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PREVIEW

This Liquid Crystal Display (LCD) controller "FA" series is designed and
manufactured by our company has features of advanced technology, high
quality and perfect maintenance services etc.
All injection molding process of this controller is centralized and
controlled by computer. It provided quick action, high efficiency, power
saving, safety and reliability.
For the purpose of using and maintenance of this machine better, this
operation manual will provide detail information and instructions as well.
Any problem do not clear, please do not hesitate to contact our service
team. We are glided to provide concerned technical communication service
and answer all kinds of question for your requires.

* Specifications are subject to change without prior notice.

CONTENT
Chapter 1System Specification
1. Standard Configuration
1- 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 Potentiometer
2- 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
4- 9
5. Core Pulling and Ejection Screen
6. Nozzle Unit and Memory Screen4 - 11
4 - 13
7. Quality Control 1 and 2 Screen

CONTENT
Chapter 5Operation and Control
1. Diagrammatic Explication of Injection Unit
5- 2
2. Diagrammatic Explication of Clamping Unit5 - 4
3. Basic Data Presetting 5 - 6
4. Manual Operation Description5 - 9
5 - 13
5. Operation mode Description
Chapter 6System Wiring
1. Power distribution diagram6 - 2
2. Main box connector distribution diagram
6- 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

Chapter 1

System Specification

1. Standard Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2


..
2. Hardware Specification and mounting dimension. . . . . . . . . . . . .1-2
...
3. Software function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
..

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

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. Transformer
5. Spare fuse
6. 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

2.

Keyboard + High speed Counter + A/D + D/A board


56 keys individual input port
4 channels high speed counter input interface
2 channels D/A voltage output interface (standard for 2, available extend to 4)
4 A/D voltage input interface

(1)

FA-1 KAD

(2)

FA-2 TC/TC-2N Temperature control board


7 zones for barrel heating, 1 zone for oil temperature
Independent MPU control and P.I.D auto tuning

(3)

FA-3 CLCD

CPU Main board


Industrial CPU chip set include 60 groups parameter memory
On-line edit port
Independent MPU hardware interrupt circuit
LCD word, GDI display interface

(4)

FA-4 IO

Operation I/O board (standard for 2, available extend to 3)


16's*2 24vdc NPN port
16'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

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-3 CLCD

FA-2 TC

+5V +15V

+5V -5V

-15V V5

VI WG

+5V,V1,V0
+5V,WG

KB
RESET

FA-4 IO

HT1

FA-6 IO3

+5V,V1,V0

V1

V1

IN1

IN17

IN2

IN18

IN3

IN19

IN4

IN20

IN5

IN21

IN6

IN22

YI

HT2

CNT1

HT3

CNT2

HT4

IN7

IN23

CNT3

HT5

IN8

IN24

CNT4

HT6

IN9

IN25

HT7

IN10

IN26

VS1

HT8

IN11

IN27

AD1+

V1

IN12

IN28

AD1-

G1

IN13

IN29

COM1

COM2

IN14

IN30

VS2

FG1
ALM1

IN15

IN31

AD2+

ALM2

IN16

IN32

AD2-

ALM3

GI

GI

FG2

ALM4

RESET

V0

ALM5

V0

VS3

ALM6

OUT1

OUT17

AD3+

ALM7

OUT2

OUT18

AD3-

ALM8

OUT3

OUT19

OUT4

OUT20

VS4

OUT5

OUT21

AD4+

OUT6

OUT22

OUT7

OUT23

OUT8

OUT24

OUT9

OUT25

OUT10

OUT26

OUT11

OUT27

OUT12

OUT28

OUT13

OUT29

OUT14

OUT30

OUT15

OUT31

OUT16

OUT32

FG3

AD4FG4

DA1+
DA1DA2+
DA2DA3+
DA3DA4+
DA5+

LCD(1)

TC1+
TC1TC2+
TC2TC3+
TC3TC4+
TC4TC5+
TC5TC6+
TC6TC7+
TC7TC8+
TC8-

LCD(2)

GO

1-3

GO

////

Control Box

(Fig. 2)

FA-1 KAD

+5V +15V

FA-3 CLCD

FA-2N

+5V -5V

-15V V5

+5V,V1,V0
+5V,WG

KB
RESET

FA-4 IO

HT1

FA-6 IO3

+5V,V1,V0

V1

V1

IN1

IN17

IN2

IN18

IN3

IN19

IN4

IN20

IN5

IN21

IN6

IN22

YI

HT2

CNT1

HT3

CNT2

HT4

IN7

IN23

CNT3

HT5

IN8

IN24

CNT4

HT6

IN9

IN25

HT7

IN10

IN26

VS1

HT8

IN11

IN27

AD1+

24V

IN12

IN28

AD1-

G1

IN13

IN29

COM1

COM2

IN14

IN30

VS2

FG1
ALM1

IN15

IN31

AD2+

ALM2

IN16

IN32

AD2-

ALM3

GI

GI

FG2

ALM4

RESET

V0

ALM5

V0

VS3

ALM6

OUT1

OUT17

AD3+

ALM7

OUT2

OUT18

AD3-

ALM8

OUT3

OUT19

OUT4

OUT20

VS4

OUT5

OUT21

AD4+

OUT6

OUT22

OUT7

OUT23

OUT8

OUT24

OUT9

OUT25

OUT10

OUT26

OUT11

OUT27

OUT12

OUT28

OUT13

OUT29

OUT14

OUT30

OUT15

OUT31

OUT16

OUT32

FG3

AD4FG4

DA1+
DA1DA2+
DA2DA3+
DA3DA4+
DA5+

LCD(1)

TC1+
TC1TC2+
TC2TC3+
TC3TC4+
TC4TC5+
TC5TC6+
TC6TC7+
TC7TC8+
TC8-

LCD(2)

GO

1-4

GO

////

Operation Panel (Fig.3)


The hole of fix
panel screw.
4 mm
WE NEED A NEW ONE
196

4 mm

Operate
panel

198

56 mm

Rear cover
198

The hole of fix


4 mm
main box screw.
4 mm
W

w'

D
L1

H
H

L2

l'
L

L1

FA type Control Box Installation


Dimension
L265 X W180 X H148
L1=10
L2=246
Unit : mm

FA type Control Box dimension


L295X W250X H200
Unit : mm

1-5

FA type Operation Panel dimension


Cover : L404 X W204 X D60
Inner : l' 388 X w' 188
Unit : (mm)

////

3.

Software function
Temperature Unit

Centralization Unit

7 zones barrel temperature control (with H/L alarm)


1 zone oil-temp monitor / control
Independent PID control
First zone constant temp. control with SCR selectable

Injection Unit

PLC ladder program editor


Multi layer password protection
30 pages display
Built-in 60 sets mold memory
3 kind of variable operation modes
Over 50 alarm message
Electrical lubrication control
Production statistic function
Operating I/O diagnosis
Real-time display

4-stages injection control


4-stages holding control
Time or position advance to holding stage
Injection target position detect

Motion Unit
Multi-stage independent absorber setting
Emergence or special action absorber

Plasticization Unit

Curve fitting for proportional output


Linear I/O modification function

2 stages suck back, 3 stages charge function


Selective depression sequence
Auto purge (Barrel Clean-up)
Screw rotation speed display

De-Molding (ejection) Unit


Oscillating ejection
Hold-on eject function

Clamping Unit

2 sets air blow function


robot connection procedure
2 sets core polling / unscrewing

4 stages opening control


4 stages clamping control
Fast speed clamping support
Auto mold height adjustment

* Specifications are subject to change without prior notice.

1-6

Chapter 1 System Specification

Chapter 2 Safety Precaution


1. Operating safety instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. .- 2
2. Installation Regarding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. .- 3
3. Power Requirement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. - 3
4. Installation of Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. -. 4
5. Wiring Requirement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. .- 4

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

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 acceptable


380v : 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

3
3

5.

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

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

2-4

Chapter 1 System Specification

Chapter 2 Safety Precaution

Chapter 3 Operating Panel Description


1. Screen Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 3
2. Operating Mode Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 3
3. Cursor Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 4
4. Numeric Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 4
5. Manual Operation Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3. - 5

Chapter 4 Screen Operation Description

Chapter 5 Operation and control

Chapter 6 System Wiring

Chapter 7 Maintenance and Trouble Shooting

Chapter 8 Services Review

3-1

LCD Display
with back-light

RESET

Key Lock
Emergence Stop

Contrast

3-2

1. Screen Selector

ACTION KEY
Monitor, temperature page (repeat pushing)
MOLD KEY
Mold close & open page
INJ. HOLD-P KEY
Injection, hold pressure page (repeat pushing)
CHARGE KEY
Charging (plasticization) page
EJECTOR NOZZLE KEY
Ejector / nozzle page
CORE KEY
Core (unscrew) page
SPC KEY
Q.C.1, Q.C.2 page
MEMORY KEY
Memory 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 mode
re-started by safety door, photo sensor or robot

MOTOR

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

HEATER

( please wait one minute before machine running)

RESET

Push this key to reset alarm and continue to product after the resolution of alarm message

3-3

3. Cursor Keys

Cursor moving direction

4. Numeric Keys
7

STU

JKL

ABC

VWX

MNO

DEF

YZ( )

PQR

CLEAR

ABC

GHI

S3 S2 S1

+ , -

ENTER

(1)

+ , -

(2)

S1

Spare

(3)

S2

Spare

(4)

S3

Spare

Clearing input data to ZERO

(5)

(6)

(7)

CLEAR

ABC

ENTER

YZ( )

0~9 Numerals or symbols change key

English character input key

Function On / Off key and data input confirmation key

3-4

5. Manual Operation Keys

MOLD OPEN KEY


Push for activate of mold opening action manually
MOLD CLOSE KEY
Push for activate of mold clamping action manually
EJECTOR RET. KEY
Push for activate of ejector retract action manually
EJECTOR ADV. KEY
Push for activate of ejector advance action manually
MOLD ADJ. KEY
Push for select mold adjustment function On / Off
M. MOLD ADJ. KEY
Push for slow manual mold adjustment function On / Off (work with Mold adjustment function)
CORE (1/2) IN KEY
Push for activate of core (1/2) IN action manually
CORE(1/2) OUT KEY
Push for activate of core (1/2) OUT action manually
MOLD ADJ. ADV. KEY
Push for activate of mold adjustment advance manually
MOLD ADJ. RET. KEY
Push 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 KEY
Spare
INJECTION KEY
Push 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 KEY


Push for activate of air blow de-molding devices manually (fix and movable platen)
SUCK BACK KEY
Push 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. KEY
Push 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. KEY
Push key for start auto lubrication at once

RESET

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

3-6

Chapter 1 System Specification

Chapter 2 Safety Precaution

Chapter 3 Operating Panel Description


Chapter 4 Screen Operation Description

1. Introduction and Welcoming Screen . . . . . . . . . . . . . . . . . . . . .4. -. 2. .

2. Monitor and Temperature Screen . . . . . . . . . . . . . . . . . . . . . . . 4. .- .3.

3. Injection and Charging Screen . . . . . . . . . . . . . . . . . . . . . . . . . 4. .-. 5.



4. Purge and Mold Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. .-.7.

5. Core Pulling and Ejection Screen . . . . . . . . . . . . . . . . . . . . . . .4. .- .9.

6. Nozzle Unit and Memory Screen . . . . . . . . . . . . . . . . . . . . . . .4. -. 11


..

