, the warning light comes on and an acousticwarning is given.

1 2

4 5

6 7

3

46

57


C.2/ INSTALLING A MOULD

C-0050

C

ATTENTION: a. Before installing the mould, check that the rotating table turns clockwise, otherwise invert a fase in the power supply plug.

b. The injection unit has 3 different injection positions (heights), check that the one selected is compatible with the mould to be used.

To install the mould, proceed as follows:

A-/ Place the mould on the fixed platen making sure that it is correctly positioned on the two 10mm diam. locating pins

B-/ Fix the lower mould half to the rotating table using four screws M10 x 25 .

C-/ Press the two START buttons to rotate the table and release the buttons, when the table is approximately 130° from the initial position, so that the mould is near the left mould guard ( if the position is not correct, repeat the procedure).

D-/ Open the left mould guard and, via the open guard, position the upper mould half on top of the lower mould half.

E-/ Press the two start buttons and keep them pressed till the mould assembly is in the correct position under the clamp piston.

F-/ In MANUAL, lower the moving platen down onto the mould assembly.

G-/ Fix the upper mould half to the moving mould platen using 4 screws M8 x 20.

H-/ Fix the lower mould half to the rotating table.

I-/ Connect the water cooling tubes and check for the correct movements of clamp and ejector pistons

L-/ Close the mould and check that the nozzle is in the correct position with respect to the mould.

(CRONOPLAST S.L. and RAMBALDI Srl are highly experienced in the design and construction of moulds, and are therefore, in a position to be able to offer their customers the possibilty of collaboration for all aspects of mould construction in order to find the best technical solutions that suit the customers needs).


C.2a/ REMOVING THE MOULD

ATTENTION: Before removing the mould, check that the rotating table turns clockwise, otherwise invert a fase in the power supply plug.

To remove the mould proceed as follows:

A-/ In MANUALclose the clamp till the mould is closed completely.

B-/ Remove the M8 x20 screws which fix the upper mould half to the moving platen.

C-/ Open the clamp completely so that the upper mould half remains on the lower mould half and thus both remain on the rotary table.

D-/ While in the page «MANUAL CLAMP» press key F5

»»»»»

E-/ Once in the page as per Fig. 2, press the two start buttons and keep them pressed, The rotating table will rotate approximately 35° and stop near the right hand mould guard. remove the upper mould half

ATTENTION: While in this page, for safety reasons, ( the complete mould cannot passunder the transparent guard) it will not be possible to make the rotating table move again.The upper half of the mould MUST be removed, exit from this page and then it will bepossible to rotate the table.

F-/ ONLY ONCE THE UPPER MOULD HALF HAS BEEN REMOVED return to the pageas perFig. 1, rotate the table to the operator side and remove the lower mould half of the mould.

F1 F2 F3 F4 F5

MANUAL: CLAMP

000.000.0mm

F1 F2 F3 F4 F5

MANUAL: CLAMP

000.000.0mm

Fig.1 Fig.2

C-0055



C.3/ DISPLAY PANEL

C.4/ PRESSURE GAUGES

These are situated on the lower left-hand side of the machine.

1 CLAMP PRESSURE GAUGEIndicates the CLAMPPRESSURE whichcorresponds to the maximumworking pressure of the machine.

(system pressure 130bar).

C-0060

A. TOUCH-SCREEN DISPLAYVisualise all data and functions of themachine as well as the synopticdiagramme of the machine. Allowsmachine parameters to be varied orsaved, by touching the various iconsor fields of data.

B. References for iconsThe following refences are used (F1-F2 etc..) to simplify the explanationsof the functions of the various iconsreferred to in this manual on the touch-screen display.

C. ALARM WARNING LIGHTLights up when an alarm is activated.At the same time a description of thealarm/fault appears on the display.

D. DIALAllows a more rapid input/changeof data.

Tool settings are set and saved via the multi-function touch-screen display. It is also possible to control the variousfunctions of the machine and handle and activate the various phases of the cycle.

2 INJECTION PRESSUREGAUGEIndicates the INJECTIONPRESSURE (1st Pressure -2nd Pressure)

C

MENU PRINCIPALE

A B C D


C-0070

C.5/ COOLING SYSTEM - WATER MANIFOLD

Regulates the water flow required for cooling:

1 mould half 1.

2 mould half 2.

3 Fixed platen.

4 Hopper area.

The zones should be regulated so as to obtain a minimum amount of water consumption, in relation to thetemperatures needed for each zone for the production cycle.

The water flow, for cooling the hydraulic oil, is regulated automatically by an electro-valve.If the oil temperature exceeds 60°C, alarm 020 OIL OVER HEATED is activated or 108 INVERTER OVERHEATED.

Situated on the left-hand side of the machine.

Icons : indicate thecooling zone.

Sphere : Indicates theactual water flow rate.

Control knobs: adjust thewater flow rate to eachzone

C

25

20

15

10

25

20

15

10

25

20

15

10

1 2 3 4


C-0080

CC.6/ SENSORE SICUREZZA CARRO INIEZIONE ARRETRATO

A B

ATTENTION: It will only be possible to rotate the rotating table if sensor B, fitted to the injectioncarriage, is activated. Adjust the position of metal plate A so that sensor B is only activated whenthe injection carriage is fully back and adjust «injection carriage time» settings as per ( Parag.D.1.7.b1 page D-0110) to a value which is enough to activate the sensor.


C-0090

C.6/ Display - Synoptic diagram

The touch-screen display, other than allowing access to the various functions and parameters of the machine,also indicates the activation of hydraulic movements, the acivation of the motor and the heaters, the openingof guards and gate and the opening and closing of the mould.

1. Page visualised.2. Actual temperatures - H1 plastif. - H2 Chamber - H3 Nozzle - H4 Mould.3. If present, indicates that the motor is ON.4. This group of three arrows indicates that the mould is closing in HIGH PRESSURE and that the hydraulic valve has been activated.5. Mould position.6. Two black squares indicate that the mould is closed.7. Indicates that the left guard is open.8. Indicates that the right hand guard is open.9. Indicates the name of the tool setting programme in use.10. Icons: touch to activate corresponding function.11. Mould heater active: Red -temperature within tolerance band, Yellow - temperature in stand-by.12. Indicates activation of ejectors and that the hydraulic valve has been activated.13. Nozzle heater active - Red -temperature within tolerance band, Yellow - temperature in stand-by14. Indicates the injection carriage forward movement and that the hydraulic valve has been activated.15. Indicates injection in progress and that the hydraulic valve has been activated16. Indicates decompression in progress and that the hydraulic valve has been activated.17. Indicates injection carriage backward movement and that the hydraulic valve has been activated.18. Injection piston position19. Indicates activation of plastification and that the hydraulic valve has been activated.20. Plastification heater active: - Red -temperature within tolerance band, Yellow - temperature in stand-by21 Chamber heater active: - Red -temperature within tolerance band, Yellow - temperature in stand-by22. Indicates that the injection guard is open.23. Indicates the closing or opening of the mould and that the corresponding hydraulic valve has been activated.

C

00.0mm

MENU PRINCIPALER1 200 R2 200 R3 200 R4 OFF

12 13 14 15 16 18

1

9

11 17

223

3

4

21

19

22 20

Ingranaggio cod 2345

000.0mm 5

6

7

8

10


C-0100

C.7/ STARTING THE MACHINE

The machine is now ready to be started. Check that it has been filled with oil to the correct level, andthat it is connected to the mains correctly.After switching on at the main switch, the SAFETY GUARD CHECKmust be carried out In order to continue. Before being able to start the motor, the safety guards must beopened and closed. If a fault is detected with any of the guard switches, it will not be possible to start themachine. Carry out the following procedures before starting the injection process:

FIRST:Install the mould and set the mould closed position, following the instructions in section 2/C

NSTALLING A MOULD (page C-050) and D1.6/ SETTING THE MOULD CLOSED POSITION.(page D-070)

SECOND:Set the plastification temperature according to the specifications indicated by the manufacturer of the

material to be injected. Set the injection chamber temperature to approximately 5/10 °C below theplastification temperature parag. D.1.7a TEMPERATURE SETTINGS (page D0090)WARNING: Plastic material, which was used for tests during the manufacturing process, will be found in theINJECTION UNIT. MAKE SURE that this material is compatible with the temperatures at which the machineis to be programmed.If the user is not experienced in the transformation of thermoplastic materials, it is advisable to begin with amaterial with a wide temperature range, such as POLYPROPYLENE, POLYSTYRENE, POLYETHYLENEABS,etc.so as to obtain best results right from the start.

THIRD:Set the shot size based on the volume of the part, the cooling time between 2 and 4 seconds, the 1st

injection pressure at approx. 50/60 bar and a time for the 1st injection pressure depending on the volume ofthe part to produce and the density of the material used (start with 1.5 - 3 seconds for example).Decompression should be set between 1 and 2 mm Parag. D.1.7b4 INJECTION SETTINGS (page D-0140)

FOURTH: Set sprue break time from 0.5 to 0.8mm see INJECTION CARRIAGE TIME parag. D1.7b1 (page D-0110). Set the opening stroke depending on the size of the part, see parag. D1.7b5 (page D-0150) and finally, setthe ejection time from 0.2 to 0.7 secs. with 2 or 3 ejector strokes. parag. D.1.7b3 (page D-0130).

FIFTHClose the material chute on the hopper and load the hopper with material as required. When the various,previously set, temperatures have been reached, open the material chute on the hopper and purge themachine according to section D.2.3 PURGE page D-0240).The machine is now ready to produce parts.

SIXTHPut the machine in semi-automatic mode and make sure that the transparent guard and covers are

closed. Place an insert in the first lower mould half and press the two START buttons till the mould rotates tothe correct position under the clamp. If the mould is in the correct position, the machine will proceed tocomplete one cycle. In the meantime, the operator should load another insert in the other lower mould half.At the end of the cycle, press the the two start buttons again to complete the rotation of the table and until theejection cycle has finished. The nozzle may cool slightly, during the first shots, as it comes into contact withthe cold mould. If so, for the first shots only, increase the nozzle temperature by approximately 5 or 10%.If good results have been achieved, repeat this process several times , adjusting the different machineparameters such as times, temperatures, pressures and material load etc.Once stabilized, make sure that, at the end of the injection cycle, the injection piston reaches a point less than3 mm (cushion) within 8 cycles (page D-0400), otherwise the machine will go into alarm injection incomplete(page D-0400) . To modify settings see parag. D.4.1 ADVANCED SETTINGS

The parameters quoted in this section are only a guide line, because the various parameters and settingsalways depend on the material used, the mould construction and the volume of the part etc.

WARNING: Some plastic materials maybe inflammable and/or explosive.

