SmartMold 9

User Manual

Date: March 31, 2020

V1.0.0

We reserve the right to change the content of this manual without prior notice. The information contained
herein is believed to be accurate as of the date of publication, however, B&R makes no warranty, expressed
or implied, with regards to the products or the documentation contained within this document. B&R shall not
be liable in the event if incidental or consequential damages in connection with or arising from the furnishing,
performance or use of these products. The software names, hardware names and trademarks used in this
document are registered by the respective companies.

Copyright © B&R – Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 1/142
SmartMold 9
User Manual

I Versions
Version Date Comment Edited by
1.0.0 Mar. 31, 2020 First Edition BRChina

Table 1: Versions

II Distribution
Name Company, Department Amount Remarks

Table 2: Distribution

III Safety Notices

Safety notices in this document are organized as follows:

Safety notice Description

Danger! Disregarding the safety regulations and guidelines can be life-threatening.
Warning! Disregarding the safety regulations and guidelines can result in severe injury or heavy damage to mate-
rial.
Caution! Disregarding the safety regulations and guidelines can result in injury or damage to material.
Information: Important information used to prevent errors.
Table 3: Safety notices

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 2/142
SmartMold 9
User Manual

IV Table of Contents
1 Technical terminology................................................................................................ 8

2 Keyboard operation .................................................................................................... 9

2.1 Keyboard layout .................................................................................................................................... 9
2.2 Operating instructions .........................................................................................................................11
2.2.1 Cursor operation ........................................................................................................................................... 11
2.2.2 List operation ................................................................................................................................................ 11
2.2.2.1 Static list .................................................................................................................................................. 11
2.2.2.2 Dynamic list ............................................................................................................................................. 12
2.2.2.3 Treeview list ............................................................................................................................................ 12
2.2.3 Dialog window operation ............................................................................................................................... 13
2.2.4 Input box operation ....................................................................................................................................... 13
2.2.4.1 Numeric input .......................................................................................................................................... 13
2.2.4.2 Text input ................................................................................................................................................ 13
2.2.5 Button operation ............................................................................................................................................ 15
2.2.5.1 Execute button ........................................................................................................................................ 15
2.2.5.2 Browse button ......................................................................................................................................... 15
2.2.6 Select box operation ..................................................................................................................................... 15
2.2.6.1 Check box ............................................................................................................................................... 15
2.2.7 Color palette operation .................................................................................................................................. 16
2.2.8 Save the current screen ................................................................................................................................ 16
2.2.9 Back to previous page................................................................................................................................... 17
2.2.10 Save error report ......................................................................................................................................... 17
2.2.11 Online help .................................................................................................................................................. 17

3 Page description ....................................................................................................... 19

3.1 Machine status ....................................................................................................................................19
3.1.1 Global page................................................................................................................................................... 19
3.1.2 Local Page .................................................................................................................................................... 21
3.1.2.1 Basic introduction .................................................................................................................................... 21
3.1.2.2 Hidden button .......................................................................................................................................... 22
3.2 Mold open and close page ..................................................................................................................23
3.2.1 Mold Close Page ........................................................................................................................................... 23
3.2.1.1 Basic introduction .................................................................................................................................... 23
3.2.1.2 Hidden button .......................................................................................................................................... 25
3.2.2 Mold Open .................................................................................................................................................... 25
3.2.2.1 Basic introduction .................................................................................................................................... 25
3.2.2.2 Hidden button .......................................................................................................................................... 26
3.2.3 Mold Height ................................................................................................................................................... 27
3.2.3.1 Basic introduction .................................................................................................................................... 27
3.2.3.2 Hidden button .......................................................................................................................................... 28
3.2.4 Core .............................................................................................................................................................. 29
3.2.4.1 Basic introduction .................................................................................................................................... 29
3.2.4.2 Hidden button .......................................................................................................................................... 31
3.2.5 Mold Close Fast ............................................................................................................................................ 32
3.2.5.1 Basic introduction .................................................................................................................................... 32
3.2.5.2 Hidden button .......................................................................................................................................... 33
3.2.5.3 Basic introduction .................................................................................................................................... 33
3.2.5.4 Hidden Button ......................................................................................................................................... 34
3.3 Injection ...............................................................................................................................................34
3.3.1 Injection......................................................................................................................................................... 35
3.3.1.1 Basic introduction .................................................................................................................................... 35
3.3.1.2 Hidden button .......................................................................................................................................... 36
3.3.2 Switchover .................................................................................................................................................... 37
3.3.2.1 Basic introduction .................................................................................................................................... 37
3.3.2.2 Hidden button .......................................................................................................................................... 38
3.3.3 Plastification .................................................................................................................................................. 39

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 3/142
SmartMold 9
User Manual

3.3.3.1 Basic introduction .................................................................................................................................... 39

3.3.3.2 Hidden butto ............................................................................................................................................ 40
3.3.4 Injection Unit ................................................................................................................................................. 41
3.3.4.1 Basic introduction .................................................................................................................................... 41
3.3.4.2 Hidden button .......................................................................................................................................... 42
3.3.5 Purge ............................................................................................................................................................ 43
3.3.5.1 Basic introduction .................................................................................................................................... 43
3.3.5.2 Hidden button .......................................................................................................................................... 44
3.3.6 Intrusion ........................................................................................................................................................ 44
3.3.6.1 Basic introduction .................................................................................................................................... 44
3.3.6.2 Hidden button .......................................................................................................................................... 45
3.3.7 Injection Unit Rotate ...................................................................................................................................... 45
3.3.7.1 Basic introduction .................................................................................................................................... 45
3.3.7.2 Hidden button .......................................................................................................................................... 46
3.4 Ejector .................................................................................................................................................47
3.4.1 Ejector ........................................................................................................................................................... 47
3.4.1.1 Basic introduction .................................................................................................................................... 47
3.4.1.2 Hidden button .......................................................................................................................................... 49
3.4.2 Air Blows ....................................................................................................................................................... 50
3.4.2.1 Basic introduction .................................................................................................................................... 50
3.4.2.2 Hidden button .......................................................................................................................................... 51
3.5 Heating ................................................................................................................................................51
3.5.1 Cylinder temperature..................................................................................................................................... 51
3.5.1.1 Basic introduction .................................................................................................................................... 51
3.5.1.2 Hidden button .......................................................................................................................................... 53
3.5.2 Cylinder Temperature Calendar .................................................................................................................... 54
3.5.2.1 Basic introduction .................................................................................................................................... 54
3.5.2.2 Hidden button .......................................................................................................................................... 55
3.5.3 Cylinder Temperature Trend ......................................................................................................................... 55
3.5.3.1 Basic introduction .................................................................................................................................... 55
3.5.3.2 Hidden button .......................................................................................................................................... 56
3.5.4 Mold Heating 1 .............................................................................................................................................. 57
3.5.4.1 Basic introduction .................................................................................................................................... 57
3.5.4.2 Hidden button .......................................................................................................................................... 58
3.5.5 Mold Temp. Trend 1 ...................................................................................................................................... 58
3.5.6 Mold Heating 2 .............................................................................................................................................. 58
3.5.7 Mold Temp. Trend 2 ...................................................................................................................................... 59
3.5.8 Mold Autotuning ............................................................................................................................................ 59
3.5.8.1 Basic introduction .................................................................................................................................... 59
3.5.8.2 Hidden button .......................................................................................................................................... 60
3.6 Oil, Lubrictin ........................................................................................................................................60
3.6.1 Basic introduction .......................................................................................................................................... 61
3.6.2 Hidden button................................................................................................................................................ 61
3.7 Delay Times ........................................................................................................................................62
3.7.1 Delay Times (1)............................................................................................................................................. 62
3.7.1.1 Basic introduction .................................................................................................................................... 62
3.7.1.2 Hidden button .......................................................................................................................................... 63
3.7.2 Delay Times (2) ............................................................................................................................................. 64
3.7.2.1 Basic introduction .................................................................................................................................... 64
3.7.2.2 Hidden button .......................................................................................................................................... 65
3.8 User Management ..............................................................................................................................65
3.8.1 Basic introduction .......................................................................................................................................... 66
3.8.2 Hidden button................................................................................................................................................ 68
3.9 Recipe .................................................................................................................................................69
3.9.1 Basic introduction .......................................................................................................................................... 69
3.9.2 Hidden button................................................................................................................................................ 70
3.10 Production .........................................................................................................................................71
3.10.1 Production (1) ............................................................................................................................................. 71
3.10.1.1 Basic introduction .................................................................................................................................. 71
3.10.1.2 Hidden button. ....................................................................................................................................... 72
3.10.2 Production (2) ............................................................................................................................................. 73
3.10.2.1 Basic introduction .................................................................................................................................. 73

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 4/142
SmartMold 9
User Manual

3.10.2.2 Hidden button ........................................................................................................................................ 74

3.10.3 SPC Setup .................................................................................................................................................. 75
3.10.3.1 Basic introduction .................................................................................................................................. 75
3.10.3.2 Hidden button ........................................................................................................................................ 77
3.10.4 SPC Buffer .................................................................................................................................................. 78
3.10.4.1 Basic introduction .................................................................................................................................. 78
3.10.4.2 Hidden button ........................................................................................................................................ 79
3.10.5 SPC Graphics ............................................................................................................................................. 80
3.10.5.1 Basic introduction .................................................................................................................................. 80
3.10.5.2 Hidden button ........................................................................................................................................ 81
3.11 IO Status ...........................................................................................................................................82
3.11.1 IO Browser .................................................................................................................................................. 82
3.11.1.1 Basic introduction .................................................................................................................................. 82
3.11.1.2 Hidden button ........................................................................................................................................ 85
3.11.2 Monitor ........................................................................................................................................................ 86
3.11.2.1 Basic introduction .................................................................................................................................. 86
3.11.2.1.1 Hidden button ..................................................................................................................................... 87
3.12 Alarms ...............................................................................................................................................87
3.12.1 Alarms ......................................................................................................................................................... 87
3.12.1.1 Basic introduction .................................................................................................................................. 88
3.12.1.2 Hidden button ........................................................................................................................................ 88
3.12.2 Alarm History .............................................................................................................................................. 88
3.12.3 Basic introduction ........................................................................................................................................ 88
3.12.3.1 Hidden button ........................................................................................................................................ 89
3.13 Audit Trail ..........................................................................................................................................90
3.13.1 Audit Trail .................................................................................................................................................... 90
3.13.1.1 Basic introduction .................................................................................................................................. 90
3.13.1.2 Hidden button ........................................................................................................................................ 91
3.13.2 Trace Graphics ........................................................................................................................................... 92
3.13.2.1 Basic introduction .................................................................................................................................. 92
3.13.2.2 Hidden button ........................................................................................................................................ 93
3.14 User log .............................................................................................................................................94
3.14.1 Basic introduction ........................................................................................................................................ 94
3.14.2 Hidden button .............................................................................................................................................. 94
3.15 Settings .............................................................................................................................................95
3.15.1 Basic introduction ........................................................................................................................................ 95
3.15.2 Hidden button .............................................................................................................................................. 96
3.16 Automatic Sequence .........................................................................................................................97
3.16.1 Automatic Sequence ................................................................................................................................... 97
3.16.1.1 Basic introduction .................................................................................................................................. 97
3.16.1.2 Hidden button ........................................................................................................................................ 98
3.16.2 Sequence Editor ......................................................................................................................................... 98
3.16.2.1 Basic introduction .................................................................................................................................. 98
3.16.2.2 Hidden button ........................................................................................................................................ 99
3.17 Free Prog. Inputs ............................................................................................................................101
3.17.1 Free Prog. Inputs ...................................................................................................................................... 101
3.17.1.1 Basic introduction ................................................................................................................................ 101
3.17.1.2 Hidden button ...................................................................................................................................... 102
3.17.2 Free Prog. Outputs.................................................................................................................................... 103
3.17.2.1 Basic introduction ................................................................................................................................ 103

4 Machine Operation ................................................................................................. 109

4.1 Motor Startup ....................................................................................................................................109
4.2 Startup Heating .................................................................................................................................109
4.3 Mode Selection .................................................................................................................................109
4.4 Machine Movement ...........................................................................................................................110
4.4.1 Mold movement .......................................................................................................................................... 110
4.4.2 Core movement .......................................................................................................................................... 111
4.4.3 Injection unit movement .............................................................................................................................. 112
4.4.4 Screw movement ........................................................................................................................................ 113
4.4.5 Ejector movement ....................................................................................................................................... 114

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 5/142
SmartMold 9
User Manual

4.4.6 Airblow ........................................................................................................................................................ 115

4.4.7 Mold Height ................................................................................................................................................. 116

5 IO Datapoints .......................................................................................................... 117

5.1 Digital Input .......................................................................................................................................117
5.2 Digital Output ....................................................................................................................................118
5.3 Analog Input ......................................................................................................................................119
5.4 Analog Output ...................................................................................................................................120
5.5 Temperature Input ............................................................................................................................120
5.6 PWM Output......................................................................................................................................120

6 Alarms ..................................................................................................................... 121

6.1 Alarms1_20 .......................................................................................................................................121
6.2 Alarms21_40 .....................................................................................................................................125
6.3 Alarms41_59 .....................................................................................................................................129
6.4 Alarms60_79 .....................................................................................................................................133
6.5 Alarms80_99 .....................................................................................................................................136
6.6 Alarms100_112 .................................................................................................................................140

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 6/142
SmartMold 9
User Manual

This manual is a B&R special injection molding machine control system —— SmartMold 9 user manual. Its content in-
cludes panel operation, screen description, IO point list, alarm analysis and machine operation, etc.

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 7/142
SmartMold 9
User Manual Technical terminology

1 Technical terminology
Plastification:pre-plastic, storage.
Injection:infusion.
Decompression:Prevent, shoot back, loose back.
Core:neutron, core pulling.
Blow:gassing.
Production cycle:Machine clamping  injection unit forward  hydraulic changeover pressure holding  cooling 
plastification  clamp opening  product demolding is a production cycle.

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 8/142
SmartMold 9
User Manual Keyboard operation

2 Keyboard operation

2.1 Keyboard layout

The keyboard can be divided into 6 areas by function, as shown in Figure 2-1.

Figure: 2-1 Keyboard layout

Area A is the function key area, including six keys F1 to F6, which are used for page changing by switching between tabs.
On some pages, they are also used as special function keys. For specific operations, please refer to the description of
the hidden buttons on each screen.
Area B: Keys for changing directly to the main page groups. The description is shown in Table 2-1.

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 9/142
SmartMold 9
User Manual Keyboard operation

Table 2-1: Page groups changing

Machine overview Clamping page Ejector page Plastification page

Temperature page Alarm page Curve tracking Settings page

Area C: Keys for changing the operation mode. The description is shown in Table 2-2.
Table 2-2: Operation mode changing

Semi-automatic
Manual mode Automatic mode Debug mode
mode

Automatic mold
Motor switch Heating switch height adjust- Automatic Purging
ment

Alarm acknow-
Spare button
ledgement
Area D: Manual movement keys. The description is shown in Table 2-3.
Table 2-3 Manual movement keys

Mold Open Mold Close

Select a core
Core In Core Out for manual
movement

Injection Plastification Decompression

Ejector back-
Ejector forward
ward

Increase the Decrease the

mold height mold height
Select an airblow
Airblow for manual acti-
vation
Injection unit Injection unit
forward backward

Area E: Keys for navigating between input fields and selecting input options. The description is shown in Table 2-4.
Table 2-4: Keys for navigating

Cursor up Cursor down Cursor left Cursor right Select key

Area F: Numerical input block and special functions. The specific description is shown in Table 2-5.
Table 2-5: Numerical input and special functions

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 10/142
SmartMold 9
User Manual Keyboard operation

Back to previous Save the current Enter the help

Cursor sequence
page screen system

F1-F6 Function
abc7 def8 ghi9
switch

jkl4 mno5 pqr6 Case switch

stu1 vwx2 yz_3 Backspace

0 . Confirm Cancel

2.2 Operating instructions

2.2.1 Cursor operation

The user can move the focus through the up , down , left and right keys in the E area of the

keyboard, and can also move the focus in a fixed tab order to the next input field through the F8 key in the F area
of the keyboard.

2.2.2 List operation

Lists include static lists, dynamic lists, and treeview lists.

2.2.2.1 Static list

The static list is shown in Figure 2-2, and all its contents are always visible.

Figure 2-2: Static list

To select content from a static list:
1. Move the focus to this static list.

2. Press the Select key in the E area to select an item in the listbox. Note: only one-way cycle selection.

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 11/142
SmartMold 9
User Manual Keyboard operation

3. Press the OK key in the F area or simply move the focus to another input field to confirm the new selection.

Press the Escape key to cancel and discard the new selection.

2.2.2.2 Dynamic list

Dynamic lists have two states: hidden and active. In the hidden state, the list only displays one record. After activation,
the list can display all records, as shown in Figure 2-3.

Figure 2-3: Dynamic list

To select content from a dynamic list:
 Move the focus to this dynamic list.

 Press the Select key in the E area to select an item in the listbox. Note: only one-way cycle selection.

 Press the OK key in the F area or simply move the focus to another input field to confirm the new selection.

Press the Escape key to cancel and discard the new selection.

2.2.2.3 Treeview list

A treeview contains a list of several items, out of which one item can be chosen. The items are not shown as a list, but in
a hierarchical treeview, where branches can be closed or opened to access the items behind.

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 12/142
SmartMold 9
User Manual Keyboard operation

Figure 2-4: Treeview list

To select content from a dynamic list:

 Move the focus to the button right to the current selection and press the OK or Select key to open the
treeview.

 Use the Arrow keys to navigate in the treeview and to open and close branches. Press

the OK key or Select key to confirm the new selection. Press the Escape key to cancel and discard the new
selection.

2.2.3 Dialog window operation

2.2.4 Input box operation

Input box includes numeric input box and text input box

2.2.4.1 Numeric input

Numbers from 0-9, “–“ and “.” can be entered in the Numeric input box.

2.2.4.2 Text input

In the text input box, you can enter numbers from 0-9, letters a-z, A-Z, symbols ‘’_ . ‘’and so on.

Move the focus to an input box. When the icon shown in Figure 2-6 is displayed at the bottom of the screen, it indi-

cates that this is a text input box.

Figure 2-6: Text input sign 1

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 13/142
SmartMold 9
User Manual Keyboard operation

The default input letter of the text input box is lowercase. Press the key in the F area of the keyboard to switch to

uppercase letters. After the switch, the icon shown in Figure 2-7 is displayed at the bottom of the screen. Press the

key again to switch back to lowercase input.

Figure 2-7: Text input sign 2

The text input box uses a circular input method to input text. Taking the input text "bR1" as an example, the specific pro-
cess is as follows:
1. Move the cursor to the text input box.

2. Press the number key 7 in the F area of the keyboard twice in succession and then pause for 1 second.
The text box displays the change shown in Figure 2-8 (a):

Figure 2-8: Text input

3. Press the key in the F area of the keyboard to switch to capital letter input.

4. Press the number key 6 in the F area of the keyboard three times in succession and then pause for 1 se-
cond. The text box displays the change shown in Figure 2-8 (b).

5. Press the number key 1 in the F area of the keyboard four times in succession and then pause for 1 se-
cond. The text box displays the change shown in Figure 2-8 (c).

6. Press the OK key in the F area of the keyboard to confirm the entry or the ESC key to cancel the
entry. You can also complete the confirmation input automatically by moving the cursor to other areas on this page.

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 14/142
SmartMold 9
User Manual Keyboard operation

2.2.5 Button operation

Buttons can be divided into execute buttons and browse buttons. To operate the buttons, just move the cursor to the

corresponding button, and then press the OK key in the F area of the keyboard or the SEL key in the E
area of the keyboard to activate the function.

2.2.5.1 Execute button

There are two types of execution buttons: Toggle type and trigger type, as shown in Table 2-6.
Table 2-6: Execute button
Type Status
Pressed / Activated / Enabled Up/unused
Toggle
type
Trigger
type

After the Toggle type execution button is activated, it remains in the pressed state, that is, the function is always execut-

ing. To stop the activated function, press the OK key in the F area of the keyboard or the SEL key in the E
area of the keyboard again. At the moment the trigger type is activated, there is a state switch, and it finally stays in the
pop-up state. The activated function will automatically stop after execution.

2.2.5.2 Browse button

The browse button is shown in Figure 2-9. After activation, the contents of the treeview list are displayed. For details on
the operation of the treeview list, see 2.2.2 List Operation. After the treeview list is displayed, you can press the ESC key

in the F area of the keyboard to cancel the selection and close the display.

Figure 2-9: Browse button

2.2.6 Select box operation

The selection box can be divided into check box and radio box.

2.2.6.1 Check box

The check boxes are shown in Figure 2-10. Taking holding pressure switchover as an example, the user can select mul-
tiple switching conditions at the same time. To operate the check box, just move the focus to the corresponding box, and

then press the OK button in the F area of the keyboard or the SEL button in the E area of the keyboard to

select the function. Press the OK or SEL button again to cancel the selection.

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 15/142
SmartMold 9
User Manual Keyboard operation

Figure 2-10: Select box

2.2.7 Color palette operation

Move the focus to the desired color and press the OK key , as shown in Figure 2-11.

Use the arrow keys to navigate in the available colors, press the OK key to confirm the

new color and replace the old one with it. Press the Escape key to cancel and discard the new color selection.

Figure 2-11: Color palette

2.2.8 Save the current screen

Press the Save Screen key in the F area of the keyboard to generate a screenshot of the current page on the USB
stick in the format of bmp picture. Before performing this operation, ensure that the USB flash drive is properly connected
to the USB interface, as shown in Figure 2-12.

Figure 2-12: USB interface

During USB stick access an icon is displayed in the bottom bar of every page, as shown in Figure 2-13. When this

state diagram disappears, it proves that the current screen is saved. After saving, users can also view the information
about the last save operation through chapter 3.14 Settings.

Figure 2-13: Save screen status

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 16/142
SmartMold 9
User Manual Keyboard operation

2.2.9 Back to previous page

Press this key to go back one page, similar to the page back functionality of a web browser. The page history
contains 10 pages. For example, during user operation the screen switching sequence is machine status page  clamp-
ing page  mold opening page  injection page. If the current screen displays the injection page, then press the key

once, the system switches to the mold opening page. Press Key again, the system switches to the clamping
page, and so on.

2.2.10 Save error report

Please refer to chapter 3.14 Settings.

2.2.11 Online help

Press the key in the F area of the keyboard under the current page, the system will display the corresponding
online help page, as shown in Figure 2-14. The user can set the process parameters according to the wizard provided in

the online help. Press the key again to leave the help system.

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 17/142
SmartMold 9
User Manual Keyboard operation

Figure 2-14: Online help system

Table 2-7: Online help
No. Description
To display the online help [6] directory, press the F1 key in the A area of the keyboard.
To display the previous page, press the F3 key in the A area of the keyboard.
To display the next page, press the F4 key in the A area of the keyboard.
To display the previous row, press the F5 key in the A area of the keyboard.
To display the next row, press the F6 key in the A area of the keyboard.
Online help contents

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 18/142
SmartMold 9
User Manual Page description

3 Page description

3.1 Machine status

Status page is composed of a global page and a local page. Other pages are also composed of global pages and local
pages.

3.1.1 Global page

The global screen refers to the part of the screen that can be seen on any page. It is distributed on the upper and lower
ends of the entire screen, as shown in Figure 3-1.

Figure 3-1: Global page

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 19/142
SmartMold 9
User Manual Page description

Table 3-1: Global page

No. Description
OEM name
Machine type
Machine current applying recipe
Current login user level
Actual mold position
Actual ejector position
Actual screw position
Actual position of injection unit
Actual screw speed
System flow
System pressure
Injection pressure
Current alarm information
Indicating which core can currently be controlled by the key
Indicating which airblow can currently be controlled by the key
The current letter case of the text input box. When the screen is saved, it is
blocked by the saved screen status.
The current pages F1-F6 have hidden function signs, which can be switched by
the CTRL key of the small keyboard. When the screen is saved, it is blocked by
the saved screen status.
System time
Current page number
Current page name
Subpages contained in the current page group. The currently active page will be
highlighted and the [23] button will display the next page of the currently active
subpage. You can use the F6 key to cycle through the subpages. If there are no
subpages in the current page group, it will be blank here, and it will also be
blank at the [23] button.
Display the page group sign. The current active page group is highlighted. You
can use the F1 to F5 keys to cycle through different page groups.
Display the next page of the currently active subpage. If there are no subpages
in the current page group, it will be blank here.

