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2 - Application ====
V68 Y4000
RUBBER INJECTION MOULDING
Technical Manual
Document: V684_2Aa
Edition: 16/06/2000 Std/A
Technical Manual V68 Y4000
Volume 2 - Application
Table of Contents
Table of Contents
Document: V684_2Aa
Edition: 16/06/2000
Chapter I - Safety ......................................................................................................................... 1
1. General safety instructions ................................................................................................. 1

1.1. Field of application .......................................................................................................... 1
1.2. Restrictions of the products used .................................................................................... 1
1.3. Main safety rules ............................................................................................................. 1
2. Personal safety devices ....................................................................................................... 3
2.1. Safety device SE ............................................................................................................. 3
2.2. Safety device S1 ............................................................................................................. 3
3. Electrical safety .................................................................................................................... 5
3.1. Main switch ..................................................................................................................... 5
3.2. Opening the cabinet door ................................................................................................ 5
3.3. Fault indicator .................................................................................................................. 5
3.4. STOP Punch button ...................................................................................................... 5
3.5. Fume extractor device ..................................................................................................... 6
3.6. Switch box ....................................................................................................................... 6
4. Hydraulic safety .................................................................................................................... 8
4.1. General ........................................................................................................................... 8
4.2. Hydraulic safety electrovalve .......................................................................................... 8
5. Closing unit safety ............................................................................................................... 9
5.1. Standard cage ................................................................................................................. 9
5.1.1. Opening of the cage elements ............................................................................. 9
V:\G8\Vol2\A\A_utilisationTDM.fm
5.1.2. Front ..................................................................................................................... 9

5.1.3. Front guard ........................................................................................................... 9
5.1.4. Rear door ........................................................................................................... 10
5.1.5. Rear guard ......................................................................................................... 10
6. Safety on injection unit ...................................................................................................... 11
6.1. Hot surfaces .................................................................................................................. 11
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6.2. Compound inlet chute ................................................................................................... 11

6.3. Ladder placements ....................................................................................................... 11
7. Tooling safety ..................................................................................................................... 12
7.1. General ......................................................................................................................... 12
7.2. Hot surfaces .................................................................................................................. 12
Chapter II - Operating the machine ...................................................................................... 13
1. Powerisation ....................................................................................................................... 13
2. Selection of an existing mould ......................................................................................... 16
2.1. Mould selection ............................................................................................................. 16
2.2. Machines connected to the network ............................................................................. 16
3. Mould start-up programming ............................................................................................ 17
4. Installation of a new tooling .............................................................................................. 18
5. Machine initialisation ......................................................................................................... 24
6. Heating the machine .......................................................................................................... 26
6.1. Mould identification ....................................................................................................... 26
7. Changing the nozzle .......................................................................................................... 27
7.1. Access from below the fixed traverse heating platen .................................................... 27
7.2. Access from above the fixed traverse ........................................................................... 27
7.3. Adjusting injection unit microcontacts ........................................................................... 30
7.4. Beardown microcontact (S48) adjustment .................................................................... 30
7.5. Auto lift microcontact (S72) adjustment ........................................................................ 31
8. Compound loading ............................................................................................................. 34
8.1. Standard use ................................................................................................................ 34
8.1.1. Compound batch conditioning ........................................................................... 34
8.1.2. Rubber strip loading ........................................................................................... 34
8.1.3. Compound monitoring ....................................................................................... 34
8.2. How to use a silicone stuffer ......................................................................................... 35

9. Starting production ............................................................................................................ 36
9.1. Preliminary conditions ................................................................................................... 36
9.2. Compound preparation ................................................................................................. 36
9.2.1. Standard use ..................................................................................................... 36
9.2.2. Using a CRB ...................................................................................................... 37
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9.3. Cycle in semi-automatic mode ...................................................................................... 37

9.3.1. Preliminary conditions ........................................................................................ 37
9.3.2. Machine fitted with S1 safety ............................................................................. 37
9.3.3. Machine fitted with SE safety ............................................................................. 38
9.4. Cycle in automatic mode ............................................................................................... 38
9.4.1. Preliminary conditions ........................................................................................ 38
9.4.2. Cycle start .......................................................................................................... 38
10.Production stop .................................................................................................................. 39
10.1.Procedure for purging in case of production stop ......................................................... 39
10.1.1.Standard use ...................................................................................................... 39
10.1.2.Using a CRB ...................................................................................................... 39
10.2.Procedure for restarting cycle. ...................................................................................... 39
10.2.1.After opening protector ....................................................................................... 39
10.2.2.After pressing P.B. STOP .................................................................................. 40
10.2.3.After an hydraulic pump unit stop. ...................................................................... 40
11.Opening the front ............................................................................................................... 42
11.1.Cleaning the guard ....................................................................................................... 42
Chapter III - Control station .................................................................................................... 45
1. Introduction ......................................................................................................................... 45
2. Operator interface .............................................................................................................. 46
2.1. The display system ....................................................................................................... 46
2.1.1. Hardware ............................................................................................................ 46
2.1.2. Display mechanism ............................................................................................ 46
2.2. The keyboard ................................................................................................................ 47
2.2.1. The associated optimisation function keys ......................................................... 48
2.2.2. The preset function keys .................................................................................... 48
2.2.3. The interface utility keys .................................................................................... 50
2.2.4. The directional keys ........................................................................................... 50
2.2.5. The utility keys of the machine ........................................................................... 51

2.2.6. The numeric keypad ........................................................................................... 51
2.2.7. The standard keyboard socket outlet ................................................................. 52
3. Control front panels ........................................................................................................... 53
3.1. The main control front panel ......................................................................................... 53
3.1.1. Powerization ...................................................................................................... 54
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3.1.2. Indicator lamps ................................................................................................. 55

3.1.3. Press operation selections ................................................................................. 55
3.1.4. Keyboard selections ......................................................................................... 58
3.1.5. Counters ........................................................................................................... 58
3.1.6. Operating mode selection ................................................................................. 60
3.1.7. Standard movement controls ............................................................................. 61
3.1.8. Optional movement controls .............................................................................. 63
3.1.9. Dual-hand control ........................................................................................... 65
3.2. The auxiliary control front panel .................................................................................... 66
3.2.1. The printer socket outlet .................................................................................... 66
3.3. Kit control buttons ......................................................................................................... 67
3.4. Ancillary cylinder control buttons .................................................................................. 68
3.5. Silicone stuffer control buttons ...................................................................................... 68
Chapter IV - Reading and programming of data ............................................................... 69
1. Screen ergonomics ............................................................................................................ 69

1.1. Introduction ................................................................................................................... 69
1.2. Heading line .................................................................................................................. 70
1.3. Message lines ............................................................................................................... 70
1.3.1. Active messages ................................................................................................ 70
1.3.2. Level of the fault messages ............................................................................... 71
1.3.3. Message display rules ....................................................................................... 72
1.3.4. Details of the alarm message line ..................................................................... 72
1.3.5. Details of the information message line ............................................................ 74
1.4. Active page ................................................................................................................... 74
1.4.1. Heading of the active page ................................................................................ 75
1.4.2. Structure of an active page ................................................................................ 75
1.5. Optimisation function .................................................................................................... 76
1.5.1. Colour code of the text keypads ........................................................................ 77
2. Programming rules ............................................................................................................ 78

2.1. Active zones ................................................................................................................. 78
2.2. Bounding box ................................................................................................................ 78
2.2.1. Bounding box shift rules .................................................................................... 78
2.3. Data input validation and deletion ................................................................................. 79
2.3.1. Validation rules for numeric settings .................................................................. 79
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2.3.2. Validation rules for a binary choice .................................................................... 79

2.3.3. Validation rules for an exclusive choice (radio buttons) ..................................... 79
2.3.4. Validation rules for a multiple choice (checkboxes) ........................................... 80
2.3.5. Validation rules of a pulldown menu item ........................................................... 80
2.4. Automatic programming ................................................................................................ 80
2.4.1. Selection rules for an optimisation function ........................................................ 80
2.4.2. Selection rules for the tolerance check .............................................................. 80
3. Use of the tables ................................................................................................................. 81
3.1. Introduction to the tables ............................................................................................... 81
3.1.1. Focus and active cells ........................................................................................ 81
3.1.2. Colour coding of the table cells .......................................................................... 81
3.2. Sequence sorting .......................................................................................................... 81
3.3. Data Screening ............................................................................................................. 82
4. Programming of the moulding parameters ...................................................................... 83
4.1. Page background design .............................................................................................. 83
4.2. Parameter display windows .......................................................................................... 84
4.2.1. Inquiry window ................................................................................................... 84
4.2.2. Programming window ......................................................................................... 84
4.2.3. Tolerance window .............................................................................................. 86
4.2.4. Colour code of the parameter windows .............................................................. 87
4.3. Activating an optimisation function ................................................................................ 87
4.3.1. Colour code of the optimisation function selection diamond. ............................. 88
5. Instructions for how to change parameters ..................................................................... 89
5.1. How to change a parameter set value .......................................................................... 89
5.2. How to change the tolerances of a parameter .............................................................. 89
Chapter V - Moulding parameters ......................................................................................... 91
1. Principle of the distribution of functions ......................................................................... 91

2. Synoptic diagrams of the parameters .............................................................................. 93

2.1. Introduction ................................................................................................................... 93
2.2. Shot size setting ............................................................................................................ 94
2.3. Different types of injection piston retraction .................................................................. 95
2.4. Mould closing ................................................................................................................ 96
2.5. Injection (dynamic phase) ............................................................................................. 97
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2.6. Injection (static phase) .................................................................................................. 98

2.7. Injection-transfer ........................................................................................................... 99
2.8. Initiation of the different time-delays ........................................................................... 100
2.9. Degassing ................................................................................................................... 101
2.10.Mould opening ............................................................................................................ 102
2.11.Ejection on the movable traverse ............................................................................... 103
2.12.Ejection on the fixed traverse ..................................................................................... 104
3. Function Compound preparation ................................................................................ 105
3.1. Base page Compound preparation ......................................................................... 105
3.1.1. Associated graphic page ................................................................................. 105
3.1.2. Main sub-functions ........................................................................................... 106
3.1.3. Parameters ...................................................................................................... 106
3.2. Optimisation page Back-pressure ........................................................................... 109
3.2.2. Optimisation sub-function ................................................................................ 109
3.2.3. Parameters ...................................................................................................... 110
3.3. Optimisation page Extruder time-delay ................................................................... 111
3.3.2. Parameters ...................................................................................................... 112
3.4. Optimisation page Extruder feed strip rupture ......................................................... 113
3.4.3. Parameters ...................................................................................................... 114
3.5. Optimisation page Shot size accuracy .................................................................... 115
3.5.3. Parameters ...................................................................................................... 116
3.6. Optimisation page Compound decompression ........................................................ 117
3.6.1. Optimisation sub-functions .............................................................................. 117
3.6.2. Parameters ...................................................................................................... 118
3.7. Optimisation page Silicone stuffer ........................................................................... 119
3.7.2. Parameters ...................................................................................................... 120

4. Function Mould closing ............................................................................................... 121
4.1. Base page Mould closing ........................................................................................ 121
4.1.3. Parameters ...................................................................................................... 122
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4.2. Optimisation page Plate approach ........................................................................... 125

4.2.1. Optimisation sub-function ................................................................................. 125
4.2.2. Parameters ....................................................................................................... 126
4.3. Optimisation page Mould height adjustment screw ................................................. 127
4.3.2. Parameters ....................................................................................................... 128
5. Function Filling ............................................................................................................. 129
5.1. Base page Filling ..................................................................................................... 129
5.1.1. Associated graphic page .................................................................................. 129
5.1.3. Parameters ....................................................................................................... 131
5.2. Optimisation page Injection profile ........................................................................... 136
5.2.3. Parameters ....................................................................................................... 138
5.3. Optimisation page Degassing .................................................................................. 140
5.3.1. Optimisation sub-functions ............................................................................... 141
5.3.2. Parameters ....................................................................................................... 142
5.4. Optimisation page Cold runner block ....................................................................... 144
5.4.2. Parameters ....................................................................................................... 145
5.5. Optimisation Page Beardown after injection ............................................................ 146
5.5.2. Parameters ....................................................................................................... 147
5.6. Optimisation page Vacuum ...................................................................................... 148
5.6.2. Parameters ....................................................................................................... 149
5.7. Optimisation page Automatic injection unit lift ......................................................... 150
5.7.2. Parameters ....................................................................................................... 151
5.8. Optimisation page 2nd transfer ................................................................................ 152
5.8.2. Parameters ....................................................................................................... 153
5.9. Optimisation page Compound pressure .................................................................. 154

5.9.2. Parameters ....................................................................................................... 155
6. Function Curing ............................................................................................................ 156
6.1. Base page Curing .................................................................................................... 156
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6.1.3. Parameters ...................................................................................................... 157
6.2. Optimisation page Curetrac Corrections ................................................................. 158
6.3. Optimisation page Curetrac communication ............................................................ 159
6.4. Optimisation page Network Link .............................................................................. 160
6.5. Optimisation page Ancillary areas ........................................................................... 161
6.5.2. Parameters ...................................................................................................... 162
7. Function Stripping and loading of inserts ................................................................. 163
7.1. Base page Stripping and loading of inserts ............................................................. 163
7.1.2. Parameters ...................................................................................................... 164
7.2. Optimisation Movable traverse ejectors ................................................................... 165
7.3. Optimisation page Movable traverse ejectors ......................................................... 166
7.3.2. Parameters ...................................................................................................... 167
7.4. Optimisation page Movable traverse ejectors with encoder .................................... 168
7.4.2. Parameters ...................................................................................................... 169
7.5. Optimisation page Mechanical ejectors ................................................................... 170
7.5.2. Parameters ...................................................................................................... 171
7.6. Optimisations Fixed traverse ejectors ...................................................................... 172
7.7. Optimisation page Fixed traverse ejectors .............................................................. 173
7.7.2. Parameters ...................................................................................................... 174
7.8. Optimisation page Fixed traverse ejectors with encoder ......................................... 175
7.8.2. Parameters ...................................................................................................... 176
7.9. Optimisation page Stripping kits .............................................................................. 178
7.9.2. Parameters ...................................................................................................... 179
7.10.Optimisation page Plate approach .......................................................................... 180

7.10.1.Optimisation sub-function ................................................................................ 180
7.10.2.Parameters ...................................................................................................... 181
7.11.Optimisation page Sliding platen ............................................................................ 182
7.11.1.Optimisation sub-function ................................................................................ 182
7.11.2.Parameters ...................................................................................................... 183
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7.12.Optimisation page Ancillary cylinders ..................................................................... 184

7.12.1.Optimisation sub-functions ............................................................................... 184
7.12.2.Parameters ....................................................................................................... 185
7.13.Optimisation page Limits ......................................................................................... 186
7.13.1.Optimisation sub-functions ............................................................................... 186
7.13.2.Parameters ....................................................................................................... 187
Chapter VI - Thermotrac ...................................................................................................... 189
1. Temperature control and Thermotrac function ........................................................... 189

1.1. Introduction ................................................................................................................. 189
1.1.1. Controls and control coefficients ...................................................................... 189
1.1.2. Software Thermotrac ..................................................................................... 189
1.2. Active Thermotrac pages .......................................................................................... 190
1.2.1. Access to the different active pages of Thermotrac ....................................... 190
1.2.2. Colour code of the output states ...................................................................... 190
2. Function Thermotrac ...................................................................................................... 191
2.1. Base page Thermotrac ............................................................................................ 191
2.1.1. Ambient temperature and cold junction measured values ............................... 192
2.1.2. Characteristics of the heating and cooling areas ............................................. 192
2.1.3. Maximum temperatures ................................................................................... 192
2.1.4. Additional characteristics of the heating and cooling areas ............................. 193
2.2. Optimisation page Identification .............................................................................. 195
2.2.1. Identification control ......................................................................................... 195
2.2.2. Referencing columns ....................................................................................... 196
2.2.3. Identification course information frame ............................................................ 196
2.2.4. Frames of the control coefficients .................................................................... 196
2.3. Optimisation page Temperature control supervision .............................................. 198
2.4. Optimisation page Identification control .................................................................. 199
3. Identification through Thermotrac ................................................................................ 200
3.1. Initiation of the identification process .......................................................................... 200

3.1.1. Identifiable areas .............................................................................................. 200
3.1.2. Starting conditions ............................................................................................ 200
3.1.3. How to start the identification cycle .................................................................. 200
3.2. Identification phases ................................................................................................... 202
4. Use of the PIDT coefficients ............................................................................................ 204
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4.1. Heating-up conditions of a tooling .............................................................................. 204

4.2. Manual programming of the PIDT coefficients ............................................................ 204
5. Error messages Thermotrac ......................................................................................... 205
Chapter VII - Mastertrac ...................................................................................................... 207
1. Introduction ...................................................................................................................... 207

1.1. Movements compatible with Mastertrac ................................................................... 207
1.2. Controls reserved for the application of Mastertrac .................................................. 209
1.3. Cycle Mastertrac ....................................................................................................... 210
2. Function Mastertrac ....................................................................................................... 211
2.1. Access to the different active pages of Mastertrac ................................................... 211
2.2. Selections associated to Mastertrac ......................................................................... 211
2.2.1. Selection of the Mastertrac cycle (cycle 31) .................................................. 211
2.2.2. Selection of the optimisation functions used in the Mastertrac cycle (cycle 31) 211
2.3. Base page Mastertrac ............................................................................................. 212
2.3.1. Movement authorization .................................................................................. 212
2.3.2. Tables of the saved sequence ......................................................................... 213
2.4. Optimisation page Learning of the sequence .......................................................... 214
2.4.1. Activation of the learning mode ....................................................................... 214
2.4.2. Tables of the saved sequence ......................................................................... 215
2.4.3. Frame of the particular operations ................................................................... 215
2.5. Optimisation page Selections .................................................................................. 216
2.6. Optimisation page Cycle selection .......................................................................... 217
3. Application Mastertrac .................................................................................................. 218
3.1. Selections prior to the application of Mastertrac ....................................................... 218
3.1.1. How to select cycle 31 ..................................................................................... 218
3.1.2. How to select the optimisation functions to integrate into the Mastertrac sequence
218
3.2. Application of the Learning function ......................................................................... 219

3.2.1. How to activate or deactivate the Learning Mode ......................................... 219
3.2.2. How to make a Mastertrac sequence ............................................................ 219
3.2.3. How to integrate a particular operation into a Mastertrac sequence ............. 220
3.2.4. How to save the last sequence executed in the learning mode ...................... 220
3.2.5. How to cancel the last step entered to a Mastertrac sequence ..................... 220
3.2.6. How to delete a Mastertrac sequence ........................................................... 221
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3.3. Use of cycle 31 ............................................................................................................ 222

3.3.1. How to test the Mastertrac sequence ............................................................ 222
3.3.2. How to work in the Automatic mode with the last Mastertrac sequence ..... 222
Chapter VIII - Preset functions ............................................................................................. 223
1. Introduction ....................................................................................................................... 223

2. Function Maintenance .................................................................................................. 225
2.1. Base page Sequential Diagnostic ............................................................................ 225
2.1.1. Presentation and application ............................................................................ 225
2.1.2. Information on the course of the sequential program ....................................... 226
2.1.3. Comparison of cycles ....................................................................................... 226
2.1.4. Information on the difference found ................................................................. 226
2.1.5. How to compare the course of the current cycle with that of the previous cycle 226
2.2. Optimisation page Digital inputs .............................................................................. 228
2.2.1. How to read the status of a digital input ........................................................... 228
2.3. Optimisation page Other inputs/outputs .................................................................. 230
2.3.3. Digital outputs .................................................................................................. 231
2.3.4. Analogue outputs ............................................................................................. 231
2.3.5. Pressure channels ........................................................................................... 231
2.3.6. Encoder channels ............................................................................................ 231
2.3.7. How to read the status of a digital output ......................................................... 232
2.3.8. How to read the value of an analogue output .................................................. 232
2.3.9. How to read the value of an analogue input ..................................................... 232
2.3.10.How to read the value of a counting channel ................................................... 232
2.4. Optimisation page Retrace inputs/outputs ............................................................... 233
2.4.2. Internal variables .............................................................................................. 234
2.4.3. Curve operating tools ....................................................................................... 234
2.4.4. Visualization of plotting curves ......................................................................... 234

2.4.5. How to display the curve of an internal variable ............................................... 234
2.4.6. How to analyse an internal variable curve ....................................................... 235
2.5. Optimisation page Preventive maintenance ............................................................ 236
2.5.2. Description of the preventive maintenance table ............................................. 237
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2.5.3. How to select/deselect a preventive maintenance operation ........................... 238

2.5.4. How to change a preventive maintenance operation ....................................... 238
2.5.5. How to reinitialize the counter triggering a preventive maintenance operation 239
2.6. Optimisation page Retrace faults ............................................................................ 240
2.6.1. Presentation and application ........................................................................... 240
2.6.2. Message filtration ............................................................................................. 240
2.6.3. Table retracing the faults encountered, ........................................................... 241
2.6.4. Process sorting ................................................................................................ 241
2.6.5. How to filter faults in the archive ...................................................................... 242
2.6.6. How to sort faults in the archive ....................................................................... 242
2.6.7. How to change the level of seriousness of a fault ........................................... 242
2.7. Optimisation page Setting software ......................................................................... 244
3. Function Production configuration ............................................................................. 245
3.1. Base page Production check ................................................................................... 245
3.1.2. Compatible parameters ................................................................................... 247
3.1.3. How to bring up a parameter window on the page Production check ........... 248
3.1.4. How to clear a parameter from the display zone ............................................. 248
3.1.5. How to modify a parameter set point using the + and - slopes ........................ 248
3.2. Optimisation page Production selection .................................................................. 250
3.3. Optimisation page Mould selection ......................................................................... 251
3.3.2. Table of stored moulds .................................................................................... 252
3.3.3. Mould duplication tool ...................................................................................... 252
3.3.4. How to select a mould ..................................................................................... 252
3.3.5. How to duplicate or create a mould ................................................................. 253
3.3.6. Using the page Mould selection with option OP227: Machine workstation RepNet-
win 253
3.4. Optimisation page Machine time ............................................................................. 254
3.4.2. Base sub-functions .......................................................................................... 255
3.4.3. Parameter ........................................................................................................ 255
3.5. Optimisation page Cycle counter ............................................................................ 257

3.5.2. Press counter ................................................................................................... 258
3.5.3. Counter RepNet-win ...................................................................................... 258
3.6. Optimisation page Cycle selection .......................................................................... 259
3.6.2. Basic cycle ....................................................................................................... 260
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3.6.3. Preset cycles .................................................................................................... 260

3.6.4. Specific cycles .................................................................................................. 264
3.6.5. How to select a cycle ....................................................................................... 264
3.7. Optimisation page Selections .................................................................................. 265
3.7.2. Optimisation functions Ejectors on fixed and movable traverses .................. 266
3.7.3. Optimisation functions Vacuum pump ........................................................... 266
3.7.4. Shortcuts .......................................................................................................... 266
3.7.5. How to select or to deselect an optimisation function ..................................... 266
3.7.6. How to use hot keys ...................................................................................... 267
3.8. Optimisation page Heating clock ............................................................................. 268
3.8.2. Stand-by temperature ...................................................................................... 268
3.8.3. Table of time ranges ........................................................................................ 269
3.8.4. the programming window for the stand-by temperature set value. .................. 269
3.8.5. Control window for the heating authorisation ................................................... 269
3.8.6. How to start up the heating clock ..................................................................... 269
3.8.7. How to reduce the temperature of areas of the mould during slack periods .... 270
4. Function Machine configuration ................................................................................. 271
4.1. Base page Machine configuration ........................................................................... 271
4.1.1. How to change the date on the machine .......................................................... 271
4.2. Optimisation page Language ................................................................................... 272
4.2.1. How to select a language ................................................................................. 272
4.3. Optimisation page Printer ........................................................................................ 274
4.4. Optimisation page Version ....................................................................................... 275
4.5. Optimisation page System ....................................................................................... 276
4.6. Optimisation page Press options ............................................................................. 277
Chapter IX - Graphic functions ............................................................................................ 279

1. Introduction to the graphic pages .................................................................................. 279

1.1. General ....................................................................................................................... 279
1.2. Using a graphic page .................................................................................................. 279
1.2.1. Display on the screen ....................................................................................... 279
1.2.2. Clearing the screen .......................................................................................... 279
1.2.3. Printing ............................................................................................................. 279
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1.3. Structure of a graphic page ........................................................................................ 280

1.3.1. Heading of the graphic page ............................................................................ 280
1.3.2. Different features of the graphic page ............................................................. 280
1.3.3. Plot axes .......................................................................................................... 281
1.4. Graph types ................................................................................................................ 283
1.5. Using the zoom ........................................................................................................... 283
1.5.1. General rules ................................................................................................... 283
1.5.2. Plot freezing ..................................................................................................... 285
1.6. Application procedures of the graphic pages .............................................................. 285
1.6.1. How to access a graphic page ......................................................................... 285
1.6.2. How to plot a graph .......................................................................................... 285
1.6.3. How to delimit the graph part to zoom? ........................................................... 285
1.6.4. How to control the zoom .................................................................................. 286
1.6.5. How to freeze a graph ..................................................................................... 286
1.6.6. How to exit the zoom ....................................................................................... 286
1.6.7. How to return to the dynamic plot .................................................................... 286
1.6.8. How to measure a point on the graph .............................................................. 287
1.7. List of the graphic pages ............................................................................................. 288
2. Graphic page Injection unit temperatures ............................................................... 289
3. Graphic page Back pressure ................................................................................... 290
4. Graphic page Extruding ............................................................................................ 291
5. Graphic page Clamping ........................................................................................... 292
6. Graphic page Injection (Time) .................................................................................. 293
6.1. Direct injection variant ................................................................................................ 293
6.2. Injection transfer variant ............................................................................................. 293
7. Graphic page Injection (Stroke) .............................................................................. 295
8. Graphic page Mould temperatures .......................................................................... 296
9. Graphic page Hydraulics .......................................................................................... 297
Index ......................................................................................................................................... 299
Previous versions 315
Document: V684_2Aa
page xiv Edition: 16/06/2000
Table of Contents
1. Technical progresses ....................................................................................................... 315

1.1. Single documentation .................................................................................................. 315
1.2. Year of manufacture of the machine ........................................................................... 315
2. One-piece front side ......................................................................................................... 316
Document: V684_2Aa
Edition: 16/06/2000 page xv
Table of Contents
Document: V684_2Aa
page xvi Edition: 16/06/2000
Chapter I - Safety
Chapter I - Safety
1. General safety instructions
1.1. Field of application

Rep presses are designed for rubber injection moulding.
WARNING: The use of the press in any other field of application is strictly forbidden.
1.2. Restrictions of the products used

Rep presses have been designed to transform, without any risk, a wide range
of elastomers except:
products that produce harmful gases,
abrasive products.
1.3. Main safety rules

REP machines are supplied with a specific safety configuration in compliance
with the safety standards in force in the user's country. Under no circum-
stances should modifications be carried out to the press inherent safety devic-
es described below without consulting the manufacturer or the official safety
bodies.
WARNING: REP will not accept liability in the event of an accident following unauthorized
modifications of the machine, its electric, hydraulic or pneumatic circuits or its
kinematic or regulating programs. Indeed, such modifications may endanger
V:\G8\Vol2\A\A_utilisation_securite.fm
the operator's safety and are therefore strictly prohibited.

REP will not accept liability for use of the machine other than normal use as
described in the technical manual or for use outside the scope of its specific
safety configuration.
General safety instructions

Document: V684_2Aa
Edition: 16/06/2000 page 1
Chapter I - Safety
In order to ensure his own safety, the safety of the staff working in his vicinity
as well as the safety of the tooling, and so as not to divert the machine inher-
ent safety function, the user must respect the basic safety rules given below,
and instruct his staff accordingly:
1. the machine must be installed properly and the safety devices checked regu-
larly:
2. the machine must only be used respecting the instructions and characteristics
of application;
3. only skilled persons who have followed a special training are allowed to use
the machine;
4. no-one except the operator must approach the machine when it is in use. Be-
fore making any movement, he must make sure that no other person is in the
immediate vicinity of the machine;
5. the whole machine must be maintained and checked regularly by competent
staff.
General safety instructions

Document: V684_2Aa
page 2 Edition: 16/06/2000
Chapter I - Safety
2. Personal safety devices

Depending on the safety regulations and standards in force in the user's coun-
try, the REP press can be fitted with an SE or S1 safety device.
Please refer to the regulations and standards in force
WARNING: SE is the sole safety device compliant with the European safety directives
and having received the EC type-examination certificate .
2.1. Safety device SE

REP machines fitted with SE safety devices are protected by a cage shroud to
stop people entering into the closing unit and injection unit movement area
during the machine operating cycle.
The SE safety device requires the user to work with the cage doors and the
safety guard closed.
REMARK: Despite this, the user can operate the options installed on the closing unit (hy-
draulic ejectors on press: OP139 and OP141), when the guard is open, if he
has turned selector S12 beforehand (Select. open guard dual-hand ejectors)
to 1 and controlled the movements dual-handed, in other words by pushing si-
multaneously on the movement control button and on S93 (P.B. dual hand)
and by maintaining the dual control during the whole movement.
refer to section 3.1.3. Press operation selections, page 55
REP machines are fitted with the SE safety device including a hydraulic safety
electrovalve on the hydraulic approach network for closing and opening
movements. This Y69 electrovalve (E.V. Hydraulic safety) is pilot controlled
directly by the closed guard end of stroke microcontact reserved for this.
REMARK: The slide position of this electrovalve is continually controlled by the machine
process-control.
2.2. Safety device S1

REMARK: This section does not concern users in European countries.
REP machines fitted with the safety device S1 allow the operator to work ei-
ther with or without the safety guard which usually prohibits access to the
closing unit movement area.
Personal safety devices

Document: V684_2Aa
Chapter I - Safety
The operating mode of the safety guard is selected via the key-operated
switch S4: (S4: selection of guard operation) which allows the following func-
tions:
Positions Operations
The press closing movements and movements of op-
0
without tions OP137a, OP139b and OP141c are authorized with
guard the guard open but they must be dual-handed-control-
led.
All movements of the press and its options can only be
1 with screen
carried out if the screen has been closed beforehand.
a. OP137: Sliding platen
b. OP139: Hydraulic ejectors of the movable traverse
c. OP141: Hydraulic ejectors of the fixed traverse
REMARK: When operating without guard, the cycle can be carried out in Manual or
Semi-automatic operating modes, but in this case the press can only be
closed with the a synchronised and continued S93 dual-handed control.
When operating with screen, the user can operate the options installed on the
hydraulic ejectors on press closing unit (OP139 and OP141), if he has turned
selector S12 beforehand (Select. open guard dual-hand ejectors) to 1 and con-
trolled the movements dual-handed, in other words by pushing simultaneously
on the movement control button and on S93 (B.P. dual hand) and by maintain-
ing the dual control during the whole movement.
refer to section 3.1.3. Press operation selections, page 55
Personal safety devices

Document: V684_2Aa
Chapter I - Safety
3. Electrical safety
3.1. Main switch

The handle of the main circuit breaker is located on the door of the switch cab-
inet. It enables the operator to switch off the electric current on the entire ma-
chine.
refer to section 3.1.1. Powerization, page 54
WARNING: The main isolating switch must be locked in position OFF prior to any electri-
cal intervention on the machine.
This type of intervention is prohibited to anyone other than authorized electri-
cal maintenance staff.
3.2. Opening the cabinet door

The door of the switch cabinet is equipped with 2 safety latches. It must be
closed and locked when the machine is being used for production or settings.
WARNING: Access inside the cabinet is prohibited to anyone other than authorized elec-
trical maintenance staff.
3.3. Fault indicator

A press fault indicator (H40) shows any anomaly that could be a potential
safety hazard.
refer to section 3.1.2. Indicator lamps, page 55
3.4. STOP Punch button

The machine is fitted out in standard version with a self-locking emergency
stop switch in the form of a punch-button which will stop the machine im-
mediately.
refer to section 3.1.1. Powerization, page 54

When the Punch button is activated, the KA1 relay contacts cut all supply
inside the electrical cabinet except 220VAC which supplies the PC UPS and the
24VDC supply.
Electrical safety
Document: V684_2Aa
Chapter I - Safety
When the Punch button has been activated, the press cannot move. Turn
and pull out the button head to reconnect the a.m. circuits to the main power
supply.
WARNING: Pushing S201 will not insulate the whole switch cabinet from its supply net-
work: the mains supply must be cut off by means of the main switch isolator
Q1 prior to any electrical intervention on the machine.
When the mains power is cut, the 220VAC voltage saved by the UPS power-
ing the machine PC is maintained for 2 minutes.
REMARK: When the machine is fitted with the option OP071: Simplified rear cage exten-
sion, a second STOP push button(S200) is installed inside the cage.
3.5. Fume extractor device

Some materials injected can give off harmful fumes.
In order to reduce the contamination caused by these fumes, a fume extrac-
tion system must be installed and connected to the REP press.
WARNING: If the user of the machine installs this kind of smoke extractor in case of emis-
sions of harmful gas, dust or fumes, he does so under his own responsibility.
However, the option OPV072: Prearrangement for fume extraction is pro-

vided to configure the REP press so that:
it can only be used when the above extraction system is in operation.
it is automatically stopped if the extraction system stops.
3.6. Switch box

Warning labels are affixed to all the machine switch boxes in order to alert the
operator to the danger of electric shock when opening these boxes. These la-
bels are rectangular, they are red on a yellow background and they show the
following symbol:
Electrical safety
Document: V684_2Aa
Chapter I - Safety
WARNING: Persons unauthorised to carry out electrical maintenance work are prohibited
from opening these switch cabinets.
Electrical safety
Document: V684_2Aa
Chapter I - Safety
4. Hydraulic safety
4.1. General
The hydraulic hoses are grouped together, to ensure that even if one hose
breaks, no dangerous movement is caused.
The control electrovalves are three-position type, so that any movement is
stopped in the event of a power cut-off.
In addition to the pressure limiter, an overflow valve mounted on the hydrau-
lic circuit at the pump outlet which prevents the pressure from exceeding the
285-bar maximum value.
WARNING: It is strictly prohibited to modify the hydraulic circuit or to replace equipment

with inappropriate equipment.
Flanges and flexible holding chains must be refitted correctly and the tighten-
ing torques for the different connection supports and hydraulic equipment re-
spected.
4.2. Hydraulic safety electrovalve

REMEMBER: The hydraulic safety electrovalve is part of the SE safety device which com-
plies with European safety directives and which has been granted the EC type-
examination certificate.
The hydraulic safety electrovalve (Y69) is an electrovalve installed upstream
from the hydraulic circuit of the closing unit.
This electrovalve is directly piloted by the microcontact cascade reserved for
this and mounted on each machine cage guard and door.
Furthermore, movement of the electrovalve spool is monitored by a position
sensor (S59: L.S. control E.V. hydraulic safety).
The closing movement is only possible if Y69 is pilot controlled.
Hydraulic safety
Document: V684_2Aa
Chapter I - Safety
5. Closing unit safety
5.1. Standard cage

The standard cage of a press is made up of a swivelling front, 2 fixed side pan-
els and a door on the rear of the unit. All the movable elements of the cage are
controlled by microcontacts.
5.1.1. Opening of the cage elements

If a movable cage element fails to close or opens during a press cycle, it will
inhibit any movement of the press.
WARNING: If a cage element should open during a cycle, the operator will have to turn
to the setting mode, to open the press to the maximum before he can restart
a production cycle.
The automatic or semi-automatic cycle is not interrupted if the safety guard
is open during the curing phase and closed before the end of this phase.
5.1.2. Front
The front of a press swivels. When open, this permits access to inside the cage
and therefore facilitates tool mounting and maintenance operations and clos-
ing unit and machine guard maintenance and cleaning operations.
When open, it also gives easy access to the injection unit and therefore facili-
tates adjusting, maintenance and cleaning operations.
These movements are controlled and secured by a microcontact.
WARNING: The front face must be kept closed with the screws supplied for this.
refer to section 11. Opening the front, page 42
5.1.3. Front guard

