Technical 150t

MICROCOMPUTER
EC100/EC100-S/CC100
Type: A03
Sequence program Small and medium-sized machines: EV 9.42 +
System software: SV 2.12 +
Analog versions: AR281: SV2.02+, ST1.51+
AR101: SV1.25+, ST1.51+
TECHNICAL MANUAL
This manual has been established for information and/or trainings.

It is no component of the instruction manual.
Manufacturer:
ENGEL - Maschinenbau Gesellschaft m.b.H.
Ludwig-Engel-Straße 1 A-4311 Schwertberg
Telefon: A+07262/620-0
Fax: A+07262/620-4009
These documents remain our property and must not be copied without our written consent. Its con-
tents may neither be made known to third parties nor be used for non-approved purposes. It only
serves the internal benefit and use. Each violation will be sued according to §12 and §13 UWG.
© Copyright by ENGEL Maschinenbau Gesellschaft m.b.H.

A-4311 Schwertberg
Microcomputer Technical Manual
Version:G/11/12/7/3
HARDWARE (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1 SAFETY HINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.1 ELECTROMAGNETIC COMPATIBILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2 SYSTEM COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.1 COMPATIBILITY TO OLDER CONTROL SYSTEM VERSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.2 SURVEY OF COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.3 CONTROL PRINCIPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.4 CARD ARRANGEMENT IN THE RACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.4.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.4.2 CC100-A03 AND EC100/COLOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.4.3 EC100-A03/MONO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.4.4 EC100-S-A03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.4.5 RACK EXPANSION POSSIBILITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.5 CONTROL CONSOLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.5.1 CC100 AND EC100/COL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.5.2 EC100/MONO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.5.3 EC100-S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.6 SCREEN DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3 ELECTRONIC MODULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.1 EPROM SURVEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.2 CARD CODING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.3 MAIN PROCESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.3.1 CPU VARIANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.3.2 GRAPHIC MODULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.4 ANALOG CARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.4.1 AR 281 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.4.2 SR161/A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.4.3 MEASURED VALUE CONVERSION AS 141 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.4.4 AR 101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.5 TEMPERATURE CHANNELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3.5.1 TT081 UND TT081/5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3.6 DIGITAL INPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3.7 PUSH-BUTTON CONNECTION MODULE K-FTC-AN/A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.8 DIGITAL OUTPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.9 POWER PACK CARD N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3.10 INTERFACES ON THE CPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3.10.1 ETHERNET INTERFACE TPI ON CU212 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
3.10.2 INTERFACE MODULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3.10.3 SI232 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.10.4 SI020 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3.10.5 SI 024 - OCCUPATION PLAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
3.10.6 SI 485 / RS422 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
3.11 PUMP ACTUATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
3.11.1 BOSCH AMPLIFIER CARD FOR MACHINES WITH TILTING ANGLE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . 61
3.11.2 OPERATIONAL SETUP GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
3.11.3 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3.12 MAGNETIC CARD READER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
PUTTING INTO OPERATION (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

1 POWER SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
2 SWITCHING-ON OF THE CONTROL VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
2.1 SWITCHING-ON WITHOUT LOADED EBIAS SEQUENCE PROGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
2.2 SWITCHING-ON WITH LOADED EBIAS SEQUENCE PROGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
2.3 WATCHDOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
3 HARDWARE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
3.1 SYSTEM AND EBIAS ERRORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
3.2 CHECK SUM TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
3.3 READ-IN OF THE EBIAS SEQUENCE PROGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
3.3.1 RELOADING AN EBIAS SEQUENCE PROGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
3.3.2 AFTER THE READ-IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
3.3.3 ANALOG CARDS - SEQUENCE PROGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
3.3.4 IN THE CASE OF A CPU EXCHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
3.4 HARDWARE CHECK IMAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
4 SWITCH ON MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
5 FLUSHING PROGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
6 OILPREHEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
7 BY-PASS FILTERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
7.1 OIL MONITORING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
8 TIME AND DATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Creation date: 20.02.2002

Printing date: 25.2.2002 3
Version:G/11/12/7/3
8.1 SETTING OF TIME AND DATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

9 SERVICE MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
9.1 PURPOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
9.2 ENTRY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
9.3 SETUP PROGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
9.3.1 MACHINE SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
9.3.2 SYSTEM - SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
9.3.3 PUSH-BUTTONS - SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
9.3.4 OPERATOR SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
9.3.5 MEMO PAGE FOR PUMP CONTROL CARDS SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
9.4 PEAK VALUE MOMENT MEASUREMENT (PROCESS ANALYSIS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
9.4.1 PLASTICIZING NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
MOVEMENT SEQUENCE / MACHINE FUNCTIONS (3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

1 MAN. OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
2 SET UP MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
3 SEMI-AUTOMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
3.1 CYCLE START CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
3.2 DIGITAL OUTPUT ’HA’ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
3.3 CYCLE END IN SEMIAUTOMATIC MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
4 FULLY AUTOMATIC MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
5 PROGRAM INTERRUPTION KEY (PU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
6 FLUSHING, OIL PREHEATING, MOULD PROTECTION, SET-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
7 AUTOMATIC CYCLE SURVEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
8 PARALLEL MOVEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
8.1 2. EHV PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
8.2 SECONDARY MOVEMENTS ON 2ND PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
8.2.1 PROGRAM EJECTOR RETURN IN PARALLEL TO MOULD CLOSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
8.2.2 PROGRAM NOZZLE FORWARD IN PARALLEL TO MOULD CLOSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
8.2.3 NOZZLE RETRACTION BEFORE MOULD OPENING (RETRACTION PROGRAM 2): . . . . . . . . . . . . . . . . . . . . . 99
8.2.4 SUNDRIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
8.3 PUMP INTERCONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
8.3.1 PUMP INTERCONNECTION AT INJECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
8.3.2 PUMP INTERCONNECTION AT PLASTICIZING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
8.3.3 PUMP INTERCONNECTION ON THE CLAMPING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
9 MOLD CLOSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
9.1 PROGRAM ITEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
9.1.1 MOULD PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
9.1.2 AUTOPROTECT CLAMPING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
9.1.3 CLAMPING PRESSURE BUILD-UP IN THE CONCEPT EHV1, EHV2 AND EHV3 . . . . . . . . . . . . . . . . . . . . . . . 107
9.1.4 SET-UP MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
9.1.5 STROKE CALIBRATION AND STROKE LINEARIZATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
9.1.6 CLAMP. FORCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
9.1.7 ELECTROHYDRAULIC CLOSING SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
10 ADVANCE CARRIAGE UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
10.1 AUTOMATIC NOZZLE CONTACT POINT DETERMINATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
10.2 CONTACT PRESSURE BUILD-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
10.2.1 CONTACT PRESSURE BUILD-UP TIME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
10.2.2 CONTACT PRESSURE BUILD-UP TIME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
11 INJECTION AND HOLDING PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
11.1 CUSHION MONITORING (SCREEN IMAGE ”HOLDING PRESSURE”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
11.2 CUSHION CORRECTION (SCREEN IMAGE ”HOLDING PRESSURE”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
11.3 SWITCHOVER TO HOLDING PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
11.4 SPEED CONTROL IN THE HOLDING PRESSURE PHASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
11.5 INCREASED INJECTION PRESSURE (SCREEN IMAGE ”INJECTION”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
11.6 POWER FACTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
11.7 INJECTION UNIT SWIEVEL OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
12 PLASTICIZING AND DECOMPRESSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
12.1 DECOMPRESSION PROGRAMS (SCREEN IMAGE ”PLASTICIZING”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
12.2 SPECIFIC BACK PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
12.2.1 BACK PRESSURE SWITCHING-OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
12.2.2 BACK PRESSURE INTERPOLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
12.2.3 ACTIVE BACK PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
13 RETURN CARRIAGE UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
13.1 LIFTING PROGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
13.2 CONTACT PRESSURE REDUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
14 MOLD OPENING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
14.1 PROGRAM ITEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
14.1.1 INCREASED OPENING FORCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

4 Printing date: 25.2.2002
Version:G/11/12/7/3
15 ADVANCE AND RETURN EJECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

15.1 EJECTION MONITORING (SCREEN PAGE ”EJECTOR”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
15.2 SET-UP MODE EJECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
16 FURTHER PROGRAM ITEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
16.1 SAFETY KEY SIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
16.2 HYDRAULIC HIGH SPEED MOULD MOUNTING DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
16.3 HANDLING SYSTEM CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
16.3.1 ENGEL HANDLING SYSTEM ERC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
16.3.2 EUROMAP 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
16.3.3 SIGNALS SETUP FOR CORE-PULL RELEASES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
16.4 SAFETY GATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
16.5 CHARGE AMPLIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
16.5.1 LV5039 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
16.5.2 LV5049 SMART AMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
16.6 POSITION MONITORING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
16.7 SOCKET / COOLING WATER SWITCHING-OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
16.8 ACOUSTIC WARNING SIGNAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
TEMPERATURE CONTROL (4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
1.1 VARIANTS: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
1.2 ZONES / GROUPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
1.2.1 SETTING 0°C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
1.2.2 HEATING-UP AUTOMATISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
1.2.3 HEATING-UP MONITORING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
1.2.4 SHORT CIRCUIT MONITORING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
1.2.5 MONITORING SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
1.2.6 ZONE DESIGNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
1.3 OPERATING ELEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
1.4 START-UP DELAY, START-UP SAFETY, SOAKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
1.5 EMPLOYMENT OF THE TEMPERATURE CONTROL CARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
2 HEATING CONTROL PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
2.1 THERMOSENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
3 TEMPERATURE CONTROL UNITS WITH EXTERNAL CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
4 DEVICE CONNECTION WITH SERIAL INTERFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
5 HOT RUNNERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
6 MICROTEMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
7 SET PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
CALIBRATION AND LINEARIZATION (5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

1 STROKE CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
1.1 CARRY OUT THE STROKE CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
1.1.1 EXAMPLE: CALIBRATE SCREW STROKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
1.1.2 DIFFERENCES AT THE STROKE CALIBRATION OF DIFFERENT MACHINE TYPES . . . . . . . . . . . . . . . . . . . 163
2 VALVE LINEARIZATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
2.1 CARRY OUT THE VALVE LINEARIZATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
2.2 LINEAR OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
2.3 SPEED LINERARIZATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
2.4 PRESSURE LINEARIZATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
2.4.1 PRESSURE TRANSDUCER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
2.4.1.1 OFFSET DETERMINATION AND MONITORING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
2.4.1.2 FURTHER MONITORINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
2.4.2 CALIBRATE BACK PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
2.5 SCREW SPEED LINEARIZATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
2.6 STROKE TRANSDUCER CALIBRATION (CONVERSION TABLE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
CLOSED LOOP CONTROL (6). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

1 CLOSED LOOP CONTROL PRINCIPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
2 SET CLOSED LOOP CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
2.1 SELF-OPTIMIZING CLOSED LOOP CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
2.2 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
2.2.1 SETTING OF THE SPEED START-UP RAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
2.2.2 SETTING OF THE PRESSURE SWITCHOVER RAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
2.2.3 SETTINGS FOR CHECKING THE CLOSED LOOP CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
2.3 CLOSED LOOP CONTROL VIA PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
2.3.1 PRINICIPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
2.3.2 INJECTION SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
2.3.3 PRESSURE LIMIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
2.3.4 HOLDING PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

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2.3.5 BACK PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

2.3.6 BACK PRESSURE SURVEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
2.4 CLOSED LOOP CONTROL VIA SERVO VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
2.4.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
2.4.2 INJECTION SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
2.4.3 PRESSURE LIMIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
2.4.4 HOLDING PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
2.4.5 BACK PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
2.5 SPEED LIMIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
2.5.1 V LIMIT AT HLS HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
2.5.2 V LIMIT AT EHV HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
ERROR SIGNALS (7). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

1 SEQUENCE ERRORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
2 SYSTEM ERRORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
2.1 SYSTEM ERROR DISPLAY ON THE SCREEN AND IN THE STATUS REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
3 COMPONENT NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
3.1 COMPONENT SURVEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
3.1.1 COMPONENT SURVEY ”LOCAL” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
3.1.2 COMPONENT SURVEY ”AR N” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
4 SYSTEM ERROR NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
4.1 GENERAL SYSTEM ERRORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
4.2 COMPONENT-SPECIFIC SYSTEM ERRORS ”LOCAL” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
4.3 COMPONENT-SPECIFIC SYSTEM ERRORS ”AR N” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
5 EBIAS ERRORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
5.1 ERROR NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
5.1.1 INTERPRETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
5.1.2 VARIABLES ACCESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
5.1.3 USER-INTERPRETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
5.1.4 DIGITAL I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
5.1.5 EBISYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
5.1.6 ENGSYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
5.1.7 AR101/AR181 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
6 MALFUNCTION MESSAGE RECORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
6.1 CALL-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
6.2 PRINTOUT OF THE MALFUNCTION MESSAGE RECORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
6.3 POSSIBLE ERROR COMMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
7 STATUS REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
TEST AND PARAMETERS (8). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223

1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
2 ENTRY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
3 CHANGE PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
3.1 CALL-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
3.2 STORAGE OF PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
3.3 READING OF PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
3.4 PARAMETER COMPARISON (PARAMETER COMPARISON INTERNAL / DISKETTE) . . . . . . . . . . . . . . . . . . . . . . 226
3.5 PRINT OUT PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
3.6 SEARCH PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
4 SIGNAL-DEBUGGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
PRINTER / TEXT INPUT (9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

1 PRINTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
1.1 PRINTER CONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
1.1.1 SETTING HINTS FOR 9-DOT-MATRIX TEXT PRINTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
1.1.2 SETTING HINTS FOR GRAPHIC PRINTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
1.2 SETTING OF THE DIP SWITCHES FOR PANASONIC PRINTER KXP1090 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
1.3 SETTING ON THE GRAPHIC PRINTER FACIT B3100 AND/OR E620 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
1.4 SETTINGS ON THE GRAPHIC PRINTER EPSON LX300+ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
1.5 PRINTOUT ON PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
1.6 SERIAL-PARALLEL CONVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
2 TEXT INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
2.1 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
2.2 TECHNICAL DETAILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235

Version:G/11/12/7/3
TABLES (10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
REVISIONS (11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295

1 INNOVATIONS IN THIS PRESENT VERSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
2 REVISION OF THE PREDECESSOR VERSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296

Version:G/11/12/7/3

Version:G/11/12/7/3
HARDWARE (1)
1 SAFETY HINT
Attention!
In connection with the operator’s manual this technical manual shows

all setting possibilities on the electronic control unit. Further, it offers
the possibility to make more radical changes on the machine function.
At the set-up and operation of the machine with different tools, moulds
and peripheral equipment it must most urgently be paid attention to the
fact that wrong settings can lead to defects on the whole plant.
Exclusion of liability
ENGEL does not take over any guarantees regarding this manual. For mistakes included in it,
consequential damage or damage in causal relation due to the information included in this
manual ENGEL cannot be made liable.
Note!
This manual documents technical contents of the control systems
EC100-A03, EC100-S-A03 and CC100-A03 for ENGEL injection moulding
machines of the sizes ES20 - ES450, tie-barless and toggle lever.
VERSIONS:
EBIAS V9.42 +
SYSTEM V2.12 +
ANALOG system V2.02 + (AR101 and AR281)
ANALOG-ST V1.51 +
Changes
In the APPENDIX 1 you find a parameter table, which defines and describes all variables and
is in direct connection with the implemented EBIAS version. Thus this manual contains the
standard of these definitions, but can also be used for control systems with special programs
as special programs only contain expansions of the definition tables. The EBIAS standard
version can be read off on the control unit on the hardware check image and in this manual on
this page.
Technical alterations are reserved for the producer and fow into the product without previous
notice so that respective parts of this documentation can be outdated.
All modules of the ENGEL injection moulding machine control units are equipped with highly
integrated components and are technologically caused very sensitive to overvoltages and thus
also to electrostatic discharge. Component parts can be destroyed by voltages and energies,
which lie far under the perception limit of the human being. Such voltages already appear
when a module is touched by an electrostatically not discharged human being. Components
which have been subjected to such overvoltages cannot be recognized as faulty immediately
in most cases as often only after longer time of operation a misguided behaviour can appear.
Components damaged by static discharge can show temporary errors e.g. at temperature
changes, shocks or load change. Only by consistent application of protection equipment and
responsible observation of the handling rules such malfunctions and failures can be avoided
effectively.
Creation date: 20.02.2002 Hardware (1)

Version:G/11/12/7/3
Attention!
It must be refrained from each handling on the control unit under volt-
age. The individual modules must not be pulled out of the rack under
voltage or be inserted there as thus undefined signal states appear and
thus damage of the operator and of the whole plant can arise.
In the dismounted state electronic elements are sensitive to electrostatic
charging. Before the handling with the modules an electric discharge
must be carried out by touching a metallic, earthed object. Component
parts should be touched as little as possible.
1.1 ELECTROMAGNETIC COMPATIBILITY

Control systems from the generation A03 are fabricated and installed in EMV-suitable
execution. For this reason changes and extensions on the control units must only be left to
authorized, correspondingly instructed personnel. It must be paid attention to that the
metallically covered control racks also on the card slide-in side (front) are covered electro-
metallically towards all sides. This is achieved by the employment of correspondingly
embedded modules (cards) and by filling the empty places with specially designed blind
printing plates.
2 SYSTEM COMPONENTS
The EC100 and CC100 microcomputer control systems are modular 32-bit and/or 16-bit high
capacity multiprocessor systems with distributed intelligence. The multilayer printed circuit
boards are equippped with highly integrated components. Due to the decentralized
architecture with a minimum of card types the highest processing speed, precision and trouble
freedom are achieved. The computer capacity is deliberately employed at those points where
time-critical functions must run off with high precision in order to assure the quality of the
injection moulded parts.
Fully automatic self-diagnostics (hardware check) and a comprehensive trouble-shooting

system belong to the standard.
By the practice-oriented concept for the user a series of advantages arise, which save
production costs on the one hand and on the other hand offer each comfort of a computer
system for the future
.
All production data, such as speeds, pressures, times, positions, counters and temperatures
for the respective function can be made visible on the screen by simply pressing a key. If a
value shall be changed, this is selected via the cursor (optical light bar) and changed via the
keyboard. When a mould is optimized, all data can afterwards be output on a printer or on
diskette by means of serial interface (V24).
Due to deviations in the hydraulic system, which inevitably arise by influences, such as
production tolerances, wear, temperature etc. in the devices, unequal pressure and speed
circumstances on the hydraulic cylinders result. In order to be able to compensate these
differences, ENGEL has developed the patented linearization program. By setting a set value
the actual value characteristic line of the corresponding proportional valve is determined. After
finishing the linearization the control system works with these really determined actual values
so that these differences are compensated automatically.
Hardware (1) Creation date: 20.02.2002

Version:G/11/12/7/3
Control system family:

EC100 -S-A03 .......... Small control with monochrome LC display Special cases
EC100-A03/mono .... Mean system with monochrome LC display Standard HL-V
EC100-A03/col ........ Middle system with color TFT display Standard HL
CC100-A03 .............. Comfort system with color TFT display Option
2.1 COMPATIBILITY TO OLDER CONTROL SYSTEM VERSIONS

In principle, all already created mould parameter diskettes of former EC88/CC90-A02 and
CC100-A01 control system versions can be read in and vice versa.
Attention!
The read-in values must be checked and/or entered newly, however as in

’younger’ versions due to program and comfort expansions always also
more parameters exist in a data set, which can of course not be updated
by reading in a data set of an ’older’ version.
Data which exist with EC88/CC90 A01 and/or CC80 versions on minicassettes can be brought
in diskette format with the program package ’PCS’. ’PCS’ runs on DOS computers; for this a
separate documentation exists.
2.2 SURVEY OF COMPONENTS
All mentioned modules and elements are in CE-suitable execution.

EC100-A03/MONO
EC100-A03/COL
EC100-S-A03
ENGEL
CC100-A03
Designation Articles- Use hint

number
Power supply modules
PD 242/A 2203 7620 x x x Voltage distribution printed board assembly
PS244/A 2203 7606 x x x x Power supply module

Input: +24VDC
Output: 5V/11A, +12V/4A, -12V/2A, +15V/0.5A, -
15V/0.5A
Power fail logic
PS244/B 2203 7651 x x x Power supply module

Input: +24VDC
Output: 5V/14A, +12V/4A, -12V/2A, +15V/0.5A, -
15V/0.5A
Power fail logic
PS243 2203 7264 x x x Power supply module

Input: +24VDC
Output: 5V/25A, +12V/4A, -12V/2A, +15V/0.5A, -
15V/0.5A
Power fail logic

Version:G/11/12/7/3
EC100-A03/MONO
EC100-A03/COL
EC100-S-A03
ENGEL
CC100-A03
number
Central modules, memory modules
CU 211/D 2203 7751 x x x CC100/EC100 central module with 32-bit pro-

cessor i80386SX/25Mhz, 2MB RAM, 2MB
Eprom
CU 211/E 2203 7692 x x x CC100/EC100 central module with 32-bit pro-

cessor i80386SX/25Mhz, 4MB RAM, 2MB
Eprom
CU211/F 2203 7693 x CC100 central module with 32-bit processor

i80486SXLC/20Mhz (40Mhz internal), 8MB
RAM, 2MB Eprom
----> IS REPLACED BY CU212 (Q2/00)
CU212 2203 7711 x CC100/central module with 32-bit processor

i80486DX4/25Mhz (75Mhz internal), 8MB RAM,
4MB Eprom
REPLACEMENT FOR CU211/F (Q2/00)
CU201/A 2203 7610 x x x x RC100 central module with 80960SB RISC pro-
cessor, 16 MHz clock, 2MB-DRam, 512 Kbyte
flash EPROM, 256 KByte EPROM
Digital I/O modules
DO 321/B 2203 7611 x x x x Digital ouptut module 32 channels plus switch-

ing, 2A, physical separation of the outputs
DO 321/16/B 2203 7612 x x x x Digital output module 16 channels plus switch-

ing, 2A, physical separation of the outputs
DI 325/B 2203 7613 x x x x Digital input module 32 physically separated

channels
RO161/A 2203 7682 x x x Relay output module, 16 outputs
Measuring and control modules
AR 181 2203 7616 x x x Analog measuring and control module with

80960 RISC processor, 16MHz clock frequency,
1MB DRAM, 0.5MB Flash
AR 181/A 2203 7656 x x x Analog measuring and control module with

80960 RISC processor, 16Mhz clock frequency,
2Mbyte DRAM, 1Mbyte FLASH, 16Kbyte SRAM
AR 181/B not used x x x Analog measuring and control module with

4Mbyte DRAM; 1Mbyte FLASH, 16Kbyte SRAM
AR 181/C 2203 7687 x x x Analog measuring and control module with

2Mbyte DRAM, 1Mbyte FLASH, 16Kbyte SRAM
AR 101 2203 6429 x x x Analog measuring and control module with

80960 RISC processor
AR281 2203 7699 x x x Analog measuring and control module with

80960KB RISC processor, 25Mhz clock fre-
quency, 4MByte DRAM, 1MByte FLASH,
16KByte SRAM

Version:G/11/12/7/3
EC100-A03/MONO
EC100-A03/COL
EC100-S-A03
ENGEL
CC100-A03
number
SR 161/A 2203 7617 x x x Sub-control module can be coupled via IEB BUS
with AR281 and AR181 (=predecessor of the
AR281)
TT081 2203 7614 x x x x Temp. measuring and control module for 8 ther-
mocouples Fe-CuNi or NiCr-Ni, 1. cooling output
1A
TT081/5 2203 7615 x Temp. measuring and control module for 5 ther-
moelements Fe-CuNi or NiCr-Ni, 1st cooling out-
put 1A
Rack complete, couple elements, blind printing plates
CR 162 2203 7601 x x x Rack with KEMRO-BUS main rack for EC100/
CC100-A03. Plug-in places: 1 power supply
PS244 or PS243, 14 modules 5 TE, 1 bus termi-
nal module BT081 or bus couple module BC082/
A
CR 092 2203 7602 x x x x Rack with KEMRO-BUS standard rack for

EC100-S, extension rack for EC100/CC100-A03.
Plug-in places: 1 power supply PS244 and/or
PS243, 8 modules 5 TE,
1 Bus terminal module BT081 or bus couple
module BC082/A
KEMRO-BUS/A 2203 7648 x x x Bus printed circuit board for rack CR162
KEMRO-BUS-8 2203 7650 x x x x Bus printed circuit board for rack CR092
CABLE CHANNEL ANGLE 2203 7643 x x x Fixing angle for cable channel for CR162
FOR CR162
CABLE CHANNEL ANGLE 2203 7644 x x x x Fixing angle for cable channel for CR092
FOR CR092
BK 082/A 2203 7622 x x x Bus couple cable for connecting two BC082/A
BC 082/A 2203 7621 x x x Bus couple module for coupling a rack CR162
with another CR162 or CR092
BT 081 2203 7603 x x x x Bus terminal module for the rack CR162
FP 004 LC 2203 7604 x x x Blind printing plate 4TE
FP005 LC 2203 7605 x x x Blind printing plate 5TE
Interfaces, connections
AS 141 2203 7153 x x x Serial stroke transducer interface
GC 201/A 2203 7217 x x Graphic interface for TFT colour display (resolu-
tion 640x480), submodule for CU211 and CU212
GC 201/A/LCD 2203 7680 x x Graphic interface for LC display, submodule for

CU211, replacement for E-CRT/EL/A starting
from SV1.16.
IF 212/1 2203 7633 x x x x Connection module for interfaces executed on

IEB1 bus of the CU211, CU212 or CU201 (IEB1
bus)

Version:G/11/12/7/3
EC100-A03/MONO
EC100-A03/COL
EC100-S-A03
ENGEL
CC100-A03
number
IF 212/2 2203 7634 x x x Connection module for interfaces executed on

IEB1 bus of the CU211, CU212 or CU201 (IEB1
bus) and IEB1 connection module to the inter-
face extension module SC101/A
SI 024/BI 2203 7243 x x x x Serial interface module (submodule for CU211 or

CU212) for bitbus connection
SC 051 2203 7677 x x x x Extension module for max. 3 CAN Bus Interface
Modules CI021/A
SC 021/A 2203 7625 x x x x Interface carrier module for taking up 2 SI sub-

modules (e.g. SI020). Can be used for CU211,
CU212, CU201, SC101
SC 101/A 2203 7619 x x x Carrier module for 3 IEB2 submodules
SI020 2203 7628 x x x x 20mA-Current Loop submodule for SC021
SI232 2203 7626 x x x x RS232 submodule for SC021
SI485/422 2203 7627 x x x x RS485 and/or 422 submodule for SC021
CI 021 2203 8127 x x x x CANBUS interface with 2 CAN BUS channels

and IEB2 interface
II030 2203 8184 x x x Axis interface module for 3 axes with incremental
stroke transducer connection IEB1-Bus for cou-
pling to CU201
Control panels complete
E-CON-CC100/A 2203 7635 x x Control panel complete for CC100-A03 and

EC100/COL systems,
consisting of:
- Touch-sensitive keyboard E-FP-CC100,
- Console controller OC101/A,
- Display connection printed board assembly K-
TFT-ANCCFT,
- TFT display LQ10D321
E-CON-EC100 2203 7636 x Control panel complete for EC100/MONO sys-

tem,
consisting of:
- Console controller OC101/A,
- Display-connection printed board assembly E-
LCD-CONV,
- B/W-LCD-Display
E-CON-EC100/S 2203 7637 x Control panel complete for EC100/S system,

consisting of:
- Console controller OC101/C (variant without
floppy controller),
- Display-connection printed board assembly E-
LCD-CONV,
- B/W-LCD-Display

Version:G/11/12/7/3
EC100-A03/MONO
EC100-A03/COL
EC100-S-A03
ENGEL
CC100-A03
number
E-SP-CCEC 2203 7638 x x x x Switch panel for EC100S/EC100/CC100,

consisting of:
- Carrier plate,
- Control button connection printed board
assembly K-FTC-AN/A
- 30 Touch-sensitive keys
- Assembly holes for 15 jack switches
- Slide-in pockets for button inscription
E-SP-CCEC/A 2203 7642 x x x Switch panel for EC100/CC100,

consisting of:
- Carrier plate,
- Control button connection printed board
assembly K-FTC-AN/A
- Assembly holes for 25 jack switches
- Slide-in pockets for button inscription
Control panels individual parts
E-FP-CC100 2203 7239 x x x x Touch-sensitive keyboard for control panel E-

CON-CC100/A, E-CON-EC100 or E-CON-
EC100/S
LCD-DISPLAY LQ10D321 2203 7164 x x VGA colour TFT display with adapter printed
board assembly. TFT connection for control con-
sole CC100/A
LCD-DISPLAY LM64P89 2203 6390 x x VGA-LC display for control panel E-CON-E100
and E-CON-EC100/S
OC 101/A 2203 7618 x x x Console controller for control panels E-CON-

CC100/A and E-CON-EC100
Functions:
Keyboard controller, floppy controller
OC 101/C 2203 7659 x Console controller for control panels E-CON-

EC100/S
Functions:
Keyboard controller
Various parts
EC88 KEY-OPERATED 2203 6231 x Key-operated switch complete with wiring

SWITCH
FD 353 2203 7224 x 3,5”-Floppy drive incl. housing, clamp carriers

set and dust-proof cover
PFD 35 2203 6300 Portable Floppy Disk 3,5” with housing Power
Supply 220V/110V, serial interface, mains cable
MR 122 2203 7244 x x x Magnetic card reader for CC100/EC100 incl.

cable for connection to the K-FT/C
MR 125 2203 6353 Magnetic card reader (track 2) with RS232 inter-
face
CC100 A03 CABLE SET x x Cable set for CC100-A03 and EC100/COL-A03

Version:G/11/12/7/3
EC100-A03/MONO
EC100-A03/COL
EC100-S-A03
ENGEL
CC100-A03
number
Valve control cards
0811 405 119 2204 0040 x x x Valve control card for porportional valves NG6,
employment at proportional valves for core-pull
or ejector
0811 405 120 2204 0065 x x x Valve control card for proportional valves NG10,
employment at proportional valves for clamping
unit, core-pull or ejector
0811 405 063 2204 0033 x x x Valve control card for proportional valves NG16,
employment at proportional valves for clamping
unit, core-pull or ejector
0811 405 110 2204 0070 x x Pump control card for radial piston pump with
electrohydraulic adjustment

Version:G/11/12/7/3
2.3 CONTROL PRINCIPLE
DO321/B AR281
DI325/B SR161/A TT081
DO321/16/B
AR101 TT081/5
CU211 SC101
SC021
V24 V24 or CL
Magnetic card reader Ext. temp. controller
Printer,
Text input
Floppy
Central computer Robot
2.4 CARD ARRANGEMENT IN THE RACK
2.4.1 GENERAL
For EMC reasons empty plug-in places must be covered with blind printing plates (See
also item ”Electromagnetic compatibility”)
FP005/B Blind printing plate 5TE wide for module places
FP004/B Blind printing plate 4TE wide for extreme right plug-in place.
Must be used when no bus couple card is employed.

Version:G/11/12/7/3
2.4.2 CC100-A03 AND EC100/COLOR
Control panel keyboard connection printed board

Slot address
assembly
Base for CU211
15 *)
10
12
13
14
16
11
1
Terminal BT081 or coupling BC082/

IF212/1
CC100: AR281, EC100: AR101
Reserved for SR161/A
CU212***)
CU211
Cardrack CR162
PD242/A **)
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
DO321/B
DI325/B
GC201/A
PS244
TT081
*) CU211 / CU212 needs 2 plug-in places Graphic module,

**) only at CC100-A03 standard Subboard on CU2xx
***) at CC100-A03: CU211/F, starting from quarter 2/2000 CU212
at EC100-A03/COLOR: CU211/E
2.4.3 EC100-A03/MONO
Slot address

assembly
Base for CU211
15 *)
10
12
13
14
16
11
1

IF212/1
CU211/E)
Reserved for SR161/A
Reserved for PD242/A

Cardrack CR162
GC201/A/LCD
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
DO321/B
DI325/B
AR101
PS244
TT081
*) CU211 needs 2 plug-in places Graphic module,

Subboard on CU211

Version:G/11/12/7/3
2.4.4 EC100-S-A03
Slot address
assembly
Base for CU211
9 *)
10
1

IF212/1
CU211/D)
Cardrack CR092
GC201/A/LCD
Reserved
Reserved
DO321/B
TT081/5
DI325/B
AR101
PS244
*) CU211 needs 2 plug-in places

Graphic module,
Subboard on CU211
The bus couple card in the plug-in place 10 is only used when the rack is employed as expansion rack for EC100 or
CC100.

Version:G/11/12/7/3
2.4.5 RACK EXPANSION POSSIBILITIES

(Not at EC100-S)
CR162 as main rack Configuration
Bus terminal
BT081 on
BC082/A plugged
Master Master
J1 of the bus printed J1 of the bus couple

circuit board module
BC082
Cable
CR162 as extension BK082/A
no bus terminal
Slave Slave

BC082
Cable
CR092 as extension BK082/A
Bus terminal
BT081 on
BC082/A plugged
BC 082/A
Slave Slave

BC082
As additional rack the standard racks CR162 and/or CR092 can be used.
The bus coupling occurs via the bus couple module BC082/A and the bus couple cable
BK082/A. Up to 8 racks would be possible.
In the additional racks only the operation of slave modules (DI325/B, DO321/B, TT081) is
possible. Master modules (CU212, CU211, CU201, AR281 and AR101) must be operated in
the main rack.

Version:G/11/12/7/3
2.5 CONTROL CONSOLES
2.5.1 CC100 AND EC100/COL
Control console
E-CON-CC100/A
(Back view)
K-TFT-AN/CCFT to the control unit:

10.4” CC100-A03 TFT cable
TFT display Connection for GC201/A
cold cathode on CU211 and/or CU212
CC100CON-PS cable
PS244
Power Supply
Fix cable screen
EC/CC100-RK-CON
OC101/A
IF212/1
Keyboard/floppy-
Controller KL1 Connection printed board
S6 assembly for CU211 and/or
S3 24V supply
Occupation KL1:
S8
0C101 floppy cable
KFTCAN-DAT cable
S9
S5 S4 Fix cable screen
S9
K-FTC-AN/A Floppy drive FD353

CC100 key-operated switch
Magnetic card reader

MR122
Printer cable
KEYB cable
is connected optionally on
OC101/A
instead of the key-operated
Switch panel
E-SP-CCEC (touch-sensitive
keys)
or
E-SP-CCEC/A (jack switch)
Fix cable screen
Fix cable screen
PC-MF102 keyboard
Key-operated switch
Printer

Version:G/11/12/7/3
2.5.2 EC100/MONO
Control console
E-CON-EC100
(Back view)
Setting display brightness
to the control unit:

E-LCD-AN
E-LCD-DAT cable
10.4” Connection for GC201/A/
LCD display LCD
monochrome
CC100CON-PS cable
PS244
Fix cable screen Power Supply
Switchover black/white to
EC/CC100-RK-CON
white/black
OC101/A
Keyboard/floppy- IF212/1
Controller KL1 Connection printed board
S6
S3 24V supply
Occupation KL1:
S8
0C101 floppy cable
KFTCAN-DAT cable
S9
S5 S4 Fix cable screen
S9
K-FTC-AN/A Floppy drive FD353


MR122
Printer cable
KEYB cable
OC101/A
Switch panel
keys)
or
E-SP-CCEC/A (jack switch)
Fix cable screen
Fix cable screen
PC-MF102 keyboard
Key-operated switch
Printer

Version:G/11/12/7/3
2.5.3 EC100-S
Control console
E-CON-EC100
(Back view)
Setting display brightness
to the control unit:

E-LCD-AN
E-LCD-DAT cable
10.4” Connection for GC201/A/
LCD display LCD
monochrome
CC100CON-PS cable
PS244
Fix cable screen
Power Supply
Switchover black/white to
white/black
OC101/C *) EC/CC100-RK-CON
IF212/1
KL1 Connection printed board
S6
S3 24V supply
Occupation KL1:
S8
KFTCAN-DAT cable
S9
S5 S4
*) Fix cable
screen
S9
K-FTC-AN/A
Floppy drive FD353 *)

MR122
Printer cable
KEYB cable
OC101/A
Switch panel
keys)
Fix cable screen

Fix cable screen
PC-MF102 keyboard *) FLOPPY IS OPTION at

Key-operated switch
EC100-S. Instead of
OC101/C OC101/A is
Printer mounted

Version:G/11/12/7/3
2.6 SCREEN DISPLAY
CC100 and EC100/col: The colour flat display is connected from the card GC201,
subprinted board assembly on CU211 and/or CU212, via
screened data line to the TFT connection printed board
assembly K-TFT-AN and from here to the display. ”TFT” =
”Thin Film Transistor”.
EC100/mono and EC100-S Equipped with LC monochrome flat display. Connection of
E-CRT-EL/A with screened data line to module E-LCD-
CONV on front panel.
The voltage for the display is switched with the control voltage switch. It is processed by the
power pack PS244 and/or PS243.
Division of the screen images:

Text pictures ..... 40 Characters per line, in special cases also 80 characters
graphic,
Set value graphics,
PD graphics,
Printer menu for individual pages,
Debugger ..... 80 Characters per line
1. Line ..... Header and time/date
2. up to 21st line ..... Texts, set values, actual values
22. up to 25th line ..... Area for interactive error message field and error messages,
input field and display of the state of operation, function keys and
system error messages
DIMMING:
In order to spare the luminous electronics of the screen, the microcomputer switches the
background lighting tubes of the screen off when no image selection key has been actuated
for approx. 10 min. By pressing an image selection key the screen switches to bright again
(cold cathode).
During the debugger function the dimming is suppressed. The bright period can be set in the
’system setup’ (see ”System setup”).
RUNNING DISPLAY:
At CC100 and EC100/col: In the front panel 2 lamps are integrated:

green lamp .......... ON ”Control unit in operation”
red lamp ............. TEMP: not used
During operation in the right upper corner of the screen the separation double point of the time
display flashes. This indicates normal computer function with regard to proper processing of
the sequence program. If this point disappears or lights permanently, the computer stops the
sequence program; e.g. due to time overloading or due to wrongly programmed permanent
loops.

Version:G/11/12/7/3
3 ELECTRONIC MODULES
3.1 EPROM SURVEY
Attention!
Before handling with Eproms and electronic modules generally please

observe item ”Safety hints”
Eproms on card CU211 and CU212:

2 Piece (for special applications and CU212 4 pieces):
System System version
CC 100 SV 2.12d SYSTEM SOFTWARE

Plug-in base 0 - 3
2001-11-18 46470 0 Eprom type: 27C801; 80ns

SGS-Thomson or ATMEL
Version date Plug-in place number

Serial number
Eproms on card AR281 and AR101:
2 Piece:
Identification number Version
AR 281 SV 2.00 ANALOG SIGNAL TREATMENT and

(and/or AR101) SERVP VALVE CONTROL
Plug-in base 0 and 1
99-02-20 0 Eprom type:
27C4001; 80ns for AR281, SV2.00
27C1001; <= 120ns for AR101, SV1.25
Version date Plug-in place number
Eprom on card TT081 and TT081/5:

1 Piece:
13189/1/6/ HEATING CONTROL

U1/0/V2.12
E-8-Thermo 12MHz
Eprom type: 27512
The calibration values are filed in a separate flash, thus the Eprom can be exchanged.

Version:G/11/12/7/3
3.2 CARD CODING

The plug-in places on the system bus (KEMRO bus) of the CC100 and EC100 can be used
freely for all cards except power pack, CPU and bus coupling. For this purpose on each card
coding switches are provided, by means of which the addresses are fixed. In extension racks
the multimaster modules CU212, CU211, CU201 and AR281 cannot be operated. In these
racks the coding numbers are continued.
An equipment with address holes is possible.
Cards- Card type Card Switch Standard- Extension rack

address number position Rack
50H TT081 and/or TT081/5 1 0 x x
54H TT081 and/or TT081/5 2 1 x x
58H TT081 and/or TT081/5 3 2 x x
... ... ... ... ... ...
6CH TT081 and/or TT081/5 16 F x x
500H DI325/B 1 0 x x
508H DI325/B 2 1 x x
510H DI325/B 3 2 x x
... ... ... ... ... ...
538H DI325/B 8 7 x x
600H DO321/B 1 0 x x
608H DO321/B 2 1 x x
610H DO321/B 3 2 x x
... ... ... ... ... ...
638H DO321/Bb 8 7 x x
600H DO321/16/B 1 0 x x
640H DO321/16/B 2 8 x x
608H DO321/16/B 3 1 x x
648H DO321/16/B 4 9 x x
610H DO321/16/B 5 2 x x
650H DO321/16/B 6 A x x
618H DO321/16/B 7 3 x x
658H DO321/16/B 8 B x x
620H DO321/16/B 9 4 x x
660H DO321/16/B 10 C x x
628H DO321/16/B 11 5 x x
668H DO321/16/B 12 D x x
630H DO321/16/B 13 6 x x
670H DO321/16/B 14 E x x
638H DO321/16/B 15 7 x x
678H DO321/16/B 16 F x x
The master modules CU212, CU211, CU201, AR101, AR281 must have different address switch positions:
--- AR281 1 4 x
--- AR281 2 5 x
--- AR281 3 6 x
--- AR281 4 7 x
--- AR101 1 4 x
a mixing AR281 and AR101 is not possible
--- CU212 1 1 x
--- CU211 1 1 x
--- CU201 1 C x
--- CU201 2 D x
--- CU201 1 1 x
RO161/A 1-16 0-F x x

Version:G/11/12/7/3
Channel and output port numbers at the digital output cards as a function of the set
address switch position:
Channel 00- 16- 32- 48- 64- 80- 96- 112- 128 144 160 176 192 208 224 240
15 31 47 63 79 95 111 127 - - - - - - - -
143 159 175 191 207 223 239 255
Outputport 0,1 2,3 4,5 4,7 8,9 10, 12, 14, 16, 18, 20, 22, 24, 26, 28, 30,
11 13 15 17 19 21 23 25 27 29 31
DO321/16/ 0 8 1 9 2 A 3 B 4 C 5 D 6 E 7 F
Adresswich
DO321/B 0 1 2 3 4 5 6 7
Adresswitch
With simultaneous use of DO321/B and DO321/16/B it must be observed that no channel
cover arises. The equipment with ’holes’ is possible.
Channel / input port numbers at the digital input cards as a function of the set address switch
position:
Channel- 0 - 31 32 - 63 64 - 95 96 -127 128-159 160-191 192-223 224-255

number
DI 325/B 0 1 2 3 4 5 6 7
Inputport

Version:G/11/12/7/3
3.3 MAIN PROCESSOR

Main processor CU211
Interface
Extension
Bus (IEB1)
interface S1
Status LEDS, red for touch-
and green sensitive
keyboard,
CU211 floppy
Battery-LED
Interface
Extension
Program loading Bus (IEB2)
key for EURO-
MAP, CAN
bus, etc.
Serial interface only when

no floppy on IEB1
B1 = coding
Battery. Drawn position switch =1
J1: Battery = on
B3 = switcho-
ver bus type
Test interface KEMRO bus
- I/O BUS
Interface colour graphic mod-
ule CG201/A for colour TFT
display or GC201/A/LCD at J2 = switcho-
monochrome display ver cycle
KEMRO bus
- I/O BUS
Status-LEDs
Watchdog,
Alarm
Standard in: Variants

EC100-S CU211/D 32 bit processor i80386SX/25Mhz, 2MB RAM, 2MB Eprom
EC100 CU211/E 32 bit processor i80386SX/25Mhz, 4MB RAM, 2MB Eprom
CC100 CU211/F 32 bit processor i80486SXLC/20Mhz (40Mhz internal), 8MB RAM, 2MB Eprom
ATTENTION: Starting from Q2/2000 CU211/F is replaced by CU212
Eproms 0 - 3 type M27C801 for system software

0... Bank 0, Low Byte... equipped
1... Bank 0, High Byte... equipped
2... Bank 1, Low Byte... not equipped
3... Bank 1, High Byte... not equipped

Version:G/11/12/7/3
Main processor CU212
Interface
Extension
Bus (IEB1)
interface S1
Status LEDS, red and green for touch-
sensitive
keyboard,
Battery-LED floppy
CU212
Interface S3,
Program loading key Extension
Bus (IEB2)
for serial
4x Eproms interfaces,
8MBit, 80ns CAN bus,
Ethernet interface for EMS etc.
and Teleservice
B1 = coding
Battery. Drawn position J1: switch =1
Battery = on
Test interface DEBUG, module

SI232 in the standard,
exchangeable for SI020
Interface colour graphic mod-

ule CG201/A for colour TFT
display KEMRO -
8MB SRAM Bus S2
Status-LEDs
Watchdog,
alarm
Standard in: Variants

CC100 CU212 32 bit processor i80486DX4/25Mhz (75Mhz internal), 8MB RAM, 4MB Eprom
CU212 is software-compatible successor of the CU211/F, in the standard starting from quarter2/
2000
Eproms 0 - 3 type M27C801 for system software


Version:G/11/12/7/3
On the CPU card there is essentially the processor unit with the system program memory
(EPROM), the sequence program memory (RAM), the data memory (RAM), the keyboard
control and the serial interfaces for printer, input keyboard, diskette device and test.
At colour representation the screen actuation occurs via the module GC201/A, at monochrome
via GC201/A/LCD
In the RAM memory the machine parameters (constants, linearization tables etc.) and the
mould parameters are stored, which are also preserved in the switched-off state by a battery.
So the CPU card is also under voltage when it is pulled out of the rack. Therefore pay
attention to short circuits with metallic objects (e.g. at the EPROM change).
In the special service case it can be necessary to load the sequence program. For this purpose
the machine is switched off, the program loading key is pressed and kept in the pressed state
until after renewed switching-on of the plant the green light emitting diode lying below flashes
alone. An independent RAM test is made. With soft key ’Floppy’ one starts the read-in of the
program. After the loading occurs an automatic resetting (RESET) of all data, mould and
machine parameters.
Pay attention to that the battery must be deactivated as voltage source via the jumper J1 (see
sketch above) in order not to load this in the storage state. So the CPU is under voltage
(approx. 3.7V) when jumper J1 is set according to sketch. When the charging state of the
battery (no accu, but lithium battery!) has fallen to a level of 3.0V, the error message ”CPU
BATTERY” appears, after which the battery shall be exchanged immediately. For this purpose
secure the stored data (mould parameters) on diskette before. Also the machine diskette with
program and machine parameters. The battery can be exchanged easily via screw terminals.
The data safety is no longer given at a battery voltage of under 2.5V.
When a machine is calibrated newly (e.g. because of hydraulic phenomena of wear, exchange
of proportional valves, exchange of proportional amplifier cards etc.), the machine diskette
must always be written newly in order not to have to calibrate newly again in case of possible
later data loss. The same applies to the change of constants.
When switching on the control unit the processor checks the system software, the EBIAS
software (sequence program) and the data memory by forming a check sum. If these check
sums are not identical with the stored values, it interrupts the test and displays it on the screen.
A so-called ”Watchdog” on the CPU card checks permanently whether the main processor
functions still run. In a case of error it switches off the machine via a direct line to a relay (SYS
ERROR 0/1). See also ”WATCHDOG”.

Version:G/11/12/7/3
3.3.1 CPU VARIANTS

CU211
EMV capsule
CU211
SC021, CI021 and/or SI024
Submodules Sixx on SC021

Channel 4 (only at SC021)
Output for SI024
occasionally: serial floppy con-

nection (submodule on CU211
GC201/A for TFT displays and/

Test interface
or GC201/A/LCD for LCD dis-
plays
Display connection for

CG201/A or GC201/A/
LCD
Short designation on rack inscrip-

tion strip
CU211
Designation of the equipment variant: on cable channel cover
CU211/D ... 2MB, without submodules
CU211/E ... 4MB, without submodules
CU211/F ... 8MB, without submodules
CU211/ . /M1 ... with GC201/A/LCD for monochrome LC display
CU211/ . /C ... with GC201 for colour TFT display
CU211/ . / . /1 ... with SI024 (Euromap15)
CU211/ . / . /2 ... with CI021 (CAN module)
CU211/ . / . /3.x.y ... with SC021 (carrier module for 2 serial interfaces)

Version:G/11/12/7/3
CU212
EMV capsule
CU212
SC021, CI021 and/or SI024
Submodules Sixx on SC021

Output for SI024

Submodule SI232 for test inter-
face, exchangeable for SI020
Ethernet interface for Teleser-

vice or EMS
GC201/A for TFT display

Test interface RS232
Display connection for

CG201/A
Short designation on rack inscrip-

tion strip
x = 4.Kanal X, Y ... 0 ... no equipment

y = 5.Kanal 1 ... SI232
2 ... SI020
3 ... not useable (bitbus, is operated with SI024)
4 ... SI422/485
CU212
Designation of the equipment variant: on cable channel cover
CU212 ... 8MB, without submodules, SI232 for Debug is installed
CU212/C ... with GC201/A for colour TFT display
CU212/M ... with GC201/LCD, EC100/mono with e.g. teleservice or more memory
CU212/./ 1 ... with SI024 (Euromap15)
CU212/./ 2 ... with CI021 (CAN module)
CU212/./ 3.x.y ... with SC021 (carrier module for 2 serial interfaces)
x = 4.Kanal X, Y ... 0 ... no equipment

y = 5.Kanal 1 ... SI232
2 ... SI020
3 ... not useable (bitbus, is operated with SI024)
4 ... SI422/485

Version:G/11/12/7/3
3.3.2 GRAPHIC MODULES

The graphic submodules GC201 serve the actuation of displays on the control console.
GC201/A: Actuation of the sharp colour TFT display of the type LQ10D321.
TFT-Display
GC201/A
K-TFT-AN/CCFT
max. 15m Electric converter for signal

adaptation
CU211 or CU212
GC 201/A/LCD: Actuation of the black-and-white LC display of the type LM64P89.
LC display
GC201/A/LCD
E-LCD-AN
max. 3m Electric converter for signal

adaptation
CU211
GC201/A/LCD replaces the graphic module E-CRT-EL/A. Can be used from system software
version SV1.16 (Q2/97). Not compatible with older graphic modules.
The modules GC 201/A and GC 201 are compatible electrically, but cannot be exchanged
mutually mechanically.
GC 201/A is the CE-conforming variant for modules with front plates and EMV cassettes. GC
201 is the compatible replacement for older systems.
E-LCD-AN enables with poti R15 the setting of the display brightness. With jumper J1 the
representation can be switched over from white/black to black/white.

Version:G/11/12/7/3
3.4 ANALOG CARDS
3.4.1 AR 281
AR281 ... Analog control card; with processor INTEL 960 KB, clock frequency: 25Mhz
Coding switch
Type 27C4001 / 80ns
8 Analog inputs: -10V up to +10V, resolution 14 bits, at 0 up to +10V 13 bits for:

ohmic stroke transducers
Hydraulic pressure transducer,
Mould cavity pressure transducer (e.g. charge amplifier Kistler),
Clamping force
3 Serial inputs, resolution 14 bits for:

ohmic stroke transducers with measured value converter AS141
when utilizing only a part of the total stroke the resolution reduces correspondingly.
2 digital inputs for:

Speed transducer bDZ,
external switchover contact bC3E, alternative clamping force pulse generator
bIE
7 Analog outputs -10 up to +10V, resolution 12bits for:

Valve amplifier cards
Functions:
- Clamping force adj
- Ramp control, profile treatment
- Software servo valve control
- Speed recording of the screw
- Flow number (Microplast/Microflow)
- Switchover functions:

Version:G/11/12/7/3
as a function of mold cavity pressure,

hydraulic pressure-dependent,
time-dependent,
stroke-dependent,
via external digital signal +24V
- Pressure recording:
Injection cylinder
Clamping cylinder
Pump system
(- Tilting angle recording:
Pump system)
AR281, configuration
Plug-in Function Position Description
bridge
Analog Input
Moduls
J0 to J7 Ai0to Ai7 B-C double ended mode (difference input)
A-B single ended mode (asymmetric)
J8 Boot mode A-B Boot from the flash (standard)

B-C Boot from the Eprom (for test operation)
J9 Boot block B-C Boot-block locked (writing-protected)

Lock/Unlock A-B Boot Lock unlocked
AR281, addressing
as card 1 Coding switch on ... 4
as card 2 Coding switch on ... 5

Version:G/11/12/7/3
AR281, occupation
EHV1 EHV2 EHV3

S R S R S R
SI0 = sfx / serial stroke transducer clamping unit
SI1 + SI0 +
SI1- SI0 -
GND SI1 = ssx / serial stroke transducer screw
SI2 +
SI2 - GND
GND SI2 = serial stroke transducer reserve
+10VR Supply voltage for analog stroke transducers

Ai0+ ph2 / clamping pressure transducer
Ai0-
Ai1+ ph3 ph3 ph3 ph3 ph3 ph3
Ai1-
Ai2-
Ai3+ sdx / analog stroke transducer nozzle
Ai3-
Ai4+ sax / analog stroke transducer ejector
Ai4-
Ai5+ pfx / mould cavity pressure (Kistler 5039 A221)
Ai5-
Ai6-
Ai7+ Special: sdtx / analog rotary table stroke transducer
Ai7-
Ao0+ --- servo sp servo sp servo
0V
Ao1+ Special: Prop.valve for ejector + cores .....
0V
Ao2+ ps/sp ps ps ps ps ps
0V
Ao3+ Volume central (Y valve)
Ao4+ Pressure central (K valve)
0V
Ao5+ if 2nd pump: Volume 2nd pump
Ao6+ if 2nd pump: Pressure 2nd pump
0V
ADi0 external switchover contact
ADi1 Screw speed transducer screw
EHV1 ... Hydraulic saving concept with EHV pump

EHV2 ... Medium-sized machines hydraulic concept with EHV - and starting from ES250 with EHV -
and fixed displacement pump
EHV3 ... Hydraulic concept with 2 EHV pumps for parallel movements
S ... position-controlled and/or pump-controlled machine
R ... servo valve-controlled machine
ph1 ... Pres. pump 1
ph2 ... Closing press
ph3 ... phx = injection pressure
sp ... Specific back pressure
ps ... Prop.valve on clamping unit
servo ... Servo valve injection unit

Version:G/11/12/7/3
3.4.2 SR161/A
SR161/A, occupation
Si3 = serial input, reserve

SI3 + SI5 +
---”---
SI3- SI5 -
Si4 = serial input, reserve
SI4 + GND
GND ---”---
SI4 - Si5 = serial input, reserve
GND
---”---
+10VR Reference voltage for stroke transducer
+10VR ---”---
Ai8+ analog input, reserve
Ai8- ---”---
Ai9- ---”---
Ai10- ---”---
Ai11- ---”---
Ai12- ---”---
Ai13- ---”---
Ai14- ---”---
Ao7+ analog output, reserve
0V ---”---
0V ---”---
0V ---”---
Ao10+ Reserve (measuring output hydraulic pressure (20mV/bar))
0V ---”---
Ao11+ Reserve (measuring output screw stroke (20mV/mm))
0V ---”---
Ao12+ Reserve (measuring output screw speed (20mV/mm/ss))
0V ---”---
0V ---”---
0V ---”---
SR161/A ... additional analog control card; extension module for AR281
7 Analog inputs: -10V up to +10V, resolution 14 bits for:
ohmic stroke transducers , hydraulic pressure transducer,
3 Serial inputs, resolution 14 bits for:
ohmic stroke transducers with measured value converter AS141
8 Analog outputs -10 up to +10V, resolution 12bits for:
Valve amplifier cards,
Measuring out- 20mV/bar Hydraulic pres
puts:
20mV/mm Screw stroke
The function of the measuring outputs must be activated on the screen page
’Operator setup’. See chapter ’Putting into operation’, item ’Operator setup’.

Version:G/11/12/7/3
SR161/A ... additional analog control card; extension module for AR281
Functions:
- Pressure record- Pump system
ing:
- Tilting angle recording: Pump system
3.4.3 MEASURED VALUE CONVERSION AS 141
Sealing (O-ring)
Connection to AR281 and SR161/

A, serial inputs Si0 - Si5
Lay screen on the control

unit side on grounding
strap Gasket
This earth connection

must be omitted at AS141
with integrated screen
cassette *)
Stroke transducer
Connect AS141
*)
Gasket
For the transformation of the analog stroke transducer measured value into a digital signal for
the serial transmission to the analog control card AR281 and/or SR161/B on the transducer a
conversion electronics is connected in series.

Version:G/11/12/7/3
Connection 2-pole, to the 24V supply for the stroke transducers the digital data signal is
superimposed.
Advantage: No disturbing influence of the digital signal, thus utilization of a data width of up to
16 bits.
*) At AS141 with integrated screen cassette the screen of the connection cable is connected
to the stroke transducer housing via the internal screen plate. Thus a completely screened
signal transmission stroke results. The stroke transducer is insulated electrically from the
machine ground. Feature of this AS141 (starting from end 1997) is the article label glued on
the front side with serial number.
3.4.4 AR 101
In the system EC100 the AR101 is employed as analog module

Essential characteristics:
8 analog inputs: +10 V, 12 bit resolution, 5 kHz scanning rate, poling-
safe, of it 4 with unsymmetrical input (‘single ended’) and
4 adjustable as difference input (‘double ended’) or ‘sin-
gle ended’ for:
ohmic stroke transducers,
Hydraulic pressure transducer,
Mould cavity pressure transducer (device Kistler
5039 A221),
Closing press
4 analog outputs +/-10 V, 12 bit resolution, 10 mA, short circuit stable, for
valve amplifier cards
3 digital inputs 0 - 30 V, switchover threshold voltage 8 V

Clamping force impulse sender bIE,
Speed transducer bDZ,
external switchover contact bC3E
Reference voltage 10 V / 200 mA output for the supply of analog transduc-

ers (potentiometers) integrated on the module
Processor Intel 80960, clock frequency 16 MHz

Data memory 1 MByte (max. 4 MBytes) dynamic RAMs
Program memory 128 kByte EPROM (optional) 512 kByte (max. 1 MByte)
Flash-EPROM
Watchdog for monitoring the program sequence in the processor
Test equipment for self-test which can be switched on in the software
(connection of in/outputs, calibration)
Functions:
- Clamping force adj
- Software servo valve control
- Speed recording of the screw
- Flow number (Microplast/Microflow)
- Switchover functions:
as a function of mold cavity pressure,
hydraulic pressure-dependent,
time-dependent,

Version:G/11/12/7/3
stroke-dependent,
via external digital signal +24V
- Pressure recording:
Injection cylinder
Clamping cylinder
Pump systems
AR101, configuration
Plug-in bridges in the stan-

dard:
Pressure transducer Ai2
Pressure transducer Ai3 J8
Pressure transducer Ai4
Kistler Ai7
drawn jumper settings are at the works.
J1 not equipped, boot load blocked

J2 not equipped, 3 alignment points
J3 Watchdog
J4 Analog Input 4 )
J5 Analog Input 7 ) B-C plugged = Difference inputs (double ended)
J6 Analog Input 2 ) A-B inserted = unsymmetrical, single ended
J7 Analog Input 3 )
Analog Inputs 0, 1, 5, 6 are switched fixed single ended
J8 A-B: System program of B-C system program from the flash. The flash is described once
Eproms, from diskette.
ST3 IEB2 plug (Interface Extension Bus = KEMRO private bus) für plug-in subprinted board assembly
(communication interface)
ST2 KEMRO bus compatible to MOTOROLA I/O channel with additional function, AR101 not multimaster
capable
AR101, addressing:
Set coding switch to 4 digits, only one card AR101 possible

Version:G/11/12/7/3
AR101, occupation
HLS1 EHV1 *) EHV2 *) Q/P

S R S R S R S R
Ai0+ sfx / analog stroke transducer clamping unit
0V
Ai1+ ssx / analog stroke transducer screw
0V

Ai2+ ph2 / clamping pressure transducer
Ai2-
Ai3+ ph1 ph3 ph1 ph3 ph3 ph3 ph3 ph3
Ai3-
Ai4+ --- ph1 --- ph1 ph1 ph1 ph1 ph1
Ai4-
Ai5+ sdx / analog stroke transducer nozzle
0V
Ai6+ sax / analog stroke transducer ejector
0V
Ai7+ pfx / mould cavity pressure (e.g. Kistler charge amplifier)
Ai7-
+12V
+12V
+12V
-12V
-12V
-12V
Ao0+ --- servo --- servo sp servo sp servo
0V
Ao1+ --- --- ps/sp ps ps ps ps ps
0V
Ao2+ Volume central (Y valve)
Ao3+ Pressure central (K valve)
0V
ADi0 external switchover contact
ADi1 Screw speed transducer screw
ADi2 reserve
NC no connection
GND 0V
*) no 2-pump operation possible
HLS1 ... Hydraulic saving concept with RK pump

EHV1 ... Hydraulic saving concept with EHV pump
EHV2 ... Medium-sized machines hydraulic concept with EHV - and starting from ES250 with EHV -
and fixed displacement pump
S ... position controlled machiine
R ... servo valve-controlled machine

Version:G/11/12/7/3
ph2 ... Closing press

ph3 ... phx = injection pressure
sp ... Specific back pressure
ps ... Prop.valve on clamping unit
servo ... Servo valve injection unit
3.5 TEMPERATURE CHANNELS
3.5.1 TT081 UND TT081/5
2 Variants: TT081 ... 8 Channels

TT081/5 ... 5 Channels for HLS machines
- EMV-suitable encapsulation
- 8 equal temperature PID controllers independent of each other with:
- 8 Heating outputs, 24V/500mA each, short circuit stable
- 8 Cooling outputs, 24V/500mA each, short circuit stable
- 8 Thermocouple inputs, separated physically from each other, thus no influ-
ence of the measuring signal by the machine earth, gilded contacts, function
of the temperature circuits is determined from software.
- Types of couples: FE-KO Standard type J, type L adjustable on the

screen
NiCr-Ni determined by software on main CPU
PT100 with card E-8-PT100 and special software
- Controller types: only display
Regulator mode
2-Point controller
3-Point controller
- Self-optimizing controllers
Possible expansions
Standard at: CC100 and 1x TT081 1 Zone for oil, 7 heating zones
EC100
EC100-S 1x TT081/5 1 Zone for oil, 4 heating zones
Expansions: CC100 and up to 120 zones (altogether 16 cards)

EC100
EC100-S altogether 2x TT081 (= 16 zones)
Remarks: Heating-up groups can be fixed in EBIAS program,

not card-dependent. The set values of the zones for
which no control card is built in must earth set to 0.

Version:G/11/12/7/3
TT081 and TT081/5, hardware
green status LED:

flashing: ready for operation
red status LED:
Watchdog
27C512 Eprom Switch B1
13189/1/10/1770
U1/0/V2.16
E-8-THERMO 12Mhz
Serial number of
the card
The calibration data are filed in a not volatile Flash eprom. The controller software (Eprom) can be exchanged from
card to card. Starting from hardware revision F1.0 (see bus plug) software V2.16 is compelling. V2.16 can be
employed downwards. Versions smaller than V2.16 do not run starting from hardware F1.0.

Version:G/11/12/7/3
TT081, connection occupation
CARD 1 (standard volume)
Terminal Front plate Description Designation Designation

designation card 1 card 2
1 0- Channel 0, thermoline. - Oil- KO8-

2 0+ Channel 0, thermoline. + Oil+ FE8+
3 1- Channel 1, thermoline. - KO1- KO9-
4 1+ Channel 1, thermoline. + FE1+ FE9+

11 5- * Channel 5, thermoline. - KO5- KO13-
12 5+ * Channel 5, thermoline. + FE5+ FE13+
14 6+ * Channel 6, thermoline. + FE6+ FE14+
16 7+ * Channel 7, thermoline.+ FE7+ FE15+
17 0 Output 0, heating H0 H8
22 5 * Output 5, heating H5 H13
25 0 Output 0, cooling KÜ0 KÜ8
30 5 * Output 5, cooling KÜ5 KÜ13
33 not occupied
34 not occupied
35 24V Supply voltage +24VC +24VC
36 GND Supply voltage 0V 0V
Wire colours at Iron-constantan (Fe-CuNi): +Pol (Fe): red, -Pol: blue

thermolines: Iron-constantan (Fe-CuNi): + Pol: black - Pol: white
Nickel chrome nickel (NiCrNi): +Pol (NiCr): red, -Pol: green

Version:G/11/12/7/3
3.6 DIGITAL INPUTS

Standard expansion:
1 Card DI325/B
Up to 8 cards in the maximum expansion
DI325/B, specification
32 Digital inputs per card
EMV encapsulated
Input voltage range 18-32 V DC
Switch limit for input voltage ’1’: >11V
Input voltage ’0’: 0 - 5V
Poling and overvoltage protection
optical galvanic separation, insulation voltage 1200V
Hardware test feature also at connected inputs
LED display per input directly on the printed board assembly
Direct connection of the input signal generators via plug-in terminals on the printed
board assembly
Maximum signal generator loading 10 mA
SMD technology
At the HARDWARE CHECK the amplifiers are actuated so that the circuit tilts into a defined
position independently of the input occupation.
Error messages on the hardware check image

Card defective .... digit input failed
Short circuit on card .... short circuit
Attention!
Push-buttons are not led on digital inputs, but are in serial data connec-
tion with the main CPU. See item ”PUSH-BUTTONS CONNECTION MOD-
ULES”.

Version:G/11/12/7/3
DI325/B, occupation
a) Card 1 (standard)
The occupation represented here corresponds to the standard HL machines. It is not changed in gen-
eral, but can vary in special cases. See to it in the help texts on the screen or in the electric plan.
Card designation Signal num- Meaning when signal carries + 24V:

on XL1 *) ber
DI0 32000 EMERGENCY STOP circuit ok

DI1 32001 Safety gate 1 closed
DI2 32002 Safety valve 1 safety gate closed
DI3 32003 Nozzle protection closed (1)
DI4 32004 Core-pull 1 moved out
DI5 32005 Core-pull 1 moved in
DI8 32008 Core-pull safety 1
DI9 32009 Safety gate 1 open
DI10 32010 Safety valve 1 safety gate open
DI11 32011 Nozzle guard open (1)
DI12 32012 Throttle valve (1)
DI13 32013 Oil filter 1 (1)
DI14 32014 Injection unit turn in (1)
DI15 32015 Cylinder heatings on (1)
DI16 32016 Mould heatings on
DI17 32017 Safety gate 1 open (closing safety)
DI18 32019 Ejection safety 1
DI19 32020 Motor 1 runs on delta
DI20 32021 Oil level
DI21 32175 Core-pull safety 2
DI22 32022 Monitoring filter motor
DI23 32023 Release mould closing 1
DI24 32025 High pressure build-up suppression 1
DI25 32544 Charge amplifier 1 rejects message (1)
DI26 Reserve
DI27 Reserve
DI28 Reserve
DI29 32030 Control card EHV pump 1 ok (1)
DI30 32031 Control card EHV pump 2 ok (1)
DI31 Reserve
+ 24 VC + 24VE
0V + 24VC
0V
*) The clamping connections on the electronic cards are designated as XL1

Version:G/11/12/7/3
b) Card 2 (option)
Card designation Signal num- Meaning when signal carries + 24V:

on XL1 *) ber
DI32 Reserve
DI33 32033 Safety gate 2 acknowledged
DI34 32034 Safety strip open safety gate 1
DI35 Reserve
DI36 Reserve
DI37 Reserve
DI38 32035 Acknowledgement key safety gate 2
DI39 Reserve
DI40 32037 Safety gate 2 open (closing safety)
DI41 32038 Safety gate 2 not acknowledged
DI42 Reserve
DI43 Reserve
DI44 32039 Mould dismounted 1 moving platen
DI45 32040 Mould dismounted 1 fixed platen
DI46 32041 Mould mounted 1 moving platen
DI47 32042 Mould mounted 1 fixed platen
DI48 32043 Safety gate 2 closed
DI51 32046 Safety gate 1 entirely open
DI52 32047 Brake safety gate 1 opening
DI53 32048 Brake safety gate 1 closing
DI54 32607 Handling system 1 switched off
DI55 32050 Safety strip close safety gate 1
DI56 32051 Safety gate 2 open
DI57 32052 Release 1 ejector 1 forward
DI58 32053 Release 1 ejector 1 return
DI59 32054 Release 1 mould closing/opening
DI60 32055 Release move in core-pulls
DI61 32056 Release move out core-pulls
DI62 32057 Release 1 continue mould opening
DI63 32058 Release 1 mould closing up to G2
+ 24 VC + 24VE
0V + 24VC
0V
*) The clamping connections on the electronic cards are designated as XL1.

Version:G/11/12/7/3
3.7 PUSH-BUTTON CONNECTION MODULE K-FTC-AN/A

The push-button panel E-SP-CCEC (touch-sensitive keys) is connected to the keyboard
controller OC101 via the connection printed board assembly K-FTC-AN/A, which is in serial
connection with the main CPU.
Via SCAN LINES and RETURN LINES a matrix is built up, in which push-buttons are
interrogated cyclically and generate so-called MARKERS (MKxxx).
You find these marker numbers and their meaning in the electric plan.
In the DEBUGGER a marker survey can be selected in order to be able to control push-
buttons for test purposes.
See also item ’Control consoles’.
Instead of the touch-sensitive keyboard E-SP-CCEC also E-SP-CC100 can be employed in

jack switch execution. The connection occurs compatibly to the touch-sensitive keyboard.
3.8 DIGITAL OUTPUTS
Digital output card DO321/B 32 Outputs/2A per card

Digital output card DO321/16/B 16 Outputs/2A per card
EMV-suitable encapsulation
All outputs short circuit stable
All outputs are switched off when one of the outputs is short circuited
Hardware test with decreased output current
LED display per output directly on the printed board assembly
+ 24V switching
Output voltage range 18-32 V DC
Overvoltage protection, clamping diode for free-wheel on used operating voltage
Direct connection of the magnets and/or relays via plug-in terminals directly on the
printed board assembly
physical separation of the outputs
4(2) output groups (of 8 outputs each) to be supplied separately, with separate power
supply
SMD technology = miniature construction
Maximum output current 2.4A
Short circuit recognition 2.4A - 5A, switching-off time approx. 0.5s (EBIAS ERROR)
Maximum sum current per group 8A (simultaneousness factor: 50%)
Overcurrent recognition 8A - 12A
At the first pass of the hardware check only the reference voltage is reduced to approx. 1/10
of its normal value. If only one output is actuated, the short circuit protection gets active
immediately, i.e. the computer finds out whether current flows through the actuated transistor
and/or the connected solenoid. In this way an interruption of an output circuit can be detected.
At the second pass the reference voltage is set to its normal value. Now the computer actuates
all outputs briefly and so recognizes whether one of the outputs is short circuited.
A simultaneous use of DO321/B and DO321/16/B is possible, it must be observed, however
that no channel overlapping of the two cards arises, e.g.

Version:G/11/12/7/3
1. Card DO321/B ... Address switch 0

2. Card DO321/16/B ... Address switch 1
3. Card DO321/16/B ... Address switch 9
4. Card DO321/B ... Address switch 2
The equipment of the control unit with Digout cards can occur with ”Gaps”, this means also for
example the configuration: Card 1, 3, 4 is possible when outputs on card 2 are not needed.
See also ’Card coding’.
Error signals:
Card is missing or contact fault ... circuit break
Short circuit at the HARDWARE CHECK ... short circuit
Short circuit during operation ... EBIAS-ERROR 60 - 75
Excess current recognition ... EBIAS-ERROR 76 - 91
Overlap of address ranges ... EBIAS-ERROR 92
Missing of the supply voltage (24V) ... EBIAS-ERROR 93

Version:G/11/12/7/3
DO321/B, occupation
a) CARD 1 (standard)
Card designation Signal Meaning when signal carries + 24V:

on XL1 *) number
DO0 5001 Mould closing

DO1 5002 Mould opening
DO2 5003 Plasticizing (1)
DO3 5004 Injection (1)
DO4 5005 Advance nozzle (1)
DO5 5006 Motor start impulse
DO6 5007 Advance ejector 1
DO7 5008 Return ejector 1
+VK10 **) VKS when standard
0V 0V
DO8 5009 Return nozzle (1)
DO9 5010 Pump 1 idling (1)
DO10 5012 Pump 2 idling (1)
DO11 5014 Rejects 1
DO12 5015 Signal release motor
DO13 5016 Injection rapid
DO14 5017 Screw retraction (1)
DO15 5018 Contact pressure relief (1)
+VK11 **) VK when standard
0V 0V
DO16 5019 Signal manual mode 1
DO17 5020 Signal (semi)automatic mode 1
DO18 5021 Signal release heatings (1)
DO19 5022 Alarm lamp 1
DO20 5023 Signal mould open position A
DO21 5024 Signal ejector 1 position L
DO22 5025 Signal ejector 1 position L1
DO23 5026 Signal mould closed 1 position B
+VK12 **) VKN when standard
0V 0V
DO24 5027 Clamping pressure reduction 1
DO25 5029 Safety solenoid 1 (closing safety)
DO26 5030 Clamping high pressure
DO27 5032 Suction valve opening
DO28 5034 Open shut-off nozzle 1 (1)
DO29 5035 Air valve 1 on
DO30 6384 Close shut-off nozzle 1 (1)
DO31 5037 Diff.solenoid clamping unit
0V 0V

**) 24V= power supply of the outputs in groups of 8 separated of each other (=port 0 up to port 3).
These supplies are switched off in ports in certain machine states. (--> electric plan).
+24VK1S = force voltage, switched off in case of emergency-off and/or open safety gate on the clamping unit
+24VK1 = force voltage, switched off in case of emergency-off
+24VKN = force voltage, NOT switched off in case of emergency-off

Version:G/11/12/7/3
b) CARD 2 (option)
Card designation Signal Meaning when signal carries + 24V:

on XL1 *) number
DO32 5039 Move out core-pull 1

DO33 5040 Move in core-pull 1
DO38 5045 Pump interconnection
DO39 5061 Signal release move in handling system
0V 0V
DO40 5048 Socket switching-off 1
DO44 5143 Cooling water switching-off 1
DO45 5051 Device 1 via week switch clock
DO46 5052 Device 2 via week switch clock
DO47 Reserve
+VK21 **)VKN when standard
0V 0V
DO48 5049 Signal core-pulls moved in
DO49 5050 Signal core-pulls moved out
DO50 Reserve
DO51 Reserve
DO52 Reserve
DO53 5046 Charge amplifier 1 reset (1)
DO54 5047 Charge amplifier 1 range (1)
DO55 Reserve
+VK22 **) VK when standard
0V 0V
DO56 5062 Safety gate 1 power-actuated
DO57 5109 Air valve 2
DO58 5530 Charge amplifier 1 release test (1)
DO59 5131 Charge amplifier 1 sensitivity (1)
DO60 5053 Dismount mould 1 moving platen
DO61 5054 Dismount mould 1 fixed platen
DO62 5481 Mount mould 1 moving platen
DO63 5484 Mount mould 1 fixed platen
0V 0V

**) 24V= power supply of the outputs in groups of 8 separated of each other (=port 0 up to port 3).
These supplies are switched off in ports in certain machine states. (--> electric plan).
+24VKS = force voltage, switched off in case of emergency-off and/or open safety gate on the clamping unit
+24VK1 = force voltage, switched off in case of emergency-off
+24VKN = force voltage, NOT switched off in case of emergency-off

Version:G/11/12/7/3
3.9 POWER PACK CARD N
Variants: PS244/A ... 11A / 5V

PS244/B ... 14A / 5V
PS243 ... 25A / 5V
In the standard extension 1 card, when using bus cards in further racks another power pack
card must be inserted per rack on the extreme left plug-in place.
- Supply + 24V direct current voltage,

Range: +19V up to (^= -20% / +30%)
+32V.
Waviness: 3,6Vss
- Ambient temperature: 0 up to 55 °C
- Output voltages: 5,15V +12V -12V +15V,-15V (sym-
metry-controlled)
max. load: 11/14/25A (ext. 4A 2A 0,5A
3A)
Tolerance: -0,15V +/- 5% +/-5% +/- 3%
- Input poling-protected
- Outputs short circuit protected
Output voltages
looped input voltage
Input voltage

Version:G/11/12/7/3
3.10 INTERFACES ON THE CPU

In the standard the control units are equipped with 2 standardized RS232/V24 interfaces.
These enable the alternative connection of the following peripheral devices:
interface number:
0. TEST INTERFACE On CPU front panel accommodated as 9-pole
bush. Connection possibility for personal com-
puter for bringing in sequence program or diag-
nostics in form of remote maintenance.
At CU212 here a SI232 module is mounted,
which can be exchanged for SI020.
1. PRINT on upper bus plug of the CPU for printer with
serial input
The connections occur via special cables supplied with the equipment.
The transmission rates (Baud rates) can be set with parameter number (P).
It is valid: P 35593 ... printer
Generally for the input of Baud rate applies:

0= not allowed 1= Special Baud rate 2= 150 Bd 3= 300 Bd
4= 600 Bd 5= 1200 Bd 6= 2400 Bd 7= 4800 Bd
8= 9600 Bd 9= 19200 Bd 10= 38400 Bd 11= 57600 Bd
12= 115200 Bd
Attention!
After changing one of these parameters the control voltage must be

switched off/on in order to enable the initialization.
2. FLOPPY on upper bus plug of the CPU: Diskette drive

interface
The connections occur via special cables supplied with the equipment
3. OC 101 on upper bus plug of the CPU: Touch-sensitive

keyboard controller
for keyboard driver, front panel, keyboard, key-operated switch and/or magnetic card reader.
4., 5. on SC 021 SI modules; at SI 024 modules the 5th interface is

not available
at SI024 module connection on CPU front panel is
’Aux0’
Aux2 ... channel 4
Aux1 ... channel 5

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3.10.1 ETHERNET INTERFACE TPI ON CU212

The Ethernet connection serves the realization of a local network (10 Mbit-LAN) according to
standard IEC 8802-3, 10base-T. Thus a fast data connection for the use of Teleservice or
Engel Monitoring System (EMS) is possible without additional hardware.
On the connector socket on the front side TPI (Twisted Pair Interface) a 8-pole RJ-45 plug
(MOD-JACK) can be inserted. As connection cable a screened cable twisted in pairs of the
category CAT3 (or better) is recommended.
Connectioin occupation
Signal designation Contact
TD + 1
TD - 2
RD + 3
N.C 4
N.C 5
RD - 6
N.C. 7
N.C. 8
Connector socket on CU212 RJ-45 plug
Meaning of the status LEDs: L and A:
The LEDs are directly above the TPI bush.
L (line): green, lights permanently as long as a connection on the network exists.

A (active): yellow, lights when data are transmitted.

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3.10.2 INTERFACE MODULES
SC 101/A coupled via IF

CU211 or CU212 SC 101/A
212/2 with CU211 and/or
CU212
SC 021 (for max. 2x
SI-x or
SI 024/12Mhz/A) Channel 4 Channel 6
Channel 5 Channel 7
Channel 8
Channel 9
Channel 10
Channel 11
SC 021 or
SI 024/12Mhz/A
(Maximum expansion)
SC 101/A: Carrier printed circuit boards which can take up up to 3 subprinted circuit
boards SC 021 or SI 024/12MHz/A.
SC 021: Carrier printed circuit board of E-HSI submodules. No Baud rate setting in
the hardware necessary. Can take up up to two submodules, also different
ones.
SI232: Submodule. V24. 9-pole DSUB bush
SI020: Submodule. 20mA-Current Loop. 9-pole DSUB bush
By means of jumpers (bridges) the loop type is set:
Transmitter active / passive
Receiver active / passive
Standard setting: Transmitter active, receiver passive.
SI485/422: Submodule for hardware ground for bitbus, central com-
puter, SPI.
SI 024/ Module for Euromap standard (Euromap 15), is based on bitbus. Use at cen-
12Mhz/A tral computer.
At present the following additional interface records exist:

Plastic ser- -Hot runner controller Lauda -Screw temperature
vice:ETR51 control
Ewikon -Temperature control Intron -Hot runner controller
devices
HB - Therm -Temperature control Syslvac -Sliding caliper
devices
Boe - Therm -Temperature control Regloplas -Temperature control
devices devices

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At present the following additional interface records exist:

GWK -Temperature control Tooltemp -Temperature control
devices devices
Single -Temperature control Conair -Temperature control +
devices cooling devices (SPI)
Piovan -Temperature control Reps -Mould cooling system
devices
Sartorius -Scales Wittmann -Flow rate controller,
Mettler -Scales Temperature control
devices
For DOS computers there are connection possibilities for EMS (ENGEL MONITORING
SYSTEM = central computer) and different process data collection and setter programs.
3.10.3 SI232
Asynchronous serial interface RS232-C. Is inserted on SC 021.
Possible up to 38400 Baud, in the software adjustable on mother printed board assembly. No
physical separation. In and outputs protected against interference voltages. Operating
temperature 0 - 70 degrees centigrade.
Connection organ: 9--pole socket board DSUB

Occupation IBM PC standard
RS232 Signal designation PIN No. In/output

RXD Receive Data 2 exit
TXD Transmit Data 3 Input
DTR Data Terminal Ready 4 Input
SGND Signal ground 5 -
DSR Data Set Ready 6 exit
RTS Request To Send 7 Input
CTS Clear To Send 8 exit
NC not occupied 1, 9 -

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3.10.4 SI020
Connection organ: 9--pole DSUB pin bar
active
passive
Transmit- Receiver
ter
The pins e and f serve as park position for the plug-in bridge. By them no connection is made.
Asynchronous serial current loop interface 20mA,TTY. Is plugged on the master printed circuit
board SC 021.
Possible up to 9600 Baud, set in the software.
Via plug-in bridges and/or soldering bridges transmitter and receiver can be switched on
active/passive separately.
Physical separation via optocoupler.
Loop current at ”0” 1mA, at ”1” 20mA (+/- 10%)
Loop voltage 17V at ”active”
Loop voltage max. 55V at receiver ”passive”
Voltage drop per receiver <= 2V, per transmitter <= 2V.
20mA CL Signal designation PIN No. In/output

TX+ Transmitter 1 Source (active and pas-
sive)
TX- Transmitter 6 Depression (active and
passive)
RX- Receiver 2 Source (active and pas-
sive)
RX+ Receiver 7 Depression (active and
passive)
To the current loop:
When several external devices are switched in loop, it must be noted that the current capacity
above all in the two-wire operation can already be exhausted with 2 interconnected devices,
i.e. a special power-supply unit must be switched into the loop for supply.

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On the basis of the following test circuit the communication capability of the interface
”with itself” can be watched in the serial I/O debugger.
3.10.5 SI 024 - OCCUPATION PLAN

The interface module SI 024/12MHz/A is provided for the settlement of the EUROMAP 15
record.
J1 J2 J3
: as no end device:
SI024
Switch occupation on 1 not occupied

9--pole socket board Submin-D (Cannon) 6 not occupied
2 GND
7 GND
3 DATA
8 DATA
4 DCLK/RTS
9 DCLK/RTS
5 GND_EXT.
Connect screen directly with protector ground (e.g.: Cable-duct clip), otherwise via plug housing.
GND_EXT. (data GND) is separated of GND physically.
3.10.6 SI 485 / RS422

The SI485/422 subprinted board assembly is employed for special applications (e.g. SPI
interface for temperature control units). By means of plug-in bridge RS485 and/or RS422 is
selected. The Baud rate is given in the software

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Connectioin occupation:
RS422-A RS485
9--pole DSUB bush
Configuration RS485 or RS422:
Line terminal
YES NO

A Transmit + 9 exit
A’ Reception + 8 Input
B Transmit - 4 exit
B’ Reception - 3 Input
GND EXT. Signal ground 5 -
A / A’ Transmit / receive - 8 In or output
B / B’ Transmit / reception - 3 In or output
CNTR-A Data flow control for repeater 4 exit
GND EXT. Signal ground 5 -
Line terminal:
If the module is at one end of the line (and only then), the plug-in bridge J1 must be set to a-c.
Thus the line is terminated with the terminal resistance (=characteristic impedance).
Otherwise the plug-in bridge remains in park position c-e.

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3.11 PUMP ACTUATION

BOSCH amplifier slide-in module for radial piston pumps with electrohydraulic
adjustment

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3.11.1 BOSCH AMPLIFIER CARD FOR MACHINES WITH TILTING ANGLE

HYDRAULIC SYSTEM
Typ: 0811 405 110
These amplifier cards are built into all machines, which are equipped with an
electrohydraulically adjustable radial piston pump (EHV).
Thus the standard proportional valves for pressure (K valve) and volume (Y valve) are omitted.
On the part of the control system the actuation in this connection remains the same. The
analog signals of the control system for pressure and volume are converted on this control
card so that the variable displacement pump is actuated and/or closed loop controlled
correctly.The card primarily controls the volume throughput, to this control circuit the pressure
control circuit being superimposed. On reaching the given pressure it is switched over to
closed loop pressure control.
A further advantage on machines with this hydraulic system is the omission of the pressure
calibration. This curve is always initialized on a straight line. The setting of the maximum
system pressure occurs on the control card. For a linear connection of actuation and actual
output in this case the control card is responsible. Only the back pressure must be calibrated
as usual because for this a separate pressure proportional valve is built in.
In these machines the existing hydraulic pressure on the pump is led on the analog card via a
separate hydraulic pressure transducer and is displayed on the Quick Setup image.
For the volume calibration (speed) there is also only one straight line. Here a rotatable
calibration curve is implemented, however so that minimum and maximum can be changed as
here e.g. an actuation of at least +5V is required in order that the pump is defelected in positive
direction. The calibration curve for the screw speed must be calibrated as usual.
The supply voltage of this card is +24V like at other valve amplifier cards. The red light emitting
diode ”UB” signals a too small supply voltage (<21V). A release of the card is reached by
setting pin Z16 on 24 V. The release on the front plate is displayed with the green light emitting
diode ”ON”.
The magnet on the valve for adjusting the stroke ring in the pump is actuated by a clocked
current controller. Depending on the valve type the card outputs max. 2.7 A (NG 6) or max. 3.7
A (NG10). Further, all outputs on this card are short circuit stable.
The piston position of the valve and the position of the stroke ring in the pump are measured
by inductive stroke transducers for the closed loop position control. These are also monitored
for cable break, which is displayed on the front plate with the yellow light emitting diode
”LVDT”.
The card is equipped with a control for oil quantity and with a control circuit for a closed loop
pressure control. The latter is superimposed to the volume control and only gets effective
when the pressure has reached the given set value. This state is displayed with the yellow LED
”ON” on the front plate. The pressure control circuit can also be deactivated via DIP switch on
the card. A deactivated pressure controller is signalled by the yellow light emitting diode
”CONTROLLER OFF”.
The individual controller shares of the PID pressure controller can be adjusted on the card with
DIP switches (rough adjustment) and on the front plate with HEX rotary switches (fine setting).
A tuning of the pressure sensor to the card occurs via potentiometer. Also the pump zero point
and the maximum volume can be set with potentiometers on the front panel. The pump zero
point can be tuned between -2V and +2V.
Further, the card is equipped with a leakage oil compensation, which can be adjusted via a
potentiometer directly on the card (increasing pressure leads to a decrease of the real volume
throughput (efficiency) of the pump).
Aim of the leakage oil compensation: Approximately the same volume throughput with
different pressures

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3.11.2 OPERATIONAL SETUP GUIDELINES
A: Settings before the motor start:

1. Presetting of the control card according to setting record of the respective machine
type: DIL 0 up to DIL 16 directly on the amplifier card; KP, KI and KD on the front
plate
2. Turn potentiometer for leakage current compensation (directly on the card) to the
left (CCW) on stop = LEAKAGE CURRENT COMPENSATION OFF
3. Control voltage off! Insert card
4. Control voltage on!
The speed closed loop control (via pump and/or via servovalve) must be switched
off:
Switch off pump closed loop control: On screen page ’Injection - control parameters’
set the switch ’Injection speed’ to NO.
Switch off servovalve closed loop control: Switch the servovalve on the injection unit
inactive (to max. throughput): In the machine setup set ”Machine type = 0 =
prop.valve closed loop controlled”.
After finishing the putting into operation of the Bosch card the concerned closed
loop control (if it has been switched on before) must be activated again!
Initialize linearization characteristic line for pressure (diagonal line between 0 and
+10 V
Initialize linearization characteristic line for speed:
For individual pumps: 0 up to +10V (Straight line)
For EHV + fixed displacement 100 + 32 K: Straight line between -3.2V and
pump: +10V
100 + 45 K Straight line between -4.5V and
+10V
100 + 63 K: Straight line between -6.3V and
+10V
Set parameter for flushing volume to 50 %
Set parameter for flushing pressure to 15 bar
Set parameters for idling volume to 10%
Set parameter for idling pressure to approx. 20 bar
B: Settings after the motor start:

5. Switch on motor, control direction of rotation
6. Control and/or set pressure relief valve (when set fixed). At the setting of the
presure relief valve set DIL 4 to ”OFF” (pressure controller off - LED ”Controller off”
lights). Afterwards set DIL 4 to ”ON” again (pressure controller switched on - LED
”Controller off” goes out), set injection to approx. 50 % speed, switch over as a func-
tion of time (in order that P6 becomes active) and set the program switch ’Stop
injection at pressure limit’ to NO.
7. Tuning Pmin (pressure sensor)
Set P6 to 10bar, activate injection, move on mechanical stop and control the display
Phx. Align with potentiometer ”P zero”.
8. Coordination Pmax (pressure sensor) :
Set P6 to maximum, activate injection, move on mech. stop and control the display
Phx. With potentiometer ”P” (P Gain) set the actual value (on the screen) so that
exactly the pressure is displayed which is preset on Pmax
Afterwards set P6 to 10 bar and adjust the display on the screen to 10 bar with the
potentiometer ”Pzero”. Possibly control the setting of Pmax once again
9. Volume setting:
10 % Set injection speed on all profile stages. Press injection and set with potenti-
ometer ”Valve” (= adjustment 0 point) up to 10mm/s actual value.
90% Set injection speed on all profile stages. Attention to reduction factors. Press
injection and align with poti ”Q-Max”.
10. Leakage current compensation:

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With proportional valve clamping unit:

a: Displace linearization straight line for proportional valve clamping unit until
at 10 % opening speed (all 3 profile stages) 20 bar are displayed on the
manometer. The reached speed must be noted.
b: Displace linearization straight line for proportional valve clamping unit until
50 bar are displayed on the manometer. Afterwards trim the potentiometer
for the leakage oil compensation on the card so that the speed reached
before is reached again.
Readjust the calibration curve again!
C: Activate cable break monitoring for pressure transducer PH1 and/or PH4:
11. Set DIL3 switch = ON. Pressure transducer must be supplied by BOSCH pump card
with +/-15V (standard from approx. April/97, see electric plan).
Check: Pull off transducer cable (plug) from PH1 ---> on BOSCH card 2 yellow Leds
flash, on the control unit the errors 2428 and/or 2431 ”Pressure transducer Phx
def.” and 2457 and/or 2458 ”VT card x defective” arise”.
With this adjustment one reaches that with different pressures always approximately the same
speed is run.
Attention!
When in the wake of the above described putting into operation the
pump or servovalve closed loop control is switched off or program
switches have been converted, the basic settings must be made again
after completing the putting into operation.
3.11.3 GENERAL
Example setting record of an ES 650/125 machine:

Pump: RKP - 80
P-max: 210 bar
DIL 0 = OFF Kp = 3
DIL 1 = OFF Ki = 4
DIL 2 = OFF Kd = 8
DIL 3 = ON ---------------------> Cable break monitoring. Condition: Power supply of the
pressure transducer from the BOSCH pump card (see
electric plan)
DIL 4 = ON
DIL 5 = OFF
DIL 6 = OFF
DIL 7 = OFF
DIL 8 = OFF
DIL 9 = OFF
DIL10= OFF
DIL11= OFF
DIL12= OFF
DIL13= OFF
DIL14= OFF
DIL15= OFF
DIL16= ON
For putting into operation and setting this card a mobile external card mounting is necessary!

