Manual Engel de Operacion1

duo
Operator Manual - Machine

DUO 16050/1500
Serial No.:175612
WARNING!
Improper use of the machine can lead to severe injury to persons and
damage to equipment!
Before operating the plant or performing any maintenance, you must
read this instruction manual carefully, and familiarize yourself with the
safety equipment.
Do not use the plant without appropriate training.
Manufacturer: ENGEL AUSTRIA GmbH

A-4311 Schwertberg
Tel.: +43.50.620.0
Fax: +43.50.620.3609
e-mail: service@engel.at www.engelglobal.com
Person responsible for Mörwald Johann

documentation
Version: G/11/31/1/38
Printing date: 21.2.2011
Language Englisch
Translation of original instruction manual
The contents of these documents remains our intellectual property and must not be copied or distributed electronically or mechanically, changed, trans-
mitted, translated into another language nor be used otherwise without our written consent in no manner of what kind ever. Furthermore, the contents
may neither be made known to third parties nor be used for non-approved purposes. These documents only serve the company-internal benefit and use.
Each violation will be prosecuted under criminal and civil law (§12 and §13 UWG).
In the wake of the technical development we reserve the right to make changes without previous notice.
© Copyright by ENGEL Austria Ges.m.b.H.
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1 PROPER USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2 NORTH AMERICAN APPLIED STANDARDS AND GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3 APPLICABLE EUROPEAN STANDARDS AND REGULATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4 TEXT FORMATTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5 SCREEN LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6 MACHINE OVERVIEW DUO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
7 INJECTION MOLDING IN GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
7.1 MOLDING CYCLE OF AN INJECTION MOLDING MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
7.2 IMPORTANT PRINCIPLES AND NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SAFETY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1 PICTOGRAPHS FOR NORTH AMERICA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2 PICTOGRAPHS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3 SURVEY SAFETY EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4 SAFETY EQUIPMENT FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.1 EMERGENCY STOP BUTTONS FOR PLANT SHUTDOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.2 FUNCTIONING OF THE SAFETY GATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.3 CLOSING AREA ACKNOWLEDGEMENT (AS OF DUO 800) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.4 AUTOMATIC SAFETY GATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.5 SAFETY GUARDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.6 STEP SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.7 MECHANICAL CLOSING SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5 ADDITIONAL EQUIPEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6 MOUNTING AID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
7 BEHAVIOR IN CASE OF FIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
8 RESCUE ACTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1 COMPONENTS OF THE CONTROL UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1.1 SWITCH PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
1.2 CONFIGURABLE KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2 OPERATOR KEY SWITCHING (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3 SCREEN STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3.1 HEADER WITH INFO PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3.2 SCREEN PAGE SELECTION AND FUNCTION KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.3 STATUS DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.4 PROGRAM KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.5 INPUT KEYBOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4 USER ACCESSS AUTHORIZATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
4.1 USER ACCESS CARD LOGIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
4.2 PASSWORD LOGIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
5 SETUP SCREEN PAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
5.1 USER ADMINISTRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
5.1.1 CREATING NEW USER ACCESS AUTHORIZATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
5.1.2 CHANGING USER ACCESS AUTHORIZATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
5.1.3 DELETING USER ACCESS AUTHORIZATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
5.1.4 SAVING USER ACCESS AUTHORIZATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
5.1.5 IMPORTING/EXPORTING USER DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
5.2 USER LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
6 OPERATION OF AN INJECTION MOLDING MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
6.1 START UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
6.2 MODES OF OPERATION OF THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
6.3 DECOMMISSIONING THE INJECTION MOLDING MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
7 HELP SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
8 ALARMS AND MESSAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
8.1 DELETING AND ACKNOWLEDGEMENT OF ALARMS AND MESSAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
8.2 INTERACTIVE MESSAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
9 SET VALUE GRAPHICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
9.1 QUICK SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
9.2 SETTING THE SPEED AND FORCE PROFILE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
CLAMPING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
1 MOLD CLOSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
1.1 CLOSING MOVEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
1.2 CLAMP FORCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
1.3 TWO-STAGE CLAMPING FORCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
1.4 MOLD PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
1.4.1 AUTOPROTECT (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
3
1.4.2 MOLD PROTECTION FORCE MONITORING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
1.4.3 MOLD PROTECTION SPEED MONITORING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
1.4.4 AUTOPROTECT SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
1.5 EXTERNAL CLOSING INTERLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
1.6 SEQUENCE PROGRAMMING POSITIONS MOLD CLOSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
1.7 MOLD HEIGHT SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
1.8 SETTING OF THE MOLD HEIGHT (DUO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
2 MOLD OPENING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
2.1 OPENING MOVEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
2.2 SEQUENCE SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
2.3 SINGLE-DIAL CONTROL (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
2.4 INCREASED OPENING FORCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
2.5 SEQUENCE PROGRAMMING POSITIONS MOLD OPENING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
3 EJECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
3.1 SET THE EJECTOR MOVEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
3.2 SETTING PART REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
3.3 EJECTOR START/STOP SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
3.4 EJECTION WITH INTERMEDIATE STOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
3.5 SPRUE EJECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
4 MOUNT MOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
4.1 PREPARATIONS FOR MOUNTING THE MOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
4.2 MOUNT MOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
5 TIEBAR PULLING DEVICE AUTOMATIC (DUO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
6 CORE (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
6.1 ACTIVATE CORE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
6.2 START POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
6.3 SPEED AND PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
6.4 SWITCHING-OFF TYPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
6.5 SHAKE CORE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
6.6 CORE WITH EXTERNAL ENERGY SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
6.7 CORE SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
6.8 CORE PRESSURE RELIEF (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
6.9 MECHANICAL CORE (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
HEAT ZONES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

1 BARREL HEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
1.1 MONITORING OF THE BARREL TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
1.2 STANDBY HEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
1.3 VIEW SETTINGS FOR HEATING ZONES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
1.4 SOAKING TEST (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
2 HEATING CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
2.1 ADDING HEATING ZONES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
2.2 DELETING A HEATING ZONE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
3 MOLD HEATINGS (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
4 HEATING-UP CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
5 AUTOMATIC HEATING OPTIMIZATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
6 EMERGENCY MODE OR GUIDANCE ZONE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
7 MEASURING GROUP TEMPERATURE MONITORING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
8 TEMPERATURE CONTROL DEVICES WITH COMMUNICATION TO MACHINE CONTROL UNIT . . . . . . . . . . . . . . . . . 143
8.1 GÜNTHER HOT RUNNER CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
INJECTION UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

1 NOZZLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
1.1 SPEED PROFILE AND STROKE POSITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
2 INJECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
2.1 INJECTION SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
2.2 SPECIFIC INJECTION PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
2.3 INJECTION TIME MONITORING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
2.4 INTRUSION PROGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
2.5 SEQUENCE PROGRAMMING POSITIONS INJECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
2.6 SWITCHOVER TO HOLD PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
2.7 CHARGE AMPLIFIER (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
2.7.1 CHARGE AMPLIFIER LV5155-SA (5049) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
2.7.2 CHARGE AMPLIFIER LV5155 WITH PRESSURE AND TEMPERATURE CHANNEL . . . . . . . . . . . . . . . . . . . . . 163
3 HOLDING PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
3.1 HOLDING PRESSURE PROFILE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
3.2 COOLING TIME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
3.3 CUSHION MONITORING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
3.4 SCREW DIAMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
4 PLASTICIZING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
4.1 PLASTICIZING PROFILE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
4.2 PLASTICIZING POWER-CONTROLLED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
4 Operator Manual - Machine | Version G/11/31/1/38

4.3 PLASTICIZING TIME MONITORING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
4.4 PLASTICIZING MAINTAINED INSTRUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
4.5 DECOMPRESSION BEFORE AND AFTER PLASTICIZING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
4.6 BACK PRESSURE IN MANUAL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
4.7 TORQUES DURING PLASTICIZING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
MACHINE SEQUENCE AND MASK EDITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

1 MACHINE SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
1.1 REPRESENTATION OF THE MACHINE SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
1.2 SEQUENCE STEP FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
1.3 STANDARD SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
1.4 LOADING A SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
1.5 STORING THE SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
1.6 PROGRAMMING A SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
1.6.1 INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
1.6.2 INSERT AN INSTRUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
1.6.3 CHANGING AN INSTRUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
1.6.4 REMOVING AN INSTRUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
1.6.5 INSTRUCTION TIME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
1.6.6 INSERTING A PARALLEL CLOSED BRANCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
1.6.7 INSERTING A PARALLEL OPEN BRANCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
1.6.8 INSTRUCTION WAIT UNTIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
1.6.9 PARALLEL OPEN BRANCH WITH SAFETY-CRITICAL MOVEMENTS FOR THE MOLD . . . . . . . . . . . . . . . . . . 193
1.6.10 SEQUENCE INSTRUCTIONS FOR EUROMAP 12/67 INTERFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
1.7 START-UP CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
1.8 STEP OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
1.9 PUSHBUTTON SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
2 SCREEN PAGE EDITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
2.1 COMPONENTS OF SCREEN PAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
2.2 EDIT SCREEN PAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
2.3 PASTE OF EXISTING STRIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
2.4 PASTE NEW STRIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
2.5 PASTE VARIABLES FROM OTHER SCREEN PAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
2.6 PASTE VARIABLES FROM A LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
2.7 SEARCH VARIABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
2.8 PASTE A COMMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
3 MACHINE SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
PRODUCTION PROGRAMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209

1 CYCLE TIME ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
2 WEEK TIMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
3 MONITORING SYSTEMS FOR THE INJECTION MOLDING PROCESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
4 PRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
4.1 START-UP CYCLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
4.2 REJECTS IN SUCCESSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
5 MOLD PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
6 DATA DIALOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
6.1 STORAGE MEDIA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
6.2 SEQUENCE PREVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
6.3 READ DATA SET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
6.4 WRITE A PARTS DATA SET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
6.5 COPY PARTS DATA SET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
6.6 COPYING ALL PARTS DATA SETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
6.7 DELETE DATA SET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
6.8 EXPORT INJECTION PROTOCOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
7 NOTEPAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
8 PLAUSIBILITY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
9 PRINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
10 INFOLOG (PRODUCTION PROTOCOL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
11 ALARM E-MAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
MICROGRAPH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
1 AUTOMATIC SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
2 MANUAL SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
3 CURVE-SPECIFIC SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
4 RECORD CURVE GROUPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
5 STORE IDEAL CURVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
5.1 IDEAL CURVE INITIALIZATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
6 MICROGRAPH MONITORING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
5
7 ZOOM FUNCTION SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
7.1 PREDEFINED ZOOM FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
7.2 USER-DEFINED ZOOM FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
8 XY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
9 PRINTING OUT CURVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
10 EXPORTING CURVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
11 ACTUAL VALUE DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
12 MICROPLAST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
13 MICROFLOW (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
14 AUTOPROTECT INJECTION (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
PROCESS DATA PACKAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271

1 PROCESS DATA RECORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
2 PROCESS DATA GRAPHICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
3 PROCESS DATA MONITORING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
4 HISTOGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
5 CORRELATION GRAPHICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
1 AIR VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
2 MINICAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
3 CONVEYING UNIT OR COLORING EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
4 PROGRAMMABLE IN AND OUTPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
4.1 FREELY PROGRAMMABLE OUTPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
4.1.1 PROGRAMMING IN THE MACHINE SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
4.2 FREELY PROGRAMMABLE INPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
4.2.1 PROGRAMMING IN THE MACHINE SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
5 SHUT-OFF NOZZLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
5.1 BARREL SHUT-OFF NOZZLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
5.2 MOLD SHUT-OFF NOZZLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
6 CENTRAL COMPUTER (HOST) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
6.1 TEXT PAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
7 ECOGRAPH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
7.1 ENERGY GRAPHIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
7.2 ENERGY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
7.3 ANALYSIS CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
7.4 DRIVES ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
8 VIRTMOLD PROGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
8.1 SYSTEM REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
8.2 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
8.3 CREATING A MACHINE SIMULATION FROM A REAL MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
8.4 VIRTMOLD MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
8.5 VIRTMOLD VERSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
8.6 START AND SCREEN STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
8.7 EDIT DATA SET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
SPECIAL PROGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331

General
General
You have decided on an ENGEL product which is produced and supplied under strictest qua-
lity controls.
This instruction manual is an important part of the injection molding machine and intended for
any staff who work with or on the machine. Keep the instruction manual throughout the service
life of the machine, and pass it on to any subsequent owners or users. It is important to inte-
grate any amendments you receive with the instruction manual.
Structure of the system documentation:
Instruction Manual - Machine
Service manual - Machine (Commissioning, Maintenance)
Operator Manual - Machine (Operation)
Manual CD contains the following documents in PDF format: Opera-

tor, Service and Technical Manual (Troubleshooting), schematics,
data sheets, spare parts list and optional Peripheral unit documenta-
tion.
Virtual Machine CC200 CD contains the installation programs for PC
simulation of the machine control unit.
Instruction Manual - Robot
Service manual - Robot (Commissioning, Maintenance)
Operator Manual - Robot (Operation)
Manual CD contains the following documents in PDF format: Opera-

tor, Service and Technical Manual (Troubleshooting), spare parts
catalog, schematics, data sheets and optional Peripheral unit docu-
mentation.
A plan of the electric system is located in the switch cabinet.
7
General
WARNING!
Improper use of the machine can lead to severe injury to persons and
damage to equipment!
Before operating the plant or performing any maintenance, you must
read this instruction manual carefully, and familiarize yourself with the
safety equipment.
Do not use the plant without appropriate training.
We recommend that you take part in training at one of Engel's training centers (www.engel-
global.com/training).
The main aim of this book is to impart the operation and all program functions of the injection
molding machine. The book provides the necessary information for setting a production pro-
cess.
The manual is also designed help eliminate production failures as rapidly as possible.
Information on accessories is available in the Special Programs chapter.
Note!
The index contains a list of alarms.

General
1 Proper Use
ENGEL products are built to the current state-of-the-art, and comply with accepted safety stan-
dards.
Note that ENGEL injection molding machines must be used for manufacturing of injection
molded parts made of thermoplastics, thermosets and elastomers only, in accordance with the
instruction manual.
To this end, make sure you follow the processing instructions given by the material manufac-
turer!
(Improper processing could lead to injury or damage to equipment!)
The injection molding machines are constructed for automatic material feed.
Automatic material feed must be present at the site prior to start of production.
In case of manual material feed, a standardized mounting aid must be used.
The mounting aid can be supplied by ENGEL if required.
A mounting aid of this kind must be present at the site prior to start of production.
[See Mounting aid on page 33.]
Installation, operations, and maintenance of this machine must be performed by staff trained
for this purpose on ENGEL machines.
For damage from improper or not as agreed use, non-observation of the specifications in the
instruction manual as well as faulty operation ENGEL GmbH is not liable.
Modifying the machine invalidates its EC conformity; you are not permitted to put the machine
into operation in this case!
2 North American Applied standards and guidelines
ANSI/SPI B151.1 Plastics Machinery - Horizontal Injection Molding Machines - Safety

Requirements for Manufacturing, Care and Use
ANSI/SPI Vertical clamping unit IMM (VCIMM) - Safety requirements for manu-
B151.29 facturing, care and use
ANSI/RIA/ISO Industrial robots and robot systems - Safety requirements

10218
NFPA79 Electrical standards for industrial machinery
9
General
3 Applicable European standards and regulations
2006/42/EG Machinery Directive
2006/95/EG Low Voltage Directive
2004/108/EG EMC Directive for Electromagnetic Compatibility
EN ISO 12100-1 Machine Safety
EN ISO 12100-2 Machine Safety
EN ISO 13857 Machine Safety, Safety Distances
EN 201 Safety Information for Injection Molding Machines
EN ISO 13850 Machine Safety, EMERGENCY STOP Equipment
EN 60204-1 Machine Safety, Electrical Equipment for Machines
EN ISO 10218 Industrial Robot Safety
4 Text formatting
The following text formatting is used to provide a clear manual layout and to emphasize parti-
cularly important information:
DANGER!
Information marked with this symbol points out immediate danger which
can lead to death or serious physical injury!
WARNING!
Information marked with this symbol warns of possible danger which

can lead to death or serious physical injury!
CAUTION!
Information marked with this pictogram warns of possible danger which

can cause injury to persons and damage to equipment!

General
CAUTION!
Possible dangers which can cause damage to the machine!
Note!
Text provided with this symbol offers tips on use and other useful information.
Example:
Information provided with this symbol offers practical examples.
Numbered sequence
1. Fixes procedure way after the numbers
2. The operator must adhere absolute to the fixed operational sequence.
5 Screen layout
Depending on the machine configuration, the screen lengths can differ. Some screens support
scrolling. The screens are divided into functional areas.
Screens
CAUTION!
The parameters in the figures are purely incidental and should not be
used as a guide for machine set up.
11
General
6 Machine overview DUO

Example: DUO ES 5550/800
Clamping unit side Injection unit side
1 2 3 4 5 6 7 8
13 12 11 10 9
[1] Ejector and ejector coupling

[2] Moving platen
[3] Stationary platen
[4] Barrel with nozzle
[5] Material container
[6] Injection unit
[7] Screw drive for plasticizing
[8] Hydraulic oil tank
[9] Main switch
[10] Switch cabinet
[11] Control panel with screen
[12] Operator workplace
[13] Moving safety gate clamping unit side

General
7 Injection molding in general

Injection molding is the most important technique for producing molded parts. Originally deve-
loped for thermoplastics, today it can be used for more or less any kind of plastics, including
thermosets (PF molding compounds),
elastomers (e.g. rubber compounds),
foaming (e.g. on polystyrene basis),
filled and unfilled molding compounds.
The injection molding process, in one single work step, leads from the molding compound to
the finished formed part. The raw material is available to the processor as a powder or gran-
ules. The machine injects a liquid or at least a viscous material into a mold under high pres-
sure. Parts with high dimensional accuracy are produced.
7.1 Molding cycle of an injection molding machine

In order to create one or more molded parts, the injection molding machine executes a series
of steps that are attuned to one another. In this regard, professionals speak of a molding cycle.
The molding cycle is judged on the time required (cycle time) or after a number of cycles set
on the production counter screen page (e.g. injection shot counter). Individual machine move-
ments can overlap each other in time.
Example of an injection molding machine sequence

Mold close
Nozzle contact
Inject
Holding pressure
Cooling time
Plasticizing
Retract nozzle
Mold opening
Take-off
Time
First step: Mold closing

The injection cycle starts when the two mold halves close. A configurable speed and force pro-
file serves to protect the mold against damage. In case of mold parts with mold cavities, the
cores also move in After closing the mold, the machine builds up great clamping force.
Second step: Nozzle contact

The injection unit nozzle is moved up to the mold, and the operator set contact pressure is built
against the sprue bushing.
Third step: Injection and hold pressure

The screw injects the melt from the screw antechamber into the mold cavity under high pres-
sure using a set speed profile. The pressure can be between 300 and 2500 bar depending on
mold and molding compound. A mechanical non-return valve prevents the backflow of the melt
into the screw channels.
13
General
The cooling time begins with the entry of the molten plastic into the mold. To prevent sink
marks or voids in the part, the machine switches over to hold pressure after the mold has been
filled. The hold pressure packs out the mold to compensate for material lost due to cooling until
the sprue freezes off (gate sealing). A hold pressure profile and time can be set by the opera-
tor. After the hold pressure, the operator set cooling time begins.
Fourth step: Plasticizing

The plastic granules fall from the material hopper through the feed throat of the injection barrel
into the feed section of the plasticizing screw. The screw turns and conveys the material for-
ward towards the nozzle through the externally heated barrel. As the screw turns, the shear
forces exerted on the material combined with the heat from the barrel cause the material to be
melted and conveyed to the front of the screw. The accumulation of melted mater.
Afterwards, for relieving the melt compressed in the screw antechamber the machine retracts
the screw (decompression). If necessary, a shut-off nozzle can ensure that no melt flows out
from the nozzle.
Fifth step: Nozzle retraction

The nozzle must sometimes be retracted from the mold in order that
the sprue shears off,
to prevent too much heat transfer from the nozzle to the sprue bushing,
to prevent the heated nozzle from being cooled down by the colder sprue bushing.
Sixth step: Ejection

At the end of cooling time, the mold opens with an operator set speed profile and the molded
part is ejected. When the moving mold half reaches the set open position, the molded part is
ejected. Ejector pins are moved through the moving mold half and push out the molded part.
The cycle is finished with the expiry of the recycle time and the machine is now ready for a new
cycle.
7.2 Important principles and notes

Several important prerequistes must be created to ensure optimal process control:
The part and mold must be designed to suit the mechanical, thermal and flow properties
of the plastic material used.
Standardized checks on incoming material.
Efficient machinery.
Well designed machine sequence.
Sequential quality test of the injection molding machine.
Systematic mold proving trials.
Optimization aids.

Safety
Safety
Injection molding machines are powerful machines that create high PRESSURES - FORCES
- TEMPERATURES that can be dangerous to persons.
To protect persons against danger of accidents, ENGEL injection molding machines are fitted
with safety equipment.
Before operating a machine perform a visual check to ensure that the safety equipment is in
good working order. Also, manually check the locking systems by opening and closing all mov-
ing safety equipment.
[See Safety equipment functions on page 24.]
If you notice that safety equipment is defective,:

1. Switch off the machine immediately at the control panel and at the main switch.
2. Carry out no further activity on the equipment.
3. Immediately contact the member of staff responsible for the safety of the machine.
4. Do not resume operations until all safety equipment is working properly.
Note!
Always keep the whole plant clean. This improves its functionality and enhances operator
safety!
The floor around the plant as well as the specified access points and working places are
to be kept free of oil and pellets.
Only use marked locations as access points or workplaces.
Protect hoses against harmful influences such as acids and mechanical damage!
If you notice leakages, damage, or breaks in media lines, switch off the machine imme-
diately!
Never use plant surfaces as work surfaces. Do not use the plant as a mounting aid.
Comply with and never remove warning signs, notices or labels from machines!
Observe the safety instructions in the manual!
No access for unauthorized persons.
WARNING!
Danger of burns in the vicinity of hot components such as the barrel and
injection mold; danger of injury due to high pressure injection!
Insufficient pre-drying or decomposition of certain plastics can cause
the material to exit the nozzle or infeed opening in an uncontrolled way.
When working on the machine, use suitable protective clothing (safety
shoes, protective gloves, face protection, ...). Observe local safety regu-
lations for operating injection molding machines!
When working in the injection mold area, make sure the nozzle is
retracted! Make sure the barrel nozzle is not touching the mold!
Observe processing and safety instructions by the material manufac-
15
Safety
turer!
In case of injection steps where clamping force is not fully built up,
install additional, fixed, separating safeguards in the injection molding
machine mold area, or attach directly to the mold!
WARNING!
Danger from gases hazardous to health!

turer. When processing materials that can cause a health risk, always
use extraction equipment.
The user is responsible for procuring and installing the extraction equip-
ment (e.g. above the injection mold, nozzle areas, material feed open-
ing).
When using nitrogen in processes, always check the oxygen content
first before all work in the pit.
WARNING!
Danger of crushing due to moving components on the machine!

During operations never reach into, or enter, component work areas,
except at positions designed for this purpose.
Never manipulate, disable, or remove safety equipment.
Do not use any molds that protrude over the mold area of the machine.
When connecting and disconnecting media lines in case of retooling
work, make sure that the system is depressurized and switch off the
motors.
Do not work or stand below moving components, even if the plant is
switched off.
CAUTION!
Danger of damage to equipment due to improper settings!

When operating the machine, use settings that precisely match the
requirements for safe operations of the machine, molds, and peripheral
units.
ENGEL is not liable for operator errors.

Safety
WARNING!
Danger of fatal injury in case of improper maintenance!

Maintenance work and repairs to the machine must be performed by
trained and skilled staff only.
You must have comprehensive knowledge of safety precautions and
controls.
Always perform the maintenance tasks described in the instruction manual at the specified
intervals.
Additionally, keep to maintenance intervals and perform maintenance tasks on all safety
devices for the protection of staff and equipment to comply with your national and/or local
safety regulations.
Any work on the machine, beyond the described activities, must be carried out by ENGEL ser-
vice engineers.
WARNING!
Danger of falling and crushing in case of failure to use fixed mounting

aids!
Use suitable mounting aids for work at heights above 1.0 m (39.4 in).
Mounting aids must be provided by owner/operator if not included in
scope of order.
Unauthorized, non-permanent mounting aids can allow staff to reach
into dangerous areas of the machine.
Before you use non-permanent mounting aids, always switch off the
injection molding machine.
If you need to use a mounting aid, use equipment that complies with
local safety regulations and prevents from falling, tripping or slipping.
Never lean ladders against the machine.
Observe the additional safety instructions found throughout this man-
ual!
17
Safety
1 Pictographs for North America

Description of the pictograms that may be affixed to the machine to indicate dangerous areas
or situations. Failure to observe safety signs can lead to severe injury.
Signs
Symbol Description
DANGER!
High speed moving parts. Do not operate with gate / guards removed or open.
Do not reach around, under, over or through gate / guards while machine is
operating. Can cause crushing injury or death.
DANGER!
High voltage. Hot surface. Turn off and lock out main power disconnect, allow
to cool before servicing. Can cause shock, severe burns or death.
DANGER!
High voltage. Before servicing turn off, lock out / tag out main power discon-
nect. Do not modify electric or hydraulic circuits unless authorized by manufac-
turer. Earth ground maschine and electrical cabinet before turning on power.
Failure to comply can cause shock, burns or death.
DANGER!
High voltage. Machine has additional disconnect(s) in other location(s). Before
servicing turn off, lock out/tag out all power disconnects. Failure to comply can
cause shock, burns or deatch.
WARNING!
High pressure molten material. Stand clear and wear protective gear when
purging and / or servicing injection system. Can cause severe burns.
WARNING!
Rotating screw. Do not operate with hopper removed or put hands or feet into
opening. Serious bodily injury can occur.
WARNING!
High pressure accumulator. Discharge all gas and hydraulic pressure before
disconnecting or disassembling tank. Can cause death or serious injury.
WARNING!
Crushing injury. If the guard over the part drop area must be modified or
removed, it is the User's responsibility to add additional guarding to prevent
reaching moving machine members when the guards are closed. Failure to fol-
low these instructions may result in serious personal injury.
WARNING!
High pressure fluid. Do not use hand to check hydraulic leaks. Relieve pressure
before loosening fittings. High pressure punctures skin. If injured, seek immedi-
ate medical help. Surgery is required to remove fluid. Can cause death or seri-
ous injury.

Safety
Signs
Symbol Description
WARNING!
High speed moving robot. Interlocked perimeter guarding must be in place and
functioning before operating robot.
Can cause serious injury.
WARNING!
Moving belt(s). Do not operate with guards removed. Can cause serious injury.
WARNING!
Arc flash and shock hazard. Refer to NFPA 70E for workplace electrical safety
and for proper Personal Protective Equipment. Failure to comply could result in
serious injury or death.
CAUTION!
Complex machine with hazards. Do not operate machine unless trained, read
and understand the Maintenance / Operator manual(s). Prior to start-up, test
safety devices per instruction manual. Do not operate machine unless inter-
locks / safety devices are in place and function properly. Do not modify machine
unless authorized by manufacturer. Failure to follow instructions could result in
injury..
CAUTION!
Only qualified persons are permitted to gain access through the keyswitch!
Remove key from keyswitch after maintenance work.
19
Safety
2 Pictographs
Description of the pictograms that may be affixed to the machine to indicate dangerous areas
or situations. Failure to observe safety signs can lead to severe injury.
Prohibitory signs
Symbol Description and examples of labels
Admittance for authorized persons only!

Standard labels on protection doors for safety guarding
Keep off the area!

Standard labels in the area of the injection unit and robot control cabinet
No admittance for persons with cardiac pacemaker!

Labels for magnetic holding plates in the clamping unit area
Working or standing below moving components and suspended loads is prohib-

ited!
Labels for machines with robots on protection doors, clamping unit and safety
guarding
No fork lift trucks!

Use of fork lifts or manual lifts for lifting the plant at this position is prohibited.
Do not use any credit cards, watches or small metal parts in the proximity!
Labels for magnetic holding plates in the clamping unit area
Mandatory Signs
Read documentation!
On the control panel of the machine control
Use protection equipment!

In the barrel area
Use face protection!

In the barrel and injection mold area
Use lifting point for transport!

At lifting points

Safety
Danger signs
Warning against hot surface!

In the barrel area
Warning against mains voltage!

On control cabinets and distribution boxes
Warning against hand injuries!
Warning against floating loads!
Warning against pinching or squeezing!

In the clamping unit area
Warning against pressurized molten material!

In the barrel area
Warning against strong magnetic field!
21
Safety
Safety hints
Symbol Description
GUIDELINES FOR WORKING ON INJECTION MOLDING MACHINES:

Labels for the machine control
1. Always observe the local safety regulations for the operating safty of injection
moulding machines and robot systems (handling systems, mould change).
Read the instruction manual.
2. Keep safety equipment in good working condition. Never remove, deactivate
or disable safety equipment.
3. Do not remove any danger or information signs and markings from the
machine or from the additional equipment.
4. Control all the safety equipment on the machine and on the additional equip-
ment for correct function and check it at regular intervals.
5. Control all high-pressure pipelines at regular intervals for their worksafe
state.
6. Pay attention to that no hard objects get into the vent as well as into the feed
opening.
7. Entering the area of the injection unit is not allowed during the machine oper-
ation.
8. If a mounting aid is required for filling the processing material container, use
such which corresponds to the local safety regulations.
9. Do not enter the ejection area and/or do not reach into it during operation.
10. Caution in the area of the heated-up material cylinder ready for operation
(danger of combustion).
11. Always observe the processing guidelines and safety hints indicated by the
material manufacturer.
12. Use extractor fans when working with a vented cylinder and when process-
ing toxic types of material; wear the prescribed protective clothing.
13. Only use shut-off nozzles allowed by the legislator.
14. Never switch the main switch under load (e. g. when heatings are switched
on).
15. Switch off the motors for all maintenance and repair work in the machine's
work areas with moving parts. Make sure that the complete hydraulics system
is depressurized. Exercise special care if you use pressure accumulators.
16. Set the machine currentless by all means in case of repairs and modifica-
tion work. Switch off main switch and secure it and control for voltage freedom.
17. Make sure that the material in the material cylinder is not under pressure
and/or is not cooled down before you dismount the nozzle and/or the material
cylinder flange.
18. Mount and check the whole safety equipment after machine repairs.
19. No admittance to the machine for unauthorized persons.
Entering the injection unit when in operation not allowed, otherwise attach suit-
able covers, which prevent reaching into the danger area of the clamping unit.
Labels for the injection unit

Safety
3 Survey safety equipment

Example: DUO 5550/800
1 2 3 4 5 6
13 12 11 10 9 8 7
[1] Clamping unit side rear sliding safety gate

[2] EMERGENCY STOP button - red
[3] Alarm lamp (flashes in case of alarm)
[4] Nozzle sliding safety gate
[5] Injection unit side safety gate
[6] Main switch and machine type plate
[7] Rating plate on inside of control cabinet door
[8] ’’Guidelines for working on injection molding machines’’
[9] EMERGENCY STOP button - red
[10] Locking safety gate
[11] Step safety
[12] Clamping unit side front sliding safety gate
[13] Fixed safety gate
23
Safety
4 Safety equipment functions

To protect persons against danger of accidents, ENGEL injection molding machines are fitted
with safety equipment.
4.1 EMERGENCY STOP buttons for plant shutdown

The EMERGENCY STOP buttons are located on the control panel of the injection molding
machine and - depending on the machine type - in the following areas:
on the rear side of the injection molding machine
on the robot manual control unit
at the safety gate of a safeguard
inside a safeguard
When an EMERGENCY STOP button is activated, the injection molding machine motors
immediately switch OFF. Message:
Emergency-off
Cause An EMERGENCY STOP function is active, e.g. EMERGENCY STOP

button pressed, rear safety gate open
Effect The cycle, motors and movements stop immediately.

The alarm lamp flashes.
Restarting after an EMERGENCY STOP

1. Make sure no dangerous situations exist.
2. Release the EMERGENCY STOP button by turning it clockwise.
3. Activate the Program Interruption switch to acknowledge the alarm.
4. Switch on the motors.
Note!
The EMERGENCY STOP function is active in each mode of operation!
4.2 Functioning of the safety gates

Opening a safety gate blocks all hazardous movements and a corresponding message is dis-
played on screen.
Clamping unit safety gate x open
Effect All machine movements are blocked
Remedy Close the safety gate.

Safety
Clamping unit safety gate interrupts cycle
Cause Safety gate has been opened in the automatic mode
Effect Cycle interruption, motor standstill, heating reduced, alarm lamp
Remedy Close the safety gates, move the machine into the start position and
start the cycle again.
Depending on the protection type, opening the rear safety gate on the clamping unit causes an
EMERGENCY STOP switch-off, or executes the same function as the operator side safety
gate.
When a safety gate on the injection unit is opened, the following message appears:
Nozzle safety gate open
Effect Blocks all injection unit side movements and close mold, cycle stop.
Remedy Close the nozzle side safety gate
In semi-automatic or manual mode, the following message appears if the safety gates have
their own monitoring modules:
Clamping unit safety gate x open-close
Cause The safety gates must be checked:

Injection unit-side safety gate, at least every 7 days.
Non operator side safety gate, at least every 30 days.
Effect Blocks all machine movements in manual mode, no motor start and
cycle start possible.
Remedy Check for correct switching sequence by opening and closing the
safety gates.
25
Safety
4.3 Closing area acknowledgement (as of DUO 800)

For safety reasons, the control unit blocks the movements of the mold and center plate after
the safety gates are closed.
ATTENTION: Closing area acknowledgement!
Help Area free
DANGER!
Danger of fatal injury due to moving components and high-pressure

injection!
Check that no persons are located in the closing area before acknowl-
edgement.
Settings, see the Var monitor group ’SafetyGate’.
4.4 Automatic safety gate

A drive supports convenient, automatic opening and closing of the clamping unit safety gate.
This is a big advantage particularly in semi-automatic mode, with manual take-off and insert-
placing of injection molded parts.
Push buttons:
Close safety gate
Opening safety gate
When the drive is switched off, move the safety gate by hand only.
When the drive is switched on the safety gate is moved with the push buttons.
Electric safety gate

Screen switch for manual or electrical operation.

Safety
Screen switch for manual or electrical operation.

Safety gate activated in sequence
Opening stroke in semi-automatic mode
+
Safety gate 1 brake opening
final position Braking limit switch Safety strip
closed
open
controller release
Direction Open Close
Safety gate activated in sequence

In semi-automatic mode, safety gate movements can be programmed in the machine
sequence.
The safety gate opens at the programmed position and waits for the start key. When the
start key is pressed, the safety gate closes and the cycle starts when the key is pressed
again.
Opening stroke in semi-automatic mode

In semi-automatic mode, the safety gate opens with an adjustable opening stroke.
Program the movements of the safety gate as usual in the machine sequence.
Note!
Automatic movements of the safety gate is possible only in semi-automatic mode.
Semiautomatic mode
Safety gate movements can be programmed in the machine sequence.
In semi-automatic mode, the safety gate opens at the programmed position and waits for the
start button. When the start button is pressed, the safety gate closes and the cycle starts when
the button is pressed again.
Sequence example:
Open safety gate with open mold and ejector advanced.
Open mold
700,0 mm
Advance ejector
95,0 mm
Open
Close
Retract ejector
70,0 mm
27
Safety
Safety edges are fitted to the safety gate to protect persons.

When the safety edge is actuated, the safety gate movement stops and the following message
is displayed:
Safety gate - safety strip - actuated
Effect No automatic mode, movements on the clamping unit and on the

injection unit side blocked. After a short standstill time the safety gate
slowly moves in the opposite direction
Remedy Safety edge relief
Close safety gate
Cause The safety gate is not closed when switching from manual to electri-
cal mode
Effect no cycle start
Remedy Close the safety gate in the manual mode of operation
4.5 Safety guarding

To safeguard the danger zone in the plant, a safety guard that contains a protection door for
entering the danger zone has been attached to the machine.
The safety guarding is generally connected to the injection molding machine in place of the
rear safety gate of the clamping unit, optionally operator side possible.
Example: safety guarding with protection door
2
1
0 3
1
4
I T
QU
30
XH
[1] EMERGENCY STOP button inside

[2] EMERGENCY STOP button outside
[3] Access request key with lamp

Safety
[4] Acknowledgement key with key-operated switch
WARNING!
Danger of fatal injury due to moving components and high-pressure

injection!
The person inside the safeguard must always possess the key from the
key-operated acknowledgement switch in order to prevent accidental
acknowledgement of safeguards, which would cause the machine to
restart.
Do not acknowledge the safety guard until the danger area is clear of
personnel and foreign bodies.
Entering the hazardous area

The protection door automatically unlocks in case of an emergency stop after a standstill of the
machine and when the machine is switched off.
The following procedure must be complied with during ongoing production:
1. Actuate the access demand button to unlock the protection door (button flashes). The
injection molding machine stops at the end of the cycle.
2. The access request key lighting up indicates that the protection door has been unlocked
and enabled for opening.
3. Before opening the protection door, remove the key from the key-operated acknowl-
edgement switch and take it in with you.
Movements of the injection molding machine are blocked when the protection door is
open.
4. After leaving the danger area, the operator must acknowledge the protection door with
the key-operated switch immediately (within 5 seconds) after closing the door, this then
locks the protection door.
5. The plant continues processing the program after the start key is actuated.
Pluggable safety gate

The safety guarding and protection door are connected to the injection molding machine via a
male connector instead of the rear safety gate on the injection unit (optionally also operator
side).
Attach the rear safety gate of the clamping unit

For example, the end of arm tooling can be changed while the injection molding machine is in
production When the safety gate on the clamping unit is connected, the protection door in the
safety guarding has no function.
1. Disconnect safety guarding with protection door.
2. Connect and close the safety gate of the clamping unit.
Connect safety guarding with protection door

For example, for shared automatic mode of the injection molding machine and the robot.
1. Disconnect and open the rear safety gate of the clamping unit.
2. Connect safety guarding with protection door.
3. Open/close the protection door and acknowledge.
29
Safety
Alarms and messages

An acknowledgement must occur after switching on the control voltage The following message
is displayed until you acknowledge the protection door:
Open-close-acknowledge safety gate x;

Acknowledge safety gate x
Effect Movements of the injection molding machine are not possible.
Remedy Open - close safety gate and acknowledge within 5 seconds using
the key-operated switch
The acknowledgement must occur within 5 seconds of, but not within 0.05 seconds after clos-
ing the protection door.
You are not permitted to press the acknowledgement key for too long (maximum of 10 sec-
onds). If these conditions are not fulfilled, the following message appears:
Safety guarding x acknowledgement time exceeded;

Clamping unit safety gate x (SIP3): acknowledgement key actu-
ated too quickly;
Clamping unit safety gate x (SIP3): acknowledgement key actu-
ated for too long
Effect Protection door not acknowledged
Remedy Open - close safety gate and acknowledge within 5 seconds using
the key-operated switch
Safety gate x acknowledgement key pressed too early
Cause Safety gate closed when acknowledgement key pressed.
Effect Motor stop, alarm lamp
Remedy Close and acknowledge safety gate within 5 s.
If the rear safety gate of the clamping unit is closed when the safety guard is connected, the
following messages appear:
Clamping unit disconnected safety gate x not open
Effect Automatic operations with machine not possible.
Remedy Completely open the rear safety gate of the clamping unit.

Safety
4.6 Step safety

Step-on plates below the mold area prevent machine movement when a person is within the
machine's safeguards.
WARNING!
Danger of fatal injury if safety equipment is not cleaned!

Keep safety floor plates (plate elements)clean at all times (e.g.: remove
sprue, injection molded parts, etc.). Parts jammed in the gap between
the steps can impact the functionality of the steps.
Clearing must only be carried out when the machine is switched-off.
Clean the step-on plates at each routine maintenance.
The following actions are blocked when step safety is actuated:

Automatic cycle start
Mould closing, mould opening
Injection, plasticizing
Advance nozzle
Ejector, core, and mold shut-off nozzle movements
Open and close safety gate electrically
In plants with robot, all robot movements (robot motors must switch off)
The number of step-on plates (= area) depends on the machine type and machine size.
Example: DUO 1000 with 5 zones; Zone 2 marked as defective in color

Step safety
Step-on safety 1 deactuated

Starting the step safety test manually
The number of step-on plates (= area) depends on the machine type and machine size.
When step safety is actuated, the following message appears:
31
Safety
Step safety - area x active
Cause: The step safety between the mold halves or between the safety gate
and mold was triggered.
Effect: Mold closing, mold opening, injection, plasticizing, advance nozzle,

movements of ejector, core and mold shut-off nozzle, and opening/
closing electric safety gate are blocked.
Remedy: Relieve safety floor plates. If needed, check limit switches.
Note!
For step safety maintenance and testing, see ’Service Manual - Maintenance of safety equip-
ment chapter’.
4.7 Mechanical closing safety

The purpose of the mechanical closing safety is to prevent the moving mold fixing platen from
closing.
If the safety gate is open, the mechanical closing safety will be locked.
If an attempt is made to move the clamping unit when closing safety is engaged, the following
message will appear:
Mechanical closing safety x moved in
Cause Mechanical closing safety not moved out.
Effect No mold movement or mold height adjustment possible and cycle

start will be disabled.
Remedy Closing safety is actuated by opening and closing the safety gate.
In an EMERGENCY STOP a jamming of the closing safety may occur. This jamming may pre-
vent the closing safety to be moved out after clearance of the EMERGENCY STOP. Proceed
as follows to free the closing safety:
1. Switch to Set-up
2. Press the key Mold opening and the Safety key at the same time in order to open the
mold a short stroke +
3. Open/close the safety gate on the clamping unit.
Note!
For mechanical closing safety maintenance, see ’Service Manual - Maintenance of safety
equipment chapter’.

