DC SCHOOL TEXT BOOK

⑦ SETTING METHOD OF TOSCAST

TOSHIBA MACHINE Co., Ltd.

DIE CAST MACHINE ENGINEERING DIV.
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For casting good die cast products, technology related to mold such as gate system, mold temperature, mo

lten metal temperature etc, and casting method such as pouring, injection, and spray. TOSCAST is designe

d as your accumulated know-how is duplicated on our die cast machine.

TOSCAST set and control casting condition by each mold such as spray, pouring, mold close, injection, eje

ctor, and carry out etc. Besides, it has monitoring function for quality, good product shot data memory fun

ction for determination of good product, product control function for lot and shift, alarm for maintenance,

failure diagnosis function, and guide function for screen operation by high performance microcomputer.  

This instruction manual is structured in order of TOSCAST functions, operation for condition setting, operat

ion for control, and monitor operation. These operation method is also indicated on TOSCAST screen by s

creen guide function. 

Please read this instruction manual carefully, and use TOSCAST functions practically and fully.

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Injection Control
Correct automatically low-speed rate, high-speed rate, pressurization time by remote control valve.
Correct high-speed changing position, and make high-speed interval even.
Start intensifying at a certain distance short of filling completed position, or start intensifying if the injection pressure is achieved a certain press
ure before reach to the position.
Measure injection position and output following LS.
Injection Forward Limit Position · Injection Backward Limit Position
Casting Pressure Control
Adjust intensify ACC pressure to correct casting pressure. Check every 5 shots and correct.
Mold Close Power Control
Preset die height position by setting mold thickness and mold clamp power.
To adjust die height and correct mold clamp power, calculate mold clamp power by measuring stretch of tie bar bottom of operation side. (The
measuring position for stretch of tie bar depends on model. )
Mold Close Operation Control
Control mold close · flow volume of hydraulic oil for mold open operation · pressure with 5 processes for mold close, 3 processes for mold ope
n. Gradient of each speed change process can be set three phases.
Low Pressure Mold Close Control
Adjust position · flow volume · pressure of mold close forth act (before mold touch) to set time to detect foreign object.
Core Operation Procedure
Procedure of mold close · core in and mold open · core return can be set. Core Pressure · Flow Volume Control
Ejector Control
Correct ejector limit position by ejector SOL off position.
Set hydraulic oil flow volume and pressure for ejector · ejector return operation.
ACC Filling Control
Fill ACC by making flow volume and pressure of hydraulic oil maximum when speed ACC pressure or intensify ACC pressure decrease.
Line Pressure · Flow Volume Control
Flow volume and pressure for each operation can be set by P-Q valve.
In case of lap operation, give priority to either one.
Pouring Volume Control
Calculate measuring position by using ladle and casting weight, and preset as the angle. Ｐ－ 3
 TOSCAST OPERATION MANUAL
TOSCAST is a control device applying TOSHIBA KIKAI die cast machine. The operation is very simple, and you can control the machine easily
with it.
 
TOSCAST is composed of three buttons; condition setting (yellow), monitor (green), and control (red).
Condition setting is a command to die cast machine. It is composed of four buttons; mold, casting, main body, and automatic machine.
・ Mold ··········· Input important mold conditions for casting such as mold thickness (reference of initial position setting screen), blank injection
stroke etc.
・ Casting ····· Set injection condition (other than multi injection), die timer, and core select etc.
・ Main Body ··· Set mold close speed, ejector stroke, and ejector delay time etc. For multi injection machine, injection is set here.
・ Automatic Machine ··· Set peripheral devices such as plunger lubrication device, carry out device, and spray device etc.  
  
Monitor is a button to watch movement of die cast machine.
・ Quality ····· Gain an understanding of casting condition such as injection wave, line data etc. Also, alarm condition can be set.
・ Good Product ··· Save injection wave and line data when good product is cast. This makes possible to compare good product condition to current
casting condition.
・ Operation ··· Gain an understanding of die cast machine movement. It is possible to see ON and OFF of limit switch, various stroke, and
pressure value.
 
