ES30-500 CM EV901 Vertical 6750-772-9998M

:
EC100 / CC100 A03

VERTICAL CLAMP,
INJECTION MOLDING MACHINES
CONTROLLER - MAINTENANCE
5630 772 9998M
55 to 300 TON
EV901.AUS
Re-Issued: 2005-11-14
These documents remain the property of ENGEL (Canada) Inc. And must
not be copied without the written consent of ENGEL (Canada) Inc.
The contents of this manual may neither be made known to third parties or
be used for non-approved purposes.
© 2005 Copyright by ENGEL CANADA INC.

Guelph, Ontario, Canada
:
EC100 / CC100 A03 MAINTENANCE:
INTRODUCTION
This manual is Part 2 of a 2 part manual.
Part 1 is the Operator Manual.
Part 2, the Maintenance Manual, contains the controller screen pages relevant to maintenance
and troubleshooting. These include the "Service Menu", "Heat P.I.D.", "P & V Control Parameters"
and "Waiting Points". Also included is other information designed for the use of trained
maintenance personnel.
It is recommended that the Operator Manual be used in conjunction with this manual. Problems
with the machine can often be resolved by a change in a set value on a screen page rather than
an actual mechanical adjustment. A listing and description of error messages, along with
corrective measures, is contained in the Operator Manual. This should be the first point of
reference should a problem occur.
WARNING!
Some procedures described in this manual, ie. a change in set values,

may affect the safe operation of the machine. Therefore only suitably
trained personnel should attempt these procedures. If any doubt exists,
as to whether machine safety would be compromised, then ENGEL
SERVICE must be consulted.
23/12/05 introduction i
23/12/05 introduction ii
EC100 / CC100 A03 MAINTENANCE
EC100 / CC100 A03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1. SYSTEM ARCHITECTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1. MICROPROCESSOR BASED CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2. TFT FACEPLATE (CC100) - REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3. CARD RACKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.4. TROUBLESHOOTING NOTE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2. HARDWARE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1. ELECTRO - STATIC SENSITIVE DEVICES (ESD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2. SURVEY OF EPROMS - CC100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3. CARD CODING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4. CPU CARD CU211 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5. LOADING THE SOFTWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6. DIGITAL INPUT CARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7. DIGITAL OUTPUT CARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
8. TEMPERATURE CARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
9. ANALOG CARD - AR181 / SR161 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
10. PRESSURE AND CLAMPFORCE TRANSDUCER . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
10.1. POSITION STROKE TRANSDUCERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
11. SERVO VALVE (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
12. PROPORTIONAL VALVE AMPLIFIER CARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
12.1. BOSCH PROPORTIONAL VALVE WITH INTEGRATED AMPLIFIER . . . . . . . . . 49
13. PS-244 POWER SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
3. PERIPHERAL DEVICE INTERFACES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
1. RS-232 SERIAL INTERFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
2. OTHER SERIAL INTERFACES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
2.1. SERIAL INTERFACES EXTENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
2.2. EXPANSION MODULE SC101A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2.3. CARRIER MODULE SC021 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3. SYSTEM EXTENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.1. EXTENSION RACKS, BUS CONNECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.1.1. Number of extension racks: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
3.1.2. Bus connection cable: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
3.1.3. Bus terminating module: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
3.1.4. Jumper settings: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
4. SPI DEVICES INTERFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4.1. SPI DEVICES INTERFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
5. CENTRAL COMPUTER (HOST) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
5.1. GENERAL PROGRAM INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
5.2. CONTROL CHARACTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
5.3. FORMATS OF "DATA POSTS" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
4. SERVICE MENU. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
1. ACCESS RIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
2. SERVICE MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
3. SETUP PROGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
3.1. MACHINE SET UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
3.2. SYSTEM SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
1 23/12/05
3.3. PUSH BUTTON SETUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
3.3.1. VARIABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
3.3.2. SET-UP/CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
3.4. OPERATOR SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
3.5. MOLD ROT. D SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
4. VALVE CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
4.1. CALIBRATION SCREEN IMAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
4.2. CALIBRATION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
4.2.1. Speed Calibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
4.2.2. Pressure Calibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
4.3. SCREW RPM CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
4.4. TOGGLE STROKE TRANSDUCER (ENGEL ONLY) . . . . . . . . . . . . . . . . . . . . . . 117
4.5. STROKE CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
4.5.1. STROKE CALIBRATION PAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
5. TEST AND PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
5.1. PROGRAM STATUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
5.2. SIGNAL DEBUGGER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
5.2.1. STEPS TO EXAMINE DIGITAL OUTPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . 130
5.2.2. STEPS TO EXAMINE DIGITAL INPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
5.2.3. STEPS TO EXAMINE INPUTS MARKERS . . . . . . . . . . . . . . . . . . . . . . . . . . 138
5.3. VARIABLE DEBUGGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
5.3.1. STEPS TO EXAMINE SET VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
5.4. SGM DEBUGGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
5.4.1. STEPS TO EXAMINE ANALOG OUTPUTS . . . . . . . . . . . . . . . . . . . . . . . . . 145
5.5. SERIAL I / O DEBUGGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
5.6. STATUS REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
5.7. DATE AND TIME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
5.8. TEMPERATURE CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
5.9. SPI STATUS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
5.10. END ACCESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
5. MACHINE FUNCTION PROFILES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
1. ROTARY TABLE SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
2. MOLD CLOSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
2.1. TYPICAL TOGGLE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
2.2. TYPICAL DIRECT HYDRAULIC MACHINE - 60 TL . . . . . . . . . . . . . . . . . . . . . . . 164
2.3. TYPICAL DIRECT HYDRAULIC MACHINE - 200TL . . . . . . . . . . . . . . . . . . . . . . . 165
2.4. CLAMPING PRESSURE BUILD UP FOR EHV PUMP MACHINES . . . . . . . . . . . 166
2.5. DESCRIPTION OF DIAGRAM SYMBOLS AND ABBREVIATIONS . . . . . . . . . . . 166
3. CARRIAGE UNIT FORWARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
3.1. PRESSURE AND SPEED DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
3.2. DESCRIPTION OF DIAGRAM SYMBOLS AND ABBREVIATIONS: . . . . . . . . . . . 170
4. INJECTION AND HOLDING PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
5. PLASTICIZING AND DECOMPRESSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
6. CARRIAGE UNIT RETURN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
23/12/05 2
6.2. DESCRIPTIONS OF DIAGRAM SYMBOLS AND ABBREVIATIONS . . . . . . . . . . 179
7. MOLD OPENING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
7.1.1. TYPICAL TOGGLE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
7.1.2. TYPICAL DIRECT HYDRAULIC MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . 181
8. EJECTOR FORWARD AND RETURN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
6. OTHER MACHINE DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
1. WAITING POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
2. HARDWARE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
3. SYSTEM AND EBIAS ERRORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
3.1. EBIAS ERRORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
3.2. SYSTEM ERRORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
3.3. SYSTEM ERROR NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
3.4. EBIAS ERROR NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
7. FINE TUNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
1. HEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
1.1. HEAT P.I.D. 0-15 - (TEMPERATURE CONTROL CARD) . . . . . . . . . . . . . . . . . . . 277
1.2. DESCRIPTION OF THE SCREEN PAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
1.2.1. OPEN LOOP CONTROL: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
1.2.2. SELF-TUNING: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
1.3. DISPLAY OF HEAT ZONE PARAMETERS: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
2. PRESSURE AND VELOCITY CONTROLS
(SERVO VALVE EQUIPPED ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
2.1. P & V - CONTROL PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
2.2. ADJUSTING P & V CONTROL PARAMETERS. . . . . . . . . . . . . . . . . . . . . . . . . . . 290
2.3. OPTIMIZING THE CONTROL PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
8. APPENDIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
1. NOTES/CONVERSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
2. DIGITAL INPUTS (STANDARD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
2.1. DI325 CARD 1 (STANDARD CONFIGURATION) . . . . . . . . . . . . . . . . . . . . . . . . . 302
2.2. DIGIN ; CARD 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
2.3. DIGIN ; CARD 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
2.4. DIGIN ; CARD 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
3. DIGITAL OUTPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
3.1. DIGOUT CARD 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
3.2. DIGOUT CARD 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
3.3. DIGOUT CARD 3 (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
3.4. DIGOUT CARD 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
4. POWERED SAFETY GATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
5. PRINTER SET-UP EXAMPLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
5.1. F5 - DEVICES SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
5.2. DEVICE PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
5.2.1. PRINTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
5.2.2. ELECTRONIC STORAGE MEDIA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
3 23/12/05
5.2.3. F6 - setup GENERAL PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
5.2.4. F7 - STOP PRINTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
5.3. FACIT PRINTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
5.4. EPSON PRINTER EX800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
5.5. OKIDATA 182 PLUS PRINTER (HIGH SPEED ONLY) . . . . . . . . . . . . . . . . . . . . 320
5.6. OKIDATA 172 & 182 PLUS PRINTER (SUPER SPEED ONLY) . . . . . . . . . . . . . 320
5.7. HEWLET PACKARD DESKJET 800 SERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
6. CLAMP FORCE TRANSDUCER (LVDT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
6.1. REPLACE OR ADJUST CLAMP FORCE TRANSDUCER - TYPE LG83 . . . . . . . 324
6.2. REPLACE OR ADJUST CLAMP FORCE TRANSDUCER - TYPE LG93 . . . . . . . 325
6.3. TROUBLESHOOTING PROPORTIONAL VALVE CIRCUIT . . . . . . . . . . . . . . . . . 326
6.4. HOW TO SET UP PRESSURE VALVE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
6.5. HOW TO SET UP SPEED VALVE TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
7. VARIABLE SET VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
VARIABLE PARAMETER LISTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
REVISION LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
23/12/05 4
1. SYSTEM ARCHITECTURE
PF SK
U U
PH
U
AR181/SR161 TT 081
DO 325 DI 321 ANALOG
CU211
SC101 / SC021
V24 V24
24oC
Printer
Text Input
Central- Ext. Temp.

Computer Control Robot
BAR CODE READER
23/12/05 1. SYSTEM ARCHITECTURE 1

EC100 / CC100 - A03 MAINTENANCE:
1.1 MICROPROCESSOR BASED CONTROL
The block diagram above represents the functional layout of a computer based control system.
The input and output blocks represent the system interfaces to the outside industrial environment.
For example, an input might be a measure of temperature, pressure, flow rate, or any other
transducer feedback relevant to the process control. It could also be a set value entered by the
operator via the screen monitor. An output might be a signal to turn on a specific solenoid which
would cause a particular action. (i.e. clamp close).
The memory block contains the instructions that are to be performed by the control and arithmetic
blocks (i.e. set values). As well, this block contains the basic machine instructions which control
how the machine uses the set values (i.e. machine parameters).
The arithmetic block represents the area where all system control calculations are carried out. It
is based on a series of logic functions which, provide a basis for complex system control.
The control block directs the flow of information from the input to the memory, to the ALU for
processing and out again through the specific output channel.
2 1. SYSTEM ARCHITECTURE 23/12/05

The subcomponents of the control system are located on separate "cards" which are plugged into
a backplane in the control unit. The backplane is also referred to as the "Motherboard". The
"Motherboard" provides all of the internal wiring (bus system) which allows the separate
subcomponents to "communicate" with each other.
For example, the address bus provides an individual location in memory to or from which data is
transferred. The data bus is the transport vehicle for the actual data and is generally half the size
of the address bus. The control bus provides the pathway for control signals such as read, write,
or enable.
The microprocessor operates on a 5 Vdc signal to carry out its logic calculations. For example, a
24V limit switch signal is read by the Digital input card and is converted to digital binary 5 volt
signal before being sent to the microprocessor. The 5 volt digital signal from the microprocessor
is converted on the Digital output card to a 24 volt analog signal before being applied to a
particular solenoid.
Since the microprocessor only deals with digital signals, when the signal it receives is analog (i.e.
pressure feedback) or when the signal it sends must be analog (K or Y valve)? The signal goes
through an analog to digital conversion (ADC) or through a digital to analog conversion (DAC).
ANALOG TO DIGITAL CONVERSION
The microprocessor makes decisions based on physical parameters such as pressure or velocity.
Since the microprocessor only deals with digital information, the analog signals must be quantified
and coded into machine language. Since analog data is representative of some physical
parameter, it is important that the analog data varies in proportion to the physical parameter it
represents. As an example of ADC, the 3 volt analog signal below, would be converted to binary
machine language as 0011 using a 4-bit system.

DIGITAL TO ANALOG CONVERSION
After processing information to be directed to an analog device (i.e. Y or K valve), the binary
machine language must be converted to an analog signal. Typically, a number of power sources
within the microprocessor are switched on or off.(i.e. ON =1 = 5 volts; OFF = 0 = 0 volts), and then
summed together to form an analog output. The example below shows a digital machine
language signal being summed together to form a 7 volt analog output signal.

1.2 TFT FACEPLATE (CC100) - REAR
CAUTION!
This unit contains Electro-static Sensitive Devices, use

safe handling procedure as described in
Chapter 2 page 1 of this manual.
Operator panel
E-CON-CC100/A
(rear view)
K-TFT-AN/CCFT
CC100-A03-TFT-CABLE
GC201/A
CC100-CON-PS-CABLE
PS244/A CONTROL
Attach cable
shield
OC101/A EC/CC100-RK-CON
IF212/1
KFTCAN - DATA - CABLE
+24V KL1
KL1 0V
0V
S3 24V power supply cable
+24V S6 (Engel manufacture)
S8
OC101 FLOPPY CABLE
S9
S5 S4 Attach
cable
shield!
S9
K-FTC-AN/A Floppy drive FD353
Option
CC100 - KEYSWITCH
KEYBOARD - CABLE
PRINTER - CABLE
Magnetic card reader MR122

is connected to connector S5 of the
OC101/A instead of the keyswitch
Switch panel
E-SP-CCEC
or
E-SP-CCEC/A
(rear view)
Attach cable Attach cable
shield! shield!
Keyswitch
MF102 PC Keyboard
Printer

FACEPLATE (EC100) - REAR
Operator panel
E-CON-EC100
(rear view)
E-LCD-AN
E-LCD-DAT-CABLE
E-CRT/EL/A
CC100-CON-PS-CABLE
PS244/A Control
Attach cable
shield!
O C1 0 1 / A
EC/CC100-RK-CON
IF212/1
K L1
KFTCCAN-DATA-CABLE
: +24V
0V S3 24V power supply cable
0V S6
+24V (Engel manufacture)
KL1
S8
OC101 FLOPPY-CABLE
S9
S5 S4 Attach cable
shield!
S9
KEYBOARD CABLE
K-FTC-ANA/A
Floppy drive FD353
CC100-KEYSWITCH CABLE
Optional:
PRINTER CABLE
Magnetic card reader MR122

is connected to connector S5 of the
OC101/A instead of the keyswitch
Switch panel
E-SP-CCEC
or
E-SP-CCEC/A
(rear view)
Attach cable Attach cable
shield! shield!
MF102 PC Keyboard Keyswitch
Printer

1.3 CARD RACKS
CAUTION!
When removing electronic cards from the rack, follow the

Electro-static sensitive Device (ESD) safe handling pro-
cedure. See chapter 2 page 1 for ESD safe handling pro-
cedure.
1.4 TROUBLESHOOTING NOTE
As soon as you receive the machine, take note of the normal state of all LED's within the
electronic cabinet. This includes Digital input cards, Digital output cards, AR161 Analog card,
E8 Temperature cards and the PS242 power supply card.
Recording the normal state of these LED's, will enable you to quickly determine the area of the
problem if you experience any minor electronic problems.
As well, if the maintenance technician is allowed access into the "TEST AND PARAMETERS"
area of the controller the activation/ de-activation state of all digital inputs and digital outputs can
be viewed on the screen monitor. See Service Menu - Test and Parameters.
If the machine is equipped with a graphics printer, these troubleshooting pages can be printed out
for future reference. This would be extremely useful for the maintenance technician in tracking
machine problems. If the technician has a printout of the state of all digital inputs and outputs
when the machine is running problem free, it will be simple to identify input or output channels that
are causing problems in the future.
Digin - Digital Input Card

If the LED is lit, a digital input signal is being received.
Digout - Digital Output Card

If the LED is lit, a digital output signal is being switched on.
PS242 Power Supply Cards

Indicates whether +12 volts, -12 volts and +5 volts are being produced.
Temperature Control Card

Red and Green status LED's and White LED's indicating that a heating or cooling output is being
activated.
Analog Card
QV1 output reset signal for mold cavity pressure transducer;
b1E mold height motor revolution count - 1 impulse per revolution;
DZ screw rpm input signal - 1 impulse per revolution;
C3E external boost to hold transfer input port.


2. HARDWARE
1 ELECTRO - STATIC SENSITIVE DEVICES (ESD)
CAUTION!
Treat all electronic cards as if they contain electrostatic

sensitive devices.
To prevent damage to electronic equipment during ser-
vicing, follow the safe handling instructions given below.
SAFE HANDLING PROCEDURE.
All electronic cards and units described in this chapter contain Electro-static Sensitive Devices.
These devices can be easily damaged by the static charge built up on a person’s body.
The simple act of standing up and walking up to a machine can generate up to 5000 Volts of static
charge. If the card or component is touched, the static field surrounding your body can damage
one or more of the semi-conductor junctions inside the integrated circuit.
The fault introduced on an integrated circuit can cause the whole card to become defective. The
fault may not become apparent until sometime later. This faulty card could seriously degrade the
performance of the machine.
Because of the possibility of damaging an integrated circuit, all the electronic cards on the
machine must be handled with special static sensitive protective precautions.
WARNING!
If the following precautions are not adhered to, the card

may become damaged and result in degraded machine
performance and/or lost production.
Before any card is removed or replaced, the maintenance technician must ensure that:
1. The machine is grounded to the mains supply earth. This can be achieved via
the mains supply cable ground conductor, even when the power is turned off.
2 A conductive mat is connected to the designated grounding point on the
electronic card rack. A green socket is provided on the left-hand side of the card
rack.
3. The maintenance technician is connected to the conductive mat, by means of a
conductive wrist strap and cable.
23/12/05 2. HARDWARE 9
Only then, after these procedures have been followed, may the technician remove a card from the
rack or the anti-static bag that the new card is supplied in.
When replacing a card in the rack:

1. Remove the card from the rack and place it on the conductive mat.
2. Remove the new card in the anti-static bag from the anti-static box.
3. Remove the new card from the anti-static bag and install it in the rack.
4. Take the old card and place it into the anti-static bag.
10 2. HARDWARE 23/12/05
2 SURVEY OF EPROMS - CC100
23/12/05 2. HARDWARE 11
3 CARD CODING
All cards, except the Power Supply card, the E-CGC card, and the CPU card, can be placed in
any location in the motherboard. The CPU card can differentiate between the separate cards by
their switch position numbers. The coding switches are the small blue plastic boxes located on the
cards below, numbered from 0-F in hexadecimal.
This can be useful when troubleshooting defective cards. For example, assume that you suspect
a defect in Digital Input card #1. Remove another Digital Input card, change the switch position to
that of the first input card, re-insert the card and see if the problem is corrected. If so, the first
digital input card was defective and a replacement card is required. Below are listed the specific
card numbers and their relevant switch position numbers.
Card type Card number Switch position

TT 081 THERMO 1 0 NOTE
TT 081 THERMO 2 1 Only 8 temperature cards are permitted
TT 081 THERMO 3 2 within the system, using other switch
TT 081 THERMO 4 3 positions will lead to address overlap
TT 081 THERMO 5 4 which may cause a system malfunction.
TT 081 THERMO 6 5
TT 081 THERMO 7 6
TT 081 THERMO 8 7
-------------------------------------------------------------------------------------------------------------------------------
DO321 1 0 NOTE
DO321 2 1 For the first 16 cards the
DO321 3 2 Jumper J1 setting must be “b - c”
DO321 4 3 If more than 16 cards are used the
DO321 5 4 Jumper J1 can be set to “a - b” and
DO321 6 5 the address codes started from “0”
DO321 7 6 again up to “F”.
DO321 8 7
DO321 9 8
DO321 10 9
DO321 11 A
DO321 12 B
DO321 13 C
DO321 14 D
DO321 15 E
DO321 16 F
-------------------------------------------------------------------------------------------------------------------------------
DI325 1 0 NOTE
DI325 2 1 For the first 16 cards the
DI325 3 2 Jumper J1 must be open circuit.
DI325 4 3 If more than 16 cards are used the
DI325 5 4 Jumper J1 can be closed and
DI325 6 5 the address codes started from “0”
DI325 7 6 again up to “F”.
12 2. HARDWARE 23/12/05
Card type Card number Switch position
DI325 8 7
DI325 9 8
DI325 10 9
DI325 11 A
DI325 12 B
DI325 13 C
DI325 14 D
DI325 15 E
DI325 16 F
-------------------------------------------------------------------------------------------------------------------------------
AR181 1 4 NOTE
AR181 2 5 Within the same rack, master
AR181 3 6 modules must not have the
AR181 4 7 same address
AR181 5 8 i.e. AR181, CU211, CU201
AR181 6 9
AR181 7 A
AR181 8 B
AR181 9 C
AR181 10 D
AR181 11 E
-------------------------------------------------------------------------------------------------------------------------------
CU211 1 1 NOTE
Within the same rack, master
modules must not have the
same address
i.e. AR181, CU211, CU201
During initialization the cards
with the address switch set to 1
get the highest priority.
When another card rack is required in order to accommodate extra cards, the bus coupling card
E-i/o-BUS-KOPPL is used.. The card numbers are continued, but the coding numbers start from
the beginning again.
RC100 Integration 1 C
2 D
Refer to chapter 3.3 of this manual for further information on System extensions.
23/12/05 2. HARDWARE 13
4 CPU CARD CU211

The CPU card is the master decision maker for the control system. Based upon certain inputs to
the CPU card's microprocessor (80386SX 32 bit), certain "decisions" are made and the CPU will
signal other cards to react to those decisions. Communication between the CPU card and most of
the other cards is effected through a "motherboard". The proportional valve amplifier card is
mounted in the card rack for convenience only. It does not plug into the motherboard.
The CPU card is equipped with 1M RAM memory for storage of the machine parameters
(linearization tables, set values, etc.). The RAM memory is maintained in control voltage "OFF"
situations by a 3.6 volt lithium battery. The battery is connected via a jumper installed as shown
on the CPU card drawing on the following page. If the battery becomes defective (i.e. voltage
potential below 3 volts), error '2 - CPU LOW BATTERY' will appear indicating that condition.
The CPU card is also equipped with 1M of EPROM memory as outlined in the EPROM summary.
The CPU card acts as the "master" to the slave cards, AR181 Analog Card and TT081 -
Temperature card. The CPU sends the AR181 Analog Card a certain mold closing profile.
The AR181 Analog Card will then take over the task of monitoring the closing profile and when the
profile has been completed, the AR181 Analog Card will "inform" the CPU card.
The Temperature card reacts in much the same way with regard to temperature profiles.
All of the instructions and communications between the CPU card and the Analog and
Temperature cards are timed. If the sequence of timed events does not go according to the
software plan, a "watchdog" timer is tripped and the machine will immediately stop cycling. If this
happens, the operator should switch the control voltage off, and then on again to activate the main
title page. The operator can then identify the specific system or EBIAS error causing the problem
by referring to the bottom display area on the screen.
The CC100-A03 requires a floppy disk interface which is achieved by the E-HSI-RS232 interface
submodule mounted on the SC021 motherboard which is then, as a unit, mounted directly onto
the CPU card.
At the top of the CPU card, there is a black push buttons which must never be pressed by the
operator. Pressing this button will totally disable the machine. An Engel trained maintenance
technician uses the black push-button to load EBIAS sequence programs into the RAM memory.
Pressing the push-button will "dump" the RAM memory and all calibrations and mold set-ups will
be lost. This will also cause re-loading of the RAM memory with stored EPROM values.
As a troubleshooting note, it is possible to identify system errors in situations when the main
monitor screen will not activate. At the bottom of the CPU card are two sets of 8 red LED's. The
bottom set displays various interrupt type situations of little interest to the maintenance technician.
The top set, however, displays component and system error numbers.
14 2. HARDWARE 23/12/05
Display of System Errors on Status LEDs
The status LEDs, located at the bottom front edge of the CPU card, show the component number
and the system error in BCD (Binary Coded Decimal) format. The data is shown in a timed
sequence, as indicated in the figure over the page.
Synchronization Sequence Component Error Number

Run Err Run Err Run Err Run Err Run Err Run Err Run Err
Bat Bat Bat Bat Bat Bat Bat
Status Status Status Status Status Status Status
7 7 7 7 7 7 7
6 6 6 6 c1 6 c3 6 e1 6 e3
5 5 5 5 5 5 5
4 4 4 4 4 4 4
3 3 3 3 3 3 3
2 2 2 2 c0 2 c2 2 e0 2 e2
1 1 1 1 1 1 1
0 0 0 0 0 0 0
REPEATING SEQUENCE
Example: Component 1234 c0 = 4; c1 = 3; c2 = 2; c3 = 1
Error Number 5678 e0 = 8; e1 = 7; e2 = 6; e3 = 5
The sequence begins with the Synchronization sequence, then the Component number
sequence, and finishes with the Error number sequence. The sequence will repeat until the error
is cancelled.
NOTE!
The Component and Error numbers are displayed in

reverse order.
Refer to the figure above for the sequence of LEDs.
Observe the sequence of the LEDs on the CPU card, and as the Synchronization sequence ends
with all LEDs off, the next sequence will be the Component number sequence, note the position
of the lit LEDs for each phase of the sequence.
23/12/05 2. HARDWARE 15
Each phase of the sequence will display two numbers via a set of eight LEDs. The set of LEDs
has two groups of four LEDs. The four LEDs represent, a four digit binary number.
A lighted LED equals one, and an unlit LED equals zero.
The binary number must to be converted to a decimal First LED = 1

number in the following manner. Second LED= 2
Third LED = 4
Fourth LED = 8
Add together the numbers that correspond to the LEDs that are on, follow the example shown on
the previous page. The first number in the component number sequence (c0), has the third LED
on. This corresponds to a binary number of 0100 or a decimal number 4. The second number
(c1), has the first and second LEDs on. These LEDs correspond to the binary number of 1100 or
decimal number of 1 + 2 = 3. The third number (c2) has the second LED on. This LED
corresponds to binary 0010 or decimal 2. The fourth number (c3) has the first LED on. This LED
corresponds to binary 0001 or decimal 1.
Note down the LEDs that are on for each sequence to derive the component number, in this case
the numbers are 4321, which gives a component number of 1234.
The Error number is then presented in the same manner. Add together the numbers that
correspond to the LEDs that are lit. In this case the numbers are 8765, which give an error number
of 5678.
16 2. HARDWARE 23/12/05
CU 211 (80386SX25)
INTERFACE EXTENSION BUS INTERFACE S1 FOR

TOUCH SENSITIVE KEYBOARDS
STATUS LEDS
RED & GREEN
BATTERY INTERFACE EXTENSION BUS (IEB1)

LED FOR EURO MAP, CAN BUS ETC. K
E
Y
B
S3 O
PROGRAM
LOAD A
BUTTON
R
CODING SWITCH = E D
CONNECTION FOR
DISKETTE INTERF.
2 EPROM B1 SWITCH
S5 BUS
0 EPROM TYPES
KEMRO
B3 OR I/O
SERIAL
3 EPROM
TEST OFF
NTERF. - 1 EPROM
LITHIUM
BATTERY J2
+ ON
CPU
386SX SWITCH CLOCK
486SLC KEMRO OR I/O
LEDS FOR I
ERRORS J1
AND BUS S8
/
O
INTERFACE COLOR
GRAPHIC MODULE B
GC201 FOR COLOR TFT DISPLAY U
WATCHDOG S
CONNECTIONS
SPECIAL NOTES REGARDING CPU CARD :

If the EPROMs are changed, ensure that they are in their correct place and properly oriented.
If the battery is soldered in, the ram components are live, i.e. set values are maintained even
when the CPU card is not in the control unit. Therefore, be careful to avoid short circuits with
metallic objects during EPROM change.
23/12/05 2. HARDWARE 17
Status LEDs and Reset button
At the top of the CPU front panel are three LEDs, two red and one green. The red LEDs indicate
error states and battery condition. The green LED indicates that the system is operating error free.
At initial switch on all the LEDs are lit during the self test function.
Error Status LED Off = System OK

Status LEDs CU211 Flashing = System Error
green, red Solid = Fatal Error
Battery low LED Battery LED Off = Battery OK
red
On = 50 hours of life left
Reset button
black Run Status LED Off = Fatal or System error
Flashing = Error free, flashing rate
denotes work rate of CPU
The "Reset button" is used for reloading Ebias and should otherwise not be pressed, see "loading
the software" in paragraph 2.5.
On card battery buffering
The static RAM and real time clock are maintained by an on - card lithium battery. The memory is
maintained even when the machine is powered down or the card is removed from the rack. The
jumper J1 must be set correctly for the battery to be in circuit. A replacement CPU card will be
shipped and/or stored with the jumper in the b to c position. The jumper must be changed to a to
b position for the battery to be in circuit.
Storage-position,bat- Battery buffer con-

tery not installed nected.
Battery type:
Lithium 3.6
- - Volt,
1/2 AA size
Note position
+ + of positive
terminal
a a
b J1 b J1
c c
During operation of the system, the battery is checked every 12 hours. The battery LED will light
when the battery is nearing the end of it's life. The battery has a nominal life of approximately five
years. The minimum life expectancy of the battery on a CPU with 1Mega Byte of RAM is 20,000
hours. To avoid data loss the following measures should be taken when the battery LED is lit:
• Re-write the machine and process diskettes.
• Leave the control voltage on until the battery is changed.
18 2. HARDWARE 23/12/05
Changing the CPU battery
Before changing the CPU battery, ensure that:
• Machine and process diskettes have been re-written.
• The control voltage is turned off.
1. Remove the CU221 from the rack.
2. Remove the cover from the CU211
WARNING!
ELECTRO - STATIC SENSITIVE DEVICES (ESD)
Treat all electronic cards as if they contain electrostatic

sensitive devices.
To prevent damage to electronic equipment during

servicing, follow the safe handling instructions given at the
beginning of this chapter.
Press in and lift the cover
23/12/05 2. HARDWARE 19
NOTE!
Ensure that the battery is properly connected.

An incorrectly connected battery can damage the card.
3. Change jumper J1 to ‘b’ - ‘c’.

4. Unscrew the battery.
5. Fit new battery, ensuring correct polarity (positive battery connection next to jumper J1).
6. Change jumper J1 to ‘a' - 'b'.
7. Fit cover on CPU case.
8. Mount CU211 into the rack.
9. Re-load the EBIAS software as described in paragraph 2.5
20 2. HARDWARE 23/12/05
CU212 (80486DX4)
Ethernet TPI
An 8-pin RJ-45 connector (MOD-JACK) can be plugged into the TPI (Twisted Pair Interface)
socket on the front panel. It is recommended that the cable is of category CAT3 (or higher), that
is a shielded, twisted pair cable.
The Ethernet connection enables a the machine to be connected to a local network via a
10 base T hub or to a PC to allow remote access via a modem or through Internet. This allows for
remote diagnostics of the injection molding machine.
Status LEDs: L and A:
The LEDs are directly located above the Ethernet TPI connector.
• L (line): green, is lit as long as there is a connection on the network.
• A (active): yellow, is lit when data is transmitted.
23/12/05 2. HARDWARE 21
On Card battery buffering
Storage-position, battery not installed Battery buffer connected.

Battery type:
Lithium 3.6 Volt,
1/2 AA size
Note position
of positive
terminal
The static RAM and real time clock are maintained by an on - card lithium battery. The memory is
maintained even when the machine is powered down or the card is removed from the rack. The
jumper J2 must be set correctly for the battery to be in circuit. A replacement CPU card will be
shipped and/or stored with the jumper in the b to c position. The jumper must be changed to a to
b position for the battery to be in circuit.
During operation of the system, the battery is checked every 12 hours. The battery LED will light
when the battery is nearing the end of it's life. The battery has a nominal life of approximately five
years. The minimum life expectancy of the battery on a CPU with 1Mega Byte of RAM is 20,000
hours. To avoid data loss the following measures should be taken when the battery LED is lit:
• Re-write the machine and process diskettes.
• Leave the control voltage on until the battery is changed.
NOTE!
To replace the battery, following the instruction for the CU211

card on the previous pages.
22 2. HARDWARE 23/12/05
5 LOADING THE SOFTWARE

If a program update is required or the battery on the CPU card is defective and the RAM is lost,
the EBIAS software must be “read in” from the “machine parameter” disk.
Certain files on the “RAMDISK” must be deleted before the new software is loaded. When the new
Ebias is loaded, the files stored on the RAMDISK will not be “dumped” automatically.
This must be done manually as follows:
TO DELETE FILES FROM THE RAMDISK
Press + - DISKETTE
1. Press F6 “Administration”
2. Press F6 “Administration” to enable the following function frame. Press F7 “Exit” at any time
to escape to the main diskette menu
3. Press F1 “Working Device”

A function frame will be displayed giving the options for the working device. If a RAMDISK is
not installed, the only working device will be the “Floppy”. Therefore this procedure does not
have to be performed. Move directly to the procedure “Steps to read in Ebias”.
4. Press F2 to select the RAMDISK as the working device.

The directory of the RAMDISK will be displayed in the lefthand half of the screen.
5. Press F7 “Exit” to escape the Working device function and return to the main menu.
6. Press F5 “Delete”. The following function frame will be displayed and the cursor will appear
on the first file of the directory listing. Move the cursor to the file to be deleted.
23/12/05 2. HARDWARE 23
7. Press F6 “Execute” to confirm the delete function.

The file name being deleted will appear on the bottom left of the screen page and on the
bottom right the advancing white bar will show the progress of the function
8. Highlight and delete the Ebias32.bin and files with the format txtxxx32.bin, e.g.txteng32.bin.
These actions will clear the RAM card so that the new software can loaded properly.
The other options are:
Press F8 etc. --> to select the file name via the alphanumeric function frame. Enter the file
name manually and the cursor will move to that filename. Only enough of the file name has to
be entered to distinguish it from the other filenames.
or
Press F7 Exit, to return to the previous function frame
Steps to read-in EBIAS software:

The Controller will compare the machine number stored on the “machine parameter” disk with
the machine number permanently stored on the CPU card. If the two numbers are not
identical, the Controller will not run the EBIAS software and will display system error 197. This
is to guarantee that one machine's EBIAS software cannot be entered into another machine.
1. Re-record the “machine parameter” and “mold parameter” disks, to guarantee that the latest
calibrations and settings are saved.
or
If a new “machine parameter” disk is being read in, record the param.bin (set values) and
lintab.bin (calibrations) onto the new “machine parameters” disk (these files are empty).
Re-record the mold set values onto the “mold parameter” disk.
NOTE!
A description of how to read-in from the diskette is contained in

the Controller Operator manual, Chapter 5, "DISKETTE" section
2. Refer to the Injection Hold screen page. Note the screw size setting at the bottom of the page.
3. Insert the machine diskette into the diskette drive on the front faceplate with the insertion
arrow on the left and facing up.
4. Switch OFF the control voltage.
5. On the CPU card, press the black button and keep it pressed.
6. Turn ON the control voltage.
24 2. HARDWARE 23/12/05
7. After 3 seconds, the green LED’s will be flashing, release the black button.
This will initiate a RAM test.
If the RAM is operating correctly, the following function frame display will appear:
Press F1 to confirm the “read in” of the Machine Parameter disk “EBIAS”.
An advancing bar indicates the progress of the “read in” process, 100% equals finished.
Also displayed is the disk type (Machine Parameter) and machine serial number.
After the EBIAS software has been successfully loaded into the Controller, the controller will
reset and the CC100 introduction page will be displayed.
8. Press the reset button on the PS244 power supply to give the Controller a “hard” reset. This
action ensures a full initialization sequence of the controller.
The Analog software is not lost when

the Power Supply PS244 reset button is
pressed
9. If necessary, read in the software for the AR281 card (ar281_1.e) from the “machine
parameter” disk.
10. If necessary, read in the software for the second AR281 card (ar281_2.e) from the “machine
parameter” disk. The controller will reset automatically, once the analog software is loaded.
NOTE!
The “read all” function only reads the param.bin and lintab.bin files
23/12/05 2. HARDWARE 25
11. Press the “read all” function key to read in the Machine Parameters, machine specific Set
Values and calibrations (param.bin and lintab.bin) from the machine parameter disk.
Turn the control voltage OFF and then ON again.
12. Read in the process specific Set Values (sgm/param.bin) from the “mold parameter” disk.
Turn the control voltage OFF and then ON again.
NOTE!
A description of how to read-in from the diskette is con-

tained in the "DISKETTE" section of Chapter 5 of the Con-
troller Operator manual
13. Select the "Quick Set-up" screen page. The value for screw diameter “SDM” will be flashing
0.0. The correct value will have to be entered manually. Move the cursor to the “SDM” line.
The range of “Screw Diameter” values will be displayed in the lower left dialog box.
Enter the correct “Screw Diameter” into the blue data entry box and press the enter key.
The message “ARE YOU SURE? PRESS ENTER FOR YES” will be displayed; press ENTER
again to confirm the setting.
NOTE!
If the range of screw values does not contain the correct

value, reload the param.bin file from the machine parame-
ter disk and turn the control voltage OFF and ON.
14. MARK THE PREVIOUS VERSION OF THE “PARAMETER” DISKS AS “OLD PARAMETER
DISKS” AND STORE IN A SAFE PLACE FOR REFERENCE.
Analog Card Hardware / Software Failure
The AR281 analog cards can sometimes detect system and Ebias errors before the main CPU
(CU211). These errors will stop the system. A hardware failure, power problems or software/
hardware incompatibility can cause the errors.
If the error is caused by a software/hardware incompatibility, the analog memory can be cleared,
to re-initialize the card, using the following procedure.
NOTE!
Perform this procedure on any suspect analog card,

before marking as defective.
26 2. HARDWARE 23/12/05
WARNING!
ELECTRO-STATIC SENSITIVE DEVICES (ESD)

This Card Contains Electrostatic Sensitive Devices.
To Prevent Damage During Servicing, Follow The Safe
Handling Instructions Given At The Beginning Of This
Chapter
NOTE!
The following is the only method of “dumping” the ana-

log software
1. Remove the analog card from the rack and note the card code switch setting for that card.
Release the cover and set the card coding selector switch to the “F” position.
2. Replace the cover and put the analog card back into the card rack. Switch on the control
voltage, wait until the green light is on and the red light is off. At this point, the flash memory
has been cleared.
3. Turn the control voltage off, remove the card and change the card coding selector switch to
the correct address for that card.
4. Load the new analog program from the “machine parameter” disk.
Analog Card Power-up Failure

If the red and green lights stay on during power up, there are two possible causes:
a) EPROMs are: -mounted upside down NOTE:
-fitted in the wrong locations AR161 - EPROM Pin 1 marker is “DOWN”
-are defective. AR181 - EPROM Pin 1 marker is “UP”.
b) The analog card is defective.
23/12/05 2. HARDWARE 27
6 DIGITAL INPUT CARD

The digital input card receives 24 volt (VE) digital signals from limit switches, proximity switches
and manual function signals from machines equipped with a free standing cabinet. The manual
function input signals are labelled with the prefix 'TM' on the input card and on the relevant
interface drawing. The lower case 'b' is also used to indicate an input on the interface drawing.
DI-325
- 32 digital inputs per card. (maximum of 32 cards)
- input voltage range 18-30V DC.(Nominally 24V DC)
- opto-isolated inputs, protected against reversed polarity and overvoltage up to 60V.
- each card has four sets of ports, each port has eight inputs.
- LED display for each separate input.
- each input is wired into a plug-in terminal block which "plugs" into the digital input card.
NOTE!
Port numbering runs sequentially through the Digin

cards. On card 1, the first eight inputs are identified as
port 0 and the next eight inputs are identified as PORT 1,
etc. Refer to the TEST and PARAMETERS pages for Digin
port numbers.
28 2. HARDWARE 23/12/05
DI - 325 CARD 1 NOT

E1
E2
E9Q
PORT 0 E8
E9
E14
E15
E16
E17
E52
BAS
PORT 1
BVT1
F2
BVT2
BZH
BWH
SAW
LS
TD
PORT 2
OEN
F1
BZ1
BZ2
BG6
SP1
SIT
PU
PORT 3
E21
E81
B30
B31 +24VE
+24VC +24VC
0V 0V
Refer to the Appendix, or the machine interface diagrams, for a digital input explanation.
23/12/05 2. HARDWARE 29
7 DIGITAL OUTPUT CARD

The digital output card sends 24 volt (VK) digital signals to solenoids or relays.
DO - 321 DIGOUT
- 32 digital outputs per card. Maximum 2 Amps per output.( maximum of 16 cards)
- output voltage range 18-32 Vdc
- overvoltage protection
- LED display for each separate output
- each output is wired into a plug-in terminal block which "plugs" into the digital output card.
- each output has OPTO-ISOLATion between the card and the solenoid.
- each output connection is checked during the hardware test every time the control
voltage is turned on.
- each card has four sets of ports, each port has eight outputs.
- all outputs are switched off if one output is short-circuited. (See EBIAS errors 76-91)
Error Messages
1. Card is missing or open digital output circuit. > circuit break < (see hardware test)
2. Short circuit identified during hardware test. > short circuit < (see hardware test)
3. Short circuit identified during machine cycle > EBIAS ERROR xx <
NOTE!
Port numbering runs sequentially through the Digout

cards. Starting at card 1, the first set of eight outputs is
port 0 and the next set of eight outputs is PORT 1, etc.
port numbers are referred to in the EBIAS error listing in
chapter 6 of this manual and on the TEST and PARAME-
TERS pages for Digouts.
30 2. HARDWARE 23/12/05
DO - 321DIGOUT CARD 1
S1
S2
S3
S4
PORT 0 S5
S6
S10
S3A
S24
S25
S26
AA
PORT 1
DFK
DFG
KRES
S6A
H
HA
HZA
FS
PORT 2 DA
DL
DL1
SB
M1
SHE
DSP
S45
PORT 3
SL1
S11
S4D
S12A 0V
24VK + 24VK
0V 0V
Refer to the Appendix, or the machine interface diagrams, for the digital output designation.
23/12/05 2. HARDWARE 31
DO - 321 DIGOUT 2 CARD
S14
S15
S16
S17
PORT 4 S40
S41
SGZ
SGA
SGN
SKE
SKA
S18
PORT 5 S19
A23
DV1
DV2
SA
S12
S4F
SPT
PORT 6 S9
SAC
SAA
S4A
DT1CK
NPA
S1P3T
S42
PORT 7 HAS
SSP
S4B
KBER 0V
24VK +24VK
0V 0V
Refer to the Appendix, or the machine interface diagrams, for the digital output designation.
32 2. HARDWARE 23/12/05
8 TEMPERATURE CARDS
The TT 081 Temperature card controls all the heating or cooling zones. This card provides closed
loop control of temperatures. The operator has the option of controlling the emphasis placed on
heating or cooling, or a combination of both heating and cooling through the use of the 'HKV'
variable on the heat control parameter page. The card is also equipped with its own
microprocessor and functions as the "slave" of the main CPU microprocessor (80386SX). The
behavior of the heat for each zone can be fine tuned through the heat P.I.D. control parameters.
A unique feature of the TT 081 is the self-tuning capability for setting the P.I.D.s. Please refer to
FINE-TUNING, CHAPTER 7 of this manual for more information on this feature.
• 8 temperature zones per card.(CC100, up to 120 zones, on 16 cards).
• If the machine has only one TT081 temperature card, the first zone controls the oil
temperature and the remaining 7 zones can be used for heating or cooling.
• Second optional heat card controls zones 8 through 15.
• Each zone, except the oil temperature zone, uses an ungrounded thermocouple.
• The triacs or solid state relays controlling each zone (heating or cooling) have 0V common.
They are switched from the card by a 24V/500mA output
STATUS LEDS
Red = Watchdog
Green flashing = ready for operation
THERMOSENSOR
INPUTS
OUTPUT TERMINALS EPROMS

AND OUTPUT LED’s
J1 JUMPER I/O BUS
24 V POWER
INPUT CODING
SWITCH
ATTENTION: The EPROMS on each heat card are specific to that particular heat card.
Never exchange EPROMS between heat cards.
23/12/05 2. HARDWARE 33
TT 081 TEMPERATURE CARD (CONFIGURED AS CARD # 1)
OL -
OIL
OL +
K01-
FE1+
K02-
FE2+
K03-
FE3+
K04-
FE4+
K05-
FE5+
K06-
FE6+
K07-
FE7+
HO
H1 TRIAC
H2 TRIAC
H3 TRIAC
H4 TRIAC
H5 TRIAC
H6 TRIAC
H7 TRIAC OV
K0
K1
K2
K3
K4
K5
K6
K7 OV
+24VC +24VC
0V OV
THERMOCOUPLES
FE - Iron KO - Constantan
If you are in doubt as to which lead is which, use a magnet. Iron is magnetic, constantan is not.
34 2. HARDWARE 23/12/05
9 ANALOG CARD - AR181 / SR161

The AR181 Analog cards (master) control all of the supply voltages to, and the signals from, the
machine transducers. This card provides the analog signal to the PA89 / 96 Amplifier card, which
drives the proportional valves. The AR181 Analog card is equipped with a microprocessor the
INTEL 80960 RISC and functions as the "slave" of the main CPU microprocessor (80386SX).
The SR161 Analog (sub) card is attached to the master AR161 Analog card by a dedicated bus
connector. This card provides analog outputs to monitor screw position, screw speed and
hydraulic injection pressure. The card also has analog output ports to provide the analog drive
signal to other proportional hydraulic amplifier cards.
AR181
- Eight Analog inputs with 14 bit resolution (-10V to +10V):
Stroke transducers.
Hydraulic pressure transducers.
Mold cavity pressure transducer.
Clamp force pressure transducer.
- Three serial inputs with 14 bit resolution for stroke transducers fitted with A/D converter AS141:
RPM transducer for screw (DZ).

External switchover to hold pressure (C3E).
Revolutions of mold height motor (bIE).
- Seven analog output channels with 12 bit resolution (0 - 10Vdc) for valve amplifier cards.
Injection unit Servo valve

Proportional valve for cores and ejectors
Proportional clamp or Specific backpressure
Y+..Speed
K+..Pressure
2nd Pump Y+ Speed
2nd Pump K+ Pressure
- Two digital input (QV1) for:
External switchover bC3E or Mold height revolutions bIE

Screw speed bDZ
23/12/05 2. HARDWARE 35
AR181 Configuration
J8
CBA
C
B
J0 A
C
B A
J1 A J9 B
C
C
J2 B
A
C
J3 B
A
C
J4 B
A
C
J5 B
A
C
J6 B
A
C
J7 B
A
Jumper Function Position Description

J0 to J7 Analog Input Ai0 B-C double ended mode (differential
to Ai7 A-B input) single ended mode
(asymmetric)
J8 Boot mode A-B Boot from the Eprom (for test)
B-C Boot from (Standard)
J9 Boot block B-C Write protected
Lock/Unlock A-B Write enabled
36 2. HARDWARE 23/12/05
Watchdog Function
The AR 181 has an in-built hardware watchdog function. That watchdog function is triggered
periodically by the operating system in order to ensure that the board is functioning properly.
If the software does not trigger the watchdog within a fixed time interval of 45 ms, the board
triggers a reset signal of 90 ms duration (AR 181 reset only and not a bus I/O reset). Following the
reset signal, the module boots up again to the point at which the higher-level central processor
board detects the defective AR 181.
Behaviour on Power Failure

The module has no buffer battery. After power is reinstated, a reset is performed and the software
restarted. The control functions have to be started by the higher-level control system. Similarly,
the safety procedures for switching on again after a power failure must be initiated from that point.
Reset Signal
NOTE!
After a reset signal, all outputs are reset to 0 V

Sensor Failure Detection
A high-impedance 12 V voltage is switched to the analog inputs. If the measured input voltage
moves outside the permissible AD converter band (above 10.3 V) this condition is interpreted as
a sensor failure and a message to that effect is transmitted.
Removing the EMC Enclosure

The EMC cover has to be removed in order to gain access to the card and coding switch.
Press in metal tab (see arrow) and lift off protective enclosure.
WARNING!
ELECTRO-STATIC SENSITIVE DEVICES (ESD)

This Cards Contains Electrostatic Sensitive Devices.
To Prevent Damage During Servicing, Follow The Safe
Handling Instructions Given At The Beginning Of This Chapter
23/12/05 2. HARDWARE 37
AR181 ANALOG CARD
Si0 + F O Mold Stroke Transducer

Si0 - F O -“-
Si1 + S O Screw Stroke Transducer
Si1 - S O -“-
Si2 + H O Mold Height Stroke Transducer
Si2 - H O -“-
+10VR O Reference voltage for stroke transducer
+10VR O -“-
SK + O Clamp force transducer
SK - O -“-
PH1 + O Injection Cylinder hydraulic pressure transducer
PH1 - O -“-
PH2 + O Reserved
PH2 - O -“-
Ai3 + D O Nozzle Stroke Transducer
Ai3 - D O -“-
Ai4 + A O Ejector Stroke Transducer
Ai4 - A O -“-
QV + O Reserved (Mold cavity pressure)
QV - O -“-
Ai6 + O Reserved
Ai6 - O -“-
Ai7 + O Reserved
Ai7 - O -“-
Serv + O Injection Unit servo valve
0V O -“-
A01 + O Reserved
0V O -“-
A02 + O Reserved
0V O -“-
A03 + Y O Proportional Speed Valve
A04 + K O Proportional Pressure Valve
0V O
bIE O Mold Height Revolutions
bDZ O Screw RPM transducer
bC3E O External switch over from boost to hold
+24VC O
GND O
38 2. HARDWARE 23/12/05
SR161
The SR161 is an analog extension card that is used in conjunction with the AR181 card.
- Seven analog inputs for stroke transducers and hydraulic pressure transducers.
- Three serial inputs with 14-bit resolution for stroke transducers fitted with A/D converter AS141:
- Eight analog output channels with 12 bit resolution (0 - 10Vdc) for:
valve amplifier cards and

measuring outputs e.g.
20 mV/bar Hydraulic pressure
20 mV/mm Screw position
20 mV/mm/s Screw speed
Functions:
- Closed loop clamping force control
- Ramp control, profile processing
- Pressure correction via proportional valve
- Speed correction via proportional valve
- Software servo valve control (E-16 only)
- Flow number (Microplast/Microflow)
- Boost to Hold Transfer:
Cavity pressure dependent

Hydraulic pressure dependent
Time dependent
Stroke dependent
External digital signal, C3E
- Screw RPM, DZx
23/12/05 2. HARDWARE 39
SR161 ANALOG SUB CARD
The SR161 Analog card is required if the options below are installed on the machine.
Si3+ O Reserved
Si3- O -“-
Si4+ O Reserved
Si4- O -“-
Si5+ O Reserved
Si5- O -“-
+10VR O Reference voltage for stroke transducer
+10VR O -“-
Ai8+ O Reserved
Ai8- O -“-
Ai9+ O Reserved
Ai9- O -“-
Ai10+ O Reserved
Ai10- O -“-
Ai11+ O Reserved
Ai11- O -“-
Ai12+ O Reserved
Ai12- O -“-
Ai13+ O Reserved
Ai13- O -“-
Ai14+ O Reserved
Ai14- O -“-
A05+ O Reserved
0V O -“-
A06+ O Reserved
0V O -“-
A07+ O Reserved
0V O -“-
A08+ O Reserved
0V O -“-
A09+ O Reserved
0V O -“-
A010+ O Reserved (measuring output for hydraulic pressure -20mV/bar)
0V O -“-
A011+ O Reserved (measuring output for screw stroke -20mV / mm)
0V O -“-
A012+ O Reserved (measuring output for screw speed - 20mV / mm/s)
0v O -“-
40 2. HARDWARE 23/12/05
Analog to digital Converter AS141
The AS141 converts the analog signal from the stroke transducer, at the transducer, in to a digital
signal for transmission to the Analog card. The digital signal is not susceptible to corruption from
any ambient electrical noise. Therefore the digital signal is more precise and can give a better
resolution of the position of the transducer.
AS141
STROKE TRANSDUCER
T500DE80
The AS141 unit is mounted inside the connector of the stroke transducer
Establishing a Ground Connection between Machine Components
Lay screen on the control

unit side on grounding strap
Connection to AR181,
SR161 serial inputs
Si0-Si5
This earth connection must be omitted on

AS141 with an internal shield bracket*
* On AS141 with a metal shield bracket, the screen of the connection cable is connected to the
stroke transducer housing via the internal bracket. This connection results in a completely
screened signal transmission. The stroke transducer is insulated electrically from the machine
ground. The AS141 A/D converter with a shield bracket is identified by a label attached to the front
side, with a serial number, as shown below.
23/12/05 2. HARDWARE 41
10 PRESSURE AND CLAMPFORCE TRANSDUCER
TO PD242 +5V
+5V
A
+ B
SK+ mV
ANALOG
CARD - C P
SK- 0V D
CLAMP
FORCE
TO PD242 0V TRANSDUCER
TO PD242 +12V +24V

A
PH1+ B
ANALOG
CARD C
P
PH1-
0V D
PRESSURE
TO PD242 -12V TRANSDUCER
42 2. HARDWARE 23/12/05
10.1 POSITION STROKE TRANSDUCERS
1
1
SI0+
ANALOG MOLD
D 2 STROKE
CARD A
2 TRANSDUCER
SI0-
3
1
6
SI1+
ANALOG SCREW
D 2 STROKE
CARD 7 A
SI1- TRANSDUCER
3
9 1
D+
ANALOG
NOZZLE
CARD 10 2
D- STROKE
TRANSDUCER
TO PD242
3
11
A+
ANALOG
12 EJECTOR
CARD A- STROKE
TRANSDUCER
TO PD242
23/12/05 2. HARDWARE 43
11 SERVO VALVE (OPTIONAL)
SERVO VALVE for CLOSED LOOP

CONTROL on the INJECTION UNIT
ANALOG
SUB CARD
Shield WHT BU9
SHLD D
BRN E
A05
0V GRY C
A03
YEL B
A04
GRN A
0V
YEL
-15V
GRN
+15V MOOG
BRN
A06 VALVE
WHT
0V
GRY A7721771
BLUE BLUE F
BU9
TB2 - Feedback
Signal
BRN BRN E
E-16 Analog - AO6
WHT
D
TB2 - Feedback 0V GRY C
GRY
TB2 - 0VDC WHT YEL
GRN YEL B
+24
TB2 - VK GRN A
3.0A
TB2 - 0VDC Y3
BOSCH
TB2 located on side of Card Rack
VALVE
These valves provide closed loop control of injection speed, injection hold pressure, and
backpressure. The Bosch valve is also used for operating the Clamp close and open function
(open loop) on some toggle machines.
44 2. HARDWARE 23/12/05
12 PROPORTIONAL VALVE AMPLIFIER CARDS

PA89.2 - Machines with single pump
PA89.3 - Machines with 2 pumps
PA96.2 - Machines with single pump
PA96.3 - Machines with 2 pumps
The Proportional Valve Amplifier card receives an analog signal at terminal Y1 for speed control
and at terminal K1 for pressure control. Machines with two pumps will have a second analog input
terminal, Y2, since these machines have a second speed control valve. The analog input signal is
typically between 2 and 9 Volts d.c.
In response to the analog input signal, the Proportional Valve Amplifier card will apply a current to
the solenoid coil of the proportional valve. The output signal to the Y-valve (speed) is conducted
over terminals Y1- and Y1+. The output signal to the K-valve (pressure) is conducted over
terminals K1- and K1+. For machines with two pumps, the output signal to the second Y-valve
(speed) is conducted over terminals Y2- and Y2+.
The Proportional Valve Amplifier cards also receive position feedback signals from the
proportional valve indicating the true valve armature position. If there is any difference between
the primary signal and the feedback signal, a corrective signal is transmitted from the Proportional
Valve Amplifier card to the proportional valve, and the error between the two signals is driven to
zero.
It is possible to employ two PA96.2 (or PA89.2) cards instead of one PA96.3 (or PA89.3) card. The
terminals for the proportional pressure valve (K-terminals) on the second card would remain
vacant.
The figure below represents the proportional valve circuit. Although this drawing displays the
proportional pressure circuit, the proportional valve circuit for speed is essentially the same.
23/12/05 2. HARDWARE 45
PROPORTIONAL VALVE AMPLIFIER CARD DIPSWITCH SETTINGS
Valve Characteristics
To account for the differences between Bosch and Rexroth valves, mini dip switches are provided
on the Proportional Valve Amplifier card. Each series of three switches (i.e. Y1, Y2, K1) must be
in either the R (Rexroth) position or the B (Bosch) position.
It is possible to run the switches in the Rexroth position although a Bosch valve is being
controlled, and visa versa.
For example, if you replace the Proportional Valve Amplifier card or the proportional valve and the
resulting calibration is not satisfactory (i.e. unable to reach 100% speed or pressure), simply
adjust the dip switches to the other position and try re-calibrating.
Y1 - Speed - all machines (to 500 tons)

K1 - Pressure - all machines (to 500 tons)
Y2 - Speed - two pump machines (300 - 500 tons)
46 2. HARDWARE 23/12/05
PA96.2 / PA89.2 CARD
(Machines with a single proportional speed valve Y1, and a single proportional pressure valve K1)
K1W1
Position
K1W2
Feedback
K1W3
K1W3 K1 VALVE
K1-
K1+
0V
K1 OV AR181
K+ ANALOG CARD
Y1W1 Position
Y1W2 Feedback
Y1W3
Y1 VALVE
Y1W3
Y1-
Y1+
0V
Y1 OV AR181
Y+ ANALOG CARD
-24VC
0V
+24VK 24VK
0V OV
23/12/05 2. HARDWARE 47
PA96.3 / PA89.3 CARD
(Machines with two proportional speed valves, Y1, Y2, and a single proportional pressure valve,
K1)
Y2W1 Position
Y2W2 Feedback
Y2W3
Y2 VALVE
Y2W3
Y2-
Y2+
0V
Y2 OV AR181
Y+ ANALOG CARD
K1W1
Position
K1W2
Feedback
K1W3
K1W3 K1 VALVE
K1-
K1+
0V
K1 OV AR181
K+ ANALOG CARD
Y1W1 Position
Y1W2 Feedback
Y1W3
Y1 VALVE
Y1W3
Y1-
Y1+
0V
Y1 OV AR181
Y+ ANALOG CARD
-24VC
0V
+24VK 24VK
0V OV
48 2. HARDWARE 23/12/05
12.1 BOSCH PROPORTIONAL VALVE WITH INTEGRATED AMPLIFIER
Y4 - CLAMP SPEED AND DIRECTION
2.5A
-15V 1 A +24V
REF 0 2 B 0V
+15V 3 INTEGRATED C REF - ZERO †
AMPLIFIER D
Signal 4
E }±10V Signal Input
F ±10V Valve Actual Pos
Ground
Screen
† DO NOT CONNECT TO
S SUPPLY ZERO
PILOT
U VALVE
S PROPORTIONAL
U VALVE
Signal Valve position

Input
0 -10V
0V
0 +10V
The figure above is a schematic representation of a Bosch pilot operated proportional control
valve with an integrated amplifier. The valve assembly is factory set for joint operation of valve and
electronics and therefore requires no set up at the time of installation.
Electrical connections and their signal names are identified on the figure.
The table shows valve position with respect to signal input voltage.
The Bosch control parameters, Kp, Ki and Kd can be viewed on the “EHV card” screen page along
with the DIL switch positions for each pump fitted. The “EHV card” screen page can be accessed
via the Mold Parameters function key. This page is for viewing only and no changes can be made
here. Any changes to the control parameters or DIL switches must be made at the Bosch card.
23/12/05 2. HARDWARE 49
13 PS-244 POWER SUPPLY
PS 244
For machines with the EL screen a high current supply is required, especially in the +12 volt and
+5 volt circuits.
PS-244 +24 volt input voltage

+5 volt max. 10 A
+/- 12 volt max. 4 A
+/- 15 volt max. 0.3 A
Outputs protected against short circuit,
Output voltage control.
50 2. HARDWARE 23/12/05
PS 244/A and /B
Terminal Design on Front Function

Panel
1 -15V/ -15 V output (symmetry controlled, protected by fuse)

300 mA
2 -- " -
3 +15V/ +- " -
4 300 mA +- " -
5 GND ground
6 ground
7 -12V/2A -12 V output (symmetry controlled, protected by fuse)

8 +12V/2A +- " -
9 + 5V/3A 5 V output, terminals on front side protected by 3 A fuse
10 GND ground
11 +24V +24 V
12 -"- intermediate connection of power supply
13 -"- for supplying other boards- " -
14 ground
15 GND ground
16 ground
17 ground
18
19 +24V +24 V input supply voltage (protection against reversed polarity)

20 -"-
21 -"-
22 -"-
23 GND ground
24 ground
25 ground
26 ground
23/12/05 2. HARDWARE 51
Removing the EMC enclosure.