C

BABYPLAST 6/10VP D

BABYPLAST 6/10VP D

D BABYPLAST 6/10VP

D.1/ MENU D.1.1/ Display Touch-screen

D-0010

F1 F2 F3 F4 F5

F6

F7

F8

MAIN MENU

000.0mm

00.0mm

Menu open

Motor status

Clamp position

Synoptic diagram

Injection position

moviment Indicators

Tool settingprogramme in use

Function key icons

PROGRAMME IN USE

BABYPLAST 6/10VP D

D-0020

D.1.2/ ICONS - Description of functions

Switch OFF the motor

Timer for starting motor

Access to tool settings

Access to machineconfigurations

Confirm - return toprevious page

Manual menu

Atomatic menu

Semi-automatic menu

Times and settings

Access to machineconfig. - password 1212

Save mould setting data

Injection in maual oraccess to injection data

Plastification inmanual oraccess to plast. data

Clamp in manual or accessto clamp dataInj. carriage in manual oraccess to inj. carriage data

Purge

Ejection in manual oraccess to ejection data

Mould closed position

Purge to start cycle

Purge to end cycle

Quality controlpassword 1212

Core pull

Exit without saving

Start automatic or semi-automatic cycle

Visualise alarmmessages

Access to manufacturersettings.

Switch heaters ON

Switch heaters OFF

Setting times

Access to temperaturespage

Activate temp. in Stand-by

Deactivate Temp. in Stand-by

Mould opening and inj.carr. in semi-automatic

Activate airblow in manualif present

Stop automatic or semi-automatic cycle

Part counter

Access to mould settings

Access to mould settingfilesSave data on USBmemory stickRetreive data from USBmemory stick

Log file: Cycle time-cushion

upgrade softwareDisplay/CPU

Information/upgradesoftware

Activate venturi loader

Save average cycle time

Access to keyboard

Switch ON the motor.

Manual movementsclamp openManual movementsclamp closed

Pressed before F1/ F3 closeand open as per programme

Manual movements to therightManual movements to the left

Overwrite or change mould

D BABYPLAST 6/10VP

D.1.3/ START UP - GATE CHECK

After turning the main switch to the 1 (ON) position, the BABYPLAST logo will appear for a few secondsfollowed by the following display:

D-0030

The clamp and injection guards should be in the closed position. At this point the user should follow thefollowing procedure:

1. Open the left guard and then close it again.2. Open the right guard and then close it again.3. Open the ijection unit guard and then close it again

The above procdure is necessary to gain access to the next menu and thus start the machine.If a fault is detected in the gate swiches, during the functional or sequence checks, the machine will go intoalarm and start up will be prevented. If the gate check is successful, the MAIN MENU will appear on thescreen (see next page).

ATTENTION! If the machine goes into alarm FAULTY GATE or GUARD SWITCH (n° 06, 07 or 08) duringthe gate check at start up, switch the machine off and then on again. If the machine goes into the samealarm while the machine is running, reset the alarm and carryout the gate check again but without switchingoff the machine.This procedure may be repeated three times after which the machine will go into alarmREPEATED FAULTY GATE SWITCH. At this point the machine must be switched off and then on again toreset the the gate check function.

CHECK GUARDS

00.0mm000.0

Indicates right guardopen

Indicates injection guardopen.

Indicates left guardopen

3

2

1

BABYPLAST 6/10VP DD.1.4/ MAIN MENU

D-0040

Press to switch on the motor. The motor symbol, in the top left hand corner of the display, will appearas long as the motor is running. press the same key again to switch off the motor. Keys F1, F2 & F3 areactivated when the motor is switched on.

ATTENTION! The heating elements are switched on by pressing key F3. The setting values will be taken fromthose stored in the tool setting programme indicated in the synoptic diagram.

ATTENTION! If the oil temperature is below the minimum value set by the manufacturer (20°C), nomovements will be possible. In order that the oil reaches the correct temperature rapidly, the motor will turn atfull speed.

Motor OFF

Machineconfiguration

Access to storedmould settings

Manual menu Automatic menu Switch heaters ON

Mould settingprogramme in use

Motor ON/OFF


Go to stored toolsettings

Timer for starting themotor and heaters

Motor status ON

F1 F2 F3 F4 F5

F6

F7

F8

F1 F2 F3 F4 F5

F6

F7

F8

MAIN MENU

MAIN MENU

Gear - art. 2345

F7

000.0mm00.0mm

000.0mm00.0mm

D BABYPLAST 6/10VP

D.1.5/ MANUAL MENU

D-0050

While in the MAIN menu, press F1 to enter the MANUAL menu.The following display will appear:

Back to previousdisplay

Temperatures

Clamp Injection carriage Plastification Injection Ejection

To activate the various movements in manual, press one of the keys to select the function required. Havingentered the function required, press one of the two keys for backward or forward movements,or the two keys up and down movements.

For the menu MANUAL: CLAMP see following page.For the menu MANUAL: EJECTION F3 will activate the optional valve for “AIR BLOW” if installed.

ATTENTION! For plastification and injection, piston movement will only be possible when the settemperatures have been reached. ( See tolerance band - user data input ).

WARNING: WHEN CHANGING FROM ONE MATERIAL TO ANOTHER, LOADING A DIFFERENT MOULD SETTING PROGRAMME OR IN CASE OF RESIDUE MATERIAL LEFT IN THE SYSTEM FROM PREVIOUS PRODUCTION, GREAT CARE MUST BE TAKEN TO SET THE CORRECT PROCESSING TEMPERATURES ACCORDING TO THE MATERIAL

MANUFATURER’S DATA SHEET. FAILURE TO DO SO MAY CAUSE DAMAGE,BLOCKAGE, OR GAS; PARTICULARLY DURING PURGING.

F1 F2 F3 F4 F5

F6

F7

F8 MANUAL MENU

000.0mm00.0mm

ATTENTION! when in any page in the MANUAL MENU except “Ejection”it will bepossible to rotate the table, by pressing the two start buttons simultaneously, under thefollowing conditions:

1. sensor for injectio carriage back, must be activated.2. sensor for ejectors back, must be activated.3. Mould must have reached fully open position.

If the above condions have not been met, at the moment the table should be rotated, then a red indicator willappear in the position in the synoptic diagrammewhere the consensus is missing.

BABYPLAST 6/10VP D

D-0053

D.1.5a/ MANUAL MENU : CLAMP

MANUAL CLAMP OPENSpeed set by manufacturer (30%)

Pressed before keys F1or F3allows the opening and closing of the

clamp at the speed set in the tool settingprogramme in use (see diagramme at bottomof page D1).

MANUAL CLAMP CLOSESpeed set by manufacturer (30%)

CLAMP DATA - please see below

Set MOULD CLOSED POSITION- please see following page

When in the menu MANUAL CLAMP press F4 to gain access to the menu for CLAMP TIMES ANDSETTINGS:

The maximum value depends on thethickness of the mould

Maximum pressure for the lowpressure clamp piston.

Maximum pressure allowed for thelow pressure clamp piston inside themould safety control range (nextline). If too high “034 mould safetyalarm”

Mould safety control range:from thedistance set in mm to the “0” mouldclosed position.

See following diagramme where:

V1: Closing speed 1V2: Closing speed 2P : Closing speed changing point0 : Mould closed position

Confirm and exit

Save values in mouldsetting programme inuse

F1 F2 F3 F4 F5

F6

F7

F8

MANUAL: CLAMP

Opening stroke 055.0 mm

Clamp pressure 050 bar

Mould safety 035 bar

Mould safety range 2.0 mm

Closing speed 1 070 %


Change closing speed 030 mm

Opening speed 1 075 %

To vary values, touch window androtate dial

0

V1

V2

Q mm

V100%

D1

50%

F1

F2

F3

F4

F5

F7

F8

F7

F8

CLAMP TIMES AND SETTINGS

ATTENTION! CLAMP CLOSED prohibited if the table is not in position (consensus from sensor)

MOULD OPEN PROHIBITED if injection carriage is forward (consensus from sensor)

D BABYPLAST 6/10VP

D.1.5.b/ MANUAL MENU: INJECTION CARRIAGE

F1 F2 F3 F4 F5

F6

F7

F8

MANUAL MENU

From the MANUAL MENU, press key F2 to gain access to the following menu:

000.000.0mm

ATTENTION : to avoid damage to the mould and nozzle,the injection carriage can only bemoved forward when the clamp is closed (in the synoptic diag. the indicators are activated).by first pressing key F6 and then pressing key F1.ATTENTION: Take care when using this function because the mould is not closed in highpressure

F1 F2 F3 F4 F5

F6

F7

F8

MANUAL: INJECTION CARRIAGE

000.000.0mm

D-0055

While in the MAIN menu, press F1 to enter the MANUAL menu. The following display will appear:

ATTENTION! when in any page in the MANUAL MENU except “Ejection”it will bepossible to rotate the table, by pressing the two start buttons simultaneously, under thefollowing conditions:

1. sensor for injectio carriage back, must be activated.2. sensor for ejectors back, must be activated.3. Mould must have reached fully open position.

If the above condions have notbeen met, at the moment thetable should be rotated, then a red indicator will appearin the position in the synopticdiagramme where theconsensus is missing.

BABYPLAST 6/10VP D

D-0060

D.1.5.c/ MANUAL MENU: EJECTION

F1 F2 F3 F4 F5

F6

F7

F8

MANUAL MENU

While in the manual menu, press key F5 to gain access to the following menu:

000.000.0mm

ATTENTION! While in the “EJECTION ” menu it is NOT possible to rotate the table. Bypresssing simulaneously the two START buttons, the ejectors will move forward as long asthe buttons are pressed. By pressing the strat bouttons a second time, the ejectors willmove backwardsATTENTION : ejector movements will only be possible if the “table in position” sensors areactivated.

F1 F2 F3 F4 F5

F6

F7

F8

MANUAL: EJECTION

000.000.0mm

While in the MAIN menu, press F1 to enter the MANUAL menu. The following display will appear:

D BABYPLAST 6/10VP

D-0070

D.1.6/ SETTING THE MOULD CLOSED POSITION

Back to previousdisplay

Confirm mouldclosed position

Install the mould, making sure that it is positioned correctly (follow pag.C-050).While in the MAIN menu, press F1 to enter the menu for mould closure in manual.Press F3 to close the mould till it is completely closedPress F5 to confirm the mould closed position.

Touch the icon so that the numeric keypad appears, digit the password 1212 and confirm.

ATTENTION! Ensure that both the symbols on the synoptic diagram, which indicate the mould closed status,turn black only when the mould is fully closed. The point at which the two symbols turn black, is the pointat which the consensus is given for mould CLOSURE IN HIGH PRESSURE.If the two symbols do not turn black, when the mould has reached the mould closed position, the machine willgo into alarm 034 “MOULD SAFETY”.

N.B. It is possible to vary the mould safety settings and sensitivity range etc. See page D. 0300 paragraphD.3.3e.

Mould closed

M

F1 F2 F3 F4 F5

F6

F7

F8

MANUAL: CLAMP

000.000.0mm

BABYPLAST 6/10VP DD.1.7/ SEMI AUTOMATIC MENU

D-0080

ATTENTION! Plastification and injection piston movements will only be possible when the settemperatures have been reached. ( See tolerance band - user’s menu, data input ). If an Automatic,Semi-automatic or purge cycle is selected, and the machine has not reached the the settemperatures, the machine will go in alarm.

