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BABYPLAST 6/10P

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INSTRUCTION MANUAL
Rev 2

BABYPLAST 6/10P

INSTRUCTION MANUAL
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 the manufacturer has specified. The manufacturer reserves the right to modify their product data or features without prior notice.

WARNING
Before starting up the machine or carrying out any maintenance work, read this instruction manual carefully

TECHNICAL ASSISTANCE

CRONOPLAST sl

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

www.babyplast.com
Last mod. 15/04/2008

BABYPLAST 6/10P

CE CONFORMITY STATEMENT
We hereby declare that the product type refered to is is a: BABYPLAST MODEL 6/10P, WITH SERIAL NUMBER: ................. MANUFACTURER : CRONOPLAST S.L. TO BE USED SOLELY FOR THE INJECTION MOULDING OF THERMOPOLYMERS: EXCLUDING INFLAMMABLE 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 292-1 UNI EN 292-2 UNI EN 201 For electromagnetic compliance directives (89/336/CEE) : CEI EN 61000-6-2:2001 CEI 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 : - CEI EN 61000-6-2, CEI EN 61000-6-4 : - CEI EN 60204-1 : Quadra report RTE002 Eletech report 50261EMC01.00 Eletech report 50261LVD01.00

BABYPLAST 6/10P

GENERAL INDEX CONTENTS


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

A/ General conditions and characteristics of BABYPLAST 6/10P.


A.1/ General conditions......................................................................................................... A-0010 A.2/ What is a BABYPLAST 6/10P and what can it do?...................................................... A-0010 A.3/ Technical data................................................................................................................A-0020 A.3.1/ General dimensions of BABYPLAST 6/10P.................................................. A-0020 A.3.2/ BABYPLAST 6/10P, Basic parts list................................................................ A-0030 A.3.3/ Technical data..................................................................................................A-0040 A.3.4/ General mould dimensions.............................................................................. A-0050 A.3.4a/ Assembly diagramme to show mould installation............................A-0060 A.3.4b/ Drawing to show mould assembly.................................................. A-0070 A.3.5/ Increasing the gap between the machine platens by 25mm........................... A-0080 A.3.6/ How to move the injection point off centre...................................................... A-0090 A.3.7/ Diagramme to show injection pressures......................................................... A-0100 A.4/ Warranty........................................................................................................................ A-0100

B/ How to install a BABYPLAST 6/10P................................................................................B-0010


B.1/ Unpacking and parts check........................................................................................... B-0010 B.2/ Position the machine on a work bench......................................................................... B-0010 B.3/ Electrical connections 400V 3 phase + N + earth....................................................... B-0020 B.4/ Electrical connections 230V 3 phase + earth............................................................... B-0020 B.5/ Cooling system............................................................................................................. B-0030 B.6/ Hydraulic oil specifications............................................................................................. B-0040

C/ Start up.............................................................................................................................C-0010
C.1/ Safety devices................................................................................................................C-0010 C.1.1/ Main switch...................................................................................................... C-0020 C.1.2/ Emergency stop...............................................................................................C-0020 C.1.3/ Hydraulic system safety device....................................................................... C-0030 C.1.4/ Safety devices for guard and transparent gate............................................... C-0040 C.2/ Installing a mould........................................................................................................... C-0050 C.3/ Display panel..................................................................................................................C-0060 C.4/ Pressure gauges................................................................................................... C-0060 C.5/ Cooling system - water manifold..............................................................................C-0070 C.6/ Display - Synoptic diagramme................................................................................C-0080 C.7/ Starting the machine.............................................................................................. C-0090

BABYPLAST 6/10P

D/ How to use a BABYPLAST 6/10P........................................................................D-0010


D.1/ Menu................................................................................................................................... D-0010 D.1.1/ Display....................................................................................................................D-0010 D.1.2/ Icons - description of functions............................................................................. D-0020 D.1.3/ Start up - gate check.............................................................................................. D-0030 D.1.4/ Main menu............................................................................................................. D-0040 D.1.5/ Manual menu......................................................................................................... D-0050 D.1.5a/ Manual menu CLAMP................................................................................ D-0060 D.1.6/Setting the MOULD CLOSED position................................................................... D-0070 D.1.7/Automatic menu...................................................................................................... D-0080 D.1.7a/ Temperature settings................................................................................. D-0090 D.1.7b/ Times and settings.................................................................................... D-0100 D-1.7b1/INJECTION CARRIAGE settings................................................. D-0110 D-1.7b2/ PLASTIFICATION settings...................................................... D-0120 D-1.7b3/ EJECTION settings.................................................................D-0130 D-1.7b4/ INJECTION settings............................................................... D-0140 D-1.7b5/ CLAMP settings.................................................................... D-0150 D-1.7b5.a/CLAMP settings....................................................................D-0155 D-1.7b6/ QUALITY CONTROL settings.................................................. D-0160 D.2/Starting a cycle........................................................................................................ D-0190 D.2.1/ Starting an automatic cycle............................................................................ D-0190 D.2.2/ Starting a semi automatic cycle.......................................................................D-0210 D.2.3/ Starting a purge cycle..................................................................................... D-0230 D.2.4/Setting up the PART COUNTER........................................................................D-0250 D.3/ Mould setting programmes........................................................................................ D-0260 D.3.1/ Loading a mould setting programme.............................................................. D-0260 D.3.2/ Create or modify a mould setting programme.................................................... D-0270 D.3.2a/Mould setting programmes - times and settings.......................................D-0280 D.3.2a.1/ INJECTION CARRIAGE..........................................................D-0280 D.3.2a.2/ LOADING.......................................... .................................. D-0290 D.3.2a.3 / EJECTION........................................................................... D-0300 D.3.2a.4/ INJECTION........................................................................... D-0310 D.3.2a.5/ CLAMP................................................................................ D-0320 D.3.2b/ Mould setting programmes TEMPERATURES............................................... D-0330 D.3.2c/ CORE PULL.................................................................................................D-0340 D.3.3/ Mould setting programmes - COPY A PROGRAMME............................................. D-0350 D.4/Machine configuration.......................................................................................................... D-0370 D.4.1/Machine configuration - Change language - Celsius/Farenheit.............................. D-0380 D.4.2/Machine configuration - Temperatures.................................................................. D-0390 D.4.3/Machine configuration - Times and settings........................................................D-0400 D.4.4/Software Upgrade.............................................................................................D-0405 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-0010 F/2 Electrical and hydraulic drawings...................................................................................F-0020 ..............................................................................................F-0140

BABYPLAST 6/10P

GENERAL SAFETY REGULATIONS


To be studied carefully before using the machine The Babyplast 6/10P injection moulding machine, for thermoplastic materials, has been constructed to meet most safety regulations actually in force. Failure to respect the following instructions, may cause 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 the precautions 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 screwed down. 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 the injection phase. 9) Before carrying out any maintenance, the machine must by disconnected from the mains and the main switch 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 not exceed 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 to standard 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 position for easy access and must have an identification sign or label. IT IS THE RESPONSIBILITY OF THE OWNER TO ENSURE THAT THE MACHINE MEETS MAXIMUM SAFETY LEVELS AT ALL TIMES, AND THAT THE OPERATOR ALWAYS RESPECTS THE SAFETY AND MAINTENANCE INSTRUCTIONS FOUND IN THIS MANUAL AND ON THE LABELS ATTACHED TO THE MACHINE. IN CASE OF DOUBT AND OR FOR ANY FURTHER CLARIFICATIONS, PLEASE CONTACT YOUR NEAREST DEALER.

BABYPLAST 6/10P

A
A.1/ GENERAL CONDITIONS

This technical documentation is intended for all those responsible for using and handling the BABYPLAST 6/10P injection moulding machine. We wish to emphasise that this injection moulding machine can only be used according to the instructions set out in this manual. Failure to follow this instruction manual correctly, may cause injuries to people and animals or damage to materials 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 such products 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 6/10P is a PATENTED model. BABYPLAST 6/10P 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 and 93 / 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 the language of the country of destination. For multi-lingual countries or those outside the European Community, the required language should be specified in the customers order.

A.2/ WHAT IS A BABYPLAST 6/10P AND WHAT CAN IT DO?


The BABYPLAST 6/10P injection moulding machine is the result of thirty years experience working in 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 area of demand: -SMALL SERIES PRODUCTION. -PROTOTYPE DEVELOPMENT. -LOW COST OF MOULDS.. -LABORATORY TESTS. -TECHNICAL TRAINING. BABYPLAST 6/10P is the ideal solution for producing small plastic-moulded parts, without using multiple 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 the final 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 6/10P machine, will help fulfil your application expectations. When handling and processing any injection moulding materials, customers must follow the material manufacturer's instructions with great care.

A-0010

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

BABYPLAST 6/10P

All dimensions are in mm.

A-0020

BABYPLAST 6/10P

A
A.3.2/ Babyplast 6/10P - BASIC PARTS LIST

1-Alarm warning light. 2-Dial for changing data 3-Display 4-Function keys. 5-Guard - Clamp piston 6-Clamp piston 7-Transducer - clamp. 8-Water connections moving mould half 9-Clamp pressure gauge 10-Emergency stop button 11-Injection pressure gauge 12-Hydraulic safety device 13-Exit chute for parts 14-Water connections fixed mould half 15-Water manifold 16-Water inlet-oulet 17-Aluminium slide rail for guards 18-Injection carriage assembly 19-Transducer - injection piston

20-Guard - injection 21-Plastification chamber 22-Plastification piston 23-Hopper cover 24-Hopper 25-Injection chamber 26-Nozzle 27-Fixed platen 28-Moving platen 29-Transparent gate 30-Access to power supply & Euromap board 31-Plastification heat guard 32-Mains power supply cable 33-Access to fuses, power board & CPU board 34-Main switch 35-Drain 36-Inspection cover for hydraulic manifold.

A-0030

A
A.3.3/ TECHNICAL DATA

BABYPLAST 6/10P

Piston diameter (mm.): Volume (cm3): Injection pressure (Kg/cm2.) : Clamp force : Opening force : Opening stroke : Ejection force: Ejection stroke : Hydraulic pressure : Oil tank capacity : Dry cycle : Rated power : Weight : Noise level : Power supply:

10 4 2.650

12 6, 5 1.830

14 9 1.340

16 12 1.030

18 15 815

6.250 Kg. cm3 62.5 KN 400 Kg. 30 - 110 mm. 750 Kg. 45 mm. 130 Kg./cm2. 12 l. (approximately) 2.4 s. 3.0 Kw ~ 150 Kg. < 70 db 3 ~ 230V. 50/60 Hz. + Earth 3 ~ 400V. 50/60 Hz. +Neutral + Earth 7.5 KN 4 KN

A circuit breaker must be used at the mains connection.

A-0040

BABYPLAST 6/10P

A
A.3.4/ GENERAL MOULD DIMENSIONS MOULD DIMENSIONS

ATTENTION:

When the machine is set up for the 25mm extra opening, the thickness of the mould must also be increased accordingly from 70mm to 95mm

MAIN DIMENSIONS FOR INSTALLING A MOULD


DISTANCE INSIDE GATE A = approx. 50mm B = approx. 60mm

Opening stroke Min. thickness

Ejector stroke

Moving mould half

Nozzle travel

Fixed mould half

All dimensions are in mm For further information on mould dimensions,please see the enlarged drawings on the follwing pages.