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MEMO PAGE FOR PUMP CONTROL CARDS SETTINGS
The values and switch positions set on the card can be recorded on a screen page. Basic
values are preset ex works. The page can be opened with user level 2 (22222222). For
changes on it user level 3 is necessary.
Image selection key . + F4 + F7
E H V - C O N T R O L C A R D 1999-01-15 14:20
DIPSWITCHES CONTROL PARAMETERS

DIL 0 16 Kp Ki Kd
PUMP1 UNIT 1 0001100000000001 0 0 0
PUMP1 UNIT 2 0001100000000001 0 0 0
THE SETTINGS OF THIS PAGE ONLY HAVE A MEMORY FUNCTION AND DO NOT INFLUENCE THE
EHV-CONTROL CARD(S) DIRECTLY
PROG. INTERRUPTION 1 M
SETUP VALVE- INPUT- TEST and DATE and EHV e t c

PROGRAM LINEAR. CALIBRIER. PARAMETER TIME CONTROL CARD --->
As memo for the settings, which have been made on the pump control card(s), this screen
page can be used. Basic values are already entered ex works.
For the switch positions of the DIP switches 0 and/or 1 can be entered. The poti positions can
be read off on the card and can be entered under the values Kp, Ki and Kd.
The inputs have only note character and have no impact on the electronics.
3.12 MAGNETIC CARD READER

Magnetic card readers for machine control units are optionally built in as replacement of the
usual key-operated switch. On a control unit either a magnetic card reader or a key-operated
switch can be mounted.
The magnetic cards contain as information the access authorization ( 1 - 10 ) and a max. 8-
digit user code, e.g. the personnel number (for recording parameter changes in the
malfunction message record).
Regarding use see ’Operator’s manual’ Magnetic card reader.
Instead of the key-operated switch the magnetic card reader MR122 is connected to the
connection S5 of the printed board assembly OC101.
See item ’Control consoles’

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In standard six magnetic cards are supplied. The user identification and the appertaining
access authorization must be announced by the customer. If the customer does without
a proposal, the cards are programmed as follows:
Card No. 1 2 3 4 5 6
Access level 8 8 6 6 4 4
User code 001 002 003 004 005 006 (Personnel number)
The magnetic cards correspond to the standard ISO 3554-1976 (credit cards - magnetic stripe
encoding for tracks 1 and 2). Thus each customer is in a position to obtain corresponding
magnetic cards independently of ENGEL if the cards correspond to the mentioned standard.
When the customer has a suitable magnetic card programming device, he can program his
cards also automatically.
Each magnetic card has several reading tracks. ENGEL uses for its application track 2. If a
customer wishes the use of his possibly existing magnetic cards for operating the ENGEL
control units, this is possible when:
- its cards correspond to ISO 3554

- Track 2 is still free.
The read-in of not-ENGEL format-conforming data of (existing) magnetic cards is not possible.
If the customer takes over the programming of his magnetic cards himself, this must
occur on track 2 according to the following format:
Character No. 1 2 3 4 5 6 7 8 9 1 1 1 1 1 1 1
0 1 2 3 4 5 6
Data B 0 0 x x x x x x x x x x x 0 F
Meaning
Format identification
Access time in1/2h

Personnel number
Password level
Start character
End character
Reserve
Fixed value * * * *
variable * * * * * * * * * * * *

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Version:G/11/12/7/3
PUTTING INTO OPERATION (2)
1 POWER SUPPLY
By switching on the control voltage the power supply transformer lies on operating voltage.
Secondarily, after rectification the transformer supplies:
+24VK: Power voltage for magnets and solenoids. Designation after the automatic cut-
outs and watchdog relay contact on the control unit 24VK. From this voltage via
a separate automatic cut-out +24VE are branched off for the limit switches and
digital inputs, and +24VKN (voltage which is not switched off in case of an
emergency-off situation.
+24VL: Logic voltage for the supply of the computer. Designation after the automatic
cut-outs on the control unit: +24VC.
-24VH. Not used
This wiring plan of the control voltage transfo is in the electric plan (in the control unit control
cabinet) on sheet 3.1 and/or enclosure 0,6 place +A, sheet.1.
2 SWITCHING-ON OF THE CONTROL VOLTAGE
2.1 SWITCHING-ON WITHOUT LOADED EBIAS SEQUENCE PROGRAM

For first switching-on WITHOUT loaded EBIAS sequence program, e.g. after CPU exchange,
battery exchange or first putting into operation see chapter ’Hardware’, item ”MAIN
PROCESSOR”
2.2 SWITCHING-ON WITH LOADED EBIAS SEQUENCE PROGRAM

On the power pack card PS244 3 green Leds light for internal computer voltages:
from above to below: +5V, 1 common Led for +/-15V and +/-12V, input voltage +24V.
The watchdog relay energizes and switches the voltages for magnets and limit switches on
(24VK1, 24VKN, +24VE).
When applying the +24VE, on the input card DI325/B green Leds light, which display the
actuation of individual limit switches and/or relay contacts.
On the main processor card CU211 and/or CU212 of the analog cards AR281 and/or AR101
and of the temperature card TT081 (TT081/5) green Leds flash as ready message.
The computer carries out a data test, a C-RAM test and afterwards the hardware test. The
HARDWARE CHECK consists of testing all digital and analog input and output channels. The
result of this test can be seen on the ”Hardware check image”.
Creation date: 20.02.2002 Putting into operation (2)

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During these tests, which can last up to 25 seconds, the screen shows:
2 0 0 0 - 1 1 - 0 2 1 5 : 4 1
SYS-V 2.11 Y2K-tested IP 128.46.66.4
M
PROG. INTERRUPTION 1
After the switching-on and positive check the machine is in MANUAL MODE. All control keys are active.
In standard execution of the control system and card equipment the following digital
outputs are connected through:
H........ man. operation
DA...... when pos. A is reached
DL...... when pos. L is reached
DL1.... when pos. L1 is reached
M1 ..... Hydraulic pump motor can be switched on
HZA ... Heatings can be switched on
FS ...... flashes when alarm exists
2.3 WATCHDOG
The total system and sequence program is tested permanently by a ”safety program”. This
safety function is carried out every 40ms by a separate program part and reacts in case of fatal
errors, the watchdog relay de-energizing. When switching on the control voltage and when the
computer runs up to speed, this relay energizes and switches on the solenoid and limit switch
supply voltage (24VK1, +24VE). By de-energizing the ”watchdog” thus all machine
movements are interrupted in the hardware.
Wiring of the watchdog relay see chapter ”HARDWARE”, item ”MAIN PROCESSOR”.
3 HARDWARE CHECK
With switching on the control voltage the machine control unit lies on the supply voltage and
carries out a test.
At this test are:
System and EBIAS errors (sequence errors) are displayed if such have arisen before
the last switching-off.
Putting into operation (2) Creation date: 20.02.2002

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the check sum is formed via the stored data and programs and compared with the also
stored old check sums. In case of non-correspondance - message.
the software and hardware configurations are displayed.
the hardware test itself is carried out and possible errors are displayed.
3.1 SYSTEM AND EBIAS ERRORS

System errors (sys errors) and Ebias errors are treated separated from the machine sequence
errors. By their appearance they produce a stop of the sequence program and produce a
figure code, which is stored in the C-Ram, instead of an error text.
System errors appear in the middle of the screen in yellow writing on red field.
EBIAS-ERRORs appear in the error display line black on red.
At all syserrors the control voltage must be switched off and on again in order to start the
computer and sequence functions again. Also after the switching-on one can read off the
number code on the screen and state the kind of error via below listing.
Ebias errors stop the sequence program, reset all analog and digital outputs, FS is set, one
can examine the reason in the debugger mode after the appearance of such an error.
The listing of these and of the whole sequence errors can be found in the chapter ”ERROR
MESSAGES”.
3.2 CHECK SUM TEST

When switching on the control unit the check sums are formed via the stored data and
programs and are compared with the also stored old check sums. When they are identical, the
sequence program is set in the mode ’Manual mode’.
A built-in bit error recognition (ECC program) is in a position, after a check sum error, which
has arisen by only a ’fallen-down’ bit, to recognize this individual bit and to adjust it again. If
several bits fall or ECC cannot correct, a syserror and entry in the malfunction message record
arises.

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e.g.: CC100 start image

2 0 0 0 - 1 1 - 0 2 1 5 : 4 1
SYS-V 2.11 Y2K-tested IP 128.46.66.4
M
If the data check sums are not identical and the ECC correction is without success, the CPU
carries out a data reset.
If the sequence program check sum is not identical and the ECC correction is without success,
the sequence program is deleted, a RAM test is carried out and the request for reading in a
sequence program is made. After reading in a data reset is released.
With not successful RAM test the SYS ERROR appears 0/39.
In this case RAM modules seem to be defective, ---> CPU exchange, see item 3.3.4.

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In case of successful memory test:

E B I A S - L O A D E R V 1 . 2 2000-11-02 10 32
Loading code
*)
... searching for host
EC/CC100 IP ADDRESS 128.46.66.4

EC/CC100 ROUTER ID ADDRESS 128.46.66.14
EC/CC100 SUBNETMASK 255.255.0.0
RC100 IP ADRRESS KBE 192.168.0.12
( C ) K E B A 1 9 8 8 - 1 9 9 7
M
PROG. INTERRUPTION
FLOPPY WRITE ACTIVATE
EBIAS NET-CONFIG
Here the control unit demands the read-in of the EBIAS sequence program.
*) The loading code announces the reason of the new loading requirement:
0... EBIAS call-up interface faulty

1... Loading key pressed
2... Checksum OK - not correctable ECC error
3... Checksum faulty - not correctable ECC error
4... Check sum faulty - ECC error correction OK - check sum faulty
3.3 READ-IN OF THE EBIAS SEQUENCE PROGRAM

After the exchange of the CPU, of the battery on the CPU or at the first putting into operation
after occurred RAM test the control unit asks for the read-in of the EBIAS sequence program,
which is supplied on the machine diskette in the file ”EBIAS32.BIN”.
The above image appears.
---> Insertion of the machine diskette in the disk drive and confirm with F1 ’FLOPPY’.
At the beginning of the read-in (file EBIAS32.BIN) appears on the screen:
load EBIAS
0% 100%
Machine parameters diskette
CC100 INFO message #30598 (e.g.)
INFO message is: e.g. short sign of the programmer and creation date
#30598: is the serial number (=machine number).
A running-along graphic bar displays the progress of the reading-in process. 100% = finished.

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After the read-in also the sequence program for the analog card(s) must be read in (file:
ARST_1.E).
The file ’’LICENSE.BIN’’ is also read in automatically in order to activate various optional
programs (from SV2.10).
At read-in problems different messages appear, after which the control unit begins with
the RAM test again:
...testing RAM ... K
possible disk error messages:

Diskette not in drive Diskette must be inserted properly
Diskette type not known a machine diskette with EBIAS sequence program existing on it must be
inserted
DEVICE ERROR >B1< appears after 10s silence. The diskette drive cannot be addressed by the
computer. Check cable, connection.
DEVICE ERROR >51< appears after 10s deathlike silence. The correct channel (function key) must
be chosen.
Machine number does not match The diskette contains a sequence program of another machine (serial num-
ber test). The program is read in nevertheless. After finishing the reading
process one of the system errors is produced:
SYS 0/196 The program can be preserved for test purposes. After switching the control
voltage off and on again the machine stands in normal operation
or SYS 0/197 The program must not be preserved. Is thus erased. After switching the con-
trol voltage off and on again the control unit asks for the read-in of the EBIAS
program automatically (after RAM test).
MACHINE NUMBER UNEQUAL appears at beginning read-in when the inserted diskette does not match the
control system. The program (EBIAS.BIN) is read nevertheless, it can be
preserved for test purposes (see above ’SYS 0/196’).
3.3.1 RELOADING AN EBIAS SEQUENCE PROGRAM

When a new sequence program shall be loaded into the control unit, one uses the following
procedure:
Switch off control voltage
Insert machine diskette into drive
actuate black program loading key on CU211 and keep it pressed
Switch on the control voltage
keep black key pressed until green LED on CU211 flashes
----> it starts the RAM test, the original program is erased,
afterwards the sequence follows like in item READ IN THE EBIAS SEQUENCE
PROGRAM
If when switching on the control voltage with pressed black key not the ”charging image”, but
a SYSTEM ERROR appears, a RESET on power pack card PS244 with switched-on control
voltage is required. Afterwards switch off control voltage once again and switch it on again with
pressed black key.

Version:G/11/12/7/3
3.3.2 AFTER THE READ-IN
After the read-in of the sequence program all parameters are set on init values. --->
RESET.
Now must also be read in:
Internal values (PARAM.BIN, machine disk)
CALIBRATIONS (KALIB.BIN, machine disk)
LINEARIZATIONS (LINTAB.BIN, machine disk)
SET VALUES (PARAM.BIN, etc., mould disk)
--> In order to reach complete initialization, the control voltage should be switched off and on
again after the read-in of parameters of the machine diskette and of calibrations.
In the case of an analog card exchange the sequence program for the analog card(s) must
also be read in.
3.3.3 ANALOG CARDS - SEQUENCE PROGRAM

The sequence program for the analog card(s) is also on the machine diskette. File: ARST_1.E
for card 1, ARST_2.E for card 2, etc. It must be read in when putting the machine into
operation after analog card exchange or for a version change. Not necessarily after charging
an EBIAS program newly.
The process corresponds exactly to the read-in of a parts data set by means of diskette dialog,
see operator’s manual, chapter 2, ’Memory devices and text input’.
After the read-in an automatic warm start occurs (= internal new acceleration, similarly to
control voltage off/on).
In case of read-in problems:

An ARST program can only be transmitted to a ’current’ analog card, i.e. the green Led on the
card front flashes. If this is not the case - the red or even no Led lights - the ARST program on
the card must be switched ’disabled/blind’ or be erased.
Disable ............... Set P35487 = 0

Read in ARST_x.E
Set P35487 = 1
Erasing .............. Control voltage off
Pull card
Set coding switch to ’F’
Insert card
Switch on control voltage, reset occurs
Control voltage off
Set coding switch to original value again
Control voltage on
Read in ARST_x.E
3.3.4 IN THE CASE OF A CPU EXCHANGE

Procedure:
Protect machine data and parts data on diskette
When on the RAM memory of the CPU there are important data, also protect these on
diskette(s)
Switch off control voltage
Pull CPU card from the rack.

Version:G/11/12/7/3
Bring battery jumper of the new CPU on position ’on’. See chapter (1), item 3.3.
Insert the machine-appertaining Eproms from the removed on the new CPU.
Insert new CPU into the rack, connect 4-pole watchdog terminal
Switch on control voltage and wait until ’EBIAS LOADER’ appears on the screen.
Press function key 1 ’Floppy’
After loading process read in machine parameters
Input screw diameter
Switch off control voltage, wait for 5 seconds, switch on control voltage again
Input date and time CORRECTLY
Read in parts data
3.4 HARDWARE CHECK IMAGE

Example of a test image, call-in with + F3
HARDWARE TEST 1999-02-15 13:09

HW configuration
CU212 #1 486DX-25Mhz
FC352/OC101
GC201
DI325 #0
DI325 #1
DO321 #0
DO321 #1
AR281 #4
TT081 #0
TT081 #1
M
MOTOR STOP 4
HW-Config HW-Test HW-Info SW-Version -SYS-Info
The hardware test image is always updated after switching on the control voltage and can be
called up with the error image selection key and function key F3.
F1 ... HW configuration displays the existing modules in the racks, which can be rec-
ognized on the Kemro bus. #Number displays the coding
according to card coding list.
F2 ... HW-Test displays open and/or short-circuited digital outputs
F3 ... HW-Info displays the existing modules with statement about serial
numbers revisions.
F4 ... SW-Version displays the software versions of the individual components.
Under ÇSpecial Software’ the customer-specific sample
number is entered.
F5 ... System info displays serial number, control system type, machine size,
machine type, drives with capacity indications and interfaces

Version:G/11/12/7/3
4 SWITCH ON MOTOR
Only after the hardware check of the control unit is finished, the pump motor(s) can be
switched on. Digital output M1 is active and condition for starting the motor. Movements in the
manual mode can only be carried out when the motor runs on delta (digital input TD active).
When a manual control key is actuated without waiting for the delta run of the motor, the motor
switching-off relay - digital output M1 - de-energizes and stops the motor, error message 184,
’PUSH-BUTTON ACTIVE’.
Also, when the digital input TD is not active, the switchover to automatic program is locked.
After the start-up circuit of the motor has switched over from star to delta, a fixed output of
pressure (P35035) and volume (P35109) occurs, which has an impact of lowest priority if no
other value setting goes to the valves. With switching over to delta also the flushing program
begins or, if the oil temperature is too low, the oil preheating program. The sequence of the
motor start sequence at machines with by-pass filtering is described in the item ”BY-PASS
FILTERING”.
5 FLUSHING PROGRAM
At flushing the volume proportional valve Y1 is set to a machine size-dependent flow rate in
order to offer the pump plant better cooling by larger oil circulation. When a machine
movement occurs in manual or automatic mode, the flushing program stops. After finishing all
movements a fixed time (P35252 = typ. 2 sec) starts to run, after whose expiry the idling
solenoid S10 de-energizes. (S10 not at HLS1).
After the expiry of a delay time (P35253= typ. 1 sec) the flushing process starts again.
A table in chapter ”MOVEMENT SEQUENCE/MACHINE FUNCTIONS”, item ”FLUSHING, OIL
PREHEATING, MOULD PROTECTION, SET-UP” describes the volume outputs and solenoid
sequences for the individual machine sizes. In the manual mode the flushing volume is set to
idling outputs before introducting a movement as well as in the 1st automatic cycle before
mould closing beginning during a time P10770 in order that start-up without jerks is enabled.
6 OILPREHEATING
If the oil temperature (with running motor, digital input TD = active) falls under the minimum
temperature, an OIL HEATING PROGRAM starts automatically, the pressure and volume
output of the computer going on corresponding machine size- dependent values. A table in
chapter ”MOVEMENT SEQUENCE/MACHINE FUNCTIONS”, item ”FLUSHING, OIL
PREHEATING, MOULD PROTECTION, SET-UP” describes the volume outputs and solenoid
sequences for the indiviudal machine sizes.
The switchover from manual to automatic mode is prevented, but machine movements can be
run normally in the manual program. Before each movement the delay time P35278 is started
while pressure and speed are switched to zero.
Oil temperature monitoring:
Screen page ’Heatings 1-7’:

Set: Act:
Oil temp.: 40,0 °C 38,6 °C
Minimum temperature 30,0 °C
Maximum temperature 50,0 °C
More details about oil temperature control in the operator’s manual, chapter”.

Version:G/11/12/7/3
7 BY-PASS FILTERING
Filtration and cooling of the hydraulic oil occur in this case not in the main stream, but in a
separate circuit with separate pump. With switched-on program (P35490 = 1) the filtration with
running pump motor is always active, but can also be started manually.
Electric components:
Drive motor (induction current motor)
Message contact for ”Partial flow motor is running”, DINF (DI22)
Pressure switch for ”Oil filter soiled”, DIF2 (DI13)
Main pump motor start instruction DOMSI (DO14)
Motor start release and/or switching-off DOM1 (DO24)
Message contact for position of the manual throttle valve between oil tank and pump.
+24V with open Flap on digital input DIF1 (DI12).
In order to be able to carry out work on the pump plant, a tank shut-off flap must be
closed against oil slick. At the putting into operation of the pump this flap must be
opened again, however. DIF1 (DI12) checks this: --> error message 152, ”TANK SHUT-
OFF FLAPS”. See section below: ’Oil monitoring’.
MOTOR START SEQUENCE

Normal operation: With the motor start key the partial flow motor starts to run if the safety gate
is closed and all start criteria are fulfilled (output DO24 must be active). When the message
comes from digital input DINF (DI13) ”Oil filtration active”, i.e. the partial flow motor is running,
the output DOMSI (DO14) for 0.5s is set. By this impulse the main motor is started. If the safety
gate should be opened again before the input DITD (DI19, motor runs on delta) is activated,
the output DOM1 (DO24) is reset, through which all pump motors are switched off again, i.e.
the safety gate must remain closed during the motor start procedure.
Motor start via week switch clock: With DOMSI both motors are switched on immediately in
succession.
OILFILTRATION
On the heating image 1 the oil temperature text group is supplemented by the following line:
ONLY OIL FILTRAT. <ON/OFF> AKTIV:
The program switch ”Only oil filtration” can be switched on manually and/or switches in
readiness automatically when the oil level gets too low (error message 40 ”OIL LEVEL LOW”).
The following sequence results:
Stop all motors by resetting digital output DOM1.
Refill oil, digital input DIOEN must go on +24V (Led)
Actuate PU key, thus activate output DOM1 for motor start
Switch on partial flow motor with motor start key
Dependent on the oil temperature the oil cooling switches on (zone 0 of the first
temperature card)
Main motor does not start, it appears the message 161, ”OIL FILTRATION ACTIVE”
Oil is now cleaned via the bypass filtering (let it run time-dependent on the filled-in oil
quantity)
Operator switches the program switch ’ONLY OIL FILTRATION’ on the heating screen
page off --> partial flow motor stops (DOM1 de-energizes)
Actuate PU key for acknowledging the errors and/or setting of DOM1.

Version:G/11/12/7/3
Switch on all motors with motor start key
7.1 OIL MONITORING

The digital inputs DIF1, DIF2 and DIOEN monitor oil filter and oil level. The inputs are
devibrated with times adjustable between 0.00 and 10.00sec.
As the oil filter inputs are used differently depending on hydraulic type, it can be selected via a
parameter per input which error message shall be set at the reaction of the monitoring.
Parame- Function preoccupied

ters
P17983 Devibration time filter input DIF1 0,5s
P17983 Devibration time filter input DIF2 0,5s
P17984 Devibration time oil level DIOEN 0,5s
P17978 Selection error message DIF1, unit 1 Tank throttle valves
P17979 Selection error message DIF2, unit 1 Check oil filter
P17985 Selection error message DIF1, unit 2 Check oil filter
P17986 Selection error message DIF2, unit 2 High-pressure filter
Range of values P17978 up to P17986

0= Monitoring deactivated
1= Tank throttle valves
2= Check oil filter
3= High-pressure filter
4= Return filter
5= No oil filtration
>5 Monitoring deactivated
As consequential action at the reaction of an oil filter alarm is fixed:
The error ’Tank throttle valves’ initiates immediate switchover to manual mode and
motor stop.
All other oil filter errors lock the start of a new automatic cycle and switch off the motor
delayed.
During oil preheating the oil filter monitorings are suppressed. Release of the monitorings
starting from reaching the operating temperature (set set value).
The monitoring of the tank throttle valve is independent of the oil temperature.
8 TIME AND DATE

In the right upper corner of the screen the display of the time and of the date in the format year
- month - day hours : minutes runs.
As readiness for operation display of the CPU the double point flashes. The display is set at
the putting into operation of the machine at the works and continues to run battery-buffered in
the switched-off state of the plant.
Also after a data reset the current time display is not lost.

Version:G/11/12/7/3
8.1 SETTING OF TIME AND DATE
This setting is protected against unintended adjustment via key-operated switch and
password and/or with magnetic card:
Image selection key ’MENU’ + Press function key F5 ’ACCESS AUTHORIZATION’.
It appears the menu with the user names and access levels. For the clock setting at least level
6 is necessary. The password for it must be input and/or the corresponding magnetic card
must be inserted.
After occured input the image selection key ’MENÜ’ is actuated once again. It exists now the
access to the ’SERVICE MENU’ with function key F4. In the row of functions keys of the
service menu it can now be called up with F4 ’TIME AND DATE’.
It appears:
Year Mon. day Std. min. Sec.
1. 2000 - 01 - 20 10 : 00 : 00
2. 2000 - 01 - 20 10 : 00 : 00
3. *) 2000 - 01 - 20 10 : 00 : 00
*)... Shadow date: Reference for program licensing (see operator’s manual)
The cursor stands over the year and can be moved with the arrow keys to the different input
fields of the lower date/time line. Begin now with the input:
e.g. 2000 - 02 - 02 13 : 25
Each input is concluded with ’ENTER’ from the input keys field, after which the cursor jumps
on the next values field. After complete input with the function key F1 ’ENTER’ the whole date
field is transmitted into the upper line and thus into the computer.
Exit with optional image selection key.
9 SERVICE MODE
With ’Service mode’ (service menu) we designate input levels which are distinguished in their
valency from the mould parameter level (set values) by a keyword identification (password) or
magnetic card code. The service mode levels are separated among each other again by
different passwords or codes.
See also ’Operator’s manual’, chapter ”COMPONENTS AND CONTROL”, item ’ACCESS
AUTHORIZATION’.
The current level and the authorized personnel number are displayed in the uppermost
screen line at the left beside date and time:
7-5 1995-11-12 12:53
In order to reach the first service mode level, key-operated switch position ’PR’ and a
password input and/or a magnetic card with corresponding authorization is necessary.

Version:G/11/12/7/3
Key- Authorization Access Person- User Lan- Values

oper- level nel num- guage unit
ated ber.
switch/
pass-
word
OFF Choose pages 0

1
ON Set value input 2

3
PR Diskette reading/ 4
writing 5
11111111 Debugger, date/ 6 1 USER ger metri-

time, system 7 1 cally
setup
22222222 Calibrations, lin- 8 2 USER ger metri-

earizations, con- 9 2 cally
trol parameters
injection unit
Inquiry Machine size 10 3 USER ger metri-
data, critical val- 3 cally
ues
9.1 PURPOSE
The service mode is above all meant for service technicians who need accesses to machine
settings at the customer which the owner of the machine should not change if possible.
Further, also the safety against unintended change of values shall be guaranteed.
9.2 ENTRY
At first create the authorization for the entrance:
Set key-operated switch to ’PR’, press image selection key ’Main menu’ + F5 ’Access
authorization’.
Select the user name (operator name) with cursor and input password
(By the input of 11111111 +ENTER one gets into the first level of the service mode)
After occurred password input authorization level and personnel number appear in the
uppermost screen line.

Version:G/11/12/7/3
Now the authorization is given and the service menu can be called up with image
selection key ’Main menu’ and F4:
S E R V I C E M E N U 6 - 1 1999-02-15 13 15
1 . . . S E T U P P R O G R A M S
2 . . . V A L V E L I N E A R I Z A T I O N
3 . . . I N P U T C A L I B R A T I O N 1
4 . . . T E S T a n d P A R A M E T E R S
5 . . . D A T E a n d T I M E
M
SETUP VALVE- INPUT- TEST and DATE and LICENSE- EHV
PROGRAM LINEAR. CALIBRIER. PARAMETER TIME SURVEY CONTROL CARD
See chapter See chapter ”CALI- See chapter See chapter See operator’s See chapter
”PUTTING INTO BRATION AND LIN- ”TEST and ”PUTTING INTO manual, chapter ’HARDWARE’, item
OPERATION”, EARIZATION” PARAMETERS” OPERATION”, ”PUTTING INTO ’Pump actuation
item ”SYSTEM item ”DATE AND OPERATION”,
SETUP” TIME” item ’License sur-
vey’
At access attempts to values or screen pages of a higher level the message appears in the
interactive error field: INPUT INTERLOCK.
Exit from the service menu with pressing an optional image selection key. Exit from the service
mode and/or before changing into another level actuate function key F5 (ACCESS END) in the
ACCESS AUTHORIZATION.
9.3 SETUP PROGRAMS
The setup programs are functions for the service technician and are divided into the
following groups:
Access
level
F1 Machine setup Machine basic configuration 10
F2 System-Setup Cursor, printer, screen settings 6
F3 Machine setup2 Machine basic configuration for 2-colour 10
machines
F4 Push-button setup Allocate push-button marker (putter into opera- 10
tion)
F5 Operator setup Program settings for the setter 8
The access authorizations are different and indicated in the right table column.

Version:G/11/12/7/3
SERVICE- SETUP-
Image selection key + F4 MENU + F1 PROGRAM
It appears the service submenu with the function keys:
F1 F2 F3 F4 F5 F6 F7 F8
MACHINE SYSTEM MACHINE PUSHBUTTONS OPERATOR SERVICE
SETUP SETUP SETUP 2 SETUP SETUP MENU
9.3.1 MACHINE SETUP

Specially at the putting into operation some basic settings are necessary, above all
what concerns the general equipment of the machine.
M A C H I N E - S E T U P 2000-08-22 10:46
Control type 0 EC100 Machine size 4 EHV3

Machine type 0 prop.controled EHV double pump 1 mounted
Safety regulations. CEN-regulations Micrograph 1mounted
Machine type 0 prop.controled EHV double pump 1 mounted

Clamping unit 1 with prop.valve Clamping cylinder 1 with pres.transd.
Mold height 0 without stroke tr Diff.connect. S12a 1 at mold opening
Actuation YS 0 reduced Mold mov.w.2 pumps. 1 activated
High speed cylinder 1 with pres.transd.
Back pressure over 1 Volume prop.valve Speed in hold.pres. 0 constant
Diff.connection S4D 1 activated Diff.connection S24 0 deactivated
Injection w.2 pumps. 1 Plastic.with 2 pumps. 0deactivated
Ejector 0 withou prop. valve

Core pull mounted 2 double Auto. Safety gate 0 not mounted
High speed mount.de. 3 single monit.2 mag Air valve 2 0 not mounted
Take-off device 12 0 no robot interf. Bus coupling RC100 0 no robot interf.
M
MACHINE SETUP SYSTEM SETUP MACHINE SETUP PUSH-BUT. OPERATOR SETUP SERVICE MENU
2 SETUP
With the switches in screen middle the indicated functions are activated/deactivated and/or
defined. The text at the right in the image comments the made setting.

Version:G/11/12/7/3
9.3.2 SYSTEM - SETUP

Access authorization at least level 10.
S Y S T E M - S E T U P 1996-04-15 14:20
C U
R S O R
d e
l a y - t i m e 0 . 4 s
a u
t o r e p e a t - t i m e 0 . 2 s
d y
n a m i c a u t o r e p e a t - t i m e 0 O F F
e n
t e r i n g z e r o ' ' 0 w i t h o u t
( w i t h / w i t h o u t p r e s e l e c t i o n )
S C R E E N
s c r e e n s a v e - t i m e 6 0 0 . 0 s
K E Y B O A R D
L a n g u a g e t y p e 0 U S
M
MACHINE SYSTEM PUSHBUTTONS SERVICE-
SETUP SETUP SETUP MENU
Setting function for the service technician and for the machine putter into operation
The following parameters can be set:

- Cursorparameter:
- Delay time (time up to the auto-repeat function)
- Autorepeat time (time interval between cursor repeats)
- dynamic Autorepeat function --> time interval between cursor repeats gets smaller
and smaller with longer pressing (min. 100ms)
- Input of ’0’: With/without preselection of the figure ’0’ when pressing the ENTER key
- Screen dimming:
- Time until the screen dimming
- Keyboard
- Occupation switchover between American and German keyboard
(Input keyboard, chapter ”PRINTER/TEXT INPUT”, item ”TEXT INPUT”.)

Version:G/11/12/7/3
9.3.3 PUSH-BUTTONS - SETUP

Access authorization at least level 10.
P U S H - B U T T O N S - S E T U P 1999-01-15 14:20
Mold height larger 6 Mold height smaller 7

Dismount fixed platen 8 Mount fixed platen 9
Dismount moving platen 16 Mount moving platen 17
Air valve 1 14
Safety gate closing 28 Safety gate opening 29
Safety gate automat.mode 31
Injection 2 32 Plasticizing 2 33
Nozzle 2 forward 34 Nozzle 2 return 35
Core 2 in 38 Core 2 out 39
Core 3 in 40 Core 2 out 41
Take-off Y in 32 Take-off Y out 33
Take-off Z at the left 34 Take-off Z at the right 35
Take-off X forward 42 Take-off X return 43
Core-pull relief 29
Couple ejector 28 Uncouple ejector 29
Screw retraction unit. 1 33 Screw retraction unit.2 34
current key code 0 M

SETUP PUSH-BUTTON PUSHBUT.
PROGRAM DELETE TAKEOVER
When connecting several optional functions, such as ejector coupling, hydraulic high speed
mounting, etc. overlaps of the push-button occupations arise inevitably. So for the putting into
operation and the retrofitting case a ’push-button setup’ is installed in order that the push-
button occupation can be adapted if necessary on the spot without software change.
Another example of the configuration of push-buttons is the combination of core movements

on one key for moving in cores and one key for moving out cores. Depending on the set core-
pull sequence then according to the moving conditions of the individual cores a core is
actuated with the one key. This function can be utilized at the ENGEL standard core-pull
program, not at the freely programmable cycle sequence as there more complex processes
prevail and not only core-pulls can be included into the sequence.
Function:
When the control unit recognizes a multiple occupation of a push-button when switching on the
control voltage, this push-button is deactivated for all concerned components, with the effect
that the concerned components no longer function in the manual mode. The deactivated push-
button can be seen on the push-button number ” ** ” at the respective component.
In this case to the concerned components a new push-button must be allocated.
Exception: Core movement push-buttons, like described in the upper paragraph.
Procedure:
Switch off motor
Press requested push-button and keep it actuated.
Whether the chosen push-button is accepted, can be recognized that at the value
”Current key code” a value unequal to ” ** ” is displayed.
Then actuate the soft key ”Take over push-button”.
After that a valid key is taken over (can be recognized at the fact that the key number at
the concerned component changes from ” ** ” to a number).

Version:G/11/12/7/3
If a key should have been chosen which has already been occupied by another
component, this is deactivated there, i.e. always the component chosen last pulls.
If an existing valid occupation shall be changed, the procedure is like above, but the current
key code at the concerned component must be deleted at first by the soft key ”Delete push-
button”.
In case of faulty operations the correct procedure is pointed out to the operator by interactive
error messages.
The made settings are stored as parameters on the machine diskette.
9.3.4 OPERATOR SETUP

Under access level 8 the machine setter is in a position to select programs which
appear on this screen page:.
O P E R A T O R S E T U P 2000-08-22 10 45
1) Cushion correction 1 0 deactivated Parallel sw.over 1 0 deactivated 10)

2) Signal type FS lamp 1 Steady light Action at.mold prot. 1 Sel.stop/opening 11)
3) Flank light beam guard 0 0 / 1 Standardized signals 0 deactivated 12)
4) HA output 3 in automatic mode Image background 1 grey 13)
5) Ejector profile 1 two-stage Choice of units 1 ISO 14)
6) Cushion correction 2 0 deactivated Parallel sw.over 2 0 deactivated 15)
7) SAW closing interl. 0 SAW1 and SAW2
8) No.shut-off nozzles 12 Tool
9) Absolute value input 1 activated
MACHINE SETUP SYSTEM SETUP MACHINE SETUP PUSH-BUT. OPERATOR SETUP SERVICE MENU
2 SETUP
With the switches in screen middle the indicated functions are activated/deactivated and/or
defined. The text at the right in the image comments the made setting.
1) Cushion correction
As a function of the remaining cushion after the injection process the stroke position point C1
is corrected automatically according to the following formula:
C1neu = C1alt + ( CP – CPx )
CP .... Cushion set value on screen page ’Holding pressure’

CPx ... Cushion actual value, on the screen page Holding pressure
C1 .... Plasticizing end
See also in the technical manual, chapter ’Movement sequence, item ’Cushion correction’.

Version:G/11/12/7/3
2 ) Signal type FS lamp

The mould protection lamp, in most cases a red warning light on the control console of the
machine, signals process or machine problems. It can be set to steady or blinker light.
Setting = 0 Blinker light in case of alarm

Setting = 1 Steady light in case of alarm
3) Side light beam gu.

An optionally connected light beam guard in the delivery chute sends a signal into the control
unit when its light beam is interrupted by a falling-down injection moulded part.
Setting = 0 0-1 Signal flank at interruption

Setting = 1 1-0 Signal flank at interruption
See also operator’s manual, chapter ’Setting of the clamping unit’, ’Ejection monitoring’.
4) HA output
The digital output HA (DO5020) can be programmed as follows:
Setting = 0 HA deactive
Setting = 1 HA active in semiautomatic mode
Setting = 2 HA active in fully automatic mode
Setting = 3 HA active in semi and fully automatic mode
See possibly also chapter ’Movement sequence/machine functions’, ’Digital output HA’.
5) Ejector profile
The number of speed and pressure stages can be set here.
Setting = 0 Ejector advance: Speed two-stage, pressure one-stage

Return ejector: Speed and pressure one-stage
Setting = 1 Ejector advance: Speed two-stage, pressure two-stage
Return ejector: Speed and pressure two-stage
6) Cushion correction 2
Cushion correction on the 2nd injection unit of a 2-colour or multicolour machine. See above,
item 1).
7) SAW closing interlock

SAW is a limit switch on the mold for securing the cores and ejector pins. When SAW is
actuated (not +24V), the ejector movements are blocked. In some cases two SAW are
mounted, e.g. in each mold half one, each one wired extra in the control unit. The control unit
rates the two inputs as series arrangement.
Setting = 0 SAW1 and SAW2. Both must be actuated for the release of the ejector movement
Setting = 1 SAW2 must be actuated for the release of the ejector movement
Setting = 2 SAW1 must be actuated for the release of the ejector movement
Setting = 3 deactive. No interlock of the ejector movement by SAW1 or SAW2
8) Number of shut-off nozzles

The total number of the used cylinder and mold shut-off nozzles must be entered here. The
settings for the individual shut-off nozzles are made on the screen page ÇSpecial’ + soft key
ÇShut-off nozzles’.

Version:G/11/12/7/3
Setting = 0 a cylinder shut-off nozzle is activated and adjustable

Setting = 1 a cylinder shut-off nozzle and a mold shut-off nozzle are active and adjustable
Setting = 2 up to 12 a cylinder shut-off nozzle and the entered number of mold shut-off nozzles are active
and adjustable
See also option description ÇShut-off nozzles’.

At 2-color machines from the setting Ç1’ 2 cylinder shut-off nozzles each are activated.
9) Absolute value input

The absolute value input is part of the standard, so activated when supplying the machine. The
operator has the possibility to switch off this function.
Setting = 0 Program is deactive

Setting = 1 Program active. The corresponding screen pages for injection, post injection (holding)
pressure and plasticizing and parameter inputs appear on the Quick Setup.
For handling and function see chapter 1, ÇAbsolute value input’.
10) Parallel switchover

As switchover mode for introducing the holding pressure also ’Parallel switchover’ can be
chosen.
Setting = 0 Program is deactive

Setting = 1 Program active. Several switchover types can be selected. The switchover criterion
reached first switches over to holding pressure.
See also operator’s manual, chapter ’Setting of the injection unit’, ’Switchover to holding
pressure’.
11) Action at mould protection

With this parameter setting a line on the screen page ’Mould closing’ can be displayed, which
offers a selection possibility for the reaction in the case of the reaction of the mould protection.
Setting = 0 The mould opens immediately after reaction of the mould protection
Setting = 1 On the screen page for mould closing a selection possibility appears for standstill or
opening the mould when the mould protection reacts
See also operator’s manual, chapter ’Setting of the clamping unit’, ’Closing speed and mould
protection’.
12) Standardized signals

With the use of an analog card AR281 and of the additional card SR161/A standardized signal
outputs are available by activating this program.
Setting = 0 inact.
Setting = 1 active
Hydraulic pressure 20mV/bar
Screw stroke 20mV/mm
Injection and plasticizing speed 20mV/mm/s
See chapter ’Hardware’, item ’SR161/A’. The electric plan shows the corresponding
connection occupation.
With variables the hardware output channel for the individual signals can be varied:
P42281 Injection pressure, standard channel occupation = 10

P42282 Screw stroke, standard channel occupation = 11
P42283 Screw speed, standard channel occupation = 12

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13) Image background

At colour screens the possibility of the selection between two variants exists:
Setting = 0 The representation appears in conventional form with black screen background and
mainly green writing.
Setting = 1 The background colour of the screen pages is kept in light-grey. The texts are tuned to
it in terms of contrast. Graphics and cursor fields show 3D effects.
At monochrome displays this switch is faded out.
14) Choice of units

The key ’A’ on the control console enables the switchover between the metric and imperial
representation.
With the adjustment of certain internal parameters the selection can be blocked or provided
with password input.
15) Parallel switchover 2

Program ’Parallel switchover’ for the 2nd unit of a 2- or multi-colour machine.
See above, item 6).
Parameter 19659 defines the switching function:

0= fixed on metric display
1= Key ’A’ switches between metric and imperial
2= fixed on imperial display
Parameter 39076 defines the access level:

0= no special access level necessary
1= at least level 6 and/or password 1111... necessary
2= at least level 8 and/or password 2222... necessary
3= at least level 10 and/or Superuser password necessary
Parameter 39077 defines the units for the host computer communication:
0= metric (iso) units
1= imperial units

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9.3.5 MEMO PAGE FOR PUMP CONTROL CARDS SETTINGS

As memo for the settings which have been made on the pump control card(s) this screen page
can be used. See techical manual, chapter 1, ’Pump actuation’.
9.4 PEAK VALUE MOMENT MEASUREMENT (PROCESS ANALYSIS)

Image selection key + F5
P R O C E S S A N A L Y S I S 1999-02-15 14 37
P E A K M O M E N T - P O S I T .
V A L U E P O I N T S K x ( m m )
M O L D P R O T E C T I O N P R E S S U R E 0 . 0 b a r 0 . 0 s 0.0 r
S S x ( m m )
I N J E C T I O N :
S P E E D 0 m m / s 0 . 0 s 0.0 r
H Y D R A U L . P R E S S U R E 0 . 0 b a r 0 . 0 s 0.0 r
H O L D I N G P R E S S U R E :
H Y D R A U L . P R E S S U R E 0 . 0 b a r 0 . 0 s r
C A V I T Y P R E S S U R E 0 . 0 b a r 0 . 0 s r
R . P . M . 0 / m i n 0 . 0 s 0.0 r
B A C K P R E S S U R E 0 . 0 b a r 0 . 0 s 0.0 r
P L A S T I C I . P E R F O R M
m e a n v a l u e 0 c c m / s
P L A S T I C I Z . N U M B E R
m e a n v a l u e 0 . 0
C Y C L E T I M E 0 . 0 s
M
MOULD- CYCLE TIME OPER.DATA TEXT PROZESS-
PARAMETER COLLECTION TEXT PAGE ANALYSE
Display function for the service technician.
After entrance into the service mode with password 2 a screen page can be called up, which
shows all peak values and the moment of their appearance.
9.4.1 PLASTICIZING NUMBER

For the documentation and monitoring of plasticizing processes the plasticizing work is
determined and displayed in a dimensionless plasticizing number on the screen page of the
process analysis. This process parameter represents -analogously to the flow number at
injection - the mean pressure at plasticizing and so gives information about the continuity (flow
characteristics etc.) at the plasticizing process.
As quantity to be measured serves the system pressure, which is proportional to the needed
force and/or torque on the plasticizing motor.
A pressure transducer on the injection unit and the analog card AR281 (in the special case
also still AR181) are prerequisite. This is true in standard of machines with EHV hydraulic
system starting from the size ES100.
At machines with electric screw drive as test signal the torque signal (0-10V) available on the
motor controllers is used.

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The plasticizing number is always determined from plasticizing beginning until plasticizing end
(no separately adjustable positions like at Microplast). It can be recorded in the quality data
documentation program QDP from shot to shot and can be monitored with CPC, provided with
tolerance limits. In case of limit exceedings the errors 179 ’PD GRAPHICS MONITORING’
and/or 180 ’PD GRAPHICS ALARM’ arise. The consequences can be programmed in the
CPC.
The plasticizing number is executed analogously for additional injection units.

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MOVEMENT SEQUENCE / MACHINE FUNCTIONS (3)
1 MAN. OPERATION
---> Press key.
From each machine sequence situation the control unit can be switched over to MANUAL
MODE.
In the graphic operation state field of the screen appears the hand symbol. A possibly running
cycle is interrupted immediately, the control keys for the individual movements get active:
In a certain frame the push-button occupation can be adapted at the putting into operation.
See to it chapter (2), item 9.3.3.
Each movement of the machine is controlled by means of manual control keys. Each individual
movement lasts as long as the respective key is actuated. The speed and pressure profiles are
passed like in automatic mode.
Exceptions:
When a core-pull program is switched on, the closing and/or opening movement is
interrupted like at the automatic operation (see description of the core-pull programs,
operator’s manual, chapter ”CLAMPING UNIT”, item ”CORE-PULL”). The opening
movement stops on pos. A.
When the key Injection is actuated, the pre-injection begins until the chosen holding
pressure switchover condition is fulfilled. The holding pressure is limited by the holding
pressure time Z2 also in manual mode if the key has not been relieved before.
When the key Plasticizing is actuated, the plasticizing begins until position C1 is
reached. When pos. C4 is set larger than 0, the screw retracts at first up to C4, then
occurs the plasticizing up to C1. When pos. C2 is set larger than 0, the screw retracts
the set C2 stroke after the plasticizing.
Optionally a separate key for screw retraction is provided. Thus the retraction occurs
without screw rotation up to position C2*. When the SIT key is actuated and held
tightly before the screw retraction key, thus the retraction can be executed up to stop.
When the key ”Ejector return” is pressed, the ejector returns until pos. L (ejector at the
back) is reached and stops then.
An advance of the ejector is only possible when the key ”Ejector forward” is pressed,
position A1 (and/or A, mould open) is reached, all core-pulls are moved out (bE14 and
bE16... actuated) and position L1 (ejector in front) is not reached and the ejector counter
is set larger than 0.
The moving-out and -in of the core-pulls is only possible when on the clamping unit the
positions for core moved in and out are reached depending on the chosen core
program.
Exception: Set-up mode: With simultaneous SIT key actuation a core movement is
possible also without regard to lockings. For this purpose the screen switch ”Eliminate
core interlocks in the set-up mode”” must be switched on.
The automatic J determination (nozzle contact point) is started AT EACH renewed
nozzle advance in the manual program.
Creation date: 20.02.2002 Movement sequence / machine functions (3)

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The nozzle return movement does not stop on pos. K, but can be returned up to the
mechanical stop.
The nozzle forward movement is run with closed mould (G2 actuated) with pressure P5, with
deactuated G2 with constant pressure, reduced to approx. 50% (P35084).
After mounting a new mould the set-up mode should be switched on. When setting the closing
movement and the position G2 observe item ”Mould mounting and setting of the mould closing
point” by all means !!! (Operator’s manual, chapter ”CLAMPING UNIT, item ”SETTING THE
MOULD HEIGHT AT DIRECT-CLOSING MACHINES”)
The individual movements run down like represented in the diagrams DIA1 - DIA7.
2 SET UP MODE
---> Press key.
Only from ’Manual mode’ the control unit can be switched over to SET-UP MODE.
In the graphic operation state field of the screen appears the set-up symbol.
The control keys for the individual movements get active.
The set-up mode corresponds to the manual mode apart from the following exceptions.
Basically this state of operation is installed for the set-up of the mould. The whole mould
closing movement occurs with mould protection pressure and reduced speed (P35041 in %).
When the ’normal’ speeds V1, V2 or V3 are smaller than P35041, those are used for the
movement.
The ejector is operated with small pressure and small volume except the normal settings
are still lower:
P35075 ... Volume
P35124 ... Pressure
At direct-closing machines the suction valves do not close when reaching the mould closing
point G2, the high pressure (clamping force) is not built up, high-pressure build-up solenoid
S1.2 does not energize.
The mould opening also occurs with constant pressure (P35082) and with the speeds V6, V7
and V8 if these are set smaller than a certain maximum value (P35042).
For the determination of the mould closing point after mounting a mould the set-up mode must
be chosen (operator’s manual chapter ”CLAMPING UNIT”, item ”SETTING THE MOULD
HEIGHT AT DIRECT-CLOSING MACHINES”).
Core and mould opening movements are possible with simultaneous actuation of the SIT key
and of the respective movement key without regard to lockings. Program ’Cancel core
interlocks’ (screen page ’Cores’) must be switched on.
For determining the nozzle contact point ”J” after mounting also the set-up mode must be
chosen.
Movement sequence / machine functions (3) Creation date: 20.02.2002

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3 SEMI-AUTOMATIC
---> Press key.
The semiautomatic mode can only be switched on when:

Motor runs on delta
no errors exist which would switch over to manual mode in automatic mode (see
possibly chapter ”Errors”)
no manual control key is actuated
Program oil preheating does not run
Program interruption key stands on ”Automatic.
In order to avoid unintended switchover into another mode of operation, also the
semiautomatic key must be actuated for some tenths of a second in order to be able to switch
over to this state. In the graphic operation state display field appears ”SEMIAUTOMATIC”. The
program semiautomatic immediately controls the cycle start conditions for an automatic cycle.
If these are not fulfilled, the program stops, the alarm lamp lights up and corresponding error
messages arise. When the conditions are fulfilled, the message ’START KEY’ appears in the
error message field.
3.1 CYCLE START CONDITIONS

Semi or fully automatic mode switched on
Stroke transducer o.k.
High speed mould mounting device o.k. (mounted or dismounted)
Ejection monitoring o.k.
Mould open (pos. ”A” reached)
at first cycle: Plasticized (pos. ’C1’ reached) and decompressed (pos. ’C2*’ reached)
at sequence cycles: After reaching the pos. ’C2*’ in the preceding cycle the plasticizing
end position C1 can be set newly and is then no longer start criterion for the sequence
cycle (e.g. for finding the correct plasticizing point without having to start the cycle newly
again and again.
no sequence error
no stop of the central computer
Safety guard closed *)
Nozzle protection / cover(s) on the injection unit closed
Unit not swivelled out
Cylinder temperatures o.k. / in tolerance
no heating lowering
no oil preheating
Moulg height o.k. (toggle lever)
Cores moved out
Mould heatings

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*) With pneumatically or electrically driven safety gate the cycle can also be started with open
safety gate. After actuating the start key the safety gate closes and afterwards the mould
closes after reaching the end position switches E1 (actuated) and E2 (deactuated) after
renewed actuation of the start key.
3.2 DIGITAL OUTPUT ’HA’
For the different states of operation a digital output (HA) is provided, which can be
programmed for the different modes of operation:
P35473 = 0 ... HA deactive
= 1 ... HA active in semiautomatic mode
= 2 ... HA active in fully automatic mode
= 3 ... HA active in semi and fully automatic mode
This setting can also be made on the screen page ’Operator setup’.
In the manual and set-up mode HA is always deactive, instead of it digital output H is active.
Safety gate opening in the semiautomatic mode and the safety regulations to be observed:
---> Operator’s manual, chapter ”CLAMPING UNIT”, item ”AUTOMATIC SAFETY GATE”
3.3 CYCLE END IN SEMIAUTOMATIC MODE
ev. TMS TMS
Demoulding time Z5
Cycle time collection)

Process date collection (PD)
TMS ... Start key

ZUS ... Cycle time peak value (time from beginning cycle until renewed begin-
ning cycle)
PD ... Process data printout
The demoulding time Z5 runs from end mould opening. In order to get more uniform cycle
times in the semiautomatic mode, the new cycle begins after the expiry of the Z5 when the
start key has been pressed during or after Z5 and the handling system release (HSP=+24V) is
active. This is also the moment of recording the ZUS and afterwards of the printing of the PD
record (and/or PD graphics). ZUS is used for cycle time analysis and production data
collection (remaining time calculation).
If TMS is not actuated, ZUS is determined after the expiry of the Z5 and the PD record is
updated (printed out). The times for cycle time analysis and production data collection run until
the actual new start of the next cycle (TMS), however).

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When the nozzle retraction delay time Z6 still runs at start Z5, the nozzle is no longer retracted.
(see also ”CARRIAGE UNIT RETURN”).
4 FULLY AUTOMATIC MODE
---> Press key.
Corresponds to the semiautomatic description.
Differences:
In the graphic operation state display field the automatic symbol appears.
The first cycle is introduced with the start key
The next cycle begins automatically, after the expiry of the pause time.
5 PROGRAM INTERRUPTION KEY (PU)

2 important tasks:
1. With switching on the PU key (manual position) the current cycle is stopped immediately. In
the graphic operation state field and also textually in the error display appears the message
”PROGRAM INTERRUPTION”.
The state of operation display field shows also: ”PROGRAM INTERRUPTION”.
All movements can be run with the manual control keys like in the manual mode. Before
switching over back in the automatic mode the starting position must be established again,
otherwise no cycle start can occur (error messages).
The state of operation is preserved via the PU function.
2. The switching ON-OFF (manual = ON, automatic = OFF) of the PU key causes an erasing
and acknowledgement of all existing errors and messages in all states of operation. Further
applied malfunctions are set again after the acknowledgement. (see also operator’s manual,
chapter ”DIAGNOSIS AND HELP”, errors”!)

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6 FLUSHING, OIL PREHEATING, MOULD PROTECTION, SET-UP
The actuation of the pump solenoids and of the proportional valves:
EHV1 EHV2 EHV3 Setting with:
Idling- Y 10% 10% 10% P35035

outputs K 8% 8% 8% P35109
between Y2 *5) 10% 10% 10% P35035
movement K2 *5) 8% 8% 8% P35109
and flushing Servo *4) 0% 0% 0% P35123
Flushing Y 50% 50% 50% P35051

K 6% 6% 6% P35098
Y2 *5) 50% 50% 50% P35979
K2 *5) 6% 6% 6% P35978
Oilpreheating S4d -- 1 *7) 1 *7)

S24 -- 1 *7) 1 *7)
Y 100% 100% 100% P35034
K *6) 42% 42% 42% P35080
Mould prot S10 1 1 1

Y V3 V3 V3 Set value
K P2 *3) P2 *3) P2 *3) Set value
Set-up S10 1 1 1
Y 10/10% 10/10% 10/10% P35041/P35042
K 32/32% 32/32% 32/32% P35086(P42263)/
Y2 *5) 10/40% 10/40% 10/40% P35082
K2 *5) 32/32% 32/32% 32/32% P35041/P35042
P35086/P35082
xx/yy means: xx for mold closing, yy for mold opening
*1) when differential connection on injection unit

*2) at proportional valve on clamping unit
*3) when program switch ”2nd mould protection active” is switched on, from the pos. G3 the 2nd mould pro-
tection pressure P2e is output (see ’Mould protection’).
*4) The empty output at a servovalve must be set so that the injection unit does not move in the idling (only
necessary when servovalves are used, which have no cover in the 0V position).
*5) only to be set when a 2nd pump for parallel movements is mounted (at EHV3 always)
*6) the pressure actuation at oil preheating is set so that the system pressure rises to 100bar (different set-
ting depending on system pressure).
*7) S24 and S4D energize then when the back pressure is produced via a separate pressure valve.
*8) when program switch ”2nd mold protection active” is switched on, from the pos. G3 the 2nd set-up pres-
sure P42263 is output (see ”Mold protection’).

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7 AUTOMATIC CYCLE SURVEY
Diagram 1 Diagram 3
Diagram 2
see start condition

Closing
CORES
Profile V=3-stage
P=2-stage
P35255 Carriage Z5A P35256 Z2 holding pressure time

Profile V=2-stage
P=1-stage
Injection Holding pressure
Profile V=10-stage Profile V=1-stage
P=1-stage P=10-stage
G2, B J
Mold closed Apply nozzle Switchover point
Diagram 4 Diagram 5 Diagram 6 ...
Z4 cooling
Plasticizing P35283 P35284 P35285 P35274 P35275 P35273

Profile V=5-stage
P=5-stage Contact pressure reduction Clamping pressure reductio
Z3 plasticizing delay (Direct closing)
Z6 retraction delay Retraction

Profile V=1-stage
P=1-stage
... Diagram 6 Diagram 7

A
Mold open
CORES
Opening
Profile V=3-stage
P=2-stage
Ejector fwd. ejector retracted
Profile V=2-stage Profile V=1-stage *)
P=1-stage *) P=1-stage *)
A1 L1 L
Ejector start Ejector forward Ejector retracted
*) The ejector profile can be switched over to 2-stage on the screen page ”Operator setup”.

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8 PARALLEL MOVEMENTS
8.1 2. EHV PUMP

At machines which are equipped with two EHV pumps, the main movements mould opening,
mould closing, injection, plasticizing and screw retraction are supplied hydraulically via the
main pump and the secondary movements, such as ejector, carriage unit and cores are
supplied by the second pump.
Thus results the possibility to actuate all movements, which are supplied by different pumps,
in parallel and/or to connect both pumps for certain movements together in order to achieve so
higher maximum speeds.
On the part of the software the functions secondary movements on 2nd pump, pump
interconnection at mould opening / mould closing, pump interconnection at plasticizing and
pump interconnection at injection can be switched on via parameters in the service mode.
The actuation of the second EHV pump occurs like at the main pump (flushing, idling solenoid
etc.).
outputs
S9 ... Output DO7 idling 2nd pump
S12 ... Output DO38 pump interconnection
Configuration switch service

P35973 e/a 1 = Operation with 2 EHV pumps
P35990 e/a 1 = Pump interconnection at plasticizing
P35991 e/a 1 = Pump interconnection at injection
P35992 e/a 1 = Pump interconnection at clamping unit
general parametes service

P35976 bar System pressure 2nd pump
P35978 % Pressure at flushing without S9
P35979 % Volume at flushing without S9
P35993 bar Threshold 2nd pump pressureless for secondary movements
P35980 s Deactuation delay S9 at flushing
P35981 s Output delay Y2 at flushing
P35986 ms Smoothing constant system pressure pump 2
8.2 SECONDARY MOVEMENTS ON 2ND PUMP

When this function is activated (only possible in the service mode), the movements nozzle
forward/return, ejector and cores are supplied via a separate EHV pump.
Also at the 2nd EHV pump there is no linearization for the Y and K channel, in this connection
there are only calibration straight lines analogously to the main pump.
By the hydraulically possible parallel movements the following changes result in the sequence:
8.2.1 PROGRAM EJECTOR RETURN IN PARALLEL TO MOULD CLOSING

This program can be switched on the screen page ”EJECTOR”.

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With switched-on program the ejector is retracted in the automatic cycle in parallel to mould
closing. When the mould has reached the control position AK and the ejector is not on the pos.
L (at the back), the mould is stopped immediately. Attention, this stop is an emergency stop
and correspondingly vehement, thus this should be avoided by a correct setting. In the manual
mode the ejector must always stand at the back in order to be able to close the mould.
8.2.2 PROGRAM NOZZLE FORWARD IN PARALLEL TO MOULD CLOSING

This program can be switched on the screen page ”NOZZLE”.
With switched-on program the nozzle movement forward is started in the automatic mode,
when the mould has reached the position DS and the ejector is at the back (as this is supplied
by the same pump.
The nozzle moves at first with decreased carriage pressure until the mould reaches the
position G2 at direct-closing machines and/or the position B at toggle lever machines. Only
then the nozzle moves the remaining movement with the set carriage pressure.
When core movements get active during the nozzle movement, these have priority before the
nozzle movement, i.e. the nozzle movement is interrupted until the respective core movement
is completed.
8.2.3 NOZZLE RETRACTION BEFORE MOULD OPENING (RETRACTION

PROGRAM 2):
This program is standard at one-pump machines and causes that the machine plasticizes at
first, then the unit is retracted on pos. K and only then the mould opens.
At machines with a second pump merely hydraulically the unit could retract in parallel to
plasticizing and mould opening, but the above mentioned sequence is seen as process
technologically required movement sequence so that here the theoretically parallel movement
is not utilized. If one wants to utilize this, the retraction program 1 (retraction after time Z6)
must be chosen.
8.2.4 SUNDRIES
To be noted at parallel operation is that the pump capacity is divided up and thus mould closing
and mould opening can no longer occur with maximum speed. This is signalled by the fact that
the speed set value settings can only be input limited upwards (e.g. 80%) and/or are reduced
correspondingly automatically. When switching off the parallel function the set values remain
uninfluenced, one must input these newly if higher values (up to 100%) are requested.
As at EHV machines a pressure transducer for each pump exists, here the pressure
information is used in order to avoid hydraulic overlappings in the hydraulic system of the
second pump not by possible delay times, but by defined pressure thresholds, these
movements depending on the setting can be started and interrupted again very often and then
possible delay times would partiallysum unnecessarily.
So before the start of pressure-sensitive movements it is controlled on the 2nd pump whether
the pressure in the system lies under an adjustable (service mode) level. If this is not the case,
on the 2nd pump pressure 0 is output until the set pressure level is reached. Only then the
corresponding movement is started.
Thus a jerky start (not corresponding to the setting) of the movement shall be avoided by high
remaining pressures in the system.
This pressure reduction happens before the following movements:

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Carriage unit forward

Return carriage unit
Ejector fwd.
Delay clamping high pressure build-up - injection:

By the possible parallel movements at certain settings it can arise that on the main pump the
injection movement would follow the clamping high pressure build-up without delay. By the
high remaining pressure in the system the injection movement would start with jerks.
Therefore here the time P36256 (at one-pump machines delay between carriage and
injection) is used as delay between high pressure build-up and start injection. In the cycle time
analysis this time is visible as extension of the closing time.
This time does not act when between high-pressure build-up and start injection a movement
on the second pump runs anyway (cores, carriage unit) so that on the main pump the pressure
can be reduced in the meantime.
8.3 PUMP INTERCONNECTION

Starting from ES250HL required for reaching the max. speeds.
8.3.1 PUMP INTERCONNECTION AT INJECTION

Switchable with parameter P35991 (1=switched on).
When the pump interconnection is activated at injection, the second pump is connected at
beginning injection by means of solenoid S12. The analog actuation of the second pump
occurs during the whole injection process (preinjection and holding pressure) in the following
way:
The volume of the second pump is run along with the volume setting of the first one, the
pressure is set to maximum in order to switch off the pressure controller of the second EHV
pump. Thus the pressure control of the whole system is taken over by the main pump.
8.3.2 PUMP INTERCONNECTION AT PLASTICIZING

When the pump interconnection is activated at plasticizing, the second pump is connected at
beginning plasticizing by means of solenoid S12. The analog actuation of the second pump
then occurs with the same actuations as the main pump.
With activated interconnection parallel movements of carriage unit, cores and ejector for
plasticizing are not possible.
8.3.3 PUMP INTERCONNECTION ON THE CLAMPING UNIT

When the pump interconnection on the clamping unit is activated, the pumps are
interconnected at closing and opening in order to reach a higher maximum closing speed. This
interconnection does not occur in each case, however, but only then when this is required (due
to the set speeds) and/or possible (due to the secondary movements possibly running in
parallel). Here the following criteria are checked:
Speeds:
When the maximally set speed on opening and/or closing does not exceed the value
which can also be reached with one pump, it is basically run with one pump in the
respective direction.
Only when a speed is set which can no longer be reached with one pump, it is switched

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over to 2-pump operation if the 2nd pump is not needed for parallel movements.
As the relative speed profile (screen values) always refers to the maximally possible
closing speed (with 2 pumps), at operation with one pump the input of the speeds on the
clamping unit is limited to that value which can be reached indeed with one pump.
For the operator there is no difference in the actual speed whether e.g. 80% closing
speed are run with one or with two pumps.
Static examination of the settings:
Here the program switches and start points of the secondary movements are checked
whether a secondary movement in the automatic mode will run in parallel to the
clamping unit, i.e. the second pump for the secondary movement will be needed. In this
case in the manual mode the set speeds are run with two pumps, but when switching
over from manual to automatic mode it is pointed out in one text line in the interactive
message field that in the automatic mode in the concerned direction the maximum
speed of the clamping unit is limited (as can only be run with one pump). Text e.g.:
’Speed mould closing limited’. If e.g. a hydraulic core-pull moves in parallel to mould
closing, at the switchover from manual to automatic mode all those closing speeds are
written down on the value which can also be reached with one pump. An increase of the
closing speeds (and/or possibly also opening speeds) is then locked in automatic
mode..
Dynamic examination of the secondary movements:
In addition to the parallel movements obvious from the various settings it is checked at
beginning opening and/or closing in the automatic mode whether just a movement is
active which the second pump needs since not all parallel movements can be seen from
the settings. When such a movement is recognized, during the automatic mode the
profiles are limited as indicated above and remain then like this until these are possibly
set higher again in the manual mode.
Position A - A1 examination:
In order to prevent that the ejector is switched to parallel operation unintentionally by
setting e.g. the pos.A bigger, but then it is forgotten to write the ejector start position A1
also high, when changing the pos.A it is checked whether the pos. A1 has been set
equal to the pos. A before. When this has been the case, the pos. A1 is pulled along with
the pos.A automatically.
If during the mould movement with two pumps a secondary movement, which the second
pump needs, should become active, the pumps are separated by de-energizing the solenoid
S12, possibly the system pressure is reduced and the corresponding secondary movement is
finally started.
Meanwhile the mould movement continues with one pump. If the second pump should get free
again during the mould movement, this is not connected again, but the movement is finished
with one pump, but at the closing movement it is controlled once again before beginning
clamping high pressure build-up whether the second pump is free, and the high pressure
build-up can then possibly be carried out with two pumps again.

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9 MOLD CLOSING
Concept EHV1, EHV2 and EHV3
Tolerance P35962
resulting clamping pressure
set clamping pressure SK [kN]
*4) P1 (6)
*5)
Output on prop.valve on the clamping unit,

during Y = P35065
Output on Y when no prop. valve on the

clamping unit
(5)
*1)
*3)
*2)
Mould protection
area
Close Clamping continue with

suction pressure nozzle
valve build-up forward
Cycle start --------mould closing
S1 ............. Mould closing, only at EHV1

S10 ........... Pump stage 1
S2.1 .......... Suction valves opening
S1.2 .......... Build up high pressure in the closing system
SEA ......... only at EHV2 and EHV3. At external high speed cylinders SEA de-energizes at high pressure
build-up in order to avoid eccentric forces on the mould clamping mechanism.
SEA as safety-technical equipment:
The deactivated SEA locks directly the oil feed to the clamping cylinder, direction mould closing.
SEA only gets active when a dangerless closing or opening movement can be introduced. Dur-
ing mould opening SEA is actuated in order to avoid the system-conditioned delay time (fixed
0.1s) between connecting-through of SEA and opening of the proportional valve.
S12A ........ Differential connection at closing. As a function of P35491 = 0: S12A at mould closing, P35491 =
1: S12A at mould opening
*1) ............. in the manual mode and at the first closing process in automatic mode the analog actuation for
mold closing is delayed by parameter P08481 [1/100s]. During P08481 suction valve opening
occurs with pressure P19600 and volume P19599.
*2).............. Delay of the analog high pressure output after setting the high pressure solenoid by the parame-
ter P08516 [1/100 sec].

Version:G/11/12/7/3
*3) ............. Delay of the solenoid switching-off S1 after high pressure build-up by the parameter P35286 [1/
10 sec]. After this time the time P10774 is running, which delays the switching-off of S1.2 (at
HLS1 and EHV1 hydraulic system). Starting from V9.01.
*4) ............. This pressure profile stage P10307 only acts if the mould opening stroke is set larger than the
max.mould opening stroke deducting stroke P10308.
*5) ............. see item ’Mould protection’
*6) .............. starting from the second automatic cycle the suction valve S2.1 remains opened after mould
opening.
(5), (6) ....... see item ’CLAMPING PRESSURE BUILD-UP IN THE CONCEPT EHV1, EHV2 UND EHV33’
At machines with a separate prop. valve on the clamping unit the speed profile is output to this
as well as on the EHV pump electronics (Y1). The pressure profile is preset to the K1
proportional valve and/or at EHV to the pump electronics.
Times:
ZF............ Mould protection time: If G2 is not reached within the ZF, the mould protection
... alarm reacts.
P35276... High pressure build-up time (direct-closing machines)
....
P35255... Nozzle forward delay time; in the automatic mode pressure and speed are
.... actuated on ”0” during this time in order to guaranteee an advance of the car-
riage unit without jerks. Before starting the time P35255 it is waited for the
clamping force measuring position P35024, however
P08481 in manual mode or at the first closing process in automatic mode the analog
..... actuation is delayed [1/100 sec]. At EHV suction valve opening during this time
P08516 Delay of the anlog high pressure output after setting the high pressure solenoid
..... [1/100 sec]
P35286... Delay of the solenoid switching-off after high pressure build-up
... [1/10 sec]
P10774 starting from V9.01: Delay of the switching-off of S1.2 as compared with S1. At
..... HLS1 and EHV1 hydraulic system. See diagrams.
Positions:
A................... Opening stroke
.....
W3 Start 2nd closing speed
....................
KS1 Intermediate stop move in core 1
..................
KS2 Intermediate stop move in core 2 Stroke values on
..................
KS3 Intermediate stop move in core 3 Platen referred
..................
W1 Start 3rd closing speed
...................
G1 Mold protec.stroke
....................
P35018 Stroke for suction valves closing (direct-closing
............ machines)
P06551......... Stroke point before G2 for ramp end in order to guarantee soft closing of
.... the mould platens despite steep braking ramp.
G2 Mould protection end, stroke value referred to toggle lever. Start fast
.................... straightening and/or high pressure build-up at direct closing machines

Version:G/11/12/7/3
Positions:
B Toggle lever locked, stroke value referred to toggle lever, SFX = 0
......................
SFx Platen position, actual value
..................
SKx Toggle lever position, actual value
.................
P35024 Stroke position on toggle lever: Start clamping force measurement impor-
............... tant especially in the case when ’B’ is set big in order to start the injection
process earlier (attention: By this measure too small (wrong) clamping
forces can be measured, which can lead to wrong closed loop controls
and to interruptions of the injection processes !!
P10308 Stroke length reduced start pressure closing (stroke pos. = max. mould
.............. stroke - P10308)
Pressures:
P35106 Clamping pressure up to G1; in the set-up mode P35086
..............
P35086 Set-up pressure at mold closing
..............
P42263 second set-up pressure from G3 at mold closing
..............
P2(a) Toggle lever: Mould protection pressure initial value and moving pressure
................... in the ’Set-up’
Direct closing: 1st mould protection pressure and moving pressure in the
’Set-up’
P2e Toggle lever: Mould protection pressure end value
................... Direct closing: 2nd mould protection pressure from pos. G3 if program is
switched on
P1 Locking pressure; reduceable with P35210
.....................
P10307 reduced start pressure closing
..............
Speeds:
V1 1. Closing speed (in the ’Set-up’ limited with P35041)
....................
V2 2. Closing speed (in the ’Set-up’ limited with P35041)
....................
V3 3. Closing speed (in the ’set-up’ limited with P35041)
....................
P35043 Toggle lever: fast straightening
............. Direct closing: Volume output after (for) braking on G2, see diagram 1D
P35068 Locking end, output after locking
.............
P35052 High pressure build-up at direct-closing machines
.............
P35065 High pressure build-up on Y if mould movement with prop. valve clamping
.............. unit

Version:G/11/12/7/3
Speed ramps:
P35171 [%] Profile start on position A, KS1, KS2, KS3
........
P35184 [%/ Max. start acceleration mould movement, as a function of time
s].......
P09320 [%/s] Max. start acceleration mould movement, as a function of time for output
...... on pump at EHV
P35131 [%] Switchover V1 - V2
........
P35139 [%] Switchover V2 - V3
........
P35132 [%] Braking on minimum speed P35043 before reaching G2
........
P35155 [%] Braking on B (P35043 on P35068)
........
P35133 [%] Braking on KS1, KS2, KS3
........
P35179 [%/ Max.acceleration /delay mould movement, as a function of stroke
mm] ..
P09319 [%/ Max.acceleration /delay mould movement, as a function of stroke on
mm] .. pump at EHV
P35193 [%/s] General outset ramp Y for switching over V3 on P35052. High pressure
...... build-up at Direct-closing machines without prop.valve clamping unit
P35195 [%/s] General outset ramp Ys for switching over V3 on P35052. High pressure
...... build-up at Direct-closing machines with prop.valve clamping unit.
Pressure ramps:
P35177 [%/s] Profile start A, KS1, KS2;
......
P35192 [bar/s] General max. pressure ramp, as a function of time
....
P35156 [%] Switchover P2e - P1, at direct-closing machines also pressure build-up
........ from P2e to P1
P35148 [%] Switchover P35106 to P2 and/or P2a
........
P35146 [%] Braking on KS1, KS2, KS3
........
P35147[%] Toggle lever machines: the mould protection pressure is interpolated
......... from P2a up to P2e,
Direct-closing machines: Mould protection pressure P2a on P2e if pro-
gram 2nd mould protection pressure switched on (see item Mould pro-
tection)
P35190 [bar/ General max. pressure ramp, as a function of stroke
mm].
P35194 [%/s] General outset ramp K for switching over from mould protection pres-
...... sure to P1 at direct closing

Version:G/11/12/7/3
9.1 PROGRAM ITEMS
9.1.1 MOULD PROTECTION
*)
Mould protection area
Closing
Manual and automatic sequence are identical.

With P35489 it can be defined whether the mould opens after the reaction of the mould
protection or does not carry out a movement any longer. The setting occurs on the
screen page ’Operator setup’. See chapter ’Putting into operation’, ’Operator setup’.
*) When the program ”2ND MOLD PROTECTION PRESSURE ACTIVE” is switched on, then
from the position G3 the 2nd mold protection pressure P2e and in the set-up mode P42263 is
output, otherwise over the whole mold protection range the pressure P2 acts).
Mould protection test: When G2 = 0: Mould closes with pressure P2e from G1 upto G2,
the pressure P2e is preserved, no high pressure build-up. Only
possible in the manual program.
9.1.2 AUTOPROTECT CLAMPING UNIT

Function and operation can be read up in the operator’s manual, chapter (6), ’Autoprotect’.
Setting hints for putting into operation

For the pressure transducer in the high speed clamping cylinder, which is mounted extra for
Autoprotect, on the input calibration image the resolution must be set. It is calculated as
follows:
max. mould protection pressure (160bar) x resolution pressure transducer (24.17mV/bar) =

3867mV
Analog input: AI7 Pressure transducer in the high speed cylinder (if mounted)
Parameters 24208 [kN] Force in the mould protection area, against which it is monitored
during initialization.
Parameters 24353 0,1mm/s minimum speed during the mould protection phase
Parameters 21317 1/10 Switch off measurement delayed
When e.g. 80 bar counterpressure are set at closing, one converts these 80 bar to mould
protection force (e.g. by means of absolute value computer) and sets the calculated value in
the parameter 24208.
With parameter 21317 it can be set in 1/10 seconds by how much the measurement shall be
switched off delayed in the mould protection case.

Version:G/11/12/7/3
At monitoring type ’Force’ it is monitored in the initialization cycle against the force set in the
parameter 24208 (maximally P2 and/or P2e).
This should be bigger than the counterpressure at closing as otherwise at the initialization a
mould protection error is recognized immediately.
The following parameters release a new initialization in the case of a new input:
Closing strokes: A,W3,W1,G1,G3,G2
Closing speeds: V1,V2,V3

35043 Speed on G2
35068 Speed on position mould closed
Clamping pressures: P2,P2e
Ramps: 35131 Brake speed on W3

35139 Brake speed on W1
35132 Brake speed on G2
35155 Brake speed on position mould closed
35171 Speed start acceleration mould closing
35147 Brake pressure on position G3

35148 Brake pressure on position G1
Minimum speed 24353 Min. speed at speed measurement

Maximum force 24208 Max. force at force measurement
Stroke tolerance 28174 Stroke tolerance for strongly dynamic curves
Switching-on of the mould protection monitoring.

Switchover from pressure to speed monitoring and vice versa.
The reference curve is not lost by switching off the control voltage.
9.1.3 CLAMPING PRESSURE BUILD-UP IN THE CONCEPT EHV1, EHV2 AND

EHV3
(5)
The parameter P35276 acts as monitoring time. This time must be set so big that the system
has enough time to build up the set clamping pressure indeed.
The purpose of this monitoring time is to prevent that in case of a malfunction in the clamping
cylinder and/or in the pressure measuring system here the machine ’gets caught’ in the cycle
with full pressure output. As consequence appears the error message 28 ’Clamping force low’
at injection.
(6)
At machines with EHV hydraulic system the following situation results:
The control card of the pump is optimized on the oil quantities to be processed on the injection
unit. At the unequally larger oil quantities to be mastered on the clamping unit therefore also a
completely different controlled member results, which cannot be employed optimally with the
control parameters for the injection unit.
Therefore here at the pressure control there is also an overshot, which has at the clamping
pressure consequences in so far as the set clamping force is exceeded about 15-20% as by
the high pressure check valve each hydraulic peak is locked.
The following measure is taken:

At the new input of the clamping force SK and/or after switching on the control voltage
P1 = Set value SK set minus P35963 (% of SK).

Version:G/11/12/7/3
Thus it is prevented that the clamping force overshoots too much at the first time mould
closing.
At each further mould closing (in each mode of operation) it is measured how far the clamping
force actual value has exceeded the set value plus the tolerance P35962. The value which
goes beyond this dead zone is subtracted at the next mould closing until the clamping force
falls into its normal swing within the dead zone.
A not-reaching of the set set value causes the correction by the measured difference set value-
actual value in each case, i.e. for a not-reaching of the clamping force there is no dead zone.
Manual mode and first automatic cycle

An additional safety measure against a too early clamping force build-up is taken in the manual
mode and in the first automatic cycle:
When the stroke point G2 is reached, here it is only switched to high pressure starting from the
recognized mould standstill. But if here the stroke transducer voltage value of the G2 should
not be reached more than 60mV, this means, the mould plates cannot hit upon each other
within this tolerance, no high pressure build-up occurs. It appears the error message 72,
’WRONG MOULD HEIGHT’.
9.1.4 SET-UP MODE
3--stage V profile like in the manual program, but speed maximum is limited with P35041.
When V1 is < P35041, V is valid1
When V1 is > P35041, P is valid35041 .
Analogously valid for V2 and V3.
At machines with prop.valve on the clamping unit V profile is output on this and also on Y.
9.1.5 STROKE CALIBRATION AND STROKE LINEARIZATION
Digital output like in the manual program, the whole closing stroke occurs with:
Volume = P35049
Pressure = P35104
see also chapter ’Calibrations, linearizations’
9.1.6 CLAMP. FORCE

At direct-closing machines:
With built-in pressure transducer on the clamping unit the clamping force build-up is checked
within a time (P35276). If this pressure (set value - P35312) is not reached, the pressure build-
up ends, the injection is not introduced (error ’CLAMPING FORCE LOW’). The alarm limit is
controlled with P35309 (error ’CLAMPING FORCE TOO HIGH’). The tuning (resolution) of the
pressure transducer is fixed on the input calibration image.

Version:G/11/12/7/3
9.1.7 ELECTROHYDRAULIC CLOSING SAFETY
Image selection key + F4
S A F E T Y G A T E 1996-05-07 09:35
C L O S I N G S A F E T Y :
E 1 E 2 X E 8 X E 8 Q E 7 V a l v
E 1 E 2 D I 0 2 D I 1 0 D I 1 7 D O 2 5
C L O S E D . 1 ❒ 0 ❒ 1 ❒ 0 ❒ 0 ❒ ❒
O P E N 0 ❒ 1 ❒ 0 ❒ 1 ❒ 1 ❒
M
MOLD OPEN- SET VALUE- AIR- SAFETY-
ING GRAPHICS VALVE GATE
When opening the safety gate on the clamping unit limit switch E7 is actuated, which closes a
safety valve (DO25). It blocks all movements on the clamping unit at open safety gate and/or
when an error situation exists. Like also the limit switches E1, E2 also E7 and the valve end
positions XE8 and XE8Q are monitored.
The display of the switch states serve the logic tables on the screen page.
’1’ and ’0’ are the ’correct’ set positions of the switches. The tags indicate the actual state.
Thus in a case of error the wrong positions can be recognized easily. With closed safety gate
all screen tags light in the row ’closed’. At open safety gate analogously.
Safety gate 1 (operator side)

Limit switch bE1 bE1, make contact actuated at safety gate closed
Limit switch bE2 bE2, break contact actuated at safety gate open
Safety valve end posi- bXE8 DI02, make contact actuated at safety gate closed
tion
Safety valve end posi- bXE8Q DI10, make contact actuated at safety gate open, valve not cur-
tion rent-carrying
Limit switch bE7 DI17, break contact actuated at safety gate open (compare bE2)
safety valve DO25 Solenoid +24V at safety gate closed and monitoring E1
with E7 ok.
Safety gate 2 (machine rear side)

In the standard case, so without peripheral unit, the rear safety gate is only monitored
electrically, but not in the software. When this is opened, the EMERGENCY STOP circuit is
interrupted by the limit switches bE3 and bE4 so that the machine switches to EMERGENCY
STOP immediately.

Version:G/11/12/7/3
Safety gate special executions

At the integration of handling systems and further peripheral equipment the safety gate
situation is adapted in each case. Each safety gate which protects the mould area is included
in the electrohydraulic closing safety and operates the 3 limit switches E1.x, E2.x and E7.x
analogously to the safety gate on the operator side ( = SG1 ). The monitorings also correspond
to those of the safety gate on the operator side.
SG1 SG2 SG3 SG4

E1 E1.2 E1.3 E1.4
E2 E2.2 E2.3 E2.4
E7 E7.2 E7.3 E7.4
Monitoring circuits
bXE8Q and bXE8:

Monitored mutually in the software. When changing the switch states the antivalent state must
appear within a fixed time (P06345, approx. 0.5s), otherwise immediate closing and motor
stop arise. Error message: ’HYDR.CLOSING SAFETY’.
bE1 and bXE8Q:

Are monitored mutually in the software. When changing the switch states the antivalent state
must appear within a fixed time (P35266, approx. 0.5s), otherwise immediate closing and
motor stop arise. Error message: ’HYDR.CLOSING SAFETY’.
Here the information ”Safety gate closed” (bE1 actuated) is linked with the information
EMERGENCY-OFF, i.e. DO25 must be antivalent to bE1 when bE1 is actuated AND DI00 is
on +24V (EMERGENCY-OFF free) as the solenoid DO25 is de-energized deliberately in case
of EMERGENCY-OFF.
bE1 and bE7:

must appear within a fixed time (P35254, approx. 0.5s), otherwise immediate closing solenoid
and safety solenoid interruptions and error message ’SG LIMIT SWITCHES DEFECTIVE’
arise’.
In further sequence the monitoring in the software bE1 and bXE8Q reacts by a de-energizing
of the safety solenoid DO25 -> motor stop and error message’.
bE1 and bE2:

must appear within a fixed time (P35254, approx. 0.5s), otherwise immediate closing solenoid
and safety solenoid interruptions and error message ’SG LIMIT SWITCHES DEFECTIVE’
arise’.
In further sequence the monitoring in the software bE1 and bXE8Q reacts by a de-energizing
of the safety solenoid DO25 -> motor stop and error message’.
When the eror ”HYDRAULIC CLOSING SAFETY” is released, this error is reset by opening-
closing this protection cover, at which its limit switches must switch correctly.

Version:G/11/12/7/3
10 ADVANCE CARRIAGE UNIT

DIA 2: Pressure and speed diagram
Switching-off
pressure at
pressure build-
up via system in manual mode *)
pressure
in automatic mode
in automatic mode
Pressure build- P35255 in automatic mode

up:
**)
via Z5a
via system
pressure
transducer
Mould closing
continue before
with
Pressure build-up Advance nozzle
injection
S5...... Advance carriage unit

S10 ... 1. Pump stage
S1 ..... Mould closing remains actuated at toggle lever machines in the automatic mode
*) In the manual mode solenoid S5 and S10 remain active as long as the push-button for ’Nozzle for-
ward’ is pressed.
**) The pressure build-up can be switched over via P10102 (see item. 10.3):
P10102 = 0 ... pressure build-up via Z5a
Pf10102 = 1 ... pressure build-up via system pressure transducer
During the movement the stroke transducer is checked for correct function. The signal must lie
within the calibrated min - max values. In a case of error immediate stop and alarm messge
’STROKE TRANSDUCER NOZZLE’.
The speed profile is output on the central Y1 proportional valve, and the pressure profile on the
central K1 proportional valve. At electrically adjustable pumps (EHV) these two signals are led
to the pump electronics.
Times:
P35255 Nozzle forward delay (only in the automatic mode). When the parameter is
.... larger than 0, the outputs for mould closing and core moving are erased. (For
advance of the nozzle without jerks)
Z5A Contact pressure build-up time
.........
P35256 Injection delay time (only in the automatic mode). The outputs for Y and K are
.... erased. When the constant is = 0, the outputs are preserved.
P36456 Waiting time after pressure build-up via system pressure
....

Version:G/11/12/7/3
Positions: (not at EC100-S)

K ........... Nozzle stroke in automatic mode
J1 .......... Start 2nd nozzle advance speed. (J1 is drawn along with K when K is set
smaller than J1.)
J ............ Nozzle contact point, is determined automatically
SDx ....... Nozzle position actual value
P35010 (typ. 5mm) Distance of the stop point of the return movement and of the
.. mechanical stop. (P35011 = calibrated max.stroke - P35010)
Speeds:
V9 ..................... 1. Speed nozzle forward
V10 ................... 2. Speed nozzle forward
P35039.............. Volume for contact pressure build-up
P35074 ............. Volume carriage without clamping pressure and no nozzle retraction (
only EC100-S)
P35040 ............. Minimum volume (nozzle)
P35054 ............. Volume stroke calibration nozzle, J determination, volume with reach-
ing J
Pressures:
P5 ..................... Pressure nozzle forward with locked toggle lever. In the program Set-
up, or when the mould is not closed, instead of P5 the constant pres-
sure P35084 is output.
P36457 ............. Tolerance for carriage pressure reached (P5-P36457 = switching-off
pressure) at pressure build-up via system pressure
Speed ramps:
P35173 [%] ...... Start acceleration nozzle forward
P35185 [%/s].... Maximum start acceleration nozzle movement
P35138 [%]....... Speed braking on J1 and Jj
P35180 [%/mm]. Maximum acceleration/delay nozzle movement
P35193 [%/s] ... General outset ramp Y for start volume pressure build-up, acceleration
Y-outputs. Attention! This ramp is also effective at other movements.
Pressure ramps:
P35194 [%/ Profile start on position ”K”, pressure build-up after reaching the nozzle
s] .... contact point ”J”.
Attention! This ramp is also effective at other movements.
10.1 AUTOMATIC NOZZLE CONTACT POINT DETERMINATION

(J determination)
At the advance of the nozzle the nozzle contact point ’J’ is determined and stored
automatically in each state of operation.

Version:G/11/12/7/3
’J’ is not yet determined:

’J’ is erased when switching on the control voltage and when switching over to set-up mode.
The nozzle moves forward with decreased speed (P35054) and with reduced pressure
(P35084). After approx. 2 sec standstill recognition time on the contact point the screen tag ’J’
lights up. This position is valid as 0 point for the stroke scales of the nozzle movement (SDx =
0).
’J’ is already determined:

Despite already determined ’J’ at each nozzle forward movement in the manual mode and in
the first automatic cycle a new determination occurs. Thus it shall be prevented that after a
mechanical change of the nozzle stroke, e.g. insertion of a shorter nozzle tip the machine
switches to contact pressure before the nozzle is still applied. It is run with normal profile (V9,
V10, stroke point J1 and ’old J’) and the contact point is determined like above.
At setting V9 or V10 = 0% no movement and no J determination either occurs.
ATTENTION: It is very advisable to switch over to set-up mode or to

switch the control voltage off/on after a mechanical change of the nozzle
stroke in order to effect a deleting and thus hence a new determination
of the contact point.
Parameter P35054 determines the sped for the determination movement.