Manual menu Automatic menu Switch heaters ON

F1 F2 F3 F4 F5

F6

F7

F8

AUTOMATIC MENUH1 200° H2 200° H3 200° H4 OFF

F1 F2 F3 F4 F5

F6

F7

F8

MAIN MENU

ATTENTION! By pressing F3 the heaters will be switched ON and the active zones will be shown in yellowduring pre-heating and red when the respective tolerance bands have been reached; The settings will be takenfrom those saved in the mould setting programme highlighted in the synoptic diagramme.

Motor OFF


Access to storedmould settings

Gear - art. 2345

Gear - art. 2345

Mould settingprogramme in use

Return to previousdisplay

Temperatures

Times and othersettings

Semi-auto. cycle Purge Part counter

Actualtemperatures

While in the MAIN menu, press F2 to gain access to the AUTOMATIC menu.The following displaywill appear:

Automatic cycleicon -present only if active in the AUTOMATIC function see pare :D-0380

000.000.0mm

000.000.0mm

D BABYPLAST 6/10VP

D.1.7a/ SETTING TEMPERATURES

D-0090

SETTING: Touch zone, which needs to be changed, in the field “Values set”. Rotate the dial M to set the valuerequired. Press F7 to return to the previous page. The modified values are changed but not saved inthe mould setting programme in useThe modified values can be saved in the mould setting programme by pressing F8 .

Oil - reading only Values set Actual values

While in the AUTOMATIC menu press F6 to gain access to the TEMPERATURES menu:

F1 F2 F3 F4 F5

F6

F7

F8


Yellow : indicates that the heaters in therelative zones are in pre-heat mode orstandbyRed that the heaters in the relative tonesare within the tolerance bands

M Gear - art. 2345

Save values in the mouldsettings programme in use

F1 F2 F3 F4 F5

F6

F7

F8

TEMPERATURESOil 045 C°

H1 200 C° 200 C° Plastific.

H2 200 C° 199 C° Chamber

H3 195 C° 195 C° Nozzle

H4 0 514 C° Mould

Confirm and exit withoutsaving values set.

STAND-BY Temperature.It is possible to activate ordeactivate stand-by. Ifactive, the zones will beshown in yellow on thesynoptic diagramme in themain menu.

It is only possible to activate or deactivate the zones fromthe pages of the mould setting programme.see page D-310

M

000.000.0mm

BABYPLAST 6/10VP DD.1.7b/TIMES AND SETTINGS

D-0100

While in the automatic menu press F5 to gain access to the menu for TIMES and SETTINGS, thefollowing display shows readings only and cannot be modified:

F1 F2 F3 F4 F5

F6

F7

F8


M

Gear - art. 2345

Return to previous display

F1 F2 F3 F4 F5

F6

F7

F8

TIMES AND SETTINGSActual cycle time 12.0 sec

Actual cushion 1.2 mm

Average actual time 12.0 sec

Average time saved 12.0 sec

Quality control NO

Cycle time error 05 %

Cushion error 1.0 mm

M

000.000.0mm

D BABYPLAST 6/10VP

D.1.7b1/ INJECTION CARRIAGE SETTINGS

D-0110


F1 F2 F3 F4 F5

F6

F7

F8





Quality control NO



M

From the “MAIN TIMES AND SETTINGS” menu, press F1 to gain access to“ INJECTION CARRIAGE TIMES AND SETTINGS “ :

Touch the field to be modified, vary the values by rotating the dial. Press F8 to save the changes in themould setting programme in use. By pressing F7 the values will be changed but not saved in the mouldsetting programme.

Set a value GREATER than “0”( from 0.5 to 0.8), the injectioncarriage moves back and away fromthe mould at each cycle andactivates the sensor for injectioncarriage in the fully back position( Par. C.6 page C-080).Please note: If the setting is “0” secor the sensor is not activated, themachine will go into alarm118“CONSENSUS INJECTIONCARRIAGE”

Varies the speed of the injectioncarriage.

F6

F7

F8Injection carr. time 0.0 sec

Inj. carriage seed 100 %

INJECTION CARRIAGE TIMES AND SETTINGS

ATTENTION : With rotating table, “injection carriage time” must be sufficient to activate the“ injection carriage fully back” sensor, which must be set so as to allow the table to rotatewith the nozzle fully back. ( see par. C.6 - page. C-0080)

BABYPLAST 6/10VP DD.1.7b2/ SETTINGS - PLASTIFICATION

D-0120


F1 F2 F3 F4 F5

F6

F7

F8





Quality control NO



M

From the “ MAIN TIMES AND SETTINGS” menu press F2 to gain access to“PLASTIFICATION TIMES AND SETTINGS” :

To use with 16/18mm diam. injectionpistons. Serves for activating a doubleplastification so as to fill completelythe above mentioned pistonsi.Settinga value, e.g. 5 sec, the plastificationis activated for this time and thenreactivated for a second time so as toreach the material load set.

Varies the plastification piston speed.

OPZIONAL : If present, the VENTU-RI LOADER can be activated ordeactivated by pressing F6.If the “suction time “ is 0, suction willstop when the sensor, installed in thehopper, detects the presence ofmaterial.Otherwise, if a value is set which is higher than 0, suction will continue after the sensor has detected material,for the time set. After 3 cycles of loading without activating the sensor, (no material present) the function deactvates.Press F6 to reactivate.ATTENTION: for a correct function use dried air.

F6

F7

F82nd shot load time 0.0 sec

Plastification speed 100 %

Suction time 0.5 sec

PLASTIFICATION TIMES AND SETTINGS


D BABYPLAST 6/10VP

D.1.7b3/ SETTINGS - EJECTION

D-0130


F1 F2 F3 F4 F5

F6

F7

F8





Quality control NO



M

Varies the ejection piston speed

N° of ejector strokes ( max 10)

Reducing this value reduces thedistance the ejector piston moves.

From the “ MAIN TIMES AND SETTINGS MENU” pressF3 to gain access to “EJECTION TIMES AND SETTINGS”:

Ejection speed 100 %

Number of strokes 2

Ejection pressure 80 bar

Ejection time 0,20 sec

Ejection return time 0,25 sec

Air blow time 0,0 sec

Ejection pause 0,0 sec

Pause end of cycle 0,0 sec

EJECTION TIMES AND SETTINGS

F6

F7

F8


BABYPLAST 6/10VP DD.1.7b4/ SETTINGS - INJECTION

D-0140


F1 F2 F3 F4 F5

F6

F7

F8





Quality control NO



M

From the “ MAIN TIMES AND SETTINGS MENU” press F4 to gain access to “INJECTION TIMESAND SETTINGS”:

INJECTION TIMES AND SETTINGS

Shot size 29.0 mm

Cooling time 4.5 sec

1st injection pressure 90 bar

1st pressure time 2.0 sec

2nd injection pressure 30 bar

2nd pressure time 1.0 sec

Decompression 0,0 mm

Injection speed 075 %

2nd injection speed 50 %

Second speed point 2,0 mm

ATTENTION: to see all the lines, movethe cursor

Set the shot size in order to obtain acushion value less than 3 mm (pre-setparameter). Maximum value 60mm - Theshot size depends on the pison sizeinstalled.

When the set time has been reached themould opens but except in the case thatplastification has not finished.ATTENTION: To obtain a constant cycletime, set a value greater than the max. timeneeded to load the injection piston.

Injection time, in which the value of the“1st injection pressure.” must be reachedotherwise the machine will go into alarm107 “PEAK NOT REACHED”.

If the second pressure is activated at apoint set in mm (see page D-0290) the line“2nd pressure setting : 00.0mm” will beseen.

When the injection piston reaches the pointset, the second injection speed is activated.


D BABYPLAST 6/10VP

DD.1.7b5/ SETTINGS - CLAMP

D-0150


F1 F2 F3 F4 F5

F6

F7

F8





Quality control NO



M

From the “ MAIN TIMES AND SETTINGS MENU” press F5 to gain access to “CLAMP TIMES ANDSETTINGS ” :

Save values in mouldsetting programme in use

The maximum value depends on thethickness of the mould

Maximum pressure for the lowpressure clamp piston.

Maximum pressure allowed for thelow pressure clamp piston inside themould safety control range (nextline). If too high “034 mould safetyalarm”

Mould safety control range:from thedistance set in mm to the “0” mouldclosed position.

See the following diag. where:

V1: Closing speed 1V2: Closing speed 2P : Closing speed changing point0 : Mould closed position

Confirm and exit









0

V1

V2

Q mm

V100%

D1

50%

F7

F8

F7

F8

CLAMP TIMES AND SETTINGS


BABYPLAST 6/10VP DD.1.7b6/ SETTINGS - QUALITY CONTROL

By setting a tolerance band, it is possible to monitor two parameters on the machine: The CYCLE TIME andCUSHION, for which it is possible to see the last 20 cycles.

D-0160


F1 F2 F3 F4 F5

F6

F7

F8





Quality control NO



M

To modify the quality control parameters press F6 and then in the next display enter the passcode1212 to gain access to the following menu:

From the “ MAIN TIMES AND SETTINGS” menu, press F6 to gain access to“ QUALITY CONTROL’ ”. The following display shows readings only and cannot be modified:

Data log “CYCLE TIME”and “CUSHION”

Confirm and exit

M

QUALITY CONTROL

F1 F2 F3 F4 F5

Quality control NO


Cushin error 1,0 mm

N° of initial cycles 10

N° cycles for alarm 20

Actual cycle time 15,0 sec

Actual avarage time 15,0 sec

Avarage time saved 15,0 sec

Actual cushion 0,0 mm

F6

F7

F8

D BABYPLAST 6/10VP

D-0170

continued....../ SETTINGS - QUALITY CONTROL

The Quality control function can be activated or deactivated by selecting YES or NO in the first line. pressF8 to save and activate the required error value in the programme in use. Press F4 to save theaverage cycle time in the programme in use. The quality control function will not be activated until thenumber of cycles, set in “N° of initial cycles”, has been reached. The first cycle, after these initial cycles, willbe used for reference by the quality control function. If the machine detects a percentage of variation whichis more than that allowed, compared to the reference cycle, for a number of cycles greater than that set inline - “N° of cycles for alarm”, the machine activates alarm 048 “cycle time out of tolerance”.

OPTIONAL: On request it is possible to have an output which is activated each time a cycle is out oftolerance, and which can be used to activate a PART REJECT device. The machine, in this case, will beable to reject parts produced which are out of tolerance and will stop, in alarm, when the value of N°CYCLES FOR ALARM has been reached.

ATTENTION! Each time the settings are modified, a new set of initial cycles is run and hence a new reference cycle is obtained.

t

Confirm and save data in the mouldsettings programme.

Confirm and exit without saving datain the mould settings programme.