A-0050

BABYPLAST 6/10P

A.3.4a/ ASSEMBLY DIAGRAMME TO SHOW MOULD INSTALLATION

2 or 4 screws - DIN 912 M.6 x 80

IMPORTANT - Coupling pin must be made so that it cannot rotate (e.g. square head).
Screw - DIN 912 M.4 x 20 Grub screws - DIN 913 m. 10 X 25

Assemble with M4 allen key. 2 or 4 screws - DIN 912 M.6 x 35

NOTE:

Locating sides A e B must be machined to high precision.

NEVER USE THE MACHINE WITHOUT A MOULD INSTALLED


For instructions on how to install a mould, please see parag. C.2 MOULD INSTALLATION page- C-0050

ATTENTION: When using heated moulds with temperatures exceeding 60 / 70C, insulation plates must be fitted around the mould and a special cooling ring (part number C10006600) must be fitted to the moving platen. Failure to do so may cause overheating to the machine and damage to seals and clamp assembly.

A-0060

BABYPLAST 6/10P

A
A.3.4b/ DRAWING TO SHOW MOULD ASSEMBLY

4,5

A-0070

A
1 2 3 4
max 180 mm

BABYPLAST 6/10P

A.3.5/ Increasing the gap between the machine platens by 25 mm.

max 205 mm

1. Column fixing screws. 2. 25mm spacer. 3. Columns. 4. Mobile platen

5. Fixed platen 6. column head. 7. Fixed platen fixing screws. 8. Column fixing block.

TO INCREASE THE GAP BETWEEN THE PLATENS, PROCEED AS FOLLOWS: Unscrew and remove the fixing screws 1 and the 25 mm spacer 2 .Unscrew, the column head 6 in order to insert the 25 mm spacer 2 into the block 8 , and the fixing screws 7 in order to move the fixed platen back 5 by 25 mm. Replace the columns ensuring that they are pushed well into their respective holes and tighten the 4 screws 1 crosswise.

ATTENTION: IN CONFIGURATION A THE MINIMUM THICKNESS OF THE MOULD IS 70mm. IN CONFIGURATION B THE MINIMUM THICKNESS OF THE MOULD IS 95mm.

A-0080

BABYPLAST 6/10P

A.3.6/ HOW TO MOVE THE INJECTION POINT OFF CENTRE

1. Centre position A. Protection fixing position - injection assembly in central position. 2. 25mm off centre position B. Protection fixing position - injection assembly in off centre position. 3. Silicon protection The Babyplast 6/10P, has two injection positions, one central and one 25mm off centre. TO MOVE THE INJECTION ASSEMBLY OFF CENTRE BY 25mm, PROCEED AS FOLLOWS: Unscrew and remove the fixing screws from position 1. Slide the columns out from position 1 and insert them into position 2 (25mm lower). Screw in and tighten the two fixing screws in the new position. IMPORTANT: Having moved the injection assembly off centre, move the connection point of the silicon protection from position A to position B

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

A-0090

A
A.3.7/ DIAGRAMME TO SHOW INJECTION PRESSURES
kg/cm2 3.000

BABYPLAST 6/10P

2.500
Specific pressure on material

Injection piston

10mm* 2.000 12mm 1.500 14mm 1.000 16mm 18mm 500

10

20

30

40

50

60

70

80

90

100

110

120 kg/cm2

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

A.4/ WARRANTY

The vendor guarantees that the material is to be supplied against all manufacturing faults, and accepts replacing any faulty part or repairing any faulty operation free-of-charge, providing the buyer notifies the vendor of said fault within 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; wear caused 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 the electrical system, the use of un-authorised lubricants, accidents and damage or any failure to observe the application and installation instructions detailed in this manual. Furthermore. the travelling expenses of a technician (hours and kilometres) as well as transport costs for replacement 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 means considered necessary, on condition that the buyer does not obstruct the work of those who the vendor has nominated responsible for carrying out the revision. WARNING: In its continual endeavour to improve its products, CRONOPLAST reserves the right to modify or vary its products features or specifications without prior notification.

A-0100

BABYPLAST 6/10P

B
B/ HOW TO INSTALL A BABYPLAST 6/10P B.1/ UNPACKING AND PARTS CHECK

First of all remove the screws in the case as shown in Fig. 1b., and lift the case lid to remove the contents (Fig. 2b), check that there are no faulty parts. If any of the parts are faulty, notify your nearest distributor immediately. Dismantle the front and rear fixing bars. You will find the following parts inside the packing case: (Fig. 3b.) a/ 1 BABYPLAST 6/10P. b/ 2 slings for transfering the machine to its work site. c/ 1 instruction manual. d/ 1 hopper. e/ 1 bag containing spare parts and their corresponding list.

B.2/ POSITION THE MACHINE ON A WORK BENCH

There are 4 guides welded underneath the BABYPLAST 6/10P chassis; pass the slings through these guides as shown in Fig. 4b. and secure them in the crane hook. (Before positioning the slings, open the 2 guards and move the transparent gate to the left, (cf: Fig. 5b.). Use a crane to lift the machine and place it above the work bench (the approximate machine weight is 120 kg). During this operation,it is very important to handle the machine with care. (Fig. 6b). The machine must be installed in a well illuminated, dry place where the surrounding temperature does not exceed 40C.

B-0010

B
B.3/ ELECTRICAL CONNECTIONS for 400V power supply 3 phase + neutral + earth - 400V - 50/60Hz

BABYPLAST 6/10P

The mains power supply fuses inside Babyplast 6/10 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 must be installed.

B.4/ ELECTRICAL CONNECTIONS for 230V power supply

3 phase +earth - 230v - 50/60Hz The mains power supply fuses inside BABYPLAST 6/10 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 6/10 will be prepared for connecting to a power supply as specified in the customers order.

Current: Max 7,5A - average 3,5A FUSES INSTALLED ON THE fm542 BOARD Fuse pos. number F501 F502 F503 F504 F505 F506 F507 F508 F509 Technical specifications 10A - 500V - rapid blow 10A - 500V - rapid blow 10A - 500V - rapid blow 8A - 250V - rapid blow 8A - 500V -extra rapid 3,15A - 500V - extra rapid 3,15A - 500V - extra rapid 6,3A - 500V - extra rapid 3,15A - 500V - extra rapid Dimensions Power rating FUNCTION

6,3X32 F 6,3X32 F 6,3X32 F 6,3X32 F 6,3X32 FF 6,3X32 FF 6,3X32 FF 6,3X32 FF 6,3X32 FF

500V/ 1.500A - 250V/10.000A 500V/ 1.500A - 250V/10.000A 500V/ 1.500A - 250V/10.000A

PHASE R PHASE S PHASE T 24V POWER

500V/ 1.500A - 250V/10.000A 500V/ 1.500A - 250V/10.000A 500V/ 1.500A - 250V/10.000A 500V/ 1.500A - 250V/10.000A 500V/ 1.500A - 250V/10.000A

Plast. heater Chamber heater Nozzle heater F. mould heater M. mould heater

B-0020

BABYPLAST 6/10P

B
B.5/ COOLING SYSTEM

This is needed to: Cool the hydraulic oil. Cool other parts of the machine. For connecting the cooling water supply to the BABYPLAST 6/10 machine, the inlet and outlet hose must be of a flexible type. Connect the inlet hose to the water supply (see diagramme), the outlet hose to the return circiuit and open the shut-off valve. The temperature of the incoming water must be between 12C (min.) and 18C (max.). However, the minimum and maximum temperatures are indicative only and depend on the machine settings and working conditions. 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 a difference between the inlet and outlet of 1.5 bar.

B-0030

B
B.6/ HYDRAULIC OIL SPECIFICATIONS

BABYPLAST 6/10P

BABYPLAST 6/10 is not supplied with hydraulic oil unless requested as an accessory. Only an oil with the following properties can be used in the machine. OIL PROPERTIES: RANGE: -15C +80C VISCOSITY: 12 100 mm /SEC.(CST) FILTRATION: 25 30 um. MINIMUM AGIP-OSO45 CASTROL-HISPIN AWS46 CHEVRON-EPHIDRAULIC OIL 11 ESSO -NUTOH48 IP-IPHYDRUS OIL 46 MACH -BP ENERGOL HLP80 MOBIL-DTE MEDIUM FIAT- RZA 40 TOTAL- AZOLLA 30 VERY IMPORTANT The 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 THE MACHINE TO GO INTO ALARM (ALARM 023) IF THE OIL LEVEL IS TOO LOW. OPERATING TEMPERATURE: 45C MAXIMUM TEMPERATURE : 60C (ALARM 020) MINIMUM TEMPERATURE : 15C (ALARM 029).Below the minimum temperature, it will only be possible to switch on the motor, heaters and consult the various menus and settings. No machine movements will be possible.

Oil return filter

Maximum hydraulic pressure adjustment valve

Oil fill cap

B-0040

BABYPLAST 6/10P

C
C./ START UP C.1/ Safety devices

Position of safety devices. Safety for the user. Mould safety. Safety standards. EN 60204 T1/1985

DIN VDE 0113 T1/02.B6

1. Main Switch

6. Safety device for clamp guard

2. Emergency stop.

7. Safety device for clamp guard

3. Hydraulic system safety device.

8. Safety device for injection guard

4. Safety device for transparent gate.

9 Safety device for injection guard

5 Safety device for transparent gate.

10. Heat guard

C-0010

C
C.1.1/ MAIN SWITCH
The main switch switches the machine ON and OFF and is found on the side of the machine (figure 1c). It has two positions (0 off - 1 on). When i n position 0 it is possible to insert a padlock to block it for safety reasons.

BABYPLAST 6/10P

fig. 1c

C.1.2/ EMERGENCY STOP


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

C-0020

BABYPLAST 6/10P

C
C.1.3/ HYDRAULIC SYSTEM SAFETY DEVICE

When the transparent gate is opened, the power supply to the valves is cut and a safety release valve is activated which diverts all the hydraulic fluid in the system to the oil tank, thus stopping all the machines movements. The safety valve (page F-0140 - pos. 21) is fitted with a switch which to monitor and ensure that it functions correctly. If the transparent guard is closed and the hydraulic safety device does not return to its working position, alarm 002 GATE OPEN is activated.

Transparent gate

Aluminium rail Hydraulic safety device Inspection hole

If the machine has not been used for a long period or after transport, the plunger on the hydraulic safety device, situated behind the aluminium rail near the transparent gate (see drawing above), may become stuck. To free the plunger, open the gate, insert a small screwdriver into the inspection hole and push the plunger in and out.

C-0030

BABYPLAST 6/10P

C.1.4/ SAFETY DEVICES FOR GUARDS AND TRANSPARENT GATE


1-2-3/ Safety devices - Transparent gate When the safety devices for the transparent gate are activated, the power supply to the electrovalves, which control the machine movements, is cut and the hydraulic safety device is activated to divert all the hydraulic oil in the system back to the tank. Alarm 002 is activated which in turn activates the alarm warning light and acoustic alarm.

4-5/ Safety devices - Clamp guard When the safety devices for the Clamp guard are activated, the power supply to the electrovalves, which control the machine movements, is cut and the hydraulic safety device is activated to divert all the hydraulic oil in the system back to the tank. Alarm 001 is activated which in turn activates the alarm warning light and acoustic alarm.

6-7/ Safety devices - Injection guard When the safety devices for the Injection guard are activated, the power supply to the electrovalves, which control the machine movements, is cut and the hydraulic safety device is activated to divert all the hydraulic oil in the system back to the tank. Alarm 003 is activated which in turn activates the alarm warning light and acoustic alarm.

