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
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