UAI Prop Eng TS

Babyplast UAI I/10P
Injection Unit
Touch screen
INSTRUCTION MANUAL
Rev 0
BABYPLAST UAI
INSTRUCTION MANUAL
Thank you for the trust you have placed in BABYPLAST.
Please read this manual carefully before operating our machinery.
The manufacturer is not responsible for and does not provide
warranty for machines used for any purpose other than that for which the
manufacturer has specified.
The manufacturer reserves the right to modify their product data or
features without prior notice.
WARNING
Before starting up the machine or carrying out any maintenance work,
read this instruction manual carefully
TECHNICAL ASSISTANCE
CRONOPLAST sl
CRONOPLAST S.L. Avinguda del Carrilet, 243 , 2 08902 HOSPITALET DEL LLOGREGAT ( Barcelona) Espaa.
Tel. (93) 338 01 25 Fax (93) 338 90 12
www.babyplast.com
Rev 0 - 15/09/05
BABYPLAST UAI
CERTIFICATE OF CONFORMITY TYPE "B
Conformity statement
Cronoplast S.L. situated in Spain (Barcellona) a Hospitalet de Llobregat, in Avenida Carrilet, 243, 2, is the manufacturer of the bench
top injection moulding machine, Babyplast 6/10P, for the transformation of thermoplastic materials
Babyplast 6/10P conforms to the following European standards:
- 98/37/CEE and subsequent modifications
- 89/336/CEE and subsequent modifications (electromagnetic compliance directives)
- 73/23/CEE and subsequent modifications (low voltage directives)
The Autonomous Injection Unit Babyplast UAI/10P has been designed and constructed according to the following standards:
For machine directives 98/37/CE :
UNI EN 292-1
UNI EN 292-2
UNI EN 201
For electromagnetic compliance directives (89/336/CEE) :
CEI EN 61000-6-2: 2001
CEI EN 61000-6-2: 2001
For low voltage directives (73/23/CEE) :
CEI EN 60204-1
The "INJECTION UNIT" of this machine may be incorporated in other machines and used for the transformation and injection of
thermoplastic materials; excluding inflammable and or explosive polymers.
IT IS FORBIDEN OPERATE THIS "INJECTION UNIT" IF THE MACHINE, ON WHICH IT IS INSTALLED, DOES NOT CONFORM TO
THE "CE" DIRECTIVES FOR MACHINES, RELATED STANDARDS, EUROPEAN STANDARDS OR RELATIVE NATIONAL
STANDARDS.
(with reference to delivery document number ................................dated.............................)
BABYPLAST UAI
GENERAL INDEX
CONTENTS
A/ General conditions and characteristics of the BABYPLAST UAI- I/10P........................... A-0010
B/ Installation of the BABYPLAST UAI- I/10P........................................................................... B-0010
C/ Before start up....................................................................................................................... C-0010
D/ MENU - How to operate a BABYPLAST UAI- I/10P............................................................... D-0010
E/ ALARMS.................................................................................................................................... E-0010
F/ Maintenance - diagrammes ..................................................................................................... F-0010
A/ General conditions and characteristics of BABYPLASTUAI-I/10P .

A.1/ General conditions................................................................................................................... A-0010
A.2/ What is a BABYPLAST UAI- I/10Pand what does it do.......................................................... A-0010
A.3/ Technical data.......................................................................................................................... A-0020
A.3.1/ General dimensions of the BABYPLAST UAI- I/10P................................................ A-0020
A.3.2/ General dimensions of theBABYPLAST UAI- I/10P INJECTION UNIT................... A-0030
A.3.2a/ Dimensions of the standard injection unit .................................................. A-0030
A.3.2b/ Dimensions of the standardhorizontal injection unit .................................... A-0040
A.3.2c/ Dimensions of the Aumented injection unit................................................... A-0050
A.3.2d/ Dimensions of the Aumentedvertical injection unit....................................... A-0060
A.3.3/ Description of the BABYPLAST UAI- I/10P, main parts......................................... A-0070
A.3.4/ General technical characteristics................................................................................ A-0080
A.3.5/Diagramme to show injection pressures..................................................................... A-0090
A.4/ Warranty and warnings............................................................................................................. A-0100
B/ Installation of the BABYPLAST UAI-I/10P........................................................................ B-0010

B.1/ Unpacking and parts check......................................................................................................
B.2/ Installing and mounting the injection unit on a mould..............................................................
B.3/ Installing and mounting the injection unit on a machine platen................................................
B.4/ Electrical connections..............................................................................................................
B.5/Cooling system..........................................................................................................................
B.6/ Filling the hydraulic oil tank......................................................................................................
B.7/ System check...........................................................................................................................
B-0010
B-0010
B-0020
B-0030
B-0040
B-0050
B-0060
C/ Before start up................................................................................................................... C-0010

C.1/ Main switch.............................................................................................................................. C-0010
C.2/ Emergency stop........................................................................................................................ C-0010
C.3/ Display panel............................................................................................................................ C-0020
C.4/ Injection pressure gauge.......................................................................................................... C-0020
C.5/ Display - Synoptic diagramme.................................................................................................. C-0030
C.6/ Safety devices.......................................................................................................................... C-0040
C.7/ Starting the machine................................................................................................................. C-0050
BABYPLAST UAI
D/ How to use a BABYPLAST UAI- I/10P ........................................................................... D-0010

D.1/ Menu...................................................................................................................................... D-0010
D.1.1/ Display..................................................................................................................... D-0010
D.1.2/ Icons - description of functions................................................................................. D-0020
D.1.3/Start up....................................................................................................................... D-0030
D.1.4/ Main menu................................................................................................................ D-0040
D.1.5/ Manual menu........................................................................................................... D-0050
D.1.6/ Automatic menu... ................................................................................................... D-0060
D.1.6a/Temperature settings................................................................................... D-0070
D.1.6b/Times and settings........................................................................................ D-0080
D.16b1/ INJECTION CARRIAGE settings..................................................... D-0090
D.16b2/PLASTIFICATION settings................................................................ D-0100
D.16b3/ INJECTION settings........................................................................ D-0110
D.16b4/ QUALITY CONTROL settings......................................................... D-0120
D.16b4a/ Quality control log files............................................................ D-0140
D.1.6c/ Setting up the PART COUNTER........................................................... D-0150
D.2/Starting a cycle.........................................................................................................................D-0160
D.2.1/ Starting a semi automatic cycle................................................................................ D-0160
D2.2/ Starting a purge cycle................................................................................................ D-0180
D.3/ Mould setting programmes......................................................................................................D-0200
D.3.1/ Loading a mould setting programme........................................................................ D-0200
D.3.2/Create or modify a mould setting programme........................................................... D-0220
D.3.2a/ Mould setting programmes - TIMES AND SETTINGS................................ D-0220
D.3.2a.1/ Mould setting programmes -INJECTION CARRIAGE.................... D-0230
D.3.2a.2/Mould setting programmes - PLASTIFICATION.............................. D-0240
D.3.2a.3/Mould setting programmes -INJECTION........................................ D-0250
D.3.2b/ Mould setting programmes TEMPERATURES........................................... D-0270
D.3.2c/ Mould setting programmes CORE PULLS................................................. D-0280
D.3.3/Mould setting programmes - COPY A PROGRAMME............................................. D-0290
D.4/ Machine configuration............................................................................................................ D-0310
D.4.1/ Machine configuration - Change language - Celsius/Farenheit................................ D-0320
D.4.2/ Machine configuration - Temperatures.................................................................... D-0330
D.4.3/ Machine configuration - Times and settings............................................................. D-0340
D.4.4/ Upgrade software................................................................................................... D-0350
D.5/ USB memory stick - Saving/retrieving mould settings............................................................D--0370
D.5.1/ Print and elaborate mould setting data on a PC..................................................................D-0390
E/ ALARMS............................................................................................................................................. E-0010
E.1/ Alarms.................................................................................................................................... E-0010
F/ Maintenance - Diagrammes............................................................................................................. F-0010

F.1/ Maintenance........................................................................................................................... F-0010
F.2/ Electical / hydraulic diagrammes............................................................................................ F-0020
.............................................................................................................. F-0190
BABYPLAST UAI
GENERAL SAFETY REGULATIONS
To be studied carefully before starting up the machine

The Babyplast 6/10P Injection Unit for injecting thermoplastic materials,has been constructed according
to the safety regulations actually in force. Failure to respect the following instructions, may cause injury to the
user or damage to the machine.
1) Do not remove the warning labels from the machine. These labels must always be clearly visible.
2) Before using a thermoplastic material, always consult the manufacturer about possible health risks and the
precautions that must be taken in order to avoid accidents.
3) To avoid the risk of electric shock, never use the machine unless it has been properly earthed.
4) All the safety guards on the machine must be positioned correctly and maintained in good working order.
5) The protective covers over the electrical and electronical compartments, must remain closed and screwed
down. The removal of the protective covers, may expose the operator to the risk of electric shock.
6) The components which guarantee safety, should not be deactivated or tampered with.
7) When working near the injection area, always wear protective gloves and suitable eye protections.
8) The injection unit must be positioned and fixed well before switching on the motor.
9) Before carrying out any maintenance, the machine must by disconnected from the mains and the main
switch must be turned off and blocked by a qualified technician.
10) The system that limits the hydraulic pressure, must always be regulated so that the pressure does not
exceed the maximum pressure of 130 bar.
11) Never start the injection unit unless it has been installed and connected correctly to a machine which
conforms to all CE safety standards.
12) Maintenance on the machine should be carried out by qualified personnel only.
13) The machine is supplied with a power supply cable but without a plug. The plug used should comply to
standard EN 60309-1 and 16A power rating.
14) The machine must be connected to the power supply via a mains switch with a rating of
of at least 4500A at 230V / 400V. The power supply socket and switch must be installed in visable position
for easy access and must have an identification sign or label.
IT IS THE RESPONSIBILITY OF THE OWNER TO ENSURE THE MAXIMUM LEVEL OF SAFETY OF THE
INJECTION UNIT, AND THAT THE OPERATOR ALWAYS RESPECTS THE SAFETY AND
MAINTENANCE INSTRUCTIONS IN THIS MANUAL AND ON THE WARNING LABELS. IN CASE OF
DOUBTS OR FOR ANY FURTHER CLARIFICATIONS, PLEASE CONTACT YOUR NEAREST DEALER.
BABYPLAST UAI
A
A.1/ GENERAL CONDITIONS
This technical documentation is intended for all those responsible for using and handling the BABYPLAST 6/10P
injection unit.
We wish to emphasise that this injection unit must only be used according to the instructions set out in this manual.
Failure to follow this instruction manual correctly, may cause injuries to people and animals or damage to
materials and things.
In the event of any problems, please contact our technical staff.
In its continual endeavour to improve its products, CRONOPLAST reserves the right to vary or modify such
products without prior notice.
It is strictly forbidden to reproduce or copy this manual without our consent, or to use said manual for unauthorised
purposes.
The BABYPLAST 6/10 injection unit is a PATENTED model.
The "Injection unit" of this machine may be incorporated in other machines and used for the transformation and
injection of thermoplastic materials; excluding inflammable and or explosive polymers.
IT IS FORBIDEN OPERATE THIS "INJECTION UNIT" IF THE MACHINE, ON WHICH IT IS INSTALLED,
DOES NOT CONFORM TO THE "CE" DIRECTIVES FOR MACHINES, RELATED STANDARDS,
EUROPEAN STANDARDS OR RELATIVE NATIONAL STANDARDS.
The manufacturer and distributor will not accept responsibility for accidents caused due to failure to observe and
follow the instructions in this manual.
The technical documentation for the injection unit is provided in the language of the country of destination if within
the European Economic Community. For multi-lingual countries or those outside the European Community, the
required language should be specified in the customers order.
A.2/ WHAT IS A BABYPLAST UAI I/10P INJECTION UNIT AND WHAT DOES IT DO?
The UAI I/10P is the result of thirty years experience working in the specific fields of plastic injection moulding
and mould design and construction.
Research and development, on the machine, began more than two years ago, in response to an important area
of demand:
-PRODUCTION OF MULTI-COMPONENT PARTS
-PRODUCTION OF MUTI-COLOUR PARTS
-INTEGRATION OF AN INJECTION UNIT IN A PRODUCTION LINE
The UAI I/10P can be used to transform an injection moulding machine into a multi component injection moulding
machine at a relatively low cost and occupying little space.
Thanks to the possibility to apply the injection unit to almost any part of the mould, the construction of the mould
for the production of multi coloured or multi component parts can be considerably simplified and cost reduced.
The UAI I/10P can be installed directly onto a production line for injecting plastic into a component in the production
line.
The UAI I/10P is COMPLETELY AUTONOMOUS and, thanks to a digital interface with free contacts, can be made
to work in synchronisation with almost any type of machine.
Thank you for the trust you have placed in us. We are confident that your UAI I/10P injection unit, will help you fulfil
your application expectations.
When handling and processing any injection moulding materials, the customer must follow the material
manufacturer's instructions with great care.
A-0010
BABYPLAST UAI
A.3/ TECHNICAL DATA

A.3.1/ GENERAL DIMENSIONS OF THE BABYPLAST UAI I/10P INJECTION UNIT
Injection Unit
All dimensions are in mm.
A-0020
BABYPLAST UAI
A.3.2/ GENERAL DIMENSIONS OF THE BABYPLAST I/10P INJECTION UNIT.

