TRAINING MANUAL

FLF XFORM G4 BASIC OPERATIONS

XFORM G4

BASIC OPERATIONS

Jun 2020

BASIC OPERATIONS
TRAINING
 TRAINING MANUAL
FLF XFORM G4 BASIC OPERATIONS

INDEX:

Ch. 1) SAFETY SYSTEM

Ch. 2) MACCHINE OVERVIEW

Ch. 3) AUXILIARIES

Ch. 4) LUBRIFICATION

Ch. 5) NETWORK

Ch. 6) HMI INTRODUCTION

Ch. 7) START UP & SHUT DOWN

Ch. 8) PROCESS E PREFORM ANALYSIS

Ch. 9) MAINTENENCE

Ch. 10) MOLD CHANGEOVER

DISCLAMER:
This technical document is informative only, meant to be a help as well as a documental support to a training
course carried out by a SIPA trainer, therefore it can’t take the place of a certified training course made by a SIPA
trainer. Don’t consider this document an appendix of the official Use and Maintenance Manual and it can’t take the
place of the above mentioned one which has always to be the official reference. This manual can’t take the place
of technical skill which operators and maintenance workers must previously have gained on similar devices or
which they will be able to achieve under the guide of already trained personnel. This document and all of the data
and information contained in it are of the exclusive property of SIPA S.p.A. and can be used only for the purposes
and in the limits established by SIPA S.p.A.. Their reproduction and/or disclosure in whole or in part to third parties
is prohibited without the prior written authorization by SIPA S.p.

BASIC OPERATIONS
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 TRAINING MANUAL
FLF XFORM G4 BASIC OPERATIONS

SAFETY SYSTEMS
\

Ch.1 - Safety System

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Ch.1 - Safety System

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Ch.1 - Safety System

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Ch.1 - Safety System

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Ch.1 - Safety System

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MACHINE OVERVIEW

Ch.2 - Machine Overview

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Ch.2 - Machine Overview

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Ch.2 - Machine Overview

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Ch.2 - Machine Overview

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Ch.2 - Machine Overview

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Ch.2 - Machine Overview

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Ch.2 - Machine Overview

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Ch.2 - Machine Overview

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Ch.2 - Machine Overview

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Ch.2 - Machine Overview

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Ch.2 - Machine Overview

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Ch.2 - Machine Overview

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Ch.2 - Machine Overview

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Ch.2 - Machine Overview

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Ch.2 - Machine Overview

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Ch.2 - Machine Overview

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AUXILIARIES

Ch. 3 - AUXILIARES
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Ch. 3 - AUXILIARES
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Ch. 3 - AUXILIARES
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Ch. 3 - AUXILIARES
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Ch. 3 - AUXILIARES
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Ch. 3 - AUXILIARES
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Ch. 3 - AUXILIARES
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Ch. 3 - AUXILIARES
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Ch. 3 - AUXILIARES
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Ch. 3 - AUXILIARES
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Ch. 3 - AUXILIARES
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Ch. 3 - AUXILIARES
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Ch. 3 - AUXILIARES
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4
LUBRICATION e WATER COOLING

LUBRIFICATION e WATER COOLING

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LUBRIFICATION e WATER COOLING

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LUBRIFICATION e WATER COOLING

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LUBRIFICATION e WATER COOLING

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LUBRIFICATION e WATER COOLING

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LUBRIFICATION e WATER COOLING

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LUBRIFICATION e WATER COOLING

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LUBRIFICATION e WATER COOLING

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LUBRIFICATION e WATER COOLING

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LUBRIFICATION e WATER COOLING

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LUBRIFICATION e WATER COOLING

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LUBRIFICATION e WATER COOLING

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LUBRIFICATION e WATER COOLING

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LUBRIFICATION e WATER COOLING

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LUBRIFICATION e WATER COOLING

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LUBRIFICATION e WATER COOLING

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LUBRIFICATION e WATER COOLING

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LUBRIFICATION e WATER COOLING

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LUBRIFICATION e WATER COOLING

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LUBRIFICATION e WATER COOLING

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NETWORK

NETWORK
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NETWORK
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NETWORK
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NETWORK
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HMI INTRODUCTION

HMI INTRODUCTION
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HMI INTRODUCTION
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HMI INTRODUCTION
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HMI INTRODUCTION
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HMI INTRODUCTION
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 START UP AND SHUT DOWN INSTRUCTIONS

With this document we want to give the instructions for the purge, start and stop machine SIPA X-FORM for
the performs production.
In the context of machine start, it can arise some special requirements and adjustments that need to be
explained to facilitate the progress of the machine start.