To gain access to the card components and fuses, remove the EMC enclosure as follows:
• Release the eight screws at A.
• Press in the sheet metal, at B, and lift the enclosure to remove.
8xA
A A
A A
A A A
A
ELECTRO-STATIC
SENSITIVE DEVICES
(ESD)
THIS CARD CONTAINS

ELECTROSTATIC SENSI-
TIVE DEVICES.
TO PREVENT DAMAGE
DURING SERVICING, FOL-
LOW THE SAFE HAN-
DLING INSTRUCTIONS
GIVEN AT THE BEGIN-
NING OF THIS CHAPTER
52 2. HARDWARE 23/12/05
3. PERIPHERAL DEVICE INTERFACES
1 RS-232 SERIAL INTERFACE
The 25 pin RS-232 serial interface, located an the bottom of the controller switch panel, and can
be employed to:
- Read/Write Diskette information.
- Printer interface.
- Transfer of data from the PD Report program in either Lotus or Excel
spreadsheet format or in ASCII text to disk or personal computer.
RS-232 Serial Interface

Pin No.
1. PGND 10. -12 volts 18. Not used

2. RXD 11. N/C 19. Not used
3. TXD 12. N/C 20. Not used
4. CTS 13. N/C 21. Not used
5. RTS 14. +5 volt TTL 22. Not used
6. DTR 15. Not used 23. Not used
7. GND 16. Not used 24. N/C
8. Not used 17. Not used 25. N/C
9. +12 volts
N/C - not connected
Baud Rate
12 = 115200 11 = 57600 10 = 38400 9 = 19200

8 = 9600 7 = 4800 6 = 2400 5 = 1200
4 = 600 3= 300 2 = 150 1 & 0 = Reserved
23/12/05 3. PERIPHERAL DEVICE INTERFACES 53

If the variable set value is changed, the control voltage must be switched off and then on again to
initialize the change.
1 PGND Protective Groun

14
2 TXD Transmitted Data
3 RXD Received Data
4 RTS Request to send
5 CTS Clear to send
6 DSR Data set ready

19 DTR Data terminal read
7 GND Ground
8
9 +12V
10 -12V
11
24 TX- Current loop receive
12 TX+ Current loop transm
25 RX- Current loop receive
13 RX+ Current loop transm
A7600392
The underlined signals are the most necessary ones for the printer.
Pins on typical peripheral device:
Printer Example:
DATA CABLE:
Printer
Control System Serial interface
RS232 / V24
Shield
1
TXD RXD
3 3
CTS DTR
4 19
SGND SGND
7 7
A7721686
54 3. PERIPHERAL DEVICE INTERFACES 23/12/05

TEXT INPUT
An IBM compatible keyboard can be connected to the interface panel. This feature provides the
ability to:
• Enter text on to the three text screen pages found under “Main Menu” + F3.
• Enter values on the screen pages where ever the cursor can be positioned
ON
OFF PR
KEYSWITCH IBM COMPUTER

KEYBOARD
RS232 SERIAL PORT CONNECTION
The text pages can be reached as follows:
• Select the “Menu” function key.
• Select F3 for the text pages.
• Page one appears first, the other pages are selected using the F2 or F3
function keys.
• Function key F7 selects the color of the text. The color of the function key
corresponds to the color of the text. The colors are available sequentially as
follows,
Red, Green, Yellow, Blue, Magenta, Cyan, and White.

Auxiliary functions of the keyboard.
PC Key Insert Switch over between:

Overwrite mode (cursor static)
Inserting mode (cursor flashing)
Backspace Deletes the character to the left of the cursor.
Delete Deletes the character at the cursor position.
Ctrl Delete Deletes the line that the cursor is on, and leaves the line empty.
Alt Delete Deletes the whole page.
Ctrl Insert Inserts a line before the line that the cursor is on.
Enter Ends the line the cursor is on and moves the cursor to the next line
down.
Page Down Selects the next page.
Page Up Selects the preceding page.
Home The cursor is move to the top left hand corner of the page.

2 OTHER SERIAL INTERFACES

The CU211 processor card has four standard serial interfaces, and they are usually assigned as
follows: SIO0 - Debugger port, SIO 1,2 and 3 - RS232 interfaces. There is the possibility of
installing up to 16 serial interfaces on the control system.
The standard control system has four interfaces.
Interface 0: SYSTEM DEBUG- Mounted on the CU211 card. This 9 pin plug, accessible
GER INTERFACE on the front panel, allows for the connection of a personal
computer or a modem for loading sequence programs or
remote diagnosis machine problems
Interface 1: PRINTER with serial input
The transmission rate (baud rate) can be set with variable
parameter 35593 (Serial interface group).
12 = 115200 8 = 9600 4 = 600
11 = 57600 7 = 4800 3 = 300
10 = 38400 6 = 2400 2 = 150
9 = 19200 5 = 1200 1 & 0 Reserved
Interface 2: KFTC (Keyboard) with serial input
Interface 3: FLOPPY on CU211
Interface 4: HOST The transmission rate (baud rate) can be set with variable
Interface 5: SPI The transmission rate (baud rate) can be set with variable
Accommodated on insert modules SC101, SC021.
HOST COMPUTER
HOT RUNNER CONTROLLER
TEMPERATURE CONTROL UNITS
SCALES
FLOW RATE CONTROLLER
DIGITAL SLIDING CALIPERS
ETC.
Interface 6 to 15: Reserved

2.1 SERIAL INTERFACES EXTENSION
a) Extension through interface submodules on the CPU card
One Serial Interface can be connected directly to the CPU card, either the SI 020, SI 232
or SI 485/422 are directly plugged into the corresponding location on the CPU card.
CU 211/A, B, C, D, E, F CU212
SI 232
SI 485/422
SI 020
RJ-45 ETHERNET
CONNECTOR
DEBUGGER
CONNECTION
GRAPHICS
MODULE
CONNECTION

b) Extension through interface modules on IEB2 interface - CU 211/A (B,C)
If more Serial Interface (SI) modules are required on the CPU card, use the Carrier module SC021
which will allow two more SI modules to be installed.
The transmit and receive LEDs on the SC021 card can be viewed through the “cut-out” on the
front panel, refer to page 3-12.
CUT-OUT FOR
LEDs ON SC021
SI 020 Serial
SI 232 Input/Output
SI 485/422 Port 4
mounted on
SC021/A
Serial
Input/Output
Port 5
Serial
Input/Output
Port 3
DUBUGGER GRAPHICS
CONNECTION MODULE
CONNECTION

c) Extension through carrier module SC101/A
If all interfaces locations on the CU211 are occupied but the application requires more
interface modules, the extension module SC101/A is employed as a carrier for up to three
sub-modules SC021/A.
The extension module SC101/A connects IEB2 submodules to the CPU via the IEB1-Bus.
The extension module SC101/A is connected to the master card via the connecting module
IF212/2. The IF 212/2 is mounted at the back of the rack before the cards are inserted.
CU 211
ST ATUS
0
A
Connecting module IF212/2
1
BATT.
LOW
2
3
CONT RO L
U
X
2 to IEB1
Master board
A A
U U
X X
0 1
SC 101/A with IEB2-

interface modules
S
I
O
1
D
E
B
U
G
7
6
5
4
KEMRObus
3
2
1
0
7
6
D
I
S
P
connection
5 L
4
A
3
2 Y
1
0
1
A
L
2
A
R
3
M
4
Possible connection:
Serial Input / Output Port numbers
6 7 8 9 10 11
SI 020 or SI 020 or SI 020 or

SI 232 or SI 232 or SI 232 or
SI 485/422 SI 485/422 SI 485/422
mounted on mounted on mounted on
SC 021/A SC 021/A SC 021/A

2.2 EXPANSION MODULE SC101A
To add the extra optional interfaces, an SC101 module is required.
SC101 The expansion module can accommodate up to three carrier modules SC021.
PORT SC021 IEB2

6 BUS
PLUG-IN
IEB1
PORT BUS
7
PORT
8 SC021 IEB2
PLUG-IN BUS
PERIPHERAL
INTERFACE
CONNECTORS
PORT
9
PORT
SC021 IEB2 I/O
10 BUS
PLUG-IN BUS
CODING
PORT
SWITCHES
11
MAIN CODING SWITCH SUB BOARD CODING SWITCHES

- SET TO ZERO
In addition to the printer and host computer interfaces, six further interfaces can be
accommodated with the addition of the SC101 module. Each SC101 module can accommodate
up to three SC021 carrier interfaces. Each SC021 carrier interface can accommodate two SI sub-
modules, making a total of six.
Extra controller interfaces could be required for: 1. Hot runner controller

2. Temperature controller
3. Scales
4. Flow rate controller
5. Digital sliding caliper

Connecting the SC 101/A to a Master Module
The SC 101/A is fitted in the slot adjacent to the master module (the master module is placed on
the right and the SC 101/A on the left). Communication with the master module takes place via an
IEB1 bus. The electrical connection is provided by the connector board IF 212/2. It is fitted to the
inside of the rear panel of the module rack before the two modules are inserted.
The power supply is taken from the KEMRObus connector. The +5 V and ±12 V supplies are
relayed to the plugged in modules.
CU 211
STATUS
0
1 A
Connector board
2 U
IF212/2 on IEB1
BATT. 3
LOW X
2
CONTROL
A A
Master module U
X
0
U
X
1
SC 101/A with IEB2

S
I
O
1 interface modules
D
E
B
U
G
7
6
5
4
3
KEMRObus
2
1
0
7
6
5
D
I
S
P
connector
4 L
3 A
2 Y
1
0
1 A
L
2 A
3 R
M
4

Connecting Modules to the SC 101/A
Up to three SC021/A modules can be fitted on the SC 101/A. The electrical connection for the
modules is made via the IEB2 bus connector. The carrier module is mounted onto the expansion
module using three screws and spacer bushes, and is also attached to the front panel via the
DSUB socket.
Physical Attachment of a Module
• Remove the SC 101/A with the power supply turned off.
• Remove EMC cover from the SC 101/A
• Remove the cover (if fitted) for DSUB socket space from the SC 101/A front panel
• Plug in the module – the DSUB connector must fit into space on the SC101/A front panel.
• Secure the module with fixing screws and screw DSUB socket to the SC 101/A front panel
(screw fixing is necessary for EMC integrity).
• Refit the EMC cover on the SC 101/A
NOTE!
Attach the SC021 carrier module using the fixing screws. Secure attachment
ensures that the module has been correctly located on the connector pins on
the expansion module. Incorrect attachment will result in damage to the module
when the power supply is switched on.
3 3 3
SC101/A
3
IEB2
2
A
3
3 2 3 3 3
1
IEB2
IEB2
1
3 2
1 SC 101/A
2 Position for fitting module
3 Position of fixing screws
IEB2
3 2
The following modules can be fitted:

• CAN module CI 021
• Encoder interface II 011
• Carrier board SC 021/A with interface modules SI 020, SI 232, SI 485/422

2.3 CARRIER MODULE SC021
This is a high speed serial interface module upon which are mounted the
submodules SC 020 or SC232
Each SC021 module can handle two different sub-modules.
MOD II pin connectors for SI modules
LEDs
CHANNEL B
IEB2 connector
on component side
CHANNEL A
IEB2 connector
NOTE!
The leds will flash to show the data being transmitted and received by each channel.
The SC021/A module can be mounted directly to the CU211 card or to the SC101/A module. Up
to three SC021/A module can be mounted on each SC101/A module for a total of six sub-module
interfaces per SC101/A module.
SI 232 The floppy disk input on the CC100 is usually installed with the
RS232 SERIAL PORT sub-module SI232 mounted on a SC021/A board. The SC021/A
is then, in this case, mounted directly on the CPU board.
SI 020 Sub-module for 20mA current loop. The loop types are set on
CURRENT LOOP PORT the board by means of jumpers.
Standard setting = Transmitter active, Receiver passive
SI 485/422 Sub-module for the Host Computer and SPI interfaces.
CAUTION!
If more than two external devices are used the current capacity of the system will be
exceeded.If extra capacity is required, a special power supply unit must be connected into
the loop.

Physical Attachment of the Modules
• Plug in the required serial interface modules onto the appropriate connectors on the carrier
board SC 021/A.
• Secure the modules with the fixing screws.
• Fit the carrier board SC 021/A together with the serial interface modules to the expansion
module SC 101/A (see previous sub-paragraph on Connecting Modules to the SC 101/A).
The DSUB sockets of the SI modules must fit in the spaces in the front panel of the SC 101/A
expansion module.
• Screw DSUB sockets to front panel of SC 101/A expansion module (screw fixing required for
EMC integrity).
SC 021
SC 021 SI modules
Plug in
SC101/A
SI module 1
Screw
A
3 2
SI module 3 2
Screw
1
3 2
NOTE!
Attach the expansion module board using the fixing

screws. Secure attachment ensures that the module has
been correctly located on the connector pins on the
expansion module. Incorrect attachment will result in
damage to the module when the power supply is
switched on.

The software configuration of the interfaces can be identified on the HARDWARE CHECK page.
NOTE!
See chapter 6.2 in this manual for a complete description

of the HARDWARE CHECK page.
Press function keys

+ F3 + F5
ERROR PAGE HARDWARE CHECK SYSTEM INFORMATION
0 ....is the Debugger

1 ... is the control faceplate serial port (RS232).
2 ... is the Keyboard interface (KFTC)
3 ... is the Floppy Disk Drive
4 ... is the Host interface
5 ... is the SPI interface
6 - 15... are optional.

3 SYSTEM EXTENSIONS
3.1 EXTENSION RACKS, BUS CONNECTION
Example:
CR 162 as master rack Configuration
Bus terminating J1 of J1 of bus connection

module BT 081 bus board board BC 082
plugged into BC 082/A
BC 082/A
CU 211/A
a
Master Master
PS 244
b
c
CR 162 as extension rack BK 082/A
J1 of J1 of bus connection
bus board board BC 082
BC 082/A
a a
PS 244
no bus termination b b
c
Slave c
Slave
CR 092 as extension rack BK 082/A
Bus terminating J1 of J1 of bus connection

module BT 081 bus board board BC 082
plugged into BC 082/A
BC 082/A
a a
PS 244
b b
c
Slave c
Slave
One rack (CR 162 or CR 092) must be defined as the master rack, all other racks as extension or
slave racks. CR 162 and CR 092 racks can be combined in any way.

3.1.1 NUMBER OF EXTENSION RACKS:
The bus connection card BC 082/A is equipped with line drivers making it possible to connect up
to 8 racks together.
Master cards (CU 211/A, CU 201/A, AR 181; AR 101) must be used in the master rack.
In the extension racks, only slave cards (DI 325/B, DO 321/B, DO 321/16/B, TT 081, TT 081/5)
may be used.
3.1.2 BUS CONNECTION CABLE:
The bus connection is achieved via a bus connection card BC 082/A and bus connection cable
BK 082/A.
The bus connection cable is plugged into one of the connectors on the bus connection card (the
two connectors are the same).
3.1.3 BUS TERMINATING MODULE:
The bus terminating module BT 081 must be plugged into the bus connecting module BC 082/A
of the first and last rack.
The LED marked “T“ on the front of the BC 082/A is lit when a BT 081 is plugged in.
3.1.4 JUMPER SETTINGS:
The jumpers J1 on the bus card of the rack and the bus connection card have to be configured
correspondingly (master or slave).
The LED marked “M“ on the front of the bus connection card BC 082/A is lit when the bus
connection card is configured as master card.

4 SPI DEVICES INTERFACE

OVERVIEW
The Engel SPI interface provides remote control of all auxiliary devices connected to the molding
machine via the controller screen.
The Engel SPI communication protocol is based on version 3.01 Sept 1990, of the Machinery
Division SPI Communication Protocol manual. For this version of the manual, eight auxiliary
devices have been defined as follows:
OPTION
1. Mold Temperature Controller 970
2. Chiller 971
3. Dryer 972
4. Loader 973
5. Melt Pump 974
6. Additive Feeder 975
7. General Self Tuning Temperature Controller 976
8. General Temperature Controller 977
These eight devices are currently supported by the system controller.
CONTROL DESCRIPTION
The Engel controller is connected to the auxiliary device controller by a single RS485
communications cable. The cable is then jumped (daisy chained) to all other device controllers to
be connected.
Each device controller will locally control the device connected to it according to the set values
sent to the device controller by the Controller. Each device controller will report the actual values
and all alarms back to the Controller.
The EC100/CC100 controller will allow for input of auxiliary device set values and will display all
actual values and alarm conditions via the molding machine monitor. The Controller will accept set
value tolerances and generate alarms based on those values. All auxiliary device set values and
setup parameters will be saved on the machine mold setup floppy disk and thus will automatically
be updated during a mold change procedure.

4.1 SPI DEVICES INTERFACE
OVERVIEW
The Engel SPI interface provides remote control of all auxiliary devices connected to the molding
machine via the controller screen.
The Engel SPI communication protocol is based on version 3.01 Sept 1990, of the Machinery
Division SPI Communication Protocol manual. For this version of the manual, eight auxiliary
devices have been defined as follows:
OPTION
1. Mold Temperature Controller 970
2. Chiller 971
3. Dryer 972
4. Loader 973
5. Melt Pump 974
6. Additive Feeder 975
7. General Self Tuning Temperature Controller 976
8. General Temperature Controller 977
These eight devices are currently supported by the system controller.
CONTROL DESCRIPTION
The Engel controller is connected to the auxiliary device controller by a single RS485
communications cable. The cable is then jumped (daisy chained) to all other device controllers to
be connected.
Each device controller will locally control the device connected to it according to the set values
sent to the device controller by the Controller. Each device controller will report the actual values
and all alarms back to the Controller.
The EC100/CC100 controller will allow for input of auxiliary device set values and will display all
actual values and alarm conditions via the molding machine monitor. The Controller will accept set
value tolerances and generate alarms based on those values. All auxiliary device set values and
setup parameters will be saved on the machine mold setup floppy disk and thus will automatically
be updated during a mold change procedure.

CONFIGURATION
The following components are required:
1. one E-HSI and one E-HSI-RS485 computer module

2. one DB9 RS485 cable to a 6 device junction box
3. 6 auxiliary device junction box (more as required)
4. DB9 RS485 cables times the number of devices connected with enough length to reach
the location specified.
All device controllers must be intelligent and conform to the SPI RS485 Protocol.
All device controllers must communicate at a baud rate of 9600.
In order to communicate with auxiliary devices, the device type and address must be correctly
set. The device type is set by default in the ENGEL control according to the SPI PROTOCOL (e.g.
Dryer device type is 22HEX). By default device addresses are 20HEX for every device type
supported by ENGEL. For additional devices with the same type, the address is incremented.
For example, a machine with one Dryer and two Mold Temperature Controllers would be
configured as follows:
Type Address
Dryer 22HEX 20HEX
Mold Temperature Controller 1 20HEX 20HEX
Mold Temperature Controller 2 20HEX 21HEX
SPI DEVICE COMMANDS
Commands supported will be as defined in the SPI protocol as a "required" command. This will
ensure that the Engel Controller will efficiently communicate with any vendor's auxiliary device.
Additional commands will be offered by different equipment manufacturers, which can be
implemented depending on Engel customer requirements.
SPI ALARMS
There are two types of auxiliary device alarm codes available as follows:
1. Process Alarms - this is a 16 bit status word returned to the controller by the auxiliary device
• markers on the screen are set according to the 16 bit pattern
• the 16 bit word is also displayed on the screen for detailed analysis
• the bit pattern decode can be found in the SPI Communications Protocol
v3.01
• some device controllers will return a value of one, which means the device
is processing
2. Communication Alarms -
251 = Communication timeout
252 = CRC* - Error Integer
253 =
254 =
255 = CRC* - Error Float

5 CENTRAL COMPUTER (HOST)

The communication between the central computer (host) and the Control System is carried out by
means of an RS-232 serial. Note that this interface is not the RS 232 serial interface on the
Control System faceplate.
If the optional host computer interface is installed, the interface connection would be conducted
through an SI (Serial Interface) submodule board.
If the SI submodule is employed, it would be mounted on the SC021 module. Each SC021 module
can handle up to two SI submodule boards. The SC021 module is mounted as standard on the
CU211 with 1 of the 2 submodule spaces employed as the floppy disk interface (SI-RS232). The
other submodule space is left vacant for optional interface connections, possibly a host computer
interface.
For any communication between the host computer and the Control System, the host computer
always plays the active part (i.e. master). For example, any set value can be called up by the host
computer and be updated. If updating is required the Control System keyswitch must be in switch
position "PR".
The Control System records errors which occur during the cycle into a special "Error Byte".
Periodically, the host computer will request an error update, and any existing error messages will
be displayed by the host computer in clear text on the screen.

5.1 GENERAL PROGRAM INFORMATION
INTERFACE DEFINITIONS:
1. Configuration of the SC021:Configured in the software
2. Data transmission: The central computer is always the active element.

Data can be transmitted in both directions.
3. Code: 7 bit ASCII
4. Synchronization: Asynchronous data transmission

The synchronization takes place at the start of each character.
5. Plug: Cannon DB-25P or similar
6. Transmission speed: can be set with set value 35595 (interface 3-9)
(baud rate) 12 = 115200 11 = 57600 10= 38400
9 = 19200 8 = 9600 7 = 4800
6 = 2400 5 = 1200 4 = 600
3= 300 2 = 150 1 & 0 Reserved
7. Data words: One data word consists of 10 bits:

Bit 1 Start = logic 0 = positive voltage
Bit 2 Databit
Bit 3 Databit
Bit 4 Databit
Bit 5 Databit
Bit 6 Databit
Bit 7 Databit
Bit 8 Databit
Bit 9 Parity
Bit 10 Stop = logic 1 = negative voltage
8. Parity: Straight line
9. Time limitation: If more than 2 seconds pass between each data word, the system
controller (Cont) stops and waits for a new call from the central
computer (CC).

ENGEL MACHINE FOREIGN
DATA CABLE: CONTROL HOST
9-pin plug 25-pin plug
TXD 2 ____________________ 3 RXD

RXD 3 ____________________ 2 TXD
DTR 6 ____________________ 6 DSR
RTS 7 ____________________ 5 CTS
CTS 8 ____________________ 4 RTS
DSR 4 ___________________ 20 DTR
GND 5 ____________________ 7 GND
9-pin plug 9-pin plug
TXD 2 ____________________ 2 RXD

RXD 3 ____________________ 3 TXD
Ground5 ____________________ 5 GND
DTR 6 ____________________ 6 DSR
RTS 7 ____________________ 8 CTS
CTS 8 ____________________ 7 RTS
DSR 4 ____________________ 4 DTR
-------------------- ENGEL MACHINE

| Current-Loop | .. .CONTROL ENGELNET
--------------------
25-Pin plug
for Card F-RCC TX+ 12 _____________________

and E-RCI TX- 24 _____________________
RX+ 13 _____________________
RX- 25 _____________________

5.2 CONTROL CHARACTERS
ASCII
character Direction Meaning
$ CC to Cont CC starts a transmission.

Is always used at the beginning of a transmission.
* Cont to CC The control is ready. The control will

always answer a $ with an *.
( CC to Cont Transfer start of a data word from

the CC to Controller (writing).
After a ( the whole data word is

transmitted and terminated with :
When the controller receives : it answers

either with ) or ?
CC to Cont End of a data word.

: or
Cont to CC
) Cont to CC Data word accepted, no error.
? Cont to CC Data word not accepted.
The reason is format error or parity

error. The data word is again
transmitted by the CC without control
characters. This can be repeated
twice, after which the communication is interrupted.
# CC to Cont Data word is desired by the CC. (reading)
[ Cont to CC Transfer of a data word from the controller to the CC.
] CC to Cont Data word accepted, no error
" CC to Cont Data word not accepted. The reason is format error
or parity error. The data word is again transmitted by
the controller without control characters. This is
repeated twice, after which the communication is
interrupted.

5.3 FORMATS OF "DATA POSTS"
The communication process is always initiated by the central computer. There are 2 types of 'Data
Posts' from the CC to the controller:
1. RGGKK
2. UGGKKXX...X
R (Report) means that this data post is a reporting telegram (Request to report).
U (Update) means that this data post is an updating telegram (Request to update).
GG is a 2-digit group number
KK is a 2-digit channel number
XX...X is a numerical value in free format (e.g. 123.3 or 27 or 0.19).

This represents a value from group GG, channel KK.
There are also 2 types of 'Data Posts' from the controller to the CC:
1. XXX...X is a numerical value in free format. This format is used as an answer to a reporting
telegram. If the question telegram is not legal (GGKK combination does not exist), the letter
E instead of XXX...X is sent as answer.
2. K is a 1-digit code, which is used as an answer to an updating telegram.
The code can assume the following values:
0 - The specified updating has been made.
1 - Updating not made because controller is not in "PR".
2 - Updating not made because the value is outside the limit values.
3 - Updating not made because updating for the specified group and channel is not allowed.

4. SERVICE MENU
To gain access to the service menu for the first time or after the ACCESS END key has been
pressed, press F5 “Access rights”.
1 ACCESS RIGHTS
Press +
The machine is protected from unauthorized adjustment by various levels of user access.
The keyswitch on the side of the display cabinet has three settings, OFF, ON and PR. The
key can be withdrawn at any of the settings to lock the switch in that position. The switch
must be in the PR position for password entry to gain access to the higher levels of autho-
rization.
To gain access to the Service menu, a password must be entered. Depending upon the
level of password entered various stages of access are available.
23/12/05 4. SERVICE MENU 77

The standard settings are described in the table below.
Keyswitch/ Acces Person-

Access User
password s level nel No
OFF Select screen pages 0
ON Input set values 2
PR Disk Read/Write 4
11111111 Debugger, Date/Time, System setup 6 1 1
22222222 Calibrations, Linearization, Control parameters injection unit 8 2 2
Service Machine size data, critical value changes 10 3 3
SUSER Temporary superuser password 4
On the “Access Rights” screen page, move the cursor to the required user level, enter the
appropriate password and press the enter key.
Superuser password
The Engel software service department can issue a temporary super user password. This
would be to enable customers to make certain changes, under the guidance of an Engel
service technician. These changes would normally only be possible under the Engel
Service password. The password will only be viable for a predetermined amount of time, as
decided by the Engel software department. Time may one day or one hour, as determined
by the task involved.
If an incorrect password has been entered, the message “Invalid password” will be
displayed.
As an option a magnetic card reader can be employed, negating the need for a keyswitch
or password levels. A card would have the password level granted to the user encoded on
a magnetic strip.
Inserting the card into the card reader, located on the side of the display cabinet, will
immediately give the user the access level granted to, that user. The access level will be
displayed on the top of the screen page. Removal of the card will immediately remove the
access level from the controller. The password card will not have the super user password
on them.
The system data report page will record the date/time and personnel number of the card
user.
The standard card as supplied by Engel will allow the same access level to all Engel
machines
Once the password has been successfully entered, press the “main Menu” function key
again and the following function frame will be displayed. The service function key has been
enable by the password entry. This function frame will remain until F2 “Access End” function
key is pressed or the “Control Voltage” is turned off.
78 4. SERVICE MENU 23/12/05

2 SERVICE MENU
PRESS
+ F4
SERVICE MENU 10 - 3
F1...... SETUP
Machine Set-up
System Set-up
Pushbutton Setup
Operator Setup
Mold Rotary device Setup
F2...... VALVE - LINEARIZATION
F3...... INPUT CALIBRATION
F4...... TEST and PARAMETERS
F5...... DATE and TIME
F6...... TEMPERATURE CARD
Passwords
There are four levels of passwords that can be entered.
1. Engel Software (6)
2. Engel Service XXXXXXXX (10 - 3) (id2)
3. Customer Level 1- 22222222 (8 - 2) (id1)
4. Customer Level 0- 11111111 (6 - 1) (id0)
The reference to id2, id1 and id0 indicates the level of password required to change various
software set value parameters. See the set value parameter listing in chapter 8 for more
information.
Depending on which level of password is entered, a different menu will appear.
The service menu shown will appear if the Engel Service password is entered and includes
within the SETUP PROGRAM, the Machine Set-up that is for ENGEL use only.
If the customer Level 1 password (22222222) is entered, the following menu will appear.
F1..... SETUP
System Setup
Operator setup
F2..... VALVE - LINEARIZATION
F3..... INPUT CALIBRATION
F4..... TEST and PARAMETERS
F5..... DATE and TIME
F6..... TEMPERATURE CARD

If the customer level 0 password (11111111) is entered, the following menu will appear.
F1..... SETUP
System Setup
F4..... TEST and PARAMETERS
F5..... DATE and TIME
Decide how much involvement with the machine your employees will be allowed and use
that evaluation to dictate the level of password to be distributed.

3 SETUP PROGRAM
3.1 MACHINE SET UP
Press SERVICE PASSWORD

10 - 3 (SM2) + F1
The following 'function frame' will be displayed
PRESS F1 MACHINE - SET-UP
NOTE!
This page is used by ENGEL to activate various programs within

the software and cannot be accessed by the customer.

3.2 SYSTEM SETUP
PRESS F2 SYSTEM - SET-UP
NOTE!
The customer CAN access this page.

The settings shown on the screen page example are factory default setting. Unless
there is a problem with the printer output, Engel suggests that the settings remain unal-
tered. Refer to the manual provided with your printer for alternative settings.
CURSOR
Delay Time
autorepeat-time
dynamic autorepeat - time
entering “zero”

By default when the ENTER key is pressed without entering a value into the “Data input
field” a zero is entered where ever the cursor is placed. The option on this line is to have
either:
0 = “entering a zero without preselection”
1 = “entering a zero with preselection”
If “with preselection” is selected a zero must be entered into the “Data input field” before the
controller will accept that value. This feature safeguards against inadvertently entering a
zero.
SCREEN
Screensaver
The screen blanking feature can be adjusted to suit the customer’s requirements; the
default is screen blanking after ten minutes (600 seconds) of inactivity. Move the cursor
down to the screen save time, enter the required delay time in seconds and press the
ENTER key to change the setting.
KEYBOARD
0 = US English
1 = German
NOTE!
Printer, Destination device and Hardcopy settings are

found under Main Menu + F1 Printer function key.

3.3 PUSH BUTTON SETUP
When connecting several optional functions, such as a mold ejector, hydraulic high-speed
mold mounting, etc. overlaping of the pushbutton matrix assignments will arise. This
'pushbutton set-up' screen page is installed to allow the pushbutton matrix assignments to
be adapted “on the spot” without requiring a software change.
3.3.1 VARIABLES
1 ... QMC Release 16

The screen page lines have a description of the manual action pushbutton and a number
detailing the assigned marker position (key code) for the switch.
2 ... Current Key Code 0

The marker for the front panel pushbutton being actuated is displayed here.

3.3.2 SET-UP/CALIBRATION
Function
When the control unit recognizes that multiple pushbuttons have the same key code
assignment when the control voltage is switched on, the pushbuttons are deactivated for all
concerned components, with the effect that the concerned components no longer function
in the manual mode. The deactivated pushbuttons are identified on the screen page by the
key code ' ** ' at the respective component.
In this case a new pushbutton key code must be allocated to the concerned components.
If a pushbutton with a valid key code already assigned to it is to be changed, the procedure
is like above, but the current key code for the concerned component must first be erased by
highlighting it and pressing the function key for 'Erase push-button'.
In case of faulty operations the correct procedure is indicated to the operator by interactive
error messages.
The pushbutton settings are stored as parameters on the machine diskette.
Pushbuttons for core-pull and air blow
Another example of the configuration of pushbuttons is the combination of core movements
on one key for moving in multiple cores and one key for moving out multiple cores.
Depending on the set core-pull sequence and the moving conditions of the individual cores,
all cores can be actuated with the one key. Both air blow 1 and air blow 2 can also share a
single pushbutton.
Procedure
• Switch off motor.
• Press requested pushbutton and keep it actuated.
• Whether the chosen pushbutton is accepted can be determined by the fact
that at the displayed value 'Current key code' changes from ' ** ' to a real
value.
• Actuate the soft key 'Take over push-button'.
• The pushbutton valid key is taken over (can be determined by the fact that
the key number at the concerned component changes from ' ** ' to a
number).
• If a key should have been chosen which has already been assigned to
another component, the old component is deactivated, i.e. the component
chosen last gets the key code.

Variable Description
Number
21188 Stationary platen quick mold change release p.b. assignment
21189 Stationary platen quick mold change secure p.b. assignment
21190 Air blow 1 pushbutton assignment
21191 AIr blow 2 pushbutton assignment
21192 Moving platen quick mold change release pushbutton assignment
21193 Moving platen quick mold change secure pushbutton assignment
21194 Safety gate closing pushbutton assignment
21195 Safety gate opening pushbutton assignment
21197 Injection unit 2 pushbutton assignment
21198 Screw feed unit 2 pushbutton assignment
21199 Carriage forward unit 2 pushbutton assignment
21200 Carriage retract unit 2 pushbutton assignment
21201 ERC reference key pushbutton assignment
21202 ERC home key pushbutton assignment
39922 Core 1 in pushbutton assignment
39923 Core 1 out pushbutton assignment
21207 Rotate table left pushbutton assignment
21208 Rotate table right pushbutton assignment
60026 RC100 quality part on demand pushbutton assignment
60027 RC100 reject part on demand pushbutton assignment
60028 Alarm bell reset pushbutton assignment
60029 Nozzle height increase pushbutton assignment
60030 Nozzle height decrease pushbutton assignment
60031 Purge slide in pushbutton assignment
60032 Purge slide out pushbutton assignment
60033 Mold ejector forward pushbutton assignment
60034 Mold ejector back pushbutton assignment
60038 Purge slide 2 in pushbutton assignment
60039 Purge slide 2 out pushbutton

3.4 OPERATOR SETUP
Cushion correction: 0 = deactivated, 1 = activated

Signal type FS lamp: 0 = Steady light, 1 = Flashing light
Side light beam gu. : 0 = 0/1, 1 = 1/0
HA output: 0 = deactivated, 1 = in semi automatic, 2 = in fully automatic, 3 = in automatic
No. shut off nozzles X in the mold
Parallel sw.over 1, 0 = decativated, 1 = activated
Action at mold protection: 0 = Opening, 1 = , Sel. stop/opening
Standardized signals: 0 == deactivated, 1 = activated
Image background: 0 = black, 1 = grey

3.5 MOLD ROT. D SETUP
NOTE!
This screen requires the Engel Service password to access.
1... Mold Rotation Device: 0 Rotary Platen/Index Plate

There are two configurations for the Mold Rotation Device.
• 0 – Rotary Platen
Allows 180 degree rotation, allows screen settable speeds, and can be configured to use
either limit switches or transducer. A rotary platen must unlock and lift before rotation can
begin.
• 1 – Index Plate
Allows 180 degrees oscillation, index plate can be mounted on the ejector, and allows
screen settable speeds and pressures, and can be configured to use either limit switches or
transducer. Index plates do not need locking pins or need to lift to rotate.
NOTE!
Set this variable to ‘0’ in order to properly set-up the rotary table.

2... Rotary Platen/Index Plate 0 with limit switch/with stroke transducer
There are two settings for this variable:
0 – With Limit Switch
The Mold Rotation Device uses limit switches to identify end and braking positions.
1 – With Stroke Transducer
The Mold Rotation Device uses a transducer to determine table angle and position. End
(and for an indexing plate, braking) positions are screen settable.
NOTE!
Set this variable to ‘1’ in order to properly set-up the rotary table.
3 ... Rotary Platen/Index Plate 0 without prop.valve/with prop.valve

There are two settings for this variable:
0 – Without Proportional Valve
Speed control is managed with the pump’s proportional speed control valve and direction
is controlled using digital outputs.
1 – With Proportional Valve
Speed control is managed using a dedicated proportional valve that is also used to
control direction with negative voltage applied to the valve resulting in CCW motion and
positive voltage resulting in CW motion. When a dedicated table proportional valve
(YCC) is equipped, the pump proportional speed valve (YC) will use the screen settable
table speeds when the table rotates or indexes.
4 ... Table Mechanical Stop

A mechanical stop is used to halt table movement either using fixed stops or a stopping
cylinder. An extension on the back of the table will come into contact with the mechanical
stop and stop table movement. There are five possible settings for the mechanical stop:
0 – Not Mounted
No mechanical stopping cylinder is mounted on the table. Table operation mode is
unrestricted.
1 – Left and Right Fix
A fixed mechanical stop has been equipped for each direction. If a locking pin is not
equipped then table is restricted to CW/CCW oscillation only; otherwise, table operation
is unrestricted.
2 – For Turning Left

The mechanical stop cylinder has been equipped and table is restricted to CCW rotation.
The cylinder moves forward to catch the extension on the bottom of the table and stop it,
then, when further rotation is required, the cylinder retracts.
3 – For Turning Right
The mechanical stop cylinder has been equipped and table is restricted to CW rotation.
The cylinder moves forward to catch the extension on the bottom of the table and stop it,
then, when further rotation is required, the cylinder retracts.
4 – Left/Right Pend.
The mechanical stop cylinder has been equipped and is restricted to CW/CCW oscillation
only. The cylinder moves forward to catch the extension on the bottom of the table and stop
it, then, when further rotation is required, the cylinder retracts.
5 ... Locking Cylinder

A locking cylinder is used to ensure correct and precise index plate/rotary table positioning
after rotation. There are three possible settings for the locking cylinder:
0 – Not Mounted
No mechanical locking cylinder is mounted.
1 – Mounted
A mechanical locking cylinder is equipped.
6– Table Brake
The table brake is used to ensure that unwanted table rotation will not occur by using either
a brake on the hydraulic table motor or an interrupter on the table pressure line. There are
three possible settings:
0 – Not Mounted
No brake is equipped.
1 – Table Brake
The hydraulic table motor is equipped with a brake.
2 – Pressure Interrupt
The hydraulic pressure line to the table motor is equipped with an interrupter that will
stop the flow of hydraulic oil when the table is not rotating.
7 ... Table Lift Parallel to Mold Opening

Setting this to ‘Yes’ will allow the table lifting to begin at a settable clamp position, DTP,
during mold opening in semi- or fully-automatic mode of operation. The variable “table lift
at clamp pos. DTP” will be displayed on the Mold Opening screen page when this feature is
enabled.

NOTE!
Only available on rotary table designs that require table lifting.
8 ... Disable Lock.Cyl.(safeties intact)

Setting this to ‘Yes’ will disable the locking pin securing action in manual or set-up mode. All
clamp safeties regarding the locking of the table will still be monitored. Starting semi or full
auto cycling or power up will reset this to ‘No’.
NOTE!
This is meant for Engel service technician use only!
SET-UP/CALIBRATION
For the standard rotary table design the Mold Rotation Device set-up screen page should
be configured as follows:
• mold rotation device set to ‘0 – rotary table’
• set rotary table to ‘1 – with stroke transducer’
• table mechanical stop set to ‘0 – not mounted’
• locking cylinder set to ‘1 – mounted’
Other variable defaults:
• variable 4545 = ‘0’
• variable 21755 = ‘0’
• variable 50001 = ‘0’

4 VALVE CALIBRATION
PRESS
SERVICE PASSWORD
(8 - 2) + F2
NOTE!
This calibration procedure is for machines that do not have the Bosch EHV
“Smart” pump fitted.
The screen initially displays all the valves in the system concerned with SPEED. Pressing
the other function keys listed will display the valves concerned with those areas. The
rectangular boxes to the right indicate whether that particular function is calibrated. If the
function is calibrated the box will be lit. If the function is not calibrated the box will be unlit.

1... When the function key F2 is pressed to select the PRESSURE calibration, a screen
image similar to the one shown below is displayed.
2... When the function key F3 is pressed to select the BACK PRESSURE calibration, a
blank screen image is shown, since the servo valve controls back pressure and its
calibration is completed in the 'SPEED' category.
2a.. When the function key F3 is pressed to select the BACK PRESSURE calibration, a
screen image similar to the one shown below is displayed.
This secondary field will only appear when the machine is not equipped with a servo
valve. If the machine is equipped with a servo valve, a manual back pressure
calibration is not required.
3... When the function key F4 is pressed to select the SCREW RPM calibration, the field
changes to a screen image similar to the one shown below.

4.1 CALIBRATION SCREEN IMAGE
To view the calibration curve for a particular valve, select the area (i.e. Speed, Pressure,
Back Pressure, Screw RPM) with the function keys.
By selecting any of the valves listed, and pressing ENTER, the operator will be presented
with the actual calibration graph associated with that valve. For example, if F1 'SPEED' is
chosen and the operator moves the cursor to the Y valve, the graph specific to calibrating
machine speed would appear. A similar graph is shown below.
The top left hand corner indicates which parameter is being calibrated (i.e. Speed), and
which specific hydraulic component is the subject of the calibration (i.e. Y - Valve).
The top right hand corner indicates the maximum value that this particular function is rated
for, when 100% is achieved. This is a value, which is stored in the machine set value
parameters and cannot be accessed by the operator.
The vertical axis of the graph represents the percentage value of speed in the graph shown.
This can represent percentage pressure or screw RPM on other calibration graphs.
The horizontal axis of the graph represents the analog voltage output from the Analog card
between 0 and ±10 volts. Notice that the servo valve calibration graph is governed by 0 to -
10 volts. The YS1/2-VALVE closing function is also governed by 0 to -10 volts.

After calibration, a certain voltage output on the horizontal axis is associated with a certain
percentage value on the vertical axis. All these values, from 0 to ±10 volts and from 0% to
100% are stored in memory and represent the calibrated values.
On the bottom half of the calibration screen image is another separate menu. This is the
menu that the operator will use to control the calibration function.
F1 ... MAIN MENU
If the operator chooses F1 on the function key pad, the screen will revert back to the main
calibration screen image.
F2 ... INITIALIZATION
If the operator chooses F2 on the function key pad, the existing calibration stored in memory
is eliminated and replaced with a linear line. After this entry, 0% would be associated with 0
volts and 100% would be associated with plus or minus 10 volts. All points in between would
be linear.
F3 ... MEASUREMENT
If the operator chooses F3 on the function key pad, the calibration function will start. Please
note that some calibrations are automatic and would start the calibration function as soon
as the '2' is entered. Read the preliminary steps that are necessary before pressing this
particular key pad.
F4 ... CHANGE TAKE OVER
If the operator chooses F4 on the function key pad, the new calibration information, as
represented by the green line during calibration, would then be entered into memory.
This new calibration curve turns red and replaces the previous red curve. An acceptable or
satisfactory calibration should be similar to the previous curve. If there is a great difference,
or the +10V value is reached before the 100% value is attained (see sample graph below),
this calibration may be considered to be unsatisfactory.

F5 ... CHANGE
WARNING!
This function should only be used by fully qualified tech-

nicians. Serious disruption to the calibrated values can
occur if this program is employed incorrectly.
If the operator chooses F5 on the function key pad, the calibrated values can be manually
adjusted. If this program is chosen, a function frame will appear as shown below
The screen image will change to show two lines of text as shown below.
50.0 % = 5.125 V (White text)
0.0 % = 0.000 V (Yellow text)
The white text shows the percentage value and corresponding analog voltage output from
the Analog card. A percentage value can be entered and the corresponding voltage value
will be displayed. The percentage value can be stepped up or down using the up or down
cursor and the corresponding voltage output will be displayed.
If the cursor is positioned on the voltage value, a new value can be entered. The F1 function
key “Take over change” must be pressed to instigate the change, the calibration curve will
redraw to reflect the new value. In this way the manual calibration curves can be adjusted
at points in between minimum and maximum points.
NOTE!
Press “Change Take over” to initiate the new calibration.

The changed values will remain in effect until re-calibration.
The yellow text indicates the voltage value at zero percent.
Pressing the “0% - Value” function will change the zero percent value between zero voltage
and the calibrated voltage value.
The function key has a yellow background when 0% =0 Volts is active (ON),
The function key has a black background when 0% = the calibrated value is active (OFF).
This facility is useful if there is movement of a machine function at a calibrated setting of
zero percent, the movement can be eliminated by selecting 0% = 0Volts.

4.2 CALIBRATION PROCEDURE
The machine hydraulic system should be calibrated after every 2000 hours of running time.
It should be viewed as a tune-up to bring the machine functions back to their rated speeds
and pressures.
A new calibration is also required when any of the proportional valves are replaced, or if the
proportional valve amplifier card is replaced.
1... Set the key switch to PR.
2... Switch to manual operation.
3... Start the electric motor.
4... Ensure that conditions exist to allow for screw movement and for a proper calibration
to be conducted.
For example:
• Safety gate must be closed.
• Nozzle protection must be closed.
• Heat zones must be within tolerance.
• Barrel must be purged out and empty.
• Oil must be at operating temperature.
5... Acknowledge all errors so that new errors resulting from the calibration can be easily
identified.
6... If the machine is equipped with a servo valve, read the note in the servo valve section
before calibrating the Y - valve.
7... Before the speed calibration is conducted, the relevant stroke calibration (mold or
screw) must be completed.
Aside from these preliminary steps, the order of valve calibration is not important.

4.2.1 SPEED CALIBRATIONS
SPEED - Y VALVE
Automatic Calibration (there is no manual calibration)

1... Press 'F3' Measurement. The machine will zero the valve and then step up the
voltage, in 0.1 volt steps, to 10 volts (or until maximum speed) and measure the
speed at each step.
2... During calibration the screen will show the measurement settings, stepping up in 0.1
Volt increments. Beneath that will be shown the “measured value” the screw speed
equal to the that voltage setting.
Also messages concerning the calibration function will be displayed, e.g. “Screw
return”, “Wait for release” and “Speed recording”
3... If the green calibration line represents a satisfactory calibration, press 'F4' - CHANGE
TAKE OVER, the calibration line will turn red.
4... After achieving a satisfactory calibration, it is advisable to maintain an updated
machine calibration record by re-recording the machine parameters on a diskette.

SPEED - SERVO VALVE
This calibration is the same for all types of servo valve.
Automatic Calibration (there is no manual calibration)

NOTE: If a Moog valve is installed and before calibration is attempted, return
to the calibration menu and curve for the Y-valve (i.e. speed) and press
"F2", Initialization. This will guarantee that the Y-valve will not interfere
with the servo valve calibration. After the servo valve has been
calibrated, return to the Y-valve calibration menu and press "F3" to re-
calibrate the Y-valve.
1... Press 'F3'. The machine will zero the valve and will then apply voltage, in 0.1 volt
steps, to -10 volts (or until maximum speed) and measure the speed at each step.
2... If the green calibration line represents a satisfactory calibration,
press 'F4' - CHANGE TAKE OVER
machine calibration record by re-recording the machine parameters on a diskette.
NOTE: The Moog brand servo valve calibration should start at approximately
-1.5 volts. If not, refer to the next page for the procedure to set the
electrical zero point.

MOOG VALVE - SETTING ELECTRICAL ZERO POINT
This adjustment is for the Moog brand servo valve only and is not required on other servo
valves.
Engel sets the electrical zero point of the Moog valve such that the valve just starts to
operate at approximately -1.5 volts analog output (A06 terminal on the Analog sub card).
Adjusting the Electrical Zero Point

• Remove the panhead screw cover to expose the adjustable potentiometer.
• Turn the potentiometer 1/4 turn at a time. Clockwise will shift the curve to the left.
Counterclockwise will shift the curve to the right.
• Re-calibrate the Moog valve and repeat the above procedure until the valve
operation begins at approximately -1.5 volts.
100 4. SERVICE MENU 23/12/05

SPEED - YS - VALVE CLOSING
NOTE!
As a precaution: For toggle machines, it is advisable to use the mold height

increase function to eliminate any possibility of the two mold
halves contacting during this speed calibration. For tiebarless
machines, it is advisable to remove the mold. The calibration
for clamp opening and closing speeds can only be done manu-
ally. In addition, set the clampforce set value to zero tons while
the speed calibration is being conducted.
Manual Calibration
up cursor -minimum decrease
down cursor -minimum increase
left cursor -maximum decrease
right cursor -maximum increase
1... In order to calibrate the minimum closing speed, the operator must first set all three
closing speeds to 10% on the 'Mold Closing' page.
2... In order to calibrate the maximum closing speed, the operator must first set all three
closing speeds to 80% on the 'Mold Closing' page.
23/12/05 4. SERVICE MENU 101

3... Press 'F3'. This will cause the secondary field to change to the display as shown
below.
ACTUAL VALUE 0.0 in/s
PEAK VALUE 0.0 in/s
Actual value is the actual speed of the mold at any time during the calibration.
Peak value is the stored maximum speed attained during the calibration. This is the
value of interest for this speed calibration.
4... To set the minimum speed (see step 1), use the up/down cursor to adjust the voltage
so that when actuating the 'Mold Close' switch, the mold is just barely moving, or it
achieves 10% of its rated maximum speed as shown in the top right hand corner.
5... To set maximum speed (see step 2), use the left/right cursors to adjust the voltage so
that when actuating the 'Mold Close' switch, the mold is moving at least 80% of its
rated maximum speed as shown in the top right hand corner.
6... If it is considered desirable, the straight line calibration can be adjusted for a more
suitable response, see paragraph 4.1 - “F5 Change” in this chapter.
machine calibration record by re-recording the calibration data on the machine
diskette.
102 4. SERVICE MENU 23/12/05

SPEED - YS - VALVE OPENING
NOTE!
As a precaution: For toggle machines, it is advisable to use the mold height

increase function to eliminate any possibility of the two mold
halves contacting during this speed calibration. For tiebarless
machines, it is advisable to remove the mold. The calibration
for clamp opening and closing speeds can only be done manu-
ally. In addition, set the clampforce set value to zero tons while
the speed calibration is being conducted.
Manual Calibration
23/12/05 4. SERVICE MENU 103

1... In order to calibrate the minimum opening speed, the operator must first set all three
opening speeds to 10% on the 'Mold Open' page.
2... In order to calibrate the maximum opening speed, the operator must first set all three
opening speeds to 80% on the 'Mold Open' page.
3... Press 'F3'. This will cause the secondary field to change the display as shown below.
PEAK VALUE 0.0 in/s
Actual value is the actual speed of the mold at any time during the calibration.
Peak value is the stored maximum speed attained during the calibration. This is the
value of interest for this speed calibration.
so that when actuating the 'Mold Open' switch, the mold is just barely moving, or it
achieves 10% of its rated maximum speed as shown in the top right hand corner.
5... To set maximum speed (see step 2), use the left/right cursor to adjust the voltage so
that when actuating the 'Mold Open' switch, the mold is moving at least 80% of its
rated maximum speed as shown in the top right hand corner.
diskette.
104 4. SERVICE MENU 23/12/05

SPEED - - ROTARY TABLE LEFT
NOTE!
For machines up to 150 Tons a value of 180° per second is usually

chosen for the maximum table speed.
For machines over 150 Tons a value of 140° per second is usually
chosen for the maximum table speed.
Manual Calibration
NOTE!
The same procedure is used for Rotary Table right (Clockwise)
23/12/05 4. SERVICE MENU 105

1. In order to calibrate the minimum table speed, the operator must set the rotation speed
VDT to 10% on the ‘MOLD ROTATION DEVICE’ - ROTARY TABLE (Ejector + F4)
screen page.
2. In order to calibrate the maximum table speed, the operator must set the rotation speed
VDT to 100% on the ‘MOLD ROTATION DEVICE’ - ROTARY TABLE (Ejector + F4)
screen page.
3. Press 'F3' Measurement. This will cause the secondary field to change the display as
shown below.
PEAK VALUE 0.0 in/s
Actual value is the actual speed of the table turning left (counterclockwise) at any time
during the calibration.
Peak value is the stored maximum speed attained during calibration. This is the value
of interest for this speed calibration.
4. To set the minimum speed (see step 1), use the up/down cursor to adjust the voltage
so that when actuating the 'Table ccw' switch, the table is achieving 10% of its rated
maximum speed as shown in the top right hand corner.
5. After adjusting the bottom of the graph, press F2 Change Take Over to adopt the new
graph. Operate the table left to check the speed is at the required percentage.
It will be necessary to rotate the table back to the right or Clockwise to be able to rotate
the table left or Counterclockwise to check the rotation speed.
6. To set maximum speed (see step 2), use the left/right cursor to adjust the voltage so
that when actuating the 'Table ccw' switch, the table is moving at 100% of its rated
maximum speed as shown in the top right hand corner.
7. After adjusting the top of the graph, press F2 Change Take Over to adopt the new
graph. Operate the table left to check the speed is at the required percentage.
It will be necessary to rotate the table back to the right or Clockwise to be able to rotate
the table left or Counterclockwise to check the rotation speed.
8. If it is considered desirable, the straight line calibration can be adjusted for a more
9. Once the calibration of the maximum and minimum speeds is satisfactory, press F1
Interrupt measurement to escape from the calibration function.
10. After achieving a satisfactory calibration, it is advisable to maintain an updated machine
calibration record by re-recording the calibration data on the machine diskette.
106 4. SERVICE MENU 23/12/05

SPEED - YA - VALVE EJECTOR (OPTIONAL)
VALVE - LINEARIZATION 8-2 95-05-31 12:30

SPEED
YA - VALVE 100%= 29.5 in/s
100%
80%
60%
40%
20%
0%
+0 +.1 +2 +3 +4 +5 +6 +7 +8 +9 + 10V
NOTE!
If this option is installed on the machine, the speed can

only be calibrated manually. The program will use the cal-
ibrated values for 'Ejector Forward' speed for both for-
ward and backward ejector movements.
Manual Calibration.
23/12/05 4. SERVICE MENU 107

1... In order to calibrate the minimum opening speed, the operator must set the 'Ejector
Forward' speed to 10% on the EJECTOR page.
2... In order to calibrate the maximum opening speed, the operator must set the 'Ejector
Forward' speed to 80% on the EJECTOR page.
3... Press 'F3'. This will cause the secondary field to change the display as shown below.
PEAK VALUE 0.0 in/s
Actual value is the actual speed of the ejector at any time during the calibration.
Peak value is the stored maximum speed attained during calibration. This is the value
of interest for this speed calibration.
so that when actuating the 'Ejector Forward' switch, the ejector is just barely moving,
or it achieves 10% of its rated maximum speed as shown in the top right hand corner.
5... To set maximum speed (see step 2), use the left/right cursor to adjust the voltage so
that when actuating the 'Ejector Forward' switch, the ejector is moving at least 80% of
its rated maximum speed as shown in the top right hand corner.
diskette.
108 4. SERVICE MENU 23/12/05

4.2.2 PRESSURE CALIBRATIONS
PRESS
SERVICE PASSWORD
(8 - 2) + F2
23/12/05 4. SERVICE MENU 109

PRESSURE-K-VALVE
PRESSURE-KA-VALVE (Optional)
If the machine is equipped with two pumps, two separate calibrations must be completed.
On the secondary calibration menu for pressure, two choices are presented.
0 ... K VALVE (2 pumps)
1 ... K VALVE (1 pump)
During most of the machine cycle two pumps supply hydraulic fluid, but during hold
pressure only the variable displacement pump is engaged. The flow from the fixed
displacement pump is routed directly to tank. Therefore, to ensure an accurate hold
pressure when the second pump drops out of the circuit, both situations must have their
own calibration. Both choices have their own calibration graph.
110 4. SERVICE MENU 23/12/05

There are also two calibrations on the 30-100 Ton machines.
K1 VALVE (1 pump)
K1 VALVE without S10
During most of the machine cycle, movements are accomplished with the pump control
solenoid S10 activated. However, some machine functions are conducted with the S10
valve de-activated. For example, on the 30-100 Ton machines, preheating and idling are
accomplished in this manner.
If the machine is equipped with a proportional valve for the ejector cores or quick mold
change, the following choice will be presented:
KA VALVE EJECTOR
In any event, both calibrations must be conducted during any pressure calibration following
the steps as outlined below.
AUTOMATIC CALIBRATION (Hydraulic Pressure Transducer Required)
1... Press 'F3' Measurement. The machine will move the screw fully forward.
2... The prompt for choosing automatic or manual will appear. Choose 'F2'. The control
system will step up the voltage, in 0.1 volt steps, to 10 volts ( or until maximum
pressure) and measure the pressure at each step.
3... MEASUREMENT automatic
MEASURED VALUE > 0 psi <
SET VALUE 0V
If the green calibration line represents a satisfactory calibration, press 'F4' - CHANGE
TAKE OVER
diskette.
23/12/05 4. SERVICE MENU 111

