TRAVERSE AUTOMATIC UNLOADER CY-600GII OPERATION MANUAL · Thank you for purchase of the Star Traverse Automatic Unloader. ... This manual includes important safety precautions relating

TRAVERSE AUTOMATIC UNLOADER

OPERATION MANUAL

CY-600GIICYS-600GIICY-800GIICYS-800GII

GⅡⅡⅡⅡ

INTRODUCTIONThank you for purchase of the Star Traverse Automatic Unloader. When linked to a molding machine,

the unloader will automatically remove products from the mold and transport them to a conveyor belt to

other designated location. This manual describes the unloader's functions and presents important

information about operating methods and precautions. Please read through this manual carefully so that

you will be able to use the unloader safely and effectively. Keep this manual in a place of easy access.

* This manual describes the standard model. For optional specifications, refer to corresponding separate

manuals.

Contents

MACHINE SECTION

1. FOR SAFE OPERATION................................................................... 11-1. Manual Organization ............................................................................................... 1

1-2. Safety-Precaution Indications .................................................................................. 1

1-3. Safety Precautions ................................................................................................... 2

1-4. Locations of Warning Labels................................................................................. 10

1-5. Mechanical Specifications ......................................................................................11

2. NAMES OF THE PARTS AND THEIR FUNCTIONS........................ 122-1. Configuration Diagram.......................................................................................... 12

2-2. Motion Patterns...................................................................................................... 12

2-3. Product-Side Vertical/Crosswise Unit ................................................................... 13

2-4. Runner-Side Vertical/Crosswise Unit (CYS model).............................................. 15

2-5. Traverse Rail Unit.................................................................................................. 17

2-6. Valve Unit .............................................................................................................. 19

2-7. Locations of Limit Switches.................................................................................. 22

3. AUTOMATIC UNLOADER SETTINGS ............................................ 243-1. Before Making Settings ......................................................................................... 24

3-2. Setting Procedure................................................................................................... 28

4. MAINTENANCE AND INSPECTION ............................................... 39

5. PARTS LIST .................................................................................... 43

6. EXPENDABLE PARTS LIST............................................................ 44

7. AIR CIRCUIT DIAGRAM ................................................................. 46

8. GENERAL DRAWING ..................................................................... 48

- 1 -

1. FOR SAFE OPERATION

1-1. Manual Organization

This manual includes important safety precautions relating precautions relating to unloader functions,

settings, maintenance, and operation. Please observe these precautions so as to ensure safe operation at

the unloader.

Note that this manual is part of a three-volume set, and must be read in conjunction with the controller

"Operation section" and "Technical section". Please read through all of these manuals carefully before

beginning use of the unloader.

1-2. Safety-Precaution Indications

Symbol of danger levelsCautions are classified depending into the following three levels on risks or damage that may arise

from improper operation.

DANGERIndicates that misapplication of the machine willlead to death or critical injury.

WARNINGIndicates that misapplication of the machine mightlead to death or critical injury.

CAUTIONIndicates that misapplication of the machine maylead to bodily injury or property damage.

Point

Important points for operation procedures are displayed with mark in this manual.

- 2 -

1-3. Safety Precautions

DANGER

Do not enter the operation range.

Do not enter the operation range of the machine. You may be caught or lodged in themachine resulting in injury.

Do not maintain the machine during operation.

Do not maintain the machine while it is in operation. Shut down the air supply and turn off thepower switch on the operation panel and the power circuit breaker before maintenance.

WARNING

Clothing must be proper for working.

Wear proper clothes for working. To avoid injury from trapping, do not wear too largeclothes or costume jewelry/accessories.

Do not modify the machine.

Do not modify the machine. STAR assumes no responsibility for accidents or failurescaused by modifications to the machine by users.

Ground the machine.

To avoid electric shock, ground the machine in accordance with the relevant regulationin your country. When a routine inspection is made or the conveyor is relocated, checkthat the machine is grounded appropriately.

Use a non-fuse circuit breaker.

To prevent fire resulting from overcurrent, use a non-fuse circuit breaker for wiring tothe power source.

Do not open the electric box.

A high voltage is applied in the electric box. Opening it may result in electric shock or injury.

- 3 -

Do not touch the machine during operation.

To prevent trapping accidents, do not insert your hand in the machine while it is running.

Shut down operation during periods of frequent power outage.

The machinery should be shut down during times when power supply is frequentlygoing off due to thunderstorm or other such external event. Operating with an irregularpower supply may lead to equipment damage.

CAUTION

Determine the supervisor for performing operation.

Determine the supervisor when teaming up with two or more operators for makingmachine adjustments, etc.

Pneumatic source

To protect pneumatic components from damage, supply dry air using a dryer. After-coolers and air dryers are available from STAR. Contact your local distributor whennecessary.

Read this instruction manual thoroughly.

Read and follow the operational procedures and precautionary remarks provided in thismanual.

Provide an enough maintenance room around the machine.

Provide a 1-m-wide or larger maintenance room around the machine for safe operation.Keep obstacles clear of the room.

Tidy up the area around the machine.

Tidy up the area around the machine, and keep the area well illuminated.

- 4 -

Perform maintenance daily.

Perform maintenance daily and check that the machine is in normal conditions. Contactyour local distributor in the event of failure.

Stop operation in the event of failure or abnormality.