Control is a button to set initial position, screen setting etc.
・ Production ··· Control production unit.
・ Maintenance ··· You can find alarm history and setting change history.
Screen ········· Initial Position Setting, Parameter Setting, Screen Setting, Screen Guide etc

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 Injection moves head off for setting biscuit thickness
short of blank injection stroke.

Chip
Sprue

Injection
Blank Injection Stroke Backward
Limit

Thickness High-Speed Low-Speed

of Biscuit Range Range

· Mold Thickness ··· Input mold thickness. Adjust die height in prospect of stretch of tie bar (about a few millimeters) based
on input value. The accurate figure must be input because this is an important value to correct mold clamp power. Measur
e approximately on 1mm scale with gauge, close mold, and make die cast machine to measure mold thickness on 0.1mm sc
ale.
① Input actual mold thickness measured manually with gauge etc.
② Adjust die height. (Auto or Manual)
③ Close mold with a few % ~ 90% of mold close power. (Measurement of mold thickness by die cast machine)
④ Screen Button → Input the figure of mold thickness (for reference) indicated on initial position set as mold thickness.
⑤ Main Body → Turn ON mold close power correct with operation select setting, select auto adjustment of die height with
operation box. Mold clamp power shall be indicated as specified figure after close mold some times. (The figure of mold cl
ose power shall be input as casting → casting setting.) 
・ Blank Injection Stroke ··· Input distance from injection backward limit to mold sprue (movable mold). This is an important
figure to set biscuit thickness and injection range by mold.
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① Change to mold change mode with operation box, and close mold.

② Move injection forward until it touches to movable mold (sprue). However, if the injection forward limit position is input sho
rter, injection stops before sprue. In this case, input larger number as injection forward limit to move injection forward.
③ Read injection stroke value with operation – main body operation, input it to blank injection stroke of mold setting.
 · Chip Diameter  ·  ·  · Input chip diameter set by die cast machine. Adjust casting pressure etc by area ratio of set chip diameter
and cylinder of die cast machine, accumulator pressure.
 · Biscuit Thickness ·  ·  · Input set biscuit thickness.
(Blank Injection Stroke) – (Biscuit Thickness) = Injection Range
 · Product Thickness ·  ·  · Input the value of thinnest area of product. (Use casting calculation only.)
As die cast; unless filling is completed within thickness(mm)×thickness (mm)×0.01sec, molten aluminium solidify and misrun occur
generally. The thinnest area solidify the first. If the first solidified area is still molten condition, other thick area shall be molten con
dition also.
 

· Casting Weight ·  ·  · Set pouring casting weight. However, ladle which set by automatic machine → automatic machine set
ting and ladle which mounted on pouring device actually shall be the same. 
· Product Weight ·  ·  · Input product weight without gate. (Use casting calculation only.) When this value is input and casting cal
culation is done, high-speed rate and high-speed range shall be indicated.
· Project Area ·  ·  · Input project area on mold parting surface. (Use casting calculation only.) When this value is input and cas
ting calculation is done, limit casting pressure and mold open power shall be indicated. 
· Gate Cross Section ·  ·  · Input gate cross section. Correction of high-speed rate shall be more accurate by inputting the val
ue accurately. ※ If the set gate cross section is smaller than actual cross section, speed rate could be faster than set spe
ed rate. (Multi injection machine doesn’t correct gate cross section.)
· Number of Cavities ·  ·  · In case of multi-cavity mold, input number of cavities. Set number of increasing of production count by
shot on production screen according to this value.
· File Information ·  ·  · Input mold name, product name, material (select screen), preparer, and comment. It is classified by mo
ld name.
If it is saved as existing mold name, it is overwritten. Ｐ－ 6
 
Injection, mold close (mold close speed is main body →mold close ejector setting), cycle timer, pouring, spra
y, carry out check timing, and core operation select are set at casting condition setting.

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Metals are deformed and fatigue by rapid temperature change. Die cast mold is also worn rapidly if it is room te
mperature at casting started. It is the best to cast with increasing speed and pressure etc slowly.

