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This Liquid Crystal Display (LCD) controller "FA" series is designed andmanufactured by our company has features of advanced technology, highquality and perfect maintenance services etc.
All injection molding process of this controller is centralized andcontrolled by computer. It provided quick action, high efficiency, powersaving, safety and reliability.
For the purpose of using and maintenance of this machine better, thisoperation manual will provide detail information and instructions as well.
Any problem do not clear, please do not hesitate to contact our serviceteam. We are glided to provide concerned technical communication serviceand answer all kinds of question for your requires.
* Specifications are subject to change without prior notice.
PREVIEW
Chapter 1System Specification 1. Standard Configuration1 - 2 2. Hardware Specification and mounting dimension 1 - 2 3. Software function1 - 6
Chapter 2Safety Precaution 1. Operating safety instruction2 - 2 2. Installation Regarding2 - 3 3. Power Requirement2 - 3 4. Installation of Potentiometer2 - 4 5. Wiring Requirement2 - 4
Chapter 3Operating Panel Description 1. Screen Selector3 - 3 2. Operating Mode Selector3 - 3 3. Cursor Keys.. 3 - 4 4. Numeric Keys3 - 4 5. Manual Operation Keys 3 - 5
Chapter 4Screen Operation Description 1. Introduction and Welcoming Screen 4 - 2 2. Monitor and Temperature Screen4 - 3 3. Injection and Charging Screen4 - 5 4. Purge and Mold Screen 4 - 7 5. Core Pulling and Ejection Screen4 - 9 6. Nozzle Unit and Memory Screen4 - 11 7. Quality Control 1 and 2 Screen4 - 13
CONTENT
Chapter 5Operation and Control 1. Diagrammatic Explication of Injection Unit5 - 2 2. Diagrammatic Explication of Clamping Unit5 - 4 3. Basic Data Presetting 5 - 6 4. Manual Operation Description5 - 9 5. Operation mode Description5 - 13
Chapter 6System Wiring 1. Power distribution diagram6 - 2
2. Main box connector distribution diagram6 - 3 3. FA-1 KAD module connection 6 - 6 4. FA-2 TC module connection 6 - 8 5. FA-3 CLCD module connection6 - 13 6. FA-4 IO module connection 6 - 14 7. FA-6 IO3 module connection6 - 16 8. Transformer color of wiring6 - 20
Chapter 7Maintenance & Trouble Shooting 1. Inspection Procedure of Controller7 - 2
2. Calibration Procedure of Machine7 - 3 3. Inspection and Maintenance7 - 4 4. Alarm Message Table7 - 5
Chapter 8Services Review 1. Product Introduction8 - 2 2. Services Centre Address8 - 5
CONTENT
Chapter 2 Safety Precaution
Chapter 3 Operating Panel Description
Chapter 4 Screen Operation Description
Chapter 5 Operation and Control
Chapter 6 System Wiring
Chapter 7 Maintenance and Trouble Shooting
Chapter 8 Services Review
Chapter 1 System Specification
1. Standard Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. Hardware Specification and mounting dimension. . . . . . . . . . . . . . . . 3. Software function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-21-21-6
1 - 1
////
1 Standard Configuration
1. Control box (Fig.1) (Fig.2)2. Operation Panel (Fig.3)3. Switching power supply (with EMI filter)4. Transformer5. Spare fuse6. Extension relay board (Temp. & H.V. control). 7. FPW-01 Power supply (I/O)8. FPV-01 Amplifier (pressure & flaw valve control)9. External numeric key lock (option)10. Surge killer
2. Hardware Specification and mounting dimension
1. Control box
(1) FA-1 KAD Keyboard + High speed Counter + A/D + D/A board56 keys individual input port4 channels high speed counter input interface2 channels D/A voltage output interface (standard for 2, available extend to 4)4 A/D voltage input interface
(2) FA-2 TC/TC-2N Temperature control board7 zones for barrel heating, 1 zone for oil temperatureIndependent MPU control and P.I.D auto tuning
(3) FA-3 CLCD CPU Main boardIndustrial CPU chip set include 60 groups parameter memoryOn-line edit portIndependent MPU hardware interrupt circuitLCD word, GDI display interface
(4) FA-4 IO Operation I/O board (standard for 2, available extend to 3)16's*2 24vdc NPN port16's*2 24vdc MOSFET port
(5) FA-6 IO3 Operation I/O board (standard for 2, available extend to 3)16's*2 24vdc NPN port
16's*2 24vdc MOSFET port
2. Operation panel box
(1) 56's mechanical key, Oil / Dust protection PET membrane
(2) 320 X 240 dot back light LCD display
1 - 2
Control Box (Fig. 1)
FA-1 KAD FA-2 TC FA-4 IO FA-6 IO3
+5V -5V +5V,V1,V0
VI WG V1
IN1
IN2
IN3
HT1 IN4
HT2 IN5
HT3 IN6
HT4 IN7
HT5 IN8
HT6 IN9
HT7 IN10
HT8 IN11
V1 IN12
G1 IN13
IN14
ALM1 IN15
ALM2 IN16
ALM3 GI
ALM4
ALM5 V0
ALM6 OUT1
ALM7 OUT2
ALM8 OUT3
OUT4
OUT5
OUT6
OUT7
OUT8
OUT9
OUT10
OUT11
OUT12
OUT13
OUT14
OUT15
OUT16
GODA5+ GO
DA3- OUT31
DA4+ OUT32
DA2- OUT29
DA3+ OUT30
DA1- LCD(2) OUT27
DA2+ OUT28
FG4 OUT24
OUT25
DA1+ OUT26
AD4+ OUT22
AD4- OUT23
FG3 LCD(1) OUT20
VS4 OUT21
AD3+ OUT18
AD3- OUT19
V0
VS3 OUT17
FG2
IN32
AD2- RESET GI
AD2+
IN29
FG1 IN30
VS2 IN31
AD1-
IN26
VS1 IN27
AD1+ COM2 IN28
IN23
CNT3 IN24
CNT4 IN25
IN20
YI IN21
CNT1 COM1 IN22
IN17
KB IN18IN19
FA-3 CLCD
+5V +15V
-15V V5 +5V,WG V1
+5V,V1,V0
RESET
CNT2
TC1+TC1-TC2+TC2-TC3+TC3-TC4+TC4-TC5+TC5-TC6+TC6-TC7+TC7-TC8+TC8-
1 - 3
////
Control Box (Fig. 2)
FA-1 KAD FA-2N FA-4 IO FA-6 IO3
+5V -5V +5V,V1,V0
V1
IN1
IN2
IN3
HT1 IN4
HT2 IN5
HT3 IN6
HT4 IN7
HT5 IN8
HT6 IN9
HT7 IN10
HT8 IN11
24V IN12
G1 IN13
IN14
ALM1 IN15
ALM2 IN16
ALM3 GI
ALM4
ALM5 V0
ALM6 OUT1
ALM7 OUT2
ALM8 OUT3
OUT4
OUT5
OUT6
OUT7
OUT8
OUT9
OUT10
OUT11
OUT12
OUT13
OUT14
OUT15
OUT16
GO
FG1
VS2
AD2+
AD2- RESET GI
YI
CNT1
CNT2
CNT3
CNT4
VS1
AD1+
AD1- IN29
IN30
IN31
IN32
IN25
IN26
IN27
COM2 IN28
COM1 IN22
IN23
IN24
IN19
IN20RESET
IN21
IN17
FA-3 CLCD
+5V +15V +5V,V1,V0
V0
-15V V5 +5V,WG V1
KB IN18
VS3 OUT17
FG2
AD3+ OUT18
AD3- OUT19
FG3 LCD(1) OUT20
VS4 OUT21
AD4+ OUT22
AD4- OUT23
FG4 OUT24
OUT25
DA1+ OUT26
DA1- LCD(2) OUT27
DA2+ OUT28
DA2- OUT29
DA3+ OUT30
DA5+ GO
DA3- OUT31
DA4+ OUT32
TC1+TC1-TC2+TC2-TC3+TC3-TC4+TC4-TC5+TC5-TC6+TC6-TC7+TC7-TC8+TC8-
1 - 4
////
Operation Panel (Fig.3)
WE NEED A NEW ONE
FA type Control Box Installation FA type Control Box dimension FA type Operation Panel dimensionDimension L295X W250X H200 Cover : L404 X W204 X D60L265 X W180 X H148 Unit : mm Inner : l' 388 X w' 188L1=10 L2=246 Unit : (mm)Unit : mm
4 mm
4 mm
The hole of fixpanel screw.
Rear cover
198
196
56 mm
Operatepanel
198
L
l'
D
W
w'
L
W
HL
W
H
4 mm
4 mm
The hole of fixmain box screw.
L2
L1
L1
1 - 5
////
3. Software function
Temperature Unit Centralization Unit
7 zones barrel temperature control (with H/L alarm) PLC ladder program editor1 zone oil-temp monitor / control Multi layer password protectionIndependent PID control 30 pages displayFirst zone constant temp. control with SCR selectable Built-in 60 sets mold memory
3 kind of variable operation modesOver 50 alarm messageElectrical lubrication controlProduction statistic function
Injection Unit Operating I/O diagnosisReal-time display
4-stages injection control4-stages holding controlTime or position advance to holding stageInjection target position detect
Motion Unit
Multi-stage independent absorber setting Plasticization Unit Emergence or special action absorber
Curve fitting for proportional output2 stages suck back, 3 stages charge function Linear I/O modification function Selective depression sequenceAuto purge (Barrel Clean-up)Screw rotation speed display
De-Molding (ejection) Unit
Oscillating ejectionClamping Unit Hold-on eject function
2 sets air blow function4 stages opening control robot connection procedure4 stages clamping control 2 sets core polling / unscrewingFast speed clamping supportAuto mold height adjustment
* Specifications are subject to change without prior notice.
1 - 6
Chapter 1 System Specification
Chapter 3 Operating Panel Description
Chapter 4 Screen Operation Description
Chapter 5 Operation and control
Chapter 6 System Wiring
Chapter 7 Maintenance and Trouble Shooting
Chapter 8 Services Review
Chapter 2 Safety Precaution
1. Operating safety instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. Installation Regarding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3. Power Requirement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. Installation of Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. Wiring Requirement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 - 22 - 32 - 32 - 42 - 4
2-1
1. Operating safety instruction
To prevent damage from human and machine, please obey the following safety caution.