MANUAL CALIBRATION
1... Turn the manual pressure gauge to position '3' (Injection pressure). Press 'F3'.
The machine will move the screw fully forward.
1b. When calibrating an optional pressure valve for ejectors, cores or quick mold change,
turn the manual gauge to position 5 (ejector pressure). Press 'F3'. The machine will
move the ejector, cores or quick mold change fully forward.
2... The prompt for choosing automatic or manual will appear. Choose 'F1'. The Control
System will step up the voltage, in 0.1 volt steps and wait at each step for the operator
to enter a pressure reading from the manual gauge.
MEASUREMENT manual.
PLEASE ENTER MEA.VALUE: > 0 psi <
SET VALUE 0 V
Enter the pressure reading at each step and press 'ENTER'.
3... If the green calibration line represents a satisfactory calibration, press 'F4'- CHANGE
TAKE OVER.
diskette.
112 4. SERVICE MENU 23/12/05

PROPORTIONAL TABLE PRESSURE CALIBRATION - KC VALVE
This calibration is for machine from 55 to 200 ton that have a proportional valve to control
the pressure from the second pump.
There is a hydraulic pressure transducer mounted in the valve manifold.
AUTOMATIC CALIBRATION (Hydraulic Pressure Transducer Required)
1... Press 'F3'.
2... The prompt for choosing automatic or manual will appear. Choose 'F2'. The control
system will step up the voltage, in 0.1 volt steps, to 10 volts ( or until maximum
pressure) and measure the pressure at each step.
3... MEASUREMENT automatic
MEASURED VALUE > 0 psi <
SET VALUE 0V
If the green calibration line represents a satisfactory calibration, press 'F4' - CHANGE
TAKE OVER
diskette.
23/12/05 4. SERVICE MENU 113

BACK PRESSURE CALIBRATION
BACK PRESSURE-K VALVE
NOTE!
If the machine is equipped with a servo valve, no back pressure

calibration is required. If the machine does not have a servo valve,
back pressure calibration must be completed.
MANUAL CALIBRATION (THERE IS NO AUTOMATIC CALIBRATION)
1... With plastic in the barrel, move the screw forward completely (i.e. inject).
2... Refill the screw and inject again.
3... Close off the nozzle by using the shut-off nozzle or by a forward movement of the
carriage with the nozzle up against a blocking plate.
4... In order to keep the nozzle pressed up against the blocking plate, or against the sprue
bushing , the toggle must be locked, and the 'B' software marker indicating that
condition, must be active. To prevent the nozzle from pushing with too much force
against the stationary mold half, reduced nozzle forward pressure is in effect when the
mold is open.
5... Choose 'F3' MEASUREMENT.
114 4. SERVICE MENU 23/12/05

6... ACTUAL VALUE 0 psi
MEASURED VALUE 0 psi
SET VALUE 0 V
Actuate the manual key for 'Screw Feed' and monitor the pressure gauge. The gauge
should be turned to position '3'. If the machine has a hydraulic pressure transducer,
the pressure reading also appears as the 'ACTUAL VALUE'.
7... Starting at zero volts, the machine will step up the analog output K1+ in 0.1 Volt
increments. At each increment, operate the manual key for “screw feed” and enter the
pressure reading. After each pressure reading entry, remember to press the ENTER
key.
NOTE!
The front half of the screw feed stroke should be used for back pressure
calibration. When the screw exceeds this position the carriage must be
moved back and the screw moved forward to the zero position. Re-
establish nozzle contact before continuing with the back pressure
calibrations.
8... When the back pressure equals or exceeds the maximum pressure allowed (typically
580 psi (40 bar)), the control system switches the calibration OFF.
9... If the green calibration line represents a satisfactory calibration, press 'F4'- CHANGE
TAKE OVER.
diskette.
23/12/05 4. SERVICE MENU 115

4.3 SCREW RPM CALIBRATION
PRESS
SERVICE PASSWORD
(8 - 2) + F2
SCREW RPM - Y VALVE
AUTOMATIC CALIBRATION (There Is No Manual Calibration)
1... Press 'F3' Measurement. The screw will pull back. Next, the machine will step up the
voltage, in 0.1 volt steps, to 10 volts (or until maximum RPM) and measure the RPM
at each step.
2... If the green calibration line represents a satisfactory calibration, press 'F4' - CHANGE
TAKE OVER.
diskette.
116 4. SERVICE MENU 23/12/05

4.4 TOGGLE STROKE TRANSDUCER (ENGEL ONLY)
PRESS
SERVICE PASSWORD
(8 - 2) + F2
POSITION TRANSDUCER
VALVE LINEARIZATION 8-2 95-05-31 12:30

POSITION TRANS.
Mold Position Trans.
23.62 in 100%
80%
60%
40%
20%
0%
0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% 26.97in.
NOTE!
This page is for ENGEL information only. Do not attempt to

calibrate this page.
23/12/05 4. SERVICE MENU 117

100%
23.62 RELATIONSHIP BETWEEN
TOGGLE LEVER AND
MOLD STROKE
0%
100%
TOGGLE LEVER STROKE
A7690458 26.97
During the initial start up of the machine, the non-linear movement of the platen was
recorded and combined with the linear movement of the toggle crosshead to come up with
a relationship between the two movements. That relationship will be exhibited by the
ACTUAL MOLD POSITION, SFx, and the ACTUAL TOGGLE LEVER POSITION, SKx, on
the mold closing page.
If this calibration is ever lost, load-in the machine diskette to calibrate the machine again.
118 4. SERVICE MENU 23/12/05

4.5 STROKE CALIBRATION
PRESS
SERVICE PASSWORD
(8 - 2) + F3
It is important to have the strokes measured at their absolute minimum and maximum
values. For this reason, the stroke calibration should only be done when there is no mold in
the machine.
If any stroke limitation devices are installed on the machine, they must be adjusted so that
the maximum stroke can be achieved.
The procedure for each stroke calibration is outlined on the following pages.
Preliminary Steps
1... Set the Key switch to PR.
2... Switch to manual operation.
3... Start the electric motor.
4... Ensure that conditions exist to allow for the individual movements of the machine (i.e.
safety gate closed, nozzle protection closed, for mold closing, L - ejector retract
position, must be reached, etc.).
5... Acknowledge all errors so that new errors resulting from the calibration can be easily
identified.
23/12/05 4. SERVICE MENU 119

4.5.1 STROKE CALIBRATION PAGE
Function key F1 “Input Cal. 1” selects the first input calibration page, some systems may
have two input calibration pages in which case there would be another function F2 for the
second page.
Function key F6 “take over change” is used when manually entering data. Move the cursor
to the value to be entered or changed. Enter the new value and press “take over change”
for the new data to be accepted.
Function key F7 “Service menu” returns the screen page to the service menu selections.l
120 4. SERVICE MENU 23/12/05

Stroke Calibration Page Variables
Minval / Maxval Maximum and minimum movement of the stroke - machine set value
parameter in inches.
Voltage range
Null Zero calibrated position (milliVolts) of stroke transducer.
Max Maximum calibrated position (milliVolts) of stroke transducer
Offset Automatically set offset (e.g. J point)
Act. Val. The actual stroke (in), corresponds to: SFX for mold stroke
SDX for nozzle stroke
SAX for ejector stroke
SSX for screw stroke
Speed The current speed (in/s) of the respective movement
iw_mv The current stroke transducer output in milliVolts
Ready This flag will light when the calibration is finished
VZ Denotes how the transducer is employed: + = retracted at zero position
- = extended at zero position
23/12/05 4. SERVICE MENU 121

4.5.1.1 MOLD STROKE CALIBRATION
NOTE!
The mold must be removed from direct hydraulic machines to calibrate

this function.
Toggle machines do not require the mold to be removed to calibrate the mold stroke (i.e.
toggle stroke). Increase the mold height so that there is mold clearance when the toggle is
locked.
1... In the set-up mode, set the mold open stroke position 'A' to the maximum value. Open
the clamp to the maximum stroke position.
2... On the stroke calibration page, move the cursor to the 'ON/OFF' zone.
3... Press '1', then 'Enter'. All stroke calibrations can now be effected.
4... Actuate manual operation key for clamp open and carefully JOG the clamp open to its
mechanical maximum position. Notice that the stroke position and “iw_mv”, the actual
transducer voltage signal, are both increasing in value.
5... Keep the clamp open manual key actuated until “Act. Val” (Actual calibrated position)
equals the “Maxval” (Absolute stroke length) and the value appearing in the “iw-av”
(actual transducer signal) datafield is transferred into the datafield for “Max” (signal
stored at maximum position).
6... Actuate manual operation key for clamp close. Notice that the “Act. Val.” (stroke
position) and iw_mv (actual transducer voltage signal) values are both decreasing.
7... Keep the clamp close manual key actuated until the ‘Act. Val.” (actual calibrated stroke
position) value equals 0.0 and the value appearing in the “iw_mv” (actual transducer
signal) datafield is transferred into the ‘Null” (signal stored at min position) datafield.
8... At this time the calibration mark lights up at the end of the column indicating that the
stroke has been calibrated.
NOTE!
After calibrating all strokes, move the cursor to the “ON/OFF” zone.
Press “0”, then “Enter”. The stroke calibration function does not turn
off automatically, it must be done manually.
122 4. SERVICE MENU 23/12/05

4.5.1.2 NOZZLE STROKE CALIBRATION
NOTE!
The stationary mold half must be removed to calibrate this function

1... On the stroke calibration page, move the cursor to the “ON/OFF” zone.
2... Press “1”, then “Enter”. All stroke calibrations are now available for change.
3... Actuate manual operation key for “nozzle back” and move the nozzle back to its
mechanical maximum position. Notice that the stroke position and “iw_mv”, the actual
transducer voltage signal, are both increasing in value.
4... Keep the “nozzle back” manual key actuated until the ‘Act. Val.” (actual calibrated
position) equals the “Maxval” (absolute stroke length) and the value appearing in the
“iw_mv” (actual transducer signal) datafield is transferred into the “Max” (signal stored
at maximum position) datafield.
5... Actuate manual operation key for “nozzle forward”. Notice that the stroke position and
“iw_mv” (actual transducer voltage signal) are both decreasing in value.
6... Keep the “nozzle forward” manual key actuated until “Act. val.” (actual calibrated
stroke position) value equals 0.0 and the value appearing in the “iw_mv” (actual
transducer signal) datafield is transferred into the “Null” (signal stored at minimum
position) datafield.
NOTE!
Press “0”, then “Enter”. The stroke calibration function does not turn off
automatically, it must be done manually.
23/12/05 4. SERVICE MENU 123

4.5.1.3 EJECTOR STROKE CALIBRATION
NOTE!
The moving mold half must be removed to calibrate this function
2... Press “1”', then “Enter”. All stroke calibrations can now be effected.
3... Actuate manual operation key for “ejector forward” and move the ejector forward to its
mechanical maximum position (max.). Notice that Act. val. (stroke position) and
“iw_mv” (actual transducer voltage signal) are both increasing in value.
4... Keep the “ejector forward” manual key actuated until “Act. val.” (actual calibrated
position) equals “Maxval”.(absolute stroke length) and the value appearing in “iw_mv”
(actual transducer signal) datafield is transferred into the “Max.” (signal stored at MAX
position) datafield.
5... Actuate manual operation key for “ejector back”. Notice that the “Act. val.” (stroke
position) and “iw_mv” (actual transducer voltage signal) are both decreasing in value.
6... Keep the “ejector back” manual key actuated until “Act. val.” (actual calibrated stroke
position) equals 0.0 and the value appearing in the “iw_mv” (actual transducer signal)
datafield is transferred into the “Null” (signal stored at minimum position) datafield.
NOTE!
Press “0”, then “Enter”. The stroke calibration function does not turn
off automatically, it must be done manually.
124 4. SERVICE MENU 23/12/05

4.5.1.4 SCREW STROKE CALIBRATION
2... Press “1”, then “Enter”. All stroke calibrations can now be effected.
3... Actuate manual operation key for “injection feed” and move the screw back to its
mechanical maximum position. Notice that “Act. val.” (stroke position) and “iw_mv”
(actual transducer voltage signal) are both increasing in value.
4... Keep the “injection feed” manual key actuated until “Act. val.” (actual calibrated
position) equals “Max.val.” (absolute stroke length) and the value appearing in the
“iw_mv” (actual transducer signal) datafield is transferred into the “Max” (signal stored
at maximum position) datafield.
5... Actuate manual operation key for “injection inject”. Notice that “Act. val.” (stroke
position) and “iw_mv” (actual transducer voltage signal) are both decreasing in value.
6... Keep the “injection inject” manual key actuated until “act. val.” (actual calibrated stroke
position) value equals 0.0 and the value appearing in the “iw_mv” (actual transducer
signal) datafield is transferred into the “Null” (signal stored at minimum position)
datafield.
NOTE!
Press “0”, then “Enter”.
The stroke calibration function does not turn off automatically, it must
be done manually.
23/12/05 4. SERVICE MENU 125

4.5.1.5 ROTARY TABLE CALIBRATION
1 Select the MOLD ROTATION DEVICE screen page via the

2. The table must be down and locked at the number 1 position, that is always 60°.
3. The transducer is then mechanically adjusted so that the Rotary table Pos. Act. Value
- SDTx line on the MOLD ROTATION DEVICE screen page, reads 60° ± 0.3°.
4 Enter the actual value for table position into the Position 1 window.
5. Rotate the table at 10% speed to position 2, either 180° or 240° lower and lock the table
with the shot pin.
6. On the MOLD ROTATION DEVICE screen page enter the Rotary table Pos. Act.
Value - SDTx into the End position 2 window.
7. If the table has a third position, rotate the table to that position and lock the table with
the shot pin. Enter the actual value into End position 3 window.
The minimum rotation speed must be set up to suit the particular mold being used, the
table should just turn at minimum table speed. The minimum table speed is the speed
that the table ramps down to before stopping. If this speed is set too low the table may
never reach the target position, and if it is set too high the table may tend to overshoot
the target position.
Adjustments made on the ROTARY TABLE page will not correct large positioning
errors. If the table stops well outside the target table position and the transducer has
been set up properly then it may be necessary to call the ENGEL service department.
8. Rotate the table and check that the table stops in the correct positions.
126 4. SERVICE MENU 23/12/05

4.5.1.6 MOLD HEIGHT TRANSDUCER (IF INSTALLED)
NOTE!
Remove the mold and lock the toggle (i.e. clamp closed) to calibrate
the mold height transducer.
The mold height; stroke transducer calibration is similar to the other stroke calibrations,
except that the minimum and maximum positions are not mechanical limits.
The maintenance technician must adjust the mold height with the keyswitch to a measured
minimum position.
1... Determine the minimum and maximum mold height distances from the machine
specifications.
2... On the stroke calibration page, move the cursor to the “ON / OFF” zone.
3... Press 1 followed by ENTER. All stroke calibrations can now be affected.
4... Actuate the manual operation key for mold height increase and move the moving
platen back to the measured maximum mold height.
The measured maximum mold height is the sum of the minimum mold height and the
maximum mold height. A 200 ton toggle machine has a minimum mold height of 5.91
inches and a maximum mold height of 40.16 inches, then the measured distance from
the stationary platen to the moving platen would be 5.91 + 40.16 = 46.07 inches.
Measure between the moving platen and the stationary platen.
5... Move the cursor to mold height “Max” datafield and manually transfer the “iw_mv”
(actual transducer voltage) reading into the “Max” (signal stored at maximum)
datafield.
6... Actuate the manual operation key for mold height decrease and move the moving
platen forward to the measured minimum mold height position. Measure between the
moving platen and the stationary platen.
7... Move the cursor to mold height “Null” datafield and manually transfer the “iw_mv”
(actual transducer voltage) reading into the “Null” (signal stored at minimum) datafield.
8... Press the F6 key “Accept Changes” to initialize the new values and save them into
memory. The maximum and minimum mold height stroke values are now calibrated.
9... At this time the calibration mark at the end of the row, lights up indicating that the mold
height stroke has been calibrated.
NOTE!
On completion of calibration of all strokes, move the cursor to the “ON /

OFF” zone. Press “0” followed by “ENTER”.
This must be done manually as the function does not turn off
automatically when stroke calibration is finished.
The stroke calibration function is now turned off.
23/12/05 4. SERVICE MENU 127

5 TEST AND PARAMETERS
PRESS
SERVICE PASSWORD
(8 - 2) + F4
This is the area where Engel service technicians examine or change machine parameters.
Speeds, pressures, times, stroke positions, signal change ramps and certain fixed values
are just some of these parameters.
Most of the program options do not concern the customer and must not be activated. Three
of the program options, however, can provide valuable and useful information to a qualified
customer maintenance technician and should be employed.
The “Signal Debugger”, F2 and the “Variable Debugger” F3 can be used to examine the
active state of digital inputs or digital outputs. The SGM Debugger F4 can be used to
examine the analog inputs and outputs to and from the analog card, respectively.
128 4. SERVICE MENU 23/12/05

5.1 PROGRAM STATUS
PROGRAM - Program staus

1. Press ‘F1’ -
DEBUGGER
NOTE!
FOR ENGEL USE ONLY
This area allows the programs running the machine to be debugged.

Information determined by using this function is only useful to ENGEL software engineers
and is used by them or in conjunction with a service technician to diagnose software
problems on the machine.
The customer alone would be unable to make use of this function.
Pressing EXIT will return to previous function frame, as shown below.
23/12/05 4. SERVICE MENU 129

5.2 SIGNAL DEBUGGER
5.2.1 STEPS TO EXAMINE DIGITAL OUTPUTS
SIGNAL
1. Press ‘F2’ -
DEBUGGER
The following function frame will appear.
2. Press ‘F1’ - DIGITAL

OUTPUT
3. The screen page as shown below will appear.
Press ‘F8’ - EXIT to return to the Test and Parameters main menu
Each digital output board is exactly the same, but the CPU needs to know the difference
between the boards, regarding specific digital outputs. For that reason, each digital input
card must be set to a different address. There is a card coding switch on the card itself,
which must be set correctly.
130 4. SERVICE MENU 23/12/05

NOTE!
See chapter 2, section 3 for the address settings for the

card coding switches.
Refer to the Appendix in this manual for a general listing of the digital output numbers and
exactly what they mean. A machine specific listing will be found in the software description
in 'Technical Data' section 2, of your machine manual. Keep in mind that the digital output
number does not necessarily indicate the actual wiring position on the card.
The digital output numbers that are highlighted, represent the fact that the CPU is activating
a digital output. This does not mean that the digital output is reaching the relevant solenoid.
There could still be a defective digital output card.
If a digital output appears to be activated on the digital output page, it only means that the
CPU card is activating the output. It does not mean that the signal is actually reaching the
intended output solenoid. The digital output card or the solenoid itself could be defective.
23/12/05 4. SERVICE MENU 131

FORCING DIGITAL OUTPUTS AT THE CPU
CAUTION!
1... DO NOT ATTEMPT THIS PROCEDURE WITH THE MAIN ELECTRICAL MOTOR
RUNNING!!!!
2... THE USE OF THIS PROCEDURE ALLOWS THE OPERATION OF THE MACHINE
IN AN UNSAFE MANNER AND THEREFORE THE USE OF THE PROCEDURE
MUST BE RESTRICTED TO ENGEL TRAINED PERSONNEL.
3... DO NOT USE THIS PROCEDURE WHEN THE MACHINE IS IN PRODUCTION.
For service or maintenance purposes it is sometimes required to force a digital output active
(Force Set 1 or Set 1). Similar to the forced digital inputs a factory set forced digital output
may be required to account for an option that is not fitted to that particular machine. Also the
manually forced outputs will return to the factory setting when the control voltage is turned
off and on again.
Output State Color and Background

Output Inactive Output number green on black
Output Active Output number black on green
Forced Inactive Output Output number red on black
Forced Active Output Output number black on red
132 4. SERVICE MENU 23/12/05

MANUAL FORCING
Manual forcing of digital outputs can be an effective way of checking circuit continuity. A
digital output can be forced on at the control and the signal can be checked with a voltmeter
at the solenoid plug. This method can save time when trouble shooting digital output
circuits. Refer to the digital output screen page, via the SIGNAL DEBUGGER screen page,
on the display.
Set 0 to force a digital output to the inactive state, but still under the influence of the
-
current Ebias program.
Set 1 to force a digital output to the active state, but still under the influence of the
-
current Ebias program.
Forced to force a digital output to the inactive state without any influence from the cur-
-
Set 0 rent Ebias program.
Forced to force a digital output to the active state without any influence from the cur-
-
Set 1 rent Ebias program.
Forced
- to force reset a digital output to the factory programmed state.
Reset
Logical the table shows the I/Os with their internal administration numbers (MF num-
DIO bers). I/Os not used by the program appear with the physical number
Physic the table shows I/Os with their physical numbers (= designation on the termi-
al DIO nals). Marking by a ’*’ in front of the number
EXIT - to return to the 'Tests and Parameter's page.
Example: To set digital output 0 (mold close) high:
1... Press function key F2 “Set 1”.

A blue data entry box will open for the entry of the digital output number to be
manually set.
2... To abort the force set, press F8 CANCEL to return to the previous function frame.
3... Enter digital output number 0 and press ENTER.
The number 0 background will become green to show that the input has been
manually set high.
23/12/05 4. SERVICE MENU 133

5.2.2 STEPS TO EXAMINE DIGITAL INPUTS
SIGNAL
1. Press ‘F2’ -
DEBUGGER
DIGITAL
2. Press ‘F2’ -
INPUT
Each digital input board is exactly the same, but the CPU needs to know the difference
between the boards, regarding specific digital inputs. For that reason, each digital input card
must be set to a different address. There is a card coding switch on the card itself, which
must be set correctly.
134 4. SERVICE MENU 23/12/05

NOTE!
See chapter 2, section 2.3 for the address settings for the
card coding switches.
Refer to the Appendix in this manual for a general listing of the digital input numbers and
exactly what they mean. A machine specific listing will be found in the software description
in 'Technical Data' section 2, of your machine manual. Keep in mind that the digital input
number does not necessarily indicate the actual wiring position on the card.
The digital input numbers that are highlighted, represent the fact that the CPU is receiving
a digital input.
If a digital input appears to be activated on the digital input page, it can be assumed that the
24VE supply, the digital input card, the motherboard and the CPU card are all operating
correctly.
23/12/05 4. SERVICE MENU 135

FORCING DIGITAL INPUTS AT THE CPU
CAUTION!
1.-DO NOT ATTEMPT THIS PROCEDURE WITH THE MAIN ELECTRICAL MOTOR
RUNNING!!!!
2... - THE USE OF THIS PROCEDURE ALLOWS THE OPERATION OF THE MACHINE
3... - DO NOT USE THIS PROCEDURE WHEN THE MACHINE IS IN PRODUCTION.
The factory installed software is designed to accommodate a wide range of optional
machine extras. The machine supplied may not have all, or any, of the options that are
available, so certain digital inputs have to be forced active (Force Set 1) or inactive (Force
Set 0) to account for those options not fitted.
All the digital inputs can be forced active or inactive to allow maintenance or troubleshooting
to be performed on the machine.
Any manually forced digital inputs will return to their factory set state when the control
voltage has been turned off and back on again.
Input State Color and Background

Input Inactive Input number green on black
Input Active Input number black on green
Input Inactive with FSet0 Input number red on black
Input Active with FSet0 Input number black on red
136 4. SERVICE MENU 23/12/05

MANUAL FORCING
For service or maintenance purposes, digital inputs can be forced active or inactive. Refer
to the DIGITAL INPUT screen page on the display, which is accessed via the SIGNAL
DEBUGGER screen page. The following function frame will be displayed.
Forced
- to force a digital input to the inactive state
Set 0
Forced
- to force a digital input to the active state
Set 1
Forced
- to force reset a digital input to the factory programmed state.
Reset
Logical the table shows the I/Os with their internal administration numbers (MF num-
DIO bers). I/Os not used by the program appear with the physical number
Physic he table shows I/Os with their physical numbers (= designation on the termi-
al DIO nals). Marking by a ’*’ in front of the number
EXIT - to return to the 'Tests and Parameter's’ page.
Example: To set digital input 5 (purge guard) high:

1... Press function key F2 “Set 1”.
A blue data entry box will open for the entry of the digital input number that is to be
forced set.
2... To abort the force set, press F8 CANCEL to return to the previous function frame.
3... Enter digital input number 5 and press ENTER.
The number 5 background will become red to show that the input has been forced
high.
If F1 “Force set 0 had been selected the number would have been displayed in red
with a black background to show that the input had been forced low.
23/12/05 4. SERVICE MENU 137

5.2.3 STEPS TO EXAMINE INPUTS MARKERS
SIGNAL
1. Press ‘F2’ -
DEBUGGER
2. Press ‘F3’ - MARKS
Input markers 64 to 127 represent internal software markers and are not referenced in this
section.
Input markers 0 to 50 are used as manual selector switch inputs. These switches are wired
directly from the manual selector switches to a row of pins on the back of the faceplate panel
and from there into the CPU via the E - SEK/B card.
138 4. SERVICE MENU 23/12/05

CAUTION!
Do not attempt to use the SET0 or SET1 functions in this program

If the input marker page is called up on the screen and a manual function switch is activated,
the marker as indicated in the table below will be active (i.e. the marker number is flagged
by a box).
This function can be used to trouble shoot manual function selector switches.
Marker Action Marker Action

0 mold opening 32 not used
1 mold closing 33 not used
2 ejector retract 34 not used
3 ejector forward 35 not used
4 core(s) in 36 not used
5 core(s) out 37 not used
6 mold height increase 38 not used
7 mold height decrease 39 not used
8 mold half release fixed platen 40 not used
9 mold half secure fixed platen 41 not used
10 injection 42 not used
11 feeding 43 not used
12 nozzle forward 44 not used
13 nozzle retract 45 not used
14 air valve 1 46 cycle start
15 air valve 2 47 program interruption
16 mold release (q.m.c.) 48 not used
17 mold secure (q.m.c.) 49 not used
18 not used 50 cores and ejector motion
19 not used 51 not used
20 manual 52 not used
21 select semi-automatic mode 53 not used
22 select fully-automatic mode 54 not used
23 select setup mode 55 not used
24 a 56 not used
26 b 58 not used
27 c 59 not used
28 safety gate closing 60 not used
29 safety gate opening 61 not used
31 safety gate automatic 63 not used
23/12/05 4. SERVICE MENU 139

5.3 VARIABLE DEBUGGER
5.3.1 STEPS TO EXAMINE SET VALUES
VARIABLE
1. Press ‘F3’ -
DEBUGGER
The function key “Single Selection” enables the operator

Single
2. Press ‘F1’ - to select or de-select a particular parameters on the
Selection
screen. Position the cursor on the line to be selected or
de-selected and press F1.
The function key “Common Selection” enables the oper-

Common
3. Press ‘F2’ - ator to select or de-select all the parameters on the
Selection
screen.
140 4. SERVICE MENU 23/12/05

SET VALUE
Set
4. Press ‘F3’ - The following screen and function frame will appear.
Value
The set values related to the areas selected on the previous page will be displayed.
Use the left or right arrow keys to scroll along the columns of variables or the up / down
arrow keys to scroll up or down through the columns of variables.
As the cursor is placed on each variable, the maximum and minimum range of that variable
will be displayed, in brackets, at the bottom left-hand corner of the screen, e.g. [0 - 999].
The set values can be changed by entering a new number. If the number being entered is
out of the range of that variable, the controller will display the prompt
“Invalid value! Change = <ENTER>“ i.e. Press enter again to confirm the change.
23/12/05 4. SERVICE MENU 141

ACTUAL VALUES
Actual
5. Press ‘F4’ - The following screen and function frame will appear.
Values
The actual set values related to the areas selected on the previous page will be displayed.
Use the arrow keys to scroll along or up and down through the lists. The actual set values
cannot be accessed or changed by the operator.
The actual set value numbers are on the left-hand side of the column and are displayed in
green.
The actual set values are on the right-hand side of the column and are displayed in white.
ACTUAL VALUE STATUS
Press either F3 or F4 to display “Set Values” or “Actual Values”
142 4. SERVICE MENU 23/12/05

VARIABLE SEARCH
Variable
6. Press ‘F5’ -
Search
The group location of a Set Value can be determined using the function “Variable Search”.
Press the function key F5 “Variable Search”, a blue data entry box will appear at the lower
left-hand side of the screen.
Input the number to be search for, omitting any zeros at the beginning of the number
(e.g. set value 00024 input as just 24).
Press the ENTER key.
The groups and parameters that the number occurs in will be tagged with an “X”.
Press F8 EXIT to return to the previous function frame.
Press function key F3 “Set Values” to display the group and parameter information.
If the entered number is invalid, when the ENTER key is press the data entry box will clear,
ready for the input of a valid set value number.
23/12/05 4. SERVICE MENU 143

The following function frame will be displayed.
The actual value status of the “Actual Value” are displayed at the bottom of the screen.
•SFx - Actual Mold Position,
•SDx - Actual Nozzle Position,
•SAx - Actual Ejector Position,
•SSx - Actual Screw Position,
•SKx - Actual Toggle position,
•Analog Inputs,
are displayed on the bottom of the screen page.
Each press of the “Act. Value Status” function key will cycle through the lists of actual value
status. This function can be used whilst displaying the “set values” or “actual values” screen
page.
EXIT
4. Press ‘F8’ - EXIT to return to the ‘Test and Parameters’ main menu.
NOTE!
Refer to Chapter 8 of this manual for a listing of the Variable Set Values
144 4. SERVICE MENU 23/12/05

5.4 SGM DEBUGGER
5.4.1 STEPS TO EXAMINE ANALOG OUTPUTS
SGM
1. Press ‘F4’ -
DEBUGGER
2. Press F3 for Analog output.

Press EXIT to return to the ‘Test and Parameters’ main menu.
TEST and PARAMETERS 8-2 95-06-06 12:00
Current output Analog card 1
HW -No Valve [mV] Prio. Perc.1 Prio. Perc.2 Prio. Perc.3

02 Prop.clamp.unit 29 *** *** *** *** *** ***
04 Centr. K valve 0 25 36 255 255 *** ***
03 Centr. Y valve 2251 25 35 255 255 *** ***
Voltage Setting Analog card 1
HW -No Valve [mV]

00 S e r v o v a l v e 800
K1 - AO00 = 800 K1 - AO01 = 1000
Error information Analog card 1
M o d u l e n u mb e r 16 S o u r c e l i n e n u mb e r 356 E r r o r n u mb e r 14
A d d r e ss 0000004C E B I A S- Er r o r - Nr 202
D a t e / T i me 9 5 - 0 6- 0 6 1 2 : 0 0
23/12/05 4. SERVICE MENU 145

1.... Current output Analog card 1
HW -No Valve [mV] Prio. Perc.1 Prio. Perc.2 Prio. Perc.3

2.... 02 Prop.clamp.unit 29 *** *** *** *** *** ***
3.... 04 Centr. K valve 0 25 36 255 255 *** ***
4.... 03 Centr. Y valve 2251 25 35 255 255 *** ***
Line 1 shows the current Analog card selected.

Line 2 displays the current output of the analog card for the selected valve.
ANALOG OUTPUTS
0 - AO00 - Servo valve system pressure; back pressure if servo not installed
1 - AO01 - Proportional Ejector.
2 - AO02 - Proportional Clamp Unit
3 - AO03 - Central Y Valve
4 - AO04 - Central K Valve
5 - AO05 - SR161
6 - AO06 - SR161
7 - AO07 - SR161
8 - AO08 -.SR161
9 - AO09 -.SR161
10 - AO010 -.SR161
11 - AO011 -.SR161
12 - AO012 -.SR161
13 - AO013 -.SR161
All analog voltage signals would be transmitted to an amplifier card, which in turn would
control the valve position.
146 4. SERVICE MENU 23/12/05

Analog Output
CPU MOTHERBOARD Analog

CARD
* Card
Analog Input
A7651768
Analog Inputs or
Outputs on Screen
FORCING ANALOG OUTPUTS AT THE CPU
CAUTION!
1... -DO NOT ATTEMPT THIS PROCEDURE WITH THE MAIN ELECTRICAL MOTOR
RUNNING!!!!
2... - THE USE OF THIS PROCEDURE ALLOWS THE OPERATION OF THE MACHINE
3... - DO NOT USE THIS PROCEDURE WHEN THE MACHINE IS IN PRODUCTION.
Functional testing of the analog card can be achieved by forcing the outputs to a
known state and checking with a volt meter that the output generated by the analog
card corresponds with the known state.
Analog outputs that are manually forced will return to their factory set state once the
control voltage has been turned off and on again.
23/12/05 4. SERVICE MENU 147

To force an Analog output, move the cursor down to the voltage setting area of the screen
page.
• On line 1 select the analog card.
• On line 2 select the valve required, the current analog output is displayed under
“Valve [mV]”.
• On line 2 select the current analog output, under “Valve [mV]” and enter the new
forced output in millivolts.
• On line 3 the forced output requested will be displayed. To delete the forced output,
move the cursor down to line 3 and press F1 “Erase Outputs”.
1.... Voltage Setting Analog card 1
HW -No Valve [mV]

2.... 00 S er vo valv e 800
3.... K1 - AO00 = 800 K1 - AO01 = 1000
MANUAL FORCING
If an output is forced set at the CPU, but does not appear at the relevant analog output port,
the analog card can be considered defective and must be replaced. Refer to the voltage
setting area of the Tests and Parameters analog output page, for the output value that
should appear at the analog card. Use a volt meter to check the analog output expected at
the analog card.
NOTE!
The voltage value shown on the display will not be exactly the
same as the reading on the volt meter, the reading should be
within a few hundredths of a volt. The reading, at the Analog
card, will depend on the accuracy and calibration state of the
volt meter used.
148 4. SERVICE MENU 23/12/05

5.5 SERIAL I / O DEBUGGER
1. Press ‘F5’ - SIO
The following screen page and function frame will appear.
SIO - Debugger
INTERFACE Baudrate Framing Info

# Name In: Out: Stopbits Databits Parity Incnt Outcnt Inerr
0 TEST 9600 9600 1 8 no 0 0 0
1 Printer 300 300 1 8 no 0 64372 0
2 KFTC 4800 4800 1 8 even 1600 1460 0
3 Floppy 115200 115200 1 8 even 59 40 0
4 Host 9600 9600 1 7 even 0 0 0
5 ????? DISABLE DISABLE 1 8 no 0 0 0
2. Highlight, with the cursor, the interface to be monitored and when F1 Details is pressed
the device using that interface will be displayed. The specifications of that interface will be
displayed on the next screen page.
23/12/05 4. SERVICE MENU 149

3. Press - F1 - DETAILS
The following screen page and function frame will appear.
The receive and transmit data, to and from the peripheral device will be displayed on the R
(receive) and T (transmit) lines confirming that the device is communicating with the control
system. The peripheral device used on the example screen page shown, is the touch
sensitive keyboard and only shows the ASCII data being sent to the device.
The customer can view this page to confirm that a peripheral device is or is not
communicating with the control system. The actual information being displayed is only
useful to ENGEL service or software departments.
The CU211 processor card has four standard serial interfaces, and they are usually
assigned as follows: SIO0 - Debugger port, SIO 1,2 and 3 - RS232 interfaces. There is the
possibility of installing up to 16 serial interfaces on the control system.
150 4. SERVICE MENU 23/12/05

The standard control system has four interfaces.
Interface 0: The System debugger interface is mounted on the CU211 card. This 9
pin plug, accessible on the front panel, allows for the connection of a
personal computer or a modem for loading sequence programs or
remote diagnosis machine problems.
Interface 1: PRINTER (Serial Input)

The transmission rate (baud rate) can be set with variable parameter
35593 (Serial interface group). The baud rate settings are:-
12 = 115200, 11 = 57600, 10 = 38400, 9 = 19200, 8 = 9600, 7 = 4800,
6 = 2400, 5 = 1200, 4 = 600, 3 = 300, 2 = 150, 1 & 0 Reserved.
Interface 2: K-FTC Touch sensitive keyboard controller. The transmission rate (baud
rate) can be set with variable parameter 35594 (Serial interface group).
Interface 3 FLOPPY DISK DRIVE. The transmission rate (baud rate) can be set with
variable parameter 35593 (Serial interface group).
Interface 4 HOST COMPUTER. The transmission rate (baud rate) can be set with
variable parameter 35595 (Serial interface group).
Interface 5 SPI. The transmission rate (baud rate) can be set with variable
Hot Runner Controller, Temperature Control Units, Scales, Flow Rate

Controllers, Digital Sliding Calipers, etc.
Interfaces 6 - 15 Reserved
4. Press ‘F2’ To toggle between STOP and START.

When the display of data is started the word START will be displayed next to the
“data entry field”. When the display of data is stopped the word STOP will be dis-
played next to the “ data entry field”.
5. Press ‘F3’ To toggle between ASCII and HEX (hexadecimal) information displayed on the
R = Receive and T = Transmit lines.
When ASCII information is selected the word ASCII will be displayed next to the
“data entry field” confirming that ASCII was selected.
When HEX information is selected the word HEX will be displayed next to the
“data entry field” confirming that HEX was selected.
6. Press ‘F8’ To EXIT to return to the TEST and PARAMETER main menu screen page.
23/12/05 4. SERVICE MENU 151

5.6 STATUS REPORT
STATUS
1. Press ‘F6’ -
REPORT
T E S T A N D P A R A M E T E R S 8 - 2 95-07-27 12:00
Status Report
The status report is a listing of the state of a machine at a given moment in time. If the
machine has a problem or an unexplainable error, which cannot be resolved by the
customer, the status report can be used to troubleshoot the problem.
The status report can be copied on to a floppy disk or downloaded to a printer for a hard
copy as a record. The status report can then be viewed by Engel service or software
engineers to resolve the machine problem.
The recommended medium is a floppy disk, as the report is approximately 200Kbytes, the
hardcopy version may be up to 20 pages of information.
Press F1 or F2 to abort either of the functions
152 4. SERVICE MENU 23/12/05

5.7 DATE AND TIME
PRESS
SERVICE PASSWORD
(SM1) + F5
DATE/TIME
This screen allows the operator to set the correct date and time which appears in the upper
right-hand corner of the video display monitor. Notice that the time is based on a 24 hour
clock (i.e. 6:00 PM equals 18:00)
1997 -01-17 14 : 10 : 35
1997 -01-17 14 : 10 : 00
When this screen page is selected, the current information stored in memory appears above
the cursor arrows.
As you enter the numerical values for each item and press the ENTER keypad, the cursor
will move automatically.
After the date and time has been set press F1 - ENTER for the controller to accept the new
date and time. The new date and time will be transferred into the right-hand corner of the
display monitor.
23/12/05 4. SERVICE MENU 153

5.8 TEMPERATURE CALIBRATION
PRESS
SERVICE PASSWORD
(SM1) + F6
TEMPERATURE CALIBRATION 95-03-14 12:00
1...... Temperature zone number: 0

2...... Actual temperature: 82 oF
3...... Thermocouple type: J-DIN
4...... Offset adjustment: - +
5...... Gain adjustment: - +
6...... Reset zone calibration: NO
Refer to the line number on the following pages for the description of each variable.
TEMPERATURE CARD CALIBRATION
Each Temperature Card is calibrated by the card manufacturer and the calibration data is
stored on the card EPROM chip.
However, since there are two main types of thermocouples, a temperature accuracy
problem could develop when replacing a defective thermocouple with the other type.
Therefore, a calibration procedure is required to compensate for the inherent differences
between the two thermocouple types.
The J-DIN thermocouple is European in origin and can be identified by its red and blue
leads. The red (iron) lead is positive and the blue (constantan) lead is negative.
The J-IEC thermocouple is North American in origin and can be identified by its white and
red leads. The white (iron) lead is positive and the red (constantan) lead is negative.
Iron Constantan
(+) (-)
-------------------------
J-DIN: Red Blue
J-IEC: White Red
154 4. SERVICE MENU 23/12/05

1 .... Temperature zone number: 1

This is where the maintenance technician would enter the number of the zone to be
calibrated. 0 is for the oil temperature, 1 is for the nozzle, etc.
2 .... Actual temperature: 440 F

Whenever a zone number is entered on line 1, the actual temperature reading of that zone
will appear on this line.
3 .... Thermocouple type: J-IEC

The thermocouple type must be identified on this line. ENGEL typically employs J-IEC type
for the nozzle and J-DIN type for other heat zones.
4 .... Offset Adjustment: - +

This is where the offset (ambient) temperature can be adjusted up or down. To increase or
decrease the calibrated offset temperature, move the cursor to the plus or minus position,
respectively, and press the 'ENTER' key. Each press of the 'ENTER' key will increase or
decrease the actual temperature reading, as displayed on line 2, by1 Celsius degree
If 'MAX.MINUS' or 'MAX.PLUS' appears to the right of this datafield, the maximum
adjustment possible has been reached.
5 .... Gain Adjustment: - +

This is where the gain (high end) in temperature readings can be adjusted up or down.
During calibration, to increase or decrease the temperature reading, move the cursor to the
plus or minus position, respectively, and press the 'ENTER' key. Each press of the 'ENTER'
key will increase or decrease the actual temperature reading, as displayed on line 2, by 1
degree Celsius.
If 'MAX.MINUS' or 'MAX.PLUS' appears to the right of this datafield, the maximum
adjustment possible has been reached.
6 .... Reset zone calibration: NO

To eliminate the adjusted calibration values of any heat zone and restore the manufacturer's
calibration values as stored on the EPROM chip, move the cursor to this line, press 1 and
then press 'ENTER'.
The original calibration values of the zone indicated on line 1, will be restored.
23/12/05 4. SERVICE MENU 155

TT 081 TEMPERATURE CARD CALIBRATION PROCEDURE
STEP: 1... Enter the zone number to be calibrated on line 1.

STEP: 2... Ensure that the correct thermocouple type has been selected on line 3 (J-DIN or
J-IEC).
STEP: 3... Disconnect the thermocouple leads for the selected zone at the edge of the
temperature card.
STEP: 4... Connect the thermocouple calibration device to the appropriate terminals for the
selected zone at the edge of the temperature card.
STEP: 5... With the thermocouple calibration device set to sourcing/calibration mode, use
the Offset adjustment (line 4) to adjust the actual temperature reading, as shown
on line 2, until it equals the temperature reading of the calibration device.
STEP: 6... With the thermocouple calibration device set to the calibrate mode, cause a
signal equivalent to 500 oC (932 oF) to be delivered to the selected temperature
zone. If required, use the Gain adjustment (line 5) to adjust the actual
temperature reading, as shown on line 2, until it equals the temperature reading
of the calibration device. If a large gain adjustment was required and/or the
ambient temperature was very high, it may be necessary to repeat steps 5 and
6 several times.
STEP: 7... Disconnect the calibration device and correctly reconnect the thermocouple to
the temperature card.
STEP: 8... Repeat steps 1 through 7 for each temperature zone to be calibrated.
9... The heat calibration values are stored along with the machine parameters. Make sure
you save these temperature zone calibration values by rewriting to the machine
parameters diskette - PARAM.BIN, NOT KALIB.BIN.
156 4. SERVICE MENU 23/12/05

5.9 SPI STATUS
PRESS F7
This screen page is accessible using the customer level 0 password (6 – 1)

MISCELLANEOUS PARAMETER
baudrate
The rate of communication between the machine controller and the peripheral device is
set in this datafield. The machine controller and peripheral device must be set to the same
baudrate. The baudrate is typically set to 8, which is 9600.
12 = 115200 11 = 57600
10 = 38400 9 = 19200
8 = 9600 7 = 4800
6 = 2400 5 = 1200
4 = 600 3 = 300
2 = 150 1&0 = Reserved
blocktransfer
0 = no block transfers
1 = block transfers (refer to peripheral device manual).
If the peripheral device allows block transfer of data, set the datafield to 1.
If the peripheral device does not allow block transfer of data the datafield must be set to 0.
23/12/05 4. SERVICE MENU 157

deviceswitch
0 = off (option turned off)
1 = on (option turned on)
This is a command from the machine controller to shut down the peripheral device.
timer a
The time set (in milliseconds) for the machine controller command signal “timeout”. This is
the amount of time the system will wait for the expected command signal to be sent. After
the time has expired and no signal is present the fault indication will light.
delay
The time set (in milliseconds) for the delay between messages from the machine controller
and the peripheral device(s).
DEVICE PARAMETER
dev
This column identifies the type of SPI device connected.
id
This is the SPI protocol defined identification number. This number can be changed within
the confines of the SPI protocol.
adr
The number here is the address of the peripheral device and must be set on the machine
controller to be the same as the address on the peripheral device.
status
The state of the peripheral equipment is indicated here i.e. pressure, flow, shutdown, etc.
The peripheral device manual will define the meaning of the status.
errors
The error count is not activated as of 22/10/98
fault
The flag lights to indicate an error or fault. Refer to “status” description for more
information.
communication
The markers will be lit when communication exists between the machine controller and the
peripheral device.
OFF/ON
Turns the communication on or off. Enter a 1 to turn the communication ON or 0 to turn the
communication OFF.
device YES/NO
Enter a 0 in this data field to turn the device screen OFF, or enter in the SPI MENU list.
Press the “S” function key to view the SPI device screen pages that are available.
158 4. SERVICE MENU 23/12/05

5.10 END ACCESS
PRESS F5 + F6
As soon as access into the service menu has been achieved, the password designation
indicator will appear at the top of the page, either 6 - 1, 8 – 2, or 10 – 3, depending upon the
password entered. Once the password has been entered, the operator can go out of the
service area and back in again without the necessity of re-entering the password.
The password should be de-activated when the need for access to the Service Menu is
ended. This will help prevent unauthorized changes.
To de-activate the password designation marker:
Press 'F5' -Access Rights on the main menu page
and then
Press F2 Access End.
Once the password designation marker has been de-activated, the password entry number
will have to be re-entered before access to the service area is allowed again.
NOTE!
The password will automatically deactivate if the control voltage

is turned off.
23/12/05 4. SERVICE MENU 159

160 4. SERVICE MENU 23/12/05

5. MACHINE FUNCTION PROFILES

1 ROTARY TABLE SEQUENCE
• Table locking pin release
• Table raise
• Table rotate (CW or CCW)
• Table locking pin secure
• Table lower
23/12/05 5. MACHINE FUNCTION PROFILES 161

SDTVE Table locking pin release

SDTVV Table locking pin secure
SDTH Table raise
SDTL Table lower
SDTCW Table rotate clockwise
SDTCCW Table rotate counter clockwise
SC Independent second pump (pump loading valve)
Times 11933 Keep shot pin down, activated after down switch activated
11934 Time delay after hold pressure to pull shot pin
11938 Pressure delay between unlock / lifting
11939 Pressure delay between turning / locking
11937 Table delay between lifting / turning
11942 Delay before mold close after table down
Speed VDT Screen set speed for table turning
11948 Table locking pin secure speed
11950 Table locking pin release speed
Pressure All rotary table pressures are manually adjusted with pressure reducing valves.
The table uses whatever pressure is required to move up to the limit of manually
adjustable pressure relief valve KCR.
Speed ramps 09365 table start speed
35926 table stop speed
162 5. MACHINE FUNCTION PROFILES 23/12/05

2 MOLD CLOSING
2.1 TYPICAL TOGGLE MACHINE
S1 Mold closing
S10 Pump stage 1
S12A Regenerative connection (starting from ES150); with core-pull program on and when the
closing movement is not interrupted by the core moving-in.

2.2 TYPICAL DIRECT HYDRAULIC MACHINE - 60 TL
S1 Mold closing
S10 Pump stage 1
S2.1 Suction valves opening (direct-closing machines)
S1.2 Build up high pressure in the closing system, de-energizes with start nozzle forward
S12A Regeneration connection, valve is ON for extra speed and OFF for high pressure.
*1 In manual and the first automatic closing, the ananlog signal for mold closing is delayed by
the time set in parameter 08481. During the delay time the suction valve opens.
*2 The high pressure analog output signal is delayed by the time set in parameter 08516.
*3 Activation of S1 is delayed by the time set in parameter 35286 after high pressure build up.
*4 This profile is only employed when the opening stroke is set greater than the maximum
opening stroke minus the stroke value set in parameter 10308.
*5 Refer to the mold protection profile.
*6 After the first automatic cycle the suction valve S2.1 remains open after mold opening.

2.3 TYPICAL DIRECT HYDRAULIC MACHINE - 200TL
S10 Pump stage 1

S2.1 Suction valves opening (direct-closing machines)
S1.2 Build up high pressure in the closing system (direct-closing machines), de-energizes with
start nozzle forward
SEA De-energises, at position G2, to eliminate any effect that the high speed closing cylinder
may have on the clampforce build up.

2.4 CLAMPING PRESSURE BUILD UP FOR EHV PUMP MACHINES
The EHV pump electronics are optimized to provide the oil requirements of the injection
unit. The amount of oil required by the clamp is totally different and control cannot be
optimized with the injection unit parameters.
Therefore during pressure control the clampforce set value SK is typically exceeded by 15
- 20%. The check valves prevent the hydraulic peaks from exceeding the safe maximum.
Because of this the following measures are implemented:
When a new clampforce SK is entered or when the control voltage is switched on, the
clampforce pressure P1 is derived from the set value SK minus parameter 35962. This
parameter is set to a predetermined percentage of SK.
So we have P1 = SK - 35963 (% of SK).
In this way, overshoot is minimized for the first mold closing.
At subsequent mold closings, the overshoot is measured and the amount the pressure
overshoots the set value plus a tolerance 35962 is subtracted from the clamp pressure for
the next mold closing, until the clampforce falls within the tolerance “deadzone”.
There is no minimum tolerance if the clampforce fail to reach the set value. In this case the
differance between the actual and set value is added to the clampforce for the next cycle.
This continues until the set clampforce is achieved.
2.5 DESCRIPTION OF DIAGRAM SYMBOLS AND ABBREVIATIONS
The description of the diagram symbols and abbreviations relate to all the diagrams shown
for mold closing. Some information is only relevant to toggle machine and will be indicated
in the text of the description. All other descriptions relate to fully hydraulic machines.
On machines with a separate proportional valve on the clamping unit, the speed profile is
output to this proportional valve. Otherwise, the profile is run by means of the central
proportional valve Y1. The pressure profile is output to the K1 proportional valve.
In the "Set-up" program the pressure set by parameter 35086 is output during closing and
the speed is limited with parameter 35041(mold close set up speed).
TIMES:
ZF Mold protection time; If G2 is not reached within the ZF, the mold protection alarm reacts.
35276 High pressure build-up time (direct-closing machineswithout pressure transducer)
35255 Nozzle forward delay time; in the automatic mode, pressure and speed are set to "0"
during this time in order to achieve a smooth carriage unit advance.

POSITIONS:
A Opening stroke.
W3 Start 2nd closing speed.
KS1 Intermediate stop core 1 moving in.
W1 Start 3rd closing speed.
G1 Mold protection stroke.
35018 Stroke for suction valves (direct-closing machines). Reset S2.1 at mold close
06551 Stroke point before G2 for ramp in order to guarantee soft closing of the mold, despite a
steep braking ramp.
G2 Mold protection end, start fast straightening and/or high pressure build-up on direct-
closing machines.
B Toggle lever locked, SFx = 0.
SFx Platen position actual value.
SKx Toggle lever position, actual value.
35024 Stroke position on toggle lever to start clamp force measuring.
SPEEDS:
V1 1st closing speed (in set up, limited by 35041).
V2 2nd closing speed (in set up limited by 35041).
V3 3rd closing speed (in set up limited by 35041).
35043 Fast straightening, G2 – B (toggle lock up).
35068 Locking end, B onwards. Set low to reduce toggle "Knock".
35052 Percent velocity of suction valves closing, high pressure build up.
PRESSURES:
35106 Clamping pressure to G1; in the set-up mode 35086 (set up clamp pressure).
P2a Mold protection pressure initial value.
P2e Mold protection pressure final value.
P1 Locking pressure; reducible with 35210.

SPEED RAMPS:
35177 Profile start on position A, KS1, KS2, KS3.

35131 Switchover V1-V2, speed after W3.
35139 Switchover V2-V3, speed braking at mold close.
35193 Switchover V3- percent velocity of suction valves closing.
35132 Braking on minimum speed 35043 before reaching G2.
35155 Braking on B (35043 - speed at toggle lock up or G2 for hydraulic machine or 35068 -
minimum speed of mold closing at B).
35133 Braking on KS1, KS2, KS3.
PRESSURE RAMPS:
35177 Profile start A, KS1, KS2; switchover P2e - P1, on direct-closing machines, also pressure
build-up from P2e to P1.
NOTE!
This parameter also affects other movements.
35148 Switchover from 35106 (closing pressure to G1) to P2 and/or P2a.
35146 Braking on KS1, KS2, KS3.
35147 Switchover from P2a to P2e on toggle machines; if on the CC100 control system the
parameter 35147 is = 0, the mold protection pressure is interpolated from P2a to P2e,
otherwise it is reduced with this ramp after reaching the calculated position.
35156 Switchover from P2 to P1 starting at G2 on toggle lever machines.

3 CARRIAGE UNIT FORWARD
3.1 PRESSURE AND SPEED DIAGRAM
in manual
P5
V9
35168 V10 35194
35173
35039
n auto 35138
35054
in auto J J1 K SDx
Time Time
35256 Z5A in auto 35255
S5
S10
S1
continues
with Pressure Advance nozzle after mold
injection build-up closing
S5 Carriage unit forward
S10 1st pump stage
S1 Mold closing, remains actuated in the automatic mode

3.2 DESCRIPTION OF DIAGRAM SYMBOLS AND ABBREVIATIONS:
The speed profile is output to the Y1 proportional valve, the pressure profile to the K1 proportional
valve.
TIMES:
35255 Nozzle forward delay (in the automatic mode only).

If the set value is set to zero, the Y & K outputs for mold closing and cores are also set to
zero (for smooth advance of nozzle).
Z5A Nozzle contact pressure time.
35256 Injection delay time, after “J” point has been detected (in the automatic mode only)
The outputs for Y and K are erased. If the parameter equals zero, the outputs are
maintained.
POSITIONS:
K Sprue break stroke

J1 Start 2nd nozzle forward speed
J Nozzle contact point, is determined automatically
SDx Nozzle position actual value
35010 (typically 5mm) Stopping distance before the mechanical stop position of the nozzle in
manual (35011 = calibrated maximum stroke minus 35010).
SPEEDS:
V9 1st speed nozzle forward

V10 2nd speed nozzle forward
35039 Velocity for carriage pressure build-up (nozzle pressure build up)
PRESSURES:
P5 Pressure nozzle forward with locked toggle lever. In the set-up program or when the mold
is not closed, the set value pressure 35086 is output instead of P5.
SPEED RAMPS:
35173 Profile start on position K - start acceleration for nozzle forward speed.
35138 Switchover V9-V10, speed braking to J1.
35039 Start velocity for pressure build-up (nozzle pressure)
NOTE!
This ramp also affects other movements.

PRESSURE RAMPS:
36457 Profile start on position "K" ,pressure built-up after reaching the nozzle contact point "J".
NOTE!
AUTOMATIC NOZZLE CONTACT POINT (IE. J=0.0) DETERMINATION:
Whenever the automatic/manual mode select switch is turned from manual to automatic,
the J-point position must be re-established by the controller.
The reason that the “J” point is erased after the automatic / manual switch is operated is
because you may have changed the mold or the nozzle. The controller has no way of
knowing if you have made these changes. The controller must have a zero reference point
for the nozzle so that injection will only occur when the nozzle is in contact with the sprue
bushing. Therefore, a new “J” point determination is conducted every time a new cycle
start is initiated (i.e. mode selection from manual to automatic). The first cycle is always
subject to a delay before injection and the timer Z5a does not function until subsequent
cycles.
35040 velocity stroke calibration, manual forward and first cycle
35027 number of measurements at nozzle standstill to determine J
35028 maximum allowed nozzle movement to accept “J” point
35029 measuring time to determine “J” point detection

4 INJECTION AND HOLDING PRESSURE
S4 Injection
S10 Pump stage 1
S4D Regenerative connection (without increased injection pressure) switchable with 35954
S24 Decompression (ES300 and up without Servo valve)
S4B Hydraulic. shut-off nozzle (special equipment)
S1 remains actuated in the automatic mode
The injection stroke is automatically divided up into 10 equal speed zones. The speed of
each zone can be set between 0.1 inches per second to the maximum injection speed on
the injection boost page.
The duration of injection stroke for each zone can be set on the “Set value Graphics”page.
Z2, the hold pressure time is also automatically divided into 10 equal zones. Each zone
can be set, by the operator, anywhere between 0 and system pressure.

S4 Injection
S10 Pump stage 1
S4D Regenerative connection (without increased injection pressure) switchable with 35954

CONFIGUREABLE SWITCHES
08517 1 = Uninterruptable mode EHV1/HLS1 unit 1

35954 1= Regenerative circuit (S4D installed)
35484 1 = S10 deactivation after injection, controlled via servo valve
35249 Active transition from hold to back pressure, on closed loop machines,
0 = pressure zero after holding pressure.
1 = switch to first back pressure after holding pressure.
TIMES:
35256 Injection delay time after “J” dectection (in the automatic mode only).
The outputs for Y and K are erased. If the set value equals 0, the outputs are maintained.
35282 Time shut off nozle is open before injection
35257 Closed loop start delay. Servo valve opening delayed to S4, K & Y to achieve constant
volume from pump at injection.
35258 Servo valve to on+ after hold pressure & S4 activation delay for fast pressure reduction.
Z1 Injection time.
Z2 Holding pressure time; is automatically subdivided into ten equal parts, for which a
holding pressure can be set in each case.
Z3 Plasticizing delay time.
Z4 Cooling time.
Z6 Nozzle retraction delay time.
POSITIONS:
C2* Calculated value: plasticizing stroke + decompression.
C3u measured screw position switchover point to holding pressure.
SSx Screw position actual value.
C1 Plasticizing stroke, the stroke positions for the ten injection speeds can be changed on
the set value graphic image. An automatic ten part division of the plasticizing stroke C1
only results when the stroke point C1 is entered 2x in succession. Otherwise the stroke
profile set before is divided up automatically in relation to the new plasticizing stroke.
SPEEDS:
V12-V2110 injection speeds, are interpolated with SERVO valve control.
35048 Maximum speed during injection.
35046 Maximum speed during hold
35241 Speed limit minimum value
35063 Volume of servo valve on+ after hold pressure (for fast pressure reduction)
35038 Minimum speed - injection

PRESSURES:
P6 Injection pressure limit.
P7-P16 10 holding pressure stages; are interpolated with servo valve control.
35092 System pressure at injection (Calculated from P6 + 35115)
35249 Active transition from hold to back pressure, on closed loop machines,
0 = pressure zero after holding pressure.
1 = switch to first back pressure after holding pressure.
35093 System pressure at hold
SPEED RAMPS:
35175 Start and switchover of the injection speeds
35186 maximum start acceleration screw absolute
35164 Speed of injection - braking at mechanical stop
35181 maximum acceleration/deceleration screw absolute
35165 Main Y valve speed ramp down during hold
PRESSURE RAMPS:
35177 Start profile acceleration pressure all motions on position C2*
35129 Pressure switchover to holding pressure
35191 Maximum pressure ramp - time dependant - all

5 PLASTICIZING AND DECOMPRESSION
S3 Plasticizing
S3A Back pressure (not on servo valve-controlled machines)
S10 First pump stage
S4D Regeneration
S4 Injection
S24 Decompression
S6A Pressure reduction (nozzle).