Ｐ－ 8
Startup setting is a scheduler for specified pre-heating by reducing speed and pressure etc automatically, when mold temperature dro
p from continuous casting such as starting of casting or shut down too long.
There are maximum of 5 phases setting for startup setting. Condition shift to startup 5 → 4 → 3 → 2 → 1.
Startup Setting Items
· Cycle Time ····· Input starting time of startup operation. If you input 5min, it means this is the condition to start when casting sh
ut down more than 5min.
· Number of Shot ··· Input number of times of startup operation.
· High-Speed Use ··· Select use or non-use high-speed.
· High-Speed Rate ··· Set high-speed rate in case of above high-speed using. The speed is set as ●●% of high-speed rate set at ca
sting condition.
· Intensify Use ····· Select use or not use intensify.
· Die Timer ····· Set die timer as ●▲% of casting condition setting.
· Mold Cleaning 1hr ··· Set timer for air blow 1 as ●×% of casting condition setting.
· Release Agent Spray Time ··· Set timer for release agent spraying as ×●% of casting condition setting.
· Mold Cleaning 2hr ··· Set timer for air blow 2 as ▲●% of casting condition setting.
· Pouring Standby ··· Input position in readiness of pouring device as forward limit or above furnace.
EX: Product isn’t removed from mold while continuous casting, stop the machine for 12min, and restart continuous casting.
For the startup setting on previous page, start from startup 3.
 
End Setting
In case of using end setting for accumulating production control, production stop operation or mold change stop operation is conduc
ted when the value reaches the setting production unit.
· Production Stop Operation ··· Pouring device is interlock, and others stop at initial position.
· Mold Change Stop Operation ··· Pouring device drain and stop at position in readiness. Mold clamp stop right before touching, an
d others stop at initial position.
 
Startup end setting is by non-casting time, however it can be set by temperature optionally. (※ temperature pattern setting)

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· Mold Close Speed ··· Set mold close speed with %. (High-Speed High-Pressure Range of Mold Close Ejector Setting 2)
· Mold Open Speed ··· Set mold open speed with %. (High-Speed High-Pressure Range of Mold Close Ejector Setting 2)
· Low Pressure Start Position ··· Input low pressure mold close start position on mold close operation. Alarm sounds when
it passed setting timer (low pressure mold close abnormal detection timer of mold close/ejector
setting 2) because mold didn’t close by resistance of foreign object while mold close operation
because of low pressure.
· High Pressure Start Position ··· Position where low pressure mold close end on mold close operation.
· Ejector Speed ··· Set ejector speed with %.
Ｐ－ 10
It is possible to change mold close speed in phases with mold close ejector setting 2. If it has angle pin, slow down right before the
head of pin get into a hole and raise the speed after the pin get in some.
· Changing Position ··· Change where mold close limit as 0.
· Draft Angle ····· Acceleration decrease in order A → B → C.
· Pressure ····· Set mold close cylinder pressure at mold clamp operation. (Apply upper limit normally.)
Ejector Operation (Ejector Operation/Ejector Return Operation) Setting
· Changing Position ··· Set stroke that ejector plate moving.
· Ejector Speed ····· Set ejector plate speed.
· Ejector Pressure ··· Set ejector plate pressure. (Apply upper limit normally.)
· Ejector Delay ····· Set delay time until transferring to ejecting operation after mold open.
· Ejector Return Time ··· Set delay time until transferring to ejector return operation after ejecting. 
※ LS Option ····· Set as mold close stroke operates when it reaches set value by LS option while mold close/open operation.
It is set as pouring start when mold stroke reaches 3mm (3mm short of close limit) while mold close operation on previous page.
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On operation select setting, you can choose of use or non-use of various correction and optional devices on operation select setting.
(Type of correction depends on the model or specification.)
 
For correction of intensify time, low-speed rate, high-speed rate, and high-speed interval; the valve opening and timing is adjusted
automatically.

