2

Contents

Notes P. 04

Main Menu Screen 0 P. 05

Basics P. 06

Function keys P. 07–08

Step 1: Machine configuration Screen 83 Setup P. 09

Step 2 User login P. 10

Step 3: Central operator side Screen 22 Machine configuation P. 11

Step 4: Load mould data Screen 45 Mould catalogue P. 12

Step 5: Set sequences Screen 18 Machine operation P. 13

Set mould sequences Screen 16 Mould operation P. 14

Step 6: Set mould Screen 10 Mould P. 15–16

Step 7: Mould protection Screen 120 Mould protection P. 17

Step 8: Set ejectors Screen 11 Ejectors P. 18

Step 9: Set cores Screen 14 Cores P. 19

Screen 16 Mould sequence P. 20

Step 10: Setting up injection unit Screen 30 Temperatures P. 21

Screen 31 Hot runner P. 22

Screen 23 Injection unit P. 23

Screen 20 Process optimisation P. 24

Screen 26 Injection profile P. 25

Step 11: Process monitoring Screen 50 PDA statistics P. 26–27

Screen 50 Actural value selection P. 28

Step 12: Process control Screen 52 Process control P. 29

Step 13: Production Screen 54 Production data P. 30

Step 14: Machine switch-off Screen 44 Switch-off matrix P. 31

User-Parameter 1Screen 222 P. 32

User-Parameter 2Screen 322 P. 33

Fault messages / Alarms P. 34 et seqq.

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3

Notes

This manual is designed to assist operators in setting up the machine.

Initially, the basic functions will be explained. This is followed by a detailed description of

the individual steps in setting up a mould through to production.

General notes on operation

Active input field (set value)

Inactive input field (set value); Dependent on sequence and program switch

Actual value (no entry possible)

Activated program switch

Active function group

Set position reached

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Main Menue (Screen 0)

Help functionPrintScreen No.ContentsUser-defined screen

Password

Configuration

Process

Production

Maintenance

Periphery

Alarms

Notes

Date and time

Screen forward

Softkey

Screenbackwards

Machinesequence

Mouldsequence

Alarm field Cycle sequenceNote field

NC5 Manual

Input field

5

Basics

• Function group Machine configuration with machine-specific functions, such as start-up and switch-off program, switch-off matrix and alarm reactions

• Function group Process with process-specific functions, such as temperatures at clamp and injection ends, process, and mould catalogue

• Function group Production with production-specific functions, such as process data acquisition, statistical process control, and reject segregation

• Function group Maintenance with maintenance-specific functions, such as diagnosis, putting into operation alarms, and events

• Function group Periphery with periphery-specific functions, such as Robot and Euromap 67

Note: Clicking on the function group will bring up the screen by the user;On clicking again (or double-clicking), the start screen of this particularfunction group will appear.

• User-defined screen is a customised screen defined by the user; selection is in screen 83 (Setup)

• Mould and Machine Sequences define sequences for cores, ejectors, valves (for descriptions see screens 16 and 18)

• Note field displays events that will not cause machine to be shut down

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Process Injection unit Statistics Maintenance Periphery Printer

Clamping unit ProductionTemperatures Alarms Robot Password

SO (customised options)

on/off

Cylinder heateron/off

Hot runneron/off

Full-automould

Semi-automould

SettingPumpon/off Hand-operated

Sprue picker/Robot

Function keys

Sprue picker/Robot

NC5 Manual

Steppedoperation

Referenceposition

Set-stop on/off

7

Mouldopen/close

Hydraulic ejectorback/forward

Coreextend/retract

Clamping elementsrotary platenextend/retract

Rotary platen centeringextend/retract

Rotary platenanti-clockwise/clockwise

Injection unit 1forward/back

Screw 1forward/back

Screw 1meter

Injection unit 2forward/back

Screw 2forward/back

Screw 2meter

Function keys

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2) Enable touch input Click once (checkmark)