If an abnormality or failure is found during operation, stop the machine and follow thedirections from your local distributor.

When running the machinery...

Never touch keys or switches with wet or dirty hands.

Do not use the machine under the following environment.

• Place where ambient temperature is 0℃ and less or 40℃ and more.

• Place where the machine is exposed to dust, chemicals or steam.

• Place where it is highly humid and condensation occurs.

• Place where strong electric field or magnetic field occurs.

• Place where it is poorly ventilated.

• Place where heavy vibration occurs.

Post clear indication of ongoing maintenance and repair work.

When carrying out inspection, repair, adjustment, cleaning, or lubrication work within theunloader's movement range, be sure to lock the POWER switch. Post an appropriate sign on theoperation Panel to ensure that no one switches on the machinery while work is in progress.

Use secure scaffolding.

Some inspection, repair, adjustment, cleaning, and lubrication work must be carried out whilestanding on a platform or scaffold. Be sure that the stand is securely set up, and wear a safety belt.

Stop all linked devices when working on the unloader.

Before carrying out inspection, repair, adjustment, cleaning, or lubrication work withinthe unloader's movement range, you must shut down not only the unloader itself but alsoall devices that are linked to it (such as the molding machine and conveyor).

- 5 -

Types of warning labels

Do not enter within the movable range.

Warning label for downward movement

Warning label for horizontal movement

Warning label for travelling movement

The unloader has a movable range at highspeed.Do not enter the movable range duringautomatic operation.Be sure to turn OFF the power and the airpressure before all or part of your body entersin this range for maintenance or any otherreason in manual operation mode.

- 6 -

Warning label for high voltage

Be sure to turn off the circuit breaker in thecontrol box during maintenance.In particular, disconnect the cable to themolding machine before performingmaintenance on the control box, and turn offthe primary power of the plant.

This label can be found at the locations(terminal block, etc.) where special attentionis required in the range of high voltagewarning.

- 7 -

Precautions for travel adjustment

Refer to the operation manual for traveladjustment of movable parts. Makeadjustments in a safe way.Even if the power and the air pressure areturned off, some pressure may remain in the aircylinder. The cylinder may move abruptly. Besure to wear protective equipment foradjustment. Avoid adjustment within themovable range.

Warning for high temperature on the motor

Temperature of the motor is high duringoperation. Do not gain access to the motorduring operation.Wait until the temperature becomes low afterthe power is turned off before touching themotor for maintenance.

- 8 -

Warning for being caught

Do not inadvertently touch the parts such asmotor, spindle, gear, pulley or belt, that maycatch, within the movable range formaintenance or any other reason.Turn off the power and the air pressure beforeaccessing the machine.

Warning for contact with blade

Do not inadvertently touch the blade ofnippers for maintenance or any other reason.Turn off the power and the air pressure beforegaining access to the machine.

- 9 -

List of hexagon wrench size and min. tightening torque

<Caution>

Tighten bolts at least with the standard torque specified above.After tightening a bolt, be sure to check that it is secured on the tightening surface.Shallow tightening tap or clogged chips inside the tap may prevent a bolt from beingtightened even when it's been tightened with the specified torque.Use values of the tightening force F and the point of application of force L3 asguides.Check bolts for looseness every month.

Boltsize

Hexagonwrench

size

Dim. C(mm)

LengthL1 x L2 (mm)

Min. Tighteningtorque Nm(kgf•cm)

Tighteningforce F as aguide (kgf)

Point ofapplication offorce L3 (mm)

M4 3 3.0 20 x 125 3.0 (30) 6.0 50

M5 4 4.0 25 x 150 6.2 (63) 6.3 100

M6 5 5.0 28 x 165 9.9 (101) 10.1 100

M8 6 6.0 32 x 180 22.0 (224) 14.9 150

M10 8 8.0 36 x 200 48.0 (490) 16.3 300

M12 10 10.0 40 x 225 86.0 (878) 14.6 600

M14 12 12.0 50 x 125 114.0 (1163) 19.3 600

M16 14 14.0 50 x 140 142.0 (1449) 24.2 600

M20 17 17.0 60 x 180 276.0 (2816) 21.7 1300

M24 19 19.0 80 x 180 495.0 (5051) 38.8 1300

- 10 -

1-4. Locations of Warning Labels

The following diagram shows the location and content of caution plates affixed to the unloader.

Example of caution plates disposition

- 11 -

1-5. Mechanical Specifications

Model CY-600GII CYS-600GII CY-800GII CYS-800GII

Power supply Single phase 200VAC ±10% 50/60Hz

Required power 0.9 kVA

Normal air pressure0.49MPa [5 kgf/cm2]

(No water content or dust allowed in air)

Maximum permissible air pressure 0.69 MPa [7 kgf/cm2]

Product-side Air cylinderVertical

Runner-sideAir cylinder

Product-side Air cylinderCrosswise

Runner-sideAir cylinder

Traverse AC servo motor

Drivingmethod

Posture Air cylinder

Product-side 600 800Vertical(mm)

Runner-side 650 850

Product-side 150Crosswise

(mm) Runner-side 100 100

Traverse (mm) 1400 1200 (1600) <1000>

Stroke

Posture Fixed at 90°

Maxi. Load weight (kg)*(including weight of chuck)

3kgCylinderoutput

(at 0.49MPa) Posture torque (Nm) 4.45 N ∙ m [45.4 kgf-cm]

Air consumption (N /cycle) 15.4 19.8 18.9 24.5

* Values in [ ] represent the conventional units.* These specifications are subject to change without prior notice.* shows 1200mm traverse stroke specification.* ( ) shows 1600mm traverse stroke specification.* < > shows 1000mm traverse stroke specification.