The safety regulations are found in the "Use and maintenance manual".

Information
This technical document is informative only, meant to be a help as well as a documental support to a training course carried out by a SIPA trainer,
therefore it can’t take the place of a certified training course made by a SIPA trainer.
Don’t consider this document an appendix of the official Use and Maintenance Manual and it can’t take the place of the above mentioned one which has
always to be the official reference.
This manual can’t take the place of technical skill which operators and maintenance workers must previously have gained on similar devices or which
they will be able to achieve under the guide of already trained personnel.
This document and all of the data and information contained in it are of the exclusive property of SIPA S.p.A. and can be used only for the purposes and
in the limits established by SIPA S.p.A.. Their reproduction and/or disclosure in whole or in part to third parties is prohibited without the prior written
authorization by SIPA S.p.A.

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Overview Control Panel

A swiveling touchscreen with sensor buttons and the e-move as main operating element enable optimum
ergonomic operation.

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Basic functions

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Screen structure
The clearly laid out screen of the control unit enables simple and fast operation of injection molding machine.
Top line

[1] Alarm and message display (alarm-specific color-scheme) with number of pending alarms and alarm
text Serial number of injection molding machine and optional robot IP address
[2] User name and user level
[3] Flag of country and language
[4] Date and time
Info Panel

[1] Switchover between the info panel injection molding machine and info panel robot
4
[2] Actual value display
[3] Orientations
One point per available infor panel; the active panel si colored.
Status display
The status display indicates the status of motors, heaters, safety gates and optional accessories.

[1] Motor injection molding machine

[2] Safety gates
[3] Barrel heating with a display of the remaining soaking time
[4] Mold heating
[5] Switching over between several pages of the status display
[6] Orientations. One point per available status display, the active page is highlighted.
[7] Motor robot

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Tapping on the status display opens the following display.

[1] Status display

[2] switch [on/off] for switching on and off the function
[3] Link to screen page
[4] Cylinder heaters also offer the possibility to [lower]

If several electrical outlets or additional devices you want displayed, such as switchable sockets for example,
are located on the machine, then they are displayed in several rows. Barrel heating and safety-relevant
functions are always displayed in the first line.
Meaning of background colors
Green Gray Flashing 5
Motors switched on switched off servo motors
interlocked
Heat Zones switched on switched off soaking active
Safety Gates access allowed acces not allowed ---

To close the switch bar tap clear area inside the witch bar or the screen page.
Status display during heating and reduce mode

[1] Heat up status

The display disappears when all set target values are reached
[2] Status reduce
Display stays active during the reduce mode

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Navigations and input area
The central area of the screen contains the central control elements:
Navigation elements (components, tasks, navigation bar)
Input and display elements (screen pages, dialogs etc.)

Example views (components, tasks, screen page)

Information
The displayed elements vary according to the relevant access level and system configuration.

Operating mode keys

[1] Teach
[2] Setup
[3] Manual
[4] Semi-automatic
6
[5] Fully Automatic
Meaning of colors of the operating mode keys
Background gray Background green
Symbol colored selectable active
Symbol gray not selectable ---

Manual Mode

Control of functions with the pushbuttons. Each movement lasts only until you actuate the relevant
pushbutton or a specific end position is reached.
Locking conditions for the movements:
Safety gates are closed.
Mold closing only when ejector is retracted. Note additional conditions of special equipment such as
cores, robots, and high speed mounting systems.
Mold opening: additional conditions like mold closing.
Ejector stroke at preset mold position only. Note special conditions of special equipment such as
cores and robots.

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 Injection only when the barrel has been heated up, the mold is closed with the clamp force built up
and the nozzle has been applied. Reduced injection with open mold or unattached nozzle, if the consent key
is not actuated.
Plasticizing and decompression only for heated barrel.
Plasticizing without back pressure only when consent key is actuated at the same time.