QUALITY CONTROL

F1 F2 F3 F4 F5

F6

F7

F8Quality control NO


Cushin error 1,0 mm






Actual cushin 0,0 mm


BABYPLAST 6/10VP D

D-0180

D.1.7b6a/ QUALITY CONTROL - Log File

To see the last 20 “ CYCLE TIMES” and “CUSHION” values, press F3 to see the followingdisplay:

Last cycle registered LOG FILE

F6

F7

F8n° Cycle Cushion

1 25 0.12

2 25 0.12

3 25 0.12

4 25 0.12

5 25 0.12

6 25 0.12

7 25 0.12

8 25 0.12

9 25 0.12

ATTENTION: to see all the lines, movethe cursor

QUALITY CONTROL

F1 F2 F3 F4 F5

Quality control NO


Cushin error 1,0 mm






Actual cushion 0,0 mm

F6

F7

F8

D BABYPLAST 6/10VP

D.2./START A CYCLE D.2.1/ Start a SEMI AUTOMATIC cycle

D-0190

Press F3 : The mould opens completely and the injectioncarriage and nozzle move away from the mould.

ATTENTION! If the temperatures have not reached the tolerance bands, it will not be possible to start the automatic cycle and the machine indicate this with an alarm message without, however, switching off the motors and heaters.The alarm will deactivate when the operating temperatures have been reached.

From the AUTOMATIC MENU press key F2 to gain access to the “SEMI AUTOMATIC CYCLE” menu:

F1 F2 F3 F4 F5

F6

F7

F8

SEMIAUTOMATIC MENUR1 200° R2 200° R3 200° R4 OFF

M

F1 F2 F3 F4 F5

F6

F7

F8

SEMIAUTOMATICR1 200° R2 200° R3 200° R4 OFF

Gear - art. 2345

Gear - art. 2345

000.000.0mm

000.000.0mm

ATTENTION! In order to operate therotating table, the sensors for:ejectors back, injection carriageback and mould open, must beactivated.

TO START A CYCLE:1. Load and isert in the lower mould half on the operator side of the rotating table.2. Press the two START buttons simultaneously and keep them pressed till the table reaches the “CLAMP” position, once this position has been reached, the clamp will close and the injection cycle will start automatically.3. Load another insert and wait for the mould to open again.4. Press the two START buttons simultaneously and keep them pressed till the ejection cylce (if set) has been completed. (ejector forward and back again).5. Repeat from point 2

BABYPLAST 6/10VP D

D-0200

When the machine is in a SEMI AUTOMATIC CYCLE, the following display will be seen:

While the machine is in operation, the following fuctions will be available:

Press F2 :The machine finishes the cycle in course and then stops.

Press F4 :To see the number set in the part counter and also check and reset the number reached.

Press F5 :To see and modify times and other settings.

Press F6 :To see and modify temperatures.

F1 F2 F3 F4 F5

F6

F7

F8

SEMIAUTOMATICR1 200° R2 200° R3 200° R4 OFF

M

Gear - art. 2345

000.000.0mm

D BABYPLAST 6/10VP

D.2.3/ Starting a PURGE CYCLE

D-0210

From the SEMIAUTOMATIC MENU press F3 to gain access to the “PURGE CYCLE” menu:

Press F1 To start PURGE AT END OF CYCLE. At the end of this cycle the injection piston will stop inthe fully forward position hence the cylinder will be empty.

Press F2 To start PURGE AT BEGINNING OF CYCLE. At the end of this cycle the injection cylinder will be loaded with the quantity of material set in the programme.

ATTENTION! If the temperatures have not reached the tolerance bands, it will not be possible to start the automatic cycle and the machine indicates this with an alarm message without, however, switching off the motors and heaters.The alarm will deactivate when the operating temperatures have been reached

F1 F2 F3 F4 F5

F6

F7

F8

SEMIAUTOMATIC MENUH1 200° H2 200° H3 200° H4 OFF

F1 F2 F3 F4 F5

F6

F7

F8

SEMIAUTAUTOMATIC MENUH1 200° H2 200° H3 200° H4 OFF

Gear - art. 2345

Gear - art. 2345

WARNING: WHEN CHANGING FROM ONE MATERIAL TO ANOTHER, LOADING A DIFFERENT MOULD SETTING PROGRAMMEOR IN CASE OF RESIDUE MATERIAL LEFT IN THE SYSTEM FROM PREVIOUS PRODUCTION, GREAT CAREMUST BE TAKEN TO SET THE CORRECT PROCESSING TEMPERATURES ACCORDING TO THE MATERIALMANUFATURER’S DATA SHEET. FAILURE TO DO SO MAY CAUSE DAMAGE, BLOCKAGE, OR GAS;PARTICULARLY DURING PURGING.

From the AUTOMATIC MENU press key F2 to gain access to the “SEMI AUTOMATIC CYCLE” menu:

000.000.0mm

000.000.0mm

BABYPLAST 6/10VP D

D

D-0220

When the machine is running in the PURGE CYCLE, the following display will be seen:

While the machine is running the following options will be available:

Press F3 : The machine will finish the cycle in course and then stop.

Press F6 : To visualise and modify temperatures.

At the end of 6 purge cycles, the machine will stop automatically and remain in idle until either another purgecycle is started (see previous page) or another function is selected.

F1 F2 F3 F4 F5

F6

F7

F8

PURGEH1 200° H2 200° H3 200° H4 OFF

M

Gear - art. 2345

000.000.0mm

D BABYPLAST 6/10VP

D.2.4/ SETTING UP THE PART COUNTER

D-0230

From the “ AUTOMATIC MENU” press F4 to gain access to the “PART COUNTER” menu:

ATTENTION! Ensure that the number of cavities shown corresponds to the actual number of cavities in themould.The number of cavities shown, corresponds to the number of cavities set in the mouldsettings programme in use. To modify, return to the MAIN MENU and press key F5 toenter the mould settings programme.By setting the value of “parts to produce “ to 000000 the part counter is excluded and themachine will produce continuously. To zero the part counter rapidly, select the first digit on theleft and change to zero. All the other digits will change to zero automatically.

F1 F2 F3 F4 F5

F6

F7

F8


Gear art. 2345

PART COUNTER

F6

F7

F8Parts to produce 0

Parts produced 000000

Nunber of cavities 2

Reset

Settings Exit without saving

Confirm and exit

Reset part counter (line - partsproduced).

To set the number of part to produce,touch the icon “ keypad” and thefollowing display will be shown:

set the required value and confirm with

0 1 2 3

4 5 6

7 8 9

0

000.000.0mm

BABYPLAST 6/10VP DD.3/ MOULD SETTING PROGRAMMES

D.3.1/ LOADING A MOULD SETTING PROGRAMME

D-0240

When in the MAIN MENU press F5 to gain access to the following display:

To select a new mould setting programme, go to the mould setting programme folder by pressing F1 .The following display will be seen (see the following page):

F1 F2 F3 F4 F5

F6

F7

F8

MAIN MENU

PROGRAMMES

Programme selected

Gear - art. 2345

F1 F2 F3 F4 F5

F6

F7

F8

Exit without saving

Confirm mould settingprogramme selected

Retrieve programmesfrom a USB memory stick

Save programmes onto aUSB memory stick

Access to mould settingprogramme selected.

Access to the mouldsetting programme folder

Gear - art. 2345

000.000.0mm

D BABYPLAST 6/10VP

D-0245

Go back a directory level

Return to the “programmes”page

Programme selected

Keypad to change name

Exit and confirmaprogramme selected

Exit without confirming

Eliminate programmeselected

Touch the file to be selected, the name will be seen in the field “file”. touch the icon to exit and confirm.

WARNING: WHEN CHANGING FROM ONE MATERIAL TO ANOTHER, LOADING A DIFFERENT MOULD SETTING PROGRAMMEOR IN CASE OF RESIDUE MATERIAL LEFT IN THE SYSTEM FROM PREVIOUS PRODUCTION, GREAT CAREMUST BE TAKEN TO SET THE CORRECT PROCESSING TEMPERATURES ACCORDING TO THE MATERIALMANUFATURER’S DATA SHEET. FAILURE TO DO SO MAY CAUSE DAMAGE, BLOCKAGE, OR GAS;PARTICULARLY DURING PURGING.

/home/root/Fm607/progs

file Plug - art. 4459

filter

Gear - art. 1111 Gear - art. 2345

Gear - art. 422 Plug - art. 4459

Plug - art. 2222

BABYPLAST 6/10VP D

D BABYPLAST 6/10VP

D.3.2/ Create or modify mould setting programmes

D-0250

From the MAIN MENU press F5 to gain access to the following display:

PROGRAMMES

Programme selected

Plug - art. 4459

F1 F2 F3 F4 F5

F6

F7

F8

Exit without saving

Confirm and exit

Retrieve mould settingprogrammes from a USBmemory stick

Save mould settingprogrammes onto a USBmemory stick

To gain access to a mouldsettings programme.

Access to mould settingprogramme folder

PROGRAMME: Plug - art 4459

F1 F2 F3 F4 F5

F6

F7

F8Customer xxx

Material POM

Part weight 0,0 gr

Shot weight 0,0 gr

Mould number 000


Last modification01.01.2008

Programme selected

Exit without saving

Save /Copy cycleprogramme

Setup core pulls

Set temperatures

General settings

Touch the field to be modified, to vary the alphanumerical values, touch the icon “keypad” for the othervalues rotate the dial. Press F7 to save the changes in the mould setting programme in use or to copythe changes into a new mould setting programme. The value “Average time saved” can only be saved in theQUALITY CONTROL function. While the date in “Last modification” , is saved automatically the moment thelast modification is made.

Press F1 to gain access to the following display:

Press F2 to enter the mould setting programme selected.

BABYPLAST 6/10VP D

D-0260

D.3.2a/ Mould setting programmes - TIMES AND SETTINGS D.3.2a1 / INJECTION CARRIAGE

Press F1 to gain access to “ INJECTION CARR. TIMES & SETTINGS “ :

By setting a value other than “0”(from 0.3 to 0.6), the injectioncarriage moves back and away fromthe mould at each cycle. If the settingis “0” sec the injection carriage willremain against the mould duringeach cycle

Varies the speed of the injectioncarriage. F6

F7

F8Injection carr. time 0.3 sec

Inj. carriage speed 100 %

INJECTION CARR. TIMES & SETTINGS

Touch the field to be modified, vary the values by rotating the dial. Press F6 to return to the previouspage without saving. Press F7 to save changes in the mould setting programme in use or to copy themould setting programme by changing the name. Press F8 to exit without saving.

MAIN TIMES AND SETTINGS

F1 F2 F3 F4 F5

F6

F7

F8

D BABYPLAST 6/10VP

D-0270

D.3.3b/ Mould setting programmes - PLASTIFICATION TIMESAND SETTINGS


F1 F2 F3 F4 F5

F6

F7

F8

Press F2 to gain access to “ PLASTIFICATION TIMES AND SETTINGS “ :

To use with 16/18mm diam. injectionpistons. Serves for activating a doubleplastification so as to fill completelythe above mentioned pistonsi.Settinga value, e.g. 5 sec, the plastificationis activated for this time and thenreactivated for a second time so as toreach the material load set.