- 12 -

2. NAMES OF THE PARTS AND THEIR FUNCTIONS

2-1. Configuration Diagram

2-2. Motion Patterns

Product side vertical unit Runner side vertical unit (CYS)

Crosswise unit

Product-side vertical unitRunner-side vertical unit

Valve unit

Traverse rail unit

- 13 -

2-3. Product-Side Vertical/Crosswise Unit

◯1 Vertical stroke adjustment stopper

This stopper sets the vertical stroke by adjusting the position.

◯2 Ascent end shock absorber

This absorber absorbs shock at the end of ascending.

◯3 Vertical cylinder

This cylinder moves the vertical arm up and down.

◯4 Vertical LM guide

This guide supports vertical movement of the arm.

◯5 Absorber bracket

This bracket sets crosswise standby position and crosswise stroke by adjusting the position.

◯6 Shock absorber for advance end

This absorber absorbs shock at the end of advancement.

◯7 Shock absorber for descent end

This absorber absorbs shock at the end of descending.

◯8 Return end automatic switch (LS-6)

This switch is used to confirm that vertical arm completes returning.

◯9 Crosswise cylinder

This cylinder is used to advance and return the vertical arm.

- 14 -

◯1 Crosswise LM guideThis guide holds crosswise straightness.

◯2 Chuck mounting plate (link bracket)The chuck plate is mounted here.

◯3 Posture action speed controllerThis controller controls the posture action speed.

◯4 Posture cylinder

This cylinder turns the posture section 90° inreverse.

◯5 Posture return speed controllerThis controller controls the posture return speed.

◯6 Ascent end proximity switch dog (for LS-3)This dog is used to activate the ascent endproximity switch

◯7 Posture return limit automatic switch (LS-8)This switch is used to confirm the posturecompleted returning.

◯8 Ascent end proximity switch (LS-3)This switch is used to confirm that the vertical armcompleted ascending.

◯9 Connection terminal for wiring of product-in-chuck confirmation limit switchWhen the product confirmation limit switch is usedinside the chuck, the switch is connected to thisplug.

POINT This connector can be connected only to themachine-type limit switch.

◯10 Release prevention vertical lock cylinderThe release prevention cylinder activates andprevents the posture section from being releasedwhen the air pressure is reduced with the pressurerelief cock, etc.

◯11 Posture action end auto-switch (LS-9)This switch is used to confirm that the posture sidecompleted action.

①

②

④

③

⑤

⑥

⑧

⑦

⑨

⑩⑪

- 15 -

2-4. Runner-Side Vertical/Crosswise Unit (CYS model)

◯1 Vertical stroke adjustment stopper plate

This plate sets the descending stroke by adjusting the position.

◯2 Runner advancement speed controller

This controller controls runner advancement speed.

◯3 Crosswise cylinder

This cylinder advances or returns the vertical arm.

◯4 Runner return speed controller

This controller controls runner return speed.

◯5 Advance end shock absorber

This absorber absorbs shock at the end of advancement.

◯6 Crosswise stroke adjustment stopper bolt

This bolt sets crosswise stroke by adjusting the position.

①

② ④③

⑤ ⑥

- 16 -

◯1 Crosswise LM guide

This guide supports the crosswise movement of the vertical unit.

◯2 Descent end shock absorber

This absorber absorbs shock at the end of descending.

◯3 Ascent end proximity switch (LS-3S)

This switch confirms that the runner chuck completed ascending.

◯4 Releaser prevention vertical lock cylinder

The release prevention cylinder activates and prevents the runner chuck section from being

released when the air pressure is reduced with the pressure relief cock, etc.

◯5 Runner confirmation sensor in the chuck (LS-4S)

This sensor confirms that the runner is securely chucked.

◯6 Runner chuck

This unit chucks the runner and unload it.

◯7 Ascent end shock absorber

This absorber absorbs shock at the end of ascending.

⑤

②

③

④

①

⑦

⑥

- 17 -

2-5. Traverse Rail Unit

◯1 Pressure reducing valve with filter(Refer to the corresponding operation manual.)

◯2 Residual pressure releasing cockThis cock reduces the air pressure of thepressure reducing valve with filer to 0 Mpa andthoroughly discharge air remaining in eachcylinder.

POINT Be sure to keep this residual pressurereleasing cock closed when using theunloader.

◯3 AC servo motor◯4 Release-side area proximity switch (LS-12)

This switch is activated when the carriage unit isnot positioned above the molding machine.

◯5 Traverse over run proximity switch (LS-2)This switch is activated when the traverse overrun position is detected.

◯6 Traverse home position proximity switch(LS-1)This switch is activated when the traversehome position is detected.

◯7 Traverse home position proximity switchdog (for LS-1)This dog turns on the traverse home positionproximity switch.

◯8 Extract-side area proximity switch (LS-10)This switch is activated when the carriage unit ispositioned in the area where products can beextracted.

◯9 Extract-side area proximity switch dog(for LS-10)This dog turns on the extract-side area proximityswitch (LS-10).