Setup Mode

Selection of the set-up mode only possible from the manual mode. Functions as in ”manual” mode, however,
you must observe the following additional items:
No mold protection monitoring
No clamp force
Limited closing and opening speeds
Limited ejector speed and force
Information
When delivered, only basic mold movements and no mold sequence movements are available when the e-
move is in Setup mode. Switch on the mold sequence movements instead of the mold movements in the
variables monitor, in the list of variables ’FrontPanelIO1’with ’Use e-move to enable mold sequences in set- 7
up mode’ Selection ’Yes’.

Teach mode Operation

Selection of teach mode possible only in the manual mode. Functions such as "setup" mode.
NOTICE! Danger of damage to equipment! The control unit saves the changes in the sequence only after
exiting the teach mode. The current settings thus do not necessarily match with the visible settings!

Semi and fully automatic mode

When working in semi-automatic mode, actuating the green start key activates a work cycle. The system
stops at the end of the cycle. In fully automatic mode, the cycle repeats on its own. The duration of the
individual functions is determined by the adjustable or preset speeds and timing elements.
Prerequisites for switching to automatic mode:
Motor switched on

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 No alarms which prevent automatic mode
Program interruption key set to automatic mode
Oil temperature within tolerance range for hydraulic machines

Start conditions for an automatic cycle:

Mold open
Plasticized and decompressed in the first cycle
Ejector at retracted position
Safety gates closed
The set barrel temperatures are within the set tolerance
Automatic mode with program interruption

Machine movements as in manual mode: Control of functions with the pushbuttons. Each movement lasts
only until you actuate the relevant pushbutton or a specific end position is reached.
Press the program interruption key to go back to the automatic mode.
Configurable pushbuttons
8

[1] Switchover between pushbuttons injection molding machine and robot

[2] Assigned keypad
[3] Free keypad

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Initial conditions:
1) Machine, robots, soft drop, and HMI, switched on.
In order to start up the machine in the correct way:
- Turn ON the power by the handle the Electrical Cabinet of the Press
- Hold down the ON/OFF key until the sensor keys light up on the Press HMI
- Wait for 4-5 minutes
- Turn ON the power by the handle the Electrical Cabinet of the Robot

Fig.1

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2) Check presence of air pressure (8-9 bar)
It is possible to check the presence of air pressure on the manometer inside of the robot area, when all the
cabinets are closed, the manometer is indicated below.

Fig.2

3) Verify the presence of water circulation with temperature of about 8-14 ° C. The temperature and flow rate
are monitored by the parameters set in the Video page area shown in the figure below.

10

Fig. 3

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4) The dried resin and temperature for plastification, normally with moisture value max 50 ppm and 170 ° C,
can be seen in the Dryer Interface page.
(See dryer handling instructions and resin drying process).

11

Fig. 4

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5) The extruder group enabled (without checkmark), or disabled, dry cycle (with checkmark).

Fig.6
6) All cabin safety must be enabled, and after the alarm reset, there must be no alarms "safety gate open" on
the alarms page, as shown in the figure.

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Fig. 7
After activation of functions: pump, driver operations, opening cabin doors ... it is always necessary to
perform alarm reset.

Fig.8

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7) Oil temperature, 45 ° C goal. The real value is shown in the figure below.
To access this page, click on the icons below.
If the pumps are switched on and whether the current oil temperature is below 37 °C the machine
automatically switches in the condition of "Preheating" until reaching 45 °C, and in this condition, it is not
possible to perform movements.

13

Fig. 9

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8) The heaters must be turned on and the temperature must be reached and stabilized. The heaters are
activated by pressing the green buttons "on/off" shown in the figure below, temperatures reached and
stabilized are confirmed by the lights of the buttons "on/off" continuous lit green.

Extruder Heating Fig.10 Mold Heating

The heating is divided into two parts to enable with the buttons above, extruder and mold.
The mold is divided into two groups to be enabled separately in the video pages, Hot runner and Nozzles.
Enabling Hot runner of mold, activating the flag "heating ON" as shown in Figure

14

Fig.11

Work - St-By - Purge Heating group

selection enable

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Enabling nozzles of mold, activating the flag "heating ON" as shown .Normally, we will enable the nozzles
when starting the extruder purging.