Safety
5 Additional equipements
The installation of additional equipment is only permitted with the permission of ENGEL.
If additional equipment is attached to the machine without ground support, a new evaluation of
the risk of tipping must be implemented.
ENGEL is only responsible for the cooperation of the machine with additional equipment if the
interfaces have been designed by ENGEL.
Sockets on the injection molding machine may only be used for the specified additional or
peripheral equipment.
Robot interface / Automation to Euromap 67 or 12

Before connecting and using an interface, risk assessment must be performed by ROBOT
vendor!
WARNING!
Danger due to missing safety gates!

If safety gates are removed to support machine operations with periph-
eral equipment (e.g. conveyor-belts, stacking devices, etc.), the user
company must implement safety measures that do not impact on safety
levels!
If the machine is then operated again without peripheral equipment,
ensure the original safety gates are restored to their original state.
The installation of additional equipment must not reduce the view into dangerous machine
areas, not must it hinder access to workplaces specified in the operating manual.
In a case of damage, ENGEL does not assume liability of any kind!
6 Mounting aid
Machines with material hopper must be equipped as per EN 201 with secure access means or
the user must provide mobile, secure access means for the machine. We recommend that a
mounting aid offered by ENGEL be used.
Proper Use:
The mounting aid is only suitable for manual filling of the material hopper in horizontal standard
injection molding machines without a robot and without additional equipment. Free usage is
prohibited!
WARNING!
Danger of crushing due to moving components!

Unauthorized, non-permanent mounting aids can allow staff to reach
into dangerous areas of the machine.
Only position the mounting aid up to the position marked on the injec-
tion molding machine by a sign. It must be impossible to reach into any
danger areas of the machine.
Maintain safety distances as per EN ISO 13857.
33
Safety
Check the safety distances as per EN ISO 13857 of the mounting aid and respective machine
before use and mark the correct position with the sign.
Example: ENGEL mounting aid for manual material feed
The mounting aid on the front side of the machine

must be moved to the position marked by a sign and
fixed in place by locking the wheels.
The mounting aid must be present at the site prior to
start of production.
WARNING!
Danger of falling due to oil and spilt granulate!

Keep mounting aid clean and do not use if contaminated.
7 Behavior in case of fire
1. Keep calm
2. Alert the fire department
3. Switch off the machine at the main switch
4. Alert all persons in the danger zone
5. If possible, close all fire doors
6. Switch of any venting and/or air conditioning units
7. As soon as possible, contain the fire with an approved fire extinguisher
8. Provide assistance and direction to anyone actively involved in fighting the fire
Use an abc class fire extinguisher

This is most suitable due to its versatility compared with other extinguishing agents.
Be familiar with the instruction label attached to the fire extinguisher.
Be aware that the fire extinguisher powder can cause an obstruction to view and will
leave a heavy residue which then must be removed from the machine.

Safety
DANGER!
Danger of fatal injury due to electric shock!

Use of water, foam or D class fire extinguishers is prohibited.
When using ABC powder fire extinguishers keep a distance of at least
one meter to electrical equipment.
Note!
If a fire has occurred on an ENGEL molding machine, it must not be put back into operation
until it has been inspected by an ENGEL Service Representative:
at your local ENGEL dealer/subsidiary, or

contact the nearest ENGEL works
35
Safety
8 Rescue actions
Perform the following rescue actions to release trapped persons from the mold area; note that
accidents of this kind can only occur in case of gross misuse or if you disable vital safety
devices!
1. 2 persons are required to provide first-aid (both must be skilled in the use of the injection
or compression molding system).
2. One of the two rescuers must mechanically secure the machine against motions, such
as lowering or clamping, that would further endanger the victim or rescuers (moving
mold mounting plate, core-pull, ejector).
3. The second rescuer must manually move the machine to a position where the victim
can be freed.
4. Leave the danger area (mold area) with the person you have rescued.
5. Give first aid.
6. Call a paramedic.

Operation
Operation
A swiveling touchscreen color monitor, combined with foil and toggle keys, enables optimal
ergonomic operation.
Control panel with side grips for two-handed

swiveling (right with unlocking).
Users need to log in to access settings and parameters.

Text and graphics editors support fast and easy customization of the machine to match your
injection molding process and free programming of the program sequence.
Data storage is to the control unit, USB memory stick or a network drive.
A help system with graphics supports operations and maintenance of the injection molding
machine.
You can install the optional VirtMold software to run the original machine visualization on a
PC. This gives you the ability to change settings independently of the injection molding
machine, and to store your changes on a Compact Flash card or USB memory stick to transfer
them to the machine.
37
Operation
1 Components of the control unit

Control voltage switch
Machine motor switch
Robot motor switch
Mold heating switch

Barrel heating switch
Sensor for the user authorization card (CC 200)
Emergency stop button

2 USB interfaces.
To connect to external devices (e.g.: memory
stick, printer, keyboard, etc..)
Color touch screen display
Configurable foil keys for the manual control of

the individual system motions.
Touch keys for manual control of the individual

machine movements.
(Optional swivel keys)
Start key
Program interruption
Safety button key

Operation
Color touch screen display

The control unit is operated by tapping the desired menu items. Virtual input keyboards and
dialog windows open so that you can edit parameters.
CAUTION!
Do not use pointed, sharp, or metal objects, including ballpoint pens or pencils, on the touch
screen. This can lead to damage.
It is recommended that the touch screen be operated with either your hand or a suitable
marker.
Control voltage switch

After the control voltage has been switched on, it takes approx. 3 minutes until the machine is
ready for operation.
Note!
After switching off the control voltage, always wait at least 1 second until switching it back on.
The electronics modules must first be able to discharge.
USB interface
To write and read machine and parts data as well as production data. If possible, use Engel-
recommended USB memory sticks.
[See Storage media on page 223.]
Key-operated safety keyswitch

Certain machine interlocks can be circumvented by the simultaneous operation of the safety
key switch and the movement switch.
[See Mode of operation Manual or Program interruption on page 60.]
Program interruption
The program interruption switch is used to interrupt the automatic cycle and to acknowledge
the messages. In the switched-on state the following message is displayed:
Program interruption key
Effect The automatic cycle stops, current messages are acknowledged, you
can run the machine as in manual mode.
Remedy Turn the program interruption switch to Automatic.
Start key
You only need the Start key to start an automatic cycle. The machine's functional units must all
be at the starting position for this. The following message appears when switching over to
automatic mode:
Press start key
Cause The machine is ready to start an automatic cycle.
39
Operation
1.1 Switch panel

The switch panel can have a membrane keyboard or toggle switches. The switch panel has a
different design depending on the machine type or version.
A manual control of the machine's movement is possible by pressing the respective key.
The function of the keys is represented by symbols.
Machine-specific key symbols
Key symbol Key explanation
Control voltage
Machine motor
Robot motor

Operation
Lamp motor overload
Mold heating
Barrel heating
Lamp moving platen magnetized
Lampe stationary platen magnetized
Mold opening
Mold close
Ejector retract
Advance ejector
Robot - Reference axes
Robot - Movement to Home position
Nozzle advance
Nozzle - retract
Screw injection
41
Operation
Screw plasticizing
Opening safety gate
Close safety gate
Locking move out safety gate
Safety key not active
Safety key active
Program interruption Automatic
Program interruption Manual
Start button
1.2 Configurable keys

The control panel has 8 foil keys that the user can individually assign functions. The configured
functions of the keys appear as symbols on the screen above the foil keys.
1 2
[1] Unassigned symbol fields

[2] Assigned symbol fields with a function
[3] Foil keys for calling up functions

Operation
Example:
Procedure for assigning a function to a foil key.
1. Press the symbol field of a configurable foil key.

A key menu with the functions that can be selected appears on the screen and the
selected field turns red.
2. Press the desired symbol in the key menu to place it on the red field.
3. Activate the associated function by pressing the foil key below it.
4. To close the key menu, press the red field.
43
Operation
When more than 60 pushbuttons are configured, a button will appear on the right to switch to
the next group.
Note!
Symbol pairs such as: Turn mold swiveling device left and right or Move in or out core can be
inserted at the same time by selecting the symbol field on the left.
To delete a function or to replace it by a different one, either press an empty field or the
desired symbol.
2 Operator key switching (option)

In certain machine versions (e.g. 2-color machines), additional operating key units simplify
machine operation. The design of these additional operating key units depends on the
machine type.
Push buttons:
Request button for additional control panel
Request button control panel
Press the ’Request button for additional control panel’ to activate the additional control panel
and to deactivate the pushbuttons of the main control panel.
The EMERGENCY STOP button and program interruption key are exempted from operator
key switching; they are thus always available. Therefore, all program interruption keys must be
set to automatic so that an automatic cycle can be started.
Running automatic cycles are not affected by operator key switching.

Operation
External operation active
Cause The operation has been demanded from an additional operation unit.
Effect Operation via the main operation unit is not possible.
Remedy Switch to the main control panel using the ’Request button for control
panel’.
45
Operation
3 Screen structure
The clearly designed touch screen of the control unit permits simple and fast programming.
3.1 Header with Info Panel

1 Data dialog 3 4 5 6
Info Panel - injection molding machine actual values
2 Mold position actual value Cooling time actual value
Clamping force actual Shot volume actual value
Specific injection pres- Cycle time s
[1] Machine number

[2] Switches the Info Panel to Injection molding machine or Robot
[3] Page title
[4] User name
[5] User accesss authorization
[6] Date/time

Operation
3.2 Screen page selection and function keys

For user-friendly operation, the following screen page selections and function keys are avail-
able:
Production, machine Setup, safety Back to a previous selection

Gate, ...
Mold closing, mold height Cycle time analysis, Weekly time

switch
Mold opening Mold parameters, notepad
Ejector Data dialog
Core Print
Inject Mask editor
Holding pressure, switchover type Machine sequence
Plasticizing Setup
Nozzle Help
Heating, heating configuration Alarms
Micrograph, quality assurance pro-

grams
Switchover of the keys on robot or

machine
47
Operation
3.3 Status display

The first line shows current messages, warnings and alarms during operation. The number to
the right of the message indicates the total number of current messages. All the messages are
also displayed on the alarms screen.
The second line shows possible operating states. Colored symbols are active, dimmed ones
are inactive.
Program
1 interruption key
2 3 4 5 6 7 8 9 10
[1] Line for messages and alarms

[2] Machine motor status symbol
[3] Robot motor status symbol
[4] Heater status symbol
[5] Data set active; read data set
[6] Status symbol Rotary table with display of active stations (option)
[7] Final backup (not active)
[8] Printer (inactive)
[9] Network access (inactive)
[10] Program keys
3.4 Program keys
Setup Teach or Semi- Fully-

Manual Automatic Automatic
Colored highlighting indicates the current mode of operation. Depending on your user level,
you can click a field to display other modes of operation.

Operation
3.5 Input keyboard

Users need to log in to select parameters. The following input keyboard appears for inputting
numerical parameters:
Set value
Input field (current value)
Display of possible input values (plausibility)
Previous value entered
intermediate deposit
Cancel key
Increment key (increase value)

Decrement key (reduce value)
Copy key, copies the value from the previous entry to the
input field
Enter key
interruption Help button for the selected parameter
The Enter key saves the value of the input field if it lies within the range of possible entries. If
this is not the case, the input field is highlighted in red and yellow.
A virtual keyboard is displayed when parameters are selected that require alphanumeric input.
Mold number
Se-
Special keys
Se-
Highlights the entire text
Highlights a portion of the text by activating this key and moving the cursor with the
arrow keys
Copies the selected text
Pastes the copied text
Parameter input process

1. Log in to the control unit with your user level.
2. Select the desired screen.
3. Press the set value to be changed.
49
Operation
4. Type the value using the input keyboard; the value is displayed in the input field. Check
whether your entry is plausible.
Position
Indicates the plausible range of values.

In this example, the range of values lies between
intermediate deposit 0.0 and 100,0.
5. If you made an error while typing, press the Delete key. You can then enter the correct
value.
6. To store the value press the enter key.
If the entered value is nevertheless too high or too low, the colors of the plausibility dis-
play in the input field change to yellow/red (see the figure below). The control unit dis-
cards the value. You need to enter a correct value.
Position
intermediate deposit
7. To copy an existing value:

Select the next set value.
Press the copy key in the input dialogue (takes over the previously typed value from
the previous entry).
Press the enter key to store the value.
Switching programs and function units on and off

Mold height Function is not
Determine mold height activated.
Mold height
Minimum mountable mold height
The following input field appears when you click a program switch:
Determine mold height
Preview
When you press the Enter key, the control takes on the switch position shown in the preview.
A field with a checkmark is active, while an empty one is inactive.

Operation
Selection window (example: Monitoring type)

Production stop An input box appears for certain entries. The selected
Warning only setting is activated by selecting the item and then con-
firming your choice. The selected setting has a colored
Production stop
background.
Dialog window (example: Write data)

Separate dialog boxes are available to interact with menu functions that require additional que-
ries or entries. The content of the dialog box depends on the menu function and can require
various entries; on the other hand, their setup is standardized.
Write active parts data on
Available drives
Name Standard
Description
Free memory
Required memory
Cancel Help Write
Collapsible screen strip

Mold height
Mold height
Mold height
51
Operation
4 User accesss authorization

To be able to enter or change parameters and settings to the plant, you must first log in to the
device using your user level. The language, user name, user level and type of units are assig-
ned to each user. The higher your user level, the more access privileges you have. Any
change to the plant is recorded automatically by the control unit with the date and time.
If you have a sufficient user level, you can also create, manage or delete your own user
names.
4.1 User access card login

The user data are stored on the user access authorization card.
Logging in and out with the user authorization card on the plant
A sensor for logging in with the authorization card is integrated into the control panel. If you
hold your authorization card in front of the sensor, you will be logged in. After a time that is set
in the control unit, the user is automatically logged out if the control unit is not put into opera-
tion.
There is also a slot for inserting the authorization card to the left of the transponder. The user
is then logged in until the authorization card is removed.
[1] User access authorization card slot

[2] Sensor
4.2 Password login

(available as an option / standard for the VC-FOCUS machine)
To login from the machine using a password:

1. Access the Setup screen page.
User login
User 2
Password
3
Logout Logout
2. Select the user from the User drop-down menu.

Operation
3. Enter the correct password in the Password field.

4. You are successfully logged in when your user name and number appear in the screen
header.
5. You can log out from the device using the Logout key.
On delivery of the device, the following users are created by default:
User name User level Pass-

word
Optimization L1 5 p
Optimization L2 6 p
Teach_L1 7 p
Teach_L2 9 p
Service_Customer 11 p
You can modify these users and add new ones. Whether you are capable of doing this
depends on your user level and the associated privileges. [See User level on page 58.]
Logout
For logout press the Logout key from the Setup screen page.
53
Operation
5 Setup screen page

Basic settings for the plant are made on the Setup screen. You can specify the language, date
and time, and can select the display mode of the units. You can also find the user login here,
with which you can register yourself on the device. You can call up the Setup screen using the
Setup check box (see figure).
Setup
Info Panel - injection molding machine actual value
Settings
Language German Unit
Date/time 18.07.2007 15:32:15 ISO Imperial
Absolute Relative
User login
User
Password
Logout Logout
Settings
In the settings, you can specify your desired language, change the date and time, and select
the display mode of the units.
Language
A few other languages are available in addition to the set one. Select your desired lan-
guage in the menu. The selected language receives a colored highlight. After you have
selected a language, a bar appears informing you of the progress of the language
change.
Date/time
To set the date and time, press the appropriate field. Please use the + or - button to set
or change the date and time. The selected field always receives a colored highlight. The
setting is saved by pressing the Enter key.
Day: 25 Month 6 Year 2005
Hour: 11 Minute 0 Second: 5
Units
You can change the display format of the units in the Setup menu item. Place a check-
mark next to your preferred setting.
ISO
Displays units in metric system
Imperial
Displays units in imperial system
Absolute
Displays absolute values

Operation
Relative
Displays relative values (percent)
Simple conversion examples
Category ISO unit Imperial unit Conversion factors
Stroke 100 mm 3,94 in 100 mm x 0.0394 = 3.94 in
Absolute tempera- 100 °C 212 °F 100 °C x 1.8 + 32 = 212 °F

ture
Pressure 100 bar 1450.3 psi 100 bar x 14.503 = 1450.3 psi
Weight 100 g 3.53 oz 100 g x 0.0353 = 3.53 oz
Weight 100 kg 220.5 lb 100 kg x 2.205 = 220.5 lb
Force 100 kN 11.24 tf 100 kN x 0.1124 = 11.24 tf
Volume 100 cm³ 6.10 in³ 100 cm³ x 0.061 = 6.10 in³
Volume 100 l 26.42 gal/US 100 l x 0.264 = 26.42 gal/US
Torque 100 Nm 73.756 lbf ft 100 Nm x 0.7375 = 73.75 lbf ft
User login
To login enter the correct user and password
5.1 User administration

Engel supplies the plant with predefined user authorizations. You can create additional user
authorizations and modify existing ones.
For creating and changing user access authorizations an user access with administrator rights
is required.
55
Operation
5.1.1 Creating new user access authorization

You can create user access authorization only with the same or a lower access authorization
level than your own.
1. Access the Setupscreen page?
2. Press the Userbutton. A dialog box appears.
3. Select the Administrationtab
User login
User login Logged on Administra-
User Local Remote Language Unit
German ISO abso-
German ISO absolute
German ISO absolute
German ISO absolute
German ISO abso-
German ISO absolute
New Delete Change
Cancel Help Ok
4. Press the Newtouch key to access the dialogue window below.

New
User Name
Password Password
Confirmation Confirmation
Local Access level on the machine
Remote Access level from network to machine
Language German Language selection
Unit ISO absolute Unit of measurement selection
Administrator Authorization for new user to create addi-

tional accounts
Cancel Help Ok
5. Enter the settings for the new user in this dialog box. Enter the selected password again
in the Confirmation line.
6. Press Ok to load the new settings.
7. The new user is stored in the control unit.

Operation
5.1.2 Changing user access authorizations

Only user access authorizations that have the same or a lower level than the current user
access can be changed.
1. Access the Setupscreen page.
2. Press the Usertouch-key to open another dialogue window.
3. In the new dialogue window select the Administrationtab.
4. Press the user authorization that you want to change. This user authorization now has
a blue highlight.
5. Press the Changekey. Another dialogue window appears.
6. You can enter the settings for the user authorization in this dialog box. You must confirm
the password for the settings to go into effect.
7. Press the Ok button to accept the modified settings.
5.1.3 Deleting user access authorization

Only user access authorizations that have the same or a lower level than the current user
access can be deleted.
4. Press the user access authorization that you want to delete. This user access authori-
zation now has a blue highlight.
5. Press the Deletekey.
6. The following dialog window appears.
Optimization L2
Delete?
Cancel Ok
7. Press the Ok button to delete the user access authorization.
5.1.4 Saving user access authorization

In the case of machines with a CC200 control unit, you must save new user access authoriza-
tions on user access authorization cards in order to be able to use them.
4. Press the user access authorization that you want to save to the card. This user access
authorization now has a blue highlight.
5. Press [Save]. Select [OK] from the dialogue window that appears to confirm.
6. Using the new card, touch the sensor with which programming is to take place.
5.1.5 Importing/exporting user data

The ’Data - dialog’ screen can be used to export the data of the generated user to an input
medium and to import them for another plant.
57
Operation
To do this, select the Setup, Export user data instruction menu button to export the data and
the Import user data to import them. The plant must be restarted after the data have been
imported.
As a result, the operator does not have to create the users for each plant from scratch.
5.2 User level
User levels and applications
Level Target group Applications
1 Start-up personnel Commissioning and decommissioning a

preset machine without the possibility of
editing the parameters.
2 Production staff (Option) Reserved for customer-specific require-

ments.
3 Setup personnel Additional parameter modifications for stan-

dard programs, reading and writing parts
data.
4 Reserved
5 Supervisor Additional parameters and programs for

optimization, Micrograph, process data
package, set value graphics (profile config-
uration), data dialog, heating optimization.
6 Reserved Additional customer-specific configuration.
7 Advanced setup personnel Additional sequence programming, heating

configuration.
8 Reserved
9 Reserved
10 Customer service techni- Additional parameters for maintenance pur-

cian poses and service tools for troubleshooting
11 Customer service techni- Additional calibration programs, variables

cian changes, loading and saving machine data,
saving the USB stick, software update
From 12 ENGEL service technician Additional functions and settings

Operation
6 Operation of an injection molding machine
CAUTION!
Incorrect settings can lead to problems with or damage to the equip-

ment, so care must be taken during the setup and operation of the
machine.
Settings must be compatible to the function of the machine, mold, mate-
rial and peripheral units.
6.1 Start up
1. Switch on the machine main electrical isolator.
2. Switch the control voltage switch to ON (1).
The control unit starts and afterwards the data dialog screen is displayed.
Data dialog
Mold position actual val- Cooling time actual value
Clamping force actual Shot volume actual value
Specific injection pres- Cycle time s
Active parts data set
Data set attributes

Name
Author
Production date
Change author
Change date
Description
3. Log in with your user authorization.

The control unit is now in manual mode, and displays your user authorization level in the
top right of the screen.
The control unit also displays the following messages:
Barrel heaters are switched off;

Machine motor switched off
Cause The cylinder heaters and the machine motor are not yet switched on
or have been switched off by the appearance of an alarm (see alarms
on the screen).
Effect Prevents switchover to automatic mode
59
Operation
4. Switch on the heating for the barrel, and set the required temperature for the plastic type
you will be processing.
CAUTION!
Always enable monitoring for barrel heating to prevent screw movement and/or damage
to the screw tip due to low material temperature.
5. Switch on the machine motor. If an EMERGENCY STOP button is pressed, you must
relieve it by clockwise rotation. The safety gates on the clamping unit must be closed.
Observe the messages on the screen.
If the oil temperature is below the set minimum when the pump motor is started, the
oil preheating program switches on automatically. Ideal operating temperature 45 °C
(113 °F).
6. Open the shut-off valve for the cooling water.
6.2 Modes of operation of the machine

Mode of operation Manual or Program interruption
Control of the functions with the manual keys. Each movement lasts as long as you actuate
the respective manual key or a certain end position is reached. The safety gates must be
closed.
Other conditions that block movements:

Mold closing when ejector is retracted only. Note additional requirements for special
equipment such as cores, robots, and high speed mounting systems.
Mold opening: Check the additional conditions as with mold closing.
Ejector stroke at preset mold position only. Note additional requirements for special
equipment such as cores and robots.
Injection only when the barrel has been heated up, the mold is closed with the clamping
force built up and the nozzle has been applied.
Reduced injection pressure with an open mold or retracted injection unit is not possible
unless the safety key and the injection key are actuated simultaneously.
Plasticizing and decompression only for heated barrel. Plasticizing without back pres-
sure only when safety key is actuated at the same time.
Mode of operation Set-up
Selection of the setup mode is only possible from the manual mode. Functions as in the ”MAN-
UAL” mode of operation, only the following additional items must be observed:
Mold protection monitoring is switched off.

The clamping force is not built up.
The closing and opening speeds are limited.
Ejector speed and ejector force are reduced.

Operation
Mode of operation Teach

Teach mode can only be selected from manual mode. Functions such as Setup mode. Addi-
tionally, the machine sequence can be set up.
Mode of operation Semi and fully automatic mode

When working in semiautomatic mode, actuating the green Start key activates a work cycle
that repeats only if the key is pressed again. In fully automatic mode, the cycle repeats on its
own. The duration of the individual functions is determined by the adjustable or preset speeds
and timing relays.
The automatic mode can only be chosen if:

The motor is switched on
No alarms that would switch to manual mode exist.
The oil temperature is within the set tolerance.
The program interruption key is set to Automatic.
An automatic cycle start only occurs if

The mold is open
Plasticized and decompressed in the first cycle
The ejector being in retracted position stops.
The safety gates are closed
The set barrel temperatures are within the set tolerance.
Sample messages when the machine is not in the Start position:
Do not open the mold, ejector not retracted, plasticizing,

Alarm with cycle stop appeared, ... ,
Effect No automatic start, the alarm lamp flashes
Remedy Produce the start conditions.
Push-button actuated
Cause A pushbutton is actuated on operating state change.
Effect Semi-automatic, automatic mode not started, alarm lamp flashing.
61
Operation
6.3 Decommissioning the injection molding machine

Recommended shutdown strategies for various plastics. Note general safety information of the
material manufacturer!
1. Close the material hopper shut-off solenoid to barrel.
2. Move the injection unit back sufficiently.
3. Relieve the clamping unit using ”Open mold” and then ”Close mold” until a gap of
approx. 2-3 mm forms between the two mold halves.
4. Empty the plasticizing cylinder. Repeat the procedure "Plasticize/inject" until no further
material exits the machine. (See also: Sensitive plastics)
Retract screw from advanced position approx. 10 % of the diameter.
5. Switch the barrel heating off.
6. Switch off the control voltage.
7. Switch off the main electrical isolator.
8. Shut off the cooling water supply main valve to the injection molding machine.
9. Shut off the compressed air stop valve.
Sensitive plastics, regarding material shutdown

1. Completely empty barrel and screw
2. Purge barrel with high viscosity HD-PE (max. back pressure; screw position: 0)
3. If necessary, purge additionally with cleaning granulate
4. Retract screw from advanced position by approx. 10 % of the diameter
5. Switch off barrel heating
Crystal clear materials with brief interruptions

1. Purge plasticized volume (screw position: 0)
2. Set barrel heating to lowering temperature.
PMMA: 100 °C (212 °F)
PC: 180 °C (356 °F)
Information regarding melt disposal

LGF-filled plastics must be cooled in a water bath due to danger of fire
PVC melt cake must be cooled in water bath and mass concentration must be avoided

Operation
7 Help system
The integrated Help provides you with specific support during commissioning, operation,
maintenance and the elimination of errors.
The Help system distinguishes between help for screens, parameters, sequence instructions
and alarms:
Screens
For each screen, the associated description can be called up using the button.
Parameters
For each parameter, the description can be called up in the associated dialog box using
the button.
Sequence instructions
For each selected sequence command, the associated description can be called up
using the button.
Alarms and messages
Highlighting a message on the ’Alarms’ screen and selecting the ’Help’ command menu
button opens the description of the alarm's cause and its elimination.
If you cannot find the desired information in this manner, a content and index directory is also
available.
Core moving platen
Help
1 2 3 4 5
5 Core (Option)
Cores are movable elements in the mold which are usually inserted into the cavity before the injec-
tion procedure and are then extracted afterwards.
Molded part, e.g.

pipe fitting
Cores
Close Back Next

8 7
[1] Home: Opens plant table of contents.

[2] Table of contents of the current manual.
[3] Go to the previous chapter in the current manual.
[4] Go to the following chapter in the current manual.
63
Operation
[5] Go to the table of contents and the list of alarms in the current manual.
[6] Scroll buttons (the Help text can also be moved directly using your finger).
[7] Return and advance to previously opened chapters.
[8] Closing the Help.
Example: plant table of contents for injection molding machine and robot
Help
Press the machine or robot symbol to open the overview of the corresponding manual. In the
manuals and the control panel - with the explanation of the manual buttons - the following is
available:.
Help
1 2
operator manual - machine(en)
service manual - machine(en)
technical manual - machine(en)
operator panel
3
[1] Book symbol opens the table of contents of the corresponding manual.
[2] Index symbol opens the table of keywords of the corresponding manual.
[3] Opens the Help for the control panel.

Operation
8 Alarms and messages

Alarms and messages that have occurred are displayed by the control unit in text format
onscreen in 2 ways:
The control unit displays the last alarm that has occurred in the red message field in the
lower left.
The ’Alarms’ screen shows all current alarms from the top down in chronological order
of their appearance.
Waiting points (class 7) are located on a separate tab on this screen.
Alarms
Info Panel
Time Class Description
Acknowledge safety gate 2
Clamping unit safety gate 2 open
Mold mounting crane not locked
Machine motor switched off
Acknowledge Settings Help
Acknowledge safety gate 2
An alarm-specific Help appears when you press the corresponding alarm and then instruction
menu button Help.
Note!
The index contains a list of alarms.
65
Operation
The symbols beside the alarm texts specifies the alarm level/type:
Class Cause Effect
Control unit system errors Immediate system stop
Electrical system fault Immediate system stop
System fault Cycle stop
Process malfunction Cycle stop
Process malfunction Cycle not stopped
Information Alarm light turns ON or screen message

displayed
Waiting points Waiting points displayed on second tab
For some process monitoring tasks, you can switch off the alarms, e.g. cycle stop, rejects sort-
ing, switch on alarm lamp or ignore.
WARNING!
Danger of fatal injury!

Only trained service personnel are authorized to troubleshoot class 1-3
alarms.
8.1 Deleting and acknowledgement of alarms and messages

Depending on the alarm class, messages are deleted in the following manner:
After restoring the conditions.
At each cycle start, error messages from the previous cycle are deleted.
Certain alarms also require a manual acknowledgement. To do this either toggle the
Program Interruption switch OFF and ON, or select the message and press the
Acknowledgment key.
Naturally, any other alarms that exist once again cause your messages and reactions.

Operation
8.2 Interactive messages

In addition to the generated error messages, interactive symbols are also used in the program
to convey particular information. The following section describes the functionality of each sym-
bol:
Wait Wait message for executing an operational step
Information The message is purely informative without consequences.
Warning The message represents a warning, which must be acknowl-

edged to execute an action.
Error Alarm that can be eliminated at the operator level.
Fatal error Fatal software and/or system error.
At the end of the text, messages can still have another function or link:
The message is backed with a link. By touching the message the target is called
up and displayed.
The help has even more information. Press a message to open help.
67
Operation
9 Set value graphics

The set value graphics are used to easily display and set speed, pressure or force profiles for
the individual functional units.
9.1 Quick setting

For quick settings, a small graphic is provided with numerical display of the current values and
graph adjustment keys for the respective movement.
Mold close
Info Panel
Closing profile
1 2 3
5
4
Mold stroke posi-
[1] Adjustment keys for the speed profile (green) and numerical display of the current value
[2] Graphic field for speed and force or pressure profile
[3] Adjustment keys for force or pressure profile (red) and numerical display of the current
value
[4] Current position marker (dark-blue) and numerical display
[5] Mold protection monitoring window (yellow)
Parallel adjustment of a curve

1. Press the corresponding Arrow key for force or speed.
A preview of the curve appears on the graphics.
2. Release the Arrow key.
Closing speed
Accept change
Cancel Help Execute
3. Press Execute.
Equalization of all graphical values

1. Press the chosen curve = key.
Numerical input field is displayed.
2. Type in the value.
3. Press the Enter key.

Operation
9.2 Setting the speed and force profile

Touching the graphic field opens a larger graphic window. The individual points on the graph
can be adjusted either by touching the screen and moving them with the finger or by typing in
values. The number of profile stages and mold protection monitoring (Autoprotect) can also be
set within this window.
Mold closing - set value graphics

Info Panel
1
3
2
Closing speed
Force during mold closing 4
Back Profile Edit Autoprotect View 5
[1] Status line

Digital display for position, speed and force of the component
Symbol for Line mode or Point mode active
Autoprotect mode active
Zoom mode active
X, Y actual value display of the selected point at the graphic setting
[2] Graphic window for speed and force profile

[3] Actual value bar (dark blue); can be switched on and off in the View menu.
69
Operation
[4] Digital setting values for speed and force with corresponding switching positions; this
table can be switched on and off in the View menu.
[5] Menu keys for further functions

Operation
Changing a profile by dragging with your finger

1. Touch the graphic window.
A larger graphic window is displayed.
2. Touch the required profile (if necessary, press Change profile ).
The selected profile appears with points that you can move. The background of the
graphics field changes to the light color of the selected profile.
3. Touch the chosen profile points and drag them to the required new setting.
The chosen point is always colored and a preview (dotted line) is displayed.
4. Press Accept.
If you want to cancel the process, press Edit and Undo
Mold closing - set value graphics

2 3
Closing speed
Force during mold closing
4 5
Cancel Dot -> Line Change profile Accept
[1] Numerical display of the chosen point coordinates

[2] Chosen point
[3] Preview profile
[4] Switchover to line displacement mode (parallel displacement of one line between two
points)
71
Operation
[5] Switchover to the other profile
Set push grid for graphical profile adjustment

1. Press Edit and Grid
2. Enter the number of desired grid lines (0 = off)
3. Press Accept
Equal division of the stroke points for the current screw stroke
1. Press Profile.
2. Press Space equally.
Set number of profile items

1. Choose the set value graphics.
2. Press Edit and Number of profile points.
Set the number of profile points
Number of points Speed points
Number of points Force points
Cancel Help Accept
3. Enter the number of the points for the required profile.

4. Press Accept.
Set zoom function

1. Press View and Zoom.
Zoom
Zoom type Defined area
Closing stroke Start
Closing speed Min
Force during mold closing Min
Cancel Help Accept
2. Choose the zoom type from the selection box:

Switched off: Display of the set stroke of the function unit.
Maximum range: Display of the maximum possible stroke of the function unit.
Defined range: The zoom start and end points are adjustable.
Autoprotect: Display of the mold protection monitored area.
3. Press Accept.
Menu key Autoprotect

Operation
Autoprotect, mold protection monitoring can be activated on the set value graphics to protect
the mold during closing. Normally, mold protection monitoring is set on the mold closing screen
page.
[See Mold protection on page 79.]
First profile point is 0
This information appears under the setpoint graphic if the first point of a profile is 0 and there-
fore a movement cannot start.
The information must first be acknowledged with ’Edit’ and ’Delete messages’.
Then correct the profile setting.
73
Operation
Step profile for injection and post-injection pressure procedure
By selecting the menu buttons ’View’ and ’Ramped’, the control shifts the profile points so that
steps result.
Set the profile in the graphic window by parallel shifting of the horizontal and vertical lines.
CAUTION!
’Undo’ function not possible!
Injection - set value graphics
Info Panel
The ramped mode requires an even number of profile points. When attempting to switch to the
ramped mode with an uneven number of profile points, the following message appears:
Ramped mode requires an even number of profile points.

Clamping unit
Clamping unit
The clamping unit has the following tasks:

To close the mold quickly and to lock the mold ready to receive the shot
To hold the mold closed against the injection pressure
When the molded part has cooled, to initially separate the mold halves slowly and to
open quickly
To eject the molded part
Main structural units of the DUO clamping unit:
1 2 3 4
7 6 5
[1] Ejector cylinder

[2] Split tie-bar nut
[3] tie-bar
[4] Pressure pad cylinder
[5] High speed cylinder
[6] Fixed mould fixing platen (FAP)
[7] Moving mould fixing platen (BAP)
75
Clamping unit
1 Mold closing
Mold closing should ideally occur as quickly as possible, but with regard to mold protection
requirements for speed and pressure reductions. When the mold is safely closed, clamp force
can be built up.
Pushbutton:
Mold close
The closing movement is enabled when

the safety gates are closed,
the ejector is retracted
Start conditions for any additional equipment that you use (e.g.: cores) are fulfilled.
1.1 Closing movement

For mold closing, a multi-stage speed and force profile can be set with the set value graphics.
[See Set value graphics on page 68.]
In the mode of operation Setup closing speed and clamping force are limited.
Mold close
Closing profile
Mold stroke posi-

Opening stroke Mold close position
Mold stroke position:

The adjustable strokes are measured from the closed mold. The current Mold stroke position
displays the control on the screen by a vertical line and in digital form.
Opening stroke
Set the Opening stroke so big that a perfect demolding of the part is possible.
Mold close position
Set Mold closed position to a value that indicates to the machine when the mold is
closed with no clamping force. The machine switches to high clamping force when the
mold closed position is reached (except in set-up mode).
Note!
Set the speed and force with consideration to the mold protection requirements.
Use ramps with fast movements to achieve smooth stops and starts.
For injection and nozzle advance the mold must be closed, otherwise the following message
is displayed:

Clamping unit
Mold not closed
Effect Injection and nozzle advance only possible with reduced pressure,
the alarm lamp flashes.
Remedy Close the mold in manual mode.
1.2 Clamp force

The clamping force is that force which is required to keep the mold closed against the injection
pressure.
The machine switches to the set clamping force after the mold closing when
the Mold close position is reached and
Operating mode ’Setup’ is switched off.
Clamp force
Clamp force
Note!
Set clamping force as high as needed for the injection process. Unnecessarily high clamping
force leads to increased energy consumption, causes wear and tear, and even damage of the
mold and mold fixing platen.
The set clamping force must be built up completely before injection can take place.
If the clampforce is too low, the following message is displayed:
Clamping force too low
Effect No injection process; the cycle finishes, the alarm lamp flashes, shot,
piece and rejects counter do not count.
Remedy Use the push-button to open and close the mold several times until
the clamping force is reached.
When the maximum clamping force is exceeded, e.g. by too high injection pressure in the cav-
ity, the following message is displayed:
Clamping force exceeded
Effect Mold closing and the injection process stop, no new cycle start, the
alarm lamp flashes.
Remedy If the error appears during injection, change the molding settings
(mean cavity pressure too high).
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Clamping unit
1.3 Two-stage clamping force

Activation in variables monitor variables list ’ClampingForce’, variable: ’Adjustable clamping
force 1 in sequence’.
CAUTION!
Danger due to pressurized, molten material.

Only use injection molds that prevent the escape of hot melt at low
clamping forces.
The control unit shows the screen line after the programming of the command ’Close mold
until clamping force 1 built up’ in machine sequence on the screen page.
Clamp force kN
Clamp force kN
Clamp force 1 kN
Example:
Scaled build-up of clamping force, e. g. for centering cores:
Close mold until clamping force 1 - Move-in core - Nozzle build up contact force - Injection -
Close mold (full clamping force) from a desired injection volume
Retract ejector
0,3 mm
Close mold until clamping force 1 built up
150,0 kN
Core moving platen
move in
Nozzle contact
51,0 kN
Screw Wait until: Screw 1 - Injection position 1

inject 60,0 cm³
Mold - close
800,0 kN
Screw - plasticize
120,0 cm³
Nozzle - retract
20,0 mm

Clamping unit
1.4 Mold protection

Mold protection is the means by which the mold is protected against damage when a part is
trapped in the mold during closing.
Mold protection is sensitive enough to react to the smallest obstacles that prevent mold clos-
ing.
Mold protection monitoring
Mold protection monitoring time
Max force for monitoring Autoprotect kN

Mold protection monitoring start
Mold stop after mold protection alarm
Multiple closings times

At the mold closing the machine measures the needed time between the positions Mold
protection monitoring start and Mold close position. If the machine needs longer
than the set Mold protection monitoring time, the mold protection alarm reacts.
Max force for monitoring Autoprotect
The set maximum force for Autoprotect was exceeded and the following message
appears:
Autoprotect maximum monitoring value
Cause Set maximum force for Autoprotect exceeded.
Effect The machine stops the multiple closing procedures (if set), cycle
interruption
Remedy Check mold area, set longer pause time, set greater opening stroke,
set greater ejector stroke or higher ejector shake counter

From this position the mold protection area begins. This area is represented in the clo-
sing profile backed yellow.
If you have activated this selection field, the mold no longer opens, but stops on the
position on which the mold protection alarm has appeared.
Multiple closings
When the counter is set bigger than zero, the mold opens and starts a new closing pro-
cess. When at the renewed closing process no mold protection alarm appears, the
machine continues the cycle.
Note!
Observe the following hints for setting the mold protection
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Clamping unit
Set for a good effective mold protection the speed against end of the closing process as
slowly as possible.
Choose just enough force, towards the end of mold closing, to close the mold without
affecting cycletime.
Set Mold protection monitoring start on the position from which damage of the mold
can arise when an injection molded part is trapped (e.g. part height + sprue).
The end of the mold protection monitoring is always the Mold close position. Set the
positon so that it is only reached when the two mold halves are applied.
Choose the Mold protection monitoring time greater than the time actually needed
for running through the monitoring area (pay attention to the actual value display).

