G6 Book

Exit
- LL GGDIGIT
I-
-,
2 APPLICATION
(Doc/901)@m)(-)
INTRODUCTIOJ
ine present
c.
document is a part of the technical manuai joined to our
machines. This manual is composed of the following -\-oiumes :
- 1 - SET-UP
2 - OPERATION
3 - MAINTENANCE
1- FLOW CHART
- - OPTIONS
z - ELECTRIC DIAGRAM
Each chapter contains information ena'oiing you to linJx :.-our mscnine

oe%ter which guarantees its best producri\pitp and a lcnq ilfetime.
7-h
I _.-1 c:;>erators sazetp instructions as well as main:-na2c2 2Q:-izii Lcr
tl-.e safety devices can be found in each of the above ,mentioLeo
:-oiumes according to their particular application.
3ur technical and commercial departments are, of course, at :.-our

entire disposal for any complementary information.
The features stipulated in this document are not contractual and we

reserve'the right to carry out any technical modificati,Qn necessary
+- improve our product.
It is strictly prohibited to remit these documents to a person not

belonging to your staff or to copy them without our approval.
VOL2CHO REP G6 Ei DIGIT I

I VOLUME 2 - OPERATION
/I
CONTENTS
I- INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l-l
_- II - OPERATOR'S SAFETY ......................... 2-l
III - OPERXTION : ............................... 3-l
3-1 - Cycle diaqramme ..................... 3-2
3-2 - Hydraulics .......................... 3-i
3-3 - Electrics ........................... 3-19
3-4 - Process control ..................... 3-23
3-5 - Temperature control ................. 3-46
IV - PRESENT.4TIONOF THE CONTROL OR&US . . . . . . . . 4-l

[I - PRESENTXTION OF THE MOLDING PARAMETERS. . . . 3-l
k-1 - SELECTION OF CYCLE AND PRESS FUNCTIONS . . . . 6-1
\--I1 - PRESS OPERATION .,.............,,,,,,,,,,.. T-l
VIII - TOOLING ASSEMBLY .,.,..,................... 8-l
APPENDICES :
A- GENERAL CONTROL OUTLAY

B- CONTROL DESK
c - ELECTRIC CABINET S&ITCH KEYBOARD
D- KEYBOARD AND DISPLAYS
E- SYNOPTIC TABLE
F- PARAMETER GRID
V2CHOOA REP G6 Ei DIGIT II

,.-
1-- GUARD POSITION DETECTORS ........................ 2-i

2 - GUARD PNEUMATIC CONNECTION DIAGRXM .............. 2-9
3 - PRINCIPLE FOR PRESSC'REAND FLOW CONTROL ......... 3-12
4 - PRESSUREAND FLOW CONTROL DIAGRAM ............... 3-14
MICROPROCESSORRACK ASSEMBLY .................... 3-26
E- BOARDS OUTSIDE THE MICROPROCESSOR............... 3-43
7 - POWEROUTPUT BOARD BSPl ......................... 3-44
8- POWEROC-TPUTBOARD BSP2 ......................... 3-45
9 - INJECTION TEMPERATURECONTROLLERCIRCUIT ........ 3-17
10 - INJECTION TEMPERATURECONTROLLER SKELETON DIAGRAM 3-4i
11 - VALVE TEMPERATURECONTROLLER FOR CIRCUIT FILLING. 3-49
12 - EEYBOARD.4ND DISPLAYS ........................... 4-13
13 - LIMIT SETTING VALUES ON B36/KlOOO ............... 7-3
14 - LIMIT SETTING VALUES ON B56/);2000 ............... i-6
15 - LI?lIT SETTING \-XLUES ON B66/h2000 ............... T-i
16 - LIMIT SETTING VALUES ON B66/K4000 ............... i-8
17 - LIMIT SETTING VALUES ON BSS/KSdOO ............... i-9
18 - LIMIT SETTING VALUES ON Bi6/64000 ............... i-10
19 - LIMIT SETTING VALL'ES ON B76/K64OO/K8000 ......... i-11
20 - CHECK MAIN PRESSURE ............................. i-16
21 - CHECK OIL LEVELS ................................ i-23
')z - TABLE OF WARNING LIGHT'S ......................... i-24
23 - TOOLING XSSEMBLYDIAGRAM ........................ 8-3
c,
21 - THERMOCOL-PLEMOUNTING ON MOULD .................. 8-3
23 - VACUUM CONNECTION ................. . ............. 8-q
26 - NOZZLE AND NOZZLE SEAT .......................... 8-1
27 - CLAMPING BLOCK IN DE\-ICE ........................ 8-6
28 - THERMOCOLTPLEASSEMBLY ........................... 8-6 - .
29 - PRINCIPLE FOR MOULD ASSEMBLY .................... 8-i
30 - KINEMATICS OF APPROACHAND OPENING STROKES ...... 8-9
31 - SIMPLE MOULD SETTING ............................ 8-11
32 - MOULD SETTING WITH PLATEN OPTION ................ 8-11
33 - MOULD SETTING WITH EJECTION BATTERY ............. 8-11
34 - EXAMPLE FOR BASIC CYCLE ......................... 8-14
35 - EXAMPLE FOR INSERT LIFT CYCLE ................... 8-14
36 - EXAMPLE FOR INSERT LIFT CYCLE AND SLIDING
PLATEN OUT ...................................... 8-14
\;2CHOOA REP G6 Ei DIGIT III

- CHAPTER I
PRESENTATION
1-1 - VOLUME "OPERATION"

p-i
This volume provides yc):l with e\-cry r,e.cessar:- ?:iec?s of

information to get the best of yol~r GB El press. lie recommend
to read it attentivelv in order to Knox 311 the possijFliti?s
offered by your press.
--2 - PROCESS-CONTROL "INTELINJECT"
The G6 Ei Dress is ZqUiDDed

-- with an Mintelin.ject" prooess-
control system offerin, d the advantage of centralizinq rhe
input and checking of the moulding parameters on a keyboard
and a display on the plastron of the electric cabinet.
fn addition, the process-control by microprocessor aila>ws for

loop control of speeds, pressures and temperatures oilerins
high precision as well as high-fidelity reproduction of ali
moulding settings.
.---. The possibility to memorize the moulding parameters for a

given mould and to call them back instantly, at will, allows\
for a very quick preparation of the press and time saving
during production.
VOL2CHl REP G6 Ei DIGIT l-1

CHAPTER II
OPERATOR'S SAFETY
/--
II-1 - GE~ERALITiES...,..............,.,~,.,...,,.,,.. 5-3

l-1 - SXFETS IXSTRUCTIONS . . . . . . . . . . . . . . . . . . . . Z-3
1-2 - DESCRIPTION OF 3.4FETY DEi:iCES ..,.,.i... 2-2
c?
II-2 - SAFETY GUARD AND PXXELLIXG ................... i- 6
2-l - SAFETY GCARD ........................... 2-6
2-2 - PANELLI?iG ..............................
,-
/--
VOL2CH2 REP G6 Ei DIGIT 2-1

--II-l - GENERALITIES
l-1 - S.AFETF ISSTRVCTIGSS

REP presses are conceived for the prodxctien cf acl.llied
rubber parts with an optimum profitability but quaranteeizg
the operator's safety.
In crder tb ,gu a rant e e this C-c.-

saLbL:, t -7J
t L?l 2 C.
- 'A
.I_.: 9 0 i '3 ': !,Ii: i p 1't3,rt
w-ith specific de-.-ices; howe\-er . the -1 5 2 r II-.. !- rps&f -GC: -
.*L. ta
strictly observe the general instr*2ctiocs a;:ci::itl,:: t3 di*:er-,

this "safety" function:
- The machine has to be installed correctly and the safet:

devices have to be checked regularlv.
- The machine has to be operated observing the instructions

and features for use.
- The machine has to be run by competent persons trained for

its operation.
- The approach of the operating machine must not be allowed

to anybody except to the operator who has to check before
each operation.
- The esisting safety systems must never be suppressed or

modified.
- Regular maintenance and checking of the whole machine are

compulsory and have to be done by experts. For these
operations, please refer to the texts concerning safety in
volume "Haintenance". Y
- The safety devices pro.per to the machine must ne:'er be modi-

fied without the manufacturer's consent. They must never be
modified either without the consent of the official safety
authorities.
l-2 - JlESCRIPTION OF SAFETY DEVICES
PROCESS-CONTROI,
According to the user's country, the press can be equipped

with a safety device S-l or S2 ire. regulations and standards
in force).
* Safety Sl
Possibility to control closing/opening of press and movc-
ment of hydraulic side ejectors while the guard is open. I-
This operation mode is selected by means of a key-switch
allowing for the following functions:
_-
l- operation with closed guard
2- operation with open guard
VOLZCHZ REP G6 Ei DIGIT 2-2

During operation with open guard. the cycle can be run in
"manual" or "semi-automatic" mode, but in this case the
press closing is possible only by means of a spnchronized
and maintained double-hand control.
FiARNING ! During this operation mode the access to the

press has to be permitted only to the operator
who is protected by the remote-control,
. s a..f.et v s.2
The difference between Sl and S2 is that in the Sl version
it is impossible to operate while the guard is open, and
there is no key-s&itch for operation with open guard.
4 safety control v-al\-e is to be assembled in series onto the
approach valve. Its flow control will be checked by the
process contol system of the machine.
l Sa.f.,e..t.i e.s ,....... 5.3. and .._. s..:!
Should the press be equipped with hydraulic e.jectors on version

Sl or S2, then a key-switch will allow to control the
e.jectors whilst the guard is opened, howe\-er it will be released
only with a dual manual synchronized and maintained control.
a) The panelling is composed of a front guard, two fised side

panels, movable panels mounted on the lower part of the
closing unit and a Guard on the-rear side of the frame.
b) The closing of the front guard is pneumatically controlled
and prohibits any physical acess to the machine. It
closes upon control of the operator acting on a service
device. This guard is equipped with an obstacle detector
operating during closing. The non closing of the safety
guard or its reopening during the cycle prohibits any
closing or opening movement of the press. Two limit
switches with opposite contacts are controlled by two cams.
4 third sensor will release thehydraulical closing control.
c) The opening of the movable panels at the bottom of the closing

unit will hinder any press motion.
Should the machine be equiped with the "head-lift" option,
a) The injection head is equiped with a clamping system in its

upper position which allows the access of the operator for the
cleaning, maintenance, purge and nozzle replacement.
2-3 REP G6 Ei DIGIT V2CHOZA

d) The estruder feed port is protected b;v a tb-rca~. T!?is
i ;hr 0 a t >as been ccnceix-ed Iscg enoash tc im!~.z,:!~ t!:.: .:'_ :.: ;z
to the ext ruder screw; ri i t h c,he fingers.
e) ~11 injection settings are to be made on the sxi~ch

keyboard of the electric cabinet in order tc facilitate
their access and keep the ad.juster axap from parts ti-;;Lt
may m may mo-e.
f) Certain parts of the injection unit may reach rither hiqh

temperatures and it is recommended to wear protective
gloves for all operations in this area.
.z) The hydraulic circuit has no accumulatcr, mna!ring tha-,:
. no Permanent pressure is maintained in the hydraulic

circuit;
. there is no explosion hazard caused by this cope of

de\-ice;
. in case of rupture of a hydraulic chaneiicg, t'ne

pressure in the circuit drops instantly impedir:s any
violent fluid projections.
b) As the hydraulic hoses are linked together, the rupture of

one of them cannot cause any dangerous swinqing.
c) The control electrovalves have three positions in order to

stop any movement in case of (voluntary or unvoluntary) e
power cutoff.
d) In addition to the pressure check valve an overfioti *V.aive T-

with a higher adjustment than the maximum service pressure
is placed'on the hydraulic circuit at the pump outlet.

I
.
E.L.E.~TR.I.C.......YN
1.T
a) The main isolator sKitch on the right hand side of the
electric cabinet cuts power off on the whole machine.
b) The door of the electric cabinet door includes a closing

device which has to be closed during the use of the
machine for production or setting. The acces inside this
cabinet is authorized only to specialists for maintenance
works.
c) Two push-button emergency switches are at the operator's
disposal. They are located on the plastron of the electric
cabinet and on the control board. In case of an emer%ency
stop during the press closing, the cycle in progress is
cancelled and it is necessary to reopen the press complete-
ly in "setting mode" in order to be able to start a new
cycle.
d) The position of the cycle selector switch can only be

modified by means of a key.
I
.
e) A synoptic board keeps the operator informed about the
proeress of the cycle.
TQQLS
a) All tools presenting some risks not covered by the safety

devices of the machine must be equipped with their own
safety devices.
b) Moulds are always heavy and it is necessary to use adapted

means of handling. Also, the moulds or accessories have to
be tightened carefully. Do always take into account the
bear-down force of the injection unit onto the mould when aI
you determine the way to fix the mould.
REP G6 Ei DIGIT
l-I--- .
In the standard version. the press is equipped with two
safety guards:
- one automated front guard
- one manually controlled rear guard.
. .J!h-x..k.iag ..zK.i.nc.i.P.l.e
- The opening and closing of the front guard is

controlled by means of compressed air electrovalves
_- YlOO and TlOl.
- The opening and closing of the rear guard (if it is

not motorized) is controlled by means of a manual
valve index 118.
- The compressed air pressure controlling the opening

of the guards has to be adjusted between 3 and- 7
bars. This ad.justment by means of a pressure
reducing valve avoids a too sudden rise.
- The rest position of the guard is the lifted

position.
- The lifting speed of the guards is ad.justed by means \

of metering valves (117 and 127) mounted on the
upper part of the cylinders.
_- - The lowering speed of the guards is adjusted by

means of valve 113 for the rear guard and valve 119
for the front guard. The latter one acts also on the
deceleration of the guard at the end of closing
stroke.
- On the bottom part of the front guard is situated a
"sensitive bar" actuating two limit switches S 62
and S 63. If the guard meets an obstacle during its
coming down (tool, forearm, etc... 1 it is lifted
instantly.
N.B. : The opening of the rear guard should be only

occasional (mould set-up). If you need. the rear guard '
to be-opened at each cycle, you must have the option
"motorized rear guard".
'v~ZCHOZX REP G6 Ei DIGIT 2-6

rlsior, 52)
I
.
I
.
PICT. 1
-
W
2-7 REP G6 Ei DIGIT VOL2cH2
.
. :
.
ns of the limit switches
The limit switches on the guards have the following
functions :
. .-
State of
Front Rear Function limit
guard guard switches
(closed guard)
s 47 s 147 control hydraulic

safety (version 2) open
s 49 s 149 end of stroke guard

,---. (1) opening (controls also open
guard deceleration)
S 50 s 150 end of stroke guard

closing closed
s 215 s 115 double end of stroke

guard closing open
(1) only with option motorized rear guard.
Warninq
The limit switches S 215 (+ S 47 in S 2) have to be

controlled during the last 10 mm of the end of stroke
guard closing.
-
: ..
VOL2CH2 REP G6 Ei DIGIT 2-8'