C-0040

BABYPLAST 6/10P

C
C.2/ INSTALLING A MOULD

Ensure that the previous instructions have been followed carefully, that there are no oil or water leaks and that the electrical connections and power supply are correct. The mould halves are installed in the cavities in the machine platens as follows: A./ Place each mould half in the corresponding cavity in each platen and slightly tighten the DIN 913 M10 x 25 grub screws to hold them in place. B-/ Fix the ejector coupling pin to the ejector piston using an M4x20 allen head screw. C-/ Secure the mould halves to the platens, using 2 or 4 DIN 912 M6 x 80 screws for each mould half, and tighten well. Tighten the four DIN 913 M10 x 25 grub screws which centre the mould halves. D-/ Each mould half should protrude at least 15mm from their respective platen in order to install cooling or heating.
( CRONOPLAST S.L. and RAMBALDI Srl are highly experienced in the design, development and construction of Babyplast moulds and are ready to provide expert service and advice in order to offer their customers complete turn key solutions).

2 or 4 screws - DIN 912 M.6 x 80

IMPORTANT - Coupling pin must be made so that it cannot rotate (e.g. square head).
Screw - DIN 912 M.4 x 20 Grub screws - DIN 913 m. 10 X 25

Assemble with M4 allen key. 2 or 4 screws - DIN 912 M.6 x 35

NOTE:

Locating sides A e B must be machined to high precision.

C-0050

C
C.3/ DISPLAY PANEL
A. TOUCH-SCREEN DISPLAY Visualise all data and functions of the machine as well as the synoptic diagramme of the machine. Allows machine parameters to be varied or saved, by touching the various icons or fields of data. B. References for icons The following refences are used (F1F2 etc..) to simplify the explanations of the functions of the various icons referred to in this manual on the touchscreen display. C. ALARM WARNING LIGHT Lights up when an alarm is activated. At the same time a description of the alarm/fault appears on the display. D. DIAL Allows a more rapid input/change of data.

BABYPLAST 6/10P

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

MENU PRINCIPALE

000.0mm 00.0mm

C.4/ PRESSURE GAUGES


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

1 2

CLAMP PRESSURE GAUGE Indicates the CLAMP PRESSURE which corresponds to the maximum working pressure of the machine. (system pressure 130bar). INJECTION PRESSURE GAUGE Indicates the INJECTION PRESSURE (1st Pressure - 2nd Pressure)

C-0060

BABYPLAST 6/10P

C
C.5/ COOLING SYSTEM - WATER MANIFOLD

Situated on the lower right-hand side of the machine.

Icons : indicate the cooling zone. Sphere : Indicates the actual water flow rate. Control knobs: adjust the water flow rate to each zone

25 20 15 10 5 0

25 20 15 10 5 0

25 20 15 10 5 0

Regulates the water flow required for cooling:

1 2 3 4

Moving mould half. Fixed mould half. Fixed platen. Hopper area.

The zones should be regulated so as to obtain a minimum amount of water consumption, in relation to the temperatures 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 60C, alarm 020 OIL OVER HEATED is activated or 108 INVERTER OVER HEATED.

C-0070

C
C.6/ Touch-Screen display - Synoptic diagram

BABYPLAST 6/10P

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 opening of guards and gate and the opening and closing of the mould.

1 2 3 H1 200

MAIN MENU H2 200 H3 200 H4 OFF

23 4 5 6 7 8 9 Gear art. 2345


000.0mm

22 21

20

19

00.0mm

10
1. 2. 3. 4. 5. 6.

11

12

13

14

15

16

17

18

Page visualised. Actual temperatures - H1 plastif. - H2 Chamber - H3 Nozzle - H4 Mould. If present, indicates that the motor is ON. Mould position. Indicates that left clamp guard is open This group of three arrows indicates that the mould is closing in HIGH PRESSURE and that the hydraulic valve has been activated. 7. Indicates the closing or opening of the mould and that the corresponding hydraulic valve has been activated. 8. Indicates activation of ejectors and that the hydraulic valve has been activated. 9. Icons: touch to activate corresponding function. 10. Indicates the name of the tool setting programme in use. 11. Mould heater active: Red -temperature within tolerance band, Yellow - temperature in stand-by. 12. Two dark squares indicate that the mould is closed. 13. Chamber heater active: - Red -temperature within tolerance band, Yellow - temperature in stand-by 14. 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 activated 16. 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 position 19. 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-by 21. Indicates that the right injection guard is open. 22. Nozzle heater active - Red -temperature within tolerance band, Yellow - temperature in stand-by 23. Indicates that the tranparent gate is open. C-0080

BABYPLAST 6/10P

C
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, and that it is connected to the mains correctly.After switching on at the main switch, the SAFETY GUARD CHECK must be carried out In order to continue. Before being able to start the motor, the safety guards must be opened and closed. If a fault is detected with any of the guard switches, it will not be possible to start the machine. 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 D1.6/ SETTING THE MOULD CLOSED POSITION. 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 the plastification 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 the INJECTION UNIT. MAKE SURE that this material is compatible with the temperatures at which the machine is to be programmed. If the user is not experienced in the transformation of thermoplastic materials, it is advisable to begin with a material with a wide temperature range, such as POLYPROPYLENE, POLYSTYRENE, POLYETHYLENE ABS,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 of the 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, if required, from 0.1 to 0.2 secs. 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, set the ejection time from 0.2 to 0.7 secs. with 2 or 3 ejector strokes. parag. D.1.7b3 (page D-0130). FIFTH Close 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 the machine according to section D.2.3 PURGE page D-0240). The machine is now ready to produce parts. SIXTH Put the machine in semi-automatic mode and make sure that the transparent gate and guards are closed. Press the START key. The machine will proceed to complete one cycle. The nozzle may cool slightly, during the first shots, as it comes into contact with the 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 in SEMI-AUTOMATIC mode, adjusting the different machine parameters such as times, temperatures, pressures and material load etc. When in AUTOMATIC mode, make sure that, at the end of the injection cycle, the injection piston reaches a point less than 3 mm (cushion) within 8 cycles, otherwise the machine will go into alarm. To modify settings see parag. D.4c ADVANCED SETTINGS (page D-0380) The parameters quoted in this section are only a guide line, because the various parameters and settings always 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-0090

BABYPLAST 6/10P

D
D.1/ MENU D.1.1/ Display

BABYPLAST 6/10P

Menu open Motor status Clamp position Synoptic diagram moviment indicators Injection position Tool setting programme in use Function key icons

MAIN MENU

F8

000.0mm 00.0mm

F7

F6
PROGRAMME IN USE

F1

F2

F3

F4

F5

D-0010

BABYPLAST 6/10P

D
Information/upgrade software upgrade software Display/CPU Mould closed position Save mould setting data Overwrite or change mould settings. Access to mould settings Access to mould setting files Save data on USB memory stick Retreive data from USB memory stick Part counter Activate temp. in Stand-by Deactivate Temp. in Stand-by Quality control password 1212 Log file: Cycle time -cushion Save average cycle time Exit without saving Mould opening and inj. carr. in semi-automatic Start automatic or semiautomatic cycle Stop automatic or semiautomatic cycle Purge Purge to start cycle Purge to end cycle Core pull Setting times Activate airblow in manual if present Activate venturi loader

D.1.2/ ICONS - Description of functions

Switch ON the motor. Switch OFF the motor Timer for starting motor Access to tool settings Access to machine configurations Access to machine config. - password 1212 Access to manufacturer settings. Switch heaters ON Switch heaters OFF Access to temperatures page Atomatic menu Semi-automatic menu Manual menu Visualise alarm messages Confirm - return to previous page Clamp in manual or access to clamp data Inj. carriage in manual or access to inj. carriage data Plastification inmanual or access to plast. data Ejection in manual or access to ejection data Injection in maual or access to injection data Times and settings Manual movements to the right - change line Manual movements to the left - change line
Pressed with F1/ F3 closes or opens as per programme

Accesso tastiera

D-0020

D
D.1.3/ START UP - GATE CHECK

BABYPLAST 6/10P

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

F8

000.0mm 00.0mm

F7

F6

F1

F2

F3

F4

F5

The guards and transparent gate should be in the closed position. At this point the user should open the clamp, injection guards and transparent gate, keep them open for at least 2 secs. and then close them so as 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 into alarm and start up will be prevented. If the gate check is successful, the MAIN MENU will appear on the screen (see next page) ATTENTION! If the machine goes into alarm FAULTY GATE or GUARD SWITCH (n 06, 07 or 08) during the gate check at start up, switch the machine off and then on again. If the machine goes into the same alarm while the machine is running, reset the alarm and carryout the gate check again but without switching off the machine.This procedure may be repeated three times after which the machine will go into alarm FAULTY GATE SWITCH REPEAT GATES. At this point the machine must be switched off and then on again to reset the the gate check function.
MAIN MENU

F8

000.0mm 00.0mm

F7

F6

F1
D-0030

F2

F3

F4

F5

BABYPLAST 6/10P

D
D.1.4/ MAIN MENU
Motor status ON

MAIN MENU

F8

000.0mm 00.0mm

F7

Motor ON/OFF

F6

Machine configuration
Go to stored tool settings Timer for starting the motor and heaters

F1

F2

F3

F4

F5

Press F7 to switch on the motor. The motor symbol, in the top left hand corner of the display, will appear as long as the motor is running. press the same key again to switch off the motor. Keys F1, F2 & F3 are activated when the motor is switched on.
ATTENTION! If the oil temperature is below the minimum value set by the manufacturer (20C), no

movements will be possible. In order that the oil reaches the correct temperature rapidly, the motor will turn at full speed.

MAIN MENU

F8
Motor OFF

000.0mm 00.0mm

F7

F6
Mould setting programme in use
Gear - art. 2345

Machine configuration
Access to stored mould settings

F1

F2

F3
Automatic menu

F4

F5

Manual menu

Switch heaters ON

ATTENTION! The heating elements are switched on by pressing key F3. The setting values will be taken from

those stored in the tool setting programme indicated in the synoptic diagram. D-0040

D
D.1.5/ MANUAL MENU
While in the MAIN menu, press F1 The following display will appear:
MANUAL MENU

BABYPLAST 6/10P

to enter the MANUAL menu.

F8
Back to previous display

F7

F6

Temperatures

F1
Clamp

F2

F3

F4
Plastification

F5
Injection Ejection

Injection carriage

To activate the various movements in manual, press one of the keys to select the function required. Having entered the function required, press one of the two keys for backward or forward 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 set temperatures 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 MANUFATURERS DATA SHEET. FAILURE TO DO SO MAY CAUSE DAMAGE, BLOCKAGE, OR GAS; PARTICULARLY DURING PURGING.

D-0050

BABYPLAST 6/10P

D
D.1.5a/ MANUAL MENU : CLAMP
MANUAL: CLAMP

F1 F2

MANUAL CLAMP OPEN Speed set by manufacturer (30%)

Pressed together with keys F1or F3 allows the opening and closing of the clamp at the speed set in the tool setting programme in use (see diagramme at bottom of page D1).