7. Quality Control 1 and 2 Screen . . . . . . . . . . . . . . . . . . . . . . . . .4. -. 13


..

Chapter 5 Operation and control

Chapter 6 System Wiring

Chapter 7 Maintenance and Trouble Shooting

Chapter 8 Services Review

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 the
boards to serve as the action procedure in the whole system to reach the most ideal
hardware interrupt effect, so the system tracks the coherence automatically in each
configuration when transferring electricity and starting the machine every time about
seconds later, the system will display the welcome page automatically to notify the operator
that 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


Page Display

Date

A
B
C

Time

07/06/1999
< MONITOR >
19:32:29
OPER.MODE : MANU
ACTIVE
PRS.Bar SPEED
TIME COUNT
INJECT 1
30
35
9.0

D
J
E
MODE POS.:234.5mm
CYC-TIME :999.9SEC
SHOT ACC.: 123456

F
G

SCREW POS.: 456.7mm

: 999 rpm
PACK ACC. : 123456

L
H
TRUE

1
2
3
4
5
6
7 OIL
236 221 219 216 214 210 --- ---

I
WARN 67 : OIL TEMP. OVER
N

Description :

Operation and monitor page of each master parameters

Instruction :

(A)
(B)
(C)
(D)
(E)
(F)
(G)
(H)
(I)
(J)
(K)
( L)
(M)
( N)

Operating mode displayed


Action name and unit column
Present active in motion and it's executive parameter displayed row
Motive graph display portion of machine
MODE POS. : present position of movable mode plate
CYC-TIME : auto cycle timer display (single cycle)
SHOT ACC. : accumulation counter of shot record
Temperature zone and unit display
TURE : actual temperature of correspondent region
SCREW POS.: present plasticizating screw position
RPM : Rotation speed per minute of placticizating screw
PACK ACC. : accumulation counter of packing record (single packing cycle)
OIL : Hydraulic oil temperature region
Warning message (Display on all page while need)

4-3

I
07/06/1999 < TEMP
TEMP.
1
2
3
TRUE
240 220 218
SET
236 221 219
UP LIM. +30 +20 +20
LO LIM. -25 -15 -15
IDLE
150 120 120

A
B
C
D
E

OIL-TEMP
30

HEAT
10

4
216
216
+20
-15
120

COOL
50

HEAT TYP : NORMAL


NZ. HEAT : 50

>
5
214
214
+20
-15
120

OVER
60

19:32:29
6
7
212 --210 --+20 ---15 --120 --STATE
NORMAL

J
K
L

IDEL FUN : OFF

Description :

Temperature parameters setting of 7 zone barrel and 1 zone oil tank

Instruction :

(A)
(B)
(C)
(D)
(E)
(F)
(G)

TURE : present temperature value display row


SET : target temperature value setting row
UP LIM.: high temperature alarm setting row
LO LIM.: low temperature alarm setting row (prevention of placticizing cool start)
IDLE : setting of temperature in idle mode
OIL-TEMP: Oil temperature value
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

4-4

3. Injection and Charging Screen

07/06/1999

B
C
D
E
F
G
H
I

INJECT 1
INJECT 2
INJECT 3
INJECT 4
HD. POS.
HD.PRS.1
HD.PRS.2
HD.PRS.3
HD.PRS.4

< INJ >


19:32:29
POS.
PRS.
SPD.
40
45
600.0
130
100
500.0
50
70
10.0
45
50
5.5
INJ.TIME:5.0SEC
PRS.
SPD.
TIME
40
50
3.8
35
45
2.0
30
43
0.9
20
40
0.3

SCREW POS.:789.9 mm

Description :

Injection parameter setting screen

Instruction :

(A)
(B)
(C)
(D)
(E)
(F)
(G)
(H)
(I)
(J)
( K)

INJECT 1 : parameter setting of stage 1 of injection data (position needless)


INJECT 2 : parameter setting of stage 2 of injection data (disable by pos.=0)
INJECT 3 : parameter setting of stage 3 of injection data (disable by pos.=0)
INJECT 4 : parameter setting of stage 4 of injection data (disable by pos.=0)
HD. POS. : switching position setting of injection to holding stages
HD.PRS.1 : parameter setting of holding stage 1
HD.PRS.2 : parameter setting of holding stage 2
HD.PRS.3 : parameter setting of holding stage 3
HD.PRS.4 : parameter setting of holding stage 4
SCREW POS. : present staying position of injection screw
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

4-5

07/06/1999
A

< CHARGE >


POS.
60.0

PRE-SUCK
CHARGE 1
CHARGE 2
80.0
CHARGE 3
90.0
CHARGEEND 120.0
SUCK-BK. + 20.0

C
D
E

: 999 RPM

19:32:29

PRS.
30
33
120
50

SPD.
35
33
75
40

45

50

SCREW POS:809.4mm

Description :

parameter setting of plasticization screen

Instruction :

(A)
(B)
(C)
(D)
(E)
(F)
(G)
(H)

PRE-SUCK : parameter setting of suck back stage 1


CHARGE 1 : parameter setting of plasticization stage 1 (position needless)
CHARGE 2 : parameter setting of plasticization stage 2 (disable by pos.= 0)
CHARGE 3 : parameter setting of plasticization stage 3 (disable by pos.= 0)
CHARGE END : accomplish position setting of charge stage
SUCK_BK : parameter setting of suck back stage 2 (decompression stage)
RPM : rotation speed display of plasticization screw
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

4-6

4. Purge and Mold Screen

07/06/1999
A

< PURGE >

PURGE
POS.
PURGE-INJ
10.0
PURGE-SUCK 30.0
PURGE-REC 100.0

B
C

PRS.
50
40
135

19:32:29
SPD.
50
30
60

TIME
E
38.0

PURGE CYC : 9 TIMES


AUTO-PURGE: OFF

D
E

Description :

special parameter setting in purge procedure (auto barrel cleaning function)

Instruction :

(A)
(B)
(C)
(D)
(E)
(F)

PURGE-INJ : inject end position and inject parameter setting row in purge
PURGE-SUCK : end position of pre-suck action and inject parameter setting row in purge
PURGE-REC : parameter setting of plasticization back action in purge procedure
PURGE CYC : frequency of purge action setting
AUTO-PURGE : switch of purge function
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

4-7

07/06/1999

A
B

CLOSE 1
CLOSE 2
PROTECT
LOCK-UP

C
D

OPEN
OPEN
OPEN
OPEN
OPEN
FAST

F
G
H
I

< MOLD >


POS.
PRS.
40
880.0
120
100.0
30
15.5
50

19:32:29
SPD. TIME
40
100
35
3.8
25
3.0

POS.

SPD.
33
100
40
30

1
2
23.8
3
650.0
4
880.0
END
889.0
CL.:

PRS.
130
68
40
30

MOLD POS.:889.9mm

Description :

movable mode plate parameter setting screen

Instruction :

(A)
(B)
(C)
(D)
(E)
(F)
(G)
(H)
(I)
(J)
(K)
(L)
( M)

CLOSE 1 : parameter setting of clamping stage 1 (position needless)


CLOSE 2 : parameter setting of clamping stage 2
PROTECT : parameter setting of protection of mold close stage
LOCK-UP : parameter setting of lock-up stage
OPEN 1 : parameter setting of mold opening stage 1
OPEN 2 : parameter setting of mold opening stage 2
OPEN 3 : parameter setting of mold opening stage 3
OPEN 4 : parameter setting of mold opening stage 4
OPEN END : position setting of mold open end
FAST CL. : Speed clamping circuit switch
PROTECT TIME : Low pressure protection timer setting
LOCK-UP TIME : High pressure protection timer setting
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

4-8

5. Core Pulling and Ejection Screen

07/06/1999

< CORE >

19:32:29

A
CORE 1 : TIME
CORE 1 IN:POS.
CORE 1
PRS.
IN
50
OUT
55

B
C
D

I
CORE 1 OUT:POS.
SPD. TIME
POS.
35
19.9
1.0
38
22.0
1.0

E
CORE 2 : TIME
CORE 2 IN:POS.
CORE 2
PRS.
IN
30
OUT
35

F
G
H

J
CORE 2 OUT:POS.
SPD. TIME
POS.
35
1.9
680.0
38
2.0
680.0

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)
(D)
(E)
(F)
(G)
(H)
(I)

IN : parameter setting of core 1 IN


OUT : parameter setting of core 1 OUT
CORE 2 : selector of core / unscrew device 2 (TIME / COUNT)
CORE 2 IN : sequence selector of core 2 IN (POS. / BE.CLP. / CLP.END)
IN : parameter setting of core 2 IN
OUT : parameter setting of core 2 OUT
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)

4-9

07/06/1999 < EJECT >


EJECT
PRS.
SPD.
EJECT FWD.
66
45
EJECT RTN.
50
50

A
B

19:32:29
STOP
3.8
G

EJECT TYP : VIB

EJECT CT :10 TIMES

BLOW
MOVE-SIDE
FIX-SIDE

DELAY
0.5
1.2

FUNT
ON
OFF

TIME
3.0
3.8

E
MOD POS.: 999.9mm
F

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)
(E)
(F)
(G)

MOVE-SIDE : switch of air blow valve A (assemble at movable plate)


FIX-SIDE : switch of air blow valve B (assemble at fix plate)
MOLD POS. : present position display of movable plate
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

4 - 10

6. Nozzle Unit and Memory Screen

A
B
C
D
E
F
G
H

07/06/1999
NZ. UNIT
NZ.U.FWD.1
NZ.U.FWD.2
NZ.U.RTN.

MOLD ADJ.
MAN. ADJ.
SLOW ADJ.
SLOW CLOSE
SLOW OPEN
PRESET
AUTO ADJ.

< NZ. UNIT >


19:32:29
PRS. SPD. TIME
30
55
40
28
0.8
40
43
PRS.
60
55
35
33
140

SPD.
30
28
35
30
100

FUNT.