TIMES:
Z3 Plasticizing delay
Z4 Cooling time
Z6 Nozzle retraction delay time
35284 Pressure reduction time for carriage unit
35287 Delay between feeding and decompression to C2
35297 EHV - Delay between S3 and S4 actuation - screwfeed
10775 Time that shut off nozzle is open before injection
POSITIONS:
CPx Cushion actual value
C2 Stroke for decompression after plasticizing
SSx Screw position actual value
C1 Plasticizing stroke; the stroke positions for the five plasticizing speeds can be set on the
set value graphics page. An automatic five part division of the plasticizing stroke 'C1',
results when the stroke point C1 is entered twice in succession.
Otherwise the stroke profile set before is divided up automatically in relation to the new
plasticizing stroke.
SPEEDS:
V24 Decompression
V22.1 - V22.5 Plasticizing speeds
35037 minimum speed - screw feed
35079 minimum speed decompression
PRESSURES:
P17 - P21 Back pressures
35103 Decompression
SPEED RAMPS:
35141 Braking to C1
35176 Plasticizing profile - start acceleration speed for screw profile
35168 Start decompression
35189 Maximum acceleration for decompression
35187 Maximum start acceleration for screw motion
35167 Speed braking to C2, C4
35188 Maximum acceleration / de-acceleration for decompression motions
35182 Maximum acceleration / de-acceleration for screw motions
PRESSURE RAMPS:
35177 Back pressure profile
35194 Start decompression
Note: This ramp also affects other movements.

6 CARRIAGE UNIT RETURN
in manual
35085
35177 in manual
35054 35157
V11
35174 35142 35142
Z6 J K SDx
Cooling time Z4 (SDx max. - 35003)
S6
S6A
S10
continues
Nozzle return with mold
open
S6 Carriage unit return
S6A Pressure reduction (nozzle)
S10 First pump stage

6.2 DESCRIPTIONS OF DIAGRAM SYMBOLS AND ABBREVIATIONS
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
35010 Nozzle retraction stop before the mechanical stop
35003 Nozzle maximum stroke
SPEED
V11 Speed, nozzle return in automatic
35054 Speed, nozzle return in manual
PRESSURE
35085 Pressure nozzle return
SPEED RAMP:
35174 Start nozzle retraction on position J
35142 Start braking stop on position K in automatic mode
35185 Max. start acceleration as a function of time
35180 Max. acceleration/delay of nozzle movement as a function of stroke
PRESSURE RAMP:
35177 Start acceleration pressure on position J
NOTE!
Note: This ramp also affects other movements

35190 Max. pressure ramp as a function of stroke
35192 Max. pressure ramp as a function of time
35157 Steep ramp to stop, all remaining motions
Retraction in Semi-automatic mode: Z6 must expire before re-cycle time Z5 in order to retract in
the current cycle.
Retraction in Automatic mode: If Z6 expires before re-cycle time Z5, then the nozzle will
retract to K position.

7 MOLD OPENING
7.1.1 TYPICAL TOGGLE MACHINE
S2 Mold opening (on machines without proportional valve on the clamping unit)
S10 Pump stage 1

7.1.2 TYPICAL DIRECT HYDRAULIC MACHINE
S2 Mold opening, on machines without proportional valve on the clamp unit.
S10 Pump stage 1
S2.1 Suction valves opening (only on direct-closing machines)
S2.2 Pressure reduction (only on direct-closing machines)

The description of the diagram symbols and abbreviations relate to all the diagrams shown
for mold closing. Some information is only relevant to toggle machine and will be indicated
in the text of the description. All other descriptions relate to fully hydraulic machines.
The speed opening profile is output to the proportional valve of the clamping unit. If no
proportional valve is mounted on the clamping unit, the speed profile is output to the
proportional valve Y1.
The pressure opening profile is output to the proportional valve K1.
TIMES (DIRECT-CLOSING HYDRAULIC MACHINES ONLY):

35273 Time that suction valves are open to release the clamp pressure.
35274 Time to release high pressure and open suction valves.
35275 Delay time mold opening; in order to encourage a smooth mold opening start.
without proportional valves, Y and K valves set to zero after pressure reduction, with
proportional valves, Y and K are set to zero before the mold is opened.
POSITIONS:
B Toggle lever locked, SFx=0.
W4 Start 2nd opening speed.
K01 Intermediate stop core 1 moving out.
W2 Start 3rd opening speed.
A Opening stroke.
A1 Ejector start position.
SFx Platen position actual value.
SKx Toggle lever position actual valve.
SPEEDS:
V6 1st opening speed (limited in the set-up by 35042).
V7 2nd opening speed (limited in the set-up by 35042).
V8 3rd opening speed (limited in the set-up by 35042).
35036 Minimum mold opening speed
35066 Speed suction valves opening (direct hydraulic machine).
PRESSURES:
35088 1st opening back pressure; in the set-up mode 35082.

(back pressure starting from ES150 without proportional valve).
35081 2nd opening pressure; in the set-up mode 35082.
(back pressure starting from ES150 without proportional valve).
35144 Pressure suction valves opening, braking to A (direct hydraulic machines).

SPEED RAMPS:
35172 Profile start on position B, K01, K02, K03

35135 Switchover V6-V7, speed after W4
35140 Switchover V7-V8, speed braking to W2
35143 Braking on A, up to A with minimum speed 35036
35136 Braking on K01, K02, K03
35193 Initial output for the Y valve to open and release the high pressure so that the suction
valve can open (direct hydraulic machines)
NOTE!
This ramp also affects other movements

35184 Maximum start acceleration (%/s), as a function of time.
35179 Maximum acceleration delay (%/mm), as a function of stroke.
PRESSURE RAMPS:
35194 Initial output for the K valve to open and release the high pressure so that the suction
valve can open (direct hydraulic machines)
NOTE!
This ramp also affects other movements

35144 Braking on A
35136 Braking on K01, K02, K03
35177 Starting on K01, K02
35192 Maximum pressure ramp (bar/s), as a function of time.
35190 Maximum pressure ramp (bar/mm), as a function of stroke.

8 EJECTOR FORWARD AND RETURN
S25 Ejector forward

S26 Ejector return
S10 Pump stage 1

TIMES:
ZA Ejector forward dwell time.
ZAV Ejector forward delay time.
Z5 Pause time (mold open timer).
10770 In manual mode - motion delay after idling
POSITIONS:
L Ejector in rear pos.
L1 Ejector in front pos.
L2 Shake position.
L3 Start second ejector forward speed.
SAx Ejector position actual value.
SPEEDS:
V25 Ejector forward.
V26 Ejector return.
V27 Second ejector forward speed.
35075 Speed in set up.
PRESSURES:
P25 Ejector forward.
P26 Ejector return.
35124 Pressure in setup.
SPEED RAMPS:
35169 Start acceleration speed for ejector forward.
35170 Start acceleration speed for ejector return.
35153 Braking on L1.
35154 Braking on L.
35183 Maximum start acceleration as a function of time.
35178 Maximum acceleration / delay as a function of stroke.
PRESSURE RAMPS:
35177 Profile start ejector forward and return.
NOTE!

35157 Braking on L1 and L.
35192 Maximum pressure ramp as a function of time.
35190 Maximum pressure ramp as a function of stroke.
36134 Pressure braking to L, L1, L2


6. OTHER MACHINE DIAGNOSTICS

1 WAITING POINTS
Press function key

+ F2
In order to further assist the maintenance technician in troubleshooting the machine, there are
waiting points which will be displayed when the machine stops. The waiting point that appears
indicates the next sequence point in the cycle that has not been reached. Therefore, the cycle
stopped in the sequence position immediately before the waiting point listed.
This function is only operative in the automatic and semi-automatic modes.
Below are listed the various cycle waiting points.
0. TMS - START BUTTON 31 CLOSED LOOP CLAMPING FORCE CONTROL

1 MOLD CLOSING END 32 CORE 1 IN
2 CARRIAGE END 33 CORE 2 IN
3 INJECTION FINISHED 34 CORE 3 IN
4 COOLING TIME END 35 CORE 1 OUT
5 DEMOLDING TIME 36 CORE 2 OUT
6 EJECTION END 37 CORE 3 OUT
7 CLOSING SPEED - POS. W1 38 CORE 1 IN - POS. KS1
8 MOLD PROTECTION BEGINNING-POS. G1 39 CORE 2 IN - POS. KS2
9 MOLD PROTECTION END - POS. G2 40 CORE 3 IN - POS. KS3
10 BREAK POSITION - POS. B1 41 CORE 1 IN - POS. KO1
11 TOGGLE LEVER LOCKED - POS. B 42 CORE 2 OUT - POS. KO2
12 MOLD STANDSTILL 43 CORE 3 OUT - POS. KO3
13 MOLD OPEN - POS. A 44 CORE 1 IN - LIMIT SWITCH E15
14 DECOMPRESS. BEFORE PLAST.- POS. C4 45 CORE 1 IN - ZE1
15 PLASTICIZING END - POS. C1 46 CORE 2 IN - LIMIT SWITCH E17
16 DECOMPRESS. AFTER PLAST. - POS. C2 47 CORE 2 IN - ZE2
17 PLASTICIZING DELAY TIME - Z3 48 CORE 3 IN - LIMIT SWITCH E19
18 INTRUSION TIME - ZIN 49 ORE 3 IN - ZE3
19 J-DETERMINATION 50 CORE 1 OUT - LIMIT SWITCH E14
20 INJECTION UNIT FRONT - POS. J 51 CORE 1 OUT - ZA1
21 PRESSURE BUILD-UP TIME Z5A 52 CORE 2 OUT - LIMIT SWITCH E16
22 NOZZLE RETRACTION DELAY Z6 53 CORE 2 OUT - ZA2
23 INJECTION UNIT REAR - POS.K 54 CORE 3 OUT - LIMIT SWITCH E18
24 EJECTOR FRONT - POS.L1 55 CORE 3 OUT - ZA3
25 EJECTOR REAR - POS.L 56 CORE 1 OUT DELAY - ZKAV1
26 EJECTOR SHAKE - POS. L2 57 CORE 2 OUT DELAY - ZKAV2
27 START EJECTOR FORWARD - POS. A1 58 CORE 3 OUT DELAY - ZKAV3
28 EJECTOR FORWARD DELAY ZAV 59 START AIR BLOWING 1 - POS. A2
29 EJECTOR BACKWARD DELAY ZA 60 AIR BLOWING TIME 1 - ZL1
30 MOLD OPENING INTERMEDIATE STOP 61 AIR BLOWING TIME 2 - ZL2
23/12/05 6. OTHER MACHINE DIAGNOSTICS 187

62 BLOWING DELAY TIME 1 - ZLV1 104 RELEASE MOLD HEIGHT SMALLER

63 BLOWING DELAY TIME 2 - ZLV2 105 RELEASE MOLD HEIGHT LARGER
64 EJECTION MONITORING - INPUT BLS 106 RELEASE MOVE IN CORE
65 CORE IN POSITION B8 107 RELEASE MOVE OUT CORE
66 CLAMPING PRESSURE REDUCTION 108 STARTING POSITION NOZZLE FORWARD
67 CLAMPING PRESSURE BUILD-UP 109 SAFETY GATE OPENING DELAY
68 MOLD HEIGHT - POS. FH 165 FRONT GATE CLOSING ACTION
69 HANDLING INTRLK - HSP 166 CYCLE START BUTTON(S) RELEASED
70 END INCREASED OPENING FORCE 167 BOTH CYCLE START BUTTON(S) PRESSED
71 BOOST TO HOLD CUT_OFF 168 NOZZLE FULLY RETRACTED
72 CONTACT PRESSURE REDUCTION 170 ROBOT INTERLOCK CORE OUT - kea
73 PROGRAM INTERRUPTION 171 ROBOT INTERLOCK CORE IN - kee
74 MOLD OPENING END 172 ROBOT INTERLOCK EJECTOR FORWARD - awv
75 STROKE CALIBRATION FINISHED 173 ROBOT INTERLOCK EJECTOR RETRACT - awz
76 CLOSED LOOP CF CONTROL START POSITION 174 ROBOT INTERLOCK MOLD OPEN/CLOSE - hsp
77 MOLD MOUNTED MOVING PLATEN 175 ROBOT INTERLOCK MOLD CLOSE - b63
78 MOLD DISMOUNTED MOVING PLATEN 176 ROBOT INTERLOCK MOLD OPEN INTERM. - fof
79 MOLD MOUNTED FIXED PLATEN 177 START AIR BLOWING 2 - POS. A3
80 MOLD DISMOUNTED FIXED PLATEN 219 SHUT-OFF NOZZLE DELAY
81 START INJECTION
82 START MOLD OPENING
83 HANDLING SYSTEM RELEASE EJECTOR FWD
84 HANDLING SYSTEM DEPOSITING FINISHED
85 TAKE-OFF POSITION AFZ
86 MOVE IN CORES FINISHED
87 MOVE OUT CORES FINISHED
88 CLAMPING FORCE CHECK
89 SAFETY GATE CLOSING E1
90 SAFETY GATE OPENING E1-FREE
91 INJECTION DELAY
92 RELEASE MOLD CLOSING
93 RELEASE MOLD OPENING
94 RELEASE PLASTICIZING
95 RELEASE INJECTION
96 RELEASE CARRIAGE UNIT FORWARD
97 RELEASE CARRIAGE UNIT RETURN
98 RELEASE EJECTOR FORWARD
99 RELEASE EJECTOR RETURN
100 RELEASE MOLD MOUNTING MOVING PLATEN
101 REL MOLD DISMOUNTING MOVING PLATEN
102 RELEASE MOLD DISMOUNTING FIXED PLATEN
103 RELEASE MOLD MOUNTING FIXED PLATEN
188 6. OTHER MACHINE DIAGNOSTICS 23/12/05

2 HARDWARE TEST
Press function key

+ F3
The hardware check information is split into five screen pages which will display:
• Hardware configuration
• Hardware test
• Hardware information
• Software version
• System information
HW - Config HW - Test HW - Info SW - Version SYS - Info Etc.

HW - CONFIGURATION
This page indicates how the hardware package of each machine is configured. The sample page
above shows the:
• CPU type and frequency,

• the sub modules associated with the CPU card.
The number of:
• Digital input cards;

• Digital output cards;
• Analog cards
• Temperature cards
Refer to the Controller maintenance manual for a fuller description of all the possible cards used
in a machine configuration

HARDWARE TEST
When the control voltage is turned on, an automatic software test is conducted. Shortly after-
wards, relay 136 is energized which connects VK (solenoids) voltage to the controller.
At this time the controller will carry out a digital output failure test and will list the results of the
test on the hardware test page as shown above.
This area gives an indication of the digital outputs which are not normally connected or‚ if the
circuit has been found to be open during the hardware test. If the usual state of these outputs are
recorded, a new‚ problem could be easily identified when a comparison is made with this listing.
This area is strictly related to digital outputs..
DO321 #0 refers to the first digital output card, the list of outputs relate to the first card.
DO321 #1 refers to the second digital output card, the list of outputs relate to the second card.
NOTE!
If any Digital Output is short circuited during the machine cycle, the short cir-
cuited channel will appear just below the "circuit breaks" area, in yellow type on
the CC100. Refer to the description of Ebias errors for a listing of typical digital
output assignments and also to your own electrical interface diagram to identify
and locate the short circuit.

HW - INFORMATION
This screen page details all the electronic hardware information, the screen page shown is repre-
sentative of a standard machine, the information will be different for a customized machines.
component This column lists the electronic cards in the rack.

no. This column lists the card number, 0 = the first card
1 = the second card, etc.
print-no. This column lists the part number of the printed circuit card
ser-no. This column lists the serial number of the card.
rev. This column lists the revision state of the card.
var. This column lists the variant of the card.
fbg-var. This column lists the card information useful to Engel service or
software department.

SW - VERSION
This screen page indicates the software versions of the “system” and all the programmable
devices within the machine hardware.
Information within the Controller Operator and Controller Maintenance manuals may be
dependant upon the “system version” software.
Check this page to confirm which software version has been installed on your machine.

SYSTEM INFORMATION
The system information page indicates:
• The machine fabrication number or serial number.
• A listing of the system drives. If the system contains a Ramdisk card or an extra memory
card, the memory size will be listed in this area.
• The number of the serial interface ports and their specific use.

3 SYSTEM AND EBIAS ERRORS
Apart from the machine error messages accessible via the error message key on the front
controller faceplate, there are also System (SYS) and Ebias error messages.
When these types of error messages are present, they will be displayed on the first screen page
that comes up after the control voltage is turned on.
3.1 EBIAS ERRORS

Specific to Ebias errors is the fact that their occurrence will also be indicated on the machine error
message page beside the error 0-EBIAS ERROR STOP.
The exact Ebias error message number will appear to the right of the error message.
For example, 0-EBIAS ERROR STOP #60 indicates a short circuit on digout card 1.
3.2 SYSTEM ERRORS

A system error is a fatal error on the operating system which causes the complete system to be
brought to a halt.
The system errors code is displayed with a red background in the middle of the display screen,
Component Number
SYSTERR 81 / 1100 / 100
Card Reference Error Number
The system error code of three numbers indicates the electronic card that caused the system
error, the component of the system error and the error number within that component. For
example system error 81 / 1100 / 100 indicates that there is an “I / O error in creating the process
image” concerning the EBIAS Interpreter and that the CPU card is the cause of that error.
The code numbers for the electronic "smart" card are as follows:
81 is local, i.e. Main CPU
61 thru 64 are AR1x1 #1 - AR1x1 #4
41 thru 44 are RC100 #1 - RC100 #4
Generally, these types of error messages indicate "fatal" software or hardware troubles, which
provides Engel software technicians with valuable information on the nature of the problem.
Before anything drastic is attempted, try to reset the error by turning the control voltage 'OFF' and
then 'ON' again. It is advisable‚ to keep a record of any errors of this type and to contact Engel
service as soon as possible with this information.

Display of System Errors
A system error is displayed on the following output devices on the EC100/CC100 system:
• Monitor
• Status report (floppy disk, printer)
• Status LEDs
Display of System Errors on Screen and in Status Report
S Y S E R R 1100 / 100
SYSERR 1100/ 100 95-08-17 17:24

MODUL 'EI $Revision: 1.9 $' line: 186 INTERRUPT: disabled
INFO: len: 2
0014
RX: taskname: 'IP_io' stop cnt: 0 run time: 25.595s
INT0: 0.1/ 0.4 INT1: 0.1/ 0.1 INT2: 0.0/ 0.1 INT3: ---------
INT4: --------- INT5: --------- INT6: 0.2/ 0.3 INT7: ---------
PR00: --------- PR01: --------- PR02: 0.1/ 16.6 PR03: 0.1/ 1.4
PR04: --------- PR05: 0.1/ 0.1 PR06: 0.1/ 47.7 PR07: 0.1/ 7.4
PR08: --------- PR09: --------- PR10: 1.0/ 369.9 PR11: 0.1/ 0.1
PR12: 0.1/ 0.1 PR13: 0.1/ 0.1 PR14: --------- PR15: ---------
PR16: --------- PR17: ---------
STACK: base: 004B06A4H size: 1024 unused: 684 Frame-ptr: 004B0A5CH
004B0A2C=00000000 004B0A50 00579F98 00000002 004B0A58 00579F22 000000BA FFFFF9C
004B0A4C=4945044C 004B0A94 0057D06F 00000014 00000008 00000004 00000000 00000000
004B0A6C=0057D397 00000206 00000000 00000003 0057DA1A 00780403 0014007F 00530078
004B0A8C=00000000 000063F6 00000000 00000000 C7C7C700 00000000 C7C7C7C7 C7C7C7C7
SYSERR Shows component number / error number, and date and time.
MODULE Shows module version and module line number from which the system error
originated as well as the interrupt status.
INFO Details additional information showing length in bytes and contents in the form of
16-bit values in hexadecimal format.
RX Details the task name, stop counter reading, run-time and performance.
STACK Gives details of stack base address, stack size, the unused stack space and the
RX frame pointer position as well as 32 x 32-bit values in hexadecimal format,
starting with the current stack pointer position.

Display of System Errors on Status LEDs
The status LEDs, located at the bottom front edge of the CPU card, show the component number
and the system error in BCD (Binary Coded Decimal) format. The data is shown in a timed
sequence, as indicated in the figure below.
Synchronization Sequence Component Error Number

Run Err Run Err Run Err Run Err Run Err Run Err Run Err
Bat Bat Bat Bat Bat Bat Bat
Status Status Status Status Status Status Status
7 7 7 7 7 7 7
6 6 6 6 c1 6 c3 6 e1 6 e3
5 5 5 5 5 5 5
4 4 4 4 4 4 4
3 3 3 3 3 3 3
2 2 2 2 c0 2 c2 2 e0 2 e2
1 1 1 1 1 1 1
0 0 0 0 0 0 0
REPEATING SEQUENCE
Example: Component 1234 c0 = 4; c1 = 3; c2 = 2; c3 = 1

Error Number 5678 e0 = 8; e1 = 7; e2 = 6; e3 = 5
The lower set of eight LEDs, on the CPU card, display the system error and component number.
The sequence begins with the Synchronization sequence, then the Component number
sequence, and finishes with the Error number sequence. The sequence will repeat until the error
is cancelled.
NOTE!
The Component and Error numbers are displayed in reverse order.
Refer to the figure above for the sequence of LEDs.

Observe the sequence of the LEDs on the CPU card, and as the Synchronization sequence ends
with all LEDs off, the next sequence will be the Component number sequence, note the position
of the lit LEDs for each phase of the sequence.
Each phase of the sequence will display two numbers via a set of eight LEDs. The set of LEDs
has two groups of four LEDs. The four LEDs represent, a four digit binary number.
A lighted LED equals one, and an unlit LED equals zero.

The binary number must to be converted to a decimal number in the following manner.
First LED = 1
Second LED = 2
Third LED = 4
Fourth LED = 8
Add together the numbers that correspond to the LEDs that are on, follow the example shown on
the previous page for second number in the component number sequence (c1), first and second
LEDs are on. These LEDs correspond to 1100 in binary or 1 + 2 = 3 in decimal.
Note down the LEDs that are on for each sequence to derive the component number, in the case
of the example the LEDs indicate that the number is

c0 = 0010 = decimal 4
c1 = 1100 = decimals 1+2 = 3
c2 = 0100 = decimal 2
c3 = 1000 = decimal 1
This corespond to component number (in reverse order) 1234
The Error number is then presented in the same manner. Add together the numbers that
correspond to the LEDs that are lit.
Component Numbers
The component number specifies the software component from which the system error has
originated.
The software components are subdivided into the following two groups:
Non-Application-Specific Components (General Software Library): these are software
components that are not allocated to any particular project and are therefore used in a wide
variety of applications (e.g. EEPROM drivers, interface drivers, operating system, etc.).
Application-Specific Components: these are software components that have been
developed specially for a particular application (EC100/CC100) (e.g. EBIAS interpreters,
data managers, etc.).
Two separate ranges of numbers have been allocated to the two different component groups as
follows:
1 ... 999 Non-application-specific components (general)
>= 1000 Application-specific components (EC100/CC100)
Important: Component 0 :
Component number 0 is reserved for “old“ EC100/CC100 system errors. These are system errors
invoked by “old” modules without component numbers.
The subdivision of system error numbers into general system error numbers and component-
specific error numbers does not apply to component number 0!

List of Components
Number Abbreviation Component designation

1 SYSERR Error Handling
2 SERCOS Sercos Driver (general)
3 SERCOSL2 Sercos Driver (close to hardware)
4 SIO Serial In- and Output
5 P3964R P3964R Data Transfer Protocol
6 RK512 RK512-Protokol (S5 - CP)
7 AS511 AS511-Protokol (S5 - PG)
8 KOS KEMRO Operating System
9 FLASH FLASH Driver
10 CI021 CI 021 Full CAN-Bus Driver
11 EEPROM Driver for Serial EEPROM
12 RXCOM KEMRObus Communication for OS RX
13 RX Operating System RX
14 MM Dynamical Memory Management
15 WKM Window- and Keyboard Manager
16 MCU Motion Control Unit (MCU) up to Version 2.29
17 KBI KEMRObus Interface (Level 2)
18 KBCOM Transmission of Variables via KEMRObus
19 PSX POSIX Interface (C-Library)
20 FSKBI File System via KEMRObus
22 CONVERT Numerical Conversion Routines
23 LZW LZW Compressing / Decompressing
24 ECC Error Checking and Correcting
25 COP CANOpen Driver
26 MT161 MOOG Driver (in RC100 valid from V2.21 on)
27 DC161 CAN-Bus Driver for DC 161 (RC100 valid from V2.21)
28 SRE3I Driver for II 030-Axis (RC100 valid from V2.21)
29 CTS CAN Temposonic Sensors
30 AC441 AC 441 Module
31 DC661 DC 661 Module
32 DC201 DC 201 Module
33 HT401 HT 401 Driver (CAN-Bus)
34 CF101 CF 101 Driver (CAN-Bus)
35 MMPAB Multi Master Process Image AR 181/RC100
36 PBDPM PROFIBUS-DP Master
37 PBDPS PROFIBUS-DP Slave
38 LAN_ETHERNET Ethernet (LAN low level driver)
39 LAN_SERIAL LAN low level driver
40 LAN_FUSION LAN Fusion-SW (High Level)
41 SEH System Exception Handling
42 IBM INTERBUS Master
43 IBS INTERBUS Slave
44 FESTO FESTO-CPV Driver

45 LENZE Driver for LENZE motion control

46 PCC_ATA ATA FLASH-Disk Driver
47 ACOPOS Driver for B&R ACOPOS control
48 COPST COP-ST Driver
Component designations EC/CC100
1000 TST Power-on Self Test
1001 AKP AKP-0 (8741-Controller)
1002 TIM Timer
1003 INT Interrupt
1004 IOB I/O Interface
1005 PA Performance Analysis
1006 SYS System
1007 PCB PCB Manager (Board Manager)
1008 EBOS EBOS Operating System Shell
1009 E2P EEPROM Intermediate Layer
1010 GI Graphical Interface
1011 GE Graphics Emulation Module
1012 KB Keyboard Interface
1013 CMD4P CMD4P Protocol
1014 DEVIO Data Output Module
1015 BMP Bitmap Manager
1016 DPM Dual Port Memory Driver for SI 024
1017 XL Firmware Hex Loader for SI 024
1018 IB Interface Board Manager on IEB1 and IEB2
1019 RTC Clock Module (Real-Time Clock)
1020 FLPY Floppy Manager
1021 PRT Printer Module
1022 SK Softkey Manager
1023 CVT Conversion Functions
1024 MODEM Modem Control Module
1100 EI EBIAS Interpreter
1101 EBI EBIAS Interface
1102 EBIO EBIAS I/O
1103 DAT Data Manager
1104 DD Dialog Module
1105 HLP Help Function
1106 HST PC-Host Connection
1107 URM Access Authorization Manager
1108 UM Unit Manager
1109 EXL EXCEL Driver
1110 DIO Digital Inputs and Outputs
1111 DM Dialog Manager
Component designations EC/CC100
1112 MFT Machine Function Table
1113 PL Plausibility Checking Function

1114 HCPY Hardcopy Function

1115 DEB Debugger
1116 DC161 CAN bus DC 161 Module Driver
1117 CB CAN-Bus Integration Module
1118 MOUNT Device Mounter
1119 HWCHK Hardware Check Function
1120 ERR Error Manager
1121 CANOP CANopen Integration
1122 CM161 CAN-Bus Module for DC 161
1123 CMLENZE CAN-Bus Module for Lenze Drive
1124 LENZE CAN-Bus Driver for Lenze Drive
1125 CM441 CAN-Bus Module for AC 441
1126 CM201 Can-Bus Module for DC 201
1127 CM661 CAN-Bus Module for DC 661
1128 NET Network
1129 TM Text Manager
1130 PD Process Data Module
1131 MTM Multi Track Measurement
1132 RAS RAS Configuration Dialog
1133 LIC Licence Management
1134 CMPT Composable Text Page
1135 KB_ETHERNET KEMRObus Ethernet Driver
1200 AR Analog Card (AR 161, AR 101)
1201 ARCOM AR Communication Module
1202 ARFLP AR Floppy Module
1203 RC RC100 Handling Module
1204 EM15 Euromap 15
1205 E8T E8Thermo
1206 SGMLT Linearizing Table Manger
1207 MIC Micrograf-Plus
1208 SGRAF Autoprotect on Clamping Unit Side
1209 APR Autoprotect on Injection Unit Side
1500 EBIAS EBIAS Application
Component designations AR
1000 MMCOM Multimaster Communication
1001 POSIX POSIX Interface (C-Library)
1002 AIO (AR 161, AR 181, AR 281), Analog Input/Output
1002 AIO (AR 101 only), Analog Input/Output
1003 EBIAS EBIAS Interface
1005 DIN Digital Input
1006 GRAFIK Graphical 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 Bus ST Interface (High Level)

1103 CTS CAN Temposonics Sensor

1104 CANDEV CI 021 General CAN-Bus ST Interface
1105 BMCAN Baumüller CAN Interface
1106 BSA Baumüller Servo Drives
1107 IE011 IE011 Incremental Encoder Emulator
1200 FB Function Blocks
1300 ST AR 1x1 ST Program Processing, Runtime System
1400 CPU_FAULT Intel 80960 CPU Fault Exceptions
Component designations RC100
1000 USER User Program
1001 RC100 Main Program
1002 PRBUF Protocol Buffer
1003 PRHDL Protocol Handler
1006 ERRTXT Error Evaluation
1007 ERROR Error Recording
1008 PROTO Display of Fault Message Report
1009 WAITP Wait Point Management
1010 LLIO Low Level I/O Interface
1011 RCIO KEMRObus KEMRObus I/O Interface
1011 RCIO-IO KEMRO I/O Bus I/O Interface
1012 ECRT ECRT Driver
1013 ECON Membrane Keyboard
1014 HTSTD HT Standard Driver
1015 KEYB Keyboard Task
1017 RTC Real Time Clock Driver
1018 UPDATE Process Image
1019 SYSPED System Parameter Editors
1020 USRPED User Editors
1021 ARDRW Representation of Workspaces
1022 PASSW Password Entry
1023 DATEI File Manager Menu
1024 FLOPPY Floppy Disk Menu
1025 SELECT Submenu Functions
1026 STATE Status Display
1027 EVENT Event Handler
1028 KEYS Softkey Management
1029 MODE Switching of Operating Modes
1030 SYSMON RC100 System Monitor
1031 LLPRT Printer Interface
1032 LOCPRT Local Printer Driver
1033 RCPRT KEMRObus Printer Interface
1034 RCVAR KEMRObus Variables Interface
1035 RCPFS KEMRObus File Interface
1035 RCPFS_IO KEMRO I/O-Bus File Interface
1036 RCCMD KEMRObus Command Interface
1037 PRINT Print Menu

Component designations RC100

1038 PRTSRV Printer Task
1039 TXTIO Read Texts
1040 USERCHK User Authentification
1041 FAULT Fault Handler
1042 SYSPROT System Error Report
1043 WAIT Wait Functions
1044 HT501 HT 501 Protocol Driver
1045 HT511 HT 511 Protocol Driver
1046 INTERNAT International Settings
1047 HASHING OPEN - Hashcoding
1050 PARIO Read / Write: MD/TD<->Editors
1100 TTSK ST Tasks
1102 STLZS ST Operating System
1103 STDBG ST Debug Functions
1105 STPRM ST Primitive Functions
1106 STCAL ST Invocation Shell
1200 ACU ACU -> MCU Adaption (not valid from V3.0 on)
1201 TEACH Teaching (EAT)
1203 MCU Motion Control Unit (MCU ab V2.30)
1300 MT161 MOOG Driver (valid up to V2.20)
1301 DC161 DC161 CAN Driver (valid up to V2.20)
1302 SRE3 Driver II 030 Axis (valid up to V2.20)
1303 DI325 Digital Input Card on KEMRObus
1304 DO321 Digital Output Card on KEMRObus
1310 DIGIO DIG I/O Status Management
1500 IOB I/O Bus Driver
1501 CMD4P CMD4P Protocol for FC 352 Driver
1502 FC352 Driver for FC 352
1503 STMAP ST Map File Evaluation
1504 HST Host
1505 HOST Host Dialog
1506 MMCOM Multimaster Communication
1510 TCPSRV TCP/IP Server (old)
1511 STEDIT_SERVER STEDIT-Server
1512 TCP_SERVER TCP/IP Server (new)
1520 SYSLD System Loader
Komponentenbezeichnungen RC100
1530 STCAN CAN-Bus Interface for ST
1531 UPM Runtime Checks (Update Manager)
1532 TLIST Linked List
1540 KB_ETHERNET KEMRObus Ethernet Interface

3.3 SYSTEM ERROR NUMBERS
General System Errors
The following system errors are non-component-specific errors, i.e. they can occur on any
component.
Error numbers 1 - 99 are reserved for these system errors.
No Symbolic Representation Explanation Correction

1 E_NO_IMPLEMENTATION Function not implemented
2 E_INV_PARAM Invalid parameter Error cannot be rectified by
customer. Call Engel service
dept.
3 E_INV_TOKEN Invalid token Ensure all necessary modules
are installed
4 E_INV_STATE Invalid status
5 E_TIMEOUT Time-out
6 E_NO_MEMORY No memory space available
7 E_NULL_PTR Invalid NULL pointer in St
filesystem
8 E_DIV_ZERO Division by zero
9 E_NO_ACCESS Illegal access
10 E_INV_CHKSUM Invalid checksum
11 E_NO_FREE_TOKEN No free token available
12 E_INV_DATA Invalid data transfer
13 E_INV_LEN Invalid length
14 E_INV_BUF_LEN Invalid buffer length
15 E_INV_DATA_LEN Invalid data length
16 E_INV_OFFSET Invalid offset
17 E_OPEN_FILE Error opening file
18 E_WRITE_FILE Error writing to file
19 E_READ_FILE Error reading file
20 E_CLOSE_FILE Error closing file
21 E_INV_PTR Invalid pointer
22 E_INV_CASE Invalid branch
23 E_UNKNOWN_INTERRUPT Undefined/unknown interrupt
24 E_POWERFAIL Power failure
25 E_WATCHDOG Watchdog
26 E_DATA_OVERFLOW Data overflow
27 E_OFFLINE No connection, off-line
28 E_INV_OPCODE Invalid opcode
29 E_INCONSISTENCE Inconsistencies encountered Change AR281 card, rev # >=
03 from serial # 2204-00474 on
30 E_INV_NR Invalid numbering
31 E_INV_TYPE Invalid type
32 E_INV_FORMAT Invalid format
33 Transmission aborted
34 Invalid address

No Symbolic Representation Explanation Correction

35 Overrun
36 Invalid mode
38 E_ATA_FLASH Invalid command - Flash disks in RC100/511
Attempted format of flash systems must not be formatted
disk failed
98 E_ASSERT Negative parameter check
99 E_NOT_OK Other general error

Component-Specific System Errors
In contrast with the general system errors, the component-specific system errors apply only to the
specified component.
Error numbers 100 upwards are reserved for these system errors.
Component 0 System Errors without Component Number

This component is an exception. The general system errors do not apply!
No. Module/Component Explanation

1 MAIN32C Watchdog - error in module
-possible bad CPU.
-possible bad or missing :F-SIC
E-HSI
RS232
RS485
-possible software problem.
-a program/routine has not released the CPU.
7 MAIN32C ILLGEAL ENABLE - error in module
-possible bad CPU.
8 MAIN32C Invalid parameter in SET_* - error in module
-possible bad CPU.
10 SYS32C System call is not implemented - error in module
-possible bad CPU.
12 SYS32C EBISYS call is not implemented - error in module
-possible bad CPU.
-possible software problem
14 MAIN32C Watchdog service “WATCHDOG“ invoked outside INIT phase.
35 MAIN32C CRC32 - EPROM checksum error - error in module
-possible bad system chips.
-possible bad CPU.
36 MAIN32C First RAM defective
-possible bad CPU.
37 MAIN32C Last RAM defective or missing
-possible bad CPU.
39 RAMT16 RAM error (RAM test)
-possible bad CPU.
49 BSIO Output string too long in STRINGOUT
50 BSIO CHAROUT or STRINGOUT invoked under disable
51 BSIO Invalid interface channel
-improper floppy channel has been selected.
52 BSIO Receive buffer is too small
53 BSIO Invalid SERINIT parameter


54 BSIO System error on E-HSI
-possible loose board.
-possible bad E-HSI.
-incompatible E-HSI software.
-bad grounding on cable.
55 BSIO E-HSI Read time-out
56 BSIO E-HSI Write time-out
57 BSIO E-HSI Command time-out
58 BSIO E-HSI command invoked under disable
96 SCREENC WRITE without OPEN
97 SCREENC CLOSE without OPEN
- possible bad ECG
98 SCREENC WRITEV output string too long
- possible bad ECG
99 PRINTC WRITE without OPEN
-possible bad printer cable.
100 PRINTC OPEN by other task
:units have not been assembled
101 PRINTC CLOSE without OPEN
102 PRINTC Invalid control character
-possible bad ECG.
-possible bad disk.
-possible bad floppy.
-language change from floppy without - ram card.
:pointer not resolved.
104 KEYBOR READ already active
-possible bad front plate.
-possible bad CPU cable.


105 KEYBOR READ input field length exceeded
106 KEYBOR Invalid format specified
112 TXTHC Invalid image definition
-possible bad software.
113 E8TDRV Error initialising driver
114 E8TDRV Addressed card not present
115 E8TDRV Invalid parameter (channel number, card number, ID)
116 E8TDRV Card tine-out on I/O bus
117 E8TDRV Invalid driver descriptor
118 E8TDRV VAR-QUEUE overflow
120 ANADRV Analog card time-out E16ANAIN - 1
-possible bad card.
-possible bad CPU.
-incompatibility with CPU.
-defective bus/socket.
-incorrect supply voltage.
-card not seated properly.
-possible bad card.
-possible bad CPU.
-possible bad card.
-possible bad CPU.
-possible bad card.
-possible bad CPU.
126 MOUNT RELEASE_DEVICE without REQUEST_DEVICE
127 MOUNT DISCONNECT_DEVICE without CONNECT_DEVICE
128 MOUNT Invalid device


130 GRFVIDC WRITE without OPEN
-possible bad temp card.
-software problem.
-possible bad CPU.
-possible bad ECG.
131 GRFVIDC OPEN without CLOSE
-software problem.
-possible bad CPU.
-possible bad ECG.
132 GRFVIDC Invalid end code in CRT string
-software problem.
-possible bad CPU.
-possible bad ECG.
133 GRFVIDC Invalid control character in CRT string
-software problem.
-possible bad CPU.
-possible bad ECG.
134 GRFVIDC GKS_TEXT string too long
-software problem.
-possible bad CPU.
-possible bad ECG.
135 GRFVIDC Function not implemented
-software problem.
-possible bad CPU.
-possible bad ECG.
136 GRFVIDC Error in graphics interpreter
-software problem.
-possible bad CPU.
-possible bad ECG.
140 PRINTC No graphics block
-software problem.
141 PRINTC Graphics block already exists
-software problem.
142 PRINTC Graphic buffer overflow
-software problem.
155 COM1KE Error initialising EM15
(Euromap 15)
156 COM1KE Error sending EM15 data
157 COM1KE EM15-HSI has reported fatal error
158 COM1KE Other fatal error on EM15


194 TEST EBIAS configuration error
-possible bad CPU.
196 EBIAS32 Machine number <> EBIAS machine number: EBIAS loaded
-machine number EBIAS loaded !
197 EBIAS32 Machine number <> EBIAS machine number: EBIAS cleared
198 - Requested memory area not available
199 - Invalid CASE number
Compo- Comp. Error

Error description Causes of Error Error correction
nent # #
Component 4 Serial Input and Output module
SIO 4 100 Invalid interface channel
SIO 4 101 Function invocation Function can not be invoked
in operating mode selected
SIO 4 102 Handshake Handshake can not be set
(status query only possible)
SIO 4 103 Interface channel not avail-
able
SIO 4 104 Use of the timer The baud rates must be the
same due to the use of the
timer
SIO 4 105 Receiving baud rate Receiving baud rate for
selected channel not avail-
able
SIO 4 106 Sending baud rate Sending baud rate for
selected channel not avail-
able
SIO 4 107 Invalid number of data bits
SIO 4 108 Parity invalid for selected
channel
SIO 4 109 Invalid number of stop bits
SIO 4 110 Selected operating mode(s) Selected operating mode(s)
not possible. not possible. From
E_SIO_UART_OVERRUN_
ERROR beginning only
descending sequence
allowed.
SIO 4 111 Loss of data due to FIFO
overflow
SIO 4 112 Incorrect parity bit received
SIO 4 113 Error in data frame Error in data frame, no valid
Stop bit received

Compo- Comp. Error

nent # #
SIO 4 114 Break received Break received, remote sta-
tion sent break telegram
SIO 4 115 Incorrect parameter
SIO 4 116 Invalid interface type
SIO 4 117 Function call Function call only permitted
under ENABLE
SIO 4 118 Number of installed channel Number of installed channel
invalid invalid, interface already
exists
SIO 4 119 Device driver can not be Device driver can not be
installed installed, invalid device no.
SIO 4 120 E-HSI command still active
SIO 4 121 System error on E-HIS
SIO 4 122 E-HSI Read time-out
SIO 4 123 E-HSI Write time-out
SIO 4 124 Interface channel already in Interface channel already in
use use by other interface
SIO 4 125 No device driver present No device driver present for
selected interface channel
SIO 4 126 Send buffer is full Send buffer is full, no more
space available
SIO 4 127 Receive buffer is full Receive buffer is full, no
more space available
SIO 4 128 No character received
SIO 4 198 General fatal error message General error message
(fatal)
SIO 4 199 General error warning mes- General error message
sage (warning)
Component 5 Siemens P3964R Data Transmission Protocol
P3964R 5 200 NAK character received NAK character received from
remote station
P3964R 5 201 Incorrect character received Incorrect character received
from remote station
P3964R 5 202 Incorrect block checksum
P3964R 5 203 Data length exceeded The amount of data received
is too big to fit in the avail-
able memory area
P3964R 5 204 Incorrect message format
P3964R 5 205 No STX character Remote station is not send-
ing STX character
P3964R 5 206 STX character received STX character received from
remote station
P3964R 5 207 Initialization conflict Initialization conflict encoun-
tered
Component 9 Flash device
FLASH 9 100 Invalid FLASH device

Compo- Comp. Error

nent # #
FLASH 9 101 Invalid address
FLASH 9 102 Invalid length
FLASH 9 110 Programming error, global
FLASH 9 111 Programming error at chip 1
FLASH 9 130 Erase error, global
FLASH 9 131 Erase error at chip 1
Component 10 CI021 Full CAN Bus driver
CI021 10 29 Full CAN Bus driver Error occurs in combinations Exchange AR 281 against
of AR 281 (Rev. 00,01,02) Rev. >= 03 (from serial
with SR 161 (Rev. >07) and number2204-00474 on)
CI 021 (Rev. Xx).
CI021 10 100 Configuration of CAN bus Configuration of a new CAN
system bus system not possible
CI021 10 101 Invalid channel no. (A or B)
CI021 10 102 Invalid baud rate
CI021 10 103 Invalid message number.
This value is generated
when function CAN _ alloc _
msg_buf is called (range: 1
to 14).
CI021 10 104 Invalid Message ID (0 -
2031)
CI021 10 105 Direction conflict The specified direction of
transmission conflicts with
that configured.
CI021 10 106 Message not yet sent/
received
CI021 10 107 No message received No message received since
last read operation
CI021 10 108 Message not yet configured
CI021 10 109 Message has been overwrit- An old message has been
ten overwritten by a new one.
The data of the latest read
access are the actual data.
CI021 10 110 No message buffer available No message buffer available
(14 FULL-CAN buffers)
CI021 10 120 Release of message buffer Release of a unreserved
message buffer
10 121 Invalid message data length Invalid message data length
(range: 0 - 8)

Compo- Comp. Error

nent # #
10 122 No more free filter token No more free filter token
available available for BASIC CAN
buffer
10 123 Quartz frequency Invalid quartz frequency
10 124 CAN-install_bus called twice The CAN-install_bus func-
tion has been called twice
per controller
Component 11 EEPROM Driver for serial EEPROM
EE- 11 100 Invalid service hours counter EEPROM defective This error cannot be cor-
PROM reading rected by the customer.
Please contact customer ser-
vice.
11 101 Verification error After programming of This error cannot be cor-
EEPROMs in the following rected by the customer.
verify a data inconsistency Please contact customer ser-
had been detected vice.
11 102 Write or Read error The EEPROM cannot be This error cannot be cor-
read or written rected by the customer.
Contact customer service.
11 103 EEPROM not found
11 104 Wrong EEPROM type
Component 12 RXCOM Kemrobus Communication Module for RX Operating system
RX- 12 100 CC100: Error opening a
COM message
12 100 RC100: No free station
12 101 CC100: send_data too long
12 101 RC100: No free bus
12 102 Invalid station number
12 103 CC100: Send data timeout
12 103 RC100: Invalid bus number
12 104 CC100: Send unit timeout
12 104 RC100: Global object name
too long
12 105 Send command timeout
12 106 Send response timeout
12 107 Error while receiving data
message
12 108 Message could not be saved
12 109 Error while receiving Unit
message
12 110 CC100: Unit could not be
saved
12 110 RC100: Evaluation error
Request-Token
12 111 CC100: Error while receiv-
ing Command message

Compo- Comp. Error

nent # #
12 112 CC100: Command could not
be saved
Send-Unit
12 113 CC100: Name too long
Command
12 114 Invalid command in server
task
12 200 No free server
12 201 SIO channel already
assigned
12 202 Message too long
12 210 Send timeout on bus
12 211 RX _ send _ data - Timeout
12 212 RX_send_unit-Timeout
12 213 Timeout transmission of
command
12 350 Message buffer overflow
12 351 No character received
12 352 SIO receive error
12 353 Send buffer full
12 354 SIO send error
12 355 Initialization conflict
12 356 Invalid acknowledge charac-
ter
12 357 CRC error
12 358 Negative acknowledge-ment
received
12 400 Error at KBI_open Error at KBI_open.
Send_data KBI-Int.handler
12 410 KBI_rd_int_msg != OK
12 411 Send_data Send_data to KBI_rd != OK.
Send_unit KBI-Int.handler
12 413 Send_unit Send_unit to KBI_rd != OK.
Send_command KBI-
Int.handler
12 415 Send_data to KBI_rd != OK
Component 13 RXCOM RX Operating system
13 100 System time 0 specified
13 101 Invalid task priority
13 102 Invalid task token
13 103 Invalid mailbox token

Compo- Comp. Error

nent # #
13 104 Invalid timer token
13 105 Invalid semaphore token
13 106 Invalid object token
13 107 Invalid object type
13 108 Too long send message
13 109 Invalid user parameter no.
13 110 Invalid task state, internal
error
13 111 Invalid region parameter
13 112 Object directory full
13 113 Pool memory empty
13 114 An assigned mail box is
being deleted
13 115 An assigned semaphore is
being deleted
13 116 Root task being deleted
13 117 Root task being suspended
13 118 Restart of root task
13 119 Sleep within root task
13 120 Wait within root task
13 121 Receive within root task
13 122 Lookup within root task
13 123 Priority change of root task
13 124 Stack overflow
13 125 Invalid ready queue, internal
error
13 126 Signaling at scheduler stop
13 127 Timeout for lookup via KBI
13 128 Catalogue: name already
existing
13 129 Enable order region-sema-
phore
13 130 Self-suspending within
region
13 200 Receive, Lookup: timeout
expired
13 201 Send message: limit reached
13 202 Send unit: limit reached
13 203 Task stack too small
13 220 Invalid number of task priori-
ties
13 221 Hardware interrupt beginning
13 222 Hardware interrupt end

Compo- Comp. Error

nent # #
Component 14 MM Dynamic Memory Manager
MM 14 100 Memory too small The available memory area
is too small for the memory
manager (MM_create_pool).
14 101 Error at MM_create_pool
MM_create_pool: block big-
ger than one segment (64kB
at PROC86)
14 102 Invocation of MM _ delete _ MM_delete_pool, although
pool blocks still assigned in pool.
14 103 Inconsistent memory man-
agement
14 104 Block bigger than one seg- MM_create_area: block big-
ment ger than one segment (64kB
at PROC86)
14 105 MM_create_area: block size
0 bytes
14 106 Function call Handover pointer to MM _ Correct software. Error can-
MM_deleta_area with invalid area_size does not point to a not be rectified by the cus-
pointer an allocated memory block tomer. Contact the service.
14 107 MM_increase_ pool: memory
overlapping
14 108 Memory overlapping in one Memory block causes incon- Correct software.
block sistency. Read INFO to see
which block.
Component 15
WKM 15 100 No free memory
15 101 No free window
15 102 Invalid window
15 103 Invalid screen
15 104 Invalid channel number
15 105 Error in queue
15 106 Input buffer full
15 140 Keyboard number too high
15 141 Keytable not correct
15 200 No free line editor
15 201 Invalid line editor
15 202 Invalid line editor window
15 220 No free parameter editor
15 221 Invalid parameter editor
15 222 Invalid parameter editor win-
dow
15 223 Invalid parameter type invalid file konst.rc or machine and parts data must
param.rc, wrong ST program have the matching version
15 224 Invalid number
15 225 Invalid conversion factor

Compo- Comp. Error

nent # #
15 226 Invalid precision
15 240 No free screen editor
15 241 Invalid screen editor
15 242 Invalid screen editor window
15 260 No free scrollbar
15 261 Invalid scrollbar
15 262 Invalid scrollbar window
15 280 No free menu
15 281 Invalid menu
15 282 Invalid menu window
Component 16
MCU 16 100 No free MCU
16 101 Invalid MCU number
16 102 Invalid axis number
16 103 MCU not installed
16 104 Axis not installed
16 105 Invalid velocity
16 106 Negative velocity value
16 107 Invalid acceleration
16 108 Negative acceleration
16 109 Invalid overlap
16 110 Negative overlap value
16 111 Invalid ramp factor
16 112 Invalid rotation mode
16 113 Invalid circle description
16 114 Invalid asynchronous veloc-
ity
16 115 Invalid position type
16 116 Invalid velocity type
16 117 Invalid acceleration type
16 118 Invalid spline description
16 119 MCU not stopped
16 121 Servo controller not ready
16 122 Hardware end switch passed After a move command, at Check position of end switch,
least one limit switch has check ST-program.
been passed.
16 123 Servo controller not ready While the axis was moving, Check servo motors, check
the servo ready signal was the causes of the reset of the
reset. servo ready signal.
16 124 CC100: Set position when
axes are turned on
16 124 RC100: Invalid manual mode
16 125 CC100: Axis not masked
(axis name)

Compo- Comp. Error

nent # #
16 125 RC100: Position set value Attempt to modify the set Check ST-program
changed when MCU not position on-line while the
stopped axes were switched on.
16 126 CC100: Motion over end
switch of software axis (axis
name)
16 126 RC100: Axis not masked Attempt to modify the set Check ST-program
position of an unmasked
axis.
16 130 Invalid repositioning number
16 131 Invalid repositioning position
16 132 Invalid ramp type
16 133 Invalid operating mode
16 140 Invalid tangent
16 141 Invalid third circle point
16 150 Manual traversing during
movement
16 151 Invalid position type
16 152 Not completely calibrated
16 153 Robot mode changes when
moving
16 154 CC100: Movement out of Movement out of working
working space space not allowed (space
number, gripper number)
16 154 RC100: Software end switch Attempt to pass the axis lim- Check configuration data
passed its defined in the software and ST-program
(dimensions of axes set in
the ACU data).
16 155 Workspace violation Attempt to move into a not Check the point data.
allowed block (workspace).
The number of the block to
be passed and the number of
the active gripper which
caused the error are dis-
played. For further informa-
tion, see description of
workspace.
16 156 Servo controller not ready Attempt to trigger move com- Check ST program
mand while the drives were
turned off.
16 157 Invalid move command
16 160 Singular differentiation

Compo- Comp. Error

nent # #
16 170 Maximum drag distance ACU higher-level lag error Check the set lag error,
exceeded monitor prevents defects in check the drive.
the control system. If the cor-
rect value is set, the error
only occurs in case the drive
system is defective. Dis-
played: axis and the drag
distance
16 171 Distance calibration switch - For referencing, the zero Move the reference cam until
zero impulse too small position of the motor must the error does not occur or
maintain a minimum distance modify the parameter "Off-
to the reference switch. If this set zero point" in the ACU
distance is not maintained data by approx. 30 degrees
this error will be displayed. (recommended, don't forget
The axis and the distance upload). At gear ratios of >
value causing the error are 1:1000, recommended: turn
displayed. off the monitoring by bit
mask.
16 175 Axis limits exceeded
16 180 Axis limits exceeded
16 185 Fifo too small
16 186 Fifo segment buffer too small
16 200 No free MCPRG
16 201 Invalid MCPRG number
16 203 MCPRG not installed
16 205 No ST function available
16 206 Invalid robot type
16 207 Spline points with unequal
frames
16 208 Invalid number of spline
points
16 209 Invalid circle description
16 210 Invalid spline description
16 211 Invalid Akima spline type
16 212 Invalid Akima weighting fac-
tor
16 213 Invalid Akima description
16 214 Invalid number of points
16 300 No free MCMAN
16 301 Invalid MCMAN number
16 303 MCMAN not installed
16 305 No ST function available

Compo- Comp. Error

nent # #
16 306 Invalid manual mode
16 308 Invalid calibration order The calibration order set in Check the configuration
the axis data is not correct [0 data.
.(number of axes -1)] (0 = 1st
ACU) - B ... axis name (X/Y/
...) - C ... If the number of
axes indicated exceeds the
actual quantity of axes, C will
indicate the number of the
first axis that is too much.
16 400 No free MCARU
16 401 Invalid MCARU number
16 402 MCARU not installed
16 403 Invalid block
16 404 Invalid gripper
16 420 Block list inconsistent
16 421 Invalid collision state
16 422 Invalid cut block
16 500 Invalid number of points
16 501 Invalid bounds
Component 17 KBI Kemrobus Interface Module (level 2)
KBI 17 100 Invalid base address The indicated base address
of the KEMRObus-Dual-
Port-Memory is invalid
17 101 Invalid KEMRObus interrupt
number
17 102 Invalid master ID Invalid master ID (permissi-
ble range: 1 to 14)
17 103 Two stations with the same The bus system includes two
ID stations with the same ID
17 104 Two stations with the same The bus system includes two
master ID stations with the same mas-
ter ID (= switch position)
17 105 A station logs on twice A station logs on twice on the
bus without sending any
logoff in between.
17 106 Number of messages trigger- The max. number of mes-
ing an interrupt sages triggering an interrupt
has been reached (define
KBI_MAX_INT_MSG_CNT
in kbi_c.h)

Compo- Comp. Error

nent # #
17 107 Number of installed reporting The max. number of installed
functions reporting functions about
logon and logoff of stations
on the bus has been reached
(define
KBI_MAX_REPORT_FUNC
_CNT in kbi_c.h).
KBI 17 108 Invalid station ID An invalid station ID has This error cannot be rectified
been indicated, e.g. 0 by the customer. Please con-
tact your after-sales service.
17 109 Station not known on the bus The indicated station is not
known on the bus.
17 110 Invalid station name An invalid station name has This error cannot be rectified
been recognized. by the customer. Please con-
17 111 Insufficient memory for open In the KEMRObus Dual-Port This error cannot be rectified
receive messages memory there is not suffi- by the customer. Please con-
cient memory for other open tact your after-sales service.
receive messages.
17 112 Wrong addressing of mem-
ory location in KEMRObus-
DPM
17 113 A message to be sent could
not be written successfully
17 114 Invalid message ID An unknown message ID This error cannot be rectified
has been recognized. by the customer. Please con-
17 115 Wrong read access to mes- Read access to message
sage which has not been opened
for receive yet
17 116 Receive message opened A receive message has been
twice opened twice.
17 117 No data on this message ID No data have been received
on this message ID
17 118 No new data received No data have been received
since the last reading of this
message.
17 119 An old message overwritten An old message not read yet
has been overwritten by
newly received message.
17 120 No request received No request from another sta-
tion has been received
(return code of function
KBI_server under MSDOS)

Compo- Comp. Error

nent # #
17 121 FIFO memory too small The FIFO memory for incom-
ing requests of other stations
is too small (this error can
only occur under MSDOS)
17 122 Invalid telegram received A station has received an This error cannot be rectified
invalid telegram. by the customer. Please con-
17 123 Response telegram cannot The response telegram to a This error cannot be rectified
be sent request cannot be sent (e.g. by the customer. Please con-
message allocated) tact your after-sales service.
17 124 I/O write error Error while writing to the indi-
cated I/O address
17 125 I/O read error Error while reading from the
indicated I/O address
17 126 Wrong uninstallation Uninstallation of a reporting
function which have never
been installed
17 127 Software version is not com- The software version of the
patible KBI component of a remote
station is not compatible with
the local software version.
17 128 Master ID not known Master ID not known on the
bus
17 200 Fatal system error from for- A foreign station has trig-
eign station gered a fatal system error.
17 201 Fatal system error from for- A foreign station has trig-
eign station (extended) gered a fatal system error
(with extended remote error
message)
Component 18 KBCOM Variable Communication Module for Kemrobus
KB- 18 103 Invalid return value Invalid return value of com-
COM pare function
18 300 No variables loaded No variables loaded even
though load procedure
started by user
18 301 Number of variables is 0 Number of variables to be
loaded is 0
18 302 Number of variables does Number of variables actually
not match loaded does not match num-
ber previously specified
18 303 Invalid variable name
18 304 Invalid variable name length
18 305 Invalid variable type
18 306 Invalid number of variable
elements
18 307 Invalid variable transfer type