117
%-
a-
0100
-Lx l
549 . f YlOO
a
T L
t
7 bars
(
CAM FOR DECELERATION OF THE
CLOSING MOVEMENT AND END dF
OPENING STROKE
P I
-lOOa YlOl
alb!
i '
diagr= I1 7001
,-
PICT. 2
2-9 REP G6 Ei DIGIT VZCH02&
Y....% -d-s- - . _.I,. -*-.- _. . - -.....-m--m. ., -

100 ElectrovalT-e,guard speed
101 Electrovalve guard opening and closing '
111 Pressure reducing valve air lubricator
112 Non-return valve guard lowering
113 Speed valve rear guard lowering
117 Speed valve front guard lifting
118 Manual control rear guard
119 Speed valve front guard lowering
127 Speed valve front guard lifting
vzoo Cylinder front guard
v201 Cylinder rear guard
2-2 - E!AN.EL.L.IN.G
The fixed part of the panelling is composed of two

fised panels on the frame sides.
These panels have also the function to support the

guards.
- On the joint of the front panel a limit switch

S 205 is actuated when the panel is open and
released when the panel is closed. This limit
switch has to be released only during the last 10
mm of the closing stroke.
V2CHOZA REP G6 Ei DIGIT 2-13

~;.HAPTER.............Z.I.I
Q.P.IF;RA.T.IQ.N
III-1 - CYCLE DIAGRAM ..................... 3-2
III-2 - HYDRAULICS ........................ 3-T
III-3 - ELECTRICS ......................... 3-19
III-3 - PROCESS CONTROL ................... 3-23
,- III-4 - TEMPERATURECONTROL I.. em. . . . . . . . . . 3-46
V2CH03A REP G6 Ei DIGIT 3-l

The sequence of various press functions is represented on the
enclosed .diagrams for a total cycle. These diagrams are quoted as
examples which are to be adapted to every specific application.
The movements are marked A to P on the ordinate whereas the cycle

run which is comprised between 0 and 18 is marked on the abscissa.
Every cycle start is reset to zero.
VZCH03A REP G6 Ei DIGIT 3-2

- - -
- - -
- - -
I
. - - -
- - -
- - -
- - -
- - -
I
- - -
- - -
- - - -
- - -
- - -
- - -
- - -
- - -
- - -
- - -
- - -
- - -
- - -
BASIC CYCLE
3-3 REP G6 Ei DIGIT VZCH03.3,
,-
V.ARIA!!T : INSERTS LIFT
V2CH03A REP G6 Ei DIGIT 3-4
-
I I I I I I I
-
-
-
-
-
-
-
-
-
-
-.
--i---O---t---+--t- -.
t
-
-
-.
-a
-
-
-
-
-
-
-
-i
0 w G c3 I x
w
C
bc 5 .d
.r(
C r
E
3.
E
rd
-i
m 0
0 5
VARIANT: PEGAVINCS
S
3-5 REP G6 Ei DIGIT V2CH03A
I I I I
5
P
VARIANT: INJECTION-CO?fPRESSION
OR
,- Ih'&CTfOK TRANSFER
2-l - HYDRAULIC DIAGRAM . ..~.,.~,,,,,.,,.,,.,,,,. 3-8
2-2 - HYDRAULIC STATION . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
a) - Motorpump group
b1 - Tank
cl - Oil return filter
d) - Cooler
2-3 - PRESSURE AND FLOW CONTROL SYSTEMS , . . . . . . . . 3-13
a) - Hydraulic part
b) - Electric part
2-4 - DISTRIBUTORS .............................. 3-li
2-5 - 17ALVES .................................... 3-18
2-6 - RECEIVERS ................................. 3-18
REP G6 Ei DIGIT 3-7

V2CH03A
The hydraulic diagram of the G6 presses is drawn up with
symbols explaining the different functions of hydraulics.
For practical reasons the hydraulic diagram is not .joined to

the technical documentation but is inside the electric
cabinet with the electric diagram.
It is important for the user to note down the numbers of the

basic wirinq diagrams for each machine in order to avoid any
risk of confusion as there may be differences between these
diagrams due to evolution and specifities.
: n ' 116580
LE.~E~.T)_~.~.~.~~.~.~~.~.~~.S for KlOOO and 2000
n' 116581 for K-&O00 and 6-100
Eu.nr.~.i..8.na.l~~~~~.d.~~.~.~ ( standard opt ions enclosed 1

0 Pressure check valve
1 Flow control device
2 Electrovalve in.jection
3 Electrovalve translation of in.jection unit
4 Electrovalve full force bear-down
5 Electrovalve approach
6 Electrovalve sliding platen
i Electrovalve clamping block
8 Electrovalve clamping
11 Overflow valve general pressure
12 Electrovalve cooling water
13 Overflow v-alve clamping pressure
14 Valve differential opening pressure
15 Non-return valve lowering injection unit
16 Non-return valve opening
17 Non-return valve clamping
19 Sliding platen selection valve
21 Pressure switch clamping
22 Check extruding back-pressure
23 Check main pressure
24 Oil return filter
25 Pilot back pressure extruding
26 Oil cooler
27 Thermostat oil temperature
29 Hydraulic pump
30 Electric motor motor-pump
50 Electrovalve top hydraulic ejectors
51 Electrovalve bottom hydraulic e.jectors
52 Metering valve opening
53 Valve back-pressure extruding
56 Check minimum / maximum oil level
63 Pressure valve translation cylinder bottom kit platen fl
64 Pressure- valve translation cylinder top kit platen
65 Selection valve differential head contact
76 Selection valve differential head contact

66 Electrovalve central e.jector
67 Compensating valve cylinder top ejectors
68 Compensating valve cyiinder bottom ejectors
69 Distributor hydraulic safety (S2)
Compensating valve cylinder top kit

Electrovalve translation top kit platen
Electrovalve cylinder top kit
Electrovalve cylinder bottom kit
Electrovalve cylinder bottom kit platen
Compensating valve bottom kit
Translation cylinder injection unit
InSection cylinder
Approach cylinders
Cylinder sliding platen
Cylinder for clamping block
Clamping cylinder
Cylinder for central ejector
Cylinders top ejectors
Cylinders bottom e.jectors
Translation cylinder top kit platen
Tanslation cylinder top kit platen
Cylinder bottom kit
Translation cylinder bottom kit platen
I
, Hydraulic motor extruder
3-9 RE? G6 Ei DIGIT V2CH03A

- The operation of the hydraulic station is to supply a
sufficient oil flow for the following outfit. Besides, it
will release both the filtering and the cooling of its
oil.
- Above hydraulic station is composed of the following

elements:
. The pump supplies an oil flow in accordance with

its capacity (i.e according to machine type) and
its rotation speed. The rotation speed is deter-.
mined by the type of the electric motor used and the
frequency of the electric power supply. (re. table
showing press features).
b 1 .T.ank
The tanks of the G6 presses contain:
- 250 1 for KlOOO and K2000
- 400 1 for K4000 and K6400
The oil level is indicated by a sight window on
the right hand side of the tank, The maximum oil
level is to be checked whenever the press is
stopped in its opened position in order to avoid
overflowing dangers. (re. table on press
characteristics)
An automatic safety device for minimum/maximum

level may be fitted as an option.
I The tank oil has to show characteristics identical to

the recommended data and is to be replaced
periodically. (re. vol. 1 "Set-Up")
cl Pi1 returnfilter
During machine operation, the permanent oil filterins
will be ensured by a filter which is set onto the main
return circuit.
Should the filter cartridge be clogged, then a by-pass
will hinder any overpressure both at oil return and on
the filter itself.
An automatic sensor for filter clogging may be supplied I.-

as an option.
REP G6 Ei DIGIT 3-10

V~CHO~A
d 1 CBQ1.er
. X hydraulic circuit is at its best output at

around 4O'C. It is therefore necessary to control
the temperature which is made as follows:
- a temperature exchanger is fitted on the oil

return circuit:
- the water supply of the eschanger is made by
means of an electrovalve;
- this electrovalve is energized by means of a

thermostat the release point of which is
adjusted to 40-C.
In addition, the thermostat controlling the oil

temperature has a second contact adjusted to 6O.C
with the function to stop the operation of the
machine (at the end of cycle) if the temperature
is abnormally exceeded. A signal light indicates
the disturbance to the operator.
r-

I
.
I
.
w
REP G6 Ei DIGIT 1'2CH03.A
3-12
- The pressures and flows are controlled by means of a
hydro-electric unit composed of:
" $bTy .,i. ".p.:~~
q:
a 1 H.n.d.raul..ic.......p.a
rt
. 1 cartridge general pressure checking
. 1 cartridge extruding back-pressure checking
. 1 proportional 2 circuit electrovalve
. 1 digital/anal09 converter board fitted at the

microprocessor output
. 1 interface board tension/intensity converter

for the control of the proportional hydraulic
devices.
The hydraulic part of the pressure and flow control is

composed of 2 types of devices :
- pressure check valves (Rexroth)
- flow regulator (Koppen)
- The pressure check valve (index 0 on the hydraulic

diagram) checking the general service pressure is
controlled by a pilot the solenoid of which is supplied
with electric power according to the pressure to be
reached.
This pilot acts on a valve having the function to

discharge the hydraulic circuit if the pressure exceeds
the programmed pressure as it has a passage big enough
to absorb the whole pump flow when no movement is in *
progress. However, a pilot pressure of 6 to 8 bars is
maintained in the circuit in order to allow the
beginning of the control process.

a
- -- ---
,r 3 ,
E
II
r-
IQ
r+
4E
II -- 1
-71
JI
II
1
I
II
I
I
PICT.4
3-1-k REP G6 Ei DIGIT l-2CH03A
The real service pressure on the active receiver is
reached in piloting the overflow valve from a hydraulic
pilot circuit coming from the flow control device (MEL),
The Pressure applied on the receivers is automatically
limited to what is strictly needed to reach the desired
speed (cylinders or extruder motor).
The maximum service pressure can be limited for esample

for clamping or injection by entering the static pres-
sure holding phase by modifying the maximum intensity
applied on the solenoid valve of the pressure pilot.
The maximum service pressure is: 250 bars
- The second pressure check valve (indexes 25 and 53 on

the hydraulic diagram) checks the extruding back-pres-
sure by its action on the upper part of the in.jection
cylinder during extruding (back-pressure is adjustable
from 0 to 40 bars).
Flow regulator
4 proportional electrovalve (index 1 on the hydraulic

diagram) following the pressure check valve, checks
very precisely the flow directed to the cylinders and
the hydraulic motor until the maximum pump flow is
reached.
The value of the flow is in relation with the intensity

sent onto the solenoid valve of the pilot, this pilot
checking the positioning of the main distribution spool
which, owing to its shape, acts like a valve.
The proportional electrovalve has 2 service ways. Each

way has its own control solenoid valve :
Yla for the way 4 supplying the extruder motor

Ylb for the way B supplying all the cylinders.
Pressure/flow is self-controlled by an energizing

channel communicating between the proportional
electrovalve and the pressure check valve, this unit,
receiving instructions by means of variable electric
power checked by the microprocessor according to the
programmed moulding parameters.
V2CH03.4 REP G6 Ei DIGIT 3-15

b) Electric part
The microprocessor gives signals allowing for energizing, -

by means of its DAC board (place CB on the microprocessor I)
rack) the proportional electrovalve and the pressure
check lralves. 3 from the 8 available channels on the CDA
I
. board are assigned to the pressure and flow control:
Channel 0 : service pressure control
Channel 1 : flow control cylinder movements or

extruder back-pressure
Channel 2 : flow control estruder motor.
On each channel, the analog signal supplied by the DAC

board is a tension between 0 and 10 V according to ;he
desired pressure or flow.
These signals are then converted from ~~~ltaqe to

intensity by means of an interface; board mounted outside s
the Rack (on the bottom in the middle of the electric
cabinet) in order to energize the solenoid valves of the
pressure or fiow control devices.
The intensity going through the solenoid valve of a pro-

portional electrovalve has to be in coincidence with the
analop signal supplied by the DAC board according to the
following chart:
ImA 1
1000 /
800
2 6 8 10 u Volt
I
.
411 the control valves used on the hydraulic circuit of the G6
presses have 3 positions which guarantee the highest operation
safety as in the case of a! power cutoff, the movements are stopped
and there is no risk of inversion as there would be with a two
position electrovalve. In addition, pressure can be cut off on
their cylinders during the end of stroke.
The electrovalve solenoids are supplied with 24V = (except for the
hydraulical safety electrovalve - index 69 on the hydraulic
diagram used for the safety device S2 which has a 1lOV supply).
r-
V2CH03A REP G6 Ei DIGI'I 3-17

In order to avoid excess pressure, this valve has
the fonction of discharging the hydraulic circuit
if pressure overshoots the admissible limits.
A leaded cover prevents unauthorized per-sons

from accessing the adjustment screw.
The adjustment value of this valve is 2TO bars.
The compensation valve serves for the opening of

the press.
It creates a differential pressure on the bottom
_- part of the approach cylinders during opening in
order to better control the changes of speeds and
the stops of intermediate strokes.
This valve limits the exceed pressure that could

arise in the clamping cylinder during injection.
The hydraulic receivers the function of which is to move the

different parts of the press are: the ex-truder motor and the
double-effect cylinders for the different machine movements.

3-1 - PRESENTATION OF THE ELECTRICAL CABINET ........ 3-20
3-2 - POWERSUPPLIES ................................ 3-21
3-3 - PROTECTIONS ................................... 3-22
I--
REP G6 Ei DIGIT 3-19

This cabinet comprises the purely electric equipment
necessary for the functioning of the REP G6 presses. The unit
is conceived to be compact (saving of floor space) but practi-
cal and of easy access.
The cabinet plastron comprises all elements necessary to the

user (selector switch, control buttons, keyboard, displays,
LEDs, etc.) enabling him to operate the machine and to access
to all functions safely. Inside the cabinet, the control part
and the power part are clearly separated with regard to
situation as well as power supply and wiring passes. This
avoids troublesome interference problems.
On G6 presses a frame connection box is placed on the left

hand side of the machine. It contains the connections on
/- terminals concerning the heater areas of the mould and their
thermocouples.
For some options, a supplementary box can be added on any

machine on top of the Intelinject cabinet.