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 20/142
SmartMold 9
User Manual Page description

3.1.2 Local Page

Figure 3-2: Machine Status

3.1.2.1 Basic introduction

Table 3-2: Animation description
No. Description
Animation of clamping unit. The graphic represents the actual mold position.
When it is completely open, it means the actual mold position is equal or bigger
than the mold open position set in the mold open profile.
Animation of ejector. The end positions that are set in the ejector forward and
backward profiles (not the maximum/minimum position) are considered as the
end positions in this graphic.
Animation of injection unit.
Animation of injection piston and screw rotation speed.
Animation of cores. Only the cores that are activated (this means the movement
code is different to Off) in the core pages are shown. If graphical sequence
programming is enabled, the state of all cores is shown.
State of cylinder heating zones. For details, see Table 3-3 below.
Animation of airblows. A red light indicates that the airblow output is on. Only
the airblows that are activated (this means movement code is different to Off)
on the airblow-page are shown. If graphical sequence programming is enabled,
the states of all airblows are shown.
Copyright © B&R - Subject to change without notice March 31, 2020
SmartMold 9 User Manual_V1.0.0.docx 21/142
SmartMold 9
User Manual Page description

State of the motor. For details, see Table 3-4 below.

Table 3-3: States of the cylinder heating zones
Animation Description
The zone is switched off, either because this single zone is not enabled or because
the cylinder heating is switched off.
The zone is either in autotuning or lowering or softstart state.
The zone temperature is below tolerance or it is already in tolerance but the release
time is still not over.
Normal heating status. The zone temperature is within the tolerance.
The zone temperature is above the tolerance.
An error occurred. For details, please refer to the alarm page (600).
Table 3-4: States of the motor
Animation Description
Motor is switched off.

Motor is starting up. The process from when the system issues a motor start
command to when the system receives the completion of the motor start.
Motor is on and running in normal condition.

An error occurred, see alarm page (600) for details.

The lower part of the animation shows the currently important actual values.
Table 3-5: Actual value description
No. Description
Actual values of the mold.
Actual values of the ejector.
Actual timer values.
Actual hydraulic values.
Actual values of the injection piston.
Actual values of the cylinder heating.
Table 3-6: Other functions
No. Description
Set this option to activate the robot. When the robot is activated, the input sig-
nals from the robot are considered for interlocking and the automatic cycle.
Additionally to this setting, the input signal Robot: Operation mode B2 must be
HIGH to activate the robot. This is an optional feature and only displayed if the
robot-option for this kind of robot-operation is enabled.
Set this option to activate the drop sensor (photocell to detect falling parts). After
every cycle, the input signal Drop Sensor is checked. If during mold open or
ejection a positive and negative edge of this input signal are detected, it is as-
sumed that the product has fallen down and automatic cycle can continue. If
not, the alarm 20-2 Part did not fall is triggered. This check is not performed in
the very first cycle, otherwise it is always done before mold close (or before first
core movement before mold close) or after the Part Detect Timeout.
Enter a page number to jump directly to the desired page. For the page number,
see [19] Current page number of the global page.

3.1.2.2 Hidden button

On this page, control-keys are available to control the automatic safety gate and the main lubrication circuit:

Figure 3-3: Hidden button

Table 3-7: Hidden button

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 22/142
SmartMold 9
User Manual Page description

No. Description
F1: Jog-Key for safety gate open. If an automatic safety gate is installed you can
use this key to open the gate at any time.
F2: Jog-Key for safety gate close. If an automatic safety gate is installed you
can use this key to close the gate at any time.
F3: Key to trigger manual lubrication.
F4: Key to start oil preheating.

3.2 Mold open and close page

Note: In all the basic action parameter pages, if a certain stage of pressure / flow / position is set to 0, it means that this
stage of control is cancelled.

3.2.1 Mold Close Page

Figure 3-4: Mold Close page

3.2.1.1 Basic introduction

Table 3-8: Mold Close setting
No. Description
Profile steps 1-3. During the movement, the actual step the mold is running
through is highlighted.
Mold protection step.
Copyright © B&R - Subject to change without notice March 31, 2020
SmartMold 9 User Manual_V1.0.0.docx 23/142
SmartMold 9
User Manual Page description

Mold lock step.

The position in every step is interpreted as target position. In the example above
this means: Move in step 1 with 40% speed and 50 bar up to the position 190
mm, then change to the next step 2 in the profile.
Start position of mold protection phase.
Start locking position = End of mold protection. At this position the mold locking
starts.
At this position, the mold locking ends.

Figure 3-5: Mold Close diagram

The graphic above explains the settings for mold closing. The profile entered is also visualized on the screen in a graphic
of pressure and speed over position. The actual position of the mold is also visualized in an animation. Below the actual
speed and position of the mold is displayed:

Table 3-9: Mold Close step

No. Description
Pressure and speed profile for the movement. The set pressure is shown in red
color. The set speed profile is shown in dark green color, for the speed profile
additionally the rampings are calculated and shown in light green color.
The graphic shows the actual position of the mold. The graphic is in the left
position when the mold is in the open position, which is specified, in the mold
open profile.
Actual values of the mold.

The time needed in the step MP is monitored. If the mold needs more time than specified as Mold Protection Timeout to
run through the mold protection step, the movement is stopped immediately and an alarm is triggered:
Table 3-10: Mold Protection
No. Description
The time in which the mold should run through the MP step.
If this option is set, when running in manual mode, the mold reopens automati-
cally after a mold protection timeout.
If this option and option are set: when running in manual mode, the mold
reopens automatically after a mold protection alarm, additionally the ejector and
cores are moved automatically as programmed.
When running in auto or semiauto mode, the mold can retry to close after a
mold protection alarm happened. The number of retries can be specified here.
Actual time when the mold runs through the mold protection step. If the mold
protection time exceeds this set time, alarm 20-6 Mold Protection timeout will
Copyright © B&R - Subject to change without notice March 31, 2020
SmartMold 9 User Manual_V1.0.0.docx 24/142
SmartMold 9
User Manual Page description

be triggered.
The parameters for moving the mold in setting mode can be adjusted on the bottom of the page:
Table 3-11: Setting mode
No. Description
Setting mode speed and pressure for mold close movement.

3.2.1.2 Hidden button

No.

3.2.2 Mold Open

Figure 3-6: Mold Open page

3.2.2.1 Basic introduction

Table 3-12: Mold Open setting
No. Description
Profile steps 1-5. During the movement, the actual step the mold is running
through is highlighted.
Pressure and speed settings for every step. The position in every step is inter-
preted as target position. In the example above this means: Move in step 1 with
30% and 50 bar up to the position 200 mm, then change to the next step in the

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 25/142
SmartMold 9
User Manual Page description

profile.
The profile entered is visualized in a graphic of pressure and speed over position. The actual position of the mold is also
visualized in an animation. Below the actual speed and position of the mold is displayed:
Table 3-13: Mold Open step
No. Description
Pressure and speed profile for the movement. The set pressure is shown in red
color. The set speed profile is shown in dark green color, for the speed profile,
additionally the rampings are calculated and shown in light green color.
The graphic shows the actual position of the mold. The graphic is in the left
position when the mold is in the open position, which is specified, in the open
profile.
Actual values of the mold.
Table 3-14: Mold Unlock
No. Description
When this option is set (checkbox), the mold will unlock early (before the normal
mold open is done).
With the dropdown the operator can decide when the early unlock should hap-
pen:
·After Injection ... Mold unlocks directly after injection & holdon pressure
·After Decomp. ... Mold unlocks directly after decompression after
Target position for the unlock movement.
Delay time for the unlock movement. After reaching the unlock position ,
speed and pressure output continue for this time.
The parameters for moving the mold in setting mode can be adjusted on the bottom of the page:
Table 3-15: Setting Mode
No. Description
Setting mode speed for mold open movement. This value has a lower limit than
the speed for manual and auto mode above.

3.2.2.2 Hidden button

No.

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 26/142
SmartMold 9
User Manual Page description

3.2.3 Mold Height

Figure 3-7: Mold Height

3.2.3.1 Basic introduction

On this page the settings for tonnage adjustment and manual mold height movement can be made.

Automatic tonnage adjustment is performed when pressing the tonnage adjustment button . The automatic tonnage
adjustment procedure can only be started in setting mode. The set tonnage and mold height for the adjustment proce-
dure can be entered here.

Table 3-16: Mold Height

No. Description
Tonnage: Set tonnage for automatic tonnage adjustment.
The checkbox enables the automatic tonnage adjustment at the end of mold
height adjustment:
At the end of the automatic mold height adjustment procedure the mold height
moves a small distance forward beyond the mold touch point. The distance of
this forward movement is calculated in a way that the tonnage reaches the set
value specified here. For a more accurate result the mold height can be speci-

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 27/142
SmartMold 9
User Manual Page description

fied in .
The calculation of the necessary forward-movement is based on a table adjust-
ed by the OEM. The result depends on the exactness of this table
(and the stiffness of the mold etc.). There is no guarantee that the desired ton-
nage is reached!
Locking Pressure: Set locking pressure for tonnage adjustment.
The checkbox enables the automatic locking pressure evaluation at the end of
mold height adjustment:
At the end of the automatic mold height adjustment the mold height is adjusted
that exactly the set locking pressure specified here is needed to lock the clamp.
During this procedure the mold will be locked and unlocked several times.
Mold Height: Set mold height for automatic tonnage adjustment.
For a more accurate result of automatic tonnage adjustment, the new mold
height can be set here. At the end of the automatic tonnage adjustment proce-
dure the mold height moves a small distance forward beyond the mold touch
point. The calculation of this distance takes also the actual mold height as input
parameter.
This setting is hidden if the mold height position is remanent or absolute. The
option of remanent storage of the mold height can be configured in sw.ini.
The mold height can only be moved in setting mode, the parameters for the movement can be specified here:
Table 3-17: Mold height setting
No. Description
Set speed.
Set pressure.
Move distance. When pressing the mold height forward or backward movement
key the mold height moves for this distance only, provided that Move by Dis-
tance is enabled.
Move by Distance: If enabled, the mold height moves only for a certain distance
when pressing the mold height forward or backward key. It stops after passing
the distance specified in . If it is disabled, the mold height keeps moving as
long as the mold height forward or backward movement key is pressed.
Table 3-18: Mold height actual position
No. Description
For the use of remanent position or absolute position encoders:
The actual mold height.
Table 3-19: Set mold height
No. Description
By pressing this button you can move the mold height to the given position. This
movement can only be started in setting mode.
By pressing this button you can move the mold height to the given position. This
movement can only be started in setting mode.

3.2.3.2 Hidden button

No.

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 28/142
SmartMold 9
User Manual Page description

3.2.4 Core

Figure 3-8: Core 1

3.2.4.1 Basic introduction

Using F6 button to cycle through the core1- core6.
Table 3-20: Core basic setting
No. Description
Activate a hydraulic core. If this setting is deactivated, only a digital output for the
core valve is set during movement (for example for pneumatic or electric cores). If
the setting Hydraulic Core is activated, set speed and set pressure are forwarded
to the pump.
With this setting, you can determine to which core group this core belongs. This
core group is used by the robot interface (Euromap67) that distinguishes between
cores of type 1 and 2 for interlocking cores of a certain group.
This field is only visible if code Rep. After Ejection (see below) is set for the core
or graphical sequence programming is enabled. Here the number of repetitions for
the core movement can be set. This setting is only considered for code Rep. After
Ejection or if in the graphical sequence editor the step, Core Repetition is pro-
grammed.
The core will not move if the number of repetitions is set to 0.
Table 3-21: Core movement

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 29/142
SmartMold 9
User Manual Page description

No. Description
This graphic shows the actual status of the core (moving in, moving out, in, out).
With this dropdown, you can select the parameter set you want to edit. Each core
supports up to 2 parameter sets; this means 2 movements with separate move-
ment parameters in each direction. Movements with parameter set 2 can only be
programmed in the graphical sequence editor.
Multiple parameter sets are optional and might not be supported by your controller.
Example: The core should move in after mold close to an intermediate stop posi-
tion and later in the cycle during injection to the end position. In this case, for the
parameter set 1 the option Int. Stop should be enabled, whereas it should be disa-
bled in the parameter set 2. In the graphical sequence editor, you need to program
the first core in movement with parameter set 1, and a second in movement during
injection with parameter set 2.
Optional: Display of core-order.
Movement code: if graphic sequence programming is disabled, the point in the
sequence when the core moves can be set here. Possible settings are:
·Before Close: Core moves before the mold close movement.
·Parallel to Close: Core moves parallel to the mold close movement, this means
core and mold are moving at the same time. The core movement starts once the
mold passes through the Release Position
·Between Close: Core moves inbetween the mold close movement. The mold
stops at the Release Position , then the core moves. After the core has
stopped, the mold is continuing to move until its end position or the next intermedi-
ate stop.
·After Close: Core moves after the mold close movement.
·Before Open: Core moves before the mold open movement.
·Parallel to Open: Core moves parallel to the mold open movement (just like
Parallel to Close).
·Between Open: Core moves inbetween the mold open movement (just like Be-
tween Close).
·After Open: Core moves after the mold open movement.
·After Injection: Core moves after injection and holdon pressure. The cooling time
starts after the core movement is finished.
·After Ejection: Core moves after the ejection process of the current cycle. If the
ejector is disabled the core will move like After Open.
·Rep. After Ejection: This option is only available for the In movement. Core will
move repeatedly (see setting Repetitions above) in and out after the ejection
process of the current cycle. If the number of repetitions are set to 0, the core will
not move. If the ejector is disabled the core will move directly after mold open. For
the Out movement the settings on the right side for Out will be used. No code can
be set for the Out movement in that case.
·Before Injection: Core moves directly before injection
·Between Injection: Core moves inbetween injection. The injection piston stops at
the Release Position , then the core moves. After the core has stopped, the
injection is continuing to move until its end position or the next intermediate stop.
·Parallel to Injection: Core moves parallel to the injection movement, this means
core and injection piston are moving at the same time. The core movement starts
once the injection piston passes through the Release Position
·After Eject Forward: Core moves after the first ejector forward movement (be-
fore repetition and backward-movement)
Delay time: Delay time to elapse before the core really starts to move.
Off Delay time: Delay that has to elapse after the core has finished its movement,
before the following movement can start.
Release Position:
Meaning for movement code Parallel to Close/Open: the core starts to move
as soon as the mold runs through this position.
Meaning for movement code Between Close/Open: The mold stops at this
position, then the core moves.
Move Mode:
·Undefined: Core does not move.

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 30/142
SmartMold 9
User Manual Page description

·Limit Switch: Core moves until the according limit switch is active.
·Time Based: Core moves until the movement time that can be specified
below is elapsed.
·Pulses: The moves for a certain number of input pulses (for rotational cores).
·Limit Switch (Edge): Core moves until the according limit switch is active, but the
state of the limit switch is not monitored anymore during the rest of the cycle (for
interlocking with other axes). This means that after a detecting a positive edge on
the limit switch input signal the end position is reached. The core will be assumed
in In or Out position for the rest of the cycle no matter what will be the state of its
limit switches.
Valve Stay On: If checked, the core valve remains actuated also after the move-
ment has finished. If it is disabled, the valve is switched off after the core move-
ment.
Speed: Set speed for core movement. Only important for hydraulic cores.
Pressure: Set pressure for core movement. Only important for hydraulic cores.
Time:
Meaning for move mode Time: movement time for time-based core movement.
Meaning for move mode Limit Switch / Pulses: Additional time the core valve
and speed and pressure valves remain further actuated after the limit switch or set
number of pulses has been reached.
Pulses: Core moves for this number of input pulses and stops after the specified
number of pulses has been counted on the input.
Timeout: If the core movement needs longer than the timeout specified here, the
alarm 20-5 Core timeout is shown.

3.2.4.2 Hidden button

No.

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 31/142
SmartMold 9
User Manual Page description

3.2.5 Mold Close Fast

Figure 3-9: Mold Close Fast

3.2.5.1 Basic introduction

Table 3-22: Mold Close Fast
No. Description
The LED icon shows the actual status of the digital output signal Mold Close
Fast (Grey = LOW, Red = HIGH). For details, see table 3-23 below.
Here the operation of the fast valve can enabled ("On") or disabled ("Off"). If it is
disabled the output signal for the valve always remains LOW. If it is enabled the
output is set based on the criteria mentioned below.
Profile step (from the mold close movement profile) when the valve output signal
is turned to HIGH. The point in time when the valve is actuated could be at the
beginning or at the end of the given profile step (check text on the left side).
Here you can set an additional delay time before the valve is actually set to
HIGH after the criteria in is fulfilled.
Profile step (from the mold close movement profile) during when the valve out-
put signal is turned to LOW. The point in time when the valve is switched off
could be at the beginning or at the end of the given profile step (check text on
the left side).
Here you can set an additional delay time before the valve is actually set to

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 32/142
SmartMold 9
User Manual Page description

LOW after the criteria in is fulfilled.

Table 3-23: Actual status of the Mold Close Fast valve
Animation Description
Mold Close Fast valve open
Mold Close Fast valve close

3.2.5.2 Hidden button

No.
3.2.6 Mold Open Fast

Figure 3-10: Mold Open Fast

3.2.5.3 Basic introduction

On this page, all settings for the mold open fast valve and mold open backpressure valve can be made.
Table 3-24: Mold Open Fast
No. Description
The LED icon shows the actual status of the digital output signal Mold Open
Fast (Grey = LOW, Red = HIGH). For details, see table 3-25 below.
Here the operation of the fast valve can enabled ("On") or disabled ("Off"). If it is
disabled the output signal for the valve always remains LOW. If it is enabled the

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 33/142
SmartMold 9
User Manual Page description

output is set based on the criteria mentioned below.

Profile step (from the mold open movement profile) when the valve output signal
is turned to HIGH. The point in time when the valve is actuated could be at the
beginning or at the end of the given profile step (check text on the left side).
Here you can set an additional delay time before the valve is actually set to
HIGH after the criteria in is fulfilled.
Profile step (from the mold open movement profile) during when the valve out-
put signal is turned to LOW. The point in time when the valve is switched off
could be at the beginning or at the end of the given profile step (check text on
the left side).
Here you can set an additional delay time before the valve is actually set to
LOW after the criteria in is fulfilled.
Table 3-25: Actual status of the Mold Open Fast valve
Animation Description
Mold Open Fast valve open
Mold Open Fast valve close
Table 3-26: Mold Open Backpressure
No. Description
The LED icon shows the actual status of the digital output signal Mold Open
Backpressure (Grey = LOW, Red = HIGH). For details, see table 3-27 below.
Here the operation of the fast valve can enabled ("On") or disabled ("Off"). If it is
disabled the output signal for the valve always remains LOW. If it is enabled the
output is set based on the criteria mentioned below.
Profile step (from the mold open movement profile) when the valve output signal
is turned to HIGH. The point in time when the valve is actuated could be at the
begin or at the end of the given profile step (check text on the left side).
Here you can set an additional delay time before the valve is actually set to
HIGH after the criteria in is fulfilled.
Profile step (from the mold open movement profile) during when the valve out-
put signal is turned to LOW. The point in time when the valve is switched off
could be at the begin or at the end of the given profile step (check text on the
left side).
Here you can set an additional delay time before the valve is actually set to
LOW after the criteria in is fulfilled.

Table 3-27: Actual status of the Mold Open Backpressure valve

Animation Description
Mold Open Backpressure valve open
Mold Open Backpressure valve close

3.2.5.4 Hidden Button

No.

3.3 Injection
Note: In all the basic action parameter pages, if a certain stage of pressure / flow / position is set to 0, it means that this
stage of control is cancelled. As shown in Figure 3-11, the system does not perform the second step of injection and
holding pressure.

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 34/142
SmartMold 9
User Manual Page description

3.3.1 Injection

Figure 3-11: Injection

3.3.1.1 Basic introduction

Injection and holding pressure can be divided into 5 steps (at least 1 step), and each step can set the speed, pressure
and position. If you want to cancel the settings in steps 3 to 5, you can set the speed of this step to 0, which will skip the
following steps starting from this step.

Table 3-28: Injection setting

No. Description
Profile steps 1-5 (executed from right to left). During the injection, the currently
active step is highlighted.
Injection speed. Set speed for the profile step. This speed can only be reached
if the movement is not limited by the set pressure.
Injection pressure. Set pressure for the profile step. This is only a limitation for
the injection pressure. If the plastic can flow without too much force or re-
sistance then this pressure is not reached.
The position in every step is interpreted as target position. The last position in
the profile is normally the target position for the injection movement. If the
switchover criteria is not reached before this position the injection process will

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 35/142
SmartMold 9
User Manual Page description

be stopped. Optionally (depending on machine manufacturer: sw.ini setting) the

last position can also be the switchover position.
Table 3-29: Holding Pressure setting
No. Description
Profile steps 1-5 (executed from right to left). During the holding phase, the
currently active step is highlighted.
Holding velocity limit. This is the maximum velocity for every holding step. Dur-
ing holding there is normally no or nearly no movement so this is usually just a
limitation.
Holding pressure. This is the set pressure for every holding step. The pressure
can only be reached if the mold is filled and the nozzle is touching the mold,
otherwise the movement is limited by the set velocity and the pressure is lower
than the set value.
Holding time. This are the set times for each holding step. Holding ends after
every step has finished.

The parameters of each step can form a graph. The injection curve shows the pressure and flow setting based on the
screw position. The holding pressure curve shows the time-based holding pressure and flow setting. The animation
shows the actual position of the screw. The right area of the animation is the output of the actual speed and actual posi-
tion of the screw.
Table 3-30: Injection Holding Pressure
No. Description
Display of the set holding pressure profile. The blue line shows the set holding
pressure and the green line the velocity limit. The profile starts at the right side
of the display (time=0) and ends on the left side (time = sum of all profile times).
Display of the set injection profile. The green line shows the injection set speed
and the red line the pressure limit. The profile starts at the right side of the dis-
play (position = dosage + decompression, time = 0) and ends on the left side of
the display (position = target, time = sum of all profile times).
Animation of the injection piston.
Display of actual injection speed, position of the screw and injection pressure.

The parameters for moving the injection piston in setting mode can be adjusted on the bottom of the page:
Table 3-31: Setting mode
No. Description
Setting mode speed for injection movement.
Setting mode pressure for injection movement.

3.3.1.2 Hidden button

No.

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 36/142
SmartMold 9
User Manual Page description

3.3.2 Switchover

Figure 3-12: Switchover

3.3.2.1 Basic introduction

Table 3-32: General setting
No. Description
Dry Cycle. When this checkbox is checked the injection-side (injection, injection
unit, nozzle closure, etc...) is not moved in automatic or semi automatic mode.
In manual mode injection and injection unit cannot be moved either.
Enable Fast Injection. This input is optional and only visible if an injection accu-
mulator or an injection regenerative valve is present on the machine. When this
checkbox is checked, the accumulator and/or the regenerative valve are used.
Table 3-33: Switchover setting
No. Description
Switchover by injection position. If this function is enabled (checkbox) than the
switchover will happen when the actual injection position gets below the set
value.
Switchover time. If this function is enabled (checkbox) than then switchover will
happen when the set time has expired. The time starts running with the begin-
ning of injection.
This time is also checked when the function is not enabled (checkbox un-
checked). In this case, this time acts like a monitoring time and if none of the
Copyright © B&R - Subject to change without notice March 31, 2020
SmartMold 9 User Manual_V1.0.0.docx 37/142
SmartMold 9
User Manual Page description

other enabled switchover criteria is fulfilled within this time the switchover is
forced and the alarm 20-28 Switchover time exceeded is triggered. To disable
this monitoring functionality the time has to be set to 0.
Release position for the pressure and cavity-pressure switchover. The actual
injection position must be below that value so that the pressure switchover can
happen.
Switchover pressure. If this function is enabled (checkbox) than the switchover
will happen when the actual injection pressure rises over the switchover value,
but only if the injection position is below the release position .
Switchover cavity (mold) pressure. If this function is enabled (checkbox) than
the switchover will happen when the actual cavity (in-mold-) pressure rises over
the switchover value, but only if the injection position is below the release posi-
tion . The release position should be used to avoid an early false trigger of
the pressure switchover if there is a peak in actual pressure when starting to fill
the mold.
External switchover: If this function is enabled (checkbox) than the switchover
will happen when the digital input signal External Switchover is HIGH.
Table 3-34: Cushion monitoring
No. Description
With this checkbox the cushion monitoring can be activated (checked) or deac-
tivated (unchecked).
If this function is enabled, after the holding pressure is completed, if the current
position of the screw is outside the maximum cushion position or the minimum
cushion position, the system triggers an alarm 20-59 overrun limit.
Table 3-35: Injection step
No. Description
Max. Cushion: HIGH limit for the cushion. The actual cushion must not exceed
this value.
Min. Cushion: LOW limit for the cushion. The actual cushion must not be below
this value.

3.3.2.2 Hidden button

No.