The front guard is a pneumatic control guard which is mounted in the front
structure.
These movements are controlled and secured by microcontacts.
REMARK: The SE safety requires the operator to close the guard before controlling any
press movement.
refer to section 2. Personal safety devices, page 3
Closing unit safety

Document: V684_2Aa
Chapter I - Safety
5.1.4. Rear door
WARNING: The rear door is fitted with 2 safety latches. Before closing the rear door,
make sure no-one is inside the cage.
5.1.5. Rear guard

The rear door can be replaced with a screen when the machine is equipped
with special option OPV037: Automated rear guard
The rear guard movements are all controlled and secured by microcontacts.
REMARK: The SE safety requires the operator to close the guards before controlling any
press movement.
refer to section 2. Personal safety devices, page 3
Closing unit safety

Document: V684_2Aa
Chapter I - Safety
6. Safety on injection unit
6.1. Hot surfaces
WARNING: As some parts of the injection unit reach relatively high temperatures, it is rec-
ommended to guard against burns by wearing safety gloves for any work car-
ried out around the injection unit.
Warning labels are affixed to the machine, near to the heating areas to alert the
operator to the danger of burns. These labels are triangular, black on a yellow
background and carry the following symbol:
6.2. Compound inlet chute

The extruder inlet is protected by a chute which is secured to the extruder bar-
rel, in front of the extruder barrel inlet hole. The length of this chute has been
designed to make it impossible for the operator to touch the extruder screw
with his fingers.
WARNING: The extruder inlet chute should in no case be removed when the machine is
in production.
The shape of the screw and of the extruder barrel has been specially de-
signed to ensure maximum efficiency of the rubber strip intake. Do not try to
help feed rubber strip into the extruder hole with any metal object.
6.3. Ladder placements

If any work is required on the upper parts of the injection unit, set a ladder up
using the locating supports provided.
see illustration Fig. 7. Ladder placements, page 29
Safety on injection unit

Document: V684_2Aa
Chapter I - Safety
7. Tooling safety
7.1. General
Any tool entailing risks which are not covered by the machine protection sys-
tems must feature its own protection devices.
As moulds are naturally heavy, appropriate handling equipment must be
used.
WARNING: In any case, attention must be paid to ensuring that the moulds or accesso-
ries are secured properly.
As all parts of an elastomer injection mould reach very high temperatures, it
is recommended to guard against burns by wearing safety gloves for any
work carried out around the mould.
7.2. Hot surfaces

Warning labels are affixed to the machine close to the heating areas to alert the
operator to the danger of burns. These labels are triangular, black on a yellow
background and carry the following symbol:
Tooling safety
Document: V684_2Aa
Chapter II - Operating the machine
1. Powerisation
Switching on electrical cabinet and starting up PC.
1. Position main circuit breaker Q1 to ON.
see section Main switch, page 54
2. Check that the Punch button S201 is released.
see section 3.4. STOP Punch button, page 5
REMARK: The PC is switched on the same time as the whole of the electrical cabinet. The
power-on page is displayed while the operating system Windows NT and
REP machine control software are loading; this may take a few minutes.
see also illustration Fig. 1., page 13
Switching process-control on
3. Press the green push button S203; the green lamp of the button lights up.
see section Push button Process control voltage on, page 54
V:\G8\Vol2\A\A_utilisation_conduite.fm
Fig. 1. power-on page
Powerisation
Document: V684_2Aa
Q1
Key Init
H40 S4* S100 P1 P2 S0
S32** S17 P3
S203 S204 S18 S38 S35 S75 S43
S201 S212 S11 S108 S33 S41 S66
S202 S213 S19 S37 S36 S76 S44
S211 S12 S107 S34 S42 S65

S93
S112 S176
S124
S175
S123
Fig. 2. Control station of a G8 press
Powerisation
Document: V684_2Aa
Switching process-control off

4. Press the red push button S202; the green lamp of the button S203 goes out.
see section Push button Process control stop, page 54
Switching hydraulic pump unit on
5. Press the yellow push button S212; the yellow lamp of the button lights up.
see section Push button Hydraulic pump unit power on, page 55
Switching hydraulic pump unit off
6. Press the red push button S211; the yellow lamp of the button S212 goes out.
see section Push button Hydraulic pump unit stop, page 55
Switching electrical cabinet off
7. Press Punch button S201.
Total insulation of electrical cabinet
8. Position main circuit breaker Q1 to OFF.
see section Main switch, page 54
REMARK: The 220VAC saved by the UPS which feeds the PC is maintained for 2 minutes
after the cabinet power supply is cut.
Powerisation
Document: V684_2Aa
2. Selection of an existing mould

For the operator, a mould consists of all the machine management and
moulding parameters programmed for a given tooling and stored under one
label.
You must choose a mould number before starting a new production.This op-
eration enables you to associate one group of parameters to a given tooling.
2.1. Mould selection

1. Select a mould number.
see section 3.3.4. How to select a mould, page 252
2. Program the mould with only the parameters needed to start up production.
see section 3. Mould start-up programming, page 17
REMARK: The mould will be stored locally on the machine hard disk.
2.2. Machines connected to the network

When a machine is connected to the network RepNet-win, all the moulds as-
sociated with all tooling previously used in the workshop are in general
stored on the hard disk central terminal RepNet-win.
Despite this, each press can also store 100 moulds.
Mould selection can therefore be made according to the following methods:
locally: by selecting a mould among those stored on the press,
see section 2.1. Mould selection, page 16
across the network: by the following procedure:
1. Select a mould number.
see section 3.3.4. How to select a mould, page 252
2. Program the mould with the parameters stored on the central terminal.
refer to volume 5 - OptionRepNet-win: machine computer V:\G8\Vol2\A\A_utilisation_conduite.fm
Selection of an existing mould

Document: V684_2Aa
3. Mould start-up programming

Start-up programming is to program a minimum number of moulding pa-
rameters enabling you to start up a new production with new tooling. These
parameters are the main parameters displayed on the 5 main function screens
corresponding to simple mould programming.
Start-up programming can then be supplemented by parameter program-
ming for the different optimisation functions chosen for the tooling during
use.
1. Press key . Program the main screen parametersCompound prepara-

tion.
2. Press the key . Program the main screen parametersMould closing.
3. Press the key . Program the main screen parametersFilling.
4. Press the key . Program the main screen parametersCuring.
5. Press the key . Program the main screen parametersStripping and

loading of inserts.
refer to section 5. Instructions for how to change parameters, page 89
REMARK: Some optimisation functions are needed depending on the tooling used: for ex-
ample, Cold runner blocks.
Mould start-up programming

Document: V684_2Aa
4. Installation of a new tooling

Checking programming for the appropriate mould parameters
1. Press key . Check that the parameters displayed are programmed; if

not program them.
see section 4.1. Base page Mould closing, page 121
2. Press key . Check that the parameters displayed are programmed; if

not program them.
see section 6.1. Base page Curing, page 156
3. If the machine is equipped with the option OP137 Sliding platen, successive-
ly press the keys and , set the displayed parameters and select
the optimisation function.
see section 7.11. Optimisation page Sliding platen, page 182
4. If the machine is equipped with the option OP139 Movable traverse ejectors,
successively press the keys and , set the displayed parameters

and select the optimisation function.
see section 7.2. Optimisation Movable traverse ejectors, page 165
5. If the machine is equipped with the option OP141 Fixed traverse ejectors,
successively press the keys and , set the displayed parameters

and select the optimisation function.
see section 7.7. Optimisation page Fixed traverse ejectors, page 173
Opening the front
REMARK: It is possible to open the front to facilitate access to inside the cage.
In this case, the front must always be closed and kept closed with the screws
provided whenever the machine is in operation.
see section 11. Opening the front, page 42
Loading and fastening the mould
6. Turn selector S0 to .
7. Open the press by pressing S34 up to the opening limit position.
see section Push button Press opening, page 62
8. If the machine is equipped with the option OP137 Sliding platen, control the
sliding platen out by pressing S44 and the dual-hand control simultaneously.
S93
see section Push button "Sliding platen in", page 64
9. Handle the new tooling with a handling H and a lift truck to position it on
the heating platen of the movable traverse.
refer to volume 9 - Tooling
Installation of a new tooling

Document: V684_2Aa
10. If the machine is equipped with the option OP137 Sliding platen, control the
sliding platen in by pressing S43 and the dual-hand control
simultaneouslyS93.
see section Push buttone Sliding platen out, page 64
If the press is equipped with standard heating platens:
11. Centre the mould and put the fastening screws near the mould without block-
ing them.
If the press is fitted with quick latch heating platens:
12. Place the stops on the heating platen of the movable traverse.
The mould is now prefastened on the movable traverse heating platen.
13. Close the press by pressing S33 until being about 20 mm away from the ap-
proach.
Check that the centring cone is aligned with the fixed traverse heating platen
hole. Close the press completely
see section Push button Press closing, page 62
If the press is equipped with standard heating platens:
14. Screw and tighten the fastening screws of the half-mould on the fixed traverse
side.
Screw and tighten the fastening screws of the half-mould on the movable
traverse side.
If the press is fitted with quick latch heating platens:
15. Tighten the half-mould vices on the fixed traverse side.
Finish tightening the stop screws on the half-mould on the movable traverse
side.
The half-moulds are now completely fastened to the heating platens.
16. Remove the retaining flanges from the different parts of the mould which stop
it opening.
WARNING: The retaining flanges which stop the mould opening must be removed before
the press opening control otherwise it and the tooling may be seriously dam-
aged.
Fastening the plate on the fixed traverse ejector bars

17. If the machine is equipped with the option OP141 Fixed traverse ejectors
and if a plate has to be fixed to the ejector bars, control the fixed traverse ejec-
tors out by pressing S76a until touching the plate.
see section Push buttonb "Fixed traverse ejectors out", page 63

18. Position the insulating studs and screw the fastening shouldered screws.
Refer to the indications of Volume 9 - Tooling
a. If the guard is open, dual-hand controls must be used.

see section 2. Personal safety devices, page 3

Document: V684_2Aa
Fastening the plate onto the movable traverse ejector bars

19. If the machine is equipped with the option OP139 Movable traverse ejectors
and if a plate has to be fixed to the ejector bars, control the movable traverse
ejectors out by pressing S66a. until touching the plate.
see section Push buttonb Movable traverse ejectors out, page 64
20. Position the insulating studs and screw the shouldered fastening screws.
Refer to the indications of Volume 9 - Tooling
Heat-up of the mould
Connect the different plugs for heating the CRB and the ancillary heaters.
Position the different thermocouples in their respective receivers.
see illustration Fig. 3., page 21
WARNING: Thermocouples used on G8 presses are insulated thermocouples. Under

no circumstances may other types of thermocouples be used on these ma-
chines.
21. Heat the mould and its ancillary areas.

see section 6. Heating the machine, page 26
It is better to wait until the different mould areas are at the right temperature
before continuing to install the mould.
Initialisation of the closing unit
22. Adjust S51 microcontact activation rod: Mould closing L.S.
REMARK: The rod end is fitted with an adjustable micro metric nut to precisely adjust
the activation of microcontact S51 and status change of the associated input I
006.
refer to section 2.2.1. How to read the status of a digital input, page 228
23. Initialise closing unit.
refer to points 2. to 4. of section 5. Machine initialisation, page 24
Adjustment of the clamping stroke
24. Check that there is enough space between the bottom of the movable traverse
and the top of the mould height adjustment nut to insert the clamping block.If
not, screw the mould height adjustment nut onto its screw to gain enough
space.
25. Move clamping block in by pressing S35.

see section Push button Clamping-block in - Clamping, page 62

Document: V684_2Aa
Refer- Function Refer- Function

ence ence
B4 Cold runner block nozzle thermocouple B10 Ancillary zone 2 thermocouple
B6 Fixed traverse platen thermocouple CRB CRB fixed connector
B7 Movable traverse platen thermocouple CH1 Ancillary zone 1 fixed connector
B8 Ancillary zone 1 thermocouple CH2 Ancillary zone 2 fixed connector
B9 Cold runner block body thermocouple
B6 CH1
B10
B9
B4
CRB B7
CH2 B8
Fig. 3. Thermocouple and heater plug connections

Document: V684_2Aa
26. Adjust the clearance between the bottom of the movable traverse and the top
of the mould height adjustment nut by tightening or untightening the mould
height adjustment nut on its screw.
REMARK: The clearance determines the clamping cylinder stroke. REP recommends the
following clearance :
= Clearance
(mm)
direct injection 6
injection-transfer 15a
a. the clearance must be adapted to the tooling used.
27. Tighten the 4 nut locking screws.
WARNING: Clamping is to be done diagonally by respecting the clamping torque (T = 6 m

daN) on the screws
S51: L.S. Mould closing Micrometric adjustment pin
Adjustable rod
Counternut
Fig. 4. Adjustment of the S51 microcontact actuating rod c

Document: V684_2Aa
End of the mould installation

29. Make sure that the front is kept closed with the screws provided.
see section 11. Opening the front, page 42
Nut screwing
=
larger clearance ()
Movable traverse
Clamping block

Mould height adjustment nut
Mould height adjust-

ment screw Nut unscrewing
=
smaller clearance ()
Fig. 5. Clearance adjustment

Document: V684_2Aa
5. Machine initialisation
1. Check that the start-up parameters are programmed; if not, program them.
Heat-up of the mould
REMARK: It is better to wait until the different mould areas are at the right temperature
before initialising the closing unit.
Heating the injection unit
REMARK: It is better to wait until the different injection unit areas are at the right temper-
ature before initialising.
Closing unit stroke initialisation
see section Selector Operating modes, page 60
3. Close the press by pressing S33a until the different mould parts mechanically
touch.
4. Continue controlling the press closing and press the key simultaneously
to initialise the counter linked to the closing unit encoder.
see section Key Initialisation, page 51
Closing unit is initialised.
Injection unit stroke initialisation
REMARK: The injection unit can only be initialised when the press is completely open or
when the injection unit is lifted.
6. Totally purge the injection unit by pressing S19.
see section Push button Purge-Injection, page 61
7. When the machine pressure increases while the injection piston is at its lowest
stroke, continue to control the purge and press the key simultaneously
to initialise the injection unit encoder counter.

The injection unit is initialised.
a. In S1 safety, if the guard is open, dual-hand controls must be used.

see section 2.2. Safety device S1, page 3
Machine initialisation
Document: V684_2Aa
Initialisation of ejector strokes

When the machine is fitted with one or several OPV040 Movable traverse
ejector encoder or OPV041 fixed traverse ejector encoder options, the oper-
ator must also initialise their strokes.
8. Control ejectors in by pressing S75a or S65a..
see sections Push button "Movable traverse ejectors in", page 63 and Push buttonb
"Movable traverse ejectors in", page 64
9. When the machine pressure rises while the ejectors are entirely in, continue to
control their run-in and press the key simultaneously to initialise the
counters linked to their encoders.
The press is fully initialised
a. If the guard is open, dual-hand controls must be used.

see section 2. Personal safety devices, page 3
Machine initialisation
Document: V684_2Aa
6. Heating the machine

1. Check that all the temperature parameters are programmed; if not, program
them.
Heating the mould and its ancillary areas
2. Press key then , check that coefficients P, I, D and T were cal-

culated at the last mould identification.
see section 2.2. Optimisation page Identification, page 195
REMARK: If there are no coefficients, you must start the mould identification process be-
fore adjusting the mould temperature.
refer to section 6.1. Mould identification, page 26
3. Turn selector S213 to 1.
see section Selector Closing unit heating, page 56
Heating the injection unit
4. Turn selector S204 to 1.
see section Selector Injection unit controller, page 55
6.1. Mould identification

The temperatures of the mould and ancillary heating areas are regulated by
digital controllers built into the machine software. These controllers use PIDT
control coefficients:
P is the coefficient for proportional action.
I is the coefficient for integral action.
D is the coefficient for derived action.
T is the sampling period.
The PIDT coefficients have to be adapted to the different tooling areas to be
controlled. They are obtained via the Thermotrac software and its mould
identification process.
REMARK: Identification is recommended for every time you control the mould and ancil-
lary zone heating areas.
refer to section 3. Identification through Thermotrac, page 200
Heating the machine

Document: V684_2Aa
7. Changing the nozzle

On a REP press, there are 2 different ways of dismounting and changing the
nozzle, each using a different access:
access from below the fixed traverse heating platen,
access from above the fixed traverse.
WARNING: Even when the controller is stopped, the nozzle may remain hot.
Before intervening, it is important to protect against burns by wearing high
temperature protective gloves.
It is better to wait until the nozzle cools down before dismounting it to avoid
the risk of jamming.
7.1. Access from below the fixed traverse heating platen

REMARK: The nozzle may only be changed from below the fixed traverse when:
the press is fully open,
the mould is dismounted,
the press is switched off.
WARNING: Even when the different heaters have been stopped, the heating plates and
the actual nozzle may remain hot.
Before intervening, it is important to protect against burns by wearing high
temperature protective gloves.
1. Control the injection unit beardown by pressing S42 until the nozzle sticks out
below the fixed traverse heating platen.
see section Push button Injection unit beardown, page 63
2. Get to the 6 sides of the nozzle from inside of the press.
Untighten and remove the old nozzle.
3. Mount the new nozzle.
7.2. Access from above the fixed traverse

WARNING: The first version of V68 presses is equipped with a front side without shutter.
In this case, it is not possible to have access to the injection unit front side in
the way described below because the front side has to be wide open and a
step-ladder is necessary.
refer to Fig. 117., page 316
Changing the nozzle

Document: V684_2Aa
1. Stop the injection unit controller by turning selector S204 to position 0.

2. Lift completely the injection unit by pressing S41.
see section Push button Injection unit lift, page 63
3. Position safety pins.
4. Stop hydraulic pump unit by pressing S211.
5. Open shutter above front guard.
6. Set a ladder up using the locating supports provided
WARNING: The safety pins must always be put into place before any intervention on the
nozzle.
see picture Fig. 6., page 28
7. Get to the 6 sides of the nozzle.

Untighten and remove the old nozzle.
Safety pins
Fig. 6. Safety pin positioning on the injection unit
Changing the nozzle

Document: V684_2Aa
Injection unit access shutter

Fig. 7. Ladder placements
Changing the nozzle

Document: V684_2Aa
8. Mount the new nozzle.

9. Close and lock shutter above front guard.
7.3. Adjusting injection unit microcontacts
WARNING: The first version of V68 presses is equipped with a front side without shutter.
In this case, it is not possible to have access to the injection unit front side in
the way described below because the front side has to be wide open and a
step-ladder is necessary.
refer to Fig. 117., page 316
There are 2 adjustable microcontacts at the bottom of the injection unit column
on the front side:
S48: Injection unit beardown L.S.,
S72: Injection unit automatic lift L.S.
REMARK: Microcontact S72 is only installed on the press when the latter is fitted with op-
tion OP120: unit injection automatic lift or option OP155: CRB prearrangement
7.4. Beardown microcontact (S48) adjustment

REMARK: It is very important to check the S48 setting at each mould change.
This is because during a cycle, the injection phase cannot start if S48 is not
activated.
However, purging outside the mould is possible when S48 is not activated.
Purging is also possible when the press is open, whatever the status of S48.
A new tooling has been mounted. A new correct nozzle for the tooling has
been installed.
1. Close the mould by pressing S33.
2. Control the injection unit beardown by pressing S42 until the nozzle touches
the mould.

5. Set a ladder up using the locating supports provided.
see illustration Fig. 7., page 29,
6. Adjust main cam to activate S48.
Changing the nozzle

Document: V684_2Aa
7. Check corresponding input status (I 005 = 1).

se reporter la section 2.2.1. How to read the status of a digital input, page 228
REMARK: When microcontact S72 is installed and used, the main cam must activate S48
even when the injection unit is in Automatic lift position.
7.5. Auto lift microcontact (S72) adjustment

REMARK: It is important to check the S72 setting at each mould change.
This adjustment allows the injection unit lift on a limited stroke, allowing only
compound decompression in the injection canals or in the CRB body. when the
latter is installed.
A new tooling has been mounted. A new correct nozzle for the tooling has
been installed.
1. Close mould by pressing S33a.
3. Control the injection unit beardown by pressing S42 until the nozzle touches
the mould.
4. Lift the injection unit on the desired stroke by pressing S41.
7. Set a ladder up using the locating supports provided.
see illustration Fig. 7., page 29,
8. Adjust main cam to activate S48.
refer to section 2.2.1. How to read the status of a digital input, page 228
10. Adjust additional cam just above S72 microcontact activator.
refer to section 2.2.1. How to read the status of a digital input, page 228 and to illus-
tration Fig. 8., page 32.

Changing the nozzle

Document: V684_2Aa
Injection unit in position Total lift:
L.S. status Input status

S72 released I 050 = 0
S72
S48
Main cam (S48 activated)
Additional cam (S72 activated)
Injection unit in position Automatic lift:

S72
S48
S48 activated I 005 = 1
Injection unit in position Beardown:

S72
S48
Fig. 8. Activation of the injection unit microcontacts
Changing the nozzle

Document: V684_2Aa
WARNING: The length of the additional S72 activation cam must not be modified. It ena-
bles the injection unit automatic lift stroke to be limited.
Changing the nozzle

Document: V684_2Aa
8. Compound loading
8.1. Standard use
8.1.1. Compound batch conditioning

The rubber compound batches must be prepared in rectangular strips with
the nominal dimensions as in volume 9 - Tooling and any length
8.1.2. Rubber strip loading

In order to avoid rubber strip intake and rupture problems, it is essential to
respect the following procedure before loading the strip into the extruder:
1. Heat up the injection unit
REMARK: It is better to wait until the different injection unit areas are at the right temper-
ature before proceeding to load the compound.
2. Turn extruder selector S11 to 1.
see section Selector Extruder, page 56
3. Introduce the strip into the compound inlet chute and help the intake by push-
ing on the first few centimetres.
REMARK: The rubber strip should be introduced into the extruder loading hole called
compound inlet chute.
The compound inlet chute round profile avoids the rubber strip from being torn.
The rubber strip can therefore be pulled by the extruder screw with a box
placed on the floor or with a detachable unrolling system.
WARNING: The extruder inlet chute should in no case be removed when the machine is
in production.
The outlines of the screw and of the extruder barrel have been specially de-
signed for ensuring the best possible intake of the rubber strip and we strong-
ly advise you against helping the rubber strip into the extruder hole with your
fingers or any metal object.
The nearness of the extruder heating area can increase the compound inlet
chute temperature, therefore we strongly advise you to wear heat-protective
gloves when manually loading the compound.
8.1.3. Compound monitoring

The press process-control can detect the end or rupture of the rubber strip and
trigger an alarm.
refer to section 3.4. Optimisation page Extruder feed strip rupture, page 113
Compound loading
Document: V684_2Aa
8.2. How to use a silicone stuffer

refer to the Silicone stuffer manual (Volume 5 - Option OP064: Silicone stuffer)
Compound loading
Document: V684_2Aa
9. Starting production
9.1. Preliminary conditions

The machine has been switched on.
see section 1. Powerisation, page 13
The machine has a cooling water supply and compressed air supply.
refer to volume 1 - Installation.
A mould has been selected.
see section 2. Selection of an existing mould, page 16
The main parameters have been programmed.
A mould has been installed on the press.The mould height adjustment nut has
been adjusted.
see section 4. Installation of a new tooling, page 18
A nozzle adapted to the tooling has been installed.
see section 7. Changing the nozzle, page 27
The injection unit microcontacts have been adjusted.
see section 7.3. Adjusting injection unit microcontacts, page 30
The machine has been heated.
The machine has been initialised.
see section 5. Machine initialisation, page 24
A rubber strip is inserted in the compound inlet chute.
see section 8. Compound loading, page 34
9.2. Compound preparation
9.2.1. Standard use

It is always advisable to purge several times before starting up a production
cycle.These successive purges are to clean the injection chamber of any cured
residues.
The extruder selector S11 is in position 1. The injection piston is in the position
defined by shot size setting parameter 30.
1. Open the press by pressing S34 or lift the injection unit by pressing S41.
see also section Push button Injection unit lift, page 63

REMEMBER: It is possible to purge outside the mould when S48 is not activated. Purging is
also possible when the press is open, whatever the status of S48.
2. Control purging by pressing S19.
By releasing S19, the extruder starts rotating. The injection piston lifts to the
position defined by shot size setting parameter 30.
3. Control several purges by pressing S19.
Starting production
Document: V684_2Aa
4. Do not forget to retrieve the purged compound.
9.2.2. Using a CRB

refer to Volume 5 - Option OP155: Cold runner block prearrangement
9.3. Cycle in semi-automatic mode

A cycle production can be done according to 2 different operating methods:
Semi-automatic,
Automatic.
9.3.1. Preliminary conditions

The press is open
The extruder selector S11 is on position 1. The injection piston is in the position
defined by shot size setting parameter 30.
An operating cycle has been chosen.
see section 3.6. Optimisation page Cycle selection, page 259
9.3.2. Machine fitted with S1 safety
2. Choose the guard operation using S4*.

see section Selector Guard operation, page 57
see also section 2.2. Safety device S1, page 3
REMEMBER: When operating without guard, the press can only be closed by pressing the
dual-handed control S93 simultaneously and continually.
When the machine runs without guard, the operator can operate the options
installed on the closing unit (hydraulic ejectors inside press: OP139 and
OP141), but first, he must turn the selector key S12 (Selection of dual-hand
controlled ejectors with guard open) to position 1 and control the movements
with the dual-hand, i.e. he must press the movement control button and S93
(P.B. dual hand) simultaneously and not release them during the whole move-
ment.
Starting production
Document: V684_2Aa
3. Control ejectors in by pressing S75a or S65a..

4. Control press closing by pressing S33a..
5. Control clamping block in by pressing S35a..
The rest of the cycle is automatic.
9.3.3. Machine fitted with SE safety

see section 2.1. Safety device SE, page 3
2. Close the guard by pressing the green button S37.
see section Push button Front guard closing, page 62
3. Control ejectors in by pressing S75 or S65.
4. Control the press closing by pressing S33.
5. Control clamping block in by pressing S35.
9.4. Cycle in automatic mode
9.4.1. Preliminary conditions

The press is open
The extruder selector is in position 1. The injection piston is in the position de-
fined by shot size setting parameter 30.
An operating cycle has been chosen.
9.4.2. Cycle start

1. Make sure that all the optimisation functions are in place before starting the
first cycle.

Starting production
Document: V684_2Aa
10. Production stop
10.1. Procedure for purging in case of production stop

To avoid all risk of the compound staying in the curing injection unit, it is ad-
visable to purge the injection unit before stopping the machine and switching
it off.
10.1.1. Standard use

1. Break the rubber strip.
WARNING: Purging does not only mean emptying the injection chamber but also means
finishing extrusion of the production compound already taken in by the ex-
truder screw and possibly replacing it with an non-curing purge compound.
In this case, it is necessary to leave the injection unit extruder and heating
rotation selectors in position 1 until the injection unit is completely purged.
2. Purge by pressing S19 several times until there is no more compound left in
the extruder.
3. Lift injection unit by pressing S41.
4. Deselect the extruder rotation by turning selector S11 to 0.
see section Selector Extruder, page 56
see section Push button front panel STOP, page 54
6. Cut off the heaters by turning selector S204 to 0.
see section Selector Closing unit heating, page 56
7. Leave the injection unit in automatic cooling.
8. When the temperature measured at parameters 61 and 62 has reached the min-
imum 43 C, switch the process-control off.
9. Isolate the machine by placing isolating switch Q1 to O.
10.1.2. Using a CRB

refer to Cold runner block manual (Volume 5 - Option OP155: CRB prearrangement)
10.2. Procedure for restarting cycle.
10.2.1. After opening protector

The voluntary opening of the safety guard or a cage door during an automatic
or semi-automatic cycle interrupts the cycle in process.
REMARK: The automatic or semi-automatic cycle is not interrupted if the guard is open
during the curing phase and closed before the end of this phase.
Production stop
Document: V684_2Aa
1. Close all protectors remaining open.
3. Open the press by pressing S34 up to the maximum opening position.
4. Reposition optimisation functions (ejectors on press, sliding platen etc.) in
their cycle start conditions.
5. Open safety guard by pressing S38.
see section Push button Front guard opening, page 62
6. Restart cycle.
see section 9. Starting production, page 36
10.2.2. After pressing P.B. STOP

Activating the STOP P.B. immediately stops the cycle in process, but does not
stop the machine control system supply.
1. Pull on Punch button S201 to deactivate.
2. Switch process-control and hydraulic pump unit off.
7. Restart cycle.
10.2.3. After an hydraulic pump unit stop.

In the event of a voluntary or accidental stop of the hydraulic pump unit (e.g.
following an electrical motor overload), the operator must solve the problem
which caused the pump unit stop and start a new cycle following the proce-
dure listed below:
1. Switch hydraulic pump unit on and check rotation.

Production stop
Document: V684_2Aa

6. Restart cycle.
Production stop
Document: V684_2Aa
11. Opening the front

The front of a press can be opened to facilitate machine and tooling mainte-
nance and cleaning operations.
1. Open the front guard by pressing S38.
2. Press Punch button S201
3. Undo the front locking screws.
refer to illustration Fig. 9., page 43
4. Open the front.
5. Perform work required inside the cage.
6. Close the front when finished.
WARNING: The front of the machine must always be closed and kept closed with the
screws provided whenever the machine is in operation.
7. Switch process-control and hydraulic pump unit on.

refer to section 1. Powerisation, page 13
11.1. Cleaning the guard

The front locking system consists of screws and springs. The springs release
the front closing control microcontacts while the locking screws are not tight-
ened. In this case, it is not possible to close the guard.
Nevertheless, there is a procedure to close the guard to clean its inside:
1. Open the guard,
2. Undo the front locking screws,
3. Keep the front closed manually,
5. Let the front open with the locking system springs,
6. Clean inside the guard.
Opening the front

Document: V684_2Aa
6 mm
Fig. 9. Position of the front locking screws
Opening the front

Document: V684_2Aa
Opening the front

Document: V684_2Aa
Chapter III - Control station
1. Introduction
The control station of a G8 press is located on the door of the switch cabinet,
it combines the following elements:
the operator interface,
the main control front panel,
the auxiliary control front panel.
Operator interface
(see page 46)
Main control front panel

(see page 53)
Dual hand
(see page 65)
V:\G8\Vol2\A\A_utilisation_commandes.fm
Auxiliary control front panel

(see page 66)
Fig. 10. Control station of a G8 press
Introduction
Document: V684_2Aa
2. Operator interface
The operator interface includes a PC with integral display system and a key-
board.
2.1. The display system

The display system is used to set the moulding parameters by means of the
keyboard and to read the information given by the process-control to the op-
erator during machine operation.
2.1.1. Hardware
Physically, the display system is a 10 inch LCD colour screen with a resolution
of 640 x 480 pixels.
2.1.2. Display mechanism

The display mechanism is controlled by the keyboard.
Refer to section 2.2., page 47
Every preset function key refers to a different main function page.
Each main function page can have up to 7 associated pages. The associated
pages or pages of associated optimisation functions are displayed using the
function keys F1 to F7 assigned to the 7 text keypads at the bottom of the
screens.
Fig. 11. Example of main page: Mould closing function
Operator interface
Document: V684_2Aa
For further information concerning the operation of the display mechanism

and the ergonomics of the screens, please refer to Chapter IV - Reading and
programming of data, page 69.
2.2. The keyboard

The keyboard is a specific Rep press keyboard. It includes 54 keys distributed
over the 6 different keypads listed below:
1. the associated optimisation function keys keypad, (see page 48)
2. the preset functions keypad, (see page 48)
3. the interface utilities keypad, (see page 50)
4. the directional keypad, (see page 50)
5. the machine utilities keypad, (see page 51)
6. the numeric keypad (see page 51)
7. a standard keyboard socket outlet is provided on the front side of the machine.
(see page 52)
2 6
3 4 5
Fig. 12. Operator interface keyboard
Operator interface
Document: V684_2Aa
2.2.1. The associated optimisation function keys
Key Function
Associated optimisation function keys
Every function key F1 to F7 is associated with one of the 7
blue keypads available at the bottom of the screen once the
F
to process-control is on.
1
These keys make the optimisation screens of each of the pre-
set functions accessible. The optimisation is described in the
text specified in the associated text keypad.
2.2.2. The preset function keys

These keys make the main screen of the corresponding function available.
Key Function
Key Compound preparation

a
see section 3.1. Base page Compound preparation, page 105
Key Mould closing

b
see section 4.1. Base page Mould closing, page 121
Key Filling
c
see section 5.1. Base page Filling, page 129
Key Curing
d
see section 6.1. Base page Curing, page 156
Key Stripping and loading of the inserts

e see section 7.1. Base page Stripping and loading of inserts,
page 163
Key Thermotrac
f
see section 2.1. Base page Thermotrac, page 191
Key Mastertrac
g
see section 2.3. Base page Mastertrac, page 212
Key Network
h refer to volume 5 - Option OP183: RepNet-win machine compu-
ter
Key Maintenance
i
see section 2.1. Base page Sequential Diagnostic, page 225
Operator interface
Document: V684_2Aa
Key Function
Key Production configuration

j
see section 3.1. Base page Production check, page 245
Key Machine configuration

k
see section 4.1. Base page Machine configuration, page 271
Operator interface
Document: V684_2Aa
2.2.3. The interface utility keys

These keys control the operator interface utilities.
Key Function
Key Escape
l This key enables to exit the Graph or Tolerance functions
in process.
Key Online Help

m
This key controls the display of the Online Help screen.
Key Tolerances
This key controls the display of the window containing the
n
tolerances associated with the active parameter
Refer to section 4.2.3. Tolerance window, page 86
Key Print
o
This key controls the printout of the active screen
Key Graphics
This key controls the display of the graphic window associat-
p
ed with the active parameter.
Refer to section 1.2. Using a graphic page, page 279
Key Short-circuit
This key is used to move between the interdependent
q
screens.
Refer to section 3.7.4. Shortcuts, page 266
2.2.4. The directional keys

These keys control the movements between the different programming areas
of the current screen.
Key Function
Key Right arrow

r
This key makes the next active area on the same line available
Key Left arrow

s This key makes the previous active area on the same line
available
Key Up arrow
t This key makes the nearest active area on the previous line
available
Operator interface
Document: V684_2Aa
Key Function
Key Down arrow
u This key makes the nearest active area on the next line avail-
able
2.2.5. The utility keys of the machine

These keys control the press utilities.
Key Function
Key Display of the active alarm messages
v Only one active alarm message can be viewed at the same

time, but the others can be successively viewed by pressing
this key.
Key Initialisation
This key is used to reset to zero the counters used on the dis-

placement axes on the machine (movable traverse, injection,
I
options) after a mains power cut.
n
it REMARK: The Init key is used according to the proce-
dure specific to stroke initialisation.
see section 5. Machine initialisation,
page 24
2.2.6. The numeric keypad

The numeric keypad comprises the following keys:
Key Function
0 Numeric keys 0 to 9.
to
Key Minus
- This key is used to diminish the selected value by successive
decrements.
Key Plus
+ This key is used to increase the selected value by successive
increments.
Key Delete
x
This key deletes the last value or function entered.
Operator interface
Document: V684_2Aa
Key Function
Key Validation
y
This key validates the last value or function entered.
2.2.7. The standard keyboard socket outlet
Socket
Function
outlet
Standard keyboard socket outlet
This DIN format socket outlet (5 socket contacts) makes pos-
sible the connection of a standard PC keyboard.
i Connection and disconnection are possible with power on
m
p REMARK: The standard keyboard is configured in AZ-
ERTY mode. This configuration can be
modified with the Control panel of
Windows NT.
WARNING: When an external keyboard is used, make sure that the numeric keypad is
activated (Num Lock = ON) before disconnecting the keyboard and reusing
the keyboard built into the machine control station.
Otherwise, the operator will not be able to type in numerical values with ma-
chine keys 0 to 9.
Operator interface
Document: V684_2Aa
3. Control front panels

The machine controls are distributed over the 2 following front panels:
The main control front panel which is always mounted on the machine, is
equipped with the basic (standard) control equipment and the control
equipment of the most frequently installed options,
The auxiliary control front panel, which is only mounted when the machine
is equipped with one or several additional options, is fitted with the control
equipment of these options.
3.1. The main control front panel

The main control panel comprises different control equipment distributed
over the 8 following separate keypads:
1. the powerization,
2. the fault display,
3. the press operation selections,
4. the keyboard selections,
5. the counters,
6. the operating mode selection,
7. the standard movement controls,
8. the optional movement controls,
9. the dual-hand control.
2 3 4 5 6
1 7 8
Fig. 13. Main control front panel

9
Control front panels

Document: V684_2Aa
3.1.1. Powerization
Position
number on
Unit electrical
Function
diagram
Main switch
Q1 allows the manual powerization and de-powerization of the switch cab-
inet.
Q1 is also used to separate the whole electrical circuit from the machine after
an incident of electrical concern (overcurrent or short-circuit).
Q1
WARNING: Never work on the electrical circuits of the machine un-

less the handle of the main switch Q1 is locked into the
OFF position by a padlock.
Push button front panel STOP

S201 controls the de-powerization of all electrical circuits of the switch cab-
inet, except the PC, the sequential software management board and the en-
S201 coders.
IMPORTANT: S201 is part of the SE safety device which is certified to be
compliant with the European guidelines and which has
been granted the type-examination certificate.
Push button Process control voltage on
S203 S203 controls the powerization of the process control circuits.
The powerization of the process control circuits is checked through H60.
H60 Power-On indicator Process control
Push button Process control stop

S202
S203 controls the de-powerization of the process control circuits.