3-2 - P.c?.KE.R
._..
.s..L:.P2.L.I.E.S
The powering
nating voltages,
cabinet
The
is supplied
following
with
diagram
three-phased
shows the
alter-
distribu-
e
tion of the different voltages in the cabinet.
( u t/- 5 % 1
I
.
. -
\ I I ,
- \ /
(36V 0; !7V 0 220v
4
t 11
, /
T4 Relais24V
Hydraulic safety
I SUPPlY Isolation + cooling
.
EV Heating contactors S2
i- 24 V transforme: ( option )
!7v 1 -L
\ b-
I
converter
3-21
T 0 27V
Converter
board
transforme
REP G6 Ei DIGIT
.
IN/OUTPUTS
multiplexe
filtred
outputs
t
RACK MOTHERBOARD
172CH03A
-
3-3 - E!.RQTECTIOSS
The electric cabinet REP is conceived to provide total safety

for the operator and longBlife for the equipment. Each electric .
device is protected efficiently and also redundantly. The
following table indicates the main lines of this proteotion.
Devices Safety elements
.Whole machine Main differential magnetothermal circuit-

cutter
.Motors : Thermal relays + aM fuses (fuses accepting the

motorpump and increase of current on starting the motor but
regulator protecting efficiently during normal opera-
tion)
.Heating areas gF fuses, specially dimensioned for each case

.Transformers Primary and secondary protection by adapted
fuses
. Direct When leaving the diode bridg?es, after

voltages eventual filtering? fuses are provided
.Yicro-rack One fuse after amplification

outputs
.Yicroprocessor Permanent checking by specialized rack

rack card of the supplied voltage and
the direct voltage provided by the supplier
block integrated in the rack.

4-l - PURPOSE OF PROCESS CONTROL ............... 3-24
4-2 - PRESENTATION OF MICROPROCESSOR RACK ...... 3-25

-
4-3 - DESCRIPTION OF BOARDS .................... 3-27
4-4 - BOARDS OC'TSIDE THE MICROPROCESSOR ........ 3-42
4-5 - PROGRAMME ................................ 3-42
,.-

A-1 - EYR,Fl.Q,S.E
._,,.
Q,.lz E&~~~,E,.s,sum.T.RQ L
Coordinates all press movements, their speed, their
,-
amplitude, their interlinking according to the cycle of the

machine selected by the operator? the safety instructions,
the options of the machine, etc....
. Has to allow for different types of operation, according to

the position of the cycle selector switch: setting, manual,
semi-automatic or automatic.
. Assures the operator's safety during all press movements

(dual hand control, press-safety, watch dog, etc. ..I
* Control of all physical components such as temperature,

pressures according to the operator's instructions,
. Communicates with the set-up man when he prepares the

production cycle, with the operator during operation and
helps to find the cause of disturbance that may occur.
. Offers the possibility to the user to keep in memory a large

quantity of parameters corresponding with 25 moulds (without
the optional extensions).
The procress-control of the intelinject machines, organized

around the Zilog Z 80 microprocessor, accomplishes all the
above functions and several less important ones during a cycle
which is shorter than 15 ms. In addition to the very best
performances obtained in all these domains, we point out the
excellent quality of the temperature control on all parts cf
the machine which is so important for the quality of the
produced articles. Owing to the quality of the communication
\iith the operator, especially for the trouble-shooting and the
possibility of connection and dialogue with the industrial
networks, the REP process-control is a first-class implement in
the modern industry of elastomer injection.

. The microprocessor rack is the heart of the machine's
process control. It is composed of a unit of 10 standard
electronic cards and of 6 optional cards which are inter-
connected through a mother board.
. This unit is disposed around the central unit board where

the microprocessor is located. From here are sent out the
instructions controlling the other elements. A big part of
these cards are only interface boards between the
microprocessor and the other machine components (ex : input
boards, output boards, diqital-analog converter boards,
analog-digital converter boards, counter card). However,
some others have more "intelligent" functions :
- A DAC board, which both receives the digital data pieces

sent out by the microprocessor, and sends out the
- microprocessor's analogical data to the boards considered.
- A supervision board, which checks at any moment the

status of all powering boards as well as the cycle
progress. In case of an abnormal function, the latter
will cut off the powering of all the functions to
be saved.
- The keyboard/display control board ( or UC board 1

relieves the microprocessor of the part concerning the
permanent display and data receipt in actual time.
Finally, the rack unit is actuated by the program read by the -r

microprocessor. Half of this is kept on the central unit card
(control program) and the other half on the REPROM card
(sequence program). In order to communicate easily with it,
an "interpreter" program is also kept in the same card. Its
function is to translate the machine language to a more
understandable language for the operator. It has thus become
very accessible.
_-

ALIM
TJC
c2
Ik c3
c4
CS
c6
Ir qhh mh II
7++ m-w1 .......... 11
I c7
(u cs
It ...n....I...
..... r-l,
a C8
cu -
tr ...n....... r-l,
G c9
L
. . . . . . . . . . . . . . . . ..m....-.
. . . . . . . . . . . . . . . . . .. . .. . . . I CA
-2 c
........I...... 1[
I f ......&I
II7 - * CB
PICT. 5 cc
cn
3-26 REP G6 Ei DIGIT VZCH03A
Fitting of the cards in the KN8+ DIGIT rack :
. RACK 240 493

i'
. XLIM .. supplier block ..................... Z-CO 503
. SURV .. supervising card ................... 240 555
. UC : central unit board ........... ...... 240 492
. co : REPROM extension board ............. 240 494
. Cl : REP-NET communicator board (opt1 ... 240 486
. c2 .. Counter board ...................... 240 556
. c3 ..
. C4 .. 32 inputs board (option)..........,. 240 541
. c5 .. 16 filtred inputs board ..,,.,...... 240 264
. C6 : 16 inputs board (option) .......... Z-10 264
. Ci : 16 inputs board (option) .......... 240 26-b
. C8 .. 32 outputs board . . . . . . . . . . . ,.... ... 240 2T2
. c9 .. 32 outputs board (option) . ..**.*1.1 240 272
* CA .. keyboard management and displays ... 240 542
. CB .. DAC 8 channels intelligent board ... 240 535

x-
. CC : DAC board 8 insulated channels ..... 210 427
1 option 1
. CD : DAC board 8 insulated channels ..... 240 427

SUPPLIER
BLOCK
(positionALIM)
AWS-lS/lS e
@J
.
OVQ Q -1sv
I3 . *-12v
. ov
. +12v
0
SW teur
Indicators and operating voltage control taps
Operating voltages : t 5 V (de t -1,79&t 5,25V)

t 15 V (de t 14 B + 16 b-1 ,
- 13 V (de - 16 h - I-! V)
- 12 V (Auxiliary not used 1
I, *,
t12vf 11 1
Supplied voltage : 220 Fm a.c. ( t/- 5 % maxi. 1
V2CH03.4 REP G6 Ei DIGIT 3-28

_- SURVEY
BOARD
(positionSURV)
.I
III I IIII-!-: -
2. 814 -1 II
GGi- -. .I -
RI 11 4
This board has several important functions and is thus a main

board of this rack.
1 - Check of power circuit, supplies and control lines

This board checks the supplies t 5v, + 12v, t 15V coming
from the ALS 5 - 13 /15 block, the supply of this block as
well as several check lines (NMI, Reset, WD, etc...)

SURVEY
BOARD
(continued
1)
I
.
-
I
I
.
l- EXTERNAL RESET
2- SAFETY TIME
3- NUMBER OF WATCH-DOG DEFECTS

I
4- WATCH-DOG INHIBITION
5 - WATCH-DOG CONTACT
V2CH03X
3-30 REP G6 Ei DIGIT
SURVEY
BOARD
(continued2)
i.
When an address is emitted by the microprocessor, it is

decoded by this function of the control board selecting
the destination board of the rack and informs it that the
microprocessor wants to contact it.
3 - iwf...~.8......I
Inside this read-write memory it is possible to keep
26 mould parameters, as the maximum general pressure
setting . These are safezuarded by a SV battery integrated
in the board in case of interruption of the machine.
&hen a disturbance occurs, on a feeder line, on a control

line.or concerning the course of the machine cycle (signal
not emitted by the main microprocessor UP principle) a
signal is emitted which enables the release of a relay
(KX73). It stops the supply of all functions to be secured.
. This board contains 3 straps (WD inhibition, 4 WD

defects can be admitted; WD time = 20 ms) and none of
them is mounted in standard version. In addition, a
position is provided for an external reset and another
one for the watch dog contact.
. When vou want to use the test board, straps 4 and 3 have
to be-placed.
V2CH03.4 REP G6 Ei DIGIT

CENTRAL
UNIT
BOARD
(position
UC)
. .
.:0;
2c
E
tb
29
:
! d-t
.u I J-
,
2.
4 i
This board, built around a microprocessor Z 80 features :
. 16 Ii non secured RAM as main memory, distributed on two

2764 housings,
. 1 REPROM socket keeping the regulation program on 32

Koctets (REPROM 27256)
. 1 interruption generator circuit and 1 circuit

controlling these interruptions
. 1 clock for the operation sequence
* 1 serial output enabling the connection of the badge

system (option)
. Another serial output which generates the dialog with the

central unit board supervises both the screen display and
the keyboard inputs on the VIDEO version.

EPROM
EXTENSION
BOARD
(positionCO)
I II i 11 b 12 1
This board contains 1 REPROM (reprogrammable memories), some

of them containing the sequential program, the others an
interpreter program which enables the user to acceed to the
sequential program in an easy language, different from the
machine language.
Attention :
If you exchange a REPROM you have to respect its position on

the board marked with a number and its orientation marked with
a notch on the REPROM itself.
This board is equipped in such a way as to receive 8 housings

that can be RAM, REPROM or EEPROM. In our standard utiliza-
tion, it contains only one REPROM 27256 supporting the whole
sequence prosram.
The 5V used on this board is a backed-up 5V.
The position of the red selector placed on the front side has
no importance.
V2CH03i\ REP G6 Ei DIGIT 3-33

REP-NET
COMMUNICATOR
BOARD
(option)(POSITION
Cl)
512 )(
l
STII
01234567
The REP-NET machine board or "communicator" enables the

dialog between the press itself and the REP-NET network.
When this board is put into service, please check that :
- no jumper is attached either on the "Display-Management"

board or onto the "DXC intelligent" board,
- check the good setting of the jumpers on selectors ST1

and ST2 on the REP-NET board.
NOTA : Please refer in any case to the specific REP-NET

manual
c - -~ -.I.- ---.
COUNTER
BOARD
(positionC2)
CONVERTER
The purpose of this board is to count the impulses coming from

the extruder sensor or the optical encoders of the injection
piston and the moving traverse and to identify the direction
of the movement.
In regular intervals the microprocessor reads the counters

giving us :
- the position of the piston and that of the moving
traverse
-
- their speed as well as the extruder speed by comparison
with the preceding reading and by dividing by the time
interval that has passed.
C'2CH03A REP G6 Ei DIGIT 3-35

32INPUTS
BOARD
( position
C4)
This board records all the inputs on the electric cabinet

plastron, except the keyboard inputs.
The keyboard inputs are recorded separately on optoelectronic

cou piers and their electronic filtering is ensured by an RC
circuit and a Zener diode. Besides, all the inputs occur under --
a 24V voltage = ON / OFF. -
0
REP G6 Ei DIGIT V2CH03A
3-36
._ . _
I___ ---ll -Il..--.pr- ..- -..-
16 FILTERED
INPUTSBOARD
[ position
C5onstandard
version
positionsC6and C7on options I
These cards are generally reserved for the inputs coming

from the machine,
Thet are isolated by optoelectronic plug connections and

comprise an electronic filtering ( by RC circuit and Zener
diode 1.
The input level is visualised by diodes, the first input

of the card corresponds with the lowest diode.
24V inputs = ON / OFF.

32OUTPUTS BOARD
[positionC8on standardversions1
I
I
[ positionC9onoptionversions
I
I -
II
These boards are isolated by optoelectronic plug connections.

The output voltage of 24V= has to be supplied from outside.
This 24V voltage is cut off by the watch dog in case of

operation disturbance Ire. control board).
These outputs are then directed to the relay and transistor

boards BSPl and BSPZ.
REP G6 Ei DIGIT V2CH03X

KEYBOARD
MANAGEMENT
ANDDISPLAY
BOARD
- (positionCAI
The function of this board is to ensure the peripheral

management of 64 multiplexed inputs and of 16 displays
with 7 segments, by means of a programmable special
integrated circuit.
- This circuit succesively selects one of the 8 entry

sets which are to,be acquired by validating one of the
8 channels marked SO to S8 on the electric diagram.
- Once these 8 channels have been read off, it will

select another set of 8 channels and it will last until
the 64 outputs have been acquired.
- The circuit validates successively the 16 displays and

sends the relevant value to be visualised on them.
- The microprocessor reads off once a cycle the values

introduced in the circuit and writes the values to be
displayed.
- This board has a 24V DC supply.
VZCH03.4 REP G6 Ei DIGIT 3-39

BOARD
DAC"intelligent" CB)
(position
This board converts a digital value from the microprocessor

into an analog signal between 0 and 1OV.
It possesses 8 outputs (from 1 to 81, 3 of them are used in

standard version, as follows :
, pressure check valve (channel 0)
. extruder back-pressure check-valve (channel 2)
. extruder flow check valve and other movements (channel 31
The output voltages can be checked by means of test points

PT19, PT18, PT17 (corresponding with channels 1, 2 and 3) with
regard to OV (PT3 on test point on the voltage/current
transformer board).
These outputs are then amplified before being fed to the

proportional electrovalves ire. chapter I-2 : flow/pressure
control).
Don't place any strap on STL.
ST2 strap to be placed on position l-2 (Eprom type 27256).