OFF
OFF

Description :

Operating screen of mold height device and injection carriage (nozzle)

Instruction :

(A)
(B)
(C)
(D)
(E)
(F)
(G)
(H)
(I)
(J)

NZ.U.FWD.1 : carriage forward setting 1 (fast stage)


NZ.U.FWD.2 : carriage forward setting 2 (cushioning stage actuate by forward sensor)
NZ.U.RTN. : carriage return parameter setting
MAN.ADJ.: mold height adjustment operating data at manual mode (F&B)
SLOW ADJ. : operating data of slow mold height adjustment (stepping / pulsation)
SLOW CLOSE : slow clamping parameter setting (enable on Mold Adj. mode only)
SLOW OPEN : slow opening parameter setting (enable on Mold Adj. mode only)
PRESET : presetting parameter and switch for amplified circuit D/A1&2 channels
AUTO ADJ.: Auto mould height adjustment function switch
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

4 - 11

A
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

Description :

Molding data memory screen

Instruction :

(A)
(B)
(C)
(D)
(E)
(F)

(1)
(2)
(3)
(4)

ACES. No. : access number selector of molding parameter (file save / load code 01-60)
LOAD / SAVE / DELE : Function selector
No. : module number (module code 01-60)
FILENAME : Module name display ( English text and number)
PAGE : inquire the current module number (01-60)
Date : date recording for the files

LOAD = loading data from inner memory for operate


SAVE = saving present operating data to inner memory
DELE = deleting file at memory area
For safety reason, LOAD data at Manual mode only

4 - 12

7. Quality Control 1 and 2 Screen

A
B

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.

C
D
E
F
G

K
L
M
N
O
P
Q

H
I

Description :

Production monitor page 1

Instruction :

(A)
(B)
(C)
(D)
(E)
(F)
(G)
(H)
(I)
(J)

COOL T. : parameter setting of cooling time


CYC.DLY. : parameter setting of cycle delay (interval time of cycle restart)
CYC.ALM. : parameter setting of cyclical time limit (cycle alarm)
CLE.ALM. : parameter setting of mold close limiting time
OPN ALM. : parameter setting of mold open limiting time
INJ.ALM. : parameter setting of injection limiting time
REC.ALM. : parameter setting of charge (plasticization) limiting time
PHO.ALM. : parameter setting of photo detector limiting time
LANGUAGE : Chinese / English display selector
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)
(M)
(N)
(O)
(P)
(Q)

INJ.MON. : Injection monitor switch (injection target detection)


INJ.UP. : injection target upper limit setting (injection target detection)
INJ.LO : injection target lower limit setting (injection target detection)
AUTO-NZB : auto carriage backward function selector (oil pressure nozzle)
PHO. USE : cycle re-start device selector (ON=photo sensor, OFF=timer)
USE ROBOT: robot selector

4 - 13

07/06/1999
< Q.C.2 >
PRO.SET
TOTAL
PACK
CURRENT
234567
123456
SET NO.
900000
090000
SHUT DOWN
ON
OFF
CLEAR NO
OFF
OFF

B
C
D
E

19:32:29
FAIL
0005
0100
ON
OFF

INTERVAL : 180 SET


LUBRI.T : 80 SEC

Description :

Production monitor page 2

Instruction :

(A)
(B)
(C)
(D)
(E)
(F)
(G)
(H)
(I)

CURRENT : Current shot counter display


SET NO. : production counter setting (shot quota)
SHUT DOWN : auto shut down function selector (counter break)
CLEAR NO : Counter reset (Clear counter valve to zero)
INTERVAL : Interval cycle of auto lubrication
LUBRI.T : Lubricating duration timer
TOTAL : Total shots amount column (include good and defect products)
PACK : Packing counter column (only accumulate good products)
FAIL : Defect / fail product shots counter

4 - 14

Chapter 1

System Specification

Chapter 2 Safety Precaution

Chapter 3 Operating Panel Description

Chapter 4 Screen Operation Description

Chapter 5 Operation and Control


1. Diagrammatic Explication of Injection Unit . . . . . . . . . . . . . . . . . . . . 5. .- .2. .
2. Diagrammatic Explication of Clamping Unit . . . . . . . . . . . . . . . . . . .5. -. .4. .
3. Basic Data Presetting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5. -. 6
4. Manual Operation Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. .-.9
5. Operation mode Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.-. 13

Chapter 6

System Wiring

Chapter 7 Maintenance & Trouble Shooting

Chapter 8 Services Review

5-1

1. Diagrammatic Explication of Injection Unit


Diagram for inject process
07/06/1999
INJECT 1
INJECT 2
INJECT 3
INJECT 4
HD. POS.

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

HD.PRS.1
HD.PRS.2
HD.PRS.3
HD.PRS.4

3. The time parameter of hold pressure stage


is the period time setting

< INJ >


19:32:29
POS. PRS. SPD.
40
45
600.0 130
100
500.0
50
70
10.0
45
50
5.5
INJ.TIME:5.0SEC
PRS. SPD. TIME
40
50
3.8
35
45
2.0
30
43
0.9
20
40
0.3

SCREW POS.:789.9 mm

Stopped position of
plasticizing/suck back

Inj. Direction

Inject Limit
0

(Decrease order)

20

30

35

40

45

50

130

40

pressure %

40

43

45

50

50

70

100

45

flow %

Hold (4)

Hold (3)

Hold (2)

Hold (1)

Inj. (4)

Inj. (3)

Inj. (2)

Inj. (1)

injection stage

789.9

Hold stage
(time control)
5.5
3.0

4.5

Inject
Low-Limit

Inject
Up-Limit

10.0

500.0

600.0

Inject Monitor
Inspect Area

5-2

789.9

Screw actual
position (mm)

////

Diagram explication for charge process

07/06/1999

< CHARGE >


POS.
60.0

1. The parameter setting are refereed to th

PRE-SUCK
CHARGE 1
CHARGE 2
80.0
CHARGE 3
90.0
CHARGEEND 120.0
SUCK-BK. + 20.0

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

19:32:29

PRS.
30
33
120
50

SPD.
35
33
75
40

45

50

setting of suck 2 have to increase


*The modification of the final charge position

: 999 RPM

SCREW POS:809.4mm

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)

Direction Of Charge/Suction Back


Injection
End Position

Suck Back pos.=Pla.(3)+Suck


=120.0+20.0
=140.0mm

(increase order)

50

Pressure
flow

Suck back

pla. (3)

pla. (1)

45
50

40

Plasticizing/
Suck Back
stage

120
75
pla. (2)

33
33

decamp.

30
35

Decompress
zone
5.0

60.0

80.0

90.0

5-3

120.0

140.0

Screw
Position (mm)

2. Diagrammatic Explication of Clamping Unit


Diagram explication for close-mold process

07/06/1999
1. The parameter settings are refereed to the right-hind

CLOSE 1
CLOSE 2
PROTECT
LOCK-UP

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

OPEN
OPEN
OPEN
OPEN
OPEN
FAST

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

< MOLD >


POS.
PRS.
40
880.0 120
100.0
30
15.5
90

19:32:29
SPD. TIME
40
100
35
3.8
25

POS.

SPD.
33
100
40
30

1
2
23.8
3
650.0
4
880.0
END 889.0
CL.:

PRS.
130
68
40
30

MOLD POS.:889.9mm

different from the setting position with


no-load / light load condition

Clamping
Stage
actual position of
movable platen (mm)
889.9

30

90

40

100

35

25

Protect

flow

120

Close 2

pressure

Close 1

Direction Of Close-Mold
(decrease order)

40

880.0

Open complete
Position

lock-up

0 > 2.0
Clamping complete
Position (actual)
lock-up
pos. set

100.0

15.5

protect
pos. set
protection
timer

5-4

Diagram explication for open mold process

07/06/1999

< MOLD >


PRS.
40
880.0 120
100.0
30
15.5
90
POS.

CLOSE 1
CLOSE 2
PROTECT
LOCK-UP

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

POS.
OPEN
OPEN
OPEN
OPEN
OPEN
FAST

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

19:32:29
SPD. TIME
40
100
35
3.8
25

PRS. SPD.
130
33
68
100
40
40
30
30
30
30
MOLD POS.:889.9mm

1
2
23.8
3
650.0
4
880.0
END 889.0
CL.:

Opening Direction
(Increase order)

68

130

Pressure

30

40

99

33

Flow

Open 2

Open 4

Open 1

40

Open 3

30

Opening
Stage

Movable platen
position (mm)
880.0

650.0

23.8

0 > 2.0

899.0
open end
pos. set

open 3 pos.
set

open 2 pos.
set

open 4 pos.
set

5-5

clamp complete
pos. (actual)

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
07/06/1999
INJECT 1
INJECT 2
INJECT 3
INJECT 4
HD. POS.
HD.PRS.1
HD.PRS.2
HD.PRS.3
HD.PRS.4

After
< INJ >
19:32:29
POS.
PRS.
SPD.
40
45
600.0
130
100
500.0
50
70
10.0
45
50
5.5 INJ.TIME:5.0SEC
PRS.
SPD.
TIME
40
50
3.8
35
45
2.0
30
43
0.9
20
40
0.3

07/06/1999
INJECT 1
INJECT 2
INJECT 3
INJECT 4
HD. POS.
HD.PRS.1
HD.PRS.2
HD.PRS.3
HD.PRS.4

SCREW POS.:789.9 mm

SCREW POS.:789.9 mm

press screen selector at once

< INJ >


19:32:29
POS.
PRS.
SPD.
40
45
600.0
130
100
100.0
50
70
10.0
45
50
5.5 INJ.TIME:5.0SEC
PRS.
SPD.
TIME
40
50
3.8
35
45
2.0
30
43
0.9
20
40
0.3

press cursor key To find out the place of the data need to be modify

ABC

ENTER

+ , -

+ , -

+ , -

press data key to input the right valve

press enter key to confirm input

Modification complete

5-6

Select function ON/OFF step


1. Open the page of the function that need to On / Off
2. Push cursor to find out the place of the function need to modify
3. Push enter key to change ON/OFF or controllable status

Example : Switch the ejection mode from OFF to Hold


Before

After

07/06/1999
EJECT
EJECT FWD.
EJECT RTN.

< EJECT >


PRS.
SPD.
66
45
50
50

EJECT TYP:OFF
BLOW
MOVE-SIDE
FIX-SIDE

07/06/1999
EJECT
EJECT FWD.
EJECT RTN.