A.3.2a/ GENERAL DIMENSIONS OF THE STANDARD INJECTION UNIT - horizontal
version.
A-0030
BABYPLAST UAI
A.3.2b/ GENERAL DIMENSIONS OF THE STANDARD INJECTION UNIT Vertical version
A-0040
BABYPLAST UAI
A.3.2c/ GENERAL DIMENSIONS OF THE AUGMENTED INJECTION UNIT

Horizontal version
All dimensions are in mm..
A-0050
BABYPLAST UAI
A.3.2d/ GENERAL DIMENSIONS OF THE AUGMENTED INJECTION UNIT

Vertical version
All dimensions are in mm
A-0060
BABYPLAST UAI
A.3.3/ INJECTION UNIT BABYPLAST I/10P,

BASIC PARTS LIST
26
27 28
29 30 31 32
25
INJECTION UNIT
24
23
22
13
14
15
16
17
18 19
20 21
6
7
8
9
10
Injection Unit
11
12
HYDRAULICAL AND ELECTRONICAL CONTROL UNIT
1. EMERGENCY STOP
2. Display
3. Keyboard
4. Alarm warning light
5. Dial to change data
6. Main switch
7. Injection pressure gauge
8. MANUAL/AUTOMATIC mode selector
9. Display chassis (portable)
10.Water manifold for hopper zone
11.Multi pin connector - display/control unit
12.Display cable storage hook
13.Power supply cable
14.Electronics cover panel
15.Hydraulics access panel
16.Water inlet / outlet
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
Injection unit multi pin socket

INPUT / OUTPUT socket
CE label
Hydraulic rapid connections IN/OUT for
injection unit
Water connections
Chamber thermocouple
Nozzle thermocouple
Nozzle heater
Injection piston and cylinder
Chamber heater
Plastification heater
Hopper
Plastification cylinder
Hopper thermocouple
Plastification thermocouple
Injection transducer.
A-0070
BABYPLAST UAI
A.3.4/ TECHNICAL DATA
STANDARD
INJECTION UNIT
Piston diameter (mm.):
Volume (cm3):
Injection pressure (Kg/cm2 ) :

Injection speed
10
(cm3/sec):
12
6, 5
AUGMENTED
INJECTION UNIT
14
16
18
16
20
24
12
15
16
25
36
2.650
1.830
1.340
1.030
815
1535
980
680
3,98
5,74
7,81
10,2
12,9
6,84
10,7
15,4
Plastification rate (gr/sec):
1,8
3,1
Injection unit weight (Kg):
25
37
Total weight (Kg):
130
142
Hydraulic pressure:
130 Kg./cm2.
Oil tank capacity :
16 l. (approx.)
Dry cycle :
1,4 s.
Rated power :
3.0 Kw
Weight :
~ 100 Kg.
Noise level:
Power supply:
< 70 db
3 ~ 230V. 50/60 Hz. + Earth
3 ~ 400V. 50/60 Hz. + Neutral + Earth
ATTENTION: A CIRCUIT BREAKER MUST BE USED AT THE MAINS CONNECTION.
A-0080
BABYPLAST UAI
A.3.5/ DIAGRAMME TO SHOW INJECTION PRESSURES (standard injection unit)

kg/cm2
3.000
*
10mm
2.000
12mm
1.500
14mm
16mm
1.000
Injection piston
Specific pressure on material
2.500
18mm
500
10
20
30
40
50
60
70
80
90
100
110
120 kg/cm2
Hydraulic pressure
* IMPORTANT NOTE: The maximum hydraulic pressure for the 10mm piston must be limited to 100 bar. This is done automatically by
setting the value of 10mm for the piston size under TIMES AND SETTINGS in the MACHINE PARAMETERS menu see section
D.4.3, page D-0400.
A.3.6/ DIAGRAMME TO SHOW INJECTION PRESSURES (Augmented version)

kg/cm2
3.000
2.000
1.500
16mm
1.000
20mm
Injection piston
Specific pressure on material
2.500
24mm
500
10
20
30
40
50
60
70
80
90
100
110
120 kg/cm2
Hydraulic pressure
A-0090
BABYPLAST UAI
A.4/ WARRANTY
The vendor guarantees that the material is to be supplied against all manufacturing faults, and accepts replacing
any faulty part or repairing any faulty operation free-of-charge, providing the buyer notifies the vendor of said fault
within a maximum period of TWELVE MONTHS from the date the machine is received at its destination.
It is clearly stated that this warranty does not include: heating elements, paint, oil and optional accessories; wear
caused through improper use and handling; knocks, in the case of damaged / broken seals on the hydraulic unit,
If the maximum authorised pressure levels have been exceeded, troubles caused by faulty connections in the
electrical system, the use of un-authorised lubricants, accidents and damage or any failure to observe the
application and installation instructions detailed in this manual.
Furthermore. the travelling expenses of a technician (hours and kilometres) as well as transport costs for
replacement parts are also excluded.
Once the TWELVE MONTH warranty period has expired, the vendor will not accept any claims or returned parts.
However, faults that the buyer issues claims for, may be checked by the vendor, using any technical means
considered necessary, on condition that the buyer does not obstruct the work of those who the vendor has
nominated responsible for carrying out the revision.
WARNING.
In its continual endeavour to improve its products, CRONOPLAST reserves the right to modify or vary its products
features or specifications without prior notification.
A-0100
BABYPLAST UAI
B/ INSTALLATION OF THE BABYPLAST UAI I/10P

B.1/ UNPACKING AND PARTS CHECK.
Upon delivery, immediately check that there are no faulty parts. If any of the parts are faulty, notify your nearest
distributor immediately.
You will find the following parts inside the packing cases:
a/ 1 BABYPLAST UAI I/10P injection unit (Control unit on wheels + injection unit).
b/ 1 instruction manual.
c/ 1 hopper.
d/ If ordered, 1 bag containing spare parts and their corresponding list.
B
B.2/ INSTALLING AND MOUNTING THE INJECTION UNIT
The BABYPLAST UAI I/10P injection unit, on request, can be supplied with anchor blocks (optional - part number
C20016500) for fixing it to a mould. The injection unit can be fitted in various configurations. Please consult the
manufacturer for further information.
ATTENTION: When handling the injection unit or fixing it to the mould, always disconnect the power
supply and handle with care.
MAIN DIMENSIONS FOR FIXING THE INJECTION UNIT TO A MOULD
Mould
Anchor blocks
C20016500
B-0010
BABYPLAST UAI
B.3/ INSTALLING AND FIXING THE INJECTION UNIT TO A MACHINE PLATEN
The BABYPLAST UAI I/10P injection unit can also be fixed to the machine bolster by using a special bracket.
Use a spacer (dim. X) to adjust the position of the injection unit in respect to the machine bolster and to obtain
the required nozzle position.The injection unit can be fitted in various configurations. Please consult the
manufacturer for further information.
ATTENTION: When handling the injection unit or fixing it to the mould, always disconnect the power
supply and handle with care.
Machine platen
Fixing
bracket
Injection point
B-0020
BABYPLAST UAI
B.4/ ELECTRICAL CONNECTIONS for 400V power supply
3 phase + neutral + earth - 400V - 50/60Hz

The mains power supply fuses inside BABYPLAST UAI I/10P injection unit have a blow rating of 3.500 A at
400V.
The machine must be connected to the mains via a 16A thermo / 0,030A differential circuit breaker,
that is suitable for the power supply used.
Attention! For power supplies with the neutral isolated from earth, a relay for permanent isolation must
be installed.
B.4/ ELECTRICAL CONNECTIONS for 230V power supply
3fasi + terra - 230v - 50/60Hz

3 phase +earth - 230v - 50/60Hz
The mains power supply fuses inside BABYPLAST UAI I/10P injection unit have a blow rating of 10.000 A at
230V.
The machine must be connected to the mains via a 16A thermo / 0,030A differential circuit breaker,
that is suitable for the power supply used.
The BABYPLAST UAI I/10P injection unit will be prepared for connecting to a power supply as specified in the
customers order.
Current: Max 7,5A - average 3,5A
FUSES INSTALLED ON THE fm542 BOARD Fuse pos.
number
Technical
specifications
Dimensions
F501
F502
F503
10A - 500V - rapid blow

6,3X32 F
6,3X32 F
6,3X32 F
F504
6,3X32 F
F505
F506
F507
F508
F509
8A - 500V -extra rapid

3,15A - 500V - extra rapid
6,3X32 FF
6,3X32 FF
6,3X32 FF
6,3X32 FF
6,3X32 FF
Power rating
FUNCTION
500V/ 1.500A - 250V/10.000A

500V/ 1.500A - 250V/10.000A
500V/ 1.500A - 250V/10.000A
PHASE R
PHASE S
PHASE T
24V POWER
500V/ 1.500A - 250V/10.000A
500V/ 1.500A - 250V/10.000A
500V/ 1.500A - 250V/10.000A
500V/ 1.500A - 250V/10.000A
500V/ 1.500A - 250V/10.000A
Plast. heater
Chamber heater
Nozzle heater
mould heater
Free
B-0020
BABYPLAST UAI
B.5/ COOLING SYSTEM
This is needed to:

Cool the hydraulic oil.
Cool other parts of the machine.
For connecting the cooling water supply to the BABYPLAST UAI I/10 P, the inlet and outlet hose must be of a
flexible type. Connect the inlet hose to the water supply (see diagramme), the outlet hose to the return circiuit
and open the shut-off valve.
The temperature of the incoming water must be between 12C (min.) and 18C (max.). However, the
minimum and maximum temperatures are indicative only and depend on the machine settings and working
conditions.
The water must be clean, otherwise a filter must be used and the calcium content controlled.
The water hardness must be between 6 grd-9grd dH, and the pressure between 3-4bar (max.) with a
difference between the inlet and outlet of 1.5 bar.
WATER IN
WATER OUT
WATER IN : INLET TUBE diam. 8 mm approx.