ADCBOARD
- [ positionCCandCD(option)
I
r
This board transforms low level analoq signals into digital
values which can be treated by the microprocessor. It is used
to process signals coming from the thermocouples and the
pressure control devices. Two corrections are considered to
refine the results :
- Cold .junction correction giving the potential difference

of the thermocouples for the ambient temperature.This
value is deduced from the potential of the measure
thermocouples. In this way you only keep the relative
temperature and this is more precise.
- Deviation correction giving the answer of the amplifier

to a 0 instruction. This value is deduced from the
amplified measure, which annuls the error caused by
amplification.
In all, 10 inputs are multiplexed, amplified and converted in

digital values at each cycle.
VZCH03.4 REP G6 Ei DIGIT 3-41

Voltage/intensity converter board
ire. picture 6 : pressure hydraulic flow control)
Relay and amplifier board ( re. pictures 7 and 8 1
These are 2 boards enabling from the 24V outputs of the 32

outputs board (position C8 on the rack), the control of
the 2dV a.c. heater contactors and the cooling valves, as
well as the 24V d.c. directional valves.
The bottom connector of the output card (connector C81) is

joined up with the BSPl board, whereas the top connector
(connector C82) is .joined up with the BSPZ board,
One of the relays is used for the watch dog reacting on

the commons.
In conclusion, these boards are mainly interfaces between

the rack, the valves and the contactors.
The software that performs the.automation is located in

REPROM in two boards.
- the part called regulation is on the central unit board,

h
- the part called sequential with its interpreter soft is

on the REPROM board.
This last part of the program is fully explained in volume

4 of this documentation.
3-42 REP G6 Ei DIGIT V2CH03X

_
I I
\CR* - CR3 - CR4
\
\ CR1
R.e:.1.a.x
-....
h.o..ard.s
(options)
PICT. 6

POWER
AMPLIFIER
CIRCUIT
BOARD
BSPl
PICT. 7
BsP.1 24v
3-4-l REP G6 Ei DIGIT I-2CH03-A

POWER
AMPLIFIER
CIRCUITBOARD
BSP2
-
Yll
KM2
r2x
rtr
rut
PICT. 8
1318
0
PICT. 9
PICT. 10

5-l - .XNJEG.XI.Q~......~I.T
_-
l-1 - J%I.N!ZIX,S (re. figure 9)
.,y&
I?*,s'.I
The thermofluid temperature controller mounted on the
injection unit allows for preheating and maintaining the
/ temperature of the rubber compound before its injection.
There are two independent oil circuits which can control

temperatures from 45 to 15O'C and both comprise a quick
cooling system in case of voluntary or unvoluntary stop of
the machine or also after an abnormally long time between two
moulding cycles.
The extruder oil circuit allows for correcting the self-

heating due to extruding, in order to reach the desired
temperature. The injection zone circuit has to maintain the
compound at the temperature it had reached when it came out
of the extruder.
As picture 10 shows, these are two independent and symmetric

circuits.
The pump D 1 sends the oil to the extruder jacket where

the heater bands controlled by KM 5 allow for heating it
and control the temperature of the extruder. The oil then
returns to the pump passing the exchanger El where it can
- be cooled operating the water valve Y13. At the entry of
the pump, the expansion basin supercharges the circuit and
allows for the pump suction being set to atmospheric
pressure.
It has the same principle and controls : injection chamber,

connection unit, nozzle tip and nozzle. This part,
extremely short and built in the nozzle tip, follows the
oil temperature.
The connection with the expansion basin is made in normal

operation by an internal connection between the pump
suctions, this connection is too narrow to permit a
noticeable temperature exchange between the two circuits :
the temperatures remain independent.

c) J3.ui.m w
It is made by the expansion basin (Z), but it is essential
to open the valve X (picture 11) as it establishes a
connection between the two circuits to assure the filling
of the injection circuit.
Make the pumps work some time to purge the circuits before
you complete the filling to the lower third of the level
which allows for thermal oil expansion without overflow.
Close the valve "X" ( re. picture 11 below 1
J!b.rJz.inB : The oil used for the temperature control has to

correspond with our recommendation in the table
of correspondence of lubricating substances (re.
volume 3 in the technical handbook). m
PICT. 11
REP G6 Ei DIGIT V2CH03A w

Turning the switch S '204 into position 1, you control the
start of the pumps by KM 3 as well as the start of the
temperature control.
.A
When you turn the switch back to zero, this stops the
temperature control and starts the quick cooling of the
unit, This safety cooling stops automatically under 45-C.
During the quick cooling the pumps continue to work.
V
0
57
69 liiiia
PICT. 1'2
The temperature control is made according to the setting

input in parameter 61. The thermocouple controlling the
temperature is placed onto the regulation jacket on the
upper part of the extruder.
When the temperature is lower than the set point, the
microprocessor gives orders to the heater bands mounted
around the extruder by the contactor KM 5, then there is a
neutral zone of a few degrees and beyond this neutral zone,
the microprocessor energizes the electrovalve (Y 13).This
cools the thermal oil in order to bring it back to the
neutral zone.
The temperature B2 will generally be, except for very soft

compounds, quite lower than the rubber temperature measured
when coming out of the extruder and thus lower than the one
of the injection chamber. However, for hard compounds, do not
adjust B2 below 9O'C.

The temperature of the injection chamber, the connection m
unit and the nozzle tip is controlled by the setting in
parameter 62. The thermocouple checking this circuit is
placed on the regulation jacket, on the upper part of the
injection cylinder (*I.
d
HAR~FLUG : the thermocouples must be touching the bottom of
their support.
When the temperature is below the set point, the micro-

processor controls the heater bands mounted around the
injection cylinder by the contactor KM 4. Beyond the set
point, the heating stops.
During quick cooling (anti-scorching safety) when the set

point is 45-C, the microprocessor stops the motorpump unit
and the cooling. This system works as soon as the machine
is on.
A sensor for the rubber temperature is placed in the

transfer channel between the extruder and the in,iection
cylinder. The corresponding temperature is displayed in
parameter 60.
Thus you know the thermal result of extruder adjustments

(temperature of B2, extruding speed, back-pressure) and you
can correct them until you obtain the desired result.
This enables you also to maintain the rubber temperature

in the injection zone in setting B3 = Bl.
HARWXG : Read the compound temperature 5 to 10 s after

extruding, During the stop, the sensor comes m
back to the temperature of the connection unit. WF

In case of voluntary stop by means of the control switch
(S 204) or when during production the set time ends, the whole
thermofluid control system passes over to quick cooling
while prohibiting extruding.
In this case, both cooling electrovalves (Y 13 and Y 141 are
open and the two exchangers (Bl and B2) assure quick cooling
of the head unit by means of the two thermofluid circuits. For
this, the pumps must continue to work, of course, during this
cooling. We point out that the cooling exchanger of the
injection circuit is only used in this case of quick safety
cooling.
When the oil temperature drops below 45'C, the microprocessor

B3 stops the quick cooling.
In case of a stop due to an abnormally long cycle, to start

again normally the control unit, you must reconnect the system
purging the injection chamber (operate push-button S 19,
press open).

5-2 - M.QGL.D
-
w
The mould temperature is controlled by two electric heater
plates, each plate disposing of the following power :
B56 : 6,5 Ku
/ B66 : 9,9 Ku
B76 : 16,8 Ku
The heating elements have been mounted in order to get the

most homogeneous temperature on the whole contact surface.
However, for a good temperature balancing it is necessary
that each part of the mould covers practically the whole
surface of the plate and is at least 50 mm thick.
The correct operation of the heating elements can be checked

by means of the g.reen LEDs situated on the upper part of the
control board plastron. si
The panelling of the machine around the mould zone avoids

temperature loss due to air flow.
The thermocouples allowing for temperature control and

regulation have to be placed as close as possible to the
mould prints and the ends of these thermocouples have to
press against the bottom of their support in order to
guarantee the maximum accuracy of reading..
It is possible to add a supplementary heating zone for an

intermediate mould plate. The connections for this are
provided in the electric cabinet.
The P.1.D control value is calculated by the REP "THERMOTRAC" =

software.

The THERMOTRACsoftware is a high developped software which
was conceived by REP and which is aimed at determining
coefficients P,I,D, and T which control the temperature.
As a matter of fact, the temperature control is considered

to be an essential factor as regards the repeatability in
the steady production of perfect quality parts.
The temperature control on REP G6 range machines is ensured

by a performing software. This control is a PID type
temperature control which appeals to the coefficients which
differ with every other press according to the mould
dimensions, to its material, to its shape, etc.
The average values for the mould PID coefficients are likely
to be introduced manually and then to be modified in
accordance with the temperature control result values
gained. The operator may use the control process which is
described in paragraph 3-4 if he has not got time left for
mould identification.
Nevertheless this programme requires very accurate

coefficients to be introduced for the temperature control as
any other high developped and performing software , as it is
the only software capable of determining the exact
coefficient values during an identification process. This
process is likely to concern several mould applications.
Besides, it is totally automated and can be performed
overnight or durin, d other non productive intervals.
Therefore the THERMOTRAC software appears as both a

practical and a necessary tooling in the present industrial
activity, which is to be permanently characterized by
profitabiltily, quality and quantity

Purpose of the "THERMOTRAC" software is to compute the optimum
coefficients for PIDT temperature control.
- Set the cycle selector on "setting"

after you have introduced the mold
number to be identified.
- Switch + -
aa
- Close the press totally in order

to initialise the frame
- Initialise inJection head

- Close the press and clamp
- Em0
- Heat the different
to mold configuration
mold
1
areas ( according
t!!i@
,
/---
- set the THERMOTRAC selector on 1

A mold identification cycle comprises 5 different phases ( PID
o to PID 4 1, which can be visualised if you select parameter
49. The number of the phase in process will appear on the
display ( re. identification phases description 1.
Any other display than PID ta to PID 4 indicates that the mold
identification process is in default.
( re, error codes list further in this chapter 1.
Should the end of the identification be abnormal, then cancel

the validation of the THERMOTRAC software, i.e reset selector
SllO to zero.
- Once PID 4 is constantly displayed on the displays up right,

it means that the process has come to an end. Now you can m-
cancel the THERMOTRAC selector and the machine can run
normally.
the coefficients P, I, D, and T which have been handed out

for each heating area have been loaded directly on the
backed-up memories of the press, as well as the 89
parameters which correspond to each mold settings.
- It is still possible to visualise the parameters which have 'i.

been calculated by the THERMOTRACsoftware. In that, once
you have introduced the concerned mold number, do call the
appropriate parameter for ane of the heating areas.
-
'YIP
Eg. Top heating platen : parameter 65.
These coefficient values will be displayed up right on the

displays if you press successively keys P, I, D and T.

a
- Phase for mold preheating (at 13O'C)
and checking of the areas to be
identified.
- Phase for temperature stabilising

( mold 15O'C and CRB 80C 1
- Phase for permanent heating which

allows for the calculation of the
parameters required for the
computing of coefficients.
Temperature may reach 25O'C.
Phase for calculating the PIDT

coefficients and transferring the
latter to the memory.
Phase for the indication of the end

of mold identification cycle.
You will have to reset the
"THERMOTRAC" selector to zero.
CAUTION : Any interruption requires the identification

cycle to be restarted completely.
_-

- Two types of errors may occur during the identification
process ( re. list of errors on next page 1
- These codes indicate a general

process default and stop the
identification. They are given up -
right of the display after the
calling of parameter 49.
- These codes indicate that one

particular heating area is in
default but do not stop the
identification process.
The exact default reasons are a

found by calling successively the -
activated heating areas, i.e
pressing key i. An error code
1001 to 1010 will appear on the
screen whenever the relevant
heating area is called.
Once the operator has checked the

reason for this trouble, he wi,ll
decide how to proceed next.

In case of erroe code Pid7 or Pid 4 with a blinking 4, the
error message may be confused with the computed value of
coefficient I. Such ambiguity is cleared by regarding P
value.
The heating area is concerned by the error code if P is

set on zero.
The cycle will be run as long as the area to be identified

is valid, i.e all the heating areas in default will stop,
The results thus gained for the valid areas may be
disturbed in such a configuration, that is to say the
operator will then have to decide which results are to be
considered as valid or not.
/-

ERROR CODE OF "I"
REMARKS PARAMETER OF CAUSE OF ERROR MANIPULATION
CODE THE ZONES
No error possible way of measure of check isolation of thermocouple

in this phase I 009 area is in short and of D.A.C. card
except if "0" circuit
figure flashes.
PID 0 In this case, see Check heater cartridges
parameter I of the Heating defect or Check depth of thermocouple
areas. I 010 insufficient heating Check connections of
power thermocouples
No error possible I 009 See PID 0 See PID 0

in this phase
except if ,,l" Check closing of screen
PID 1 figure flashes. Failure of stabili- Check EV for CRB
See parameter I of I 001 zation of Check earth connection of DAC
areas temperature measure card
Check the good wiring of
thermocouple
No error possible I 009 See PID 0 I See PID 0

in this phase
PID 2 except if W2"
figure flashes Insufficient heating Check heater cartridges
See parameter I of I 002 power Check depth of thermocouple
the areas Check wiring of thermocouples
This phase is
PID 3 quick and the X X X
operator does not
see it on display
L
The coeff. of all You have to inactivate 'the
areas have been THERMOTRAC selector to get in
computed. To read X regulation
PID 4 them request the (enter the regulation settings)
PIDT parameters of
each area
This code indicates Indicates that 5 min You have to inactivate the
always a general after the THERMOTRAC THERMOTRAC selector, select the
error selection no area to areas to be identified and
PID 5 be identified has activate the THERMOTRAC selector
been activated again
This code indicates See :

always a general I 001 PID 1 All areas to Inactivate the THERMOTRAC
PID 6 error I 002 PID 2 be identified selector and activate it again
If "6" figure I 009 PID 0 were stopped without inactivating the
is flashing check I 010 PID 0 as they are heatings
parameters I of all not in order. ,-
Their failures are _
areas to be
identified. from I 001 to I 010
"6" does not flash X All heating areas

had been stopped by Inactivate the THERMOTRAC
inactivation of the selector and activate it again
selectors even if without inactivating the
the stop was heatings
accidental and short
PID 7 error in computing Computing impossible contact REP's Technical,

phase in one or 17 as values collected Assistance Service
more areas during cycle are
erroneous
GENERAL ERROR The mould is open close the mould ; inactivate

PID 8 X after THERMOTRAC THERMOTRAC selector and activate
selection it again
Once the PID and T coefficients computed by the identification
program Thermotrac, they become simple coefficients and mould
features.
.
Warnlna : These parameters remain valid only if the mould is
used on the same machine type as the one where it has been
identified. Example : a mould identified on a B 56 can only be
used on another B 56. If you want to use it on a B 66 where
the sizes of the heater plates and the heating powers are
different, a new identification is necessary in order to
determine the correct PIDT coefficients.
The PID and T coefficients can be loaded manually as

follows :
- Open the press at end of opening stroke,
- Put the keyboard selector switch S 100 in position "keyboard

accessl',
- Call in the parameter of the desired heating area

(example : top mould half, parameter 65). It is now possible
to load the 4 coefficients of this heating area.
- Press down key P. Maintain the key pressed and type the @
value of this coefficient on the keyboard. Without releasing
key P, press down the validation key S 107. The value, eg.
PO15 appears on the displays up right. Then release key P.
- Follow the same method for the keys I, D and T. All the
coefficients of your heating zone are now memorized.
- Call in successively the parameters of the other heating

areas of your mould and proceed in the same way.
3-63 REP G6 Ei DIGIT V2CH03A --

The average coefficients are :
P = 11
/ I = 17
D = 10
T = 45
The following correction may improve this control :
. if the controller triggers off too suddenly, increase T but

not beyond 80
* if the system controls below the setting, increase D, 2 by 2
. if the system controls above the setting, reduce D, 1 by 1

-
N.B. : For an optimum control, it is necessary to use

THERMOTRAC to determine the best control coefficients
for the mould.

