Yudo YUCON-500 Operation Manual

Control box for unloader

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Control Box for Unloader

Operation Manual

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< Technical Edition >

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Summary of Contents for Yudo YUCON-500

Page 1 Control Box for Unloader Operation Manual < Operation Edition > < Technical Edition >...
Page 2: Table Of Contents
Table of Contents ◈ What’s in the User Manual ..................1 ■ About the Warning Label ....................2 ■ Types of Warning Label ....................3 ◎ Danger Zones ......................9 ■ High-voltage area ....................9 ■ Unloader Moving Zone ..................10 <...
Page 3 5. Return-to-Origin ....................... 25 5-1. When the vertical arm is inside the mold ................25 5-2. When the vertical arm is outside the mold ................27 6. Emergency stop ......................28 7. Setting the Mode ......................29 7-1. Mode screen ........................29 7-2.
Page 4 11. Setting the Mold ...................... 66 11-1. Condition Memory ......................66 11-2. Reading the condition memory ..................68 11-3. Writing the condition memory ................... 69 11-4. Erasing the condition memory ................... 70 12. I/O Display ......................71 12-1. I/O Screen and I/O code list ....................71 ■...
Page 5 < Technical > 1. Before operation ......................93 1-1. Safety Precautions ......................93 ■ Indication of the level of danger ..................93 ■ About points ........................93 ■ Repairs ........................... 94 ■ Ending work ........................95 1-2. Specifications ........................96 ●...
Page 6 7. List of major parts for YUCON-500................. 130 8. CHECK LIST ......................131 9. Schematic diagram...
Page 8 ※ This manual describes the standard model. For optional specifications, refer to corresponding separate manuals. ※ For a description of operation methods, refer to the operation manual “Controller for YUDO-STAR Automatics Unloader”(YUCON-500). ● Model SIGMA – L(s) , i(s) , (s) TYPE MEGA –...
Page 9: About The Warning Label
UNLOADER SAFETY GUIDE ■ About the Warning Label Thank you for purchase of the Star Automatic Unloader. This safety guide explains important information about operating methods and precautions, etc. to use the unloader safety Before performing operation or maintenance on the unloader, Read this safety guide and the instructions carefully to understand operating methods and precautions thoroughly and perform.
Page 10: Types Of Warning Label
■ Types of Warning Label Some caution plates may not be used on this machine. ※ ● Moving zone Off-limits Unloader has its moving zone where it Caution for danger of lowering moves with high speed. It is prohibited to enter into the moving zone while it's on automatic operation.
Page 11 ● Caution for high voltage electrical shock Make sure to cut off the breaker of controller while maintenance work is being done. Especially during such work for inside the box, disconnect connecting cable with molding machine and cut off primary power supply of the factory. This label can be found at the locations (terminal block, etc.) where special attention is required in the range of high...
Page 12 ● Warning for stroke adjustment To adjust stroke of movable components see instruction manual and do in safety. Even after disconnecting the power supply and pressurized air supply, some pressurized air may remain in the air cylinder, causing some parts of the unit to move suddenly.
Page 13 ● Caution for danger of enfolding To work in the moving zone for maintenance or other purposes, do not touch carelessly with such parts as motor, rotary axis, gear, pulley, belt which have danger of enfolding you. Cut off power supply and air pressure to work.
Page 14 ● Off limits in liquid medicine spray extent Do not enter the range where liquid medicine is sprayed. Be sure to turn off the power of the control box and the spraying equipment before you enter in this range for maintenance or any other reason. ●...
Page 15 ● Caution for carrying heavy weight Use the hoist, crane, etc. when carrying the parts of the unloader, etc. that weigh more than 15kg. Do not carry without the carrying equipment. ● Caution for static electricity The unloader has its moving zone in which it moves at high speed.
Page 16: Danger Zones
◎ Danger Zones ■ High-voltage area: Controller Do not open the front cover when the power is switched on or during operations. The unit contains exposed high-voltage terminals and recharged areas that could potentially cause electric shocks. Ensure that the power switch has been turned OFF before attempting to open the cover and touch any of the internal parts during maintenance.
Page 17: Unloader Moving Zone
■ Unloader Moving Zone The area marked with is dangerous. Entering this area while the unit is in operation may cause serious accidents resulting in severe injury. The unloader has its moving zone in which it moves at high speed. Do not enter this moving zone during automatic operation.
Page 19: Before Operation
1. Before Operation ■ Indication of the level of danger Safety precautions written on the warning labels are classified into 3 levels as indicated below. Pay particular attention when handling machine with high danger levels. Death or serious personal injury may result if the instructions are not Danger followed.
Page 20: Terminating Work
■ Terminating work Warning ● Do not separate or change the box covers and switch covers installed for safety without the permission of the manufacturer. ● Do not modify or change the equipment that may deterioirate the safety of the unloader, ●...
Page 21: Component Parts
2. Component Parts ⑨ 2-1. Pendant and operation panel ① ⑤ ⑦ ④ ⑧ ③ ② ⑥ ⑪ ⑩...
Page 22 1. Emergency stop button ......Press this button to immediately stop operation. ※ To reset the machine, turn the button to the direction of the arrow to unlock, and turn the power back on. 2. Power lamp .......... This lamp turns green when the power is on. 3.