WATER OUT: RETURN TUBE diam. 11 mm approx.
B-0030
BABYPLAST UAI
B.6/ FILLING THE HYDRAULIC OIL TANK

The BABYPLAST UAI/10P injection unit is not supplied with hydraulic oil unless the oil was requested as an
accessory. Only oils with the following characteristics should beused in the machine.
Characteristics of the oil:
RANGE: -15C +80C

VISCOSITY: 12 100 MM/SEC.(CST)
FILTRATION: 25 30 um. MINIMUM
AGIP-OSO45
CASTROL-HISPIN AWS46
CHEVRON-EPHIDRAULIC OIL 11
ESSO -NUTOH48
IP-IPHYDRUS OIL 46
MACH -BP ENERGOL HLP80
MOBIL-DTE MEDIUM
FIAT- RZA 40
TOTAL- AZOLLA ZS46
VERY IMPORTANT
The guarantee on the machine will be void if any oils other than those listed above are used in the machine.
CRONOPLAST does not accept any responsibility in such cases.
How to fill the machine with hydraulic oil.
Remove the oil cap and fill the tank until the level reaches the mark on the dipstick. attached to the oil cap.
ATTENTION: THERE IS A SENSOR WITH A FLOAT, INSIDE THE OIL TANK, WHICH CAUSES THE
MACHINE TO GO INTO ALARM (ALARM 023) IF THE OIL LEVEL IS TOO LOW.
WORKING TEMPERATURE
MAXIMUM TEMPERATURE
MINIMUM TEMPERATURE
:
:
:
45C
60C (ALARM 020)
20C (ALARM 029) - Under the minimum temperature, it is only possible
to switch on the motor, heaters and consult the various menus. No
movements are possible.
Maximum hydraulic
pressure adjustment
valve
Oil return filter
Oil fill cap
B-0040
BABYPLAST UAI
B.7/ SYSTEM CHECK
Check that the previous steps have been carried out exactly and that there are no water or oil leaks. Also
check that the electrical connections are correct.
B.7/ INSTALLING THE INJECTION UNIT

The injection unit must be fixed to a mould or injection moulding machine which conforms to the latest safety
standards.
An optional anchor plate can also be supplied, on request, for fixing the unit to a mould.
( CRONOPLAST S.L. and RAMBALDI Srl are highly experienced in the design, development and construction
of Babyplast moulds and are ready to provide expert service and advice in order to offer their customers
complete turn key solutions).
B-0040
BABYPLAST UAI
C/ BEFORE START UP
C.1/ Main switch
MAIN SWITCH / EMERGENCY STOP

Switches the machine on and off It has two
positions (0 off - 1 on).
When in position 0 a safety padlock may be
applied.
Attention: activate only if the mould has been

installed on a machine which conforms to the
safety standards in force.
IN CASE OF AN EMERGENCY, THE MAIN

SWITCH CAN BE USED TO STOP THE
MACHINE COMPLETELY.
C.2/ EMERGENCY STOP

In case of an emergency, the machine can be stopped by pressing the EMERGENCY STOP button,which is
situated on the control panel (see drawing below), or by turning the MAIN SWITCH, which is situated on the front
of the hydraulics & electronics cabinet (see previous drawing) , to position 0.
Pushing the button switches off the motor pump, all the electro-valves and all the heating elements, and
activates alarm 031 EMERGENCY STOP. The two OUTPUT contacts (17 - 25), situated in the multi pin
INPUT / OUTPUT socket also open to give an emergency out.
In the same socket there are also two free contacts (1-9), which can be used to activate the EMERGENCY
STOP from an external source.
C-0010
BABYPLAST UAI
C.3/ DISPLAY PANEL

Tool settings are set and saved via the multi-function touch-screen display. It is also possible to control the various
functions of the machine and handle and activate the various phases of the cycle.
A. EMERGENCY STOP BUTTON
Pressing this button switches off the motor
& heaters and the message
EMERGENCY ALARM is shown on the
display.
B. TOUCH-SCREEN DISPLAY
Visualise all data and functions of the
machine as well as the synoptic
diagramme of the machine. Allows
machine parameters to be varied or saved,
by touching the various icons or fields of
data.
MAIN MENU
00.0mm
C. REFERENCES FOR ICONS

The following refences are used (F1-F2
etc..) to simplify the explanations of the
functions of the various icons referred to
in this manual on the touch-screen display
D. SELECTOR KEY
Allows a more rapid input of data.
E. DIAL
Gives consesus to START a cycle via the
display panel (MANUAL) or via an external
source (AUTOMATIC).
F. ALARM LIGHT
Lights up when an alarm is activated. At the same time a
description of the fault appears on the display.
C.4/ INJECTION PRESSURE GAUGE
INJECTION PRESSURE GAUGE

Indicates the 1st and 2nd injection pressure
Maximum pressure is 130bar. With 10mm diam. piston, max. pressure is
100 bar (to set the injection piston diam. see ADVANCED SETTINGS).
C-0020
BABYPLAST UAI
C.5/ DISPLAY - SYNOPTIC DIAGRAMME
This display indicates hydraulic movements, motor and heating element status.
1
2
MAIN MENU
H1 200
H2 200
H3 200 H4 OFF
3
15
14
13
00.0mm
5
6
7
Gear art. 2345
1
2
3
4
5
6
7
8
9
10
11 12
13
14
15
10
11
12
Menu visualised
Actual temperatures - H1 plastif. - H2 chamber - H3 nozzle - H4 mould.
When present, indicates that the motor is on.
When red, indicates that external consensus is missing, Switch open (Input 3-11interface socket)
Nozzle heater element ON. Red :Temp. in tolerance band- Yellow: Temp. in stand-by.
Indicates the cycle programme number in use.
Icons: touch to activate corresponding function.
Indicates injection carriage forward movement and that the electro-valve is functioning.
Indicates that injection has been activated and that the electro-valve is functioning.
Indicates that the decompression process has been activated and that the electro-valve
is functioning.
Indicates injection carriage backward movement and that the electro-valve is
functioning.
Injection piston position.
Indicates that plastification has been activated and that the electro-valve is functioning.
Plastification heater active: - Red -temperature within tolerance band, Yellow - temperature in stand-by
Chamber heater active: - Red -temperature within tolerance band, Yellow - temperature in stand-by
C-0030
BABYPLAST UAI
C.6/ SAFETY DEVICES
Position of safety devices.

Safety for the user.
Injection Unit
1
2
3
4
5
C-0040
Heat shield.
Emergency stop button
Main switch and emergency stop
Input (pin 1-9) emergency from external source.
Imput consensus from external guard / protection (pin 3-11)
BABYPLAST UAI
STARTING THE MACHINE

The machine is now ready to be started. Check that it has been filled with oil to the correct level, and that
it is connected to the mains correctly.
FIRST:
Adjust the plastification temperature in accordance with the specifications indicated by the
manufacturer of the material to be injected. Adjust the injection chamber temperature to approximately
5/10 C below the plastification temperature parag. D.1.6a TEMPERATURE SETTINGS (page D0070)
WARNING: There is plastic material in THE INJECTION UNIT which was used for tests during the
manufacturing process. MAKE SURE that this material is compatible with the temperatures at which the
machine is to be programmed. If the user is not experienced in the transformation of thermoplastics, it is
advisable to begin with a material with a wide temperature range, such as POLYPROPYLENE,
POLYSTYRENE, POLYETHYLENE ABS,etc.so as to obtain best results right from the start.
SECOND:
Set the shot size based on the volume of the part, the cooling time between 2 and 4 seconds, the 1st
injection pressure at approx. 50/60 bar and a time for the 1st injection pressure depending on the volume of
the part to produce and the density of the material used (start with 1.5 - 3 seconds for example).
Decompression should be set between 1 and 2 mm Parag. D.1.6b3 INJECTION SETTINGS (page D-0110)
THIRD:
Set sprue break time, if required, from 0.1 to 0.2 secs. see INJECTION CARRIAGE TIME parag. D1.6b1
(page D-0090).
FORTH:
Close the material chute on the hopper and load the hopper with enough material to carry out the required
tests. When the various, previously set, temperatures are reached, open the material chute on the hopper
and purge the machine according to section D.2.2/PURGE. (page 190) The machine is now ready to produce
some parts.
FIFTH
Make sure that the unit is connected correctly to the main machine, put the machine in semi-automatic
mode and start a production cycle. The machine will proceed to complete one cycle. The nozzle may cool
slightly, during the first shots, as it comes into contact with the cold mould. If so, for the first shots only,
increase the nozzle temperature by approximately 5 or 10%.
If good results have been achieved, repeat this process several times, adjusting the different machine
parameters such as times, tempertures, pressures and material load.
Select AUTOMATIC mode by turning the selector key. In this mode the START will be given by an external
source (i.e. main machine)
Make sure that, at the end of the injection cycle, the injection piston position is less than 3 mm (cushion)
(page D0340), otherwise the machine will go into alarm after 8 cycles.These two parameters can be modified,
please see par. D.4.3 advanced settings.
The parameters quoted in this section are only a guideline, because parameters always depend on the
materials, the mould construction and the volume of the part.
WARNING: Some plastic materials maybe inflammable and/or explosive.
C-0050
BABYPLAST UAI
BABYPLAST UAI
D.1/ MENU
D.1.1/ Display
MAIN MENU
Menu open
F8
Motor status
Synoptic diagram
F7
Movement
indicators
00.0mm
Injection position
F6
Programme in use
PROGRAMME
Function key icons
F1
D-0010
F2
F3
F4
F5
BABYPLAST UAI
D.1.2/ ICONS - Description of functions

Switch ON the motor.
Switch OFF the motor
Information/upgrade
software
upgrade software
Display/CPU
Timer for starting motor
Save mould setting data
Access to tool settings
Overwrite or change
mould settings.
Access to machine
configurations
Access to machine
config. - password 1212
Access to manufacturer
settings.
Switch heaters ON
Access to mould settings

Access to mould setting
files
Save data on USB
memory stick
Retreive data from USB
memory stick
Switch heaters OFF
Part counter
Access to temperatures
page
Activate temp. in Stand-by
Atomatic menu
Semi-automatic menu
Manual menu
Visualise alarm
messages
Confirm - return to
previous page
Inj. carriage in manual or
access to inj. carriage data
Deactivate Temp. in
Stand-by
Quality control
password 1212
Log file: Cycle time
-cushion
Save average cycle time
Exit without saving
Start automatic or semiautomatic cycle
Plastification inmanual or
access to plast. data
Injection in maual or
access to injection data
Stop automatic or semiautomatic cycle
Times and settings
Purge to start cycle
Manual movements to the

right - change line
Purge to end cycle
Manual movements to the

left - change line
Core pull
Access to keyboard
Setting times
Activate venturi loader
Activate airblow in manual

if present
Purge
D-0020
BABYPLAST UAI
D.1.4/ Start up
ATTENTION: before switching on at the main switch, the injection unit must be fixed to an injection
moulding machine which conforms to the safety standards in force and connected to an external
EMERGENCY STOP signal (input / output socket, pin 1-9. See page F-0140).
After turning the main switch to the 1 (ON) position, the BABYPLAST logo will appear for a few seconds
followed by the following display:
MAIN MENU
F8
F7
00.0mm
F6
PROGRAMME
F1
D-0030
F2
F3
F4
F5
BABYPLAST UAI
D.1.4/ MAIN MENU
Motor status ON
MAIN MENU
F8
F7
Motor ON/OFF
F6
Machine
configuration
00.0mm
00.0mm
Go to stored tool
settings
F1
F2
F3
F4
Timer for starting the

motor and heaters
F5
Press F7 to switch on the motor. The motor symbol, in the top left hand corner of the display, will appear
as long as the motor is running. press the same key again to switch off the motor. Keys F1, F2 & F3 are
activated when the motor is switched on.
ATTENTION! If the oil temperature is below the minimum value set by the manufacturer (20C), no movements
will be possible. In order that the oil reaches the correct temperature rapidly, the motor will turn at full speed.
MAIN MENU
F8
F7
Motor OFF
F6
Machine
configuration
00.0mm
00.0mm
Mould setting
programme in use
Gear - art. 2345

Access to stored
mould settings
F1
F2
Manual menu
F3
Automatic menu
F4
F5
Switch heaters ON
ATTENTION! The heating elements are switched on by pressing key F3. The setting values will be taken from
those stored in the tool setting programme indicated in the synoptic diagram.
D-0040
BABYPLAST UAI
D.1.5/ MANUAL MENU

While in the MAIN menu, press F1
to enter the MANUAL menu. The following display will appear:
MAIN MENU
F8
F7
00.0mm
F6
Gear art. 2345
F1
F2
F3
F4
F5
The following display will be seen:

MANUAL MENU
F8
F7
Back to previous
display
F6
Temperatures
00.0mm
F1
F2
Injection carriage
F3
F4
Plastification
F5
Injection
Air blow
To activate the various movements in manual, press one of the keys to select the function required. Having
entered the function required, press one of the two keys
for backward or forward movements.
Key F5
will activate the optional valve for AIR BLOW if installed.
ATTENTION! For plastification and injection, piston movement will only be possible when the set
temperatures have been reached. ( See tolerance band - user data input ).
WARNING: WHEN CHANGING FROM ONE MATERIAL TO ANOTHER, LOADING A DIFFERENT MOULD SETTING PROGRAMME OR
IN CASE OF RESIDUE MATERIAL LEFT IN THE SYSTEM FROM PREVIOUS PRODUCTION, GREAT CARE MUST BE
TAKEN TO SET THE CORRECT PROCESSING TEMPERATURES ACCORDING TO THE MATERIAL MANUFATURERS
DATA SHEET. FAILURE TO DO SO MAY CAUSE DAMAGE,
D-0050
BABYPLAST UAI
D.1.6/ AUTOMATIC MENU