F8

F7

F3 F4 F5

MANUAL CLAMP CLOSE Speed set by manufacturer (30%) CLAMP DATA - please see below Set MOULD CLOSED POSITION - please see following page

F6

F1

F2

F3

F4

F5

When in the menu MANUAL CLAMP press F4 SETTINGS:


To vary values, touch window and rotate dial

to gain access to the menu for CLAMP TIMES AND

The maximum value depends on the thickness of the mould Maximum pressure for the low pressure clamp piston. Maximum pressure allowed for the low pressure clamp piston inside the mould safety control range (next line). If too high 034 mould safety alarm Mould safety control range:from the distance set in mm to the 0 mould closed position.

CLAMP TIMES AND SETTINGS Opening stroke Clamp pressure Mould safety Mould safety range Closing speed 1 Closing speed 2 Change closing speed Opening speed 1 055.0 050 035 2.0 070 020 030 075 mm bar bar mm % % mm %

F8

F7

See following diagramme where: V100% V1: Closing speed 1 V2: Closing speed 2 P : Closing speed changing point 0 : Mould closed position
50%

V1 V2

F8

Save values in mould setting programme in use Confirm and exit

F7

D1

0 mm

D-0060

BABYPLAST 6/10P

D.1.6/ SETTING THE MOULD CLOSED POSITION

Install the mould, making sure that it is positioned correctly. Ensure that it is firmly fixed in place and connect the ejection return pin to the ejection piston, using an M4 screw. 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 closed and then F5 Touch the icon to confirm the mould closed position.

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

Mould closed
MANUAL: CLAMP

F8

000.0mm 00.0mm

F7
M

F6
Back to previous display

F1

F2

F3

F4

F5

Confirm mould closed position

ATTENTION! Ensure that both the symbols on the synoptic diagram, which indicate the mould closed status, turn dark grey only when the mould is fully closed. The point at which the two symbols turn dark grey, is the point at which the consensus is given for mould CLOSURE IN HIGH PRESSURE. If the two symbols do not turn grey, after the mould has reached the mould closed position, the machine will go into alarm 034 MOULD SAFETY. N.B. It is possible to vary the mould safety settings and sensitivity range etc. See page D. 0320 paragraph D.3.3e.

D-0070

BABYPLAST 6/10P

D
D.1.7/ AUTOMATIC MENU
MAIN MENU

F8

000.0mm 00.0mm

F7

Motor OFF

F6
Mould setting programme in use
Gear - art. 2345

Machine configuration Access to stored mould settings

F1

F2

F3

F4

F5

Manual menu

Automatic menu

Switch heaters ON

ATTENTION! By pressing F3 the heaters will be switched ON and the active zones will be shown in yellow during pre-heating and red when the respective tolerance bands have been reached; The settings will be taken from those saved in the mould setting programme highlighted in the synoptic diagramme. While in the MAIN menu, press F2 appear:
AUTOMATIC MENU H2 200 H3 200

to gain access to the AUTOMATIC menu.The following display will

Actual temperatures
H4 OFF

H1

200

F8
Return to previous display Temperatures

000.0mm 00.0mm

F7

F6
Gear - art. 2345

Times and other settings

F1

F2

F3

F4

F5

Automatic cycle

Semi-auto. cycle

Purge

Part counter

ATTENTION! Plastification and injection piston movements will only be possible when the set temperatures have been reached. ( See tolerance band - users menu, data input ). If an Automatic, Semi-automatic or purge cycle is selected, and the machine has not reached the the set temperatures, the machine will go in alarm.
D-0080

BABYPLAST 6/10P

D.1.7a/ AUTOMATIC MENU - SETTING TEMPERATURES


Yellow : indicates that the heaters in the relative zones are in pre-heat mode or standby Red that the heaters in the relative tones are within the tolerance bands
H4 OFF

H1

200

AUTOMATIC MENU H2 200 H3 200

F8

000.0mm 00.0mm

F7

F6
Gear - art. 2345

F1

F2

F3

F4

F5
to gain access to the TEMPERATURES menu: Save values in the mould settings programme in use

While in the AUTOMATIC menu press F6

Oil - reading only

Values set

Actual values

TEMPERATURES Oil H1 H2 H3 H4 045 200 200 195 0 C C C C 200 C Plastific. 199 C Chamber 195 C Nozzle 514 C Mould

F8

F7
M

F6
Confirm and exit without saving values set. STAND-BY Temperature. It is possible to activate or deactivate stand-by. If active, the zones will be shown in yellow on the synoptic diagramme in the main menu.

F1

F2

F3

F4

F5

It is only possible to activate or deactivate the zones from the pages of the mould setting programme.see page D-330

SETTING: Touch zone, which needs to be changed, in the field Values set. Rotate the dial M to set the value required. Press F7 to return to the previous page. The modified values are changed but not saved in the mould setting programme in use The modified values can be saved in the mould setting programme by pressing F8 . D-0090

BABYPLAST 6/10P

D
D.1.7b/ AUTOMATIC MENU - TIMES AND SETTINGS

H1

200

AUTOMATIC MENU H2 200 H3 200

H4

OFF

F8

000.0mm 00.0mm

F7
M

F6
Gear - art. 2345

F1

F2

F3

F4

F5

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

TIMES AND SETTINGS Actual cycle time Actual cushion Average actual time Average time saved Quality control Cycle time error Cushion error 12.0 1.2 12.0 12.0 NO 05 1.0 % mm sec mm sec sec

F8

F7
M

F6
Return to previous display

F1

F2

F3

F4

F5

D-0100

D
D.1.7b1/ INJECTION CARRIAGE SETTINGS

BABYPLAST 6/10P

TIMES AND SETTINGS Actual cycle time Actual cushion Average actual time Average time saved Quality control Cycle time error Cushion error 12.0 1.2 12.0 12.0 NO 05 1.0 % mm sec mm sec sec

F8

F7
M

F6
Return to previous display

F1

F2

F3

F4

F5

From the MAIN TIMES AND SETTINGS menu, press F1 INJECTION CARRIAGE TIMES AND SETTINGS :

to gain access to

By setting a value other than 0 ( from 0.3 to 0.6), the injection carriage moves back and away from the mould at each cycle. If the setting is 0 sec the injection carriage will remain against the mould during each cycle Varies the speed of the injection carriage.

INJECTION CARRIAGE TIMES AND SETTINGS Injection carr. time Inj. carriage seed 0.0 100 sec %

F8

F7

F6

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

D-0110

BABYPLAST 6/10P

D
D.1.7b2/ SETTINGS - PLASTIFICATION

TIMES AND SETTINGS Actual cycle time Actual cushion Average actual time Average time saved Quality control Cycle time error Cushion error 12.0 1.2 12.0 12.0 NO 05 1.0 % mm sec mm sec sec

F8

F7
M

F6
Return to previous display

F1

F2

F3

F4

F5
to gain access to

From the MAIN TIMES AND SETTINGS menu press F2 PLASTIFICATION TIMES AND SETTINGS :

To use with 16/18mm diam. injection pistons. Serves for activating a double plastification so as to fill completely the above mentioned pistonsi.Setting a value, e.g. 5 sec, the plastification is activated for this time and then reactivated for a second time so as to reach the material load set. Varies the plastification piston speed.

PLASTIFICATION TIMES AND SETTINGS 2nd shot load time Plastification speed 0.0 100 sec %

F8

F7

Suction time

0.5

sec

F6

OPZIONAL : If present, the VENTURI LOADER can be activated or deactivated by pressing F6. If the suction time is 0, suction will stop when the sensor, installed in the hopper, detects the presence of material. 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. Touch the field to be modified, vary the values by rotating the dial. Press F8 to save the changes in the mould setting programme in use. By pressing F7 the values will be changed but not saved in the mould setting programme.

D-0120

D
D.1.7b3/ SETTINGS - EJECTION
TIMES AND SETTINGS Actual cycle time Actual cushion Average actual time Average time saved Quality control Cycle time error Cushion error 12.0 1.2 12.0 12.0 NO 05 1.0 % mm sec mm sec sec

BABYPLAST 6/10P

F8

F7
M

F6
Return to previous display

F1

F2

F3

F4

F5

From the MAIN TIMES AND SETTINGS MENU pressF3 EJECTION TIMES AND SETTINGS:

to gain access to

EJECTION TIMES AND SETTINGS

Varies the ejection piston speed


Ejection speed 100 2 80 0,20 0,25 0,0 0,0 0,0 bar sec sec sec sec sec %

F8

N of ejector strokes ( max 10) Reducing this value reduces the distance the ejector piston moves.

Number of strokes Ejection pressure Ejection time Ejection return time Air blow time Ejection pause Pause end of cycle

F7

F6

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

D-0130

BABYPLAST 6/10P

D
D.1.7b4/ SETTINGS - INJECTION
12.0 1.2 12.0 12.0 NO 05 1.0 % mm sec mm sec sec

TIMES AND SETTINGS Actual cycle time Actual cushion Average actual time Average time saved Quality control Cycle time error Cushion error

F8

F7
M

F6
Return to previous display

F1

F2

F3

F4

F5

From the MAIN TIMES AND SETTINGS MENU press F4 SETTINGS: Set the shot size in order to obtain a cushion value less than 3 mm (pre-set parameter). Maximum value 60mm - The shot size depends on the pison size installed. When the set time has been reached the mould opens but except in the case that plastification has not finished. ATTENTION: To obtain a constant cycle time, set a value greater than the max. time needed to load the injection piston. Injection time, in which the value of the 1st injection pressure. must be reached otherwise the machine will go into alarm 107 PEAK NOT REACHED. If the second pressure is activated at a point set in mm (see page D-0310) the line 2nd pressure setting : 00.0mm will be seen. When the injection piston reaches the point set, the second injection speed is activated.

to gain access to INJECTION TIMES AND

INJECTION TIMES AND SETTINGS Shot size Cooling time 1st injection pressure 1st pressure time 2nd injection pressure 2nd pressure time Decompression Injection speed 2nd injection speed Second speed point 29.0 4.5 90 2.0 30 1.0 0,0 075 50 2,0 mm sec bar sec bar sec mm % % mm

ATTENTION: to see all the lines, move the cursor

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

D-0140

D
D.1.7b5/ SETTINGS - CLAMP
TIMES AND SETTINGS Actual cycle time Actual cushion Average actual time Average time saved Quality control Cycle time error Cushion error 12.0 1.2 12.0 12.0 NO 05 1.0 % mm sec mm sec sec

BABYPLAST 6/10P

D
F8

F7
M

F6
Return to previous display

F1

F2

F3

F4

F5

From the MAIN TIMES AND SETTINGS MENU press F5 SETTINGS : The maximum value depends on the thickness of the mould Maximum pressure for the low pressure clamp piston. Maximum pressure allowed for the low pressure clamp piston inside the mould safety control range (next line). If too high 034 mould safety alarm Mould safety control range:from the distance set in mm to the 0 mould closed position.

to gain access to CLAMP TIMES AND

CLAMP TIMES AND SETTINGS Opening stroke Clamp pressure Mould safety Mould safety range Closing speed 1 Closing speed 2 Change closing speed Opening speed 1 055.0 050 035 2.0 070 020 030 075 mm bar bar mm % % mm %

F8

F7

See the following diag. where: V1: Closing speed 1 V2: Closing speed 2 P : Closing speed changing point 0 : Mould closed position

V100% 50%

V1 V2

F8 Save values in mould setting programme in use F7 Confirm and exit

D1

0 mm

Touch the field to be modified, vary the values by rotating the dial. Press F8 to save the changes in the mould setting programme in use. By pressing F7 the values will be changed but not saved in the mould setting programme. D-0150

BABYPLAST 6/10P

D
D.1.7b6/ SETTINGS - QUALITY CONTROL

By setting a tolerance band, it is possible to monitor two parameters on the machine: The CYCLE TIME and CUSHION, for which it is possible to see the last 20 cycles.
TIMES AND SETTINGS Actual cycle time Actual cushion Average actual time Average time saved Quality control Cycle time error Cushion error 12.0 1.2 12.0 12.0 NO 05 1.0 % mm sec mm sec sec

F8

F7
M

F6
Return to previous display

F1

F2

F3

F4

F5

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:
QUALITY CONTROL Quality control Cycle time error Cushin error N of initial cycles N cycles for alarm Actual cycle time Actual avarage time Avarage time saved Actual cushion NO 10 1,0 10 % mm

F8

F7
20 15,0 15,0 15,0 0,0 sec sec sec mm

F6
Confirm and exit

F1

F2

F3

F4

F5

Data log CYCLE TIME and CUSHION

To modify the quality control parameters press F6 and then in the next display enter the passcode 1212 to gain access to the following menu:

D-0160

D
continued....../ SETTINGS - QUALITY CONTROL
Quality control Cushin error N of initial cycles N cycles for alarm Actual cycle time Actual avarage time Avarage time saved Actual cushin QUALITY CONTROL NO 10 1,0 10 % mm

BABYPLAST 6/10P

Cycle time error

F8

Confirm and save data in the mould settings programme.