Varies the plastification piston speed.

OPZIONAL : If present, the VENTU-RI LOADER can be activated ordeactivated by pressing F6.If the “suction time “ is 0, suction willstop when the sensor, installed in thehopper, detects the presence ofmaterial.Otherwise, if a value is set which is higher than 0, suction will continue after the sensor has detected material,for the time set. After 3 cycles of loading without activating the sensor, (no material present) the function deactvates.Press F6 to reactivate.ATTENTION: for a correct function use dried air.

F6

F7

F82nd shot load time 0.0 sec

Plastification speed 100 %

Suction time 0.5 sec

PLASTIFICATION TIMES AND SETTINGS


BABYPLAST 6/10VP D

D-0280

D.3.3c/ Mould setting programmes - EJECTION TIMES ANDSETTINGS


F1 F2 F3 F4 F5

F6

F7

F8

Press F3 to gain access to “ EJECTION TIMES AND SETTINGS “ :

Varies the ejection piston speed

N° of ejector strokes ( max 10)

Reducing this value reduces thedistance the ejector piston moves.

This function may be activated afterinstalling the ejector sensor ontothe moving platten. The sensor issupplied in the accessory pack withthe machine. Activate this functionby selecting YES. The sensor willdetect whether the ejectors havefired or re-entered. In case of fault,the machine will go into alarm 039EJECTORS DID NOT FIRE or 040EJECTORS DID NOT RE-ENTER.

Only in SEMIAUTOMATIC cycle.If active, at end ofSEMIAUTOMATIC cycle. Theejectors remain out and re-enteronly when the start key is pressedfor start cycle.

EJECTION TIMES AND SETTINGS

F6

F7

F8Ejection speed 00 %

Number of strokes 2

Ejection pressure 80 bar

Ejection time 0,20 sec

Ejection retur time 0,25 sec

Air blow time 0,0 sec

Ejection pause 0,0 sec

Pause end of cycle 0,0 sec

Ejection sensor NO

Out at end of cycle NO

Touch the grey fields to changethe values. The lines in boldprint can only be changed inthe MOULD SETTINGPROGRAMME pages.

The values in the white fields canbe changed, both in the MOULDSETTING PROGRAMME pagesand in TIMES AND SETTINGSpages while the machine isrunning.


D BABYPLAST 6/10VP

D-0290

D.3.3d/ Mould setting programmes - INJECTION TIMES AND SETTINGS

INJECTION TIMES AND SETTINGS

Shot size 29.0 mm

Cooling time 4.5 sec

1st injection pressure 90 bar

1st pressure time 2.0 sec

2nd injection pressure 30 bar

2nd pressure time 1.0 sec

Decompression 0,0 mm

Injection speed 075 %

2nd injection speed 50 %

Seconnd speed point 0.0 mm

Injection mode Peak

Accumulator OFF

ATTENTION: to see all the lines, movethe cursor.


PEAK: (de-fault) - At the end of injection time and on condition that the 1st injection pressure has beenreached, the machine will change over to the 2nd injection pressure.

POSITION (Pos.) : The 1st injection pressure will be maintained till the position, previously set in the injectionmenu, has been reached. At this point, the machine will change over to the 2nd injection pressure

Optional: Activates the output which controlsthe hydraulic accumulator (if installed) duringthe injection phase.

Set the shot size in order to obtain a cushionvalue less than 3 mm (pre-set parameter).Maximum value 60mm - The shot sizedepends on the pison size installed.

When the set time has been reached themould opens but except in the case thatplastification has not finished.ATTENTION: To obtain a constant cycletime, set a value greater than the max. timeneeded to load the injection piston.

Injection time, in which the value of the “1stinjection pressure.” must be reachedotherwise the machine will go into alarm 107“PEAK NOT REACHED”.

If the Injection Mode is activated“POSITION”the line “2nd pressure setting : 00.0mm”will be seen.

When the injection piston reaches the pointset, the second injection speed is activated.



F1 F2 F3 F4 F5

F6

F7

F8

BABYPLAST 6/10VP D

D-0300

D.3.3e/ Mould setting programmes - CLAMP TIMES AND SETTINGS


F1 F2 F3 F4 F5

F6

F7

F8

The number of cavities set, conditions thepart counter

Depends on the mould height. Withminimum mould h. 120 the maximumpossible is 110mm

Pressure setting for clamp pistonN.B. the larger piston for high pressure (6,25t.) is activated only when the mould is inthe fully closed position.

The maximum pressure allowed for theclamp piston in low pressure. If reached themachine goes in alarm 034 Mould safety

The alarm in mould closing will be activestarting from the position of the mouldsafetyr setting to the position of the mouldsafety exclusion settingN.B.Outside this range (mould safety andmould safety exclusion) the maximumpressure allowed is the pressure set inclamp pressure.

his function is used to regulate thesensitivity of the MOULD CLOSEDposition. The range can be set betweenapprox. 0,03 to 0,3 mm. Change the value to modify thesetting.

F7

F8

F6


Present only if YES is set in the line AUTOMATIC (D-0380) Open guard: NO if the guard remains closed at end of cycle. YES if the guard remains open at end of cycleGuard mov. in alarm: NO machine in alarm guard closed YES machine in alarm guard open

TEMPI E QUOTE CHIUSURANumber of cavities 2




Mould safety setting 2.0 mm

Mould safety excl. pos. 0.10 mm






Open guard NO

Guard mov. in alarm NON° of moulds on table 2

2 set: TWO mould halves are present: the sensor, situated onthe rotating protection, needs to be activated every half turn(two screws need to be fitted A1-A2 to the protection).1 set: one mould half is present: the sensor, situated on therotating protection, needs to be activated every complete turn(remove screw A2 which activates the sensor fitted behind themould in respect to the rotation of the table).

Mouldposition

A1

A2

D BABYPLAST 6/10VP

D-0310

D.3.2b/ Mould setting programmes - TEMPERATURES

N.B. : The valves, EV 1-2-3-4 (water manifold) are optional. However, in any case the values can be set as areminder using the same values as the water manifold ( 5-10-15-20-25).

PROGRAMME: Plug art. 4459

F1 F2 F3 F4 F5

F6

F7

F8Customer xxx

Material POM

Part weight 0,0 gr

Shot weight 0,0 gr

Mould number 000


Last modification 01.01.2008

Programme selected

Exit without saving


Setup core pulls

Set temperatures

General settings

Touch the field to be modified, to vary the alphanumerical values, touch the icon “keypad” for the othervalues rotate the dial. Press F7 to save the changes in the mould setting programme in use or to copythe changes into a new mould setting programme. The value “Average time saved” can only be saved in theQUALITY CONTROL function. While the date in “Last modification” , is saved automatically the moment thelast modification is made.


TEMPERATURES

F6

F7

F8H1 Heater plastif. 215 C° % XH2 Heater inj. chamber 215 C° % XH3 Heater nozzle 215 C° % XH4 Heater mould 215 C° % X

V1 Cooling fixed platen 0 C° % XV2 Cooling hopper 0 C° % XV3 Cooling fixed mould 0 C° % XV4 Cooling moving mould 0 C° % XHotrunner 0

ACTIVE zone NON ACTIVE zone

to activate a zone, press directly on the symbol C° (% only in case of emergency), then on the corresponding “valuefield” and rotate the dial to set the value required.press X to deactivate the zone completely.

M

BABYPLAST 6/10VP D

D-0320

D.3.5/ Mould setting programmes - core pull


PROGRAMME

F6

F7

F8Core pull A Core pull B

Disabled

Pos Status Time Cons.

1 OFF 0.0 OFF

2 OFF 0.0 OFF

3 OFF 0.0 OFF

4 OFF 0.0 OFF

5 OFF 0.0 OFF

2

3

4

Sch 1

Indication of the page,core pull A or B, being visualised

5

1

Digit the words “activate” or “deactivate” toactivate or deactivate the core pull functionin the respective page A or B.

Ejection

Mould open

Cooling

Mould closed

Injection

On request, a socket can be fitted for 24V output (output A - J708) (output B - J709) and the two respectivePNP input sockets for cycle consensus (A J306 - BJ307). The two outputs A or B can be activated for anindefinite length of time when ON is set (status column), and 00s set (time column). The same outputs canalso be activated for specific length of time by setting ON (status column) and a specfic time (time column).When ON is selected in the cons. column (consensus), the cycle will not start without the input (for consensusto continue) from an external source.Positions 1,2,3,4 & 5 represent the positons during the cycle when the outputs A or B will be activated (seefollowing diagram). This function can also be used to activate a valve for air blow for example.To activate or deactivate the output A or B, select by touching the relative heading (Core pull A or Core pull B).

PROGRAMME: Plug - art. 4459

F1 F2 F3 F4 F5

F6

F7

F8Customer xxx

Material POM

Part weight 0,0 gr

Shot weight 0,0 gr

Mould number 000



Programme selected

Exit without saving


Setup core pulls

Set temperatures

General settings

D BABYPLAST 6/10VP

D.3.3/ TOOL SETTING PROGRAMMES - How to copy a programme.

D-0330

If a new programme has to be created, which is similar to an existing programme, it is possible to copy theexisting programme and make modifications if necessary.Do as follows:

Example: Programme to copy : Gear ANew pragramme : Gear B

From the main menu press F5 to gain access to the following display:

Press F7 to gain access to the following display: (see following page):

PROGRAMMES

Programme selected

Gear A

F1 F2 F3 F4 F5

F6

F7

F8

Exit without saving

Confirm and exit

Retrieve mould setingprogrammes from USB memory stick

Save mould settingprogrammes on a USB memory stick

To gain access to a mouldsettings programme.

Access to the mould settingprogrammes folder

PROGRAMME: Gear A

F1 F2 F3 F4 F5

F6

F7

F8Customer xxx

Material POM

Part weight 0,0 gr

Shot weight 0,0 gr

Mould number 000



Programme selected

Exit without saving


Check that the mould setting programme selected is the one to be copied,(to select another programme see page D-0240) press F2 to enter the programme

BABYPLAST 6/10VP D

D-0340

Press “Change” :

PROGRAMME: Gear A

F1 F2 F3 F4 F5

F6

F7

F8Customer xxx

Material POM

Part weight 0,0 gr

Peso stampata 0,0 gr

Numero stampo 000

Tempo m YESdio salvato 10.4 sec

Last modification01.01.2008

Save changes in the mouldsetting programme in use

Change programme nameby creating a newprogramme

Exit without saving

/home/root/Fm607/progs

file Gear A

filter

Programme selected

Key to change name

Confirm and exitprogramme selected

Exit without confirming

Eliminate programmeselected

Press the icon “ keypad” digit the new programme name (eg: Gear B)confirm and exit from keypad by pressing . The new programme created will be seen in the field “file”( E.g. gear B) press the icon to confirm and exit.