Page 23 12. Operation keys ......... Resets the system when an error or alarm screen is displayed, and displays the initial screen........Turns the operation of the unloader into an automatic mode. Press AUTO key and the START key to operate the equipment in the automatic mode........
Page 24: Using Pendant
2-2. Using pendant You may hold the pendant in your hand when you manually operate the unloader or set each data. Caution · Applying impact to the pendant, or dropping the pendant, may lead to equipment malfunction. · Do not bend, step on or pull the cable.. 1.
Page 25: Operation Procedure
3. Operation Procedure 3-1. Major movements of the unloader The operation of the unloader is mainly classified into the return-to-origin operation, manual operation and automatic operation. ■ Return-to-origin operation This operation is performed when the power is turned on or the automatic operation is activated. The operation differs depending on the position of the vertical arm.
Page 26: Automatic Operation
● Free interlock motion Moves to the set direction while the key is pressed regardless of the setting. ■ Automatic operation The unloader is automatically operated by the pre-input data. Data input AUTO START * Return to origin first prior to operating the unloader. * Open chucks (LS4V <OFF>) prior to starting the operation.
Page 27: Operation (Routine Operation) Based On Preset Operation Data
The major operating sequences may be based on preset operation data or changed operation data. 3-2. Operation (routine operation) based on preset operation data · Conducts an inspection of work-start prior to turning the power on. Power On · Conducts an inspection of work-start after turning the power on. ·...
Page 28: Operation After Changing Operation Conditions
3-3. Operation after changing operation conditions Operates after selecting pre- Operates after combining Operates after partially input operation data. and inputting new operation changing pre-input data. operation data. Power On Sets the conditions of data setting mode, axis position, timer and packing, in sequence.
Page 29: Connecting And Disconnecting The Power
4. Connecting and disconnecting the power 4-1. Connecting the power Danger Cables or wires with damaged covering may lead to leakage or short-circuits. Check the condition of wires or cables prior to connecting the power. If any damage is discovered or there is a possibility of short-circuit, inform a qualified electrician immediately for an appropriate action.
Page 30 ( Main screen ) ◎ IN/OUT ....Checks the condition of the input/output signals of the unloader and the molding machine. ◎ COUNT ....Sets and verifies the total quantity, product quantity and the amount of sprayed air blow. ◎ FREE ...... Each axis and the cylinder can be operated freely regardless of the mode and teach settings.
Page 31 ◎ EXT CYCL ..... Monitors the total extract time in the AUTO mode. MLD CYCL .... Monitors molding time in the AUTO mode. ◎ ◎ TOTAL SPEED ..Adjusts the movement of entire axes in 10 speeds, regardless of automatic or manual operation.
Page 32: Disconnecting The Power
4-2. Disconnecting power 1. Verify the unloader is not in operation. 2. Turn the power switch to the left to turn the power off. ※ The power lamp will turn off. 3. Turn the main power off. 4. Turn the power connector off to disconnect from the primary power supply (Relay connector box of the molding machine) Safety Precautions...
Page 33: Return-To-Origin
5. Return-to-Origin 5-1. When the vertical arm is inside the mold If, during the automatic operation, the machine makes an emergency stop when an alarm occurs inside the mold or while the arm is inside the mold (L3, which has ascended to the product, and L3S, which has ascended to the runner, are in the state of <OFF>...
Page 34 7. Press the action key after selecting the vertical axis. Use to raise the runner arm to outside the mold (LS3S ON) (when the runner axis is selected). 8. If the product and runner axes have ascended, press , followed by the 9.
Page 35: When The Vertical Arm Is Outside The Mold
the vertical arm is outside the mold 5-2. When Be sure to perform the return-to-origin operation after connecting the power or starting the automatic operation. Warning · Make sure there are no persons or obstacles within the range of unloader movement before the operation.
Page 36: Emergency Stop
6. Emergency stop In order to stop the operation of the unloader immediately to prevent an equipment malfunction, follow these steps. The emergency stop button is located on the Panel Unit. ● Emergency stop button Press this button to halt all operation immediately. (A screen shown on the left will be displayed.) To reset the emergency stop, turn the emergency stop button clockwise, turn the power switch off, and after...
Page 37: Setting The Mode
7. Setting the Mode The mode sets the operation of the unloader. Set the mode after confirming the operation pattern of each mode in [7-3. Mode Description]. Point Mode setting is not available in the automatic operation or when the arm has not been fully raised (LS3 and LS3S are OFF condition).
Page 38 ■ Mode screen display 1. I.M.M SIDE MODE can be accessed by touching at the bottom of each page. 1). The I.M.M SIDE mode screen executes the action of the extract area. Press to display the next screen. Press to display the previous screen. EXTRACT EXTRACT MODE...
Page 39 3. RELA SIDE MODE: Touch at the bottom of each screen to display the following screen. The RELA SIDE mode screen is composed of 3 screens. Press display the previous/next screen. RELA RELA MODE MODE screen3 screen1 4.OPTION MODE: Touch at the bottom of each screen to switch to the following screen.
