IPC Echo Series Quick start guide

Injection Molder
Setup & Operational Manual
I l l i n o i s P r e c i s i o n C o r p .
1 2 0 0 5 E . D a v i s L a n e
P : 8 1 2 - 735- 2 4 0 1
F : 8 1 2 - 7 3 5 - 4 2 1 8
R e v 1 .6

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ECHO SERIES Rev 1.6
Rev 1.2 04/11/2011 Author: Joshua W. George
A general build of the ECHO series manual, first series distributed.
Rev 1.5 04/15/2011 Author: Joshua W. George
Build up of Table of Contents and added How To’s.
Rev 1.6 06/21/2011 Author: Joshua W. George
Fixed some errors in the calibration section, updated some wire numbers, and replaced some
screen shots with new.

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ECHO SERIES Rev 1.6

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ECHO SERIES Rev 1.6
Table of Contents
Contents
Section 1 –UNCRATING & INSTALLATION .............................................................................................10
INTRODUCTION ....................................................................................................................................11
MACHINE INSPECTION ........................................................................................................................11
MACHINE PLACEMENT AND LEVELING ...........................................................................................11
HYDRAULIC FLUID ...............................................................................................................................11
BARREL CYLINDER INSTALLATION (OPTIONAL).............................................................................13
SHOT SIZE SENSOR INSTALLATION ...................................................................................................14
POWER REQUIREMENTS .....................................................................................................................15
ELECTRICAL INSTALLATION..............................................................................................................16
INSTALLATION WITH A TRANSFORMER ......................................................................................16
INSTALLATION WITH 208V..............................................................................................................16
INSTALLATION WITH 240V..............................................................................................................17
TESTING ELECTRICAL INSTALLATION.............................................................................................18
ELECTRICAL START UP....................................................................................................................18
CIRCUIT BREAKER START UP .........................................................................................................18
WATER HEAT EXCHANGER FOR OIL COOLING (STANDARD) ........................................................19
AIR HEAT EXCHANGER FOR OIL COOILING (OPTIONAL) ...............................................................19
WATER MANIFOLD WITH ROTATING UNION (OPTIONAL) ...........................................................20
DISCONNECTING DEVICES FROM WATER ....................................................................................20
INSTALLATION OF POWER FOR MOLD HEATER CAROUSEL (OPTIONAL) ...................................21
Section 2 - SYSTEMS ...................................................................................................................................23
COMPONENT LAYOUT .........................................................................................................................24
DISPLAY .................................................................................................................................................25
SECURITY...........................................................................................................................................25
MOVING THROUGH THE SCREENS.................................................................................................26
SOFT KEYS..........................................................................................................................................26
SCREEN KEYS.....................................................................................................................................27
SCREEN CAPTURE .............................................................................................................................27
SCREEN NUMBER ..............................................................................................................................28
USB & MEMORY STICK PORTS.............................................................................................................28
OPERATOR CONTROLS.........................................................................................................................29
HYDRAULIC CONTROLS.......................................................................................................................29
LOCATION OF HEAT EXCHANGER .....................................................................................................30

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ECHO SERIES Rev 1.6
LOCATION OF THE OIL FILTER ..........................................................................................................30
ROTARY MOLD TABLE.........................................................................................................................31
MACHINE POSITION VS TABLE POSITION.........................................................................................31
SHOT SIZE SENSOR ...............................................................................................................................32
PRESSURE TRANSDUCER.....................................................................................................................32
SPRUE TRIMMER ..................................................................................................................................33
WATER MANIFOLD WITH ROTATING UNION (OPTIONAL) ...........................................................34
MOLD HEATING CARROUSEL (OPTIONAL) .......................................................................................35
Section 3 –SCREEN SET-UP PROCEDURES ..............................................................................................37
MODES OF OPERATION........................................................................................................................38
CYCLE MODES ...................................................................................................................................38
SINGLE................................................................................................................................................38
CONTINUOUS.....................................................................................................................................38
OPERATION MODES..........................................................................................................................38
STANDBY ............................................................................................................................................38
RUN .....................................................................................................................................................38
PURGE.................................................................................................................................................39
MANUAL .............................................................................................................................................39
SHUTTLE MODE................................................................................................................................39
TABLE SELECTIONS..............................................................................................................................42
ALL MOLDS MINI SCREEN ...................................................................................................................42
CLAMP DURATION............................................................................................................................42
LOAD/UNLOAD TIME .......................................................................................................................43
SCREW POSITION ..............................................................................................................................43
BACK PRESSURE ................................................................................................................................43
PROD. CNT (PRODUCTION COUNTER) ...........................................................................................44
MODES ................................................................................................................................................44
ALARM ................................................................................................................................................44
DAISY DIAL ............................................................................................................................................45
HEATS.....................................................................................................................................................47
H EN (HEAT ENABLE)........................................................................................................................47
SP1/SP2................................................................................................................................................47
TEMP WATCHDOG............................................................................................................................48
LO ALARM ..........................................................................................................................................48
HI ALARM ...........................................................................................................................................48
DEV +/- (DEVIATION +/- ALARM) ...................................................................................................48
INJECTION PROFILE .............................................................................................................................50
POSITION 13 .......................................................................................................................................51

