TMC TMC 30E Manual de usuario

Injection Molding Machine

Operation ManualV3.0

For System TM11

TMC Technology Corp.

No.726, Jieh Shou Road, Sec. 2, Pa Teh,

Taoyuan, Taiwan

Tel : 866-3-3688127

Fax : 886-3-3684959

E-mail : [email protected]

Website : Http://www.tmcint.com

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Content Ver. 3.0

Chapter 1: Safety

1. Operator safety protection……………..……………………………………………………… 1-1

1.1 Electrical ............................................................................................................................. 1-2

1.2 Hydraulic safety device....................................................................................................... 1-2

1.3 Machinery safety device .....................................................................................................1-3

2. Safety operation of machine …...……………………………………………………………... 1-4

2.1 Operation environment........................................................................................................ 1-4

2.2 Disposal of scrap products or waste.................................................................................... 1-4

2.3 Clamping unit...................................................................................................................... 1-4

2.4 Injection unit ....................................................................................................................... 1-4

2.5 Hydraulic unit...................................................................................................................... 1-5

2.6 Electrical unit...................................................................................................................... 1-5

3. Safety labels and alarm devices...……………………………………………………………... 1-6

3.1 Definition of labels.............................................................................................................. 1-6

3.2 Adhering position................................................................................................................ 1-6

3.3 Alarm light and buzzer........................................................................................................ 1-8

3.4 Escape when trapped in machine........................................................................................ 1-8

4. Machine maintenance warranty……………………………………………………………….. 1-8

Chapter 2:Machine specifications

1. Machine specifications………..…………………………………...………………………….. 2-1

2. Machine dimensions………….……………………………………………………………….. 2-4

3. Operating position…………………………………………………………………………….. 2-5

4. Safety devices layouts…..…………………………………………………………………….. 2-6

5. Position of signs and labels…..……………………………………………………………….. 2-7

Chapter 3: Preparation of installation and test running

1. Placing of the machine............................................................................................................... 3-1

2. Foundation of the machine......................................................................................................... 3-1

3. Transportation ............................................................................................................................ 3-2

3.1 Transportation preparation..................................................................................................3-2

3.2 Process of transportation..................................................................................................... 3-2

4. Leveling……………………………………………………………………………………….. 3-6

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5. Adjusting of mounting pad………………………..………………………………………….. 3-7

6.Ventilation……………………………………..……………………………………………….. 3-8

7. Preparation before operation………………………………………………………………….. 3-9

7.1 Power supply....................................................................................................................... 3-9

7.2 Cooling water...................................................................................................................... 3-10

7.3 Main power/water connection position............................................................................... 3-10

7.4 Material............................................................................................................................... 3-10

7.5 Hydraulic oil, lubrication oil and grease............................................................................. 3-11

7.6 Operating temperature and humidity .................................................................................. 3-11

8. Pre-operation checkpoints…………………………………………………………………….. 3-12

4.1 Check before power ON...................................................................................................... 3-12

4.2 Check before motor starting................................................................................................ 3-12

4.3 Motor starting inspection .................................................................................................... 3-12

4.4 Check the mold condition ................................................................................................... 3-14

Chapter 4: Operation

1. Operation panel………………………………………………………………………………... 4-1

1.1 Screen /function selection key............................................................................................ 4-1

1.2 Number/alphabet key.......................................................................................................... 4-1

1.3 Direction/screen operation instruction key......................................................................... 4-1

1.4 Manual operation switch.....................................................................................................4-1

2. Screen layout and operation…………………………………………………………………… 4-3

2.0 Main page of operation screen............................................................................................ 4-5

2.1 Main page of operation screen............................................................................................ 4-7

2.2 Machine monitoring screen................................................................................................ 4-8

2.3 Clamp open/close setting....................................................................................................4-9

2.4 Clamping parameters.......................................................................................................... 4-11

2.5 Ejector setting..................................................................................................................... 4-13

2.6 Ejector parameter................................................................................................................ 4-15