(1) Equipment must be operating under correct power. (install a Voltage Stabilizer for unstable power supply)
(2) GND terminal must be connected to qualified terminal. (T/T system)
(3) All electric elements with GND terminal, it is necessary for users to connect with the GND terminal
(4) Electrical box must have good heat dissipation to prevent fire.
(5) Cables must be appropriated and qualified. (include shield)
(6) The high-power cables should be separated from the low-power cables to avoid interfere.
(7) All electric elements must be avoided mechanic shock
(8) Never hit the panel with hard thing to avoid electric shock.
(9) To prevent fire or hazard shock, do not expose the unit to rain or moistly place.
(10) Please understanding the operation process before use.
(11) When system shut down, Wait 10 seconds for re-start.
(12) Wait for 10 seconds or each starting of machine ( include heating elements ) .
2-2
2. Installation Regarding
(1) The control box must be places at up right position for heat dissipation
(2) Installing the operation panel and control box in oilless, dustless and ventilative places.
(3) To prevent interfere, controller should distant to breaker, contactor, transformer or heavy load equipment
(4) 5 VDC power cable must be more than cross-section of 2mm, and the distance between controller and power supply must be less than 1m.
(5) The coil of AC contactor must be connected with the surge killer to eliminate the spark
(6) The PC cable ( 2.5m ) between control panel and main box can not be connected arbitrarily.
(7) Potentiometer conductor should use a shielded cable to avoid magnetic field interfere.
(8) The elements (like power filter220VAC) must be connected with the right polar terminal
(9) All component must be grounded to prevent damage of thunder attack and static electricity.
(10) To prevent eddy current, do not connect together with different power source. (Whatsoever, the marked voltage is same or not, include VI , VO , QV , GI , GO and FG)
(11) Any load-specific element (excluding arico controller) can not be modify in this system.
3. Power Requirement
Single phase , 3 line, 220v/380vac, 50hz (china), 60hz (Taiwan) stable AC power. (IEE. T/T system)
Notes: 220v : 200v~250v is acceptable380v : 350v~400v is acceptable
2-3
4. Installation of Potentiometer
1. Make sure of the machine stroke that you want to measure
2. For safety, the total stroke must be longer than needed stroke about 10~20 mm
3. Wiring diagram
4. 1, 3 are connected to power, 2 is the output signal. Never connect 2 to power, this will make potentiometer and controller damaged
5. Mould or screw, moving toward center of machine shall be display a smaller value approximately to "0" .If the trend of position display reversed, just change pin 1 and 3
5. Wiring Requirement
1. To prevent DC signal disturbance, never put the AC and DC wiring together on the same duct
2. To eliminate surge, it is always recommended to use a filter in control line
3. Most of the electric elements must be grounded to prevent accident
4. Every wiring (include signal line) must use the qualified cable
213 12
3
2-4
Chapter 1 System Specification
Chapter 2 Safety Precaution
Chapter 4 Screen Operation Description
Chapter 5 Operation and control
Chapter 6 System Wiring
Chapter 7 Maintenance and Trouble Shooting
Chapter 8 Services Review
Chapter 3 Operating Panel Description 1. Screen Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. Operating Mode Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3. Cursor Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. Numeric Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. Manual Operation Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 - 33 - 33 - 43 - 43 - 5
3 - 1
LCD Displaywith back-light
Emergence StopKey Lock
Contrast
RESET
3 - 2
1. Screen Selector
ACTION KEYMonitor, temperature page (repeat pushing)
MOLD KEYMold close & open page
INJ. HOLD-P KEYInjection, hold pressure page (repeat pushing)
CHARGE KEYCharging (plasticization) page
EJECTOR NOZZLE KEYEjector / nozzle page
CORE KEYCore (unscrew) page
SPC KEYQ.C.1, Q.C.2 page
MEMORY KEYMemory page
2. Operating Mode Selector
MANUAL : Operating machine by manual key
SEMI AUTO : Operate machine in semi-auto recycling and re-started by safety door open and close again
AUTO : Machine operating at fully automatic production modere-started by safety door, photo sensor or robot
Push this key to start or stop motor(s)( please wait one minute before machine loading)
Push this key to start or stop the heating( please wait one minute before machine running)
Push this key to reset alarm and continue to product after the resolution of alarm message RESET
MOTOR
HEATER
3 - 3
3. Cursor Keys
Cursor moving direction
4. Numeric Keys
(1) 0~9 Numerals or symbols change key
(2) Spare
(3) Spare
(4) Spare
(5) Clearing input data to ZERO
(6) English character input key
(7) Function On / Off key and data input confirmation key
S1
S2
9 Y Z ( )
0+ , -
CLEAR
S3
ENTER
ABC
7 S T U
4 J K L
8 V W X
1 A B C
2 D E F
5 M N O
S3 S2
9 Y Z ( )
0+ , -
6 P Q R
CLEAR
S1 ENTER
3 G H I
ABC
3 - 4
5. Manual Operation Keys
MOLD OPEN KEYPush for activate of mold opening action manually
MOLD CLOSE KEYPush for activate of mold clamping action manually
EJECTOR RET. KEYPush for activate of ejector retract action manually
EJECTOR ADV. KEYPush for activate of ejector advance action manually
MOLD ADJ. KEYPush for select mold adjustment function On / Off
M. MOLD ADJ. KEYPush for slow manual mold adjustment function On / Off (work with Mold adjustment function)
CORE (1/2) IN KEYPush for activate of core (1/2) IN action manually
CORE(1/2) OUT KEYPush for activate of core (1/2) OUT action manually
MOLD ADJ. ADV. KEYPush for activate of mold adjustment advance manually
MOLD ADJ. RET. KEYPush for activate of mold adjustment retract manually
CORE USE KEY * Push one time to open CORE USE function, and LED will bright * Push one time to close CORE USE function, and LED will OFF
F1 KEYSpare
INJECTION KEYPush for activate of injection manually(Disable by material temperature is lower than protection setting)
CHARGE KEY Push for start or stop of plasticization manually
(Disable by material temperature is lower than protection setting)
3 - 5
AIR BLOW KEYPush for activate of air blow de-molding devices manually (fix and movable platen)
SUCK BACK KEYPush for activate of suck back action manually
(Disable by material temperature is lower than protection setting)
NOZZLE ADV. KEY Push for activate of nozzle advance action manually
NOZZLE RET. KEYPush for activate of nozzle retract action manually
Under manual mode, push this key to start auto purge(Disable by material temperature is lower than protection setting)CORE USE: push on-push off key Under manual mode, on this key to use core
MANU LUB. KEYPush key for start auto lubrication at once
EMERGENCY STOP KEY* Push key for stop all actions and to void any dangerous and damage* If emergency stop key control the controller power supply , push key for stop the power
and the actions. If it control INPUT's point IN22,then push it for stop pump and actions
CONTRAST KEY* Adjust the monitor contrast, it according to ambiance and visual angle until the screen is clear to see
KEY LOCK KEY* For the number key function is unavailable or available. If the key lock is available, the number
key is unavailable. If unavailable, the number key is available* Wiring : the wiring point is the IN9 point of INPUT. If IN9 and GI are on line, the key lock
is available. If not, the key lock is unavailable
RESET
3 - 6
Chapter 1 System Specification
Chapter 2 Safety Precaution
Chapter 3 Operating Panel Description
Chapter 5 Operation and control
Chapter 6 System Wiring
Chapter 7 Maintenance and Trouble Shooting
Chapter 8 Services Review
Chapter 4 Screen Operation Description
1. Introduction and Welcoming Screen . . . . . . . . . . . . . . . . . . . . . . . . . 2. Monitor and Temperature Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . 3. Injection and Charging Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. Purge and Mold Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. Core Pulling and Ejection Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . 6. Nozzle Unit and Memory Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . 7. Quality Control 1 and 2 Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 - 24 - 34 - 54 - 74 - 94 - 114 - 13
4 - 1
1. Introduction and Welcoming Screen
WELCOME :
ARICO TECHNOLOGY CO., LTD. FA-TYPE CONTROL SYSTEM T E L: T E L:
< PRESS ANY KEY CONTINUE >
"FA" type control system is formed from the high speed INTEL CPU and MPU in theboards to serve as the action procedure in the whole system to reach the most idealhardware interrupt effect, so the system tracks the coherence automatically in eachconfiguration when transferring electricity and starting the machine every time aboutseconds later, the system will display the welcome page automatically to notify the operatorthat it boot well. Then we can press any key to start of system operating.
* Against to technical improvement, some pages may different from present.