F7
20 15,0 15,0 15,0 0,0 sec sec sec mm

Confirm and exit without saving data in the mould settings programme.

F6

F1

F2

F3

F4

F5

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

The Quality control function can be activated or deactivated by selecting YES or NO in the first line. press F8 to save and activate the required error value in the programme in use. Press F4 to save the t average cycle time in the programme in use. The quality control function will not be activated until the number of cycles, set in N of initial cycles, has been reached. The first cycle, after these initial cycles, will be used for reference by the quality control function. If the machine detects a percentage of variation which is more than that allowed, compared to the reference cycle, for a number of cycles greater than that set in line 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 of tolerance, and which can be used to activate a PART REJECT device. The machine, in this case, will be able 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.

D-0170

BABYPLAST 6/10P

D
D.1.7b6a/ QUALITY CONTROL - Log File

QUALITY CONTROL Quality control Cycle time error Cushin error N of initial cycles N cycles for alarm Actual cycle time Actual avarage time Avarage time saved Actual cushion NO 10 1,0 10 20 15,0 15,0 15,0 0,0 sec sec sec mm % mm

F8

F7

F6

F1

F2

F3

F4

F5

To see the last 20 CYCLE TIMES and CUSHION values, press F3 display:

to see the following

Last cycle registered


n 1 2 3 4 5 6 7 8 9 Cycle 25 25 25 25 25 25 25 25 25

LOG FILE Cushion 0.12 0.12 0.12 0.12 0.12 0.12 0.12 0.12 0.12

F8

F7

F6

ATTENTION: to see all the lines, move the cursor

D-0180

D
D.2./STARTING A CYCLE
D.2.1/ STARTING AN AUTOMATIC CYCLE
AUTOMATIC MENU H2 200 H3 200

BABYPLAST 6/10P

H1

200

H4

OFF

F8

000.0mm 00.0mm

F7
M

F6
Gear - art. 2345

F1

F2

F3

F4

F5

From the AUTOMATIC MENU press F1

to gain access to the AUTOMATIC CYCLE menu:

H1

AUTOMATIC MENU 200 H2 200 H3 200

H4

OFF

F8

000.0mm 00.0mm

F7
M

F6
Gear - art. 2345

F1

F2

F3

F4

F5

Press F2 to

start the machine in an AUTOMATIC CYCLE

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 D-0190

BABYPLAST 6/10P

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

H1

200

AUTOMATIC MENU H2 200 H3 200

H4

OFF

F8

000.0mm 00.0mm

F7
M

F6
Gear - art. 2345

F1

F2

F3

F4

F5

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


Press F1 :Go directly into a SEMI AUTOMATIC CYCLE without stopping the machine

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. :To see and modify times and other settings.

Press F5

Press F6

:To see and modify temperatures.

D-0200

D
D.2.2/ Start a SEMI AUTOMATIC cycle
H1 AUTOMATIC MENU 200 H2 200 H3 200 H4 OFF

BABYPLAST 6/10P

F8

000.0mm 00.0mm

F7
M

F6
Gear - art. 2345

F1

F2

F3

F4

F5

From the AUTOMATIC MENU press F2

to gain access to the SEMI AUTOMATIC CYCLE menu:

H1

200

SEMIAUTOMATIC H2 200 H3

200

H4

OFF

F8

000.0mm 00.0mm

F7
M

F6
Gear - art. 2345

F1

F2

F3

F4

F5

Press F2 Press F3 :

to start a SEMI AUTOMATIC CYCLE. The mould opens completely and the injection carriage 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. D-0210

BABYPLAST 6/10P

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

H1

200

SEMI AUTOMATIC H2 200 H3 200

H4

OFF

F8

000.0mm 00.0mm

F7
M

F6
Gear - art. 2345

F1

F2

F3

F4

F5

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


Press F1 :Go directly into a SEMI AUTOMATIC CYCLE without stopping the machine

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. :To see and modify times and other settings.

Press F5

Press F6

:To see and modify temperatures.

D-0220

D
D.2.3/ Starting a PURGE CYCLE
H1 AUTOMATIC MENU 200 H2 200 H3 200 H4 OFF

BABYPLAST 6/10P

F8

000.0mm 00.0mm

F7

F6
Gear - art. 2345

F1

F2

F3

F4

F5

From the AUTOMATIC MENU press F3

to gain access to the PURGE CYCLE menu:

H1

200

AUTOMATIC MENU H2 200 H3 200

H4

OFF

F8

000.0mm 00.0mm

F7

F6
Gear - art. 2345

F1
Press F1 Press F2

F2

F3

F4

F5

To start PURGE AT END OF CYCLE. At the end of this cycle the injection piston will stop in the fully forward position hence the cylinder will be empty. 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
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 MANUFATURERS DATA SHEET. FAILURE TO DO SO MAY CAUSE DAMAGE, BLOCKAGE, OR GAS; PARTICULARLY DURING PURGING.

D-0230

BABYPLAST 6/10P

D
D

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

H1

200

H2

PURGE 200 H3

200

H4

OFF

F8

000.0mm 00.0mm

F7
M

F6
Gear - art. 2345

F1

F2

F3

F4

F5

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 purge cycle is started (see previous page) or another function is selected.

D-0240

D
H1 AUTOMATIC MENU 200 H2 200 H3 200 H4 OFF

BABYPLAST 6/10P

D.2.4/ AUTOMATIC MENU - SETTING UP THE PART COUNTER

F8

000.0mm 00.0mm

F7

F6
Gear - art 2345

F1

F2

F3

F4

F5

From the AUTOMATIC MENU press F4

to gain access to the PART COUNTER menu:

Settings
PART COUNTER Parts to produce 0

Exit without saving

F8

Parts produced Nunber of cavities

000000 2

F7

Reset

F6

Confirm and exit Reset part counter (line - parts produced). ATTENTION! Ensure that the number of cavities shown corresponds to the actual number of cavities in the mould.The number of cavities shown, corresponds to the number of cavities set in the mould settings programme in use. To modify, return to the MAIN MENU and press key F5 to enter the mould settings programme. By setting the value of parts to produce to 000000 the part counter is excluded and the machine will produce continuously. To zero the part counter rapidly, select the first digit on the left and change to zero. All the other digits will change to zero automatically. D-0250

BABYPLAST 6/10P

D
D.3/ MOULD SETTING PROGRAMMES
D.3.1/ LOADING A MOULD SETTING PROGRAMME
MAIN MENU

F8

000.0mm 00.0mm

F7

F6
Gear - art. 2345

F1
When in the MAIN MENU press F5

F2

F3

F4

F5

to gain access to the following display:

PROGRAMMES

Exit without saving

F8
Programme selected

Confirm mould setting programme selected

F7
Gear - art. 2345

Retrieve programmes from a USB memory stick Save programmes onto a USB memory stick Access to mould setting programme selected.

F6

F1

F2

F3

F4

F5

Access to the mould setting programme folder

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):

D-0260

BABYPLAST 6/10P

Go back a directory level


/home/root/Fm607/progs

Return to the programmes page


Gear - art. 2345
Plug - art. 4459

Gear - art. 1111 Gear - art. 422 Plug - art. 2222

Programme selected

Keypad to change name Exit and confirma programme selected


file filter

Plug - art. 4459

Exit without confirming

Eliminate programme selected

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

D-0265

BABYPLAST 6/10P

D
From the MAIN MENU press F5
PROGRAMMES

BABYPLAST 6/10P

D.3.2/ Create or modify mould setting programmes

to gain access to the following display: Exit without saving

F8
Confirm and exit
Programme selected

F7
Plug - art. 4459

Retrieve mould setting programmes from a USB memory stick Save mould setting programmes onto a USB memory stick To gain access to a mould settings programme.

F6

F1

F2

F3

F4

F5

Access to mould setting programme folder

Press F2

to enter the mould setting programme selected.

PROGRAMME: Plug - art 4459 Customer Material Part weight Shot weight Mould number Average time saved Last modification xxx POM 0,0 0,0 000 10.4 sec gr gr

Programme selected

F8
Exit without saving

F7

Save /Copy cycle programme Setup core pulls

01.01.2008

F6

Set temperatures

F1

F2

F3

F4

F5

General settings

Touch the field to be modified, to vary the alphanumerical values, touch the icon keypad for the other values rotate the dial. Press F7 to save the changes in the mould setting programme in use or to copy the changes into a new mould setting programme. The value Average time saved can only be saved in the QUALITY CONTROL function. While the date in Last modification , is saved automatically the moment the last modification is made. Press F1 D-0270 to gain access to the following display:

BABYPLAST 6/10P

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

F8

F7

F6

F1

F2

F3

F4

F5

Press F1

to gain access to INJECTION CARR. TIMES & SETTINGS :

By setting a value other than 0 (from 0.3 to 0.6), the injection carriage moves back and away from the mould at each cycle. If the setting is 0 sec the injection carriage will remain against the mould during each cycle Varies the speed of the injection carriage.

INJECTION CARR. TIMES & SETTINGS Injection carr. time Inj. carriage speed 0.0 100 sec %

F8

F7

F6

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

D-0280

BABYPLAST 6/10P

D.3.3b/ Mould setting programmes - PLASTIFICATION TIMES AND SETTINGS

MAIN TIMES AND SETTINGS

F8

F7

F6

F1

F2

F3

F4

F5

Press F2

to gain access to PLASTIFICATION TIMES AND SETTINGS :


PLASTIFICATION TIMES AND SETTINGS 2nd shot load time Plastification speed 0.0 100 sec %

To use with 16/18mm diam. injection pistons. Serves for activating a double plastification so as to fill completely the above mentioned pistonsi.Setting a value, e.g. 5 sec, the plastification is activated for this time and then reactivated for a second time so as to reach the material load set. Varies the plastification piston speed.

F8

F7

Suction time

0.5

sec

F6

OPZIONAL : If present, the VENTURI LOADER can be activated or deactivated by pressing F6. If the suction time is 0, suction will stop when the sensor, installed in the hopper, detects the presence of material. 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.