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 38/142
SmartMold 9
User Manual Page description

3.3.3 Plastification

Figure 3-13: Plastification

3.3.3.1 Basic introduction

Table 3-36: Plastification setting
No. Description
Profile steps for decompression before (DEC), Plastification (1-3) and decom-
pression after (DEC). Each step is highlighted when the according movement
and profile step is active.
Rotation speed for the plastification. This is the set value for the screw rotation.
Backpressure. These are the set values for backpressure during plastification.
The backpressure is the pressure applied to the plastic during screw recovery
(plastification) by the injection piston. It prevents the screw from moving back
without force.
These settings are only visible if a backpressure actuator is present (on some
machine the backpressure is adjusted manually).
Speed for the decompression movements.
Pressure for decompression and for screw rotation during plastification. Per
default, there is only 1 set value for plastification pressure. Optionally (sw.ini
setting) there can be separate pressure settings for every profile step.
Table 3-37: Plastification step

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 39/142
SmartMold 9
User Manual Page description

No. Description
Position for:
·Decompression Before: Per default, this position is the absolute target position
for the front decompression movement. Optionally (sw.ini setting) this can be
also a stroke relative to the cushion. If you set this value to 0 than no decom-
pression before takes place.
·Plastification: Target position for each plastification step (1-3). The last target
(of the active steps) is the set dosage.
·Decompression After: Per default, this position is the absolute target position
for the rear decompression movement. Optionally (sw.ini setting) this can be
also a stroke relative to the dosage.
Display of the actual plastification profile. The green curve shows the set screw
speed and the red curve the set backpressure.
Display of actual values for the plastification process.
Table 3-38: Plastification mode
No. Description
Plastification Mode: Determines when the plastification process (decompres-
sion, plastification, injection unit back) is done in automatic mode. Plastification
always starts at the end of injection and holding pressure. The following settings
are possible:
·Sequential: The plastification takes place parallel to cooling, mold open only
starts when the plastification process is finished.
·Parallel to Mold Open: The plastification takes place parallel to cooling and
mold open and ejection. The next cycle (including mold close) starts only when
the plastification process has finished. This setting is only available if the ma-
chine uses a multiple pump system. It cannot be selected on machines with a
single pump system.
·Parallel to Mold Close: The plastification takes place parallel to cooling, mold
open, ejection and mold close. The injection process will only start when the
plastification process has finished. This setting is only available if the machine
uses multiple pump system. It cannot be selected on machines with single pump
system.
·Before Injection: The plastification (and decompression) after is done before
injection (after mold is closed). Decompression before is done directly after
injection end.
No Back Pressure Valve: This is an optional feature and not available on all
machines. If this zero backpressure valve option is enabled then plastification
happens without backpressure, therefore a digital output signal No Backpres-
sure Valve is set to HIGH during plastification.
The parameters for moving the plastification and decompression in setting mode can be adjusted on the bottom of the
page:
Table 3-39: Setting mode
No. Description
Setting mode (rotation) speed for plastification. This value has a lower limit than
the set (rotation) speed for manual and auto mode above.
Setting mode pressure for plastification. This is the pressure to rotate the screw
and not the backpressure. Backpressure is not controlled in setting mode. This
value has a lower limit than the set pressure for manual and auto mode above.
Setting mode speed for decompression. This value has a lower limit than the set
speed for manual and auto mode above.
Setting mode pressure for decompression. This value has a lower limit than the
set pressure for manual and auto mode above.

3.3.3.2 Hidden butto

No.

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 40/142
SmartMold 9
User Manual Page description

3.3.4 Injection Unit

Figure 3-14: Injection unit

3.3.4.1 Basic introduction

Table 3-40: Injection unit setting
No. Description
Profile steps 1 and "NP" (nozzle protection). During the forward movement, the
actual active step is highlighted. The movement is executed from right to left.
Forward speed.
Forward pressure limit. For the nozzle protection step, this can also be a set
pressure setting if one of the analog input signals Inj. Unit Actual Pressure or
Main Pump Actual Pressure is connected. The forward movement of the injec-
tion unit is continued until this pressure minus a configured tolerance is reached.
End position of the profile step.
After the end position of the "NP" profile step is reached and the actual pressure
is inside the tolerance (criteria is only checked if one of the analog input signals
Inj. Unit Actual Pressure or Main Pump Actual Pressure is connected) the
injection unit forward movement will continue for this delay time.
Profile steps of the injection unit backward movement. The steps are executed
from left to right.
Backward speed.

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 41/142
SmartMold 9
User Manual Page description

Backward pressure limit.

Table 3-41: Injection unit
No. Description
Graph of the pressure and speed profile of the injection unit forward movement.
Graph of the pressure and speed profile of the injection unit backward move-
ment.
The animation shows the injection unit and injection piston position. The Injec-
tion unit is shown on the left end position after the nozzle forward movement
has finished and on the right end, position after injection unit backward move-
ment has finished.
Actual speed, position and pressure of the injection unit.
Table 3-42: Injection unit backward mode
No. Description
Dropdown box for the position of the injection unit backward movement in the
automatic sequence. Possible selections are:
·Off: Injection unit backward movement is disabled.
·After Decomp. Before: The injection unit moves back after the first decom-
pression phase and before plastification starts.
·After Plastification: The injection unit moves back after the plastification
phase and before the rear decompression (decompression after plastification).
·After Decomp. After: The injection unit moves back after the rear decom-
pression phase (decompression after plastification).
·After Holding Pressure: The injection unit moves back after the holding pres-
sure phase.
·After Cooling: The injection unit moves back after plastification has finished
and cooling time is over
The parameters for moving the injection unit in setting mode can be adjusted on the bottom of the page:
Table 3-43: Setting mode
No. Description
Setting mode speed for injection unit movement. This value has a lower limit
than the speed settings for manual and auto mode above.
Setting mode pressure for injection unit movement. This value has a lower limit
than the pressure settings for manual and auto mode above.

3.3.4.2 Hidden button

No.

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 42/142
SmartMold 9
User Manual Page description

3.3.5 Purge

Figure 3-15: Purge

3.3.5.1 Basic introduction

Press the automatic purging key in area C of the keyboard, and the system will start to perform the purging se-
quence.
Table 3-44: Purge
No. Description
Purge Mode:
·Empty Barrel: The purge cycle (steps 3 to 7) is repeated until a plastification
timeout occurs, which indicates that the barrel is empty. The purge continues
afterwards for the set number of repetitions (setting in the table General).
·Change Color: The purge cycle (steps 3 to 7) is repeated for the set number
of repetitions (setting in the table General). If a plastification timeout occurs
before having finished the purge cycles the alarm 20-56 Purge timeout is trig-
gered.
Purge step: Move injection unit fully back. This step is executed only once at the
beginning of the purge process. The icon is highlighted when the step is active.
Purge step: Inject to purge position (setting in the table Injection). The icon
Copyright © B&R - Subject to change without notice March 31, 2020
SmartMold 9 User Manual_V1.0.0.docx 43/142
SmartMold 9
User Manual Page description

is highlighted when the step is active.

Purge step: Decompression with special purge settings (settings - in the
table Decompression). The icon is highlighted when the step is active.
Purge step: Plastification with special purge settings (settings - in the
table Plastification). The icon is highlighted when the step is active. The actual
plastification time (up counting) is displayed on the right side of the icon.
Purge step: Purge Delay (setting in the table General). The icon is high-
lighted when the step is active. The actual delay time (down counting) is dis-
played on the right side of the icon.

3.3.5.2 Hidden button

No.

3.3.6 Intrusion

Figure 3-16: Intrusion

3.3.6.1 Basic introduction

Table 3-45: Intrusion
No. Description

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 44/142
SmartMold 9
User Manual Page description

Activate Intrusion. Only when this checkbox is checked intrusion will take place.
Set screw rotation speed for intrusion.
Set plastification pressure for intrusion.
Set time for intrusion. The intrusion (screw rotation) will stop after this time and
injection will be done.
Backpressure for the intrusion process. This value should be set high enough so
that the screw will not be pushed backwards.
Intrusion: Kp. This is an optional setting (default: 0). Setting this value to some-
thing bigger than 0 would activate a position control to keep the screw at its
actual position during intrusion (by increasing the backpressure).
If the backpressure is set high enough this position control is not necessary.

3.3.6.2 Hidden button

No.

3.3.7 Injection Unit Rotate

Figure 3-17: Injection unit rotate

3.3.7.1 Basic introduction

Table 3-46: Injection unit rotate
No. Description
Speed for rotating out.

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 45/142
SmartMold 9
User Manual Page description

Pressure for rotating out.

Target position for rotating out. It is only needed if a position transducer is used as
senor type.
Velocity for injection movement in setting mode when Injection Unit is swiveled out.
Pressure for injection movement in setting mode when Injection Unit is swiveled
out.
Velocity for decompression movement in setting mode when Injection Unit is swiv-
eled out.
Pressure for decompression movement in setting mode when Injection Unit is swiv-
eled out.
Speed for plastification (screw rotation) in setting mode when Injection Unit is swiv-
eled out.
Pressure for plastification (screw rotation) in setting mode when Injection Unit is
swiveled out.

3.3.7.2 Hidden button

No.

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 46/142
SmartMold 9
User Manual Page description

3.4 Ejector

3.4.1 Ejector

Figure 3-18: Ejector

3.4.1.1 Basic introduction

Table 3-47: Ejector setting
No. Description
Profile steps 1-2 for normal forward movement. During the movement, the actu-
al step the ejector is running through is highlighted.
The position in every step is interpreted as target position. In the above example
only one profile step is active, thus the ejector will stop at the target for profile
step 1. If a second profile step is enabled the profile step 2 will get active when
the position of profile step 1 is reached. The position inputs are only visible if a
position transducer is used on the ejector. For a movement based on limit
switches no inputs are visible. For a time based ejector movement you can
enter the movement times here.
Selection whether separate parameters should be used for repetition. If this
checkbox is unselected the parameters for repetition ( , ) will disappear
and the repetition takes place with the standard parameters ( )
Repetition movement parameters. During the repetition movement, the step
Copyright © B&R - Subject to change without notice March 31, 2020
SmartMold 9 User Manual_V1.0.0.docx 47/142
SmartMold 9
User Manual Page description

"REP" is highlighted. See also the diagram above for an explanation on the
ejector repetition movements.
Target position for the repetition movement. This position can be different to the
target position for the normal movement.
If the option Ejector Stay Forward is enabled the ejector will stay forward at the
end of the cycle in semi automatic mode. It will move back then at the beginning
of the next cycle. In all other operation modes, this setting has no effect.
If repetition by time is enabled (checkbox) the repetition will not stop at the given
target but will end after the given time. The software assumes that the ejec-
tor always passes through the whole distance in the given time (for safety inter-
locks) if this function is enabled.
Profile steps 1-2 for normal backward movement. During the movement, the
actual step the ejector is running through is highlighted.
The position in every step is interpreted as target position. In the above example
only one profile step is active, thus the ejector will stop at the target for profile
step 1. If a second profile step is enabled the profile step 2 will get active when
the position of profile step 1 is reached.
The position inputs are only visible if a position transducer is used on the ejec-
tor. For a movement based on limit switches no inputs are visible. For a time
based ejector movement you can enter the movement times here.
Repetition movement parameters. During the repetition movement the step
"REP" is highlighted. See also the diagram above for an explanation on the
ejector repetition movements.
Target position for the repetition movement. This position can be different to the
target position for the normal movement.
If an ejector confirm back input is connected to the controller than it can be
activated here (the input must be HIGH than to allow mold close, mold height or
core movements).
If repetition by time is enabled (checkbox) the repetition will not stop at the given
target but will end after the given time. The software assumes that the ejec-
tor always passes through the whole distance in the given time (for safety inter-
locks) if this function is enabled.
Table 3-48: Ejector
No. Description
Pressure and speed profile for the normal backward movement. The set pres-
sure is shown in red color. The set speed profile is shown in dark green color,
for the speed profile, additionally the rampings are calculated and shown in light
green color.
Pressure and speed profile for the normal forward movement. The set pressure
is shown in red color. The set speed profile is shown in dark green color, for the
speed profile additionally the rampings are calculated and shown in light green
color.
Repetition movement parameters. During the repetition movement, the step
"REP" is highlighted. See also the diagram above for an explanation on the
ejector repetition movements.
Target position for the repetition movement. This position can be different to the
target position for the normal movement.
Table 3-49: Ejector mode
No. Description
The ejector mode defines when the ejection happens in the automatic se-
quence:
·Off: Ejection is disabled
·Sequential: Ejection happens after Mold Open is finished
·Mold Open: Ejection happens parallel to Mold Open starting at the given re-
lease position . This option is only available on multi pump machines.
·Manual (Seq.): Optional (not available on all controllers). Ejection can (must)
be done manually in semi-automatic mode (possible after mold open with the
jog-keys -movement of ejector possible also when safety gate is open!). In full
automatic mode, ejection happens after Mold Open is finished.
·Gate (Seq.): Optional (not available on all controllers). After the first ejector
forward movement (in semi-automatic mode), the safety gate must be opened
Copyright © B&R - Subject to change without notice March 31, 2020
SmartMold 9 User Manual_V1.0.0.docx 48/142
SmartMold 9
User Manual Page description

and closed before the ejector movement continues (repetition and back-
movement). The next cycle is not started again but has to be started manually
again. In full automatic mode, the ejector moves sequentially to the mold.
·Programmed: Graphical sequence
The release position is the minimum mold opening that is needed to move the
ejector forward. If the mold position is smaller than the release position, the
ejector forward movement is not allowed. It is also used as start position for
parallel operation for the ejector. This setting is limited by the ejection stroke
(Max. forward position - Min. backward position) plus a safety stroke (fixed OEM
setting).
Number of ejector repetitions. If this value is set to 1 only the main forward and
backward movements are executed. If it is set to a higher value, the repetition
movements are executed before the ejector is moved back. For example if this
value is set to 3 then the ejector is moved forward with the normal parameters,
then it is moved forward and backward 2 times with the repetition parameters
and finally it is moved back with the normal parameters. See also the diagram
above. If this value is set to 0 then no ejector movement takes place.

Figure 3-19: Ejector repetition movement

Table 3-50: Setting mode
No. Description
Setting mode speed and pressure for ejector forward and backward movement.

3.4.1.2 Hidden button

No.

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 49/142
SmartMold 9
User Manual Page description

3.4.2 Air Blows

Figure 3-20: Airblow

3.4.2.1 Basic introduction

Table 3-51: Airblow setting
No. Description
Index of the airblow (airblow number). When the according air-blow output is
active the index text is highlighted (orange background-color)
Index of the airblow (airblow number). When the according air-blow output is
active the index text is highlighted (orange background-color)
Release position for the airblow. The airblow will only start if the position of the
mold exceeds this value.
ATTENTION: The release position is also taken into consideration when graph-
ical programming is enabled and the airblow is not programmed parallel to the
mold. So if the airblow should be active while the mold is closed, the release
position must be set to 0.
Delay time for the activation of the airblow. The time gets active once the clamp
has reached the release position.
Display of the actual delay time (down counting).
Blow time. The airblow output is active for this time once the release position
was reached and the delay time has expired.
Pulse on-time. If the air-blow output should pulse during the set blow-time the
Copyright © B&R - Subject to change without notice March 31, 2020
SmartMold 9 User Manual_V1.0.0.docx 50/142
SmartMold 9
User Manual Page description

on-time (time during which the output is HIGH) can be set here. If this value is
set to 0 the pulsing is disabled and the output is HIGH during the whole set
blow-time ( ).
Pulse off-time. If the air-blow output should pulse during the set blow-time the
off-time (time during which the output is LOW) can be set here. The pulsing will
happen periodically with the set on- and off-time (period time = + )
Display of the actual blow time (up counting).

3.4.2.2 Hidden button

No.

3.5 Heating

3.5.1 Cylinder temperature

Figure 3-21: Cylinder temperature

3.5.1.1 Basic introduction

Table 3-52: Cylinder temperature
No. Description
Copyright © B&R - Subject to change without notice March 31, 2020
SmartMold 9 User Manual_V1.0.0.docx 51/142
SmartMold 9
User Manual Page description

Display of the heating zone (Nozzle, Cylinder 1, Cylinder 2....)

Set temperature for each individual zone.
Positive tolerance for each individual zone. The actual temperature of the zone
must be below the set temperature plus this tolerance. Only if the actual tem-
perature is within the tolerance and additionally a certain release time has ex-
pired (to ensure a fully heated resin) the screw can be moved.
Negative tolerance for each individual zone. The actual temperature of the zone
must be above the set temperature minus this tolerance. Only if the actual tem-
perature is within the tolerance and additionally a certain release time has ex-
pired (to ensure a fully heated resin) the screw can be moved.
Lowering temperature. When the lowering function is activated by pressing the
button in the screenshot below, the zones will heat to this temperature.
Enable for each individual zone. If a zone is not enabled (checkbox not
checked), then it will not be heated and the temperature will not be monitored.
Be careful not to disable temperature zones that actually are needed on the
machine. The screw can be destroyed!
Display of the actual temperature for each individual zone.
Actual output [0-100%] to the heating actuator. The heating actuator/relay is
controlled by the digital output signals Nozzle / Cyl. Zone#1..7 Heat. At 100%
the corresponding output signal is constantly HIGH, otherwise the output signal
is pulsing and the ratio of on and off time complies with this value.
If the zone is configured only for manual operation, you can input the set output
here directly. If you want to manually control the cooling output, you need to
enter a negative value here.
Actual output [0-100%] to the cooling actuator. The cooling actuator/relay is
controlled by the digital output signals Nozzle / Cyl. Zone#1..7 Cool. At 100%
this output is constantly on, otherwise the output is pulsing and the ratio of on
and off time complies with this value.
The status of each individual zone is visualized by different icons and colors.
Table 3-53: Status of each individual zone
Animation Description
Zone is off.
Zone is auto tuning or in thermal mode or is performing a softstart.
Zone is on and temperature is below or within tolerance but the release time
(warm up time) has not expired yet.
Zone is on and the release time (warm up time) has expired, screw movement is
possible.
Zone is on, temperature is above tolerance.
Temperature failure. For details, please refer to the alarm page (600).
Table 3-54: Lowering temperature
No. Description
For each zones two LED icons are shown. The left icon indicates the actual
status of the digital heating output signal (grey: off, red: on). The right icon indi-
cates the actual status of the digital cooling output signal (grey: off, blue: on).
With this button you can turn the lowering on or off. When the "lowering" is ac-
tive the set temperature for every zone is reduced to the lowering set-
temperature (see above).
Display of the actual traverse cooling output signal (grey LED: off, blue LED: on)
and the actual traverse temperature.
Temperature at which the cooling output for the traverse is turned on.
Temperature at which the cooling output for the traverse is turned off.
Traverse release temperature. If the actual traverse temperature is above that
value all screw movements are locked.
Table 3-55: Status of lowering cooling valve
Animation Description
Lowering cooling valve open
Lowering cooling valve close
Table 3-56: Heating softstart

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 52/142
SmartMold 9
User Manual Page description

No. Description
Softstart: If this checkbox is checked then a softstart will be performed every
time the heating is turned on.
Softstart temperature. All zones will heat up to this intermediate temperature
before they start heating to their final temperature.
Softstart percentage. During softstart the heating output during the first stage
(heat up to intermediate temperature) can be limited. Here the maximum heat-
ing output for every zone can be set.
Softstart delay. After all zones have reached the intermediate softstart tempera-
ture this time has to expire before the zones start to heat up to their normal set
temperature.

Figure 3-22: Heating softstart diagram

3.5.1.2 Hidden button

No.

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 53/142
SmartMold 9
User Manual Page description

3.5.2 Cylinder Temperature Calendar

Figure 3-23: Temperature Calendar

3.5.2.1 Basic introduction

On this page, it is possible to program a weekly calendar for the heating. With the help of this calendar heating can
be turned on or off automatically on a weekly basis.
Table 3-57: Temperature Calendar
No. Description
Enable: Only when this setting is "On" than the according calendar-entry is
active.
Action to be performed on the specified time:
·Nothing .. no action
·Cylinder Heating On .. cylinder heating will be turned on
·Mold Heating On .. mold heating will be turned on
·Oil PreHeat .. oil pre-heating will be started
·Cylinder Lowering On .. cylinder heating lowering (standby) will be activated
·Mold Lowering On .. mold heating lowering (standby) will be activated
Day during the week that the specified action should be performed:
·None .. no day
·Monday .. only on Mondays
·Tuesday .. only on Tuesdays

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 54/142
SmartMold 9
User Manual Page description

·Wednesday .. only on Wednesdays

·Thursday .. only on Thursdays
·Friday .. only on Fridays
·Saturday .. only on Saturdays
·Sunday .. only on Sundays
·Mo. to Fr. .. on Mondays to Fridays
·All week .. all week (ever day)
·Weekend .. only on weekends (saturdays and sundays)
Time (hour) when the specified action should be performed (0-23).
Time (minute) when the specified action should be performed (0-59).

3.5.2.2 Hidden button

No.

3.5.3 Cylinder Temperature Trend

Figure 3-24: Temperature Trend

3.5.3.1 Basic introduction

Table 3-58: Temperature trend setting
No. Description
Copyright © B&R - Subject to change without notice March 31, 2020
SmartMold 9 User Manual_V1.0.0.docx 55/142
SmartMold 9
User Manual Page description

Maximum value of the graphic's temperature range. You can change the scaling
of the graph here.
Minimum value of the graphic's temperature range. You can change the scaling
of the graph here.
Temperature scale for the graphic. Units: °C
Time scale for the graphic. The real time (clock) for the displayed samples is
shown here.
Drawing area. Here the curves for actual and set temperatures are displayed.
The visibility of the curves can be freely configured below the graph (checkbox-
es in the screenshot).
The vertical lines show the cursor position. At the intersection with a curve, a
square is shown. The actual temperature values at the cursor position are
shown below the graph (see and in the screenshot).
Display of the heating zone names for which the following settings apply.
With these checkboxes, you can control the visibility of the actual temperature
curves. If they are checked, the according curves are visible in the graph.
With this color picker control, you can select the color of the actual temperature
curves in the graph. Just press the OK key when you have focused the colored
box and select a new color from the pop-up.
Actual temperature at cursor position.
With these checkboxes you can control the visibility of the set temperature
curves. If they are checked, the according curves are visible in the graph.
With this color picker control, you can select the color of the set temperature
curves in the graph. Just press the OK key when you have focused the colored
box and select a new color from the pop-up.
Set temperature at cursor position.

3.5.3.2 Hidden button

Figure 3-25: Hidden button

Table 3-59: Hidden button
No. Description
Zoom In: Press this key to zoom in the graph (time axis will be stretched).
Zoom Out: Press this key to zoom out the graph (time axis will be compressed).
Scroll Left: Press this key to scroll to the historic data (older samples will be displayed).
Scroll Right: Press this key to scroll to the actual data (newer samples will be displayed).
Cursor Left: Press this key to move the cursor to the left (toward the older samples).
Cursor Right: Press this key to move the cursor to the right (toward the newer samples).

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 56/142
SmartMold 9
User Manual Page description

3.5.4 Mold Heating 1

Figure 3-26: Mold heating 1

3.5.4.1 Basic introduction

Table 3-60: Mold heating
No. Description
Module number where the temperature input is connected. There is only a mod-
ule number shown if the temperature input is connected to an X20 module. After
changing the IO-mapping of the mold temperature inputs in the IO-Configurator
a warm restart is necessary to update this list.
If this check box is enabled the mold heating gets switched on/off with the cylin-
der heating.
Button for enabling the mold heating. If the checkbox is enabled this button has
no effect.
Starts the Lowering of all 16 mold heating zones. The temperature will be low-
ered to the "Lowering" temperature. If lowering is deactivated, all zones will heat
up again to set temperature.
Softstart of all 16 mold heating zones. Further description of this function is
given on the "Cylinder Heating" help page 500

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 57/142
SmartMold 9
User Manual Page description

3.5.4.2 Hidden button

No.

3.5.5 Mold Temp. Trend 1

Figure 3-27: Mold Temp. Trend 1

On this page, the temperature trend for mold zone 1 to 8 can be seen.
Please open the cylinder heating Pages >> Heating >> Temperature Trend for a detailed function description.

3.5.6 Mold Heating 2

On this page, settings for the mold heating zones 9 to 16 can be made.
The Settings table and the status table with the animation is similar to the cylinder heating. So please open the Pages >>
Heating >> Cylinder Temperature help for a detailed description of this input and feedback fields.
There are also some functions on Pages >> Heating >> Mold Temperature 1 taking effect on this page. They are de-
scribed in the corresponding Help of the page Pages >> Heating >> Mold Temperature 1.

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 58/142
SmartMold 9
User Manual Page description

3.5.7 Mold Temp. Trend 2

On this page, the temperature trend for mold zone 9 to 16 can be seen.
Please open the cylinder heating Pages >> Heating >> Temperature Trend for a detailed function description.