Compo- Comp. Error

nent # #
18 308 Invalid variable owner speci-
fied
18 309 Invalid variable access
authorization
18 310 Invalid variable index Invalid variable index, no
entry in the variable list
18 312 Invalid PAB variable address
18 313 Invalid remote variable index
18 314 Multiple owners of the same Local station and remote sta-
variable tion are both owner of the
same variable
18 315 Data types do not match Specified data type of local
and remote variable do not
match
18 316 Number of elements do not Specified number of ele-
match ments of local and remote
variable do not match
18 317 Transfer types do not match Specified transfer type of
local and remote variable do
not match
18 318 Two variables with the same The variable list contains two
name variables with the same
name
18 319 Load local variables before All local variables must be
remote variables entered in the variable
before the remote variables
are entered
18 320 Reference to a variable with Reference to a variable for
no owner which no owner could be
found
18 321 Negative return code from Negative return code from
Get_var(). user function Get_var().
Get_packet_var() user function
Get_packet_var
Put_var() user function Put_var()
KB- 18 324 Wrong request of variable A variable packet has been
COM packet requested even though no
template has been sent
18 325 Blank variable packet tem- The specified variable packet
plate template is blank
18 326 Invalid PAB group Invalid PAB group (permissi-
ble values 0 to 6)
18 327 Invalid station number
18 328 Own station number
18 329 Unknown station number

Compo- Comp. Error

nent # #
18 330 Wrong number of received The number of the block/
block/segment segment received did not
match that expected when
transferring unstructured
data
18 331 Mismatching length of a data The length of a data block
block entered entered by the user does not
match that expected
18 332 Too many local PAB variable
specified
18 333 A remote station has too
many PAB variables
18 334 Not all messages received When reading a PAB group it
was found that not all mes-
sages belonging to the group
had been received again
since the last Read operation
Rd_data_blk() user function Rd_data_blk()
18 336 Data type not permissible for The specified data type is not
a PAB variable permissible for a PAB vari-
able at a specific station
18 337 Data exchange to remote A remote station is attempt-
station not installed ing to exchange unstructured
data with the local station
even though no function for
servicing data instructions
has been installed on that
station
18 338 Invalid invocation of Function KBCOM_exit
KBCOM_exit() invoked while data communi-
cation with another station
was still active
18 400 Inconsistent interlinking Interlinking of temporary vari-
able list is inconsistent
18 401 Wait period has expired The max. wait period for
sending the variable list has
expired even though the lay-
ers 2 and 7 are still active on
the remote station
18 402 Wait period has expired The max. wait period for
requesting the variable list
has expired even though the
layers 2 and 7 are still active
on the remote station
18 403 Invalid result Invalid result received from
remote station

Compo- Comp. Error

nent # #
18 404 Invalid result Invalid result received from
remote station
18 405 Dynamic memory is full The dynamic memory
requested for copying the
variable descriptions is full
18 406 Too many VLIST or DATA Too many VLIST or DATA
instructions instructions received at a
station
18 407 Too many variable instruc- Too many variable instruc-
tions tions received at a station
18 408 Too many variable packet Too many variable packet
instructions instructions received at a
station
18 409 Invalid message type Message with an invalid
received message type received
18 411 Error sending a request mes-
sage
18 412 Error sending a response
message
18 413 Message send lag A send message can not be
sent within the time specified
18 414 Message not received An expected message has
not been received within the
specified time
18 415 Error in structure of PAB Error calculating the struc-
ture of the PAB
18 417 KBCOM layer restart not reg- KBCOM layer restart on
istered remote station not registered
18 418 Name length is not a multiple The packed name length is
of 4 not a multiple of 4
18 419 Invalid segment length Invalid segment length within
a data block
18 420 Software version of KBCOM The software version of the
component not KBCOM component on a
compatible remote station is not compat-
ible with the software version
on the local station
18 600 Initiate message coult not be Could not send initiate mes-
sent sage because receive mes-
sage is busy on remote
station
18 601 Variable list is already com- Variable list is already com-
plete plete. All variables have
been assigned to an owner
18 602 The variable list has already
been sent
18 603 The variable list has already
been received

Compo- Comp. Error

nent # #
Component 19 PSX POSIX Interface module (C library)
PSX 19 100 No thread pointer for task
present
19 101 No Stdio pointer present
19 102 No Exit pointer present
19 103 NULL pointer while FREE
19 104 Duplicate semaphore_signal
19 105 Write to stdin
19 106 Read from stdout or stderr
Component 20 FS File System
FS 20 100 Access not permitted Eliminate the write protection
of the diskette Diskette writ-
ingprotected
20 101 Invalid handle The file system function has
been called with an invalid
file handle.
20 102 Invalid argument or opera- The file system function has Check the transfer parame-
tion been called with an invalid ters.
parameter or an unallowed
function.
20 103 Too many open files Close the files you don't
need any more.
20 104 Device not present
20 105 Device no longer available A device driver has already
been installed for the defined
device.
20 106 File not found The indicated file not found.
20 107 Directory not found
20 108 Invalid absolute path of file
name
20 109 No more storage space
available
20 110 Directory not empty The directory to be deleted Delete the files in the direc-
still contains files (not empty) tory to be deleted.
20 111 Destination and source Attempt to rename a direc-
directory not the same tory or a file, but the drive let-
ters are not the same.
20 112 No entry found The function FS_findfirst or
FS_findnext does not find
any more entries.
20 113 Path and file name too long Path and file name too long A max. of 80 characters are
Use a shorter path and file- possible.
name.
20 114 File function aborted The function for displaying a
directory (FSU_dir) has been
cancelled.
20 115 invalid directory entry

Compo- Comp. Error

nent # #
20 150 File locked Error while calling the func-
tion FS_do_lock when the
file is already locked.
20 151 File not locked Error while calling the func-
tion FS_do_unlock when the
file is not locked any more.
20 160 BPB parameter not sup- Invalid BIOS parameter
ported block.
20 161 Internal error
20 170 Fatal system error in multi-
task interface module
20 200 No connection with disk drive
20 201 No disk in drive
20 202 Disk is read only
20 203 Invalid format (disk unformat-
ted?)
20 204 Invalid sector number The device driver (e.g. for
FC352) has recognized an
invalid sector number.
20 205 Invalid track number The device driver (e.g. for
FC352) has recognized an
invalid track number.
20 206 Read error (checksum) The device driver (e.g. for The floppy disk may be
FC352) has recognized a defective.
read error (checksum error).
20 207 Write error (verify) The device driver (e.g. for
FC352) has recognized a
write error (verify error).
20 300 Unknown PFD35 error
20 400 Storage medium changed
20 401 Asynchronous error Error on FC352 interface
402 Hardware error Hardware error on FC352
interface
500 communication to server
aborted
Component 21 FSKBI File System for Kemrobus
FSKBI 21 100 FSKBI-Server not ready
101 Client-Mailbox not installed
102 KEMRO-Bus - Timeout
103 No free entries in MBX-table
104 Station number does not
exist
105 Server sends invalid func-
tion code
106 Max. path length exceeded
107 Server has received an
invalid command

Compo- Comp. Error

nent # #
108 Server has received invalid Invalid number of parame-
parameters ters at call of fstat Correct
software. This error cannot
be rectified by the customer.
Please contact the after-
sales service.
109 Invalid data length has been
transmitted
110 Invalid return code
111 Invalid rename buffer han-
dling
112 No rename buffer available
113 File buffer has not been gen-
erated
114 Too many response mes-
sages have been refused
115 Too many response tasks in
response cancel table
116 Cancel counter not found
Comonent 24
ECC 24 100 RAM error corrected A bit error has been recog- A bit error has been recog-
nized in the static RAM of the nized in the static RAM of the
CPU and corrected. CPU and corrected.
101 RAM error cannot be cor- Several bit errors occurred in Check the battery voltage!
rected the static RAM of the CPU. After the error occurred, per-
Because of the set hamming form a download in all cir-
distance these errors cannot cumstances. If the error
be corrected. occurs several times the
card must be changed.
Component 25
COP 25 110 CAN interface has no mes- CAN interface has no mes-
sage buffer sage buffer FA in 7-segment
display of CU 312/313,
111 Timeout for enabling SDO
communication expired
112 Timeout for response to SDO
request expired
113 Timeout for enabling APDO
114 Timeout for response to
APDO-RTR request expired
115 Timeout for enabling NMT
116 MSG15 filter entry could not
be created
117 A cyclic read PDO could not A cyclic read PDO could not Read error in CANopen
be read be read driver

Compo- Comp. Error

nent # #
118 Error message from one One module has sent an Emergency: A B, B= error
module emergency error message text :-- No error - General
error-- input current below
minimum --output short circut
-- output current below mini-
mum -- output voltage miss-
ing -- transmission error --
transmission error BUS-
OFF! -- external error --
unknown error
119 Protocol error has occurred
120 Error during SDO transfer,
'abort' by user
121 Parameter error of SDO data
122 The access to an object is
not possible in the current
state
123 The access to an SDO is not
possible
124 Hardware error, therefore no
SDO access
125 nodeguarding: incorrect nodeguarding: node sends
answer of a node incorrect answer
127 nodeguarding: response tim- nodeguarding: response tim-
eout eout
Component 26
MT161 26 100 CC100: Invalid servo number
100 RC100: Invalid channel
token
101 Invalid axis number
102 CC100: No response from
servo axis
102 RC100: No free MT161
driver
103 CC100: Invalid message
received
103 RC100: Invalid cycle time
104 CC100: No message has
been received
104 RC100: No CAN message
buffer free
105 Message has been overwrit-
ten
106 CAN-Bus failure
107 Not allowed interrupt
108 Download not successful

Compo- Comp. Error

nent # #
109 Time exceeded during down-
load
110 CC100: Parameter not
acknowledged
110 RC100: No response from A defined servo axis does Check the configuration
servo axis not respond. data, check the CAN bus
connection, check the servo
controller in the MOOG rack.
111 CC100: Time exceeded at
parameter
111 RC100: Invalid CAN-Bus The RC100 has received an Check the CAN bus connec-
message received invalid CAN bus message. tion, check the controller in
the MOOG rack.
112 CC100: Error during pro-
gramming
112 RC100: No actual value data During the cyclic update no Check the CAN bus connec-
received actual value telegram has tion, check the controller in
been the MOOG rack.
received.
113 Time exceeded during pro-
gramming
114 Servo axis: global error
115 Servo axis: interpolator error
116 Servo axis: CAN bus failure
117 Servo axis: short circuit
118 Servo axis: overheating
119 Servo axis: parameter error
120 CC100: Servo axis: resolver
error
120 RC100: Download not suc- The start of the download Check the configuration
cessful has not been acknowledged data; check if the controller in
by one or several controllers. the MOOG rack prevents the
download.
121 CC100: Servo axis: motor
temperature
121 RC100: Timeout during The 'start download' instruc- Check which controller in the
download tion of the RC100 has not MOOG rack does not
been acknowledged by one acknowledge the download.
or several controllers within
the set time.
122 CC100: Servo axis: bridge
temperature
122 RC100: Parameter not One or several controllers in Check the configuration data
acknowledged the MOOG rack did not and the MOOG software to
acknowledge a parameter. find out which controller in
the MOOG rack does not
acknowledge the parameter.

Compo- Comp. Error

nent # #
123 CC100: Servo axis: overvolt-
age
123 RC100: Timeout while writ- One or several controllers Check the configuration data
ing parameters have not acknowledged the and the MOOG software to
downloading of the parame- find out which controller in
ters for a longer time. the MOOG rack does not
acknowledge the parame-
ters.
124 CC100: Servo axis: power
failure
124 RC100: EEPROM cannot be One or several controllers in Check the MOOG software;
programmed the MOOG rack have not check which MOOG control-
acknowledged the EEPROM ler does not acknowledge
programming instruction. the programming of the
EEPROM.
125 EEPROM cannot be pro- One or several controllers in Change the corresponding
grammed the MOOG rack could not MOOG controller.
program the EEPROM
130 Servo: global error A controller of the MOOG Change the MOOG control-
rack signalizes a global error. ler.
131 Servo: interpolator error A set value of the control has Turn off/on the power supply
not been accepted by the of the control. If the error
MOOG controller. occurs several times change
the MOOG controller.
132 Servo: CAN bus error A CAN bus protocol error Check the CAN bus line; turn
prevents the cyclic data off/on the power supply of
exchange. the control. If the error
occurs several times check
why protocol errors continue
occurring on the CAN bus.
For all other MOOG
error messages, contact your
after-sales service regarding
the causes...
133 Servo: short circuit Hardware problem in MOOG Contact your after-sales ser-
rack vice.
134 Overheating in MOOG servo Load of servo is too high, Reduce axis speeds, provide
controller or in servo motor. speeds are too high, down- for longer downtimes, check
Motor temperature > 120°C, times are too short, brake axis for manual movability.
Bridge temperature > 70°C activated, mechanical friction
is too high
135 Servo: parameter error A wrong or unknown param- Check the software versions.
eter has been entered; the
MOOG software is not com-
patible with the RC100 soft-
ware.
136 Servo: resolver error The resolver does not yield Check the resolver signal.
any actual values.

Compo- Comp. Error

nent # #
137 Servo: motor temperature The servo motor has got too Wait until the servo motor
hot. cools down. Check axis
speeds,
axis accelerations and path
velocities.
138 Servo: bridge temperature A controller signals that the Check the device for slug-
maximum allowed tempera- gishness, check the brake,
ture of the final power stage check the controller parame-
(85°C) has been exceeded. ters.
The drive is turned off imme-
diately. The ID of the control-
ler is displayed with the
parameter "B".
139 Servo: overvoltage A controller signals an over- Check the power supply volt-
voltage or an undervoltage. age. If the error is caused by
Causes: Failure of power the opening of a guard dur-
supply (e.g. opening of ing the movement, the robot
guards during the move- can continue moving imme-
ment). The backfeed power diately after the guard has
from the motor is too high, been closed.
the interm. circuit voltage is
more than 420 V, Tempera-
ture > 110 °C
140 Servo: power failure Error in +5V or ±15V power Check the hardware.
supply on MOOG
141 Servo: no command tele- No valid command telegram Check the CAN bus connec-
gram has been received. tion.
142 Servo: no actual telegram No valid actual telegram has Check the CAN bus connec-
been received. tion.
143 Servo: limit switch Contact after-sales service.
144 Servo: lag error The controller could not fol- Check the parameter of the
low the set value. closed position control loop,
check the MOOG software.
145 Servo: quick stop Contact after-sales service.
150 received servo type wrong received servo type wrong
Component 27
DC161 27 100 Invalid channel token
101 Invalid module number
102 Invalid cycle time
103 No free DC161 driver
104 No free CAN message buffer
105 Digital input message had
been already read (new
message is missing)
106 New digital input message
received although old mes-
sage not had been read.

Compo- Comp. Error

nent # #
107 CI 021 module signals CAN- Bus interrupt
Bus error
108 DC 161 module signals short
circuit of a digital output.
109 DC 161 module signals error Synchronizing or digital out-
in communication protocol. put message not ready in a
cycle.
110 No response from module A configured module does Check the configuration
not respond. data, check the CAN bus
connection, check the mod-
ule IDs of the DC161 on the
CAN bus, change DC161.
111 Invalid message received An invalid CAN message Check the CAN bus connec-
prevents the cyclic data tion; change the module
exchange causing the error.
112 No message received The actual value telegram of Check the CAN bus connec-
a module, that is required for tion, change the module.
the cyclic process image has
not been received.
113 Short circuit A short circuit occurred at an Eliminate cause of short cir-
output of the DC161. cuit.
114 CAN protocol error Due to a CAN bus protocol Check the CAN bus connec-
error, the cyclic data tion.
exchange cannot be per-
formed any more.
115 Unknown message An unknown CAN message Check the CAN bus connec-
has been received. tion.
116 CAN message buffer is Message buffer overflow of Check the CAN bus connec-
occupied. CAN module tion, change the module.
Component 28
SRE3I 28 100 Invalid servo number
101 CC100: Invalid axis number
101 RC100: Invalid servo token
102 CC100: Counter value can-
not be read
102 RC100: Invalid axis number
(error CC100/101)
103 CC100: Count deviation
103 RC100: Slot already
assigned
104 Zero pulse is missing
105 Transducer power failure
106 Test not successful
107 Slot already assigned
110 Count cannot be read The actual values required Change the II030 card.
for the controller could not be
read.

Compo- Comp. Error

nent # #
111 The count between two zero Different counts have been Check the resolver signal
impulses is differing. measured between 2 lines.
resolver zero impulses.
112 Zero impulse is missing No zero impulse has been Check the zero impulse sig-
detected after 2 resolver nal line.
rotations.
113 Transducer power failure The sense line is defective. Check the sense line.
114 Hardware test result not suc- Reversed polarity of connec- Check the connections.
cessful tions.
Component 29
CTS 29 100 Invalid channel token
101 Invalid port number
102 Invalid cycle time
103 No free CTS driver
104 No free CAN message buffer
105 Invalid command
106 No confirmation message
107 Invalid confirmation
110 Invalid sensor status Invalid sensor status Replace ultrasound position
detected. transducer.
111 No sensor data available Sensor does not support Check power supply of ultra-
actual data for the necessary sound position transducer,
cyclic updating of the pro- replace transducer.
cess data base.
112 General CAN bus error General CAN-Bus error, Check CAN-Bus lines and
update of actual values of connectors.
sensor data is not possible
120 Node already existing Two or more sensors in the Activate erasing of
CAN line have the same EEPROMs in ultrasound
node number (check during position transducers, switch
start up). control supply voltage off/on.
121 Sensor cannot be pro- Two or more sensors in the Check CAN-Bus lines,
grammed CAN line cannot be pro- replace sensors.
grammed.
122 Type and length are not The parametrized sensor Check configuration data.
compatible length is not compatible to
the existing sensor type.
123 Unknown sensor type No fitting sensortype avail- Check configuration data.
able to the set sensor length.
124 Sensor not on bus No sensor with the set serial Check configuration data.
number in the CAN line.
125 Two nodes with same ID on Two or more sensors with Activate erasing of the
CAN line the same node number are EEPROM, switch power sup-
in a CAN line. ply off/on.
Component 33
HT401 33 100 No more CAN bus system
can be configured

Compo- Comp. Error

nent # #
101 Invalid channel (A or B)
102 Invalid baud rate
103 Invalid message buffer num-
ber (1 .. 14)
104 Invalid message ID (0 ..
2031)
107 No new data since last read No new data have been
access received since last read
access
109 Data overwritten several The data have been over-
times written several times since
last read access
110 No more free message
buffer available (14)
120 Attempt of enabling mes-
sage buffer Attempt of
enabling message buffer that
has not been reserved
before
121 Invalid message data length
(0 .. 8)
122 No more filter can be config-
ured
123 Invalid quartz frequency
124 Function CAN_install_bus The function
called twice CAN_install_bus has been
called twice for one controller
Component 35
MMPA 35 100 No KBI_init performed
B
101 Warning: KBCOM is shut Warning: KBCOM is shut
down down for loading the vari-
ables list
102 MMPAB_start_update, MMPAB_start_update:
MMPAB_check_inconsistenc Sender has not been found
y for all receive variables at
first start.
MMPAB_check_inconsistenc
y: The send station of the
requested variable has
logged off with
MMPAB_stop_variable
103 After the restart, not all send- After the restart, not all send-
ers available ers are available; these
senders have logged off reg-
ularly with
MMPAB_stop_update.

Compo- Comp. Error

nent # #
104 MMPAB_start_update not MMPAB_start_update not
possible possible for MMPAB _ read
_pab is not cyclically called
by the system environment
105 KBCOM could not be shut MMPAB_install_ comm:
down KBCOM could not be shut
down within
MMPAB_STARTUP_TIMEO
UT_ MS
106 Invalid KBI station number
107 Invalid PAB priority
108 PAB maintenance cycle tim- PAB maintenance cycle tim-
eout eout; new cyclic PAB data
has not been received for a
too long time.
109 Invalid state in cyclic process The cyclic process image
image maintenance maintenance is in an invalid
state
110 No sender found No sender could be found for
one or several receive vari-
ables.
111 Invalid PAB variable name Invalid PAB variable name,
or PAB variable name could
not be found at MMPAB
_check_inconsistency.
112 Variable is no receive vari- The variable at
able MMPAB_check_inconsistenc
y is no receive variable.
Component 38
LAN _ 38 102 79C970A initializing failed
ETH-
ERNET
103 79C970A not accessable via
PCI-Bus
Component 41
SEH 41 103 Instruction Bound address from which an
instruction should be read
does not correspond to oper-
ating mode and/or to bound
registers (e.g. wrong address
calculation, memory area ? )
104 Data Bound address of variable to be
read or written does not cor-
respond to operating mode
and/or to bound registers
(e.g. wrong address calcula-
tion, wrong pointer, memory
area ? )

Compo- Comp. Error

nent # #
105 Address Error Load load operation from
unaligned address has been
detected.
106 Address Error Store storage operation to
unaligned address has been
detected.
107 Instruction Bus Error bus error while reading
(Codefetch)
108 Data Bus Error bus error while writing or
reading
111 Reserved Instruction an invalid opcode should be
executed
112 CoProcessor Unusuable the coprocessor is not avail-
able
113 Integer Overflow at a calculation the value
range has been exceeded or
has not been reached (e.g.
division by 0)
114 Trap a trap-opcode has been exe-
cuted - should not happen in
the system, except in an
assembler program
116 Floating Point Exception an error occurred in a float-
ing point calculation (for fur-
ther information, see
Floating-Point-Cause-Regis-
ter)
117 Floating Point Exception Inexact the exact calculation
of the value is not possible or
produces an overflow (check
the arguments !) Software:
check arguments.
118 Floating Point Exception Underflow the result of a cal-
culation is too small. This
might lead to an error in the
following calculations.
119 Floating Point Exception Overflow the result of a cal-
culation is greater than the
possible value
range.
120 Floating Point Exception Division by Zero the divisor is F3 in 7-segment display of
0 and causes an undefined CU 312/313
result.
121 Floating Point Exception Invalid one or both operands
of an operation are not valid
(e.g.
multiplication by 0, division 0/
0 etc. )

Compo- Comp. Error

nent # #
122 Floating Point Exception Unimplemented the corre-
sponding floating point oper-
ation is not implemented.
124 Watch Exception a certain code position has
been reached or a data area
has been read/written.
150 A cache error has been trig- cache error has been trig-
gered. gered.
160 Interrupt without processing an interrupt without process-
function ing function has been trig-
gered.
170 Parity error in GALILEO chip the GALILEO chip on the
on CU312 CU312 signals a parity error.
200 Power failure triggered if no other process-
ing function is implemented.
Component 45
LENZE 45 100 Lag error
101 Controller inhibition
102 TRIP Error
103 Quick stop
104 No response from controller
105 MCU cycle time too large (>
13 ms)
106 Maximum number of drivers
exceeded
Component 47
ACO- 47 100 Maximum number of ACO- Maximum number of ACO-
POS POS drivers exceeded POS drivers in the system
has been exceeded.
101 The update cycle inbetween Update cycle interval must Set valid value of update
6 and 12 ms be between 6 and 12 ms cycle time.
102 Maximum number of CAN- Too many devices for this Assign device to another
Bus devices exceeded CAN bus circuit are config- CAN bus.
ured
105 Overflow in mailbox of error Too many error inputs from This error cannot be rectified
info ACOPOS controller in a by the customer. Please con-
short time tact the after-sales service.
110 File open failed File is not loaded on the con- Load file to control
trol
111 File read error File is defective/not complete Reload file to control
113 File not copied The file could not be copied Check if the file exist on this
drive
114 File not created The file could not be created Check if the drive exists and
if the required memory is
available

Compo- Comp. Error

nent # #
115 File write error File could not be written suc- Check if the required mem-
cessfully ory is available
149 Controller did not respond to Defective CAN connection or Check CAN connection and
request telegram (timeout 10 wrong CAN configuration CAN configuration (CAN
ms) bus, CAN-ID, ...)
150 Controller responded to a A wrong parameter or com- see B&R documentation
request telegram with an mand had been sent to the
error telegram ACOPOS controller
151 SW reset failed After a reset the ACOPOS
controller is not in the
expected status
152 Starting of operating system After a start the ACOPOS
of ACOPOS controller failed controller is not in the
expected status
153 Timeout when reading the e.g. after a SW-Reset the
boot status ACOPOS controller does not
respond to a status request
154 Timeout when reading the The ACOPOS controller
status during write process does not respond to a
of ACOPOS firmware request of the status during
write process of the operat-
ing system
155 Firmware upgrade of ACO- Failure during transmission
POS controller failed or write process of operating
system
156 Error in write process of Error message of ACOPOS
ACOPOS firmware controller during write pro-
cess of operation system
157 The ACOPOS firmware The ACOPOS firmware
upgrade could not be started upgrade could not be started
because function because stop of motion
"MC_stop_all()" failed failed
158 Init of ACOPOS controller An error at startup caused
failed that init of ACOPOS could
not be completed
159 Minimum version of operat- The minimum operating sys- Replace controller or carry
ing system tem version of ACOPOS out upgrade
controller is V3.96
160 Different version of operating ACOPOS controllers have Replace controller or carry
system different versions of operat- out upgrade
ing system
161 No operating system The ACOPOS controller has Replace controller or carry
no operation system out upgrade
162 Asynchronous message An asynchronous message Too much traffic on the CAN
could not be sent could not be sent during sev- bus. This error cannot be
eral cycles rectified by the customer.
Please contact the after-
sales service.

Compo- Comp. Error

nent # #
170 Parameter descriptor to No existing entry to parame-
parameter-ID could not be ter-ID in file
found "ACP10MAN.PAR"
171 Data type not supported ACOPOS driver does not
recognize this data type
200 Cyclic actual value mes- In an update cycle no cyclic Check CAN bus connection
sages from controller lost actual value telegram from
one controller had been
received
201 ACOPOS is not synchro- An ACOPOS controller
nized reports synchronize error
compared to the cyclic
SYNC messages
202 Transducer error at ACO- An ACOPOS controller Check connection to trans-
POS reports loss of reference ducer
position
203 Timeout at handshake after The ACOPOS controller
ACOPOS controller switch- does not respond to a
on command switch-on command
204 ACOPOS activates quick- An ACOPOS controller
stop reports a quickstop
205 ACOPOS hang-up in QSP An ACOPOS controller did
(2s) not finish quickstop after at
least 2 seconds
206 Error message read from The ACOPOS controller see B&R documentation
ACOPOS controller reported an internal entry in
it's error buffer which had
been read and displayed by
the control
207 Maximum number (5) of Five times in short sequence
restart attempts reached the ACOPOS driver acti-
vated a quickstop immedi-
ately after switching on the
controller. For security rea-
sons the driver changes to a
status which will request a
power off/on
208 Quickstop failed for one axis The controller did not Analysis required. Maybe an
response to a quickstop adaption of system software
command within10 cycles. or controller software is nec-
essary.
220 File for error texts could not File is not loaded on the con- Load file to control
be found or opened trol
221 Error when reading header File is defective or incom- Load file to control
of error file plete
222 Error text file is empty File does not contain data Load file to control

Compo- Comp. Error

nent # #
POST 1000 <100 see description of errors with
(powr on component designation
self test) "ALLG" in section "General
components"
AKP-0 1001 <100 see description of errors with
(8741 component designation
control- "ALLG" in section "General
ler) components"
Timer 1002 <100 see description of errors with
component designation
"ALLG" in section "General
components"
INT 1003 <100 see description of errors with
(interupt) component designation
components"
INT 1003 100 Divide error
101 Debug exception
103 Breakpoint
104 INTO-detected overflow
105 BOUND range exceeded
106 Invalid opcode
107 Coprocessor not available
108 Double fault
109 Coprocessor segment over-
run
110 Invalid task state segment
111 Segment not present
112 Stack fault
113 General protection
114 Page fault
116 Coprocessor error
120 Invalid interrupt enable in an
interrupt routine
IO bus 1004 <100 see description of errors with
access component designation
for "ALLG" in section "General
KEMRO- components"
bus
IOB 1004 100 General Kemrobus LCA
error
Perfor- 1005 <100 see description of errors with
mance component designation
analysis "ALLG" in section "General
components"

Compo- Comp. Error

nent # #
System 1006 <100 see description of errors with
component designation
components"
100 Write access(es) to EBIAS An invalid write access to the Store EBIAS for diagnostics
RAM EBIAS RAM had been at the next start-up.
detected by the cyclic diag-
nosis.
PCB 1007 <100 see description of errors with
manage- component designation
ment "ALLG" in section "General
components"
100 I/O ready error: digital input
(DI325/DI326)
101 I/O ready error: digital output
(DO321)
102 I/O ready error: digital input/
output
103 I/O ready error: analog input
104 I/O ready error: analog out-
put
105 I/O ready error: analog input/
output, (AR161,
AR101)
PCB 1007 106 I/O ready error: temperature
control card (E8-Thermo,
TP081, ...)
107 I/O ready error: graphical
interface (GC201, ECRT)
108 I/O ready error: serial inter-
faces (E-HSI, SC021)
111 I/O ready error: RC100
(CU211)
112 IO-Ready Error: CAN-Bus-
Interface
113 IO-Ready Error: Floppy drive
OC101
150 No response from RC han- Unknown address at the bus. Change RC handling CPU.
dling CPU I/O ready error caused by the Check card configuration
RC handling. Maybe wrong
configured or defective card
in rack.
151 PCB list is full, no more
entries possible

Compo- Comp. Error

nent # #
152 Error accessing EEPROM Defective EEPROM Change EEPROM. The
board with the defective
EEPROM can be detected
by evaluating the INFO in the
statusreport
153 No free handle found during
PCB_open
154 Function invoked with invalid
handle
155 The installed function for
increasing the service hours
counter reading returned an
error
156 PCB-Close not invoked
(time-out)
200 Invalid, unknown PCB type
201 No more entries found in
PCB list; end of list encoun-
tered
202 Invalid action during PCB
logging
EBOS 1008 <100 see description of errors with
operating component designation
system "ALLG" in section "General
components"
100 Max. number of EBOS tasks
exceeded
101 Invalid EBOS task number
102 Max. number of EBOS
semaphores exceeded
103 Invalid EBOS semaphore
number
104 Max. number of EBOS
events exceeded
105 Invalid EBOS event number
106 No free memory available for
task stack
110 GET_MEMORY function
invoked for static memory
after DELDATA initialisation
phase
EE- 1009 <100 see description of errors with
PROM component designation
interme- "ALLG" in section "General
diate components"
layer

Compo- Comp. Error

nent # #
Graph- 1010 <100 see description of errors with
ical component designation
interface "ALLG" in section "General
components"
Graphics 1011 <100 see description of errors with
emulatio component designation
n module "ALLG" in section "General
components"
Key- 1012 <100 see description of errors with
board component designation
inter- "ALLG" in section "General
face components"
CMD4P 1013 <100 see description of errors with
proto- component designation
col "ALLG" in section "General
components"
Data 1014 <100 see description of errors with
output component designation
module "ALLG" in section "General
components"
BMP 1015 <100 see description of errors with
bitmap component designation
manager "ALLG" in section "General
components"
BMP 1015 100 Incorrect interface type
101 Invalid bitmap number
102 No more space available for
bitmaps
103 Bitmap not present
DPM 1016 <100 see description of errors with
(dual port component designation
memory "ALLG" in section "General
driver for components"
SI 024)
DPM 1016 101 Invalid acknowledgement
from KPC
102 Invalid request from KPC
103 Unknown interrupt
104 Data buffer too long
105 Data buffer too small
106 Acknowledgement while writ-
ing
XL firm- 1017 <100 see description of errors with
ware hex component designation
loader for "ALLG" in section "General
SI 024 components"
101 No memory received for boot
record

Compo- Comp. Error

nent # #
102 No memory received for data
buffer
103 Error while opening the boot
file
104 Unknow boot record type
105 Boot record read error
106 Boot checksum error
107 Address too low
108 Address too high
109 KPC does not respond
110 No end record
120 No memory received for
monitor record
121 Unknown monitor record
type
122 Monitor checksum error
123 Monitor record read error
124 Error while opening monitor
file
125 No end record
130 No memory received for
record
131 Unknown firmware record
type
132 Firmware checksum error
133 Firmware record read error
134 Error while opening the firm-
ware file
135 No end record
140 Incorrect request from KPC
IEB1 1018 <100 see description of errors with
and component designation
IEB2 "ALLG" in section "General
interface components"
board
manager
RTC 1019 <100 see description of errors with
(real time component designation
clock "ALLG" in section "General
module) components"
100 Real-time clock not present
or not functioning
Floppy 1020 <100 see description of errors with
manager component designation
components"

Compo- Comp. Error

nent # #
PRT 1021 <100 see description of errors with
(printer component designation
module) "ALLG" in section "General
components"
100 Print function invoked with-
out OPEN
101 CLOSE invoked without
OPEN
102 Invalid control character
140 Print buffer not present
(BEGINPRINT not executed)
141 Print buffer already in use
142 Not enough space in print
buffer
Soft- 1022 <100 see description of errors with
key component designation
man- "ALLG" in section "General
ager components"
Con- 1023 <100 see description of errors with
ver- component designation
sion "ALLG" in section "General
func- components"
tions
Modem 1024 <100 see description of errors with
control component designation
components"
EI 1100 <100 see description of errors with
EBIAS component designation
inter- "ALLG" in section "General
preter components"
100 I/O error creating process
image
EBIAS 1101 <100 see description of errors with
interface component designation
components"
100 Machine number <> EBIAS- EBIAS machine number and Load EBIAS with the correct
machine number, EBIAS programmed machine num- machine number.
deleted ber in EPROM must be
equal. A difference had been
detected by the system.
101 EBIAS memory error, EBIAS memory error detected at 1.Store EBIAS on disk for
has not been deleted start-up diagnosis (Softkey F7),
2.load new EBIAS.
I/O component designation
components"

Compo- Comp. Error

nent # #
DAT 1103 <100 see description designation
data "ALLG" in section "General
manager of errors with component
components"
100 End of file list reached
101 Wrong disk type
102 Wrong filename
103 Wrong index
104 Error reading EBIAS
105 Error when reading language text(s) and EBIAS build and load language
TXTxxx32.BIN. The read-in don't fit. text(s) and EBIAS anew.
language text is too long and
would exceed the text range.
106 Error reading TXTxxx.BIN
107 Expand error
108 no INFO-File available
109 DAT_FILE_READ was not
set
110 DAT_FILE_WRITE was not
set
111 File already existing in list
112 Switching to other languages Dynamically memory too Repeat language switching,
does not work small. From Sys.V1.16 on no switching in the automatic
system error will be gener- mode is not recommended
ated. A return code will be as the system needs more
sent to the calling function. dynamic memory in this
case.
113 SYSERR during language This error may occur in sys- It is recommended to acti-
switching tem verstion V1.15. vate the language switching
in the manual mode. The
system doesn't need so
much memory in this case.
114 Invalid version number of file
to be read.
Data 1104 <100 see description of errors with
dialog component designation
components"
Help 1105 <100 see description of errors with
function component designation
components"
PC- 1106 <100 see description of errors with
Host component designation
connect- "ALLG" in section "General
ion components"

Compo- Comp. Error

nent # #
Access 1107 <100 see description of errors with
authori- component designation
zation "ALLG" in section "General
manager components"
Unit 1108 <100 see description of errors with
man- component designation
ager "ALLG" in section "General
components"
EXCEL 1109 <100 see description of errors with
driver component designation
components"
Digital 1110 <100 see description of errors with
inputs component designation
and "ALLG" in section "General
outputs components"
Dialog 1111 <100 see description of errors with
manager component designation
components"
Machine 1112 <100 see description of errors with
function component designation
table "ALLG" in section "General
components"
Plaus- 1113 <100 see description of errors with
ibility component designation com-
checking ponents" "ALLG" in section
function "General
Hard- 1114 <100 see description of errors with
copy component designation
function "ALLG" in section "General
components"
Debug- 1115 <100 see description of errors with
ger component designation
components"
CAN 1116 <100 see description of errors with
DC 161 component designation
mod- "ALLG" in section "General
ule components"
driver
CB 1117 <100 see description of errors with
(CAN- component designation
Bus "ALLG" in section "General
integra- components"
tion mod-
ule)

Compo- Comp. Error

nent # #
100 Syserr warning function for
component DC161 can not
be mounted (table full)
MOUNT 1118 <100 see description of errors with
device component designation
mounter "ALLG" in section "General
components"
100 RELEASE _DEVICE invoked
without REQUEST _DEVICE
having been invoked
101 DISCONNECT_DEVICE
invoked without CONNECT
_DEVICE having been
invoked
102 Device already mounted
Hard- 1119 <100 see description of errors with
ware component designation
check "ALLG" in section "General
function components"
Error 1120 <100 see description of errors with
components"
CANO 1121 <100 see description of errors with
P component designation
(CAN- "ALLG" in section "General
open components"
integra-
tion)
200 Wrong length at error infor-
mation
201 Definition of a processing
function for SYSERRWARN-
ING not possible
202 CANOP _NUM_TYPES
does not correspond to
MODUL_TYPE_FUNC
CM161 1122 <100 see description of errors with
CANBus component designation
for DC components"
161
200 Too many DC161 modules
201 Definition of a processing
function for SYSERR-
WARNING not possible
202 Wrong length at error infor-
mation

Compo- Comp. Error

nent # #
for AC 44 components"
200 Installation error
201 Too many AC441 modules
202 Error configuration of inputs
203 Error configuration of outputs
204 Input: operating mode not
allowed
205 Output: operating mode not
allowed
206 Linearization table does not
contain enough points
207 Wrong sync factor in EBIAS
208 One AC441 could not be
started
for DC components"
201
207 Wrong SYNC factor in
EBIAS
208 One DC201 could not be
started
for DC components"
661
207 Wrong SYNC factor in
EBIAS
208 One DC661 could not be
started
Net- 1128 <100 see description of errors with
work component designation
components"
Text 1129 <100 see description of errors with
components"

Compo- Comp. Error

nent # #
Pro- 1130 <100 see description of errors with
cess component designation
data "ALLG" in section "General
module components"
AR 1200 <100 see description of errors with
analog component designation
card "ALLG" in section "General
components"
100 No EBIAS table present for
this card
101 EBIAS table too big
102 Not a valid EBIAS variable
type
103 Too many points in a linear-
ization table (> 200)
104 AR card with specified num-
ber not present on system
106 Invalid linearization table
number
107 Too many local boards on an
AR
108
110 Graphic entry error on com-
ponent GRF
112 Too many AR cards in sys-
tem
113 Error during Digout transmis-
sion from AR
114 Too many entries in Multi-
master send definition
master send definition
master receive definition
118 Unknown teleservice mes- teleservice This error cannot be rectified
sage transmitted by the customer. Please con-
tact after-sales service.
119 Teleservice data have invalid teleservice This error cannot be rectified
length by the customer. Please con-
120 Unknown teleservice mes- teleservice This error cannot be rectified
sage transmitted by the customer. Please con-
121 Injection supervisory not Injection supervisory is not Check version of analog soft-
implemented implemented at the AR card ware. Change to AR version
from V2.01, V8.55, V9.43 on
122 Data transfer not imple- Data transfer is not imple- Change to AR version from
mented mented at the AR card V2.01, V8.57, V9.43 on

Compo- Comp. Error

nent # #
ARCOM 1201 <100 see description of errors with
(AR com- component designation
munica- "ALLG" in section "General
tion components"
module)
100 Total number of transferred
data bits not equal to the
requested file length when
communication stop function
invoked
101 The total of the data blocks
written is greater than the
total file length
102 Error reading a file
103 Error writing to a file
104 Send instruction with invalid
data type
105 Communication error when
sending data (KEMRObus
layer 7)
106 Communication error when
retrieving data (KEMRObus
layer 7)
107 Order of transmission blocks
not correct
108 Attempt to transmit to card
not connected to bus
109 Requested AR card not con-
nected to bus after comple-
tion of start-up phase
110 Message length for RX mes-
sages (96 bytes) exceeded
111 Too many AR cards in rack
112 AR card didn't log onto bus
until after completion of start-
up phase
113 AR card has logged off bus
114 A communication mailbox
required on the AR could not
be found
115 Invalid RX message data
received
116 High-priority communication
message with invalid type
received
117 Error while calling function
KBI alarm

Compo- Comp. Error

nent # #
ARFLP 1202 <100 see description of errors with
AR component designation
floppy "ALLG" in section "General
components"
100 Invalid file name
101 File transfer request to non-
existent AR card
102 Communication error
(KEMRObus layer 7)
103 Attempt to transmit an invalid
Lintab (checksum, error
response from a KAL_xxx
function)
RC 1203 <100 see description of errors with
(RC100 component designation
handling "ALLG" in section "General
module) components"
200 Key mailbox not installed
201 Key filter function not
installed
202 Unknown I/O command
300 Pfs mailbox not installed
301 Time-out during file transfer
302 File name too long
303 Remote device table full
304 Remote device table not
installed
400 Unknown printer command
500 Var mailbox not installed
501 Var queue overflow
502 Unknown variable command
503 Unknown variable type
504 Error at SIO_send_string()
600 Cmd mailbox not installed
601 Unknown command
602 Mode can not be set
603 Transmission time-out
604 Program state can not be set
605 Program name too long
609 Co-ordinates can not be set
612 Invalid PCB handler

Compo- Comp. Error

nent # #
700 Command mailbox not
installed
701 CMD4P temporary buffer too
small
702 Data length too long
EM15 1204 <100 see description of errors with
(Euro- component designation
map15) "ALLG" in section "General
components"
100 Error at EM15 initialization
101 Error while sending EM15
data
102 Event indication
103 Other fatal error at EM15
E8T 1205 <100 see description of errors with
Thermo component designation
components"
113 Error initializing driver, all
drivers in use
114 Addressed card (card/chan-
nel) not present
115 Parameter monitoring error
116 Card time-out 2-cardrack configuration: Set the backplane-jumper of
both backplane-jumpers set the extension cardrack to
to master slave.
117 Invalid driver descriptor
118 VAR-QUEUE overflow
119 Other fatal error 2-cardrack configuration: Set the backplane-jumper of
both backplane-jumpers set the extension cardrack to
to master. slave.
Linear- 1206 <100 see description of errors with
izing component designation
table "ALLG" in section "General
man- components"
ager
Micro- 1207 <100 see description of errors with
graph component designation
Plus "ALLG" in section "General
components"
Auto- 1208 <100 see description of errors with
protect component designation
clamp "ALLG" in section "General
unit components"
side

Compo- Comp. Error

nent # #
Auto-pro- 1209 <100 see description of errors with
tect injec- component designation
tion side "ALLG" in section "General
components"
applica- component designation
tion "ALLG" in section "General
components"
MMCOM 1000 <100 see description of errors with
(multi- component designation
master "ALLG" in section "General
commu- Errors"
nication)
100 Reading over array size
101 Writing over array size.
102 Number of read data
unequal to required data
length
103 Number of written data
unequal to requested data
length
104 Error when opening file
105 Error when closing file
106 Error Init call layer 2
107 Error start call layer 2
108 Error Init call layer 7
109 Error start call layer 7
110 Memory not sufficient
111 Unknown data ID
112 Error when writing to Flash
113 No program in FLASH
114 KBCOM_fetch_data yields
error return
115 KBCOM_send_data yields
error return
116 Block number not continuous
117 Wrong ID switch position
118 Wrong station ID
119 Receive mailbox does not
exist
200 Too many variables in the
MMCOM EBIAS definitions
201 No corresponding variable
name found on any other
station
202 Too many cyclic process
images are missing

Compo- Comp. Error

nent # #
203 Sender for receive variable
missing
204 Incorrect variable type in
address list
205 Incorrect priority in EBIAS
definition
206 Remote card number not
allowed
207 Timeout establishing PAB
communication
208 Too many remote cards
POSIX 1001 <100 see description of errors with
interface component designation
(C- "ALLG" in section "General
library) Errors"
100 Posix server has received
invalid message
101 No POSIX_init_share has
been performed in this task
AIO 1002 <100 see description of errors with
Analog component designation
input/ "ALLG" in section "General
output Errors"
100 AR 181: Error while reading
back analog outputs to the
analog inputs, possibly short
circuit on output
100 AR 101: AIO port number too
high
101 AR 181: Hardware compara-
tor with invalid port number
101 AR 101: Invalid operating
mode for AIO port
102 AR 181: Invalid hardware
comparator channel number
102 AR 101: Error while initializ-
ing the component
103 AR 181: Attempt of operating
too many SR161 boards on
one AR1x1
back analog outputs for cali-
bration
104 AR 181: Invalid value for
analog reference voltage is
stored in EEPROM

Compo- Comp. Error

nent # #
104AR 101: Invalid value for
analog reference voltage is
stored in EEPROM
reference voltage in
EEPROM
reference voltage in
EEPROM
106 AR 181: Hardware compara-
tor: Between the switching
event and the comparator
call, there is not exactly one
hardware update. Problem
regarding switch-over syn-
chronisation, orcomparator
not on 2ms leve
106 AR 101: Access to analog
interface while A/D conver-
sion is running
115 AR 181: Invalid token
115 AR 101: Invalid token
inter- component designation
face "ALLG" in section "General
Errors"
100 Invalid EBIAS definiton type
(Profil, Outset, ..)
101 Invalid EBIAS definition num-
ber within a type
102 Invalid EBIAS variable ID
(not setpoint, actual
value, mark, ..)
106 EBIAS actual value number
>= 1024
109 EBIAS actual value Dword
number >= 1024
110 EBIAS mark number >=
2000
111 WRITE_GRAFIK call with
too many graphic
points
112 Communication message of
unknown type received
113 EBIAS definition with more
than 500 elements
114 No free ST object of this type
available

Compo- Comp. Error

nent # #
115 More than 128 ST objects
simultaneously active
116 Invalid ST object type ( Profil,
Outset, ...)
117 Invalid ST object number
within a type
118 Control parameters at
BLOCKSTOP command> 2
119 Invalid ST start/stop com-
mand (not START, STOP or
BLOCKSTOP)
120 Interpolating stop point not
allowed
121 Profile defined without profile
points
122 Invalid high priority commu-
nication message received
123 No free high priority commu-
nication message
124 No ST objects initialized
125 GO command while ST run-
time system is running
127 Invalid ideal graphics index
injection supervisory: invalid
ideal graphics inde >3. Info:
A A ... Ideal graphics index
128 Invalid Data index AR data
transfer: invalid data index >
2. Info: A A ... Data index
DIN 1005 <100 see description of errors with
(digital component designation
input) "ALLG" in section "General
Errors"
100 Error during start-up of digital
input test. Possibly 24V not
connected on AR161
GRAFIK 1006 <100 see description of errors with
(graph- component designation
ical "ALLG" in section "General
record- Errors"
ing)
100 Channel number of
PAR_GRAFIK too high
101 Too many graphic points
102 Error in address list for
graphics component
103 Memory not sufficient for
graphical recording

Compo- Comp. Error

nent # #
108 Access with invalid ideal Injection supervisory: access
graphics inde to supervisor channel with
invalid ideal graphics
index>3.
109 Access with invalid data AR data transfer: access to
index data channel with invalid
data index > 2.
SYS 1009 <100 see description of errors with
(gen- component designation
eral "ALLG" in section "General
system Errors"
mod-
ules)
100 Quick sort algorithm stack
overflow
102 Number of interrupt functions
exceeded
103 Invalid interrupt source
104 Watchdog has triggered
105 Invalid FLASH type recog-
nized
106 AR 181 with 1 MB memory Change AR 181 (1 MB) to
can not execute the function one equipped with 2 MB
called.
HW 1011 <100 see description of errors with
hard - component designation
ware "ALLG" in section "General
interface Errors"
101 ST program too long for
FLASH
102 FLASH programming error
103 FLASH erase error
104 DRAM defective
105 EEPROM read error
106 Invalid FLASH type
XIO 1012 <100 see description of errors with
extend component designation
ed "ALLG" in section "General
input/ Errors"
output
100 XIN or XOUT channel num-
ber is higher than maximum
channel number
103 XIN_config_channel on MSA
channel without preceding
MSA_config_axis
104 Invalid input type

Compo- Comp. Error

nent # #
105 Call of XIN_speed on input
type without calculation of
speed
106 No free device channel at
CONFIG_CHANNEL
107 Invalid channel number Channel number in function Software: First parametrize,
passed at XIN access. XIN had not been created then access channel.
(using PAR_XIN) before
function XIN was called.
MT161 1101 <100 see description of errors with
MOOG component designation
CAN "ALLG" in section "General
bus Errors"
driver -
low
level
100 Invalid servo number
101 Invalid axis number
102 No response from servo axis
103 Invalid message received
104 No message received
105 Message has been overwrit-
ten
106 CAN bus failure
107 Not allowed interrupt
108 Download not successful

109 Time exceeded at beginning
of download
110 Parameter not acknowl-
edged
111 Time exceeded during down-
load of a parameter
112 Error when programming
MOOG drive into EEPROM
113 Time exceeded when pro-
gramming MOOG drive into
EEPROM
114 Message servo axis: global
error
115 Message servo axis: interpo-
lator error
116 Message servo axis: CAN
bus error
117 Message servo axis: short
circuit

Compo- Comp. Error

nent # #
118
Message servo axis: over-
heating
119 Message servo axis: param-
eter error
120 Message servo axis: resolver
error
121 Message servo axis: motor
temperature
122 Message servo axis: bridge
temperature
123 Message servo axis: over-
voltage
124 Message servo axis: power
failure
125 Error when configuring a
CAN message
126 Error when installing CAN
error interrupt
127 Operating mode Drive is
Sync-Master: no sync mes-
sage for a too long time
128 Operating mode Drive is
Sync-Master: no interrupt
function parameterized for
sync message
129 Sync-Msg cannot be sent
MSA 1102 <100 see description of errors with
MOOG component designation
CAN "ALLG" in section "General
bus ST Errors"
interface
- high
level
100 Axis with this number is not
configured
101 Output to axis without OK
from MSA _ start_axis; MSA
_ start _calib without OK
from MSA _start_axis
102 Position value too high at
non-periodical axis
103 Error download of parameter
104 MSA_set_position, MSA _
start_calib with position
value higher than position
period

Compo- Comp. Error

nent # #
105 Invalid motor parameter for
motor increments per revolu-
tion
106 Lag error
107 Position offset is not allowed
at periodical axis
CTS 1103 <100 see description of errors with
(CAN component designation
Tem- "ALLG" in section "General
posonics Errors"
sensor)
100 No free message buffer in
CI021
101 Port number is higher than
maximum number of CTS
ports
102 Attempt of assigning a port
which is already assigned to
another sensor
104 Sensor cannot be pro-
grammed
105 Parameterized sensor length
is incorrect
106 Parameterized channel num-
ber is higher than maximum
number of CTS channels
107 Access to not configured
CTS channel
108 Access to not configured
CTS port
111 Attempt of sending a not
supported command to a
sensor
112 Incorrect confirmation mes-
sage received
113 CAN bus error while reading
actual value message
114 Invalid confirmation mes-
sage received
115 Error installation of CAN
error function
117 Node number available sev-
eral times
CI 021 1104 <100 see description of errors with
general component designation
CAN bus "ALLG" in section "General
ST inter- Errors"
face

Compo- Comp. Error

nent # #
CAN- 100Invalid IEB port number
DEV transmitted
101 No CI021 is connected to the
requested IEB port
102 Invalid CI021 subchannel
number
103 Invalid baudrate parameter
104 CANDEV_install not possible
for this I/O type
106 Device number is higher
than maximum number of
CAN devices of this type
107 No CANDEV_install for
driver with this number
108 Another CAN driver has
already been installed with
this device number.
109 CAN-Bus Interface works
only with AR 181 equipped
with 2 MB DRAM at least
BMCAN 1105 <100 see description of errors with
(Bau- component designation
müller "ALLG" in section "General
CAN Errors"
interface)
200 CAN bus port number is Port number (axis number) is Check port number (axis
higher than maximum num- not in valid range number)
ber of axes per CAN line and
unequal to BROADCAST
number
202 An unallowed Unknown message type Check message type
BMCAN_MSG_TYP has
been transferred
203 While reading the CAN bus CAN driver returns invalid Check version of CAN driver
the CAN driver returned an value
unknown return code
204 The broadcast number has The port number must be a Set port number with axis
been returned instead of a valid axis number and not number
valid axis number the broadcast number
205 A command allowing only The port number must be the Set port number with broad-
the broadcast number as broadcast number cast number
port number has been called.
206 Invalid size or type of vari- Unknown type of variable Check type of variable
able
207 An invalid parameter ele- Unknown parameter element Check parameter element
ment has been returned

Compo- Comp. Error

nent # #
208 An error occurred while writ- Parameter is write-protected, Check parameter value and
ing a parameter value parameter value is too high parameter number
or too small or of wrong type
209 The controller returned an Unknown response of con- Check software version of
unknown response to a troller controller
parameter write command
210 An error occurred while read- Parameter does not exist Check if a parameter with the
ing a parameter value returned number exists in the
controller
unknown response to a troller controller
parameter read command
212 An error occurred while set- An invalid parameter number Check parameter number for
ting the parameters of the has been returned actual values
actual values
unknown response to the troller controller
parameter setting of the
actual values
214 Read attempt to unconfig- The requested CAN mes- Check if a message of this
ured CAN message sage has not been config- type has been configured
Baumüller ured or has been configured
for a wrong axis.
215 An invalid object type has Invalid object type returned Check plausibility of object
been indicated. type and object number
216 An invalid object size has Invalid object size returned Check plausibility of object
been indicated. size and object number
217 An error occurred while writ- Object is write-protected, Check object value and
ing an object value value is too high or too small object number
or of wrong type.
unknown response to an troller controller
object write command
219 An error occurred while read- Object does not exist Check if an object with the
ing an object value returned number exists
220 The controller returned an Check software version of
unknown response to an controller
object read command
221 A REQUEST function to read
data from the controller has
been called although the
data is evaluated via an
interrupt
222 A send command executed
before has not been com-
pleted yet

Compo- Comp. Error

nent # #
223 Attempt to request parame- Send command failed or was Check if a send command
ter setting confirmation from not executed has been called or evaluate
the CAN bus although the the return code if an error
send parameter command has been returned.
has not been called.
224 Attempt to request parame-
ter setting confirmation from
CAN bus although the corre-
sponding command has not
been called
225 The function
BMCAN_read_param has
received a write confirmation
226 The function
BMCAN_write_param has
received a read confirmation
227 A parameter write or read A parameter write or read Wait for completion of last
command has been called access has not been com- access
although the last access pleted yet
from the controller was not
completed.
228 The parameters of a mes- The parameters of an Set the parameters of a mes-
sage for a parameter write already parameterized message once only
access or read access can sage have been set once
only be set once. again
BSA 1106 <100 see description of errors with
(Baum- component designation
üller "ALLG" in section "General
servo Errors"
drives)
500 Two controllers with the Two or more controllers have set the DIP switch on the
same ID at the bus had been the same CAN-BUS address controller at the right position
detected.
501 No CAN Bus communication The communication to the check CAN cable and DIP
to BM controller controller is interrupted switch at controller
502 Wrong value had been read After writing the position Check brake or stopping of
after a set position value another value had the drive.
been read back
503 Controller ready-signal Controller is not ready Check status of controller
(Digin) is missing and ready-signal
504 Drive signals a warning via Controller had set a warning BUS 6 V error messages
CAN-Bus signal (see manual of drive)
505 Invalid operating mode set in Only mode "Gleichlauf" (syn- Change mode using
the controller. A change from chron) is allowed. PCBASS and save data
this is not possible. block.
506 Invalid operating mode had Check operating mode (see
been transmitted BSA operating manual)

Compo- Comp. Error

nent # #
507 Error when writing a BM Evaluate error information
object, PE data or a broad-
cast command (all axis
STOP)
508 Error when reading a BM Evaluate error information
parameter via CAN Bus
509 Error when writing a BM Evaluate error information
parameter via CAN Bus
510 Invalid status of data set To permit data set manipula- Evaluate error information
management. tions the data set manage-
ment must be in STAND_BY
mode.
511 Timeout: loading from data The controller could not load Ask controller supplier for
set management the required data set within information to changes in
40 seconds. data set load time of control-
ler.
512 Invalid Baumüller variables Only type 0 or 1 is allowed In the functions
type BSA_READ_PARAM and
BSA_WRITE_PARAM the
types 0 (WORD) or 1 (REAL)
is permitted, in
BSA_PARACCESS_SEND
only type 1 (REAL) is
allowed.
513 Unknown parameter type The controller requests the Contact controller manufac-
had been detected by drive. type of parameter when turer.
reading or writing parame-
ters and this type is not
known.
514 Baumüller data set manage- An error occured when data The error information con-
ment returns with error. set had been stored. tains the parameter which
caused the error.
515 Timeout: BM drive manager The drive does not react to a Check security circuit.
does not switch over to mode change within a
requested mode. requested time interval.
516 The drive reports an error via A motor error had been Evaluate error information.
CAN-Bus. reported.
517 Invalid CAN interrupt mes- A CAN-Bus interrupt had Evaluate error information.
sage been set which could not be
handled.
518 Motor error had not been Default SYSERR will be trig- Include error handling in
handled by the user error gered when the USER_ERROR_HANDLER.
handler. USER_ERROR function had
been called and did not
responde with OK.
519 Too many Baumüller motor More than 20 motor error Check controller
errors. messages active.