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

D-0290

BABYPLAST 6/10P

D
D.3.3c/ Mould setting programmes - EJECTION TIMES AND SETTINGS
MAIN TIMES AND SETTINGS

F8

F7

F6

F1
Press F3

F2

F3

F4

F5

to gain access to EJECTION TIMES AND SETTINGS :


EJECTION TIMES AND SETTINGS Ejection speed Number of strokes Ejection pressure Ejection time Ejection retur time Air blow time Ejection pause Pause end of cycle Ejection sensor Out at end of cycle 00 2 80 0,20 0,25 0,0 0,0 0,0 NO NO bar sec sec sec sec sec %

Varies the ejection piston speed N of ejector strokes ( max 10) Reducing this value reduces the distance the ejector piston moves. This function may be activated after installing the ejector sensor onto the moving platten. The sensor is supplied in the accessory pack with the machine. Activate this function by selecting YES. The sensor will detect whether the ejectors have fired or re-entered. In case of fault, the machine will go into alarm 039 EJECTORS DID NOT FIRE or 040 EJECTORS DID NOT RE-ENTER. Only in SEMIAUTOMATIC cycle. If active, at end of SEMIAUTOMATIC cycle. The ejectors remain out and re-enter only when the start key is pressed for start cycle.

F8

F7

F6

Touch the grey fields to change the values. The lines in bold print can only be changed in the MOULD SETTING PROGRAMME pages.

The values in the white fields can be changed, both in the MOULD SETTING PROGRAMME pages and in TIMES AND SETTINGS pages while the machine is running.

Touch the field to be modified, vary the values by rotating the dial. Press F6 to return to the previous page without saving. Press F7 to save changes in the mould setting programme in use or to copy the mould setting programme by changing the name. Press F8 to exit without saving. D-0300

D
MAIN TIMES AND SETTINGS

BABYPLAST 6/10P

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

F8

F7

F6

F1
Press F3

F2

F3

F4

F5
ATTENTION: to see all the lines, move the cursor.

to gain access to the following display:

Set the shot size in order to obtain a cushion value less than 3 mm (pre-set parameter). Maximum value 60mm - The shot size depends on the pison size installed. When the set time has been reached the mould opens but except in the case that plastification has not finished. ATTENTION: To obtain a constant cycle time, set a value greater than the max. time needed to load the injection piston. Injection time, in which the value of the 1st injection pressure. must be reached otherwise the machine will go into alarm 107 PEAK NOT REACHED. If the second pressure is activated at a point set in mm (see page D-0310) the line 2nd pressure setting : 00.0mm will be seen. When the injection piston reaches the point set, the second injection speed is activated.

INJECTION TIMES AND SETTINGS Shot size Cooling time 1st injection pressure 1st pressure time 2nd injection pressure 2nd pressure time Decompression Injection speed 2nd injection speed Seconnd speed point Injection mode Accumulator 29.0 4.5 90 2.0 30 1.0 0,0 075 50 0.0 Peak OFF mm sec bar sec bar sec mm % % mm

Optional: Activates the output which controls the hydraulic accumulator (if installed) during the injection phase.

PEAK: (de-fault) - At the end of injection time and on condition that the 1st injection pressure has been reached, 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 injection menu, has been reached. At this point, the machine will change over to the 2nd injection pressure Touch the field to be modified, vary the values by rotating the dial. Press F6 to return to the previous page without saving. Press F7 to save changes in the mould setting programme in use or to copy the mould setting programme by changing the name. Press F8 to exit without saving. D-0310

BABYPLAST 6/10P

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

F8

F7

F6

F1
Press F5

F2

F3

F4

F5

to gain access to the following display:

The number of cavities set, conditions the part counter Depends on the mould height. With minimum mould h. 70 (95 increased vers.) the maximum possible is 110mm Pressure setting for clamp piston N.B. the larger piston for high pressure (6,25 t.) is activated only when the mould is in the fully closed position. The maximum pressure allowed for the clamp piston in low pressure. If reached the machine goes in alarm 034 Mould safety The alarm in mould closing will be active starting from the position of the mould safetyr setting to the position of the mould safety exclusion setting N.B.Outside this range (mould safety and mould safety exclusion) the maximum pressure allowed is the pressure set in clamp pressure. his function is used to regulate the sensitivity of the MOULD CLOSED position. The range can be set between approx. 0,03 to 0,3 mm. Change the value to modify the setting.
CLAMP TIMES AND SETTINGS Number of cavities 2 Opening stroke Clamp pressure Mould safety Mould safety setting Mould safety excl. pos. Closing speed 1 Closing speed 2 055.0 050 035 2.0 0.10 070 020 030 0.10 075 mm bar bar mm mm % % mm mm %

F8

F7

F6

Change closing speed Mould safety range Opening speed 1

The lines in bold print highlight the values which can only be modified in the MOULD SETTING PROGRAMME pages . The other values can be modified in the respective pages both in the MANUAL and AUTOMATIC menu while the machine is running.

D-0320

D
D.3.4/ Mould setting programmes - TEMPERATURES
PROGRAMME: Plug art. 4459 Customer Material Part weight Shot weight Mould number Average time saved Last modification xxx POM 0,0 0,0 000 10.4 sec gr gr

BABYPLAST 6/10P

Programme selected

F8
Exit without saving

F7

Save /Copy cycle programme Setup core pulls

01.01.2008

F6

Set temperatures

F1

F2

F3

F4

F5

General settings

Touch the field to be modified, to vary the alphanumerical values, touch the icon keypad for the other values rotate the dial. Press F7 to save the changes in the mould setting programme in use or to copy the changes into a new mould setting programme. The value Average time saved can only be saved in the QUALITY CONTROL function. While the date in Last modification , is saved automatically the moment the last modification is made. Press F2 to gain access to the following display:
ACTIVE zone NON ACTIVE zone

TEMPERATURES H1 Heater plastif. H2 Heater inj. chamber H3 Heater nozzle H4 Heater mould V1 Cooling fixed platen V2 Cooling hopper V3 Cooling fixed mould Hotrunner 215 215 215 215 0 0 0 0 C C C C C C C C % % % % % % % % X X X X X X X X

F8

F7
M

F6

V4 Cooling moving mould 0

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

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

D-0330

BABYPLAST 6/10P

D
D.3.5/ Mould setting programmes - core pull
Programme selected
xxx POM 0,0 0,0 000 10.4 sec gr gr

PROGRAMME: Plug - art. 4459 Customer Material Part weight Shot weight Mould number Average time saved Last modification

F8
Exit without saving

F7

Save /Copy cycle programme Setup core pulls

01.01.2008

F6

Set temperatures

F1

F2

F3

F4

F5

General settings

Press F3

to gain access to the following display:

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

Digit the words activate or deactivate to activate or deactivate the core pull function in the respective page A or B.

Mould closed Injection

5 1 2 3 4

PROGRAMME Core pull A Pos 1 2 3 4 5 Core pull B Disabled Status OFF OFF OFF OFF OFF Time 0.0 0.0 0.0 0.0 0.0 Cons. OFF OFF OFF OFF OFF
Sch 1

F8
Cooling

F7

Mould open Ejection

F6

On request, a socket can be fitted for 24V output (output A - J708) (output B - J709) and the two respective PNP input sockets for cycle consensus (A J306 - BJ307). The two outputs A or B can be activated for an indefinite length of time when ON is set (status column), and 00s set (time column). The same outputs can also 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 consensus to 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 (see following 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). D-0340

BABYPLAST 6/10P

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


If a new programme has to be created, which is similar to an existing programme, it is possible to copy the existing programme and make modifications if necessary. Do as follows: Example: Programme to copy New pragramme : Gear A : Gear B to gain access to the following display: Exit without saving

From the main menu press F5


PROGRAMMES

F8
Programme selected

Confirm and exit

F7
Gear A

Retrieve mould seting programmes from USB memory stick Save mould setting programmes on a USB memory stick To gain access to a mould settings programme.

F6

F1

F2

F3

F4

F5
Access to the mould setting programmes folder

Check that the mould setting programme selected is the one to be copied, (to select another programme see page D0260) press F2 to enter the programme PROGRAMME: Gear A Customer Material Part weight Shot weight Mould number Average time saved Last modification xxx POM 0,0 0,0 000 10.4 sec gr gr

Programme selected

F8
Exit without saving

F7

Save /Copy cycle programme

01.01.2008

F6

F1
Press F7

F2

F3

F4

F5

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

D-0350

BABYPLAST 6/10P

D
PROGRAMME: Gear A Customer Material Part weight POM gr gr 0,0 Peso stampata SAVE PROGRAMME 0,0 Gear A 000 Numero stampo xxx

F8

F7

Save changes in the mould setting programme in use Change programme name by creating a new programme Exit without saving

Change Tempo m Yes YESdio salvato Last modification

Cancel sec 10.4 01.01.2008

F6

F1

F2

F3

F4

F5

Press Change :

/home/root/Fm607/progs

Gear 1111 Gear 4422 Plug 2222

Gear 2345
Gear A

Programme selected

Key to change name Confirm and exit programme selected


file filter

Gear A

Exit without confirming

Eliminate programme selected

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.

D-0360

D
D.4/MACHINE CONFIGURATION
MAIN MENU

BABYPLAST 6/10P

F8

000.0mm 00.0mm

F7

F6
Gear part. n 2345

Advanced settings

F1

F2

F3

F4

F5

From the main menu press F6

to gain access to the following display:

SET UP 15:25:33
February Sun 1 8 15 22 Mon 2 9 16 23 Tue 3 10 17 24 Wes 4 11 18 25 Thu 5 12 19 26 Fri 6 13 20 27 2008 Sat 7 14 21 28

F8

F7

F6
Manufacturer

F1

F2

F3

Advanced settings User

F4

F5

Press F4

and enter PASSCODE 1212

to gain access to ADVANCED USER SETTINGS:

D-0370

BABYPLAST 6/10P

D
D.4a/ MACHINE CONFIGURATION - ADVANCED SETTINGS Change language - Celsius/Farenheit
and enter the pass code1212 (see previous page) to gain access to

From DISPLAY SET UP press F4 the following display :

Change language
Language

MACHINE PARAMETERS English Celsius 1 000045 000045 001555 reset

Change to Celsius/Farenheit Machine identification number - ( see page D-0410) Meter - hours . every 1500 hours there will be a reminder to change the oil return filter. Press the word reset to reset. Total hours counter. Cannot be reset. Total cycles counter. Cannot be reset. If is selected, the settings can only be modified by digiting the user password 1212

F8

Degrees Machine ID number Meter - Hrs Total hours Total cycles

F7

F6

Modification with password

F1

F2

F3

F4

F5

Press F3

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

INFO

F8

F7
Software version display Software version CPU Software version - prop. valve Software version INVERTER Upgrade software: The icon is only active if the USB memory stick is inserted in the USB port on the machine. ( see page. D-0405) D-0380
FMP237 FM607 Sw. Ver.: 1.10 FMP237 FM542 Sw. Ver.: 4.10 FMP237 FM542DSPSw. Ver.: 1.60 FMP000 FM549 Sw. Ver.: 1.01AV

F6

D
From DISPLAY SET UP press F4 to the following display: Change language
Language

BABYPLAST 6/10P

D.4b/ MACHINE CONFIGURATION - ADVANCED SETTINGS TEMPERATURES


and enter the pass code 1212 (see previous page) to gain access
MACHINE PARAMETERS English Celsius 1 000045 000045 001555 reset

Change to Celsius/Farenheit Machine identification number (see page D-0410) Meter - hours . every 1500 hours there will be a reminder to change the oil return filter. Press the word reset to reset.