SAVE PROGRAMME Gear A

Yes Change Cancel

Gear 1111 Gear 2345

Gear 4422 Gear A Gear A

Plug 2222

D BABYPLAST 6/10VP

D-0350

D.4/MACHINE CONFIGURATION

From the main menu press F6 to gain access to the following display:

Press F4 and enter PASSCODE 1212 to gain access to ADVANCED USER SETTINGS:

Manufacturer

Advanced settings User

F1 F2 F3 F4 F5

F6

F7

F8

Advancedsettings

MAIN MENU

Gear part. n° 2345

F1 F2 F3 F4 F5

F6

F7

F8

SET UP 15:25:33

February 2008

Sun Mon Tue Wes Thu Fri Sat

1 2 3 4 5 6 7

8 9 10 11 12 13 14

15 16 17 18 19 20 21

22 23 24 25 26 27 28

000.000.0mm

BABYPLAST 6/10VP D

D-0360

D.4a/ MACHINE CONFIGURATION - ADVANCED SETTINGSChange language - Celsius/Farenheit

From DISPLAY SET UP press F4 and enter the pass code1212 (see previous page) to gain accessto the following display :

Press F3 to see the software versions installed in the 4 microprocessors mounted in the machine.

INFO

F6

F7

F8

FMP266 FM607 Sw. Ver.: 1.10

FMP266 FM542 Sw. Ver.: 2.00

FMP266 FM542DSPSw. Ver.: 1.60

FMP000 FM549 Sw. Ver.: 1.01AV

MACHINE PARAMETERS

F1 F2 F3 F4 F5

F6

F7

F8Language English

Degrees Celsius

Machine ID number 1

Meter - Hrs 000045 reset

Total hours 000045

Total cycles 001555

Modification with password

Software version display

Software version CPU

Software version - prop. valve

Software version INVERTER

Upgrade software: The icon is onlyactive if the USB memory stick isinserted in the USB port on themachine. ( see page. D-0390)

Change language

Change to Celsius/Farenheit

Machine identification number - (see page D-0410)

Meter - hours . every 1500 hoursthere will be a reminder to changethe oil return filter. Press the word“reset” to reset.

Total hours counter. Cannot bereset.

Total cycles counter. Cannot bereset.

If is selected, the settingscan only be modified by digitingthe user password 1212

D BABYPLAST 6/10VP

D-0370

D.4b/ MACHINE CONFIGURATION - ADVANCED SETTINGS -TEMPERATURES

From DISPLAY SET UP press F4 and enter the pass code 1212 (see previous page) to gain accessto the following display:

Press F4 to gain access to Machine parameters TEMPERATURES:

Touch the field to be modifed, change the value by rotating the dial.

ATTENTION: If the actual temperatures exceed by more than double the value set in “Tol. band max. error”, themachine will go in alarm “112..116 OVER TEMPERATURE..” - Motor and heaters will be switched off.

TEMPERATURES

Tol. band max. error 25 C°

Temperature in stand-by 80 %

Timeout for alarm 3 min

Pre-heating time 180 sec

When the heaters are switched on, they willremain at the stand-by temperature for thelength of time set for “pre-heating time”

MACHINE PARAMETERS

F1 F2 F3 F4 F5

F6

F7

F8Language English

Degrees Celsius

Machine ID number 1


Total hours 000045

Total cycles 001555


Change language


Machine identification number -(see page D-0410)


The value set, will be the toleranceband for thetemperature in use. If the operating temperatureincreases or decreases by a value greater thanthis set temperature, (i.e. goes out of the toleranceband) the machine goes into alarm Tol. band maxerror. Manual operation of the injection piston andplastification will not be possible nor will it bepossible to enter an automatic cycle until theoperating temperatures are within this toleranceband.

The stand-by temperature always depends onthe temperatures set in each of the mouldsetting programmes and when active, theheater zones will be seen in yellow. Thestand-by temp. activates in the followingcases:1.When the heaters are switched on inautomatic.2.When the machine is in alarm for a greaterlength of time than the time out alarm.3.When the heaters are switched onmanually.

If the machine is in alarm for a time greaterthan that set fo “time out alarm”, the heaterswill go into the stand-by mode. After doublethe length of time, the heaters and motor willbe switched off.

BABYPLAST 6/10VP D

D-0380

D.4c/ MACHINE CONFIGURATION - ADVANCED SETTINGS -TIMES AND SETTINGS

From display set up press F4 and enter the pass code 1212 (see previous page) to gain access tothe following display:

Press F5 to gain access to MACHINE PARAMETERS - TIMES AND SETTINGS:

MACHINE PARAMETERS

F1 F2 F3 F4 F5

F6

F7

F8Language English

Degrees Celsius

Machine ID number 1


Total hours 000045

Total cycles 001555


Change language


Machine identification number -(see page D-0410)


Touch the field to be modifed, change the value by rotating the dial.

Set date and time

ATTENTION: The value of 10mm MUST beset if a 10mm injection piston is installed onthe machine. This setting will limit themaximum injection pressure to 100 bar.

Maximum injection pressure in manual andpurge.

Maximum cushion. If the cushion is more,than the value set, for a number of cyclesgreater than that set in the line “Injectionincomplete” (next line), the machine will gointo alarm 036 INJECTION INCOMPLETE

If the cushion is more, than the value set inthe previous line (Cushion), for a number ofcycles greater than that set in this line(Injection incomplete), the machine will gointo alarm 036 INJECTION INCOMPLETE

If the clamp does not reach the “0” mouldposition (mould closed) within the set time,The machine will go into alarm 042TIMEout mould closed

Clamp speed in manual mode

Activate / deactivate the second openingspeed.When active, it will be possible to set thepoint at which the speed changes, in theCLAMP TIMES AND SETTINGS menu.

Piston diameter 14 mm

Injection pressure 60 bar

Cushion 3,0 mm

Injection incomplete 8

Timeout clamp close 4,0 sec

Closing speed in manual 30 %

Opening speed 2 NO

Intrusion programme NO

Automatic mode NO

Select NO (default): Cycle only in semi-automaticSelect YES : cycle in automatic/semiautomatic -with possiblity of guard open or not at end of cyclein case of alarm ( see manual page D-300)

TIMES AND SETTINGS

If NO is set (default): Standard cycle.If YES is set:Produces a pre-injection.and a line will appear, in the INJECTION menu,where it will be possible to set a time to activateplastification before the injection phase.

D BABYPLAST 6/10VP

D-0390

MACHINE PARAMETERS

F1 F2 F3 F4 F5

F6

F7

F8Language English

Degrees Celsius

Machine ID number 1

Meter 000045 reset

Total hours 000045

Total cycles 001555

Modify with password

D.4.4/ UPGRADE SOFTWARE

Change language

Change Celsius/Farenheit

Machine identification number- (see page.D-0410)


Total hours counter. Cannot bereset.

Total cycles counter. Cannot bereset.

If is selected, the settings canonly be modified by digiting theuser password 1212

From the page DISPLAY SETTINGS press F4 and insert the assword 1212 (see previous page) togain access to the following screen :

Peress F3 to see the software versions loaded on the 4 microprocessors fitted to the machine

ATTENTION: Upgrade diplay: The folder “FM607”, suppplied by the manufacturer, should beloaded onto a USB memory key

Upgrade CPU: The file“FMP282_FM542Appl_V.....”.mot should be present

Remove the cover found on the bottom side the display, and insert the USB memory stick into one of the twoUSB ports as indicated.

BABYPLAST 6/10VP D

D-0400

F6

F7

F8

SOFTWARE UPGRADE

FM607 (Display) Upgrade

FM542 (CPU) Upgrade

F8

INFO

F6

F7

F8

FMP282 FM607 Sw. Ver.: 1.10

FMP282 FM542 Sw. Ver.: 2.00

FMP282 FM542DSPSw. Ver.: 1.60

FMP000 FM549 Sw. Ver.: 1.01AV

Press F3 to see the software versions loaded onto the 4 micrprocessors fitted to the machine:ATTENTION: It is only possible to gain access to the following pages with the motor OFF

Software version of the Display

Software version of the CPU

Software version of the Prop. valve

Software version of the INVERTER

Software upgrade icon is only activewhen the USB memory key isinserted.

Key “FM607 (display) to loadupgrade file for the display from theUSB memory key

Key “FM542 (CPU) to loadupgrade file for the CPU from theUSB memory key


To upgrade software do as follows:

FM607 Display: press the corresponding key, the numeric key pad will apear, digit the password 1122 andconfirm. At the end press F7, remove the USB key switch off the machine at the mainswitch and then switch it on again.

FM542 CPU: press the corresponding key, the numeric key pad will apear, digit the password 1122 andconfirm the main directory of the USB key will appear, select the file:FMP282_FM542Appl_V.....” and confirm. At the end press F7, remove the USB key switchoff the machine at the main switch and then switch it on again.

ATTENTION: When upgrading the CPU and Display together, it is possible to swith the machine OFF andon again at the end of both operations.

D BABYPLAST 6/10VP

D-0410

D.5/ USB MEMORY STICK - Saving/downloading

From the MAIN MENU press F5 to gain access to the following display:

Remove the cover found on the bottom side the display, and insert the USB memory stick into one of the twoUSB ports as indicated.

F1 F2 F3 F4 F5

F6

F7

F8

MENU PRINCIPALE

Ingranaggio cod 2345

000.000.0mm

BABYPLAST 6/10VP D

D-0420

By pressing the icon F4, a folder will be created in the USB memory stick called: BabyFMP282_ID001 this folder will contain ALL the “mould setting programme” files found in the machine. ATTENTION :If the folder already exists, any files, contained inside this folder, with the

same name will be overwritten

By pressing F5 all mould setting programmes in the folder BabyFMP282_ID001 will be loaded ontothe machine. ATTENTION the files with the same name will be overwritten.

ATTENTION: do NOT change the name of the folder created , the names of the files inside can bechanged, but not that of the folder otherwise it will not be possible to load the files (mouldsetting programmes) not the machine

If more than one Babyplast are owned and in the case that each machine should have its own mould settingprogrammes, it is possible to give each Babyplast a different ID number (machine Identification number ( eg:01 - 02 - 03 ecc.) on the “MACHINE PARAMETERS” ( see page D-0360).In this case, even if only one USB memory stick is used, different folders will be created with different namesbased on the machine ID numberFor example: BabyFMP282_ID001

BabyFMP282_ID002BabyFMP282_ID003....ecc.

It will be possible to modify the position of files (mould setting programmes) and change their names insidethe various folders via a PC.

ATTENTION: the icons F4 and F5 are only activeif the USB memory stick is inserted into one of the USB ports.

PROGRAMMES

Programme selected

Gear - art. 2345

F1 F2 F3 F4 F5

F6

F7

F8

D BABYPLAST 6/10VP

D-0430

1. Copy the folder “BP_Program_Viewer_v100” into a directory on a PC

2.Open the programme BP_Program_Viewer_v100 found inside.

3.Select “ Open”

4. using “browse” select the folder “BabyFMP66_ID001” where the mould setting programmes (files) havebeen previously saved. (see paragraph D.5 page D-0410)

D.5.1/ PRINT AND ELEBORATE MOULD SETTING DATA ON A PC

BABYPLAST 6/10VP D

D-0440

5. Select the folder “Progs” and then the mould setting programme (file) required

6. Open

7. Once the mould setting programme (file) has been opened, it will be possible to print it, copy and past itinto another programme (such as Microsoft Word / exel etc) save it in a different format.


