Manual Welltec TTI 200C (Cosmo) INJETORA DE PLASTICO

PRECISION INJECTION MOLDING MACHIN
C2-SERIES
TTI - 90C
TTI - 120C
TTI - 160C
TTI - 200C with
TTI - 260C ?
TTI - 320C C O N T R O L S Y S T E MCIMtrol
How Do I
Version 1.0, 1992
Tai Tung Industrial Building,

29-33 Tsing Yi Road, Tsing Yi, N.T. Hong Kong
Serial number:
Date of dispatched:
Copyright C 1991 by Welltec Industrial

Equipment Ltd. All rights reserved. All listed
products are trademarks or registered
trademarks of Welltec Industrial Equipment Ltd.
Other brand and product names are trademarks
of their respective holders.
Version no. Revision History Date
1.00 Original version for C-series machine and 30-10-1991

control system CIMtrol V1r1
2.00 Second edition for C-series machine 10-1-1993
Serial no.
Date of dispatched:
Copyright ? 1994 by Welltec Machinery Limited. All rights

reserved. All listed products are trademarks or registered
trademarks of Welltec Industrial Equipment Limited. Other
brand and product names are trademarks of their respective
holders.
Preface
Proper handling and careful maintenance of the machine are essential for the proper
function of the machine. The Welltec Injection Moulding Machine is designed and
manufactured with advance production technology and years of experience. The result is
a machine of superior performance. However, improper handling and maintenance of the
machine will degrade the performance of the machine, and even worse, the service life
may be shorten and the machine may be damaged. Should it be the case, the
manufacturer will not assume the responsibility for the defects. This instruction manual
describes how the machine shall be handled and maintained. Read this manual
thoroughly before using the machine.
If there is anything that is not clear in the manual, or if there is any question, or if any
further information that is not included in the manual is required, do not hesitate to write
to us at any of the office listed below.
Sales Department,
Welltec Industrial Equipment Ltd.,
Tai Tung Industrial Building, 29-33 Tsing Yi Road,
Tsing Yi, N.T.,
Hong Kong
Tel: (852) 4312111
Telex: 38264 TAIND HX
Fax: (852) 4337060, 4330130
Welltec U.S.A., Inc.

6328 Gross Point Road, Niles,
Illinois 60648
U.S.A
Tel: (01) 708-647-1392
Fax: (01) 708-647-1394
Notice to customers:
This manual is the property of Welltec and shall not be disclosed to any
third party or be copied in any form, and must be returned to us at our
request.
i
Warranty
The Welltec TTI-C series Injection moulding machines and parts are subject to the
following warranty:
(A) WARRANTY PERIOD
The warranty is valid for twelve (12) months from the date of delivery (FOB
Hong Kong), or 2000 pump running hours whichever comes first. Exceptions
for special parts (related to the electrical system, hydraulic and pneumatic
system, and screw assembly) are stated in Clause F.
(B) SCOPE OF WARRANTY
Should any defects be found with the machines during normal handling and
maintainance conforming with the operation manual and/or other instructions
applicable to the machines, we will repair or replace all parts found defective at
no cost, excluding the cases specified in Clause C. However, repair parts cost
shall be borne by the customer if any of the defective parts that have been
replaced is not returned to us or to a place specified by us.
The warranty does not cover any consequential or special losses, damages or
expenses including, but not limited to, loss of time, loss of profit or earning
directly or indirectly occasioned to the customer by reason of the defects or due
to repairs or other works done to the machines to remedy such defects.
(C) EXEMPTIONS
In the following cases, repair expenses shall be borne by the customer in the
period or warranty:
Damage resulting from improper or inadvertent operation or handling of the

machines.
Damage caused by inappropriate or defective shop facilities (such as ceiling,

floor, power source, grounding, cooling water piping, quality of water, etc) or by
insufficient maintenance.
Any damage attributed to the primary defects which have been left unrepaired.
Damage of the machines which have been subjected to any repair, modification or
reinstallation by the customer without our approval.
ii
Damage resulting from the use of machines in combination with any unauthorized
auxiliary equipment
Damage of machines caused by any parts supplied or specified by the customer.
Defects and damage of the machines which have been overhauled.
Defects and damage of the second-hand machines which have been resold to the
customer without our written approval.
All the defects and damage resulting from any cause that is not to be attributed to
the machine manufacturer's responsibility.
(D) CUSTOMER'S OBLIGATION
During the warranty period, the customer may cause the necessary repairs or
replacement to be made elsewhere which is deemed suitable for the purpose. In
that event, the customer shall give a notice in its details in writing to us. In this
case, we shall have the right to verify by our representative the nature and
extents of the defects complained of.
(E) REPAIR EXPENSES AND COST
Repair expenses and cost for damage that occurs after the expiration of the
warranty period, and those incurred in the cases described in Clause C, shall be
borne by the customer in accordance with our standard rate. These expenses and
cost will comprised parts cost, shipping charge and personnel expenses (including
traveling expenses)
iii
(F) EXCEPTIONAL PARTS FROM NORMAL WARRANTY STANDARD AND
PERIOD
Unwarranted parts 6-month warranted parts

Electrical
Parts
Signal lamps, Fuses, Nozzles, Nozzle cylinder Plasticizing cylinder heaters (set
(cylinder head) heaters and thermocouples, temperature 370oC or below), Auxiliary
Resin temperature monitoring thermocouples, relays Magnetic contractors and Limit
and Connectors. switches (excluding proximity switches)
Hydraulic, pneumatic,
and lubricating parts
Filter elements, Zinc bars for oil cooler, Seals, Valves (servo valves, electro-proportional
Flow unit, Nylon tubes and sleeves for use solenoid valves, directional control valves,
other than lubrication. pressure control valves, flow control valves,
temperature control valves , etc.), Oil
temperature gauges, Flow meters, Float
switches, High-pressure rubber hoses,
Gauge cocks, Pressure gauges, Pressure
switches, Flow dividing valves, and
Lubrication nylon tubes and sleeves.
Warranty period for individual parts depends on the operating conditions roughly
classified into four groups below:
A: When processing ordinary resins (PE, PP, GPPS, AS, PA, POM, PMMA,PC,PET)
B: When processing resins less than 30% or more in glass fiber content (PC-GF, POM-GF,
PA-GF, PBT-GF) or equivalent abrasive resins.
C: When processing resins of 30% or more in glass fiber content (PCGF, POM-GF, PA-GF,
PBT-GF) or equivalent abrasive resins, when processing corrosive resins (flame-retarded
ABS, flame-retarded PC, flame-retarted PBT, etc.).
D: When setting temperature of 400oC or above when applying higher injection pressure than
specified or when processing resins containing ceramic fibers, carbon fiber, ferrite,
aluminum, mica, and other mineral fiber, or when processing resins impregnated with
lubricants such as silicon oils.
Standard Wear and Wear and corrosion Wear and corrosion High melting
corrosion resistant resistant resistant temperature
A B C D A B C D A B C D A B C D
Plasticizing cylinder 6 12 12 12 12
Screw 12 12 12 6 6
Screw assembly parts
Screw head 6 6 6 X
Check ring 6 6 6 X X X X X
Seal ring 6 6 X 6
Needle 6 X X X 6 X X / / / / / / / /
Torpedo 6 6 / / / / / / / /
Nozzle (with needle valve) 6 6 / / / / / / / /
Nozzle (open) 6 6 6 X X X 6 X X X
Lever 6 6 6 6 6 6 / / / / / / / /
Note :1. 6 : 6- month warranty counting from the date of delivery (FOB Hong Kong)
12 : 12-month warranty counting from the date of delivery (FOB Hong Kong)
X : Unwarranted
/ : No pertinent part
2. Screw heads shall be unwarranted in the damageable operation such as
inadequate time setting of the screw head protection device (less than 15
minutes)
iv
Table Of Contents
Preface i
Warranty ii
1. General Safety Practices 1
1.1. Hydraulic Oil, Lubricating Oil, And Nitrogen Gas Pressure . . . . . . . . . 1
1.2. Hydraulic Oil Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3. Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.4. Wires For Heating Element In The Heat Zones . . . . . . . . . . . . . . . . . . . . 2
1.5. Clamping Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.5.1. Safety Precaution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.5.2. Safety Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.5.3. Mechanical Safety Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.6. Between Nozzle And Stationary Platen (Mold) . . . . . . . . . . . . . . . . . . . . . 3
1.7. Between Injection Unit And Stopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.8. Cylinder Hopper Opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.9. Mold Thickness Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.9.1. Safety Precaution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.10. Heating Cylinder And Nozzle Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.10.1. Safety Precaution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.10.2. Safety Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.11. Earthing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.12. Electric Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.13. Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.14. Barrel Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.15. Operation Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.15.1. Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.15.2. Emergency Stop Button Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.16. Operation And Clothing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.17. Resin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2. Machine Features And Specifications . . . . . . . . . . . . . . . . . . . 7
2.1. Machine Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.2.1. Model Number & Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.2.2. Injection Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.2.2.1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.2.2.2. Injection Pressure Vs. Hydraulic Pressure Diagram . . . . . 10
2.2.2.3. Shot Weight Vs. Screw Stroke Diagram . . . . . . . . . . . . . . . . . 10
2.2.2.4. Injection Unit Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.2.2.5. Swivel Of Injection Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.2.2.6. Heating Barrel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.2.3. Clamping Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.2.3.1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.2.3.2. Clamping Force Vs. Hydraulic Pressure Diagram . . . . . . . 18
2.2.3.3. Clamping Unit Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.2.3.4. Mold Platen Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.2.3.5. Sliding Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.2.4. Electrical Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.2.4.1. Limit Switch Function And Location (fig. 2-13) . . . . . . . . . . . 23
2.2.4.2. Operation Cycle Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.2.5. Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.2.5.1. Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.2.5.2. Working Cycle Of Hydraulic System (Double Pump) . . . . 27
2.2.5.3. Manifolds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.2.5.4. Hydraulic Valves And Hydraulic Circuit Diagrams . . . . . . . 29
2.2.5.5. Hydraulic Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.2.5.6. Oil Level And Temperature Control . . . . . . . . . . . . . . . . . . . . . 40
2.2.5.7. Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.2.6. Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2.2.6.1. Guard Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2.2.6.2. Mechanical Interlocks (fig. 2-22) . . . . . . . . . . . . . . . . . . . . . . . . 41
2.2.6.3. Hydraulic Interlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.2.6.4. Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2.2.7. Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
2.2.7.1. Flow Rate Regulator (fig. 2-24) . . . . . . . . . . . . . . . . . . . . . . . . . 44
2.2.7.2. Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.2.8. Memory Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
2.2.9. Power Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
2.2.10. Machine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.2.11. Control System - CIMtrol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3. Machine Installation And Preparation . . . . . . . . . . . . . . . . . . . 49
3.1. Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3.2. Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3.3. Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3.4. Oil Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3.5. Power Supply Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3.6. Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3.7. Cleaning Of Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3.8. Lubricating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
4. Switch Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
4.1. Emergency Stops - Front & Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
4.2. Pump Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
4.3. Operation Modes Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
4.3.1. Manual Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
4.3.2. Setup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
4.3.3. Semi-Automatic Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
4.3.4. Automatic Mode ............................................ 58
4.3.5. Photo Sensor Cycle (Optional) ............................. 58
4.3.6. Mold Height Adjustment Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
4.4. Clamp Opening And Closing Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
4.5. Injection And Plasticizing Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
4.6. Ejector Forward And Backward Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
4.7. Carriage Forward And Backward Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
4.8. Mold Height Adjustment Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
4.9. Core Setting Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
4.10. Core Pulling Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
4.11. Decompression Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
4.12. Multiple Ejection Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
4.13. Air On .......................................................... 63
5. Membrane Keyboard And Color Monitor . . . . . . . . . . . . . . . . . 64
5.1. Color Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
5.2. Membrane Keyboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
5.3. Hard Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
5.3.1. - Main Screen Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
5.3.2. - Clamping Screen Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
5.3.3. - Core Screen Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
5.3.4. - Mold Setup Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
5.3.5. - Time Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
5.3.6. - Injection Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
5.3.7. - Metering Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
5.3.8. - Graphic Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
5.3.9. - Temperature Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
5.3.10. - Monitoring Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
5.3.11. - Production Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
5.3.12. - Daily Maintenance Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
5.3.13. - Storage Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
5.3.14. - Diagnostic Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
5.4. Soft Key ......................................................... 68
5.5. Cursor Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
5.6. Numeric Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
5.6.1. Numeric Entry Of The Machine Settings :- . . . . . . . . . . . . . . . . . . . 68
5.6.2. Selection Of Machine Options :- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
5.7. Special Function Key And Mode Selection Key . . . . . . . . . . . . . . . . . . . . 70
5.7.1. - Help Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
5.7.2. - Print Screen Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
5.7.3. - Toggle Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
5.8. Memory Card Slot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
5.8.1. "Card Inserted" LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
5.8.2. Read/Write LED ............................................ 71
6. Control Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
6.1. Main Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
6.1.1. Access Code Entry : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
6.1.2. Access Code Modification : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
6.1.3. Access Code Assignment (For Access Level 4 Only): . . . . . . . . 75
6.2. Clamping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
6.2.1. Pause Time ............................................... 76
6.2.2. Cooling Time .............................................. 76
6.2.3. Rebound Count ........................................... 77
6.2.4. Closing Time .............................................. 77
6.2.5. Opening Time ............................................. 77
6.2.6. Cycle Time ................................................ 77
6.2.7. Close Changeover Positions For Speed And Pressure . . . . . 77
6.2.8. Mold Close Pressure Setup ................................ 78
6.2.9. Mold Close Speeds ........................................ 78
6.2.10. Mold Open Speed And Pressure Changeover Positions .... 79
6.2.11. Mold Open Pressure ..................................... 79
6.2.12. Mold Opening Speed ..................................... 79
6.2.13. Actual As Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
6.3. Ejector And Air Blast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
6.3.1. Ejector Start Position ...................................... 81
6.3.2. Air Start Position .......................................... 81
6.3.3. Ejector Backward Stop Position, Pressure And Speed . . . . . . 81
6.3.4. Ejector Forward Position, Speed And Pressure . . . . . . . . . . . . . 82
6.3.5. Ejector Dwell Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
6.3.6. Ejector Count . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
6.3.7. Rattle ...................................................... 82
6.3.8. Air Blast On Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
6.3.9. Actual As Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
6.4. Side Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
6.4.1. Core Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
6.4.2. Core In/Out Process Usage ............................... 85
6.4.3. Core In/Out Termination Method (Timer/ Position) . . . . . . . . . . . . 85
6.4.4. Core Pressure And Speed ................................. 85
6.4.5. The Core In/Out Timer .................................... 85
6.4.6. Priority .................................................... 86
6.4.7. The Core Push Position .................................... 86
6.4.8. The Core Pull Position ..................................... 86
6.4.9. Actual As Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
6.5. Barrel Temperature .............................................. 87
6.5.1. Operation Mode ........................................... 87
6.5.2. The +Tol Alarm ............................................ 88
6.5.3. Range For + Tol Bar Graph ................................ 88
6.5.4. The Actual Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
6.5.5. The Set Temperature ...................................... 88
6.5.6. Reduce Set Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
6.5.7. Range For - Tol Bar Graph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
6.5.8. The -Tol ................................................... 88
6.5.9. The Actual Duty (%) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
6.5.10. Control Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
6.5.11. The Actual Oil Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
6.6. Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
6.6.1. No. Of Injection Stages .................................... 90
6.6.2. Filling Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
6.6.3. Injection Delay ............................................. 91
6.6.4. Injection Speed Changeover Position ...................... 91
6.6.5. Injection Speed Profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
6.6.6. Maximum Pressure Control ................................ 91
6.6.7. Injection Set Profile Graph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
6.6.8. Cut-Off Mode Parameters And Criteria .................... 91
6.6.9. Actual Screw Position , Injection Speed, And Hydraulic 92
Pressure In Injection Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.6.10. Actual As Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
6.7. Holding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
6.7.1. Holding Time Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
6.7.2. Holding Pressure Profile Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
6.7.3. Hold Pressure Set Profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
6.7.4. Holding Velocity ........................................... 94
6.7.5. Cushion Length, +Tol And - Tol ........................... 94
6.8. Metering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
6.8.1. No. Of Metering Stages .................................... 95
6.8.2. Decompression Delay ..................................... 95
6.8.3. Metering Delay ............................................ 95
6.8.4. Metering Time ............................................. 95
6.8.5. Back Pressure Switchover Position ........................ 96
6.8.6. Back Pressure Profile ..................................... 96
6.8.7. Actual Screw Position, Back Pressure And Screw Rotating 96
Speed (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.8.8. Metering Speed Profile .................................... 96
6.8.9. Metering Speed Switchover Position ....................... 96
6.8.10. Decompress Before Metering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
6.8.11. Decompression After Metering ............................ 96
6.8.12. Decompress Before Metering Position, Pressure And Speed 96
...............................................................
6.8.13. Decompression After Metering Position, Pressure And 97
Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.8.14. Actual As Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
6.9. Mold Data Internal Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
6.9.1. Mold Reference No. ....................................... 98
6.9.2. Data Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
6.9.3. Data Retrieval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
6.9.4. Mold Data Preview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
6.10. IC Card Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
6.10.1. Auto Card Size Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
6.10.2. Page Number Tag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
6.10.3. Position Of Page In Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
6.10.4. Mold Reference No. ...................................... 100
6.10.5. Data Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
6.10.6. Data Retrieval From IC Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
6.10.7. Mold Data Preview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
6.11. Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
6.11.1. Reject Rate .............................................. 102
6.11.2. Cavity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
6.11.3. Shot Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
6.11.4. Material .................................................. 102
6.11.5. Std Reject Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
6.11.6. Std Cycle Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
6.11.7. Lot Required ............................................. 103
6.11.8. Lot Finished . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
6.11.9. Production Counter Reset ................................ 103
6.11.10. No. Of Parts Per Lot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
6.11.11. Part Finished . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
6.11.12. Reject Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
6.11.13. Part Rejected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
6.11.14. Parts Reject During Start Up ............................ 103
6.11.15. Maximum No. Of Parts For Continue Reject . . . . . . . . . . . . . . . 104
6.11.16. Average Cycle Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
6.11.17. Estimated Production Time Remained . . . . . . . . . . . . . . . . . . . . . 104
6.11.18. Estimated Material Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
6.12. Op Setup ....................................................... 105
6.12.1. Communication Interface Specification . . . . . . . . . . . . . . . . . . . . 105
6.12.2. Language Selection ...................................... 105
6.12.3. Screen Dwell Delay ....................................... 106
6.12.4. Key Click Sound On /Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
6.12.5. Measuring Unit ........................................... 106
6.12.6. Help Window Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
6.12.7. Printer Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
6.12.8. Real Time Date And Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
6.13. Mold Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
6.13.1. Auto Mold Height Adjust Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
6.13.2. Procedure For Setting Up Auto Mold Height Adjustment: . . . 109
6.13.3. Auto Purge Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
6.13.4. Auto Purge Cycle Start Up Procedure: . . . . . . . . . . . . . . . . . . . . . 110
6.13.5. Clamping Force .......................................... 110
6.13.6. Injection Complete Position Of Auto Purge ................ 110
6.13.7. Injection Pressure And Speed For Auto Purge ............ 110
6.13.8. Decompression Pressure And Speed For Auto Purge ..... 111
6.13.9. Decompression Stop Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
6.13.10. Metering Pressure And Speed .......................... 111
6.13.11. Metering Stop Position .................................. 111
6.13.12. Monitoring Time ......................................... 111
6.13.13. No. Of Cycle ............................................ 111
6.13.14. Auto Purge .............................................. 111
6.13.15. Auto Mold Height Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
6.13.16. Monitoring Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
6.14. Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
6.14.1. Carriage Mode ........................................... 112
6.14.2. Actual Readings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
6.14.3. Carriage Forward Switchover Position .................... 113
6.14.4. Carriage Forward Pressure And Speed Setup . . . . . . . . . . . . . 113
6.14.5. Carriage Pull ............................................. 113
6.14.6. Carriage Backward Switchover Position ................... 113
6.14.7. Carriage Backward Pressure And Speed Setup ........... 113
6.14.8. Monitoring Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
6.14.9. Actual As Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
6.15. Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
6.15.1. Pause Timer ............................................. 114
6.15.2. Carriage Forward Delay .................................. 114
6.15.3. Carriage Backward Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
6.15.4. Metering Delay ........................................... 114
6.15.5. Ejector Dwell ............................................. 115
6.15.6. Air Blow 1 Timer .......................................... 115
6.15.7. Injection Delay ........................................... 115
6.15.8. Decompression Delay .................................... 115
6.15.9. Cooling Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
6.15.10. Pre-Extruding Time (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
6.15.11. Filling Time ............................................. 115
6.15.12. Metering Time ........................................... 116
6.15.13. Mold Close Time ........................................ 116
6.15.14. Cycle Time .............................................. 116
6.15.15. Monitoring Parameter: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
6.16. TCU Parameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
6.16.1. Actual Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
6.16.2. Setpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
6.16.3. Self Tune ................................................. 117
6.16.4. ST Status, Maximum, Minimum And Status . . . . . . . . . . . . . . . . . 117
6.16.5. Kp ....................................................... 118
6.16.6. Ki ........................................................ 118
6.16.7. Kd ....................................................... 118
6.16.8. Man. Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
6.16.9. Sampling Time ........................................... 118
6.16.10. ZU ..................................................... 118
6.16.11. ZL ...................................................... 118
6.16.12. Mode ................................................... 118
6.16.13. Self Tuning Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
6.17. Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
6.18. Graphic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
6.18.1. Curve .................................................... 121
6.18.2. Color ..................................................... 121
6.18.3. Set ....................................................... 121
6.18.4. Auto Scale ............................................... 122
6.18.5. Actual As Set ............................................. 122
6.19. Product Certificate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
6.20. Diagnostic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
6.21. Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
6.22. Machine Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
6.23. Daily Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
6.23.1. Lubrication Interval ....................................... 127
6.23.2. Lub. Interval Leave, Replace Filter After, Replace Hyd. Oil 127
After . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.24. Machine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
6.24.1. Offset .................................................... 128
6.24.2. Gain ..................................................... 128
6.24.3. Ramp .................................................... 128
6.25. Summary 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
6.25.1. Clamp Speed And Pressure Switchover Position . . . . . . . . . . 129
6.25.2. Clamping Pressures And Speeds ......................... 129
6.25.3. Ejector Start Position ..................................... 129
6.25.4. Air Start Position ......................................... 130
6.25.5. Carriage Pressure And Speed Switchover Positions . . . . . . . 130
6.25.6. Carriage Pressures And Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . 130
6.25.7. Carriage Pull ............................................. 130
6.25.8. Carriage Mode ........................................... 130
6.25.9. Pre-Extruding (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
6.25.10. Pre-Extrusion Time (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
6.25.11. Ejector Positions ........................................ 131
6.25.12. Ejector Pressures And Speeds .......................... 131
6.25.13. Rattle ................................................... 131
6.25.14. Ejector Cycle Count ..................................... 131
6.26. Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
6.26.1. Analog Output Port ....................................... 132
6.26.2. Analog Input Channel .................................... 132
6.26.3. Clamp Setup Pressure And Speed ........................ 133
6.26.4. Ejector Setup Pressure And Speed ....................... 133
6.26.5. Core Setup Pressure And Speed ......................... 133
6.26.6. Carriage Setup Pressure And Speed ...................... 133
6.26.7. Injection Setup Pressure And Speed ...................... 133
6.26.8. Metering Setup Pressure And Speed ..................... 133
6.26.9. Calibration Of Scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
6.26.10. Monitoring Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
6.27. Heater Timer Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
6.27.1. Whole Day On/Off Switch ................................. 134
6.27.2. Specific Operating Mode ................................. 134
6.27.3. Starting Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
6.27.4. Shift Schedule (Not Yet Released). . . . . . . . . . . . . . . . . . . . . . . . . . 134
6.28. Summary 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
6.29. Hopper Dryer Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
6.30. Setup Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
6.31. Shift Scheduler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
6.32. Down Time Reject Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
6.33. Data Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
6.34. Monitoring Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
6.35. Monitoring Graph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
6.36. Input Diagnostic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
6.37. Input 2 Diagnostic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
6.38. Output Diagnostic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
6.39. Analog I/O Diagnostic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
6.40. Internal Flag Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
6.41. Machine Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
6.41. Numbering Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
7. Machine Setting Procedures ........................... 150
7.1. Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
7.2. Machine Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
7.3. Setting Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
7.4. Setting Control For Clamp/Ejector System . . . . . . . . . . . . . . . . . . . . . . . . . 152
7.4.1. Clamp Motion Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
7.4.2. Ejector Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
7.5. Cooling Time Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
7.6. Core Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
7.7. Injection Unit Set-Up And Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
7.7.1. Initial Injection Unit Settings ............................... 157
7.7.2. Recommended Injection Unit Start-Up And Purging 159
Procedures ..................................................
7.8. Final Injection Unit Setting ...................................... 161
7.9. Machine Shutdown Procedure .................................. 162
8. Tips On Best Molding .................................. 167
8.1. Setting The Injection Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
8.1.1. Mold Inside Pressure And Quality Of The Formed Product . . . 168
8.1.2. Calculations For Setting The Conditions . . . . . . . . . . . . . . . . . . . . . . 169
8.1.2.1. Causes Of Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
8.1.2.2. Countermeasures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
8.1.2.3. Example For Program Setting . . . . . . . . . . . . . . . . . . . . . . . . . . 171
8.1.3. Basic Methods For Setting Injection And Holding Pressure 172
Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.2. Molding Fault And Countermeasures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
8.2.1. Molding Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
8.2.1.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
8.2.1.2. Short Shots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
8.2.1.3. Parts Flashing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
8.2.1.4. Sink Marks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
8.2.1.5. Bubbles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
8.2.1.6. Poor Welds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
8.2.1.7. Material Discoloration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
8.2.1.8. Warpage & Shrinkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
8.2.1.9. Dimensional Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
8.2.1.10. Sticking In The Mold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
8.2.1.11. Sticking Of Sprue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
8.2.1.12. Nozzle Drooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
8.2.1.13. Excessive Cycle Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
8.2.1.14. Splay-Mica-Flow Marks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
8.3. Summary On Molding Inferiorities And Countermeasures . . . . . . . . . . 188
8.4. Standards For Molding Temperature Setting . . . . . . . . . . . . . . . . . . . . . . . 189
9. Machine Maintenance And Repair . . . . . . . . . . . . . . . . . . . . . . . 190
9.1. Regular Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
9.1.1. Daily Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
9.1.2. Weekly Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
9.1.3. Monthly Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
9.1.4. Annual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
9.2. Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Appendix A Quick Reference of Control Parameters
Appendix B Listing of Error/Warning Messages
Section 1 GENERAL PRECAUTIONS
General safety practices