F8

Degrees Machine ID number Meter - Hrs Total hours Total cycles

F7

F6

Modification with password

F1
Press F4 to

F2

F3

F4

F5

gain access to Machine parameters TEMPERATURES:


TEMPERATURES Tol. band max. error Temperature in stand-by Timeout for alarm Pre-heating time 25 80 3 180 C % min sec

The value set, will be the toleranceband for the temperature in use. If the operating temperature increases or decreases by a value greater than this set temperature, (i.e. goes out of the tolerance band) the machine goes into alarm Tol. band max error. Manual operation of the injection piston and plastification will not be possible nor will it be possible to enter an automatic cycle until the operating temperatures are within this tolerance band.

The stand-by temperature always depends on the temperatures set in each of the mould setting programmes and when active, the heater zones will be seen in yellow. The standby temp. activates in the following cases: 1.When the heaters are switched on in automatic. 2.When the machine is in alarm for a greater length of time than the time out alarm. 3.When the heaters are switched on manually.

When the heaters are switched on, they will remain at the stand-by temperature for the length of time set for pre-heating time

If the machine is in alarm for a time greater than that set fo time out alarm, the heaters will go into the stand-by mode. After double the length of time, the heaters and motor will be switched off. 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, the machine will go in alarm 112..116 OVER TEMPERATURE.. - Motor and heaters will be switched off.
D-0390

BABYPLAST 6/10P

D
D.4c/ MACHINE CONFIGURATION - ADVANCED SETTINGS TIMES AND SETTINGS
and enter the pass code 1212 (see previous page) to gain access to
MACHINE PARAMETERS Language English Celsius 1 000045 000045 001555 reset

From display set up press F4 the following display: Change language Change to Celsius/Farenheit Machine identification number (see page D-0410) Meter - hours . every 1500 hours there will be a reminder to change the oil return filter. Press the word reset to reset.

F8

Degrees Machine ID number Meter - Hrs Total hours Total cycles

F7

F6

Modification with password

F1
Press F5

F2

F3

F4

F5

to gain access to MACHINE PARAMETERS - TIMES AND SETTINGS:

ATTENTION: The value of 10mm MUST be set if a 10mm injection piston is installed on the machine. This setting will limit the maximum injection pressure to 100 bar. Maximum injection pressure in manual and purge. Maximum cushion. If the cushion is more, than the value set, for a number of cycles greater than that set in the line Injection incomplete (next line), the machine will go into alarm 036 INJECTION INCOMPLETE If the cushion is more, than the value set in the previous line (Cushion), for a number of cycles greater than that set in this line (Injection incomplete), the machine will go into alarm 036 INJECTION INCOMPLETE If the clamp does not reach the 0 mould position (mould closed) within the set time, The machine will go into alarm 042 TIMEout mould closed Clamp speed in manual mode Activate / deactivate the second opening speed. When active, it will be possible to set the point at which the speed changes, in the CLAMP TIMES AND SETTINGS menu.

TIMES AND SETTINGS Piston diameter Injection pressure Cushion Injection incomplete Timeout clamp close Closing speed in manual Opening speed 2 Intrusion programme 14 60 3,0 8 4,0 30 NO NO sec % mm bar mm

Set date and time

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 activate plastification before the injection phase.

Touch the field to be modifed, change the value by rotating the dial.
D-0400

D
D.4.4/ UPGRADE SOFTWARE
From the page DISPLAY SETTINGS press F4 access to the following screen : Change language
Language

BABYPLAST 6/10P

and insert the assword 1212 (see previous page) to gain

MACHINE PARAMETERS English Celsius 1 000045 000045 001555 reset

Change Celsius/Farenheit Machine identification number(see page.D-0410) Meter - hours . every 1500 hours there will be a reminder to change the oil return filter. Press the word reset to reset. Total hours counter. Cannot be reset.
Total cycles counter. Cannot be reset.

F8

Degrees Machine ID number Meter Total hours Total cycles Modify with password

F7

F6

F1

F2

F3

F4

F5

If is selected, the settings can only be modified by digiting the user password 1212 Peress F3 ATTENTION: to see the software versions loaded on the 4 microprocessors fitted to the machine Upgrade diplay: Upgrade CPU: The folder FM607, suppplied by the manufacturer, should be loaded onto a USB memory key The fileFMP237_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 two USB ports as indicated.

D-0405

BABYPLAST 6/10P

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
INFO

F8

F7
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 active when the USB memory key is inserted. ( see page........) Press F7 to gain access to the following display:
SOFTWARE UPGRADE FMP237 FM607 Sw. Ver.: 1.10 FMP237 FM542 Sw. Ver.: 4.10 FMP237 FM542DSPSw. Ver.: 1.60 FMP000 FM549 Sw. Ver.: 1.01AV

F6

F8
Key FM607 (display) to load upgrade file for the display from the USB memory key Key FM542 (CPU) to load upgrade file for the CPU from the USB memory key
FM607 (Display) Upgrade

F7
FM542 (CPU) Upgrade

F6

To upgrade software do as follows: FM607 Display: press the corresponding key, the numeric key pad will apear, digit the password 1122 and confirm. At the end press F7, remove the USB key switch off the machine at the main switch and then switch it on again. FM542 CPU: press the corresponding key, the numeric key pad will apear, digit the password 1122 and confirm the main directory of the USB key will appear, select the file: FMP237_FM542Appl_V..... and confirm. At the end press F7, remove the USB key switch off the machine at the main switch and then switch it on again. When upgrading the CPU and Display together, it is possible to swith the machine OFF and on again at the end of both operations. D-0406

ATTENTION:

D
D.5/ USB MEMORY STICK - Saving/downloading

BABYPLAST 6/10P

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

MAIN MENU

F8

000.0mm 00.0mm

F7

F6
Gear - art. 2345

F1

F2

F3

F4

F5

From the MAIN MENU press F5

to gain access to the following display:

D-0410

BABYPLAST 6/10P

ATTENTION:

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

PROGRAMMES

F8
Programme selected

F7
Gear - art. 2345

F6

F1

F2

F3

F4

F5

By pressing the icon F4, a folder will be created in the USB memory stick called: BabyFMP237_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 BabyFMP237_ID001 will be loaded onto the 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 be changed, but not that of the folder otherwise it will not be possible to load the files (mould setting programmes) not the machine

If more than one Babyplast are owned and in the case that each machine should have its own mould setting programmes, 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-0390). In this case, even if only one USB memory stick is used, different folders will be created with different names based on the machine ID number For example: BabyFMP237_ID001 BabyFMP237_ID002 BabyFMP237_ID003....ecc. It will be possible to modify the position of files (mould setting programmes) and change their names inside the various folders via a PC.

D-0420

D
1. Copy the folder 2.Open the programme BP_Program_Viewer_v100 into a directory on a PC BP_Program_Viewer_v100 found inside.

BABYPLAST 6/10P

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

3.Select Open

4. using browse select the folder BabyFMP237_ID001 where the mould setting programmes (files) have been previously saved. (see paragraph D.5 page D-0410)

D-0430

BABYPLAST 6/10P

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 it into another programme (such as Microsoft Word / exel etc) save it in a different format.

D-0440

BABYPLAST 6/10P

D-0450

BABYPLAST 6/10P

D-0460

BABYPLAST 6/10P

E
E.9/ ALARMS
N

BABYPLAST 6/10P

MESSAGE

CAUSE
Clamp guard open Transparent guard open Injection guard open The motor has over heated Thermocouple analog inputs faulty Faulty guard / gate switch or switches are not synchronised with the hydraulic safety valve. Fault eeprom on CPU Inconsistency in the gate check proceedure

ACTION
Close guard and ensure that the corresponding indicator, on the synoptic diag., goes out. Check the power supply to the motor. Alarm is only present durng testing by manufacturer Swich off at the main switch. Check the position of the magnets in the gate and guards.Repeat gate check. Switch machine OFF and then ON again. If persists contact a technician. Swich off at the main switch. Check the position of the magnets in the gate and guards.Repeat gate check.

001 LEFT GUARD OPEN 002 GATE OPEN 003 RIGHT GUARD OPEN 004 MOTOR OVER HEATED 005 OFFSET ANALOG INPUT FAULTY 006 FAULTY SWITCH L/H GUARD 007 FAULTY GATE SWITCH 008 FAULTY SWITCH R/H GUARD 010 EEPROM FM542 ERROR 011 INCONSISTENT GATE CHECK

012 FAULTY THERMOCOUPLE PLATEN 013 FAULTY THERMOCOUPLE HOPPER 014 FAULTY THERMOCOUP. PLASTIF. 015 FAULTY THERMOCOUP. INJ. CHAM. 016 FAULTY THERMOCOUPLE NOZZLE 017 FAULTY THERMO. FIXED MOULD 018 FAULTY THERMO. MOVING MOULD 019 HOPPER OVER HEATED

Thermocouple faulty

Check thermocouple, wires and connections. Change if necessary.

020 OIL OVER HEATED 021 FAULTY INTERN. COMPENS. T/C 022 FAULTY EXTERN. COMPENS. T/C 023 OIL LEVEL LOW

Insufficient cooling at base of hopper. If more than 70C, machine goes into alarm Insufficient cooling. Temperaturover 60C Faulty thermocouple cold joint compensator on circuit board. Faulty thermocouple cold joint compensator in socket. Oil level is too low

Check water flow and the temperature of the cooling system. Check water flow and the temperature of the cooling system. Contact a technician Check wires and contacts change NTC component. Check for leaks, check oil level float and connections. Fill tank to correct level.

024 NEUTRAL PHASE MISSING 026 PHASE MISSING 027 CURRENT FAULT 028 INVERTER ALARM 029 OIL COLD

030 FAULTY OIL COMPENS. T/C 031 EMERGENCY 032 CHANGE FILTER 033 EJECTORS OUT

Check power supply connections Check power supply connections Check power supply voltage Contact a technician Inverter faulty Oil temperature less than 20C Switch on the motor and / or wait for the oil temperature to go above the minimum temperature allowed. Check wires and connectioins or Oil thermocouple cold joint change NTC component compensator faulty Emergency stop button activated Reset button or check external alarm source. or input from external alarm. Change return filter and and reset hour The machine has worked for metre 1500 hrs. Make ejectors return in manual mode. Trying to start a cycle with Check the M4 x 20 screw which ejectors out and ejector return connects the ejector pin in mould to the sensor active. ejector piston on machine Neutral phase not connected Phase not connected

E-0010

BABYPLAST 6/10P

E
CAUSE
1. Object trapped between two the mould halves 2.Mould safety set too sensitive. 3.Mould safety range too low

MESSAGE

ACTION
Remove the object which is stopping the mould from closing. Increase Mould safety (page D-0150) Enter the mould setting programme in use , clamp page (D-320) line mould safety range increase the value set. Switch the machine OFF and then ON again. 1. Incomplete or no injection due to a part stuck in the mould cavity or a blocked nozzle. 2.Material load set too high. Reduce until cushion is under 3mm. 1.No material in hopper 2.Hopper chute blocked Check hopper or plastification valve Check mould or min mould open setting. 1.Check mould 2.Check position of ejector sensor. 3.If sensor is not present, deactivate function. Check screw in eject. pist. Check at which point in the cycle, the machine stopped. 1.Increase closing speed / pressure. 2.Increase mould safety pressure. 3.Check for the mould closed indicators on the synoptic diag.