4 - 2
2. Monitor and Temperature Screen
Description : Operation and monitor page of each master parameters
Instruction : (A) Operating mode displayed(B) Action name and unit column(C) Present active in motion and it's executive parameter displayed row(D) Motive graph display portion of machine (E) MODE POS. : present position of movable mode plate(F) CYC-TIME : auto cycle timer display (single cycle)(G) SHOT ACC. : accumulation counter of shot record(H) Temperature zone and unit display( I ) TURE : actual temperature of correspondent region( J ) SCREW POS.: present plasticizating screw position(K) RPM : Rotation speed per minute of placticizating screw( L) PACK ACC. : accumulation counter of packing record (single packing cycle)(M) OIL : Hydraulic oil temperature region( N) Warning message (Display on all page while need)
07/06/1999 < MONITOR > 19:32:29 OPER.MODE : MANU ACTIVE PRS.Bar SPEED TIME COUNT INJECT 1 30 35 9.0
MODE POS.:234.5mm SCREW POS.: 456.7mm CYC-TIME :999.9SEC : 999 rpm SHOT ACC.: 123456 PACK ACC. : 123456
1 2 3 4 5 6 7 OIL TRUE 236 221 219 216 214 210 --- ---
A
C
E
H
F
I
L
J
K
B
D
G
M
Page DisplayDate Time
WARN 67 : OIL TEMP. OVERN
4 - 3
Description : Temperature parameters setting of 7 zone barrel and 1 zone oil tank
Instruction : (A) TURE : present temperature value display row(B) SET : target temperature value setting row(C) UP LIM.: high temperature alarm setting row (D) LO LIM.: low temperature alarm setting row (prevention of placticizing cool start)(E) IDLE : setting of temperature in idle mode(F) OIL-TEMP: Oil temperature value(G) HEAT TYP: operating mode selector
NORMAL : heating the barrel for normal production state IDLE : heating the barrel at idling value for standby purpose
(H) NZ. HEAT : enforced heating zone output ratio control, higher ratio higher temperature result (especially for no probe environment)
( I ) HEAT : preheating temperature value of hydraulic oil( J ) COOL : cooling temperature value of hydraulic oil(K) OVER : over heat protection value of hydraulic oil temperature( L) STATE : hydraulic oil temperature state display(M) IDLE FUN : selector for idling mode switching against auto shut down operation
07/06/1999 < TEMP > 19:32:29 TEMP. 1 2 3 4 5 6 7 TRUE 240 220 218 216 214 212 --- SET 236 221 219 216 214 210 --- UP LIM. +30 +20 +20 +20 +20 +20 --- LO LIM. -25 -15 -15 -15 -15 -15 --- IDLE 150 120 120 120 120 120 --- OIL-TEMP HEAT COOL OVER STATE 30 10 50 60 NORMAL
HEAT TYP : NORMAL IDEL FUN : OFF NZ. HEAT : 50
A
C
D
H
G
E
B
I
F
J
K
L
M
4 - 4
3. Injection and Charging Screen
Description : Injection parameter setting screen
Instruction : (A) INJECT 1 : parameter setting of stage 1 of injection data (position needless)(B) INJECT 2 : parameter setting of stage 2 of injection data (disable by pos.=0)(C) INJECT 3 : parameter setting of stage 3 of injection data (disable by pos.=0)(D) INJECT 4 : parameter setting of stage 4 of injection data (disable by pos.=0)(E) HD. POS. : switching position setting of injection to holding stages(F) HD.PRS.1 : parameter setting of holding stage 1(G) HD.PRS.2 : parameter setting of holding stage 2(H) HD.PRS.3 : parameter setting of holding stage 3( I ) HD.PRS.4 : parameter setting of holding stage 4( J ) SCREW POS. : present staying position of injection screw( K) INJECT TIME : time limit setting of positioning injection
(1) Injection stage 2 to 4 is decreasing order of start position setting and disable by that stage position = 0(2) holding stage 1 to 4 are controlled by their own duration timer only
07/06/1999 < INJ > 19:32:29 POS. PRS. SPD. INJECT 1 40 45 INJECT 2 600.0 130 100 INJECT 3 500.0 50 70 INJECT 4 10.0 45 50 HD. POS. 5.5 INJ.TIME:5.0SEC PRS. SPD. TIME HD.PRS.1 40 50 3.8 HD.PRS.2 35 45 2.0 HD.PRS.3 30 43 0.9 HD.PRS.4 20 40 0.3
SCREW POS.:789.9 mm
A
C
D
H
G
E
B
F
I
J
K
4 - 5
Description : parameter setting of plasticization screen
Instruction : (A) PRE-SUCK : parameter setting of suck back stage 1 (B) CHARGE 1 : parameter setting of plasticization stage 1 (position needless)(C) CHARGE 2 : parameter setting of plasticization stage 2 (disable by pos.= 0)(D) CHARGE 3 : parameter setting of plasticization stage 3 (disable by pos.= 0)(E) CHARGE END : accomplish position setting of charge stage(F) SUCK_BK : parameter setting of suck back stage 2 (decompression stage)(G) RPM : rotation speed display of plasticization screw(H) SCREW POS. : present position display of plasticization screw
(1) Position parameter in suck back 1 is the end position setting. the position parameter in charge 2 and 3 is the start position setting. (increasing order setting)
(2) Suck back 2 is a independent backward added value position setting EX : charge-complete stage is 120.0, suck back2 is 2.0 , and the ending position is 140
(3) Precision of storage materials rotate speed display (RPM) is according to the number of sensorial cam
07/06/1999 < CHARGE > 19:32:29 POS. PRS. SPD. PRE-SUCK 60.0 30 35 CHARGE 1 33 33 CHARGE 2 80.0 120 75 CHARGE 3 90.0 50 40 CHARGEEND 120.0 SUCK-BK. + 20.0 45 50 : 999 RPM SCREW POS:809.4mm
A
C
D
E
B
F
H
G
4 - 6
4. Purge and Mold Screen
Description : special parameter setting in purge procedure (auto barrel cleaning function)
Instruction : (A) PURGE-INJ : inject end position and inject parameter setting row in purge(B) PURGE-SUCK : end position of pre-suck action and inject parameter setting row in purge(C) PURGE-REC : parameter setting of plasticization back action in purge procedure(D) PURGE CYC : frequency of purge action setting (E) AUTO-PURGE : switch of purge function (F) Duration setting of exciting purge Re-charge action
(1) before executing of purge action, the computer will check the temperature parameter, and execute in coordination(2) parameters in this page are used for executing in purge action only, and doesn't affect any normal operation data
07/06/1999 < PURGE > 19:32:29
PURGE POS. PRS. SPD. TIME PURGE-INJ 10.0 50 50 PURGE-SUCK 30.0 40 30 PURGE-REC 100.0 135 60 38.0 PURGE CYC : 9 TIMES AUTO-PURGE: OFF
A
C
DE
B E
4 - 7
Description : movable mode plate parameter setting screen
Instruction : (A) CLOSE 1 : parameter setting of clamping stage 1 (position needless)(B) CLOSE 2 : parameter setting of clamping stage 2(C) PROTECT : parameter setting of protection of mold close stage (D) LOCK-UP : parameter setting of lock-up stage(E) OPEN 1 : parameter setting of mold opening stage 1(F) OPEN 2 : parameter setting of mold opening stage 2(G) OPEN 3 : parameter setting of mold opening stage 3(H) OPEN 4 : parameter setting of mold opening stage 4( I ) OPEN END : position setting of mold open end( J ) FAST CL. : Speed clamping circuit switch(K) PROTECT TIME : Low pressure protection timer setting( L ) LOCK-UP TIME : High pressure protection timer setting( M) MOLD POS. : present position display of movable plate
Note : (1) The position setting should be decreasing order while mold close, increasing in mold open (2) The settings of mold opening and closing stages all are their starting advanced position
07/06/1999 < MOLD > 19:32:29 POS. PRS. SPD. TIME CLOSE 1 40 40 CLOSE 2 880.0 120 100 PROTECT 100.0 30 35 3.8 LOCK-UP 15.5 50 25 3.0 POS. PRS. SPD. OPEN 1 130 33 OPEN 2 23.8 68 100 OPEN 3 650.0 40 40 OPEN 4 880.0 30 30 OPEN END 889.0 FAST CL.: MOLD POS.:889.9mm
A
CD
E
B
F
G
H
L
I
J
K
M
4 - 8
5. Core Pulling and Ejection Screen
Description : parameter setting of core pulling or unscrewing function
Instruction : (A) CORE 1 : selector of core / unscrew device 1 TIME LIMIT : completing procedure by setting of time field COUNT : unscrewing purpose counting by pulse (employ time field as frequency)
(B) CORE 1 IN : sequence selector of core 1 IN POS. : starting procedure by positioning of mold plate BE. CLP. : starting procedure before clamping CLP.END : starting procedure at clamp end position
(C) IN : parameter setting of core 1 IN(D) OUT : parameter setting of core 1 OUT(E) CORE 2 : selector of core / unscrew device 2 (TIME / COUNT)(F) CORE 2 IN : sequence selector of core 2 IN (POS. / BE.CLP. / CLP.END)(G) IN : parameter setting of core 2 IN(H) OUT : parameter setting of core 2 OUT( I ) CORE 1 OUT : sequence selector of core 1 OUT
POS. : starting procedure by positioning of mold plate BF. OPEN. : starting procedure before mold opening OPEN END : starting procedure at mold opening end position
( J ) CORE 2 OUT : sequence selector of core 2 OUT (POS. / BF.OPEN / OPEN END)
07/06/1999 < CORE > 19:32:29 CORE 1 : TIME CORE 1 IN:POS. CORE 1 OUT:POS. CORE 1 PRS. SPD. TIME POS. IN 50 35 19.9 1.0 OUT 55 38 22.0 1.0