For safety reasons, read the instructions below carefully.
HYDRAULIC OIL, LUBRICATING OIL, AND NITROGEN GAS PRESSURE
Before starting the machine,
check the oil levels of the hydraulic reservoir and lubricating pump unit,
check the nitrogen gas pressure,
if accumulator is installed, ensure the oil levels and the gas pressure are within
the specified limits.
HYDRAULIC OIL TEMPERATURE
Check the temperature of the hydraulic oil frequently during machine operation.
The temperature shall be within 40 to 55 degree Celsius. The ideal temperature
shall be 45 to 55 degree Celsius. If the temperature is out of the range, the
following shall be done,
adjust the temperature control valve at the cooling water outlet of the oil cooler,
check if sufficient water is flowing,
check if the temperature of the water at the inlet of oil cooler is too high.
If the hydraulic oil temperature is not stable, too high or too low, the
dimensional accuracy of the mouldings and the machine functions will be
adversely affected. Often the hydraulic oil will be quickly deteriorated.
LUBRICATION
Carefully check the nylon lubrication pipes for any damage. Examine to see if
the sliding parts are properly lubricated and greased. If these parts are not
properly lubricated, the machine service life may be shortened. Also the
machine function may become abnormal.
WIRES FOR Heating element in the heat zones
The wires for heater bands are conducted through narrow space. When an
heating element is replaced with a new one, make sure that none of the wires
are in contact with the injection unit positioning cylinder, the inner wall or the
edge of the recess hole in the stationary mould platen and the other stationary
parts near the wires when the injection unit moves forwards and backwards. If
the wires are in contact with these parts during carriage motion, quick damage
of the wires may be resulted and unexpected hazards from electric shorts or
sparks can occur.
Clamping area
safety precaution
Turn off the main power switch and tag with a proper sign plate to prevent the
main switch from being turned on by mistake during inspection or maintenance
of the machine.
Do not touch the mold or the clamp components during operation with guard
door closed.
Never go to the upper part of the clamping area nor take product out during
operation.
Never get into rear side of movable platen (linkage mechanism side) during
operation. Follow the same procedure in (1) above when working inside.
Never get into the inside portion of clamping fixed cover during operation.
safety device
The operation side guard door protects with three safety devices: the electrical,
hydraulic and mechanical interlock. The non-operation side guard door protects
with two safety devices: the electrical and hydraulic interlock.
Electrical interlock :- Two limit switches at operation side and two limit
switches at non-operation side are provided. When the guard door is opened
during manual and full automatic operation, the limit switch is actuated by the
1
GENERAL PRECAUTIONS
cam attached to guard. The control circuits for the clamping unit will be turned
off and the clamping operation will be stopped. However, the pump motor and
heater circuits will not be turned off.
Hydraulic interlock : When the operation side or the non-operation side guard
door is opened during mold closing process, a lever will be pressed by the
guard door. The clamp motion directional valve will then be set to neutral
position by hydraulic control circuit connected, putting mold closing and opening
process to a halt.
Mechanical safety device
When guard door at operation side is opened during mold closing process, a
shutter will be lowered to provide a mechanical stop for mold closing.
Between nozzle and stationary platen (mold)
When advancing the nozzle, make sure that no operator with the whole nor with
any part of his body gets into the space between the stationary platen and the
nozzle.
During nozzle advance, never take molten resin from the nozzle by hand to
avoid possible pressing of the hand between the nozzle and the platen.
Between injection unit and stopper
Never insert your hand between injection unit and stopper
If work by hand is necessary there, stop the pump motor.
Cylinder hopper opening
When the hopper is removed, never insert your hand in the cylinder hopper
opening.
With the hopper attached and work by hand inside the hopper is necessary,
close the shutter completely and stop the machine.
If the cylinder is overheated, the resin inside may decompose and generate gas
which can splash hot resin out from the hopper opening. Keep away from the
hopper opening.
Mold thickness adjustment
Safety Precaution
When adjusting the mold thickness, do not touch the mold thickness adjusting
shaft.
Heating cylinder and nozzle unit
Safety Precaution
Heating cylinder and nozzle unit are heated to high temperature. Keep hands off.
When replacing the nozzle, hot molten resin may splash out. Therefore, wear
heat insulated clothing.
Molten resin has a very high temperature. Do not touch!
During molding and purging, hot molten resin may splash out. Keep a sufficient
distance from the nozzle and operate from the guard door side.
During operation, always keep the rear side door of the purge guard closed. Use
it only when exchanging the nozzle or the cylinder.
If the screw cylinder is overheated, the resin inside may decompose and
generate gas, which may leads to an explosion. Also, hot resin may splash out
from the hopper opening or the nozzle hole and causes burns. Screw, nozzle,
cylinder head may be damaged or burst out. Injury may be resulted. Therefore,
pay sufficient attention during operation.
Safety Device
Purge Guard
Installed at the stationary platen. To guard against burns caused by molten resin
splashing out during purging.
2
GENERAL PRECAUTIONS
Earthing
Check that the earth wires of the machine and the control board are connected
correctly and the connections are not damaged.
Connect the earth wires according to the instructions on the sign plate.
Electric Motor
During inspection, maintenance and replacement of the motor, turn off the main
power switch.
Control board
Turn off the main power switch before maintenance or inspection of electrical
or electronic equipment .
Turn off the main power switch before exchanging parts inside the boards or
parts like local box, solenoid valve, limit switch, etc.
When switching the main power between ON and OFF, always use the right
hand. Do not touch any equipment with the left hand.
Do not insert the hand inside the board.
During operation, always keep the door of the control board closed.
Barrel heater
Switch off the main power before
inspecting or replacing the heater, or
removing the heater cover.
Operation method
Safety Precautions
The machine shall be operated by a person who has studied this manual well
and is familiar with the safety precautions and operations of the machine.
Before starting operation, follow the instructions on the sign plates and carry
out pre-operation inspection.
In case of abnormal function of the machine, immediately stop the operation.
Inform the person in charge and act according to his instructions.
When two or more persons are working at the machine, always mutually confirm
your movements to the other before proceeding to the next step. Especially
when re-starting the machine after maintenance, confirm that all persons have
left the machine area before re-starting.
Do not allow anybody to come near the machine except those concerned with
the operation. Talking to the operator shall be forbidden to avoid mistakes.
Do not modify or change the design of the machine without prior approval of the
manufacturer. The manufacturer will not responsible for any accident arising
from unapproved modification or change to the machine.
Turn off the main power when machine will stop over 24 hrs.
Emergency stop button switches
Two emergency switches, one at the local box and the other at the rear side of
the stationary platen are provided.
By pressing either of these switches, the pump motor stops and all operations
except mold thickness adjusting are blocked.
Operation and clothing
Always wear safety shoes, helmet and full sleeve work jacket to avoid burns.
The working site should be sufficiently illuminated.
Order and tidiness around the machine are essential for efficient and safe
operation.
Install fire-fighting equipment at specified positions for fire prevention.
Resin
3
GENERAL PRECAUTIONS
Depending on the type of resin, smells or toxic gas may be generated. Ensure a
sufficient ventilation and use protective equipment if necessary.
The same as in (1) also applies to purging resin.
Consult the resin manufacturer about the characteristics of the resin (corrosion
resistance, abrasion resistance, decomposing, dangers, etc.)
4
Section 2 MACHINE FEATURES AND SPECIFICATIONS
Machine features and specifications
MACHINE FEATURES
The plasticizing screw and barrel are designed and manufactured in Europe,
featuring high strength and high resistance to abrasion. Nitrided steel and highly
corrosion resistant alloy-coated steel are used.
Injection speed profile allows 2, 5 or 10 injection phases.
Holding pressure profile allows 1,5, 10 phases of holding pressure.
Back pressure profile and screw speed profile allow 1,2 or 5 phases during the
metering stroke. Independent switchover positions for back pressure and screw
speed.
Display and preset an optimised pressure curve, which can be stored into the
computer, according the change in injection rate, back pressure and screw rev.
speed in an interval. Generate the upper and lower limit, signal alarm when
pressure out of the limit.
Digital, microcomputer-based self-optimizing temperature control circuits with

digital input, actual temperature monitor and status indicators (on/off) display for
all barrel heating zones and the nozzle heating zone.
Screw start-up protection: All heating zones must have reached their lower
temperature limit before the screw can move.
Injection unit pivots to one side for easy screw removal.
Automatic central lubrication with electrical monitoring.
4 stages clamp closing and opening speeds. Maximum pressure preset. Stepless
clamping force control.
Hydraulic central ejector eject allowed during mold opening for cycle time
shortening.
Automatic mold height adjustment.
Mould fixing layout and mould centering designed according to EUROMAP

standard.
Mechanical, electrical and hydraulic safety protection system comply with

international standards.
If the mould protection is triggered the mold automatically opens, ejects again,
repeats the closing sequence. If the low pressure mold protection is again
triggered the mold opens and indicates an alarm.
7
MACHINE FEATURES AND SPECIFICATIONS
Time, temperature, pressure, speed and stroke distance can be set digitally set for
easy and accurate operation.
Clogging indicator provided for oil filter ensure the cleanliness of hydraulic oil.
Hydraulic oil level and temperature sensor provided. Machine stop automatically
when oil level or temperature is out of limit.
Timer controlled automatic cycle operation.
SPECIFICATIONS
MODEL NUMBER & DESCRIPTION
T T I - XXX C
MACHINE MODEL
CLAMPING FORCE
MACHINE SERIES
8
INJECTION UNIT
Proportion, integral plus derivative (PID) control for barrel temperature improves
overall temperature accuracy.
Better length to diameter (L/D) ratio, from 17 to 22.5 enhances plasticizing and
mixing througout.
Up to 10 stages injection speed and holding pressure can be set.
Up to 5 stages metering speed and back pressure control.
Convenient swivelling mechanism for easier screw and barrel maintenance.
1.17.2.1 Specifications
Screw Diameter mm 85 90
Length/Diameter Ratio L/D 21 20
Theoretical Shot Volume cc 2,559 2,869
Shot Weight g 2,365 2,651
Shot Weight oz 83.4 93.5
Injection Rate cm3/sec 578 648
Injection Pressure Max. Kg/cm2 1,845 1,645
Plasticizing Capacity (PS) Kg/hr 331 373
Screw Stroke mm 451
Screw Rev. Speed rpm 170
Nozzle Contact Force ton 10.5
Nozzle Stroke mm 340
9
1.17.2.2 Injection Pressure Vs. Hydraulic Pressure Diagram
TTI - 160C
2500
? 45
2000
? 50
1500
Injection ? 55
Pressure
(kg/cm^2)
1000
500
0
0 20 40 60 80 100 120 140
Hydraulic Pressure (bar)
Fig 2-1
1.17.2.3 Shot Weight Vs. Screw Stroke Diagram
TTI - 160C
450
? 55
400
350 ? 50
300
? 45
Shot Weight 250
PS (g) 200
150
100
50
0
0 20 40 60 80 100 120 140 160 180 200
Screw Stroke (mm)
Fig. 2-2
10
1.17.2.4 Injection Unit Assembly

Refer to fig. 2-3
PART LIST
Part No. Part Name
1 Heating Barrel
2 Cylinder Tube
3 Cylinder Front Cap
4 Injection Cylinder
5 Piston
6 Piston Rod
7 Stud
8 Hopper
9 Cylinder Rear Cap
10 Sealand Housing
11 Limit Block
12 Adjusting Nut
13 Hydraulic Motor
14 Pivot
15 Pivot Base
16 Upper Sliding Base
17 Guide Bar Saddle
18 Sleeve
19 Injection Base
20 Guide Bar
21 Lower Sliding Base
22 Pivot Base Cylinder
23 Guide Beam
24 Guide Beam Cover
25 Barrel Base
26 Supporting Base
27 Barrel Support
11
Fig. 2-3
12
1.17.2.5 Swivel Of Injection Unit

When changing injection screw, distributor and screw washer, it is usually
required to turn the injection unit so that the injection nozzle can point outward
for convenient maintenance. To facilitate this the machine is designed with a pivot
cylinder. The mechanism is shown in fig. 2-4 .
Fig. 2-4
13
Follow the procedures below for the injection unit swivel.
Move injection unit to its end position.
Press down the emergency stop button to stop the hydraulic motor operation.
Loosen the connection between piston rod flange and fixed platen.
Unscrew the four screws connecting the injection unit base and machine frame.
Inspect the pivot to make sure it is installed properly.
Open the injection unit's guard door to its end position.
Release the emergency stop button and start the hydraulic motor.
Use one hand to hold down the pressure button and use the other hand to operate
the directional control valve. Turn the injection unit until it reaches the maximum
angle. After maintenance, reverse the above procedures. When fastening the
screws, make sure the injection unit is in correct position. Use centre point of the
position hole in the fixed platen as reference, and use a compass to check the
accuracy. After aligning the centre point of the heating barrel, tighten up the
screws uniformly.
14
1.17.2.6 Heating Barrel Assembly

refer to fig. 2-5
PART LIST
PART NO. PART NAME
1 Nozzle
2 End Cap
3 Distributer
4 Collar
5 Screw Washer
6 Injection Screw
7 Heating Barrel
8 Key
9 Split Ring
10 Flange
11 Split Ring
15
11
10
9
8
7
6
5
Left Hand Thread

4
3
2
1
Fig. 2-5
16
1.17.2.7 Hopper
The capacity of the hopper with various machine can be found on the table below. The
plastic resin content can be found through the hopper window. When the hopper
position and slide the chute gate to the opening position, Therr is a spring under the
chute gate for preventing position shifting during machine operating. The tightness of
the spring can be adjusted by turning the lock nut.
Hopper
Resin Release Window

Handle Plate
Lock Nut Chute Gate
Open Close
Clamping Level
Model Volume Weight PS
(dm3) (kg)
Release Opening
TTI-3C 41 39
TTI-8C 58 55
TTI-12C 58 55
TTI-17C 42 45
TTI-20C 72 68
TTI-28C 90 85
Fig. 2-6
To remove the remaining plastic resin from the hopper, close the chute gate and release
the clamping lever. Pull the handle plate to move the hopper th the end. Prepare a bag
under the release opening. Open the chute gate to release the plastic resin.
CLAMPING UNIT
17
The clamping system uses a computer optimised 5-point vertical toggle

mechanism which can provide long opening stroke.
Simultaneous mold opening and ejection function is provided to reduce the cycle
time.
Electrical, hydraulic and mechanical interlock system for greater safety.
4-stages clamping pressure and speed control provides extra smooth clamping.
Turcite coated bearing used in supporting moving platen reduces wear of

frequent clamping motion.
Mold rebound counter provision.
Computerised finite element analysis (FEA) is utilised in the design of platens

and structure. Hence distortion of platen is minimised for enhanced dimensional
accuracy of products.
Versatile, fast and accurate auto mold height adjustment cater for different mold
heights and stepless clamping force control.
Lubrication of clamp toggles is automatically controlled with reference to the

elapsed cycles.
1.17.2.8 Specifications
Clamping Forces ton 200
Clamping Stroke (Adjustable) mm 295-525
Max. Mould Thickness Range mm 200-550
Max. Daylight mm 1,075
Distance Between Tie Bar mm 480x480
Ejector Force ton 7.3
Ejector Stroke mm 180
No. Of Ejector Pins unit 5
18
1.17.2.9 Clamping Force Vs. Hydraulic Pressure Diagram
TTI - 200C
200
180
160
140
120
Clamping
Force 100
(ton)
80
60
40
20
0
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140
Hydraulic Pressure (bar)
Fig. 2-7
19
1.17.2.10Clamping Unit Assembly

refer to fig. 2-8
PART LIST
Part No. Part Name
1 Mold Position Unit
2 Clamping Cylinder Tube
3 Nut Clamp
4 Adjusting Nut
5 Sun Gear
6 Stationary Platen
7 Linkpin
8 Rear Link
9 Link Pin Clamp
10 Front Link
11 Ejector Cylinder Tube
12 Safety Rod Mount
13 Safety Rod
14 Apron Mount
15 Safety Rod Cover
16 Fixed Platen
17 Tie Bar
18 Movable Platen
19 Guide Bar
20 Sliding Block
21 Pin
22 Movable Platen Link
23 Linkpin Clamp
24 Linkpin
25 Sub-Link
26 Pulling Plate
27 Cross-Head Link
20
Fig. 2-8
21
1.17.2.11Mold Platen Dimensions

The standard machine use T-slot platens. The dimensions of T-slot and location of
ejector holes are designed according to the European standard EUROMAP
(EUROMAP-1 is standard in C-series machine). If the user has special request, the
platen position holes and ejector holes can be specially designed. There are 4 other
choices for selection: EUROMAP2, EUROMAP3, JIS and SPI standard. For detailed
information, contact the local supplier. Fig. 2-9 is the layout drawing of the mold platen
that is ordered with the machine. T-slots screws come with the standard machine. If
they are lost or damaged, contact to the local supplier or directly to the manufacturer.
The user can also make the screw according to fig. 2-10.
Fig. 2-9 EUROMAP-1
TTI-3C TTI-8C TTI-12 TTI-17 TTI-20 TTI-28

C C C C
A 595 660 685 750 890 965
B 400 410 445 480 580 635
C - - - - 210 210
D - - - - - 50.8
E - - - - - 203.2
F 125 125 125 160 160 160
G 140 155 170 190 210 230
H 595 624 718 750 890 965
a 28 28 28 28 38 38
b 12 12 12 12 16 16
c 18 18 18 18 22 22
d 30 30 30 34 36 36
e - - - - 52 52
f 125 125 125 160 160 160
22
30 ?
1.5X45 ?
M20
20
58
R1
25
11.8 54
44
16 200
For TTI-260C, TTI-320C
30 ?
1.5X45 ?
M16
M16
38
R0.6
25
9 52
28
12 120
Technical Requirment
T-slot Screw Heat Treatment: Hardness HRc33~40
Material : 45 (0.45% carbon) Other 12.5
(Carbon Steel) Blacking
For TTI-90C, TTI-120C, TTI-160C, TTI-200C
Fig. 2-10
23
1.17.2.12Mold Open Positioning Unit

This position unit is used to reduce the position shifting during mold opening so that
every mold open can stop at the required position. If robot arm is used to pick the
products, the mold is required to stop at the same open position. This unit can provide
the accuracy. Mold open positioning unit is shown figure 2-11.
Follow the procedures below for adjustment:
Release handle 1 by turning it to direction A.
To reduce the mold opening distance, turn handle 1 & 2 together towards
direction B, the pointer will move forward. Sop turning when the required distance
is reach. To increase the opening distance, turn handle 1 & 2 together towards
direction A. The pointer will move backward. When the required distance is
reached, turn half more circle forward to compensate for the backlash.
After adjustment, hold handle 2 and tighten handle 1 by turning it towards

direction B.
If accuracy is not required, adjust the pointer to the end. Everything will operate
as usual. Oil release hole shall be blocked by pipe plug. When oil accumulates
inside the unit, unscrew the pipe plug to release the oil.
Fig. 2-11
24
1.17.2.13Sliding Block
To reduce the stress of the tie bars, the movable platen has an adjustable sliding shoes,
shown in the figure 2-12. The sliding shoes are used to support the weight of the mold
and movable platen. The sliding shoes slide smoothly along the track 4 which is fixed
to the machine frame. During every 1000 hrs. of operation, check whether there is a gap
between the sliding shoes and the track. If there is a gap, follow the procedure below to
adjust it.
Use a wrench to loose the lock nut 2
Adjust the bolt 1.
Tight up the lock nut after adjustment.
Note: The sliding shoes shall be adjusted before mold installation. The three bolts on
both side must be adjusted with uniform forces.
Abrasive resistant rubber is attached to the bottom of sliding block 3. It will be

lubricated automatically by the central lubrication control system. To prevent damage
of the abrasive resist rubber, the cleanliness of the track is very important.
Fig. 2-12
25
ELECTRICAL CONTROL SYSTEM
The electrical system of the machine are controlled by a microcomputer, and A.C.
200 - 220 volts/50 Hertz. Heaters are directly actuated by A.C. 200 - 220 volts.
The electrical power for hydraulic system is D.C. 24 volts. If the user has special
request in the control system power supply, specify when ordering.
1.17.2.14Limit Switch Function And Location (fig. 2-13)

LS1 on each side of guard door, clamp only when door is close.
LS2 when guard door is open, clamping motion cannot start even LS1 is
manually activated.
LS3 mold height adjustment, front limit.
LS4 mold height adjustment, rear limit.
LS5 injection stop when injection guard door open.
LS6 all motion stop when injection unit turn.
26
Fig. 2-13
27
1.17.2.15Operation Cycle Diagram
SAFETY DOOR CLOSE
MOLD CLOSE EJECTOR BACKWARD
LOW PRESSURE CLAMP EJECTOR FORWARD
HIGH PRESSURE CLAMP MOLD OPENING STOP
CLAMP STOP MOLD OPEN
CARRIAGE FORWARD CARRIAGE STOP
CARRIAGE STOP CARRIAGE BACKWARD
INJECTION START DECOMPRESSION
PRESSURE HOLDING PLASTICIZATION
28
HYDRAULIC SYSTEM
The hydraulic system provides the main driving force to the machine. Totally five
proportional valves are used in the system to provide accurate and responsive control
of position, velocity and pressure. Two fixed volume pumps are used to increase the
injection speed and to save energy.
1.17.2.16Hydraulic Oil
The viscosity index of hydraulic oil used should be above 90, at 40癈 the viscosity
should be between 32 - 48 cSt. Hydraulic oil temperature is controlled by an oil
temperature regulator. Thus the hydraulic system is stable even after long operating
Coil number
Motion of machine 1 2 3 4 5 6 7 8 9 1 1 1 1 1 1 1
0 1 2 3 4 5 6
A High Speed Clamping * * + +
B Low Pressure Clamping * * + +
C High Pressure Clamping * * +
D Clamping Stop
E Carriage forward * * +
F Injection # + * * + +
G Plastication # + * * * +
H Decompression # + * * +
I Carriage Backward * *
J Low Speed, High * * +
Pressure Mold Opening
K High Speed, High * * +
L Low Speed, High * * +
M Mold Open Stop
N Ejector Forward * * +
time.
1.17.2.17Working Cycle Of Hydraulic System (Double Pump)

Remarks:
(a) Coils number 4, 5, 6 are proportional coils
(b) Coils marked with " * " are the motions that the proportional coil require
maximum control current.
(c) Coils marked with "+" are ordinary valves.
29
1.17.2.18Manifolds
The machine has 3 manifolds, their locations are shown in fig. 2-15A.And fig. 2-15B.
For TTI-90C, TTI-120C, TTI-160C, TTI-200C, refer to fig. 2-15A.
Fig. 2-15A
TTI-260C and TTI-320C, refer to fig. 2-15B
1 3 2
Mot or
Clamping Unit Inj ect ion Unit
Fig. 2-15B
30
1.17.2.19Hydraulic Valves And Hydraulic Circuit Diagrams

The following table listed all the hydraulic valves used in the machine. For the locations
and hydraulic circuit diagram, refer to figures 2-15, 2-16, 2-17 and 2-18.
H1 Directional valve, ejector motion control

H3 Cartridge valve, quick clamping control
H4 Cartridge valve, hydraulic interlock control
H5 Directional valve, mold clamping and opening
control
H6 Directional valve, core motion control
H7 Directional valve, core motion control
H8 Proportional pressure valve, large pump pressure
control
H9 Cartridge valve, whole pump pressure control
H10 Proportional flow valve, large pump flow control
H11 Proportional flow valve, whole pump flow control
H12 Cartridge valve, pumps connection control
H13 Directional valve, injection and decompression
control
H14 Proportional pressure valve, back pressure control
H15 Directional valve, plasticizing control
H16 Directional valve, injection carriage movement
control
H17 Check valve, carriage control
H18 Check valve, quick clamping
H19 Direct operated pressure relief valve
31
Fig. 2-16A - Hydraulic circuit diagram for TTI-500E and up
32
Fig. 2-16B - Hydraulic circuit diagram for TTI-160C and TTI-200C
33
Fig. 2-16C - Hydraulic circuit diagram for TTI-260C and TTI-320C
34
Fig. 2-17A - Hydraulic valves for TTI-90C, TTI-120C, TTI-160C and TTI-200C
Location No. 1
35
Fig. 2-17B - Hydraulic valves for TTI-90C, TTI-120C, TTI-160C and TTI-200C
Location no. 2
36
Fig. 2-17C - Hydraulic valves for TTI-90C, TTI-120C, TTI-160C and TTI-200C
Location no. 3
37
Fig. 2-18A - Hydraulic valves for TTI-260C and TTI-320C
Location no. 1
38
Fig. 2-18B - Hydraulic valves for TTI-260C and TTI-320C
Location no. 2
39
Fig. 2-18C - Hydraulic valves for TTI-260C and TTI-320C
Location no. 3
40
1.17.2.20Hydraulic Oil Filter