P35027 ..... n Number of measurements at standstill of the nozzle (contact point reached)
P35028 ..... 0,1 mm allowed nozzle movement during the determination
P35029 ..... 0.01 Meas.ti
10.2 CONTACT PRESSURE BUILD-UP

At CC100 EC100 the pressure build-up can be switched over via P10102:
0 .. Pressure build-up via Z5a
1 .. Pressure build-up via system pressure transducer
at EC100-S only the pressure build-up is supported via system pressure.
10.2.1 CONTACT PRESSURE BUILD-UP TIME

(Not at EC100-S).
As soon as at the advance of the nozzle the pos. ’J’ is reached, the contact pressure build-up
time Z5A starts to run. This time can be set on the screen in hundredths of a second. During
this time the pressure P5 (with not closed mould P35084) as well as the volume V9 are output.
Z5A is not effective in the manual mode.
10.2.2 CONTACT PRESSURE BUILD-UP TIME

The following criteria are valid for contact pressure built up:
1.at open mould:
PHx [bar] > contact pressure (P35084) [converted in bar via maximum pressure] - tolerance
for contact pressure (P36457) [bar] and waiting time after pressure build-up (P36456) [1/100
sec] run down
2.with closed mould:
PHx[bar] > contact pressure P5 [converted in bar via maximum pressure and red.factor]
- Tolerance for contact pressure (P36457) [bar]) and waiting time after pressure build-up
(P36456) [1/100 sec] run down

Version:G/11/12/7/3
11 INJECTION AND HOLDING PRESSURE

DIA3-1: Injection and holding pressure WITHOUT servo valve
Pressure actual value
Speed actual value
Cooling time Z4
Holding pressure time Z2 Pre-injection time (Z1)
**) S4B_cl
S4B_op
Plasticizin *)
g delay
time Z3
Retraction
delay time
Z6
Holding pressure Injection Nozzle
forward
before
S4............... Injection
S10 ........... Pump stage
S4D .......... Differential connection (without increased injection pressure), switchable with P35954
(1 ... Differential connection with s4d), dependent on the injection unit
S4B_op ...... open hydr. shut-off nozzle (Special equipment)
*) P35282 for standard nozzle control. When the optional program ”Mould shut-off nozzles” is
built in, this delay time can be set on screen page ”Special/shut-off nozzles”.
S4B_cl ...... close hydr. shut-off nozzle (Special equipment)
**) Closing of the shut-off nozzle is dependent on the plasticizing. If plasticizing does not occur
immediately after end holding (post injection) pressure, S4B_cl energizes as a function of time
and thus closes the nozzle.
S24 ........... Differential connection (without increased injection pressure), switchable with P08517
(1 ... Continuous piston rod at HLS and EHV1 hydraulic system)
Injection profile and holding pressure profile are interpolated. At beginning injection with a
ramp P35175 the first speed stage is actuated and from here on it is interpolated linearly up to
the end point of the respective next stage. At machines with EHV hydraulic system it is
possible to closed loop control the injection speed via the volume set value setting on the
pump. Further, the closed loop pressure control, which occurs via the electronics of the pump,
can be improved in the dynamics by means of ”offshore” closed loop control of the pressure
set value setting. On the screen image ’PV control parameters’ the closed loop controls for
injection and holding pressure can be switched off and/or on (see chapter ’Closed loop
control’).
P35463 = 0: pump closed loop controlled

P35463 = 1: Servovalve controlled

Version:G/11/12/7/3
DIA3-2: Injection and holding pressure WITH servo valve
Plimit
Servo
Servo Pressure actual value
Vlimit
Speed actual value
Cooling time Z4 Holding pressure time Z2 Pre-injection time (Z1)
**) S4B_cl
S4B_op
*)
Plasticizin
g delay
time Z3
Nozzle
Retraction
delay time
Holding pressure Injection forward
before
Z6
S4............... Injection (solenoid not mounted, is replaced by the servo valve)

S10 ........... Pump stage
S4D .......... Differential connection (without increased injection pressure), switchable with P35954
(1 ... Differential connection with s4d), dependent on the injection unit
*) P35282 for standard nozzle control. When the optional program ”Mould shut-off nozzles” is
built in, this delay time can be set on screen page ”Special/shut-off nozzles”.
**) Closing of the shut-off nozzle is dependent on the plasticizing. If plasticizing does not occur
immediately after end holding (post injection) pressure, S4B_zu energizes as a function of time
and thus closes the nozzle.
Injection profile and holding pressure profile are interpolated. At beginning injection with a
ramp P35175 the first speed stage is actuated and from here on it is interpolated linearly up to
the end point of the respective next stage.
The injection speed is closed loop controlled via set value setting on the servo valve by means
of closed loop position control. Further, the holding pressure is closed loop controlled via set
value setting on the servo valve by means of closed loop pressure control.
The outputs on the pump must be set so that they do not exert any influence on the closed loop
control (output enough volume and pressure on pump)
On the screen image ’PV control parameters’ the closed loop controls for injection, holding
pressure and pressure limit can be switched off and/or on (see chapter ’Closed loop control’).
With the closed loop injection control the closed loop pressure limit control is switched on
automatically.

Version:G/11/12/7/3
Configuration switch:
P08517... 1 = continuous piston rod at EHV1/HLS unit
P35954... 1 = Differential connection (s4d mounted)
P35484... 1 = S10 switching-off after injection for fast pressure reduction
P35249... Program switch for active pressure transition from holding pressure to 1st back pressure
= 0 ... Pressure 0 after holding pressure
= 1 ... immediately 1st back pressure after holding pressure (see also active back pressure)
Times:
P35256.. Injection delay (only in automatic mode). In this time the idling outputs get effective !
P35282.. Time open shut-off nozzle before injection
P08479... Delay between S4 and analog actuation in case of operation without servo valve.
P35257... Closed loop control employment delay: Servo valve opens delayed to S4, Y and K in order to get
a constant volume from the pump from injection beginning.
Z1... Injection time
Z2... Holding pressure time; is divided into ten equal parts automatically, for which one holding pres-
sure each can be set.
P35258... Servo valve on + after holding pressure and S4 deactuation delay for fast pressure reduction
P35256... Injection delay (only in automatic mode). In this time the idling outputs get effective !
P35282.. Time open shut-off nozzle before injection
Positions:
C1 ..... Metering stroke, the stroke positions for the ten injection speeds can be changed on the set value
graphic image. An automatic tenth part formation of the metering stroke C1 only results when the
stroke point C1 is input 2x in succession. Otherwise the stroke profile set before is divided up auto-
matically in relation to the new metering stroke.
C2* .... Calculated value: Metering stroke + decompression
C3u ... measured switchover point to holding pressure
SSx .... Screw position actual value
Speeds:
V12-V21. 10 Injection speeds interpolating
P35038.. Minimum speed
P35048... Maximum volume during injection on Y at servo closed loop control
P12814.. Volume injection from stop
P35046.. Volume holding (post injection) pressure on Y at servo closed loop control
P35241.. Speed limit minimum value only at HLS hydraulic system
P35063.. Volume servo valve on + after holding pressure for fast pressure reduction
Pressures:
P6 ........... Injection pressure limit
P35092 ... System pressure at injection (pressure on K at servo closed loop control). Calculated from P6 +
P35115... K headroom for closed loop injection and holding pressure control)
P7 - P16 . 10 Holding pressure stages interpolating
P35249 .. at closed loop con- P35249 = 0 .. Pressure 0 after holding pressure
trolled machines:
P35249 = 1 .. immediately 1st back pressure after holding
pressure (see also active back pressure)
P35093 ... System pressure at holding pressure (pressure on K at servo closed loop control). Calculated
from highest holding pressure value + P35115... K headroom for closed loop injection and hold-
ing pressure control.

Version:G/11/12/7/3
Speed ramps:
P35175 [%s] ......... Start acceleration speed injection
P35186 [mm/s2] .... Maximum start acceleration screw absolute
P35164 [%] ........... Speed injection - braking on stop
P35181 [mm/s/mm] Maximum acceleration/delay screw absolute
P35165 [%s] ......... Outset speed switchover to holding pressure at HLS hydraulic system
Pressure ramps:
P35191bar/s].......... Maximum pressure ramp absolute, time-dependent (all movements)
P35129 [%]............ Switchover from switchover actual pressure to holding pressure
11.1 CUSHION MONITORING (SCREEN IMAGE ”HOLDING PRESSURE”)

The injection cushion, to be read off on the ”Holding pressure” screen image in the field CPx,
can be monitored with a window. The program is in function when the max.value is set bigger
than 0. At the beginning of the cooling time it is then tested whether the actual value of the
cushion, CPx, lies within the limits Min and Max.
CPx is determined in the holding pressure as smallest reached stroke.
If CPx falls outside the window, a rejects and corresponding error message (CUSHION TOO
BIG and/or CUSHION TOO SMALL) comes).
The rejects output AA is activated until the beginning of the next closing process and the
rejects counter/time unit and rejects total counter are incremented. The cushion max. limit is
determined by parameter P35006 (typ. 25 mm).
11.2 CUSHION CORRECTION (SCREEN IMAGE ”HOLDING PRESSURE”)

Special equipment !
Can be activated on the screen page ’Operator setup’. See chapter ’Putting into operation’,
item ’Operator setup’.
Only with active program on the screen the cushion set value appears.
By setting the cushion set value CP bigger than 0 the correction program - irrespective of the
cushion monitoring - is effective. With beginning of the cooling time the difference of cushion
actual value CPx and cushion set value CP is formed, and thus proportionally the metering
stroke (C1M, C2M) as well as the window positions C17 and C18 of the flow number
measurement are calculated newly. If the correction yields a bigger value than the parameter
P35006 (typ. 25 mm), the error ”CUSHION ERROR” arises. The cycle is finished, the alarm
lamp is set.
11.3 SWITCHOVER TO HOLDING PRESSURE
A fulfilled switchover criterion introduces the holding pressure at injection.

Possibilities: Adjustable on screen page ’INJECTION’ + F2 (SWITCHOVER TYPE)
As a function of mould cavity pressure ......... PF
Hydraulic pressure-dependent ........ PH
Stroke-dependent ........................ C3
via external device .............. C3E: at AR281 ... input ADi0
C3E: at AR101 ... input ADi2
Time-dependent ......................... Z1
Each switchover mode can be chosen on the screen, but always only one mode can be active
(mutual locking).

Version:G/11/12/7/3
No rule without special case: Parallel switchover C3d activable with P35482 = 1
On the screen appears: Parallel switchover YES/NO
Switchover area C3d = ...,. mm
From the chosen stroke position area C3d that criterion switches to holding pressure which is
switched on and fulfilled first.
11.4 SPEED CONTROL IN THE HOLDING PRESSURE PHASE

The speed profile is continued as a function of stroke during the holding pressure phase and
the corresponding speed tag remains actuated. Only when the screw is on stop, the constant
value P35045 is output as speed value.
At machines with HLS hydraulic system the speed control is limited with P35045 in the whole
holding pressure.
11.5 INCREASED INJECTION PRESSURE (SCREEN IMAGE ”INJECTION”)

With P35954 or P08517 = 1 activable when the construction of the unit allows a difference
circuit. It appears the screen line ’Increased injection pressure Yes/no’.
P35954: Differential connection with S4D
P08517: Differential connection with S24, continuous piston rod
In the normal program, i.e. without increased injection pressure, with injection solenoid S4 the
differential solenoid S4D energizes. Thus the injection movement occurs faster by oil return
and thus with decreased pressure. The maximum speed is filed in the parameter P35033,
according to which also the speed calibration occurs.
When switching on the program ”INCREASED INJECTION PRESSURE” a recalibration of the

speed values according to parameter P35032 (e.g. at ES150 P35032 is = 95 mm/s).
If in the speed profile for the injection values larger than the P35032 should be set, those are
limited to the new maximum speed, namely P35032.
The injection now occurs without differential solenoid S4D. When switching off the program the
recalibration on P35033 occurs again. The values possibly reduced to P35032 are not written
on the original value automatically.
11.6 POWER FACTOR

For the optimum utilization of the pump power a total power factor (P35128) can be set which
indicates the max. injection speed in relation to the injection pressure. Putting the injection
pressure higher automatically lowers the max. injection speed according to the following
connection:
P35128
V injection max = -----------------------
Injection pressure
P6
When the pump power is designed so that no limitation is necessary, the power factor can be
written on zero, thus this function is switched off.

Version:G/11/12/7/3
11.7 INJECTION UNIT SWIEVEL OUT

The injection unit can be swivelled out in order to be able to pull out the screw forward. At
machines with accu or machines with open method of construction on the injection unit (only
nozzle safety gate) the swivelled-in position is monitored with a limit switch (E52, DI32014). In
the swivelled-out state E52 is deactuated, contact open.
Survey
Methods of
E52
construction
closed no, input on control unit bridged. Limit switches E9/E9Q take over the E52 function.
open yes, led in control unit, at swivelled out: Error message 64, ÇUNIT SWIVELLED
OUT’.
FS is set, no cycle start possible, unit movements stopped, injection as expansion
help for the screw and/or material cylinder is only possible with safety key and lim-
ited speed.
closed + accu yes, in the emergency stop circuit. Input on control unit bridged
open + accu yes, in the emergency stop circuit. Input on control unit bridged

Version:G/11/12/7/3
12 PLASTICIZING AND DECOMPRESSION

3)
Time Z4
Time Z6
P35297 P35297
Time Z3 2) 2)
1)
**)
Plasticizing Decompressi Pressure continue

Holding Decompressi
on after reduction with
pressure on before
plasticizing nozzle nozzle
before plasticizing
return
Delay
decompressi
on
S3 .......... Plasticizing
S3A ........ Back pressure (not at machines with separate back pressure valve, servo and prop. valve)
S10 ........ Pump stage
*) P35282 for standard nozzle control. When the optional program ”Mould shut-off noz-
zles” is built in, this delay time can be set on screen page ”Special/shut-off nozzles”.
**) Closing of the shut-off nozzle is dependent on the plasticizing. If plasticizing does not
occur immediately after end holding (post injection) pressure, S4B_zu energizes as a
function of time and thus closes the nozzle.
S24 ........ Decompression ( 1)) only at open loop controlled EHV1 machines with continuous piston
rod, P08517 = 1)
S4D......... Differential connection, instead of postsuction
S4 .......... Injection solenoid (only at and EHV1). From EV9.32: Does not energize when all back
pressure set values are set smaller than P37242. P37242 preoccupied with 1 bar.
S6A ........ Pressure reduction nozzle
2) .......... Delay time only acts at EHV1 machines

3) .......... P35249 ... active back pressure: 0 ... pressure 0 after holding pressure
at 1 ... immeditely 1st back pressure value after holding pressure
At servo valve-controlled machines the back pressure profile is interpolated, at beginning

plasticizing with one ramp P35177 being controlled on the first back pressure stage and from
here on being interpolated linearly up to the end point of the respective next stage.
At not servo valve-controlled machines the pressure is controlled via the electronics of the
pump and the volume is run position controlled via the pump.

Version:G/11/12/7/3
Times:
Z3 .................... Plasticizing delay
Z4 .................... Cooling time
Z6 .................... Nozzle retraction delay time
P35284............. Pressure reduction time for carriage unit
P35287 ............ Delay decompression after plasticizing (for more exact positioning of C2)
P35297 ............ Delay at HLS and EHV1 between S3 and S4 actuation
P10775 ............ Delay of the deactuation of pressure and volume after decompression (after deactuation
of S24) at EHV (starting from V9.01).
Positions:
CPx .................. Cushion actual value
C2 .................... Stroke for decompression after plasticizing
SSx .................. Screw position actual value
C1 .................... Metering stroke; the stroke position for the 5 plasticzing speeds can be set on the set
value graphic image. An automatic fifth part formation of the metering stroke C1 only
results when the stroke point C1 is input 2x in succession. Otherwise the stroke profile set
before is divided up automatically in relation to the new metering stroke.
Speeds:
V24 .................. Decompression
V22.1 - V22.5 .. 5 Plasticizing speeds
P35037 ............ Minimum speed screw rotation
P35079 ............ Minimum speed decompression (set larger than 0)
Pressures:
P17 - P21 ......... Back pressures
P35103 ............ Decompression
Speed ramps:
P35176 [%] ...... Start acceleration screw speed profile
P35168 [%] ...... Start decompression
P35141 [%] ...... Braking screw speed on C1
P35189 [%/s] ... Maximum start acceleration decompression
P35187 [%/s] ... Maximum start acceleration screw movement
P35167 [%] ..... Braking decompression on C2, C4
P35188 [%/mm] Maximum acceleration/delay decompression
P35182 [%/mm] Maximum acceleration/delay screw rotation
Pressure ramps:
P35177 ............ General start ramp pressure for back pressure profile
P35192 [bar/s] .. General maximum pressure ramp as a function of time start and soft stop
P35161 [%] ...... Braking on C1
P35190 [bar/mm] General maximum pressure ramp as a function of stroke
Attention! This ramp is also effective at other movements
12.1 DECOMPRESSION PROGRAMS (SCREEN IMAGE ”PLASTICIZING”)
DECOMPRESSION BEFORE THE PLASTICIZING (1)

Is chosen with setting the screw set value C4 larger than 0. Immediately after the expiry of the
holding pressure time Z2 (beginning cooling time Z4) the screw retracts with the solenoids S24
and S10 (shut-off nozzle opens with S4B) with the speed V24. Starting from pos. C4 the
plasticizing delay time Z3 begins to run, after whose expiry the plasticizing starts.

Version:G/11/12/7/3
DECOMPRESSION AFTER THE PLASTICIZING (2)

Is switched on with setting the set value C2 bigger than 0. After end plasticizing, pos. C1
reached, the screw retracts with the solenoids S24 and S10 (shut-off nozzle does not open),
with the speed V24 the set C2 stroke. C2 must not be input as screw position, but as distance
starting from pos. C1 although in the sequence program C2 is valued as position, e.g. at the
starting condition examination for the automatic program.
The switching-on of BOTH PROGRAMS yields the following sequence:

Begin.cool.time: Decompression 1 up to pos. C4
Plasticizing delay time Z3,
Plasticizing profile up to pos. C1
Decompression 2 with stroke C2
Push-button for screw retraction

Optionally a separate key for screw retraction is provided so that the retraction occurs without
screw rotation up to position C2*. When before the screw retraction key the SIT key is actuated
and held tight, with it the retraction can be executed up to stop.
12.2 SPECIFIC BACK PRESSURE
12.2.1 BACK PRESSURE SWITCHING-OFF

When in the manual mode in the moment of the key actuation for ”Plasticizing” the key-
operated button ”SIT” is actuated, as back pressure set value 0 bar is output independently of
the back pressure values set on the screen.
12.2.2 BACK PRESSURE INTERPOLATION

The profiles on the injection unit are output to the servo valve and/or prop. valve interpolated,
i.e. the output does not occur according to the jerky setting on the screen, but in straight lines
from the end point of one stage to the end point of the next stage.
12.2.3 ACTIVE BACK PRESSURE

It is possible to switch the servovalve from the last holding pressure stage on the first back
pressure stage. Thus, when the plasticizing shall begin immediately after holding pressure, a
jumping back of the screw shall be prevented.
P35249 =0 ...... Pressure 0 after holding pressure (= standard setting)

=1 ...... active back pressure

Version:G/11/12/7/3
13 RETURN CARRIAGE UNIT

in manual mode
in manual mode
Cooling time Z4
Plasticizing
before
Return nozzle continue with

mould opening
S6 ................... Return carriage unit

S6A ................. Contact pressure relief
S10 ................. Pump stage
With built-up carriage pressure this must at first be reduced. See this chapter item
”CARRIAGE PRESSURE REDUCTION”
Pressure profile output occurs on pump actuation electronics, pressure input K1

Speed output occurs on pump actuation electronics, volume input Y1
Times:
Z4 .................... Cooling time
Z6 .................... Nozzle retraction delay time
Positions:
K ...................... Nozzle stroke in the automatic mode
J ....................... Nozzle contact point, is determined automatically
SDx .................. Nozzle position actual value
P35010 ............ Stop in front of stop nozzle at the back
Speeds:
V11 .................. Speed nozzle return in automatic mode
P35054 ............ Speed nozzle return in manual mode
Pressures:
P35085 ............ Pressure nozzle return

Version:G/11/12/7/3
Speed ramps:
P35174 [%] ...... Profile start on position J
P35142 [%/] ..... Profile stop on position K in automatic mode and max.stroke position in manual mode
P35185 [%/s].... Max. start acceleration nozzle movement, as a function of time
P35180 [%/mm] Acceleration / delay, as a function of stroke
Pressure ramps:
P35177 [%] ....... Pressure profile start K for start of position J;
P35190 [bar/mm] General max. pressure ramp as a function of stroke
P35192 [bar/s] ... General max. pressure ramp as a function of time
P35157 [bar/mm] General steep ramp on end position for position K and max. stroke pos. in manual mode
13.1 LIFTING PROGRAM
On screen image ’CARRIAGE UNIT’ ’RETRACT NOZZLE 1 AFTER Z6’
is adjustable: 0 no retraction
1 after Z6
2 before mould opening
Retraction in semiautomatic Z6 must have run down before pause time Z5 in order
mode: to retract in the current cycle.
Retraction in fully automatic When Z6 runs off during pause time, the nozzle
mode: retracts, pos. ”K” then becomes the start condition for
the next cycle.

Version:G/11/12/7/3
13.2 CONTACT PRESSURE REDUCTION
iwz4a=Z4-clamping pressure reduction time
Mold opening
iwz4b=P35274-contact pressure reduction
Mold opening
Mould opening delayed
1... Plasticizing within Z4 and before clamping pressure reduction

2... Plasticizing is interrupted
3... Plasticizing interrupts clamping pressure reduction
Before the retraction of the carriage unit and/or mould opening the contact pressure must be
reduced. The pressure value is given with set value ’P5b’ on the screen image ’Carriage unit’.
HOLDING PRES.AT DEMOLDING P5b = ... %

From suction valves opening (P35273) no parallel movement may be allowed since from this
moment the valve actuation for suction valves opening gets effective.
As for the clamping pressure reduction only an electric actuation of the reduction solenoid is
required, this occurs in parallel to plasticizing or screw retraction.
Contact presssure reduction P5b > 0: Contact presssure reduction P5b = 0:

Reduction to set pressure Reduction to idling pressure
P35283 P35284 P35285 P35284

K (P5b) K (0)
Y (P35069) Y (0)
S5 S5
S6a S6a

Version:G/11/12/7/3
14 MOLD OPENING
Concept EHV1, EHV2 and EHV3
Cooling time Z4
Pressure reduction and Nozzle

continue with
Mould
Mould opening
opening suction valves opening return
ejection
only at direct-closing before
machines
S2 .................... Mould opening, only at EHV1

S10 .................. Pump stage 1
S12A.................. Differential connection, de-energizes delayed on pos. ’A’
*) at HL machines from ES125HL the program ÇIncreased opening
force’ (screen page ÇMold opening’) can be chosen. See this chap-
ter, item 14.1.2.
S2.1 ................. Open suction valves. Remain open in automatic mode until mould is
closed again.
S2.2 ................. Pressure reduction
SEA ................ High speed switching-off starting from EHV2, remains energized in
automatic mode until mould has closed on G2 again.
The speed opening profile is output on the proportional valve of the clamping unit. The
pressure opening profile is output on the pump electronics K1. If no proportional valve is
mounted on the clamping unit, the speed profile is output on the pump electronics Y1.
Times:
P35273............. Actuation suction valves opening
P35274............. Pressure reduction before opening
P35275............. At Q/P and HLS1: Delay time mould opening in order to enable a start-up without jerks
for mould opening (speed and pressure actuation on ”0”).
At EHV: Delay of the analog outputs after setting the suction valve solenoid
P35286 ............ Deactuation delay of S12a and/or S1 and/or SEA
P17977 ............ delays the release for mould closing in manual and automatic mode (in 1/100mm). To
be set at least so long until S2 is de-energized. From case to case S2 is de-energizing-
delayed by a free-wheel diode dependent on the mechanical situation

Version:G/11/12/7/3
Positions:
B ...................... Toggle lever locked, SFX = 0
W4 ................... Start 2nd opening speed
KO1 ................. Intermediate stop move out core 1
W2 ................... Start 3rd opening speed
A ...................... Opening stroke
A1 .................... Ejector start position
A2 ................... Start air blowing, air valve 1
A3 ................... Start air blowing, air valve 2
P06552 ............. Braking position before ’A’, in order to be able to set as steep as possible ramps
SFx .................. Platen position actual value
SKx .................. Toggle lever pos.act.value
P35009 .............. Stroke tolerance before start-up from stop point
Speeds:
V6 .................... 1. Opening speed (in the ’Set-up’ limited with P35042)
P35036 ............ Minimum speed mould opening
P35066............. Speed suction valves opening (direct-closing machine)
P35077 ............ Volume before mould opening (only at Q/P and HLS hydraulic system
P35072 ............ 1. Opening speed on B8
Pressures:
P35088............. 1. Opening pressure; in the set-up mode P35082 (’counterpessure’ starting from ES100
without prop.valve)
P35081............. 2. Opening pressure; in the set-up mode P35082 (’counterpessure’ starting from ES100
without prop.valve)
P35114............. Pressure suction valves opening (direct-closing machines)
P35126 ............ Pressure before mould opening (only at Q/P and HLS hydraulic system
Speed ramps:
P35172 [%]....... Profile start on position B, KO1, KO2, KO3
P35145 [%] ...... Pressure and speed - mould braking at emergency stop/soft stop
P35184 [%/s] .... Max. start acceleration mould movement, as a function of time
P09320 [%/s] .... Max. start acceleration, as a function of time for output on pump at EHV
P35135 [%] ...... Switchover V6 - V7
P35140 [%] ...... Switchover V7 - V8
P35143 [%] ...... Braking on forward position to ’A’, up to ’A’ with minimum speed P35036
P35136 [%] ...... Braking on KO1, KO2, KO3
P35160 [%] ...... Braking on b8 at mould opening
P35179 [%] ...... Max. acceleration / delay, as a function of stroke
P09319 [%/mm] Max.acceleration /delay, as a function of stroke for output on pump at EHV
P35193 [%/mm] General outset ramp Y for suction valve opening at direct-closing machines.
Pressure ramps:
P35177 [%] ....... Profile start of position B, KO1, KO2
P35192 [bar/s] ... General max. pressure ramp, as a function of time
P35144 [%] ....... Braking on A
P35162 [%] ....... Braking on KO1, KO2, KO3
P35190 [bar/mm] General max. pressure ramp, as a function of stroke
P35194 [%/s] .... General outset ramp K for suction valve opening at direct-closing machines.

Version:G/11/12/7/3
14.1 PROGRAM ITEMS
14.1.1 INCREASED OPENING FORCE

At machines with differential connection for mold opening (realized from ES125) the program
ÇIncreased opening force’ can be chosen. At the works at these machine types the parameter
P35491 is set = 1.
P35491 = 1 ........... Differential connection at mould opening

P35491 = 0 ........... Differential connection at mould closing
Screen page ’Mould opening’:

INCREASED OPENING FORCE YES/NO WAK= . . . . . mm
”YES” = upto position WAK it is opened without S12A (yields increased
opening force due to larger piston area), only from WAK S12A
energizes. Mold closing occurs without S12A.
”NO” = the mould opens with S12A (small, differential area of the pis-
ton) up to pos. ”A”. Mould closing occurs without S12A.

Version:G/11/12/7/3
15 ADVANCE AND RETURN EJECTOR

Ejector Ejector
advance return
Cycle end
Ejector with 2-stage profile (option)
P25 P26
36134 36134 36134
35177 P27 P28 35177
V25 V26
35169 35163 36134 36134 35170

V27 V28
35158
35153 SAx 35154 SAx
L L3 L1 L L4 L2 L1
ZAV ZA
ZA Z5
10770 10770
S 25 S26
S 10 S10
Ejector for- Ejector back-

ward ward
Cycle end in automatic mode

B R 11 _192
S25 .................. Ejector fwd.

S26 .................. ejector retracted
S10 .................. Pump stage 1
Pressure (K) and speed profile (Y) are output on the pump electronics. In case of optional use
of a prop. valve (YA) the speed output occurs there identically to the output on the pump
electronics, but with separate ramps for maximum acceleration for Y

Version:G/11/12/7/3
Times:
ZA .................... Ejector residence time
ZAV .................. Ejector forward delay time
Z5 ..................... Pause time
P10770 ........... starting from V9.01: Delay of the movement beginning in manual mode because of high
flushing quantity at EHV
Positions:
L ....................... Ejector retracted
L1 ..................... Ejector forward
L2 .................... Shaking position (is drawn along with L when L is set larger than L2)
L3 ................... Start 2nd speed ejector forward
SAx .................. Ejector position actual value
Speeds:
V25 .................. 1. Speed ejector forward
V26 .................. ejector retracted
V27 .................. 2. Speed ejector forward
P35075 ............ Volume in ’Set-up’
Pressures:
P25 .................. Ejector fwd.
P26 .................. ejector retracted
P35124 ............ Pressure in ’Set-up’
Speed ramps:
P35169 [%]....... Profile start ejector forward
P35170 [%]....... Profile start ejector return
P35153 [%]....... Braking on L1
P35154 [%]....... Braking on L
P35158 [%]....... Braking on L2
P35183 [%/s].... Max. start acceleration, as a function of time
P35178 [%/mm] Max. acceleration / delay, as a function of stroke
P19639 [%/s].... Max. start acceleration for Y at operation with prop. valve, time-dependent
P19638 [%/mm] Max. acceleration / delay for Y at operation with prop. valve, stroke-dependent
P35163 [%]....... Braking on L3
Pressure ramps:
P35177 ............ Genral pressure profile start for ejector forward and return.
P36134 ............ .Braking on L1, L2 and L
P35192 ............ General max. pressure ramp, as a function of time
P35190 ............ General max. pressure ramp, as a function of stroke
15.1 EJECTION MONITORING (SCREEN PAGE ”EJECTOR”)

A contact of a check weigher, ejection plate or light beam guard can be evaluated with digital
input bLS.
By the input of the figure ”1” into the cursor field ”YES/NO” this program is activated. It only
acts in the automatic mode. At operation with ejector the ejection monitoring gets sharp from
reaching the position ’A1’ - start ejector advance -, at operation without ejector from beginning
mould opening. The falling-out part must actuate the ejection detector and make it free again
(impulse) in order that a next cycle can be introduced.
The polarity of the detector signal can be determined with P35486:

Version:G/11/12/7/3
P35486 = 0 ... -Impulse of bLS
P35486 = 1 ... -Impulse of bLS
In a case of error appears the message ”EJECTION MONITORING” and the alarm lamp lights.
When the light beam guard switches in the pause time (=demoulding time), the next cycle is
started immediately. Also the ejector shaking is interrupted if the light beam guard switches.
15.2 SET-UP MODE EJECTOR

Speed:
Analog output with volume P35075, but if the screen value for volume V25, V26 or V27 is set
smaller than the fixed set-up volume, the smallest set value is output.
When V25, V26 or V27 < P35075, V25, V26 or V27 is valid27
otherwise P35075 is valid as set-up volume
Pressure:
Analog output with pressure P35124, but if the screen value for pressure P25 or P26 is set
smaller than the fixed set-up pressure, the pressure P25 is output.
When P25 or P26 is < P35124, P25 or P is valid26
otherwise P35075 is valid as set-up pressure
16 FURTHER PROGRAM ITEMS
16.1 SAFETY KEY SIT

The safety key SIT, executed as key-operated switch and mounted beside the EMERGENCY-
OFF key, has the following functions:
On machines delivered to France SIT must also be actuated with closed safety gate for
core and ejector movement.
With swivelled-out injection unit (limit switch bE52 actuated) the movements carriage
forward, carriage unit return, plasticizing, screw retraction and injection are locked.
When SIT is switched on, all movements on the injection unit are allowed. The injection
speed is limited to 20 mm/s (parameter 35058), however.
When is the limit switch mounted? See the same chapter, item 11.7, ÇSwivel out
unit’.
When in manual mode the SIT key is pressed and afterwards the push-button
”Plasticizing” is actuated, always with back pressure equal to zero is output.
Core and mould opening movements possible at set-up without locking when program
’Cancel core interlocks’ (screen page ’Cores’) is switched on.
At rotary table VHSO machines: Mould opening in set-up possible with SIT for loosening
the possibly jammed crashdown safety.
In the manual mode the SIT together with the injection key allows the injection with
normal profile also with not applied nozzle or open mold.

Version:G/11/12/7/3
At multi-color machines:
Start of the premolding cycle (Start button + SIT)
When a core is set in the ENGEL standard core-pull program as ÇSliding split mold
core-pull’, the actuated SIT allows the mold closing without moved-out core.
In the program ÇCycle freely programmable’ with activated single-dial control the whole
mold closing and/or mold opening process can be released with all core movements by
actuating SIT at the same time with the push-buttons for mold closing and/or mold
opening (Manual mode).
In the program ÇAutomatic cylinder cleaning’ in the manual mode a purging process is
released with SIT and at the same time soft key F6 ÇPush-button Cylinder cleaning’.
Ejector coupling in the set-up program:
Couple ejector with SIT and push-button ÇCouple ejector’.
Ejector forward and return with SIT and respective push-button, even when ejector
is neither coupled nor uncoupled.
High speed mounting device in the set-up program:

Mounting and/or dismounting with SIT and respective push-button
Mold opening, when not mounted, with SIT and push-button ÇMold opening’
reduced clamping force build-up, when not mounted, with SIT and push-button
ÇMold closing’
In special programs SIT can be programmed for certain functions. See then in the
special program documentation.
16.2 HYDRAULIC HIGH SPEED MOULD MOUNTING DEVICE
Limit switch:
DI32041 Switch: Mould mounted, moving mould fixing platen
DI32042 Switch: Mould mounted, fixed mould fixing platen
DI32039 Switch: Mould dismounted, moving mould fixing platen (often blank)
DI32040 Switch: Mould dismounted, fixed mould fixing platen (often blank)
Depending on the mechanical execution these inputs are executed with series arrangements
of 2 or 4 limit switches.
For mould mounting/dismounting separate push-buttons are provided for both mould fixing
platens.
outputs:
DO5053 Output dismounting, moving mould platen
DO5054 Output dismounting, fixed mould platen
DO5081 Output mounting, moving mould platen
DO5084 Output mounting, fixed mould platen
For safety-technical reasons the solenoids for high speed mounting device de-energize when
opening the safety gate. Therefore a solenoid with locked mid-position (=2 magnets) is used
whereby the solenoid remains actuated after reaching the end position. When opening the
safety gate and/or when the safety gate stands in undefined position (error 84, ’Safety gate
limit switch defective’), all solenoids of the high speed mounting device are deactivated.
When the high speed mounting device is in a defined end position, the appertaining output is
activated automatically when the safety gate is closed again and/or no error of the safety gate
exists.

Version:G/11/12/7/3
When putting into operation the mounting device is defined by means of parameter P35475
(Set-Up):
P35475 = 0 no mounting device control. Limit switch inputs need not be bridged
P35475 = 1 simple control, only mounted situation monitored (DI32041, DI32042).
one magnet per mould fixing platen
Automatic start only possible at ’mounted’,
Mould closing allowed at DO5053/DO5054 = 0, deactive, and DI32041, DI32042 =1 or closing
allowed at DO5053/DO5054=active and DI32041, DI32042 = 0, otherwise alarm message ’HIGH
SPEED MOUNTING DEFECTIVE’,
Mould opening in not mounted situation with decreased speed (P35067 = typ. 20%) possible.
The operator must control optically whether all wedges are moved out.
Mould closing and mould opening is only possible in ”mounted” or ”dismounted” state.
P35475 = 2 double control, mounted and dismounted situation monitored,
one magnet per mould fixing platen
Automatic start only possible at ’mounted’,
Mould opening and mould closing only possible when it is mounted or dismounted and/or: Clos-
ing allowed at DO5053/DO5054 = 0 deactive and DI32041, DI32042=1 or closing allowed at
DO5053/DO5054=active and DI32039/DI32040=1, otherwise error message ’HIGH SPEED
MOUNTING DEFECTIVE’.
P35475 = 3 simple control, only mounted situation monitored (DI32041, DI32042).
Function like 1, but 2 magnets per mould fixing platen
P35475 = 4 double control, mounted and dismounted situation monitored,
Function like 1, but 2 magnets per mould fixing platen
Attention!
After setting the parameter P35475 the control voltage must be switched
off and on again for the purpose of initialization !
HINTS:
When mould dismounting is activated and the control voltage is switched off and on
again, the dismounting is activated again automatically.
With dismounted mould no automatic cycle can be introduced.
With dismounted mould mould opening is only possible with simultaneous actuation of
the SIT key. Error message 51, ’MOULD NOT MOUNTED’.
Conditions for mounting and/or dismounting:

Choose set-up mode
Safety guard closed
Mould closing
Return injection unit on safety position DSP (screen page ’Carriage unit’)
P19612 [mV] = Millivolt value for setting the safety position DSP on nozzle stroke.
Actuation of the push-buttons for mounting and/or dismounting at the same time with
the SIT key
The push-button for mounting (and SIT) must remain actuated so long until both display
tags on the screen page ”Mold parameters” light up in the column ”mounted” (for
approx. 3s). Thus it is guaranteed that the wedges move in completely.
The actuation of solenoid and pump remains as long as the push-buttons are actuated.
After-running time = parameter P36190.

Version:G/11/12/7/3
Note!
The following measure is recommended when mounting:
After the mold halves have been applied in the set-up mode and before now the clamping
wedges are moved in, one switches over to manual mode and builds up a clamping force of
approx. 3% with the push-button ”Mold closing”. Afterwards switch to set-up mode again and
mount the mold.
For mould mounting/dismounting separate push-buttons are provided for both mould fixing
platens.
When mould dismounting is activated and the control voltage is switched off and on again, the
dismounting is activated again automatically.
With dismounted mould mould opening is only possible with simultaneous actuation of the SIT
key.
Image selection key
MOUNTED DISMOUNTE DISMOUNT MOUNT

H I G H S P E E D M O L D M O U N T I N G S Y S T E M
MOVING PLATEN DI 982 ❒❒ DI 984 ❒ DO 980 ❒ DO 978 ❒ 1)
FIXED PLATEN DI 981 ❒❒ DI 983 ❒ DO 979 ❒ DO 977 ❒ 1)
M
MOLD- PARAME- CYCLE TIME PROD.DATA COL- SELECTABLE PROCESS ANALY-
TERS LECTION TEXT PAGE SIS
Display limit switch Display limit switch plus

after-running time
1) The signal designations vary. They depend on the current wiring of the machine (electric plan and/or help text)
16.3 HANDLING SYSTEM CONNECTIONS
16.3.1 ENGEL HANDLING SYSTEM ERC

Variant ÇHandling system integrated’
The control CPU of the handling system is integrated in the machine control system. Thus it
also communicates release and blocking signals via the control bus system with the main
CPU. The switch for the bus communication must be switched on.
The state of the release and blocking signals can be made visible by activating the screen
page ’Handling system releases’. Then also an individual configuration of the core release
signals is possible. See to it item ’Signals setup for core-pull releases’.

Version:G/11/12/7/3
Variant ÇHandling system Stand Alone’

The handling system possesses a separate control unit in the handling system control cabinet.
This control unit communicates with the machine control unit via the standardized Euromap 12
interface. See item ’Euromap 12’.
16.3.2 EUROMAP 12
With parameter P35470 (and/or on screen page ”MACHINE_SETUP”) the EUROMAP 12
program (the above inputs become effective and display of the following screen page) is
activated:
P35470 =0 No interface action, no screen page for Euromap 12

=1 With handling system screen page for Euromap 12 can be called up with the image
selection key ’Handling system’
Screen page + F3
E U R O M A P 1 2 2000-10-09 14 33
M O L D O P E N I N G S T R O K E A = 0 . 0 m m ❒
M I N . O P E N . S T R . H A N D L . S Y S T A H = 0 . 0 m m ❒
T A K E O F F - / I N T E R M E D . S T O P A F Z = 0 . 0 m m ❒
M O L D P O S I T I O N A C T U A L V A L U E S F x = 0 . 0 m m
T A K E O F F W I T H M O L D I N T . S T O P N O
Component with ejector function 0 Ejector
F R O M S T A T E
H A N D L I N G M A C H I N E
AWV ❒ E J E C T O R F O R W A R D ❒ D L 1
AWZ ❒ E J E C T O R R E T U R N ❒ D L
KEE ❒ C O R E I N ❒ S K E
HOF ❒ KEA ❒ C O R E O U T ❒ S K A
FOF ❒ HSP ❒ M O L D O P E N I N G ❒ D A ❒ S H E
B63 ❒ HSP ❒ M O L D C L O S I N G ❒ S B ❒ A A
M
EUROMAP 12
Attention!
After changing the parameter the control unit must be switched off and
on again.
For the connection of a handling device communication signals are needed:
By applying +24VE on the above inputs (FROM THE HANDLING SYSTEM) the respective
movements are allowed.
Outputs (STATE MACHINE) deliver +24V to the handling device in the active state.

Version:G/11/12/7/3
Digital inputs and appertaining error messages

Digin Signal Function message
DI32052 AWV Release advance ejector 5457
DI32053 AWZ Release return ejector 5458
DI32054 HSP Release mould closing / mould opening 5459
DI32055 KES Release move in cores (injection position) 5463
DI32056 KEA Release move out cores (demoulding position) 5462
DI32057 FOF Release mould opening starting from intermediate stop posi- 5460
tion
DI32058 B63 Release mould closing up to position ”B” 5461
DI32607 HOF Handling system OFF, signal at handling system switched off
When one of the above mentioned movements in the manual mode is interrupted due to a
missing handling system signal, the collective error message 95, ”HANDLING SYSTEM
INTERLOCK” appears and in addition a message which movement is interrupted. See table
above.
.
In automatic mode no error message occurs. The movement waits so long until the release
signal is active.
Signal HOF: Message that handling system is switched off. The release signals are bridged in
the software due to HOF (releases given).
Digital outputs:
Digout ... Signal ... Function
DO5023 ... DA ... Mould open, position ”A” reached
DO5026 ... SB ... Mould closed, position ”B” reached
DO5024 ... DL ... Ejector retracted
DO5025 ... DL1 ... Ejector forward
DO5061 ... SHE ... Start move in handling system, position ”AFZ” reached
DO5049 ... SKE ... Cores moved in, in injection position
DO5050 ... SKA ... Cores moved out, in demoulding position
DO5014 ... AA ... Rejects message
Starting from stroke position AFZ at mould opening release for moving in handling system
(signal SHE active) exists).
Program ’Take-off with mould intermediate stop’:

Mould opening stops on stroke position AFZ and gives release for moving in handling
system, signal SHE
with signal FOF, from the handling system, the mould opening is continued
Important hint:
Attention!
Signal in and outputs of the electric equipment on the injection mould-

ing machine may only be wired tied. In case of other use and appearing
injury to persons, plant or machine damage ENGEL cannot be made lia-
ble.
At the connection of peripheral equipment to the injection moulding
machine the owner has to take care that no movements dangerous for
persons can arise. This can be achieved e.g. with suitable safety hoods.

Version:G/11/12/7/3
16.3.3 SIGNALS SETUP FOR CORE-PULL RELEASES

For ENGEL ERC handling system and for EUROMAP 12 interface.
To each core-pull in addition to the standard releases separate release and inhibiting signals
for moving out and/or in can be allocated.
Thus it is possible to control each core-pull alternatively via different signal types from the
handling system:
via the standard signals KEE, KEA
via the ejector signals AWV, AWZ
via individual signals release1, release2, etc.
no (without) release, the cores moves independently of the handling system
Also several core-pulls can be controlled via one of these separate signals.
See screen page below.
With the setting of the parameter P14289 = 1 the function key ’Handling system releases’
appears on the screen page ’Cores’, with which the screen page is called up for the
configuration of the signals and status display.
Image selection key + F3 (and/or Fx at more than 4 core-pulls)
HANDL.SYS.RELEASES CORES 2000-09-25 14:49
SELECTION RELEASE STATUS OUT IN

STANDARD DIxxxx ❒ ❒ DOxxxx DIxxxx ❒ ❒ DOxxxx
EJECTOR DIxxxx ❒ ❒ DOxxxx DIxxxx ❒ ❒ DOxxxx
CORE 1 0 Standard RELEASE 1 DIxxxx ❒ ❒ DOxxxx DIxxxx ❒ ❒ DOxxxx
CORE 2 4 Release 2 RELEASE 2 DIxxxx ❒ ❒ DOxxxx DIxxxx ❒ ❒ DOxxxx
CORE 5 1 without release. RELEASE 5 DIxxxx ❒ ❒ DOxxxx DIxxxx ❒ ❒ DOxxxx
M
MOVE IN CORE MOVE OUT CORE HANDL.SYS.
1-4 1-4 RELEASES
The settings are exemplary
Note
At EUROMAP 12 interface the communication signals are used in form of digital inputs
(DIxxxx) and/or digital outputs (DOxxxx).
At an ERC interface the signal exchange occurs via data communication; on the screen only
”Tags” are displayed.
For example in the above screen page

Core 1 is controlled with the signals KEE and KEA (standard)

Version:G/11/12/7/3
Cores 2 and 3 are controlled with ”Release 2”, also the message to the handling system
(Doxxxxx signal) is only activated when both cores are in end position
Core 4 is controlled by the signals ’Release 1’
Core 5 moves independently of the handling system
Selection possibilities:
Number: Release:
0 ... Standard
1 ... no release
2 ... Ejector
3 ... Release 1
4 ... Release 2
5 ... Release 3
6 ... Release 4
... ... ...
Output and input occupation

The designations DIxxxx and/or DOxxxx in the above screen page are replaced on the control
screen page by the current terminal designation of the respective machine in order to be
exactly identical with the electric plan and the text in the help system.
At integrated handling system, where no digital in and outputs are needed for the
communication, only the luminous marks are represented without designator.
Function of the separate core-pull releases:

In order to be able to initiate a movement at a core-pull, the respective appertaining release by
the handling system must be given during the whole movement.
When the release is missing, the movement is stopped. When the release exists again, the
core starts anew. Error 95, ’HANDLING SYSTEM INTERLOCK’ is set in manual mode when
the release is missing. In certain situations additional error messages are output for the more
detailed explanation.
inputs:
Signal number: MF number: Function:
DI60 DI32055 ... Euromap 12: Release move in core(s) (Standard)
DI61 DI32056 ... Euromap 12: Release move out core(s) (Standard)
DIxxxx DI32895 ... Euromap 12: Release 1, move in core
DIxxxx DI32894 ... Euromap 12: Release 1, move out core

Version:G/11/12/7/3
outputs:
Signal number: MF number: Function:
DO62 DO5049 ... Euromap 12: Cores moved in (Standard)
DO63 DO5050 ... Euromap 12: Cores moved out (Standard)
DOxxxx DO5854 ... Euromap 12: End position 1, core moved in
DOxxxx DO5853 ... Euromap 12: End position 1, core moved out
Parameters:
Group of variables core service
P14289 [] ... Handling system releases for cores:
0 = Standard release
1 = Individual releases and activation of the screen page ’Handling system
releases’
16.4 SAFETY GATE

For the switching and monitoring elements of the safety gate on the operator side the screen
page ’Safety gate’ (function key at ’Mould opening’) is installed.
See operator’s manual, chapter (3), ’Safety gate’.
The automatic safety gate opening function described in the following is only possible in the
semiautomatic mode.
For the pneumatic and/or electric safety gate operation the following parameters must be set:
P35472 ... Kind of the function

0= manual, system pressureless
1= pneumatic function (special equipment)
2= electric function (special equipment)

Version:G/11/12/7/3
After changing the parameter P35472 the control unit must be switched
off and on again.
P35474 ... Automatic start selection

0= Actuate start key TMS 2x
1. time for gate closing (or TMGZ)
2. time for automatic start after gate closed
1= Actuate start key TMS 1x for safety gate closing;
Cycle starts starting from closed safety gate position.
The setting P35474 = 1 does not correspond to the CEN regulations and
may only be made after obtaining a permission from the local safety au-
thority.
control
The control unit monitors the limit switches/inputs bE1 and bE2 for antivalence (inequality).
Signal transition within the fixed time P35254 (0.1s monitoring time for safety gate limit switch
E1/E2).
In a case of error error 84 ”SAFETY GATE LIMIT SWITCH DEF.” appears with motor stop,
alarm lamp and switchover to manual mode. Motor start only possible after error elimination!
For reasons of safety monitoring programs of this kind lie in the EPROM memory failure-safe
against program loss.
Error acknowledgement
In a case of error the error state is stored.
For the error elimination an error-free movement cycle of the safety gate must occur, i.e. the
signal states must change within the fixed time P35254 corresponding to the above survey. If
an error appears, this is not reset by switching the control voltage and/or the main switch off/
on..
Pneumatic safety gate
Function elements:
outputs: SGN ... Pneumatic main valve
0 = System relieved, protection can be led manually
1 = System under pressure, pneumatic operation.
SGA ..... Safety guard open
SGZ ..... Close safety gate fast
inputs: BSGN ... Pneumatic main switch (no digital input, but marker)
0 = Manual mode, system relieved
1 = Pneumatic operation
TMGA .. Push-button safety gate opening
TMGZ .. Push-button safety gate closing
E1 ........ closed contact (+24V) at SG closed
E2 ........ open contact at SG closed
E30 ...... Close safety gate slowly (SGA and SGZ are de-energized)
DWR .... Pressure wave safety strip in direction opening (make contact)
DWV .... Pressure wave safety strip in direction closing (make contact)
After switching on the control unit the pneumatic system remains at first pressureless, no
function element is active.
Only after actuating a button (TMGA, TMGZ, TMS) SGN energizes at the same time with SGA
and/or SGZ. Thus the system is filled with compressed air and carries out the chosen
movement immediately.
During the filling phase at first slow, later, after connecting through a safety valve, normal. This
safety valve connects through from filling beginning (SGN active) only after reaching a certain
pressure (approx. 80%) in order not to get too strong, possibly unwanted movements during
the filling.

Version:G/11/12/7/3
This process repeats itself in each case when the pneumatic main control element SGN has
de-energized and afterwards a pneumatic movement is chosen.
SGN de-energizes at:

EMERGENCY-OFF: All safety gate outputs deactuate at EMERGENCY-OFF
BSGN on ‘MANUAL’: Pneumatic main switch on ‘MANUAL’
DWR is actuated (make contact)
DWV is actuated (make contact)
The gate can be opened and/or closed with the push-buttons in each mode of operation
(manual, automatic). An opening in the automatic mode before end injection (holding
pressure) produces a total stop of the cycle, switchover to manual mode and the error 59,
’SAFETY GATE INTERRUPTS CYCLE.’.
An opening from beginning cooling time leads to cycle stop depending on programmed safety
regulation. See item ”SAFETY PRESCRIPTIONS”.
On actuating the safety strips DWR and/or DWV (make contact) an immediate, short
countermovement of the gate appears. All safety gate control elements de-energize then, the
system gets pressureless. A slight after-running of the gate is possible. From reached bE1
(safety gate closed entirely) the countermovement is suppressed. The actuated DWV locks in
each case immediately all movements on the clamping unit.
When bSGZB is reached during the closing of the gate (+24V, remains until SG closed
actuated), SGZ de-energizes. Thus the gate continues to close slowly via difference area.
When the open position of the safety gate does not reach beyond the leaving of the bSGZB,
e.g. at closed mould, the open safety gate being applied on the moving mould platen, a timer
gets active when closing the gate (TMGZ = 1), after whose expiry SGZ de-energizes. (Timer
replaces the bSGZB function. P35280 = time in 1/10s).
Electric safety gate

outputs: inputs:
SGA .. Open safety gate fast BSGN .. Safety gate main switch (no digital input, but
marker)
0 = man. operation,
1 = Electric operation
SGAB.. Open safety gate slowly energizes TMGA .. Push-button safety gate opening
in addition to SGA
SGZ ... Close safety gate fast TMGZ .. Push-button safety gate closing
SGZB.. Close safety gate slowly ener- E1 .... closed contact (+24V) at SG closed
gizes in addition to SGZ
S51 ... Phases switching-off at safety E2 ... open contact at SG closed
gate braking
bSGA... Safety gate open (SGA and SGAB de-energize)
bSGAB.. Open safety gate slowly (SGA and SGAB)
bSGZ... Safety gate closed (SGZ and SGZB de-ener-
gize)
bSGZB.. Close safety gate slowly (SGZ and SGZB)
DWR ... Pressure wave safety strip in direction opening
DWV ... Pressure wave safety strip in direction closing
In principle, the sequence of the movements of the electric safety gate corresponds to that of
the pneumatic one. The function of a main switch similar to SGN is omitted at the pneumatic
gate. The movements are carried out with an electric motor (Dahlander) via toothed belts.
The switch bSGN switches from manual mode to electric mode:

bSGN = off ... Gate can be moved manually, the electric brakes are released
bSGN = on ... electric mode
When introducing movements by means of push-buttons or in the automatic mode the electric
brakes are released and the movements are carried out correspondingly.
On actuating the safety strips, on reaching the closed (bE1) and/or open (bSGA) position the
motor stops, the brake moves in.

Version:G/11/12/7/3
On reaching the brake positions bSGAB, bSGZB in addition to the moving solenoids the
braking elements SGZA and/or SGZB energize, with which the Dahlander motor switches to
less speed.
Also the start-up of the movements occurs as a function of time via lower speed of the
motor:
P35289 ... Safety gate start time for slow opening
P35290 ... Safety gate start time for slow closing
P35280 ... Time of the phases switching-off at braking
The braking and end position switches move along with the mould platen, i.e. that at the
opening of the safety gate during or before the mould opening movement the gate runs into
the platen stop where it is braked at first and is stopped then. From the stop moment a delay
time starts to run (P35288), after whose expiry the safety gate starts again.
In special cases for the electric safety gate an opening delay time is built in, which can be set
so that the mould open position ”A” is reached at the same time with the safety gate open
position ”bSGA”, through which a running of the gate into the mould platen is avoided.
After switching on the control voltage the open gate must be closed at first (E1 actuated) in
order to be able to introduce the running-into movement (safety measure against unallowed
complete opening of the gate when this has been run further than up to the mould platen stop
before switching off the control voltage.
The switchover from manual to automatic can only be carried out at closed safety gate. The
error message 190, ’CLOSE SG MANUALLY’ indicates this.
16.5 CHARGE AMPLIFIER

Special equipment !
Charge amplifiers transform test signals of charge sensors into electric voltage. Here at
injection moulding machines one applies this possibility in order to record mould cavity
pressures, to display and to monitor courses.
The models Kistler LV5039 and LV5049 SmartAmp deliver the measuring signal in 2 voltages
ranges to the control unit, which switches over the ranges, calibrates the measuring signal and
causes the release (resetting) of the charge amplifier.
As opposed to LV5039, LV5049 offers the function of the automatic switchover to holding
pressure due to a switchover point recognition self-learned in the process.
Options of the amplifiers:

5039A221Q03 with test function Kistler designation 5039A221-Y42
5049A221Q03 Smart Amp with test function Kistler designation 5049A221-Y40/Y42
221 means: 2 ... large measuring range =20000

2 ... small measuring range = 5000
1 ... TNC bush (Voltage output -10V up to +10V)
When using sensor cables with BNC plug,

like used at type 50x9A222,
an adaptor from TNC bush on BNC bush must be used.
(Engel article number 02220-7016)
About setting and operation it can be read up in the operator’s manual, chapter 6.
Measuring ranges LV5039 and LV5049:

5000: +10 Volt at 5000 pC (Pico-Coulomb)
20000: +10 Volt at 20000 pC

Version:G/11/12/7/3
Resolution of the test signal at LV5039 and LV5049:

Device supplies: 0 to +10 Volt
12 Bit resolution olf the control system: 0 to 4095 bit
Range 5000 pC: 10 V corresponds 5000 pC
10 V corresponds 4095 bit
e.g.: Sensitivity = 9 pC / bar:
so max. 5000 / 9 = 556 bar meßbar
10 V / 556 bar = 18 mV / bar
4095 bit / 556 bar = 7.3 bit / bar
Range 20000 pC: 10 V corresponds 20000 pC
10 V corresponds 4095 bit
e.g.: Sensitivity= 2,5 pC / bar
so max. 20000 / 2,5= 8000 bar meßbar
10 V / 8000 bar= 1,25 mV / bar
4095 bit / 8000 bar= 0,5 bit / bar
16.5.1 LV5039
Charge amplifier 5039A221Q03 with test function
+24V
PS244 I = ~30mA
0V
AR 181,
AR281, and/ Uout
or AR 101 *)
Upeak
DO 321 (2nd Test

card)
DO 321 (2nd Range

card)
Connection pin plug on
DO 321 (2nd Operate the 5039 A221-Y42
card)
-
Mould cavity pressure transducer
*) at AR101 connections Ai7 + / Ai7 -
16.5.2 LV5049 SMART AMP

When using the LV5049 in its whole function volume an extended digital interface is required:
control unit LV5049

dokres (DO5046) ===> OPERATE activates the measuring function
dokber (DO5047) ===> RANGE Range switchover
dok_test (DO5530) ===> TEST Release of the test function
dok_sens (DO5531) ===> SENSITIVITY Switchover threshold in learning phase
dik_fix (DI32544) <=== SL/FIX Signal switchover point

Version:G/11/12/7/3
Sensitivity output SENSITIVITY II (DO5531):

The Sensitivity output sets the threshold for the fixed switchover at the 1st shot of the learning
phase of the 5049. Depending on the sensitivity of the sensor the control unit configures the
Sensitivity input of the 5049 in order that at the first shot it is always switched over at approx.
100 bar.
Realization:
When an amplifier sensitivity of smaller than 5.00pC/bar and/or 5.00pC/N (depending on the
selected transducer type) is set, the output 5531 is set. At the same time the selection of the
large measuring range (20000pC) is locked, and/or it is set down to the small range of
5000pC.
fixed switchover
Sensitivity output Sensor Range Range
at the 1st shot
high 2,5 pC/bar II *) 8000 bar approx. 100 bar

(e.g. 6158A..., 6159A..., 6190A...)
high 2,5 pC/bar II 2000 bar approx. 100 bar

(e.g. 6158A..., 6159A..., 6190A...)
low 9,4 pC/bar I 2000 approx. 100 bar

(e.g. 6157B..., 6152A...)
low 9,4 pC/bar II 500 bar approx. 100 bar

(e.g. 6157B..., 6152A...)
*) forced small area

Range I = 20000pC/bar
Range II = 5000pC/bar
Charge amplifier 5049A221Q03 with test function
DO 321 (2nd
card)
AR 181,
AR281, and/
or AR 101 *)
DI325
2.Board
PS244 I = ~60mA
PS244
*) at AR101 connections Ai7 + / Ai7 -

Version:G/11/12/7/3
16.6 POSITION MONITORING

The position monitoring tests position variations of a movement when the movement is not
activated by the control unit.
Outlet:
Every 2 seconds it is checked whether the movement is actuated or not. When the movement
is actuated, the actual position is stored, the monitoring is ineffective then.
With the end of the movements the actual value is stored once again after 2s delay. From this
moment then the actual value is checked with the stored value until a movement is recognized
again.
If the difference of actual value and stored value exceeds the set tolerance, an error message
is written out, the current cycle is stopped and the motor is switched off.
During a mould height adjustment movement the position monitoring of the mould is switched
off.
P35022 ... [mm10] Stroke position monitoring at standstill mould stroke

0 = off, >=1 = on
P35023 ... [mm10] Stroke position monitoring at standstill ejector stroke
0 = off, >=1 = on
Error 146 ... ”MOLD STROKE POS”
Error 147 ... ”EJECTOR STROKE POS”
16.7 SOCKET / COOLING WATER SWITCHING-OFF
2 Program possibilities:
1) In the normal case the output DO_STAB is always active and switches on sockets
connected to it and/or a cooling water valve. In case of malfunctions which entail a
machine standstill DO_STAB de-energizes time-delayed (P35298). With actuating
the PU key DO_STAB connects through again. An actuation of the PU key during
that delay time prevents a switching-off of DO_STAB.
2) DO_STAB is switched directly with the pump motor(s). Digital input’Star-delta’ DITD
= 1 ---> DO_STAB = active.
Parameters: P35298 ... Switching-off delay time in 0.1sec.

P35493 ... 0 = without, 1 = with switching-off, 2 = switching-off directly with
motor off
In many cases the socket switching-off output DO_STAB is multiplied. See electric plant of the
respective machine. The function of each output corresponds to that of the DO_STAB.
DO5048 Socket switching-off 1 ( = DO_STAB)

DO5167 Socket switching-off 2
16.8 ACOUSTIC WARNING SIGNAL

In semi or fully automatic mode with the appearance of an alarm signal an acoustic warning
signal reacts at the same time with the warning light (FS).
The actuation of an optional touch-sensitive key on the front panel or the expiry of an
adjustable time delete the message again, the alarm lamp remaining uninfluenced.
P8393 maximum duration of the acoustic warning signal

P22591 Interval type: 0 = interval, 1 = duration

Version:G/11/12/7/3

Version:G/11/12/7/3
TEMPERATURE CONTROL (4)
1 GENERAL
1.1 VARIANTS:
The temperature modules fulfill the most different temperature control tasks in the injection
moulding process.
TT081 ... 8 Channel, Fe-Cu-Ni couple

PP081 ... 8 Channel, PT100 couple
TT081/5 ... 5 Channel, Fe-Cu-Ni couple, for HLS machines
1.2 ZONES / GROUPS

By means of software zones are summarized in groups according to their function. To each
group (not to each zone) minimum and maximum temperature deviations are allocated.
A typical standard occupation is:

Zone 0 Oil no group separate min/max, heating page 1
Zone 1-5 Cylinder heatings Group 0... Pos./neg. deviation, heating page 1
Zone 6 Reserve (e.g. mould Group 1... Pos./neg. deviation, heating page 2
heating.)
Zone 7 Feedthroat no group Positive deviation, heating page 1
Optional mould heatings are allocated to group 1; the tolerances must be set on heating page
2.
1.2.1 SETTING 0°C

When setting a zone set value to 0°C the control and all monitoring functions for this zone are
switched off. On the heating and/or cooling output no outputs occur. The luminous tag
’Interlock’ on the control parameter screen page lights up. The actual value display remains in
action, however. Thus ’free’ zones can be utilized for temperature displays.
1.2.2 HEATING-UP AUTOMATISM

At the heating-up each group works according to its set parameters and/or set values.
Parameters P35326, P35329, ... (height of the heating-up stages for group x) determine a
temperature stage which is not exceeded by the zones among each other, i.e. when a zone of
a group reaches a distance >= P35326, P35329,..., the further heating-up of this zone stops,
it ”waits” until one of the other zones of the same group has caught up with the defined
distance again.
1.2.3 HEATING-UP MONITORING

During the output of the adjustable for heating in the undisturbed operation the temperature
changes corresponding to the heating capacity. The built-in monitoring function checks the
temperature change as long as the adjustable stands on 100% and the lower tolerance limit
(max. neg. deviation) is not reached. If this amounts to less than 2 °C after the time (typ. 2 to
Creation date: 20.02.2002 Temperature control (4)

Version:G/11/12/7/3
8 min) set with the parameter P35328 (group 0, cylinder heatings) and/or P35331 (group 1,
mould heatings), the messages 70 ’CYLINDER HEATING DEFECTIVE’ and/or 127 ’MOULD
HEATING DEFECTIVE’ are output.
If no transmission of the time parameter (dummy) occurs, the card initializes on 6553.5 sec.
1.2.4 SHORT CIRCUIT MONITORING

After the reaction of the short circuit monitoring in the hardware of an output - in manual like in
automatic mode - it is tried by software to activate the output again, all outputs being
interrogated several times in order to recognize the problem output clearly and to switch it off.
After 5 false attempts (in case of real short circuit) a collective short circuit message is
generated (167 ’SHORT CIRCUIT TEMP.CARD’). The concerned zone is marked in the
display field on the screen page ’Heatings’ by the lighting-up of the red error tag.
The heatings are lowered delayed, the motor is switched off delayed, the alarm lamp lights. A
current automatic cycle stops at the end of the cycle.
A failure of the 24V supply voltage of the module also leads to a short circuit message.
The short circuit state is stored and can only be erased by switching the control unit off-on.
1.2.5 MONITORING SWITCH

Start-up delay, start-up safety, soaking’.
Important hints for the operator stand in the operator’s manual, chapter ÇSetting of the
injection unit’, items ÇMONITORING FOR NEG. TEMPERATURE TOLERANCE’ and ÇMAX.
NEG. TEMPERATURE DEVIATION’.
1.2.6 ZONE DESIGNATOR
With the following parameters the individual zones can be occupied with names:
For Meaning:
Zone 1: P35393 = ... 0 = Empty text 14 = Mould fixed platen 2-point
Zone 2: P35394 = ... 1 = Nozzle 15 = Mould fixed platen 3-point
Zone 3: P35395 = ... 2 = Cylinder 2-point. 16 = Barrel - outer zone
- - ... 3 = Cylinder 3-point. 17= Barrel 3-p.outer zone
- - ... 4 = Mould 2-point. 18 = Barrel ceramic
Zone 23: P35415 = ... 5 = Mould 3-point. 19 = Hot runner 1
6 = Feedthroat 20 = Hot runner 2
7 = Materi. 21 = Material drier
8 Microtemp 22 = Melt temperature
9 = Flange 23 = Chiller
10 = Temp.control unit. 24 = Hot Sprue
11= Hotrunner 25 = Mold temp.moving platen
12= Mould-moving platen 2- 26 = Mold temp.fixed platen
point
13= Mould-moving platen 3- 27 = Sensor general
point
With the setting of the zone designators also the use of the respective zone is fixed at the
same time.
1.3 OPERATING ELEMENTS
On the button panel of the machine switches for cylinder and mould heatings are
accommodated separately. They supply a digital signal to the control unit:
bZH = 1 ... Cylinder heatings switched on
bWH = 1 ... Mould heatings switched on
Temperature control (4) Creation date: 20.02.2002

Version:G/11/12/7/3
In the switched-off state the error messages 132 ’CYLINDER HEATING OFF’ and/or 133
’MOULD HEATING OFF’ appear when at least one zone set value of a group does not stand
on ’0°C’. Further, the error message ’Thermocouple break’ is suppressed when the controller
mode of operation stands on ’Controller’ or ’Regulator’, so larger than ’0’.
A digital output switches the supply of all heatings on/off in the heavy current:
HZA = 1 ... Heating supplies on
1.4 START-UP DELAY, START-UP SAFETY, SOAKING

After switching on the control unit the system delays the release of the screw movement by
approx. 8 s (P35279). During this time the temperatures oscillate on the correct values. Only
then the temperature program runs in the sequence control. When at this moment all individual
zone actual values are within their tolerance zones, the screw movements are allowed. If the
temperatures have sunk under the negative limit or the machine must only be heated up, the
screw movements are locked. A red tag flashes on each heating image until the temperatures
are in tolerance againi and the period of time has passed which begins starting from this
tolerance limit. This period of time serves the better heat penetration in order to temperature-
control above all the screw chamber safely, and can be influenced with paramter P35277 (typ.
120s).
The message ’SOAKING’ appears. Switching off and on again the machine during this phase
does not start this time any longer, it occurs the release of the screw movements when the
heatings are in tolerance, immediately after the swinging-in of the temperature actual values.
If the temperatures fall under the negative tolerance during operation, the waiting phase
begins again when reaching the tolerance limit again.
The green tag ’ready for production’ in line 2 of each heating page lights at release.
Restriction at ’Soaking’:
The soaking function acts at a heating group then when the zone text of at least one zone of
the corresponding group stands on ’Cylinder-2P’, ’Cylinder-3P’ or ’Flange’ and the set value is
set bigger than 0.

Version:G/11/12/7/3
1.5 EMPLOYMENT OF THE TEMPERATURE CONTROL CARD
T.contr.unit
e.g.: 3-point controller
external Fe/Co couples
1. Temperature control
Heating card
E-8-THERMO
Cooling
OIL-
OIL+
-KO1
+FE1
-KO2
+FE2
-KO3
+KO3
-KO4
+FE4
-KO5
+FE5
-KO6
+FE6
-KO7
+KO7
H0
H1
H2
H3
H4
Heating H5
H6
H7
K0
K1
K2
K3
K4
Cooling K5
K6
K7
E.g.: 2-point
controller, cylin- +24V
der heating Heater band 0V

Version:G/11/12/7/3
2 HEATING CONTROL PARAMETERS

Image selection key ‘CONTROL PARAMETERS 0 - 15’ + F4
C O N T R O L P A R A M E T E R S 0 - 1 5 1996-05-08 15 28
Zone xph tn tv t0 HKV cb Pact emergency % controller optimiza-
tion type
C sec sec sec C % mode Mode Interl
0. 1.0 0.0 0.0 10.0 1.00 1.0 0 NO 2 OFF ❒ 5J
1. 61.1 115.2 23.0 3.2 1.00 57.0 35 NO NO 2 OFF ❒ 5J
2. 219.1 716.8 143.4 25.6 1.00 192.0 14 NO NO 2 OFF ❒ 5J
3. 217.6 716.8 143.4 25.6 1.00 189.0 6 NO NO 2 OFF ❒ 5J
4. 162.4 614.4 122.8 25.6 1.00 154.0 10 NO NO 2 OFF ❒ 5J
5. 50.0 700.0 120.0 15.0 1.00 40.0 18 NO NO 2 OFF ❒ 5J
6. 50.0 700.0 120.0 5.0 1.00 40.0 4 NO NO 3 OFF ❒ 5J
7. 50.0 400.0 100.0 0.2 1.00 40.0 2 NO NO 3 OFF ❒ 5J
8. 0.0 0.0 0.0 0.0 0.00 0.0 0 NO NO 0 OFF ❒ 5J

9. 0.0 0.0 0.0 0.0 0.00 0.0 0 NO NO 0 OFF ❒ 5J
10. 0.0 0.0 0.0 0.0 0.00 0.0 0 NO NO 0 OFF ❒ 5J
11. 0.0 0.0 0.0 0.0 0.00 0.0 0 NO NO 0 OFF ❒ 5J
12. 0.0 0.0 0.0 0.0 0.00 0.0 0 NO NO 0 OFF ❒ 5J
13. 0.0 0.0 0.0 0.0 0.00 0.0 0 NO NO 0 OFF ❒ 5J
14. 0.0 0.0 0.0 0.0 0.00 0.0 0 NO NO 0 OFF ❒ 5J
15. 0.0 0.0 0.0 0.0 0.00 0.0 0 NO NO 0 OFF ❒ 5J
Temperature correction factor for outer zones - zone 1-7: 000.0 zone
M 8-15: 000.0 °C
HEATING HEATING HEATING REG.PARAM. REG.PARAM.
It mean:
Zone: Zone number ... Zone 0 = oil cooling, Zone 1 = nozzle, etc.
Xph: Proportional band in 0,1 °C, range: 0.1...1000.0 °C temperature range, within which
there is a proportional connection between temperature difference and per cent
value of the clock time. Outside this band heating/cooling output 100% of the clock
time (full heating/cooling) is active. Larger Xph mean smaller amplification and vice
versa.
T/ °C
Actual temperature
Set e.g. 200 °C

Xph e.g.: 20 °C
{
Switching-on time
100 %
{
Scanning time T0

Version:G/11/12/7/3
Tn: Readjusting time in 0.1 sec (integral share), range: 0...6553,5 sec
Tn can maximally be 255 time T0. For larger Tn T0 must be increased. The
smaller Tn, the stronger the I share acts. For Tn = 0 the I share is switched off.
Tv: Rate time in 0.1 sec (differential share), range: 0...6553.5 sec
Tv can maximally be 255 time T0. For larger Tv T0 must be increased. The larger
Tv, the stronger the D share acts. For Tv = 0 the D share is switched off.
T0: Cycle time of the controller in 0.1 sec, range: 0.1...25.5 sec
As guide time the time within which the temperature rises by 1 °C with full heating
capacity can be used. It occurs maximally a switching operation on the final con-
trol element per cycle time (controller cycle).
HKV: Heating / cooling ratio, range 0,10...10,00
Here at three-point controllers the ratio heating capacity to cooling capacity must
be set. When heating capacity is equal to cooling capacity, set HKV = 1.00. When
e.g. the cooling capacity is 10 x as strong as the heating capacity, HKV must be
set to 0.1, etc.
If e.g. the actual values lies under the set value by 5 °C, a certain heating capac-
ity is calculated and output on the heating output of the zone. In the reverse case
(actual value over set value) also this calculation is carried out, multiplied by the
HKV value and output on the cooling output of the zone.
Setting of the HKV:

- When a zone is only heated (the cooling capacity cannot be closed loop controlled (2-
point controller), the HKV setting is without meaning.
- When the heating as well as the cooling capacity can be closed loop controlled (3-point
controller), the HKV value can be calculated in several ways:
maximum heating capacity

e.g.: HKV =
maximum heating capacity
Time for cooling off by 20 degrees around the set value with maximum cooling
or: HKV =
Time for heating up by 20 degrees around the set value with maximum heatin
Example:
In order to heat up from 40 degrees to 60 degrees (heating switched on fully) the time Th = 60
s is needed.
In order to cool off from 60 degrees to 40 degreees (cooling switched on fully) the time Tk = 40
s is needed.
40 s
This yields: HKV = = 0,6 ...... 0,7s
60 s

Version:G/11/12/7/3
Cbh: Cut back, proportional band for heating-up, range: 0.1...1000.0 °C

With Cbh that difference to the temperature set value can be fixed, at which the
controller switches over from full heating capacity to PID closed loop control dur-
ing heating-up. Wtih correct setting Cbh prevents the overswing at heating-up. At
the heating-up optimization the value is calculated automatically and can be
readjusted manually when bad transient response appears. When Cbh has the
value 0, Cbh is inactive and the switchover occurs at Xph.
Pakt: Capacity display in %, range -100...+100 %
The light-dark ratio of the controller output within one cycle represents the raised
heating and/or cooling capacity. 100 % means full connecting-through of the out-
put.
100 % Heating wattage 50 % Heating wattage
Original state Original state
active
inact.
0 0,5 1 1,5 2 2,5 3 0 0,5 1 1,5 2 2,5 3
e.g.: Scanning time t0=1Sec. e.g.: Scanning time t0=1Sec.
Emergency Selector switch for automatic switching-on of the regulator mode after
mode: thermocouple break, yes/no.
See operator’s manual, chapter ”INJECTION UNIT”, item ’EMER-
GENCY MODE’.
%-Regul.: Regulator mode, yes/no manual switchover of controller mode to regu-
lator mode.
See operator’s manual, chapter ”INJECTION UNIT”, item ’REGULATOR
MODE’.
Mode: Zone mode of operation, setting range: 0 - 3
Adjustable in the service mode, at least access level 6.
0... no control function, external heating switch bZH and/or bWH is inef-
fective (starting from Ebias 9.30)
at zone set value = 0 only actual value display,
at zone set value larger than 0 the monitoring functions run like at the
closed loop control
1... Regulator mode (% controller)
2... 2 Point controller --> heating or cooling
3... 3 Point controller, --> heating/cooling
Optimization: Self-determination of the controller parameters, yes/no selector switch
for self-optimization of the controller.
See operator’s manual, chapter ”INJECTION UNIT”, item ’SELF-OPTI-
MIZATION’.
Interl: Controller function display
Tag lights --> controller is blocked. Either the zone set value stands 0 or
the appertaining group switch on the control panel is switched off.

Version:G/11/12/7/3
2.1 THERMOSENSOR
With the following parameters the individual zones can be set to different thermocouple
types:
For zone P35369 up to P35392 Meaning
0 to 23: =0 no measurement, actual value = 0, no couple break message
=1 Voltage measurement 0 - 10000
=2 PT100 (only with E-8PT100 card)
=3 FECUNI according to DIN 43710, type L
=4 NICRNI according to DIN 43710, type K
=5 FECUNI according to IEC 548-1, type J
=6 NTC
Mainly FECUNI (= iron-constantan) are used. The TT081 cards are tuned to the types ’J’ and
’K’. The standard setting of all zone parameters is ’5’, according to IEC548-1, type J. On the
control parameters image therefore only ’3’ and ’5’ can be set. Other settings need soft and/or
hardware adaptations (option). Corresponding thermocouples must be connected to the
TT081. Thermocouples are recognized by the colours of the connection wires:
Type J ... + black / - white

Type L ... + red / - blue
Note!
HINT: Wrongly set parameters yield wrong displays and closed loop
controls of the temperatures.
3 TEMPERATURE CONTROL UNITS WITH EXTERNAL

CONTROLLER
Temperature control units without built-in controller can utilize control zones of the card TT081.
The thermocouple can be accommodated on the medium (mould) or in the temperature
control unit and is led on the TT081. The zone outputs (Hx) of the card control heating and/or
coooling contactors in the temperature control unit.
With the parameter HKV (image Control parameters, fast call key ’HEATINGS’ + F4/F5,
heating-cooling ratio can be set.
For the control parameter and HKV setting see this chapter, item ”HEATING PARAMETERS”.
4 DEVICE CONNECTION WITH SERIAL INTERFACE

The coupling of temperature control units or hot runner controllers can also occur by serial
interface. The temperature controller for the devices communicates with the injection moulding
machine control unit via a data line, which corresponds to the specifications of RS232C, -V24,
RS422 or 20mA Current Loop or also RS485.
Of data are exchanged:
Setvalues
Actual value
IMM control unit T.contr.unit
Error signals
Also the software record must correspond on both sides to exact specifications in order to
reach the communication. The following records are realized at ENGEL:

Version:G/11/12/7/3
Common, same record: Records different from each other:

HB-THERM LAUDA
REGLOPLAS INTRON
BOETHERM EWIKON
TOOLTEMP PLASTIC-SERVICE
GWK CONAIR (SPI)
WITTMAN
PIOVAN
The electric connection (interface occupation) differs between the different manufacturers and
can be taken from the ’electric plans’, included in the documentation package of the machine.
More details about the interface hardware (E-HSI, etc.) chapter ”HARDWARE”, item
”INTERFACES” shows”.
With parameter P35596 the Baud rate for the transmission must be set (typ. 3, corresponds to
4800 Bd).
Parameter P06559 describes the number of connected external zones.
About the operation the operator’s manual gives further information in the chapter
”INJECTION UNIT”, item ”TEMPERATURE CONTROL UNITS WITH SERIAL
CONNECTION”.
5 HOT RUNNERS
With the heating card TT081 scanning times up to 0.2 sec. are possible. Therefore it is suitable
for the closed loop control of fast heating types, e.g. hot runners. The connection of
thermocouples and heating output is similar to that of cylinder heatings.
6 MICROTEMP
Calibration range
positive
temperature
deviation
P35442
Set value
P35443
positive
temperature
deviation
P35441 Calibration range
Start calibration
Temperature control of the mould by means of cooling water flow. A function description is in
the operator’s manual, chapter ”SPECIAL PROGRAMS”, item ”MICROTEMP - MOULD
COOLING”. The following sketch illustrates the switching points and setting of parameters.
See also this chapter, item ’SET PARAMETERS’.

Version:G/11/12/7/3
7 SET PARAMETERS
Excerpt from the list of parameters. The entered values are settings, which need not be
changed in the standard case. When adding the TT081 card later, the following listed-up
parameters must be controlled and/or updated, however.
Start-up safety:
Parameter Pre/after- Meaning
decimal
point
35277,kohverz ,,,4,1,”s” screw start-up delay after heating up
35279,koheatdel ,,,4,1,”s” delay time for temperature check after switching on the control unit
19730 ,,,3,0”s” lower plausibility for first possible start-up zone
19731 ,,,3,0”s” upper plausibility for last possible start-up zone
Oilpreheating:
35278,koovwhnd ,,,4,1,”s” ;delay time at manual movements during oil preheating
35080,kod0 ,,,3,0,”%” ;pressure at oil heating-up
35034,koq0 ,,,3,0,”%” ;volume at oil preheating
Limits for temperature controller:

35318,kotmp0 ,,,3,1,””C” ;setting limitation for cylinder heating
35319,kotmp1 ,,,3,1,””C” ;setting limitation for mould heating
35320,kotmp2 ,,,3,1,””C” ;setting limitation for maximum oil temperature
35321,kotmp3 ,,,3,1,””C” ;setting limitation for minimum oil temperature
35322,kotmp5 ,,,3,1,””C” ;switching-off tolerance for oil temperature too low in automatic mode
35323,kotmp6 ,,,5,0 ;heating-up mode
35324,kotmp7 ,,,3,1,””C” ;limit for motor stop at oil temperature
35325,kotmp8 ,,,5,0,”min” ;min maximum time for 2 degrees for temperature change oil temper-
ature
35326,kohaufst ,,,3,1,””C” ;height of the heating-up stages group 0
35327,kozthoch ,,,4,1,”s” ;delay for temperature - high group 0
35328,koztaufh ,,,4,1,”s” ;monitoring time heating-up for min 2°C group 0
35329,kohaufst1 ,,,3,1,””C” ;height of the heating-up stages group 1
35330,kozthoch1 ,,,4,1,”s” ;delay for temperature - high group 1
35331,koztaufh1 ,,,4,1,”s” ;monitoring time heating-up for min 2°C group 1
35344,kotmp10 ,,,3,1,””C” ;setting limitation for temperature deviation
Zone designator:
35393,kotxt01 ,,,5,0 ;text for heating zone 1 0 = empty text
35394,kotxt02 ,,,5,0 ;text for heating zone 2 1 = nozzle
35395,kotxt03 ,,,5,0 ;text for heating zone 3 2 = cylinder
35396,kotxt04 ,,,5,0 ;text for heating zone 4 3 = cylinder 3-point.
35397,kotxt05 ,,,5,0 ;text for heating zone 5 4 = mould 2-point
35398,kotxt06 ,,,5,0 ;text for heating zone 6 5 = mould 3-point
35399,kotxt07 ,,,5,0 ;text for heating zone 7 6 = traverse
35400,kotxt08 ,,,5,0 ;text for heating zone 8 7 = material
35401,kotxt09 ,,,5,0 ;text for heating zone 9 8 = microtemp
35402,kotxt10 ,,,5,0 ;text for heating zone 10 9 = flange

Version:G/11/12/7/3
Zone designator:
35403,kotxt11 ,,,5,0 ;text for heating zone 11 10 = temperature control unit
35404,kotxt12 ,,,5,0 ;text for heating zone 12 11 = hot runner
35405,kotxt13 ,,,5,0 ;text for heating zone 13 12 = mould moving platen 2-point controller
35406,kotxt14 ,,,5,0 ;text for heating zone 14 13 = mould moving platen 3-point controller
35407,kotxt15 ,,,5,0 ;text for heating zone 15 14 = mould fixed platen 2-point controller
35408,kotxt16 ,,,5,0 ;text for heating zone 16 15 = mould fixed platen 3-point controller
35409,kotxt17 ,,,5,0 ;text for heating zone 17 16 = cylinder outer zone
35410,kotxt18 ,,,5,0 ;text for heating zone 18 17 = cylinder 3-point outer zone
35411,kotxt19 ,,,5,0 ;text for heating zone 19
Temperature control devices:

35596,kobdk3 ,,,5,0 ;baud rate temperature control unit
06559,kotempger ,,,5,0 ;temperature control unit number of the temperature control units
Microtemp:
35439,komt00 ,,,4,1,”s” ;microtemp: control employment delay all zones
35440,komt01 ,,,4,1,”s” ;microtemp: temperature increase monitoring
35441,komt02 ,,,3,1,””C” ;microtemp: start calibration before set value
35442,komt03 ,,,3,1,””C” ;microtemp: maximum positive temperature deviation
35443,komt04 ,,,3,1,””C” ;microtemp: maximum negative temperature deviation
35444,komt05 ,,,5,0 ;microtemp: maximum cycles with deviation after calibration
35445,komt06 ,,,5,0 ;microtemp: calibration value correction factor zone 1
35453,komt14 ,,,4,1,”s” ;microtemp: flow rate check delay
35454,komt15 ,,,4,1,”s” ;microtemp: time base for volume closed loop control
35455,komt16 ,,,5,0 ;microtemp: maximum flow rate
35456,komt17 ,,,3,1,””C” ;microtemp: minimum temperature change at calibration
35457,komt18 ,,,5,0 ;microtemp: number of calibration cycles
35458,komt19 ,,,4,1,”s” ;microtemp: delay advance temperature monitoring after flow rate
Modes of operation of the zone controllers:

35345,kotra0 ,,,5,0 ;mode,zone 0 0 = measurement channel
35346,kotra1 ,,,5,0 ;mode,zone 1 1 = regulator mode
35347,kotra2 ,,,5,0 ;mode, zone 2 2 = 2-point controller
35348,kotra3 ,,,5,0 ;mode, zone 3 3 = 3-point controller
... ... ...
35368,kotra23 ,,,5,0 ;mode, zone 23
Determination of the couple type:

35369,kotfuehl00 ,,,5,0 ;couple type zone 0 - oil temperature
35370,kotfuehl01 ,,,5,0 ;couple type zone 1
... ... ;...

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CALIBRATION AND LINEARIZATION (5)
In order to record strokes, pressures and speeds of the individual function units of the machine
and to transfer them to the machine control unit, different calibrations and linearizations of the
analogously working transducers and valves must be carried out.
Here ENGEL employs its patented calibration program, by whose help signs of wear and
production tolerances of those components can be compensated.
are calibrated: Stroke transducer

Are linearized: Proportional and servo valves.
The linearization and calibration data are stored on the machine diskette, which is supplied
with the machine. If the processor loses these data for defect reasons - e.g. discharge of the
buffer battery on the CPU -, a read-in of the machine diskette suffices for the reputting into
operation.
It must always be linearized and/or calibrated then when an exchange or a readjustment of a

mentioned peripheral element has occurred or a wear can be recognized. The new data must
be transmitted to the machine diskette.
Entry into the calibration level

Selection of the access level 9 or larger. See chapter ”PUTTING INTO OPERATION”, item
”SERVICE MODE”.
Press the image selection key
It appears the MENU survey with the row of function keys:

PRINT DISKETTE TEXT PAGES SERVICE ACCESS
MENU AUTHORIZATI
With F4 call up the service menu. It shows the row of function keys:
SETUP VALVE INPUT TEST and DATE and
PROGRAMS LINEARIZATI CALIBRATIO PARAMETER TIME
1 STROKE CALIBRATION
In order to record the strokes of the individual function units and to transmit them to the
machine control unit, corresponding calibrations must be made. For this purpose no injection
mould may be mounted in order that all strokes can be passed maximally. The calibrated data
remain stored in the control unit and are transmitted to the machine diskette together with all
Creation date: 20.02.2002 Calibration and linearization (5)

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other machine parameters.at the end of the putting into operation at the works. If these data
get lost for defect reasons (possibly memory battery on CPU module empty), one reads in the
machine diskette anew.
Note!
When a new stroke transducer is mounted, one carries out the stroke
calibration for the corresponding function unit (without mould) and
stores the machine parameters on the machine diskette.
For the exact measurement of the strokes ohmic stroke transducers are used. These
transducers are especially distinguished by a good resolution (0.01mm) and by a good
linearity.
Ohmic stroke transducer:

mechanical stroke
electric useful stroke
calibrated stroke
The transducers are supplied by the control unit, analog card AR101, AR281/SR161.
Serial inputs: The stroke transducers are supplied via the measured value converter
AS141 (integrated into plug on the stroke transducer) with a voltage of +3/-3V. On the
connection 2 the analog voltage for the stroke position is tapped off, converted into a
digital signal and transmitted to the AR281/SR161 serially.
(see also chapter ”HARDWARE”, item ”MEASURED VALUE TRANSDUCER AS141”)
Analog inputs: The stroke transducers are supplied with a voltage of +10V. The test
signal is led on the AR101 and/or AR281/SR161.
Connections, power supply for stroke transducer:
Stroke transducer examination

At 64ms intervals all stroke transducers are checked for correct function. The transducer
signal must lie within the calibrated zero / max values. In the error case the test intervals
accelerate to 8ms. After 5 consecutive measurement errors the message (e.g.) ”MOULD
STROKE TRANSDUCER DEF” arises.”
Calibration and linearization (5) Creation date: 20.02.2002

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1.1 CARRY OUT THE STROKE CALIBRATION

With ”F3” select the input calibration 1. It appears:
INPUT-CALIBRATION.1 1996-04-23 15 17
STROKE CALIBRATIONS
Analog minval maxval null max offset act.val speed. iw_mv ready VZ
Moldstr 0.0 600.0mm 0 10000 0mv 0.0mm 0mm/s 0mv ❒ +
Nozzle 0.0 350.0mm 0 10000 0mv 0.0mm 0mv ❒ +
Ejector 0.0 130.0mm 0 10000 0mv 0.0mm 0mm/s 0mv ❒ +
Screw 0.0 200.0mm 0 10000 0mv 0.0mm 0mm/s 0mv ❒ +
Systempr. PH1 0.0 200.0bar 0 4834 0mv 0.0bar 0mv ❒
Cavity Pr 0.0 1800.0bar 0 10000 0mv 0.0bar 0mv ❒
Digital minval maxval imp/revolut. speed counting value finished

RPM 6 480/min 1 0 ❒
M
INPUT- TAKEOVER SERVICE
CALIBR.1 TAKEOVER MENU
Explanation of the abbreviatons:
Range of values:
Minval/Maxval Maximum stroke of the movement - machine constant in (mm).
At number of revolutions: r/60sec, e.g. =6: If no impulse comes within
10sec, the number of revolutions actual value is set to 0.
Voltage range:
Zero Zero stroke calibrated in Volt. This voltage the stroke transducer gives
off at position ”0” (e.g. screw entirely in front).
Max When reaching the maximum stroke this voltage has beeen measured
and stored.
Offset J determination = nozzle contact point determination and mould closing
point are self-determining offset values. For pressure transducers the
offset can be adjusted manually or automatically (see item 2.4.1). The
not-reaching of the offset by 200mV is valued as cable break. Error
message ’PRESSURE TRANSDUCER xxx DEF.’
Act.val Display of the stroke in (mm). Corresponds to the value SFX for mould
stroke, SDX for nozzle stroke, SAX for ejector stroke and SSX for
screw stroke.
Speed. Display of the current speed of the respective movement
iw_mv Display of the current stroke transducer voltage, in Millivolt
finish ”Calibrated”; when the calibration of a movement is finished, the tag
lights up.
SI ”Algebraic sign”; depending on how the stroke transducer is mounted,
the algebraic sign must be set to ”+” or ”-”
Set machine to manual mode and establish the conditions for the respective
movements.