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· For correction of intensify time, low-speed rate, high-speed rate, and high-speed interval; the valve opening and timing is a
djusted automatically.
· Casting pressure shall be adjusted depending on gas volume at the time within adjustable range.
If actual casting pressure is higher than setting casting pressure, reduce pressure by draining oil from ACC. If actual casting p
ressure is lower than setting casting pressure, increase pressure by pouring oil in ACC.
※ Sometimes ACC pressure increase by rising the hydraulic oil temperature. Adjust it by draining oil from ACC in case of c
asting pressure correction is ON.
If the pressure doesn’t decrease to setting casting pressure after draining oil completely, correction will not run. Release gas fr
om ACC, conduct V-check in accordance with manual to make it setting casting pressure.
· Mold close power is corrected by moving die height as close the thermal expansion mold with the specified constant power (
casting condition setting. Turn “mold close power correct” ON to make die height adjusting of operation box auto. H
owever, correction shall be done rightly by inputting mold thickness to TOSCAST accurately. (Refer to mold setting.)
· Ejector limit is corrected by adjusting pressurization time of ejection cylinder.
· Pouring cycle is corrected by adjusting backward stand-by time of pouring device as match with cycle time derived from f
ull-auto cycle just before 1 cycle.
Except for backward stand-by time (ladle inside furnace, slight slope start, pouring return start, injection delay), it is operated acc
ording to the input value at automatic machine setting.
※ If pouring device is late for mold close even “pouring cycle correct” is ON, it is also late often with making backward st
and-by time 0. In this case, make shorter “ladle inside furnace timer” or “pouring return time”. It is required to re-adjust c
asting weight because sometimes pouring volume fluctuate.
· Injection Learning Control ··· Only for multi-injection.
If actual wave is different from setting injection wave largely, adjust servo valve timing and opening as match with setting w
ave. The control shall be done as below.
① Change casting starting or injection setting.
② Cast with valve opening under blank injection status against injection setting for once. (Indicate “on real time feedback c
ontrol” on the bottom right corner of injection wave.)
③ Adjust valve opening and timing to bring the previous shot wave close to setting wave. (Indicate “on learning control” on t
he bottom right corner of injection wave.)
④ Bring actual casting wave close to setting wave with about 5shots. End learning control when it closes. (Indicate “on l
ock” on the bottom right corner of injection wave.)
⑤ When you restart learning control, push lock release key on injection wave screen.
Ｐ－ 13
Injection Setting
(Only for Multi Injection Machine)

Ｐ－ 14
Multi injection machine is required to set the speed by many points. It is possible use 9points maximum. Any point can be use or non-use. However,
high-speed change point must be specified surely.
· Speed Setting Select ··· Decide use or not use specified point.
 
· Position ····· Set position of using point. It is not able to set it where short of previous point of using point. In that case, change the
previous point to short, then move it.
 
· Injection Speed ··· Input the speed at a point. It happens that upper limit of imputable speed becomes lower than 10m/s depends on previous point
position and speed. Extend acceleration interval (space between setting point and previous point) to increase speed up to 10m/s. 10mm is enough for
this.
 
· High-Speed Change Point ··· Specify starting point of high-speed interval.
 
· Pressure Starting Position ··· Input a point to start transferring pressure from ACC to intensify cylinder. It is indicated as ●●mm short of setting
filling complete position (blank injection stroke – setting biscuit thickness).
· Blank Injection Stroke ··· Input blank injection stroke. (Refer to mold setting.)
· Biscuit Thickness ··· Input biscuit thickness.
· Forward Limit Position ··· Input forward limit position where injection follows.

· Intensify Time ····· Input time until the pressure reaches casting pressure after high-speed injection completed. If intensify time is too short,
casting pressure transfers immediately and it may clear porosity but cause of burr.
· Casting Pressure ··· Input casting pressure. Measure gas volume filling in ACC by V-check, and indicate castable range ●● ~ ×× Mpa. If the
target casting pressure is out of the range, filling or release ACC gas and V-check again to change the range.

Ｐ－ 15
 
Core Squeeze Setting
Setting shall be done with operation before injection and operation after injection. Decide operation order here. And also,
input the speed and pressure of each operation.
Squeeze setting shall be done with speed, pressure, start time, and return time.
Start and return time shall be set with high-speed start position or starting pressure. (Starting pressure is optional.)
· High-Speed Start Position ··· Set start and return time with time after injection speed changed to high-speed.
· Starting Pressure ··· Set start and return time with time after casting pressure reaches set starting pressure.