Fig.12
Check Press, Extruder and Injector temperatures

15

Fig.13 Extruder heating video page Fig. 14 Injector heating video page

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 16

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 Check temperatures of hot runner and nozzles

17

Fig.15 Hot runner heating video page Fig.16 Nozzle heating controlled by power %

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Preforms evacuation
Turn on the soft drop (if present, in the configuration chosen field must be set to "2", if is present traditional
download, must be set to "1"), enable it with the start key of the electrical panel, the green light will be ON to
indicate that there are no alarms, then enable selecting the flag as shown in the figure below. Place the
containers for good and bad preforms.

18

Fig.17

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Pumps start
With doors closed (safe condition), reset alarms, turn on the pumps by pressing the button "on/off" button.
Wait for oil temperature to arrive at 45 C°.

Enabling oil pump

Fig.18

Press opening
1) If the oil has reached 45 ° C, in order to move slowly, select set-up button indicated below.

19

Fig.19

2) With the button shown below, open the press, it will stop at the preset position.

Fig.20

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Robot axis movements:
1) Turn on the drivers using the button indicated in the figure below, then reset alarms.

Fig.21

2) To move the Cooler axis, to position “take preforms” from the mold, the press must be in the open position.
There are two ways to move electric axes in manual mode:
A) Fast curve disabled, the axis moves with setting speed (low speed) imposed in a separate page, the
movement does not consider the set quotes.
B) Fast curve enabled, the movement will be faster with acceleration and deceleration, it will stop in the set
quotes.
3) To move in slow mode, disable “release of fast profile” on the robot menu.
20

Fig.22

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Moving Translating axis of "Pin Station"

Fig.23
4) The first time, perform reset by pressing the left button of the desired movement for 1 second, as indicated
by the central arrow in the figure below. After the reset, the left button can be used to move.
5) Move the preforms Pin Station back or forward with manual control as shown in the figure below, repeating
with the same button you will sequentially reach all positions.
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Movement
after reset Movement

Reset 1 sec.
Fig.24

Actual
position

Fig.25

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Moving rotating axis of “Pin Station"

Fig.26
6) Rotating Pin Station in vertical position 90°.

22
Reset 1 sec.
Movement
after reset Movement
Fig.27
7) To stop in the exact location, enabling handling with fast profile, see figure in step 3.
8) Press and hold the rotation button until arrival at the position.
Repeat the command until you sop vertically 90 °, in the figure indicates the current position field.

0,00° - 90,00°

Fig.28

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Moving translating axis of "Cooling tube plate" EOAT

9) If it is the first axis movement after switching ON the machine, perform reset by pressing the button
indicated by the left arrow for 1 second.
Move the cooler outside the press with manual command as shown in the figure below.
If enabled fast profile, repeating the command with the same button, you will sequentially reach all positions,
hold the control until you get a set quota, then release and repeat for access to other quotas.

Movement
Fig.29
Reset 1 sec. Movement after reset
23

Actual
position

Fig.30
10) Now we have confirmation of operation of the 3 axes of the robot.
11) To work easily during the mold purging or mold changeover, you can move the horizontal axes until the
position - 100mm selecting low speed and using manual button.

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Instructions for Pin Station Valve

24

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Cooling Preforms

Ejection preforms and Pin Station Backward

25

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Pin Station Rotation

26
Discharging Preforms

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Pin Station Rotation and Forward Movement

When the Pin Station is in position, the cycle reinitializes with the Cooling of Preforms.
27

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The press movements
There are 2 types of press movement:
1) Selecting SET-UP, it moves at slow speed and with reduced pressure, can be stopped in any position, the
speed cannot be set.

Fig.31

2) Selecting MANUAL, it can move from the position of open to closed and vice versa with an acceleration
and deceleration profile automatically generated, we can only set the maximum speed and the weight of the
cold half in motion…

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OPEN

CLOSE
Fig.32

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 29

Fig.33
Set maximum Set maximum Closing
Speed for Opening Speed for Closing Force

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To move the press
To move the press, the oil must have reached 45 ° C, the pumps must be switched on, the cabin doors
closed with safeties activated.
The cooler must be outside of the press moving area.
The extractor position should be back.
The Mold Height should have been already measured.
Preforms ejector in back position :
You cannot close the press if the machine does not know the location of the performs ejector back.
Then you must select "Determine ejector retracted position" where shown on the figure below.