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Switching on the calibration by the input of ”1 ENTER”. In the cursor zone stands ”ON”.
One function unit each can now be run with the manual control keys. The movements
are carried out with separate pressure and speed outputs (constant values see list of
constants) and the respective valves. They remain actuated as long as the key is
actuated. Limit switches and positions except pos. ”L” (ejector at the back) remain
unconsidered.
All function units, such as clamping unit, ejector, screw and carriage unit can be
calibrated with the same procedure. The whole strokes are calibrated when all 5 tags
light.
Attention!
The ejector can be run in each mould position!

With the manual control keys move the unit on maximum stroke. On the screen watch
the columns ”Actual value” and ”iw_mv”. Both must show an increasing course during
the movement.
After the unit has run on maximum stroke (mechanical stop of the hydraulic cylinder),
have the manual control key still actuated until in the ”Actual value” zone the value from
the ”Maxval” zone appears. From zone ”max” the appertaining stroke transducer
voltage is transmitted. Afterwards the maximum stroke is calibrated.
With the manual control key actuate the unit in the other direction. The columns ”Actual
value” and ”iw_mv” show falling values.
When reaching the zero point (mechanical stop of the hydraulic cylinder) have the
manual control key still actuated until in the ”iw_mv” zone the value 0.0 appears. At the
same time also into the ”ZERO” zone the stroke transducer voltage existing at this
moment is transmitted. The lighting-up of the tag beside the ”iw_mv” zone displays the
finished calibration process.
Afterwards move in the other direction again. ”The ”iw_mv” value now corresponds to
exactly the run value in (mm).
These items can be repeated at will.
Write these data on the machine diskette, having to be considered that also all other
machine constants and linearization tables are also transmitted.
Note!
Do not forget! At the end or after intended interruption of the calibration
process the calibration must be switched off: Press ”0” and ”ENTER” -
in the cursor field stands ”OFF”.
1.1.1 EXAMPLE: CALIBRATE SCREW STROKE

Actuate manual control key for screw retraction, the screw moves up to the maximum
stroke slowly; watch the columns ”Actual value” and ”iw_mv” on the screen in the row
”Screw”. Both must show an increasing course during the movement.
After the screw has run on maximum stroke, have the manual control key still actuated
until in the ”iw_mv” zone the value from the ”maxval” zone appears. From zone ”ZERO”
the appertaining stroke transducer voltage is transmitted. Afterwards the maximum
stroke is calibrated.

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Actuate manual control key for injection, the screw moves forward slowly up to stop.
The columns ”Actual value” and ”iw_mv” show decreasing values.
When reaching the mechanical stop have the manual control key still actuated until in
the ”iw_mv” zone the value 0.0 appears. At the same time also into the ”ZERO” zone the
stroke transducer voltage existing at this moment is transmitted. The lighting-up of the
’calibrated’ tag beside the ”iw_mv” zone displays the calibration process finished for the
mould stroke.
Afterwards retract screw again. The ”iw_mv” value now corresponds to the run value
exactly in [mm].
1.1.2 DIFFERENCES AT THE STROKE CALIBRATION OF DIFFERENT MACHINE

TYPES
Direct-closing machines with mould stroke transducer:

The mould stroke transducer takes over the linear movement of the mould.
Calibration occurs like described above.
Toggle lever machines with toggle lever stroke transducer:

On the screen appears the text ’TOGGLE LEVER’ instead of ’MOULD’ in first position. The
toggle lever stroke is calibrated just as described above. But since some stroke position set
values (and actual values) are input and/or read off on the screen referring to the direct platen
stroke, a conversion of the toggle lever characteristic line into the linear platen stroke is
necessary. As this type of linearization is similar to the output linearizations, this conversion is
carried out by means of automatic table take-up under the valve calibrations (see section
Valve calibration).
Machines with mould height stroke transducer:

The mould height transducer is calibrated similarly like the other strokes, but the value take-up
of the Min and Max does not occur automatically as no standstill monitoring of the adjusting
motor can occur (no suitable mechanical limit of the mould height stroke). So one approaches
the minimum and/or the maximum stroke carefully with the push-buttons and hands over these
limit values to the control unit on reaching the end value by typing in the ”iw_mv” value into the
”ZERO” and/or ”max” value and by the following pressing of ”F6” (”TAKE OVER CHANGE”).
2 VALVE LINEARIZATION
At this process the characteristic lines of the proportional valves and of the servo valve are
taken up. Voltage values are given by the control unit and the reactions of the valve to be
linearized are recorded as actual values and stored in tables. At the output of set values then
the computer accesses to the corresponding table value.
The data are transmitted to the machine diskette together with all other machine parameters
at the end of the putting into operation at the works.
If these data are lost for defect reasons, either one carries out the linearizations once again or
reads in the machine diskette anew.
Distinction into different linearization types:
a) Linear output:
Only setting of the 0 point and max. point. The connection (explicitly the output on the valve)
occurs with a straight line between these points.
The setting of the points (rotation of the initialized straight line) happens with the cursor keys.
At hydraulic systems with electrically adjustable variable displacement pump (EHV) a linear
output is applied.

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b) Speed linearization:
In an automatic linearization cycle the computer presets voltage values to the valve and
measures the actual extent of the movement. At first it determines the 0 point of the movement
and then climbs up with constant voltage steps until no increase of the speed is recognized
any longer. It enters the measured data in a table, to which it can access later at the set value
setting. (Mainly for Q/P throughput hydraulic systems).
c) Pressure linearization:
Analogously to the speed linearization. At closed loop controlled machines (EHV generally
pressure closed loop controlled).
The pressure linearization can also be carried out manually.
d) Number of revolutions linearization:

Analogously to the speed linearization.
e) Stroke transducer calibration:

Due to the similar program for taking up a table which allows a conversion of the calibrated
toggle lever stroke into the linear platen stroke in this menu this input calibration type is
accommodated.
valves Calibration type by means of

Y1,volume central, 1 pump b) Injection movement
Y1, volume central, 2 pumps b) Injection movement
K1, pressure central c) Injection movement
(Screw is entirely in front (0)
Y1,screw speed d) Screw rotation
Servo valve injection b) Injection movement
YS, proportional valve closing a) Closing movement
YS, proportional valve opening a) Opening movement
YA, prop. for ejector and core-pull a) Ejector movement
Strokes
M.str.transd. e) Opening/closing
When in the special case further valves are mounted, which need a linearization, these appear
on the linearization menu.
For the calibrations from the works certain internal parameters are set (pressure, speed,
ramps and time fixed values), which shall only be changed in case of need (see tables,
chapter. (11) ).
Preparations:
Set machine to manual mode
Switch on motor, wait for delta run
Bring hydraulic oil temperature to 40 up to 45 degrees centigrade (possibly start the oil
preheating program)
Establish the conditions for the individual movements:
Safety guard closed
Close nozzle guard
Unit must not be swivelled out
Close plexi guard (limit switch EA)
Establish the conditions for screw movement and retract the nozzle from a possibly
built-in mould
For the closing movement pos. L ”Ejector at the back” must be reached

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2.1 CARRY OUT THE VALVE LINEARIZATION

In order that the valve calibration program can be selected via the menu image, the key-
operated switch must be brought on position ”PR”. Selection of the access level 9 or bigger
(see chapter ”PUTTING INTO OPERATION”, item ’Service mode’).
Call up valve calibration program via menu image and function key ’F4 - service menu’.
It appears the following row of function keys :

SETUP VALVE INPUT TEST and DATE and
PROGRAMS LINEARIZATI CALIBRATIO PARAMETER TIME
By actuating the function key F2 the VALVE LINEARIZATIONS, range ”SPEED” are called up.
When another range is wanted, e.g. ”PRESSURE”, then switch over by means of soft keys.
V A L V E L I N E A R I Z A T I O N 1996-04-15 14 37
Y V A L V E ❒
Y S V A L V E M O U L D C L O S I N G ❒
Y S V A L V E M O U L D O P E N I N G ❒
S E R V O V A L V E ❒
M
SPEED- PRESSURE BACK PRES- R.P.M. e t c
. SURE ---->
The position of the cursor displays the valve to be linearized.

The screen tags at the right beside the text light up when it has already been calibrated.
Now the individual calibration curves of the valves can be selected by selecting with the cursor
and by pressing the ”ENTER” key.
2.2 LINEAR OUTPUT

Only setting of the 0 point and max. point. The connection (explicitly the output on the valve)
occurs with a straight line between these points.
The setting of the points (rotation of the initialized straight line) occurs with the cursor keys.
Example: Valve opoening YS
This is no automatic linearization, the movements are run by hand.

Selection from the linearization main menu:
Soft key ”SPEED”, ”YS VALVE MOULD OPENING” and key ”ENTER”.

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S P E E D S
Y S V A L V E M O U L D O P E N . 1 0 0 % = * * * m m / s
100%
80%
60%
40%
20%
0%
0 +1 +2 +3 +4 +5 +6 +7 +8 +9 +10
S Y S T E M P R E S S U R E p u m p 1 4 , 9 b a r
M
MAIN MENU INITIAL- MEASUREM TAKEOVER CHANGE e t c
IZATION TAKEOVER ---->
On this image the calibrated curve of the valve is represented on a per cent axis of 0 up to
100% and a voltage axis of 0 up to +10V. When it is not yet calibrated, a linear curve of 0%,0V
up to 100%,+10V is represented.
By means of soft key now different processes can be started.

F1 ... MAIN MENU
back again into the menu ”CALIBRATION”
F2 ... INITIALIZATION
A distance of 0%,OV up to 100%,(-)+10V is drawn (linear values for presetting the proportional
amplifiers)
F3 ... MEASUREM
It appear the actual values for current speed and peak value (red characterisitic line).
Screen lines: ACT. VAL.: ... mm/s

PEAK VAL: ... mm/s
At first occurs the 0 point determination. For this purpose one has to input the speed values of
1% on the standard screen page for the respective mould movement, then one runs the
movement and sets the straight line on the graphics with the cursor keys (up/down) so that the
mould still moves.
When setting the speed set values = 0 the mould should at switched-off soft key F3
”0%-Value” = calibrated zero, do not move any longer.
Afterwards the maximum value is set. For this purpose the speed set values on the screen for
the movement are set to 100%. Watching the two actual values on the linear image (green
characteristic line) one moves the mould and controls the cursor keys (at the left/at the right)
so that the maximum value of the speed is just reached. With F2 ”TAKE OVER CHANGE” the
new values are taken over, it enters data in a table, to which it can access later at the set value
setting.

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Cursor keys
100%
80%
60%
40%
20%
0%
0 +1 +2 +3 +4 +5 +6 +7 +8 +9 +10
Cursor keys
F4 ... TAKE OVER CHANGE

The changed curve is activated
F5 ... CHANGE
It appear the screen lines:

0.0% = 0.00V (white)
0.0% = 0.00V (yellow)
and the soft key strip:

TAKE OVER 0% - VALUE etc
CHANGE ---->
White line:
By typing in a ”%” value an optional % value and its voltage value can be selected and/or the
appertaining voltage value can be changed. By means of the cursor keys up/down the % value
as well as the voltage value can be changed in steps.
Note!
Do not forget F1 = TAKE OVER CHANGE !
Yellow line:
By touching F2 ”0% value” it is chosen whether 0% = calibrated 0% corresponding voltage
value (F2 backed black = OFF) or 0% corresponds = 0V (F2 backed yellow = ON).

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2.3 SPEED LINERARIZATION

Not applied at EHV hydraulic systems.
In an automatic linearization cycle the computer sets voltage values for the valve and
measures the actual extent of the movement. At first it determines the 0 point of the movement
and then moves up with constant voltage steps until the maximum speed (100%) is reached.
It enters the measured data into a table, to which it can access later at the set value setting.
Selection from the linearization main menu: SPEED, VALVE MOULD OPENING YS and
key ”ENTER”.
S P E E D S
Y S V A L V E M O U L D O P E N . 1 0 0 % = * * * m m / s
100%
80%
60%
40%
20%
0%
0 +1 +2 +3 +4 +5 +6 +7 +8 +9 +10
M
MAIN MENU INITIAL- MEASUREM TAKEOVER CHANGE e t c
IZATION TAKEOVER ---->
Example: Speed valve mould opoening (YS)
As starting curve the graphics shows the curve stored at the last linearization on a per cent
axis of 0 to 100% and on a voltage axis of 0 to +10V. If it is not yet calibrated, a linear curve of
0%, 0V to 100%,+10V is represented.
By means of soft keys now different processes can be started.

F1 ... MAIN MENU
back again into the menu ”LINEARIZATION”
F2 ... INITIALIZATION
A distance of 0%,OV up to 100%,(-)+10V is drawn (linear values for presetting the proportional
amplifiers).
F3 ... MEASUREM
By this instruction the calibration is started and the valve is actuated in steps.
At the left above the status code (red zone) is faded in, which is only important for the
troubleshooting at programming.
For the measurement the screw returns entirely and the pressure valve is actuated with a
mean value. The voltage value (adjustable) is increased until the screw moves, then the
voltage value is taken back again until the screw stands still again: Zero point

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Now the voltage value increases by 0.1V and the injection speed is measured and displayed.
Then the screw returns again and the process is repeated until the max. speed is reached.
The characteristic line (green) is drawn in per cent of the max. value.
F4 ... TAKE OVER CHANGE

The characteristic line (green) determined last is taken over into the memory).
F5 ... CHANGE
At the calibration the microprocessor gives certain voltage stages as actuation on the
concerned valve and then stores the reached value. Between the individual stages it
calculates itself a linear characteristic line. But if a valve between the indicidual stages is
especially non-linear, each individual per cent stage can be recorrected with ”CHANGE”.
0.0% = 0.00V (white)

0.0% = 0.00V (yellow)
and the soft key strip:

TAKE OVER 0% - VALUE etc
CHANGE ---->
White line:
By typing in a ”%” value an optional % value and its voltage value can be selected and/or the
appertaining voltage value can be changed. By means of the cursor keys up/down the % value
as well as the voltage value can be changed in steps.
Note!
Do not forget F1 = TAKE OVER CHANGE !
Yellow line:
By touching F2 ”0% value” it is chosen whether 0% = calibrated 0% corresponding voltage
value (F2 backed black = OFF) or 0% corresponds = 0V (F2 backed yellow = ON).
2.4 PRESSURE LINEARIZATION

Analogously to the speed linearization. A pressure linearization is not applied at closed loop
controlled machines (standard at EHV). For measurement the screw at first advances entirely.
Then the voltage value for the pressure valve is increased in steps until the maximum value is
reached. The pressure increase can be watched on the manometer and/or on the screen by
the actual value display.
The pressure linearization can also be carried out manually by starting the measurement with
’F3’, by selecting the ”measurement manually” with ”F1”, by reading off the pressure values on
the manometer and entering them into the computer. With ’F2’ the measurement is carried out
automatically.
The pressure is measured by means of a pressure transducer built into the injection cylinder.
In the standard a pressure transducer is used for a pressure range of up to 414 bar. It is
supplied with a voltage of 24V and supplies an output signal of 24.17 mV/bar.
Also pressure transducers with other calibration and resolution can be used. These values
must be set on the screen image ’Input calibrations’, see this chapter item 1.1, with offset,
Maxval and Max.

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2.4.1 PRESSURE TRANSDUCER

Depending on the machine execution a different number of pressure transducers exists.
In the standard:
PH1 ... Pump 1 system pressure
PH2 ... Closing press
PH3 ... Inject.Press
PH4 ... Pump 2 system pressure
Pressure transducer (example)
Electric connection
1 Supply voltage (+)

2 Supply voltage (-)
3 Signal (+)
4 Signal (-)
2.4.1.1 OFFSET DETERMINATION AND MONITORING
Manual offset input

At 0 bar pressure the transducer signal is +10mV up to +60mV (offset voltage, readable on the
input calibration image under ’iw_mv’). A readjustment is possible at certain types with the
adjusting screw ”N”. Above all when connecting pressure transducers with bigger offset
voltage the voltage value which the transducer produces at 0 bar must be input in the input
calibration image under ’offset’.
Automatic offset determination

This function can be chosen for each individual pressure transducer. For this purpose per
pressure transducer one minimum (typ. 4mV) and one maximum (typ. 110mV) offset value can
be set. The offset determination is not carried out when the voltage value existing at the offset
determination lies outside these limits. In this case also an error identification is set. Whether
and how this error information is evaluated, can be set via a separate parameter per
transducer. When the parameter for the offset maximum value is set to 0, determination as well
as monitoring is switched off.
Function sequence of the automatic offset determination

When the motor is switched off, the offset determination is started after expiry of a delay time
(P36343, adjustable in minute steps, typ. 2min), after which one can assume that all systems
are pressureless if the motor (not the filtration motor either) has not been started again
meanwhiles. At the pressure transducer on the clamping unit the mould must be open in
addition.
The currently measured voltage of the pressure transducer is taken over as offset (controlable
on screen page ”Input calibration”) and the analog card is initialized newly.
When now a voltage is determined outside the above mentioned tolerances, the error action
can be released via a parameter:

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Example P23958: 0 ... no error message

1 ... only error message (e.g. OFFSET PRESSURE PH1)
2 ... Error message, mould protection lamp, motor stop delayed
3 ... Error message, mould protection lamp, motor stop immediately
MIND:
The offset determination does not occur after emergency stop switch actuation
Error signals:
1.Unit:
’OFFSET PRES. PH1’ , 4944
2. Unit:
OFFSET PRES. PH1.2’, 4948
’OFFSET PRES. PH3.2’, 4949
Acknowledgement of the error:

Start offset determination newly, this means, switch off motor, wait for 2 minutes (and/or
P36343), afterwards actuate PU key
Parameters:
P36343 ..... Delay time between motor switching-off and offset determination (in min) typ. 2min
P36344 ..... max. voltage value for offset phx (EHV: Injection pressure, HLS: System pressure) typ. 80mV
P23951 ..... min. voltage value for offset phx (EHV: Injection pressure, HLS: System pressure) typ. 4mV
P23952 ..... max. voltage value for offset phx2 (EHV: System pressure) typ. 80mV
P23953 ..... min. voltage value for offset phx2 (EHV: System pressure) typ. 4mV
P23954 ..... max. voltage value for offset phx3 (system pressure 2nd pump) typ. 80mV
P23955 ..... min. voltage value for offset phx3 (system pressure 2nd pump) typ. 4mV
P23956 ..... max. voltage value for offset sk (clamping pressure) typ. 80mV
P23957 ..... min. voltage value for offset sk (clamping pressure) typ. 4mV
P23958 ..... Error action at offset error phx (EHV: Injection pressure, HLS: System pressure)
P23959 ..... Error action at offset error phx2 (EHV: System pressure)
P23960 ..... Error action at offset error phx3 (system pressure 2nd pump)
P23961 ..... Error action at offset error sk (clamping pressure)
P23962 ..... max. voltage value for offset phx.2 unit 2 (EHV: Injection pressure)
P23963 ..... min. voltage value for offset phx.2 unit 2 (EHV: Injection pressure)
P23964 ..... max. voltage value for offset phx2.2 unit 2 (system pressure)
P23965 ..... min. voltage value for offset phx2.2 unit 2 (system pressure)
P23966 ..... Error action at offset error phx.2 unit.2
P23967 ..... Error action at offset error phx2.2 unit.2
2.4.1.2 FURTHER MONITORINGS
The offset voltage is checked cyclically every 64ms deducting further 200mV. If a
measurement error appears, the cycle accelerates to 8ms. After further 3 measurement errors
the error message ’PRESSURE TRANSDUCER xxx DEFECTIVE’ arises’.
2428 PRESSURE TRANSDUCER PH1 defective


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In addition to the cyclic testing all pressure transducers are checked for maximum signal
before an automatic start. If the signal voltage exceeds the Çmax’ value (screen image ÇInput
calibrations’) plus an adjustable tolerance (in mV), the error ÇPRESSURE TRANSDUCER
PHx DEF.’ arises. By setting the tolerance values correspondingly high the monitoring can be
switched off deliberately. Standard setting is 1208mV (50bar).
The maximum value can only be measured with a precision manometer and be compared with
the screen value ”PHx”. (At certain types a readjustment with the adjusting screw ”B” is
possible).
Parameters, only for EHV machines

P37881 Tolerance for maximum voltage value of the injection pressure transducer PH3 (PHx)
P37882 Tolerance for maximum voltage value of the system pressure transducer PH1 (PHx2)
P37883 Tolerance for maximum voltage value of the system pressure transducer PH4 (PHx3)
P37884 Tolerance for maximum voltage value of the clamping pressure transducer PH2 (Sk)
P37885 Tolerance for maximum voltage value of the injection pressure transducer PH3.2 (PHx.2)
P37886 Tolerance for maximum voltage value of the system pressure transducer PH1.2 (PHx2.2)
At machines without EHV hydraulic system there is the possibility of the pressure calibration
without idling solenoid S10. This is necessary for specially small injection pressures.
2.4.2 CALIBRATE BACK PRESSURE

The back pressure calibration can only be carried out with material.
At servo valve-controlled machines a back pressure calibration is not possible as a pressure
calibration on the servo valves even with the used hydraulic circuit cannot be carried out.
Procedure:
Fill material into the material hopper, plasticize and purge
Close nozzle (e.g. by approaching a fully injected mould)
set approx. 80% plasticizing speed
Select and start back pressure calibration

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B A C K P R E S S U R E
K S V A L V E 1 0 0 % = 4 0 b a r
100% 0.000 V
80%
60%
40%
20%
0%
0 +1 +2 +3 +4 +5 +6 +7 +8 +9 +10
Measured val 0.0 bar
P l e a s e i n p u t m e a s u r e d v a l u e
M
MAIN MENU INITIALIZA- MEASUREM TAKEOVER CHANGE e t c
TION TAKEOVER ---->
Switch on plasticizing and observe the reached back pressure (ACTUAL VALUE).
Instead of ”MEASURED VALUE” ”PLEASE INPUT MEASURED VALUE > < is faded in.
Here the back pressure measured as actual value must be entered and ”ENTER” must
be pressed”.
the process must be repeated until the max. back pressure (40 bar) is reached whereby
the adjustable is increased by 1V each time.
When the maximum metering stroke is reached, the nozzle must be retracted and be purged
again meanwhiles.
Specific back pressure
Injection unit open loop controlled

Injection unit Calibration
Back pressure Back pressure servo.controled
controlled with prop. closed
loop controlled
HLS central K valve --- Servo valve at open loop con-

trolled separate
calibration.
EHV1 --- Closed loop con- Servo valve ---
trol via Ys valve
EHV2 separate back Closed loop con- Servo valve at open loop con-
pressure trol via Ys valve trolled
prop.valve YKs separate calibra-
P35463 = 0 P35463 = 0 tion.
P09628 = 0 P09628 = 1
EHV3 -“- -“- -“- -“-

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2.5 SCREW SPEED LINEARIZATION

Analogously to the speed linearization. The hydraulic motor for the screw drive is actuated.
2.6 STROKE TRANSDUCER CALIBRATION (CONVERSION TABLE)

Take-up of the conversion table toggle lever stroke/platen stroke. Can be read in from the
machine diskette as this ratio does not change and has been set at the works.
If this calibration should be required nevertheless, a stroke transducer for the platen stroke
must be mounted and connected instead of this on the input for the nozzle stroke transducer
(card AR281, terminal Ai3+, Ai3-, card AR101, terminal Ai5+, 0V) during the calibration
process.
M O U L D S T R O K E T R A N S D U C E R
100%
80%
60%
40%
20%
0%
0 +1 +2 +3 +4 +5 +6 +7 +8 +9 +10
MAIN MENU INITIALIZA- PROG. INTERRUPTION 1

TION MEASUREM TAKEOVER CHANGE e t c
The program handling runs like at the speed linearization. It must be ensured that the toggle
lever can straighten entirely and the stroke of the toggle lever is already calibrated.
At ‘F3’ - (MEASUREMENT) the mould closes completely, then opens up to maximum stroke.
Afterwards occurs the characteristic line recording during repeated, slow closing movement.
The graphic image displays this process by recording the curve from right above to below.

Version:G/11/12/7/3
CLOSED LOOP CONTROL (6)
1 CLOSED LOOP CONTROL PRINCIPLE

The reproducibility of each mould filling process depends on the repeatability of the required
injection speed, of the holding pressure and of the back pressure. In order to achieve the
demand for observing tightest tolerances and avoiding each secondary finishing, the system
can be supplemented by a speed and/or pressure closed loop control on the injection unit.
In a control circuit basically a set-actual value comparison occurs, the difference being
reinforced correspondingly and being output as correction value according to special
calculation algorithms. As control element in the control circuit a servo valve is used. At
machines with electrically adjustable pump the pump itself can be employed for closed loop
pressure and speed control. The actual value transducer for the feedback of the actual value
signal is a hydraulic pressure transducer for the pressure control circuit, a stroke transducer
for the speed control circuit..
2 SET CLOSED LOOP CONTROLS
2.1 SELF-OPTIMIZING CLOSED LOOP CONTROLS

The self-optimization is an experimental process, which adapts the necessary controller
parameters to the present circumstances of the machines optimally by repeated injection.
The process is characterized by the fact that it can be used at the putting into operation without
material as well as for the postoptimization with material and mould as well as also at the
different machine sizes and hydraulic variants.
The result of the self-optimization are automatically set controller parameters for the injection
speed controller adapted to the respective process conditions.
Information about the optimizations is in separate documents:

Self-optimization injection speed closed loop control SOC-V
Self-optimization pressure overswinger SOC-PP
Creation date: 20.02.2002 Closed loop control (6)

Version:G/11/12/7/3
2.2 GENERAL
Screen page + F4
P V - R E G U L . P A R 1996-05-09 16:18
INJECTION SPEED: ON
kr tn tv umin umax -- ks tr
(sec) (sec) (mV) (s)
200 0.000 0.000 0 10000 0.900 0,000
PRESSURE LIMIT: ON P6 = 90,0 bar

kr tn tv umin umax -- ks
(sec) (sec) (mV)
0.300 0.000 0.100 -1600 0 1,000
HOLDING PRESSURE: OFF

kr tn tv umin umax -- ks
(sec) (sec) (mV)
30 0.000 0.030 0 5000 1.0
BACK PRESSURE:
kr tn tv umin umax ustart
(sec) (sec) (mV)
200 0.150 0.010 300 10000 2500
M
ON - SWICHOVER- SET VALUE CONTROL-
JECTION MODE GRAPHICS PARAMETER
Only selectable in service mode with corresponding authorization. See chapter ”PUTTING INTO OPERATION”, item
”SERVICE MODE”. The image shows the settings for closed loop control via pump.
The closed loop control occurs via standard PID. The control parameters are transmitted to the
analog card via the controller definition. Various basic settings are made on the screen page
”PV control parameters” and by means of constants.
kr ... Reinforcement controller branch, P share

tn ... Reset time in sec, I share
tv ... Rate time in sec, D share
umin ... min. correcting variable
umax ... max. correcting variable
ustart ... Initialization value at back pressure controller
Closed loop control (6) Creation date: 20.02.2002

Version:G/11/12/7/3
2.2.1 SETTING OF THE SPEED START-UP RAMP

In order that the injection speed can be closed loop controlled via the position controller, it is
necessary to set the injection profile so that the machine can also duplicate this profile. This is
above all valid for the start-up ramp; if this is set too steep, the machine cannot duplicate this
setting at the start-up where then with reaching the set value this initial limping-after is caught
up again by means of closed loop position control).
To be set is the ”maximum start acceleration screw absolute”
Typical settings:
var 35175,koavspr = 100 % Start acceleration speed injection
var 35186,koavssb = 1000 mm/s/s maximum start acceleration screw absolute
At machines with servovalve the start acceler-
ation can possibly be set steeper as the reac-
tion time of the servovalve is less than that of
the pump.
e.g.: at 1000 [mm/s/s] in 100ms the set value
is increased by 100mm/s
2.2.2 SETTING OF THE PRESSURE SWITCHOVER RAMP

When switching over to holding pressure the pressure set value is set on the actual pressure.
By means of a time-dependent ramp then the pressure set value is calculated on the set
holding pressure.
Typical settings:
var 35129,ko0 = 25% Switch over pressure to holding pressure
e.g. at 25(%) in 100ms the set value is
increased from 0 to 250 bar
var 35191,koapmaxz = 10000 bar/s maximum pressure ramp as a function of time
As this maximum ramp is also employed for
other movements, it shall not be adjusted.

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2.2.3 SETTINGS FOR CHECKING THE CLOSED LOOP CONTROL

For checking the control parameters and the start-up ramp the following profile is set:
I N J E C T I O N 1996-10-09 09:02’
I N C R E A S E D S P E C I F I C I N J E C T I O N P R E S S U R E N O
M A X I N J E C T I O N S P E E D : 1 5 6 m m / s
I N J E C T I O N S P E E D . : A C T = 0 m m / s S E T :
8 0 8 0 8 0 2 0 2 0
8 0 8 0 8 0 8 0 8 0
I N J E C T I O N P R E S S U R E L I M I T P 6 = 1 0 0 . 0 b a r
H Y D R . P R E S S U R E A C T . V A L . P H x = 0 . 0 b a r
S C R E W P O S I T I O N S S x = 8 0 . 4 m m
I N J E C T I O N T I M E M O N I T O R I N G
M I N = 0 . 0 0 M A X = 0 . 0 0 Z S x = 0 . 0 0 s
I N T R U S I O N T I M E Z I N = 0 . 0 s
I N T R U S I O N S P E E D . V 2 3 = 0 %
At closed loop control via servo valve the 4th speed can also be set to 80mm/s
M
INJECTION SWITCHOVER SET VALUE CONTROL PARAM-
MODE GRAPHICS ETERS
Plasticizing stroke
The setting of the metering stroke C1 is dependent on the machine size. For checking the set
speed profile the metering stroke should be set to approx. 80% of the maximum stroke.
Maximum speed
The maximum speed must be reached in each case.

Version:G/11/12/7/3
Setting profile for injection speed
The actual speed can be represented on the Micrograph:
M I C R O G R A P H P L U S 1 9 9 6 - 1 0 - 0 9 0 8 4 5
Speed Pressure SCALES: SELECTION 1

AG-1 VSx 100 mm/s
AG-1 PHx 100 ,0 bar
AG-1 SSx 200.0 mm
Strok ACT.VAL:
AG-1 VSx ***.* mm/s
AG-1 PHx ***.* bar
AG-1 SSx ****.* mm
SWOV.POINT UNIT 1
M
MICROGRAPH MICROFLOW
MICROPLAST
Setting profile for closed loop holding pressure control
For checking the closed loop holding pressure control the following pressure profile is
set:
H O L D I N G P R E S S U R E 1996-10-09 14:37’
P O S T I N J . : P R E S S U R E : P 7 T O P 1 6 ( b a r )
8 0 . 0 8 0 . 0 8 0 . 0 8 0 . 0 0 . 0
8 0 . 0 8 0 . 0 8 0 . 0 8 0 . 0 8 0 . 0
H O L D I N G P R E S S U R E T I M E Z 2 = 2 . 0 s
C O O L I N G T I M E A C T = 0 . 0 Z 4 = 0 . 0 s
C U S H I O N M O N I T O R I N G N O
M I N = 0 . 0 M A X = 0 . 0 C P x = 0 . 0 m m
M E T E R I N G S T R O K E C 1 = 0 . 0 m m
S C R E W P O S I T I O N S S x = 0 . 0 m m
H Y D R . P R E S S U R E A C T . V A L . P H x = 0 . 0 b a r
H O L D I N G P R E S S U R E P E A K V A L P N S = 0 . 0 b a r
S C R E W D I A M E T E R S D M = 0 . 0 m m
Set holding pressure time to 2s
M
HOLDING PRES- SET VALUE
SURE GRAPHICS

Version:G/11/12/7/3
M I C R O G R A P H P L U S 1996-10-09 08 45
Pressure SCALES: SELECTION 1

AG-1 VSx 100 mm/s
AG-1 PHx 100 ,0 bar
AG-1 SSx 200.0 mm
ACT.VAL:
AG-1 VSx ***.* mm/s
AG-1 PHx ***.* bar
AG-1 SSx ****.* mm
SWOV.POINT UNIT 1
M
MICROGRAPH MICROPLAST
MICROFLOW
2.3 CLOSED LOOP CONTROL VIA PUMP
2.3.1 PRINICIPLE
Pressure transducer
Injection cylinder
Hydraulic motor for screw

rotation
Stroke transducer
Prop.valve back pres-
Pressure transducer sure
Speed Y
VS
Injection pressure limit P6

P6
EHV pump
Holding pressure K
PN
Specific back pressure YS EHV pump amplifier card

PS
Analog card

Version:G/11/12/7/3
2.3.2 INJECTION SPEED

At machines with EHV pump the injection speed is closed loop controlled via the set value
setting on the pump. The speed profile for injection is processed by means of closed loop
position control.
Advantages of the position-referred closed loop injection control:

- better absolute accuracy
- better precise reproducibility
- less counterpressure dependence
- simple setting
Setting of the closed loop position control:

The position closed loop control is distinguished by a simple setting. A parameter (kr = P
share) must be set. The position controller controls on the basis of set/actual position of the
screw and supplies an adjustable in Volt.
Closed loop control with pilot control value:

With the factor ’ks’ a so-called pilot control value (also control circuit amplification) can be set,
which acts as basic value for the controller output and stems directly from the linearization
table. At ks of e.g.: 0.9 the open loop controlled output is set to 90%. The rest is compensated
by the controller.
ks = ... 90% of the open loop controlled setting (the remaining 10% are
0,900 closed loop controlled)
Kr = 200 ... the control circuit amplification must be set correspondingly
smaller as 90% of the output are set open loop controlled.
umin =0 ... min.output value = 0, dependent on pump electronics
umax = ... max. output value = 10V
10000
tn, tv = ... I and P share on zero
0,000
tr = ... Closed loop control employment delay
0,000
Starting from the basic setting the controller can still be optimized. Set (increase) the
amplification kr so that a minimum overswing can be reproduced. Max. overswinger of 5mm/s
(at a set value of 80mm/s) allowed. At the braking to a small speed the underswinger must not
have more than 5mm/s. After 200ms at the latest the transient effect must be finished. A
decrease of ks brings more of controller employment, i.e. the control circuit amplification kr
must be increased.
2.3.3 PRESSURE LIMIT

At machines with EHV hydraulic system without servo valve the pressure limit is closed loop
controlled by the EHV pump electronics on set value P6 with the system pressure transducer
as measuring system. Moreover, a software controller superimposes the hardware control
circuit by influencing P6.
The set D share (tv) is only effective in the pressure increase time. With reaching the pressure
limit this share is disconnected in order to get an improved control behaviour.
Setting of the pressure limit:

Parameters Presettings typ. after alignment
kr 0,100 0,300

Version:G/11/12/7/3

tv 0,000 0,100 sec
tn 0,000 0,000 sec
umin -2000 -1600 mm
umax 0 0 mm
ks 1,0 1,0
increase kr until first oscillation tendencies arise, afterwards decrease tn with a kr without
oscillation tendencies until the transient process can be accepted.
In order to avoid a too large overswing, also the correcting variable limitations can be adjusted.
As the pressure limit is often set by means of approach to mechanical stop, an overswing can
hardly be avoided, but moulding trials have shown that at a real pressure limit with material the
closed loop control reacts fast enough.
2.3.4 HOLDING PRESSURE

In order to increase the accuracy of the closed loop pressure control, it is possible to connect
to the pressure limit controller of the pump still a controller in series on the analog card. This
measure compensates overdynamic processes and deviations, which can be caused by the
open loop controlled setting.
The PID controller for the holding pressure must be switched on on the screen page ’PV
control parameters’. It controls on the basis of pressure set/actual value and supplies an
adjustable in Volt.
Setting of the closed loop holding pressure control:

kr 10 30
tv 0,0 0,030 sec
tn 0,0 0,000 sec
umin 0 -1000 mV
umax +10000 +10000 mV
ustart --- --- mV
ks 1,0 1,0
Increase kr so long until first tendencies towards oscillations arise, afterwards increase tv with
a kr without tendencies towards oscillations until the building-up transient oscillation can be
accepted.
2.3.5 BACK PRESSURE

The back pressure controller is realized with a PID controller and delivers an adjustable in volts
on the basis of pressure set/actual value difference.
Setting of the closed loop back pressure control:

kr 100 200
tv 0 0,010 sec
tn 1,0 0,150 sec
umin +300 +300 mV
umax +10000 +10000 mV
ustart 2000 2500 mV
ks 0 0

Version:G/11/12/7/3
increase kr at a mean plasticizing speed and a back pressure set value of 10 bar until first
tendencies towards oscillations arise, then decrease tn with a kr without tendencies towards
oscillations until the building-up transient oscillation can be accepted.
In order to avoid a too large overshoot, also the start voltage (ustart) can be adjusted.
If with the setting of kr and tn the tendency towards oscillations cannot be eliminated
completely, by means of small tv setting (D share of 10ms) a considerable improvement can
be reached. The D share must not be chosen too big, however as otherwise the tendency
towards oscillations increases again.
Start value for the controller initialization:

At machines with a separate back pressure proportional valve (EHV1-3 without servovalve) for
the controller a start value USTART can be input. Thus one dampens the overswinger at the
beginning of the control process.
The start value corresponds to that voltage which the controller outputs when starting the
closed loop control if actual = set.
Typical value: ustart: approx. 2500 mV
Start value for controller initialization at active back pressure:

When the active pressure transition from holding pressure to back pressure is activated
(P35249 = 1), the start value USTART must be set smaller as at too large start value the valve
opens and the pressure is reduced immediately.
2.3.6 BACK PRESSURE SURVEY
Specific back pressure
Injection unit without servo valve

Injection unit Calibration
servo.con-
Back pressure Back pressure with prop. closed troled
controlled loop controlled
HLS central K valve --- Servo valve at open loop controlled sep-
arate calibration.
EHV1 --- Closed loop control via Ys valve Servo valve ---
EHV2 separate back Closed loop control via Ys valve Servo valve at open loop controlled sep-
pressure arate calibration.
prop.valve YKs P35463 = 0
P35463 = 0 P09628 = 1
P09628 = 0
EHV3 -“- -“- -“- -“-
2.4 CLOSED LOOP CONTROL VIA SERVO VALVE
2.4.1 GENERAL
In order to be able to reach the best precise repeatability and tightest tolerances, in many
application cases a servo valve is employed on the injection unit in order to closed loop control
with this fast control element the injection speed, the holding and the back pressure.
During the mould filling phase a software position closed loop control occurs. The system
observes the requested speed by setting calculated stroke positions. A closed loop pressure
limit control begins when a maximum pressure (P6) given for sparing the mould is reached. In

Version:G/11/12/7/3
the transition from mould filling to packing phase the switchover from closed loop position
control to closed loop holding pressure control (switchover point) occurs. Here a speed limit is
defined, which follows the speed profile setting up to the 10th profile point.
Principle of the closed loop control with servo valve
Hydraulic pressure transducer
Injection cylinder
Servo valve
Set value setting hydraulic pressure
Stroke transducer
Set value setting speed

Main stream filter
Switchover speed to pressure

Hydraulic
closed loop control
system
Pilot system

Version:G/11/12/7/3
Method of operation of electronically position-controlled valves:
Posit. con- Pilot con- Main con-

troller trol piston trol piston
Position
transducer
0
The term ”Servo” quite generally states that a small input variable causes a big output variable.
In electrohydraulic pressure and speed control circuits servo valves are employed due to their
fast reaction.
For an exact conversion independent of disturbing influences if possible of the electric input
signal in flow or pressure the control piston is position-controlled.
An electric input signal (set value UQS) is given on the position controller integrated in the
valve, which drives current through the torque motor coils.
Like at the mechanically position-controlled valves this causes a pressure difference on the
faces of the control piston and causes its displacement.
The position transducer supplied via an oscillator measures the position of the control piston
(actual value ULI). This actual value rectified by a demodulator is returned to the position
controller, which compares it with the set value UQS. The position controller actuates the
torque motor until set and actual value are the same. Thus the position of the control piston is
proportional to the electric set value. To simplify matters the position set value is designated
as flow set value. The acutal flow from the valve to the consumer depends on the valve
pressure drop.
The following SERVO VALVES are employed:

Two-stage MOOG SERVOVALVES with electronic position control
Three-stage MOOG SERVO VALVES with electronic closed loop position control
BOSCH SERVO VALVES
Detailed documents about functioning and/or sectional drawings can be had at ENGEL after-
sales service for service cases.

Version:G/11/12/7/3
Servo valve connection:

The servovalve is connected directly with the analog control card AR181 and/or AR101,
analog output Ao0+ and Ao0-. Concrete connection occupations shows the electric plan, sheet
15.1 and/or enclosed in the machine. 29.9.
2.4.2 INJECTION SPEED

The speed profile for injection is processed by means of closed loop position control. One
parameter (kr = P share) must be adjusted. The position controller controls on the basis of set/
actual position of the screw and supplies a correcting variable in Volt.
Setting of the closed loop position control:

kr 0 600
tv 0,000 0,000 sec
tn 0,000 0,000 sec
umin -10000 -10000 mV
umax +10000 +10000 mV
ustart --- --- mV
ks 0,000 0,000
Afterwards the amplification kr must be set so that a minimum overswing can be reproduced.
Max. overswing of 5mm/s (at a set value of 80mm/s) is allowed. When braking to a small
speed the underswinger must not have more than 5mm/s. After 200ms at the latest the
transient effect must be finished.
Closed loop control employment delay:

As at the closed loop control via a servo valve the delay of the pump at start injection shall not
go in, the pump is actuated earlier by the time P35257 [1/100 sec] before the controller gets
active on the servo valve.
2.4.3 PRESSURE LIMIT

By the closed loop control of the pressure limit with servovalve on the set value setting P6 the
pressure limit can be closed loop controlled regardless of the speed controller.
The always effective pump controller runs with set value P6 plus an adjustable tolerance
range.
The pressure limit closed loop control occurs via a PID controller algorithm and acts on the
speed set value setting at servo valve closed loop control.
Before reaching the pressure limit a PD controller without I share (tn) acts. After reaching the
injection pressure limit a PI controller without D share (tv) becomes active, through which in
the pressure closed loop control phase larger stability is reached.
The stroke point of the first exceeding is marked with a red line in the set value graphics for
injection.

kr 0,100 1,400
tv 0,000 0,150 sec
tn 0,050 0,050 sec
umin 0 0 mV
umax +2000 +2000 mV
ustart --- ---
ks --- ---

Version:G/11/12/7/3
increase kr so long until first tendencies towards oscillations arise, afterwards increase tv with
a kr without tendencies towards oscillations so long until the overshooter drops to an
acceptable value without that the system begins to swing.
The pressure limit closed loop control should best be set to material cushion. If this is not
possible, one can set the closed loop control also to stop, but must consider that the behaviour
could worsen with material.
For the setting to stop a pressure value of 90% of the maximum injection pressure shall be set.
Start position for the control of the pressure limit closed loop control is always the front screw
position (ssx = 0.0mm)
2.4.4 HOLDING PRESSURE

After switching over to holding pressure the PI holding pressure controller gets active.
The PI controller must be switched on on the screen page ’PV control parameters’. It controls
on the basis of pressure set/actual value and supplies a correcting variable in Volt.
Setting of the closed loop holding pressure control:

kr 0 70
tv 0 0,000 sec
tn 10,000 0,700 sec
umin -5000 -5000 mV
umax +5000 +5000 mV
ustart --- --- mV
ks 0 1,2
(only in case of leakage oil
compensation)
Increase kr until first tendencies to oscillate arise, afterwards decrease tn with a kr without
tendencies to oscillate until the transient effect can be accepted.
Leakage oil compensation (only at closed loop control with servo valve):
At machines with Moog valve the covering of the valve can be compensated by means of a
leakage oil compensation (P35483 = 1). For this purpose it is necessary to take up a
linearization of the pressure via the valve. The value from the linearization table * ks
(correction factor) is then added to the determined adjustable.
With leakage oil compensation a part of the integral share is covered by means of
compensation, thus the I share of the PI controller can decrease.
Another advantage of the leakage oil compensation lies in the fact that at the switchover to
holding pressure the controller is set on the open loop controlled value immediately and thus
an underswing can be avoided.
2.4.5 BACK PRESSURE

The back pressure controller is run via a PI controller and supplies a correcting variable in Volt
on the basis of pressure set/actual value difference.

kr 0 250
tv 0 0,000 sec

Version:G/11/12/7/3

tn 1,0 0,150 sec
umin -1000 -200 mV
umax +10000 +10000 mV
ustart 0 0 mV
ks 0 0
Increase kr until first tendencies to oscillate arise, afterwards decrease tn with a kr without
tendencies to oscillate until the transient effect can be accepted.
2.5 SPEED LIMIT
2.5.1 V LIMIT AT HLS HYDRAULIC SYSTEM

As speed limit on closed loop controlled machines the last servo valve output is used, which
acts as an adjustable limitation.
If this correcting variable limitation is smaller than the set minimum limitation, the minimum
limitation (adjustable as P35241) is used.
At open loop controlled HLS machines a fixed holding pressure volume is output (P35046 )
2.5.2 V LIMIT AT EHV HYDRAULIC SYSTEM

The speed profile is continued as a function of stroke during the holding pressure phase and
acts as speed limit. The corresponding speed tags remain actuated during this time.
On mechanical stop the volume gets effective on stop (P12814), which is approached via the
ramp P35164. See

Version:G/11/12/7/3
ERROR SIGNALS (7)
In the control systems it is distinguished between 3 types of error messages:

Sequence errors
System error
Ebias errors
1 SEQUENCE ERRORS
Sequence errors appear on the screen in the ”Sequence error field” with black text on
red underground.
Sequence error field Number of the existing errors
OIL LEVEL 1
MOLD- CYCLE TIME PROD.DATA SELECTABLE PROCESS
PARAMETER COLLECTION TEXT PAGE ANALYSIS
S
The warning triangle appears at the appearance of an error
e.g.: Sequence errors show in plain language messages, warnings and problems.
Note!
The listing of the error texts, consequences and elimination the chapter
”DIAGNOSTICS AND HELP” shows in the operator’s manual. Also, there
are descriptions of the functions of the error acknowledgement and pro-
gram interruption key.
An error help function (Error Help) displays on the control unit descrip-
tion, impact, elimination hint and resetting of an error. See operator’s
manual, chapter ”DIAGNOSTICS AND HELP”
2 SYSTEM ERRORS
A system error message is composed of:
Component number
Error number
Error information
The component number specifies the software component, in which the system error has
appeared and/or has been released.
Creation date: 20.02.2002 Error signals (7)

Version:G/11/12/7/3
A system error produces an immediate stop of the whole plant and is displayed on the
following output devices:
screen display
Status report (diskette, printer)
Status leds
System errors are distinguished depending on releasing module:

local CU211 and/or (EC100/CC100)
CU212
AR n AR1x1 (Analog card)
RC n CU201 (RC100); see handling system description
2.1 SYSTEM ERROR DISPLAY ON THE SCREEN AND IN THE STATUS REPORT
After the appearance of a system error a screen image appears with information for
localising the error
locally S Y S E R R 1012 / 5
SYSERR: locally 1012 / 5 software version: ’ 1.15x ’ 0/ 1/ 81
INFO: ''
01 00 00 00
Module ’KB ’ Line-#: 382 Rev: 1. 14
CPU: 00000202 00000000 00000000 00000000 00000000 00000000 00000000 00000000
RX: 70.410s stop_cnt: 1 task: 'KB_KFTC_task' prior: 8/ 8 region-cnt: 0
stack-size: 1020 unused: 228 base: 00496D98H frame: 00497150H
run: 0.100ms / 0.5%
Call-Stack: 0052FF1F 00532378
HW-Interrupts:
0.45/0.45/0.25/ 5.2 ------- 0.10/0.10/0.05/ 0.0 -------
------- ------- ------- -------
RX-Prior:
------- ------- 0.55/0.55/0.40/ 8.5 0.15/0.15/0.10/ 0.5
------- ------- 0.35/0.35/0.30/ 1.6 0.30/0.15/0.10/ 0.1
0.65/0.60/0.10/ 1.2 ------- 13.7/13.2/0.95/19.0 -------
280/ 279/95.0/20.9 ------- 0.30/0.25/0.20/ 0.0 -------
SYSERR
Releasing structural unit: Station number:
‘local’ CU211 and/or CU212 81 - 84
‘AR n’ Analog card AR1xx (n = 1 - 4) 61 - 64
‘RC n’ RC100 (CU201) (n = 1 - 4) 41 - 44
Component number
Error number
SW version designation
Bus type
Master ID
Station number
Error signals (7) Creation date: 20.02.2002

Version:G/11/12/7/3
INFO
Additional information:
as ASCII string (under ‘ ‘)
as Hex codes (10 00 ...)
MODUL
Module name
Module line number
Module revision
CPU
CPU reister:
CU211 and/or EFLAGS
CU212
CU201 PSR, ASR
RX
General information
RX-Run-Time
Stop-Counter
Task-Information:
Taskname
Priority
Region-Counter
Stop-Counter
Stack-Size
unused Stack
Stack-Base
Frame-Pointer
run-time
run time in % to the total run time
Call-Stack
Return addresses of the last function call-ups
Performance
HW-Interrupts
RX priorities
3 COMPONENT NUMBERS
The component number specifies the software component, in which the system error
has been released.
The software components are divided into the following two groups:
Application-independent components (General Software Library): These are software
components which are allocated to now special project and are therefore employed in
most different applications (e.g.: EEPROM driver, interface driver, operating system, ...)
Application-dependent components: These are software components, which have been
developed specially for a certain application (EC100/CC100) (e.g.: EBIAS interpreter,
data administration, ...)

Version:G/11/12/7/3
For the two component groups two value ranges have been defined:
1 ... 999 Application-independent components (general)
>= 1000 Application components (EC100/CC100)
Attention!
Component 0: The component 0 is reserved for ”old” EC100/CC100 sys-

tem errors. This are system errors which are called up from ”old” mod-
ules without component number.
For the component 0 the division of the system error numbers into gen-
eral system error numbers and component-specific error numbers does
not apply either !
3.1 COMPONENT SURVEY
3.1.1 COMPONENT SURVEY ”LOCAL”
application-independent (general):
Number Short designation Long designation
1 SYSERR SYSERR treatment
4 SIO Serial in and output
5 P3964R Siemens P3964R data transmission record
10 CI021 Full CAN bus driver
11 EEPROM Driver for serial EEPROM
12 RXCOM Kemrobus communication for operating system RX
13 RX Operating system RX
14 MM dynamic memory administration
17 KB Kemrobus Interface (Level 2)
18 KBCOM Variables communication for Kemrobus
19 PSX POSIX interface for C-Library
20 FS File system (MS-DOS-compatible)
21 FSKB File system via Kemrobus
22 CONVERT Numbers converting routines
23 LZW LZW - compression / decompression
24 ECC Error Checking & Correcting
25 COP CAN open driver
26 MT161 Moog driver
27 DC161 CAN DC161 module driver
28 SRE3I Driver for II030 axis
29 CTS CAN Temposonic sensors
30 AC441 CAN Analog Module 4 In, 4 Out
31 DC661 CAN Digital Module 16 In, 16 Out
32 DC201 CAN Digital Module, 32 In
33 HT401 Driver for HT401 on the CAN bus
35 MMPAB Multi-master process image AR181/RC100
dependent on application (EC100/CC100):
SYS386
1000 TST Power On Self Test
1001 AKP AKP-0
1002 TIM Timer
1003 INT Interrupt

Version:G/11/12/7/3
dependent on application (EC100/CC100):
SYS386
1004 IOB I/O - Interface
1006 SYS System
1007 PCB PCB administration (card administration)
1008 EBOS EBOS operating system shell
1009 E2P EEPROM intermediate layer
1010 GI Grafik Interface
1011 GE Grafik Emulation
1012 KB Keyboard Interface
1013 CMD4P CMD4P record
1014 DEVIO Data output DEVIO
1015 BMP Bitmap administration
1016 DPM Dual Port Memory driver for SI024
1017 XL Firmware Hex-Loader for SI024
1018 IB Administration of the Interface Boards on IEB1 and IEB2
1019 RTC Clock module (Real time clock)
1020 FLPY Floppy administration
1021 PRT Printer
1022 SK Soft key administration
KEBASYS
1100 EI EBIAS Interpreter
1101 EBI EBIAS Interface
1103 DAT Data administration
1104 DD Data dialog
1105 HLP Help function
1106 HST PC-Host
1107 URM Access rights administration
1108 UM Units administration
1109 EXL Excel - Treiber
1110 DIO Digital in and outputs
1111 DM Dialog Manager
1112 MFT Machine function table
1113 PL Plausibility check
1114 HCPY Hardcopy
1115 DEB Debugger
1116 DC161 CAN bus driver for DIO module DC161
1117 CB CAN bus inclusion
1118 MOUNT Mount work devices
1119 HWCHK Hardware check
1120 ERR Error administration
1121 CANOP CanOpen inclusion
1122 CM161 Can bus module for DC161
1123 CMLENZE Can bus module for Lenze drives
1124 LENZE Can bus driver for Lenze drives
1125 CM441 CAN bus module for AC441
1126 CM201 CAN bus module for DC201
1127 CM661 CAN bus module for DC661
ENGSYS
1200 AR Analog card (AR161, AR101)
1201 ARCOM AR communication
1202 ARFLP AR - Floppy
1203 RC RC100 Handling
1204 EM15 Euromap 15
1205 E8T E8thermo

Version:G/11/12/7/3
3.1.2 COMPONENT SURVEY ”AR N”

At present of the following AR1x1 components system errors are released.
application-independent (general):
4 SIO Serial in and output
10 CI021 Full CAN bus driver
11 EEPROM Driver for serial EEPROM
12 RXCOM KEMRO bus communication for operating system RX
13 RX Operating system RX
14 MM Dynamic memory administration
17 KBI KEMRObus Interface (Level 2)
18 KBCOM KEMRObus Interface (Level 7)
26 MT161 Moog driver
28 SRE3I Driver for II030 axis
29 CTS CAN Temposonic sensors
35 MMPAB Multi-master process image AR181/RC100
application-dependent (AR1x1):
1000 MMCOM Multi-master communication AR1x1
1001 POSIX POSIX interface (C Library )
1002 AIO Analog Input/Output
1003 EBIAS EBIAS interface
1005 DIN Digital Input
1006 GRAPHICS Graphic recording
1009 SYS General system modules
1011 HW Hardware interface
1012 XIO Extended Input/Output
1101 MT161 MOOG CAN bus driver (low level)
1102 MSA MOOG CAN ST interface (high level)
1103 CTS CAN-Temposonics-Sensor
1104 CANDEV CI021 general CAN bus ST interface
1200 FB Function modules
1300 ST AR1x1 ST program treatment
1400 CPU_FAULT Intel 80960 CPU-Fault-Exeptions
2000 USER Errors which are released by the user with the ST call-up
ERROR
4 SYSTEM ERROR NUMBERS
4.1 GENERAL SYSTEM ERRORS

These system errors are component-independent errors, i.e. they can appear in each
component.
For this error the range of 1 - 99 is reserved.
Valid for ”local” and ”AR n”.
Val. Symbol Meaning

1 E_NO_IMPLEMENTATION Function not implemented
2 E_INV_PARAM invalid parameter
3 E_INV_TOKEN invalid token
4 E_INV_STATE invalid status
5 E_TIMEOUT Timeout
6 E_NO_MEMORY no memory space existing any longer
7 E_NULL_PTR invalid ZERO pointer
8 E_DIV_ZERO Division by zero
9 E_NO_ACCESS unallowed access, no access right
10 E_INV_CHKSUM invalid check sum

Version:G/11/12/7/3
11 E_NO_FREE_TOKEN no free token existing any longer

12 E_INV_DATA invalid data
13 E_INV_LEN invalid length
14 E_INV_BUF_LEN unallowed buffer length
15 E_INV_DATA_LEN unallowed data length
16 E_INV_OFFSET unallowed offset
17 E_OPEN_FILE Error at file opening
18 E_WRITE_FILE Writing error
19 E_READ_FILE Read Error
20 E_CLOSE_FILE Error at file closing
21 E_INV_PTR invalid pointer
22 E_INV_CASE invalid branching
23 E_UNKNOWN_INTERRUPT undefined and/or unknown Interrupt
24 E_POWERFAIL Power failure)
25 E_WATCHDOG Watchdog
26 E_DATA_OVERFLOW Data overflow
27 E_OFFLINE no connection, offline
28 E_INV_OPCODE invalid opcode
29 E_INCONSISTENCE Inconsistancies recognized
30 E_INV_NR Numbering invalid
31 E_INV_TYPE Type invalid
32 E_INV_FORMAT Format invalid
33 E_ABORTED interrupted transmission
34 E_INV_ADR invalid address
35 E_INV_OVERRUN Overflow
36 E_INV_MODE wrong mode
98 E_ASSERT Negative parameter examination
99 E_NOT_OK general, other error
4.2 COMPONENT-SPECIFIC SYSTEM ERRORS ”LOCAL”

In contrast with the general system errors the component-specific system errors are only valid
for the specified component. For these errors the range starting from 100 is reserved.
(Exception component 0)
Component 0 system errors without component number

This component represents an exception. The general system errors are invalid!
Val. Modul Meaning
1 MAIN32C Watchdog
7 MAIN32C ILLGEAL ENABLE
8 MAIN32C invalid parameter at SET_*
10 SYS32C System call-up is not implemented
12 SYS32C EBISYS call-up is not implemented
14 MAIN32C Call-up of the watchdog maintenance ”WATCHDOG” outside the INIT phase
35 MAIN32C CRC32 - EPROM check sum error
36 MAIN32C first RAM defective
37 MAIN32C last RAM defective or missing
39 RAMT16 RAM error (Ram test)
49 BSIO too long output string at STRINGOUT
50 BSIO Call-up of CHAROUT or STRINGOUT under disable
51 BSIO invalid interface channel
52 BSIO Reception buffer is too small
53 BSIO invalid SERINIT parameter
54 BSIO System error appeared on the E-HSI
55 BSIO E-HSI Read Timeout
56 BSIO E-HSI Write Timeout
57 BSIO E-HSI command Timeout
58 BSIO Call-up of an E-HSI command under disable
96 SCREENC WRITE without OPEN
97 SCREENC CLOSE without OPEN
98 SCREENC WRITEV with too long output string
99 PRINTC WRITE without OPEN
100 PRINTC OPEN of other task
101 PRINTC CLOSE without OPEN
102 PRINTC invalid control character
104 KEYBOR READ already active
105 KEYBOR READ input zone length exceeded
106 KEYBOR invalid format indication
112 TXTHC invalid image definition
113 E8TDRV Error at driver initialization
114 E8TDRV addressed card not existing
115 E8TDRV invalid parameter (channel number, card number, ID)
116 E8TDRV Card timeout on the I/O bus
117 E8TDRV invalid driver descriptor
118 E8TDRV VAR-QUEUE overflow
120 ANADRV Analog card timeout E16ANAIN - 1
126 MOUNT RELEASE_DEVICE without REQUEST_DEVICE
127 MOUNT DISCONNECT_DEVICE without CONNECT_DEVICE
128 MOUNT invalid device
130 GRFVIDC WRITE without OPEN

Version:G/11/12/7/3
Component 0 system errors without component number

131 GRFVIDC OPEN without CLOSE
132 GRFVIDC invalid end characteristic in the CRT string
133 GRFVIDC invalid control character in the CRT string
134 GRFVIDC GKS_TEXT - text string too long
135 GRFVIDC Function not implemented
136 GRFVIDC Error at graphic interpreter
140 PRINTC no graphic manifold
141 PRINTC Graphic manifold already exists
142 PRINTC Grafikpuffer overflow
155 COM1KE (Euromap 15) Error at EM15 initialization
156 COM1KE Error when transmitting EM15 data
157 COM1KE EM15-HSI signals fatal error
158 COM1KE other fatal error at EM15
194 TEST EBIAS configuration error
196 EBIAS32 Machine number <> EBIAS machine number: EBIAS loaded
197 EBIAS32 Machine number <> EBIAS machine number: EBIAS erased
198 - demanded memory area not available
199 - invalid CASE number
Component 4 general
SIO Serial in and output
Val. Symbol Meaning
100 E_SIO_INV_CHANNEL invalid interface channel
101 E_SIO_INV_MODE Function must not be called up in the chosen mode of operation
102 E_SIO_INV_HS
103 E_SIO_CHANNEL_NOT_AVAIL
104 E_SIO_PAR_BAUD_EQ Interface channel is not available
105 E_SIO_PAR_BAUD_RECV
106 E_SIO_PAR_BAUD_SEND
107 E_SIO_PAR_DATA_BITS
108 E_SIO_PAR_PARITY
109 E_SIO_PAR_STOP_BITS
110 E_SIO_PAR_MODE
111 E_SIO_UART_OVERRUN_ERROR
112 E_SIO_UART_PARITY_ERROR
113 E_SIO_UART_FRAMING_ERROR
114 E_SIO_UART_BREAK_DETECTED
115 E_SIO_INV_PARAM
116 E_SIO_INV_TYPE
117 E_SIO_CALL_UNDER_DISABLE Function call-up may only occur under ENABLE
118 E_SIO_INV_DEVICE_NUMBER
119 E_SIO_INV_DEVICE
120 E_SIO_CMD_ACTIVE E-HSI command is still active
121 E_SIO_HSI_ERROR System error appeared on the E-HSI
122 E_SIO_READ_DATA_TIMEOUT E-HSI Read Timeout
123 E_SIO_WRITE_DATA_TIMEOUT E-HSI Write Timeout
124 E_SIO_CHANNEL_ALREADY_INSTALLED
125 E_SIO_CHANNEL_NOT_INSTALLED
126 E_SIO_SEND_BUF_FULL Transmission buffer is full, no space free any longer
127 E_SIO_RECV_BUF_FULL Reception buffer is full, no space free any longer
128 E_SIO_NO_CHAR_RECVD no character received
198 E_SIO_GENERAL_SYSERR
199 E_SIO_GENERAL_WARNING
Component 5 general
P3964R Siemens P3964R data transmission record
Val. Symbol Meaning
200 E_P3964R_NAK_RECVD NAK sign received from the partner station (negative acknowledgement).
201 E_P3964R_UNDEF_CHAR_RECVD Wrong sign received from the partner station.
202 E_P3964R_BCC_ERROR Wrong block test sum
203 E_P3964R_DATA_BUFFER_TOO_SMALL The received data are longer than the made available memory range.
204 E_P3964R_FORMAT_ERROR Faulty telegram format
205 E_P3964R_NO_STX_RECVD Partner station does not send any STX sign.
206 E_P3964R_STX_RECVD STX sign received from the partner station.
207 E_P3964R_INIT_CONFLICT Initialization conflict appeared.
Component 10 general
CI021 Full CAN bus driver
Val. Symbol Meaning
100 E_ CAN_ NO_ FREE_ BUS_ TOKEN For the configuration of another CAN bus system no ressources are available any
longer.
101 E_CAN_INV_CHANNEL Invalid channel number
102 E_CAN_INV_BAUDRATE Invalid Baud rate
103 E_ CAN_ INV_ MSG_ BUF_ NR Invalid message buffer number. This value is allocated by calling up the function
CAN_alloc_msg_buf (range of values: 1 to 14).
104 E_CAN_INV_MSG_ID Invalid message ID (0 - 2031)
105 E_CAN_INV_DIRECTION The indicated transmission direction is in contradiction to the configured one.
106 E_CAN_MSG_NOT_TRANSFERED Message has not yet been transmitted and/or not yet been received.
107 E_CAN_OLD_MSG_DATA Since the last reading access no new message has been received yet.
108 E_CAN_MSG_INVALID Message has not yet been configured.

Version:G/11/12/7/3
109 E_CAN_MSG_LOST Since the latest reading access to this message buffer the data contents has been
overwritten once or several times. The data read out in the current reading access
are the (most current) data received last).
110 E_ CAN_ NO_ FREE_ MSG_ BUF Of the 14 FULL CAN message buffers none is available any longer.
120 E_ CAN_ MSG_ BUF_ ALREADY_ FREE It has been attempted to release a message buffer which has not been reserved
before.
121 E_ CAN_ INV_ MSG_ LEN Invalid message data length (range of values: 0 - 8)
122 E_ CAN_ NO_ FREE_ FILTER_TOKEN For hanging in an additional filter for the BASIC CAN buffer no ressources are
available any longer.
123 E_ CAN_ INV_ QUARTZ Invalid quartz frequency
124 E_ CAN_ BUS_ ALREADY_ INSTALLED The function CAN_install_bus has been called up for a controller twice in a row.
EEPROM driver for serial EEPROM
Val. Symbol Meaning
100 E_EEPROM_INV_BSZ_VALUE invalid machine hours counter
101 E_EEPROM_VERIFY_ERROR Check error (verify)
102 E_EEPROM_RD_WR_ERROR Writing or reading error
103 E_EEPROM_NOT_FOUND EEPROM not found
104 E_EEPROM_WRONG_TYP Unallowed EEPROM type
RXCOM Kemrobus communication for operating system RX
Val. Symbol Meaning
100 E_RXCOM_OPEN_MSG Error when opening a message
101 E_RXCOM_INV_MSG_LENGTH send_data with too long data
102 E_RXCOM_INV_STATION_NR Invalid station number
103 E_RXCOM_SEND_DATA_TIMEOUT Daten-Sende-Timeout
104 E_RXCOM_SEND_UNIT_TIMEOUT Unit-Sende-Timeout
105 E_RXCOM_SEND_CMD_TIMEOUT Command-Sende-Timeout
106 E_RXCOM_SEND_RSP_TIMEOUT Response-Sende-Timeout
107 E_RXCOM_RECV_DATA_RD_MSG Reception error at data message
108 E_RXCOM_RECV_DATA_MBOX_ERR Message could not be stored
109 E_RXCOM_RECV_UNIT_RD_MSG Reception error at Unit Message
110 E_RXCOM_RECV_UNIT_SEMA_ERR Unit could not be stored
111 E_RXCOM_RECV_CMD_RD_MSG Reception error at Command Message
112 E_RXCOM_RECV_CMD_MBOX_ERR Command could not be stored
113 E_RXCOM_INV_NAME_LENGTH Name length too big
114 E_RXCOM_INV_COMMAND Invalid command in server task
200 E_RXCOM_NO_FREE_SERVER No server entry free
201 E_RXCOM_INV_CHANNEL_NR SIO channel already occupied
202 E_RXCOM_INV_MSG_LENGTH Message too long
210 E_RXCOM_SEND_TIMEOUT Sende- Timeout am Bus
211 E_RXCOM_SEND_DATA_TIMEOUT RX_ send_ data- Timeout -
212 E_RXCOM_SEND_UNIT_TIMEOUT RX_ send_ unit- Timeout -
213 E_RXCOM_SEND_CMD_TIMEOUT Timeout command transmission
350 E_RXCOM_SIO_MSG_OVERRU Message buffer overflow
351 E_RXCOM_SIO_RX_TIMEOUT No sign received
352 E_RXCOM_SIO_RX_ERROR SIO reception error
353 E_RXCOM_SIO_TX_TIMEOUT Transmission buffer full
354 E_RXCOM_SIO_TX_ERROR SIO transmission error
355 E_RXCOM_SIO_INIT_CONFLICT Initialization conflict
356 E_RXCOM_SIO_INV_ANSWER Invalid acknowledgement sign
357 E_RXCOM_SIO_CRC_ERROR CRC- Fehler
358 E_RXCOM_SIO_NAC_RECVD Negative acknowledgement received
400 E_RXCOM_OPEN_MSG Error at KBI_open. Send_data KBI interrupt handler
410 E_RXCOM_RECV_DATA_RD_MSG KBI_ rd_ int_ msg != OK
411 E_RXCOM_RECV_DATA_MBOX_ERR Send_ data nach KBI_ rd != OK Send_ unit KBI-Interrupthandler
412 E_RXCOM_RECV_UNIT_RD_MSG KBI_ rd_ int_ msg != OK
413 E_RXCOM_RECV_UNIT_SEMA_ERR Send_ unit nach KBI_ rd != OK Send_ command KBI-Interrupthandler
414 E_RXCOM_RECV_CMD_RD_MSG KBI_ rd_ int_ msg != OK
415 E_RXCOM_RECV_CMD_MBOX_ERR Send_data after KBI_rd != OK
RX operating system RX
Val. Symbol Meaning
100 E_RX_INV_TICK_TIME System time 0 specified
101 E_RX_INV_TASK_PRIOR invalid task priority
102 E_RX_INV_TASK_TOKEN invalid task token
103 E_RX_INV_MBOX_TOKEN invalid mailbox token
104 E_RX_INV_SEMA_TOKEN invalid semaphore token
105 E_RX_INV_TIMER_TOKEN invalid timer token
106 E_RX_INV_OBJECT_TOKEN invalid object token
107 E_RX_INV_OBJECT_TYPE invalid object type
108 E_RX_INV_MSG_LENGTH too long transmission message
109 E_RX_INV_USER_PARAM invalid user parameter number
110 E_RX_INV_TASK_STATE invalid task state
111 E_RX_INV_SEMA_PARAM Invalid region parameters
112 E_RX_NO_OBJECT_ENTRY Object directory is full
113 E_RX_NO_POOL_MEM Pool memory is empty
114 E_RX_MBOX_DELETE Erasing of an occupied mail box
115 E_RX_SEMA_DELETE Erasing of an occupied semaphore

Version:G/11/12/7/3
116 E_RX_ROOT_DELETE Erasing of the Root Task
117 E_RX_ROOT_SUSPEND Suspension of the Root Task
118 E_RX_ROOT_RESTART New start of the Root Task
119 E_RX_ROOT_SLEEP Sleep within the Root Task
120 E_RX_ROOT_WAIT Wait within the Root Task
121 E_RX_ROOT_RECEIVE Receive within the Root Task
122 E_RX_ROOT_LOOKUP Lookup within the Root Task
123 E_RX_ROOT_SET_PRIOR Change priority of the Root task
124 E_RX_STACK_OVERFLOW Stack overflow
125 E_RX_INV_READY_QUEUE invalid Ready Queue
126 E_RX_SCHEDUL_STOPPED Signaling with locked scheduler
127 E_RX_LOOKUP_TIMEOUT Lookup-Timeout über KEMRObus-Interface
128 E_RX_DUPLICATE_NAME Catalog: Name already existing
129 E_RX_EXIT_REGION Release order region sema.
130 E_RX_INV_SUSPEND Self-suspend within region
200 E_RX_TIMEOUT Receive, lookup: time run down
201 E_RX_MBOX_LIMIT Send Message: Limit reached
202 E_RX_SEMA_LIMIT Send Unit: Limit reached
220 E_RX_PRIOR_CONFIG Invalid number of the task priorities
221 E_RX_INT_BEG HW - interrupt - beginning
222 E_RX_INT_END HW- Interrupt - Ende
MM dynamic memory administration (Memory Manager)
Val. Symbol Meaning
100 E_MM_SIZE_TOO_SMALL The memory space made available is too small for the memory administration.
101 E_MM_POOL_NOT_IN_ONE_SEGMENT Error in the free memory list
102 E_MM_POOL_IN_USE Call-up of the function MM_delete_pool although not yet all areas have been allowed.
103 E_MM_INCONSISTENT Inconsistency in the memory administration.
104 E_MM_AREA_SIZE_GT_64K The ordered memory space exceeds the segment size.
105 E_MM_AREA_SIZE_0 The ordered memory has the size 0.
106 E_MM_INV_AREA_PTR Call-up of the function MM_delete_area with an invalid area pointer.
107 E_MM_OVERLAP MM_increase_pool: Memory overlapping
WKM Window and Keyboard Manager
Val. Symbolic designation Meaning
100 E_WKM_NO_FREE_MEMORY no memory available any longer
101 E_WKM_NO_FREE_WINDOW no window available any longer
102 E_WKM_INV_WINDOW invalid window
103 E_WKM_INV_SCREEN invalid screen
104 E_WKM_INV_CHANNEL invalid channel number
105 E_WKM_QUEUE_HEAD Error in the linkage
106 E_WKM_KEY_MBOX_FULL Input buffer flows over
140 E_WKM_INV_KEYBOARD Keyboard number too big
141 E_WKM_INV_KEYTABLE Keytable not correct
200 E_WKM_NO_FREE_LINED no Line Editor available any longer
201 E_WKM_INV_LINED invalid Line Editor
202 E_WKM_INV_LINED_BUFFER invalid Line Editor window
220 E_WKM_NO_FREE_PARED no Parameter Editor available any longer
221 E_WKM_INV_PARED invalid Parameter Editor
222 E_WKM_INV_PARED_WINDOW invalid Parameter Editor window
223 E_WKM_INV_PARAM_TYPE invalid parameter type
224 E_WKM_INV_CV_PR_NR invalid number
225 E_WKM_INV_CONV_FACTOR invalid conversion factor
226 E_WKM_INV_PRECISION invalid indication of the precision
240 E_WKM_NO_FREE_SCRED no Screen Editor available any longer
241 E_WKM_INV_SCRED invalid Screen Editor
242 E_WKM_INV_SCRED_WINDOW invalid Screen Editor window
260 E_WKM_NO_FREE_SCBAR no Scrollbar available any longer
261 E_WKM_INV_SCBAR invalid scroll bar
262 E_WKM_INV_SCBAR_WINDOW invalid scroll bar window
280 E_WKM_NO_FREE_MENU no menu available any longer
281 E_WKM_INV_MENU invalid menu
282 E_WKM_INV_MENU_WINDOW invalid menu window
KB Kemrobus Interface (Level 2)
Val. Symbol Meaning
100 E_KBI_INV_DPM_BASE_ADR The indicated basis address of the Kemrobus Dual Port Memories is not valid.
101 E_KBI_INV_INT_NR invalid Kemrobus interrupt number
102 E_KBI_INV_MASTER_ID invalid master ID
103 E_KBI_DOUBLE_STATION In the bus system there are stations with the same station identification
104 E_KBI_DOUBLE_MASTER_ID In the bus system there are stations with the same Master ID (switch position)
105 E_KBI_SAME_MASTER_LOGON At station announces itself at the bus twice without that a notice of withdrawal (logoff)
has been sent in between.
106 E_KBI_MAX_INT_MSG_CNT The max. number of the interrupt-capable messages is exhausted.
107 E_KBI_MAX_REPORT_FUNC_CNT The max. number of installed information functions about the announcement and
giving notice of stations at the bus is exhausted.
108 E_KBI_INV_STATION invalid station identification (e.g..: 0)

Version:G/11/12/7/3
109 E_KBI_UNKNOWN_STATION The indicated station has not yet announced itself at the bus.
110 E_KBI_INV_STATION_NAME invalid station name
111 E_KBI_NO_DPM_MEMORY In the Kemro bus dual port memory no memory space is free any longer for open
reception messages.
112 E_KBI_INV_BLK_NR Wrong addressing of a memory space in the Kemrobus DPM.
113 E_KBI_ABORT A message to be transmitted could not be written successfully
114 E_KBI_INV_MSG_ID invalid message ID
115 E_KBI_MSG_NOT_OPEN Reading access to a message which has not yet been opened for the reception.
116 E_KBI_MSG_ALREADY_OPEN Double opening of a reception message
117 E_KBI_NO_MSG_DATA No data yet have arrived on this message ID.
118 E_KBI_OLD_MSG_DATA Since the last read-out of this message contents no new data have arrived yet.
119 E_KBI_MSG_OVERFLOW An old message contents which has not yet been read out has been overwritten by a
newly received message.
120 E_KBI_NO_IND_RCVD No order of another station has been received.
121 E_KBI_MAX_IND_CNT The FIFO memory for arriving orders of other stations is too small.
122 E_KBI_INV_TEL_RCVD invalid telegram received.
123 E_KBI_SEND_RES_ERROR The Response telegram to an order cannot be sent.
124 E_KBI_IO_WR_ERROR Error when writing on the indicated I/O address.
125 E_KBI_IO_RD_ERROR Error when reading from the indicated I/O address.
126 E_KBI_FUNC_NOT_INSTALLED Deinstallation of an information function, but which has never been installed.
127 E_KBI_SW_VERSION_INCOMPATIBLE The software version of the KBI component of a foreign station is not compatible with
the own software version.
128 E_KBI_UNKNOWN_MASTER_ID The indicated master ID is not known on the bus.
200 E_KBI_REMOTE_ERROR A foreign station has released a fatal system error.
201 KBI E_ KBI_ REMOTE_ ERROR_EXTENDED A foreign station has released a fatal system error (with extended information
provision).
KBCOM Communication of variables via Kemrobus
Val. Symbol Meaning
103 E_ BTREE_ INV_ CMP_ RC Invalid return value of the comparison function
300 E_KBCOM_VLIST_NO_ENTRY_LOADED No variables have been loaded although the loading process has been started by the
user.
301 E_KBCOM_VLIST_VAR_CNT_NULL Number of the variables to be loaded is 0
302 E_KBCOM_INV_VLIST_VAR_CNT The number of the really loaded variables is not identical with the number announced
before.
303 E_KBCOM_INV_VAR_NAME invalid variable name
304 E_KBCOM_INV_VAR_NAME_LEN invalid variable name length
305 E_KBCOM_INV_VAR_DATA_TYPE invalid variable type
306 E_KBCOM_INV_VAR_ELEM_CNT invalid variable element number
307 E_KBCOM_INV_VAR_TRANSFER_TYPE invalid variable transfer type
308 E_KBCOM_INV_VAR_OWNER invalid indication for the owner of the variable
309 E_KBCOM_INV_VAR_ACCESS_RIGHT invalid variable access rights
310 E_KBCOM_INV_VAR_IDX invalid variable index, no entry in the list of variables existing.
311 E_KBCOM_INV_VAR_LEN invalid variable length
312 E_KBCOM_INV_PAB_VAR_ADR invalid PAB variable address
313 E_KBCOM_INV_REMOTE_VAR_IDX invalid index of a remote variable
314 E_KBCOM_INV_REMOTE_VAR_OWNER Together with a foreign station the own station is owner of one and the same variable.
315 E_KBCOM_INV_REMOTE_VAR_DATA_TYPE The indication of the data type of the local and of the remote variable is not identical.
316 E_KBCOM_INV_REMOTE_VAR_ELEM_CNT Element number of the local and of the remote variables are not identical.
317 E_KBCOM_INV_REMOTE_VAR_TRANSFER_T The indication of the transfer type of the local and of the Remote variables is not
YPE identical.
318 E_KBCOM_DUPLICATE_VAR_NAME In the list of variables two variables are entered with the same name.
319 E_KBCOM_REMOTE_VAR_EXPECTED At the loading of the list of variables at first all local variables must be loaded before
the Remote variable.
320 E_KBCOM_VAR_NO_OWNER Reference to a variable to which no owner has been determined yet.
321 E_KBCOM_GET_VAR_ERROR negative Return code of the user function Get_var.
322 E_KBCOM_GET_PACKET_VAR_ERROR negative Return code of the user function Get_packet_var.
323 E_KBCOM_PUT_VAR_ERROR negative Return code of the user function Put_var.
324 E_KBCOM_NO_VAR_TEMPLATE A package of variables has been ordered although no template has been sent yet.
325 E_KBCOM_EMPTY_VAR_TEMPLATE The indicated variables package template is empty.
326 E_KBCOM_INV_PAB_GROUP invalid PAB group (allowed values 0 up to 6)
327 E_KBCOM_INV_STATION invalid station number
328 E_KBCOM_OWN_STATION separate station number
329 E_KBCOM_UNKNOWN_STATION unknown station number
330 E_KBCOM_DATA_INCONSISTENT At the transfer of unstructured data the number of the received manifold and/or
segment is not identical with the awaited one.
331 E_KBCOM_DATA_INV_BYTE_CNT The length of a data manifold handed over by the user is not identical with the
expected one.
332 E_KBCOM_TOO_MANY_PAB_VARS Too many local PAB variables have been specified.
333 E_KBCOM_TOO_MANY_REMOTE_PAB_VARS A remote station possesses too many local PAB variables.
334 E_KBCOM_PAB_DATA_INCONSISTENT When reading out a PAB group not yet all appertaining messages have been received
newly since the last read-out process.
335 E_KBCOM_RD_DATA_BLK_ERROR negative Return code of the user function Rd_data_blk
336 E_KBCOM_PAB_VAR_DATA_TYPE_NOT_ALLO The indicated data type is not allowed for a PAB variable on a certain station.
WED
337 E_KBCOM_DATA_FUNC_NOT_INSTALLED A foreign station wants to exchange unstructured data with the own station although
on this station still no function has been installed by the user for the servicing of data
orders.
338 E_KBCOM_DATA_TRANSFER_ACTIVE The function KBCOM_exit has been called up during a still active data transfer with
another station.
400 E_KBCOM_TMP_VLIST_INCONSISTENT The linkage of the temporary list of variables is faulty.
401 E_KBCOM_SEND_VLIST_TIMING the list of variables has run down although on the partner station the layer 2 and layer
7 are still active.
402 E_KBCOM_FETCH_VLIST_TIMING The max. waiting time when requesting the list of variables has run down although on
the partner station the layer 2 and layer 7 are still active.
403 E_KBCOM_SEND_VLIST_INV_RESULT Invalid result received from the partner station.
404 E_KBCOM_FETCH_VLIST_INV_RESULT Invalid result received from the partner station.
405 E_KBCOM_VLIST_DESC_ARRAY_FULL The ordered dynamic memory for recopying the variable descriptions is full.
406 E_KBCOM_MAX_VLIST_DATA_IND_CNT Too many VLIST or DATA orders have been received on one station

Version:G/11/12/7/3
407 E_KBCOM_MAX_VAR_IND_CNT Too many orders of variables have been received on one station.
408 E_KBCOM_MAX_VAR_PACKET_IND_CNT Variables package orders received on a station.
409 E_KBCOM_INV_TEL_TYP A telegram with unknown telegram type has been received.
411 E_KBCOM_SEND_REQ_ERROR Error when sending a Request telegram.
412 E_KBCOM_SEND_RES_ERROR Error when sending a Response telegram.
413 E_KBCOM_SEND_TEL_TIMEOUT A telegram to be transmitted cannot be sent within the given time.
414 E_KBCOM_RECV_TEL_TIMEOUT An expected telegram is not received within a given time.
415 E_KBCOM_PAB_CALC_INCONSISTENT Error in the calculation of the structure of the PAB.
417 E_KBCOM_INV_RESTART_PARAM A new start of the KBCOM layer of a partner station has not been registered.
418 E_KBCOM_INV_MAX_PACK_NAME_LEN The packed name length is no multiple of 4.
419 E_KBCOM_INV_DATA_BLK_SEG_LEN Invalid segment length within a data manifold.
420 E_KBCOM_SW_VERSION_INCOMPATIBLE The software version of the KBCOM component of a remote station is not compatible
with the own Software version.
600 E_KBCOM_VLIST_NO_INITIATE Initiate telegram could not be transmitted as at the partner the reception message is
occupied.
601 E_KBCOM_VLIST_ALREADY_COMPLETE already complete. All variables are allocated to one owner.
602 E_KBCOM_VLIST_ALREADY_SENT The list of variables has already been transmitted.
603 E_KBCOM_VLIST_ALREADY_RECVD The list of variables has already been received.
PSX POSIX interface (C-Library)
Val. Symbol Meaning
100 E_PSX_INV_THREAD_PTR No Thread-Ptr existing for task
101 E_PSX_INV_STDIO_PTR No Stdio-Ptr existing
102 E_PSX_INV_EXIT_PTR No Exit-Ptr existing
103 E_PSX_INV_MEM_PTR ZERO pointer at FREE
104 E_PSX_SEMA_SIGNAL double semaphore_signal
105 E_PSX_WRITE_STDIN Writing on stdin
106 E_PSX_READ_STDOUT Reading on stdout or stderr
FS Filesystem
Val. Symbol Meaning
100 E_FS_ACCES Access not allowed
101 E_FS_BADF invalid handle
102 E_FS_INVAL invalid argument or operation
103 E_FS_MFILE too many open files
104 E_FS_NODEV Device not existing
105 E_FS_NOFDEV Device is no longer free
106 E_FS_NOFILE File not found
107 E_FS_NOENT Directory not found
108 E_FS_INVPATH invalid absolute path or file name
109 E_FS_NOSPC no memory space free any longer
110 E_FS_NOTEMPTY Directory is not empty
111 E_FS_NOTSAM Aim and source drive not equal
112 E_FS_NMFILE no entry found
113 E_FS_NAMETOLONG Path and file name too long
114 E_FS_BREAK Interruption of a file function
115 E_ FS_ INV_ ENTRY Directory entry invalid
150 E_FS_FLCK File locked
151 E_FS_NOFLCK File not locked
160 E_FS_INVBPB not supported BFB parameters
161 E_FS_INTRN internal error
170 E_FS_SEMA_SIGNAL Syserr-Fatal in the Multitask Interface
200 E_FS_CONNECT No connection to the diskette drive
201 E_FS_NODISK No diskette inserted
202 E_FS_WRPROT Diskette writing-protected
203 E_FS_INVFMT invalid format
204 E_FS_INVSEC invalid sector number
205 E_FS_INVTRACK invalid track number
206 E_FS_READSEC Reading error (check sum)
207 E_FS_WRITESEC Writing error (Verify)
300 E_FS_PFD35 unknown PFD35 error
400 E_FS_DEVCHG Memory medium changed
401 E_FS_ASYNC asynchronous error
402 E_FS_HW Hardware error
500 E_ FS_ SERVER_ TIMEOUT Communication to the server interrupted
FSKB file system via Kemrobus
Val. Symbol Meaning
100 E_ FSKBI_ SERV_ NOT_ READY File system via Kemro bus server not ready
101 E_ FSKBI_ NO_ CLIENT_ MBX Client mail box not installed
102 E_ FSKBI_ MBX_ TIMEOUT KEMRObus Timeout
103 E_ FSKBI_ MBX_ TABLE_ FULL No free entries in MBX table
104 E_ FSKBI_ INV_ STATION Station number not existing.
105 E_ FSKBI_ INV_ SERV_ RSP Server sends invalid function code.
106 E_ FSKBI_ INV_ PATHLEN Max. path length exceeded
107 E_ FSKBI_ INV_ CMD Server has received invalid command.
108 E_ FSKBI_ INV_ PARAM Server has received invalid parameters.
109 E_ FSKBI_ INV_ DATALEN Invalid data length transmitted

Version:G/11/12/7/3
110 E_ FSKBI_ INV_ RETCODE Invalid return code
111 E_ FSKBI_ INV_ RENAME_ TOKEN Rename buffer - handling system incorrect
112 E_ FSKBI_ NO_ RENAME_ BUFFER No rename buffer available any longer
113 E_ FSKBI_ FBR_ NOT_ EXISTANT File buffer not created
114 E_ FSKBI_ RSP_ CANCEL_ OVL Too many response messages rejected
115 E_ FSKBI_ RSP_ TABLE_ FULL Too many tasks in response cancel table
116 E_ FSKBI_ CANC_ CNT_ NOTFOUND Cancel counter not found
CONVERT numbers converting routine
In this software component no system errors are released at present.
LZW LZW - compression / decompression
ECC Error Checking and Correcting
Val. Symbol Meaning
100 E_ECC_ERROR_CORRECTED RAM error recognized and corrected.
In the static RAM of the CPU a bit error has been recognized and corrected.
Check the battery voltage. In each case the error should be watched over a longer
period of time. If it appears several times, it is useful to exchange the card.
101 E_ECC_UNCORRECTABLE RAM error recognized and cannot be corrected.
In the static RAM of the CPU several bit errors have appeared.
Due to the set Hamming distance these cannot be corrected any longer.
Check the battery voltage. After the appearance of this error a download must be
carried out by all means. If this error appears several times, the card must be
exchanged.
COP CAN open driver
Val. Symbol Meaning
110 E_COP_NO_FREE_MSG CAN interface has no message buffer
111 E_COP_SDO_TIMEOUT Waiting time for release of the SDO communication has run down
112 E_COP_SDO_CNF_TIMEOUT Waiting time for answer to a SDO request has run down
113 E_COP_APDO_TIMEOUT Waiting time for release of the APDO communication has run down
114 E_COP_APDO_CNF_TIMEOUT Waiting time for answer to a APDO-RTR request has run down
115 E_COP_NMT_TIMEOUT Waiting time for release of the NMT communication has run down
116 E_COP_NO_EMERGENCY_MSG no MSG15 filter entry could be started
117 E_COP_READ a cyclic read PDO could not be read
118 E_COP_EMERGENCY a module has sent an error message
119 E_COP_SDO_COM a record error has appeared
120 E_COP_SDO_ERR Error at the SDO transfer, ’abort’ by user has appeared
121 E_COP_SDO_PARAM Parameter error of the data of a SDO
122 E_COP_SDO_STATE the access to an object is not possible at the current state
123 E_COP_SDO_ACCESS the access to a SDO is not possible
124 E_COP_SDO_HW HW error, thus no SDO access
MT161 MOOG driver
Val. Symbol Meaning
100 E_MT161_INV_SERVO invalid servo number
101 E_MT161_INV_AXIS invalid axis number
102 E_MT161_NO_RESPONSE no answer from servo axis
103 E_MT161_MSG_INVALID invalid message received
104 E_MT161_MSG_OLD no message has been received
105 E_MT161_MSG_LOST Message has been overwritten
106 E_MT161_BUS_OFF CAN bus failed
107 E_MT161_UNEXPECTED_INT unallowed Interrupt
108 E_MT161_NACK_DOWNLD Download not successful
109 E_MT161_TIMEOUT_DOWNLD Time exceeding at Download
110 E_MT161_NACK_PARAM Parameters not taken over
111 E_MT161_TIMEOUT_PARAM Time exceeding at parameter
112 E_MT161_NACK_EEPROM Error at the programming
113 E_MT161_TIMEOUT_EEPROM Time exceeding at programming
114 E_MT161_AT_GLOBAL Servo axis: global error
115 E_MT161_AT_INTERPOLATOR Servo axis: Interpolator error
116 E_MT161_AT_CANBUS Servo axis: CAN bus error
117 E_MT161_AT_SHORT_CIRCUIT Servo axis: Short circuit
118 E_MT161_AT_THERMAL_WARN Servo axis: Overheating
119 E_MT161_AT_PARAMETER Servo axis: Parameter error

Version:G/11/12/7/3
120 E_MT161_AT_RESOLVER Servo axis: Resolver error
121 E_MT161_AT_MOTOR_TEMP Servo axis: Motor temperature
122 E_MT161_AT_BRIDGE_TEMP Servo axis: Bridge temperature
123 E_MT161_AT_BUS_OVERVOLTAGE Servo axis: excessive voltage
124 E_MT161_AT_POWER_SUPPLY Servo axis: Power failure
DC161 CAN bus driver for DC161
Val. Symbol Meaning
100 E_DC161_INV_TOKEN Invalid channel token
101 E_DC161_INV_MODUL No further DC161 module installable or wrong DC161 module number.
102 E_ DC161_ INV_ TCYCLE Invalid cycle time
103 E_ DC161_ NO_ FREE_ TOKEN No DC161 driver free
104 E_ DC161_ NO_ FREE_ MSG No CAN message buffer free
105 E_DC161_MSG_OLD This digital input message has already been read (new one is missing).
106 E_DC161_MSG_LOST New digital input message received although old one has not yet been read.
107 E_DC161_BUS_OFF CI021 module signals CAN bus error (bus interruption ?)
108 E_DC161_SHORT_CIRCUIT DC161 module signals short circuit of a digital output.
109 E_DC161_MSG_ERROR DC161 module signals communication record error (synchronisation message or
digital output message violates cycle time).
110 E_ DC161_ NO_ RESPONSE No answer from the module
Check configuration data, check CAN bus connection, check module IDs of the
DC161 in the CAN bus, exchange DC161.
111 E_ DC161_ MSG_ INVALID Invalid message received
An invalid CAN message prevents the cyclic data exchange.
Check CAN bus connection, exchange module which causes the error.
112 E_ DC161_ OLD_MSG_ DATA No message received
The actual value telegram necessary for the cyclic processor image of a module is
missing.
Check CAN bus connection, exchange module.
113 E_ DC161_ SHORT_CIRCUIT Short circuit appeared on DC161 channel
114 E_ DC161_ MSG_ ERROR CAN record error
Check CAN bus connection.
115 E_ DC161_ MSG_ UNKNOWN Message contents unknown
Check CAN bus connection.
116 E_ DC161_ MSG_ BFRFULL CAN message buffer is occupied.
SRE3I driver for II030 axis
Val. Symbol Meaning
100 E_SRE3I_INV_SERVO invalid servo number
101 E_SRE3I_INV_AXIS invalid axis number
102 E_SRE3I_READ_LOOP Counter count cannot be read
103 E_SRE3I_COUNTER Counter count deviates
104 E_SRE3I_NULLIMPULS Zero impulse is missing
105 E_SRE3I_POWERSUPPLY Transducer voltage failed
106 E_SRE3I_STOERTEST Malfunction test not successful
107 E_SRE3I_INV_SLOT Slot already occupied
CTS CAN Temposonic sensors
Val. Symbol Meaning
100 E_CTS_INV_TOKEN invalid channel token
101 E_CTS_INV_PORT invalid Port number
102 E_CTS_INV_CYCLE invalid cycle time
103 E_CTS_NO_FREE_TOKEN no CS driver free
104 E_CTS_NO_FREE_MSG no CTS Message Buffer free
105 E_CTS_INV_CMD invalid command
106 E_CTS_INV_CNF_MSG no reception confirmation
107 E_CTS_INV_CONFIRMATION_DATA invalid reception confirmation
110 E_CTS_INV_SENSOR_STATUS invalid sensor status
111 E_CTS_INV_NO_SENSOR_DATA no sensor data existing
112 E_CTS_INV_CAN_ERROR general CAN bus error
120 E_CTS_NODE_EXISTS Knot already existing
121 E_CTS_PROG_SENSOR Sensor cannot be programmed
122 E_CTS_INV_SENSOR_LEN Sensor type and length do not match
123 E_CTS_INV_SENSOR_TYPE Sensor type not known
124 E_CTS_SENSOR_NOT_FOUND Sensor not on the bus
125 E_CTS_SAME_NODE_ID two equal knots in the CAN circuit
AC441 CAN analog module 4 In, 4 Out

Version:G/11/12/7/3
DC661 CAN digital module 16 In, 16 Out
DC201 CAN digital module 32 In
HT401 driver for HT401 on the CAN bus
Val. Symbol Meaning
100 E_CAN_NO_FREE_BUS_TOKEN no further CAN Bus System configurable any longer
101 E_CAN_INV_CHANNEL invalid channel (A or B)
102 E_CAN_INV_BAUDRATE invalid Baudrate
103 E_CAN_INV_MSG_BUF_NR invalid message buffer number (1 .. 14)
104 E_CAN_INV_MSG_ID invalid message ID (0 .. 2031)
107 E_CAN_OLD_MSG_DATA since last reading access no new data have been received
109 E_CAN_MSG_LOST since the last reading access the data contents has been overwritten several times
110 E_CAN_NO_FREE_MSG_BUF no Message Buffer available any longer (14)
120 E_CAN_MSG_BUF_ALREADY_FREE attempted release of a message buffer, which has not been reserved before
121 E_CAN_INV_MSG_LEN invalid message data length (0 .. 8)
122 E_CAN_NO_FREE_FILTER_TOKEN no further filter configurable any longer
123 E_CAN_INV_QUARTZ invalid quartz frequency
124 E_CAN_BUS_ALREADY_INSTALLED the function CAN_install_bus has been called up for a controller twice in succession
MMPAB Multi-Master process image AR181/RC100
Val. Symbol Meaning
100 E_MMPAB_NO_KBI_INIT no KBI_init carried out
101 E_MMPAB_SHUTTING_DOWN_KBCOM Warning: KBCOM is switched off for loading the list of variables
102 E_MMPAB_SENDER_MISSING MMPAB_start_update: at the first start not for all reception variables a transmitter has
been found. MMPAB_check_inconsistency: the transmission station of the asked
variable has reported off duty with MMPAB_stop_variable
103 E_MMPAB_RESTART_SENDER_MISSING at the restart not all needed transmitters transmit, these have reported off duty
regularly by MMPAB_stop_update
104 E_MMPAB_NO_CYCLIC_READ_PUB_CALL MMPAB_start_update not possible as MMPAB_read_pab is not called up cyclically by
the system environment
105 E_MMPAB_STARTUP_TIMEOUT MMPAB_install_comm: KBCOM could not be run run within
MMPAB_STARTUP_TIMEOUT_MS
106 E_MMPAB_INV_STATION invalid KBI station number
107 E_MMPAB_INV_PUB_PRIO invalid PAB priority
108 E_MMPAB_COM_CYCLE_TIMEOUT Cycle exceedings of the PAB maintenance, no new cyclic PAB data have been
received too long
109 E_MMPAB_INV_STATE the cyclic process image maintenance is in a state invalid in the requested action
110 E_MMPAB_NO_OWNER_VAR for one or several reception variables no transmitter could be found
111 E_MMPAB_INV_VAR_NAME a PAB variable name is invalid or could not be found at MMPAB_check_inconsistency
112 E_MMPAB_NO_RECEIVE_VAR the variable at MMPAB_check_inconsistency is no reception variable.
Component 1000 EC100/CC100

TST acceleration test POST (Power On Self Test)

AKP AKP-0 (8741-Controller)
In this software component no application-specific system errors are released at present.