MAIN MENU
F8
F7
Motor OFF
F6
Machine
configuration
00.0mm
Mould setting
programme in use
Gear - art. 2345
Access to stored
mould settings
F2
F1
F3
Manual menu
F4
Automatic menu
F5
Switch heaters ON
ATTENTION! By pressing F3 the heaters will be switched ON and the active zones will be shown in yellow during
pre-heating and red when the respective tolerance bands have been reached; The settings will be taken from
those saved in the mould setting programme highlighted in the synoptic diagramme.
While in the MAIN menu, press F2

appear:
H1
200
AUTOMATIC MENU
H2 200 H3 200
to gain access to the AUTOMATIC menu.The following display will
Actual temperatures
H4
OFF
F8
F7
Return to previous
display
00.0mm
Temperatures
F6
Gear - art. 2345
F1
F2
F3
Semi-auto. cycle
Times and other

settings
F4
Purge
F5
Part counter
ATTENTION! Plastification and injection piston movements will only be possible

when the set temperatures have been reached. ( See tolerance band - users menu,
data input ). If an Automatic, Semi-automatic or purge cycle is selected, and the
machine has not reached the the set temperatures, the machine will go in alarm.
D-0060
D
D.1.6a/
H1
200
AUTOMATIC MENU
H2 200 H3 200
BABYPLAST UAI
AUTOMATIC MENU - TEMPERATURE SETTINGS

Yellow : indicates that the heaters in the
relative zones are in pre-heat mode or
standby
Red that the heaters in the relative tones
are within the tolerance bands
H4
OFF
F8
F7
00.0mm
F6
Gear - art. 2345
F2
F1
F3
F4
While in the AUTOMATIC menu press F6
Oil - reading only
Values set
F5
to gain access to the TEMPERATURES menu:
Save values in the mould
settings programme in use
Actual values
TEMPERATURES
Oil
045
F8
H1
200
200 C Plastific.
H2
200
199 C Chamber
H3
195
195 C Nozzle
H4
F7
514 C Mould
040 C Hopper
F6
Confirm and exit without
saving values set.
F1
F2
F3
It is only possible to activate or

deactivate the zones from the
pages of the mould setting
programme.see page D-330
F4
F5
Hopper temperature, VISUAL

ONLY
UAI in alarm if over 70C
STAND-BY Temperature.
It is possible to activate or
deactivate stand-by. If
active, the zones will be
shown in yellow on the
synoptic diagramme in the
main menu.
SETTING: Touch zone, which needs to be changed, in the field Values set. Rotate the dial M to set the value
required. Press F7
to return to the previous page. The modified values are changed but not saved in the
mould setting programme in use
The modified values can be saved in the mould setting programme by pressing F8
.
D-0070
BABYPLAST UAI
D.1.6b/ AUTOMATIC MENU - TIMES AND SETTINGS
H1
200
AUTOMATIC MENU
H2 200 H3 200
H4
OFF
F8
F7
00.0mm
F6
Gear - art. 2345
F1
F2
F3
F4
F5
While in the automatic menu press F5

to gain access to the menu for TIMES and SETTINGS, the
following display shows readings only and cannot be modified:
TIMES AND SETTINGS

Actual cycle time
12.0
sec
Actual cushion
1.2
mm
Average actual time
12.0
sec
Average time saved
12.0
sec
Quality control
NO
Cycle time error
05
Cushion error
1.0
mm
F1
F2
F3
F8
F7
M
F4
F6
Return to previous display
F5
While in TIMES AND SETTINGS, press keys F1 - F2 - F4 - F6 to gain access to: INJECTION CARRIAGE PLASTIFICATION - INJECTION - QUALITY CONTROL (see following pages).
D-0080
BABYPLAST UAI
D.1.6b1/ INJECTION CARRIAGE SETTINGS
TIMES AND SETTINGS

Actual cycle time
12.0
sec
Actual cushion
1.2
mm
Average actual time
12.0
sec
Average time saved
12.0
sec
Quality control
NO
Cycle time error
05
Cushion error
1.0
mm
F1
F2
F3
F8
F7
M
F4
F6
F5
From the MAIN TIMES AND SETTINGS menu, press F1

INJECTION CARRIAGE TIMES AND SETTINGS :
By setting a value other than 0

( from 0.3 to 0.6), the injection
carriage moves back and away from
the mould at each cycle. If the setting
is 0 sec the injection carriage will
remain against the mould during each
cycle
Varies the speed of the injection
carriage.
to gain access to
INJECTION CARRIAGE TIMES AND SETTINGS

Injection carr. time
0.0
sec
Inj. carriage speed
100
F8
F7
F6
Touch the field to be modified, vary the values by rotating the dial. Press F8
to save the changes in the
mould setting programme in use. By pressing F7
the values will be changed but not saved in the mould
setting programme.
D-0090
BABYPLAST UAI
D.1.6b2/
PLASTIFICATION SETTINGS
TIMES AND SETTINGS

Actual cycle time
12.0
sec
Actual cushion
1.2
mm
Average actual time
12.0
sec
Average time saved
12.0
sec
Quality control
NO
Cycle time error
05
Cushion error
1.0
mm
F1
F2
F3
F8
F7
M
F4
F6
F5
From the MAIN TIMES AND SETTINGS menu press F2

PLASTIFICATION TIMES AND SETTINGS :
To use with 16/18mm diam. injection

pistons. Serves for activating a double
plastification so as to fill completely
the above mentioned pistonsi.Setting
a value, e.g. 5 sec, the plastification
is activated for this time and then
reactivated for a second time so as to
reach the material load set.
Varies the plastification piston speed.
to gain access to
PLASTIFICATION TIMES AND SETTINGS

2nd shot load time
0.0
sec
Plastification speed
100
F8
F7
Suction time
0.5
sec
F6
OPZIONAL : If present, the VENTURI

LOADER can be activated or
deactivated by pressing F6.On the
synoptic diag. the words ON/OFF will
appear on the hopper. If the suction
time is 0, suction will stop when the
sensor, installed in the hopper, detects
the presence of material ( Indicator ON
on hopper).
Otherwise, if a value is set which is higher than 0, suction will continue after the sensor has detected material, for
the time set. After 3 cycles of loading without activating the sensor, (no material present) the function deactvates.
Press F6 to reactivate.
ATTENTION: for a correct function use dried air.
setting programme.
D-0100
BABYPLAST UAI
D.1.6b3/ INJECTION SETTINGS

TIMES AND SETTINGS
Actual cycle time
12.0
sec
Actual cushion
1.2
mm
Average actual time
12.0
sec
Average time saved
12.0
sec
Quality control
NO
Cycle time error
05
Cushion error
1.0
mm
F1
F2
F3
F8
F7
M
F4
F6
F5
From the MAIN TIMES AND SETTINGS MENU press F4

SETTINGS:
Set the shot size in order to obtain a
cushion value less than 3 mm (pre-set
parameter). Maximum value 60mm - The
shot size depends on the pison size
installed.
to gain access to INJECTION TIMES AND

INJECTION TIMES AND SETTINGS
Shot size
29.0
Cooling time
4.5
sec
1st injection pressure
90
bar
When the set time has been reached the

mould opens but except in the case that
plastification has not finished.
ATTENTION: To obtain a constant cycle
time, set a value greater than the max. time
needed to load the injection piston.
1st pressure time
2.0
sec
2nd injection pressure
30
bar
Injection time, in which the value of the

1st injection pressure. must be reached
otherwise the machine will go into alarm
107 PEAK NOT REACHED.
If the second pressure is activated at a point
set in mm (see page D-0310) the line 2nd
pressure setting : 00.0mm will be seen.
When the injection piston reaches the point
set, the second injection speed is activated.
Output to control a hotrunner needle valve
(optional). Depends on injection time. e.g.:
Needle valve delay : 01.0 sec
Needle valve time : 01.5 sec
The output signal to the needle valve will
activate 1 sec after the start of the 1st
injection time (previous display) remain
active for 1,5 sec.
mm
2nd pressure time
1.0
sec
Decompression
0,0
mm
Injection speed
075
2nd injection speed
50
Second speed point
2,0
mm
Pause and of cycle
0,0
sec
Needle valve delay
0,0
sec
needle valve time
0,0
sec
Air blow time
0,0
sec
Accumulator point
0,0
mm
ATTENTION: to see all the lines, move the

cursor
Optional: if present the accumulator will activate at the point
set.
Output to control airblow (optional). The output signal will
activate at the end of the cooling time and remain active for
the time set.
setting programme.
D-0110
BABYPLAST UAI
D.1.6b4/ QUALITY CONTROL SETTINGS
By setting a tolerance band, it is possible to monitor two parameters on the machine: The CYCLE TIME and
CUSHION, for which it is possible to see the last 20 cycles.
TIMES AND SETTINGS

Actual cycle time
12.0
sec
Actual cushion
1.2
mm
Average actual time
12.0
sec
Average time saved
12.0
sec
Quality control
NO
Cycle time error
05
Cushion error
1.0
mm
F1
F2
F3
F8
F7
M
F4
F6
F5
From the MAIN TIMES AND SETTINGS menu, press F6

to gain access to
QUALITY CONTROL . The following display shows readings only and cannot be modified:
QUALITY CONTROL
Quality control
NO
Cycle time error
10
Cushin error
1,0
mm
N of initial cycles
10
N cycles for alarm
20
Actual cycle time
15,0
sec
Actual avarage time
15,0
sec
Avarage time saved
15,0
sec
Actual cushion
0,0
mm
F8
F7
F1
F2
F3
F4
F6
Confirm and exit
F5
To modify the quality control parameters press F6

passcode 1212 to gain access to the following menu:
Data log CYCLE TIME

and CUSHION
and then in the next display enter the
D-0120
BABYPLAST UAI
D.1.6b4/ continued...QUALITY CONTROL SETTINGS
QUALITY CONTROL
Quality control
NO
Cycle time error
10
Cushin error
1,0
mm
N of initial cycles
10
N cycles for alarm
20
Actual cycle time
15,0
sec
Actual avarage time
15,0
sec
Avarage time saved
15,0
sec
Actual cushion
0,0
mm
F8
F7
F1
F2
F3
F4
Confirm and save data in the mould

settings programme.
Confirm and exit without saving data

in the mould settings programme.
F6
F5
setting programme.
The Quality control function can be activated or deactivated by selecting YES or NO in the first line. press
F8
to save and activate the required error value in the programme in use. Press F4
to save the
t
average cycle time in the programme in use. The quality control function will not be activated until the number
of cycles, set in N of initial cycles, has been reached. The first cycle, after these initial cycles, will be
used for reference by the quality control function. If the machine detects a percentage of variation which is
more than that allowed, compared to the reference cycle, for a number of cycles greater than that set in line N of cycles for alarm, the machine activates alarm 048 cycle time out of tolerance.
OPTIONAL: On request it is possible to have an output which is activated each time a cycle is out of
tolerance, and which can be used to activate a PART REJECT device. The machine, in this case, will
be able to reject parts produced which are out of tolerance and will stop, in alarm, when the value of
N CYCLES FOR ALARM has been reached.
ATTENTION! Each time the settings are modified, a new set of initial cycles is run and hence a
new reference cycle is obtained.
D-0130
BABYPLAST UAI
D.1.6b4a/ QUALITY CONTROL - Log File
QUALITY CONTROL
Quality control
NO
Cycle time error
10
Cushin error
1,0
mm
N of initial cycles
10
N cycles for alarm
20
Actual cycle time
15,0
sec
Actual avarage time
15,0
sec
Avarage time saved
15,0
sec
Actual cushion
0,0
mm
F8
F7
F2
F1
F3
F4
F6
F5
To see the last 20 CYCLE TIMES and CUSHION values, press F3

display:
Last cycle registered
to see the following
LOG FILE
Cushion
Cycle
25
0.12
25
0.12
25
0.12
25
0.12
25
0.12
25
0.12
25
0.12
25
0.12
25
0.12
F8
F7
F6

cursor
D-0140
BABYPLAST UAI
D.1.6c/ AUTOMATIC MENU - SETTING UP THE PART COUNTER
H1
200
AUTOMATIC MENU
H2 200 H3 200
H4
OFF
F8
F7
00.0mm
F6
Gear art. 2345
F2
F1
F3
F4
From the AUTOMATIC MENU press F4

Settings
F5
to gain access to the PART COUNTER menu:
Exit without saving

To set the number of part to produce,
touch the icon
keypad and the
following display will be shown:
PART COUNTER
Parts to produce
Parts produced
Nunber of cavities
F8
F7
000000
2
Reset
F6
set the required value and confirm with
Confirm and exit

Reset part counter (line - parts
produced).
ATTENTION! Ensure that the number of cavities shown corresponds to the actual number of cavities in the
mould.The number of cavities shown, corresponds to the number of cavities set in the mould
settings programme in use. To modify, return to the MAIN MENU and press key F5
to
enter the mould settings programme.
By setting the value of parts to produce to 000000 the part counter is excluded and the
machine will produce continuously. To zero the part counter rapidly, select the first digit on the
left and change to zero. All the other digits will change to zero automatically.
D-0150
BABYPLAST UAI
D.2/ STARTING A CYCLE