19:32:29
STOP
3.8

EJECT TYP:HOLD

EJECT CT:10 TIMES

FUNT
ON
OFF

DELAY
0.5
1.2

BLOW
MOVE-SIDE
FIX-SIDE

TIME
3.0
3.8

FUNT
ON
OFF

EJECT CT:10 TIMES


DELAY
0.5
1.2

Press screen selector to choose screen

19:32:29
STOP
3.8

MOD POS.: 999.9mm

MOD POS.: 999.9mm

< EJECT >


PRS.
SPD.
66
45
50
50

press cursor key To find out the place of the data need to be modify

ENTER

press enter key to switch and confirm input

Modification Finish

5-7

TIME
3.0
3.8

Read / write step of module memory


1. Open the page of module memory
2. 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 /Number
4. Push 0~9 to input annotated module
5. Move the cursor to read/write place and push enter to confirm input
6. Push enter again to confirm input
Example : Saving operating data at memory 01

FILE NAME : DISK

Before

After
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

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)

ABC

press key at once, then press

to charge decided character

DEF

Repeat the step 3 & 4 to complete input characters "DISK"

press cursor key to SAVE field and press

ENTER

to confirm

(the computer will show "Please push <enter> again to confirm" )

If you confirm all data is correct, please repeat push

Saving Operating Data Procedure complete

5-8

ENTER

to confirm input

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

(2)

Release

core key at once to start function


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

RESET

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

RESET

to stop the action

(If M. MOLD ADJ. Function Is "ON", press above key once for move one gear (pulse))

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

(2)

Press

MOTOR

MOTOR

key at once to start the motor

key at once to stop

Heater :

(1)

Press

HEATER

(2)

Press

HEATER

key at once to start heater

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.

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 6
1.
2.
3.
4.
5.
6.
7.
8.

System Wiring

Power distribution diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . .6. -. .2


Main box connector distribution diagram. . . . . . . . . . . . . . . . . .6. -. .3.
FA-1 KAD module connection . . . . . . . . . . . . . . . . . . . . . . . . 6. .-. 6
FA-2 TC module connection . . . . . . . . . . . . . . . . . . . . . . . . . .6. -. 8
FA-3 CLCD module connection . . . . . . . . . . . . . . . . . . . . . . . .6. -. 13
FA-4 IO module connection . . . . . . . . . . . . . . . . . . . . . . . . . . .6. -. 14
FA-6 IO3 module connection . . . . . . . . . . . . . . . . . . . . . . . . . . 6. .- 16
Transformer color of wiring . . . . . . . .. . . . . . . . . . . . . . . . . . .6. -. .20
..

Chapter 7 Maintenance and Trouble Shooting

Chapter 8 Services Review

6-1

1. Power distribution diagram


Emergency Stop SW

Transformer F-4

White

F-4

5A
220VAC
or 380V

L
N

Red

Yellow

5A
Black
Yellow

0V
200V
220V
380V
15V
0V
15V
E

1.5A

1.5A
1.5A
5A
8A

0V
24V
50V
0V
24V
50V
0V
21V
0V
21V

Purple
Coffee
Light-green

Ash
Pink

Blue
L
I
N
E

Yellow-Green
White

Wiring =1.25mm2

21V
21V

FPW-01

OUTPUT ELEMENT
POWER SOURCE

VO
GO
VI
GI

FILTER

L
O
A
D

Red

POWER
SUPPLY
VPE-3

Red

POWER BOARD

EMI

INPUT ELEMENT
POWER SOURCE

21V 21V

-12V 0V +12V 0V

5V

AC
IN

MAIN BOX
FBUS-05

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 ohm
Pac = 1A x 40 ohm = 40V ; Because 40V close 50V ,
So Pac please choose AC 50V. And Fac = 10V ,
Pac
So please choose Fac AC 24V.
AMPLIFIER POWER SOURCE
15V
0
15V
PRESSURE VALVE
FLOW VALVE

0-1A

FLOW VALVE
POW.SOURCE
Fac
FPV-01
AMPLIFIER

P+ P- F+ F- Vp+ Vp- Vf+ Vf201 202 203 204

0-1A

Refer VOLT
INPUT

Note:

1. The wiring from power supply to transformer : distance<60cm uses #14 (1.25mm) cable
If distant >60, 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 cable
3. 10 pressure proportional valve : FPV-01 board JP1,JP2,JP3 shorted pin of 1&2, PAC=24VAC
4. 40 pressure proportional valve : FPV-01 board JP1,JP2,JP3 shorted pin of 2&3,PAC=50VAC
5. 10 flow proportional valve : FPV-01 board JP4,JP5,JP6 shorted pin of 1&2, PAC=24VAC
6. 40 flow proportional valve : FPV-01 board JP4,JP5,JP6 shorted pin of 2&3,PAC=50VAC

6-2

2. Main box connector distribution diagram

FA-1 KAD

FA-2 TC

J1
T6

FA3 CLCD

FA-4 IO

FA-6 IO3

J2

VPE-3

T8

T10

T2
J3
T1
T3

J4
T4
T7

T9

T11

T5

(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)

J1 is (FA-1 KAD board) keyboard socket connecting to operation panel


T2 is (FA-1 KAD board) pulsation and his power input
T3 is (FA-1 KAD board) channels of A/D 1&2
T4 is (FA-1 KAD board) channels of A/D 3&4 (option)
T5 is (FA-1 KAD board) 4 channels D/A output
T6 is (FA-2 TC) board 24VDC output of heater control
T7 is socket of 8 channels of thermocouple input at (FA-2 TC) board
J2 is (FA-3 CLCD) board down load PLC program port
J3 is (FA-3 CLCD) board monitor PLC program port
J4 is (FA-3 CLCD) board LCD socket connecting to operation panel
T8 are input ports 1-16 at (FA-4 IO) board "1
T9 are output ports 1-16 at (FA-4 IO) board "1
T10 are input ports 17-32 at (FA-6 IO3) board "2
T11 are output ports 17-32 at (FA-6 IO3) board "2

6-3

+5v
+5v
0
0
-12v
+12v

FA-1 KAD

FA-2N

J1
T6

FA3 CLCD

FA-4 IO

FA-6 IO3

J2

VPE-3

T8

T10

T2
J3
T1

T3

J4
T4
T7

T9

T11

T5

(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)

J1 is (FA-1 KAD board) keyboard socket connecting to operation panel


T2 is (FA-1 KAD board) pulsation and his power input
T3 is (FA-1 KAD board) channels of A/D 1&2
T4 is (FA-1 KAD board) channels of A/D 3&4 (option)
T5 is (FA-1 KAD board) 4 channels D/A output
T6 is (FA-2N) board 24VDC output of heater control
T7 is socket of 8 channels of thermocouple input at (FA-2 N) board
J2 is (FA-3 CLCD) board down load PLC program port
J3 is (FA-3 CLCD) board monitor PLC program port
J4 is (FA-3 CLCD) board LCD socket connecting to operation panel
T8 are input ports 1-16 at (FA-4 IO) board "1
T9 are output ports 1-16 at (FA-4 IO) board "1
T10 are input ports 17-32 at (FA-6 IO3) board "2
T11 are output ports 17-32 at (FA-6 IO3) board "2

6-4

+5v
+5v
0
0
-12v
+12v

Data bus bar diagram (FBUS-05)

T1
+5v
+5v
0v

SLOT 05

SLOT 04

SLOT 03

SLOT 02

SLOT 01

0v

If screw ditch flat Board on


behalf Release condition
Board can push/pull

push / pull handle

If screw ditch up Board on behalf


Lock conditionBoard can not
push/pull

Fix screw
(Before push/pull the board must be flat the screw

-12v
+12v

Enable insert or pull


Disable 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.

6-5

3FA-1 KAD board AD/DA moduleHigh speed counter and Operate panel connection diagram

Keyboard inter face connection diagram

LCD
Operate

panel

D-SUB 37 PIN

JJ 11

J4
D-SUB 15 PIN

FA-1 KAD

Insert
to FA-3
CLCD
FA-3
CLCD

boardLCD(1)
LCD(1)
port

high speed counter input

wiring
T2

input element power "VI 24V+

150

RPM speed pulsing input

151

(GI-)

unscrewing 1 pulsing input


unscrewing 2 pulsing input
mold adjusting pulsing input

V1
CNT1

152

CNT2

153

CNT3

154

CNT4
T3

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)

155

VS1

156
AD1+

157

AD1-

158

FG1

159

VS2

160

AD2+

161

AD2-

162

FG2
T4

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)

163
163

VS3

164
164

AD3+

165
165

AD3-

166
166

FG3
FG3

167
167

VS4

168
168

AD4+

169
169

AD4-

170
170

FG4
FG4
T3

T5

D/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)

201
202
203
204
205
206
207
208

6-6

DA1+
DA1DA2+
DA2DA3+
DA3DA4+
DA4T3

KB

FA-1 KAD board wiring diagram


high speed counter input
FPW-01
GI -

150

RPM speed pulsing input

151

(GI-)

unscrewing 1 pulsing input


unscrewing 2 pulsing input
mold adjusting pulsing input

NPN
Sensor

Injection potentiometer

2
2
1

Clamping potentiometer

2
2
1

153
154

1
2
3

Carriage
potentiometer

1
2
3

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)

155

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)

Fac
FPV-01
amplifier
P/Q board

P+ P- F+ F- Vp+ Vp- Vf+ Vf-

Wiring to FA-1 KAD board


(reference voltage output)

CNT2
CNT3
CNT4

VS1

156
157
158
159
160
161
162

163
164
165
166
167
168
169
170

Proportional valve
reference voltage signal

50 51

CNT1

AD1+
AD1FG1
VS2
AD2+
AD2FG2
T4

Ejector
potentiometer

15V
0
15V

152

V1

T3
1

Pac

T2

input element power "VI 24V+

52 53

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)

VS3
AD3+
AD3FG3
VS4
AD4+
AD4FG4
T3

T5
201

DA1+

202

DA1-

203

DA2+

204

DA2-

205

DA3+

206

DA3-

207

DA4+

208

DA4T3

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 current
VR2 (F down) : ramp down regulator for flow current
VR6 (P down) : ramp down regulator for pressure current
VR3 (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

6-7

4FA-2 TC Temperature control module connection diagram

connecting element

wiring

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)

301

DC24V+source (FPW-01"VO")
DC24V-source (FPW-01"GO")

302
303
304
305
306
307
308

T6

HT1
HT2
HT3
HT4
HT5
HT6
HT7
HT8

VO

VI

GO

GI
T 12

66

SPARE
SPARE
SPARE
SPARE
SPARE
SPARE
SPARE
SPARE

67
68
69
70
71
72
73

ALM1
ALM2
ALM3
ALM4
ALM5
ALM6
ALM7
ALM8

T7

(TC1+)
(TC1-)
(TC2+)
(TC2-)
(TC3+)

401

Thermocouple zone 3 (TC3-)


Thermocouple zone 4 (TC4+)

406

Thermocouple zone 4 (TC4-)


Thermocouple zone 5 (TC5+)

408

Thermocouple zone 1
Thermocouple zone 1
Thermocouple zone 2
Thermocouple zone 2
Thermocouple zone 3

Thermocouple zone 5 (TC5-)


Thermocouple zone 6 (TC6+)
Thermocouple zone 6
Thermocouple zone 7
Thermocouple zone 7
Thermocouple zone 8

(TC6-)
(TC7+)
(TC7-)
(TC8+)

Thermocouple zone 8 (TC8-)