TIM Timer

INT Interrupt
Val. Symbol Meaning
100 E_INT_DIVIDE_ERROR Devide Error
101 E_INT_DEBUG_EXCEPTION Debug Exception
103 E_INT_BREAKPOINT Breakpoint
104 E_INT_INTO NTO-detected Overflow

Version:G/11/12/7/3

105 E_INT_BOUND_EXCEPTION BOUND Range Exceeded
106 E_INT_INVALID_OPCODE Invalid Opcode
107 E_INT_COP_NOT_AVAIL Coprocessor Not Available
108 E_INT_DOUBLE_FAULT Double Fault
109 E_INT_COP_SEG_OVERRUN Coprocessor Segment Overrun
110 E_INT_INVALID_TSS Invalid Task State Segment
111 E_INT_SEG_NOT_PRESENT Segment Not Present
112 E_INT_STACK_FAULT Stack Fault
113 E_INT_GEN_PROTECTION General Protection
114 E_INT_PAGE_FAULT Page Fault
116 E_INT_COP_ERROR Coprocessor Error
120 E_INT_INV_ENABLE invalid Interrupt-Enable in an Interrupt routine
see also Intel 386-Programmer’s Reference Manual.

IOB IO-bus accesses for Kemrobus
Val. Symbol Meaning
100 E_IOB_LCA_ERROR general error of the Kemrobus LCAs

SYS System

PCB PCB (cards) administration
Val. Symbol Meaning
100 - IO-Ready Error: Digital Input (DI325/DI326)
101 - IO-Ready Error: Digital Output (DO321)
102 - IO-Ready Error: Digital Input/Output
103 - IO-Ready Error: Analog Input
104 - IO-Ready Error: Analog Output
105 - IO-Ready Error: Analog Input/Output (AR181, AR101)
106 - IO-Ready Error: Temperaturregelkarte (E8-Thermo, ...)
107 - IO-Ready Error: Grafikinterface (GC201, E-CRT)
108 - IO-Ready Error: serielle Schnittstellen (E-HSI, SC021)
111 - IO-Ready Error: RC (CU211)
112 - IO-Ready Error: CAN-Bus-Interface
113 - IO-Ready Error: Floppy drive OC101
151 E_PCB_PCB_LIST_FULL The PCB list is full, no entry possible any longer.
152 E_PCB_EEPROM Error at the access to the EEPROM
153 E_PCB_NO_HDL No free handle found at PCB_open
154 E_PCB_ILL_HDL Call-up of a function with an invalid handle.
155 E_PCB_BSZ_INC_FUNC The installed function for increasing the machine hours counter has supplied an error.
156 E_PCB_CLOSE_TIMEOUT PCB-Close has not been called up (sequence of the Timeout time).
200 E_PCB_ILL_TYPE invalid, not known PCB type
201 E_PCB_LIST_END No further entry in the PCB list existing, list end reached.
202 E_PCB_INV_ACTION invalid action at the PCB recording.

EBOS EBOS operating system switch
Val. Symbol Meaning
100 E_EBOS_NO_FREE_TASK Max. number of EBOS tasks has been exceeded.
101 E_EBOS_INV_TASK_NO invalid EBOS task number
102 E_EBOS_NO_FREE_SEMA Max. number of EBOS semaphore has been exceeded.
103 E_EBOS_INV_SEMA_NO invalid EBOS semaphore number
104 E_EBOS_NO_FREE_EVENT Max. number of EBOS events has been exceeded
105 E_EBOS_INV_EVENT_NO invalid EBOS event number
106 E_EBOS_NO_FREE_MEMORY No free memory for task stack available.
110 E_EBOS_INV_GET_MEMORY Call-up of the function GET_MEMORY for static memory after the DELDATA
initialization phase.

E2P EEPROM intermediate layer

GI graphic interface

Version:G/11/12/7/3

GE Grafik - Emulation

KB Keyboard Interface

CMD4P CMD4P record

DEVIO data output

BMP Bitmap administration
Val. Symbol Meaning
100 E_BMP_INV_INTERFACE wrong interface type
101 E_BMP_INV_NR invalid bit map number
102 E_BMP_NO_MORE_BMPS no space for further bit maps
103 E_BMP_BMP_NOT_DEFINED Bit map not existing

DPM Dual Port Memory driver for SI024
Val. Symbol Meaning
101 E_DPM_UNEXPECTED_QUIT_FROM_KPC Invalid acknowledgement of KPC
102 E_DPM_UNEXPECTED_ORDER_FROM_KPC invalid demand of KPC
103 E_DPM_UNKNOWN_INTERRUPT_FROM_KPC unknown interrupt
104 E_DPM_DATABUFFER_TOO_LONG Data buffer too big
105 E_DPM_DATABUFFER_TOO_SMALL Data buffer too small
106 E_DPM_WRITE_KPC_QUIT Acknowledgement when writing

XL firm ware Hex Loader for SI024
Val. Symbol Meaning
101 E_XL_BOOT_REC_NO_MEM No memory obtained for Boot Record
102 E_XL_BOOT_BUF_NO_MEM No memory obtained for data buffer
103 E_XL_BOOT_OPEN_FILE Error when opening the Boot file
104 E_XL_BOOT_UNDEF_RECORD_TYPE Unknown Boot record type
105 E_XL_BOOT_READ_RECORD Boot record reading error
106 E_XL_BOOT_CHECKSUM Boot Check sum error
107 E_XL_BOOT_ADR_TO_LOW Address too small
108 E_XL_BOOT_ADR_TO_HIGH Address too big
109 E_XL_BOOT_KPC_TIMEOUT KPC does not reply
110 E_XL_BOOT_NO_END_RECORD No end record
120 E_XL_MONI_REC_NO_MEM No memory obtained for Monitor Record
121 E_XL_MONI_UNDEF_RECORD_TYPE Unknown Monitor Record type
122 E_XL_MONI_CHECKSUM Monitor Check sum error
123 E_XL_MONI_READ_RECORD Monitor Record reading error
124 E_XL_MONI_OPEN_FILE Error when opening the Monitor file
125 E_XL_MONI_NO_END_RECORD No end record
130 E_XL_FIRM_REC_NO_MEM No memory obtained for Record
131 E_XL_FIRM_UNDEF_RECORD_TYPE Unknown firmware record type
132 E_XL_FIRM_CHECKSUM Firmware check sum error
133 E_XL_FIRM_READ_RECORD Firmware record reading error
134 E_XL_FIRM_OPEN_FILE Error when opening the firmware file
135 E_XL_FIRM_NO_END_RECORD No end record
140 E_XL_KPC_ORDER KPC wrong request

IB administration of the Interface Boards on IEB1 and IEB2

Version:G/11/12/7/3

RTC clock module (real time clock)
Val. Symbol Meaning
100 E_RTC_ERROR Real time clock not existing or not operational

FLPY floppy administration

PRT printer
Val. Symbol Meaning
100 E_PRINT_WITHOUT_OPEN Call-up of a printing function without OPEN
101 E_CLOSE_WITHOUT_OPEN Call-up of CLOSE without OPEN
102 E_ILLEGAL_CTRL_CHARACTER Invalid control character
140 E_NO_GRF_BUFFER Printing buffer not existing (no BEGINNING PRINT carried out)
141 E_EXISTING_GRF_BUFFER Printing buffer already occupied.
142 E_GRF_BUFFER_TO_LONG Too little space existing in the printing buffer.

SK soft key administration

EI EBIAS Interpreter
Val. Symbol Meaning
100 E_EI_IO_TRANS IO error at process copy establishment

EBI EBIAS Interface

DAT data administration
Val. Symbol Meaning
100 E_DAT_END_OF_LIST End of the file list reached
101 E_DAT_INV_DISK_ID Wrong diskette type
102 E_DAT_INV_FILE_NAME Wrong file name
103 E_DAT_INV_IDX Wrong index
104 E_DAT_READ_EBIAS Error at Ebias reading
105 E_DAT_READ_EBIAS_TXT Error at reading
106 E_DAT_READ_TXT Error when reading TXTxxx.BIN
107 E_DAT_ERR_LZW_EXPAND Error at expanding
108 E_DAT_NO_INFO_FILE no INFO file existing
109 E_DAT_FILE_NOT_READ DAT_FILE_READ has not been set
110 E_DAT_FILE_NOT_WRITE DAT_FILE_WRITE has not been set
111 E_DAT_FILE_EXIST File already exists in the list
112 E_DAT_LZW_BUF_MEMORY LZW buffer too small
113 E_DAT_LZW_ACTIVATE LZW already active
114 E_DAT_INV_VERS_NR Invalid version number of the file to be read.

DD Data dialog

HLP help function

Version:G/11/12/7/3

HST PC-host connection

URM access rights administration

UM units administration

EXL EXCEL - Treiber

DIO Digital in and outputs

DM Dialog manager

MFT machine function table

PL plausibility check

HCPY Hardcopy

DEB Debugger

DC161 CAN bus driver for DC161, see description component 27

CB CAN bus inclusion
Val. Symbol Meaning
100 E_CB_SYSERR_WARNING_FUNC Syserr warning function for the component DC161 cannot be hung in (table full)

Version:G/11/12/7/3

Mount MOUNT work devices
Val. Symbol Meaning
100 E_MOUNT_RELEASE_WITHOUT_REQUEST Call-up of RELEASE_DEVICE without call-up of REQUEST_DEVICE
101 E_MOUNT_DISCON_WITHOUT_CONNECT Call-up of DISCONNECT_DEVICE without call-up of CONNECT_DEVICE
102 E_MOUNT_INV_DEVICE Device is already mounted

HWCHECK Hardware-Check

ERR error administration

CANOP CanOpen inclusion
Val. Symbol Meaning
200 E_CANOP_EMERGENCY_LEN Wrong length at error info
201 E_CANOP_ERROR_FUNC Hanging in a treatment function for SYSERR WARNING not possible
202 E_CANOP_NUM_TYPES CANOP_NUM_TYPES is not identical with MODUL_TYPE_FUNC

CM161 Can bus module for DC161
Val. Symbol Meaning
200 E_CM161_NUM_DC161 too many DC161
201 E_CM161_ERROR_FUNC Hanging in a treatment function for SYSERR WARNING not possible
202 E_CM161_ERRINFO_LEN wrong length at error info

CMLENZE Can bus module for Lenze drives

LENZE Can bus driver for Lenze drives

CM441 CAN bus module for AC441
Val. Symbol Meaning
200 E_CM441_INSTALL Error at the installation
201 E_CM441_NUM_AC441 too many AC441
202 E_CM441_IN_CONFIG Error at the configuration of the inputs
203 E_CM441_OUT_CONFIG Error at the configuration of the outputs
204 E_CM441_IN_MODE Input: Mode of operation not allowed
205 E_CM441_OUT_MODE Output: Mode of operation not allowed
206 E_CM441_POINTS_LINTAB Linearization table contains too few items
207 E_CM441_SYNC wrong Sync factor in the EBIAS
208 E_CM441_START an AC441 could not be started

Val. Symbol Meaning
207 E_CM201_SYNC in the EBIAS a wrong SYNC factor has been indicated
208 E_CM201_START a DC201 could not be started

Version:G/11/12/7/3

Val. Symbol Meaning
207 E_CM661_SYNC in the EBIAS a wrong SYNC factor has been indicated
208 E_CM661_START a DC661 could not be started

AR analog card /AR181, AR101)
Val. Symbol Meaning
100 E_AR_NO_EBIAS_TYPTAB No EBIAS table for this card existing.
101 E_AR_LIMIT_EBIAS_TAB EBIAS table too large.
102 E_AR_EBIAS_VARNR No valid EBIAS variable type.
103 E_AR_LIMIT_LINTAB Too many items in a linearization table (> 200).
104 E_AR_CARD_NOT_EXIST AR card with this number not existing in the system.
106 E_AR_LINTABNR Invalid lintab number.
107 E_AR_NR_LOCAL_BOARDS Too many local boards on an AR.
108 E_AR_SEMA_UNITS
110 E_AR_GRAFIK_UPDATE Error at graphics entry in component GRF.
112 E_AR_LIMIT_MAX_NR_AR Too many AR cards existing in the system.
113 E_AR_DIGOUT_MSG Error at Digout transmission from the AR.
114 E_AR_ANZ_MMCOM_SEND_DEFS Too many entries in Multi-Master transmission definition.
115 E_AR_ANZ_MMCOM_SEND_ITEMS Too many entries in Multi-Master transmission definition.
117 E_AR_ANZ_MMCOM_RECV_ITEMS Too many entries in Multi-Master reception definition.

ARCOM AR communication
Val. Symbol Meaning
100 E_ARCOM_RD_SIZE At the call-up of the communication stop function the total number of the transmitted
data bytes is unequal to the ordered file length.
101 E_ARCOM_WR_SIZE The sum of the written data blocks is bigger than the whole file length.
102 E_ARCOM_RD_FILE Error at the reading access to a file.
103 E_ARCOM_WR_FILE Error at the writing access to a file.
104 E_ARCOM_UNDEF_MSG_ID Transmission order with invalid data type.
105 E_ARCOM_SEND_DATA Communication error when transmitting data (KEMBRO bus layer-7)
106 E_ARCOM_FETCH_DATA Communication error when fetching data (KEMBRO bus layer-7)
107 E_ARCOM_BLKNR Order of the transmission blocks not observed.
108 E_ARCOM_CARD_NOT_EXIST Transmission attempt to card which is not on the bus.
109 E_ARCOM_STARTUP_TIMEOUT Requested AR card is not yet on the bus after the expiry of the acceleration time.
110 E_ARCOM_RX_MSG_LEN Message length for RX message (96 bytes) exceeded.
111 E_ARCOM_LIMIT_NR_AR Too many AR cards in the rack.
112 E_ARCOM_AR_BOOT_AFTER_STARTUP AR card has reported on the bus only after the expiry of the acceleration time.
113 E_ARCOM_KBI_BUS_OFF AR card has reported off duty on the bus.
114 E_ARCOM_COM_MBX_NOT_EXIST A necessary communication mail box on the AR has not been found.
115 E_ARCOM_RXMSG_DATA Invalid RX message data received.
116 E_ARCOM_UNDEF_HI_PRIO_COM_TYP High prior communication message with invalid type received.

ARFLP AR - Floppy
Val. Symbol Meaning
100 E_ARFLP_INV_FILENAME invalid file name
101 E_ARFLP_CARD_NOT_EXIST File transmission on not existing AR card
102 E_ARFLP_COM_ERROR Communication error (KEMRO bus layer-7)
103 E_ARFLP_INV_LINTAB Transmission attempt of an invalid lintab (check sum, error feedback of a KAL_xxx
function)

RC RC100 Handling
Val. Symbol Meaning
200 E_RCX_KEY_MBOX_TIMEOUT Key mail box not installed
201 E_RCX_INSTALL_KEYFILTER Key filter function not installed
202 E_RCX_IO_INV_CMD unknown IO command
300 E_RCX_PFS_MBOX_TIMEOUT Pfs mail box not installed
301 E_RCX_COPY_FILE_TIMEOUT Timeout at file transmission
302 E_RCX_MAX_PATH_LENGTH File name too long
400 E_RCX_PRT_INV_CMD Unknown printer command
500 E_RCX_VAR_MBOX_TIMEOUT Var mail box not installed
501 E_RCX_VAR_QUEUE_OVERFLOW Var Queue overflow
502 E_RCX_VAR_INV_CMD unknown variable command
503 E_RCX_VAR_INV_VARTYPE unknown variable type
600 E_RCX_CMD_MBOX_TIMEOUT Cmd mail box not installed
601 E_RCX_INV_CMD unknown command
602 E_RCX_INV_MODE Mode not adjustable
603 E_RCX_MODE_TIMEOUT Transmission timeout
604 E_RCX_INV_PROGRAM_STATE Program state not adjustable
605 E_RCX_INV_PROGRAM_NAME Program name too long

Version:G/11/12/7/3

606 E_RCX_PROGRAM_TIMEOUT Transmission timeout
607 E_RCX_QUIT_TIMEOUT Transmission timeout
608 E_RCX_ROBOT_MODE_TIMEOUT Transmission timeout
609 E_RCX_INV_COORDINATES Coordinates not adjustable
610 E_RCX_COORDINATES_TIMEOUT Transmission timeout
611 E_RCX_HOME_TIMEOUT Transmission timeout

EM15 Euromap 15

E8T E8thermo
Val. Symbol Meaning
113 E_LIMIT Error at driver initialization, all drivers occupied.
114 E_EXIST Addressed card (card/channel) not existing
115 E_PARAM Parameter monitoring
116 E_IOB_TIME Card timeout
117 E_IOB_EXIST invalid driver-descriptor
118 E_VAR_QUEUE VAR-QUEUE overflow
119 other error
4.3 COMPONENT-SPECIFIC SYSTEM ERRORS ”AR N”

In contrast with the general system errors the component-specific system errors are only valid
for the specified component.
Component 1000 AR1x1

MMCOM Multi-master communication AR1x1
Val. Symbol Meaning
100 RD_SIZE Reading over data field limit
101 WR_SIZE Writing over data field limit.
102 RD_LEN Number of read data unequal to the required data length
103 WR_LEN Number of written data unequal to the ordered data
104 OPEN_FILE Error at file opening
105 CLOSE_FILE Error at file closing
106 KBI_INIT Error at the Init call-up layer 2
107 KBI_START Error at the start call-up layer 2
108 KBCOM_INIT Error at the Init call-up layer 7
109 KBCOM_START Error at the start call-up layer 7
110 MEMM_SIZE Too little memory available
111 UNDEF_ID Unknown data ID
112 WRITE_FLASH Error when writing into the Flash
113 NO_PROGRAM No program in the FLASH
114 FETCH_DATA KBCOM_fetch_data delivers error return
115 SEND_DATA KBCOM_send_data delivers error return
116 BLKNR Block number not consecutive
117 WRONG_ID_SWITCH Wrong ID switch position
118 WRONG_STATION Wrong station identification
119 MBX_NOT_EXIST Reception mail box does not exist
200 NR_PAB_VARS Too many variables in the MMCOM EBIAS definitions
201 VARNAME_MISSING No identical variable name found on another station
202 COM_CYCLE_TIME Too many cyclic process image messages are missing
203 MISSING_SENDER Transmitter for Receive variable is missing
204 VAR_TYPE Var type in address list not correct
205 VAR_PRIO Priority in EBIAS definition not correct
206 REMOTE_CARD_NR Remote card number not allowed
207 STARTUP_TIMEOUT Timeout build-up PAB communication
208 NR_REMOTE_CARDS Too many Remote cards

POSIX POSIX interface (C Library )
Val. Symbol Meaning
100 INV_MSG Posix server has received invalid message
101 NO_SHARE no POSIX_init_share carried out at this task

Version:G/11/12/7/3

AIO Analog Input/Output
Val. Symbol Meaning
100 INV_PORT_NO (only AR101) AIO port number too big
101 INV_PORT_MODE (only AR101) Invalid mode of operation for AIO port
100 ANA_READ (only AR161, AR181) Error when reading back the analog outputs on the analog inputs, possibly short circuit
on the output
101 COMP_PORT_NO (only AR161, AR181) HW comparator parametrized with invalid port number
102 COMP_CHANNEL_NO Invalid HW comparator channel number
103 NR_SR161_BOARDS Attempt to operate too many SR161 boards on an AR1x1
104 UREF_VALUE In the EEPROM an invalid value for the analog reference voltage is stored
105 RD_UREF Error when reading the reference voltage in the EEPROM
106 CYCLE_CNT HW comparator: Between the switching event and the comparator call-up there is not
exactly a HW update. Problem at switchover synchronization or comparator not on
2ms plane
115 TOKEN Invalid token

EBIAS EBIAS interface
Val. Symbol Meaning
100 EBIAS_DEF_TYP Invalid EBIAS definition type ( profile, outset, .. )
101 EBIAS_DEF_NR Invalid EBIAS definition number within a type
102 EBIASVAR Invalid EBIAS variable identification ( no set value, actual value, marker, .. )
106 EBIASVAR_MAXIW EBIAS actual value number >= 1024
109 EBIASVAR_MAXID EBIAS actual value Dword number >= 1024
110 EBIASVAR_MAXMK EBIAS marker number >= 2000
111 ANZ_GRF_VALUES WRITE_GRAPHICS call-up with too many graphic points
112 COM_MSG_TYP Communication message of unknown type received
113 SIZE_EBIAS_STRUCT EBIAS definition with more than 500 elements
114 NO_FREE_OBJECT No free ST object of this type existing
115 ANZ_ACTIVE_OBJ More than 128 ST objects active at the same time
116 OBJ_NR Invalid ST object type ( profile, outset, ...)
117 OBJ_INDEX Invalid ST object number within a type
118 STOP_BLOCK Control parameters at BLOCK STOP command > 2
119 PRG_CMD_TYP Invalid ST start/stop command ( not START, STOP or BLOCK STOP )
120 PROF_STOPP_INTERP No interpolating stop point allowed
121 ANZ_PROF_PKTE Profile without profile points defined
122 TYP_HI_PRIO_COM Invalid High Prio communication message received
123 NO_FREE_HI_PRIO_MSG No High Prio communication message free
124 NO_OBJ_INIT No ST objects initialized
125 INV_GO_CMD GO command at running ST running time system

DIN Digital Input
Val. Symbol Meaning
100 DIGINTEST Error at the startup digin test. At AR161 possibly 24V not connected

GRAPHICS Graphic recording
Val. Symbol Meaning
100 MAX_KANAL Channel number too big at PAR_GRAPHICS
101 ANZ_GRAF_VALUES Too many graphic points
102 INV_GRAFIK_ADRLIST Error in address list for graphic module
103 NO_GRAFIK_MEMORY Too little memory for graphic recording

SYS General system modules
Val. Symbol Meaning
100 QSORT_STACK_OVERFLOW Quick Sort algorithm stack overflow
102 INTHD_NO_FREE_INT_FUNC Number of the Interrupt functions exceeded
103 INTHD_INV_INT_SRC Invalid Interrupt source
104 WATCHDOG_RESET Watchdog has released
105 INV_FLASH_DEVICE Invalid FLASH type recognized

HW Hardware interface
Val. Symbol Meaning
101 ST_PROG_LEN ST program too long for FLASH
102 FLASH_PROGRAM FLASH programming error
103 FLASH_ERASE FLASH erasing error
104 DRAM_VERIFY DRAM faulty
105 HW_EEPROM_RD EEPROM reading error
106 INV_FLASH_DEVICE Invalid FLASH type

Version:G/11/12/7/3

XIO Extended Input/Output
Val. Symbol Meaning
100 LIMIT_CHANNEL_NR XIN and/or XOUT channel number is bigger than maximum channel number
103 NO_MSA_CONFIG XIN_config_channel on MSA channel without previous MSA_config_axis
104 INV_INPUT_TYPE Invalid input type
105 NO_SPEED_FUNC Call-up of XIN_speed on input type without speed determination
106 NO_FREE_DEV_CHAN No free device channel at CONFIG_CHANNEL

MT161 MOOG CAN bus driver ( Low Level )
Val. Symbol Meaning
100 INVALID_SERVO Invalid servo number
101 INV_AXIS Invalid axis number
102 NO_RESPONSE No answer from servo axis
103 MSG_INVALID Invalid message received
104 MSG_OLD No message received
105 MSG_LOST Message has been overwritten
106 BUS_OFF CAN bus failed
107 UNEXPECTED_INT Unallowed Interrupt
108 NACK_DOWNLD Download not successful
109 TIMEOUT_DOWNLD Time exceeding at beginning Dowload
110 NACK_PARAM Parameters not taken over
111 TIMEOUT_PARAM Time exceeding at Download of a parameter
112 NACK_EEPROM Error when programming into the EEPROM of the MOOG drive
113 TIMEOUT_EEPROM Time exceeding when programming into the EEPROM of the MOOG drive
114 AT_GLOBAL Message servo axis: Global error
115 AT_INTERPOLATOR Message servo axis: Interpolator error
116 AT_CANBUS Message servo axis: CAN bus error
117 AT_SHORT_CIRCUIT Message servo axis: Short circuit
118 AT_THERMAL_WARN Message servo axis: Overheating
119 AT_PARAMETER Message servo axis: Parameter error
120 AT_RESOLVER Message servo axis: Resolver error
121 AT_MOTOR_TEMP Message servo axis: Motor temperature
122 AT_BRIDGE_TEMP Message servo axis: Bridge temperature
123 AT_BUS_OVERVOLTAGE Message servo axis: Excessive voltage
124 AT_POWER_SUPPLY Message servo axis: Power failure
125 CONFIG_MSG Error at the configuration of a CAN message
126 ERROR_FUNC Error at the installation of the CAN error Interrupt
127 NO_DRIVE_SYNC Mode of operation Drive is Sync master: too long no Sync message
128 NO_SYNC_INT_FUNC Mode of operation Drive is Sync master: No interrupt function for Sync message
parametrized
129 SEND_SYNC_MSG Sync message cannot be sent off

MSA MOOG CAN bus ST interface (High Level )
Val. Symbol Meaning
100 INVALID_AXIS_NR Axis with this number is not configured
101 AXIS_NOT_READY Output on axis without OK from MSA_start_axis; MSA_start_calib without OK from
MSA_start_axis
102 POS_MAX Position value too big at not periodic axis
103 DOWNLOAD_ERR Error at parameter Download
104 OUT_OF_PERIOD MSA_set_position, MSA_start_calib with position value bigger than position period
105 INV_INC_ROT Invalid motor parameter for motor increments per revolution
106 POS_DIFF Lag error
107 INV_POS_OFFSET At periodic axis no position offset is allowed

CTS CAN-Temposonics-Sensor
Val. Symbol Meaning
100 CONFIG_MSG No free message buffer in the CI021
101 LIMIT_PORT_NR Port number is bigger than maximum CTS port number
102 WRONG_PORT Attempt to assign to a sensor a port which is already occupied by another sensor
104 PROG_SENSOR Sensor cannot be programmed
105 INVALID_LEN Parametrized sensor length is not correct
106 LIMIT_CHANNEL_NR Parametrized channel number is bigger than maximum CTS channel number
107 NO_CONFIG_CHANNEL Access to not configured CTS channel
108 NO_CONFIG_PORT Access to not configured CTS port
111 INV_CMD Attempt to send not supported command to a sensor
112 CONF_DATA Received confirmation message is not correct
113 CAN_ERROR CAN bus error when reading the actual value message
114 INV_CNF_MSG Invalid confirmation message received
115 ERROR_FUNC Error when installing the CAN error function
117 SAME_NODE_ID Knot number existing several times

Version:G/11/12/7/3

CANDEV CI021 CAN bus interface
Val. Symbol Meaning
100 INV_IEB_ADDR Handing-over of an invalid IEB port number
101 NO_CIO21 On the requested IEB port there is no CI021
102 INV_SUB_CHAN Invalid CI021 subchannel number
103 INV_BAUD_RATE Invalid Baud rate parameter
104 INV_DEVICE_TYPE No CANDEV_install for this IO type possible
106 LIMIT_DEVICE_NR Device number is bigger than maximum number of the CAN device of this type
107 NO_INSTALL No CANDEV_install for driver with this number
108 CANDEV_DEVICE_NR_USED With this device number already a CAN driver of this type has been installed.
109 CANDEV_DRAM_TOO_SMALL CAN bus interface only at AR 181 with at least 2 MB DRAM.

FB Function modules
Val. Symbol Meaning
100 PROF_ANZPKTE Profile with less than 2 points
101 NO_PROF_PARAM INIT_FB_VSGEN or INIT_FB_YXGEN without previous parametrization
102 NO_PROF_PKTE PAR_FB_VSGEN or PAR_FB_YXGEN with profile without point definitions
103 NO_STOP_PKTE Inconsistent stop point data
104 NO_MARKEN_PKTE Inconsistent tag point data
105 KENNL_ANZ_PKTE Characteristic line with less than 2 or more than 1000 points
107 KANAL_NR Invalid channel number
108 PORT_NR Invalid port number
109 PRIOR_NR Invalid priority number at APRIOR
110 CYCLE_TIME_NR Invalid cycle time plane at FB_ANAIN
111 IOBUS_DISABLED E16-Digout+ IOBUS Disable
112 IOBUS E16-Digout+ unallowed IOBUS status
113 IOBUS_UPDATE E16-Digout+ error at IOBUS update
114 LIMIT Limiting value exceeded
115 TOKEN Invalid token
116 LIMIT_UNDEF_X_BAND FB_xxGEN period mode. Not defined x area is bigger than x period
117 INV_X_VALUE FB_xxGEN period mode. When leaving the not defined x area the difference between
calculated and measured x value is too big

ST AR1x1 ST program treatment, running time system
Val. Symbol Meaning
100 NR_OBJFILES Number of the ST files too big
101 FOPEN ST files not found
102 LINK_LOAD Link Loader error
103 CYCLE_NR Invalid number for a ST running time plane
104 CYCLE_TIME Running time exceeding of a cyclic ST program plane
105 LLD_FATAL fatal ST Linker error
106 POOL too few ST pool elements available
107 DELETE internal: erasing from empty queue
108 NEXT_STEP internal: no successor step existing
109 STEP_CODE internal: Step successor no transition
110 TRANS_CODE internal: Transition successor no step
111 START_SEQ wrong pd->state at START_SEQUENCE
112 STOP_SEQ wrong pd->state at STOP_SEQUENCE
113 NO_SYS_FUNC no primitive function existing
114 MSA_AXIS_NOT_READY Output on MSA axis without release

CPU_FAULT Intel 80960 CPU-Fault-Exeptions
Val. Symbol Meaning
100 E_TRACE_FAULT SW break point by not eliminated ”fmark instruction”
101 E_INVALID_OPCODE Invalid opcode in the program code
102 E_INVALID_OPERAND Invalid operand for this operation
103 E_OPERATION_FAULT_RES Operation fault reserved for future expansion
104 E_INTEGER_OVERFLOW Overflow at Integer Operand
105 E_INTEGER_ZERO_DIVIDE Integer division by zero
106 E_ARITHMETIC_FAULT Not closer defined arithmetic error
107 E_FLOAT_OVERFLOW Real Operand too big for representation of numbers
108 E_FLOAT_UNDERFLOW Real Operand too small for representation of numbers
109 E_FLOAT_INV_OPERATION Real Operand in invalid format for this operation
110 E_FLOAT_ZERO_DIVIDE Real division by zero
111 E_FLOAT_INEXACT Real event cannot be represented ( in connection with FLOAT_OVERFLOW,
FLOAT_UNDERFLOW )
112 E_FLOAT_RESERVED_ENCODING Real operand is invalid for normalized Real representation
113 E_FLOAT_KOMBINATION Simultaneous appearance of several Floating Point Faults
114 E_CONSTRAINT_RANGE Not implemented Fault Handler
115 E_CONSTRAINT_PRIVILEGED Attempt to use supervisor mode only action in the user mode
116 E_CONSTRAINT_FAULT_RES reserved for future expansion
117 E_PROTECTION_FAULT Sys-Call with number outside the system procedure table
118 E_TYPE_FAULT Attempt to use modpc statement although processor is in the user mode
119 E_UNKNOWN_FAULT Unknown processor fault ( default branch in the Switch statement )
120 E_INV_2MB_CALL Call-in of a function which needs an AR181 with at least 2 MB-DRAM.

Version:G/11/12/7/3

USER Errors which are released by the user with the ST call-up ERROR
Val. Symbol Meaning
100 ERR_ANZPROFIL Error max.number of the speed profiles
101 ERR_ANZENDS Error max.number of the limit switches
102 ERR_ANZOUTSET Error max.number of the Outsets
103 ERR_ANZPVKAL Error max.number of the pv calibs
104 ERR_ANZKALIN Error max.number of the calins
105 ERR_ANZKALOUT Error max.number of the calouts
106 ERR_ANZIGRAF Error max.number of the curve parameters
107 ERR_ANZMGRAF Error max.number of the Micrograph parameters
108 ERR_ANZLINTAB Error max.number of the characteristic lines
109 ERR_ANZWGRAF Error max.number of the actual curve data
110 ERR_ANZREGLER Error max.number of the controllers
111 ERR_ANZINKAL Error max.number of the in-calibs
112 ERR_ANZFLIESS Error max.number of the flow number def.
113 ERR_ANZPROZES Error max.number of the process def.
114 ERR_ANZSTILL Error max.number of the calm def.
115 ERR_ANZSPRITZ Error max.number of the injection def.
116 ERR_ANZNDREG Error max.number of the holding pressure control def.
117 ERR_ANZSPITZ Error max.number of the calm def.
118 ERR_ANZDOABS Error max.number of the Doabs def.
119 ERR_ANZDEBUG Error max.number of the Ardeb def.
122 ERR_ANZMULPZ Error max.number of the Multiproces def.
123 ERR_ANZCANDEV Error max.number of the CAN devices
124 ERR_ANZCTS_PORT Error max.number of the CAN Temposonic Ports
125 ERR_ANZMSA_AXIS Error max.number of the Moog servodrive axes (CAN)
126 ERR_ANZMSA_MOOG Error max.number of the Moog servodrive axes (CAN) General def.
127 ERR_ANZBSA_AXIS Error max.number of the Baumüller servodrive axes (CAN)
128 ERR_ANZBSA_DRIVE Error max.number of the Baumüller servodrive axes (CAN) controller
200 ERR_REGTYP Error wrong controller type employed
201 ERR_PROFTYP Error wrong profile type employed
202 ERR_KALINTYP Error wrong calin type employed
203 ERR_COMPKANAL Error wrong COMP channels used
204 ERR_ANZENDSGRP Error number of limit switches per calin exceeded.
5 EBIAS ERRORS
Ebias errors appear in the sequence error zone:
Sequence error field Number of the existing errors
EBIAS ERROR STOP 1

MOLD- CYCLE TIME PROD.DATA SELECTABLE PROCESS
PARAMETER COLLECTION TEXT PAGE ANALYSIS
S
The stop character appears when an error appears
The computer stops the movement sequence of the machine immediately. Heatings and
peripheral unit continue to be active if no digital or analog outputs are needed for it.
On the ”Error image” the EBIAS ERROR error number can be read off.
The state of the computer situation in the moment of the error appearance is stored and can
be evaluated after switching off and on again the control voltage in the ”Status report.
See also chapter ”PUTTING INTO OPERATION”, item ”Status report”

Version:G/11/12/7/3
EBIAS error display in the status report

EBIERR 200 date/time: 95-09-15 10:14
*** no EBIAS stop address available
RX: taskname: 'IP_io' stop cnt: 1 run time: 12.850s
INT0: 0.1/ INT1: 0.0/ INT2: 0.0/ INT3: ---------
0.4 0.0 0.1
INT4: --------- INT5: --------- INT6: 0.2/ INT7: ---------
0.3
PR00: --------- PR01: --------- PR02: 0.1/ PR03: 0.1/
2676.1 1.0
PR04: --------- PR05: 0.1/ PR06: 0.1/ PR07: 0.1/
0.1 46.4 4.9
PR08: --------- PR09: 0.2/ PR10: 1.0/ PR11: ---------
0.2 43.7
PR12: --------- PR13: --------- PR14: --------- PR15: ---------
PR16: --------- PR17: ---------
STACK: base: 004B0EB0H size: 1024 unused: 620 Frame-ptr: 004B1268H
004B1 000000 004B1 0057F 000000 000000 004B1 005AD 000000
15C= 00 170 113 C8 02 180 016 C8
004B1 000500 004B1 005AE 004B1 004B1 CA010 004B1 004B1
17C= 00 1B0 F7B 20E 206 14C 1FC 1EC
004B1 FFFFF FF990 000000 000000 004B1 004B1 0053F 004B1
19C= F99 064 00 20 1E4 1C4 875 1E4
004B1 003D1 000000 004B1 00524 000000 004B1 005239 000007
1BC= 1E4 20 22C DEF 3A 1E4 12 F5
004B1 FFFFF 626B0 006400 0032F 444E4 544144 49545 554F4
1DC= F38 011 3D F99 553 5F F41 54D
004B1 4F435 20432 CA010 000000 449400 288004 3DAC0 8FAC0
1FC= 852 E4D 14C 48 00 04 404 402
004B1 004B0 005395 054000 004B1 004B1 00524 000000 000000
21C= 404 62 3A 1E4 23C E67 6A 6A
004B1 004B1 0051C 004B1 004B0 005200 000000 000000 004A7
23C= 244 1B5 2A0 020 04 20 20 978
004B1 000000 004B1 004B1 000000 000008 0048B 00000 00533
25C= 01 2A0 278 00 00 980 A0A E68
004B1 004800 000002 00580 000000 007804 001400 005300 000000
27C= 18 06 B74 01 02 7F 78 00
004B1 000032 000000 000000 C7C7C 000000 C7C7C C7C7C C7C7C
29C= 2D 00 00 700 00 7C7 7C7 7C7
004B1 C7C7C C7C7C C7C7C C7C7C C7C7C C7C7C C7C7C C7C7C
2BC= 7C7 7C7 7C7 7C7 7C7 7C7 7C7 7C7
2DC= 7C7 7C7 7C7 7C7 7C7 7C7 7C7 7C7
2FC= 7C7 7C7 7C7 7C7 7C7 7C7 7C7 7C7
31C= 7C7 7C7 7C7 7C7 7C7 7C7 7C7 7C7
33C= 7C7 7C7 7C7 7C7 7C7 7C7 7C7 7C7
EBIERR
Display of the EBIAS error as well as of date and time.
RX
Display of the task name, of the stop counter, of the Run Time and of the Performance.

Version:G/11/12/7/3
STACK
Display of the stack basis address, of the stack size, of the unused stack area and of the RX
frame pointer as well as 32 x 32-bit values in the hex format, beginning at the current stack
pointer.
5.1 ERROR NUMBERS
5.1.1 INTERPRETER
Val. Designation
7 RETURN without CALLSUB and/or SWITCHSUB
8 at subrout call-ups the max. nest depth has been exceeded
9 invalid EBIAS instruction code
10 invalid EBIAS variable number when reading variables
11 invalid EBIAS variable number when reading variables
12 invalid EBIAS variable number when writing variables
13 invalid EBIAS variable number when writing variables
15 invalid EBIAS variable number when reading signals
16 invalid EBIAS variable number when writing signals
5.1.2 VARIABLES ACCESS
Val. Designation
28 invalid EBIAS vairable number at GETVARREFDWORD
29 invalid EBIAS variable number at PUTVARIABLE_NOREF
30 invalid EBIAS variable number at GETVARWORD, GETVARDWORD, GET-
VARIABLE
31 invalid EBIAS variable number at GETVARIABLE
32 invalid EBIAS variable number at PUTVARDWORD, PUTVARIABLE
33 invalid EBIAS variable number at PUTVARIABLE
35 invalid EBIAS variable number at SIGIN
36 invalid EBIAS variable number at SIGOUT
5.1.3 USER-INTERPRETER
Val. Designation
50 invalid EBIAS instruction code
5.1.4 DIGITAL I/O
Val. Designation
60 Short circuit on DO-Port 0 or 1

Version:G/11/12/7/3

76 Excess current recognition on DO-Port 0 or 1
78 Excess current recogniton on DO-Port 4 or 5
92 Overlap of DO or DI ports (address range overlap)
5.1.5 EBISYS
Val. Designation
96 Recursive call-up of stroke calibration or J determination
97 Invalid parameter at closed loop clamping force control (KO for t/Imp. = 0)
98 maximum nest of the call-ups exceeded (Quick Setup)
99 Queue overflow at KL_put_data
5.1.6 ENGSYS
Val. Designation
101 LSSEC examination capacity too small
185 SGMGRF- graphic error
5.1.7 AR101/AR181
Val. Designation
200 Error on 1st AR101/AR181
201 Error on 2nd AR181
202 Error on 3rd AR181
203 Error on 4th AR181
More detailled information to the AR101/AR181 EBIAS errors can be found in the status report
or in the Analog Debugger.

Version:G/11/12/7/3
6 MALFUNCTION MESSAGE RECORD

In the malfuncton message record interruptions, errors, state changes and operation
manipulations are recorded. The display of the record on the screen or the output on diskette
or printer occurs alternatively chronologically or arranged according to event category (buffer)
with indication of a serial number, date/time and current shot number.
List lengths Function-
Range max. entries Contents

key
System F1 256 Entries System errors, main events, such as date/time settings,
control unit on/off, Ebias charging, reset, etc.
Error F2 1024 Entries Sequence error messages
Input F3 512 Entries Set value inputs, read in diskette, read in license file
State F4 64 Entries State of operation changes
User F5 64 Entries Waiting points in case of cycle time exceeding
All F6 - chronological arrangement of the entries
Certain messages (e.g. START KEY in the semiautomatic mode), which appear permanently
at each cycle, are not entered into the malfunction message record as these would only fill the
memory unnecessarily.
When the respective maximum number of entries is reached, a new entry pushes the oldest
one from the list.

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6.1 CALL-UP
With image selection key and function key F4 open the malfunction message
record page.
MALFUNCT.MES.REC. 10-3 1999-12-20 15 35
13 99-12-20 10:49:40 0 Input: User: USER 3 Pers#: 3

DISK: LICENSE.BIN
12 99-12-20 10:47:34 0 User level: 4 -->10
11 99-12-20 10:37:42 0 User level: 10 -->4
SW35470 old: 0 new: 1
SW35471 old: 0 new: 1
08 99-12-20 10:25:50 0 User level: 4 -->10
07 99-12-20 10:24:24 0 User level: 0 -->4
06 99-12-20 10:24:15 0 RUN / DELDATA
05 99-12-20 10:24:15 0 ECC 000D6D6CH/*
04 99-12-20 10:24:09 99999999 STOP
03 99-12-20 10:22:21 99999999 EBIAS load 0
02 99-12-20 10:24:17 99999999 RUN / RESET
01 99-12-20 10:24:17 99999999 ECC 00035528H/*
M
System Error Input State User All etc
-->
On the screen the chronological area ’All’ of the malfunction message record appears.
By means of the leafing keys and it can be leafed forward and/or backward.
The individual buffer areas can be called up with function keys.
With F8 ’etc.’ function keys for printing out the status report come on the screen. See to it item
7, ’Status report’.
Another actuation of F8 ’etc.’ leads back to the function keys operation of the general error
page:
MACHINE WAITING- HARDWARE- MALFUNCTIO VALUES OUT. etc.

ERRORS POINTS CHECK N MESSAGE OFF RANGE
6.2 PRINTOUT OF THE MALFUNCTION MESSAGE RECORD

Choose printer menu (main menu + function key F1)
Depending on the connected printer in the menu ’Selection of devices’ the correct
setting must be made. See possibly also in the operator’s manual, chapter ”MEMORY,
TEXT INPUT”.
With F3 ’Print malfunction message record’ select individual block or make other
individual selection
Start printout with function key F5

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6.3 POSSIBLE ERROR COMMENTS
1. Buffer: ”System”
Electronic interruptions and errors (red display at colour displays)
e.g: 59 95-05-30 20:50 177 SYSTEM ERROR . . . 81/ 0/ 196
current number Date Time Shot counter Display of the event
STOP ...................... The control voltage has been switched off and/or interrupted
RUN ........................ The control voltage is switched on and/or exists again
TIME OLD................ Someone has set a new time
TIME NEW
SYSTEM-ERROR ... An electronic system error has appeared (e.g. at software change, software error,
card error), error numbers see Technical manual, part 2 - tables.
In front of the error number there is an identification for the module which has sig-
nalled the error:
81 ... CU211 and/or CU212
61 - 64 ... AR1x1 (card 1-4)
41 ... RC100 (CU201)
EBIAS ERROR ........ Sequence errors. Error numbers see this chapter
POWER FAIL .................. The supply voltage has been interrupted (by the power supply electronic module)
RUN/RESET .................... a reset of the control unit has taken place.
RUN/DELDATA .............. When switching on the control voltage an error has been detected at the check sum
test and a reset has been carried out.
EBIAS load............... EBIAS load process from diskette has been introduced.
In addition, a code for the reason of the EBIAS program loss is displayed.
0 ... EBIAS end address faulty (address area conflict)
1 ... Loading key pressed
2 ... Checksum OK - not correctable ECC error
3 ... Checksum faulty - not correctable ECC error
4 ... Checksum faulty - ECC error correction OK
ECC ....................... ##xxxxxxxx/nn entry of the error bit recognition (ECC program, see chapter ’Putting
into operation’ / item ’Check sum test’. The 8-digit number shows the address of the
error place.
nn ... number of the faulty bit ( * if not correctable)
2. Buffer: ”Error”
Error message (yellow display at colour displays)
e.g: 388 95-10-14 08:16 322 ERROR BEGIN...50....EJECTOR NOT AT THE B
current number Date Time Shot counter Error display
further display types:

ERROR END .................... The error has been reset by the program
QUITT-ALL-ERRORS ....... The errors have been reset with the program interruption key
QUIT ERROR ................ The error has been reset with the acknowledgement key
An exact description about the error comments can be found in the operator’s manual, chapter
”DIAGNOSIS AND HELP”

Version:G/11/12/7/3
3.Buffer: ”Input ”
Set value and constant changes (green at colour displays)

current number Date Time Shot counter Operator (from access authorization)
e.g: 12389 95-10-12 13:25 356 INPUT: User: Key
SW 2100 old: 1000 new: 300

Param. number old value new value
By means of this function the last set value changes are displayed. In the above represented
example someone has changed the parameter 2100 (metering stroke C1) from 1000 (100
mm) to 300 (30 mm). ’User’ is coupled with the access authorization system and identifies the
changing person.
’Key’ indicates a person who has made the change with the key-operated switch, position ’ON.
For the parameters there are the following short designations:

SW SOLLWWORD 2 Byte length
SD SOLLWDWORD 4 Byte length
ST SOLLWTEXT 20 Byte length
Set values (SW, SD, ST) can be taken from the corresponding lists of the ”Technical manual”,
”Part 2, tables”.
further display type:

INPUT: EBIAS32.BIN ....... new EBIAS program has been read in
PARAM.BIN ....... new parameters have been read in by floppy or host
KALIB.BIN ....... Calibration table has been read in
TXTENG.BIN ....... English screen text has been read in
LINTAB.BIN ....... Linearization table(s) has (have) been read in
etc
SCREEN LINES, function key F7:

With opening the input buffer additional function key F7 ’Screen Lines’ appears’.
For easier finding of changed values a list can be displayed with F7, from which the placing of
the set values with indication of the appertaining screen page(s) follows. No edition possibility.
4. Buffer: ”State ”
State of operation changes (at colour display blue / green)
State of operation change

new state old state
e.g: 388 95-10-14 08:16 322 STATE: 4 0
current number Date Time Shot counter Display type
By means of this function key the last 64 state of operation changes are displayed. In the
shown example the machine has been switched over from MANUAL to FULLY AUTOMATIC.

Version:G/11/12/7/3
further display type:

It means: 0 ... man. operation
1 ... Program interuption,
actuated in semi or fully automatic mode
2 ... Set-up
3 ... Semi-automatic
4 ... Fully automatic mode
User level ... Access authorization changed
5. Buffer: ”User”
In case of error message ”Cycle monitoring” here the waiting points are entered.
7 STATUS REPORT
The status report represents an instrument, with which at certain moments and machine
situations snapshots can be taken. This report, released manually by pressing a function key,
is output alternatively on printer or floppy. The contents gives the service technician detailled
information about error states appeared last, implemented software and hardware versions,
states of outputs and inputs, markers and interfaces and much more.
Call-up:
Image selection key + F8 ’etc.’. It appears:
Statusrep. Statusrep. Statusrep. Statusrep. etc.

Floppy Printer Abort Host --->
With F1 and/or F2 start the status report. With F3 it can be interrupted.

F4 only when host connection (EMS) existing (option).
The status report can also be selected via the service menu.
Image selection key + F4 + F6.

Version:G/11/12/7/3
TEST AND PARAMETERS (8)
1 GENERAL
PARAMETERS, also designated as machine parameters or fixed values, are filed in the
buffered RAM and in general do not appear on the screen pages like set and actual values.
They are tuned when putting the machine into operation and need no longer be changed in the
normal case.
After occurred optimization and completed putting into operation the parameters together with
all calibrations and linearization tables are filed on diskette, which must be filed in the control
cabinet writing-protected. On this diskette are also the sequence program and possible special
program descriptions.
After the first switching-on of the control unit when putting into operation or after a reset, at
which all data are erased, the parameters are preset according to a list contained in the
program after reading in the sequence program (default values).
The parameters can be changed via screen after the service mode has been activated via
password or with corresponding magnetic card.
In order to reach a total survey of the logic states of the sequence process, a ’SIGNAL
DEBUGGER’ is installed. When calling up this function the screen, supported also by the ’Help
function’, shows tables of digital inputs, digital outputs and marker flags.
2 ENTRY
In order to be able to change or watch machine parameters or to call up the signal debugger,
one must enter into the SERVICE MENU:
At first choose in the access rights system access level 7 or higher ----> chapter ”PUTTING
INTO OPRATION”,
then screen key ”MENU” + function key F4 ”SERVICE MENU” and again
Press F4 ”Test and parameters”.
3 CHANGE PARAMETERS
3.1 CALL-UP
After the entry procedure the row of control function keys of the debugger appears:
Program Signal Variable IMM Serial I/O Status report etc

status debugger Debugger debugger debugger --->
Creation date: 20.02.2002 Test and parameters (8)

Version:G/11/12/7/3
With F3 the ’debugger of variables’ is called up. It appears:

Test and parameters 8-2 1996-04-12 14 05
[
Hydraulic system parameters - X Stroke [mm]
Mould closing service - X Speed[% ]
Mold opening serv. X X Speed [mm/s]
Injection/Holding pres.servic - - Pressure [bar]
Carriage service - - Pressure [%]
Ejector service - - Ramp [%]
Plasticizing/screw retraction service - - Time [s]
Core service - - Force [kN]
Configuration switch service - - Revolution [/min]
General parameters service - - Voltage [mV]
Central lubricat. - - Maximum ramps [%/mm]
Clamping force - - Maximum ramps [mm/s2]
Heating service - - Maximum ramps [%/s]
Interfaces - - Maximum ramps [bar/mm]
Safety gate - - Maximum ramps [bar/s]
Mold closing - - Maximum ramps [/s]
M
Select. Select. indicators indicators Exit
individua. total Set value Act.val
The parameters are divided into ’set values’ and ’actual values’, to be called up with the
respective function keys F3 and/or F4. F3 and F4 only apear when in both columns ’Groups’
and ’Units’ at least one selection has been made. The parameters are provided with a clear P
number (formerly machine function number, MF number) and list up on the screen ordered
according to it. Set values which are set on the individual screen pages as well as ’internal
values’ (formerly ’Constants’) are represented together, the actual values are represented
separately of it.
In order to get to the requested values faster from this big list, the parameters are ordered in
groups and units, which are selected with cursor up/down, left/right and function keys.
When more groups/units than the columns can display exist, the cursor scrolls through the
lists. The position of the cursor display the central scroll bars.
F1 marks the selected group/unit. Erasing of the choice by renewed actuation of F1.
F2 marks all groups and/or units depending on in which column the cursor is.
Renewed actuation erases all markings.
The display of all groups can be reached when neither units nor groups are selected and the
cursor stands on a certain unit. After actuating F3 and/or F4 this unit is considered as selected
for all groups.
The display of all units can be reached when neither units nor groups are selected and the
cursor stands on a certain group. After actuating F3 and/or F4 for this group all units are
considered as selected.
Test and parameters (8) Creation date: 20.02.2002

Version:G/11/12/7/3
With F3 and/or F4 the selection between set values and actual values occurs.
TEST and PARAMETERS 8-2 1996-11-12 14 05

Mould closing service
Strok Speed Speed. Time

[mm] [mm/s] [%] [s]
* 9311 500.0 35062 700 35041 23 35259 0.5
* 9312 100.0 35043 70 35264 1.0
*12690 700.0 35049 30 *35266 1.5
*12692 1400.0 35060 2 35281 0.3
*12694 700.0 35061 50 36168 0.00
*12696 1400.0 35068 10 *36174 1.5
*35000 2350.0 35200 100 *36176 0.10
*35001 2350.0 36043 10 36182 0.20
*35008 830.0 36046 5 36183 0.2
*35009 0.5 36047 20 36184 10.0
35012 0.5 36048 30 36186 0.20
35022 0.0 36049 20 36187 0.10
35024 1.0 36050 60 36188 0.3
36000 20.0 36051 60 36191 0.5
36007 3.0 36060 1 36192 2.5
SFx=900.2 [mm] SDx=127.4 [mm] SAx=15.9 [mm] SSx=102.0 [mm]

M
Setvalues Actual valueActual value Exit
Status
The parameters are displayed in 4 columns. The columns can be scrolled with the arrow keys
up/down in lines and with the leafing keys in pages. The scroll bars show the present position
in the respective table.
It can be scrolled horizontally when several columns, i.e. units and/or groups are selected
which no longer fit on the screen.
A parameter which also exists in other groups is noted with the sign.
In the lowest line of the screen page 4 actual values are faded in in order to design more easily
e.g. at speed ramp settings in order to be able to watch the actual positions of the strokes more
easily. With the function key F5 further 4 actual values (speeds or pressures) can be faded in.
For changing a parameter approach this with the cursor, input the requested value with the
numeric keypad and conclude with ’ENTER’. The value is displayed immediately in the
parameter field.
Implausible parameters flash.
Attention!
Certain parameters are only valued in initializations when the control

unit runs up to speed, i.e. switch off the control voltage after changing a
parameter-and on again. When a plausibilization (restriction of the range
of values) exists, minimum and maximum limit are displayed in the dia-
log zone in brackets. Certain parameters are subject to a higher change
level or cannot be changed at all. These values are determined when
putting the machine into operation or by the sequence program itself
and must no longer be changed.

Version:G/11/12/7/3
Note!
The ’Parameter list’, a compilation of all existing parameters, can be
found in the appendix.
3.2 STORAGE OF PARAMETERS

The ’internal values’ (internal parameters) as well as set values (mould parameters) are stored
and administered in a battery-buffered RAM of the CPU. Thus they are protected against
power failure. If the data should get lost nevertheless, e.g. for CPU defect reasons, it is
advisable to bring the file’PARAM.BIN’ on the machine diskette up to date after a parameter
change:
Eliminate possible writing protection from the ’machine diskette’
’Insert machine ’diskette’ into the floppy drive.
Call up the diskette menu: Main menu key + function key F2.
The diskette table of contents is listed up in the left screen half.
Afterwards press function key F2 ’WRITING’.
Move the cursor with the arrow keys over the entry ’PARAM.BIN’ and press function key
F6 ’START WRITING’.
The writing process is completed when in the dialog field ’WRITING OK’ appears.
3.3 READING OF PARAMETERS

When putting the machine into operation or after data loss at first the parameter ranges are
occupied automatically with basic values (defaults) from the EBIAS sequence program. In
order to get to the optimized settings, one reads in the data again from the machine diskette:
Insert machine diskette into the floppy drive.
Call up the diskette menu: Main menu key + function key F2
Afterwards press function key F1 ’READING’.
The drive gets active, the diskette table of contents is listed up on the screen.
Move the cursor with the cursor keys over the entry ’PARAM.BIN’ and press function
key F6 ’START READING’.
The reading process is completed when in the dialog field ’READING OK’ appears.
After occurred reading-in the control voltage must be switched off and on again for the
complete takeover of the new values (new calculations, initialization).
Regarding diskette operations see also in the operator’s manual, chapter ”MEMORY, TEXT
INPUT”.
3.4 PARAMETER COMPARISON (PARAMETER COMPARISON INTERNAL /

DISKETTE)
With the possibility to compare files with each other also e.g. the parameter lists of different
machines can be compared with each other. The differences are shown on the screen and can
also be output on floppy or printer.
See operator’s manual, chapter ”MEMORY, TEXT INPUT”.

Version:G/11/12/7/3
3.5 PRINT OUT PARAMETERS

A parameter list of the ’internal’ values - these are the values which are filed on the machine
diskette in the file ’PARAM.BIN’ - can be output on a printer or on floppy:
Image selection key ’Main menu’ + F1 (Printer) + F2 (Print parameters)
Depending on the connected printer in the menu ’Selection of devices’ the correct setting must
be made. See possibly also in the operator’s manual, chapter ”MEMORY, TEXT INPUT”.
3.6 SEARCH PARAMETERS

When a parameter number is known, the appertaining groups and units can be found rapidly:
Press F5 ’Search’
Input of the paramter number + ’Enter’
--> in the selection list group(s) and unit(s) are marked
Press F8 ’Exit’
Press F3 and/or F4
--> Group + unit are displayed.
4 SIGNAL-DEBUGGER
After the entry procedure the row of control function keys of the debugger appears:
Program Signal Variable IMM Serial I/O Status report etc

status debugger Debugger debugger debugger --->
Further, with F2 the Signal Debugger is called up. It appears:
Digital Digital Marks t EXIT

Output Input
The following selection F1, F2 or F3 shows the tables of the digital signals.
Especially together with the ’Help function’, call-up with the fast call key , an
extensive survey results.

Version:G/11/12/7/3
Display example of the digital outputs with logic numbers:

Test and parameters 8-2 1998-03-12 14 05
M
Set Set Forced Forced Forced logical physical EXIT
0 1 Set 0 Set 1 Reset DIO DIO
The function keys serve to preoccupy the signals for test purposes.
It mean:
F1 Set 0 Set signal to 0. It can be changed by the sequence pro- green shift
gram, however. Only for outputs.
F2 Set 1 Set signal to 1. It can be changed by the sequence pro- black writing on
gram, however. Only for outputs. green background
F3 Forced Set0 Fix signal on 0. Control voltage off/on cancels the fixing. red writing
F4 Forced Set 1 Fix signal on 1. Control voltage off/on cancels the fixing. black writing on red
background
F5 Forced Reset Cancel fixing again
F6 logical DIO the table shows the I/Os with their internal administration
numbers (MF numbers). I/Os not used by the program
appear with the physical number
F7 physical DIO the table shows I/Os with their physical numbers (= desig- Marking by a ’*’ in
nation on the terminals). front of the number
NOT INSTALLED This output and/or input card is not mounted.

Version:G/11/12/7/3
PRINTER / TEXT INPUT (9)
1 PRINTER
1.1 PRINTER CONNECTION

To the serial front panel interface of the EC100 - and CC100 - control unit a printer can be
connected. Starting from the software versions SV1.17 and EV9.20 besides 9-dot-matrix
printers also ink jet printers, e.g. Eposon Stylus Color or HP870Cxi, are supported. When
connecting a printer which is delivered from here ex works no special setting processes must
be carried out any longer. If another printer model shall be operated, corresponding setting
information can be taken from the appertaining description.
A parallel interface (Centronics) is not provided in the control unit for communication with
printer or text input. Therefore when purchasing a printer pay attention to a serial connection
RS232-V24 existing on it. Ink jet printers are usually not executed with a serial interface and
need a converter which can be obtained at ENGEL. See to it item ’Serial-parallel converter
towards the end of this chapter.
On 9-dot-matrix printers the devices LX300 (Epson), B3100 (Facit) and E620 (Facit) can be
used checked.
The ink jet printers (Inkjet) HP895Cxi and HP880C (both Hewlett&Packard) can be used
checked. Also Stylus Color 900 (Epson), but only from ENGEL system version SV2.10b.
Basically all printers can be used on the control unit, which support the protocols ESC/P2
(Epson) and/or PCL-3 (HP). The experience shows, however that 100% compatibility (
statement of the manufacturer ) does not necessarily deliver equivalent printouts. The
printouts will probably be okay, but detail problems can appear. Therefore we recommend to
use only printers tested by us.
The following ink jet printers support the record standard, but are not checked indeed, i.e.
function without 100% guarantee:
Manufacturer: Hewlett Packard Epson Epson

Type: Inkjet 24-Dot-matrix Inkjet
Record: HPPCL3+ ESC/P2 ESC/P2
printer type: DeskJet 420C LQ570/1070 SQ870/1170
DeskJet 690C LQ100, 300 Stylus 200, 300, 400
DeskJet 690C+ LQ870/1170 Stylus 800+, 820, 850
DeskJet 890C LQ570+ Stylus 1000, 1500, 1520
DeskJet 895C DLQ-3000 Stylus Color II, IIs, 200, 500, 600, 800, 850, 3000
Deskjet 990Cxi LQ1070+ Stylus Pro, Pro XL, Pro XL+
LQ2070, 2170
checked: HP895Cxi Stylus Color 900 (from ENGEL system version

SV2.10b)
HP880
After connecting the printer the printer type must be selected on the screen:
Open printer menu: Main menu key and F1 ’Printer’
It appears the printer menu. With function key F5 one chooses printer type (text-deskjet, 24-
dot-matrix printer, floppy, etc.) and the printer function (see operator’s manual, chapter (2),
item 2, ’Printout and recording’).
Creation date: 20.02.2002 Printer / text input (9)

Version:G/11/12/7/3
1.1.1 SETTING HINTS FOR 9-DOT-MATRIX TEXT PRINTER
(e.g. EPSON LX300 or PANASONIC KX-P1090)

- Baud rate: With parameter P35593 the Baud rate is set (standard: 300 Baud)
Baud rates 12 = 115200 11 = 57600
10 = 38400 9= 19200 8= 9600
7= 4800 6= 2400 5= 1200
4= 600 3= 300 2= 150
Note!
After changing the parameters SWITCH control voltage OFF and ON
again in order that the Baud rate is taken over correctly.
On the printer also set the same Baud rate (procedure see printer manual)
Further set on the printer:
German character set
7 - Bit data word length (7 data bits)
gerade Parität (even parity)
1 Stopbit
Data cable 9-dot-matrix text printer: (e.g. PANASONIC KX-P1090, EPSON LX300)
Control unit, control panel Serial printer interface

25--pole 25 -pole
Pins Pins
3 TXD 3 RXD
2 at CC80
4 CTS 20 DTR
5 at CC90-A01
7 SGND 7 SGND
1.1.2 SETTING HINTS FOR GRAPHIC PRINTER

(e.g. FACIT B3100 or E620, EPSON LX300 with colour option)
Baudrate:
basically 9600 Baud. The control unit initializes on 9600 automatically when it is
switched over to graphic printer.
German character set
8 - Bit data word length (8 data bits)
no parity)
1 Stopbit
Printer / text input (9) Creation date: 20.02.2002

Version:G/11/12/7/3
Data cable 9-dot-matrix graphic printer: (e.g. FACIT B3100, E620 or also EPSON LX300)
Control unit, control panel Serial printer interface

25--pole 25 -pole
Pins Pins
3 TXD 3 RXD
2 at CC80
4 CTS 20 DTR
5 at CC90-A01 19 at FACIT
7 SGND 7 SGND
1.2 SETTING OF THE DIP SWITCHES FOR PANASONIC PRINTER KXP1090

Base plate:
switch Position
5 6 7
1 OFF
2 ON on on on USA
3 OFF on on off France
4 ON on off on Germany
5 on off off England
6 off on on Denmark
7
8 OFF off on off Sweden
off off on Italy
off off off Spain
(Text printer)
Settings on the serial interface:

RS232C ADAPTER:
switch switch 1 Baud Rate Setting Baud
1 ON Baud rate 300 OFF ON ON 110
2 OFF Baud rate 300 ON OFF ON 300
3 ON Baud rate 300 OF OFF ON 600
4 OFF datalength 7 bit ON ON OFF 1200
5 OFF with parity OFF ON OFF 2400
6 ON even parity ON OFF OFF 4800
7 ON reverse channel mark OFF OFF OFF 9600
8 ON remained bytes 152 ON ON ON selftest
1.3 SETTING ON THE GRAPHIC PRINTER FACIT B3100 AND/OR E620

At the works the FACIT printer is set as follows.
Please take the setting procedure from the printer manual.
PRINTER COMMAND MODE

PRINTER COMMAND MODE ....................................... FACIT or FACIT/EPSON

Version:G/11/12/7/3
GENERAL
COLOUR RIBBON ........................................................ COLOUR
CHARACTER SET ........................................................ IBM 2
ESC G/H FUNCTION .................................................... NQL
DRAFT PRINT QUALITY .............................................. STANDARD
BI-DIRECTIONAL NLQ PRINTING ............................... NOT VALID
CR FUNCTION ............................................................. NO AUTO LF
LF FUNCTION............................................................... NO AUTO CR
ZERO DESIGN ............................................................. 0
PAPER & FORMAT

FORMAT LENGTH (inch) .............................................. 12
LINE SPACE .................................................................. 6
SKIP ZONE (inch) ......................................................... 0
LINE LENGTH (characters) ........................................... 80
TEAR OFF FUNCTION ................................................. NOT VALID
COMMUNICATION
INTERFACE .................................................................. Serial
WORD LENGTH ........................................................... 8 bits
INPUT PUFFER ............................................................ 10K Bytes
PROTOCOLL ............................................................... READY / BUSY
BAUD RATE .................................................................. 9600 BPS
PARITY .......................................................................... Disable
READY / BUSY POLARITY ........................................... Ready = High
SHEET FEEDER
SHEET FEEDER .......................................................... NOT INSTALLED
FORMAT BIN 1 (inch) ................................................... 12
SKIP ZONE BIN 1, TOP (inch) ..................................... 0
SKIP ZONE BIN 1, BOTTOM (inch) ............................. 0
FORMAT BIN 2, TOP (inch) .......................................... 12
SKIP ZONE BIN 2, TOP (inch) ..................................... 0
SKIP ZONE BIN 2, BOTTOM (inch) ............................. 0
SPECIAL FEATURES
FEATURE 1 ................................................................... NOT USED
1.4 SETTINGS ON THE GRAPHIC PRINTER EPSON LX300+

On the part of the factory the EPSON LX300+ is set as follows.
You can print out the following protocol by pressing the ÇTear-Off’ key and keep it pressed
while switching on the printer. Please take further instructions for setting and also handling the
printer from the printer instruction manual.
LX300+, model P170A

Current setting
Side length for tractor 12 inches
Jumper over margin strip perforation off
Separation automatism off
Autom.Z advance off
Printing direction bidirectional
Operating system ESC/P
Zero representation ononon
Quick draft ononon

Version:G/11/12/7/3
LX300+, model P170A

I/F mode Automatic
Waiting time for automatic I/F recognition 10 Seconds
Baud rate 9600BPS
Parity None
Parallel I/F bidirectional mode ononon
Package mode Automatic
Table of characters PC437
International character set for Italic Italic U.S.A.
Waiting time for manual feed 1.5 Seconds
Acoustic signal ononon
Autom. carriage return (IBM 2380 plus) off
IBM table of characters Table of characters 2
1.5 PRINTOUT ON PC
Data cable control - PC
Control unit, control panel Serial interface on the PC (COMx), 9-pole

25--pole DSub connection
Pins Bushes
3 TXD 2 RXD
2 RXD 3 TXD
7 SGND 7 SGND
With a PC terminal program, standard at each Windows surface, a printer can be simulated.
Start the program and actuate the printing function on the control unit (e.g. individual pages
printing).

Version:G/11/12/7/3
1.6 SERIAL-PARALLEL CONVERTER

Ink jet printers come on the market almost thoroughly with Centronics interface. In order to
guarantee the connection to the ENGEL control unit, a serial-parallel converter is necessary,
which is used instead of the printer cable.
ENGEL serial-parallel converter
2m
Translator
ENGEL number 02203-6453
The converter gets its power supply from the signals of the interfaces and usually does not
need any additional, external power pack.
The setting of the RS232 parameters is made manually on the converter by means of DIL
switches. These are accesible after opening the converter housing on the printed circuit board
underside. Please caution in the handling!
For the connection ENGEL control unit - printer the switches must be set so:
DIL switch settings on the converter

Baudrate S1 S2 S3 Data bit S4 Handshake Parity S5 S6 S7 S8
9600 off on on off DTR optional off off off on
Converters of other manufacturers

Most serial-parallel converters do not possess any integrated interface cable, this means a
serial cable must be produced or one uses the ENGEL original cable and modifies it in the
following way:
other serial-parallel converters
Modification when ENGEL cable is

used
ENGEL printer cable Converters, e.g..

3277-760-11-00-284 ROLINE SXP325

Version:G/11/12/7/3
2 TEXT INPUT
2.1 OPERATION
In the operator’s manual, chapter ”MEMORY, TEXT INPUT”, item ”TEXT INPUT” read up
about the possibilities of the text input.
In the ’system setup’ (chapter ”PUTTING INTO OPERATION”) the switchover between US and
German keyboard occupation can be made.
2.2 TECHNICAL DETAILS

As keyboard for the text input a standard IBM PC keyboard is used. It is connected to the 5-
pole DIN bush of the front panel and can thus be employed immediately.
So-called ’IBM-compatible’ keyboards are not always compatible indeed and thus function
sometimes only conditionally. It is recommended to use IBM-PC/AT-MF102 keyboards,
obtainable from your local dealer.
The Baud rate for the data transmission is set fixed to 1200 bd.