Enable
by flag
30

Back position memorized

Fig.34
Press the green button (e-move) to start the automatic search of the back position.
Within seconds the ejector moves forward, then backward, stores the location and the flag disappears.
On the field "Ejector retracted position “ appears the stored position.

Start Find
back position

Fig.35

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Mold Height (if requested by machine) :
The molds may have different heights, then the replacement of a mold, or other important parameter
variations, generate the request to perform the "Mold Height" function, in order to correct the position of the
back plate of the press.
Open the press, select "Determine mold height" as shown in the figure below, under the Video page, it will
show the message "Press start button".

Actual
mold
height

Enable by
flag
31

Fig.36
Press the green start button to start the automatic search of the mold height.

Start mold height

measurement
Fig.37

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In a few minutes (in the case of a larger mold), the cold half of mold moves forward to touch the hot half, then
back, then moves the rear press plate and again closes the mold, now the press memorizes the position and
the flag disappears.
On "Mold height" field, the new mold height value is stored.

32

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Clamping force (if requested by machine):
If it is a mold just installed, for the first movements, set a tonnage not exceeding 1000kN (100 tons)
Before start production, sure that the tonnage set value is suitable for the product to be produced, you can
check and change the set value on the field shown in the figure below. Fig. 49

Actual
Clamping
Force 33

Clamping
Force Set

To obtain the set value of the tonnage, select manual mode, open and close the press 3 times using the
commands shown in the next figure.
During the three movements the machine adjusts the press to obtain the tonnage within the tolerance of
1.5% (with error greater of 5% the machine goes into alarm)

OPEN

CLOSE
Fig.38

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Mold closing point:

The mold closing point is the point at which the mold halves touch. The mold closing point therefore
corresponds with the zero point for the mold movements. Based on this, additional positions are set along the
mold stroke. An example is the ’mold close position’, which is generally set at 0.2 mm (0.01 in) before the
mold closing point.
When the mold has reached this position, it has the following effects:
End of mold protection monitoring
Braking to ’speed in case of platen contact’
Beginning clamp force build-up
The determination of the mold closing point is therefore a prerequisite for the proper function of the clamping
unit. The mold closing point is always determined in the ’setup’ mode when the mold halves contact during
’mold closing’. In the ’manual’ mode, the mold closing point is only determined, if the mold height is defined
and the clamping force has been set. If only the clamping force is changed, the mold closing point is
automatically corrected. The mold closing point must not be re-determined.
The mold closing point is calculated via the rigidity of the machine when building up the clamping force and
normally no longer has to be determined via a specifically reduced movement for the mold closing point
determination.
If the tonnage variation was consistent, the machine can ask to perform the "Determination of mold closing
point", very important operation for the "Mold protection" function.
34
OPEN

CLOSE
Once the production clamping force is reached, the mold closing point is determined automatically in the
following cycle. During this cycle, the mold closes at reduced speed leading to increased cycle time.
Therefore the cycle time monitoring time is automatically increased by an adjustable time. Following the
determination of the mold closing point, the clamping force is built up fully and production continues as usual.

NOTICE!
During automatic determination of the mold closing point, parallel injection is interlocked for safety reasons
and only released once clamping force has been reached!

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Mold Protection
Mold protection is a function that stops the press, in case that there is something between the mold faces
during the closing.
The good "Mold Protection" operation, depends on the correct determination of the closing point of the mold.

Fig.41

35

Fig.42

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Soft Drop Stop Start Emergenc Emergency
button button y Reset button

36

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Start Up in Dry Cycle
Enable dry cycle by checking “Dry cycle – Extruder – Injection unit”.
Reset alarms.
Select continuous cycle and confirm by special window.
Start cycle by green button.
Fig.55

Flag here

Fig.43 Reset alarms

37

Select automatic cycle

Start
cycle
Fig.44

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Colorant doser – switch on before to purge

Turn on the colorant doser (masterbatches)

Fig.45

Turn on the colorant aspirator ( if it is granular)

38

Fig.46

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Extruder purge:
Place the extruder completely back and the purge box under the nozzle.
To move back the group press and hold on the button indicated in the figure, until the group arrive in back
position.