-
- - #. :
CRAPTER IV
QESCRIPTION OF CONTROL DEVICES
_ .
/
/ . . :
.IV-1 - SYNOPTIC TABLE Jo................,........,... 4-2

IV-2 - STARTING AND STOPPING ......................... 4-3
IV-3 - SAFETY GUARD .................................. 4-4

IV-4 - CYCLE-SELECTOR SWITCH ......................... 4-6
,- IV-5 - PRESS CLOSING AND OPENING ..................... 4-7
IV-6 - TEMPERATURE HEATER PLATES ..................... 4-8

IV-7 - TEMPERATURE INJECTION UNIT .................... 4-9
IV-8 - EXTRUDING ..................................... 4-10
IV-9 - HEAD BEAR-DOWN ................................ 4-11
IV-10 - INJECTION ..................................... 4-12
IV-11 - SELECTOR SWITCH KEYBOARD ACCESS ............... 4-14
IV-12 - KEYBOARD SELECTION OF FUNCTIONS ............... 4-15
IV-13 - KEYBOARD MOULDING PARAMETERS INPUT . . . . ...*.... 4-16
IV-14 - DISPLAY .,.........................*..,,,.....* 4-17
IV-15 - SLIDING PLATEN (OPTION) . . . . . . . . . . . . . . ...*.*... 4-18
IV-16 - HYDRAULIC EJECTORS INSIDE PRESS (OPTION) . ..a.. ,4-19

IV-17 - COLD RUNNER BLOCK ( CRB OPTION ) a...*........* 4-20
IV-18 - MOLD AND BRUSHESPLATES ( KIT OPTION ) ..* . . . . . 4-21
.
RE, CONTROL DESK AND KEYBOARD IN APPENDIX
I
VOL2CH4 REP G6 Ei DIGIT 4-l

.
- -. . .. :
. -
A -._
. ._
IV-l i SYNOPTIC TABLE
- .
- . /'-
/ . :' 1.2: : ;
INDEX 1 FUNCTION
The synoptic table is composed of three

distinct parts :
a) Control signal lamps :
S 60 - Power ON process-control
S61 - Start motor-pump
Hl to H14 - Check functions and motions
H 48 - Check press closing
H 62 H 63 H 64 - Heating top plate
H 68 H 69 H 70 - Heating ancillary plate ( option )
H 65 H 66 H 67 - Heating bottom plate
H 71 - H 72 - Temperature control injection chamber
H 73 - H 74 - Temperature control extruder
b) Safety signal . tg :
llnh
H 41 - .Available
H 42 - Maxi. Level hydraulic oil ( option
H 43 - Minimum level hydraulic oil
,- - Hydraulic filter clogging (option)
H 44
H 45 - Maximum temperature hydraulic oil
H 50 - Available
H 51 - Strip rupture (option)
H 52 - Available
I
c) Counters :
Pl - Totalling injection counter ' 1

i
P2 - Daily injection counter
P3 - Hourly counter (option)
VOLZCH4 REP G6 Ei DIGIT 4-2

;-
r
IV-2 - STARTING AND STOPPING
,
./
INDEX 1 FUNCTION I
Q 1 Main isolator switch
.-
s 212 Starting of hydraulic motor-pump
s 211 Stopping of hydraulic motor-pump
S 203 Power ON process-control
s 202 Power OFF process-control
EMERGENCY STOP
The actuating of this "push button" cuts off

the electric power supply on the power circuits
and controls, thus stopping every movement.
s 201
After a stop, for resetting, you have to pull
this button. In case of an emergency stop during
a cycle, you have to go back to "setting"
position and to reinitialise the press.

. : .
IV-3 - SAFETY GUARD
. /
INDEX I FUNCTION
ACCORDING TO THE DIFFERENT COUNTRIES, THE PRESSES ARE EQUIPPED

WITH SAFETY VERSION Sl OR S2 (re. "OPERATOR'S SAFETY")
s 93 Doubleihand control protecting the operator

during manual control of options such as :
- sliding platen, ejectors, plate ... 1
s 37 Manual control guard closing
Manual control guard opening
In case of wanted guard opening during the cycle,

S 38 any press movement is stopped and it is necessary
to come back to the point of cycle start by means -I
of manual control before starting a new cycle.
,- ,
Selector switch for operation with :
.
0 Guard open
s4 1 Guard closed
ONLY PRESSES WITH SAFETY VERSION Sl ARE EQUIPPED

*WITH THIS SELECTOR SWITCH A
Warning .
In case of operation with "guard open" the closing
and opening movements of the press can be controlled
only manually by means of the double-hand control.
/
The key has to be taken off during operation with

"guard closed".
I
It is possible to control manually the lowering of

the guard even when the guard selector switch S 4
is in 0 position.
.
I . . :
IV-3 - SAFETY GUARD ( continued )
INDEX I FUNCTION
I
Once the press is outfitted with a motorized rear guard

(option), you can select its operation with either one
or two guards as follows :
- Operation with front guard only.
- Operation with rear guard only.
- Both guards are operating when switch S139/S140 is

in intermediate position.
VOL2CH4 REP G6 Ei DIGIT

.
. :
/--
IV-4 - CYCLE SELECTOR SWITCH
.'
INDEX 1 FUNCTION
THE CYCLE SELECTOR SWITCH C'OMPRISESSEVERAL INDEX CONTACTS:

SO, Sl, S2, S3. THE COMBINATION OF ALL THESE CONTACTS GIVES
THE FOLLOWING FUNCTIONS :
"SETTING" OPERATION
In this condition, it is possible to control
the guard, to esecute approaching and opening
in low speed only, and drive the clamping block in.
This facilitates the set up of a tool.

During (lsetting", it is not possible to clamp
or to inject.
"MANUAL" OPERATION
With manual control it is possible to' run

a complete cycle with injection by means of
the manual control devices.
This condition allows for the preparation of
the moulding conditions. .
"SEMI-AUTOMATIC" OPERATION
In "semi-automatic" operation, the closing of

the guard and the press are controlled manually
and then the rest of the cycle continues auto-
matically.
1, OMATIC" OPERATION
The selected automatic cycle can be started
by closing the guard by means of control
s 37,
RE. ALSO CHAPTER 6 FOR THE PROGRAMMINGOF FUNCTIONS

-
IN PARAMETER 48.

IV-5 - CLOSING AND OPENING OF PRESS
INDEX 1 FUNCTION
Manual press closing control in cycles:

"Setting, Manual or Semi-automatic".
s 33
In "Automatic" cycle, the guard closing releases
the press closing.
s 34 Manual press opening control according to selected

cycle.
B 32 Optical encoders measuring press closing stroke.
At each starting of the press it is necessary to reset

the stroke measuring to 0. For this, close the mould
completely in "setting" cycle.
The system is initialized once the mould is entirely
closed. The detection micro-switch must be actuated at
the end of the closing stroke (S51).

.
. :
IV-6 - TEMPERATURE HEATER PLATES
. /
INDEX I FUNCT,ION
Control of heating of the heater plates

S 213 according to the temperatures that are
displayed in fields 65 and 67.
( see check lights on synoptic table )
s 220 Control preheating of ancillary platen n'l (option 1
s 221 Control preheating of ancillary platen n-2 (option)
CAUTION
SEE CHAPTER 3 "TEMPERATURE CONTROL" FOR MOLDS
AND ANCILLARY PLATES TEMPERATURE CONTROLS, AS WELL
AS FOR PIDT TEMPERATURE CONTROL AND THE OPERATION
-.
OF THE THERMOTRACSOFTWARE.
VOLZCH4 REP G6 Ei DIGIT 4-a

IV-7 - TEMPERATURE INJECTION UNIT
INDEX I FUNCTION
Control of heating of thermoregulator

s 204 according to the temperatures
displayed in fields 61 and 62.
( re. warning lights in appendix Synoptic Table 1

IV-8 - EXTRUDING
INDEX t FUNCTION
Starting of extruder motor (only if the

injection unit is being heated) according
to the speed preselected in field 20
s 11 (to make the motor run, the time lag for
extruding (field 50) has to be over (except after
a purge or in setting mode).
s 51 Strip rupture warning light ( option )

IV-9 - INJECTION UNIT BEAR-DOWN
I
) INDEX j FUNCTION I
.
Manual head lift control,

This operation is necessary: when dismantling a
mould, for an injection purge, for the heatins of
the machine or for cleaning.
s 41
If you have to work on the in.jection unit when it is
in lifted position, it is absolutely necessary to
put in the safety pins.
Manual control of lowering of the injection unit

S 42 and bear-down on the mould.
/
( INJECTION HEAD AUTOMATIC RETRACT :
SEE CHAPTER 6 : SELECTIG&

SEE CHAPTER 7 : SETTING
- Function selector for strong bear-down of injection

unit onto mold (option)
s 17
CAUTION (I
The strong bear down can be selected only with the
cold runner block option, Both CRB and mold assembly
have to be enough dimensioned to resist a strong
bear down.
REP G6 Ei DIGIT V.2CH0 4'?"

,--
I--
IV-10 - INJECTIOK
l
INDEX- 1 FUNCTION
Manual control injection piston lowering (purge).
This operation can only be done when

s 19 the press is completely open.
This control allows for initialization of the

injection strokes before starting by simultaneous
control with the keyboard key (S 105).
Manual control of injection piston lift

S 18 (is senerallp used for a cleaning operation)
Pl Totalling injection counter

1
P2 I Injection counter with reset to zero (option)

i
P3 Hourly counter (option)
,.-

intelinject
PICTURE 12
I 4-13 REP G6 Ei DIGIT VOL2CH4

I
-
IV-11 - SELECTOR SWITCH KEYBOARD ACCESS

( re. picture 12 )
I
INDEX DESIGNATION
I
Access programming keyboard
- allows for charging the parameters in

RAM memory
s 100
- inhibits the operation of the machine
- no possibility to take the key off
Adjustment setting cam boards

- allow for modifying the parameters of :
. speeds
. pressures
. times ,
+ . temperatures
lE!l by means of the + or - keys
- possibility to take off the key
Eil
WARNING : The values obtained by means of
the cam boards do not modify the memorized
parameters. If the obtained parameters are
satisfactory, go back to keyboard acces and
reprogram them. They are thus memorized for
the case of a microprocessor cutoff.
Keyboard neutralizing
- allows for reading all parameters
and field (49) /trouble shooting
s 101
,-
- inhibits any modification of parameter
setting
T----
- possibility to take off the key.

IV-12 - KEYBOARD SELECTION OF FUNCTIONS
L
t I
INDEX 1 FUNCTION
I
s 102 . Call-in mould number
(only with selector switch keyboard access

on S 100)
s 103 . Call-in parameter number
Check general pressure
. For setting of general pressure, press down

s 104 alternately the t or - keys
Setting to be made onls in mode "t" or 1)-(1 and
end of opening stroke
Pressure to be checked on the display : 250 bars
c ..
. Initialization of injection strokes
The strokes have to be initialized at each

starting of the press as follows:
s 105
Frame
Close the press totally with the manual control.
The detector S51 end of stroke must be controlled
in order to release H48.
Iniectioq
.
When the press is open, execute a purge operation
by means of control S 19 and at the end of the
purge v maintaining S 19, press down key S 105.
c.M.S.B . Selection of variables to be tested

by means of field 49/trouble shooting.
Mold temperature control coefficients ( re. chapter
?.I.D.T I l on mold temperature control and on Thermotrac SllO)

I
IV-13 - KEYBOARD MOULDING PARAMETERS INPUT
INDEX I FUNCTION
- Cancellation
allows for cancellation of the last parameter

S 106 programmed before validation.
- Validation
s 107 allows for validation of the last mould

number call-ins, the parameter being programmed
- Keys from zero to nine (0 to 9)

. allow for two-figure call-in
of a mould number
I allow for two-figure call-in
of a parameter number
. allow for 4-figure programming of a
parameter
c
+ - t key
allows for incrementing the parameters
speed, pressure, time or temperature.
- - key
allows for decrementing the same parameters
N.B : Both keys + and - also allow for function

selections ( re. chapter VI-2 1

IV-14 - DIGITAL DISPLAY
INDEX 1 FUNCTION
All moulding settings can be shown on a display

(re. enclosure B)
This display comprises 5 sub-assemblies :
a1 - on top left hand side : two-figured

"mould number"
b) - bottom, centre : two-figured

"parameter number"
c) - bottom left hand side: "setting" corresponding

with selected 4-figured
parameter
d) - bottom right hand side: "measurement" of the

selected 4-figured parameter
e) - on top right hand side: a 4-figured "block" which

can indicate :
. either INIT indicating that the machine has

not yet been initialized ;
. either "general pressure" ;

.
. either "phase number" if the "test"
phase 49 is used ;
. either the "emergency signal" in case

of wrong temperatures ;
,--
. either the values of P.I.D.T. coefficients if
a parameter between 61 and 69 is displayed.
,-

-
IV-15 - SLIDING PLATEN (OPTION)
INDEX I FUNCTION
I
s 7 Selector switch sliding platen
i-
s 43 Manual control sliding platen IN
s 44 Manual control sliding platen OUT
,I
,-
VOL2CH4 REP G6 Ei DIGIT I 4-18

IV-16 - HYDRAULIC EJECTORS ( OPTION )
. k
I 1
I INDEX 1 FUNCT,ION
s 12 ~110~s for operation of ejectors while guard is open

(double-hand control)
S 65 Manual control top ejectors IN
s 66 Manual control top ejectors OUT
s 75 Manual control bottom ejectors IN
S 76 Manual control bottom ejectors OUT
s 174 Operation selector with hydraulic ejector outside press

(kit option)

-
IV-17 - MOLD AND BRUSHES PLATES ( KIT OPTION )
. /
INDEX I FUNCTION
S 23 - Selection end of cycle with platen mounted in mold

inside press
S 24 - Selection end of cycle with platen mounted outside

mold outside press
- If selector S23/S24 is set on zero, the press is
operating without plates
s 222 - Operation selector with 2 plates
s 112 - Operation selector with platen(s) in continuous cycle

( guard closed )
s 119 - Operation selector with brushing when platen is

sliding out
s 120 - Operation selector with brushing when platen is

sliding in
Besides, this selector allows for the operation with
both plates or without plates !