3.5.8 Mold Autotuning

Figure 3-28: Mold autotuning

3.5.8.1 Basic introduction

On this page the mold auto tuning and the sensor type of additional X20 temperature modules can be configured.
Table 3-61: Mold autotuning
No. Description
Display of the Mold heating zones 1 to 8. The heating zones 2 to 16 are dis-
played in the second table on this page
Proportional gain of the zone
Integral action time (I-component) of the zone
Derivative action time (D-component) of the zone
Differential filtering time for temperature PID control.
Actual temperature of the mold zone

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 59/142
SmartMold 9
User Manual Page description

Tuning Status of the mold zone tuning. Possible states are:

0: Ready to Tune
20: Waiting for actual temperature to stabilize
21: Determining maximum slope and dead time
45: Calculation of control parameters Kp, Tn, Tv
49: Reset controller function block
50: Tuning is complete

3.5.8.2 Hidden button

No.

3.6 Oil, Lubrictin

Figure 3-29: Oil, Lubrication

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 60/142
SmartMold 9
User Manual Page description

3.6.1 Basic introduction

Table 3-62: Oil temperature control
No. Description
Maximum oil temperature. If the hydraulic oil temperature rises above this value,
the alarm 20-22 Oil temperature high is triggered.
Set temperature for oil preheating. After oil preheating was turned on, it will
continue until the hydraulic oil temperature reaches this value. This setting is
only visible if oil preheating is enabled on the machine.
The oil cooling is turned on if the hydraulic oil temperature rises above this val-
ue.
The oil cooling is turned off again if the hydraulic oil temperature falls below this
value.
Press this button to start oil preheating. Press the button a second time to stop
oil preheating again. The button is only visible if oil preheating is enabled on the
machine.
Actual hydraulic oil temperature (sensor signal Oil).
Table 3-63: Lubrication
No. Description
Press this button to turn on the lubrication pump manually. The lubrication pump
is activated several times (multiple lubrication), if in a number bigger than 1
is entered.
Automatic cycle interval to start lubrication. Lubrication is started automatically
after this number of automatic cycles was reached. The number of lubrication
repetitions for automatic mode (multiple lubrication) is fixed and can be specified
in the Setup Wizard. Caution - it is different to manual lubrication repetitions that
can be set in .
[Number of lubrication cycles for multiple lubrication (valid for manual lubrica-
tion). As soon as a lubrication is requested either by pressing the button manu-
ally or after a certain number of automatic cycles were done, the lubrication
pump can be activated several times (multiple lubrication). The number of lubri-
cations that should be performed can be specified here. Enter 1 to do only 1
single lubrication.
Lubrication cycle counter. During performing a multiple lubrication, it counts up
until the set value has been reached.

3.6.2 Hidden button

No.

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 61/142
SmartMold 9
User Manual Page description

3.7 Delay Times

3.7.1 Delay Times (1)

Figure 3-30: Delay times (1)

3.7.1.1 Basic introduction

Table 3-64: Delay times (1)
No. Description
Cycle Timeout: If a molding cycle lasts longer than this timeout, the alarm 20-8
Cycle timeout is triggered and the cycle is stopped.
On the right side the actual cycle time and the time of the last finished cycled is
displayed. The cycle time is measured from the start of the cycle to the end of
the cycle (the idle-time e.g. in semi-automatic mode to wait for the start-
command is not measured).
Cycle Interval Time: Time between the end of the last cycle and the actual time.
This interval time considers also the idle-time to wait for a new cycle start (in
automatic mode it is identical to the cycle time). After changing to manual mode,
the time is reset to 0.
Cooling Time: After holding pressure, the part is completely molded and needs
to stay in the mold for a certain time to cool down, before the mold is opened
again. The minimum time during which the mold stays closed after holding pres-
sure can be specified here. This timer is running parallel to plastification, so if
Copyright © B&R - Subject to change without notice March 31, 2020
SmartMold 9 User Manual_V1.0.0.docx 62/142
SmartMold 9
User Manual Page description

plastification lasts longer, it can happen that the actual cooling time is higher.
For details see the diagram below.
Actual Cooling Time: This timer is measuring the time the mold remains closed
after holding pressure. This time can be longer than the Cooling Time , de-
pending on the duration of plastification. For details see the diagram below.
Mold Close Delay: This is the delay time before closing the mold. It is not active
during the first cycle. It is not active in semi automatic mode either.
Mold Close Timeout: If a molding closing (including core movements inbetween
mold closing) lasts longer than this timeout, the alarm 20-12 Mold close
timeout is triggered and the cycle is stopped.
Mold Closed Time: This timer is measuring the overall time the mold stays
closed in a molding cycle.
Mold Open Timeout: If a molding opening (including core movements inbetween
mold opening) lasts longer than this timeout, the alarm 20-11 Mold open
timeout is triggered and the cycle is stopped.
Mold Opened Time: This timer is measuring the overall time the mold stays
opened in a molding cycle.
Ejection Timeout: If ejection (including ejector repetitions, forward and backward
delay times) lasts longer than this timeout, the alarm 20-9 Ejection timeout is
triggered and the cycle is stopped.
Ejector Forward Delay: This is the delay time before moving the ejector forward.
It is only active for the very first ejector forward movement and not for ejector
repetitions.
Ejector Backward Delay: This is the delay time before moving the ejector back-
ward. If there are ejector repetitions set, this delay time is running before the
first ejector retraction (before all repetitions).
Robot Release Timeout: If the machine waits for the robot longer than this
timeout, the alarm 20-26 Cycle stopped by robot is triggered and the cycle is
stopped. There is only one timeout setting for all kinds of robot signals.
Part Detection Timeout: If the Drop Sensor function is activated (see Pages >>
Machine Overview), than the part must be detected within this time (time starts
at the beginning of mold open) otherwise the alarm 20-2 Part did not fall is set
and the cycle is stopped. If this time is set to 0, the timeout is disabled and the
check if the part has fallen happens before mold close (or before core move-
ment if a core is programmed before mold close). The same happens if the time
is set to long.

3.7.1.2 Hidden button

No.

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 63/142
SmartMold 9
User Manual Page description

3.7.2 Delay Times (2)

Figure 3-31: Delay times (2)

3.7.2.1 Basic introduction

Table 3-65: Delay times (2)
No. Description
Pre-Injection Delay: This is the delay time before pre-injection. Pre-Injection is
an optional feature and might not be shown on your controller.
Injection Delay: This is the delay time before injection.
Injection Time: This timer is measuring the time for injection and holding pres-
sure.
If the max. set time is exceeded the injection is stopped, the alarm 20-100 Injec-
tion timeout is set and the automatic sequence is stopped at the end of the
current cycle (this function is disabled if the time is set to 0).
Decompression Delay: This is the delay time before the first decompression (i.e.
the injection piston backward movement before plastification).
Plastification Delay: This is the delay time before plastification.
Plastification Timeout: If plastification lasts longer than this timeout, the alarm
20-10 Plastification timeout is triggered and the cycle is stopped. The timeout-
function is disabled if the timeout is set to 0.
Suckback Delay: This is the delay time before the second decompression (i.e.
the injection piston backward movement after plastification).
Copyright © B&R - Subject to change without notice March 31, 2020
SmartMold 9 User Manual_V1.0.0.docx 64/142
SmartMold 9
User Manual Page description

Injection Unit Forward Delay: This is the delay time before the injection unit
advance movement.
Injection Unit Forward Time: This timer is measuring the time for the injection
unit advance movement.
Injection Unit Retract Delay: This is the delay time before the injection unit
backward movement.
Injection Unit Backward Time: This timer is measuring the time for the injection
unit retraction.

3.7.2.2 Hidden button

No.

3.8 User Management

On this page, users can login and logout from the SmartMold 9 controller. Depending on the access level of the user that
is logged in, some pages, functions or input fields can be locked.

There are 5 user levels:

(0) None: After booting, no user is logged in. The machine can be operated and recipes can be loaded, but no parame-
ters can be changed.
(10) Operator: Full machine operation is possible, mold parameters can be modified, additional access to special pages
like Trace.
(20) Supervisor: Same like operator, additional access to special pages like Audit Trail.
(30) OEM: Same like OEM, additionally all pages in the Setup Wizard can be accessed to modify machine data.
(40) B&R: Same like OEM, additional access to B&R factory settings.
For a complete list of page access levels, see the table at the end of this chapter.
For every user level a default user is existing: The input field User Name must be left empty and only the correct pass-
word for the default user should be entered to log in at a certain access level with the default user.
If it is desired to distinguish between single machine users, for every access level some new users (with a particular user
name) can be created.
Whether the current access level remains after power off/power on can be configured in sw.ini. Per default, after power
off/power on the access level is reset to None.
If after power up automatically an access level other to None should be activated, change the password of the corre-
sponding default user to an empty password (press button to change the password). This access level will be default
level and also active after a logout.

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 65/142
SmartMold 9
User Manual Page description

3.8.1 Basic introduction

Table 3-66: User Login
No. Description
Choose the name of the user that should login. All available users are shown in
the list. Leave this field empty to log in as default user.
Enter the correct password of the user selected in . If this field is left empty,
you should enter here the password of a default user. Only numbers can be
used in the password. The password entered is not shown on the screen, in-
stead an asterisk '*' is shown as placeholder
for every number. Confirm the password with the OK key. After pressing OK, the
user is logged in automatically, assumed that the correct password was entered.
Name and access level of the user that is currently logged in. The current user
level is also displayed on top of the screen, see the picture below.
Press the VNC-button to change the passwords for the VNC-server. This button
is only visible when a user of OEM-Level or higher is logged in. Otherwise this
function is not available.
Press the logout button to log out from SmartMold 9 controller.
Press this button to change the password of the user that is currently logged in
(shown in fields ). The supervisor can also change the default-passwords for
operator- or supervisor level here.
For details see the explanation of the dialog Change Password below.
The current user level is also displayed on top of the screen:

After pressing the Change Password button , the following dialog appears on the screen:

Table 3-67: Change password

No Description
Enter here the (old) password of the user that is currently logged in. If changing
the default passwords for operator- and supervisor-level the according pass-
word for that level must be entered.
Enter here the new password, you have to enter the same password again in
field . A password only can contain numbers, not characters.
Confirm the new password by entering it a second time here.
Press the OK button to confirm the change of password. Provided that the
contents of fields and are equal, the password is changed.
Press the Cancel button to keep the old password.
After pressing the VNC button, the following dialog appears on the screen. With this dialog you can change the password
for the VNC-server. VNC-viewers can only access the visualization with the correct password, otherwise access is de-
nied.
Copyright © B&R - Subject to change without notice March 31, 2020
SmartMold 9 User Manual_V1.0.0.docx 66/142
SmartMold 9
User Manual Page description

Table 3-68: Change VNC-viewer password

No. Description
Select here which password you want to change:
·View Only .. Password for "View Only" mode
·Operate .. Password for "View" and "Operate" (change pages etc.)
Enter here the new password, you have to enter the same password again in
field .
Confirm the new password by entering it a second time here.
Press the OK button to confirm the change of password. Provided that the con-
tents of fields and are equal, the password is changed.
Press the Cancel button to keep the old password.
After pressing the Edit button or Add button , the following dialog appears on the screen:

Table 3-69: Change user

No. Description
Enter here the user name of the new user. This name will appear then in the user-
list and dropdown for login.
Enter here the password, you have to enter the same password again in field .
Confirm the password by entering it a second time here.
Select the access level for this user.
Press the OK button to confirm the change of user data or the creation of a new
user.
Provided that the contents of fields and are equal, the new user is creat-
ed.
Press the Cancel button to keep the old data or cancel the creation of a new user.
Login and logout of users are logged in the audit trail:

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 67/142
SmartMold 9
User Manual Page description

All pages can be accessed with user level None, except the pages that are listed in the following table:
Table 3-70: Administration authority
Page Number Page Title Required Access Level
141 Sequence Editor Supervisor
534 Mold Autotuning Supervisor
620 Audit Trail Supervisor
700 Trace Setup Operator
701 Trace Graphics Operator
710 SPC Setup Operator
711 SPC Buffer Operator
712 SPC Graphics Operator
712 SPC Distribution Operator
720 Drive Parameters OEM
721 Drive Trace Config 1 OEM
722 Drive Trace Config 2 OEM
723 Drive Trace Config 3 OEM
810 IO Browser Operator
811 IO Monitor Operator
820 Free Prog. Outputs Supervisor
821 Free Prog. Inputs Supervisor
830 Calibration Supervisor
840 Setup Wizard OEM
2000-2211 Setup Wizard OEM
2202 B&R Service Info B&R
Input fields which are locked because the access level of the user currently logged in is not high enough are greyed out:
Table 3-71: Input state
Locked Input Accessible Input

3.8.2 Hidden button

No.

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 68/142
SmartMold 9
User Manual Page description

3.9 Recipe

Figure 3-32: Recipe

3.9.1 Basic introduction

Table 3-72: Recipe
No. Description
Select the type of file that should be loaded, saved, copied or deleted. The file
types are listed depending on the current user level. For example an Operator
can only manipulate recipe data, whereas Supervisors can also manipulate
fixdata.
Select the directory, to which a file should be saved and which contents should
be displayed in the list . For the file type RECIPE the following directories
are available:
·C:\DATA\: This is a directory on the onboard Compact Flash of the Smart-
Mold 9 controller.
·USB\: USB stick that is plugged on the port USB1.
List of all files of file type that can be found in directory . Select here the
file that should be loaded, copied or deleted. As soon as a file is selected, all
information regarding this file is displayed in the box File Information - .
The files Default.rec and Default.fix are B&R default data that cannot be de-
leted.

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 69/142
SmartMold 9
User Manual Page description

Full name of the currently selected file. All file types have different extensions.
The date and time when this file was last modified.
The user who created this file.
File size.
File type. It corresponds to the file type selection made in dropdown .
Comment on the contents of the file. When saving a file, an additional comment
on the contents of the file can be entered in the field .
For recipe data, a preview is displayed. The most important mold settings are
displayed in the preview as soon as a file is selected in the list . This feature
should help the operator to check whether the correct file was selected, before
actually loading it.
Press this button to load the file that is currently selected in list . After load-
ing a recipe (mold data), the recipe file name is displayed in the top area of the
screen. After loading fixdata (machine data), the machine name is displayed in
the top area of the screen.
It is not possible to load files in semi automatic or automatic mode.
By default it is only possible to load mold data (files of type RECIPE) that were
saved on the same machine or machines with the same "machine-name" (op-
tionally this behavior can be disabled).
Press this button to copy the file that is currently selected in list to the se-
cond file device, either from Compact Flash to USB or viceversa. It is only pos-
sible to copy files with user level Operator or higher.
Press this button to delete the file that is currently selected in list . A dialog
appears asking for confirmation. If confirmed, the file is permanently deleted. It
is only possible to delete files with user level Operator or higher. It is not possi-
ble to delete the Default recipe and fixdata.
Enter here the name of the file that should be saved. You can freely choose the
filename, except when fixdata is saved on the Compact Flash. It is only possi-
ble to save fixdata under the name Machine.fix on the Compact Flash.
Enter here a comment to the file that should be saved. As soon as a file is
selected in list later on, its comment is displayed in field .
Press this button to save the current data to a file with the name specified in
field including the comment specified in field on the device selected in
. It is only possible to save files with user level Operator or higher.

3.9.2 Hidden button

No.

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 70/142
SmartMold 9
User Manual Page description

3.10 Production

3.10.1 Production (1)

Figure 3-33: Production (1)

3.10.1.1 Basic introduction

Table 3-73: Setting
No. Description
Number of mold-cavities (number of parts produced with each shot).
Press this button to reset the total cycle and part counter .
Total cycle counter. After every cycle, this value is incremented by 1. It can be
reset by pressing the button .
Total part counter. After every cycle this value is incremented by the number of
parts produced per shot . It can be reset by pressing the button .
Press this button to reset the shift counter or to restart a new shift after the last
was finished. The actual shift part-counters will be set to 0 and the auto-
matic cycle can be started again for the next shift.
Number of required cycles to finish a shift. After reaching the number of shift
cycles the machine stops production and the alarm 20-45 Reset counter is
Copyright © B&R - Subject to change without notice March 31, 2020
SmartMold 9 User Manual_V1.0.0.docx 71/142
SmartMold 9
User Manual Page description

triggered. By changing this value also the required number of parts is

changed accordingly.
Number of required parts to finish a shift. By changing this value also the num-
ber of cycles is set accordingly. This value can only be a multiple value of
the mold-cavities . When a value is entered that is not a multiple of this
value it will rounded up automatically.
Before the number of required shift cycles is reached, a pre-alarm can be trig-
gered. Example: If Pre-Cycles for shift-alarm is set to 10 and Nr. of shift
cycles is set to 100, after 90 cycles the alarm 20-44 Shift finished is triggered
to notify the operator that the shift will end soon.
Selection whether only the good parts are counted for the shift (checkbox
checked) or all parts (checkbox unchecked).
Actual counter of finished products (parts) in shift (counter shows only good
parts if selection "Count only Good Parts" is active). The amount of produced
part compared to the total among of need parts in the shift is displayed in the
pie chart on the left.
Actual counter of bad parts produced in shift (this counter is only visible when
selection "Count only Good Parts" is active).
Set this option to turn off the heating automatically after the machine stops
production at the end of a shift.
Set this option to turn on heat lowering automatically after the machine stops
production at the end of a shift.
Set this option to turn off the motor automatically after the machine stops pro-
duction at the end of a shift.
Number of automatic purge repetitions after shift end. If set to a value other
than 0, purging is done automatically for the specified number of repetitions at
the end of a shift.
Table 3-74: Operating times
No. Description
Total operating time of the SmartMold 9 controller.
Total time the motor was switched on.
Total time the machine was in automatic mode. It counts the time the machine
is actually switched to automatic mode, not necessarily really running (produc-
ing) in automatic mode. It does not count the time the machine is in semiauto-
matic mode.

3.10.1.2 Hidden button.

No.

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 72/142
SmartMold 9
User Manual Page description

3.10.2 Production (2)

Figure 3-34: Production (2)

3.10.2.1 Basic introduction

The interval settings refer to a digital output signal Cycle Interval (DO#382) that can be switched on after a certain num-
ber of cycles for a certain time. This signal can be used for example to activate a conveyor belt.
Table 3-75: Interval settings
No. Description
Interval signal mode. This setting refers to the exact point of switching on the
interval output signal.
·Off: The interval signal is not used.
·At Cycle End: The signal is switched on at the end of the cycle (after Mold
Open and Ejection).
·After Injection: The signal is switched on after injection and holding pressure.
·After Mold Close: The signal is switched on after the mold close movement.
The output signal is not switched on at every cycle, but only at the specified
interval, for example after every 100 cycles.
Right to the set interval the actual counter of interval cycles is displayed. When
the actual counter reaches the required interval cycles, the output signal is
switched on.
Selection whether only the good parts (checkbox checked) are used for in-

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 73/142
SmartMold 9
User Manual Page description

creasing the actual interval counter or all parts (checkbox unchecked).

The time the output signal Cycle Interval remains HIGH after being activated.
Table 3-76: Unmanned mode
No. Description
Activate unmanned mode. When unmanned mode is activated, the machine is
not producing and is not operated (no keys are pressed) the following actions
are taken after the set timeout:
·Motor(s) off
·Mold-Heating off or standby (optional)
·Barrel-Heating off or standby (optional)
·Alarm-Horn Off (optional)
The actions may very depending on manufacturer and machine-type
If this option is selected additionally (to the in mentioned actions), the mold is
unlocked.
When the machine is not operated the actions are not taken immediately,
but this timeout has to pass without any action by the operator (no key
pressed). The time must be set to a value bigger than 0, otherwise the un-
manned mode is disabled!
Table 3-77: RunIn cycles
No. Description
Set number of run-in cycles. During this number of cycles, the part is regarded
to have "bad" quality and the reject-output is set.
Actual number of executed run-in cycles.
Time after which the actual run-in counter is reset to 0. If the machine is not
producing (not running in semi-automatic or automatic mode - e.g. in manual
mode or waiting for start command) the run-in cycle counter is reset after that
time and the run-in function is started again when the machine is restarted.
Table 3-78: Safety gate
No. Description
Safety Gate Mode. Determines when in the sequence the gate will be opened
(in semiautomatic mode):
·Off: The gate is not operated in the sequence
·After Injection: The gate is opened directly after injection
·After Plastification: The gate is opened directly after plastification
·During Mold Open: The gate is opened during mold open (at the given re-
lease position )
·After Mold Open: The gate is opened when the mold is fully opened.
Mold Release position for operating the gate parallel to mold open (see ).
Time for opening the gate. This time is only necessary when the gate has no
opened-sensor and the opening happens only time-based.

3.10.2.2 Hidden button

No.

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 74/142
SmartMold 9
User Manual Page description

3.10.3 SPC Setup

Figure 3-35: SPC Setup

3.10.3.1 Basic introduction

Table 3-79: SPC Setup
No. Description
With this control you can open a tree-view-window from which you can select
the parameter you want to record. The parameter-name will then be displayed
on the left side. Please see further below for a list of the available datapoints.
Reject. If you activate this checkbox a violation of the limits will set the reject-
signal (output, robot).
The limits of parameters that are evaluated until the end of injection are
checked immediately after injection and will set the reject-signal in the actual
cycle. The other parameters are checked at the end of the cycle and will affect
the reject-signal for the next cycle (see list below, entry "PreTrigger").
MIN-Limit for the recorded parameter. If the recorded value is below that limit
the alarm 20-41 SPC value exceeded min/max range is set and the reject-
signal is set (if configured – see above). Checking if MIN/MAX-Limit is disabled
if both limits are set to 0.
MAX-Limit for the recorded parameter. If the recorded value is above that limit
the alarm 20-41 SPC value exceeded min/max range is set and the reject-
signal is set (if configured – see above). Checking if MIN/MAX-Limit is disabled

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 75/142
SmartMold 9
User Manual Page description

if both limits are set to 0.

With the "Start SPC"-button you can start and stop the recording of the config-
ured list. If any parameter-selection has changed since the last recording the
data in the record-buffer is lost (there will be a pop-up window to inform you
about that).
With the "Clear All"-button you can clear all the recorded data (a dialog has to
be confirmed before this is done).
By activating "Enable File Logging" the data is written to a file on the USB-stick
as well (a USB device has to be connected!!).
The created file is csv-text-file (Unicode UTF8-encoded) which contains the
values of all configured parameters. At the beginning of the file is the header
containing the datapoint names and units, and after that at the end of every
cycle a new line is added with all actual values from the cycle.
Each line starts with the actual date and time (YYYY.MM.DD hh:mm:ss), then
comes the SPC record index (starting with 0 at the start of the logging) and
after that the machine cycle number. After that general information the actual
values of the configured datapoints are entered. After each value a column is
added that contains information whether the value was outside the set limits
("X") or caused a reject ("R") or was ok ("").
Table 3-80: Datapoints
Mold
Mold Open Position of the mold when it was opened. The sample is
Position taken after the mold open movement is finished.
Mold Open Time Time for the mold open process. The time is measured from
the start to the complete end of mold opening. If cores are
programmed in between mold open or the robot moves in
between open this actions are also part of this time.
Mold Close Time Time for the mold close process. The time is measured from
the start to the complete end of mold closing. If cores are
programmed in between mold close this core-movements
are also part of this time.
Mold Max Position Max. Position of the mold during the cycle. While the "Mold
Open Position" is a single sample taken after the end of
mold opening this value contains the max. position that was
reached (overshoots are considered here).
Ejector
Ejector Forward Position Position of the ejector when it was in forward position. The
sample is taken after the end of the forward-movement.
Ejector Backward Position Position of the ejector when it was in backward position. The
sample is taken after the end of the backward-movement.
Ejector Time Time of the ejection process. Time from start of first ejector
forward movement to the end of the ejections (when option
"Ejector Stay Forward" the process ends in semi-automatic
mode when the ejector is forward, otherwise it ends when
the ejector is back).
Ejector Min Position Min. Ejector position reached during the cycle
Ejector Max Position Max. Ejector position reached during the cycle.
Injection Unit
Inj. Unit Forward Time Time from start to the end of the injection unit forward
movement.
Inj. Unit Backward Time Time from start to the end of the injection unit backward
movement.
Nozzle Temperature Temperature of the nozzle at the end of injection
Inj. Unit Backward Position Position of the injection unit after the end of the backward
movement.
Injection
Max. Injection Pressure Max. Injection Pressure during injection and holdon-
pressure phase.
Injection Speed Max. Injection velocity.
Switchover Position Position of the injection screw at the switchover from injec-
tion to holdon-phase.
Switchover Time Time from start of injection to the switchover from injection
Copyright © B&R - Subject to change without notice March 31, 2020
SmartMold 9 User Manual_V1.0.0.docx 76/142
SmartMold 9
User Manual Page description

to holdon-phase.
Dosage Position of the injection screw after the end of the plastifica-
tion movement.
Cushion Cushion position. This is the minimum position reached
during holdonpressure phase or optionally the position at the
end of the holdon-pressure phase.
Switchover Pressure Injection pressure at the switchover from injection to holdon-
phase.
Plastification Time Time of the plastification process.
Injection Back Position Position after end of the decompression after movement.
Injection Max Position Max. position reached by the injection piston during the
cycle.
Cylinder
Nozzle Temperature of Nozzle
Cylinder #1 Temperature of Cylinder zone 1
Cylinder #2 Temperature of Cylinder zone 2
Cylinder #3 Temperature of Cylinder zone 3
Cylinder #4 Temperature of Cylinder zone 4
Cylinder #5 Temperature of Cylinder zone 5
Cylinder #6 Temperature of Cylinder zone 6
Cylinder #7 Temperature of Cylinder zone 7
Cylinder #8 Temperature of Cylinder zone 8
Cylinder #9 Temperature of Cylinder zone 9
Cylinder #10 Temperature of Cylinder zone 10
Cylinder #11 Temperature of Cylinder zone 11
Cylinder #12 Temperature of Cylinder zone 12
Cylinder #13 Temperature of Cylinder zone 13
Cylinder #14 Temperature of Cylinder zone 14
Cylinder #15 Temperature of Cylinder zone 15
General
Cycle Time Cycle Time of the machine. Time from start of the cycle to
the end of the cycle.
Cycle Interval Cycle Interval time. Time between the actual end of cycle
and the end of the last cycle (this time considers also the
idle time in semi-automatic mode, otherwise it is identical to
"Cycle Time").
Production Time Time from start of the cycle to the end of the cycle or to the
opening of the safety gate (if gate is opened before cycle
end, e.g. parallel to mold open). When the gate is not
opened during cycle this time is equal to the "Cycle Time",
otherwise it is shorter.
Acopos
ServoPump #1..#3
SPump#1..#3 Motor Temp Temperature of the servo-motor of the SmartPump
SPump#1..#3 Heatsink Temperature of the heat-sink (servo-drive) of the
Temp SmartPump
SPump#1..#3 Load Mot- Motor Load (0..100%) of the servo-motor of the SmartPump
Model
SPump#1..#3 Load Continuous current load (0..100%) of the servo-drive of the
ContCurr SmartPump
SPump#1..#3 Load Peak current load (0..100%) of the servo-drive of the
PeakCurr SmartPump
SPump#1..#3 Load Power Power load (0..100%) of the servo-drive of the SmartPump

3.10.3.2 Hidden button

No.