To ensure the cleanliness of hydraulic oil of the hydraulic system, an oil filter is
installed at the inlet of the oil pump. The assembly is indicated in fig. 2-19.
When the machine is running, the control system checks the condition of the oil filter. If
the filter element is clogged and the filter cannot function properly, pressure controller
1 will send a signal to control system to stop the machine. Check the condition of the oil
filter periodically, clean the filter element if necessary.
Filter element cleaning procedures:
Turn handle 6 until spring 10 is fully released.
Unscrew the six bolts 15 and remove the front cover.
Clean the filter element 13 in separate tank with cleaning fluid, use a soft brush if
necessary. Use compressed air to dry.
Note: There is a limit switch 14 at the top cover. The machine cannot operate when the
cover is removed. Check the O-ring 7,8,9 condition during assembly, and replace if it is
damaged. After the top cover is assembled, remember to tighten the handle 6.
15
Fig. 2-19
41
1.17.2.21Oil Level And Temperature Control

This is a oil level gauge at the front side of oil tank for viewing the level of the oil
content directly. At the top of the oil tank, there is an oil level indicator and a
temperature indicator for indicating the oil level and temperature automatically. The
optimum operation temperature for hydraulic oil is 30癈 - 50癈. The oil temperature is
controlled by oil cooler. There is a temperature sensor at the cooling water inlet. The
sensor detects the temperature and adjust the flow rate of cooling water automatically.
The higher the temperature, the faster the flow rate. Through this close loop control
can make sure the hydraulic oil is in normal operation condition if cool water supply is
stopped or temperature sensor is malfunction, the oil temperature will be out of
control. When the oil temperature is over 50癈, oil pump will stop automatically to
protect the hydraulic system. At the same time if the oil level is below its lower limit,
the oil pump will also stop. Therefore, it is necessary to check the oil level frequently. If
oil level is too low, open the cap at the top of the tank to refill, remember that the
refilled oil must be the same kind of the oil inside the tank.
1.17.2.22Air Filter
An air filter is installed on the top of oil tank (fig. 2-20). Air passing in or out of the oil
tank are cleaned by the air filter. When oil level inside the oil tank is low, remove the oil
cap to refill. In highly contaminated environment, the filter element will be easily
clogged. It is recommended to check the filter element monthly.
Fig.2-20
42
1.17.2.23Back Oil Filter

To prevent the impurities the piping from entering the oil tank, a filter is installed at the
main oil return inlet, as shown in fig.2-21. Clogging of the filter element by
contaminants will increase the back pressure, or cause malfunctioning of the hydraulic
system. To maintain the back oil filter in good operating condition. it is very important
to check te filter periodcally.
The filter used in the machine is the disposable type filter element for filtering and has
equipped a electro-photo clogging sensor. When the filter element is clogged, alarm
signal will be given and it is time to replace the filter element.
Changing the filter element can follow the procedures below:
Release the screws fixing the top cover
Remove the cover and take out the filter element and housing
Replace a new 20 um thick paper filter
Note :Before replacing the filter element, check the O-ring condition, replace if it is
damaged.
43
SAFETY EQUIPMENT
1.17.2.24Guard Door
For safety purpose, the clamping unit has a completely enclosed shielding structure.
When using robot arm for picking, the protect shielding above the movable platen can
be removed. At the end of clamping unit are fixed protect shielding which is connected
to the top protect shielding. At the front side are guard doors, which is used for picking
the mold during manual operation. At the front end of injection unit there is protection
shielding. On the right side are fixed shielding. On the left side are movable guard
door. When the machine is running, all the guard doors must be closed. To ensure that,
all the movable doors has been installed with limit switches. Therefore the machine
cannot operate when the doors are not completely closed.
1.17.2.25Mechanical Interlocks (fig. 2-22)

When the front guard door is closed, the roller of safety board is pressed down, causing
the board to rotate and unblock the mechanical drop bar. When the door is opened,
the safety board will return back to position by its weight and block the drop bar.
During mold closing, the safety board blocks the drop bar movement and the mold
cannot close completely. Therefore, each time when the mold is changed, it is required
to adjust the position of drop bar. The gap between the tip of the drop bar and the
safety board shall be 5 -10 mm. Make sure that during mold opening, the drop bar can
retract out of the safety board.
Movable Platen Stationary
Platen
5~10mm
Fig. 2-22
44
1.17.2.26Hydraulic Interlocks
The clamping unit has been installed with limit switch and mechanical interlocks on
both side of movable guide door. Also it has equipped with hydraulic interlocks for the
third protection. Refer to fig. 2-23
When the safety door is opened, the oscillating level presses down the direction valve
and stop the oil supply to the hydraulic valve, so that the clamping motion stop
immediately. The unit has an electrical limit switch connected with direction valve for
safety purpose.
Fig. 2-23
45
1.17.2.27Safety Precautions
The safety equipment used in this machine is used to prevent personal injuries and
machine damage. Operators must strictly follow the instructions below when
operating the machine :
Do not start the machine until the specification & operation procedures is
familiar.
Check all the safety equipment before operating the machine.
Do not operate the machine when the protect shielding is removed or safety
device is malfunction.
Do not change or remove any safety device.
When the machine is operating, do not touch the moving mechanism.
Make sure no obstacles get between the machines.
No more than one person is allowed to operate one machine at the same time
except mounting mold.
Periodically inspect the limit switches of the safety doors and hydraulic safety
unit.
46
COOLING SYSTEM
1.17.2.28Flow Rate Regulator (fig. 2-24)

The cooling water circulation system in the machine is designed to cool the mold and
heating barrel. The flow rate regulator is used to control the amount of cooling water
flow and to check the water temperature passing through the regulator. Hose 1, 2, 3, 4
has already been connected for mold temperature control, and hose 5 is used for the
cooling of the heating barrel.
Fig. 2-24
47
1.17.2.29Oil Cooler
When the temperature of hydraulic oil is higher than the preset temperature, cool
water will be used to cool the hot hydraulic oil which passes through the cooling unit.
There is a temperature sensor at the water inlet as shown in fig.2-26. Adjust the
temperature controller to the desired temperature, usually 40 癈 . Cooling will start
when temperature is above 40癈.
Fig. 2-26
48
mEMORY CARD
Process parameters, mold settings can be stored in memory card. Data can be
transferred to other machine via the use of memory card.
PCMCIA V2.0 IC memory card are used. This card is more reliable than other
storage media as no moving parts are involved.
Memory card is accessed in pages of 32K byte. 18 sets of molding parameters

can be hold in every 32K byte.
Automatic detection of memory card inserted.
Up to 1M byte memory card is supported. (32 pages or 576 sets of parameters)
POWER OUTPUT
Electrical Power (volts) Single Phase AC 220 ? 10 % or Local STD. ? 10 %
Three Phase AC 380 ? 10 % or Local STD. ? 10 %
Control Power DC 24 volts
Electric Motor Power hp 40

kW 30
Electric Motor Rev. Speed RPM 960
Hydraulic Pump Capacity US gal/min 47.5
Liter/min 180
Electric Heater Rate kW 18.45
Oil Tank Capacity US gal 93
Liter 360
49
MACHINE DIMENSIONS
A B C D E F G H I
TTI-90 1,690 1,240 4,560 5,170 5,630 790 1,955 160 1,100
C
TTI-12 1,720 1,250 4,844 5,890 6,035 790 2,050 210 1,100
0C
TTI-16 1,715 1,300 5,177 5,980 6,577 790 2,110 300 1,160
0C
Fig. 2-27
50
CONTROL SYSTEM - CIMTROL
The standard Welltec CIMtrol control system provides the user with sophisticated
control capabilities and ensure cycle to cycle repeatability and machine efficiency. Fast
and accurate machine setup, process monitoring, graphic display and hard copy
capabilities are just a few of the standard features of the system that help the molder to
optimise product quality, consistency, and productivity and thus overall profitability.
Setup of all functions can be accomplished via the operator panel, which is
conveniently located at the main electrical cabinet. This operator panel features a 10"
color monitor with 3-dimensional window graphic and membrane type keyboard. The
80 character by 25 line (640 x 480 pixel) display is easy for reading characters and
graphics. The menu displays, on screen prompts and message, allow the user to enter
precise digital settings of all parameters.
Up to 18 molds data can be stored in internal memory to allow fast, repeatable setup.
Control parameters for additional molds can be stored in memory cards.
The CIMtrol control utilises Welltec customised software and modular designed
multiple microprocessor control system configured with: a programmable controller, a
temperature control module, a process control module, various digital input and
output modules, and the operator control panel with built-in operator interface board.
The modular design provides fast response and is easily expandable for greater
flexibility.
51
Section 3 MACHINE INSTALLATION AND PREPARATION
52MACHINE INSTALLATION AND PREPARATION

Lifting
Use a crane or hoist to lift the machine. To avoid scratching the tie bars, protect
it with soft materials. The machine can be lifted as shown in Fig. 3-1
Fig. 3-1
90C 120C 160C 200C 260C 320C
A0 <90 <90 <90 <90 <90 <90
Weight (ton) 5.5 6.3 7.6 8.7 12.2 13.5
Leveling
The machine shall be laid on solid horizontal ground. Minor adjustment can be
done by using anchor bolt or mounting pads. Fig. 3-2. shows the installation
location. To ensure proper leveling, a precision spirit level shall be placed on the
52
MACHINE INSTALLATION AND PREPARATION
tie bars for checking Fig. 3-3.
Fig. 3-2
Inspection
After installation, check for any physical damages in its hydraulic, mechanical and
electrical systems during transportation. If any significant damages is found,
consult the local supplier or the manufacturer immediately.
53
Oil Filling
The oil tank shall be thoroughly cleaned before oil filling. Remove all scum and
impurities floating on the surface. Fill the oil according to the specifications.
Power supply Connections
Connect a 3-phase/4 line power supply to the terminal block at the bottom right
corner of the electric cabinet (Fig. 3-2). There are 3 live and 1 ground lines, the
black one in cabinet is for ground connection. To screen out electromagnetic
wave interference, there shall be another blue earth wire of less than 10 ohm
resistance to be connected to the metal body of the cabinet.
Piping
Cool water is used for cooling the hydraulic oil, the mold and the water jacket.
The flow rate shall be adjusted according to the water temperature.
Water pressure : 2 - 6 kg/cm2
Pipe Diameter : 1" both for mold temperature controller and hydraulic cooler.
Positions : Two groups of inlet/outlet are at the back of the machine, shown in
Fig. 3-3
Connections : It makes no difference whether the two ports for oil cooler are
used as inlet or outlet. However, for the mold temperature controller ports, the
direction of flow must follow the label.
Mold temperature controller bridge plate : There are five groups. One of which,
marked '5', is connected for mold temperature water circulation. moving
Their location is shown in Fig. 3-3 and the diameter of the copper parts
pipes on the bridge plate is 12 mm (or 1/2"). of the
Cleaning of Machine clampi
After the power supply and cooling water supply have been ng unit
properly connected, the machine should be cleaned thoroughly, with
especially the tie bars, cylinder piston rods and platen surfaces. Fig. 3-3 this
Kerosene or diesel oil shall be used but never alcohol or thinners. system
Lubricating .
The clamping unit of the machine is equipped with an automatic Before
central lubricating system. Lubricating oil is supplied to the startin
g the machine, the lubricating pump must be filled with lubricating oil. The
lubricating oil is discharged automatically at preset intervals. The lubricating oil
pumping machine has been preset to 30 cc oil at 50 - 60 seconds interval.
If lubricating oil is found to be too much or less, adjust the interval time above.
There is a container to collect used oil. If there are too many foreign particles
and water, the oil must be filtered and cleaned before it becomes reusable.
The lubricating oil pumping machine will send out an alarm when the oil level is
low. Refill when the buzzer sounds. In addition to the central automatic lubricating
system, there are nipples located at various moving parts. Fig. 3-5 shows their
locations and the suitable type of oil or grease.
54
55
56
Fig. 3-4
57
Fig.3-5
58
Section 4 SWITCH PANEL
switch Panel
Alarm lamp
Power on lamp Motor on lamp
Operation mode Injection and

switch
plasticizing switch
Clamping switch
Carriage forward
and backward
switch
Ejector switch Core group

switch
Mold height Core in and

adjustment switch core out switch
Mold height
mode button Multiple ejection
switch
Decompression Air blast button
button
Setup mode button
Photo-sensor button
Pump start button Emergency

stop button
Emergency Stops - Front & rear
Front and rear emergency stops are provided for turning off the pump motor. Just
press any one of them can be effective.
59
SWITCH PANEL
Pump Start
For starting the pump motor. Press once to start the first motor ( Left hand side first
button ). Press the Button in the middle to start the second one.
Note: Before starting the pump, the following conditions should be checked.
The power for the controller shall be "On".
Front and rear emergency button has released.
Suction filter Flange have been closed.
There is sufficient hydraulic oil in the oil tank.
The injection or metering switch must in the middle position
Mode selector in manual position.
Operation modes Selection
1.1.12 Manual Mode
Manual mode is obtained by rotating the switch to the middle. In this mode, all
manual motions can be used with the corresponding switch or button.
60
SWITCH PANEL
1.1.13 Setup Mode
The setup mode is obtained by rotating the switch to manual mode and by pressing
the mold setup key. The setup mode is used for slow speed operation. The pressure
and speed for clamping, carriage move and ejector motion can be input from the
"service" screen ( section 6.26).
1.1.14 Semi-Automatic Mode
The semi-automatic mode is obtained by rotating the switch to the left. In this mode
the machine will go through one complete machine cycle. To trigger the next cycle
the front operator gate shall be opened and then closed.
1.1.15 Automatic Mode
The automatic mode is obtained by rotating the switch to the right. The machine will
cycle continuously. The previous cycle will be completed when the pause timer run
out.
1.1.16 Photo Sensor Cycle (Optional)
For use in automatic mode. If the button is pressed, the machine will cycle
continuously provided at the end of a machine cycle the photo sensor is triggered by,
for example, a falling product.
61
SWITCH PANEL
1.1.17 Mold Height Adjustment Mode
Mold height adjustment mode is obtained by pressing the above first two buttons to
"on" and rotate the above last button to as shown.
Clamp opening and closing switch
For use in manual mode or setup mode.

The front and rear door guard must be closed.
Rotate the switch to the right will close the mold. Mold closing will be stopped if the
mold close stopped position is reached, or the guard door is opened suddenly, or
even when the switch is released from the right.
Rotate the switch to the left will open the mold. Mold opening will be stopped if the
mold open stopped position is reached, or the guard door is opened, or even when
the switch is released from the left.
Note: When robot is also used, the mold close and mold close interlock signal from
robot interface plug should be "ON" for mold closing. The mold open signal from
robot interface plug should be "ON" for mold opening. If robot is not installed, plug in
the original short circuit plug.
Injection and plasticizing Switch
For use in manual or setup mode.

The purge guard must be close, front and rear guard door must be closed, and
barrel/nozzle temperature must be within barrel temperature setpoint and its
negative tolerance.
Rotate the switch to the left will inject material from the barrel during set-up or
purging operation.
Rotate the switch to the right will rotate the plasticizing screw for metering.
Ejector Forward and Backward Switch
For use in manual or setup mode

For ejector backward check that the movable platen must passed the ejector start
position. The ejector signal from robot interface plug should be "on".
Rotate the switch to the left will retract the ejector plate.
The ejector will stop when the ejector backward stopped position is reached or the
selector is released.
62
SWITCH PANEL
For ejector forward the mold must passed over the ejector start position. Core 1 out
and core 2 out limit switch must be activated. Also ejector signal from robot interface
plug should be ON.
Rotate the switch to the right will move the ejector plate forward for part ejection.
The ejector will stop when the ejector forward stop position has been reached or the
selector is released.
Note: If Robot is not installed with machine, plug in original short circuit plug for
proper ejection function.
Carriage Forward and Backward Switch

The purge guard must be closed.
Rotate the switch to the left will move the carriage forward.
The carriage will stop when the carriage forward stop position has been reached or if
the selector is released.
Rotate the switch to the right will move the carriage backward.
The carriage will stop when the carriage backward stop position has been reached or
the selector is released.
Mold height Adjustment switch
For use in mold height adjustment mode
Rotate the switch to the left will increase the mold height allowed. Rotate the switch
to the right will decrease the mold height allowed.
The movement will stop when the mold height over travel limit switch is actuated.
Note: All other manual motions are disabled in this mode.
Core setting switch
Two cores control are available for standard machines.
Check that the ejector has been retracted to backward stop position.
Select core 1 or core 2 to set.
Rotate the switch in anti-clockwise direction will set the core.
Note: Correspond core operation mode can be selected in the Core setup screen.
63
SWITCH PANEL
Core pulling switch

Check that the ejector has been retracted to backward stop position.
Rotate the switch in clockwise direction will pull the core.
Note: Corresponding core operation mode can be selected in the Core setup screen.
Decompression button
Decompression is to pull the screw back; to aid in filling the barrel for the first shot;
decompressing the plastic melt; or to separate the screw drive from the screw.
For use in manual mode or setup mode.
Check that the purge guard is closed.
Press the decompression switch to decompress.
Decompression stops after decompression stop position is reached.
Multiple Ejection button
Multiple ejection is for moving the ejection platen forward and backward continuously
as long as the multiple ejection button is pressed.
Use the manual or setup mode.
Check that the core 1 out limit and core 2 out limit is activated.
Press the multiple ejection key for multiple ejection.
AIR ON
The air on button
Air on function is to activate the air blast as long as the key is pressed.
Use manual or setup mode.
Press the air on button for air on function.
64
Section 5 MEMBRANE KEYBOARD AND COLOR MONITOR
Membrane keyboard and Color monitor

color MONITOr
A 10" color monitor is used for data and settings display. A total of 40 screens
are provided for comprehensive machine control. All screens can be accessed
within two key strokes.
Membrane keyboard
A membrane keyboard is provided for controlling the display and the large
number of machine functions. It can be divided into the following groups.
Hard keys
Soft keys
Cursor keys
Numerical keypad
Special functions keys
67
OPERATOR CONTROL PANEL
Membrane keyboard and color
68
Hard Keys
Twenty keys are provided for accessing the various screens. With proper access
level, the user can enter or change the machine settings on selected screen.
- Main screen key
Invokes "main" screen. In this screen, the operator can enter and/or modify his
own access code. He also can clear the access level previous entry. If the
operator have an access code of access level 4, he can also modify the access
code and access level of individual operator here.
- Clamping screen Key
Invokes "clamping" screen. Allow parameters set up for clamp movement, ejector
movement and air blast function.
- Core screen key
Invokes "side core" screen. Allow parameters set up for core sequence.
- Mold setup key
Invokes "mold setup" screen. Allow setting up auto purge cycle and auto mold
height adjustment cycle.
- Time key
Invokes "timer" screen. Allow parameters set up for delay and monitoring timer
for automatic cycle and motor stop criteria.
- Injection Key
Invokes "injection" screen. Allow parameters set up for injection speed profile,
injection-holding switch over criteria, delay and monitoring timer for injection
process, holding pressure profile and cushion length monitoring.
69
- Metering Key
Invokes "metering" screen. Allows setting up the metering back pressure profile,
metering rotating speed and delay and monitoring timer for metering process.
- Graphic key
Invokes "graphic" screen. Displays the preset and the actual curve for injection
velocity profile, holding pressure profile and metering back pressure profile.
- Temperature Key
Invokes "temperature" screen. Allows setting up the temperature zones
parameters, +tol and -tol for temperature zones, reduce temperatures and
operating mode of individual heater zone.
- Monitoring Key
Invokes "monitoring" screen. Monitors 6 important parameters of the last 11
automatic cycles for the operating machine.
- Production Key
Invokes "production" screen. Allows setting up the production process parameters
for a particular mold., e.g. no. of batch required, no. of product per batch and the
total parts produced by machine.
- Daily Maintenance Key
Invokes "daily maintenance" screen. Allows setting up the lubrication interval of
the toggle pin.
- Storage Key
Invokes "memory card" screen. Allows storage and loading of mold settings to
and from the memory card.
70
- Diagnostic key
Invokes "input diagnostic" screen. Monitors the status of individual input point.
Together with softkey, also monitors status of digital output and analog
input/output status.
SOFT key
Six keys allow the operator to access the functions associate with the current
control screen. The functions are displayed on the right most part of the current
control screen and they can be selected by pressing the soft key adjacent to the
function displayed on the right part of the screen.
Cursor Keys
Four directional keys and a home arrow are provided for cursor
movement. The cursor in a field is present by a cyan field instead of the normal
gray field. When a new screen is invoked the cursor lies in the first field in the
upper left corner (home position) of the control screen. Pressing a directional key
will move the cursor in the direction as indicated by the key itself. When the
cursor reaches the far end position, pressing the cursor will move the cursor to
the opposite end. Pressing the home arrow will move the cursor to the first field
in the upper left corner of the screen. The cursor will be locked if the parameter
in the cursor position is changed. Press either the or to unlock the cursor.
Numeric Keypad
Fourteen keys are provided for numeric entry of the machine settings and
selection of machine options. They are the numeral keys "0" to "9", minus key "-",
decimal key "." which is also the "selection" key, cancel key and the enter key
Numeric entry of the machine settings :-

Select the desired screen using hard key or soft key.
Move the cursor to the designated field using the cursor keypad.
Enter the required value using the numeral keys, minus key and the decimal key.
Finally press once to finish. If a wrong value is entered, reenter the correct
value or press the cancel key before pressing the enter key to correct the value.
Selection of machine options :-
Select the desired screen using hard key or soft key.
Move the cursor to the designated field using the cursor keypad.
Press the selection key . once to display the machine options.
Press or to select the required option.
Finally press to finish.
Note: If there are less than 3 options, the options will be displayed on the right
most part of the monitor adjacent to the soft keys. Selection is also possible with
soft keys then.
71
Selection window Selection
72
Special function Key and mode selection key

- Help key
Invokes the on-line help window which is associated with the current field of the
current screen. Important information about the field will be given for machine
setting. The position and information displayed in the help window will be
changed according to the position of cursor. To turn off the help window press
again.
Help Window for Operation Mode
- Print screen key