Fig. 47
In the display shown in the figure, you can read the position of the extruder.

39

Fig. 48

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1) Open the valve of the hopper to allow the resin to enter into the extruder.

Extruder commands:

Melt 40

Screw Transfer
filling until until set
set point

Injection

Double click
to add screw
filling until
set

TRAINING
2) Introduction: to avoid the difficulty of fusion of PET blocks, residues in the extruder and injector, before
the machine is switched off, it is advisable to discharge all of the melt present in the extruder and the injector.
As above, in the machine start time, we do not have the material in the extruder screw and into the injector,
then, after opening the hopper valve, you have to load the extruder with a special manual control of the
operator panel as shown in the figure.

Fig.49
You can verify that the material is filling the extruder observing the quote of screw position in to display (A)
shown in the video page and looking at the blue line indicated in the graph (B). The screw will stop turning
when its position will be to the set value and the purple LED (C) will be on.

41
B

C
A

Fig.50

TRAINING
3) When the extruder will be loaded to set position, transfer the melt from extruder to injector with
appropriate command shown in the figure below.
Melt
(Transfer)

Fig.51
You can check the completeness of the transferring or dosage on the video page of the figure, the injector will
be loaded when the position set has reached and the led will be ON.
42

INJECTOR
LOADED
INJECTOR
POSITION

Fig.52

TRAINING
4) Empty the injector into the purge tray with the appropriate command indicated.
By double clicking on the indicated button, the machine will execute simultaneously the extruder charging
and the injector emptying.

INJECT
+
Plasticizing

Fig.53
5) Repeat steps 2 and 3 until the melt output will be of a good quality.

43

TRAINING
Purge with the mold open:
Open extruder nozzle protection.
Remove the purged material box.
Clean with special brass tools the extruder nozzle and the entry of the mold.
Close the protection of the extruder nozzle.
Move forward the extruder group by specific command, until the nozzle will push in mold entry, hold on the
command until the led "Position reached nozzle contact" will be ON (purple color led).

Extruder
Fig.54 forward
Hold until the forward position in contact with the mold is reached and the lighting of the LED, violet LED
indicates that the contact pressure is increased up to the set "Contact Force value".
44

Fig. 55

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Select the setup status with specified command

Fig. 56
Open the press with manual control shown in the figure on the left, the press will open slowly to the set quota.
To facilitate the mold purge operation you can override the quota of mold open, up an aperture of about
800mm, this is possible by actuating the key command (SIT-KEY), indicated in the figure below,
simultaneously with the press opening command.

OPEN

45

CLOSE
Fig.57

Open the door

Apply an anti-spray protection in front of the cold half (eg. a panel)
Close the door
Extruder and injection should be charged, if it were not so you have to load them. Select the manual status,
and proceed to inject the material inside the mold with the same command used for emptying the injector,
using the same commands used to purge the extruder, reload the screw and transfer melt to injector, it is also
possible to inject with double click to load the extruder simultaneously.
Repeat the operations as necessary to clean the hot runner.
Observe that plastic comes out by all cavities and ensure that the colour is acceptable.

TRAINING
Open the door and turn off the pumps.
Remove waste and clean the cavity, even with air blow, in order to remove small debris that might prevent a
complete closure of the mold.
Close the door
Reactivate the pumps

Return the press in normal work position, quota less than that of press opened.
Execute press open, release the button when stops in set position.

OPEN

CLOSE

46

Fig.58

TRAINING
Limitations of purging with the mold closed:
1) It can be done when the machine was not stopped for a long time with heating on (material degraded
inside the mold).

It can be done when the heating for the extruder and the mold was enabled for a short period of time and the
temperature reached spies have just stopped blinking, so we can think that, the resin didn’t reached a high
level of degradation, so the purging can happen with the mold closed.

2) If you are not sure that resin is not degraded, you cannot purge with mold closed! The yellow degraded
material may stick to the threads and cones of neck ring and cores!

3) After purging is done, it is good practice to work a few times with single cycle in order to control the quality
of preforms before placing them in the cooler.

Starting up in Single Cycle with or without purging the mold:

Make sure that the cooling water is flowing through the cold half of the mold (neck rings and cores) and PMC
is ready (Water flow, vacuum…).