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 77/142
SmartMold 9
User Manual Page description

3.10.4 SPC Buffer

Figure 3-36: SPC Buffer

3.10.4.1 Basic introduction

Table 3-81: SPC buffer
No. Description
Index of the record. This is a continuous index that starts with 1 whenever the
SPC-recording is started new.
Machine cycle. This is the value of the cycle counter when the data-set was
recorded.
Values recorded for the selected parameter. On this page up to 5 datapoints
are shown simultaneously. If more parameters are recorded, it is possible to
scroll through the parameters using the function keys.
Values are displayed (highlighted) in red color if they have violated the set
limits.
Table 3-96: SPC management
No. Description
Mean value. Here the mean (average) value for the parameter is displayed.
Here the standard deviation for the parameter is shown. It shows how much
variation there is from the average value. A low standard deviation indicates
that the data points tend to be very close to the mean, whereas high standard

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 78/142
SmartMold 9
User Manual Page description

deviation indicates that the data is spread out over a large range of values. For
a normal distributed value 68% of all samples are within the range of +/-1 x
standard deviation from the average value.
Specified limit for the parameter.
Maximum measured value in the recording period.
Minimum measured value in the recording period.

3.10.4.2 Hidden button

Figure 3-37: Hidden button

Table 3-82: Hidden button
No. Description
Moves one line up (newer data) in the displayed record data. Works only if not
already the newest data is shown.
Moves one line down (older data) in the displayed record data. Works only if
not already the oldest data is shown.
Scroll Left. Display different (first) parameters. This button can be used to scroll
through the parameters if more than 5 were selected.
Scroll Right. Display different (last) parameters. This button can be used to
scroll through the parameters if more than 5 were selected.
Moves on page up (newer data) in the displayed record data. Works only if not
already the newest data is shown.
Moves one page down (older data) in the displayed record data. Works only if
not already the oldest data is shown.

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 79/142
SmartMold 9
User Manual Page description

3.10.5 SPC Graphics

Figure 3-38: SPC Graphics

3.10.5.1 Basic introduction

Table 3-83: SPC Graphics
No. Description
Value-Scale for the graph. The values refer to only one curve from the graph. It
can be selected by the radio-buttons (see below) which scale should be dis-
played.
Time-scale for the graph. It shows the record-index for the values.
Graph drawing area. Here the different curves (color can be selected - see
below) are displayed.
Cursor. The cursor is displayed as a vertical line. At the intersection with the
curves a rectangular is drawn.
This radio buttons are used to determine which vale is used as a reference for
the value-scale in the graph.
With this soft-button you can scroll back to the oldest values in the record buff-
er.
With this soft-button you can show/hide the cursor. If the cursor is disabled also
the outputs for cursor-values and the cursor-keys are hidden.
With the dropdown you can select which recorded parameter should be dis-
played. If you set the selection to "" than the curve will not be visible.
Copyright © B&R - Subject to change without notice March 31, 2020
SmartMold 9 User Manual_V1.0.0.docx 80/142
SmartMold 9
User Manual Page description

With this color-picker control, you can select the color for each curve. Just
press enter when you have selected the colored box and select the new color
from the pop-up window.
Value of the parameter at the actual cursor position.
Min. Limit for the scaling of the graph. As Default the specified min. limit for
recording is used. Changing this value affects only the scaling of the graph but
not the limits that are used for recording (reject).
Max. Limit for the scaling of the graph. As Default the specified max. limit for
recording is used. Changing this value affects only the scaling of the graph but
not the limits that are used for recording (reject).

3.10.5.2 Hidden button

Figure 3-39: Hidden button

Table 3-84: Hidden button
No. Description
Zoom In. If you press this key less values are displayed in the graph (curves are
stretched). Only works if the max. possible zoom-factor is not reached yet.
Zoom Out. If you press this key more values are displayed in the graph (curves
are compressed). Only works if the min. possible zoom-factor is not reached
yet.
Move cursor left. Moves the cursor to the left side of the screen (toward older
values).
Move cursor right. Moves the cursor to the right side of the screen (toward new-
er values).
Scroll the display to the left (older, historic data).
Scroll the display to the right (newer, actual data).

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 81/142
SmartMold 9
User Manual Page description

3.11 IO Status

3.11.1 IO Browser

Table 3-40: IO Browser

3.11.1.1 Basic introduction

Table 3-85: IO Browser
No. Description
Dropdown to change the view and display different information on the right side
of the screen:
·IOs .. Display IO-datapoints for selected module
·Configuration .. Display configuration for selected module
·Status .. Display status-information for selected module
·Information .. Display general information for selected module
·PLC .. Display information about used PLC
Physical Status of the IO (status at the connector):
·Input LOW
·Input HIGH
·Output LOW
·Output HIGH
·IO not connected, module not connected

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 82/142
SmartMold 9
User Manual Page description

Short description of the IO and the IO-index. The following descriptions are
possible:
·DI .. digital input
·DO .. digital output
·AI .. analog input
·AO .. analog output
·AT .. temperature input
·RO .. digital (relay) output
·PM .. PWM output
Name of the connected controller-parameter.
A checkbox indicates whether the IO is inverted. This feature is only available
for digital inputs. For all other IOs this checkboxes are hidden.
With this checkbox you can change the force-status of the IO. When you click
on the checkbox the force-dialog (see below) will appear that allows you the set
the force-status and force-value of the IO.
Forced IOs will be highlighted with a checked checkbox with red back-color
(like first IO in example).
Forcing is only 83possible for users with access-level “Supervisor” or higher.
Value of the IO-parameter in the software (this value already regards the invert-
flags etc.)
For digital signals the following force-dialog will be shown:

Just select the force status from the drop-down menu:

·Disable Force .. IO will not be forced
·Force ON .. IO will be forced to HIGH (on)
·Force OFF .. IO will be force to LOW (off)
The dialog will automatically close once you have selected something from the drop-down or pressed
cancel (force-status will not change than).
For analog signals the following force-dialog will be shown:

Table 3-86: Force

No. Description
Set the force status:
·Off .. IO will not be forced
·On .. IO will be forced
Force-value. This value will be applied to the IO when the force-status is "on".
Units may vary depending on IO-type.
To activate the new force-values you need to press this soft-button.
When you have selected the configuration view then you can see the possible configuration-settings for the selected
module. If no configuration is necessary or available for that module that screen stays empty.

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 83/142
SmartMold 9
User Manual Page description

When you have selected the status view then you can see the available status-information for that module. The type of
information displayed here depends on the module-type - in the following example the readback-status of digital outputs
is displayed.

When you have selected the information view then you can see the module-information that is identical for all modules:

Table 3-87: Module-information

No. Description
Serial-number of the module
Module ID (identification number). The full serial number of the module consists
of the Module ID and the serial number above .
Hardware Variant. Represents the hardware-revision of the selected module.
Firmware. Version-number of firmware used by the selected module.
When you have selected the PLC-information view then you can see information about the used CPU (Panel):

Table 3-88: PLC-information

No. Description
Name (order-code) of the used CPU (Panel).
Serial number of the PLC.
Module ID (identification number). The full serial number of the PLC consists of
this Module ID and the serial number above .

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 84/142
SmartMold 9
User Manual Page description

The diagnosis-function and the diagnosis-screen can be activated with the key F3 on this page (see below). It will give
you information about which modules are configured and which are really plugged:

Table 3-89: Module diagnosis

No. Description
Status of the listed module. If a module is plugged incorrectly or missing the
whole line is highlighted with red back-color. The following states are possible:
·Missing .. module is configured but not connected
·Not. conf. .. the connected module is not configured
·OK .. module is configured and at its correct position
·Wrong .. wrong module connected
Routing to the module. Gives the exact routing-path to that module (the last
number is always the node-number of the module).
Name of the configured module
Name of the plugged (connected) module

3.11.1.2 Hidden button

Figure 3-41: Hidden button

Table 3-90: Hidden button
No. Description
Select next module in list
Select previous module in list
Open diagnosis-screen
Reload the actual IO-configuration from the PLC. A confirmation dialog will
appear after you pressed this button.
Reloading the IO-configuration is normally not necessary unless it was changed
by an external source.

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 85/142
SmartMold 9
User Manual Page description

3.11.2 Monitor

Figure 3-42: IO monitor

3.11.2.1 Basic introduction

Table 3-91: IO monitor
No. Description
Here the functional group can be selected, for which all related IO-datapoints
are displayed. The following groups can be selected:
·Hydraulic Main
·Hydraulic Aux
·Endswitches
·Motor, Lubrication
·General
·Safety Gate
·Temperature Cylinder
·Temperature Mold 1
·Temperature Mold 2
·Robot
·Cores
·Jog Buttons
·Free Programmable
Outputs are displayed in red color.

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 86/142
SmartMold 9
User Manual Page description

For digital outputs, a LED-icon is displayed that is red when the output is on
(HIGH) or grey if it is off (LOW).
For analog outputs the actual signal is shown in red letters.
The datapoint name is shown in grey (like in the example) when the IO-
datapoint is not connected (not assigned to a physical IO-point) or black if it is
actually assigned to an IO module.
Outputs are displayed in green color.
For digital outputs, a LED-icon is displayed that is green when the input is ac-
tive (HIGH) or grey if it is inactive (LOW).
For analog inputs, the actual signal is shown in green letters.
The datapoint name is shown in grey (like in the example) when the IO-
datapoint is not connected (not assigned to a physical IO-point) or black if it is
actually assigned to an IO module.

3.11.2.1.1 Hidden button

No.

3.12 Alarms

3.12.1 Alarms

Figure 3-43: Alarms

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 87/142
SmartMold 9
User Manual Page description

3.12.1.1 Basic introduction

Table 3-92: Alarms
No. Description
Display of the alarm-number. For specific alarm information, please refer to
chapter 6 Alarms.
Date and time when the status-changed happened.
Alarm text.
Display of the actual alarm status.

3.12.1.2 Hidden button

No.

3.12.2 Alarm History

Figure 3-44: Alarm history

3.12.3 Basic introduction

Table 3-93: Alarm history
Copyright © B&R - Subject to change without notice March 31, 2020
SmartMold 9 User Manual_V1.0.0.docx 88/142
SmartMold 9
User Manual Page description

No. Description
Display of the alarm-number. For specific alarm information, please refer to
chapter 6 Alarms.
Date and time when the status-changed happened.
Alarm-Text.
Display of the changed alarm status.

3.12.3.1 Hidden button

Figure 3-45: Hidden button

Table 3-94: Hidden button
No. Description
Move to first (newest) entries in list
Scroll Up - show newer entries in list
Scroll Down - show older entries in list
Save alarm-history to USB-stick. When you press this key, a confirm-dialog
pops up before the data is saved to a file.

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 89/142
SmartMold 9
User Manual Page description

3.13 Audit Trail

3.13.1 Audit Trail

Figure 3-46: Audit Trail

3.13.1.1 Basic introduction

Table 3-95: Audit Trail
No. Description
Scroll-Bar that indicates the position of the actual shown entries in the whole
record. If the bar is on top it means that the newest entries are shown. If it is at
the bottom，the oldest entries are shown.
Type of event. The following events are recorded:
·Value Changed .. A recipe-parameter (operator setting) was changed
·Value Limited .. A recipe-parameter was limited (after loading a recipe-file or
after changing a machine-parameter)
·FixValue Changed .. A machine-parameter (OEM setting) was changed
·Recipe Loaded .. A recipe-file was loaded
·Recipe Saved .. A recipe-file was saved
·User logged in .. A user has logged in
·User logged out .. The current user has logged out
·CPU-time changed .. The CPU-time (clock) was changed

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 90/142
SmartMold 9
User Manual Page description

·Motor On .. The motor was turned on

·Motor Off .. The motor was turned off
·Wizard created basic recipe .. The molding wizard has created a basic reci-
pe
·Wizard changed .. The molding wizard has changed a value
·Wizard undid last changes .. The molding wizard undid its last change
·DI forced .. A digital input was forced
·DO forced .. A digital output was forced
·AI forced .. A analog input was forced
·AO forced .. A analog output was forced
·AT forced .. A temperature input was forced
·DI unforced .. The force of a digital input was reset
·DO unforced .. The force of a digital output was reset
·AI unforced .. The force of a analog input was
·AO unforced .. The force of an analog output was reset
·AT unforced .. The force of a temperature input was reset
Date and time of the recorded event
Additional information for the event. The following information is entered:
·Value Changed .. parameter-name: old value -> new value
·Value Limited .. parameter-name: new value
·FixValue Changed .. parameter-name: old value -> new value
·Recipe Loaded .. file-name
·Recipe Saved .. file-name
·User logged in .. user-name (user-level)
·User logged out .. -
·CPU-time changed .. new CPU time
·Motor On .. -
·Motor Off .. -
·Wizard created basic recipe .. -
·Wizard changed .. parameter-name: old value -> new value
·Wizard undid last changes .. -
·DI forced .. Datapoint-name of connected variable or (if no variable connect-
ed) the IO-datapoint description
·DO forced .. Datapoint-name of connected variable or (if no variable connect-
ed) the IO-datapoint description
·AI forced .. Datapoint-name of connected variable or (if no variable connect-
ed) the IO-datapoint description
·AO forced .. Datapoint-name of connected variable or (if no variable connect-
ed) the IO-datapoint description
·AT forced .. Datapoint-name of connected variable or (if no variable connect-
ed) the IO-datapoint description
·DI unforced .. Datapoint-name of connected variable or (if no variable con-
nected) the IO-datapoint description
·DO unforced .. Datapoint-name of connected variable or (if no variable con-
nected) the IO-datapoint description
·AI unforced .. Datapoint-name of connected variable or (if no variable con-
nected) the IO-datapoint description
·AO unforced .. Datapoint-name of connected variable or (if no variable con-
nected) the IO-datapoint description
·AT unforced .. Datapoint-name of connected variable or (if no variable con-
nected) the IO-datapoint description

3.13.1.2 Hidden button

No.

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 91/142
SmartMold 9
User Manual Page description

3.13.2 Trace Graphics

Figure 3-47: Trace Graphics

3.13.2.1 Basic introduction

Table 3-96: Trace Graphics
No. Description
Scale for the Y-axis of the graph. Here either the scale for Speed, Pressure or
Position is shown - this can be selected by the radio-buttons (see below).
Scale for the x-axis of the graph. Here the index of the samples (0-400) is being
displayed.
Drawing area. Here the curves for the different values are drawn:
·Orange .. set speed
·Green .. actual speed
·Brown .. set pressure
·Violet .. actual pressure
·Yellow .. actual position
The cursor (red) and reference-cursor (green) are displayed as vertical lines. At
the intersection with the curves a rectangular is drawn.
With this soft-button you can scroll back to the beginning (deactivate scroll).
With this soft-button you can zoom in - the graph is stretched (less samples are
displayed on the screen).
With this soft-button you can zoom out - the graph is compressed (more sam-
Copyright © B&R - Subject to change without notice March 31, 2020
SmartMold 9 User Manual_V1.0.0.docx 92/142
SmartMold 9
User Manual Page description

ples are displayed on the screen).

With this soft-button you can hide / show the cursor. When the button is
pressed the cursor is visible, if it is released the cursor and all controls for the
cursor are hidden.
With this soft-button you can hide / show the reference-cursor. When the button
is pressed the reference-cursor is visible, if it is released the reference-cursor
and all controls for the cursor are hidden.
This time shows the position of the cursor (time since start of tracing).
This time shows the time-difference between the cursor-position and the refer-
ence-cursor position.
With this radio-buttons you can select which scale should be used for the Y-
axis of the graph (Speed, Pressure or Position).
Scaling for the Y-axis of the graph. You can select a MIN- and MAX-value for
the speed-curves (set and actual speed), the pressure curves (set and actual
pressure) and the position curve (actual position).
Set-values (Speed, Pressure) at the actual cursor-position. These outputs are
hidden if the cursor is disabled.
Actual values (Speed, Pressure, Position) at the actual cursor-position. These
outputs are hidden if the cursor is disabled.
Set-value difference (Value at cursor-position minus value at reference-cursor-
position) for Speed and Pressure. These outputs are hidden if the reference-
cursor is disabled.
Actual value difference (Value at cursor-position minus value at reference-
cursor-position) for Speed, Pressure and Position. These outputs are hidden if
the reference-cursor is disabled.

3.13.2.2 Hidden button

Figure 3-48: Hidden button

Table 3-97: Hidden button
No. Description
Scroll Left. Older values are being displayed. This function only works if you are
zoomed in (less than 400 samples are displayed in the graph) and if you have
not reached the oldest value (sample 0) yet.
Scroll Right. Newer values are being displayed. This function only works if you
are zoomed in (less than 400 samples are displayed in the graph) and if you
have not reached the newest value (sample 400) yet.
Move Cursor Left. By pressing this button, you move the cursor to the left (older
values). This key is hidden when the cursor is disabled.
Move Cursor Right. By pressing this button you move the cursor to the right
(newer values). This key is hidden when the cursor is disabled.
Move Reference-Cursor Left. By pressing this button you move the reference-
cursor to the left (older values). This key is hidden when the reference-cursor is
disabled.
Move Reference-Cursor Right. By pressing this button you move the reference-
cursor to the right (newer values). This key is hidden when the reference-cursor
is disabled.

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 93/142
SmartMold 9
User Manual Page description

3.14 User log

Figure 3-49: User log

3.14.1 Basic introduction

Table 3-98: User log
No. Description
Display user log information. The information mainly includes time, information
description and parameter change records.

3.14.2 Hidden button

Figure 3-50: Hidden button

Table 3-99: Hidden button
No. Description
Display the latest user log, corresponding to the F1 key in the A area of the
keyboard.
Display the previous page user log, corresponding to the F2 key in the A area of
the keyboard.
Copyright © B&R - Subject to change without notice March 31, 2020
SmartMold 9 User Manual_V1.0.0.docx 94/142
SmartMold 9
User Manual Page description

Display the previous user log, corresponding to the F3 key in the A area of the
keyboard.
Display the next user log, corresponding to the F4 key in the A area of the key-
board.
Display the next page of the user log, corresponding to the F5 key in the A area
of the keyboard.
Export the user log to a USB flash drive in the form of a file, corresponding to
the F6 key in the A area of the keyboard. Note: When enabling this function,
please make sure that the USB flash drive is correctly connected to the USB
interface, otherwise the system will report a path error.

3.15 Settings

Figure 3-51: Settings

3.15.1 Basic introduction

Table 3-100: IP settings
IP-Address that should be used by the controller.
Subnet-Mask that should be used by the controller.
Default Gateway that should be used by the controller.
Table 3-101: Panel-setting
No. Description
Copyright © B&R - Subject to change without notice March 31, 2020
SmartMold 9 User Manual_V1.0.0.docx 95/142
SmartMold 9
User Manual Page description

With this soft-button you can scroll through the available languages. For the
current active language, the national flag is shown. You have to press this
button until the desired language appears.
After this time (if no key is pressed on the panel), the backlight will be switched
off and the screen goes dark.
Here you can set the brightness of the display (0-100%).
Table 3-102: Screenshot
No. Description
Device where the screenshot (bitmap) is saved to (fixed: USB1 - first USB-slot)
Status of the screenshot-operation:
·OK .. last screenshot successful
·Error .. error occurred at last screenshot (USB-device connected?)

The error report is a summary of the controller settings and actual data that will be saved to the USB device. In case of
an error on the controller this system dump will help the software development to find the problem quickly. Please always
make such an error report when an unknown problem occurs with the controller, it is most useful to save the error report
immediately after the problem happened.
Table 3-103: Error report
No. Description
Current software version used on the controller
Exact software revision used on the controller
To create an error report you need to press this button. A confirmation dialog
will appear before the error report is really written.
Table 3-104: Time settings
No. Description
Date to be set on the controller
Time to be set on the controller
Press this soft-button to activate the settings for data and time .

3.15.2 Hidden button

No.

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 96/142
SmartMold 9
User Manual Page description

3.16 Automatic Sequence

3.16.1 Automatic Sequence

Figure 3-52: Automatic sequence

3.16.1.1 Basic introduction

On this page, the currently active automatic sequence can be seen. The individual steps are represented by icons. Each
step lasts as long as the action it represents. As long as a step is active, it is highlighted in red color. Multiple steps may
be active at the same time if the steps are programmed parallel.
On the left side of the page, the actual times for the steps are displayed:
Table 3-105: Automatic sequence
No. Description
In this column the times from the actual cycle are displayed (up counting).
In this column the times from the last cycle are displayed (static).
The main steps are listed here. If one of them is active the row will be highlight-
ed in orange color. The first line is always active as it represents the complete
cycle.
Actual Sequence. All steps are shown here. If the amount of steps exceeds the
size of the page, scroll icons are displayed and the sequence will automatically

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 97/142
SmartMold 9
User Manual Page description

scroll to the active steps when the sequence is running.

3.16.1.2 Hidden button

No.

3.16.2 Sequence Editor

Figure 3-53: Sequence editor

3.16.2.1 Basic introduction

Table 3-106: Sequence editor
No. Description
With this option, graphic sequence programming can be enabled (otherwise the
sequence is automatically generated from the settings on the individual pages).
When this checkbox is active, all settings on the other pages that refer to the
sequence are locked and marked as Programmed. The sequence can then
only be changed from the editor here.
With this button the actual active sequence can be loaded to the editor. This
function can be used to undo all changes that were made in the editor after the
sequence was activated the last time (by pressing button ) or to upload a
complicated sequence that was generated using the settings on the other pag-
Copyright © B&R - Subject to change without notice March 31, 2020
SmartMold 9 User Manual_V1.0.0.docx 98/142
SmartMold 9
User Manual Page description

es.
With this button the edited sequence can be activated on the machine. The
sequence on Pages >> Automatic Sequence is then identical to the one you
have programmed.
With this button the last change can be undone (if the button is not visible an
undo is not possible). It works only for the last change, no multiple undoes are
possible. This button is only displayed when an undo is possible.
List of available default-sequences (dropdown).
Comment stored in the actual selected sequence. The comment will be dis-
played as soon as the selection is changed in . This text may contain
Unicode characters.
With this button the selected sequence ( ) can be loaded and activated. That
means that the sequence will get active immediately after loading the data
(loading is not allowed when the automatic sequence is active).
Sequence to be edited. You can use the cursor keys to move through the
steps. The selected step will be highlighted (red background color).
Information on all possible steps and the icons used can be found in the docu-
mentation Pages >> Automatic Sequence.