CORE 2 : TIME CORE 2 IN:POS. CORE 2 OUT:POS. CORE 2 PRS. SPD. TIME POS. IN 30 35 1.9 680.0 OUT 35 38 2.0 680.0
A
C
D
E
B
F
G
H
I
J
4 - 9
Description : De-molding devices (Ejector / air blow) operating screen
Instruction : (A) EJECT FWD. : parameter setting of ejector forward stage(B) EJECT RTN. : parameter setting of ejector retract stage(C) EJECT TYP : ejector operate mode selector
CONT. : Continue ejection completed by EJECT CT setting (whole stroke) VIB. : Vibratory ejecting (less stroke oscillating at eject forward end sensor) HOLD : single ejection and held on forward end position OFF : disable of ejection device
(D) MOVE-SIDE : switch of air blow valve A (assemble at movable plate)(E) FIX-SIDE : switch of air blow valve B (assemble at fix plate)(F) MOLD POS. : present position display of movable plate(G) EJECT CT : setting for ejection frequency
(1) Air blow A & B are simultaneous with mold opening, and completed by during time setting.(2) Air blow A & B will be forced to stop against clamping actuate
07/06/1999 < EJECT > 19:32:29 EJECT PRS. SPD. STOP EJECT FWD. 66 45 3.8 EJECT RTN. 50 50 EJECT TYP : VIB EJECT CT :10 TIMES BLOW FUNT DELAY TIME MOVE-SIDE ON 0.5 3.0 FIX-SIDE OFF 1.2 3.8 MOD POS.: 999.9mm
A
C
D
E
B
F
G
4 - 10
6. Nozzle Unit and Memory Screen
Description : Operating screen of mold height device and injection carriage (nozzle)
Instruction : (A) NZ.U.FWD.1 : carriage forward setting 1 (fast stage)(B) NZ.U.FWD.2 : carriage forward setting 2 (cushioning stage actuate by forward sensor)(C) NZ.U.RTN. : carriage return parameter setting(D) MAN.ADJ.: mold height adjustment operating data at manual mode (F&B)(E) SLOW ADJ. : operating data of slow mold height adjustment (stepping / pulsation)(F) SLOW CLOSE : slow clamping parameter setting (enable on Mold Adj. mode only)(G) SLOW OPEN : slow opening parameter setting (enable on Mold Adj. mode only)(H) PRESET : presetting parameter and switch for amplified circuit D/A1&2 channels( I ) AUTO ADJ.: Auto mould height adjustment function switch( J ) Carriage forward cushioning stage duration setting
(1) Carriage forward cushioning stage only run on semi-auto or auto mode only(2) Carriage cushioning procedure : at automatic mode process, when carriage forward touched the
limiting switch, timer to go to count down the remaining forward duration(3) Mold adjustment data of pressure (PRS.) & speed (SPD.) are both way setting of thinning & thickening
07/06/1999 < NZ. UNIT > 19:32:29 NZ. UNIT PRS. SPD. TIME NZ.U.FWD.1 30 55 NZ.U.FWD.2 40 28 0.8 NZ.U.RTN. 40 43 MOLD ADJ. PRS. SPD. FUNT. MAN. ADJ. 60 30 SLOW ADJ. 55 28 SLOW CLOSE 35 35 SLOW OPEN 33 30 PRESET 140 100 OFF AUTO ADJ. OFF
A
C
D
E
B
F
G
HI
J
4 - 11
Description : Molding data memory screen
Instruction : (A) ACES. No. : access number selector of molding parameter (file save / load code 01-60)(B) LOAD / SAVE / DELE : Function selector(C) No. : module number (module code 01-60)(D) FILENAME : Module name display ( English text and number)(E) PAGE : inquire the current module number (01-60)(F) Date : date recording for the files
(1) LOAD = loading data from inner memory for operate(2) SAVE = saving present operating data to inner memory(3) DELE = deleting file at memory area(4) For safety reason, LOAD data at Manual mode only
07/06/1999 < M.MEMORY > 19:32:29 ACES No.: 59 FILENAME : CUP LOAD SAVE DELE PAGE : 1/06 (No) FILENAME DATE 01 DISK 03/10/1999 02 ARICO 28/12/1999 03 VERDURE 08/10/2000 04 05 06 07 08 09 10
A
B
C
D
E
F
4 - 12
7. Quality Control 1 and 2 Screen
Description : Production monitor page 1
Instruction : (A) COOL T. : parameter setting of cooling time(B) CYC.DLY. : parameter setting of cycle delay (interval time of cycle restart)(C) CYC.ALM. : parameter setting of cyclical time limit (cycle alarm)(D) CLE.ALM. : parameter setting of mold close limiting time(E) OPN ALM. : parameter setting of mold open limiting time(F) INJ.ALM. : parameter setting of injection limiting time(G) REC.ALM. : parameter setting of charge (plasticization) limiting time(H) PHO.ALM. : parameter setting of photo detector limiting time(I) LANGUAGE : Chinese / English display selector(J) S.B.FUNT : sequence selector of suck back function
AFTER CO : suck back acts at cooling end and before mold open AFTER RE : suck back start from charge complete
(K) INJ.TYP. : Injection stage completion mode selector POS. : injection stage switch to holding stage by position TIME : injection stage switch to holding stage by time
(L) INJ.MON. : Injection monitor switch (injection target detection)(M) INJ.UP. : injection target upper limit setting (injection target detection)(N) INJ.LO : injection target lower limit setting (injection target detection)(O) AUTO-NZB : auto carriage backward function selector (oil pressure nozzle)(P) PHO. USE : cycle re-start device selector (ON=photo sensor, OFF=timer)(Q) USE ROBOT: robot selector
07/06/1999 < Q.C.1 > 19:32:29 COOL T. :123.5SEC S.B.FUNT : AFTER CYC.DLY.: 2.5SEC INJ.TYP. : POS. CYC.ALM.:999.9SEC INJ.MON : OFF CLE.ALM.: 99.8SEC INJ.UP :023.5mm OPN.ALM.: 90.0SEC INJ.LO :015.3mm INJ.ALM.: 60.0SEC AUTO-NZB : OFF REC.ALM.: 60.0SEC PHO.USE : OFF PHO.ALM.: 35.0SEC USE ROBOT: OFF LANGUAGE: ENG.
A
C
D
E
B
FG
I
J
KL
M
N
O
H
PQ
4 - 13
Description : Production monitor page 2
Instruction : (A) CURRENT : Current shot counter display(B) SET NO. : production counter setting (shot quota)(C) SHUT DOWN : auto shut down function selector (counter break)(D) CLEAR NO : Counter reset (Clear counter valve to zero)(E) INTERVAL : Interval cycle of auto lubrication(F) LUBRI.T : Lubricating duration timer(G) TOTAL : Total shots amount column (include good and defect products)(H) PACK : Packing counter column (only accumulate good products)( I ) FAIL : Defect / fail product shots counter
07/06/1999 < Q.C.2 > 19:32:29 PRO.SET TOTAL PACK FAIL CURRENT 234567 123456 0005 SET NO. 900000 090000 0100 SHUT DOWN ON OFF ON CLEAR NO OFF OFF OFF INTERVAL : 180 SET LUBRI.T : 80 SEC
A
C
D
E
B
F
G H I
4 - 14
Chapter 1 System Specification
Chapter 2 Safety Precaution
Chapter 3 Operating Panel Description
Chapter 4 Screen Operation Description
Chapter 6 System Wiring
Chapter 7 Maintenance & Trouble Shooting
Chapter 8 Services Review
Chapter 5 Operation and Control
1. Diagrammatic Explication of Injection Unit . . . . . . . . . . . . . . . . . . . . . . . . . 2. Diagrammatic Explication of Clamping Unit . . . . . . . . . . . . . . . . . . . . . . . . 3. Basic Data Presetting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. Manual Operation Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. Operation mode Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 - 25 - 45 - 65 - 95 - 13
5 - 1
1. Diagrammatic Explication of Injection Unit
Diagram for inject process
1. The setting parameters are referred to the right-hand table for injection parting-stage data
2. The position setting of inject stage must be settled decreasingly , but increasing with alarm
3. The time parameter of hold pressure stage is the period time setting
Hol
d (1
)
30 404540
2043 45
35
5045
7050
100
130
Inj.
(1)
inje
ctio
n st
age
Hol
d (2
)
Hol
d (4
)
Hol
d (3
)
4050
Hold stage(time control)
pressure %flow %
Screw actualposition (mm)
3.0789.9600.0500.010.0
InjectLow-Limit Inject Monitor
Inspect Area
0 789.9
Inj. Direction
(Decrease order)
Inject LimitStopped position of
plasticizing/suck back
5.5
InjectUp-Limit
4.5
Inj.
(2)
Inj.
(3)
Inj.
(4)
07/06/1999 < INJ > 19:32:29 POS. PRS. SPD. INJECT 1 40 45 INJECT 2 600.0 130 100 INJECT 3 500.0 50 70 INJECT 4 10.0 45 50 HD. POS. 5.5 INJ.TIME:5.0SEC PRS. SPD. TIME HD.PRS.1 40 50 3.8 HD.PRS.2 35 45 2.0 HD.PRS.3 30 43 0.9 HD.PRS.4 20 40 0.3
SCREW POS.:789.9 mm
5 - 2
////
Diagram explication for charge process
1. The parameter setting are refereed to th right-hand table for charge
2. The position setting of suck 1 and charge must be settled decreasingly , but increasing with alarm
3. The position parameter of suck 2 is the position setting of suck 2 have to increase *The modification of the final charge position would not change the stroke of suck 2 but ending position
4. The final-stop position of screw maybe little different from the setting position of charge/suck II (It depends on the inertia of mechanic motion and system)
4550
3035 33
3375120
4050
5.0 60.0 140.0120.090.080.0
0
Pressureflow
(increase order)
Plas
ticiz
ing/
Suck
Bac
kst
age
Direction Of Charge/Suction Back
deca
mp.
pla.
(1)
pla.
(2)
InjectionEnd Position
ScrewPosition (mm)
Suck Back pos.=Pla.(3)+Suck =120.0+20.0 =140.0mm
pla.