2.7 Corepull setting................................................................................................................... 4-17

2.8 Corepull parameters............................................................................................................ 4-19

2.9 Injection setting .................................................................................................................. 4-20

2.10 Injection parameters........................................................................................................... 4-22

2.11Injection closed loop control .............................................................................................. 4-24

2.12 Charge/Carriage setting..................................................................................................... 4-26

2.13 Charge/Carriage parameters .............................................................................................. 4-28

2.14 Temperature setting........................................................................................................... 4-30

2.15 Temperature parameters .................................................................................................... 4-31

2.16 Molding data store…….………………………………………………………………... 4-33

2.17 SPC data …………………………………………………………………………………. 4-34

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2.18 Function setting/pressure testing ....................................................................................... 4-36

2.19 Production management .................................................................................................... 4-38

2.20 Automatic mold adjustment............................................................................................... 4-39

2.21 Automatic purge function.................................................................................................. 4-41

2.22 External I/O monitor.......................................................................................................... 4-42

2.23 Charge record..................................................................................................................... 4-46

2.24 Alarm record...................................................................................................................... 4-47

2.25 Maintenance check point................................................................................................... 4-48

2.26 Molding support................................................................................................................. 4-50

2.27 System self diagnostic function......................................................................................... 4-51

2.28 Internal IO monitor............................................................................................................ 4-52

2.29 T/C setting ......................................................................................................................... 4-53

2.30 Screen print........................................................................................................................ 4-54

3. Machine operation procedures ................................................................................................... 4-55

4. Start up…..……………………………………………………………………….…………... 4-55

4.1 Manual operation................................................................................................................ 4-55

4.2 Semi-automatic operation................................................................................................... 4-56

4.3 Fully automatic operation................................................................................................... 4-57

4.4 Emergency stop .................................................................................................................. 4-57

4.5 Alarm clearance.................................................................................................................. 4-57

4.6 Re-start after safety interlock devices were tripped ........................................................... 4-58

5. Molding operation…………………………………………………………………………….. 4-58

5.1 Preparation before molding operation ................................................................................. 4-58

5.2 Check before molding operation ......................................................................................... 4-58

5.3 Molding condition setting.................................................................................................... 4-59

5.4 Start molding ....................................................................................................................... 4-60

5.5 Change material or color change......................................................................................... 4-60

5.6 Store/read molding condition by memory card................................................................... 4-60

6. Machine shutdown procedures 4-61

Chapter 5: Trouble shooting

1. Mechanical unit……………………………………………………………………………….. 5-1

1.1 Motor can not be started...................................................................................................... 5-1

1.2 No clamp close.................................................................................................................... 5-1

1.3 No clamp open .................................................................................................................... 5-2

1.4 No ejector advance.............................................................................................................. 5-2

1.5 No ejector retract................................................................................................................. 5-2

1.6 No injection......................................................................................................................... 5-3

1.7 No suck back....................................................................................................................... 5-3

1.8 No charge............................................................................................................................ 5-4

1.9 No carriage advance and backward..................................................................................... 5-4

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1.10 No mold adjustment........................................................................................................... 5-5

1.11 No automatic clamping force............................................................................................. 5-5

1.12 Core failure......................................................................................................................... 5-6

1.13 Temperature control abnormal........................................................................................... 5-6

2. Electric unit…………………………………………………………………………………… 5-7

2.1 Warning screen description................................................................................................. 5-7

2.2 Warning content and maintenance message indication ...................................................... 5-8

2.3 System message and description......................................................................................... 5-14

3. Hydraulic unit…………………………………………………………………………………. 5-15

Chapter 6: Maintenance

1. Safety device inspection………………………………………………………………………. 6-1

1.1 Electric safety...................................................................................................................... 6-1

1.2 Hydraulic safety .................................................................................................................. 6-1

1.3 Mechanical safety................................................................................................................ 6-1

2. Periodic inspection…………………………………………………………………………….. 6-2

2.1 Daily inspection items......................................................................................................... 6-2

2.2 Monthly inspection items....................................................................................................6-2

2.3 Halt-year inspection items................................................................................................... 6-2

2.4 Maintenance and check chart.............................................................................................. 6-3

3. Cleaning……………………………………………………………………………………….. 6-5

3.1 Screw removal/installation and cleaning ............................................................................ 6-5

3.2 Barrel removal/installation and cleaning ............................................................................ 6-6

3.3 Cooler removal/installation and cleaning............................................................................ 6-7

3.4 Hopper window glass replacement ..................................................................................... 6-7

3.5 Filter removal/installation and cleaning.............................................................................. 6-7

3.6 Water distributor removal/installation and cleaning........................................................... 6-8

4. Lubrication…………………………………………………………………………………….. 6-9

4.1 Toggle system lubrication.................................................................................................... 6-9

4.2 Grease lubrication ................................................................................................................ 6-10

4.3 Lubrication points and timing…………………………………………………………….. 6-11

4.4 Lubrication for die height adjustment gear……………………………………………….. 6-12

5. Spare parts…………………………………………………………………………………….. 6-13

Chapter 7: Adjustments

1. Mechanism adjustments……………………………………………………………………... 7-1

1.1 Adjustment of carriage center height.................................................................................. 7-1

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1.2 Adjustment of moving platen shoes.................................................................................... 7-2

2. System adjustments.................................................................................................................... 7-3

2.1 Adjustment of transducer…………………………………………………………………. 7-3

2.2 Adjustment of proportional valve………………………………………………………… 7-5

2.3 Adjustment of motor overload protector…………………………………………………. 7-6

Appendix A

1 Hydraulic sequence ………………………………………………………… A-1

2 How to re-open clamp when it locked …………………………………………………. A-17

Appendix B

Notes on motion/no motion…………………. ……………………………………………… B-1

Appendix C: Robot Connection………………………………………………………………….. C-0

Appendix D: USB file operation…………………………………………..…………………….. D-0

Chapter 8：Drawings

1. Description of major component parts and their positions installed on the machine

1.1 View from operational side

1.2 View from rear operation side

2. Appearance dimension drawing

3. Screw/Barrel unit assembling drawing

4. Hydraulic circuit drawing

5. Hydraulic manifold drawing

5.1 Injection manifold

5.2 Clamp manifold

5.3 Ejector manifold

6. Oil pipes layout drawing

7. Electrical wiring diagram

8. Control box layout drawing

InjectionMoldingMachine Chapter1

1-0 V3.0

Chapter 1：Safety

1. Operator safety protection………..…... 1-1

1.1 Electrical device .............................. 1-2

1.2 Hydraulic safety device ................... 1-2

1.3 Mechanical safety device................ 1-3

2. Safe operation of machine………….. 1-4

2.1 Operation environment.................... 1-4

2.2 Disposal of scrap products or waste 1-4

2.3 Clamping unit .................................. 1-4

2.4 Injection unit.................................... 1-4

2.5 Hydraulic unit .................................. 1-5

2.6 Electrical unit................................... 1-5

3. Safety labels and alarm devices……… 1-6

3.1 Definition of labels........................... 1-6

3.2 Adhering position............................. 1-6

3.3 Alarm light and buzzer..................... 1-8

3.4 Escape when trapped in machine ... 1-8

4. Machine maintenance warranty.......... 1-8

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Chapter 1：Safety

This machine has equipped with mechanical，hydraulic and electrical triple safety devices，

however，only qualified personnel by the user company can operate this machine, the user

company must have the operators to read and execute all safety rules to ensure safety.

Only manufacture or manufacture’s agent qualified technical personnel can perform

maintenance or repair works on the machine, the technical personnel must have sufficient

knowledge regarding all safety precautions and operating elements.

1 Operator safety protection

Daily inspections shall be performed in accordance with the maintenance and checklists

displayed upon the operation of the machine to ensure the safety of the operator and

machine.

V1: 0/ 0 0/ 0V2:

0/ 0P1: 0/ 0 P2:100.0mm

100.0mm110.0mm

1.0mm

ACTION STATUS

02D05M07Y

10h250m10s

20°C3W

DAILY CHECK & MAINTENANCE

F2F1 F3 F4 F5 F6 F7 F8

17 MAINTEN. SUPPORT I/O

MAINT.

LIST

1.PUSH EMERGENCY BUTTON TO CHECK PUMP STOP.

3.CK. SAFETY DROP BAR MOVES SMOOTH.

4.CK. BARREL COVER IS FIXED.

5.CK. LUB. OF MOVING PARETS ARE OK.

10.CK.HYD.& LUB.OIL ARE ENOUGH.(NO RECYCLE OIL)

7.CK. COLD START PROTECT. TIME AND DANGER

8.CK. TEMP. SET OF HYD. OIL & COLLAR ARE OK.

9.CK IF PUMP HAS ANY NOISE.

6.CK. NO PARTS IS LOOSENED OR ABNORMAL.

11.CK. NO HOSE/PIPE IS LOOSENED/LEAKING.

12.CK. NO AIR IS BLENDED INTO HYD. SYSTEM.

13.CK. ALL GROUDINGS ARE CONNECTED OK.

14.CK. MOLD CLAMP ARE TIGHT.

15.CK. MOLD PROTECTION DEVICE IS OK.

2.CK.NO LEAKING IN HYD. SYSTEM.

1.CK.AND CLEAN HYD. FILTER.

3.CK.AND CLEAN OIL COOLER.

4.CK.NO MOVING PARTS ARE LOOSENED.

5.CK.AND CLEAN ELECTRIC CABINET.

6.TIGHT ALL WIRING TERMALS.

8.TEST PRESS. AND SPEED LINEARILITY.

7.CLEAN AND ADJUST ALL

9.CLEAN WASTE OIL.

HALF YEARLY CHECK AND MAINTENANCE

1.CK.PALTEN'S PARALLELISM.

2.CHANGE HYD. SYSTEM OIL.

3.CK.SCREW/BARREL FUNCTION WELL.

4.MACHINE LEVELING ADJUST.

MONTHLY CHECK & MAINTENANCE

LOG MOLD EXTERN

TEMP. SET OK. THERMOCOUPLES.

2.CK. I/O 101,103,109 FUNCTION BY OPEN/CLOSE DOOR.

Screen 1-1

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1.1 Electrical device

1.1.1 Emergency button：Each machine is equipped with two emergency buttons located

respectively on the control panel and rear operation side. Upon emergency，press the

emergency button nearby. When the emergency condition is cleared，rotate emergency

button clockwise to release it.

1.1.2 Safety door switch：Change screen to EXTERNAL I/O screen，open/close all safety

doors and check corresponding I/O status，they must be normally ON/OFF.

Opening the front operation door，I/O 101，I/O 109 must be OFF (highlighting disappears)，

opening rear safety door or other side doors，I/O 103 must be OFF. Close front door to have

I/O 101，I/O109 on，close rear door to have I/O 103 on.

1.1.3 Mold height limit switch：Upon pressing the minimum mold thickness limit switch，or

actuate the proximity switch，I/O 111 must be OFF；upon actuate the maximum mold

thickness switch，I/O 112 must be OFF

1.2 Hydraulic safety device

Inspect hydraulic safety valve V35 on clamping manifold ，when opening the front operation

door，I/O 101，109 must be OFF，and mold close is disabled at the time. For testing，unplug

the electrical plug of V35，and close the operation door then close mold manually，mold close

operation cannot be performed at the time.

Emergency

Button Emergency

Button

V35 Mold-clamping safety

valve

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1.3 Mechanical safety device

A Open/close the front operation door，and check the action of drop bar plate for

smoothness.

B Barrel guard：check barrel cover，injection nozzle guard fixing screws.

Drop bar Barrel cover

Injection nozzle guard

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