.
. . :
,--
IV-18 - COLD RUNNER BLOCKS ( CRB OPTION )
. d3
INDEX I FUNCTION
1
s 90 - Operation selector with cold runner blocks
NOTA :
Selector S17 allows for a strong bear-down of the

injection unit.
Careful1 ! In such a case the CRB and mold settings

must be enough dimensioned

-.
.
. :
CHAPTER if
DESCRIPTION OF MOULDING PARAMETERS
V-l - SETTING OF CLOSING STROKES ................... 5-2
V-2 - SETTING OF CLOSING SPEEDS .................... 5-3
V-3 - SETTING OF INJECTION UNIT SPEEDS ............. j-4
V-4 - SETTING OF INJECTION UNIT STROKES ............ 5-5
V-5 - SETTING OF PRESSURES......................... 5-6
V-6 - SETTING OF DELAY-TIMES ....................... 5-i

SETTING OF TEMPERATURES...................... 5-8
v-a - SETTING OF EJECTOR SPEEDS .................... 5-9
v-9 - SETTING OF EJECTOR PRESSURES ................. 5-10
v-10 - REP-NET SPECIFIC PARAMETERSET ............... 5-11

-.
SEE PARAMETERGRID ENCLOSED

UNIT
FUNCTION V-l - SETTING OF CLOSING STROKES OF
MEASURE
00 - Start high speed opening 0,l mm
01 - End of stroke high speed 0,l mm

opening
,--- 02 - End of stroke inserts lift
03 - Start of high speed closing
04 - End of stroke high speed 0,l mm

closing
05 - Tolerance zero point end of stroke 0,l mm

closing
06 - Start of stroke intermediate low speed 0,l mm

opening
07 - End of stroke intermediate low speed 0,l mm

opening
08 - Start of stroke intermediate low speed 0,l mm

closing
09 - End of stroke intermediate low speed ' 0,l mm

closing
_-
VOL2CH5 REP G6 Ei DIGIT

I 1
I I CNIT --
Flw?iCTION v-2 - SETTING OF CLOSING SPEEDS OF 7
ME.ASURE
.O - Low speed opening
11 - High speed opening mm/s
12 - Low speed closing mm/s
! / 4
13 - High speed closing
14 - Clamping speed I %
15 - Sliding platen speed %
6 - Deceleration end of strokes

sliding platen
I.
5-3 REP G6 Ei DIGIT VZCHOS.4

I
UbiIT
FL?iCTION v-3 - SETTIKG OF II'iJECTIOti UXIT SPEEDS iI I
MESJRE
I
I
20 - Speed estruder rotation tr/mn
21 I - InSection speed in range 1 I mm/s
22 - Injection speed in range 2 mm/s
23 - In.jection speed in range 3
24 - Injection speed in range 4
25 - Injection speed in range 5
27
Compound temperature checked by the

CURETRAC software
_-

LNIT i
FUNCTION v-4 - SETTING OF INJECTION UNIT STROKES OF --
MEASURE
30 - End of stroke shot size measuring 0,l mm
31 - End of stroke speed control range no. 1 0,l mm
32 - End of stroke speed control range no, 2 0,l mm
34 - End of stroke speed control range no. 4 O,l mm

and passing over to in.jection pressure
control
36 - Position of release point of 0,l mm

first degassinq

second degassing
38 - Position of release point of O,l.mm

third degassing

fourth degassing
I
.
5-5 REP G6 Ei DIGIT V2CHO5.4
I UXIT
FUNCTION V-j - SETTING OF PRESSURES / OF
MEASURE
40 - Extruding back-pressure bar
41 - Injection holding pressure no. 1
- Injection holding pressure no. 2
43 - Clamping pressure
..
44 - Accostins pressure end of approach
45 - Check compound pressure inside mold bar

( option 1
4.7 - Average of injection pressures during the bar

dynamical phase ( REP-NET and CURETRAC
calculations 1
4% - Selector cycles operation and secondary

functions ( re. chapter 6 1
49 - Operation test and trouble-shooting

(by means of keys E.M.S.B.1
V2CHOSA REP G6 Ei DIGIT' 5-6

UNIT
v-6 - SETTING OF TIME-DELAYS OF
MEASCRE
t
50 - Time-delay start of extruding mn/s

(started at end of injection)
51 - Time of holding injection pressure no. 1 mn/s
52 - Time of holding injection pressure no. 2 mn/s
53 - Time-lag of first delayed degassing mn/s

startins with passing to holding pressure
(Parametre 35)
I
3 54 - Duration of degassings 0,l s
55 - Time-lag of second delayed degassing mn/s

(like 53)
56 mn/s
6
57 - Time for safety cooling on injection mn/s

unit after starting of (last) extruding
58 - Time-delay for automatic head-lift mn/s

after end of maintaining injection
(option)
59
REP G6 Ei DIGIT V2CHO5X

f
.- i 1 ! L?iiT i
'FUNCTIOti V-T - SETTING OF TEMPERATCRES OF
I I YEASURE
I
60 - Compound temperature
!
61 . 1 - Estruder temperature C
!
I
62 - Injection chamber temperature C
63 - Temperature secondary nozzles in 'C

case of cold runner block
I ( PIDT control - THERMOTRAC 1
64 II - Temperature cold runner block

( PIDT control - THERMOTRAC 1
LL+
- Temperature top plate i
(PIDT control - THERMOTRAL' 1
I
66 - Ancillary heating no. 1 'C

(PIDT control - THERMOTRAC 1
6i - Temperature bottom plate 'C

(PIDT control - THERMOTRAC )


V2CHOSA REP G6 Ei DIGIT 5-8

- SETTItiG OF EJECTOR SPEEDS
( options )
71 / - Speed hydrauiic bottom ejectors % V max.

I
!
I
72 I - Speed hydraulic top e.jectors % V max.
73 - Speed translation arm kit platen I % V max.
/
T-i - Speed e.jector outside press ( KIT 1 % 1' mas.
I
II
.
;;5, I
/
76 - Coefficient 1 issued by CURETRAC
A1
7-i - Coefficient 2 issued by CURETRAC

x2

A3
$9 - Coefficient 4 issued by CURETRAC

A4
L
5-9 REP G6 Ei DIGIT L'2CHO5A

FU::NCTION v-9 - SETTIXG OF EJECTOR PRESSURES
( options 1
81 - Pressure hydraulic bottom ejectors
82 - Pressure hydraulic top ejectors bar
83 - Pressure translation arm kit plate bar
84 - Pressure ejector outside press ( KIT 1 bar
) I
83

A5
.
8'7 I - Coefficient 6 issued by CURETRAC

X6

A 5

A8 actuated heating areas
VZCH03A REP G6 Ei DIGIT . 3-10

I I
FUNCTIOh V-10- REP-KET SPECIFIC PARAMETERSET OF w
I ( options ) MEASURE
I
50 - ?fould number I 0 to 99
( tenths and units 1
91 - Press status 0 to 8
92 - Introduce operator's code 0 to 9999
93 - Introduce date of compound preparation 0 to 9999

code ( day and month 1
91 - Introduce compound type 0 to 5999

I
I
96 - Press operation time S
Q!
- Time for item removal S
W
'I'2CHOESA REP G6 Ei DIGIT 5-11
VI-1 - BASIC CYCLE CHART . . . . . . . . . . . . . . . . . . . . . . . 6-3
VI-2 - CSCLE AND FUNCTION SELECTION WITH

PARAMETER 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
2-l - Cycle selection with ejectors

inside press . . . . . . . . . . . . . . . . . . . . . . 6-3
2-2 - Function selection . ..I............ 6-7
V2CH06A REP G6 Ei DIGIT 6-l

1 2 3 4 5 6 7 0 9 10 11 12 13 14 15 16 17 18 19 x)
Sliding platen in Al 1
Guard: cl .osing B 1 1,
Press cl osing Pv L, EV I, PV , A !
Ch 1 ,
Clamping : block in 0. b 17
Injection head L
contact E-
Clamping F
E Injection
k
G- I 1
b Curing
k w
I . ii
F Extruding
k
p Unclamping J 1 1, t 1,
Clamping block
ii out Kk 1, I IIL
ei L, 4- ,PV ,,EV , Pv ,,
Press opening r I
\
Inserts lift M
Guard opening
N -- -d
Sliding platen
out Ov
Stripping'
P-
?
i rl
VI-1 - .BA.SIG ...I_
~XCL~..G;.HART
/--
t 9 $
The cycle chart opposite represents the sequential flow of

the different functions of the press during a complete cycle.
This chart is regarded as examples and are to be adapted
according to the requests.
The active functions are marked A to P (ordinate) and the

cycle flow is comprised between 0 and 18 (abscissa), Each
cycle beginninq starts from zero.
/--
V2CH06A REP G6 Ei DIGIT . 6-3

Pe.slr;.r.in.lii.on....of cycles
niti...ej.n.~.h.~sr.rs......in.s,.i.de~..
.p.re s.s
I-
Cith bortor
6-4 REP G6 DIGIT V2CH06A

VI-2 - CYG..LE ,._..
AND EIlN,C.T..I.Q.N $E.LE.CT..I.QN ._._._
H.LTH ._...
PARAMETER 48
,-
Numerous cycles or selectioni are available on G6 Ei presses

so that the key selectors which are located on the electric
cabinet switch keyboard enable a direct putting intd service
of some functions or cycles ( re. chapter "control organs" 1:
whereas others are actuated bp parameter -18 ire. description
in the following paragraphs).
2-l - .!Z:E.G..~.~
s..d.e.c.t. i..m .._..
w.i.t..h e,.j..e,:..km..s.._..
i.n.s..i.de 9r.e.s s
- Set keyboard selector on "keyboard access" (~100)

- Call in parameter 48
- Enter your cycle selection and \-alidate
( re. opposite description on a\-aiiable cycles )
1'2CH06X REP G6 Ei DIGIT 6-3

Description of the. avai~able.....fu.nc.tions
Function
number Designation Symbol
0 Injection/transfer
1 I _I
rutomatic Lift of the in.jection
I unit TJ
v
2 \-olumetric degassing
I
3 Delayed degassing
4 i Simultaneous motions of ejectors

i
I %aGP -
I for closing 1 opening 8
I
--
e
I
3 Option
6 Vacuum pump intermittent @g&s -II).
7 Vacuum pump continuous lZE&L'I-

I
I
0
t:
8 inserts lift :
I- d
9 End of REP.NET cycles emission *
REP G6 Ei KJIGIT
L_ .Q -- . _- - 2 -
,-
2-2 - S e.l.e.c..t..ian......
n.f .....fwnc t i 0 n s
- Set the selector on @t@j
- Cali in parameter 18
" SEL" is displayed at the right bottom of the display
- sress the Be:-s in order to set the cursor
on your selection and validate
( re. opposite description of functions 1
A flashing point appears on the display above your

selection.
- Sex-era1 functions may be seiected at one time, i.e for one

cycle.
REP G6 Ei DIGIT 6-T

CHAPTER VII
MACHINE OPERATION
VII-1 - PUTTING INTO SERVICE ......................... 7-2
l-l - Charging ; .................................. 7-2
l-2 - Selection of operation mode ................ 7-3
1'11-2 - SETTING ORDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

2-l - Limit setting values ....................... i-4
2-2 - blandatory parameters ,.....l....,..I..,,,... 'i-12

2-3 - Injection parameters ,....,.....,..,.,...... i-13
2-4 - Degassings 1.,,,,~,..,~,.,..,~~~,,,,,.,,,,,~ 7-15

2-5 - Check main pressure . . . . . . . . . ..~..........., 7-17
VII-3 - SETTING OF STROKES . . . . . . . ..I................. f-18
3-l - Opening / Closing . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19

3-2 - Bear-down and retract of injection unit . . . . 7-20
3-3 - Initialisation of frame strokes
and injection . . . . . . . . . . . . . . . ..*............ 7-21
VII-4 - OPERATION SUPERVISION ........................ 7-23
4-l - Before the press starts up ................. 7,-23
4-2 - During the running of the press .... . ....... 7-24
VII-5 - PRODUCTION STOP . . . . . . . . . . . . . . . . . . ..*.......... 7-25 ,-
VOL2CH7 REP G6 Ei DIGIT 7-l

-_
. . II
l-1 - CBAR?G
I I!m
V2CHOi.4 REP G6 Ei DIGIT 7-2

.-
I
I l-2 - SEL.E.CT.ION.OF ..QPERATIONMODE
Yanual :
- used for fine adjustment of
moulding
I - the manual controls have to be
used to execute a complete cycle
I Setting : Semi-automatic :
I
- used for -,he used fcr c.pFra:ion

mould see-up with inLerrupti.on
I at each cycle
- -ilillJh-S Or;i>- for
closing and
opening of press - the cycle is
in low speed cta7teri hv
1
closing the
press manually
I
.
I Automatic :
- used for operation without

interruption between cycles
- the first cycle starts when
the guard closing control is
released (S37).
\2CHOiA REP G6 Ei CiIGIT i-3 5P

VII-2 - SETTING ORDERS
2-l - LIMIT SETTING VALUES
WARKING :
The "Intelinject" press has to be programmed within the limit
of the machine capacities.
These limits are conditioned by the technology of the press
for some parameters (strokes, speeds and pressures).
But, for other parameters as temperature, the limits are

fixed by buffer values included in the programme,
These buffer values will replace automatically the pro-
grammed settings if these are higher.
The different limit setting values are given in the

following figures :
- figure 13 - B 56 : 1000 figure 17 - B 66 : 6400

- figure 14 - B 56 : 2000 figure 18 - B 76 : 4000
- figure 15 - B 66 : 2000 figure 19 - B 76 : 6400
- figure 16 - B 66 : 4000
N.B.
These values are expressed in 4 figures as they are shown on
the display. I*

-
I ii
0
- 80
3 =
=:
71
- 81 91
-I-
z
-b
I :-2 - 52
= 72
-
;;
82 92
jf z
=:
t z
=
$3 - - 13
- 83 93
ri 0d t
IrJ 371, ., I I4 34
-
1
I ..
5
L ., i6
- 41 45 96
L.
-7 i7 42
,.38
8 - 48 -
;8 43 47 98
1I.
-
9 49 hL 48
39
PICT, 13
7-5 REP ~6 Ei !lIC-IT VOL2CH7