3) Input field Click once (green means activated)

4) Start page recommended start page is page 22 (any other page is also possible)

1) Touch control on/off (click on hand symbol)

Step 1: Machine configuration

Setup (Screen 83)

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1) LoginClick on key symbol

2a) Input by keyboard Enter password

or

2b) USB stick Insert USB stick and user will be indentified automatically

Step 2: User login

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Process overviewwithout details (Profiles are only shown on level 1)

Navigate to:MouldEjectorProductionInjectionInjection unitTemperaturesProfiles

Profiles are displayedactive/inactive

Set reference position and ejector zero point

Ejector and dry cycleon/off

Step 3: Central operators side

Machine Configuration (Screen 22)

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1) Select data selected data is marked in blue

2) Click on load (green means activated)

3) Component selection opens, select and confirm by clicking ‘Yes‘

Step 4: Load Mould Data

Mould Catalogue (Screen 45)

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1) Select machine sequence Click on softkey, sequence selection opens

2) Select sequence (from opened list box)

3) Accept sequence

Step 5: Set Sequences

Machine Operation (Screen 18)

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1) Mould total sequence Click on softkey, Selection window opens

2) Select sequence Select ‘mould close sequence‘ and ‘mould open sequence‘ from predefined sequences

3) Accept sequence

Step 5: Select Mould Sequence

Mould Sequence (Screen 16)

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1) Set mould height After installing mould, move mould to contact platens in setup mode, then clicking on switch; (mould height will be accepted, mould actual position will be ‘0‘ mm)

2) Enter speed Select speed level (are marked in green), enter speed and path points

3) Mould options Enter pressure and speed in setting mode

Step 6: Set mould (hydr. machine)

Mould (Screen 10)

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1) Set clamping force Set toggle to desired clamping force using ‘mould height adjustment‘ buttons and lock ‘start‘ position

3) Mould options Select pressure and speed in setting mode

Step 6: Set Mould (toggle machine)

Mould (Screen 10)

NC5 Manual

2) Enter speed Select speed level (are marked in green) Enter speed and path points

16

1) Select basic monitoring

2) Select safety force and basic monitoring Enter safety force and positions for start and end of monitoring. Close and reopen mould

3) Select curve Enter safety force and position for end of curve monitoring

4) Store curve Close mould again. This will cause protective curve to be stored

Step 7: Mould Protection

Mould Protection (Screen 120)

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1) Click on ‘ejector‘ program switch (green means activated)

2) Set zero point Click on action switch; this will set ejector position at ‘0‘.

3) Set ejector Positions, pressures, and speed for extension and retraction

Step 9: Set ejectors

Ejector (Screen 11)

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1) Click on ‘Cores‘ program switch (green means activated)

2) Set core pullers Enter pressure and speed

Step 9: Set Cores

Cores (Screen 14)

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2) With standard sequence selected, the function mode will appear in blue direction arrow

3) Dynamic Softkey The softkey will bring up the screen associated with the marked symbol (e.g. Screen 14 – Cores)

1) Select core pull sequence Select standard sequences for ‘mould open and mould close‘.

Step 9: Set cores

Mould Sequence (Screen 16)

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1) Select mode Set all heating zones to ‘Control‘ (for further modes, see operating instructions)

2) Enter set values and tolerances

4) Oil preheating Activate by clicking

3) Synchronous heating On starting heating, all zones of the same temperature level will be controlled to set value.

Step 10: Setting up of Injection Unit

Temperatures (Screen 30)

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2) Name individual zones

5) Boost function During start-up, selected zones may be varied for an adjustable time to a boost temperature.