Page 40: Mode Setting
5. TOTAL MONITOR MODE: Touch to display the following screen. 1). Shown on the left side is the total monitor mode screen. 2). The ON/OFF status of all current modes can be monitored on this screen. 7-2. Mode setting 1. Display the screen containing the mode to set. ※...
Page 41: Mode Description
7-3. Mode description ● Product-side action ● Runner-side action Origin ⑫ Traverse return (to extract side) ⑧ Traverse return ⑪ Posture (to extract side) return ⑥ Traverse ① Descend ⑥ Traverse (To release side) (To release side) ① Descend ⑦ Posture ⑤...
Page 42 Code Name Description Motion EJECTOR Turn this mode ON if the product MDE-ON MDE-OFF LINK is thin, or if the product is to be Ejector link Ejector independent released after extraction. The Link based on the RY-7 remains ON linking of the molding machine signal interlocking because there is no ejector and a reliable product...
Page 43 Code Name Description Motion MDCS UNDER- The product is extracted by sliding the chuck plate after EXTRACTIO closing the product chuck. ※ Sliding tools are needed for the chuck plate MDSS RELEASE When this mode is turned ON, the SIDE posture turns 90°...
Page 44 Code Name Description Motion MDTB RETURN When this mode is turned ON, the MIDWAY product opens after a gate cut from the MDTB- RELEASE release side to the nipper inside the chuck (optional) or to the NT gate cut nipper (optional), and after that, the sprue runner opens at the midway position when the traverse is returned.
Page 45 Code Name Description Motion MDTA When this mode is turned ON, long ADVANCE products are extracted in the vertical direction. The arm advances into a posture action, and starts moving. This operation helps to avoid interference with the safety door or carriage rail. The output timing of the cycle start (RY-3) signal being sent to the molding machine is turned ON when the posture operation...
Page 46 Code Name Description Motion MDKT DESCENT If the chuck opens after further STAND-BY descending from the extraction standby position, further descent can be done to reduce the cycle time. MDKO FIXED The product is extracted from the MOLD fixed side in case the product is EXTRACT formed on the fixed side of the mold.
Page 47 Code Name Description Motion MDR1-0N When this mode is turned ON, the MDR1 PROD product rotates inside the mold ROTATION after being extracted. After the MODE1 rotation, the product ascends and traverses to the release side. ※ The product rotates to avoid interference when it ascends after being extracted in case the product is larger than the tie-bar...
Page 48: Setting The Position Point
8. Setting the Position Point This mode sets the point (moving distance) or the speed of the TARVERS, PRODUCT, PROVERT, RUNNER and RUNVER at each teach (position) point. It also sets the packing of the extracted product. Point If the mold memory is executed for the first time, start working after the chuck plate actually used is mounted.
Page 49: Setting The Extraction Position
■ Setting the extraction position In case the unloader (Robot) is operated for the first time after it is installed, or if the extraction traverse stop position (Arm descending position inside the mold) is changed, use the following methods to set the extraction position: Top view During the normal operation, set the unloader position to...
Page 50: Teach Point Screen
8-1. Teach point screen Point Changing the distance value during the automatic operation can be dangerous. Exercise caution when changing. If you set the position screen during the automatic operation, the password screen will be displayed. Make sure you set the point manually if the moving axis is actually activated.
Page 51: List Of Point Selection Screen
■ List of point selection screen ※ Touching the extract descent screen will display the position setting screen shown on the right side. <I.M.M SIDE screen> ① Moving the set screen ....Touching this key will move the screen backward. ②...
Page 52 ⑥ VALUE ........Displays the point set position. (unit: mm) There are 2 types of setting methods. 1) Touching the desired axis will display ten keys at the bottom of the screen. Use these ten keys to input the set point of the desired axis. 2) If no problem is expected after the current POSITION is changed through the JOG operation or fine-adjustment, touch [Enter] on the screen to input the current value into the set point automatically.
Page 53: Setting The Teach Point
8-2. Setting the Teach Point 1. Displays the setting screen of each point. ※ Refer to [8-1. Teach Point Screen]. 2. Touch the set point or the speed of the axis to set. 3. Touch to move the screen forward or backward.
Page 54 ● Setting the operation Set value by actually moving the unloader. ※ Select the axis to set. The traverse axis selected in red will move. 1. While pressing the action key, press to move the carriage to a selected position. Caution Be careful not to have the chuck plate collide with the safety cover or rail when moving the unloader.
Page 55: Description Of Teach Points
8-3. Description of teach points  I.M.M SIDE AVOID POS. Sets the front and rear positions of the unloader in case the unloader is not used. EXTRACT Sets the position where the vertical arm and chuck can descend inside the mold without DESCENT any interference from the I.M.M side.
Page 56 Caution ● If the value is set by numerical input, be sure to check the numerical value prior to the automatic operation. While each point setting screen is displayed, press the manual operation key to move each axis to the set point, and verify if the current value is the same as the set point. ●...
Page 57: Packing Teach
8-4. Packing teach Sets the position, speed and sequence for the product extracted from the molding machine to be released parallel on the conveyor or in the box. Point The value cannot be set during the automatic operation. Always change data manually. 1.