-
:1
0
0
10
z
=:
D
I
31
T 51 -
T 8
z
80
81
90
91
II - . -
-T-
zN 5: t
0
z
-
12 ,
. -
. 32 = - 82 92
=: t z
g z.
!L ,
. -*
,
33 - ! - 83 93
0 J t
s
.
14
- 1
. - . - 84 34
= z
z 4
z
15 .
- - 35
6
1
16 . - - 41 as 96
0
17
- . 37
- - - 42 46 37
18
-- . 38
- - . - 43 47 98
19 1
7
:
39 c49 - 44 48 99 .
. -
PICT. 14
VOL2CH7 REP G6 EiDIGIT 7-6

I
- IO
- - 30
II 0 90
iz
0
- 11, 31
- '1 91
- 12 - 32 = '2
- 92
sf z
0
3
3 8 0
- L 33 '3
- 93
- -14 - 35 34
0 E
=: z
- -50 - 35
- L 35
36
- Al !I!!! 96
17 - 37
- ;7 42 c&.-- 97
48
-I8 . - 38
- A3 A7 98
29 A4 40
19 39
PICT. 5 a
7-7 REP G6 Ei DIGIT VOL2CH7

B66 4000
:L 4
T
0 /
s c
0 c
0 0
b . m
30 80 90
=
B =
.
i&L
GL L
0
-
. 31 51
-
s; 91
I
E-I-
32 62 82
0 $ t
5: =:
L c
8 0
.
1
22
.
C
. 63
83
I
0
E t
sf
c
2; . 35 5G
84
0
s:
0 =:
0 0
. N
.i I
1 25
= -. - I E
26 36 56 96
I - - -
I
17
- - 27
-
37
-
6;
-
L
s:
18 38 I
7. 68 A7
! -- 28 - -
r
29 I 48 99 -
u 19 39
.
Lzi
PICT, 16
VOL2CH7 QEP G6 Ei DIGIT 7-R

I
B666400
70 80
T z=
! - . 51 71 81 31
0
-t zt
z
0
52
s
82 32
t f=
=:
! -1 ! 53 - 83 93
I 0
=:
z t
c
-r - . gr, 34
3 55 15
3 - Al G-- 16
D
3 K-
3 A7
1I 3 48
,.-
PICT, 17 ai
7-9 REP ~-6 Ei DIClIT VOL2CH7
,-
51
-
T
t0"
80
0
z
s9
L
31
82' 32
t 0'
z
803' 93
t 1
56
- Al AS 36
42 4L
A7 38
48 39 "-
PICT. 18
VOL2CH7 !?ZP C6 Ei DINT 7-10

10
-
L
z
E
70
71
-
T 80
z0
89
3
0
90
91
t z
b
12
- 72 82
0 0
0
E E t
=
; 53 ; 8:
8 t
=:
I4 34
- 74
- 84 34
z 8
z
z z
c.5 I
-5 L 35
9
T
e.56 AS 96
5 -
I7
-
c.57
- a-- A! 37
-8 - 1. C
58
- A3 38
9 zc ip: A4 39
PICT. 19
7-11 REPG6 Ei DIGIT VOLZCH7

2-2 - MANDATC!RY. PARAMETERS
.-
The following arameters must have a set value to

enable the precs to oberate.
00
06
To..1e .r a n ce:. z e..r.Q po..i.n.t......end Q..f st.ro.ke.. .clos..i.Is :
clT example of programming : 0020 l/LO mm
cl
10
Low ogening.....s.p.eed :
1
Qgy example of programming : 0050 mm/s
I
,-
I I
12
Low clo,s.i.ng~...s.p..e,ed :
f
-!izzu example of programming : 0050 mm/s
b L1
Clampin.g.....spe.e.d :
example of programming : 0100 %
I,nj..e.c.t i.on.....s.p.e.e.d :
esample of programming : 0060 mm/s
D~e.t.~e.~..t..i
o..n......e in.0x.t i.0 n :
n.d....~.f......s.~t;..ra.k.~.......
example of programming : 0050 l/10 mm
R e 1 ea s e..,._ c.aa..l..ing:
s..a.f.,e..Lx.....
example of programming : 0600 mm/s
,-
- Besides, enter the selected functions or cycles in
parameter 48 ( re. chapter "selection of cycle and press
functionsV ).
_-- Enter the other parameters according to the part to be
molded.
V2CH07.A REP G6 Ei DIGIT

The inSection setting can be achieved in various ways with the
parameter grid.
The inSection phase is divided into two parts :
. 1st phase = dynamic phase during which the piston speed is

set in closed loop
. 2nd phase = pressure holding phase or end of filling phase,

i.e when no speed can be controlled any more.The
pressure is set in closed loop at this time.
The transition from the dynamic phase to the pressure holding

phase is dependant on the injection stroke and can be
programmed in parameter 35.
The first dynamic phase is likely to be divided into 5 steps '

which correspond to different sppeds. Both the strokes and 4)
speeds can be programmed for each step ( i.e respectively
entered in parameters 31 to 35 and 21 to 25 1.
The second pressure holding phase comprises two progressive

programmable pressure steps ( 41 and 42 1 whereby these
pressures are held during the respectiv-e programmable times 51
and 52.
The progressive reducing of the injection speed up to the

injection progression when the pressure required tends to
increase is one of the examples for the application of the
above mentionned possibilities. Thus you are able to maintain _
appropriate setting conditions and the cycle will repeat
correctly from one cy.cle to the other.
7-13 REP G6 Ei BIGIT V2CHOIA

0
l The compound proportionning inside the injection chamber
is managed by parameter 30. Then the compound volume
will vary -for a sole injection piston stroke in
accordance with the injection unit shot volume.
Hereafter the correspondance stroke / shot volume for

our standard injection units :
K 1000 0,l mm = 0,331 cm3

K 2000 0,l mm = 0,521 cm3
K 4000 0,l mm = 0,816 cm3
K 6400 0,l mm = 1,021 cm3
Ii 8000 0,l mm = 1,276 cm3
NOTA :
0,l mm = 1 unit in parameter 30

2-4 - I>EXAS.S.I.N.GS
There are two types of deqassings :
a) The volumetric degassings (they are 4) are carried out

by opening the mould by a stroke determined during the
dynamic in.jection phase.
The 4 release points of these desassings which have to

be situated in the injection stroke correspond with the
values entered in parameter 54 :
Injection is stopped during degassing and the duration

of the mould openins is given by the value entered in
parameter :
DELAY......T.IME.S
b) The delayed degassings are released at the end of the _

time entered in parameters
from the end of injection (moment where the inSection or

\I
piston meets point B).
The opening time is given by
parameter
Note : All non-used degassing parameters have to be set to

zero. I,-
Y-15 REP G6 Ei DIGIT
I -7--- -.-.* - -.-_ -. Irl-- .--. .--_---.--I- -

PICT.20

VII-2 - GENE.RAL.~...E.R.ESS.UR.E.......CH.ECKIG
( fig . 20 1
P.URPO.S.E....
..(>.E.......ERE.S.S.URE....
..C.QN.T
ROL
For the first utilization of a microprocessor equipment or after

deletion of the RAM memories, it is necessary to calibrate the
maximum service pressure: 250 bars.
This calibration allows for ha\-ing a correct computing for ail non-
controlled pressure values.
SE.TT.1N.GE.R.Q,C.E.D.U,RE
It is useful to check and cai ibrate now and again the general
pressure as follows :
. ?ut the keyboard sr;itch in position "keyboard access":
. program a mould number: example 01 ;
l press down the key "pressure checking" and check the obtained
vaiue on the top right hand side ;
. I
* iI the vaiue read on the generai pressure gauge 1s not conform,
calibrate as foliows : reduce or increase pressure by pressing
down simultaneously the keys "pressure checking" and l'+'l or <-"
according to your needs.
NOT.4 : follow the pressure e\-olut ion on the d S~plap being careful
not to overshoot 250 bars.
T-17 REP G6 Ei DIGIT L-2CHOi.A

VII-3- STRO.KE...ADJ.VS.T.MENT
Y---
3-l-l - C.L..Q.S.
I 5.G
- 'iiie end of ciosing stroke is done with

reduced pressure, and this pressure can
be set in parameter 44. The start of
passing to low pressure is controlled
at the same time as the passing to low
speed accosting (parameter 03).
- X limit tolerance must be introduced in parameter 05.
- The end of stroke mould closing is detected by means of an

adjustable rod acting upon limit switch S31 in parallel with the
zero obtained by the optical encoder. Said end of stroke is
displayed by a flashing light (H48) up left of the electric
cabinet ( re. Appendis 1
- It is necessary to set the nut between the clampins cylinder'and the

transiation platen in order to enable the lodging of the swivel
platen according to the mould height. A setting tolerance of about
5 mm is let between the swivel platen and the adjustment screw
(escept for the in.jection-compression function where it has to be
set in accordance with the compression or withathe transfer stroke)-.
The minimum mould height has to be absolutely regarded according to
the press type.
V2CHOTA REP Gd Ei IjIGIT . 7-18

WARNING :
The mould height setting nut is to be locked with 4 screws which m
to be located at its bottom part. These 4 screws have to be
mandatorily tightened symetricallg and regularly once the press is
clamped.
I
I
0 /
I I
I d-3-4-2
e
3-l-2 - OPEHING
I
Hereafter you find the maximum openins strokes
I according to the B press concerned :
- B56 : 400 mm
- BG6 : 300 mm
I - B76 : 650 mm
I
.
REP G6 Ei DIGIT L2CHOT.A

3-2 - HEAD. BEAR.~DQW... AND .LI.FT
End of injection
AutoI head-lift
WZ.ZL.E.......
CCNTACT
.-
- The contact position of the nozzle onto the mould is
checked by limit switch S 32. This limit switch has to
be controlled when the injection head is down in order to
release the injection process.
- The automatic head-lift (if programmed) takes place

after injection after the time programmed in parameter
58 has run out.
- The lift stroke can be adjusted by means of the cane

controlling limit-switch S 31. Above.micro-switch is then-
unactuated and must be controlled once the injection head
is in its low position.
,-
12CHO7.4 REP G6 Ei DIGIT T-20

Y
t
3-3 - TN.I..T.I.AL.~.ZAT..I.~ErOF.. .ERAME.-AND ...INJ.EC.T..ION S.TROKES
I
I
INTRO.D.U.C.TIQN
The strokes are measured by means of two incremental optical

I encoders. This solution has been chosen because of its "digitai"
functioning which is easily treated by microprocessor. As a matter
of fact, the impulses supplied by the encoders are receil-ed on a
counting board and the value of the counters determines the strokes.
Two counters are associated with each encoder one for counting and
the other for counting down so as to take into consideration the
displacement direction of the movable element.
OPERATION ,..,QE . THE Q.PTI.,CAL. ENCODEBS
An encoder is associated with the movable plate. The second one is

associated with the injection piston. The connection between the
mo\-able element with linear displacement and the (rotative) encoder
is made by means of a pinion fixed on the encoder axis and a notch
belt.
The display unit of the stroke is lil0 mm.
When the machine is charged, the counters of the counting Loard can
have any value. It is therefore necessary to reset them to zero in
order to get a reference position. This operation Ls tailed Initiali-
zation,
This initialization has to take place in the following <cases :
DAILY RESTARTI5G
: RESTARTING AFTER POKER CUTOFF
. hEST.\RTiNG AFTER ?iOULD CHANGE
, REST.ARTING AFTER EMERGE?iCY STOP '
The necessity to initialize is indicated on the displa:- on the top
rizht hand side : "INIT".
* FRAME : for the movable plate (frame strokes) the zero point is
situated while the mould is closed. Therefore the operator
will have to entirely close the press in order to
initialize the frame.
* INJECTION : the zero point is situated at the end of bottom

stroke of the injection piston. Therefore, you .
have to lower the piston by ordering the purge.
This initialization has to be made when the
movable platen is at end of opening stroke.
Second possibility : you can leave the plate in

lifted position but you have to lift the ,-
injection unit.
I-..~_-
_..-_-.- ,
x--
JIOW TO INITIALIZE
Put the cycle selector switch (S 0) in Setting position,
This "setting" position is compulsory as when the machine has not

been initialized, the speeds cannot be computed and thus speed
control is impossible. It is therefore necessary to remain in low
speed.
a) Charging :
. charge the electric cabinet by means of the main isolator

switch ;
. charge the process control by means of push-button S 203 ;
0 start the motorpump by means of push-button S 212.
b) Programming of mould number

_- if the mould settings are already memorized, go over to (C),
otherwise program the parameters which are necessary for a
first initialization (speeds 10, 12, 21 and pressure 41).
c) Put the keyboard selector switch back in "neutralization" or

"cam board + et -I) position.
d) Initialization of frame :
. close the guard

. close the press fully
The press can now be opened until end of opening stroke so as .

to allow for head initialization.
e) Head initializatioq :
Control the purge by means of selector switch S 19 and when
the piston is at end of stroke, press down simultaneously the
function key "head initialization" (S 105).
IMPORTANT : If the procedure has been carried out correctly,

the machine is now completely initialized. The
word INIT on the 4 displays on top right hand side
has now to go out.