47

Fig.59 Taps cooling water cold half input Fig.60 Taps cooling water robot input

TRAINING
Select manual operating mode with the indicated button.

Fig.61

There should not be preforms on cores (this machine does not restore).

Remember that the machine will not start if injector and extruder screw are not loaded with the selected dose,
if necessary to load them, use the same commands used in the purge phase.
The press must be in to open position " Opening Stroke” position, the LED must be on.

48

Fig.62

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The extruder nozzle must be fully forward, to move forward the group, hold on the button indicated.

Fig.63

Hold the button until the forward position, until contact with the mold and elevated pressure in the cylinder,
until you reach the "contact force” purple LED, indicated below, must be ON.

49

Fig.64
Set temporary safety parameters.

TRAINING
Safety parameters
To facilitate starting the machine, you can change some parameters, after start restore normal production
values.
1) We need to increase by 10% the switchover position, the threshold value is indicated

Fig.65
2) It is good to increase by 20% the cooling time, the value of the cooling time indicated.
50

Fig.66

TRAINING
3) To be able to see, to count, and evaluate the preforms before the extraction, it is good to increase the
"ejector forward delay" and "ejector retract delay" of about two seconds or more, the value of the delay times
are indicated in the figure (delaying ejector forward is possible that the press lost the opening position, due to
effect of movement of the extractor mass, then it will be necessary to restore the press position to continue.
Fig. 67

51

TRAINING
Now select the semi-automatic / single cycle button by the indicated button.

Fig.68
Check for alarms on the alarm screen (soft drop ...).
The machine is now ready to start, pressing the appropriate button to start the cycle indicated.
Pressing this command, the machine will perform a single cycle (a single preform sample), single cycle ends
after the discharge of performs, free in the air and with the open press, the cooler does not enter into the
press.

52

Fig.69
Now look at the product obtained and to evaluate the quality of the sample, bubbles, color, form, ect.
In order to observe better the preforms is possible to stop the cycle before extraction, actuating the cycle
interrupt command with the newly open press, so it will block the extraction of the preforms, the interrupt
command is shown in the active position on the figure.

Fig.70

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After cycle interruption will need to download the preforms manually, moving the ejector with the commands
shown

Fig.71
To perform the retraction of the preforms ejector may need to reset the control photocells of preforms transit
between the mold and cooler.
In the case of cycle interruption, or alarms caused by injection or by preform jam not fully extracted, you must
reset the photocells control, to allow a new cycle, if single-cycle or continuous automatic. You can perform
reset by the flag on the field "reset by looking edge monitoring" shown in FIG.

53

Fig.72
Repeat the single cycle operation 2-3 times, to make sure that the preforms are of good quality :
full preforms necks, good compaction, no bubbles, clear color, no crystallization.
Doing so you will have the certainty of having an optimum and easy insertion of preforms in the cavities of the
cooler.

TRAINING
Start of blowerl for preform production:
The Vacuum Pump starts automatically when the Robot is Enabled in Automatic mode.
During cooling, the preforms are pushed in the Cooling Tubes of the Robot by atmospheric pressure because
there is vacuum, generated by the pump, inside the Cooling Tubes.

Fig.73
During the transfer of preforms from Cooler to the Pin Station another type of depressurization is used,
generated by the Blower pump which is empowered at the Start up of the Machine. 54

Blower Vacuum Enable/Disable

Fig.74

TRAINING
Start machine for preform production in Automatic Cycle:
Select the automatic cycle function by enabling the bellow command:

Fig.75
Check the presence of preform on the cores.
Check the presence of allarms on the allarm page
The machine will not start if injector and extruder are not loaded with the selected dose, if necessary, use the
same commands used in the purge phase.
The press must be at the open quote, check “Mold stroke position”, the led “Opening stroke” should be
purple.

55

Fig.76

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The extruder must be fully forward, to move forward the group hold the power button until the purple LED
appears.
Fig. 77

56

The machine is ready to start.

To start automatic cycle, press the green button as shown in the figure.
The preforms are inserted in the cooling tubes of the Cooler.