Page 58 ① ② ③ ④ ⑤ ⑥ ① RESET ........If you change the set point in manual mode, be sure to touch the reset. If you do not touch the reset after changing the data, the packing operates based on the existing data. JOG SELECTION SWITCH ..Touch the desired axis during JOG moving or fine adjustment, and the axis changes to red.
Page 59: Setting The Numerical Value
Caution This numerical value is memorized even if the power is disconnected or in the manual operation. The unloader releases products according to this numerical value. Be sure to check the numerical value of each axis prior to the automatic operation, and change the numerical value if necessary. In addition, save the data with the reset key in manual mode after changing the numerical value.
Page 60: Limit Setting
8-5. Limit setting Enable to set the limit value on takeout side and release side. 1. Select ‘set position’ on main menu. 2. When you see the screen like left picture, push the ‘start button’ and ‘operation key’ and then ‘push button’.
Page 61: Setting The Timer
9. Setting the Timer The timer is set in automatic operation for efficient operation. 9-1. Timer setting screen 1. Shown on the left side is the main screen. 2. Touch on the main screen to switch to the following screen. 3.
Page 62: Setting The Timer
9-2. Setting the Timer 1. Display the timer setting screen. 2. Touch the timer to set. 3. Touching to move the page forward or backward. 4. Press or click to switch back to the main screen. 5. Pressing on the screen will display ten keys shown on the left side.
Page 63: Setting The Alarm Timer
9-3. Setting the alarm timer Caution Usually, the alarm timer set points remain unchanged. Setting the alarm set points with an extreme value may cause trouble. Exercise caution when changing the set points. 1. Display the timer set screen. 2. Press to display the alarm timer screen.
Page 64: Set Time For Standard Timer
9-4. Set time for Standard timer Code Name Maximum value Initial value Remarks EXT DESCENT 99.99 00.00 ADVANCE 99.99 00.00 EJECTOR ADV 99.99 00.00 CHUCK CLOSE 99.99 00.00 RETURN 99.99 00.00 RUNNER OPEN 99.99 00.00 POSTURE 99.99 00.00 MDSS/MDTF (B) Standard REL DESCENT 99.99...
Page 65: Standard Timer Operation Diagram
9-5. Standard timer operation diagram MDTF or MDTD is ON. Runner midway release Posture action Midway posture Release descent Product extract MDE-ON Ejector link Nipper Under cut release Ejector Point Set points within the operating distance.
Page 66: Standard Timer Operation List
9-6. Standard timer operation list Code Name Description Remarks Setup time between the arm descent time and the DESCENT advance time on the I.M.M side ADVANCE Setup time between the start of arm advance and the chuck close or the arm advance complete EJECTOR Setup time between chuck close and the arm return start Only when ejector is linked.
Page 67 Code Name Description Remarks NT NIPPER Setup time between the start of the NT gate cut pull When an NT nipper CUT OPEN return (OFF) and the start of the NT gate cut pull return (MDNT) is used. (OFF) Setup time between the start of the position movement When an NT nipper POSITION of the NT gate cut nipper and the start of the NT gate...
Page 68 Code Name Description Remarks RY3 OFF . This mode can set or change the output time of the molding machine cycle start signal (RY-3) during the automatic operation. . When the mold open complete time (MO)<ON> and the ascent complete (LS-3) product confirmation (LS-4) are turned ON after the product is extracted, the cycle start signal (RY-3 ) is also turned ON.
Page 69: Manual Operation
10. Manual operation 10-1. Manual operation Point · Use this manual operation to verify a movement or to conduct the return-to-origin operation when starting the automatic operation. · Any movement, the mode of which is not set, cannot be operated. ·...
Page 70 Press the action key and manual keys to: 1: Ascent 2: Descent 3: Return 4: Advance 5: Chuck close 6: Chuck open 7: Return 8: Action 9: Extract side 10: Release side The numbers attached to the arrows indicating the action in the following figure correspond to the numbers attached to the above operation keys.
Page 71 5. Functions of the manual option keys : Using the nipper action mode (MDCN) will activate the nipper unit cylinder. : Using the air blow mode (MDRS) will activate the solenoid valve of the air blow. : Using the under cut mode (MDCS) will activate or return the cylinder of the chuck slide.
Page 72: Free Interlock Action
10-2. Free interlock action Each function key can be freely used by resetting the interlock of each action regardless of the mode or teaching setting. Actions that may cause trouble can be blocked in the program, allowing free action. For example, if the product ascent complete <LS-3> and runner ascent complete <LS-3S> are turned OFF while the release area (LS-12) is turned OFF, the traverse action will not be available.
Page 73 7. Touch to display the Valve Free screen. 8. Touch the following keys to execute valve free actions: : Activates the posture cylinder. : Returns the posture cylinder. : Activates the Rotation cylinder. : Returns the Rotation cylinder. 9. When the free action is completed, press to switch back to the main screen.
Page 74: Setting The Mold
11. Setting the Mold The mold setting can memorize up to 50 patterns (50 types). The unloader data are read by designating the registered block numbers matching the mold. Data are registered (or re- registered), if needed, in case new working conditions are set or if the stored working conditions are corrected and/or changed.
Page 75 ① Current condition memory: Displays the block number and file name of the condition memory data currently used. Selecting commands: Select among the following commands for the condition memory. ② READ ..... Reads the condition memory data registered in the memory. ③...