3.16.2.2 Hidden button

Figure 3-54: Hidden button

Table 3-107: Hidden button
No. Description
Insert a new step after the selected step (sequential). When you press this key
the Insert Step dialog will be displayed (see below).。
Insert a new step parallel to the selected one (parallel movement). When you
press this key the Insert Step dialog will be displayed (see below).
Delete the selected step. The deletion will happen immediately without a confirm
dialog. If you have pressed this key unintentionally, you can use the Undo but-
ton to restore the step again.
Close a parallel brace after the selected step. If you press this button, the next
open layer will be closed.
If there are two layers open and you want to close the next but one layer you
need to close both layers first (press this key twice) and remove afterwards the
closed brace from the layer which you do not want to be closed by pressing key
. See also the screenshots below.
Remove the closed brace after the selected step (open the layer again). You
need to select the last step in a parallel (already closed) layer. If you press this
key the closed brace will be removed (layer will be open again).
By pressing this key you are directed automatically to the page where the set-
tings for the currently selected step can be made. For example if the Ejection
step is selected you will be directed to Pages >> Ejector.
Explanation on key (how to close the next but one layer):

After pressing a key for inserting a new step, the following dialog is displayed:

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 99/142
SmartMold 9
User Manual Page description

Table 3-108: Insert step

No. Description
Here you can select where the step should be exactly inserted (depending on
the key you have pressed to open that dialog the respective insert mode will be
preselected). The possible settings are:
·After Selected Step .. the new step will be inserted sequentially after the
selected step
·Before Selected Step .. the new step will be inserted sequentially before the
selected step
·Parallel to Selected Step .. the new step will be inserted parallel in a new
layer to the selected step
·Replace Selected Step .. the selected step will be replaced (old step will be
deleted)
Here you can select the step that you want to insert. See also the documenta-
tion on page Automatic Sequence for an explanation on all steps.
Additional settings for the step to be inserted (different settings are shown de-
pending on the selected step). In the screenshot above an intermediate stop
can be optionally programmed. See also and for further examples of
additional settings.
Additional settings for the step to be inserted (different settings are shown de-
pending on the selected step). In the screenshot above the intermediate stop
position can be entered (if an intermediate stop is enabled). See also and
for further examples of additional settings.
To complete the action and insert the new step you have to press this button.
Press this button to cancel the action. The sequence will not be changed.
Further example for additional settings for the step to be inserted (different set-
tings are shown depending on the selected step). In the screenshot above the
index for an airblow or core can be chosen (airblow or core number).
Further example for additional settings for the step to be inserted (different set-
tings are shown depending on the selected step). In the screenshot above the
parameter set for the core movement can be selected.

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 100/142
SmartMold 9
User Manual Page description

3.17 Free Prog. Inputs

3.17.1 Free Prog. Inputs

Figure 3-55: Free Prog. Inputs

3.17.1.1 Basic introduction

Table 3-109: Inputs
No. Description
With this dropdown you can select the input that you want to edit/view. In the list
the number of the input (e.g. "#1:") will appear and maybe the description text (if
one was configured).
By checking the checkbox the input will be inverted. That means that the config-
ured action (see below) will be executed when the input is LOW. Normally the
action is only performed when the input is HIGH.
With this dropdown you can enable or disable the whole free programmable
input function. If it is "Disabled" than the configured action will never be per-
formed. If it is "Enabled", then the action will be performed when the input has
the desired status.
Description text for the input. This text will appear everywhere the input is used
(e.g. also in the alarm- or diagnosis-message that will be set.
Copyright © B&R - Subject to change without notice March 31, 2020
SmartMold 9 User Manual_V1.0.0.docx 101/142
SmartMold 9
User Manual Page description

Table 3-110: Additional condition

No. Description
Type of condition (please see Table Action below)
Depending on the condition that you have chosen you can enter the compare-
value here.
If a condition is chosen that need an IO-datapoint you can select this datapoint
here.
With this checkbox you can logically invert the condition (e.g. in the example
above the condition is inverted - so it is TRUE when the mold is NOT opened).
Table 3-111: Action
No. Action
With this first dropdown you can select the type of action:
·None: Nothing will be done
·Set Alarm: The alarm 20-60/61/62/63/64 Free Input#1/2/3/4/5: Description
Text is set
·Set Alarm (Edge): The alarm 20-60/61/62/63/64 Free Input#1/2/3/4/5: De-
scription Text is set when a positive edge on the input (and condition) occurs
·Block Movement: A movement is blocked without a diagnosis message
·Block Movement (+Diag): A movement is blocked and a diagnosis message
is given
·End Cycle (Alarm): The alarm 20-60/61/62/63/64 Free Input#1/2/3/4/5:
Description Text is set and the cycle is stopped at the end of the current cycle
·Stop Cycle (Alarm): The alarm 20-60/61/62/63/64 Free Input#1/2/3/4/5:
Description Text is set and the cycle is stopped immediately
If the input should block a movement you can select the axis here that should
be blocked.
If the input should block a movement you can select the direction that should be
blocked:
·Both: both direction
·Negative: only block negative direction
·Positive: only block positive direction
Table 3-112: Actual status
No. Description
Display of the physical status of the IO (status at the connector-pin): Grey =
LOW, Green = HIGH
Display of the logical status of the free programmable input (considering invert
and condition): Grey = LOW, Green = HIGH(active)

3.17.1.2 Hidden button

No.

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 102/142
SmartMold 9
User Manual Page description

3.17.2 Free Prog. Outputs

Figure 3-56: Free prog. outputs

3.17.2.1 Basic introduction

Table 3-113: Free prog. outputs
No. Description
The LED-icon is showing the actual status of the selected free programmable
output (grey = LOW, red = HIGH).
With this dropdown you can select the free programmable output you want to
edit. In the list the number of the output is shown (e.g. "#1:") and maybe the
description text for the output (if a text was assigned).
With this dropdown you can select whether the output is enabled ("on") or disa-
bled ("off"). If it is disabled than the output is always LOW and the logic is not
executed. If it is enabled, then the output is set according to the programmed
logic.
Here you can enter a description text for the output. This text will appear every-
where the output is used (e.g. in IO-list etc.).
Table 3-114: Condition
No. Description
Information about the condition used in the selected ladder-step. In the top bar,
the type of condition is displayed. In the field below the compare value or the IO-
datapoint is displayed if necessary for the selected step.
Copyright © B&R - Subject to change without notice March 31, 2020
SmartMold 9 User Manual_V1.0.0.docx 103/142
SmartMold 9
User Manual Page description

Table 3-115: Type

No. Description
Information about the logic used in the selected ladder-step. In the top bar, the
text for the used logic is displayed. In the field below, the icon used is displayed.
If necessary also the delay-time for the step is displayed here.
In the ladder-logic different steps can be linked using different logical connection.
You can navigate through the logic using the normal cursor-keys. The actual cursor-position is displayed by a thin rec-
tangular around the selected step. At first this rectangular is grey (inactive) as the focus is on the setting-inputs (see
above). Once you move the focus down (cursor-key down) then the rectangular turns red (gets active) and the function
keys (see below) are displayed. You can then navigate through the steps. If you are in the top-line of the logic and move
the focus further up (cursor-key up) then the setting-inputs get active again and the rectangular turns grey again (function
keys will disappear again).
In the ladder-display icons for the used logic are displayed. If necessary the used condition or the set
delay-time is displayed below the icon.
If the output is enabled then the signal-status is displayed in the logic using an orange background (signal = HIGH) for all
the symbols and connections. With this power-flow you can monitor the exact function of the logic.
The last column in the ladder-logic is reserved for defining the type of output (direct, indirect, set, reset).

When you decide to insert a new step (see description of function keys further below) in one of the first three columns
(logical connection) then the following dialog will appear:

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 104/142
SmartMold 9
User Manual Page description

Table 3-116: Change settings

No. Description
Here you can select the type of logical connection that should be inserted (see
below for list of possible connections).
Here the icon for the selected logical connection is displayed
Here the delay time can be entered if an according logical connection (On-Delay
or Off-Delay) is selected.
For "Normally Opened"- and "Normally Closed"-steps you can select the used
condition here. This condition defines whether the contact is closed or not.
Depending on the condition that you have chosen you can enter the compare-
value here.
If a condition is chosen that needs an IO-datapoint you can select this datapoint
here.
When all the settings are okay and you want to insert the step at the actual
position you have to press this soft-button.
When you do not want to insert the new step you can cancel the operation by
pressing this soft-button.
When you decide to insert a new step (see description of function keys further below) in the last column (output) then the
following dialog will appear:

Table 3-117: Change settings

No. Description
Here you can select the type of output you want to set (see below for list of
possible outputs).
Here the icon for the selected output is displayed
When all the settings are okay and you want to insert the step at the actual
position you have to press this soft-button.
When you do not want to insert the new step you can cancel the operation by

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 105/142
SmartMold 9
User Manual Page description

pressing this soft-button.

The following function keys will appear automatically once you have moved the focus to the ladder logic:

Table 3-118: Hidden button

No. Description
Make or remove the vertical connection to the higher layer after the selected
step.
Insert a link (connection without logical function) at the current position
Insert a new step at the current position. After pressing this key the insert-dialog
(see above) will appear.
Remove the step at the current position. The field will be empty after pressing
this key.
The following logical connections may be inserted:
Link. The status of the input will be passed to the output without
any logical connection.

Normally Opened Contact. When the assigned condition is TRUE

than the status of the input will be passed to the output. If the
condition is FALSE than the output-status is always LOW.

Normally Closed Contact. When the assigned conditions is TRUE

than the output-status is always LOW. If it is FALSE than the
status of the input will be passed to the output.

On-Delay. When the status on the input turns from LOW to HIGH
this change is delayed on the output for the set delay-time. When
the input turns from HIGH to LOW this change is passed to the
output immediately. No condition is used for this step.
Off-Delay. When the status on the input turns from HIGH to LOW
this change is delayed on the output for the set delay-time. When
the input turns from LOW to HIGH this change is passed to the
output immediately. No condition is used for this step.
Positive Edge. The output status of this step is HIGH for one cycle
(2ms) when a positive edge (change from LOW to HIGH) occurs
on the input of this step.

Negative Edge. The output status of this step is HIGH for one
cycle (2ms) when a negative edge (change from HIGH to LOW)
occurs on the input of this step.

The following conditions may be used for the logical connections:

Direct. The status of the input of this symbol is passed directly to
the output.

Inverted. The status of the input is inverted and then passed to

the output (e.g. if input is LOW the output is set to HIGH).

Set. If the status on the input of this symbol is HIGH than the
output is set to HIGH. When the status of the input returns to
LOW the output remains HIGH. The status of the output can only
be set to LOW again by the output-type "Reset".

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 106/142
SmartMold 9
User Manual Page description

Reset. If the status on the input of this symbol is HIGH than the
output is set to LOW. When the status of the input returns to LOW
the output remains LOW. The status of the output can only be set
to HIGH again by the output-type "Set".
The following conditions may be used for the logical connections:
Mold ·Mold Opened. TRUE if mold is at or higher open position.
·Mold Closed. TRUE if mold is closed and locked.
·Mold Touch. TRUE if mold position is smaller than mold lock start position.
·Mold Position >. TRUE if mold position is greater than given compare position.
·Mold Position <. TRUE if mold position is smaller than given compare position.
·Mold Closing. TRUE if mold close movement is active.
·Mold Opening. TRUE if mold open movement is active.
·Mold Protection Phase active. TRUE if mold close movement is in mold protec-
tion phase.
·Mold Locking Phase active. TRUE if mold locking is active.
·Mold Open Profile Step. TRUE if mold open move is active and profile-step
(velocity/pressure-profile) is identical to compare value.
·Mold Close Profile Step. TRUE if mold close move is active and profile-step
(velocity/pressure-profile) is identical to compare value.
Ejector ·Ejector is Forward. TRUE if ejector is in its normal forward position.
·Ejector is Backward. TRUE if ejector is in its normal backward position.
·Ejector Position >. TRUE if ejector position is bigger than given compare posi-
tion.
·Ejector Position <. TRUE if ejector position is smaller than given compare posi-
tion.
·Ejector is Forward (Rep.). TRUE if ejector is in its repetition forward position.
·Ejector is Backward (Rep.). TRUE if ejector is in its repetition backward position.
·Ejector Moves Forward. TRUE if ejector forward movement (any) is active.
·Ejector Moves Forward. TRUE if ejector forward movement (any) is active.
Inj. Unit ·Inj. Unit is Backward. TRUE if Inj. Unit is back (retracted position).
·Inj. Unit is Forward. TRUE if Inj. Unit is forward (touching mold)
·Inj. Unit Moves Backward. TRUE if Inj. Unit is moving backward.
·Inj. Unit Moves Forward. TRUE if Inj. Unit is moving forward.
Injection Injection Forward End. TRUE if injection is forward (after injection)
Holding Pressure Active. TRUE if holding pressure phase is active.
Injection Active. TRUE if injection movement is active.
Plastification Active. TRUE if plastification is active.
Plastification Finished. TRUE when plastification is okay (material ready).
Dec. Before Active. TRUE if decompression before movement is active.
Dec. After Active. TRUE if decompression after movement is active.
Injection Position >. TRUE if injection position is bigger than compare position.
Injection Position <. TRUE if injection position is smaller than compare position.
Injection Pressure >. TRUE if injection pressure is bigger than compare pres-
sure.
Injection Holding Time >. TRUE if injection holding time is bigger than compare
time.
Cores ·Core#X is In. TRUE if core is in.
·Core#X is Out. TRUE if core is out.
·Core#X Moves In. TRUE if core in movement is active
·Core#X Moves Out. TRUE if core out movement is active.
Airblows ·Airblow#X Active. TRUE if airblow is active (output HIGH).
·Any Airblow Active TRUE if any of the airblows is active (any output HIGH).
Modes Manual or Setting TRUE if machine is in manual or setting mode.
Manual TRUE if machine is in manual mode
Setting TRUE if machine is in setting mode
Automatic or Semiautomatic TRUE if machine is in automatic or semi-automatic
mode.
Automatic TRUE if machine is in automatic mode
Semiautomatic TRUE if machine is in semiautomatic mode
Calibration TRUE if machine is in calibration (service) mode
Waiting for Start Command TRUE if machine is in automatic or semi-automatic
Copyright © B&R - Subject to change without notice March 31, 2020
SmartMold 9 User Manual_V1.0.0.docx 107/142
SmartMold 9
User Manual Page description

mode and waiting for the start-command.

Cooling Time Active TRUE as long as cooling time is active.
Cooling Finished TRUE from end of cooling time to start of next cycle.
Alarms Any Alarm not Acknowledged TRUE if a alarm is pending on the HMI.
Alarm (Index) Active TRUE if the alarm with the given index (compare value) is
active.
Alarm (Index) not Acknowledged TRUE if the alarm with the given index (com-
pare value) is pending on HMI.
Diagnosis Pending TRUE if a diagnosis dialog is visible on HMI.
Heating Cylinder Heating On TRUE if a cylinder (barrel) heating is turned on.
Mold Heating ON TRUE if the mold heating is turned on.
Cylinder Heating Lowering TRUE if cylinder (barrel) heating is in lowering
(standby).
Mold Heating Lowering TRUE if the mold heating is in lowering (standby).
Signals ·Cylinder Heating On TRUE if a cylinder (barrel) heating is turned on.
·Mold Heating ON TRUE if the mold heating is turned on.
·Cylinder Heating Lowering TRUE if cylinder (barrel) heating is in lowering
(standby).
·Mold Heating Lowering TRUE if the mold heating is in lowering (standby).
IO Digital Output TRUE if the selected digital output is HIGH
Datapoints Digital Input TRUE if the selected digital input is HIGH
Analog Output >= TRUE if the signal of the selected analog output is bigger than
the compare value.
Analog Input >= TRUE if the signal of the selected analog input is bigger than the
compare value.
Temperature Input >= TRUE if the signal of the selected temperature input is
bigger than the compare value.

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 108/142
SmartMold 9
User Manual Machine Operation

4 Machine Operation

4.1 Motor Startup

Press this key to switch on or off the hydraulic motor or Acopos servo pump. The LED is indicating the status of
the motor:
Off: Motor is off or a motor error occurred.
On: Motor is running.
Blinking fast: Motor is starting up.
Blinking slow: Hydraulic oil preheating is active.

4.2 Startup Heating

Press this key to switch on or off the cylinder heating. The LED is indicating the status of the cylinder
heating:
Off: Heating is switched off.
On: Heating is switched on.
Blinking fast: Heating is in error state or the temperatures are above the maximum temperature.
Blinking slow: Autotuning or lowering is active.

4.3 Mode Selection

Keys for changing the operation mode. For a detailed explanation of all operation modes see the table below. Every key
has a LED indicating the mode, which is currently active.
Table 4-1: Operation mode
Key Mode Description
Manual mode Press this key to change to manual mode. In manual
mode all movements can be started by pressing the
manual movement keys (see detailed description of
the manual movement keys below). The movement is
carried out with the normal settings (speed, pres-
sure...) made on the respective page. The same set-
tings are applied in the automatic mode. The move-
ment lasts until the manual movement key is released
or the target position is reached.
Semi automatic Press this key to change to semi automatic mode. In
mode semi-auto mode a full molding cycle is carried out after
closing the safety gate or pressing the cycles-start
button (depending on configuration). The cycle repeats
after opening and closing the safety gate or pressing
the cycle-start button again.
Full automatic Press this key to change to full automatic mode. In
mode auto mode full molding cycles are carried out repeated-
ly after once pressing the Mold Close or cycle start
key (alternatively also by opening and closing the
safety gate - depending on machine configuration).
Setting mode Press this key to change to setting mode. In setting
mode all movements can be started by pressing the
manual movement keys (details see below). The
Copyright © B&R - Subject to change without notice March 31, 2020
SmartMold 9 User Manual_V1.0.0.docx 109/142
SmartMold 9
User Manual Machine Operation

movement is carried out with reduced speed and pres-

sure. The movement lasts until the manual movement
key is released. The movement does not stop at target
position. Certain interlocks are bypassed in setting
mode.

4.4 Machine Movement

4.4.1 Mold movement

Table 4-2: Mold movement
Key Movement Mode Description
Mold open Manual Press this key to open the mold using movement
profiles.
Semi Pressing this key has no effect.
automatic
Full auto- Pressing this key has no effect.
matic
Setting Press this key to open the mold using setting
mode parameter without end target.
Mold close Manual Press this key to close the mold using movement
profiles.
Semi Press this key to start automatic molding cycles.
automatic
Full auto- Pressing this key has no effect.
matic
Setting Press this key to close the mold using setting
mode parameter without end target.

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 110/142
SmartMold 9
User Manual Machine Operation

4.4.2 Core movement

Table 4-3: Core movement
Key Movement Mode Description
Core In Manual Press this key to move the currently selected core
in. During the Core In movement, the current
button indicator flashes continuously. When the
final core position is reached, the current button
indicator is always on. Note: The core advance
operation can be performed only when the mold
position meets the conditions set in 3.2.4 Core 1
page.
Semi Pressing this key has no effect.
automatic
Full auto- Pressing this key has no effect.
matic
Setting Same as the manual mode. Note: In this mode,
the core advance operation ignores the mold
position conditions set in 3.2.4 Core 1 page.
Core Out Manual Press this key to move the currently selected core
out. During the core retreat, the current button
indicator flashes continuously. When the final core
position is reached, the current button indicator is
always on. Note: The CoreOut operation can only
be performed when the mold position meets the
conditions set in 3.2.4 Core 1 page.
Semi Pressing this key has no effect.
automatic
Full auto- Pressing this key has no effect.
matic
Setting Same as the manual mode. Note: In this mode,
the CoreOut operation ignores the mold position
conditions set in 3.2.4 Core 1 page.
Select a Manual Press this key to select a core for manual
core movement. In the bottom line on every page
the currently selected core is shown. This
core can be moved then with the CoreIn and
CoreOut buttons. For the core number, refer to
3.1.1 Global Page Number [14].
Semi Pressing this key has no effect.
automatic
Full auto- Pressing this key has no effect.
matic
Setting Press this key to select a core. In the bottom line
on every page the currently selected core is
shown. This core can be moved then with the
CoreIn and CoreOut buttons. For the core num-
ber, refer to 3.1.1 Global Page Number [14].

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 111/142
SmartMold 9
User Manual Machine Operation

4.4.3 Injection unit movement

Table 4-4: Injection unit movement
Key Movement Mode Description
Injection Manual Press this key to move the injection unit (nozzle)
unit for- forward. During the movement, the current button
ward indicator flashes continuously. When the final
seating position is reached, the current button
indicator is always on.
Semi Pressing this key has no effect.
automatic
Full auto- Pressing this key has no effect.
matic
Setting Press this key to move the injection unit (nozzle)
forward using setting mode parameter without end
target.
Injection Manual Press this key to move the injection unit (nozzle)
unit back- backward. During the movement, the current but-
ward ton indicator flashes continuously. When the final
seating position is reached, the current button
indicator is always on.
Semi Pressing this key has no effect.
automatic
Full auto- Pressing this key has no effect.
matic
Setting Press this key to move the injection unit (nozzle)
backward using setting mode parameter without
end target..

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 112/142
SmartMold 9
User Manual Machine Operation

4.4.4 Screw movement

Table 4-5: Screw movement
Key Movement Mode Description
Injection Manual Press this key to move the injection piston
forward and keep holdon pressure. During the
injection, the current button indicator flashes
continuously. When the final injection position
is reached, the current button indicator is
always on. Note: Make sure that the barrel
temperature reaches the set temperature
before injection.
Semi Pressing this key has no effect.
automatic
Full auto- Pressing this key has no effect.
matic
Setting Press this key to Injection using setting mode
parameter without end target. Note: Make
sure that the barrel temperature reaches the
set temperature before injection.
Plastification Manual Press this key to plasticize. During the plas-
tification, the current button indicator flashes
continuously. When the final injection position
is reached, the current button indicator is
always on. Note: Make sure that the barrel
temperature reaches the set temperature
before injection.
Semi Pressing this key has no effect.
automatic
Full auto- Pressing this key has no effect.
matic
Setting Press this key to Plastification using setting
mode parameter. Note: Make sure that the
barrel temperature reaches the set tempera-
ture before injection.
Front decom- Manual Press this key to do front decompression or
pression rear suckback (depending on the actual posi-
tion of the injection piston). During the front
decompression, the current button indicator
flashes continuously. When the final decom-
pression position is reached, the current but-
ton indicator is always on. Note: Make sure
that the barrel temperature reaches the set
temperature before front decompression.
Semi Pressing this key has no effect.
automatic
Full auto- Pressing this key has no effect.
matic
Setting Press this key to do front decompression or
rear suckback (depending on the actual posi-
tion of the injection piston) using setting mode
parameter without end target. During the front
decompression, the current button indicator
flashes continuously. When the final decom-
pression position is reached, the current but-
ton indicator is always on. Note: Make sure
that the barrel temperature reaches the set
temperature before front

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 113/142
SmartMold 9
User Manual Machine Operation

4.4.5 Ejector movement

Table 4-6: Ejector Movement
Key Movement Mode Description
Ejector Manual Press this key to move the ejector backward.
backward During the movement, the current button indicator
flashes continuously. When the final ejector back-
ward position is reached, the current button indi-
cator is always on.
Semi Pressing this key has no effect.
automatic
Full auto- Pressing this key has no effect.
matic
Setting Press this key to move the ejector backward using
setting mode parameter without end target.
Ejector Manual Press this key to move the ejector forward. During
forward the movement, the current button indicator flashes
continuously. When the final ejector forward posi-
tion is reached, the current button indicator is
always on. Note: The ejection operation can be
performed only when the mold position meets the
conditions set in 3.4.1 Ejector Page.
Semi Pressing this key has no effect.
automatic
Full auto- Pressing this key has no effect.
matic
Setting Press this key to move the ejector forward using
setting mode parameter without end target. Note:
The ejection operation can be performed only
when the mold position meets the conditions set in
3.4.1 Ejector Page.

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 114/142
SmartMold 9
User Manual Machine Operation

4.4.6 Airblow
Table 4-7: Airblow
Key Movement Mode Description
Airblow Manual Press this key to activate an airblow. In the bottom
line on every page, the currently selected airblow
is shown.
Semi Pressing this key has no effect.
automatic
Full auto- Pressing this key has no effect.
matic
Setting Same as the manual mode.
Airblow Manual Press this key to select an airblow for manual
selection activation. In the bottom line on every page the
currently selected airblow is shown. This airblow
can be activated then with the Airblow button.
Semi Pressing this key has no effect.
automatic
Full auto- Pressing this key has no effect.
matic
Setting Press this key to select an airblow. In the bottom
line on every page the currently selected airblow
is shown. This airblow can be activated then with
the Airblow button.