For sending the current screen information to an external printer. The key can
only function if the machine is connected to a printer. Screen dumping will give
beep sound. The current screen will be locked on the monitor and no other
screens can be accessed until the beeper sound is off. For printer installation
information refer to OP set-up screen. The following printers can now be
supported:
HP laserjet series laser printer or compatible
Epson FX series 9 pin dot matrix printer or compatible
Epson LQ series 24 pin dot matrix printer or compatible
Cannon bubble jet series bubble jet printer
IBM proprinter XL24E series printer
and also their compatibles.
- Toggle key
This key can only be used when the cursor is in an selection field. Pressing this
key will toggle between the options associated with the current field.
Memory Card slot
For memory card insertion. Allow the storage of 18 sets of mold data per memory
card of 32K Byte of memory and 36 sets of mold data per memory card of 64K
Byte. Memory card is a solid state device without moving parts for off-line
storage of data.
"Card Inserted" LED
73
A LED for proper memory card insertion into the memory card slot.
Read/Write LED
A LED for indication of Memory Card Read/Write process in progress.
74
Section 6 CONTROL SCREENS
control screens
The CIMtrol monitor and membrane keyboard provide the user a media to
monitor and control the machine.
This section of the manual presents the user a general understanding of the
control screens, the minimum required access code levels, functional
descriptions, and general considerations. The descriptions of the screens are
designed to include various possible combinations of parameters. The
parameters on any particular machine will depends on the machine size and the
options supplied with the machine. Notes have been inserted within the text to
differentiate between optional and standard equipment.
75
CONTROL SCREENS
Main screen
ACCESS METHOD: Press
This screen displays the software level version, the current date and time, as
well as the active access level. The operator access code (password) can be
entered from this screen by pressing the "Access Code Entry" soft key. This
page will pop up automatically whenever the controller is reset or the power is
turned on.
Access code is used in CIMtrol for controlling the access of different control
screens and modification of the fields on the control screens. Only with an
access level higher than or equal to that required by a particular field can the
field be modified. Access level of each field is stated in the corresponding
session marked with "Access Level". When the machine is turned on, the access
level is reset to zero.
The controller can store 20 access codes with corresponding access levels.
Only the Operator Identity Number 1 can have the access level 4. Other 19
operators can have only up to access level 3. Maximum length of each access
code is 7 digits.
76
CONTROL SCREENS
Access Code Entry :
Press the "Access Code Entry" softkey, and access code entry window will be
displayed on the screen.
Use the numerical key pad to enter your accesscode, and press enter to
confirm when finished.
Access Code Modification :
Enter your password as in above section.
77
CONTROL SCREENS
Press the "Access Code Modification" softkey the access code modification
window will be displayed on screen.
If the access code level is 3 or below, only your own access code can be
modified.
Enter the desired access code with the numeric keypad. Press the "Confirm
Access Code Modification" softkey after finished.
Access Code Assignment (for access level 4 Only):
Enter your own access code as in section 5.1.1.
Press the "Access Code Modification" softkey. Access code modification

window will pop up on the screen.
Press the selection key . to pop up the selection window of individual access
code.
Press or to select the access code to change.
Press enter to confirm the selection.
Press once to move cursor to new code field.
Use numeric keypad to enter your desired new code. Press enter key to
confirm.
Press to move cursor to access level field.
78
CONTROL SCREENS
Use the toggle key to change access level, or use selection key to pop up
the selection window and change access level.
Press the "Confirm Access Code Modification" softkey to confirm your change.
79
CONTROL SCREENS
Clamping
6.2.1 6.2.4
6.2.2 6.2.5
6.2.3 6.2.6
6.2.7
6.2.8
6.2.9
6.2.10
6.2.11
6.2.12
The clamp related parameters for position, speed, pressure, and time are listed
on the clamping screen in order of occurrence as in a standard machine
sequence.
Pause Time (ACCESS LEVEL: 1)
For setting the pause time between automatic cycles.
The yellow field beside monitors the actual pause time passed.
Cooling Time (ACCESS LEVEL: 1)
For setting the duration for the molded product to cool in the mold before being
knocked out.
The yellow field beside monitors actual cooling time elapsed.
80
CONTROL SCREENS
Rebound count (ACCESS LEVEL: 1)
When the mold cannot lock within the close time setting, the mold will open,
eject, and try to lock again. The machine will retry this process at a preset
value. The rebound count is to set this value.
The yellow field beside monitors the actual rebound.
Closing time (ACCESS LEVEL: 1)
For setting the time limit for the clamp to travel from the mold opened position
to mold closed position. If the mold close process cannot finished within the
time limit the alarm will ring.
The yellow field beside monitors the actual closing time.
Opening time (ACCESS LEVEL: 2)
This setting limits the amount of time that the clamp travels from the mold
locked up position to mold fully open position. If the mold open process cannot
finished within the time limit, then an alarm will be given.
The yellow field beside monitors the actual time needed for mold opening
process
Cycle time (ACCESS LEVEL: 1)
This setting limits the amount of time for the whole cycle to finish. If the
automatic cycle cannot finish within this setting an alarm will be issued.
The yellow field beside monitors the actual cycle time.
Close Changeover positions for Speed and Pressure (ACCESS LEVEL:1)
Four positions are offered. Counting from the left; Close 1, Close 2, As for high
pressure mold close and mold close stopped position is set by two limit switch
located at the cress head of the toggle system. The setting is the distance from
zero position of the clamp scale.
Close 1 is the position where the starting clamping pressure and speed will
change to the second setting.
Close 2 is usually the position where the low pressure mold close starts.
Close 3 is usually the position where high pressure of clamp locking start. This
position should be set to the point where the mold halves just touch. ( For
81
CONTROL SCREENS
machine model >320 ton adjust by limit switch at toggle system. Key in value at
this field does not have any effect. )
Close stopped is the position of the mold where the clamp is fully locked up. (
For machine model >320 ton adjust by limit switch at toggle system. Key in
value at this field does not have any effect. )
Mold close pressure setup (ACCESS LEVEL: 1)
Counting from the left, P1, P2, P3 (low pressure mold close), P4 (lock up
pressure).
P1 and P2 pressures provide a smooth transition for the start up of mold

clamping.
P3 (low pressure mold close) is the safety pressure to protect the mold in case
the product is not ejected from the mold.
P4 (high pressure lock up) controls the pressure of the clamping cylinder during
lock up phase. On initial machine set-up this should be adjusted for maximum
(140bar). With proper mold height setting, maximum machine rated tonnage will
be developed. If conditions suggest a reduced clamp tonnage, this can easily be
done by reducing the mold locking pressure setting.
VELOCITY PRESSURE
V2 P4
P2
V3
V1 P1
V4
P3
Position Position
l 2o s e close2l3o s e c3losel o s e
closel1o s e 1cclose c l o s e 1close2 c l o s e c3lose
sto
s pt o p stop
mold Close Speeds (ACCESS LEVEL: 1)
Four speeds can be allowed in mold closing. From the left V1, V2, V3 and V4
can be set. Maximum speed setting is 100%.
V1 and V2 are for the smooth transition of mold from stationary to fast clamp
closing.
82
CONTROL SCREENS
V3 is the low speed mold close to provide a damping effect for the mold clamp
to slow down before two mold halves to touch.
VELOCITY PRESSURE
V4 is the Four
locking V3 positi
P1
speed for ons
mold lock P2 are
P3
up. V2 allow
ed.
Mold Open From
V4 P4
speed and the
V1
pressure right,
changeover Position Position they
positions open 4 open 3 open 2 open 1 open 4 open 3 open 2 open 1
are
(ACCESS Open
LEVEL:1) 1,
Open 2, Open 3 and Open stopped. The setting is the distance from zero of the
scale.
Open 1 is the position where the clamp change from mold open slow break
pressure P1 and speed V1 to mold open pressure P2 and speed V2.
Open 2 is the position when the clamp change from mold open speed V2 and
pressure P2 to mold open speed V3 and pressure P3.
Open 3 is the position where the clamp change from speed V3 and pressure P3
to mold open slow speed V4 and pressure P4.
Open stopped position is the position where the clamp is fully open. When mold
damage may result due to an over travel condition, consideration should be
given to installation and adjustment of the mechanical mold over travel stops
(optional).
Mold Open pressure (ACCESS LEVEL: 1)
Four pressure settings are allowed for mold opening. They are, from the right,
P1, P2, P3 and P4. Maximum allowed pressure is 140 bar.
P1 is the mold slow break pressure to control the pressure for the separation of
the two mold halves during clamp opening.
P2 and P3 control the pressure of clamp cylinder for fast mold opening.
P4 control the pressure of the clamp opening stop.
83
CONTROL SCREENS
mold Opening speed (ACCESS LEVEL: 1)
Four available speeds are, from the right, V1, V2, V3 and V4. Maximum speed is
100%.
V1 control the speed for the separation of the two mold halve.
V2 and V3 are for fast mold opening.
V4 is for slow mold opening stop.
84
CONTROL SCREENS
Ejector and air blast
ACCESS METHOD : Press
6.3.1 6.3.2
6.3.3
6.3.4 6.3.8
6.3.7
6.3.6
6.3.5
The control of ejector and air blast motion is on the same screen as the
clamping screen.
Ejector start position (ACCESS LEVEL: 1)
This is the position of the clamp during the mold opening where the ejection
start. The setting is the distance from the zero position of clamp scale. The
machine supports ejector forward during mold opening to reduce the cycle time.
( Note : for machine with only one pressure and speed proportional valve,
ejector can only start when mold platen pass over mold open stop position. )
Air start position (ACCESS LEVEL: 1)
This is the position of the clamp during the mold open where the air valve start
blasting. The setting is the distance from the absolute zero position of clamping
scale.
Ejector Backward stop position, pressure and speed (ACCESS LEVEL: 1)
This position is the stopped position for the retracting ejector. The pressure
and speed settings control the ejector retraction.
Ejector Forward Position, Speed And Pressure (ACCESS LEVEL: 1)
Two settings are provided for each position, speed and pressure control of the
ejector forward position.
85
CONTROL SCREENS
The first position is the changeover position for speed and pressure. The
second position is the stopped position for the forward moving ejector. The
setting is distance from the absolute zero position of the ejector scale. If rattle
ejector function is selected, the ejector will switchover from backward motion
to forward motion when the first position has been passed.
Two ejector forward speeds control the ejector forward speed.
Two ejector forward pressures in bar control the ejector forward pressure.
Ejector Dwell time (ACCESS LEVEL: 1)
Sets the time for the ejector to hold forward before retract during the ejection
sequence.
The yellow field below monitors the actual dwell time passed.
Ejector Count (ACCESS LEVEL: 1)
For setting the number of cycles for the ejector sequence.
The yellow field below monitors the actual ejection cycle completed.
Rattle (ACCESS LEVEL: 2)
For control the use of rattling ejector function.
The yellow fields below monitor the actual position, pressure and speed of the
ejector.
Air Blast on timer (Optional, ACCESS LEVEL: 1)
Sets the duration of the air blast in second.
The yellow field below monitors the actual air blast elapsed.
side core
86
CONTROL SCREENS
6.4.1
6.4.2
6.4.3
6.4.4
6.4.5
6.4.6
6.4.7
6.4.8
The core pull provides the operator with up to 30 combinations of core pull/set
sequences. Note that the core in/core out limit switch are supplied as an option.
Each core can separately operate in 5 different sequence:
87
CONTROL SCREENS
Core sequence A
1 Core in at mold fully open position
2 Mold close
3 Inject
4 Mold open to preset stopped position
5 Cores out
6 Continue to open clamp to fully open position
Core sequence B
1 Mold close
2 Core in at mold fully position
3 Inject
4 Core out at mold fully closed position
5 Mold open
6 Eject
Core sequence C
1 Core in at mold fully open position
2 Mold close
3 Inject
4 Mold open
5 Core out at mold fully open position
6 Eject
Core sequence D
1 Mold close during core in
2 Inject
3 Mold open during core out
4 Eject
Core sequence E
1 Mold close to preset position
2 Core in
3 Mold close
4 Inject
5 Mold open to preset position
6 Core out
7 Mold open
8 Eject
88
CONTROL SCREENS
Core Sequence (ACCESS LEVEL: 1)
This field is to select the desired core sequence for the mold. Following is a list
of all options provided.
No Selections No Selections
. .
1 No side core 17 core 1 sequence B, core 2
sequence D
2 core 1 sequence C, no core 2 18 core 1 sequence D, core 2
sequence C
3 core 1 sequence B, no core 2 19 core 1 sequence C, core 2
sequence B
4 core 1 sequence A, no core 2 20 core 1 sequence B, core 2
sequence A
5 core 1 sequence D, no core 2 21 core 1 sequence A, core 2
sequence D
6 core 1 sequence C, core 2 22 core 1 sequence E, no core 2
sequence C
7 core 1 sequence B, core 2 23 core 1 sequence E, core 2
sequence B sequence C
8 core 1 sequence A, core 2 24 core 1 sequence E, core 2
sequence A sequence B
9 core 1 sequence D, core 2 25 core 1 sequence E, core 2
sequence D sequence A
10 core 1 sequence B, core 2 26 core 1 sequence E, core 2
sequence C sequence D
11 core 1 sequence A, core 2 27 core 1 sequence C, core 2
sequence B sequence E
12 core 1 sequence D, core 2 28 core 1 sequence B, core 2
sequence A sequence E
13 core 1 sequence C, core 2 29 core 1 sequence A, core 2
sequence D sequence E
14 core 1 sequence A, core 2 30 core 1 sequence D, core 2
sequence C sequence E
15 core 1 sequence D, core 2 31 core 1 sequence E, core 2
sequence B sequence E
16 core 1 sequence C, core 2
sequence A
89
CONTROL SCREENS
Core In/out process usage (ACCESS LEVEL: 1)
If "Yes" is selected in this field, the according core in / out sequence is

activated during mold close / open process.
Core in/out termination method (timer/ position, ACCESS LEVEL: 1)
If timer is selected, the core in/out process will be terminated after a preset
period in core timer field. If limit switch is selected, the core in/out process will
be terminated after the corresponding limit switch is actuated.
Core pressure and speed (ACCESS LEVEL: 1)
The hydraulic pressure can be set in this field for controlling the core pull and
core set. The maximum pressure is 140 bar. The speed for core in/out can be
set in this field. Maximum speed is 100%.
The Core In/Out timer (ACCESS LEVEL: 1)
This field can be set to control the time limit for core in/out process when
"Timer" is selected as the core in/out termination method. If "Limit Switch" is
selected as the core in/out termination method then this field is immaterial.
Priority (ACCESS LEVEL: 1)
If the same sequence is selected for both cores, this field can determine which
core is activated before the other.
The Core Push Position (ACCESS LEVEL: 1)
If core sequence E is selected and "Yes" is selected for the core usage field,
this field can be used to set the stopped position of clamp for core in during the
mold close travel.
The Core Pull Position (ACCESS LEVEL: 1)
If core sequence A/E is selected and the "Yes" is selected for the core usage
field, this field can be used to set the position of clamp stop for core out during
mold open.
Note :
Core function is dependent on installation and operation of the "core fully in"
and the "core fully out" limit switches. These switches are installed in the mold
and supplied by the user. Welltec provides a limit switch input terminal (located
90
CONTROL SCREENS
at rear of the machine) and related hard wiring from the box to the controller
input point only.
91
CONTROL SCREENS
Barrel Temperature
6.5.1
6.5.2
6.5.3
6.5.4
6.5.5
6.5.6
6.5.7
6.5.8
6.5.9
6.5.10
6.5.11
The barrel temperature screen allows the operator to select various values and
functions for the temperature zones, the nozzle temperature, and the oil
temperature. The no. of temperature zones for different model is as follow:
Model No. of temperature zones

TTI-90C 4
TTI-120C 5
TTI-160C 5
TTI-200C 6
TTI-260C 6
TTI-320C 7
Operation Mode (ACCESS LEVEL: 1)
With the selection key, "Off", "On" , "Reduce" or "Heater Timer" modes can be
selected.
The "On" mode turns on all the heaters and heat to set values.
The "Reduce" mode also turns on all the heaters but keep the barrel at the
"Reduce" temperature.
The "Off" mode turns off all the heaters.
92
CONTROL SCREENS
For the heater timer mode, the status of the heating zones is controlled by time
schedule input in the "Heater Timer" screen.
The +TOL Alarm (ACCESS LEVEl: 1)
This set a tolerance alarm for the temperature zones. If the actual temperature
is above the designated temperature plus this tolerance, an alarm will be given.
For example, if the set temperature is as 2000C and the +TOL is set to 1, a high
temperature alarm will be given at 2100C. The maximum entry for +TOL is 255.
Range for + tol Bar graph (ACCESS LEVEL: 1)
This value sets the maximum range for the +Tol bar graph.
The Actual temperature
Displays the actual temperatures of the individual zones and the nozzle,
measured at the heaters.
The Set temperature (ACCESS LEVEL: 1)
For use in "On" mode. This row of fields control the desired temperature
settings for the temperature zones. When operating in the PID (closed loop)
control mode, the controller will maintain the temperature of the temperature
zones to these preset values.
Reduce set point (ACCESS LEVEL: 1)
For use in "Reduce" mode. This row control a lower set of temperatures. An
example of an application would be to reduce barrel temperature during
downtimes.
Range for - tol Bar graph (ACCESS LEVEL: 1)
This value set the maximum range for the -Tol bar graph.
The -TOL (ACCESS LEVEL: 1)
This set a tolerance alarm for the temperature zones. If the actual temperature
is lower than the designated temperature minus the tolerance, an alarm will be
given.
Note that when the actual temperature is lower than the set temperature by 50
degrees some machine functions will be inhibited, such as, screw rotation,
injection, pullback and the semi-automatic and automatic. Also alarm will be
given and an alarm message will be displayed.
93
CONTROL SCREENS
The Actual Duty (%)
This is the percentage of time that the heater zones is actually being heated.
This reading will be displayed when the temperature control mode has been
selected to operate in either PID or manual. During normal heating operation
this reading shall have a value of less than 100%. If the reading exceeds 100%
then the zones are not heating, and if a means of cooling the barrel and nozzle
was available, the controller would be in a cooling mode.
control mode (aCCESS LEVEL: 3)
This row of fields set the control mode of the temperature zone.
Manual mode:- Temperature control using open loop control. Temperature of

individual zones is maintained at the set values or reduce values.
PID mode:- Temperature control using close loop control. Temperature of
VELOCITY
V5
V3
V4
V1
V6 V2
V7
V8
V10 V9
Position VP9 VP8 VP7 VP6 VP5 VP4 VP3 VP2 VP1
individual zones is maintained at the set values or reduce values.
Off mode:- Individual zone can be switched off with this mode.
the Actual Oil Temperature
Monitor the actual oil temperature.
94
CONTROL SCREENS
Injection
6.6.1
6.6.3 6.6.2
6.6.4
6.6.7
6.6.5
6.6.6
6 . 6. 8
6.6.9
The "Injection Screen" allows up to 10 stages of injection velocities and

pressures .
No. of Injection stages (ACCESS LEVEL: 2)
For controlling the maximum number of injection and holding stages in the
profile according to the complexity of parts mold. The followings are the
options:
Options No. No. of injection No. of holding

stages stages
1 2 1
2 5 1
3 5 5
4 10 5
5 10 10
Filling Time (ACCESS LEVEL: 1)
The filling time controls the maximum time in second of the injection phase to
prevent the machine from remaining in boost for an extended period of time.
Actual filling time is monitored in the field on the right side.
Injection Delay (ACCESS LEVEL: 1)
95
CONTROL SCREENS
This parameter controls the time delay for injection to start after the carriage
have touched the mold. The unit is in second. Actual injection delay is monitored
in the field on the right side.
Injection Speed Changeover Position (ACCESS LEVEL: 1)
This row of fields setup the position of the screw where the injection speed and
pressure will switchover from the current settings to that of the next stage. The
value is distance in mm from the absolute zero of the screw scale. The value
must follow a descending order from the right.
Injection Speed Profile (ACCESS LEVEL: 1)
Up to ten velocities can be set up. This row of fields control the speed profile of
the screw during injection. The unit is mm/sec or in/sec.
Maximum Pressure control (ACCESS LEVEL: 1)
This field control the maximum hydraulic pressure apply to the injection
cylinder during injection to prevent flashing of the mold when improper setting
of cut off parameter is set. The maximum pressure is 140 bar.
Injection set profile graph
A graph for showing the set injection speed profile in a line curve. Only for
injection stages less than or equal to 5.
Cut-off Mode Parameters and Criteria (ACCESS LEVEL: 1)
The parameters associated with the cut-off mode include position, time,
injection pressure, and cavity pressure. If cut-off by position, cavity pressure or
hydraulic pressure are selected, set the filling time to a value which is slightly
greater than the time actually required. This setting will function as a back-up
for the position or pressure setting, preventing the machine from remaining in
boost for an extended period of time.
If "Position" mode is selected, the position of the screw for cut-off shall be set.
Set also the "filling time" to a value larger than that required for the screw to
reach the cut-off position.
If "Time" mode is selected, the time for cut-off shall be set.
If "Time or Position" mode is selected. Then both the time field and position
field shall be set. Cut-off will be triggered whichever comes first.
96
CONTROL SCREENS
If "Injection Pressure After Position" mode is selected, cut-off is triggered by

the injection pressure on condition that the screw has passed a certain position.
Both the pressure and the position has to be entered. It is recommended that
the position shall be between the cushion length and the maximum shot size.
If "Injection Pressure After Time" mode is selected, cut-off is triggered by the

injection pressure on condition that a certain time has passed. Enter both the
pressure and time setttings. It is recommended that the time setting shall be
less than the fill time.
If "Cavity Pressure After Position" is selected, cut-off will be triggered by the

cavity pressure on condition that a certain position is reached. Enter both the
cavity pressure and position setting. The position shall be that for 90% cavity
fill up.
If "Cavity Pressure After Time" mode is selected, cut-off will be triggered by

the cavity pressure. Enter both the pressure and time. The time shall be set for
that for 90% cavity up.
Actual Screw Position , Injection Speed, And Hydraulic pressure in Injection

cylinder
97
CONTROL SCREENS
Holding
6.7.1
6.7.2
6.7.3
6.7.5
6.7.4
After the cut-off has been reached, the holding pressure will be applied to the
injection cylinder .
Holding Time Setup (ACCESS LEVEL: 1)
This row of fields control the time for each stage of holding pressure to be
applied to the injection cylinder.
Holding Pressure profile setup (ACCESS LEVEL: 1)
This row of fields control the pressure to be applied to the injection cylinder.
Hold pressure set profile
This graph shows the set holding pressure profile when the no. of injection
stage is less than or equal to 5 only.
HOLDING HOLDING
PRESSURE PRESSURE H P 5
HP4
HP3
HP1
HP2 HP6 HP2

HP3
HP1
HP4 HP8 HP7
HP5 HP9
HP10
TIME TIM
E
T5 T4 T
3 T2 T1 T10 T9 T8 T
7 T 6 T5 T4 T3 T
2 T1
98
CONTROL SCREENS
Holding Velocity (ACCESS LEVEL: 1)
This field can be set to control the speed of the screw during holding phase.
Cushion length, +tol and - tol (ACCESS LEVEL: 1)
This field can be set to control the desire cushion length at the end of holding
phase. This value is entered as distance in mm of screw position from the
absolute zero position of the screw scale. "+tol" and "-tol" tolerance for cushion
length. For example, if the cushion length is set at 150 mm, the "+tol" is 3 mm
and "-tol" is 3mm then an alarm will be given when the screw position at the
end of holding phase does not fall between 147mm to 153 mm. The field at the
bottom monitors the actual cushion length.
99
CONTROL SCREENS
Metering
6.8.1
6.8.4
6.8.2
6.8.3
6.8.5
6.8.6
6.8.7
6.8.8
6.8.9
6.8.10
6.8.11
6.8.12
6.8.13
No. of Metering Stages (ACCESS LEVEL: 1)
This field controls the no. of stages of metering to be used. Three options are
available: 1 stage, 2 stages and 5 stages. When this parameter is changed, the
screen will change accordingly.
Decompression Delay (ACCESS LEVEL: 1)
This parameter controls the time for delay of decompression after the holding
phase is finished. The actual decompression delay is monitored by the field
beside.
Metering Delay (ACCESS LEVEL: 1)
This timer controls the time for delay of metering start sequence after the end
of the decompression. This timer is used primarily with very heat sensitive
materials and is otherwise set to 0.0 seconds. A 0.3 to 0.5 second delay is
recommended for materials that are prone to splay. This allows for natural
decompression prior to screw rotate. The actual metering delay is monitored by
the field beside.
Metering Time (ACCESS LEVEL: 1)
This field limits the time of the metering process, thus preventing the machine
from keep on metering if the material have run out or some other problem
occurred. The actual metering time is shown on the field beside.
100
CONTROL SCREENS
Back pressure switchover position (ACCESS LEVEL: 1)
This row of fields set the positions of the screw where the back pressure will
switchover to that of the next stage. The value is distance from the absolute
zero of the screw scale.
Back pressure Profile (ACCESS LEVEL: 1)
This row of fields control the back pressure when the screw is metering.
Maximum value shall not exceed 100 bar.
Actual Screw Position, Back pressure and screw rotating speed (OPTIONAL)
These readings are shown on this box.
Metering speed Profile (ACCESS LEVEL: 1)
This row of fields control the metering speed profile. Metering ends when the
metering end position is reached.
Metering Speed switchover position (ACCESS LEVEL: 1)
This row of fields control the switchover positions for the rotation speed of the
screw. The value is distance in mm from absolute zero of the screw scale.
Decompress before metering (ACCESS LEVEL: 2)
The decompress before metering function is for screw pulling back a distance
before the screw rotation sequence begins. A in the check box indicates this
function is in use, while a indicates the opposite.
Decompression after metering (ACCESS LEVEL: 2)
The decompress before metering function is for screw pulling back a distance
before the screw rotation sequence begins. A in the check box indicates this
function is in use, while a indicates the opposite.
Decompress before metering Position, pressure and speed (ACCESS LEVEL: 1)
The pressure field controls the pressure during decompression. The speed field
controls the velocity of decompression. The distance field sets the distance at
which decompression will be completed and this setting must be smaller than
the back pressure switchover position.
Decompression after metering Position, pressure and Speed (ACCESS LEVEL:

1)
101
CONTROL SCREENS
The decompress after metering function is for the screw pulling back a distance
after the screw rotation sequence ends. The pressure, speed and distance fields
are similar to that of last section.
102
CONTROL SCREENS
Mold data Internal storage
ACCESS METHOD: + softkey "INTERNAL MEMORY"
6.9.1
The Internal Mold Data Screen allows the operator to transfer all mold set-up
information to and from the active system memory and internal memory.
Mold Reference No. (ACCESS LEVEL: 2)
Individual mold number can be named with a number of up to twelve digits.
Data storage
To store current mold setup data into internal memory
Move the cursor to the desire mold no.
Key in the mold no. and then press the enter key.
Press the "SAVE" softkey on the right hand side of the screen. If the data is
stored successfully, the date for that mold no. will be replaced by current date
and a message will be displayed on the screen. After data storage is finished,
the data previous store in that mold no. will replace the current data.
Data retrieval
To retrieve the previous stored data from the internal memory.
103
CONTROL SCREENS
Press the "LOAD" softkey on the right hand side of the screen. After data
loading is finished, the data currently used will be replaced by the data stored in
that mold no.
The data can only be loaded when the machine is in manual or setup mode ).
Mold data preview
This function is to display some important parameters of a particular mold data

before loading the data into the machine.
To use preview, press "preview" softkey on the right of the screen.
To finish, press "End of preview" softkey.
104
CONTROL SCREENS
IC card memory
6.10.1
6.10.3
6.10.2
6.10.4
The IC Card storage screen allows the operator to transfer all mold set-up
information to and from the active system memory and IC card
Auto card size detection
When a memory card is inserted into the memory card slot, the machine can
automatically detect the memory size of the card and displays on the screen.
Card of size up to 1M byte can be supported.
Page number tag
When a memory card has more than 32K byte memory, the card will be divided
into pages of 32K byte. Each page is given a page number shown in the page
number tag.
position of page in card
The relative position of a particular page in a card is shown by the small

rectangle in the bar. The left side stands for the beginning of the card while the
right side stands for the end of the card.
Mold Reference No. (ACCESS LEVEL: 2)
Individual mold no. can be named with a number of up to twelve digits.
105
CONTROL SCREENS
Data storage
To store current mold setup data into IC card
Insert the IC card into the IC card slot on the right hand side of the operator
panel. The "Card in" LED lights up for correct insertion.
Move the cursor to the desire mold no.
Key in the mold no. and then press the enter key.
Press the "SAVE" softkey on the right hand side of the screen. If the data is
successfully stored, the date for that mold no. will be replaced by current date
and a message will be displayed on the screen. After data storage is finished,
the data previous store in that mold no. will replaced the current data.
Data retrieval from iC card
To retrieve the previous stored data from the IC card
Insert the IC card on the IC card slot.
Press the "LOAD" softkey on the right hand side of the screen. After data
loading is finished, the data currently used will be replaced by the date stored in
that mold no.
The data can only be loaded when the machine is in "MANUAL" or "SETUP"
mode ).
Mold data preview
This function is to display some important parameters of a particular mold data

before loading the data into the machine.
To use preview, press "preview" softkey on the right of the screen.
To finish, press "End of preview" softkey.
106
CONTROL SCREENS
Production
6.11.2 6.11.1
6.11.3 6.11.4
6.11.5 6.11.6
6.11.7 6.11.8
6.11.9
6.11.10 6.11.11
6.11.12 6.11.13
6.11.14
6.11.15
6.11.16
6.11.17
6.11.18
This screen allow the operator to monitor production information for this mold.
Which include the part required to produce, no. of part finished, and material
required etc.
Reject rate (ACCESS LEVEL: 2)
Not yet released.
cavity (ACCESS LEVEL: 2)
Number of cavities in the mold. This number is used in the calculations of the
number of parts produced when each cycle is finished.
Shot Weight (ACCESS LEVEL: 2)
This is the weight of material required to fill the mold during one cycle. This
value is used by the system to calculate the amount of material to completion.
Material (ACCESS LEVEL: 2)
The operator can select the type of material to be used.
Std reject rate
Not yet released.
107
CONTROL SCREENS
Std cycle time
Not yet released.
lot required (ACCESS LEVEL: 2)
The no. of lot required can be set in this field. This figure is used to calculate
the run time and estimated material.
Lot finished
This field monitors the no. of lots of product made.
Production Counter reset (ACCESS LEVEL: 2)
This parameter is used to reset the number of lot completed and number of
pieces finished.
no. of parts per lot (ACCESS LEVEL: 2)
The no. of parts per lot can be set in this field. This figure is used to calculate
the run time and estimated material.
part finished
Pieces are the total number of parts produced by the machine. This value is
calculated by multiplying the number of machine cycles by the number of mold
cavities. If the result is greater than the number of pieces per lot than
subtracting result by the number of pieces per lot and take the remainder, and
increase the number of lot finished by 1.
reject adjustment
Not yet released.
part rejected
Not yet released.
parts reject During start up (ACCESS LEVEL: 2)
Not yet released.
Maximum no. of parts for continue reject
Not yet released.
108
CONTROL SCREENS
Average cycle time
The average cycle time is monitored in this field.
estimated Production time remained
This is the amount of time necessary to produce the desired number of good
parts. This amount of time is calculated by dividing the parts to be completed by
the number of cavities and then dividing that value by the instantaneous cycle
rate. Note that the standard cycle time will be used instead of the instantaneous
cycle rate until a value for instantaneous cycle rate can be obtained from the
actual production .
Estimated material required
The estimated material required = (Parts to be completed / Number of cavities)

x (Shot Weight )
109
CONTROL SCREENS
OP setup
ACCESS METHOD: + softkey ''OP Setup"
6.12.1
6.12.2
6.12.3
6.12.4
6.12.8
6.12.5
6.12.6
6.12.7
The OP Setup Screen allows authorized people to access various parameters

which contain interfacing set-up information, format information, printer type,
system date and time. The audible clicking when the keypads are pressed, and
the display language can also be selected from this screen.
Communication interface specification (ACCESS LEVEL: 3)
Operator can setup different communication parameters for the printer and port
4 here. These parameters include baud rate, no. of data bit, no. of stop bit and
the parity bit. The setting are options field and are altered by pressing the
key.
Note: CIMtrol provides a RS-232 serial port for printer connection. The printer
to be connected must have a RS-232 serial port and suitable cables. Consult
Welltec Service Department or your agent for cable or if you want to connect to
a printer only have a parallel interface.
Language selection (ACCESS LEVEL: 3)
The operator can choose between 3 system language. The operator panel can
be displayed in 3 different languages (e.g. Chinese, English, German). To
change the display language, press the key.
Screen dwell delay (ACCESS LEVEL: 1)
110
CONTROL SCREENS
In order to increase the service life of the monitor, the display will be off when
the keyboard is unheeded for a period which is specified in this field. The unit is
in minute.
Key Click sound On /off (ACCESS LEVEL: 3)
This parameter controls the beeper sound when the key pad is pressed. To
switch the beeper sound on or off press the toggle key or use the selection key.
With the beeper turned on, a valid keystroke will be confirmed by an audible
signal.
Measuring unit (ACCESS LEVEL: 3)
To select between Metric and British conversion press the toggle key or use
the selection key. When change from Metric to British or vice versa, the values
and units of all fields will be changed instantly using the following conversion
factors.
Metric to British
From To Conversion
g oz /28.35
mm in x25.4
bar psi x1000/69
Celsius Fahrenheit x9/5 + 32
kgf lbf x110/10000
British to Metric
From To Conversion
oz g x28.35
in mm /25.4
psi bar x69/1000
Fahrenheit Celsius -32 x 0.556
lbf kgf x10000/110
Some round off error can be resulted due to limited number of significant digit
used, eg. pressure.
Help Window Display (ACCESS LEVEL: 4)
This field controls the delay for the display of the help window when the cursor
moves to the other field. With this control flicking of help window on the screen
111
CONTROL SCREENS
when the cursor moves can be prevented. (NOTE: the help window is displayed
when is pressed .)
Printer type (ACCESS LEVEL: 3)
The operator can select the printer type. To change to different printer type,
use the toggle key or the selection key. The following are the printer types
supported by this machine.
HP Laserjet series laser printer or compatible
Canon BJ series bubble jet printer
Epson LQ series 24 pin dot matrix printer or compatible
Epson FX series 9 pin dot matrix printer or compatible
IBM Proprinter XL24E series printer
real time date and clock (ACCESS LEVEL: 3)
This is a clock showing the current date and time. To adjust,
Move cursor over the year field. Enter the desired year.
Move cursor over the month field. Use options key to display selection window.
Select using cursor arrows and confirm with enter key.
Move cursor over the date field. Enter the desired date.
Move cursor over the day of the week field. Use options key to display
selection window. Select using cursor arrows and confirm with enter key.
Repeat with the minute and second field.
Finally move the cursor to set field , press the "set" softkey at the right hand
side of the screen at the right time.
112
CONTROL SCREENS
mold setup
6.13.5
6.13.15
6.13.12
6.13.14
6.13.13
6.13.6
6.13.7
6.13.16
6.13.8
6.13.10
6.13.9
6.13.11
This screen allow the control for auto purging cycle and auto mold height
adjustment.
AUTO MOLD HEIGHT ADJUST CYCLE
In a auto mold height adjust cycle the machine go through the following process.
Close the mold.
If the mold cannot reach the stop position before the mold close timer run out,
the mold will open again. If the mold stop position can be reached, then go to
step 5 directly.
The "mold height adjustment mechanism" will adjust the mold height thicker.
The mold will close again.
The "mold height adjustment mechanism" will adjust the mold height thinner
until two mold halve touch each other.
The mold will open again.
The "mold height adjustment" will adjust the mold forward according the mold
clamping force input.
113
CONTROL SCREENS
Procedure for setting up AUTO MOLD HEIGHT ADJUSTMENT:
Press
Enter the required clamping force on the "clamping force" field.
Switch to "SERVICE SCREEN" by pressing the key and then press "Service"
soft key.
Input the setting for clamp setup pressure and clamp setup speed (Note: the
clamp setup pressure and setup speed shall be just sufficient to move the
platen. Normally 25 bar and 20 % is sufficient. If the mold halves are very
heavy, alter the settings according to the condition.)
Switch to the clamping screen by pressing .
Setup the "clamp closing time" sufficient long for the clamp to reach the mold
close stopped position with the clamp setup speed and setup pressure.
Switch back to the mold setup screen by pressing .
On the switch panel use the setup mode.
Move the cursor over the "Auto Mold Height Adjustment" field.
Close all guard doors first.
Press the toggle key or "ON" softkey locate at the right hand side of the
screen to change setting to on. The "auto mode height adjustment mechanism"
will start.
After the process have been finished, the "Auto Mold Height Adjustment" field
will return to "off" automatically.
AUTO PURGE CYCLE
This cycle is used to clean up the barrel before the machine is going to be shut
down a longer time than usual for some reasons e.g. LONG HOLIDAY. In this
cycle, the machine will go through the following steps.
Injection starts until the screw stop position is reached.
114
CONTROL SCREENS
Decompression starts.
Metering start after decompression has been finished.
The above process will go through a number of times as specified in the "auto
purge cycle count" field.
AUTO PURGE CYCLE start up procedure:
Press
Enter all the position, pressure and speed settings for the injection,
decompression and metering for the auto purging process.
Entere the metering monitoring time for auto purge.
Entere the no. of cycles for auto purge.
Use setup mode.
Move the cursor to "auto purge" field.
Close all guard doors first.
Press the toggle key or "ON" softkey at the right hand side of the screen
turn on auto purging. Auto purging will start now.
After the auto purging process is finished. Switch the "auto purge" field from
"ON" to "OFF".
Clamping Force (ACCESS LEVEL: 2)
It is the clamping tonnage is required for this mold. For use in automatic mold
height adjustment.
Injection complete position of Auto Purge (ACCESS LEVEL: 2)
This is position of the screw for termination of injection process during the auto
purging. The value is distance from absolute zero of the screw scale.
Injection pressure and speed for Auto Purge (ACCESS LEVEL: 2)
This fields control the injection pressure and injection speed of the auto purge
cycle.
115
CONTROL SCREENS
Decompression pressure and speed for Auto Purge (ACCESS LEVEL: 2)
This field controls the decompression pressure and decompression speed of the
auto purge cycle.
Decompression stop position (ACCESS LEVEL: 2)
This is the position for decompression stop of the auto purge cycle. The value
is distance from the absolute zero position of the screw scale.
Metering pressure and speed (ACCESS LEVEL: 2)
This fields control the hydraulic pressure and rotating speed of the screw
motor.
Metering stop position (ACCESS LEVEL: 2)
This field control the metering end position during the auto purge cycle.
Monitoring Time (ACCESS LEVEL: 2)
Monitoring time control the total metering time for a metering sequence for
during auto purge cycle. If the screw cannot reach the metering stop position
within the period, the metering process will be terminated and injection process
will start.
No. of cycle (ACCESS LEVEL: 2)
This number control the no. of auto purge cycle to be used.
AUTO PURGE (ACCESS LEVEL: 2)
To activate auto purging cycle set this field to "on". To turn off the auto purging
cycle set this field to "off".
AUTO MOLD HEIGHT ADJUSTMENT (ACCESS LEVEL: 2)
To activate the "auto mold height adjustment" function switch this field to "on".
To turn off the function switch this field to "off".
Monitoring parameters
Actual screw position, hydraulic pressure in injection cylinder, metering time,

actual screw rpm (OPTIONAL) and actual auto purge counter can be found in
this box.
carriage
116
CONTROL SCREENS
ACCESS METHOD: + softkey "Carriage"
6.14.1
6.14.2
6.14.6
6.14.3
6.14.4
6.14.7
6.14.5
6.14.8
In this screen the operation mode of the carriage, three stages of carriage
forward / backward movement can be set up. Graphs indicating the set speed
and pressure profile for carriage forward and backward movement are shown.
Carriage Mode (ACCESS LEVEL: 1)
This field controls the operation mode of the carriage during semi-automatic or
fully automatic cycles. Using the options key the following modes can be set.
Stall Mode : - The carriage will stay in the carriage stop position during the
cycle.
Retract before : - The carriage will be retracted to retract stop position prior to
the metering start. Normally this mode is used with the machine which has
installed a cut-off nozzle.
Retract after : - If this mode is selected, the carriage will be retracted to retract
stopped position after metering finished.
Actual readings
Carriage position, pressure and speed are monitored.
Carriage forward switchover position (ACCESS LEVEL: 1)
This row of fields control the positions where the carriage forward pressure and
speed will switchover to that of the next stage. The carriage forward stop
117
CONTROL SCREENS
position control the position when the carriage stop its forward motion. The
values are distance from the mechanical zero position of the carriage scale.
Carriage forward pressure and speed setup (ACCESS LEVEL: 1)
This row of fields control the pressure and speed for each stage of carriage
forward motion.
Carriage pull (ACCESS LEVEL: 2)
This field is a for selection between the use of carriage pull or not. If carriage
pull is used, the carriage will be pulled against the mold platen during injection
and metering when the carriage has passed thorough the carriage forward
stopped position.
Carriage backward switchover position (ACCESS LEVEL: 1)
This row of fields control the position where the carriage backward pressure
and speed will switchover to the pressure and speed of the next stage. The last
field on the right is the carriage backward stopped position for controlling the
position when the carriage stop its backward motion. The value is distance from
the absolute zero position of the carriage scale .
Carriage backward pressure and speed setup (ACCESS LEVEL: 1)
This row of fields control the pressure and speed for each stage of carriage
backward motion.
Monitoring curves
Speed and pressure for carriage forward and backward motion are monitored in
these curves.
118
CONTROL SCREENS
Timer
6.15.15
6.15.1
6.15.7 6.15.5
6.15.4 6.15. 6
6.15.8 6.15.2
6.15.10 6.15.
6.15.9
6.15.14
6.15.12
6.15.11
6.15.13
Most the timer parameters can be changed and monitored in this screen except
the holding timer.
Pause timer (ACCESS LEVEL: 1)
This field controls the time that the machine will stop before the next cycle
during automatic mode.
Carriage forward delay (ACCESS LEVEL: 1)
This field controls the time delay for the carriage to move forward after the
clamp has locked up.
Carriage backward delay (ACCESS LEVEL: 1)
This field controls the time delay for the carriage to move backward after the
metering process has finished.
Metering Delay (ACCESS LEVEL: 1)
This field controls the time delay of the metering process after the screw has
reached the decompression before position.
Ejector Dwell (ACCESS LEVEL: 1)
119
CONTROL SCREENS
This field set the time for the ejector to remain at the forward stopped position
before the retraction.
Air Blow 1 timer (ACCESS LEVEL: 1)
This field set the time for the Air Blast 1 to last.
Injection Delay (ACCESS LEVEL: 1)
This field controls the time delay for the injection process after the carriage has
reached the forward stopped position.
Decompression delay (ACCESS LEVEL: 1)
This field controls the time delay for decompression before metering after the
holding phase has finished.
Cooling Time (ACCESS LEVEL: 1)
This field set the duration for the product to start in mold after holding phase is
finished.
Pre-extruding time (OPTIONAL, ACCESS LEVEL: 1)
This field set the duration for pre-extruding before injection start. After the
clamp is locked up, the machine will perform the metering before injection start.
This is pre-extrusion. The time for pre-extrusion is controlled by this timer.
With pre-extrusion, more material than the nominal shot weight will be injected
into the mold. However, the surface finish and quality of product will not be
very good.
Filling time (ACCESS LEVEL: 2)
This field controls the maximum time allowed for injection. If the machine
cannot switchover to holding phase within this time limit, an alarm will be given.
Then the machine will switchover to the holding phase as soon as this timer is
run over, and machine stop cycling at the end of current cycle. The motor will
stop at the end of the cycle if a "tick" in the last field on the right is chosen. The
motor will not stop if a "cross" is chosen. ( Note : as for heater off & Mold
Heater off selection is not yet Release. )
Metering time (ACCESS LEVEL: 2)
This field controls the maximum time allowed for metering phase. If the machine
cannot reach the metering stopped position within this time limit, an alarm will
be given. Also the machine will switchover to the next process as soon as this
120
CONTROL SCREENS
timer is run over, and machine stop cycling at the end of current cycle. The
motor will stop at the end of the cycle if a "tick" in the last field on the right is
chosen. The motor will not stop if a "cross" is chosen.( Note : as for heater off
& Mold Heater off selection is not yet Release. )
Mold Close time (ACCESS LEVEL: 2)
This field controls the maximum time allowed for mold clamping phase. If the
machine cannot lock up within this time limit, the clamp will open again, eject,
and try to lock up the clamp again. The no. of cycle that the machine will retry
depends on the set value of mold rebound count. An alarm will be generated if
the clamp cannot lock up after no. of rebound counter has been reached. The
motor will stop cycling after the last retry. The machine will stop at the end of
the cycle if a "tick" in the last field on the right is chosen. The machine will not
stop if a "cross" is chosen.( Note : as for heater off & Mold Heater off selection
is not yet Release. )
Cycle time (ACCESS LEVEL: 2)
This field controls the maximum time allowed for the whole machine cycle. If
machine cannot finish the cycle within this time limit, an alarm will be given.
Also the machine will stop cycling at the end of current cycle. The machine will
stop at the end of the cycle if a "tick" in the last field on the right is chosen. The
machine will not stop if a "cross" is chosen.( Note : as for heater off & Mold
Heater off selection is not yet Release. )
Monitoring parameter:
Actual values for the corresponding settings are shown in this column of fields.
121
CONTROL SCREENS
TCU parameter
ACCESS METHOD: Press + softkey
6.16.1
6.16.2
6.16.3
6.16.4
6.16.13
6.16.5
6.16.6
6.16.7
6.16.8
6.16.9
6.16.10
6.16.11
6.16.12
This screen allow setting up the parameters for controlling temperature. All
parameters have been setup for optimum performance before the machine is
shipped.
IMPORTANT: The description in this section has to be studied carefully before

any adjustment to parameters in this screen is to be made. If any problem
regarding the setting of the parameters arises, contact your dealer or the
manufacturer for information.
Actual temperature
The actual temperature of each heating zone is shown in this row of fields.
setpoint (ACCESS LEVEL: 1)
This row of fields show the set temperatures for each heating zone.
Self tune (ACCESS LEVEL: 3)
Not yet released.
ST status, Maximum, minimum and status
Not yet released.
KP (ACCESS LEVEL: 3)
122
CONTROL SCREENS
The proportional gain parameter for proportional action branch of close loop
control.
KI (ACCESS LEVEL: 3)
The integral time parameter for integral action branch of close loop control.
KD (ACCESS LEVEL: 3)
The derivative action time parameter for derivative action branch of close loop
control.
Man. Output
This row of fields monitor the percentage heating of that heating zone if the
temperature control mode is operated in manual mode. If 50% is entered in a
field, the heater for that heating zone will turn on 50% of the time and turn off
50% of the time.
Sampling time (ACCESS LEVEL: 3)
This field controls the time base for the temperature controller to sampling the
ADC channel.
ZU (Access Level: 3)
This field controls the upper control zone of closed loop control. If the actual
temperature is higher than the set temperature by this value, the closed loop
control process will stop, and 0% of heating will be resulted.
ZL (Access Level: 3)
This field controls the lower control zone of closed loop control. If the actual
temperature is lower than the set temperature by this value, the closed loop
control process will terminate, and 100% of heating will be resulted. Thus
increase the respond time of the control.
Mode (ACCESS LEVEL: 3)
This row of fields control the operation mode of each heating zone. Use the
toggle key or the selection key to select the following modes.
Manual mode : - Heating of the particular zone is determined by a percentage.

The percentage heating of the zone is determined by the "Man. Output" zone.
Normally this mode it used when the thermocouple is faulty.
123
CONTROL SCREENS
PID mode : - This mode is used for close loop temperature control process.
Off mode : - The particular heating zone will be switched off. .
Self tuning status
Not Yet Released.
124
CONTROL SCREENS
Monitoring
Access Level : 2
The 6 Most Important Parameters Of The Last 10 Shots Will Be Displayed In

This Screen For Instant Reference. These 6 Parameters Can Be Selected Out
Of A Total 15 Parameters (Shown In The Table Below) By Using The
Selection Key Or The Toggle Key At The Fields.
VP position VP time VP pressure
VP cavity pressure Metering time Filling time
Filling time after stage 1 Filling time after stage 2 Mold close time
Mold open time Cycle time Cushion length
Oil temperature Nozzle temperature Metering end position
125
CONTROL SCREENS
Graphic
6.18.4
6.18.1
6.18.2
6.18.3
6.18.5
The following curves for actual readings can be displayed in this screen:
Injection speed vs position, injection pressure vs position, holding pressure vs
time, cavity pressure vs position, cavity pressure vs time, back pressure vs
position. The corresponding set curves can be displayed together as an option.
The curves will only be displayed when the corresponding process is finished.
Curve (ACCESS LEVEL: 1)
For selecting the desired curve to be displayed. The following choices are
available: Injection speed, injection pressure, holding pressure, cavity pressure
vs time, cavity pressure position, back pressure. Use the selection key or the
toggle key to select. Two curves can be displayed when using both curve fields
on the left and right part of screen.
Color (ACCESS LEVEL: 1)
For selecting the desired color of the curve to be displayed on the screen. The
following choices are available: white, yellow, red, blue, cyan, green, black and
magenta. Use the selection key or toggle key to change.
Set (ACCESS LEVEL: 1)
For displaying the set curve together with the actual curve. Use the toggle key
to change from "cross" to "tick".
Auto scale (ACCESS LEVEL: 1)
126
CONTROL SCREENS
For optimizing the scale of the curve to be displayed on screen. Use the toggle
key to change from "cross" to "tick".
127
CONTROL SCREENS
product certificate
ACCESS METHOD: Press + softkey "Product Certificate"
Not yet released.
128
CONTROL SCREENS
Diagnostic
ACCESS METHOD: Press + softkey "Diagnostic"
This screen displays the last 18 alarms. Information of the alarm include: Error
message no., description of the alarm, time of alarm on and off. The color
monitor displays only 6 alarm messages. Use "Scroll" softkey to display another
pages.
Some messages such as operation alarms and machine breakdowns will stay on
the screen even after the alarms have been turned off. To clear them, press .
follows by .
129
CONTROL SCREENS
breakdown
ACCESS METHOD: Press + Softkey "Breakdown"
This screen displays the locations of the problems. The upper part of the screen
shows the description of the breakdown. The lower part of the screen displays
the possible locations of the breakdown with the color and number of the alarm.
This screen displays only 6 messages. To view another messages, press the
"Scroll" softkey. Maximum no. of stored messages is 18.
130
CONTROL SCREENS
Machine status
ACCESS METHOD: Press + softkey "Machine Status".
This screen display various active components of the machine. These include:
Operating mode, cushion length, cycle count, ejector count, cycle time, filling
time, metering time, mold protection time, cooling time
Positions of the clamp, ejector, injection screw and carriage
Temperatures of heating zones
Pressures and speeds of both pumps
Oil temperature
Injection speed and pressure
Metering speed.
Current locations or operation of individual stroke.
131
CONTROL SCREENS
Daily maintenance
6.23.1
6.23.2
Lubrication Interval (ACCESS LEVEL: 1)
This field controls the lubrication pump to pump the lubrication oil to the toggle
pin after the desired clamping cycle.
Lub. interval leave, replace filter after, replace hyd. oil after
Not yet released
132
CONTROL SCREENS
machine data
ACCESS METHOD: Press + softkey "Summary" + softkey "Machine Data"
6.24.1
6.24.2
6.24.3
IMPORTANT : This screen shall be used by servicemen and technician from