Compo- Comp. Error

nent # #
520 Violation of maximum num- At parameter download too Maximum number of param-
ber of motor parameters. many parameters had been eters is 50.
transmitted.
521 Invalid axis number A maximum of 3 axis for Check transmitted axis num-
each CAN Circuit is allowed. ber(0..2 or 0xBB for broad-
cast at axis stop)
522 Wrong actual value type had Actual values only may be of Check type of actual value
been transmitted type (0..5)
523 Position value overflow When position actual value Monitoring must be set inac-
detected. check is active the controller tive when drives with one
position value (32Bit) will be rotation direction are used (in
checked against overflow. BSA_CONFIG_AXIS)
524 Not logical AUX actual value The AUX_IW1 is to be used Check distribution of actual
distribution where AUX_IW1 only at one aditional actual values.
== 0 and AUX_IW2 != 0 value.
525 Status of BAPS interface, Check actual value numbers.
invalid number of parameters
had been selected.
526 Status of BAPS, one actual One additional actual value Assign this actual value to
value had been assigned to had been assigned to mes- message 2.
an invalid actual value message 1 and it does not fit into
sage. the 1st message.
527 Status of BAPS interface, A minimum cycle time of 500 Check parametrized cycle
input of a wrong cycle time or µs at two actual value mes- times
a wrong combination sages allowed.
528 Read access to actual value This error is triggered if too Check CAN connection
message before message long motor data are sent. against errors in wiring and
was received. (maybe CAN connection bus termination.
problems)
529 Drive is in invalid operation Setting of value for rpm only Switch controller in the
state. allowed in status BETRIEB approbiate state using func-
FREIGEGEBEN. Setting of tions BSA_start_axis and
actual position not allowed in BSA_stop_axis.
state BETRIEB FREIGEGE-
BEN
530 Transmition of an invalid IEB An invalid IEB address had For ARx81 is allowed:
port number. been transmitted for the IEB1_1 to IEB1_3, for
IE011. CU312RT additional IEB2.
531 No IE011 found at the No IE011 found at the Check presence of hard-
expected IEB port. expected IEB port. ware modules
532 Invalid IE011 sub channel Only channel number 0 and Check transmitted channel
number 1 are allowed number
533 Error occured at installation Error on IE011 configuration. Compare returncode in
of IE011 driver. errorhandler with that of
component IE011 (1107)
534 LCA could not be loaded The LCA on IE011 could not Compare returncode in
be loaded successfully. errorhandler with that of
component IE011 (1107)

Compo- Comp. Error

nent # #
535
Attemption to change the The hardware output could Compare returncode in
state of IE011 (DISABLE, not be switched to the errorhandler with that of
ENABLE), return of invalid expected state. component IE011 (1107)
state.
536 Switching of the drive man- This message occures if the Analyse the reason for the
ager to the state controller is sitched from change of state.
FREIGEGEBEN (free) state BETRIEB FREIGEGE-
caused a stop of the IE011 BEN to another state.
output.
537 Hardware check of inte- Transducer input cards Let the manufacturer check
grated transducer inputs of maybe exchanged incor- the transducer input cards, to
Baumüller controller detects rectly. ensure reliable operation.
invalid configuration.
538 No data consistency after After a parameter send com- Software: Wait until function
sending of Baumüller param- mand the controller did not returns with OK or trigger a
eter. acknowledge or detected an timeout error and terminate
error. the send process with
BSA_PARACCESS_CLOSE
.
539 An invalid data set is loaded Attempt to start an axis by a Watch startup behavior of
into the controller. controller with an invalid data the controller.
set. The controller could
have been rebooted.
540 Too many errors in error han- An error could not be over- Try to minimize the error
dling. taken in the error handling number (cyclic errors first)
because the message box is
full.
541 Access to the actual position If monitoring of the Perform no access to the
value when the monitoring of IE011actual position value is IE011 actual value or switch
the position actual value is switched off an access of the on monitoring of actual
switched off. position register is not value.
allowed.
542 An access to a parameter is Before a new command can Software: Wait until the com-
not possible because the be executed the old send mand is completed or trigger
confirmation of the last com- command must be fully com- a timeout error and close the
mand at the CAN-BUS had pleted. send process with
not been received. BSA_PARACCESS_CLOSE
.
IE011 1107 <100 see description of errors with
increm- component designation
ental "ALLG" in section "General
encoder Errors"
emulator
300 An invalid channel number The IE011 sub board has 2 Correct channel number (0
had been transmitted. channels (outputs), accessa- or 1)
ble with 0 or 1.

Compo- Comp. Error

nent # #
301 Attemption to create a port A IE011 cahnnel may be cre- Correct channel number or
(basic address and channel ated only once. basic address.
number) which had been
configured before.
302 Violation of maxum number Only 8 IE011 channels for Correct channel number or
of IE011 ports. each analog board can be basic address.
accessed.
303 Position value is going to If monitoring of actual posi- Switch off monitoring when
overflow. tion value is activated the using drives with one direc-
position register (24Bit) is tion of revolution (in
monitored. BSA_CONFIG_AXIS).
304 Control register cannot be Fatal error at access of Change subboard.
set correct. IE011 control register.
FB 1200 <100 see description of errors with
(function component designation
blocks) "ALLG" in section "General
Errors"
100 Profile with less than 2 or The number of profile points Check number of profile
more than 1000 points must be in the range of 2 to points
1000
101 INIT_FB_VSGEN or
INIT_FB_YXGEN without
preceding parameterizing
102 PAR_FB_VSGEN or
PAR_FB_YXGEN with pro-
file without point definitions
103 Inconsistent stop point data
104 Inconsistent mark point data
105 Characteristic line with less
than 2 or more than 1000
points
107 Invalid channel number

108 Invalid port number
109 Invalid priority number at
APRIOR
110 Invalid cycle time level at
FB_ANAIN
111 E16-Digout+ IOBUS disable
112 E16-Digout+ not allowed
IOBUS status
113 E16-Digout+ error at IOBUS
update
114 Limit exceeded
115 Invalid token

Compo- Comp. Error

nent # #
116FB_xxGEN period mode: not
defined x-area greater than
x-period
117 FB_xxGEN period mode:
When the not defined x-area
is left, the difference between
calculated and measured x-
value is too high
ST (AR 1300 <100 see description of errors with
ST pro- component designation
gram "ALLG" in section "General
process- Errors"
ing)
100 Number of ST files too high
101 ST files not found
102 Link loader error
103 Invalid number for ST run-
time level
104 Run-time exceeded on cyclic
ST program level
105 Fatal ST linker error
106 Not enough ST pool ele-
ments available
107 Internal: deleting from empty
queue
108 Internal: no successor step
available
109 Internal: step successor is no
transition
110 Internal: transition succes-
sor is no step
111 Wrong pd->state at
START_SEQUENZ
112 Wrong pd->state at
STOP_SEQUENZ
113 No primitive function avail-
able
114 Output to MSA axis without
enabling output
CPU_F 1400 <100 see description of errors with
AULT component designation
(Intel "ALLG" in section "General
80960 Errors"
CPU fault
excep-
tions)

Compo- Comp. Error

nent # #
100 Software breakpoint through
not eliminated "fmark state-
ment"
101 Invalid Op code in program
code
102 Invalid operand for this oper-
ation
103 Operation fault reserved for
future extension
104 Overflow at integer operand
105 Integer division by zero
106 Arithmetics error not defined
in detail
107 Real operand too high for
numerical notation
108 Real operand too small for
numerical notation
109 Real operand in invalid for-
mat for this operation
110 Real division by zero
111 Real result cannot be repre-
sented (in connection with
FLOAT_OVERFLOW,
FLOAT_UNDERFLOW)
112 Real operand invalid for nor-
malized real representation
113 Several floating point faults
occur at the same time
114 Fault handler not imple-
mented
115 Attempt of using supervisor-
mode-only action in user
mode
116 Reserved for future exten-
sion
117 Sys call with number out of
system procedure table
118 Attempt of using modpc
statement although proces-
sor is in user mode
119 Unknown processor fault
(default branch in switch
statement)
120 Call of a function requiring
AR181 with at least 2 MB-
DRAM

3.4 EBIAS ERROR NUMBERS
General Description
An EBIAS error is an error in the run-time program (EBIAS) which causes the run-time program
to stop running, i.e. the machine is stopped (operating system continues to run).
The occurrence of an EBIAS error on the EC100/CC100 system is indicated to the operator as
follows:
• Display of an EBIAS stop error icon as shown

• Run-time error 0
More precise information about the last EBIAS error that has occurred can be obtained from the
Status Report of the System Debugger.
Display of EBIAS Error in the Status Report
EBIERR 200 date/time: 95-09-15 10:14
*** no EBIAS-Stopaddress available
RX: taskname: 'IP_io' stop cnt: 1 run time: 12.850s

INT0: 0.1/ 0.4 INT1: 0.0/ 0.0 INT2: 0.0/ 0.1 INT3: ---------
INT4: --------- INT5: --------- INT6: 0.2/ 0.3 INT7: ---------
PR00: --------- PR01: --------- PR02: 0.1/2676.1 PR03: 0.1/ 1.0
PR04: --------- PR05: 0.1/ 0.1 PR06: 0.1/ 46.4 PR07: 0.1/ 4.9
PR08: --------- PR09: 0.2/ 0.2 PR10: 1.0/ 43.7 PR11: ---------
PR12: --------- PR13: --------- PR14: --------- PR15: ---------
PR16: --------- PR17: ---------
STACK: base: 004B0EB0H size: 1024 unused: 620 Frame-ptr: 004B1268H
004B115C=00000000 004B1170 0057F113 000000C8 00000002 004B1180 005AD016 000000C8
004B117C=00050000 004B11B0 005AEF7B 004B120E 004B1206 CA01014C 004B11FC 004B11EC
004B119C=FFFFFF99 FF990064 00000000 00000020 004B11E4 004B11C4 0053F875 004B11E4
004B11BC=003D11E4 00000020 004B122C 00524DEF 0000003A 004B11E4 00523912 000007F5
004B11DC=FFFFFF38 626B0011 0064003D 0032FF99 444E4553 5441445F 49545F41 554F454D
004B11FC=4F435852 20432E4D CA01014C 00000048 44940000 28800404 3DAC0404 8FAC0402
004B121C=004B0404 00539562 0540003A 004B11E4 004B123C 00524E67 0000006A 0000006A
004B123C=004B1244 0051C1B5 004B12A0 004B0020 00520004 00000020 00000020 004A7978
004B125C=00000001 004B12A0 004B1278 00000000 00000800 0048B980 00000A0A 00533E68
004B127C=00480018 00000206 00580B74 00000001 00780402 0014007F 00530078 00000000
004B129C=0000322D 00000000 00000000 C7C7C700 00000000 C7C7C7C7 C7C7C7C7 C7C7C7C7
004B12BC=C7C7C7C7 C7C7C7C7 C7C7C7C7 C7C7C7C7 C7C7C7C7 C7C7C7C7 C7C7C7C7 C7C7C7C7
004B12DC=C7C7C7C7 C7C7C7C7 C7C7C7C7 C7C7C7C7 C7C7C7C7 C7C7C7C7 C7C7C7C7 C7C7C7C7
004B12FC=C7C7C7C7 C7C7C7C7 C7C7C7C7 C7C7C7C7 C7C7C7C7 C7C7C7C7 C7C7C7C7 C7C7C7C7
004B131C=C7C7C7C7 C7C7C7C7 C7C7C7C7 C7C7C7C7 C7C7C7C7 C7C7C7C7 C7C7C7C7 C7C7C7C7
004B133C=C7C7C7C7 C7C7C7C7 C7C7C7C7 C7C7C7C7 C7C7C7C7 C7C7C7C7 C7C7C7C7 C7C7C7C7
EBIERR Shows EBIAS error as well as date and time.

RX Details the task name, stop counter reading, run-time and the performance.
STACK Gives details of stack base address, stack size, the unused stack space and the RX
frame pointer position as well as 32 x 32-bit values in hexadecimal format, starting
with the current stack pointer position.

Comp- Error
Error Short Description Causes of Error
onent No#
EBIAS 7 RETURN without CALLSUB /
SWITCHSUB
8 Nesting level exceeded Max. nesting level exceeded in subroutine call
9 Invalid EBIAS command code
10 Invalid EBIAS variable number Invalid EBIAS variable number when reading vari-
ables (GETVARWORD, GETVARDWORD)
11 Invalid EBIAS variable number Invalid EBIAS variable number when reading vari-
ables (GETVARIABLE)
12 Invalid EBIAS variable number Invalid EBIAS variable number when writing variables
(PUTVARWORD, PUTVARDWORD)
13 Invalid EBIAS variable number Invalid EBIAS variable number when writing variables
(PUTVARIABLE)
15 Invalid EBIAS variable number Invalid EBIAS variable number when reading signals
16 Invalid EBIAS variable number Invalid EBIAS variable number when writing signals
28 Invalid EBIAS variable number Invalid EBIAS variable number in GETVARREFDWORD
29 Invalid EBIAS variable number Invalid EBIAS variable number in
PUTVARIABLE_NOREF
30 Invalid EBIAS variable number Invalid EBIAS variable number in GETVARWORD,
GETVARDWORD
31 Invalid EBIAS variable number Invalid EBIAS variable number in GETVARIABLE
32 Invalid EBIAS variable number Invalid EBIAS variable number in PUTVARWORD,
PUTVARDWORD
33 Invalid EBIAS variable number Invalid EBIAS variable number in PUTVARIABLE
35 Invalid EBIAS variable number Invalid EBIAS variable number in SIGIN
36 Invalid EBIAS variable number Invalid EBIAS variable number in SIGOUT
40 free (E-16-ANAIN)
50 Invalid EBIAS command code
60 Short circuit Short circuit on DO port 0 or 1

Comp- Error
onent No#
76 Excess current Excess current detected on DO port 0 or 1
92 Overlap of DO or DI ports Overlap of DO or DI ports (address range overlap)
96 Recursive travel Recursive travel calibration or J calculation call
97 Invalid parameter Invalid parameter for software component control (KO
for t/Imp. = 0)
98 Nesting depth exceeded Max nesting depth of calls exceeded (Quick-Setup)
99 Queue overflow Queue overflow at KL_put_data function
101 LSSEC check capacity LSSEC check capacity too small
110 Short circuit on DC161 module 1st DC161 module, chan 0-7
111 Short circuit on DC161 module 1st DC161 module, chan. 8 - 15 or DC661 module- 1
112 Short circuit on DC161 module 2nd DC161 module, chan. 0 -7 or DC661 module- 2
113 Short circuit on DC161 module 2nd DC161 module, chan. 8 - 15 or DC661 module- 3
114 Short circuit on DC161 module 3rd DC161 module, chan. 0 -7 or DC661 module- 4
115 Short circuit on DC161 module 3rd DC161 module, chan. 8 - 15 or DC661 module- 5
116 Short circuit on DC161 module 4th DC161 module, chan. 0 -7 or DC661 module- 6
117 Short circuit on DC161 module 4th DC161 module, chan. 8 - 15 or DC661 module- 7
118 Short circuit on DC161 module 5th DC161 module, chan. 0 -7 or DC661 module-id 8
123 Short circuit on DC161 module 7th DC161 module, chan. 8 - 15 or DC661 module 13
124 Short circuit on DC161 module 8th DC161 module, chan. 0 -7 or DC661 module 14

Comp- Error
onent No#
128 Short circuit on DC161 module 10th DC161 module, chan 0 -7 or DC661 module 18
131 Short circuit on DC161 module 11th DC161 module, chan 8 - 15 or DC661 module 21
133 Short circuit on DC161 module 12th DC161 module, chan 8 - 15 or DC661 module 21
140 Module error LENZE
141 CAN error LENZE
142 Module error AC441
143 CAN error
144 Module error DC201
145 Module error DC661
185 SGMGRF graphics error
190 Error on RC100 handling module
200 Error on 1st AR101/AR161
201 Error on 2nd AR161
202 Error on 3rd AR161
203 Error on 4th AR161
204 Variables number of set value out At startup too many set value variables had been
of range requested
205 Variables number of actual value At startup too many actual value variables had been
out of range requested
206 Variables number of mark out of At startup too many marker variables had been
range requested

Comp- Error
Error Short Description Causes of Error Error Correction
onent No#
ABLAU 0 EBIAS error stopped run- An EBIAS error has occurred on
F time program the system which has caused the
run-time program to stop running
1 Reserved
2 CPU battery low The cyclic test of the CPU battery the battery should be
(performed every time system is replaced as soon as possi-
booted or every 12 hours) has ble.
detected that the battery capacity
has reached its lower limit.
3 At least one setpoint is out- The cyclic setpoint plausibility adjust setpoint values
side the defined range check has detected at least one
setpoint is outside defined range
4 A floppy disk error has Write error or floppy disk error The special program can not
occurred while a special pro- access the disk again until
gram, - PD-Protokoll, - the error has been acknowl-
Micrograf-Plus curve sets, edged.
was writing data to a floppy.
5 File can not be printed (e.g. Repair printer. Printing can
printer not connected, ...). not be resumed until error
has been acknowledged
6 Not enough dynamic mem- Hard copy function can not
ory for hard copy function -> be invoked again until error
copy function not possible. has been acknowledged.
7 Runtime errorlist is full Too many runtime errors are repair logged errors at
active. Error buffer is full. machine to free buffer
space.
8 RAM DISK err or RAM Disk error had been detected If possible delete unused
during storage of micrograph data. data (e.g. text, graphs) or
Insufficient free memory. change defective RAM-Disk.
9 Reserved
10 Reserved
11 Reserved
12 Reserved
13 RC100 handling error refer RC100 handling errors
14 Analog module does not run
15 Broken connection between close or repair connection.
CAN bus interface CI021
and connected DC161
16 Other CAN bus error. This e.g. unknown interrupt or invalid
error should not occur under CAN Bus channel or unknown
normal operating conditions. message received or communica-
tion protocol error.
17 Reserved
18 All other DC161 errors
19 Signal from host to the oper- switch to the host screen
ator to switch to host screen

7. FINE TUNING
1 HEATS
1.1 HEAT P.I.D. 0-15 - (TEMPERATURE CONTROL CARD)
Press
+ F4
NOTE!
CHECK WHETHER THE CONTROLLER IS SET TO: - METRIC OR IMPERIAL UNITS –

DO NOT SET A FAHRENHEIT VALUE WHERE CENTIGRADE IS REQUIRED.
For further information on function keys F1, F2 and F3 please refer to the operator manual.
There are 13 parameters per line arranged in columns. The following pages contain a description
of each of these parameters and how to use this program.
23/12/05 7. FINE TUNING 277

1.2 DESCRIPTION OF THE SCREEN PAGE
ZONE: The heating zone number.
xPH: The proportional band in 0.2 OF (range 0.2..1800.0 OF).The temperature range
within which a proportional relationship between temperature difference
(setpoint - actual) and percent value of the clock time exists. Once the
temperature difference has exceeded this band, the heating/cooling output will
be active for 100% of the clock time (t0). A larger xPH will result in a smaller
amplification and vice versa.
tn: Reset time in 0.1 sec (range 0.0.to.6553.5 sec). This factor represents the
integral share and has a maximum limit of 255 x t0 (clock time). If a larger tn is
required, the t0 must be increased. The integral share has a stronger influence
the smaller that the tn setting is.
When tn = 0, the I share has no influence on the control loop.
tv: Rate time in 0.1 sec (range 0.0.to.6553.5 sec). This factor represents the
differential share and has a maximum limit of 255 x t0 (clock time). If a larger tv
is required, the t0 must be increased. The differential share has a stronger
influence the larger that the tv setting is.
When tv = 0, the D share has no influence on the control loop.
t0: Clock time of the control loop in 0.1 sec (range 0.1 to 999.9). A nominal setting
for t0 should be the amount of time required for the actual temperature of the
zone to increase 1.0 OC when heating at full capacity (100%). A maximum of 1
switching action shall occur during the clock time.
HKV: Heating/cooling ratio (range 0.10 .to. 1000). When a zone is used as a 3-point
temperature controller, the ratio of heating capacity to cooling capacity must be
set. If the heating capacity is equal to the cooling capacity then set HKV = 1.00.
When a zone is used as a 2-point temperature controller (for either heating only
or cooling only), set HKV = 1.00.
If a temperature zone is to be completely controlled by employing both heating
and cooling outputs, the variable HKV must be set.
e.g. if the actual value is 5 degrees below the set value, a certain heat output is
calculated based on the P.I.D. parameters and then applied to the zone.
If the actual value is 5 degrees above the set value, a certain cooling output is
calculated based on the same P.I.D. parameters, multiplied by HKV, and then
applied to the zone.
The HKV variable, represents a heating/cooling efficiency ratio. An HKV value
greater than 1 represents a zone which requires a greater output for cooling to
achieve a decrease of 1 degree than a heating output requires to achieve an
increase of 1 degree.
HKV = 1.0
This represents a zone which is equally efficient in cooling and in heating
278 7. FINE TUNING 23/12/05

HKV (cont.) HKV = 10.0
This represents a zone, which takes ten times longer to cool down 1 degree
than it takes to heat up 1 degree.
HKV = 0.1
This represents a zone, which takes 1/10 of the time to cool down 1 degree than
it takes to heat up 1 degree.
cooling time
e.g. HKV= --------------
heating time
1) It has been determined that to heat a particular zone from 40oC to 60oC with
the heating output turned on fully, requires a time of 60 seconds.
2) It has been determined that to cool the same zone from 60oC to 40oC with
the cooling output turned on fully, requires a time of 40 seconds.
Therefore, HKV should be set to: 40 seconds
-------------------- =0 .67
60 seconds
In this case, it would be reasonable to set HKV to 0 .6 or 0 .7 and expect a good
level of temperature control.
Cb: oF: Cut back - proportional band for heating - up phase. (Range: 0.2...1800.0oF).
Using Cbh, a temperature value can be set, at which the controller switches
over from full heating capacity to PID control during the “heating - up” phase
before the set value has been reached. During the “heating - up” optimization
this “cut-back” value is automatically calculated. However, if poor transient
control occurs, this value can be adjusted manually. Cbh is disabled when set
0, and then switchover from full capacity to PID control occurs at Xph.
Pakt %: Percentage action - (range -100%..+100%) is an actual value indicating the

current duty cycle of the action output where 100% means that the output is
active for 100% of the clock time. A "+" value indicates that the heating output
is the action output and a "-" value indicates that the cooling output is the action
output i.e. if the ACTN value for zone 2 is +50% and the t0 for zone 2 is set to
10.0 seconds then the heating output for zone 2 will be on for 5 sec. and off for
5 sec.- if the ACTN value were to change to +25% then the heating output
would now be on for 2.5 sec and off for 7.5 sec.
Emg-Mode : A YES / NO selector used to determine the action taken in the event of a
thermocouple break alarm for the zone where:
NO = the heat zone will not automatically switch over to open loop control mode
(default setting).
YES = the heat zone will automatically switch over to open loop control mode
and continue controlling the heat by the percent set value for that zone.
If the following three conditions are met, then the heating will continue without
errors in the regulation mode using a percentage output equal to the mean of
the Pakt % of the last 6 heat cycles:
23/12/05 7. FINE TUNING 279

1. The Emg mode (enter 1 at the required heat zone(s)) is set to YES
2. The actual temperature before the thermocouple break was within 1 °C
of the set temperature.
3. The percent heat output (Pakt %) has not been at 100% within the last
six heat cycles (six times the value of t0)
NOTE!
If any one of these conditions are not met then the thermocouple
break error is displayed and the heats are shut down.
% Regul. A manual selector for the type of control loop that will be used by the zone (YES
= Open or NO = Closed loop). When set to NO, the setpoint for the zone will be
in oC and will be displayed as such on the appropriate heat display page. When
set to YES, the setpoint for the zone will be in percent and will be displayed as
such on the appropriate heat display page. The percent setpoints for open loop
zones can be set in a range from -100 to 100 and directly adjusts the ACTN
value for the heat zone. (see above)
Mode: The mode of zone operation (range 0..3). The access for setting this variable
requires password level 8 as a minimum. The modes of operation are:
0) no control function. The zone only monitors the actual value and, when the
setpoint is greater than 0.0 oC, will display temp. high, temp. low and
thermocouple break alarms.
1) open loop control.
2) 2-point controller for heating or cooling.
3) 3-point controller for heating and cooling.
Optimiz: A selector (ON/OFF) for initializing the self tuning of the P.I.D. parameters for
this zone (see the section on SELF TUNING).
Interl: When the indicator is colored, the temperature control loop for this zone has
been disabled by an alarm or the setpoint for this zone is at 0.
Type This column denotes the type of thermocouple used.

Generally type 3 or 5 are used,
3 = L Type
5 = J Type
280 7. FINE TUNING 23/12/05

1.2.1 OPEN LOOP CONTROL:
Each individual zone can be configured as an open loop control on the HEAT P.I.D. display page.
This enables the use of temperature control zones that do not have a thermocouple attached.
When a control zone is set for open loop;

• the duty cycle of the active output (heating or cooling) is directly controlled by
the zone setpoint (in percent).
• all alarm monitoring except short circuit detection is disabled.
• the mode selection is automatically set to 1.
• the setpoint variable on the appropriate heat display page is changed to a
percent variable with a range of -100 to 100.
1.2.2 SELF-TUNING:
On the HEAT P.I.D. page, each zone has a selector for switching the self-tuning feature of the
Temperature Control card on or off. The self-tuning feature is used to determine the optimum
values for xPH, tn, tv and t0 (the P.I.D. parameters) for controlling the heat. Self tuning of the P.I.D.
parameters is a procedure that is carried out in much the same way as one would calibrate the
hydraulic pressure, for example. It is NOT a feature that is always running and adapting the values
of the P.I.D. parameters.
PROCEDURE FOR HEATING UP OPTIMIZATION
BEFORE YOU START:

1. All zones that will influence each other should be tuned at the same time, i.e. all of the
barrel zones or all of the stationary mold half zones, etc.
2. The actual temperatures of the zones to be tuned must be stable and at or near ambient
temperature.
3. Because of the high probability that the actual temperature of the heat zones to be tuned
will overshoot the setpoint, it is best to tune barrel heat zones without material in the
barrel.
4. For best results, as many factors as possible that will be influencing the heat controls
should also be present during the self-tuning procedure. For example if the machine will
be running with feed throat cooling then do the self-tuning with the feed throat cooling in
operation.
5. Verify that all unused zones are off, i.e. 32 oF (0 oC), and that zones are set up for
optimization execution (barrel set values 35318 to 35343).
23/12/05 7. FINE TUNING 281

PROCEDURE:
1. Set the heat master switch on the operator station to the OFF position.
2. Select heat setpoint values that are a minimum of 90.0o F (50 oC) above the current
actual temperature for each zone. It is best to use setpoints that are in the same
temperature range as what will be used when in production. Select set points that do not
vary more than 50.0o F (30o C) from each other.
DO NOT CHANGE THE SET POINTS DURING THE OPTIMIZATION HEAT UP OR
COOL DOWN
3. Set the plus and minus tolerances to 90.0 oF (50 oC) in order to avoid alarms that may
interrupt the tuning process.
4. Set the mode of each zone to be tuned (2 or 3).
5. Use the following P.I.D. settings as a starting point:
NOTE!
Temperature values for xPH and Cbh are given in FAHRENHEIT
Zone Usage xPH tn tv t0 HKV Cbh

Nozzle 65.0 °F (18 °C) 100.0 25.0 0.2 1.00 50 °F (0.0 °C)
Barrel 120.0 °F (48 °C) 600.0 200.0 0.2 1.00 50 °F (0.0 °C)
Mold Heat 120.0 °F (48 °C) 600.0 200.0 0.2 1.00 50 °F (0.0 °C)
Hot Runner 50.0 °F (10 °C) 50.0 15.0 0.2 1.00 50 °F (0.0 °C)
6. Switch the CONTROL VOLTAGE to OFF and back to ON.
7. Start the self-tuning by setting the SELF TUNE screen selector on the PID page for each
zone to the ON position.
8. Set the HEAT MASTER SWITCH on the operator station to the ON position.
When the self tuning process is first started the t0 value will automatically change to 0.2 seconds.
The heat zone(s) will begin heating at full capacity (Actn of 100%) until the maximum rate of heat
rise is determined. The heat zone(s) will then stop heating in order to determine the cooling
characteristics of the heat load. Heating will be started again and the calculation of the P.I.D.
values will be finalized.
When the self-tuning process is completed the xPH, tn, tv and t0 values will be updated with the
optimum values and the self-tuning selector will be automatically switched OFF. The heat zone
will then resume heating to the selected setpoint. The plus and minus tolerances can now be reset
to the desired values (if EPROM version is less than 2.08).
The self-tuning process will require from 15 to 30 minutes depending on the heat load.
The mold parameter disk must be updated with the new temperature optimization PID values (if
the Temperature control card has an EPROM version equal to or greater than 2.08 then perform
'procedure B' before saving the mold parameters on to the disk).
282 7. FINE TUNING 23/12/05

PROCEDURE FOR OPERATING POINT OPTIMIZATION
BEFORE YOU START:

1. The HEAT MASTER SWITCH on the operator station must be in the ON position.
All temperatures should be at a reasonable processing temperature.
2. Set the minus tolerance to 50o F (30o C) in order to avoid alarms that may interrupt the
tuning process.
PROCEDURE (EVEN ZONES):

1. Select all even numbered zones (zone 2, zone 4 etc.....) to be optimized first.
Note that no two zones are adjacent and therefore do not directly affect each other.
2. Raise the set point of any even barrel zone that lies between two odd barrel zones (or
any even zone which cools very slowly) by 35o F (19o C). Wait until the actual
temperatures have stabilized at the new set point.
3. All even zones should be stable, AT or within 1o F BELOW the set point.
4. Initialize the self-tuning by setting the “TUNE” screen selector on the PID page for each
even zone, to the ON position.
5. The heat zone(s) will begin to cool down (Actn of 0 %) until the temperature is about
18o F (10o C) below the set point. The control will then heat up each zone to the set point
again.
6. The self-tuning process is now complete for the zone(s) and the “xPH, tn, tv and To”
values will be updated with the optimum values automatically. The self-tuning selector(s)
will be automatically switched OFF. The heat zone(s) will then resume heating to the
selected setpoint.
PROCEDURE (ODD ZONES):

1. Select all odd numbered zones (zone 1, zone 3, zone 5.....) for optimization.
Note that no two zones are adjacent and therefore do not directly affect each other.
2. Raise the set point of all odd numbered zones by 35o F (19o C). Any odd barrel zone that
lies between two even barrel zones (or any odd zone which cools very slowly) raise by
70o F (38o C). Wait until the actual temperatures have stabilized at the new set point.
3. All odd zones should be stable, AT or within 1o F BELOW the set point.
4. Initialize the self-tuning by setting the SELF TUNE screen selector on the PID page for
each odd zone, to the ON position.
5. The heat zone(s) will begin to cool down (Actn of 0 %) until the temperature is about
18o F (10o C) below the set point. The control will then heat up each zone to the set point
again.
6. The self-tuning process is now complete for the zone(s) and the “xPH, tn, tv and To”
values will be updated with the optimum values automatically. The self-tuning selector(s)
will be automatically switched OFF. The heat zone(s) will then resume heating to the
selected setpoint.
WHEN COMPLETED:
1. The mold and machine parameter disks (the “param.bin” file on machine parameter disk)
should be updated with the new temperature optimization PID values.
2. The plus and minus tolerances can now be reset to the desired values. The procedure is
finished.
23/12/05 7. FINE TUNING 283

1.3 DISPLAY OF HEAT ZONE PARAMETERS:
With the Temperature Control card, all temperature setpoints and actual values are displayed in
0.1 degrees. Each heat zone has two setpoints; one in degrees for closed loop temperature
control and one in percent for open loop temperature control. Only one of these setpoints
(degrees or percent) is displayed depending on whether open or closed loop has been selected
on the P.I.D. setup page. For each zone a yellow screen flag is used to indicate whether the actual
temperature is within the + and - tolerance limits of the setpoint. When the thermocouple circuit is
open for a zone, the actual value display will change from numerical values to "*****".
HEAT ERROR MESSAGES:
An actual temperature that is less than the zone temperature setpoint minus the temperature "-"
tolerance will result in the display of one of the two error messages that indicate low temperature:
# 53."BARREL TEMP. LOW" or #125."MOLD TEMP. LOW". All screw movements shall also be
interlocked.
When a heat zone is selected for closed loop operation and the setpoint is greater than 0.0 "C but
the thermocouple circuit is open, error message number 67 "THERMOCPL.BRK Z.xx" will be
displayed where xx represents the thermocouple input zone number. The following actions shall
also be taken:
1. If the zone number is 0 (oil temperature), switching off the M1 output will disable the
motor(s) and the alarm lamp shall flash.
2. If the zone number is greater than 0, and the “Emg-Mode” selection on the P.I.D.
PARAMETERS page is at "NO", the heat control loop for that zone will be disabled, the
alarm lamp shall flash and further automatic cycling will be disabled.
3. If the zone number is greater than 0, and the “Emg-Mode” selection on the P.I.D.
PARAMETERS page is at "YES", the heat control will automatically switch to open loop
mode and automatic cycling of the machine will continue with that zone running open
loop heat control.
An actual temperature that is greater than the zone temperature setpoint plus the temperature "+"
tolerance will result in the display of error message number 65 "TEMP.TOO HIGH Z.xx" where xx
represents the heat zone number. The following actions shall also be taken:
1. The alarm lamp begins to flash,
2. Automatic cycling shall be interrupted and
3. Switching off the HZA output will disable all heating zones.
Error message # 70 "HEAT DEFECT. Z.xx" (where xx indicates the heat zone number) will occur
when the actual temperature for that zone fails to rise 2 "C when that zone's control loop is
performing the heating function. The following actions shall also be taken:
3. Switching off the HZA output will disable all heating zones.
284 7. FINE TUNING 23/12/05

The hardware detection of an over-current situation on either the heating or the cooling output of
a zone will result in the display of error message #167 "SHORT CCT. E8-Z.xx" where xx
represents the heat zone number. The following actions shall also be taken:
3. All heating zones will be disabled by switching off the HZA output.
TEMPERATURE CONTROL CARD TROUBLESHOOTING
Heat Grouping:
A temperature zone runs up to set value at start up without waiting for the zone grouping.
Solutions:
1. The problem can be caused by the incorrect setting of set value 35323. The set value
should be set to a '1'. If the machine is set to a '2' this will disable the zone grouping
Machine stops with no error message.
Some machines with Temperature Control cards can experience an over temperature alarm that
will stop the machine but will not shut the temperature zone down. No message will appear on the
controller. The condition can only be cleared by turning the CONTROL VOLTAGE to OFF and
back to ON. Contact Engel service department if the problem persists.
Heating Defective Alarm:
Some machines with Temperature Control cards can experience a heating defective alarm that is
not valid. The alarm is normally displayed when an expected temperature change is not seen by
the controller. Turning the CONTROL VOLTAGE to OFF and back to ON can clear the invalid
alarm.
The invalid alarm is caused by a timing error or improper optimization of the Temperature Control
card.
Solution:
1. The EPROM on the Temperature Control card must be version 2.08 or greater.
2. The temperature zones operating points must be re-optimized.
Difficult Temperature Applications
Some machines with difficult temperature control applications may require manual tuning of the
PID's after the automatic tuning process is complete.
23/12/05 7. FINE TUNING 285

1. Extreme temperature oscillations before molding.
Using the PD GRAPHICS program, measure the cycle time of the temperature oscillation
'tk' and adjust the PID values for the zone as follows:
tk = time period of the temperature oscillations

Tn = 0.5 x tk
Tv = 0.12 x tk
Xph : continue observing the actual values and INCREASE Xph gradually
until the oscillations stop
2. Extreme temperature oscillations during molding.
Using the PD GRAPHICS program, measure the cycle time of the oscillation 'tp' and adjust
the PID values for the zones as follows:
tp = time period of the temperature oscillations and molding process time.

Tn, Tv : Do not modify these values
Xph : continue to observe the actual values and DECREASE Xph gradually
until the oscillations stop.
3. Extreme temperature overshoot or undershoot.

Contact Engel service department
286 7. FINE TUNING 23/12/05

2 PRESSURE AND VELOCITY CONTROLS

(SERVO VALVE EQUIPPED ONLY)
The customer service password must be entered to access this screen page.
Press
+ F4
2.1 P & V - CONTROL PARAMETERS
In order to fine tune the injection, hold pressure, and back pressure processes, a closed loop
control is provided. An actual value feedback signal is compared to a set value and any difference
or error that appears will be corrected by automatically adjusting the output signal to the valve.
This is the essence of closed loop control.
By comparing the voltage signal coming from the screw stroke transducer over time, the actual
value for speed control can be calculated.
The actual value feedback signal from the hydraulic pressure transducer, provides the information
required to control pressure.
The Control System will react to the feedback information and apply the closed loop control
signals based on the P.I.D. control parameters relevant to each function. It is important to note that
only one set of control parameters will be in effect at any one time. It is important to remember that
this program is only for fine tuning the process. Very good control is still possible with the factory
set values, but tampering with the settings by untrained personnel could disable the valve.
If you do change the existing values, keep a record of those values so you can always return to
the original set-up. A printout of the P & V CONTRL. PARAM page is the best insurance against
total confusion.
For further information on function keys F1, F2 & F3 please refer to operator manual.
23/12/05 7. FINE TUNING 287

Refer to the section "Adjusting P&V - Control Parameters" for a description of how to set each of
the 4 control areas.
Common to each zone are the variables: Kr, tn, tv, -umin and umax.
Kr Amplification factor - closed loop. (Proportional share)
tn Reset time in seconds (Integral share)
tv Rate time in seconds (Differential share)
umin Sets minimum valve limit
umax Sets maximum valve limit
Ks Amplification factor – open loop:
ustart Start value for back pressure control
The variables Kr, tn, tv, -umin and umax, the speed limit and the ON OFF variables, are all stored
on the machine parameter diskette.
288 7. FINE TUNING 23/12/05

Kr Proportional Share – Closed loop amplification
This component is the product of the proportional factor and the difference between the
present set value and the last measured actual value.
Kr * (SV - AV)
If the present set value is greater than the present actual value, then the proportional
component will be positive. If the present set value is less than the present actual value,
then the proportional component will be negative.
Ks is an amplification factor, too little gain and the set value will never be reached. Too much
gain and the actual value will overshoot the set value and oscillate wildly about the set point.
An optimum value for Kr must be found that gives a fast rise time with little or no overshoot.
Tn Integral Share – Reset time

This component is the product of the integral factor and the sum of all previous set value/
actual value differences.
j=n-1
Tn * S (SV - AV) j
j=0
The integral components cover the full range of all set value/actual value differences. It
prevents a constant deviation of control which could result from using a proportional control
only.
Tn detects the steady state error and resets the actual value closer to the set value, the
higher the number the slower the response. Small numbers mean more resets in a given
time period.
Tv Differential Share – Rate time

This component is the product of the differential factor and the value of the difference
between the set values and the actual values of the current measurement and the last
measurement.
Tv responds to the rate at which the actual pressure approaches the setpoint, this causes
the corrective action to stabilize faster. The main effect is to control overshoot oscillations.
Tv * (( SV - AV)n - (SV - AV) n-1 )

The differential component counteracts the tendency to oscillate or vibrate around the set
value. Think of it as a shock absorber.
23/12/05 7. FINE TUNING 289

2.2 ADJUSTING P & V CONTROL PARAMETERS
Increasing the value of the parameter leads to:

Ks Open loop control amplification 1. open loop response
(i.e. no feedback compensation. Entering the value 1
equals fully open loop, values less than 1 are a
percentage of open loop plus the final portion as
closed loop control. The closer to 1 the setting is,
means greater open loop response and less closed
loop control.)
Kr Closed loop control amplification 2. faster response

3. instability (oscillations)
tn Integral action time 4. increasing correction time

5. less overshoot
tv Derivative action time instability (only use small values for optimization).
A INJECTION SPEED ON
Kr Tn Tv -umin umax ks
sec sec mV mV
600 0.000 0.00- 10 000 10 000 0.000
NOTE!
This function must be switched 'ON' to have any effect.

Move the cursor to the ON/OFF area, press 1, then ENTER.
1. Set the machine to inject over the full stroke without material.
2. Use a stroke cut-off set at 0.3” to avoid a pressure increase when bottoming out the
screw.
3. Typical setting of Kr equals 600.
Set Tn Tv and Ks to zero.
Set -umin to -10 000 and umax to +10 000.
4. Set an extreme injection speed profile.
e.g. 80% 80% 80% 20% 20% 80% 80% 80% 80% 20%
5. Set up the Micrograph to monitor screw speed. Use a scale that reflects the percentage
speed settings in step 4.
290 7. FINE TUNING 23/12/05

6. Manually inject and adjust Kr only to achieve this extreme injection speed profile.
To ensure the set values are being reached in a reasonable time without oscillation,
adjust Kr for a maximum optimum value as follows:
Manually inject and monitor the injection speed graph on the Micrograph page.
If oscillation occurs around the set point reduce the Kr value.
The typical setting given for Kr is only a starting point; the value of Kr is dependent upon
the machine, process and material being used.
Parameters that affect this process:
P 35175 start acceleration - speed injection (%)
P 35186 maximum start acceleration screw absolute (mm/s)
P 35257 closed loop start delay (seconds)
P 35175 control the injection starting ramp. P 35175 is a percentage of P 35186.

and
P35186
P 35257 is a delay to allow the pump to stroke up before the servo valve begins
its control function.
23/12/05 7. FINE TUNING 291

292 7. FINE TUNING 23/12/05

B PRESSURE LIMIT P6 = 1500 psi ON

Kr Tn Tv -umin umax
sec sec mV mV
0.40 0.050 0.00 -10000 5000
Pressure Limit Control (PI Control)
This area of the P & V - Control Parameters is for the pressure limit feedback control. The
pressure limit P6, limits the hydraulic injection pressure if the pressure limit function is switched
on. If the pressure limit function is switched off, hydraulic injection pressure will be allowed to
reach maximum system pressure. However, in order to maintain speed control, actual hydraulic
injection pressure must not reach the P6 level. It must be at least 200-300 psi below the P6 level.
If the actual injection pressure does reach the P6 level during injection speed control, two things
will happen.
1. The control will switch to the above pressure limit feedback control. In effect, limiting
pressure at the expense of speed control
2. The screw position where control of the speed was lost (PHx = P6) will be indicated on
the set value graphics page by a vertical red line and by the variable Sp.
Speed Limit Control
The Hold Pressure speed limit is defined by the set boost speed at the moment of boost to hold
pressure cut over. The boost speed profile is active from stroke position C1 to 0.0 inches. At the
cutover point the control has a set boost speed. This speed will be the speed limit during hold
pressure if parameter 9356 is equal to zero.
Parameter 9356 Mode for speed control during hold pressure.

0 = Constant speed setting during hold using parameter 35241.
1 = Via the speed control. The speed limit be the speed setting at cutover.
Parameter 35241 Speed limit minimum value (set in mV millivolts).

At the cutover point, if the actual voltage output from the analog card is
less than the value set in the parameter 35241, then the control will use the
mV value set in 35241 as the minimum output voltage for hold pressure
control. This is for a minimum speed during hold pressure control so that
the closed loop pressure control will function correctly. If the speed is too
low, the closed loop pressure control will not function correctly
23/12/05 7. FINE TUNING 293

To set these control parameters:
1. Presetting of the control parameters:Kr, set to 0.040

Tv set to 0
Tn set to 0.050
umin set to -10 000
umax set to +5 000
2. Move the screw to the forward position.

3. Set the boost to hold transfer method to time. Set Z1 = 10 seconds.
4. Set up the Micrograph to monitor injection boost pressure.
5. Set various pressures for P6.
6. While monitoring the Micrograph, activate the injection function and increase Kr to
minimize overshoot at the beginning of pressure regulation.
Continue to increase Kr to minimize overshoot but not too high or the valve will oscillate.
It is important to note that a slight overshoot will be difficult to avoid for the single P6 settings. This
control parameter is designed to operate with a changing pressure situation and in any event will
only be called upon when the pressure limit has been exceeded.
The pressure and speed limits serve a monitoring function and will only react when the injection
speed is out of control.
Typical settings: Kr approx. 0.040

Tn approx. 0.050
294 7. FINE TUNING 23/12/05

C INJECTION HOLD PRESSURE ON

Kr Tn Tv -umin umax Ks
sec sec mV mV
70 0.700 0.00 -5000 5000 0.9
Pre-setting of the control parameters: (PI control)

Tn .....10.0
Kr .....0.00
Tv, .....0.0
umin - 5000
umax +5000
NOTE!
This function must be switched 'ON' to have any effect. Move

the cursor to the ON/OFF area, press 1, then ENTER.
If all control parameters are set to 0, the servo valve cannot

control the holding pressure.
1. Move the screw forward without material, until the stop position.
2. Set the hold pressures to 1450 psi, the hold pressure time Z2 to 10 seconds, and the
injection time Z1 to 0 seconds.
3. Set up the Micrograph to monitor injection and hold pressure.
4. Manually activate the injection function and hold the switch until the end of hold pressure.
Kr is increased until the actual value begins to oscillate. Decrease Kr until the actual
value does not oscillate to achieve the correct setting. If Kr is increased too much, the
valve will become unstable.
Tn is then decreased until the given set value is reached in the shortest time possible or
exceeded without starting to oscillate.
Tv is usually left set to zero.
Alternately, adjust Kr and Tn until no further improvements are noticed.
The settings should now be optimized with material since the plastic cushion could affect
the control.
Typical settings: Tr approx. 70
Tn approx 0.700 seconds
umin approx. -5000mV
umax approx 5000mV
Ks: approximately 0.9 (Moog valve only)
23/12/05 7. FINE TUNING 295

For Moog valve equipped machines, the performance of the valve can be enhanced by means of
oil leakage compensation. To provide a linearization curve for this function P 35483 must be set
to 1 and a pressure calibration must be completed.
The value from the linearization table multiplied the correction factor Ks is then added to the
calculated output.
With oil leakage compensation a portion of the integral share tn is covered by the compensation
and therefore the integral share tn of the PI controller can be decreased.
Another advantage of the oil leakage compensation is that when switching over into hold
pressure, the controller is switched to the open loop controlled value immediately, so that any
overswing can be avoided.
Hold Pressure Control Reaction Test

1. Set the hold pressure time Z2 to 1 second and set the following hold pressure profile
from P7 to P16:
1800 1800 1800 1800 1800 300 1800 1800 1800 1800 psi
2. Move the screw to the forward position until it comes to the mechanical stop.
4. Manually activate the injection function and hold the switch until the end of hold pressure.
A curve similar to the one shown below should appear.
Hold Pressure
Curve
296 7. FINE TUNING 23/12/05

Adjustment of the Injection to Hold Pressure Change-over Ramp
1. Move the screw to the forward position.

2. The first ramp setting (SW35129) is completed without material.
3. Set injection boost pressure P6 to 1500 psi and injection hold pressures P7 - P16 to 750
psi.
4. Set injection boost time Z1 to 1 second and injection hold pressure time Z2 to 10
seconds.
6. Manually activate the injection function and monitor the curve on the Micrograph.
7. Adjust SW35129 so that, if possible, no oscillation of the pressure curve occurs during
change-over.
P (bar)
100
Ram p too large (long)
50
Ideal ram p
Ram p too sm all (short)
0 t
sec
A7 7 2 1 6 9 1
23/12/05 7. FINE TUNING 297

D BACK PRESSURE: closed loop

Kr Tn Tv -umin umax ustart
sec sec mV mV mV
200 0.10 0.000 -0.200 10 000 2 000
Pre-setting of the control parameters: (PID Control)
K 10.0
Tn 1.0
Kr 0.0
Tv, 0.0
umin -1000
umax +6000
ustart 0.0
1. Set the screw refill stroke to half the maximum stroke and use a constant screw refill
speed. This adjustment can only be done with material.
2. Set-up the Micrograph to monitor back pressure. In order to use the Micrograph you
must first briefly turn the manual inject key to start the Micrograph and then turn the key
to the refill function.
3. Increase Kr until the Micrograph shows a tendency to oscillate.
4. Decrease Tn until the oscillations mostly disappear.
Typical settings: Kr approx. 200
Tn approx. 0.100 seconds
umin approx. -200 mV
umax approx +10 000 mV
ustart approx 2 000 mV
A value can be entered into “ustart” to dampen the effects of the change over from hold pressure
to back pressure.
When entering a value into “ustart” avoid setting the value too high, the greater the “ustart” setting
the lower the back pressure. 10 000 milliVolts equals no back pressure.
Set the “ustart” value close to the typical output for any particular back pressure setting. The back
pressure output can be monitored via the display of analog outputs. Analog output 00 is employed
for injection speed, hold pressure and back pressure.
298 7. FINE TUNING 23/12/05

2.3 OPTIMIZING THE CONTROL PARAMETERS
Standard Procedure
k (increase)
setup gets worse setup is same or better
k (decrease)
setup gets worse setup is same or better
use previous setup
If there is more than one good setup, select the middle one (so that there is no borderline
situation). Use above procedure to do all parameters tn, kr, tv, tv2. If factor k is set below 10.0 all
control parameters are influenced.
23/12/05 7. FINE TUNING 299

300 7. FINE TUNING 23/12/05

8. APPENDIX
1 NOTES/CONVERSIONS
A. The Control System software program was written in Europe and reflects metric values.
If your machine has been ordered with imperial measurement values (i.e. psi, inches, Fahrenheit
degrees, etc.), a slight rounding error could be evident. The Control System first measures in
metric and then converts to the imperial measure.
For example, if you select 400 degrees Fahrenheit, the Control System might display 399
degrees. The Celsius temperature equivalent is converted to Fahrenheit degrees and a slight
rounding error would enter into the conversion.
As well, if a pressure reading is hovering at the transition point between two pressure values (e.g.
100 bar and 101 bar), a psi value, after the conversion, could fluctuate by 14.5 psi. (e.g. 1450 psi
and 1464.5 psi).
B. 1 inch = 25.4 mm 1 pound of force = 4.44 Newtons

1 Bar = 14.5 psi 150 Tons of force = 1332 K Newtons(KN)
0 Celsius = 32 Fahrenheit
23/12/05 8. APPENDIX 301

2 DIGITAL INPUTS (STANDARD)

2.1 DI325 CARD 1 (STANDARD CONFIGURATION)
NOTE!
Refer to the Software description in section 2 of the Machine

Manual for digital input card configuration for your machine.
Digin Digin Description

# name
00 not 0v = emergency stop
01 e1 +24v = light curtain not interrupted/safety gate closed
02 e8 +24v = hydraulic clamp interlock monitor
03 e9 +24v = nozzle guard closed
04 e14 +24v = core 1 is out
05 e15 +24v = core 1 is in
07 e17 +24v = core 2 is in
08 saw +24v = permit cores in
09 e2 +24v = safety gate not closed
10 e8q +24v = hydraulic clamp interlock monitor
11 e9q +24v = nozzle guard open
12 f1 +24v = suction filter o.k.
13 f2 +24v = high pressure filter & injection filter o.k.
14 e52 +24v = injection unit aligned
15 bzh +24v = barrel heats are on
16 bwh +24v = mold heats are on
17 e7 +24v = hydraulic clamp interlock actuated
18 e8 +24v = hydraulic clamp interlock (safety gate open)
19 ls +24v = ejectiob detection
20 td +24v = motor running.
21 oen +24v = oil level ok
22 nf +24v = monitoring filter motor
23 sp1 +24v = mold closing interlock
24 b52 +24v = machine doors and covers closed
25 bg6 +24v = hydraulic clamp high pressure interlock
26 bsuva +24v = suva monitoring input
27 bsich +24v = suva protection circuit active
28 bz1 +24v = lubrication oil pressure ok (toggle machine)
29 bz2 +24v = lubrication oil level ok (toggle machine)
30 bvt1 amplifier card for ehv pump 1
31 bvt2 amplifier card for ehv pump 2
302 8. APPENDIX 23/12/05

2.2 DIGIN ; CARD 2
NOTE!
Refer to the Software description in section 2 of the Machine

Manual for digital input card configuration for your machine.