Clamping unit
When a mold protection alarm is triggered off, the following message appears:
Mold protection
Cause The mold protection has reacted, e.g. by an injection molded part
which got stuck between the mold halves.
Effect If multiple closing is set to zero, the message Multiple closing end
appears at the same time, otherwise the set multiple closing pro-
cesses start.
Remedy Check the mold, set greater opening stroke if necessary, set longer
pause time, set greater ejector stroke or higher ejector shake counter.
After the expiry of the counter Multiple closings the message appears:
Multiple closing end
Cause The mold protection has reacted and Multiple closings has reached
the set number.
Effect Switchover to manual mode, motor stops delayed and heatings

reduce delayed.
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Clamping unit
1.4.1 Autoprotect (option)

This mold protection program has been developed to give more sensitivity and faster reaction.
The controller compares, during mold closing, the force or speed in the mold protection area
with the force or speed from the previous cycle.
Close mold Autoprotect

Info Panel
+
Setup Re-initialize
Monitoring type Force monitoring

Initialize every cycle
Force tolerance kN

Max force for monitoring Autoprotect kN
Multiple closings times
Possible monitoring types

Force monitoring
Speed monitoring

Clamping unit
1.4.2 Mold protection force monitoring

The mold closes with a set speed profile and the force required in the mold protection area is
recorded. The force is compared with a reference curve determined previously. If the actual
value of the force exceeds the reference curve by the set tolerance, the mold protection alarm
reacts. The known Mold protection monitoring time is active at the same time.
Example:
Reaction of the mold protection, force-monitored:
8 kN
Reference curve with pos. tolerance
Hitting an obstacle
Force profile
br11_214
0 kN
Mold protection monitoring start Mold closed
Recording of the reference curves (initialization)

By pressing the Re-initialize key the control unit determines the reference curve at the next
mold closing process. Autoprotect is then not active during this cycle, only the usual mold pro-
tection time monitoring. The same goes for adjusting a closing movement parameter.
When Initialize every cycle is switched on, the controller always determines a new reference
curve for the next cycle. The reference curve determined from the preceding successful cycle
is used for monitoring.
1.4.3 Mold protection speed monitoring

The machine closes the mold with a given speed and measures that speed in the mold protec-
tion area. It also monitors the speed and compares that speed with a reference speed curve
determined previously. If the speed actual value remains under the reference curve by an
adjustable tolerance, the mold protection alarm reacts. The known Mold protection monitor-
ing time is active at the same time.
Example:
Reaction of the mold protection, speed-monitored:
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Clamping unit
8 kN
Actual speed of the mold
Hitting an obstacle
Reference curve with neg. tolerance
0 kN
Mold protection monitoring start Mold closed
1.4.4 Autoprotect settings

Setup Autoprotect
Speed axis scale
Minimum speed for monitoring
Automatically calculate the Y axis scale
Force axis scale
Max. force for monitoring
Position Mold closed
Cancel Help Accept
Speed axis scale

Force axis scale
If not the automatic scaling is activated, representation of the speed axis with the here
indicated scale.
Automatically calculate the Y axis scale
Automatic determination of the scale.
Minimum speed for monitoring
Max. force for monitoring
These values must not be exceeded/remain under during initialization, cyclic initializa-
tion and during monitoring. The maximum force must be set bigger than the necessary
force during mold closing as otherwise a mold protection error appears immediately
during initialization.
Standard settings:
Maximum force 80% of the max. mold protection force
Minimum speed 0.1 mm/sec
From this position, a jammed molded part may damage the mold (e. g. from part height
+ sprue).
Mold close position
End of mold protection monitoring. (e. g. mold halves contact point without clamping
force).

Clamping unit
1.5 External closing interlock

There is also a possibility of preventing the mold closing using a separate limit switch on the
injection mold (e. g. for the ejector plate).
External closing interlock

External closing interlock 1
If the release signal is not present when actuating the pushbutton ’Mold closing’, the following
message appears:
External closing interlock
Cause The enabling signal for mold closing is missing
Effect Mold closing stops.
Remedy Check the injection mold and the actuation of the safety switch.
1.6 Sequence programming positions mold closing

For the sequence programming, freely adjustable positions are provided such as mold inter-
mediate stop for move in cores, start position for parallel movements, etc. The positions used
in the closing sequence appear on the screen page Mold close.
Sequence programming positions
Closing position 1
Closing position 2
Closing position 3
Mold not closed on position
Cause The mold is for the requested movement not on the position pro-
grammed in the sequence.
Effect The requested movement cannot be executed.
1.7 Mold height setting

Mold height
Info Panel
+ Mold height
Mold height
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Clamping unit
Note!
The mold height must be redetermined, after mounting a new mold or after reading in a new
data set.
Actuating the Mold closing pushbutton, when the mold height is not determined, will display
this message:
Cause The actual mold position has reached a value less than the calibrated
zero position or the mold height has not been set after reading in new
parts data.
Effect Mold closing and ejector advance is not possible.
Remedy Set the mold height.
Procedure:
1. Before mounting a mold on the machine, the clamping unit is at an undetermined mold
height. In Setup mode, open the moving platen until there is enough space to install the
new mold.
2. Mount the mold on the stationary platen.
3. Close the safety gates.
4. Completely retract the ejector.
ATTENTION to the ejector rod, ensure that it is not held forward during mold height
determination!
5. Switch on Determine mold height.
The machine will now move at setup speed and with setup force. The message Auto-
matic mold height determination enabledappears.
6. Press the start button or move the platen to the mold and keep the pushbutton actuated
until the screen flag lights up. The control unit takes over the current value on Mold
height.
Value Minimum mountable mold height indicates the smallest possible mold height for this
machine.
When the moving mold fixing platen reaches this position, the following message appears:
Mold clamping mechanism on stop
Cause The clamp, on the direct-closing machine is at the mechanical stop

(e.g. the mold is too small).
Effect No clamping force build-up
Remedy Mount a spacer plate.

Clamping unit
1.8 Setting of the mold height (DUO)
+
Optimum locking position determined
Mold height
Mold height maximum
Note!
After mounting a new mold the mold height must be redetermined.
When you move the moving mold fixing platen towards the mold after mounting a mold with
smaller mold height, appears the message:
Cause Zero point of last set mold height exceeded when closing mold in
’MANUAL’ operating mode.
Effect Mold closing and ejector advance stop immediately. No automatic
start, the alarm lamp flashes.
Remedy Reset the mold height.
Procedure:
1. Before mounting a mold on the machine, the clamping unit is at an undetermined mold
height. In Setup mode, open the moving platen until there is enough space to install the
new mold.
2. Mount the mold on the stationary platen.
3. Close the safety gates
4. Completely retract the ejector.
ATTENTION to the ejector rod, ensure that it is not held forward during mold height
determination!
5. Switch on Determine mold height.
The machine will now move at setup speed and with setup force. The message Auto-
matic mold height determination enabledappears.
6. Press the start button or move the platen to the mold and keep the pushbutton actuated
until the screen flag Mold height determined lights up and the tie bars have run to the
calculated position. The control unit takes over the current value on Mold height.
Value Minimum mountable mold height indicates the smallest possible mold
height for this machine.
The value Mold height maximum displays the largest possible mold height for this
machine.
Check mold height
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Clamping unit
Note!
Check the new mold height by closing the mold once, in manual mode, after entering or
"reading in" a new Mold height.
When the machine is switched to automatic mode without checking the new mold height, the
following message is displayed:
Check mold height
Cause Mold height not checked.
Effect Closing movement runs with setup speed, automatic start is blocked.
Remedy Check mold height by mold closing in manual mode.
Operation with spring split mold
Note!
Spring loaded split molds must be prevented from forcing the mold open during closing pro-
cess of the tie bar nuts (Danger of damage).
Spring split mold

Operation with spring split mold
The program, if enabled, actuates the high speed cylinders in the mold closing direction when
the tie bar nuts are locked and unlocked.
2 Mold opening
At the end of cooling time and reduction of clamp force, the mold opens at an operator set
speed profile, the injection molded part being ejected from the moving mold half.
Pushbutton:
Mold opening
The opening movement is enabled if:

The safety gates are closed
Locking conditions for any additional equipment that you use (e.g.: cores) are fulfilled
Message examples depending on the setting of the safety conditions when the movement is
not enabled:
Ejector not back

Core 1 moving platen not moved in
Effect Opening movement is blocked
Remedy In manual mode, move the corresponding functional unit into the correct
position; Check the safety conditions;

Clamping unit
2.1 Opening movement

Mold opening
Info Panel
Opening profile
Mold stroke position

Opening stroke
A multi-stage speed profile can be set for mold opening with the set value graphics. [See Set
value graphics on page 68.]
Note!
Coordinate the speed with ejection
Use ramps with fast movements to achieve smooth stops and starts
Opening speed and opening force are limited in ”Setup” mode.
The adjustable strokes are measured from the closed mold. The current Mold stroke position
is displayed on the screen by a vertical line and also as a value.
Set the Opening stroke large enough so that the part can be safely ejected.
The mold must be open at the start of an automatic cycle, if not, the following message is dis-
played:
Mold not open
Effect No cycle start possible, the alarm lamp flashes.
Remedy Move the mold to the start position in manual mode.
2.2 Sequence settings

Cancel mold safety
In set-up mode you can cancel the safety conditions calculated in sequence programming for
mold, ejector and core movements.
Sequence settings
Cancel mold safety Individual movement
89
Clamping unit
CAUTION!
Danger of mold damage!
No linked movement conditions for mold, ejector and cores.
The Setup symbol changes:
Cancel mold safety - Individual movement
Individual movements function with the respective pushbutton without safety conditions
No movement to home position and single-dial control possible.
Cancel mold safety - Single-dial control (option)

Individual movements and single-dial control function without safety conditions. No
movement to home position possible.
The safety conditions take effect automatically after switching to manual mode.
Movement to Home position

After pressing a pushbutton or before the cycle start in automatic mode, the machine moves
to the start position as follows:
Plasticizing
Mold opening (with core movements)
Allow movement to home position
Pushbutton Movement to home position Mold opening
Allow movement to home position in automatic mode
Allow movement to home position

If the program switch is activated, you can use the preset pushbutton to move the
machine to the cycle start position.
Pushbutton Movement to home position
Options for the movement to home position pushbutton:
+ Mold opening + safety key
+ Machine movement to home position + safety key
+ Robot movement to home position + safety key
Mold opening
Allow movement to home position in automatic mode

If the program switch is activated, the machine automatically moves to the cycle start
position after the start key is pressed.

Clamping unit
2.3 Single-dial control (Option)

Single-dial control makes it possible to run through the opening or closing sequence by press-
ing the Open mold / Close mold key. In this case, all the movements that are programmed in
the corresponding sequence are executed.
Single-dial control with SIT key
Selection options for single-dial control:

deactivated
with SIT key + /
without SIT key /
2.4 Increased opening force

Increased opening force
Increased opening force with high
with high speed
speed
Increased opening force upto position
This program allows the mold halves to be opened with Increased opening force.
The machine opens the mold slowly up to an adjustable stroke position with increased force.
Selection possibility:
Switched off: Opening force approximately 3% of the maximum clamping force
with high speed cylinder: Increased opening force, approx. 6% of the max. clamping
force
with pressure pad: Increased opening force, approx. 10% of the max. clamping force,
very slow movement
Force stroke correction:

Facilitates the resetting of the force stroke of the pressure pad cylinders.
Note!
At certain machine executions a separate pump for pressure pad movements is available.
In this case the resetting occurs parallel to mold movements and to the take-off.
The switch on the screen is omitted at these executions.
Resetting pressure pad with open mold
Make force stroke correction, if possible, at end mold opening,

parallel to demolding, as a result no cycle time loss.
Additional possibility, force stroke correction after mold closing and before tie bar nuts
locking.
91
Clamping unit
2.5 Sequence programming positions mold opening

For the sequence programming freely adjustable positions are provided such as mold interme-
diate stop for move in cores, start position for parallel movements, etc. The positions used in
the opening sequence appear on the screen page Mold open.
Opening position 1
Opening position 2
Opening position 3
Mold not open on position
Cause The mold is for the requested movement not on the position pro-
grammed in the sequence.
Effect The requested movement cannot be executed.

Clamping unit
3 Ejector
The ejector takes the molded part from the injection mold.
1 2 3 4 5
[1] Ejector drive

[2] Ejector coupling
[3] Ejector connection rod
[4] Ejector plate of injection mold
[5] Ejector pins
Push buttons:
Ejector forward / return
CAUTION!
Danger of damaging the injection mold by the force of the ejector drive!
The injection mold can also fall down if the fastening is insufficient or in
the case of magnetic holding plates!
Set the ejector force as low as possible.
Set the ejector advanced and ejector retracted positions precisely.
Observe the braking paths when changing speed.
Release conditions for ejector movement:

Safety gates closed
Ejector start position reached
Any additional equipment (e.g. cores, robot) in release position
93
Clamping unit
3.1 Set the ejector movement

Ejector
Advance profile
retract profile
Ejector stroke position

Ejector retracted position Ejector advanced position
Advance profile and retract profile

Multi-stage force and speed profiles, with switchover positions, can be set on the set value
graphics, for ejector advance and return.
Forces and speeds are limited in setup mode.
As soon as the ejector position, despite actuation, does not change within a set time, the fol-
lowing message appears:
Ejector motion monitoring
Effect Cycle interruption, alarm lamp
Remedy Check the stroke transducer, check the set monitoring time

Measurement is carried out from the rear mechanical position of the machine ejector. The con-
trol unit displays the current value onscreen as vertical lines in graphical and digital form.
1 2 3 4 5
[1] Rear mechanical position

[2] Ejector retracted position
[3] Ejector stroke
[4] Ejector advanced position
[5] Front mechanical position

Clamping unit
Ejector retracted position and Ejector advanced position

The ejector stroke is the difference of the ejector position retracted and the ejector
advanced position.
For example, if the ejector is not retracted during mold closing, the following message appears
in the standard case:
Ejector not back
Effect Depending on the sequence setting, blocks e.g. mold closing, core
moving-in, etc..
Remedy Retract the ejector, check ejector plate and ejector pins.
Example:
Procedure for coupling and setting the ejector:
CAUTION!
Danger of crushing when coupling the ejector!

Spring-loaded mold ejectors can cause uncontrolled movements of the
ejector components.
Insert the ejector rod centrally into the ejector coupling.
1. Switch on operating mode Set-up.
2. If you are using an ejector coupling, move the machine ejector to the ejector rod and
couple it.
3. For trouble-free part removal, move the ejector accordingly far forwards.
4. Set the displayed ejector position as Ejector advanced position.
5. Move to the rear position. The ejector pins are not permitted to protrude outside of the
mold cavity.
6. Set the displayed ejector position as Ejector retracted position.
7. Switch to manual mode and check the set position again.
3.2 Setting part removal

Ejector shaking is used for molded parts that are difficult to remove.
When the Shake ejector instruction is inserted in the machine sequence, the associated set-
ting parameters appear on the screen.
95
Clamping unit
Example: Machine sequence with Shake ejector
Open mold
200,0 mm
Ejector - shaking
2 times
Part removal
Ejector shake counter times
Ejector shake position
Ejector advance delay
Ejector retract delay
Pause time
Ejector shake counter

To shake, set the value to 1 + the desired number of shaking movements.
Example with ejector shake counter, 2 times

1 2 3 4 5
[1] Rear mechanical position

[2] Ejector retracted position
[3] Ejector shake position
[4] Ejector advanced position
[5] Front mechanical position
[6] Shaking stroke
Ejector shake position

The shaking stroke results from the ejector advanced position and the ejector shaking
position.
Ejector advance delay
Has an effect the first time that the ejector is advanced.
Ejector retract delay
Has an effect each time that the ejector is retracted.
Position at cycle end
retracted
The ejector retracts after shaking.
advanced
The ejector remains advanced until the start of the next cycle (e.g. to remove molded
parts).
Pause time
Starts at the end of ejector movement and delays the next cycle start (e.g. so that the
molded parts can fall out).

Clamping unit
Ejection control
Position at cycle end retracted
No ejection at mold protection

Ejection not possible with rejects
Ejection control
Starting at mold opening until the end of the pause time, additional equipment, e.g. a
light beam guard, scales or video camera, monitors the part removal procedure. If the
ejection control does not issue a signal, the following message appears:
Ejection control
Cause A molded part was not removed - ejection control was activated.
Effect The alarm lamp flashes, new cycle will not start.
Remedy Eject the injection molded part.
No ejection at mold protection

In the case of a mold protection alarm, the mold is opened without ejector movement.
When a reject is recognized, the injection molding machine interrupts the current cycle
before ejection so that the operator can check the part just produced. The following
message appears:
Cause Rejects recognized.
Effect Cycle interruption, ejector movement blocked
Remedy Remove molded part, press program interruption key
Ejector active hold retracted on mold movement (option)

Due to the forces occurring during the acceleration or braking of the mold, it is neces-
sary to actively hold back the ejector during mold movement.
Machine settings in the variables monitor under the variables group ’Ejector’.
Ejector active hold retracted on mold movement
Robot take off on

In the case of machines with a robot, the setting parameter appears on the screen when
the Shake ejector instruction is inserted in the machine sequence.
Robot take off on first ejector stroke
first ejector stroke

Activation of the robot vacuum/compressed air circuits on the first ejector stroke.
97
Clamping unit
last ejector stroke

Activation of the robot vacuum/compressed air circuits on the last ejector stroke.
3.3 Ejector start/stop settings

Start, stop settings
Opening stroke
Ejector advance start position
Ejector check position
Ejector advance start position

In the case of machines without parallel movement, the start position must always be
set so that it is the same as the opening stroke. As a result, the ejector starts after the
mold is completely open.
In the case of machines with several pumps, you can set simultaneous movement of the
ejector for mold movement in the machine sequence. During opening, simultaneous
movement then occurs when the start position is reached.
Note!
A reduction of the maximum speed during parallel movements can result as the second pump
is not available for the mold movement.

If the ejector moves simultaneously as mold closing, it must be at the rear at the preset
check position (mold position).
Include corresponding braking stroke when setting the control position!
Message:
Ejector not retracted (check position)
Effect Mold closing stops. In automatic mode, movement waits until the
ejector is retracted and then continues.
Remedy Retract ejector.
3.4 Ejection with intermediate stop

Ejection with intermediate stop is used for special part removal procedures.
In the machine sequence, you can set the instruction Ejector advance up to intermediate stop.

Clamping unit
Sample setting: Sorting sprue with a delivery chute
Open mold Delivery chute

200,0 mm Ejection direction rejects position
Ejector advance up to intermediate stop

40,0 mm
Delivery chute
Ejection direction good part position
Advance ejector
80,0 mm
Retract ejector
3,0 mm
This position appears on the ejector side.
Part removal
Ejector advance intermediate stop position
99
Clamping unit
3.5 Sprue ejector

The program is used for the separate sprue removal with the ejector, usually with a shorter
ejector stroke.
Certain instructions for the sprue removal in the machine procedure activate the settings on
the Sprue ejector screen. This parameter functions in the same way as for the standard ejec-
tor. [See Set the ejector movement on page 94.]
Example: Machine sequence with sprue ejection
Mold opening up to position 1

200,0 mm
Ejector - shake sprue ejector
2 times
Open mold
400,0 mm
Advance ejector
80,0 mm
Retract ejector
20,0 mm
Sprue ejector
Info Panel
Advance profile
+
retract profile
Sprue ejector end position
Part removal
Sprue shake counter times
Sprue shake position
Sprue ejector advance delay
Sprue ejector retraction delay
In case of rejects, move to ejector advanced position

Start, stop settings
Opening stroke
Start sprue ejector advance
The ejector check position is identical to that for the standard ejector.
Additional setting parameter:

In case of rejects, move to ejector advanced position
When switched on, the ejector immediately advances all the way if there are rejects and
thus ejects the sprue together with the molded part, for example.

Clamping unit
4 Mount mold
WARNING!
Danger due to hot barrel and pressurized molten material.

Danger of serious eye injury and burns to skin!
Wear suitable protective clothing and face protector.
Make sure the barrel is depressurized by purging until empty.
4.1 Preparations for mounting the mold

Check that there is enough space on the machine to mount the mold.
Standard nozzle radius must be smaller than the radius of the sprue bushing or nozzle
contact position of the mold.
Mold centering must be approx. 0.1 mm (0.004 in) smaller than the centering bore on
the mold fixing platens.
Sufficient clamping force (approx. 3 kN per cm² projected mold area or ca. 2 tn per in²
projected mold area).
Check the mold height.
Sufficient opening stroke for ejecting the part.
Sufficient injection volume and specific injection pressure.
Ejector stroke (possibly air valve).
Special equipment (cores, mold heating etc.).
Maximum allowed mold weight for the moving platen (see the machine instruction man-
ual).
Clean the mounting surfaces of the mold fixing platens and mold, and whet them with
an oil stone if needed. The contact areas must be clean and free of grease, to enable
good friction contact Do not use grease paper; possibly lubricate lightly to pre-
vent corrosion (possibly with anti-corrosive spray ).
The lifting eye must be exactly above the center of gravity of the mold to allow the crane
to lift it as vertically as possible.
Use sufficient fastenings (taking the required opening forces into consideration). The
opening force is considerable for long cores (e.g. buckets, fittings). The best approach
is to screw down the mold directly to avoid spring travel. The formula for minimum reach
of screws is: Screw diameter x 1.5. The property class of the screws should be 8.8 or
10.9.
Match the ejector bolts to the machine (bolt length, ejector lock).
Prepare the hoses for cooling or temperature control, also any required temperature
control units or special equipment.
101
Clamping unit
4.2 Mount mold
WARNING!
Danger to life and limb, and danger of crushing due to floating loads!
Floating load hazard.
Molds must be mounted only by skilled staff who are familiar with trans-
portation of injection molds.
Example:
Procedure for mounting an injection mold with connected mold halves.
1. Switch to ”Setup” mode of operation. Pay attention to low closing and opening speed.
2. Open the moving platen wide with Mold opening.
3. Retract nozzle sufficiently.
4. Use a bridge to join the mold halves and insert them into the machine. Align with the
mold fixing platen where the (more exact) centering lug of the mold is located; this is
normally the nozzle side.
5. Fix mold on the right mold fixing platen.
If you have a quick mounting system, press the Mount mold on stationary platen-
pushbutton to do this. The safety gate on the clamping unit must be closed.
6. Set mold height: Close the clamping unit safety gate and switch to ”Setup” mode, with
the Mold closing key, bring the moving platen cautiously to the mold .
TOGGLE LEVER MACHINES and FULLY ELECTRIC MACHINES: Measure and enter
mold height, then switch on mold height setting.
DUO MACHINES: Before mold closing switch on the program switch Determine mold
height .
7. ATTENTION! Ejector fully back. When using an hydraulic ejector, an ejector rod which
maybe integrated into the mold, must be introduced centrally into the ejector lock. After-
wards with applied mold fixing platen keep the key pressed shortly until the mold posi-
tion actual value displays ”0” on the screen. For checking whether the new mold height
has been stored, by a minimum opening the distance of the mold fixing platen to the
mold can be compared with the display of the actual mold stroke position.
8. Set the clamping force, and actuate up, down and up a few times in manual mode.
9. Fix mold on the left mold fixing platen.
If you have a quick mounting system, press the Mount mold on moving platenpush-
button to do this. The safety gate on the clamping unit must be closed.
10. Remove the connecting elements between the mold halves.
11. Cautiously open the mold, paying attention to the function of the mold as well as any
additional equipment (cores, solenoids etc.).
12. Move the ejector with low pressure and speed to the ejector rod and attach this into the
ejector lock. Set the ejector back position on the screen.
13. Provide the mold with the required connections and any additional equipment (such as
heating/cooling temperature control circuits, pay attention to the return flow restrictor).

Clamping unit
5 Tiebar pulling device automatic (DUO)

One tie bars must be pulled to bring in molds that are larger than the gap between the tie bars.
After pulling the tie-bar, it is far simpler to transport the mold between the fixing platens.
Push buttons:
Tie-bar retraction device - tie-bar retraction
Tie-bar retraction device - tie-bar insertion
Stroke-tie-bar pulling device
Disconnect the pressure pad and the fixed mold fixing platen for tie-bar pulling.
The tie-bar is pulled completely into the stationary mold fixing platen. (tie-bar does not
protrude into the mounting surface)
A separate pushbutton is available for semi-automatic tie-bar pulling or threading.
Tiebar pulling device

Tiebar pulling device
tie-bar
+
pull =40-Y13 =40-S23
thread =40-Y14 =40-S22
Braking limit switch =40-S24
Pressure pad clamping
Open =40-Y12 =40-S26.1
Close =40-S25.1
Pull tie-bar Thread tie-bar
Tiebar positioning Thread tie-bar
Open pressure pad clamping Close pressure pad clamping
Pull tie-bar
Tie-bar pulling and threading is only possible when the following conditions are ful-
filled:
Safety gates closed
103
Clamping unit
Set-up switched on
Safety key actuated
no emergency stop
Motors run
Units entirely at the back
Material hopper in production position
Pull tie-bar:
By pressing the push-button ’Tie-bar pulling’ the following sequence results:
1. Move tie-bar in pressure pad to maximum position:
This prevents the tie-bar tilting during pulling.
2. Open pressure pad clamping:
Pressure pad clamping is opened hydraulically.
Condition: Tie-bar threaded
3. Pull tie-bar:
The tiebar is pulled until reaching the limit switch ’Pull out tiebar stop’ pulled.
Condition: Pressure pad clamping open
Thread tie-bar:
By pressing the push-button ’Tie-bar threading’ the following sequence results:
1. Thread tie-bar:
The tie-bar moves at high speed to the braking position (limit switch), and is threaded at
low speed up to the limit switch ’Tie-bar fully threaded’.
2. Close pressure pad clamping:
Pressure pad clamping is closed hydraulically
Condition: Tie-bar threaded
For the operation of the machine the following conditions must be fulfilled:
Tie-bar threaded
Pressure pad clamping closed
Tiebar not threaded
Cause The tie-bar is not threaded.
Effect All movements on the machine are locked.
Remedy Thread tie-bar.

Clamping unit
Pressure pad clamping not clamped
Cause The pressure pad clamping is not clamped.
Effect All movements on the machine are locked.
Remedy Close pressure pad clamping.
Operating state not in SET-UP
Effect Tiebar pulling and threading blocked
Remedy Choose mode of operation Set-up
Safety key not pressed
Effect Tiebar pulling and threading blocked
Remedy Press safety key
Monitoring unit rear:

For tie-bar pulling, the injection unit must be at ’Carriage unit retracted’ position.
If this is not the case, the following message appears:
Unit not at the back
Cause The injection unit is not in the rear position
Effect Tiebar pulling is blocked
Remedy Retract unit to position ’Carriage unit retracted’.
Monitoring tie-bar nut locking:

For tie-bar pulling, the tie-bar nut locking mechanism must be open on the clamping unit side.
If this is not the case, the following message appears:
105
Clamping unit
Locking not open
Cause The locking is not moved out and it has been attempted to pull a tie-
bar
Remedy Opening of the locking
Monitoring Material hopper in production position:

During tiebar pulling on the operator side of the injection molding machine exists danger of col-
lision with the material hopper.
Material hopper not in position for tiebar pulling
Cause The material hopper does not stand in production position and it has
been attempted to pull a tiebar
Remedy Displace material hopper in production position

Clamping unit
6 Core (Option)
Cores are movable elements inside the mold, which generally move into the mold before the
injection process and move out afterwards.
Push buttons:
Move out core moving platen
Move in core moving platen
Move out core stationary platen
Move in core stationary platen
Injection molded
part:
Cores
The core movement is enabled if:

the safety gates on the clamping unit are closed,
the 2 limit switches Core safety 1 and Core safety 2 have been actuated,
in France, in manual mode the push-buttons and the safety key must be pressed.
In addition, depending on the equipment of the machine and setting of the program sequence,
certain safety conditions must be fulfilled. Message examples:
Mold not open

Ejector not back
Core x moving platen not moved in
Core x moving platen not moved in on intermediate stop
Effect Core movement is blocked
Remedy In manual mode, move the corresponding functional unit into the correct
position; Check the safety conditions;
Each core is equipped with a separate pushbutton for moving in and out. The same locking
conditions as in Automatic are valid (mold position, situation of the core positions, etc.).
107
Clamping unit
When a core moves out of position (limit switch deactuated) during the mold movement, the
movement stops immediately - message:
Core x end position left
Effect Mold, ejector, other core movements are blocked, also injection if the
mold is not open. In automatic mode cycle stop.
Remedy Move the core in/out in manual mode, check the limit switch.
CAUTION!
Danger of damage to equipment due to improper settings!

When operating the machine, use settings for freely programmable
cores that precisely match the requirements for safe operations of the
machine and mold.
When you save the sequence, the control unit will perform calculations
to prevent some incorrect settings.
Additional safety is offered by deliberately ”bridging” of unused end position limit switches with
a jumper plug.
Core x jumper plug moved in/out is missing
Cause If a core is not activated or is time-dependent, normally the limit

switch signals must be activated by a jumper plug. See screen flags
at the core settings.
Effect Clamping unit movements blocked.
Remedy Attach the jumper plug or correct the programming.
The program checks the chosen core setting in connection with the end position jumper.
In case of error, message:
Core x limit switch defective
Cause Core limit switches are defective or actuated at the same time.
Remedy Check the limit switches

Clamping unit
Core x move in limit switch defective
Cause Core moved out time-dependent and simultaneously limit switch

moved in active.
Core x move out limit switch defective
Cause Core moved in time-dependent and simultaneously limit switch

moved out active.
6.1 Activate core

Procedure:
1. Enter the core move in/out symbol at the appropriate positions in the machine
sequence. [See Machine sequence on page 175.]
2. By the choice of the sequence you fix at the same time where the core shall move:
at mold open
at mold closed with clamp force
at a mold intermediate position
parallel to the mold movement
Example: Move core in and out with open mold
Closing sequence Opening sequence
Closing sequence Opening sequence
Retract ejector Open mold

25,0 mm 300,0 mm
Core moving platen Core moving platen
move in move out
Mold - close Ejector - shaking
100,0 kN 1 times
Nozzle - build up contact force
Opening sequence
47,0 kN
Closing sequence
109
Clamping unit
3. Remove the jumper plug and connect the limit switches and safety switches.
4. Switch the core on at the screen.
Two green flags next to Move in and Move out indicate that the core is included
in the sequence.
Screen page Core moving platen
Core moving platen

Info Panel
Core moving platen 1
Mold position actual value
move in move out
Mold check position
With ext. energy supply
Switch off at end position
Time-dependent
Core actuation time
Monitoring time
Speed output
Pressure output
Hold pressure output
Ejector and core movements on pump
Core actuation
Core in end position
Core end position status
The respective flag for Core actuation lights during a core movement dark-red.
A dark-green flag for Core in end position position displays the respective end position for
moved in or moved out.
The flag for Core end position status indicates whether the core is retracted or advanced
(this is valuable information especially in time-dependent operation).
Core safety limit switch

The actuation of both limit switches is displayed by the flags bottom right and enables the core
move-in If not actuated, the following message appears:

Clamping unit
Core safety x active
Cause Limit switch Core safety not actuated
Effect Core move-in blocked
Remedy Check the position of the ejector plate and ejector pins
The machine runs the cycle sequence without core movements if the core is switched off with
a jumper plug. If you press the pushbutton, the following message appears:
Core x deactivated in the sequence
Cause The core has been actuated with the pushbutton although it is not
used in the sequence or is deactivated in the sequence.
Effect The core will not be actuated
Remedy Check the sequence; activate the core
6.2 Start position

The setting in the machine sequence determines to which mold position the core should travel
to.
Mold check position
Additional monitoring of core position from this mold position.
Calculate applicable braking distance for the mold movement!
Message:
Core x not moved in/out (check position)
Effect Mold closing stops. In automatic mode, the movement waits until the
core has moved.
Remedy Move core in/out.
6.3 Speed and pressure

Speed output
Pressure output
Hold pressure output
You can configure a separate speed and pressure in each direction of movement for each
core. The hold pressure outputs only work when the cores are not switched off at the final posi-
tion and the machine is equipped with a 2-pump hydraulic system.
Switch off at end position
111
Clamping unit
The core switches off when the end position is reached.

When this screen switch is unchecked, after moving-in, the core only switches off at the end of
hold pressure. You may have to manually adjust a pressure relief valve to ensure that excess
pressure is not applied to the core cylinders during further machine movements. Check this
adjustment with the manometer!
Pressure reduction valve

(turn counterclockwise to reduce pressure)
Manometer
6.4 Switching-off type

Time-dependent 1
Core actuation time 1
Monitoring time
The cores' movements are limit switch-controlled or time-dependent.
Switched off time-dependent :

The core continues to move until the respective limit switch is reached.
An adjustable Monitoring time is effective when the value is set greater than 0. The fol-
lowing message appears if the core needs longer:
Core x monitoring time moving in exceeded

Core x monitoring time moving out exceeded
Cause The core has not reached the limit switch for the stop position within
the set monitoring time.
Effect Mold, ejector, core movements and the automatic cycle are stopped.
Remedy Move the core in and out in manual mode to check the limit switch.
Also, in manual mode maintain the timing of the set core sequence.
Switched on time-dependent:
The core continues to move until the actuation time has expired.
Note!
Bridge the unused limit switches with the jumper plug.
6.5 Shake core

Just like for the ejector you can demold molded parts by shaking the cores.
Activate core shaking by programming a Shake core step at the required position in the
sequence.

Clamping unit
After programming core shaking, the setup parameters are displayed on the screens in ques-
tion.
Screen page Core moving platen

Delay time
Core shake counter times

Position at cycle end moved out
Finish core shaking on ejection control
Delay time
You can set delays for moving in and out for core shaking. The move in delay is only
effective for the first move in.
Core shake counter
Number of shaking strokes the core performs.
If you set the shaking counter to 0 the core shaking step is not active in the sequence.
Position at cycle end
If you need to move the core in, for example to take off a molded part, select moved in.
The core will not move out until before the start of the next cycle in this case.
Finish core shaking on ejection control
Core shaking stops immediately when the ejection control monitor triggers, and the
sequence continues.
In manual mode core movements are controlled by pushbuttons.

If the shake counter is set to 0, the following message appears when the pushbuttons are
pressed in manual mode:
Core x shaking counter deactivated
Effect Shaking movement not possible.
Remedy Set core shaking counter.
6.6 Core with external energy supply

With ext. energy supply
Program for pneumatically or electrically operated cores. Activation of the 24V outputs without
hydraulic pressure and speed actuation.
6.7 Core signals

The core signals screen gives you an overview of the end position status of all cores for the
machine, along with core safety.
113
Clamping unit
Example screen page Core Signals

Core signals
Info Panel
Core(e) moving platen
move in move out
DO DI DO DI
1 2 3
DO DI DO DI
DI DI
DO DI DO DI
DO DI DO DI
Core(e) stationary platen
move in move out
DO DI DO DI
DO DI DO DI
Core safety
Core safety 1 DI
DI
4
Core safety 2
Cores pressure relief
Cores pressure relief moving platen DO 5
[1] Core actuation
Lights up when the core is actuated.
[2] Core in end position
Lights up when the core has reached the corresponding limit switch.
[3] Core end position status
Lights up when the control unit has executed the corresponding core movement
depending on time or on the limit switch.
[4] Core safety
Lights up when the corresponding core safety switch is actuated.
[5] Cores pressure relief
Lights up when the pressure relief valve is actuated.
6.8 Core pressure relief (Option)

The hydraulic lines can be under pressure despite the fact that the pump is switched off. The
hose coupling cannot be released under these conditions. Therefore, relieve this line first
using the pushbutton for pressure relief.
Pushbutton:
Pressure relief all cores

Clamping unit
6.9 Mechanical core (Option)

Mechanically actuated
CAUTION!
For this function an adaptation of the hydraulic valves is necessary.

Program for mechanically operated core. No activation of the hydraulic valves in the automatic
mode as the core mostly runs by a mold movement.
In manual mode the actuation remains active in order to be able to possibly run the core,
hydraulically, into the end position.
In the sequence program you must program the core movement parallel e.g. to the corre-
sponding mold movement in order that the safety conditions for the core final positions are
effective.
115
Clamping unit

Heat Zones
Heat Zones
1 Barrel heating
Precisely controlled barrel heaters are required for producing a thermally uniform melt. The
shear forces, during plasticizing, produce 60 to 85% of the energy required for melting the
material. The melt temperature is affected by the barrel temperature, depending on the resi-
dence time in the barrel.
1 2 3 4 5 6
8 7
[1] Nozzle [4] Thermosensor [7] Feed throat with cooling

[2] Flange [5] Screw [8] Heater bands
[3] Material barrel [6] Feed opening for material
An increase of the melt temperature:

decreases the visibility of weld lines
increases the crystallinity
decreases the viscosity
decreases the orientation
decreases the pressure losses in the mold
increases the thermal stress in the melt and promotes gas production (thermal decom-
position)
decreases the mechanical loading (shear) of the melt caused by tearing the molecule
chains in the nozzle - gating system, as well as by numerous narrow cross-sections in
the mold
reinforces the shrinkage of the molded part
increases the cooling time slightly
WARNING!
Danger of burns in the vicinity of hot components such as the barrel and
injection mold; danger of injury due to high pressure injection!
Insufficient preliminary drying or the decomposition of certain plastics
can lead to accidental purging out of the nozzle of the feed opening.
117
Heat Zones
turer! When processing materials that can cause a health risk, always
use extraction equipment!
Maximum permitted barrel operating temperature:
+ 350 °C (662 °F)
Pushbutton:
Barrel heating
Before switching on, the following message appears:
Barrel heaters are switched off
Cause The barrel heaters are not yet switched on or have been switched off
by the appearance of another alarm (see alarms on the screen).
Effect No cycle start possible
Remedy Switch on the main switch for barrel heaters on the control panel.
Eliminate the primary error.
All zone groups are automatically heated up to reach the set point at approximately the same
time..
If all barrel heaters have dropped below the lower tolerance limit, two minutes of heat soaking
starts, to protect the screw tip. The following message is displayed:
Barrel heat soaking is active
Effect All screw movements are blocked, no cycle start possible, when actu-
ating the start button the warning light flashes.
Soaking symbol appears in the zones
The set values for the individual heating and cooling zones, and the tolerances can be set on
screen. Click the icon in question to view a descriptive text for the zone.

Heat Zones
Barrel heating
Info Panel
Zones Group Control parame-
Set value
pos. tolerance
neg. tolerance
Minimum monitoring
Reduce to standby temperature
Set value pos. tolerance neg. tolerance

Compact
Heating switched on (Switch on the control panel)
A graphic field with symbol is displayed for each temperature zone with the following settings:
Set value (dark line)
Actual value (red and/or blue bar with digital display)
Tolerance band (green field)
Status display for:
119
Heat Zones
Zone switched off
Zone not within the tolerance
Heating active (red), cooling active (blue)
Heats are reducing to standby temperature
Optimization: active (yellow)
Heating defective, thermocouple break
Heating soaking
The set values and tolerances can be set individually. Set them equal with [=] all zones of a
group or displace them proportionally with the arrow keys. Observe the given tolerances from
the material manufacturer.
The feed throat temperature (material feed opening) is closed loop controlled with water cool-
ing. Temperature control is important for feed performance and flow capability of the material
(no lump formation, uniform plasticizing time).
A temperature profile that increases towards the nozzle is often required with a standard
screw. Machines that use barrier screws would use a decreasing temperature profile.
The screw type in the barrel heating group parameters can be set as of user level 11.
Screw type Standard
Standard
Barrier
Barrier screw
Barrier screws can be used for semi-crystalline and amorphous thermoplastics. Excellent plas-
ticizing performance and improved homogeneousness of the molten material can be expected
due to the modified screw geometry.
To allow for sufficient surface fusing and melting upstream of the barrier area, you need to set
far higher temperatures for the inlet area than for the 3-zone screw.
A temperature profile that drops towards the nozzle is also recommended.
Setting too low a temperature at the inlet leads to a drop in plasticizing performance and to
undissolved particles being transported towards the screw tip, and thus to far higher wear and
tear.
If the machine has a barrier screw, and you set a rising profile, the following message appears:

Heat Zones
Values out of range
Caution: barrier screw!

Due to the modified screw geometry of barrier screws, the temperature characteristic for
the barrel must be set differently from that of a 3-zone screw.
To allow for sufficient surface fusing and melting upstream of the barrier area, you need
to set far higher temperatures for the inlet area than for the 3-zone screw.
A temperature profile that drops towards the nozzle is also recommended.
Setting too low a temperature at the inlet leads to a drop in plasticizing performance and
to undissolved particles being transported towards the screw tip, and thus to far higher
wear and tear.
Cases of wear and tear due to incorrect temperature settings are not covered by warran-
ty!
Read and understood?
Cancel Help Execute
The control unit will not apply the values you have entered until you press Execute.
Recommended procedure when optimizing the cylinder temperature profile:

1. Based on the required material temperature you can set a constant temperature profile
from the nozzle to the inlet.
2. If this setting leads to reproducible and constant plasticizing performance, you can
increase the inlet temperature gradually.
The plasticizing time should decrease as infeed temperatures increase. Recommended
temperature vector between the inlet zone and the metering zone: 20 to 40 °C (36 °F to
72 °F).
3. The inverse temperature profile results in a more consistent temperature distribution
and thus in improved quality of molten material.
Higher inlet temperatures will only increase the material temperature slightly.
If infeed problems occur, reduce the temperature at the start of the inlet area by approx.
10 °C (18 °F).
4. Set the specific back pressure in this area between 20 to 50 bar (290 to 725 psi). As
back pressure rises, plasticizing performance falls more than proportionally.
5. Due to the low shear stress of the melt an average higher screw speed can be set than
when using a 3-zone screw.
121
Heat Zones
1.1 Monitoring of the barrel temperature

A maximum positive and negative tolerance can be set for the safety of the material and screw.
Set value
pos. tolerance
neg. tolerance
Minimum monitoring
If the positive tolerance is exceeded, the following message is displayed:
Barrel heating zone x too hot Mold heating zone x too hot
Cause The actual value of at least one zone is above the set positive toler-
ance.
Effect At barrel heaters: Alarm lamp flashes, current cycle is finished, motor
switches off delayed, heatings switch off immediately.
In mold heaters, the error reaction can be set in the ’Heating configu-
ration’.
Remedy Possibly change the heating settings (set temperature differences

between individual zones too great, a hotter zone heats up a neigh-
bouring zone), possibly reduce the plasticizing speed (shear forces
too great), turn on the cooling for feed throat temperature.
If the negative tolerance is not reached, the following message is displayed:
Barrel heating zone x too cold Mold heating zone x too cold
Cause The actual value of at least one monitored zone lies below the set
negative tolerance.
Effect At barrel heaters: All screw movements are blocked, current cycle is
finished, no cycle start possible.
In mold heaters, the error reaction can be set in the ’Heating configu-
ration’.
Remedy Wait until the temperatures are within the tolerance limits.
Note!
Switching off Minimum monitoring is possible only with a certain access authorization level.
Danger of the screw tip breaking (see Technical Manual -)!

Heat Zones
1.2 Standby heats

All barrel heater groups are lowered to standby temperature in order to avoid thermal damage
to the polymer melt.