Ｐ－ 16
 

Ｐ－ 17
Setting of Automatic Machine
Pouring Device
· Select using ladle type from select window.
· Set casting weight. It is recommended to check setting casting weight before casting start.
· High-Speed Pouring ··· Speed at pouring start and end.
· Low-Speed Pouring ··· Intermediate speed at pouring.
· Stand-by Position ··· Stand-by position of ladle until die cast machine preparation completed.
Timer
· Ladle in Furnace ··· Time while ladle is in furnace.
· Slight Slope Start Time ··· Time from pulling ladle out furnace with sloping to becoming horizontal.
· Pouring Return Time ··· Set a time from pouring complete to starting return.
· Injection Delay ····· Set a time from pouring complete to injection start.
· Backward Stand-by ··· Set a time for empty ladle stand-by above furnace after pouring. When pouring cycle is corrected,
backward stand-by time is adjusted.
Spray Device (It may differ depends on specification.)
· Spray Start Timer ··· Time from spray lower start to air blow start. Air blow start before the spray get in a mold if
earlier time than lower time is input.
· Mold Cleaning 1hr ··· Time for air blow after spray start timer end.
· Release Agent Spray Time ··· Time for spray release agent after air blow completed.
· Mold Cleaning 2hr ··· Timer for air blow after release agent spray.
· Spray Up Timer ·····Time from release agent spray completed to spray up starting. If it is shorter than mold cleaning 2hr, it
comes away from mold with air blowing.
· Swing Operation ··· Select use or not use spray swing operation.
Carry Out Device (It may differ depends on specification.)
· Product Check 1, 2 ··· Select use or not use product check device 1or 2.
· Carry In Position ··· Select carry in position of carry out device as pull out position or pull out return position.
· Chuck Operation ··· Select chuck before product ejecting or after.
· Stand-by Position ··· Set a stand-by position by moving forward before carry in operation. Close the mold with mold change mode,
and bring catty out device closer manually where to stand-by. Under this status, read a drive axis by operation → automatic machi
ne operation and input it as stand-by position.
Ｐ－ 18
 Cursor

Injection Wave (Inside memory can save up to 10 shots.)

Indication item, overwriting setting, and axis setting on injection wave screen shall be set by screen → screen setting.
Select indication start position of screen and wave.
1. Entire ····· Indicate from injection started, and also indicated process of low-speed, high-speed, intensify.
2. From High-Speed ·····Indicate from high-speed started.
3. From Intensify ····· Indicate from intensify started.
Select wave and indication method of wave.
1. 1 shot ····· Indicate the latest wave every 1 shot.
2. Overwriting ····· Overwrite continuous N shot. (N shall be by screen → screen setting.)
3. Still ····· Stand still wave indication. It is applied for indication of wave of floppy etc, and indication
of specific shot wave on N shot overwriting. You can’t go back and see before the 11 shot
because the inside memory can save only the latest 10 shots. When it is put in a still mode, line
indication is also put in a still mode.
Cursor ····· Indicate time on line, wave, speed, and pressure etc as figure on center right of the screen
by moving cursor (white line) with right and left keys.
Good Product Wave ··· Indicate difference between good product wave and current shot wave in the square of area
difference.
Ｐ－ 19
Line Indication
12 items are indicated on one screen. Another 12 items are indicated by pushing setting key. The screen can show tot
al 24 items, 50 shots.
If it is put in a still mode on injection wave screen, it shall not be renewed even line data is on continuous operation.
· Select monitoring item by quality → quality condition setting. 　　　　　　　　　　　　　　　　　　　　　　　　　　　　　　　　　　　　　　
· Set upper limit and lower limit by quality → quality condition setting randomly. It is possible to select operation such a
s alarm and cycle stop etc, if it goes over both limits.
 
Cursor ····· Indicate date and hour of a shot indicated in outline characters on white background.
For the shot on start-up controlling, S5 ~ S1 is indicated the side of shot number.
Unmeasurable item (high-speed rate at low-speed injection only) is indicated with N.
Unmeasurable item is indicated with L.
Ｐ－ 20
Trend Indication
Indicate within upper and lower limit that is set on quality condition setting.
Indicate as good product value is on center while good product setting (good product setting button) is ongoing.
※ Calculate and indicate maximum value, minimum value, average, and standard deviation value for 50 shots.
※ When “Next Page” key is pushed, twelfth item is indicated.