TRAINING
Fig.78
Observe the first machine cycles and be ready to stop the cycle in case of severe abnormalities, in particular,
pay attention to the transfer phase of the preforms to the Cooler, the cycle interruption command is shown in
Figure bellow:

57
Fig.79

Once the Cooler is filled, undo the changed security parameters to the original value of normal production
(switching, cooling, delay times).

TRAINING
Stop cycle from Production:
The proposed goal is to stop the machine with the least possible waste of resin and also to make it easier for
the next start up.
A) All resin accumulated in the front of the Extruders Screw needs to be used.
B) All the produced preforms need to be unloaded from the machine in containers.
C) The screw shouldn’t have melt residue in the front, it must be stopped all the way forward to facilitate the
purging during the next start up of the machine after cooling.
D) The injector shouldn’t have any melt residue in the front, it must be completely forward before it is cooled,
to ease the purging during the next Start up of the machine.
To satisfy point A:
1) Close the resin outlet valve from the hopper.
2) Wait for the consumption of resin present in the extruder inlet tube and extruder back, to stop the machine.
A system that helps to identify the last plasticizing cycle is the observation of the time for filling of the screw,
shown in the below figure, in fact when the screw begins to lack resin, this will enlarge the time, attention to
the tenths of a second, if the time exceeds to much, the machine will stop, for alarm on the filling time.
Another way is to know (from experience) how many cycles the machine can make since the hopper outlet
valve has been closed.

58

Fig.80
3) Stand ready to stop the machine in the correct cycle and in the right time in the cycle, enabling the single
cycle during the ejection phase of preforms from the mold.

TRAINING
To satisfy point B:
4) When the machine works in a Automatic cycle, exactly during the entry of the cooler into the press, select
the command "single-cycle operation" shown in the figure, in this way the machine will unload the latest
preforms on the cooler, it will stop with the open press, the cooler will stop in 0,00 mm position to load
preforms for cooling.

Fig.100
5) When the machine is stopped, select the "Manual operation" as shown in the figure.

59

Fig.81
6) Enable the dry cycle with the activation flag in the box indicated in the figure. (Injection Unit Disable).

Fig. 82
7) Select "Automatic operation cycle".
8) Press the green button mushroom to restart the machine with continuous cycle (vacuum on, without
plastic). Now the cycle will continue as during normal production, but lacking the injection there will not be
produced other preforms, as desired, all the preforms present in the Cooler, cycle after cycle will come out
from the machine.

TRAINING
9) When all the preforms are discharged into containers, you can stop the machine by selecting "Operation
in single cycle".

To satisfy points C and D:

10) When the machine is stopped, select "Manual operation".
11) To purge, enable Extruder group, disable the dry cycle by turning off the flag in the appropriate page of
the injector box.
12) Move backward the Extruder group.
13) Place the collecting tray under the Extruders nozzle.
14) Proceed further by emptying the Shooting Pot (Injection), don’t double-click the button, because now
we want only to purge without loading again the Extruders Barrel.
15) Transfer the remaining melt from the extruder to the injector.
16) Purge again the Shooting Pot (Injection).
17) Continue until you empty completly the Extruder and the Shooting Pot (Injector).

Final Shut down

Save modified data
Turn off the heaters, pumps, drivers and soft-drop.
Cool down the dryer. 60
Close air and water of the machine, on the hot half close the water only when the mold temperature has
dropped to 80°C, on the dryer only at the end of the cooling cycle.
Turn off air conditioner only after closing the water, to prevent condensation.
Turn off machine, chiller, compressor.

TRAINING
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PROCESS & PREFORM

ANALYSIS

Ch.8 - PROCESS e PREFORM ANALYSIS

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MAINTENANCE

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10

MOLD CHANGEOVER

Ch. 10 - MOLD CHANGEOVER

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Mold. Installation: steps regarding the installation of the mold

inside the XFORM GEN 4

Ch. 10 - MOLD CHANGEOVER

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10.1 INSTALLATION OF THE HOT HALF

Ch. 10 - MOLD CHANGEOVER

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10.2 INSTALLATION OF THE COLD HALF

Ch. 10 - MOLD CHANGEOVER

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10.3 MOLD RECIPE

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10.4 ROBOT INSTALLATION

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OFFSEAT of EOAT

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10.5 DRY CYCLE

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Ch. 10 - MOLD CHANGEOVER

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