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ECHO SERIES Rev 1.6
SETTING UP A PROFILE.......................................................................................................................52
SHOTSIZE ...........................................................................................................................................53
SPEED..................................................................................................................................................53
PRESSURE...........................................................................................................................................53
INJECTION TIME ...............................................................................................................................53
TRIMMER/KNOCKOUT/CLAMP/MOLDING...................................................................................53
CHANGE TBL DIR (CHANGE TABLE DIRECTION) .........................................................................53
SETUP SELECTIONS..............................................................................................................................54
COUNT POSITION..............................................................................................................................54
LEFT MC BYPASS (LEFT MICROSWITCH BYPASS) ........................................................................54
RIGHT MC BYPASS (RIGHT MICROSWITCH BYPASS) ...................................................................54
KO LIMIT SW (KNOCKOUT LIMIT SWITCH BYPASS) ....................................................................55
MACHINE MONITOR.............................................................................................................................56
I/O CR STATUS ......................................................................................................................................57
INPUTS/OUTPUTS ............................................................................................................................57
CR NUM...............................................................................................................................................57
SECURITY CHANGE ..............................................................................................................................58
DEFAULT PASSWORDS.....................................................................................................................58
ALARM LOG ...........................................................................................................................................60
BYPASS TIMER...................................................................................................................................60
MANAGING RECIPES ............................................................................................................................61
CALIBRATION ........................................................................................................................................63
RLD VIEWER..........................................................................................................................................67
LOGIC DISPLAY .................................................................................................................................67
COLOR CODING .................................................................................................................................67
SHOW/HIDE LABELS.........................................................................................................................68
INCREMENT .......................................................................................................................................68
FIND ....................................................................................................................................................68
TABLE TIMERS ......................................................................................................................................69
TABLE TIMERS ..................................................................................................................................69
SHUTTLE TIMERS .............................................................................................................................70
SHUTTLE INITIALIZE TIMERS ........................................................................................................70
MANUAL TIMERS ..............................................................................................................................70
ALL MACHINE TIMERS.........................................................................................................................71
FUNCTION TIMERS...........................................................................................................................71
INJECTION TIMERS...........................................................................................................................72
Section 4 –MACHINE SET-UP....................................................................................................................74
HOW TO ADJUST/SET PRESSURES .....................................................................................................75