Ｐ－ 21
Quality Condition Setting
Select indication item, upper limit value, lower limit value, and alarm output of a monitoring data.
12 items are indicated on one monitoring data page and another 12 items by “Next Page” of function key. 24 items total are indicated.
 
If you want to change indicated item; move to the item, push setting key, and select from item list on right side. Don’t forget to push “Item Select
Settle” after changing.
 
Alarm Value ····· It is possible to output alarm when the value goes over limit, by giving upper and lower limit to the item. There are some
type for output such as alarm indication, signal release, cycle stop, output 1, output2, and indication Bz (buzzer). If measuring value is not within
limit, it is not indicated on trend indication.
Ｐ－ 22
It is possible to set current indicated wave data as standard of good product.
It is also possible to set indicating data by still mode as good product. (Wave for 10 shots remaining on inside memory.)
 
It makes possible to determine what and how much current status differ from setting good product wave.

Ｐ－ 23
Cycle Diagram
Indicate current cycle, previous shot cycle, and good product shot cycle. Entire cycle time and total of each
operation time doesn’t match because there is some overlaps of each operation. 　
Spray ····· From lower start to up completed. (at no swinging)
　　 　 ····· From swing start to swing return completed. (at with swinging)
Core In ····· From the first core in return start to the last core in completed.
Mold Close ····· From mold close start to mold close completed.
Pouring ····· From pouring on command to pouring return start.
Injection ····· From injection start to intensify start.
Product Cooling ··· From intensify start to die timer completed.
Mold Open ····· From mold open start to mold open completed.
Core Return ····· From the first core return start to the last core return completed.
Ejection ····· From ejection start to return completed.
Take Out ····· From carry out start to backward limit after running.
Ｐ－ 24
Main Body Operation
Indicate operation of the die cast machine body. Green ● is lighting while the limit switch is on. Each command signal (solen
oid for core or ejector) is indicated by green (initial position) or red (operation side) in ■. This screen is also applied for meas
uring injection stroke on blank injecting stroke measurement.
 
Sometimes initial position is misplaced even it is operating after injector returned, but the initial position limit of injector is not
on. Initial position shall be set when stroke doesn’t become 0 even the limit is on mechanically.
Initial position shall be set by screen → screen control → initial position set.
Ｐ－ 25
Automatic Machine Operation
Green ● is on when limit switch is in. Each command signal (solenoid for core or ejector) is indicated by green (initial position) or red
(operation side) in ■.

Ｐ－ 26
For cumulative production control, control production units every mold. When casting data is called up, cumulative production da
ta is cleared. Cleared data are a planned total production unit, number of defective, and stopping time. In case of printing out or
saving the production data, it shall be done before casting data is called up.
Planned Total Production Unit ····· It is the production unit of products. When it is set as 2-cavity on mold setting section, it shall b
e twice as number of shot. It is applied for automatic end setting, remains production, and calculation of remained time.
Automatic Start-Up (Setting) ····· When it is applied, start-up control is conducted. Start-up control shall be by casting → start-up e
nd setting.
Completion Notice
It is noticed before setting time of completion notice time on ●● minutes before.
It is noticed before setting number of products of planned total production unit at ▲▲ pieces before.
○○ hr ×× min is noticed by setting time. Completion notice time is derived from cycle time and remains production of good pro
duct.
Automatic End
Remains production stops as 0 if it is applied. Select stopping timing at which production stop and mold change stop by casting
→ start-up end setting.
Ｐ－ 27
Shift Production Control
Shift production control shall be done with shift starting time as a delimiter. When shift starting time and casting data is called up
, shift production data shall be cleared.
Input shift start time on operating time setting of screen setting.
It can be set up to three-shift per day, and controlled 9-mold shift production data maximum per day.  
Shift Planned Total Production Unit ····· Input production unit by shift. In case of two-cavity, it shall be twice as number of shot. I
t is applied for remains production and calculation of remained time.
 
Stop for Taking a Break ····· The cycle stops at a break time of shift when it is applied.
 
Number of Defective ····· Input defective 1 ~ 4 and others to draw a pareto diagram. The alarm of quality monitor A is
automatically input the number of over the alarm range.
 