D.2.1/ Starting a semi-automatic cycle (selector in MANUALE)
MENU PRINCIPALE
00.0mm
START - external
START - keypad
Position the selector, as shown above, on
MANUAL and proceed as follows:
ATTENZIONE: if the selector is positioned on AUTOMATIC

a cycle can only be started by an
external source (e.g. another machine) closing contacts 8-16 on the INPUT /OUTPUT socket (see page
F0140)
H1
200
AUTOMATIC MENU
H2 200 H3 200
H4
OFF
F8
F7
00.0mm
F6
Gear art. 2345
F1
F2
While in the AUTOMATIC MENU, press key F2
F3
F4
F5
to gain access to the following display:
D-0160
BABYPLAST UAI
D.2.1/ Continued...Starting a semi-automatic cycle (selector in MANUAL)
H1
200
AUTOMATIC MENU
H2 200 H3 200
H4
OFF
F8
F7
00.0mm
F6
Gear art. 2345
F2
F1
Press F2
F3
F4
F5
to start a SEMI AUTOMATIC CYCLE (only one complete cycle will be made)
ATTENTION! If the temperatures have not reached the tolerance bands, it will not be possible to start the
automatic cycle and the machine indicate this with an alarm message without, however,
switching off the motors and heaters.The alarm will deactivate when the operating temperatures
have been reached.
During the function SEMI AUTOMATIC CYCLE, the following display will be shown.
AUTOMATIC MENU
H1
200
H2
200
H3
200
H4
OFF
F8
F7
00.0mm
F6
Gear art. 2345
F1
F2
F3
F4
F5
While the machine is in operation, the following fuctions will be available:

Press F4
:To see the number set in the part counter and also check and reset the number
reached.
Press F5
:To see and modify times and other settings.
Press F6
:To see and modify temperatures.
D-0170
BABYPLAST UAI
D.2.2/ Starting a PURGE CYCLE
H1
200
AUTOMATIC MENU
H2 200 H3 200
H4
OFF
F8
F7
00.0mm
F6
Gear art. 2345
F2
F1
F3
F4
From the AUTOMATIC MENU press key F3
H1
200
PURGE CYCLE
H2 200 H3 200
H4
F5
to gain access to the PURGE CYCLE menu:
OFF
F8
F7
00.0mm
F6
Gear art. 2345
F1
Press key F1
Press key F2
F2
F3
F4
F5
To start PURGE AT END OF CYCLE. At the end of this cycle the injection
piston will stop in the fully forward position hence the cylinder will be empty.
To start PURGE AT BEGINNING OF CYCLE. At the end of this cycle the injection cylinder
will be loaded with the quantity of material set in the programme.
ATTENTION! If the temperatures have not reached the tolerance bands, it will not be possible to start the
automatic cycle and the machine indicates this with an alarm message without, however,
switching off the motors and heaters.The alarm will deactivate when the operating temperatures
have been reached
WARNING: WHEN CHANGING FROM ONE MATERIAL TO ANOTHER, LOADING A DIFFERENT
MOULD SETTING PROGRAMME OR IN CASE OF RESIDUE MATERIAL LEFT IN THE
SYSTEM FROM PREVIOUS PRODUCTION, GREAT CARE MUST BE TAKEN TO SET
THE CORRECT PROCESSING TEMPERATURES ACCORDING TO THE MATERIAL
MANUFATURERS DATA SHEET. FAILURE TO DO SO MAY CAUSE DAMAGE,
BLOCKAGE, OR GAS; PARTICULARLY DURING PURGING.
D-0180
BABYPLAST UAI
continued..../ Starting a PURGE CYCLE
D
When the machine is running in the PURGE CYCLE, the following display will be seen:
H1
200
H2
PURGE
200 H3
200
H4
OFF
F8
F7
00.0mm
F6
Gear - art. 2345
F1
F2
F3
F4
F5
While the machine is running the following options will be available:

Press F3 :
The machine will finish the cycle in course and then stop.
Press F6 :
To visualise and modify temperatures.
At the end of 6 purge cycles, the machine will stop automatically and remain in idle until either another purge
cycle is started (see previous page) or another function is selected.
D-0190
BABYPLAST UAI
D.3/ MOULD SETTING PROGRAMMES

D.3.1/ LOADING A MOULD SETTING PROGRAMME
MAIN MENU
F8
F7
00.0mm
F6
Gear - art. 2345
F1
F2
When in the MAIN MENU press F5
F3
F4
F5
PROGRAMMES
Exit without saving
F8
Confirm mould setting
programme selected
Programme selected
F7
Gear - art. 2345
F6
Retrieve programmes from

a USB memory stick
Save programmes onto a
USB memory stick
programme selected.
F1
F2
F3
F4
F5
Access to the mould

setting programme folder
To select a new mould setting programme, go to the mould setting programme folder by pressing F1
The following display will be seen (see the following page):
D-0200
D
CONTINUED........
BABYPLAST UAI
LOADING A MOULD SETTING PROGRAMME
Go back a directory level

sachin@mimindia.net
/home/root/Fm607/progs
Gear - art. 1111
Gear - art. 2345
Gear - art. 422
Plug - art. 4459
Return to the programmes

page
Programme selected
Plug - art. 2222
Keypad to change name

Exit and confirma programme
selected
file
Plug - art. 4459
Exit without confirming
filter
Eliminate programme
selected
Touch the file to be selected, the name will be seen in the field file. touch the icon
WARNING:
D-0210
to exit and confirm.
WHEN CHANGING FROM ONE MATERIAL TO ANOTHER, LOADING A DIFFERENT MOULD SETTING PROGRAMME
OR IN CASE OF RESIDUE MATERIAL LEFT IN THE
SYSTEM FROM PREVIOUS PRODUCTION, GREAT CARE
MUST BE TAKEN TO SET THE CORRECT PROCESSING TEMPERATURES ACCORDING TO THE MATERIAL
MANUFATURERS DATA SHEET. FAILURE TO DO SO MAY CAUSE DAMAGE, BLOCKAGE, OR GAS;
PARTICULARLY DURING PURGING.
BABYPLAST UAI
D.3.2/ Creat or modify a mould setting programme

D.3.2a/ TIMES AND SETTINGS
From the MAIN MENU press F5
PROGRAMMES
Exit without saving
F8
Confirm and exit
Programme selected
F7
Retrieve mould setting

programmes from a USB
memory stick
F6
Save mould setting

programmes onto a USB
memory stick
Plug - art. 4459
To gain access to a mould

settings programme.
F1
F2
Press F2
F3
F4
F5

programme folder
to enter the mould setting programme selected.
PROGRAMME: Plug - art 4459

Customer
xxx
Material
POM
Part weight
0,0
gr
Shot weight
0,0
gr
Mould number
000
Average time saved
10.4
Last modification
01.01.2008
Programme selected
F8
Exit without saving
F7
sec
F6
Save /Copy cycle

programme
Setup core pulls
Set temperatures
F1
F2
F3
F4
F5
General settings
Touch the field to be modified, to vary the alphanumerical values, touch the icon keypad
for the other
values rotate the dial. Press F7
to save the changes in the mould setting programme in use or to copy the
changes into a new mould setting programme. The value Average time saved can only be saved in the
QUALITY CONTROL function. While the date in Last modification , is saved automatically the moment the
last modification is made.
Press F1
D-0220
BABYPLAST UAI
D.3.2a.1/ Mould setting programmes - INJECTION

CARRIAGE
MAIN TIMES AND SETTINGS
F8
F7
F6
F1
Press F1
F2
F3
F4
F5
to gain access to INJECTION CARR. TIMES & SETTINGS :
Delay START: the start signal from

the outside will have a delay equal
to the set value
By setting a value other than 0
(from 0.3 to 0.6), the injection
carriage moves back and away from
the mould at each cycle. If the setting
is 0 sec the injection carriage will
remain against the mould during each
cycle
INJECTION CARR. TIMES & SETTINGS

Injection carriage delay
0.0
sec
Injection carr. time
0.0
sec
Inj. carriage speed
100
F8
F7
F6
Varies the speed of the injection

carriage.
to return to the previous
page without saving. Press F7
to save changes in the mould setting programme in use or to copy the
mould setting programme by changing the name. Press F8
to exit without saving.
D-0230
BABYPLAST UAI
D.3.2a.2/ Mould setting programmes - PLASTIFICATION
F8
F7
F6
F1
Press F2
F2
F3
F4
F5
to gain access to PLASTIFICATION TIMES AND SETTINGS :
To use with 16/18mm diam. injection

pistons. Serves for activating a double
plastification so as to fill completely
the above mentioned pistonsi.Setting
a value, e.g. 5 sec, the plastification
is activated for this time and then
reactivated for a second time so as to
reach the material load set.
Varies the plastification piston speed.
PLASTIFICATION TIMES AND SETTINGS

2nd shot load time
0.0
sec
Plastification speed
100
F8
F7
Suction time
0.5
sec
F6
OPZIONAL : If present, the VENTURI

LOADER can be activated or
deactivated by pressing F6.On the
synoptic diag. the words ON/OFF will
appear on the hopper. If the suction
time is 0, suction will stop when the
sensor, installed in the hopper, detects
the presence of material ( Indicator ON
on hopper).
Otherwise, if a value is set which is higher than 0, suction will continue after the sensor has detected material, for
the time set. After 3 cycles of loading without activating the sensor, (no material present) the function deactvates.
Press F6 to reactivate.
ATTENTION: for a correct function use dried air.
D-0240
BABYPLAST UAI
D.3.2a.3/ Mould setting programmes - INJECTION
F8
F7
F6
F1
Press F4
F2
F3
F4
F5
Set the shot size in order to obtain a

cushion value less than 3 mm (pre-set
parameter. pag. D-0340). Maximum value
60mm - The shot size depends on the pison
size installed.
When the set time has been reached the
mould opens but except in the case that
plastification has not finished.
ATTENTION: To obtain a constant cycle
time, set a value greater than the max. time
needed to load the injection piston.

Shot size
29.0
mm
Cooling time
4.5
sec
1st injection pressure
90
bar
1st pressure time
2.0
sec
2nd injection pressure
30
bar
2nd pressure time
1.0
sec
2nd pressure setting
0.0
mm
Injection time, in which the value of the

1st injection pressure. must be reached
otherwise the machine will go into alarm
107 PEAK NOT REACHED.
Decompression
0,0
mm
njection speed
075
2nd injection speed
50
If the second pressure is activated at a point

set in mm (see page D-0310) the line 2nd
pressure setting : 00.0mm will be seen.
Seconnd speed point
0.0
mm
Pause end off cycle
0.0
sec
When the injection piston reaches the point

set, the second injection speed is activated.
ATTENTION: to see the lines below, move the cursor.