Page 76: Reading The Condition Memory
11-2. Reading the condition memory 1. Press on the CONDITIION MEMORY screen to display the following screen. 2. Shown on the left is the CONDITION READ screen. 3. This screen calls out the stored mold. 4. Press on the CONDITION READ screen to display the following ten keys.
Page 77: Writing The Condition Memory
11-3. Writing the condition memory To operate by combining new conditions, enter the data, including the mode, point and timer settings, first and register the data in the memory. 1. Shown on the left is the CONDITION MEMORY screen. 2. Touch on the CONDITION MEMORY screen to display the following screen.
Page 78: Erasing The Condition Memory
11-4. Erasing the Condition memory 1. Touch on the CONDITION MEMORY screen. 2. The following CONDITION ERASE screen will be displayed. 3. The CONDITION ERASE screen is used to erase the stored mold. 4. Press on the CONDITION ERASE screen to display the following ten keys.
Page 79: I/O Display
12. I/O Display 12-1. I/O Screen and I/O code list When an alarm message is displayed during the manual or automatic operation, check the condition of related I/O signal. Check the condition of I/O signal on the following I/O screen. 1.
Page 80: Viewing The I/O Screen
■ Viewing the I/O screen The I/O screen displays I/O in the order of limit I/O → valve I/O → I/O of molding machine and external equipment → overall monitor. <Limit Input check> Description of display --- Limit ON --- Limit OFF <Valve output check>...
Page 81 I/O code list INPUT Code Name OUTPUT Code Name Safety door close RY-1 Mold open safety circuit Mold open complete RY-2 Mold close safety circuit Signal Mold close complete RY-3 Cycle start Relay from Ejector advance complete RY-4 output molding Molding defect RY-5 signal...
Page 82: Setting The Menu
13. Setting the Menu 13-1. Menu screen 1. Shown on the left is the main screen. 2. Touch on the main screen to display the following screen. 3. Shown on the left is the menu screen composed of 6 items. 4.
Page 83 2. Shown on the left is the home position setting screen. 3. Press switch back to the main screen. 4. The home position of each axis can be adjusted on this screen. 5. The initial speed set point is “8”. Touch the axis to enter, and the ten keys will be displayed on the left side of the screen.
Page 84: Setting The Pass
13-3. Setting the pass Shown on the left is the manual set screen. 2.Touch on the manual set screen to display the following screen. 3. Shown on the left side is the Pass set (I.M.M side) screen. Press switch back to the previous screen. 4.
Page 85 7. Refer to the following figures on pass action when using pass. (Extract pass: 20, min. ~ 100, max.) Ascent Descent Retreat Advance 20 30 40 50 60 70 80 90 Descending pass (In the case of 70%) Ascending pass (In the case of 70%) EX).
Page 86: Setting The Acceleration
13-4. Setting the Acceleration 1. Shown on the left is the menu screen. 2. Touch on the screen to display the following screen. 3. Shown on the left is the ACCEL SETTING screen. 4. Press to switch back to the previous screen. 5.
Page 87: Initializing The Data
13-5. Initializing the DATA 1. Shown on the left is the menu screen. 2. Touch on the menu screen to display the following screen. 3. Shown below is the DATA clear screen. 4. Press switch back to the previous screen. 5.
Page 88: Alarm History Monitor
13-6. Alarm history monitor 1. Shown on the left is the menu screen. 2. Touch on the menu screen to display the following screen. 3. Shown below is the alarm history screen. 4. Press switch to the previous screen. 5. Touch on the alarm history screen to erase the alarm history on the screen.
Page 89: Data (Speed And Position) All Display Method
13-7. DATA (speed and position) all display method Shown on the left is the menu screen. 2. Touch on the menu screen to display the following screen. 3. Shown on the left is the All Display screen. 4. Press to switch to the menu screen.
Page 90: System Settings Screen
2. Touch on the menu screen to display the following screen. 3. Press switch to the menu screen. 4. Version is now available. MODEL, PLC,TOUCH are available on list. PASSWORD 5. Touch then input screen will be displayed. "YUDO:STAR". Password is...
Page 91: Setting The Counter
14. Setting the counter 14-1. Counter setting and clear display The number of product extraction or the counter used in an option action can be set or reset on this screen. Point The counter display is memorized even after the power is turned off. Check the counter display prior to starting the automatic operation or manual operation, and reset the counter if needed.
Page 92: Setting The Counter
14–2. Setting the counter Point The counter can be set only in the manual operation. 1. Display the counter setting screen. 2. Set value: Sets the number of counts according to the option. 3. Cur value: Displays the current counter number when setting the counter.
Page 93: Set Initial Discharge Counter
14–3. Set initial discharge counter 1. Display the counter setting screen. 2. Touch on the screen to display the following screen. 3. Shown on the left is the Set initial discharge counter screen. 5. Products at the counter fill in the target quantity in the system mode screen to ON to when a goal is reached, the production quantity completed, the alarm is raised.
Page 94: Miscellaneous
15. Miscellaneous 15–1. Password screen during automatic operation 1. If the unloader sets the position on the main screen during the automatic operation, the password setting screen will be displayed. (Not applicable to the manual mode) 2. The position password screen will be displayed. 3.