(3)
Suck
bac
k
Decompress zone
07/06/1999 < CHARGE > 19:32:29 POS. PRS. SPD. PRE-SUCK 60.0 30 35 CHARGE 1 33 33 CHARGE 2 80.0 120 75 CHARGE 3 90.0 50 40 CHARGEEND 120.0 SUCK-BK. + 20.0 45 50 : 999 RPM SCREW POS:809.4mm
5 - 3
2. Diagrammatic Explication of Clamping Unit
Diagram explication for close-mold process
1. The parameter settings are refereed to the right-hind table for close mold
2. The position parameters of close-mold stage are the initial position setting
3. The position parameters of close-mold stage are settled decreasingly , but increasing with alarm
4. The time parameter of low-pressure stage is the alarm of time-limit
5. The final stop position of close mold may be little different from the setting position with no-load / light load condition
pressure
flow
120
actual position ofmovable platen (mm)
Direction Of Close-Mold(decrease order)
lock-up
2590
3530
100
ClampingStage
Open completePosition
880.0889.9 15.5100.0 Clamping completePosition (actual)
0 > 2.0
lock-uppos. set
protectpos. set
protectiontimer
40
Clo
se 1
40
07/06/1999 < MOLD > 19:32:29 POS. PRS. SPD. TIME CLOSE 1 40 40 CLOSE 2 880.0 120 100 PROTECT 100.0 30 35 3.8 LOCK-UP 15.5 90 25 POS. PRS. SPD. OPEN 1 130 33 OPEN 2 23.8 68 100 OPEN 3 650.0 40 40 OPEN 4 880.0 30 30 OPEN END 889.0 FAST CL.: MOLD POS.:889.9mm
Clo
se 2
Prot
ect
5 - 4
Diagram explication for open mold process
1. The parameter setting is referred to the right hand table for open-mold
2. The position parameter of open-mold stage is the initial position setting
3. The position parameter must be settled increasingly , but increasing with alarm
4. The final-stop position of open mold may be little different from the setting position
Pressure
Flow40
Movable platenposition (mm)
Opening Direction(Increase order)
33
130
9968
40
OpeningStage
23.8
clamp completepos. (actual)
0 > 2.0
open 2 pos.set
650.0
open endpos. set
899.0880.0
open 3 pos.set
open 4 pos.set
Ope
n 4
30
30
07/06/1999 < MOLD > 19:32:29 POS. PRS. SPD. TIME CLOSE 1 40 40 CLOSE 2 880.0 120 100 PROTECT 100.0 30 35 3.8 LOCK-UP 15.5 90 25 POS. PRS. SPD. OPEN 1 130 33 OPEN 2 23.8 68 100 OPEN 3 650.0 40 40 OPEN 4 880.0 30 30 OPEN END 889.0 30 30 FAST CL.: MOLD POS.:889.9mm
Ope
n 3
Ope
n 2
Ope
n 1
5 - 5
3. Basic Data Presetting
Modification step of parameter 1. Find out the data screen need to be modify 2. Push cursor key to find out the place of the data need to be modify 3. Input the final Modifiable Parameter 4. Push enter key to confirm input or move out the cursor key same as input confirm
Example : Modify Injection Position stage 3 from 500 to 100
Before After
press screen selector at once
press cursor key To find out the place of the data need to be modify
press data key to input the right valve
press enter key to confirm input
Modification complete
ENTER
1 A B C
0+ , -
0+ , -
0+ , -
07/06/1999 < INJ > 19:32:29 POS. PRS. SPD. INJECT 1 40 45 INJECT 2 600.0 130 100 INJECT 3 100.0 50 70 INJECT 4 10.0 45 50 HD. POS. 5.5 INJ.TIME:5.0SEC PRS. SPD. TIME HD.PRS.1 40 50 3.8 HD.PRS.2 35 45 2.0 HD.PRS.3 30 43 0.9 HD.PRS.4 20 40 0.3
SCREW POS.:789.9 mm
07/06/1999 < INJ > 19:32:29 POS. PRS. SPD. INJECT 1 40 45 INJECT 2 600.0 130 100 INJECT 3 500.0 50 70 INJECT 4 10.0 45 50 HD. POS. 5.5 INJ.TIME:5.0SEC PRS. SPD. TIME HD.PRS.1 40 50 3.8 HD.PRS.2 35 45 2.0 HD.PRS.3 30 43 0.9 HD.PRS.4 20 40 0.3
SCREW POS.:789.9 mm
5 - 6
Select function ON/OFF step
1. Open the page of the function that need to On / Off2. Push cursor to find out the place of the function need to modify3. Push enter key to change ON/OFF or controllable status
Example : Switch the ejection mode from OFF to Hold
Before After
Press screen selector to choose screen
press cursor key To find out the place of the data need to be modify
press enter key to switch and confirm input
Modification Finish
ENTER
07/06/1999 < EJECT > 19:32:29 EJECT PRS. SPD. STOP EJECT FWD. 66 45 3.8 EJECT RTN. 50 50 EJECT TYP:HOLD EJECT CT:10 TIMES BLOW FUNT DELAY TIME MOVE-SIDE ON 0.5 3.0 FIX-SIDE OFF 1.2 3.8 MOD POS.: 999.9mm
07/06/1999 < EJECT > 19:32:29 EJECT PRS. SPD. STOP EJECT FWD. 66 45 3.8 EJECT RTN. 50 50 EJECT TYP:OFF EJECT CT:10 TIMES BLOW FUNT DELAY TIME MOVE-SIDE ON 0.5 3.0 FIX-SIDE OFF 1.2 3.8 MOD POS.: 999.9mm
5 - 7
Read / write step of module memory1. Open the page of module memory2. Move the cursor the "save number" and input one of "1~60" that you need to read/write in module 3. Move the cursor to MOLD NAME and input Name Of English /Number4. Push 0~9 to input annotated module5. Move the cursor to read/write place and push enter to confirm input6. Push enter again to confirm input
Example : Saving operating data at memory 01 FILE NAME : DISKBefore After
press screen selector at once
press cursor key to ACES field and input "01"
press cursor key to FILENAME field and input "DISK" (to input "DISK", please refer to these steps list below)
press key at once, then press to charge decided character
Repeat the step 3 & 4 to complete input characters "DISK"
press cursor key to SAVE field and press to confirm (the computer will show "Please push again to confirm" )
If you confirm all data is correct, please repeat push to confirm input
Saving Operating Data Procedure complete
ENTER
ABC2 D E F
ENTER
07/06/1999 < M.MEMORY > 19:32:29 ACES No.: 01 FILENAME : DISK LOAD SAVE DELE PAGE : 1/06 (No) FILENAME DATE 01 DISK 03/10/1999 02 03 04 05 06 07 08 09 10
07/06/1999 < M.MEMORY > 19:32:29 ACES No.: 01 FILENAME : LOAD SAVE DELE PAGE : 1/06 (No) FILENAME DATE 01 02 03 04 05 06 07 08 09 10
5 - 8
4. Manual Operation Description
Push manual key at once (Let machine return to Manual Mode)
Open mold action:
(1) Push key till the mold stop the final position(Machine will co-operate with CORE and Robot devices automatically)
(2) Release , then stop output
Close mold action
(1) Please close the emergency door(s) first
(2) Push key till the mold stop the final position(Machine will co-operate with CORE and Robot devices automatically)
(3) Release , to stop the action
Nozzle advance
(1) Push key to make the table forward(Manual operation will not affected by limiting switch)
(2) Release to stop the action
Nozzle retreat
(1) Push key to make the table backward(Manual operation will not affected by limiting switch)
(2) Release to stop the action
Injection action
(1) Push to do injection motion(Disable by actual temperature lower than "LO Limit" setting)
(2) Release to stop the action
5 - 9
Suck Back(1) Push to do the suck back action
(Disable by actual temperature lower than "LO Limit" setting)
(2) Release to stop action
Auto Purge:
(1) Push key to start auto purge function , and LED will be ON(Disable by actual temperature lower than "LO Limit" setting)
(2) Repeat Push key to stop purge action and LED will be OFF
Plasticization :
(1) Push key to start charging action. Push again to stop(Disable by actual temperature lower than "LO Limit" setting)
Ejector Retract :
(1) Push key to start ejector retraction(active on mold opening end position only)
(2) Release to stop the action
Ejector Advance :
(1) Push key to start ejector retraction(active on mold opening end position only)
(2) Release to stop the action
Core Function
(1) Press core key at once to start function
(2) Release core key to stop the action
CORE (1/2) IN :
(1) Press key to active Core "1/2" (unscrew) IN to the mold(Enable on suitable position of movable platen only)
(2) Release to stop the action
5 - 10
CORE (1/2) OUT :
(1) Press key to active Core "1/2" (unscrew) OUT to the mold(Enable on suitable position of movable platen only)
(2) Release to stop the action
Air Blowing :
(1) Press key to active air blow A & B valve
(2) Release to stop the action
Mold height adjustment function switch :
(1) Press key at once to switch ON the mold height adjustment function(Clamping and Opening with switch to Slow Close and Open mode automatically)
(2) Press key at once to stop the action
Slow mold height adjustment function switch :
(1) Press key at once to switch ON the Slow mold height adjustment function
(2) Press key at once to stop
Mold adjustment retract (thickening) :
(1) Press key to active mold adjustment retract action
(2) Release or Push to stop the action(If M. MOLD ADJ. Function Is "ON", press above key once for move one gear (pulse))
Mold adjustment advance (thinning) :
(1) Press key to active mold adjustment advance action
(2) Release or Push to stop the action(If M. MOLD ADJ. Function Is "ON", press above key once for move one gear (pulse))
RESET
RESET
5 - 11
Manual Lubrication :
(1) Press key at once to start the lubrication at once
(2) Press key at once to stop
Motor :
(1) Press key at once to start the motor
(2) Press key at once to stop
Heater :
(1) Press key at once to start heater
(2) Press key at once to stop
Note.: 1. We system shut down, please wait one minute for re-start.2. After motor started, please wait one minute for loading.
MOTOR
MOTOR
HEATER
HEATER
5 - 12
5. Operation mode Description
Manual mode :
(1) press once to take operation by manually keys
Semi-auto mode :
(1) press once to take operation at semi-auto mode
(2) Open and close the front door to start semi-auto cycle
(3) Until De-molding (ejection) complete, open and close the front door to re-start next cycle
(4) press at once to stop all action immediately and return to manual mode
Auto mode :
(1) press once to take operation under fully auto mode
(2) Open and close the front door to start auto cycle
(3) Until De-molding (ejection) complete, open and close the front door to re-start next cycle or
(4) use interval timer, robot or photo sensor to recover
(5) press at once to stop all action immediately and return to manual mode
Note : Never LOAD data from memory under semi-auto or auto mode
5 - 13
Chapter 1 System Specification
Chapter 2 Safety Precaution
Chapter 3 Operating Panel Description
Chapter 4 Screen Operation Description
Chapter 5 Operation and Control
Chapter 7 Maintenance and Trouble Shooting
Chapter 8 Services Review
Chapter 6 System Wiring
1. Power distribution diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. Main box connector distribution diagram. . . . . . . . . . . . . . . . . . . . . . 3. FA-1 KAD module connection . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. FA-2 TC module connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. FA-3 CLCD module connection . . . . . . . . . . . . . . . . . . . . . . . . . . 6. FA-4 IO module connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7. FA-6 IO3 module connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8. Transformer color of wiring . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .
6 - 26 - 36 - 66 - 86 - 136 - 146 - 166 - 20
6 - 1
1. Power distribution diagram
How to select Pac and Fac power source of FPV-01 Amplifier board ?There are AC 50V and AC 24V 2 kinds specification .FPV-01 Amplifier board applicable specification like below :
(PRESSURE VALVE COIL) P = 1A 50 ohm(FLOW VALVE) F = 1A 24 ohm
Please follow below formula :V = I x R ; Voltage = Current x Resistance
For Example : Use YUKEN Pressure/Flow proportion valve ,(Pressure Coil) P = 40 ohm , (Flow Coil) F = 1A 10 ohmPac = 1A x 40 ohm = 40V ; Because 40V close 50V ,So Pac please choose AC 50V. And Fac = 10V ,So please choose Fac AC 24V.