Compact
A standby temperature set to 0 causes the heat zones to be switched off. If the standby tem-
perature is set equal to or greater than the highest zone value, the temperature is not reduced.
Standby is active:
when switching the program on manually with the screen switch for the group
when an alarm appears which brings the machine to a standstill for all zones
Message:
Barrel heating reduces to standby temperature, Mold heating

reduces to standby temperature
Effect Message only
Remedy After eliminating the main error and switching off the screen switch,
the group heats up to the set value.
123
Heat Zones
1.3 View settings for heating zones

In order to improve clarity if there are a large number of barrel or mold heating zones, the heat-
ing screens can be switched to a compact representation. In addition, the scaling of the tem-
perature bar can be changed with the zoom function.
Mold heating
Info Panel
+ Zones Group Control parame- Heating ele-

View
Switch on the zoom function

To switch on the zoom function, press ’View’ and ’Zoom’. In the zoom view, the scaling of the
temperature bar changes from between 0 °C and maximum temperature to the set tempera-
ture +/- 50 °C.
Switch to compact view

To switch between compact and normal view, press ’View’ and ’Compact’.
To change the settings, tap the bar graph of a zone:

Heat Zones
The dialog window for changing the zone settings and control parameters opens:
Hot runner 1
Zone Control parame-
Values
Set value
pos.tolerance
neg.tolerance
Minimum monitoring
Accept for all zones of this type

Values Accept
Set value
pos.tolerance
neg.tolerance
Minimum monitoring
Cancel Help Accept
Changes can be made for the selected zone in the line ’Values’ . In the line ’Accept for all
zones of this type’ , you can use the screen switches to accept the changed values for zones
of the same type.
125
Heat Zones
1.4 Soaking test (option)

To protect the screw and screw tip, the control unit checks the maximum torque after the heat-
ing of the barrel during the first plasticizing.
Message:
Soaking inspection active
Effect 5 s screw rotation at max. 0.100 m/s (0.328 ft/s), no back pressure for
hydraulic injection units.
If there is no exceeding of torque limits, the next plasticizing occurs
with the set values.
Remedy Purge and plasticize again
Soaking inspection was active
Cause Production start after plasticizing with soaking inspection
Effect Rejects counter
If the maximum value is exceeded on testing the torque, the screw stops turning and post-
soaking is performed.
Soaking inspection: Maximum torque reached
Cause The material is not yet fully plasticized and the maximum torque was
exceeded.
Effect Post-soaking time starts, plasticizing stops
Remedy If the error occurs multiple times in succession, the barrel tempera-
tures may be set too low.
Postsoaking active - no screw movement possible!
Effect No screw movement possible.
Remedy Wait for postsoaking time.
Soaking inspection restarts the next time the screw rotates.

Heat Zones
2 Heating configuration
The heating configuration gives you the ability to configure heating or cooling of the machine
to meet your requirements. You can add heating groups, and assign these groups on the
machine to existing heating zones. Each heating group is displayed on a separate screen.
Heating configuration screen
Heating configuration
Info Panel
+ Heating Attributes Parame-

Barrel heating1
Element attributes
Nozzle 1
Name Nozzle
barrel 2
User-defined name
barrel 3
Number
barrel 4
Hardware designation AIn2
barrel 5
Use zone
Feedthroat
Mold heating1
Mold 1
Mold 2
Mold 3
Mold 4
Oil temperature control
Heating Edit View
Name
Selection box for the name with icon for heating zone. This icon is displayed on screen;
the name appears when you press the icon.
User-defined name
Freely configurable text for a heating zone name. This is shown on the screen in ques-
tion.
Number
Freely configurable number for the icon display on the heating screen.
127
Heat Zones
Hardware designation
Information which electronic module and which zone is used for this heating.
Use zone
It is possible to switch a zone off, if you do not need it for a mold. The zone is not visible
on the heating screens in this case.
For a clear operation, only the heaters required for the production will be visible and
active.
If a zone with an attached sensor is deactivated, the following alarm appears:
Zone 9 (card - TI 1- 0) not activated
Effect Injection blocked
Remedy Add the zone to a group and activate.
Zone parameters
Info Panel
+ Heating Attributes Parame-

Barrel heating 1
Zone parameters
Nozzle 1
Zone tolerances
barrel 2
Use group attributes
barrel 3
Cooling
barrel 4
Controller type
barrel 5
Sensor type
Feedthroat
Monitoring type Production stop
Mold heating1
Delay time for upper deviation
Mold 1
Delay time for lower deviation
Mold 2
Mold 3
Mold 4
Zone tolerances
Definition of absolute and relative tolerance limits for the settings on the heat pages. For each
tolerance limit of a group always set either all absolute or all relative.
Setting Text on the heat pages

absolute rXMax Maximum value
absolute rXMin Minimum value
relative rXWMax pos. tolerance

Heat Zones
Setting Text on the heat pages

relative rXWMin neg. tolerance
absolute rXMin and absolute rXMax Minimum value and maximum value
absolute rXMin and relative rXWMax Minimum value and pos. tolerance
relative rXWMin and absolute rXMax neg. tolerance and maximum value
relative rXWMin and relative rXWMax neg. tolerance and pos. tolerance
Use group attributes

Defining whether this zone is considered:
at the simultaneous set value and tolerance setting
during the heat reduction to standby
at the error messages
Cooling
Switch on if this zone is for cooling.
Controller type
Measuring oper- Only serves the temperature measurement without closed loop control
ation
Regulation Enables the operation of a heating without thermocouple. Actuation in
mode percent of the zone.
PID_2PT Two-point controller for a heating or a cooling
PID_3PT Three-point controller for a heating with cooling
Guided opera- Used to operate a heater without a thermocouple. The set value and
tion the closed loop control are taken over from a guidance zone. The guid-
ance zone is selected on the Control parameters page.
Sensor type
The sensor types used by Engel can be selected here.
J-FeCuNiIEC according to IEC 584

K-NiCrNi according to DIN 43710
L-FeCuNiDIN according to DIN 43710
PT100
NTC
Color codes for various standards:
129
Heat Zones
Type norm Leads Jacket
J Europe + black black

IEC 584 - white
J Germany --- ---

DIN 43710
J North America + white black

ANSI MC 96.1 - red
L Europe --- ---

IEC 584
L Germany + red blue

DIN 43710 - blue
L North America --- ---

ANSI MC 96.1
K Europe + green green

IEC 584 - white
K Germany + red green

DIN 43710 - green
K North America + yellow yellow or red

ANSI MC 96.1 - red
Monitoring type
The selection determines the reaction of the machine when temperature monitoring in the
zone in question is triggered.
Delay time for upper/lower deviation

If the deviation occurs for longer than the delay time, an alarm is triggered depending on the
monitoring type.
2.1 Adding heating zones
Example:
Follow these steps to add a heating zone to a heating group.
1. Select the heating group to which you wish to add a heating zone.
Info Panel
Heating Attributes Parame-
Barrel heating 1
Element attributes
Mold heating 1
Name Mold heating 2
Mold heating 2
Use group

Heat Zones
2. Press the Heating and Change zonesmenu buttons. The following dialog box appears.
Zones configuration
Available elements Selected elements
Zone 13 (AIn13)
Zone 15 (AIn15)
Zone 16 (AIn16)
Zone 17 (AIn17)
Zone 18 (AIn18)
Zone 19 (AIn 19)
Zone 20 (AIn20)
Zone 21 (AIn21)
Zone 22 (AIn22)
Zone 23 (AIn23)
Zone 24 (AIn24)
Zone 25 (AIn25)
Zone 26 (AIn26)
Zone 27 (AIn27)
Zone 28 (AIn28)
Zone 29 (AIn29)
Zone 30 (AIn30)
Zone 31 (AIn31)
Zone 32 (AIn32)
Cancel Help Execute
131
Heat Zones
3. Select a zone in the left-hand column of the dialog, and press the button > to move this
zone to the right-hand column.
To move all zones from the left to the right-hand column, press the button >>>.
Zones configuration
Zone 18 (AIn18) Zone 13 (AIn13)
Zone 19 (AIn 19) Zone 15 (AIn15)
Zone 22 (AIn22)
Zone 23 (AIn23)
Zone 24 (AIn24)
Zone 25 (AIn25)
Zone 26 (AIn26)
Zone 27 (AIn27)
Zone 28 (AIn28)
Zone 29 (AIn29)
Zone 30 (AIn30)
Zone 31 (AIn31)
Zone 32 (AIn32)
Cancel Help Execute
4. Press Execute to add the heating zones to the group.
Info Panel
Heating Attributes Parame-
Barrel heating 1
Element attributes
Mold heating 1
Name Mold heating 2
Mold heating 2
Use group
Zone 13 (AIn13)
Zone 15 (AIn15)
Zone 16 (AIn16)
Zone 17 (AIn17)
5. You have now added the heating zones to the heating group.

Heat Zones
Note!
Depending on how you use the individual zones, you may need to parameterize the zones.
2.2 Deleting a heating zone
Example:
Follow these steps to delete a heating zone from a heating group.
1. Select the heating group from which you wish to delete a zone and press the menu but-
tons Heating and Change zones. A dialog box appears.
2. Select a zone in the right-hand column of the dialog window and press the button < to
move this zone to the left-hand column.
To move all zones from the right- to the left-hand column, press the button <<<.
Zones configuration
Zone 19 (AIn 19) Zone 15 (AIn15)
Zone 22 (AIn22)
Zone 23 (AIn23)
Zone 24 (AIn24)
Zone 25 (AIn25)
Zone 26 (AIn26)
Zone 27 (AIn27)
Zone 28 (AIn28)
Zone 29 (AIn29)
Zone 30 (AIn30)
Zone 31 (AIn31)
Zone 32 (AIn32)
Cancel Help Execute
3. Press Execute to remove the heating zones from the group.
133
Heat Zones
3 Mold heatings (Option)

Mold heating
Info Panel
+ Zones Group Control parame-
Set value
pos. tolerance
neg. tolerance
Minimum monitoring
Set value
pos. tolerance
neg. tolerance
Minimum monitoring

Compact
Pushbutton:
Mold heating
You must switch on the mold heatings with a separate switch on the control panel. The follow-
ing message is displayed before switching on:

Heat Zones
Mold heating is switched off
Cause The mold heatings are not yet switched on or have been switched off
by the appearance of an alarm (see Alarm page on the screen).
Effect Message only
Remedy Switch on the mold heating at the control panel or eliminate the main
error.
For mold heating controls, see barrel heating. [See Barrel heating on page 117.]
The zones available on the machine can be displayed or hidden as needed. It is also possible
to enable monitoring of individual error reactions.
[See Heating configuration on page 127.]
Preheat zone
To preheat selected mold zones before other zones, you can set a pre-heating zone with a pre-
heating limit.
To do this, select the required pre-heating zones in the ’Control parameters’ tab.
Mold heating
Info Panel
Zones Group Control parame- Heating ele-
Optimization
Heating wattage
Heat up zones to-
Pre-heating zone
Set the pre-heating limit in the ’Group’ tab. All pre-heating zones must exceed this limit before
the remaining zones start heating up for the mold heating.
Pre-heating limit
Mold heating x Zone x Pre-heating active
Cause Heating of pre-preheating zone active
Effect Standard zones only start heating after the set pre-heating limit of the
pre-heating zones is exceeded
135
Heat Zones
4 Heating-up circuit
If the ’Heat up zones together’ switch is set on the control parameter page, the zones within
the group will heat up together.
If the difference between two zones in the group is too large, the group will stop heating until
the difference is within tolerance.
Heat-up with reduced heating wattage

A heating wattage of 50% helps to protect sensitive heating cartridges or media that you need
to heat from too fast an increase in temperature. Condensate can cause damage to molds.
Select the group parameter page to set the heating phase.
Mold heating
Info Panel
Always optimize on heat up

Fifty percent heating output
Fifty percent heating output active in at least one zone
Heating-up threshold
Always optimize on heat up

Optimization occurs automatically during every heating procedure from a cold state. To
avoid wiring errors, temperature increase monitoring of the zones in relation to one
another is activated.
Fifty percent heating output
Reduces the heating output to 50% to the heating-up threshold.
Fifty percent heating output active in at least one zone
The flag shows that the 50% heating output is active. It disappears when the heating-up
threshold has been reached in all zones.
Up to this percentage of the set value, the zone will heat at half wattage when half-wave
circuit is activated. After this, heating occurs at full power up to the preset value.
Example:
Zone set value = 150 °C (270 °F)
Heat-up threshold = 80 %, corresponding to 120 °C (216 °F).
The zone heats up to 120 °C (216 °F) at half power.
Heating-up ramp of the group
Evaporation time
+ Evaporation tolerance
Max. difference between the zones
Soaking
Delay time reduce group to standby/switch off group

Heat Zones
Heating-up ramp of the group

Configurable temperature change up to heat-up threshold.
Evaporation time
The temperature stays at the heat-up threshold value for this time. After the steam evac-
uation time the zone continues to heat up at full power up to the set value.
Evaporation tolerance
Lower tolerance for heat-up threshold. The steam evacuation time does not start until all
zones in the group have reached this threshold.
Max. difference between the zones
If the heat-up ramp is too steep, the group will follow the slowest zone if the max. vector
is exceeded.
Soaking
Soaking starts when the last zone has reached the lower tolerance of the set value.
Automatic operations cannot start until soaking has been completed.
As of access level 11, a soaking time can be set only for the mold heaters.
Delay time reduce group to standby/switch off group
If an alarm that causes the heater to be switched off or reduced is triggered, the delay
time for this heating group starts. Message during the delay time:
Delay - reduce heater x

Delay - switch off heater x
Cause Heater reduces temperature due to alarm.
Effect Activation of Delay time reduce group to standby/switch off

group.
Controlled heating with evaporation time

This program with its heat-up ramp takes a heating group up to the heat-up threshold gently to
avoid wear and tear. Switch on by setting heat-up ramp for group greater than 0.
T
Set value
Evaporation toler-
ance
Heating-up ramp Evaporation time t [s]
137
Heat Zones
5 Automatic heating optimization

When mounting a new mold with other heating elements, a new heating optimization will be
necessary for precise closed loop control of the temperature.
A red symbol next to the optimization button also shows when a temperature is fluctuating too
much.
Mold heating
Info Panel
Optimization
Emergency mode is enabled
Guidance function permitted
Guidance zone
Heating wattage
Heating-up optimization
Prerequisites and procedure:

1. Switch off heating switch on the switch panel.
2. Wait until all heating zones have reached room temperature.
3. Set the set values to operating temperature (at least 50 °C (122 °F) above current tem-
perature).
4. Switch on neighboring coolers, as they affect the controls in operation (e.g. Crossbar
cooling).
5. Switch off theFifty percent heating output for the group.
6. Set the PIDT1 gain greater than ’’0’’ (0 = control loop switched off).
Typical basic settings:
Heating type PIDT1 Integrator Differentiator Controller cycle

time
Nozzle 25,00 100,0 25,0 5,0
barrel 10,00 600,0 200,0 10,0
Mold 10,00 600,0 200,0 10,0
Hot runner 50,00 50,0 15,0 0,5
7. Switch on all optimization switches for the corresponding zones.
8. Switch on the heatings at the control panel.
9. The self-determination begins and lasts between 1 minute and 2 hours depending on
the rapidity of the heating. Display by screen flag
10. Optimization switches off automatically upon completion and zones heat up to the set
value.
Alarms

Heat Zones
Error in the wiring of zone x
Cause A zone became too hot during automatic optimization.
Effect Heating group switched off, alarm lamp flashing.
Possible error in the wiring of zone x
Cause This is the coldest zone during automatic optimization.
Effect Alarm lamp flashes.
Note!
The preset zone temperature can be exceeded during optimization. Thus, you should perform
trial heat up without material at first.
Zone for cooling

If you use a zone for cooling (e.g. oil radiator, crossbar cooling, mold cooling), you cannot opti-
mize the zone. Set the following standard control parameters for this zone:
Heating type PIDT1 Integrator Differentiator Controller cycle

time
Cooling 1000,0 0,0 0,0 5,0
Operating point optimization

For optimum control at the operating point you can optimize in automatic mode.
Prerequisites and procedure:

1. Current optimizations must be completed, (all optimization switches are switched off).
2. All temperatures must be approximately within the same working range and are not
allowed to fluctuate to a greater extent. Perform heat-up optimization otherwise.
3. The negative temperature vector should not be set to too small a value.
4. Switch optimization switches on individually or for several non-neighboring zones (due
to mutual influence). Optimization achieves cooling by 10°C (50°F).
5. When optimization is complete, the zone temperature is restored.
139
Heat Zones
6 Emergency mode or guidance zone

If the switch Emergency mode is enabled is switched on for a zone, production continues at
the average heating wattage of the last 6 controller cycle times despite the thermocouple
break. The heating wattage can then also be set in % on the screen.
The setting Guidance function permittedis used to determine a guidance zone for a zone
with a thermocouple break. As a result, continued production with the set value and the control
parameters of the guidance zone is possible.
Emergency mode is enabled
Guidance function permitted
Guidance zone
Heating wattage
Setting a guidance zone:

1. Activate screen switch Guidance function permitted for the zone with a thermocouple
break. A message regarding setting the guidance zone appears:
Warning
Set a valid zone for the guidance
function.
Continue
2. In selection box Guidance zone , select a neighboring or similar zone.
Nozzle (Aln2)
Barrel zone 3 (AIn3)
Traverse 8 (Aln8)
3. Then a graphic of the guidance zone is shown in place of the actual value in the Zones
overview.
Set value
pos. tolerance
neg. tolerance
Minimum monitoring

Heat Zones
CAUTION!
Danger of overheating! No temperature measurement possible.

The following message appears in the case of a thermocouple break with emergency mode:
Emergency service - thermocouple break heating x (Card x - TI

x)
Cause Thermocouple break
Effect Zone is switched to percentage operation. The emergency service is

maintained when switching the control voltage off/on.
Remedy Replace the thermocouple of the zone. Then manually deactivate the
emergency mode in the heating configuration. Set the controller type
back to 2-point controller, for example.
The following message appears in the case of a thermocouple break with guidance zone:
Guided operation - thermocouple break heater x (card x - TI x)
Cause Thermocouple break
Effect Zone is switched to guided operation. Guided operation remains in

effect even if the control voltage is switched off/on.
Remedy Replace the thermocouple of the zone. Then manually deactivate

guided operation in the heating configuration. Set the controller type
back to 2-point controller, for example.
141
Heat Zones
7 Measuring group temperature monitoring

The interface for temperature monitoring enables the connection of a thermocouple for
measuring the mold temperature.
The measured value is also available in the quality assurance programs.
The zones available on the machine can be grouped together in the heating configuration as
needed. [See Heating configuration on page 127.]
Measuring group 1
Info Panel
+ Zones
Maximum temperature
Minimum temperature
Delay upper limit
Delay lower limit
Maximum and minimum temperature

Temperature limits for monitoring the zones.
Delay upper/lower limit
If the value exceeds or drops below the temperature limits, the associated delay time
starts with the following alarm display. If the temperature returns to within the tempera-
ture limits during the delay time, no alarm is issued.
The monitoring type can be selected in the heating configuration (no monitoring, rejects,
alarm, etc.).
Note!
If you do not choose an error impact at the monitoring type, no thermocouple break monitor-
ing occurs either.

Heat Zones
8 Temperature control devices with communication to ma-

chine control unit
The devices heat or cool a tempering medium, e.g. for an injection mold.
CAUTION!
Danger of burning!
Escaping tempering medium and hot pipes can cause burns.
Check temperature control devices and connection pipes for correct
condition and leaks.
Wear protective clothing.
The machine control unit transmits set values to the connected temperature control devices
and displays the actual values from the temperature control devices.
Note!
For operation and maintenance of the temperature control devices supplied by ENGEL, see
temperature control device documentation on the Manual CD.
143
Heat Zones
Temperature control device

Info Panel
+ Communication - machine control <-> external temperature control unit

Reduction to standby delay time
Zones Parame-
Set value
pos. tolerance
neg. tolerance
Reduction value 55,0 55,0 55,0 55,0 55,0 55,0 55,0 55,0
Reduction to stand-
Zone on
A graphical field with symbol and the following displays is provided on the screen for every
temperature control device:
Set value (dark line)
Actual value (red and/or blue bar with digital display)
Tolerance band (green field)
Status display of temperature control devices with the following symbols:
Switched off
Siphon
Closed loop control
Cooling
stand-by
optimizing
Regulation mode
Setting procedure:
1. Starting up the temperature control devices (see temperature control device documen-
tation on the CD).
2. Zone
Switch on the required temperature control devices on the screen.
3. Set value
Set the temperature for the tempering medium.
4. Tolerances
Set relative to set value.

Heat Zones
5. Reduction value
Set lowering temperature. The temperature control devices reduce temperature
together with the other heating units in the case of an alarm. If not required, set the low-
ering temperature equal to the set temperature.
A separate switch enables immediate manual temperature reduction.
6. Reduction to standby delay time
Delays temperature reduction for all temperature control devices in the case of an
alarm.
7. Communication - machine control <-> external temperature control unit
Switch on to transmit set and actual values.
Temperature control device

Info Panel
+ Communication - machine control <-> external temperature control unit
Reduction to standby delay time
Zones Parame-
Heating wattage 34 34
Monitoring type
Heating wattage
Positive percentage = heating, negative percentage = cooling.
Monitoring type
Selection options for effects in case of alarm:
Production stop
Rejects and alarm
Rejects
Alarm
none
If an actual value falls outside set tolerances, the following message appears:
Temperature control device Temp. zone x too low / too high
Effect Depending on the selected monitoring type
Remedy Check temperature control unit.
145
Heat Zones
Temperature control device x delay time temperature reduction
Cause Production stop by alarm (see screen page).
Effect Alarm lamp, temperature control device temperature reduction after

delay time.
Display of possible error messages from temperature control devices:
Temperature control device Initialization of temperature control

device failed
Temperature control device Level zone x too low,
Temperature control device Flow rate zone x too low,
Temperature control device stopping injection unit,
Temperature control device Set value for zone x not plausible,
Temperature control device Limit value zone x exceeded,
Temperature control device Thermocouple break zone x,
Temperature control device Heating zone x is defective,
Temperature control device Cooling zone x is defective,
Temperature control device Pump of zone x defective,
Temperature control device Communication error in zone x ,
Temperature control device Error No. in zone x.
Effect Alarm lamp, production stop
Remedy See temperature control device documentation
Temperature control device: Zone x blocking injection unit
Cause Zone x out of tolerance.

During mold temperature control only when the monitoring type pro-
duction stop is also selected and the nozzle is applied.
Effect Plasticizing, injection blocked
Remedy Zone x must be within tolerance
Temperature control devices with flow control

Activation in variables monitor variables list TempDevice1, Protocol type: Engel Flow
Temperature control devices with flow rate display enable flow rate monitoring.

Heat Zones
Zones Parame- Flow rate
+ Flow rate l/min
min. flow rate l/min
max. flow rate l/min
in tolerance
Monitoring type
Flow rate
Actual flow rate.
Min/max flow rate
Adjustable tolerance range with green tolerance display.
If the flow rate of a monitored zone lies outside the tolerance, the following alarm appears:
Temperature control device x: flow rate zone x too low / too high
Effect Depending on the selected monitoring type
Remedy Check temperature control device for any leaks or blockages.
147
Heat Zones
8.1 Günther hot runner controller

Günther hot runner controller
Activation in variables monitor variables list TempDevice1, Protocol type: Günther
Setup procedure, see temperature control devices.

Additional settings also permit emergency mode and regulation mode.
CAUTION!
Danger of overheating!
No temperature control in emergency mode and regulation mode.
Zones Parame-
+
Heating wattage 34 55
Monitoring type
Emergency mode
Regulation mode
Set heating capac- 55
Emergency mode
When emergency mode is switched on (permitted), production continues despite ther-
mocouple break. The control unit outputs the last actual power automatically for the
zone as Set heating capacity.
Regulation mode
Serves for tempering zones without thermocouples with adjustable Set heating capac-
ity in percent.

Injection unit
Injection unit
The injection unit has the following tasks:

To melt and uniformly mix the material.
To move the nozzle to the mold and hold the nozzle against the mold under injection
pressure.
To inject the material into the mold cavity with high pressure.
WARNING!
Danger due to hot barrel and pressurized molten material!

Exiting material can cause serious eye injury and burns to skin.
Wear suitable protective clothing and face protector.
Main structural units of an injection unit:

1 2 3 4 7 6 5
[1] Electrically heated nozzle

[2] Electrically heated barrel
[3] Material hopper
[4] Cooled infeed zone (traverse)
[5] Hydraulic motor for screw drive
[6] Hydraulic injection cylinder
[7] Position display for screw
1 Nozzle
The injection unit moves with the nozzle to the sprue bushing of the mold and builds up an
adjustable contact force. To prevent the nozzle from cooling off too much, or to tear off the
sprue, cyclic retraction can be set, if necessary.
149
Injection unit
Push buttons:
Return nozzle
Advance nozzle
Locking conditions:
Nozzle advance is released when the safety gates on the clamping and injection unit
are closed.
Nozzle return is released when the safety gates on the injection unit are closed. In the
manual mode you can always return up to the maximum stroke.
1.1 Speed profile and stroke positions

Nozzle
Info Panel
Advance profile
retract profile
Multi-stage speed profiles can be set, for the advance and return of the nozzle, with the set
value graphics.
Note!
When setting, ensure that the nozzle makes smooth contact with the mold.

Injection unit
Nozzle stroke position
Nozzle contact position
Nozzle stroke position

Nozzle contact position reached
Nozzle stroke
Force build-up time
Contact force
Nozzle contact position reached

The nozzle contact position is redetermined each time in manual mode or during the first
automatic cycle.
CAUTION!
Danger due to high pressure injection!

The nozzle must make close contact with the mold sprue so that mate-
rial cannot exit.
Clean the nozzle and mold sprue first so that the control unit does not
determine an incorrect nozzle contact position.
Set sufficient contact force.
The nozzle moves forward with decreased speed and reduced force until the contact
point is reached.
After approx. 2 s standstill recognition on the contact point the screen flag lights up
(zero point for the stroke measurement).
Nozzle stroke
If a value greater than 0 is set for the nozzle stroke, the nozzle retracts in automatic
mode.
Force build-up time
A force buildup time of approximately 0.2 to 0.3 s is required to permit a contact force to
build up.
Contact force
The Contact force is the force which presses the nozzle against the mold at the injection
and plasticizing process.
Set the force high enough so that no material escapes between nozzle and mold.
151
Injection unit
Occurring nozzle contact force against injection pressure and aperture D
Nozzle contact force (kN)
D = sealing diameter
specific injection pressure [bar]
Standard nozzle Extended/

The nozzle radius RN should long-reach
be 5 mm smaller than the nozzle
sprue radius RT.
Contact force during part removal
Delay time retraction

Nozzle safety position
Contact force during part removal

Effective force for contacting nozzle without built up clamping force.
Observe the load bearing ability of the right mold half in case of open mold!
Delay time retraction
The nozzle retracts, depending on the set sequence program, at the end of plasticizing
or at the end of hold pressure, after the Delay time retraction.
Nozzle safety position
To prevent squeezing and shearing points in the nozzle area, the nozzle stroke is limited
in automatic and manual mode. In manual mode, you need to actuate the safety button
to fully advance and return the nozzle.
If the nozzle is not within the limited nozzle stroke, the following message is displayed:

Injection unit
Nozzle position out of area
Effect No automatic start
Remedy Press the safety key again to move the nozzle into the permitted noz-
zle stroke range.
The nozzle contact position must be ascertained before switching over to automatic mode;
otherwise the following message is displayed:
Determine nozzle contact position
Effect No automatic start
Remedy Ascertain nozzle contact position in manual mode
The nozzle must make contact to inject; otherwise the following message is displayed:
Nozzle contact position not reached
Effect Injection only possible with reduced pressure, the warning light
flashes.
Remedy In manual mode, move the nozzle up to the mold.
Start nozzle in parallel

In the standard case the nozzle moves forward after the mold closing.
Start nozzle in parallel
Start position nozzle advance
On machines with parallel movements the advancing starts parallel with mold closing. The set
Start position nozzle advance refers to the mold stroke.
153
Injection unit
2 Inject
1 2 3
[1] Cavity pressure

[2] Specific injection pressure
[3] Non-return valve
During injection, the screw, with a non-return valve, becomes a piston. The molten material is
injected into the mold, under high pressure at a set speed profile, by the forward movement of
the screw. The melt freezes quickly in layers closed to the walls of the mold. The mold filling
phase is specially critical for the surface appearance, orientation, crystallinity of the part.
Pushbutton:
Screw injection
Locking conditions:
All safety gates closed
Barrel temperature within the tolerance
When the mold is closed, for purging the preselected clamp force must be reached.
Reduced injection occurs with an open mold or unapplied nozzle when the safety button
is not actuated at the same time;

Injection unit
2.1 Injection speed

To visualize the injection process as well as possible, the different areas in the set value
graphic use different colors.
Inject
Info Panel - injection molding machine ac-
Injection unit
Injection profile
1 2 3
Shot volume
[1] Material cushion set value

[2] Switchover point to holding pressure
[3] Decompression after plasticizing
A multi-stage speed profile can be set for the injection process with the "set value graphics".
The speed peak value (green field) and the current speed display are available as additional
process information on the screen.
Essential influences of the injection speed on the molded part:

Burning, entrapped air (air cannot escape rapidly enough)
Jetting, injection speed too high (incorrect mold gate position)
Incompletely filled parts (material cools off before the cavity is filled)
Record effect (the melt freezes too early, through which the frontal/laminar flow is dis-
turbed)
2.2 Specific injection pressure

The injection pressure required at injection depends upon:
the viscosity of the material
the temperature of mold and material
the injection speed
the mechanical design of the mold (Sprue cross-sections, wall thickness of the injection
molded part, length of the melt flow path).
155
Injection unit
Injection pressure
Specific injection pressure limit
Specific injection pressure peak value
Stop injection at pressure limit
Increased specific injection pressure
The set Injection pressure limit can be considered as a safety setting for the mold. The injec-
tion resistance changes due to variations in viscosity of the material or fluctuations in temper-
ature during production. For consistant quality the machine must closed loop control the set
speed exactly until reaching the switchover point. This is only possible then when the injection
pressure limit is set higher than the actual injection pressure. Ensuring tha).
Example:
Injection process
6
2
3 4 5
s
t
Inject Holding pressure
[1] Set injection pressure limit (e.g. 10% higher than injection pressure peak value)
[2] Required injection pressure for overcoming the injection resistance
[3] Set injection speed
[4] Set switchover point
[5] Mechanical end position of the screw
[6] Holding pressure
Increased specific injection pressure

It is possible to switch to increased specific injection pressure, if the maximum pressure is not
sufficient. A lower maximum injection speed is the trade off, for higher injection pressure.
Stop injection at pressure limit

The molding stops when reaching the pressure limit (e.g. with blocked cavity, ...) when the
screen switch is switched on.

Injection unit
Pressure limit at x ccm exceeded
Effect The set injection speed cannot be reached. Cycle continues to run
with injection hold pressure time (without pressure), shot is consid-
ered as rejects, no new cycle start.
Remedy Possibilities: Check cavities, increase pressure limit, switch over to

increased injection pressure, set injection speeds lower
2.3 Injection time monitoring

Injection time monitoring
Minimum injection time Max. injection time
Switchable monitoring for the injection procedure.

Injection stops when the minimum/maximum monitoring time responds. Message:
Injection time exceeded
Cause Possibilities: Switchover position to hold pressure not reached, sprue

frozen-in, cavity not demolded, incorrect temperatures.
Effect Production stop, rejects
Remedy Check the feed channels, cavity(ies) and temperatures.
Injection time not reached
Cause Changeover pressure to hold pressure reached too early due to:
Sprue frozen-in and/or sprue channels blocked, cavity not demolded,
temperatures not correct.
Effect Production stop, rejects
2.4 Intrusion program

Intrusion
Intrusion time
Intrusion speed
157
Injection unit
An increase of the maximum shot volume is possible in special cases by the intrusion, but it
must be plasticized up to the mechanical stop before in order that the screw can be supported.
By setting the intrusion time higher than 0 the screw turns before the injection and intrudes
material into the mold with the set speed.

Injection unit
2.5 Sequence programming positions Injection

The instruction ’Wait until’ in the machine sequence also enables the setting of the screw posi-
tions for starting movements or functions.
Screw positions used appear on the injection screen page.

Injection volume 1 cm³
2.6 Switchover to hold pressure

After the injection phase, the control switches over to hold pressure to reduce shrinkage. For
the production of consistant quality parts, the mold must always be completely filled before
switching over. To compensate for possible variations in the process, other switchover possi-
bilities are available:
Volume-dependent switchover
Time-dependent switchover
Injection pressure-dependent switchover
Switchover as a function of mold cavity pressure
External switchover via additional device
Choose the method of switchover that produces the greatest repeatability of part quality. Only
one method of switchover to hold pressure is possible. When one method is selected the pre-
vious is automatically switched off.
If the ’move in cycles with mold safety’ program switch is activated in the move in cycles tab
on the production screen when you select ’Volume-dependent switchover’ , the following dia-
log box appears.
Startup cycles mold safety active
Start-up cycles check switchover volume!
Switchover volume
Start-up cycles switchover volume
Cancel Help Execute
The chosen method of switchover, indicated by a flag, along with the current switchover value
is available as important processing information.
Volume-dependent switch over

Switchover type
Info Panel
+ Volume-dependent switch over

Switchover volume
Switchover volume actual value
This switchover method has generally proved successful if there are fluctuations in viscosity
and temperature.
159
Injection unit
A different switchover value may be needed on starting up production. The start-up cycle
switchover volume applies for the number of start-up cycles set. [See Production on
page 216.]
Time-dependent switch over

Time-dependent switch over
Switchover time
When time dependent switchover method is used, hold pressure is initiated after the set swi-
tchover time.
Injection pressure-dependent switch over

Injection pressure-dependent swi-
Specific switchover pressure
Switchover range
Specific pressure at switch over
This switchover method has mainly proved successful when volume variations are the main
problem. Some reasons for volume variations are e.g.:
Addition of re-grinded material
Low back pressure
Irregular closing of the non-return valve e.g. due to slow acceleration on injection, or fail-
ure to set decompression
With unbalanced multi-cavity molds (gate problems)
The injection pressure - less the injection resistance - is always proportional to the cavity pres-
sure.
The pressure increase, which arises when the cavities are filled, will cause switchover. There-
fore, always choose a switchover pressure lower than the injection pressure limit.
Injection pressure-dependent switchover also provides good mold safety as the machine
always switches to hold pressure immediately at a certain pressure setting.
A pressure spike at the beginning of injection will cause a premature switchover, a Switchover
window must be set so that the machine switches to hold pressure within that window.
P
possible pressure peak
Switchover pressure
Switchover range
INJECTION HOLD PRESSURE
t
The injection pressure peak value and the current pressure display also provide important
process information on screen.
External switchover
External switchover
External switchover DI

Injection unit
A signal from an external device enables the switchover to hold pressure, when "External swi-
tchover" is selected.
Parallel switchover (option)

This is sometimes used as an additional safety setting.
Parallel switch over
Switchover range
On parallel switchover the activated switchover type whose criteria are fulfilled first triggers the
switchover process after reaching the switchover area.
161
Injection unit
2.7 Charge amplifier (Option)

The charge amplifier and a pressure or force transducer built into the mold measure the cavity
pressure.
With the charge amplifier types LV5039 or LV5155 you can use the signal for the changeover
to hold pressure for recording and logging the pressure profile with the Micrograph.
The ’Transducer type’ (pressure or force transducer) used in the mold and sensitivity settings
must be made on a separate screen page.
When using a force transducer in the mold, set the ’Number of charge attenuators 10:1’
according to the charge attenuators used.
Selection of the measuring range will correspond to the expected cavity pressure.
Charge amplifier
Info Panel
Settings
+
Charge amplifier type
Transducer type Force
Associated injection unit
Force transducer
Force transducer sensitivity
Pin diameter
Force measuring range
Number of charge attenuators 10:1
Time cavity pressure peak value

Internal mold cavity pressure
Cavity pressure actual value
Charge amplifier test Test
Switchover as a function of mold cavity pressure

Cavity pressure-dependent switchover
Switchover pressure
Cavity pressure at switchover
+
Cavity pressure peak value during holding pressure
This switchover method has proven itself mainly with single-cavity molds, especially when
constant weight is an important quality criterion. The machine switches to hold pressure after
reaching the set cavity pressure.

Injection unit
2.7.1 Charge amplifier LV5155-SA (5049)

This charge amplifier analyzes the cavity pressure profile and can determine, with a handle-
able curve profile, the required switchover point from injection to hold pressure independently.
Note!
Before selecting the internal mold temperature dependent switchover function, make sure
that this function is suitable for controlling your injection process. Consult the charge amplifier
manual before you make this decision.
Switchover point determination after mold change

1. On the control unit set the External changeover . When this changeover type is not
active, the LV5155-SA works as a normal charge amplifier like the LV5039 or charge
amplifier 5155.
2. For safety reasons it is recommended setting the injection time monitoring and possibly
the cushion monitoring. The control unit indicates this with the message:
Note
Activate injection time monitoring
Help taken note
3. The learning phase starts automatically after reading in a parts data set or by typing in
a value on the screen page of the charge amplifier, the control unit rating the produced
parts as rejects. Message:
Charge amplifier x rejects at learning phase
Effect Rejects sorting active, rejects monitoring not active
4. After a successful learning phase, within 10 machine cycles, the machine produces
using the determined switchover point. If the learning phase is unsuccessful, the follow-
ing message is displayed:
Charge amplifier x changeover point not recognized
Effect The alarm lamp flashes and the current cycle is finished
Remedy Check whether the injection process is suitable for automatic switcho-
ver point recognition. Possibly set switchover point manually.
Further procedures are available in the Kistler documents.
2.7.2 Charge amplifier LV5155 with pressure and temperature channel

These amplifiers (types 5155A22A1 or 5155A22C1) have a temperature channel besides the
pressure channel. This means that mold wall temperature is acquired and logged as a pro-
cess-critical factor. The internal mold temperature can also be used as a switchover criterion.
A mold cavity pressure and a temperature signal can be applied at the same time.
163
Injection unit
Cavity pressure actual value

Internal mold temperature actual value °C
+
The current temperature value is displayed in addition to the cavity pressure.

Switch over internal mold temperature-de- °C
Wall temperature at start injection °C
Mold internal temperature at the switchover °C
+ Mold internal temperature peak value °C
Activate temperature-dependent switchover on the switchover type screen. All current values
relevant to the injection process are also shown here.
The optimum switchover temperature is automatically determined by the charge amplifier.
There is no need to set a preset value.
Note!
Before selecting the internal mold temperature dependent switchover function, make sure
that this function is suitable for controlling your injection process. Consult the charge amplifier
manual before you make this decision.
For safety reasons it is recommended setting the injection time monitoring and possibly the
cushion monitoring. The control unit indicates this with the message:
Note
Activate injection time monitoring
Help taken note
Further procedures are available in the Kistler documents.
3 Holding pressure
The screw still presses on material via the fluid center of the molded part during the first coo-
ling phase in order to compensate for the shrinkage of the material. The injection hold pres-
sure compresses the melt and therefore produces those quality characteristics which depend
on part density.

Injection unit
3.1 Holding pressure profile

Holding pressure
Info Panel
Holding pressure profile
Holding pressure time
For the hold pressure phase for the different optimization aims a multi-stage hold pressure pro-
file can be set with the set value graphics. [See Set value graphics on page 68.]
The hold pressure peak value (green field) and the current pressure display are available in
addition as important process information on the screen.
Too low hold pressure causes: Too high hold pressure causes:
Sink marks and voids Tensions near the sprue
Greater shrinkage Flash formation
Smaller molded-part dimensions Tensile stresses in the outer layers
Greater dimensional variations Demolding difficulties
Internal orientation due to melt back-flow

The injection hold pressure time should last until the gate freezes. Too short injection hold
pressure time causes:
Sink marks and voids
Internal orientation due to melt back-flow
Greater warpage, especially of partially crystalline materials
Underweight and smaller dimensions
Greater dimensional variations
Greater shrinkage
An increase of the melt temperature, of the mold wall temperature and of the holding pressure
delays the gate freezing off.
165
Injection unit
3.2 Cooling time

Cooling time
Cooling time
As the mold has a different temperature to the melt, the cooling time begins with the entry of
the melt into the mold.
With the end of hold pressure, the set cooling time starts. Upon expiry the mold opens. The
cooling time essentially depends on the plasticizing process and on the demoldability of the
molded part.
Too short cooling time has the following impact:

Increases the warpage.
Increases the mechanical deformations during demolding.
On thick-walled molded parts, this leads to the re-melting of cooled part layers at the
surface because of the high heat capacity of the fluid center.
In a dry cycle (all injection units deactivated), the control unit uses the ’Cooling time during dry
cycle’, which can be set in the variables list ’CoolingTime’ in the variables monitor.
3.3 Cushion monitoring

Cushion monitoring
Minimum cushion Maximum cushion
Cooling time
Cooling time
Shot volume
Shot volume
The control unit displays on the screen the material cushion, which still remains in the screw
antechamber of the barrel until the end of hold pressure. The remaining melt cushion should
be approx. 5 to 10 % of the shot volume.
Monitoring is also provided. When monitoring is switched on, the following impact is seen,
when the measured value lies outside the set tolerances:
Message:
Cushion too small
Cause The melt cushion is under the set limit, e.g. due to volume variations
of the material, escape of material between nozzle and sprue bush,
leaks on the non-return valve,
Effect Rejects
Remedy Increase the metering stroke, back pressure, contact pressure of the
nozzle, replace the non-return valve on the screw

Injection unit
Cushion too large
Cause The melt cushion is over the set limit. Possibilities: Sprue frozen-in or
blocked, one cavity has not been demolded, temperatures incorrect.
Effect Rejects
3.4 Screw diameter

Screw diameter
Screw diameter
After the installation of a barrel with another screw diameter for calculating the specific injec-
tion pressure the correct screw diameter must be set. Message:
Set screw diameter
Cause No screw diameter corresponding to the injection unit is set
Effect Calculation of the specific injection pressure is wrong
167
Injection unit
4 Plasticizing
1 2 3 4
[1] Filled cavities

[2] Screw antechamber for melt (specific back pressure)
[3] Feed throat for the material
[4] Closed loop back pressure control
The nozzle is usually in contact during plasticizing and is sealed by the previously filled cavi-
ties. The screw conveys the material, plasticized by the shear forces and hot inner barrel wall,
into screw antechamber and builds up pressure. A closed loop back pressure control ensures
uniform plastification.
Pushbutton:
Screw plasticizing
+ Screw plasticize without back pressure
Locking conditions:
All safety gates closed
Barrel temperature within the tolerance

Injection unit
4.1 Plasticizing profile

Plasticizing
Info Panel
Plasticizing profile
Shot volume
Shot volume
Plasticizing delay time

Metering performance 101,4
The entire cooling time is available for plasticizing in hydraulic machines, without lengthening
the cycle time. In standard cases, they reduce the clamping force shortly before cooling time
elapses, even if the plasticizing sequence is still running.
Toggle lever machines reduce the clamping force after the plasticizing sequence so that, if the
entire cooling time is used for the plasticizing sequence, the cycle time is lengthened.
The set value graphic enables the setting of multi-stage profiles for peripheral velocity and
back pressure. [See Set value graphics on page 68.]
The current peripheral velocity of the screw ’’v’’ as well as the back pressure peak value
(green field) and back pressure actual value are available as information on the screen.
A too low value causes: A too high value causes:
Unplasticized material Thermal degradation of the melt
Insufficient mixing of additves increased wear of cylinder and screw
Shortening of glass fibers
Shot volume
Sufficient shot volume must be set, for filling the mold. The required residual melt cushion at
the end of hold pressure should be approximately 5 to 10% of the plasticizing stroke. For a
mold filling study at start-up, a short shot must be set initially and then must be increased grad-
ually. In the ideal case the plasticizing stroke shall lie in the range between 1 and 3 screw
diameters. Otherwise especially thermal problems, surface marks and volume variations can
arise.
Plasticizing delay time

A plasticizing delay time is provided for thermally sensitive materials during long cooling times.
This allows the dwell time of the melt in front of the screw to be shortened. The time starts after
decompression before plasticizing.
Metering performance
The actual value display is an optimization aid for plasticizing. Changes during set production
can be related to the melt temperature, batch fluctuations and infeed problems.
169
Injection unit
The metering performance is also available for selection in the process data package for
recording and monitoring.
4.2 Plasticizing power-controlled

This program is used in machines with hydraulic screw drives to utilize the maximum plastici-
zing performance at the highest possible speed.
Example: Performance diagram injection unit 35050
by power control newly opened up operation area
Volume limit
1000
Q [l/min] at plasticizing (and/or speed)
900
Layout point
Limit: 271kW
800
conventional operation area
700
600
500
p limit
400
300
130
140
150
160
170
180
190
210
220
230
240
250
120
200
phydr. [bar] at the plasticizing (and/or torque)

P = const
Plasticizing
Info Panel
Plasticizing profile power controlled
Plasticizing profile power controlled

The program increases the maximum adjustable plasticizing speed and the maximum
torque of the plasticizing drive.
Depending on the torque required, the plasticizing speed ’v’is only limited when maxi-
mum motor utilization is reached.

Injection unit
Torque
last current
Torque peak value
Torque mean value
Torque
Max. torque
4.3 Plasticizing time monitoring

Plasticizing time monitoring
Minimum plasticizing time Maximum plasticizing time
Plasticizing time most recent cycle
If plasticizing time monitoring is activated, and if the measured value is outside the preset
tolerance, plasticizing stops.
Plasticizing time exceeded
Cause The set plasticizing monitoring time has been exceeded e.g. by feed
problems or insufficient material.
Effect The alarm lamp flashes and the plasticizing stops, the current cycle is
finished, delayed motor stop and delayed switch to standby tempera-
ture.
Remedy Refill material, check material feed chute and feed throat tempera-
ture.
Plasticizing time not reached
Cause The set plasticizing monitoring time has not been reached. Previous
cycle screw stroke was too short.
Effect The alarm lamp flashes and the plasticizing stops, the current cycle is
finished, delayed motor stop and delayed switch to standby tempera-
ture.
Remedy Check feed channels, cavity(ies), temperatures, back pressure and

screw speed.
In addition, the plasticizing time Last cycle and the current time are displayed on the screen,
as important process information.
171
Injection unit
4.4 Plasticizing maintained instruction

If you hold down the plasticize pushbutton for a longer period in manual mode, the machine
will automatically plasticize until the preset shot volume has been reached, even if you release
the pushbutton.
The following criteria stop automatic plasticizing:

Plasticizing stroke performed
Plasticize button re-pressed
Program interruption button pressed
Sequence for max. plasticizing time with plasticizing time monitoring activated
Switchover to automatic mode
Opening a safety gate
Plasticizing time monitor-

Minimum plasticizing time 11,0 Maximum plasticizing time 15,0
Max. plasticizing time manual mode 15,0

Last cycle
Max. plasticizing time manual mode (option)

Max. plasticizing time manual mode is always active in manual mode, even if plasticizing time
monitoring is switched off.
You can set the value to 0 s to disable the maintained instruction.
Automatic plasticizing active
Cause Plasticizing with maintained instruction is active.
Effect The machine automatically plasticizes until the preset shot volume
has been reached.
4.5 Decompression before and after plasticizing

Decompression (screw retraction) before plasticizing serves to relieve the pressure of the mol-
ten material in the hot runner and barrel. Decompression after plasticizing serves to relieve the
pressure of the molten material in the barrel and guarantees a more even clamping behavior
of the non-return lock on injection (e.g. decompression volume 5-10% of shot volume).
Decompression
Decomp. before plasticiz- Decomp. after plasticizing
Decompression end
Decompression speed before plasticizing
Decompression speed after plasticizing
Normally the decompression speed must be coordinated approximately to the retraction

speed of the screw during plasticizing.
Relief end is composed of shot volume and relief volume after plasticizing. This position of the
screw is also a start condition for the 1st automatic cycle.
4.6 Back pressure in manual pressure

Specific back pressure for plasticizing in manual mode, e.g. with open nozzle.

Injection unit
Back pressure in manual pressure

Back pressure output in manual mode
Note!
This program can be activated in the Variables Monitor, in the ’Plasticizing’variables list by
setting the variable Release separate back pressure in manual mode.
4.7 Torques during plasticizing

These values help in optimizing the plasticizing process. Any changes during a fixed set-up
production are related to melt temperature, batch variations and feed problems:
Torque
last current
Torque peak value
Torque mean value
Torque
Max. torque
173
Injection unit

Machine sequence and Mask Editor
1 Machine sequence
The machine sequence serves the graphic representation, change and creation of program
sequences. The representation of the sequence is possible in each mode of operation and in
each user level. For creating or changing a sequence you need the user level 7 or higher.
Moreover, the machine must be in the mode of operation Teach .
The machine sequence is divided into 3 sequences:

Closing sequence
Injection sequence
Opening sequence
Into these sequences you can program the different machine movements and instructions.
Machine sequence
Info Panel
Machine sequence 1
Instructions: 2
Mold 3
Nozzle
Retract ejector
Screw
20 mm
Ejector Mold - close
200,0 kN
Core moving platen Nozzle - build up contact force
All cores 23,5 kN
Freely programmable
Time
Wait until
4 5 6 7 8
Standard Times Program Edit View
[1] Sequence selection

Switchover between machine sequence, additional sequence and start sequence
[2] Selection window Instructions
This screen lists all the instructions you need to program your sequence. Select the
required instruction by clicking on it.
[3] Sequence window
Graphical display of the selected program sequence with short description. The window
can be scrolled horizontally and vertically.
[4] Standard menu key
This function supports loading of sample sequences. Not selectable in Teach mode.
[5] Menu key Times
Overview of available delay times.
175
[6] Menu key Program

Functions: Print sequence, save.
[7] Menu key Edit
Functions: Copy, Insert, Cut, Delete, Undo, Redo, Close sequences, Set pushbutton
sequence, Delete pushbutton sequence, Step mode, Delete messages.
These functions serve the programming of the sequence.
[8] Menu key View
Place, Coupling, Go to pointer, Step pointer, Text view, Grid, Grid size, Selection box,
Message box, Full screen.
By pressing a function you fade it in or out.

1.1 Representation of the machine sequence

The machine sequence represents the individual movements of the machine, step by step,
from the top down.
For a better overview, the sequence is subdivided into three sequences. These sequences
contain individual program steps.
Click the + Icon to the left of the sequence to open the sequence. This displays all the program
steps programmed for the sequence.
Example closing sequence
Retract ejector
20,0 mm
Mold - close
200,0 kN
23,5 kN
Next to the program steps is a short text which describes the step.
Example: Ejector retract

Ejector - chosen machine movement
Retract ejector retract - the ejector executes this movement

20 mm
20.0 mm - the ejector retracts to this position
You can fade the text in and out with the menu key View + display text.
Select a step by tapping the symbol. The selected step is now shown with a red border.
Retract ejector
20,0 mm
When you touch the symbol once again, a dialog window is displayed
177
Example dialog box Ejectors - Retract

Ejector
Movement retract
Ejector retracted position
Ejector position actual value

Attention - Already programmed
Cancel Help Execute
The dialog box is used to configure the selected step in the sequence.
Depending on the selected movement set and actual values may be available.
The set value in the dialog box is the same set value as shown on the screen for the current
movement.
The dialog box may also contain programming notes for the display e.g. Attention - already
programmed.
1.2 Sequence step functions

The machine sequence is processed step by step. The next step in the sequence does not
start until the previous step has been successfully completed.
In fully or semi-automatic mode, the control unit will display a green arrow to indicate the cur-
rent step if you have enabled the Step pointer . Steps that have been successfully completed
are marked with a green checkmark.
Step successfully com- Advance ejector

pleted 20,0 mm
Mold - close
Step currently active
500,0 kN
In a parallel closed branch, all movements must be completed before the next movement can
start.
All parallel steps com-

pleted.
Mold - close Core moving platen
500,0 kN move in
Next step starting. Nozzle - build up

contact force
In a parallel open branch, the next step in the main branch starts without waiting for the step in
the parallel open loop to complete.

Step in parallel open branch still active
Step in main branch com- Mold - close Air valve - blowing

pleted 500,0 kN 5,00 s
Step in main branch start- Nozzle - build up
ing contact force
Inactive steps are indicated by a red strike-through. These steps are ignored when the
sequence runs.
Step successfully com- Open mold

pleted 350,0 mm
Step inactive - will be Core moving platen
ignored. move out
Next step starting. Ejector - shaking
2 times
1.3 Standard sequence

Engel supplies the machine with predefined sequence templates. These sequences are
stored as parts data sets on harddisk0 . The parts data sets do not contain machine settings
but simply sequence data.
The icons in the data dialog show you which parts data sets contain sequence data and
machine settings, or simply sample sequences.
Parts data set icons in the data dialog

Parts data set with sequence and machine settings
Parts data set with sample sequence data (write-protected)
Depending on your machine configuration, various data sets with sequence templates may
exist.
179
For example, standard sequence: STANDARD_SEQUENCE
Retract ejector Open mold
Mold - close Ejector - shaking

1 times
Nozzle - build up con-
tact force
Screw
inject
Screw - plasticize
Nozzle - retract
1.4 Loading a sequence

The sequence is stored as a parts data element. When you load a parts data set, you load the
sequence at the same time.
You can use the Data dialog and the machine sequence to load the sequence separately.
However, you can only load sample sequences in the machine sequence.
Note!
Save the current parts data set before loading a sequence in order to save the changes you
made.
Procedure for loading a sequence in the data dialog:

1. Change to the screen page Data dialog.
Data dialog
Info Panel
Active parts data set: NOTSTANDARD+COREFIX
Data set attributes

NOTSTANDARD+COR Name STANDARD+COREFIX
STANDARD+CORE- System name STANDARD+COREFIX
Injection molding ma- Author User 9

Sequence data Production date
Machine settings Change author User 9
2. Press the + symbol for the data set you wish to load.
3. Touch the + Symbol in front of injection molding machine.
4. Select sequence data.

5. Press Parts data and Read.

6. If you have changed the current parts data set, a dialog window appears.
Changed data will be lost!
STANDARD+COREFIX
Cancel Help Execute
Cancel
Cancels the parts data reading
Execute
Starts the parts data reading. Changes you made which were not saved are lost
7. When the parts data reading starts, a window appears. When this window disappears,
the parts data reading is completed
Read
Process is running, please wait
Loading a sample sequence in the machine sequence:

1. Change to the ’Machine sequence’screen.
2. Select the ’Standard’ menu button.
3. The following dialog box appears.
Sequential sequence
Compression sequence
Cancel Display Help Execute
4. Select the required sequence.

Cancel
Cancels the parts data reading.
Display
Shows a preview of the sequence.
Execute
Loads the selected sequence into the machine sequence.
181
When you load a sequence with components unavailable on the machine, the following mes-
sage is displayed:
Movement not available
Effect Machine motor stops, no movement possible
Remedy Finish setting state.
A note appears on the machine sequence screen telling you which movement is not available.
Component not available: Mold swivelling device 1 does not exist
Component not available: Nozzle 2 does not exist
Component not available: Screw 2 does not exist
Times Program Edit View
If you press the blue arrow, the indicator will jump to the position in the sequence where the
missing movement is programmed.
These movements are tagged with a caution icon in the machine sequence.
Mold swivelling device 1 does not exist
1.5 Storing the sequence

If you change the sequence, you must save the change in order that the machine can calculate
the safeties. Only after saving machine movements are possible.
Save sequence - safeties not current
Effect All movements are blocked.
Remedy Save sequence.
There are two ways to save the sequence.
1. Saving by pressing the keys Program + Save

You save the sequence. The machine remains in mode of operation Teach.
2. Saving by exiting Teach mode.
By pressing the Manual program key Teach mode is exited. The following dialog window
is displayed.
Save machine sequence
Do you want to store the sequence change?
Cancel Help Undo Execute
Cancel
Cancels exiting Teach mode. The sequence is not saved.
Undo
Teach mode is exited. No sequence changes are saved.

Execute
Teach mode is exited, the changes to the sequences are saved.
When an incorrect setting is detected during the calculation of the safeties an error appears
and the following message is displayed:
Wrong setting in the sequence
Effect An incorrect setting is programmed into the sequence.
Remedy Eliminate the incorrect setting and save the sequence.
The machine sequence message window displays a note on the step in the sequence that is
causing the error. Press the blue arrow at the end of the message to jump to the position in the
sequence.
Movement as single movement not allowed: Mold closing 500.0 kN
Note!
The sequence is saved in the parts data. Therefore rewrite the parts data after saving the
sequence.
183
1.6 Programming a sequence

The machine sequence visualizes the program sequence, step by step, top down. To program
the machine sequence, you need to add instructions in the sequence editor.
The following conditions must be fulfilled in order to program a sequence.

User access authorization 7 or higher
Teach mode of operation
CAUTION!
Due to the freely programmable nature of the sequence editor, it is very

easy to make setting mistakes. Pay close attention to the settings
because incorrect settings can lead to equipment damage.
How to switch into Teach mode of operation

1. Finish any automatic cycle that is running.
2. Press the Manual program key
3. Press the Teach program key
When you switch to Teach mode, the machine sequence background switches from gray to
white.
The following message is displayed:
Editing mode active
Effect Movements with the pushbuttons like in setup mode. Writing and
reading of data sets is not possible

Example: Machine sequence in Teach mode of operation

Machine sequence
Info Panel
Machine sequence
Instructions
Mold
Nozzle
Retract ejector
Screw
20 mm
Ejector Mold - close
200,0 kN
Core moving platen
Core stationary platen 23,5 kN
All cores
Air valve
Purging into the screw
Venting
Freely programmable
Delivery chute
Vacuum equipment

Robot
Time
Wait until
Parallel closed branch
Parallel open branch
Times Program Edit View
You program the machine sequence by inserting or removing instructions from the sequences.
Thus you can adapt the machine sequence to your demands. Engel delivers the machine with
a standard sequence.
Note!
Write the parts data before programming a sequence in order to store the parameter changes
you made.
If you change the sequence, you must save the change in order that the machine can calculate
the safeties. Only after saving machine movements are possible.
185
Save sequence - safeties not current
Effect All movements are blocked.
Remedy Save sequence.
When an incorrect setting is detected during the calculation of the safeties an error appears
and the following message is displayed:
Wrong setting in the sequence
Effect An incorrect setting is programmed into the sequence.
Remedy Eliminate the incorrect setting and save the sequence.
The machine sequence message window displays a note on the step in the sequence that is
causing the error. Press the blue arrow at the end of the message to jump to the position in the
sequence.
Movement as single movement not allowed: Mold closing 500.0 kN
1.6.1 Instructions
Movement and structure instructions are available for programming the machine sequence.
The number of available instructions depends on the machine equipment. The most common
instructions are listed here.
Movement instructions
Symbol Name Function description
Mold Mold opening, closing, to position. If you select Mold

opening/closing to position , the position appears
on screen after saving the sequence.
Nozzle Nozzle build up contact force, advance without con-

tact pressure, retract, relieve contact pressure
Screw Injection or plasticizing
Ejector Advance, retract, shaking
Core moving platen Move in or move out cores on the moving mold fixing
platen

Core stationary Move in, move out cores on the stationary mold fixing
platen platen
All cores Stop all cores
Air valve
Freely programma- Activating and deactivating programmable inputs

ble in/outputs
Cooling time
structure instructions
Additional Starts the additional sequence.

sequence
Acknowledgement Wait for acknowledgement. The next step in the

sequence does not start until the start button is pressed.
Time Waits until the set time has expired, only afterwards the
sequence continues. 6 adjustable times are available
Wait until Wait for preset condition to be fulfilled.
Parallel closed Adds a parallel branch; this must also be processed

branch before starting with the next step in the sequence.
Parallel open Inserts a parallel branch, but does not wait for the end of
branch the parallel sequence.
1.6.2 Insert an instruction

For activating a function it is sometimes necessary to insert an instruction into the sequence.
Example:
Inserting the Air valve - blowing instruction after mold opening in the opening sequence
1. Select the air valve in the instructions dialog.
187
2. Click the position in the machine sequence where you wish to insert the air valve. In this
case Mold - opening.
Core stationary platen Opening sequence
All cores Open mold

350,0 mm
Air valve
Advance ejector
Time 65,0 mm
Retract ejector
Robot marker
20,0 mm
Wait until
Opening sequence
3. A dialog window is displayed. In this window you can set the necessary parameters for
the instruction.
Air valve
Number
Action Blowing
Blowing time
Blowng time actual value
Cancel Help Execute
4. Press Execute. You have now added the instruction to the machine sequence!
1.6.3 Changing an instruction

Changing the parameters of an instruction.
Example:
Change the blowing time of an air valve to 2 seconds.
1. In the machine sequence, double click the instruction you wish to modify. A dialog box
appears.
Air valve
Number
Action Blowing
Blowing time
Cancel Help Execute
2. In the dialog window you can change the parameters of the instruction. Change the
blowing time from 1 to 2s.
3. Press Execute. The changed parameters are taken over and the dialog window closes.

1.6.4 Removing an instruction

Remove one or several instructions from the machine sequence. You cannot remove
sequences.
Example:
Removing the Air valve - blowing instruction from the opening sequence.
1. Highlight the Air valve - blowing instruction in the machine sequence by tapping it. The
instruction is now outlined in red, and is thus selected.
Open mold
350,0 mm
Air valve - blowing
1s
Advance ejector
20,0 mm
Retract ejector
20,0 mm
2. Press the menu keys Edit and Remove. The instruction is now erased from the
machine sequence.
You can undo the removal by pressing the keys Edit + Undo.
1.6.5 Instruction Time

The instruction Time offers you the possibility to program freely defined delay times in the
sequence. You can program up to 6 different time values, but you can also program one time
value several times:
Time
Number
Action Start
Delay time
Delay time actual value
Activated
Cancel Help Execute
Press the Times menu key to display an overview of all programmable delay times.
189
Overview of delay times
Machine sequence
Info Panel
Machine sequence
Instructions Se- Times

Mold
1. Delay time (not used) Activated
Nozzle
Screw
Ejector
Core moving platen
Core stationary platen
All cores
Air valve
Purging into the screw
Venting
Freely programmable
Delivery chute
Vacuum equipment
Robot
Time
Wait until
Parallel closed branch
Sequence Program Edit View
Press the Sequence menu key to go back to the full-screen view of the sequence.
used
This delay time is programmed in the sequence.
not used
This delay time is not programmed in the sequence.
Activated
To make a time programmed in a sequence effective, you need to activate it. If a delay
time is programmed in a sequence but not active, the delay time is skipped.
1.6.6 Inserting a parallel closed branch

The program sequence lets you perform specific functions in parallel. For hydraulic machine
functions, the machine must first be fitted with a corresponding hydraulics system.
You can program a parallel closed branch only within a sequence.
All functions must be completed in parallel closed branches to allow the next step in the
machine sequence to start.

Example:
Core moving platen1 needs to move in parallel to mold closing
1. Start by selecting the step in the machine sequence that parallel movements will be per-
formed with.
2. Select the Parallel closed branch instruction in the instruction dialog.
Core stationary platen Mold - close

200,0 kN
All cores Nozzle - build up contact
force
Air valve
Closing sequence
Time
Robot marker Injection sequence
Wait until Opening sequence

Parallel closed
3. To insert, click to the side of the selected instruction in the machine sequence.
4. Select the Core moving platen instruction in the instruction dialog.
5. Touch at the desired point in the parallel closed branch in order to insert the instruction.
Core moving
Core stationary platen Mold - close

200,0 kN
All cores
Air valve
6. A dialog box for the required settings appears.

Core moving platen
Number 6
Movement move in 6
Cancel Help Execute 7
7. Press Execute.
8. You have now programmed Move in core parallel to mold close. To activate the
sequence, save the program and enable the core on the screen.
Mold - close Core moving platen

200,0 kN move in
191
1.6.7 Inserting a parallel open branch

Using the parallel open branch you can now program a parallel movement.
In contrast to a ’Parallel closed branch’ , the movement in the ’Parallel open branch’ does not
need to be completed in order to start the next step in the machine sequence.
Example:
Air valve - blowing parallel to mold opening, blowing time 1s.
1. Select the Parallel open branch instruction in the instruction dialog.

2. To insert, click on the machine sequence in front of the mold opening instruction.
3. Select the instruction Air valve in the window.
4. Touch at the parallel open branch in order to insert the instruction Air valve there.
All cores
Air valve Open mold

350,0 mm
5. A dialog box for the required settings appears.

Air valve
Action Blowing 6
Blowing time 6
Cancel Help Execute 7
6. Press Execute.
7. You have now programmed the air valve parallel to mold close. To activate the
sequence, save the program and enable the air valve on the screen.
Open mold Air valve - blowing

300,0 mm 1,0 s
Ejector - shaking
2 times
1.6.8 Instruction Wait until

This instruction means that the next step in the machine sequence will not start until the con-
figurable condition is fulfilled.
Example:
We want the air valve to start at a pre-configurable mold position (80 mm) parallel to mold
open.
1. Select the Wait until instruction in the instruction dialog.

2. In the sequence press the line above the air valve to add the Wait until command.
Robot marker
Open mold Air valve - blowing
Wait until
300,0 mm 1,0 s
Parallel closed Ejector - shaking
2 times
3. A dialog window is displayed in which you make the settings for the instruction:
Wait until
Equipment Mold
Movement opened to position 1
Opening position 1
Cancel Help Execute
4. Press Execute in order to insert the instruction.
Open mold Wait until: Mold opened to position 1

300,0 mm 80,0 mm
Ejector - shaking Air valve - blowing
2 times 1,0 s
The air valve will not start until the mold has reached opening position 1. You can also set the
position in the Mold open screen after saving the sequence.
1.6.9 Parallel open branch with safety-critical movements for the mold
Safety-critical movements for the mold are e.g.: Ejector, cores, mold. Movements programmed
in a parallel open branch can take longer than the sequence in which they started.
Safety-critical movements for the mold in a parallel open branch must be queried using a ’Wait
until’ command in an additional sequence in the left main branch.
Example:
In the parallel open loop, Move-out core is programmed at injection as a safety-critical move-
ment.
193
Screw Wait until: Screw - Injection position 1

inject 40 cm³
Screw - plasticize Core moving platen
78,5 cm³ move out
Nozzle - retract 50 mm
The core must be moved out when the ejector is moved at the latest.
1. Select the Wait until instruction in the instruction dialog.
2. In the machine sequence click on the line above Shake ejector instruction to insert the
instruction at this position.
Wait until
Parallel closed branch Open mold

300 mm
Ejector - shaking
1 times
3. A dialog box appears. You can use the window to enter settings for the Wait until com-
mand. Select the last safety-critical movement in the parallel open branch (core 2)
Wait until
Equipment Core moving platen
Number
Movement moved in up to end position
Cancel Help Execute
4. Press Execute in order to insert the instruction.
Note!
If you do not use ’Wait until’ to query a parallel open branch with a safety-critical movement, a
message appears in the message window, and you cannot save the sequence

1.6.10 Sequence instructions for Euromap 12/67 interface

The injection molding machine transfers release and blocking signals to the robot via these
instructions.
Movement instruction
Robot start Robot start release, used for specific starting of robot,
e. g. to move cores beforehand, to turn the mold swiv-
elling device, etc.
Robot signal mold Enables multiple closings in clamping unit; necessary

closed for venting, compression
Robot
Action Signal Mold closed
Activated
Cancel Help Execute
Action
Selection of movement instruction to be added to machine sequence.
Activated
Activates/deactivates the selected action in the machine sequence.
Example:
Start robot after mold swivelling.
Open mold
350,0 mm
Mold swivelling device - swivel
2 Stations
Robot
Start
Advance ejector
80,0 mm
Retract ejector
0,0 mm
195
Example:
Venting with instruction robot signal mold closed.
Screw Wait for: Screw 1 - Venting start po-

inject sition 5.0 cm³
Venting - venting sequence
1 times
Robot
Signal Mold closed
Screw - plasticize
120,0 cm³
Nozzle - retract
20,0 cm³
1.7 Start-up cycle

It is possible to program a start-up cycle that should only be active during the first automatic
cycle.
Example:
Start-up cycle with core movement.
1. Select ’Start sequence’ in Combo-Box.

2. Programming the required instructions.
Machine sequence
Info Panel
Start sequence
Instructions:
Mold
Nozzle
Core stationary platen
Screw
move in
Ejector Core stationary platen
move out
Core moving plat-
Core stationary

3. Insert ’Start sequence Start’ instruction in the machine sequence.
Machine sequence
Info Panel
Machine sequence
Instructions:
Mold
Nozzle
Start sequence
Screw Start
Ejector Retract ejector
3,0 mm
Core moving plat- Mold - close
Core stationary 100,0 kN
All cores
Nozzle contact Nozzle contact
Air valve
15,0 kN 10,0 kN
Electric safety
Purging into the
Venting
Shut-off nozzle
Start sequence
Freely program-
1.8 Step operation

Step mode allows the complete machine sequence to be executed step by step with the start
button. This is particularly helpful during mold start-up as the machine can be monitored step
by step. Another advantage is the simple operation with just one pushbutton (the start button).
To activate/deactivate the step mode, select the menu buttons ’Edit’ and ’Step mode’in the
machine sequence.
When step mode is activated, the program buttons for setup and manual change to the follow-
ing displays:
Note!
Step mode is only possible in the operating modes Setup and Manual.
197
Example of step mode display
Retract ejector
20 mm
Mold - close
200,0 kN
23,5 kN
51,0 kN
Procedure:
1. Switch to the operating mode Setup or Manual.
2. Activate the step mode with the menu buttons ’Edit’ and ’Step mode’in the machine
sequence.
3. When pressing the start button, the waiting step pointer appears at the first
sequence instruction.
4. Press and hold the start button again until the sequence instruction (movement) is com-
pletely executed (green checkmark next to the instruction). When the start button is
released, the waiting step pointer moves to the next sequence instruction.
Step mode activated
Effect No automatic operation, no cycle start,

Stepwise processing of sequence only possible with start key.
1.9 Pushbutton sequence

The pushbutton sequence allows you to mark sequence instructions or entire sequences in
the machine sequence and to execute these with a separate pushbutton.
This allows you to set up a partial sequence for test purposes without changing the machine
sequence.
Pushbutton:
Pushbutton sequence
To set up a pushbutton sequence, mark the required sequence instructions and assign a push-
button sequence symbol to them using the menu buttons ’Edit’ and ’Set pushbutton
sequence’.
Remove unwanted pushbutton sequence symbols using the menu buttons ’Edit’ and ’Delete
pushbutton sequence’.
The pushbutton sequence symbols have no effect in automatic mode and therefore do not
have to be removed from the sequence.

Example of a pushbutton sequence
Retract ejector
20 mm
Mold - close
200,0 kN
Core moving platen
move in
51,0 kN
Core moving platen

move out
Open mold Air valve - Blow

350,0 mm 2,00 s
Advance ejector
80,0 mm
Retract ejector
3,0 mm
Activate pushbutton sequence

1. Assign ’Pushbutton sequence’to a configurable button.
2. Change to the operating mode ’Manual’.
3. Press and hold the ’Pushbutton sequence’. The pushbutton sequence will then run with-
out interruption.
The instructions that are not used are displayed in gray shading.
Pushbutton sequence activated
Effect No automatic operation, no cycle start
Note!
If the pushbutton sequence does not include safety-relevant movements, the machine will
interrupt the sequence. This is displayed on the alarm page.
The pushbutton sequence symbols have no effect in automatic mode and therefore do not
have to be removed from the sequence.
If you want to run through the pushbutton sequence step by step, you also need to activate the
step mode.
199
2 Screen page editor

The screen page editor enables screen pages to be created and edited.
You can also change standard screen pages. However you can only add screen lines and vari-
ables or erase added screen lines and variables.
How to start the screen page editor:

1. Change to the screen page which you want to edit.
2. Press the screen page selection key Screen page editor.
3. The following dialog window appears.

What do you want to do?
Create new screen
Create new screen page in machine data set

Delete this screen
Edit this screen page
Cancel Help Execute
Create new screen

Opens the mask editor to create a new screen page. The control unit stores the
screen page in the parts data set when the page is ’Quit’.
Create new screen page in machine data set
Opens the mask editor to create a new screen page. The control unit stores the
screen page in the machine data set when the page is ’Quit’.
Delete this screen
To delete the displayed page. You can only delete user-defined screen pages.
Edit this screen page
Opens the screen page editor for editing the screen page to which you have
changed. Only the addition of lines and variables is possible on standard screen
pages.
4. Select the required action and press Execute. If you have selected Create new screen
page, Create new screen page in machine data set or Edit this screen page , the
mask editor will start.

Screen page
Info Panel
2 3
Screen page 1 Properties View
Strips 1
Properties
Actual value
Name Screen page
Set value
flag Quick call-up key
Comment Screen authorization
Strips 2 Symbol
Set value Parts data set
Memory place
New Edit Finish View 4
[1] Structured view of the current screen page

[2] Properties
Shows the parameters of the selected element in the Structure view.
[3] View
Preview window of the selected screen page.
[4] Menu keys
New with instructions for adding strips, variables and comments.
Edit with instructions for editing a screen page.
Finish closes the screen configuration.
View with the commands: Selection window on/off, Message window on/off and
Maximize/Minimize.
201
2.1 Components of screen pages

The structure of a screen page is built up as follows:
Screen page
Screen page
Properties View
Strips 1
Strips 1
Actual value
Actual value
Set value
Set value
flag
flag
flag flag
Comment Comment
Strips 2 Strips 2
Set value Set value
A Screen page consists of one or several strips.

In the strips you can insert variables . There are several variants of variables. For example:
Actual value, set value, markers, switches, etc.
2.2 Edit screen pages

You can adapt the screen page Freely composeable page to your requirements.
How to edit a screen page:

1. Change to the screen page which you want to edit. In this case to the Freely compose-
able page.
2. Press the key Screen page editor.
3. In the dialog window choose Edit this screen page and press Execute.
4. The screen page editor starts. In the screen page editor you change the settings for this
screen page
Composeable page
Info Panel
Composeable page Properties View

User
Properties
Name Composeable page
Quick call-up key
Screen authorization
Symbol
Memory place Parts data set
Name
Designation of screen page. This name is displayed in the header.System.

Quick call-up key

Assign a position to the quick call-up key of the new page. You can choose between
machine and robot quick access. You can assign the quick call-up key only to a posi-
tion which is marked with unoccupied.
Screen authorization
Set the user level from which the new screen page can be edited.
Symbol
Select a symbol for the quick call-up key of the screen page.
Memory place
Storage location of screen page
2.3 Paste of existing strips

You can insert strips from existing screen pages into another screen page.
Inserting an existing strip:

1. Press the menu key New and Strips from screen.
2. A dialog window appears with a selection of the screen pages.
Select screen
Shut-off nozzles
Conveyor-belt
Delivery chute
Screen page
Mold close
Closing profile

Clamp force

Vacuum program
Cancel Help Execute
3. Choose the requested strip. In this case the line Clamp force of the screen page Mold
close.
4. Press Execute.
Now you have inserted the strip into your screen page.
2.4 Paste new strips

Besides the existing strips you can also insert new user-defined strips into the screen page.
Inserting a new strip:

1. Press the menu key New and Strips.
2. A new strip has been inserted into the screen page.
203
3. Name the strip according to your requirements at Name.
Screen page Properties View

Strips 1 2
Properties
Name Strips 1 3
Actual value right
Actual value cen-
2.5 Paste variables from other screen pages

You can insert variables into your screen page which are in use on other screen pages.
How to insert variables from other screen pages into your screen page.
1. Choose the strip into which you want to insert the variable.
2. Press the menu key New and Variable from screen.
3. A dialog window appears in which you can select the requested variable.
Select screen
Screen page
Mold close
Closing profile
Opening stroke
open
Mold close position
closed without clamping force
Clamp force
Cancel Help Execute
4. Choose the requested variable.

5. Press Execute.
Now you have inserted a variable from an existing screen page into your screen page.
2.6 Paste variables from a list

You can insert variables from a defined list into your screen page.
How to insert variables from other screen pages into your screen page.
1. Choose the strip into which you want to insert the variable.
2. Press the New and Variable from listbuttons.

3. A dialog window appears in which you can select the requested variable.
Choose variables
Machine list
SafetyGateNozzle1
SGConfirmation2
ShotCounter
sv_AlarmClmpForceLow
sv_BDEParam
Cycle time actual value
Cycle time set value

Remaining production time
Cycle time deviation
Shot weight total

sv_Fuld
Show variables text
Cancel Help Execute
4. Choose the requested variable.

5. Press Execute.
Now you have inserted a variable from a list into your mask.
2.7 Search variable

The function Search variable gives you the ability to search for a variable in the variable list,
and to insert the variable into the mask.
Search variable
Search criteri- Search result
Search for
Restrict to
System name
Long text
Short text
Unit
Delete parameters
Cancel Help Search
Search for
205
To search for a variable, you need to enter known parameters for the variable. The more
parameters you know and enter, the more exact the search results will be.
Restrict to
Select a variable group to restrict the search to this group
System name
Variable name in the software e.g. Mold1.sv_rMldOpenPos
Long text
Clear text for variable e.g. Opening stroke
Short text
Additional information e.g. swa
Unit
Unit for variable e.g. mm, bar, s, etc. (in, psi, s, etc.)
Press Delete parameters to delete your input.
After entering the parameters, press Search to start searching

The view switches to the Search results tab.
Search variable
Search criterion Search result
Opening stroke
Opening stroke
2 Elements found
Search finished
Robot Help Execute
Depending on the search parameters you set, a number of elements may be found.
Select the required variable and press Execute to insert the variable into the mask.
2.8 Paste a comment

Comments give you the possibility to insert a freely defineable text line into the screen page.
Inserting a comment:
1. Choose the stripe into which you want to insert the comment.
2. Press the menu key New and Comment.
3. You have inserted the comment in the line.
4. Enter the requested text into the line Comment.
3 Machine setup
Machine setup gives you the ability to rename machine components, such as cores, air valves
and ejectors, as well as delay times and sequence positions, to match your requirements.

Machine setup screen
Machine setup
+ Equipment Element Attributes - movement

Core stationary platen 1 Name move in
Core stationary platen 2 User-defined name Screwing
Core moving platen 1 Element Attributes - Wait until

move in moved in up to end position
Name
move out Screwing completed
User-defined name
shaking
Air valve 1
Air valve 2
Ejector
Sprue ejector
Screw
Positions
Times
Text Edit View
Element attributes
For each component you can change both the name of the component, and the names of
movements, positions or times.
Function unit
Name for machine components e.g. core moving platen 1
This is displayed on screen
Movement
Designation of a movement in the machine sequence e.g. move in
Wait until
Designation for a wait until instruction in the machine sequence, e.g. move in until end
position
Position
Designation for sequence position, e.g. closing position 1
Time
Designation of a time in the machine sequence e.g. time 1
207
To change a designation, enter the required designation in the User-defined name field for
the Element Attributein question.
You can use the Text menu key to Display user texts and Delete user tests.

Production programs
Production programs
1 Cycle time analysis

This overview shows the individual time components of the complete cycle time of the func-
tions. It helps in the optimization of the cycle time by time-optimizing the individual functions.
Cycle time analysis
Info Panel
Cycle time analysis
last current
Mold close
Nozzle
Inject
Holding pressure
Cooling time
Plasticizing
Mold opening
Ejector
Cores
Part removal
Total time
View
1 2 3 4
[1] Scroll window to the left
[2] Set to full cycle time
[3] Magnify and minimize
[4] Scroll window to the right
The current and the last cycle are displayed separately in seconds, and on two-line bar graph-
ics. The top bar shows the current cycle, the lower bar the last one. Dark points on the bars
indicate force/pressure build-up and reduction as well as movement direction changes.
Screen flags mark the function that is currently active.
209
Production programs
Separate display of the total time.

Adjustable times for a zoom section and keys for making changes.
Start time display

Instead of the movement duration, the Start time display measures the time from the start of
the injection cycle to the start of the movement in question.
After startup, the text Start times is located above the bar graph under menu key View.
2 Week timer
The week timer function is used to switch the plant on and off at freely selectable times within
a week.
Week timer
Info Panel
+ Activate weekly schedule

Switch off weekly schedule manually
Switch on weekly schedule manually
Selection options Switching Delay times
Automatically via switch timer

Devices Status Main switch
switch on switch off
Motor
Barrel heating 1 to reduction tem- switch off
Mold heating 1 to reduction tem- switch off
Mold heating 2 to reduction tem- switch off
Device 1
Temperature con-
Zone 1 do not switch on do not switch off
Activate weekly schedule

You must enable this selection box to allow the week timer to switch on and off at the
required times.
For the premature switching-off of the machine check off this selection field.
For the premature switching-on of the machine check off this selection field.
Motor
Switch off automatically via switch timer
The week timer automatically switches the machine motor off at the defined switch-
ing times.
Switch on automatically via switch timer
The week timer automatically switches the machine motor on at the defined switch-
ing times.
Attention: automatic motor start by week timer
Condition No emergency stop, safety gates closed.

Production programs
WARNING!
Danger due to motor start!

The week timer can automatically switch the machine motor on when
the program is activated.
Switch off and secure the main switch before commencing maintenance
and repair work.
Barrel heating (mold heating,temperature control device)
You can select various variants for switching on and off per heating group.
switch on
do not switch on: The heating remains switched off.
to reduced temperature: The heating switches on, but heats only to the set
reduced temperature.
Switch to operating temperature by actuating the program interruption key.
to operating temperature: The heating switches on and heats to the set value.
switch off
do not switch off: The heating remains switched on.
to lowering temperature: The heaters reduce to the lowering temperature, but
remain switched on. The switch on the heating screen page activates automatically.
switch off: The heating switches off completely.
Device 1
When the main switch is switched off, the device always remains switched off.
If the week timer switches a device off, you can reactivate it by switching the main switch
off and on.
211
Production programs
Schedule programming
Week timer
Info Panel

Week timer
Day
Switch-on time Switch-off time
Monday
Tuesday
Wednesday
Thursday
Friday
Saturday
Sunday
A switch-on and switch-off time can be set for each day. The timer is inactive when set to
00:00.
Delay times
Week timer
Info Panel

Switch-on delay Switch-off delay Unit

Devices Status
Set Act Set Act
Motor min
Barrel heating 1 min
Mold heating 1 min
Mold heating 2 min
Device 1 min
Temperature control de-
Zone 1 min
Zone 2 min
A separate switch on/off delay time with actual value display is available for each device and
each temperature control device zone. The delay times become active each time the switch
time switches on/off. This makes it possible to set any switching on/off sequence.
Procedure for activating the week timer

1. Select the devices that you want to switch on or off using the week timer.
2. Program the switching-on and switching-off moments for the individual weekdays.
3. If desired, program the switch-on and switch-off delay times. These times are listed in
minutes.