Page 95: Setting The Option Mode
15–2. Setting the option mode 1. Touch ”Option Mode” on the mode screen to display the option mode screen. 2. Touch “Title Screen” or to avoid the screen from the mode screen. (You may opt to do the same in the option mode selection screen.) 3.
Page 96: Automatic Operation
16. Automatic operation ● Standard automatic operation diagram Origin ⑫ Traverse return ⑪ Posture return ⑥ Traverse (Release side) ① Descend ⑦ Posture action ⑤ Ascend ⑩ Ascend ⑧ Descend ② Advance ④ Retreat ③ Chuck ⑨ Chuck close open 1.
Page 97 Point Since the molding machine maintains the <Auto> signal (MA), the unloader will stop even if the molding machine is changed to <Semi-auto> or <Manu> other than Full-auto. · If the machine is not used for an extended period of time, stop the machine where there is a less risk for potential trouble (e.g., the vertical arm is ascending in the release area).
Page 98: Safety Precautions
Safety Precautions · Do not operate the machine with the safety cover or any part of safety devices removed or with the high-voltage terminals exposed. · Do not remove or change the position of the limit switches, dogs or interlocking system. ·...
Page 99 If the product side (LS-4. LS-4S. LS-4T. LS-4V) signal cannot be entered due to unknown reasons, or if the product side input signal is turned on within the sequence of a simulation act, products can be confirmed using the following methods. Caution Prior to executing a cycle test, be sure to check whether there are any products or runner remaining in the mold.
Page 102: Before Operation
1. Before Operation 1-1. Safety Precautions ■ Indication of the level of danger Safety precautions written on the warning labels are classified into 3 levels as indicated below. Pay particular attention when handling machine with high danger levels. Death or serious personal injury may result if the instructions are not Danger followed.
Page 103: Repairs
■ Repairs Danger  To prevent others from connecting the power by mistake or touching the control box during the repair, place a sign reading [Under repair. Do not touch operation box or control box.] in a clearly visible place. ...
Page 104: Ending Work
■ Ending Work Warning  Stop all operation of the ejector and turn off the operating switches of the control box prior to cleaning the ejector and its surrounding areas.  If the ejector is not used for an extended period of time, replace the plug with an interlock jumper plug between the ejector and molding machine.
Page 105: Specifications
1-2. Specifications ● Operating conditions Item Specifications Power supply AC200~220V±15%, 50/60Hz Power supply capacity 5.0KVA Ambient operating temperature 0~40℃ (Average temperature over 24 hours) Storage temperature -10~+65℃ Ambient humidity 30~90%RH (0~50℃) (Shall be free of dew) Ambient atmosphere · Shall be free of corrosive gas ·...
Page 106: Operation And Display Specifications
● Operation and display specifications Item Specifications Pendant interface RS422 & RS232C Pendant LCD display 320 ×240 dot graphics LCD (color) Emergency stop button Push-lock reset type press button Manual SW Standard operation switch: 10 each Function SW 8 each Display function Timer Mode...
Page 107: Controller Specifications
● Controller Specifications Item Specifications No. of control axis 3 axes – 5 axes AC SERVO (Can be expanded to 16 axes) Operating mode Manual mode, origin mode, and automatic mode Standard input/output Input ;32 points Output ;32 points (Input/output extensibility:MAX256 POINT) S.M.P.S capacity : DC24V, 3.5A Axis control function Interpolation function...
Page 108: Operation Error Display Function
2. Operation error display function 2-1. Operation error display function This function allows an error message to display when operating procedures or operating mode settings are not correctly followed. Error messages are classified into 3 types—operation error, origin error and setting error.
Page 109: List Of Error Messages
2-2. List of error messages Error message Remarks Operation error (01) . Continue descent until a message reading descent Descent is not completed comp leted is displayed.. Operation error (02) Ascent is not completed. Continue ascent until a message reading ascent completed is displayed. Operation error (03) Movement to the extract descent side is not completed.
Page 110 Error message Remarks Operation error (19) Nipper in chuck mode (MDCN) is not in use. Operation error (20) Posture action mode (MDSS) is not in use. Posture action cannot be executed. Operation error (21) Product arm mode (MDW) is not in use. Product arm operation cannot be executed. Operation error (24) Execute the return-to-origin operation.
Page 111 Error message Remarks Operation error (43) Has not moved to the NT gate cut position. Execute descent. Operation error (44) Has not moved to the NT gate cut standby position. Execute retreat. Operation error (45) Has not moved to the NT gate cut advance position. Execute advance. Operation error (46) NT gate pull (V9) is turned OFF.
Page 112 Error message Remarks Setting error (73) Not in the manual mode. Set values after switching to the manual mode. Press Reset key. Setting error (74) Ascent end (L3,L3S) is turned OFF. Change after executing ascent. Setting error (75) Product confirmation side mode (MD4), Confirm in chuck mode (MD4T) and vacuum confirmation mode (MDCV) cannot be turned OFF simultaneously.