② ① ⑦⑥⑤④

③

⑨⑧

- 18 -

◯1 Toothed belt for traverse (iron rubber AT belt)

◯2 Transverse LM guide

This guide supports movement of the carriage unit.

◯3 Release-side traverse end stopper

This stopper adjusts the release-side traverse position.

* This stopper is also used for possible runaway of the machine.

◯4 Link-less cable chain

This chain guides and protects the wire and pipe.

◯5 Traverse over run proximity switch dog (for LS-2)

This dog turns on the traverse over run proximity switch.

◯6 Release-side area proximity switch dog (for LS-12)

This switch dog turns on the release-side area proximity switch.

②①

③ ⑥⑤

④

- 19 -

2-6. Valve Unit

CAUTION• Never attempt to adjust the air cylinder while automatic operation

is in progress, as this can be dangerous. Switch operation toMANUAL mode before making the adjustment.

• Do not set the air cylinder speed too high, as this may result inequipment damage. Begin adjustment at slow speed, andincrease the speed gradually to the appropriate level.

• When possible, avoid using the manual operation button on thesolenoid valve. Instead, execute operation from the control box.If you cannot avoid using the switch on the valve, proceed withcare. Note that wiring and piping may move in unison with the aircylinder: be careful to avoid entanglement.

• Note that the solenoid valve may become hot during operation,and may remain hot for some time after power is shut off. Don'ttouch the solenoid until you are sure it has cooled off.

POINT

Be sure to set the controller POWER switch to OFF before using the manual operation

button on the solenoid.

Note that forward and return operation may not be available.

- 20 -

② ①③

④

⑤

⑥⑬

⑰

⑫

⑪

⑩

⑨

⑧

⑦

⑮

⑭

⑯

- 21 -

◯1 Unload-side descending high speed control

◯2 Produce-side descending speed control

◯3 Runner-side descending speed control

◯4 Product-side ascending speed control

◯5 Runner-side ascending speed control

◯6 Manual operation button for the product side high speed descent

If pressed concurrently with 16, the product side vertical arm descends with high speed.

◯7 Posture action manual operation button

Pressing this button starts the posture of the product chuck section.

◯8 Produce-side advancement manual operation button

Pressing this button advances the product-side vertical arm and releasing the button returns the

arm.

◯9 Runner-side advancement manual operation button

Pressing this button advances the runner-side vertical arm and releasing the button returns the arm.

◯10 Runner-side chuck opening manual operation button

Pressing this button opens the runner chuck and releasing the button closes the chuck.

◯11 Product-side chuck opening manual operation button

Pressing this button opens the produce-side chuck and releasing the button closes the chuck.

◯12 Sprue chuck opening manual operation button

Pressing this button opens the sprue chuck and releasing the button closes the chuck.

◯13 Absorption manual operation button

Pressing the button when the power is off releases absorption and releasing the button starts

absorption.

◯14 Vacuum generator

(Refer to the corresponding operation manual.)

◯15 Runner-side descending manual operation button

Pressing this button moves down the runner side vertical arm and releasing the button moves up

the arm.

◯16 Product-side descending manual operation button

Pressing this button moves down the product side vertical arm and releasing the button moves up

the arm.

◯17 Posture return manual operation button

Pressing this button returns the posture of the product chuck section.

- 22 -

2-7. Locations of Limit Switches

No. Symbol Name Remarks

◯1 LS-6 Product-side return end auto switch

◯2 LS-3 Product-side ascent end proximity switch

◯3 LS-8 Posture return end auto switch

◯4 LS-4S Runner confirmation sensor in chuck CYS model

◯5 LS-3S Runner-side ascent end proximity switch CYS model

◯6 LS-9 Posture action end auto switch

⑤

①

④

②

③ ⑥

- 23 -

No. Symbol Name Remarks

◯1 LS-12 Release-side area proximity switch

◯2 LS-2 Traverse over run proximity switch

◯3 LS-10 Extract-side area proximity switch

◯4 LS-1 Traverse home position proximity switch

① ② ③ ④

- 24 -

3. AUTOMATIC UNLOADER SETTINGS

POINT

For full information about how to set the unloader, refer also to <Operation section>.

3-1. Before Making Settings

CAUTIONBefore making settings of the unloader or manually checking itsoperation, lower the speed of each cylinder with the speed controller.

Wiring

Connect the molding machine to the control box of the unloader, and use the control box to verify the

signals between the molding machine and unloader.

1. Connecting the molding machine to the unloader

WARNING• If you are going to operate the molding machine independently

(unlinked), you should first move the carriage unit to the releaseside (outside of the molding machine).

• If jumper is plugged into the relay metal connector box, themolding machine will remain able to execute mold open/closeeven while the unloader's vertical arm is in lowered position withinthe mold. This can result in damage to the mold and/or the arm.

Connect the unloader's metal plugs to the junction metal

connector box installed on the molding machine.

* When running only the molding machine, disconnect

the interlock metal plug and connect the jumper plug

in its place.

Relay junction metal connector box

Jumper plug

Interlockmetal connector

Powermetal connector

- 25 -

2. Checking the signals in the control box

Turn on the power switch on the pendant unit. The

power lamp lights up on the pendant unit.

The following screen appears on the LCD and initial

check starts.

When initial check has been completed normally, the initial screen is displayed.

Bring up the I/O display screen using the key.

When the input signals from the molding machine indicated on the screen are under normal

conditions, wiring is completed.

ON........... In reverse video

OFF ......... In normal video (characters in black)

♦♦♦♦ I/O signals from molding machine

Symbol Name Symbol Name

MD Safety door closed ME Ejector advance-end

MO Mold opening completed MN Molding defect

MC Mold closing completed MA Automatic

- 26 -

Piping

Connect the primary-side air hose you have prepared to

the <IN> of the filter regulator.

Setting the air pressureFilter regulator

Pull the air pressure adjustment knob and turn it to

adjust the air pressure. After adjustment has been

completed, push the knob securely.

Set the air pressure to 0.49Mpa [5kgf/cm2]

Releasing air in the cylinderInterrupt air with the air adjustment knob when

releasing air by adjusting crosswise stroke and open the

residual pressure releasing cock to completely release

residual air in the cylinder.

POINT

Be sure to keep the residual pressure releasing cock

completely closed when operating the unloader.

To use the vacuum generation deviceWhen the vacuum generation device is used to extract

a product with the suction pad, provide the vacuum

generation device with air by opening the suction

ON/OFF cock. When the device is not used, close the

cock tightly.

Primary-side hose

LowerHigher

Release

Fix

Air pressureadjustmentknob

Residualpressurereleasingcock

SuctionON/OFF cock

- 27 -

Unloading and Release Positions

Unloading position

When operating the unloader for the first time after

installing it, be sure to input a point (value) within the

extract side area so that the center of the unloader

carriage unit comes at the center of the mold.

POINT

If the runner chuck cannot be aligned because of the

runner shape, loosen the bolt on the vertical arm and

adjust the position of the runner chuck. (CYS model)

Release position

Adjust the releasing position of the unloader with the

release-side end proximity switch dog, the release-side

area proximity switch dog and the release-side travel end

stopper.

POINT

• Adjust the release-side travel end stopper to the

position detected by the release-side end proximity

switch.

• Be sure to conduct <PS operation> when adjusting the

unload and release-side travel end stopper and the

position of the proximity switch dog.

2025

Release-side endproximity switch

Release-side areaproximity switch

Carriage unitDo not hit.

Release-sidearea proximityswitch dog

Release-sideend proximityswitch dog

Release-sidetravel endadjustmentstopper

- 28 -

3-2. Setting Procedure

1. Product Chuck Replacement

Move the vertical unit to the position where the chuck can be mounted by manual operation

<MANU>.

* When the manual mode is not set, press the key.

Press OPERAT key and key of travelling and

stop the carriage unit at the release-side descend

position.

To descend the vertical arm, press the OPERAT key

and the key of the arm.

POINT

• When descending, turn on the release side descent mode (MD2) in advance.

• When replacing the product chuck in a state of posture returned, turn off the release-side

posture mode (MDSS).

After chuck plate replacement, turn on the release-side posture mode (MDSS) at the arm

ascent end and adjust the speeds of posture action and return (refer to "2-3").

Mount the chuck, and perform piping and wiring.

Return the unloader to the home position as follows.

Press OPERAT key and key concurrently and return the unloader to the home position.

Release-side endproximity switch dog

- 29 -

2. Product-Side Crosswise Standby Position Setting

Interrupt supply of power and air to the unloader.

Loosen the bolt of the absorber bracket with the

hexagonal wrench.

Manually move the vertical unit to the position where the

product is chucked and decide the advance position.

Fully press the shock absorber for advancement against

the vertical unit and fix it by tightening the fixation bolts

of the absorber bracket with the hexagonal wrench.

Supply air after completion of adjustment.

1021

1022

- 30 -

3. Product-Side Crosswise Stroke


Loosen the fixation bolt of the rod clamp with the

hexagonal wrench.

Completely pull out the cylinder rod.

POINT

Adjust the stroke after completely pulling out the

cylinder rod of the crosswise cylinder because the

setting position may be misaligned when supplying

air.

Move the vertical unit to the position where the

product can be removed from the mold.

Tighten the fixation bolt of the rod clamp with the

hexagonal wrench.

Supply power and air after adjustment is completed.

1023

1024

1025

1026

- 31 -

4. Product-Side Vertical Stroke Setting

Measure a distance A from the center of the nozzle of the

chuck plate to the center of the nozzle of the molding

machine.

Please note that the center position of the chuck

plate may not match with height of the center of

the nozzle of the molding machine due to structure

of the chuck plate.

Adjust the distance so that the distance from the lower

side of product-side vertical stopper when completely

ascended to the head section of the descent end shock

absorber fully pressed back will be the same as "distance

A" mentioned in ◯1 .

CAUTION• Never adjust the stroke when the vertical arm is lowered. It is

very dangerous because the stopper is loaded.• Adjust the stroke when the vertical arm is at the ascent end. The vertical

arm may descend and it is very dangerous if it is not at the ascent end.

Loosen the fixation bolt of the vertical stopper with the

hexagonal wrench and adjust it.

CAUTIONBe sure to additionally tighten the fixation boltafter adjustment.

1027

1028

A

- 32 -

5. Runner-Side Crosswise Standby Position Setting (CYS model)


Loosen the fixation bolt of the rod clamp at the

runner side with the hexagonal wrench.

Completely pull out the cylinder rod.

POINT

Adjust the stroke after completely puling out the cylinder

rod of the crosswise cylinder because the setting position

may be misaligned when supplying air.