Version:G/11/12/7/3

Version:G/11/12/7/3
TABLES (10)
The list of parameters describes the variables (these are set values, internal values and actual
values) which are used in the debugger of variables with their single-valued numbers (formerly
MFTAB numbers.
The list is valid for Small and medium-sized machines from ES25 up to ES450
EBIAS version 9.42+.
The symbol list for the parameters is adapted to the equipment of the respective machine. Due
to the clearness of its numbers (P numbers) this list mentioned here can be used permanently.
Additions due to special programs do not influence this list. They are included and described
in the respective special documentation.
===============================================================================
MACHINE FUNCTION NUMBERS TABLE
===============================================================================
Parameter legend:
+--------------------- Param. number
| +------------------ Parameter name
| | +-------------- Group
| | | +----------- Channel
| | | | +-------- Display format: VK, NK, unit *)
| | | | | +---- Comment
| | | | | |
var P1,P2 ,P3,P4,P5 ;P6
*) VK... predecimal points, NK...afterdecimal points
A ’*’ in front of a parameter number means that this

parameter also exists in other groups of variables !
Number of parameters: 4320 creation date: 06.02.2002
-------------------------------------------------------------------------------
Group of variables hydraulic system parameters - hydraulic system parameters
-------------------------------------------------------------------------------
*** (Unit: Pressure [bar] )

35083,kod4,,,3,1,”bar” ;system pressure
35110,kod40,,,3,1,”bar” ;maximum injection pressure at screw diameter 1
35116,kod47,,,3,1,”bar” ;maximum injection pressure at screw diameter 1 increased
35693,ko2d4,,,3,1,”bar” ;system pressure 2nd unit
35712,ko2d40,,,3,1,”bar” ;maximum injection pressure at screw diameter 1 2nd unit
35717,ko2d47,,,3,1,”bar” ;maximum injection pressure at screw diameter 1 increased injection pressure 2nd unit
35718,ko2d48,,,3,1,”bar” ;maximum injection pressure at screw diameter 2 increased injection pressure
35976,kod4_2,,,3,1,”bar” ;system pressure 2nd pump
*** (Unit: Time [s] )

17982,kozpr_f1,,,3,2,”s” ;devibration time filter input f1
17984,kozpr_oen,,,3,2,”s” ;devibration time input oil level
*** (Unit: Voltage [mV] )

23951,kominoffsphx,,,5,0,”mV” ; min. voltage value for offset phx
23952,komaxoffsphx2,,,5,0,”mV” ; max. voltage value for offset phx2
23953,kominoffsphx2,,,5,0,”mV” ; min. voltage value for offset phx2
23954,komaxoffsphx3,,,5,0,”mV” ; max. voltage value for offset phx3
23955,kominoffsphx3,,,5,0,”mV” ; min. voltage value for offset phx3
23956,komaxoffssk,,,5,0,”mV” ; max. voltage value for offset sk
23957,kominoffssk,,,5,0,”mV” ; min. voltge value for offset sk
23962,ko2maxoffsphx,,,5,0,”mV” ; max. voltage value for offset phx unit.2
23963,ko2minoffsphx,,,5,0,”mV” ; min. voltage value for offset phx unit.2
23964,ko2maxoffsphx2,,,5,0,”mV” ; max. voltage value for offset phx2 unit.2
23965,ko2minoffsphx2,,,5,0,”mV” ; min. voltage value for offset phx2 unit.2
28886,komaxoffspheil,,,5,0,”mV” ; max. voltage value for offset high speed pressure
28887,kominoffspheil,,,5,0,”mV” ; min. voltage value for offset high speed pressure
32861,komaxoffsph5,,,5,0,”mV” ;max. voltage value for offset ph5
32862,kominoffsph5,,,5,0,”mV” ;min. voltage value for offset ph5
36344,komaxoffsphx,,,5,0,”mV” ; max. voltage value for offset phx
37881,kophxmax_tol,,,5,0,”mV” ; tol. for max. voltage value phx
37882,kophx2max_tol,,,5,0,”mV” ; tol. for max. voltage value phx2
Creation date: 20.02.2002 Tables (10)

Version:G/11/12/7/3
37883,kophx3max_tol,,,5,0,”mV” ; tol. for max. voltage value phx3

37884,koskmax_tol,,,5,0,”mV” ; tol. for max. voltage value sk
37885,ko2phxmax_tol,,,5,0,”mV” ; tol. for max. voltage value phx.2
37886,ko2phx2max_tol,,,5,0,”mV” ; tol. for max. voltage value phx2.2
38264,ko_mvanschlag,,,5,0,”mV” ; voltage threshold for stop recognition clamping cylinder
42523,kopmxmax_tol,,,5,0,”mV” ; tol. for max. voltage value pmx unit.1
42524,komaxoffspmx,,,5,0,”mV” ; max. voltage value for offset pmx unit.1
42525,kominoffspmx,,,5,0,”mV” ; min. voltage value for offset pmx unit.1
42529,ko2pmxmax_tol,,,5,0,”mV” ; tol. for max. voltage value pmx unit.2
42530,ko2maxoffspmx,,,5,0,”mV” ; max. voltage value for offset pmx unit.2
42531,ko2minoffspmx,,,5,0,”mV” ; min. voltage value for offset pmx unit.2
*** (Without unit)

17978,ko_error_f1,,,1,0 ;selection error message filter f1 unit.1
; 0 = monitoring deactivated
; 1 = ’tank throttle valves”
; 2 = ’check oil filter”
; 3 = ’high-pressure filter”
; 4 = ’return filter”
; 5 = ’no oil filtration”
17985,ko2_error_f1,,,1,0 ;selection error message filter f1 unit.2
23958,koerroffsphx,,,1,0 ; error action at offset error phx
23959,koerroffsphx2,,,1,0 ; error action at offset error phx2
23960,koerroffsphx3,,,1,0 ; error action at offset error phx3
23961,koerroffssk,,,1,0 ; error action at offset error sk
; 0 ..... no error message
; 1 ..... only error message
; 2 ..... error message, mould protection lamp, motor stop delayed
; 3 ..... error message, mould protection lamp, motor stop immediately
23966,ko2erroffsphx,,,1,0 ; error action at offset error phx.2 unit.2
23967,ko2erroffsphx2,,,1,0 ; error action at offset error phx2.2 unit.2
; 0 ..... no error message
; 1 ..... only error message
; 2 ..... error message, mould protection lamp, motor stop delayed
; 3 ..... error message, mould protection lamp, motor stop immediately
28888,koerroffspheil,,,1,0 ; error action at offset error high speed pressure
32863,koerroffsph5,,,1,0 ;error action at offset error ph5
38270,ko2cfg_mot,,,1,0 ;separate motor for unit 2
42526,koerroffspmx,,,1,0 ; selection error action pmx unit.1
42532,ko2erroffspmx,,,1,0 ; selection error action pmx unit.2
*** (Unit: Time [min] )

36343,kozoffs,,,5,0,”min” ; minimum time between the determinations
*** (Unit: Speed [mm/s] )

35030,kovsyse,,,4,0,”mm/s” ;maximum system speed at
;increased injection pressure
35031,kovsys,,,4,0,”mm/s” ;maximum system speed
35032,kovspre,,,4,0,”mm/s” ;maximum injection speed at
;increased injection pressure
35033,kovspr,,,4,0,”mm/s” ;maximum injection speed
35668,ko2vsyse,,,4,0,”mm/s” ;2.maximum system speed at increased injection pressure
35669,ko2vsys,,,4,0,”mm/s” ;2.maximum system speed
35670,ko2vspre,,,4,0,”mm/s” ;2.maximum injection speed at increased injection pressure
35671,ko2vspr,,,4,0,”mm/s” ;2.maximum injection speed
35977,kovsys_2,,,4,0,”mm/s” ;maximum system speed 2nd pump
-------------------------------------------------------------------------------
Group of variables mould closing service - mould closing service
-------------------------------------------------------------------------------
*** (Unit: Stroke [mm] )

06551,kosg2_stop,,,4,1,”mm” ;position before g2 minimum speed
10308,kosstart,,,4,1,”mm” ;stroke with reduced start pressure closing
10423,kosstart_r,,,4,1,”mm” ;calculation value stroke with red.start pressure end
10424,kosstart_sr,,,4,1,”mm” ;calculation value stroke with red.start pressure start
35000,kos10,,,4,1,”mm” ;maximum opening stroke mould
35001,kos10k,,,4,1,”mm” ;maximum opening stroke for toggle lever stroke transducer
35009,kos18,,,4,1,”mm” ;stroke tolerance for start-up from stop point
35012,kos23,,,4,1,”mm” ;maximum mould movement at standstill recognition
35018,kos29,,,4,1,”mm” ;s2.1 erasing at closing
35019,kos30,,,4,1,”mm” ;measuring end speed calibration closing
;measuring beginning speed calibration opening (toggle lever)
35022,kos33,,,4,1,”mm” ;stroke position monitoring at standstill sfx
35024,kos35,,,4,1,”mm” ;start clamping force measurement
28174,swfs_stol,,,3,2,”mm” ;stroke tolerance for strong gradients - dynamic course
*** (Unit: Per cent value [%] )

17775,komaxvschl,,,3,0,”%” ;maximum closing speed in pct (calculated value)
*** (Unit: Speed [%] )

21752,koqhdr1p,,,3,0,”%” ;volume high pressure build-up with 1 pump at ehv3
35041,koq7,,,3,0,”%” ;speed closing at the set-up
35043,koq9,,,3,0,”%” ;speed at straightening (toggle lever)
;speed on g2 (at direct closing)
35049,koq14,,,3,0,”%” ;volume stroke calibration mould closing -y1/proportional valve
35052,koq19,,,3,0,”%” ;volume high pressure build-up
35060,koq27,,,3,0,”%” ;minimum speed closing
35065,koq34,,,3,0,”%” ;volume on y1 at high pressure-
;build-up with proportional valve
Tables (10) Creation date: 20.02.2002

Version:G/11/12/7/3
35068,koq46,,,3,0,”%” ;minimum volume mould closing on position b

35200,kored1,,,3,0,”%” ;reduction factor closing speed
*** (Unit: Pressure [%] )

10307,kodstart,,,3,0,”%” ;reduced start pressure closing
10422,kodstart_r,,,3,0,”%” ;calculation value reduced start pressure
35086,kod7,,,3,0,”%” ;pressure at set-up mould closing
35087,kod8,,,3,0,”%” ;pressure at closing speed calibration
35096,kod16,,,3,0,”%” ;minimum pressure for mould closing
35104,kod25,,,3,0,”%” ;pressure - stroke calibration closing
35106,kod27,,,3,0,”%” ;clamping pressure up to bg1 and closing speed calibration
35210,kored11,,,3,0,”%” ;reduction factor clamping pressure
35211,kored12,,,3,0,”%” ;reduction factor mould protection pressure
42263,kod7g3,,,3,0,”%” ;pressure at set-up mold closing from g3
*** (Unit: Ramp [%] )

35131,koa2,,,3,0,”%” ;speed after w3 (closing)
35132,koa3,,,3,0,”%” ;speed before and/or after g2 (closing.)
35133,koa5,,,3,0,”%” ;speed braking on ks
35139,koa12,,,3,0,”%” ;brake speed to w1
35145,koa19,,,3,0,”%” ;pressure and speed - mould braking at manual mode
35146,koa24,,,3,0,”%” ;pressure braking pressure on ks
35147,koa26,,,3,0,”%” ;pressure ramp on 2nd mould protection pressure (g3)
35148,koa31,,,3,0,”%” ;pressure on mould protection pressure (g1)
35155,koa40,,,3,0,”%” ;brake speed to pos.b
35156,koa41,,,3,0,”%” ;pressure change p2/p1 starting from g2
35157,koa42,,,3,0,”%” ;pressure steep ramp end position remaining movements
35159,koa44,,,3,0,”%” ;speed braking on b8 at closing.
35171,koavsch,,,3,0,”%” ;start acceleration speed mould closing
35177,koapst,,,3,0,”%” ;start acceleration pressure all movements
06345,kozehsi,,,4,1,”s” ;monitoring time for defined end position
06550,kozsfx_g2,,,4,1,”s” ;mould standstill monitoring time starting from g2
35259,kozsfx,,,4,1,”s” ;mould standstill monitoring time
;at the automatic mould height setting
;without mould height stroke transducer
35264,kozsp21,,,4,1,”s” ;standstill time adjusting motor
;at the automatic mould height setting
;without mould height stroke transducer
35266,kozhy,,,4,1,”s” ;monitoring time for hydraulic closing safety be8
35281,kozcd,,,4,1,”s” ;delay core/mould and/or closing-opening
;when mould has been stopped in front of g2
35286,kozvs12a,,,4,1,”s” ;deactuation delay of s1.2, s1 at direct closing
;deactuation delay between s1 and s12a at toggle lever
36452,kozsfxtol,,,4,1,”s” ; mold standstill monitoring time for handling system
21317,kofs_mess_delay,,,3,1,”s” ;switch off measurement delayed after mould protection error
08481,kozvschl,,,3,2,”s” ;delay between solenoids and analog-

;output at closing
08516,kozv_hdr,,,3,2,”s” ;delay between s1.2 and high pressure output
10774,kozv_s1_s1p2,,,3,2,”s” ;deactuation delay between s1 and s1.2
;at ehv1, hls1
17977,kozvs2_s1,,,3,2,”s” ;delay between de-energizing s2 and setting s1
22590,kozvpfs,,,3,2,”s” ;pressure reduction time after reaction of mould protection
35276,kozpsch,,,3,2,”s” ;pressure build-up time direct closing without transducer
; / monitoring time pressure build-up with pressure transducer
35294,kozpsch2,,,3,2,”s” ;additional pressure build-up time
;for start-up cycles direct closing without transducer
35295,kotnl1,,,3,2,”s” ;recharging time at direct closing
;in the manual mode
35296,kotnl2,,,3,2,”s” ;recharging time calculated...
35961,kotnl3,,,3,2,”s” ;recharging time at direct closing with pressure transducer

20174,kohyg2_p,,,2,2,”mm” ;hysteresis g running in front2
20175,kohyg2_n,,,2,2,”mm” ;switching-off hysteresis g2
35005,kos14,,,5,0,“mV“ ;[ar: mv/ e8: bit]
;0-point monitoring
;at direct-closing machines
;(how far the 0 point of the mould without
;set-up program may be passed)
35633,koksfx_null,,,5,0,”mV” ;zero value input calibration
35634,koksfx_max,,,5,0,”mV” ;max.value input calibration
35635,kosfx_null,,,5,0,”mV” ;zero value input calibration
35636,kosfx_max,,,5,0,”mV” ;max.value input calibration
*** (Unit: Counter [times] )

35304,kopschanf,,,4,0,” ;clamping pressure build-up start-up-
;cycle counter set value
*** (Without unit)

08959,kortyp_fb,,,1,0 ; ramp clamping unit 1 = stroke ramp
; 0= root ramp
35485,koea16,,,1,0 ;at direct closing with pressure transducer:
; 0=without recharging time
; 1=with recharging time
35616,koklksfx_kf,,,1,0 ;input calibration calibration finished
35617,koklsfx_kf,,,1,0 ;input calibration calibration finished
35628,kovzksfx,,,1,0 ;configuration algebraic sign input calibration
19920,kopropmax,,,2,0 ;1 .. reduction factors speed opening/closing

;do not act on prop. valve clamping unit
20781,koeaph_eil,,,2,0 ;pressure transducer in high speed cylinder= 1
35465,koprop,,,2,0 ;proportional valve clamping unit = 1
35468,kophsch,,,2,0 ;pressure transducer in the clamping cylinder= 1
35489,koea19,,,2,0 ;mould stop after mould protection alarm = 1

Version:G/11/12/7/3
35491,koea21,,,2,0 ;differential connection s12a:

; 0=at closing
; 1=at opening
35953,kopropyks,,,2,0 ;1 = proportional valve clamping unit (0v-10v)
42451,kocfg_saw_close,,,2,0 ;selection saw closing interlock
17774,koliter_s,,,5,0 ;required specific power output closing
*** (Unit: Maximum ramps [%/mm] )

09319,koavfb_y,,,5,0,”%/mm” ; maximum acceleration/delay mould movement
; on ehv pump if prop. valve clamping unit
35179,koavfb,,,5,0,”%/mm” ; maximum acceleration/delay mould movement
; on prop. valve, at hls on pump
*** (Unit: Maximum ramps [%/s] )

09320,koavsfb_y,,,5,0,”%/s” ; maximum start acceleration mould movement
35184,koavsfb,,,5,0,”%/s” ; maximum start acceleration mould movement

35062,koq29,,,4,0,”mm/s” ;maximum closing speed
-------------------------------------------------------------------------------
Group of variables mould opening service - mould opening service
-------------------------------------------------------------------------------

06552,kosa_stop,,,4,1,”mm” ;position before a minimum speed
35000,kos10,,,4,1,”mm” ;maximum opening stroke mould
35001,kos10k,,,4,1,”mm” ;maximum opening stroke for toggle lever stroke transducer
35008,kos17,,,4,1,”mm” ;opening stroke at the automatic
; mould height setting program
; (without stroke transducer)
35019,kos30,,,4,1,”mm” ;measuring end speed calibration closing
;measuring beginning speed calibration opening (toggle lever)
35020,kos31,,,4,1,”mm” ;input limit minimum opening stroke handling system
35022,kos33,,,4,1,”mm” ;stroke position monitoring at standstill sfx
*** (Unit: Ramp [%] )

14379,koa_lue_pos,,,5,0,”%” ;v braking on venting position

17776,komaxvoef,,,3,0,”%” ;maximum opening speed in pct (calculated value)

09129,koredlue_o,,,3,0,”%” ;reduction factor opening speed venting
19599,koqsaug_s,,,3,0,”%” ;volume suction valves opening at start closing
35036,koq2,,,3,0,”%” ;minimum speed (opening)
35042,koq8,,,3,0,”%” ;speed opening at the set-up
35053,koq20,,,3,0,”%” ;volume stroke calibration mould opening -y1/proportional valve
35066,koq44,,,3,0,”%” ;volume for suction valves on
35067,koq45,,,3,0,”%” ;volume at opening with
;dismounted mould
35072,koq53,,,3,0,”%” ;1.opening speed on stop point b8
35201,kored2,,,3,0,”%” ;reduction factor opening speed

19600,kodsaug_s,,,3,0,”%” ;pressure suction valves opening at start closing
35081,kod2,,,3,0,”%” ;pressure at opening
35082,kod3,,,3,0,”%” ;pressure at opening - set-up
35088,kod9,,,3,0,”%” ;counterpressure at 1st opening speed
35097,kod17,,,3,0,”%” ;minimum pressure for mould opening
35114,kod44,,,3,0,”%” ;pressure for suction valves opening
*** (Unit: Ramp [%] )

35135,koa7,,,3,0,”%” ;speed after w4 (opening)
35136,koa8,,,3,0,”%” ;speed braking on koe
35140,koa13,,,3,0,”%” ;speed braking on w2
35143,koa17,,,3,0,”%” ;speed braking on a
35144,koa18,,,3,0,”%” ;pressure braking on a
35145,koa19,,,3,0,”%” ;pressure and speed - mould braking at manual mode
35160,koa45,,,3,0,”%” ;speed braking on b8 at opening.
35162,koa47,,,3,0,”%” ;pressure braking on koe (mould)
35172,koavoef,,,3,0,”%” ;start acceleration speed mould opening

35286,kozvs12a,,,4,1,”s” ;deactuation delay of s1.2, s1 at direct closing
;deactuation delay between s1 and s12a at toggle lever
42460,kozv_stps2,,,4,1,”s” ;deactuation delay analog outputs - s2
35273,kosvoef,,,3,2,”s” ;duration suction valves opening

35274,kozpabb,,,3,2,”s” ;duration high pressure reduction
35275,kozpv0,,,3,2,”s” ;without proportional valve: y and k = 0 after
;pressure reduction with proportional valve: actuation before mould opening

20174,kohyg2_p,,,2,2,”mm” ;hysteresis g running in front2
20175,kohyg2_n,,,2,2,”mm” ;switching-off hysteresis g2

35633,koksfx_null,,,5,0,”mV” ;zero value input calibration
35634,koksfx_max,,,5,0,”mV” ;max.value input calibration
35635,kosfx_null,,,5,0,”mV” ;zero value input calibration
35636,kosfx_max,,,5,0,”mV” ;max.value input calibration

Version:G/11/12/7/3
*** (Without unit)

08959,kortyp_fb,,,1,0 ; ramp clamping unit 1 = stroke ramp
; 0= root ramp
35616,koklksfx_kf,,,1,0 ;input calibration calibration finished
35617,koklsfx_kf,,,1,0 ;input calibration calibration finished
35628,kovzksfx,,,1,0 ;configuration algebraic sign input calibration
19920,kopropmax,,,2,0 ;1 .. reduction factors speed opening/closing

;do not act on prop. valve clamping unit
; 0=at closing
; 1=at opening
35492,koea22,,,2,0 ;prop.valve ng16 with one valve
;(s1 at mould opening ) = 1
19915,koliter_o,,,5,0 ;required specific power output opening

09319,koavfb_y,,,5,0,”%/mm” ; maximum acceleration/delay mould movement
35179,koavfb,,,5,0,”%/mm” ; maximum acceleration/delay mould movement
09320,koavsfb_y,,,5,0,”%/s” ; maximum start acceleration mould movement
35184,koavsfb,,,5,0,”%/s” ; maximum start acceleration mould movement

35064,koq33,,,4,0,”mm/s” ;maximum opening speed
*** (Unit: Clamping force [tons] )

39920,ko0sk,,,4,1,”tn” ;value for clamping force reduced
-------------------------------------------------------------------------------
Group of variables injection/holding pressure service - inject./hold.pressure service
-------------------------------------------------------------------------------

35002,kos11,,,4,1,”mm” ;maximum screw stroke
35006,kos15,,,4,1,”mm” ;maximum cushion and maximum correction
35241,kopnrres1,,,4,1,”mm” ;speed limit minimum value
37415,koopg_sbrems,62,56,4,1,”mm” ;optimization pressure limit braking position

35091,kod12,,,3,1,”bar” ;setting limitation for injection
35092,kod13,,,3,1,”bar” ;system pressure at injection
35093,kod14,,,3,1,”bar” ;system pressure at holding pressure
35105,kod26,,,3,1,”bar” ;minimum pressure for injection
35115,kod46,,,3,1,”bar” ;pct k1 headroom for-
;injection and holding pressure closed loop control
37418,kop_ueberschw,,,3,1,”bar” ;max. value for overswinging at the injection
37474,iwoverswing,62,60,3,1,”bar” ;pressure overswinging at the injection
38603,kodpurge,,,3,1,”bar” ;k valve purge pressure
37412,koopg_tol,62,53,4,0,”bar” ;tolerance deviation for monitoring
35094,kod15,,,4,1,”bar” ;maximum mould cavity pressure

35095,kdd15,,,4,1,”bar” ;resolution mould cavity pressure-pressure transducer

23379,kokr_nd_pan,,,3,0,”%” ;reinforcement adaptation holding pressure on stop unit.1
23380,kokr_pgr_pan,,,3,0,”%” ;reinforcement adaptation pressure limit on stop unit.1
39443,swgm_tol_pos_1,,,3,0,”%” ;1.unit: positive tolerance monitoring_1
39444,swgm_tol_neg_1,,,3,0,”%” ;1.unit: negative tolerance monitoring_1

16265,kovstol,,,3,0,”%” ;tolerance speed deviation for new start
18965,koqkomp_kal,,,3,0,”%” ;screw retraction at valve calibration
35038,koq4,,,3,0,”%” ;minimum speed (injection)
35048,koq13,,,3,0,”%” ;maximum volume during injection
35056,koq23,,,3,0,”%” ;volume stroke calibration screw
35058,koq25,,,3,0,”%” ;volume for injection at
;swivelled-out unit
35063,koq32,,,3,0,”%” ;volume moog on + after holding pressure
35203,kored4,,,3,0,”%” ;reduction factor injection speed
35951,kospryoffs,,,3,0,”%” ;offset on y at closed loop controlled
;injection = per cent value of absolute speed set value
41698,kovstol_w,,,3,0,”%” ;tolerance speed dev.work
41705,kovstol_a,,,3,0,”%” ;tolerance speed deviation accu
41712,kovstol_wa,,,3,0,”%” ;tolerance speed deviation accu

28450,kooffsyks,,,3,0,”%” ;actuation back pressure valve in the idling unit.1
35122,kod53,,,3,0,”%” ;pressure - stroke calibration screw
35123,kod55,,,3,0,”%” ;actuation on p/q servo valve in the idle running
35212,kored13,,,3,0,”%” ;reduction factor injection pressure
35213,kored14,,,3,0,”%” ;reduction factor holding pressure
*** (Unit: Ramp [%] )
35129,koa0,,,3,0,”%” ;pressure switchover to holding pressure
35164,koa49,,,3,0,”%” ;speed injection - braking on stop
35175,koavspr,,,3,0,”%” ;start acceleration speed injection
35994,koay2spr,,,3,0,”%” ;ramp injection speed 2nd pump on 0
37417,koopg_abrems,62,58,3,0,”%” ;optimization pressure limit braking ramp

Version:G/11/12/7/3
38601,koapurge,,,4,0,”%” ;ramp injection purge speed

39438,swgm_t_measure_1,,,5,0,”s” ;1.unit: measuring time (in sec) monitoring_1
35258,kozmoog,,,4,1,”s” ;moog on + after holding pressure

;and s4 deactuation delay
35277,kohverz,,,4,1,”s” ;screw start-up delay
;after heating up
35300,kozsfpvs,,,4,1,”s” ;injection and holding pressure-
;peak value measuring delay
39439,swgm_t_delay_1,,,4,1,”s” ;1.unit: measuring delay (in sec) monitoring_1
08479,kozvspr_ana,,,3,2,”s” ;delay between s4 and analog actuation-

;at open loop controlled operation unit 1
10210,kovz_sum,,,3,2,”s” ; calculated value sum of delays to be expected before injection
35250,koz_as,,,3,2,”s” ;calculation value !!! time active back pressure
35256,kozajd,,,3,2,”s” ;injection delay after reaching ”j”
35257,kozcld,,,3,2,”s” ;control employment delay
35282,kozvv,,,3,2,”s” ;time open shut-off nozzle
;before injection
36455,kozvspr,,,3,2,”s” ;injection delay after intrusion unit 1
37419,koz_anstieg,,,3,2,”s” ;max. value for pressure increase at the injection
37475,iwrisetime,62,61,3,2,”s” ;pressure increase time at the injection
15887,kotr_spr,,,2,3,”s” ;controller downtime and/or employment delay time

35222,kotv_spr,,,2,3,”s” ;injection closed loop control tv
35223,kotn_spr,,,2,3,”s” ;injection closed loop control tn
35235,kotv_pgrenz,,,2,3,”s” ;pressure limits closed loop control tv
35236,kotn_pgrenz,,,2,3,”s” ;pressure limits closed loop control tn
35244,kotv_nach,,,2,3,”s” ;holding pressure closed loop control tv
35245,kotn_nach,,,2,3,”s” ;holding pressure closed loop control tn
39771,kotot_sys,,,2,3,”s” ;system dead time t0 for ana 1.50
41696,kotr_spr_w,,,2,3,”s” ;spr_reg.tr work
41697,kotot_sys_w,,,2,3,”s” ;spr_reg t0 work
41699,kotv_spr_w,,,2,3,”s” ;spr_reg.tv work
41700,kotn_spr_w,,,2,3,”s” ;spr_reg.tn work
41703,kotr_spr_a,,,2,3,”s” ;spr_reg.tr accu
41704,kotot_sys_a,,,2,3,”s” ;spr_reg t0 accu
41706,kotv_spr_a,,,2,3,”s” ;spr_reg.tv accu
41707,kotn_spr_a,,,2,3,”s” ;spr_reg.tn accu
41710,kotr_spr_wa,,,2,3,”s” ;spr_reg.tr accu
41711,kotot_sys_wa,,,2,3,”s” ;spr_reg t0 accu
41713,kotv_spr_wa,,,2,3,”s” ;spr_reg.tv accu
41714,kotn_spr_wa,,,2,3,”s” ;spr_reg.tn accu

35220,kdumax_spr,,,5,0,”mV” ;injection closed loop control umax
35221,kdumin_spr,,,5,0,”mV” ;injection closed loop control umin
35233,kdumax_pgrenz,,,5,0,”mV” ;pressure limits closed loop control umax
35234,kdumin_pgrenz,,,5,0,”mV” ;pressure limits closed loop control umin
35242,kdumax_nach,,,5,0,”mV” ;holding pressure closed loop control umax
35243,kdumin_nach,,,5,0,”mV” ;holding pressure closed loop control umin
35641,kossx_null,,,5,0,”mV” ;zero value input calibration
35642,kossx_max,,,5,0,”mV” ;max.value input calibration
35901,ko2phx_null,,,5,0,”mV” ;zero value input calibration
*** (Unit: Shot [Sh] )

39445,swgm_cnt_init_1,,,2,0,”Sch” ;1.unit: number initialization cycles monitoring_1
*** (Without unit)

22801,koscrewtype,,,1,0 ; 0 = standard screw, 1 = barrier screw unit.1
23377,swpgr_error,08,59,1,0 ;pressure limit releases injection stop
28179,koomode_v,,,1,0 ;optimization mode injection closed loop control
28180,kostart_opt_v,,,1,0 ;speed optimization start
35219,koverea,,,1,0 ;injection closed loop control on/off
35232,koverpgr,,,1,0 ;pressure limits closed loop control on/off
35239,kopnrea,,,1,0 ;holding pressure closed loop control on/off
35249,kocfg_as,,,1,0 ;active pressure transition holding pressure-back pressure
35483,koea14,,,1,0 ;leakage oil compensation at holding pressure-
;closed loop control via servovalve = 1
35484,koea15,,,1,0 ;switching-off after injection
; for fast pressure reduction = 1
35620,koklssx_kf,,,1,0 ;input calibration calibration finished
35631,kovzssx,,,1,0 ;configuration algebraic sign input calibration
37411,koomode_pp,62,52,1,0 ;optimization mode pressure limit closed loop control
37414,koopp_eabrems,62,55,1,0 ;optimization pressure limit braking point switch onoff
37422,kostart_opt_pp,,,1,0 ;pressure optimization selection
39440,swgm_pr_mon_1,,,1,0 ;1.unit: program switch monitoring_1
39446,swgm_pr_cycinit_1,,,1,0 ;1.unit: program switch initalization cycles monitoring_1
09342,kocfg_vsd,,,2,0 ;shut-off nozzle type 0 = nozzle 1 = mould

09356,kocfg_vnach,,,2,0 ;mode: speed control in the
;holding pressure phase 0.. const
;1 .. via speed profile
35463,komode,,,2,0 ;mode: 0 = proportional valve-controlled
; 1 = servovalve-controlled
35476,koea7,,,2,0 ;cushion correction: 0=without, 1=with
35482,koea13,,,2,0 ;parallel switchover = 1
35954,kocfg_s4d,,,2,0 ;1 = differential connection
; (s4d mounted)
39441,swgm_sel_abort_1,,,2,0 ;1.unit: selection interruption action monitoring_1
35225,koks_spr,,,2,3 ;injection closed loop control ks

35237,kokr_pgrenz,,,2,3 ;pressure limits closed loop control kr
35238,koks_pgrenz,,,2,3 ;pressure limits closed loop control ks
41695,koks_spr_w,,,2,3 ;spr_reg.ks work
41702,koks_spr_a,,,2,3 ;spr_reg.ks accu
41709,koks_spr_wa,,,2,3 ;spr_reg.ks accu

Version:G/11/12/7/3
35247,koks_nach,,,3,1 ;holding pressure closed loop control ks

35248,kokf_nach,,,3,1 ;holding pressure closed loop control correction factor
35128,kopfakt,,,5,0 ;power factor for determining

;the maximum injection speed (= vemin * pmax)
;at machines with hls hydraulic system
35224,kokr_spr,,,5,0 ;injection closed loop control kr
35246,kokr_nach,,,5,0 ;holding pressure closed loop control kr
37413,swo_pp_state_r,62,54,5,0 ;status of pgr optimization
39436,swgm_sel_chan_1,,,5,0 ;1.unit: index on measuring channel for monitoring_1
39437,swgm_sel_mod_1,,,5,0 ;1.unit: mode bits for measurement on monitoring_1
39442,swgm_sel_idk_1,,,5,0 ;1.unit: number of the ideal curve monitoring_1
41694,kokr_spr_w,,,5,0 ;spr_reg.kr work
41701,kokr_spr_a,,,5,0 ;spr_reg.kr accu
41708,kokr_spr_wa,,,5,0 ;spr_reg.kr accu
42145,swo_v_state_r,60,07,5,0 ;screen display speed optimization unit.1
*** (Unit: Maximum ramps [mm/s2] )

35186,koavssb,,,5,0,”mm/s2” ; maximum start acceleration screw absolute

35165,koa50,,,5,0,”%/s” ;speed switchover to holding pressure
*** (Unit: Maximum ramps [(mm/s)/mm] )

35181,koavsb,,,5,0,”/s” ; maximum acceleration/delay screw absolute

39447,sdgm_t_monle_1,,,4,2,”s” ;1.unit: monitoring window left edge monitoring_1
39448,sdgm_t_monri_1,,,4,2,”s” ;1.unit: monitoring window right edge monitoring_1
12814,koqanschl,,,4,0,”mm/s” ;volume injection on stop
35046,koq11,,,4,0,”mm/s” ;volume holding pressure at hls hydraulic system
;volume holding pressure on y at servo closed loop control
35059,koq26,,,4,0,”mm/s” ;auxiliary variable in ar_prof.def
37416,koopg_vbrems,62,57,4,0,”mm/s” ;optimization pressure limit braking speed
-------------------------------------------------------------------------------
Group of variables carriage unit service - injection unit service
-------------------------------------------------------------------------------

35003,kos12,,,4,1,”mm” ;maximum nozzle stroke
35010,kos21,,,4,1,”mm” ;stop in front of stop nozzle at the back
35011,kos22,,,4,1,”mm” ;calculation value, reserved !!!!
35028,kosj,,,4,1,”mm” ;allowed nozzle movement j recognition

10099,kop5_ab,,,3,1,”bar” ; contact pressure switching-off value
10101,kop5red_ab,,,3,1,”bar” ; contact pressure red.switching-off value
36457,kod56,,,3,1,”bar” ;tolerance for reached contact pressure
;j = reached at (p5-kod56)

10185,kored21,,,3,0,”%” ;reduction factor nozzle return speed
35039,koq5,,,3,0,”%” ;volume at the nozzle pressure build-up
35040,koq6,,,3,0,”%” ;minimum speed (nozzle)
35054,koq21,,,3,0,”%” ;volume stroke calibration nozzle, j determination
35069,koq47,,,3,0,”%” ;volume pressure reduction carriage
35074,koq58,,,3,0,”%” ;volume carriage without clamping pressure
;and no nozzle retraction
35202,kored3,,,3,0,”%” ;reduction factor nozzle forward speed

35084,kod5,,,3,0,”%” ;pressure at carriage (b not actuated)
35085,kod6,,,3,0,”%” ;pressure at nozzle return
35102,kod23,,,3,0,”%” ;minimum pressure for nozzle
35121,kod52,,,3,0,”%” ;pressure - stroke calibration nozzle
35216,kored17,,,3,0,”%” ;reduction factor nozzle forward pressure
*** (Unit: Ramp [%] )
35137,koa9,,,3,0,”%” ;speed start nozzle forward,k
35138,koa10,,,3,0,”%” ;speed braking on j1,j
35142,koa15,,,3,0,”%” ;speed braking on k
35173,koavduv,,,3,0,”%” ;start acceleration speed nozzle forward
35174,koavduz,,,3,0,”%” ;start acceleration speed nozzle return

35029,kozjrl,,,4,1,”s” ;measurement time at j determination
35255,koznfd,,,3,2,”s” ;nozzle forward delay in automatic mode

35283,kozvp5r,,,3,2,”s” ;time pressure build-up before pressure reduction carriage
35284,kozp5r,,,3,2,”s” ;time pressure reduction carriage
35285,koznp5r,,,3,2,”s” ;time k,y,s5 delayed after pressure reduction carriage
36456,kozduv,,,3,2,”s” ;waiting time after nozzle pressure build-up
35637,kosdx_null,,,5,0,”mV” ;zero value input calibration

35027,kozjm,,,4,0,” ;number of measurements at stand=
;still of the nozzle (j determination)
*** (Without unit)

10102,kocfg_p5,,,1,0 ;contact pressure build-up
; 0 = via time z5a

Version:G/11/12/7/3
; 1 = via system pressure

35618,koklsdx_kf,,,1,0 ;input calibration calibration finished
35629,kovzsdx,,,1,0 ;configuration algebraic sign input calibration
35638,kosdx_max,,,5,0 ;max.value input calibration

35180,koavdb,,,5,0,”%/mm” ; maximum acceleration/delay nozzle movement

35185,koavsdb,,,5,0,”%/s” ; maximum start acceleration nozzle movement
-------------------------------------------------------------------------------
Group of variables ejector service - ejector service
-------------------------------------------------------------------------------

35004,kos13,,,4,1,”mm” ;maximum ejector stroke
35007,kos16,,,4,1,”mm” ;safety distance for a1/l1
35023,kos34,,,4,1,”mm” ;stroke position monitoring at standstill sax

02218,koqawk,,,3,0,”%” ; volume ejector return when uncoupled
35050,koq17,,,3,0,”%” ;minimum speed (ejector)
35055,koq22,,,3,0,”%” ;volume stroke calibration ejector
35071,koq49,,,3,0,”%” ;volume on y at movements
;via ejector proportional valve y2
35075,koq59,,,3,0,”%” ;volume ejector in set-up mode
35206,kored7,,,3,0,”%” ;reduction factor ejector forward speed
35207,kored8,,,3,0,”%” ;reduction factor ejector return speed

02220,kodawk,,,3,0,”%” ; pressure ejector forward when uncoupled
09631,kod21,,,3,0,”%” ;minimum pressure for ejector
35120,kod51,,,3,0,”%” ;pressure - stroke calibration ejector
35124,kod59,,,3,0,”%” ;pressure ejector in set-up mode
35214,kored15,,,3,0,”%” ;reduction factor ejector forward pressure
35215,kored16,,,3,0,”%” ;reduction factor ejector return pressure
*** (Unit: Ramp [%] )
08509,koavl4,,,3,0,”%” ;speed ramp on l4 (ejector)
35153,koa38,,,3,0,”%” ;speed braking on l1
35154,koa39,,,3,0,”%” ;speed braking on l
35158,koa43,,,3,0,”%” ;speed braking on l2
35163,koa48,,,3,0,”%” ;speed ramp on l3 (ejector)
35169,koavawv,,,3,0,”%” ;start acceleration speed ejector forward
35170,koavawz,,,3,0,”%” ;start acceleration speed ejector return
36134,koa53,,,3,0,”%” ;brake pressure to l, l1, l2
07942,kozvawv,,,3,2,”s” ;ejector forward delay

35639,kosax_null,,,5,0,”mV” ;zero value input calibration
35640,kosax_max,,,5,0,”mV” ;max.value input calibration
*** (Without unit)

21322,swausw_akt,38,62,1,0 ;ejector releases regarding handling system
35619,koklsax_kf,,,1,0 ;input calibration calibration finished
35630,kovzsax,,,1,0 ;configuration algebraic sign input calibration
35466,koawprp,,,2,0 ;proportional valve ejector = 1

40765,koawstep,,,2,0 ;1 = ejector profile two-stage
19638,koavab_y,,,5,0,”%/mm” ; maximum acceleration/delay ejector movement
; on ehv pump if prop. valve ejector
35178,koavab,,,5,0,”%/mm” ; maximum acceleration/delay ejector movement

19639,koavsab_y,,,5,0,”%/s” ; maximum start acceleration ejector movement
; on ehv pump if prop. valve ejector
35183,koavsab,,,5,0,”%/s” ; maximum start acceleration ejector movement

35070,koq48,,,4,0,”mm/s” ;maximum speed ejector return
35073,koq54,,,4,0,”mm/s” ;maximum speed ejector forward
-------------------------------------------------------------------------------
Group of variables plasticizing/screw retraction service-plast./decompres.service
-------------------------------------------------------------------------------

35002,kos11,,,4,1,”mm” ;maximum screw stroke
35006,kos15,,,4,1,”mm” ;maximum cushion and maximum correction

35100,kod20,,,3,1,”bar” ;setting limitation for back pressure
37242,kopsmin,,,3,1,”bar” ; minimum reachable back pressure at ehv1 unit.1
18965,koqkomp_kal,,,3,0,”%” ;screw retraction at valve calibration
19911,koqkom_endl,,,3,0,”%” ;last speed decompression
19912,ko2qkom_endl,,,3,0,”%” ;last speed decompression unit.2
35037,koq3,,,3,0,”%” ;minimum speed (plasticizing)
35056,koq23,,,3,0,”%” ;volume stroke calibration screw
35057,koq24,,,3,0,”%” ;volume for back pressure calibration

Version:G/11/12/7/3
35079,koqkom_min,,,3,0,”%” ;minimum speed decompression

35204,kored5,,,3,0,”%” ;reduction factor plasticizing speed
35205,kored6,,,3,0,”%” ;reduction factor retraction speed

10046,kopdosmax_sdm1,,,3,0,”%” ;max. pressure at plasticizing screw 1 unit.1
35101,kod22,,,3,0,”%” ;maximum pressure at plasticizing
35103,kod24,,,3,0,”%” ;pressure - screw retraction
35122,kod53,,,3,0,”%” ;pressure - stroke calibration screw
*** (Unit: Ramp [%] )

35141,koa14,,,3,0,”%” ;speed braking on c1
35161,koa46,,,3,0,”%” ;pressure braking on c1
35167,koavkome,,,3,0,”%” ;speed braking on c2,c4
35168,koavkoms,,,3,0,”%” ;speed start decompression
35176,koavdos,,,3,0,”%” ;start acceleration speed plasticizing
*** (Unit: Revolution [/min] )

34798,komaxdz,,,3,0,”/min” ;max.rpm-stop when exceeded.
35315,korpm_min,,,3,0,”/min” ;minimum screw speed
35316,korpm,,,3,0,”/min” ;maximum screw speed

;after heating up
10775,kozv_s24,,,3,2,”s” ;delay after decompression

35250,koz_as,,,3,2,”s” ;calculation value !!! time active back pressure
35263,kosfpss,,,3,2,”s” ;back pressure peak value measurement delay
35287,kozvs24,,,3,2,”s” ;delay between plasticizing and decompression
35297,kozs4,,,3,2,”s” ;s100 hls delay:
;plasticizing: s4 energizes delayed to s3
;and s3 de-energizes delayed to s4
34687,kotv_dz,,,2,3,”s” ;closed loop speed control tv

34688,kotn_dz,,,2,3,”s” ;closed loop speed control tn
34691,kot0_dz,,,2,3,”s” ;speed closed loop control tr
35228,kotv_stau,,,2,3,”s” ;closed loop back pressure control tv
35229,kotn_stau,,,2,3,”s” ;closed loop back pressure control tn

10362,kdustart_stau,,,5,0,”mV” ;back pressure control ustart
34685,kdumax_dz,,,5,0,”mV” ;closed loop speed control umax
34686,kdumin_dz,,,5,0,”mV” ;closed loop speed control umin
35226,kdumax_stau,,,5,0,”mV” ;closed loop back pressure control umax
35227,kdumin_stau,,,5,0,”mV” ;closed loop back pressure control umin
35641,kossx_null,,,5,0,”mV” ;zero value input calibration
35642,kossx_max,,,5,0,”mV” ;max.value input calibration
*** (Without unit)

15865,ko_ser_f1,,,1,0 ;filter mounted on servodrive
23279,koea_komp_serv,,,1,0 ;decompression 1=with moog valve
28327,koenable_dz,,,1,0 ;allow closed loop speed control
34684,kotst_dz,,,1,0 ;closed loop speed control on-off
35249,kocfg_as,,,1,0 ;active pressure transition holding pressure-back pressure
35620,koklssx_kf,,,1,0 ;input calibration calibration finished
35631,kovzssx,,,1,0 ;configuration algebraic sign input calibration
09628,kocfgyks_reg,,,2,0 ;back pressure valve ehv2/3 open loop controlled unit.1:

;0 .. pressure proportional valve
;1 .. flow control valve
;2 .. servo control valve
35317,koimp,,,2,0 ;impulses per screw revolution
34690,koks_dz,,,2,3 ;closed loop speed control ks

35231,koks_stau,,,2,3 ;closed loop back pressure control ks
09357,kolk_dreh,,,3,2 ; waste oil compensation factor screw rotation
34689,kokr_dz,,,5,0 ;closed loop speed control kr

35230,kokr_stau,,,5,0 ;closed loop back pressure control kr
35182,koavdr,,,5,0,”%/mm” ; maximum acceleration/delay screw rotation
35188,koavkomb,,,5,0,”%/mm” ; maximum acceleration/delay decompression movement

35187,koavsdr,,,5,0,”%/s” ; maximale start acceleration screw movement
35189,koavskomb,,,5,0,”%/s” ; maximum acceleration decompression movement

41518,koeldos_verz,,,4,2,”s” ;delay between controller release>
;and analog output in manual mode
-------------------------------------------------------------------------------
Group of variables core service - core service
-------------------------------------------------------------------------------

01097,swc5,38,59,4,1,”mm” ;core trigger point on screw stroke
02159,swko4,09,19,4,1,”mm” ;mould relief position

Version:G/11/12/7/3
32851,sw2c5,35,00,4,1,”mm” ;core trigger point on screw stroke unit 2


02924,swvke1i,37,88,3,0,”%” ;core 1 in volume on intermediate stop
03325,swvka1i,37,87,3,0,”%” ;core 1 out volume on intermediate stop
11390,swvkhold,,,3,0,”%” ;core holding volume
35217,kored19,,,3,0,”%” ;reduction factor cores speed

03224,swpke1i,37,94,3,0,”%” ;core 1 in pressure on intermediate stop.
03327,swpka1i,37,93,3,0,”%” ;core 1 out pressure on intermediate stop.
11389,swpkhold,,,3,0,”%” ;core holding pressure
35218,kored20,,,3,0,”%” ;reduction factor cores pressure
*** (Unit: Ramp [%] )
35133,koa5,,,3,0,”%” ;speed braking on ks
35136,koa8,,,3,0,”%” ;speed braking on koe
35146,koa24,,,3,0,”%” ;pressure braking pressure on ks
35159,koa44,,,3,0,”%” ;speed braking on b8 at closing.
35160,koa45,,,3,0,”%” ;speed braking on b8 at opening.
35162,koa47,,,3,0,”%” ;pressure braking on koe (mould)

01897,swzka3i,39,80,4,1,”s” ;core 3 moving-out time on intermediate stop.
04135,swzke1i,39,75,4,1,”s” ;core 1 moving-in time on intermediate stop.
04963,swkztime1,38,50,4,1,”s” ;core timer 1
19608,kozkerne,,,3,2,”s” ;pressure build-up time cores in after reaching limit switch

22904,kozkerna,,,3,2,”s” ;pressure build-up time cores out after reaching limit switch
*** (Without unit)

01497,swprawso,08,63,1,0 ;ejector safeties
02575,swprkern,39,00,1,0 ;core main switch
04142,swkez1i,39,81,1,0 ;move in core 1 as a function of time on intermediate stop.
04145,swkaz1i,39,84,1,0 ;move out core 1 as a function of time on intermediate stop.
04777,swkazwang1,38,44,1,0 ;move out k1 compulsorily with end moving-in.
06533,swprkadt1,40,00,1,0 ;core 1 alternating rotary table-dependent
14289,kocfghndl_kf,,,1,0 ; handling system release for cores:
; 0 = standard release
; 1 = individual releases
15841,kobridge1,,,1,0 ;bridging configuration core 1
28380,swpronebut,09,93,1,0 ;one-button operation sequence control in manual mode
28382,kocfg_onebut,,,1,0 ;enable one-button operation
32745,swablschls,33,75,1,0 ;sequence control with programmed mould movement
41634,kointlimsw,,,1,0 ;intermediate stop limit switch cores mounted
04044,sw_k_wpkt1,39,01,2,0 ;core waiting point 1


Version:G/11/12/7/3

35469,kokern,,,2,0 ;number of core-pulls (0 - 3)
42451,kocfg_saw_close,,,2,0 ;selection saw closing interlock
04081,sw_k_step1,39,38,3,0 ;core step 1

22875,iw_mldstp_s,,,5,0 ;stop point closing

22876,iw_mldstp_o,,,5,0 ;stop point opening
35198,koaykern,,,5,0,”%/s” ;outset acceleration y outputs core-pull
35199,koakkern,,,5,0,”%/s” ;outset pressure increase k outputs core-pull
-------------------------------------------------------------------------------
Group of variables configuration switch service - prog./config.switches service
-------------------------------------------------------------------------------
10102,kocfg_p5,,,1,0 ;contact pressure build-up
; 0 = via time z5a
10107,ko2cfg_p5,,,1,0 ;contact pressure build-up
; 0 = via time z5a
17564,ko_iso_imp,,,1,0 ; 0 = iso-units active
; 1 = imp-units active
22801,koscrewtype,,,1,0 ; 0 = standard screw, 1 = barrier screw unit.1
23822,ko2screwtype,,,1,0 ; 0 = standard screw, 1 = barrier screw unit.2
35480,koea11,,,1,0 ;sk-offs error stops cycle = 1
35483,koea14,,,1,0 ;leakage oil compensation at holding pressure-
;closed loop control via servovalve = 1
35484,koea15,,,1,0 ;switching-off after injection
; for fast pressure reduction = 1
35487,koarst,,,1,0 ;enable ar161 start
35490,koea20,,,1,0 ;oil filter unit mounted = 1
35493,koea30,,,1,0 ;socket / cooling water switching-off
35779,ko2ea14,,,1,0 ;leakage oil compensation at holding pressure-
;closed loop control via servovalve = 1 unit 2
35780,ko2ea15,,,1,0 ;s10 switching-off after injection 2
;for fast pressure reduction = 1
35785,ko2ea18,,,1,0 ;e52 of unit 1 also locks unit 2 = 1
35952,komodebit,,,1,0 ;mode word (switch for offset 2nd injection process)
35956,kocfgpvrg,,,1,0 ;1 = control parameter image unit 1 activated
35957,ko2cfgpvrg,,,1,0 ;1 = control parameter image unit 2 activated
35959,ko2cfgyks,,,1,0 ;1 = back pressure valve mounted unit 2
35960,koskkorr,,,1,0 ;1 = clamping force correction switched on
39076,kouomac,,,1,0 ;access level restricted unit change
; 0 = no access level required for unit change.
; 1 = access level 1111... required for unit change

Version:G/11/12/7/3
; 2 = access level 1111... required for unit change

; 3 = access level super user required for unit change
39077,kohostuom,,,1,0 ;default units for host communications
; 0 = metric (iso) units
; 1 = imperial units
08517,kocfg_kolb,,,2,0 ;1 = continuous piston rod at

;ehv1/hls1 unit 1
17863,ko2cfg_kolb,,,2,0 ;1 = straight piston rod at ehv1 unit 2
19659,ko_enable_imp,,,2,0 ;default units:
; 0 = machine is metric only
; 1 = a key switches units
; 2 = machine is in imperial only
20781,koeaph_eil,,,2,0 ;pressure transducer in high speed cylinder= 1
35466,koawprp,,,2,0 ;proportional valve ejector = 1
35469,kokern,,,2,0 ;number of core-pulls (0 - 3)
35470,kohndl,,,2,0 ;handling system connection = 1
35473,koea4,,,2,0 ;output ha: 0 = off
; 1 = semiautomatic mode
; 2 = fully automatic mode
; 3 = automatic mode
35475,koea6,,,2,0 ;high speed mounting: 0=deactive
; 1=single monitored
; 2=double monitored
35477,koea8,,,2,0 ;output fs: 0 = permanent
; 1=flashing
35478,koea9,,,2,0 ;air valve 2 mounted = 1
35481,koea12,,,2,0 ;control system type: 0=ec88/ec100
; 1=cc100
35482,koea13,,,2,0 ;parallel switchover = 1
35486,koea17,,,2,0 ;light beam guard: 0=flank 0/1
; 1=flank 1/0
35488,konorm_out,,,2,0 ;standardized output vssx,ssx,phx = 1
35489,koea19,,,2,0 ;mould stop after mould protection alarm = 1
; 0=at closing
; 1=at opening
35492,koea22,,,2,0 ;prop.valve ng16 with one valve
;(s1 at mould opening ) = 1
35494,kodv1off,,,2,0 ;devices switching-off output dodv1
35495,kodv2off,,,2,0 ;devices switching-off output dodv2
;0 only via week switch clock
;1 week switch clock and also at motor stop
35502,kocfg02,,,2,0 ;configuration reserved !!
35776,ko2ea7,,,2,0 ;cushion correction = 1 unit 2
35778,ko2ea13,,,2,0 ;parallel switchover = 1 unit 2
35782,ko2winkel,,,2,0 ;built-on variants unit 2:
;0....no angle unit
;1....angle unit
35783,ko2e52,,,2,0 ;limit switch unit 2 swivelled out:
;0....not mounted
;1....mounted
35786,ko2ea20,,,2,0 ;di2e9p injection position limit switch unit 2:
;0....not mounted
;1....mounted/locks s3.2,s4.2,s5.2
;2....like 1 and also locks s5 unit 1
; (danger of collision)
35787,ko2mode,,,2,0 ;unit 2: 0 = proportional valve-open loop controlled
35954,kocfg_s4d,,,2,0 ;1 = differential connection
; (s4d mounted)
35955,ko2cfg_s4d,,,2,0 ;1 = differential connection unit 2
; (2s4d mounted)
35958,kocfgyks,,,2,0 ;1 = back pressure valve mounted unit 1
35973,koehvdopp,,,2,0 ;1=operation with 2 ehv pumps
35990,kodos_2p,,,2,0 ;plasticizing with 2 pumps
35991,kospr_2p,,,2,0 ;injection with 2 pumps
35992,koschls_2p,,,2,0 ;clamping unit with 2 pumps
41535,komsize,,,2,0 ;machine size:
; 0 = direct closing ehv1
41536,ko2msize,,,2,0 ;machine size unit2:
-------------------------------------------------------------------------------
Group of variables general parameter service - general parameter service
-------------------------------------------------------------------------------

35459,kosdm1,,,4,1,”mm” ;screw diameter 1
35772,ko2sdm1,,,4,1,”mm” ;screw diameter 1 unit 2

35127,kolimphx,,,3,1,”bar” ;idling pressure limit hls hydraulic system
35840,ko2limphx,,,3,1,”bar” ;idling pressure limit pump 2 at hls

Version:G/11/12/7/3
35993,kop2_0,,,3,1,”bar” ;threshold 2nd pump pressureless
35094,kod15,,,4,1,”bar” ;maximum mould cavity pressure

35095,kdd15,,,4,1,”bar” ;resolution mould cavity pressure-pressure transducer
35699,ko2d15,,,4,1,”bar” ;maximum mould cavity pressure unit 2
35700,kd2d15,,,4,1,”bar” ;resolution mould cavity pressure transducer unit 2

35034,koq0,,,3,0,”%” ;volume at oil preheating
35035,koq1,,,3,0,”%” ;idling volume with s10
35044,koq10,,,3,0,”%” ;volume high speed mounting
35047,koq12,,,3,0,”%” ;volume pressure calibration without s10
35051,koq18,,,3,0,”%” ;volume at flushing without s10
35061,koq28,,,3,0,”%” ;volume pressure calibration 1st pump
35672,ko2q0,,,3,0,”%” ;volume at oil preheating unit 2
35673,ko2q1,,,3,0,”%” ;idling volume with s10 unit 2
35679,ko2q12,,,3,0,”%” ;volume pressure calibration without s10 unit 2
35681,ko2q18,,,3,0,”%” ;volume at flushing without s10 unit 2
35687,ko2q28,,,3,0,”%” ;volume pressure calibration 1st pump unit 2
35690,ko2q62,,,3,0,”%” ;volume on ys at oil preheating unit 2
35979,koq18_2,,,3,0,”%” ;volume at flushing without s9

28450,kooffsyks,,,3,0,”%” ;actuation back pressure valve in the idling unit.1
28451,ko2offsyks,,,3,0,”%” ;actuation back pressure valve in the idling unit.2
35080,kod0,,,3,0,”%” ;pressure at oil heating-up
35089,kod10,,,3,0,”%” ;pressure at high speed mould mounting
35090,kod11,,,3,0,”%” ;pressure at stroke calibration opening
35098,kod18,,,3,0,”%” ;pressure at flushing without s10
35099,kod19,,,3,0,”%” ;pressure at moog speed calibration
35107,kod28,,,3,0,”%” ;pressure speed calibration (screw forward)
35108,kod29,,,3,0,”%” ;pressure screw speed calibration
35109,kod34,,,3,0,”%” ;idling pressure with s10
35123,kod55,,,3,0,”%” ;actuation on p/q servo valve in the idle running
35692,ko2d0,,,3,0,”%” ;pressure at oil heating-up unit 2
35701,ko2d18,,,3,0,”%” ;pressure at flushing without s10 unit 2
35702,ko2d19,,,3,0,”%” ;pressure at moog speed calibration unit 2
35708,ko2d28,,,3,0,”%” ;pressure speed calibration (screw forward) unit 2
35709,ko2d29,,,3,0,”%” ;pressure screw speed calibration unit 2
35710,ko2d30,,,3,0,”%” ;pressure speed calibration (screw return) unit 2
35711,ko2d34,,,3,0,”%” ;idling pressure with s10 unit 2
35723,ko2d55,,,3,0,”%” ;actuation on p/q control valve in the idle running unit 2
35978,kod18_2,,,3,0,”%” ;pressure at flushing without s9
*** (Unit: Ramp [%] )

35735,ko2apst,,,3,0,”%” ;start acceleration pressure all movements
35949,ko2a42,,,3,0,”%” ;pressure steep ramp end position remaining movements

08393,koz_fshupe,,,4,1,”s” ;maximum hooting duration mould protection horn
35252,kozs10,,,4,1,”s” ;deactuation delay s10 at flushing
35253,kozy1,,,4,1,”s” ;output delay y1 at flushing
35266,kozhy,,,4,1,”s” ;monitoring time for hydraulic closing safety be8
35267,kozma,,,4,1,”s” ;delayed motor switching-off
35268,kozwkal,,,4,1,”s” ;standstill time at stroke calibration
35278,koovwhnd,,,4,1,”s” ;delay time at manual movements during oil preheating
35293,koze9ueb,,,4,1,”s” ;monitoring time for nozzle guard limit switch
35298,kozstab,,,4,1,”s” ;socket / cooling water switching-off delay time
35299,koznotueb,,,4,1,”s” ;monitoring time for emergency-off circuit
35754,ko2zs10,,,4,1,”s” ;deactuation delay s10 at flushing 2nd unit
35755,ko2zy1,,,4,1,”s” ;output delay y1 at flushing 2nd unit
35761,ko2zwkal,,,4,1,”s” ;standstill time at stroke calibration 2nd unit
35770,ko2ze9ueb,,,4,1,”s” ;monitoring time for nozzle guard limit switch 2nd unit
35980,kozs9,,,4,1,”s” ;deactuation delay s9 at flushing
35981,kozy2,,,4,1,”s” ;output delay y2 at flushing
36190,kozssp,,,4,1,”s” ;after-running time mount/dismount high speed mounting device
38272,kodbar,,,4,1,”s” ;monitoring time closing safety
10770,kozvawh,,,3,2,”s” ;delay movements in manual mode
;after flushing
39071,koztd,,,3,2,”s” ;time for pump motor to reach full rpm

08023,koph50,,,5,0,”mV” ;offset accu pressure transducer
08025,koph5_null,,,5,0,”mV” ;zero value
08026,koph5_max,,,5,0,”mV” ;max.value
12065,koph_eil0,,,5,0,”mV” ;offset pressure high speed cylinder
12067,koph_eil_null,,,5,0,”mV” ;zero value pressure high speed cylinder
12068,koph_eil_max,,,5,0,”mV” ;max.value pressure high speed cylinder
16325,kopmx_null,,,5,0,”mV” ; zero value melt pressure unit.1
16326,kopmx_max,,,5,0,”mV” ; maximum value melt pressure unit.1
19612,kodsp,,,5,0,”mV” ; nozzle safety position (in mv) unit.1
20832,ko2phx0,,,5,0,”mV” ;offset hydraulic pressure transducer 1 unit 2
32766,ko2pmx_null,,,5,0,”mV” ; zero value melt pressure unit.2
32767,ko2pmx_max,,,5,0,”mV” ; maximum value melt pressure unit.2
34600,kopmx0,,,5,0,”mV” ; offset melt pressure transducer unit.1
34601,ko2pmx0,,,5,0,”mV” ; offset melt pressure transducer unit.2
35025,kophx0,,,5,0,”mV” ;offset hydraulic pressure transducer 1
35645,kophx_null,,,5,0,”mV” ;zero value input calibration
35646,kophx_max,,,5,0,”mV” ;max.value input calibration
35647,kopfx_null,,,5,0,”mV” ;zero value input calibration
35648,kopfx_max,,,5,0,”mV” ;max.value input calibration
35649,koskx_null,,,5,0,”mV” ;zero value input calibration
35650,koskx_max,,,5,0,”mV” ;max.value input calibration
35651,kophx2_null,,,5,0,”mV” ;zero value input calibration
35652,kophx2_max,,,5,0,”mV” ;max.value input calibration
35839,ko2dsp,,,5,0,”mV” ;nozzle safety position (in mv) unit.2
; (at angle machines !)

Version:G/11/12/7/3
; this stroke transducer voltage value must be

; set so high that no damage of the
; 2.carriage cylinder by the clamping unit
; is possible !
35969,ko2phx20,,,5,0,”mV” ;offset hydraulic pressure transducer 2 unit 2
35984,kophx3_null,,,5,0,”mV” ;zero value input calibration
35985,kophx3_max,,,5,0,”mV” ;max.value input calibration
*** (Without unit)

28244,stehv_dip,,,17,0 ;settings bosch cards dip switches pump1 unit.1
28248,stehv_dip_2,,,17,0 ;settings bosch cards dip switches pump2 unit.1
28252,st2ehv_dip,,,17,0 ;settings bosch cards dip switches pump1 unit.2
35508,ktho01,,,20,0 ;standstill reason

08024,koklph5_kf,,,1,0 ;
08044,koklydtl_kf,,,1,0 ;output calibration prop.v.rt.calib.finished
08045,koklydtr_kf,,,1,0 ;output calibration prop.v.rt.calib.finished
08047,ko2klm_kf,,,1,0 ;output calibration finished
08048,ko2klmvor_kf,,,1,0 ;output calibration finished
08049,ko2klmrue_kf,,,1,0 ;output calibration finished
08050,ko2klv_kf,,,1,0 ;output calibration finished
08051,ko2klmp_kf,,,1,0 ;output calibration finished
08052,ko2klyd_kf,,,1,0 ;output calibration finished
08053,ko2klks_kf,,,1,0 ;input calibration finished
08055,ko2klphx_kf,,,1,0 ;input calibration finished
08056,ko2klpfx_kf,,,1,0 ;input calibration finished
08057,ko2kldz_kf,,,1,0 ;input calibration finished
12066,koklph_eil_kf,,,1,0 ;pressure high speed cylinder finished
22591,kocfg_fshupe,,,1,0 ;signal type mp horn 0 = interval 1 = duration
28295,kocfg_qdp,,,1,0 ; calculated value, do not change !
28297,kocfg_mgraf,,,1,0 ; calculated value, do not change !
28298,kocfg_mplast,,,1,0 ; calculated value, do not change !
28299,kocfg_mflow,,,1,0 ; calculated value, do not change !
28310,kocfg_telser_t,,,1,0 ; 1 = teleservice active temporarily
32768,ko2klpmx_kf,,,1,0 ; input calibration melt pressure finished unit.2
34694,koklpmx_kf,,,1,0 ; input calibration melt pressure finished unit.1
35602,kokly_kf,,,1,0 ;output calibration calibration finished
35603,koklk_kf,,,1,0 ;output calibration calibration finished
35605,koklysch_kf,,,1,0 ;output calibration calibration finished
35606,koklyoef_kf,,,1,0 ;output calibration calibration finished
35607,koklm_kf,,,1,0 ;output calibration calibration finished
35608,koklmvor_kf,,,1,0 ;output calibration calibration finished
35609,koklmrue_kf,,,1,0 ;output calibration calibration finished
35610,koklv_kf,,,1,0 ;output calibration calibration finished
35611,koklmp_kf,,,1,0 ;output calibration calibration finished
35612,koklyawz_kf,,,1,0 ;output calibration calibration finished
35613,koklyd_kf,,,1,0 ;output calibration calibration finished
35614,koklks_kf,,,1,0 ;output calibration calibration finished
35615,koklyawv_kf,,,1,0 ;output calibration calibration finished
35622,koklphx_kf,,,1,0 ;input calibration calibration finished
35623,koklpfx_kf,,,1,0 ;input calibration calibration finished
35624,koklskx_kf,,,1,0 ;input calibration calibration finished
35625,koklie_kf,,,1,0 ;input calibration calibration finished
35626,kokldz_kf,,,1,0 ;input calibration calibration finished
35627,koklphx2_kf,,,1,0 ;input calibration calibration finished
35895,ko2kly_kf,,,1,0 ;output calibration finished
35896,ko2klk_kf,,,1,0 ;output calibration finished
35964,ko2klphx2_kf,,,1,0 ;input calibration calibration finished
35974,kokly2_kf,,,1,0 ;output calibration calibration finished
35975,koklk2_kf,,,1,0 ;2.pump
35983,koklphx3_kf,,,1,0 ;output calibration calibration finished
41637,koklm_kf_akku,,,1,0 ;output calibration accu finished
43526,konowait,,,1,0 ;no waiting for accu charging finished
43948,kocfg_sched,,,1,0 ; calculated value, do not change !
43949,kocfg_host,,,1,0 ; calculated value, do not change !
43950,kocfg_comm,,,1,0 ; calculated value, do not change !
11906,koskanzschli,,,2,0 ;number high speed pistons

11907,koskanzausw,,,2,0 ;number ejector pistons
11908,koskanzdues,,,2,0 ;number carriage cylinders
11914,ko2skanzdues,,,2,0 ;number carriage cylinders unit.2
21188,kotmwef,,,2,0 ; selection ht dismount mould fixed platen
21189,kotmwsf,,,2,0 ; selection ht mount mould fixed platen
21190,kotml1,,,2,0 ; selection ht air valve 1 blowing
21191,kotml2,,,2,0 ; selectioin ht air valve 2 blowing
21192,kotmweb,,,2,0 ; selection ht dismount mould moving platen
21193,kotmwsb,,,2,0 ; selection ht mount mould moving platen
21194,kotmgz,,,2,0 ; selection ht close safety gate
21195,kotmga,,,2,0 ; selection ht open safety gate
21196,kobsgn,,,2,0 ; selection ht safety gate automatic
21197,ko2tm04,,,2,0 ; selection ht injection unit.2
21198,ko2tm03,,,2,0 ; selection ht plasticizing unit.2
21199,ko2tm05,,,2,0 ; selection ht carriage unit 2 forward
21200,ko2tm06,,,2,0 ; selection ht carriage unit 2 return
21201,kotmref,,,2,0 ; selection push-button referencing erc/er-hli
21202,kotmheiml,,,2,0 ; selection push-button home run erc/er-hli
21203,kotm17,,,2,0 ; selection ht move in core 2

Version:G/11/12/7/3
21204,kotm16,,,2,0 ; selection ht move out core 2

21205,kotm19,,,2,0 ; selection ht move in core 3
21206,kotm18,,,2,0 ; selection ht move out core 3
21207,kotmdtl,,,2,0 ; selection ht index plate left
21208,kotmdtr,,,2,0 ; selection ht index plate right
21209,kotmye,,,2,0 ; selection ht move in vertical stroke
21210,kotmya,,,2,0 ; selection ht move out vertical stroke
21211,kotmzl,,,2,0 ; selection ht turn take-off to the left
21212,kotmzr,,,2,0 ; selection ht turn take-off to the right
21213,kotmxv,,,2,0 ; selection ht take-off stroke forward
21214,kotmxz,,,2,0 ; selection ht take-off stroke return
21215,kotmgrz,,,2,0 ; selection ht gripper closing
21216,kotmgra,,,2,0 ; selection ht gripper opening
21217,kotmkzp,,,2,0 ; selection ht core-pull pressure relief
21218,kotmawk_ein,,,2,0 ; selection ht couple ejector coupling
21219,kotmawk_aus,,,2,0 ; selection ht uncouple ejector coupling
21220,kotm24,,,2,0 ; selection ht screw retraction
28221,ko2tm24,,,2,0 ; selection ht screw retraction unit.2
28245,koehv_kp,,,2,0 ;contr.par.kp ehv card pump1 unit.1
28246,koehv_ki,,,2,0 ;contr.par.ki ehv card pump1 unit.1
28247,koehv_kd,,,2,0 ;contr.par.kd ehv card pump1 unit.1
28249,koehv_kp_2,,,2,0 ;contr.par.kp ehv card pump2 unit.1
28250,koehv_ki_2,,,2,0 ;contr.par.ki ehv card pump2 unit.1
28251,koehv_kd_2,,,2,0 ;contr.par.kd ehv card pump2 unit.1
28253,ko2ehv_kp,,,2,0 ;contr.par.kp ehv card pump1 unit.2
28254,ko2ehv_ki,,,2,0 ;contr.par.ki ehv card pump1 unit.2
28255,ko2ehv_kd,,,2,0 ;contr.par.kd ehv card pump1 unit.2
28286,kotm_fb,,,2,0 ;selection hat conveyor-belt
29228,kotm_g1e,,,2,0 ; sucker/gripper 1 on
29229,kotm_g1a,,,2,0 ; sucker/gripper 1 off
29236,kotm_conl,,,2,0 ; depositing conveyor-belt erhli (at the left)
29237,kotm_conr,,,2,0 ; depositing conveyor-belt erhli at the right
29240,kotm_ypos,,,2,0 ; increment y-axis
29241,kotm_yneg,,,2,0 ; decrement y-axis
29242,kotm_xpos,,,2,0 ; increment x-axis
29243,kotm_xneg,,,2,0 ; decrement x-axis
29244,kotm_cpos,,,2,0 ; increment c
29245,kotm_cneg,,,2,0 ; decrement c
29246,kotm_zpos,,,2,0 ; increment z-axis
29247,kotm_zneg,,,2,0 ; decrement z-axis
32227,kotmlueft,,,2,0 ; selection push-button ventilation
35847,ko2skanz,,,2,0 ;number injection plunger number unit.2
37879,kotm_apos,,,2,0 ; increment a-axis
37880,kotm_aneg,,,2,0 ; decrement a-axis
38825,kotm_qual,,,2,0 ; key deposit quality part
39922,kotm15,,,2,0 ; selection pb move in core 1
39923,kotm14,,,2,0 ; selection pb move out core 1
*** (Unit: Stroke - weak resolution [mm] )

11902,kokdmadues,,,4,0,”mm” ;carriage cylinder diameter
11903,kokdmausw,,,4,0,”mm” ;ejector cylinder diameter
11904,kokdmaschli,,,4,0,”mm” ;high speed cylinder diameter
11905,kokdmmschli,,,4,0,”mm” ;high speed piston rod diameter
11913,ko2kdmadues,,,4,0,”mm” ;carriage cylinder diameter unit.2
19916,kokdmmdues,,,4,0,”mm” ;carriage piston rod diameter
19917,ko2kdmmdues,,,4,0,”mm” ;carriage piston rod diameter unit.2
35844,ko2kdma,,,4,0,”mm” ;injection cylinder diameter d1 unit.2
35845,ko2kdmm,,,4,0,”mm” ;screw retraction diameter d2 unit.2
35846,ko2kdmi,,,4,0,”mm” ;injection piston rod diameter d3 unit.2
*** (Without unit)

08027,koklph5_gf,,,5,0 ;[ms] smoothing constant accu pressure
12069,koklph_eil_gf,,,5,0 ;[ms] smoothing constant high speed
16327,koklpmx_gf,,,5,0 ; [ms] smoothing factor melt pressure unit.1
17259,kogrfgl_ksfx,,,5,0 ;smoothing factor at ksfx measurement
17773,koliter_p1,,,5,0 ;maximum specific power output main pump
17774,koliter_s,,,5,0 ;required specific power output closing
19915,koliter_o,,,5,0 ;required specific power output opening
32769,ko2klpmx_gf,,,5,0 ; [ms] smoothing factor mold cavity pressure unit.2
35498,kogrfglaett,,,5,0 ;smoothing factor at hardware measurement
35499,ko2grfglaett,,,5,0 ;smoothing factor at hardware measurement
35659,koklphx_gf,,,5,0 ;[ms] smoothing constant hydraulic pressure
35660,koklpfx_gf,,,5,0 ;[ms] smoothing constant mould cavity pressure
35661,koklskx_gf,,,5,0 ;[ms] smoothing constant clamping force
35662,koklphx2_gf,,,5,0 ;[ms] smoothing constant 2nd hydraulic pressure
35747,ko2klphx_gf,,,5,0 ;[ms] smoothing constant hydraulic pressure
35748,ko2klpfx_gf,,,5,0 ;[ms] smoothing constant mould cavity pressure
35832,ko2cfg00,,,5,0 ;configuration reserved !!
35967,ko2klphx2_gf,,,5,0 ;smoothing constant 2nd hydraulic pressure
35986,koklphx3_gf,,,5,0 ;[ms] smoothing constant 3rd hydraulic pressure
42058,swmachnumb,,,5,0 ;machine number
28383,sdintidk1,,,8,0 ;integral ideal curve 1

28384,sdintistk1,,,8,0 ;integral actual curve 1
28385,sdintidk2,,,8,0 ;integral ideal curve 2
28386,sdintistk2,,,8,0 ;integral actual curve 2
28387,sd2intidk1,,,8,0 ;integral ideal curve 1 unit.2
28388,sd2intistk1,,,8,0 ;integral actual curve 1 unit.2
28389,sd2intidk2,,,8,0 ;integral ideal curve 2 unit.2
28390,sd2intistk2,,,8,0 ;integral actual curve 2 unit.2

Version:G/11/12/7/3
35193,koay,,,5,0,”%/s” ;outset acceleration y outputs

35194,koak,,,5,0,”%/s” ;outset pressure increase k outputs
35195,koays,,,5,0,”%/s” ;outset acceleration ys outputs
35196,koamv,,,5,0,”%/s” ;outset acceleration m outputs
35749,ko2ay,,,5,0,”%/s” ;acceleration y outputs
35750,ko2ak,,,5,0,”%/s” ;pressure increase k outputs
35751,ko2amv,,,5,0,”%/s” ;acceleration m outputs
41632,koay_leer,,,5,0,”%/s” ;outset acceleration y outputs idling
41633,koak_leer,,,5,0,”%/s” ;outset pressure increase k outputs idling
41635,ko2ay_leer,,,5,0,”%/s” ;outset acceleration y outputs idling
41636,ko2ak_leer,,,5,0,”%/s” ;outset pressure increase k outputs idling
*** (Unit: Maximum ramps [bar/mm] )

35190,koapmaxw,,,5,0,”bar/mm” ;maximum pressure ramp as a function of stroke (all)
35744,ko2apmaxw,,,5,0,”bar/mm” ;maximum pressure ramp as a function of stroke (all)
*** (Unit: Maximum ramps [bar/s] )

35191,koapmaxz,,,5,0,”bar/s” ;maximum pressure ramp as a function of time (all)
35192,koapmaxs,,,5,0,”bar/s” ;maximum pressure ramp as a function of time at
;start and soft stop all movements
35197,koaak,,,5,0,”bar/s” ;outset pressure increase k outputs abs
35745,ko2apmaxz,,,5,0,”bar/s” ;maximum pressure ramp as a function of time (all)
35746,ko2apmaxs,,,5,0,”bar/s” ;maximum pressure ramp as a function of time at
;start and soft stop all movements
35752,ko2aak,,,5,0,”bar/s” ;pressure increase k outputs

35251,kozat,,,4,2,”s” ;measurement delay at speed calibration
35269,kozkal0,,,4,2,”s” ;measurement delay for automatic pressure calibration
35270,kozkal1,,,4,2,”s” ;measurement delay for automatic back pressure calibration
35271,kozkal2,,,4,2,”s” ;measurement delay for screw speed calibration
35753,ko2zat,,,4,2,”s” ;measurement delay at speed calibration 2nd unit
35762,ko2zkal0,,,4,2,”s” ;measurement delay for automatic pressure calibration 2nd unit
35763,ko2zkal1,,,4,2,”s” ;measurement delay for automatic back pressure calibration 2nd unit
35764,ko2zkal2,,,4,2,”s” ;measurement delay for screw speed calibration 2nd unit
44363,kozat_akku,,,4,2,”s” ;measuring delay at speed calibration with accu

43951,swvmms10,,,3,1,”mm/s” ;variable to store the injection speed unit.1
43952,sw2vmms10,,,3,1,”mm/s” ;variable to store the injection speed unit.2
*** (Unit: Force [kN] )

12070,kokneil,,,4,1,”kN” ;maximum value force high speed cylinder
-------------------------------------------------------------------------------
Group of variables central lubrication - central lubrication
-------------------------------------------------------------------------------

35260,kozzs,,,4,1,”s” ;relubrication time central lubrication
35261,kozz1,,,4,1,”s” ;monitoring time central lubrication
35262,kozz2,,,4,1,”s” ;maximum reaction time lubricating oil-
;niveauschalter bz2
-------------------------------------------------------------------------------
Group of variables clamping force - clamping force
-------------------------------------------------------------------------------
35021,kos32,,,4,1,”mm” ;mould height stroke tolerance for clamping force check
35024,kos35,,,4,1,”mm” ;start clamping force measurement

12100,iwskx,01,09,3,1,”bar” ;clamping force display
35314,komld10,,,3,1,”bar” ;resolution clamping force/pressure
42625,kop1_sspw,,,3,1,”bar” ;reduced clamping pressure at high speed mounting (calculated value)
43041,swp1rw,,,3,1,”bar” ;clamping pressure for clamp force

35963,koredsk,,,3,0,”%” ;reduction factor clamping force

21752,koqhdr1p,,,3,0,”%” ;volume high pressure build-up with 1 pump at ehv3
35043,koq9,,,3,0,”%” ;speed at straightening (toggle lever)
;speed on g2 (at direct closing)
35052,koq19,,,3,0,”%” ;volume high pressure build-up
35065,koq34,,,3,0,”%” ;volume on y1 at high pressure-
;build-up with proportional valve
06000,swp1,00,74,3,0,”%” ;clamping pressure
35210,kored11,,,3,0,”%” ;reduction factor clamping pressure
42626,kop1_ssp,,,3,0,”%” ;per cent value of clamping force for high speed mounting
*** (Unit: Ramp [%] )

35156,koa41,,,3,0,”%” ;pressure change p2/p1 starting from g2

35265,kozsk,,,4,1,”s” ;monitoring time for adjusting motor
08516,kozv_hdr,,,3,2,”s” ;delay between s1.2 and high pressure output

35276,kozpsch,,,3,2,”s” ;pressure build-up time direct closing without transducer
; / monitoring time pressure build-up with pressure transducer
35294,kozpsch2,,,3,2,”s” ;additional pressure build-up time
;for start-up cycles direct closing without transducer
35295,kotnl1,,,3,2,”s” ;recharging time at direct closing
;in the manual mode
35296,kotnl2,,,3,2,”s” ;recharging time calculated...

Version:G/11/12/7/3
35961,kotnl3,,,3,2,”s” ;recharging time at direct closing with pressure transducer

19914,swskx0,,,5,0,”mV” ;offset clamping pressure (force) transducer

35304,kopschanf,,,4,0,” ;clamping pressure build-up start-up-
;cycle counter set value
*** (Without unit)

35480,koea11,,,1,0 ;sk-offs error stops cycle = 1
35960,koskkorr,,,1,0 ;1 = clamping force correction switched on
35313,komld9,,,5,0 ;x.xx conversion factor phx2 ==> skx

35972,swskh_entpr,,,5,0 ;alarm delay for clamping force - high monitoring

07885,kosk_min,,,4,1,”tn” ;min. clamping force for injection.
12000,swsk,07,73,4,1,”tn” ;clamping force-set
35308,komld4,,,4,1,”tn” ;clamping force normal
35309,komld5,,,4,1,”tn” ;clamping force alarm limit
35312,komld8,,,4,1,”tn” ;distance of clamping force - set value for
;lower clamping force limit for injection
35962,kotolplus,,,4,1,”tn” ;kn positive dead zone for clamping force correction
-------------------------------------------------------------------------------
Group of variables heatings service - heatings service
-------------------------------------------------------------------------------
*** (Unit: Temperature relative [°C] )

35318,kotmp0,,,3,1,”„C” ;setting limitation for cylinder heating
35319,kotmp1,,,3,1,”„C” ;setting limitation for mould heating
35320,kotmp2,,,3,1,”„C” ;setting limitation for maximum oil temperature
35321,kotmp3,,,3,1,”„C” ;setting limitation for minimum oil temperature
35322,kotmp5,,,3,1,”„C” ;switching-off tolerance for oil temperature
;too low in automatic mode
35324,kotmp7,,,3,1,”„C” ;limit for motor stop at oil temperature
35326,kohaufst,,,3,1,”„C” ;height of the heating-up stages group 0
35329,kohaufst1,,,3,1,”„C” ;height of the heating-up stages group 1
35344,kotmp10,,,3,1,”„C” ;setting limitation for temperature deviation
40749,kotolneggrp0,,,3,1,”„C” ;setting limitation for temperature deviation negative cylinder heating
40750,kotolneggrp1,,,3,1,”„C” ;setting limitation for temperature deviation negative mould heating

;after heating up
35279,koheatdel,,,4,1,”s” ;delay time for temperature check
;after switching on the control unit
35327,kozthoch,,,4,1,”s” ;delay for temperature - high group 0
35328,koztaufh,,,4,1,”s” ;monitoring time heating-up for min 2”c group 0
35330,kozthoch1,,,4,1,”s” ;delay for temperature - high group 1
35331,koztaufh1,,,4,1,”s” ;monitoring time heating-up for min 2”c group 1
*** (Without unit)

35345,kotra0,,,1,0 ; mode,zone 0 0 = measurement channel
35346,kotra1,,,1,0 ; mode, zone 1 1 = regulator mode
35347,kotra2,,,1,0 ; mode, zone 2 2 = 2-point controller
35348,kotra3,,,1,0 ; mode, zone 3 3 = 3-point controller
35349,kotra4,,,1,0 ; mode, zone 4
35350,kotra5,,,1,0 ; mode, zone 5
35351,kotra6,,,1,0 ; mode, zone 6
35352,kotra7,,,1,0 ; mode, zone 7
35353,kotra8,,,1,0 ; mode, zone 8
35354,kotra9,,,1,0 ; mode, zone 9
35355,kotra10,,,1,0 ; mode, zone 10
35356,kotra11,,,1,0 ; mode, zone 11
35357,kotra12,,,1,0 ; mode, zone 12
35358,kotra13,,,1,0 ; mode, zone 13
35359,kotra14,,,1,0 ; mode, zone 14
35360,kotra15,,,1,0 ; mode, zone 15
35361,kotra16,,,1,0 ; mode, zone 16
35362,kotra17,,,1,0 ; mode, zone 17
35363,kotra18,,,1,0 ; mode, zone 18
35364,kotra19,,,1,0 ; mode, zone 19
35365,kotra20,,,1,0 ; mode, zone 20
35366,kotra21,,,1,0 ; mode, zone 21
35367,kotra22,,,1,0 ; mode, zone 22
35368,kotra23,,,1,0 ; mode, zone 23
35369,kotfuehl00,,,1,0 ;couple type zone 0 - oil temperature
35370,kotfuehl01,,,1,0 ;couple type zone 1

Version:G/11/12/7/3

06559,kotempger,,,5,0 ;temperature control unit number of the temperature control units

19730,kozo_u,,,5,0 ;start-up circuit, first zone
19731,kozo_o,,,5,0 ;start-up circuit, last zone
35323,kotmp6,,,5,0 ;heating-up mode
35393,kotxt01,,,5,0 ;text for heating zone 1 0 = empty text
35394,kotxt02,,,5,0 ;text for heating zone 2 1 = nozzle
35395,kotxt03,,,5,0 ;text for heating zone 3 2 = cylinder
35396,kotxt04,,,5,0 ;text for heating zone 4 3 = cylinder 3-point.
35397,kotxt05,,,5,0 ;text for heating zone 5 4 = mould 2-point.
35398,kotxt06,,,5,0 ;text for heating zone 6 5 = mould 3-point.
35399,kotxt07,,,5,0 ;text for heating zone 7 6 = traverse
35400,kotxt08,,,5,0 ;text for heating zone 8 7 = material
35401,kotxt09,,,5,0 ;text for heating zone 9 8 = microtemp
35402,kotxt10,,,5,0 ;text for heating zone 10 9 = flange
35403,kotxt11,,,5,0 ;text for heating zone 11 10 = temperature control unit
35404,kotxt12,,,5,0 ;text for heating zone 12 11 = hot runner
35405,kotxt13,,,5,0 ;text for heating zone 13 12 = mould-moving platen 2-point.
35406,kotxt14,,,5,0 ;text for heating zone 14 13 = mould-moving platen 3-point.
35407,kotxt15,,,5,0 ;text for heating zone 15 14 = mould-fixed platen 2-point
35408,kotxt16,,,5,0 ;text for heating zone 16 15 = mould fixed pl.3p.
35409,kotxt17,,,5,0 ;text for heating zone 17 16 = cylinder outer zone
35410,kotxt18,,,5,0 ;text for heating zone 18 17 = cylinder 3-point outer zone
35411,kotxt19,,,5,0 ;text for heating zone 19 18 = cylinder ceramic
35412,kotxt20,,,5,0 ;text for heating zone 20 19 = hot runner 1
35413,kotxt21,,,5,0 ;text for heating zone 21 20 = hot runner 2
35414,kotxt22,,,5,0 ;text for heating zone 22 21 = material drier
35415,kotxt23,,,5,0 ;text for heating zone 23 22 = melt temperature
35416,kotsav01,,,5,0 ;aim diskette zone

35325,kotmp8,,,5,0,”min” ;min.maximum time for 2 degrees for
;temperature change oil temperature
-------------------------------------------------------------------------------
Group of variables interfaces - serial interface
-------------------------------------------------------------------------------
35593,kobdd,,,5,0 ;baud rate printer
;2=150/ 3=300/ 4=600/ 5=1200/ 6=2400
;7=4800/ 8=9600/ 9=19200/ 10=38400
;11=57600/ 12=115200 baud
35595,kobdk2,,,5,0 ;baud rate host
35596,kobdk3,,,5,0 ;baud rate temperature control unit
35597,kobdk4,,,5,0 ;baud rate pc-host
35598,kobdk5,,,5,0 ;baud rate spi interface
35599,kobdk6,,,5,0 ;baud rate reserve
35600,kobdk7,,,5,0 ;baud rate reserve
-------------------------------------------------------------------------------
Group of variables safety gate - safety guard
-------------------------------------------------------------------------------

33005,swzvsga,03,21,4,1,”s” ;safety gate delayed opening

Version:G/11/12/7/3
35254,koe1e2,,,4,1,”s” ;e1/e2 limit switch monitoring

35280,kopnsg,,,4,1,”s” ;pneumatic safety gate: close as a function of time
;electric safety gate: phases switching-off time
35288,kozelsg,,,4,1,”s” ;braking time electric safety gate after
;reaching the braking limit switch at opening
35289,kozelsglo,,,4,1,”s” ;start time electric safety gate opening slowly
35290,kozelsgls,,,4,1,”s” ;start time electric safety gate closing slowly
35968,kozelbr,,,4,1,”s” ;braking time electric safety gate (before antirotation)
35988,kozelgl,,,4,1,”s” ;antirotation time electric safety gate (safety strip)
35989,kozpnsgauf,,,4,1,”s” ;opening time pneumatic safety gate
*** (Without unit)

18005,swpr6,07,88,1,0 ;automatic safety gate opening
35474,koea5,,,1,0 ;safety gate:
;0 = 2x push button for cycle start
;1 = 1x push button for cycle start
;2 = safety gate start
;3 = 2 start buttons with non tie down
35472,koea3,,,2,0 ;safety gate: 0 = manual

; 1 = pneum
; 2 = electric
-------------------------------------------------------------------------------
Group of variables mould closing - mould closing
-------------------------------------------------------------------------------

02000,swa,00,00,4,1,”mm” ;pos a-mould open
02002,swa2,00,21,4,1,”mm” ;pos a2-command air blowing 1
02004,sww1,00,17,4,1,”mm” ;pos w1-start 3rd closing speed
02006,sww3,00,19,4,1,”mm” ;pos w3-start 2nd closing speed
02008,swg1,00,08,4,1,”mm” ;pos g1-mould protection beginning
02009,swg2,00,25,4,1,”mm” ;pos g2-mould protection end screen value
02010,swb,00,47,4,1,”mm” ;pos b-mould closed
02500,iwsfx,01,03,4,1,”mm” ;mould position - actual
02505,iwksfx,01,13,4,1,”mm” ;toggle lever position - actual
02510,iwsfxs,01,18,4,1,”mm” ;mould opening stroke stored
04591,swg3,03,67,4,1,”mm” ;beg. 2nd mould protection pressure moving-in c.
23863,kohlisich,,,4,1,”mm” ;hli safety
42625,kop1_sspw,,,3,1,”bar” ;reduced clamping pressure at high speed mounting (calculated value)

04000,swv1,02,40,3,0,”%” ;1.closing speed
06000,swp1,00,74,3,0,”%” ;clamping pressure
06001,swp2,00,77,3,0,”%” ;mpould protection pressure initial value
06002,swp2r,00,79,3,0,”%” ;mould protection pressure end value
42626,kop1_ssp,,,3,0,”%” ;per cent value of clamping force for high speed mounting
08002,swzlv1,03,03,4,1,”s” ;air blowing delay time 1
08004,swzl1,02,97,4,1,”s” ;air blowing time 1
08438,swz_lue_start,62,72,3,1,”s” ;ventilation start delay

19052,swz_lue_s,62,77,3,1,”s” ;closed time
08006,swzf,02,99,2,2,”s” ;mould protection time
08500,iwzfx,01,22,2,2,”s” ;mould protection time
10001,swfsz,03,57,4,0,” ;mould protection counter
*** (Without unit)

04543,swprfstp,07,70,1,0 ;mould stop after mould protection
09632,swprg3,01,55,1,0 ;prog.switch 2nd mould protection pressure
12072,swprgrafueb,,,1,0 ;mould protection over pressure monitoring
18006,swpr7,07,95,1,0 ;air valve 1 function
20572,swprzykref,,,1,0 ;reference mould protection monitoring cyclically
20573,swprpueb,,,1,0 ;mould protection pressure/speed-monitored
04502,iwvschx,01,16,4,0,”mm/s” ;mould closing speed
20403,swfsmassv,,,4,0,”mm/s” ;scale speed mould protection
20571,swvfs_tol,,,3,1,”mm/s” ;mould protection monitoring speed tolerance

24353,swfsminspeed,,,3,1,”mm/s” ;minimum speed at mould protection monitoring speed.

20404,swfsmassp,,,4,1,”kN” ;scale pressure mould protection
20570,swpfs_tol,,,4,1,”kN” ;mould protection monitoring pressure tolerance
20814,swap2,,,4,1,”kN” ;mould protection force absolute initial value
20815,swap2r,,,4,1,”kN” ;mould protection force absolute end value
24208,swfsmaxforce,,,4,1,”kN” ;mould protection which is monitored
;during initialization
06503,iwpskx,01,14,4,1,”tn” ;clamping pressure at <= es50

Version:G/11/12/7/3
-------------------------------------------------------------------------------
Group of variables mould opening - mould opening
-------------------------------------------------------------------------------

01472,swafz,00,61,4,1,”mm” ;mould position move in handling system
02000,swa,00,00,4,1,”mm” ;pos a-mould open
02005,sww2,00,18,4,1,”mm” ;pos w2-start 3rd opening speed
02007,sww4,00,20,4,1,”mm” ;pos w4-start 2nd opening speed
02454,swah,00,60,4,1,”mm” ;minimum opening stroke handling system
05212,swwak,08,02,4,1,”mm” ;start differential connection at opening
17668,swpos_lue,62,73,4,1,”mm” ;venting pos.on mould stroke
23863,kohlisich,,,4,1,”mm” ;hli safety

04003,swv6,02,45,3,0,”%” ;1.opening speed
04455,swv_lue_o,62,75,3,0,”%” ;venting speed.