Page 113 Error message Remarks Original position error (94) Slide action (V12) is turned ON. Return to origin. Original position error (95) NT PULL (V9) is turned ON. Return to origin. Original position error (97) NT Gate Act-end (L13) is turned ON. Return to origin. Original position error (98) The MDSS2 mode is turned ON while the MDSS mode is turned OFF.
Page 114: Alarm Messages
3. Alarm Messages 3-1. Alarm messages This function allows an alarm message to display if an error occurs after the power is connected or during the manual or automatic operation. Alarm messages is classified into system alarm, SPC alarm, Limit switch error, molding machine input error, Cycle over, chuck miss, Product release and product open miss.
Page 115: Alarm Types
3-2. Alarm types Alarm Description Stop method name ● This alarm indicates the control sy3 error, data error, harness disconnection or communication errors. It is displayed if an error System occurs when the power is connected or during the data reading. SPC alarm Full stop(*) alarm...
Page 116: Alarm Reset
3-3. Alarm Reset The buzzer will sound in the automatic operation. In the manual mode, however, the buzzer will not sound.  In case of temporary step stop alarm If an error occurs in the automatic operation, an alarm goes off and alarm messages are displayed. The automatic operation will stop.
Page 117: List Of Alarm Messages
3-4. List of alarm messages  SPC alarm Alarm name Alarm display, cause and corrective action SPC alarm (01) Encoder input error Encoder input error. Check the condition of the encoder harness’ wiring and input. Alarm Remarks SPC alarm (02) Servo Off error Servo turned OFF.
Page 118 Alarm name Alarm display, cause and corrective action SPC alarm (07) U,V,W error Alarm U,V,W detection error. Check the condition of the encoder. Remarks SPC alarm (08) Return-to-origin execution error Alarm Return-to-origin error. Check the origin sensor and drive. Remarks SPC alarm (09) Output value error...
Page 119  Table alarm Alarm display, cause and corrective action Alarm (01) Limit switch error RUN-ARM HOME (LS-3S) is not turned OFF. Check the setting of the ascent watch timer Alarm T27. Check the operating condition and wiring of the LS-3S limit switch. Remarks Alarm (02)
Page 120 Alarm display, cause and corrective action Alarm (12) Limit switch error Extract area(LS-10), Ascent-end(LS-3,LS-3S) and the release side (LS-12) are turned OFF Alarm simultaneously. Check the operating condition and wiring of the traverse limit and Ascent- end. Remarks Alarm (13) Limit switch error The limit switches of the extract area (LS-10) and release side (LS-12) are turned ON Alarm...
Page 121 Alarm display, cause and corrective action Alarm (18) Limit switch error Air pressure (PS) is turned OFF. Check the operating condition of the compressor, the Alarm pressure of the air unit and the operating condition and wiring of the air pressure switch. Remarks Alarm (19)
Page 122 Alarm display, cause and corrective action Alarm (24) Product release The product fell of while being carried to the release side. Alarm Check the operating condition and wiring of LS-4T limit switch. Remarks Alarm (25) Product release The product fell of while being carried to the release side. Alarm Check the operating condition and wiring of LS-4V limit switch.
Page 123 Alarm display, cause and corrective action Alarm (32) Chuck miss Runner detect (LS-4S) is turned OFF. Chuck missed. Alarm Check the operating condition and wiring of LS-4S limit switch. Remarks Alarm (35) Product open miss Product side (LS-4) cannot be turned OFF. Product open missed. Alarm Check the operating condition and wiring of LS-4 limit Remarks...
Page 124 Alarm display, cause and corrective action Alarm (42) Limit switch error Mold-open complete (MO) is also turned OFF when the release side (LS-12) is turned OFF. Alarm Molding machine input error. Check the mold-open complete circuit of the molding machine, and the interlock signal wiring between the unloader and the molding machine. Remarks Alarm (49)
Page 125 Alarm (68) Cycle over Posture return end (LS-8) is turned OFF. Check the operation of posture cylinder through Alarm manual operation, adjust the speed with the speed cone and check the operating condition and wiring of LS-8 limit switch. Remarks Alarm (69) Cycle over...
Page 126: Troubleshooting Other Than Alarm Messages
4. Troubleshooting other than alarm messages ※ Refer to the following table for errors other than alarm messages: Symptom Check Corrective action Power will not turn 1) Is the power supply switch turned 1) Turn ON the power supply switch. 2) Is it making a clean contact with 2) Insert the connector securely.
Page 127 Symptom Check Corrective action Will not advance. 1) Are input conditions satisfied? 1) Refer to Manual operation and Automatic operation. 2) Are CRWS LM guide operating 2) Inject grease. properly? 3) Is the advance speed controller 3) Gradually open until the valve excessively closed? system starts advancing.
Page 128 Symptom Check Corrective action Will not ascend. 1) Are input conditions satisfied? 1) Check the conditions of manual operation and automatic operation. 2) Is the system operating in the free 2) Try operating in free interlock operation? interlock. 3) Is the ascent speed control valve 3) Gradually open until the closed too tight? system starts ascending.
Page 129: Control Box
5. Control box 5-1. Hardware configuration Control box Machine Carriage Interlock PCB I/O relay board Power board Encoder Operating Main motor board Encoder Drive CRWS board motor Encoder Pendant TT5-3 Vertical motor...