SEE FOLLOWING PAGE....
D-0250
BABYPLAST UAI
continued..../ Mould setting programmes - INJECTION

cursor.
Output to control a hotrunner needle valve
(optional). Depends on injection time. e.g.:
Needle valve delay : 01.0 sec
Needle valve time : 01.5 sec
The output signal to the needle valve will
activate 1 sec after the start of the 1st
injection time (previous display) remain active
for 1,5 sec.
Output to control airblow (optional). The
output signal will activate at the end of the
cooling time and remain active for the time
set.
Needle valve delay
0,0
sec
Needle valve time
0,0
sec
Air blow time
0,0
sec
Accumulator point
0,0
mm
Injection mode
peak
Accum. Plastification
NO
Optional. Active if a hydraulic accumulator

is fitted to the machine
YES : Injection and plastification
NO: Injection
PEAK: (de-fault) - At the end of injection
time and on condition that the 1st injection
pressure has been reached, the machine
will change over to the 2nd injection
pressure.
POSITION (Pos.) : The 1st injection
pressure will be maintained till the
position, previously set in the injection
menu, has been reached. At this point, the
machine will change over to the 2nd
injection pressure
Optional.
Active line, if a hydraulic accumulator is installed,
the accumulator will start to work in the following
mode:
YES : injection and plastification
NO: injection
D-0260
BABYPLAST UAI
D.3.2b/ Mould setting programmes - TEMPERATURES

PROGRAMME: Plug art. 4459
Programme selected
Customer
xxx
Material
POM
Part weight
0,0
gr
Shot weight
0,0
gr
Mould number
000
Average time saved
10.4
Last modification
01.01.2008
F8
Exit without saving
F7
sec
F6
Save /Copy cycle

programme
Setup core pulls
Set temperatures
F1
F2
F3
F4
General settings
F5
Touch the field to be modified, to vary the alphanumerical values, touch the icon keypad
for the other
values rotate the dial. Press F7
to save the changes in the mould setting programme in use or to copy the
changes into a new mould setting programme. The value Average time saved can only be saved in the
QUALITY CONTROL function. While the date in Last modification , is saved automatically the moment the
last modification is made.
Press F2

ACTIVE zone
NON ACTIVE zone
TEMPERATURES
H1 Heater plastif.
215
C %
H2 Heater inj. chamber
215
C %
H3 Heater nozzle
215
C %
H4 Heater mould
215
C %
F8
F7
M
V1 Cooling hopper
C %
F6
to activate a zone, press directly on the symbol C (% only in case of emergency), then on the corresponding value
field and rotate the dial to set the value required.
press X to deactivate the zone completely.
N.B. : The valve, EV 1 (water manifold) is optional. However, in any case the value can be set as a reminder using
the same value as the water manifold ( 5-10-15-20-25).
D-0270
BABYPLAST UAI
D.3.5/ Mould setting programmes - CORE PULLS
PROGRAMME: Plug - art. 4459

Customer
xxx
Material
POM
Part weight
0,0
gr
Shot weight
0,0
gr
Mould number
000
Average time saved
10.4
Last modification
01.01.2008
Programme selected
F8
Exit without saving
F7
sec
F6
Save /Copy cycle

programme
Setup core pulls
Set temperatures
F2
F1
Press F3
F3
F4
General settings
F5
Indication of the page,

core pull A or B,
being visualised
Digit the words activate or deactivate to

activate or deactivate the core pull function
in the respective page A or B.
PROGRAMME
Core pull A
Core pull B
Injection
Decompression
Plastificat.
Cooling
Air Blow
F8
Disabled
Pos
Status
Time
Cons.
OFF
0.0
OFF
OFF
0.0
OFF
OFF
0.0
OFF
OFF
0.0
OFF
OFF
0.0
OFF
F7
F6
Sch 1
On request, a socket can be fitted for 24V output (output A - J708) (output B - J709) and the two respective
PNP input sockets for cycle consensus (A J306 - BJ307). The two outputs A or B can be activated for an
indefinite length of time when ON is set (status column), and 00s set (time column). The same outputs can
also be activated for specific length of time by setting ON (status column) and a specfic time (time column).
When ON is selected in the cons. column (consensus), the cycle will not start without the input (for consensus
to continue) from an external source.
Positions 1,2,3,4 & 5 represent the positons during the cycle when the outputs A or B will be activated (see
following diagram). This function can also be used to activate a valve for air blow for example.
To activate or deactivate the output A or B, select by touching the relative heading (Core pull A or Core pull B).
D-0280
BABYPLAST UAI
D.3.3/ TOOL SETTING PROGRAMMES - How to copy a programme.

If a new programme has to be created, which is similar to an existing programme, it is possible to copy the
existing programme and make modifications if necessary.
Do as follows:
Example:
Programme to copy
New pragramme
: Gear A
: Gear B
From the main menu press F5

Exit without saving
PROGRAMMES
F8
Confirm and exit
Programme selected
F7
Retrieve mould seting

programmes from USB
memory stick
F6
Save mould setting

programmes on a USB
memory stick
Gear A
To gain access to a mould

settings programme.
F1
F2
F3
F4
F5
Access to the mould setting
programmes folder
Check that the mould setting programme selected is the one to be copied, (to select another programme see page D0260) press F2
to enter the programme
PROGRAMME: Gear A
Programme selected
Customer
xxx
Material
POM
Part weight
0,0
gr
Shot weight
0,0
gr
Mould number
000
Average time saved
10.4
Last modification
01.01.2008
F1
Press F7
D-0290
F2
F3
F8
Exit without saving
F7
sec
F4
F6
F5
to gain access to the following display: (see following page):
Save /Copy cycle

programme
BABYPLAST UAI
PROGRAMME: Gear A
Customer
xxx
Material
Part weight
0,0
PROGRAMME
SAVE
Peso stampata
0,0
A
Gear
Numero stampo
000
Save changes in the mould

setting programme in use
Change programme name by
creating a new programme
F8
POM
gr
gr
Change
Tempo m Yes
YESdio salvato
Cancel sec
10.4
Last modification
01.01.2008
F7
F6
Exit without saving
F1
F2
F3
F4
F5
Press Change :
/home/root/Fm607/progs
Gear 1111
Gear 2345
Gear 4422
Gear A
Programme selected
Plug 2222
Key to change name

Confirm and exit
programme selected
file
Gear A
Exit without confirming
filter
Eliminate programme
selected
digit the new programme name (eg: Gear B)

Press the icon keypad
. The new programme created will be seen in the field file
confirm and exit from keypad by pressing
to confirm and exit.
( E.g. gear B) press the icon
D-0300
BABYPLAST UAI
D.4/MACHINE CONFIGURATION
MAIN MENU
F8
F7
00.0mm
F6
Gear part. n 2345
F2
F1
From the main menu press F6
F3
F4
Advanced
settings
F5
SET UP
15:25:33
February
F8
2008
Sun
Mon
Tue
Wes
Thu
Fri
Sat
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
F7
F6
Manufacturer
F1
Press F4
D-0310
F2
F3
Advanced settings User
F4
and enter PASSCODE 1212
F5
to gain access to ADVANCED USER SETTINGS:
BABYPLAST UAI
D.4.1/ MACHINE CONFIGURATION

Change language - Celsius/Farenheit
From DISPLAY SET UP press F4

the following display :
and enter the pass code1212 (see previous page) to gain access to
Change language
MACHINE PARAMETERS
Change to Celsius/Farenheit
Plastif. STANDARD:
plastification occurs before the
injection carriage movement
(default).
Plastif. DELAYED:
plastification occurs after the
injection carriage movement.
To use when the Babyplast shut
off nozzle is intalled.
Allows the mould to be opened
while plastification is in progress.
Language
English
Degrees
Celsius
Plastificat.
Standard
Machine ID number
F8
F7
Meter - Hrs
000045
Total hours
000045
Total cycles
001555
reset
F6
Modification with password
Machine identification number ( see page D-0370)

Meter - hours . every 1500 hours
there will be a reminder to change
the oil return filter. Press the word
reset to reset.
Total hours counter. Cannot be
reset.
F1
F2
F3
F4
F5
If
is selected, the settings can only be modified by
digiting the user password 1212
Total cycles counter. Cannot be

reset.
Press F3
to see the software versions installed in the 4 microprocessors mounted in the machine.
INFO
F8
F7
Software version display
Software version CPU
FMP252 FM607 Sw. Ver.: 1.00
F6
FMP252 FM542 Sw. Ver.: 2.22
Software version - prop. valve

Software version INVERTER
FMP252 FM542DSPSw. Ver.: 1.60

FMP000 FM549 Sw. Ver.: 1.02AV
Upgrade software: The icon is only

active if the USB memory stick is
inserted in the USB port on the
machine. ( see page. D-0350)
D-0320
BABYPLAST UAI

Temperatures
From DISPLAY SET UP press F4
to the following display:
and enter the pass code 1212 (see previous page) to gain access
Change language
MACHINE PARAMETERS
Plastif. STANDARD:
(default).
Plastif. DELAYED:
Language
English
Degrees
Celsius
Plastificat.
Standard
Machine ID number
F8
F7
Meter - Hrs
000045
Total hours
000045
Total cycles
001555
reset
F6
F1
Press F4 to
F2
F3
F4
F5
gain access to Machine parameters TEMPERATURES:
The value set, will be the toleranceband for the

temperature in use. If the operating temperature
increases or decreases by a value greater than
this set temperature, (i.e. goes out of the
tolerance band) the machine goes into alarm Tol.
band max error. Manual operation of the injection
piston and plastification will not be possible nor
will it be possible to enter an automatic cycle until
the operating temperatures are within this
tolerance band.
The stand-by temperature always depends on

the temperatures set in each of the mould
setting programmes and when active, the
heater zones will be seen in yellow. The standby temp. activates in the following cases:
1.When the heaters are switched on in
automatic.
2.When the machine is in alarm for a greater
length of time than the time out alarm.
3.When the heaters are switched on manually.
If the machine is in alarm for a time greater
than that set fo time out alarm, the heaters
will go into the stand-by mode. After double
the length of time, the heaters and motor will
be switched off.
When the heaters are switched on, they will
remain at the stand-by temperature for the
length of time set for pre-heating time
TEMPERATURES
Tol. band max. error
25
Temperature in stand-by
80
Timeout for alarm
min
Pre-heating time
180
sec
Heaters ON delay
00
min
The UAI machine can be powered up via an

external source, and in this case it is possible to set
a time to delay the moment that the heaters are
switched on. This function can be useful in the case
when the UAI machine is powered up by the main
injection moulding machine, and the UAI heats up
much faster than the main machine. By setting a
time delay, the heaters on the UAI machine will be
switched on later so that the UAI and main machine
can arrive at the working temperaures at virtually the
same time. This function is particularly useful when
Touch the field to be modifed, change the value by rotating the dial.
ATTENTION: If the actual temperatures exceed by more than double the value set in Tol. band max. error, the
machine will go in alarm 112..116 OVER TEMPERATURE.. - Motor and heaters will be switched off.
D-0330
BABYPLAST UAI

Times and settings
From display set up press F4
the following display:
and enter the pass code 1212 (see previous page) to gain access to
Change language
Plastif. STANDARD:
(default).
Plastif. DELAYED:
MACHINE PARAMETERS
Language
English
Degrees
Celsius
Plastificat.
Standard
Machine ID number
F8
F7
Meter - Hrs
000045
Total hours
000045
Total cycles
001555
reset
F6
F1
Press F5
F2
F3
F4
F5
to gain access to MACHINE PARAMETERS - TIMES AND SETTINGS:
ATTENTION: The value of 10mm MUST be

set if a 10mm injection piston is installed
on the machine. This setting will limit the
maximum injection pressure to 100 bar.
TIMES AND SETTINGS

Piston diameter
14
mm
Maximum injection pressure in manual and

purge.
Injection pressure
60
bar
Cushion
3,0
mm
Maximum cushion. If the cushion is more,

than the value set, for a number of cycles
greater than that set in the line Injection
incomplete (next line), the machine will go
into alarm 036 INJECTION INCOMPLETE
Injection incomplete
Beep at end of cycle
NO
Intrusion programme
NO
If the cushion is more, than the value set in

the previous line (Cushion), for a number of
cycles greater than that set in this line
(Injection incomplete), the machine will go
into alarm 036 INJECTION INCOMPLETE
If YES is selected, an acoustic sound
(beep) will be heard at end of each cycle.
If NO is set (default): Standard cycle.
If YES is set:Produces a pre-injection.
and a line will appear, in the INJECTION
menu, where it will be possible to set a
time to activate plastification before the
injection phase.
Set date and time
Touch the field to be modifed, change the value by rotating the dial.
D-0340
BABYPLAST UAI
D.4.4/ UPGRADE SOFTWARE
From the page DISPLAY SETTINGS press F4

access to the following screen :
and insert the assword 1212 (see previous page) to gain
Change language
MACHINE PARAMETERS
Plastif. STANDARD:
(default).
Plastif. DELAYED:
Language
English
Degrees
Celsius
Plastificat.
Standard
Machine ID number
F8
F7
Meter - Hrs
000045
Total hours
000045
Total cycles
001555
reset
F6
F1
Peress F3
ATTENTION:
F2
F3
F4
F5
to see the software versions loaded on the 4 microprocessors fitted to the machine
Upgrade diplay:
Upgrade CPU:
The folder FM607, suppplied by the manufacturer, should be

loaded onto a USB memory key
The fileFMP252_FM542Appl_V......mot should be present
Remove the cover found on the bottom side the display, and insert the USB memory stick into one of the two
USB ports as indicated.
D-0350
BABYPLAST UAI
Press F3
to see the software versions loaded onto the 4 micrprocessors fitted to the machine
:
ATTENTION: It is only possible to gain access to the following pages with the motor OFF
INFO
F8
F7
Software version of the Display
Software version of the CPU
FMP252 FM607 Sw. Ver.: 1.00
F6
FMP252 FM542 Sw. Ver.: 2.22
Software version of the Prop. valve

Software version of the INVERTER
FMP2527 FM542DSPSw. Ver.: 1.60

FMP000 FM549 Sw. Ver.: 1.01AV
Software upgrade icon is only active

when the USB memory key is
inserted. ( see page........)
Press F7

UPGRADE SOFTWARE
F8
Key FM607 (display) to load
upgrade file for the display from the
USB memory key
Key FM542 (CPU) to load
upgrade file for the CPU from the
USB memory key
FM607 (Display) Upgrade
F7
FM542 (CPU) Upgrade
F6
To upgrade software do as follows:

FM607 Display: press the corresponding key, the numeric key pad will apear, digit the password 1122 and
confirm. At the end press F7, remove the USB key switch off the machine at the main
switch and then switch it on again.
FM542 CPU:
press the corresponding key, the numeric key pad will apear, digit the password 1122 and
confirm the main directory of the USB key will appear, select the file:
FMP252_FM542Appl_V..... and confirm. At the end press F7, remove the USB key switch
off the machine at the main switch and then switch it on again.
ATTENTION:
When upgrading the CPU and Display together, it is possible to swith the machine OFF and
on again at the end of both operations.
D-0360
BABYPLAST UAI
D.5/ USB MEMORY STICK - Saving / retrieving mouldsettings
Remove the cover found on the bottom side the display, and insert the USB memory stick into one of the two
USB ports as indicated.
MAIN MENU
F8
F7
00.0mm
F6
Gear - art. 2345
F1
From the MAIN MENU press F5
D-0370
F2
F3
F4
F5
BABYPLAST UAI
ATTENTION:
the icons F4 and F5 are only activeif the USB memory stick is inserted into one of
the USB ports.
PROGRAMMES
F8
Programme selected
F7
Gear - art. 2345
F6
F1
F2
F3
F4
F5
By pressing the icon F4, a folder will be created in the USB memory stick called:
BabyFMP252_ID001 this folder will contain ALL the mould setting programme files found in the
machine. ATTENTION :If the folder already exists, any files, contained inside this folder, with the
same name will be overwritten
By pressing F5 all mould setting programmes in the folder BabyFMP252_ID001 will be loaded onto
the machine. ATTENTION the files with the same name will be overwritten.
ATTENTION: do NOT change the name of the folder created , the names of the files inside can be changed, but
not that of the folder otherwise it will not be possible to load the files (mould setting programmes)
not the machine
If more than one Babyplast are owned and in the case that each machine should have its own mould setting
programmes, it is possible to give each Babyplast a different ID number (machine Identification number ( eg: 01
- 02 - 03 ecc.) on the MACHINE PARAMETERS ( see page D-0320).
In this case, even if only one USB memory stick is used, different folders will be created with different names
based on the machine ID number
For example: BabyFMP252_ID001
BabyFMP252_ID002
BabyFMP252_ID003....ecc.
It will be possible to modify the position of files (mould setting programmes) and change their names inside the
various folders via a PC.
D-0380
BABYPLAST UAI
D.5.1/ PRINT AND ELEBORATE MOULD SETTING DATA ON A PC
1. Copy the folder

2.Open the programme
BP_Program_Viewer_v100 into a directory on a PC

BP_Program_Viewer_v100 found inside.
3.Select Open
4. using browse select the folder BabyFMP252_ID001 where the mould setting programmes (files) have been
previously saved. (see paragraph D.5 page D-0370)
D-0390
BABYPLAST UAI
5. Select the folder Progs and then the mould setting programme (file) required
6. Open
7. Once the mould setting programme (file) has been opened, it will be possible to print it, copy and past it into
another programme (such as Microsoft Word / exel etc) save it in a different format.
D-0400
BABYPLAST UAI
BABYPLAST UAI
E.1/ ALARMS
N
MESSAGE
CAUSE
ACTION
002EXTERNAL INPUT MISSING
Contact 3-11 open
Check guard or contact
004 MOTOR OVER HEATED
The motor has over heated
Check the power supply to the motor
005 OFFSET ANALOG INPUT FAULTY
Thermocouple analog inputs

faulty
Fault eeprom on CPU
Alarm is only present durng testing by

manufacturer
Switch machine OFF and then ON
again. If persists contact a technician.
Thermocouple faulty
Check thermocouple, wires and

connections. Change if necessary.
019 HOPPER OVER HEATED
Insufficient cooling at base of

hopper. If more than 70C,
machine goes into alarm
Check water flow and the

temperature of the cooling system.
020 OIL OVER HEATED
Insufficient cooling.
Temperaturover 60C
Faulty thermocouple cold joint
compensator on circuit board.
Faulty thermocouple cold joint
compensator in socket.
Check water flow and the

temperature of the cooling system.
Contact a technician
010 EEPROM FM542 ERROR

013 FAULTY THERMOCOUPLE HOPPER
014 FAULTY THERMOCOUP. PLASTIF.
015 FAULTY THERMOCOUP. INJ. CHAM.
016 FAULTY THERMOCOUPLE NOZZLE
017 FAULTY THERMO. FIXED MOULD
021 FAULTY INTERN. COMPENS. T/C

022 FAULTY EXTERN. COMPENS. T/C
023 OIL LEVEL LOW
Oil level is too low
024 NEUTRAL PHASE MISSING

026 PHASE MISSING
027 CURRENT FAULT
028 INVERTER ALARM
029 OIL COLD
Neutral phase not connected

Phase not connected
030 FAULTY OIL COMPENS. T/C

031 EMERGENCY
032 CHANGE FILTER
036 INJECTION INCOMPLETE
037 TIMEOUT MATERIAL LOAD
041 MAX CYCLE TIME EXCEEDE

043 TIMEOUT HIGH PRESSURE
E-0010
Check wires and contacts change NTC

component.
Check for leaks, check oil level float and
connections. Fill tank to correct level.
Check power supply connections

Check power supply connections
Check power supply voltage
Contact a technician
Inverter faulty
Oil temperature less than 20C Switch on the motor and / or wait for the
oil temperature to go above the
minimum temperature allowed.
Check wires and connectioins or
Oil thermocouple cold joint
change NTC component
compensator faulty
Emergency stop button activated Reset button or check external alarm
or input from external alarm.
source.
The machine has worked for
Change return filter and and reset hour
1500 hrs.
metre
The injection piston has not
1. Incomplete or no injection
reached the correct cushion
due to a part stuck in the mould cavity
positon (less than 3mm) for 8
or a blocked nozzle.
consecutive cycles see
2.Material load set too high. Reduce
pag.D-340
until cushion is under 3mm.
Activates if material does not
1.No material in hopper
load within 23 Sec. from the
2.Hopper chute blocked
start of plastification
Check hopper or plastification valve
Cycle has not been
completed within 90 sec.
No impulse from injection
pressure switch within 3 sec
from the start of high pressure.
Check at which point in the cycle, the

machine stopped.
Check the setting of the injection
pressure switch and that it functions
correctly. (page F-140 pos. 11)
BABYPLAST UAI
MESSAGE
CAUSE
Decompression point not reached

within 3 sec.
End of production batch.
045 END OF PRODUCTION BATCH
Faulty proportional valve
046 DSP COMMUNICATION PROBLEM
047 PROBLEM WITH CIRCUIT BREAKER Faulty circuit breaker
048 CYCLE TIME OUT OF TOLERANCE The quality control function is
activated and the cycle time has
gone out of tolerance
051 FAULTY INJECTION TRANSDUCER Faulty transducer readings
044 TIMEOUT DECOMPRESSION
052 CUSHION OUT OF TOLLERANCE

054 TIME-OUT CORE PULL A
055 TIME-OUT CORE PULL B
064 TIME-OUT PLASTIF. HEATER
065 TIME-OUT INJ. CHAMBER HEATER
066 TIME-OUT NOZZLE HEATER
067 TIME-OUT MOULD HEATER
069 TIME-OUT MACCHINA FERMA
Activates if the heaters have not

072 NOT REACHED PLASTIFIC. TEMP.
073 NOT REACHED INJ. CHAMBER TEMPyet entered within the tolerance
bands and the operator attempts
074 NOT REACHED NOZZLE TEMP.
to use plastification or injection
075 NOT REACHED MOULD TEMP.
functions.
080 ERROR PLASTIFICATION TEMP.
081 ERROR INJ. CHAMBER TEMP.
082 ERROR NOZZLE TEMP.
083 ERROR MOULD TEMP.
Temperatures out of tolerance

(+ 0 -) band during cycle.
106 SHORT CIRCUIT PROP. VALVE
Faulty proportional valve
108 INVERTER OVER HEATED
Check the injection valve.

Reset counter / start a new batch.
Contact a technician.
Contact a technician.
Check the cause Increase the % set for tolerance band.
Check connections
Quality control function activated Check the cause / cycle parameters.

Increase the % set for tolerance band.
- cushion value out of tolerance
check mould and connection of sensors
No consensus for core pull
Activates when the heaters do not

reach the set temperature within
30mins.
(manufacturer setting by default)
Activates when machine remains
with heaters and motor ON, but
without running a cycle, for more
than 30 mins. (manufacturer
setting by default)
070 AUTO-OFF FOR MACHINE STOPPED Activates after the machine has
been in alarm for more than 6
mins. (user setting page D-0330).
Motor and heaters are switched
OFF.
Faulty CPU
071 CONNECTION PROBLEM FM542
107 PEAK NOT REACHED
ACTION
Reset the alarm, switch the machine

OFF and check heaters and
connections.
Reset the alarm and switch ON the

motor and heaters.
Reset the alarm and switch ON the

motor and heaters.

Exit from Automatic/Semiautomatic/
Purge and wait for the temperatures to
enter within the respective tolerance
bands
Check thermocouples and connections.
Switch the machine OFF and ON again

If persists contact a technician.
Set injection pressure not reached Increase injection time.
Check injection pressure transducer
connections.
Check cooling circuit , valve and
Inverter temperature has gone
thermocouple which control the tempeover the operating temperature
rature.
allowed.
E-0020
E
N
MESSAGE
CAUSE
BABYPLAST UAI
ACTION
112 OVER TEMPERATURE PLAST.

113 OVER TEMPERATURE CHAMBER
114 OVER TEMPERATURE NOZZLE
115 OVER TEMPERATURE FIXED MOULD
116 OVER TEMPERATURE MOV. MOULD
The actual temperature has gone 1. Set a higher temperature setting that
is within the tolerance band or wait for
out of tolerance by double the
the machine to cool to a suitable
maximum tol. temp .set
temperature.
(page D-0390) because:
2. Contact a technician.
1. A temperature has been
changed while the machine is still
hot and the new value is out of the
tolerance band by double.
2. A faulty triac or optoisolator has
caused a short circuit in the heater.
128 DATA LOAD FM542 KO

129 DATA LOAD INVERTER KO
130 COMUNICATION FM542 KO
131 COMUNICATION INVERTER KO
Data load failure while starting

machine
E-0030

E-0020
BABYPLAST UAI
F/ MAINTENANCE - DIAGRAMMES
F.1/ Maintenance
All the materials used in the construction of BABYPLAST 6/10 have been studied so that
they require minimum maintenance and are easy to replace.
OIL:
The oil and filters must be kept clean and must be replaced within the recommended
periods so that the hydraulic equipment does not wear prematurely.
RECOMMENDED PERIODS FOR OIL CHANGE: = 2000 to 5000 HOURS ( acc. to oil type)
FILTER: = 1500 HOURS
COOLING SYSTEM
If treated water is used, so as to avoid calcium deposits from forming, no maintenance is
required. If treated water is not used, the system will have to be cleaned depending on calcium
level in the water.
MOVEABLE PARTS:
All the moveable parts, that are subject to friction, are lined with TEFLON, including the
mobile platen with the STD bushings, and therefore, apart from the normal cleaning, no
maintenance is required. (However, the wear on the bushings ought to be checked
regularly).
GASKETS:
All the gaskets are fitted with bronze reinforced PTFE friction strips, and O-ring
seal. Check the that the surfaces correspond before joining.
ELECTRICAL EQUIPMENT.
Inspect the ventilator in the electrnics compartment, particularly in hot weather, keep the
unit dry and clean, and make sure the connections are well-maintained. Do not use used
parts when replacing elements, especially where FUSES AND TRIACS are concerned.
Electrical maintenance should be carried out by qualified personel only.
HEATING EQUIPMENT:
Seeing as all the heating elements are standard and the thermocouples are independent,
they are easy to maintain. If other thermocouples are used,they should be a ground
isolated "J"-type to avoid disturbances from electrical noise. The Nozzle has an
armoured heating element which is fixed in place by a cup shaped protecive cover.
Keep this assembly as clean as possible and check the condition of wiring regularly for
damage etc.
INJECTION CHAMBER
has two 8 x 80 diameter bulb type 230 W 110 V heating elements which need to
be checked regularly. Keep this assembly as clean as possible and check the condition
of wiring regularly for damage etc.
PLASTIFICATION CHAMBER
The plastification chamber is heated by a - 230V 1000W 37mm diam x 76mm heater band for
the standard UAI and a 230V 1000W 60 diam. x 120mm heater band for the augmented
version. These heater bands guarantee an optimal and uniform heat distribution which is
essential for technical polymers. Keep this assembly as clean as possible and check the
condition of wiring regularly for damage etc.
F-0010
BABYPLAST UAI
F.2/ Electro-mechanical diagramme
F-0020
BABYPLAST UAI
F
F.2/ Electrical diagrammes- Power connections
F-0030
BABYPLAST UAI
F.2/Electrical diagrammes - OUTPUT connections
F-0040
BABYPLAST UAI
F
F.2/ Electrical diagrammes - INPUT connections
F-0050
BABYPLAST UAI
F.2/ Electrical diagrammes- Inverter/CPU/Display connections
F-0060
BABYPLAST UAI
F
F.2/ Electrical diagrammes- DISPLAY PANEL Connection
F-0065
BABYPLAST UAI
F.2/ Electrical diagrammes- Interface boards INPUTS /OUTPUTS part n 30902600 (FM578)
F-0070
BABYPLAST UAI
F.2/ Electrical diagrammes- CPU board UAI part n 30902700 (542-1uai) Layout
F-0080
BABYPLAST UAI
F.2/ Electrical diagrammes- Power board part n 30902800 (542-2UAI) Layout
F-0090
BABYPLAST UAI
F.2/ Electrical diagrammes - Display board part n 30903200 (FM607A) Layout
F-0100
BABYPLAST UAI
F.2/ Electrical diagrammes - Inverter board part number 30902300 (FM549BP) Layout
ATTENTION:
F-0110
When removing, do not separate the electronic board from the aluminium
base. Otherwise damage can be caused to the board.
BABYPLAST UAI
F.2/ Electrical diagrammes-Interface board. INPUTS / OUTPUTS part n 30902600 (FM578)