I
VII-4 - CHEC.KS.._....
Q.E QEE.RATI.O.N
4-l - C.H.ECKS BEEQRE S.TAR.T.ING
Thermal oil
level
mui
1
mini
Hydraulic oil
live1
Jll#Xi
mini
I
.
Opening cooling
water -4
I. PICT.21
i-23 REP G6 Ei DIGIT V'CHO7A

i,
.-
ti Q51
H40
a e52
I
Check synoptic table for warning lights, ,=
marking ( re. Appendix ) PICT.22
,-
V2CH07A REP G6 Ei DIGIT i-24
,---
- The press has to be stopped at end of cycle after the

injection unit has been purged.
,-
Temperature control Estruder motor

injection
4
Mould heating 4 Heating
block
cold
(option)
runner
Heating ancillary
4 non allocated
piate (optioni
_--
m
stop stop
process control motorpump
Em
gain interrupter switch

?Smn mini
,-
7-25
V2CHOiA REP G6 Ei DIGIT
-.
CHAPTER VIII
MOULD SET-UP
_-
VIII-1 - MOULD SET-UP .,.,..,,....,.......,,..,..... 8-2
VIII-2 - MECHANICAL SETTING OF THE PRESS ........... 8-5
VIII-3 - FIXATION OF A MOULD ....................... 8-8
VIII-4 - KIKEMATICS OF MOULD MOVEMENTS............. 8-10

VIII-1 - MOULD SET-UP
PREPARATION
- Make sure the mould height is comprised between the minimum and
maximum admissible heights (re. following table).
I 7
min. mould height max. mould height diam.
centering
Press with without with without ring
types sliding sliding sliding sliding
platen platen platen platen (toler. H9)
B 56 135 200 400 465 100

B 66 170 250 500 580 125
I B 76 350 435 650 735
_-
Observation :
In case the mould thickness is below the admissible minimum value,

put in a compensation bolster-plate.
If a bolster-plate of considerable height is used, see to it that

the insulating plate and the heater plate are mounted on top of it
(in such case, the holes for the centering pins are bored in the
bottom part of the bolster-plate at the same time as the fixation
holes for the bolster-plate and the mould).
,-

I
I Ii
iegend F'icture 23 :
1 - siiding piaten (option)

<- - insulating piate
: - heater plate
4a - thin bolster-plate
4b - thick bolster-plate
- mould
i - centering pins
- Check diameter of centering ring.
- Check (in the case cf a new mould) the distance between centers.
the diameter and the depth of tapping cf the mould fisation hoies
(minimum tapping: 1.3 iI). iie recommend at least 4 holes for each
mould half'.
- .As c e r f, d I r'* r;hat the sprue-bushing made in the maui.d has a YCI : z;r>e
_ r
and xhat its depth does not exceed 25 mm.
- IL is r ecomnended, except for some particular case, that ali sprue-

5ushings be made to the same depth: we recommend 15 mm.
- Yake sure that the thermocouple fixation holes ha\-e been bored in
the rear face of the mould, and in each plate tre. figure 24).
PICT.24
REP G6 Ei DIGIT
- Should the mould have been designed to operate with a I-acuum pump,
then check that the hole/s for the I-acuum draught has/have been bored
according to the dimensions of figure 25.
18 ,,
. a 4
d (1
min. 0 for key-

'E passage
Q
PICT. 25
- Check the diameter of the compound inlet in the mould (diam. S).
- Bore the nozzie and taper internally at 2 % of the sprue-bxshinq

diameter - 1 mm ire, figure 26).
PICT. 26
CAUTION : the nozzle sprue-bushing diameter must 1 mm less than.the'-
diameter of the mould runners.
V2CH080, REP G6 Ei DIGIT 8-4

VIII-2 - ME.(;;HAN..T~A.L....S.ETT.I.MG.....
OR......
THE....PRESS
- Hydraulically lift the injection head (mechanic safety in its high

position).
- Put in the nozzle and tighten it home on the nozzle tip.

- Ascertain that the e.jectors are in low position.
- Reduce the ciamp force to approximately half the masimum value.
- Put cycle selector switch on position "adjustment".
- Enter the mould into the press. Two possibilities for doing so :
a) directly with a fork lift,
b) if the machine is equipped with the sliding platen option, the

mould may be put into the press by means of a fork-lift or an
overhead crane while the slidins platen is out in the front.
!For sliding platen travel, set a low speed).
- Approximately center the mould.
- Close the press at low speed.
- Readjust the mould centering in relation with the top traverse.
- Fis the mould on its top and bottom parts (re. paragraph XI-3 of
this chapter).
- ?fake sure that there is room for the clamping-block to pass

underneath the mould height adjustment screw.
al?
- Enter clamping-block and set the operational clearance between the
mould ad.justment screw and the clamping-block (minimum clearance 3
mm) - re. figure 27. The operational clearance determines the
clamp piston stroke. In certain moulding cases, said stroke may be
over 3 mm.
8-5 REP G6 Ei DIGIT V2CH08.A

PICT. 27
,-
- Tighten the mould height ad.justment screw immobilizing s;vstem,
- Cause ciamping-block to travel out and open the machine.
- Set the clamping pressure according to the conditions for use.
- Insert the thermocouples, ascertaining that there is a correct

contact of same with the bottom of their housings.
\\
\
k.
PICT. 28
- Ad,,iust the side ejectors on the press ire. option).
\-2CH08A REP G6 Ei DIGIT 8-6

D C
PICT.29
I REP G6 Ei PIGIT
I 8-7
_-
VIII-3 - FIXATION OF A MOULD
a) Direct fixation to the heater plates 'with lugs, either fixed out
the mould, or from the solid in each mould part (for practical
reasons the thickness of the lugs on all moulds to be used with
the same press type has to be the same).
b) Fixation from above and from below : check the depth of the
tappings in the mould which should be 2 D (not less than 1,5 D).
c) Fixation by means of flanges :
- this is to be advised against, in particular for the top part

of the mould because of the stress exerted by the injection
head bearing-down at the time of purging, particularly when a
cold-runner block is used.
d) Fixation at the partingline : to be avoided as it entails setting-

up and taking-off the moulds in two parts.
Figure 29 shows the various modes of mould fixation. We recommend

the modes A and B, with CHc screws of class 12-9.
VOLZCH8 REP G6 Ei VIDEO 8-8

O-VI
I-
:6-V&
:3-vt
Platen IN
u-4
0 Platen OUT 1
:7-n
:2-VI
PICT. 30
,-
lr
8-9 REP G6 Ei DIGIT voLZcI18

VIII-4 - JCINEMATICS OF MOULD HOVEMENTS
The purpose of this adjustment is to get, with a given mould, the

shortest possible press opening and closing timeSwithout danger of
deterioration of the tooling in continuous operation.
For such settings, we have two kinds of parameters on the control -

.cabinet :
a) setting of opening and closing strokes
b) setting of opening and closing speeds.
For each press, the maximum closing and opening strokes are as
follows :
. B 56 : 400 mm
: B 66
76 : 650
500 mm
The opening stroke is dependent of the mould thickness. Both at

opening and at closing, said stroke is decomposed into three speed
areas, pre-set independently.
STROKES (figure 30)
. 3 closing phases :
- C2 start
- C3 approach of high speed
- C4 accosting (end of closing)
. 3 opening phases :
- C5 set-off
- C6 opening at high speed
- C7 accosting (end of opening)
/--

FIG. 31
FIG. 32
e
I
I
--em-
---- J
Cl
-
I I ,-
I
FIG. 33
--
.---
SPEEDS
The setting for the two speeds usable at closing (Vl and VZ) is
independent of the two speeds usable at opening (V3 and V4).
Examples :
a) example of setting for a simple mould (re. figure 31)
b) example of setting for a mould with intermediate plate (injection

transfer, re. figure 32)
c) example for setting for a mould with ejection battery (re. figure
33)
- In all cases we have to try for the maximum approach and opening
stroke length at high speed that is compatible with the tooling.
EJECTION
Certain toolings are designed with ejector battery, stripping plate,

hanging cores, intermediate frame, etc. and thus require that such.
ancillaries are immobilized in intermediate positions.
According to the equipment of the machine, the ejectors have to be

adjusted consequently.
,- INSERTS LIFT
Sometimes it is necessary to release or to call back the ejectors or

a plate once the ejection is effected (e. g. for putting-in metal
inserts). For this purpose, there is the "INSERT LIFT" stroke C8,
figure 30. This stroke is adjustable, its lifting speed being
equivalent to Vl.
Insert lift is possible in the "manual", "semiautomatic" and

"automatic" cycles, the guard opening at the end of the insert lift.
f--

/-
SLIDING PLkTEN TRAVEL
The selector-switch used for programming the insert lift also allows
for causing the sliding platen to travel after the insert lift.
Note : The speed for the sliding platen travel (out/in) is

adjustable.
MOULD HEATING
After ascertaining that the two temperature feelers have been

correctly inserted, the heat may be put on for both mould hall-es
after approach and clamp.
aVote : Take care of causing the injection head to lift so as not to

leave the nozzle in contact with the mould and pre\*ent any
scorching in the nozzle.

I
1cs-v3
I
CS-V3
I
C6-vi
c7-v3
I
I
FIG. 34
I
----mm
L-VI
a-v2 Cb-Vb
i
CI-v 1
I W-V3
---m-w - f C&VI
FIG. 35
-w---e
I-
FIG. 36
-
w
8 -14 REP G6 Ei DIGIT VOL2CH8

LEGEND OF FIGURES : 30. 34. 35 and 36
Cl Total stroke closing and opening
Ci Stroke low speed beginning* of cl'osing.
c3 Stroke high speed closing
c4 Stroke low speed accosting
C5 Stroke low speed beginning of opening
C6 Stroke high speed opening
CT Stroke low speed ejection
C8 Stroke low speed inserts lift

-
Vl Low speeds closing
v2 High speeds closing

V3 Low speeds opening
V4 High speeds opening
Vj Travel speed sliding platen OUT
V6 Travel speed sliding platen IN
EXAMPLE OF CYCLES
The operator has the following three possibilities :
Figure 34 - basic cycle
Figure 35 - cycle with inserts lift
Figure 36 - cycle with inserts lift and sliding Platen OUT
VOL2CH8 REP G6 Ei VIDEO 8-15

/--
A,.p,,,
p..EN.I).,
I ,J,,ES
A - GENERAL OIIiL.AY OF THE CONROLS
B- CONTROL DESK
c - SWITCH CONTROL DESK
D- I<ETBO.ARDAND DISPLAI-S
_ri - SE-NOPTIC TABLE
F- PARAMETER GRID
,-
REP G6 Ei DIGIT
APPENDIX A ;---
GENERAL OUTLAY OF
-THE CONTROLS
..._.._....._...._..~.~.~~........~~~..~..~
~..~_._.-.._..-__.._...........-....
_.._..
.-._
-.__._-...._.-...
._...-.....
.._...
..__
_..
1
II 1
intelinject
REP G6 Ei DIGIT
REP G6 Ei DIGIT
ANNEXE C
REP 06 Ei DIGIT
APPENDIX
_..-,._.
--._.D: KEYBOARD
-_-.---_- ANDDISPLAYS
..._-.I__.__,...._"
__.__l__.__l__.,_l_
".
Ii
e60
e61
!k!3!! 648
.-
H e47
850
& e59
t2 e52
REP G6 Ei DIGIT
APPENDIX
._......-- E: SYNOPTIC
..._..._-...... ---TABLE
--__--.-...... -_..._.._
-.."-.----. _
intelinject @
REP G6 Ei DIGIT
APPENDIX
-.- F : PARAMETER
--.-..--_GRID
.-.--.......__
00 10 20 30 I 40 I 50 I 60 70 60 SC
&a?
bq 1
i !qggl 0 _-_-.
!z3
I 5/m
v v G
01 11 21 31 61 .Q 1
b
,
fQ$Jj j
v
02 22 32
I
.-.62 72 62 92
ta@
0
I- -53-p
v 99
c it :
03 23 33 43 53 63. 93
b 1*995
f&lgg?i& 0
v v a6
04 24 34 44 54 64 a4
! 1+999
G+gU' 0
; fv
0.1 0 d
05 25 35 45 55 65 75 95
-Lb
&gg@J Ba
1
y!y
16 26 46 66 A( 9 -6
curetrac*
tI!El
0 K
07 17 27 37 47 57 67 A2 A6 a7
b
9 l \- .'
lzzi
x
vh
18 56 66 A3 A7
0
ia 5s 69 A4 99
C-
6
FtEP G6 Ei DIGIT

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Each chapter contains information ena'oiing you to linJx :.-our mscnine

3ur technical and commercial departments are, of course, at :.-our

The features stipulated in this document are not contractual and we

It is strictly prohibited to remit these documents to a person not

VOL2CHO REP G6 Ei DIGIT I

IV - PRESENT.4TIONOF THE CONTROL OR&US . . . . . . . . 4-l

\--I1 - PRESS OPERATION .,.............,,,,,,,,,,.. T-l

VIII - TOOLING ASSEMBLY .,.,..,................... 8-l

A- GENERAL CONTROL OUTLAY

V2CHOOA REP G6 Ei DIGIT II

1-- GUARD POSITION DETECTORS ........................ 2-i

\;2CHOOA REP G6 Ei DIGIT III

1-1 - VOLUME "OPERATION"

This volume provides yc):l with e\-cry r,e.cessar:- ?:iec?s of

--2 - PROCESS-CONTROL "INTELINJECT"

The G6 Ei Dress is ZqUiDDed

fn addition, the process-control by microprocessor aila>ws for

.---. The possibility to memorize the moulding parameters for a

VOL2CHl REP G6 Ei DIGIT l-1

II-1 - GE~ERALITiES...,..............,.,~,.,...,,.,,.. 5-3

1-2 - DESCRIPTION OF 3.4FETY DEi:iCES ..,.,.i... 2-2

2-l - SAFETY GCARD ........................... 2-6

2-2 - PANELLI?iG ..............................

VOL2CH2 REP G6 Ei DIGIT 2-1

l-1 - S.AFETF ISSTRVCTIGSS

In crder tb ,gu a rant e e this C-c.-

strictly observe the general instr*2ctiocs a;:ci::itl,:: t3 di*:er-,

- The machine has to be installed correctly and the safet:

- The machine has to be operated observing the instructions

- The machine has to be run by competent persons trained for

- The approach of the operating machine must not be allowed

- The esisting safety systems must never be suppressed or

- Regular maintenance and checking of the whole machine are

- The safety devices pro.per to the machine must ne:'er be modi-

l-2 - JlESCRIPTION OF SAFETY DEVICES

According to the user's country, the press can be equipped

2- operation with open guard

VOLZCHZ REP G6 Ei DIGIT 2-2

FiARNING ! During this operation mode the access to the

l Sa.f.,e..t.i e.s ,....... 5.3. and .._. s..:!

Should the press be equipped with hydraulic e.jectors on version

a) The panelling is composed of a front guard, two fised side

c) The opening of the movable panels at the bottom of the closing

Should the machine be equiped with the "head-lift" option,

a) The injection head is equiped with a clamping system in its

2-3 REP G6 Ei DIGIT V2CHOZA

e) ~11 injection settings are to be made on the sxi~ch

f) Certain parts of the injection unit may reach rither hiqh

.z) The hydraulic circuit has no accumulatcr, mna!ring tha-,:

. no Permanent pressure is maintained in the hydraulic

. there is no explosion hazard caused by this cope of

. in case of rupture of a hydraulic chaneiicg, t'ne

b) As the hydraulic hoses are linked together, the rupture of

c) The control electrovalves have three positions in order to

d) In addition to the pressure check valve an overfioti *V.aive T-

VOL2CH2 REP G6 Ei DIGIT 2-4

b) The door of the electric cabinet door includes a closing

d) The position of the cycle selector switch can only be

a) All tools presenting some risks not covered by the safety

b) Moulds are always heavy and it is necessary to use adapted

- one automated front guard

- one manually controlled rear guard.

- The opening and closing of the front guard is

strictly observe the general instr2ctiocs a;:ci::itl,:: t3 di:er-,

Eu.nr.~.i..8.na.l~~~.d..~.~ ( standard opt ions enclosed 1