Note: 1. The wiring from power supply to transformer : distance60, uses 2.5mm cross section cable
2. The power line of power supply and controller must use the line with > 2.0 MM cross section cable3. 10 pressure proportional valve : FPV-01 board JP1,JP2,JP3 shorted pin of 1&2, PAC=24VAC4. 40 pressure proportional valve : FPV-01 board JP1,JP2,JP3 shorted pin of 2&3,PAC=50VAC5. 10 flow proportional valve : FPV-01 board JP4,JP5,JP6 shorted pin of 1&2, PAC=24VAC6. 40 flow proportional valve : FPV-01 board JP4,JP5,JP6 shorted pin of 2&3,PAC=50VAC
POWER BOARD
MAIN BOXFBUS-05
FPV-01AMPLIFIER
PRESSURE VALVEFLOW VALVE
Refer VOLTINPUT
FLOW VALVEPOW.SOURCE
AMPLIFIER POWER SOURCE
FPW-01
OUTPUT ELEMENTPOWER SOURCE
INPUT ELEMENTPOWER SOURCE
ACIN
220VACor 380V
POWERSUPPLY
VPE-321V 21V E 5V+12V 0V0V-12V
EMI
FILTER
LOAD
LINE
21V21V
VOGO
VIGI
FacPac
P+ P- F+ F- Vp+ Vf+Vp- Vf-
015V
15V
201 202 203 204
Emergency Stop SW
Wiring =1.25mm2
5A
NL
5A
Transformer F-4
F-40V
200V220V380V15V0V
15VE
0V24V50V0V
24V50V0V
21V0V
21V
1.5A
1.5A
1.5A
5A
8A
Purple
Coffee
Yellow-Green
YellowBlack
Yellow
White
Red Light-green AshPink
Blue
Red
Red
White
0-1A
0-1A
6 - 2
2. Main box connector distribution diagram
(1) J1 is (FA-1 KAD board) keyboard socket connecting to operation panel(2) T2 is (FA-1 KAD board) pulsation and his power input(3) T3 is (FA-1 KAD board) channels of A/D 1&2 (4) T4 is (FA-1 KAD board) channels of A/D 3&4 (option) (5) T5 is (FA-1 KAD board) 4 channels D/A output(6) T6 is (FA-2 TC) board 24VDC output of heater control(7) T7 is socket of 8 channels of thermocouple input at (FA-2 TC) board(8) J2 is (FA-3 CLCD) board down load PLC program port(9) J3 is (FA-3 CLCD) board monitor PLC program port(10) J4 is (FA-3 CLCD) board LCD socket connecting to operation panel(11) T8 are input ports 1-16 at (FA-4 IO) board "1(12) T9 are output ports 1-16 at (FA-4 IO) board "1(13) T10 are input ports 17-32 at (FA-6 IO3) board "2(14) T11 are output ports 17-32 at (FA-6 IO3) board "2
+5v+5v00-12v+12v
FA-1 KAD
J1
T2
T3
T4
T5
FA-2 TC
T6
T7
FA3 CLCD
J2
J3
J4
FA-6 IO3
T10
T11
FA-4 IO
T8
T9
T1
VPE-3
6 - 3
(1) J1 is (FA-1 KAD board) keyboard socket connecting to operation panel(2) T2 is (FA-1 KAD board) pulsation and his power input(3) T3 is (FA-1 KAD board) channels of A/D 1&2 (4) T4 is (FA-1 KAD board) channels of A/D 3&4 (option) (5) T5 is (FA-1 KAD board) 4 channels D/A output(6) T6 is (FA-2N) board 24VDC output of heater control(7) T7 is socket of 8 channels of thermocouple input at (FA-2 N) board(8) J2 is (FA-3 CLCD) board down load PLC program port(9) J3 is (FA-3 CLCD) board monitor PLC program port(10) J4 is (FA-3 CLCD) board LCD socket connecting to operation panel(11) T8 are input ports 1-16 at (FA-4 IO) board "1(12) T9 are output ports 1-16 at (FA-4 IO) board "1(13) T10 are input ports 17-32 at (FA-6 IO3) board "2(14) T11 are output ports 17-32 at (FA-6 IO3) board "2
+5v+5v00-12v+12v
FA-1 KAD
J1
T2
T3
T4
T5
FA-2N
T6
T7
FA3 CLCD
J2
J3
J4
FA-6 IO3
T10
T11
FA-4 IO
T8
T9
T1
VPE-3
6 - 4
Data bus bar diagram (FBUS-05)
Enable insert or pullDisable insert or pull
Note : (1) T1 is terminal of power supply(2) Slot 01 to Slot 05 are the Data Bus of Europe ISA 96 Type, please unplug the pin first,
and then pull / push the board.
SLO
T 0
1
SLO
T 0
5
SLO
T 0
2
SLO
T 0
3
SLO
T 0
4
+5v
0v
0v
+12v
-12v
T1
+5v
If screw ditch upBoard on behalfLock conditionBoard can notpush/pull
If screw ditch flatBoard onbehalf Release conditionBoard can push/pull
Fix
scre
w(B
efor
e pu
sh/p
ull t
he b
oard
mus
t be
flat t
he sc
rew
push
/ pu
ll ha
ndle
6 - 5
3FA-1 KAD board AD/DA moduleHigh speed counter and Operate panel connection diagram
Keyboard inter face connection diagram
D-S
UB
37
PIN
LCD
T 3
J 4
J 1
201
202
203
204
205
206
207
208
FA-3 CLCD LCD(1)
CNT1
T 2
151
152
153
150
154
V1
D-S
UB
15
PIN
T 3155
156
157
158
159
160
161
162
T 4163
164
165
166
167
168
169
170
CNT2
CNT3
CNT4
AD1+
VS1
AD1-
FG1
VS2
AD2+
AD2-
FG2
AD3+
VS3
AD3-
FG3
VS4
AD4+
AD4-
FG4
T 3
DA1-
DA1+
DA2+
DA2-
DA3+
DA3-
DA4+
DA4-
T 5
D-S
UB
37
PIN
LCDOperatepanel
T 3
J 4
J 1
Insert to FA-3 CLCDboard LCD(1) port
FA-1 KAD
KB
FA-1 KAD
KB
CNT1
T 2
151
152
wiring
153
150
154
V1
D-S
UB
15
PIN
T 3155
156
157
158
159
160
161
162
T 4163
164
165
166
167
168
169
170
CNT2
CNT3
CNT4
AD1+
VS1
AD1-
FG1
VS2
AD2+
AD2-
FG2
AD3+
VS3
AD3-
FG3
VS4
AD4+
AD4-
FG4
T 3
DA1-
DA1+
DA2+
DA2-
DA3+
DA3-
DA4+
DA4-
T 5D/A 1 + (ref.volt of amplifier)D/A 1 - (ref.volt of amplifier)D/A 2 + (ref.volt of amplifier)D/A 2 - (ref.volt of amplifier)D/A 3 + (spare)D/A 3 - (spare)D/A 4 + (spare)D/A 4 - (spare)
input element power "VI 24V+RPM speed pulsing input (GI-)unscrewing 1 pulsing input
mold adjusting pulsing inputunscrewing 2 pulsing input
high speed counter input
inj. potentiometer power (V1)inj. potentiometer signal (V1in)inj. potentiometer common(G1)inj. potentiometer earthing (E1)mold potentiometer power (V2)mold potentiometer signal (V2in)mold potentiometer com. (G2)mold potentiometer earthing (E2)
ejector potent. power (V3)ejector potent. signal (V3in)ejector potent. common (G3)ejector potent. earthing (E3)carriage potent. power (V4)carriage potent. Signal (V4in)carriage potent. common (G4)carriage potent. earthing (E4)
6 - 6
FA-1 KAD board wiring diagram
Note (1) Rheostat (VR1-8) on FPV-01 amplifier are :VR1 (F up) : ramp up regulator for flow current VR5 (P up) : ramp up regulator for pressure currentVR2 (F down) : ramp down regulator for flow current VR6 (P down) : ramp down regulator for pressure currentVR3 (F min) : adjustment of the bias of flow valve VR7 (P min) : adjustment of the bias of pressure valve
(dead band) (dead band)VR4 (F max) : adjustment of maximum gain of flow valve VR8 (P max) : adjustment of maximum gain of pressure valve
(2) FPV-01 amplifier are well designed for most commonly proportional valve brand as VICKERS, YUKEN, REXROTH & DAIKIN etc. .. Specific connection as follows,
* 10 pressure proportional valve : FPV-01 board JP1,JP2,JP3 shorted pin of 1&2, PAC=24VAC* 40 pressure proportional valve : FPV-01 board JP1,JP2,JP3 shorted pin of 2&3,PAC=50VAC* 10 flow proportional valve : FPV-01 board JP4,JP5,JP6 shorted pin of 1&2, PAC=24VAC* 40 flow proportional valve : FPV-01 board JP4,JP5,JP6 shorted pin of 2&3,PAC=50VAC
201
202
203
204
205
206
207
208
50 51 52 53
Wiring to FA-1 KAD board(reference voltage output)
T 3
CNT1
T 2
151
152
153
150
154
V1
T 3155
156
157
158
159
160
161
162
T 4163
164
165
166
167
168
169
170
CNT2
CNT3
CNT4
AD1+
VS1
AD1-
FG1
VS2
AD2+
AD2-
FG2
AD3+
VS3
AD3-
FG3
VS4
AD4+
AD4-
FG4
T 3
DA1-
DA1+
DA2+
DA2-
DA3+
DA3-
DA4+
DA4-
T 5
T 3
DA1-
DA1+
DA2+
DA2-
DA3+
DA3-
DA4+
DA4-
T 5
Ejectorpotentiometer
Carriagepotentiometer
1
0
3
2
1
0
3
2
Clamping potentiometer
Injection potentiometer1
1
1
1
2
2
2
2
3
3
3
3
FPV-01amplifierP/Q board
FacPac
P+ P- F+ F- Vp+ Vf+Vp- Vf-
015V
15V
D/A 1 + (pro. Press.Valve signal)D/A 1 - (pro. Press.Valve signal)D/A 2 + (pro. Flow Valve signal)D/A 2 - (pro. Flow Valve signal)D/A 3 + (spare)D/A 3 - (spare)D/A 4 + (spare)D/A 4 - (spare)
Proportional valvereference voltage signal
ejector potent. power (V3)ejector potent. signal (V3in)ejector potent. common (G3)ejector potent. earthing (E3)carriage potent. power (V4)carriage potent. Signal (V4in)carriage potent. common (G4)carriage potent. earthing (E4)
inj. potentiometer power (V1)inj. potentiometer signal (V1in)inj. potentiometer common (G1)inj. potentiometer earthing (E1)mold potentiometer power (V2)mold potentiometer signal (V2in)mold potentiometer com. (G2)mold potentiometer earthing (E2)
input element power "VI 24V+RPM speed pulsing input (GI-)unscrewing 1 pulsing input
mold adjusting pulsing inputunscrewing 2 pulsing input
high speed counter input
NPNSensor
FPW-01GI -
6 - 7
4FA-2 TC Temperature control module connection diagram
wiringFA-2 TC
T 7
T 12
66
67
68
69
70
71
72
73
301
302
303
304
305
306
307
308
VO
GO
401
402
403
404
405
406
407
408
409
410
411
412
413
414
415
416
HT2
HT1
HT3
HT4
HT5
HT6
HT7
HT8
GI
VI
ALM2
ALM1
ALM3
ALM4
ALM5
ALM6
ALM7
ALM8
TC1-
TC1+
TC2+
TC2-
TC3+
TC3-
TC4+
TC4-
TC5-
TC5+
TC6-
TC6+
TC7+
TC7-
TC8+
TC8-
T 6
SPARESPARESPARESPARESPARESPARESPARESPARE
connecting element
DC24V-source (FPW-01"GO")
Barrel zone 1 output -24v (SSR)Barrel zone 2 output -24v (SSR)Barrel zone 3 output -24v (SSR)Barrel zone 4 output -24v (SSR)Barrel zone 5 output -24v (SSR)Barrel zone 6 output -24v (SSR)Barrel zone 7 output -24v (SSR)Oil zone "8" output -24v (SSR)DC24V+source (FPW-01"VO")
Thermocouple zone 5 (TC5-)
Thermocouple zone 1 (TC1+)Thermocouple zone 1 (TC1-)Thermocouple zone 2 (TC2+)Thermocouple zone 2 (TC2-)Thermocouple zone 3 (TC3+)Thermocouple zone 3 (TC3-)Thermocouple zone 4 (TC4+)Thermocouple zone 4 (TC4-)Thermocouple zone 5 (TC5+)
Thermocouple zone 6 (TC6+)Thermocouple zone 6 (TC6-)Thermocouple zone 7 (TC7+)Thermocouple zone 7 (TC7-)Thermocouple zone 8 (TC8+)Thermocouple zone 8 (TC8-)
6 - 8
FA-2 TC board wiring diagram
Note: if the temperature zone is not applicable, please connect Tc+ & Tc- Short circuit, then the temperature reading is equal to room temperature.