Document: V684_2Aa
Position
number on
Unit electrical
Function
diagram
Push button Hydraulic pump unit power on

S212 S212 controls the powerization of the hydraulic pump unit motor.
The powerization of the hydraulic pump unit is checked through H61.
H61 Power-On indicator Hydraulic pump unit
Push button Hydraulic pump unit stop

S211
S211 controls the de-powerization of the hydraulic pump unit motor.
3.1.2. Indicator lamps
Position
number on
Unit electrical
Function
diagram
H40 Indicator Press fault
Push button Indicator test

S32 is only available when the machine is equipped with the OP302 option
S32
(European safety).
S32 allows to check the lighting of all control panel indicator lamps.
3.1.3. Press operation selections

Each control panel selector becomes active when its lever (or key) is turned to
position 1.
Position
number on
Unit electrical
Function
diagram
Selector Injection unit controller

S204
S204 controls the start of the injection unit temperature controller.

Document: V684_2Aa
Position
number on
Unit electrical
Function
diagram
Selector Closing unit heating

S213 S213 controls the initiation of the heating and the regulation of the different
mould heating zones.
Selector Extruder
S11 authorises the extruder operation.
The extruder rotation only becomes effective when all the following condi-
tions are fulfilled simultaneously:
S11 the shot size stroke defined by parameter 30 is not reached,
the injection unit temperature controller selector is on position 1 (see S204,
page 55),
the extruder delay-time defined by parameter 50 has elapsed or is disa-
bled.The last condition is not to be fulfilled when the press is in the Ad-
justment mode or when it is open and in the manual operating mode.
Selector dual-hand controlled ejectors with open guard
S12 is a key selector which is only available when the machine is equipped
with the option OP139 (Movable traverse ejectors) or the option OP141
S12 (Fixed traverse ejectors).
S12 authorises the operation of the ejectors with the guard open. In this case,
the control must be bi-manual.
refer to dual-hand control S93, page 65

Document: V684_2Aa
Position
number on
Unit electrical
Function
diagram
Selector Full-force beardown

with the option OP119 (Full-force beardown).
S17 controls the hydraulic fluid distribution over the full section of the injec-
tion unit beardown cylinder in order to increase the beardown force of the
nozzle on the mould during the injection or purge.
Full-force beardown is recommended when injecting through a cold runner
block (C.R.B.)
WARNING: Before making any use of the full-force beardown it is

S17 essential to inspect and check the fastening of the fixed
traverse half-mould, as the beardown forces present
during a purge when the mould is open are very high:
F
(daN)
V68 Y4000 19,635
Selector Guard operation

with the option OP301 (S1 level safety).
S4 selects the machine operation:
position 0: Without guard (safety guard open)
position 1: With guard (safety guard closed)
S4
WARNING: It is highly recommended to remove the key from selec-

tor S4 when it is positioned on 1 (with guard).

Document: V684_2Aa
3.1.4. Keyboard selections
Position
number on
Unit electrical
Function
diagram
Selector Keyboard
S100-S101 is a 3-position key selector. Each position authorises a specific
keyboard function:
: Keyboard access
the position Keyboard access (S101) authorises the reading and program-
ming of the parameters set points; it prohibits all press movements.
: Slopes + and -
the position Slopes authorises the reading and the modification of the pa-
rameters set points by successive increments or decrements.
: Keyboard inhibition
S100-S101 the Keyboard inhibition (S100) position authorises the reading of all pa-
rameters, but prohibits any modification.
WARNING: It is highly recommended to remove the key from selec-

tor S100-S101 when it is in position Keyboard inhibi-
tion.
3.1.5. Counters
Position
number on
Unit electrical
Function
diagram
Total cycle counter

P1
P1 is incremented at each cycle during the injection. It can't be reset to zero.
Cycle counter with reset to zero

P2 is only available when the machine is equipped with the option OP205
P2 (Cycle counter with reset to zero).
P2 is incremented at each cycle during the injection. P2 can be reset to zero
when pressing the push button on the front panel.

Document: V684_2Aa
Position
number on
Unit electrical
Function
diagram
Hour counter
P3 is only available when the machine is equipped with the option OP122
P3 (Hour counter).
P3 displays the number of operation hours performed by the hydraulic
pump unit.

Document: V684_2Aa
3.1.6. Operating mode selection
Position
number on
Unit electrical
Function
diagram
Selector Operating modes

S0-S1 is a 4-position key selector. Each position authorises a specific operat-
ing mode:
: Adjustment
the Adjustment operating mode authorises the operator to control all
press movements manually, except the clamping and injection. The press
opening and closing only take place at low speed.
WARNING: The Adjustment operating mode is used for the adjust-

ment of the mould peripherals, that is why it is essential
to take particular care when controlling the option
movements inside the press, for they are not checked
by their respective microcontacts.
: Manual
S0 the Manual operating mode authorises the operator to control all press
S1 movements manually, including the clamping and injection. The operator
can run a comprehensive manually controlled cycle.
: Semi-automatic
the Semi-automatic operating mode authorises the operator to control the
press movements manually until reaching the movement clamping-block
in. The remaining cycle stages are completed automatically.
: Automatic
the Automatic operating mode authorises the operator to control the
guard closing manually (button S37) to launch the cycle which is completed
automatically.
This operating mode is the current production mode.

Document: V684_2Aa
3.1.7. Standard movement controls

A standard press movement is generally controlled by pressing the corre-
sponding push button and maintaining it pressed down during the desired
stroke.
When the push button is released, the movement stops automatically.
NOTE: The opening and closing movements of the guard are executed by pressing
once on their respective controls.
As with the Manual operating mode, clamping block in, clamping block out,
clamping, unclamping and injection are controlled by pressing once on their re-
spective controls.
Position
number on
Unit electrical
Function
diagram
Push button Injection piston retraction

S18
S18 controls the retraction of the injection piston.
Push button Purge-Injection

S19 controls the purge regardless of the selected operating mode.
S19 also controls the injection in the Manual operating mode.
REMARK: In the Adjustment mode, S19 is used for the initialisation
S19 of the injection unit strokes. The initialisation is carried out
by simultaneously pressing S19 and the key Init on

the keyboard while the press is open and the injection pis-
ton is in the mechanical stop position end of injection
stroke.
Push button Forward step-by-step learning cycle

S108
refer to section 1.2., page 209.
Push-button Reverse step-by-step learning cycle

S107

Document: V684_2Aa
Position
number on
Unit electrical
Function
diagram
Push button Front guard opening

S38 controls the immediate opening of the front guard and stops the execu-
tion of the current cycle.
S38
REMARK: The cycle is not interrupted if the guard opening is initiated
during the curing phase and the closing of the guard before
the end of the curing time (parameter 56).
Push button Front guard closing
S37 controls the closing of the front guard.
S37 also controls the cycle start in the Automatic operating mode.
S37
REMARK: Because the guard movements are controlled automatical-
ly, it is essential to check the opening and the closing of the
guard each time a new cycle is launched in the Manual,
Semi-automatic and Automatic operating modes.
Push button Press closing
S33a controls the press closing in the Adjustment, Manual and Semi-auto-
matic operating modes.
S33 REMARK: In the Adjustment mode, S33 is used for the initialisation
of the closing unit strokes. The initialisation takes place
when simultaneously pressing S33 and the key Init on

the keyboard while the press is closed, that is while the
parting lines of the different mould parts are in contact.
Push button Press opening

S34 S34a controls the press opening in the Adjustment and Manual operating
modes.
Push button Clamping-block in - Clamping

S35a controls the clamping-block in movement of the press in the Adjust-
S35 ment operating mode.
S35a controls the clamping-block in and clamping movement in the Manu-

al and Semi-automatic operating modes.
Push button Unclamping-Clamping-block out
S35a controls the clamping-block out movement of the press in the Adjust-
S36 ment operating mode.
S35 controls the unclamping and clamping-block out movement of the press
in the Manual operating mode.

Document: V684_2Aa
Position
number on
Unit electrical
Function
diagram
Push button Injection unit lift

S41
S41 controls the injection unit lift regardless of the operating mode.
Push button Injection unit beardown

S42 controls the beardown of the injection unit regardless of the operating
mode.
S42
IMPORTANT: In the Semi-automatic and Automatic operating modes,
the injection phase is not completed, if the injection unit is
not forced down; in order to cause the injection phase to be
completed, the microcontact S48 must be enabled.
a. If the press is equipped with the selector key S4 and if the latter is set to 0 (with no guard), the dual-handed control
must be used. Refer to the indications relating to S93.
3.1.8. Optional movement controls

Optional movements are controlled by pressing the corresponding push but-
ton and by keeping it pressed down during the desired stroke.When the push
button is released, the movement stops automatically.
Position
number on
Unit electrical
Function
diagram
OP141a
S75 Push buttonb "Movable traverse ejectors in"
S76 Push buttonb "Fixed traverse ejectors out"


Document: V684_2Aa
Position
number on
Unit electrical
Function
diagram
OP139c
S66 Push buttonb Movable traverse ejectors out
S65 Push buttonb "Movable traverse ejectors in"
OP137d
S43 Push buttone "Sliding platen in"
S44 Push buttone Sliding platen out
a. These push-buttons are only available when the machine is equipped with the option OP141: Fixed traverse ejectors.
They are only active when one of the cycles implying the option is selected.
b. If the press is equipped with the selector key S12 and if the latter is set to 1, the dual-handed control must be used.
Refer to the indications relating to S93.
c. These push-buttons are only available when the machine is equipped with the option OP139: Movable traverse ejec-
tors. They are only active when one of the cycles implying the option is selected.
d. These push-buttons are only available when the machine is equipped with the option OP137: Sliding platen
e. The movements of the sliding platen must always be operated with the dual-handed controls. Refer to the indications
relating to S93.

Document: V684_2Aa
3.1.9. Dual-hand control
Position
number on
Unit electrical
Function
diagram
Push button Dual-hand

S93 is the push button located on the left side of the switch cabinet.
To guarantee the operator's safety during movements outside the area pro-
tected by the cage of the machine and regardless of the operating mode cho-
sen, certain movements are initiated only if S93 is activated
simultaneously with the corresponding push buttons.
1 When the press is equipped with the S1 safety level and the selector S4
(Selector Guard operation) is in position 0 (without guard), S93 must be
activated with the following push buttons:
S33 for the press closing,
S35 for the clamping-block in movement and the clamping.
2 When the machine is equipped with option OP141 (Fixed traverse ejec-
tors) and the selector S12 (Selector dual-hand controlled ejectors with
S93 open guard) is in position 1, S93 must be activated simultaneously with
the following push buttons:
S75 for the run-in of the fixed traverse ejectors,
S76 for the run-out of the fixed traverse ejectors.
3 When the machine is equipped with the option OP139 (Movable traverse
ejectors) and the selector S12 (Selector dual-hand controlled ejectors
with open guard) is in position 1, S93 must be activated simultaneously
with the following push buttons:
S66 for the run-out of the movable traverse ejectors,
S65 for the run-in of the movable traverse ejectors.
4 When the machine is equipped with the option OP137 (Sliding platen),
S93 must be activated simultaneously with the following push-buttons:
S44 for the run-out of the sliding platen,
S43 for the run-in of the sliding platen.

Document: V684_2Aa
3.2. The auxiliary control front panel

The auxiliary control front panel includes different selection and control ele-
ments distributed over the 4 keypads listed below:
1. the different selector keys and controls,
2. the additional option selector keys,
3. the optional printer socket outlet,
4. the additional option movement controls,
CELLS
RESET
1 2 4
Fig. 14. Auxiliary control front panel
The legends (logic diagrams) correspond to the additional selections and op-
tions on the press.
3.2.1. The printer socket outlet

The printer socket [format HE5 (subD), 25 female contacts] allows the connec-
tion of any printer to the parallel port.
REMARK: The printer driver is to be installed on the PC operating system.

Document: V684_2Aa
3.3. Kit control buttons

The kit movement control buttons are located on the auxiliary control front
panel when the machine is configured with one of the following options:
OP146: Top rear stripping kit
OP147: Bottom front stripping kit.
Position
number on
Unit electrical
Function
diagram
S123 Push button Plate in
S124 Push button Plate out
S175 Push button Kit ejector in
S176 Push button Kit ejector out
S112 Selector Continuous cycle
CELLS
RESET
S310 Push button Front cell resetting
H310 Indicator Front cell resetting
For further information concerning the operation and the controls of the kits, please
refer to volume 5 - Option: Stripping kits.

Document: V684_2Aa
3.4. Ancillary cylinder control buttons

The ancillary cylinder movement control buttons are located on the auxiliary
control front panel when the machine is prearranged for them.
Position
number on
Unit electrical
Function
diagram
S401 Push button Ancillary cylinder 1 out
S400 Push button Ancillary cylinder 1 in
S403 Push button Ancillary cylinder 2 out
S402 Push button Ancillary cylinder 2 in
For further information concerning the operation and the controls of the ancillary cyl-
inders, please refer to the machine customization manual, volume 10 - Specials.
3.5. Silicone stuffer control buttons

The ancillary cylinder movement control buttons are located on the control
box of the silicone stuffer when the machine is configured with the option
OP050: prearrangement for silicone stuffer.
For further information concerning the operation and the controls of the silicone
stuffer, please refer to volume 5 - Option: OP064-Silicone stuffer.

Document: V684_2Aa
Chapter IV - Reading and programming of data
1. Screen ergonomics
1.1. Introduction
The G8 screen is divided into 5 distinct areas:
1. the line for the heading,
2. the line for the alarm messages,
3. the line for the information messages,
4. the active page,
5. the keypads of the associated optimisation functions.
4
V:\G8\Vol2\A\A_utilisation_ecrans.fm
Fig. 15. Details of a G8 screen page
Document: V684_2Aa
1.2. Heading line
The heading line displays the following information:
Back-
Position on Name of the
Function ground col-
Fig. 16. zone
our
A Date Displays the current date
B Time Displays current time
Grey
Digital manom- Display of the measured service pressure value
C
eter (expressed in bars)
(a)
D Heading Displays base function heading Light blue or
Dark blue
E Mould Displays current mould number Grey
a. See section 1.4.1. Heading of the active page, page 75
1.3. Message lines
1.3.1. Active messages

Alarm messages
When a fault is detected on the machine, it is declared to be active, until be-
ing cleared; the corresponding message is stored and can be displayed on the
alarm message line.
A B C D E
05/12/00 10:01:25 0 bar Mould closing Mould: V58Y20

Self-check door A disabled 05/12/00 09:56:12
Open and close door A Phase 0
Fig. 16. Details of the heading line
Document: V684_2Aa
Information messages
The machine process-control automatically generates information messages
intended for the operator. Generally, an information message is part of a contex-
tual machine use advice (example: please close the safety guard).
An information message remains active until being effectively cleared by the
operator as a response to the message. It may be overlapped by a new mes-
sage. Information messages are not stored.
1.3.2. Level of the fault messages

Alarm messages
Alarm messages are classified according to the 3 following levels:
Fault level Line

Action upon the back-
Signalling
No Descriptiona cycle run ground
colour
Alarm message display
4 Cycle lock Immediate stop + blinkerb + flashing lampc Red
+ klaxond
Production stop at + blinkerb + flashing lampc
the end of the clamp-
3 Production stop Klaxond when Orange
ing phase of the next
cycle the press
stops
2 Flashing light blank Yellow
+ blinkerb + flashing lampc
a. Refer to section 2.6. Optimisation page Retrace faults, page 240
b. see H40, page 55
c. only if the machine is equipped with option OP190 Flashing alarm
d. In case of specific outfit.
REMARK: The user can change the initial fault levels of the alarm messages 3, 2 or 1 by
eventually assigning a higher or lower level between 1 and 3 to the message
concerned. An alarm message downgraded to 1 becomes an information mes-
sage; it is displayed on the line available for this purpose, but unlike the other
current information messages, it is stored.
Information messages are classified according to the following levels:

0 = current messages
1 = alarm messages downgraded to 1 by the operator
Document: V684_2Aa
Fault level Line

Action upon the Type of mes- back-
Signalling
No Descriptiona cycle run sage ground
colour
1 stored Information
Information blank message dis- Grey
0 not stored play
a. Refer to section 2.6. Optimisation page Retrace faults, page 240
1.3.3. Message display rules

Alarm messages
Only one fault message can be displayed at the same time on the alarm mes-
sage line.
If several faults are active simultaneously, the following rule is to be applied:
1. the message of higher level is displayed first,
2. between 2 messages of the same level, the more recent message is displayed
first.
3. the operator can scroll all messages when pressing the key .
(see page 51).
REMARK: If one or several messages are generated during the scrolling asked for by the
operator, they come first and are governed by the above mentioned rule.
The information message line always displays the latest information generat-
ed by the machine process-control.
1.3.4. Details of the alarm message line

This line displays the following information:
F G H

Fig. 17. Details of the alarm message line
Document: V684_2Aa
Line back-
Position on
Name of the zone Function ground
Fig. 17.
colour
F Alarm Displays active fault message (a)
G Fault date Displays the date the fault occurred on the press Grey or
Yellow or
Displays the time the fault occurred on the Orange or
H Fault time
press Red
a. See section 1.3.2. Level of the fault messages, page 71
Document: V684_2Aa
1.3.5. Details of the information message line

This line displays the following information:
Line back-
Position on
Name of the zone Function ground
Fig. 18.
colour
J Information message Displays active information message
Displays the name of the active sequential Grey
K Sequential phase
phasea
a. The indication of the current sequential phase is very helpful for servicing operations completed on phone by the
Technical Assistance Department of REP. Don't forget to indicate it.
1.4. Active page

The active page is the area displayed in the middle part of the screen.
Its content differs according to the function selected on the keyboard.
The active page is depending on the case:
a base page called by one of the preset function keys,
(refer to section 2.2.2., page 48),

J K
Fig. 18. Details of the information message line
Document: V684_2Aa
an optimisation page called by one of the 7 optimisation function keys

(refer to section 2.2.1., page 48).
REMARK: When powerizing the machine, the active page displayed is the base page
Production check.
1.4.1. Heading of the active page

Heading of the base page
The base page heading is always displayed on the screen heading line. (refer
to position D section 1.2., page 70).
The base page heading is displayed on a background which may be different:
light blue background if the base page is active,
dark blue background if the base page has an optimisation page and if this
page is active.
Optimisation page headings
The optimisation page headings are displayed in the text keypads associated
with the optimisation function keys.
The text keypads associated to the optimisation function keys are displayed
in a changing background colour:
the one of the active optimisation page is displayed on a light blue back-
ground,
the ones of the other accessible pages are displayed on a dark blue back-
ground,
those of the other inaccessible pages are displayed on a light grey back-
ground.
also see section 1.5. Optimisation function, page 76
1.4.2. Structure of an active page

An active page can contain information relating to:
the machine configuration,
the production configuration
the moulding parameters,
the maintenance,
the online help.
The active page can combine the following areas:
a page background design,

display areas,
Document: V684_2Aa
active zones.
either arranged in different points of the active page,
or arranged in tables with several lines and columns

refer to section 3. Use of the tables, page 81
either arranged in multiple-choice lists with checkboxes
choice 1 (not validated)

choice 2 (validated)
Fig. 19. Example of a multiple-choice list
either arranged in exclusive-choice lists with radio buttons

Fig. 20. Example of an exclusive-choice list
or presented as a pulldown menu (exclusive choice)
choice x (validated)
Fig. 21. Example of a pull-down menu

1.5. Optimisation function

A base page may have up to 7 optimisation functions represented by the key-
pads at the bottom of the screen.
REMARK: Depending on the optional equipment available on the machine, the 7 optimi-
sation functions may not all be accessible.
The description of every optimisation function is given in the text keypad as-
sociated with one of the 7 optimisation function keys.
Document: V684_2Aa
1.5.1. Colour code of the text keypads

Every optimisation function keypad can be displayed according to a particu-
lar colour code.
Keypad Keypad out-

Texts Status of the function
background line
Light grey without without No optimisation function
Light grey Dark grey without No access to the function on the machine
without Function accessible and disabled
Dark blue White Function accessible and enabled

Orange One of the parameters of the optimisation page is ac-
tive.
without Disabled function displayed on the active page.
Light blue a White
Orange Enabled function displayed on the active page.
a. Only 1 of the 7 keypads can be light blue.

see also 4.3. Activating an optimisation function, page 87
Page can be accessed

Active page but function not active
Page can be ac-

Page cannot be accessed, function active
cessed
Fig. 22. Example of colours of the optimisation functions' keypads
Document: V684_2Aa
2. Programming rules
2.1. Active zones

Active areas are data input fields enabling the operator to:
enter or modify a numeric value,
make a choice,
Active areas can also be interaction areas allowing the operator to directly get
to another page (shortcuts).
2.2. Bounding box

The bounding box makes it possible to localise the active area among those dis-
played on the page.
REMARK: Generally, the focus is a black-shaded bounding box delimiting the zone.
Only one area can be activated at the same time.
refer to section 2.2.1. Bounding box shift rules, page 78
2.2.1. Bounding box shift rules

When powerizing the machine and displaying an active page for the first
time, the focus is positioned on the active zone located at the top left of the
active page.
Then, when displaying the same page again, the active zone is the zone which
was last active during the previous display.
The bounding box shift rules are listed below:
Use the arrow keys to move the focus from one active area to another (see
page 50).
Access by moving to the area nearest the initial active area.
The shifts are limited to the margins of the active page (example: no shift to
the right at the end of a line).
The key Validation performs the same move as the key Right arrow.
If one window combines several active areas, the above mentioned shift
rules are applicable inside the window.
Programming rules
Document: V684_2Aa
If one page contains several active area windows, the above mentioned shift
rules are applicable to pass from one window to the other.
WARNING:
The data input into an active area can be validated only by the key
(Validation key).
In the same way, the data input into one or several active zones combined in
the same window can only be validated by the key before shifting the
focus to another window.
2.3. Data input validation and deletion
2.3.1. Validation rules for numeric settings

When activating the area, the previous value is deleted. Only separating
characters are displayed (double point, decimal point).
All numbers are to be entered in order to complete the whole area from left
to right.
REMARK: The quantity of numbers to program depends on the active area.
The last value entered is validated only by using the key .

The last value entered whether complete or not is deleted by using the key
.
If the operator shifts the bounding box by using one of the arrows before
validating the last value entered, the previous value is restored.
If the operator validates or tries to shift the cursor when the last value en-
tered is outside the limits, the display area is deleted and an information
message displayed.
2.3.2. Validation rules for a binary choice
The last value selected is validated only by using the key .

The last selected value is deleted by using either the key Deletion or by
pressing the key once more.
2.3.3. Validation rules for an exclusive choice (radio buttons)
The radio button on which the focus is set is validated by the key .
The radio button which has been validated last is disabled by the validation
of another radio button.
Programming rules
Document: V684_2Aa
2.3.4. Validation rules for a multiple choice (checkboxes)
The checkbox on which the focus is set is validated by the key .
The latest checkbox validated is disabled by the key .
2.3.5. Validation rules of a pulldown menu item
The key opens the pulldown menu.

The bounding box can be shifted to the required menu item by using the
keys and .
The menu item activated the latest is validated by the key .
2.4. Automatic programming
2.4.1. Selection rules for an optimisation function

An optimisation function can be used only if all the parameters relating to this
function are set.
To simplify its selection, the following rules are established:
The input and validation of all set values of all parameters relating to an op-
timisation function automatically validate its selection.
When entering a zero value to a set value of one of the parameters relating
to an optimisation function its selection is automatically cancelled.
2.4.2. Selection rules for the tolerance check

The parameter tolerance check can't be used if no tolerance is set.
To simplify its selection, the following rules are established:
The tolerance check status must be forced to ON,
The input and validation of a value which is not equal to zero within the
limits set for one of the tolerances associated with a parameter automatical-
ly force the other tolerance to the same value, if it is zero.
The reset to zero of the 2 tolerances associated with a parameter deactivates
the tolerance check of this parameter.
Programming rules
Document: V684_2Aa
3. Use of the tables
3.1. Introduction to the tables

The tables display lists of data arranged in cells. Each cell shows one of the
data characteristics.
Each item of data is split over one line of several cells.
Each column of the table groups the cells of features common to different
items of data.
The title of each column shows the feature displayed in the column.
3.1.1. Focus and active cells

Some cells can be active and others not, depending on the type of data pre-
sented in the table.
The focus can be moved from one active cell to another either by moving be-
tween the headings or between data cells.
When the bounding box is positioned on a data cell, the operator can change
any cell content whatsoever following the rules described in section 2.3. Data
input validation and deletion, page 79
3.1.2. Colour coding of the table cells

Each cell is displayed with a particular colour code.
Bounding Cell back- Cell bound-

Type of cell
box ground ing box
deactivated Dark blue without
Heading cell
activated Light blue Orange
deactivated Light grey without
Data cell
activated Light grey Black
3.2. Sequence sorting

When the bounding box reaches a table heading cell, the operator can order a
sequence sorting over the whole table by validating the position of the bound-
ing box with the key .

Sort and sequence is an intuitive sort which arranges the data as a function of
the type of information presented in the column from which the sort begins :
if the information is numerical, sorting is in ascending numerical order,
if the information is textual, sorting is in ascending alphanumerical order,
if the information is chronological (date, time), sorting is in ascending
chronological order.
Use of the tables

Document: V684_2Aa
3.3. Data Screening

Some tables permit the data in them to be screened as a function of criteria
specifically included in an exclusive choice list.
refer to section 2.3.3., page 79
Use of the tables

Document: V684_2Aa
4. Programming of the moulding parameters

The moulding parameters are distributed over the different base pages relat-
ing to the preset functions and their optimisation pages.
REMINDER: A moulding parameter can be inquired, programmed or modified on the same
page.
The position of the keyboard selector key (see S100-S101, page 58) is the
only element to define the authorization regarding the programming and mod-
ification of the parameter set values.
4.1. Page background design

Every base or optimisation function has a background design.
REMARK: The same function may have several background designs. In such a case, the
only design displayed is determined by the press configuration.
The page background design represents the following elements:
the simplified design of the mechanical press elements involved in the cur-
rent function. This graphic representation is deliberately different from a
particular mechanical configuration (horizontal or vertical presses).
the 5 axes of the physical events each materialised by a white, horizontal
line and a symbol representative of the event:
Physical
Symbol Units used
events
minutes and seconds (mm. ss)

Time
or 1/10 second (0.1 s)
temperatures degrees Celsius (C)
Strokes 1/10 millimetre (0.1 mm).

millimetre per second (mm/s)

Speeds or 1/10 millimetre per second(0.1 mm/s)
or percentage of a maximum value (%).
Pressures bar (bar)
Programming of the moulding parameters

Document: V684_2Aa
4.2. Parameter display windows

The information of each moulding parameter of an active page is displayed in
a window aligned with one of the white screen background lines representing
the physical event of the parameter.
The design and content of the window are different according to the position
of the keyboard selector key (see S100-S101, page 58) :
selector key positioned on Keyboard inhibition or Modification by
slopes + and -, the window is an inquiry type window.
selector key positioned on Keyboard access, the window is a programming
type window.
There is a third type of window (tolerance window) allowing to display or
program the information regarding the parameter associated tolerances.
The number and positioning of the windows displayed on a given page de-
pend on the press configuration.
4.2.1. Inquiry window

The parameter inquiry window is made up of 3 areas at the maximum (see il-
lustration Fig. 23., page 84.):
the parameter set value displayed on a white background,
the parameter number displayed on a yellow background,
the measured parameter value displayed in bold characters on a variable
colour background
(refer to section 4.2.4. Colour code of the parameter windows, page 87).
REMARK: The inquiry window of a parameter has no measure area, if there is no meas-
ured value for this parameter.
Moreover, on the Filling base and optimisation pages, only the inquiry win-
dow of parameter 30 has a measure area among the inquiry windows of the
injection unit stroke parameters.
The inquiry window is active when showing the black-shaded bounding box
(the focus).
4.2.2. Programming window

When an inquiry window is active, it changes into a programming window
when positioning the keyboard selector key to Keyboard access.
parameter number
set value measured value
1545 00 1289 4630 30 4630
window not activated window activated
Fig. 23. Details of the inquiry windows

Document: V684_2Aa
A programming window has a more important size than a display window;

it consists of the following areas (see picture Fig. 24., page 85):
the heading of the parameter on a yellow background,
the min. and max. programming values,
the reminder of the symbol and measuring unit of the physical event of the
parameter,
the parameter set value displayed on a white background,
the parameter number displayed on a yellow background,
the parameter measure displayed in bold characters on a variable colour
background
(refer to section 4.2.4. Colour code of the parameter windows, page 87).
the status box of the parameter associated tolerance check, if the parameter
allows tolerances. The check box is activated if the tolerances have been ac-
tivated in the tolerance window.
REMARK: A programming window is systematically active when being displayed. The in-
itial active zone is the set value input zone framed with a bounding box (the
focus).
symbol for the physical

event
heading
max. program-
ming value
Fixed platen heating
min. programming
value 0 250 C measuring unit
195 65 195
status box of the associ-
ated tolerance
set value
parameter number measured value
Fig. 24. Details of a programming window


Document: V684_2Aa
4.2.3. Tolerance window

Only the parameters allowing tolerances have an associated tolerance win-
dow.
The tolerance window is displayed when the operator presses the key Toler-
ance on the keyboard (see page 50).
REMARK: The information of the tolerance window can be changed only when position-
ing the keyboard selector to Keyboard access.
There are 2 separately programmable tolerances :
Tolerances Application
Triggers an alarm if the parameter measure exceeds the set
value by a value at least equal to (+)
(+)
Alarm if Measure [Set value + (+)]
Triggers an alarm if the parameter measure is below the set
value by a value at least equal to ()
()
Alarm if Measure [Set value - ()]
The tolerance window displays the following information (see picture Fig. 25.,
page 86):
the heading of the window and the measuring unit of the physical event of
the parameter,
the tolerance value (+),
the tolerance value (),
the tolerance check status (ON or OFF),
measuring unit tolerance check condi-

tion
tolerance value (+)
Tolerance C
(+)
15 ON
() 5
function cycle lock :

tolerance value () status ENABLED
Fig. 25. Details of a tolerance window

Document: V684_2Aa
the status of the cycle lock function:
= disabled, i.e. no cycle lock at the cycle end,
= enabled, i.e. cycle lock at the cycle end when stating measured val-
ues outside the tolerances,
REMARK: If the keyboard selector is positioned on Keyboard access, a tolerance win-
dow is systematically active when being displayed. The initial active zone is the
input zone of the tolerance (+), it is framed with a bounding box (the focus).
4.2.4. Colour code of the parameter windows

Set value
The parameter set value zone always has a white background.
Parameter number
The parameter number zone always has a yellow background.
Measured value
If the tolerance check selection is active, the area giving the measured value of
the parameter has a variable colour background depending on the measured
deviation [Set value - Measure] and the tolerances linked to the parameter.
Measured devia- Area Measure

Tolerances
tion Background colour Example
Disabled Any White 195 65 150
Below the toler- 195 65 195

Green
ance
Enabled
Above the toler- 195 65 150
Red
ance
4.3. Activating an optimisation function

The following conditions must be satisfied for an optimisation function to be
active:
all the set values of the parameters associated with it must be valid,

Document: V684_2Aa
the function must be selected.

REMARK: An optimisation function is selected :
when its checkbox displayed on the page Selections is ticked,
refer to section 3.7.5., page 266.
or when the associated diamond-shaped box is blue
refer to section 4.3.1., page 88.
4.3.1. Colour code of the optimisation function selection diamond.
State of the opti- Diamond-shaped box

misation func-
tion Background colour Example
activated Blue
Deactivated White

Document: V684_2Aa
5. Instructions for how to change parameters
5.1. How to change a parameter set value

1. Move the bounding box to the inquiry window of the parameter to change by
using the keys , , and .
2. Set the keyboard selector S100-S101 to the position .

3. As the inquiry window is active, it changes into a programming window.
refer to section 4.2.2. Programming window, page 84
4. Enter the new set value, making sure that it is within the maximum value pro-
grammed.
5. Validate the new set value entered with the key .
REMARK: If a set value greater than the maximum is entered, it will be cut off at the max-
imum programmed value.
To change the set value of another parameter:
6. Repeat steps 1. to 5.
To stop changes :
7. Exit the position .
5.2. How to change the tolerances of a parameter

1. Move the bounding box to the inquiry window of the parameter to change by
using the keys , , and .

As the inquiry window is active, it changes into a programming window.
refer to section 4.2.2. Programming window, page 84
3. Press the key .