08439,swz_lue_o,62,76,3,1,”s” ;venting time

19046,swcnt_lue_hub,62,79,4,0,” ;venting strokes
*** (Without unit)

01982,swproef_c2,03,73,1,0 ;opening from c2* unit.1
05554,sw2proef_c2,08,15,1,0 ;opening from c2* unit.2
18171,swpr_fzh,07,72,1,0 ;switch intermediate stop mould opening
19036,swprak,08,08,1,0 ;increased opening force
-------------------------------------------------------------------------------
Group of variables injection/holding pressure-injection/hold.pressure
-------------------------------------------------------------------------------

02100,swc1,00,01,4,1,”mm” ;metering stroke
02102,swc2,00,02,4,1,”mm” ;decompression stroke after plasticizing
02103,swc2m,01,01,4,1,”mm” ;decompression stroke after plasticizing corrected
02104,swc3,00,03,4,1,”mm” ;pos c3-position for switchover holding pressure
02106,swcp,00,07,4,1,”mm” ;cushion ”ideal value”
02107,swcpmin,00,26,4,1,”mm” ;cushion minimum length
02108,swcpmax,00,27,4,1,”mm” ;cushion maximum length
02109,swc17,11,48,4,1,”mm” ;flow number measurement start position
02110,swc18,11,50,4,1,”mm” ;flow number measurement end position
02111,swc2b,00,30,4,1,”mm” ;switchover to 2nd injection speed
02112,swc2c,00,31,4,1,”mm” ;switchover to 3rd injection speed
02113,swc2d,00,32,4,1,”mm” ;switchover to 4th injection speed
02114,swc2e,00,33,4,1,”mm” ;switchover to 5th injection speed
02115,swc2f,00,34,4,1,”mm” ;switchover to 6th injection speed
02116,swc2g,00,35,4,1,”mm” ;switchover to 7th injection speed
02117,swc2h,00,36,4,1,”mm” ;switchover to 8th injection speed
02118,swc2i,00,38,4,1,”mm” ;switchover to 9th injection speed
02119,swc2j,00,40,4,1,”mm” ;switchover to 10th injection speed
02124,swc3b,00,58,4,1,”mm” ;window at hydraulic pressure switchover holding pressure
02125,swc3d,00,59,4,1,”mm” ;window at parallel switchover
02183,swpos_lue_start,62,74,4,1,”mm” ;venting pos.on screw stroke
02503,iwssx,01,04,4,1,”mm” ;screw position -actual
02511,iwcpx,01,02,4,1,”mm” ;cushion length - actual
05064,swc3a,31,4,4,1,”mm” ;switchover point to holding pressure when moving in mould unit.1
06513,iwc3u,05,18,4,1,”mm” ;screw position at switchover
22100,swstift,07,83,4,1,”mm” ;kistler:pin diameter
39124,kostop,,,4,1,”mm” ;stop purging position
43475,swc3l,50,53,4,1,”mm” ;purging position

16001,swkfp,11,45,2,2,”bar” ;flow number-closed loop control-correction factor
06100,swp6,00,83,3,1,”bar” ;injection pressure

06101,swp7,00,85,3,1,”bar” ;1.holding pressure
06116,swph,00,05,3,1,”bar” ;hydraulic pressure switchover value
06500,iwphx,01,07,3,1,”bar” ;hydraulic pressure-actual
06502,iwphx2,01,11,3,1,”bar” ;hydraulic pressure 2
06510,iwphu,05,17,3,1,”bar” ;hydraulic pressure at switchover to holding pressure
06514,iwpvs,05,21,3,1,”bar” ;hydraulic pressure peak value via injection
06515,iwpns,05,19,3,1,”bar” ;hydraulic pressure peak value via holding pressure
12107,iwph5,15,38,3,1,”bar” ;accu pressure
16003,swfzpt,11,39,3,1,”bar” ;flow number-tolerance-closed loop control
16011,iwkorrp,05,83,3,1,”bar” ;positive correction size of the flow number calculation

Version:G/11/12/7/3
16012,iwkorrm,05,84,3,1,”bar” ;negative correction size of the flow number calculation

17275,swsk_einspr_bar,12,84,3,1,”bar” ;clamping force for injection (bar) corrected waiting point
23433,idkorr_fz,08,87,3,1,”bar” ;+/- correction size of the flow number calculation
02506,iwpmx,,,4,1,”bar” ; melt pressure actual value unit.1

06117,swpf,00,06,4,1,”bar” ;mould cavity pressure switchover value
06501,iwpfx,01,08,4,1,”bar” ;mould cavity pressure display
06511,iwpfu,05,16,4,1,”bar” ;mould cavity pressure at switchover to holding pressure
06512,iwpfs,05,15,4,1,”bar” ;mould cavity pressure peak value holding pressure
06517,iwpmu,,,4,1,”bar” ; pm at switchover to holding (post injection) pressure unit.1
10066,iwpms,,,4,1,”bar” ; melt pressure peak value holding (post injection) pressure unit.1
22116,swpm,,,4,1,”bar” ; melt pressure switchover set value unit.1
32771,iw2pms,,,4,1,”bar” ; melt pressure peak value holding (post injection) pressure unit.2
32777,iw2pmx,,,4,1,”bar” ; melt pressure actual value unit.2
34693,kopm_max,,,4,1,”bar” ; maximum melt pressure unit.1
34697,iw2pmu,,,4,1,”bar” ; pm at switchover to holding (post injection) pressure unit.2

06227,iwc3u2,19,69,3,2,”mm” ;host:c3u in 1/100 for process data
06229,iwcpx2,19,70,3,2,”mm” ;host:cushion in 1/100 for process data

04115,swv23,02,76,3,0,”%” ;intrusion speed

04900,swspv,02,60,4,1,”s” ;injection delay time unit 1
08101,swz2,02,92,4,1,”s” ;holding pressure time
08103,swzin,03,02,4,1,”s” ;intrusion time
08505,iwz4x,01,27,4,1,”s” ;cooling time running along
08438,swz_lue_start,62,72,3,1,”s” ;ventilation start delay

08439,swz_lue_o,62,76,3,1,”s” ;venting time
19052,swz_lue_s,62,77,3,1,”s” ;closed time
08100,swz1,02,91,3,2,”s” ;injection time

08106,swzs0,03,26,3,2,”s” ;injection time minimum
08107,swzs1,03,27,3,2,”s” ;injection time maximum
08502,iwzsx,01,23,3,2,”s” ;injection time
34634,sdzylvdon_zeit,35,01,3,2,”s” ; cylinder shut-off nozzle connection delay unit.1
34635,sdzylvdof_zeit,35,02,3,2,”s” ; cylinder shut-off nozzle switching-off delay unit.1
39074,kozvpns,,,3,2,”s” ;s100 peak hold press. measuring delay

24373,kokitestmin,,,5,0,”mV” ;kistler test minimum voltage unit.1
24374,kokitestmax,,,5,0,”mV” ;kistler test maximum voltage unit.1

05016,swcntpurge,50,50,2,0,” ;purging counter
*** (Without unit)

05595,swprfz,60,06,1,0 ;flow number unit 1 on/off
05596,sw2prfz,15,15,1,0 ;flow number unit 2 on/off
15679,swplast_new,05,13,1,0 ;autom.param.setting mplast
17279,swprspr_par,60,19,1,0 ;program injection from g3
18001,swpr2,07,85,1,0 ;increased injection pressure
18002,swpr3,07,91,1,0 ;external switchover to holding pressure
18009,swpr10,07,97,1,0 ;stroke-dependent switchover
18010,swpr11,07,98,1,0 ;time-dependent switchover
18011,swpr13,07,92,1,0 ;flow number
18012,swpr16,07,99,1,0 ;hydraulic pressure-dependent switchover
18013,swpr17,10,00,1,0 ;mould cavity pressure-dependent switchover
18014,swpr18,10,01,1,0 ;cushion monitoring
18017,swpr21,10,04,1,0 ;switchover parallel
18019,swpr24,07,94,1,0 ;force/pressure transducer
18080,swpragg,03,41,1,0 ;unit switch 1
22102,swkbereich,07,80,1,0 ;kistler:force measuring range
22104,swdbereich,07,82,1,0 ;kistler:pressure measuring range
22115,swprumpm,,,1,0 ; switch over as a function of melt pressure unit.1
24303,kolv_type,,,1,0 ;kistler charge amplifier type
28811,kokisttest,,,1,0 ;1= kistler test output activated
37423,swpro_tol_pp,62,59,1,0 ;action to be released when monitoring outside tolerance
38639,swpreinfahr,31,3,1,0 ;moving-in circuit active
05957,swfz_def,08,40,3,1 ;flow number set value

08914,sw2fz_def,08,61,3,1 ;flow number set value unit.2
16000,swfz,11,43,3,1 ;flow number set value
16002,swfzft,11,47,3,1 ;flow number-tolerance-monitoring
16010,iwfzx,05,82,3,1 ;flow number
06228,iwfzx2,19,68,3,2 ;host: flow number in 1/100 for process data

22101,swkempf,07,79,3,2 ;kistler:force transducer sensitivity
22103,swdempf,07,81,3,2 ;kistler:pressure transducer sensitivity

10073,sdz2j,08,16,4,2,”s” ; holding pressure part-time 10/10
10074,sdz2i,08,17,4,2,”s” ; holding pressure part-time 9/10
10075,sdz2h,08,18,4,2,”s” ; holding pressure part-time 8/10
10076,sdz2g,08,19,4,2,”s” ; holding pressure part-time 7/10
10077,sdz2f,08,20,4,2,”s” ; holding pressure part-time 6/10
10078,sdz2e,08,21,4,2,”s” ; holding pressure part-time 5/10
10079,sdz2d,08,22,4,2,”s” ; holding pressure part-time 4/10
10080,sdz2c,08,23,4,2,”s” ; holding pressure part-time 3/10
10081,sdz2b,08,24,4,2,”s” ; holding pressure part-time 2/10
10082,sdz2a,08,25,4,2,”s” ; holding pressure part-time 1/10
39449,idgm_t_dev_1,,,4,2,”s” ;1.unit: deviation moment monitoring_1
04100,swv12,02,59,4,0,”mm/s” ;1.injection speed

Version:G/11/12/7/3

04500,iwvsprx,01,15,4,0,”mm/s” ;speed actual value at speed calibration
04501,iwvsprmax,01,20,4,0,”mm/s” ;maximum injection speed
23883,kovplim,,,4,0,”mm/s” ;mm/s injection purge speed limit
38600,kovplim_swiv,,,4,0,”mm/s” ;mm/s purge speed at swivelled unit 1

17274,swsk_einspr,12,83,4,1,”tn” ;clamping force-set for injection.
-------------------------------------------------------------------------------
Group of variables carriage unit - injection unit
-------------------------------------------------------------------------------

02200,swj1,00,09,4,1,”mm” ;pos j1-start 2nd nozzle speed forward
02201,swk,00,10,4,1,”mm” ;pos k-nozzle retracted
02501,iwsdx,01,05,4,1,”mm” ;nozzle position - actual
03763,swduv_start,08,07,4,1,”mm” ;start position nozzle forward

04200,swv9,02,51,3,0,”%” ;1.nozzle speed forward
04201,swv10,02,55,3,0,”%” ;2.nozzle speed forward
04202,swv11,02,57,3,0,”%” ;nozzle speed return

06200,swp5,00,81,3,0,”%” ;contact pressure
06201,swp5a,02,15,3,0,”%” ;holding pressure carriage unit

04252,swzab,08,13,4,1,”s” ;ec100s nozzle retraction time
08200,swz6,02,96,4,1,”s” ;nozzle retraction delay time
08201,swz5a,02,98,3,2,”s” ;contact pressure build-up time

05735,swsdx0s,00,56,5,0,”mV” ;offset-sdx-zero value [mm]
*** (Without unit)

03960,swprduv_par,03,66,1,0 ;nozzle forward in parallel to mould closing
18016,swpr20,10,03,1,0 ;nozzle retraction
-------------------------------------------------------------------------------
Group of variables ejector - ejector
-------------------------------------------------------------------------------

01984,swawk,08,06,4,1,”mm” ;control position ejector at the back
02001,swa1,00,15,4,1,”mm” ;pos a1-command ejector forward
02300,swl,00,14,4,1,”mm” ;pos l-ejector at the back
02301,swl1,00,13,4,1,”mm” ;pos l1-ejector in front
02302,swl2,00,16,4,1,”mm” ;pos l2-ejector shaking position
02303,swl3,08,04,4,1,”mm” ;pos l3-start 2nd ejector forward speed/pressure
02455,swl4,31,07,4,1,”mm” ;pos 14-start 2nd ejector return speed/pressure
02502,iwsax,01,06,4,1,”mm” ;ejector pos.-actual

04300,swv25,02,78,3,0,”%” ;ejector forward speed
04301,swv26,02,79,3,0,”%” ;ejector return speed
04407,swv27,08,05,3,0,”%” ;ejector forward 2nd speed
04410,swv28,31,08,3,0,”%” ;ejector return 2nd speed

02219,swp27,31,05,3,0,”%” ;2.ejector forward pressure
06300,swp25,02,07,3,0,”%” ;1.ejector forward pressure
06301,swp26,02,08,3,0,”%” ;1.ejector return pressure
24195,swp28,31,06,3,0,”%” ;2.ejector return pressure

08300,swza,03,00,4,1,”s” ;ejector in front time
08301,swzavv,03,01,4,1,”s” ;ejector forward delay time

10000,swaz,03,56,4,0,” ;ejector counter
*** (Without unit)

01983,swpraw_par,03,65,1,0 ;ejector return in parallel to mould closing
03323,swprawfs,09,10,1,0 ;ejection after mould protection error
18020,swpr26,10,06,1,0 ;ejector in front after cycle end
21340,swprvspr_aw,09,04,1,0 ;premoulding cycle with ejection
21341,swprvspr_hn,09,09,1,0 ;premoulding cycle with handling system take-off.
10306,swprogaz,03,70,5,0 ;current ejector

04503,iwvawx,01,17,4,0,”mm/s” ;ejector speed
-------------------------------------------------------------------------------
Group of variables plasticizing/back pressure/screw retraction-plast./back press./decompres.
-------------------------------------------------------------------------------

Version:G/11/12/7/3

02100,swc1,00,01,4,1,”mm” ;metering stroke
02101,swc1m,01,00,4,1,”mm” ;metering stroke corrected
02102,swc2,00,02,4,1,”mm” ;decompression stroke after plasticizing
02103,swc2m,01,01,4,1,”mm” ;decompression stroke after plasticizing corrected
02105,swc4,00,04,4,1,”mm” ;pos c4-decompression 1 end
02106,swcp,00,07,4,1,”mm” ;cushion ”ideal value”
02107,swcpmin,00,26,4,1,”mm” ;cushion minimum length
02108,swcpmax,00,27,4,1,”mm” ;cushion maximum length
02120,swc4b,00,42,4,1,”mm” ;switchover to 2nd plasticizing speed
02121,swc4c,00,44,4,1,”mm” ;switchover to 3rd plasticizing speed
02122,swc4d,00,45,4,1,”mm” ;switchover to 4th plasticizing speed
02123,swc4e,00,46,4,1,”mm” ;switchover to 5th plasticizing speed
09719,iwssxs,03,68,4,1,”mm” ;metering stroke stored unit.1
39124,kostop,,,4,1,”mm” ;stop purging position

06111,swp17,02,02,3,1,”bar” ;1.back pressure
06516,iwpss,05,20,3,1,”bar” ;back pressure peak value

04110,swvdz1,02,75,3,0,”%” ;1.screw speed
04116,swv24,02,77,3,0,”%” ;screw retraction speed

10100,iwdzx,01,12,3,0,”/min” ;screw speed display

08102,swz3,02,93,4,1,”s” ;plasticizing delay time
08104,swzdmax,03,24,4,1,”s” ; plasticized time maximum
08105,swzdmin,03,25,4,1,”s” ; plasticized time minimum
08501,iwzdx,01,21,4,1,”s” ;plasticizing time
29490,iwzdx2,19,08,3,2,”s” ;plasticizing time
*** (Without unit)

01982,swproef_c2,03,73,1,0 ;opening from c2* unit.1
18015,swpr19,10,02,1,0 ;plasticizing time monitoring
-------------------------------------------------------------------------------
Group of variables core -core
-------------------------------------------------------------------------------

02011,swb8,00,48,4,1,”mm” ;pos b8-move core in/out
02012,swks1,00,11,4,1,”mm” ;pos ks1- move in core
02015,swko1,00,12,4,1,”mm” ;pos ko1- move out core
02018,swksk1,00,49,4,1,”mm” ;pos ks1k-core 1 in control position
02021,swkok1,00,52,4,1,”mm” ;pos ks1k-core 1 out control position

04400,swv30,02,80,3,0,”%” ;core 1 out volume
04401,swv31,02,81,3,0,”%” ;core 1 in volume
06400,swp30,02,09,3,0,”%” ;core 1 out pressure
06401,swp31,02,10,3,0,”%” ;core 1 in pressure

08400,swzke1,03,06,4,1,”s” ;core 1 moving in time
08401,swzke2,03,07,4,1,”s” ;core 2 moving-in time
08402,swzke3,03,08,4,1,”s” ;core 3 moving-in time
08403,swzka1,03,09,4,1,”s” ;core 1 moving out time
08404,swzka2,03,10,4,1,”s” ;core 2 moving-out time
08405,swzka3,03,11,4,1,”s” ;core 3 moving-out time
08406,swzke1ueb,03,12,4,1,”s” ;core 1 moving in monitoring
08407,swzke2ueb,03,13,4,1,”s” ;move in core 2 monitoring
08408,swzke3ueb,03,14,4,1,”s” ;move in core 3 monitoring
08409,swzka1ueb,03,15,4,1,”s” ;core 1 moving out monitoring
08410,swzka2ueb,03,16,4,1,”s” ;move out core 2 monitoring
08411,swzka3ueb,03,17,4,1,”s” ;move out core 3 monitoring
08412,swzkav1,03,18,4,1,”s” ; core 1 moving out delay

Version:G/11/12/7/3
08413,swzkav2,03,19,4,1,”s” ; move out core 2 delay

08414,swzkav3,03,20,4,1,”s” ; move out core 3 delay

10008,swkrz1,03,58,4,0,” ;shake counter core 1
10009,swkrz2,03,59,4,0,” ;shake counter core 2
*** (Without unit)

02639,swprko4,,,1,0 ;stop point ko4- on/off
04562,swprkz1s,06,93,1,0 ;core 1 as sliding split mould-core
09421,swprk_einr,11,23,1,0 ;core set-up mode
18200,swpak3,10,07,1,0 ;program type core 3 (ejector/core)
18207,swprke1,10,14,1,0 ;core 1 moving in
18208,swprke2,10,15,1,0 ;move in core
18209,swprke3,10,16,1,0 ;move in core
18210,swprka1,10,17,1,0 ;core 1 moving out
18211,swprka2,10,18,1,0 ;move out core
18212,swprka3,10,19,1,0 ;move out core
18213,swkez1,10,20,1,0 ;core 1 moving in as a function of time
18214,swkez2,10,21,1,0 ;move in core 2 as a function of time
18215,swkez3,10,23,1,0 ;move in core 3 as a function of time
18216,swkaz1,10,25,1,0 ;core 1 moving out as a function of time
18217,swkaz2,10,27,1,0 ;move out core 2 as a function of time
18218,swkaz3,10,29,1,0 ;move out core 3 as a function of time
18219,swkepar1,10,31,1,0 ;move in core 1 in parallel
18222,swkapar1,10,37,1,0 ;move out core 1 in parallel
18225,swkepv1,10,43,1,0 ;core 1 without pressure, volume moving in
18228,swkapv1,10,49,1,0 ;core 1 without pressure, volume moving out
18231,swkedl1,10,55,1,0 ;core 1 pressureless after moving in
18234,swkav1,10,61,1,0 ;move out core 1 delayed
19551,swprks1,,,1,0 ;stop point ks1- on/off
19552,swprks2,,,1,0 ;stop point ks2 - on/off
19553,swprks3,,,1,0 ;stop point ks3- on/off
19557,swprb8s,,,1,0 ;stop point b8 at closing on/off
19558,swprb8o,,,1,0 ;stop point b8 at opening on/off
05980,swprkzso,09,88,2,0 ;choice standard core/sequence control

12625,swhndl_kf1,12,88,2,0 ; selection handling system release core 1
18201,swkep1,10,08,2,0 ;priority move in core
18204,swkap1,10,11,2,0 ;priority move out core
19545,swprog_ke1,,,5,0 ;program number move in first core

19546,swprog_ke2,,,5,0 ;program number move in second core
19547,swprog_ke3,,,5,0 ;program number move in third core
19548,swprog_ka1,,,5,0 ;program number move out first core
19549,swprog_ka2,,,5,0 ;program number move out second core
19550,swprog_ka3,,,5,0 ;program number move out third core
-------------------------------------------------------------------------------
Group of variables mould height - mould height
-------------------------------------------------------------------------------

06009,swfhx,00,55,4,1,”mm” ;pos.mould height actual value calculated from
;minimum mould height and determined offset
35008,kos17,,,4,1,”mm” ;opening stroke at the automatic
; mould height setting program
; (without stroke transducer)
35021,kos32,,,4,1,”mm” ;mould height stroke tolerance for clamping force check
-------------------------------------------------------------------------------
Group of variables program/configuration switches -program/configuration switches
-------------------------------------------------------------------------------
03301,swfiltra,07,71,1,0 ;switch oil filtration on/off

04543,swprfstp,07,70,1,0 ;mould stop after mould protection
-------------------------------------------------------------------------------
Group of variables general parameters - general parameters
-------------------------------------------------------------------------------

02194,iwwpvs,05,48,4,1,”mm” ;hydraulic pressure peak value pre-injection stroke
02195,iwwpss,05,50,4,1,”mm” ;back pressure peak value stroke

Version:G/11/12/7/3
02196,iwwdzs,05,52,4,1,”mm” ;screw speed peak value stroke

02197,iwwpfss,05,54,4,1,”mm” ;mould protection pressure peak value stroke
02198,iwwsks,05,55,4,1,”mm” ;clamping force peak value stroke
02199,iwwvsprs,05,56,4,1,”mm” ;injection speed peak value stroke
04874,iw2wpvs,05,49,4,1,”mm” ;hydraulic pressure peak value pre-injection stroke
04875,iw2wpss,05,51,4,1,”mm” ;back pressure peak value stroke
04876,iw2wdzs,05,53,4,1,”mm” ;screw speed peak value stroke
04877,iw2wvsprs,05,57,4,1,”mm” ;injection speed peak value stroke
20004,swmg_mass0,11,59,4,1,”mm” ;graphics: screw position...0
24010,iwhs15,19,15,4,1,”mm” ;host:cushion actual value
24011,iwhs16,19,16,4,1,”mm” ;host:metering stroke
24012,iwhs17,19,17,4,1,”mm” ;host:decompression after plasticizing
24013,iwhs18,19,18,4,1,”mm” ;host:screw position switchover point
24038,iw2hs15,19,61,4,1,”mm” ;host:cushion actual value
24040,iw2hs17,19,49,4,1,”mm” ;host:decompression after plasticizing
24041,iw2hs18,19,60,4,1,”mm” ;host:screw position switchover point
25039,iw2hs16,19,62,4,1,”mm” ;host:metering stroke

22237,swzmotein,16,63,3,1,”min” ;delay motor on via switch clock
22238,swzmotaus,16,64,3,1,”min” ;delay motor off via switch clock
22239,swzheizein,16,65,3,1,”min” ;delay heating on via switch clock
22240,swzheizaus,16,66,3,1,”min” ;delay heating off via switch clock
22241,swzg1ein,16,67,3,1,”min” ;delay device 1 on via switch clock
22242,swzg1aus,16,68,3,1,”min” ;delay device 1 off via switch clock
22243,swzg2ein,16,69,3,1,”min” ;delay device 2 on via switch clock
22244,swzg2aus,16,70,3,1,”min” ;delay device 2 off via switch clock
22247,iwzmotein,12,15,3,1,”min” ;delay motor on switch clock
22248,iwzmotaus,12,16,3,1,”min” ;delay motor off switch clock
22249,iwzheizein,12,17,3,1,”min” ;delay heating on switch clock
22250,iwzheizaus,12,18,3,1,”min” ;delay heating off switch clock
22251,iwzg1ein,12,19,3,1,”min” ;delay device 1 on switch clock
22252,iwzg1aus,12,20,3,1,”min” ;delay device 1 off switch clock
22253,iwzg2ein,12,21,3,1,”min” ;delay device 2 on switch clock
22254,iwzg2aus,12,22,3,1,”min” ;delay device 2 off switch clock

01601,iwhs50,19,46,3,1,”bar” ;host:hydraulic pressure peak value via holding pressure
01602,iwhs51,19,47,3,1,”bar” ;host:back pressure peak value
02177,iwpfss,05,26,3,1,”bar” ;mould protection pressure peak value
02240,iw2hs50,01,24,3,1,”bar” ;host:hydraulic pressure peak value via holding pressure
02241,iw2hs51,01,26,3,1,”bar” ;host:back pressure peak value
04412,iwphx3,53,00,3,1,”bar” ;hydraulic pressure ehv pump 2
24030,iwhs39,19,39,3,1,”bar” ;host:phs-hydraulic pressure peak value
24031,iwhs40,19,40,3,1,”bar” ;host:phu-hydraulic pressure switchover value
24034,iwhs43,19,43,3,1,”bar” ;host:holding pressure correction positive
24035,iwhs44,19,44,3,1,”bar” ;host:holding pressure correction negative
24045,iw2hs39,19,54,3,1,”bar” ;host:phs-hydraulic pressure peak value
24046,iw2hs40,19,55,3,1,”bar” ;host:phu-hydraulic pressure switchover value
24050,iw2hs44,19,59,3,1,”bar” ;host:holding pressure correction negative
25049,iw2hs43,19,58,3,1,”bar” ;host:holding pressure correction positive
20006,swmg_mass2,11,62,4,1,”bar” ; graphics: hydraulic pressure...2

20007,swmg_mass3,11,65,4,1,”bar” ;graphics: mould cavity pressure...3
24028,iwhs37,19,37,4,1,”bar” ;host:pfs-mould cavity pressure peak value
24029,iwhs38,19,38,4,1,”bar” ;host:pfu-mould cavity pressure switchover value
24043,iw2hs37,19,52,4,1,”bar” ;host:pfs-mould cavity pressure peak value
24044,iw2hs38,19,53,4,1,”bar” ;host:pfu-mould cavity pressure switchover value
*** (Unit: Temperature absolute [°C] )

24000,iwhs00,19,00,3,1,”„C” ;host interlock
24002,iwhs02,19,02,3,1,“„C“ ;host:
24014,iwhs21,19,21,3,1,”„C” ;host:temperature zone 1
24021,iwhs28,19,28,3,1,”„C” ;host: temperature zone 8 / 2 oil temperature
24027,iwhs34,19,34,3,1,”„C” ;host:oil temperature
24042,iw2hs34,19,51,3,1,”„C” ;host: oil temperature unit 2
*** (Unit: Temperature QSU [°C] )
00020,swtg1,07,75,3,0,”„C” ;temperature of temperature control unit 1
00023,swmtg,07,89,3,0,”„C” ;temperature of material drying unit
00030,sw2mtg,03,40,3,0,”„C” ;temperature of material drying unit
*** (Unit: Injection rate [ccm/s] )

02176,iwdls,05,24,4,0,”ccm/s” ;plasticizing capacity mean value
04864,iw2dls,05,25,4,0,”ccm/s” ;plasticizing capacity mean value

04529,swmg_iabwp,12,70,3,0,”%” ;maximum positive integral deviation ideal curve 1
04530,swmg_iabwn,12,71,3,0,”%” ;maximum positive integral deviation ideal curve 1
04531,swmg_iabwp2,12,72,3,0,”%” ;maximum positive integral deviation ideal curve 2
04532,swmg_iabwn2,12,73,3,0,”%” ;maximum positive integral deviation ideal curve 2
20010,swmg_abwp,11,81,3,0,”%” ;maximum positive deviation ideal curve 1
20011,swmg_abwn,11,83,3,0,”%” ;maximum negative deviation ideal curve 1
20025,swmg_abwp2,11,89,3,0,”%” ;maximum positive deviation ideal curve 2
20026,swmg_abwn2,11,91,3,0,”%” ;maximum negative deviation ideal curve 2
22010,idzuabw,01,59,3,0,”%” ;cyle time deviation (integer)
28394,sw2mg_iabwp,12,59,3,0,”%” ;maximum positive integral deviation ideal curve 1 unit.2

Version:G/11/12/7/3
28395,sw2mg_iabwn,12,62,3,0,”%” ;maximum positive integral deviation ideal curve 1 unit.2

28396,sw2mg_iabwp2,12,63,3,0,”%” ;maximum positive integral deviation ideal curve 2 unit.2
28397,sw2mg_iabwn2,12,64,3,0,”%” ;maximum positive integral deviation ideal curve 2 unit.2
28398,sw2mg_abwp,12,65,3,0,”%” ;maximum positive deviation ideal curve 1 unit.2
28399,sw2mg_abwn,12,66,3,0,”%” ;maximum negative deviation ideal curve 1 unit.2
28400,sw2mg_abwp2,12,67,3,0,”%” ;maximum positive deviation ideal curve 2 unit.2
28401,sw2mg_abwn2,12,82,3,0,”%” ;maximum negative deviation ideal curve 2 unit.2

02178,iwsks,05,27,5,0,”kN” ;clamping force peak value
02179,iwsku,05,28,5,0,”kN” ;clamping force switchover value
03074,iwhs07,19,07,5,0,”kN” ;host:clamping force stored
04865,iw2sku,05,29,5,0,”kN” ;clamping force switchover value

02175,iwdzs,05,22,3,0,”/min” ;screw speed peak value
04863,iw2dzs,05,23,3,0,”/min” ;screw speed peak value
05739,iwhsdzx0,19,63,3,0,”/min” ;host:screw speed for process data
05960,iw2hsdzx0,19,66,3,0,”/min” ;host:screw speed for process data
24032,iwhs41,19,41,3,0,”/min” ;host:dzx-screw speed actual value
24047,iw2hs41,19,56,3,0,”/min” ;host:dzx-screw speed actual value

02034,swzanfz,08,12,5,0,”s” ;start-up counter new start in manual mode
20001,swgraftm,11,30,5,0,”s” ;measurement time graphics in sec
01603,iwhs52,19,48,4,1,”s” ;host:cooling time running along

01677,sw2z4,06,90,4,1,”s” ;intermediate cooling time
02185,iwzpvs,05,32,4,1,”s” ;hydraulic pressure peak value pre-injection time
02186,iwzpns,05,34,4,1,”s” ;hydraulic pressure peak value holding pressure time
02187,iwzpfs,05,36,4,1,”s” ;mould cavity pressure peak value holding pressure time
02188,iwzpss,05,38,4,1,”s” ;back pressure peak value time
02189,iwzdzs,05,40,4,1,”s” ;screw speed peak value time
02190,iwzpfss,05,42,4,1,”s” ;mould protection pressure peak value time
02191,iwzsks,05,43,4,1,”s” ;clamping force peak value time
02192,iwzsku,05,44,4,1,”s” ;clamping force switchover value time
02193,iwzvsprs,05,46,4,1,”s” ;injection speed peak value time
04867,iw2zpvs,05,33,4,1,”s” ;hydraulic pressure peak value pre-injection time
04868,iw2zpns,05,35,4,1,”s” ;hydraulic pressure peak value holding pressure time
04869,iw2zpfs,05,37,4,1,”s” ;mould cavity pressure peak value holding pressure time
04870,iw2zpss,05,39,4,1,”s” ;back pressure peak value time
04871,iw2zdzs,05,41,4,1,”s” ;screw speed peak value time
04872,iw2zsku,05,45,4,1,”s” ;clamping force switchover value time
04873,iw2zvsprs,05,47,4,1,”s” ;injection speed peak value time
05024,swtmonpurge,50,48,4,1,”s” ;purging monitoring time
08000,swz4,02,94,4,1,”s” ;cooling time
08001,swz5,02,95,4,1,”s” ;pause time
08007,swzu,03,28,4,1,”s” ;cycle monitoring time
08352,swtdelpurge,50,49,4,1,”s” ;delay time purging
08503,iwzux,01,25,4,1,”s” ;cycle time running along
08504,iwzus,01,28,4,1,”s” ;cycle time of the preceding cycle
20000,swgraft0,11,33,4,1,”s” ;measurement delay graphics
22000,swpzzu,09,16,4,1,”s” ;cycle time for bde
24009,iwhs12,19,12,4,1,”s” ;host:cycle time peak value
08373,swzv_fb,09,26,3,1,”s” ;conveyor-belt start delay

08435,swz_fb,09,27,3,1,”s” ;conveyor-belt running time
05740,iwhszdx,19,64,3,2,”s” ;host:plasticizing time for process data

05961,iw2hszdx,19,67,3,2,”s” ;host:plasticizing time for process data
24007,iwhs10,19,10,3,2,”s” ;host:injection time
24008,iwhs11,19,11,3,2,”s” ;host:plasticizing time last cycle
24036,iw2hs10,19,45,3,2,”s” ;host:injection time
24037,iw2hs11,19,65,3,2,”s” ;host: plasticizing time
24006,iwhs09,19,09,2,2,”s” ;host:mould protection time

12994,iwmvpfx,,,5,0,”mV” ; ai values pfx in mv
12995,iwmvphx,,,5,0,”mV” ; ai values phx in mv
12996,iwmvphx2,,,5,0,”mV” ; ai values phx2 in mv
12997,iwmvphx3,,,5,0,”mV” ; ai values phx3 in mv
12998,iwmvssx,,,5,0,”mV” ; ai values ssx in mv
12999,iwmvsax,,,5,0,”mV” ; ai values sax in mv
13000,iwmvsdx,,,5,0,”mV” ; ai values sdx in mv
13001,iwmvsfx,,,5,0,”mV” ; ai values sfx in mv
13003,iwmvksfx,,,5,0,”mV” ; ai values ksfx in mv
13004,iwmvskx,,,5,0,”mV” ; ai values skx in mv
13005,iw2mvpfx,,,5,0,”mV” ; ai values 2 pfx in mv
13006,iw2mvphx,,,5,0,”mV” ; ai values 2 phx in mv
13007,iw2mvphx2,,,5,0,”mV” ; ai values 2 phx2 in mv
13008,iw2mvssx,,,5,0,”mV” ; ai values 2 ssx in mv
13009,iw2mvsdx,,,5,0,”mV” ; ai values 2 sdx in mv
42527,iwmvpmx,,,5,0,”mV” ; melt pressure mv value unit.1
42533,iw2mvpmx,,,5,0,”mV” ; melt pressure mv value unit.2
*** (Unit: Weight [g] )

03920,sd2tgew,02,84,5,1,”g ;parts weight
22002,sdtgew,09,18,5,1,”g ;parts weight

10002,iwafx,01,57,2,0,”Sch” ;rejects sequence counter
10006,swaf,03,99,2,0,”Sch” ;rejects sequence counter
10004,swanfz,04,01,3,0,”Sch” ;start-up rejects counter

10005,swasz,03,98,3,0,”Sch” ;number of rejects
10010,iwaszx,01,56,3,0,”Sch” ;rejects counter
10011,swanfzx,01,58,3,0,”Sch” ;start-up rejects counter
10032,swint_fb,09,24,3,0,”Sch” ;conveyor-belt interval

Version:G/11/12/7/3
10007,swatzx,08,03,5,0,”Sch” ;rejects total counter actual value

24004,iwhs05,19,05,5,0,”Sch” ;host:rejects counter
24005,iwhs06,19,06,5,0,”Sch” ;host:rejects total counter
00100,sdsz,09,20,8,0,”Sch” ;shot set value

00102,sdszx,09,21,8,0,”Sch” ;shot actual value
24003,idhs03,19,50,8,0,”Sch” ;host:shot counter
*** (Unit: Piece [Pcs] )

00101,sdst,09,22,8,0,”Stk” ;piece set value
00103,sdstx,09,23,8,0,”Stk” ;piece actual value
*** (Without unit)

32007,stwz_code,17,48,12,0 ;host:mould code set
00000,stwkn,13,40,16,0 ;mould number

00001,stspn,13,41,16,0 ;injection moulded part number
00002,stmtn,13,42,16,0 ;material number
00003,stmcn,13,43,16,0 ;machine number
00005,stanr,13,45,16,0 ;order number
00006,st2mtn,03,22,16,0 ;material number 2
09737,kt machine type,,,20,0 ;machine type plain language designation

12539,ktparamsatz,,,20,0 ;identification of the read-in
;parameter phrase
40390,ktmusternr,,,20,0 ;special software version
00024,swmfg,07,90,1,0 ;material conveyer yes/no

03301,swfiltra,07,71,1,0 ;switch oil filtration on/off
05029,swprpurge,50,47,1,0 ;program choice purging
05559,sw2prpurge,50,54,1,0 ;program choice purging
17062,swprhopper,50,52,1,0 ;hopper barrage when purging
18000,swpr1,07,84,1,0 ;ejection monitoring
18018,swpr22,10,05,1,0 ;cycle time monitoring
18089,swasmel,03,49,1,0 ;unit 1 signals rejects in the following cycle
18116,swpr_fb,09,28,1,0 ;conveyor-belt program switch
18148,swmode_fb,09,25,1,0 ;conveyor-belt mode of operation
19605,swresetstill0,19,74,1,0 ;autoreset host standstill reason 0
19607,swhosterror,19,86,1,0 ;host signals error
22200,swschuhr,07,93,1,0 ;week switch clock program switch
22229,swmotein,16,53,1,0 ;motor on via switch clock
22230,swmotaus,16,54,1,0 ;motor off via switch clock
22231,swheizein,16,55,1,0 ;heating on via switch clock
22232,swheizaus,16,56,1,0 ;heating off via switch clock
22233,swg1ein,16,57,1,0 ;device 1 on via switch clock
22234,swg1aus,16,58,1,0 ;device 1 off via switch clock
22235,swg2ein,16,59,1,0 ;device 2 on via switch clock
22236,swg2aus,16,60,1,0 ;device 2 off via switch clock
22245,swg1on,16,61,1,0 ;device 1 main switch
22246,swg2on,16,62,1,0 ;device 2 main switch
22255,swuhrman,12,23,1,0 ;week switch clock switching-off manual
24001,swhs01,19,01,1,0 ;release by host
28457,koser0prot,,,1,0 ;selection record test interface
;0=tcp/ip 1=debug
32005,swdl_requ,12,68,1,0 ;host:downloadrequest host
32038,iwautorunning,19,87,1,0 ;host machine runs automatically
37070,kospi,,,1,0 ;spi val reserved
37298,sw2pranpr,60,18,1,0 ; carriage at injection
37533,swpranpr,52,32,1,0 ; carriage at injection
39090,swweighon,50,76,1,0 ;weigh scale on / off on screen
42147,swhostcommerr,,,1,0 ;error action at host communication error
43477,sw2prhopper,50,59,1,0 ;hopper barrage when purging
28456,swtr_mgraf,08,62,2,0 ;trigger criterion for micorgraph additional curve

42277,kohwdt,,,2,0 ; hardware input channel rotary table
42278,kohweil,,,2,0 ; hardware input channel force high speed channel
42279,kohwph5,,,2,0 ; hardware input channel pressure accu
42280,kohwyd,,,2,0 ; hardware output channel electric plasticizing
42281,kohwnsphx,,,2,0 ; hardware output channel for standardized signal phx unit 1
42282,kohwnsssx,,,2,0 ; hardware output channel for standardized signal ssx unit 1
42283,kohwnsvssx,,,2,0 ; hardware output channel for standardized signal injection and plasticizing speed unit 1
42284,ko2hwnsphx,,,2,0 ; hardware output channel for standardized signal phx unit 2
42285,ko2hwnsssx,,,2,0 ; hardware output channel for standardized signal ssx unit 2
42286,ko2hwnsvssx,,,2,0 ; hardware output channel for standardized signal injection and plasticizing speed unit 2
42522,kohwpmx,,,2,0 ; hardware input channel melt pressure analog card unit.1
42528,ko2hwpmx,,,2,0 ; hardware input channel melt pressure analog card unit.2
24033,iwhs42,19,42,3,1 ;host:fzx-flow number actual value

24048,iw2hs42,19,57,3,1 ;host:fzx-flow number actual value
24685,iw_plast,08,56,3,1 ;plasticizing number unit.1
24686,iw2plast,08,58,3,1 ;plasticizing number unit.2
00025,swfa,13,33,5,0 ;number of cavities)
01899,iwjahr,01,29,5,0 ;year
03698,swmemabs,05,14,5,0 ;marker heating lowering after control voltage on/off
03809,swmg_udsp0,07,62,5,0 ;switchover point-display selection 1

Version:G/11/12/7/3
03813,swmg_fdsp0,07,66,5,0 ;flow number display selection 1

04270,sw2memabs,01,19,5,0 ;heating lowering after control voltage on/off
20002,swmg_kan0,11,24,5,0 ; channel a allocation (0-3)
20003,swmg_kan1,11,27,5,0 ; channel b allocation (0-3)
20014,swmg_cideal,11,87,5,0 ;channel c ideal
22001,swbdecode,09,17,5,0 ;standstill code for bde
22011,iwpzstd,09,11,5,0 ;production remaining time hours
32004,iwdl_state,17,47,5,0 ;host:downloadstatus host
41069,swchanbit0,,,5,0 ;bit mask for micrograph curves analog.1
41077,swmessidx0,,,5,0 ;measuring channel index for analog card 1
41085,sw2chanbit0,,,5,0 ;bit mask for micrograph curves analog.2
41093,sw2messidx0,,,5,0 ;measuring channel index for analog card 2
41101,kokalin_max,,,5,0 ;maximum number input calibrations analog card 1
41102,kokalout_max,,,5,0 ;maximum number output calibrations analog card 1
41103,ko2kalin_max,,,5,0 ;maximum number input calibrations analog card 2
41104,ko2kalout_max,,,5,0 ;maximum number output calibrations analog card 2
01900,iwmonat,01,30,0x82,0 ;month
01901,iwwotag,01,31,0x82,0 ;weekday
01902,iwtag,01,32,0x82,0 ;day
01903,iwstunde,01,33,0x82,0 ;hour
01904,iwminute,01,34,0x82,0 ;minute
22012,iwpzmin,09,12,0x82,0 ;production remaining time minutes
22013,iwpzsec,09,13,0x82,0 ;production remaining time seconds
22201,swmose,05,87,0x82,0 ;monday switching-on hour
22202,swdise,05,88,0x82,0 ;tuesday switching-on hour
22203,swmise,05,89,0x82,0 ;wednesday switching-on hour
22204,swdose,05,90,0x82,0 ;thursday switching-on hour
22205,swfrse,05,91,0x82,0 ;friday switching-on hour
22206,swsase,05,92,0x82,0 ;saturday switching-on hour
22207,swsose,05,93,0x82,0 ;sunday switching-on hour
22208,swmome,05,94,0x82,0 ;monday switching-on minute
22209,swdime,05,95,0x82,0 ;tuesday switching-on minute
22210,swmime,05,96,0x82,0 ;wednesday switching-on minute
22211,swdome,05,97,0x82,0 ;thursday switching-on minute
22212,swfrme,05,98,0x82,0 ;friday switching-on minute
22213,swsame,05,99,0x82,0 ;saturday switching-on minute
22214,swsome,12,00,0x82,0 ;sunday switching-on minute
22215,swmosa,12,01,0x82,0 ;monday switching-off hour
22216,swdisa,12,02,0x82,0 ;tuesday switching-off hour
22217,swmisa,12,03,0x82,0 ;wednesday switching-off hour
22218,swdosa,12,04,0x82,0 ;thursday switching-off hour
22219,swfrsa,12,05,0x82,0 ;friday switching-off hour
22220,swsasa,12,06,0x82,0 ;saturday switching-off hour
22221,swsosa,12,07,0x82,0 ;sunday switching-off hour
22222,swmoma,12,08,0x82,0 ;monday switching-off minute
22223,swdima,12,09,0x82,0 ;tuesday switching-off minute
22224,swmima,12,10,0x82,0 ;wednesday switching-off minute
22225,swdoma,12,11,0x82,0 ;thursday switching-off minute
22226,swfrma,12,12,0x82,0 ;friday switching-off minute
22227,swsama,12,13,0x82,0 ;saturday switching-off minute
22228,swsoma,12,14,0x82,0 ;sunday switching-off minute

10003,swminz,04,00,4,0,”min” ;minimum counter for rejects examination
*** (Without unit)

15838,stk_verw1,38,56,13,0 ;use core 1
15839,stk_verw2,38,57,13,0 ;use core 2
15840,stk_verw3,38,58,13,0 ;use core 3
*** (Unit: Weight [lb] )

22014,swmatkg,09,14,5,0,”kg” ;remaining material demand [kg]
*** (Unit: Weight [g] )

22015,swmatg,09,15,0x83,0,”g ;remaining material demand [g]

00026,swsdm,07,74,4,1,”mm” ;screw diameter

Version:G/11/12/7/3
00028,sw2sdm,03,23,4,1,”mm” ;screw diameter

01379,sdzua_schl,17,29,4,2,”s” ;cycle analysis:closing set value
01380,sdzua_duv,17,30,4,2,”s” ;cycle analysis:carriage set value unit.1
01381,sdzua_spr,17,31,4,2,”s” ;cycle analysis:injection set value unit.1
01382,sdzua_z2,17,32,4,2,”s” ;cycle analysis:holding pressure set value unit.1
01383,sdzua_z4,17,33,4,2,”s” ;cycle analysis:cooling time set value
01384,sdzua_oef,17,34,4,2,”s” ;cycle analysis:mould opening set value unit.1
01385,sdzua_ausw,17,35,4,2,”s” ;cycle analysis:ejection set value
01386,sdzua_z5,17,36,4,2,”s” ;cycle analysis:demoulding set value
01387,sdzua_ges,17,37,4,2,”s” ;cycle analysis:total time set value
01556,sdzuat_schl,17,38,4,2,”s” ;cycle analysis: closing tolerance
01557,sdzuat_duv,17,39,4,2,”s” ;cycle analysis:carriage tolerance unit.1
01558,sdzuat_spr,17,40,4,2,”s” ;cycle analysis:injection tolerance unit.1
01559,sdzuat_z2,17,41,4,2,”s” ;cycle analysis:holding pressure tolerance unit.1
01560,sdzuat_z4,17,42,4,2,”s” ;cycle analysis:cooling time tolerance
01561,sdzuat_oef,17,43,4,2,”s” ;cycle analysis:mould opening tolerance
01562,sdzuat_ausw,17,44,4,2,”s” ;cycle analysis:ejection tolerance
01563,sdzuat_z5,17,45,4,2,”s” ;cycle analysis:demoulding tolerance
01564,sdzuat_ges,17,46,4,2,”s” ;cycle analysis:total time tolerance
10695,idzua_dos_s,12,58,4,2,”s” ;cycle analysis:plasticizing time stored
22400,idzua_schl_x,12,41,4,2,”s” ;cycle analysis:closing current
22401,idzua_duv_x,12,42,4,2,”s” ;cycle analysis:carriage current
22402,idzua_spr_x,12,43,4,2,”s” ;cycle analysis:injection current
22403,idzua_z2_x,12,44,4,2,”s” ;cycle analysis:holding pressure current
22404,idzua_z4_x,12,45,4,2,”s” ;cycle analysis:cooling time current
22405,idzua_oef_x,12,46,4,2,”s” ;cycle analysis:mould opening current
22406,idzua_ausw_x,12,47,4,2,”s” ;cycle analysis:ejection current
22407,idzua_ges_x,12,48,4,2,”s” ;cycle analysis:timer level current
22408,idzua_schl_s,12,49,4,2,”s” ;cycle analysis:closing stored
22409,idzua_duv_s,12,50,4,2,”s” ;cycle analysis:carriage stored
22410,idzua_spr_s,12,51,4,2,”s” ;cycle analysis:injection stored
22411,idzua_z2_s,12,52,4,2,”s” ;cycle analysis:holding pressure stored
22412,idzua_z4_s,12,53,4,2,”s” ;cycle analysis:cooling time stored
22413,idzua_oef_s,12,54,4,2,”s” ;cycle analysis:mould opening stored
22414,idzua_ausw_s,12,55,4,2,”s” ;cycle analysis:ejection stored
22415,idzua_z5_s,12,56,4,2,”s” ;cycle analysis:demoulding stored
22416,idzua_ges_s,12,57,4,2,”s” ;cycle analysis:total time stored
22599,idzua_dos_x,12,61,4,2,”s” ;cycle time analysis plasticizing current
22612,idzua_z5_x,12,60,4,2,”s” ;cycle time analysis demoulding current
22654,id2zua_duv_x,08,41,4,2,”s” ;cycle analysis:carriage unit 2 current
22655,id2zua_spr_x,08,42,4,2,”s” ;cycle analysis:injection unit 2 current
22656,id2zua_z2_x,08,43,4,2,”s” ;cycle analysis:holding pressure unit 2 current
22657,id2zua_dos_x,08,44,4,2,”s” ;cycle time analysis:plasticizing unit 2 current
22658,id2zua_duv_s,08,45,4,2,”s” ;cycle analysis:carriage unit 2 stored
22659,id2zua_spr_s,08,46,4,2,”s” ;cycle analysis:injection unit 2 stored
22660,id2zua_z2_s,08,47,4,2,”s” ;cycle analysis:holding pressure unit 2 stored
22661,id2zua_dos_s,08,48,4,2,”s” ;cycle analysis:plasticizing time unit 2 stored
22679,sd2zua_duv,08,50,4,2,”s” ;cycle analysis:carriage set value unit.2
22680,sd2zua_spr,08,51,4,2,”s” ;cycle analysis:injection set value unit.2
22681,sd2zua_z2,08,52,4,2,”s” ;cycle analysis:holding pressure set value unit.2
22682,sd2zuat_duv,08,53,4,2,”s” ;cycle analysis:carriage tolerance unit.2
22683,sd2zuat_spr,08,54,4,2,”s” ;cycle analysis:injection tolerance unit.2
22684,sd2zuat_z2,08,55,4,2,”s” ;cycle analysis:holding pressure tolerance unit.2
39449,idgm_t_dev_1,,,4,2,”s” ;1.unit: deviation moment monitoring_1
39962,id2gm_t_dev_1,,,4,2,”s” ;2.unit: deviation moment monitoring_1

02184,iwvsprs,05,30,4,0,”mm/s” ;injection speed peak value
04866,iw2vsprs,05,31,4,0,”mm/s” ;injection speed peak value
20005,swmg_mass1,11,68,4,0,”mm/s” ;graphics: injection speed...1

12064,iwph_eil,03,64,3,2,”kN” ;hydraulic pressure high speed cylinder
22593,sdzykgraf_min,,,6,3,”s” ;cycle time analysis bar display-zero value
22594,sdzykgraf_max,,,6,3,”s” ;cycle time analysis bar display-max.value
22595,idzykgraf_t1,,,6,3,”s” ;cycle time analysis bar display-part-time 1
-------------------------------------------------------------------------------
Group of variables heatings - heatings
-------------------------------------------------------------------------------

02693,iwtgt05,31,93,3,1,”„C” ;temperature control unit actual value zone 5 temperature control unit
14000,swzo1,04,02,3,1,”„C” ;temperature zone 1

Version:G/11/12/7/3

14041,swoelt,04,30,3,1,”„C” ;temperature for oil
14400,swoeltmin,16,06,3,1,”„C” ;minimum oil temperature
14401,swoeltmax,16,09,3,1,”„C” ;maximum oil temperature
14404,swhabs,14,96,3,1,”„C” ;heating lowering value group 0
14407,swhabs1,16,03,3,1,”„C” ;heating lowering value group 1
14410,swhabs2,16,16,3,1,”„C” ;heating lowering value group 3
15200,iwzo1x,01,60,3,1,”„C” ;temperature zone 1
15241,iwoeltx,01,75,3,1,”„C” ;oil temperature
16833,swtgt07ptol,31,71,3,1,”„C” ;temperature control unit plus tolerance zone 7
16835,swtgt07ntol,31,75,3,1,”„C” ;temperature control unit minus tolerance zone 7
16837,swtgt07abs,31,79,3,1,”„C” ;temperature control unit lowering value zone 7
16839,swtgt07,31,83,3,1,”„C” ;temperature control unit set value zone 7
21966,kotol_halte,19,90,3,1,”„C” ;temperature value before the threshold value, from which the-
;heating-up waiting is started
22903,sw_xkorr_1,2,70,3,1,”„C” ;size of the external disruptive influence group 1
23253,sw_xkorr_2,8,49,3,1,”„C” ;size of the external disruptive influence group 2
41393,swzowzg_tp_1,52,24,3,1,”„C” ; mould temperature fixed platen tol.pos. 1
41394,swzowzg_tn_1,52,25,3,1,”„C” ; mould temperature fixed platen tol.neg. 1
41398,swzowzg_tp_2,52,28,3,1,”„C” ; mould temperature moving platen tol.pos. 2
41399,swzowzg_tn_2,52,29,3,1,”„C” ; mould temperature moving platen tol.neg. 2
41405,iwzo_1,09,33,3,1,”„C” ; mould temp.actual value fixed platen 1
41429,swzowzg_tp_3,52,36,3,1,”„C” ; mould temperature fixed platen tol.pos. 3
41430,swzowzg_tn_3,52,37,3,1,”„C” ; mould temperature fixed platen tol.neg. 3
41434,swzowzg_tp_4,52,40,3,1,”„C” ; mould temperature moving platen tol.pos. 4
41435,swzowzg_tn_4,52,41,3,1,”„C” ; mould temperature moving platen tol.neg. 4

14402,swtabpos,14,92,3,1,”„C” ;maximum positive temp.deviation group 0
14403,swtabneg,14,94,3,1,”„C” ;maximum negative temp.deviation group 0
14405,swtabpos1,14,99,3,1,”„C” ;maximum positive temperature deviaiton group 1
14406,swtabneg1,16,01,3,1,”„C” ;maximum negative temperature deviation group 1
14408,swtabpos2,16,12,3,1,”„C” ;maximum positive temperature deviation group 3
14409,swtabneg2,16,14,3,1,”„C” ;maximum negative temp.deviation group 3
14414,swtabpost,16,18,3,1,”„C” ;maximum positive temp.deviation traverse cooling
14417,sw2tabpost,16,24,3,1,”„C” ; maximum positive temperature deviation traverse cooling unit 2

Version:G/11/12/7/3
02742,swkpzo1,04,49,4,1,”„C” ;control parameter heating

02746,swkpzo2,04,54,4,1,”„C” ; control parameter heating
04414,swcb0,03,74,4,1,”„C” ;control parameter heating
04423,swcb9,03,83,4,1,”„C” ; control parameter heating
12705,swkpzo0,16,46,4,1,”„C” ;control parameter heating

02965,sdstell04,11,02,3,0,”%” ;set adjustable in pct zone 4
02994,idhy00,05,58,3,0,”%” ;heating capacity controller 00
03302,swanf_schw,16,50,3,0,”%” ;start-up circuit threshold
16842,iwtgt07hl,31,90,3,0,”%” ;temperature control unit power actual value zone 7 temperature control unit

Version:G/11/12/7/3
23201,iwtgt01hl,12,25,3,0,”%” ;temperature control unit capacity actual value zone 1 temperature control unit

41395,swzvwzg_1,52,26,2,1,”s” ; alarm delay fixed platen 1
41402,swzvwzg_2,52,30,2,1,”s” ; alarm delay moving platen 2
03782,swanf_zhalte,19,88,4,1,”s” ;holding time on the threshold value

21662,swanf_zaufheiz,19,89,4,1,”s” ;heating-up time up to the threshold value
*** (Without unit)

02928,swstellyn09,14,20,1,0 ;regulator mode yes/no zone 9
02971,swhnot01,14,50,1,0 ;emergency mode yes/no zone 1
09397,swhoptzo0,,,1,0 ;self-optimization zone 00
14200,swhm01,04,03,1,0 ;monitoring zone 01

Version:G/11/12/7/3

14800,swpr_anf,16,20,1,0 ;program switch start-up circuit
16829,swtgt07com,31,63,1,0 ;temperature control unit communication zone 7
16831,swtgt07absea,31,67,1,0 ;temperature control unit lowering on/off zone 7
16841,iwtgt07hlvz,31,89,1,0 ;temperature control unit power +/- zone 7 temperature control unit
18008,swpr9,07,86,1,0 ;heating lowering j/n
18056,swtgtonoff,10,87,1,0 ;temperature control unit communication main switch
18090,sw2pr9,03,50,1,0 ; heating lowering unit 2 y/n
18091,swpr9wz,03,51,1,0 ; heating lowering remaining heatings
23200,iwtgt01hlvz,12,24,1,0 ;temperature control unit capacity +/- zone 1 temperature control unit
41396,swprwzg_alrm_1,52,27,2,0 ; monitoring fixed platen 1
41403,swprwzg_alrm_2,52,31,2,0 ; monitoring moving platen 2
41404,iwzonr_1,09,32,2,0 ; mold temp. fixed platen 1
41406,iwzonr_2,09,34,2,0 ; nnumber mould temp. fixed platen 2
41432,swprwzg_alrm_3,52,39,2,0 ; monitoring fixed platen 3
41437,swprwzg_alrm_4,52,80,2,0 ; monitoring moving platen 4
02700,swhkvzo1,04,53,2,2 ; control parameter heating

15009,swhkvzo0,16,29,2,2 ;control parameter heating
02745,swt0zo1,04,52,3,1 ; control parameter heating
12708,swt0zo0,16,49,3,1 ;control parameter heating


Version:G/11/12/7/3
02743,swkizo1,04,50,4,1 ; control parameter heating

02744,swkdzo1,04,51,4,1 ; control parameter heating
12706,swkizo0,16,47,4,1 ;control parameter heating
12707,swkdzo0,16,48,4,1 ;control parameter heating
03308,swzo_u,16,51,5,0 ;start-up circuit, 1st zone, area beginning

03309,swzo_o,16,52,5,0 ;start-up circuit, last zone, area end
16847,iwtgt07reg,31,99,5,0 ;temperature control unit controller state zone 7
-------------------------------------------------------------------------------
Group of variables microtemp - microtemp
-------------------------------------------------------------------------------

02203,iwmt0x,12,32,3,1,”„C” ;microtemp: zone 0
02211,iwmtvx,12,40,3,1,”„C” ;microtemp: advance
22300,swmtempv,16,71,3,1,”„C” ;microtemp:advance temperature set value
22302,swmtemp0,16,73,3,1,”„C” ;microtemp:set value zone 1
22301,swmtempvabw,16,72,3,1,”„C” ;microtemp:advance temperature deviation
35441,komt02,,,3,1,”„C” ;microtemp:start calibration before set value
35442,komt03,,,3,1,”„C” ;microtemp:maximum positive temperature deviation
35443,komt04,,,3,1,”„C” ;microtemp:maximum negative temperature deviation
35456,komt17,,,3,1,”„C” ;microtemp:minimum temperature change at calibration

35439,komt00,,,4,1,”s” ;microtemp:control employment delay all zones
35440,komt01,,,4,1,”s” ;microtemp:temperature increase monitoring
35453,komt14,,,4,1,”s” ;microtemp:flow rate check delay
35454,komt15,,,4,1,”s” ;microtemp:time base for closed loop volume control
35458,komt19,,,4,1,”s” ;microtemp: delay advance temperature monitoring after flow rate
*** (Without unit)

22334,swmtr0,16,81,1,0 ;microtemp:type of closed loop control zone 1

Version:G/11/12/7/3

22350,swmtfl0,16,97,1,0 ;microtemp:monitoring valve 1
35444,komt05,,,5,0 ;microtemp:maximum cycles with deviation after calibration

35445,komt06,,,5,0 ;microtemp:calibration value correction factor zone 1
35455,komt16,,,5,0 ;microtemp:maximum flow rate
35457,komt18,,,5,0 ;microtemp:number of calibration cycles
*** (Unit: Flow rate [l/min] )

01852,swmthfl0,17,21,2,1,”l/min” ;microtemp:flow rate zone 1 in manual
22342,swmtmfl0,16,89,2,1,”l/min” ;microtemp:flow rate zone 1
-------------------------------------------------------------------------------
Group of variables quicksetup - quicksetup
-------------------------------------------------------------------------------
22758,swqc3,33,20,3,1,”mm” ; quick setup
35568,kog2_0,,,4,1,”mm” ;quick setup g2 -value at sk= 0 - 9 pct
35579,kofhm,,,4,1,”mm” ;mould height at direct-closing machines
*** (Unit: Pressure - weak resolution [bar] )

22745,swqpspr,33,07,4,0,”bar” ; quick setup
22759,swqpstau,33,21,4,0,”bar” ; quick setup
22763,swqpnach,33,25,4,0,”bar” ; quick setup
42606,iwqphx,,,4,0,“bar“
35567,koqmaxps,,,5,0,”bar” ;quick setup maximum back pressure

35578,koqmaxpn,,,5,0,”bar” ;quick setup maximum injection pressure

22752,swqh1,33,14,3,0,”„C” ; quick setup
35580,koqoeltmin,,,3,0,”„C” ;quick setup minimum oil temperature
35581,koqoelt,,,3,0,”„C” ;quick setup oil temperature set value
35892,ko2qoeltmin,,,3,0,”„C” ;”c minimum oil temperature
35893,ko2qoelt,,,3,0,”„C” ;”c oil temperature set value
35894,ko2oelzone,,,3,0,”„C” ; oil temperature controller zone container 2
42593,iwqh1,,,3,0,“„C“
42594,iwqh2,,,3,0,“„C“
42595,iwqh3,,,3,0,“„C“
42596,iwqh4,,,3,0,“„C“
42597,iwqh5,,,3,0,“„C“
42598,iwqh6,,,3,0,“„C“
42605,iwqoeltx,,,3,0,“„C“

22739,swqv6,33,01,3,0,”%” ; quick setup
22740,swqv7,33,02,3,0,”%” ; quick setup
22744,swqvaw,33,06,3,0,”%” ; quick setup
22746,swqdz,33,08,3,0,”%” ; quick setup
22747,swqdzr,33,09,3,0,”%” ; quick setup
22750,swqv1,33,12,3,0,”%” ; quick setup
22751,swqv3,33,13,3,0,”%” ; quick setup
22775,swqvduv,33,38,3,0,”%” ; quick setup

22738,swqpaw,33,00,3,0,”%” ; quick setup
22766,swqp2,33,28,3,0,”%” ; quick setup
22773,swqp5,33,35,3,0,”%” ; quick setup
35891,ko2qp5,,,3,0,”%” ;maximum contact pressure

Version:G/11/12/7/3

42603,iwqdzx,,,3,0,“/min“

22765,swqzu,33,27,4,0,”s” ; quick setup
22769,swqz4,33,31,4,0,”s” ; quick setup
42607,iwqzux,,,3,0,“s“
22770,swqzf,33,32,2,1,”s” ; quick setup

42592,swqzs,33,36,3,1,”s” ; quick setup
22748,swql,33,10,3,0,”mm” ; quick setup
22760,swql1,33,22,3,0,”mm” ; quick setup
22776,swqsdm,33,39,3,0,”mm” ; quick setup
42601,iwqsax,,,3,0,“mm“
22764,swqaz,33,26,1,0,” ; quick setup
*** (Without unit)
22778,swqnew,33,41,1,0 ; quick setup

22749,swqw4,33,11,4,0,”mm” ; quick setup
22761,swqa,33,23,4,0,”mm” ; quick setup
22762,swqg1,33,24,4,0,”mm” ; quick setup
22772,swqk,33,34,4,0,”mm” ; quick setup
42599,iwqsfx,,,4,0,“mm“
42600,iwqsdx,,,4,0,“mm“
42602,iwqssx,,,4,0,“mm“
42604,iwqshx,,,4,0,“mm“
*** (Without unit)

42608,iwqcursor,,,5,0

22742,swqvspr,33,04,4,0,”mm/s” ; quick setup

22741,swqsk,33,03,4,1,”tn” ; quick setup
-------------------------------------------------------------------------------
Group of variables control system parameters - control system parameters
-------------------------------------------------------------------------------

35582,kosskdelay,,,4,1,”s” ;keyboard repetition delay
35583,kosskrep,,,4,1,”s” ;keyboard repetition time
35585,kossscreen,,,4,1,”s” ;screen dimming delay
17984,kozpr_oen,,,3,2,”s” ;devibration time input oil level
*** (Without unit)

35584,kosskdyn,,,1,0 ;keyboard dynamic repetition
35591,kossenter,,,1,0 ;0-input at enter:
;0=without preselection, 1=with preselection
35592,kokeyb,,,1,0 ;0=us keyboard, 1=German keyboard
40428,kocolbackgr,,,2,0 ; selection screen background (only colour screen)

; 0 = black, 1 = light-grey
09686,ko_prt_hcopy,,,5,0 ;hardcopy 0..with/ 1..without soft key

19602,ko_prt_act_dev,,,5,0 ;active output device
35589,ko_prt_line_feed,,,5,0 ;1= additional line advance
35590,ko_prt_blank,,,5,0 ;1= insert empty character when printing out
38848,ko_prt_fmt_txt,,,5,0 ;paper format text printer
38850,ko_prt_skip_txt,,,5,0 ;perforation jump text printer
38851,ko_prt_fmt_9,,,5,0 ;paper format 9-dot-matrix graphic printer
38853,ko_prt_skip_9,,,5,0 ;perforation 9-dot-matrix graphic printer
38854,ko_prt_fmt_24,,,5,0 ;paper format 24-dot-matrix graphic printer
38856,ko_prt_skip_24,,,5,0 ;perforation 24-dot-matrix graphic printer
38857,ko_prt_fmt_dj,,,5,0 ;paper format hp-deskjet 800

Version:G/11/12/7/3
38858,ko_prt_skip_dj,,,5,0 ;perforation hp-deskjet

38859,ko_prt_fmt_floppy,,,5,0 ;file format floppy
38860,ko_prt_fmt_ramd,,,5,0 ;file format ram disk
38861,ko_prt_fmt_host_1,,,5,0 ;file format host drive 1
38862,ko_prt_fmt_host_2,,,5,0 ;file format host drive 2
40427,ko_prt_txt_grfmode,,,5,0 ;print text in the graphic mode
-------------------------------------------------------------------------------
Group of variables absolute values service - absolute values service
-------------------------------------------------------------------------------

35543,koapemx1,,,4,0,”bar” ;maximum specific injection pressure increased screw diameter 1
35547,koapmx1,,,4,0,”bar” ;maximum specific injection pressure screw diameter 1
35552,koapsmx1,,,4,0,”bar” ;maximum specific back pressure screw diameter 1
35866,ko2apmax,,,4,0,”bar” ;maximum specific injection pressure input limit
35867,ko2apemx1,,,4,0,”bar” ;maximum specific injection pressure increased screw diameter 1
35871,ko2apmx1,,,4,0,”bar” ;maximum specific injection pressure screw diameter 1
35876,ko2apsmx1,,,4,0,”bar” ;maximum specific back pressure screw diameter 1
45671,ko2apsemx1,,,4,0,”bar” ;maximum specific back pressure increased screw diameter 1
35542,koapmax,,,5,0,”bar” ;maximum specific injection pressure input limit
35551,koapsmax,,,5,0,”bar” ;maximum specific back pressure input limit
35875,ko2apsmax,,,5,0,”bar” ;maximum specific back pressure input limit
*** (Unit: Stroke volume [ccm] )

35527,kohvmax,,,4,1,”ccm” ;maximum stroke volume input limit
35528,kohvmx1,,,4,1,”ccm” ;maximum stroke volume screw diameter 1
35532,kophv,,,4,1,”ccm” ;maximum cushion volume input limit
35563,kophvmx1,,,4,1,”ccm” ;maximum cushion volume input limit screw diameter 1
35851,ko2hvmax,,,4,1,”ccm” ;maximum stroke volume input limit
35852,ko2hvmx1,,,4,1,”ccm” ;maximum stroke volume screw diameter 1
35856,ko2phv,,,4,1,”ccm” ;maximum cushion volume input limit
35887,ko2phvmx1,,,4,1,”ccm” ;maximum cushion volume input limit screw diameter 1

35533,kosstrmax,,,4,0,”ccm/s” ;maximum injection rate input limit
35534,kossemx1,,,4,0,”ccm/s” ;maximum injection rate screw diameter 1 increased injection pressure
35538,kossmx1,,,4,0,”ccm/s” ;maximum injection rate screw diameter 1
35857,ko2sstrmax,,,4,0,”ccm/s” ;maximum injection rate input limit
35858,ko2ssemx1,,,4,0,”ccm/s” ;maximum injection rate screw diameter 1 increased injection pressure
35862,ko2ssmx1,,,4,0,”ccm/s” ;maximum injection rate screw diameter 1
*** (Unit: Speed of rotation [m/min] )

35556,kovumax,,,4,1,”m/min” ;maximum rotational speed input limit
35557,kovumx1,,,4,1,”m/min” ;maximum rotational speed screw diameter 1
35880,ko2vumax,,,4,1,”m/min” ;maximum rotational speed input limit
35881,ko2vumx1,,,4,1,”m/min” ;maximum rotational speed screw diameter 1

Version:G/11/12/7/3
*** (Without unit)

35561,kopsspc,,,1,0 ; 1=back pressure via fka-fki
; 0=back pressure via fkm-fki
35562,koabsini,,,1,0 ; calculation of the absolute value input limits
35885,ko2psspc,,,1,0 ; 1=back pressure via fka-fki
; 0=back pressure via fkm-fki
35886,ko2absini,,,1,0 ; calculation of the absolute input limits
35523,koskanz,,,2,0 ;number of injection plungers

35520,kokdma,,,4,0,”mm” ;injection cylinder diameter d1
35521,kokdmm,,,4,0,”mm” ;screw retraction diameter d2
35522,kokdmi,,,4,0,”mm” ;injection piston rod diameter d3
35524,kokdmba,,,4,0,”mm” ;external injection plunger diameter calculated
35525,kokdmbm,,,4,0,”mm” ;medium injection plunger diameter calculated
35526,kokdmbi,,,4,0,”mm” ;internal injection plunger diameter calculated
35848,ko2kdmba,,,4,0,”mm” ;external injection plunger diameter calculated
35849,ko2kdmbm,,,4,0,”mm” ;medium injection plunger diameter calculated
35850,ko2kdmbi,,,4,0,”mm” ;internal injection plunger diameter calculated
-------------------------------------------------------------------------------
Group of variables absolute values - absolute values
-------------------------------------------------------------------------------

03038,swaph,07,29,5,0,”bar” ;hydraulic pressure switchover value
03039,swap6,07,31,5,0,”bar” ;injection pressure
03040,swap7,07,33,5,0,”bar” ;1. holding pressure
03050,swap17,07,53,5,0,”bar” ;1. back pressure
03102,iwaphx,01,96,5,0,”bar” ;specific injection pressure actual value
03104,iwapsx,05,00,5,0,”bar” ;specific back pressure actual value
03105,iwapns,05,02,5,0,”bar” ;specific holding pressure peak value
03106,iwapss,05,04,5,0,”bar” ;specific back pressure peak value
03108,iwaphu,05,08,5,0,”bar” ;switchover pressure
03109,iwapvs,05,10,5,0,”bar” ;pre-injection peak value
03188,sw2aph,07,30,5,0,”bar” ;hydraulic pressure switchover value
03189,sw2ap6,07,32,5,0,”bar” ;injection pressure
03190,sw2ap7,07,34,5,0,”bar” ;1. holding pressure
03200,sw2ap17,07,54,5,0,”bar” ;1. back pressure
03207,iw2aphx,01,97,5,0,”bar” ;specific injection pressure actual value
03209,iw2apsx,05,01,5,0,”bar” ;specific back pressure actual value
03210,iw2apns,05,03,5,0,”bar” ;specific holding pressure peak value
03211,iw2apss,05,05,5,0,”bar” ;specific back pressure peak value
03213,iw2aphu,05,09,5,0,”bar” ;switchover pressure
03214,iw2apvs,05,11,5,0,”bar” ;pre-injection peak value
*** (Unit: Stroke volume [ccm] )

03000,swac1,06,49,4,1,”ccm” ;metering stroke
03001,swac2,06,51,4,1,”ccm” ;decompression stroke after plasticizing
03002,swac2m,01,86,4,1,”ccm” ;decompression stroke after plasticizing corrected
03003,swac3,06,53,4,1,”ccm” ;pos c3-position for switchover holding pressure
03004,swac3b,06,55,4,1,”ccm” ;window at hydraulic pressure switchover holding pressure
03005,swac3d,06,57,4,1,”ccm” ;window at parallel switchover
03006,swac4,06,59,4,1,”ccm” ;position c4-decompression 1 end
03007,swacp,06,61,4,1,”ccm” ;cushion ”ideal value”
03008,swacpmin,06,63,4,1,”ccm” ;cushion minimum length
03009,swacpmax,06,65,4,1,”ccm” ;cushion maximum length
03010,swac4b,06,67,4,1,”ccm” ;switchover to 2nd plasticizing speed
03011,swac4c,06,69,4,1,”ccm” ;switchover to 3rd plasticizing speed
03012,swac4d,06,71,4,1,”ccm” ;switchover to 4th plasticizing speed
03013,swac4e,06,73,4,1,”ccm” ;switchover to 5th plasticizing speed
03014,swac2b,06,75,4,1,”ccm” ;switchover to 2nd injection speed
03015,swac2c,06,77,4,1,”ccm” ;switchover to 3rd injection speed
03016,swac2d,06,79,4,1,”ccm” ;switchover to 4th injection speed
03017,swac2e,06,81,4,1,”ccm” ;switchover to 5th injection speed
03018,swac2f,06,83,4,1,”ccm” ;switchover to 6th injection speed
03019,swac2g,06,85,4,1,”ccm” ;switchover to 7th injection speed
03020,swac2h,06,88,4,1,”ccm” ;switchover to 8th injection speed
03021,swac2i,06,91,4,1,”ccm” ;switchover to 9th injection speed
03022,swac2j,06,94,4,1,”ccm” ;switchover to 10th injection speed

Version:G/11/12/7/3
03103,iwassx,01,98,4,1,”ccm” ;stroke volume actual value

03107,iwac3u,05,06,4,1,”ccm” ;switchover volume
03110,iwacpx,05,12,4,1,”ccm” ;cushion actual value
03150,sw2ac1,06,50,4,1,”ccm” ;metering stroke
03151,sw2ac2,06,52,4,1,”ccm” ;decompression stroke after plasticizing
03152,sw2ac2m,01,87,4,1,”ccm” ;decompression stroke after plasticizing corrected
03153,sw2ac3,06,54,4,1,”ccm” ;pos c3-position for switchover holding pressure
03154,sw2ac3b,06,56,4,1,”ccm” ;window at hydraulic pressure switchover holding pressure
03155,sw2ac3d,06,58,4,1,”ccm” ;window at parallel switchover
03156,sw2ac4,06,60,4,1,”ccm” ;pos c4-decompression 2 end
03157,sw2acp,06,62,4,1,”ccm” ;cushion ”ideal value”
03158,sw2acpmin,06,64,4,1,”ccm” ;cushion minimum length
03159,sw2acpmax,06,66,4,1,”ccm” ;cushion maximum length
03160,sw2ac4b,06,68,4,1,”ccm” ;switchover to 2nd plasticizing speed
03161,sw2ac4c,06,70,4,1,”ccm” ;switchover to 3rd plasticizing speed
03162,sw2ac4d,06,72,4,1,”ccm” ;switchover to 4th plasticizing speed
03163,sw2ac4e,06,74,4,1,”ccm” ;switchover to 5th plasticizing speed
03164,sw2ac2b,06,76,4,1,”ccm” ;switchover to 2nd injection speed
03165,sw2ac2c,06,78,4,1,”ccm” ;switchover to 3rd injection speed
03166,sw2ac2d,06,80,4,1,”ccm” ;switchover to 4th injection speed
03167,sw2ac2e,06,82,4,1,”ccm” ;switchover to 5th injection speed
03168,sw2ac2f,06,84,4,1,”ccm” ;switchover to 6th injection speed
03169,sw2ac2g,06,86,4,1,”ccm” ;switchover to 7th injection speed
03170,sw2ac2h,06,89,4,1,”ccm” ;switchover to 8th injection speed
03171,sw2ac2i,06,92,4,1,”ccm” ;switchover to 9th injection speed
03172,sw2ac2j,06,95,4,1,”ccm” ;switchover to 10th injection speed
03208,iw2assx,01,99,4,1,”ccm” ;stroke volume actual value
03212,iw2ac3u,05,07,4,1,”ccm” ;switchover volume
03215,iw2acpx,12,69,4,1,”ccm” ;cushion actual value
41479,swac3a,34,00,4,1,”ccm” ; switchover point in moving-in phase
41480,sw2ac3a,34,01,4,1,”ccm” ;switchover point in moving-in phase

03023,swav12,06,97,4,0,”ccm/s” ;1. injection speed
03101,iwavsprx,01,94,4,0,”ccm/s” ;injection rate actual value
03173,sw2av12,06,98,4,0,”ccm/s” ;1. injection speed
03206,iw2avsprx,01,95,4,0,”ccm/s” ;injection rate actual value
*** (Unit: Speed of rotation [m/min] )

03033,swavdz1,07,19,4,1,”m/min” ;1. screw speed
03100,iwadzx,01,92,4,1,”m/min” ;screw rotational speed
03183,sw2avdz1,07,20,4,1,”m/min” ;1. screw speed
03205,iw2adzx,01,93,4,1,”m/min” ;screw rotational speed
*** (Without unit)

44978,kocfg_abs,,,2,0 ;configuration switch absolute value input
-------------------------------------------------------------------------------
Group of variables quality data statistics - quality data statistics
-------------------------------------------------------------------------------
11004,swphu,17,53,3,1,”bar” ;hydraulic pressure switchover
11010,swpns,17,59,3,1,”bar” ;holding pressure peak value
11011,swpss,17,60,3,1,”bar” ;back pressure peak value
11014,swphuptol,17,63,3,1,”bar” ;hydraulic pressure switchover
11020,swpnsptol,17,69,3,1,”bar” ;holding pressure peak value
11021,swpssptol,17,70,3,1,”bar” ;back pressure peak value
11024,swphuntol,17,73,3,1,”bar” ;hydraulic pressure switchover
11030,swpnsntol,17,79,3,1,”bar” ;holding pressure peak value
11031,swpssntol,17,80,3,1,”bar” ;back pressure peak value
11037,swpfuoegx,17,86,3,1,”bar” ;upper contact limit
11038,swpfuuegx,17,87,3,1,”bar” ;lower contact limit
11041,swphuoegx,17,90,3,1,”bar” ;upper contact limit
11042,swphuuegx,17,91,3,1,”bar” ;lower contact limit
11057,swpfsoegx,32,06,3,1,”bar” ;upper contact limit
11058,swpfsuegx,32,07,3,1,”bar” ;lower contact limit
11065,swpnsoegx,32,14,3,1,”bar” ;upper contact limit
11066,swpnsuegx,32,15,3,1,”bar” ;lower contact limit
11069,swpssoegx,32,18,3,1,”bar” ;upper contact limit
11070,swpssuegx,32,19,3,1,”bar” ;lower contact limit
11085,swmassphux,32,34,3,1,”bar” ;scale
11103,swmasspnsx,32,52,3,1,”bar” ;scale

Version:G/11/12/7/3
11106,swmasspssx,32,55,3,1,”bar” ;scale
11151,sw2phu,10,24,3,1,”bar” ; hydraulic pressure switchover
11157,sw2pns,10,36,3,1,”bar” ; holding pressure peak value
11158,sw2pss,10,38,3,1,”bar” ; back pressure peak value
11161,sw2phuptol,10,44,3,1,”bar” ; hydraulic pressure switchover
11167,sw2pnsptol,10,56,3,1,”bar” ; holding pressure peak value
11168,sw2pssptol,10,58,3,1,”bar” ; back pressure peak value
11171,sw2phuntol,10,64,3,1,”bar” ; hydraulic pressure switchover
11177,sw2pnsntol,10,76,3,1,”bar” ; holding pressure peak value
11178,sw2pssntol,10,78,3,1,”bar” ; back pressure peak value
11184,sw2pfuoegx,10,86,3,1,”bar” ;upper contact limit x_cross
11185,sw2pfuuegx,10,88,3,1,”bar” ;lower contact limit x_cross
11188,sw2phuoegx,10,91,3,1,”bar” ;upper contact limit x_cross
11189,sw2phuuegx,10,92,3,1,”bar” ;lower contact limit x_cross
11204,sw2pfsoegx,11,42,3,1,”bar” ;upper contact limit x_cross
11205,sw2pfsuegx,11,44,3,1,”bar” ;lower contact limit x_cross
11212,sw2pnsoegx,11,55,3,1,”bar” ;upper contact limit x_cross
11213,sw2pnsuegx,11,56,3,1,”bar” ;lower contact limit x_cross
11216,sw2pssoegx,11,63,3,1,”bar” ;upper contact limit x_cross
11217,sw2pssuegx,11,66,3,1,”bar” ;lower contact limit x_cross
11226,sw2massphux,11,77,3,1,”bar” ;scale
11244,sw2masspnsx,14,00,3,1,”bar” ;scale
11247,sw2masspssx,14,05,3,1,”bar” ;scale
11039,swpfuoegs,17,88,3,2,”bar” ;upper specific limit

11040,swpfuuegs,17,89,3,2,”bar” ;lower specific limit
11043,swphuoegs,17,92,3,2,”bar” ;upper specific limit
11044,swphuuegs,17,93,3,2,”bar” ;lower specific limit
11059,swpfsoegs,32,08,3,2,”bar” ;upper specific limit
11060,swpfsuegs,32,09,3,2,”bar” ;lower specific limit
11067,swpnsoegs,32,16,3,2,”bar” ;upper specific limit
11068,swpnsuegs,32,17,3,2,”bar” ;lower specific limit
11071,swpssoegs,32,20,3,2,”bar” ;upper specific limit
11072,swpssuegs,32,21,3,2,”bar” ;lower specific limit
11083,swmasspfus,32,32,3,2,”bar” ;scale
11086,swmassphus,32,35,3,2,”bar” ;scale
11098,swmasspfss,32,47,3,2,”bar” ;scale
11104,swmasspnss,32,53,3,2,”bar” ;scale
11107,swmasspsss,32,56,3,2,”bar” ;scale
11186,sw2pfuoegs,10,89,3,2,”bar” ;upper specific limit
11187,sw2pfuuegs,10,90,3,2,”bar” ;lower specific limit
11190,sw2phuoegs,10,93,3,2,”bar” ;upper specific limit
11191,sw2phuuegs,10,94,3,2,”bar” ;lower specific limit
11206,sw2pfsoegs,11,46,3,2,”bar” ;upper specific limit
11207,sw2pfsuegs,11,49,3,2,”bar” ;lower specific limit
11214,sw2pnsoegs,11,57,3,2,”bar” ;upper specific limit
11215,sw2pnsuegs,11,60,3,2,”bar” ;lower specific limit
11218,sw2pssoegs,11,69,3,2,”bar” ;upper specific limit
11219,sw2pssuegs,11,70,3,2,”bar” ;lower specific limit
11224,sw2masspfus,11,75,3,2,”bar” ;scale
11227,sw2massphus,11,78,3,2,”bar” ;scale
11239,sw2masspfss,11,95,3,2,”bar” ;scale
11245,sw2masspnss,14,01,3,2,”bar” ;scale
11248,sw2masspsss,14,07,3,2,”bar” ;scale
11003,swpfu,17,52,4,1,”bar” ;mould cavity pressure switchover

11008,swpfs,17,57,4,1,”bar” ;mould cavity pressure peak value
11013,swpfuptol,17,62,4,1,”bar” ;mould cavity pressure switchover
11018,swpfsptol,17,67,4,1,”bar” ;mould cavity pressure peak value
11023,swpfuntol,17,72,4,1,”bar” ;mould cavity pressure switchover
11028,swpfsntol,17,77,4,1,”bar” ;mould cavity pressure peak value
11082,swmasspfux,32,31,4,1,”bar” ;scale
11097,swmasspfsx,32,46,4,1,”bar” ;scale
11150,sw2pfu,10,22,4,1,”bar” ; mould cavity pressure switchover
11155,sw2pfs,10,32,4,1,”bar” ; mould cavity pressure peak value
11160,sw2pfuptol,10,42,4,1,”bar” ; mould cavity pressure switchover
11165,sw2pfsptol,10,52,4,1,”bar” ; mould cavity pressure peak value
11170,sw2pfuntol,10,62,4,1,”bar” ; mould cavity pressure switchover
11175,sw2pfsntol,10,72,4,1,”bar” ; mould cavity pressure peak value
11223,sw2masspfux,11,74,4,1,”bar” ;scale
11238,sw2masspfsx,11,94,4,1,”bar” ;scale

11005,swc3u,17,54,3,2,”mm” ;stroke-dependent switchover point
11009,swcpx,17,58,3,2,”mm” ;cushion length-qds
11015,swc3uptol,17,64,3,2,”mm” ;stroke-dependent switchover point
11019,swcpxptol,17,68,3,2,”mm” ;cushion length-qds
11025,swc3untol,17,74,3,2,”mm” ;stroke-dependent switchover point
11029,swcpxntol,17,78,3,2,”mm” ;cushion length-qds
11088,swmassc3ux,32,37,3,2,”mm” ;scale
11100,swmasscpxx,32,49,3,2,”mm” ;scale
11152,sw2c3u,10,26,3,2,”mm” ; stroke-dependent switchover point
11156,sw2cpx,10,34,3,2,”mm” ; cushion length-qds
11162,sw2c3uptol,10,46,3,2,”mm” ; stroke-dependent switchover point
11166,sw2cpxptol,10,54,3,2,”mm” ; cushion length-qds
11172,sw2c3untol,10,66,3,2,”mm” ; stroke-dependent switchover point
11176,sw2cpxntol,10,74,3,2,”mm” ; cushion length-qds
11229,sw2massc3ux,11,80,3,2,”mm” ;scale
11241,sw2masscpxx,11,97,3,2,”mm” ;scale

05313,swqp1_1pa,13,94,3,0,”%” ;intervention probability
11129,swfz_1pa,32,78,3,0,”%” ;intervention probability
11130,swpfu_1pa,32,79,3,0,”%” ;intervention probability
11131,swphu_1pa,32,80,3,0,”%” ;intervention probability
11132,swc3u_1pa,32,81,3,0,”%” ;intervention probability
11133,swzsx_1pa,32,82,3,0,”%” ;intervention probability
11134,swzdx_1pa,32,83,3,0,”%” ;intervention probability

Version:G/11/12/7/3
11135,swpfs_1pa,32,84,3,0,”%” ;intervention probability

11136,swcpx_1pa,32,85,3,0,”%” ;intervention probability
11137,swpns_1pa,32,86,3,0,”%” ;intervention probability
11138,swpss_1pa,32,87,3,0,”%” ;intervention probability
11270,sw2fz_1pa,14,51,3,0,”%” ;intervention probability
11271,sw2pfu_1pa,14,53,3,0,”%” ;intervention probability
11272,sw2phu_1pa,14,55,3,0,”%” ;intervention probability
11273,sw2c3u_1pa,14,57,3,0,”%” ;intervention probability
11274,sw2zsx_1pa,14,59,3,0,”%” ;intervention probability
11275,sw2zdx_1pa,14,61,3,0,”%” ;intervention probability
11276,sw2pfs_1pa,14,63,3,0,”%” ;intervention probability
11277,sw2cpx_1pa,14,65,3,0,”%” ;intervention probability
11278,sw2pns_1pa,14,67,3,0,”%” ;intervention probability
11279,sw2pss_1pa,14,69,3,0,”%” ;intervention probability

11047,swc3uoegs,17,96,2,3,”mm” ;upper specific limit
11048,swc3uuegs,17,97,2,3,”mm” ;lower specific limit
11063,swcpxoegs,32,12,2,3,”mm” ;upper specific limit
11064,swcpxuegs,32,13,2,3,”mm” ;lower specific limit
11089,swmassc3us,32,38,2,3,”mm” ;scale
11101,swmasscpxs,32,50,2,3,”mm” ;scale
11194,sw2c3uoegs,10,97,2,3,”mm” ;upper specific limit
11195,sw2c3uuegs,11,22,2,3,”mm” ;lower specific limit
11210,sw2cpxoegs,11,53,2,3,”mm” ;upper specific limit
11211,sw2cpxuegs,11,54,2,3,”mm” ;lower specific limit
11230,sw2massc3us,11,82,2,3,”mm” ;scale
11242,sw2masscpxs,11,98,2,3,”mm” ;scale

05310,swqp1_p10,13,91,3,1,”%” ;exceeding share
11119,swfz_p10,32,68,3,1,”%” ;exceeding share
11120,swpfu_p10,32,69,3,1,”%” ;exceeding share
11121,swphu_p10,32,70,3,1,”%” ;exceeding share
11122,swc3u_p10,32,71,3,1,”%” ;exceeding share
11123,swzsx_p10,32,72,3,1,”%” ;exceeding share
11124,swzdx_p10,32,73,3,1,”%” ;exceeding share
11125,swpfs_p10,32,74,3,1,”%” ;exceeding share
11126,swcpx_p10,32,75,3,1,”%” ;exceeding share
11127,swpns_p10,32,76,3,1,”%” ;exceeding share
11128,swpss_p10,32,77,3,1,”%” ;exceeding share
11260,sw2fz_p10,14,31,3,1,”%” ;exceeding share
11261,sw2pfu_p10,14,33,3,1,”%” ;exceeding share
11262,sw2phu_p10,14,35,3,1,”%” ;exceeding share
11263,sw2c3u_p10,14,37,3,1,”%” ;exceeding share
11264,sw2zsx_p10,14,39,3,1,”%” ;exceeding share
11265,sw2zdx_p10,14,41,3,1,”%” ;exceeding share
11266,sw2pfs_p10,14,43,3,1,”%” ;exceeding share
11267,sw2cpx_p10,14,45,3,1,”%” ;exceeding share
11268,sw2pns_p10,14,47,3,1,”%” ;exceeding share
11269,sw2pss_p10,14,49,3,1,”%” ;exceeding share

11006,swzsx,17,55,3,2,”s” ;injection time
11007,swzdx,17,56,3,2,”s” ;plasticizing time
11016,swzsxptol,17,65,3,2,”s” ;injection time
11017,swzdxptol,17,66,3,2,”s” ;plasticizing time
11026,swzsxntol,17,75,3,2,”s” ;injection time
11027,swzdxntol,17,76,3,2,”s” ;plasticizing time
11091,swmasszsxx,32,40,3,2,”s” ;scale
11094,swmasszdxx,32,43,3,2,”s” ;scale
11153,sw2zsx,10,28,3,2,”s” ; injection time
11154,sw2zdx,10,30,3,2,”s” ; plasticizing time
11163,sw2zsxptol,10,48,3,2,”s” ; injection time
11164,sw2zdxptol,10,50,3,2,”s” ; plasticizing time
11173,sw2zsxntol,10,68,3,2,”s” ; injection time
11174,sw2zdxntol,10,70,3,2,”s” ; plasticizing time
11232,sw2masszsxx,11,85,3,2,”s” ;scale
11235,sw2masszdxx,11,90,3,2,”s” ;scale

11045,swc3uoegx,17,94,2,2,”mm” ;upper contact limit
11046,swc3uuegx,17,95,2,2,”mm” ;lower contact limit
11061,swcpxoegx,32,10,2,2,”mm” ;upper contact limit
11062,swcpxuegx,32,11,2,2,”mm” ;lower contact limit
11192,sw2c3uoegx,10,95,2,2,”mm” ;upper contact limit x_cross
11193,sw2c3uuegx,10,96,2,2,”mm” ;lower contact limit x_cross
11208,sw2cpxoegx,11,51,2,2,”mm” ;upper contact limit x_cross
11209,sw2cpxuegx,11,52,2,2,”mm” ;lower contact limit x_cross

11049,swzsxoegx,17,98,2,2,”s” ;upper contact limit
11050,swzsxuegx,17,99,2,2,”s” ;lower contact limit
11053,swzdxoegx,32,02,2,2,”s” ;upper contact limit
11054,swzdxuegx,32,03,2,2,”s” ;lower contact limit
11196,sw2zsxoegx,11,25,2,2,”s” ;upper contact limit x_cross
11197,sw2zsxuegx,11,28,2,2,”s” ;lower contact limit x_cross
11200,sw2zdxoegx,11,36,2,2,”s” ;upper contact limit x_cross
11201,sw2zdxuegx,11,38,2,2,”s” ;lower contact limit x_cross
11051,swzsxoegs,32,00,2,3,”s” ;upper specific limit

11052,swzsxuegs,32,01,2,3,”s” ;lower specific limit
11055,swzdxoegs,32,04,2,3,”s” ;upper specific limit
11056,swzdxuegs,32,05,2,3,”s” ;lower specific limit
11092,swmasszsxs,32,41,2,3,”s” ;scale
11095,swmasszdxs,32,44,2,3,”s” ;scale
11198,sw2zsxoegs,11,31,2,3,”s” ;upper specific limit
11199,sw2zsxuegs,11,34,2,3,”s” ;lower specific limit

Version:G/11/12/7/3
11202,sw2zdxoegs,11,40,2,3,”s” ;upper specific limit

11203,sw2zdxuegs,11,41,2,3,”s” ;lower specific limit
11233,sw2masszsxs,11,86,2,3,”s” ;scale
11236,sw2masszdxs,11,92,2,3,”s” ;scale

05077,swqds_umfangq,13,51,2,0,”Sch” ;measurement volume (number of measurements/spot checks)
11000,swqds_umfang,17,49,2,0,”Sch” ;measurement volume (number of measurement/spot checks)
11001,swqds_anzahl,17,50,2,0,”Sch” ;measurement number (number of spot checks/card)
05272,swqds_abstandq,13,53,3,0,”Sch” ;measuring distance (shot number between the spot checks)
11002,swqds_abstand,17,51,3,0,”Sch” ;measuring distance (shot between the spot checks)
05076,sdqpschussz,13,50,8,0,“Sch“ ;schussistw-q
*** (Without unit)

05300,swmassqp1fix,13,81,1,0 ;fixed scale j/n
05303,swmassqp2fix,13,84,1,0 ;scale
05306,swmassqp3fix,13,87,1,0 ;scale
05307,swqp1_mode,13,88,1,0 ;control card with/without given limiting value
11073,swprqstop,32,22,1,0 ;after tolerance exceeding cycle stop?
11075,swprtime,32,24,1,0 ;print also time
11076,swprszx,32,25,1,0 ;print also szx
11077,swqdsaussch,32,26,1,0 ;when exceeding the specific limit, rejects
11078,swprspezstop,32,27,1,0 ;after tolerance exceeding cycle stop?
11081,swmassfzfix,32,30,1,0 ;scale
11084,swmasspfufix,32,33,1,0 ;scale
11087,swmassphufix,32,36,1,0 ;scale
11090,swmassc3ufix,32,39,1,0 ;scale
11093,swmasszsxfix,32,42,1,0 ;scale
11096,swmasszdxfix,32,45,1,0 ;scale
11099,swmasspfsfix,32,48,1,0 ;scale
11102,swmasscpxfix,32,51,1,0 ;scale
11105,swmasspnsfix,32,54,1,0 ;scale
11108,swmasspssfix,32,57,1,0 ;scale
11109,swfz_mode,32,58,1,0 ;control card with/without given limiting values
11110,swpfu_mode,32,59,1,0 ;control card with/without given limiting values
11111,swphu_mode,32,60,1,0 ;control card with/without given limiting values
11112,swc3u_mode,32,61,1,0 ;control card with/without given limiting values
11113,swzsx_mode,32,62,1,0 ;control card with/without given limiting values
11114,swzdx_mode,32,63,1,0 ;control card with/without given limiting values
11115,swpfs_mode,32,64,1,0 ;control card with/without given limiting values
11116,swcpx_mode,32,65,1,0 ;control card with/without given limiting values
11117,swpns_mode,32,66,1,0 ;control card with/without given limiting values
11118,swpss_mode,32,67,1,0 ;control card with/without given limiting values
11222,sw2massfzfix,11,73,1,0 ;scale
11225,sw2masspfufix,11,76,1,0 ;scale
11228,sw2massphufix,11,79,1,0 ;scale
11231,sw2massc3ufix,11,84,1,0 ;scale
11234,sw2masszsxfix,11,88,1,0 ;scale
11237,sw2masszdxfix,11,93,1,0 ;scale
11240,sw2masspfsfix,11,96,1,0 ;scale
11243,sw2masscpxfix,11,99,1,0 ;scale
11246,sw2masspnsfix,14,03,1,0 ;scale
11249,sw2masspssfix,14,09,1,0 ;scale
11250,sw2fz_mode,14,11,1,0 ;control card with/without given limiting value
11251,sw2pfu_mode,14,13,1,0 ;control card with/without given limiting value
11252,sw2phu_mode,14,15,1,0 ;control card with/without given limiting value
11253,sw2c3u_mode,14,17,1,0 ;control card with/without given limiting value
11254,sw2zsx_mode,14,19,1,0 ;control card with/without given limiting value
11255,sw2zdx_mode,14,21,1,0 ;control card with/without given limiting value
11256,sw2pfs_mode,14,23,1,0 ;control card with/without given limiting value
11257,sw2cpx_mode,14,25,1,0 ;control card with/without given limiting value
11258,sw2pns_mode,14,27,1,0 ;control card with/without given limiting value
11259,sw2pss_mode,14,29,1,0 ;control card with/without given limiting value
05271,swqds_anzahlq,13,52,2,0 ;measurement number (number of spot checks/card)

05297,swklassenq,13,78,2,0 ;number of quality parameter classes for histogram
11074,swklassen,32,23,2,0 ;number of classes for histogram
05287,swqp1oegs,13,68,2,3 ; qp1 upper contact limit s

05288,swqp1uegs,13,69,2,3 ; qp1 lower contact limit s
05299,swmassqp1s,13,80,2,3 ;scale s
05302,swmassqp2s,13,83,2,3 ;scale
05305,swmassqp3s,13,86,2,3 ;scale
11035,swfzqoegs,17,84,2,3 ;flow number upper specific limit
11036,swfzquegs,17,85,2,3 ;flow number lower specific limit
11080,swmassfzs,32,29,2,3 ;scale
11182,sw2fzqoegs,10,84,2,3 ;flow number upper specific limit
11183,sw2fzquegs,10,85,2,3 ;flow number lower specific limit
11221,sw2massfzs,11,72,2,3 ;scale
05273,swqps1,13,54,3,2 ;quality parameter 1

05276,swqp1mess,13,57,3,2 ;quality measurement value 1
05279,swqp1ptol,13,60,3,2 ;tolerance quality parameter 1
05282,swqp1ntol,13,63,3,2 ;tolerance quality parameter 1

Version:G/11/12/7/3
05285,swqp1oegx,13,66,3,2 ; qp1 upper contact limit x

05286,swqp1uegx,13,67,3,2 ; qp1 lower contact limit x
05298,swmassqp1x,13,79,3,2 ;scale x
05301,swmassqp2x,13,82,3,2 ;scale
05304,swmassqp3x,13,85,3,2 ;scale
11012,swfzqptol,17,61,3,2 ;flow number **** upper limit
11022,swfzqntol,17,71,3,2 ;flow number **** lower limit
11032,swfzq,17,81,3,2 ;flow number-qds
11033,swfzqoegx,17,82,3,2 ;flow number upper intervention limit x_cross
11034,swfzquegx,17,83,3,2 ;flow number lower intervention limit x_cross
11079,swmassfzx,32,28,3,2 ;maximum which is displayed in the graphics
11159,sw2fzqptol,10,40,3,2 ; flow number **** upper limit
11169,sw2fzqntol,10,60,3,2 ; flow number **** lower limit
11179,sw2fzq,10,80,3,2 ; flow number-qds
11180,sw2fzqoegx,10,82,3,2 ;flow number upper intervention limit x_cross
11181,sw2fzquegx,10,83,3,2 ;flow number lower intervention limit x_cross
11220,sw2massfzx,11,71,3,2 ;maximum which is displayed in the graphics
-------------------------------------------------------------------------------
Group of variables peripheral unit-peripheral devices
-------------------------------------------------------------------------------

19913,swhli_wegtol_auto,61,44,3,1,”mm”;setting range in automatic mode
41525,swhli_x_pos_memo,62,78,3,1,”mm”;hli note position setting x-axis +
41526,swhli_y_pos_memo,62,80,3,1,”mm”;hli note position setting y-axis +
41738,swhli_x_neg_memo,62,31,3,1,”mm”;hli note position setting x-axis -
41739,swhli_y_neg_memo,62,32,3,1,”mm”;hli note position setting y-axis -
19670,swhli_z_startpos,61,14,4,1,”mm” ;z start pos.