TC1+

402

TC1-

403

TC2+

404

TC2-

405

TC3+
TC3-

407

TC4+
TC4-

409

TC5+

410

TC5-

411

TC6+

412

TC6-

413

TC7+

414

TC7-

415

TC8+

416

TC8-

6-8

FA-2 TC

FA-2 TC board wiring diagram


Heater connector output

read as
follow page

FPW-01
power board
output element power
21V
21V

VO
GO
VI
GI

wiring

Barrel zone 1 output -24v (SSR)


Barrel zone 2 output -24v (SSR)
Barrel zone 3 output -24v (SSR)

301

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)

304

DC24V+source (FPW-01"VO")

VO

DC24V-source (FPW-01"GO")

302
303

305
306
307
308

Barrel TC 2

Barrel TC 3

Barrel TC 4

Barrel TC 5

Barrel TC 6

Barrel TC 7

Oil tank TC 8

HT2
HT3
HT4
HT5
HT6
HT7
HT8
VI

GO

GI
T 12

66
67
68
69
70
71
72
73

Thermocouple zone 1
Thermocouple zone 1
Thermocouple zone 2
Thermocouple zone 2
Thermocouple zone 3

(TC1+)
(TC1-)
(TC2+)
(TC2-)
(TC3+)

Thermocouple zone 3 (TC3-)


Thermocouple zone 4 (TC4+)
Thermocouple zone 4 (TC4-)
Thermocouple zone 5 (TC5+)
Thermocouple zone 5 (TC5-)
Thermocouple zone 6 (TC6+)
Thermocouple zone 6
Thermocouple zone 7
Thermocouple zone 7
Thermocouple zone 8

(TC6-)
(TC7+)
(TC7-)
(TC8+)

Thermocouple zone 8 (TC8-)

Note: if the temperature zone is not applicable, please connect Tc+ & Tc- Short circuit,
then the temperature reading is equal to room temperature.

6-9

ALM1
ALM2
ALM3
ALM4
ALM5
ALM6
ALM7
ALM8

T7

Temperature Sensor line


+

HT1

input element power

SPARE
SPARE
SPARE
SPARE
SPARE
SPARE
SPARE
SPARE

Barrel TC 1

T6

401
402
403
404
405
406
407
408
409
410
411
412
413
414
415
416

TC1+
TC1TC2+
TC2TC3+
TC3TC4+
TC4TC5+
TC5TC6+
TC6TC7+
TC7TC8+
TC8-

FA-2N Temperature control module connection diagra


connecting element

wiring

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)

301

DC24V+source (FPW-01"VO")
DC24V-source (FPW-01"GO")

302
303
304
305
306
307
308
VO

T6

HT1
HT2
HT3
HT4
HT5
HT6
HT7
HT8
24V

GO

GI
T 12

66

SPARE
SPARE
SPARE
SPARE
SPARE
SPARE
SPARE
SPARE

67
68
69
70
71
72
73

ALM1
ALM2
ALM3
ALM4
ALM5
ALM6
ALM7
ALM8

T7

(TC1+)
(TC1-)
(TC2+)
(TC2-)
(TC3+)

401

Thermocouple zone 3 (TC3-)


Thermocouple zone 4 (TC4+)

406

Thermocouple zone 4 (TC4-)


Thermocouple zone 5 (TC5+)

408

Thermocouple zone 1
Thermocouple zone 1
Thermocouple zone 2
Thermocouple zone 2
Thermocouple zone 3

Thermocouple zone 5 (TC5-)


Thermocouple zone 6 (TC6+)
Thermocouple zone 6
Thermocouple zone 7
Thermocouple zone 7
Thermocouple zone 8

(TC6-)
(TC7+)
(TC7-)
(TC8+)

Thermocouple zone 8 (TC8-)

402
403
404
405

407

409
410
411
412
413
414
415
416

6 - 10

TC1+
TC1TC2+
TC2TC3+
TC3TC4+
TC4TC5+
TC5TC6+
TC6TC7+
TC7TC8+
TC8-

FA-2N

FA-2N board wiring diagram


Heater connector output

read as
follow page

FPW-01
power board
output element power
21V
21V

VO
GO
VI
GI

wiring

Barrel zone 1 output -24v (SSR)


Barrel zone 2 output -24v (SSR)
Barrel zone 3 output -24v (SSR)

301

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)

304

DC24V+source (FPW-01"VO")

VO

DC24V-source (FPW-01"GO")

302
303

305
306
307
308

Barrel TC 2

Barrel TC 3

Barrel TC 4

Barrel TC 5

Barrel TC 6

Barrel TC 7

Oil tank TC 8

HT2
HT3
HT4
HT5
HT6
HT7
HT8
24V

GO

GI
T 12

66
67
68
69
70
71
72
73

Thermocouple zone 1
Thermocouple zone 1
Thermocouple zone 2
Thermocouple zone 2
Thermocouple zone 3

(TC1+)
(TC1-)
(TC2+)
(TC2-)
(TC3+)

Thermocouple zone 3 (TC3-)


Thermocouple zone 4 (TC4+)
Thermocouple zone 4 (TC4-)
Thermocouple zone 5 (TC5+)
Thermocouple zone 5 (TC5-)
Thermocouple zone 6 (TC6+)
Thermocouple zone 6
Thermocouple zone 7
Thermocouple zone 7
Thermocouple zone 8

(TC6-)
(TC7+)
(TC7-)
(TC8+)

Thermocouple zone 8 (TC8-)

Note: if the temperature zone is not applicable, please connect Tc+ & Tc- Short circuit,
then the temperature reading is equal to room temperature.

6 - 11

ALM1
ALM2
ALM3
ALM4
ALM5
ALM6
ALM7
ALM8

T7

Temperature Sensor line


+

HT1

input element power

SPARE
SPARE
SPARE
SPARE
SPARE
SPARE
SPARE
SPARE

Barrel TC 1

T6

401
402
403
404
405
406
407
408
409
410
411
412
413
414
415
416

TC1+
TC1TC2+
TC2TC3+
TC3TC4+
TC4TC5+
TC5TC6+
TC6TC7+
TC7TC8+
TC8-

FA-2 TC/FA-2N board heater output connecting to solid state relay (SSR)
FA2-TC/FA-2N (heater output)

output power
(FPW-01)
VO
H
m/c

302

301
H1
+ IN

303

H2
-

+ IN

+ IN

305

304
H4

H3
-

H5
-

+ IN

+ IN

306

307

H6
-

+ IN

H7
-

+ IN

308
H8
+ IN

(OUT)
LOAD

(OUT)
LOAD

(OUT)
LOAD

(OUT)
LOAD

(OUT)
LOAD

(OUT)
LOAD

(OUT)
LOAD

(OUT)
LOAD

(zone1)
heater

(zone2)
heater

(zone3)
heater

(zone4)
heater

(zone5)
heater

(zone6)
heater

(zone7)
heater

(zone8)
heater

high
speed
fuse
(HRC)
R
S
T

FA-2 TC/FA-2N board heater output connecting to magnetic connecter (M/C)


(zone 1) 58

H1

(zone 2) 59

H2

(zone 3) 60

H3

(zone 4) 61

H4

(zone 5) 62

H5

(zone 6) 63

H6

FPW-01(VO power)
VO

6 5 4 3 2 1

VS

RELAY 04
Load Isolation

6A 6C 5A 5C 4A 4C 3A 3C 2A 2C 1A 1C
H m/c

6 - 12

MC1
R

MC2
R

MC3
R

MC4
R

MC5

MC6
R

M/C
Coil

Surge Killer
(RC)

5. FA-3 CLCD

module connection diagram

Editor (PLC
language)

FA-3 CLCD

9 PIN

J2

COM1

PLC program
input port

9 PIN

J3

COM2

Insert to FA1 KAD board


KB port

J4

*On Line Editing Extension*

6 - 13

D-SUB 15 PIN

LCD
Operate
panel

D-SUB 37 PIN

J1

LCD(1)

PLC program
monitor port

6. FA-4 I0 Input & Output interface module connection diagram


(Board "1" In 1-16, Out 101-116)
wiring

T8

FA-4 I0

input connecting electment


input element power "VI" 24V+

VI

( GI -)

Clamping end
Photo detector
Ejector advance end

( GI -)

(GI -)

(GI -)

Carriage forward end

(GI -)

Carriage backward end

(GI - )

(GI - )
(GI - )

Ejector retract end

front door switch


rear door

Data Key lock


(GI -)
Mold adj. thinning end (GI - )
M ld adj.
dj thickening
d
d (GI
Mold
end )(GI - )
Core 1 adv. end
Core 1 ret. end
Core 2 adv. end
Core 2 ret. end
Motor start complete
input element common

(GI - )
(GI - )
(GI - )
(GI - )

1
2
3
4
5
6
7
8

10

10

11

11

12

12

13

13

14

14

15

15

(GI - )

16

(GI -)

GI

16
17

JP1

18

A
T9

output connecting electment


output element power (VO" 24V)

VO

clamping valve

(24v+)

101

clamp protection valve

(24v+)

102

speed clamp valve

(24v+)

103

opening valve

(24v+)

104

opening buffer valve

(24v+)

105

carriage forward valve

(24v+)

106

injection valve

(24v+)

107

suck back valve

(24v+)

108

(24v+)

109

carriage backward valve (24v+)

110

ejector advance valve

(24v+)

111

ejector retract valve

(24v+)

112

mold adj. thinning valve (24v+)

113

mold adj. Thicken valve (24v+)

114

core 1 advance valve

115

plasticization valve

core 1 retract valve


OUTPUT COMMON

(24v+)
(24v+)
(GO-)

116
GO

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18

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

6 - 14

FA-4 I0 board(NO.1) wiring diagram


wiring

T8

input connecting electment

NPN
NPN
NPN

VI
GI
VO
GO

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 -)

VI

Data Key lock


(GI -)
Mold adj. thinning end (GI -)
M
ld adj.
dj thickening
d
d (GI
Mold
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 -)

10

10

11

11

12

12

13

13

14

14

15

15

16

16

17

GI

18

FPW-01
power board
T9

output connecting electment


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+)
plasticization valve
carriage backward valve
ejector advance valve
ejector retract valve
mold adj. thinning valve
mold adj. thicken valve
core 1 advance valve
core 1 retract valve
OUTPUT COMMON

6 - 15

(24v+)
(24v+)
(24v+)
(24v+)
(24v+)
(24v+)
(24v+)
(24v+)
(GO-)