# name
32 ie +24v = mold height motor impulse input
33 dwr +24v = security released safety gate 1 open
34 bas +24v = machine doors and covers closed (plexi-prot.).
35 bweb +24v = moving mold haldf released (qmc)
36 bwef +24v = stationary mold half released (qmc)
37 bwgb +24v = moving mold half secured (qmc)
38 bwgf +24v = stationary mold half secure (qmc)
40 e19 +24v = core 3 is in
41 bsga +24v = powerd safety gate is open
42 bsgab +24v = powered safety gate opening slow down
43 bsgzb +24v = powered safety gate closing slow down
44 dwv +24v = powered safety gate front safety edge OK
45 awv +24v = permit ejector forward (robot)
46 awz +24v = permit ejector back (robot)
47 hsp +24v = permit mold close/open (robot)
48 kee +24v = permit core(s) in (robot)
49 kea +24v = permit core(s) out (robot)
50 fof +24v = permit mold open from intermediate positon (robot)
51 b63 +24v = permit mold close (robot)
52 pu +24v = program interrupt
53 bmtf7 +24v = flow microtemp zone 8
61 e15_1 +24v = core 1 on intermediate stop moving in
62 e14_1 +24v = core 1 on intermediate stop moving out
23/12/05 8. APPENDIX 303

2.3 DIGIN ; CARD 3

# name
67 bdth +24v = mold indexing is raised
68 bdte1 +24v = mold indexing in ccw position (left)
69 bdter +24v = mold indexing in cw position (right)
70 dtvv +24v = mold indexing is locked (shot pins)
71 dtve +24v = mold indexing is unlocked (shot pins)
72 bdt1 +24v = mold indexing in ccw position (left)
73 bdtr +24v = mold indexing in cw position (right)
74 bdt1br +24v = mold indexing ccw braking switch (left)
75 bdtrbr +24v = mold indexing cw braking switch (right).
76 bdtve +24v = rotary table shot pin 1 unlocked
77 bdtvv +24v = rotary table shot pin 1
78 lg_qui +24v = monitoring light curtain 1 acknowledgement
79 aw_platte1 +24v = ejector safety switch 1 OK
83 1saw +24v = permit corepull 1 station 1
86 ein1_fehl +24v = insert process failed
87 sit_hbg +24v = hand terminal confirmation switch
88 bmsg +24v = light curtain connected
89 bzaun +24v = robot guarding with safety gate 1 connected
90 e1_2 +24v = safety gate 2 closed
91 e2_2 +24v = safety gate 2 not closed
92 e7_2 +24v = 2e7 ehsi hydraulic interlock 2nd gate
93 tms1 +24v = push button cycle start 1
304 8. APPENDIX 23/12/05

2.4 DIGIN ; CARD 4

# name
96 tms4 push button cycle start 4
97 e1_lg light curtain 1 not interrupted
98 e2_lg light curtain 1 interrupted
99 e81 be8.1 hydraulic clamp interlock monitor OK
100 e21 mechnaical interlock released
101 sit cores and ejector motion keyswitch
102 pu_can program interrupt
103 bsgaq powered safety gate is not open
104 rnop +24v = robot not operational
105 pdc +24v = purge door is closed
106 pdo +24v = purge door is open
107 2l +24v = ejector 2 is retracted
108 2l1 +24v = ejector 2 is forward
109 b74 +24v = prefill oil tank level OK
110 b75 +24v = permit mold indexing (robot)
111 mfsi +24v = mold flash safety interlock
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
23/12/05 8. APPENDIX 305

3 DIGITAL OUTPUTS
3.1 DIGOUT CARD 1
Digout Digout Description

# name
DIGOUT card 1 / port 0 (24vk) (NA)
00 S1 mold close
01 SEA fast closing cylinder shut off
02 S2 mold open
03 S3 screw rotation
04 S4 injection
05 S5 injection carriage forward
05 S6 injection carriage retract
06 MSI motor start impulse
07 S25 ejector 1 forward
DIGOUT ; card 1 / port 1 (24vk) (NA)
08 S26 ejector 1 retract
09 S6 Injection carriage retract
10 S10 pump 1 enable
11 S3A back pressure
12 S9 pump 2 enable
13 S3A_S11 mold protection 1
14 AA reject parts recognised
15 M1 motor 1 enable
DIGOUT ; card 1 / port 2 (24vkn) (NA)
16 S4D regenerative injection
17 S24 decompression
18 S6A release carriage contact pressure
19 H manual/set-up mode (robot signal)
20 HA automatic mode (robot signal)
21 HZA heat enable
22 FS machine alarm lamp
23 DA mold is open (robot signal)
DIGOUT ; card 1 / port 3 (24vk) (NA)
24 DL ejector is retracted (robot signal)
25 DL1 ejector is forward (robot signal)
26 SB mold is closed (robot signal)
27 S2P2 release clamp high pressure (hydraulic clamp)
28 ESHI electro hydraulic interlock safety valve
29 S1P1 clamping high pressure (hydraulic clamp)
30 DFK nozzle height decrease
31 DFG nozzle height increase
306 8. APPENDIX 23/12/05

3.2 DIGOUT CARD 2

# name

32 S2P1 open clamp suction valve (hydraulic clamp)
33 S11 mold protection pressure (toggle clamp)
34 SVDZ_OP shut off nozzle open
35 SL1 air valve 1
36 DSP lubrication oil pump (toggle clamp)
37 S12A regenerative clamp (toggle clamp)
38 S3A_S12A back pressure (TL hydraulic clamp)
39 S14 core 1 out/unscrewing 1
DIGOUT card 2 / port 5 (24vkn) (NA)
40 S15 core 1 in / rewind 1
41 S16 core 2 out / unscrewing 2
43 S18 core 3 out / unscrewing 3
45 S12 combine pumps
46 KRES kistler- cavity pressure amplifier reset
47 KBER kistler- cavity pressure amplifier
48 STAB socket disconnection
49 SKE all cores are in (spi robot signal)
50 SKA all cores are out (spi robot signal)
51 DV1 weekly schedule device 1
52 DV2 weekly schedule device 2
53 S40 release moving mold half (qmc)
54 S41 release stationary mold half (qmc)
55 SGZ powered safety gate close

56 SGA powered safety gate open
57 SGZB safety gate 1 move slowly
58 S1P3T *** clamping high pressure (toggle vertical clamp)
59 SGPA safety gate
60 SEA_H1 fast closing cylinder shut off (TL)
61 SHE mold is at intermediate position
62 SGN powered safety gate air supply
63 S12 air valve 2
23/12/05 8. APPENDIX 307

3.3 DIGOUT CARD 3 (OPTIONAL)

# name
64 A23 alarm bell
65 T8 microtemp zone 8
67 T6 microtemo zone 6
73 2S6A release carriage 2 contact pressure
74 2S25 ejector 2 forward
*** left table ejector forward (shuttle table)
75 2S26 ejector 2 retract
*** left table ejector retract (shuttle table)
76 2SAC screw 2 anti-creeping
77 2S3S not used
78 2S62 kistler cavity pressure amplifier 2 control output
SPSU *** purge slide open (vertical machines)
79 2S63 kistler cavity pressure amplifier 2 range
SPSD *** purge slide closed (vertical machines)
80 SDTL move table counter clockwise (left)
SHL (* shuttle, move shuttle table left)
81 SDTR move table clockwise (right)
SHR (* shuttle, move shuttle table right)
82 SDTVEL table locking pin secure
83 SDTVER table locking pin release
84 SDTH table raise
85 SDTD table lower
86 S11A mold protection enable
87 S11B mold closing pressure relief (vertical clamp)
88 SGFREI table safe to enter lamp
89 2S42 mold gate 2 open
90 2HAS mold gate 2 close
91 L91 nozzle(s) are back lamp
92 2HZA heat 2 enable
93 MSI 2nd motor start
94 S94 injection flow vent unit 1
95 S4A injection flow vent unit 2
308 8. APPENDIX 23/12/05

3.4 DIGOUT CARD 4

# name
96 3S3 screw rotation 3
97 3S4 injection 3
98 3S5 injection carriage 3 forward
99 3S6 injection carriage 3 back
100 3S24 decompression 3
101 3S4D regenerative injection 3
102 3S10 pump 3 enable
103 3S3A back pressure (plasticizing 3)
104 3S4B shut-off nozzle 3 open
105 3S6A release carriage 3 contact pressure
106 3S42 mold gate 3 open
107 3HAS mold gate 3 close
108 3SAC screw 3 anti-creeping
109 3S3S positive screw stop 3
110 3S62 kistler cavity pressure amplifier 3 control output
111 3S63 kistler cavity pressure amplifier 3 range
112 S112 not used
113 SEA_HL fast closing cylinder shut off (tiebarless)
114 SAE coining (used only with coining cylinder)
115 _STAB cooling water receptacle
116 SGAB electric safety gate
117 SGZB electric safety gate
118 3S25 ejector 3 forward (vertical clamps)
119 3S26 ejector 3 retract (vertical clamps)
120 S120 hydraulic cooling motor enable
121 3S4_1 decompression drain unit 3
122 S122 mold wiper in
123 3HZA heat 3 enable
124 NHDEC nozzle height decrease
125 NHINC nozzle height increase
126 WSRJ reject weigh scale
127 EHSI electro hydraulic interlock safety valve
23/12/05 8. APPENDIX 309

4 POWERED SAFETY GATE

Set value parameter 35472 is the selector that configures the powered safety gate program for the
type of powered safety gate that is used on the machine. The selections available for set value
35472 are:
0 = manual
1 = old style gate
2 = new style gate (rodless cylinder)
The inputs, outputs and output truth table for each powered safety gate types are given below.
Inputs: DITMS -cycle start button (optionally installed)
DITMGZ -gate close manual selector switch (not used with EL front panel)
DITMGA -gate open manual selector switch (not used with EL front panel)
DIE1 -gate closed limit switch
DIE30 - +24v = start slow gate closing speed limit switch
Outputs: DOSGN -air supply

DOSGA -gate open
DOSGZ -fast gate close
Truth Manual Idle Fast Slow Gate Fast Slow Gate

Table: Output State State Close Close Closed Open Open Open
SGN OFF OFF ON ON ON ON N/A ON
SGA OFF OFF OFF OFF OFF ON N/A ON
SGZ OFF OFF ON OFF OFF OFF N/A OFF
RODLESS PNEUMATIC CYLINDER

inputs: DI46 DITMS +24V Cycle start button (optionally installed)
Marker DITMGZ -gate close manual selector switch
Marker DITMGA -gate open manual selector switch)
DI01 DIE1 +24V Gate closed
DI02 DIE2 +24V Gate not closed
DI07 DIE7 or 8 +24V Gate open
DI62 DIDWV +24V Gate front safety edge
DI59 DIBSGZB +24V Gate closing slow down
DI51 DIBSGAB +24V Gate opening slow down
DI50 DIBSGA +24V Gate is open
DI45 DIDWR +24V Gate rear edge interrupted
Outputs: DO40 DOSGN -air supply

DO39 DOSGA -gate open
DO38 DOSGZ -gate close
310 8. APPENDIX 23/12/05

Truth Table: Output SGN SGZ SGA

Power off, no motion OFF OFF OFF
Power on, no motion ON OFF OFF
Gate open to moving platen ON OFF ON
Gate stops at moving platen ON OFF OFF
Gate close ON ON OFF
Variables associated with the safety gate.
35472 Safety gate type:

0 = manual.
1 = old style gate.
2 = new style gate ( rodless cylinder ).
35288 Pressurize time. Time to allow cylinder to pressurize after the gate is turned on.
36004 Time delay between turning SGZ off and starting gate open ( SGA).
36002 Time delay between first detecting a gate safety strip error and then checking to
confirm if the error still exists a second time.
36003 When a safety strip error is detected the gate will move in the opposite direction
for this amount of time.
Error messages associated with the safety gate.
138 Safety gate strip. - This error is displayed when the control has detected
that one of the safety strips has been activated.
226 SPI switch required. - This error is displayed when a program selection for
the gate has been selected that will cause the gate to
open before the cycle is finished and the SPI key-
switch is currently off.
23/12/05 8. APPENDIX 311

The basic functions are performed in the same manner for all three types of powered safety gate.
MANUAL OPERATION:
GATE OPEN:
To open the safety gate, the operator must hold the GATE OPEN manual selector switch
on until the gate has reached the open position. If the switch is released before the gate is
open then the gate will go into the idle state. If the gate reaches the gate is open limit
switch while the operator is still holding the GATE OPEN selector switch the gate will stop.
If the rear safety strip is touched while the gate is opening, the gate will immediately stop
opening and reverse direction for the time period set and then go to the manual state.
GATE CLOSE:
To close the safety gate, the operator must hold the GATE CLOSE manual selector switch
on until the gate has reached the closed position. If the switch is released before the gate
is closed then the gate will go into the idle state. If the front safety strip is touched while the
gate is closing, the gate will immediately stop closing and reverse direction for a set time
and then go to the manual state.
When the safety gate is in the idle state (not opening and not closing or closed), and either
one of the safety strips is touched, the gate will switch to the manual state.
If the gate is in the manual state and either gate opening or closing is selected, then the
gate will power itself up and move in the indicated direction clearing the error in the
process.
All manual gate functions are overridden by the gate program selector ( located on the
display page for MOLD OPENING, shown above) when it is in the off position (i.e. set
equal to 0).
AUTOMATIC OPERATION:
On machines equipped with cycle start pushbutton(s) (TMS), the safety gate will close in
automatic by either pushing and holding the cycle start button(s), or using the manual
selector switch for GATE CLOSE. The automatic cycle will not start until the cycle start
pushbutton is pressed with the gate in the closed position.
An automatic machine cycle will not be initiated while the "GATE SAFETY STRIP" error
message is displayed.
On machines without cycle start pushbutton(s) the automatic cycle will be started when the
gate has been opened and closed.
Opening the gate at any point during a fully automatic cycle will cause the cycle to be
interrupted.
The safety gate can be selected to open at various points in the semi-automatic cycle
depending on the selection made at the powered safety program selector switch where;
312 8. APPENDIX 23/12/05

0 = off.
1 = end of cycle.
2 = end of feed C2*.
This selection can be found on the bottom of the mold opening page.
To operate selection 2 as listed above, the Cores + Ejector keyswitch must be activated. If
selection 2 is selected while the Core and Ejector keyswitch is not active, then the control
will switch you to selection 1 automatically and display the error “SPI SWITCH
REQUIRED”.
NOTE!
Before activating the Cores and Ejector keyswitch read the

precautions in the safety section of the Controller Operator
manual regarding this switch.
SGA output marker indicates that the digital output for the automatic safety gate opening has
been activated.
SGZ output marker indicates that the digital output for the automatic safety gate closing has been
activated.
SGN output marker indicates that the digital output for the air supply is active.
In all program cases, the safety gate will mot move beyond limit switch bSGA mounted on the
moving platen.
23/12/05 8. APPENDIX 313

5 PRINTER SET-UP EXAMPLES

For SYSTEM VERSION SV2.00 or greater, only these settings shown below are displayed.
NOTE!
Printer, Destination device and Hardcopy settings are found under

Main Menu + F1 Printer function key.
NOTE!
Printer must have a serial interface and be set to emulate an EPSON!

Ensure that your printer is selected under ”Device Selection” and set up under “Device
Parameters” and “General Parameters”.
The HP Deskjet will require a serial to parallel converter, these are commercially
available, such as the “Extended Systems ESI-2634 SerialLink, or from Engel as part
number C2202.3032.
All printer functions will operate normally.
314 8. APPENDIX 23/12/05

5.1 F5 - DEVICES SELECTION
The current output device is displayed at the bottom of the “Printing” screen pages. The output
device can be selected on this screen page.
Pressing F5 will display the screen page shown below.
Move the cursor to the device required and press F1 “Select Device”.
Press F2 to set up the “Device Parameters”.
23/12/05 8. APPENDIX 315

5.2 DEVICE PARAMETERS
5.2.1 PRINTERS
All the printer selections require these parameters to be set
5.2.2 ELECTRONIC STORAGE MEDIA
The choices here are between FLOPPY DISK or RAM DISK. If FLOPPY is selected the data will
be saved to a floppy disk. If the RAMDISK is selected the data will be saved internally in memory
on the CPU card. Machine and process disk information can be saved to the RAMDISK. The
contents of the RAMDISK can be browsed from the “DISKETTE” functions screen page.
ASCII = Normal plain text

UNICODE = Symbolic characters
5.2.3 F6 - SETUP GENERAL PARAMETERS
Hardcopy of screen pages: NO = WITH, YES = WITHOUT soft key function frame.
5.2.4 F7 - STOP PRINTING
If the operator presses 'STOP PRINTING', the printing function will terminate as soon as the last
page, within the printer's memory, has been printed out.
316 8. APPENDIX 23/12/05

CITIZEN GSX-190 (Recommended)
Check your printer manual for the proper connection terminals, however, all printers must have
connections for RXD, DTR and SGND. The pin connections for the Engel controller appear as a
standard, on the left hand side of the drawing below.
Engel RS232Citizen GSX-190

Serial Interface Printer Interface
The Citizen GSX-190 printer is set up using the printer software. Refer to the Citizen manual for
the set-up procedure. The Citizen GSX-190 printer set-up for the controller is shown below.
INSTALL 1
RIBBON COLOR
A.S.F. OFF
EMULATION EPSON
PRINT STYLE
FONT DRAFT
EMPHASIZED OFF
PITCH 10 CPI
FONT LOCK OFF
PAGE LAYOUT
LINE SPACING 6 LPI
FORM LENGTH LETTER
PAGE SKIP OFF
PRINT MODE
NLQ DIR BI-DIR
GRAPHIC DIR BI-DIR
CHARACTER
SLASH ZERO OFF
CHARACTER SET ITALICS
INTL CHAR SET USA
INSTALL 2
TEAR OFF ON
PAPER OUT ENABLE
AUTO LF OFF
COPY MODE OFF
23/12/05 8. APPENDIX 317

ENVELOPE OFF
SETTINGS FOR THE CITIZEN GSX-190 (continued)
SERIAL I/F
BAUD RATE 9600 (Set I.M.M. Parameter 35593 to 8)
PARITY NONE
DATA BIT 8 BIT
STOP BIT 1 BIT
PROTOCOL DTR
The switches located under the removeable panel on the righthand corner of the printer, should
be set as follows:
318 8. APPENDIX 23/12/05

5.3 FACIT PRINTER
Engel RS232 Facit Printer
Serial Interface Interface
The Facit printer is set up using the printer software. Refer to the Facit manual for the set-up
procedure. The Facit printer set-up is shown below.
CURRENT VALUES
PRINTER COMMAND MODE

PRINTER COMMAND MODE IBM PRO-PRINTER
GENERAL
COLOUR RIBBON COLOUR
SHEET FEEDER NOT INSTALLED
ESC G/H FUNCTION DOUBLE-STRIKE
CR FUNCTION NO AUTO LF
LF FUNCTION AUTO CR
NATIONALITY USA
ZERO DESIGN 0
PAPER & FORMAT

FORMAT LENGTH (inch) ....................... 11
LINE SPACE (lines/inch) ......................... 6
SKIP ZONE (inch) ................................... .0
LINE LENGTH (characters) ..................... 80
TEAR OFF FUNCTION ........................... NOT VALID
COMMUNICATION
INTERFACE ...................................... Serial
WORD LENGTH ................................ 8 bits (A01 - 7 bits)
INPUT BUFFER ................................. 256 BYTES
DC1/DC3 FUNCTION .........................VALID
PROTOCOL ...................................... READY/BUSY
BAUD RATE ...................................... 9600 BPS
PARITY .............................................. Disable (A01-Enable/even)
READY/BUSY POLARITY .................. Ready=high
23/12/05 8. APPENDIX 319

5.4 EPSON PRINTER EX800
The Epson printer has the following pin connections:

RXD - pin 3
DTR - pin 2
SGND - pin 5
The Engel connections remain the same.
The Epson printer also has two banks of DIP switches that must be set.
SW1 OFF OFF ON OFF OFF ON ON ON
1 2 3 4 5 6 7 8
SW2 OFF OFF OFF OFF ON ON OFF OFF
5.5 OKIDATA 182 PLUS PRINTER (HIGH SPEED ONLY)
The Okidata 182 Plus printer (High Speed Serial Interface) has the following pin connections:
RXD - pin 3
DTR - pin 11
SGND - pin 7
The Okidata High Speed Serial Interface Board has one bank of DIP Switches that must be set.
OFF ON ON ON * ON OFF *
SW1 1 2 3 4 5 6 7 8
* not used
5.6 OKIDATA 172 & 182 PLUS PRINTER (SUPER SPEED ONLY)
The Okidata 172 & 182 Plus Printer (Super Speed Serial Interface) has the following pin
connections:
RXD - pin 3
DTR - pin 11
SGND - pin 7
The Super Speed Serial Interface Board has two banks of DIP switches that must be set. If you
wish to use pin 20 (DTR) instead of pin 11, set switches 7 and 8 to ON (bank 1).
SW1 OFF OFF OFF ON ON ON OFF ON
1 2 3 4 5 6 7 8
SW2 OFF ON ON OFF ON ON ON *
* not used
320 8. APPENDIX 23/12/05

5.7 HEWLET PACKARD DESKJET 800 SERIES
The HP Deskjet uses a parallel port and a parallel printer cable when connected to a computer.
As the Engel controller only has a serial port, a serial to parallel converter is required plus a
special serial cable.
The cable and converter information is given in the following figures.
The converter can be purchased commercially or supplied by Engel (part # C2202.3032). The
cable can be supplied by Engel (part # 6750.950.1805C) or can be manufactured by the
customer, using the information in the figure above.
23/12/05 8. APPENDIX 321

NOTE!
Ensure that the Control System printer baud rate is set to corre-
spond with the baud rate setting of the printer. The baud rate of
the Control System is adjusted using a software constant. The
baud rate of the printer is adjusted using DIP switches, or the
printer software, depending on the printer employed.
The controller baud rate is set in parameter 35593 by entering a number that corresponds to the
required baud rate, the choices are:
• 12 = 115200
• 11 = 57600
• 10 = 38400
• 9 = 19200
• 8 = 9600
• 7 = 4800
• 6 = 2400
• 5 = 1200
• 4 = 600
• 3 = 300
• 2 = 150
• 1 and 0 = Reserved
NOTE!
If a graphic printer is employed, the Control System must

be adjusted to be in the graphic printer mode.
1. Press Main Menu

2. Press 1-Printer
3. Select Graphic Printer
GRAPHIC PRINTER will be highlighted on the screen.
322 8. APPENDIX 23/12/05

6 CLAMP FORCE TRANSDUCER (LVDT)

The clamp force transducer measures the tonnage generated when the clamp closes and the
toggle lever locks up. When the clamp closes, the compressive forces cause the tie bars to
stretch. It is the clamp force transducer's function to measure the amount of tie bar stretch.
Engel machines use an LVDT (linear variable differential transformer), which is connected to a
movable rod inserted into one of the tie bars, to measure the exact amount of stretch. Based on
the amount of stretch, a specific electrical feedback signal is sent to the electrical control unit.
Typically, the amount of total tie bar stretch is usually within the range of 0.014” to 0.047" (0.35
mm to 1.2 mm), depending on the clamp force of the particular machine. The working range of the
transducer feedback signal is between +50mV as a minimum and +500mV as a maximum.
Inductive Transducer (LVDT)

Transducer Pin
Transducer Housing
Cable Connection
Lock Nut
Lock Nut (coarse adjustment)
Movable Rod Tie-bar Disc Springs
A4501769
(fine adjustment)
With reference to the drawing above, as clamp force increases, the tie bar will stretch along its
total length. As the tie bar stretches, the disc springs will force the movable rod to the left. The
transducer pin, which is screwed into the movable rod, will move in unison with it as clamp force
increases. For every .01 of a millimeter that the transducer pin moves, a signal of approximately
+1.2 mV will be transmitted to the electronic control unit.
23/12/05 8. APPENDIX 323

6.1 REPLACE OR ADJUST CLAMP FORCE TRANSDUCER - TYPE LG83
NOTE!
As a preventive maintenance suggestion, the maintenance tech-

nician should record the millivolt signal that appears across SK3
(plus) and SK4 (minus) with the mold open completely to the 'A'
position and locked up at full tonnage.
Analog Card
0V from PD242
grey green
SK +
SK -
white yellow
+5V from PD242
• Open the mold completely to the 'A' position.
• Screw the transducer pin all the way into the movable rod and tighten the fine
adjustment lock nut.
• With caution, screw the transducer housing in until you can just feel the transducer pin
bottom out within the housing and then turn the housing out again approximately three
complete turns.
• Connect the cable and then turn on the control voltage.
• Check the transducer supply voltage (+5 Volts) at the transducer plug, pins A and B.
Ensure you are reading plus millivolt to start.
• With your voltmeter leads across SK+ and SK-, adjust the offset voltage by turning the
transducer housing until you read the correct offset voltage (See note above). It will
be approximately +70 mV. The transducer has a range of -5 volts to +5 volts.
• Tighten the lock nut (coarse adjustment).
• If further adjustment is required, use the transducer pin position as a fine adjustment
and then tighten the fine adjustment lock nut after completion.
If full tonnage cannot be achieved after these adjustments, call the ENGEL
service department
324 8. APPENDIX 23/12/05

6.2 REPLACE OR ADJUST CLAMP FORCE TRANSDUCER - TYPE LG93
Installing the Transducer

1. Open the mold to position 'A'.
2. Introduce the rod of the transducer into the hole in the Tiebar.
3. When the rod reaches the bottom of the hole, there must be a gap between the transducer
body and the end of the tiebar of between 0.060 and 0.120" (1.5 to 3mm).
4. Mount the transducer to the tiebar with two 5 mm cap screws.
To set-up the Clamp Force Transducer.

5. Using a 3 mm Allen key remove the screw cover from the center of the transducer body.
6. Connect the cable to the transducer.
7. Turn on the Control Voltage.
8. Using a digital volt meter, check the transducer supply voltage (+5 Volts) at the transducer
plug, pins A and B.
9. Transfer the volt meter leads to SK+ and SK- on the analog card.
10. Using a 1.5 mm Allen key, adjust the transducer through the hole of the screw cover
removed in step 5.
11. Adjust the transducer for a reading of 70 mV d.c. on the volt meter.
12. Clamp up the mold using the maximum clamp force for the mold installed.
13. Check that the 'Clamp Force: Actual' is within the set tolerance to the 'Clamp Force: Set'.
14. Open the mold to position 'A' and check that the volt meter still reads 70 mV.
GAP OF 0.060 TO 0.120"

TIEBAR 5mm CAP 3mm SCREW
SCREW (2) COVER
TRANSDUCER
HOUSING
MOVABLE CABLE
SPRING SPRINGS
ROD CONNECTION
RETAINING
NUT
23/12/05 8. APPENDIX 325

6.3 TROUBLESHOOTING PROPORTIONAL VALVE CIRCUIT
This is a typical wiring diagram of a PA89 / PA96 proportional valve circuit for machines with a
single proportional speed valve Y1, and a single proportional pressure valve K1.
K1W1 Position
K1W2 Feedback
K1W3
K1W3 K1 VALVE
K1-
K1+
0V OV AR181
K1 K+ ANALOG
Y1W1 Position
Y1W2 Feedback
Y1W3
Y1W3 Y1 VALVE
Y1-
Y1+
0V OV AR181
Y1 Y+ ANALOG
-24VC
0V
+24VK 24VK
0V OV
326 8. APPENDIX 23/12/05

Preventive Troubleshooting
It is always easier to troubleshoot a problem when you know what to expect normally.
On the following pages, the steps are outlined to measure the normal signals that should be
present on the proportional valve circuit. As well, space is provided for you to record those
measurements.
Measure and record the measurements and keep this information for future troubleshooting
reference. Remember that valve calibrations may change some of these signals slightly, so keep
this document as your original and record your measurements on a photocopy. Re-record the
measurements after any valve calibrations.
Step 1. Is the analog signal present ?
• Check for 0-10 Vdc at K1 for pressure or at Y1 for speed, while the valve is operating.
NOTE!
There will always be a signal present during idling.
Step 2. Is the amplifier output signal present ?
• On the dc scale, check for a voltage across K1- and K1+ for pressure, and across Y1-
and Y1+ for speed, while the valve is operating.
Step 3. Is the feedback transducer supply voltage present ?
• On the ac scale, check for the feedback transducer supply voltage across K1W1 and
K1W3 (not shield) for pressure and across Y1W1 and Y1W3 (not shield) for speed.
You should measure approximately 10 VAC.
Step 4. Is the feedback transducer signal consistent and stable ?
• On the ac scale, check for a voltage across K1W2 and K1W3 for pressure and across
Y1W2 and Y1W3 for speed, while the valve is operating.
• As the valve function increases, pressure or speed, you should measure a increasing
voltage. From minimum to maximum valve function, there will be a voltage spread of
approximately 3/4 to 1 volt. For example, at 300 psi K-valve pressure to 2900 psi K-
valve pressure you might see a spread of 5.3 V a.c. to 6.3 V a.c., respectively.
23/12/05 8. APPENDIX 327

6.4 HOW TO SET UP PRESSURE VALVE TEST
1. Disconnect solenoid plug S25 from the ejector forward directional control valve. T
2. On the EJECTOR screen page, set ejector forward speed V25 to 30 %.
3. On the EJECTOR screen page, set ejector forward pressure P25 to various levels as set
out below.
4. Operate the MANUAL EJECTION switch to FORWARD and hold while the measurements
are being taken.
5. Using a multimeter, record the readings at each step.
NOTE!
The ejector forward pressure is normally subject to a reduction

factor (i.e. Parameter 35214 = 80%)
This test is valid only if the ejector is controlled by the K-valve. If

not, a different manual function must be employed.
Pressure - K1
Measure between K1 & 0V(dc) K1- & K1+(dc) K1W2 & K1W3(ac)
idle ______ _____________ _______________
P25 - 10% ______ _____________ _______________
P25 - 20% ______ _____________ _______________
P25 - 30% ______ _____________ _______________
P25 - 40% ______ _____________ _______________
P25 - 50% ______ _____________ _______________
P25 - 60% ______ _____________ _______________
P25 - 70% ______ _____________ _______________
P25 - 80% ______ _____________ _______________
P25 - 90% ______ _____________ _______________
P25 - 100% ______ _____________ _______________
Measure between K1W1 & K1W3(AC) for the transducer supply voltage _________________
328 8. APPENDIX 23/12/05

6.5 HOW TO SET UP SPEED VALVE TEST
1. Disconnect solenoid plug S25 from the ejector forward directional control valve. T
2. On the EJECTOR screen page, set ejector forward pressure P25 to 30%.
3. On the EJECTOR screen page, set ejector forward speed V25 to various levels as set out
below.
4. Operate the MANUAL EJECTION switch to FORWARD and hold while the measurements
are being taken.
5. Using a multimeter, record the readings at each step.
NOTE!
The ejector forward speed is not normally subject to a reduction

factor (i.e. Parameter 35206 = 100%).
This test is valid only if the ejector is controlled by the Y1 valve.
Speed - Y1
Measure between Y1 & 0V(dc) Y1- & Y1+(dc) Y1W2 & Y1W3(ac)
idle ______ _____________ _______________
V25 - 0% ______ _____________ _______________
V25 - 10% ______ _____________ _______________
V25 - 20% ______ _____________ _______________
V25 - 30% ______ _____________ _______________
V25 - 40% ______ _____________ _______________
V25 - 50% ______ _____________ _______________
V25 - 60% ______ _____________ _______________
V25 - 70% ______ _____________ _______________
V25 - 80% ______ _____________ _______________
V25 - 90% ______ _____________ _______________
V25 -100% ______ _____________ _______________
Measure between Y1W1 & Y1W3(AC) for transducer supply voltage ____________
23/12/05 8. APPENDIX 329

If the machine has a two pump hydraulic system, there will be two proportional speed valves.
Measure and record those readings as well. There will be a second amplifier card to control the
second proportional speed valve. In any event, the wiring termination points are as indicated
below.
Speed - Y2
Measure between Y2 & 0V(dc) Y2- & Y2+(dc) Y2W2 & Y2W3(ac)
idle ______ _____________ _______________
V25 - 0% ______ _____________ _______________
V25 - 10% ______ _____________ _______________
V25 - 20% ______ _____________ _______________
V25 - 30% ______ _____________ _______________
V25 - 40% ______ _____________ _______________
V25 - 50% ______ _____________ _______________
V25 - 60% ______ _____________ _______________
V25 - 70% ______ _____________ _______________
V25 - 80% ______ _____________ _______________
V25 - 90% ______ _____________ _______________
V25 -100% ______ _____________ _______________
Measure between Y2W1 & Y2W3(AC) for transducer supply voltage ____________
This test is valid only if the ejector is controlled by the Y1 and Y2 valve. If not, a different manual
function must be employed.
330 8. APPENDIX 23/12/05

7 VARIABLE SET VALUES
NOTE!
The Variable Set Values listing for YOUR machine is in the

Machine Manual, section 2, entitled “Software Description”.
ENGEL injection molding machines are all specially customized, and therefore no two customer’s
machines have exactly the same set value listing.
The Machine Manual is provided for each machine and will have a serial number or set of serial
numbers relevant to your machines, on the spine. The machine manual must not be used in
reference to a machine with a different serial number.
The Variable Set Values listing contains certain information that could be useful to a trained
maintenance technician. For example, Variable Set Value 35041 is the variable employed to
control the toggle locking speed from toggle lever position G2 to toggle locked position B. The
technician would enter a percentage speed into this set value parameter and the toggle would
move at that speed during the G2-B speed range.
There is other useful information listed as well, e.g. the set value 06000 line appears as shown:
Param. Default Group & Disk Reduction Description

# Value Channel Loc. Factor
06000 0 00 62 set 35210 closing pressure
Param. # - refers to the variable parameter number
Default Value - refers to the default value of the variable, in metric units (factory setting).
Group and Channel - refers to the group and channel numbers of that variable.
Disk Location - refers to the disk that the parameter is saved on,
i.e. set = process disk and mch = machine disk
Reduction factor - refers to the percentage amount that is parameter is reduced to protect
that function from excess speed or pressure. The factor, as in this case,
refers to another variable with a default setting.
Closing pressure refers to the function or description of the variable.
THE VARIABLE UNITS

It is important to recognize the variable units before examing or changing the variable value.
Unit Description Unit Description

Val Numerical value without dimension %/s percentage per second
mm millimetres bar Bar (1 bar = 14.5 psi)
mm/s millimetres per second bar/mm Bar per millimetre
s second bar/s Bar per second
% percentage oC Degress celsius
%/mm percentage per millimetre
23/12/05 8. APPENDIX 331

Variable Group names
Listed below are all the groups, the group name abbreviation and a guide to whether the variable
is a machine setting or a process setting. The set values are grouped together in machine
functional areas, for example there is the mold closing group and mold closing service group. The
groups names with “service” ending are the factory or machine settings and influence the basic
function of the machine. The other groups are for the process settings which are concerned with
the production of the molded parts.
Abbreviation Variable Group Name Machine / Process

vgabs Absolute Values machine
vgabss Absolute Values Service machine
vgzsch Central Lubrication process
vgsk Clamping Force process
vgsyss Control-Systemparameter process
vgkrn Core process
vgkrns Core Service machine
vgaw Ejector process
vgaws Ejector Service machine
vggen General Parameter process
vggens General Parameter Service machine
vgtmp Heating process
vgtmps Heating Service machine
vgsysm Hydraulic-Systemparameter machine
vgsprs Inject./hold pressure service machine
vgdus Injection Unit process
vgduss Injection Unit Service machine
vgsspr Injection/hold pressure process
vgmtmp Microtemp process
vgsch Mold closing process
vgschs Mold closing service machine
vgoef Mold opening process
vgoefs Mold opening service machine
nogrp No Groups process
vgdos Plast./Back Press./Decompres. process
vgdoss Plast./Decompres. Service machine
vgeas Prog./Config. Switches Service machine
vgea Program/Configuration Switches process
vgqds Quality Data Statistics process
vgqsu Quicksetup process
vgdreh Rotary table process
vgseri Serial Interface process
332 8. APPENDIX 23/12/05

Param# Default Group & Disk Reduct. Description

value Channel Loc. factor
VARIABLE PARAMETER LISTING

CENTRAL LUBRICATION TIME
---------------------------------------------------------------------
35260 250 mch lubrication time after
lubrication pressure (bz1) was reached
35261 500 mch lubrication monitoring time(lubrication
press.must be reached within this
time)
35262 5 mch max.response time lubrication
level switch bz2
36274 10 mch shut-off nozzle delay activation
CENTRAL LUBRICATION SHOT

----------------------------------------------------------------------
35301 500 mch maximum for central lubrication counter
35302 10 mch fixtime for central lubrication
after switching on the machine
35303 80 mch central lubrication counter set-value
CLAMPING FORCE PRESSURE

----------------------------------------------------------------------
35210 100 mch val red.factor clamping pressure
CLAMPING FORCE no unit

---------------------------------------------------------------------
12000 0 07 73 set clamp force-set-value
12100 01 09 set clamp force display
35305 2 mch impulse reduction (revolut.of
mold height mot.after it was
turned off)
35306 40 mch tons/impulse
35307 15 mch impulse/0.1mm
35308 1750 mch nominal clamp force
35309 1925 mch clamp force alarm limit
35310 35 mch tolerance for clamp force control
35312 175 mch max.minus deviation clamp
force actv.from clamp force
setv.to allow inj.
35313 40 mch x.xx calc.factor pressure in clamp
cyl.(phx2)==>clamp force skx
35314 1750 mch resolution clamp force pressure
35962 100 mch kn positive deadzone for clamp force
-correction
23/12/05 VARIABLE PARAMETER LISTING 333


35972 0 mch duration allotted for clamp force
too high monitor.
35468 0 mch press.transducer in the closing
cylinder= 1
35480 0 mch sk-offs-error stopped cycle = 1
35485 0 mch for full-hydraulic with
press.transducer:
0=without recharge time
1=with recharge time
35960 0 mch 1 = clamp force-correction switched on
CLAMPING FORCE STROKE

---------------------------------------------------------------------
35021 20 mch die height stroke tolerance for
clamp force check
35024 50 mch start clamp force measuring
CLAMPING FORCE VELOCITY

---------------------------------------------------------------------
35043 100 mch speed for lockup (toggle)
speed on g2 (for full hydraulic machines)
35052 100 mch volume high pressure build up
35065 100 mch volume on y1 for high pressure
build up with proportional valve
CLAMPING FORCE RAMP

---------------------------------------------------------------------
35156 100 mch pct10/mm10 p-ramp mold protection.
press.
p2 to clamp.press.p1 at
pos.g2 (mold closing)
CLAMPING FORCE TIME

--------------------------------------------------------------------
35265 2 mch mon.time nozzle height motor
stopped (for alarm purposes)
35276 40 mch press buildup time fully hyd. without
press transducer.
/ monitor time pressure buildup with
press transducer.
35294 10 mch additional press.build-up time
for start of cycle full-hydraulic
without transducer.
35295 20 mch recharge time fully hydraulic
in manual mode
35296 0 mch recharge time calculated...
334 VARIABLE PARAMETER LISTING 23/12/05


35961 20 mch recharge time fully hyd.m/e with
press transducer
08516 0 mch delay between s1.2 and high pressure
output.
35311 3 mch time dependent activation of
mold height motor
CLAMPING FORCE COUNTER

----------------------------------------------------------------------
35304 0 mch initial closing build-up press.-
cycle counter set-value
CLAMPING FORCE PERCENTAGE

----------------------------------------------------------------------
35963 0 mch reduction factor clamp force
CONTROL-SYSTEMPARAMETER no unit
----------------------------------------------------------------------
08904 0 mch password for reminder switch
35584 0 mch key dynamic repeat
35586 2592 mch printer page length
35587 144 mch printer space/interval
35588 216 mch printer basis line
35589 0 mch blank lines after line-feed
35590 0 mch empty lines in the 40 character mode
35591 0 mch 0-input with enter:
0=without warning, 1=with warning
35592 0 mch 0=us-key, 1=german keyboard
09686 0 mch hardcopy 0..with/ 1..without function
key
19602 1 mch printer type selection
37021 0 mch 1= insert blankline
37023 0 mch hardcopy 0..mit/ 1..ohne softkey
38848 0 mch paper format text printer
38851 0 mch paper format 9-pin-graphic printer
38853 144 mch perforation 9-nadel-grafikdrucker
38854 0 mch paper format 24-pin-graphic printer
38856 216 mch perforation 24-nadel-grafikdrucker
38857 0 mch paper format hp-deskjet 800
38858 216 mch perforation hp-deskjet
37024 0 mch active output device
40428 1 mch background color selection
0 = black, 1 = grey
CONTROL-SYSTEMPARAMETER TIME
----------------------------------------------------------------------


35582 4 mch key repeat delay
35583 2 mch key repeat time
35585 6000 mch screen blanking delay
36469 210 mch printer timeout
CORE STROKE
----------------------------------------------------------------------
02010 0 00 47 set pos b-mold closed
02011 0 00 48 set pos b8-core move in/out
02012 0 00 11 set pos ks1- core 1 move in
02015 0 00 12 set pos ko1- core 1 move out
02018 0 00 49 set pos ks1k-core 1 in control-position
02021 0 00 52 set pos ks1k-core 1 out control-position
CORE VELOCITY
---------------------------------------------------------------------
04400 0 02 80 set 35217 core 1 out speed
04401 0 02 81 set 35217 core 1 in speed
04403 0 02 83 set 35217 core 2 in speed
04405 0 02 86 set 35217 core 3 in speed
CORE PRESSURE
----------------------------------------------------------------------
06400 0 02 09 set 35218 core 1 out pressure
06401 0 02 10 set 35218 core 1 in pressure
CORE TIME
----------------------------------------------------------------------
08400 0 03 06 set core 1 moving in time
08403 0 03 09 set core 1 moving out time


08406 0 03 12 set core 1 moving in monitoring
08409 0 03 15 set core 1 moving out monitoring
08412 0 03 18 set core 1 moving out delay
CORE no unit
----------------------------------------------------------------------
18200 0 10 07 set program selection core 3 (ejector/core)
18201 0 10 08 set priority core 1 in
18202 0 10 09 set priority core 2 in
18203 0 10 _10 set priority core 3 in
18204 0 10 11 set priority core 1 out
18207 0 10 14 set core 1 in
18208 0 10 15 set core 2 in
18209 0 10 16 set core 3 in
18210 0 10 17 set core 1 out
18211 0 10 18 set core 2 out
18212 0 10 19 set core 3 out
18213 0 10 20 set core 1 in time dependent
18216 0 10 25 set core 1 out time dependent
18219 0 10 31 set core 1 in parallel
18222 0 10 37 set core 1 out parallel
18225 0 10 43 set core 1 in without pressure,volume
18228 0 10 49 set core 1 out without pressure,volume
18231 0 10 55 set core 1 without pressure after moving in


09421 0 set cores in set-up selection
CORE SERVICE STROKE

---------------------------------------------------------------------
35009 15 mch stroke tolerance for start from
stop-position
CORE SERVICE RAMP

----------------------------------------------------------------------
35133 6 mch pct10/mm v-braking to ks
35136 10 mch pct10/s10 v-braking to koe
35146 100 mch pct10/mm p-mold braking to ks
35159 20 mch pct10/mm v-at b8 during closing
35160 20 mch pct10/mm v-at b8 during opening
35162 100 mch pct10/mm p-mold braking to koe
CORE SERVICE MAX.RAMP

----------------------------------------------------------------------
35198 6000 mch outset acceleration y-output corepull
35199 30000 mch outset press-buildup k-output corepull
CORE SERVICE VELOCITY

---------------------------------------------------------------------
35217 100 mch val red.factor cores speed
CORE SERVICE PRESSURE

---------------------------------------------------------------------
35218 100 mch val red.factor cores press.
CORE SERVICE no unit

---------------------------------------------------------------------
35469 0 mch number of core-pulls (0 - 3)
EJECTOR TIME
---------------------------------------------------------------------
09379 3 mch s10.2 deactivation delay when using
fixed pump
08300 0 03 00 set ejector return delay
08301 0 03 01 set ejector-fwd.-delay time
25129 0 66 29 set ejector 3 return delay
25130 0 66 30 set ejector 3 forward delay


EJECTOR STROKE
---------------------------------------------------------------------
02001 0 00 15 set pos a1-command ejector for
02300 0 00 14 set pos l-ejector retracted
02301 0 00 13 set pos l1-ejector fully forward
02302 0 00 16 set pos l2-ejector shake position
02303 0 08 04 set pos l3-start 2.ejector fwd.speed
02502 01 06 set ejector position - actual
01984 2500 08 06 set control-position ejector retracted
25132 0 66 32 set pos 3a1-trigger ejector 3 forward
EJECTOR VELOCITY
----------------------------------------------------------------------
04300 0 02 78 set 35206 ejector fwd.speed
04301 0 02 79 set 35207 ejector ret.speed
04407 0 08 05 set 35206 ejector fwd. 2.speed
25127 0 66 27 set ejector 3 fwd.speed
25128 0 66 28 set ejector 3 ret.speed
EJECTOR PRESSURE
---------------------------------------------------------------------
06300 0 02 07 set 35214 ejector forward pressure
06301 0 02 08 set 35215 ejector retract pressure
25124 0 66 24 set ejector 3 fwd. press.
25125 0 66 25 set ejector 3 ret. press.
EJECTOR no unit
----------------------------------------------------------------------
10306 0 03 70 set actual ejector
18020 0 10 06 set ejector extended at end of cycle
01983 0 03 65 set ejector ret.parallel to mold closing
25126 0 66 26 set ejector 3 position at end of cycle
25133 0 66 33 set trigger ejector back with tms
EJECTOR COUNTER
----------------------------------------------------------------------
10000 0 03 56 set ejector counter
25123 0 66 23 set ejector 3 counter
EJECTOR VELOCITY
---------------------------------------------------------------------
04503 01 17 set ejector speed
EJECTOR SERVICE STROKE

---------------------------------------------------------------------


35004 1300 mch max. stoke ejector
35007 50 mch safety distance between a1/l
35023 20 mch stroke position monitoring at sax
standstill
37002 50 mch safety distance for moving platen
ejector
EJECTOR SERVICE VELOCITY

---------------------------------------------------------------------
35050 0 mch minimum speed (ejector)
35055 20 mch volume stroke calibration ejector
35071 100 mch volume on y for motions
using the ejector proportional valve y2
35075 10 mch volume ejector in setup mode
35206 100 mch val red.factor ejector fwd.speed
35207 100 mch val red.factor ejector ret.speed
EJECTOR SERVICE VELOCITY

----------------------------------------------------------------------
35070 200 mch maximum speed ejector
35073 200 mch maximum speed ejector forward/ extend
EJECTOR SERVICE PRESSURE

---------------------------------------------------------------------
09631 5 mch minimum pressure for ejector
35120 40 mch pressure - stroke calibration ejector
35124 15 mch pressure ejector in setup-mode
35214 100 mch val red.factor ejector fwd.press.
35215 100 mch val red.factor ejector ret.press.
EJECTOR SERVICE RAMP

----------------------------------------------------------------------
35153 65 mch pct10/s10 v-braking to l1(eject. fwd.)
35154 100 mch pct10/s10 v-braking to l (eject. ret.)
36134 100 mch braking pressure at l, l1, l2
35158 100 mch pct10/s10 v-braking to l2(ejector ret.)
35163 100 mch speed ramp after l3 (ejector)
35169 50 mch start acceleration velocity ejector
forward
35170 100 mch start acceleration velocity ejector
retract
EJECTOR SERVICE MAX.RAMP

----------------------------------------------------------------------
35178 2 mch maximum acceleration/delay ejector
movements


EJECTOR SERVICE MAX.RAMP

----------------------------------------------------------------------
35183 10000 mch maximum start acceleration ejector
movements
EJECTOR SERVICE TIME

----------------------------------------------------------------------
07942 0 mch ejector forward delay
10770 0 mch ejector delay in manual after pump
flushing
EJECTOR SERVICE no unit

---------------------------------------------------------------------
35466 0 mch proportional valve ejector = 1
35619 0 mch input calibration finished
35630 1 mch configuration signal input calibration
EJECTOR SERVICE VOLTAGE

---------------------------------------------------------------------
35639 0 mch zero value input calibration
35640 10000 mch max-value input calibration
GENERAL PARAMETER no unit

---------------------------------------------------------------------
00001 "Spri 13 41 set item part number
00102 0 09 21 set shot set value
00103 0 09 23 set piece actual value
00024 0 07 90 set material conveyor unit yes/no
00025 0 13 33 set cavity number
00026 0 07 74 set screw diameter
00027 0 07 78 set sensitivity mold cavity
press.transducer
22001 0 09 17 set stand still code for bde
10007 0 08 03 set total reject counter actual
32004 17 47 set host:download status host
32005 0 12 68 set host:download request host
32007 "0000 17 48 set host:mold code setvalue
18000 0 07 84 set ejection control
18018 0 10 05 set monitor cycle time
03698 0 05 14 set marker heat heat-stand-by after
cycling control voltage
03301 0 07 71 set oil filtration on/off
07913 0 set analog debugger parameter 1


20002 0 11 24 set channel a associate with(0-3)
20003 0 11 27 set channel b associate with(0-3)
20014 0 11 87 set channel c ideal
03809 0 07 62 set cut-off display selection 1
03813 0 07 66 set flownumber display selection 1
41069 0 set bit mask for micrograph curve analog.1
41077 0 set measuring channel index for analog
card 1
card 1
card 1
card 1
card 1
card 1
card 1
card 1
41101 0 mch maximum number input calibration
analog card 1
41102 0 mch maximum number output calibration
analog card 1
22200 0 07 93 set weekly schedule
22201 0 05 87 set Monday turn on time: hour
22202 0 05 88 set Tuesday turn on time: hour
22203 0 05 89 set Wednesday turn on time: hour
22204 0 05 90 set Thursday turn on time: hour
22205 0 05 91 set Friday turn on time: hour
22206 0 05 92 set Saturday turn on time: hour


22207 0 05 93 set Sunday turn on time: hour
22208 0 05 94 set Monday turn on time:minute
22209 0 05 95 set Tuesday turn on time:minute
22210 0 05 96 set Wednesday turn on time:minute
22211 0 05 97 set Thursday turn on time:minute
22212 0 05 98 set Friday turn on time:minute
22213 0 05 99 set Saturday turn on time:minute
22214 0 12 00 set Sunday turn on time:minute
22215 0 12 01 set Monday turn off time:hour
22216 0 12 02 set Tuesday turn off time:hour
22217 0 12 03 set Wednesday turn off time:hour
22218 0 12 04 set Thursday turn off time:hour
22219 0 12 05 set Friday turn off time:hour
22220 0 12 06 set Saturday turn off time:hour
22221 0 12 07 set Sunday turn off time:hour
22222 0 12 08 set Monday turn off time:minute
22223 0 12 09 set Tuesday turn off time:minute
22224 0 12 10 set Wednesday turn off time:minute
22225 0 12 11 set Thursday turn off time:minute
22226 0 12 _12 set Friday turn off time:minute
22227 0 12 13 set Saturday turn off time:minute
22228 0 12 14 set Sunday turn off time:minute
22229 0 16 53 set motor on with weekly schedule
22230 0 16 54 set motor off with weekly schedule
22231 0 16 55 set heat on with weekly schedule
22232 0 16 56 set heat off with weekly schedule
22233 0 16 57 set unit 1 on with weekly schedule
22234 0 16 58 set unit 1 off with weekly schedule
22235 0 16 59 set unit 2 on with weekly schedule
22236 0 16 60 set unit 2 off with weekly schedule
22245 0 16 61 set unit 1 main switch (screen)
22246 0 16 62 set unit 2 main switch (screen)
22255 0 12 23 set weekly schedule off manual
02178 05 27 set clamp force peak value
02179 05 28 set clamp force umschaltwert
01899 01 29 set year
01900 01 30 set month
01901 01 31 set day
01902 01 32 set tag
01903 01 33 set hour
01904 01 34 set minute
10011 0 01 58 set start-up reject counter
24001 0 19 01 set enabled from host
24003 19 50 set host:shot counter
24033 19 42 set host:fzx-flow number act.value
22011 09 11 set remaining production time hours


22012 09 12 set remaining production time minute
22013 09 13 set remaining production time seconds
22014 09 14 set remaining material needed [kg]
22015 09 15 set remaining material needed [g]
28456 0 08 62 ko0 trigger criterium for micrograph
additional curve
36913 0 34 02 mch start encoder table null point
recognition
36276 0 mch 1 = shut-off nozzle mounted
36275 1 33 71 set shut-off nozzle selection
36285 0 mch 0 - s10 on for clamp opening
1 - s10 off for clamp opening
32038 19 87 ko0 host:machine runs automatically
28457 1 mch selection protocol test interface
0=tcp/ip 1=debug
GENERAL PARAMETER SHOT

---------------------------------------------------------------------
00100 0 09 20 set shot set value
10004 0 04 01 set initial reject counter
10005 0 03 98 set reject number
10006 0 03 99 set consecutive reject counter
10010 01 56 set reject counter
10002 01 57 set consecutive rejects
24004 19 05 set host:reject counter
24005 19 06 set host:reject absolute counter
GENERAL PARAMETER PIECE

---------------------------------------------------------------------
00101 0 09 22 set piece set value
GENERAL PARAMETER WEIGHT

---------------------------------------------------------------------
22002 0 09 18 set parts weight
GENERAL PARAMETER TEMPERATURE

---------------------------------------------------------------------
00020 0 07 75 set temperature from temp-unit 1
00023 0 07 89 set temperature from material dryer-unit
GENERAL PARAMETER TIME

---------------------------------------------------------------------
22000 0 09 16 set cycle time for bde
08000 0 02 94 set cooling time


08007 0 03 28 set cycle monitoring time
02034 0 08 12 set initial counter cycle start in manual
20000 0 11 33 set messuring delay graphic
20001 0 11 30 set messuring time-base graphic in sec
22237 0 16 63 set delay motor on with weekly schedule
22238 0 16 64 set delay motor off with weekly schedule
22239 0 16 65 set delay heat on with weekly schedule
22240 0 16 66 set delay heat off with weekly schedule
22241 0 16 67 set delay unit 1 on with weekly schedule
22242 0 16 68 set delay unit 1 off with weekly schedule
22243 0 16 69 set delay unit 2 on with weekly schedule
22244 0 16 70 set delay unit 2 off with weekly schedule
22247 12 15 set delay motor on weekly schedule
22248 12 16 set delay motor off weekly schedule
22249 12 17 set delay heat on weekly schedule
22250 12 18 set delay heat off weekly schedule
22251 12 19 set delay unit 1 on weekly schedule
22252 12 20 set delay unit 1 off weekly schedule
22253 12 21 set delay unit 2 on weekly schedule
22254 12 22 set delay unit 2 off weekly schedule
02185 05 32 set hydraulic pressure peak value
injection boost
02186 05 34 set hydraulic pressure peak value hold
pressure
02187 05 36 set cavity pressure peak value hold -time
02188 05 38 set back pressure peak value -time
02189 05 40 set rpms peak value -time
02190 05 42 set mold protection peak value -time
02191 05 43 set clamp force peak value -time
02192 05 44 set clamp force value at cut-over -time
02193 05 46 set injection speed peak value -time
08503 01 25 set cycle time actual
08504 01 28 set cycle time previous cycle
24006 19 09 set host:mold protection time
24007 19 10 set host:injection time
24008 19 11 set host:screw feed time last cycle
24009 19 12 set host:cycle time peak value
01603 19 48 set host:cooling time actual
05740 19 64 set host:screw feed time for process
data report
22400 12 41 ko0 cycle analysis:mold closing current
22401 12 42 ko0 cycle analysis:carriage current
22402 12 43 ko0 cycle analysis:injection current
22403 12 44 ko0 cycle analysis:hold current
22404 12 45 ko0 cycle analysis:cooling current
22612 12 60 ko0 cycle analysis:acknowledgement current


22599 12 61 ko0 cycle analysis:plasticizing current
22405 12 46 ko0 cycle analysis:mold open current
36996 12 61 ko0 cycle analysis:rotary table current
22406 12 47 ko0 cycle analysis:ejector current
22407 12 48 ko0 cycle analysis:cycle time current
22408 12 49 ko0 cycle analysis:mold closingstored
22409 12 50 ko0 cycle analysis:carriage stored
22410 12 51 ko0 cycle analysis:injection stored
22411 12 52 ko0 cycle analysis:hold stored
22412 12 53 ko0 cycle analysis:cooling stored
10695 12 58 ko0 cycle analysis:plasticizing stored
22413 12 54 ko0 cycle analysis:mold open stored
36997 12 55 ko0 cycle analysis:rotary table stored
22414 12 55 ko0 cycle analysis:ejector stored
22415 12 56 ko0 cycle analysis:acknowledgement stored
22416 12 57 ko0 cycle analysis:cycle time stored
22593 0 ko0 cycle time analysis graph scale-minimum
22594 10000 ko0 cycle time analysis graph scale-maximum
22595 ko0 cycle time analysis graph scale-
interval 1
interval 2
interval 3
interval 4
01379 0 17 29 set cycle analysis:mold closing set value
01380 0 17 30 set cycle analysis:carriage set value
unit 1
01381 0 17 31 set cycle analysis:injection set value
unit 1
01382 0 17 32 set cycle analysis:hold set value unit 1
01383 0 17 33 set cycle analysis:cooling time set value
01384 0 17 34 set cycle analysis:mold open set value
unit 1
36994 0 17 34 set cycle analysis:rotary table set value
01385 0 17 35 set cycle analysis:ejector set value
01386 0 17 36 set cycle analysis:acknowledgement set
value
01387 0 17 37 set cycle analysis:cycle time set value
01556 0 17 38 set cycle analysis:closing tolerance
01557 0 17 39 set cycle analysis:carriage tolerance
unit 1
01558 0 17 40 set cycle analysis:injection tolerance
unit 1
01559 0 17 41 set cycle analysis:hold tolerance unit 1


01560 0 17 42 set cycle analysis:cooling time tolerance
01561 0 17 43 set cycle analysis:mold open tolerance
36995 0 17 44 set cycle analysis:rotary table tolerance
01562 0 17 44 set cycle analysis:ejector tolerance
01563 0 17 45 set cycle analysis:acknowledgement
tolerance
01564 0 17 46 set cycle analysis:cycle time tolerance
25131 0 66 31 set demold time
GENERAL PARAMETER TIME

----------------------------------------------------------------------
10003 0 04 00 set minimum counter for reject checking
GENERAL PARAMETER STROKE

----------------------------------------------------------------------
20004 0 11 59 set graphic: screw position ...0
injection boot position
02195 05 50 set back pressure peak value position
02196 05 52 set rpms peak value position
02197 05 54 set mold protection pressure peak value
position
02198 05 55 set No Description
02199 05 56 set injection speed peak value position
24010 19 15 set host:cushion act.value
24011 19 16 set host:screw stroke
24012 19 17 set host:k-decompression after screw feed
24013 19 18 set host:screw position at cut-over
37517 10 mch min change for nozzle height
GENERAL PARAMETER VELOCITY

---------------------------------------------------------------------
20005 0 11 68 set graphic: injection speed ...1
02184 05 30 set injection speed peak value
GENERAL PARAMETER PRESSURE

---------------------------------------------------------------------
20006 0 11 62 set graphic: hydraulic pressure...2
20007 0 11 65 set graphic: cavity pressure ...3
02177 05 26 set mold protection pressure peak value
24028 19 37 set host:pfs-cavity pressure peak value
24029 19 38 set host:pfu-cavity pressure at cut-over
24030 19 39 set host:phs-hydraulic pressure peak value
24031 19 40 set host:phu-hydraulic pressure at cut-over
24034 19 43 set host:hold pressure correction positiv
24035 19 44 set host:hold pressure correction negativ


01601 19 46 set host:hydraulic pressure peak value
- hold
01602 19 47 set host:back pressurepeak value
04412 03 64 set hydr.pressure ehv-pump 2
36051 1600 mch maximum accumulator pressure
GENERAL PARAMETER PERCENTAGE

---------------------------------------------------------------------
20010 0 11 81 set max. positive deviation idealcurve 1
20011 0 11 83 set max. negative deviation idealcurve 1
20025 0 11 89 set maximum positive deviation ideal
curve 2
20026 0 11 91 set maximum negative deviation ideal
curve 2
04529 0 12 70 set max. positive integral deviation
ideal curve 1
04530 0 12 71 set max. negative integral deviation
ideal curve 1
04531 0 12 72 set max. positive integral deviation
ideal curve 2
04532 0 12 73 set max. negative integral deviation
ideal curve 2
22010 01 59 set cycle time deviation (integer)
GENERAL PARAMETER VOLTAGE

---------------------------------------------------------------------
12994 set ai-cavity pressure pfx in mv
12995 set ai-hydraulic pressure phx in mv
12996 set ai-hydraulic pressure 2 phx2 in mv
12997 set ai-hydraulic pressure ehv pump 2
phx3 in mv
12998 set ai-screw position ssx in mv
12999 set ai-ejector position sax in mv
13000 set ai-nozzle position sdx in mv
13001 set ai-mold position sfx in mv
13002 set ai-rate shx in mv
13003 set ai-toggle position ksfx in mv
13004 set ai-clamp force skx in mv
GENERAL PARAMETER ROTATION

---------------------------------------------------------------------
02175 05 22 set screw rpms peak value
24032 19 41 set host:dzx-screw rpms act.value
05739 19 63 set host:screw rpms for process data report
GENERAL PARAMETER INJECTION


---------------------------------------------------------------------
02176 05 24 set srew feed power avarage value
GENERAL PARAMETER TEMPERATURE

---------------------------------------------------------------------
24000 19 00 set host disabled
24002 19 02 set host:
24014 19 21 set host:temperature zone 1
24021 19 28 set host:temperature zone 8 / 2.
oiltemperature
24027 19 34 set host:oil temperature
GENERAL PARAMETER FORCE

---------------------------------------------------------------------
03074 19 07 set host:clamp force latched
GENERAL PARAMETER SERVICE no unit

---------------------------------------------------------------------
09361 100 mch v10 nozzle safety position (in 1/10 v)
for indexing,opening and closing
08044 0 mch output prop.valve rotary table
calibrated
08045 0 mch output prop.valve rotary table
calibrated
35498 2 mch smoothing factor with hardware-meas.
35499 2 mch smoothing factor with hardware-meas.
28383 0 mch integral idealkurve 1 <021219-
mgraphplus>
28384 0 mch integral istkurve 1 <021219-
mgraphplus>
28385 0 mch integral idealkurve 2 <021219-
mgraphplus>
28386 0 mch integral istkurve 2 <021219-
mgraphplus>
35602 0 mch output calibration finished


35659 0 mch [ms] smoothing constant hydr.pressure
35660 0 mch [ms] smoothing constant mold-cavity
pressure
35661 0 mch [ms] smoothing constant clamp force
35662 0 mch [ms] smoothing constant 2.hydr.pressure
35975 0 mch 2.pump
35986 0 mch [ms] smoothing constant 3.hydr.pressure
60022 0 mch output yc valve rotary table left
calibrated
60023 0 mch output yc valve rotary table right
calibrated
37000 0 mch selector for simulation mode
11921 0 mch 1=allow eject.ret. with sg open and spi
36007 0 mch calculated value ***
36137 0 mch 1 = weekly schedule selected
36135 0 mch 1 = light curtain is used
36052 1 mch 1 = table ejector mounted
36053 0 mch 1 = top ejector mounted
11955 0 mch 1=s10 on during mold prot.
36250 0 mch 1 = kc valve used on machine
36269 1 31 0 mch s10 control during boost to hold
0 = standard (s10 remains on)
1 = s10 off at cutover


37025 2 34 00 mch max gate selection
21188 6 mch selection ht tool entspannen feste
platte
21189 7 mch selection ht tool spannen feste platte
21190 14 mch air blow 1 pushbutton assighment
21191 15 mch air blow 2 pushbutton assighment
21192 16 mch quick mold change release pushbutton
assignment
21193 17 mch quick mold change secure pushbutton
assignment
21194 28 mch safety gate closing pushbutton
assignment
21195 29 mch safety gate opening pushbutton
assignment
21201 8 mch erc reference key pushbutton assignment
21202 9 mch erc home key pushbutton assignment
39922 4 mch core 1 in pushbutton assignment
39923 5 mch core 1 out pushbutton assignment
21207 36 mch rotate table left pushbutton assignment
21208 37 mch rotate table right pushbutton assignment
60026 42 mch rc100 quality part on demand pushbutton
assignment
60027 43 mch rc100 reject part on demand pushbutton
assignment
60028 30 mch alarm bell reset pushbutton assignment
60029 18 mch nozzle height increase pushbutton
assignment
60030 19 mch nozzle height decrease pushbutton
assignment
60031 48 mch purge slide in pushbutton assignment
60032 49 mch purge slide out pushbutton assignment
60033 51 mch mold ejector forward pushbutton
assignment
60034 52 mch mold ejector back pushbutton assignment
GENERAL PARAMETER SERVICE TIME

---------------------------------------------------------------------
09383 3 mch non tie-down timer for cycle start
buttons
11915 15 mch mechanical interlock:
when=0 - not monitored
when>1 - monitored + alarm delay time