"WELLTEC" only. All parameters in this screen are factory standards and must
not be changed by the user under any circumstances. Improper setup of
parameters in this screen may cause damage to the machine.
Offset (ACCESS LEVEL: 1)
This is the dead band of the analog output. Output level within this region will
not generate any physical output. The unit is in mV.
Gain (ACCESS LEVEL: 1)
This is the maximum change of analog output level for 100% of physical output.
The unit is in mV. Max. is 10000mV.
ramp (ACCESS LEVEL: 1)
This is the ramp up & ramp down time for individual analog output channel. (
Note : 1 unit = 1ms )
133
CONTROL SCREENS
Summary 2
ACCESS METHOD: + softkey "Summary 1" + "Summary 2"
6.25.1
6.25.2
6.25.3
6.25.4
6.25.5
6.25.6
6.25.9
6.25.7
6.25.8
6.25.10
6.25.11
6.25.12
6.25.13
This screen summarizes all settings for clamp movement, ejector movement and
carriage movement into one screen. All the parameters for above mentioned can
be set up in this screen, without going through several screens to minimize the
setup time.
Clamp speed and pressure switchover position (ACCESS LEVEl: 1)
These settings are the position where the clamping pressure and speed will
switchover to that of the next stage. The values are distance from the absolute
zero of the clamp scale.
Clamping pressures and speeds (ACCESS LEVEL: 1)
These settings control the pressures and speeds of clamping. For pressure
setting maximum value is 140 bar. For speed setting maximum value is 100%
Ejector start position (ACCESS LEVEL: 1)
During clamp opening, the ejector sequence will start when the clamp has
passed a preset position. This position can be set in this field. The value is the
distance from the absolute zero position of clamp scale. ( Note : this field can
be function or not 5 depend for machine only have one pressure & flow
proportional control value, ejector can only start after mold fully open. )
Air start position (ACCESS LEVEL: 1)
134
CONTROL SCREENS
During clamp opening, the air valve 1 will start blasting when the clamp has
passed a preset position. This position can be set in this field. This position is
the distance from the absolute zero position of clamping scale.
Carriage pressure and speed switchover positions (ACCESS LEVEL: 1)
These are the positions where the carriage pressure and speed will switchover
to that of the next stage. The value entered must obey the following rule:
carriage forward stop < to carriage forward 3 < to carriage forward 2 <
carriage backward stop position and Carriage backward stopped position > to
carriage backward 3 > to carriage backward 2 > carriage forward stop position
)
Carriage pressures and speeds (ACCESS LEVEL: 1)
These settings control the pressure and speed of the carriage.
Carriage pull (ACCESS LEVEL: 2)
This parameter controls the pulling of the carriage against the mold during
injection or metering. When "tick" is selected in this field, then if the actual
carriage position has passed over the carriage forward stopped position during
injection and metering phase, the carriage will be pulled against the mold platen,
otherwise carriage will not pulled.
Carriage Mode (ACCESS LEVEL: 1)
The operation mode of the carriage during semi-automatic or fully automatic

cycles can be selected in this field. Using the toggle key, soft key or the
selection key the following modes can be selected.
Stall Mode : - The carriage will state in the carriage stopped position during the
cycle.
Retract before : - The carriage will retract to its backward stopped position
prior to the metering start. Normally this mode is used with the machine which
have install a cut-off nozzle.
Retract after : - The carriage will return to its backward stopped position after
metering has been finished.
Pre-extruding (optional, ACCESS LEVEL: 2)
For selection of whether to use pre-extrusion or not.
Pre-extrusion time (Optional, ACCESS LEVEL: 1)
135
CONTROL SCREENS
For setting the pre-extrusion time.
Ejector positions (ACCESS LEVEL: 2)
These settings control the backward stopped position, forward stopped position
and forward switchover position for speed and pressure of the ejector. The
value is the distance from the absolute zero of the ejector scale.
Ejector pressures and speeds (ACCESS LEVEL: 2)
These settings control the pressures and speeds of the ejector.
Rattle (ACCESS LEVEL: 2)
The use of the rattle ejector can be selected in this field.
ejector Cycle Count (ACCESS LEVEL: 1)
This field control the number of cycles for the ejector sequence.
136
CONTROL SCREENS
Service
ACCESS METHOD: Press + softkey "Service"
6.26.2
6.26.1
6.26.10
6.26.3
6.26.6
6.26.4
6.26.7
6.26.5
6.26.8
6.26.9
This screen provide the some parameters for servicing and testing purposes.
Analog output Port (ACCESS LEVEL: 3)
These output ports can be used to directly control output voltage of individual
analog channel for testing purpose. To use this function, follow the procedure
below:
The machine must be in the "SETUP" mode.
Press the emergency button to turn off the pump.
Release the emergency button.
Enter a value between 0 -100 in the analog output port that is under testing.
Use digital voltmeter to measure if the analog I/O function is OK. The output
shall be proportional to the value entered.
Analog input channel (ACCESS LEVEL: 3)
These settings inform controller the corresponding physical reading

corresponding to 10V of that input channel for AD conversion purpose.
IMPORTANT: These parameters shall not be altered by the user under any
circumstances.
137
CONTROL SCREENS
Clamp Setup pressure and speed (ACCESS LEVEL: 3)
These settings control the pressure and speed in the clamping cylinder in the
"setup" mode. The maximum pressure setting is 140 bar max speed is 100% .
Normally these values should be set to 20 bar and 15%.
Ejector setup pressure and speed (ACCESS LEVEL: 3)
These settings control the pressure and speed of ejector in "setup" mode. The
maximum pressure setting is 140 bar, and speed setting is 100%. Normally
these values should be set to 20 bar and 15%.
Core setup pressure and speed (ACCESS LEVEL: 3)
These settings control the pressure and speed of core in "setup" mode. The
maximum pressure is 140 bar and maximum speed is 100%. Normally these
values shall be set to 20 bar and 15%.
Carriage setup pressure and speed (ACCESS LEVEL: 3)
These settings control the pressure and speed of the carriage "setup" mode.
The maximum pressure is 140 bar, and maximum speed is 100%. Normally
these values should be set to 20 bar and 15%.
Injection setup pressure and speed (ACCESS LEVEL: 3)
These settings control the pressure and speed of injection in "setup" mode. The
maximum pressure is 140 bar and maximum speed is 100% . Normally these
values should be set to 20 bar and 15%.
Metering setup pressure and speed (ACCESS LEVEL: 3)
These settings control the pressure and speed of metering in "setup" mode. The
maximum pressure is 140 bar and max speed is 100%. Normally these values
should be set to 20 bar and 15% . (NOTE: The metering setup pressure is the
same for manual, semi-automatic and automatic mode).
Calibration of scale
This switch is used to preset the cement position of the corresponding stroke as
zero point use to toggle it from "off" to "on" and to "off" again.
Monitoring parameters
Actual value for all analog input channel are shown.
138
CONTROL SCREENS
heater timer screen
ACCESS METHOD: Press + "heater timer" softkey
6.27.1
6.27.2
6.27.3
6.27.4
Whole day on/off switch (ACCESS LEVEL: 2)
This field is for the control of the use of heater timer for a certain weekday. If
"off" is selected, the heater timer function will not be used. If "on" is selected
and "using heater timer" is selected in the operation mode of the "barrel
temperature" screen ( section 6.5).
specific operating mode (ACCESS LEVEL: 2)
This field is used to select the among the operating modes of heating: "on", "off"
and "reduce".
starting time (ACCESS LEVEL: 2)
The starting time for the operating mode as specified in section 6.27.2 is
entered here.
shift schedule (Not yet released).
139
CONTROL SCREENS
summary 1
ACCESS METHOD: Press + "summary" softkey
Some important settings in the "injection & holding" screen or "metering" screen
can be set in this screen.
140
CONTROL SCREENS
hopper dryer temperature control
ACCESS METHOD : Press + "hopper dryer temperature control" softkey
Not yet released.
141
CONTROL SCREENS
setup guide
ACCESS METHOD: Press + "setup guide" softkey
This screen is used to provide a setup guide line for the operator to setting
some individual parameters.
Operator use cursor key to select which kind of parameters

for setting.
Then press the open menu window softkey at left hard side of screen to open
the menu for that item.
Use cursor key to select the item for setting.
Press "Access Item" softkey to go to the screen for setting that prameter.
If desirable item isnot displayed in the window. Use "scroll up" or "scroll down"
softkey to display other setting in this item.
If the desire item is not find, use "close menu window" softkey to close the
selection windows.
142
CONTROL SCREENS
shift scheduler
ACCESS METHOD: Press + "Shift scheduler" softkey
Not yet released.
143
CONTROL SCREENS
down time reject record
ACCESS METHOD: Press + "down time reject record"
Not yet released.
144
CONTROL SCREENS
data log
Access method : Press F3 key.
This screen will logging last 40 data settling have been modified. If the
previous data setting is preferable use cursor key to highlight the
comporting data setting. And press the modification reversal softkey will
reversal that data setting to if previous value. ( Note : if not data setting have
been change. The operator can not access this screen. )
145
CONTROL SCREENS
monitoring data
Not yet released.
146
CONTROL SCREENS
monitoring graph
ACCESS METHOD: Press + "monitoring graph"
Not yet released.
147
CONTROL SCREENS
Input diagnostic
This screen shows the actual status of digital input card 1:
The corresponding input is activated.
The corresponding input is not activated.
Note : the description next to the input point is for standard TTI-C
Series machine only. For other series machine the connection of
individual point please refer to wiring diagram supplied together with the
machine.
148
CONTROL SCREENS
input 2 diagnostic
ACCESS METHOD: Press + "input 2 diagnostic"
This screen show the actual status of digital input card 2. The status of inputs is
explained in section 6.36.
Note : the description next to the input point is for standard TTI-C
Series machine only. For other series machine the connection of
individual point please refer to wiring diagram supplied together with the
machine.
149
CONTROL SCREENS
output diagnostic
ACCESS METHOD: Press + "output diagnostic"
This screen show the actual status of the digital output card ( output for
hydraulic directional solenoid, alarm lamp etc.)
The corresponding output is activated.
The corresponding output is not activated.
Note : the description next to the output point 5 only for standard TTI-C
Series machine. For other series machine the connection of individual
point please refer to wiring diagram supplied together with the machine.
150
CONTROL SCREENS
analog I/O diagnostic
ACCESS METHOD: Press + "analog I/O diagnostic" softkey
This screen is for monitoring the current status of all analog input and output
channel. The input and output level for corresponding analog input and output
channel is shown by a red pointer on a scale from 0% to 100%. 0% is the
minimum input or output level while 100% is the maximum input or output level.
151
CONTROL SCREENS
Internal flag monitoring
ACCESS METHOD: Press + "internal flag monitoring" softkey
This screen is for monitoring the actual status of internal M relay used in the
sequence program. The use of this screen is for trouble shooting when the
machine have problem. The title at the left stand for the first 3 significant digit
of the M relay. The 0-9 digit in the table on the right is the least significant
digit. For example, M0015 & M0018 is on for the above screen. If different M
relay page is to be selected, press the toggle key or press selection key to
select. Only M000 - M1279 is effective.
152
CONTROL SCREENS
machine configuration
ACCESS METHOD: Press + "machine configuration" softkey
This screen is only for the use by technician from WELLTEC.
153
numbering screen
ACCESS Method : + number screen softkey.
In the screen it will display all the screen which is available in the controller.
Operator can used the to highlight which screen to go. Then
press the screen access softkey to access the corresponding screen. So the
operator does not need to play with the hard key to access the screen.
154
Section 7 MACHINE SETTING PROCEDURES
machine setting procedures

Safety
It is the responsibility of the employer or the owner of this machine to instruct
and train his/her operators the safety operation and the use of safety devices of
this machine. MAKE SURE all the operators have read and understood the safety
precaution as stated in section 1 "General safety practices".
MACHINE START-UP
The CIMtrol control provides the operator with 'finger-tip' control of machine
set-up variables. Before proceeding any further, the operator shall be familiar
with the CIMtrol control, which is described in previous chapters. Having been
familiar with the controller and all safety features, the operator may proceed to
the following.
It is advised to use the following checklist before starting the pump motor.
Make a visual inspection of the machine to make sure that no components have
been removed for maintenance or servicing. Be certain that all guards are in
place.
Verify that the machine and machine area are clear of all rags, tools, spare parts,
raw material, scrap, etc. that could interfere with safe machine operation. Verify
that the floor is dry and free of oil, grease and water.
Service the entire machine in accordance with the instructions on the lubrication
sign, located on the machine base, operator side and clamp end. Refer also to the
Maintenance and Troubleshooting section of the Manual.
Open the cooling water supply valves and make certain water is circulating
through the heat exchanger and the injection unit feed throat.
Refer to the caution tag located on the front guard door, and check all the items
listed. For example; front operator gate mechanical, electrical and hydraulic
interlocks; rear and front fixed guards. Also check the operation of the
emergency stop button and the purge guard. Refer to the "general safety
practices" section in this manual for additional information.
If everything is ready, press the motor start up button once to start the electric
motor.
Setting TEMPERATURE CONTROL
All parameters that are required to set the temperature are accessible on the
temperature screen.
Press the temperature screen key .
Setup the desire temperature of each heating zone for the material which is going
to be processed. Check the specifications provided by material manufacturer if
necessary.
Setup the +tol and -tol as required
Move the cursor to "operation mode" field and use the toggle key or the "On"
soft-key to turn on the heater .
Following is an example setting for the temperature screen.
153
MACHINE SETTING PROCEDURES
154
SETTING CONTROL FOR CLAMP/EJECTOR SYSTEM

All the parameters that are required to set the clamp and ejector can be accessed
on the clamping screen. For detailed explanations of the various parameters,
please refer the clamping screen description, located in SECTION 6 of this
manual
After the mold is installed, the motor is switched on and the proper access code is
entered, perform the following procedure.
CLAMP MOTION SETUP
Invoke the service screen by pressing and "service" softkey.
Enter the setup pressure and speed for clamp movement.
Use setup mode by pressing and selecting
Invoke the clamping screen by pressing .

Set the mold clamping stop position to 5 mm.
Fully extend the clamp by rotating to right the switch .
If the clamp cannot fully extend, increase the mold height by rotating the switch
"mold height adjustment" to left using mold height adjustment mode
Repeat (6) after switching on the left button and repeat (7) until the clamp can
fully extend.
Rotate the mold movement switch in anti-clockwise direction to open the clamp to
the desired fully open position ( for proper part ejection ). If the clamp cannot be
fully open ( the mold open speed and pressure signals are interrupted by the mold
opened position setting), enter a value greater than the current clamp position for
mold fully open position and open the clamp again until the required stroke is
attained.
Note the current clamp position on the screen and enter the same value for the
mold fully open position.
Set the mold open slow position to about 50 - 100 mm less than the mold fully
opened position, which is just entered above. Initially set the slow mold open
speed and pressure to a low value to avoid the possibility of damaging the
machine.
Set the fast mold open position to a point where the clamp has unlocked but the
mold face have not yet parted. There will be no possibility of damaging the
machine if the clamp is set to fast open while the mold is near to the fully closed
position. The speed and pressure settings can also be entered to maximum values.
To ensure the safety of the mold, set the low pressure slow close position to a
larger than required 100-150mm (approximately halfway between mold fully
closed and mold fully open positions).
Set the speed and pressure to low values for safety reason.
Set the fast mold close speed low to ensure mold safety
155
Set the mold safe endposition as the position of clamping platen when the mold
faces just touch. Set the speed and pressure to just sufficient required for locking
the clamp.
Close the mold. Make sure the mold faces are together before further proceed (if
they are not together, refer to step 12.c below). Note the actual position readout
on the clamp screen. Open the mold.
Set the mold safe position to 5 to 10 mm greater than the figure observed in the
preceding step. Close the mold again. Again check the actual position and ensure
that the mold safe end position was reached (if not reached, then refer to Step
12.c below). If the mold safe position is reached, but the clamp cannot lockup,
refer to Step 12.a below. Or if the machine does lock up but a greater tonnage is
desired, refer to step 12.b below. Open the mold.
(a) If the clamp will not lock up, increase the mold height a short distance, and try
to close the clamp. Repeat this procedure until the clamp lock up.
(b) If the clamp can lockup, decrease the mold height slightly and try to close the
clamp again. Repeat until the clamp cannot lock up, then increase the mold height.
Note that when adjusting the clamp in the direction of decreasing mold height,
that the mold safe position may not be able to be reached. Therefore, ensure that
the mold safe position is reached before deciding that the clamp will not lockup is
due to the mold height being too short. If lockup is satisfactory, proceed to Step
13.
(c) If the mold faces cannot touch each other, there is a possibility that the "low
pressure/slow close" pressure setting is not high enough to close the mold faces
together because of cams, etc., in the mold. If the clamp stop before the mold
faces touch, increase the pressure setting and try to close the mold again. If the
actual clamp position reading decreases when the "low pressure/slow close"
pressure is increased, and the mold faces still not touch each other, continue to
increase the pressure in small increments until the mold halves touch. If
increasing the pressure does not decrease the actual clamp position reading or if
the slow close pressure setting is excessive for the type of mold being used,
refer to the list of possible problems following this paragraph and eliminate any
possible faults before proceeding. Mold cams, linkages may sometimes require
pressure setting of 25 to 35 and mold spring may sometimes require pressure
setting of 40 to 45.
Possible problems:
Leader pin alignment
Lubrication to the toggle mechanism
Platen shoe adjustment
Obstruction between mold halves
Unknown springs within the mold
Other mold related possibilities
After observing clamp movement, adjust the clamp speeds to allow for the fastest
speeds with the smoothest operation possible
As the speeds are increased, the position set points may be overridden and
therefore it may be necessary to slightly readjust the position settings for
optimum performance.
Measure the clamping time required
156
Set the mold close timer to 1 sec. greater than the value measure in step 15 and
set the no. of mold rebound counter as desired.
(10)
(11)
EJECTOR SETUP
Set the Ejector start position. Ideally, the ejector start position should be set to a
position for which ejector reaches the ejector forward stopped position at the
same time that the clamp reaches the fully open position.
Enter the position, speed and pressure for the ejector forward and retract
motions. It is desirable to limit the pressure due to the limited strength of the
mold. Once the desired speeds have been set, pressure can be reduced to a value
affecting speed, then increase the pressure slightly.
The ejector stroke shall be set for positive ejection of parts. Use features such as
count eject (multiple-stroke), eject forward hold time as required.
Operate the clamp in the semi-automatic mode to ensure that the machine
operates as desired with the current settings. Make any necessary adjustments at
this time.
COOLING TIME SETUP
Press the timer key
157
Set the required cooling time.
CORE SETTING
The optional core set and pull sequences can be selected from core screen.
Press the core screen Key
Select the core sequence required. For detail information of the core sequence
refer to the description of the core screen in Section 6. If no side core is needed,
select "not use" in the "core sequence" field. (Note: although NO CORE is
selected, for safety reason, the Core 1 out (X013) and Core 2 out limit (X015)
must both be activated to safety guard the ejector motion during semi-automatic
or fully automatic sequence).
Select "Limit Switch" or "Timer" according to the structure of the core. If timer is
selected, enter the desired time for core in and core out motions.
Select the use of individual core in and core out process according to mold
requirement.
If the core function is used during mold closing or opening (depend on the core
sequence selected, for detail information please refer to Section 5), enter the
position of clamp for which core in or core out.
(2)
(3)
158
injection UNIT SET-UP AND OPERATION

INITIAL INJECTION UNIT SETTINGS
Read all technical data for the material that is to be processed. The technical data
shall be available from the material manufacturer. Failure to follow the
recommended processing procedures can result in serious bodily injury and
damage to the machine the mold. All the parameters that are required to set-up
the injection unit are accessible on the "carriage" Screen, the "injection and
holding" screen, and the "metering" screen. Perform the following steps to set the
injection unit.
Turn on the heater from the temperature screen .
Invoke the metering screen by pressing the key. If decompression before
or after metering is required, enter the desired position, pressure and speed
settings. Use a "tick" or a "cross" for selection between using the decompression
function or not.
Set the metering stopped position. This can be found by referring to the individual
mold specification sheet. It is advisable to start set-up with a reduced shot size
to prevent overpacking of the mold. Caution: when calculating the first shot, be
ware of the fact that some short shots cannot be ejected properly.
Invoke the "injection and holding" screen by pressing . Select the desired
cut-off mode; position,time, position or time, injection pressure after position,
injection pressure after time, cavity pressure after position or cavity pressure
after time. Enter the cut-off settings for the selected mode.
Select the desired no. of stages of injection. Enter the desired values for the
velocity set points.
Select the desired no. of stages of holding pressure. Enter the holding pressure
and time settings. Set the parameters as low as possible for individual molding
conditions.
Invoke the metering screen by pressing . Select the desired no. of metering
stage. Enter the desired pressure,position and speed settings for back pressure
and metering.
Following is an example setting for injection and holding screen.
159
Following is the example setting for "metering" screen
Following is the example setting for the carriage screen
RECOMMENDED INJECTION UNIT START-UP AND PURGING PROCEDURES

Ensure the water supply to the injection unit feed throat is turned on .
Ensure that the barrel and nozzle heating zones are properly set .
Wait for the nozzle and barrel to be heated to the set temperature. The time for
the barrel and nozzle to be heated to the settings was approximately half an hour.
It is recommended that an additional half hour shall be allowed to thoroughly heat
the plastic material before rotating the screw.
Check all safety devices as outlined on the "Operator Gate Caution Tag" at this
time. Always check the DANGER and WARNING Tags located on the machine.
Invoke the carriage screen pressing key and "carriage" soft-key. Enter all
position, speed and pressure settings for carriage motion.
Perform the following procedures to clear the old material in the barrel and fill
with new material.
160
(a) Fill the hopper with clean, dry material. An approved

safety ladder with safety tread steps and hand rails should
be used when filling the hopper.
DANGER - NEVER STAND ON THE METAL SHIELD
THAT COVERS THE BARREL HEATING BANDS. IT IS
NOT DESIGNED TO BEAR LOADS
(b) Follow these purging practices:

Wear long sleeves.
Wear gloves that overlap the sleeves.
Wear approved face protection.
Close the purge guard.
The nozzle heat must be up to proper temperature to
prevent freeze off.
DANGER - NEVER ATTEMPT TO CLEAR A

CLOGGED NOZZLE BY INJECTING MATERIAL.
(c) With the injection carriage in a retracted position, place a

piece of cardboard or sheet metal in front of or between the
stationary platen and nozzle.
(d) Rotate the screw. Visually check the screw rotating speed.
Increase the screw rotating speed slightly. Ensure that you
are in the correct screw speed range for the material being
processed.
(e) Slowly introduce material into the feed section by pulling

the material shutoff slide outward. When filling material to
an empty barrel or chamber, do so on a gradual basis so as
not to convey raw granules into the front or metering zone
of the screw. This may create sudden power overload on
the screw and drive system.
(f) With the material feeding in the open position rotate the
screw for approximately 10 seconds, and wait for about 30
seconds and rotate the screw again. Repeat this procedure
until the screw starts to retract. The screw can then be
rotated continuously.
(g) As filling continues, the screw will retract until the

metering stopped position is reached. The screw will then
stop rotating.
(h) Empty the barrel using injection by rotating injection

switch anticlockwise. The purge guard and both guard
door must be closed.
161
(i) Purge all the old material from the barrel.
final INJECTION UNIT SETTING

Complete the following procedure to optimize machine operation.
Seat the nozzle against the mold sprue bushing. Move the nozzle against the mold
slowly to ensure that nozzle seats properly.
Try several shots using the initial setting before making adjustments. It may be
necessary to increase the screw speed and the injection speed to obtain the best
overall cycle time and the most efficient cycle.
Adjust the back pressure in small increments until the desired performance is
attained.
To prevent material from drooling into the mold while the mold is opened, it may
be desirable to adjust the decompress before or decompress after screw rotation
parameters.
If the mold is designed to operate automatically, the machine may now be placed
in the automatic mode.
Select the "injection and holding" screen by key. Enter velocity settings. If
the mold is a straight forward design with a simple runner system and few gates,
then a velocity profile with only a few set points will be sufficient. If the mold is
complex with numerous runner branches and gates, as many as ten velocity set
points may be required. With the help of the graphic screen, adjustments can be
made to the velocity settings to produce the desired velocity profile. With the
velocity setting cycle the machine a few times to allow the process to respond to
the changes.
Also in the "injection and holding" screen, enter holding pressure settings. If the
mold is a straight forward design with a simple runner system and few gates, a
profile with only a few settings will be sufficient. If the mold is complex with
numerous runner branches and gates, as many as ten pressure settings may be
required. With the use of the graph on the screen, adjustments can be made to
the pressure settings to produce the desired pressure profile. After the
adjustment, cycle the machine a few times to allow the process to respond to the
changes.
Invoke the metering screen by pressing key. Enter pressure and position
settings for back pressure. Monitor the actual back pressure on the graph and
make adjustments to the back pressure setting when required. After the
adjustment has been made, cycle the machine a few times to allow the system to
respond to the change.
If a cavity transducer is installed, invoke the cavity pressure profile screen to
monitor the cavity pressure graphically .
Invoke the "injection and holding" screen, enter the desired positions for cushion
and the tolerance. The velocity, hold pressure, and recovery profiles can be
monitored in the graphic screen.
Record the mold data in internal memory or on a memory card. Refer to the
internal memory or IC card screen description in section 6 for additional
information.
MACHINE SHUTDOWN PROCEDURE
After production and before proceeding with the machine shutdown, it is
recommended that the mold data resident in active memory be downloaded to
internal memory. This will provide a back-up and eliminate the possibility of
someone inadvertently alter the parameters. (Refer to the Internal Memory Screen
162
description in Section 6.) The following procedure should be helpful when shutting
the machine down. While operating in the semi-automatic mode, shut the hopper
feed off.
Continue running the machine until the screw barrel feed throat is empty of
material.
Stop the machine cycle and operate in the manual mode.
Retract the nozzle away from the mold.
Using the manual screw motion switch to rotate the screw, purge the screw of as
much as possible. Follow the safe purging practices.
NOTE : IT MAY BE NECESSARY FOR SOME MATERIALS TO BE PURGED

COMPLETELY FROM THE BARREL. THIS CAN BE DONE BY EITHER REMOVING
AND CLEANING THE SCREW AND BARREL OR PURGING WITH A DIFFERENT
MATERIAL. CONTACT YOUR MATERIAL SUPPLIER FOR HIS
RECOMMENDATIONS. IN EITHER CASE, USE MANUAL CONTROLS TO
INITIALLY REMOVE AS MUCH RESIDUAL MATERIAL AS POSSIBLE.
DO NOT rotate the screw for extended periods without material in the screw
barrel chamber. The material acts as a lubricant and prevents direct metal to
metal contact.
Using the screw motion switch to move the screw to the forward position.
Open the clamp if desired, coat the mold with a rust preventative. Close the mold
until the mold faces just touch. ( DO NOT leave the clamp in a locked up
condition.)
Turn off the pump motor(s) and disconnect main power .
Turn off the water to the feed throat .
If applicable, turn off the auxiliary equipment .
163
Section 8 TIPS ON BEST MOLDING
Tips on best molding