Production programs
4. Activate the weekly time switch by checking off the selection field Activate weekly time
switch.
If the week timer switches off, the machine continues the current cycle to the end (plasticizing
as per settings in production program ’Plasticize after production end’).
The individual devices then switch off after the respective delay times elapse and the following
message appears:
Weekly timer has switched off
Effect Heating and temperature control units reduce the temperature as a

function of the reduction value or switch off. The set delay times
remain in effect. The turn-on functions via the timer remain active.
Note!
In order that the heatings heat up to the set value after the switching-on, you must acknowl-
edge after the switching-on with the key Program interruption .
213
Production programs
3 Monitoring systems for the injection molding process

Clear display of all process monitoring systems so that they can be switched on/off and set
together.
Monitorings
Info Panel
+ Monitorings
Activation
Switch the monitoring systems back on
Switch off all monitoring systems
Injection time monitoring

Minimum injection time Max. injection time
Cushion monitoring
Minimum cushion Maximum cushion
Plasticizing time monitoring

Minimum plasticizing time Maximum plasticizing time
Plasticizing time most recent cycle
Cycle monitoring time
Max. cycle monitoring time
Cycle time until start button

Autoprotect injection
Ideal curve evaluation active
Micrograph
Activation
Switch for switching on/off all monitoring systems.
Monitorings
[See Injection time monitoring on page 157.]
[See Cushion monitoring on page 166.]
[See Plasticizing time monitoring on page 171.]
[See Autoprotect (option) on page 82.]
[See Micrograph monitoring on page 256.]
Cycle monitoring time

After optimizing the injection molding process, the cycle monitoring time serves to safeguard
fully automatic production. The control unit always stores the previous cycle time at the end of
the mold pause time.
To activate this, set the Max. cycle monitoring time to a slightly longer value than the Last
cycle time and switch on monitoring.
In case of an error, the following message appears:

Production programs
Cycle time overrun and delayed motor stop
Effect The machine stops cycling immediately and switches into ’MANUAL’
mode. A delayed motor stop and delayed switch to standby heats is
initiated, the alarm lamp flashes.
Remedy Check at which movement the machine stopped. You can refer to the
alarm screen to determine which error caused the malfunction. You
should also check the waiting points. Then move the machine to the
start position.
215
Production programs
4 Production
Production data is displayed on a dedicated screen page.
Production
Info Panel
Production Start-up cycles Rejects in suc- Batch size Multicolor
Production counter
Piece counter Shot counter
Number of cavities pcs
Production set value pcs shts
Production good parts pcs shts
Production total pcs shts
Stop production with reached Production good parts
Plasticize after production end
Reject - startup cycles pcs shts
Production rejects pcs shts
Total rejects pcs shts
Good parts Rejects rate
Production counter
Number of cavities
The piece counters always count with the set cavity number.
Production set value
After the desired production amount is input, the corresponding shot and piece counters
count in the automatic cycle.
Production good parts
Counter for good parts
Production total
Production good parts + rejects total
Stop production with reached
Selection option whether production should be stopped when the production set value
is equal to ’Production good parts’ or ’Production total’ .
Plasticize after production end
If switched on, the machine plasticizes again at end of production or production stop.
Reject - startup cycles
Rejects counter for set start-up cycles at start of production or when the cycle is inter-
rupted.
Production rejects
Rejects during production occur when monitoring systems are triggered, such as the
injection cycle, Micrograph, quality programs, mold temperature.
Total rejects
Start-up cycles rejects + production rejects

Production programs
Good parts
A green pie diagram shows the ratio of good parts produced to the set good parts pro-
duction.
Rejects rate
A red pie diagram shows the reject rate related to actual total production.
Message when the piece counter for good parts or the total rejects counter elapses:
Shot counter expired, or Parts counter expired
Effect The alarm lamp flashes, the cycle finishes, a delayed motor stop and
heat reduction to standby is initiated.
Remedy To continue production, use the [R] key to reset the actual shot or
piece value back to 0.
Calculation of remaining production time

Calculation of remaining production time
Cycle time actual value
Cycle time deviation

Input for calculating the cycle time deviation from the cycle time actual value and the
remaining production time.
Calculation with the remaining number of pieces and the cycle time set value.
Material demand calculation

Material demand calculation
Shot weight
Remaining material requirement
Shot weight
Input for calculating the remaining material requirement.
Remaining material requirement
Display of the remaining material requirement for the remaining number of pieces.
When inputting the available amount of material, the set piece value can be calculated.
217
Production programs
4.1 Start-up cycles

Two adjustable counters permit automatic rejects sorting at the start of production or the start
of an automatic cycle with adjustable mold safety.
Production
Info Panel
Production Start-up cycles Rejects in suc- Batch size
Start-up settings
Start-up cycles set value shts
Start-up cycles actual value shts
Start-up cycles after automatic interruption of at least

Post injection pressure in percent of production parameters
Start-up cycles with own switchover volume - set value shts
Start-up cycles with own switchover volume - actual value shts

Switchover volume actual value
Start-up settings
Start-up cycles set value
Adjustable total amount of start-up cycles with rejects sorting and post injection pres-
sure in percent of production parameter.
Start-up cycles actual value
Display of the start-up cycles with the reset key
Start-up cycles after automatic interruption of at least
The machine starts again with the start-up cycles after an interruption to the cycle that
lasts longer than the preset time .
Start-up cycles with own switchover volume - set value
Adjustable number of parts of the start-up cycles set value with a separate Start-up
cycles switchover volume.
Additional start-up settings (option)

Injection pressure limit in percent of production parameters
Back pressure in percent of production parameters
In manual mode with run-in parameters
Switch for activating the start-up parameters in manual mode.
During the start-up cycles the following message is displayed:

Production programs
Start-up phase active
Cause Production is currently in the start-up phase with the set start-up
cycles.
Effect The minimum plasticizing and injection time monitoring, as well as

the Microplast, Microflow and Micrograph monitors, are not active.
Rejects is active.
Remedy Automatically after the completion of the start-up cycles.
If the start-up cycles are set with their own switchover volume, a switchover volume must be
set; otherwise, the following message appears:
Adjust moving-in switchover point
Effect Automatic cycle start not possible. Alarm lamp lit.
Remedy Set the start-up cycle switchover volume to a volume that just about
fills the mold.
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Production programs
4.2 Rejects in succession

Rejects during production occur when monitoring systems are triggered, such as the injection
cycle, Micrograph, quality programs, mold temperature.
A reject signal serves to sort manufactured parts with a follow-on unit (robot, delivery flap,
conveyor-belt), or stop production after a number of reject moldings.
Production
Info Panel
Production Start-up cycles Rejects in suc- Batch size
Rejects
Rejects signal
Maximum rejects per time shts
Actual rejects shts
Time period for rejects min
Maximum rejects in succession shts

Actual rejects in succession shts
Action for sequence max. rejects/max. rejects in succession Production stop
Good part production possible from operation mode Fully automatic
Rejects
2 rejects counters are available to control production, they can be activated by a set value set-
ting larger than 0.
Maximum rejects per time
Resetting the rejects counter actual value after Time period for rejectshas elapsed.
Max. rejects sequence
Adjustable rejects directly in succession. Automatic reset for good part production.
Action for sequence max. rejects/max. rejects in succession
Optional actions Warning or Production stop when reject counter elapses.
The message rejects counter lapsed or maximum rejects in succession:
Rejects counter expired
Effect Depending on the action you selected warning only or production

stop
Remedy Determining the cause of rejects with the help of additional alarm
messages.
Switch the program interruption key on/off.
Good part production possible from operation mode

Option to enable good part production in semi-automatic or only in fully automatic
mode. If you select fully automatic , the control unit will assume all moldings in semi-
automatic mode to be rejects.

Production programs
5 Mold parameters
This screen is used to save mold-specific information.
You can use the screen editor to add strips and variables, e.g. for additional units to this
screen.
Mold parameters
Info Panel
+ Mold data
Mold number Recorder housing
Molded part number
Material number
Machine number
Order number Order number
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Production programs
6 Data dialog
The data dialog box is used to save and load data sets on the machine or on external storage
media (Compact Flash, USB stick, network).
The screen page appears after switching on the control unit and/or after pressing the screen
page selection key.
Data dialog
Info Panel
\harddisk 0 1 Active parts data set: Standard sequence 2
\harddisk 0 3 Data set attributes 4

STANDARD+CORE- Name SIDE_WALL_01
STANDARD INJ.RED. Author
STANDARD_PARALL Production date
STANDARD_SEQUEN Change author
Change date
Description
Machine number
Mold image
6
Parts data Edit Setup View 7
[1] Selecting a medium

Press the down arrow key to access all possible drive selections.
hard disk0 System Flash card
usbmassstorage plugged-in USB stick
harddisknet Network drive connection
[2] Status information

Displays status (symbol) and the name of the active set (selection key to display the
attributes and the mold image).
[3] Dialog box with settings data sets (project selection)
Touch the required selection to display the data attributes on the right side of the screen.

Production programs
[4] Data set attributes

Shows all data in the selection window of the selected project. Can be modified depend-
ing on user privileges.
Name Selectable project file name = file name in selection list
Author Name of the creator
Production date
Change date, author Date and name of the user making the latest changes.
Description user defined descriptive text
[5] Mold image

The image that was saved along with the parts data set is displayed here. Using instruc-
tion menu buttons Edit and Mold image , you can load an image with the format *.jpg
or *.png and then save it along with the parts data set.
[6] Message window shows dialogs for completed actions, error messages, information
and so on. Can be hidden and displayed in the Viewmenu. Appears when an action is
being carried out.
[7] Instruction menu keys
Parts data using the instructions: Sequence preview, Read, Write, Copy, Copy all,
Delete and Injection protocol.
Edit using the instructions Delete message and Load mold image.
Setup using the instructions: Export user data, Import user data, System flashcard,
Software update, License update, Read machine data, Write machine data and Dis-
play active machine data.
View with the instructiions: Selection window on/off, message window on/off, maxi-
mizing/minimizing.
6.1 Storage media

The following USB devices have been tested by Engel - their functioning is thus ensured.
Device Manufacturer Type
floppy drive Mitsumi D353GUE
Memory stick SanDisk Cruzer Mini USB 2.0 256 MB,

Cruzer Micro USB 2.0 512 MB,
Cruzer crossfire 1 GB, 2 GB
Memory stick Memory Corp Memory Corp MC512USB9
Memory stick PNY Technologies PNY USB 2.0 Flash Drive 1 GB
Memory stick E.T. Technologies HUSSAR E.T. Technologies
Memory stick Xmore Xmore USB Stick 2 GB

Xmore USB Stick 4 GB
Note!
Problems may occur if you use other USB devices that have not been tested.
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Production programs
If you select a data carrier with insufficient free storage space, the program will cancel the save
operation and display a message. The message shows which data carrier is full, along with the
last file that was completely stored on the data carrier.
Flash card full X
Effect Cancelling save to data carrier.
Remedy Select a data carrier with more free space and try to save again.

Production programs
6.2 Sequence preview

When you save a parts data set, a sequence preview of the machine sequence is automati-
cally created. This is useful to check the sequence settings before loading a parts data set.
Example:
Procedure for opening a sequence preview.
1. Select parts data and then injection molding machine.
Parts data
Injection molding ma-
2. Press the instruction menu key parts data and sequence preview.
3. A window with the sequence preview appears:
Sequence preview
Retract ejector
20,0 mm
Mold closing up to position 1
200,0 mm
Move in core stationary platen
Mold - close
0,0 kN
20,0 kN
Screw injection
Screw - plasticize
Help OK
4. Press OK to close the window.
Note!
The sequence preview is stored as a parts data element. To make sure the preview is up to
date, always save your parts data after changing the machine sequence.
A preview of the robot sequence is not possible.
If a preview is not available for a parts data set, the following message is displayed:
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Production programs
Sequence preview
Preview could not be loaded!
OK
6.3 Read data set

A parts data set consists of the sequence and setting data of machine and robot. You can eit-
her read in the whole parts data set or only certain data. When you only read in a certain part
of the parts data, only these change. The other data are preserved.
Parts data
Injection molding ma-
Sequence data
Machine settings
Robot
Sequence data
Machine settings
Sequence data
In the sequence data only the machine or robot sequence is stored. When you only read in the
sequence data, only the sequence changes. Parameters such as speeds, pressures, posi-
tions,... do not change.
Machine settings
In the setting data all parameters such as speeds, pressures, positions,... are stored. When
you only read in the setting data, only these parameters change. The sequence does not
change.
Example:
Procedure when loading an existing parts data set from a data carrier.
1. Switch the machine to manual mode.

2. Select the storage medium. usbmassstorage.0.0.0\ is a USB memory stick,
harddisk0\ is the control unit's internal memory.
3. Select the setting data set from the list.
Display of the information in the window Data set attributes
4. Press ’Parts data’ and ’Read’.
A window with a clock is displayed. The control unit loads the chosen parts data set and
overwrites the current machine setting. The manual control keys of the machine are not
active during loading.
If the read values cannot be set (plausible), the following message appears:

Production programs
Values corrected
Effect Message only
Remedy On the Plausibility check screen page, open the window corrected
values and check which parameters have been corrected. [See
Plausibility check on page 233.]
Acknowledge the message in this window.
Note!
If you read a parts data set from another plant, the following message is displayed:
EMOTION_TEST
The data set has not been created with this machine
Continue anyway?
Cancel Help Execute
6.4 Write a parts data set
Example:
Procedure for saving an active parts data set on a storage medium.
1. Select the active parts data set with the key at the top right of the screen.
2. Enter name and information in the Data set attributes window.
3. Select the storage medium. usbmassstorage.0.0.0\ is a USB memory stick,
harddisk0\ is the control unit's internal memory.
4. Press ’Parts data’ and ’Write’.
The following window is displayed
Write active parts data on
Available drives
Name Parts data
Description
Free memory C:\5632
Required memory C:\231
Cancel Help Write
5. Change the set attributes, when necessary, and confirm with Write.
The control unit stores the parts data set on the selected drive.
6. If a data set with the same name already exists on the data carrier, the dialog window
’Overwrite ??’is displayed. If YES, press Execute.
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Production programs
6.5 Copy parts data set

Procedure when copying a parts data set to another data carrier.
1. Select the storage medium (usbmassstorage.0.0.0\ is a USB memory stick).
2. Press to select a Settings data set from the list.
3. Press the ’Parts data’ and ’Copy’menu key.
A window is displayed, with drive option, name proposal and description.
Copy chosen parts data on
Available drives
Name Copy 1 of training 4
Parts data set for training

Description
Free memory C:\5632
Cancel Help Copy
4. Choose a drive and enter requested changes.

5. Press Copy.
6.6 Copying all parts data sets

Procedure for copying all data sets on a storage medium to another storage medium
1. Press the ’Parts data’ and ’Copy all’menu buttons The following dialog box appears.
Copy all data sets
Source drive hard disk0
Aim drive usbmassstorage.0.0.0
Cancel Help Execute
2. Select the Source drive and the Aim drive to which you will be copying the data sets.
3. Press Execute to start the copying process.
4. The dialog box disappears once the copying process has been completed.
If you attempt to copy a data set from the source drive that has the same name as an existing
data set on the aim drive, the following message appears:
Overwrite?
.Standard sequence
Cancel Help Execute
Cancel
This data set will not be copied to the aim drive. Continuing copying other data sets.
Execute
The data set on the aim drive will be overwritten by the data set on the source disk.

Production programs
6.7 Delete data set

Procedure when deleting a data set
(As of user privilege level 5):
1. From the selection window, choose the drive that contains the data set.
2. From the directory list, select the data set.
3. Press Parts data and Delete.
The following data dialog box is displayed ’Really delete data set?’ with the name of the
selected data set.
4. By confirming with the Execute key, the data set is deleted.
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Production programs
6.8 Export injection protocol

The export function gives you the ability to export the settings data and machine and robot
sequences in various file formats.
You can export to the following file formats:

CSV for e.g. Excel
TXT for e.g. Word
HTML for e.g. Internet Explorer
Exporting machine and robot sequences is only possible in HTML file format The sequences
are additionally saved as PNG images.
Example:
Follow these steps to export the settings data for the machine.
1. Press the Parts data and Injection protocol keys. The following dialog box appears:
Export
0 of 34 selected
Production
Freely programmable in/outputs

Composeable page
Mold close
Mold height
Mold opening
Ejector
Sprue ejector
Machine sequence Robot sequence
Cancel Help Delete Select all OK
2. In the dialog box, select the screens you wish to export.

To select all screens, press Select all.
To remove the selection, press Delete.
To export the machine and robot sequence, activate the matching screen switches.

Production programs
3. Select the screens for the protocol, and press OK to continue. The following dialog box
appears.
Save
Choice:
File name:
File type:
Cancel Help Save
4. Select the drive you wish to export to, as well as the file name and the file type.
If you selected the machine or robot sequence, you can only select HTML as a file type.
The sequences are additionally stored as PNG images with the file name and extension
’_imm_xxx’ or ’_erc_xxx ’.
5. Press Save to start exporting. The following dialog box appears.
Export
Cancel
6. A progress indicator appears for the Export process. The dialog is closed after success-
fully completing the export.
231
Production programs
7 Notepad
The note screen page is used to store special production information.
Notepad
Info Panel
+ Notes
Training (se-
Pre-drying of the material 3 hours

Training (se-
5 Start-up cycles set with rejects
New Edit Save Delete Cancel
The left column shows, for selection, all message with titles and author's user name.
New
Creates a new note; you can enter your own title and content.
Edit
Lets you edit the selected note.
Save
Saves the new/changed note.
Delete
Deletes the highlighted note.

Production programs
8 Plausibility check
This program is used to check values for plausibility (e.g. Exceeding of machine-typical limit
values) and to correct implausible values. The machine control unit checks parameter settings
for plausibility when they are being set, but implausible values can still occur, e.g. by loading
data sets from other machines.
Manual correction
The operator can use the menu button ’Test’ in the Manual correction tab to check whether
plausible values have been set for all injection molding machine parameters. Parameters with
implausible values are displayed by the control unit in this tab. The operator must then change
the implausible values manually to plausible values in the New column.
When the menu button Acceptis pressed (only possible in manual mode), the control unit
transfers the set values from the New column into the screen pages. If a plausible value has
been set for all listed parameters, no parameters will be displayed when a new test is carried
out.
If the control unit finds implausible values when it switches to automatic mode, then these will
also be displayed in this tab.
Example: Parameter with implausible value

Plausibility check
Info Panel
Display variable text
+
manual correction automatic correction
Long text Actual New Unit
Testing Accept
Long text
Designation of implausible parameters When the program switch Display variable text
is activated, the control unit displays the parameter in clear long text.
Actual
Display of currently set value in control unit.
New
Field to input a plausible value.
233
Production programs
Automatic correction
The operator can use the menu button ’Autocorrect’ in the Automatic correction tab to check
whether plausible values have been set for all injection molding machine parameters. Param-
eters with implausible values are displayed by the control unit in this tab and the values are
automatically corrected to the next plausible value. In addition, it is possible to enter a plausi-
ble value manually in the Newcolumn. When the menu button Acceptis pressed (only possible
in manual mode), the control unit transfers the set values from the New column into the Cur-
rent column and the screen pages. The control unit transfers the previous value from the Cur-
rent column into the Oldcolumn.
All parameters with plausible values disappear when the Autocorrect menu button is pressed
again.
If the control unit finds implausible values after reading in a data set, then these will also be
displayed in this tab and automatically changed to a plausible value.
Example: Parameter with implausible value
Plausibility check
Info Panel
+ Display variable text
manual correction automatic correction
Long text Old Actual New Unit
Maximum cushion
Nozzle retraction force
Autocorrection Accept
Long text
Designation of implausible parameters When the program switch Display variable text
is activated, the control unit displays the parameter in clear long text.
Old
Saved value from a read in data set or accepted value from the Currentcolumn.
Actual
Display of currently set value in control unit.
New
Field to input a plausible value.

Production programs
9 Print
The control system offers printing processes from different programs as well as the printing-
out of screen pages. The CC200 control system supports printers which are PCL-3-capable
and whose manufacturers observe this specification exactly. For printing on the spot at the
machine you must connect one printer to a USB interface on the front panel.
When the machine is connected to a LAN network, printing to the networked printers is possi-
ble.
Local printer for CC200 with USB connection:
Manufacturer Type
Hewlett Packard HP Deskjet 990 Cxi
Hewlett Packard HP Deskjet 995 C
Hewlett Packard HP Business Inkjet 1000
Hewlett Packard HP Business Inkjet 1100D
Hewlett Packard HP Deskjet 6840
Hewlett Packard HP Deskjet 6940
Hewlett Packard HP Officejet Pro K550
Hewlett Packard HP Officejet Pro K5400
Hewlett Packard HP Laserjet 2605DN
Brother Laserprinter HL-5270DN
Hewlett Packard HP Color Laserjet CP 2025DN
Hewlett Packard HP Officejet Pro 8000
Network printers (Postscript)
Manufacturer Type
Hewlett Packard HP Laserjet 4100dtn
Hewlett Packard HP Laserjet 4000 PS
Hewlett Packard HP Laserjet 2605DN
The control unit offers the following printing possibilities of screen pages (masks):
a hard copy of the current screen page with screen page selection keys
a graphic printout of the current screen page
several graphic printouts of a selection of screen pages
textual printout of the current screen page
textual printout of a selection of screen pages
235
Production programs
A hard copy as PNG picture and graphic printouts of individual or several screen pages can be
stored in Postscript format as file.
An export function in the Data dialog permits text output in file format.
Example:
Graphic or textual printout of screen pages on a local printer:
1. Connect a printer with USB cable and switch the printer on.
2. Choose the printer menu
Print
Screen page selection

Current screen page
Hardcopy
Text printing
Cancel Help Setup OK
3. Press Setup
Settings for screen page output
Printer settings
Output on printer
Compress PS
Settings for printing to file
Print to file
Type
Directory
File name
Cancel Help OK
4. Switch on Output on printer . In addition, the selection possibility print to file is still
available. [See Output of the current screen page as hard copy in file format: on
page 237.]

Production programs
5. When switching over to ’Output on printer’ the printer dialog appears of the currently set
printer. Select the local printer and press OK.
Print

Current screen page
Hardcopy
Text printing
Cancel Help Setup OK
6. When you want to have a text printing, switch on Text printing.

7. Click on Screen page selection and confirm with OK.
0 of 65 selected
Production
Freely configurable screen
Shut-off nozzles
Minicam
Mold close
Set value graphics
Mold height
Mold opening
Cancel Help Delete Select all OK
8. Select the required screen pages from the selection of screens.

9. Press OK to start the printing process.
Output of the current screen page as hard copy in file format:

1. Choose the printer menu
237
Production programs
2. Press Setup
Settings for screen page output
Printer settings
Output on printer
Compress PS
Settings for printing to file
Print to file
Type
Directory
File name
Cancel Help OK
3. Switch on Print to file.

4. Select the Type of the screen page (File format).
5. In Directory the output file is fixed.
Save
Choice:
Cancel Help Save
6. The path is filed by save and the window is closed.

7. Enter in the mask Settings for the screen page output a designation in the line File
name.
8. With OK start the output process to file.

Production programs
10 Infolog (Production protocol)

The production protocol is an important aid for analyzing and documenting production. It
records all events in a table, such as interruptions, setting changes, alarms etc.
The list can be sorted in increasing or decreasing order by tapping the header of the corre-
sponding column.
Infolog
Info Panel
+ Time CPU-Id Counter Description User
Machine motor switched
Mold heating 1 is
Tool heating 1 zone 9
Screw offset pressure
No oil temperature con-
Mold heating 1 is switched
Screw offset pressure
Value: „Mold height” 493.0 -> User 9
Automatic mold height
Value: „Determine mold User 9
Automatic mold height
Value: „Determine mold User 9
Operating state changes:
Operating state changes:
User logout 11
User login 9
Filter on Setup Save Print Help List keep
Columns in the protocol

Time
Date and time of the event.
Counter
Value of the shot counter at the moment of the event.
Description
Sample text: The mold height set value has been changed, and then the Determine
mold height program was switched on.
Display:
239
Production programs
Value: ’’Mold height’’ 493.0 -> 410.0 mm

Value: ’’Determine mold height’’ No -> Yes
Sample alarm text with status display:
Automatic mold height determination activated!
For alarm entries there are the following status displays:
Alarm is set and not acknowledged.
Alarm is set and has been acknowledged by the operator (but not by the control
unit).
Alarm is set and has been acknowledged by the control unit (but not by the oper-
ator).
Alarm is reset (deleted).
The current list can be stored and printed out. Also, the entries can be recorded to a file.
Menu keys:
Filter on/off
Activates the filter for the entries in the Infolog.
Setup
Filter settings for the entries in the Infolog.
Logfile On
Also record entries on file (on/off).
Save
Store Infolog list on file.
Print
Print Infolog list.
Help
Help texts on Infolog list.
List free/hold
The control unit automatically scrolls the list for new entries.
filter
The entries shown in the Infolog can be restricted by means of various filter conditions.
You can select the Setup and Filter menu keys to open a dialog box where you can define fil-
ter settings.

Production programs
filter
Alarms System Error Application

Alarm 1 System message Information Value change
Alarm 2 Change of modules Warning File operation

Alarm 3 SPS action Error Mode of operation
Alarm 4 Teach action Critical error User change
Alarm 5 PDP error protocol. Fatal error HMI application
Alarm 6 Application SPS1
Alarm 7 Application SPS2
Search From Upt
Cancel Help OK
Alarms
Alarms 1-7 ; 30 Entries per class
System
Number Example, comment
System message 100 System start/stop
Change of modules 100 Replacing an electronics card
SPS action 512 System message when loading parts of

the application software (abbreviated FU -
Function Unit)
Teach action 300 not used
PDP error protocol 100 Process data monitoring
Error
Information 100 from system software
Warning 100 from system software
Error 100 from system software
Critical error - not used
Fatal error - not used
241
Production programs
Application
Value change 300 Parameter modification
File operation 100 Reading parts data
Mode of operation 100 Machine operating mode switchover
User change 100 Logging on a new user
HMI application 100 Software update, or writing a data set
Application SPS1 100 Application software information
Application SPS2 100 Application software information
If the entries exceed the number in the table, the oldest values are deleted. Overall, 2000
entries is the maximum.

Production programs
11 Alarm e-mail
When the machine is connected to a network, the control unit can send an e-mail automatically
when certain alarms appear, the e-mail text consisting of the alarm text itself and of an additi-
onal freely definable text.
Procedure for setting:

1. Choose the alarm mail page
Hmi-Alarm-Mails
Info Panel
+ Addresses Text
Address book receiver

max.mustermann@engel.at
Add Save Delete Test Status report
2. Use ’Add’ to enter the required address or select the address(es) in the ’Address book’.
3. Transfer with ’>’ to ’Recipient’.
4. Press ’Store’.
243
Production programs
5. Select the ’Text’tab.
Hmi-Alarm-Mails
Info Panel
Addresses Text
Alarm selection
Alarm class 1 Alarm class 2 Alarm class 3
Alarm class 4 Alarm class 5 Alarm class 6
Alarm delay Activation Domain name

Delay Mail machine
Alarm text
Test alarm
6. Select the alarm classes for which an e-mail will be sent. A delay time can also be set.
7. Enter an additional alarm text.
8. Click on the Address tab and press ’Test’ to send a test mail and check your settings.
9. Switch on ’Activate mail’
The control unit now always sends an e-mail with the current error message and the entered
alarm text when an error of the specified class(es) appears.

Production programs
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Production programs

Micrograph
Micrograph
The micrograph allows you to record process parameters for quality control purposes that help
you analyze, optimize and monitor the injection molding process. These are basically injection
unit parameters, such as: injection pressure, injection speed, screw stroke, cavity pressure.
You can save red ’ideal curves’ to be able to compare individual cycles and monitor the injec-
tion molding process.
Power characteristics
Automatic quick setup with preconfigured measurement intervals.
[See Automatic setting on page 250.]
Free choice and composition of up to 8 curves at the same time.
[See Manual setting on page 251.]
Zoom function: fast access to full, half, quarter of screen, user defined movable sub-
screens.
[See Zoom function settings on page 259.]
Scales can be shown or hidden, modified now or later.
Digital display of an actual value for a chosen curve position.
[See Actual value display on page 265.]
Digital display of the switchover point, of the flow number and of the flow number mea-
surement window.
All set parameters and ideal curves stored on the parts data set.
2 Ideal curves for the selected parameters.
[See Store ideal curve on page 254.]
Logging curve groups, and extrapolating an ideal curve.
[See Record curve groups on page 253.]
Tolerance monitoring or integral monitoring with monitoring window
[See Micrograph monitoring on page 256.]
Export function for curves.
[See Exporting curves on page 262.]
Printing out curves
[See Printing out curves on page 261.]
247
Micrograph
Micrograph
Info Panel
Flow num- 1
AVSx Injection speed ASSx Shot volume ac- APHx specific

Max = 90.0 cm³/s tual value Max = 950.0 bar 3
Setup Zoom Curve Start func- View 4
[1] Status line: Shows the current flow number and depending on the switched-on function
e.g. at a monitoring the moment of a tolerance violation.
For machines with multiple injection units this is an option that lets you assign the micro-
graph to the injection unit. This ensures that automatic setup and the flow number and
switchover point display refer to the assigned machine.
[2] Graphic: Display of all graphical information:

individual curves or curve groups in the selected color, ideal curve always in red.
Displays positions as vertical lines, e.g. switchover point as a white line, actual value as
a red line, flow number measurement positions by two blue lines and tolerance
exceeded by a dashed blue line when monitoring is switched on.
Scaling:
Left side Y-axis: The scale is represented as a general percent value relating to the
set maximum value of the curve.
Right side Y-axis: The scale represents the units and the set values of the selected
curve in the same color as the curve.
X axis: Shows the time axis without start delay. Can be toggled to screw volume or
screw stroke. Toggling possible with View and XY view.

Micrograph
[3] Caption: Description of displayed curves with possibility of changing specific attributes
of a curve (color, Y-scale, etc.). You can display up to 8 curves simultaneously.
[4] Instruction menu keys:

Setup with the instructions automatic setting, manual setting, Ideal curve 1 and 2,
Transfer 1 and 2, Set export and Flow number.
Zoom offers various zoom possibilities.
Curve groups with the instructions Setup, Start/Stop, Delete shot, Delete all and
Invisible/Visible.
Start functions with the Start/Stop instructions for printing, export, measurement,
initialization 1 and 2.
View with the instructions Scale Y-axis, Actual value view, XY/TY view, Maximize/
Minimize.
249
Micrograph
1 Automatic setting
Automatic setting allows simple setting of a recording of a running injection molding process.
Three predefined templates are available.
Procedure:
1. Press Setup and Automatic setting.
Automatic setting
Micrograph active
Template
Inject
Plasticizing
Injection and plasticizing
Cancel Help Execute
2. Check the "Micrograph active" box and select a template.

Depending on the chosen template the following settings are made automatically.
Template Measurement duration Curve selection
Inject Start injection until the end Specific injection pressure with ideal
of injection hold pressure curve, hydraulic injection pressure,
injection speed, shot volume
Plasticizing Start plasticizing until the Speed, shot volume, motor torque with
end of decompression ideal curve
Injection and Start of injection until the Specific injection and back pressure
plasticizing end of decompression with ideal curve, injection and plasticiz-
ing speed, shot volume
3. Press Execute.
As a result the control unit takes over the settings for Micrograph corresponding to the
chosen template.
The next time the machine injects, the Micrograph logs the actual values. The ideal
curve is kept for comparison with the next cycle.

Micrograph
2 Manual setting
For individual setting of Micrograph, the manual setting dialog window is provided. The win-
dow is divided into 4 sections which are designated as template, measurement duration, curve
selection and properties.
Note!
Any ideal curves you have stored prior to changing the settings are discarded.
Procedure:
1. Select Setup and Manual setting.
Similarly to automatic setup, you can select a template to preconfigure the settings. The
User-defined settings template contains either the current configuration for the Micro-
graph or one that was created previously. In contrast to automatic setup, you can edit
selected template with the other steps.
Set Micrograph
Tem- Measure- Curve selection Properties
Micrograph active
Template
User-defined settings
Inject
Plasticizing
Injection and plasticizing
2. Choose Measurement duration

In this step the control unit offers a menu with start conditions and the possibility to set
a start delay and a measurement duration.
Set Micrograph
Start condition Start injection
Start delay time
Measurement duration
3. Press Curve selection

In this step the control unit offers a menu with available curves. By touching lightly (high-
lighting) an Available curve and pressing the arrow key [>] the selection is moved to
251
Micrograph
the Selected curves and vice versa.

The double arrow key [<<] moves all the "selected curves" back simultaneously.
Set Micrograph
Available curves Selected curves

Curve selection ASSx Shot volume actual value
APHx Specific injection pressure APHx Specific injection pressure
AVSx Injection speed AVSx Injection speed
ASSx Shot volume actual value
M Torque
PDx Metering performance

PFx Cavity pressure actual value
4. Press Properties
At this step you can select color assignments, curve groups logging, and display of indi-
vidual curves. [See Record curve groups on page 253.]
Set Micrograph
Color Curve Curve Groups Display
APHx Specific injection pres- Curve Groups

AVSx Injection speed Curve Groups
ASSx Shot volume actual value Curve Groups
Cancel Help Execute
5. Press Execute.
As a result the control unit takes over the settings for the Micrograph and stores them
under the template User-defined settings

Micrograph
3 Curve-specific settings
In the legend field, keys marked with the curve color are provided. Press the key to open a win-
dow with the curve-specific properties and change the settings.
APHx Specific injection pressure
Scale
Scale Apply settings for Y scaling by executing
Accept proposal based on the latest re-
Proposal corded sample.
Accept proposal
Display scale Check box to display Y-axis scale on the

right of the graph.
Curve
Color Color selection for Curve.
Display
Curve Groups Display Curve selection possibility:
Invisible (not displayed, but recorded), In-
dividual curve, Curve groups.
Cancel Help Execute
4 Record curve groups

For checking the scattering of the injection molding process or for deriving an ideal curve for
quality assurance, curves from several cycles can be recorded and displayed together.
Procedure:
1. Choose Curve groups and Setup.
The window for setting Micrograph with the properties tab displayed.
2. Switch on the recording of the curve groups for a previously set curve.
3. At Display choose the setting Curve groups.
4. Press Execute.
Micrograph can record up to 60 curves, afterwards it deletes always the oldest curve.
The recording of curve groups can be stopped and started in the instruction menu Curve
groups.
253
Micrograph
5 Store ideal curve

During optimization it is appropriate to store current curves without monitoring for comparing
the curves from cycle to cycle.

1. Select Settings and e.g. Ideal curve 1.
Ideal curve 1
Curve selection Range Error action
Monitoring Active visible
Curve APHx Specific injection pressure
Monitoring type Pos.tol. Neg.tol.

Tolerance
Integral
Derive from curve groups

Initialization for injection set value change
Initialization for plasticizing set value change
Initialization counter shts
Cancel Help Execute
2. Switch on tolerance monitoring.

3. Set the tolerances to 0.
4. Schalten Sie Überwachung sichtbar ein.
5. Select the requested Curve.
6. If you want to store the individual curve recorded last as ideal curve, switch off Derive
from curve groups.
7. Press Execute.
The chosen curve is now stored in red and can be compared from cycle to cycle with the
current curve.
8. If you want to store the same ideal curve again, e.g. after changing a setting, you must
press Setup and Transfer for the respective curve.

Micrograph
5.1 Ideal curve initialization

The initialization derives an ideal curve from future cycles.
Procedure during the initialization of an individual curve:

1. Item 1 to 5 [See Store ideal curve on page 254.]
2. Press Execute.
A red ideal curve is now displayed, formed from the last curve.
3. If you now want to derive an ideal curve from the future curves, press Start functions
and Start initialization.
Procedure during the initialization of a curve group:

1. Switch on curve groups recording for the requested curve. [See Record curve groups on
page 253.]
2. Item 1 to 5 [See Store ideal curve on page 254.]
3. Check the box Derive from curve groups.
4. Set the required number of shots.
5. Press Execute.
A red ideal curve is now displayed, formed from the last curves.
6. If you now want to derive an ideal curve from the future curves, press Start functions
and Start initialization.
An initialization counter appears in the legend box for the selected graph. After the
counter has elapsed, you might see a red range, depending on the scatter; the range is
delimited by the two outer curves, and any +/- tolerances you have set.
Initialize on changing injection unit set values

If this box is checked, automatic initialization occurs at a set value change for the injection pro-
cess, changeover point, hold pressure, plasticizing process or intrusion.
255
Micrograph
6 Micrograph monitoring
Micrograph is an extremely important aid for process monitoring and as a result for injection
molding quality assurance. Each Micrograph possesses the possibility to monitor two curves
in one definable area.

1. Select Settings and e.g. Ideal curve 1.
Ideal curve 1
Monitoring Active visible
Curve APHx Specific injection pressure
Monitoring type Pos.tol. Neg.tol.

Tolerance
Integral
Derive from curve groups

Initialization for injection set value change
Initialization counter shts
Cancel Help Execute
2. Monitoring
Switch the recording to Visible and Active.
Monitoring only becomes active after the ideal curve evaluation is switched on in the
dialog ’Error action’.
3. Curve
Select the Curve to be monitored.
4. Monitoring type
Switch on the required monitoring type and set the tolerances for the horizontal X and
vertical Y directions.
Two monitoring types are provided:

Tolerance monitoring with an adjustable pos./neg. tolerance in horizontal and vertical
direction (X = time axis, Y = values axis).
Integral monitoring with an adjustable pos./neg. tolerance. The percent value refers
to the integral of the ideal curve.
5. Derive from curve groups

If you want to derive the ideal curve from a previously recorded group of curves, check
the box ’Derive from curve groups’ . Here the whole currently recorded group of curves
is always considered.
The set number of shots ’Sht’ of the initialization counter is not in effect.
6. Initialization for injection set value change
Switch on the respective screen switch when the next recorded curve should be auto-
matically set as the new ideal curve if the settings have changed.
The setting of the initialization counter is effective when deriving from a curve group.

Micrograph
7. Select the tab Range.

Ideal curve1
smaller larger
Cancel Help Execute
8. Set the monitoring range by repeatedly pressing the smaller and larger keys.
Use your finger to move the red monitoring range to the required position.
9. Select the Error actiontab.
Ideal curve 1
Action if tolerance exceeded no action

Cancel Help Execute
10. Action if tolerance exceeded

Set the required action:
No action, error+lamp, reject or production stop
11. Ideal curve evaluation active
Switch monitoring on with the ideal curve evaluation.
12. Press Execute.
257
Micrograph
Example: Hose monitoring of specific injection pressure

Max = 90.0 cm³/s tual value Max = 950.0 bar
The ideal curve is now visible as a red tube, which has been formed by the set tolerance.
If you have derived the ideal curve from a group of curves, a tube is visible which has been
formed by the two extreme curves plus the set tolerance.
The control unit shows the monitoring range as a horizontal line below the X axis in the color
of the curve being monitored. The current curve should always run within the tube area.
If not, then following message is displayed:
Micrograph x tolerance exceeded
Cause Batch variation, temperature fluctuation, change of the machine set-

ting, ...
Effect Depending on the chosen error action.

Micrograph shows the moment in which the tolerance is exceeded by
a blue, vertical dotted line. In the status line the moment is shown in
digital form.
Remedy Check how the change has arisen.

Micrograph
7 Zoom function settings

The zoom functions are provided for better readability of individual portions of the graph.
7.1 Predefined zoom functions

For quick zooming, 25% and 50% zoom functions are available.
Procedure:
1. Press Zoom and then Zoom 25% or Zoom 50%.
A scaled up view of the left part of the graph with a horizontal scroll box appear showing
you which section is currently visible. Additionally, horizontal scroll keys appear at the
right bottom of the screen.
Micrograph
Info Panel
Flow num-

Setup Zoom Curve Start func- View
2. Using the scroll keys select the required portion of the graph.
This zoom function remains set until you choose another view (e.g. zoom 100%).
259
Micrograph
7.2 User-defined zoom function

A user-defineable zoom function enables a chosen section to be enlarged.
Procedure:
1. Press Zoom and User-defined.
Micrograph
Info Panel
Flow num-

Cancel Reset Accept
2. Press Reset.
3. Define the area required by touching two diagonally opposite points on the graph. A red
rectangle is displayed, which can be repositioned with the finger.
4. Press Accept.
The enlarged graphic is now displayed with horizontal and vertical scroll bars.

Micrograph
8 XY view
The control unit offers, as an additional option, a stroke-dependent graphical view of the curve.
To do so, however, the curve for the shot volume must be selected for recording. Enable the
display by means of the View and XY-view commands.
This view is static and is derived from the last recorded curve after being activated. In order to
display the complete cycle, set the measurement duration to the current cycle time [See Man-
ual setting on page 251.].
Micrograph
Info Panel
Flow num-

Setup Zoom Curve Start func- View
9 Printing out curves

Start function and Start printing prints out the current graphic, including the set start condi-
tion, start delay time and measurement duration. In addition, the individual curves are printed
as captions with the corresponding curve colors and percentage scale.
If the screen button ’Start printing’ is grayed out, you must first set up the printer. [See Print on
page 235.]
261
Micrograph
10 Exporting curves
For a more extensive documentation of the injection molding process, Micrograph has the
capability to export the recorded files to one of the flash cards.
The control unit creates a separate file with each export process. These files are formatted
with tabulators and ignore characters for simple further processing in spreadsheet programs.
Procedure:
1. Press Settings and Export settings.
Export settings
Mode Curve selection Format
Mode Last shot
Export interval
Number of exports
File name
Cancel Help Execute
2. Select in Mode when the curves shall be exported:

Last shot
Cyclic (at this mode you must also set the Export interval and the Number of the
exports )
Last shot with curve groups
Only in case of rejects
3. Choose the File name

Enter a filename with or without a path (default setting drive H1, flash or memory stick
in front panel of control unit). The control unit adds a 3-digit index to the filename; the
index is incremented by 1 for each export.