E-0010

E.9/ ALARMS

N° MESSAGE CAUSE ACTION001 LEFT GUARD OPEN002 RIGHT GUARD OPEN003 INJ. GUARD OPEN004 MOTOR OVER HEATED

005 OFFSET ANALOG INPUT FAULTY

006 FAULT SWITCH - LEFT GUARD007FAULT SWITCH - RIGHT GUARD008 FAULTY SWITCH INJ. GUARD010 EEPROM FM542 ERROR

011 INCONSISTENT GATE CHECK

012 FAULTY THERMOCOUPLE PLATEN013 FAULTY THERMOCOUPLE HOPPER014 FAULTY THERMOCOUP. PLASTIF.015 FAULTY THERMOCOUP. INJ. CHAM.016 FAULTY THERMOCOUPLE NOZZLE017 FAULTY THERMO. FIXED MOULD018 FAULTY THERMO. MOVING MOULD019 HOPPER OVER HEATED

020 OIL OVER HEATED

021 FAULTY INTERN. COMPENS. T/C

022 FAULTY EXTERN. COMPENS. T/C

023 OIL LEVEL LOW

024 NEUTRAL PHASE MISSING026 PHASE MISSING027 CURRENT FAULT028 INVERTER ALARM029 OIL COLD

030 FAULTY OIL COMPENS. T/C

031 EMERGENCY

032 CHANGE FILTER

033 EJECTORS OUT

Mould guard openInjection guard openThe motor has over heated

Thermocouple analog inputsfaultyFaulty guard / gate switch orswitches are not synchronisedwith the hydraulic safety valve.Fault eeprom on CPU

Inconsistency in the gate checkproceedure

Thermocouple faulty

Insufficient cooling at base ofhopper. If more than 70°C,machine goes into alarmInsufficient cooling.Temperaturover 60°CFaulty thermocouple cold jointcompensator on circuit board.Faulty thermocouple cold jointcompensator in socket.Oil level is too low

Neutral phase not connectedPhase not connected

Inverter faultyOil temperature less than 20°C

Oil thermocouple cold jointcompensator faultyEmergency stop button activatedor input from external alarm.The machine has worked for1500 hrs.Trying to start a cycle withejectors out and ejector returnsensor active.

Close guard and ensure that thecorresponding indicator, on the synopticdiag., goes out.Check the power supply to the motor.

Alarm is only present durng testing bymanufacturerSwich off at the main switch. Check theposition of the switches in theguards.Repeat gate check.Switch machine OFF and then ONagain. If persists contact a technician.Swich off at the main switch. Check theposition of the switches in theguards.Repeat gate check.

Check thermocouple, wires andconnections. Change if necessary.

Check water flow and thetemperature of the cooling system.

Check water flow and thetemperature of the cooling system.Contact a technician

Check wires and contacts change NTCcomponent.Check for leaks, check oil level float andconnections. Fill tank to correct level.

Check power supply connectionsCheck power supply connectionsCheck power supply voltageContact a technicianSwitch on the motor and / or wait for theoil temperature to go above theminimum temperature allowed.Check wires and connectioins orchange NTC componentReset button or check external alarmsource.Change return filter and and reset hourmetreMake ejectors return in manual mode.Check the M4 x 20 screw whichconnects the ejector pin in mould to theejector piston on machine

E


E-0020

N° MESSAGE CAUSE ACTION034 MOULD SAFETY ALARM

035 RECURENT FAULTY SWITCH

036 INJECTION INCOMPLETE

037 TIMEOUT MATERIAL LOAD

038 TIMEOUT MOULD OPENING

039 EJECTORS DID NOT FIRE

040 EJECTORS DID NOT RE-ENTER

041 MAX CYCLE TIME EXCEEDED

042 TIMEOUT MOULD CLOSURE

043 TIMEOUT HIGH PRESSURE

044 TIMEOUT DECOMPRESSION

045 END OF PRODUCTION BATCH046 DSP COMMUNICATION PROBLEM047 PROBLEM WITH CIRCUIT BREAKER048 CYCLE TIME OUT OF TOLERANCE

050 FAULTY MOULD TRANSDUCER051 FAULTY INJECTION TRANSDUCER052 CUSHION OUT OF TOLLERANCE

054 TIME-OUT CORE PULL A055 TIME-OUT CORE PULL B056 CHECK GUARDS AND GATE

1. Object trapped between two the mould halves2.Mould safety set too sensitive.

3.Mould safety range too low

1.Incorrect gate switch sequence.2.Switch not incorrect positionThe injection piston has notreached the correct cushionpositon (less than 3mm) for 8consecutive cycles seepag.D-380Activates if material does not loadwithin 23 Sec. from the start ofplastificationMould does not open or wrongsetting for min. mould opening The ejector sensor is active anddid not detect ejectors fired.The ejector sensor is active anddid not detect ejectors re-enteredCycle has not beencompleted within 90 sec.The mould does not close within3 sec.

No impulse from injection pressureswitch within 3 secfrom the start of high pressure.Decompression point not reachedwithin 3 sec.End of production batch.Faulty proportional valveFaulty circuit breakerThe quality control function isactivated and the cycle time hasgone out of toleranceFaulty transducer readings

The quality control function isactivated and the cushion value isout of toleranceNo consensus for core pull

Guard / gate check not completed.

Remove the object which is stoppingthe mould from closing. Increase “ Mould safety”(page D-0150)Enter the mould setting programme inuse , clamp page (D-320) line “mouldsafety range” increase the value set.

Switch the machine OFF and then ONagain.

1. Incomplete or no injectiondue to a part stuck in the mould cavityor a blocked nozzle.2.Material load set too high. Reduceuntil cushion is under 3mm.1.No material in hopper2.Hopper chute blockedCheck hopper or plastification valveCheck mould or min mould opensetting.1.Check mould2.Check position of ejector sensor.3.If sensor is not present, deactivatefunction. Check screw in eject. pist.Check at which point in the cycle, themachine stopped.1.Increase closing speed / pressure.2.Increase mould safety pressure.3.Check for the mould closed indicators on the synoptic diag.

1.Check the setting of the injectionpressure switch and that it functionscorrectly. (page F-140 pos. 11) Check the injection valve.

Reset counter / start a new batch.Contact a technician.Contact a technician.Check the cause -Increase the % set for tolerance band.

Check connections

Check the cause / cycle parameters.Increase the % set for tolerance band.

check mould and connection of sensors

Open guards, wait for at least 2 secsand then close again.

E


N° MESSAGE CAUSE ACTION064 TIME-OUT PLASTIF. HEATER065 TIME-OUT INJ. CHAMBER HEATER066 TIME-OUT NOZZLE HEATER067 TIME-OUT MOULD HEATER068 TIME-OUT MOV. MOULD HEATER069 TIME-OUT MACHINE STOPPED

070 AUTO-OFF FOR MACHINE STOPPED

071 CONNECTION PROBLEM FM542

072 NOT REACHED PLASTIFIC. TEMP.073 NOT REACHED INJ. CHAMBER TEMP074 NOT REACHED NOZZLE TEMP.075 NOT REACHED MOULD TEMP.076 NOT REACHED MOV. MOULD TEMP.078 GATE OPEN DURING CYCLE079 INJ. GUARD OPEN DURING CYCLE080 ERROR PLASTIFICATION TEMP.081 ERROR INJ. CHAMBER TEMP.082 ERROR NOZZLE TEMP.083 ERROR MOULD TEMP.084 ERROR MOVING MOULD TEMP.106 SHORT CIRCUIT PROP. VALVE

107 PEAK NOT REACHED

108 INVERTER OVER HEATED

111 TIMEOUT HIGH PRESS. MOULD

112 OVER TEMPERATURE PLAST.113 OVER TEMPERATURE CHAMBER114 OVER TEMPERATURE NOZZLE115 OVER TEMPERATURE FIXED MOULD116 OVER TEMPERATURE MOV. MOULD

128 DATA LOAD FM542 KO129 DATA LOAD INVERTER KO130 COMUNICATION FM542 KO131 COMUNICATION INVERTER KO

Activates when the heaters donot reach the set temperaturewithin 30mins.(manufacturer setting by default)

Activates when machine remainswith heaters and motor ON, butwithout running a cycle, for morethan 30 mins. (manufacturersetting by default)Activates after the machine hasbeen in alarm for more than 6mins. (user setting page D-0370).- Motor and heaters are switchedOFF.Faulty CPU

Activates if the heaters have notyet entered within the tolerancebands and the operator attemptsto use plastification or injectionfunctions.Guard / gate open

Temperatures out of tolerance(+ 0 -) band during cycle.

Faulty proportional valve

Set injection pressure notreached

Inverter temperature has goneover the operating temperatureallowed.Clamp piston does not reachhigh pressure 130bThe actual temperature hasgone out of tolerance by doublethe max imum tol. temp .set(page D-0390) because:1. A temperature has beenchanged while the machine is stillhotand the new value is out of thetolerance band by double.2. A faulty triac or optoisolatorhas caused a short circuit in theheater.Data load failure while startingmachine

Reset the alarm, switch the machineOFF and check heaters andconnections.

Reset the alarm and switch ON the motor and heaters.

Reset the alarm and switch ON themotor and heaters.

Switch machine OFF and then ONagain. If persists contact a technician.Exit from Automatic/Semiautomatic/Purge and wait for the temperatures toenter within the respective tolerancebands

Reset alarm and close guard / gate

Check thermocouples and connections.

Switch the machine OFF and ON againIf persists contact a technician.Increase injection time.Check injection pressure transducerconnections.Check cooling circuit , valve andthermocouple which control the tempe-rature. Check hydraulic line pressure and thatclamp high pressure valve activates.

1. Set a higher temperature setting thatis within the tolerance band or wait forthe machine to cool to a suitabletemperature.2. Contact a technician.

Switch machine OFF and then ONagain. If persists contact a technician.

E-0030

E


132 PROBLEM WITH CAN-BUS133 CAN-BUS IN ERROR144 EXCESS VOLTAGE - INVERTER145 INSUF. VOLTAGE - INVERTER146 INVERTER OVER HEATED

147 MOTOR OVERHEATED

148 POWER FAULT - INVERTER

149 EXCESS CURRENT - INVERTER150 PROTECTION IXT INVERTER151 PROTECTION I2T MOTOR152 INVERTER PARAMETERS KO

153 OFFSET CURRENT OUT OF RANGE

154 POWER SUP. VOLTAGE TOO HIGH155 MOTOR OVER LOAD

Bad connection CPU - Euromap

Inverter voltage too highInverter voltage too lowInverter heat exchangertemperauture too high

Mtor temperature too high

Faulty inverter board

Inverter current too highInverter current too highCurrent to motor too highInverter data load KO

Error with inverter parameters

Power supply voltage too highCurrent to motor too high

Check and/ or replace cable CPU/Euromap.Check power supply voltage or contacttechnician.Check valve and water flow.Check heat exchanger thermocouple

Check phases, power supply cables tomotor and thermocouple.Re-set adn switch on motor. Contacttechnician. Contact technician.