Setting the Injection pattern
During the injection process, the resin flows from the sprue through runner and
gate into the cavity. In order to keep an undisturbed flow, to form an evenly
stable skin and to avoid an increasing viscosity, the main point during this process
is to finish the filling in a possibly short time. For this purpose it is most effective
to control the injection speed by setting its program in several steps in order to
precisely adjust the flow speed of the resin according to the form of the cavity.
Inferiorities due to incorrect adjustment of the injection process are flow marks,
surface color and gloss changes, weld marks, drops, burns, jetting, etc., and with
the traditional one-speed injection it is very difficult to solve all these various
problems. For instance, if the speed is increased intending to avoid flow marks,
on the other hand this causes new problems like jetting, burns or drops.
In other words, since the most adequate injection speed to avoid such an
inferiority and the respective control position differ, the only way to a
fundamental solution is to control the speed according to the cavity form.
Under holding pressure, the resin filled into the mold is cooled and therefore
contracts, and in order to supply the contracted part, the resin is replenished
under adequate holding pressure. When this holding pressure is adjusted
according to the temperature changes of the resin inside the mold, inferiorities
like cambers and drops can be avoided.
With such a control, even forming of complicated high-quality products, which
was impossible with the traditional constant speed and holding pressure, is
possible now, and at the same time, the range of applicable forming conditions
becomes wider. Therefore the quality of the formed products can be maintained
constantly and a shortening of the time for a cycle can be expected.
Since at the moment of switching over from injection to holding pressure the
injection speed can be lowered, an instantaneous high pressure inside the cavity
can be avoided, which prevents burrs. Therefore, in some cases a machine with a
smaller clamping force can be used.
Basic calculations for the conditions to set the program control conditions and
practical examples are explained following.
NOTE: The term "orientation" means the flowing direction and the reaction of the
resin inside the mold. Since cooling and hardening process of the product differ
on the skin and inside, also the flowing behavior of the resin changes. This can
specially be influenced by changing the molding conditions and the direction.
Generally, products with rectangular flowing direction are weaker than those with
a stable direction; they keep inner residual force (strain), and their heat
resistance, etc., decrease.
Mold inside pressure and quality of the formed product
The speed when filling the resin into the mold, and the pressure after filling have
a great influence on the quality of the formed product. Their relations are as
follows.
The filling process influences the surface quality of the product and is decisive
for appearance and orientation.
The compression process influences the final form of the product. If too high,
burrs occur, and the mold may be damaged; if too low, short shots are the result.
The holding pressure process influences the contraction of the product. If the
contraction is too much, drops or voids follow. Together with the cooling
process, it decides the product's inner orientation and crystallization.
An over-pack in this process leads to cambers, trouble with the product's inner
tension and sticking to the mold.
167
TIPS ON BEST MOLDING
During the cooling process, the cooling continuing from the holding pressure
proceeds according to the mold temperature and becomes visible in a drop of the
mold inner pressure.
Calculations for setting the conditions

In the Right figure, A shall indicate
clouding and jetting, B shall indicate
flow marks, and at the whole body
are burrs.
Before thinking about a solution, first
let us consider what causes such
faults.
168
Causes of faults
First, let us look at the motion
of the molten resin in area A.
Molten resin intrudes from

the sprue runner.
Filling into the cavity starts.
Because the molded product

has steps, the molten resin
continues to flow in before
filling out the steps.
The molten resin wraps the
stepped areas. Air and
volatile matter of the resin are
left in stepped areas.
As the molten resin continues to flow in, the air and gas contained in the stepped area are
dragged by the flowing resin, which causes cloudiness due to gas inclusion. As the resin
flows in, the part contacting the mold starts to set quickly.
As molten resin continues to

flow in the areas where the
resin has already set, the resin
temperature falls. Therefore,
cases occur where the mold
face and the skin do not come
in contact.
The filling process continues
in this way until it is finished,
but since it is carried out in
high speed, the pressure
inside the cavity momentarily
raises very high, which causes
burrs.
Countermeasures
Item Mold Resin Injection speed Hold pressure
Fault temperature temperature
Jetting Increase Increase Decrease -
Clouding due to gas Increase Decrease Decrease -
inclusion
Flow mark Increase Increase Increase Increase
Flash Decrease Decrease Decrease Decrease
The table shows countermeasures for solving faults.

As can be seen from the table, it is impossible to change mold temperature and
resin temperature within one cycle. Also in regard to shortening of the molding
169
cycle, it is not desirable to raise mold or resin temperature. Therefore, the best
way to solve fault problems is to increase the injection speed conditions and to
keep the temperature possibly low to keep the cycle short
Example for program setting
Fill the sprue runner in high
speed to shorten the cycle. Fill
resin slowly into the stepped
Mold
areas to prevent air and gas
inclusions and jetting.
In order to prevent flow marks,
Injection Speed
fill the area of flow marks in
high speed.
Before the filling process is 3
completed, slow down the
injection speed to prevent 1
burrs. 4
2
Basic Methods for Setting Injection and Holding Pressure Programs
Inferiority Program Setting
Weld line Weld lines on the back face of the
draft hole are prevented by raising
the speed and thus avoiding a
decrease of the resin temperature
Holding Transfer the weld to a less not-

pressure
iceable position by changing
the changeover position
Drop Decrease the speed at At the end sections, decrease

thick-walled sections to the speed and increase the holding
stablilize the skin pressure
Jetting, Decrease the speed when the resin

silver marks
passes the gate
and burn
around the
gate
170

Flow mark If the flow mark is If the flow marks is
caused by an incre- caused by a decreas-
ased flow speed due ed resin temperature
to a narrowed flow and flow turb-
way, decrease the ulence at thick-
flow speed. walled sections,
increase the
speed
Burr
Decrease the speed before the filling prcess is
completed to avoid a pressure peak in the cavity.
Together with a more precise changeover position
of the holding pressure, this to mold with a smaller
clamping force
Holding pressure changeover
Gas burn
Decrease the speed in the areas of gas burn to
let the gas escape.
Gate
balance In case of multi-piece molding, increase the speed
so that the resin runs into the cavities simultane-
ously in order to prevent spattering between the
cavities.
Camber, Decrease the holding pressure in

residual Completion of
stress steps according to the cooling of
hold pressure
the resin inside the mold
Start of hold
pressure
171

Drop, burr
For thin-walled products For thick-wa-
drops are eliminated lled products,
by raising the pressure set the press-
of the first step for a ure of the
short time. first step low.
172
Molding fault and Countermeasures

MOLDING FAULTS
GENERAL
Because of the nature of the material, the many variables in the process, and the
mold design characteristics, many faults occur in injection molding. Also,
practices in the work place often lead to related problems. It can be said then
that molding problems are the result of machine, mold, material and user.
Listed below are types of faults by category, with those wherein some faults are
correctable or preventable by process control, so indicated.
In most instances, the fault suggests the remedy. Reference to standard plastics
reference material, manufacturer's literature and pamphlets will be helpful in
adjusting temperatures, pressure, times, etc.
Before attempting any correction of the molding fault, short shoot the mold (but
be sure parts will still eject okay) to be certain that all cavities are filling equally.
If not, balance the gates or runners. You must be able to mold consistently
(though quality may still be questionable) before continuing. Process control will
not compensate for obvious defects in the mold or machine, or grossly
misadjusted pressures or times.
Category of Fault Correctable or
Minimized by
Process Control
Short shots yes
Parts flashing yes
Sink marks yes
Bubbles *
Poor welds *
Material discoloration *
Warpage and shrinkage yes
Dimensional control yes
Sticking in mold yes
Sticking in sprue no
Nozzle drool no
Excessive cycle time *
Splay mica, flow marks *
* Qualified yes. Other extraneous problems that are not process control
correctable, must first be eliminated prior to initiating process control.
Refer to the following fault causes for possible corrective action.
SHORT SHOTS
Short shots are usually caused by lack of sufficient effective pressure on the
material in the cavity during the injection cycle. It may require some rework of
the mold to increase the size of the nozzle, sprue, runner, gate stem. Improving
the mold design or redesigning the part may be necessary. Process Control can
be used effectively to maintain control when pressures, and/or filling times cause
problems during injection.
Insufficient injection pressure.
Injection speed too slow.
Injection time too short.
Injection boost time too short.
Flow properties of material too low for the part.
173
No material in the hopper.

Insufficient feed.
Machine capacity too small for shot.
Runners too small.
Gates too small.
Cold slug to large, blocking flow.
Inadequate venting.
Unequal filling rates of cavities.
Interrupted flow in cavities to cure, balance gates.
Improper gate location.
Insufficient number of gates.
Cylinder temperature settings too low.
Nozzle temperature setting too low.
Increase nozzle flow or opening hole diameter and reducing land length.
Raise back pressure.
Uneven mold temperature control.
Incorrect mold temperature control system.
Inconsistent cycles operator caused.
Inconsistent cycles, mold caused.
Inconsistent cycles, machine caused.
Excessive feed which can cause loss of injection pressure due to too much
cushion in front of injection ram.
Feed system operating incorrectly.
Temperature control system operating incorrectly.
Heater band(s) inoperative.
Thermocouple(s) inoperative.
Loss of injection pressure during cycle.
PARTS FLASHING
Parts flashing are caused by a mold deficiency Insufficient clamp pressure,
excessive injection pressure, excessive barrel temperature, and incorrect
operating conditions are other causes. Process Control can be used to
compensate for excessive injection pressure and the effects of material viscosity
upsets.
Injection/Pack pressure too high.
Boost/Velocity cutoff late.
Injection speed too fast.
Material temperature too high.
Material flow is too high
Cavities and cores not sealing.
Cavities and cores out of line.
Mold plates are not parallel.
Mold not sealing off because of foreign materials₩ (flash) between surfaces.
Insufficient support in the mold for cavities and cores.
Projected area of parts too large for machine clamp force.
Insufficient venting.
Vent clearances too large.
Land area too large around cavities.
Unequal filling rates of cavities.
Interrupted flow into cavities.
Machine not set up correctly.
Clamp pressure not maintained.
Machine platens not parallel.
174
Feed setting too large.

Clamp pressure too low.
Boost time too long.
Inconsistent cycle operator caused.
Inconsistent cycle mold caused.
Inconsistent cycle machine caused.
SINK MARKS
Sink marks are usually caused by insufficient effective pressure on the part in
the cavity, insufficient material, or a part design problem. They occur when there
are heavy sections, particularly adjacent to thinner sections. Process control can
be used effectively to maintain consistent injection pressure, injection rate, and
packing or hold pressure.
Increase injection/pack pressure.
Increase injection speed.
Insufficient material in the mold (see SHORT SHOTS).
Increase injection pack/hold time.
Increase boost time.
Increase cushion.
Increase back pressure.
Material too hot causes excessive shrinkage.
Material too cold causes incomplete filling.
Moisture in material.
Machine capacity too low.
Mold temperature too low.
Over-heated core pins.
Mold temperature control system incorrect.
Lubricate material.
Increase gate size.
Increase runner size.
Increase sprue diameter.
Increase nozzle flow increase temp., open up diameter of hole, reduce land.
Unequal filling of cavities.
Interrupted flow into cavities.
Improper gate location.
Uneven wall thickness (ribs, bosses). Core where possible.
BUBBLES
Bubbles are caused by insufficient plastic in the cavity. The resulting voids are
not due to acuum effects? but to internal shrinkage, volume reduction, after the
outside surface have hardened.
Process Control can be used effectively to help eliminate bubbles in molded parts
by insuring that desired fill rate and mold, packing, pressure are consistently
maintained from shot to shot. It is assumed that the cycle is consistent and that
the mold is balanced regarding filling.
Injection rate too low.
Injection pressure too low.
Insufficient material (see SHORT SHOTS).
Nozzle and sprue cross section too small.
Runners too small.
Gates too small.
175
Material too hot.

Injection pack/hold time insufficient.
Injection boost time insufficient.
Clamp pressure too high, if more venting required or volatiles present.
Increase mold temperature.
Maintain uniform mold temperature.
Air entrapment, Vent, relocate gate, See "Poor Welds.
Vent mold.
Dry hygroscopic material.
Pieces cooled too long in mold. Prevents pieces from shrinking from outside.
Put parts in hot water for cooling.
POOR WELDS
Poor welds are caused by insufficient pressure and temperature at the weld
location.
Process control can help to minimize poor welds when induced by injection
pressure variations, or when variations in pressure caused by temperature or
injection speed variations are minimized.
It is assumed that the cycle is consistent and that the mold is balanced regarding
filling.
Injection pressure too low.
Increase injection speed/change velocity profile.
Excessive pressure loss in system.
Uneven melt temperature.
Material too cold.
Nozzle too cold.
Increase mold temperature.
Insufficient venting at weld.
Add run-offs from weld section where possible.
Insufficient venting of parts.
Runners too small.
Gates too small.
Sprue and nozzle openings too small.
Gate too distant from weld.
Lubricate material.
Contaminated material can reduce knitting properties.
Walls too thin causing premature freezing.
Shifting cores causing too thin walls.
Shot too large for the machine.
MATERIAL DISCOLORATION
Material is most often discolored by burning and the degradation of the material.
This is caused by excessive temperatures and the material hanging up somewhere
in the system.
Process control generally will not correct for a discoloration problem but will
minimize its occurrence if caused by variations in injection rate or injection
pressure.
It is assumed that the cycle is consistent and the mold is balanced regarding
filling.
Contaminated material.
Dirty machine.
Dirty atmosphere. Colorants can float in the air and settle in the hopper and
grinders.
176
Dirty hopper drier.

Remove and clean nozzle.
Purge screw barrel.
Reseat barrel.
Clean barrel.
Temperature control system malfunctioning.
Heater band(s) not operating.
Thermocouple(s) not operating.
Cracked barrel.
Decrease material temperature.
Reduce clamp pressure.
Slow injection rate.
Decrease injection pressure.
Decrease booster time.
Decrease cycle.
Preheat hygroscopic material, or use vented barrel.
Vent mold.
Increased gate size.
Change gating pattern.
Remove lubricant and oil from mold.
Investigate mold release agent.
Material may be releasing volatiles.
Material may be degrading.
Colorants may be degrading.
Additives may be degrading.
Put in smaller shot capacity machine.
Decrease back pressure.
WARPAGE & SHRINKAGE
Warpage and shrinkage are usually caused by molding conditions. In polylefins,
improper gating locations will cause source warpage. Heavy sections contribute
to this problem. High stress levels are a major factor in warpage.
Process control can maintain consistent pressure and fill rate once these have
been established. Any change in these variables will be automatically
compensated by the process control system, thus assuring those conditions do not
produce a bad part.
It is assumed that the cycle is consistent and that the mold is balanced regarding
filling.
Decrease injection pressure.
Decrease material pressure.
Decrease mold temperature (when attempting to reduce the temperature of the
molded part).
Increase cycle time.
Decrease mold breakaway speed.
Decrease injection forward time.
Decrease injection boost time.
Increase mold temperature (when attempting to reduce the stress level in the
molded part).
Prevent core pins from overheating.
Slow down ejection system.
Change gate size. Gates that are too large permit packing of material, and high
stress levels. Gates that are too small do not permit enough material to enter the
cavities and cause shrinking.
177
Change gating pattern.

Insufficient venting, particularly on deep draw parts.
Insufficient ejection area on piece.
Uneven ejection from mold.
Cool in fixture.
Cool in water.
Anneal parts after molding.
Reinforce warping sections by thickening walls and adding ribs.
Change part design.
Use faster setting material.
Wrong mold dimensions cause parts to appear to have shrunk excessively.
DIMENSIONAL CONTROL
Dimensional Variations are caused by inconsistent machine control, wrong
molding conditions, and poor part design. Process control can help to minimize
dimensional variations when they are induced by pressure and fill time variations.
Process control will help stabilize the molding process.
Injection pressure variation.
Increase injection pressure.
Incorrect mold dimensions causing parts to appear out of tolerance.
Distortion during ejection. See ticking in the Mold?
Malfunctioning feed mechanisms.
Malfunctioning barrel temperature control system.
Adjust pack/hold profile.
Inoperative heating band(s).
Inoperative thermocouple(s).
Inconsistent screw speed.
Uneven back pressure adjustment.
Uneven mold temperature control.
Leakage by non-return valve.
Uneven screw stop circuit function.
Uneven mold filling.
Interrupted mold filling.
Incorrect gate size.
Decrease material temperature.
Large difference in particle size in hopper.
Variation of particle size from batch to batch.
Check cycle time consistency.
Insufficient machine capacity.
STICKING IN THE MOLD
Parts stick in the mold primarily because of mold defects, insufficient knockout
(KO) and packing of material into the mold.
Process control will help to minimize problems if due to excessive packing
pressure.
Mold and part design problems are generally not correctable with process control.
It is assumed that the machine is correctly adjusted and capable of producing
good parts with no sticking.
Reduce injection/pack pressure.
Shorten time to cutoff of boost
Undercut(s) in mold.
178
Burring, scratching, and pitting of the mold.

Insufficient part taper (draft).
Adjust velocity profile.
Poor mold surface or improper mold surface for material being molded.
Insufficient KO.
Improper KO location.
Improper operation of KO system (plates not moving in proper sequence, cams
loose).
Cores shifting during injection.
Cavities and cores misaligned.
Add additional KO systems, such as air injection.
Break vacuum in deep drawn moldings.
Insufficient mold release agent.
Incorrect mold release agent.
Decrease gate size.
Relocate gate.
Uneven mold filling causing some parts to pack.
Interrupted mold filling.
Reduce feed.
Reduce injection forward time.
Reduce injection boost time.
Reduce mold temperature if on stationary half, increase if on moving half.
Part too hot for ejection.
Inconsistent cycle - operator caused.
Inconsistent cycle - mold caused.
Inconsistent cycle - machine caused.
Contaminated material.
Lubricate material.
Part degrading and losing mechanical strength.
Redesign part.
Radius and reinforce where possible.
If part remains on wrong side, undercut other side, change tapers, provide mold
temperature differential, i.e. cool core additionally.
STICKING OF SPRUE
Sprue sticking is caused by improperly fitted sprue/nozzle interface, pitted sprue,
inadequate pull-back and packing.
Process control will generally not eliminate sprue sticking problems.
Check nozzle-sprue seating.
Be sure that nozzle orifice is smaller than sprue orifice.
Polish sprue.
Increase decompress after rotate.
Radius sprue-runner conjunction.
Increase sprue diameter (if too small for strength) or decrease sprue diameter if
too large for cooling.
Increase sprue taper.
Use sprue-break. (Injection unit moves back slightly braking contact between
nozzle and sprue.)
Reduce injection pressure.
10. Reduce injection hold time.
11. Reduce feed.
12. Reduce mold temperature.
13. Reduce material temperature.
179
14. If sprue is too hot, cool as required.

15. See if material is contaminated.
NOZZLE DROOLING
Nozzle drooling is generally caused by a low viscosity or crystalline material at
too high a temperature.
Process control will generally not eliminate or reduce nozzle drooling.
Use nozzle shut-off.
Use reverse taper nozzle.
Reduce nozzle orifice diameter.
Increase "pull-back" (decompression).
Reduce nozzle temperature.
Reduce material temperature.
Dry hygroscopic material.
EXCESSIVE CYCLE TIME
Excessive cycles are usually caused by insufficient plasticizing capacity,
inadequate cooling channels and cooling water, erratic cycles, and poor
management.
Process control can help stabilize molding conditions, pressure, fill rate, etc.,
thus minimizing the cycle variations which can lead to an upset of the cycle.
Generally, however, it will be necessary to correct the causes before process
control will be effective.
Adjust velocity profile.
Incorrect setting of controls (cure time, pack/hold time, speed setting).
Increase screw RPM.
Malfunctioning of machine.
Decrease back to pressure.
Platen motion slowdown excessive.
Low pressure closing time excessive.
Erratic cycle caused by machine, mold, and operator.
Insufficient plasticizing capacity.
Insufficient mold cooling channels.
Inadequate water cooling capacity.
Material temperature too high.
Material too slow in setting up.
Too much for the operator to do, and so is not ready for the next cycle.
SPLAY-MICA-FLOW MARKS
Splay-mica-flow marks can be due to contaminated or degraded material, or
material that is too cold and fills too slowly.
Process control can minimize the formation of these appearance defects if they
are induced into the system because of a change in fill rate (slower). It is obvious
that if contaminated material or degraded material is the cause, process control
cannot correct.
SUMMARY ON MOLDING INFERIORITIES AND COUNTERMEASURES
Increase injection pressure

* * * * * * *
Decrease injection pressure
* * * * * *
Increase cylinder temperture
* * * * * * * * * * * * *
180
Decrease cylinder temperature

* * * * * * * *
Increase holding pressure and holding time
* * * * * * *
Decrease holding pressure and holding time
* * * * * *
Raise nozzle temperature
* * * * * * * * *
Nozzle shut
*
Confirm nozzle seal
* * *
Increase screw rotation frequency
*
Decrease screw rotation frequency
* * * * * * * * * * * * *
Nozzle is loosened
*
Inappropriate choice of nozzle
* * * * * * * *
Increase clamp force
*
Immediate hold pressure drop
* * * *
Decrease injection speed
* * * * * * * * * * * * * *
Increase injection speed
* * * * * * * * * *
Increase back pressure
* * * * * * * * * * * * * * *
Decrease back pressure
* *
Use a release-type nozzle with large opening
dia.
* * * * * * * * *
Increase mold temperature
* * * * * * * * * * * * * * *
Decrease mold temperature
* * * * * * * *
Clean mold and rounden edges
* * * *
check mold
* * * * * * * * * * *
Clean sprue, gate an runner
* * * *
Widen sprue and gate
* * * * * * * * * * * * * * *
provide an air outlet hole
* * * * * * *
Pre-dry the resin
* * * * * * * * * * *
Contaminated material
* * * * *
Hopper is empty. or hopper inlet is closed
* *
Limit switch for weighing is not correctly set
* * *
Provide the mold with an adequate cold slug
* * * * * * * * * * * * *
Adjust the nozzle touch precisely
* * * * *
Check diameters of nozzle and sprue bush
* * * * * *
Decrease temperature of material feed
opening (contrary in case of nylon)
*
Bridge inside the hopper
* * *
In case of multi-piece molding, fill the
cavities simulaneously
* * * *
Carry out air ejection
*
Increase cooling and rest time
* * * * *
Decrease cooling and rest time
*
Standards for molding temperature setting

Resin Cylinder Set Temperature (oC) Back Mold temp. Dry temp. Dry time
pressure (oC) (oC) (h)
(kg/cm2)
H1 H2 H3 NH
Polyethylen (Low
e PE Density) 140-200 160-220 200-230 200-230
LDPE 3-15 10-17
(High
Density) 180-230 200-250 210-260 210-260
HDPE
Polypropylene PP 170-270 190-290 190-310 190-310 3-15 15-80
181
Polystyrene (General)
PS GPPS 160-250 170-270 180-280 180-280
5-20 10-65 60-80 2-4
(Impact
Resistant) 170-240 180-260 180-270 180-280
HIPS
Vinyl (Soft) PVC

chloride 140-200 150-210 160-220 160-220 3-15 4-60
PVC
(Hard) PVC
150-200 160-210 170-220 160-220 5-20 50-80 60-80 2-4
Polybutylene-terphtalate 200-250 210-260 230-270 230-270 3-15 60-80 120-140 3-3

PBT
Acryl PMMA 170-240 180-250 190-260 190-260 3-15 40-90 70-80 4-6
Polyacetal POM 160-200 170-210 180-220 180-220 2-20 40-100 80-90 3-4
Polycarbonate
250-300 260-330 270-340 270-340 3-15 80-120 110-120 4-8
Polyamide PA6
PA(Nylon) 200-230 220-250 230-260 230-260 3-15 20-90 75-80 5-10
PA66 250-280 260-290 270-300 270-300
ABS 180-240 190-260 200-280 200-280 5-20 40-70 80-90 2-3
SAN (AS) 170-230 180-250 190-260 190-260 5-20 30-80 70-85 2-5
Denatured PPO 190-220 200-240 210-270 220-270 5-15 100-130 120-140 3-5
PPS 250-300 270-320 280-330 280-330 5-20 60-80 120-140 2-2