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 115/142
SmartMold 9
User Manual Machine Operation

4.4.7 Mold Height

Table 4-8: Mold height
Key Movement Mode Description
Mold height Manual Pressing this key has no effect.
increase
Semi Pressing this key has no effect.
automatic
Full auto- Pressing this key has no effect.
matic
Setting Press this key to increase the mold height
The machine moves according to the parameters
set in 3.2.3 Mold Height.
Mold height Manual Pressing this key has no effect.
decrease
Semi Pressing this key has no effect.
automatic
Full auto- Pressing this key has no effect.
matic
Setting Press this key to decrease the mold height.
The machine moves according to the parameters
set in 3.2.3 Mold Height.

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 116/142
SmartMold 9
User Manual IO Datapoints

5 IO Datapoints

5.1 Digital Input

Table 5-1: Digital Input
Type Trigger action
Mold Mold Lock End
Start Mold Lock
Mold Blocked Hyd.
Mold Blocked Mech.
Jog: Mold Open
Jog: Mold Close
Mold Open Confirm
Ejector Ejector Confirm Backward
Ejector Backward
Ejector Backward (Pre, IStop)
Ejector Forward
Ejector Forward (Pre, IStop)
Jog: Ejector Forward
Jog: Ejector Backward
Injection unit Inj. Unit Forward
Inj. Unit Forward (Pre)
Inj. Unit Backward
Inj. Unit Backward (Pre)
Jog: Inj. Unit Backward
Jog: Inj. Unit Forward
Screw Change
Inj. Unit Rotate In
Inj. Unit Rotate In (Pre)
Inj. Rotate Out
Inj. Unit Rotate Out (Pre)
Jog: Inj. Unit Rotate In
Jog: Inj. Unit Rotate Out
Injection External Switchover
Jog: Decompression
Jog: Injection
Jog: Plastification
Gas Unit in Motion
Gas Unit Stop Cycle
Accumulator: Pressure OK
Core Core#1..6: Core In
Core In (IStop)
Core Out
Core Out (IStop)
Core In (Pulse)
Jog: Core In
Jog: Core Out
Mold Height Mold Height Dec. Limit
Mold Height Inc. Limit
Mold Height Motor Ok
Jog: Mold Height Dec.
Jog: Mold Height Inc.
Safety Gate Safety Gate Closed
Safety Gate Closed (Redundant)
Safety Gate Not Closed (Redundant)
Safety Gate Close Slowdown
Safety Gate Opened
Safety Gate Open Slowdown
Safety Gate Prot. (Close)

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 117/142
SmartMold 9
User Manual IO Datapoints

Safety Gate Prot. (Close, Redundant)

Safety Gate Prot. (Open)
Safety Gate Motor OK
Bypass Interlocks
Jog: Safety Door Close
Jog: Safety Door Open
Rear Gate Closed
Rear Gate Closed (Redundant)
Nozzle Cover Closed
Motor/Hydraulics Motor 1..3: Overload
On

Oil Filter #1 Dirty

Oil Filter #2 Dirty
Hyd. Oil Level Low
Lubrication Lubrication Pressure OK
1-3: Level Low
Robot Robot: Emergency stop A1
Robot: Mold area free A3
Robot: Operation mode B2
Robot: Enable ejector back B3
Robot: Enable ejector forward B4
Robot: Cores(1) In enable B5
Robot: Cores(1) Out Enable B6
Robot: Cores(2) In Enable B7
Robot: Cores(2) Out Enable B8
Robot: Enable mold closure A6
Robot: Enable full mold opening A7
Robot: Cycle Start
General Emergency Stop
Drop Sensor
Cycle Start
Free Prog. In- FP Fix In: FP Fix In #1..
puts #5: Desc. Text
FP Rec In: FP Rec In#1..
#5: Desc. Text

5.2 Digital Output

Table 5-2: Digital Output
Type Trigger action
Mold DV Mold Open
DV Mold Close
DV Mold Protection
Mold Close Fast
Mold Open Fast
Mold Backpressure
Ejector DV Ejector Forward
DV Ejector Backward
Injection Injection unit backward directional valve.
Unit Injection unit forward directional valve.
Injection unit rotate in directional valve.
Injection unit rotate out directional valve.
Injection DV Injection
DV Decompression
DV Plastification
Injection Regenerative Valve
Nozzle Closure
Accumulator: Load
Accumulator: Inject
Accumulator: Unload
No Backpressure Valve
Copyright © B&R - Subject to change without notice March 31, 2020
SmartMold 9 User Manual_V1.0.0.docx 118/142
SmartMold 9
User Manual IO Datapoints

Cores Core#1..6: DV Core In

DV Core Out
Mold DV Mold Height Dec.
Height DV Mold Height Inc.
Safety Safety Gate Close
Gate Safety Gate Close (Slow)
Motor Motor 1..3: Main Contact
Star Contact
Delta Contact

Servo Pump Main Contact

1:
Pumps Basic: Pump Sel.
Valve#1..#5

Pump#1..#2: DynValve#1..#4

Lubrication Basic: Lubrication Central Pump On

Lubrication Central Error

Lubrication Pump On
1-3: Error

Robot To Robot: Emergency stop ZA1

To Robot: Safety Gate Closed ZA2
To Robot: Reject ZA5
To Robot: Mold closed ZA6
To Robot: Mold open position ZA7
To Robot: Intermediate mold opening position ZA8
To Robot: Automatic ZB2
To Robot: Ejector back position ZB3
To Robot: Ejector forward position ZB4
To Robot: Cores (1) In ZB5
To Robot: Cores (1) Out ZB6
To Robot: Cores (2) In ZB7
To Robot: Cores (2) Out ZB8
General Part Reject
Cycle Interval
Alarm Light
Alarm Horn
Wait for Cycle Start
Heating Basic: Oil Cooling On
Mold Cooling On
Cylinder Heating On
Mold Heating on
Traverse Cooling On
Nozzle Zo- Heat
ne: Cool
Barrel 1..7: Heat
Cool
Mold Zone Heat
1..16: Cool
AirBlows AirBlow #1..#4
Free Prog. FP Fix Out FP Fix Out#1..
Outputs #8: Desc. Text
FP Rec Out FP Rec Out#1..
#8: Desc. Text

5.3 Analog Input

Table 5-3: Analog Input
Copyright © B&R - Subject to change without notice March 31, 2020
SmartMold 9 User Manual_V1.0.0.docx 119/142
SmartMold 9
User Manual IO Datapoints

Type Trigger action

Mold Mold Actual Stroke
Mold Actual Pressure
Ejector Ejector Actual Stroke
Injection Injection Actual Stroke
Injection Actual Pressure
Injection Unit Inj. Unit Actual Stroke
Pumps Main Pump Actual Pressure
Sec. Pump Actual Pressure

5.4 Analog Output

Table 5-4: Analog Output
Type Trigger action
Mold Mold Servo Valve
Ejector Ejector Servo Valve
Injection Injection Servo/Backprs. Valve
Plast. Set Rotation
Pumps Main Pump Pressure Valve
Main Pump Flow Valve
Sec. Pump Pressure Valve
Sec. Pump Flow Valve

5.5 Temperature Input

Table 5-5: Temperature Input
Type Trigger action
Cooling Hydraulic oil temperature
Lowering temperature
Barrel Nozzle temperature
Barrel 1..7 Temperature
Mold Mold 1..16 Temperature

5.6 PWM Output

Table 5-6: PWM output
Type Trigger action
Mold Mold servo valve
Ejector Ejector servo valve
Injection Injection servo valve
Plastification speed setting
Pumps Pump 1 pressure
Pump 1 flow
Pump 2 pressure
Pump 2 flow

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 120/142
SmartMold 9
User Manual Alarms

6 Alarms

6.1 Alarms1_20
The following alarms are described in this document:
20-0 Emergency button pressed
20-1 Hydraulic oil level low
20-2 Part did not fall
20-3 Rear gate open
20-4 System pressure sensor error
20-5 Core timeout
20-6 Mold protection timeout
20-7 Motor overload
20-8 Cycle timeout
20-9 Ejection Timeout
20-10 Plastification timeout
20-11 Mold open timeout
20-12 Mold close timeout
20-13 Lubrication (main) oil level low
20-14 Oil filter dirty
20-15 Invalid fix data
20-16 Error in toggle linearization data
20-17 Error in calculation of automatic sequence
20-18 IO module communication error
20-19 Screw lubrication timeout
20-20 Injection unit not advanced
20-0 Emergency button pressed

Description The emergency-stop input (DI#321) is active.

·The emergency stop button was pressed.
Cause ·Malfunction of emergency-stop circuit (short circuit?)
·Commissioning: Wrong input connected or inverted.
·Motor is turned off
·All movements are blocked
Reaction
·Cycle is stopped immediately
·Alarm-Light is On
·Release the pressed emergency-stop button
Remedy ·Check emergency stop circuit
·Commissioning: Check input in IO-configurator and whether it must be inverted
20-1 Hydraulic oil level low
The input for "Hyd. Oil Level Low" (DI#265) is active. This indicates the the hydraulic
Description
oil level in the tank is low.
·Oil in the tank is low
Cause ·Oil level-sensor malfunction
·Commissioning: Wrong input connected or inverted

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 121/142
SmartMold 9
User Manual Alarms

·Motor is turned off

·All hydraulic movements are blocked
Reaction
·Cycle is stopped immediately
·Alarm-Horn and -Light.
·Fill Oil in tank
Remedy ·Check sensor signal and sensor
·Commissioning: Invert Signal in IO-configurator if necessary
20-2 Part did not fall
The "Drop Sensor"-function is active and no part was detected before the first core
Description movement or before mold-close was started. To detect a part a positive and negative
edge is necessary on the "Drop Sensor"-input (DI#322).
·Part did not fall (still in mold)
·Dropout-"Box" is full and part still detected by drop sensor (no negative edge)
Cause
·Mold Close Delay (Pages >> Delay Times(1)) is too short
·Sensor did not recognize falling part
·Alarm-Horn and -Light
Reaction
·Cycle is stopped immediately
·Check if part is still in mold and remove it
Remedy
·Increase Mold Close Delay (Pages >> Delay Times(1))
20-3 Rear gate open

Description The rear gate was opened when the motor was running

·Rear Gate was opened

Cause
·Rear Gate closed sensor defect
·Motor is stopped
Reaction ·Alarm-Horn and -Light
·Cycle is stopped immediately
Remedy ·Close Rear-Gate and re-start Motor

20-4 System pressure sensor error

The signal of the pressure sensor for the main PQ-system is out of range - outside
Description of the configured MIN- and MAX-voltage (Main PumpSys Setup -> Pressure Sensor ->
Main Pump: Pressure Sensor Min. Signal / Main Pump: Pressure Sensor Max. Signal)
·Sensor disconnected or short-circuit on input
Cause ·Commissioning: Sensor not configured correctly (MIN/MAX voltage)
·Commissioning: Error limit for checking MIN- and MAX-range too low.
Reaction ·Alarm-Horn and -Light
·Check connection to sensor
Remedy ·Commissioning: Check voltage-range of sensor
·Commissioning: Check error-limits for checking
20-5 Core timeout
The core-movement (Pages >> Core) timed out before the limit-switch was reached
Description
(input HIGH).
·Core cannot reach limit-switch
·No limit switch connected
Cause
·Limit switch failure
·Timeout (Pages >> Core) set too short
·Alarm-Horn and -Light
Reaction
·Cycle is stopped immediately
·Check core-settings (Pages >> Core) if everything is set correctly
Remedy ·Check core-limit switch
·Increase timeout
20-6 Mold protection timeout
The mold did not pass through the mold-protection area within the set timeout (Pages
Description
>> Mold Close). In automatic mode all configured retries where unsuccessful.

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 122/142
SmartMold 9
User Manual Alarms

·Part is stuck in mold

Cause ·Mold protection pressure to low
·Mold protection timeout to low
·Alarm-Horn and -Light
Reaction
·Cycle is stopped immediately
·Check if anything is stuck in the mold
Remedy ·Increase mold protection timeout
·Increase mold protection pressure
20-7 Motor overload
One of the digital input signals "Motor 1..3: Overload" (DI#261) was HIGH when the
Description
motor was turned on.
·Motor overload input is active
Cause ·Commissioning: Motor overload input signal connected incorrectly or must be
inverted
·Alarm-Horn and -Light
Reaction ·Cycle is stopped immediately
·Motor is stopped
Remedy ·Check why motor got overloaded (min. off-time too short)

20-8 Cycle timeout

Description The machine cycle took longer than the set timeout (Pages >> Delay Times(1) ).

·Cycle got stuck for some reason

Cause
·Cycle Timeout set too short
·Alarm-Horn and -Light
Reaction
·Cycle is stopped immediately
·Check where and why the sequence got stuck
Remedy
·Increase cycle timeout
20-9 Ejection Timeout
The ejection process (ejector forward, repetition and back) took longer than the adjust-
Description
ed timeout (Pages >> Delay Times (1)).
·Ejector did not reach one of its targets
Cause
·Ejection timeout too short
·Alarm-Horn and -Light
Reaction
·Cycle is stopped immediately
·Check why ejector got stuck
Remedy ·Check target positions for ejector movement
·Increase ejection timeout
20-10 Plastification timeout
The ejection process (ejector forward, repetition and back) took longer than the adjust-
Description
ed timeout (Pages >> Delay Times (1)).
·No more material (hopper empty or inlet congested)
Cause
·Plastification timeout to short
·Cycle is stopped at the end of current cycle
·If plastification time exceed 2x timeout than the plastification is stopped and cycle
Reaction
continues
·Alarm-Horn and -Light
·Fill hopper with new material
Remedy ·Check material inlet at barrel
·Increase plastification timeout
20-11 Mold open timeout
The mold open process (from first start of the mold to reaching the target position) took
Description
longer than the adjusted timeout (Pages >> Delay Times (1)).
·Mold could not reach target position
Cause ·Core movement in-between clamp open did not finish
·Mold open timeout is too short

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 123/142
SmartMold 9
User Manual Alarms

·Alarm-Horn and -Light

Reaction
·Cycle is stopped immediately
·Check mold open target position
Remedy ·Check core moving between clamp open
·Increase mold open timeout
20-12 Mold close timeout
The mold close process (from first start of the mold to reaching the target position)
Description
took longer than the adjusted timeout (Pages >> Delay Times (1)).
·Mold could not reach target position
·Mold could not lock
Cause
·Core movement in-between clamp close did not finish
·Mold close timeout is too short
·Alarm-Horn and -Light
Reaction
·Cycle is stopped immediately
·Check mold close target position
Remedy ·Check core moving between clamp close
·Increase mold close timeout
20-13 Lubrication (main) oil level low
The lubrication oil level in the main lubrication cycle is low. The input "Lubrication 1-3
Description
Level Low" (DI#283) is HIGH.
·Lubrication oil level is low
Cause ·Commissioning: Sensor malfunction
·Commissioning: Sensor inverted
·Alarm-Horn and -Light
Reaction
·Cycle is stopped at end of current cycle
·Check lubrication oil
Remedy
·Commissioning: Check wiring and if signal is inverted
20-14 Oil filter dirty
One of the oil filters ("Oil Filter #1 Dirty"-DI#263, "Oil Filter #1 Dirty"-DI#264) indicates
Description
that it is dirty (obstructed)
·One of the oil filter obstructed
Cause ·Commissioning: Sensor malfunction
·Commissioning: Sensor inverted
·Alarm-Horn and -Light
Reaction
·Cycle is stopped at end of current cycle
·Check oil filter and clean it
Remedy
·Commissioning: Check wiring and if signal is inverted
20-15 Invalid fix data
There is no valid fix-data loaded on the machine. The data got lost and neither the
Description
"Machine.fix"- nor the "Default.fix"-file could be loaded.

Cause ·Permanent data lost and files are missing on flash-disc

·Alarm-Horn and -Light

Reaction
·Cycle is stopped immediately
·Load valid fix-data (from USB-stick)
Remedy
·Restore fix-data-files on flash
20-16 Error in toggle linearization data
The given toggle linearization data is not correct (not compatible to the clamp dimen-
Description
sion or other error in data).
·Length of clamp bigger than biggest entry in table
Cause
·Entries in table not ascending
·Alarm-Horn and -Light
Reaction
·Operation of machine locked (no movement possible)
·Correct linearization data
Remedy
·Adjust clamp strokes

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 124/142
SmartMold 9
User Manual Alarms

20-17 Error in calculation of automatic sequence

Description There was an internal error when generating the step-sequence for automatic mode

Cause ·Internal error

·Alarm-Horn and -Light

Reaction
·Cycle cannot be started
Remedy ·Send error-report of actual situation to your supplier

0-18 IO module communication error

Description There is no communication with one or more of the configured IO-modules

·Module is not connected
·Incorrect IO-configuration
Cause
·Module or backplane is damaged
·Error in X2X-wiring
·Alarm-Horn and -Light
Reaction
·Cycle is stopped immediately
·Check modules (go to IO Browser page (Pages >> IO Browser) and activate diagno-
sis function - missing modules will be shown)
Remedy
·Check wiring
·Check IO-configuration
20-19 Screw lubrication timeout

Description The mold-height screw lubrication time has expired - this is a periodically event!

Cause ·Mold height screw lubrication time has expired

Reaction ·Alarm-Light
·Lube screw and quit alarm
Remedy
·Alarm can only be quit by operator with access-level >= supervisor
20-20 Injection unit not advanced
This alarm is currently not used!

6.2 Alarms21_40
The following alarms are described in this document:
20-21 Oil temperature low
20-22 Oil temperature high
20-23 Mold locked
20-24 Cushion exceeded
20-25 Improper cushion control
20-26 Cycle stopped by robot
20-27 Lubrication (main) failure
20-28 Switchover time exceeded
20-29 Injection out of tolerance
20-30 Invalid recipe data
20-31 Default fix data was loaded
20-32 Default recipe data was loaded
20-33 Lubrication #2 failure

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 125/142
SmartMold 9
User Manual Alarms

20-34 Lubrication #3 failure

20-35 Software Error
20-36 Oil preheat error
20-37 Dosage already reached
20-38 Invalid operation mode
20-39 Motor on delay
20-40 Oil preheating not possible - motor running
20-21 Oil temperature low

Description The motor is on and the oil-temperature is below the minimum value.
·Oil temperature low
Cause ·Minimum oil temperature value to high
·Temperature sensor error (disconnected or short circuit)
·Oil pre-heating is started (if enabled)
Reaction ·Cycle is stopped at end of current cycle
·Alarm-Light is On
·Do oil-preheating
Remedy
·Set minimum oil temperature to lower value
20-22 Oil temperature high

Description The oil temperature is above the maximum value.

·Oil temperature to high (oil cooling error?)
Cause ·Maximum oil temperature value set to low
·Sensor error (disconnected or short circuit)
·Cycle is stopped at end of current cycle
Reaction ·Motor is not allowed to start
·Alarm--Light
·Check oil cooling settings (Pages >> Oil, Lubrication)
·Wait until oil is cooled down
Remedy
·Increase max. oil temperature value
·Check sensor
20-23 Mold locked
The toggle-clamp is locked in a forbidden status - motor is off or lock-time is longer
Description
than alarm-limit.
Motor turned off when toggle-clamp was locked
Cause
Toggle clamp was locked to long
Alarm-Light
Reaction
Cycle is stopped at end of current cycle
Turn on motor and open toggle clamp
Remedy
Increase or disable (set to 0) the alarm-time
20-24 Cushion exceeded
This alarm is currently not used.
20-25 Improper cushion control
This alarm is currently not used.

20-26 Cycle stopped by robot

The cycle was stopped by a missing robot-release signal. The cycle is first delayed by
Description
the missing signal and after a timeout this alarm is set.

Cause Robot release was missing for the set timeout

Alarm--Light
Reaction
Cycle is stopped immediately
Copyright © B&R - Subject to change without notice March 31, 2020
SmartMold 9 User Manual_V1.0.0.docx 126/142
SmartMold 9
User Manual Alarms

Check robot release signals

Remedy
Increase or disable robot timeout
20-27 Lubrication (main) failure
An error has occurred during lubrication of the main circuit. The feedback from lubrica-
Description
tion was not OK before the timeout.
·Timeout when waiting for the pressure-ok-signal during lubrication (oil)
Cause ·Timeout when waiting for the 2 pulses from the pressure-sensor during lubrication
(grease)
·Alarm-Light
Reaction
·Cycle is stopped at end of current cycle
·Check lubrication circuit
Remedy ·Check lubrication oil level
·Increase lubrication timeout
20-28 Switchover time exceeded
The injection switchover-criteria was not reached. Switchover to holding happened due
Description
to timeout (Pages >> Switchover).

Cause ·Injection switchover criteria was not reached before timeout

·Alarm-Light
Reaction
·Cycle is stopped at end of current cycle
·Check switch-over criteria
Remedy
·Increase timeout
20-29 Injection out of tolerance
This alarm is currently not used.
20-30 Invalid recipe data
The recipe-data is not valid. The data was corrupted and the default-data could not be
Description
loaded.
·Data corrupted (Panel-Barrer low)
Cause
·Default-data-file (Default.rec) not present on flash-disc
·Alarm-Light
Reaction
·Cycle is stopped at end of current cycle
·Load recipe from file
Remedy
·Copy default-recipe to flash
20-31 Default fix data was loaded
The default fix-data (Default.fix) was loaded from the flash since the data on the PLC
Description
were corrupted

Cause ·Fix-Data corrupted (lost), software update

Reaction ·Alarm-Light

Remedy ·Load correct fix-data from file

20-32 Default recipe data was loaded

The default recipe-data (Default.rec) was loaded from the flash since the data on the
Description
PLC was corrupted

Cause Recipe data corrupted (lost), software-update

Reaction ·Alarm-Light

Remedy ·Load correct fix-data from file

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 127/142
SmartMold 9
User Manual Alarms

20-33 Lubrication #2 failure

An error has occurred during lubrication of circuit #2. The feedback from lubrication
Description
was not OK before the Timeout.
·Timeout when waiting for the pressure-ok signal during lubrication (oil)
Cause ·Timeout when waiting for the 2 pulses from the pressure-sensor during lubrication
(grease)
·Alarm-Light
Reaction
·Cycle is stopped at end of current cycle
·Check lubrication circuit.
Remedy
·Increase lubrication timeout
20-34 Lubrication #3 failure
An error has occurred during lubrication of circuit #3. The feedback from lubrication
Description
was not OK before the Timeout.
·Timeout when waiting for the pressure-ok signal during lubrication (oil)
Cause ·Timeout when waiting for the 2 pulses from the pressure-sensor during lubrication
(grease)
·Alarm-Light
Reaction
·Cycle is stopped at end of current cycle
·Check lubrication circuit.
Remedy
·Increase lubrication timeout
20-35 Software Error

Description There is an internal error in the software – the controller is not ready to operate.

Cause ·Error in code added in the binary project version

Reaction ·All operation on controller is locked

·Check entries in CPU-logbook "User"
Remedy
·Check code added in "binary project"
20-36 Oil preheat error
During oil pre-heating the oil-temperature did not rise. The oil must rise by a certain
Description
temperature within the observation period.
·Oil temperature did not rise
Cause ·Min. rise configured to high
·Oil temperature sensor error
·Alarm-Light
Reaction ·Oil preheat is interrupted
·Motor is turned off
·Check oil preheat-settings
Remedy
·Check oil temperature sensor signal
20-37 Dosage already reached

Description Info to operator in manual: Plastification not possible, dosage already reached

Cause ·Plastification key was pressed although dosage already reached

Reaction -

Remedy -

20-38 Invalid operation mode

INFO: A action was requested by the operator which is not possible in the current
Description
operation mode
·Toggle data should have been calculated when the machine was in semiautomatic-
Cause or automatic-mode
·Fix-data should have been copied when the machine was in semiautomatic or auto-

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 128/142
SmartMold 9
User Manual Alarms

matic-mode
·Motor should have been turned on when the machine was in semiautomatic or auto-
matic-mode
Reaction -

Remedy -

20-39 Motor on delay

Description Motor should have been turned on during the minimum off-time.

Cause ·Operator tried to turn on motor during minimum off-time

Reaction -

Remedy ·Decrease minimum off-time

20-40 Oil preheating not possible - motor running

Oil-preheating was activated when the motor was already running (Pages >> Oil Tem-
Description
perature).

