10.01.

01 PUMP CALIBRATION MID SIZE MACHINE 390MJ THRU 950MJ

SOL-VF (VOLUME) ADJUSTMENT

WARNING! THIS PROCEDURE SHOULD BE PERFORMED BY QUALIFIED PERSONNEL ONLY. 1. Insure that the barrel heaters are up to the proper temperature for the material in the barrel.

2. Connect AMP1 and VF to the ammeters connectors, J3 and CON D8, equipped inside the electrical control cabinet. 3. Turn OFF the Closed Loop Control. Go to screen 13F Push the upper case letters button, the LED will illuminate. Enter the key word OPTIONDA and press the enter key. Go to address No. 103 INJECTION SPEED CLOSED LOOP CONTROL and enter 00 Go to address No. 112 INJECTION PRESSURE CLOSED LOOP CONTROL and enter 00 Turn the Main Power OFF and then ON. Clear the Low Temp Alarm by turning all the manual switches to the right and the back too neutral with pump off. Activate LS16 (carriage forward) with a coin or piece of metal. The LED on the switch will illuminate. Note: LS15A (carriage back) should not be made. Push the Pump Stop Button. Turn ON the NFB for M1 only (Leave the NFB for M2 OFF) SELECT THE MEASURE MODE (the purpose of this function is to measure 20mm and150mm of stroke): Go to screen 13F and input the Keyword OPSWITCH. Select 4 (measure) in the address Adjustment. Set the data on injection screen 6-a as shown below 1
STEP 1 2 3 4 5 6

4. 5. the 6.

7. 8. 9.

10.

V->P switch

( 1:posn
POSN

2: time
> > > > > >

3:press)
SPEED **.* **.* 20.0 10.0 10.0 10.0 99.00 1.0 slope TP sec 0.00 0.00 0.00 0.00s VI% PRESSURE PH % 99.9 99.9 50.0 10.0 10.0 10.0 VOID TL sec

INJECTION

V->P SWITCH STEP PRESSURE CURE TIM 1 2 3

LI mm 372.0 300.0 ***.* 100.0 20.0 10.0 TIME TA sec POSN LS6 mm PRESS PHL psi time TB sec 0.00 0.00 0.00 TC SEC

PRESSURE 0.0 0.0 0.0

PL %

10.01.02 PUMP CALIBRATION MID SIZE MACHINE 390MJ THRU 950MJ

SOL-VF (VOLUME) ADJUSTMENT

12. Adjust the SPAN and NULL of the AMP1 Amplifier, for the correct machine size, according to the following table (A) and the Injection time displayed in Screen 6A TABLE (A) SET THE DESIGNATED DATA IN THE VI1 AND VI2. SET 280.0 IN LI3 WHEN YOU ADJUST NULL AND SET 150.0 IN LI3 WHEN YOU ADJUST SPAN. Adjust the null and span of AMP1 as shown in the table below. Repeat this procedure a couple of times.
NULL/SPAN SET POINT AMP/VOLUME INJECTION UNIT 390MJ-40 -60 -40 500MJ-60 -80 -60 610MJ-80 -110 -80 720MJ-110 -160 -110 950MJ-160 -240 -160 1200MJ-240 -340 MEASURING POINT NULL (20mm) AMP1/VR 5 RANGE OF AMPERAGE INJ. TIME mA SEC < REFER. > 3.20-3.27 4.08-4.16 2.76-2.82 3.52-3.59 4.60-4.69 2.61-2.66 3.41-3.48 4.35-4.43 2.51-2.56 3.19-3.25 4.33-4.41 2.63-2.68 3.56-3.63 4.63-4.72 3.56-3.63 4.63-4.72 6.44-6.57 SCREEN 6-A 250 250 260 260 260 270 270 270 275 275 275 290 290 290 290 290 290 NO. 1 SPAN L13=150.0 SET DATA VI1 & VI2 % 99.9 99.9 99.9 99.9 99.9 63.0 63.0 63.0 46.0 46.0 46.0 43.0 43.0 43.0 43.0 43.0 43.0 (150mm) AMP1/VR4 RANGE OF AMPERAGE INJ. TIME mA SEC < REFER. > 1.18-1.21 1.50-1.55 1.02-1.05 1.30-1.33 1.69-1.74 1.52-1.57 1.99-2.05 2.54-2.61 2.00-2.06 2.55-2.63 3.46-3.56 2.25-2.31 3.05-3.14 3.96-4.07 3.05-3.14 3.96-4.07 5.50-5.67 SCREEN -6-A 670 670 780 780 780 650 650 650 650 650 650 780 780 780 780 780 780 NO. 1

LI3-280.0 SET DATA V11 & V12 % 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5

NOTE: *610 MJ*: There are some 610 MJ machines in the US that have the Screw rotation speed up option J608AAA001, J608AAA002, J608AAA003, J608AAA004, J608AAA005. These machines have larger Ppumps and special software.

10.01.03 PUMP CALIBRATION MID SIZE MACHINE 390MJ THRU 950MJ

SOL-VF (VOLUME) ADJUSTMENT

13. CHECK OF MAXIMUM INJECTION SPEED USING PUMP M2: Turn OFF Pumps Turn ON NFB for the M2 motor. Set Injection Speed for 99.9 % at VI1 and VI2. Push Pump Start button Check the actual injection time displayed on screen 6A. It should be between the lower and upper values as in the table below.
SET POINT MACHINE MODEL LI3=150.0 DISTANCE OF LI2-LI3=150MM SET DATA RANGE OF V11 & V12 INJ. TIME % SEC

AMPERAGE mA < REFER. >

390MJ-40 -60 -40 500MJ-60 -80 -60 610MJ-80 -110 -80 720MJ-110 -160 -110 950MJ-160 -240 -160 1200MJ-240 -340

99.9 99.9 99.9 99.9 99.9 99.9 99.9 99.9 99.9 99.9 99.9 99.9

0.94-0.98 1.22-1.29 1.56-1.64 0.90-0.94 1.14-1.20 1.55-1.62 0.94-0.99 1.27-1.34 1.66-1.74 1.27-1.34 1.66-1.74 2.30-2.42

14.

Reset the Measure Mode Go to Screen 13F and input the key word OPSWITCH. Enter 0 (normal) in the adjustment address. Turn ON the Closed Loop Control Go to screen 13F Push the upper case letters button, the LED will illuminate. Enter the key word OPTIONDA and press the enter key. Go to address No. 103 INJECTION SPEED CLOSED LOOP CONTROL and enter FF Go to address No. 112 INJECTION PRESSURE CLOSED LOOP CONTROL and enter FF

15.

10.01.04 PUMP CALIBRATION MID SIZE MACHINE 390MJ THRU 950MJ

SOL-VP (PRESSURE) ADJUSTMENT

1. 2. 3. Insure that the barrel heaters are up to the proper temperature for the material in the barrel. Connect AMP1 to the ammeters equipped inside the electrical control cabinet. Confirm the Actual Injection Pressure displayed in Screen 6A is 0 with the Pump OFF. If the displayed value is not 0 adjust the Pressure Sensor Amplifier. Turn OFF the Closed Loop Control. Go to screen 13F Push the upper case letters button, the LED will illuminate. Enter the key word OPTIONDA and press the enter key. Go to address No. 103 INJECTION SPEED CLOSED LOOP CONTROL and enter 00 Go to address No. 112 INJECTION PRESSURE CLOSED LOOP CONTROL and enter 00 Turn the Main Power OFF and then ON. Clear the Low Temp Alarm by turning all the manual switches to the right and the back too neutral with pump off. Activate LS16 with a coin or piece of metal. The LED on the switch will illuminate. Note: LS15A should not be made. In the Injection Screen 6A at the address V-> P switch enter a 1 for (position). At the address for time TA sec, enter 0.0. At the address for posn LS6 mm, enter 1.0 mm. At the addresses for injection speed VI1 ~ VI6 enter 20%. Adjust the SPAN and NULL of the AMP1 AMPLIFIER using the table below for the correct injection unit size, during the Injection Holding phase. NOTE: The milliamp readings are approximate use the actual hydraulic pressure reading.
NULL/SPAN Amp & Volume No. Hold Pressure set

4.

5. 6. the 7.

8.

9.

Injection Pressure
display (psi)
40 HD 60 HD 80 HD 110 HD 160 HD 240 HD 5150 70 5150 70 5150 70 5180 70 5160 70 5130 70

NULL VR10 ON AMP1 PL3 = 20% Hydraulic Pressure kg/cm psi

34 34 34 34 34 34 483 483 483 483 483 483

Amperage (mA)
100 100 100 100 100 100

Injection Pressure
display (psi)
25740 + 250 25740 + 250 25740 + 250 25880 + 250 25810 + 250 25670 + 250

SPAN VR9 ON AMP1 PL3 = 99.9% Hydraulic Pressure kg/cm psi

170 170 170 170 170 170 2417 2417 2417 2417 2417 2417

Amperage (mA)
600 600 600 600 600 600

10. 11.

Adjust the CRT readout with the Span and Null on the MIU / DIU board. Turn ON the Closed Loop Control Go to screen 13F Push the upper case letters button, the LED will illuminate. Enter the key word OPTIONDA and press the enter key. Go to address No. 103 INJECTION SPEED CLOSED LOOP CONTROL and enter FF Go to address No. 112 INJECTION PRESSURE CLOSED LOOP CONTROL and enter FF

10.01.05 PUMP CALIBRATION MID SIZE MACHINE 390MJ THRU 950MJ

SOL-SP (BACK PRESSURE) ADJUSTMENT

1. 2. 3. Insure that the barrel heaters are up to the proper temperature for the material in the barrel. Connect AMP2 to the ammeters equipped inside the electrical control cabinet. Confirm that the Actual Injection Pressure display, in screen 6A, reads 0 with the Pumps turned OFF. If the displayed value is not 0 adjust the Pressure Sensor Amplifier. Move the screw completely forward. Disconnect Y362 (SOL-SR) (Screw Rotate) from the terminal in the lower control cabinet and isolate it electrical tape. Jumper between Y356 (SOL-IF) and DOS. Turn the manual selector switch for Screw Rotate to run and adjust the SPAN and NULL of the AMP2 AMPLIFIER for the proper Injection unit size according to the table below. NOTE: When you change the Back Pressure set up value, you have to return the manual switch for rotate to the neutral position and back again to realize the change. Input the values for screw rotate according to the table below. The screw should not rotate for this check. DO NOT readjust the Span and Null of the MIU / DIU to calibrate the CRT. This is done when calibrating VP.
NULL / SPAN Amp & Volume No. Back Pressure Setting Injection Unit Size Screw Speed Setting % INJECTION PRESSURE (PSI)

4. 5. with 6. 7.

screw

NULL VR5 on AMP2 BPB1 ~ BPB3 = 5%

HYDRAULIC PRESSURE kg/cm (PSI) AMPERAGE (mA) INJECTION PRESSURE (PSI)

SPAN VR4 on AMP2 BPB1 ~ BPB3 = 99%

HYDRAULIC PRESSURE kg/cm (PSI) AMPERAGE (mA)

40 HD 60 HD 80 HD 110 HD 160 HD 240 HD

5.0 4.0 3.0 3.0 2.0 2.0

249 20 249 20 249 20 249 20 249 20 249 20 8.

1.6 1.6 1.6 1.6 1.6 1.6

23 23 23 23 23 23

130 130 130 130 130 130

4980 + 50 4980 + 50 4980 + 50 4980 + 50 4980 + 50 4980 + 50

33 33 33 33 33 33

469 469 469 469 469 469

675 675 675 675 675 675

Remove the jumper between Y356 and DOS and connect Y362 as before.

10.01.06 PUMP CALIBRATION MID SIZE MACHINE 390MJ THRU 950MJ

SOL-CP (CLAMP PRESSURE) ADJUSTMENT

1. PROPORTIONAL RELIEF VALVE CP CLAMP PRESSURE CONTROL VALVE a) Install a pressure gauge in CP-1. a) Adjust the SPAN and NULL of AMP2 as shown below on clamp pressure. Set "clamp force % and check the display "clamp force ton" on the screen 4- A. Adjustment should be repeated a few times. NOTE: When you change the clamp pressure setting value,, you have to turn off the clamp switch, then turn it back on again to see a new reading. Remember you should adjust the SPAN first and then the NULL. NULL / SPAN SET POINT AMP / POT CLAMP 390MJ 500MJ 610MJ 720MJ 950MJ 1200MJ ALLOWANCE TEST POINT NULL CLAMP FORCE = 50% AMP2/VR10 HYD. CLAMP AMPERAGE PRESSURE FORCE ma PSI US ton < REFER. > 1152 193 440 1152 248 440 1152 303 440 1152 358 445 1152 468 445 1152 579 445 14 2 CP-1 SCREEN 4-A NO.2 AMPMETER SPAN CLAMP FORCE = 99.9% AMP2/VR9 HYD. CLAMP PRESSURE FORCE PSI PSI 2304 386 2304 496 2304 606 2304 716 2304 937 2304 1157 28 + 2% -0 -1% CP-1 SCREEN 4-A

AMPERAGE ma < REFER. > 795 795 795 805 805 805 805 NO.2 AMPMETER