VO

101

102

103

104

105

106

107

108

109

10

110

11

111

12

112

13

113

14

114

15

115

16

116

17

GO

18

7. FA-6 I03 Input & Output interface module connection diagram


(Board "2" In 17-32, Out 117-132)
input element

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 -)
SPARE
(GI -)
input element COMMON "GI-"

wiring

T10

FA-6 IO3

VI

17

18

19

20

21

22

23

24

25

10

26

11

27

12

28

13

29

14

30

15

31

16

32

17

GI

18

JP1
A

T11

output element
output element power
(VO"24
)
core 2 advance
valve
(24 2)retract valve
core
(24
)
air blowing
A valve
(24blowing
)
air
B valve
(24 )
plasticizing
back press
(24
)
robot activate signal m/c
(24 )
lubricating
pump
m/c
(24
)
alarm indicator
m/c
(24
)
alarm buzzer
m/c
(24 ) control
heating
m/c
(24 )contractor
motor
m/c
(24
)
photo detector
m/c
(24 )
SPARE
(24
d heater
)
nozzle
contractor
(24 )
SPARE
(24 d )
SPARE
(24
d element
)
output
COMMON "GO-"

VO

117

118

119

120

121

122

123

124

125

10

126

11

127

12

128

13

129

14

130

15

131

16

132

17

GO

18

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

6 - 16

FA-6 I03 board(NO.2) wiring diagram


input element

wiring
T10

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 -)

NPN
NPN

SPARE
(GI -)
SPARE
(GI -)
SPARE
(GI -)
SPARE
(GI -)
SPARE
(GI -)
SPARE
(GI -)
SPARE
(GI -)
SPARE
(GI -)
input element COMMON "GI-"

VI
GI
VO

VI

17

18

19

20

21

22

23

24

25

10

26

11

27

12

28

13

29

14

30

15

31

16

32

17

GI

18

FPW-01
power board

GO

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 )indicator
alarm
m/c
(24
)
alarm buzzer
m/c
please see follow page of
external power control

T11

output element

(24
) control
heating
m/c (24v+)
motor contractor
m/c (24v+)
photo detector
m/c (24v+)
SPARE
(24 d heater
)
nozzle
contractor (24v+)
SPARE
(24 d )
SPARE
(24
d element
)
output
COMMON "GO-"

6 - 17

VO

117

118

119

120

121

122

123

124

125

10

126

11

127

12

128

13

129

14

130

15

131

16

132

17

GO

18

FA-6 IO3 module connecting to external power control wiring

(122)
(123)
(124)
(125)
(126)

FPW-01(GO)
GO

(127)

6 5 4 3 2 1 G
RELAY 05
isolation Relay board

6A 6C 5A 5C 4A 4C 3A 3C 2A 2C 1A 1C

Load 1

Load 2
R

Load 3
R

Load 4

Load 5

loading
contractor
coil

Load 6

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)

surge killer
(RC)

N
Note .: Please make sure of voltage specification of output device before connection

(121)

FPW-01(GO)
GO

RELAY 05

6 5 4 3 2 1 G

isolation Relay board

1A - 1C : robot activate signal


2A - 2C : spare relay connector
3A - 3C : spare relay connector
4A - 4C : spare relay connector
5A - 5C : spare relay connector
6A - 6C : spare relay connector

6A 6C 5A 5C 4A 4C 3A 3C 2A 2C 1A 1C

Note: 1. Please make sure of voltage specification of output device before connecting
2. Relay 05 board employ GO" (DCV-) for COMMON port to control 24V output elements.

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)

element

wire

S5,S6

input element power "

VI

F4-IO

VI

INPUT# 33 ~ 48

optional input
port 33 ~ 48

input element COMMON GI

GI

output element power "VO

VO

JP 1

A B

"GO

B
Board ""
Input 01 ~ 16
Output 101 ~116

OUTPUT# 133 ~ 148

optional output
port 133 ~ 148
output COMMON

Board ""
Input 17 ~ 32
Output 117 ~132

GO

Board ""
Input 33 ~ 48
Output 133 ~148

S7,S8

Note : 1. FA-4 IO board 1, 2 & 3 have the same physical circuit laying and identify by the jumper setting of JP1
2. 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)

6 - 19

8. Transformer color of wiring

Transformer F-4

White
Blue
Orange

0V
200V
220V

Red
Yellow
Black
Yellow

380V
15V
0V
15V

Green/Yellow

1.5A

1.5A

1.5A
5A
E

8A

6 - 20

0V
24V
50V

Purple
Coffee
Blackish Green
0V Ash
24V Pink
50V Light Blue
0V White
21V White
0V Red
21V Red

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 7 Maintenance & Trouble Shooting


1. Inspection Procedure of Controller . . . . . . . . . . . . . . . . . . . . . . . .7. - 2
2. Calibration Procedure of Machine . . . . . . . . . . . . . . . . . . . . . . . .7. -. 3
3. Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7. - 4
4. Alarm Message Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7. - 5

Chapter 8 Services Review

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 power, then plug the FA-3 CLCD board, recheck every board are plugged tightly and correctly
,and screws is on right locking position '' ''
Turn on the power and stay 2 min, then check if there is any elements working anomalously or over-heating

To check the input wiring and switch is mapped to the LED on FA-4 IO board

The direction of reading from potentiometer is correct

Check heater, accontactor, and thermal line are correct, then prepare to turn on the 3-phase power

Note : If you want to do any modification or the circuit, you must to shut down the power.
(Include the installation of FA-1~FA-6 board)

7-2

2. Calibration procedure of mechanic and hydraulic parts.


To check the mechanic and hydraulic parts are installed properly and the wiring is tight

Fuel the hydraulic oil to tank

Unplug the screws of the potentiometer to prevent damage caused by the starting of motor

Connect two 2A ampere meters in series at pressure & flow proportional valve

Adjust the knob of relief value to minimum position

Start the motor and stay 5 min. (check the direction of Motor)

Use Preset mode to regulating the amplifier (proportional valve)

Start every motion step by step under the setting parameter : PRS. 30%, SPD. 50%

While inspection every motion, if you find the input command and output motion is not correspondent
Please check:
1. the motion of display and keyboard is correspondent?
2. if the display and the keyboard are mapped to the output led of FA-4 board. It means the wiring of solenoid
(hydraulic values) is not correct

The stroke of potentiometer is settled, in factory, it is not necessary for users to adjust anymore

To proceed the adjustment that defined by yourself

7-3

3. Controller inspection and elemental maintenance

Please prepare a normal board to inspect the machine. It is hard for user to repair and calibrate the board to
find the bug by charging the board step by step.
If the 5 board (FA-1~FA-6) is working properly, please check :
Check every wiring is connected tightly and robustly
The power supply that used is the same as we propose. And the wiring is confirmed correct
The GND line is connected tightly and qualifiedly. (To decrease the resistance, please select the bigger
section of wiring)
Check every board, connection plug and PC plug are plugged tightly and properly
I/O, potentiometer and proportional value are connected correctly (there is not short circuit or open circuit)
Sundries will cause short or bad contacted in board
The temperature of electric box is less than 65

Potentiometer inspection:
Loose the screw of potentiometer
To measure the voltage of 1,3 terminal
Move the potentiometer slowly to check the output voltage is stable and proportional or not

Output inspection:
inspection of proportional valves: observe the current meter to check the output current is correspond to command
I/O inspection : please refer to wiring diagram
You can find the reason why fuse burned by inspecting the condition of fuse. (see below)
Normal

Overload

Short

7-4

4. Alarm Message Table


ERROR ALARM
CODE MESSAGE

00

NON-FACTORY

MESSAGE
NV-RAM chip no load password

DEFAULT

01

CPU BOARD NOT

No insert FA-3 CLCD board

SOLUTION
Contact your supplier,
take password and load it.
Insert theFA-3 CLCD board

READY

02
03
04

RTC CHIP ERROR


NV-RAM CHIP ERROR

TEMP. BOARD NOT

RTC CHIP ERROR (Timer)


NV-RAM CHIP ERROR
No insert FA-2 TC board

Change RTC chip of FA-3 board

Temperature board error

Change FA-2 TC board

No insert FA-1 KAD board

Insert theFA-1 KAD board

FA-1 AD analog input board error


No insert FA-1 KAD board

Change FA-1 KAD board


Insert theFA-1 KAD board

Zone 1 thermocouple fail

Change zone 1 thermocouple

Zone 2 thermocouple fail

Change zone 2 thermocouple

Zone 3 thermocouple fail

Change zone 3 thermocouple

Zone 4 thermocouple fail

Change zone 4 thermocouple

Zone 5 thermocouple fail

Change zone 5 thermocouple

Zone 6 thermocouple fail

Change zone 6 thermocouple

Zone 7 thermocouple fail

Change zone 7 thermocouple

Zone 8 thermocouple fail

Change zone 8 thermocouple

Zone 1 thermocouple reverse

Exchange zone 1
thermocouple ,
Exchange zone 2
thermocouple ,
Exchange zone 3
thermocouple ,
Exchange zone 4
thermocouple ,
Exchange zone 5
thermocouple ,

Change NV-RAM chip


Insert theFA-2 TC board

READY

05

TEMP. BOARD
ERROR

06

PANEL BOARD NOT


READY

07
08

ANALOG I/P ERROR


ANALOG I/P NOT
READY

16

ZONE 1 THERMO.
FAIL

17

ZONE 2 THERMO.
FAIL

18

ZONE 3 THERMO.
FAIL

19

ZONE 4 THERMO.
FAIL

20

ZONE 5 THERMO.
FAIL

21

ZONE 6 THERMO.
FAIL

22

ZONE 7 THERMO.
FAIL

23

ZONE 8 THERMO.
FAIL

24

ZONE 1 THERMO.
REV.

25

ZONE 2 THERMO.

Zone 2 thermocouple reverse

REV.

26

ZONE 3 THERMO.

Zone 3 thermocouple reverse

REV.

27

ZONE 4 THERMO.

Zone 4 thermocouple reverse

REV.

28

ZONE 5 THERMO.

Zone 5 thermocouple reverse

REV.

7-5

ERROR ALARM
CODE MESSAGE

29

ZONE 6 THERMO.

MESSAGE
Zone 6 thermocouple reverse

REV.

30

ZONE 7 THERMO.

Zone 7 thermocouple reverse

REV.

31

ZONE 8 THERMO.

Zone 8 thermocouple reverse

REV.