Contact technician.Switch machine of and on againif problem repeats, contact technician.Switch machine of and on againif problem repeats, contact technician.Check power supplyCheck connections to motor/ oilviscosity/ contact technician.

N° MESSAGE CAUSE ACTION

E

117 TIMEOUT ROTAZIONE TAVOLA

118 CONSENSO CARRO INIEZIONE

119 CONSENSUS MOULD OPEN

120 CONSENSUS MOULD POSITION

121 INTERVENTION PHOTOCELL

128 DATA LOAD FM542 KO129 DATA LOAD INVERTER KO130 COMUNICATION FM542 KO131 COMUNICATION INVERTER KO

Timeout activation of rotatingtable sensorInjection carriage sensor notactivated

Mould open setting notreached.Mould position sensor notactivatedDuring the rotation of the table,the photocells have detected an

intrusion.

Data load failure while starting machine

Check sensors and rotation of table.

Check sensor functions correctly andits position. Check injection carriagemoves fully backCheck setting and movement for mouldopen.Check position of sensor (par. D.3.2a5pag. D-0320)1. Check that nothing is in front of theguard photocells, reset and return tableto correct position.

2.Check cable and contacts.

Switch machine OFF and then ONagain. If persists contact a technician.


F-0010

F/ MAINTENANCE

All the materials used in the construction of BABYPLAST have been studied so that they require minimummaintenance and are easy to replace.

OIL:The oil and filters must be kept clean and must be replaced within the recommendedperiods so that the hydraulic equipment does not wear prematurely.RECOMMENDED PERIODS FOR OIL CHANGE: = 2000 to 5000 HOURS ( acc. to oil type)FILTER: = 1500 HOURS

REFRIGERATION UNIT:If treated water is used, so as to avoid calcium deposits from forming, no maintenance isrequired. If treated water is not used, the system will have to be cleaned depending on calciumlevel in the water.

MOVEABLE PARTS:Injection piston and cylinder: periodically check the area behind the injection piston and cylinderand remove any residue plastic material which may have accumulated during normal function.Hydraulic parts : periodically check for oil leaks and, if necessary replace any damaged seals.(Complete sets of seals are available for each assembly).Moving platen: The moving platen is fitted with STD bushes lined with TEFLON, which allowmovement.

Rotating table: keep the space between the rotating table and fixed platen well lubricated.

GASKETS:All the gaskets are fitted with bronze reinforced PTFE friction strips, and O-ringseal. Check the that the surfaces correspond before joining.

ELECTRICAL EQUIPMENT.Inspect the ventilator in the electrnics compartment, particularly in hot weather, keep theunit dry and clean, and make sure the connections are well-maintained. Do not use usedparts when replacing elements, especially where FUSES AND TRIACS are concerned.Electrical maintenance should be carried out by qualified personel only.

HEATING EQUIPMENT:Seeing as all the heating elements are standard and the thermocouples are independent,they are easy to maintain. If other thermocouples are used,they should be a groundisolated "J"-type to avoid disturbances from electrical noise. The Nozzle has anarmoured heating element which is fixed in place by a cup shaped protecive cover.Keep this assembly as clean as possible and check the condition of wiring regularly fordamage etc.

NOZZLEThe Nozzle has an armoured spiral heating element which is fixed in place by a cup shaped

protecive cover. Keep this assembly as clean as possible and check the condition of wiringregularly for damage etc.

INJECTION CHAMBERhas two 8 x 80 diameter bulb type 200 W heating elements which need tobe checked regularly. Keep this assembly as clean as possible and check the conditionof wiring regularly for damage etc.

PLASTIFICATION CHAMBERThe plastification chamber is heated by a - 230V 1000W 37mm diam. heater band(diam. 60 x 120mm 230V 1100W for augmented version) which guarantees an optimal and uniformheat distribution which is essential for technical polymers. Keep this assembly as clean as

possible and check the condition of wiring regularly for damage etc.

F


F

When the machine is out of service, we recommend that is is removed from the production area andthat a suitable suitable label, indicating the machine status, is placed on the machine in a visible area.

Once the machine is out of service, we recommend that the various parts are divided and grouped bythe various material types for recycling or disposal.

All materials used in the machine construction ar non toxic and do not present a health hazard and socan be handled without taking any particular precautions.

ATTENTION! The hydraulic oil must be disposed of according to local laws in force at the time and must not be dispersed in the atmosphere.

ATTENTION! At the end of the working life of the machine, it must be dismantled and disposed of by qualified personel only. Only suitable lifting and moving equipment must be used according to local laws in force at the time.

F-0015

F.1/ Machine out of service


F-0020

F/ Electrical drawings - Electro-mechanical diagramme

F


F-0030

F/ Electrical drawings - 400V - 3Ph Power connections

F


F-0035

F/ Electrical drawings - 230V -3Ph Power connections


F-0040

F/ Electrical drawings - Gate switch connections

F


F-0050

F/ Electrical drawings -Outputs

F


F-0060

F/ Electrical drawings -Inputs

F


F-0070

F/ Electrical drawings -Inverter,CPU & Display connections

F


F-0075

F/ Electrical drawings - ROTARY TABLE Inputs

in2+


F-0080

F/ Electrical drawings -Euromap 67.1 connections (optional)


F-0090

F/ Electrical drawings board CPU board layout (FM542-1) part n° C30903100


F-0100

F/ Electrical drawings Power board layout (FM542-2) part n° C30902000

F


F-0110

F/ Electrical drawings Display layout (FM607A) part n° 0903200

F


F-0120

F/ Electrical drawings inverter (FM549BP) part n° C30902300

ATTENTION: When removing this board, do not separate the board from the aluminiumbase. Failure to do so may cause serious damage.

F


F-0130

FF/ LAYOUT HEATER THERMOCOUPLE CONNECTIONS

CRONOPLAST s.l.

Detail A

THERMOCOUPLE HOPPER302.6651400

ZONE H1: PLASTICATIONHeater 30301400Thermocouple 30201400

ZONE H2: CHAMBERHeater 30300800Thermocouple 30201000

ZONE H3: NOZZLEHeater 30300400Thermocouple 302.6651200


F-0140

F/ HYDRAULIC SYSTEM

OIL TANK

OIL TANK

C40203600C40203700043306105600000

12

OC9001053

13

OC9001003

14

40203900

15

30706800

16

402.6950200

17

2C10006500

18

C30400300

19

40202900

20

407.6801200402.6252710407.200113410000500

8

91011

ES-OD02

ES-OD02111

1111

1111111Valve VED8I4306.58K34.44NCD215

Solenoid S8.356HRL.24DC 20W Cl.FProp. valve VEP5A2R10.77K0604NASolenoid S5L35HRL 12VDC 23W Cl.H

Screw M8x8 with diam.0,5mm holePressure switch 110/107bar (160bar)Pressure transducer 250 bar - 10vPressure gauge 160 bar

Motor 3 phase - 330V - 50hzPump 3,5lReturn filterMaximum pressure reg. DBDSSuction filterRadiator assembly

AFT valve

Screw M6x6 with diam. 0,6mm hole

Solenoid S8.356HRL.24DC 20W Cl.F

Solenoid S8.356HRL.24DC 20W Cl.FValve VED8I4206.58K40.30NCC215

Valve VED8I4306.58K32.44NCD215

Valve VSON.08A

Hydraulic diagrammeBABYPLAST 6/10PV

21 40203400 Safety Valve assembly 1

23 40202300 No return valve vuz 18BSP 5 PSI 1/81

24 10000800 Safety valve11

22 40201600 Primer valve

OFEO7806RL0001

cronoplast sl

402.20011001-4-6 3ES-OD02

2-3

6402.2001102

5

2

7

2402.2001101 1

2

15

1619 20

1817

F


F-0150

12

Scre

w M

8x8

with

dia

m.0

,5m

m h

ole

Pres

sure

sw

itch

110/

107

bar (

160b

ar)

Pres

sure

tran

sduc

er 2

50 b

ar -

10v

Scre

w M

6x6

with

dia

m. 0

,6m

m h

ole

Sole

noid

S8.

356H

RL.

24D

C 2

0W C

l.F

Sole

noid

S8.

356H

RL.

24D

C 2

0W C

l.FVa

lve

VED

8I42

06.5

8K40

.30N

CC

215

Valv

e VE

D8I

4306

.58K

32.4

4NC

D21

5

Valv

e VS

ON

.08A

Hyd

raul

ic b

lock

BAB

YPL

AST

6/1

0PV

2

4B4A3

9

1111

1212

OFE

O78

06R

L000

1

cron

opla

st s

l

402.

2001

100

1-4-

63

ES-O

D02

2-3

640

2.20

0110

2

5

2

7

240

2.20

0110

112

C40

2036

00C

4020

3700

0433

0610

5600

000

OC

9001

053

OC

9001

003

4020

3900

3070

6800

891011

ES-O

D02

ES-O

D02

1111111

Con

nect

ions

A-B

-C-D

-E-F

-G-H

-I-J-

K-L

--P

RS

1-: G

1/8

C

onne

ctio

ns P

-T-T

RS:

G1/

4

1A :

INJE

CTI

ON

1B: D

EC

OM

PR

ESS

ION

2 :P

LAST

IFIC

ATI

ON

3 : E

JEC

TIO

N

4A :

CLA

MP

H. P

.4B

: C

LAM

P L

. P.

5A :

MO

ULD

OPE

N5B

: PR

ES. R

ELE

ASE

6A :

NO

ZZLE

BAC

K6B

: NO

ZZLE

FO

RW

AR

D

Valv

e VE

D8I

4306

.58K

34.4

4NC

D21

5So

leno

id S

8.35

6HR

L.24

DC

20W

Cl.F

Prop

. val

ve V

EP5A

2R10

.77K

0604

NA

Sole

noid

S5L

35H

RL

12VD

C 2

3W C

l.H

6B6A

7

1 2 3 4 5 6

10 8I

T

P

5B5A

1B1A

F/ Hydraulic manifold

F


F-0160

F


F-0170

B

A

A 10

0030

00

B 10

0005

00

Part

num

ber

N°

DES

CR

IPTI

ON

Mot

or -

pum

p as

sem

bly

Hea

t exc

hang

er a

ssem

bly

P

art n

°

D

escr

iptio

n

F/ Motor - pump assembly

F


F-0180

F/ Standard injection unit 6/10VP

F

Part

num

ber

CR

ON

OPL

AST

s.l.

N°

Not

eQ

.tyD

ESC

RIP

TIO

N


F-0190

F/ Augmented injection unit 6/25VP

F

CR

ON

OPL

AST

s.

l.

N°

Not

eP

art n

umbe

rD

ESC

RIP

TIO

NQ

ty

Documents

r4 Vert Tavrot Ing Ts 2009