1) Click on ‘hot runner‘ program switch

4) Enter set values and tolerances

3) Select mode Set all heating zones to control (for further modes, see operating instructions)

Step 10: Setting up of Injection Unit

Hot Runner (Screen 31)

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3) Select function of IU

2) Set reference position of IU Advance IU with mould locked in setting-up mode and click on switch

4) Set IU Set values for speed, pressure and position for advance and retraction

1) Click on ‘Injection unit‘ program switch

Step 10: Setting up of Injection Unit

Injection Unit (Screen 23)

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2) Profiles Click to change to respective screen, profile symbol turns green on a profile being programmed.

1) Enter set values for speed, positions, pressures and times. Click on program switches for desired functions.

3) Injection options Setting of pressure and speed at manual injection and metering.

Step 10: Setting up of Injection Unit

Process Optimisation (Screen 20)

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2) Injection phase is shown inside the two blue lines

1) Enter set points for speed, positions and pressures (with pressure-limit profile activated)

Step 10: Setting up of Injection Unit

Injection Profile (Screen 26)

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Display of thelast 15 cycles

Freeze imageOn clicking on camera,values on screen arefrozen, but actual valuescontinue to be recorded in background. On settingaction switch to ‘inactive‘‚(grey), values are updated.

Selection menu:The mean values of theactivated parameters areaccepted as set values inprocess control.

Shot counterGreen indication: allparameters monitoredare within tolerance.Red indication: there isat least one parameterout of tolerance. Thevalue of the parameteris shown in red.

Step 11: Process Control

Process Control Statistics (Screen 50)

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Step 11: Process control

Process Control Statistics (Screen 50)

NC5 Manual

Transfer set valueActivate allDisable all

Transfer set valueActivate allDisable all

1) Activate standard transfers all parameters

2) Delete calculation

Activate allAll Parameters available in Process Control Statistic will be activated .

Unchanged set value

Transfer set valueCurrent averages will be transfered asset values to processcontrol.

27

1) Selection of parameters In the first 16 columns parameters can be individually selected. To do so, click on black triangles and select desired parameter.

Step 11: Process control

PDA Actual Value Selection (Screen 50)

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1) Activating the parameters to be monitored

2) Input tolerances Enter tolerances relative to set value.

3) Enter number of permissible deviations

4) Enter number of cycles to be monitored

5) Click on ‘tolerance deviation‘ program switch

Step 12: Process control

Process Control (Screen 52)

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1) Enter order data Data on order, material and article can be entered here.

2) Enter total of good parts

3) Start of production Clicking on ‘Reset counter‘ causes cycle counter and number of parts produced to be reset. Clicking on ‘Reset all‘ causes set values for cavities, shotweight, total parts, boxes and pallets to be set at ‘0‘.

Step 13: Production

Production Data (Screen 54)

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1) Select events and components Click on appropriate program switch

2) Enable by clicking on switch-off events required

3) Set cycle time monitor and switch-off delay

4) Click on switch-off matrix

Step 14: Machine Switch-off

Switch-off Matrix (Screen 44)

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1) Select parameter Click on action switches and select parameter. If any line is to be unassigned, use the ‘FREE‘ parameter.

The screens ‚UserParameter 1–4‘ permitparameter selectionto be customised.

User Parameters 1 (Screen 222)

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1) Select parameter Click on action switches and select parameter. If any line is to be unassigned, use the ‘FREE‘ parameter.

The screens ‚UserParameter 1–4‘ permitparameter selectionto be customised.

User Parameters 2 (Screen 322)

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Fault Messages / Alarms

Leitfaden NC5

2S216/7 made or defectiveMinimum or maximum mould height is achieved.

Changes log session activeSet value changes are entered into the Event log.Here the reason for change is a reason selected once.

Startup rejects activeThe machine is in the startup program.

Startup program activeYou have initiated the start-up program (screen 42). In line with yourprogramming, the given number of shots are processed as per settings for„Step 1“ or „Step 2“, before continuingto operate on the setting for „Normaloperation“.Note: Set „Reset start-up program“ switch before restarting the program.

Ejector not backA tick against the ejector symbols „forward“ and „retract“ (Screen 11) indicatesthat the set position has been reached.