Page 130: Main Board (Dmc-3Xy)
5-2. Main board (DMC-3XY) (Switch to JP6) 10M (extension)/LAN communication: transmission: CN9, CN10 Signal Name Name Signal [TB1:7P]Main power, regenerative resistance Terminal Description Main power input (Switch to JP7) terminal Earth Signal Signal Regenerativ e resistance connector Do not connect [TB2:4P] X-axis power (U.V.W) connection.
Page 131: Drive Board (2-Atom)
5-3. Drive board (2-ATOM)
Page 132: Power Board
5-4. Power board...
Page 133: Interlock Board
5-5. Interlock board YUDO-STAR Relay 1 3 5 7 9 1113 P24 N24 SG2 SG1 N24 CON7 interlock input/output terminal ● Code Name P24V (Power supply) N24V (Power supply) N24V MA (molding machine fully- automatic) SG2 (Conveyor output) SG1 (Conveyor output)
Page 134 ● Interlock input/output terminal Code Name CON1 P24V (Power supply) (Molding machine input signal) MD (Safety door signal) MO (Mold open signal) MC (Mold close signal) ME (Ejector signal) MN (Defective product signal) MA (molding machine fully- automatic) RD (Release descent approved) OD (Release side safety) CON2 Reserved...
Page 135: Relay Board Layout
CON11 OUTPUT INPUT YUDO-STAR YSR040-R0 * When the DC power has been connected to the relay board, the red LED turns on. * The pin numbers 1, 2, 21 and 22 of the input connector are P24V, and the pins 19, 20, 39 and 40 are reserved terminals.
Page 136: Functions Of The Relay Board Pins(Sigma Type)
6-1. Functions of the relay board pins (SIGMA TYPE) INPUT LIST YSR040/ DMC 3XY NAME Assortment Remarks YSINT01 SYMBOL DC 24V POWER (+24V) DC 24V POWER (+24V) Confirmation in Product CN5-23 CN1-2 Robot input Confirmation in chuck LS4T CN5-24 CN1-5 LS4S Runner detect CN5-25...
Page 137: Functions Of The Relay Board Pins(Mega Type)
6-2. Functions of the relay board pins (MEGA TYPE) INPUT LIST YSR040/ DMC 2XY NAME Assortment Remarks YSINT01 SYMBOL DC 24V POWER (+24V) DC 24V POWER (+24V) Confirmation in Product CN3-23 CN1-2 Robot input Confirmation in chuck LS4T CN3-24 CN1-5 LS4S Runner detect CN3-25...
Page 138: Interlock Molding Machine Harness
6-3. Interlock molding machine harness Line Line color Connector No. Terminal description Remarks number M1-A White M1-B 3-phase power supply Black M1-C M1-D Earth Black1 M2-A Emergency stop (molding machine) White1 M2-B Red1 M2-C Common line Automatic operation of molding Green1 M2-D machine...
Page 139 7. List of major parts for YUCON-500 NAME SPEC Q’TY REMARKS MAIN BOARD DMC-3XY, DMC-2XY DYNAX PENDANT DYNAX Regenerative resistance 300W /60 ohm La Ra Electronics BUZZER EB1124-DC24V STAR SEIKI INTERLOCK P.C.B YSINT01 Tae-sung Electronics POWER BOARD PWR401 Tae-sung Electronics...
Page 140 8. CHECK LIST ◆ Procedure check list vol.1 Mold No.: Mold Name: Password: Ejector position setting Point name Axis name Set point Speed Return-to-origin Traverse Product CRWS Runner CRWS Product vertical Runner vertical Extract standby position Traverse Product CRWS Runner CRWS Product vertical Runner vertical Extract chuck position...
Page 141 ◆ Procedure check list vol.2 Mold No.: Mold name: Password: Halfway open axis position setting Point name Axis name Set point Speed Posture action position Traverse Product CRWS Runner CRWS Product vertical Runner vertical Runner open position Traverse Product CRWS Product vertical Runner CRWS Product vertical...
Page 142 ◆ Procedure check list vol.3 Mold No.: Mold name: Password: Release side axis position setting Point name Axis name Set point Speed Release standby Traverse position Product CRWS Runner CRWS Product vertical Runner vertical Release ascending Traverse position Product CRWS Runner CRWS Product vertical Runner vertical...
Page 143 ◆ Procedure check list vol.4 Mold No.: Mold name: Password: Name of standard timer setting Set time (sec) Product release descent Produce advance Ejector advance start Chuck close Product retreat Runner chuck open Posture action Release descends Product chuck open Nipper cut close Nipper cut open Midway open descend...
Page 144 ◆ Procedure check list vol.5 Mold No.: Mold name: Password: Mode setting Molding machine-related mode 1 Code Mode name Option Product arm Used - Unused Runner arm Used - Unused Ejector link Used - Unused MDKO Fixed side release Used - Unused Molding machine-related mode 2 Code Mode name...
Page 145 Release side-related mode 2 Code Mode name Option MDCN Nipper in chuck Used - Unused MDNT NT gate cut Used - Unused MDNT2 NT position Used - Unused MDR1 Rotation in mold Used - Unused MDR2 Traverse rotation Used - Unused MDR3 Release side rotation Used - Unused...