Manually move the vertical unit to the position where

the product can be removed from the mold and decide

the return position.

Tighten the fixation bolt of the rod clamp with the

hexagonal wrench.


1030

1031

1032

1033

- 33 -

6. Runner-Side Crosswise Stroke Setting (CYS model)


Loosen the stopper for adjustment of runner-side

crosswise stroke with the spanner.

Manually move the vertical unit to the position where

the runner can be chucked and decide the crosswise

stroke.

Completely push back the shock absorber with the

stopper and tighten it with a bolt.

CAUTIONBe sure to additionally tighten thestopper bolt after adjustment.


1034

1035

1036

- 34 -

7. Runner-Side Vertical Stroke Setting (CYS model)

CAUTIONNever adjust the stroke when the vertical arm is lowered. It is verydangerous because the stopper is loaded.

Measure a distance A from the chuck position of the

runner chuck to the center of the nozzle.

POINT

The runner may be caught at the position other than

center of the nozzle of the molding machine

according to the shape of the runner.

Adjust the distance so that the distance from the

lower side of product-side vertical stopper when

completely ascended to the head section of the

descent end shock absorber fully pressed back will be

the same as "distance A" mentioned in .

Loosen the bolt of the stopper plate with the

hexagonal wrench to adjust it.

CAUTIONBe sure to additionally tighten the bolt after adjustment.

1037103710371037

1038103810381038

1039103910391039

- 35 -

8. Selection and Checking of Product Confirmation Limit Switch

Check the product manually and verify that this is shown on the control box's I/O display screen.

For product-side vertical unit

The confirmation limit switch depends on the product extracting method, so select the

corresponding mode first.

POINT

For detail on how to set these modes, see the operation manual for the controller.

a. Single-cavity product confirmation limit switch (LS-4, option)

Adjust this switch with the product runner chucked to

the position which can be detected when the product-

side vertical arm ascends with the mounting hardware.

* Turn on the MD4 product confirmation mode.

b. Chuck-internal product confirmation switches (LS-4T)

These switches are located within the chuck plate (one switch for each product). Execute

chucking and confirm that all limit switches can produce correct detection. Adjust as necessary.

* Turn on the MD4T chuck confirmation mode.

2057

- 36 -

c. Suction-confirmation sensor (LS-4V)

This sensor is contained in the vacuum generator.

Confirm that the sensor turns on when all suction pads

suck a product and that the sensor turns off when any

suction pad releases a product.

* Turn on the MDCV suction confirmation mode.

Runner-Side Vertical Unit (CYS model)

It is contained in the sensor (LS-4S) chuck in the

chuck.

Confirm it when the runner is being chucked.

POINT

It is necessary to turn on the MDS runner extract

mode.

1041

- 37 -

Setting the detection area

Observe the lamp to find the position at which

detection is made with the runner chucked.

a. Loosen the set screws.

b. Slide the runner confirmation auto switch up on

down depending on the thickness of the runner.

When the runner is thick: Slide the switch up.

When the runner is shin: Slide the switch down.

POINT

Make sure that the sensor is OFF when there is no

runner (chuck is open or completely closed).

1043

2065206520652065

- 38 -

9. Position while Travelling Setting

Press OPERAT key and key or key for

travelling to move the carriage unit to the position to

set.

POINT

Set it to the position where the runner does not go into

the safety door of the molding machine when the

runner is open.

Set the release-side area proximity switch dog with

the release-side area proximity switch (LS-12).

POINT

Adjust it to the position where the ON lamp of the

proximity switch comes on.

Set the mode and the timer referring to the operation section of the manual after the above

mechanical setting is completed.

CAUTION

• Be sure to additionally tighten each bolt adjusted when setting before startingthe automatic operation.

• Check to see that the tools used for mechanical adjustment are not left on theunloader or inspection table again before starting manual or automaticoperation after adjusting the machine. If something drops, workers may beinjured or machines may be damaged.

POINT

The next preparation time can be reduced by recording the set dimension for each mold.

1044104410441044

Release-side area proximity switch

ON lamp

Release-side areaproximity switch dog

- 39 -

4. MAINTENANCE AND INSPECTIONTo prolong the service life of the unloader and to prevent accidents, inspect the unloader regularly (once

a month).

Tightening loose nuts and bolts

The loader and molding machine are exposed to storing impact for a long period of time. Therefore,

exercise added care to avoid loose nuts and bolts, which may cause breakage of the loader and mold of

the molding machine.

• Looseness of mounting bolts of each limit switch for ascending, travelling, advancement and

confirmation of the products

• Looseness of the lock bolts of stopper for vertical stroke adjustment and the absorber bracket

• Looseness of ascent and descent end shock absorber fixing nut and advance end shock absorber fixing

nut

• Looseness of the terminal in the terminal box which is a relay between the carriage unit and the

control box (It may cause a malfunction.)

Lubricating parts subject to friction

Apply grease periodically according to the lubrication diagram.

Cleaning LM guide and traverse rail surfaces

Scratches, grease and dirt on the surface of the vertical and crosswise LM guides and the traverse LM

guide on the traverse rail top may impede smooth operation, so clean them off periodically.

Replacing damaged air tubes

Bent or damaged air tubes interfere with the proper flow of air. If there is air leak from any joint or air

tube, replace et immediately.