35251 15 mch measurem.del.for speed cal.
35252 10 mch s10 s10 deact.delay for idling
35253 20 mch del.for pump idle velocity y1
35266 15 mch monitoring time for hydraulic safety be8
35267 1200 mch motor stop delay after error
delayed motor stop
35268 20 mch meas.del.no movem.stroke cal.
35269 10 mch meas.del.auto pressure cal.
35270 10 mch meas.del.back pressure cal.
35271 80 mch meas.del.screw rpm cal.
35278 2 mch del.oil preheating after man.
movement , del.man.movem.
during oil preheating
35293 10 mch monitor time for nozzle protection
switch.
35298 100 mch receptacle / cool water switch off
delay time
35299 10 mch monitoring time for emergency stop
circuit.
35980 10 mch shut off delay of s9 during idle
35981 20 mch output delay y2 during idle
11918 30 mch delay of mechanical intrlk. in
36059 20 mch s10 bell silence time
36302 0 set delay for checking permit for mold
indexing
0 = without delay
>0 = delay for re-checking
GENERAL PARAMETER SERVICE VOLTAGE

---------------------------------------------------------------------
35025 0 mch offset hydraulic pressure transducer 1
35026 0 mch offset hydraulic pressure transducer 2
35982 0 mch offset hydr.pressure transd. 3
GENERAL PARAMETER SERVICE VELOCITY

---------------------------------------------------------------------


35034 100 mch volume during oil pre-heat
35035 5 mch idle volume with s10
35044 100 mch volume quick mold change
35047 80 mch volume pressure calibration without s10
35051 20 mch volume for idle without s10
35061 50 mch volume pressure calibration 1 pumpe
35979 20 mch speed for idle without s9
06040 5 mch idle volume with s10
for pump 2
11954 50 mch flow for kc valve cal.
GENERAL PARAMETER SERVICE PRESSURE

---------------------------------------------------------------------
35080 53 mch pressure for oil heating
35089 100 mch pressure for q.m.c.
35090 100 mch pressure for stroke calibration mold
open
35098 0 mch pressure during idle without s10
35099 100 mch pressure for moog speed calibration
35107 70 mch pressure speed calibration (screw
forward)
35108 0 mch pressure screw rpm calibration
35109 0 mch idle pressure with s10
35123 10 mch activation on p/q servo valve in idle
35978 0 mch pressure for idle without s9
GENERAL PARAMETER SERVICE PRESSURE

---------------------------------------------------------------------
35094 18000 mch maximum cavity pressure
35095 18000 mch resolution cavity pressure-transducer
35127 0 mch idle pressure limit hls-hydraulic
35993 200 mch threshold 2.pump pressure off
GENERAL PARAMETER SERVICE MAX.RAMP

---------------------------------------------------------------------
35190 400 mch maximum press ramp stroke
dependent(all)

---------------------------------------------------------------------
35191 10000 mch maximum press ramp time dependent(all)
35192 1000 mch maximum press ramp time dependent
during
start and stoftstop all movements
35197 30000 mch outset press-buildup k-output abs


----------------------------------------------------------------------
35193 6000 mch outset acceleration y-output
35194 30000 mch outset press-buildup k-output
35195 6000 mch outset acceleration ys-output
35196 6000 mch outset acceleration m-output
GENERAL PARAMETER SERVICE STROKE

----------------------------------------------------------------------
35459 400 mch screw diameter 1
HEATINGS TEMPERATURE
---------------------------------------------------------------------
14414 0 16 18 set maximum positive temperature deviation
feed throat cooling
14402 0 14 92 set maximum positive temperature deviation
group 0
14403 0 14 94 set maximum negative temperature deviation
group 0
14405 0 14 99 set max. pos. temperature deviation group 1
14406 0 16 01 set max. neg. temperature deviation group 1
14408 0 16 12 set max. pos. temp. deviation group 3
14409 0 16 14 set max. neg. temp. deviation group 3
HEATINGS no unit
---------------------------------------------------------------------
14800 0 16 20 set program switch soft-start
03308 0 16 51 set soft-start, 1. zone, start range
03309 0 16 52 set soft-start, last zone, end range
12706 0 16 47 mch close-loop parameter heat
02743 0 04 50 35416 close-loop parameter heat


09397 0 mch self tuning timer zone 00
14200 0 04 03 set monitoring zone 01
02970 0 14 02 mch open/close loop yes/no zone 0
14501 0 14 04 35416 open/close loop yes/no zone 1
14506 0 14 _14 35421 open/close loop yes/no zone 6
02971 0 14 50 35416 alarm operation yes/no zone 1


02771 0 04 85 35423 control paramter heat
02788 0 06 _06 35427 control paramter heat
14207 0 04 17 set monitoring time zone 08


14214 0 04 32 set self optimizing zone 15
14508 0 14 18 35423 open loop mode yes/no zone 8
02978 0 14 64 35423 emergency mode yes/no zone 8


18008 0 07 86 set heat stand-by yes/no
36060 set thermocouple type for zone 0


HEATINGS PERCENTAGE
----------------------------------------------------------------------
03302 0 16 50 set soft-start threshold
02969 0 10 98 set op-loop set-value in pct zone 0
02994 05 58 set heat proformance regulator 00
14527 0 11 06 set open-loop setvalue in pct zone 8
14532 0 11 _11 set open-loop setvalue in pct zone 13
03057 05 66 set heating power zone 08


HEATINGS TEMPERATURE
---------------------------------------------------------------------
14041 0 04 30 set temperature for oil
14000 0 04 02 set temperature zone 1
14001 0 04 _04 set temperature zone 2


14400 0 16 06 set minimum oil temperaturee
14401 0 16 09 set maximum oil temperaturee
14404 0 14 96 set heat lowering group 0
15200 01 60 set temperature zone 1
15241 01 75 set oil temperaturee
14407 0 16 03 set heat stand-by value group 1


14410 0 16 _16 set heat stand-by group 3
36068 set uncalibrated actual temp oil
36069 set uncalibrated actual temp zone 1
36076 set calibrated temp setting oil
36077 set calibrated temp setting zone 1


HEATINGS SERVICE no unit

---------------------------------------------------------------------
35416 2 mch target diskette zone


35393 1 mch text for heat zone 1 0 =
35394 2 mch text for heat zone 2 1 = nozzle
35395 2 mch text for heat zone 3 2 = barrel
ceramic
35397 2 mch text for heat zone 5 4 = mold 2-
point control
35398 0 mch text for heat zone 6 5 = mold 3-
point control
35399 0 mch text for heat zone 7 6 = feed throat
35400 0 mch text for heat zone 8 7 = material
35401 0 mch text for heat zone 9 8 = used
for microtemp
35402 0 mch text for heat zone 10 9 = hot runner 1
35403 0 mch text for heat zone 11 10 = hot runner 2
35404 0 mch text for heat zone 12 11 = thermolator
35405 0 mch text for heat zone 13 12 = hopper dryer
35406 0 mch text for heat zone 14 13 = melt
temp. monitor
35407 0 mch text for heat zone 15 14 = chiller
35408 0 mch text for heat zone 16 15 = hot sprue
35409 0 mch text for heat zone 17 16 = mold
temp. monitor
3-point control
35411 0 mch text for heat zone 19


35323 1 mch heating mode
35345 2 mch control mode zone 0 0 = measuring
channel
35346 2 35416 control mode zone 1 1 = output
operation
35347 2 35417 control mode zone 2 2 = 2-point
control
35348 2 35418 control mode zone 3 3 = 3-point
control
35349 2 35419 control mode zone 4
35369 5 mch thermocouple type zone 0 - oil
temperature
35370 5 35416 thermocouple type zone 1


36010 32896 mch cal.factor zone - oil
36011 32896 mch cal.factor zone - 1
HEATINGS SERVICE TIME

---------------------------------------------------------------------
35279 80 mch delay for check the temp.
after turning contr.volt.on
35327 600 mch delay temp.high alarm group 0
35328 2400 mch monitor time for heating 2 degrees
group 0
group 1
group 2


group 3
group 4
group 5
HEATINGS SERVICE TEMPERATURE

---------------------------------------------------------------------
35318 5000 mch setting limitation for cylinder heat
35319 5000 mch setting limitation for mold heat
35320 600 mch setting limitation for maximum oil
temperature
35321 0 mch setting limitation for minimum oil
temperature
35322 100 mch shut-off tolernance for oiltemp too
low in automatic.
35324 700 mch oil temp.alarm limit to turn off motor
35326 150 mch heating step size group 0
35344 500 mch max.input limit for temp.tol.
HEATINGS SERVICE TIME

---------------------------------------------------------------------
35325 5 mch max.time for alter oil temp
2 deg during oil preheating
HYDRAULIC-SYSTEMPARAMETER VELOCITY
---------------------------------------------------------------------
35030 144 mch maximum system speed for
increased injection pressure
35031 218 mch maximum system speed
35032 126 mch maximum injection speed for
increased injection pressure
35033 192 mch maximale injection speed
35977 144 mch maximum system speed 2.pump
HYDRAULIC-SYSTEMPARAMETER PRESSURE
--------------------------------------------------------------------


35083 2000 mch system pressure
35110 1500 mch maximum injection pressure with
screw diameter 1
screw diameter 2
screw diameter 3
screw diameter 4
35116 1500 mch maximum injection pressure for srcew
diameter 1 increased
35117 2000 mch maximum injection pressure for screw
35976 2000 mch system press. 2.pump
INJECT./HOLD.PRESSURE SERVICE VELOCITY

---------------------------------------------------------------------
09432 10 mch v - purging in manual
35038 0 mch minimum speed (injection)
35046 30 mch 35203 maximum speed during hold
35048 100 mch maximum volume during injection boost
35056 20 mch volume stroke calibration screw
35058 20 mch volume for injection boost with
unit not alligned
35063 30 mch volume moog open + after hold
35203 100 mch val red.factor inj.boost speed
35951 2 mch offset to y for close-loop
injection = percent val.via absolute
speed set-value
INJECT./HOLD.PRESSURE SERVICE PRESSURE

---------------------------------------------------------------------
08917 10 mch p - purging in manual
35105 0 mch minimum pressure injection
35122 25 mch pressure - stroke calibration screw
35123 10 mch activation on p/q servo valve in idle
35212 100 mch val red.factor inj.boost press.
35213 100 mch val red.factor inj.hold press.
INJECT./HOLD.PRESSURE SERVICE STROKE

----------------------------------------------------------------------
35002 2000 mch max.stoke screw


35006 250 mch maximum cushion and correction
INJECT./HOLD.PRESSURE SERVICE VELOCITY

---------------------------------------------------------------------
35059 144 mch help variable in ar_prof.def
INJECT./HOLD.PRESSURE SERVICE PRESSURE

---------------------------------------------------------------------
35091 1500 mch setup limit for injection boost
35092 2000 mch system pressure during injection boost
35093 2000 mch system pressure during hold
35094 18000 mch maximum cavity pressure
35095 18000 mch resolution cavity pressure-transducer
35115 1600 mch pct k1-headroom for injection and
hold close loop
36962 2000 mch k pressure value purge pressure
INJECT./HOLD.PRESSURE SERVICE no unit

----------------------------------------------------------------------
35128 16000 mch power factor to determine
the maximum injection speed (= vemin
* pmax)
for machines with hls-hydraulic
35219 0 mch injection control on/off
35224 800 mch injection control kr
35225 0 mch injection control ks
35232 0 mch press.limit control on/off
35237 40 mch press.limit control kr
35238 0 mch press.limit control ks
35241 1000 mch speed limit set value
35246 100 mch hold press control kr
35247 0 mch hold press control ks
35248 100 mch hold press control correction factor
35249 0 mch 1 = preset back pressure between
injection hold and feeding
35463 0 mch mode : 0 = proportional valve-cl-loop
1 = servo-valve-cl-loop
35476 0 mch cushion correction: 0=without, 1=with
35482 0 mch parallel cut-over = 1
35483 1 mch servo-valve type: 0=bosch
1=moog
35484 1 mch deactivation after injection
for quick press.release = 1
35954 0 mch 1 = differencial switching


(s4d monitoring)
09356 0 mch mode:speed control during inj.hold
0 .. constant
1 .. by speed profile
35239 0 mch hold close loop ctrl on/off
INJECT./HOLD.PRESSURE SERVICE RAMP

--------------------------------------------------------------------
35129 100 mch bar10/s10 p-cut-off boost to hold
35164 100 mch speed injection braking to end-stop
35175 80 mch start acceleration velocity injection
35177 100 mch start acceleration press all other
movements
35994 100 mch rampe injection speed 2.pump to 0
36838 50 mch ramp injection purge speed
INJECT./HOLD.PRESSURE SERVICE MAX.RAMP

--------------------------------------------------------------------
35165 50 mch v-speed cut-off boost to hold

---------------------------------------------------------------------
35181 10 mch maximum acceleration/delay screw
absolute

---------------------------------------------------------------------
absolute
INJECT./HOLD.PRESSURE SERVICE VOLTAGE

---------------------------------------------------------------------
35220 10000 mch injection control umax
35221 -1000 mch injection control umin
35233 50 mch press.limit control umax
35234 -50 mch press.limit control umin
35242 5000 mch hold press control umax
35243 -5000 mch hold press control umin
INJECT./HOLD.PRESSURE SERVICE TIME

--------------------------------------------------------------------
35222 0 mch injection control tv
35223 0 mch injection control tn
35235 0 mch press.limit control tv


35236 50 mch press.limit control tn
35244 0 mch hold press control tv
35245 700 mch hold press control tn
35250 0 mch calculated value!! time active back
pressure
35256 10 mch injection del.after reach.pos
nozzle fwd.in auto(y & k = 0)
35257 10 mch delay for closed loop control
after start injection boost
35258 1 mch hold moog valve open + after
injection hold
35277 1200 mch delay time for screw movem.
allowed aft.min.temp.reached
35282 10 mch time shut-off nozzle open before
injeciton
35300 0 mch injection and hold pressure peak value
measuring delay.
36455 0 mch injection distortion after intrusion
nozz unit 1
08479 0 mch delay between s4 and analog control
during
control of nozzle unit 1
INJECTION UNIT STROKE

---------------------------------------------------------------------
02200 0 00 09 set pos j1-start 2.nozzle speed fwd.
02201 0 00 10 set pos k-nozzle retracted
02501 01 05 set nozzle position - actual
03763 2500 08 07 set startposition nozzle fwd.
37138 127 mch pos j1-start (caution!!!)
if too small then mechanical damage
to yoke
INJECTION UNIT VOLTAGE

--------------------------------------------------------------------
05735 0 00 56 set offset-sdx-zero-point [mm]
INJECTION UNIT no unit

--------------------------------------------------------------------
04200 0 02 51 set 35202 1.opening speed
18016 0 10 03 set sprue break
02959 0 08 14 set ec100s nozzle contact pressure with
clamp force
03960 0 03 66 set nozzle fwd. parallel to mold closing
INJECTION UNIT VELOCITY


--------------------------------------------------------------------
04202 0 02 57 set 10185 nozzle retract speed
INJECTION UNIT PRESSURE

--------------------------------------------------------------------
06200 0 00 81 set 35216 nozzle fwd.pressure
06201 0 02 15 set 35216 holding pressure carriage unit
INJECTION UNIT TIME

--------------------------------------------------------------------
08200 0 02 96 set nozzle retract delay time
08201 0 02 98 set nozzle press.build-up time
04252 0 08 13 set ec100s nozzle retract time
INJECTION UNIT SERVICE STROKE

--------------------------------------------------------------------
35003 3500 mch max. stoke nozzle
35010 50 mch stop before mechanical stop nozzle
backed up
35011 1950 mch calculated value,reserved !!!!
35028 10 mch allowed nozzle motion during j-detection
INJECTION UNIT SERVICE COUNTER

--------------------------------------------------------------------
35027 3 mch number of measurments after
standstill of the nozzle (j-detection)
INJECTION UNIT SERVICE TIME

-------------------------------------------------------------------
35029 5 mch measureing time for j-detection
35255 10 mch nozzle forward delay in auto
after mold closing(y & k = 0)
35283 10 mch time press buildup bef.press reduction
nozzle.
35284 15 mch time press reduction nozzle
35285 10 mch time k,y,s5 delay after press
reduction nozzle.
36456 10 mch ec100s wait time after nozz press
build up.
INJECTION UNIT SERVICE VELOCITY

-------------------------------------------------------------------
35039 100 mch volume for build up nozzle pressure
35040 2 mch minimum speed (nozzle)


35054 10 mch volume stroke calibration nozzle,
j-detection
35069 20 mch volume pressure reduction carriage
35074 10 mch volume carriage without clamp force
and no sprue break
35202 50 mch val red.factor nozzle fwd.speed
10185 100 mch val red.factor noz. retract speed
INJECTION UNIT SERVICE PRESSURE

---------------------------------------------------------------------
35084 25 mch pressure for carriage (b not reached)
35085 40 mch pressure for nozzle back up (sprue
break)
35102 0 mch minimum pressure for nozzle
35121 40 mch pressure - stroke calibration nozzle
35216 100 mch val red.factor nozzle fwd.press.
37136 35 mch pressure for nozzle fwd initial
pressure to j1
INJECTION UNIT SERVICE PRESSURE

---------------------------------------------------------------------
10099 0 set nozzle contact pressure switch off value
10101 0 mch reduced noz. contact press. switch
off val.
36457 30 mch ec100s tolerance for nozzle pressure
reached
j=reached at (p5-kod56)
INJECTION UNIT SERVICE RAMP

--------------------------------------------------------------------
35137 100 mch pct10/s10 v-start nozzle fwd.
35138 50 mch pct10/mm v-braking to j1 (nozzle)
35142 50 mch pct10/mm v-braking to k (nozzle)
35157 100 mch pct10/mm10 p-at stroke end limits
35173 50 mch start acceleration velocity nozzle
forward
35174 100 mch start acceleration velocity nozzle
retract
movements
37137 50 mch pct10/mm p-braking to j1
INJECTION UNIT SERVICE MAX.RAMP

-------------------------------------------------------------------
35180 20 mch maximum acceleration/delay nozzle
movement


INJECTION UNIT SERVICE MAX.RAMP

-------------------------------------------------------------------
35185 500 mch maximum acceleration/delay nozzle
movement
INJECTION UNIT SERVICE no unit

-------------------------------------------------------------------
10102 0 mch nozzle contact pressure building
0 = over z5a time
1 = over system pressure
INJECTION UNIT SERVICE VOLTAGE

-------------------------------------------------------------------
INJECTION/HOLD.PRESSURE STROKE
-------------------------------------------------------------------
02100 0 00 01 set plasticizing stroke
02102 0 00 02 set decompression stroke after plasticizing
02103 0 01 _01 set corrected decompression stroke after
plasticizing
02104 0 00 03 set pos c3-position for hold pressure
cut-over
02106 0 00 07 set cushion "ideal value"
02107 0 00 26 set cushion minimum lenght
02108 0 00 27 set cushion miximum lenght
02109 0 11 48 set measuring flow number startposition
02110 0 11 50 set measuring flow number end-position
02111 0 00 30 set cuto-over to 2.injection speed
02124 0 00 58 set window at hydraulic press.cut-off:
hold press.
02125 0 00 59 set window at parallel cut-over
02503 01 04 set screw postition - actual
06513 05 18 set screw position at cut-over


06227 19 69 set host:c3u in 1/100 for process data
report
06229 19 70 set host:cushion in 1/100 for process
data report
02511 01 02 set cushion actual value
INJECTION/HOLD.PRESSURE no unit
--------------------------------------------------------------------
18001 0 07 85 set Increased injection pressure
16000 0 11 43 set micro-flow number set-value
16002 0 11 47 set micro-flow number-tolerance-monitoring
18017 0 10 04 set parallel cutoff
18002 0 07 91 set external trigger for cut-off
18009 0 07 97 set cut-off stoke dependent
18010 0 07 98 set cut-off time dependent
18011 0 07 92 set flow number
18012 0 07 99 set cut-off hydraulic press. dependent
18013 0 10 00 set cut-off cavity press. dependent
18014 0 10 01 set monitor cushion
18019 0 07 94 set force/pressure transducer
18080 0 03 41 set injection unit 1 on
22100 0 07 83 set kistler: pin diameter
22101 0 07 79 set kistler: force transducer sensitivity
22102 0 07 80 set kistler:force meassuring range
22103 0 07 81 set kistler:pressure transducer sensitivity
22104 0 07 82 set kistler:pressure meassuring range
06228 19 68 set host:flow number in 1/100 for process
data report
16010 05 82 set flow number
INJECTION/HOLD.PRESSURE VELOCITY
-------------------------------------------------------------------
04100 0 02 59 set 35203 1.injection speed
04500 01 15 set speed act.value during speed
calibration
04501 01 20 set maximale speed injection during
calibration


36037 51 mch mm/s injection purge speed limit
36965 13 mch mm/s purge speed unit swivelled
36923 51 mch max. purge speed plausibility
INJECTION/HOLD.PRESSURE VELOCITY
--------------------------------------------------------------------
04115 0 02 76 set 35204 intrusion speed
INJECTION/HOLD.PRESSURE PRESSURE
--------------------------------------------------------------------
06100 0 00 83 set 35212 injection boost pressure
06101 0 00 85 set 35213 1.hold pressure
06116 0 00 05 set hydraulic press.cut-off value
06117 0 00 06 set moldcavity press.cut-over value
16001 0 11 45 set micro-flow number-close-loop
correct.factor
16003 0 11 39 set micro-flow number-tolerance-cl-loop
06500 01 07 set hydraulic pressure - actual
06501 01 08 set cavity pressure display
06502 01 11 set hydraulic pressure 2
06510 05 17 set hydraulic pressure at cut-over
06511 05 16 set cavity pressure at cut-over
06512 05 15 set cavity pressure peak value holdpressure
injection boost
06515 05 19 set hydraulic pressure peak value hold
pressure
16011 05 83 set positiv correction dimension for
flow number calc.
16012 05 84 set negativ correction dimension for
flow number cals.
38180 62 80 set melt pressure actual value
INJECTION/HOLD.PRESSURE TIME
---------------------------------------------------------------------
08100 0 02 91 set injection boost time
08101 0 02 92 set hold press.time


10073 0 08 16 set hold press. time portion 10/10
08103 0 03 02 set intrusion time
08106 0 03 26 set injection time min
08107 0 03 27 set injection time max
08502 01 23 set injection time
08505 01 27 set cooling time actual
MICROTEMP TIME
--------------------------------------------------------------------
35439 0 mch micro-temp:delay for cl-loop control
all zones
35440 6000 mch micro-temp:temperaturee rise monitoring
35453 5 mch micro-temp:flow-through varification
delay
35454 100 mch micro-temp:timebase for close-loop
speed
35458 100 mch micro-temp:delay monitoring of
preliminary temp after flow-through
MICROTEMP TEMPERATURE
---------------------------------------------------------------------
35441 20 mch micro-temp:start calib fwd setvalue
35442 30 mch micro-temp:maximum positive
temperatureee deviation
35443 30 mch micro-temp:maximum negative
temperatureee deviation
35456 20 mch micro-temp:minimum temperaturee
alteration for calibrating
MICROTEMP no unit
----------------------------------------------------------------------
35444 3 mch micro-temp:maximum cycle with
deviation after calib.
35445 100 mch micro-temp:calibration correction
factor zone 1
factor zone 2


factor zone 3
factor zone 4
factor zone 5
factor zone 6
factor zone 7
factor zone 8
35455 54 mch micro-temp:maximum flow-through speed
35457 10 mch micro-temp:number of calibration cycle
MOLD CLOSING STROKE

-------------------------------------------------------------------
02000 0 00 _00 set pos a-mold open
02002 0 00 21 set pos a2-command air blow 1
02004 0 00 17 set pos w1-start 3.closing speed
02006 0 00 19 set pos w3-start 2.closing speed
02008 0 00 08 set pos g1-mold protection begin
02009 0 00 25 set pos g2-mold protection end schirmwert
04591 0 03 67 set beg. 2. mold prot. pressure
02500 01 03 set mold position - actual
02504 01 10 set die high position absolute
02505 01 13 set toggle position - actual
02510 01 18 set mold opening stroke stored
06008 0 52 48 set mold protection position step 2
MOLD CLOSING VELOCITY

----------------------------------------------------------------------
04000 0 02 40 set 35200 1.closing speed
06012 0 52 _52 set 35200 mold protection speed step 1
06013 0 52 53 set 35200 mold protection speed step 2


MOLD CLOSING PRESSURE
---------------------------------------------------------------------
06001 0 00 77 set 35211 mold protection press. starting value
06002 0 00 79 set 35211 mold protection press.end value
06003 0 52 43 set 35211 mold protection pressure step 1
MOLD CLOSING TIME

----------------------------------------------------------------------
08002 0 03 _03 set air blow delay time 1
08003 0 03 04 set air blow delay time 2
08004 0 02 97 set air blow time 1
08006 0 02 99 set mold protection time
08500 01 22 set mold protection time
MOLD CLOSING COUNTER

---------------------------------------------------------------------
10001 0 03 57 set mold protection counter
MOLD CLOSING no unit

---------------------------------------------------------------------
18006 0 07 95 set function air valve 1
04543 0 07 70 set stop mold after mold protection fault
01982 0 03 73 set opening at c2* injection 1
09632 0 01 55 set prog.selector for 2nd mold prot.press.
06503 01 14 set clamp pressure for <= es50
MOLD CLOSING VELOCITY

---------------------------------------------------------------------
04502 01 16 set mold closing speed
MOLD CLOSING SERVICE TIME

---------------------------------------------------------------------
11915 15 mch mechanical interlock:
when=0 - not monitored
when>1 - monitored + alarm delay time
35259 20 mch measuring time for mold not
moving during auto mold
height adjustment (without
mold height transducer)


35264 10 mch time to determine mold height
mot.stopped during auto mold
height set-up
(without mold height transd.)
35266 15 mch monitoring time for hydraulic safety be8
35272 2 mch soft mold stop in manual
35276 40 mch press buildup time fully hyd. without
press transducer.
/ monitor time pressure buildup with
press transducer.
35281 3 mch del.between core/mold movem.
35286 0 mch drop of delay from s12a
35294 10 mch additional press.build-up time
for start of cycle full-hydraulic
without transducer.
35295 20 mch recharge time fully hydraulic
in manual mode
35296 0 mch recharge time calculated...
35961 20 mch recharge time fully hyd.m/e with
press transducer
06550 2 mch mold stand-still monit.time ab g2
08481 10 mch delay between spooling valve and
analog output
during closing
08516 0 mch delay between s1.2 and high pressure
output.
10774 20 mch drop off delay between s1 and s1.2
for ehv1, hls1
11918 30 mch delay of mechanical intrlk. in
11920 20 mch counter press. release time
vertical hydr. clamp
37026 10 mch mold opening standstill monitoring
time rc100
MOLD CLOSING SERVICE STROKE

---------------------------------------------------------------------
35000 6000 mch max. mold open stroke die
35001 6000 mch max. mold open stroke toggle
stop-position
35012 3 mch max. mold movement during standstill
detection
35018 100 mch reset s2.1 during mold closing
35019 1000 mch measurment stop speed calibration
mold close
meas.start speed cal.mold open toggle


35022 20 mch storke position monitoring at sfx
standstill
35024 50 mch start clamp force measuring
06551 5 mch position minimum speed before g2
10308 0 mch closing stroke with reduced start
pressure
10423 0 mch calc. closing pos.to end red. start
press.
10424 0 mch calc. closing pos.to start red.
start press.
MOLD CLOSING SERVICE VOLTAGE

---------------------------------------------------------------------
35005 60 mch [ar: mv/ e8: bit]
0-minimum position monitoring
at full hydraulic machines
(how far the 0-point is allowed to be
over runned in setup )
MOLD CLOSING SERVICE VELOCITY

--------------------------------------------------------------------
35041 10 mch speed mold close during setup
35043 100 mch speed for lockup (toggle)
speed on g2 (for full hydraulic machines)
35049 8 mch volume for stroke calibration mold
closing with -y1/proportional valve
35052 100 mch volume highpressure build up
35060 2 mch minimum speed mold close
35065 100 mch volume on y1 for highpressure
build up with propportional valve
35068 15 mch mimum volume mold closing on b position
35076 0 mch volume before mold closing
35200 100 mch val red.factor closing speed
11919 60 mch speed to yc during clamp closing
MOLD CLOSING SERVICE VELOCITY

---------------------------------------------------------------------
35062 1100 mch maximum close speed
MOLD CLOSING SERVICE PRESSURE

---------------------------------------------------------------------
35086 40 mch pressure for mold close - in setup mode


35087 80 mch pressure for mold close during speed
claibration
35096 0 mch minimum pressure for clamp close
35104 40 mch pressure - stroke calibration mold close
35106 100 mch mold close pressure to bg1 und mold
close speed calibration
35125 0 mch pressure before mold closing
10307 50 mch reduced start pressure for closing
10422 0 mch calculated val. reduced start pressure
35210 100 mch val red.factor clamping pressure
35211 100 mch val red.factor mold prot.press.
MOLD CLOSING SERVICE RAMP

----------------------------------------------------------------------
35131 11 mch pct10/mm v-after w3 (closing)
35132 100 mch pct10/s10 v-after g2 (closing)
35133 6 mch pct10/mm v-braking to ks
35139 10 mch pct10/mm v-braking to w1 (clos.)
35145 4 mch pct10/s10 vp-mold brak.in manual
35146 100 mch pct10/mm p-mold braking to ks
35147 20 mch pct10/s10 v-mold prot. steps
35148 100 mch pct10/mm10 p- mold prot. steps
35155 10 mch pct10/mm10 v-brak.to b(mold clos.)
35156 100 mch pct10/mm10 p-ramp mold prot.press.
p2 to clamp.press.p1 at
pos.g2 (mold closing)
35159 20 mch pct10/mm v-at b8 during closing
35171 70 mch start acceleration velocity mold closing
movements
MOLD CLOSING SERVICE MAX.RAMP

---------------------------------------------------------------------
35179 3 mch maximum acceleration/delay mold
movements
09319 6 mch max.accel./delay mold movement at
y-pump for ehv1 with 0-10v prop
MOLD CLOSING SERVICE MAX.RAMP

---------------------------------------------------------------------
35184 1000 mch maximum start acceleration mold
movements


MOLD CLOSING SERVICE COUNTER
---------------------------------------------------------------------
35304 0 mch intitial closing build-up press.-
cycle counter set-value
MOLD CLOSING SERVICE no unit

---------------------------------------------------------------------
35465 0 mch proportional valve clamp end = 1
cyclinder= 1
press.transducer:
35489 1 mch mold stop after mold protect.alarm = 1
35491 0 mch differential switching s12a:
0=with closing
1=with opening
35953 0 mch 1 = proportional valve clamp end
(0v-10v)
36132 1 mch 1=s1 on during clamp high press.
MOLD CLOSING SERVICE PRESSURE

---------------------------------------------------------------------
06039 100 52 87 mch clamp closing counter pressure
MOLD HEIGHT STROKE

---------------------------------------------------------------------
02400 0 00 57 set pos mold height set-value
06009 0 00 55 set pos mold height act-value calculated
minimum mold height and determined offset
35008 200 mch mold opening stroke for automatic
die - high adjustment program
(without die-high transducer)
35013 4610 mch max. mold hight
35014 0 mch min. mold hight
35015 4610 mch calculated value, reserved
35016 0 mch mold height minimum mechanical stop,
reserved
35017 4610 mch mold height maximum mechanical stop,
reserved
35021 20 mch die height stroke tolerance for
clamp force check


MOLD HEIGHT no unit

---------------------------------------------------------------------
18004 0 07 87 set automatic die height
35467 1 mch stroke transducer - auto nozzle
height = 1
MOLD HEIGHT VOLTAGE

---------------------------------------------------------------------
MOLD OPENING STROKE

---------------------------------------------------------------------
02000 0 00 _00 set pos a-mold open
02005 0 00 18 set pos w2-start 3.opening speed
02007 0 00 20 set pos w4-start 2.opening speed
05212 0 08 02 set start differencial switching with
beim oeffnen
02454 0 00 60 set minimum opening stroke handling
01472 0 00 61 set clamp position for robot moving in
MOLD OPENING VELOCITY

---------------------------------------------------------------------
MOLD OPENING TIME

---------------------------------------------------------------------
08002 0 03 _03 set air blow delay time 1
08003 0 03 04 set air blow delay time 2
MOLD OPENING no unit

--------------------------------------------------------------------
19036 0 08 _08 set increased mold open force


MOLD OPENING SERVICE STROKE
---------------------------------------------------------------------
35000 6000 mch max. mold open stroke die
35001 6000 mch max. mold open stroke toggle
35008 200 mch mold opening stroke for automatic
die - high adjustment program
(without die-high transducer)
stop-position
35019 1000 mch measurment stop speed calibration
mold close
meas.start speed cal.mold open toggle
35020 1000 mch input limitation minimum opening
stoke robot
35022 20 mch storke position monitoring at sfx
standstill
06552 5 mch position minimum speed before a
MOLD OPENING SERVICE VELOCITY

-------------------------------------------------------------------
35036 2 mch minimum speed (open)
35042 10 mch speed mold open during setup
35053 3 mch volume stroke calibration mold open
-y1/proportional valve
35066 40 mch volume for open suction valves
35067 15 mch volume for mold open with
mold unsecure
35072 20 mch 1. mold open speed on stop position b8
35077 0 mch volume before mold opening
35201 100 mch val red.factor opening speed
MOLD OPENING SERVICE VELOCITY

--------------------------------------------------------------------
35064 1000 mch maximum mold open speed
MOLD OPENING SERVICE PRESSURE

--------------------------------------------------------------------
35081 100 mch pressure for mold open
35082 40 mch pressure for mold open - in setup mode
35088 100 mch counter pressure for 1. mold open speed
35097 0 mch minimum pressure for clamp opening
35114 30 mch pressure for open suction valves
35126 0 mch pressure before mold opening
MOLD OPENING SERVICE RAMP

--------------------------------------------------------------------


35135 15 mch pct10/mm v-after w4 (opening)
35136 10 mch pct10/s10 v-braking to koe
35140 13 mch pct10/mm v-braking to w2 (clos.)
35143 15 mch pct10/mm v-braking to a (open.)
35144 100 mch pct10/mm p-braking to a
35145 4 mch pct10/s10 vp-mold brak.in manual
35160 20 mch pct10/mm v-at b8 during opening
35162 100 mch pct10/mm p-mold braking to koe
35172 80 mch start acceleration velocity mold opening
movements
MOLD OPENING SERVICE MAX.RAMP

--------------------------------------------------------------------
35179 3 mch maximum acceleration/delay mold
movements
MOLD OPENING SERVICE MAX.RAMP

---------------------------------------------------------------------
35184 1000 mch maximum start acceleration mold
movements
MOLD OPENING SERVICE TIME

---------------------------------------------------------------------
35272 2 mch soft mold stop in manual
35273 10 mch time to open suction valves (fully hyd)
35274 70 mch time to release clamp high press.
(fully hydraulic)
35275 0 mch y & k =0 after release clamp press.
(fully hydraulic machines)
35286 0 mch drop of delay from s12a
MOLD OPENING SERVICE no unit

---------------------------------------------------------------------
0=with closing
1=with opening
35492 0 mch prop-valve ng16 with a valve
(s1 with mold opening ) = 1


(0v-10v)
MOLD OPENING SERVICE VOLTAGE

---------------------------------------------------------------------
PLAST./BACK PRESS./DECOMPRES. STROKE

---------------------------------------------------------------------
02100 0 00 01 set plasticizing stroke
02101 0 01 00 set corrected plasticizing stroke
02102 0 00 02 set decompression stroke after plasticizing
02103 0 01 _01 set corrected decompression stroke after
plasticizing
02105 0 00 04 set pos c4-decompression 1 end
02106 0 00 07 set cushion "ideal value"
02107 0 00 26 set cushion minimum length
02108 0 00 27 set cushion maximum length
02120 0 00 42 set cut over to 2.screw feed speed
09719 03 68 set feeding stroke stored
PLAST./BACK PRESS./DECOMPRES. VELOCITY

---------------------------------------------------------------------
04110 0 02 75 set 35204 1.screw speed
04111 0 02 87 set 35204 2.screw speed
04112 0 02 88 set 35204 3.screw speed
04113 0 02 89 set 35204 4.screw speed
04114 0 02 90 set 35204 5.screw speed
04116 0 02 77 set 35205 screw decompression speed
PLAST./BACK PRESS./DECOMPRES. PRESSURE

----------------------------------------------------------------------
06111 0 02 _02 set ko100 1.back pressure
06112 0 02 03 set ko100 2.back pressure
06516 05 20 set back pressure peak value


PLAST./BACK PRESS./DECOMPRES. TIME

---------------------------------------------------------------------
08102 0 02 93 set plasticzing delay time
08104 0 03 24 set maximum plasticzing time
08105 0 03 25 set minimum plasticzing time
08501 01 21 set screw feed time
PLAST./BACK PRESS./DECOMPRES. no unit

---------------------------------------------------------------------
18015 0 10 02 set monitor screw feed time
01982 0 03 73 set opening at c2* injection 1
PLAST./BACK PRESS./DECOMPRES. ROTATION

--------------------------------------------------------------------
10100 01 12 set screw rpms display
PLAST./DECOMPRES.SERVICE STROKE
---------------------------------------------------------------------
35002 2000 mch max.stoke screw
35006 250 mch maximum cushion and correction
PLAST./DECOMPRES.SERVICE VELOCITY
---------------------------------------------------------------------
35037 0 mch minimum speed (screw feed)
35056 20 mch volume stroke calibration screw
35057 100 mch volume for back pressure calibration
35079 1 mch minimum speed decompression
35204 100 mch val red.factor screw refill speed
35205 30 mch val red.factor decompression
PLAST./DECOMPRES.SERVICE PRESSURE
--------------------------------------------------------------------
35100 400 mch input limit for back pressure
PLAST./DECOMPRES.SERVICE PRESSURE
--------------------------------------------------------------------
35101 100 mch maximum pressure during screw feed
35103 100 mch pressure - suck back
35122 25 mch pressure - stroke calibration screw
PLAST./DECOMPRES.SERVICE RAMP
---------------------------------------------------------------------
35141 100 mch pct10/mm v-braking to c1
35161 100 mch pct10/mm p-braking to c1
35167 100 mch v-speed braking at c2,c4


35168 100 mch v-speed start decompression
35176 100 mch start acceleration velocity screw feed
movements
PLAST./DECOMPRES.SERVICE MAX.RAMP
--------------------------------------------------------------------
feeding
35188 50 mch max.acceleration/delay decompression
release movements
PLAST./DECOMPRES.SERVICE MAX.RAMP
--------------------------------------------------------------------
feeding
35189 1000 mch max.acceleration decompression
release movements
PLAST./DECOMPRES.SERVICE VOLTAGE
-------------------------------------------------------------------
35226 10000 mch back press.control umax
35227 0 mch back press.control umin
10362 2000 mch back press.control ustart
PLAST./DECOMPRES.SERVICE TIME
---------------------------------------------------------------------
35228 0 mch back press.control tv
35229 120 mch back press.control tn
35250 0 mch calculated value!! time active back
pressure
35263 1 mch delay for back press. peak meas.value
35287 20 mch delay between screw feed and
decompression.
35297 6 mch s100 hls- delay time:
screw feed: s4 pull delay to s3 on
and: s3 drop delay to s4 off
10775 10 mch delay after decompression
PLAST./DECOMPRES.SERVICE no unit
---------------------------------------------------------------------
35230 250 mch back press.control kr
35231 0 mch back press.control ks
09357 0 mch leakage oil compensation factor


for screw turning
35249 0 mch 1 = preset back pressure between
injection hold and feeding
35317 1 mch impulse per screw rotation
09628 0 mch back press. valve ehv2/3 open loop
inj.unit 1:
0 .. press. proportional valve
1 .. flow control valve
PLAST./DECOMPRES.SERVICE ROTATION
---------------------------------------------------------------------
35315 6 mch minimum screw rpm
35316 480 mch maximum screw rpm
PROG./CONFIG.SWITCHES SERVICE no unit

---------------------------------------------------------------------
09358 0 mch hbg-ht2 on/off
09359 1 mch hbg-key click on/off
09384 1 mch 1=fully automatic mode disabled
09388 0 mch ejector/core with fixed pump
09390 0 mch 2 cycle start buttons
09391 0 mch ejector safety switches: 1/2/3 or 4
09693 1 mch corepull with mold mounting released
35464 0 mch machine size:
0 = full-hydraulic es25hl-es350hl
1 = full-hydraulic hls1
2 = full-hydraulic ehv1
5 = toggle es65-100
6 = toggle es100-350
35466 0 mch proportional valve ejector = 1
35467 1 mch stroke transducer - auto nozzle
height = 1
cylinder= 1
35469 0 mch number of core-pulls (0 - 3)
35470 0 mch robot connected = 1
35471 0 mch coupling rc100 = 1


35473 3 mch output ha: 0 = out
1 = semi-automatic
2 = full-automatic
3 = automatic
35475 0 mch quick mold change: 0=deactive
1=single monitoring
2=double monitoring
35477 1 mch output fs: 0=steady
1=flashing
35478 1 mch air valve 2 mounted yes/no
35480 0 mch sk-offs-error stopped cycle = 1
35481 1 mch control type: 0=ec88/ec100
1=cc100
35482 0 mch parallel cut-over = 1
35483 1 mch servo-valve type: 0=Bosch
1=moog
35484 1 mch deactivation after injection
for quick press.release = 1
press.transducer:
35486 0 mch light beam guard: 0=trigger 0/1
1=trigger 1/0
35487 1 mch enable ar161 start
35488 0 mch normalized out-put vssx,ssx,phx = 1
35489 1 mch mold stop after mold protect.alarm = 1
35490 0 mch oil filter unit monitoring = 1
0=with closing
1=with opening
35492 0 mch prop-valve ng16 with a valve
(s1 with mold opening ) = 1
35493 0 mch recept. / cooling water deactivation
35494 0 mch device deactivation output dodv1
35495 0 mch device deactivation output dodv2
0 only with weekly schedule
1 weekly schedule and also with motor stop
10102 0 mch nozzle contact pressure building
0 = over z5a time
1 = over system pressure
35973 0 mch 1=operation with 2 ehv-pumps
35990 0 mch plasticzing with 2 pumps
35991 0 mch injection with 2 pumps
35992 0 mch clamp end with 2 pumps


35952 0 mch mode-word (switch for offset
2.inj.process)
(0v-10v)
35954 0 mch 1 = differential switching
(s4d monitoring)
35956 0 mch 1 = close-loop parameter unit 1
activated
35958 0 mch 1 = back press.valve monitoring unit 1
35960 0 mch 1 = clamp force-correction switched on
08517 0 mch 1 = continuous piston rod with
ehv1 unit 1
36912 0 34 01 mch tr electronic table angle encoder
on/off
36466 1 mch default units for host
communications:
0 = metric units
1 = imperial units
37100 0 mch raise purge slide when clamp at g2
36277 0 mch default units:
0 = A key switches units
1 = machine is metric only
2 = machine is in imperial only
36278 0 mch access level restricted unit change:
0 = no access level required for
unit change.
1 = access level 1 required for unit
change.
change.
change.
PROG./CONFIG.SWITCHES SERVICE TIME

--------------------------------------------------------------------
09360 7 mch beep time hbg
PROGRAM/CONFIGURATION SWITCHES no unit

---------------------------------------------------------------------
01084 1 15 09 set release moving platen with mold open
04543 0 07 70 set stop mold after mold protection fault
03301 0 07 71 set oil filtration on/off
QUICKSETUP PRESSURE
---------------------------------------------------------------------
35567 40 mch quick-setup maximum back pressure


35578 160 mch quick-setup maximum injection pressure
QUICKSETUP STROKE
---------------------------------------------------------------------
35568 40 mch quick-setup g2 -value when sk= 0
- 9 pct
- 19 pct
- 29 pct
- 39 pct
- 49 pct
- 59 pct
- 69 pct
- 79 pct
- 89 pct
- 99 pct
35579 1500 mch quick-setup minimum mold height with
fully hydraulic machines
QUICKSETUP TEMPERATURE
---------------------------------------------------------------------
35580 200 mch quick-setup minimum oil temperature
35581 400 mch quick-setup oil temperature set-value
ROTARY TABLE TIME

---------------------------------------------------------------------
09381 3 mch delay for nozzle forward & auto
eject.program end
04906 0 08 38 set monitoring time table without
transducer index CCW
04907 0 08 39 set monitoring time table without
transducer index CW
09396 5 mch delay after 0-output for rotary table
04902 0 02 64 set rotary table braked start left time
04903 0 02 66 set rotary table braked start right time
04904 0 08 36 set rotary table bounce duration left
04905 0 08 37 set rotary table bounce duration right
35939 3 mch time table soft stop


08070 2 mch table motion delay after unlocking/
lowering
08071 2 mch locking pin forward delay after
table rotation
50004 2 34 06 set delay table movement after table
brake released/press.line enabled
50005 2 34 07 set delay table brake secure after table
locked/delay press.
line interruption after table rotation
complete
50007 0 34 09 set table rotation shut down delay in
set-up
11937 1 mch table delay between lift-> turn
11942 2 mch analog shut down delay after table
lowering input
ROTARY TABLE ANGLE

--------------------------------------------------------------------
02616 0 00 62 set stroke rotary table braking
10252 3150 set end position for 0-crossing output CCW
10253 450 set end position for 0-crossing output CW
04708 01 88 set rotary table position actual value
degree
10250 set actual table position to move in
locking cylinder
35914 50 mch break stroke table / index plate
tolerance for table end positions
35915 1800 mch angle degree maximum degree table
08061 600 mch table position 1 with 2 stations
08072 5000 mch virtual table position for motion
profile
13027 150 mch angle distance from table stop
positions to move
pneumatic mech.stop cylinder in
10213 150 mch actual table angle to move in
pneu.mech.stop cylinder
10200 0 mch (brake pos. 1 left for profil.def)
10203 0 mch (brake pos. 1 right for profil.def)


60008 100 34 10 mch angle from end pos.for slow movement
60010 100 34 12 mch pos.hysteresis for table pos.1 from
below (CW)
60011 150 34 13 mch neg.hysteresis for table pos.1 from
below (CW)
below (CW)
below (CW)
below (CW)
below (CW)
above (CCW)
above (CCW)
above (CCW)
above (CCW)
above (CCW)
above (CCW)
ROTARY TABLE no unit

---------------------------------------------------------------------
08089 1 mch rotary table with prop.valve = 1
51038 1 mch rotary table icon
05101 0 02 37 set 35208 speed table turning left
05103 0 02 39 set 35208 speed table turning right
18082 0 03 43 set rotary table program on/off
18098 3 50 54 set rotary table number of stations
04557 1 50 53 set rotary table function
0 ... left rotation
1 ... right rotation
2 ... oscillation (only bei 2 station.)
05040 1 12 89 mch table lift parallel to opening
18083 0 03 44 set brake limit switch left yes/no
18084 0 03 45 set brake limit switch right yes/no
18087 0 03 47 set table mounted on ejector
02655 0 03 48 set activate table during mold closing
04791 0 03 46 set rotary table before / after ejection
10251 0 set current table station
35912 1 mch table with transducer = 1


35913 0 mch kind of turn table:
0 = rotary table
1 = index plate
04545 0 03 55 nonum rotary / index table power source
from corepull
35928 50 mch [percent / degree] speed maximum
ramp table
35934 0 mch input calibration done
35937 1 mch conf.sign input calibration
35940 0 mch value rotary table / index plate
standard input jumpered (left stop
position b39)
if table / index plate not used
0 ... hardware wise
1 ... software wise
software wise only, if not dummy
plug for standard
inputs / outputs provided if table
/ indexing off and
standard i/o used the signal will
be jumpered by
08090 1 mch pushbutton execution
0 ... 1 pushbutton for both directions
1 ... 2 pushbuttons (left / right)
11769 1 mch 0 ... without table locking pin
1 ... with table locking pin
21755 0 mch 1 = pneumatic locking and mechanical
stop cylinders
11770 0 mch 0 ... without table mechanical stop
1 ... with fixed mechanical stop
(left/right)
2 ... with mech.stop (for turning
left, table w/ trans.)
3 ... with mech.stop (for turning
right, table w/ trans.)
4 ... with mech.stop (for 2 station
right/left oscillation)
37075 1 mch 1 = multiple mechanical stop cylinders
wenn im rotary table for den 2 and
3-station operation
alle anschlagzylinder vorbereitet
and montiert sind
wirkt der winkel drehtischanschlag
einfahren forward
der anzusteuernden drehtischstation !
37101 1 mch 1 = pendelbetrieb durch nulldurchgang


wenn pendelbetrieb nur durch
nulldurchgang possible ist
pos1 entspricht in diesem fall dem rechten
drehtischanschlag, pos.2 dem linken
anschlag
0 = oscillation motion between
stations does not cross
the 0/360 point
1 = oscillation motion between
stations passes through
the 0/360 point
10206 0 mch (profile step for table position 1
on/off)
on/off)
on/off)
06023 1 52 62 set table position 1 on
50000 1 mch 0 = pull the shot pin std.
1 = pull the shot pin after hold
50001 0 34 03 mch rotary table with in position limit
switch bdtl
50002 0 34 04 set previous turning direction of table
0 = ccw 1 = cw
50003 1 34 05 mch table brake selection
0 = not mounted
1 = table brake SDTB installed
2 = pressure line interrupter SCC
installed
50006 0 34 08 set table position bypass switch
50008 0 set run table without locking pin (with
all locking safeties)
50009 0 set on/off cycle time saving mode for
3 station with 2
stations turned off (ejector station
also used as
insert station)
60036 0 34 24 mch angle encoder auto reset at position
1 on/off
ROTARY TABLE VELOCITY

---------------------------------------------------------------------
08041 80 mch 35208 output on yc-valve during table turning


05100 0 02 36 set 35208 speed table turning left from braking
pos.
05102 0 02 38 set 35208 speed table turning right from
braking pos.
35923 5 mch minimum speed indexing
35924 10 mch speed - rotary table in calib./set-up
35208 100 mch reduction factor table speed
08073 10 mch speed bolt in/out on rotary table
06038 0 52 77 set table lift speed
11946 50 mch table lower speed
ROTARY TABLE ANGLE

---------------------------------------------------------------------
08042 12 93 set actual table speed
08043 200 mch maximum speed table prop.valve
ROTARY TABLE RAMP

---------------------------------------------------------------------
09365 100 mch velocity ramp for table rotation
start through 0-crossing
35925 50 mch pressure braking table to stop
35926 50 mch speed braking table to stop
v-ramp braking station #1
35927 50 mch ramp: v-indexing soft stop
35929 100 mch start acceleration speed volume table
35930 100 mch start acceleration speed pressure table
08854 50 mch v-ramp braking station #2
08855 50 mch v-ramp braking station #3
ROTARY TABLE PRESSURE

---------------------------------------------------------------------
04801 0 00 92 set 35209 rotary table turning left braking
04802 0 00 94 set 35209 rotary table turning left braking
04803 0 00 96 set 35209 rotary table turning right braking
04804 0 00 98 set 35209 rotary table turning right braking
35919 100 mch table left / right turning pressure
35920 100 mch table braking pressure left / right
35921 3 mch minimum press. indexing
35922 10 mch press.- indexing in calib./set-up
35209 100 mch reduction factor table pressure
08074 50 mch pressure bolt in/out on rotary table
06030 0 52 69 set table lift pressure
11947 100 mch table lower pressure
ROTARY TABLE STROKE

---------------------------------------------------------------------


35917 30 mch l-limit when using rotary table
35918 800 mch l1 minimum limit, if index plate
mounted on ejector
60006 500 03 44 set clamp position for parallel table
lifting
ROTARY TABLE MAX.RAMP

---------------------------------------------------------------------
35931 10000 mch start acceleration speed maximum table
35932 100 mch speed start acceleration with out
transducer
35933 100 mch percent degree speed ramp braking
without transducer
08059 1000 mch start acceleration speed table 0-
crossing
08060 1000 mch start acceleration pressure table
0-crossing
ROTARY TABLE VOLTAGE

---------------------------------------------------------------------
35935 0 mch null value rotary table input
calibration
35936 10000 mch maximum value rotary table input
calibration
SAFETY GUARD TIME

---------------------------------------------------------------------
33005 0 03 21 set safety gate delayed opening
35254 10 mch e1/e2 lim.switch monitor.time
35280 5 mch powered safety gate soft start
time
35288 0 mch braking time electric.saf.gate after
reaching
braking switches during opening.
35289 2 mch starttime electric safety gate slowly
opening
35290 2 mch starttime electric safety gate slowly
closing
35968 3 mch brake time pneumatic safety gate
(bef. reverse direction)
35988 3 mch reverse direct time pneu.safety gate
(secruity ledge)
35989 20 mch opening time pneumatic safety gate
SAFETY GUARD no unit

---------------------------------------------------------------------


18005 0 07 88 set automatic safty gate
06476 0 15 00 set safety gate 1 (closing range) open
before
table indexing, and again after closing
35472 0 mch safety gate: 0 = manual
1 = pneum
2 = electric
35474 0 mch cycle start by:
0=safety gate closing
1=single start button pressed once
2=single start button pressed twice
3=2 start buttons with non-tiedown
SERIAL INTERFACE no unit

---------------------------------------------------------------------
35593 3 mch baudrate printer
35594 3 mch baudrate keyboard
35595 8 mch baudrate host
35596 7 mch baudrate temp.unit
35597 10 mch baudrate pc-host
35598 8 mch baudrate reserve
no groups no unit
--------------------------------------------------------------------
00000 "Werk 13 40 set ac_20 mold number
00002 "Mate 13 42 set ac_20 material number nummer
00003 "Masc 13 43 set ac_20 machine number
00005 "Auft 13 45 set ac_20 order number
35500 0 mch configuration reserved !!
35508 " mch ac_60b down-time reason


35995 0 mch val 0 or 10000 (see pginit)
35996 0 mch switch calibration speed algoritim
35997 5 mch switch rpm numbercalibration algoritim
35998 0 mch switch dialog speed calibration
35999 0 mch switch dialog rpm calibierung
03000 06 49 set plasticizing stroke
03001 06 51 set decomp. stroke after plasticizing
03002 01 86 set corr.decomp.str. -"-
03003 06 53 set pos c3-dep.boost cut off
03004 06 55 set window hydr. dep. boost cut-off
03005 06 57 set window by parallel switchover
03006 06 59 set pos c4-komplentl1 ende
03007 06 61 set cushion set value
03008 06 63 set cushion min.length
03009 06 65 set cushion max.length
03010 06 67 set switchover to 2.plast speed
03023 06 97 set 1.injection speed
03027 07 _07 set 5.injection speed
03033 07 19 set 1.screw speed


03038 07 29 set hydraulic pressure switchover
03039 07 31 set injection pressure
03040 07 33 set 1.injection hold pressure
03050 07 53 set 1.back pressure
03100 01 92 set screw rotaton turning value
03101 01 94 set injection flow value
03102 01 96 set specific injection pressure
03103 01 98 set stroke volume value
03104 05 00 set specific back pressure value
03105 05 02 set specific hold press. value
03106 05 04 set specific plasticizing value
03107 05 06 set cut-over volume
03108 05 08 set cut-over pressure
03109 05 10 set injection boost
03110 05 12 set cushion value
37022 mch 1= additional linefeed
38850 mch perforations jump textprinter
38859 mch file format floppy
38860 mch file format ramdisk
38861 mch file format host drive 1
38862 mch file format host drive 2

REVISION LIST
DATE NATURE OF REVISION ORIGINAL REVISED

PAGE PAGE
14/11/05 Up-date and reissue in Framemaker format
23/12/05 403
404 23/12/05

ES30-500 CM EV901 Vertical 6750-772-9998M

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ES30-500 CM EV901 Vertical 6750-772-9998M

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EC100 / CC100 A03

© 2005 Copyright by ENGEL CANADA INC.

This manual is Part 2 of a 2 part manual.

Part 1 is the Operator Manual.

Some procedures described in this manual, ie. a change in set values,

Central- Ext. Temp.

BAR CODE READER

23/12/05 1. SYSTEM ARCHITECTURE 1

2 1. SYSTEM ARCHITECTURE 23/12/05

ANALOG TO DIGITAL CONVERSION

23/12/05 1. SYSTEM ARCHITECTURE 3

4 1. SYSTEM ARCHITECTURE 23/12/05

This unit contains Electro-static Sensitive Devices, use

K-FTC-AN/A Floppy drive FD353

Magnetic card reader MR122

23/12/05 1. SYSTEM ARCHITECTURE 5

Magnetic card reader MR122

MF102 PC Keyboard Keyswitch

6 1. SYSTEM ARCHITECTURE 23/12/05

When removing electronic cards from the rack, follow the

1.4 TROUBLESHOOTING NOTE

Digin - Digital Input Card

Digout - Digital Output Card

PS242 Power Supply Cards

Temperature Control Card

23/12/05 1. SYSTEM ARCHITECTURE 7

8 1. SYSTEM ARCHITECTURE 23/12/05

1 ELECTRO - STATIC SENSITIVE DEVICES (ESD)

Treat all electronic cards as if they contain electrostatic

SAFE HANDLING PROCEDURE.

If the following precautions are not adhered to, the card

When replacing a card in the rack:

2 SURVEY OF EPROMS - CC100

Card type Card number Switch position

4 CPU CARD CU211

Synchronization Sequence Component Error Number

Bat Bat Bat Bat Bat Bat Bat

Status Status Status Status Status Status Status

Example: Component 1234 c0 = 4; c1 = 3; c2 = 2; c3 = 1

Error Number 5678 e0 = 8; e1 = 7; e2 = 6; e3 = 5

The Component and Error numbers are displayed in

The binary number must to be converted to a decimal First LED = 1

INTERFACE EXTENSION BUS INTERFACE S1 FOR

BATTERY INTERFACE EXTENSION BUS (IEB1)

SPECIAL NOTES REGARDING CPU CARD :

Error Status LED Off = System OK

Storage-position,bat- Battery buffer con-

ELECTRO - STATIC SENSITIVE DEVICES (ESD)

Treat all electronic cards as if they contain electrostatic

To prevent damage to electronic equipment during

Press in and lift the cover

Ensure that the battery is properly connected.

3. Change jumper J1 to ‘b’ - ‘c’.

Status LEDs: L and A:

Storage-position, battery not installed Battery buffer connected.

To replace the battery, following the instruction for the CU211

5 LOADING THE SOFTWARE

This must be done manually as follows:

TO DELETE FILES FROM THE RAMDISK

3. Press F1 “Working Device”

4. Press F2 to select the RAMDISK as the working device.

7. Press F6 “Execute” to confirm the delete function.

Steps to read-in EBIAS software: