10-1 pump calibration 390mj ~ 950mj.pdf

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” 4. Turn the Main Power OFF and then ON. 5. Clear the “Low Temp Alarm” by turning all the manual switches to the right and the back too neutral with the pump off. 6. 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. 7. Push the Pump Stop Button. 8. Turn ON the NFB for M1 only (Leave the NFB for M2 OFF) 9. 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”. 10. Set the data on injection screen 6-a as shown below

V->P switch 1 ( 1:posn 2: time 3:press)

STEP POSN L I mm SPEED V I % PRESSURE PH % 1 372.0 > **.* 99.9 2 300.0 > **.* 99.9

INJECTION 3 ***.* > 20.0 50.0 4 100.0 > 10.0 10.0 5 20.0 > 10.0 10.0 6 10.0 > 10.0 10.0

TIME TA sec 99.00 VOID TL sec V->P SWITCH POSN LS6 mm 1.0

PRESS PHL psi STEP time TB sec slope TP sec PRESSURE PL %

1 0.00 0.00 0.0 PRESSURE 2 0.00 0.00 0.0

3 0.00 0.00 0.0 CURE TIM TC SEC 0.00s


390MJ THRU 950MJ


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 NULL SPAN SET POINT LI3-280.0 (20mm) L13=150.0 (150mm)

AMP/VOLUME AMP1/VR 5 AMP1/VR4 INJECTION

UNIT SET DATA V11 & V12

%

RANGE OF INJ. TIME

SEC

AMPERAGE mA

< REFER. >

SET DATA VI1 & VI2

%

RANGE OF INJ. TIME

SEC

AMPERAGE mA < REFER. >

390MJ-40 5 3.20-3.27 250 99.9 1.18-1.21 670 -60 5 4.08-4.16 250 99.9 1.50-1.55 670 -40 5 2.76-2.82 260 99.9 1.02-1.05 780

500MJ-60 5 3.52-3.59 260 99.9 1.30-1.33 780 -80 5 4.60-4.69 260 99.9 1.69-1.74 780 -60 5 2.61-2.66 270 63.0 1.52-1.57 650

610MJ-80 5 3.41-3.48 270 63.0 1.99-2.05 650 -110 5 4.35-4.43 270 63.0 2.54-2.61 650

-80 5 2.51-2.56 275 46.0 2.00-2.06 650 720MJ-110 5 3.19-3.25 275 46.0 2.55-2.63 650

-160 5 4.33-4.41 275 46.0 3.46-3.56 650 -110 5 2.63-2.68 290 43.0 2.25-2.31 780

950MJ-160 5 3.56-3.63 290 43.0 3.05-3.14 780 -240 5 4.63-4.72 290 43.0 3.96-4.07 780 -160 5 3.56-3.63 290 43.0 3.05-3.14 780

1200MJ-240 5 4.63-4.72 290 43.0 3.96-4.07 780 -340 5 6.44-6.57 290 43.0 5.50-5.67 780

MEASURING SCREEN NO. 1 SCREEN NO. 1 POINT 6-A -6-A

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 “P-2” pumps and special software.


390MJ THRU 950MJ


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 LI3=150.0 DISTANCE OF LI2-LI3=150MM

MACHINE MODEL

SET DATA V11 & V12

%

RANGE OF INJ. TIME

SEC

AMPERAGE mA < REFER. >

390MJ-40 -60 -40

500MJ-60 -80 -60 99.9 0.94-0.98

610MJ-80 99.9 1.22-1.29 -110 99.9 1.56-1.64

-80 99.9 0.90-0.94 720MJ-110 99.9 1.14-1.20

-160 99.9 1.55-1.62 -110 99.9 0.94-0.99

950MJ-160 99.9 1.27-1.34 -240 99.9 1.66-1.74 -160 99.9 1.27-1.34

1200MJ-240 99.9 1.66-1.74 -340 99.9 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. 15. 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”


390MJ THRU 950MJ

SOL-VP (PRESSURE) ADJUSTMENT

1. Insure that the barrel heaters are up to the proper temperature for the material in the barrel. 2. Connect AMP1 to the ammeters equipped inside the electrical control cabinet. 3. 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. 4. 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” 5. Turn the Main Power OFF and then ON. 6. Clear the “Low Temp Alarm” by turning all the manual switches to the right and the back too neutral with the pump off. 7. Activate LS16 with a coin or piece of metal. The LED on the switch will illuminate. Note: LS15A should not be made. 8. 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%. 9. 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 NULL SPAN Amp & Volume No. VR10 ON AMP1 VR9 ON AMP1 Hold Pressure set PL3 = 20% PL3 = 99.9%

Injection Hydraulic Amperage Injection Hydraulic Amperage Pressure Pressure (mA) Pressure Pressure (mA) display (psi) kg/cm² psi display (psi) kg/cm² psi

40 HD 5150 ± 70 34 483 100 25740 + 250 170 2417 600 60 HD 5150 ± 70 34 483 100 25740 + 250 170 2417 600 80 HD 5150 ± 70 34 483 100 25740 + 250 170 2417 600 110 HD 5180 ± 70 34 483 100 25880 + 250 170 2417 600 160 HD 5160 ± 70 34 483 100 25810 + 250 170 2417 600 240 HD 5130 ± 70 34 483 100 25670 + 250 170 2417 600

10. Adjust the CRT readout with the Span and Null on the MIU / DIU board. 11. 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”


390MJ THRU 950MJ

SOL-SP (BACK PRESSURE) ADJUSTMENT

1. Insure that the barrel heaters are up to the proper temperature for the material in the barrel. 2. Connect AMP2 to the ammeters equipped inside the electrical control cabinet. 3. 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. 4. Move the screw completely forward. 5. Disconnect Y362 (SOL-SR) (Screw Rotate) from the terminal in the lower control cabinet and isolate it with electrical tape. 6. Jumper between Y356 (SOL-IF) and DOS. 7. 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 screw 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 NULL SPAN Amp & Volume No. VR5 on AMP2 VR4 on AMP2

Back Pressure Setting BPB1 ~ BPB3 = 5% BPB1 ~ BPB3 = 99% Injection Screw Speed INJECTION HYDRAULIC AMPERAGE INJECTION HYDRAULIC AMPERAGE

Unit Setting PRESSURE PRESSURE (mA) PRESSURE PRESSURE (mA) Size % (PSI) kg/cm² (PSI) (PSI) kg/cm² (PSI)

40 HD 5.0 249 ± 20 1.6 23 130 4980 + 50 33 469 675 60 HD 4.0 249 ± 20 1.6 23 130 4980 + 50 33 469 675 80 HD 3.0 249 ± 20 1.6 23 130 4980 + 50 33 469 675 110 HD 3.0 249 ± 20 1.6 23 130 4980 + 50 33 469 675 160 HD 2.0 249 ± 20 1.6 23 130 4980 + 50 33 469 675 240 HD 2.0 249 ± 20 1.6 23 130 4980 + 50 33 469 675

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


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 NULL SPAN SET POINT CLAMP FORCE = 50% CLAMP FORCE = 99.9% AMP / POT AMP2/VR10 AMP2/VR9

CLAMP

HYD. PRESSURE

PSI

CLAMP FORCE US ton

AMPERAGE ma

< REFER. >

HYD. PRESSURE

PSI

CLAMP FORCE

PSI

AMPERAGE ma

< REFER. > 390MJ 1152 193 440 2304 386 795 500MJ 1152 248 440 2304 496 795 610MJ 1152 303 440 2304 606 795 720MJ 1152 358 445 2304 716 805 950MJ 1152 468 445 2304 937 805

1200MJ 1152 579 445 2304 1157 805 ALLOWANCE ±14 ± 2 ±28 + 2% 805

-0 -1% TEST POINT CP-1 SCREEN

4-A NO.2

AMPMETER CP-1 SCREEN

4-A NO.2

AMPMETER

10-1 pump calibration 390mj ~ 950mj.pdf

Documents