Confirmation of Pressure-reducing Valve with Filter

Confirm the adjustment method and precautions for pressure reducing valve with the operation manual

for filter and regulator (AW series) described later.

Confirmation of Vacuum Generator

Confirm the adjustment method and precautions for the vacuum generator with the corresponding

operation manual.

Checking expendable parts and sub expendable parts

Check and replace expendable parts in accordance with the expendable parts list.

- 40 -

Maintenance and Inspection Table

Inspection

Wor

k N

o.

Dai

ly

Mon

thly

Eve

ry th

ree

mon

ths

Hal

f-yea

rly

Year

ly

Eve

ry tw

oye

ars Inspection point Method Item Action

1 Air pressure VisualPressuregauge(0.49MPa)

2 Bolt, nutWrench,spanner

Damage,looseness

Re-tighten.

3 Timing belt Damage, tension Adjust.

4LM guide(grease)

Visual Damage, dirtSupply oiland clean.

5 Pipes, wires Visual DamageClean orreplace.

6 Air cylinder Air leakageReplacepacking.

7Element(filter, regulator)

VisualDirt, blocking,drain

Clean orreplaceelement.

8 Silencer Visual Dirt, blockingClean orreplace.

9Vacuum filter(suction unit)

Suctionpressure

Check suctionpressure.

Clean orreplace.

10Generaldiagnosis**

By StarConsultwith Star.

* If you gave any questions regarding inspection methods, items and actions, contact the technical

service staff at our sales office.

** General diagnosis will be provided at your company's expense. Please consult the sales staff at our

sales office.

- 41 -

Lubrication diagram

No. Location No. of points Interval Model

Crosswise LM guide for product 4

Vertical LM guide for product 2

Crosswise LM guide for runner 2 CYS

Traverse LM guide 4

Greasing every3 months

③

②

②

①

①

①

④

- 42 -

Oiling

LM guide

1. Feed grease by the grease pump from the grease

nipple.

2. Supply grease until the casing just overflows.

3. Wipe the excessive grease using a cloth, etc.

Grease

* Supply grease from the grease nipple periodically (refer to "Lubrication Diagram").

* Use lithium grease #0.

1047

- 43 -

5. PARTS LIST

Part Name Type Purpose Manufacturer Qty Code No.

TL-Q5MC1-C with connector

Traverse home position Extract-side area Release-side area Product side ascent end (Runner side ascent end)

Star Seiki 4 (5) 196257

Proximity switch with connector

TL-Q5MC2-C with connector Traverse over run Star Seiki 1 193838

D-C73 Posture action end Posture return end SMC 2 030140

D-97-90 (Runner confirmation) (Sensor in chuck) SMC (1) 030119Auto switch

D-C73 Product side return end SMC 1 030140

AS2201F-01-04S Posture action Posture return SMC 2 001873

Speed controller AS2201F-01-06S

Product side advance Product side return (Runner side advance) (Runner side return)

SMC 2 (4) 001878

Filter regulator AW30-03BDE Air adjustment SMC 1

Vacuum generator unit

ZM101M-A5G-E15-X247 Suction SMC 1

Check valve AKB02A-02S SMC 1 001876

Residual pressure exhaust valve IN-289-731 Release of residual pressure SMC 1 080169

AC servo motor MSMA042A1E Traverse Matsushita 1

Gear with motor VRKF-S9C-400 Traverse SHIMPO 1

- 44 -

6. EXPENDABLE PARTS LIST

Product-side vertical unit

No. Code No. Product Name TypeManufact

urerQty

Replacementinterval

Remarks

1 Packing set ARDB32- 610- R3118 TANHAY1

SET3000 km

Vertical cylinder(600GII)