32

ZONE 1 TEMP. TOO


LOW

33

ZONE 2 TEMP. TOO


LOW

34

ZONE 3 TEMP. TOO


LOW

35

ZONE 4 TEMP. TOO


LOW

36

ZONE 5 TEMP. TOO


LOW

37

ZONE 6 TEMP. TOO


LOW

38

ZONE 7 TEMP. TOO


LOW

39

ZONE 8 TEMP. TOO


LOW

40

ZONE 1 TEMP. TOO


HIGH

41

ZONE 2 TEMP. TOO


HIGH

Zone 1 temperature less low than


low alarm limit
Zone 2 temperature less low than
low alarm limit
Zone 3 temperature less low than
low alarm limit
Zone 4 temperature less low than
low alarm limit
Zone 5 temperature less low than
low alarm limit
Zone 6 temperature less low than
low alarm limit
Zone 7 temperature less low than
low alarm limit
Zone 8 temperature less low than
low alarm limit

SOLUTION
Exchange zone 6
thermocouple ,
Exchange zone 7
thermocouple ,
Exchange zone 8
thermocouple ,
(1)Check zone1 heater, is it broke
(2)Waiting zone1 heating to
set value
(1)Check zone2 heater, is it broke
(2)Waiting zone2 heating to
set value
(1)Check zone3 heater, is it broke
(2)Waiting zone3 heating to
set value
(1)Check zone4 heater, is it broke
(2)Waiting zone4 heating to
set value
(1)Check zone5 heater, is it broke
(2)Waiting zone5 heating to
set value
(1)Check zone6 heater, is it broke
(2)Waiting zone6 heating to
set value
(1)Check zone7 heater, is it broke
(2)Waiting zone7 heating to
set value
(1)Check zone8 heater, is it broke
(2)Waiting zone8 heating to
set value

Zone 1 temperature more than high alarm limi (1)Check thermocouple fix position
(2)Check cylinder and screw
there are no rub
(3)During PID autotuning, please
wait 10 minute to be return
Zone 2 temperature more than high alarm limi (1)Check thermocouple fix position
(2)Check cylinder and screw
there are no rub
(3)During PID auto-tuning, please
wait 10 minute to be return

7-6

ERROR ALARM
CODE MESSAGE

42

ZONE 3 TEMP. TOO


HIGH

43

ZONE 4 TEMP. TOO


HIGH

44

ZONE 5 TEMP. TOO


HIGH

45

ZONE 6 TEMP. TOO


HIGH

46

ZONE 7 TEMP. TOO


HIGH

47

ZONE 8 TEMP. TOO


HIGH

48
49

CLOSE ALARM
MOLD CLOSE
PROTECT

50
51

OPEN ALARM
NZ. UNIT FWD.

MESSAGE

SOLUTION

Zone 3 temperature more than high alarm limi (1)Check thermocouple fix position
(2)Check cylinder and screw
there are no rub
(3)During PID auto-tuning, please
wait 10 minute to be return
(1)Check
thermocouple fix position
Zone 4 temperature more than high alarm limi
(2)Check cylinder and screw
there are no rub
(3)During PID auto-tuning, please
wait 10 minute to be return
Zone 5 temperature more than high alarm limi (1)Check thermocouple fix position
(2)Check cylinder and screw
there are no rub
(3)During PID auto-tuning, please
wait 10 minute to be return
Zone 6 temperature more than high alarm limi (1)Check thermocouple fix position
(2)Check cylinder and screw
there are no rub
(3)During PID auto-tuning, please
wait 10 minute to be return
Zone 7 temperature more than high alarm limi (1)Check thermocouple fix position
(2)Check cylinder and screw
there are no rub
(3)During PID auto-tuning, please
wait 10 minute to be return
Zone 8 temperature more than high alarm limi (1)Check thermocouple fix position
(2)Check cylinder and screw
there are no rub
(3)During PID auto-tuning, please
wait 10 minute to be return
Inter protect timer over
Check hydraulic or machine parts
Protect timer reach but not arrive lock-up
Lock-up position too smaller or
position
protect timer set too short
Inter protect timer over
Check hydraulic or machine parts
Inter protect timer over
Check hydraulic or machine parts

ALARM

52

NZ. UNIT RTN.

53
54

SUCK BACK ALARM

Inter protect timer over

Check hydraulic or machine parts

Inter protect timer over


Inter protect timer over

Check hydraulic or machine parts


(1)Pour the materials and recharge
(2)Protect timer is too small

ALARM
CHARGE NOT MADE

7-7

ERROR ALARM
CODE MESSAGE

55
56

DETECTOR ON

57

EJECT RTN. ALARM

58

FRONT GATE

EJECT FWD. ALARM

CLOSED

MESSAGE

SOLUTION

PHOTOSENSOR RAY BLOCK


Inter protect timer over
Inter protect timer over and tests before
other actions

RELEASE THE BLOCK UP PARTS

Semi-auto cycle finish, and alarm to


notify operator take out product

Open the door and take out the


product; and prepare working

Check hydraulic or machine parts


Check hydraulic or machine parts

next semi-auto cycle


59
60

ROBOT ALARM

61

LOT END ALARM

62

INJ. OVER PACKING

63

DROP DETECT FAIL

65

INJ. SHORT SHOT

67

OIL TEMP. OVER

6
6
7
7
7

CORE 1 IN ALARM

8
9
0
1
2

75
76
78

GATE OPENED

CORE 1 OUT ALARM


CORE 2 IN ALARM
CORE 2 OUT ALARM

MOTOR OVER
OIL LEVEL TOO LOW

AUTO-ADJ END
SCHEDULE END
ALARM

79
80
81

PURGE END

83

NZ. DOOR OPENED

ROBOT NOT IN POS.


CYCLE TIME OVER

Robot not ready, IN20 not ON


Machine is already ready for automatic cycle. Close the front and rear door,
starts the automatic cycle
PC is waiting for door close to touch off
automatic cycle.
Open and close door one time
Package set = Package account
to touch off next package
calculation cycle.
When injection finish but PC check is over
(1) Regulate the injection 4
position or reduce INJ. LO position
injection low limit (INJ. LO) position.
(2) Change to Timer function
injection.
Check the mold then close
After ejection 10 seconds,
the door.
electric photo nothing pass .
When injection finish but PC check is not
(1) Regulate the injection 4
position or add INJ. UP position.
reach injection up limit (INJ. UP) position.
(2) Change to Timer function
injection.
Oil temperature (TC zone 8) over
Shut down machine waiting oil
cool then re-start the machine.
Incorrect action order
Check the action order
Incorrect action order
Check the action order
Incorrect action order
Check the action order
Incorrect action order
Check the action order
Motor over load.
(1)Wait 3 Minutes and reset OL.
IN 16 = ON
(2)Check motor.
Input point = ON
Clear all leakage and full oil.
Auto mold adjustment is finish.
Press RESET key.
Total set = Total account
Open and close door one time
to touch off next total
calculation cycle.
Auto page complete.
Press RESET key.
Robot not in position. IN 20 = OFF
Check robot.
Cycle time over, but machine cycle not finish. (1)Check hydraulic or machine parts
First, injection and then
(2)Increase the cycle time.
Nozzle door not close.
Close the nozzle door.
CHECK THE ROBOT FUNCTION

7-8

ERROR ALARM
CODE MESSAGE

MESSAGE

84

CHARGE END

Screw position is more then charge 3 position.

85

Without material

Inter protect timer over

87

THIN ALARM

88

THICK ALARM

90

TEMP. ERROR

Mold adjust forward alarm.


Inter protect timer over
Mold adjust backward alarm.
Inter protect timer over
Before or during injection, PC will pre-check
temperature value, if there is temperature alarm,

91

THIN LIMIT ALARM

92

THICK LIMIT ALARM

93

OPEN END

PC will stop injection and show alarm.


Mold adjust backward to terminal position.
IN 9 = ON
Mold adjust backward to terminal position.
IN 10 = ON
Already in mold open finish position.

94

CLOSE END

Already in mold close finish position.

95
96
97

CORE 1 IN END
CHARGE END

Already in core1 in finish position.


Already in core1 out finish position.
Already in charge finish position.

98

EJECT FWD. END

Already in eject forward finish position.

99

EJECT RTN. END

Already in eject backward finish position.

CORE 2 IN END

Already in core2 in finish position.


Already in core2 out finish position.
Inter protect timer over
Inter protect timer over
No motor start finish signal.

10
10
10
10
10

0
1
2
3
4

CORE 1 OUT END

CORE 2 OUT END


PRE-SUCK ALARM
INJ. ALARM
MOTOR NOT WORK

MADE

motor starting.

After motor ON, but Input point not


feedback to PC.
Mold not in finish position, but there is
press EJECTOR key.

HEATER NOT WORK

When execute injection, but heater key no ON.

10 5
10 6

MOTOR STARTING

10 7

MOLD OPEN NOT

MOTOR START FAIL

SOLUTION
Injection in advance and then
execute charge.
(1)Check hydraulic or machine
parts.
(2)Full hopper.
Check hydraulic or machine parts

or press "Reset" key


Check hydraulic or machine parts

or press "Reset" key


(1)Check Heater.
(2)Check Thermocouple.
Change appropriate depth mold.
Change appropriate depth mold.
Please execute another action
don't press MOLD OPEN key.
Please execute another action
don't press MOLD CLOSE key.
Press RESET key.
Press RESET key.
Please execute another action
don't press CHARGE key.
Please execute another action
don't press EJECT FWD. key.
Please execute another action
don't press EJECT RTN. key.
Press RESET key.
Press RESET key.
Check hydraulic or machine parts
Check hydraulic or machine parts

Press MOTOR key and waiting


for it finish.
Waiting motor start finish.
(1)Check Input point wiring.
(2)Check motor contactor.
(1)Mold open to finish position a

nd then press EJECTOR key.


(2)Check hydraulic or machine parts

10 8

7-9

Press HEATER key to set ON.

ERROR ALARM
CODE MESSAGE

10 9
11 0

EMG. STOPPING
CORE 1 OUT NOT

MESSAGE
Input point = ON
Core1 not go to back limit switch position.

MADE

11 1

CORE 2 OUT NOT

SOLUTION
Release Emergency button.
(1)Check core1 limit switch.
(2)Check hydraulic or machine parts

Core2 not go to back limit switch position

MADE

(1)Check core2 limit switch.


(2)Check hydraulic or machine parts.

11 2

LOCK-UP ALARM

Mold lock-up monitor timer reach but


clamp finish limit switch not ON.

11 3

EJ. RTN. NOT MADE

Input point = OFF ejector not backward

11 4

SEM_AUTO CYC. OK

11 5

SUCK O.K

to position.
To notify operator this semi-auto cycle
already finish, hurry up take out product.
Already in suck finish position.

11 6

AUTOCG FUN. OFF

When execute auto purge, but

11 7
11 8

DEFECT END ALARM

(1)Regulate lock-up timer.


(2)Adjust clamp finish limit
switch position.
(1)Check ejector limit switch.
(2)Check hydraulic or machine parts.

Finish work procedure and


continue next cycle.
Please execute another action
don't press EJECT FWD. key.
Please set AUTO PURGE = ON.

AUTO PURGE = OFF of PURGE page function.

FAIL SET = FAIL ACCOUNT

MOLD ADJ. FUN. OFF

When execute mold adjustment, but the panel

USE MANUAL TO
CLOSE MOLD

key MOLD USE = OFF.


It is not in mold clamp finish position when
you execute mold auto adjustment.

12 0

CORE HAS USE

You have select core function.

12 1

PROTECT SCREW

Screw protect timer not finish.