34

Fault Messages / Alarms

Leitfaden NC5

Direct operation activeThe Direct Operation function is switched on in Screen (13).In direct mode, all machine functions can be activated, independent of theprogramming and the set positions.

Cable breakThe thermocouple on a heating circuit has failed.An actual temperature of >700°C is indicated for the relevant heating circuit;see screen (30), screen (31) and screen (38)WARNING: The heating switches off.If program switch „Control by wire breaks“ has been activated prior to the cablebreak, the heating will continue to function with a given regulating variable.

Drive nozzle to operating rangeThe injection unit has been fully retracted during start-up.The reference position of the injection unit has to be set again.

Edit mode alarm properties activeThe setting mode for alarms is active; see screen (102). Configurations can becarried out.If this message is present, no reactions to alarms are carried out.

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Fault Messages / Alarms

Leitfaden NC5

EEPROM ErrorAn error occured writing to the machine‘s EEPROM.Note: - Only insert genuine Demag Plastics Group EEPROMs.

- If an error message persists, contact you Demag Plastics Group Service Department.

Mould safety time„Mould closed“ position has not been reached within the set mould safety time,see screen (10).Note: - Remove component or sprue

- Increase mould protection force (Screen 10)- Increase mould protection time (Screen 10)

Optimising hot runner heatingThe programming switch for optimising the hot runner is activated in screen (95).

No holding pressure (stroke, time, pressure)The selected change-over criterion to holding pressure has not been attained.If the non-activated change-over criteria in screen (22) have been set at „0“,they will no longer be active for monitoring.

Production count reachedThe set production count is reached, see screen (54). Depending on the setting,this will cause the machine to be shut down or only a note to be displayed.

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Fault Messages / Alarms

Leitfaden NC5

Clamping force exceeded or to highThe locking operation has been interrupted because the selected machine settingis liable to result in too high a clamping force and, consequently, damage tothe tie bars.

Screw back not reachedThe screw has not reached the set position, that‘s why the cycle isn‘t started.Note: Complete metering in manual mode and retract the screw; then change

back to semi- or fully automatic operation.

Injection pressure overrun IUThe injection pressure required for control of the injection speed has reachedthe selected set value level.

Tolerance deviation: parameterFrom PDE, Parameter is completedThe limit for the frequency of tolerance deviation for one parameter has beenreached, see screen (52).

Dry cycle ativeThe function dry cycle is active, see screen (22) or screen (20)

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Fault Messages / Alarms

Leitfaden NC5

Preventative maintenance:

User defined tast „x“ is in „overdue“The user-specific function „x“ of the Maintenance Programis now due.Note: Please carry out the required action and acknowledge the action.

Standard task „x“ is in „overdue“The standard function „x“ of the maintenance program is now due.Note: Please carry out the required action and acknowledge the action

Cannot read PMSD.txt, file does not existsThe maintenance file wasn‘t found.

Error in reading PMSD.txt in lineThe existing file could not be interpreted.

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Fault Messages / Alarms

Leitfaden NC5

Warning limits reached: parameterfrom PDE, Parameter is completedThe indicated parameter has transgressed the warning limits on screen (52).

Waiting on 2B87 (Ejector platen monitoring)The limit switch for monitoring the ejector end position on the mould has notbeen operated.

Mould height end switch activatedMinimum or maximum mould height has been reached.

Permissible deviations of tolerances exceeded: ParameterThe number of of permissible deviations of tolerances on process monitoring(screen 52) has been exceeded and can be reset by means of the „Reset actual deviation“ action switch.

Cylinder heating not controlled – cable break„Cable break“ switch has been set on screen (30).After a thermocouple has failed, the machine operates in this particular heatingzone using the given percentage operating factor. The relevant heating zone canbe seen on screen (30), because an incorrect actual temperature of>700°C isindicated.Note: Decide whether you wish to complete job production in this mode or

replace the damaged thermocouple straight away.