Stop Time ····· Input stop 1 ~ 5 and others to draw a pareto diagram.
 
※ Indication of production data is the same as cumulative production control except for by shift. Ｐ－ 28
Machine Check
Input the check date after each items have been checked. It moves to next by ”Next Item”.
When number of shot is input in shot counter for maintenance, it reduces the number of 1 by one-shot. A message appears when it turns 0.
Cumulative operation time and cumulative shot are the data from installing.

Ｐ－ 29
Machine Diagnosis
When alarm number is input indicated by Maintain → Alarm History, the details is indicated. 
Occurrence Number ····· The number is set in order of alarm occurrence. The alarm description shall be indicated by inputtin
g alarm number indicated by maintain → alarm history.
Alarm Item ····· Indicate with classification code (B etc) and three figure.
Class B: Follow-Up Maintenance It indicates after occurrence of abnormal.
Class P: Preventive Maintenance It indicates for prevention before occurrence of abnormal and check items.
Class Q: Quality Monitor Alarm of quality monitor.
Class E: Forenotice Signal of Production Control
Class D: Indication of Miss-Operation
The numbers are indicated in response to a inside relay in sequence.
Operation Mode ··· It indicates a mode which alarm occurred.
Process ····· It indicates the process of alarm occurrence.
Alarm diagnosis ····· It indicates description and countermeasure of alarm.

Ｐ－ 30
Alarm Item ····· 10-section, 140 items are memorized on inside memory. It shall be indicated by pushing “Next Page”.
When the number is input at machine diagnosis, the details of alarm are indicated.

Ｐ－ 31
It indicates 10 sections, 140 items of maintenance history.

Ｐ－ 32
Setting Change History
It indicates 10 sections, 140 items of change history of casting data and screen setting etc. It is possible to trace the history by “Precious Page”.
※ The setting returns previous one by changing current setting value to previous setting value.

Ｐ－ 33
It indicates inside relay.

Ｐ－ 34
Screen Control Window
When you push screen with direct key, above screen appears.
It indicates all items that possible to indicate.
In case of setting initial position, transfer to initial position set because it can be done only by this screen.
Screen guide shall be indicated by screen → screen guide.
Ｐ－ 35
Initial Position Set
It indicates current value of each device. It needs to set the initial position when it misalign such as a injector is operated manually and the indicated
figure is not 0mm even return limit is on. The operation that makes reading value force to match to specified value (setting value) is called initial
position set.
Initial Position Set for Injection Stroke
① Operate the device to check if mechanical limits match to standard.
② Move cursor to a item to make the point the specified value, and push the start button.
③ Input specified value and end setting.
It is also possible to decide open level by manual without using valve open control.
① Move cursor a item to a valve which you want to operate, and push “motion start”.
② When the increase and decrease button is kept pushing, the valve starts operation. (Injection valve doesn’t operate with multi-injection.
Injection valve doesn’t operate if injection is not at initial position.)
③ Initial position set for valve opening shall be done by pushing origin set button to set valve closing condition as initial position of
valve opening 0.
※ Mold thickness is also indicated on this screen (for reference). Input this value on mold setting screen. (When mold thickness (fore
reference) is not input and unless mold clamp power goes more than a certain percent, it is indicated.)
Ｐ－ 36
Screen Guide ····· When Screen → Screen Guide is specified, it is indicated the explanation of previous screen. For example, if Screen → Screen
Guide is specified after automatic machine setting is indicated, it is indicated the screen guide of automatic machine.
At the same time, display structure, input method, TOSCAST index are indicated as function key.

Ｐ－ 37
Ｐ－ 38
Screen Setting ····· Set input limits such as mode select or select indication item as wave.
 
Shot No. ····· Input current shot number. The cursor moves to shot No by pushing “shot No setting” of function key to input
figures. Push “shot No set” surely after inputting figures.
 
Mode Setting ····· There are operation mode, setting mode, quality monitor indication, auto screen off, history save alarm as mo
de setting.
 
Operation Mode ····· It is possible to limit casting condition input.
· It is not able to set casting condition by normal control.
· It is able to set casting condition by setting control, however it is not able to change parameter etc.
· It is possible to change all by detail control.
 