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ECHO SERIES Rev 1.6
FACTORY SETTINGS.........................................................................................................................75
HOW TO ADJUST THE MAIN RELIEF VALVE ....................................................................................77
HOW TO REMOVE THE BARREL CYLINDER (OPTIONAL) ...............................................................78
CLEANING THE NOZZLE - THERMOPLASTICS ONLY ......................................................................79
HOW TO ADJUST THE EJECTOR CYLINDER SENSOR ......................................................................80
LIGHT CURTAIN ...................................................................................................................................81
HOW TO LINE UP LIGHT CURTAIN ................................................................................................81
LUBRICATION........................................................................................................................................82
GREASING THE UPPER FRAME.......................................................................................................82
GREASING THE TABLE.....................................................................................................................82
HYDRAULIC OIL ................................................................................................................................83
OIL FILTER.........................................................................................................................................83
SCREW OR BARREL REMOVAL ............................................................................................................84
PRELIMANARY PROCEDURE ...........................................................................................................84
SCREW REMOVAL PROCEDURE ......................................................................................................85
BARREL AND SCREW REMOVAL PROCEDURE ..............................................................................86
CLEANING OF SCREW AND BARREL...............................................................................................86
HOW TO ADJUST THE SCREW OVER-TRAVEL MICRO SWITCH .....................................................87
HOW TO ADJUST THE FLAG ...............................................................................................................88
ANGLE.................................................................................................................................................88
HEIGHT...............................................................................................................................................88
HOW TO ADJUST BARREL MICRO SWITCH .......................................................................................89
Section 5 - ADDITIONAL SCREENS ...........................................................................................................91
Section 6 –MACO I/O DESIGNATION .......................................................................................................94
Section 7 –ECHO SERIES PARTS ...............................................................................................................98
FRAME..................................................................................................................................................105
INJECTION CYLINDERS......................................................................................................................106
HEATER BANDS...................................................................................................................................106
REAR OF FRAME .................................................................................................................................107
RIGHT SIDE OF FRAME ......................................................................................................................111
TABLE COMPONENTS ........................................................................................................................117
HYDRAULIC VALVES AND GAUGES .................................................................................................119
CORD TRAYS........................................................................................................................................120
TANK FRONT .......................................................................................................................................121
PUMP, HYDRAULIC.............................................................................................................................122
BOSCH BOARD .....................................................................................................................................123
TRIMMER OPTION..............................................................................................................................124
LPM OPTION ........................................................................................................................................126

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ECHO SERIES Rev 1.6
WATER MANIFOLD OPTION .............................................................................................................127
RAMP OPTION .....................................................................................................................................128
HOSE ORDER FORM (PLEASE MAKE COPIES)......................................................................................130

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ECHO SERIES Rev 1.6

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ECHO SERIES Rev 1.6
Section 1 –UNCRATING & INSTALLATION

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ECHO SERIES Rev 1.6
INTRODUCTION
The IPC injection mold press utilizes a Windows based microprocessor Eurotherm MACO
Compact Controller.
It is recommended that the production engineer read this manual and the Eurotherm
manual, and become familiar with the overall machine operation.
Any machine subjected to continuous production work may develop malfunctions.
MACHINE INSPECTION
After uncrating, visually inspect machine for possible shipping damages. If damage is
found, notify your carrier immediately. The machine should be stored in a dry area of the
plant until installation. A plastic tarp to cover is recommended.
MACHINE PLACEMENT AND LEVELING
The machine has mounting holes at the bottom of each leg. Anchor bolts or leveling
devices may be used through the holes, if needed.
HYDRAULIC FLUID
Each machine has been thoroughly tested at the factory under actual operating
conditions. However, prior to shipping, the hydraulic oil was drained.

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ECHO SERIES Rev 1.6
The oil filler cap is located at the rear of the machine. Add approximately 50 gallons
of MOBIL DTE 25 ANTI-WEAR HYDRAULIC OIL.
The dual function oil gauge measures both oil level and oil temperature. It is located
at the front lower left side of the machine.
The pump must be primed before starting the motor.
WARNING:
Never operate machine
when the OIL LEVEL
GAUGE shows less than
minimum oil level.

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ECHO SERIES Rev 1.6
BARREL CYLINDER INSTALLATION (OPTIONAL)
1. Position the barrel cylinder on the top plate so that the cylinder shaft lines
up with the threaded hole.
2. Tighten the cylinder shaft onto the top plate with a 7/8 open end wrench.
Make sure that the small 5/16” holes in the barrel cylinder plate lines up
with the guide rods.
3. Now install and tighten the two 5/16 screws through the barrel cylinder
plate and into the end of the guide rods.

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ECHO SERIES Rev 1.6
SHOT SIZE SENSOR INSTALLATION
1) Carefully unpack the shot size sensor.
2) Attach the shot size sensor to the barrel cylinder plate, with two 10/32
screws and two washers.
3) Attach the cable to the shot size sensor
connector. Make sure the cable is not
in the way of the hoses.
4) Adjust the shot size sensor so that it is
square with the machine and that the
tip is “just” touching the screw housing
plate.

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ECHO SERIES Rev 1.6
POWER REQUIREMENTS
This machine can be connected to any of the following:
This Echo model needs 208v or 240v 40 amp 3 phase service with a neutral and a
ground.
480v, 20 amp 3 phase service with ground and optional 3 KVA transformer.
If optional transformers were not ordered with machine, wiring should be performed by a
qualified individual who is familiar with all local electrical codes for standard industrial
installation.