wiring
T 7
T 12
66
67
68
69
70
71
72
73
301
302
303
304
305
306
307
308
VO
GO
401
402
403
404
405
406
407
408
409
410
411
412
413
414
415
416
HT2
HT1
HT3
HT4
HT5
HT6
HT7
HT8
GI
VI
ALM2
ALM1
ALM3
ALM4
ALM5
ALM6
ALM7
ALM8
TC1-
TC1+
TC2+
TC2-
TC3+
TC3-
TC4+
TC4-
TC5-
TC5+
TC6-
TC6+
TC7+
TC7-
TC8+
TC8-
T 6
SPARESPARESPARESPARESPARESPARESPARESPARE
Barrel TC 1 -+
Barrel TC 7 -+
Barrel TC 2 -+
Barrel TC 3 -+
Barrel TC 4 -+
Barrel TC 5 -+
Barrel TC 6 -+
Oil tank TC 8 -+
Heater connector output
FPW-01power board
21V21V
VOGO
VIGI
output element power
input element power
read asfollow page
DC24V-source (FPW-01"GO")
Barrel zone 1 output -24v (SSR)Barrel zone 2 output -24v (SSR)Barrel zone 3 output -24v (SSR)Barrel zone 4 output -24v (SSR)Barrel zone 5 output -24v (SSR)Barrel zone 6 output -24v (SSR)Barrel zone 7 output -24v (SSR)Oil zone "8" output -24v (SSR)DC24V+source (FPW-01"VO")
Temperature Sensor line
Thermocouple zone 5 (TC5-)
Thermocouple zone 1 (TC1+)Thermocouple zone 1 (TC1-)Thermocouple zone 2 (TC2+)Thermocouple zone 2 (TC2-)Thermocouple zone 3 (TC3+)Thermocouple zone 3 (TC3-)Thermocouple zone 4 (TC4+)Thermocouple zone 4 (TC4-)Thermocouple zone 5 (TC5+)
Thermocouple zone 6 (TC6+)Thermocouple zone 6 (TC6-)Thermocouple zone 7 (TC7+)Thermocouple zone 7 (TC7-)Thermocouple zone 8 (TC8+)Thermocouple zone 8 (TC8-)
6 - 9
FA-2N Temperature control module connection diagra
wiringFA-2N
T 7
T 12
66
67
68
69
70
71
72
73
301
302
303
304
305
306
307
308
VO
GO
401
402
403
404
405
406
407
408
409
410
411
412
413
414
415
416
HT2
HT1
HT3
HT4
HT5
HT6
HT7
HT8
GI
24V
ALM2
ALM1
ALM3
ALM4
ALM5
ALM6
ALM7
ALM8
TC1-
TC1+
TC2+
TC2-
TC3+
TC3-
TC4+
TC4-
TC5-
TC5+
TC6-
TC6+
TC7+
TC7-
TC8+
TC8-
T 6
SPARESPARESPARESPARESPARESPARESPARESPARE
connecting element
DC24V-source (FPW-01"GO")
Barrel zone 1 output -24v (SSR)Barrel zone 2 output -24v (SSR)Barrel zone 3 output -24v (SSR)Barrel zone 4 output -24v (SSR)Barrel zone 5 output -24v (SSR)Barrel zone 6 output -24v (SSR)Barrel zone 7 output -24v (SSR)Oil zone "8" output -24v (SSR)DC24V+source (FPW-01"VO")
Thermocouple zone 5 (TC5-)
Thermocouple zone 1 (TC1+)Thermocouple zone 1 (TC1-)Thermocouple zone 2 (TC2+)Thermocouple zone 2 (TC2-)Thermocouple zone 3 (TC3+)Thermocouple zone 3 (TC3-)Thermocouple zone 4 (TC4+)Thermocouple zone 4 (TC4-)Thermocouple zone 5 (TC5+)
Thermocouple zone 6 (TC6+)Thermocouple zone 6 (TC6-)Thermocouple zone 7 (TC7+)Thermocouple zone 7 (TC7-)Thermocouple zone 8 (TC8+)Thermocouple zone 8 (TC8-)
6 - 10
FA-2N board wiring diagram
Note: if the temperature zone is not applicable, please connect Tc+ & Tc- Short circuit, then the temperature reading is equal to room temperature.
wiring
T 7
T 12
66
67
68
69
70
71
72
73
301
302
303
304
305
306
307
308
VO
GO
401
402
403
404
405
406
407
408
409
410
411
412
413
414
415
416
HT2
HT1
HT3
HT4
HT5
HT6
HT7
HT8
GI
24V
ALM2
ALM1
ALM3
ALM4
ALM5
ALM6
ALM7
ALM8
TC1-
TC1+
TC2+
TC2-
TC3+
TC3-
TC4+
TC4-
TC5-
TC5+
TC6-
TC6+
TC7+
TC7-
TC8+
TC8-
T 6
SPARESPARESPARESPARESPARESPARESPARESPARE
Barrel TC 1 -+
Barrel TC 7 -+
Barrel TC 2 -+
Barrel TC 3 -+
Barrel TC 4 -+
Barrel TC 5 -+
Barrel TC 6 -+
Oil tank TC 8 -+
Heater connector output
FPW-01power board
21V21V
VOGO
VIGI
output element power
input element power
read asfollow page
DC24V-source (FPW-01"GO")
Barrel zone 1 output -24v (SSR)Barrel zone 2 output -24v (SSR)Barrel zone 3 output -24v (SSR)Barrel zone 4 output -24v (SSR)Barrel zone 5 output -24v (SSR)Barrel zone 6 output -24v (SSR)Barrel zone 7 output -24v (SSR)Oil zone "8" output -24v (SSR)DC24V+source (FPW-01"VO")
Temperature Sensor line
Thermocouple zone 5 (TC5-)
Thermocouple zone 1 (TC1+)Thermocouple zone 1 (TC1-)Thermocouple zone 2 (TC2+)Thermocouple zone 2 (TC2-)Thermocouple zone 3 (TC3+)Thermocouple zone 3 (TC3-)Thermocouple zone 4 (TC4+)Thermocouple zone 4 (TC4-)Thermocouple zone 5 (TC5+)
Thermocouple zone 6 (TC6+)Thermocouple zone 6 (TC6-)Thermocouple zone 7 (TC7+)Thermocouple zone 7 (TC7-)Thermocouple zone 8 (TC8+)Thermocouple zone 8 (TC8-)
6 - 11
FA-2 TC/FA-2N board heater output connecting to solid state relay (SSR)
FA-2 TC/FA-2N board heater output connecting to magnetic connecter (M/C)
FPW-01(VO power)
VO
H1
H2
H3
H4
H5
H6
6 2345 VS1
5A6C6A 4A5C 4C 2C2A3C3A 1C1A
MC1
R
MC6
R
MC5
R
MC4
R
MC3
R
MC2
R
N
LH m/c
LOAD(OUT)
-+ IN
H1
Hm/c
LOAD(OUT)
-+ IN
H2
LOAD(OUT)
-+ IN
H3
LOAD(OUT)
-+ IN
H4
LOAD(OUT)
-+ IN
H5
LOAD(OUT)
-+ IN
H6
LOAD(OUT)
-+ IN
H7
LOAD(OUT)
-+ IN
H8301 306 307304 305302 303 308
VO
R
S
T
output power(FPW-01)
FA2-TC/FA-2N (heater output)
(zone8)heater
(zone7)heater
(zone6)heater
(zone5)heater
(zone4)heater
(zone3)heater
(zone2)heater
(zone1)heater
highspeedfuse
(HRC)
(zone 1) 58(zone 2) 59(zone 3) 60
(zone 4) 61
(zone 5) 62(zone 6) 63
RELAY 04Load Isolation
M/CCoil
Surge Killer(RC)
6 - 12
5. FA-3 CLCD module connection diagram
FA-3 CLCD
9 P
IN
J 3
9 P
IN
J 2
Editor (PLClanguage)
*On Line Editing Extension*
COM1
COM2
LCD(1)
D-S
UB
37
PIN
LCDOperatepanel
J 4
J 1
Insert to FA1 KAD boardKB port
D-S
UB
15
PIN
PLC programinput port
PLC programmonitor port
6 - 13
6. FA-4 I0 Input & Output interface module connection diagram(Board "1" In 1-16, Out 101-116)
Every I/O board is the same, JP1 position decide I/O board NO. ; if JP1=00 (NO.1 board), IO point list is IN1~16 and OUT1~16
A B
JP1
FA-4 I0wiring
T9
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
VO
GO
VI
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
GI
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
T8input connecting electment
Data Key lock (GI -)
input element power "VI" 24V+Clamping end ( GI -)Photo detector ( GI -)Ejector advance end (GI -)Ejector retract end (GI -)Carriage forward end (GI -)Carriage backward end (GI - )front door switch (GI - )rear door (GI - )
Mold adj. thinning end (GI - )M ld dj d d (GI )Mold adj. thickening end (GI - )Core 1 adv. end (GI - )Core 1 ret. end (GI - )Core 2 adv. end (GI - )Core 2 ret. end (GI - )Motor start complete (GI - )input element common (GI -)
plasticization valve (24v+)
output element power (VO" 24V)clamping valve (24v+)clamp protection valve (24v+)speed clamp valve (24v+)opening valve (24v+)opening buffer valve (24v+)carriage forward valve (24v+)injection valve (24v+)suck back valve (24v+)
carriage backward valve (24v+)ejector advance valve (24v+)ejector retract valve (24v+)mold adj. thinning valve (24v+)mold adj. Thicken valve (24v+)core 1 advance valve (24v+)core 1 retract valve (24v+)OUTPUT COMMON (GO-)
output connecting electment
6 - 14
FA-4 I0 board(NO.1) wiring diagram
T8
NPN
NPN
NPN
wiring
T9
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
VO
GO
VI
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
GI
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
input connecting electment
Data Key lock (GI -)