Setting Mode ····· It only can indicate saved data to memory in TOSCAST while continuous casting etc.
· “Normal” shows current operation of die cast machine or casting condition.
· “Edit” doesn’t show current operation of die cast machine or casting condition. If the saved data is called up under edit mode, it is
not affected operation of die cast machine.

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Quality Monitor Setting ····· It is possible to indicate saved wave or line data in external memory (FD or memory card) to TOSCAST.
· Online indicates a data on monitoring currently.
· FD data (memory data) indicates a data called up from external. It calls up saved data (wave/monitoring data) in external
memory by external memory operation, and select one when it is indicated on quality monitor.
 
Auto Screen Off ····· Screen saver runs if any operation has not been done for more than 5min. The screen turns back with any key.
 
History Save Alarm ····· When it is on, alarm shall be output before history data becomes full. When it is off, data iis erased in order
of obsoleting sequentially.
 
Injection Wave Indication Setting
Indication ····· Turn items ON that are needed to indicate such as injection speed, casting pressure, injection position, and settin
g wave etc.
Overwriting ····· Select continuous or N shot. The continuous overwriting shows every shot wave without erasing. The wave is erase
d when the screen is changed or wave clear key is pushed.
 
For time, speed, pressure, and position etc, the indicating axis range shall be set by auto setting or manual setting.
 
Operating Time Setting
Shift Start Time, Break Time ····· Input start time and break time of shift 1, 2, and 3. It is for start time of shift production control. When
break time stop of shift production control is applied, the cycle stops at setting time.
※ If you don’t want to use this function, don’t input figures.
 
Quality Printer Setting/Quality Floppy Setting
Set printing out the data after each shot or once per certain shot, once per certain minutes etc, and saving the data to external media.
It is possible to save the data only when the alarm sounds (it goes out of quality condition setting range).
 
Continuous ····· When it turns ON, continuous print and continuous save shall run.
Auto Output Condition ····· Set shot and time so that the data is printed out and saved at the setting time. If it turns on at alarm sounds
, the data is saved and printed out only when the alarm sounds.
 
End ····· Input the condition for end. Saving and printing shall end at specified shot or time. Normally, it is fine to input
99999 shot or 99999 minute.

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Ｐ－ 41
 External Memory Operation
Floppy disk is applied for before TOSCAST555 version, and memory card for after 555.
Casting data can be saved to inside memory for 64-mold. Floppy disk also can save 64-mold casting data.
Wave data can be saved to inside memory for 10-shot. Floppy disk can save 200-shot wave data.
Monitoring data can be saved to inside memory for 50-shot. Floppy disk can save 2300-shot monitoring data.
· Save All Casting Data ····· Save all data saved to internal memory to external memory.
· Call Up All Casting Data ····· Replace all casting data input on external memory with the data saved to internal memory.
All data saved to internal memory originally shall be erased.
· Save One Casting Data ····· Specify just one data saved to internal memory, and save it to external memory.
· Call Up One Casting Data ····· Save just one casting data saved to external memory to internal memory additionally.
· Call Up Monitoring Data ····· Call up monitoring data saved to external memory. The data called up is indicated by changing quali
ty monitor indication: online → FD data, on screen → screen setting.
· Call Up Wave Data ····· Call up wave data saved to external memory. The data called up is indicated by changing quality moni
tor indication: online → FD data, on screen → screen setting, and making the wave stationary mode on quality → injectio
n wave.
· Save History Data ····· Save history of alarm, maintenance, and setting change indicated on maintenance screen to external mem
ory.
· Call Up Name Data ····· Call up the name of person who is in charge of it. Create the name (up to 100 names with 4 and less Chine
se character ) that is input with text format in extension of “.OPE”. File name shall be within 8 one-byte characters.

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Parameter can’t be set with pump ON. Be sure to turn OFF the hydraulic pump before operation.
· Set flow volume and pressure etc for mold close at mold change. Input it when it needs to make mold close speed slower at
mold change.
· HRT (Intensify OFF timer)
·· It is time doing increase pressure maintenance after the ejection end. But maintenance time depends on a Dai timer in the case of a short Dai timer from
ダ営技
HRT time.
　 05.01.11
渡 辺

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