2 Packing set ARDB32 –810-R3118 TANHAY1

SET3000 km


3 Packing setARDBA32-150-C73KS-R3110

TANHAY1

SET3000 km Crosswise cylinder

4 Packing set ARDB32-65-C73KS-R3112 TANHAY1

SET3000 km Posture cylinder

5 Packing set ACQ2B25-10T-R3123 TANHAY1

SET3000 km

Drop preventioncylinder

6 120484 DU bush DUB0808 DAIDO 2 1 year Posture

7 220031 DU thrust washer DUT06 DAIDO 2 1 year Posture

8 Shock absorbor KBM10-50-11-SCMK2 KYB 12 million

timesAscent end

9 100858 Shock absorbor KBM10-50-12C KYB 12 million

timesDescent end

10 100854 Shock absorbor KBMT12-20-7 KYB 12 million

timesAdvance end

Runner-side vertical unit

No. Code No. Product Name Type Manufacturer

Qty Replacementinterval

Remarks

1 Packing set ARDB25-660-R3117 TANHAY1

SET3000 km


2 Packing set ARDB25-860-R3117 TANHAY1

SET3000 km


3 Packing set ARDBA32-100-R3115 TANHAY1

SET3000 km Crosswise cylinder

4 Packing set ACQ2B25-10T-R3123 TANHAY1

SET3000 km

Drop preventioncylinder

5 Shock absorbor KBMT12-20-8 KYB 12 million

timesAscent end

6 100858 Shock absorbor KBM10-50-12C KYB 12 million

timesDescent end

7 100854 Shock absorbor KBMT12-20-7 KYB 12 million

timesAdvance end

- 45 -

Valve unit

No. Code No. Product Name Type Manufacturer

Qty Replacementinterval

Remarks

1 182837 Solenoid valve SY3140-5MO SMC 520 million

times

Product sidecrosswiseRunner sidecrosswiseRunner chuckProduct chuckSprue chuck

2 182841 Solenoid valve SY7120-5MO-02 SMC 120million

timesRunner sidevertical

3 182838 Solenoid valve SY3240-5MO SMC 120 million

timesPosture actionreturn

4 182836 Solenoid valve SY9120-5MO-03 SMC 120million

timesProduct sidevertical

5 210675 Solenoid valve VP542R-5G-03A SMC 120million

timesProduct sidedescent low speed

6 001877 Silencer AN110-01 SMC 2 1 year Manifold

7 Suction filter ZM-SF SMC 1 1 year Vacuum generator

8 Silencer Ass’y ZM-SA SMC 1 1 year Vacuum generator

9 Filter element AF30P-060S SMC 1 1 year Filter regulator

Traverse rail unit

No. Code No. Product Name TypeManufact

urerQty

Replacementinterval

Remarks

1 Timing belt 025-AT10-0416E-L NOK 1 2 years 1400TR



* Classification of expendable parts

Parts which are replaced within 1 year .......................Expendable parts

Parts which are replaced between 1 and 2 years.........Sub expendable parts

* The above replacement intervals are decided based on the documents presented by the manufacturer.

The replacement intervals may vary depending on frequency of use of the unloader and operating

environment.

(The replacement intervals are given as a guide only, and do not refer to a guarantee period.)

* Parts used in the unloader are subject to change without prior notice.

- 46 -

7. AIR CIRCUIT DIAGRAM

19 Taper plug with hexagon hole 1/8-8 10 18 Speed controller AS2201F-01-06S SMC 2 17 Speed controller AS2201F-01-04S SMC 2 16 Ace ball 1/4 2 15 Check valve AKB02A-02S SMC 1 14 Vacuum pressure GZ46-K-01 SMC 1 13 Vacuum generation unit ZM101M-A5G-E15-X247 SMC 1 12 Valve for removing residual air pressure IN-289-731 SMC 1 11 Silencer AN110-01 SMC 2 10 Valve with silencer ASN2-04 SMC 3 9 Blanking plate ass'y SY3000-26-9A SMC 3 8 Solenoid valve SY3140-5MO SMC 3 7 Solenoid valve SY3240-5MO SMC 1 6 Manifold SS5Y3-42-07-01 SMC 1 5 Blanking plate ass'y SY7000-26-22A SMC 1 4 Three-port solenoid valve VP542R-5G-03A SMC 1

3-2 Gasket (bis) SY9000-11-3A SMC 1 3-1 Solenoid valve SY9120-5MO-03 SMC 1 2 Manifold 302384-101-0 STARTECHNO 1 1 Filter regulator AW30-03BDE SMC 1

No. Name Type Manufacturer Qty Remarks

CY-600GII CY-800GII

This diagram shows a type without S side vertical unit.

- 47 -

20 Taper plug with hexagon hole 1/8-8 7 19 Union Y KQ2U06-00 SMC 1 18 Speed controller AS2201F-01-06S SMC 4 17 Speed controller AS2201F-01-04S SMC 2 16 Ace ball 1/4 2 15 Check valve AKB02A-02S SMC 1 14 Vacuum pressure GZ46-K-01 SMC 1 13 Vacuum generation unit ZM101M-A5G-E15-X247 SMC 1 12 Valve for removing residual air pressure IN-289-731 (6*6) SMC 1 11 Silencer AN110-01 SMC 2 10 Valve with silencer ASN2-04 SMC 5 9 Blanking plate ass'y SY3000-26-9A SMC 1 8 Solenoid valve SY3140-5MO SMC 5 7 Solenoid valve SY3240-5MO SMC 1 6 Manifold SS5Y3-42-07-01 SMC 1

5-3 Screw M4*31 (For SY7000) SMC 2 5-2 Gasket SY7000-11-9 SMC 1 5-1 Solenoid valve SY7120-5MO-02 SMC 1 4 Three-port solenoid valve VP542R-5G-03A SMC 1

3-2 Gasket (bis) SY9000-11-3A SMC 1 3-1 Solenoid valve SY9120-5MO-03 SMC 1 2 Manifold 302384-101-0 STARTECHNO 1 1 Filter regulator AW30-03BDE SMC 1

No. Name Type Manufacturer Qty Remarks

CYS-600GIICYS-800GII

This diagram shows a type with S side vertical unit.

- 48 -

8. GENERAL DRAWING

CY-600GIICY-800GII

Dimension within ( ) indicates dimension for 600st.Dimension within < > indicates dimension for 1000TR.Dimension within { } indicates dimension for 1200TR.Dimension within [ ] indicates dimension for 1600TR.1400TR regular operation

- 49 -

CYS-600GIICYS-800GII

Dimension within ( ) indicates dimension for 600st.Dimension within < > indicates dimension for 1000TR.Dimension within { } indicates dimension for 1200TR.Dimension within [ ] indicates dimension for 1600TR.1400TR regular operation

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Documents

TRAVERSE AUTOMATIC UNLOADER CY-600GII OPERATION MANUAL · Thank you for purchase of the Star Traverse Automatic Unloader. ... This manual includes important safety precautions relating