Layout
F-0120
F-0130
female
0 Volt
578 J3 (2)
8-16
7-15
4-12
START. - UAI starts a cycle and is activated by

closed contacts (impulse) i.e. mould closed.
POWER ON/OFF IN
External impulse to switch on/off
motor and heating elements. Example,
if main machine is programmed to
switch on at a set time, it can also
switch on the UAI. close contact ON
close contact again OFF - Functions
only if programme present in software.
MANUAL / AUTOMATIC
select function mode. Closed:
automatic & unit can be started by
machine Open: manual & unit started
via control panel only
578 J2(4-9)
578 J2(1-9)
578 J2(3-9)
SAFETY DEVICES: When closed Injection unit can

3-11 start cycle. used if additional protection is used for 578 J2(2-9)
example.
EMERGENCY IN: When open, Injection unit is in 542 J513

alarm - pump and heaters are off
1-9
Connector
DESCRIPTION
INPUTS
PIN
male
578 J5(4-11)
OUT END CYCLE

Closed when the injection unit has finished the
cycle & main machine can continue cyle.
OUT END INJECTION

Closed when the injection unit has finished the
injection & main machine can continue cyle.
REJECT OUT
closed for 5 sec. if Q.C. has failed
MODE OUT
20-28
21-29
23-31
24-32
Closed: key set on automatic (without alarms).

Open: key set on manual. Can be used to prevent
main machine starting UAI when in manual mode.
578 J5(6-11)
OUT READY
closed when Injection unit is ready to
accept START (motor ON - Temperatures
within tolerance bands)
19-27
578 J5(3-11)
578 J5(2-11)
578 J5(1-11)
Injection unit stopped (e.g. end of batch, not in 578 J5 (7-10)

temp.) Closed: UAI in alarm, heaters & motor on
EMERGENCY OUT
Emergency
Open: Injection unit in alarm or motor OFF. Used Stop Button
to send main machine in alarm.
DESCRIPTION
18-26
17-25
PIN
OUTPUTS
CRONOPLAST
Input / output sockets
BABYPLAST UAI
F.2/ Interface INPUTS / OUTPUTS
IN
Hopper cooling
OUT
Cooling fluid
IN
Cooling fluid
INPUT / OUTPUT cooling fluid
OUT
Hopper cooling
Decompression
Injection
Plastific. back
Plastification
Injection carriage forward
Injection carriage back
Hydraulic and cooling outputs for Injection unit
F
BABYPLAST UAI
F.2/ Hydraulic and water connections - Injection unit
F-0140
F-0150
POWER SUPPLY TO DISPLAY +

CANBUS
1 (+) Brown
2 (CAN) Grey
6 (CAN) White
7 (- ) Metal shield
3-8 EMERGENCY
4-9 EMERGENCY OUT
5-10 Selector Manual/Autom.
INPUT / OUTPUT Consol
11 Brown
23 Yellow Injection transducer
12 Blue
24 Metal sleeve
10(+)-22(-) Hopper thermocouple
9 - 21 Compensation sensor
7(+)-19(-) Chamber thermocouple

8(+)-20(-) Nozzle thermocouple
6(+)-18(-) Plastific. thermocouple
3-15 Nozzle heating element
2-14 Chamber heating element
1-13 Plastification heating element
INPUT / OUTPUT Injection unit
BABYPLAST UAI
F.2/ INPUT / OUTPUT CONNECTIONS - Injection unit consol
INJECTION
INJECTION
CARRIAGE
OIL TANK
PLASTIF ICATION
PRESSURE
C30400300
40202900
402.6950200
30706800
402.2001257
OC9001003
043306105600000
OC9001053
C40203700
C40203600
13
12
11
10
9
8
7
6
Solenoid S5L35HRL 12VDC 23W Cl.H

Prop. valve V EP5A2R10.77K0604NA
Screw M6x6 with diam. 0,6mm hole
Pressure transducer 250 bar - 10v

Pressure switch 50 - 150bar
Screw M8x8 with diam.0,5mm hole
Valve VSON.08A
1
1
1
1
1
Nozzle forward
Nozzle back
1
BABYPLAST UAI I/10P
2
1
2
1
1
1
1
1
OFEO8506RL0101
Solenoid S8.356HRL.24DC 20W Cl.F

Valve ES OD 14315843
402.2001098
40202000
Hydraulic diagramme

Valve OD 1510181AS00

Valve VED8I4306.58K32.44NCD215
Valve ES OD 1502182
402.2001098
402.2001100
402.2001098
402.2001102
402.2001098
40201900
Pressure release
1
1
1
1
1
1
1
1
1
1
Plastification
Suction filter
Return filter
Maximum pressure reg. DBDS
Motor 3 phase - 330V - 50hz
Pump 3,5l
Pressure gauge 160 bar
Valve Accumuletor (optional)

Radiator assembly
Injec tion
Decom pression
10000500
407.2001134
407.6801200
402.6252710
40201900
A CCUMULETOR
OPTIONAL
18
17
16
15
14
F
BABYPLAST UAI
F.2/ Hydraulic diagramme
F-0160
A 10003000
B 10000500
F-0170
Heat exchanger assembly
Motor - pump assembly
BABYPLAST UAI
F.2/ MOTOR - PUMP assembly
BABYPLAST UAI
F.2/ STANDARD UAI INJECTION UNIT max 15cc
F-0180
BABYPLAST UAI
Part number
DESCRIPTION
F.2/ AUGMENTED UAI INJECTION UNIT max 36cc
F-0190
BABYPLAST UAI
F.2/ Diagramme to show connections for VENTURI loader (Optional)
C1
B1
D
C
B
E
AIR
Venturi
IN
AIR
Venturi
1. Insert the venturi valve A into tube B. connect the tubeB
to connection point B1 and return tube C to C1.
2. Connect sensor D to the socket on the control cabinet via
the cable included.
E1
3. Connect the 6mm diam. air supply tube to E and E1.
4. Insert the stainless steel suction tube A into the container
F which contains the plastic granuals ready for suction.
5. Insert the free end of the return tube C into the container
but do not insert it into the granuals.
6. Connect the external air supply to connection point G
G
(IN).
IN
7. To activate the venturi loader, see page on
PLASTIFICATION in the AUTOMATIC menu (Instruction
manual pag. D-0100 Par. D)
ATTENTION: in case of difficulties for the granuals to fall into the plastification cylinder of the machine, it is
possible to insert a 4mm air tube inside the hopper, connected to connection point H to help solve the
problem. See following pages.
ATTENTION: USE DRIED AIR ONLY
F-0200
BABYPLAST UAI
F.2/ Air blow connection for Venturi loader

ATTENTION: in the case of using soft materials (TPE or similar) it can happen that there are problems for
the material to fall from the venturi hopper into the machine plastification cylinder. In such a case it is possible
to insert a small 4mm tube inside the hopper, so that it arrives near the throat of the hopper where the
material falls through. In this way it is possible to activate air blow into the material each cycle and ensure
that the material falls through.
Connect an airtube from connection point H on the hopper to connection point H1 on the control cabinet. To
activate airblow during the cycle, set a time on the line air blow time in the injection page (page D-120), and
for each cycle the valve will activate for the time set.
Via key F5 in the MANUAL MENU ( page D-050) it is possible to activate it manually.
H
H
4mm
AIR
Venturi
AIR
Venturi
H1
IN
IN
ATTENTION: USE DRIED AIR ONLY
F-0210

UAI Prop Eng TS

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Babyplast UAI I/10P

CERTIFICATE OF CONFORMITY TYPE "B

A/ General conditions and characteristics of BABYPLASTUAI-I/10P .

B/ Installation of the BABYPLAST UAI-I/10P........................................................................ B-0010

C/ Before start up................................................................................................................... C-0010

D/ How to use a BABYPLAST UAI- I/10P ........................................................................... D-0010

F/ Maintenance - Diagrammes............................................................................................................. F-0010

GENERAL SAFETY REGULATIONS

To be studied carefully before starting up the machine

A.3/ TECHNICAL DATA

All dimensions are in mm.

A.3.2/ GENERAL DIMENSIONS OF THE BABYPLAST I/10P INJECTION UNIT.

All dimensions are in mm.

A.3.2b/ GENERAL DIMENSIONS OF THE STANDARD INJECTION UNIT Vertical version

All dimensions are in mm.

A.3.2c/ GENERAL DIMENSIONS OF THE AUGMENTED INJECTION UNIT

All dimensions are in mm..

A.3.2d/ GENERAL DIMENSIONS OF THE AUGMENTED INJECTION UNIT

All dimensions are in mm

A.3.3/ INJECTION UNIT BABYPLAST I/10P,

HYDRAULICAL AND ELECTRONICAL CONTROL UNIT

Injection unit multi pin socket

A.3.4/ TECHNICAL DATA

Injection pressure (Kg/cm2 ) :

Plastification rate (gr/sec):

Injection unit weight (Kg):

Total weight (Kg):

Oil tank capacity :

ATTENTION: A CIRCUIT BREAKER MUST BE USED AT THE MAINS CONNECTION.

A.3.5/ DIAGRAMME TO SHOW INJECTION PRESSURES (standard injection unit)

Specific pressure on material

A.3.6/ DIAGRAMME TO SHOW INJECTION PRESSURES (Augmented version)

Specific pressure on material

B/ INSTALLATION OF THE BABYPLAST UAI I/10P

MAIN DIMENSIONS FOR FIXING THE INJECTION UNIT TO A MOULD

B.3/ INSTALLING AND FIXING THE INJECTION UNIT TO A MACHINE PLATEN

All dimensions are in mm.

B.4/ ELECTRICAL CONNECTIONS for 400V power supply

3 phase + neutral + earth - 400V - 50/60Hz

B.4/ ELECTRICAL CONNECTIONS for 230V power supply

3fasi + terra - 230v - 50/60Hz

10A - 500V - rapid blow

8A - 250V - rapid blow

8A - 500V -extra rapid

500V/ 1.500A - 250V/10.000A

B.5/ COOLING SYSTEM

This is needed to:

WATER IN : INLET TUBE diam. 8 mm approx.

B.6/ FILLING THE HYDRAULIC OIL TANK

Characteristics of the oil:

RANGE: -15C +80C

Oil return filter

Oil fill cap

B.7/ SYSTEM CHECK

B.7/ INSTALLING THE INJECTION UNIT

MAIN SWITCH / EMERGENCY STOP

Attention: activate only if the mould has been

IN CASE OF AN EMERGENCY, THE MAIN

C.2/ EMERGENCY STOP

C.3/ DISPLAY PANEL

C. REFERENCES FOR ICONS

C.4/ INJECTION PRESSURE GAUGE

INJECTION PRESSURE GAUGE