130-200
182
Section 9 MACHINE MAINTAIN AND REPAIR
machine maintenance and repair
To obtain the longest service life and to ensure the best performance at all time,
the machine shall be checked periodically. The O-rings or oil seals in the machine
may deteriorate with time and lose their function. They shall therefore be
replaced by parts with the same specifications. When the machine has been
stopped for a prolong period, or when a different resin is to be used, the machine
must be purged so that all remaining material in the barrel of the last operation is
removed. If it is necessary to remove the heating barrel for cleaning, take care
during re-assemble. Heat resistant lubrication oil shall be applied to the screw
thread of nozzle, distributer and the screw fixing the nozzle unit.
REGULAR INSPECTION
Daily Inspection
Check the oil level in the central lubrication system. Refill if necessary.
WEEKLY INSPECTION
Grease all movable parts that require lubrication.
Check for possible loose limit switches.
Check for possible oil leakage in the pipings or fittings. Tighten or reconnect
them if required.
MONTHLY INSPECTION
Check for possible loose electrical wiring .
Make sure that the hydraulic oil is clean. Refill when necessary.
Clean oil filters.
Check the condition of the fans, clean the dust filter or replace if necessary.
ANNUAL INSPECTION
Refill the tank with new hydraulic oil. This will increase the life of all hydraulic
components.
Clean every thermocouple contact point.
Check every connection of the electric wires in the cabinet. Check also if the
coating of the wires has hardened and fallen off so as to avoid possible short
circuit.
190
MACHINE MAINTAIN AND REPAIR
Check all LEDs.
Clean the motor and all hydraulic valves. If there are some dust on the surface of
the motor, it leads to difficult radiation of heat for motor.
TROUBLE SHOOTING
During machine operation, it is hard to avoid any trouble. Some trouble just occurs
in electric, mechanical or hydraulic components. Below are some possible trouble
with the machine and the shooting methods.
BREAKDOWN POSSIBLE CAUSES REMEDIES

1.Electric motor a. Power has been cut. 1) Check if main fuse has been
burnt.
2) Check if auto-breaker has
tripped off.
3) Check if the leftmost
magnetic contactor (1M) in
the star-delta circuit works
properly.
b. motor burnt out, giving Repair or replace motor
distinctive burning smell and according to its specifications.
smoke. Repair or replace pump.
c. Jammed or damaged oil
pump.
2. No pressure a. Burnt coil or loosen Check voltage across solenoid;

built-up although proportional pressure relief if open circuit; replace valve.
motor and pump valve inlet and outlet.
work properly. b. Clogged of the proportional Dismantle valve and clean it with
pressure relief valve inlet and paraffin.
outlet.
c. Dirt accumulation hindering Clean filter and replace
hydraulic oil flow. hydraulic oil.
d.Internal oil leakage of pump Repair or replace pump.
due to prolonged use, worn,
or dirty hydraulic oil.
e. Oil leakage in hydraulic Replace components to
cylinders, hoses and pipe eliminate leakage.
fittings.
f. Jammed solenoid valve Check if spool moves Properly.
191

3. No mold clamping a. Loose or damaged wires of Tighten properly or replace
safety door limit switches. switches.
b. Burnt coil of mold opening and Clean or replace valve.
clamping solenoid spool by
foreign particles.
c. Solenoid valve does not revert Rinse valve with paraffin.
to its normal position.
d.Ejector does not retract Check if ejection motion is
normal.
4. No injection a. Burnt coil of injection solenoid Rinse or replace valve.

valve, or jammed spool by
foreign particles.
b. Injection pressure too low. Set higher injection pressure.
c. Barrel temperatures too low. Raise temperature to required
level. After adjustment,
temperatures are still too low,
check if the heater bands and
fuses have been burnt or
loosen. If damaged, replace it.
d.Loose or bad contact of wires Tighten properly.
in injection limit switches.
5. Too-slow or no a. Incorrect parameters setting. Set the parameters

screw rotation correctly.Adjust to obtain an
appropriate flow rate.
b. Improper setting of throttle Rinse or replace it.
valve.
c. Burnt coil of plasticizing Check if heater bands have
solenoid valve or jammed been burnt.
spool by foreign particles.
d.Too-low plasticizing barrel Replace if burnt. (stop motor to
temperature, leading to avoid damaging screw).
overload of hydraulic motor.
6. Rotating screw a. Too-high back pressure, or Adjust or replace injection check

but no melt improper setting of flow valve.
injection at control valve.
nozzle. b. In sufficient cooling water in Increase cooling water flow rate;
feeding zone, causing resin to remove carefully solidified melt.
be prematurely melted which
then blocks further resin entry
c. Empty hopper. Add resin to hopper.
192

7. No injection a. Incorrect setting of injection Reset the correct parameter.
carriage carriage movement.
movement b. Burnt coil of the injection Rinse or replace it.
carriage solenoid valve, or
jammed spool by foreign
particles.
8. Failure of mold a. Lock nuts on tie bar have Clean welded tie bars and nuts.
height been welded up due to Add molybdenum disulfide
adjustment. accumulation of dirt or lack of afterwards.
lubricant.
b. Electric motor damage or bad Change electric motor or inspect
electrical connection. electrical connection.
9. Noisy mold a. Loose locating bolt in slow Adjust until desired slow speed
opening. speed solenoid valve, or has been achieved.
jammed spool.
b. Position of mold opening limit Adjust mold opening position.
switch too short leading to
impact of piston onto clamping
cylinder flange.
c. Worn toggle components or Adjust or replace them.
their loose locating screws.
10. Hydraulic oil a. Pump pressure too high. Adjust pressure according to
temperature too molding requirements.
high b. Damaged pump, or oil Check pump and quality of oil.
viscosity too high.
c. Inadequate hydraulic oil. Add more oil.
d.Malfunctioning of cooling Adjust or repair cooling system.
system or in adequate cooling
water circulation.
11. Semi-Automatic a. Certain limit switches or Observe when the malfunction

cycle timers are not properly occurs in a cycle, then with
malfunctions. actuated or ineffective. reference to 'operational cycle'
adjust or replace the concerned
control components.
12. Fully automatic a. Loose mounting screw or Adjust or tighten photo-sensor

cycle misalignment of optical properly.
malfunctions. principle axis for photosenor.
b. Malfunction or damage of Adjust or replace it.
timer.
193

13. Malfunction of a. Damaged heaters. Replace it.
heater bands b. Improper connection of Tighten it.
thermocouple.
c. Damaged thermocouple. Replace it.
d.Bad or damaged A/D board. Replace it.
194
Appendix A QUICK REFERENCE OF CONTROL PARAMETERS
SCREEN CONTENT
1 Main Screen
Setpoints:
access code entry
Monitoring:
model numbers
serial numbers of machine
serial number of controller
software version number
access code level
2 Metering Screen
Setpoints
no. of stages
back pressure profile
back pressure switchover position
rotating speed profile
rotating speed switchover position
decompression delay time
metering delay time
metering monitoring time
decompression before metering pressure, speed and stop position
decompression after metering pressure, speed and stop position
Monitoring
Screw actual position
actual back pressure
actual screw RPM (OPTION)
metering timer
metering delay timer
decompression delay timer
A-1
QUICK REFERENCE OF CONTROL PARAMETERS
3 Barrel Temperature
Setpoints:
heater operation mode
Setting temperature of each heating zone
reduce temperature of each heating zone
+tol, -tol of each temperature zone
temperature bar graph scale range
Monitoring:
Actual temperature of each heating zone
difference between set temperature and actual temperature in bar graph format
Actual oil temperature
Percentage of heating for each heating zone
4 TCU Parameter Screen
Setpoints:
self-tuning of PID parameter for the heating zone (NOT YET AVAILABLE)
operation mode of each zone
PID parameter for each heating zone
manual output heating percentage settings
sampling time interval for each heating zone
Upper and Lower control zone for each heating zone
Monitoring
Actual temperature for each heating zone
Actual status of the self turning status
5 Mold Setup Screen
Setpoints:
mold clamping force
pressure, speed & position for injection process of auto purge cycle
pressure, speed and position for decompression process of auto purge cycle
A-2
pressure, speed and position for metering process of auto purge cycle
monitoring time for metering process of auto purge cycle
No of cycle count for auto purge cycle
Start automatic mold height adjust cycle
Start automatic purging cycle
criteria for motor during automatic cycle

----- filling time is over
----- metering time is over
------ mold closing time is over
----- cycle time is over
Monitoring
Actual process time of auto purge cycle
Actual cycle count of auto purge cycle
actual screw position
actual backpressure
actual screw rotating speed (OPTION)
6 Injection & Holding Screen
Setpoints:
no. of injection stage
Switchover position for injection speed
injection pressure
injection speed
holding pressure switchover criteria:
switchover timer
switchover position
switchover hydraulic pressure
switchover cavity pressure
injection delay
Maximum filling time. of holding stage
set value for holding speed
timer setting for each holding step
pressure setting for each holding step
Cushion length
+tol of cushion length variation
A-3
-tol of cushion length variation
Monitoring:
Actual screw position
Actual Injection speed
Actual Injection pressure
Actual switch over time
Actual switch over position
Actual switch over hydraulic pressure
Actual switch over cavity pressure
Actual filling time. Actual cushion length
Actual hydraulic pressure in injection cylinder
Actual holding time have finished
7 Clamping Screen
Setpoints:
cycle pause timer
closing time
rebound count
switchover position for clamp opening and closing
pressure for clamp opening and closing
speed for clamp opening and closing
ejector forward and backward position
ejector start position
ejector dwell time
ejector count
air ejector on time
air ejector start position
ejector pressure and speed
Monitoring:
actual position of mold platen
actual position of ejector
current pressure for mold platen movement
current speed for mold platen movement
A-4
current pressure for ejector movement
current speed for ejector movement
ejector count
ejector dwell time
air ejector on time
mold rebound count
mold closing timer
8 IC Card Memory Screen
Setpoints:
Save and retrieve mold setting parameters from the memory card.
Monitoring:
Which mold setup parameters is store in the memory card.
9 Internal Mold Data Screen
Setpoints:
Save and retrieve mold setting parameters from the Internal memory.
Monitoring:
Which mold setup parameters is store in the Internal memory.
10 Timer Screen
Setpoints:
pause time
carriage forward delay time
carriage backward delay time
metering delay time
ejector dwell time
air blow 1 timer
Injection delay time
cooling time
A-5
pre-extruding time
Filling time
metering time
mold close time
cycle time
Monitoring:
pause time
carriage forward delay time
carriage backward delay time
metering delay time
ejector dwell time
air blow 1 timer
Injection delay time
cooling time
pre-extruding time
Filling time
metering time
mold close time
cycle time
11 Monitoring Screen
Monitoring following parameters for the last 10 production cycle:
Holding pressure switchover position
Holding pressure switchover hydraulic pressure
Holding pressure switchover time
nozzle temperature
Cushion length
Filling time
12 Graphic Screen
Setpoints:
A-6
Actual and set Curves for monitoring
Color for the curve
Monitoring:
Actual and Set curve for various injection process
13 Diagnostic Screen
Monitoring
The on / off time of the alarm message which have been happened previously.
14 Breakdown Screen
Monitoring:
The on / off time of the alarm messages, also indicate the position of the breakdown on an
machine schematic graphic
15 Production
Setpoints
material used
no. of cavity
shot weight,
no. of lot required
no. of piece required
no of part rejected during start up
Monitoring:
No of parts finished
No of lot finished
No of material required
No of parts rejected
average cycle time
Estimated no of production time required to finish this batch
16 Product Certificate Screen
Monitoring:
A-7
zone temperatures
cushion length
cycle time
filling time
metering time
HP s/w position
HP s/w time
HP s/w hydraulic pressure
HP s/w cavity pressure
17 Op Setup
Setpoints:
baud rate for printer and communication channel
No of data bit for printer and communication channel
No of stop bit for printer and communication channel
The parity format for printer and communication channel
selection of language
selection of printer
selection for key kick sound on/off
selection of measuring unit
selection of help window delay
Real time date setting
18 Service Screen
Setpoints:
direct analog output from: channel 0 - 7
max. rotating speed
max. injection speed
ejector transducer stroke,
carriage transducer stroke,
clamp transducer stroke
screw transducer stroke
max. injection pressure
max. cavity pressure
A-8
setup phase pressure and speed of clamping,
setup phase pressure and speed of ejector,
setup phase pressure and speed of core,
setup phase pressure and speed of carriage
setup phase pressure and speed of injection
setup phase pressure and speed of metering
stroke calibration of ejector
stroke calibration of clamping,
stroke calibration of carriage
stroke calibration of screw
Monitoring:
Actual screw rotating speed (OPTION)
Actual injection speed
Actual ejector position
Actual Carriage position
Actual Clamp position
Actual Screw position
Actual hydraulic pressure
Actual cavity pressure
19 Carriage Screen
Setpoints:
carriage mode
carriage backward motion switchover position
carriage backward pressure and speed
carriage forward motion switchover position
carriage forward pressure and speed
carriage touch down position
Monitoring:
Actual carriage position
current carriage movement pressure
current carriage movement speed
A-9
20 Side Core Screen
Setpoints:
core sequence
Core 1 in usage
Core 1 in position control type
Core 1 in speed
Core 1 in time
Core 1 in priority
Core 1 in position
Core 2 in usage
Core 2 in position control type
Core 2 in speed
Core 2 in time
Core 2 in priority
Core 2 in position
Core 1 out usage
Core 1 out position control type
Core 1 out speed
Core 1 out time
Core 1 out priority
Core 1 out position
Core 2 out usage
Core 2 out position control type
Core 2 out speed
Core 2 out time
Core 2 out priority
Core 2 out position
Monitoring:
clamp opened position
clamp lockup position
current core 1 in pressure
current core 1 in speed
current core 2 in pressure
A-10
current core 2 in speed
current core 1 out pressure
current core 1 out speed
current core 2 out pressure
current core 2 out speed
21 Daily Maintenance Screen
Setpoints
No. of clamp cycle to initiate the lubrication pump
Monitoring:
No. of clamp cycle have start after last lubrication cycle.
No. of day for filter element replacement
No. of day for hydraulic oil replacement
22 Machine Status Screen
Monitoring:
Operation Mode
Cushion Length
Cycle count
Ejector count
Cycle time
Filling Time
Metering time
Mold Protection time
Cooling time
Clamping force
Actual clamp position
Actual ejector position
Actual screw position
Actual carriage position
Barrel temperature
hydraulic oil temperature
pumps pressure and speed
A-11
23 Machine Data
Setpoints
Offset
Gain
Ramp
24 Summary 2
Setpoints
Clamp speed and pressure switchover position
clamping pressure and speeds
ejector start position
air start position
carriage pressure and speed switchover positions
carriage pressures and speeds
carriage pull
carriage mode
pre-extruding (optional )
pre-extrusion time (optional)
ejector positions
ejector pressures and speeds
rattle
ejector cycle count
25 Service
setpoints
analog output port
analog input port
clamp setup pressure and speed
ejector setup pressure and speed
core setup pressure and speed
carriage setup pressure and speed
injection setup pressure and speed
metering setup pressure and speed
A-12
monitoring
analog input port
26 Heater Timer Screen
setpoints
whole day on/off switch
specific operating mode
starting time
shift schedule
27 Summary 1
setpoints
no. of injection stages
injection switchover positions
injection speeds
injection pressure
no. of holding stages
holding time
holding pressure
holding speed
no. metering stages
metering pressure
VP Position
VP pressure
rot position
rotation vel.
decompression before
decompression after
decompression position
decompression pressure
decompression velocity
holding pressure switchover criteria
HP s/w over cap. press
A-13
Appendix B LISTING OF ERROR/WARNING MESSAGES
1 Operation Unit Message
Message Code Description Remark

1 Setvalue above upper limit, press CE key to Set again.
2 Setvalue below lower limit, press CE key to Set again.
3 Online is not possible, Offline press Enter or other key to restart.
4 You can't change this condition in Auto Operation.
5 Wrong Read in, Machine model is different
6 Wrong Read in, No of heating zone is different.
7 Insert memory Card please.
8 No write permitted. Confirm data memory switch.
9 Write completed.
10 Read completed.
11 Abnormality happened during data transmission.
12 Set value updated.
13 Press 'CE' key to abort data or 'ENTER' to accept.
14 Fail to load data due to corruption of data.
15 Memory card is not inserted or battery is exhausted.
16 Access level is too low.
17 Printing has not finished yet.
18 Dumping screen image in auto-mode operation is not allowed.
127 System Error.....Please Contact 'Welltec Industrial Equipment

Ltd.'
B-1
LISTING OF ERROR/WARNING MESSAGES
2 Temperature Control Unit Message

128 1. Pos. Tol. exceeded nozzle heat zone
129 1. Neg. Tol. felt below nozzle heat zone
130 2. Pos. Tol. exceeded nozzle heat zone
131 2. Neg. Tol. fell below nozzle heat zone
132 Setup. Value of nozzle heat. zone too high
133 Setup. Value for Lowering nozzle heat zone too high
134 Thermocouple of noz. heat. defect., no replacem.
135 Thermocouple of noz. heat. defect., replacem. act.
136 1. Pos. Tol. exeeded cylinder zone 1
137 1. Neg. Tol. fell below cylinder zone 1
140 Setup. Val. of cylinder zone 1 too high
141 Setup. Val. for Lowg. Temp. of cyl. zone1 too high
142 Thermoc. of cylinder zone1 defect., no replacem.
143 Thermoc. of cylinder zone1 defect., replacem. act.
148 Setup. Val. of cylinder zone 2 Temp. too high
149 Setup. Val. for Lowg. cyl. zone 2 Temp. too high
150 Thermoc. of cyl. zone 2 defect., no replacement
151 Thermoc. of cyl. zone 2 defect., replacem. active
156 Setup. Val. of cyl. zone 3 Temp. too high
B-2

182 Thermoc. of cyl. zone 6 defect, no replacement
183 Thermoc. of cyl. zone 6 defect, replacement active
189 Setup. Val. for Lowg. cylinder zone7 Temp. too high
190 Thermoc. of cylinder zone 7 defect., no replacem.
191 Thermoc. of cyl. zone 7 defect, replacement act.
B-3

196 Setup. Val. of cylinder zone 8 too high
197 Setup. Val. for Lowering cylinder zone 8 too high
198 Thermoc. of cylinder zone 8 defect, no replacement
199 Thermoc. of cylinder zone 8 defect,replacement act
200 1. Pos. Tol. exeeded cooling ring
201 1. Neg. Tol. fell below cooling ring
202 2. Pos. Tol. exeeded cooling ring
203 2. Neg. Tol. fell below cooling ring
204 Setup. Val. of cooling ring Temp. too high
205 Setup. Val. for Lowering cooling ring too high
206 Thermoc. of cooling ring defect., no replacement
207 Thermoc. of cooling ring defect., replacement act.
208 1. Pos. Tol. exeeded moving die part
209 1. Neg. Tol. fell below moving die part
210 2. Pos. Tol. exeeded moving die part
211 2. Neg. Tol. fell below moving die part
212 Setup. Val. for Lowering fixed die part too high
213 Setup. Val. for Lowering mov.die part too high
214 Thermoc. of mov.die part defect., no replacement
215 Thermoc. of mov.die part defect., replacement act.
216 1. Pos. Tol. exeeded fixed die part
217 1. Neg. Tol. fell below fixed die part
218 2. Pos. Tol. exeeded fixed die part
219 2. Neg. Tol. fell below fixed die part
220 Setup. Val. of fixed die part Temp. too high
221 Setup. Val. for Lowering fixed die part too high
222 Thermoc. of fixed die part defect, no replacement
223 Thermoc. of fixed die part defect, replacement act
224 Oil Temperature exceed 65 Degree C
225 Oil Temperature below 20 Degree C
B-4
B-5
3 Operation Message
Only appear when this message happen but will not log the on/off time of this message.
320 Front guard opened.
321 Real guard opened.
322 Front emergency button pressed.
323 Real emergency button pressed.

324 Purge guard opened.
325 Please Open front guard door.
326 Please open purge guard.
327 Injection unit not retract to backward stop.
328 Please press the mold setup button.
329 Please turn on the motor first.
330 Close front guard please.
331 Close real guard please.
332 Close real guard please.
333 Now heating. Wait a bit.
334 Please Turn Heater On.
335 Core 1 out limit not reached.
336 Core 2 out limit not reached.
337 First bell rung. Molding No. soon completed.
338 Automatic purging cycle is running.
339 Automatic purging cycle completed.
340 Automatic mold height adjustment cycle is running.
341 Automatic mold height adjustment cycle is finished.
342 ACC now charging. wait a bit.
343 Mold height adjustment front limit hit.
344 Mold height adjustment real limit hit.
345 More than one selector switch is on.
346 Mold too thick.
347 Mold too thin.
348 Please retract carriage before starting auto purging cycle.
349 Zero adjustment of Ejector Encoder, please.
350 Zero adjustment of Mold height adjustment Encoder, please.
B-6

351 Zero adjustment of Clamping Encoder, please.
352 Zero adjustment of Screw Encoder, please.
353 Automatic mold height adjustment not complete.
354 Screw revolution 1 over
355 Screw revolution 1 under
364 Backpressure 1 over
365 Backpressure 1 under
374 1st injection speed over
375 1st injection speed under
376 2nd injection speed over
377 2nd injection speed under
378 3rd injection speed over
379 3rd injection speed under
380 4th injection speed over
381 4th injection speed under
B-7

394 1st holding pressure over
395 1st holding pressure under
396 2nd holding pressure over
397 2nd holding pressure under
398 3rd holding pressure over
399 3rd holding pressure under
400 4th holding pressure over
401 4th holding pressure under
414 Short shot
415 Overpack
B-8
4 Operation Alarm

435 Cycle time is over, Machine stopped.
436 Filling time is over, Machine stopped.
437 Mold close time is over, Machine stopped.
438 Metering time is over, Machine stopped.
439 Repeat lot completed, Machine stopped.
440 No Mold close signal from Part extractor.
441 No Mold open signal from Part extractor.
442 No Ejector signal from Part extractor.
443 No Cycle start signal from Part extractor.
444 Continue rejector happened.
445 Ejector not returned.
446 Part not drop out.
B-9
5 Machine Breakdown Message
This message type have to logging the on/off the time and display on breakdown screen.
466 Lubrication line broken, call serviceman.
467 Guard door limit switch broken, call serviceman.
468 Suction filter element clogged, replace it.
469 Return filter element clogged, replace it.

470 Suction filter flange removed, Caution please.
471 Lubrication oil level too low, refill please.
472 Hydraulic oil level too low, refill please.
473 Hydraulic safety lock abnormal, Please check.
474 Nozzle heater band have damaged.
475 Heater band 1 have damaged.
486 Encoder channel 1 is abnormal.
490 ACC charge abnormal. Pressure not built up.
491 A/D Ejector channel is abnormal.
492 A/D Carriage channel is abnormal.
493 A/D Clamping channel is abnormal.
494 A/D Screw channel is abnormal.
B - 10
B - 11

Manual Welltec TTI 200C (Cosmo) INJETORA DE PLASTICO

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Manual Welltec TTI 200C (Cosmo) INJETORA DE PLASTICO

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PRECISION INJECTION MOLDING MACHIN

Tai Tung Industrial Building,

Copyright C 1991 by Welltec Industrial

1.00 Original version for C-series machine and 30-10-1991

Copyright ? 1994 by Welltec Machinery Limited. All rights

Welltec U.S.A., Inc.

(A) WARRANTY PERIOD

(B) SCOPE OF WARRANTY

Damage resulting from improper or inadvertent operation or handling of the

Damage caused by inappropriate or defective shop facilities (such as ceiling,

Damage of machines caused by any parts supplied or specified by the customer.

Defects and damage of the machines which have been overhauled.

(D) CUSTOMER'S OBLIGATION

(E) REPAIR EXPENSES AND COST

Unwarranted parts 6-month warranted parts

General safety practices

Machine features and specifications

Injection speed profile allows 2, 5 or 10 injection phases.

Holding pressure profile allows 1,5, 10 phases of holding pressure.

Digital, microcomputer-based self-optimizing temperature control circuits with

Injection unit pivots to one side for easy screw removal.

Automatic central lubrication with electrical monitoring.

Automatic mold height adjustment.

Mould fixing layout and mould centering designed according to EUROMAP

Mechanical, electrical and hydraulic safety protection system comply with

Timer controlled automatic cycle operation.

MODEL NUMBER & DESCRIPTION

Up to 10 stages injection speed and holding pressure can be set.

Up to 5 stages metering speed and back pressure control.

Convenient swivelling mechanism for easier screw and barrel maintenance.

1.17.2.2 Injection Pressure Vs. Hydraulic Pressure Diagram

Hydraulic Pressure (bar)

1.17.2.3 Shot Weight Vs. Screw Stroke Diagram

Screw Stroke (mm)

1.17.2.4 Injection Unit Assembly

1.17.2.5 Swivel Of Injection Unit

Follow the procedures below for the injection unit swivel.

Move injection unit to its end position.

Open the injection unit's guard door to its end position.

1.17.2.6 Heating Barrel Assembly

Left Hand Thread

Resin Release Window

Lock Nut Chute Gate

The clamping system uses a computer optimised 5-point vertical toggle

Electrical, hydraulic and mechanical interlock system for greater safety.

Turcite coated bearing used in supporting moving platen reduces wear of

Mold rebound counter provision.

Computerised finite element analysis (FEA) is utilised in the design of platens

Lubrication of clamp toggles is automatically controlled with reference to the

1.17.2.9 Clamping Force Vs. Hydraulic Pressure Diagram

Hydraulic Pressure (bar)

1.17.2.10Clamping Unit Assembly

1.17.2.11Mold Platen Dimensions

Fig. 2-9 EUROMAP-1

TTI-3C TTI-8C TTI-12 TTI-17 TTI-20 TTI-28

For TTI-260C, TTI-320C

Material : 45 (0.45% carbon) Other 12.5

(Carbon Steel) Blacking

For TTI-90C, TTI-120C, TTI-160C, TTI-200C

1.17.2.12Mold Open Positioning Unit

Follow the procedures below for adjustment:

Release handle 1 by turning it to direction A.

After adjustment, hold handle 2 and tighten handle 1 by turning it towards