The tolerances window opens.

refer to section 4.2.3. Tolerance window, page 86
4. Enter the new set value for the tolerance (+).
5. Validate the tolerance entered (+) and move the bounding box to the 2nd tol-
erance by using the key .
6. Enter the new set value for the tolerance (+).
Instructions for how to change parameters

Document: V684_2Aa
7. Validate the new tolerance entered () by using the key .
8. Press the key to close the tolerances window.
Instructions for how to change parameters

Document: V684_2Aa
Chapter V - Moulding parameters
1. Principle of the distribution of functions

A Rep press is expected to produce parts through rubber injection mould-
ing.
To do so, the press must successively execute the particular actions described
here-below:
1. prepare the compound,
2. close the mould,
3. fill the mould with the compound,
4. cure the compound inside the mould,
5. strip the parts and load the inserts, if available.
The process-control of the G8 type press has been developed with the aim of
simplifying the inquiry and programming of the moulding parameters for the
operator. The operator interface presents the production cycle split into the
main functions equivalent to the actions listed above.
The moulding parameters of a G8 type Rep press are distributed over the dif-
ferent active pagesa relating to each of the 5 preset functions and their associ-
ated optimisation functions, available by means of the keyboard keys.
see illustration Fig. 26., page 91 and table Tab. 1., page 92
Access keys to the preset

functions
V:\G8\Vol2\A\A_utilisation_parametres.fm
a. An active page is a screen displayed on the terminal operator.
Document: V684_2Aa
page

92
Access keys
Base pages Optimisation pages
Compound Back-pres- Extruder feed Shot size ac- Compound

preparation sure Extruder strip rupture curacy Silicone
decompres-
time-delay stuffer
page 105 page 109 page 113 page 115 sion
page 111 page 119
: page 289 : page 290 : page 291 : page 291 page 117
Mould closing Mould height

Plate ap-
adjustment
page 121 proach
screw
: page 292 page 125
page 127

Injection pro- Automatic in- 2nd transfer
Filling Cold runner Beardown af-
file Degassing Vacuum jection unit
block ter injection Compound
page 129 lift
page 136 page 140 page 148 pressure
page 293) page 144 page 146
: page 295 page 150 page 152
Curing Curetrac
Curetrac Cor- Network Ancillary are-
communica-
page 156 rections Link as
tion
: page 296 page 158 page 160 page 161
page 159
Document:
Edition:
Stripping and Movable Fixed

Plate ap- Ancillary cyl-
loading of in- traverse ejec- traverse ejec- Stripping kits Sliding platen Limits
proach inders
serts tors tors
page 178 page 182 page 186

page 180 page 184
16/06/2000
V684_2Aa
Tab. 1.Functions, function keys and associated active pages
2. Synoptic diagrams of the parameters
2.1. Introduction
The synoptic diagrams of the following pages allow to rapidly visualise the
interdependence of the parameters involved in the press movements and be-
longing to different physical events.
Every synoptic diagram represents several vertical axes, each symbolising
one of the parametrizable physical events, the parameters involved for eve-
ry function or sub-function.
The base function and their parameters are represented in grey-shaded boxes.
The optimisation functions and their associated parameters appear in white
background boxes.
displacement limit
Direction of movement given by the arrows
XX
Optimisation function
Optimisation VV
parameter
YY
Base function Base parame-
ters
WW PP
Optimisation Function
TT
displacement limit
Strokes Speeds Pressures Times

Physical events
Fig. 27. Symbolisation of the synoptic diagrams
Synoptic diagrams of the parameters

Document: V684_2Aa
2.2. Shot size setting
Max.shot size
30
Shot size setting

2A (see page 115)
3A
Back pressure
40 (see page 109)
Proportioning Feed strip rupture detec-

(see page 105) 20 4C tion
(see page 113)
Injection unit heater

57 safety
(see page 105)
0.75 s 20 Progressive start-up

5C
(see page 113)
0 t
point zero
Fig. 28. Synoptic diagram of shot size

Document: V684_2Aa
2.3. Different types of injection piston retraction
Max.shot size
3C
Piston retraction after

2B 4B extruding
(see page 117)
30
Proportioning
20
(see page 105)
3B
Piston retraction before

2B 4B extruding
(see page 117)
point zero
Strokes Speeds Pressures
Fig. 29. Synoptic diagram of the injection piston retractions

Document: V684_2Aa
2.4. Mould closing
Injection-transfer
(see Fig. 33., page 99)
point zero
Adjustment of the clear-

Clamping ance under the clamping
43
(see page 121) block
05
Low speed approach 0B

stage 12 44
(see page 121)
04
13
09
High speed closing Intermediate low speed
stage 13 12 44 stage
(see page 121) (see page 125)
08
13
03
Low speed closing stage

02 12
(see page 121) Insert lift
12
(see page 170)
L.S. mould open

Fig. 30. Synoptic diagram of the mould closing

Document: V684_2Aa
2.5. Injection (dynamic phase)
Max.shot size
1st volumetric degas- 2nd volumetric degas-

sing sing
30
Injection pressure limita-

21 48 tion
36 (see page 136)
31
37
1st speed level during

the dynamic injection 2nd speed level during
phase 21 the dynamic injection
(see page 129) phase
(see page 136)
22
35
Static injection
point zero
Fig. 31. Synoptic diagram of the dynamic injection phase

(example shown with 2 speed levels)

Document: V684_2Aa
2.6. Injection (static phase)
Max.shot size
30
Injection (dynamic phase)

35
Initiation of the different

time-delays
41 51
1st pressure holding

stage of the static injec- 41 51
tion phase
(see page 129)
2nd pressure holding

stage of the static injec-
42 52 tion phase
(see page 136)
point zero
Strokes Pressures Times
Fig. 32. Synoptic diagram of the static injection phase

Document: V684_2Aa
2.7. Injection-transfer
point zero
Clamping
43 51
(see page 121)
-1-
Clamping
05 block in 05
2nd transfer stage
1E 4E (see page 152)
0E
-2-
Opening 1st transfer stage
1D 4D (see page 129)
Mould closing
(see Fig. 30., Injection (dynamic phase)
page 96) (see Fig. 31., page 97)
0D 0D
-3- -4-
Excess Slight 43
clamping
0D +

L.S. mould open
Fig. 33. Synoptic diagram of the injection transfer

Document: V684_2Aa
2.8. Initiation of the different time-delays
Injection unit heater

57 safety
(see page 105)
Curing time
(see page 156) 56
Extruder time-delay
50 (see page 111)
Automatic lift after injec-

54 58 tion
(see page 150)
Kinematics of a degas-
sing process
(see Fig. 35., page 101) Beardown holding after
5A injection
2nd delayed degassing (see page 146)
(see page 140) 55
2nd pressure holding

52 stage of the static injec-
54 tion phase
Injection
(dynamic phase)
Kinematics of a degas- (see Fig. 31.,
sing process page 97)
1st pressure holding
1st delayed degassing 51 stage of the static injec-
(see page 140) 53 tion phase
35
Times Strokes Times
Fig. 34. Time diagram

Document: V684_2Aa
page 100 Edition: 16/06/2000
2.9. Degassing
point zero
-1- Extraction pressure limi-

Unclamping 1A 46 tation
Opening (see page 186)
0A
Kinematics of a degas-
sing process
(see page 140)
-2-
54 Opening time
point zero
-3-
Clamping 43
0A
Fig. 35. Kinematics of degassing processes

Document: V684_2Aa
Edition: 16/06/2000 page 101
2.10. Mould opening
point zero
Low speed extraction Extraction pressure limi-

stage 10 46 tation
00
11
06
High speed opening Low intermediate speed
stage 11 10 86 stage
07
11 Opening stroke limita-

tion
(see page 186)
01
Low speed ejection Ejection pressure limita-
stage 10 86 tion
0F
L.S. mould open

Fig. 36. Synoptic diagram of the mould opening

Document: V684_2Aa
page 102 Edition: 16/06/2000
2.11. Ejection on the movable traverse
Max.stroke
9C
7C
9B
In-stroke of the movable

traverse ejectors with
encoder 71 81
(see page 168)
Out-stroke of the mova-

ble traverse ejectors with 71
encoder
(see page 168)
9A
point zero
Fig. 37. Synoptic diagram of the movable traverse ejectors in/out

Document: V684_2Aa
Edition: 16/06/2000 page 103
2.12. Ejection on the fixed traverse
point zero
9D
Out-stroke of the fixed

encoder
(see page 173) 72
In-stroke of the fixed

encoder
72 82
(see page 173)
9E
7F
9F
Max. stroke
Fig. 38. Synoptic diagram of the fixed traverse ejectors in/out

Document: V684_2Aa
page 104 Edition: 16/06/2000
3. Function Compound preparation
3.1. Base page Compound preparation

3.1.1. Associated graphic page

see section2. Graphic page Injection unit temperatures, page 289
Fig. 40. Base page Compound preparation
Function Compound preparation

Document: V684_2Aa
Edition: 16/06/2000 page 105
3.1.2. Main sub-functions
Associated param-
Base sub-functions
eters
Proportioning 20 30
(page 94) (page 108) (page 108)
61
Extruder heating
(page 107)
62
Heating of the injection chamber
(page 107)
60
Compound temperature indicator
(page 107)
Injection unit heater safety 57

(page 94) (page 106)
Tab. 2.Sub-functions available on the base page Compound preparation
3.1.3. Parameters
Default
N Description
value
Times
57 Safety time of the injection unit

Parameter 57 is a delay-time initiated at the beginning of the extrusion phase
expressed and defining the rated time the compound is allowed to stay in the injection
in minutes chamber without any risk of pre-curing.
and seconds When elapsed, the delay-time 57 stops the heaters in the injection unit areas
and cools the whole injection unit safely until the temperature 62 of the injec-
tion chamber is stabilized below 43C. The cycle is interrupted. 9959
REMARK: During the safety cooling, the temperature controller of the in-
jection unit continues to run in order to favour the evacuation
of the calories carried over by the thermal oil with the water
flow circulating through the exchangers.

The delay-time 57 is reset to zero with a new injection, a manual purge control
or a controller stop.
Tab. 3.Parameters of the base page Compound preparation

Document: V684_2Aa
page 106 Edition: 16/06/2000
Default
N Description
value
Temperatures
60 Temperature indicator at the extruder outlet

Parameter 60 indicates the temperature of the material at the outlet of the ex-
expressed truder.
in Celsius
REMARK: Parameter 60 is not an active parameter of the machine, as
there is no resulting effect on the machine; however it can be parameter
used by the peripheral software programs Curetrac and set value
62
RepNet-win .
This value is processed by the software Curetrac to evaluate the heat of the
compound during each shot size setting.
This value can be used by RepNet-win to monitor the above mentioned heat-
ing.
61 Extruder temperature
Parameter 61 defines the temperature of the extruder barrel.
expressed
REMARK: The control of the heating area 61 takes place in a closed
in Celsius
loop; the temperature measurement is done by the thermo-
couple B2.
The mechanical pressure of the extruder screw exerted on without
the compound rapidly results in a temperature increase of the
extruder barrel. Consequently, the extruder circuit is cooled
down immediately whenever an excessive value of the 61 set
value is detected. The said cooling lasts proportionally to the
difference between the measured value and the temperature
set value.
62 Injection chamber temperature

Parameter 62 defines the temperature of the injection chamber.
expressed
in Celsius
loop; the temperature is measured by the thermocouple B3, without
and when the set value is exceeded, there is no cooling.
The only possible cooling for the injection chamber circuit is

the safety cooling controlled by the delay-time 57 or by the
manual stop of the temperature controller.
Tab. 3.Parameters of the base page Compound preparation(cont.)

Document: V684_2Aa
Edition: 16/06/2000 page 107
Default
N Description
value
Strokes
30 Shot size setting stroke

Parameter 30 is a point on the injection piston axis defining:
expressed
the end of the shot size setting stroke executed at the rotation speed 20
in 0.1 mm
the beginning of the first stage of the dynamic injection phase executed at without
the injection speed 21.
Parameter 30 is also present on the base page Filling (refer to section 5.1.,
page 129) and on the optimisation page Injection profile (refer to section
5.2., page 136).
Speeds
20 Rotation speed of the extruder screw

Parameter 20 defines the rotation speed of the extruder screw stabilised after
expressed the progressive starting stages, optionally set in 5C.
without
in rpm Extruding starts once the time 50, if set, has elapsed and lasts until the injection
piston, pushed by the compound, reaches point 3A, if set, or otherwise point
30.
2C Rotation speed of the extruder screw

Parameter 2C defines the average rotation speed of the extruder screw on the
expressed whole shot size setting stroke.
in rpm parameter
REMARK: Parameter 2C is not an active parameter of the machine, as set value
there is no resulting effect on the machine; however it can be 20
used by the peripheral software program RepNet-win.
Tab. 3.Parameters of the base page Compound preparation(cont.)


Document: V684_2Aa
page 108 Edition: 16/06/2000
3.2. Optimisation page Back-pressure

The optimisation page Back-pressure is always accessible.

see section 3. Graphic page Back pressure, page 290
3.2.2. Optimisation sub-function
Associated
Optimisation sub-function
parameters
Back pressure 40
Tab. 4. Sub-function available on the optimisation page Back-pressure

Fig. 41. Optimisation page Back-pressure

Document: V684_2Aa
Edition: 16/06/2000 page 109
3.2.3. Parameters
Default
N Description
value
Pressures
40 Back pressure
Parameter 40 defines the back-pressure captured in the rear of the injection without
expressed piston during extruding.
in bars
Tab. 5. Back-pressure optimisation page parameters

Document: V684_2Aa
page 110 Edition: 16/06/2000
3.3. Optimisation page Extruder time-delay

The optimisation page Extruder time-delay is always accessible.
Associated
parameters
Extruder time-delay 50
(page 100) (page 112)
Tab. 6. Sub-function available on the optimisation page Extruder time-delay

Fig. 42. Optimisation page Extruder time-delay

Document: V684_2Aa
Edition: 16/06/2000 page 111
3.3.2. Parameters
Default
N Description
value
Time
50 Delayed extruder start

REMARK: Parameter 50 is not used in the setting and manual oper-
expressed ating modes.
in minutes During direct injection, parameter 50 is a delay-time initiated at the end of the
and seconds static injection phase, i.e. once 52 has elapsed, if set, otherwise when 51 has
elapsed.
without
During injection-transfer, parameter 50 is a delay-time initiated at the end of
the pressure holding time, i.e. when 51 has elapsed.
Parameter 50 defines the delay between the end of the last injection and the ex-
truder start.
When elapsed, the time-delay 50 controls the rotational movement of the ex-
truder screw, if selector S204 is positioned on 1. (refer to S204, page 55)
Tab. 7. Extruder time-delay optimisation page parameters

Document: V684_2Aa
page 112 Edition: 16/06/2000
3.4. Optimisation page Extruder feed strip rupture

The optimisation page Extruder feed strip rupture is always accessible.

see section 4. Graphic page Extruding, page 291
Associated
parameters
Progressive start-up 5C
Feed strip rupture detection 4C

Tab. 8. Sub-function available on the optimisation page Extruder feed strip rupture
Fig. 43. Optimisation page Extruder feed strip rupture

Document: V684_2Aa
Edition: 16/06/2000 page 113
3.4.3. Parameters
Default
N Description
value
Time
5C Progressive extruder start

Parameter 5C is a time-delay defining the duration of the increase in speed.
expressed speed
in minutes
and seconds
20
4 seconds
times
0 5C
Pressures
4C Extruding average (Extruder feed strip rupture) (recom-

mended
Parameter 4C defines the limit value of the pressure used during shot size set-
default
expressed ting after the starting stages of the extruder set in 5C.
value) av-
in bars
Parameter 4C is used to detect a sudden drop in extruder service pressure erage ex-
caused by a rubber feed strip rupture. truding
pressure
over 3 cy-
cles
Tab. 9. Extruder feed strip rupture optimisation page parameters V:\G8\Vol2\A\A_utilisation_parametres.fm

Document: V684_2Aa
page 114 Edition: 16/06/2000
3.5. Optimisation page Shot size accuracy

The optimisation page Shot size accuracy is always accessible.

see section 4. Graphic page Extruding, page 291
Associated param-
eters
Shot size setting 2A 3A

(page 94) (page 116) (page 116)
Tab. 10. Sub-function available on the optimisation page Shot size accuracy
Fig. 44. Optimisation page Shot size accuracy

Document: V684_2Aa
Edition: 16/06/2000 page 115
3.5.3. Parameters
Default
N Description
value
Strokes
3A Stroke of the extruder screw at low rotation speed

(recom-
Parameter 3A defines the low-speed rotation transition point of the extruder mended
expressed screw 2A on the axis of the injection piston. Slowing-down is used to obtain adefault
in 0.1 mm more accurate shot size setting. value)
Stroke 30 -
REMARK: The low speed 2A becomes only effective when the value 3A
10 mm
is below the value 30.
Speeds
2A Low rotation speed of the extruder screw ((recom-

mended
Parameter 2A defines a low-speed rotation of the extruder screw to be used at
default
expressed the end of the shot size setting, in order to obtain a more accurate shot size set-
value)
in rpm ting.
Speed 20
divided by
2
Tab. 11. Shot size accuracy optimisation page parameters

Document: V684_2Aa
page 116 Edition: 16/06/2000
3.6. Optimisation page Compound decompression

The optimisation page Compound decompression is always accessible.
3.6.1. Optimisation sub-functions
Optimisation sub-functions Associated parameters
Piston retraction before extruding 3B

(page 95) 2B (page 118) 4B
Piston retraction after extruding (page 118) 3C (page 118)
Tab. 12. Sub-functions available on the optimisation page Compound decompression

Fig. 45. Optimisation page Compound decompression

Document: V684_2Aa
Edition: 16/06/2000 page 117
3.6.2. Parameters
Default
N Description
value
Strokes
3B Piston retraction before extruding

Parameter 3B is a point on the injection piston axis defining:
expressed the limit point of the injection piston with automatic piston retraction,
in 0.1 mm without
the beginning of the shot size setting stroke.
The piston retraction before extruding starts when the time 50, if set, has
elapsed and is used to decompress the injection circuit before the extruder
starts.
3C Piston retraction after extruding

Parameter 3C defines the limit point of the injection piston with automatic pis-
expressed ton retraction. without
in 0.1 mm
The piston retraction after extruding is used to relieve the compound stored
in the injection chamber from any back-pressure.
Speeds
2B Piston retraction
Parameter 2B defines the retraction speed of the injection piston: (manual-
expressed when being controlled manually, ly control-
in 0.1 mm/ led)
sec when being controlled automatically before shot size setting on the stroke
delimited by the points 35 and 3B or after shot size setting on the stroke de- 200
limited by the points 30 and 3C.
Pressures
4B Piston retraction
Parameter 4B defines the retraction pressure of the injection piston: (manual-
expressed ly control-
when being controlled manually, led)
in bars
when being controlled automatically before shot size setting on the stroke
delimited by the points 35 and 3B or after shot size setting on the stroke de- 80
limited by the points 30 and 3C.
Tab. 13. Compound decompression optimisation page parameters

Document: V684_2Aa
page 118 Edition: 16/06/2000
3.7. Optimisation page Silicone stuffer

REMARK: The optimisation page Silicone stuffer is only accessible when the machine
is configured with the option OP122: Silicone stuffer.
Associated param-
eters
77 87
Silicone stuffer
(page 120) (page 120)
Tab. 14. Sub-function available on the optimisation page Silicone stuffer

Fig. 46. Optimisation page Silicone stuffer

Document: V684_2Aa
Edition: 16/06/2000 page 119
3.7.2. Parameters
Default
N Description
value
Speeds
77 Silicone stuffer movement speed

Parameter 77 defines the speed of the silicone stuffer movements. without
expressed
in%
Pressures
87 Service pressure of the silicone stuffer

Parameter 87 defines the service pressure of the silicone stuffer. without
expressed
in bars
Tab. 15. Silicone stuffer optimisation page parameters

Document: V684_2Aa
page 120 Edition: 16/06/2000
4. Function Mould closing
4.1. Base page Mould closing


see section 5. Graphic page Clamping, page 292
Fig. 47. Base page Mould closing
Function Mould closing

Document: V684_2Aa
Edition: 16/06/2000 page 121
Base sub-functions Associated parameters
Low speed closing stage 03 12

(page 96) (page 122) (page 123)
High speed closing stage 03 04 13

(page 96) (page 122) (page 122) (page 123)
Low speed approach stage 04 05 12 44

(page 96) (page 122) (page 123) (page 123) (page 124)
Clamping 43
Tab. 16. Sub-functions available on the base page Mould closing
4.1.3. Parameters
Default
N Description
value
Strokes
03 Beginning of high speed closing

Parameter 03 is a point on the closing unit axis defining:
without
expressed the end of the low speed closing stroke (12),
in 0.1 mm
the beginning of the high speed closing stroke (13).
04 End of high speed closing

expressed without
the end of the high speed closing stroke (13),
in 0.1 mm
the beginning of the approach stroke executed at low speed (12) and safety
pressure (44),
Tab. 17. Parameters of the base page Mould closing


Document: V684_2Aa
page 122 Edition: 16/06/2000
Default
N Description
value
05 Mould safety
Parameter 05 is a point on the closing unit axis used as the tolerance of the ZE-
expressed RO point of the closing stroke and defining:
in 0.1 mm
the end of the approach stroke executed at low speed (12) and safety pres-
sure (44),
the beginning of the clamping-block-in phase (for the machines with 3-
stroke type closing).
the end of the 30-second time-out for the closing phase. without
To protect the tooling, the information mould closed given by the parameter
05 is coupled to the information of microcontact S51 (L.S. mould closing).
REMARK: The microcontact S51 does not exist on the vertical V48 type
machines.
Parameter 05 is also used for the Filling function when the press operates in
the injection-transfer mode.
see section 5.1. Base page Filling, page 129
Speeds
12 Low speed closing

Parameter 12 defines:
expressed
in mm/s the closing speed which is always used in the setting mode,
without
the closing speed used in other operating modes than the setting mode,
outside the stroke limited by the points 03 and 04,
the closing speed used by the optimisation function Plate approach.
refer to section 4.2. Optimisation page Plate approach, page 125.
13 High speed closing

Parameter 13 defines the closing speed used in the operating modes other than
expressed the setting mode on the stroke limited by the points 03 and 04 outside the without
in mm/s areas defined by the optimisation function Plate approach.
Tab. 17. Parameters of the base page Mould closing(cont.)

Document: V684_2Aa
Edition: 16/06/2000 page 123
Default
N Description
value
Pressures
43 Clamping
Parameter 43 defines during direct injection the clamping pressure applied to
expressed the mould once the clamping block is in,
in bars
Parameter 43 can also be used for the injection transfer moulding
refer to section 5.1. Base page Filling, page 129.
without
WARNING: Never clamp the press without a mould in place or with

a mould thinner than the mini mould.
44 Approach
expressed
in bars the safety pressure applied to the closing cylinders on the low speed ap-
proach stroke 12 delimited by the points 04 and 05, without
the safety pressure applied to the closing cylinders when the function Plate
approach is used.
Tab. 17. Parameters of the base page Mould closing(cont.)

Document: V684_2Aa
page 124 Edition: 16/06/2000
4.2. Optimisation page Plate approach

REMARK: The optimisation page Plate approach is only accessible when the machine
is configured with one of the following options:
OP133: Mechanical ejectors,
OP139: Hydraulic ejectors of the movable traverse,
OP141: Hydraulic ejectors of the fixed traverse.
Optimisation sub-function Associated parameters
Intermediate low speed stage 08 09 12 44

Tab. 18. Sub-function available on the optimisation page Plate approach

Fig. 48. Optimisation page Plate approach

Document: V684_2Aa
Edition: 16/06/2000 page 125
4.2.2. Parameters
Default
N Description
value
Strokes
08 Beginning of the low intermediate closing speed

expressed the end of the first closing stroke completed at high speed (13), without
in 0.1 mm
the beginning of the intermediate closing stroke completed at low speed (12)
and safety pressure (44),
09 End of the low intermediate closing speed

expressed without
the end of the intermediate closing stroke completed at low speed (12) and
in 0.1 mm
safety pressure (44),
the beginning of the second high speed closing stroke (13),
Speeds
12 Low speed closinga

without
expressed Parameter 12 defines the closing speed over the stroke delimited by the points
in mm/s 08 and 09.
Pressures
44 Approach a
Parameter 44 defines the safety pressure applied to the closing cylinders for
without
the low speed intermediate stroke 12 delimited by the points 08 and 09.
expressed
in bars
Tab. 19. Plate approach optimisation page parameters

a. The parameters 12 and 44 are also used for the base function Mould closing. (refer to section 4.1., page 121).

Document: V684_2Aa
page 126 Edition: 16/06/2000
4.3. Optimisation page Mould height adjustment screw

The optimisation page Mould height adjustment screw is always accessible.
Associated
parameters
Adjustment of the clearance under the clamping block 0B

Tab. 20. Sub-function available on the optimisation page Mould height adjustment screw
Fig. 49. Optimisation page Mould height adjustment screw

Document: V684_2Aa
Edition: 16/06/2000 page 127
4.3.2. Parameters
Default
N Description
value
Strokes
0B Adjustment of the clamping stroke

Parameter 0B is a point on the closing unit axis defining a precise stop during
expressed the mould opening, to allow the adjustment of the clamping stroke, i.e. the ad-
in 0.1 mm justment of the clearance between the mould height adjustment nut and the
clamping block of the 3-stroke closing machines.
It is only useful in the setting mode after having selected cycle 30 and by fol-
lowing the procedure described below:
1 Closing,
without
2 Loosen the mould height adjustment nut to leave sufficient space for the
clamping block,
3 Clamping block in,
4 Reopening with forced stop at point 0B,
5 Fasten the mould height adjustment nut until touching the clamping block,
6 Closing,
7 Clamping block out,
8 Opening.
Tab. 21. Mould height adjustment screw optimisation page parameters

Document: V684_2Aa
page 128 Edition: 16/06/2000
5. Function Filling
5.1. Base page Filling

REMARK: The base page Filling is a page configured by selecting the type of injections
which can be:
either direct injection,
or injection-transfer.

see section 6. Graphic page Injection (Time), page 293
Fig. 50. Base page Filling with direct injection
Function Filling
Document: V684_2Aa
Edition: 16/06/2000 page 129
62
Heating of the injection chamber
(page 131)
1st speed level during the dynamic injection phase 21 30 35

with injection-transfer : 1st transfer stage 05 0D 1D 4D

with direct injection : 1st pressure holding stage of the static

35 41 51
injection phase
(page 133) (page 133) (page 131)
(page 98)
35 43 51
Transfer holding pressure (with injection-transfer)
(page 133) (page 134) (page 131)
47
Average injection pressure (with direct injection)
(page 134)
4F
Average transfer pressure ( (with injection-transfer))
(page 135)
Tab. 22.Sub-functions available on the base page Filling
Fig. 51. Base page Filling with injection-transfer
Function Filling
Document: V684_2Aa
page 130 Edition: 16/06/2000
5.1.3. Parameters
Injection Default
N Description
type value
Times
51 Duration of the 1st injection holding pressure

Parameter 51 is a delay-time used with direct injection, and it is
Direct injection
expressed launched at the end of the dynamic injection phase when reaching
in minutes the point 35.
and seconds It defines the application time of pressure 41 during the first stage without
of the static injection phase.
When elapsed, the time-delay 51 controls the initiation of the time-
delay 52, if set, otherwise it controls the initiation of the time-de-
lays 50, 56, 58 and 5A.
Duration of the clamping pressure holding time

Injection-transfer
Parameter 51 is a delay-time used with injection-transfer, where it

is launched after the transfer at the transition to point 05.
It defines the application time of pressure 43 during pressure without
holding.
When elapsed, the time-delay 51 controls the initiation of the time-
delays 50, 56, 58 and 5A.
Temperatures
62 Injection chamber temperature

Parameter 62 defines the temperature of the injection chamber.
expressed
REMARK: The control of the heating area 62 takes place in a
in Celsius
closed loop; the temperature is measured by the
thermocouple B3, and when the set value is ex-
ceeded, there is no cooling. The only possible without
cooling for the injection chamber circuit is the
safety cooling controlled by the delay-time 57 or
by the manual stop of the temperature controller.
Parameter 62 is also present on the base page Compound prepa-
ration (refer to section 3.1., page 105)
Tab. 23.Parameters of the base page Filling
Function Filling
Document: V684_2Aa
Edition: 16/06/2000 page 131
Injection Default
N Description
type value
Strokes

Injection-transfer
05 Mould safety
Parameter 05 is a point on the closing unit axis defining the end of
expressed the transfer stages begun at point 0D. without
in 0.1 mm
Parameter 05 is also used for the base function Mould closing
(refer to section 4.1., page 121).
0D Mould opening during injection-transfer

Parameter 0D is a point on the closing unit axis defining the accu-
expressed rate mould opening stroke at the end of the slight clamping re-
in 0.1 mm leasing the injection,
Parameter 0D is also the starting point of the first transfer stage ex-
Injection-transfer
ecuted at speed 1D and pressure 4D,

REMARK: The value 0D must always be above the value 05.
without
WARNING: The value 0D must be 3 mm below the clear-

ance under the clamping block, to ensure an
oil cushion under the clamping piston pre-
venting mechanical locking in the event of an
incident, such as double injection.

expressed
the end of the shot size setting stroke executed at the rotation
in 0.1 mm speed 20
without
the beginning of the first stage of the dynamic injection phase
executed at the injection speed 21.
Parameter 30 is also present on the base pages Compound prep-
aration (refer to section 3.1., page 105) and Injection profile (re-
fer to section 5.2., page 136).
Tab. 23.Parameters of the base page Filling(cont.)
Function Filling
Document: V684_2Aa
page 132 Edition: 16/06/2000
Injection Default
N Description
type value
35 Transition to holding pressure

Direct injection

expressed the end of the last stage of the dynamic injection phase executed without
in 0.1 mm
at one of the injection speeds 21 to 25,
the transition to the static injection phase with the initiation of
delay-time 51.
Transition to the transfer phase

Injection-transfer
Parameter 35 is a point on the injection piston defining:

the end of the last stage of the dynamic injection phase executed without
the transition to the first transfer stage by applying pressure 4D
and speed 1D.
Speeds
1D Transfer speed during the first stage

Injection-transfer
Parameter 1D defines the transfer speed applied:

expressed either to the stroke delimited by the points 0D and 05,
in% without
or only to the stroke delimited by the points 0D and 0E when the
optimisation function 2nd transfer is active.
see section 5.8. Optimisation page 2nd transfer, page 152
Parameter 1D is associated with pressure 4D.

Injection-transfer
21 Injection speed during the first stage

Direct injection
Parameter 21 defines the injection piston speed during the first

expressed stage of the dynamic injection phase for the stroke starting at without
in 0.1 mm/s point 3C, if set, or otherwise at point 30 and delimited by the point
31, if set, or otherwise by point 35.
Pressures
41 1st holding pressure after injection

Direct injection
Parameter 41 only used with direct injection, defines the pressure

expressed applied to the injection piston during the first stage of the static in-
in bars without
jection phase, i.e. during the time 51.
REMARK: The speed, during the pressure stage, is only lim-
ited by the maximum pump displacement value.
Function Filling
Document: V684_2Aa
Edition: 16/06/2000 page 133
Injection Default
N Description
type value
43 Injection-transfer Holding pressure after transfer

Parameter 43 used with injection-transfer defines the holding
expressed pressure applied to the mould after the transfer(s) at the transition
in bars without
to point 05.
Parameter 43 can also be used with direct injection.
refer to section 4.1. Base page Mould closing, page 121.
47 Average injection pressure

REMARK: Parameter 47 is not an active parameter of the
expressed machine, as there is no resulting effect on the ma-
in bars chine; however it can be used by the peripheral
software programs Curetrac and RepNet-win.
Direct injection
Parameter 47 defines the average pressure value during the injec-

tion, i.e. as long as the injection piston is moving. without

This value is used by the software Curetrac to assess the viscosity
of the compound during every injection by calculating how much
energy is needed for its injection.
This value can be used by the RepNet-win software to monitor

this viscosity and to check that every injection is progressing sat-
isfactorily.
4D Transfer pressure during the first stage

Injection-transfer
Parameter 4D defines the transfer pressure applied:

expressed
in bars either to the stroke delimited by the points 0D and 05,
without
or only to the stroke delimited by the points 0D and 0E when the
optimisation function 2nd transfer is active.
refer to section 5.8. Optimisation page 2nd transfer, page 152.
Parameter 4D is associated with speed 1D.

Function Filling
Document: V684_2Aa
page 134 Edition: 16/06/2000
Injection Default
N Description
type value
4F Average transfer pressure

expressed
REMARK: Parameter 4F is not an active parameter of the
in bars
machine, as there is no resulting effect on the ma-
chine; however it can be used by the peripheral
software programs Curetrac and RepNet-win.
Injection-transfer
Parameter 4F defines the average value of the closing pressure

during the transfer phase, i.e. on the stroke delimited by the
points 0D and 05. without
This value is used by the Curetrac software to assess the viscosity

of the compound during every transfer by calculating how much
energy is needed for its transfer.
This value can be used by the RepNet-win software to monitor

this viscosity and to check that every transfer is progressing satis-
factorily.

Function Filling
Document: V684_2Aa
Edition: 16/06/2000 page 135
5.2. Optimisation page Injection profile

The optimisation page Injection profile is always accessible.

see section 7. Graphic page Injection (Stroke), page 295
Function Filling
Document: V684_2Aa
page 136 Edition: 16/06/2000
Proportioning 30
2nd speed level during the dynamic injection phase 22 31

(page 97) (page 139) (page 138)
23 32
3rd speed level during the dynamic injection phase
(page 140) (page 138)
35
(page 139)
24 33
4th speed level during the dynamic injection phase
(page 140) (page 139)
25 34
5th speed level during the dynamic injection phase
(page 140) (page 139)
Injection pressure limitation 48

2nd pressure holding stage of the static injection phase 42 52

(page 98) (page 140) (page 138)
Tab. 24.Sub-functions available on the optimisation page Injection profile

Fig. 52. Optimisation page Injection profile
Function Filling
Document: V684_2Aa
Edition: 16/06/2000 page 137
5.2.3. Parameters
Injection Default
N Description
type value
Times

Direct injection
52 Duration of the 2nd injection pressure holding time

Parameter 52 is a delay-time used with direct injection, initiated
expressed when 51 has elapsed; it determines the application time of pres- without
in minutes sure 42 during the second stage of the static injection phase.
and seconds
Strokes

expressed
the end of the shot size setting stroke executed at the rotation
in 0.1 mm
speed 20
without
the beginning of the first stage of the dynamic injection phase
Parameter 30 also features on the base page Compound prepa-
ration (refer to section 3.1., page 105) and on the base page Fill-
ing (refer to section 5.1., page 129).
31 Beginning of the 2nd stage of the dynamic injection phase

expressed
the end of the first stage of the dynamic injection phase executed without
in 0.1 mm
at the injection speed 21.
the beginning of the second stage of the dynamic injection phase
32 Beginning of the 3rd stage of the dynamic injection phase

expressed
the end of the second stage of the dynamic injection phase exe- without
in 0.1 mm
cuted at the injection speed 22.
the beginning of the third stage of the dynamic injection phase
Tab. 25.Injection profile optimisation page parameters
Function Filling
Document: V684_2Aa
page 138 Edition: 16/06/2000
Injection Default
N Description
type value
33 Beginning of the 4th stage of the dynamic injection phase

expressed the end of the third stage of the dynamic injection phase execut- without
in 0.1 mm
ed at the injection speed 23.
the beginning of the fourth stage of the dynamic injection phase
34 Beginning of the 5th stage of the dynamic injection phase

expressed
the end of the fourth stage of the dynamic injection phase exe- without
in 0.1 mm
cuted at the injection speed 24.
the beginning of the 5th stage of the dynamic injection phase ex-
ecuted at the injection speed 25.
35 Transition to holding pressure

Direct injection
expressed
in 0.1 mm at one of the injection speeds 21 to 25,
the transition to the static injection phase with the initiation of
delay-time 51.
The same parameter 35 also features on the base page Filling (re-
fer to section 5.1., page 129).
Injection-transfer
Transition to the transfer phase

Parameter 35 is a point on the injection piston defining:
the transition to the first transfer stage by applying pressure 4D
and speed 1D.
Speeds
22 Injection speed during the 2nd stage

Parameter 22 defines the speed of the injection piston during the
expressed second stage of the dynamic injection phase for the stroke starting without
in 0.1 mm/s at point 31 and delimited by point 32, if set, or otherwise delimited
by point 35.
Tab. 25.Injection profile(cont.) optimisation page parameters
Function Filling
Document: V684_2Aa
Edition: 16/06/2000 page 139
Injection Default
N Description
type value
23 Injection speed during the 3rd stage

expressed second stage of the dynamic injection phase for the stroke starting without
by point 35.
24 Injection speed during the 4th stage

expressed fourth stage of the dynamic injection phase for the stroke starting without
by point 35.
25 Injection speed during the 5th stage

Parameter 25 defines the speed of the injection piston during the without
expressed fifth stage of the dynamic injection phase for the stroke starting at
in 0.1 mm/s point 34 and delimited by point 35.
Pressures
42 2nd holding pressure after injection

Direct injection
Parameter 42 only used with direct injection, defines the pressure

expressed applied to the injection piston during the second stage of the static
in bars without
injection phase, i.e. during the time 52.
REMARK: The speed, during the pressure stage, is only lim-
ited by the maximum pump displacement value.