034 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

1.Incorrect gate switch sequence. 2.Magnet missing or not in correct position The injection piston has not reached the correct cushion positon (less than 3mm) for 8 consecutive cycles see pag.D-380 Activates if material does not load within 23 Sec. from the start of plastification Mould does not open or wrong setting for min. mould opening The ejector sensor is active and did not detect ejectors fired. The ejector sensor is active and did not detect ejectors re-entered Cycle has not been completed within 90 sec. The mould does not close within 3 sec.

No impulse from injection pressure 1.Check the setting of the injection pressure switch and that it functions switch within 3 sec correctly. (page F-140 pos. 11) from the start of high pressure. 044 TIMEOUT DECOMPRESSION Decompression point not reached Check the injection valve. within 3 sec. Reset counter / start a new batch. 045 END OF PRODUCTION BATCH End of production batch. Contact a technician. 046 DSP COMMUNICATION PROBLEM Faulty proportional valve Contact a technician. 047 PROBLEM WITH CIRCUIT BREAKER Faulty circuit breaker Check the cause 048 CYCLE TIME OUT OF TOLERANCE The quality control function is activated and the cycle time has Increase the % set for tolerance band. gone out of tolerance Check connections 050 FAULTY MOULD TRANSDUCER Faulty transducer readings 051 FAULTY INJECTION TRANSDUCER Check the cause / cycle parameters. 052 CUSHION OUT OF TOLLERANCE The quality control function is activated and the cushion value is Increase the % set for tolerance band. out of tolerance check mould and connection of sensors 054 TIME-OUT CORE PULL A No consensus for core pull 055 TIME-OUT CORE PULL B Open guards and gate, wait for at least 056 CHECK GUARDS AND GATE Guard and gate check not 2 secs and then close again. completed. 043 TIMEOUT HIGH PRESSURE

E-0020

E
Cod

BABYPLAST 6/10P

MESSAGGIO

CAUSA

RISOLUZIONE

064 TIME-OUT PLASTIF. HEATER 065 TIME-OUT INJ. CHAMBER HEATER 066 TIME-OUT NOZZLE HEATER 067 TIME-OUT MOULD HEATER 068 TIME-OUT MOV. MOULD HEATER 069 TIME-OUT MACHINE STOPPED

Reset the alarm, switch the machine Activates when the heaters do OFF and check heaters and not reach the set temperature connections. within 30mins. (manufacturer setting by default)

Activates when machine remains Reset the alarm and switch ON the motor and heaters. with heaters and motor ON, but without running a cycle, for more than 30 mins. (manufacturer setting by default) 070 AUTO-OFF FOR MACHINE STOPPED Activates after the machine has Reset the alarm and switch ON the motor and heaters. been in alarm for more than 6 mins. (user setting page D-0370). - Motor and heaters are switched OFF. Switch machine OFF and then ON Faulty CPU 071 CONNECTION PROBLEM FM542 again. If persists contact a technician. Activates if the heaters have not Exit from Automatic/Semiautomatic/ 072 NOT REACHED PLASTIFIC. TEMP. 073 NOT REACHED INJ. CHAMBER TEMP yet entered within the tolerance Purge and wait for the temperatures to bands and the operator attempts enter within the respective tolerance 074 NOT REACHED NOZZLE TEMP. to use plastification or injection bands 075 NOT REACHED MOULD TEMP. 076 NOT REACHED MOV. MOULD TEMP. functions. 077 L/H GUARD OPEN DURING CYCLE Reset alarm and close guard / gate Guard / gate open 078 GATE OPEN DURING CYCLE 079 R/H GUARD OPEN DURING CYCLE 080 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 Temperatures out of tolerance (+ 0 -) band during cycle. Check thermocouples and connections.

Switch the machine OFF and ON again If persists contact a technician. Increase injection time. Set injection pressure not 107 PEAK NOT REACHED Check injection pressure transducer reached connections. Check cooling circuit , valve and Inverter temperature has gone 108 INVERTER OVER HEATED over the operating temperature thermocouple which control the temperature. allowed. The actual temperature has gone 1. Set a higher temperature setting that 112 OVER TEMPERATURE PLAST. is within the tolerance band or wait for out of tolerance by double the 113 OVER TEMPERATURE CHAMBER max imum tol. temp .set (page D- the machine to cool to a suitable 114 OVER TEMPERATURE NOZZLE temperature. 115 OVER TEMPERATURE FIXED MOULD 0390) because: 2. Contact a technician. 116 OVER TEMPERATURE MOV. MOULD 1. A temperature has been changed while the machine is still hotand the new value is out of the tolerance band by double. 2. A faulty triac or optoisolator has caused a short circuit in the heater. Switch machine OFF and then ON Data load failure while starting 128 DATA LOAD FM542 KO again. If persists contact a technician. machine 129 DATA LOAD INVERTER KO 130 COMUNICATION FM542 KO 131 COMUNICATION INVERTER KO Faulty proportional valve

E-0030

BABYPLAST 6/10P

E
F/ MAINTENANCE

All the materials used in the construction of BABYPLAST 6/10P have been studied so that they require minimum maintenance and are easy to replace. OIL: The oil and filters must be kept clean and must be replaced within the recommended periods 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 is required. If treated water is not used, the system will have to be cleaned depending on calcium level in the water. MOVEABLE PARTS: All the moveable parts, that are subject to friction, are lined with TEFLON, including the mobile platen with the STD bushings, and therefore, apart from the normal cleaning, no maintenance is required. (However, the wear on the bushings ought to be checked regularly). GASKETS: All the gaskets are fitted with bronze reinforced PTFE friction strips, and O-ring seal. Check the that the surfaces correspond before joining. ELECTRICAL EQUIPMENT. Inspect the ventilator in the electrnics compartment, particularly in hot weather, keep the unit dry and clean, and make sure the connections are well-maintained. Do not use used parts 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 ground isolated "J"-type to avoid disturbances from electrical noise. NOZZLE: The Nozzle has an armoured 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 for damage etc. INJECTION CHAMBER has two 8 x 80 diameter bulb type 200 W heating elements which need to be checked regularly. Keep this assembly as clean as possible and check the condition of wiring regularly for damage etc. PLASTIFICATION CHAMBER The plastification chamber is heated by a - 230V 1000W 37mm diam. heater band which guarantees an optimal and uniform heat 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-0010

F
F/ Electrical drawings - Electro-mechanical diagramme

BABYPLAST 6/10P

F-0020

BABYPLAST 6/10P

F
F/ Electrical drawings - Power connections

F-0030

F
F/ Electrical drawings - Gate switch connections

BABYPLAST 6/10P

F-0040

BABYPLAST 6/10P

F
F/ Electrical drawings -Outputs

F-0050

F
F/ Electrical drawings -Inputs

BABYPLAST 6/10P

F-0060

BABYPLAST 6/10P

F/ Electrical drawings -Inverter,CPU & Display connections

F-0070

BABYPLAST 6/10P

F/ Electrical drawings -Euromap 67 connections (optional)

F-0080

BABYPLAST 6/10P

F/ Electrical drawings board CPU board layout (FM542-1) part n C30901900

F-0090

BABYPLAST 6/10P

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

F-0100

BABYPLAST 6/10P

F/ Electrical drawings Display layout (FM607A) part n C30903200

F-0110

BABYPLAST 6/10P

F/ Electrical drawings inverter (FM549BP) part n C30902300

ATTENTION: When removing this board, do not separate the board from the aluminium base. Failure to do so may cause serious damage.
F-0120

BABYPLAST 6/10P

OIL TANK

Connections A-B-C-D-E-F-G-H-I-J-K-L--PRS1-: G1/8 Connections P-T-TRS: G1/4

I
2 10 2 12 12 3 T 4A 4B 3

1A

1B

1A : INJECTION 1B: DECOMPRESSION

CLAMP
2 :PLASTIFICATION 3 : EJECTION 4A : CLAMP H. P. 4B : CLAMP L. P.
4

P
5 5A 11 6 11 9 8 7 5B

EJECTION
6A 6B

5A : MOULD OPEN 5B: PRES. RELEASE

F/ HYDRAULIC SYSTEM
6A : NOZZLE BACK 6B: NOZZLE FORWARD

PLASTIFICATION INJECTION
21

HYDRAULIC SAFETY
15

22 21 20 19 18 17 16 15 14 13 12 11 10 9 8

7 5 2-3
19 16 18 17

INJECTION CARRIAGE

1-4-6

40201900 40201300 10000500 407.2001134 402.6252710 407.6801200 40202900 C30400300 C10006500 402.6950200 30706800 40203900 OC9001003 OC9001053 043306105600000 C40203700 C40203600 ES-OD02 402.2001101 ES-OD02 402.2001102 ES-OD02 402.2001100

Safety Valve assembly Safety Valve assembly Radiator assembly Suction filter Maximum pressure reg. DBDS Return filter Pump 3,5l Motor 3 phase - 330V - 50hz AFT valve Pressure gauge 160 bar Pressure transducer 250 bar - 10v Pressure switch 110/107 bar Screw M8x8 with diam.0,5mm hole Screw M6x6 with diam. 0,6mm hole Valve VSON.08A Solenoid S5L35HRL 12VDC 23W Cl.H Prop. valve VEP5A2R10.77K0604NA Solenoid S8.356HRL.24DC 20W Cl.F Valve VED8I4306.58K34.44NCD215 Solenoid S8.356HRL.24DC 20W Cl.F Valve VED8I4206.58K40.30NCC215 Solenoid S8.356HRL.24DC 20W Cl.F Valve VED8I4306.58K32.44NCD215

1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 2 1 2 2 6 3
OFEO7806RL0001 Hydraulic diagramme

PRESSURE
20

OIL TANK

BABYPLAST 6/10P
cronoplast sl

F-0140

F-0150

F/ Clamp unit

Pos.

PART NUMBER

DESCRIPTION

Q.ty

BABYPLAST 6/10P

CRONOPLAST S.L.

BABYPLAST 6/10P

F
F/ Injection unit

F-0160

F-0170

B A

F/ Motor - pump assembly drawing

Motor - pump assembly Heat exchanger assembly

BABYPLAST 6/10P

A 10003000 B 10000500
Part n

Description

BABYPLAST 6/10P

15 14 13 12 11 10 9 23 8
4
0

22 21 20 19 18 17 16

F/ Main parts drawing

5
Part n DESCRIPTION

6 7

Part n

DESCRIPTION

30903200 100.2160110 Hopper 30301400 30300500 20018100 30300400 20101700 30901200

Board Display

100.6750310 Heat guard - plastification chamber 100.2230110 Hydraulic plastific. cylinder assembly Plastification heating element Chamber heating element 2x8x80 Injection unit assembly Nozzle heating element Clamp guard Power supply 230VAC/24VDC - 240W

30702400

Linear Transducer L. 125 mm

402.6950200 Pressure gauge

30706900

Main switch

30707000

Emergency stop

500.6300200 Water Manifold

.......... .............

Water inlet/outlet

302.6651200 Nozzle thermocouple ty J - 3x40 100.6750300 Transparent safety guard

302.6651400 Chamber thermocouple

30702400

Linear Transducer L. 75 mm

30201400

Plastification thermocouple

20101600

Injection guard

N 13 14 15 16 17 18 19 20 21 22 23

N 1 2 3 4 5 6 7 8 9 10 11 12

F-0180

302.6702800 Plastification thermocouple