Micrograph
4. Select the Curve selectiontab.

Export settings
Available curves Selected curves

ASSx Shot volume actual value
APHx Specific injection pressure
AVSx Injection speed
Cancel Help Execute
All curves selected for the recording in the Micrograph are entered automatically in the
list Selected curves and are therefore selected for the export.
By selecting a curve and pressing the "back" arrow key [<] that curve is deselected and
returned to the Available curves column.
5. To set the export format and other information, select the Formattab.
Export settings
Additional information optional text
Unit
Action when memory full no action
Cancel Help Execute
6. Select the required action, if the data memory is full (reject, cycle stop, or no action). If
you select no action, the control unit will overwrite the oldest existing file when you
export data.
7. Press Execute.
8. Press Start functions and Start export.
Now an individual or cyclic export function starts.
263
Micrograph
Example:
CC200 Micro-
graph Exportfile
Version: V1.00
Machine number 44332
Machine size VC33/80 Tech
Additional informa- Injection in manual

tion mode
Start delay time 0.0 s
Measurement 10.0 s
duration
Start condition Start injection
Measurement until End injection
Specific injection Shot volume actual Injection speed

pressure value
Time APHx ASSx AVSx
Shot counter 135 135 135
Time Tue Feb 14:31:32 Tue Feb 14:31:32 Tue Feb 14:31:32
2007 2007 2007
s bar cm³ cm³/s
0 6 206,766 0
0,04 36 206,766 0
0,08 77 206,697 9,526
0,12 135 206,315 34,002
0,16 167 205,859 54,488
.,.. ... ...,... ..,...
Each curve comprises 500 individual sample values. If the memory is full, the following mes-
sage appears:
Export memory full
Effect Depending on the action you selected: reject, cycle stop or no action.
Remedy Use new memory.

Micrograph
11 Actual value display

For precise analysis of the curve you can show a vertical red line in the View Current value
menu. A rough line position is quickly achieved by clicking on the required position
within the graph. Use the keys for fine positioning and/or to set the view to the switch
point. The control unit shows the current value of the line position in the status line at
the top, and the corresponding current value of the curves in the legend field at the bot-
tom.
Micrograph
Info Panel
Flow Act.X pos.

Actual value = 134.5 Actual value = 34.63 Actual value = 3022,7
Quitting Start function Left right
265
Micrograph
12 Microplast
The Microplast program determines the mean value of the injection pressure (flow number)
during the dynamic mold filling phase. The flow number is used as a measure for the energy
consumption and the flow characteristics during the mold filling process. This allows viscosity
variations of the raw material and temperature fluctuations to be recorded and monitored.
You can select the flow number setting window with Setup and Flow number.
Flow number
Microplast Microflow
Program Microplast
Flow number set value
Flow number
Tolerance range flow number
Start flow number measurement
Stop flow number measurement

Automatic parameter setting
Flow number reject
Help Close
When the machine is in production, Automatic parameter setting can be switched on. Then
the control unit sets the measuring positions, measures the flow number during the next mold-
ing cycle and takes over this value as a set value.
At the beginning of injection the injection pressure level depends on the acceleration of the
screw and at the end of injection on the compression of the material. Therefore the flow num-
ber is measured in the middle portion of the injection stroke.
The control unit displays the flow number in the status line and the measuring positions by two
vertical lines on the graphic image.
If the measurement is set too short or not completed before reaching the changeover position
to hold pressure, the following message is displayed:
Flow number measuring range set wrong
Effect No injection hold pressure correction with Microflow.
Remedy Set flow number measuring positions correctly.
For monitoring an adjustable +/- tolerance range is provided. When the tolerance is exceeded,
the following message is displayed:
Flow number reject
Cause The flow number has exceeded the tolerance range e.g. because of
batch variation, temperature fluctuation or change of the machine set-
ting.
Effect Rejects signal, the rejects counter counts, no Microflow correction.

Micrograph
13 Microflow (Option)
Microflow corrects the switchover pressure or injection hold pressure when the flow number
changes due to the viscosity of the material. A change in viscosity causes, especially with lon-
ger flow paths, a change of the cavity pressure and so a change of the shot weight and dimen-
sions. Correction of the switchover pressure or injection hold pressure can compensate for
this.
Flow number
Microplast Microflow
Correction type No correction
Correction factor
Hold pressure correction
Switchover point correction
Tolerance range for pressure correction

Specific injection pressure
Flow number reject
Help Close
When pressure-dependent switchover to injection hold pressure is set, you can also choose
the switchover pressure as a Correction type . If not, only the injection hold pressure can be
used for correction.
The Correction factor determines how great the correction is.
Calculated correction: (Flow number actual value - Flow number point set value) x correction
factor.
In other words, if the flow number increases due to increased injection resistance, positive cor-
rection of the pressure occurs. If the flow number drops, negative correction occurs.
You must determine the size of the correction factor empirically when a change of the viscosity
appears.
An adjustable Tolerance range for pressure correction shall protect the mold against dam-
age. No correction occurs when the tolerance is exceeded.
267
Micrograph
14 Autoprotect Injection (Option)

The Autoprotect injection program protects the mold against overmolding. It compares a
stored ideal curve with the current curve for the process parameter in question. Configurable
tolerances give you the ability to detect any critical deviations immediately, and trigger a reac-
tion to them.
Characteristics:
Graphical monitoring selection based on injection pressure, injection speed, injection
stroke, and cavity pressure assuming this equipment exists.
Selectable error reaction in the case of exceeding the set tolerances (interrupt injection,
switch over to hold pressure and sort rejects)).
Initialization phase with manual or automatic transfer into the ideal curve - transfer every
cycle is possible.
Actual value cursor, zoom function, hardcopy printout possible, storage of the ideal
curve on parts diskette.

Micrograph
Autoprotect injection
+ Flow num-
AVSx Injection speed ASSx Shot volume actu-

Max = 200.0 cm³/s Max = 350.0 cm³
Setup Zoom Family of Start func- View
The operation is very similar to the Micrograph program [See Micrograph on page 247.]
Two parameters can be recorded and monitored at the same time, therefore, monitoring can
be assigned to each curve. The recording occurs every cycle. The start condition coresponds
with the start of injection.
During the automatic setting the following settings are made:

Curve for shot volume and injection pressure
Tolerance monitoring for injection pressure 5% only visible, but not active
Recording of the whole injection process including hold pressure
When you activate the monitoring, the actual value of the chosen curve must be within toler-
ance during injection. If not, this message is displayed:
269
Micrograph
Injection monitoring tolerance exceeded
Cause Cavity blocked, batch variation, change of the machine setting, ...
Effect Depending on the selected action e.g. stop movement (= switchover

to post injection pressure with 0 post injection pressure, that is, wait
for post injection time), cycle stop at end of cycle.
Changeover to hold pressure, does not stop at the end of the cycle.
A blue, vertical dotted line shows the point at which the tolerance was
exceeded. The numerical value of the point is shown in the status
line.
Remedy Check cavities and sprue channels.
Injection monitoring memory full
Effect Depending on the action you selected: reject, cycle stop or no action
If you select no action, the control unit will overwrite the oldest exist-
ing file when you export data.
Remedy Use new memory.

Process data package
The process data package (PDP) enables numerical and graphical recording of all process
data measured by the control unit. This serves as an aid for analyzing, monitoring and docu-
menting the injection molding process.
The package consists of the programs:
Process data record
Process data graphics
Process data monitoring
Histogram
Correlation graphics
1 Process data record

The program records the numerical process data on the machine and stores the data in a file
for further processing on a PC.
PD record
Info Panel
+ Interval 1 shot
Ideal value 3
Minimum
Maximum
Difference 4
Mean value
Stop Setup Accept on ideal value View 5
[1] Line for parameter designation (Tool tip for long text)
[2] List of parameters with a maximum of 50 lines. When the rejects monitor reacts during
the recorded cycle, an error symbol is displayed in the left column.
[3] Adjustable ideal values (process parameter for optimal quality)
The ’Accept on ideal value’ button saves the process data from the last shot as ideal val-
ues.
The ideal value line helps, e.g. for a rapid comparison during production start.
[4] Analysis of the parameters logged since the last protocol start. You can use Sample
size in the Properties tab of the settings dialog to set the maximum Shot count to sam-
ple for this analysis (default 20).
[5] Function and menu keys
271
Setting up and starting recording:

1. Select Setup.
Settings PD protocol
Measurement Parameter selec- Properties
Measurement type Start delay

Time-dependent recording Shot
Interval
Shot
Number of recordings
Shot-dependent recording
Recording
on file
on printer
Action at protocol error no action
Unit
ISO Imperial
Absolute Relative
Cancel Help Accept
2. Set the measurement parameters. A shot-dependent recording can be set for injection
molding process analysis and quality documentation. The setting example above
means:
After the start of the program the control unit records shot-dependent immediately.
Each shot (interval 1).
From program start to program stop (number of recordings 0 = always on).
3. If required, you can set recording to a file (enter the disk and filename). Select the
required action in case of a logging error (no action or cycle stop).
PDP data memory full
Cause The memory of the destination device is full or the connection is inter-
rupted.
Effect Depending on chosen action.
Remedy Check the destination device.
4. It is also possible to choose the Unit of the process parameters.

5. Select the Parameter selectiontab.

Available parameters Selected parameters

All variables Injection time actual value
+ Machine parameters Flow number
+ Production parameters Plasticizing time actual value
+ Process variables Torque mean value current cy-
+ Temperatures Cycle time until end demolding
+ Cycle times Cushion volume actual value
User-defined Parameters Add
6. Select an available parameter or a preconfigured group of parameters. You can create

and store your own sperate group with User-defined for later use.
Only ENGEL service engineers can add parameters.
7. Transfer the parameter or group with [>] into the Selected parameterswindow.
8. If needed, select the Properties tab and set a color for each column in the log.
You can set the sample size for min/max evaluation in the log.
Selected parameters
Injection time actual value Columns
Flow number Column color
Plasticizing time actual value
Torque mean value current cycle

Cycle time until end demolding
Cushion volume actual value
Spot checks
number of shots
interruption Help Ok
9. Press Ok. The control unit will switch to the logging page and display the selected
parameter in the line for parameter logging.
10. Press Start. Now the recording starts according to the set measurement parameters.
273
If you have set output to a file or a printer, the log header with the mold parameters appears at
the head of the log.
Example PDP Log CC200
PD record Date / time

Molded part number
Machine number 44332
Mold number
Material number
Order number
Machine type VC33/80 Tech
SZx Shot counter

ZSx Injection time actual value
FZx Flow number
ZDx Plasticizing time actual value
Mm Torque mean value current cycle
ZUs Cycle time until end demolding
ACPx Cushion volume actual value
Measuring start: Date / time

The logging data appears after the header.
SZx ZSx FZx ZDx Mm ZUs ACPx

338 0,74 1285,6 1,58 327,9 6,51 1,45
339 0,76 1287,6 1,60 331,2 6,50 1,43
... ... ... ... ... ... ...
An exclamation mark to the left of the parameters shows that rejects monitoring was trig-
gered in this cycle.
After stopping logging, the analysis with the minimum, maximum, differential and average val-
ues is transferred.

2 Process data graphics

The program is used for simultaneous logging of maximum 6 process parameters as graphs
for convenient analysis of interdependencies and deviations.
PD graphics
Info Panel
+ Interval 1 shot Actual samples 704 1
Correlation ACPn to:
Shot
4
Mm torque mean value ZDx plasticizing time ac- ACPx cushion volume
1065,4 Nm 1,26 s 55,65 cm³
5
APVs spec. injection ACPn screw volume APHu specific pressure
771,0 bar 54,15 cm³ 771,0 bar
Stop Recording Zoom 6 View
[1] Measurement settings and counters for the number of the recorded measurements
[2] Line for correlation display in % to the curve chosen in the legend field
[3] Horizontal graphics for process parameters (the graphics show all measurements with
zoom 50% and every second with zoom 100%)
[4] Lines for measurement number and time or piece counter
[5] Curve legend with selection possibility for correlation analysis and key for curve-specific
settings
275
Setting up and starting recording a process data graph

1. Select Recording and Setup.
Settings PD graphics
Measurement type Start delay

Time-dependent recording Shot
Interval
Shot
Number of recordings
Shot-dependent recording
Display history
until X division
Cancel Help Accept
2. Set the measuring parameters. To analyze the injection molding process, you can either
set shot or time dependent recording. The previous settings mean:
The control unit will start shot-dependent recording immediately after launching the
program
each shot (Interval 1)
From program start to program stop (number of samples 0 = always on)
The graph will scroll down 50 recordings after 500 recordings (one tenth of the X
scale)

3. Select the Parameter selectiontab.

Available parameters Selected parameters

All variables
+ Machine parameters Torque mean value current cy-
+ Production parameters Plasticizing time actual value
+ Process variables Cushion volume actual value
+ Temperatures
User-defined
Cancel Help Accept
4. Select an available parameter.

5. Use the [>] key to transfer the parameter or the group into the selected parameters win-
dow.
6. Select the Propertiestab.
Selected parameters
Plasticizing time actual value Lines
Torque mean value current cycle Line color
Cushion volume actual value
Cancel Help Accept
7. Select the respective parameter and set a line color.

8. Press Accept. The control unit switches to the graphics page and displays the chosen
parameters in the legend field.
277
9. Press in the legend field for curve-specific settings
Settings for plasticizing time actual value
Injection time actual value
Scale
Curve
Line color
Visible
Display scale
Cancel Help Accept
10. Set the scale for Y scaling to 100% and 0% . Use the Set scale switch to display a curve
in the curve display on the right for scaling. If the curves overlap, you can use the Dis-
play button to hide a curve, or move the curve by changing the scale.
11. Press Accept.
12. Press Start. Now the recording starts according to the set measurement parameters.
Actual value display
For a precise value of the graphical curves a vertical red bar can be displayed by pressing
View and the key Actual value . The bar can be displaced to the left or right with the keys pro-
vided. The control unit displays the current actual value of the bar position (x-value) in the sta-
tus line above and the appertaining actual values of the curves in the legend field below.

PD graphics
Info Panel
+ Interval 1 shot Measurement Actual x value 447
Correlation ACPn to:
Mm torque mean value ZDx plasticizing time ac- ACPx cushion volume
1065,4 Nm 1,26 s 55,65 cm³
APVs spec. injection ACPn screw volume APHu specific pressure

771,0 bar 54,15 cm³ 771,0 bar
Quitting Left right
Statistics and correlation display
By touching the legend field of the respective curve the control unit displays in the line above
the graphics the correlation to the other recorded curves.
A positive % value means, the other curve changes in the same direction.
A negative % value means, the other curve changes in the opposite direction.
The size of the % value indicates how strongly the respective curve correlates to the chosen
curve.
You can select View and Statisticsto display an overview of correlations and statistical char-
acteristics.
279
Statistics
Character- Correlation analysis
Mm ZDx ACPx APVs ACPn APHu
Mm
ZDx
ACPx
APVs
ACPn
APHu
Statistics
Character- Correlation analysis
Mm ZDx ACPx APVs ACPn APHu
Actual
x Mean value
Deviation
s
Print
It is possible to send the current graphics with Recording and Print to a printer connected to
the machine or a printer on the local area network.
If you enable automatic printout, printing does not start until the screen is full (500 samples).

3 Process data monitoring

Online quality monitoring for maximum 20 parameters with calculation of statistic values Indi-
vidually selectable graphical display of parameters with monitoring limits.
PD monitoring
Info Panel
+ Interval 1 shot Actual samples 114 1
Mm torque mean value IO injection work FZx Flow number

1590,1 Nm 0,327 Wh 117,4 bar
APVs specific injection ZUs cycle time to end 5
201,0 bar 15,23s
Stop Recording Zoom 6 View
[1] Measurement setting and current number of measurements

[2] Line for statistical characteristic values
[3] Horizontal graph for one process parameter each displaying:
Set value (blue)
Actual value (turquoise)
Mean value of sample (ocher)
Overall mean value (green)
Contact limits (yellow)
Specification limits (red)
[4] Lines for measurement number and shot counter and/or time
[5] Curve legend with keys for curve-specific settings. Selection possibility for the display of
the curve-specific statistical characteristic values.
281

Setting and starting a recording of the process data monitoring:
[See Setting up and starting recording a process data graph on page 276.]
In addition to setting the process data graph, there is another tab for the error action on
exceeding a threshold.
Settings PD monitoring
Measurement Parameter selec- Properties Error action
Torque mean value current cycle
Flow number
Specification limits exceeded Alarm lamp and rejects
Intervention limits exceeded Alarm lamp
Cancel Help Accept
After touching the respective process parameter lightly, an error reaction can be set.
The intervention limits refer to the mean value of the set sample. You can select cycle stop,
alarm lamp only, or no reaction.
The specification limits refer to the individual value. So you can also sort rejects in addition.
283
Curve-specific settings
Which curve shall be displayed as graphics, you can determine by touching the respective leg-
end field lightly.
In the legend field, keys with the curve color are provided. With these keys a window can be
opened with the curve-specific properties and changes can be made to the settings.
Settings current changeover volume
Actual value
Scale
TolCounter+ TolCounter-
x set
x total
Curve
Line color
Cancel Help Accept
Limiting values
All limiting values can be set manually or the control unit can calculate them in an initialization
run.
The scale refers to 0% and 100% of the Y scaling of the graphics. All limiting values of the
curve selected in the legend field are faded in at the right on the Y scaling.
The intervention limits (UEG, OEG) are mainly used to detect systematic interfering factors in
the injection molding process. They are designed to alert in case of systematic impact on the
process. If the mean value x , which is calculated from the last sample, exceeds this limit, the
selected error action and error message occur.
Control limit PD monitoring exceeded/not reached
Cause The injection molding process has changed.
Effect Depending on chosen action.
As additional important process information the control unit shows the whole mean value
xges, calculated from the beginning of the recording.
The specification limits (USG, OSG) essentially serve the online process monitoring and sort-
ing of rejects. If an indidividual value exceeds this limit, the set error action and error message
occurs.
Specification limit PD monitoring exceeded/not reached
Cause During the last molding cycle a process parameter has changed.
Effect Depending on the chosen action. two counters TolCounter +/- count
the occurred deviations appeared since the start of monitoring.

Initialization
An initialization program is provided for a quick setup of the recording, the control unit auto-
matically calculates the following values, according to the set spot check size:
Scale for recording curves.
Specification limits for current scatter and set range.
Intervention limits for x .
Nominal mean value xset.
Standard deviation s.
Procedure:
1. For presetting the initialization run press Recording and Set initialization
Set initialization
Spot check
Spot checks
Tolerance based on the next 50 samples
Specification limit range
Cancel Help Accept
Here you can enter the spot check size necessary for the statistical calculation of the
limits and the area for the specification limit calculatiion. You can also choose the calcu-
lation of past or future cycles.
The spot check quantity is also valid for later cyclic calculation of x-bar and process
capability, using always the last recorded values.
2. Press Accept.
3. Press Recording and Start initialization.
Start initialization
Initial. Parameters Actual
Barrel zone 1
Switchover volume actual
Injection time actual value
4. Choose the curves to be initialized.

5. Press Start initialization.
6. After the initialization cycles have been completed, the control unit automatically sets
the calculated limit values for the curves you opted to initialize. The header contains the
factors for machine capability Cm and Cmk.
Initialization with graphical selection
With Recording and Graphical area selection you can graphically select an previously
recorded area and initialize it. You can freely position the area in the diagram upto the end of
the curve and adjust the width with keys provided.
285
Graphical area selection
Cancel Help Accept
Machine capability characteristic values (Cm, Cmk)
Quality-relevant process parameters are used to examine the machine capability. This means,
is the machine capable of production with the current setting and within the specification limits.
The factor Cm shows the ratio of the scattering to the set tolerance distance. For calcuation
the set spot check quantity and the following formula are used:
OSG - USG
Cm
Cp =
6s
Cm does not include any statement about the position of this scattering, however. The factor
Cmk considers the shortest distance of the mean value to the upper or lower specification
limit.
OSG - x x - USG
Cmk
Cpk = or
3s 3s
The greater the factor, the greater the probability is that the machine will be able to produce
within the specification limits (if possible > 2).
Process capability characteristic values (Cp, Cpk)
The calculation is made as for Cm and Cmk, but with all the measured values since the start
of recording.

4 Histogram
The control can present the distribution of the relevant quality process parameters from the
injection molding process in the form of a bar chart (histogram).
PD histogram
Info Panel
Statistics
+
PD program PD record
Parameters Spec. injection pres-
Min Max
Deviation Deviation %
Shot
Setup Get data Delete
The distribution form of the histogram can infer either accidental or special reasons for varia-
tions.
Special causes of variations:

Material batch
Material not dried correctly
Defects or worn non-return valve
Closed loop controls
Errors on the production line
Common causes of variations:
287
Arbitrary fluctuations in values create a symmetric bell-shaped curve in a histogram (normal

distribution). The curve is characterized by the average value (x-mean) which is also the most
common value.
The standard deviation (s) is the distance between the inflection point of the curve to the mean
value and a metric of value distribution.
Normal distribution (bell-shaped curve)
s Turning point of the curve

(Change of direction of turning point)
Measured Measured value

value -3s -2s -1s x 1s 2s 3s
68,26%
95,46%
99,73%
_2 s = standard deviation of a sample

(x i - x) xi = Individual measured value of a sample
s= x = Mean value of the measured values of a sample
n-1 n = Number of the measured values of a sample
Procedure when recording a histogram:
Recording in the PD record or a PD graphic must exist or be in progress.

1. Setup opens a dialog for setting classes.
Settings PD histogram
Setting of classes
Classes
Cancel Help Accept
2. Set the number of the Classes (number of the bars) for the histogram and press .
3. Select the PD record or PD graphic in the PD program.
4. Choose the required Parameters.
5. PressRetrieve data.
The control unit displays the histogram, calculates x-mean, the standard deviation s and
the standard deviation in %.

5 Correlation graphics
Connections between two selectable process parameters can be analyzed by means of the
correlation graphics.
PD correlation
Info Panel
PD program PD graphics Zoom factor
+
X-axis Cycle time post in- Correlation coefficient... -86,467
Y-axis Screw volume end Shot counter 100 Shot
Shot
-0,2 -0,1 0 0,1 0,2

11,42 0,2
10,66 0,1
10,34 0
9,80 -0,1
9,26 -0,2
-0,27 2,52 5,32 8,12 10,91
Get data Delete
Procedure when recording a correlation graphics:

1. Using Set the same dialog as at the process data protocol is opened. Measuring param-
eters and parameters. [See Setting up and starting recording: on page 272.]
2. Set a recording
3. Press Start.
4. Select a parameter at X-axis.
5. Select a parameter at Y-axis.
6. PressGet data.
The control unit shows the correlation graphics of the maximally 500 last measurements
and calculates the correlation coefficient.
It is a measure for the strength of the connection of the selected parameters (X-/Y-axis).
The represented points are colored from light green (first measurement) to black (last
measurement).
289

Options
Options
1 Air valve
A solenoid air valve offers the possibility to switch on compressed air for certain mold or
machine functions. The valve is mounted near to the stationary platen.
Air valve
Info Panel
+ Air valve
Blowing time 1,00
Air valve 1 actuation DO021
For activating the air valve switch on the screen swich and insert in the machine sequence the
instructon ’Air valve - start’ for the air valve on the corresponding position. The air valve
switches off after the set ’Blowing time’ , only afterwards the sequence continues.
The instruction ’Air valve - Stop’ enables the stopping of the air valve before the blowing time
expires.
Example:
Air-supported demolding of a molded part.
Actuate air valve as of opening position 1 and stop after blowing time has elapsed or at end of
ejector movement.
Open mold Wait until: Mold open on position 1
Ejector - shaking Air valve - start

1 times
Air valve
Stop
Pushbutton:
Open air valve
WARNING!
Danger of squeezing when safety gate is open!

Air valves are not actuated when the safety gate is open. However, a
movement can occur due to the failure of the compressed air supply or
291
Options
loosening of a hose.
Attach suitable additional safety gates so that no movements that could
endanger persons can occur.

Options
2 Minicam
The Minicam program enables the start-up of a new mold. Based on setting material and parts
data, the control unit calculates settings for the injection unit. Also, with a reduced number of
parameters to set, a quick initial set-up of the clamp unit is possible. Excluded are peripheral
equipment, cores and program settings for e.g.: Weekly time switch, quality programs, etc.
Minicam
Info Panel
+ Start page Machine settings

Molded part Machine type
Screw diameter
Temperatures
Screw Standard
Mold close
Minicam parameters
Mold opening
Material type
Ejector
Material density
Nozzle
Plasticizing
Inject
Go to screen Delete all Transfer View
The Minicam setting is divided into 10 screen pages and the control unit marks pages with
newly calculated Minicam parameters with an arrow . Only when pressing the Transmis-
sion key does the control unit takes over the calculated values into the current setting.
Note!
Machine settings are current values, and are, when changed, effective immediately.
Proceed with the setting approximately as follows:

1. Select the Start page and select the Material type from the offered list. With this action,
temperatures and other parameters are already calculated on other pages.
293
Options
2. Choose the page Molded part
Minicam
Info Panel
+ Start page Minicam parameters
Molded part Shot weight
Temperatures Molded part volume
Mold close Shot volume
Mold opening Surface quality good
Representative wall thickness

Ejector
Cooling time
Nozzle
Holding pressure
Plasticizing
Filling time
Inject
3. Enter a shot weight or molded part volume.

4. Select the surface quality for the calculation of the mold temperature.
5. Enter the representative wall thicknesses from the points of the part which are qualita-
tively important for:
die Cooling time,
the hold pressure,
the mold filling time.
6. Now choose the pages marked with the arrow and check the calculated values. Press
the Transmit key to take over the parameters into the current setting.
7. Select the other movements one after the other and select a speed profile: slow,
medium, fast or unchanged.
When the Transmit key is pressed, the control unit divides the profile points to the set
stroke distance evenly and takes over the chosen speed profile.
Example Mold closing fast
Example Mold closing slow

Options
3 Conveying unit or coloring equipment

For actuating a material conveying unit or coloring equipment, a signal is activated during the
plasticizing process and also, possibly during intrusion, if set. The signal is deactivated at the
end of screw rotation. The signal is not active during decompression.
295
Options
4 Programmable in and outputs

This program permits the individual control of peripheral units and the blocking of machine
movements.
A variety of programmable digital input and output signals are available, which can be pro-
grammed in accordance with the requirements.
4.1 Freely programmable outputs

Info Panel
+ Ejector Output 2 Output 3 Output 4 Input 1 Input 2 Input 3
Designation Ejector
Output
Mode of operation fully automatic mode
Evaluation of parts deactivated
activate deactivate Unit

Activated in the sequence
Switch point Expanded ... Mold close
Position criterion
Signal criterion Plasticizing
Signal state Not inverted
Alarm condition
Designation
Text input for individual designation of the output.
Output
Short text and red flag for the output when it is active.
If you tap the designation, the label of the terminals in the electrical diagram appears
where the peripheral unit is to be connected.
Mode of operation
The output shall react in the requested mode of operation.
deactivated, function is switched off
always, output active in each mode of operation
manual, output only active in Manual and Set-up
semiautomatic
fully automatic mode
automatic, active in semi and fully automatic mode
Automatic without start-up cycles, active in semiautomatic and fully automatic
mode, but not during the set start-up cycles
Evaluation of parts
deactivated output activated no matter whether reject or good part
Reject output activated only when reject is detected
Good part output activated for good part only

Options

Activates following instructions in sequence:
Wait until: Equipment settings ’Programmable inputs/outputs’ and Action ’Output x
active’ or ’Output x not active’.
Freely programmable in/outputs: [See Programming in the machine sequence on
page 300.]
Switch point
The output wil be activated or deactivated when the switching point is reached when
a predetermined condition (e.g. stroke position) must be fulfilled.
List of the switching points and conditions for outputs
deactivated
permanent Permanent signal. On automatic start in automatic

mode
in case of error i.e. when the warning light is activated
Expanded A signal choice browser appears in the input field

for the signal selection. As a result it is possible to
make the freely programmable outputs dependent
on all digital inputs and outputs.
Cycle start
Mold closing Position criterion
clamp force is built up
Mold protection
Mold opening Position criterion
Mold close without clamp force
Nozzle forward x Position criterion
Nozzle return x Position criterion
Injection unit x Position criterion
Injection hold pressure unit x Position criterion
Plasticizing unit x Position criterion
Cooling time
Ejector forward x Position criterion
Ejector return x Position criterion
Safety gate closed
297
Options
List of the switching points and conditions for outputs
Move in core x
Move out core x
Programmable alarm The dialog window is supplemented by the alarm

input and the option for selecting existing alarms.
via sequence control Command in the machine sequence
Programmable alarm not active The dialog window is supplemented by the alarm
input and the option for selecting existing alarms.
If you select the criterion Extended, signal selection is then available.

Start condition selection
Criterion Expanded
Signal selection In/outputs System variable
Signal criterion
Cancel Help Execute
Press Inputs/Outputs to open the Select IOdialog. You can select required digital inputs or
outputs in the dialog.
Select IO
Cancel Help Execute
The selected signal is displayed below Signal criteria on screen.
When you choose the criterion Programmable alarm , the window Selection start criterionis
extended. Only alarms can be used which exist at present on the screen page Alarms.

Options
Example alarm cushion too small

Start condition selection
Criterion Programmable alarm
Number
Alarm input
Alarm message Cushion too small
Main alarm id InjectionUnit.er_CushionSmallLarge
Subalarm Id1
Subalarm Id2
Subalarm Id3
Subalarm Id4
Of pending alarms Alarm: Cushion too small
Cancel Help Execute
1. By pressing the key Of existing alarms you transmit all alarms, which exist at present
on the alarm page, into the opposite selection box.
2. In the selection box select the requested alarm. All characteristics of the alarm are
transmitted into the screen page Alarm input (Alarm message, alarm ID).
3. With Execute confirm the input and leave the screen page.
Alarm condition
Indicates the selected alarm on the screen page.
Signal state
Not inverted
Switching the output when reaching the switching point and fulfilling the set conditi-
ons.
Inverted
Switching of the output as long as the switch point has not been reached and the cri-
teria have not been fulfilled.
Delay time
Condition fulfilled
Set interval shts
Actual interval shts

Data type Parts
Delay time
The activation and deactivation of the output can be delayed by time settings.
Condition fulfilled
The yellow flag beside the position flag displays whether the set condition has been
met.
Interval
A number of intervals can be set so that the output only reacts after that many appea-
299
Options
rances of the switching point.

The interval counter only acts in the automatic modes of operation. The actual state is
always reset by actuating the PU key.
Data type
The programmed inputs and outputs can be written into the machine or parts data set
according to the selection made here.
4.1.1 Programming in the machine sequence

Instruction
The following dialog box appears when you insert the instruction.
Dialog window
Action Activate output 1
Cancel Help Execute
Select activation or deactivation of the required output in the dialog box, and press Execute to
insert the action into the sequence.
To activate the programming, switch the screen switch ’Activated in the sequence’ on in the
dialog window or in the ’Programmable inputs/outputs’ screen.
Note!
If you activate an output in a sequence, you also need to deactivate the output, as the output
will not be automatically deactivated when a new cycle starts.
Example:
Activating the output before mold closing, and deactivating after mold closing
Retract ejector
20,0 mm
Activate output 1
Mold - close
800,0 kN
Deactivate output 1
27,0 kN

Options
4.2 Freely programmable inputs

By means of programmable inputs, movements of the machine or of a peripheral unit can be
blocked or enabled under set conditions.
Freely programmable inputs/outputs

Info Panel
+ Output 1 Output 2 Output 3 Output 4 Input 1 Input 2 Input 3 Input 4
Designation Input 1
Programmable input signal used in sequence
Blocking signal selection Programmable input signal 1
Signal state
Mode of operation always
Blocked movement Mold close
Position criterion fro mm
Delay time s
Blocking active
Monitoring Permanent signal
Error handling Manual
Data type Parts
Designation
Here can be entered text for the a more detailed description of the switching input.
Blocking signal selection

Selection of the digital input from list (electrical schematic designation) and green flag for the
switch when it is active. When you touch this flag, information is display, via which modules the
signal runs in the control unit. The switch must be connected corresponding to the specifica-
tions in the electrical schematic.
Signal state
Choose which input state releases the switching point.
Mode of operation
Choose in which operation mode the signal and the setting are effective.
Blocked movement
Select movement which is influenced by the signal.
It is also possible to set Only error evaluation without blocking a movement.
Position criterion
Position to which or as of which the blocking signal for the movement is effective.
Delay time
switching points that are not stroke-dependent can be time-delayed.
Blocking active
301
Options
The flag lights when all set criteria are met.
Monitoring
Signal edge: Movement starts from signal edge. Movement remains, regardless of the signal,
until a sequence-conditioned stop occurs . Not effective in the manual mode.
Permanent signal: Movement starts and stops with the signal. Also acts in the manual mode.
Error handling
Selection in which mode of operation (manual, automatic) a message is to be displayed and
which actions are to take place in the case of an active signal. Effective only together with a
continuous signal if monitoring is switched on.
The following message then appears when the signal is active:
Input x (programmable input signal x)
Effect Depending on the set error evaluation
Data type
The programmed inputs and outputs can be written into the machine or parts data set accord-
ing to the selection made here.

Options
4.2.1 Programming in the machine sequence

You can program the programmable inputs in the machine sequence.
The wait until instruction has been extended to include programmable inputs/outputs for this.
Wait until dialog box

Wait until
Equipment Freely programmable in/outputs
Action Programmable input signal 1 active
Cancel Help Execute
Press Execute to insert the instruction at the required position in the sequence.
After programming the input in the sequence, the settings for this input are not active on the
programmable input/output screen.
Example:
Mold closing does not start until programmable input signal 1 is active.
Retract ejector
20,0 mm
Wait until: Programmable Inputs/Outputs
Programmable input signal 1 active
Mold - close
800,0 kN
27,0 kN
303
Options
5 Shut-off nozzles
The program is used to actuate the hydraulically or pneumatically actuated shut-off nozzles.
Settings such as time, stroke or pressure-dependent, or programming in the machine
sequence, permit flexible use.
Barrel shut-off nozzle Mold shut-off nozzle
WARNING!
Danger of injury due to high-pressure injection!

Insufficient pre-drying or decomposition of certain plastics can cause
the material to exit the nozzle or infeed opening in an uncontrolled way.
Machine movements of any kind are blocked according to the regulations EN 201 with the rel-
evant open gates and/or are deactuated when a gate is opened.
The machine operator has to ensure that, when opening a gate, no dangerous movement can
occur. This can be achieved with suitable safety gates.
Before carrying out maintenance and repair work, absolutely heed the notes in the Instruction
Manual in chapter ’Maintenance’, sections ’General note’ and ’Air maintenance unit’.
5.1 Barrel shut-off nozzles

A barrel shut-off nozzle prevents material from exiting the nozzle during plasticizing. A pneu-
matically or hydraulically actuated piston blocks or opens the melt channel in the nozzle.
The shut-off nozzles can be controlled via time, position or pressure.
A bar diagram shows the switching status of the shut-off nozzles during injection from right to
left, dependent on the time.

Options
Shut-off nozzles
Info Panel
+ Unit Shut-off nozzles Shut-off nozzles options
Barrel shut-off nozzles
Blue bar shows the set opening duration with the set switch points. Red vertical lines show the
start of injection, the start of holding pressure and the end of holding pressure.
If the opening/closing points cannot be allocated time-dependent (for example, in mode of

operation with sequence control), the bar is dashed.
The holding pressure in the bar diagram can be switched on/off in the display menu.
Set the barrel shut-off nozzle

The shut-off nozzle opens in automatic and manual mode during injection as specified in the
associated settings.
Tap the bar diagram to select the shut-off nozzle for settings, highlighting it in yellow.
Edit + Edit or tapping the bar diagram twice opens the dialog window.
Barrel shut-off nozzle 1
Mode of operation Time from start injection
Opening delay
Mode of operation Stroke during decompres-
Closing position
Cancel Help Accept
Mode of operation Opening

Time from start injection
The shut-off nozzle opens at start of injection with an adjustable delay time.
A negative time setting (only possible in this mode of operation) opens the shut-off
nozzle in advance.
Time from start of building up contact force
The shut-off nozzle opens at start of building up nozzle contact pressure with an
adjustable delay time.
Permanent
The shut-off nozzle is always open.
Sequence control
The shut-off nozzle opens when the instruction ’Shut-off nozzle trigger point x’ is
reached in the machine sequence. 4 trigger points are available; assignment takes
place in the dialog window of the corresponding shut-off nozzle.
305
Options
Sequence example:
Retract ejector
Mold - close Wait until: Mold - closed to position 1
Nozzle - build up Shut-off nozzle

Trigger point 1
Shut-off nozzle dialog window:

Trigger point
Mode of operation Closing

Time from end of holding pressure
The shut-off nozzle closes at end of post-injection pressure with an adjustable delay
time.
Stroke during decompression
The shut-off nozzle closes when the screw position is reached during the plasticizing
process (including the decompression ranges before/after plasticizing).
End of cooling time, End of plasticizing, End of decompression before plasticiz-
ing, End of decompression after plasticizing, Start of plasticizing
The shut-off nozzle closes when the event in question has occurred.
The screens Shut-off nozzles and Shut-off nozzle options are used to set the parameters
for opening/closing and displaying the valve states.
Shut-off nozzles
Info Panel

Unit. Open Close Valve
delay/pos. delay/pos. close/open
Shut-off nozzles
Info Panel
Unit Shut-off nozzles Shut-off nozzles options

Mode of operation
Open Close
Time from start injection Stroke during decompression
Note!

Options
Opening a gate or EMERGENCY STOP active:

When a safety gate is opened or the EMERGENCY STOP key is actuated, the current position
of the shut-off nozzle remains unchanged.
Closing the gates and resetting the emergency stop:
When all the gates are closed and an EMERGENCY STOP has been reset, the shut-off nozzle
closes automatically in machines with a safety gate on the injection unit.
In machines with an open design on the injection unit (only a nozzle safety gate), the shut-off
nozzle is not actuated until a movement starts.
e.g. plasticizing (close shut-off nozzle), injection (open shut-off nozzle), start automatic cycle
(close shut-off nozzle).
307
Options
5.2 Mold shut-off nozzles

Mold shut-off nozzles are integrated in the injection mold (e.g. in a hot runner). Pneumatically
or hydraulically actuated barrels move a needle in the mold that opens/closes a runner, depen-
ding on the application.
CAUTION!
Danger of damage to equipment!

Opening a safety gate always switches the actuation of the shut-off noz-
zles off for safety reasons.
Pushbutton:
Mold shut-off nozzle - opening
The shut-off nozzles can be controlled via time, position or pressure.

A bar diagram shows the switching status of the shut-off nozzles during injection from right to
left, dependent on the time.
Shut-off nozzles
Info Panel
Mold shut-off nozzles
Blue bars show the set opening duration with the set switch points, red vertical lines show start
of injection, start of post-injection pressure and end of post-injection pressure.
If the opening/closing points cannot be allocated time-dependent (for example, for pressure-
dependent shut-off nozzle control), the bar is dashed..
The holding pressure in the bar diagram can be switched on/off in the display menu.
Edit - Add
This adds an additional line for the selected shut-off nozzle on the Shut-off nozzles screens,
thus permitting a further switching process. The additional lines are indicated by a + in front of
the shut-off nozzle number.
Edit - Delete
Delete an additional line.
Set mold shut-off nozzle

Each individual shut-off nozzle can be activated with a screen switch.

Options
If it is switched on, the shut-off nozzle opens in automatic or manual mode during injection as
specified in the associated settings.
Condition in manual mode: pushbutton switched on, nozzle advanced to the nozzle contact
position and mold heating within tolerance.
Tap the bar diagram to select the shut-off nozzle for settings, highlighting it in yellow.
Edit + Edit or tapping the bar diagram twice opens the dialog window.
Mold shut-off nozzle 1
Activated
Mode of operation Opening Time from start injection
Opening delay
Mode of operation Closing Time from end of holding
Closing position
Opening with holding pressure
Open with pushbutton
Hydraulic shut-off nozzle
Cancel Help Accept
Mode of operation Opening

Time from start injection
The shut-off nozzle opens at start of injection with an adjustable delay time.
A negative time setting (only possible in this mode of operation) opens the shut-off
nozzle in advance.
Start of plasticizing, time from start of cooling, time from start of building up
contact pressure, time from start of post-injection pressure, sequence control
The shut-off nozzle opens with start of action with an adjustable delay time.
Stroke during injection
The shut-off nozzle opens when the screw position is reached during injection.
Permanent
The shut-off nozzle is always open.
CAUTION!
Opening a safety gate always switches the actuation of the shut-off nozzles off for
safety reasons.
Pressure during injection
The shut-off nozzle opens when the hydraulic or specific injection pressure is
reached.
CAUTION!
Reinforced shut-off nozzles are required for continuous operation.
Mould cavity pressure (option)
The shut-off nozzle opens when the cavity pressure is reached. With several charge
amplifiers, the allocation is made in the dialog window.
Charge amplifier
Injection phase (Option)

An assignment for the shut-off nozzle is also necessary in the option injection phase.
This can be set in the dialog window or in the screen ’Shut-off nozzles options’.
Injection phase
Mode of operation Closing
309
Options
Time from end of holding pressure

The shut-off nozzle closes at end of post-injection pressure with an adjustable delay
time.
Stroke during injection
The shut-off nozzle closes when the screw position is reached during injection.
Stroke during decompression
The shut-off nozzle closes when the screw position is reached during the plasticizing
process (including the decompression ranges before/after plasticizing).
End of cooling time, end of plasticizing, end of decompression after plasticiz-
ing, start of plasticizing
The shut-off nozzle closes when the event in question has occurred.
based on time
The shut-off nozzle closes after the elapsed time.
Mould cavity pressure (option)
The shut-off nozzle closes when the cavity pressure is reached. With several charge
amplifiers, the allocation is made in the dialog window.
Opening with holding pressure

If the screen switch has been activated, the shut-off nozzle opens during the entire post-
injection pressure, even if it was already closed previously.
Open with pushbutton
If the screen switch has been activated, the shut-off nozzle opens in manual mode when
the ’Open mold shut-off nozzles’pushbutton is pressed.
Hydraulic shut-off nozzle
To activate the machine hydraulics with hydraulic shut-off nozzles, switch on the screen
switch.
To only actuate the valves with pneumatic shut-off nozzles, switch off the screen switch.