Direct injection
48 Injection pressure limitation

Parameter 48 defines the maximum pressure value possible to use
expressed during the dynamic injection phase, i.e. from the beginning of the 250 bar
in bars injection to point 35.
Tab. 25.Injection profile(cont.) optimisation page parameters

5.3. Optimisation page Degassing

The optimisation page Degassing is always accessible.
Function Filling
Document: V684_2Aa
page 140 Edition: 16/06/2000
1st volumetric degassing 36

2nd volumetric degassing 37

(page 97) 0A 1A 54 (page 143)
1st delayed degassing (page 143) (page 143) (page 142) 53

(page 100) (page 142)
2nd delayed degassing 55

(page 100) (page 142)
Tab. 26.Sub-functions available on the optimisation page Degassing

Fig. 53. Optimisation page Degassing
Function Filling
Document: V684_2Aa
Edition: 16/06/2000 page 141
5.3.2. Parameters
Default
N Description
value
Times
53 Postponement of the first time-delayed degassing

Parameter 53 is a delay-time initiated at the end of the dynamic injection phase
expressed when reaching point 35 and determining the postponement of the first de-
in minutes layed degassing relative to the end of the dynamic injection phase.
and seconds
When elapsed, the delay-time 53 controls the release of the first delayed degas-
sing according to the procedure listed below: without
1 pressure relief on the clamping cylinder,

2 opening on the stroke delimited by point 0A,
3 initiation of the degassing time-delay 54,
4 clamping at the end of time-delay 54.
54 Opening time during degassing

Parameter 54 is a delay-time initiated during degassing when starting the
expressed opening at point 0A and defining:
in 0.1 s without
the mould opening time during degassing and before its clamping,
the initiation of time-delay 55 of the second time-delayed degassing.
When elapsed, time-delay 54 controls the mould clamping.
55 Postponement of the 2nd delayed degassing

Parameter 55 is a delay-time initiated at the end of the opening time 54 during
expressed the first delayed degassing, determining the postponement of the second de-
in minutes layed degassing versus the first.
and seconds
When elapsed, the delay-time 55 controls the release of the second delayed de-
gassing according to the procedure listed below: without

Tab. 27.Degassing optimisation page parameters
Function Filling
Document: V684_2Aa
page 142 Edition: 16/06/2000
Default
N Description
value
Strokes
0A Opening stroke during degassing

Parameter 0A is a point on the closing unit axis defining the end of the mould without
expressed opening stroke during degassing.
in 0.1 mm
36 Initiation of the 1st volumetric degassing

Parameter 36 defines, on the injection piston axis, the release point of the first
expressed volumetric degassing which takes place according to the following proce-
in 0.1 mm dure:
1 injection stop, without
37 Initiation of the 2nd volumetric degassing

Parameter 37 defines, on the injection piston axis, the release point of the sec-
expressed ond volumetric degassing which takes place according to the following pro-
in 0.1 mm cedure:
1 injection stop, without
Speeds
1A Opening speed during degassing

Set value
Parameter 1A defines the mould opening speed during degassing on the
of parame-
expressed stroke delimited by point 0A. ter 10
in mm/s
Tab. 27.Degassing(cont.) optimisation page parameters
Function Filling
Document: V684_2Aa
Edition: 16/06/2000 page 143
5.4. Optimisation page Cold runner block

REMARK: The optimisation page Cold runner block is only accessible when the ma-
chine is configured with the option OP155: Pre-arrangement for Cold Runner
Block,
see illustration Fig. 54., page 144.
Associated param-
eters
63 64
Injection with cold runner block
(page 145) (page 145)
Tab. 28.Sub-function available on the optimisation page Cold runner block
Fig. 54. Optimisation page Cold runner block
Function Filling
Document: V684_2Aa
page 144 Edition: 16/06/2000
5.4.2. Parameters
Default
N Description
value
Temperatures
63 Nozzle(s)
Parameter 63 defines the thermal oil temperature of the control circuit of the
expressed secondary nozzles of a Cold Runner Block (C.R.B.).
in Celsius
loop; the temperature measurement is done by the thermo-
without
couple B4.
The throttling work of the compound during the injection rap-
idly leads to a temperature increase of the secondary noz-
zles. Consequently, the secondary nozzle circuit is cooled
down immediately whenever an excessive temperature value
of the 63 set value is detected.
64 Cold runner block

Parameter 64 defines the thermal oil temperature of the C.R.B. body control
expressed circuit, provided this option is available on the machine.
in Celsius
REMARK: The temperature control of the heating area 64 takes place in
a closed loop; the temperature measurement is done by the
thermocouple B9. without
Whenever an excessive temperature value versus set value
64 is detected, the block is cooled down immediately.
Safety cooling controlled by delay-time 57 or by the manual
stop of the circulator (simultaneous with the manual stop of
the injection unit controller) is also possible on the cold runner
block circuit.
Tab. 29.Cold runner block optimisation page parameters

Function Filling
Document: V684_2Aa
Edition: 16/06/2000 page 145
5.5. Optimisation Page Beardown after injection

The optimisation page Beardown after injection is always accessible.
Associated
parameters
Beardown holding after injection 5A

(page 100) (page 147)
Tab. 30.Sub-function available on the optimisation page Beardown after injection
Fig. 55. Optimisation page Beardown after injection
Function Filling
Document: V684_2Aa
page 146 Edition: 16/06/2000
5.5.2. Parameters
Default
N Description
value
Times
5A Injection unit beardown after injection

Parameter 5A is a delay-time initiated:
expressed
in minutes during direct injection, at the end of the static injection phase, i.e. once 52 has
and seconds elapsed, if set, otherwise when 51 has elapsed.
without
with injection-transfer, at the end of the transfer pressure holding time, i.e.
when 51 has elapsed.
Delay-time 5A defines the holding time of the injection unit beardown move-
ment after the injection; when elapsed, it controls the stop of the injection unit
beardown movement.
Tab. 31.Beardown after injection optimisation page parameters

Function Filling
Document: V684_2Aa
Edition: 16/06/2000 page 147
5.6. Optimisation page Vacuum

REMARK: The optimisation page Vacuum is only accessible when the machine is con-
figured with the option OP111: Pre-arrangement for vacuum pump.
Associated
parameters
59
Vacuum before injection
(page 149)
Tab. 32.Sub-function available on the optimisation page Vacuum
Fig. 56. Optimisation page Vacuum
Function Filling
Document: V684_2Aa
page 148 Edition: 16/06/2000
5.6.2. Parameters
Default
N Description
value
Times
59 Vacuum prior to injection

Parameter 59 is a time-delay initiated simultaneously with the mould clamp-
expressed ing.
in minutes Delay-time 59 defines the time for which the start of injection is postponed, al-
and seconds lowing the generation of a vacuum inside the clamped mould; when elapsed, without
it controls the injection.
REMARK: Vacuum may be used in two different modes.
see section 3.7.3. Optimisation functions Vacuum pump,
page 266
Tab. 33.Vacuum optimisation page parameters

Function Filling
Document: V684_2Aa
Edition: 16/06/2000 page 149
5.7. Optimisation page Automatic injection unit lift

The optimisation page Automatic injection unit lift is always accessible.
Associated
parameters
Automatic lift after injection 58

(page 100) (page 151)
Tab. 34.Sub-function available on the optimisation page Automatic injection unit lift
Fig. 57. Optimisation page Automatic injection unit lift
Function Filling
Document: V684_2Aa
page 150 Edition: 16/06/2000
5.7.2. Parameters
Default
N Description
value
Times
58 Automatic injection unit lift after the injection

Parameter 58 is a delay-time initiated:
expressed
in minutes during direct injection, at the end of the static injection phase, i.e. once 52 has
and seconds elapsed, if set, otherwise when 51 has elapsed.
without
with injection-transfer, at the end of the pressure holding time, i.e. when 51
has elapsed.
Delay-time 58 defines the postponement of the injection unit lift movement af-
ter the end of the last injection; when elapsed, it controls the injection unit lift
movement.
Tab. 35.Automatic injection unit lift optimisation page parameters

Function Filling
Document: V684_2Aa
Edition: 16/06/2000 page 151
5.8. Optimisation page 2nd transfer

REMARK: The optimisation page 2nd transfer is a page only accessible when the injec-
tion type chosen is injection-transfer.
with injection-transfer: 2nd transfer stage 0E 1E 4E

Tab. 36.Sub-function available on the optimisation page 2nd transfer
Fig. 58. Optimisation page 2nd transfer
Function Filling
Document: V684_2Aa
page 152 Edition: 16/06/2000
5.8.2. Parameters
Injection Default
N Description
type value
Strokes

Injection-transfer
0E Stroke of the 2nd transfer stage

Parameter 0E is a point on the closing unit axis defining:
expressed the end of the first transfer stage which started at the point 0D, without
in 0.1 mm
the beginning of the second transfer stage executed at speed 1E
and pressure 4E and finishing once point 05 has been reached.
Speeds

Injection-transfer
1E Transfer speed during the second stage

Parameter 1E defines the transfer speed for the stroke delimited by
expressed points 0E and 05. without
in% Parameter 1E is associated with pressure 4E.
Pressures

Injection-transfer
4E Transfer pressure during the 2nd stage

Parameter 4E defines the transfer pressure for the stroke delimited
expressed by the points 0E and 05. without
in bars Parameter 4E is associated with speed 1E.
Tab. 37.2nd transfer optimisation page parameters

Function Filling
Document: V684_2Aa
Edition: 16/06/2000 page 153
5.9. Optimisation page Compound pressure

REMARK: The optimisation page Compound pressure is a page only accessible when
the injection type chosen is direct injection and when the machine is configured
with the special option OPV073: Compound pressure,
Associated
parameters
45
Compound pressure check inside the mould
(page 155)
Tab. 38.Sub-function available on the optimisation page Compound pressure
Fig. 59. Optimisation page Compound pressure
Function Filling
Document: V684_2Aa
page 154 Edition: 16/06/2000
5.9.2. Parameters
Injection Default
N Description
type value
Pressures

Direct injection
45 Compound pressure inside the mould

Parameter 45 defines the compound pressure measured inside the
expressed mould. without
in bars
Tab. 39.Compound pressure optimisation page parameters

Function Filling
Document: V684_2Aa
Edition: 16/06/2000 page 155
6. Function Curing
6.1. Base page Curing


see section 8. Graphic page Mould temperatures, page 296
Associated
Base sub-functions
parameters
Curing time 56
(page 100) (page 157)
65
Heating of the fixed traverse platen
(page 157)
67
Heating of the movable traverse platen
(page 157)
Tab. 40.Sub-functions available on the base page Curing
Fig. 60. Base page Curing
Function Curing
Document: V684_2Aa
page 156 Edition: 16/06/2000
6.1.3. Parameters
Default
N Description
value
Times
56 Curing time
Parameter 56 is a delay-time initiated at the end of the static injection phase,
expressed i.e. once 52 has elapsed, if set, otherwise when 51 has elapsed.
in minutes without
Delay-time 56 defines the curing time of the last parts moulded; when elapsed,
and seconds
it controls the mould unclamping and opening.
REMARK: The rubber holding time inside the mould is equal to 51 + 52
+ 56.
Temperatures
65 Temperature of the heating platen of the fixed traverse

Parameter 65 defines the temperature of the mould part which is mounted on
expressed the heating platen of the fixed traverse.
without
in C
thermocouple B6.
67 Temperature of the heating platen of the movable traverse

Parameter 67 defines the temperature of the mould part which is mounted on
expressed the movable traverse heating platen.
without
in C
thermocouple B7.
Tab. 41.Parameters of the base page Curing

Function Curing
Document: V684_2Aa
Edition: 16/06/2000 page 157
6.2. Optimisation page Curetrac Corrections

Fig. 61. Optimisation page Curetrac Corrections
Function Curing
Document: V684_2Aa
page 158 Edition: 16/06/2000
6.3. Optimisation page Curetrac communication

Fig. 62. Optimisation page Curetrac communication
Function Curing
Document: V684_2Aa
Edition: 16/06/2000 page 159
6.4. Optimisation page Network Link

Fig. 63. Optimisation page Network Link
Function Curing
Document: V684_2Aa
page 160 Edition: 16/06/2000
6.5. Optimisation page Ancillary areas

REMARK: The optimisation page Ancillary areas is only made accessible when the ma-
chine is configured with one of the following options:
OP115: Heater ancillary area No 1,
OP116: Heater ancillary area No 2,
OPV117: OP117: Heating ancillary area N3,
Associated
Optimisation sub-functions
parameters
66
Heating ancillary area No 1
(page 162)
68
(page 162)
69
(page 162)
Tab. 42.Sub-functions available on the base page Ancillary areas

Fig. 64. >Optimisation page Ancillary areas
Function Curing
Document: V684_2Aa
Edition: 16/06/2000 page 161
6.5.2. Parameters
Default
N Description
value
Temperatures
66 Temperature of the ancillary area No 1

Parameter 66 defines the temperature of the mould part heated by the ancil-
expressed lary area N1.
without
in C
thermocouple B8.

expressed lary area N2.
without
in C
thermocouple B10.

expressed lary area N3. without
in C
loop; the temperature is measured by the thermocouple B11.
Tab. 43.Ancillary areas optimisation page parameters
Function Curing
Document: V684_2Aa
page 162 Edition: 16/06/2000
7. Function Stripping and loading of inserts
7.1. Base page Stripping and loading of inserts

Low speed extraction stage 00 10

(page 102) (page 164) (page 164)
High speed opening stage 00 01 11

Low speed ejection stage 01 10

(page 102) (page 164) (page 164)
Tab. 44.Sub-functions available on the base page Stripping and loading of inserts
Fig. 65. Base page Stripping and loading of inserts
Function Stripping and loading of inserts

Document: V684_2Aa
Edition: 16/06/2000 page 163
7.1.2. Parameters
Default
N Description
value
Strokes
00 Beginning of high speed opening

without
expressed the end of the extraction stroke executed at low speed (10),
in 0.1 mm
the beginning of the opening stroke executed at high speed (11).
01 End of high speed opening

without
expressed
the end of the opening stroke executed at high speed (11);
in 0.1 mm
the beginning of the low speed ejection stroke (10).
Speeds
10 Low speed opening

expressed
in mm/s the opening speed always used in the setting mode,
without
the opening speed used in operating modes other than the setting mode,
outside the stroke delimited by the points 00 and 01,
the opening speed used by the optimisation function Plate approach.
11 High speed opening

Parameter 11 defines the opening speed used in operating modes other than
expressed the setting mode on the stroke delimited by the points 00 and 01 outside the without
in mm/s areas defined by the optimisation function Plate approach.
Tab. 45.Parameters of the base page Stripping and loading of inserts


Document: V684_2Aa
page 164 Edition: 16/06/2000
7.2. Optimisation Movable traverse ejectors

The optimisation page Movable traverse ejectors is specific to one of the 3
optimisation functions relating to the movable traverse ejection and which
can be installed on the machine:
movable traverse hydraulic ejectors
movable traverse hydraulic ejectors (with encoder)
mechanical ejectors.
Press options available on the machine

Optimisation functions OP133 OP139 OPV040
Movable traverse hydraulic ejectors

X
Movable traverse hydraulic ejectors with encoder

X X
Mechanical ejectors
X

Document: V684_2Aa
Edition: 16/06/2000 page 165
7.3. Optimisation page Movable traverse ejectors

REMEMBER: The optimisation page Movable traverse ejectors is a page accessible only
when the machine is configured with the option OP139: Side hydraulic ejectors
on the movable traverse.
Associated param-
eters
71 81
Ejection on the movable traverse
(page 167) (page 167)
Tab. 46.Sub-functions available on the optimisation page Movable traverse ejectors
Fig. 66. Optimisation pageMovable traverse ejectors

Document: V684_2Aa
page 166 Edition: 16/06/2000
7.3.2. Parameters
Default
N Description
value
Speeds
71 Speed of the movable traverse ejectors

Parameter 71 defines the speed of the movable traverse hydraulic ejectors without
expressed when not equipped with encoders.
in%
Pressures
81 Pressure of the movable traverse ejectors

Parameter 81 defines the maximum service pressure of the movable traverse without
expressed hydraulic ejectors on their full in-stroke and out-stroke.
in bars
Tab. 47.Movable traverse ejectors optimisation page parameters


Document: V684_2Aa
Edition: 16/06/2000 page 167
7.4. Optimisation page Movable traverse ejectors with encoder

REMEMBER: The optimisation page Movable traverse ejectors is a page accessible only
when the machine is configured with the options OP139: Side hydraulic ejec-
tors on the movable traverse and OPV040: Encoder on movable traverse ejec-
tors.
Out-stroke of the movable traverse

7C 9B 9C DJ
ejectors with encoder
(page 103) 71 81
In-stroke of the movable traverse ejec- (page 169) (page 170)
9A
tors with encoder
(page 169)
(page 103)
Fig. 67. Optimisation page Movable traverse ejectors with encoder

Document: V684_2Aa
page 168 Edition: 16/06/2000
7.4.2. Parameters
Default
N Description
value
Strokes
9A End of the in-stroke of the movable traverse ejectors

Parameter 9A is a point on the axis of the movable traverse ejectors defining without
expressed the end of their in-stroke executed at speed 71 and pressure 81.
in 0.1 mm
9B Beginning of the low speed out-stroke of the movable traverse ejectors

Parameter 9B is a point on the axis of the movable traverse ejectors defining without
expressed the end of their out-stroke executed at high speed 71 and pressure 81 and the
in 0.1 mm beginning of their out-stroke executed at low speed 7C and pressure 81.
9C End of the out-stroke of the movable traverse ejectors

Parameter 9C is a point on the axis of the movable traverse ejectors defining without
expressed the end of their out-stroke executed at low speed 7C and pressure 81.
in 0.1 mm
DJ tolerance on the out-stroke of the movable traverse ejectors
10
expressed
in 0.1 mm
Speeds
71 Speed of the movable traverse ejectors

Parameter 71 defines the speed of the hydraulic ejectors of the movable without
expressed traverse on their full in-stroke and on their out-stroke delimited by the points
in mm/s 9A and 9B.
7C Low out-stroke speed of the movable traverse ejectors

Parameter 7C defines the low speed of the out-stroke end of the hydraulic without
expressed
ejectors of the movable traverse on the stroke delimited by the points 9B et 9C.
in mm/s
Pressures
Tab. 49.Parameters of the optimisation page Movable traverse ejectors with encoder

Document: V684_2Aa
Edition: 16/06/2000 page 169
Default
N Description
value
81 Pressure of the movable traverse ejectors

Parameter 81 defines the maximum service pressure of the movable traverse without
expressed hydraulic ejectors on their full in-stroke and out-stroke.
in bars
Tab. 49.Parameters of the optimisation page Movable traverse ejectors with encoder(cont.)
7.5. Optimisation page Mechanical ejectors

REMEMBER: The optimisation page is a page accessible only with the machine configu-
ration including the option OP133: Movable traverse mechanical ejectors
Fig. 68. Optimisation page Mechanical ejectors

Document: V684_2Aa
page 170 Edition: 16/06/2000
Associated param-
eters
Insert lift 02 DG
(page 96) (page 171) (page 171)
Ejection pressure limitation 86

(page 102) (page 171)
7.5.2. Parameters
Default
N Description
value
Strokes
02 Insert lift
Parameter 02 is a point on the closing unit axis defining the mould opening at
expressed the end of the cycle. The Insert lift stroke can start after the full opening of
in 0.1 mm the machine and the automatic closing executed at the low closing speed (12) without
up to point 02.
The insert lift position is used to reload the inserts on the insert holder plate
once the latter has been emptied by the mechanical ejectors.
DG Tolerance on the insert lift stroke
10
expressed
in 0.1 mm
Pressures
86 Ejection pressure limit

Parameter 86 defines the limit value of the pressure used at the low speed without
expressed opening 10 on the mould opening stroke delimited by the point 01 and the end
in bars of the opening stroke defined in table or by parameter 0F.
Tab. 51.Mechanical ejectors optimisation page parameters

Document: V684_2Aa
Edition: 16/06/2000 page 171
7.6. Optimisations Fixed traverse ejectors

The optimisation page Fixed traverse ejectors is specific to one of the 2 op-
timisation functions relating to the fixed traverse ejection and which can be
installed on the machine:
fixed traverse hydraulic ejectors
fixed traverse hydraulic ejectors (with encoder)
Press options available on the

machine
Optimisation functions OP141 OPV040
Fixed traverse hydraulic ejectors

X
Fixed traverse hydraulic ejectors with encoder

X X

Document: V684_2Aa
page 172 Edition: 16/06/2000
7.7. Optimisation page Fixed traverse ejectors

REMEMBER: The optimisation page Fixed traverse ejectors is a page accessible only
when the machine is configured with the option OP141: Side hydraulic ejectors
of the fixed traverse.
Associated param-
eters
72 82
Ejection on the fixed traverse
(page 174) (page 174)
Tab. 52.Sub-functions available on the optimisation page Fixed traverse ejectors

Fig. 69. Optimisation page Fixed traverse ejectors

Document: V684_2Aa
Edition: 16/06/2000 page 173
7.7.2. Parameters
Default
N Description
value
Speeds
72 Fixed traverse ejector speed

Parameter 72 defines the speed of the fixed traverse hydraulic ejectors when without
expressed not equipped with encoders.
in%
Pressures
82 Pressure of the fixed traverse ejectors

Parameter 82 defines the maximum service pressure of the fixed traverse hy- without
expressed draulic ejectors on their full in-stroke and out-stroke.
in bars
Tab. 53.Fixed traverse ejectors optimisation page parameters

Document: V684_2Aa
page 174 Edition: 16/06/2000
7.8. Optimisation page Fixed traverse ejectors with encoder

REMEMBER: The optimisation page Fixed traverse ejectors is a page accessible only
when the machine is configured with the options OP141: Side hydraulic ejec-
tors of the fixed traverse and OPV040: Encoder on movable traverse ejectors.
Out-stroke of the fixed traverse ejectors with enco-

72 7F 82 9E 9F
der
(page 104)
In-stroke of the fixed traverse ejectors with enco-

9D
der
(page 176)
(page 104)
Tab. 54.Sub-functions available on the optimisation page Fixed traverse ejectors

Fig. 70. Optimisation page Fixed traverse ejectors with encoder

Document: V684_2Aa
Edition: 16/06/2000 page 175
7.8.2. Parameters
Default
N Description
value
Strokes
9D End of the in-stroke of the fixed traverse ejectors

Parameter 9D is a point on the axis of the fixed traverse ejectors defining the without
expressed end of their in-stroke executed at speed 72 and pressure 82.
in 0.1 mm
9E Beginning of the low speed out-stroke of the fixed traverse ejectors

Parameter 9E is a point on the axis of the fixed traverse ejectors defining the without
expressed end of their out-stroke executed at speed 72 and pressure 82, and the begin-
in 0.1 mm ning of their out-stroke executed at low speed 7F and pressure 82.
9F End of the out-stroke of the fixed traverse ejectors

Parameter 9F is a point on the axis of the fixed traverse ejectors defining the without
expressed end of their out-stroke executed at low speed 7F and pressure 82.
in 0.1 mm
Speeds
72 Fixed traverse ejector speed

Parameter 72 defines the speed of the fixed traverse hydraulic ejectors on their without
expressed full in-stroke and their out-stroke delimited by the points 9D and 9E when the
in mm/s ejectors are equipped with encoders.
7F Low out-stroke speed of the fixed traverse ejectors

Parameter 7F defines the low speed of the out-stroke end of the hydraulic without
expressed ejectors of the fixed traverse on the stroke delimited by the points 9E et 9F.
in mm/s
Tab. 55.Parameters of the optimisation page Fixed traverse ejectors with encoder

Document: V684_2Aa
page 176 Edition: 16/06/2000
Default
N Description
value
Pressures
82 Pressure of the fixed traverse ejectors

Parameter 82 defines the maximum service pressure of the fixed traverse hy- without
expressed draulic ejectors on their full in-stroke and out-stroke.
in bars
Tab. 55.Parameters of the optimisation page Fixed traverse ejectors with encoder(cont.)

Document: V684_2Aa
Edition: 16/06/2000 page 177
7.9. Optimisation page Stripping kits

NB: The optimisation page Stripping kits is a page accessible only with the ma-
chine configuration including one of the following options:
OP146: Top rear stripping kit
OP147: Bottom front stripping kit
Associated param-
eters
Single-plate translation 73 83
Double-plate translation (page 179) (page 179)
74 84
Ejection on stripping kit
(page 179) (page 179)
Tab. 56.Sub-functions available on the optimisation page Stripping kits
Fig. 71. Optimisation page Stripping kits

Document: V684_2Aa
page 178 Edition: 16/06/2000
7.9.2. Parameters
Default
N Description
value
Speeds
73 Plate translation speed

Parameter 73 defines the plate-out speed outside the press and plate-in speed without
expressed inside the press.
in%
74 Kit ejector speed

Parameter 74 defines the in/out speed of the stripping kit ejector. without
expressed
in%
Pressures
83 Plate translation pressure

Parameter 83 defines the maximum service pressure during the plate moving without
expressed outside and inside the press.
in bars
84 Kit ejector pressure

Parameter 84 defines the maximum service pressure during the out-stroke and without
expressed in-stroke of the stripping kit ejector.
in bars
Tab. 57.Stripping kits optimisation page parameters


Document: V684_2Aa
Edition: 16/06/2000 page 179
7.10. Optimisation page Plate approach

REMARK: The optimisation page Plate approach is a page accessible only when the
machine is configured with one of the following options:
OP133: Mechanical ejectors
OP139: Hydraulic ejectors of the movable traverse.
Low intermediate speed stage 06 07 10 86

Tab. 58.Sub-function available on the optimisation page Plate approach
Fig. 72. Optimisation pagePlate approach

Document: V684_2Aa
page 180 Edition: 16/06/2000
7.10.2. Parameters
Default
N Description
value
Strokes
06 Beginning of the low intermediate opening speed

expressed the end of the first opening stroke executed at high speed (11), without
in 0.1 mm
the beginning of the intermediate opening stroke completed at low speed
(10) and safety pressure (86),
07 End of the low intermediate opening speed

expressed without
the end of the intermediate opening stroke completed at low speed (10) and
in 0.1 mm
safety pressure (86),
the beginning of the second opening stroke executed at high speed (11),
Speeds
10 Low speed openinga

without
expressed Parameter 10 defines the opening speed on the stroke delimited by the points
in mm/s 06 and 07.
Pressures
86 Approach a
Parameter 86 defines the maximum service pressure applied to the closing cyl- without
expressed
inders while opening on the intermediate stroke completed at low speed 10
in bars
delimited by the points 06 and 07.
Tab. 59.Plate approach optimisation page parameters

a. The parameters 10 and 86 are also used for the base function Stripping and loading of inserts. (refer to section 7.1.,
page 163).

Document: V684_2Aa
Edition: 16/06/2000 page 181
7.11. Optimisation page Sliding platen

REMARK: The optimisation page Sliding platen is a page accessible only when the ma-
chine is configured with the option OP137: Sliding platen.
15 16 17
Sliding platen
(page 183) (page 183) (page 183)
Tab. 60.Sub-function available on the optimisation page Sliding platen
Fig. 73. Optimisation page Sliding platen

Document: V684_2Aa
page 182 Edition: 16/06/2000
7.11.2. Parameters
Default
N Description
value
Speeds
15 Sliding platen out speed

Parameter 15 defines the sliding platen moving out speed until having without
expressed reached the microcontact S45 (L.S. sliding platen slow-down).
in%
16 Sliding platen out dampening speed

Parameter 16 defines the sliding platen moving out speed on the stroke delim-
expressed ited by the microcontacts S45 (L.S. sliding platen slow-down) and S55 (L.S. slid-
in% without
ing platen out).
Parameter 16 is used to dampen the stop of the sliding platen by absorbing its
kinetic energy.
17 Sliding platen in speed

Parameter 17 defines the sliding platen in speed until having reached the mi- without
expressed crocontact S54 (L.S. sliding platen in).
in%
Tab. 61.Sliding platen optimisation page parameters


Document: V684_2Aa
Edition: 16/06/2000 page 183
7.12. Optimisation page Ancillary cylinders

REMARK: The optimisation page Ancillary cylinders is a page accessible only when the
machine is configured with one of the following options:
OPV066: Pre-arrangement for ancillary cylinder No 1,
OPV067: Pre-arrangement for ancillary cylinder No 2.
Associated param-
eters
70 80
1st ancillary cylinder
(page 185) (page 185)
75 85
2nd ancillary cylinder
(page 185) (page 185)
Tab. 62.Sub-functions available on the optimisation page Ancillary cylinders
Fig. 74. Optimisation page Ancillary cylinders

Document: V684_2Aa
page 184 Edition: 16/06/2000
7.12.2. Parameters
Default
N Description
value
Speeds
70 Speed of ancillary cylinder No 1

Parameter 70 defines the speed of the movements of the 1st ancillary cylinder without
expressed system.
in%
75 Speed of ancillary cylinder No 2

Parameter 75 defines the speed of the movements of the 2nd ancillary cylinder without
expressed system.
in%
Pressures
80 Pressure of the ancillary cylinder No 1

Parameter 80 defines the maximum service pressure during the movements of without
expressed the 1st ancillary cylinder system.
in bars
85 Pressure of the ancillary cylinder No 2

Parameter 85 defines the maximum service pressure during the movements of without
expressed the 2nd ancillary cylinder system.
in bars
Tab. 63.Ancillary cylinders optimisation page parameters


Document: V684_2Aa
Edition: 16/06/2000 page 185
7.13. Optimisation page Limits

The page Limits is always accessible.
Associated param-
eters
Opening stroke limitation 0F DF

(page 102) (page 187) (page 187)
Extraction pressure limitation 46

(page 102) (page 187)
Tab. 64.Sub-functions available on the optimisation page Limits
Fig. 75. Optimisation page Limits

Document: V684_2Aa
page 186 Edition: 16/06/2000
7.13.2. Parameters
Default
N Description
value
Strokes
0F End of the opening stroke

Parameter 0F is a point on the closing unit axis defining the mould opening, in
expressed turn triggering the end of the cycle.
without
in 0.1 mm
REMARK: The precise stop position can only be obtained when the ma-
chine is equipped with the option OP171: Mould opening
stroke limit.
DF Opening stroke tolerance
10
expressed
in 0.1 mm
Pressures
46 Extraction pressure limit

Parameter 46 defines the maximum pressure value which may be applied to
expressed the low speed extraction stroke 10 starting at point zero mould closed and
without
in bars delimited by the point 00.
The pressure force 46 controls the part extraction at the beginning of the mould
opening.
Tab. 65.Limits optimisation page parameters


Document: V684_2Aa
Edition: 16/06/2000 page 187

Document: V684_2Aa
page 188 Edition: 16/06/2000
Chapter VI - Thermotrac
1. Temperature control and Thermotrac function
1.1. Introduction
1.1.1. Controls and control coefficients

The temperatures of the heating and cooling areas of a G8 type REP press are
controlled by digital controllers integrated into the machine software, using
PIDT control coefficients matching the different areas to control.
REMINDER: P is the coefficient for proportional action.
I is the coefficient for integral action.
D is the coefficient for derived action.
T is the sampling period.
WARNING: There is no direct link between the control coefficients calculated by Thermo-
trac of previous generations (I and II) and those calculated by
Thermotrac III.
1.1.2. Software Thermotrac
The temperature control software Thermotrac III equipping the REP G8

presses consists of 2 parts:
the calculating software executing for each heating area a study to define
the PIDT control coefficients; the software afterwards takes the different pa-
rameters into account to ensure the thermal continuity of the tooling.
the temperature control software using the coefficients to stabilize the tem-
peratures and to ensure a quick and efficient temperature control.
V:\G8\Vol2\A\A_utilisation_Thermotrac.fm
The control software Thermotrac can operate in 3 different modes:

by using coefficients determined by the identification:
This mode is the best for precise control.
by using coefficients entered manually :
In this case, the precision of control will depend on the accuracy of the co-
efficients.
without initial coefficients:
In this case, the precision of control will depend on the time allowed for the
software to determine the most appropriate coefficients for the mould.
Document: V684_2Aa
Edition: 16/06/2000 page 189
1.2. Active Thermotrac pages
1.2.1. Access to the different active pages of Thermotrac
Information relating to the Thermotrac function is distributed over the dif-

ferent active pages of the Thermotrac preset function and the associated op-
timisation functions, accessible through the keyboard keys.
see table Tab. 66., page 190
Access keys
Main pages Optimisation pages
Temperature
Identification
Thermotrac Identification control super-
control
vision
page 191 page 195
page 199
page 198
1.2.2. Colour code of the output states
On the different active pages of the Thermotrac function, the status of the
process control outputs relating to a heating or cooling command is repre-
sented through the following colours:
Keypad background Output status

Heating Cooling Heating Cooling
Heating running, the corresponding
Orange - -
output is controlled
Cooling running, the corresponding
- Green -
output is controlled
Heating stopped, the corresponding Cooling stopped, the corresponding
White
output is not controlled output is not controlled
Heating impossible: the area has no Cooling impossible: the area has no
Greyish
assigned output assigned output
Document: V684_2Aa
page 190 Edition: 16/06/2000
2. Function Thermotrac
2.1. Base page Thermotrac

The base page Thermotrac controls the heatings of the different machine ar-
eas. The base page screen is divided into 4 different areas:
A - the display line of the ambient temperature and cold junction measured val-
ues,
B - the columns for the recap of the heating and cooling areas characteristics,
C - the columns for the maximum set values (cooling and heating),
D - the columns for the recap of the heating and cooling areas additional charac-
teristics,
A a b
c d e g h i j k l n
f
B m D
Fig. 76. Base page Thermotrac
Function Thermotrac
Document: V684_2Aa
Edition: 16/06/2000 page 191
2.1.1. Ambient temperature and cold junction measured values

a - The window ambient displays the workshop ambient temperature meas-
ured at the rear of the switch cabinet on top of the hydraulic tank.
b - The window switch cabinet displays the cold junction temperature
measured inside the switch cabinet on the Thermocouples card N1.
2.1.2. Characteristics of the heating and cooling areas

REMARK: None of the elements listed below can be modified on the page Thermotrac.
c - The column Channel indicates the order number of the temperature channel
(heating/cooling area).
d - The column Assignment displays the channel denomination.
e - The column indicates the statusa of the heating output associated with
the channel.
f - The column indicates the statusa of the cooling output associated with
the channel.
g - The column Set value displays the temperature set value programmed for
the channel.
h - The column Para. displays the moulding parameter number associated with
the temperature channel.
i - The column Measured value displays the channel temperature measured
value.
2.1.3. Maximum temperatures
j - The column makes it possible to enter the cooling threshold, i.e. the
cooling limitation set value. Cooling lasts as long as the thermocouple indi-
cates a value above the cooling limit value - 3 C.
The default cooling limitation set value is 45C.
a. The status of the output is defined by the colour of the small window.
refer to section 1.2.2. Colour code of the output states, page 190
Function Thermotrac
Document: V684_2Aa
page 192 Edition: 16/06/2000
refer to illustration Fig. 77., page 193.

k - The column max displays the maximum temperature value during the
heating.
2.1.4. Additional characteristics of the heating and cooling areas

l - The 3 columns Heating and cooling type indicate the heating and cooling
configuration on the channel, which is defined by the REP sequential software:
= heating,
= cooling,
= safety cooling,
m - The column Pid displays the temperature channel identification character-
T (C)
Cooling limit (High limit)

Cooling stop (Low limit)
3C
t (s)
Temperature
0
t (s)
Status of the cooling output
Fig. 77. Cooling range
Function Thermotrac
Document: V684_2Aa
Edition: 16/06/2000 page 193
istics that may be:
Select
the
Box Output status
check-
box
Greyish - Channel non-identifiable
deselected Channel identifiable, the PID coefficients have not

been defined
White
selected Channel identifiable, the PID coefficients have been
defined
n - The column Stand-by displays the temperature channel stand-by character-

istics that may be:
Select
the
Box Output status
check-
box
Greyish - Stand-by impossible
deselected Stand-by possible, but not actuated

White
selected Stand-by actuated
Function Thermotrac
Document: V684_2Aa
page 194 Edition: 16/06/2000
2.2. Optimisation page Identification

The optimisation page Identification controls the identification process. Its
screen is divided into 5 different areas:
A - the identification control
B - the reference columns of the different areas,
C - the identification course information frame,
D - the frames of the control coefficients.
2.2.1. Identification control

The identification of the temperature channels is actuated when the box
Identification is selected.
REMARK: The identification of a temperature channel is only possible if its heating selec-
tor has been positioned on 1 and its identification set value programmed.
A d
a b c e f g h i j k l m
B D
Fig. 78. Optimisation page Identification
Function Thermotrac
Document: V684_2Aa
Edition: 16/06/2000 page 195
2.2.2. Referencing columns

a - The column Channel indicates the order number of the temperature channel
(heating/cooling area).
b - The column Assignment displays the channel denomination.
c - The column Para. displays the moulding parameter number associated with
the temperature channel.
2.2.3. Identification course information frame

d - The window Duration displays a timer which starts when the box Identifi-
cation ref. A is selected.
REMARK: The timer only stops when all identification areas have reached the end of the
identification cycle either successfully or unsuccessfully, in which case a de-
fault message is displayed.
e - The column Set value displays the temperature set value programmed for
the channel.
REMARK: There is a single identification set value for the different mould areas. Only the
identification set value for the mould areas can be programmed:
Identification
Injection unit areas Mould areas
set value
Type fixed programmable
Value 100C 220C > set value > 120Ca
a. default value = 120 C
f - The column Phase indicates the identification phase number when the iden-
tification process is running.
g - he column indicates the statusa of the heating output associated with the
channel.
2.2.4. Frames of the control coefficients

The frame Cooling displays the cooling coefficients of the different channels
with a configuration including a cooling. It consists of the 2 following col-
umns:
h - The column P gives the value of the P coefficient for cooling,
i - The column T gives the value of the T coefficient for cooling,

REMARK: P and T have default values of respectively 1 and 15.
a. The status of the output is defined by the colour of the small window.
refer to section 1.2.2. Colour code of the output states, page 190
Function Thermotrac
Document: V684_2Aa
page 196 Edition: 16/06/2000
The frame Heating displays all the heating coefficients relating to the mould ar-
eas.
j - The column P gives the P coefficient value calculated during the last identi-
fication phase,
k - the column I gives the I coefficient value calculated during the last identifi-
cation phase,
l - the column D gives the D coefficient value calculated during the last identi-
fication phase,
m - the column T gives the T coefficient value calculated during the last identi-
fication phase,
REMARK: The coefficients of the heating channels can be modified manually.
Function Thermotrac
Document: V684_2Aa
Edition: 16/06/2000 page 197
2.3. Optimisation page Temperature control supervision

REMARK: This page is only used for the display of the different data required for the cal-
culations of the temperature control in the different areas of the injection unit
and the mould.
This page is not very interesting for the machine operator. However, it is made
accessible to simplify the dialogue with the REP Technical Assistance Division
in the event of anomalies associated with the thermal control.
Fig. 79. Optimisation page Temperature control supervision
Function Thermotrac
Document: V684_2Aa
page 198 Edition: 16/06/2000
2.4. Optimisation page Identification control
REMARK: This page is only used for the display of the different data required for the cal-
culations during the identification of the injection unit and the mould different
areas.
This page is not very interesting for the machine operator. However, it is made
accessible to simplify the dialogue with the REP Technical Assistance Division
in the event of anomalies associated with the identification carried out by Ther-
motrac.
Fig. 80. Optimisation page Identification control
Function Thermotrac
Document: V684_2Aa
Edition: 16/06/2000 page 199
3. Identification through Thermotrac
3.1. Initiation of the identification process
3.1.1. Identifiable areas

All heating areas of the REP press can be identified, except the extruder and
injection chamber areas, for their correction coefficients have been defined
by the REP Technical Department and cannot be modified.
3.1.2. Starting conditions

Before launching the temperature channel identification phase through Ther-
motrac, make sure that:
the injection unit is in the lifted position (above all when using sensitive
compounds likely to vulcanize during the identification cycle),
the selector switches for the heating up of the areas to identify are posi-
tioned on 1.
REMARK: To initiate the identification of the mould heating areas it is not necessary to
close the mould. However, the coefficients obtained after an identification per-
formed with a mould could prove to be unsuitable once the mould being closed.
If the same mould is used on another press of identical type, the identification
process does not have to be repeated.
3.1.3. How to start the identification cycle
1. Go to the optimisation page Identification by pressing the keys and
successively.