input element power "VI" 24V+Clamping end ( GI -)Photo detector ( GI -)Ejector advance end (GI -)Ejector retract end (GI -)Carriage forward end (GI -)Carriage backward end (GI -)front door switch (GI -)rear door (GI -)
Mold adj. thinning end (GI -)M ld dj d d (GI )Mold adj. thickening end (GI -)Core 1 adv. end (GI -)Core 1 ret. end (GI -)Core 2 adv. end (GI -)Core 2 ret. end (GI -)Motor start complete (GI -)input element common (GI -)
plasticization valve (24v+)
output element power (VO" 24V)clamping valve (24v+)clamp protection valve (24v+)speed clamp valve (24v+)opening valve (24v+)opening buffer valve (24v+)carriage forward valve (24v+)injection valve (24v+)suck back valve (24v+)
carriage backward valve (24v+)ejector advance valve (24v+)ejector retract valve (24v+)mold adj. thinning valve (24v+)mold adj. thicken valve (24v+)core 1 advance valve (24v+)core 1 retract valve (24v+)OUTPUT COMMON (GO-)
output connecting electment
FPW-01power board
VOGO
VIGI
6 - 15
7. FA-6 I03 Input & Output interface module connection diagram(Board "2" In 17-32, Out 117-132)
Every I/O board is the same, JP1 position decide I/O board NO. ; if JP1=10 (NO.2 board), IO point list is IN17~32 and OUT17~32
FA-6 I03 board 1 and 2 have the same physical circuit laying and identify by the jumper setting of JP1
wiring
A B
JP1
FA-6 IO3
T11
117
118119
120
121
122
123
124
125
126
127
128
129
130
131
132
VO
GO
VI
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
GI
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
T10input element
alarm buzzer m/c(24 )
output element power(VO"24 )core 2 advance valve(24 )core 2 retract valve(24 )air blowing A valve(24 )air blowing B valve(24 )plasticizing back press(24 )robot activate signal m/c(24 )lubricating pump m/c(24 )alarm indicator m/c(24 )
heating control m/c(24 )motor contractor m/c(24 )photo detector m/c(24 )SPARE(24 d )nozzle heater contractor(24 )SPARE(24 d )SPARE(24 d )output element COMMON "GO-"
SPARE (GI -)
input element power "VI" 24V+motor over-load relay (GI -)hydraulic oil level low (GI -)lubrication oil level low (GI -)lube oil pressure low (GI -)robot arm retract end (GI -)emergency stop (GI -)SPARE (GI -)SPARE (GI -)
SPARE (GI -)SPARE (GI -)SPARE (GI -)SPARE (GI -)SPARE (GI -)SPARE (GI -)SPARE (GI -)input element COMMON "GI-"
output element
6 - 16
FA-6 I03 board(NO.2) wiring diagram
FPW-01power board
VOGO
VIGI
NPN
NPN
wiring
T11
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
VO
GO
VI
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
GI
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
T10input element
SPARE (GI -)
input element power "VI" 24V+motor over-load relay (GI -)hydraulic oil level low (GI -)lubrication oil level low (GI -)lube oil pressure low (GI -)robot arm retract end (GI -)emergency stop (GI -)SPARE (GI -)SPARE (GI -)
SPARE (GI -)SPARE (GI -)SPARE (GI -)SPARE (GI -)SPARE (GI -)SPARE (GI -)SPARE (GI -)input element COMMON "GI-"
alarm buzzer m/c(24 )
output element power(VO"24 )core 2 advance valve (24v+)core 2 retract valve (24v+)air blowing A valve (24v+)air blowing B valve(24 )plasticizing back press. (24v+)robot activate signal m/c (24v+)lubricating pump m/c(24 )alarm indicator m/c(24 )
heating control m/c (24v+)motor contractor m/c (24v+)photo detector m/c (24v+)SPARE(24 d )nozzle heater contractor (24v+)SPARE(24 d )SPARE(24 d )output element COMMON "GO-"
output element
please see follow page ofexternal power control
6 - 17
FA-6 IO3 module connecting to external power control wiring
Load 1 : lube pump (122) Load 2 : indicator (123)Load 3 : buzzer (124)Load 4 : heater (125)Load 5 : motor (126)Load 6 : nozzle (129)
Note .: Please make sure of voltage specification of output device before connection
1A - 1C : robot activate signal2A - 2C : spare relay connector3A - 3C : spare relay connector4A - 4C : spare relay connector5A - 5C : spare relay connector6A - 6C : spare relay connector
Note: 1. Please make sure of voltage specification of output device before connecting2. Relay 05 board employ GO" (DCV-) for COMMON port to control 24V output elements.
FPW-01(GO)GO
(121)
6 2345 G1
5A6C6A 4A5C 4C 2C2A3C3A 1C1A
RELAY 05isolation Relay board
surge killer(RC)
RELAY 05isolation Relay board
FPW-01(GO)GO
6 2345 G1
5A6C6A 4A5C 4C 2C2A3C3A 1C1A
L
(122)(123)(124)
(125)
(126)(127)
RR R R R R
N
loadingcontractor
coil
Load
1
Load
2
Load
6
Load
5
Load
4
Load
3
6 - 18
FA-4 IO Input & Output interface module wiring diagram(Optional board "3" In 33-48, Out 133-148)
The Input and Output Card (FA-4 IO) of FA-type system is the same in basic wiring. It depends on the jumper pin selector (JP1). (Please see below)
Note : 1. FA-4 IO board 1, 2 & 3 have the same physical circuit laying and identify by the jumper setting of JP12. Any power of I/O board and system can not be connected together. (even if the annotated voltage is the same ) If the voltage is unstable / variable, it will cause eddy current to damage system. (like VI, VO, GI, GO)
F4-IOelement wire
TS5,S6input element power " VI VI
INP
UT# 33 ~ 48
GIinput element COMMON GI
optional inputport 33 ~ 48
~
S7,S8
output element power "VO VO
OU
TPU
T# 133 ~ 148
GOoutput COMMON "GO
optional outputport 133 ~ 148
~A B
A BBoard ""
Input 01 ~ 16 Output 101 ~116
Board ""Input 17 ~ 32
Output 117 ~132
Board ""Input 33 ~ 48
Output 133 ~148
JP 1
6 - 19
8. Transformer color of wiring
Blackish Green
Transformer F-4
0V24V50V
1.5A
1.5A
5A
8A
0V200V
1.5A220V380V15V
15V0V
E
WhiteBlueOrangeRedYellow
Yellow
Green/Yellow
Black
PurpleCoffee
PinkAsh
Light BlueWhiteWhiteRedRed
0V24V50V
0V21V
0V21V
6 - 20
Chapter 1 System Specification
Chapter 2 Safety Precaution
Chapter 3 Operating Panel Description
Chapter 4 Screen Operation Description
Chapter 5 operation and Control
Chapter 6 System Wiring
Chapter 8 Services Review
Chapter 7 Maintenance & Trouble Shooting
1. Inspection Procedure of Controller . . . . . . . . . . . . . . . . . . . . . . . . . 2. Calibration Procedure of Machine . . . . . . . . . . . . . . . . . . . . . . . . . . 3. Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. Alarm Message Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 - 27 - 37 - 47 - 5
7 - 1
1. Inspection Procedure of controller
Initial check procedure of controller
Re-check the wiring of each power, to make sure the wiring is connect (include GND)
Make sure the connection of Input & Output equipment is correct
Make sure that there are NO any sundries on fan and main board
Unplug the board of FA-1~FA-6 in main box, then prepare to turn on the power
First, turn on the single power to check every power supply is correct
Under the correct power supply, shut down the power and then plug the FA4,FA6 IO board After turn ON the power, set the FA1, FA2 in controller
Turn on the power again to check the relative power light is on correctly
Shut down the