19673,swhli_z_entnpos,61,16,4,1,”mm” ;z take-off pos.
19676,swhli_z_rasterpos,61,18,4,1,”mm” ;z screen pos.
19685,swhli_z_ablausgp,61,26,4,1,”mm” ;z depositing starting point
19695,sdhli_zrabs,61,36,4,1,”mm” ;z screen distance
21279,swhli_z_ico,61,71,4,1,”mm” ;z rejects position
22131,swhli_z_agabl,61,95,4,1,”mm” ;hli act. Z-sprue depositing pos
24140,swhli_z_ablausgp2,62,01,4,1,”mm”;z depositing starting point 2
24149,swhli_z_rasterpos2,62,10,4,1,”mm”;z screen pos. 2
34597,id_lenze_position,61,90,4,1,”mm” ;lenze actual position
37723,swhli_z_qual,62,18,4,1,”mm” ;z-qual position

19669,swhli_referenz_v,61,13,3,0,”%” ;speed referencing
19671,swhli_startpos_v,61,15,3,0,”%” ;vmax z start pos.
19674,swhli_entnpos_v,61,17,3,0,”%” ;vmax z take-off pos.
19677,swhli_rasterpos_v,61,19,3,0,”%” ;vmax z screen pos.
19877,swhli_hand_v,61,48,3,0,”%” ;vmax manual mode
19879,swhli_heimlauf_v,61,50,3,0,”%” ;vmax home run
21278,swhli_ico_v,61,70,3,0,”%” ;vmax rejects depositing
21533,swhli_agt_v,61,77,3,0,”%” ;speed settings
22130,swhli_agabl_v,61,94,3,0,”%” ;speed settings
24148,swhli_rasterpos2_v,62,09,3,0,”%” ;vmax z screen pos. 2
37722,swhli_qual_v,62,17,3,0,”%” ;vmax quaco position

19696,swhli_uebvz,61,37,4,1,”s” ;takeover delay
19697,swhli_uebz,61,38,4,1,”s” ;take-off time
19698,swhli_ablvz,61,39,4,1,”s” ;depositing delay
19699,swhli_ablz,61,40,4,1,”s” ;depositing time
19700,swhli_fb_zeit,61,41,4,1,”s” ;conveyor-belt running time
19894,swhli_vz_awv,61,65,4,1,”s” ;delay awv
19895,swhli_vz_awz,61,66,4,1,”s” ;delay awz
21282,swhli_fk_zeit,61,74,4,1,”s” ;running time control conveyor-belt
21540,swhli_agtz,61,84,4,1,”s” ;hli sprue separation time
22136,swhli_z6,62,00,4,1,”s” ;hli fb running time sprue depositing
37725,swhli_fq_zeit,62,20,4,1,”s” ;running time control conveyor-belt
41016,swhli_uebvz_ang,62,43,4,1,”s” ;hli takeover delay sprue
41017,swhli_uebz_ang,62,44,4,1,”s” ;hli takeover time sprue
41018,swhli_ablvz_ang,62,45,4,1,”s” ;hli depositing delay sprue
41019,swhli_ablz_ang,62,46,4,1,”s” ;hli depositing time sprue
03073,swzavera,15,02,3,1,”s” ;depositing delay take-off

05098,swzvgresch,15,03,3,1,”s” ;delay time gripper closing
08416,swzevera,15,00,3,1,”s” ;delay take-off return
08417,swzlvera,15,01,3,1,”s” ;delay take-off turning
*** (Unit: Piece [Pcs] )

19689,swhli_zranz,61,30,8,0,”Stk” ;z-screen number
19690,swhli_xranz,61,31,8,0,”Stk” ;x screen number
19691,swhli_yranz,61,32,8,0,”Stk” ;y screen number
37726,swhli_qual_soll,62,21,8,0,”Stk” ;quality part counter set value
*** (Without unit)
01551,sweraox,15,07,1,0 ;era - sequence without x-axis
03758,swprerag,15,05,1,0 ;era - gripper monitoring
04023,sweraein,15,06,1,0 ;era - yes/no
04329,swpos_z_start,15,11,1,0 ;startposition z-achse fuer era
06560,koeaera,,,1,0 ;0=era-old, 1=era-new-b, 2=era-new-a
18292,swpos_x_start,15,12,1,0 ;startposition x-achse fuer era

Version:G/11/12/7/3
18293,swpos_y_abl,15,10,1,0 ;move in y-axis when depositing

18766,swpos_x_zl,15,08,1,0 ;x-axis position when turning the z-axis to the left
18838,swlenze_ul,61,42,1,0 ;lenze param. download
18839,swlenze_dl,61,43,1,0 ;lenze param. upload
19662,swhli_ein,61,00,1,0 ;program switch hli on
19663,swhli_greifer1_ein,61,01,1,0 ;sucker 1
19664,swhli_greifer1_tuw,61,02,1,0 ;monitoring of parts 1
19665,swhli_greifer1_euw,61,03,1,0 ;end position monitoring 1
19668,swhli_greifer2_euw,61,06,1,0 ;end position monitoring 2
19679,swhli_x_entnpos,61,20,1,0 ;x take-off pos.
19680,swhli_y_entnpos,61,21,1,0 ;y take-off pos.
19681,swhli_c_entnpos,61,22,1,0 ;z take-off pos.
19682,swhli_x_startpos,61,23,1,0 ;x start pos.
19683,swhli_y_startpos,61,24,1,0 ;y start pos.
19684,swhli_c_startpos,61,25,1,0 ;z start pos.
19686,swhli_x_ablausgp,61,27,1,0 ;x depositing starting point
19687,swhli_y_ablausgp,61,28,1,0 ;y depositing starting point
19688,swhli_c_ablausgp,61,29,1,0 ;c depositing starting point
19878,swhli_ico_aw,61,49,1,0 ;eject rejects
19888,kohlispcagabl,62,26,1,0 ;configuration with sprue depositing
19889,swhli_fruehstart,61,60,1,0 ;early start
19890,swhli_keine_entn,61,61,1,0 ;no take-off by hli
19891,swhli_x_ausfp1,61,62,1,0 ;x position after take-off
19892,swhli_y_ausfp1,61,63,1,0 ;y position after take-off
19893,swhli_c_ausfp1,61,64,1,0 ;c position after take-off
21275,swhli_x_ico,61,67,1,0 ;x pos. at rejects depositing
21276,swhli_y_ico,61,68,1,0 ;y pos at rejects depositing
21277,swhli_c_ico,61,69,1,0 ;c pos. at rejects depositing
21280,swhli_ico,61,72,1,0 ;prgsch rejects depositing
21281,swhli_x_drucklos,61,73,1,0 ;prgsch take-off x pressureless
21531,swhli_ausf_awv,61,75,1,0 ;move out prgsch with ejector in front
21532,swhli_agt,61,76,1,0 ;program switch sprue separation
21536,swhli_x_vor_agt,61,80,1,0 ;hli x-axis before sprue separation
21537,swhli_x_agt,61,81,1,0 ;hli x-axis at sprue separation
21538,swhli_y_agt,61,82,1,0 ;hli y-axis at sprue separation
21539,swhli_c_agt,61,83,1,0 ;hli c-axis at sprue separation
22129,swhli_agabl,61,93,1,0 ;program switch sprue depositing
22133,swhli_x_agabl,61,97,1,0 ;hli x-axis at sprue depositing
22134,swhli_y_agabl,61,98,1,0 ;hli y-axis at sprue depositing
22135,swhli_c_agabl,61,99,1,0 ;hli c-axis at sprue depositing
22909,swhli_a_ablausgp,61,58,1,0 ;a-axis depositing pos.
24144,swhli_x_ablausgp2,62,05,1,0 ;x depositing starting point 2
24178,swhli_aggr_vor_l1,61,59,1,0 ;hli sprue gripping forward l1
32984,swhli_fb_abraeumen,62,81,1,0 ;clear up conveyor-belt
37719,swhli_x_qual,62,14,1,0 ;x-pos.at quaco position
37720,swhli_y_qual,62,15,1,0 ;y-pos.at quaco position
37721,swhli_c_qual,62,16,1,0 ;c-pos bei quako-position
37724,swhli_qual,62,19,1,0 ;prg.switch quaco position
37729,swhli_agabl_vor,62,23,1,0 ;sprue depositing before depositing of parts
37730,swhli_agabl_nach,62,24,1,0 ;sprue depositing after depositing of parts
38816,swhli_a_agabl,62,50,1,0 ;a-axis sprue depositing
38817,swhli_a_qual,62,51,1,0 ;a-axis qual depositing pos.
40374,swhli_aggr,62,25,1,0 ;sprue gripper
40375,kohlispcaggr,62,27,1,0 ;config: sprue gripper
40376,kohlispcxdrucklos,62,28,1,0 ;config: switch x pressureless
41005,swhli_y_zw_ablage,62,33,1,0 ;y-axis between part depositing
41006,swhli_y_zw_aggr,62,34,1,0 ;y-axis between part depositing and sprue depositing
41007,swhli_teil_greifen,62,35,1,0 ;grip part
41008,swhli_ico_fb_r,62,36,1,0 ;ico belt at the right (forward)
41009,swhli_qual_fb_r,62,37,1,0 ;qual belt at the right (forward)
41010,swhli_aggr_fb_r,62,38,1,0 ;unit belt at the right (forward)
41012,swhli_a_ico,62,39,1,0 ;hli a-axis at rejects depositing
41013,swhli_a_startpos,62,40,1,0 ;hli start position a-axis
41014,swhli_a_entnpos,62,41,1,0 ;hli take-off position a-axis
41015,swhli_a_ausfp1,62,42,1,0 ;hli a-axis after take-off
41020,swhli_entn_prg,62,47,1,0 ;take-off program selector switch
41021,swhli_anguss_prg,62,48,1,0 ;sprue program selector switch
41022,swhli_gr_als_aggr,62,49,1,0 ;gripper program selector switch
41180,swhli_ht_qual,62,29,1,0 ;push-button qual.part
41181,swhli_home_teil,62,30,1,0 ;prg.switch home run with part
41753,komont_hli,,,1,0 ;robot er-hli mounted
41754,komont_erc,,,1,0 ;robot erc mounted
42521,swhli_ausf_form,62,99,1,0 ;prg switch move out during mold opening
44212,swprhli_ablz4,62,98,1,0 ;hli depositing only with beginning cooling time
18025,swpreras,15,04,2,0 ;era - program switch

35471,kocfg_robot,,,2,0 ;choice of devices robot (in the setup instead of korc100)
;0...no robot
; 1...erc
; 2...er-hli
19692,swhli_ist_zranz,61,33,5,0 ;z screen actual number

19693,swhli_ist_xranz,61,34,5,0 ;x screen actual number
19694,swhli_ist_yranz,61,35,5,0 ;y screen actual number
19874,swhli_xrfolg,61,45,5,0 ;screen sequence x
19875,swhli_yrfolg,61,46,5,0 ;screen sequence y
19876,swhli_zrfolg,61,47,5,0 ;screen sequence z
19881,swhli_hand_vn,61,52,5,0 ;vmax manual mode normalized
19882,swhli_referenz_vn,61,53,5,0 ;vmax referencing normalized

Version:G/11/12/7/3
19883,swhli_heimlauf_vn,61,54,5,0 ;vmax home run normalized

19884,swhli_startpos_vn,61,55,5,0 ;vmax z start pos. normalized
19885,swhli_entnpos_vn,61,56,5,0 ;vmax z take-off pos. normalized
19886,swhli_rasterpos_vn,61,57,5,0 ;vmax z screen pos. normalized
21535,swhli_agt_vn,61,79,5,0 ;speed normalized
22132,swhli_agabl_vn,61,96,5,0 ;speed normalized
34592,sw_lenze_steuerwort,61,85,5,0 ;lenze control word
34593,sw_lenze_position,61,86,5,0 ;lenze position setting
34594,sw_lenze_v,61,87,5,0 ;lenze speed setting
34595,sw_lenze_a,61,88,5,0 ;lenze acceleration setting
34596,iw_lenze_statuswort,61,89,5,0 ;lenze status word
34598,iw_lenze_1,61,91,5,0 ;lenze actual value 1
34599,iw_lenze_2,61,92,5,0 ;lenze actual value 2
37727,swhli_qual_ist,62,22,5,0 ;quality part counter actual value
42431,swstd_hli,61,78,5,0 ;machine hours counter hli motor
18079,kdc_foelire,,,8,0 ;lenze parameter 143 conveyor-belt left/right

18837,kdc_anz_gre,,,8,0 ;lenze parameter 141 number sucker/gripper
18840,kdc0011_000,,,8,0 ;lenze parameters 0

Version:G/11/12/7/3

19701,kdc_fap_bap,,,8,0 ;lenze parameter 145 assembly place fixed/moving platen
19927,kdc0168_001,,,8,0 ;lenze parameter 129 current error state
19928,kdc0183_000,,,8,0 ;lenze parameter 130 current drive state
19929,kdc0168_002,,,8,0 ;lenze parameter 131 last error state
19930,kdc0168_003,,,8,0 ;lenze parameter 132 last but one error state
19931,kdc0168_004,,,8,0 ;lenze parameter 133 last but two error state
19932,kdc0168_005,,,8,0 ;lenze parameter 134 last but three error state
19933,kdc0168_006,,,8,0 ;lenze parameter 135 fifth last error state
19934,kdc0168_007,,,8,0 ;lenze parameter 136 last but five error state
19935,kdc0168_008,,,8,0 ;lenze parameter 137 last but six error state
19936,kdc0178_000,,,8,0 ;lenze parameter 138 machine hours counter
19937,kdc0179_000,,,8,0 ;lenze parameter 139 mains duration of connection
19938,kdcdummy_13,,,8,0 ;lenze parameters 140
37878,kdc_a_achse,,,8,0 ;lenze parameter 144 a-axis
41011,kdc_foe_abr,,,8,0 ;lenze parameter 142 clear conveyor-belt
-------------------------------------------------------------------------------
Group of variables spi interface -spi communication interface
-------------------------------------------------------------------------------

01253,swmoldthigh,51,02,3,0,”„C” ;mold temperature upper tolerance
01254,swmoldtlow,51,03,3,0,”„C” ;mold low tolerance
01257,swdryrthigh,51,06,3,0,”„C” ;dryer high tolerance
01258,swdryrtlow,51,07,3,0,”„C” ;dryer low tolerance
01259,swdryrthighdew,51,08,3,0,”„C” ;dryer upper moisture tolerance
01262,swchilthigh,51,11,3,0,”„C” ;chiller high tolerance
01263,swchiltlow,51,12,3,0,”„C” ;chiller low tolerance
01280,swmol2thigh,51,29,3,0,”„C” ;mould high tol 2
01336,swmol2tlow,51,30,3,0,”„C” ;mould temperature low tolerance 2
01339,swdry2thigh,51,33,3,0,”„C” ;dryer high tolerance
01340,swdry2tlow,51,34,3,0,”„C” ;dryer low tolerance
01341,swdry2thighdew,51,35,3,0,”„C” ;dryer high dew tolerance
37068,swmzhigh,51,68,3,0,”„C” ;multi zone control high tolerance
37069,swmzlow,51,69,3,0,”„C” ;multi zone control low tolerance

01271,swmeltpset,51,20,5,0,”bar” ;pressure setval
01272,swmeltphigh,51,21,5,0,”bar” ;pressure high tol
01273,swmeltplow,51,22,5,0,”bar” ;pressure low tol
01355,iwmeltpin,,,5,0,”bar” ; melt pump inlet pressure
01356,iwmeltpout,,,5,0,”bar” ; melt pump outlet pressure

01246,swmoldtset,51,01,3,0,”„C” ;mold temperature set value
01256,swdryrtset,51,05,3,0,”„C” ;dryer temperature set value
01261,swchiltset,51,10,3,0,”„C” ;chiller temperature set value
01279,swmol2tset,51,28,3,0,”„C” ;mould temp setval 2
01338,swdry2tset,51,32,3,0,”„C” ;dryer temperature set value
01342,iwmoldtdel,,,3,0,”„C” ; mold temperature controller actual value
01345,iwdryrtdel,,,3,0,”„C” ; dryer temperature actual value
01347,iwdryrtdew,,,3,0,”„C” ; dryer dew point actual value

Version:G/11/12/7/3
01349,iwchiltdel,,,3,0,”„C” ; chiller temperature actual value

01362,iwmol2tdel,,,3,0,”„C” ; mold temperature controller actual value 2
01365,iwdry2tdel,,,3,0,”„C” ; dryer temperature actual value 2
01367,iwdry2tdew,,,3,0,”„C” ; dryer dew point actual value 2
37037,swmzt01,51,37,3,0,”„C” ;multi zone control temperature zone 01
43492,iwmzt01,,,3,0,”„C” ; multiple zones actual temp. zo 01
*** (Without unit)

01245,swmoldonoff,51,00,1,0 ;mould communication on/off
01255,swdryronoff,51,04,1,0 ;dew point is available on the dryer
01260,swchilonoff,51,09,1,0 ;chiller communication on/off
01264,swloadonoff,51,13,1,0 ;loader communication on/off
01267,swmeltonoff,51,16,1,0 ;melt pump communication on/off
01274,swfeedonoff,51,23,1,0 ;feeder communication on/off
01278,swmol2onoff,51,27,1,0 ;mould communication on/off 2
01337,swdry2onoff,51,31,1,0 ;dewpoint is available on dryer 2
37036,swmzonoff,51,36,1,0 ;multi zone temperature control communication on/off
37095,kospistp,,,1,0 ;0 = spi communication error does not stop cycle
;1 = spi communication error does stop cycle
38746,kospimold,,,1,0 ;spi val reserved
38747,kospimld2,,,1,0 ;spi val reserved
38748,kospidry,,,1,0 ;spi val reserved
38749,kospidry2,,,1,0 ;spi val reserved
38750,kospichil,,,1,0 ;spi val reserved
38751,kospiload,,,1,0 ;spi val reserved
38752,kospimelt,,,1,0 ;spi val reserved
38753,kospifeed,,,1,0 ;spi val reserved
38754,kospimult,,,1,0 ;spi val reserved
38771,komold_um,,,1,0 ;mould temperature controller 1
;0 = works with iso-units
;1 = works with imperial-units
38772,komld2_um,,,1,0 ;mould temperature controller 2
38773,kodry_um,,,1,0 ;spi dryer 1
38774,kodry2_um,,,1,0 ;spi units dryer 2
38775,kochil_um,,,1,0 ;chiller

Version:G/11/12/7/3

38776,komelt_um,,,1,0 ;melt pump
38777,komult_um,,,1,0 ;multi zone
43487,swdrysign,51,70,1,0 ;dryer dew point sign
43488,swdry2sign,51,72,1,0 ;dryer dew point sign 2
43524,iwdrysign,,,1,0 ; sign for dew point
43525,iwdry2sign,,,1,0 ; sign for dew point
08939,komoldtyp,,,3,0 ;spi type mould temperature controller 1

08940,komoldadd,,,3,0 ;spi address mould temperature controller 1
08941,kodryrtyp,,,3,0 ;spi type dryer 1
08942,kodryradd,,,3,0 ;spi address dryer 1
08943,kochiltyp,,,3,0 ;spi type chiller
08944,kochiladd,,,3,0 ;spi address chiller
08945,koloadtyp,,,3,0 ;spi type loader
08946,koloadadd,,,3,0 ;spi address loader
08947,komelttyp,,,3,0 ;spi type melt pump
08948,komeltadd,,,3,0 ;spi address melt pump
08949,kofeedtyp,,,3,0 ;spi type additive feeder
08950,kofeedadd,,,3,0 ;spi address additive feeder
08951,komol2typ,,,3,0 ;spi type mould temperature controller 2
08952,komol2add,,,3,0 ;spi address mould temperature controller 2
08953,kodry2typ,,,3,0 ;spi type dryer 2
08954,kodry2add,,,3,0 ;spi address dryer 2
15608,kospion,,,3,0 ;0 = do not turn spi devices on
;1 = turn spi devices on via software
15609,kospiblkt,,,3,0 ;0 = single poll commands only
;1 = blanket poll commands allowed
15611,kozfm,,,3,0 ;s10 delay time between device communication switch
37067,swmznum,51,67,3,0 ;multi zone control number of zones
37087,komztyp,,,3,0 ;spi type multi zone
37088,komzadd,,,3,0 ;spi address multi zone
37093,kospidew,,,3,0 ;0 = no dewpoint available on dryer
;1 = dew point is available on the dryer
43489,iwmzonoff,,,3,0 ; multiple zones on/off switch
43522,iwmol1text,,,3,0 ; text selection for status mold temp.contr..1
43523,iwmol2text,,,3,0 ; text selection for status mold temp.contr..1
01343,iwmoldstatus,,,5,0 ; mold temperature controller status

01344,iwmoldcom,,,5,0 ; mold temperature controller communication status
01346,iwdryrstatus,,,5,0 ; dryer status
01348,iwdryrcom,,,5,0 ; dryer communication status
01350,iwchilstatus,,,5,0 ; chiller temperature status
01351,iwchilcom,,,5,0 ; chiller communication status
01352,iwloadstatus,,,5,0 ; conveyor status
01353,iwloadcom,,,5,0 ; conveyor communication status
01357,iwmeltstatus,,,5,0 ; melt pump status
01358,iwmeltcom,,,5,0 ; melt pump communication status
01360,iwfeedstatus,,,5,0 ; mixer status
01361,iwfeedcom,,,5,0 ; mixer communication status
01363,iwmol2status,,,5,0 ; mold temperature controller status 2
01364,iwmol2com,,,5,0 ; mold temperature controller communication status 2
01366,iwdry2status,,,5,0 ; dryer status 2
01368,iwdry2com,,,5,0 ; dryer communication status 2
15610,koztimera,,,5,0 ;timer a spi
43490,iwmzcom,,,5,0 ; multiple zones communication on/off switch
43491,iwmzstatus,,,5,0 ; multiple zones status
*** (Unit: Speed [rev/min] )

01268,swmeltrset,51,17,3,0,”U/min” ;rpm setval
01269,swmeltrhigh,51,18,3,0,”U/min” ;rpm high tol
01270,swmeltrlow,51,19,3,0,”U/min” ;rpm low tol
01354,iwmeltrret,,,3,0,”U/min” ; speed melt pump
*** (Unit: Time [sec] )

01265,swloadtimea,51,14,3,0,”s ;loader timer a set value
01266,swloadtimeb,51,15,3,0,”s ;loader timer b set value
*** (Unit: Metered amount [g/min] )

01275,swfeedrtset,51,24,3,0,”g/m” ;additive feed rate setval
01276,swfeedrfset,51,25,3,0,”g/m” ;material/additive feed time
01277,swfeedadset,51,26,3,0,”g/m” ;feed volume setting
01359,iwfeedaret,,,3,0,”g/m” ; mixer additional rate
-------------------------------------------------------------------------------
Group of variables machine diagnostics
-------------------------------------------------------------------------------
*** (Unit: Stroke [km] )

39837,kddiag_s_aw_km,,,10,0,”km” ;ejector stroke [km]
39864,kddiag_s_sdm_circ_km,,,10,0,”km”;screw rotational stroke [km]
39865,kddiag_s_mold_km,,,10,0,”km” ;mold stroke [km]
43364,kddiag_s_screw_km,,,10,0,”km” ;screw stroke [km]
45758,kddiag_s_screw_km_m,,,10,0,”km”;screw stroke km
45759,kddiag_s_screw_km_ref,,,10,0,”km”;screw stroke km reference
45761,kddiag_s_aw_km_m,,,10,0,”km” ;ejector stroke km
45762,kddiag_s_aw_km_ref,,,10,0,”km” ;ejector stroke km reference
45764,kddiag_s_mold_km_m,,,10,0,”km” ;mold stroke km
45765,kddiag_s_mold_km_ref,,,10,0,”km”;mold stroke km reference

39871,kddiag_t_cykmax,,,8,1,”s” ;cycle times
39921,kddiag_t_cykmin,,,8,1,“s“
43369,kddiag_t_cyk,,,8,1,”s” ;mean cycle time
43370,kddiag_t_feed,,,8,1,”s” ;mean plasticizing time

Version:G/11/12/7/3
39882,kddiag_t_inj,,,7,2,”s” ;mean injection time
*** (Without unit)

39817,kddiag_f_cl1,,,10,0
39818,kddiag_f_cl2,,,10,0
39819,kddiag_f_cl3,,,10,0
39820,kddiag_f_cl4,,,10,0
39821,kddiag_f_cl5,,,10,0
39826,kddiag_p_inj1,,,10,0
39827,kddiag_p_inj2,,,10,0
39828,kddiag_p_inj3,,,10,0
39829,kddiag_p_inj4,,,10,0
39830,kddiag_p_inj5,,,10,0
39831,kddiag_s_mh1,,,10,0 ;mould height
39832,kddiag_s_mh2,,,10,0
39833,kddiag_s_mh3,,,10,0
39834,kddiag_s_mh4,,,10,0
39835,kddiag_s_mh5,,,10,0
39836,kddiag_s_mh6,,,10,0
39866,kddiag_s_scr1,,,10,0 ;screw stroke
39867,kddiag_s_scr2,,,10,0
39868,kddiag_s_scr3,,,10,0
39869,kddiag_s_scr4,,,10,0
39870,kddiag_s_scr5,,,10,0
39872,kddiag_t_cyk1,,,10,0
39873,kddiag_t_cyk2,,,10,0
39874,kddiag_t_cyk3,,,10,0
39875,kddiag_t_cyk4,,,10,0
39876,kddiag_t_cyk5,,,10,0
39877,kddiag_t_inj1,,,10,0 ;injection times
39878,kddiag_t_inj2,,,10,0
39879,kddiag_t_inj3,,,10,0
39880,kddiag_t_inj4,,,10,0
39881,kddiag_t_inj5,,,10,0
39883,kddiag_pwr_inj1,,,10,0 ;injection capacity
39884,kddiag_pwr_inj2,,,10,0
39888,kddiag_t_feed1,,,10,0 ;plasticizing times
39889,kddiag_t_feed2,,,10,0
45756,kddiag_t_stamp,,,10,0 ;date
*** (Unit: Time [Hours] )

39813,sdstdtotal_ctrl,,,10,0,”Std” ;hours of operation total control voltage on
39814,sdstdtotal_motor,,,10,0,”Std” ;hours of operation total motor on
39815,sdstdtotal_auto,,,10,0,”Std” ;hours of operation total automatic mode
39839,kddiag_c_ophr_on1,,,10,0,“Std“
39852,kddiag_c_ophr_auto1,,,10,0,”Std” ;machine hours counter automatic mode
39853,kddiag_c_ophr_auto2,,,10,0,“Std“
39797,swstd_int1,,,5,0,”Std” ;set hours interval 1

39798,swstd_int1x,,,5,0,”Std” ;actual hours interval 1
39803,swstdmin_int2,,,5,0,”Std” ;set hours interval 2 minus 10 per cent
39804,swstdmax_int2,,,5,0,”Std” ;set hours interval 2 plus 10 per cent
39851,swdiag_month,,,5,0,”Std” ;current month

39838,kddiag_c_cyk,,,10,0,” ;cycle counter
45769,kddiag_c_cyk_m,,,10,0,” ;cycles counter
45770,kddiag_c_cyk_ref,,,10,0,” ;cycles counter reference

39823,kddiag_p_inj_max,,,3,1,”bar” ;maximum injection pressure

Version:G/11/12/7/3

45750,swmaint_int1,,,3,0,”%” ;set interval 1
45751,swmaint_int1x,,,3,0,”%” ;actual interval 1
45752,swmaintmin_int1,,,3,0,”%” ;set interval 1 90 percent
45753,swmaintmax_int1,,,3,0,”%” ;set interval 1 110 percent

39816,kddiag_f_cl_max,,,5,0,”kN” ;clamping force
*** (Without unit)

45614,swdiag_preset,,,1,0 ;resetting of diagnostic parameters
45754,kddiag_t_day_ref,,,4,1 ;days reference

45755,kddiag_t_day_m,,,4,1 ;days actual
39893,swdiag_operator,,,5,0 ;error counter, operator

39894,swdiag_info,,,5,0 ;error counter, general
39895,swdiag_digin,,,5,0 ;error counter, limit switch error
39896,swdiag_anain,,,5,0 ;error counter, analog input
39897,swdiag_hydr,,,5,0 ;error counter, hydraulics
39898,swdiag_clamp,,,5,0 ;error counter, clamping unit
39899,swdiag_inject,,,5,0 ;error counter, injection unit
39900,swdiag_oil,,,5,0 ;error counter, oil
39901,swdiag_lubrif,,,5,0 ;error counter, lubrication
39902,swdiag_waste,,,5,0 ;error counter, decrease
39903,swdiag_perif,,,5,0 ;error counter, peripheral unit
39904,swdiag_qual,,,5,0 ;error counter, quality
39905,swdiag_safety,,,5,0 ;error counter, safety equipment
39906,swdiag_control,,,5,0 ;error counter, control unit
39907,swdiag_moldtemp,,,5,0 ;error counter, mould temperature
39908,swdiag_mold,,,5,0 ;error counter, mould
39909,swdiag_prod,,,5,0 ;error counter, production

39822,kddiag_s_aw_mm10,,,8,1,”mm” ;ejector stroke [mm]
39824,kddiag_s_sdm_circ_mm10,,,8,1,”mm”;screw rotational stroke [mm]
39825,kddiag_s_mold_mm10,,,8,1,”mm” ;mold stroke [mm]
43365,kddiag_s_screw_mm10,,,8,1,”mm”;screw stroke [mm]
45757,kddiag_s_screw_mm_m,,,8,1,”mm”;screw stroke mm
45760,kddiag_s_aw_mm_m,,,8,1,”mm” ;ejector stroke mm
45763,kddiag_s_mold_mm_m,,,8,1,”mm”;mold stroke mm
-------------------------------------------------------------------------------
Group of variables accumulator
-------------------------------------------------------------------------------

06118,swakku_p_spr,15,20,3,1,”bar” ;accu pressure set value for injection
06120,swpakku,12,87,3,1,”bar” ;accu pressure set value
06317,swpamin,15,21,3,1,”bar” ;calculated switching-on pressure accu charging
07829,kodakku_max,,,3,1,”bar” ;bar/10 max. accu pressure (in the plaus.ec)
07897,koakkumax_24vk,,,3,1,”bar” ;max. accu pressure for the motor start in case of error 24vk
08029,kodhyst_n,,,3,1,”bar” ;bar accu pressure negative hysteresis
08035,kodakku,,,3,1,”bar” ;bar/10 for input calibration accu pressure

08031,koqakkul_p1,,,3,0,”%” ;pct volume accu charging
08972,koqakkul_p2,,,3,0,”%” ;pct volume accu charging
45203,koqakkul_p1ha,,,3,0,”%” ;pct volume accu charging in the manual mode (reduced)
45204,koqakkul_p2ha,,,3,0,”%” ;pct volume accu charging in the manual mode (reduced)

08030,kodakkul_p1,,,3,0,”%” ;pct druck akku lad
08971,kodakkul_p2,,,3,0,”%” ;pct druck akku lad
08028,kodruckab_n_l,,,3,2,”s” ;s100 pressure reduction time after accu charging
*** (Without unit)
08034,koklkomp_kf,,,1,0 ;output calibration calibration finished
18052,swpr_spa,15,22,1,0 ;injection with accu

08033,koqkompm,,,4,0,”mm/s” ;val max.speed screw return
-------------------------------------------------------------------------------
Group of variables rotary table - rotary table
-------------------------------------------------------------------------------
35917,koawlmax,,,4,1,”mm” ;l limitation if with rotary table
35918,koawl1min,,,4,1,”mm” ;l1 minimum limitation when index plate
;mounted on ejector !

05100,swvdtlb,02,36,3,0,”%” ;rotary table turning at the left braking
05101,swvdtl,02,37,3,0,”%” ;rotary table turning at the left
05102,swvdtrb,02,38,3,0,”%” ;rotary table turning at the right braking
05103,swvdtr,02,39,3,0,”%” ;rotary table turning at the right
08041,koqdty,,,3,0,”%” ;output on y-valve at rotary table turning
35208,kored9,,,3,0,”%” ;reduction factor rotary table volume
35923,koqdtmin,,,3,0,”%” ;minimum speed rotary table turning
35924,koqdtkal,,,3,0,”%” ;volume rotary table calibration/set-up
04801,swpdtlb,00,92,3,0,”%” ;rotary table turning at the left braking
04802,swpdtl,00,94,3,0,”%” ;rotary table turning at the left
04803,swpdtrb,00,96,3,0,”%” ;rotary table turning at the right braking

Version:G/11/12/7/3
04804,swpdtr,00,98,3,0,”%” ;rotary table turning at the right

35209,kored10,,,3,0,”%” ;reduction factor rotary table pressure
35919,koddt,,,3,0,”%” ;rotary table turning pressure at the left/at the right
35920,koddtb,,,3,0,”%” ;rotary table braking pressure at the left/at the right
35921,koddtmin,,,3,0,”%” ;minimum pressure rotary table turning
35922,koddtkal,,,3,0,”%” ;pressure-rotary table calibration/set-up
*** (Unit: Ramp [%] )

21783,koapdt_r,,,3,0,”%” ;pressure turn rotary table to the right brake on end position
21784,koavdt_r,,,3,0,”%” ;speed turn rotary table to the right brake on end position
35925,koapdt_l,,,3,0,”%” ;pressure turn rotary table to the left brake on end position
35926,koavdt_l,,,3,0,”%” ;speed turn rotary table to the left brake on end position
35927,koadtsoft,,,3,0,”%” ;speed pressure rotary table soft stop
35929,koavdts,,,3,0,”%” ;speed start acceleration speed rotary table
35930,koapdts,,,3,0,”%” ;pressure start acceleration speed rotary table

35939,kodtsfstp,,,4,1,”s” ;time rotary table soft stop
04902,swdtlgs,02,64,3,1,”s” ;rotary table braked starting at the left time

04903,swdtrgs,02,66,3,1,”s” ;rotary table braked starting at the right time
04904,swzpreli,08,36,3,1,”s” ;rotary table hitting duration at the left
04905,swzprere,08,37,3,1,”s” ;rotary table hitting duration at the right
04906,swdtbl,08,38,2,2,”s” ;monitoring time right end position - braking limit switch at the left
04907,swdtbr,08,39,2,2,”s” ;monitoring time right end position - braking limit switch at the left

35935,kosdtx_null,,,5,0,”mV” ;zero value input calibration
35936,kosdtx_max,,,5,0,”mV” ;max.value input calibration
*** (Without unit)

02655,swprdtfs,03,48,1,0 ;rotary table actuation at mould closing
04545,swdtbt,03,55,1,0 ;rotary table/index plate operation via core-pull x
04791,swprdvnaw,03,46,1,0 ;rotary table turning before/after ejection
08089,kodtprp,,,1,0 ;with rotary table prop.valve = 1
18082,swprdt,03,43,1,0 ;program rotary table yes/no
18083,swprbli,03,44,1,0 ;braking limit switch at the left yes/no
18084,swprbre,03,45,1,0 ;braking limit switch at the right yes/no
18087,swprdawm,03,47,1,0 ;rotary table mounted on ejector
32865,kodtmitbrends,,,1,0 ;1= rotary table with limit switch mounted
35912,koeadtp,,,1,0 ;rotary table with helical potentiometer = 1
35913,ko2ea16,,,1,0 ;mould swivelling device:
;0 = rotary table
;1 = index plate
35934,koklsdtx_kf,,,1,0 ;input calibration finished
35937,kovzsdtx,,,1,0 ;conf.algebraic sign input calibration
35940,kodtbueg,,,1,0 ;val rotary table/index plates-
;bridging of the standard input (left
;end position b39) at disassembly of the mould swivelling device
; 0 ... in the hardware
; 1 ... in the software
;(in the software only when no blind plug
;for standard in/outputs is provided.
;the bridging in the software is activated-
;automatically when the mould swivelling-
;device is switched off and the
;operation is set via standard-
;in/outputs.)
10054,koavdtby,,,5,0 ;[pct/degree] speed maximum ramp rotary table y valve
35928,koavdtb,,,5,0 ;[pct/grad] speed maximum ramp rotary table

10053,koavsdtby,,,5,0,”%/s” ;speed maximum start acceleration rotary table y valve
35931,koavsdtb,,,5,0,”%/s” ;speed maximum start acceleration rotary table
35932,koavdtow,,,5,0,”%/s” ;speed start acceleration without potentiometer
35933,koavdtbow,,,5,0,”%/s” ;pct/degree speed ramp braking output without potentiometer
*** (Unit: Angle [„] )
02610,swdtl,00,37,3,1,”„” ; pos rotary table at the left
02611,swdtlb,00,39,3,1,”„” ; pos rotary table at the left braking
02612,swdtr,00,41,3,1,”„” ; pos rotary table at the right
02613,swdtrb,00,43,3,1,”„” ; pos rotary table at the right braking
02616,swdtb,00,62,3,1,”„” ; stroke rotary table braking
04708,iwsdtx,01,88,3,1,”„” ;rotary table position actual value in degrees
35914,kodtb,,,3,1,”„” ;braking stroke rotary table/index plate
35915,kosdtmax,,,3,1,”„” ;angle degree maximum degree rotary table
*** (Unit: degrees/s [degrees/sec] )

08042,iwvdtx,12,93,3,0,”„/s” ;rotary table speed

08043,koqmaxdtp,,,4,0,”mm/s” ;max. speed rotary table prop.valve
-------------------------------------------------------------------------------
Group of variables 2nd injection/holding pressure service 2nd inject./hold.pressure service
-------------------------------------------------------------------------------

35663,ko2s11,,,4,1,”mm” ;maximum screw stroke
35665,ko2s15,,,4,1,”mm” ;maximum cushion and maximum correction
35827,ko2pnrres1,,,4,1,”mm” ;minimum value speed limit
41623,ko2opg_sbrems,62,66,4,1,”mm” ;optimization pressure limit braking position unit.2
35696,ko2d12,,,3,1,”bar” ;setting limitation for injection
35697,ko2d13,,,3,1,”bar” ;system pressure at injection
;with moog valve

Version:G/11/12/7/3
35698,ko2d14,,,3,1,”bar” ;system pressure at holding pressure

;with moog valve
35707,ko2d26,,,3,1,”bar” ;minimum pressure for injection
35716,ko2d46,,,3,1,”bar” ;k1 headroom for injection-
;and holding pressure control
38675,ko2dpurge,,,3,1,”bar” ;k valve purge pressure 2
41626,ko2p_ueberschw,,,3,1,”bar” ;max.value for overswinging at injection unit.2
41630,iw2overswing,62,70,3,1,”bar” ;pressure overswinging at injection stroke.2
41620,ko2opg_tol,62,63,4,0,”bar” ;tolerance speed deviation for screen display speed optimization unit.2
35699,ko2d15,,,4,1,”bar” ;maximum mould cavity pressure unit 2

35700,kd2d15,,,4,1,”bar” ;resolution mould cavity pressure transducer unit 2

23381,ko2kr_nd_pan,,,3,0,”%” ;reinforcement adaptation holding pressure on stop unit.2
23382,ko2kr_pgr_pan,,,3,0,”%” ;reinforcement adaptation pressure limit on stop unit.2
39956,sw2gm_tol_pos_1,,,3,0,”%” ;2.unit: positive tolerance monitoring_1
39957,sw2gm_tol_neg_1,,,3,0,”%” ;2.unit: negative tolerance monitoring_1

28340,ko2vstol,,,3,0,”%” ;tolerance speed deviation for new start
35675,ko2q4,,,3,0,”%” ;minimum speed (injection)
35680,ko2q13,,,3,0,”%” ;maximum volume during injection
35683,ko2q23,,,3,0,”%” ;volume stroke calibration screw
35685,ko2q25,,,3,0,”%” ;volume for injection at
;swivelled-out unit
35688,ko2q32,,,3,0,”%” ;volume moog on + after holding pressure
35793,ko2red4,,,3,0,”%” ;reduction factor injection speed
41721,ko2vstol_w,,,3,0,”%” ;tolerance speed dev.work

28451,ko2offsyks,,,3,0,”%” ;actuation back pressure valve in the idling unit.2
35722,ko2d53,,,3,0,”%” ;pressure - stroke calibration screw
35723,ko2d55,,,3,0,”%” ;actuation on p/q control valve in the idle running unit 2
35796,ko2red13,,,3,0,”%” ;reduction factor injection pressure
35797,ko2red14,,,3,0,”%” ;reduction factor holding pressure
*** (Unit: Ramp [%] )

35725,ko2a49,,,3,0,”%” ;speed injection - braking on stop
35733,ko2avspr,,,3,0,”%” ;start acceleration speed injection
35941,ko2a0,,,3,0,”%” ;pressure switchover to holding pressure
41625,ko2opg_abrems,62,68,3,0,”%” ;optimization pressure limit braking ramp unit.2
38674,ko2apurge,,,4,0,”%” ;ramp injection purge speed 2

39951,sw2gm_t_measure_1,,,5,0,”s” ;2.unit: measuring time (in sec) monitoring_1
35759,ko2zmoog,,,4,1,”s” ;moog on + after holding pressure

;and s4 deactuation delay
35841,ko2sfpvs,,,4,1,”s” ;injection and holding pressure peak value measurement delay
39952,sw2gm_t_delay_1,,,4,1,”s” ;2.unit: measuring delay (in sec) monitoring_1
08140,ko2zvspr,,,3,2,”s” ;injection delay after intrusion unit 2

08480,ko2zvspr_ana,,,3,2,”s” ;delay between s4 and analog actuation with controlled operation unit 2
10211,ko2vz_sum,,,3,2,”s” ; calculated value sum of delays to be expected before injection unit.2
35757,ko2zajd,,,3,2,”s” ;injection delay after reaching ”j”
35758,ko2zcld,,,3,2,”s” ;control employment delay
35765,ko2zvv,,,3,2,”s” ;shut-off nozzle opening before injection
35843,ko2z_as,,,3,2,”s” ;calculation value !!! time active back pressure
41627,ko2z_anstieg,,,3,2,”s” ;max.value for pressure increase at injection stroke.2
41631,iw2risetime,62,71,3,2,”s” ;pressure increase time at injection unit.2
28339,ko2tr_spr,,,2,3,”s” ;controller downtime and/or employment delay time

35802,ko2tv_spr,,,2,3,”s” ;closed loop injection control 2 tv
35803,ko2tn_spr,,,2,3,”s” ;closed loop injection control 2 tn
35815,ko2tv_pgrenz,,,2,3,”s” ;pressure limit closed loop control 2 tv
35816,ko2tn_pgrenz,,,2,3,”s” ;pressure limit closed loop control 2 tn
35822,ko2tv_nach,,,2,3,”s” ;holding pressure closed loop control 2 tv
35823,ko2tn_nach,,,2,3,”s” ;holding pressure closed loop control 2 tn
41719,ko2tr_spr_w,,,2,3,”s” ;spr_reg.tr work
41720,ko2tot_sys_w,,,2,3,”s” ;spr_reg t0 work
41722,ko2tv_spr_w,,,2,3,”s” ;spr_reg.tv work
41723,ko2tn_spr_w,,,2,3,”s” ;spr_reg.tn work
42059,ko2tot_sys,,,2,3,”s” ;system dead time t0 for ana 1.50
35800,kd2umax_spr,,,5,0,”mV” ;closed loop injection control 2 umax
35801,kd2umin_spr,,,5,0,”mV” ;closed loop injection control 2 umin
35813,kd2umax_pgrenz,,,5,0,”mV” ;pressure limit closed loop control 2 umax
35814,kd2umin_pgrenz,,,5,0,”mV” ;pressure limit closed loop control 2 umin
35820,kd2umax_nach,,,5,0,”mV” ;holding pressure closed loop control 2 umax
35821,kd2umin_nach,,,5,0,”mV” ;holding pressure closed loop control 2 umin
35899,ko2ssx_null,,,5,0,”mV” ;zero value input calibration
35900,ko2ssx_max,,,5,0,”mV” ;max.value input calibration
35902,ko2phx_max,,,5,0,”mV” ;max.value input calibration
35903,ko2pfx_null,,,5,0,”mV” ;zero value input calibration
35904,ko2pfx_max,,,5,0,”mV” ;max.value input calibration
35965,ko2phx2_null,,,5,0,”mV” ;zero value input calibration
35966,ko2phx2_max,,,5,0,”mV” ;max.value input calibration
39958,sw2gm_cnt_init_1,,,2,0,”Sch” ;2.unit: number initialization cycles monitoring_1
*** (Without unit)
23378,sw2pgr_error,08,60,1,0 ;pressure limit 2 releases injection stop
23822,ko2screwtype,,,1,0 ; 0 = standard screw, 1 = barrier screw unit.2
28337,ko2omode_v,,,1,0 ;optimization mode injection closed loop control

Version:G/11/12/7/3
28338,ko2start_opt_v,,,1,0 ;speed optimization start

35779,ko2ea14,,,1,0 ;leakage oil compensation at holding pressure-
;closed loop control via servovalve = 1 unit 2
35780,ko2ea15,,,1,0 ;s10 switching-off after injection 2
;for fast pressure reduction = 1
35799,ko2verea,,,1,0 ;closed loop injection control 2 on/off
35812,ko2verpgr,,,1,0 ;pressure limit closed loop control 2 on/off
35819,ko2pnrea,,,1,0 ;holding pressure closed loop control 2 on/off
35842,ko2cfg_as,,,1,0 ;active pressure handing-over holding pressure-back pressure
35897,ko2klssx_kf,,,1,0 ;input calibration finished
35906,ko2vzssx,,,1,0 ;configuration algebraic sign input calibration
39953,sw2gm_pr_mon_1,,,1,0 ;2.unit: program switch monitoring_1
39959,sw2gm_pr_cycinit_1,,,1,0 ;2.unit: program switch initalization cycles monitoring_1
41619,ko2omode_pp,62,62,1,0 ;optimization mode pressure limit closed loop control unit.2
41622,ko2opp_eabrems,62,65,1,0 ;optimization pressure limit braking point switch onoff unit.2
41628,ko2start_opt_pp,,,1,0 ;pressure optimization selection unit.2
09343,ko2cfg_vsd,,,2,0 ;shut-off nozzle type 0 = nozzle 1 = mould

09425,ko2cfg_vnach,,,2,0 ;mode: speed control in the
;holding pressure phase 0.. const
;1 .. via speed profile
35776,ko2ea7,,,2,0 ;cushion correction = 1 unit 2
35778,ko2ea13,,,2,0 ;parallel switchover = 1 unit 2
35955,ko2cfg_s4d,,,2,0 ;1 = differential connection unit 2
; (2s4d mounted)
39954,sw2gm_sel_abort_1,,,2,0 ;2.unit: selection interruption action monitoring_1
35805,ko2ks_spr,,,2,3 ;closed loop injection control 2 ks

35817,ko2kr_pgrenz,,,2,3 ;pressure limit closed loop control 2 kr
35818,ko2ks_pgrenz,,,2,3 ;pressure limit closed loop control 2 ks
41718,ko2ks_spr_w,,,2,3 ;spr_reg.ks work
35825,ko2ks_nach,,,3,1 ;holding pressure closed loop control 2 ks

35826,ko2kf_nach,,,3,1 ;holding pressure closed loop control 2 correction factor
35724,ko2pfakt,,,5,0 ;power factor for determining the maximum injection speed

;(= vemin * pmax) at machines with hls hydraulic system
35804,ko2kr_spr,,,5,0 ;closed loop injection control 2 kr
35824,ko2kr_nach,,,5,0 ;holding pressure closed loop control 2 kr
39949,sw2gm_sel_chan_1,,,5,0 ;2.unit: index on measuring channel for monitoring_1
39950,sw2gm_sel_mod_1,,,5,0 ;2.unit: mode bits for measurement on monitoring_1
39955,sw2gm_sel_idk_1,,,5,0 ;2.unit: number of the ideal curve monitoring_1
41621,sw2o_pp_state_r,62,64,5,0 ;screen display pp optimization unit.2
41717,ko2kr_spr_w,,,5,0 ;spr_reg.kr work
42146,sw2o_v_state_r,60,17,5,0 ;screen display speed optimization unit.2
*** (Unit: Maximum ramps [mm/s2] )

35740,ko2avssb,,,5,0,”mm/s2” ;maximum start acceleration screw absolute
35726,ko2a50,,,5,0,”%/s” ;speed switchover to holding pressure
*** (Unit: Maximum ramps [(mm/s)/mm] )

35737,ko2avsb,,,5,0,”/s” ;maximum acceleration / delay screw absolute
39960,sd2gm_t_monle_1,,,4,2,”s” ;2.unit: monitoring window left edge monitoring_1
39961,sd2gm_t_monri_1,,,4,2,”s” ;2.unit: monitoring window right edge monitoring_1

12993,ko2qanschl,,,4,0,”mm/s” ;volume injection on stop
35686,ko2q26,,,4,0,”mm/s” ;auxiliary variable in ar2prof
35730,ko2q11,,,4,0,”mm/s” ;volume holding pressure at hls hydraulic system
;volume holding pressure on y at servo closed loop control
41624,ko2opg_vbrems,62,67,4,0,”mm/s” ;optimization pressure limit braking speed unit.2
-------------------------------------------------------------------------------
Group of variables 2nd carriage unit service - 2nd injection unit service
-------------------------------------------------------------------------------

35664,ko2s12,,,4,1,”mm” ;maximum nozzle stroke
35666,ko2s21,,,4,1,”mm” ;stop in front of stop nozzle at the back
35667,ko2s22,,,4,1,”mm” ;calculation value, reserved !!!!
35829,ko2sj,,,4,1,”mm” ;allowed nozzle movement j recognition

10103,ko2p5_ab,,,3,1,”bar” ; contact pressure switching-off value
10104,ko2p5red_ab,,,3,1,”bar” ; contact pressure red.switching-off value
10105,ko2d56,,,3,1,”bar” ;tolerance for reached contact pressure
;j = reached at (p5-kod56)
35705,ko2d23,,,3,1,”bar” ;minimum pressure for nozzle

10186,ko2red21,,,3,0,”%” ;reduction factor nozzle return speed
35676,ko2q5,,,3,0,”%” ;volume at the nozzle pressure build-up
35677,ko2q6,,,3,0,”%” ;minimum speed (nozzle)
35682,ko2q21,,,3,0,”%” ;volume stroke calibration nozzle
35689,ko2q47,,,3,0,”%” ;volume pressure reduction carriage
35792,ko2red3,,,3,0,”%” ;reduction factor nozzle forward speed

35694,ko2d5,,,3,0,”%” ;pressure at carriage (b not actuated)
35695,ko2d6,,,3,0,”%” ;pressure at nozzle return
35721,ko2d52,,,3,0,”%” ;pressure - stroke calibration nozzle
35798,ko2red17,,,3,0,”%” ;reduction factor nozzle forward pressure

Version:G/11/12/7/3
*** (Unit: Ramp [%] )

35731,ko2avduv,,,3,0,”%” ;start acceleration speed nozzle forward
35732,ko2avduz,,,3,0,”%” ;start acceleration speed nozzle return
35942,ko2a10,,,3,0,”%” ;speed braking on j1
35944,ko2a15,,,3,0,”%” ;speed braking on k
35949,ko2a42,,,3,0,”%” ;pressure steep ramp end position remaining movements

35830,ko2zjrl,,,4,1,”s” ;measurement time at j determination
10106,ko2zduv,,,3,2,”s” ;waiting time after nozzle pressure build-up

35756,ko2znfd,,,3,2,”s” ;nozzle forward delay in automatic mode
35766,ko2zvp5r,,,3,2,”s” ;pressure build-up before pressure reduction carriage
35767,ko2zp5r,,,3,2,”s” ;pressure reduction carriage
35768,ko2znp5r,,,3,2,”s” ;k,y,s5 delayed after pressure reduction carriage

05736,sw2sdx0s,08,11,5,0,”mV” ;offset-sdx-zero value in mm 2.a.
08087,ko2sdx_null,,,5,0,”mV” ;zero value input calibration
35898,ko2sdx_max,,,5,0,”mV” ;max.value input calibration

35828,ko2zjm,,,4,0,” ;number of measurements at standstill of the nozzle (j determination)
*** (Without unit)
08054,ko2klsdx_kf,,,1,0 ;input calibration finished
10107,ko2cfg_p5,,,1,0 ;contact pressure build-up
; 0 = via time z5a
35905,ko2vzsdx,,,1,0 ;configuration algebraic sign input calibration

35736,ko2avdb,,,5,0,”%/mm” ;maximum acceleration / delay nozzle movement

35739,ko2avsdb,,,5,0,”%/s” ;maximum start acceleration nozzle movement
-------------------------------------------------------------------------------
Group of variables 2nd plasticizing/screw retraction service -2nd plast./decompres.service
-------------------------------------------------------------------------------
35663,ko2s11,,,4,1,”mm” ;maximum screw stroke
35665,ko2s15,,,4,1,”mm” ;maximum cushion and maximum correction

35703,ko2d20,,,3,1,”bar” ;setting limitation for back pressure
37243,ko2psmin,,,3,1,”bar” ;minimum reachable back pressure at ehv1 unit.2
35674,ko2q3,,,3,0,”%” ;minimum speed (plasticizing)
35683,ko2q23,,,3,0,”%” ;volume stroke calibration screw
35684,ko2q24,,,3,0,”%” ;volume for back pressure calibration
35691,ko2qkom_min,,,3,0,”%” ;minimum speed decompression
35794,ko2red5,,,3,0,”%” ;reduction factor plasticizing speed
35795,ko2red6,,,3,0,”%” ;reduction factor retraction speed

35704,ko2d22,,,3,0,”%” ;maximum pressure at plasticizing
35706,ko2d24,,,3,0,”%” ;pressure screw retraction
35722,ko2d53,,,3,0,”%” ;pressure - stroke calibration screw
*** (Unit: Ramp [%] )

35728,ko2avkome,,,3,0,”%” ;speed braking on c2,c4
35729,ko2avkoms,,,3,0,”%” ;speed start decompression
35734,ko2avdos,,,3,0,”%” ;start acceleration speed speed plasticizing
35943,ko2a14,,,3,0,”%” ;speed braking on c1
35950,ko2a46,,,3,0,”%” ;pressure braking on c1

35789,ko2rpm_min,,,3,0,”/min” ;minimum screw speed
35790,ko2rpm,,,3,0,”/min” ;maximum screw speed

10776,ko2zv_s24,,,3,2,”s” ;delay after decompression
35760,ko2sfpss,,,3,2,”s” ;back pressure peak value measurement delay
35769,ko2zvs24,,,3,2,”s” ;delay between plasticizing and decompression on c2
35771,ko2zs4,,,3,2,”s” ;hls: plasticizing: s4 energizes delayed to s3 and: s3 de-energizes delayed to s
35843,ko2z_as,,,3,2,”s” ;calculation value !!! time active back pressure
28332,ko2tv_dz,,,2,3,”s” ;speed closed loop control tv unit.2

28333,ko2tn_dz,,,2,3,”s” ;speed closed loop control tn unit.2
28336,ko2t0_dz,,,2,3,”s” ;speed closed loop control tr unit.2
35808,ko2tv_stau,,,2,3,”s” ;closed loop back pressure control 2 tv
35809,ko2tn_stau,,,2,3,”s” ;closed loop back pressure control 2 tn

10364,kd2ustart_stau,,,5,0,”mV” ;back pressure control 2 ustart
28330,kd2umax_dz,,,5,0,”mV” ;speed closed loop control umax unit.2
28331,kd2umin_dz,,,5,0,”mV” ;speed closed loop control umin unit.2
35806,kd2umax_stau,,,5,0,”mV” ;closed loop back pressure control 2 umax
35807,kd2umin_stau,,,5,0,”mV” ;closed loop back pressure control 2 umin
35899,ko2ssx_null,,,5,0,”mV” ;zero value input calibration
35900,ko2ssx_max,,,5,0,”mV” ;max.value input calibration
*** (Without unit)

28328,ko2enable_dz,,,1,0 ;allow speed closed loop control unit.2

Version:G/11/12/7/3
28329,ko2tst_dz,,,1,0 ;speed closed loop control on-off unit.2

35842,ko2cfg_as,,,1,0 ;active pressure handing-over holding pressure-back pressure
35897,ko2klssx_kf,,,1,0 ;input calibration finished
35906,ko2vzssx,,,1,0 ;configuration algebraic sign input calibration
09629,ko2cfgyks_reg,,,2,0 ;back pressure valve ehv2/3 open loop controlled unit.2:

;0 .. pressure proportional valve
;1 .. flow control valve
;2 .. servo control valve
28335,ko2ks_dz,,,2,3 ;speed closed loop control ks unit.2

35811,ko2ks_stau,,,2,3 ;closed loop back pressure control 2 ks
10044,ko2lk_dreh,,,3,2 ; waste oil compensation factor screw rotation
28334,ko2kr_dz,,,5,0 ;speed closed loop control kr unit.2

35791,ko2imp,,,5,0 ;impulses per screw revolution
35810,ko2kr_stau,,,5,0 ;closed loop back pressure control 2 kr

35738,ko2avdr,,,5,0,”%/mm” ;maximum acceleration / delay screw rotation
35742,ko2avkomb,,,5,0,”%/mm” ;maximum acceleration / delay pressure relief movement
35741,ko2avsdr,,,5,0,”%/s” ;maximale start acceleration screw movement
35743,ko2avskomb,,,5,0,”%/s” ;maximum start acceleration pressure relief movement
-------------------------------------------------------------------------------
Group of variables 2nd injection/holding pressure - 2nd injection/hold.pressure
-------------------------------------------------------------------------------

02126,sw2c1,14,88,4,1,”mm” ; metering stroke
02127,sw2c1m,01,89,4,1,”mm” ; metering stroke corrected
02128,sw2c2,14,89,4,1,”mm” ; decompression stroke after plasticizing
02129,sw2c2m,01,90,4,1,”mm” ; decompression stroke after plasticizing corrected
02130,sw2c3,14,90,4,1,”mm” ; pos c3-position for switchover holding pressure
02132,sw2cp,14,97,4,1,”mm” ; cushion ”ideal value”
02133,sw2cpmin,16,02,4,1,”mm” ; cushion minimum length
02134,sw2cpmax,16,04,4,1,”mm” ; cushion maximum length
02138,sw2c17,14,93,4,1,”mm” ; flow number measurement start position
02139,sw2c18,14,95,4,1,”mm” ; flow number measurement end position
02140,sw2c2b,16,05,4,1,”mm” ; switchover to 2nd injection speed
02141,sw2c2c,16,08,4,1,”mm” ; switchover to 3rd injection speed
02142,sw2c2d,16,11,4,1,”mm” ; switchover to 4th injection speed
02143,sw2c2e,16,13,4,1,”mm” ; switchover to 5th injection speed
02144,sw2c2f,16,15,4,1,”mm” ; switchover to 6th injection speed
02145,sw2c2g,16,17,4,1,”mm” ; switchover to 7th injection speed
02146,sw2c2h,16,19,4,1,”mm” ; switchover to 8th injection speed
02147,sw2c2i,16,21,4,1,”mm” ; switchover to 9th injection speed
02148,sw2c2j,16,23,4,1,”mm” ; switchover to 10th injection speed
02153,sw2c3b,16,33,4,1,”mm” ; window at hydraulic pressure switchover holding pressure
02154,sw2c3d,16,35,4,1,”mm” ; window at parallel switchover
04684,iw2ssx,01,36,4,1,”mm” ;screw position -actual
04692,iw2c3u,01,44,4,1,”mm” ;screw position at switchover
04705,iw2cpx,01,91,4,1,”mm” ;cushion length - actual
22105,sw2stift,14,77,4,1,”mm” ;kistler 2: pin diameter
40433,sw2c3a,60,05,4,1,”mm” ; switchover point to holding pressure when moving in mould unit.2
43478,sw2c3l,50,60,4,1,”mm” ;purging position

04654,sw2kfp,03,61,2,2,”bar” ;flow number-closed loop control-correction factor
04622,sw2p6,00,65,3,1,”bar” ; injection pressure
04623,sw2p7,00,66,3,1,”bar” ; 1.holding pressure
04641,sw2ph,00,88,3,1,”bar” ; hydraulic pressure switchover value
04656,sw2fzpt,03,63,3,1,”bar” ;flow number-tolerance-closed loop control
04685,iw2phx,01,37,3,1,”bar” ;hydraulic pressure-actual
04687,iw2phx2,01,39,3,1,”bar” ;hydraulic pressure 2
04689,iw2phu,01,41,3,1,”bar” ;hydraulic pressure at switchover to holding pressure
04693,iw2pvs,01,45,3,1,”bar” ;hydraulic pressure peak via injection
04694,iw2pns,01,46,3,1,”bar” ;hydraulic pressure peak value via holding pressure
04701,iw2korrp,01,53,3,1,”bar” ;positive correction size of the flow number calculation
04702,iw2korrm,01,54,3,1,”bar” ;negative correction size of the flow number calculation
23434,id2korr_fz,03,72,3,1,”bar” ;+/- correction size of the flow number calculation unit.2
04642,sw2pf,00,90,4,1,”bar” ; mould cavity pressure switchover value

04686,iw2pfx,01,38,4,1,”bar” ;mould cavity pressure display
04690,iw2pfu,01,42,4,1,”bar” ;mould cavity pressure at switchover to holding pressure
04691,iw2pfs,01,43,4,1,”bar” ;mould cavity pressure peak holding pressure
32765,ko2pm_max,,,4,1,”bar” ; maximum melt pressure unit.2
34696,sw2pm,,,4,1,”bar” ; melt pressure switchover set value unit.2

06230,iw2c3u2,19,72,3,2,”mm” ;host:c3u in 1/100 for process data
06232,iw2cpx2,19,73,3,2,”mm” ;host:cushion in 1/100 for process data

Version:G/11/12/7/3
04618,sw2v23,02,34,3,0,”%” ; intrusion speed

04644,sw2z2,02,44,4,1,”s” ;holding pressure time (2nd unit or gasmelt)
04647,sw2zin,02,50,4,1,”s” ;intrusion time (2nd unit or gasmelt)
04901,sw2spv,02,62,4,1,”s” ;injection delay time unit 2
04643,sw2z1,02,42,3,2,”s” ;injection time (2nd unit or gasmelt)

04650,sw2zs0,02,54,3,2,”s” ;injection time min (2nd unit or gasmelt)
04651,sw2zs1,02,56,3,2,”s” ;injection time max (2nd unit or gasmelt)
04697,iw2zsx,01,49,3,2,”s” ;injection time
10083,sd2z2j,08,26,3,2,”s” ; holding pressure part-time 10/10 (2nd unit)
34636,sd2zylvdon_zeit,35,03,3,2,”s” ; cylinder shut-off nozzle connection delay unit.2
34637,sd2zylvdof_zeit,35,04,3,2,”s” ; cylinder shut-off nozzle switching-off delay unit.2
39075,ko2zvpns,,,3,2,”s” ;s100 peak hold 2 press. measuring delay

24375,ko2kitestmin,,,5,0,”mV” ; kistler test minimum voltage unit.2
24376,ko2kitestmax,,,5,0,”mV” ; kistler test maximum voltage unit.2

05557,sw2cntpurge,50,57,2,0,” ;purging counter
*** (Without unit)

01905,sw2prft,03,54,1,0 ;injection in mould parting surface unit 2
03745,swpraggw,06,87,1,0 ;unit selection 1st component
04657,sw2pr3,03,29,1,0 ; external switchover to holding pressure
04659,sw2pr10,03,30,1,0 ; stroke-dependent switchover
04660,sw2pr11,03,31,1,0 ; time-dependent switchover
04661,sw2pr13,03,32,1,0 ; flow number
04662,sw2pr16,03,33,1,0 ; hydraulic pressure-dependent switchover
04663,sw2pr17,03,34,1,0 ; mould cavity pressure-dependent switchover
04664,sw2pr18,03,35,1,0 ; cushion monitoring
04667,sw2pr21,03,38,1,0 ; switchover parallel
04668,sw2pr2,03,39,1,0 ; increased injection pressure
15680,sw2plast_new,05,85,1,0 ;autom.param.setting mplast
18081,sw2pragg,03,42,1,0 ; unit switch 2
18092,sw2pr24,03,52,1,0 ; force/pressure transducer kistler 2
18118,sw2asmel,03,53,1,0 ; unit 2 signals rejects
22107,sw2kbereich,14,81,1,0 ;kistler 2nd force measuring range
22109,sw2dbereich,14,85,1,0 ;kistler 2nd pressure measuring range
24305,ko2lv_type,08,57,1,0 ;kistler charge amplifier type
28812,ko2kisttest,,,1,0 ;1= kistler test output activated
34695,sw2prumpm,,,1,0 ; switch over as a function of melt pressure unit.2
41629,sw2pro_tol_pp,62,69,1,0 ;action to be released when monitoring outside tolerance unit.2
04653,sw2fz,03,60,3,1 ;flow number set value

04655,sw2fzft,03,62,3,1 ;flow number-tolerance-monitoring
04698,iw2fzx,01,50,3,1 ;flow number
06231,iw2fzx2,19,71,3,2 ;host: flow number in 1/100 for process data

22106,sw2kempf,14,79,3,2 ;kistler2: force transducer sensitivity
22108,sw2dempf,14,83,3,2 ;kistler2: pressure transducer sensitivity

10084,sd2z2i,08,27,4,2,”s” ; holding pressure part-time 9/10 (2nd unit)
10085,sd2z2h,08,28,4,2,”s” ; holding pressure part-time 8/10 (2nd unit)
10086,sd2z2g,08,29,4,2,”s” ; holding pressure part-time 7/10 (2nd unit)
10087,sd2z2f,08,30,4,2,”s” ; holding pressure part-time 6/10 (2nd unit)
10088,sd2z2e,08,31,4,2,”s” ; holding pressure part-time 5/10 (2nd unit)
10089,sd2z2d,08,32,4,2,”s” ; holding pressure part-time 4/10 (2nd unit)
10090,sd2z2c,08,33,4,2,”s” ; holding pressure part-time 3/10 (2nd unit)
10091,sd2z2b,08,34,4,2,”s” ; holding pressure part-time 2/10 (2nd unit)
10092,sd2z2a,08,35,4,2,”s” ; holding pressure part-time 1/10 (2nd unit)
39962,id2gm_t_dev_1,,,4,2,”s” ;2.unit: deviation moment monitoring_1
04603,sw2v12,02,19,4,0,”mm/s” ; 1.injection speed
04699,iw2vsprx,01,51,4,0,”mm/s” ;speed actual value at speed calibration
04700,iw2vsprmax,01,52,4,0,”mm/s” ;maximum injection speed
38672,ko2vplim,,,4,0,”mm/s” ;mm/s injection purge speed limit 2
38673,ko2vplim_swiv,,,4,0,”mm/s” ;mm/s purge speed at swivelled unit 2
-------------------------------------------------------------------------------
Group of variables 2nd carriage unit - 2nd injection unit
-------------------------------------------------------------------------------

02236,sw2j1,14,98,4,1,”mm” ; pos j1-start 2nd nozzle speed forward
02237,sw2k,16,00,4,1,”mm” ; pos k-nozzle retracted
04683,iw2sdx,01,35,4,1,”mm” ;nozzle position - actual

04600,sw2v9,02,16,3,0,”%” ; 1.nozzle speed forward
04601,sw2v10,02,17,3,0,”%” ; 2.nozzle speed forward
04602,sw2v11,02,18,3,0,”%” ; nozzle speed return

04620,sw2p5,00,63,3,0,”%” ; contact pressure
04621,sw2p5a,00,64,3,0,”%” ; holding pressure carriage unit

Version:G/11/12/7/3

04646,sw2z6,02,48,4,1,”s” ;nozzle retraction delay time (2nd unit or gasmelt)
04652,sw2z5a,02,58,3,2,”s” ;contact pressure build-up time (2nd unit or gasmelt)
*** (Without unit)

04666,sw2pr20,03,37,1,0 ; nozzle retraction
-------------------------------------------------------------------------------
Group of variables 2nd plasticizing/back pressure/screw retraction -2nd plast./back press./decompres.
-------------------------------------------------------------------------------

02126,sw2c1,14,88,4,1,”mm” ; metering stroke
02127,sw2c1m,01,89,4,1,”mm” ; metering stroke corrected
02128,sw2c2,14,89,4,1,”mm” ; decompression stroke after plasticizing
02129,sw2c2m,01,90,4,1,”mm” ; decompression stroke after plasticizing corrected
02131,sw2c4,14,91,4,1,”mm” ; pos c4-decompression 1 end
02132,sw2cp,14,97,4,1,”mm” ; cushion ”ideal value”
02133,sw2cpmin,16,02,4,1,”mm” ; cushion minimum length
02134,sw2cpmax,16,04,4,1,”mm” ; cushion maximum length
02149,sw2c4b,16,26,4,1,”mm” ; switchover to 2nd plasticizing speed
02150,sw2c4c,16,28,4,1,”mm” ; switchover to 3rd plasticizing speed
02151,sw2c4d,16,30,4,1,”mm” ; switchover to 4th plasticizing speed
02152,sw2c4e,16,31,4,1,”mm” ; switchover to 5th plasticizing speed
09711,iw2ssxs,03,69,4,1,”mm” ;metering stroke stored unit.2

04633,sw2p17,00,78,3,1,”bar” ; 1.back pressure
04695,iw2pss,01,47,3,1,”bar” ;back pressure peak value
04613,sw2vdz1,02,29,3,0,”%” ; 1.screw speed
04619,sw2v24,02,35,3,0,”%” ; screw retraction speed

04688,iw2dzx,01,40,3,0,”/min” ;screw speed display

04645,sw2z3,02,46,4,1,”s” ;plasticizing delay time (2nd unit or gasmelt)
04648,sw2zdmax,02,52,4,1,”s” ;plasticized time maximum (2nd unit or gasmelt)
04649,sw2zdmin,02,53,4,1,”s” ;plasticized time minimum (2nd unit or gasmelt)
04696,iw2zdx,01,48,4,1,”s” ;plasticizing time
32858,iw2zdx2,19,13,3,2,”s” ;plasticizing time
*** (Without unit)

04665,sw2pr19,03,36,1,0 ; plasticizing time monitoring
05554,sw2proef_c2,08,15,1,0 ;opening from c2* unit.2
-------------------------------------------------------------------------------
Group of variables without dimension
-------------------------------------------------------------------------------
35500,kocfg00,,,* ;configuration reserved !!

35833,ko2cfg01,,,* ;configuration reserved !!
35836,ko2cfg04,,,* ;configuration reserve
35995,kdmax_neg_s,,,* ;val 0 or 10000 (see pginit)
35997,ko_a_vd,,,* ;switch screw speed calibration algorithm
35998,ko_d_vy,,,* ;switch dialog speed calibration
35999,ko_d_vd,,,* ;switch dialog screw speed calibration
35996,ko_a_vy,,,* ;switch speed calibration algorithm

Version:G/11/12/7/3

Version:G/11/12/7/3
REVISIONS (11)
Change directory for technical manual
1 INNOVATIONS IN THIS PRESENT VERSION

The revision of the control software EV9.42 and the introduction of the system software
SV2.12b represent adaptations to the main revision EV9.40. EV9.42 includes no functional
extension in comparison with the EV9.40.
The main revision of the control software EV9.40 and system software SV2.11 has been
condition for the introduction of a new machine series (Raccoon) and options connected with
it and prepared in the standard, which are cleared order-referred by compiling or license
granting. EV9.40 also includes the North American standard with separate options frequently
used there.
Essential characteristic towards the outside is the new screen surface, which presents itself in
an optically appealing outfit with grey background and 3D effects.
Versions EV9.42, SV2.12+ Help

Date / origin / new edition / auditor 15.01.2002 / G/11/12/7/2 / G/11/12/7/3 / sei text
Reason Revision subject Chapter/

item.
Version V Version table update (1)1 -
Supplement V SIT key functions (3)/16.1 -
Adaptation V Putting into operation guidelines Bosch amplifier card added (1)/3.11.2 -
SDD1672 High speed mounting with 2 magnets, improved sequence (3)16.2 x

supplement V
Supplement V Reference to self-optimization (6)/2.1new -
Supplement V Pressure transducer, overview improved, text corrections (5)/2.4.1, -

2.4.1.1 and
2.4.1.2 new
Supplement V Absolute value input can be switched on-off in the operator setup (2)/9.3.4 -
Supplement V Selection for function of the ejector safety SAW1 and SAW2 added in (2)/9.3.4 -
the operator setup
Supplement V Selection for the number of the shut-off nozzles possible in the operator (2)/9.3.4 -
setup
Supplement Kistler amplifier type designation corrected (3)/16.5 -

C
Supplement Swivel out unit (only documentation) (3)/11.7new -

new
Supplement V Printer model HP990cxi added, setting list for LX300+ inserted (9)/1.1, -
1.4new
Version V List of variables (10)/ -
Supplement Changeover to Frame 6.0, standard format (Chapter) all -

C
Creation date: 20.02.2002 Revisions (11)

Version:G/11/12/7/3
2 REVISION OF THE PREDECESSOR VERSION
Versions EV9.40, SV2.11 Help

Reason Revision subject Chapter/

item.
Version N Version table update (1)1 -
Version N Start image (2)/2.2, 3.2, -
Adaptation N Control families (1)/2 -
Adaptation N Putting into operation guidelines Bosch amplifier card added (1)/3.11.2 -
Supplement typical offset voltages for pressure transducer (5)/2.4.1 -

C
Supplement V Type CU212/M added for EC100/mono (1)/3.3.1 -
Supplement Adaptation printer types, data cable, serial-parallel converter (9)/1.1, 1.1.2,
C 1.4, 1.5new
Correction C Increased opening force: Designation stroke position WAK instead of (3)/15, 14.1.2 x
WA4
Revision Kistler charge amplifier (3)/16.5 x
ECM Euromap 12 / SPI: Divided-up error messages (3)/16.3
Extension Serial-parallel converter for ink jet printer connection (9)/1.5 new
Adaptation Digital input-digital output occupation adapted (1)/3.6, 3.8 -
List of vari- List of variables update (10) -

ables
SDD71 Separate core releases at ERC and Euromap 12 (3)/16.3 x

revised
SDD87 Screen page Operator setup (1)/3.4.2, x

(2)/9.3, 9.3.1,
9.3.4new,
(3)/3.2, 9.1.1,
11.2
SDD1567 Heating zones monitoring circuit protected better (4)/ x

1.2.5added.
SDD1672 High speed mounting device with 2 magnets per mould fixing platen (3)/17.2 x
SDD1682 More heating zone texts (only Var-Text) (4)/1.2.6 -
SDD1684 One push-button for core-pull: Setting possibility via push-button setup (2)/9.3.3 -
SDD1685 Display of sample number in the hardware check under ’SW version’ (2)/3.4 -
SDD1687 Autoprotect mould protection: Reference curve is not lost with control (3)/9.1.2 x
voltage off/on.
SDD1699 Docu charge amplifier revised (3)/16.5.2 x
SDD1807 Ejector with 2-stage profile (option) (3)/7, 15 x
Revisions (11) Creation date: 20.02.2002

Version:G/11/12/7/3
Versions EV9.40, SV2.11 Help

SDD1821 HLS1 hydraulic and toggle lever schemes taken out (1)/3.4.1, -
Closed loop clamping force control taken out, 3.4.2,
hydraulic-mechanical closing safety taken out (3)9, 9.1.1,
erased:
9.1.3,9.1.7,9.
1.8,9.1.9,
9.1.10, 14.1.
changed
10, 10.1,
13.2, 14,
(5)/1.1.2,
2.6erased.
SDD1823 Oil temperature maximum limited to 50°C (2)/6 -
SDD1830 Open suction valve before beginning closing in manual mode and 1st (3)/9 -
automatic cycle can be set with pressure and volume
SDD1848 Shut-off nozzle with double magnet (3)/11, 12 -

Safety-technical hints also for signal in and output wiring, Euromap12
(3)/16.3.2
SDD1851 Socket switching-off multiple (3)/16.7 -
SDD1855 2. Set-up pressure at mould closing with spring split mould (3)/6, 9.1.1 x
Creation date: 20.02.2002 Revisions (11)

Version:G/11/12/7/3
Revisions (11) Creation date: 20.02.2002

Version:G/11/12/7/3
Symbols Cooling time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

%-Regul. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153 Core movements on one key . . . . . . . . . . . . . . . . . . . . . . . . . .83
CPU - BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
CPx . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Numerics CU211/D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
24VK1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
CU211/E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
24VK1S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
CU211/F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28, 29
24VKN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
CU212 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
24VKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Current loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
5039A221 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142
Cushion correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84, 117
CUSHION ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
A Cut back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101 Cycle time analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
A1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100 CYLINDER HEATING DEFECTIVE . . . . . . . . . . . . . . . . . . . . 148
Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 Cylinder heatings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
acoustic warning signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145
active back pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .183 D
Alarm lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
d HP870CXi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
AR 281 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Data loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
AR101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39, 186
DECOMPRESSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
AR161 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .186
Decompression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
AR181 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
DI325 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
ARST program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
DIF1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
as 141 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
DIF2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
As a function of mould cavity pressure . . . . . . . . . . . . . . . . .117
Differential connection at mould closing . . . . . . . . . . . . . . . . 128
AS141 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .160
Differential connection at mould opening . . . . . . . . . . . . . . . 128
Automatic offset determination . . . . . . . . . . . . . . . . . . . . . . . .170
Dimming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Autoprotect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
DINF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
DIOEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
B DO_STAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Back pressure calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . .172 DO25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Back pressure controller . . . . . . . . . . . . . . . . . . . . . . . . 182, 187 DO321 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27, 48
Back pressure equal to zero . . . . . . . . . . . . . . . . . . . . . . . . . .131 DO321/16/B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Back pressure profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120 DO321/B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
BOSCH SERVO VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . .185
Bright period of time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 E
Bus couple card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
E-8-THERMO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Bypass filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
Ebias errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
EBIAS32.BIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
C EBIAS-ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
C1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121 E-BT-AN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
C1M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117 EC100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
C2M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117 EC100-A03/mono . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Cable break monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63 EC100-S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Calibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .159 EC100-S-A03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Capacity display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153 ECC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
Capacity indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74 ECC program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
Carriage unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111 E-CRT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Cbh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153 E-CRT/EL/A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30, 33
CC100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 E-CRT-EL/A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
CC100-A03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17, 18 EHV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Change parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .223 EHV1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36, 96
Charge amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142 EHV2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36, 96
Check sum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 EHV3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36, 96
Check sum error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69 Ejection balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Check sums . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69 Ejector forward delay time . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Clock time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152 Ejector fwd. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Closed loop control employment delay . . . . . . . . . . . . . . . . .186 Ejector residence time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
CLOSED LOOP CONTROL VIA PUMP . . . . . . . . . . . . . . . .180 ejector retracted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Closed loop position control . . . . . . . . . . . . . . . . . . . . . 181, 183 Ejector shaking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Closed loop speed control . . . . . . . . . . . . . . . . . . . . . . . . . . . .175 EJECTOR STROKE POS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Coding numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 EL display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Colour flat display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 E-LCD-AN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22, 23, 33
Component number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .191 electric safety gate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Contact pressure build-up time . . . . . . . . . . . . . . . . . . . . . . . .111 electrohydraulic closing safety . . . . . . . . . . . . . . . . . . . . . . . . 109
Contact pressure relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123 Electromagnetic compatibility . . . . . . . . . . . . . . . . . . . . . . . . . .10
continuous piston rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118 Emergency mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
CONTROL PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . .151 EMV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Control voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67 Eproms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Controller mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153
Creation date: 20.02.2002 Printing date: 25.2.2002

299
Version:G/11/12/7/3
Epson Stylus Colo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229 ks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

Error signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
E-SEK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 L
E-SP-CC100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Leakage oil compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
E-SP-CCEC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 LICENSE.BIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
EUROMAP 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 Light barrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Extension rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Linearizations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Logic voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
F LV5039 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
FAST VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 LV5049 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142, 143
FECUNI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154 LX300+ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
FLOPPY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 M
Flushing program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 M1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
FULLY AUTOMATIC M. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Machine size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Magnetic card reader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
G Malfunction message record . . . . . . . . . . . . . . . . . . . . . . . . . 218
GATE LIMITSW.DEF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 MANUAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
GC201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24, 33 Matrix printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
GC201/A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Graphic submodules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Mold cavity pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 Mold opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
mold protection lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
H MOLD STROKE POS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
HA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 MOLD TRANSDUC.DEF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
HA output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Monitoring switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Handling device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 MOOG SERVO VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Handling system integrated . . . . . . . . . . . . . . . . . . . . . . . . . . 134 Motor on delta . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Handling system Stand Alone . . . . . . . . . . . . . . . . . . . . . . . . 134 MOTOR START SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . 76
Hardware test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 MOULD HEATING DEFECTIVE . . . . . . . . . . . . . . . . . . . . . . 148
Hardware test image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Mould heatings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Heat penetration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 Mould height stroke transducer . . . . . . . . . . . . . . . . . . . . . . . 163
Heating / cooling ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152 Mould prot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Heating-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 Mould protection test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
High pressure build-up time . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Mould stroke transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
High speed cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 mount/dismount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
High speed mould mounting device . . . . . . . . . . . . . . . . . . . 132 MR122 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
HKV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
HOLDING PRES.AT DEMOLDING . . . . . . . . . . . . . . . . . . . . 125 N
Holding pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182 NG//12-9-1-5//#D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
Hydraulic pressure-dependent . . . . . . . . . . . . . . . . . . . . . . . . 117 Nozzle contact point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Nozzle forward delay time . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
I
IBM PC keyboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235 O
Idling outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 OC 101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
in ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49, 50, 51 OC101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
INCREASED INJECTION PRESSURE . . . . . . . . . . . . . . . . 118 of the nozzle contact point . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Increased opening force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 Offset determinat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Injection cushion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Oil filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Injection delay time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 OIL HEATING PROGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Injection pressure limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 Oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
INJECTION SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181 OIL MONITORING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Injection unit swievel out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 Oil preheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Ink jet printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229 Oil tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Interface occupation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 Oil temperature monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
interface records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Operator setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Optimization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Interl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Iron-constantan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154 P
Pakt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
J PARALLEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
J determination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 Parallel operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Parallel switchover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
K PARAM.BIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
Keyboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235 Partial flow motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
K-FTC-AN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
K-FTC-AN/A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Pause time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Kistler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 PD record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Kr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181 Peripheral equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

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Personnel number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64 Screw speed linearization . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

Pilot control value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .181 SEA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Plasticizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120 Search . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
Plasticizing delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121 SEARCH PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
Plasticizing number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88 SECONDARY MOVEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Plasticizing stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116 SELF-OPTIMIZATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Plasticizing work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88 SEMIAUTOMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
P-number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .224 Semiautomatic mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Position monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145 Sequence errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
POWER FACTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118 Service menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
Power voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67 Service mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
PP081 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147 Servo valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Precise repeatability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .183 SET UP MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
Pres.control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .175 Setting profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Pressure limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181, 186 Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Pressure linearization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .164 SHE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Pressure opening profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126 Short circuit monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Pressure reduction before opening . . . . . . . . . . . . . . . . . . . .126 Shut-off nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116, 120
Pressure reduction nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . .120 SI 024/BI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Pressure switchover ramp . . . . . . . . . . . . . . . . . . . . . . . . . . . .177 SI020 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55, 57
Pressure transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108, 169 SI232 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55, 56
Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .229 SI485/422 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55, 58
Production data collection . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94 Signal-Debugger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223, 227
PROGRAM INTERRUPTION . . . . . . . . . . . . . . . . . . . . . . . . . .95 SIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Program loading key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 SmartAmp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Proportional band . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151 Soaking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148, 149
PS243 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52 Sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
PS244 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67 Special Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
PS244/A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52 Specific back pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
PS244/B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52 Speed limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
PU key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95 Speed linearization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Pump control card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64, 88 SR161/B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
PUMP INTERCONNECTION . . . . . . . . . . . . . . . . . . . . . . . . .100 standardized signal outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Push-button occupation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83 Start-up delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Push-button setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80 Start-up ramp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Putting into operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .223 Start-up safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Start-up zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
R Status report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190, 222
RAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30, 223 Stroke calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
RAM test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70 stroke linearization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Rate time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152 Stroke transducer calibration . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Readjusting time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152 Stroke transducer examination . . . . . . . . . . . . . . . . . . . . . . . . 160
Re-cycle time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131 Stroke-dependent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Regulator mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153 Switchover area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Release and blocking signals . . . . . . . . . . . . . . . . . . . . . . . . .137 Switchover point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Remaining time calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . .94 Switchover type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
RESET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30, 72 swivelled out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
RETRACT NOZZLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124 System error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189, 194
Return carriage unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
RETURNLINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48 T
RS 485 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58 T0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
RS232-C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56 TANK SHUT-OFF FLAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
Tank shut-off flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
S TEMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
S12A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102, 128 Temperature control devices . . . . . . . . . . . . . . . . . . . . . . . . . . 154
S6A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123 TEMPERATURE CONTROL UNITS WITH SERIAL CONNEC-
Safety button SIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131 TION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Safety gate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93 TEMPERATURE DEVIATION . . . . . . . . . . . . . . . . . . . . . . . . . 148
SAFETY GATE INTERRUPTS CYCLE . . . . . . . . . . . . . . . . .141 Text input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
Safety gate special executions . . . . . . . . . . . . . . . . . . . . . . . .109 Text printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
Safety program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68 TFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Safety shut-off valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109 Thermocouple break . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
SC 021 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55 Three-point controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
SC 101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55 TIME AND DATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
SCANLINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48 Time-dependent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Screen background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87 Tn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
SCREEN LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .221 Toggle lever machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Screw position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116 Toggle lever stroke transducer . . . . . . . . . . . . . . . . . . . . . . . . 163
Screw retraction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91, 122 TT081 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25, 42, 147
TT081/5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

301
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Tv . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
U
User code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
USTART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
V
Valve calibration program . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
W
Waiting points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Watchdog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Watchdogs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Week switch clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
WRONG MOLD HEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
X
XE8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
XE8Q . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Xph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Z
Z5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
ZA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
ZAV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Zone mode of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
ZUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

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MICROCOMPUTER

This manual has been established for information and/or trainings.

© Copyright by ENGEL Maschinenbau Gesellschaft m.b.H.

PUTTING INTO OPERATION (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Creation date: 20.02.2002

8.1 SETTING OF TIME AND DATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

MOVEMENT SEQUENCE / MACHINE FUNCTIONS (3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Creation date: 20.02.2002

15 ADVANCE AND RETURN EJECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

TEMPERATURE CONTROL (4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

CALIBRATION AND LINEARIZATION (5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

CLOSED LOOP CONTROL (6). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

Creation date: 20.02.2002

2.3.5 BACK PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

ERROR SIGNALS (7). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

TEST AND PARAMETERS (8). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223

PRINTER / TEXT INPUT (9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

Creation date: 20.02.2002

TABLES (10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237

REVISIONS (11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295

Creation date: 20.02.2002

Creation date: 20.02.2002

In connection with the operator’s manual this technical manual shows

Creation date: 20.02.2002 Hardware (1)

1.1 ELECTROMAGNETIC COMPATIBILITY

Fully automatic self-diagnostics (hardware check) and a comprehensive trouble-shooting

Hardware (1) Creation date: 20.02.2002

Control system family:

2.1 COMPATIBILITY TO OLDER CONTROL SYSTEM VERSIONS

The read-in values must be checked and/or entered newly, however as in

2.2 SURVEY OF COMPONENTS

All mentioned modules and elements are in CE-suitable execution.

Designation Articles- Use hint

Power supply modules

PD 242/A 2203 7620 x x x Voltage distribution printed board assembly

PS244/A 2203 7606 x x x x Power supply module

PS244/B 2203 7651 x x x Power supply module

PS243 2203 7264 x x x Power supply module

Creation date: 20.02.2002 Hardware (1)

All mentioned modules and elements are in CE-suitable execution.

Central modules, memory modules

CU 211/D 2203 7751 x x x CC100/EC100 central module with 32-bit pro-

CU 211/E 2203 7692 x x x CC100/EC100 central module with 32-bit pro-

CU211/F 2203 7693 x CC100 central module with 32-bit processor

CU212 2203 7711 x CC100/central module with 32-bit processor

Digital I/O modules

DO 321/B 2203 7611 x x x x Digital ouptut module 32 channels plus switch-

DO 321/16/B 2203 7612 x x x x Digital output module 16 channels plus switch-

DI 325/B 2203 7613 x x x x Digital input module 32 physically separated

RO161/A 2203 7682 x x x Relay output module, 16 outputs

Measuring and control modules

AR 181 2203 7616 x x x Analog measuring and control module with

AR 181/A 2203 7656 x x x Analog measuring and control module with

AR 181/B not used x x x Analog measuring and control module with

AR 181/C 2203 7687 x x x Analog measuring and control module with

AR 101 2203 6429 x x x Analog measuring and control module with

AR281 2203 7699 x x x Analog measuring and control module with

Hardware (1) Creation date: 20.02.2002

All mentioned modules and elements are in CE-suitable execution.

Rack complete, couple elements, blind printing plates

CR 092 2203 7602 x x x x Rack with KEMRO-BUS standard rack for

FP 004 LC 2203 7604 x x x Blind printing plate 4TE

FP005 LC 2203 7605 x x x Blind printing plate 5TE

AS 141 2203 7153 x x x Serial stroke transducer interface