3. Move the bounding box to one of the windows of column ref. e by using the
keys , , and .
4. Enter a reference value for the mould area identification between 120C and
220C.
5. Move the bounding box to the checkbox Identification by using the keys
, , and .
6. Select the box by using the key .
Identification through Thermotrac

Document: V684_2Aa
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The identification process is now launched.

REMARK: The values of the coefficients P, I, D and T cannot be changed during the iden-
tification cycle.Thermotrac.
The identification time depends on the mould inertia. The identification time is
therefore shorter on a smaller mould.

Document: V684_2Aa
Edition: 16/06/2000 page 201
3.2. Identification phases

The identification phases of each one of the heating areas are numbered from
0 to 11.
Phase Time Description

Preliminary phase
During this phase, all heating areas are set to 0 and the PID coef-
ficients are saved. Different tests are completed before starting
the identification cycle:
0 60 s testing of the identification reference values,
testing of the deviation between the set value and the meas-
ured value which should be above or equal to 60C.
During this phase, the machine also defines the sampling period
T.
Measuring phase of the initial temperatures
1 180 s
The initial temperatures of all areas to identify are measured.
Full power heating phase
In case there should be a CRB, if the reference value is below
variable 120C, heating takes place until reaching the value [Reference -
depend- 20C].
2
ing on the
mould As for a mould area, if the reference value is above 120C, heat-
ing takes place until reaching the value [Reference - 30C].
Once this value being reached, the system goes on to Phase 3.
Proportional phase
Heating is controlled according to the deviation between the set
value and the instantaneous measurement.
3 variable
REMARK: Heating is controlled according to the propor-
tional phase principle until the end of the identi-
fication.
4
5 Process analysis phase
variable
6 The heating curve is modelised by different internal calculations.

Document: V684_2Aa
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Phase Time Description

8 variable Calculation phase of the P, I and D coefficients
Memorization phase of the P, I and D phases
9 variable The transfer takes place only if the identification has been suc-
cessful. If it has not, the previous coefficients are preserved.
10 variable Memorization phase of the identification conditions.
Holding phase of the heating
variable The heating of the areas where the identification is finished is
depend- maintained while the other areas are finishing their identifica-
11
ing on the tion process. As soon as all areas have been identified, the iden-
mould tification is de-activated and the control starts according to the
latest coefficients validated.

Document: V684_2Aa
Edition: 16/06/2000 page 203
4. Use of the PIDT coefficients
4.1. Heating-up conditions of a tooling

To heat up a tooling, the heating areas must have been programmed with a
temperature reference and the PIDT control coefficients of all areas must have
been memorized.
REMARK: If the identification has been completed in normal conditions, the coefficients
are memorized automatically.
When starting a production with the PID coefficients being zero, a self-adapt-
ing process replaces the identification; the calculated coefficients are likely to
be inaccurate.
Coefficients matched to a mould ensure the dependable stability of the area
temperature around the reference value. It is therefore possible to adjust the
temperature references of the different areas to their maximum value without
taking the risk of exceeding these values.
4.2. Manual programming of the PIDT coefficients

The machine adjuster can program the values of the PIDT coefficients when
he has no time to run an identification cycle.
The PIDT coefficients can also be changed at any time if the temperature con-
trol is insufficient. In this case it is recommended to try the following correc-
tions:
to correct a hunting effect, act upon the P coefficient by decrementing it
by 1.
for an energy relating correction, act upon the coefficient P in the following
way:
increment P by 1 if the temperature control is below the reference value,
decrement P by 1 if the temperature control is above the reference value.
for a long term correction, act upon the coefficient I:
increment I by 1 if the temperature control is above the reference,
decrement I by 1 if the temperature control is below the reference.
CAUTION Don't misuse such an advice; better study your manufacturing process. REP
points out that the thermal processes are slow and that it is recommended to
allow the temperature to stabilize during the equivalent of 20T (which means
20 times the time set for the T coefficient of the area) before performing any
modification.
Use of the PIDT coefficients

Document: V684_2Aa
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5. Error messages Thermotrac

Messages Causes Remedy
Temperature: The instantane- The measuring chain on the channel
ous measurement of one does not detect any temperature
channel of the injection unit is
increase.
fixed Check that the associated ther-
REMARK: the fact that there is no
mocouple is not faulty.
Temperature: The instantane- temperature increase is a means of
ous measurement of a mould detection limiting the risks of mate-
channel is fixed rial deterioration and fire.
The measured value is above 150C

Temperature: Excessive
whereas the set value can't exceed Check that the associated ther-
safety measurement on a
150C in an area of the injection mocouple is not faulty.
channel of the injection unit
unit. Check the heater contacts.
Temperature: Excessive The measurement is above 250C Check the condition of the ther-
safety measurement on a whereas the reference value can't mostats of heater plates.
mould channel exceed 250C in a mould area.
Temperature: The instantane-
ous measurement of a chan-
nel of the injection unit is The measurement indicates a tem-
zero. Check that the associated ther-
perature equal to zero whereas this
mocouple is not faulty.
Temperature: The instantane- is not possible.
ous measurement of a mould
channel is equal to zero
Temperature: Relay sticking The relay is not activated but it
alarm on a channel of the remains stuck.
injection unit This is like a permanent heating
Cut the press power supply off.
control, with a risk of deterioration of
Temperature: Relay sticking the heating components, the ther-
alarm on a mould channel mal oil and a risk of fire.
No heating area has been selected
Temperature: No channel before initiating the identification.
Select at least one area.
selected for Thermotrac REMARK: This message is dis-
played only after 60s.
The identification reference is not
Temperature : Thermotrac Change the reference value
compatible with the Thermotrac against a positive value.
reference zero or below zero

operation.
Temperature: Measurement No remedy; wait until one of the
The area temperature is below or other channels arrives at phase
of the channel below or equal
equal to zero.
to zero 3 and de-activate Thermotrac
Temperature: Deviation Ref- For a dependable operation, the Increase the reference value
erence less Measurement deviation should be above or equal which should remain below
below 60C to 60C. 220C.
Error messages Thermotrac

Document: V684_2Aa
Edition: 16/06/2000 page 205
Messages Causes Remedy

Turn the heating selector switch
Temperature: Heating selec- The heating selector of the area to to 1 or wait until one of the other
tor switch not reset identify is not positioned on 1 channels passes to phase 3 to
de-activate Thermotrac
Check the circuit breakers and
contacts of the heating areas
Temperature: Measurement The thermocouple detects that the
concerned.
below Initial measurement + 3 heating is not quick enough. The
Check that the size of the tool-
after 30 minutes heating at installed heating power is insuffi-
ing is compatible with the heat-
100% cient.
ing power installed on the
machine.
Temperature: Incoherent The thermocouple in charge of the
A value equal to 20C will be
ambient temperature meas- ambient temperature finds an inco-
considered by default.
urement herent value
If possible, reduce the initial
Temperature: Initial tempera- The reference value asked for
temperature, but it would be
ture above the reference shows a value below the initial tem-
easier to change the reference
value perature of the area.
value.
Check the circuit breakers and
contacts of the heating areas
Temperature: Measurement The thermocouple detects that the
concerned.
below Initial measurement + heating is not quick enough. This
Check that the size of the tool-
10 after 1 hour of heating at means that the installed heating
ing is compatible with the heat-
100% power is insufficient.
ing power installed on the
machine.
Error messages Thermotrac

Document: V684_2Aa
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Chapter VII - Mastertrac
1. Introduction
Mastertrac is a software enabling the user to program, store and reproduce
a sequence of movements in addition to the basic kinematics of the machine.
This sequence is generally used for the stripping of moulded parts by control-
ling the movements of the optimisation functions installed on the press in a
precise order depending on the tooling.
The full machine cycle composed of the basic cycle movements associated
with the sequence set by Mastertrac is called the Mastertrac cycle or cycle
31.
REMARK: Cycle 31 is linked to the mould number, i.e. that it is stored with the mould
parameters relating to a specific mould number.
The software Mastertrac includes the 2 following distinct functions:

the learning function during which the operator makes and stores the se-
quence of movements.
the application function of cycle 31.
1.1. Movements compatible with Mastertrac

The movements that can be integrated into the sequence made during the
Mastertrac learning phase are listed below:
Movements relating to the machine guard.
Movements relating to certain machine optimisation functions.
Particular operations outside the machine kinematics.
refer to table Tab. 67., page 208
V:\G8\Vol2\A\A_utilisation_Mastertrac.fm
The Mastertrac software can be used only, if the optimisation functions re-
lating to the movements to execute have been:
installed on the press before,
refer to section 4.6. Optimisation page Press options, page 277
selected before,
refer to section 2.2.2. Selection of the optimisation functions used in the Master-
trac cycle (cycle 31), page 211
Introduction
Document: V684_2Aa
Edition: 16/06/2000 page 207
Movable traverse ejectors
Fixed traverse ejectors
Ancillary cylinder 1
Ancillary cylinder 1
Description
Bottom front kita

Sliding platen
External PLC
Top rear kita
Brushing
Brushing
option
OPV061
OPV066
OPV067
Phase
OP137
OP139
OP141
OP146
OP147
OP151
OP152
No
Movement
N
01 Guard(s) opening standard movement

02 Sliding platen in x
03 Guard(s) closing standard movement
12 Sliding platen out x
13 Fixed traverse ejectors out x
14 Fixed traverse ejectors in x
15 Movable traverse ejectors out x
16 Movable traverse ejectors in x
Plate out x x
17
Brushing while plate is moving out x x x x
Plate in x x
18
Brushing while plate is moving in x x x x
19 Kit ejector out x x
20 Kit ejector in x x
24 Ancillary cylinder 1 in x
25 Ancillary cylinder 1 out x
26 Ancillary cylinder 2 in x
27 Ancillary cylinder 2 out x

30 Manual operation operated only by Mastertrac
31 External PLC operation x
Tab. 67.Movements compatible with Mastertrac

a. Mastertrac is only compatible with the single-plate kits.
Introduction
Document: V684_2Aa
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1.2. Controls reserved for the application of Mastertrac
Position
number on
Unit electrical
Function
diagram
Push-button Forward step-by-step learning cycle
S108 When the selected operating mode is Adjustment or Manual, the S108
push-button controls the execution of each step of cycle 31 in ascending nu-
merical order.
Push button Step-by-step learning cycle (reverse)
S107 When the selected operating mode is Adjustment or Manual, the S107
push-button controls the execution of each step of cycle 31 in descending
numerical order.
Introduction
Document: V684_2Aa
Edition: 16/06/2000 page 209
1.3. Cycle Mastertrac
Special case of Special case of

Phase N Step N Sequence description the safety device the safety device
SEa S1a
03 n +2 Guard closing Guard closingb
- n +3 (n + 3) th movement
Manual and dur-

- n +4 th ing setting :
(n + 4) movement Linking move-
Linking movements by pressing
ments by pressing simultaneously
- - S108 or S107. on S108 or S107
In automatic and and S93 (dual-
semi-automatic : handed com-
- - Automatic link- mands)
ing of movements
- m mth movement
< Cycle N31 >
Automatic linking see section 3.6.2.,

04 to 11 Basic cycle
of movements page 260
- 1 1st movement
Manual and dur-

- 2 2nd movement ing setting : Linking move-
Linking movements by pressing
ments by pressing simultaneously
- - - S108 or S107. on S108 or S107
In automatic and and S93 (dual-
semi-automatic : handed com-
- - - Automatic link- mands)
ing of movements
- n nth movement
01 n +1 Guard opening Guard opening
a. see section 3.6.2., page 260

b. The guard opening and closing movements can be included in cycle 31. In this case, they must be programmed by
the function learning mode.
Introduction
Document: V684_2Aa
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2. Function Mastertrac
2.1. Access to the different active pages of Mastertrac

Information relating to the Mastertrac function is distributed over the differ-
ent active pages of the Mastertrac preset function and the associated optimi-
sation functions, accessible through the keyboard keys.
see table Tab. 68., page 211
Access keys
Learning of
Mastertrac Selections Cycle selection
the sequence
page 214
2.2. Selections associated to Mastertrac
2.2.1. Selection of the Mastertrac cycle (cycle 31)

The user must select the cycle 31 - Mastertrac, to use the machine with the
Mastertrac cycle or to set a new sequence.
refer to section 2.6. Optimisation page Cycle selection, page 217
2.2.2. Selection of the optimisation functions used in the Mastertrac cycle (cycle 31)
Before setting a cycle 31 or using a previously stored cycle 31, the user must
select all machine optimisation functions involved in the cycle 31.
refer to section 2.5. Optimisation page Selections, page 216.
Function Mastertrac
Document: V684_2Aa
Edition: 16/06/2000 page 211
2.3. Base page Mastertrac

The base page Mastertrac displays the latest movement sequence saved
through the optimisation page Learning of the sequence.
The base page Mastertrac is divided into 3 different areas:
A - the checkbox Movement authorization,
B - the table displaying the beginning of the saved sequence,
C - the table displaying the continuation of the saved sequence.
2.3.1. Movement authorization

The checkbox Movements authorised allows the operator to leave the Mas-
tertrac sequence instantaneously, for example after a mechanical trouble.
REMARK: If no Mastertrac sequence is saved, the button Movements authorised is in-
operative.
If the operator selects the checkbox Movements authorised and the Set-
ting operating mode, he can execute all press movements by using the tradi-
tional push-buttons, and reset the press to the initial position.
a b c a b c
B C
Fig. 81. Base page Mastertrac
Function Mastertrac
Document: V684_2Aa
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2.3.2. Tables of the saved sequence

The 2 tables are consecutive (the 2nd table is completed only if the Master-
trac sequence includes mores than 14 steps). They show the sequence saved
during the learning phase.
REMARK: The sequence can include up to 28 successive steps or movements; a move-
ment can be repeated several times.
Both tables are composed of the 3 following columns:
a - the column Step No displays the order number of each movement of the saved
sequence.
REMARK: The column Step No looks different according to the selection of cycle 31:
if the step numbers are displayed, the cycle 31 is selected; otherwise another
cycle is selected.
b - the column Mastertrac sequence saved displays the wording of every movement
of the saved sequence.
c - the last column from the right specifies the execution mode of every move-
ment:
the symbol specifies that the corresponding movement has to be exe-

cuted with the 2-hand control, i.e. by pressing the push-button S107 or the
push-button S108 simultaneously with S93.
This is the case with a movement executed with the safety guard being
open.
the empty field means that the corresponding movement is executed either
in the automatic mode either when simply pressing the push-button S107 or
S108.
This is the case with a movement executed with the safety guard being
closed.
Function Mastertrac
Document: V684_2Aa
Edition: 16/06/2000 page 213
2.4. Optimisation page Learning of the sequence

The optimisation page Learning of the sequence authorises the operator to
make the sequence of movements to be integrated into the Mastertrac cycle
The optimisation page Learning of the sequence is divided into 4 distinct ar-
eas:
A - the checkbox Activation of learning mode,
B - the table displaying the beginning of the stored sequence,
C - the table displaying the continuation of the stored sequence.
D - the frame containing the particular operations possible to integrate into the
Mastertrac cycle.
2.4.1. Activation of the learning mode

The checkbox Enabling the learning mode is used for 2 different purposes:
when being selected, the checkbox allows the selection of the learning
mode, in order to make a sequence of movements.
when the operator de-selects the checkbox after having made a sequence of
movements, a final step Sequence End is made and the sequence stored
d e g
A D
f h
a b c a b c
B C
Fig. 82. Optimisation pageLearning of the sequence
Function Mastertrac
Document: V684_2Aa
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2.4.2. Tables of the saved sequence

These 2 tables are exactly the same as those dealt with in the section 2.3.2.,
page 213.
2.4.3. Frame of the particular operations

The frame makes it possible to select one of the 5 radio buttons listed below:
d - The 1st radio button validates the latest movement controlled on the machine,
in order to add it to the sequence.
REMARK: The wording specified on the right of the 1st radio button literally indicates the
last movement. The bounding box automatically focuses on the said radio but-
ton once the checkbox Enabling the learning mode is selected; the wording
is then Phase 0.
e - the radio button Manual intervention allows a manual intervention to be inte-
grated to the Mastertrac cycle; this forces the operator to release the controls,
in order to complete an intervention on the tooling.
f - The radio button Deletion of the last movement allows the operator to delete the
last step of the sequence being saved.
g - The radio button External PLC-unit makes it possible to complement the se-
quence with the movements of a stripping PLC which are executed outside the
press, and to resume the stored sequence run after having received the state-
ment specifying the execution of the external movements.
REMARK: The output O 06 (press cycle end signal) controls the micro-relay KA84 send-
ing the signal electrically isolated contact to the external PLC unit.
The relay KAxx of the external PLC unit sends a signal electrically isolated
contact back, that supplies the input I 022 (Automatic cycle start signal).
The integration of this function into the Mastertrac sequence requires the
availability of the option Cycle end signal sending on the press.
h - The radio button Cycle deletion deletes the latest sequence displayed on the
screen, regardless of whether being stored or not. After deletion, the bounding
box goes back to step No 1 in order to save a new cycle.
Function Mastertrac
Document: V684_2Aa
Edition: 16/06/2000 page 215
2.5. Optimisation page Selections

The optimisation page Selections makes it possible to select the optimisa-
tion functions relating to the movements to be integrated into the Mastertrac
sequence.
The optimisation page Selections displays as many lines as the press com-
prises optimisation functions likely to be integrated into a Mastertrac se-
quence. Such optimisation functions must have been configured on the
machine.
refer to section 4.6. Optimisation page Press options, page 277
REMARK: The selections made on the Selections page of Mastertrac are taken up on
the page Selections of the function Production configuration and vice versa.
This page can be used in the same way as page Selections of the function
Production configuration, especially the hot keys.
refer to section 3.7. Optimisation page Selections, page 265
Fig. 83. Optimisation pageSelections
Function Mastertrac
Document: V684_2Aa
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2.6. Optimisation page Cycle selection

The optimisation page Cycle selection is shared by the basic functions
Mastertrac and Production configuration.
It enables the Mastertrac operator to select the cycle 31 reserved for Master-
trac among the different cycles offered in the standard version.
REMARK: Its application is described more detailed in section 3.6. Optimisation page
Cycle selection, page 259.
see also illustration Fig. 84., page 217
Radio button for

the cycle selection

Mastertrac
Fig. 84. Optimisation pageCycle selection
Function Mastertrac
Document: V684_2Aa
Edition: 16/06/2000 page 217
3. Application Mastertrac
3.1. Selections prior to the application of Mastertrac
3.1.1. How to select cycle 31
1. Go to the page Cycle selection by successively pressing the keys and
.
2. Select cycle 31 by shifting the bounding box to the corresponding radio button
by means of the keys and .
4. Confirm the choice by means of the key .
3.1.2. How to select the optimisation functions to integrate into the Mastertrac sequence
1. Go to the page Selections by successively pressing the keys and
.
2. Select the desired function by shifting the white line background by means of
the keys and .
4. Select the line associated checkbox by means of the key .

REMARK: It is possible to set the parameters required for the application of the selected
optimisation function by using the hot keys.
refer to section 3.7.4. Shortcuts, page 266
Application Mastertrac
Document: V684_2Aa
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3.2. Application of the Learning function
3.2.1. How to activate or deactivate the Learning Mode
1. Go to the page Learning of the sequence by pressing the keys and
successively.
2. Move the bounding box to the checkbox Enabling the Learning mode by us-
ing the keys , , and .

To disable the Learning mode :
4. De-select the checkbox by using the key .

The step Sequence End is integrated into the sequence.
To enable the Learning mode :
6. Select the checkbox by using the key .
3.2.2. How to make a Mastertrac sequence

1. Select cycle 31.
2. Select the optimisation functions to integrate into the Mastertrac sequence.

3. Go to the page Learning of the sequence by successively pressing the keys
and .
4. Enabling the Learning mode


6. Control the first movement to integrate into the sequence until actuating the
limit switch microcontact.
Document: V684_2Aa
Edition: 16/06/2000 page 219
The wording of the executed movement is displayed beside the ref. d radio
button of the illustration Fig. 82., page 214.
7. Confirm the integration of the movement into the sequence by means of the
key .
8. Repeat the operation (points 6. to 7.) for the other movements.
9. Disabling the Learning mode by saving the sequence.
3.2.3. How to integrate a particular operation into a Mastertrac sequence

1. Start making the sequence.

3. Shift the bounding box to the radio button corresponding to the desired oper-
ation (ref. e or ref. g of the illustration Fig. 82., page 214) by using the keys
, , and .
3.2.4. How to save the last sequence executed in the learning mode
The latest sequence is saved when the Learning mode is disabled.
refer to points 1. to 4. of section 3.2.1., page 219
3.2.5. How to cancel the last step entered to a Mastertrac sequence

Sequence making has already started and the last step entered is a mistake.
2. Control the opposite movement of the movement to delete until actuating the
limit switch microcontact.
The wording of the executed movement is displayed beside the ref. d radio
button of the illustration Fig. 82., page 214.
Document: V684_2Aa
page 220 Edition: 16/06/2000
Shift the bounding box to the radio button Deletion (ref. f of the illustration
Fig. 82., page 214.) by using the keys , , and .

The step is deleted.
3.2.6. How to delete a Mastertrac sequence

1. Go to the page Learning of the sequence by successively pressing the keys
and .
2. Enabling the Learning mode

Shift the bounding box to the radio button Sequence deletion (ref. h of the il-
lustration Fig. 82., page 214.) by using the keys , , and

The sequence is deleted.
Document: V684_2Aa
Edition: 16/06/2000 page 221
3.3. Use of cycle 31
3.3.1. How to test the Mastertrac sequence

1. Select cycle 31.
2. Select the optimisation functions used in the Mastertrac sequence.

3. Go to the page Mastertrac by pressing the key .

5. Press the push-button S108 by successive impulses. If the guard is open, press
the push button S93 (P.B. dual-handed control) simultaneously.
REMARK: Each time the operator presses S108, the movement is controlled step-by-step
in the ascending order of the step numbers. The movement of the next step
cannot be controlled as long as the microcontact of the current movement limit
switch is not actuated.
6. Press the push-button S107 to return to the previous step. If the guard is open,
press the push button S93 (P.B. dual-handed control) simultaneously.
REMARK: Each time the operator presses S107, the movement is controlled step-by-step
in the descending order of the step numbers. The movement of the previous
step cannot be controlled as long as the microcontact of the current movement
limit switch is not actuated.
7. Go on like this until reaching the sequence end.
REMARK: In case of a trouble, the operator should shift the bounding box to the checkbox
Movements authorised and select the checkbox by means of the key .

He can now take over again the control of the machine and handle the usual
control push-buttons of the control panel, to reset the optimisation functions to
their initial positions
3.3.2. How to work in the Automatic mode with the last Mastertrac sequence
1. Select cycle 31.
2. Select the optimisation functions used in the Mastertrac sequence.

2. Press the push-button S108 to start the cycle.
Document: V684_2Aa
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Chapter VIII - Preset functions
1. Introduction
The preset functions are the 3 following functions:
Maintenance,
Configuration of the production run,
Configuration of the machine
The 3 keyboard keys associated with these 3 functions give access to the main
screen of each function and to the screens of their respective sub-functions.
see illustration Fig. 85., page 223 and table Tab. 69., page 224
Access keys to the preset

functions
V:\G8\Vol2\A\A_utilisation_utilitaires.fm
Introduction
Document: V684_2Aa
Edition: 16/06/2000 page 223
page
Introduction

224
Access keys
Other in-
Sequential Di- Retrace in- Preventive Setting soft-
Digital inputs puts/outputs Retrace faults
agnostic puts/outputs maintenance ware
Maintenance
page 225 page 233 page 236 page 244
: page 297
Production Production Mould selec- Cycle selec-

Machine time Cycle counter Selections Heating clock
check selection tion tion
page 254 page 257 page 265 page 268
Production page 245 page 250 page 251 page 259

configuration
Machine con-
Language Printer Version System Press options
figuration
page 272 page 274 page 275 page 274 page 277
page 271
Tab. 69.Preset functions and preset function keys

Document:
Edition:

16/06/2000
V684_2Aa
2. Function Maintenance
REMARK: The following information will allow the user to learn how to have access and
use the different screen pages dedicated to the maintenance of a machine.
However, you will find thorough maintenance information in volume 3 - Main-
tenance, section Trouble shooting aids.
2.1. Base page Sequential Diagnostic
2.1.1. Presentation and application

The page Sequential Diagnostic makes it possible to collect the information
necessary to understand the trouble occurred during a given cycle (current
cycle) by comparing the latter with the previous cycle.
REMARK: It can be interesting to consult this page before calling the maintenance staff
or the REP Technical Assistance Department.
The active area of the page is divided into 3 different areas:
A - the frame giving information on the progress of the sequential program,
B - the frame comparing the current automatic cycle with the previous cycle,
C - the frame giving information on the differences found in the cycle.
A a b
c
B
d e
f
g i
h j
Fig. 86. Base page Sequential Diagnostic
Function Maintenance
Document: V684_2Aa
Edition: 16/06/2000 page 225
2.1.2. Information on the course of the sequential program

The frame displays 3 text areas indicating:
a - the complete denomination of the actual sequential phase,
b - the actual sub-program,
c - the actual operating mode.
2.1.3. Comparison of cycles

The frame displays the following elements:
d - a green indicator lamp which only lights up when the Automatic operating
mode has been selected.
REMARK: The function Comparison of cycles can only be used when the operating
mode previously selected is the Automatic mode.
e - a red indicator lamp which lights up when the comparison of the latest cycle
(current cycle) with the cycle that has preceded it (previous cycle) shows a dif-
ference in the evolution of the logical status of a sequential variable.
REMARK: the result of the comparison is only given at the end of the current cycle
f - the windows of the texts Previous cycle and Current cycle.
REMARK: When the course of the current cycle is 100% identical to the course of the pre-
vious cycle, the elements of the frame Comparison of cycles remain the
same.
2.1.4. Information on the difference found

When a difference between the course of the previous cycle and the course of
the current cycle is detected, the red indicator lamp lights up and the text ar-
eas at the bottom of the screen give the following information:
g - the name of the variable which has changed from one cycle to the other,
h - its status during the current cycle,
i - the name of the phase during which the variable has changed,
j - the name of the sub-program during which the variable has changed.
2.1.5. How to compare the course of the current cycle with that of the previous cycle
1. Go to the page Sequential Diagnostic by pressing the key .

2. Turn the operating mode selector key S0-S1 to position . The green indi-
cator lamp ref. d must light up.
Document: V684_2Aa
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If the red indicator lamp ref. e does not light up, the course of the current cycle
is identical to the course of the previous cycle.
If the red indicator lamp ref. e lights up, the course of the current cycle is dif-
ferent from the course of the previous cycle.
In this case, the information concerning the difference detected is displayed by
the following windows:
ref. g : the name of the variable which has changed from one cycle to the oth-
er,
ref. h : its status during the current cycle,
ref. i: the name of the phase during which the variable has changed,
ref. j: the name of the sub-program during which the variable has changed.
REMARK: This information may be passed on to the REP Technical Assistance Depart-
ment for interpretation.
Document: V684_2Aa
Edition: 16/06/2000 page 227
2.2. Optimisation page Digital inputs

The active area of the optimisation page Digital inputs displays the status
of the system digital inputs in a 17-line table, each line displaying 8 inputs.
The writing format of a digital input is always I xyz where xyz is a number
between 001 and 136.
An input is supplied at 24VDC when the associated green indicator lamp on
the left of the input number is lit. Its logical status is then I xyz = 1.
REMARK: To make searching the electrical diagram easier, the screen gives the page
numbers of the diagram where the input circuits relating to the input numbers
and the name of the connector on which the inputs are installed can be looked
up.
2.2.1. How to read the status of a digital input
1. Go to the page Digital inputs by pressing the keys and suc-

cessively.
2. Note the number of the desired input.
Fig. 87. Optimisation page Digital inputs
Document: V684_2Aa
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If the green indicator lamp to the left of input number is lit, the electrical level
of the input is 24VDC and its logical level is 1.
If the green indicator lamp to the left of input number is not lit, the electrical
level of the input is 0VDC and its logical level is 0.
Document: V684_2Aa
Edition: 16/06/2000 page 229
2.3. Optimisation page Other inputs/outputs

see section 9. Graphic page Hydraulics, page 297

The optimisation page Other inputs/outputs makes it possible to read the
following values:
logical status upstream of each digital output,
conversion value of the analogue numerical converter upstream of each an-
alogue output,
value of the first analogue reading on the analogue inputs,
value of counters on the encoder channels
The active zone of the optimisation page Other inputs/outputs is divided
into 4 distinct areas:
A - the digital outputs table,
B - the analogue outputs,
C - the analogue pressure inputs,
D - the counting channels.
B a b c
d d d
e f g
C
h i i
j k l
D m m m
Fig. 88. Optimisation page Other inputs/outputs
Document: V684_2Aa
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2.3.3. Digital outputs

The top of the active zone of the page shows the status of the system's digital
outputs grouped in a table of 10 lines with 8 inputs on each.
The writing format of a digital output is always O yz where yz is a number
between 001 and 080.
An output supplies a 24V signalDC when the associated red indicator lamp
left of the output number is lit. Its logical status is then O yz = 1.
REMARK: To make searching the electrical diagram easier, the screen gives the page
numbers of the diagram where the output circuits relating to the output num-
bers and the name of the connector on which the outputs are installed can be
looked up.
2.3.4. Analogue outputs

The lower part of the active zone of the optimisation page Other inputs/out-
puts shows the measurement of 6 analogue output channels of which only 3
are used in a standard configuration:
a - CNA1 = main pressure control analogue output
b - CNA2 = back-pressure control analogue output
c - CNA3 = flow rate control analogue output
d - Non allocated analogue outputs
REMARK: Measurements are displayed in tenths of millivolts (0,1 mV).
2.3.5. Pressure channels

puts shows the measurement of 6 analogue pressure inputs of which only 4
are used in a standard configuration:
e - B30 = measured value of main pressure
f - B42 = clamping pressure measurement channel
g - B31 = back-pressure measurement channel
h - B43 = mould pressure measurement channel
i - None allocated pressure measurement channels
REMARK: The measured values are displayed in bars.
2.3.6. Encoder channels

puts shows the measured value of 6 displacement control channels of which
only 3 are used in a standard configuration:
j - B34-B35 = extruder rotation measurement channel
k - U32 = movable traverse stroke measurement channel
l - U33 = injection piston stroke measurement channel
m - Non allocated displacement control channels
REMARK: Measurements are displayed in tenths of millimetres (0,1 mm).
Document: V684_2Aa
Edition: 16/06/2000 page 231
2.3.7. How to read the status of a digital output
1. Go to the page Other inputs/outputs by pressing the keys and
successively.
2. Note the number of the desired output.

If the red indicator lamp to the left of the output number is lit, the electrical lev-
el of the output is 24VDC and its logical level is 1.
If the green indicator lamp to the left of the output number is not lit, the elec-
trical level of the output is 0VDC and its logical level is 0.
2.3.8. How to read the value of an analogue output
successively.
2. Note the number of the desired output.

The value is expressed in tenths of millivolts and may vary between 0 and
100000.
2.3.9. How to read the value of an analogue input
successively.
2. Note the number of the desired input.

100000.
2.3.10. How to read the value of a counting channel
successively.
2. Note the number of the desired counting channel.