Options
The screen Shut-off nozzles is a display overview of the settings and displays of valve states
for all shut-off nozzles. It is also used to activate the shut-off nozzles and set the time delays
and positions for opening/closing.
Shut-off nozzles
Info Panel

Open Close Valve
delay/pos. delay/pos. close/open
Pressure relief 1 shut-off nozzles
Pressure relief shut-off nozzle

(Option only for hydraulic shut-off nozzles)
Hydraulic connections pressure is relieved by opening all shut-off nozzles and simulta-
neously actuating the pressure relief valve.
Pushbutton:
Mold shut-off nozzle pressure relief
Procedure for pressure relief of hydraulic shut-off nozzles:

1. Close clamp unit safety gate.
2. Press pushbutton ’Mold shut-off nozzle pressure relief’.
Sequence of pressure relief:

1. Open hydraulic mold shut-off nozzles.
2. Open pressure relief valve (if existing).
3. After the pushbutton is released, the mold shut-off nozzles close. The pressure relief
valve remains open until the next time the shut-off nozzle is opened.
311
Options
The screen Shut-off nozzle options is a display overview of the settings for all shut-off noz-
zles. It is also used to set the operating mode for opening/closing the shut-off nozzles.
Shut-off nozzles
Info Panel

Mode of operation Unit. open dur- open with
Open Close Holding Pushbut-
Stroke during in- Stroke during in-
Stroke during in- Stroke during in-
Time from start in- Stroke during in-
Time from start in- Stroke during in-
Stroke during in- Stroke during de-
Sequence control Stroke during de-

Permanent
Close mold shut-off nozzles at the latest end of plasticizing
Close mold shut-off nozzles at the latest

All shut-off nozzles close at this time at the latest. Exception: the Permanent mode of
operation.
Unit.
Injection unit assignment in multicolor machines
Open mold shut-off nozzle with sequence control

Select mode of operation sequence control.
Sequence control
The shut-off nozzle opens when the instruction ’Shut-off nozzle trigger point x’ is
reached in the machine sequence. 4 trigger points are available; assignment takes
place in the dialog window of the corresponding shut-off nozzle.
Sequence example:
Retract ejector
Mold - close Wait until: Mold - closed to position 1
Nozzle - build up Shut-off nozzle

Trigger point 1
Shut-off nozzle dialog window:

Trigger point

Options
6 Central computer (Host)

The central computer interface is used to transfer parts data sets, individual set or actual
values, process data, as well as standstill reasons, error and operating states, to the host
(uploading). It is also used to transfer parts data sets or individual set values to the control unit
(downloading). To do this, select the number of the desired parts data set and switch Demand
transmission on. The transfer starts if the data set exists in the central computer.
Central computer
Info Panel
+ Order data
Order number
Molded part number
Mold number
Material number
Dataset number
Demand transmission
Status information
Status Start Error Code Ready
Host communication error no message
Status information
The screen flags indicate the status of the transmission:
START Transmission started
ERROR Transmission error, transmission interrupted
CODE Parts data set code (SET) does not exist on the host
FINISH Transmission completed successfully
Three error reactions can be set in the line Host communication errors :
no message:
Message and no cycle stop:
In automatic mode, the error message is deleted when the next cycle starts, but is still
documented in the malfunction message log.
Message and cycle stop:
Host communication
Effect Either message only or message and cycle stop
313
Options
Standstill reason:
Standstill reason
Autoreset Autoreset
Set up machine no material

+
Machine defective no personnel
Mold defective Overcapacity
Mold sampling no release
Clean machine other reasons
no order out of action
Code
The entry Code permits a message to the host in order to notify it of the current standstill rea-
son for the machine. The number can be found in the listed menu of standstill reasons (num-
bers 1 to 12).
The user can change the text of the standstill reasons.
The control unit checks at each automatic start whether the switch Autoreset is switched on
at that standstill reason to which the current standstill code corresponds. When this is the
case, the standstill code is written on the value 0 automatically.
The host can suppress the next automatic start. Message:
Host stops cycle
Effect Automatic start not possible
Remedy Acknowledge with PU key.
6.1 Text pages

Separate screen pages serve the transmission of additional text information to the central
computer and to the machine. A red symbol on the status line draws the attention to the input
of a new information.
Also after reading in CC100 parts data set the text information is visible on these pages.
Text pages
Info Panel
+ Text page 1 Text page 2 Text page 3

Options
7 Ecograph
The Ecograph is used to determine and display energy consumption in detail. The calculation
is based on motor, heating and parts data.
7.1 Energy graphic

Display of power input and energy consumption for the last cycle (green bar) and the current
cycle (yellow bar).
In addition, display of the specific energy consumption based on the total energy consumption
and the set shot weight. When the shot weight changes, the value in the production screen
page also changes.
ecograph
Info Panel
+ Energy graphic Energy Analysis cycle Drives analysis
last current
Power input
Drives
Heating
Total
Energy consumption
Drives
Heating
Total
Specific energy consumption

Total
Shot weight
Shot weight
The bar maximum display can be adjusted in each screen section.

The recordings are only active in the automatic mode.
315
Options
7.2 Energy
The peak values and mean values in the power and energy data refer to the set cycles. If the
cycles are not reached after the control unit is switched on, the program uses the number of
completed cycles for the calculation.
ecograph
Info Panel
Performance data
Actual value Peak value Mean value
Drives
Heating
Total
current shts
Initialization of peak, mean and consumption values
Energy data
Actual value Peak value Mean value Consump-
Drives
Heating
Total
Cycles last shts
Initialization of peak, mean and consumption values
Energy consumption
Consump- since Reset all
Drives
Heating
Total
Total
Shot weight
Shot weight
Performance data
Actual value shows the actual power (kW) of the current cycle.
Program switch Initialization of peak, mean and consumption values starts a new
calculation of values from the current cycle. The data from previous cycles are no longer
input into the calculation.
Energy data
Actual value shows the energy (kWh) of the last cycle.
In the display Consumption the total energy of the set cycles can be read.
Program switch Initialization of peak, mean and consumption values starts a new calcu-
lation of values from the current cycle. The data from previous cycles are no longer input
into the calculation.
Energy consumption
When the switch Reset is activated, the corresponding energy counter is deleted and
the current date is replaced by the system time. All counters are reset when the switch
in the column Allis activated.
The energy measured starting at this time is displayed continuously.
Calculated from the shot weight and energy consumption of the last cycle.

Options
Shot weight
Input for calculation of the specific energy consumption.
When the shot weight changes, the value in the production screen page also changes.
7.3 Analysis cycle

The control unit uses the times of the cycle time analysis and energy analysis values for the
calculation.
ecograph
Info Panel
last current
Mold close
Nozzle
Inject
Holding pressure
Cooling time
Plasticizing
Mold opening
Ejector
Part removal
Mold swivelling device
Dry cycle
The current actual values are displayed continuously in automatic mode as bar charts and fig-
ures. The top bar (yellow) shows the current cycle, the lower bar (green) the last cycle.
The bar maximum display can be adjusted at the lower side margin.
317
Options
7.4 Drives analysis

Display of energy consumption values for individual drives or hydraulic pumps for the last cycle
(green bar) and the current cycle (yellow bar).
This tab can be activated in the variables monitor.
ecograph
Info Panel
last current
Pump 1
Pump 2
Pump 3
The recordings are only active in the automatic mode.

Options
8 VirtMold Program
The program VirtMold is used to simulate ENGEL injection molding machines and robots with
CC200 control units. It enables the creation, editing and testing of parts data sets on a PC wit-
hout interrupting the production process. The data sets can be exchanged at any time between
the real machine and VirtMold.
8.1 System requirements

Operating system Windows 2000, Windows XP or Windows Vista
Processor > 1,5 Ghz
Memory 1 GB RAM
Hard disk space for the VirtMold basic installation approx. 80 MB, plus approx. 100 MB
per machine simulation
Monitor resolution 1280 x 1024 Pixel recommended
Compact Flash memory card reader or USB interface
CD-ROM drive
Note!
Before installing VirtMold, close all other applications.
8.2 Installation
A VirtMold consists of the VirtMold basic installation and one or more machine simulations.
Note!
The installation of additional machine simulations does not require a new installation of the
VirtMold basic installation.
VirtMold Installation - Basic installation

If you have already installed VirtMold or an eTrainer, first check the VirtMold version [See Virt-
Mold Version on page 325.]. If it is a current version (Version 3.0.4.0 or higher) continue with
the installation of the machine simulation.
If you have an old version of VirtMold (before 3.0.4.0), uninstall this version before you con-
tinue. Then go on to install the current version of VirtMold.
To do this, follow the instructions of the installation program on the installation CD
(README.htm).
Machine simulation installation (Copy Virtual Machines)

The window ’Copy Virtual Machines’ appears automatically after completing the installation, or
it can be selected via ’Start menu - Programs/VirtMold/Copy machines’.
There are 2 standard machines on the installation CD.
If you want to create a machine simulation of a real machine, switch to [See Creating a
machine simulation from a real machine on page 320.].
Select the desired machine in selection box ’Virtual Machines to be installed’ (check the field
in front of the machine number or name ) and click ’Install’.
Files are now copied to your computer, and then displayed in the ’Virtual Machines already
installed’field.
319
Options
In order to remove a machine from the PC, select the machine in selection box ’Virtual
Machines already installed’ and click the ’Remove’button.
Finish the installation process by pressing ’Exit’.
8.3 Creating a machine simulation from a real machine

You can create a machine simulation for the VirtMold from any real machine with a CC200
control unit.
To create a machine simulation, you need either an empty USB stick or an empty Compact
Flash memory card with a memory capacity of at least 256 MB or a network connection to the
machine.
Note!
Creating a machine simulation by copying to a USB stick or Compact Flash memory card
requires access to user level 11. Contact a person with the appropriate authorization to imple-
ment this activity.
Procedure for copying the system flashcard:

1. Insert the storage medium into the machine.

Options
2. Switch to the ’Data dialog’ screen and press ’Setup - System Flashcard’
Data dialog
Info Panel
/hard disk1 Active parts data set Screw cap_small
Data set attributes

Name Screw cap_small
Mold code
Author
Production date
Change author
Change date
Export user data
Description Import user data
Machine num- JNI Report
System flash card
Archive delivery status
Software update
License update
Read machine data
Write machine data
Display active machine data
Parts data Edit Setup View
3. The ’Save Flashcard’dialog box appears. Select the drive with the storage medium to
which you want to copy the system flashcard. Press ’Save’ to start copying.
Save flash card
Available drives
Directory
Cancel Help Save
4. The ’Save Flash’dialog box appears.

Back-up Flash
Cancel
5. The dialog box disappears as soon as the copying process is completed.
Procedure for installing the machine simulation
321
Options
1. Boot your PC.

2. Attach the storage medium with the copy of the system flashcard to your PC.
3. Launch the Copy machines program. To do this, select ’Programs/VirtMold/Copy
machines’in the start menu.
4. The ’Copy Virtual Machines’window appears
5. In ’Select location of Virtual Machines folder’ , select the storage medium with the copy
of the system flashcard. To do this, use ’Select Folder’ to open a search window and
select the drive with the storage medium from it. Now the machine number of the
machine from which you have created the system flashcard appears in selection field
’Virtual Machines to be installed’.
E:\
6. Select the field in front of the machine number and press ’Install’. The installation
procedure starts and the installation progress is shown in the ’Progress’ tab.
7. The installation procedure is completed when Done is displayed in the ’Status’ tab. The
machine number is displayed in the field ’Virtual Machines already installed’ . Quit the
Copy Virtual Machines program with the ’Exit’button.

Options
8. Before removing the storage medium from the PC, select ’Remove or eject hardware’.
Failure to do so could damage the data on the storage medium.
Procedure for installing the machine software via network:

1. Boot your PC.
2. Launch the Copy machines program. To do this, select ’Programs/VirtMold/Copy
machines’in the start menu.
3. The ’Copy Virtual Machines’window appears
4. Enter the IP address of the machine in ’Select location of Virtual Machines folder’ . The
machine number of the machine is then displayed in the selection field ’Virtual Machines
to be installed’.
10.2.67.5
323
Options
5. Select the field in front of the machine number and press ’Install’. The installation
procedure starts and the installation progress is shown in the ’Progress’ tab.
6. The installation procedure is completed when Done is displayed in the ’Status’ tab. The
machine number is displayed in the field ’Virtual Machines already installed’ . Quit the
Copy Virtual Machines program with the ’Exit’button.
After successfully installing the machine simulation, launch VirtMold and select the desired
machine in the selection window.
8.4 VirtMold menu

The VirtMold menu icon appears on the right side of the toolbar to indicate that a machine sim-
ulation is running . Use the right mouse button to select.
This menu lets you select the basic settings for the simulation by left clicking.
Menu items
Configuration
This window displays all the links and settings for the simulation. These settings cannot
be changed after the installation.
Windows
This selection opens an additional menu where you can enable/disable all windows in
the machine simulation. You can use the mouse to arrange the open windows and to
scale the windows.
Example of a simulation window selection menu:
Cascade
Arranges all windows selected in the ’Windows’ dialog behind one another. The actual
window arrangement is however lost in this procedure.
Load/Save windows cfg
You can use these functions to store the window layout for the simulation, and open the
same layout at any time later. This function is useful if several people work with a
machine simulation, but prefer different window layouts.
Select Machine
You can change the machine simulation with this function. The function can be selected
after stopping the current simulation (menu item Stop Machine). The same dialog box
as during launching of the simulation appears. [See Start and screen structure on
page 325.]
Stop Machine/Start Machine
You can select ’Stop Machine’ to stop the current machine simulation. The selection tog-

Options
gles to ’Start Machine’. This option lets you start the machine you stopped (e.g. to rem-
edy a malfunction in the simulation).
However, you can select another machine simulation by selecting ’Select Machine’.
Tutorial (Option)
Opens an interactive training session for the machine control unit.
Help (Option)
Only activates the online help on a machine simulation.
About
Provides information about the simulation variants. [See VirtMold Version on
page 325.]
Exit
This selection terminates VirtMold (complete simulation).
8.5 VirtMold Version

To do so, open the VirtMold menu and select ’About’. A window with information about the
’Basic Components’ and ’VM_Loader’ versions appears. If both are higher than 3.0.4.0 , you
do not need to reinstall VirtMold.
Press ’Ok’ to close the window.
8.6 Start and screen structure

After the installation, an icon with the name ’VirtMold’ is created on your computer desktop.
Double-click on the icon to start VirtMold.
VirtMold
It is also possible to start the program in the Start menu by selecting ’Programs/VirtMold/Virt-
Mold’.
When the program loads it displays a dialog where you can select the machine. This is man-
datory for using multiple machines. Select the machine you need and press ’OK’ to continue.
325
Options
Selection window
Note!
With some PCs, it takes a few minutes until the simulation has started completely. Do not start
VirtMold again in this time!
When the simulation is up and running, at least 3 windows are visible. VirtMold controls are
identical to those for the actual machine. Use the PC mouse to navigate the screen.
Display example with combined windows:
1 2
1. Control unit user interface

2. Switch panel
3. Safety gate overview
4. Machine simulation
You can arrange the windows to suit your own preferences, and select windows with additional
functions. These settings are performed in the VirtMold menu.

Options
For a better overview, you can combine various windows to form one window by dragging
them together with the mouse. The Docking Manager appears. Depending on where you pull
the window in the Docking Manager, both windows are then anchored in place.
Docking Manager
Arrange windows next to each other according to position selected
Arrange windows on top of each other, select using the tabs
In order to change the sequence of tabs, pull the tab to the required position. You can change
the position of windows next to each other in the same way.
To separate combined windows, pull the respective window by the tab or header line away
from the other window.
8.7 Edit data set

In order to use a machine parts data set in the simulation, you need a Compact Flash memory
card reader or a USB port on the PC.
The ’Data Dialog’ on the VirtMold shows you all the PC drives (including network drives) that
are available as memory drives for managing or archiving parts data sets.
When saving data, VirtMold automatically creates a DATA folder in the root directory of the cur-
rent drive. To view the data sets later, make sure you do not move the folder to a subdirectory.
Example:
Data dialog
Info Panel
C:\ Active parts data set: Screw cap_small
Screw cap_small Data set attributes

MACHINE DATA Name Screw cap_small
Production date
1. Store the parts data set for the machine on a Compact Flash memory card or USB stick.
2. Connect the storage medium to the PC.
3. Select the storage medium drive in the VirtMold ’Data dialog’.
4. Upload data set to VirtMold and then run the simulation with it.
5. To back up the data set, select any drive in the ’Data dialog’ and save. Save the data set
on your PC on a Compact Flash memory card or USB stick; select ’Remove or eject
hardware’. Failure to do so could damage the data on the storage medium.
6. Reading a parts data set into the machine.
Note!
To simplify managing the data sets of several machine simulations, it is possible to save
directly in the machine directory. To do this, select the simulation drive (normally drive O:) as
the storage drive in the Data dialog box. The simulation drive is visible in the selection window
when the machine simulation is started.
327
Options
Simulation drive (Mounted to:)

This drive is automatically assigned
by VirtMold; normally, it is drive O:
If this is already occupied by another
application, an available drive is
assigned.

Options
329
Options

Special programs
Special programs
331
Special programs

Symbols *Mechanical closing safety x moved in . . . . . . . . . . . . . . . .32
*Micrograph tolerance exceeded . . . . . . . . . . . . . . . . . . . .258
*Acknowledge safety gate x . . . . . . . . . . . . . . . . . . . . . . . . 30
*Adjust moving-in switchover point . . . . . . . . . . . . . . . . . 219 *Mold clamping mechanism on stop . . . . . . . . . . . . . . . . . .86
*Mold heating is switched off . . . . . . . . . . . . . . . . . . . . . . .135
*Alarm with cycle stop appeared . . . . . . . . . . . . . . . . . . . . 61
*Mold heating reduces . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
*Automatic motor start by week switch clock . . . . . . . . . . 210
*Automatic plasticizing active . . . . . . . . . . . . . . . . . . . . . . 172 *Mold heating x too cold . . . . . . . . . . . . . . . . . . . . . . . . . .122
*Mold heating x too hot . . . . . . . . . . . . . . . . . . . . . . . . . . .122
*Autoprotect maximum monitoring value . . . . . . . . . . . . . . 79
*Mold heating x Zone x Pre-heating active . . . . . . . . . . . .135
*Barrel heat soaking is active . . . . . . . . . . . . . . . . . . . . . . 118
*Barrel heater at standby . . . . . . . . . . . . . . . . . . . . . . . . . 123 *Mold not closed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
*Mold not closed on position . . . . . . . . . . . . . . . . . . . . . . . .85
*Barrel heaters are switched off . . . . . . . . . . . . . . . . . . . . 118
*Mold not open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
*Barrel heating x too cold . . . . . . . . . . . . . . . . . . . . . . . . . 122
*Barrel heating x too hot . . . . . . . . . . . . . . . . . . . . . . . . . . 122 *Mold not open at position . . . . . . . . . . . . . . . . . . . . . . . . . .92
*Mold protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
*Charge amplifier x changeover point not recognized . . . 163
*Movement not available . . . . . . . . . . . . . . . . . . . . . . . . . .182
*Charge amplifier x rejects at learning phase . . . . . . . . . 163
*Check mold height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 *Multiple closing end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
*Nozzle contact position not reached . . . . . . . . . . . . . . . .153
*Clamping force exceeded . . . . . . . . . . . . . . . . . . . . . . . . . 77
*Nozzle position out of area . . . . . . . . . . . . . . . . . . . . . . . .153
*Clamping force too low . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
*Clamping unit disconnected safety gate x not open . . . . . 30 *Nozzle safety gate open . . . . . . . . . . . . . . . . . . . . . . . . . . .25
*Open-close-acknowledge safety gate x . . . . . . . . . . . . . . .30
*Clamping unit safety gate interrupts cycle . . . . . . . . . . . . 25
*Operating state not in SET-UP . . . . . . . . . . . . . . . . . . . . .105
*Clamping unit safety gate open . . . . . . . . . . . . . . . . . . . . 24
*Clamping unit safety gate x acknowledgement key actuated for *PDP data store full . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .272
*Piece counter expired . . . . . . . . . . . . . . . . . . . . . . . . . . . .217
too long . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
*Plasticizing not reached . . . . . . . . . . . . . . . . . . . . . . . . . . .61
*Clamping unit safety gate x acknowledgement key actuated too
quickly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 *Plasticizing time exceeded . . . . . . . . . . . . . . . . . . . . . . . .171
*Plasticizing time not reached . . . . . . . . . . . . . . . . . . . . . .171
*Clamping unit safety gate x open-close . . . . . . . . . . . . . . 25
*Possible error in the wiring of zone x . . . . . . . . . . . . . . . .139
*Close safety gate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
*Core deactivated in the sequence . . . . . . . . . . . . . . . . . 111 *Postsoaking active - no screw movement possible . . . . .126
*Pressure limit at x ccm exceeded . . . . . . . . . . . . . . . . . . .157
*Core end position left . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
*Pressure pad clamping open . . . . . . . . . . . . . . . . . . . . . .105
*Core limit switch defective . . . . . . . . . . . . . . . . . . . . . . . 108
*Core monitoring time exceeded . . . . . . . . . . . . . . . . . . . 112 *Program interruption key . . . . . . . . . . . . . . . . . . . . . . . . . .39
*Pump motor switched off . . . . . . . . . . . . . . . . . . . . . . . . . .59
*Core not moved in/out . . . . . . . . . . . . . . . . . . . . . . . . . . 107
*Push-button actuated . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
*Core safety x active . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
*Core x move in limit switch defective . . . . . . . . . . . . . . . 109 *Pushbutton sequence activated . . . . . . . . . . . . . . . . . . . .199
*Rejects counter expired . . . . . . . . . . . . . . . . . . . . . . . . . .220
*Core x move out limit switch defective . . . . . . . . . . . . . . 109
*Safety gate - safety strip - actuated . . . . . . . . . . . . . . . . . .28
*Core x not moved in/out (check position) . . . . . . . . . . . . 111
*Safety gate x acknowledgement key pressed too early . . .30
*Cushion too large . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
*Cushion too small . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166 *Safety guarding x acknowledgement time exceeded . . . . .30
*Safety key not pressed . . . . . . . . . . . . . . . . . . . . . . . . . . .105
*Cycle time exceeded . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
*Save sequence - safeties not current . . . . . . . . . . . . . . . .186
*Delay heater x reduction . . . . . . . . . . . . . . . . . . . . . . . . . 137
*Delay switch off heater x . . . . . . . . . . . . . . . . . . . . . . . . . 137 *Set screw diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .167
*Shot counter expired . . . . . . . . . . . . . . . . . . . . . . . . . . . .217
*Delayed motor stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
*Soaking inspection active . . . . . . . . . . . . . . . . . . . . . . . . .126
*Determine mold height . . . . . . . . . . . . . . . . . . . . . . . . 86, 87
*Determine nozzle contact position . . . . . . . . . . . . . . . . . 153 *Soaking inspection Maximum torque reached . . . . . . . . .126
*Soaking inspection was active . . . . . . . . . . . . . . . . . . . . .126
*Editing mode active . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
*Start key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
*Ejection control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
*Ejection not possible with rejects . . . . . . . . . . . . . . . . . . . 97 *Start-up phase active . . . . . . . . . . . . . . . . . . . . . . . . . . . .219
*Step mode activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . .198
*Ejector motion monitoring . . . . . . . . . . . . . . . . . . . . . . . . . 94
*Step safety active . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
*Ejector not back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
*Ejector not retracted (check position) . . . . . . . . . . . . . . . . 98 *Switch clock has switched off . . . . . . . . . . . . . . . . . . . . . .213
*Temperature control device Communication error in zone x .
*Emergency mode - thermocouple break heater x . . . . . . 141
146
*Emergency-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
*Error in the wiring of zone x . . . . . . . . . . . . . . . . . . . . . . 139 *Temperature control device Cooling zone x is defective .146
*Temperature control device Error No. in zone x . . . . . . . .146
*Export memory full . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
*Temperature control device Flow rate zone x too low . . .146
*External closing interlock . . . . . . . . . . . . . . . . . . . . . . . . . 85
*External operation active . . . . . . . . . . . . . . . . . . . . . . . . . 45 *Temperature control device Heating zone x is defective .146
*Temperature control device Initialization of temperature control
*Flash card full . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
device failed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146
*Flow number measuring range set wrong . . . . . . . . . . . 266
*Flow number reject . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266 *Temperature control device Level zone x too low . . . . . .146
*Temperature control device Limit value zone x exceeded 146
*Guided operation - thermocouple break heater x . . . . . . 141
*Temperature control device Pump of zone x defective . .146
*Host communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
*Host stops cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314 *Temperature control device Set value for zone x not plausible
146
*Injection monitoring memory full . . . . . . . . . . . . . . . . . . . 270
*Temperature control device stopping injection unit . . . . .146
*Injection monitoring tolerance exceeded . . . . . . . . . . . . 270
*Injection time exceeded . . . . . . . . . . . . . . . . . . . . . . . . . 157 *Temperature control device Temp. zone x too low / too high .
145
*Injection time not reached . . . . . . . . . . . . . . . . . . . . . . . . 157
*Temperature control device Thermocouple break zone x 146
*Input x (programmable input signal x) . . . . . . . . . . . . . . 302
*Jumper plug for core moved in/out is missing . . . . . . . . 108 *Temperature control device x delay time temperature reduction
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146
*Locking not open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
*Temperature control device x flow rate zone x too low/high 147
*Machine home position run active . . . . . . . . . . . . . . . . . . 90
*Material hopper not in production position . . . . . . . . . . . 106 *Temperature control device Zone x blocking injection unit 146
*Tiebar not threaded . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104
333
*Tolerance limit PD monitoring exceeded/not reached . . 284 e-Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
*Unit not at the back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Ejector intermediate stop . . . . . . . . . . . . . . . . . . . . . . . . . . 98
*Value corrected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227 Ejector movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
*Warning limit PD monitoring exceeded/not reached . . . . 284 Ejector start/stop settings . . . . . . . . . . . . . . . . . . . . . . . . . . 98
*Wrong setting in the sequence . . . . . . . . . . . . . . . . . . . . 186 Ejector stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
*Zone x not activated . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 Electric safety gate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Emergency mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
A EMERGENCY STOP function . . . . . . . . . . . . . . . . . . . . . . 24
Activate core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Energy (Ecograph) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
Add mold shut-off nozzle switching process . . . . . . . . . . . 308 Energy graphic (Ecograph) . . . . . . . . . . . . . . . . . . . . . . . 315
Adding heating zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 Export injection protocol . . . . . . . . . . . . . . . . . . . . . . . . . . 230
Additional equipements . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Air valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291 F
Alarms and messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Force stroke correction . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Autoprotect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Freely programmable inputs . . . . . . . . . . . . . . . . . . . . . . 301
Autoprotect injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268 Freely programmable inputs in the machine sequence . . 303
Autoprotect settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Freely programmable outputs . . . . . . . . . . . . . . . . . . . . . 296
B G
Back pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169 Guidance zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Back pressure in manual pressure . . . . . . . . . . . . . . . . . . 172 Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Barrel heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Guidelines for working on the injection molding machine . 22
Barrel shut-off nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . 304 Günther hot runner controller . . . . . . . . . . . . . . . . . . . . . . 148
Barrier screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Behavior in case of fire . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 H
Header with Info Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
C Heating configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Cancel mold safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Heating configuration - Deleting a heating zone . . . . . . . 133
Central computer (Host) . . . . . . . . . . . . . . . . . . . . . . . . . . 313 Heating optimization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Changing user access authorizations . . . . . . . . . . . . . . . . . 57 Heating regulation mode . . . . . . . . . . . . . . . . . . . . . . . . . 129
Charge amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162 Heating-up circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Charge amplifier LV5155 with pressure and temperature channel Heating-up optimization . . . . . . . . . . . . . . . . . . . . . . . . . . 138
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163 Heat-up with reduced heating wattage . . . . . . . . . . . . . . . 136
Charge amplifier LV5155-SA (5049) . . . . . . . . . . . . . . . . 163 Help system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Clamp force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Histogram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
Clamping force, two-stage . . . . . . . . . . . . . . . . . . . . . . . . . 78 Holding pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Clamping unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Holding pressure profile . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Closing area acknowledgement . . . . . . . . . . . . . . . . . . . . . 26 Hydromechanical DUO machine . . . . . . . . . . . . . . . . . . . . 75
Components of screen pages . . . . . . . . . . . . . . . . . . . . . . 202
Components of the control unit . . . . . . . . . . . . . . . . . . . . . . 38 I
Configurable keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Ideal curve initialization . . . . . . . . . . . . . . . . . . . . . . . . . . 255
Conveying unit or coloring equipment . . . . . . . . . . . . . . . 295 Importing/exporting user data . . . . . . . . . . . . . . . . . . . . . . 57
Cooling time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166 Increased opening force . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Copy parts data set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228 Info Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Copying parts data sets . . . . . . . . . . . . . . . . . . . . . . . . . . 228 Infolog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Infolog (Production protocol) . . . . . . . . . . . . . . . . . . . . . . 239
Core signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Injection molding in general . . . . . . . . . . . . . . . . . . . . . . . . 13
Core speed and pressure . . . . . . . . . . . . . . . . . . . . . . . . . 111 Injection molding machine cycle . . . . . . . . . . . . . . . . . . . . 13
Core with external energy supply . . . . . . . . . . . . . . . . . . . 113 Injection speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Cores pressure relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Injection time monitoring . . . . . . . . . . . . . . . . . . . . . . . . . 157
Correlation graphics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289 Injection unit large machines . . . . . . . . . . . . . . . . . . . . . . 149
Creating a VirtMold based on a physical machine . . . . . . 320 Input keyboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Creating new user access authorization . . . . . . . . . . . . . . . 56 Installation of VirtMold . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
Cushion monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166 Interactive messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Cycle analysis (Ecograph) . . . . . . . . . . . . . . . . . . . . . . . . 317 Intrusion program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Cycle monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Cycle time analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209 L
Loading machine sequence . . . . . . . . . . . . . . . . . . . . . . . 180
D
Danger signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 M
Data dialog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Machine capability characteristic values (Cm, Cmk) . . . . 286
Data dialog - Copy all parts data sets . . . . . . . . . . . . . . . . 228 Machine sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Data dialog - Export . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
Machine sequence - Changing an instruction . . . . . . . . . 188
Decommissioning the injection molding machine . . . . . . . . 62
Machine sequence - Inserting an instruction . . . . . . . . . . 187
Decompression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172 Machine sequence - Instruction Time . . . . . . . . . . . . . . . 189
Delete data set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
Machine sequence - Instruction Wait until . . . . . . . . . . . . 192
Deleting user access authorization . . . . . . . . . . . . . . . . . . . 57
Machine sequence - Parallel open branch . . . . . . . . . . . . 192
Drives analysis (Ecograph) . . . . . . . . . . . . . . . . . . . . . . . . 318 Machine sequence - Removing an instruction . . . . . . . . . 189
Machine sequence - standard sequence . . . . . . . . . . . . . 179
E Machine sequence - visualization of machine sequence . 177
Ecograph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315 Machine sequence and Mask Editor . . . . . . . . . . . . . . . . 175
Editing the data set (VirtMold) . . . . . . . . . . . . . . . . . . . . . 327

Machine setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206 Process data package . . . . . . . . . . . . . . . . . . . . . . . . . . . .271
Machine-specific key symbols . . . . . . . . . . . . . . . . . . . . . . 40 Process data record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .271
Mandatory Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Production counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .216
Mask editor - Paste a comment . . . . . . . . . . . . . . . . . . . . 206 Programmable in and outputs . . . . . . . . . . . . . . . . . . . . . .296
Mask editor - Paste new strips . . . . . . . . . . . . . . . . . . . . . 203 Programmable outputs in the machine sequence . . . . . . .300
Mask editor - Paste of existing strips . . . . . . . . . . . . . . . . 203 Programming machine sequence . . . . . . . . . . . . . . . . . . .184
Mask editor - Paste variables from a list . . . . . . . . . . . . . 204 Prohibitory signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Mask editor - Paste variables from existing screen pages 204 Proper Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Mask editor - Search variable . . . . . . . . . . . . . . . . . . . . . 205 Pushbutton sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . .198
Measuring group temperature monitoring . . . . . . . . . . . . 142
Mechanical closing safety . . . . . . . . . . . . . . . . . . . . . . . . . 32 R
Mechanical core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 Read parts data set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .226
Metering performance . . . . . . . . . . . . . . . . . . . . . . . . . . . 169 Record Micrograph curve groups . . . . . . . . . . . . . . . . . . .253
Microflow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267 Rescue actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Micrograph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
Micrograph - Volume or stroke dependent view . . . . . . . . 261 S
Micrograph actual value display . . . . . . . . . . . . . . . . . . . . 265
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Micrograph Curve-specific settings . . . . . . . . . . . . . . . . . 253 Safety equipment - overview . . . . . . . . . . . . . . . . . . . . . . . .23
Micrograph exporting curves . . . . . . . . . . . . . . . . . . . . . . 262
Safety equipment function . . . . . . . . . . . . . . . . . . . . . . . . . .24
Micrograph monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
Safety hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Micrograph printing of curves . . . . . . . . . . . . . . . . . . . . . . 261 Save machine sequence . . . . . . . . . . . . . . . . . . . . . . . . . .182
Micrograph Store ideal curve . . . . . . . . . . . . . . . . . . . . . . 254
Saving user access authorization . . . . . . . . . . . . . . . . . . . .57
Micrograph XY view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
Screen layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Micrograph zoom function settings . . . . . . . . . . . . . . . . . 259 Screen page editor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .200
Microplast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
Screen page editor - Edit screen page . . . . . . . . . . . . . . .202
Minicam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
Screen page selection and function keys . . . . . . . . . . . . . .47
Mold closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Screen structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Mold heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Screw diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .167
Mold height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Sequence instructions for Euromap 12/67 interface . . . . .195
Mold height adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Sequence preview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .225
Mold height setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Sequence programming positions Injection . . . . . . . . . . . .159
Mold opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Sequence programming positions mold closing . . . . . . . . .85
Mold parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221 Sequence programming positions mold opening . . . . . . . . .92
Mold protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Sequence settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
Mold shut-off nozzle - Activation . . . . . . . . . . . . . . . . . . . 308
Set Micrograph automatically . . . . . . . . . . . . . . . . . . . . . .250
Mold shut-off nozzle - Pressure relief . . . . . . . . . . . . . . . . 311
Set Micrograph manually . . . . . . . . . . . . . . . . . . . . . . . . . .251
Mold shut-off nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308 Set mold shut-off nozzle . . . . . . . . . . . . . . . . . . . . . . . . . .308
Monitoring of the barrel temperature . . . . . . . . . . . . . . . . 122
Set the barrel shut-off nozzle . . . . . . . . . . . . . . . . . . . . . . .305
Monitoring systems for the injection molding process . . . 214
Set value graphics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
Mount mold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 Setting the number of profile items . . . . . . . . . . . . . . . . . . .72
Mounting aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Setting the speed and force profile . . . . . . . . . . . . . . . . . . .69
Movement to Home position . . . . . . . . . . . . . . . . . . . . . . . 90
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Shake core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
N Shake ejector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
Notepad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232 Shut-off nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .304
Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 Signs for North America . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Nozzle contact position . . . . . . . . . . . . . . . . . . . . . . . . . . 151 Single-dial control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
Nozzle speed profile and stroke positions . . . . . . . . . . . . 150 Soaking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137
Nozzle stroke position . . . . . . . . . . . . . . . . . . . . . . . . . . . 151 Soaking inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126
Sprue ejector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
O Standstill reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .314
Open mold shut-off nozzle with sequence control . . . . . . 312 Start and screen structure of VirtMold . . . . . . . . . . . . . . . .325
Operating point optimization . . . . . . . . . . . . . . . . . . . . . . 139 Start sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .196
Operator key switching (option) . . . . . . . . . . . . . . . . . . . . . 44 Start up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Start-up cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .196
P Start-up cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .218
Parallel open branch with safety-critical movements for the mold Status display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193 Step operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .197
Part removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Step profile for injection and plasticizing procedure . . . . . .74
Pictographs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Storage media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .223
Plasticizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168 Switch panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Plasticizing maintained instruction . . . . . . . . . . . . . . . . . . 172 Switchover to hold pressure . . . . . . . . . . . . . . . . . . . . . . .159
Plasticizing power-controlled . . . . . . . . . . . . . . . . . . . . . . 170
Plasticizing profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169 T
Plasticizing time monitoring . . . . . . . . . . . . . . . . . . . . . . . 171 Temperature control devices . . . . . . . . . . . . . . . . . . . . . . .143
Plausibility check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233 Temperature control devices with communication to machine
Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235 control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143
Printing textually and graphically . . . . . . . . . . . . . . . . . . . 236 Temperature control devices with flow control . . . . . . . . . .146
Process data graphics . . . . . . . . . . . . . . . . . . . . . . . . . . . 275 Text formatting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Process data monitoring . . . . . . . . . . . . . . . . . . . . . . . . . 281 Text pages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .314
335
Tiebar pulling device automatic (DUO) . . . . . . . . . . . . . . . 103
Torques during plasticizing . . . . . . . . . . . . . . . . . . . . . . . . 173
U
Units ISO, Imperial, Absolute, Relative . . . . . . . . . . . . . . . 55
USB storage media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
User access authorization - login with card . . . . . . . . . . . . 52
User access authorization - password login . . . . . . . . . . . . 52
User administration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
User level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
V
View settings for heating zones . . . . . . . . . . . . . . . . . . . . 124
VirtMold menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
VirtMold Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
VirtMold system requirements . . . . . . . . . . . . . . . . . . . . . 319
VirtMold Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
W
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Week timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
Write a parts data set . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

ENGEL AUSTRIA GmbH. 4311 Schwertberg
tel: +43.(0)50.620.0 fax: +43.(0)50.620.3609
e-mail: service@engel.at www.engelglobal.com

Manual Engel de Operacion1

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Operator Manual - Machine

Manufacturer: ENGEL AUSTRIA GmbH

e-mail: service@engel.at www.engelglobal.com

Person responsible for Mörwald Johann

HEAT ZONES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

INJECTION UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

4 Operator Manual - Machine | Version G/11/31/1/38

MACHINE SEQUENCE AND MASK EDITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

PRODUCTION PROGRAMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209

PROCESS DATA PACKAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271

SPECIAL PROGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331

6 Operator Manual - Machine | Version G/11/31/1/38

Structure of the system documentation:

Instruction Manual - Machine

Service manual - Machine (Commissioning, Maintenance)

Operator Manual - Machine (Operation)

Manual CD contains the following documents in PDF format: Opera-

Instruction Manual - Robot

Service manual - Robot (Commissioning, Maintenance)

Operator Manual - Robot (Operation)

Manual CD contains the following documents in PDF format: Opera-

A plan of the electric system is located in the switch cabinet.

Information on accessories is available in the Special Programs chapter.

8 Operator Manual - Machine | Version G/11/31/1/38

2 North American Applied standards and guidelines

ANSI/SPI B151.1 Plastics Machinery - Horizontal Injection Molding Machines - Safety

ANSI/RIA/ISO Industrial robots and robot systems - Safety requirements

NFPA79 Electrical standards for industrial machinery

3 Applicable European standards and regulations

2006/42/EG Machinery Directive

2006/95/EG Low Voltage Directive

2004/108/EG EMC Directive for Electromagnetic Compatibility

EN ISO 12100-1 Machine Safety

EN ISO 12100-2 Machine Safety

EN ISO 13857 Machine Safety, Safety Distances

EN 201 Safety Information for Injection Molding Machines

EN ISO 13850 Machine Safety, EMERGENCY STOP Equipment

EN 60204-1 Machine Safety, Electrical Equipment for Machines

EN ISO 10218 Industrial Robot Safety

Information marked with this symbol warns of possible danger which

Information marked with this pictogram warns of possible danger which

10 Operator Manual - Machine | Version G/11/31/1/38

Possible dangers which can cause damage to the machine!

6 Machine overview DUO

Clamping unit side Injection unit side

[1] Ejector and ejector coupling

12 Operator Manual - Machine | Version G/11/31/1/38

7 Injection molding in general

7.1 Molding cycle of an injection molding machine

Example of an injection molding machine sequence

First step: Mold closing

Second step: Nozzle contact

Third step: Injection and hold pressure

Fourth step: Plasticizing

Fifth step: Nozzle retraction

Sixth step: Ejection

7.2 Important principles and notes

14 Operator Manual - Machine | Version G/11/31/1/38

[See Safety equipment functions on page 24.]

If you notice that safety equipment is defective,:

Danger from gases hazardous to health!

Danger of crushing due to moving components on the machine!

Danger of damage to equipment due to improper settings!

Safety gate activated in sequence

Opening stroke in semi-automatic mode