Cause ·Oil-preheating was activated when the motor was already running

Reaction -

Remedy -

6.3 Alarms41_59
The following alarms are described in this document:
20-41 SPC value exceeded min/max range
20-42 Safety gate motor error
20-43 Mold height motor error
20-44 Shift finished
20-45 Reset counter
20-46 Oil Change Required
20-47 Recipe value limited - see audit trail
20-48 Mold height adjustment finished
20-49 Purge finished
20-50 Fix data loaded from file
20-51 Error loading software configuration
20-52 Calibration: stroke sensor signal out of range
20-53 Calibration: maximum speed for flow lin. could not be reached
20-54 Toggle geometry not correct
20-15 Oil filter dirty
20-56 Purge timeout
20-57 Mold height adjustment: limits exceeded
20-58 Mold height adjustment active
20-59 Cushion exceeded limits
20-41 SPC value exceeded min/max range
Copyright © B&R - Subject to change without notice March 31, 2020
SmartMold 9 User Manual_V1.0.0.docx 129/142
SmartMold 9
User Manual Alarms

A value recorded in the SPC was outside the given MIN/MAX-range (Pages >> SPC
Description
Setup)
·Recorded SPC-value changed for some reason
Cause
·MIN/MAX-range for value to small

Reaction ·Alarm-Light
·Find reason for change of SPC-value
Remedy
·Increase MIN/MAX-range
20-42 Safety gate motor error
A error occurred on the electric motor that drives the automatic safety gate (LOW sig-
Description
nal on input "Safety Gate Motor OK" (DI#244))
·Motor overheated or other motor-error
Cause ·Wrong signal (wire break)
·Commissioning: Signal configured wrong (position, inverted?)
Reaction ·Alarm-Light
·Check motor and motor-switch
Remedy ·Check wiring to PLC
·Commissioning: Check if signal should be inverted
20-43 Mold height motor error
A error occurred on the electric motor that drives the mold height (LOW signal on input
Description
"Mold Height Motor Ok" (DI#223))
Motor overheated or other motor-error
Cause Wrong signal (wire break)
Commissioning: Signal configured wrong (position, inverted?)
Reaction ·Alarm-Light
·Check motor and motor-switch
Remedy ·Check wiring to PLC
·Commissioning: Check if signal should be inverted
20-44 Shift finished
The machine has nearly finished a shift - the set number of shift cycles (Pages >>
Description Production (1)) is nearly reached. Alarm is set a number of cycles (Pages >> Produc-
tion (1)) before the final number of cycles is reached.
·Shift nearly finished
Cause
·Shift counter set incorrectly or unwittingly

Reaction ·Short Alarm-Horn

·Reset shift-counter when shift is finished
Remedy
·Deactivate shift-function by setting shift set-count to 0
20-45 Reset counter
The end of the current shift is reached - the set number of shift cycles (Pages >> Pro-
Description duction (1)) is reached. The new cycle cannot be started unless the shift-counter is
reset.
·Shift is finished
Cause
·Shift counter set incorrectly or unwittingly
·Production not possible any more
·Reactions according to operator settings (Pages >> Overview >> Production (1)):
Reaction
Heating turned off, - Activate lowering for heating, Motor off, Purge with the set number
of purge-cycles
Remedy ·Reset shift-counter and restart machine

20-46 Oil change required

The service-interval for "Oil Change" has expired. The operator is reminded that the
Description
hydraulic oil needs to be changed.

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 130/142
SmartMold 9
User Manual Alarms

Cause ·Service interval expired

Reaction ·Short Alarm-Horn output

·Change oil and quit alarm
Remedy
·Alarm can only be quit by operator with access-level >= supervisor
20-47 Recipe value limited - see audit trail
A recipe-value (operator-setting) was limited after changing a fix-value or after loading
Description a recipe- or fixdata-file. Details can be found in the audit-trail (Pages >>
Alarms >> AuditTrail ).
Cause ·Recipe-value limited because it was outside of set limits

Reaction -

Remedy -
20-48 Mold height adjustment finished
The automatic mold height adjustment process has finished. The new mold height is
Description
adjusted

Cause ·Automatic Mold Height adjustment finished.

Reaction ·Short Alarm-Horn

Remedy -
20-49 Purge finished

Description INFO: The purge process has finished

Cause ·Purge process finished

Reaction ·Short Alarm-Horn

Remedy -

20-50 Fix data loaded from file

During booting of the PLC the fix-data was loaded from the local fix-datafile (Ma-
Description
chine.fix)

Cause ·Fix-data in permanent memory corrupted or lost

Reaction ·Alarm-Light
·Check if data is still ok (if file was actual)
Remedy
·Alarm can only be quit by operator with access-level >= supervisor
20-51 Error loading software configuration
An error has occurred during booting: The content of the file "SW.ini" could not be
Description read without errors. A detailed description of the error can be found in the CPU Log-
book "User". It can be accessed via the page "Logbooks" (2203).
·"SW.ini"-file is not present
Cause
·Content of file corrupted
·Alarm-Light
Reaction
·Machine- and software-options might be incorrect. Different machine behavior.
·Check if file is on flash (F:\CONFIG\SW.ini).
Remedy ·Check content of file (variable-names, line-breaks )
·Alarm can only be quit by opertor with access-level >= supervisor
20-52 Calibration: stroke sensor signal out of range
Copyright © B&R - Subject to change without notice March 31, 2020
SmartMold 9 User Manual_V1.0.0.docx 131/142
SmartMold 9
User Manual Alarms

Error during calibration of a potentiometer (stroke-sensor): At one of the end positions,

Description
the voltage from the sensor is below the minimum voltage.
·Sensor is mounted incorrectly (min poti-limit reached before physical limit is reached)
Cause
·Sensor is to short (range smaller than movement range of axis)

Reaction ·Alarm-Light

Remedy Mount potentiometer correctly

20-53 Calibration: maximum speed for flow lin. could not be reached
An error has occurred during the automatic flow linearization: the maximum screw
Description
speed could not be reached
·Max. screw speed set to high
·Signal to pump pressure actuator to low
Cause
·Stabilization time to measure rotation speed is to low
·Hydraulic valves set incorrectly
Reaction ·Alarm-Light

Remedy ·Check settings (see Cause).

20-54 Toggle geometry not correct

Error occurred during calculating the toggle linearization table: The given toggle data is
Description
not valid (impossible data),
·Incorrect toggle geometry entered (take especially care about the angle
Cause
"beta": its unit is "radiant" and not "degrees").

Reaction ·Alarm-Light

Remedy ·Enter correct toggle geometry and try again

20-55 Purge is active

Description INFO: The purge process is active

Cause ·Purge process started

Reaction -

Remedy -

20-56 Purge timeout

Description Error during purge process (mode "Color Change"): A plastification timeout occurred

·No more material or inlet obstructed

Cause
·Timeout for purge (Pages >> Injection >> Purge) set to short
·Alarm-Light
Reaction
·Purge is stopped
·Check material in hopper
Remedy ·Check material inlet
·Increase timeout
20-57 Mold height adjustment: limits exceeded
Error during automatic mold height adjustment: the min. or max. mold height was
Description
reached during adjustment

Cause ·Mounted mold to big or to small

·Alarm-Light
Reaction
·Mold Height Adjustment is stopped

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 132/142
SmartMold 9
User Manual Alarms

Remedy ·Try to adjust mold height manually

20-58 Mold height adjustment active

Description INFO: the automatic mold height adjustment is active

Cause ·Mold Height Adjustment started

Reaction -

Remedy -
20-59 Cushion exceeded limits
During active cushion monitoring the cushion was outside of the set limits (Pages >>
Description
Injection >> Switchover)

Cause ·Cushion outside of limits

·Alarm-Light
Reaction
·Reject-Signal is set
Remedy ·Change cushion limits

6.4 Alarms60_79
The following alarms are described in this document:
20-60 Free Input#1:
20-61 Free Input#2:
20-62 Free Input#3:
20-63 Free Input#4:
20-64 Free Input#5:
20-65 Fix Input#1:
20-66 Fix Input#2:
20-67 Fix Input#3:
20-68 Fix Input#4:
20-69 Fix Input#5:
20-70 Motor feedback missing
20-71 Cooling water pressure not ok
20-72 Cycle stopped by open gate
20-73 Acopos drive not connected
20-74 Acopos servo pump motor temperature high
20-75 Lubrication (2) oil level low
20-76 Lubrication (3) oil level low
20-77 Error setting mold temp. Sensor type
20-78 Audit trail nearly full
20-79 Hardware switchover error – disabled
20-60 Free Input#1:
20-61 Free Input#2:
20-62 Free Input#3:

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 133/142
SmartMold 9
User Manual Alarms

20-63 Free Input#4:

20-64 Free Input#5:
Alarm set by free programmable input ("FP Rec In#1..#5: Desc. Text" (DI#362).
Description Alarm text is configured with free programmable user-inputs (Pages >> Free Prog.
Inputs)
Cause ·Condition for free programmable input TRUE

·Alarm-Light
Reaction
·Additional reaction according to configuration of input (Stop Cycle, End Cycle)
Remedy ·Depends on input-configuration

20-70 Motor feedback missing

The feedback from a motor "Motor 1..3: On" (DI#262) is LOW although the motor is
Description turned on. The signal "motor is on" is checked with a certain delay after the motor is
turned on.
·Motor did not turn on
Cause ·Feedback signal error
·Delay for checking feedback to short
Reaction ·Alarm-Light
·Check if motor turned on - if not, find reason
Remedy ·Commissioning: Check is signal is wired correctly
·Increase delay for checking feedback
20-71 Cooling water pressure not ok
The pressure in the cooling water line is not ok (signal "Cooling Water Pressure
Description
Low" (DI#328) is HIGH)
·Cooling water not turned on
·Cooling water pressure low
Cause
·Sensor defect
·Commissioning: Sensor signal wired incorrectly or inverted
Reaction ·Alarm-Light
·Turn on cooling water
Remedy ·Check pressure sensor and wiring
·Commissioning: Check if sensor-signal needs to be inverted
20-72 Cycle stopped by open gate
The safety gate was opened during automatic- or semiautomatic-mode and blocked
Description
a movement
·Safety gate was opened
Cause
·Safety gate sensor defect

Reaction ·Cycle is stopped immediately

Remedy ·Close gate and restart cycle

20-73 Acopos drive not connected

Description A necessary servo-drive for a servo driven pump is not connected

·Servo drive not connected or missing
·Incorrect wiring to servo-drive
Cause ·Power supply for servo-drive missing
·Servo drive damaged
·Node-number of servo-drive not set correctly
·Cycle is stopped immediately
Reaction
·Alarm-Horn and -Light
Remedy ·Check servo drive (power supply, node number, wiring)

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 134/142
SmartMold 9
User Manual Alarms

20-74 Acopos servo pump motor temperature high

This alarm is currently not used
20-75 Lubrication (2) oil level low

Description The lubrication oil level in lubrication circuit #2 is low

·Lubrication oil level is low
Cause ·Commissioning: Sensor malfunction
·Commissioning: Sensor inverted
·Cycle is stopped at end of current cycle
Reaction
·Alarm-Light and -Horn
·Check lubrication oil
Remedy
·Commissioning: Check wiring and if signal is inverted
20-76 Lubrication (3) oil level low

Description The lubrication oil level in lubrication circuit #3 is low

·Lubrication oil level is low
Cause ·Commissioning: Sensor malfunction
·Commissioning: Sensor inverted
·Cycle is stopped at end of current cycle
Reaction
·Alarm-Light and -Horn
·Check lubrication oil
Remedy
·Commissioning: Check wiring and if signal is inverted
20-77 Error setting mold temp. Sensor type
An error occurred during changing the sensor-type for the mold-heating temperature
Description
sensors
·Temperature-module is not plugged
Cause
·Set sensor-type (Pages >> Mold Autotuning) is not supported

Reaction ·Alarm-Light
·Check if module is plugged
Remedy
·Check sensor-type setting and whether it is supported by module
20-78 Audit trail nearly full
The max. entries for the audit-trail is nearly reached since the last export of the
audit-trail-data.
Description
Remark: The audit-trail is a ring-buffer so it will not stop recording once the max. num-
ber of entries is reached. Only the oldest entries will be lost then.
Cause ·Max. number of audit-trail entries nearly reached

Reaction -

Remedy -

20-79 Hardware switchover error – disabled

Configuring the hardware (XX419-module) to support the injection-switchover failed.
Description A exact description of the error can be found in the CPU-logbook "User". It can be
accessed via the page "Logbooks" (2203).
Cause ·Module does not support switchover

Reaction ·Alarm-Light

Remedy ·Make error-report, contact development

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 135/142
SmartMold 9
User Manual Alarms

6.5 Alarms80_99
The following alarms are described in this document:

20-80 PWM output 01 error

20-81 PWM output 02 error
20-82 Cycle stopped by motor
20-83 Synchronization error on mainboard
20-84 Not enough plastic
20-85 Safety gate not fully closed
20-86 Acopos servo pump feedback missing
20-87 Clamp lock timeout
20-88 Safety gate stopped by protection sensor
20-89 Clamp unlock timeout
20-90 Low clamping force
20-91 Battery low - change CPU battery
20-92 Delivery flap timeout
20-93 Selected Option not present on machine
20-94 Recipe-Parameter not supported
20-95 No mold height movement
20-96 Hydraulic safety malfunction
20-97 Clamp Force High
20-98 Accu did not finish loading
20-99 Accu Load Timeout

PWM output 01 error

PWM output 02 error
A error has occurred on the first or second PWM-output (high or low current, high
Description
temperature - see Pages >> PWM Outputs)

Cause ·Overload on PWM-output

·Alarm-Light
Reaction
·Cycle is stopped at end of current cycle
·Check exact error on IO-Browser page (Status of PWM-output). To determine
whether over temperature or over-current has occurred
Remedy
·Check if valve needs more current than XX419 can deliver
·Check if short-circuit is present on output
20-82 Cycle stopped by motor

Description The motor was turned off during automatic- or semiautomatic-mode

Cause ·Motor was turned off

Reaction ·Cycle is stopped immediately

Remedy ·Turn on motor again. Restart cycle

20-83 Synchronization error on mainboard

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 136/142
SmartMold 9
User Manual Alarms

Description Internal error - contact machine-manufacturer

Cause -

Reaction -

Remedy -
20-84 Not enough plastic
The injection piston has reached the target-position before it has reached the switch-
Description
over-criteria (Pages >> Injection >> Switchover)
·Not enough plastic (dosage low)
Cause ·Switchover-criteria set incorrectly
·Target-position set incorrectly
·Alarm-Light
Reaction
·Cycle is stopped at end of current cycle
Remedy ·Correct parameters

20-85 Safety gate not fully closed

The safety gate is not fully closed. A part of the safety-gate-limit-switches indicates
"closed" others "opened". The status of the gate is evaluated by the following
Description
signals: "Safety Gate Closed" (DI#231), "Safety Gate Closed (Redundant)" (DI#232)
and "Safety Gate Not Closed (Redundant)" (DI#233)
·Gate not fully closed
Cause ·Check-Time set to short.
·Limit-switch malfunction
Reaction -
·Close or open gate fully
Remedy ·Increase Check-Time
·Check limit-switch function
20-86 Acopos servo pump feedback missing

Description The servo-drive for the servo driven pump did not turn on within 2 seconds

·Servo drive malfunction

Cause
·....
·Alarm-Light
Reaction
·...
Remedy ·...

20-87 Clamp lock timeout

This alarm is currently not used
Direct Clamp: The locking did not complete before the configured timeout (Pages >>
Description
Mold >> Mold Close)
·Clamp cannot be locked
Cause
·Timeout set to short
·Locking of clamp is interrupted
Reaction ·Alarm-Light
·Cycle is stopped immediately
·Check locking parameters
Remedy
·Increase timeout
20-88 Safety gate stopped by protection sensor

Description The automatic safety gate movement was stopped by a protection sensor

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 137/142
SmartMold 9
User Manual Alarms

·Something is inside the gate

Cause
·Protection sensor malfunction
·Cycle is stopped immediately
Reaction
·Alarm-Light
Remedy ·Check gate

20-89 Clamp unlock timeout

Direct Clamp: The unlocking did not complete before the configured timeout (Pages
Description
>> Mold >> Mold Open)
·Clamp cannot unlock
Cause
·Timeout set to short
·Cycle is stopped immediately
Reaction
·Alarm-Light
·Check unlocking parameters
Remedy
·Increase timeout
20-90 Low clamping force
Direct Clamp: The closing force is too low for injection. This alarm is set when the
Description actual locking pressure is below the set locking pressure (Pages >> Mold >> Mold
Close) minus a configured tolerance when the injection is started.
·Pressure dropped in locking cylinders
Cause
·Pressure-tolerance to low
·Alarm-Light
Reaction ·Cycle is stopped at end of current cycle
·Injection is skipped
·Check why pressure has dropped
Remedy
·Increase pressure tolerance

20-91 Battery low - change CPU battery

Description The battery of the CPU is low - it needs to be replaced

Cause ·Battery is discharged

Alarm-Light
Reaction
Permanent data might be lost when PLC is turned off
Remedy ·Change battery

20-92 Delivery flap timeout

Description Delivery flap movement did not finish before the set timeout
·Delivery flap is jammed
Cause ·Delivery flap malfunction
·Timeout set to short
Reaction ·Cycle is stopped immediately
·Check delivery flap (mechanics)
Remedy
·Increase timeout
20-93 Selected Option not present on machine
A option that is active in the currently loaded fix-data is not supported by the software
Description
(Option disabled in "SW.ini")

Cause ·Option is disabled

Reaction ·Alarm-Light

Remedy ·Check whether operation with the data is still OK

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 138/142
SmartMold 9
User Manual Alarms

20-94 Recipe-Parameter not supported

A setting in the currently loaded recipe-data is not supported by the software (Option
Description
disabled in "SW.ini")

Cause ·Option is disabled

Reaction ·Alarm-Light

Remedy ·Check whether operation with the data is still OK

20-95 No mold height movement

The mold height did not move during the configured timeout Setup >> Mold Height
Description
although a movement was active.
·Mold Height does not move
Cause ·Mold Height sensor signal error
·Timeout to short
Reaction ·Alarm-Light
·Check why mold height is not moving
Remedy ·Check mold height pulse sensor
·Increase timeout
20-96 Hydraulic safety malfunction
The hydraulic safety valve did not engage when the safety gate was opened within
Description
the configured delay
·Hydraulic safety malfunction
Cause
·Delay to short
·Alarm-Light
Reaction
·Cycle is stopped immediately
·Check why safety is not working (close and open gate again
Remedy
·Increase timeout
20-97 Clamp Force High
The measured clamp force (toggle clamp) is to high (it exceeds the alarm-limit (Mold
Description
Height)
·Tonnage set to high
Cause
·Delay to short
·Cycle is stopped at end of current cycle
Reaction ·Alarm-Light
·Clamp close is stopped and clamp is opened
Remedy ·Increase mold height

20-98 Accu did not finish loading

Description The accumulator was not fully loaded at end of cooling time

Cause ·Accumulator needs longer time to load

Reaction ·Alarm-Light
·Increase cooling time
Remedy
·Increase loading flow
20-99 Accu Load Timeout

Description The accumulator did not finish loading within the configured timeout

·Problem with loading the accumulator

Cause
·Load Timeout to short

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 139/142
SmartMold 9
User Manual Alarms

·Alarm-Light and -Horn

Reaction ·Cycle is stopped immediately
·Loading of accumulator is interrupted
·Check Accumulator
Remedy
·Increase timeout

6.6 Alarms100_112
The following alarms are described in this document:
20-100 Injection Timeout
20-101 Emergency Stop Robot
20-102 Mold Height Position out of range
20-103 Hopper empty
20-104 Mold Mech. Lock Error
20-105 Robot: Mold Close Enable Missing
20-106 Robot: Mold Open Enable Missing
20-107 Robot: Eject Bwd Enable Missing
20-108 Robot: Eject Fwd Enable Missing
20-109 Robot: Core Out Enable Missing
20-110 Robot: Core In Enable Missing
20-111 Robot: Cycle Start Enable Missing
20-112 Inverter Error
Injection timeout

Description The injection was stopped due to a timeout (see Pages >> Delay Times (2))
·Timeout (Pages >> Delay Times (2)) set to short
Cause ·Switchover-criterion (Pages >> Injection >> Switchover) not reached.
·Injection (Nozzle) congested
·Alarm-Light
Reaction ·Alarm-Horn
·Cycle is stopped at end of current cycle
·Increase timeout
Remedy ·Correct switch-over criterions
·Check nozzle
20-101 Emergency Stop Robot

Description The emergency-stop from the robot is active.

·The emergency stop button on the robot interface was pressed.
Cause ·Malfunction of the robot-interface
·Commissioning: Wrong input connected or inverted.
·Motor is turned off
·All movements are blocked
Reaction
·Cycle is stopped immediately
·Alarm-Light is On
·Release the pressed emergency-stop button
Remedy ·Check robot-interface circuit
·Commissioning: Check input in IO-configurator and whether it must be inverted
20-102 Mold Height Position out of range

Description The actual mold height position is out of range (exceeds given min/max-range)
·The mold height position was not set correctly (see Pages >> Mold >> Mold Height)
Cause ·The mold height position was re-initialized after software-update
·Commissioning: Mold-height data (scaling, min. or max. positions) set incorrectly
Copyright © B&R - Subject to change without notice March 31, 2020
SmartMold 9 User Manual_V1.0.0.docx 140/142
SmartMold 9
User Manual Alarms

(see Mold Height)

·Motor is turned off

·All movements are blocked
Reaction
·Cycle is stopped immediately
·Alarm-Light is On
·Release the pressed emergency-stop button
Remedy ·Check emergency stop circuit
·Commissioning: Check input in IO-configurator and whether it must be inverted
20-103 Hopper Empty
No more material in the hopper. Alarm is set when the input Hopper Empty is active for
Description
more than 2 seconds.
·No more material in the hopper
Cause ·The signal from the hopper empty sensor is not correct.
·Commissioning: The signal from the hopper empty signal maybe has to be inverted.
·Alarm-Light and Alarm horn
Reaction
·Machine is stopped at end of current cycle
·Refill material
Remedy ·Check sensor signal
·Commissioning: Maybe invert input
20-104 Mold Mech. Lock Error
The mechanical lock of the clamp did not engage within the set time after the safety
Description
gate was closed.
·Mech. Lock jammed or other defect.
Cause
·Commissioning: Timeout set to low.
·Alarm-Light
Reaction
·Machine is stopped at end of current cycle
·Check Mech. Lock (safety bar)
Remedy
·Commissioning: Increase or disable timeout
20-105 Robot: Mold Close Enable Missing
Addition information for alarm 20-26 Cycle stopped by robot: The signal "Enable
Description Mold Closure (A6)" is missing. The time for this signal starts after the clamp close
delay time and after all core movements that happen before mold close.
Cause See main alarm.

Reaction See main alarm.

Remedy See main alarm.

20-106 Robot: Mold Open Enable Missing

Addition information for alarm 20-26 Cycle stopped by robot: The signal "Enable
Full Mold Opening (A7)" is missing.
Description
The time for this signal stars after all core-movements that happen before mold
open.
Cause See main alarm.

Reaction See main alarm.

Remedy See main alarm.

20-107 Robot: Eject Bwd Enable Missing

Addition information for alarm 20-26 Cycle stopped by robot: The signal "Enable
Description
Ejector Back (B3)" is missing.

Cause See main alarm.

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 141/142
SmartMold 9
User Manual Alarms

Reaction See main alarm.

Remedy See main alarm.

20-108 Robot: Eject Fwd Enable Missing

Addition information for alarm 20-26 Cycle stopped by robot: The signal "Enable
Description
Ejector Forward (B4)" is missing.

Cause See main alarm.

Reaction See main alarm.

Remedy See main alarm.

20-109 Robot: Core Out Enable Missing

Addition information for alarm 20-26 Cycle stopped by robot: The signal "Cores(1)
Description
Out Enable (B6)" and/or "Cores(2) Out Enable (B8)" is missing.

Cause See main alarm.

Reaction See main alarm.

Remedy See main alarm.

20-110 Robot: Core In Enable Missing

Addition information for alarm 20-26 Cycle stopped by robot: The signal "Cores(1)
Description
In Enable (B5)" and/or "Cores(2) In Enable (B7)" is missing.

Cause See main alarm.

Reaction See main alarm.

Remedy See main alarm.

20-111 Robot: Cycle Start Enable Missing

Addition information for alarm 20-26 Cycle stopped by robot: The signal "Cycle
Description
Start" is missing from the robot.

Cause See main alarm.

Reaction See main alarm.

Remedy See main alarm.

20-112 Inverter Error

One of the motors signalized a inverter error. The alarm is set when the inverter-error
Description
signal is TRUE after the motor has been turned on (and the on delay has expired).
·One or more motor-inverters defective (check inverter).
Cause
·Commissioning: Motor On Delay time set to short
·Alarm-Light
Reaction
·Machine is stopped at end of current cycle
·Check Inverter
Remedy ·Commissioning: Increase Motor On Delay
·Commissioning: Invert Input-Signal?

Copyright © B&R - Subject to change without notice March 31, 2020

SmartMold 9 User Manual_V1.0.0.docx 142/142