100000.
Document: V684_2Aa
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2.4. Optimisation page Retrace inputs/outputs

The page Retrace inputs/outputs allows the user of the machine to track the
plotted curves of the 6 internal variables which can be selected from all the
variables available.
The plotted lines of the 6 curves are synchronous, they can be likened to the
plotting lines on a 6 channel oscilloscope.
The page Retrace inputs/outputs is also used for:
diagnosis of complex breakdowns that may involve both the control part
and the sequential part of the machine.
diagnosis of breakdowns linked only to problems on the sequential inputs.
The active zone of the optimisation page Retrace inputs/outputs is divided
into 2 distinct areas:
A - the frame containing the plotting curve operating tools,
B - set of 6 graphics forming the plotting curve display element.
a b
A
e
c d
B
Fig. 89. Optimisation page Retrace inputs/outputs
Document: V684_2Aa
Edition: 16/06/2000 page 233
2.4.2. Internal variables

The page Retrace inputs/outputs allows the user of the machine to plot the
curves of 6 internal variables that he can select from the following different
families:
Bool : Boolean variable
Cons : set point value of a parameter
Cst : constant
Ent : sequential input
Mes : measured value of a parameter
Num : numeric variable
Sort : sequential output and analogue output set value
Stat : static variable
2.4.3. Curve operating tools

a - the luminous button permits selection of the plotting curve scrolling mode :
when the button indicator lamp is green the curves are scrolling continu-
ously.
when the indicator lamp is black, the curves are fixed but storage of them
continues.
b - when the indicator lamp of the luminous button ref. a is black although the
plotting curves are fixed, the shift arrows allow the curve to be scrolled in ei-
ther direction.
2.4.4. Visualization of plotting curves

Selection of the variable to be tracked is done via the following pull-down help
menus :
c - Pulldown variable type selection menu :
The type of variable can be selected from the different types presented in the
section 2.4.2., page 234.
d - Selecting the variable :
the variable can be selected from all the variables of a given type.
Once the variable has been selected, the curve is plotted in the next frame :
e - Selected variable plotting window :
The curve is plotted in blue between its 2 upper and lower limits which are cal-
culated automatically and configured as a function of the variable selected.
2.4.5. How to display the curve of an internal variable
1. Go to the page Retrace inputs/outputs by pressing the keys and
successively.
2. Check that the indicator of the luminous button ref. a is green.

3. Select one of the plotting windows ref. e by positioning the focus on the varia-
ble type selection menu ref. c.
Document: V684_2Aa
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4. Select a type of variable ref. c.

5. Select the variable to be checked ref. d
The plotting scale is automatically configured and plotting starts.
2.4.6. How to analyse an internal variable curve
1. Go to the page Retrace inputs/outputs by pressing the keys and
successively.
2. Position the focus on the indicator of the luminous button ref. a.
3. Freeze the curves by means of the key .

The indicator of the luminous buttonref. a changes to black.
To analyse the earlier part of the plotted curve :
4. Position the focus on the key .
5. Scroll the plotted curve using the key .
To return to the later part of the curve :
6. Position the focus on the key .
7. Scroll the plotted curve using the key .
To reactivate scrolling of the curve :

8. Position the focus on the indicator of the luminous button ref. a.
9. Reactivate scrolling by means of the key .

The indicator of the luminous buttonref. a changes to green.
Document: V684_2Aa
Edition: 16/06/2000 page 235
2.5. Optimisation page Preventive maintenance

The page Preventive maintenance allows the machine maintenance staff to:
schedule requests for the various preventive maintenance operations.
to validate the requests for the various preventive maintenance operations
which have been scheduled and carried out on the machine,
The active zone of the optimisation page Preventive maintenance is ar-
ranged as a table with several columns.
a b c d f
e
Fig. 90. Optimisation page Preventive maintenance
Document: V684_2Aa
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2.5.2. Description of the preventive maintenance table

a - The column Operation lists the preventive maintenance operations that the
operator can select by checking the box to the left of the line.
REMARK: There are 2 types of operation :
The first 7 operations are defined by REP;
The remaining 8 operations are not allocated, the user can program them
as he wishes.
You only have to enter the name of the operation to be carried out on the
line of your choice using a standard PC keyboard (102 keys) which can be
easily connected to the power supply.
b - The column Set value permits programming of the number of cycles or the
time expressed in hours before the preventive maintenance request.
The operator simply changes the set value to reset the counter to zero and clear
the request from view.
c - The column Counter indicates the number of cycles or the time in hours
elapsed since the last change of the preventive maintenance set value.
d - The column to the right of the column Counter gives Set value and
Counter programming type:
Number of cycles to be entered.
Units of time to be entered (unit = hour).
e - The next to last column indicates the status of the preventive maintenance
request :
The black indicator lamp means that the set value has not been
reached.
The red indicator lamp means that the set value has been reached
and that the request is been treated.
f - The last column permits the programming or reading of an event linked to a

preventive maintenance request.
Events may be evaluated as being of one of the following 3 levels of gravity :
Information :
a request for a maintenance operation is displayed on a white ground, like
a message on the information messages line.
Blinking :
a request for a maintenance operation is displayed on a yellow ground like
a message on the alarm messages line and the fault indicator lamp H40 will
blink at the same time.
Production stop :
a request for a maintenance operation is displayed on an orange ground like
a message on the alarm messages line: the fault indicator lamp H40 blinks
at the same time and production is stopped at the end of the current cycle.
Document: V684_2Aa
Edition: 16/06/2000 page 237
2.5.3. How to select/deselect a preventive maintenance operation
1. Go to the page Preventive maintenance by pressing the keys and
successively.
2. Select the maintenance operation to be validated.

3. Move the bounding box to the checkbox corresponding to the operation re-
quired by using the keys and .
Check the box to validate the operation with the key .
Deselect the box to invalidate the operation with the key.
2.5.4. How to change a preventive maintenance operation

1. Go to the page Preventive maintenance by successively pressing the keys
and .
2. Select the maintenance operation to be validated.
3. Select the column in which the characteristic to be changed appears with the
and keys.

To change the set value;
5. Move the bounding box on to the cell to be changed in the column ref. b using
the keys and .
6. Enter the new set value and validate with the key .

To change the programming type;

8. Move the bounding box on to the cell to be changed in the column ref. d using
the keys and .
9. Select the input in number of cycles or in time using the key .
Document: V684_2Aa
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To change the type of event on expiry of the counter;

11. Move the bounding box on to the cell to be changed in the column ref. f using
the keys and .
12. Open the pulldown menu using the key .
13. Select one of the lines using the keys and .
2.5.5. How to reinitialize the counter triggering a preventive maintenance operation
1. Go to the page Preventive maintenance by pressing the keys and
successively.
2. Select the maintenance operation to be reinitialized.
3. Move the bounding box to the column ref. b using the keys and
5. Move the bounding box on to the cell to be changed using the keys and
.
6. Validate by means of the key .

The corresponding counter is reset to zero.
Document: V684_2Aa
Edition: 16/06/2000 page 239
2.6. Optimisation page Retrace faults

The page Retrace faults allows the user and the machine maintenance staff
to:
display all the different information or alarm messages appearing on the
machine,
sort the different messages according to their characteristics,
change the level of gravity of each of the events causing the fault,
filter the message display by level of gravity.
This page consists of 2 distinct zones :
A - the message filtration frame by level of seriousness,
B - the table recapping the faults encountered,
C - the seriousness level programming frame.
2.6.2. Message filtration

The frame at the top of the active window allows the messages to be filtered
according to the level of seriousness.
A a b
c d e
B
f
Fig. 91. Optimisation page Retrace faults
Document: V684_2Aa
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When the operator selects a level of seriousness, the only elements that will be
displayed are this level of seriousness and the levels of seriousness greater
than the latter.
REMINDER: The levels of seriousness are classified in a descending order as follows:
Cycle blocking,
Production stop,
Signal lamp,
Information.
a - The 4 radio buttons make it possible to select the minimum level to display.
b - The checkbox System faults makes it possible to select the display of the
faults inherent to the PC.
2.6.3. Table retracing the faults encountered,

Each message is listed in the table as a function of the following
characteristics :
c - The column Fault title shows the identification number and the description
of the message.
d - The column Status shows the status of the fault which may be :
either 1 when the event relating to the fault has not disappeared yet,
or 0 when the event relating to the event has disappeared.
The status of the fault is displayed on a coloured background which repre-
sents the message current level a of seriousness.
see section 1.3.2. Level of the fault messages, page 71
e - The column Date shows the day and the time the message appeared.
f - The table has a vertical scrollbar which gives access to all error messages
stored in memory.
REMARK: The scrollbar is always controlled by the keys and .

When the bounding box is on the scrollbar, it can only get out of it by means of
the keys and .
2.6.4. Process sorting

The table can be sorted over all columns.
a. The seriousness level of a message can be modified according to the rules set in section 1.3.2. Level of the fault messa-
ges, page 71
Document: V684_2Aa
Edition: 16/06/2000 page 241
2.6.5. How to filter faults in the archive
1. Go to the page Retrace faults by pressing the keys and suc-

cessively.
2. Move the bounding box using the keys and on to the mini-
mum seriousness level to be displayed in the table (position number ref. a)

The table is now filtered.
2.6.6. How to sort faults in the archive

cessively.
2. Move the bounding box to the caption of the column (position number ref. c to
ref. e) where the sorting is to be carried out by means of the keys and

The table is sorted according to the ascending order of the data in the column
selected.
4. Validate once again by pressing the key .

The table is sorted according to the descending order of the data in the column
selected.
2.6.7. How to change the level of seriousness of a fault

cessively.
3. Move the bounding box on to the scrollbar ref. f by means of the keys
and .
4. Select the fault for which the level of seriousness should be changed by means
of the keys and .
Document: V684_2Aa
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5. Move the bounding box out of the scrollbar by using the key . The fault
then appears on a grey background.
6. Move the bounding box on to the new level of seriousness by means of the
keys and .
REMARK: The colour of the memorised message level of seriousness is displayed in the
column ref. d and remains the same. The new level of seriousness will be tak-
en into account when the message reappears.
Document: V684_2Aa
Edition: 16/06/2000 page 243
2.7. Optimisation page Setting software

The page Setting software allows the machine maintenance staff to carry
out the various adjustments on:
the control card for variable displacement pumpsAY201,
the back pressure module,
the various hydraulic valves.
The active zone of the page is divided into 3 zones :
A - the pressure calibration frame,
B - the valve calibration frame,
C - the back pressure setting frame.
REMARK: Because this page is a utility for the exclusive use of the machine maintenance
staff, all information relating to its use is given in volume 3 - Maintenance.
B
Fig. 92. Optimisation page Setting software
Document: V684_2Aa
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3. Function Production configuration
3.1. Base page Production check

The page Production check can be personalized and it allows the user to:
select the parameters considered essential for the current production run,
display the same moulding parameters by splitting them between families,
change certain moulding parameters using + and - slopes.
REMARK: This page is the default page which appears when the machine is first
switched on.
A
Fig. 93. Base page Production check
Function Production configuration

Document: V684_2Aa
Edition: 16/06/2000 page 245
The active zone of the page Production check is divided into 2 different ar-
eas:
A - the parameter display zone is divided into 5 families:
injection unit speeds and strokes,
pressures,
times,
injection unit temperatures,
mould temperatures.
B - the combobox for the selection of parameters to be displayed or changed.

Document: V684_2Aa
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3.1.2. Compatible parameters

Only the moulding parameters listed in the table can appear in the display
zone and only those followed by +/- can be changed.
Injection unit
Injection unit Mould tempera-
speeds and Pressures Times
temperatures tures
strokes
see see see see see

Mod
Mod
Mod
Mod
Mod
No No No No No
page page page page page
20 108 +/- 40 110 +/- 50 112 +/- 60 107 +/- 65 157 +/-
21 133 +/- 41 133 +/- 51 131 +/- 61 107 +/- 66 162 +/-
22 139 +/- 42 140 +/- 52 138 +/- 62 107 +/- 67 157 +/-
23 140 +/- 43 124 +/- 53 142 +/- 63 145 +/- 68 162 +/-
24 140 +/- 44 124 +/- 54 142 +/- 64 145 +/- 69 162 +/-
25 140 +/- 45 155 +/- 55 142 +/-
2A 116 +/- 46 187 +/- 56 157 +/-
2B 118 +/- 47 134 +/- 57 106 +/-
2C 108 +/- 48 140 +/- 58 151 +/-
30 108 no 4B 118 +/- 59 149 +/-
31 138 no 4C 114 +/- 5A 147 +/-
32 138 no 4D 134 +/- 5C 114 +/-
33 139 no 4E 153 +/-
34 139 no 4F 135 +/-
35 133 no
36 143 no
37 143 no
3A 116
no
3B 118 no
3C 118 no
Tab. 70.Parameters compatible with the page Production check

Document: V684_2Aa
Edition: 16/06/2000 page 247
3.1.3. How to bring up a parameter window on the page Production check
1. Go to the page Production check by pressing the key .

2. Select the desired parameter from the combobox. The list can be scrolled using
the keys , , and .
3. Validate the selected parameter display by means of the key .

The parameter is then displayed in the column reserved for it.
3.1.4. How to clear a parameter from the display zone

the keys , , and .
3. Validate the deletion of the selected parameter by means of the key .

The parameter is then deleted.
3.1.5. How to modify a parameter set point using the + and - slopes

the keys , , and .

If the parameter appears on the line of the combobox with a red box on its
right, its set value cannot be changed.
If the parameter appears on the line of the combobox with a green check box
on its right, its set value may be changed.
4. Press the key to increase the set value by one unit. Repeat from the be-
ginning as required.

Document: V684_2Aa
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5. Press the key to decrease the set value by one unit. Repeat the operation
if necessary.
WARNING: The set value resulting from the last change using the + or - slopes is saved
automatically.

Document: V684_2Aa
Edition: 16/06/2000 page 249
3.2. Optimisation page Production selection

The page Production selection is exclusively reserved for the use of Cure-
trac program machine module.
refer to Volume 5 : OP192 Curetrac Machine System

Document: V684_2Aa
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3.3. Optimisation page Mould selection

The page Mould selection allows the user of the machine to:
display all the different moulds programmed and stored on the machine
(max. 100 moulds),
select the current mould from the 100 moulds stored,
copy one mould on to another.
REMINDER: For the operator, a mould consists of all the machine management and
moulding parameters programmed for a given tooling and stored under one la-
bel.
The mould also stores the selected cycle.
The Mould selection consists of the following 2 elements:

A - the table presenting the moulds stored and consisting of 5 columns in the cen-
tre of the screen,
B - the mould duplication tool consisting of blue columns to the left and right of
the table A.
a
f b c d e g
B
Fig. 94. Optimisation page Mould selection

Document: V684_2Aa
Edition: 16/06/2000 page 251
3.3.2. Table of stored moulds

The table presenting the stored moulds consists of 5 columns on a grey back-
ground:
a - The radio buttons column permits selection of one of the moulds from the 100
available.
b - The column Numbera indicates the available mould numbers.
c - The 3rd column is used to identify the mould literallya (the wording is entered
via a keyboard external to the machine).
d - The column Start of last use gives the date on which the mould was last
used.
e - The column End of last use gives the date of the last cycle produced with the
mould before it was changed.
3.3.3. Mould duplication tool

The mould duplication tool consists of 2 columns outside the table presenting
the moulds:
f - The column Source permits definition of the mould to be copied.
g - The column Destination permits definition of the mould to be created or
modified.
3.3.4. How to select a mould
1. Go to page Mould selection by pressing the keys and succes-

sively.
2. Place the focus on the radio buttons column and move the pointer to the line
desired using the keys and .
4. Validate the selection by means of the key .

After loading for a few seconds, the new mould number is displayed at the top
right of the screen

a. The mould number can be modified when the bounding box is positioned on the mould number cell.
The caption of the 3rd column can also be modified when the bounding box is positioned on the corresponding cell.
In both cases, you only have to enter the text to be modified using a standard PC keyboard (102 keys) which can be
easily connected to the power supply.

Document: V684_2Aa
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3.3.5. How to duplicate or create a mould
1. Go to page Mould selection by pressing the keys and succes-

sively.
2. Place the focus in the Source column and move the pointer over the blue
ground to the desired line.
3. Place the focus in the Destination column and move the pointer over the
blue ground to the desired line.
5. Control the duplication by means of the key .

6. Several situations may occur:
If the destination line is empty : a new mould is created by copying the
source mould.
If the destination line is not empty: the old mould is deleted by the copy of
the source mould.
If the mould line is empty: a new mould is created and all the set values of
the parameters are nil.
3.3.6. Using the page Mould selection with option OP227: Machine workstation RepNet-win
WARNING: When option OP227: machine system RepNet-win is used, moulds are usu-
ally saved and stored on the central terminal.
They are transferred on request to the presses where they become inde-
pendent moulds of the central terminal.
In other words, the page Mould selection must be used with particular care,
for if a modification of the parameters of the mould used on the machine has
been validated for the running production, it must be transferred to the central
terminal to be stored, at the risk of being lost for good.
On the other hand, the mould number transferred from the central terminal
should not be changed on the machine. If this was the case, its transfer to the
central terminal runs the risk of erasing a mould with the same number or the
data base supervisor would create a mould with an unknown RepNet-

winnumber.
In short, only one line on the table of page Mould selection is to be used and
the mould duplication functions must not be used when option OP227: Ma-
chine systemRepNet-win is used on the machine.
refer to volume 5 - Option OP227: Machine System RepNet-win

Document: V684_2Aa
Edition: 16/06/2000 page 253
3.4. Optimisation page Machine time

The page Machine time programs the different time parameters used by the
software RepNet-win to monitor the production.
Fig. 95. Optimisation page Machine time

Document: V684_2Aa
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3.4.2. Base sub-functions
Associated param-
Main sub-functions
eters
C0
Monitoring of sequential cycle time (out of curing)
(page 255)
C1
Stripping time monitoring
(page 255)
C2
Extruding time monitoring
(page 255)
C3
Injection time monitoring
(page 256)
C4
Total cycle time monitoring
(page 256)
Tab. 71.Sub-functions available on the base page Machine time
3.4.3. Parameter
Default
No Description
value
Times
C0 Machine time
Parameter C0C0 is a timer which starts when the press closing phase begins.
expressed It measures the cycle duration until the end of the opening stroke, once all
0
in seconds programmed option movements have been performed.
REMARK: The curing time 56 is not taken into account in time C0.
C1 Stripping time
Parameter C1 is a timer which starts at the end of the cycle once all pro-
expressed grammed sequential movements have been performed. It measures the dura- 0
in seconds tion of manual stripping operations from the guard closing to the beginning
of the next press closing.
C2 Extruding time
Parameter C2 is a timer which starts together with the rotation of the extruder 0
expressed screw and which measures the duration of the extrusion phase.
in seconds
Tab. 72.Parameters of the base page Machine time

Document: V684_2Aa
Edition: 16/06/2000 page 255
Default
No Description
value
C3 Injection time
Parameter C3 is a timer which starts simultaneously to the injection and which 0
expressed times the dynamic injection phase up to point 35.
in seconds
C4 Cycle time
Parameter C4 is the sum of the Machine, Stripping and Extruding times:
expressed 0
C4 = C0 + C1 + 56.
in seconds
Parameter C4 represents the total duration of a cycle.
Tab. 72.Parameters of the base page Machine time(cont.)

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3.5. Optimisation page Cycle counter

The page Cycle counter allows the user of the machine to:
program the number of cycles to be performed,
to display the number of cycles programmed locally on the machine and the
number of cycles completed,
to display the number of cycles programmed on the central terminal Rep-
Net-win and the number of cycles completed.
c
Fig. 96. Optimisation page Cycle counter

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3.5.2. Press counter

a - The Number of cycles to be done window of the Local counter frame per-
mits local input of the number of cycles the press is to complete.
b - The Number of cycles done window of the Local counter frame displays
the number of cycles that the machine has already completed.
3.5.3. Counter RepNet-win
c - The Counter RepNet-win frame is displayed only when the option OP227
Machine terminal RepNet-win is installed on the machine. It makes it pos-
sible to display the set value and the status of the cycle counter programmed
from the central terminal.

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3.6. Optimisation page Cycle selection

The page Cycle selection allows the user of the machine to select a machine
operating cycle among the different cycles presented in a standard version:
a - basic cycle,
b - preset cycles,
c - specific cycles.
Selection is completed by validating one of the lines on the screen. The kine-
matics corresponding to a cycle other than the standard cycle is then dis-
played in the white part of the active zone.
REMARK: Cycles 1 to 7 and cycle 31 are attached to the mould number, i.e. they are
stored with the moulding parameters relating to a mould number. The cycle
stored in a mould is automatically validated when the mould number is select-
ed and activated.
see section 3.3. Optimisation page Mould selection, page 251
b
Fig. 97. Optimisation page Cycle selection

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3.6.2. Basic cycle

The basic cycle of the machine (also called the standard cycle or cycle 1) is
the sequence of different movements of the machine completed during a pro-
duction cycle from the moment the mould starts to close to the end of the
mould reopening after injection and curing.

Phase No Description of the movement the safety device the safety device
SEa S1b
03 Guard closing
04 Mould closing Dual-handed con-
05 Clamping block in trols
06 Clamping
07 Injection
< Basic cycle >
08 Curing Automatic chain- Automatic chain-

ing of movements ing of movements
Unclamping and clamping
09
block out
10 Opening
Dual-handed con-
11 Insert lift option
trols
01 Guard opening
a. In accordance with the SE-type safety regulation (European Safety), the front safety guard must be closed before
allowing the closing unit to move.
b. The S1-type safety regulation, applied in certain countries, allows the cycles to be run with the safety guard open.
3.6.3. Preset cycles

There are 6 pre-programmed cycles which are worked out through the se-
quence of movements before and after the basic cycle.

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Cycle N2

SEa S1a
03 Guard closing
see section 3.6.2.,
< Cycle N2 >

page 260
Automatic chain-
15 Movable traverse ejectors out
ing of movements Dual-handed con-
16 Movable traverse ejectors in trols
01 Guard opening
Cycle N3

SEa S1a
03 Guard closing
Dual-handed con-
16 Movable traverse ejectors in
trols
< Cycle N3 >
Automatic chain- see section 3.6.2.,

ing of movements page 260
Dual-handed con-
trols
01 Guard opening

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Cycle N4

SEa S1a
03 Guard closing
Dual-handed con-
14 Fixed traverse ejectors in
trols
< Cycle N4 >

Dual-handed con-
13 Fixed traverse ejectors out
trols
01 Guard opening
Cycle N5

SEa S1a
03 Guard closing
Dual-handed con-
14 Fixed traverse ejectors in
trols
see section 3.6.2.,
Automatic chain-
< Cycle N5 >
page 260
ing of movements
Dual-handed con-
16 Movable traverse ejectors in
trols
13 Fixed traverse ejectors out
01 Guard opening

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Cycle N6

SEa S1a
03 Guard closing
16 Movable traverse ejectors in Dual-handed con-
14 Fixed traverse ejectors in trols
< Cycle N6 >

15 Movable traverse ejectors out Dual-handed con-
13 Fixed traverse ejectors out trols
01 Guard opening
Cycle N7

SEa S1a
03 Guard closing
14 Fixed traverse ejectors in Dual-handed con-
16 Movable traverse ejectors in trols
< Cycle N7 >

15 Movable traverse ejectors out Dual-handed con-
13 Fixed traverse ejectors out trols
01 Guard opening

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3.6.4. Specific cycles

Cycle N30
Cycle 30 is not a production cycle but an adjustment cycle. It facilitates the set-
ting of the clamping stroke and should be used after having programmed the
0B parameter.
refer to page 128.
Cycle N 31 or Mastertrac cycle
The Mastertrac cycle is a programmable cycle defined in accordance with a
learning mode procedure
refer to Chapter VII - Mastertrac.
3.6.5. How to select a cycle
1. Go to page Cycle selection by pressing the keys and succes-

sively.
2. Select the cycle you want by moving the focus on to one of the radio buttons
using the keys and .

The corresponding sequence of movements is displayed in the white window
in the right hand part of the active zone.
4. Validate the radio button associated with the line using the key .

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3.7. Optimisation page Selections

The page Selections allows the user of the machine to:
select the optimisation functions installed on the machine and associate
them with the tooling currently in use,
access directly the parameter programming pages relating to these func-
tions.
The page Selections thus shows the value of programming only the param-
eters necessary and essential for the current production run.
The active zone of the page Selections displays:
A - the list of the optimisation functions along with their checkboxes.
B - an indication of the possibility of using the hot key when there is one, to go
directly to the programming page for the parameters associated with the func-
tion.
REMARK: Only the optimisation functions for which the corresponding optional equip-
ment has been declared on the machine appear on the page Selections.
The list may appear over 2 columns when the number of optimisation functions
makes it necessary.
A B
Fig. 98. Optimisation page Selections

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3.7.2. Optimisation functions Ejectors on fixed and movable traverses

The 2 optimisation functions Fixed traverse ejectors and Movable traverse
ejectors cannot be selected on page Selections.
The fixed traverse or movable traverse ejectors can be selected :
either by the selection of a cycle using these functions,
refer to section 3.6. Optimisation page Cycle selection, page 259
or when the Mastertrac function is active.
refer to Chapter VII - Mastertrac.
3.7.3. Optimisation functions Vacuum pump

There are 2 vacuum application modes which can be selected for use on their
own:
Vacuum pump alternative mode
The vacuum pump turns continuously but the vacuum drawing electrovalve
operates only during the clamping block insertion, clamping and injection
phases.
Vacuum pump continuous mode
The vacuum pump turns continuously and the vacuum drawing electrovalve
also operates continuously.
REMARK: Whatever the selected application mode, it is possible to delay injection by us-
ing the parameter 59.
see parameter 59: Vacuum prior to injection, page 149
3.7.4. Shortcuts
The hot keys give the user the possibility to have direct access to the pro-
gramming page for the parameters associated with an optimisation function.
The user only has to press the key Hot keys (see page 50).
REMARK: When the programming page for the parameters associated with an optimisa-
tion function is displayed on the screen, the user is offered the same option of
going directly to the Selections page.
see also section 3.7.6., page 267
3.7.5. How to select or to deselect an optimisation function

1. Go to the page Selections by pressing the keys and succes-

sively.
the keys and .

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To select an optional function :
4. Select the box associated to the line by means of the key .
REMARK: When the box is checked, the corresponding diamond-shaped box on the pa-
rameter programming page associated with the function is blue.

To deselect an optional function already selected :
6. Deselect the box associated with the line by means of the key .
REMARK: When the box is deselected, the corresponding diamond-shaped box on the
parameter programming page associated with the function is white.
3.7.6. How to use hot keys
1. Go to page Selections by pressing the keys and .

the keys and .
3. Press the key to access directly the parameter programming page as-
sociated with the function selected.
The parameter programming page is now displayed.

5. Enter the set values of the parameters associated with the optional functions.
If the optimisation function is not validated :
6. Place the focus on the diamond-shaped selection box for the optimisation
function and press the key . The diamond-shaped box changes to blue.

Or if the optimisation function has already been validated:
REMARK: The user only has to press the key again in order to go back to page
Selections.

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3.8. Optimisation page Heating clock

The page Heating clock makes it possible to control the injection unit and
mould heating start and stop times.
It also permits programming of a temperature setting for the heating zones of
the mould and to activate the stand-by function for the different time ranges
of the clock.
The Heating clock consists of the following 2 elements:
A - the table of heating time ranges,
B - the programming window for the stand-by temperature set value.
C - the control window for the heating authorisation.
3.8.2. Stand-by temperature

The stand-by temperature is common to the different zones of the mould. It
should be lower than the temperature settings for the different areas of the
mould and in this case, it permits substantial savings of the energy needed to
keep the mould heated during times when production is halted.
a B
C
A b c d f
Fig. 99. Optimisation page Heating clock

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3.8.3. Table of time ranges

The heater clock is a seven-day clock which makes it possible to program:
7 daily heating ranges of the injection unit areas.
7 daily heating ranges of the areas of the mould.
a - The heating clock is active only if the Start running box is checked. If not
checked, heating of the different areas is controlled only by the S204 and S213
selectors.
b - The cells of the Start injection unit heater indicate the time that heating of the
areas of the injection unit started.
c - The cells of the Start mould heater indicate the time that heating of the areas
of the mould started.
d - The cells of the Stop heater indicate the time that heating of the areas of the
injection unit and the mould stopped.
e - The Continuous programming key permits permanent activation of the
heater by programming the weekly ranges with same heating start (fixed at
00.00 h) and stop (fixed at 24.00 h) times.
f - The check boxes of the cells in the Stand-by column indicate that a holding
heat has been activated at the temperature programmed in the Stand-by tem-
peraturewindow.
REMARK: The heaters will be activated only if the heating selectors corresponding to the
zones are turned to 1.
see selector keys S204, page 55 and S213, page 56.
3.8.4. the programming window for the stand-by temperature set value.
A stand-by temperature can be maintained over the areas of the mould during
the period from the time programmed in the column Stop heater to the time
programmed in the column Start mould heater.
The stand-by temperature is the temperature programmed in the Stand-by
temperature window.
REMARK: The stand-by is only effective if the daily range check box is checked.
refer to section f -, page 269
3.8.5. Control window for the heating authorisation

This window shows the status of the heater clock output virtual contacts.
When the clock is not actuated, the outputs are on ON. When the clock is
actuated, the outputs are either on OFF if the consultation takes place out-
side the heating time range or on ON if the consultation takes place during
the heating time range.
3.8.6. How to start up the heating clock
1. Go to the page Heating clock by pressing the keys and suc-

cessively.
2. Make sure the clock is programmed with coherent values.

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3. Place the focus on the Start running check box (position number a of Fig. 99.,
page 268).
3.8.7. How to reduce the temperature of areas of the mould during slack periods
1. Go to the page Heating clock by pressing the keys and suc-

cessively.
2. Make sure the clock is programmed with coherent values.
3. Place the focus on the Stand-by window (position number B of Fig. 99.,
page 268).
5. Enter a temperature set value and validate with the key .

6. Select the slack periods during which a stand-by temperature should be main-
tained by positioning the bounding box on the corresponding checkboxes and
validate each time with the key .

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4. Function Machine configuration
4.1. Base page Machine configuration

The page Machine configuration allows the user to modify the machine
time counter.
4.1.1. How to change the date on the machine
1. Go to the page Machine configuration by pressing the key .

2. Select the year, the month, the day or the time to be modified by moving the
white line background using the keys and .

4. Enter the new value.

Fig. 100. Base page Machine configuration
Function Machine configuration

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4.2. Optimisation page Language

This page permits selection of one of the 5 languages in which the screens can
be displayed.
In the standard version, the languages available are:
French,
English,
German,
Spanish,
Italian.
4.2.1. How to select a language
1. Access the Language page by pressing the and keys succes-

sively.

3. Select the desired language by moving the white line background by means of
the keys and .
Fig. 101. Optimisation page Language

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The screen appears in the new language.


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4.3. Optimisation page Printer

This page makes it possible to select a printer driver among those installed on
the PC of the machine.
REMARK: The printer drivers are management utilities for the various printers on the mar-
ket. They must be correctly installed a on the machine PC and must be select-
ed for printing to take place.
Fig. 102. Optimisation page Printer
a. Refer to the installation documentation supplied with the printer

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4.4. Optimisation page Version

This page allows the different versions of the Rep programs installed on the
machine to be displayed.
Fig. 103. Optimisation page Version

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4.5. Optimisation page System

This page allows the different versions of the system programs installed on
the machine to be displayed.
Fig. 104. Optimisation page System

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4.6. Optimisation page Press options

The page Press options lists all the options which can be installed on a REP
machine.
The various options are referenced by their numbers but the description of
each them is displayed in the window at the bottom of the active zone when
the focus is positioned on it.
The Press options page shows which options are activated on the machine.
REMARK: For an option to be active, it must:
be installed on the machine,
be declared on the page Press options, i.e. the corresponding checkbox
located before its number must be checked.
WARNING: The page Press options is programmed by REP. It can be modified at the
client's premises after the installation of an additional option. In this case, only
members of the REP Technical Assistance Department are allowed to per-
form the programming.
A password is needed to validate a new option.
Fig. 105. Optimisation page Press options

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Chapter IX - Graphic functions
1. Introduction to the graphic pages
1.1. General
The graphic pages are used to introduce the moulding parameters to the press
user, so as to enable him to make comparisons and to assess the evolution
trends.
A graphic page is always associated with a non graphic moulding parameter
setting page a, whether it is a base page or an optimisation page.
refer to section 1.7. List of the graphic pages, page 288
1.2. Using a graphic page

1.2.1. Display on the screen

If the graphic page exists, it can be called for display from its associated (non
graphic) page by means of the keyboard key: .
1.2.2. Clearing the screen

When a graphic page is displayed, there are 2 different ways to delete it:
either by using the keyboard key: , it then gives way to its associated
(non graphic) page ;
or when using one of the 5 preset function keys or one of the 7 optimisation
functions; it then gives way to the corresponding base page or optimisation
page.
V:\G8\Vol2\A\A_utilisation_graphique.fm
1.2.3. Printing
The keyboard key allows the full screen containing the graphic page
to be printed.
a. Except the graphic page Hydraulics which is associated with the page Other inputs/outputs which is not a
parameter programming page. (see section 2.3., page 230)
Introduction to the graphic pages

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1.3. Structure of a graphic page
1.3.1. Heading of the graphic page

The heading is the same as the heading of the associated active page (non
graphic page).
see section1.4.1. Heading of the active page, page 75
1.3.2. Different features of the graphic page

a - Graph or plot of the measured value
The graph is the continued 2-dimensional plotting of a physical event meas-
ured on the machine and depending on another physical event.
see also section 1.4. Graph types, page 283
b - Plot of the set values
If the plotted physical event is obtained through the measured value of a
moulding parameter, the set value of the parameter is also plotted.
REMARK: A set value is generally plotted, i.e. as soon as the page is displayed; it then
takes place simultaneously with the plotting of the measured value.
d
c
h
b
h
a
g
Fig. 106. Features of a graphic page

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c - Plotting cursor
The plotting cursor is the vertical yellow line preceding the current graph val-
ue. It is displayed while the plotting takes place and it allows the current po-
sition of the dynamic plot to be materialised and followed.
REMARK: The plotting cursor is enabled when no zoom cursor is displayed. In this case,
the plotting cursor becomes the measured value cursor. Its top side looks like
a down-pointed triangle and the actual value of the currently plotted physical
event is displayed in the information box.
d - Zoom cursors
The zoom cursors are 2 other vertical dark-blue lines that the user displays
when necessary in order to delimit the horizontal graph area before zooming
it.
REMARK: Every displayed zoom cursor is active when its top side looks like a down-
pointed triangle. In this case, the zoom cursor becomes the measured value
cursor and the value of the physical event at the cursor/graph intersection is
displayed in the information box.
refer to section 1.5. Using the zoom, page 283
e - Information box
The information box is the text area right above the graphs. It displays for eve-
ry plot (represented through a line of different colour) the following informa-
tion:
the graph heading (parameter N, denomination, etc.);
the value of the plotted event at the intersection with the active cursor;
the set value at the intersection with the active cursor;
the measuring unit of the plotted physical event.
REMARK: If the graphic page displays the plots of several physical events, it contains 2
information boxes. Every information box is linked with the vertical measured
value axis of the physical event right below.
f - Information on the abscissa axis
The event expressed on the abscissa axis of the graph as well as the unit used
are indicated in the screen area which separates the 2 information boxes from
each other.
When a cursor is active, this area also displays the abscissa value at the inter-
section with the active cursor.
1.3.3. Plot axes

g - Horizontal axis
There is only one horizontal axis or X-axis. It is located at the bottom of the
active screen area. The horizontal axis is graduated according to the self-
matching scale and the measuring unit used appears in the area ref. f.

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h - Vertical axis
The vertical axis or ordinates can be simple or double; when having 2 axes,
they are totally independent.
REMARK: When having 2 vertical axes, the graphic page then displays 2 graphs of 2 dif-
ferent physical events where each of them depends on a third physical event,
which is the same for the 2 events and represented by the horizontal axis.
The vertical axes are graduated according to the (min. / max.) span of the
physical event.
The measuring unit used on each axis is specified in the information box.

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1.4. Graph types

There are 2 types of graph :
Standard Graph
Plotting of the standard graph begins only :
when the graphic page is displayed,
when the press works in the status which defines the plotting period
(example : in the shot size setting cycle to plot the graph of the extrusion
pressure)
Pulldown graph
The pulldown graph plotting is permanent. It is a recording-type plotting
from the right to the left side of the screen.
The machine user can only read the instantaneous graph status, i.e. the part
limited to the horizontal axis scale. The previous points are deleted.
1.5. Using the zoom
1.5.1. General rules

Using the zoom functions
The zoom functionsa can be used on all graphic pages with or without meas-
ured value plot.
The zoom cursors (2) are blue vertical lines delimiting the zoomed part or part
to be zoomed.
The zoom is active once the zoom symbol is displayed on the screen.
The graph remains frozen as long as it is zoomed.