12 2

IDLEING

Heater mode cause manual selection or alarm,

12 3

SCHEDULE END

11 9

Clear FAIL ACCOUNT


Please set MOLD USE = ON.
(1)Mold close finish in advance
and then work mold auto
adjustment.
In CORE page set
CORE1 or 2 = OFF.
(1)Waiting timer reach.
(2)Set timer PROTECT = 0
Set HEAT TYP. = NORMAL

so go to idleing mode.(Hold temperature mode)

12 4
12 5

Total set = Total account and shut down


machine.

Reset TOTAL account value.

ALARM
LOT END

Package set = Package account and shut down

Reset PACKAGE account value.

SHUTDOWN

machine.

DEFECT END

Fail set = Fail account and shut down machine.

Reset FAIL account value.

Parameter vary in matter, manual mode use


only.Auto and semi- auto mode is stop.

please notify to machinery


supplier to handle it.

SHUTDOWN

12 6

ERROR

7 - 10

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 7 Maintenance & Trouble Shooting

Chapter 8 Services Review


1. Product Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8. - 2
2. Services Centre Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8. .- 5

8-1

1. Product Introduction
(1) M type (high-level) multi-function industrial process controller
I. PC-BASE hardware configuration, expandable to optional main unit box
II. 10.4", 640 X 480 pixel, color, TFT wide view angle LCD, VGA standard display
III. Ethernet monitoring data treatment
IV. 48-point input, 48-point output hardware circuit (upgradeable to 128X128)
V. 5 channel 12 bits A/D, 4 channel 12 bitsD/A and 3 axis 16 bit encoder input interface
VI. Ladder programming, curve, PID control, QA etc. powerful software control functions

(2) MA type (precision) plastic processing machine controller


I. 8.4", 640 X 480 pixel , color, TFT wide wide view angle LCD, VGA standard display
II. PC-BASE hardware configuration
III. 32-point input, 32-point output and 4 channel 12 bits D/A, 5 chaannels 12 bits A/D (upgradeable 64 X 64 I/O)
IV. Ladder programming, PID temperature control algorithm and several software control functions

(3) FA type (standard) plastic processing machine controller


I. 5.7", 320X240 pixel, mono LCD display
II. 16-bit high speed CPU
III. 32-point input, 32-point output and 2 sets of D/A, 2 sets of A/D (other options available)
IV. 12-screen data exchange treatment, over 50 warning messages, 100 data memory functions

(4) FC series plastic processing machine controller


I. 5.7", 320*240 pixel color TFT LCD and touch-screen human machine interface
II. 16-bit high speed CPU
III. 32-point input /32-point output and 2 unit D/A, 2 unit A/D (other options available)
IV. 12-screen data exchange treatment, over 50 warning messages, 100 data memory functions

(5) TC5 series temperature controller for mold


I. TC-5000 series use HMI monitoring and can control as many as 200-point temperature zones
II. TC5E controller has options of zero and phase angle output modes, compatible with commercially
standard controllers
III. TC5M controller uses single piece 2-zone control, with communication and current detection functions, HMI to
monitor and set up as many as 200-point temperature zones.
IV. TC5F controller uses TC5E advanceantage and adds RS485 communication interface and current display.

(6) TC5V multiple-stage timing controller


I. 3 timing control modes available, including pressure-hold mode, providing multiple signal input /output selections

8-2

(7) VERDURE/HAMADA TC2 series temperature controller


I. C.E. international certification, best seller in Taiwan
II. Logic digital input, analog precision output control, with control-loop check
III. Upgradeable up to five auxiliary outputs, flexible machine dimension (48 X 96 mm)

(8) VERDURE TC series temperature controller


I. Numerical or turn-knob input setup, proportional output monitoring
II. Options available for several auxiliary temperature control output
III. Heater broken check, flexible machine dimension

(9) ARICO P series temperature controller


I. Numerical PID parameter setup, proportional monitoring output
II. Options available for several auxiliary temperature control outputs
III. Heater broken check, international machine dimension, LCD tri-color display

(10) ARICO V series temperature controller


I. PV/SV dual line display, plug-pull installation
II. PID automatic algorithm, auto or manual output function
III. 4 sets of output: primary/secondary output and alarm 1/2

(11) ARICO S series temperature controller


I. PID-AT algorithms temperature control precision
II. Simple structure, simple replacement
III. Manual/auto output function, hot plug-pull design

(12) Solid state relay


I. 12~32 VDC, 200~280 VAC and VR input selection
II. 3 AMP to 40 AMP AC load output selection
III. High efficiency alloy heatsink, accommodating 1~4 solid state relays

(13) Temperature sensing wire


I. Japan compensating wire, alloy soldered probe
II. Many types of probes available, custom-made available

(14) Other industrial process controllers and circuit boards


I. Hydraulic proportional valve amplifier
II. Cold hot water/oil pump controller
III. Automatic feeder controller

8-3

The Asia-Pacific Exclusive Agent for Italy GEFRAN products


Linear position transducer (potentiometer)
1. Puller type potentiometer (LT series)
(1) Measurement range 50~900 mm, linear precision 0.05%
(2) Displacement end speed 5 M/S, usage life over 25,000,000 times
(3) Industrial protection level IP 60, usage temperature range -30C ~100C

2. Slider type potentiometer (PK series)


(1) Measurement range 100~2000MM, linear precision 0.05%
(2) Displacement end speed 4 M/S, usage life over 25,000,000 times

3. Small potentiometer (PA1 series)


(1) Measurement range 25~150MM, linear precision 0.05%
(2) Displacement end speed 5 M/S, usage life over 100,000,000 times

4. Micro potentiometer (PY2 series)


(1) Measurement range 25~50MM, linear precision 0.1%
(2) Usage life over 100,000,000 times, spring return, stainless steel head

5. Pressure sensor
(1) Output range 0~10 V/4~20 MA, precision 0.5%
(2) Power source range 10~30 VDC, measurement range 0~500 BAR

6. Industrial machinery controller


(1) HPC, CPU, ladder programming
(2) Italian and international certified production standards
Note: Since GEFRAN is a listed company in Italy and has a variety of product lines. If you are interested
in any product, please contact ARICO Technology Co., Ltd.Or agent for product information.

8-4

2. Services Centre Address


Headquarters
8F., No.1, Alley. 1, Lane 235, Baociao Rd., Sindian District, New Taipei City, Taiwan.

Zip Code: 23145

TEL: +886-2-2910-1266FAX: +886-2-2915-9434


Web site: www.arico.com.twE-mail: info@arico.com.tw

Taipei Factory
5F/6F., No.10, Lane 235, Baociao Rd., Sindian District, New Taipei City, Taiwan.

Zip Code: 23145

TEL: +886-2-2910-1077FAX: +886-2-2910-1056

Taichung Branch
No.95, Dalian N. St., Beitun Dist., Taichung City, Taiwan.

Zip Code: 40667

TEL: +886-4-2291-7011FAX: +886-4-2292-4021

Tainan Branch
No.240, Yan ping St., Yung kang District, Tainan City, Taiwan.

Zip Code: 71082

TEL: +886-6-253-9940FAX: +886-6-253-9945


Web site: www.gefran.com.tw

Hong Kong Exclusive Distributor: (Hong Kong)


RM.13, 8/F, Block C, Wah Lok Industrial Centre, 31~35 Shan Mei ST., Fotan, Hong Kong. China.
TEL: +852-2947 7913E-mail: verdure@hknet.com

South China Exclusive Distributor: (Dong Guan)


2nd Chang Wu industrial zone, Chiao Li, Chang Ping, Dong Guan City, Guangdong Province.
TE: +86-769-8390-2101-3

East China Exclusive Distributor: (Shanghai)


Room 2104, No.9, Lane 1283, Shanxi Rd(N.), Putuo District, Shanghai.
TEL: +86-21-6111-5256-9

8-5

PRC 200060

PRC 523586

Wiring Diagram of Control system


J2
panel

J3
panel

Input element
Add. from
00 ~ 15
(I/O PCB.#1)

6
7
8
9
10
11
12
13
14
15

35
36

Input element
Add. from
32 ~ 47
(I/O PCB.#3)
(Option)

37
38
39
40
41
42
43
44
45
46
47

High speed
Pulsing interface

A/D 1
input

A/D 2
input

A/D 3
input

A/D 4
input

1
2

V1
V1in

3
4
1
2

G1
E1
V2
V2in

3
4

G2
E2

1
2

V3
V3in

3
4
1
2

G3
E3
V4
V4in

3
4

G4
E4

1
2
3
4
5

S 1

4 (output)

(input)

S
34

1
2
3
4
5
6
7
8

7 (output)
S
T

33

1
2
3
4
5
6
7
8

32

8 (output)

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18

31

(T.C. input)

30

29

5 (spare)

28

4 (temp output)

27

Pro. Pressure valve

Pro. Flow valve

P+ P- F+ FPower board
(FPV-01)

Vp+

50

Vp-

51

Vf+

52

Vf-

53

T 3 (D/A-amp.)

T2

T 1 (power)

1 2 3 4 5 6 7 8

1 2

1 2 3 4 5 6

26

FA type controller
(Injection Molding Machine)

25

T 11

24

T 12 (A/D 1,2 in)

23

(input)

Input element
Add. from
16 ~ 31
(I/O PCB.#2)

22

T 13 (A/D 3,4 in)

21

S 2

20

(input)

19

S 5

18

(input)

17

S 6

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18

16

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18

100
101
102
103
104

Output element
Add. from
100 ~ 115
(I/O PCB.#1)

105
106
107
108
109
110
111
112
113
114
115

GO

GI

Potentiometer Input
Voltage Divider

VI

T 10 (output)

3 (output)

(input)

T 7

(input)

T 8

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18

9 (output)

J1
panel

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18

116
117
118

1
2
3
4
5
6
7
8

119

Add. 121~131 employ an


External power source
(not 24vdc) please make
connect with External
Relay 05 board to isolate

125

120
121
122
123
124

126
127
128

External Relay
Solenoid
of PCB Relay 05

129
130
131

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

Output element
Add. from
116 ~ 131
(I/O PCB.#2)

132
133
134
135
136

Output element
Add. from
132 ~ 147
(I/O PCB.#3)
(Option)

137
138
139
140
141
142
143
144
145
146
147

TC1 +
TC1 TC2 +
TC2 TC3 +
TC3 -

Thermocouple
Input of
Zone 1 ~ 8

TC4 +
TC4 TC5 +
TC5 TC6 +
TC6 TC7 +
TC7 TC8 +
TC8 -

Spare Socker
Aux. contact
of output 125

H1

1
2
3
4
5
6
7
8
9
10

H2

Heater control output zone


1~8 SSR common 24vdc +

H3
H4

Employ an External power source


(not 24vdc) please make connect
with External Relay 04 board
to isolate

H5
H6
H7
H8

Switching Power
for computery

D/A Output
D/A 1 ~ 4

Power board
(FPW-01)
G I

GO

V I

VO

-12V
0V
+12
0V
5V

Power supplies
(VPE - 3)

Control
Panel

VO