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ECHO SERIES Rev 1.6
ELECTRICAL INSTALLATION
Electrical installation should be performed by a qualified individual who is familiar
with all local electrical codes for standard industrial installation.
INSTALLATION WITH A TRANSFORMER
If the machine has the optional 3 KVA transformer and your 3 phase
service is 208v, 240v, or 480v:
1. Connect the 3 phase to the top of the main disconnect.
2. The primary of the transformers should be wired for 208
volts, 240 volts, or 480 volts, depending on your service.
The secondary of the transformers should be wired for
240 volts with the neutral output connected to the
machine ground and neutral terminal in the controller
enclosure.
3. The motor controller setting should be adjusted to; 22
amps for a 208v or 240v connection, 11 amps for a 480v
connection.
4. Connect ground to cabinet.
5. Follow the procedures on "Testing Electrical
Installation"
INSTALLATION WITH 208V
If the machine does not have the 3KVA transformer option and the 3 phase service is 208 volts:
1. Connect the 3 phase to L1, L2, and L3 on the main wireway.
2. The motor controller setting should be adjusted to 22 amps.
3. Connect ground to ground terminal strip just left of main disconnect.
4. Connect neutral to neutral terminal strip just left of main disconnect.
5. Follow the procedures on "Testing Electrical Installation".

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ECHO SERIES Rev 1.6
INSTALLATION WITH 240V
If the machine does not have the 3KVA transformer option and the 3 phase service is 240 volts:
1. Connect the 3 phase to the top of L1, L2, and L3 of the wireway.
2. The B Phase (Wild Phase) should be connected to the center terminal
(L2).
3. The motor controller setting should be adjusted to 22 amps.
4. Connect ground to ground terminal strip.
5. Connect neutral to the neutral terminal strip.
6. Follow the procedures on "Testing Electrical Installation".

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ECHO SERIES Rev 1.6
TESTING ELECTRICAL INSTALLATION
ELECTRICAL START UP
When starting the machine for the first time, or when moving the machine to a new location,
the following procedures should be followed:
1. Ensure all the circuit breakers are in the off position.
2. Turn the main disconnect switch to the on position.
3. The pump must be primed before the next step.
4. Bump the motor around by pressing the white contact pins on the motor starter and
then releasing them. Use a flashlight to observe the rotation of the fan on the motor. It
must rotate in a clockwise direction.
5. If the motor is rotating backwards, turn off power going to the machine and then
reverse the outer two wires of the feed-in on L1 and L3. And re-prime the pump. Turn
on power. Repeat step 3 to observe proper operation of the motor.
CIRCUIT BREAKER START UP
1. The first breaker to turn on is Power Supply circuit breaker (Far right 3A AC double
pole). After turning it on, the light on the power supply should be on. Once it is on,
check for 24 VDC between any wire 1580 (+) and wire 1581 (-).
2. The next breaker to turn on is for the Maco Controller (second from left, 3A DC).
3. Then turn on the Op Station breaker (far left 2A DC).
4. You may now turn the remaining circuit breakers on.

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ECHO SERIES Rev 1.6
WATER HEAT EXCHANGER FOR OIL COOLING (STANDARD)
The water heat exchanger should be connected to a water cooling system if the oil temperature
exceeds 120 degrees Fahrenheit.
AIR HEAT EXCHANGER FOR OIL COOILING (OPTIONAL)
The air heat exchanger is an optional installation that requires no additional hookups.

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ECHO SERIES Rev 1.6
WATER MANIFOLD WITH ROTATING UNION (OPTIONAL)
DO NOT USE SOLID PIPE when installing water lines from molds to water ports. Only use
FLEXIBLE HOSE.
Do not install hose taut, and do not use any exterior bracing which would prevent the housing
from moving.
Connect a water feed to the hose labeled FEED, and a water drain to the hose labeled DRAIN.
WARNING: Do not turn the water on until the water union is connected to the necessary
device/s.
DISCONNECTING DEVICES FROM WATER
1) Turn off water.
2) Relieve pressure from water lines.
3) Blow out water lines. This is necessary to
prevent water from leaking down into the
table.
4) Disconnect water lines from device/s.