Disabling the zoom functions
Once a graphic page is displayed on the screen, its zoom functions are disa-
bled.
Press the key to disable the zoom.

To fade the zoom cursor out, press the key .

Enabling the zoom cursors
The first zoom cursor is displayed and becomes active when pressing the key
; it may be moved by using the keys and .
a. The zoom functions are: the 2 zoom cursors and the zoom itself.

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The second zoom cursor is displayed and becomes active when pressing the
key again; it may be moved by using the keys and .
Enabling the zoom

The part of the measured and set value plots delimited by the 2 zoom cursors
is zoomed when pressing the key .
Dynamic plot X
Active cursor = Plotting cursor
X page function Dynamic plot X

non graphic + cursor of zoom 1
Active cursor = Zoom cursor 1
Active zoom = Frozen X plot Dynamic plot X

No active cursor + cursor of Zoom 1 and 2

Active cursor = Zoom cursor 2
Fig. 107. Graphic functions

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1.5.2. Plot freezing

A plot is frozen (fixed) on the screen, once the zoom is active. The plot is nev-
ertheless updated if the machine fulfils the corresponding plotting condi-
tions, but it is not displayed. This new plot will be displayed only once the
zoom is disabled.
1.6. Application procedures of the graphic pages
1.6.1. How to access a graphic page
1. Go to the non graphic pagea associated with the graphic page you want to dis-
play.
2. Press the key : .

The graphic page is displayed on the screen.
1.6.2. How to plot a graph

A graphic page is displayed on the screen.
1. Set the machine in the required situation for the graph to be plotted.
refer to sections 2., page 289 to 9., page 297.
1.6.3. How to delimit the graph part to zoom?

1. Cause the first zoom cursor to be displayed by pressing the key .

2. Move this first cursor to the position representing the left zoom limit by using
the keys and .
3. Cause the second zoom cursor to be displayed by pressing the key .

4. Move this second cursor to the position representing the right zoom limit by
using the keys and .

a. The pages associated with a graphic page are listed in the section 1.7., page 288

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1.6.4. How to control the zoom

The 2 zoom cursors delimit the graph part to zoom.
1. Control the zoom by pressing the key .
The zoom symbol appears on the screen. The graph was zoomed accord-
ing to the limits set when positioning the zoom cursor. The graph is frozen.
REMARK: It is possible to repeat the operation several times until the limits represent the
sampling periodicity of the graph.
1.6.5. How to freeze a graph

refer to section 1.6.4. How to control the zoom, page 286
1.6.6. How to exit the zoom
The zoom symbol is displayed on the screen.
1. Press key .
The 2 zoom cursors are displayed again and delimit the zoomed graph part.
1.6.7. How to return to the dynamic plot

1. Exit the zoom.
The 2 zoom cursors delimit the zoomed graph part.
2. Press key .
The zoom cursor delimiting the right graph part is faded out.
REMARK: A pulldown plot continues to pull down and the zoom cursor moves by preserv-
ing its abscissa.
A standard plot causes the last dynamic plot stored to be displayed on the
screen.

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1.6.8. How to measure a point on the graph

If the plotting is being carried out (standard or pulldown graph), the informa-
tion boxes display the value of the plotted event and the set value at the inter-
section with the plotting cursor.
If the plotting has been completed (standard graph), it is possible to read the
value of one point of the graph and the set value at the intersection with the
active cursor:
1. Press the key to display the first zoom cursor which becomes active.
2. Move the cursor to the point to be measured using the keys and
.
3. Read the measures displayed in the information boxes.
refer to position number e -, page 281

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1.7. List of the graphic pages
Access keys Access key
Optimisation
Main pages Graphic pages
pages
Injection unit temperatures

-
page 289
Back-pressure Back pressure

Compound prepa- page 109 page 290
ration
Extruder feed strip
page 105
rupture
page 113 Extruding
Shot size accuracy page 291
page 115
Mould closing Clamping

-
page 121 page 292
Injection (Time)
-
Filling page 293
page 129 Injection profile Injection (Stroke)

page 136 page 295
Curing Mould temperatures

-
page 156 page 296
Other inputs/out-
Maintenance Hydraulics
puts
page 225 page 297

page 230
Tab. 73. Pages associated to the graphics pages

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2. Graphic page Injection unit temperatures

Vertical
Axes Horizontal
to the left to the right
Temperatures of
- the areas 60, 61
Measured and 62
Time
events
Temperaturesa of
- areas 63 and 64
Units (hh:mm:ss)b - (C)
Plotting time Continuous plotting
a. according to the C.R.B. optimisation function selection

b. format: hour, minutes and seconds
Fig. 108. Graphic page Injection unit temperatures
Graphic page Injection unit temperatures

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3. Graphic page Back pressure

Vertical
Axes Horizontal
Measured Compound tem-

Time Back-pressure perature (area
events
Units (seconds) (bars) (C)
Extrusion running or suspended even though shot size

Plotting time
setting is not reached
Fig. 109. Graphic page Back pressure
Graphic page Back pressure

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4. Graphic page Extruding

Vertical
Axes Horizontal
to the right to the left
Measured
Time Main pressure Extruder speed
events
Units (seconds) (bars) (rpm)
Extrusion running or suspended even though shot size

Plotting time
setting is not reached
Fig. 110. Graphic page Extruding
Graphic page Extruding

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5. Graphic page Clamping

Vertical
Axes Horizontal
Measured Clamping pres-

Time -
events sure
Units (seconds) (bars) -
Plotting time Clamping, injection and curing phases
Fig. 111. Graphic page Clamping
Graphic page Clamping

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6. Graphic page Injection (Time)

The graph Injection (Time) can show 2 variants, which are either direct in-
jection or injection-transfer.
The variant is determined by the optimisation function selected Transfer or
Compression.
refer to section 3.7. Optimisation page Selections, page 265
6.1. Direct injection variant
Vertical
Axes Horizontal
Measured Injection piston

Time Main pressure
events speed
Units (seconds) (bars) (0.1 mm/s)
Plotting time Dynamic and static injection phases
6.2. Injection transfer variant
Vertical
Axes Horizontal
Injection piston
up to point 35a Main pressure
speed
Measured
Time
events Clamping pres-
from point 35 -
sure
Units (seconds) (bars) (0.1 mm/s)

Plotting time Dynamic and transfer injection phases
a. see section2.7. Injection-transfer, page 99
Graphic page Injection (Time)

Document: V684_2Aa
Edition: 16/06/2000 page 293
Direct injection variant
Injection transfer variant
Fig. 112. Graphic page Injection (Time)
Graphic page Injection (Time)

Document: V684_2Aa
page 294 Edition: 16/06/2000
7. Graphic page Injection (Stroke)

Vertical
Axes Horizontal
Measured Injection piston Injection piston

Main pressure
events position speed
Units (0.1 mm) (bars) (0.1 mm/s)
Plotting time Dynamic and static injection phases

Fig. 113. Graphic page Injection (Stroke)
Graphic page Injection (Stroke)

Document: V684_2Aa
Edition: 16/06/2000 page 295
8. Graphic page Mould temperatures

Vertical
Axes Horizontal
Temperatures of
-
areas 65 and 67
Measured
Time
events
Temperaturesa of
- areas 66, 68 and
69
Units (hh:mm:ss)b - (C)
a. according to the selected optimisation functions

b. format: hour, minutes and seconds
Fig. 114. Graphic page Mould temperatures
Graphic page Mould temperatures

Document: V684_2Aa
page 296 Edition: 16/06/2000
9. Graphic page Hydraulics

Vertical
Axes Horizontal
DAC pressure
Measured control
Time Main pressure
events DAC flow rate
control
Units (seconds) (bars) (V)

Fig. 115. Graphic page Hydraulics
Graphic page Hydraulics

Document: V684_2Aa
Edition: 16/06/2000 page 297
Graphic page Hydraulics

Document: V684_2Aa
page 298 Edition: 16/06/2000
Index
Index
Document: V684_2Aa
Edition: 16/06/2000
- page 92
A
abscisses 281
access
C
- inside the cage 18
- inside the guard 42
C.R.B. 37, 39, 144
active
channels
- cells 81
- pressure measurement 231
- page 69, 74, 91
clamping 292
adjustment 60
cleaning the guard 42
- of the mould height screw 127
clearance under clamping block 22, 23
- software 244
closing L.S. 20, 22
ambient temperature 192
closing unit stroke initialisation 24
ancillary
cold
- cylinders 68, 184
- junction 192
- heating areas 161
- junction temperature 192
automatic 60
- runner block 144
automatic injection unit lift 150
- runner blocks 37, 39
compound
- batches 34
- decompression 117
B
V:\G8\Vol2\A\A_utilisationIX.fm
- preparation 105
- pressure inside the mould 154
compound temperature
back-pressure 109, 290 - see: temperature (60) temperature indicator at
base the extruder outlet
- function 92 configuration
Document: V684_2Aa
Edition: 16/06/2000 page 299
Index
- of the machine 271

- of the production 245 D
connect thermocouples 21
control
- coefficients 196 DAC 230, 297
- station 14, 45 data input deletion 79
controls 45 date 70
- dual-hand 65 degassing 101, 140
- manual 53 detection of extruder feed strip rupture
cooling 193 - see: average extruding pressure (4C)
- ranges 193 diagnostic 225
- temperature 192 diamond-shaped box 88
- threshold 192 digital
counters 230 - input test 228, 230
- P1 : cycle counter with reset to zero 58 - inputs 228, 230
- P1 : time counter 59 - manometer 70
- P1 : total cycle counter 58 displacements
- RepNet-win 258 - measurement encoders 231
counting channels 230 display system 46
creating vacuum dual-hand 45, 65
- see: vacuum - see: push button S93: dual-hand
Curetrac 158, 250, 254
Curetrac communication 159, 160
curing 156
cursor E
- see: focus
cursors
- graphic plotting 281 ejection
- see: focus - on fixed traverse
cycle - with encoder 104, 175
- counters 257 - with no encoder 173
- in automatic mode 38 - on movable traverse
- in semi-automatic mode 37 - with encoder 103, 168

- locking 86 - with no encoder 166
- see: operating modes - on the fixed traverse 172
cycles - on the movable traverse 165
- 31 Mastertrac 207, 210, 217, 222 encoders 231
exclusive-choice lists 76
Document: V684_2Aa
page 300 Edition: 16/06/2000
Index
extruder delay 111 - curing 156

extruding 291 - sub-function: ancillary areas 161
- sub-function: Curetrac communication
159
- sub-function: Curetrac corrections 158
- sub-function: Network link 160
F - filling 129
- sub-function: 2nd transfer 152
- sub-function: automatic injection unit lift
fastening the mould 18 after injection 150
filling 129 - sub-function: cold runner block 144
focus 78, 81 - sub-function: compound pressure 154
- shift rules 78 - sub-function: degassing 140
front 18, 42 - sub-function: injection profile 136
front panels - sub-function: injection unit beardown af-
- of ancillary controls 66 ter injection 146
- of main controls 53 - sub-function: vacuum 148
function - graphics 279
- maintenance - maintenance
- sub-function: retrace inputs/outputs 233 - base function: sequential diagnostic 225
functions - sub-fonction: digital inputs 228
- configuration of the machine - sub-fonction: other inputs/outputs 230
- sub-function: language 272 - sub-fonction: preventive maintenance
- sub-function: press options 277 236
- sub-function: printer 274 - sub-function: retrace inputs/outputs 240
- sub-function: system 276 - sub-function: setting software 244
- sub-function: version 275 - Mastertrac
- configuration of the production 245 - sub-function: cycle selection 217
- base function : production check 245 - sub-function: learning of the sequence
214
- sub-function: cycle counter 257
- sub-function: selections 216
- sub-function: heating clock 268
- mould closing 121
- sub-function: machine time 254
- sub-function: clamping stroke adjust-
- sub-function: mould selection 251
ment 127
- sub-function: production selection 250
- sub-function: plate approach 125
- sub-function: selection of cycle 259
- preparing the compound 105
- sub-function: selections 265
- sub-function: backpressure 109
- sub-function: compound decompression
Document: V684_2Aa
Edition: 16/06/2000 page 301
Index
117
- sub-function: extruder delay 111 H
- sub-function: shot size accuracy 115
- sub-function: silicone stuffer 119
- sub-function: strip rupture 113 heading of
- stripping and loading of inserts 163 - the graphic page 280
- sub-function: ancillary cylinders 184 - the screen page 70
- sub-function: fixed traverse ejectors 173 heating 26, 268
- sub-function: limits 186 - clock 268
- sub-function: movable traverse ejectors - connectors 21
165 hot surfaces 11, 12
- sub-function: plate approach 180 how to
- sub-function: sliding platen 182 - activate or deactivate the Learning Mode
- sub-function: stripping kits 178 219
- Thermotrac - adjust clamping stroke 20
- sub-function: identification 195 - adjust injection unit microcontacts 30
- sub-function: identification supervision - adjust S48 30
199 - adjust S51 22
- sub-function: regulation supervision 198 - adjust S72 31
- analyse an internal variable curve 235
- assess the evolution trends 279
- bring up a parameter window on the Pro-
duction Controlpage. 248
G - cancel the last step entered to a Mastertrac
sequence 220
- change a parameter set point using the +
graph 280 and - slopes 248
- pulldown type 283 - change a parameter set value 89
- standard type 283 - change a preventive maintenance operation
graph axes 281 238
graphs - change PIDT coefficients 204
- back pressure 290 - change the date on the machine 271
- clamping 292 - change the level of gravity of a fault 242
- extruding 291 - change the nozzle 27

- hydraulics 297 - change the time on the machine 271
- injection (stroke) 295 - change the tolerances of a parameter 89
- injection (time) 293 - choose a mould 16
- injection unit temperatures 289 - clean the injection chamber 36
- mould temperatures 296
Document: V684_2Aa
page 302 Edition: 16/06/2000
Index
- clear a parameter on the Production Con- - select a preventive maintenance operation

trolpage from the screen. 248 238
- compare the course of the current cycle - select an optimisation function 266
with that of the previous cycle 226 - select cycle 31 218
- create a new mould 253 - select the optimisation functions to be in-
- delete a Mastertrac sequence 221 volved in the Mastertrac sequence 218
- deselect a preventive maintenance opera- - sort faults in the archive 242
tion 238 - start the identification cycle 200
- deselect an optimisation function 266 - start up production 36
- display an internal variable curve 234 - start up the PC 13
- duplicate a mould 253 - start-up the heating clock 269
- fasten an intermediate mould plate on the - stop production 39
ejection bars 19
- stop scrolling of an internal variable curve
- filter faults in the archive 242 235
- heat the machine 26 - switch hydraulic pump unit off 15
- initialise the strokes 24 - switch hydraulic pump unit on 15
- install new tooling 18 - switch process-control off 15
- integrate a particular operation into a Mas- - switch process-control on 13
tertrac sequence 220
- switch the electrical cabinet off 15
- load the compound 34
- switch the electrical cabinet on 13
- make a Mastertrac sequence 219
- test the Mastertrac sequence 222
- reactivate scrolling of an internal variable
- totally insulate electrical cabinet 15
curve 235
- use shortcuts 267
- read the status of a digital input 228
- work in the Automatic mode with the last
- read the status of a digital output 232
Mastertrac sequence 222
- read the value of a counting channel 232
hydraulics 297
- read the value of an analogue input 232
- read the value of an analogue output 232
- reduce the temperature of areas of the
mould during slack periods 270
- reinitialize the counter triggering a preven- I
tive maintenance operation 239
- restart a cycle after a break 39
- save the last sequence executed in the lear- I/O 230
ning mode 220

identifiable heating areas 200
- select a cycle 264
identification 26, 195
- select a language 272
- phases 202
- select a mould 252
- reference values 196
- select a mould with RepNet-win 253
indicators
- H310: front cell resetting 67
Document: V684_2Aa
Edition: 16/06/2000 page 303
Index
initialisation of ejector strokes 25 - access to graphics 288

initiation of the identification process 200 - access to the function and sub-functions
injection 129, 293, 295 - compound preparation 92
- direct injection 294 - curing 92
- dynamic phase 97 - filling 92
- profile 136 - machine configuration 224
- static phase 98 - maintenance 224
- transfer moulding 99, 152, 294 - Mastertrac 211
injection unit - mould closing 92
- beardown after injection 146 - production configuration 224
- stroke initialisation 24 - stripping and loading of inserts 92
- temperatures 289 - access to the preset functions 223, 224
inquiry windows 84 keys 47
insert lift 96, 170 kit ejection 178
inserts 96, 163, 170
installation
- new tooling 18
- of new options 277
L
ladders 11
K ladders and step-ladders 316
language 272
learning of cycle No 31: 207
keyboard 47 level
- access to associated optimisation functions - of seriousness of the messages 71
48 levels
- access to functions - safety 3
- preset 48 lights
- access to preset functions 92 - H40: press fault 55
- directional keys 50 - H60: process-control power on light 54
- see: keys - H61: hydraulic pump unit power on 55
- utilities limit
- operator interface 50 - of the extraction pressure 186
- the machine 51 - of the opening stroke 186
keyboard access 58 limit switches
keyboard inhibition 58 - see: microcontacts
keyboard keys loading
Document: V684_2Aa
page 304 Edition: 16/06/2000
Index
- of inserts 163 - opening 102

- the mould 18 - temperatures 296
moulding parameter
- parameter C1: 255
moulding parameters
- parameter 00: 164
M
- parameter 01: 164, 181
- parameter 02: 171
- parameter 03: 122
machine
- parameter 04: 122
- configuration functions 271
- parameter 05 : 123
- process-control 91
- parameter 05: 132
main
- parameter 06: 181
- circuit breaker Q1 54
- parameter 08: 126
- parameters 17
- parameter 09: 126
- pressure 70, 297
- parameter 0A: 143
maintenance 225, 297
- parameter 0B: 128
maintenance functions 225
- parameter 0D: 132
manual 60
- parameter 0E: 153
Mastertrac 207
- parameter 0F: 187
- access to the active pages 211
- parameter 10: 164
- associated selections 211
- parameter 11: 164
Mastertrac functions 212
- parameter 12: 123, 126
measured value 85
- parameter 13: 123
measured values
- parameter 15: 183
- displacements 231
- parameter 16: 183
measurement
- parameter 17: 183
- of pressures 231
- parameter 1A: 143
mechanical ejection 96, 170
- parameter 1D: 133
messages 69, 70
- parameter 1E: 153
microcontacts
- parameter 20: 108
- S48: Injection unit plate L.S. 30, 32
- parameter 21: 133
- S51: Press closing L.S. 22
- parameter 22: 139

- S51: press closing L.S. 22
- parameter 23: 140
- S72: Injection unit automatic lift L.S. 30, 32
- parameter 24: 140
modification of the parameters 79
- parameter 25: 140
mould 16
- parameter 2A: 116
- closing 96, 121
- parameter 2B: 118
- height adjusting screw 127
Document: V684_2Aa
Edition: 16/06/2000 page 305
Index
- parameter 2C: 108 - parameter 60: 107

- parameter 30: 108, 132, 138 - parameter 61: 107
- parameter 31: 138 - parameter 62: 107, 131
- parameter 32: 138 - parameter 63: 145
- parameter 35: 133, 139 - parameter 66: 162
- parameter 3A: 116 - parameter 69: 162
- parameter 3B: 118 - parameter 70: 185
- parameter 45: 155 - parameter 7C: 169
- parameter 46: 187 - parameter 7F: 176
- parameter 48: 140 - parameter 81: 167, 170
- parameter 4B: 118 - parameter 82: 174
- parameter 4D: 134 - parameter 84: 179
- parameter 4E: 153 - parameter 85: 185
- parameter 4F: 135 - parameter 86: 171, 181
- parameter 51: 131 - parameter 9A: 169
- parameter 52: 138 - parameter 9B : 169
- parameter 53: 142 - parameter 9C: 169
- parameter 54: 142 - parameter 9D: 176
- parameter 55: 142 - parameter 9E: 176
- parameter 56: 157 - parameter 9F: 176

- parameter 57: 106 - parameter C0: 255
- parameter 5A: 147 - parameter C4: 256
- parameter 5C: 114 - parameter DF: 187
Document: V684_2Aa
page 306 Edition: 16/06/2000
Index
- parameter DG: 171 optimisation

- parameter DJ: 169 - function 76, 92
- pressures - page 92, 190, 211, 224
- see: pressures ordinates 282
- speeds outputs 230
- see: speeds
- strokes
- see: strokes
- temperatures
P
- see: temperatures
- times
- see: times
page
movements compatible with Mastertrac 208
- base page 190, 211, 224
multiple-choice lists 76
page background 83
pages
- associated to the graphics pages 288
- graphic
N - see: graphs
parameter
- measuring units 83, 85
new mould 18 - programming 17, 18, 78, 79, 83
new tooling 18 - set value 85
number - validation 79
- of the mould 70 password 277
- of the parameter 85 PC 46
physical events 83, 281
PIDT 26, 189, 204
piston retraction 95, 117
plate 178
O
- approach 125, 180
- translation 178
plots
one-piece front side 316

- of the measured value 280
opening the front 18, 42
- of the set values 280
operating
power-on 13
- modes 60
- page 13
- the machine 13
- screen 13
operator interface 45, 46
preset
Document: V684_2Aa
Edition: 16/06/2000 page 307
Index
- cycle - 4C: Extruding average 114

- N2 261 - 4D: transfer pressure during the first stage
- N3 261 134
- N4 262 - 4E: transfer pressure during the 2nd stage
153
- N5 262
- 80: pressure of the ancillary cylinder N1
- N6 263
185
- N7 263
- 81: pressure of the movable traverse ejec-
- function 91 tors 167
- functions 223 - with encoder 170
preset functions - 82: pressure of the fixed traverse ejectors
- machine configuration - with encoder 177
- see: machine configuration function - with no encoder 174
- maintenance - 83: plate translation pressure 179
- see: function maintenance - 84: kit ejector pressure 179
- production configuration - 85: pressure of the ancillary cylinder N2
- see: production configuration function 185
press - 86: approach 181
- field of application 1 - 86: ejection pressure limit 171
- options 277 - 87: silicone stuffer 120
- use 1 preventive maintenance 236
pressure previous versions 315
- and flow rate control 231 printer 274, 275, 276
- readings 230 production check 245
pressures 83, 230 programming
- 40: back-pressure 110 - value
- 41: 1st holding pressure after injection 133 - max. 85
- 42: 2nd holding pressure after injection 140 - min. 85
- 43 - windows 84
- with direct injection: clamping 124 pull-down menu 76
- with injection-transfer: holding pressure punch button 5
after transfer 134 purging 36, 39
- 44: approach 124, 126 push buttons
- 45: compound pressure inside the mould - S107: step-by-step learning cycle (reverse)
155 61, 209
- 46: extraction pressure limit 187 - S108: forward step-by-step learning cycle
- 47: average injection pressure 134 61
- 48: injection pressure limit 140 - S108: step-by-step learning cycle (forward)
- 4B: piston retraction 118 209
- S112: continuous cycle selector 67
Document: V684_2Aa
page 308 Edition: 16/06/2000
Index
- S123: plate in 67
- S124: plate out 67 R
- S175: kit ejector in 67
- S176: kit ejector out 67
- S18: injection piston lift 61 RepNet-win 16, 253
- S19: purge injection 61 retrace
- S201: front panel STOP 54 - faults 240
- S202: process-control stop 54 - inputs and outputs 233
- S203: process-control power on 54 rubber 34
- S211: hydraulic pump unit stop 55
- S212: hydraulic pump unit power on 55
- S310: front cell resetting 67
- S32: light tests 55 S
- S33: press closing 62
- S34: press opening 62
- S35: clamping block in clamping 62 S1 and SE 3
- S36: unclamping clamping block out 62 S51 activation rod 20
- S37: front guard closing 62 safety 1
- S38: front guard open 62 - cooling 193
- S400: ancillary cylinder 2 in 68 - devices 3
- S401: ancillary cylinder 1 out 68 - electrical 5
- S402: ancillary cylinder 2 in 68 - Europe (SE type) 3
- S403: ancillary cylinder 2 out 68 - except Europe (S1 type) 3
- S41: injection unit lift 63 - hydraulic 8
- S42: injection unit bear-down 63 - injection unit safety pins 28
- S43: sliding platen in 64 - on closing unit 9
- S44: sliding platen out 64 - on injection unit 11
- S65: movable traverse ejectors in 64 - on tooling 12
- S66: movable traverse ejectors out 64 - guard
- S75: fixed traverse ejectors in 63 - operation 3, 4
- S76: fixed traverse ejectors out 63 - instructions 1
- S93: dual-hand 65 - rules 1
screen 46, 69
- active zones 76
- background 83
- resolution 46
- see: active page
screening of the data of a table 82
Document: V684_2Aa
Edition: 16/06/2000 page 309
Index
scrolling an internal variable curve 235 - 17: sliding platen in speed 183
second transfer 152 - 1A: opening speed during degassing 143
selection of - 1D: transfer speed during the first stage 133
- cycle 259 - 1E: transfer speed during the second stage
- the batch 254 153
- the language 272 - 20: rotation speed of the extruder screw 108
- the mould 251 - 21: injection speed during the first stage
133
- the optimisation functions 265
- 22: injection speed during the second stage
- the printer 274, 275, 276
139
- the production 250
- 23: injection speed during the third stage
selectors 140
- S0 - S1: operating modes 60 - 24: injection speed during the 4th stage 140
- S100 - S101: keyboard 58 - 25: injection speed during the 5th stage 140
- S11: extruder 56 - 2A: low rotation speed of the extruder
- S12: open guard dual-hand ejectors 56 screw 116
- S17: full-force beardown 57 - 2B: piston retraction 118
- S204: injection unit controller 55 - 2C: average rotation speed of the extruder
- S213: closing unit heating 56 screw 108
- S4: guard operation 57 - 70: speed of ancillary cylinder N1 185
semi-automatic 60 - 71: speed of the movable traverse ejectors
sequential diagnostic 225 - with encoder 169
shortcuts 266 - with no encoder 167
shot size 94 - 72: speed of the fixed traverse ejectors
- accuracy 115 - with encoder 176
- setting 291 - with no encoder 174
silicone stuffer 35, 68, 119 - 73: plate translation speed 179
sliding platen 182 - 74: kit ejector speed 179
slopes + and - 58 - 75: speed of ancillary cylinder N2 185
software - 77: silicone stuffer 120
- Mastertrac 207 - 7C: low out-stroke speed of the movable
traverse 169
- Thermotrac 189
- 7F: low out-stroke speed of the fixed traver-
speeds 83 se 176
- 10: low speed opening 164, 181 standard keyboard socket 47, 52
- 11: high speed opening 164 stand-by 194, 268
- 12: low speed closing 123, 126 stand-by temperature 194, 268
- 13: high speed closing 123 starting up
- 15: sliding platen out speed 183 - the heating clock 269
- 16: sliding platen out damping speed 183 - the machine 13
Document: V684_2Aa
page 310 Edition: 16/06/2000
Index
start-up programming 17 transfer phase 133, 139

STOP 54 - 36: initiation of the 1st volumetric degas-
strip rupture 113 sing 143
stripping - 37: initiation of the 2nd volumetric degas-
sing 143
- and loading of inserts 163
- 3A: low extruder speed 116
- kits 67, 178
- 3B: piston retraction before extruding 118
strokes 83
- 3C: piston retraction after extruding 118
- 00: beginning of high speed opening 164
- 9A: end of the in-stroke of the movable tra-
- 01: end of high speed opening 164
verse ejectors 169
- 02: insert lift 171
- 9B: beginning of the low speed out-stroke of
- 03: beginning of high speed closing 122 the movable traverse ejectors 169
- 04: end high speed closing 122 - 9C: end of the out-stroke of the movable tra-
- 05: mould safety 123, 132 verse ejectors 169
- 06: beginning of the low intermediate ope- - 9D: end of the in-stroke of the fixed traverse
ning speed 181 ejectors 176
- 07: end of the low intermediate opening - 9E: beginning of the low speed out-stroke of
speed 181 the fixed traverse ejectors 176
- 08: beginning of the low intermediate clo- - 9F: end of the out-stroke of the fixed traver-
sing speed 126 se ejectors 176
- 09: end of the low intermediate closing - DF: opening stroke end tolerance 187
speed 126 - DG: tolerance on the insert lift stroke 171
- 0A: opening stroke during degassing 143 - DJ: tolerance on the out-stroke of the mova-
- 0B: adjustment of the clamping stroke 128 ble traverse ejectors 169
- 0D: mould opening during injection-trans- sub-functions
fer 132 - see: functions
- 0E: stroke of the 2nd transfer stage 153 - see: optimisation functions
- 0F: end of the opening stroke 187 symbolisation of the physical events 83, 85
- 30: shot size setting stroke 108, 132, 138 synoptic diagrams of the moulding parameters 93
- 31: beginning of the 2nd stage of the dyna- - degassing processes 101
mic injection phase 138
- dynamic injection 97
- 32: beginning of the 3rd stage of the dyna-
- ejection with encoder on fixed traverse 104
- ejection with encoder on movable traverse
- 33: beginning of the 4th stage of the dyna-
103
- injection-transfer 99
- 34: beginning of the 5th stage of the dyna-
mic injection phase 139 - mould closing 96
- 35 - mould opening 102
- with direct injection: transition to hol- - piston retraction 95
ding pressure 133, 139 - shot size 94
- with injection-transfer: transition to the - static injection 98
Document: V684_2Aa
Edition: 16/06/2000 page 311
Index
- time-delays 100 - identification phases 196

- identification process duration 196
- identification set value 196
- identification supervision 199
time 70, 83
T
- C0: machine time 255
- C1: stripping time 255
- C2: extruding time 255
tables 81
- C3: injection time 256
technical progresses 315
- C4: cycle time 256
temperature
time-delays 100
- control 26, 189
times
- control coefficients 26, 189, 204
- 50: delayed extruder start 112
- controllers 189
- 51
- regulation supervision 198
- with direct injection: duration of the 1st
- see: hot surfaces
injection holding pressure 131
temperatures 83
- with injection-transfer: duration of the
- 60: temperature indicator at the extruder 1st clamping holding pressure 131
outlet 107
- 52: duration of the 2nd injection holding
- 61: extruder temperature 107 pressure 138
- 62: injection chamber 107, 131 - 53: postponement of the first time-delayed
- 63: nozzles 145 degassing 142
- 64: cold runner block 145 - 54: opening time during degassing 142
- 65: temperature of the fixed traverse hea- - 55: postponement of the second time-de-
ting platen 157 layed degassing 142
- 66: temperature of the ancillary area N1 - 56: cure time 157
162 - 57 : injection unit safety 106
- 67: temperature of the movable traverse - 58: automatic injection unit lift after injec-
heating platen 157 tion 151
- 68: temperature of the ancillary area N2 - 59: vacuum prior to injection 149
162
- 5A: injection unit beardown after injection
- 69: temperature of the ancillary area N3 147
162
- 5C: progressive extruder start 114
test outputs
tolerance
- analogue 230
- check condition 86
- digital 230
- values 86
text keypad 46
tolerances 80, 85, 86
thermocouples 21
- on the insert lift stroke 171
Thermotrac 26, 189
- on the opening stroke 187
- functions 191
Document: V684_2Aa
page 312 Edition: 16/06/2000
Index
- on the out-stroke of the movable traverse vulcanization 156

ejectors 169
tooling 18
- see: new tooling
V year of manufacture of the machine 315
vacuum 148, 266

- before injection 149
- pump 148
Z
- alternative mode 266
- continuous mode 266
zoom 281
- see also: vacuum pump
zoom cursors 281
Document: V684_2Aa
Edition: 16/06/2000 page 313
Index
Document: V684_2Aa
page 314 Edition: 16/06/2000
Appendix A - Previous versions
1. Technical progresses
1.1. Single documentation

The REP products take account of continuous technical progresses. In order
to have a single documentation, we have decided to create this appendix
which gathers the various illustrations and explanations of the product pre-
vious versions.
The reader will have to refer to the section or to the illustration corresponding
to the version of his machine.
1.2. Year of manufacture of the machine

The year and week of manufacture of the machine can be read from its assem-
bly reference number: this number is made of the 4 digits (from the 8th to the
11th character) of the identification number engraved on the type plate on the
right-hand side of the switch cabinet.
The mounting reference consists of the last 2 figures

of the year and the 2 figures of the mounting week.
V 6 8 Y 4 0 W y y w w n n n n
V:\G8\Vol2\A\A_utilisation_annexe.fm
Press reference
Fig. 116.
Technical progresses
Document: V684_2Aa
Edition: 16/06/2000 page 315
2. One-piece front side
WARNING: When the front side has no upper shutter, you have to
open it and use a step-ladder to have access to the front
side of the injection unit.
V:\G8\Vol2\A\A_utilisation_annexe.fm
Fig. 117. Ladder and step-ladder placements.
One-piece front side

Document: V684_2Aa
page 316 Edition: 16/06/2000

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RUBBER INJECTION MOULDING

Chapter I - Safety ......................................................................................................................... 1

1. General safety instructions ................................................................................................. 1

5.1.2. Front ..................................................................................................................... 9

6.2. Compound inlet chute ................................................................................................... 11

Chapter II - Operating the machine ...................................................................................... 13

8.2. How to use a silicone stuffer ......................................................................................... 35

9.3. Cycle in semi-automatic mode ...................................................................................... 37

Chapter III - Control station .................................................................................................... 45

2.2.5. The utility keys of the machine ........................................................................... 51

3.1.2. Indicator lamps ................................................................................................. 55

Chapter IV - Reading and programming of data ............................................................... 69

1. Screen ergonomics ............................................................................................................ 69

2. Programming rules ............................................................................................................ 78

2.3.2. Validation rules for a binary choice .................................................................... 79

Chapter V - Moulding parameters ......................................................................................... 91

1. Principle of the distribution of functions ......................................................................... 91

2. Synoptic diagrams of the parameters .............................................................................. 93

2.6. Injection (static phase) .................................................................................................. 98

3.7.2. Parameters ...................................................................................................... 120

4.2. Optimisation page Plate approach ........................................................................... 125

5.9. Optimisation page Compound pressure .................................................................. 154

6.1.2. Main sub-functions ........................................................................................... 156

7.10.Optimisation page Plate approach .......................................................................... 180

7.12.Optimisation page Ancillary cylinders ..................................................................... 184

Chapter VI - Thermotrac ...................................................................................................... 189

1. Temperature control and Thermotrac function ........................................................... 189

3.1. Initiation of the identification process .......................................................................... 200

4.1. Heating-up conditions of a tooling .............................................................................. 204

Chapter VII - Mastertrac ...................................................................................................... 207

1. Introduction ...................................................................................................................... 207

3.2. Application of the Learning function ......................................................................... 219

3.3. Use of cycle 31 ............................................................................................................ 222

Chapter VIII - Preset functions ............................................................................................. 223

1. Introduction ....................................................................................................................... 223

2.4.4. Visualization of plotting curves ......................................................................... 234

2.5.3. How to select/deselect a preventive maintenance operation ........................... 238

3.5. Optimisation page Cycle counter ............................................................................ 257

3.6.3. Preset cycles .................................................................................................... 260

Chapter IX - Graphic functions ............................................................................................ 279

1. Introduction to the graphic pages .................................................................................. 279

1.3. Structure of a graphic page ........................................................................................ 280

Index ......................................................................................................................................... 299

Previous versions 315

1. Technical progresses ....................................................................................................... 315

1. General safety instructions

1.1. Field of application

1.2. Restrictions of the products used

1.3. Main safety rules

the operator's safety and are therefore strictly prohibited.

General safety instructions

General safety instructions

2. Personal safety devices

2.1. Safety device SE

2.2. Safety device S1

Personal safety devices

Personal safety devices

3.1. Main switch

3.2. Opening the cabinet door

3.3. Fault indicator

3.4. STOP Punch button

refer to section 3.1.1. Powerization, page 54

3.5. Fume extractor device